Komatsu PLANTER D61EM-23M0 Repair Service Manual SEN06814-01 by www.heydownloads.com

SEN06814-01

PLANTER

D61EM -23M0 SERIAL NUMBERS

B10001

and up

SHOP MANUAL

D61E -23M0 Model

Serial Number

D61E -23M0

B 0001 and up

00 Index and foreword

D61EM-23M0

00-1

00 Index and foreword Index

Index

00 Index and foreword - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 00-1 Foreword, safety and general information - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 00-13 Important safety notice - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 00-13 Precautions to prevent fire- - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 00-18 How to read the shop manual - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 00-20 Explanation of terms for maintenance standard - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 00-22 Handling equipment of fuel system devices- - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 00-24 Handling of intake system parts - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 00-25 Handling of hydraulic equipment - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 00-26 Method of disconnecting and connecting of push-pull type coupler - - - - - - - - - - - - - - - - - - 00-28 Handling of electrical equipment - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 00-31 How to read electric wire code - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 00-39 Precautions when performing operation - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 00-42 Practical use of KOMTRAX - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 00-47 Standard tightening torque table - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 00-48 List of abbreviation - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 00-54 Conversion table - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 00-59 01 Specification - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 01-1 Table of contents - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 01-2 Specifications - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 01-3 Specification drawing - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 01-3 Specifications- - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 01-4 Weight table- - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 01-9 Table of fuel, coolant, and lubricants- - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 01-11 10 Structure and function - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 10-1 Table of contents - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 10-2 Engine and cooling system- - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 10-3 Engine related parts - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 10-3 Cooling system - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 10-5 Cooling fan motor - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 10-7 Oil cooler bypass and HST charge safety valve- - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 10-13 Power train - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 10-19 Power train system - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 10-19 Damper - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 10-22 Hydraulic component layout of HST - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 10-23 Steering and brake control- - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 10-24 HST pump - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 10-26 HST motor - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 10-41 Charge pump - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 10-56 Solenoid valve - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 10-57 Final drive - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 10-66 Undercarriage and frame - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 10-70 Main frame - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 10-70 Suspension - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 10-71 Track frame and idler cushion - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 10-73 Hydraulic system - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 10-75 Hydraulic component layout of work equipment- - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 10-75 Work equipment control system - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 10-76 Hydraulic tank - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 10-77 CLSS - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 10-79 Work equipment and cooling fan pump - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 10-82 00-2

D61EM-23M0

00 Index and foreword Index

Control valve - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 10-93 Accumulator - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 10-119 Work equipment- - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 10-121 Planter unit- - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 10-121 Cab and its attachments - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 10-122 ROPS cab - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 10-122 Cab mount - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 10-124 Electrical system - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 10-125 Engine control system - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 10-125 Cooling system control system - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 10-128 HST control system - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 10-130 Parking brake control system - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 10-141 System operating lamp function - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 10-144 Battery disconnect switch function - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 10-145 Machine monitor system - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 10-147 KOMTRAX system - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 10-170 System component parts - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 10-173 HST controller - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 10-176 Sensor - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 10-188 20 Standard value tables - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 20-1 Table of contents - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 20-2 Standard service value table - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 20-3 Standard value table for engine - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 20-3 Standard value table for machine - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 20-4 Standard value table for electrical system - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 20-10 30 Testing and adjusting - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - Table of contents - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - Related information on testing and adjusting - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - Tools for testing and adjusting - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - Sketch of tools for testing and adjusting - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - Engine and cooling system - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - Testing engine speed - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - Testing boost pressure - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - Testing exhaust gas color - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - Testing and adjusting valve clearance - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - Measuring compression pressure - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - Testing blowby pressure - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - Testing engine oil pressure - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - Testing fuel pressure - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - Testing fuel discharge, return and leakage- - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - Bleeding air from fuel system - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - Testing fuel circuit for leakage - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - Handling cylinder cutout mode operation- - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - Handling no-injection cranking operation - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - Testing of installed condition of cylinder heads and manifolds - - - - - - - - - - - - - - - - - - - - Testing engine piping for damage and looseness - - - - - - - - - - - - - - - - - - - - - - - - - - - - - Check alternator belt, replace- - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - Power train - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - Testing and adjusting HST oil pressure - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - Testing output pressure of solenoid valve - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - Testing if machine travels straight - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - Simple test procedure for brake performance - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - Adjusting deceleration/brake pedal - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - -

30-1 30-2 30-4 30-4 30-7 30-9 30-9 30-11 30-13 30-15 30-18 30-21 30-22 30-23 30-28 30-33 30-35 30-36 30-37 30-38 30-39 30-40 30-42 30-42 30-47 30-51 30-52 30-53

D61EM-23M0

00-3

00 Index and foreword Index

Adjusting parking brake lever- - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - Move disabled machine urgently - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - Undercarriage and frame - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - Adjusting idler clearance - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - Checking sprocket wear - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - Testing and adjusting track tension- - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - Hydraulic system - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - Releasing remaining pressure in work equipment cylinder - - - - - - - - - - - - - - - - - - - - - - Testing and adjusting work equipment oil pressure - - - - - - - - - - - - - - - - - - - - - - - - - - - Testing source pressure of control circuit - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - Testing outlet pressure of work equipment EPC valve and fan EPC valve - - - - - - - - - - - Testing internal oil leakage of work equipment cylinder - - - - - - - - - - - - - - - - - - - - - - - - Testing fan speed - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - Testing fan circuit oil pressure - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - Bleeding air from hydraulic circuit- - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - Work equipment - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - Adjusting work equipment lock lever- - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - Electrical system - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - Special functions of machine monitor - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - Adjustment method when HST controller has been replaced - - - - - - - - - - - - - - - - - - - - Adjustment method when electric or hydraulic device has been replaced- - - - - - - - - - - - Adjusting rearview camera angle - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - Handling voltage circuit of engine controller - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - Handling battery disconnect switch - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - Testing diodes - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - Pm clinic- - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - Pm Clinic service - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - Pm Clinic check sheet- - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - -

30-56 30-58 30-61 30-61 30-62 30-63 30-64 30-64 30-65 30-67 30-68 30-70 30-71 30-72 30-73 30-74 30-74 30-76 30-76 30-146 30-149 30-150 30-151 30-152 30-153 30-154 30-154 30-156

40-1 40-2 40-8 40-8 40-10 40-12 40-14 40-31 40-35 40-37 40-39 40-41 40-44 40-58 40-97 40-102 40-107 40-115 40-115 40-117 40-118 40-119 40-120 40-122 40-124 40-125

00-4

D61EM-23M0

00 Index and foreword Index

Failure code [B@CRNS] HST Oil Overheat - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 40-126 Failure code [B@CRZG] HST Charge Press Low- - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 40-127 Failure code [CA111] ECM Critical Internal Failure - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 40-128 Failure code [CA115] Eng Ne and Bkup Speed Sens Error - - - - - - - - - - - - - - - - - - - - - - - 40-129 Failure code [CA122] Chg Air Press Sensor High Error - - - - - - - - - - - - - - - - - - - - - - - - - 40-130 Failure code [CA123] Chg Air Press Sensor Low Error - - - - - - - - - - - - - - - - - - - - - - - - - - 40-132 Failure code [CA131] Throttle Sensor High Error - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 40-134 Failure code [CA132] Throttle Sensor Low Error - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 40-136 Failure code [CA144] Coolant Temp Sens High Error - - - - - - - - - - - - - - - - - - - - - - - - - - - 40-138 Failure code [CA145] Coolant Temp Sens Low Error - - - - - - - - - - - - - - - - - - - - - - - - - - - 40-140 Failure code [CA153] Chg Air Temp Sensor High Error- - - - - - - - - - - - - - - - - - - - - - - - - - 40-142 Failure code [CA154] Chg Air Temp Sensor Low Error - - - - - - - - - - - - - - - - - - - - - - - - - - 40-144 Failure code [CA187] Sensor 2 Supply Volt Low Error - - - - - - - - - - - - - - - - - - - - - - - - - - 40-146 Failure code [CA221] Ambient Press Sensor High Error - - - - - - - - - - - - - - - - - - - - - - - - - 40-148 Failure code [CA222] Ambient Press Sensor Low Error - - - - - - - - - - - - - - - - - - - - - - - - - 40-150 Failure code [CA227] Sensor 2 Supply Volt High Error - - - - - - - - - - - - - - - - - - - - - - - - - - 40-152 Failure code [CA234] Eng Overspeed - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 40-153 Failure code [CA238] Ne Speed Sensor Supply Volt Error- - - - - - - - - - - - - - - - - - - - - - - - 40-154 Failure code [CA271] IMV/PCV1 Short Error - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 40-155 Failure code [CA272] IMV/PCV1 Open Error - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 40-157 Failure code [CA322] Inj #1(L#1) Open/Short Error - - - - - - - - - - - - - - - - - - - - - - - - - - - - 40-159 Failure code [CA323] Inj #5(L#5) Open/Short Error - - - - - - - - - - - - - - - - - - - - - - - - - - - - 40-161 Failure code [CA324] Inj #3(L#3) Open/Short Error - - - - - - - - - - - - - - - - - - - - - - - - - - - - 40-163 Failure code [CA325] Inj #6(L#6) Open/Short Error - - - - - - - - - - - - - - - - - - - - - - - - - - - - 40-165 Failure code [CA331] Inj #2(L#2) Open/Short Error - - - - - - - - - - - - - - - - - - - - - - - - - - - - 40-167 Failure code [CA332] Inj #4(L#4) Open/Short Error - - - - - - - - - - - - - - - - - - - - - - - - - - - - 40-169 Failure code [CA342] Calibration Code Incompatibility - - - - - - - - - - - - - - - - - - - - - - - - - - 40-171 Failure code [CA351] Injectors Drive Circuit Error - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 40-172 Failure code [CA352] Sensor 1 Supply Volt Low Error - - - - - - - - - - - - - - - - - - - - - - - - - - 40-173 Failure code [CA386] Sensor 1 Supply Volt High Error - - - - - - - - - - - - - - - - - - - - - - - - - - 40-175 Failure code [CA428] Water in Fuel Sensor High Error - - - - - - - - - - - - - - - - - - - - - - - - - - 40-176 Failure code [CA429] Water in Fuel Sensor Low Error - - - - - - - - - - - - - - - - - - - - - - - - - - 40-178 Failure code [CA435] Eng Oil Press Sw Error - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 40-180 Failure code [CA441] Battery Voltage Low Error - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 40-181 Failure code [CA442] Battery Voltage High Error - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 40-183 Failure code [CA449] Rail Press Very High Error - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 40-184 Failure code [CA451] Rail Press Sensor High Error - - - - - - - - - - - - - - - - - - - - - - - - - - - - 40-185 Failure code [CA452] Rail Press Sensor Low Error - - - - - - - - - - - - - - - - - - - - - - - - - - - - 40-187 Failure code [CA488] Chg Air Temp High Torque Derate- - - - - - - - - - - - - - - - - - - - - - - - - 40-189 Failure code [CA553] Rail Press High Error - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 40-190 Failure code [CA689] Eng Ne Speed Sensor Error - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 40-191 Failure code [CA731] Eng Bkup Speed Sens Phase Error- - - - - - - - - - - - - - - - - - - - - - - - 40-193 Failure code [CA757] All continuous Data Lost Error - - - - - - - - - - - - - - - - - - - - - - - - - - - 40-195 Failure code [CA778] Eng Bkup Speed Sensor Error - - - - - - - - - - - - - - - - - - - - - - - - - - - 40-196 Failure code [CA2185] Throt Sensor Sup Volt High Error - - - - - - - - - - - - - - - - - - - - - - - - 40-201 Failure code [CA2186] Throt Sensor Sup Volt Low Error- - - - - - - - - - - - - - - - - - - - - - - - - 40-202 Failure code [CA2249] Rail Press Very Low Error - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 40-203 Failure code [CA2311] IMV Solenoid Error - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 40-204 Failure code [CA2555] Grid Htr Relay Volt Low Error - - - - - - - - - - - - - - - - - - - - - - - - - - - 40-205 Failure code [CA2556] Grid Htr Relay Volt High Error - - - - - - - - - - - - - - - - - - - - - - - - - - - 40-207 Failure code [D130KA] Neutral relay Open - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 40-209 Failure code [D130KB] Neutral relay Short circuit- - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 40-211 Failure code [D130KY] Neutral relay: Hot Short - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 40-213 Failure code [D19JKZ] Personal Code Relay Abnormality- - - - - - - - - - - - - - - - - - - - - - - - 40-215 D61EM-23M0

00-5

00 Index and foreword Index

Failure code [D811MC] KOMTRAX Error - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - Failure code [D862KA] GPS Antenna Open Circuit - - - - - - - - - - - - - - - - - - - - - - - - - - - Failure code [D8ALKA] Operating Lamp Open Circuit (KOMTRAX)- - - - - - - - - - - - - - - - Failure code [D8ALKB] Operating Lamp Short Circuit (KOMTRAX) - - - - - - - - - - - - - - - - Failure code [D8AQKR] CAN2 Discon (KOMTRAX)- - - - - - - - - - - - - - - - - - - - - - - - - - - Failure code [DAF0MB] Monitor ROM Abnormality - - - - - - - - - - - - - - - - - - - - - - - - - - - Failure code [DAF0MC] Monitor Error- - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - Failure code [DAF8KB] Camera Power Supply Short Circuit- - - - - - - - - - - - - - - - - - - - - Failure code [DAF9KQ] Model Selection Abnormality- - - - - - - - - - - - - - - - - - - - - - - - - - Failure code [DAFGMC] GPS Module Error - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - Failure code [DAFLKA] Operating Lamp Open Circuit (Monitor) - - - - - - - - - - - - - - - - - - Failure code [DAFLKB] Operating Lamp Short Circuit (Monitor) - - - - - - - - - - - - - - - - - - Failure code [DAFQKR] CAN2 Discon (Monitor) - - - - - - - - - - - - - - - - - - - - - - - - - - - - - Failure code [DAJ000] HST controller: Abnormality in controller - - - - - - - - - - - - - - - - - - Failure code [DAJ0KQ] HST controller: Type select signal - - - - - - - - - - - - - - - - - - - - - - Failure code [DAJ0KT] HST controller: Abnormality in controller - - - - - - - - - - - - - - - - - - Failure code [DAJ0MC] HST Con Error - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - Failure code [DAJ1KK] HST controller: Source voltage low - - - - - - - - - - - - - - - - - - - - - Failure code [DAJ2KK] HST controller: Output voltage low - - - - - - - - - - - - - - - - - - - - - - Failure code [DAJ5KK] HST: Sensor volt 5V (0) Out of normal range- - - - - - - - - - - - - - - Failure code [DAJ6KK] HST: Sensor volt 5V (1) Out of normal range- - - - - - - - - - - - - - - Failure code [DAJLKA] Operating Lamp Open Circuit (HST Con) - - - - - - - - - - - - - - - - - Failure code [DAJLKB] Operating Lamp Short Circuit (HST Con) - - - - - - - - - - - - - - - - - Failure code [DAJPMA] Inconsistency of Option Selection (HST) - - - - - - - - - - - - - - - - - Failure code [DAJQKR] CAN2 Discon (HST Con) - - - - - - - - - - - - - - - - - - - - - - - - - - - - Failure code [DAJRKR] CAN1 Discon (HST Con) - - - - - - - - - - - - - - - - - - - - - - - - - - - - Failure code [DB2QKR] CAN2 Discon (Engine Con) - - - - - - - - - - - - - - - - - - - - - - - - - - Failure code [DD12KA] Shift up SW: Open - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - Failure code [DD12KB] Shift up SW: Short Circuit - - - - - - - - - - - - - - - - - - - - - - - - - - - - Failure code [DD13KA] Shift down SW: Open - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - Failure code [DD13KB] Shift down SW: Short Circuit - - - - - - - - - - - - - - - - - - - - - - - - - - Failure code [DD14KA] Parking lever SW: Open - - - - - - - - - - - - - - - - - - - - - - - - - - - - - Failure code [DD14KB] Parking lever SW: Short circuit - - - - - - - - - - - - - - - - - - - - - - - - Failure code [DDKAKA] Blade float Sw: Open - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - Failure code [DDKAKB] Blade float Sw: Short circuit - - - - - - - - - - - - - - - - - - - - - - - - - - Failure code [DDKFL4] Left Angle Sw: Signal mismatch- - - - - - - - - - - - - - - - - - - - - - - - Failure code [DDKGL4] Right Angle Sw: Signal mismatch - - - - - - - - - - - - - - - - - - - - - - Failure code [DDKHKA] iB Sw: Open - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - Failure code [DDKHKB] iB Sw: Short circuit - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - Failure code [DDNLKA] Weq lock Sw: Open - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - Failure code [DDNLKB] Weq lock Sw: Short circuit - - - - - - - - - - - - - - - - - - - - - - - - - - - Failure code [DDP6KA] Brake Pressure Sensor: Open - - - - - - - - - - - - - - - - - - - - - - - - Failure code [DDP6KB] Brake Pressure Sensor: Hot Short- - - - - - - - - - - - - - - - - - - - - - Failure code [DDP6MA] Brake pressure sensor: Malfunction - - - - - - - - - - - - - - - - - - - - Failure code [DDU1FS] Parking lever Switch 2: Signal mismatch - - - - - - - - - - - - - - - - - Failure code [DDU1KA] Parking lever Sw2: Open - - - - - - - - - - - - - - - - - - - - - - - - - - - - Failure code [DDU1KY] Parking lever Sw2: Hot Short - - - - - - - - - - - - - - - - - - - - - - - - - Failure code [DFA4KX] Blade lift lever: Main and Sub Error - - - - - - - - - - - - - - - - - - - - - Failure code [DFA4KZ] Blade lift lever: Main and Sub Error - - - - - - - - - - - - - - - - - - - - - Failure code [DFA4L8] Blade lift lever: Signal mismatch - - - - - - - - - - - - - - - - - - - - - - - - Failure code [DFA5KA] Blade lift lever1: Open - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - Failure code [DFA5KB] Blade lift lever1: Hot Short- - - - - - - - - - - - - - - - - - - - - - - - - - - - Failure code [DFA6KA] Blade lift lever2: Open - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - Failure code [DFA6KB] Blade lift lever2: Hot Short- - - - - - - - - - - - - - - - - - - - - - - - - - - - 00-6

40-218 40-219 40-220 40-222 40-223 40-224 40-225 40-226 40-227 40-228 40-229 40-231 40-232 40-233 40-234 40-235 40-236 40-237 40-239 40-241 40-244 40-246 40-248 40-249 40-250 40-251 40-252 40-256 40-258 40-260 40-262 40-264 40-267 40-271 40-273 40-275 40-277 40-279 40-281 40-283 40-286 40-289 40-291 40-293 40-295 40-298 40-301 40-303 40-304 40-305 40-306 40-309 40-311 40-313

D61EM-23M0

00 Index and foreword Index

Failure code [DFA7KX] Blade tilt lever: Main and Sub Error - - - - - - - - - - - - - - - - - - - - - - 40-315 Failure code [DFA7KZ] Blade tilt lever: Main and Sub Error- - - - - - - - - - - - - - - - - - - - - - - 40-316 Failure code [DFA7L8] Blade tilt lever: Signal mismatch - - - - - - - - - - - - - - - - - - - - - - - - - 40-317 Failure code [DFA8KA] Blade tilt lever1: Open - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 40-318 Failure code [DFA8KB] Blade tilt lever1: Hot Short - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 40-321 Failure code [DFA9KA] Blade tilt lever2: Open - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 40-323 Failure code [DFA9KB] Blade tilt lever2: Hot Short - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 40-326 Failure code [DGS1KA] HST oil temp sensor: Open - - - - - - - - - - - - - - - - - - - - - - - - - - - - 40-328 Failure code [DGS1KX] HST oil temp sensor: Out of normal range - - - - - - - - - - - - - - - - - 40-330 Failure code [DH21KA] Weq pressure sensor: Open - - - - - - - - - - - - - - - - - - - - - - - - - - - 40-331 Failure code [DH21KB] Weq pressure sensor: Hot Short - - - - - - - - - - - - - - - - - - - - - - - - 40-333 Failure code [DHA4KA] Air Cleaner Clog Sensor Open Circuit - - - - - - - - - - - - - - - - - - - - 40-335 Failure code [DHH7KA] LF HST Pressure Sensor: Open - - - - - - - - - - - - - - - - - - - - - - - - 40-337 Failure code [DHH7KB] LF HST Pressure Sensor: Hot Short - - - - - - - - - - - - - - - - - - - - - 40-339 Failure code [DHH8KA] RF HST Pressure Sensor: Open - - - - - - - - - - - - - - - - - - - - - - - - 40-341 Failure code [DHH8KB] RF HST Pressure Sensor: Hot Short - - - - - - - - - - - - - - - - - - - - - 40-343 Failure code [DHH9KA] LR HST Pressure Sensor: Open - - - - - - - - - - - - - - - - - - - - - - - - 40-345 Failure code [DHH9KB] LR HST Pressure Sensor: Hot Short - - - - - - - - - - - - - - - - - - - - - 40-347 Failure code [DHHAKA] RR HST Pressure Sensor: Open- - - - - - - - - - - - - - - - - - - - - - - - 40-349 Failure code [DHHAKB] RR HST Pressure Sensor: Hot Short - - - - - - - - - - - - - - - - - - - - - 40-351 Failure code [DK30KA] ST lever1: Open - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 40-353 Failure code [DK30KB] ST lever1: Hot Short - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 40-356 Failure code [DK30KX] ST lever: Main and Sub Error- - - - - - - - - - - - - - - - - - - - - - - - - - - 40-358 Failure code [DK30KZ] ST lever: Main and Sub Error - - - - - - - - - - - - - - - - - - - - - - - - - - - 40-359 Failure code [DK30L8] ST lever: Signal mismatch - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 40-360 Failure code [DK31KA] ST lever2: Open - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 40-361 Failure code [DK31KB] ST lever2: Hot Short - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 40-364 Failure code [DK40KA] Decel/Brake potentiometer: Open- - - - - - - - - - - - - - - - - - - - - - - - 40-366 Failure code [DK40KB] Decel/Brake potentiometer: Hot Short- - - - - - - - - - - - - - - - - - - - - 40-369 Failure code [DK55KX] FR lever: Main and Sub Error- - - - - - - - - - - - - - - - - - - - - - - - - - - 40-371 Failure code [DK55KZ] FR lever: Main and Sub Error- - - - - - - - - - - - - - - - - - - - - - - - - - - 40-372 Failure code [DK55L8] FR lever: Signal mismatch - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 40-373 Failure code [DK56KA] FR lever1: Open - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 40-374 Failure code [DK56KB] FR lever1: Hot Short - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 40-377 Failure code [DK57KA] FR lever2: Open - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 40-380 Failure code [DK57KB] FR lever2: Hot Short - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 40-383 Failure code [DLM0KX] HST Motor Speed Sensor: Left/Right Error - - - - - - - - - - - - - - - - - 40-385 Failure code [DLM1KA] Left HST motor speed sensor: Open - - - - - - - - - - - - - - - - - - - - - 40-386 Failure code [DLM1KB] Left HST motor speed sensor: Short circuit - - - - - - - - - - - - - - - - - 40-388 Failure code [DLM1MA] Left HST motor speed sensor: Malfunction - - - - - - - - - - - - - - - - - 40-390 Failure code [DLM2KA] Right HST motor speed sensor: Open - - - - - - - - - - - - - - - - - - - - 40-391 Failure code [DLM2KB] Right HST motor speed sensor: Short circuit- - - - - - - - - - - - - - - - 40-393 Failure code [DLM2MA] Right HST motor speed sensor: Malfunction- - - - - - - - - - - - - - - - 40-395 Failure code [DLM3KA] Fan rev. sensor: Open - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 40-396 Failure code [DLM3KB] Fan rev. sensor: Short circuit - - - - - - - - - - - - - - - - - - - - - - - - - - - 40-398 Failure code [DLM3MB] Fan control: Mismatch - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 40-400 Failure code [DN21FS] Decel/Brake pedal SW: Signal mismatch - - - - - - - - - - - - - - - - - - 40-401 Failure code [DR21KX] Camera 2 Picture Rev. Drive Abnormality - - - - - - - - - - - - - - - - - - 40-403 Failure code [DR31KX] Camera 3 Picture Rev. Drive Abnormality - - - - - - - - - - - - - - - - - - 40-404 Failure code [DV20KB] Back-up alarm: Short circuit - - - - - - - - - - - - - - - - - - - - - - - - - - - - 40-405 Failure code [DW4BKA] Parking brake solenoid: Open- - - - - - - - - - - - - - - - - - - - - - - - - - 40-407 Failure code [DW4BKB] Parking brake solenoid: Short circuit - - - - - - - - - - - - - - - - - - - - - 40-409 Failure code [DW4BKY] Parking brake solenoid: Hot Short - - - - - - - - - - - - - - - - - - - - - - - 40-411 Failure code [DW7BKA] Fan reverse solenoid: Open - - - - - - - - - - - - - - - - - - - - - - - - - - - 40-413 D61EM-23M0

00-7

00 Index and foreword Index

Failure code [DW7BKB] Fan reverse solenoid: Short circuit - - - - - - - - - - - - - - - - - - - - - - 40-415 Failure code [DW7EKA] Slow brake solenoid: Open - - - - - - - - - - - - - - - - - - - - - - - - - - - 40-416 Failure code [DW7EKB] Slow brake solenoid: Short circuit - - - - - - - - - - - - - - - - - - - - - - - 40-418 Failure code [DW7EKY] Slow brake solenoid: Hot Short - - - - - - - - - - - - - - - - - - - - - - - - 40-420 Failure code [DWN5KA] Fan EPC: Open - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 40-422 Failure code [DWN5KB] Fan EPC: Short circuit- - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 40-424 Failure code [DWN5KY] Fan EPC: Hot Short - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 40-425 Failure code [DXA4KA] LF HST pump EPC: Open - - - - - - - - - - - - - - - - - - - - - - - - - - - - 40-427 Failure code [DXA4KB] LF HST pump EPC: Short circuit - - - - - - - - - - - - - - - - - - - - - - - - 40-429 Failure code [DXA4KY] LF HST pump EPC: Hot Short- - - - - - - - - - - - - - - - - - - - - - - - - - 40-430 Failure code [DXA5KA] LR HST pump EPC: Open - - - - - - - - - - - - - - - - - - - - - - - - - - - - 40-432 Failure code [DXA5KB] LR HST pump EPC: Short circuit- - - - - - - - - - - - - - - - - - - - - - - - 40-434 Failure code [DXA5KY] LR HST pump EPC: Hot Short - - - - - - - - - - - - - - - - - - - - - - - - - 40-436 Failure code [DXA6KA] RF HST pump EPC: Open - - - - - - - - - - - - - - - - - - - - - - - - - - - - 40-438 Failure code [DXA6KB] RF HST pump EPC: Short circuit- - - - - - - - - - - - - - - - - - - - - - - - 40-440 Failure code [DXA6KY] RF HST pump EPC: Hot Short - - - - - - - - - - - - - - - - - - - - - - - - - 40-441 Failure code [DXA7KA] RR HST pump EPC: Open - - - - - - - - - - - - - - - - - - - - - - - - - - - - 40-443 Failure code [DXA7KB] RR HST pump EPC: Short circuit - - - - - - - - - - - - - - - - - - - - - - - 40-445 Failure code [DXA7KY] RR HST pump EPC: Hot Short - - - - - - - - - - - - - - - - - - - - - - - - - 40-446 Failure code [DXHRKA] Blade lift up EPC: Open - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 40-448 Failure code [DXHRKB] Blade lift up EPC: Short circuit - - - - - - - - - - - - - - - - - - - - - - - - - 40-451 Failure code [DXHRKY] Blade lift up EPC: Hot short - - - - - - - - - - - - - - - - - - - - - - - - - - - 40-453 Failure code [DXHSKA] Blade lift down EPC: Open - - - - - - - - - - - - - - - - - - - - - - - - - - - - 40-455 Failure code [DXHSKB] Blade lift down EPC: Short circuit - - - - - - - - - - - - - - - - - - - - - - - 40-458 Failure code [DXHSKY] Blade lift down EPC: Hot short - - - - - - - - - - - - - - - - - - - - - - - - - 40-460 Failure code [DXHTKA] Blade tilt left EPC: Open- - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 40-462 Failure code [DXHTKB] Blade tilt left EPC: Short circuit - - - - - - - - - - - - - - - - - - - - - - - - - 40-464 Failure code [DXHTKY] Blade tilt left EPC: Hot short - - - - - - - - - - - - - - - - - - - - - - - - - - - 40-465 Failure code [DXHUKA] Blade tilt right EPC: Open - - - - - - - - - - - - - - - - - - - - - - - - - - - - 40-467 Failure code [DXHUKB] Blade tilt right EPC: Short circuit - - - - - - - - - - - - - - - - - - - - - - - - 40-469 Failure code [DXHUKY] Blade tilt right EPC: Hot short - - - - - - - - - - - - - - - - - - - - - - - - - - 40-470 Failure code [DXJ4KA] Weq lock Sol.: Open - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 40-472 Failure code [DXJ4KB] Weq lock Sol.: Short circuit - - - - - - - - - - - - - - - - - - - - - - - - - - - - 40-474 Failure code [DXJCKA] Blade angle left EPC: Open - - - - - - - - - - - - - - - - - - - - - - - - - - - 40-476 Failure code [DXJCKB] Blade angle left EPC: Short circuit - - - - - - - - - - - - - - - - - - - - - - - 40-477 Failure code [DXJCKY] Blade angle left EPC: Hot short - - - - - - - - - - - - - - - - - - - - - - - - - 40-478 Failure code [DXJDKA] Blade angle right EPC: Open - - - - - - - - - - - - - - - - - - - - - - - - - - 40-480 Failure code [DXJDKB] Blade angle right EPC: Short circuit - - - - - - - - - - - - - - - - - - - - - - 40-481 Failure code [DXJDKY] Blade angle right EPC: Hot short - - - - - - - - - - - - - - - - - - - - - - - - 40-482 Failure code [DXK1KA] Left HST motor EPC: Open- - - - - - - - - - - - - - - - - - - - - - - - - - - - 40-484 Failure code [DXK1KB] Left HST motor EPC: Short circuit - - - - - - - - - - - - - - - - - - - - - - - 40-486 Failure code [DXK1KY] Left HST motor EPC: Hot Short- - - - - - - - - - - - - - - - - - - - - - - - - 40-487 Failure code [DXK2KA] Right HST motor EPC: Open - - - - - - - - - - - - - - - - - - - - - - - - - - 40-489 Failure code [DXK2KB] Right HST motor EPC: Short circuit - - - - - - - - - - - - - - - - - - - - - - 40-491 Failure code [DXK2KY] Right HST motor EPC: Hot Short- - - - - - - - - - - - - - - - - - - - - - - - 40-492 Troubleshooting of electrical system (E-mode) - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 40-494 E-1 Engine does not start (Engine does not crank) - - - - - - - - - - - - - - - - - - - - - - - - - - - - 40-494 E-2 Manual preheating system does not work - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 40-500 E-3 Automatic preheating system does not work - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 40-503 E-4 While preheating is working, preheating monitor does not light up- - - - - - - - - - - - - - - 40-505 E-5 When starting switch is turned to ON position, machine monitor displays nothing - - - - 40-507 E-6 When starting switch is turned to ON position (with engine stopped), basic check monitor lights up - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 40-510 E-7 Air cleaner clogging monitor lights up in yellow while engine is running - - - - - - - - - - - 40-511 00-8

D61EM-23M0

00 Index and foreword Index

E-8 Charge level monitor lights up in red while engine is running - - - - - - - - - - - - - - - - - - - 40-512 E-9 Engine coolant temperature monitor lights up in red while engine is running - - - - - - - - 40-513 E-10 Engine oil pressure monitor lights up in red while engine is running - - - - - - - - - - - - - 40-514 E-11 HST charge pressure monitor lights up in red while engine is running- - - - - - - - - - - - 40-515 E-12 Hydraulic oil temperature monitor lights up in red while engine is running - - - - - - - - - 40-516 E-13 HST oil filter clogging monitor lights up in red while engine is running - - - - - - - - - - - 40-517 E-14 Fuel level gauge does not indicate correct level - - - - - - - - - - - - - - - - - - - - - - - - - - - 40-518 E-15 Engine coolant temperature gauge does not indicate correct temperature - - - - - - - - 40-521 E-16 Hydraulic oil temperature gauge does not indicate correct temperature - - - - - - - - - - 40-522 E-17 Operation mode does not change - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 40-523 E-18 Service mode cannot be selected - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 40-524 E-19 Operating customize switch does not display customize screen- - - - - - - - - - - - - - - - 40-525 E-20 Modifying setting on customize screen does not change setting of machine - - - - - - - 40-526 E-21 Service meter is not displayed, while starting switch is in OFF position- - - - - - - - - - - 40-527 E-22 Work equipment does not operate - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 40-528 E-23 Foot heater does not operate - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 40-530 E-24 Horn does not sound - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 40-535 E-25 Horn does not stop sounding - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 40-537 E-26 Backup alarm does not sound - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 40-538 E-27 Backup alarm does not stop sounding- - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 40-539 E-28 Headlamp does not light up - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 40-540 E-29 Rear lamp does not light up - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 40-543 E-30 No wiper operates continuously or intermittently- - - - - - - - - - - - - - - - - - - - - - - - - - - 40-546 E-31 Front wiper does not operate - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 40-548 E-32 Rear wiper does not operate - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 40-550 E-33 Left door wiper does not operate (failed in both continuous and intermittent operations) 40-552 E-34 Right door wiper does not operate (failed in both continuous and intermittent operations)- 40-556 E-35 Front washer does not operate - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 40-560 E-36 Rear washer does not operate - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 40-562 E-37 Left door washer does not operate - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 40-564 E-38 Right door washer does not operate - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 40-566 E-39 KOMTRAX system does not operate normally - - - - - - - - - - - - - - - - - - - - - - - - - - - - 40-568 Troubleshooting of hydraulic and mechanical system (H-mode) - - - - - - - - - - - - - - - - - - - - - - - 40-570 Information described in troubleshooting table (H-mode) - - - - - - - - - - - - - - - - - - - - - - - - 40-570 Failure mode and cause table - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 40-571 H-1 Neither RH nor LH of tracks does not travel forward nor reverse (None of the travel system operates) - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 40-574 H-2 Either RH or LH of track does not travel forward nor reverse (Only RH or LH of travel system operates) - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 40-576 H-3 Either RH or LH of track travel only forward or reverse (Only forward or reverse of RH or LH of travel system does not operate) - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 40-577 H-4 Travel speed or power is low - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 40-579 H-5 Shock is large when machine starts or stops - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 40-580 H-6 Machine deviates largely - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 40-581 H-7 Machine drift on a slope is large - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 40-583 H-8 Engine stalls during travel or engine speed drops significantly - - - - - - - - - - - - - - - - - 40-584 H-9 Unusual noise is heard from around HST pump or motor - - - - - - - - - - - - - - - - - - - - - 40-586 H-10 All work equipment do not operate - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 40-587 H-11 All work equipment operates slowly or lacks power - - - - - - - - - - - - - - - - - - - - - - - - 40-589 H-12 Front work equipment lift speed or power is low - - - - - - - - - - - - - - - - - - - - - - - - - - - 40-590 H-13 Front work equipment side swing speed or power is low - - - - - - - - - - - - - - - - - - - - - 40-591 H-14 Hydraulic drift of lifted front work equipment is large - - - - - - - - - - - - - - - - - - - - - - - - 40-592 H-15 Unusual noise is heard from around work equipment pump or control valve - - - - - - - 40-593 H-16 HST oil temperature (hydraulic oil temperature) rises too high- - - - - - - - - - - - - - - - - 40-594 D61EM-23M0

00-9

00 Index and foreword Index

H-17 Fan speed is abnormal (high, low, or no rotation)- - - - - - - - - - - - - - - - - - - - - - - - - H-18 Unusual noise is heard from around fan - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - Troubleshooting of engine (S-mode) - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - Method of using troubleshooting charts - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - S-1 Starting performance is poor - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - S-2 Engine does not start - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - S-3 Engine does not pick up smoothly - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - S-4 Engine stops during operations - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - S-5 Engine does not rotate smoothly - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - S-6 Engine lacks output (or lacks power) - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - S-7 Exhaust smoke is black (incomplete combustion) - - - - - - - - - - - - - - - - - - - - - - - - - S-8 Oil consumption is excessive (or exhaust smoke is blue) - - - - - - - - - - - - - - - - - - - - S-9 Oil becomes contaminated quickly - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - S-10 Fuel consumption is excessive- - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - S-11 Oil is in coolant (or coolant spurts back or coolant level goes down) - - - - - - - - - - - S-12 Oil pressure drops - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - S-13 Oil level rises (Entry of coolant or fuel) - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - S-14 Coolant temperature becomes too high (overheating) - - - - - - - - - - - - - - - - - - - - - S-15 Abnormal noise is made - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - S-16 Vibration is excessive - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - -

40-596 40-598 40-599 40-599 40-603 40-604 40-607 40-608 40-609 40-610 40-611 40-612 40-613 40-614 40-615 40-616 40-617 40-618 40-619 40-620

D61EM-23M0

00 Index and foreword Index

Disassembly and assembly of recoil spring - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 50-121 Removal and installation of track roller assembly - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 50-125 Disassembly and assembly of track roller assembly - - - - - - - - - - - - - - - - - - - - - - - - - - - - 50-127 Removal and installation of carrier roller assembly - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 50-130 Disassembly and assembly of carrier roller assembly - - - - - - - - - - - - - - - - - - - - - - - - - - - 50-132 Removal and installation of segment teeth - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 50-134 Separation and connection of track shoe assembly (Standard type track shoe) - - - - - - - - - 50-135 Overall disassembly and assembly of track shoe assembly (Standard type track shoe) - - - 50-138 Disassembly and assembly of one track link assembly in field (Standard type track shoe) - 50-154 Removal and installation of pivot shaft assembly - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 50-160 Removal and installation of equalizer bar assembly - - - - - - - - - - - - - - - - - - - - - - - - - - - - 50-162 Removal and installation of equalizer bar side bushing - - - - - - - - - - - - - - - - - - - - - - - - - - 50-164 Hydraulic system - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 50-165 Removal and installation of hydraulic tank assembly - - - - - - - - - - - - - - - - - - - - - - - - - - - 50-165 Removal and installation of control valve assembly - - - - - - - - - - - - - - - - - - - - - - - - - - - - 50-169 Disassembly and assembly of hydraulic cylinder assembly - - - - - - - - - - - - - - - - - - - - - - - 50-172 Work equipment- - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 50-175 Removal and installation of planter unit assembly - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 50-175 Removal and installation of center frame assembly - - - - - - - - - - - - - - - - - - - - - - - - - - - - 50-177 Cab and its attachments - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 50-179 Removal and installation of ROPS cab assembly - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 50-179 Removal and installation of operator's cab glass (adhesion glass) - - - - - - - - - - - - - - - - - - 50-183 Removal and installation of operator's seat - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 50-189 Removal and installation of seat belt - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 50-190 Removal and installation of foot heater assembly - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 50-191 Disassembly and assembly of foot heater assembly- - - - - - - - - - - - - - - - - - - - - - - - - - - - 50-193 Removal and installation of air conditioner unit assembly - - - - - - - - - - - - - - - - - - - - - - - - 50-194 Removal and installation of air conditioner compressor assembly - - - - - - - - - - - - - - - - - - 50-198 Electrical system - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 50-200 Removal and installation of machine monitor assembly - - - - - - - - - - - - - - - - - - - - - - - - - 50-200 Removal and installation of engine controller assembly - - - - - - - - - - - - - - - - - - - - - - - - - 50-201 Removal and installation of HST controller assembly - - - - - - - - - - - - - - - - - - - - - - - - - - - 50-203 Removal and installation of KOMTRAX terminal - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 50-204 60 Maintenance standard - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 60-1 Table of contents - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 60-2 Engine and cooling system - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 60-3 Engine mount - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 60-3 Cooling fan motor - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 60-4 Oil cooler bypass and HST charge safety valve - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 60-6 Power train - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 60-7 Damper - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 60-7 HST pump - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 60-8 HST motor - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 60-10 Charge pump - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 60-11 Solenoid valve - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 60-12 Final drive - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 60-13 Sprocket- - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 60-14 Full-scale drawing of sprocket tooth profile - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 60-15 Undercarriage and frame - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 60-16 Suspension - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 60-16 Track frame and idler cushion - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 60-18 Idler - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 60-20 Track roller - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 60-22 Carrier roller - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 60-24 D61EM-23M0

00-11

00 Index and foreword Index

Track shoe- - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 60-25 Hydraulic system - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 60-28 Hydraulic tank - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 60-28 Work equipment and cooling fan pump - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 60-29 Control valve - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 60-32 Anti-drop valve - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 60-39 Work equipment - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 60-41 Planter unit - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 60-41 Lift cylinder - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 60-44 Swing cylinder - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 60-45 Cab and its attachments- - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 60-46 Cab mount- - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 60-46 Electrical system - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 60-47 Electric steering lever - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 60-47 80 Appendix- - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 80-1 Table of contents - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 80-2 Air conditioner components - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 80-3 Precautions for refrigerant - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 80-3 Air conditioner component- - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 80-4 Configuration and function of refrigeration cycle - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 80-7 Outline of refrigeration cycle - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 80-8 Air conditioner unit - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 80-10 Dual pressure switch - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 80-14 Pressure switch - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 80-15 Compressor - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 80-16 Condenser- - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 80-17 Receiver drier - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 80-19 Procedure for testing and troubleshooting- - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 80-20 Electrical circuit diagram - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 80-23 System diagram - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 80-24 Parts and connectors layout - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 80-26 Testing relays- - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 80-31 Troubleshooting chart 1- - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 80-33 Troubleshooting chart 2- - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 80-34 Information described in troubleshooting table- - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 80-36 A-1 Troubleshooting for condenser fan - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 80-37 A-2 Troubleshooting for compressor and refrigerant system (Air is not cooled) - - - - - - - - - - 80-40 A-3 Troubleshooting for blower motor system (No air comes out or air flow is abnormal) - - - 80-44 A-4 Troubleshooting for temperature control - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 80-46 Troubleshooting with gauge pressure - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 80-49 Connection of service tool - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 80-52 Precautions for disconnecting and connecting hoses and tubes in air conditioner circuit - - - 80-54 Handling of compressor oil - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 80-56 90 Diagrams and drawings - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 90-1 Table of contents - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 90-2 Hydraulic circuit diagram - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 90-3 Symbols in hydraulic circuit diagram- - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 90-3 Hydraulic circuit diagram - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 90-7 Electric circuit diagram - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 90-9 Symbols in electric circuit diagram - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 90-9 Electric circuit diagram - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 90-13 Index- - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 00-12

D61EM-23M0

00 Index and foreword

Foreword, safety and general information

Foreword, safety and general information Important safety notice

1 (Rev. 2012/10)

• Appropriate servicing and repair are extremely important to ensure safe operation of the machine. The shop manual describes the effective and safe servicing and repair methods recommended by Komatsu. Some of these methods require the use of the special tools designed by Komatsu for the specific purpose. • The symbol mark k is used for such matters that require special cautions during the work. The work indicated by the caution mark should be performed according to the instructions with special attention to the cautions. Should hazardous situation occur or be anticipated during such work, be sure to keep safe first and take every necessary measure. General precautions k Inappropriate handling causes an extreme

danger. Read and understand what is described in the operation and maintenance manual before operating the machine. Read and understand what is described in this manual before starting the work. • Before performing any greasing or repairs, read all the safety labels stuck to the machine. For the locations of the safety labels and detailed explanation of precautions, see the operation and maintenance manual. • Locate a place in the repair workshop to keep the tools and removed parts. Always keep the tools and parts in their correct places. Always keep the work area clean and make sure that there is no dirt, water or oil on the floor. Smoke only in the areas provided for smoking. Never smoke while working. • When performing any work, always wear the safety shoes and helmet. Do not wear loose work cloths, or clothes with buttons missing.

•

• •

•

1. Always wear the protective eyeglasses when hitting parts with a hammer. 2. Always wear the protective eyeglasses when grinding parts with a grinder, etc. When performing any work with 2 or more workers, always agree on the working procedure before starting. While working, always keep conversations of the work between your fellow workers and your self on any step of the work. During the work, hang the warning tag of "UNDER WORKING" in the operator's compartment. Only qualified workers must perform the work and operation which require license or qualification. Keep the tools in good condition. And learn the correct way to use the tools, and use the proper ones among them. Before starting the work, thoroughly check the tools, lift truck, service vehicle, etc. If welding repairs is required, always have a trained and experienced welder with good

D61EM-23M0

knowledge of welding perform the work. When performing welding work, always wear welding gloves, apron, shielding goggles, cap, etc. • Before starting work, warm up your body thoroughly to start work under good condition. • Avoid continuing work for long hours and take rests with proper intervals to keep your body in good condition. Take a rest in a specified safe place. Safety points Good arrangement Correct work clothes Observance of work standard Practice of making and checking signals Prohibition of operation and handling by 5 unlicensed workers 6 Safety check before starting work Wearing protective goggles (for cleaning or 7 grinding work) Wearing shielding goggles and protectors (for 8 welding work) 9 Good physical condition and preparation Precautions against work which you are not 10 used to or you are used to too much 1 2 3 4

Preparation • Before adding oil or making any repairs, place the machine on a firm and level ground, and apply the parking brake and chock the wheels or tracks to prevent the machine from moving. • Before starting work, lower the work equipment (blade, ripper, bucket, etc.) to the ground. If it is not possible to lower the equipment to the ground, insert the lock pin or use blocks to prevent the work equipment from falling. And be sure to lock all the work equipment control levers and hang a warning tag on them. • When performing the disassembling or assembling work, support the machine securely with blocks, jacks, or stands before starting the work. • Remove all of mud and oil from the steps or other places used to get on and off the machine completely. Always use the handrails, ladders of 00-13

00 Index and foreword

Foreword, safety and general information

steps when getting on or off the machine. Never jump on or off the machine. When the scaffold is not provided, use steps or stepladder to secure your footing. Precautions during work • For the machine equipped with the battery disconnect switch, check that the system operating lamp is turned off before starting the work. Then, turn the battery disconnect switch to OFF (Q) position and remove the switch key. For the machine not equipped with the battery disconnect switch, remove the cable from the battery before starting the work. Be sure to remove the negative end (-) of the battery cable first. • Release the remaining pressure in the circuits completely before the work when the parts in the circuits of oil, fuel, coolant and air are disconnected or removed. When the cap of the oil filter, drain plug or oil pressure pickup plug is removed, loose them slowly to prevent the oil from spurting out. • When removing or installing the checking plug or the piping in the fuel circuit, wait 30 seconds or longer after the engine is shut down and start the work after the remaining pressure is released from the fuel circuit. • Immediately after the engine is shut down, the coolant and oil in the circuits are hot. Be careful not to get scalded by the hot coolant and oil. Start the work after checking that the coolant and oil are cooled down sufficiently. • Start the work after the engine is shut down. Be sure to shut down the engine when working on or around the rotating parts in particular. When checking the machine without shutting down the engine (measuring oil pressure, rotational speed, oil or coolant temperature), take extreme care not to get caught in the rotating parts or the working equipment. • The hoist or crane must be used to sling the components weighing 25 kg or heavier. Check the slings (wire rope, nylon sling, chain and hook) for damage before the work. Use the slings with ample capacity and install them to the proper places. Operate the hoist or crane slowly to prevent the component from hitting any other part. Do not work with any part still raised by the hoist or crane. • When removing the part which is under internal pressure or reaction force of the spring, always leave 2 bolts in diagonal positions. Loosen those 2 bolts gradually and alternately and release the pressure, then, remove the part. • When removing the part, be careful not to break or damage the electrical wiring. The damaged wiring may cause electrical fires. 00-14

• When removing piping, prevent the fuel or oil from spilling out. If any fuel or oil drips onto the floor, wipe it off immediately. Fuel or oil on the floor can cause you to slip and can even cause fires. • As a general rule, do not use gasoline to wash parts. Do not use gasoline to clean the electrical parts, in particular. • Reinstall the parts removed to their original places. Replace the damaged parts and the parts which must not be used with new ones. When installing the hoses and wiring harnesses, be careful that they are not damaged by contacting with other parts when the machine is operated. • When connecting the high pressure hoses and tubes, make sure that they are not twisted. The damaged high pressure hoses and tubes are very dangerous when they are installed. So, be extremely careful when connecting the high pressure pipings. In addition, check that their connections are correct. • When assembling or installing the parts, be sure to tighten the bolts to the specified torque. When installing the protective parts such as guards, or the parts which vibrate violently or rotate at high speeds, be sure to check that they are installed correctly. • When aligning 2 holes, never insert your fingers or hand into the holes. Align the holes with care so that your fingers are not caught in the hole. • When measuring hydraulic pressure, check that the measuring tools are correctly installed. • Pay attention to safety when removing and installing the tracks of the track type machines. When removing the track, it separates suddenly. The workers should not stand at either end of the track. • If the engine is operated for a long time in a closed place which is not ventilated well, you may suffer from gas poisoning. Accordingly, open the windows and doors to ventilate the place well. Precautions for slinging work and making signals • Only one appointed worker must make signals and co-worker must communicate with each other frequently. The appointed signaler must make specified signals clearly at the place where the signaler is well seen from the operator's seat and where the signaler can see the working condition easily. The signaler must always stand in front of the load and guide the operator safely. 1. Do not stand under the load. 2. Do not step on the load. • Check the slings before starting sling work. D61EM-23M0

00 Index and foreword

Foreword, safety and general information

• Keep putting on the gloves during sling work. (Put on the leather gloves, if available.) • Measure the weight of the load by the eye and check its center of gravity. • Use the proper sling according to the weight of the load and method of slinging. If too thick wire ropes are used to sling a light load, the load may slip and fall. • Do not sling a load with 1 wire rope only. If do so, the load may rotate or the sling gets loose and the sling may slip off. Install 2 or more wire ropes symmetrically.

• Apply wire ropes to the middle part of the hook. a Slinging near the tip of the hook may cause the rope to slip off the hook during hoisting. The strength of the hook is maximum at its central part.

k Slinging with one rope may cause turning

of the load during hoisting, untwisting of the rope, or slipping of the rope from its original slinging position on the load, which can result in a dangerous accident. • Hanging angle must be 60 deg. or smaller as a rule. • When hanging a heavy load (25kg or heavier), the hanging angle of the rope must be narrower than that of the hook. a When slinging a load with 2 ropes or more, the larger the hanging angle is, the larger the tension of each rope. The figure bellow shows the variation of allowable load in kg when hoisting is made with 2 ropes, each of which is allowed to sling up to 9.8 kN {1,000kg} a load vertically, at various hanging angles. When the 2 ropes sling a load vertically, up to 2,000 kg of total weight can be suspended. This weight is reduced to 1,000 kg when the 2 ropes make a hanging angle of 120 deg.. If the 2 ropes sling a 2,000 kg load at a hanging angle of 150 deg., each rope is subjected to a force as large as 4,000 kg.

• Do not use twisted or kinked wire ropes. • When slinging up a load, observe the following. 1. Wind up the rope slowly until the wire rope tensions. When putting your hands on the wire ropes, do not grasp them but press them down from above. If you grasp them, your fingers may be caught. 2. After the wire ropes are stretched, stop the crane and check the condition of the slung load, wire ropes, and pads. 3. If the load is unstable or the wire rope or chains are twisted, lower the load and lift it up again. 4. Do not lift up the load at an angle. • When lowering a load, pay attention to the following. 1. When lifting down a load, stop it temporarily at 30 cm above the floor, and then lower it slowly. 2. Check that the load is stable, and then remove the sling. 3. Remove kinks and dirt from the wire ropes and chains used for the sling work, and put them in the specified place. Precautions for using mobile crane a Read the Operation and Maintenance Manual of the crane carefully in advance and operate the crane safely. Precautions for using overhead traveling crane k The hoist or crane must be used to sling the

• When installing wire ropes to an angular load, apply pads to protect the wire ropes. If the load is slippery, apply proper material to prevent the wire rope from slipping. • Use the specified eye bolts and fix wire ropes, chains, etc. to them with shackles, etc. D61EM-23M0

components weighing 25 kg or heavier. A part weighing 25 kg or heavier in "disassembly and assembly" section is indicated with the symbol of 4 .

00-15

00 Index and foreword

Foreword, safety and general information

• Before starting work, check the wire ropes, brake, clutch, controller, rails, over winding prevention device, ground fault circuit interrupter for electric shock prevention, crane collision prevention device, and energizing warning lamp, and check the following safety items. • Observe the signals for sling work. • Operate the hoist at a safe place. • Be sure to check the directions of the direction indication plate (north, south, east and west) and the operating button. • Do not sling a load at an angle. Do not move the crane while the slung load is swinging. • Do not raise or lower a load while the crane is moving longitudinally or laterally. • Do not drag a sling. • When lifting up a load, stop it just after it leaves the ground and check safety, and then lift it up. • Consider the travel route in advance and lift up a load to a safe height. • Place the control switch in a position where it will not be an obstacle to work and passage. • After operating the hoist, do not swing the control switch. • Remember the position of the main switch so that you can turn off the power immediately in an emergency. • Shut down the main switch when the hoist stops because of a blackout. When turning on a switch which is turned OFF by the ground fault circuit interrupter for electric shock prevention, check that the devices related to that switch are not in operating condition. • If you find an obstacle around the hoist, stop the operation. • After finishing the work, stop the hoist at the specified position and raise the hook to at least 2 meters above the floor. Do not leave the sling attached to the hook. Selecting wire ropes • Select adequate ropes depending on the weight of the parts to be hoisted, referring to the table below Wire rope (JIS G3525, 6 x 37 - Type A) (Standard Z twist wire ropes without galvanizing) Nominal diameter of rope mm 10 12 14 16 18 20 25 30 40

00-16

Allowable load kN 8.8 12.7 17.3 22.6 28.6 35.3 55.3 79.6 141.6

ton 0.9 1.3 1.7 2.3 2.9 3.6 5.6 8.1 14.4

Nominal diameter of rope mm 50 60

Allowable load kN 221.6 318.3

ton 22.6 32.4

a The allowable load is calculated as one sixth of the breaking load of the rope to be used (safety coefficient: 6). Precautions for disconnecting and connecting hoses and tubes in air conditioner circuit Disconnection k When replacing the air conditioner unit, air

conditioner compressor, condenser or receiver drier, etc., collect the refrigerant (air conditioner gas: R134a) from the air conditioner circuit before disconnecting the air conditioner hoses. a Ask a qualified person for collecting, adding and filling operations of the refrigerant (air conditioner gas: R134a). (Only registered persons can work.) a Never release the refrigerant (air conditioner gas: R134a) to the atmosphere. k If refrigerant gas (air conditioner gas: R134a)

gets in your eyes, you may lose your sight. And if it touches your skin, you may suffer from frostbite. Put on protective eyeglasses, gloves and working clothes with long sleeves while collecting the refrigerant or filling the air conditioner circuit with the refrigerant. • When loosening the nuts fixing air conditioner hoses and tubes, be sure to use 2 wrenches; use one wrench to fix and use the other one to loosen the nut. Connection • When installing the hose for the air conditioner circuit, take care not to allow invasion of dirt, dusts and water into the hose. • Check that the O-rings are fitted to the joints when connecting the air conditioner piping. • Once an O-ring is used, it is deformed and deteriorated. Accordingly, do not reuse it. • When removing the O-rings, use a soft tool so that the piping is not damaged. • Check that the O-ring is not damaged or deteriorated. • Apply compressor oil for refrigerant (R134a) to the O-ring. a However, do not apply oil to the threaded part of a bolt, nut or union.

D61EM-23M0

00 Index and foreword

Foreword, safety and general information

Manufacturer DENSO VALEO THERMAL SYSTEMS SANDEN

Part name ND-OIL8 ZXL100PG (equivalent to PAG46) SP-10

• When tightening nuts of the air conditioner hoses and tubes, be sure to use 2 wrenches. Use one wrench to fix and tighten the nut with the other wrench to the specified torque (Use a torque wrench for tightening). a Example of fitting of O-ring • An O-ring is fitted to every joint of the air conditioner piping.

For tightening torques, see "Others", "Precautions for disconnection and connection of air conditioner piping".

D61EM-23M0

00-17

00 Index and foreword

Foreword, safety and general information

Precautions to prevent fire

• Fire caused by fuel, oil, coolant or window washer fluid Do not bring any flame or fire close to flammable substances such as fuel, oil, coolant or window washer fluid.There is danger that they may catch fire. Always observe the following. • Do not smoke or use any flame near fuel or other flammable substances. • Shut down the engine before adding fuel. • Do not leave the machine when adding fuel or oil. • Tighten all the fuel and oil caps securely. • Be careful not to spill fuel on overheated surfaces or on parts of the electrical system. • After adding fuel or oil, wipe up any spilled fuel or oil. • Put greasy rags and other flammable materials into a safe container to maintain safety at the workplace. • When washing parts with oil, use a nonflammable oil. Do not use diesel oil or gasoline.There is danger that they may catch fire. • Do not weld or use a cutting torch to cut any pipes or tubes that contain flammable liquids. • Determine well-ventilated areas for storing oil and fuel. Keep the oil and fuel in the specified place and do not allow unauthorized persons to enter. • When performing grinding or welding work on the machine, move any flammable materials to a safe place before starting.

•

• Fire caused by accumulation or attachment of flammable material 00-18

• Remove any dry leaves, chips, pieces of paper, coal dust, or any other flammable materials accumulated or attached to or around the engine exhaust manifold, muffler, or battery, or on the undercovers. • To prevent fires from being caught, remove any flammable materials such as dry leaves, chips, pieces of paper, coal dust, or any other flammable materials accumulated around the cooling system (radiator, oil cooler) or on the undercover. Fire coming from electric wiring Short circuits in the electrical system can cause fire. Always observe the following. • Keep all the electric wiring connections clean and securely tightened. • Check the wiring every day for looseness or damage. Reconnect any loose connectors or refasten wiring clamps. Repair or replace any damaged wiring. Fire caused by piping Check that all the clamps for the hoses and tubes, guards, and cushions are securely fixed in position. If they are loose, they may vibrate during operation and rub against other parts. There is danger that this may lead to damage to the hoses and cause high-pressure oil to spurt out, leading to fire and serious personal injury or death. Fire around the machine due to highly heated exhaust gas Some machines are equipped with KDPF (Komatsu Diesel Particulate Filter). KDPF is a system for purifying soot in exhaust gas. Its exhaust gas discharged during purification process (regeneration) can be at higher temperature than that from existing models. Do not bring any flammable material close to the outlet of the exhaust pipe. • When there are thatched houses, dry leaves or pieces of paper near the work site, set the system to disable the regeneration before starting work to prevent fire hazards due to highly heated exhaust gas. See the operation and maintenance manual for the setting procedure. Explosion caused by lighting equipment • When checking fuel, oil, battery electrolyte, or coolant, always use lighting equipment with anti-explosion specifications. • When taking the electrical power for the lighting equipment from the machine itself, follow the instructions in the operation and maintenance manual.

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Actions if fire occurs

(ALL-0000-17A-K-01-A)

• Turn the starting switch to OFF position to stop the engine. • Use the handrails and steps to get off the machine. • Do not jump off the machine. You may fall or suffer serious injury. • The fume generated by a fire contains harmful materials which have a bad influence on a human body when they are sucked. Don't breathe a fume. • After a fire, there may be harmful compounds left. If it touches your skin it may have a bad influence on your body. Be sure to wear rubber gloves when handle the materials left after the fire. The material of the gloves, which is recommended is polychloroprene (Neoprene) or polyvinyl chloride (in the lower temperature environment). When wearing cotton-work-gloves, wear rubber gloves under them.

Dispose of waste materials

(ALL-0000-99A-K-02-A)

To prevent pollution, pay full attention to the way to dispose of waste materials. • Always put the oil and coolant drained from the machine in containers. Never drain the oil and coolant directly onto the ground or dump into the sewage system, rivers, the sea, or lakes. • Observe the related laws and regulations when disposing of harmful objects such as oil, fuel, coolant, solvent, filters, and batteries.

Some kinds of rubber and plastics may produce poisonous gas harmful to human body when they are burned. • As for rubber, plastics, or parts (hoses, cables, and wiring harnesses, etc.) which contain those materials, ask the industrial waste treatment firms for their disposals in accordance with the local regulations.

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How to read the shop manual

1 (Rev. 2012/10)

• Some attachments and optional parts described in this shop manual may not be arranged for certain areas. Contact your Komatsu distributor if one or some of them are required. • Materials and specifications are subject to change without notice. • The shop manuals are available for "Machine part" and "Engine part". For the engine, see the shop manual for the same model of the engine as the one which is mounted on the machine. Composition of shop manual • This shop manual describes the technical information required for the services performed in a workshop. The shop manual is divided into the following chapters for the convenience of use. 00. Index and foreword • This section includes the index, foreword, safety and basic information. 01. Specification • This section explains the specifications of the machine. 10. Structure and function • This section explains the structure and function of the machine. The section of "Structure and function" serves not only to give an understanding for the structure of each component, but also serves as reference material for troubleshooting. 20. Standard value table • The standard values for a new machine and trouble shooting are indicated. This standard value table is used for testing and adjusting, and determining a failure at troubleshooting. 30. Testing and adjusting • This section describes the measuring tools and how to measure, and how to adjust various parts. As for the standard value and failure criterion, see the standard value table. 40. Troubleshooting • This section describes the troubleshooting in a suspected area when a failure occurs and the remedy for the failure. Troubleshooting is described by each failure mode. 50. Disassembly and assembly • This section explains the procedures for removing, installing, disassembling, and assembling each part or component and the special tools for the works as well as precautions for doing them safely. In addition, tightening torque, and quantity and weight of coating material, oil, grease, and coolant required for the works are also explained. 60. Maintenance standard • This section describes the maintenance standard values for each component. This section gives the criterion values for each component and required remedy at disassembly or maintenance. 80. Appendix • The structure and function, testing and adjusting, and troubleshooting for all of the other components or equipment which can not be separately classified are explained together in the appendix. 90. Diagrams and drawings • This section gives hydraulic circuit diagrams and electrical circuit diagrams.

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Symbol Important safety and quality portions are marked with the following symbols so that the shop manual is used practically. Symbol

Item

Safety

Caution

Weight

Tightening torque

Coat

Oil, coolant

Drain

Remarks The special safety precautions required for performing work are described. The special technical precautions or other precautions for preserving standards required when performing work are described. The weight of part or component and the cautions required when selecting hoisting wire or when working posture is important are indicated. The tightening torques that require special attention during assembly work are indicated. The places to be coated with adhesives, grease, etc. during assembling are indicated. The places where oil, coolant, etc. must be added and the quantity to be added are indicated. Places where oil, coolant, etc. must be drained and the quantity to be drained are indicated.

Unit • In this shop manual, the units are indicated with International System of units (SI). • For reference, Gravitational System of units which is used to be used is indicated in parentheses of { }.

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Explanation of terms for maintenance standard

1 (Rev. 2012/10)

• The chapter of maintenance standard shows judgement criteria to determine the products to be replaced or to be reused. The judgement criteria are described by using the following terms. Standard dimension and tolerance • To be accurate, the finished dimension of a part is slightly different from one to another. • The finished dimension of a part specifies the allowable difference from the standard dimension which is set first. • The dimension set as the standard is called the standard dimension and the range of difference from this standard dimension is called the "tolerance". • An indication example of a standard dimension and tolerance is shown in the following table. (The standard dimension is entered on the left side and the tolerance is entered with a positive or negative symbol on the right side) Example: Standard dimension

Tolerance -0.022 -0.126

120

• The tolerance may be indicated in the text and a table as "standard dimension (upper limit of tolerance/lower limit of tolerance)." Example: 120(-0.022/-0.126) • Usually, the dimension of a hole and the dimension of a shaft to be inserted into the hole are indicated by the same standard dimension and different tolerances of the hole and shaft. The tightness of fit is decided by the tolerance. • An indication example of a shaft and hole is shown in the following table. (The standard dimension is entered on the left side and the tolerance of the shaft is entered with a positive or negative symbol at the center and that of the hole on the right side) Standard dimension 60

Tolerance Shaft -0.030 -0.076

Hole +0.046 0

Standard clearance and standard value • The clearance made when new parts are assembled is called the standard clearance, which is indicated by the range from the minimum clearance to the maximum clearance. • When some parts are repaired, the clearance is generally adjusted to the standard clearance. • The values indicating performance and function of new products or equivalent are called the "standard value", which is indicated by a range or a target value.

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• When some parts are repaired, the value of performance/function is set to the standard value.

Standard interference • When the diameter of a hole of a part shown in the given standard dimension and tolerance table is smaller than that of the shaft to be inserted, the difference between those diameters is called the "interference". • Subtract the maximum dimension of the hole from the minimum dimension of the shaft and call it (A). Subtract the minimum dimension of the hole from the maximum dimension of the shaft and call it (B). The range between (A) and (B) is the "standard interference". • After repairing or replacing some parts, measure the dimension of their hole and shaft and check that the interference is in the standard range. Repair limit and allowable value or allowable dimension • The dimensions of parts change because of the wear or deformation while they are used. When the dimension changes exceeding certain value,

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the parts can not be used any longer. This value is called "repair limit". • If a part is worn to the repair limit, it must be replaced or repaired. • The performance and function of the products lower while they are used. When the value of the performance and function lowers exceeding a certain limit and it influences the operation etc., this value is called the allowable value or allowable dimension. • A product whose dimension is out of the allowable value, must be repaired. However, since the allowable values are generally estimated through various tests or experiences in most cases, the judgement must be made in consideration of the operating condition and customer's requirement. Allowable clearance • 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 "allowable clearance". • If the clearance between the parts exceeds the allowable clearance, they must be replaced or repaired. Allowable interference • The allowable maximum interference between the hole of a part and the shaft of another part to be assembled is called the "allowable interference". • The allowable interference shows the repair limit of the part of smaller tolerance. • The parts whose interferences are out of the allowable interference must be replaced or repaired.

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Handling equipment of fuel system devices

(Rev. 2012/01) • The common rail fuel injection system (CRI) consists of more precise parts than the parts used in the conventional fuel injection pump and nozzle. If foreign material enters this system, it may cause a failure. Use special care to prevent entry of the foreign material when servicing the fuel system. Use care for working environment • Avoid filter change or repairing the machine in rain or high winds, or at places where there is a lot of dust. Sealing openings • Plug the pipes and the openings of the components which are removed with the caps, tapes, vinyl bags, etc. to prevent foreign material from entering. Never perform repair works under the condition that the openings are left as they are or plugged with cloths as foreign material may enter or environment may be polluted by the oil leaked. Do not discard the waste oil somewhere or other. Hand it over to your customer for disposal, or dispose it by yourself. How to clean parts when dirt is stuck • If any dirt or dust sticks the parts of the fuel system, clean it off thoroughly with clean fuel. Precautions for replacing fuel filter cartridge • Be sure to use the Komatsu genuine fuel filter cartridge. • The common rail fuel injection system (CRI) consists of more precise parts than the parts used in the conventional fuel injection pump and nozzle. In order to prevent foreign material from entering this system, the filter employs a specially high performance of filter element. If a filter element other than the genuine one is used, the fuel system may have a failure. Accordingly, never use such a filter element.

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Handling of intake system parts

(Rev.2013/10) • The Komatsu Variable Geometry Turbocharger consists of more precise parts (variable mechanism) than the parts used in the conventional turbocharger. If foreign material enters this system, it may cause a failure. Use special care to prevent entry of the foreign material when servicing the air intake system. Be careful of working environment • Avoid the repair work of the machine in rain or strong wind or at the places where there is a lot of dust. Sealing openings • Plug the pipes and the openings of the components which are removed, with the caps, tapes, vinyl bags, etc. to prevent foreign material from entering. Never perform repair works under the condition that the openings are left open or plugged with rag since foreign material may enter.

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Handling of hydraulic equipment

1 (Rev. 2012/10)

• With the increase in pressure and precision of the hydraulic components, the most common cause of a failure is dirt (foreign material) in the hydraulic circuit. Therefore, the special care must be taken when adding hydraulic oil,or when disassembling or assembling the hydraulic components. Be careful of working environment • Avoid adding hydraulic oil, replacing filters, or repairing the machine in rain or high winds, or at places where there is a lot of dust. Disassembly and maintenance work in the field • When disassembly or maintenance work of the hydraulic is performed in the field, there is danger of dust entering the components. It is also difficult to check the performance of the components after repairs, so it is desirable to use the component exchange service. The disassembly and assembly of the hydraulic components must be performed in the specially arranged dustproof workshop and the performance test of the components must be performed with the special testing equipment.

Plugging of opening (prevention of flowing out of oil) • Plug the pipes and the openings of the components which are removed (when plugs are not prepared, seal with caps, tapes, vinyl bags, etc.) to prevent entry of foreign material and flowing out of oil. Never leave the openings of the pipes and hoses without being covered or plugged with cloth as foreign material may enter them or environment may be polluted by the oil leaked. Do not discard the waste oil somewhere or other. Hand it over to your customer for disposal, or dispose it by yourself.

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Preventing intrusion of foreign materials during refilling operations. • Care must be taken when adding hydraulic oil so that foreign material does not enter. Keep the oil filler port and the area around it, oil supply pump and oil container clean. If an oil cleaning device is used, it is possible to remove the dirt that is collected during storage. It is a surer means.

Replacing hydraulic oil while its temperature is high • When the hydraulic oil is warm, it flows easily. In addition, sludge can also be drained from the circuit together with the oil. So, it is better to change the hydraulic oil while it is warm. When changing the hydraulic oil, the old oil must be drained as much as possible. (Drain the oil not only from the hydraulic tank, but also from the filter housing and the drain plug hole in the circuit.) If the old oil is left in the system, the contaminant and sludge in the oil mix with the new oil and shorten the life of the new hydraulic oil.

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Flushing operations • After disassembling the equipment or when changing the hydraulic oil with new one, flush the system to remove the contaminant and sludge left in the hydraulic circuit as well as the oil which includes them. Normally, flushing is performed twice. Primary flushing is performed by use of the flushing oil and the secondary flushing is performed by use of the specified hydraulic oil.

Cleaning operations • After repairing the hydraulic equipment (pump, control valve, etc.) or when the machine is in operation, perform oil cleaning to remove the sludge or contaminant in the hydraulic oil circuit. The oil cleaning equipment can remove the ultra fine (approximately 3 μm) particles that the filter built in the hydraulic equipment can not remove. So, it is an extremely effective device.

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Method of disconnecting and connecting of push-pull type coupler

(Rev. 2012/01) k Loosen the oil filler cap of the hydraulic tank slowly to release the remaining pressure in the

hydraulic tank. k Even if the remaining pressure is released from the hydraulic tank, some hydraulic oil flows out

when the hose is disconnected. Accordingly, prepare an oil container.

Type 1

(ALL-C930-925-P-01-A)

Disconnection 1. Hold adapter (1) and push hose joint (2) into mating adapter (3). (Fig. 1) a It can be pushed in by approximately 3.5mm. a Do not hold rubber cap portion (4). 2. While pushing hose joint (2) into adapter (3), push rubber cap (4) against adapter (3) until "click" is heard. (Fig. 2) 3. Hold hose adapter (1) or hose (5) and pull it out. (Fig. 3) a Since some hydraulic oil flows out, prepare an oil container.

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Connection 1. Hold hose adapter (1) or hose (5) and insert it in mating adapter (3) aligning them with each other. (Fig. 4) a Do not hold rubber cap part (4). 2. After inserting the hose fitting in the adapter on the other side perfectly, pull it back to check the connecting condition. (Fig. 4) a When the hose fitting is pulled back, the rubber cap will move approximately 3.5mm toward the hose, however, it is not a problem.

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Type 2

(ALL-C930-925-P-02-A)

Disconnection 1. While holding the fitting, push body (7) in straight until sliding prevention ring (6) hits contact surface (a) at the hexagonal part on the male side. (Fig. 6) 2. While keeping the condition of Step 1, turn lever (8) to the right (clockwise). (Fig. 7) 3. While keeping the conditions of Steps 1 and 2, pull out whole body (7) to disconnect it. (Fig. 8)

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Connection 1. While holding the fitting, push body (7) in straight until sliding prevention ring (6) hits contact surface (a) at the hexagonal part on the male side to connect it. (Fig. 9)

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Type 3

(ALL-C930-925-P-03-A)

Disconnection 1. While holding the fitting, push body (9) in straight until sliding prevention ring (8) hits contact surface (b) at the hexagonal portion on the male side. (Fig. 10) 2. While keeping the condition of Step 1, push cover (10) straight until it hits contact surface (b) of the hexagonal portion on the male side. (Fig. 11) 3. While keeping the conditions of Steps 1 and 2, pull out whole body (9) to disconnect it. (Fig. 12)

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Connection 1. While holding the fitting, push body (9) in straight until sliding prevention ring (8) hits contact surface (a) at the hexagonal portion on the male side to connect them. (Fig. 13)

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Handling of electrical equipment 1 (Rev. 2012/11) • To maintain the performance of the machine over a long period, and to prevent failures or troubles before they occur, correct "operation", "maintenance and inspection" "troubleshooting", and "repairs" must be performed. This section deals particularly with correct repair procedures for mechatronics components and is aimed at improving the quality of repairs. For this purpose, it describes the working procedures in "Handling of electrical equipment". Precautions for handling electric equipment Handling wiring harnesses and connectors • Wiring harnesses consist of wires connecting one component to another component, connectors used for connecting and disconnecting one wire from another wire, and protectors or tubes used for protecting the wires. • Compared with other electrical components fitted in boxes or cases, wiring harnesses are more likely to be affected by the direct effects of rain water, heat, or vibration. Furthermore, during inspection and repair operations, they are frequently removed and installed again, so they are likely to suffer deformation or damage. For this reason, it is necessary to be extremely careful when handling the wiring harnesses.

Main failures occurring in wiring harness Defective contact of connectors (defective contact between male and female connectors) • Problems with defective contact are likely to occur because the male connector is not properly inserted into the female connector,or because one or both of connectors are deformed or the position is not correctly aligned, or because there is corrosion or oxidization of the contact surfaces. The corroded or oxidized contact surfaces may become shiny again (and contact may become normal) by connecting and disconnecting the connectors approximately 10 times.

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Defective crimping or soldering of connectors • The pins of the male and female connectors are attached to wires by crimping or soldering. If excessive force is applied to the wire, the joining area may become loose, which may result in a defective connection or breakage.

Disconnections in wiring • If the wiring harness is pulled to disconnect the connector, or the components are lifted with a crane while the wiring harness is still connected, or a heavy object hits the wiring harness, the crimping of the connector may separate, or the soldering may be damaged, or the wiring harness may be broken.

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blow it with compressed air and spray it with electrical contact restorer. a When wiping the joint portion of the connector, be careful not to apply excessive force or deform the pins. a If there is oil or water in the compressed air, it causes the contacts to become dirtier. So, remove the oil and water from the compressed air completely before cleaning the connector with the compressed air.

High-pressure water entering connector • The connector is designed to make it difficult for water to enter (drip-proof structure), but if highpressure water is sprayed directly on the connector, water may enter the connector, depending on the direction of the water jet. Accordingly, take care not to spray water over the connector. The connector is designed to prevent water from entering, but once water does enter, it is difficult to drain it. If water should get into the connector, the pins will be short-circuited by the water. So if any water gets in, immediately dry the connector or take other appropriate action before passing electricity through it.

Removing, installing, and drying connectors and wiring harnesses Disconnecting connectors 1. Hold the connectors when disconnecting. • Disconnect connectors by holding the connector bodies. For the connectors held by a screw, loosen the screw fully, then hold the male and female connectors with each hand respectively and pull them apart horizontally. For the connectors with lock stopper, press down the stopper with your thumb and pull the connectors apart. a Never pull the connector with one hand.

Entry of water, mud or dirt when disconnecting a connector • If any water, mud or dirt is stuck to the outside surface of a connector, it can enter inside the connector when the connector is disconnected. Before disconnecting the connector, wipe off any stuck water or dirt by using a piece of dry cloth or blow it with compressed air. Oil, mud or dirt stuck to connector • If any oil or grease is stuck to the connector and an oil film is formed on the mating surface of the male and female pins, the oil prevents electricity from passing through, resulting in defective contact. If any oil or grease, mud or dirt is stuck to the connector, wipe it off with a dry cloth or

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2. When removing from clips • Both of the connector and clip have stoppers, which are engaged with each other when the connector is connected.

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• Check that there is no oil, dirt or water stick to the connector pins (joint portion). • Check that the connector pins are free from deformation, defective contact, corrosion, or damage. • Check that external surfaces of the connectors are free from damage or breakage.

• When removing a connector from a clip, pull the connector in a parallel direction to the clip for removing stoppers. a If the connector is pried up and down or to the right and left, the housing may break.

a If any oil, water or dirt is stuck to the connector, wipe it off with a dry cloth. If any water is inside the connector, warm the connector and the inside of the wiring harness with a dryer. But be careful not to make it too hot as it causes short circuit. a If there is any damage or breakage, replace the connector. 2. Fix the connector securely. • Align the connectors correctly, and fit them securely. For the connectors with the lock stopper, push in the connectors until "click" is heard.

3. Action to take after removing connectors • After removing the connector, cover it with the vinyl bag to prevent entry of dust, dirt,oil or water in the contact portion. a If the machine is left disassembled for a long time, it is particularly easy for improper contact to occur, so always cover the connector.

3. Correct the protrusion of the boot and misalignment of the wiring harness • For connectors fitted with the boot, correct any extrusion of the boot. In addition, if the wiring harness or the clamp is out of the position, put it in its original position. a If the connector cannot be corrected easily, remove the clamp and adjust the position.

Connecting connectors 1. Check the connector visually.

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• If the connector clamp is removed, be sure to return it to its original position. And check that it is securely installed.

Drying wiring harness • If there is any oil or dirt on the wiring harness, wipe it off with a dry cloth. Avoid washing by using steam. If the wire harness must be washed in water, do not apply high pressure water or steam directly to the wiring harness. If water gets directly on the connector, do as follows. 1. Disconnect the connector and wipe off the water with a dry cloth. a If the connector is to be blown with dry compressed air, there is a risk that oil in the air may cause defective contact of the conditioner, remove oil and water in the air before starting air blow.

Handling of Deutsch connector (DT8-pin, DT12pin) Disconnection 1. While pressing locks (a) and (b) from each side respectively, pull out female connector (2).

2. Dry the inside of the connector with a dryer. If water gets inside the connector, use a dryer to dry the connector.

Connection 1. Push in female connector (2) horizontally until the lock clicks. (Arrow: x) 2. Since locks (a) and (b) may not be set completely, push in female connector (2) with curving movement until the locks are set normally. (Arrow: x, y, and z)

a Hot air from the dryer can be used, but regulate the time to use hot air in order to prevent the connector or related parts from becoming too hot, as it causes deformation or damage to the connector.

a Lock (a) in the figure is pulled down (not set completely), and lock (b) is set completely.

3. Perform a continuity test on the connector. After drying, leave the wiring harness disconnected and perform a continuity test to check for any short circuits between pins caused by water. a After the connector is completely dried, blow the contact restorer and reassemble them. 00-34

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Handling of connectors used on engine

2. While pressing lock (L2), pull out connector (1).

Slide, lock type (FRAMATOME-3, FRAMATOME-2) Disconnection 1. Slide lock (L1) to the right. 2. While pressing lock (L2), pull out connector (1) toward you. a In the case that even if lock (L2) is pressed, connector (1) cannot be pulled out toward you unless part A floats, float part A with a small flat-head screwdriver while pressing lock (L2), and then pull out connector (1) toward you.

a Lock (L2) is located in the back of connector (1).

Connection 1. Insert the connector securely until a click is heard. (FRAMATOME-24) Disconnection 1. Slide down lock (red) (L1).

Connection 1. Insert the connector securely until a click is heard. Pull lock type (PACKARD-2) Disconnection 1. Disconnect the connector (2) by pulling lock (B) (on the wiring harness side) of connector (2) outward.

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Connection 1. Insert the connector securely until a click is heard. Push lock type (BOSCH-3) Disconnection 1. While pressing lock (C), pull out connector (3) in the direction of the arrow.

Connection 1. Insert the connector securely until a click is heard. (AMP-3) Disconnection 1. While pressing lock (E), pull out connector (5) in the direction of the arrow.

• 114 series

Connection • 107 series

1. Insert the connector securely until a click is heard. (SUMITOMO-2) Disconnection 1. While pressing lock (E), pull out connector (5) in the direction of the arrow.

a If the lock is located on the underside, use flat-head screwdriver [1] since you cannot insert your fingers. While pushing up lock (C) of the connector with flat-head screwdriver [1], pull out connector (3) in the direction of the arrow.

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Connection 1. Insert the connector securely until a click is heard. D61EM-23M0

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(SUMITOMO-3) Disconnection 1. While pressing lock (E), pull out connector (5) in the direction of the arrow. a Pull the connector straight up.

Connection 1. Insert the connector to the end while aligning its grove to the other. 2. Turn housing (H1) in the direction of the arrow until it "clicks". Connection 1. Insert the connector securely until a click is heard. (SUMITOMO-4) Disconnection 1. While pressing lock (D), pull out connector (4) in the direction of the arrow.

Handling controller • The electronic circuits for control including the microcomputers are assembled in the controller. These electronic circuits in the controller must be handled with care as they control the machine. • Do not place objects on top of the controller. Connection 1. Insert the connector securely until a click is heard. Turn-housing type (Round green connector) (CANNON-4) Disconnection 1. Turn housing (H1) in the direction of the arrow. a Unlock the connector by turning housing (H1). When the lock is release the housing is felt tight to turn. 2. Pull out housing (H1) in the direction of the arrow. a Housing (H1) is left on the wiring harness side.

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• Cover the control connectors with tape or a vinyl bag. Never touch the connector contacts. • During rainy weather, do not leave the controller in a place where it is exposed to rain. • Do not place the controller on oil, water, or soil, or in a place that can be heated to a high 00-37

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temperature even for a short period of time. (Place it on a suitable dry stand.)

• Precautions when performing arc welding When performing arc welding on the machine body, disconnect all the wiring harness connectors connected to the controller. Put the arc welding ground to the place close to the welding point. Precautions for troubleshooting electrical circuits • Be sure to turn the starting switch to "OFF" position before disconnecting or connecting the connectors. • Before performing troubleshooting, check all the related connectors for loose connection. a Check the related connectors for their performance by disconnecting and connecting them several times. • Be sure to connect all the disconnected connectors before proceeding to the next step. a If the starting switch is turned to "ON" position with the connectors disconnected, the failure which is not related to the part which is actually failed. • When performing the troubleshooting for the circuit (measurement of voltage, resistance, continuity, current, etc.), shake the related wiring harnesses and connectors several times and check that the multimeter reading does not change. a If there is any value change on the multimeter, there may be a defective contact in the circuit.

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How to read electric wire code

1 (Rev. 2012/10)

• In the electrical circuit diagram, material, thickness and color of each electric wire are indicated by symbols. The wire code is helpful in understanding the electrical circuit diagram. Example) AEX 0.85 L: Indicates blue, heat-resistant, low-voltage wire for automobile, having nominal No. of 0.85 Indicates type of wire by symbol. Type, symbol, and material of wire are shown in Table 1. AEX (Since the use of AV and AVS wires depends on size (nominal No.), their symbols are not indicated on the diagram.) Indicates size of wire by nominal No. 0.85 Size (Nominal No.) is shown in Table 2. Indicates color of wire by color code. L Color codes are shown in Table 3. Type, symbol, and material • AV and AVS are different in thickness and outside diameter of the coating. CAVC has a circular compressed conductor. It differs from AV and AVS in the outside diameter of conductor and thickness of the coating. And AEX is similar to AV in thickness and outside diameter of the coating but different from AV and AVS in material of the coating. (Table 1) Type

Symbol

Low-voltage wire for AV automobile Thin-cover low-voltage wire for AVS automobile (Type 1) Thin-cover low-voltage wire for CAVS automobile (Type 2) Heatresistant lowvoltage wire AEX for automobile

D61EM-23M0

Conductor material

Insulator material

Temperature range (°C) in use

Example of use For large current wiring (nominal No. 5 and above)

Soft polyvinyl chloride

-30 to +60

Annealed copper for electric appliance

General wiring (nominal No. 3 and lower)

For mid- to small-size excavators (nominal No. 1.25 and lower)

Heat-resistant cross linked polyethylene

-50 to +110

General wiring for extremely cold weather specification Wiring at high ambient temperature place

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Dimensions (Table 2)

Coating D

(0.5) 0.75f (0.85) 1.25f (1.25) Nominal No. 0.5f Number of 20/ strands/ 30/ 11/ 50/ 16/ 7/0.32 Diameter of 0.18 0.18 0.32 0.18 0.32 strand Conductor Crosssectional 0.51 0.56 0.76 0.88 1.27 1.29 area (mm2) d (approx.) 1.0 1.2 1.5 AVS Standard 2.0 2.2 2.5 — — — AV Standard AEX

Standard

2.0

2.2

2.7

37/ 0.26

26/ 0.32

58/ 0.26

41/ 0.32

65/ 0.32

1.96

2.09

3.08

3.30

5.23

1.9 2.9 —

2.3 3.5 —

2.4 3.6 —

3.0 — 4.6

3.0

3.1

—

3.8

4.6

Coating D

Nominal No. 8 15 20 30 40 Number of strands/ 50/0.45 84/0.45 41/0.80 70/0.80 85/0.80 Diameter of strand Conductor Crosssectional 7.95 13.36 20.61 35.19 42.73 area (mm2) d (approx.) 3.7 4.8 6.0 8.0 8.6 — — — — — AVS Standard AV Standard 5.5 7.0 8.2 10.8 11.4 10.8

100

108/ 0.80

127/ 0.80

169/ 0.80

217/ 0.80

54.29

63.84

84.96

109.1

9.8 — 13.0

10.4 — 13.6

12.0 — 16.0

13.6 — 17.6

13.0

13.6

16.0

17.6

Nominal No. Number of strands/ Diameter of strand Conductor Crosssectional area (mm2) d (approx.)

0.5f

0.5

0.75f

0.85

1.25f

1.25

—

7/round compression

—

11/round compression

—

16/round compression

—

0.56

—

0.88

—

1.29

—

0.9

—

1.1

—

1.4

—

1.6

—

1.8

—

2.1

Standard

8.2

5.3

CAVS

7.0

Standard

Coating D

AEX

11.4

a "f" of nominal No. denotes "flexible".

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Color codes table (Table 3) Color Code B Br BrB BrR BrW BrY Ch Dg G GB GL Gr GR GW GY L LB Lg LgB LgR

Color of wire Black Brown Brown & Black Brown & Red Brown & White Brown & Yellow Charcoal Dark green Green Green & Black Green & Blue Gray Green & Red Green & White Green & Yellow Blue Blue & Black Light green Light green & Black Light green & Red

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

Color of wire Light green & White Light green & Yellow Blue & Red Blue & White Blue & Yellow Orange Pink Red Red & Black Red & Green Red & Blue Red & White Red & Yellow Sky Blue Yellow Yellow & Black Yellow & Green Yellow & Blue Yellow & Red Yellow & White

a Remarks: In a color code consisting of 2 colors, the first color is the color of the background and the second color is the color of the marking. Examples) GW means that the background is "Green" and marking is "White". Types of circuits and color codes Type of wire Charge Ground Start Light Instrument Signal Type of circuit Others

D61EM-23M0

R B R RW Y G L Br Lg O Gr P Sb Dg Ch

WG — — RB YR GW LW BrW LgR — — — — — —

AVS, AV, CAVS — — — — — — RY RG YB YG GR GY LR LY BrR BrY LgY LgB — — — — — — — — — — — —

AEX — — — RL YL GB LB BrB LgW — — — — — —

— — — — YW GL — — — — — — — — —

R B R D Y G L — — — — — — — —

— — — — Gr Br — — — — — — — — —

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Precautions when performing operation

1 (Rev. 2012/11)

• When performing "testing and adjusting" of the machine, "removal and installation" and "disassembly and assembly" of the components, observe the following general cautions. Precautions for removal and disassembly work • If the cooling water contains coolant, dispose of it correctly as chemicals. Do not drain it to the sewage rashly. • After disconnecting the hoses or tubes, plug them to prevent dirt or dust from entering. • When draining oil, prepare a container with sufficient capacity. • Check the match marks which indicate the installing position, and put match marks on the places where they seem necessary before removal of the components to prevent any mistake when assembling. • To prevent any excessive force from being applied to the wiring, always hold the connectors when disconnecting the connectors. Do not pull the wires. • Attach the tags to wires and hoses to show their installing positions to prevent any mistake when installing. • Check the number and thickness of the shims, and keep them in a safe place. • When hoisting the components, prepare the slings with sufficient strength. • When using forcing screws to remove any component, tighten the forcing screws uniformly and alternately. • Before removing any component, clean the surrounding area and cover the component to prevent any foreign material from entering after removal. • After disconnecting the piping or removing a pipe joint, install the following plugs. a The O-rings in the table are emergency parts used for disassembly or transportation of the machine. When assembling, confirm the part numbers in the parts book and use the parts conforming to the using condition. Disconnection of face seal type hoses and tubes

Nominal No. 02 03 04 05 06

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Hose side Plug (1) 07376-70210 07376-70315 07376-70422 07376-70522 07376-70628

Pipe joint side Nut (2) 02789-00210 02789-00315 02789-00422 02789-00522 02789-00628

O-ring (3) 02896-11008 02896-11009 02896-11012 02896-11015 02896-11018

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Disconnection of taper seal type hoses and tubes

Nominal No. 02 03 04 05 06 10 12 14

Hose side Plug (1) 07376-50210 07376-50315 07376-50422 07376-50522 07376-50628 07376-51034 07376-51234 07376-51443

Pipe joint side Nut (2) 07222-00210 07222-00312 07222-00414 07222-00515 07222-00616 07222-01018 07222-01219 07222-01422

Disconnection of split flange type hoses and tubes

No- Bolt pitch (mm) Hose side minal a Flange (1) b No. 0737904 38.1 17.5 00400 0737905 42.9 19.8 00500 0737906 47.6 22.2 00640 0737910 52.4 26.2 01044 0737958.7 30.2 01250 12 0737966.7 31.8 01260 0737914 69.9 35.8 01460 D61EM-23M0

Tube side Split flange Sleeve head O-ring (4) (2) (3) 07371-30400 07378-10400 07000-12021 07371-30500 07378-10500 07000-13022 07371-30640 07378-10600 07000-13025 07371-31049 07378-11000 07000-13032 07371-31255 07378-11200 07000-13038 07371-51260 07378-11210 07000-13038 07371-31465 07378-11400 07000-13048

Bolt (5) 0101080825 0101080830 0737251035 0737251035 0737251035 0101081245 0737251240

Washer (6) 01643-50823 01643-50823 01643-51032 01643-51032 01643-51032 01643-51232 01643-51232

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No- Bolt pitch (mm) Hose side minal a Flange (1) b No. 0737979.4 36.5 01470 0737977.8 42.8 02071 20 0737996.8 44.5 02080 0737924 88.9 50.8 02484 0737930 106.4 62 03010 34

120.6

69.8

130.2

77.8

152.4

Tube side Split flange Sleeve head O-ring (4) (2) (3)

Bolt (5)

07371-51470 07378-11410 07000-13048 07371-32076 07378-12000 07000-12060 07371-52080 07378-12010 07000-12060 07371-12484 07378-12400 07000-12070 07371-13010 07378-13000 07000-12085

07379-03411 07371-13411 07378-13400 07000-12100 0737904012

07371-14012 07378-14000 07000-12110

07379-05011 07371-15011 07378-15000 07000-12135

0101081455 0737251240 0101081865 0737251240 0737251650 0737251650 0737251650 0737251655

Washer (6) 01643-31445 01643-51232 01643-31845 01643-51232 01643-51645 01643-51645 01643-51645 01643-51645

Removal of pipe joints of O-ring boss type

Nominal No. 08 10 12 14 16 18 20 24 30 33 36 42 52

00-44

Plug (1) 07040-10807 07040-11007 07040-11209 07040-11409 07040-11612 07040-11812 07040-12012 07040-12412 07041-13012 07040-13316 07041-13612 07040-14220 07040-15223

O-ring (2) 07002-10823 07002-11023 07002-11223 07002-11423 07002-11623 07002-11823 07002-12034 07002-12434 07002-13034 07002-13334 07002-13634 07002-14234 07002-15234

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Removal of pipe joints of taper pipe thread type

Nominal No. 01 02 03 04 06 10 12 14 20

Nominal thread size R 1/ 8 R 1/ 4 R 3/ 8 R 1/ 2 R 3/ 4 R1 R1 1/4 R1 1/2 R2

Plug (1) Square head type (A) 07042-00108 07042-00211 07042-00312 07042-00415 07042-00617 07042-01019 07042-01222 07042-01422 07042-02026

Hexagonal socket head (B) 07043-00108 07043-00211 07043-00312 07043-00415 07043-00617 07043-01019 07043-01222 07043-01422 07043-02026

Precautions for installation and assembly work • Tighten the bolts and nuts (sleeve nuts) to the specified torque (KES), unless otherwise specified. • Install the hoses without twist and interference, and securely fasten the clamps located in-between if they are. • Replace all of the gaskets, O-rings, cotter pins, and lock plates with new parts. • Bend the cotter pins and lock plates securely. • When applying adhesive, clean and degrease the part, and apply 2 to 3 drops of adhesive to the threaded part. • When applying liquid gasket, clean and degrease the surface, and apply it uniformly after making sure that the surface is free from dirt or damage. • Clean all of the parts, and repair any damage, dents, burrs, or rust found on them. • Coat the rotating parts and sliding parts with engine oil. • Coat the surfaces of the press-fitting parts with molybdenum disulfide lubricant (LM-P). • After installing the snap ring, check that the snap ring is settled in the ring groove completely. • When connecting wiring harness connectors, clean the connectors to remove oil, dirt, or water, then connect them securely. • Use the eye bolts with no fatigue and deformation and screw them in securely. Match the directions of the eyes and the hook. • When installing split flanges, tighten the bolts uniformly and alternately to prevent excessive tightening on one side. • As a rule, apply liquid gasket (LG-5) or liquid sealant (LS-2) to the threaded part of each taper male screws which receives pressure. However, if the threaded part is difficult to degrease, you may use a seal tape. • When winding a seal tape onto a right-handed taper male screw, wind it clockwise in the advancing direction of the threads, seeing from the screw end and starting at the third thread. a If you wind the seal tape in the opposite direction, it becomes loose and comes off or its end part is pushed out, and that can cause oil leakage.

D61EM-23M0

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a When the hydraulic cylinder is used for the first time after reassembly of the hydraulic equipment such as the hydraulic cylinder, pump, etc. and piping after removing them for repair, be sure to perform air bleeding of the hydraulic circuit according to the following procedure. 1. Start the engine, and run it at low idle. 2. Repeat the operation to extend and retract each cylinder of the work equipment to approximately 100 mm before the stroke end 4 to 5 times. 3. Operate the hydraulic cylinder 3 to 4 times to the end of its stroke. a After the completion of repair and when operating the machine which is stored long term, perform the air bleeding with the same procedure as the one described above. Precautions at the time of completing work Refilling of coolant, oil and grease • When the coolant is drained, tighten the drain valve securely, then refill the coolant reservoir with the coolant Komatsu recommends to the specified level. Start the engine to circulate the coolant in the piping, and add the coolant to the specified level again. • When the hydraulic components are removed and installed, refill the oil reservoir with the oil Komatsu recommends to the specified level. Start the engine to circulate the oil in the piping, and add the oil to the specified level again. • If the hydraulic piping or hydraulic equipment is removed, be sure to bleed air from the system after rebuilding the parts, by referring to "Testing and adjusting". • Supply the specified amount of grease to the work equipment parts. Testing installed condition of cylinder heads and manifolds • Check the cylinder head and intake and exhaust manifold mountings for looseness. • If any bolt is loose, retighten it. a For the tightening torques, see the "Disassembly and assembly". Testing of engine piping for damage and looseness Check the piping for damage, the mounting bolts and nuts for looseness, and the joints Intake and exhaust for air suction and exhaust gas leakage. system If any part is loosely installed or damaged, retighten the bolts or repair the parts. Check the piping for damage, the mounting bolts and nuts for looseness, and the joints for water leakage. Cooling system If any part is loosely installed or damaged, retighten the bolts or repair the parts. Check the piping for damage, the mounting bolts and nuts for looseness, and the joints for fuel leakage. Fuel system If any part is loosely installed or damaged, retighten the bolts or repair the parts. Check of KDPF or muffler and exhaust pipe for damage and looseness • Visually check the KDPF or muffler, exhaust pipe and their mounting parts for a crack and damage. If any part is damaged, replace it. • Check the mounting bolts, nuts, and clamps of the KDPF or muffler, exhaust pipe and their mounting parts for looseness. If any part is loosely installed, retighten the bolts. Check of KDPF or muffler function • Check the KDPF or the muffler for unusual noise comparing to the noise when they are new. If any unusual noise is heard, repair KDPF or muffler, referring to "Troubleshooting" and "Disassembly and assembly".

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Practical use of KOMTRAX

1 (Rev. 2012/10)

KOMTRAX system transmits various machine information by use of the radio communication and KOMTRAX operator can refer this information in the office and provide various services to the customers. When KOMTRAX is installed on the machine, the machine information can be checked through the KOMTRAX system and the testing and troubleshooting can be performed efficiently. (KOMTRAX may not be installed on the machine in some countries or areas.) Merit of using KOMTRAX • The working place of the machine can be checked in the map on PC. • Operation information such as service meter reading, operating hours, fuel consumption, occurred caution and failure code can be checked. • The hours used and replacement time of consumable parts of the machine such as fuel filter, hydraulic oil filter, hydraulic oil and engine oil can be checked. • The information of machine working condition (idling time, traveling time, digging time, relieving time, etc.) can be checked and the machine operating condition can be presumed with these information. • Various reports such as "Fuel saving operation support", "Summary of operation", etc. can be generated and utilized as an advice as well for the user and operator. How to use KOMTRAX practically With KOMTRAX, following support activities will be available. 1. Quick response to sudden request of repair 1) When receiving a repair request from a user, check the displayed caution and failure code, etc. through KOMTRAX. 2) Arrange the necessary tools, replacement parts, etc, immediately in accordance with the displayed failure code. 3) By using the map of KOMTRAX, find the location of the failed machine and visit the customer there. 2. Proactive maintenance 1) Check the service summary screen of KOMTRAX, and find the machine which has high priority failure code indicated by a red or yellow flag. 2) Check the condition of the machine with the customer and make a plan to visit. 3) Arrange necessary tools, replacement parts, etc, immediately in accordance with the displayed failure code. 3. Practice of periodic maintenance and periodic inspection service 1) Check the service summary screen of KOMTRAX, and find the machine of which the usage limits for the consumable parts indicated by red flags are over. 2) Submit an estimate sheet for the consumable parts to be replaced and the labor cost for the replacement work to the customer. 3) Propose the periodic inspection (PM clinic, etc.) according to the service meter reading. How to operate KOMTRAX For the operating method of each screen of KOMTRAX, see "Global KOMTRAX Web Reference Manual (For Key Person)".

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Standard tightening torque table 1 (Rev. 2012/10) Table of tightening torque for bolts and nuts Unless otherwise specified, tighten the metric bolts and nuts to the torque shown in the table below.

Thread diameter (mm) 6 8 10 12 14 16 18 20 22 24 27 30 33 36 39

Width across flats (mm) 10 (*2) 10 13 (*2) 12 17 (*1, *2) 14 19 (*1, *2) 17 22 24 (*1) 22 27 30 32 36 41 46 50 55 60

Tightening torque (Nm {kgm}) 11.8 to 14.7 {1.2 to 1.5} 27 to 34 {2.8 to 3.5} 59 to 74 {6.0 to 7.5} 98 to 123 {10.0 to 12.5} 157 to 196 {16 to 20} 245 to 309 {25 to 31.5} 343 to 427 {35 to 43.5} 490 to 608 {50 to 62} 662 to 829 {67.5 to 84.5} 824 to 1,030 {84 to 105} 1,180 to 1,470 {120 to 150} 1,520 to 1,910 {155 to 195} 1,960 to 2,450 {200 to 250} 2,450 to 3,040 {250 to 310} 2,890 to 3,630 {295 to 370}

*1: Split flange bolt. *2: Flanged bolt.

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a Tighten the following flanged bolt on which "7" is stamped on its top to the tightening torque shown in the following table.

Thread diameter (mm) 6 8 10 12

Width across flats (mm) 10 12 14 17

Tightening torque (Nm {kgm}) 5.9 to 9.8 {0.6 to 1.0} 13.7 to 23.5 {1.4 to 2.4} 34.3 to 46.1 {3.5 to 4.7} 74.5 to 90.2 {7.6 to 9.2}

Unless otherwise specified, tighten the unified coarse threaded bolts and nuts to the torque shown in the table below.

Type of bolt Nominal No. threads per inch, type of thread 1/4-20UNC 5/16-18UNC 3/8-16UNC 7/16-14UNC 1/2-13UNC 9/16-12UNC 5/8-11UNC 3/4-10UNC 7/8-9UNC 1-8UNC 1 1/8-7UNC 1 1/4-7UNC 1 1/2-6UNC

D61EM-23M0

A Tightening torque (Nm {kgm})

B Tightening torque (Nm {kgm})

Range

Target

Range

Target

9.8 to 14.7 {1 to 1.5} 24.5 to 34.3 {2.5 to 3.5} 44.1 to 58.8 {4.5 to 6} 73.5 to 98.1 {7.5 to 10} 108 to 147 {11 to 15} 157 to 216 {16 to 22} 226 to 294 {23 to 30} 392 to 530 {40 to 54} 637 to 853 {65 to 87} 883 to 1,196 {90 to 122} 1,187 to 1,608 {121 to 164} 1,598 to 2,157 {163 to 220} 2,354 to 3,177 {240 to 324}

12.7 {1.3} 29.4 {3} 52.0 {5.3} 86.3 {8.8} 127 {13} 186 {19} 265 {27} 461 {47} 745 {76} 1,040 {106} 1,393 {142} 1,873 {191} 2,765 {282}

2.9 to 3.9 {0.3 to 0.4} 6.9 to 8.8 {0.7 to 0.9} 9.8 to 14.7 {1 to 1.5} 19.6 to 24.5 {2 to 2.5} 29.4 to 39.2 {3 to 4} 44.1 to 58.8 {4.5 to 6} 63.7 to 83.4 {6.5 to 8.5} 108 to 147 {11 to 15} 177 to 235 {18 to 24} 245 to 333 {25 to 34} 333 to 451 {34 to 46} 451 to 608 {46 to 62} 657 to 892 {67 to 91}

3.43 {0.35} 7.8 {0.8} 11.8 {1.2} 21.6 {2.2} 34.3 {3.5} 51.0 {5.2} 68.6 {7} 127 {13} 206 {21} 284 {29} 392 {40} 530 {54} 775 {79}

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Unless otherwise specified, tighten the unified fine threaded bolts and nuts to the torque shown in the table below.

Type of bolt Nominal No. threads per inch, type of thread 1/4-28UNF 5/16-24UNF 3/8-24UNF 7/16-20UNF 1/2-20UNF 9/16-18UNF 5/8-18UNF 3/4-16UNF 7/8-14UNF 1-14UNF 1 1/8-12UNF 1 1/4-12UNF 1 1/2-12UNF

A Tightening torque (Nm {kgm})

B Tightening torque (Nm {kgm})

Range

Target

Range

Target

14.7 to 19.6 {1.5 to 2} 34.3 to 39.2 {3.5 to 4} 53.9 to 68.6 {5.5 to 7} 83.4 to 108 {8.5 to 11} 127 to 167 {13 to 17} 186 to 245 {19 to 25} 255 to 343 {26 to 35} 441 to 598 {45 to 61} 716 to 961 {73 to 98} 1,020 to 1,373 {104 to 140} 1,353 to 1,844 {138 to 188} 1,804 to 2,432 {184 to 248} 2,707 to 3,658 {276 to 373}

17.7 {1.8} 37.3 {3.8} 61.8 {6.3} 96.1 {9.8} 147 {15} 216 {22} 294 {30} 520 {53} 843 {86} 1,196 {122} 1,598 {163} 2,118 {216} 3,177 {324}

3.9 to 4.9 {0.4 to 0.5} 7.8 to 9.8 {0.8 to 1} 14.7 to 19.6 {1.5 to 2} 24.5 to 29.4 {2.5 to 3} 34.3 to 49.0 {3.5 to 5} 49.0 to 68.6 {5 to 7} 73.5 to 98.1 {7.5 to 10} 127 to 167 {13 to 17} 196 to 265 {20 to 27} 284 to 382 {29 to 39} 382 to 520 {39 to 53} 510 to 686 {52 to 70} 765 to 1,030 {78 to 105}

4.41 {0.45} 8.8 {0.9} 16.7 {1.7} 26.5 {2.7} 41.2 {4.2} 58.6 {6} 83.4 {8.5} 147 {15} 226 {23} 333 {34} 451 {46} 598 {61} 892 {91}

Table of tightening torque for O-ring boss piping joints a Unless otherwise specified, tighten the pipe joint for O-ring boss to the torque shown in the table below.

Nominal No. 02 — 03, 04 05, 06 00-50

Thread diameter (mm) 14 18 20 24

Width across flats (mm)

Range

Target

Varies depending on type of connector.

35 to 63 {3.5 to 6.5} 59 to 98 {6.0 to 10.0} 84 to 132 {8.5 to 13.5} 128 to 186 {13.0 to 19.0}

44 {4.5} 78 {8.0} 103 {10.5} 157 {16.0}

Tightening torque (Nm {kgm})

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Nominal No. 10, 12 14

Thread diameter (mm) 33 42

Width across flats (mm)

Tightening torque (Nm {kgm}) Range

Target

363 to 480 {37.0 to 49.0} 746 to 1,010 {76.0 to 103}

422 {43.0} 883 {90.0}

Table of tightening torque for O-ring boss plugs a Unless otherwise specified, tighten the plug for O-ring boss to the torque shown in the table below.

Nominal No. 08 10 12 14 16 18 20 24 30 33 36 42 52

Thread diameter (mm) 8 10 12 14 16 18 20 24 30 33 36 42 52

Width across flats (mm) 14 17 19 22 24 27 30 32 32 — 36 — —

Tightening torque (Nm {kgm}) Range

Target

5.88 to 8.82 {0.6 to 0.9} 9.8 to 12.74 {1.0 to 1.3} 14.7 to 19.6 {1.5 to 2.0} 19.6 to 24.5 {2.0 to 2.5} 24.5 to 34.3 {2.5 to 3.5} 34.3 to 44.1 {3.5 to 4.5} 44.1 to 53.9 {4.5 to 5.5} 58.8 to 78.4 {6.0 to 8.0} 93.1 to 122.5 {9.5 to 12.5} 107.8 to 147.0 {11.0 to 15.0} 127.4 to 176.4 {13.0 to 18.0} 181.3 to 240.1 {18.5 to 24.5} 274.4 to 367.5 {28.0 to 37.5}

7.35 {0.75} 11.27 {1.15} 17.64 {1.8} 22.54 {2.3} 29.4 {3.0} 39.2 {4.0} 49.0 {5.0} 68.6 {7.0} 107.8 {11.0} 127.4 {13.0} 151.9 {15.5} 210.7 {21.5} 323.4 {33.0}

Table of tightening torque for hose (taper seal type and face seal type) a Unless otherwise specified, tighten the hose fittings (taper seal type and face seal type) to the torque shown in the table below. a The table is applied to the threads coated with engine oil (wet threads)

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Nominal No. of hose

Width across flats (mm)

03 04 05 06 (10) (12) (14)

22 24 27 32 36 41 46 55

Tightening torque (Nm {kgm})

Taper seal

Range

Target

34 to 54 {3.5 to 5.5} 34 to 63 {3.5 to 6.5} 54 to 93 {5.5 to 9.5} 59 to 98 {6.0 to 10.0} 84 to 132 {8.5 to 13.5} 128 to 186 {13.0 to 19.0} 177 to 245 {18.0 to 25.0} 177 to 245 {18.0 to 25.0} 197 to 294 {20.0 to 30.0} 246 to 343 {25.0 to 35.0}

44 {4.5} 44 {4.5} 74 {7.5} 78 {8.0} 103 {10.5} 157 {16.0} 216 {22.0} 216 {22.0} 245 {25.0} 294 {30.0}

Face seal Nominal No. - Thread root diameter Thread size threads per (mm) inch, type of (mm) (reference) thread 9 — /16-18UN 14.3 — — 14 11/16-16UN — 17.5 — — 18 13/16-16UN 20.6 22 24 1 -14UNS 25.4 3 30 1 /16-12UN 30.2 — — 33 — — 36 — — 42

Table of tightening torque for face seal joints a The tightening torque table below applies to the seal joint (sleeve nut type) a The table is applied to the threads coated with engine oil (wet threads).

Width Outside diameter of across flats (mm) pipe (mm) 8 10 12 15 {16} 22 {20}

19 22 24 {27} 30 {32} 36

Tightening torque (Nm {kgm}) Range

Target

14 to 16 {1.4 to 1.6} 24 to 27 {2.4 to 2.7} 43 to 47 {4.4 to 4.8} 60 to 68 {6.1 to 6.8} 90 to 95 {9.2 to 9.7}

15 {1.5} 25.5 {2.6} 45 {4.6} 64 {6.5} 92.5 {9.4}

Face seal Thread root Nominal No. threads per inch, diameter (mm) (reference) type of thread 9/16-18UN 14.3 11/16-16UN 17.5 13/16-16UN 20.6 1 -14UNS 25.4 1 3/16-12UN 30.2

Reference: The face seal joint of the dimension in ( ) is also used, depending on the specification. Tightening torque table for bolts and nuts on 102,107 and 114 series engines a Unless otherwise specified, tighten the metric threads bolts and nuts used on the 102, 107 and 114 series engines to the torques shown in the table below. Thread diameter (mm) 6 8 10 12 14

00-52

Tightening torque (Nm {kgm}) 10 ± 2 {1.02 ± 0.20} 24 ± 4 {2.45 ± 0.41} 43 ± 6 {4.38 ± 0.61} 77 ± 12 {7.85 ± 1.22} —

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Tightening torque table for 102, 107, and 114 series engines (joint bolts) a Unless otherwise specified, tighten the metric joint bolts used on the 102, 107, and 114 series engines to the torque shown in the table below.

Thread diameter (mm) 6 8 10 12 14

Tightening torque (Nm {kgm}) 8 ± 2 {0.81 ± 0.20} 10 ± 2 {1.02 ± 0.20} 12 ± 2 {1.22 ± 0.20} 24 ± 4 {2.45 ± 0.41} 36 ± 5 {3.67 ± 0.51}

Tightening torque table for tapered screws on 102,107, and 114 series engines (National taper pipe thread (NPT)) a Unless otherwise specified, tighten the National taper pipe threaded (NPT) screws used on the 102, 107, and 114 series engines to the torques shown in the table below. Material of female screw Nominal thread size 1/16 1/ 8 1/ 4 3/ 8 1/ 2 3/ 4

D61EM-23M0

In cast iron or steel Tightening torque (Nm {kgm}) 15 ± 2 {1.53 ± 0.20} 20 ± 2 {2.04 ± 0.20 25 ± 3 {2.55 ± 0.31} 35 ± 4 {3.57 ± 0.41} 55 ± 6 {5.61 ± 0.61} 75 ± 8 {7.65 ± 0.82}

In aluminum Tightening torque (Nm {kgm}) 5 ± 1 {0.51 ± 0.10} 15 ± 2 {1.53 ± 0.20} 20 ± 2 {2.04 ± 0.20} 25 ± 3 {2.55 ± 0.31} 35 ± 4 {3.57 ± 0.41} 45 ± 5 {4.59 ± 0.51}

00-53

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List of abbreviation

1 (Rev. 2013/03)

• This list of abbreviations includes the abbreviations used in the text of the shop manual for parts, components, and functions whose meaning is not immediately clear. The spelling is given in full with an outline of the meaning. • Abbreviations that are used in general society may not be included. • Special abbreviations which appear infrequently are noted in the text (marked with a). • This list of abbreviations consists of 2 parts. The first part is a list of the abbreviations used in the text of the manual, and the second part is a list of the abbreviations used in the circuit diagrams. List of abbreviations used in the shop manual Abbreviation

ABS

AISS

AJSS

ARAC

ARSC

ASR ATT BCV CAN CDR

CLSS

CRI

ECM

00-54

Actual word spelled out

Purpose of use (major applicable machine (*), or equipment/device)

Explanation

With this function, when the tires skid (wheels stop rotating), the brakes are released, and when the wheels start to rotate, the brakes are applied again. Automatic Idling This function automatically sets the idle Engine Setting System speed. A lever is used to perform the steering Steering operations instead of a steering wheel. Advanced Joystick Steering System Moreover, it shifts gear and changes direction (WA) (FORWARD or REVERSE). When the accelerator pedal is released while Travel and brake the machine is traveling downhill, this function Automatic Retarder automatically applies the retarder with a Accelerator Control (HD, HM) constant braking force. When the accelerator pedal is released while the machine is traveling downhill, this function Travel and brake Automatic Retarder automatically applies the retarder to ensure Speed Control (HD, HM) that the machine speed does not accelerate above the speed set by the operator. When the tires spin on soft ground surfaces, Travel and brake Automatic Spin this function automatically uses the optimum Regulator (HD, HM) braking force to drive both wheels. A device that can be fixed onto a machine in Work equipment Attachment order to enable it to do different jobs. When the retarder is not being used, this Brake Brake cooling oil valve bypasses part of the brake cooling oil to control valve (HD) reduce the load on the hydraulic pump. Controller Area Communication and One of communication standards that is used Network electronic control in the network on the machine. A regulator valve which is installed to KCCV Crankcase Depression Engine ventilator. It is written as CDR valve and it is Regulator not used independently. This system can simultaneously actuate multiple actuators regardless of the load Closed-center Load Hydraulic system (provides better combined operation than O.L. Sensing System S.S.). Engine controller electronically controls supply pump, common rail, and injector. This Common Rail Injection Engine function maintains optimum fuel injection amount and fuel injection timing. Electronic control device uses the signals from the sensors on the machine. This signal Electronic Control Electronic control system indicates the optimum actuation to the Module actuators. (Same as E.C.U.) Anti-skid Brake System

Travel and brake (HD, HM)

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Abbreviation ECMV

ECSS

ECU

EGR

EMMS EPC

FOPS

F-N-R GNSS GPS

HSS

Actual word spelled out

Purpose of use (major applicable machine (*), or equipment/device)

Proportional electromagnetic valve that gradually increases oil pressure to engage clutch and reduces transmission shock. This system ensures smooth high-speed Electronically Travel travel by absorbing vibration of machine Controlled Suspension during travel with hydraulic spring effect of (WA) System accumulator. Electronic control device uses the signals from the sensors on the machine. This signal Electronic Control Unit Electronic control system indicates the optimum actuation to the actuators. (Same as E.C.M.) This function recirculates part of exhaust gas to combustion chamber in order to reduce Exhaust Gas Engine combustion temperature, controls emission of Recirculation NOx. This system allows data (filter, oil replacement Equipment interval, malfunctions on machine, failure Management Machine monitor code, and failure history) from each sensor on Monitoring System the machine to be checked on the monitor. Electromagnetic This mechanism allows actuators to be Hydraulic system Proportional Control operated in proportion to the current supplied. This structure protects the operator's head from falling objects. (Falling Object Protective Falling Object Structure) Cab and canopy Protective Structure This performance is standardized as ISO 3449. Forward-NeutralOperation Forward-Neutral-Reverse Reverse Global Navigation A general term for positioning system using Communication Satellite System satellites such as GPS, GALILEO, etc. Communication Global Positioning This system uses satellites to determine the (KOMTRAX, KOMTRAX current location on the earth. System Plus) This function uses a combination of hydraulic motor and bevel shaft to control difference in Steering Hydrostatic Steering travel speed of right and left tracks. System (D) Accordingly machine can turn without using Electronic Control Modulation Valve

Transmission (D, HD, WA, etc.)

HST

Hydro Static Transmission

Transmission (D, WA)

ICT

Information and Communication Technology

Intelligent Machine Control

IMA

Inlet Metering Actuator Engine

IMU

Inertial Measurement Unit

Intelligent Machine Control

IMV

Inlet Metering Valve

Engine

KCCV

Komatsu Closed Engine Crankcase Ventilation

D61EM-23M0

Explanation

steering clutch. This function uses a combination of hydraulic pump and hydraulic motor to shift the speed range steplessly without using gears. A general term for the engineering and its socially applied technology of information processing and communication. This valve is installed at inlet port of pump, and it adjusts fuel intake amount in order to control fuel discharge of supply pump. Same as I.M.V. This is a device to detect the angular velocity and acceleration of the 3 axes that control motions. This valve is installed at inlet port of pump, and it adjusts fuel intake amount in order to control fuel discharge of supply pump. Same as I.M.V. (I.M.A.) This mechanism separates oil in blowby gas and returns it to the intake side to afterburn it there. It primarily consists of filters. 00-55

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Foreword, safety and general information

Abbreviation

Actual word spelled out

Purpose of use (major applicable machine (*), or equipment/device)

KCSF

Komatsu Catalyzed Soot Filter

Engine

KDOC

Komatsu Diesel Oxidation Catalyst

Engine

KDPF

Komatsu Diesel Particulate Filter

Engine

KTCS

Komatsu Traction Control System

Travel and brake (HM system)

KVGT

Komatsu Variable Geometry Turbocharger

Engine

LCD

Liquid Crystal Display

Machine monitor

LED

Light Emitting Diode

Electronic parts

LIN

Local Interconnect Network

Communication and electronic control

Load Sensing

Hydraulic system

LVDS

Low Voltage Differential Signaling

Communication and electronic control

MAF

Mass Air Flow

Engine

MMS

Multimedia Messaging Communication Service

Normally Closed

Electric and hydraulic systems

Normally Open

Electric and hydraulic systems

OLSS

Open-center Load Sensing System

Hydraulic system

Pressure Compensation

Hydraulic system

PCCS

Palm command control Steering system (D)

PCV

Pre-stroke Control Valve

00-56

Engine

Explanation This filter captures soot in exhaust gas. It is built in to KDPF. The catalyst used for purifying exhaust gas. This is built in KDPF or assembled with the muffler. This component is used to purify the exhaust gas. KDOC (catalyst) and KCSF (filter to capture soot) are built-in it. It is installed in place of the conventional muffler. This function recovers the drive force of the wheels by braking automatically with the optimum force and at the same time activates the inter-axle differential lock when the wheels idle while the machine travels on the soft ground road. The turbocharger on which the cross-section area of the exhaust passage is made variable. Image display equipment such as a monitor which assembles in the liquid crystal element. It refers to semiconductor element that emits light when the voltage is applied in forward direction. One of communication standards that is used in the network on the machine Function that detects differential pressure of pump and controls discharge amount corresponding to load. One of communication standards that is used in the network on the machine This indicates engine intake air flow.It is not used independently but it is used as combined with sensor.Mass air flow sensor can be called as MAF sensor. Service that allows transmission and reception of short messages consisting of characters or voice or images between cell phones. Device actuated to open electric or hydraulic circuits that are normally closed if not actuated. Device actuated to close electric or hydraulic circuits that are normally open if not actuated. Hydraulic system that can operate multiple actuators at the same time, regardless of the load. A function used to correct oil pressure. System in which a controller instantly analyses data from each lever, pedal, and dial, and performs optimum electronic control of the engine and transmission. This valve is installed at inlet port of pump and it adjusts fuel intake amount in order to control fuel discharge amount of supply pump.

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Abbreviation PPC PPM PTO PTP

ROPS

Actual word spelled out

Purpose of use (major applicable machine (*), or equipment/device)

Proportional Pressure Hydraulic system Control Piston Pump and Motor Power Take Off Power Tilt and power Pitch dozer

Hydraulic system (D, PC, etc.) Power transmission Work equipment (D)

Roll-Over Protective Structure

Cab and canopy

Le Systeme International d’ Unites Unit (International unit system)

SOL

Solenoid

Electric system

TWV

2-Way Valve

Hydraulic and electric systems

VFT

Variable Flow Turbocharger

Engine

Explanation Used for controlling proportional pressure. This system moves actuators in proportion to the oil pressure. Piston pump and motor. Power take-off mechanism This function performs hydraulic control of the tilt and pitch of the bulldozer blade. If a machine tips over, this structure protects the operator with the seat belt fastened from being crushed. (Operator Protective Structure When Tipping) This performance is standardized as ISO 3471. Abbreviation for the "International System of Units". It is the universal unit system and "a single unit for a single quantity" is the basic principle applied. It refers to an actuator consisting of a solenoid and an iron core that is moved by the magnetic force when the solenoid is energized. Solenoid valve that switches over direction of flow. Turbocharger variable in route of exhaust passage.

*1: Code for applicable machine family D: Bulldozer HD: Dump truck HM: Articulated dump truck PC: Hydraulic excavator WA: Wheel loader List of abbreviations used in the circuit diagrams Abbreviation A/C A/D A/M ACC ADD AUX BR CW CCW ECU ECM ENG EXGND F.G. GND IMA NC D61EM-23M0

Actual word spelled out Air Conditioner Analogue-to-Digital Air Mix Damper Accessory Additional Auxiliary Battery Relay Clockwise Counter Clockwise Electronic Control Unit Electronic Control Module Engine External Ground Frame Ground Ground Inlet Metering Actuator No Connection 00-57

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Foreword, safety and general information

Abbreviation S/T STRG SIG SOL STD OPT OP PRESS SPEC SW TEMP T/C T/M

00-58

Actual word spelled out Steering Signal Solenoid Standard Option Pressure Specification Switch Temperature Torque Converter Transmission

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Conversion table

1 (Rev. 2012/10)

Method of using the conversion table • The unit conversion table enables the simple conversion in the figures between the different units. For further details of the method of use of the conversion table, see the examples given below. Example: Method of using the conversion table to convert a unit from millimeters to inches Conversion of 55 mm into inches 1. Locate the number 50 in the vertical column at the left side, take this as (A), and then draw a horizontal line from (A). 2. Locate the number 5 in the row across the top, take this as (B), then draw a vertical line down from (B). 3. Take the point where the 2 lines cross as (C). This point (C) gives the value when converting the unit from millimeters to inches. Therefore, 55 mm = 2.165 in. Conversion of 550 mm into inches 1. The number 550 does not appear in the table, so divide it by 10 (move the decimal point one place to the left) to get 55 mm. 2. Then convert 55 mm to 2.165 in by the same procedure as above. 3. The original value (550 mm) was divided by 10, so multiply 2.165 inches by 10 (move the decimal point one place to the right) to get the original value. This gives 550 mm = 21.65 in. Therefore, 550 mm = 21.65 in. Millimeters to inches (B)

(A)

0 10 20 30 40

0 0 0.394 0.787 1.181 1.575

1 0.039 0.433 0.827 1.220 1.614

2 0.079 0.472 0.866 1.260 1.654

3 0.118 0.512 0.906 1.299 1.693

4 0.157 0.551 0.945 1.339 1.732

50 60 70 80 90

1.969 2.362 2.756 3.150 3.543

2.008 2.402 2.795 3.189 3.583

2.017 2.441 2.835 3.228 3.622

2.087 2.480 2.847 3.268 3.661

2.126 2.520 2.913 3.307 3.701

D61EM-23M0

5 0.197 0.591 0.984 1.378 1.772 (C) 2.165 2.559 2.953 3.346 3.740

6 0.236 0.630 1.024 1.417 1.811

7 0.276 0.669 1.063 1.457 1.850

2.205 2.598 2.992 3.386 3.780

2.244 2.638 3.032 3.425 3.819

1 mm = 0.03937 in 8 9 0.315 0.354 0.709 0.748 1.102 1.142 1.496 1.536 1.890 1.929 2.283 2.677 3.071 3.465 3.858

2.323 2.717 3.110 3.504 3.898

00-59

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Millimeters to inches

0 10 20 30 40 50 60 70 80 90

0 0 0.394 0.787 1.181 1.575 1.969 2.362 2.756 3.150 3.543

2 0.079 0.472 0.866 1.260 1.654 2.047 2.441 2.835 3.228 3.622

3 0.118 0.512 0.906 1.299 1.693 2.087 2.480 2.847 3.268 3.661

4 0.157 0.551 0.945 1.339 1.732 2.126 2.520 2.913 3.307 3.701

5 0.197 0.591 0.984 1.378 1.772 2.165 2.559 2.953 3.346 3.740

6 0.236 0.630 1.024 1.417 1.811 2.205 2.598 2.992 3.386 3.780

7 0.276 0.669 1.063 1.457 1.850 2.244 2.638 3.032 3.425 3.819

1 mm = 0.03937 in 8 9 0.315 0.354 0.709 0.748 1.102 1.142 1.496 1.536 1.890 1.929 2.283 2.323 2.677 2.717 3.071 3.110 3.465 3.504 3.858 3.898

1 2.20 24.25 46.30 68.34 90.39 112.44 134.48 156.53 178.57 200.62

2 4.41 26.46 48.50 70.55 92.59 114.64 136.69 158.73 180.78 202.83

3 6.61 28.66 50.71 72.75 94.80 116.85 138.89 160.94 182.98 205.03

4 8.82 30.86 51.91 74.96 97.00 119.05 141.10 163.14 185.19 207.24

5 11.02 33.07 55.12 77.16 99.21 121.25 143.30 165.35 187.39 209.44

6 13.23 35.27 57.32 79.37 101.41 123.46 145.51 167.55 189.60 211.64

7 15.43 37.48 59.53 81.57 103.62 125.66 147.71 169.76 191.80 213.85

1 kg = 2.2046 lb 8 9 17.64 19.84 39.68 41.89 61.73 63.93 83.78 85.98 105.82 108.03 127.87 130.07 149.91 152.12 171.96 174.17 194.01 196.21 216.05 218.26

1 0.264 2.906 5.548 8.189 10.831 13.473 16.115 18.756 21.398 24.040

2 0.528 3.170 5.812 8.454 11.095 13.737 16.379 19.020 21.662 24.304

3 0.793 3.434 6.076 8.718 11.359 14.001 16.643 19.285 21.926 24.568

4 1.057 3.698 6.340 8.982 11.624 14.265 16.907 19.549 22.190 24.832

5 1.321 3.963 6.604 9.246 11.888 14.529 17.171 19.813 22.455 25.096

6 1.585 4.227 6.869 9.510 12.152 14.795 17.435 20.077 22.719 25.361

1 l = 0.2642 U.S.Gal 7 8 9 1.849 2.113 2.378 4.491 4.755 5.019 7.133 7.397 7.661 9.774 10.039 10.303 12.416 12.680 12.944 15.058 15.322 15.586 17.700 17.964 18.228 20.341 20.605 20.870 22.983 23.247 23.511 25.625 25.889 26.153

1 0.039 0.433 0.827 1.220 1.614 2.008 2.402 2.795 3.189 3.583

Kilograms to pounds

0 10 20 30 40 50 60 70 80 90

0 0 22.05 44.09 66.14 88.18 110.23 132.28 154.32 176.37 198.42

l to U.S. Gallons

0 10 20 30 40 50 60 70 80 90

00-60

0 0 2.642 5.283 7.925 10.567 13.209 15.850 18.492 21.134 23.775

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l to U.K. Gallons

0 10 20 30 40 50 60 70 80 90

0 0 2.200 4.399 6.599 8.799 10.998 13.198 15.398 17.598 19.797

1 0.220 2.420 4.619 6.819 9.019 11.281 13.418 15.618 17.818 20.017

2 0.440 2.640 4.839 7.039 9.239 11.438 13.638 15.838 18.037 20.237

3 0.660 2.860 5.059 7.259 9.459 11.658 13.858 16.058 18.257 20.457

4 0.880 3.080 5.279 7.479 9.679 11.878 14.078 16.278 18.477 20.677

5 1.100 3.300 5.499 7.699 9.899 12.098 14.298 16.498 18.697 20.897

6 1.320 3.520 5.719 7.919 10.119 12.318 14.518 16.718 18.917 21.117

1 l = 0.21997 U.K.Gal 7 8 9 1.540 1.760 1.980 3.740 3.950 4.179 5.939 6.159 6.379 8.139 8.359 8.579 10.339 10.559 10.778 12.528 12.758 12.978 14.738 14.958 15.178 16.938 17.158 17.378 19.137 19.357 19.577 21.337 21.557 21.777

6 43.4 115.7 188.1 260.4 332.7 405.1 477.4 549.7 622.0 694.4 766.7 839.0 911.4 983.7 1,056 1,128 1,201 1,273 1,345 1,418

1 kgm = 7.233 ft.lb 8 9 57.9 65.1 130.2 137.4 202.5 209.8 274.9 282.1 347.2 354.4 419.5 426.8 491.8 499.1 564.2 571.4 636.5 643.7 708.8 716.1 781.2 788.4 853.5 860.7 925.8 933.1 1,005 998.2 1,071 1,078 1,143 1,150 1,215 1,222 1,288 1,295 1,360 1,367 1,432 1,439

kgm to ft.lb

0 10 20 30 40 50 60 70 80 90 100 110 120 130 140 150 160 170 180 190

D61EM-23M0

0 0 72.3 144.7 217.0 289.3 361.7 434.0 506.3 578.6 651.0 723.3 795.6 868.0 940.3 1,013 1,085 1,157 1,130 1,302 1,374

1 7.2 79.6 151.9 224.2 296.6 368.9 441.2 513.5 585.9 658.2 730.5 802.9 875.2 947.5 1,020 1,092 1,165 1,237 1,309 1,382

2 14.5 86.8 159.1 231.5 303.8 376.1 448.5 520.8 593.1 665.4 737.8 810.1 882.4 954.8 1,027 1,099 1,172 1,244 1,316 1,389

3 21.7 94.0 166.4 238.7 311.0 383.4 455.7 528.0 600.3 672.7 745.0 817.3 889.7 962.0 1,034 1,107 1,179 1,251 1,324 1,396

4 28.9 101.3 173.6 245.9 318.3 390.6 462.9 535.2 607.6 679.9 752.2 824.6 896.9 969.2 1,042 1,114 1,186 1,259 1,331 1,403

5 36.2 108.5 180.8 253.2 325.5 397.8 470.2 542.5 614.8 687.1 759.5 831.8 904.1 976.5 1,049 1,121 1,193 1,266 1,338 1,410

7 50.6 123.0 195.3 267.6 340.0 412.3 484.6 556.9 629.3 701.6 773.9 846.3 918.6 990.9 1,063 1,136 1,208 1,280 1,353 1,425

00-61

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kg/cm2 to lb/in2

0 10 20 30 40 50 60 70 80 90 100 110 120 130 140 150 160 170 180 190 200 210 220 230 240

00-62

0 0 142.2 284.5 426.7 568.9 711.2 853.4 995.6 1,138 1,280 1,422 1,565 1,707 1,849 1,991 2,134 2,276 2,418 2,560 2,702 2,845 2,987 3,129 3,271 3,414

1 14.2 156.5 298.7 440.9 583.2 725.4 867.6 1,010 1,152 1,294 1,437 1,579 1,721 1,863 2,005 2,148 2,290 2,432 2,574 2,717 2,859 3,001 3,143 3,286 3,428

2 28.4 170.7 312.9 455.1 597.4 739.6 881.8 1,024 1,166 1,309 1,451 1,593 1,735 1,877 2,020 2,162 2,304 2,446 2,589 2,731 2,873 3,015 3,158 3,300 3,442

3 42.7 184.9 327.1 469.4 611.6 753.8 896.1 1,038 1,181 1,323 1,465 1,607 1,749 1,892 2,034 2,176 2,318 2,460 2,603 2,745 2,887 3,030 3,172 3,314 3,456

4 56.9 199.1 341.4 483.6 625.8 768.1 910.3 1,053 1,195 1,337 1,479 1,621 1,764 1,906 2,048 2,190 2,333 2,475 2,617 2,759 2,901 3,044 3,186 3,328 3,470

5 71.1 213.4 355.6 497.8 640.1 782.3 924.5 1,067 1,209 1,351 1,493 1,636 1,778 1,920 2,062 2,205 2,347 2,489 2,631 2,773 2,916 3,058 3,200 3,343 3,485

6 85.3 227.6 369.8 512.0 654.3 796.5 938.7 1,081 1,223 1,365 1,508 1,650 1,792 1,934 2,077 2,219 2,361 2,503 2,646 2,788 2,930 3,072 3,214 3,357 3,499

1 kg/cm2 = 14.2233 lb/in2 7 8 9 99.6 113.8 128.0 241.8 256.0 270.2 384.0 398.3 412.5 526.3 540.5 554.7 668.5 682.7 696.9 810.7 825.0 839.2 953.0 967.2 981.4 1,095 1,109 1,124 1,237 1,252 1,266 1,380 1,394 1,408 1,522 1,536 1,550 1,664 1,678 1,693 1,806 1,821 1,835 1,949 1,963 1,977 2,091 2,105 2,119 2,233 2,247 2,262 2,375 2,389 2,404 2,518 2,532 2,546 2,660 2,674 2,688 2,802 2,816 2,830 2,944 2,958 2,973 3,086 3,101 3,115 3,229 3,243 3,257 3,371 3,385 3,399 3,513 3,527 3,542

D61EM-23M0

00 Index and foreword

Foreword, safety and general information

Temperature Conversion of Fahrenheit to Celsius • A simple way to convert a Fahrenheit temperature reading into a Celsius temperature reading or vice versa is to see the number in the center column of the following table. The figures on the following table show the temperatures in both Fahrenheit and Celsius. • When converting from Fahrenheit to Celsius degrees, consider the center column to be a table of Fahrenheit temperatures and read the corresponding Celsius temperature in the column at the left. • When converting from Celsius to Fahrenheit degrees, consider the center column to be a table of Celsius values, and read the corresponding Fahrenheit temperature on the right. °C -40.4 -37.2 -34.4 -31.7 -28.9 -28.3 -27.8 -27.2 -26.7 -26.1 -25.6 -25.0 -24.4 -23.9 -23.3 -22.8 -22.2 -21.7 -21.1 -20.6 -20.0 -19.4 -18.9 -18.3 -17.8 -17.2 -16.7 -16.1 -15.6 -15.0 -14.4 -13.9 -13.3 -12.8 -12.2

D61EM-23M0

-40 -35 -30 -25 -20 -19 -18 -17 -16 -15 -14 -13 -12 -11 -10 -9 -8 -7 -6 -5 -4 -3 -2 -1 0 1 2 3 4 5 6 7 8 9 10

°F -40.0 -31.0 -22.0 -13.0 -4.0 -2.2 -0.4 1.4 3.2 5.0 6.8 8.6 10.4 12.2 14.0 15.8 17.6 19.4 21.2 23.0 24.8 26.6 28.4 30.2 32.0 33.8 35.6 37.4 39.2 41.0 42.8 44.6 46.4 48.2 50.0

°C -11.7 -11.1 -10.6 -10.0 -9.4 -8.9 -8.3 -7.8 -7.2 -6.7 -6.1 -5.6 -5.0 -4.4 -3.9 -3.3 -2.8 -2.2 -1.7 -1.1 -0.6 0 0.6 1.1 1.7 2.2 2.8 3.3 3.9 4.4 5.0 5.6 6.1 6.7 7.2

11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30 31 32 33 34 35 36 37 38 39 40 41 42 43 44 45

°F 51.8 53.6 55.4 57.2 59.0 60.8 62.6 64.4 66.2 68.0 69.8 71.6 73.4 75.2 77.0 78.8 80.6 82.4 84.2 86.0 87.8 89.6 91.4 93.2 95.0 96.8 98.6 100.4 102.2 104.0 105.8 107.6 109.4 111.2 113.0

°C 7.8 8.3 8.9 9.4 10.0 10.6 11.1 11.7 12.2 12.8 13.3 13.9 14.4 15.0 15.6 16.1 16.7 17.2 17.8 18.3 18.9 19.4 20.0 20.6 21.1 21.7 22.2 22.8 23.3 23.9 24.4 25.0 25.6 26.1 26.7

46 47 48 49 50 51 52 53 54 55 56 57 58 59 60 61 62 63 64 65 66 67 68 69 70 71 72 73 74 75 76 77 78 79 80

°F 114.8 116.6 118.4 120.2 122.0 123.8 125.6 127.4 129.2 131.0 132.8 134.6 136.4 138.2 140.0 141.8 143.6 145.4 147.2 149.0 150.8 152.6 154.4 156.2 158.0 159.8 161.6 163.4 165.2 167.0 168.8 170.6 172.4 174.2 176.0

°C 27.2 27.8 28.3 28.9 29.4 30.0 30.6 31.1 31.7 32.2 32.8 33.3 33.9 34.4 35.0 35.6 36.1 36.7 37.2 37.8 40.6 43.3 46.1 48.9 51.7 54.4 57.2 60.0 62.7 65.6 68.3 71.1 73.9 76.7 79.4

1°C = 33.8°F °F 81 177.8 82 179.6 83 181.4 84 183.2 85 185.0 86 186.8 87 188.6 88 190.4 89 192.2 90 194.0 91 195.8 92 197.6 93 199.4 94 201.2 95 203.0 96 204.8 97 206.6 98 208.4 99 210.2 100 212.0 105 221.0 110 230.0 115 239.0 120 248.0 125 257.0 130 266.0 135 275.0 140 284.0 145 293.0 150 302.0 155 311.0 160 320.0 165 329.0 170 338.0 175 347.0

00-63

00 Index and foreword

Foreword, safety and general information

00-64

D61EM-23M0

SHOP MANUAL

D61E -23M0 Model

Serial Number

D61E -23M0

B 0001 and up

01 Specification 2 01 Specification

D61EM-23M0

01-1

01 Specification Table of contents

Table of contents

01 Specification - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 01-1 Table of contents - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 01-2 Specifications - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 01-3 Specification drawing - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 01-3 Specifications- - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 01-4 Weight table- - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 01-9 Table of fuel, coolant, and lubricants- - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 01-11

01-2

D61EM-23M0

01 Specification Specifications

Specifications

Specification drawing

D61EM-23M0

Planter head with ROPS cab

Item Machine weight Engine model Engine rated horsepower • SAE J1995 (gross) (*1) • ISO 14396 • ISO 9249/SAE J1349 (net) (*2) A Overall length Overall height (including KOMTRAX B antenna) C Overall width Forward Travel speed (1st) Reverse (Quick shift mode) (1st) Travel speed Forward (Variable shift mode) Reverse

Unit kg —

D61E -23M0 600 mm single grouser shoe Komatsu SAA6D107E-1 diesel engine

127 {170} / 2,200 {2,200} 126 {169} / 2,200 {2,200} 125 {168} / 2,200 {2,200}

km/h

3.4

km/h

4.1

km/h km/h

0.8 to 0.8 to

kW {HP}/ min-1 {rpm}

*1: Indicates the value of the basic engine (without cooling fan). *2: Indicates the value at the minimum cooling fan speed. a The engine rated horsepower is indicated in the net value and gross value. The gross denotes the flywheel horsepower measured on the basic engine unit, while the net denotes the value measured of an engine under the condition essentially the same as that when it is installed on a machine. a Following shows the rated horsepower (net) at the maximum cooling fan speed. 113 kW {152 HP}/2,200 min-1 {2,200 rpm}

D61EM-23M0

01-3

01 Specification Specifications

Specifications

D61EM-23M0 Machine model

Unit

Serial number Weight Machine weight Bare tractor and ROPS cab Bare tractor, , and ROPS cab Bare tractor, , and ROPS cab Performance Min. turning radius Gradeability Stability (front, rear, right, left) Travel speed • Quick shift mode Forward (1st) Reverse (1st) • Variable shift mode Forward Reverse Ground pressure Bare tractor and ROPS cab Bare tractor, , and ROPS cab Bare tractor, , and ROPS cab

01-4

D61E -23M0 600 mm single grouser shoe B 0001 and up

15,610 kg

— deg.

[Counter-rotation turn] 30 35

km/h

3.4 4.1

km/h

0.8 to 0.8 to 40.5{0.41}

kPa {kg/cm2}

D61EM-23M0

01 Specification Specifications

Machine model

Unit

Serial number Dimensions Overall length Bare tractor and ROPS cab Bare tractor, , and ROPS cab Bare tractor, !, and ROPS cab (blade full angling) Overall width Bare tractor " # $% & ' ( $ $ ) Overall height When ROPS cab is installed Track gauge Length of track on ground Shoe width (Standard track shoe) Min. ground clearance Engine Name

D61E -23M0 600 mm single grouser shoe B 0001 and up

4,940 mm

2,500

1,900 3,165 600 390

—

Type

—

No. of cylinders - bore x stroke Total piston displacement Performance Engine rated horsepower • SAE J1995 (gross) (*1) • ISO 14396 • ISO 9249/SAE J1349 (net) (*2)

mm l {cc}

SAA6D107E-1 4-cycle, water-cooled, in-line vertical, common rail, turbocharged, and airaftercooled type 6－107 × 124 6.69 {6,690}

kW {HP}/ min-1 {rpm}

127 {170} / 2,200 {2,200} 126 {169} / 2,200 {2,200} 125 {168} / 2,200 {2,200}

Max. torque (*2)

Nm {kgm}/ min-1 {rpm}

753 {76.8} / 1,400 {1,400}

Max. speed with no load Min. speed with no load

min-1 {rpm}

2,280 {2,280} 975 {975}

g/kWh 216 {161} {g/HPh} Starting motor — 24 V, 5.5 kW — 24 V, A Alternator Battery (*3) 12 V, 140 Ah x 2 pieces — Radiator core type Corrugated aluminum — *1: Indicates the value of the basic engine (without cooling fan). *2: Indicates the value at the minimum cooling fan speed. *3: The battery capacity (Ah) is indicated in the 5-hour rate. Fuel consumption rate at rated horsepower

a The engine rated horsepower is indicated in the net value and gross value. The gross denotes the flywheel horsepower measured on the basic engine unit, while the net denotes the value measured of an engine under the condition essentially the same as that when it is installed on a machine. a Following shows the rated horsepower (net) at the maximum cooling fan speed. 113 kW {152 HP}/2,200 min-1 {2,200 rpm} D61EM-23M0

01-5

01 Specification Specifications

Machine model

Unit

Serial number

D61E -23M0 600 mm single grouser shoe B 0001 and up

Power train HST pump • Main pump Type x quantity Discharge Set pressure • Charge pump Type x quantity Discharge Set pressure

— cm3/rev MPa {kg/ cm2}

Variable displacement swash plate piston type x 2 125 × 2 41.2 {420}

Fixed displacement gear type x 1 — cm3/rev 56 MPa {kg/ 17.2 {175} cm2}

HST motor Type x quantity Discharge Final drive Undercarriage Suspension method Carrier roller Track roller Track shoe Assembly type, single grouser,

01-6

—

Variable displacement bent axis piston type (with parking brake) x 2 200 Double reduction type planetary gear, splash lubrication type

— — —

Semi-rigid, balancing beam type 2 (each side) 8 (each side)

—

Width: 600 mm, Number on each side: 42, pitch: 190 mm

— cm3/rev

D61EM-23M0

01 Specification Specifications

Machine model

Unit

Serial number

D61E -23M0 600 mm single grouser shoe B 0001 and up

Work equipment hydraulic system Work equipment, cooling fan pump Type x quantity Discharge Max. discharge

— cm3/rev MPa {kg/ cm2}

Variable displacement swash plate piston type x 1 90 27.4 {280}

Cooling fan motor Type Motor capacity Control valve Type x quantity Operating method Lift cylinder Type Cylinder bore Piston rod outside diameter Piston stroke Max. distance between pins Min. distance between pins * ' cylinder Type Cylinder bore Piston rod outside diameter Piston stroke Max. distance between pins Min. distance between pins Hydraulic tank Hydraulic oil filter Oil cooler

D61EM-23M0

— cm3/rev

Fixed displacement swash plate type piston motor 28

— —

-spool valve x 1 Hydraulic pilot type

— mm mm mm mm mm

Double-acting piston type 100 55 1, 856

— mm mm mm mm mm — — —

Double-acting piston type 1 Box type (external control valve type) Tank return side Air-cooled (laminated aluminum)

01-7

01 Specification Specifications

Machine model

Unit

Serial number Work equipment • " Type " support method Performance + & $, ' $% + $ $ ' $% + ' ' -$ $. ($ ! & ! ) * ' /% ( & 0 ' ) * ' /% ( ) * ' $ '

01-8

D61E -23M0 600 mm single grouser shoe B 0001 and up

—

Hydraulic ' Hydraulic cylinder type

mm mm '

mm '0%

D61EM-23M0

01 Specification Specifications

Weight table

D61EM-23M0

k This weight table is prepared for your reference when handling or transporting the components.

Machine model Serial number Engine and pump assembly • Engine assembly (including mounting bracket, mufler, exhaust piping, damper, etc.) • Engine and damper assembly (excluding coolant and oil) • Damper assembly • Hydraulic pump assembly (including pump mounting parts) • HST pump • Work equipment/ cooling fan pump • Charge pump Cooling fan support bracket assembly (including cooling fan, cooling fan motor, guard, bracket, shroud, and hinge) Cooling assembly • Radiator • Oil cooler (including oil cooler bypass/ HST charge safety valve) • Aftercooler Fuel tank assembly (excluding fuel, including control valve ( V)) • Control valve 2spool valve (including accessories and mounting plate) Main frame assembly (including piping mounting bracket) • Main frame • Equalizer bar • Pivot shaft (each side) • Front underguard • Center underguard (front) • Center underguard (rear) • Rear underguard Track frame assembly (each side) • Idler assembly • Recoil spring assembly • Track roller (single flange type) • Track roller (double flange type) • Carrier roller • Final drive assembly (including sprocket) • HST motor Track shoe assembly (each side) Single grouser shoe (600 mm) Hydraulic tank assembly (excluding hydraulic oil) (including washer tank, battery, and a part of piping) " ! ( % ' . ' . ) ( ) • " ( $ $ .) Lift cylinder assembly * ' ! !

D61EM-23M0

Unit: kg D61E -23M0 B 0001 and up 1,165 837 675 6.6 354 260 43 9 295 44.3 39.5 27.0

2, 2, 153 96 13 25 18 13 3,290 235 208 46.4 x 6 50.6 x 2 28.2 x 2 769 281 1,245 445

01-9

01 Specification Specifications

Machine model Serial number # . ! ( % ' $% ' . $% ) • # . ! ROPS cab assembly (including floor and air conditioner) • Operator's seat Mechanical suspension seat (low back) Mechanical suspension seat (high back) Rear mask assembly Engine hood assembly (including door, pre-cleaner, and air cleaner)

01-10

Unit: kg D61E -23M0 B 0001 and up 1,100 52 53 80 348

D61EM-23M0

01 Specification Specifications

Table of fuel, coolant, and lubricants

a For details of notes (Note 1, Note 2...) in the table, see Operation and Maintenance Manual.

Applicable portion Engine oil pan Idler (each of right and left) Final drive case (each of right and left) Hydraulic oil system Cooling system (including sub-tank) Fuel tank

D61EM-23M0

Specified capacity 31 0.22 8.3 45 372

Unit: l Refill capacity 29 0.22 8.1 101 — —

01-11

01 Specification Specifications

01-12

D61EM-23M0

SHOP MANUAL

D61E -23M0 Model

Serial Number

D61E -23M0

B 0001 and up

10 Structure and function 3 10 Structure and function

D61EM-23M0

10-1

10 Structure and function Table of contents

Table of contents

10 Structure and function - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 10-1 Table of contents - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 10-2 Engine and cooling system- - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 10-3 Engine related parts - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 10-3 Cooling system - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 10-5 Cooling fan motor - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 10-7 Oil cooler bypass and HST charge safety valve- - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 10-13 Power train - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 10-19 Power train system - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 10-19 Damper - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 10-22 Hydraulic component layout of HST - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 10-23 Steering and brake control- - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 10-24 HST pump - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 10-26 HST motor - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 10-41 Charge pump - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 10-56 Solenoid valve - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 10-57 Final drive - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 10-66 Undercarriage and frame - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 10-70 Main frame - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 10-70 Suspension - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 10-71 Track frame and idler cushion - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 10-73 Hydraulic system - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 10-75 Hydraulic component layout of work equipment- - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 10-75 Work equipment control system - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 10-76 Hydraulic tank - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 10-77 CLSS - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 10-79 Work equipment and cooling fan pump - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 10-82 Control valve - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 10-93 Accumulator- - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 10-119 Work equipment - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 10-121 Planter unit - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 10-121 Cab and its attachments- - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 10-122 ROPS cab - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 10-122 Cab mount- - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 10-124 Electrical system - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 10-125 Engine control system- - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 10-125 Cooling system control system - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 10-128 HST control system - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 10-130 Parking brake control system- - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 10-141 System operating lamp function - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 10-144 Battery disconnect switch function - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 10-145 Machine monitor system - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 10-147 KOMTRAX system - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 10-170 System component parts- - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 10-173 HST controller - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 10-176 Sensor - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 10-188

10-2

D61EM-23M0

10 Structure and function

Engine and cooling system

Engine related parts

1. Muffler 2. Air cleaner (*1) 3. Dust indicator 4. Rear engine mount 5.Fuel pre-filter 6. Fuel main-filter 7. Air conditioner compressor 8. Front engine mount 9. Auto-tensioner 10.Engine oil filter 11.Starter 12. Alternator 13. Turbo 14. Vibration damper (*1) *1: For details, see Engine Shop Manual.

D61EM-23M0

10-3

10 Structure and function Engine and cooling system

Structure • The cooling assembly and cooling fan are installed to the rear end of the machine. The intake air and coolant are led to the rear of the machine through the piping. • Air conditioner compressor (8) is installed to the front of the engine and driven by the alternator belt. • Air cleaner (2), pre-cleaner, and exhaust pipe are installed above or near the engine hood.

10-4

D61EM-23M0

10 Structure and function

Engine and cooling system

Cooling system

1. Bleeder 2. Radiator outlet port hose 3. Radiator inlet port hose 4. Radiator 5. Radiator cap 6. Oil cooler 7. Aftercooler inlet port 8. Reservoir tank 9. Aftercooler 10. Aftercooler outlet port hose 11. Oil cooler bypass and HST charge safety valve 12. Coolant drain valve (2 pieces) 13. Cooling fan motor 14. Shroud 15. Cooling fan

Specifications Item Core type Fin pitch (mm) D61EM-23M0

(D61-B000-030-K-00-A)

Radiator Laminated aluminum

Oil cooler Laminated aluminum

Aftercooler Laminated aluminum 10-5

10 Structure and function Engine and cooling system

Item Total heat dissipation area (m2) Cracking pressure of pressure valve (kPa {kg/cm2}) Cracking pressure of vacuum valve (kPa {kg/ cm2})

10-6

Radiator

Oil cooler

Aftercooler

110 ± 15 {1.1 ± 0.15}

4.8 to 10.3 {0.05 to 0.11}

D61EM-23M0

10 Structure and function

Engine and cooling system

Cooling fan motor

P: From cooling fan pump T: To oil cooler TC: To hydraulic tank

D61EM-23M0

10-7

10 Structure and function Engine and cooling system

1. Output shaft 2. Case 3. Thrust plate 4. Piston 5. Cylinder block 6. Valve plate 7. End cover 8. Center spring 9. Cooling fan speed sensor 10.Suction valve 11.Cooling fan reverse solenoid valve 12.Pilot valve 13.Spool (for reversible valve)

10-8

D61EM-23M0

10 Structure and function

Engine and cooling system

Structure • This fan motor is installed within the blade width as shown in the figure.

Specifications

(D61-B5L0-030-K-00-A)

Model Type Motor capacity (cm3/rev) Rated speed (rpm) Rated flow rate (l/min) Cracking pressure of safety valve (MPa {kg/cm2}) Cracking pressure of check valve (MPa {kg/cm2})

Hydraulic motor Function

LMF28 Fixed displacement swash plate type piston motor 28 1,700 46.2 24.5 {250} 0.044 {0.45}

(D65-B5N0-041-K-00-A)

(D65-B5N0-042-K-00-A)

• 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

(D65-B5N0-04B-K-00-A)

• The pressurized oil sent from the pump flows through valve plate (7) into cylinder block (5). This pressurized oil can flow into cylinder chambers on only to one side of the (supply side) (Y - Y) line connecting the top dead center and bottom dead center of the stroke of piston (4). • The pressurized oil sent to one side of cylinder block (5) presses piston (4) [2 or 3 pieces] and generates force (F1) [F1 (kg) = P (kg/cm2) x xD2/4 (cm2)]. • This force is applied to thrust plate (2). Since thrust plate (2) is fixed at an angle of ("a") degrees to the output shaft (1), the force is divided into components (F2) and (F3). • Among them, radial component (F3) generates torque (T = F3 x ri) against the (Y - Y) line connecting the top dead center and bottom dead center. • The result of this torque [T=s(F3 x ri)] rotates cylinder block (5) through the piston (4). • Since this cylinder block (5) is splined to the output shaft (1), the output shaft (1) rotates to transmit the torque.

D61EM-23M0

10-9

10 Structure and function Engine and cooling system

Suction valve Function

(D61-B6D0-040-K-00-A)

(D61-B6D0-042-K-00-A)

• When the pump stops rotating, the hydraulic oil does not flow into the motor. Since the motor continues rotation by the force of inertia, the pressure at the outlet of the motor increases. • 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), compensating for the lack of oil on that side to prevent cavitation.

Operation

(D61-B6D0-044-K-00-A)

1. When pump is started

• The pressurized oil from work equipment/ cooling fan pump (1) is supplied to port (P) through control valve (2). When the pressure on the (MA) side increases and generates starting torque in the motor, the motor starts to rotate. The pressurized oil on the motor outlet (MB) side returns to the hydraulic tank through port (T). 2. When pump is stopped

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Engine and cooling system

• When the engine is stopped and the input speed of work equipment/ cooling fan pump decreases to 0 rpm, no pressurized oil is supplied from work equipment/ cooling fan pump (1) to port (P) through control valve (2). As the pressurized oil is not supplied to (MA) side of the motor, the motor speed decreases gradually to stop. • When the motor shaft is rotated by the force of inertia while the oil flow in port (P) is decreasing, the oil in port (T) on the outlet side is sent by suction safety valve (3) to the (MA) side to prevent cavitation.

Reversible valve

(D61-B6E0-040-K-00-A)

Operation 1. When reversible valve ON-OFF solenoid is "de-energized" • When reversible valve ON-OFF solenoid (3) is "de-energized", the pressurized oil sent from work equipment/ cooling fan pump (1) through control valve (2) is cut off by ON-OFF selector valve (4), and port (C) is connected to the tank circuit. • As a result, reversible valve spool (5) is pushed to the right by reversible valve spring (6), the motor port (MA) opens, the pressurized oil flows in, and the motor begins normal rotation [clockwise].

2. When reversible valve ON-OFF solenoid is "energized" • When reversible valve ON-OFF solenoid (3) is "energized", ON-OFF selector valve (4) switches and the pressurized oil from work equipment/ cooling fan pump (1) flows through control valve (2) and port (C) into spool chamber (D). • The pressurized oil in chamber (D) pushes reversible valve spool (3) to the left against reversible valve spring (6). As a result, motor port (MB) opens and pressurized oil flows in and the motor begins reverse rotation [counterclockwise].

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10 Structure and function Engine and cooling system

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10 Structure and function

Engine and cooling system

Oil cooler bypass and HST charge safety valve

a HST: Abbreviation for Hydrostatic Transmission a This valve consists of the oil cooler bypass valve and HST charge safety valve.

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10 Structure and function Engine and cooling system

C1: To oil cooler inlet C2: From oil cooler outlet P1: From charge filter P2: From cooling fan motor T: To hydraulic tank TS: Plug PP: Plug 1. Oil cooler bypass valve 2. HST charge safety valve 3. Oil cooler

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10 Structure and function

Engine and cooling system

Oil cooler bypass valve

1. Charge pump 2. HST pump 3. HST charge safety valve 4. Oil cooler bypass valve 5. Oil cooler

4A. Poppet 4B. Spring 4C. Plug

Function

(D61-B8PB-042-K-00-A)

• Oil cooler bypass valve (4) is installed together with HST charge safety valve (3). It regulates oil pressure inside the oil cooler (5) to the set pressure. Set pressure: 0.49 MPa {5 kg/cm2} (cracking pressure)

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10 Structure and function Engine and cooling system

HST charge safety valve a HST: Abbreviation for Hydrostatic Transmission

1. Charge pump 2. HST pump 3. HST charge safety valve 4. Oil cooler bypass valve 5. Oil cooler

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Engine and cooling system

3A. Valve 3B. Spring 3C. Valve seat 3D. Poppet 3E. Spring 3F. Adjustment screw

Function

(D61-C2V0-042-K-00-A)

• HST charge safety valve (3) is installed together with oil cooler bypass valve (4). It regulates oil pressure inside HST charge circuit to the set pressure. Set pressure: 2.7 MPa {28 kg/cm2} (cracking pressure)

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10 Structure and function Engine and cooling system

Operation

(D61-C2V0-044-K-00-A)

• Port (A) is connected to the charge circuit. Port (B) is connected to the drain circuit. Port (C) is connected to the tank drain circuit through the oil cooler. Oil flows through orifice (a) of valve (3A) to fill chamber (D). Poppet (3D) is in firm contact with valve seat (3C).

• When abnormal pressure is generated in the circuit or when the oil pressure in port (A) and chamber (D) increases to the pressure set with spring (3E) while the shuttle valve of the HST motor is in the neutral position, puppet (3D) is pushed to the right and the oil in chamber (D) flows into port (B), thus the pressure in chamber (D) decreases.

• When the oil pressure in chamber (D) decreases, orifice (a) of valve (3A) generates differential pressure between port (A) and chamber (D). Valve (3A) is pushed to the right by the pressure in port (A) and the oil in port (A) is released. As a result, the pressure in the charge circuit does not increase.

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Power train system

Structure • The power generated by engine (1) is reduced in torsional vibration by damper (2), and then transmitted to the HST pump input shaft. • In HST pump (3), the swash plate type piston pumps for the right and left travels are coupled in tandem. The hydraulic power is transmitted from each pump through high-pressure hoses (4) to right and left HST motors (5) respectively. • HST pump (3) changes the direction and quantity of discharge steplessly by the movement of the swash plate of each pump in accordance with the operation of the joystick (steering, directional and gear shift lever) to change the rotation direction and speed of the right and left HST motors and control the travel direction and turning of the machine. • The hydraulic power transmitted to HST motor (5) is output as mechanical power through the motor output shaft and transmitted to final drive (6). • Final drive (6) consists of a double-stage planetary gear system, reduces the speed, and rotates sprocket (7) to drive track shoes (8).

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10 Structure and function Power train

1. Engine 2. Damper 3. HST pump 4. Work equipment/ cooling fan pump 5. High-pressure hose 6. HST motor 7. Final drive 8. Sprocket 9. Track shoe 10. Charge pump

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Power train

HST closed circuit a HST: Abbreviation for Hydrostatic Transmission

1. Charge pump 2. HST charge safety valve 3. Suction safety valve 4. HST pump 5. HST motor 6. Shuttle valve 7. Charge relief valve

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Damper

1. Coupling 2. Boss 3. HST pump input shaft 4. Flywheel 5. Cover

Function

(D61-CB00-042-K-00-A)

• The damper reduces torsional vibration caused by fluctuation of the engine torque to protect the drive system after the engine from the torsional vibration. • The power from the engine is transmitted through flywheel (4) to coupling (1). The torsional vibration of the power is absorbed by coupling (1) and the power is transmitted through boss (2) to the HST pump.

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Hydraulic component layout of HST

a HST: Abbreviation for Hydrostatic Transmission

1. HST pump 2. Solenoid valve 3. Charge pump 4. R.H. HST motor 5. Charge filter 6. Oil cooler bypass and HST charge safety valve 7. L.H. HST motor 8. Accumulator

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Steering and brake control

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Power train

1. Decelerator/ Brake pedal 2. Brake limit switch 3. HST controller 4. Joystick (steering, directional, and gear shift lever) (PCCS lever) 5. Fuel control dial 6. Electric steering lever 7. Parking brake limit switch 1 8. Parking brake limit switch 2 9. Parking brake lever 10. Decelerator/ Brake pedal potentiometer Structure • Electric steering lever (6) sends electric signals according to the stroke of joystick (steering, directional and gear shift lever) (4) to HST controller (3). Upon receiving this signal, HST controller (3) sends the signals to the EPC valve of the HST pump to change the flow rate in the HST pump to control the HSS motor. • If joystick (steering, directional and gear shift lever) (4) is tilted forward and leftward a little, the machine turns to the left gradually. If it is tilted leftward fully, the machine makes a left counter-rotation turn to the left. • Decelerator/ Brake pedal potentiometer (10) sends electric signals according to the stroke of decelerator/ Brake pedal (1) to HST controller (3). Upon receiving this signal, HST controller (3) sends the signals to the EPC valve of the HST pump to decelerate both right and left tracks simultaneously. • If brake pedal (1) is depressed fully when parking brake lever (9) is in "FREE" position, HST controller (3) receives electric signals from brake pedal potentiometer (10) and operates the right and left HST hydraulic brakes simultaneously. After the machine stops, HST controller (3) stops sending the signals to the parking brake solenoid valve. At the same time, brake limit switch (2) operates the relay to stop sending the signals to the slow brake solenoid valve. After sending the signals to the parking brake solenoid valve or the slow brake solenoid valve is stopped, the parking brakes built in the right and left HST motors operate. • When parking brake lever (9) is set to "LOCK" position or joystick (steering, directional and gear shift lever) (4) is set in "NEUTRAL" position or fuel control dial (5) is set to "SLOW" position, the HST controller receives electric signals from parking brake limit switch 1 (7), electric steering lever (6), fuel control dial (5), and neutral brake and stops sending signals to the parking brake solenoid valve. At the same time, parking brake limit switch 2 (8) stops sending signals to the slow brake solenoid valve. After sending the signals to the parking brake solenoid valve or the slow brake solenoid valve is stopped, the parking brakes built in the right and left HST motors operate.

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HST pump

a HST: Abbreviation for Hydrostatic Transmission

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Power train

A1: Max. capacity adjustment screw (left FORWARD) A2: Max. capacity adjustment screw (right FORWARD) B1: Max. capacity adjustment screw (left REVERSE) B2: Max. capacity adjustment screw (right REVERSE) CPA: Charge pressure input port CPA1: Pressure pickup port (left FORWARD) CPA2: Pressure pickup port (right FORWARD) CPB1: Pressure pickup port (left REVERSE) CPB2: Pressure pickup port (right REVERSE) CSA1: Pressure pickup port (left FORWARD EPC pressure) CSA2: Pressure pickup port (right FORWARD EPC pressure) CSB1: Pressure pickup port (left REVERSE EPC pressure) CSB2: Pressure pickup port (right REVERSE EPC pressure) LF: Pilot current (left FORWARD) LR: Pilot current (left REVERSE) PA1: Pump discharge port (left FORWARD) PA2: Pump discharge port (right FORWARD) PB1: Pump discharge port (left REVERSE) PB2: Pump discharge port (right REVERSE) RF: Pilot current (right FORWARD) RP1: Tow receiving plug RP2: Tow receiving plug RR: Pilot current (right REVERSE) T1: Drain port TS1: Drain port D61EM-23M0

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10 Structure and function Power train

TS2: Drain port 1. Piston pump 2. EPC valve 3. Suction safety valve 4. Servo valve • The pump consists of the variable displacement swash-plate type tandem piston pump, servo valve, EPC valve, and suction safety valve.

1. Shaft 2. Cradle bearing 3. Rocker cam 4. Case 5. Servo piston 6. Slider 7. Cylinder block 8. Valve plate 9. End cap 10. Bearing 11. Piston 12. Spline 13. Shoe 14. Bearing 15. Servo spool Structure • Cylinder block (7) is supported on shaft (1) through spline (12). Shaft (1) is supported on the front and rear bearings (14) and (10). 10-28

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• The tip of piston (11) has a spherical hollow in which shoe (13) is being held by crimping. Piston (11) and shoe (13) forms a spherical bearing. • Rocker cam (3) has flat surface (A) and shoe (13) is always pressed against this surface while sliding in a circular pattern. Rocker cam (3) rocks on cradle bearing (2) between case (4) and cylindrical surface (B). • Piston (11) moves relatively in the axial direction in each cylinder chamber of cylinder block (7). • Cylinder block (7) rotates relatively to valve plate (8) while sealing the pressurized oil and the oil pressure is balanced properly on this plane. The oil is sucked in and discharged from each cylinder chamber in cylinder block (7) through valve plate (8).

Specifications

(D61-C172-030-K-00-A)

Model Type Theoretical discharge (cm3/rev) Rated discharge pressure (MPa {kg/cm2}) Rated speed (rpm)

Function

HPV125+125 Variable displacement swash plate type tandem piston pump 125 x 2 41.2 {420} 2,280

(D61-C172-042-K-00-A)

• Torque transmitted to the shaft is converted into hydraulic energy and discharges pressurized oil according to the load. • It is possible to change the discharge by changing the swash plate angle. (Forward discharge <=> Zero <=> Reverse discharge)

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10 Structure and function Power train

Operation of pump

(D61-C172-044-K-01-A)

• Cylinder block (9) rotates together with shaft (1) and shoe (7) slides on plane (A). At this time, angle (a) between center line (X) of rocker cam (4) and the axis of cylinder block (9) changes. Angle (a) is called the swash plate angle. • While angle (a) is made between center line (X) of rocker cam (4) and the axis of cylinder block (9), plane (A) works as a cam for shoe (7). • Piston (8) reciprocates inside cylinder block (9) and a difference is made between volumes (E) and (F) in cylinder block (9) and oil is sucked in and discharged by (F) - (E). • Oil is discharged while cylinder block (9) rotates and the volume of chamber (F) decreases. On the other hand, oil is sucked in when the volume of chamber (E) increases.

• As center line (X) of rocker cam (4) matches the axis of cylinder block (9) (swash plate angle = zero), the difference between volumes (E') and (F') inside cylinder block (9) is 0. The pump does not carry out any suction or discharge of oil.

• Piston (8) reciprocates inside cylinder block (9) and a difference is made between volumes (E") and (F") in cylinder block (9) and oil is sucked in and discharged by (F") - (E"). • That is, oil is discharged while cylinder block (9) rotates and the volume of chamber (E") decreases. On the other hand, oil is sucked in when the volume of chamber (F") increases. When the swash plate angle is reversed, suction and discharge through ports (PA) and (PB) are reversed.

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Control of discharge

(D61-C172-044-K-02-A)

• If swash plate angle (a) increases, the difference between volumes (E) and (F) increases, and consequently discharge (Q) increases. Servo piston (5) changes swash plate angle (a). • Servo spool (7) moves according to the command from the EPC valve. Servo piston (5) reciprocates linearly according to the command pressure output from servo spool (7). • This linear reciprocating motion is transmitted through slider (6) to rocker cam (4). Rocker cam (4) supported on the cylindrical surface of cradle bearing (3) rocks around the cylindrical surface. • The maximum swash plate angle (a) of this pump is ± 16.7 degrees.

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Operation of servo valve

D61EM-23M0

(D61-C2B0-044-K-00-A)

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When lever is operated Operation of servo spool • The command current from pump controller (1) flows to the EPC valve solenoid. • This command current acts on the EPC valve and outputs signal pressure. This signal pressure is led into chambers (sa) and (sb) through ports (SA) and (SB). The force pushing servo spool (2) is changed by the signal pressure. • Servo spool (2) stops at a position where the force pushing servo spool (2) is balanced with the force of spring (3). • The command current value is decided by the software of pump controller (1) on the basis of the information of the operation distance of joystick (steering, directional and gear shift lever) (4), pump pressure, etc. Operation of servo piston • When servo spool (2) moves to the left, ports (CP) and (A) are connected, and chamber (a) is pressurized. At the same time, ports (B) and (T) are connected and chamber (b) is drained, thus servo piston (5) moves to the left. • When servo piston (5) moves to the left and ports (CP) and (A) are disconnected, servo piston (5) stops moving. • That is, servo piston (5) moves by the moving distance of servo spool (2). • Similarly, when servo spool (2) moves to the right, ports (CP) and (B) are connected, and chamber (b) is pressurized. At the same time, ports (A) and (T) are connected, and chamber (a) is drained, and servo piston (5) moves to the right until ports (CP) and (B) are disconnected. When lever is in neutral • When pressurized oil does not enter from the EPC valve, servo spool (2) does not operate. Servo piston (5) is held at the neutral position by the force of spring (6) and the main pump is kept in the neutral state.

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Power train

Suction-safety valve

(D61-C2VE-041-K-00-A)

1. Suction safety valve 1A. Valve 1B. Rod 1C. Sleeve 1D. Spring 1E. Spring 1F. Plug

Function

(D61-C2VE-042-K-00-A)

In high-pressure safety valve mode • This valve limits the maximum pressure in HST circuit to protect the circuit. In suction valve mode • It secures the amount of oil flow in the HST closed circuit. It prevents charge flow from flowing into pump high-pressure side (discharge side).

Operation

(D61-C2VE-044-K-00-A)

In high-pressure safety valve mode (Valve on discharge side of piston pump) • Port (A) is connected to the pump circuit and port (B) is connected to the charge circuit. The pressurized oil also fills port (C) through hole (a) of valve (2A). • High-pressure port (A) is also connected to port (D) through passage groove (b) of the body. • Valve (2A) is in firm contact with sleeve (2C). • When abnormal pressure is generated in the circuit, if the oil pressure in ports (A) and (D) increases to the pressure set by spring (2D), valve (2A) is pushed to the right to relieve the oil in port (A) into port (B) and the oil pressure in port (A) decreases.

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Power train

In suction valve mode When HST pump discharge is 0 • The HST closed circuit is sealed and the charge pressurized oil does not flow into the HST circuit.

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10 Structure and function Power train

When HST pump discharges oil from port (PA) Valve on discharge side of piston pump • When pressurized oil is discharged from port (PA) side of HST pump (3), port (PA) becomes the highpressure side. • The pressurized oil in port (PA) flows into port (D) through passage (b) of the body. • At this time, sleeve (2C) is pushed to the left because of the area difference (A1 > A2). • As a result, the pressurized oil from charge lamp (1) does not flow in.

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Valve on suction side of piston pump • On the other hand, port (PB) becomes the suction side and its pressure is low. Sleeve (2C) is pushed to the right because of area difference of (A1) < (A2) and the charge pressurized oil in port (B), thus its seat opens. • As a result, the charge pressurized oil in port (B) flows into port (PB) through this clearance and charges the HST circuit.

Towing valve

D61EM-23M0

(D61-C2VF-410-K-00-A)

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10 Structure and function Power train

Function

(D61-C2VF-042-K-00-A)

• This valve is installed to 2 places for the F side (for the L.H. track) and R side (for the R.H. track). • When the machine has a trouble, you can tow it by connecting HST circuit. • However, you must release the motor shaft brakes at that time.

Operation

(D61-C2VF-044-K-00-A)

• To operate the tow receiving valve, loosen the 2 valves up to 4.5 mm (3 turns).

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HST motor

a HST: Abbreviation for Hydrostatic Transmission L.H. HST motor Rotation direction (facing drive shaft) Inflow from MA: Counterclockwise rotation Inflow from MB: Clockwise rotation

B: Parking brake release signal port MA: (High pressure during reverse travel) Discharge port MB: (High pressure during forward travel) Discharge port P: Capacity control signal port T: Drain 1. Speed sensor 2. Charge relief valve

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10 Structure and function Power train

R.H. HST motor Rotation direction (facing drive shaft) Inflow from MA: Counterclockwise rotation Inflow from MB: Clockwise rotation

B: Parking brake release signal port MA: (High pressure during forward travel) Discharge port MB: (High pressure during reverse travel) Discharge port P: Capacity control signal port T: Drain 1. Speed sensor 2. Charge relief valve

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Power train

1. Motor case 2. End cover 2A. Sleeve 2B. Seat 2C. Servo spring 2D. Servo spool 2E. Servo piston 3. Pin 4. Valve plate D61EM-23M0

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5. Cylinder block 6. Piston 7. Charge relief valve 8. Dierctional shuttle valve Structure • Seven pistons (6) are attached to the disc portion of the drive shaft like spherical joints, and stored in cylinder block (5) at a certain angle to the drive shaft. • The inclination of cylinder block (5) and pistons (6) varies with the capacity control input current of the EPC valve.

B: Parking brake release signal port MA: (High pressure during forward travel) Discharge port MB: (High pressure during reverse travel) Discharge port P: Capacity control signal port T: Drain

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Power train

1. Steplessly-variable displacement bent axis type piston motor 2. Servo piston 3. Servo valve 4. Low-pressure shuttle valve 5. Charge relief valve 6. High-pressure selection check valve 7. Parking brake 8. Speed sensor 9. Hydraulic tank

Specifications

(D61-C173-030-K-00-A)

Model Type Theoretical displacement (cm3/rev) Charge relief valve set pressure (MPa {kg/ cm2})

Function

KMV200 Steplessly-variable displacement bent axis type piston motor 86 to 200 Min. 2.67 {27.2}

(D61-C173-042-K-00-A)

• This device maximizes the motor capacity when the servo piston is at the lowest position. • This device minimizes the motor capacity when the servo piston is at the highest position. • The motor capacity is decided according to the command current to the EPC valve when the servo piston is between the above two positions. • The relationship between the current and the displacement is shown below.

Piston motor Operation

(D61-C400-041-K-00-A)

(D61-C400-042-K-00-A)

Principle of operation • Supposed that the axis of the disc is supported and the disc can rotate freely. When force (F) is applied to the disc diagonally, force (F) is divided into vertical force to the disc (F1) and circumferential force (F2). (F1) pushes the disc to axis direction, and (F2) rotates the disc clockwise. • Instead, when force (F'), not force (F) is applied to the disc, the force (F') is also divided into (F'1) and (F'2), and (F2') rotates the disc counterclockwise.

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• The pressurized oil sent from the main piston pump enters the piston motor inlet port, and the oil pressure is applied to the back of the piston, and the drive shaft is rotated by inclination (Q) of the piston and cylinder block.

Change of steplessly-variable type motor capacity

(D61-C400-042-K-01-A)

• The servo mechanism portion has chambers (A), (B), and (C). • The self pressures in chambers (A) and (C) act on their respective pressure receiving areas , and servo piston (1) operates according to the balance of the forces acting on the chambers. • When the output pressure from EPC valve (2) is 0 MPa {0 kg/cm 2}, servo piston (1) is at the lowest position. (Max. side) • The capacity control pressure is supplied from EPC valve (2) to chamber (B) according to the command current to EPC valve (2). • Servo spool (3) leads the self pressure into chamber (C) up to the set motor capacity, according to the balance of the force generated by the capacity control pressure in chamber (B) and the force of servo spring (4).

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Power train

When motor capacity is maximum

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When motor capacity is minimum

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Operation of shuttle valve

(D61-C4G0-044-K-00-A)

a For sections C-C and E-E in the illustration, see the external assembly drawing. • The higher one of pressures (MA) and (MB) is sent to chamber (A) of main piston (2) by two check valves (1). • In section (E)-(E), when (MA) > (MB), low-pressure shuttle spool (3) moves up and (MB) is selected as the lower pressure and sent to the charge relief valve.

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10 Structure and function Power train

• When (MA) < (MB), low-pressure shuttle spool (3) moves down and (MA) is selected as the lower pressure and sent to the charge relief valve.

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Charge relief valve

(D61-C4J0-041-K-00-A)

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

Function

(D61-C4J0-042-K-00-A)

• The charge relief valve is installed inside the end cover. It prevents the pressure on the low pressure side of the HST main circuit selected by the low-pressure shuttle spool (charge pressure) from increasing above the specified level and relieves the oil of the specified flow rate into the motor case to prevent overheating of the motor. • The charge relief valve also discharges the dirtiest oil in the HST main circuit to outside to keep the inside of the HST main circuit clean.

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Operation

(D61-C4J0-044-K-00-A)

• Port (A) is connected to the low pressure side (charge circuit) of the HST motor main circuit selected by the low-pressure shuttle spool. • Port (B) is connected to the tank drain circuit through the HST motor case. • Pressurized oil also fills chamber (C) through orifice (g) of valve (1). Poppet (2) is in firm contact with valve seat (3).

• When abnormal pressure is generated in the circuit, if the oil pressure in port (A) and chamber (C) increases to the pressure set by spring (4), poppet (2) is pushed to the right to relieve the oil in chamber (C) into port (B) and the oil pressure in chamber (C) decreases.

• If the oil pressure in chamber (C) decreases, differential pressure is generated by orifice (g) of valve (1) between port (A) and chamber (C). • Valve (1) is pushed to the right by the pressurized oil in port (A) and the oil in port (A) is relieved into port (B). • TAccordingly, the pressure in the charge circuit doesn't increase more.

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Parking brake operation

(D61-C4A0-044-K-00-A)

When parking brake valve is "de-energized" • When parking brake valve (1) is "de-energized", the pressurized oil from charge pump (2) is cut off and port (B) is connected to the hydraulic tank. • As a result, brake piston (3) is pushed down by brake spring (4) to press discs (5) and plates (6) together, thus the brake is applied.

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When parking brake valve is "energized" • When parking brake valve (1) is "energized", the valve operates and the pressurized oil from charge pump (2) flows through port (B) to brake chamber (A). • The pressurized oil in chamber (A) pushes up brake piston (3) against brake spring (4). As a result, discs (5) and plates (6) are separated and the brake is released.

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HST motor speed sensor

(D61-C7P1-041-K-00-A)

1. Hall IC (with magnet) 2. P.C.B. 3. Housing 4. Wire 5. O-ring 6. Rubber cap 7. Rubber cap 8. Heat shrink tube 9. Connector

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10 Structure and function Power train

Charge pump

Structure • The HST charge pump is installed to the rear end of the work equipment / cooling fan pump, and is driven simultaneously with the HST pump and the work equipment / cooling fan pump. • The HST charge pump adds oil to the low-pressure side of the HST main circuit and supplies pilot pressure to the HST pump, solenoid valve, and cooling fan EPC. • The discharge pressure is decided by the HST charge safety valve and the charge relief valve in the HST motor. • The charge pump sucks in oil from the hydraulic tank.

Specifications

(D61-C2Z0-030-K-00-A)

Model Type Theoretical discharge (cc/rev)

Operation

SAR (2) 56 Gear pump 56.5

(D61-C2Z0-044-K-00-A)

• The charge pump is connected to the work equipment/ cooling fan pump through the coupling to rotate the drive gear. The drive gear rotates the driven gear.

10-56

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10 Structure and function

Power train

Solenoid valve

A1: To work equipment $ valve A2: 3$ $ . 4% ! $ $ , , A3: To R.H. HST motor port (P) A4: To L.H. HST motor port (P) A5: To R.H. and L.H. HST motor ports (B) A6: 3$ $ . 4% ! $ $ , , A7: Plug (hand pump connection port) P: From charge filter outlet T: To hydraulic tank 1. Block 2. Towing valve 3. Towing valve plate 4. Towing valve plate fixing bolt 5. Work equipment lock solenoid valve 6. R.H. HST motor EPC valve 7. L.H. HST motor EPC valve 8. Slow brake solenoid valve 9. Parking brake solenoid valve

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10 Structure and function Power train

10. Brake pressure sensor Structure • In block (1), three solenoid valves (5), (8), and (9), two EPC valves (6) and (7), towing valve (2), and brake pressure sensor (10) are installed. • Upon receiving the parking brake operation signal from the HST controller, parking brake solenoid valve (9) drains the selection oil pressure and operates the parking brake built in the HST motor. • When the machine stops and the signal of the limit switch which operates when the brake pedal is depressed fully or the signal of the limit switch interlocked with the parking brake is stopped to be sent to slow brake solenoid valve (8), slow brake solenoid valve (8) drains the selection oil pressure gradually through the orifice in it to operate the parking brake built in the HST motor. • Upon receiving the signal of the joystick (steering, directional and gear shift lever) from the HST controller, R.H. HST motor EPC valve (6) and L.H. HST motor EPC valve (7) output oil pressure according to the received signal to increase or decrease the HST motor capacity. • Work equipment lock solenoid valve (5) is installed between the charge filter outlet and work equipment PPC valve. When the work equipment lock lever is set in the "FREE" position, the work equipment lock switch operates work equipment lock solenoid valve (5) to open the work equipment control circuit so that the operator can operate the work equipment.

• Towing valve (2) is installed between parking brake solenoid valve (9) and HST motor. If the parking brake cannot be released because of an engine trouble, it can be release by removing towing valve plate (3), screwing towing valve (2), and applying parking brake release pressure from outside. a For the releasing procedure of the parking brake, see Testing and adjusting, "Releasing procedure of parking brake". a Work equipment lock solenoid valve (5) is described below as a sample of solenoid valve. Slow brake solenoid valve (8) and parking brake solenoid valve (9) operate similarly, too.

10-58

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10 Structure and function

Power train

C: To work equipment PPC valve P: From charge filter outlet T: To hydraulic tank 1. Nut 2. Plunger 3. Coil 4. Connector 5. Push pin 6. Spring 7. Spool 8. Block

Operation

(D61-C7W0-044-P-00-A)

1. When solenoid is "de-energized"

• Since no signal current flows into the solenoid valve, coil (3) is de-energized. • Accor0dingly, spool (7) is pushed to the left by spring (6). • Accordingly, port (A) is closed and the pressurized oil from the pump does not flow into actuator (9). • The oil from actuator (9) is drained through ports (B) and (C). 2. When solenoid is "energized"

D61EM-23M0

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10 Structure and function Power train

• When the signal current flows into the solenoid valve, coil (3) is energized and rightward thrust is generated in plunger (2). • Accordingly, spool (7) is pushed to the right by push pin (5). • The pressurized oil from the pump flows through ports (A) and (B) into actuator (9). • Port (C) is closed and no oil is drained.

10-60

D61EM-23M0

10 Structure and function

Power train

EPC valve

(D61-C4E9-041-K-00-A)

C: To HST motor port (P) P: From charge filter outlet T: To hydraulic tank 1. Body 2. Spool 3. Rod 4. Coil 5. Plunger 6. Connector 7. Return spring

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10 Structure and function Power train

Function

(D61-C4E9-042-K-00-A)

• The EPC valve consists of the proportional solenoid and the hydraulic valve. • When signal current (i) from the controller is received, an EPC output pressure proportional to the amperage of current is generated and output to the actuator.

10-62

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10 Structure and function

Power train

Operation

(D61-C4E9-044-K-00-A)

When signal current is zero (coil de-energized)

• • • •

When the signal current from the controller is not flowing through coil (14), coil (14) is de-energized. Spool (11) is pushed to the right by spring (12). Port (P) is closed and the pressurized oil from the pump does not flow into the actuator. The pressurized oil from the actuator is drained to the tank through port (C) and port (T).

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10 Structure and function Power train

When signal current is minute (coil is energized)

• When minute signal current flows through coil (5), coil (5) is energized and thrust is generated to push plunger (6) to the left. • Rod (4) pushes spool (2) to the left, and the pressurized oil from port (P) flows to port (C). • The pressure in port (C) increases and the total of the force applied on surface (a) of spool (2) and the force of spring (3) becomes larger than the thrust of plunger (6). • Spool (2) is pushed to the right, and ports (P) and (C) are disconnected. • Port (C) connects to port (T). • Spool (2) moves to a position where the thrust of plunger (6) is balanced with the total of the force caused by the pressure in port (C) and the force of spring (3). • The circuit pressure between the EPC valve and the control valve is controlled in proportion to the signal current.

10-64

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10 Structure and function

Power train

When signal current is maximum (coil is energized)

• • • •

Coil (5) is energized when the signal current flows to coil (5). As the signal current is maximum at this time, the thrust of plunger (6) is also maximized. Spool (2) is pushed to the left by rod (4). The pressurized oil flows from port (P) to port (C) at the maximum rate, and the circuit pressure between the EPC valve and control valve is maximized. • Port (T) closes, and no pressurized oil flows to the tank.

D61EM-23M0

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10 Structure and function Power train

Final drive

10-66

D61EM-23M0

10 Structure and function

Power train

a Figure shows - 5 2

1. Oil level plug 2. Drain plug 3. No. 1 sun gear (number of teeth: 15) 4. No. 2 sun gear (number of teeth: 21) 5. No. 1 planetary carrier 6. Cover 7. Sprocket 8. No. 2 planetary carrier 9. Floating seal 10. HST motor 11. Hub 12. No. 2 planetary pinion (number of teeth: 43) 13. Ring gear (number of teeth: 108) 14. No. 1 planetary pinion (number of teeth: 46)

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10 Structure and function Power train

Structure • The final drive uses a double stage planetary gear reduction system. • The lubrication is of splash type using the rotation of the gears. • The final drive can be removed and installed in a single unit. • The floating seal is installed to the rotating sliding portion of the sprocket to prevent entry of dirt or sand and leakage of lubricating oil.

Specifications Reduction ratio

10-68

(D61-DF10-030-K-00-A)

-[(15+108)/15] × [(21+108)／21] ＋ 1＝-49.371

D61EM-23M0

10 Structure and function

Power train

Power transmitting route a

Figure shows D61EM-23M0

Power from HST motor O No. 1 sun gear (1) O No. 1 planetary pinion (2) O No.1 planetary carrier (3) O No. 2 sun gear (4) O No. 2 planetary pinion (5) O Ring gear (6) O Hub (7) O Sprocket (8)

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10 Structure and function Undercarriage and frame

Undercarriage and frame

Main frame

1. Engine mount 2. Frame assembly 3. Underguard Structure • Frame assembly (2) has a full-frame structure consisting of a main frame and an underguard (3).

10-70

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10 Structure and function

Undercarriage and frame

Suspension a

The figure shows D61EM-23M0

D61EM-23M0

10-71

10 Structure and function Undercarriage and frame

a The figure shows - 5 2

1. Equalizer bar 2. Center pin 3. Pivot shaft 4. Side pin 5. Bushing 6. Seal 7. Seal 8. Bushing 9. Plug (oil filler port) 10. Cover 11. Bushing (small) 12. Bushing (large) 13. Seal • The front of the track frame rocks up and down by using the pivot shafts (3) at the rear of the track frame as a fulcrum. • Equalizer bar (1) rocks by using center pin (2) as a fulcrum, and is connected to the right and left track frames by side pins (4).

Specifications Amount of movement at center of equalizer bar side pin

10-72

Upward Downward

- 5 2 54.5 54.5

D61EM-23M0

10 Structure and function

Undercarriage and frame

Track frame and idler cushion a

The figure shows D61EM-23M0

D61EM-23M0

10-73

10 Structure and function Undercarriage and frame

a The figure shows - 5 2

1. Idler 2. Carrier roller 3. Track frame 4. Sprocket teeth 5. Track roller end guard 6. Track roller center guard 7. Track roller 8. Recoil spring 9. Yoke 10. Seal 11. Piston 12. Wear ring 13. U-packing 14. Cabin 15. Nut 16. Lubricator 17. Cylinder 18. Bushing 19. Holder

Specifications - 5 2

Q'ty on each side 8 pieces

Type of flange and arrangement S, S, D, S, S, D, S, S

S: Single flange D: Double flange

Function

(D61-DTA0-042-K-00-A)

• Recoil spring (8) is used for adjusting the track tension by charging or discharging grease from lubricator (16) to move piston (11) forward or backward. Recoil spring (8) also dampens sudden shocks applied to idler (1).

10-74

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10 Structure and function Hydraulic system

Hydraulic system

Hydraulic component layout of work equipment

1. Swing cylinder 2. Lift cylinder 3. Work equipment lock solenoid 4. Accumulator 5. Control valve

D61EM-23M0

6. Hydraulic oil filter 7. Hydraulic tank 8. Work equipment/ cooling fan pump 9. Cooling fan motor 10. Oil cooler

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10 Structure and function Hydraulic system

Work equipment control system

1. Work equipment lock lever 2. Work equipment control lever 3. HST controller 4. Work equipment electric lever 5. Work equipment lock limit switch 6. Auto /manual switch (if equipped) 7. Pause switch

Function q

When work equipment lock lever (1) is set to "LOCK" position, work equipment limit switch (5) sends a signal to HST controller (3), and then HST controller (3) stops sending signals to the work equipment lock solenoid valve. The operator can move work equipment control lever (2) but cannot operate the work equipment. This is the electrical control system which sends signals to HST controller (3) to control EPC valve for spools of control valve. Signals for work equipment control (lift) are sent to HST controller (5) by operating work equipment electric lever (4) with work equipment control lever. The machine can be stopped temporarily by pressing pause switch (7) during operation in Auto Mode.

10-76

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10 Structure and function Hydraulic system

Hydraulic tank

1. Oil filler cap 2. Breather 3. Hydraulic tank 4. Strainer 5. Drain plug 6. Sight gauge 7. Bypass valve 8. Hydraulic oil filter element

Specifications

(D61-PM30-030-K-00-A)

Tank capacity (l) Oil quantity in tank (l) Bypass valve set pressure (MPa {kg/cm2}) Cracking pressure of pressure valve (kPa {kg/cm2}) Operating pressure of vacuum valve (kPa {kg/cm2})

D61EM-23M0

134 101 0.15 ± 0.03 {1.5 ± 0.3} 17 ± 2.5 {0.17 ± 0.025} 2 ± 0.3 {0.02 ± 0.003}

10-77

10 Structure and function Hydraulic system

Breather

(D61-PM38-041-K-00-A)

1. Nut 2. Cover 3. Filter element 4. Case 5. Valve assembly 6. Body Prevention of negative pressure in tank • Since the hydraulic tank is pressurized and sealed, if the oil level in it decreases, negative pressure is generated in it. At this time, valve (5) is opened by the differential pressure between the tank pressure and the ambient pressure, and outside air is sucked in to prevent generation of negative pressure in the tank. (Set pressure of vacuum valve: 2 ± 0.3 kPa {0.02 ± 0.003 kg/cm2 }) Prevention of pressure rise in tank • While the hydraulic circuit is in operation, the pressure in the hydraulic tank increases as the oil level and the temperature in the hydraulic tank rise according to the operation of the hydraulic cylinders. When the pressure in the tank exceeds the set pressure, valve assembly (5) is pushed up to release the pressure in the tank and prevent pressure rise. (Set pressure of air bleeding valve: 17 ± 2.5 kPa {0.17 ± 0.025 kg/cm2 })

10-78

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10 Structure and function Hydraulic system

CLSS

a CLSS: Abbreviation for Closed center Load Sensing System

Structure of CLSS

(D61-PNJ1-041-K-00-A)

a CLSS: Abbreviation for Closed center Load Sensing System

Features The CLSS has the following features. • Fine controllability not influenced by load • Control performance that allows digging even under fine control operation condition • Easy combined operation ensured by the flow dividing performance that is determined by the opening areas of spools during combined operations • Energy saving by variable discharge pump control Configuration • CLSS consists of variable capacity piston pumps, control valves, and respective actuators. • The pump consists of the main pump, fixed throttle valve, PC valve, and LS valve. Basic principle Pump swash plate angle control • The pump swash plate angle (pump discharge) is controlled so that LS differential pressure (dPLS) which is the differential pressure between pump discharge pressure (PP) and LS pressure (PLS) (actuator load pressure) at the control valve outlet is constant. [LS differential pressure (dPLS) = Pump discharge pressure (PP) - LS pressure (PLS)] D61EM-23M0

10-79

10 Structure and function Hydraulic system

• When LS differential pressure (dPLS) is lower than the set pressure of the LS valve (the actuator load pressure is high), pump swash plate moves in the maximum angle direction. When it is higher than the set pressure (the actuator load pressure is low), pump swash plate moves in the minimum angle direction. LS differential pressure (d d PLS) and pump swash plate angle

10-80

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10 Structure and function Hydraulic system

a For explanation of the operation, see "Work equipment and cooling fan pump". Pressure compensation control

• A pressure compensation valve is installed to the outlet port side of the control valve to balance the load. • When actuators are operated in combined operations, the pressure difference (dP) between the upstream (inlet port) and downstream (outlet port) of the spool of each valve is kept the same among them, regardless the level of the load (pressure) by pressure compensation valve. • The flow of oil from the pump is divided (compensated) in proportion to the areas of openings (S1) and (S2) of each valve.

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10 Structure and function Hydraulic system

Work equipment and cooling fan pump

P1: Pump discharge port P1L: Pump pressure input port PD: Drain port PD2: Drain plug POP: Control source pressure input port PEN: Control pressure pickup plug PLS: Load pressure input port PS: Pump suction port 1. Pump body 2. Servo valve 3. Bleeder

10-82

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10 Structure and function Hydraulic system

Pump body

PA: Control source pressure output port PD4: Drain port PD5: Drain port PE: Control pressure input port

D61EM-23M0

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10 Structure and function Hydraulic system

1. Bearing 2. Ball retainer 3. Shaft 4. Oil seal 5. Spring 6. Sleeve 7. Servo piston 8. Shoe retainer 9. End cap 10. Valve plate 11. Cylinder block 12. Piston 13. Shoe 14. Rocker cam 15. Case 16. Shuttle valve 17. Filter

10-84

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10 Structure and function Hydraulic system

Structure • Cylinder block (11) is supported on shaft (3) through spline (a). Shaft (3) is supported on the front and rear bearings. • The tip of piston (12) is shaped as a concave sphere and is crimped with shoe (13). Piston (12) and shoe (13) constitute a spherical bearing. • Rocker cam (14) is supported by case (15) and ball retainer (2) and has plane (A). Shoe (13) is kept pressed against the plane and slides in a circular pattern. Shoe (13) transmits high-pressure oil to form a static pressure bearing for its sliding. • Piston (12) moves relatively in the axial direction in each cylinder chamber of cylinder block (11). • Cylinder block (11) rotates relatively to valve plate (10) while blocking the pressurized oil. • The oil pressure is balanced properly on this plane. • The pressurized oil is sucked in and discharged from each cylinder chamber in cylinder block (11) through valve plate (10).

Specifications

(D61-D8B0-030-K-00-A)

Model Type Theoretical discharge (cm3/rev) Rated discharge pressure (MPa {kg/cm2}) Fan drive pressure (MPa {kg/cm2}) Rated speed (rpm)

Function

LPV90 Variable displacement swash plate type piston pump 90 27.4 {280} 16.1 {164} 2,200

(D61-D8B0-042-K-00-A)

• This pump converts the rotation and torque of the engine transmitted to its shaft into hydraulic pressure and discharges pressurized oil according to the load. • It is possible to change the discharge by changing the swash plate angle.

Operation

(D61-D8B0-044-K-00-A)

Operation of pump • Cylinder block (2) rotates together with shaft (1) and shoe (3) slides on plane (A). • Rocker cam (4) pivots on ball retainer (5), and accordingly angle (a) between center line (X) of rocker cam (4) and the axis of cylinder block (6) changes. • Angle (a) is called the swash plate angle.

• While angle (a) is made between center line (X) of rocker cam (4) and the axis of cylinder block (2), plane (A) works as a cam for shoe (3). • Piston (6) slides inside cylinder block (2) and a difference is made between volumes (E) and (F) in cylinder block (2). • Oil in amount of (F)-(E) is sucked in and discharged from each piston (6). • Oil is discharged while cylinder block (2) rotates and the volume of chamber (E) decreases. • Oil is sucked in when the volume of chamber (F) increases.

D61EM-23M0

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10 Structure and function Hydraulic system

• When center line (X) of rocker cam (4) matches the axis of cylinder block (2) (the swash plate angle is 0), the difference between volumes (E) and (F) inside cylinder block (2) is 0. • Pressurized oil is not sucked or discharged, namely pumping action is not performed. (Actually, however, the swash plate angle does not become 0 deg.) • The pump discharge is in proportion to swash plate angle (a).

Discharge control • If swash plate angle (a) increases, the difference between volumes (E) and (F) increases, and consequently discharge (Q) increases. • Swash plate angle (a) is changed by servo piston (7). • Servo piston (7) reciprocates linearly according to the signal pressure from the PC and LS valves. • This linear motion is transmitted to rocker cam (4). • Rocker cam (4) supported on ball retainer (5) slides around ball retainer (5).

10-86

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10 Structure and function Hydraulic system

Servo valve

(HM300-C2B0-041-K-00-A)

P1: Pump discharge pressure port PE: Control pressure output port T: Drain port

D61EM-23M0

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10 Structure and function Hydraulic system

PC valve T: Drain PA: Pump pressure input PPL: PC valve output pressure LS valve PA: Pump pressure input PE: Control piston pressure PLS: LS pressure input PPL: PC valve output pressure PPLS: LS pump pressure input 1. Lever 2. Spring 3. Retainer 4. Seat 10-88

D61EM-23M0

10 Structure and function Hydraulic system

5. Spool 6. Sleeve 7. Piston 8. Seal 9. Piston 10.Nut 11.Plate 12.Plug 13.Spring 14.Seat 15.Spool 16.Plug

LS valve

(HM300-C2J0-042-K-00-A)

Function • The LS valve controls the pump discharge according to the travel of the control lever, or the flow demanded by the actuator. • The LS valve detects the flow rate demanded by the actuator from differential pressure (dPLS) between inlet pressure (PPLS) and outlet pressure (PLS) of the control valve and controls pump discharge (Q). [(PPLS) is called the LS pump pressure, (PLS) the LS pressure, and (dPLS) the LS differential pressure.] • In other words, pressure loss [= LS differential pressure (dPLS)], which occurs when the oil flows through the passage in control valve spool, is detected, and pump discharge (Q) is controlled to maintain the pressure loss at a constant level. Through this operation, the pump can discharge the proper volume of oil as demanded by the actuator. • Pump discharge pressure (PP), LS pump pressure (PPLS), and LS pressure (PLS) are led into the LS valve. The relationship between LS differential pressure (dPLS) and pump discharge (Q) changes as shown in the following figure.

D61EM-23M0

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10 Structure and function Hydraulic system

PC valve

(HM300-C2K0-042-K-00-A)

Function • The PC valve limits the oil flow to a certain level (depending on the discharge pressure) even if the travel of the control valve is increased extremely so that the horsepower absorbed by the pump does not exceed the engine horsepower, when pump discharge pressure (PA) is high. • In other words, the PC valve decreases the pump discharge when the actuator load is increased and the pump discharge pressure rises, and increases it when the pump discharge pressure lowers. • The relationship between the pump pressure and pump discharge is shown below.

Operation

(HM300-C2K0-044-K-00-A)

Action of spring • The spring force of spring (2) in the PC valve is determined by the angle of the swash plate. • When servo piston (6) moves to the right, spring (2) is compressed through lever (1) and the spring force changes. When pump pressure (PA) is low • The pressing force of piston (5) is decreased and spool (3) is a little closer to the right (Fig. 1). At this time, port (C) is connected to port (D) and the pressure transmitted to the LS valve becomes drain pressure (PT). • When port (F) is connected to port (G) of the LS valve, the pressure in port (J) becomes drain pressure (PT) and servo piston (6) moves to the left. • Consequently, the pump discharge is increased. • As servo piston (6) moves, lever (1) moves to the left and spring (2) expands and the spring force is decreased. Consequently, spool (3) moves to the left and port (C) is disconnected from port (D) and connected to pump discharge port (B). • As a result, the pressure in port (C) rises and the piston pressure is increased and servo piston (6) stops moving to the left.

10-90

D61EM-23M0

10 Structure and function Hydraulic system

When load is light (Fig. 1)

When pump pressure (PA) is high • The pressing force of piston (5) is increased and spool (3) is a little closer to the left (Fig. 2). At this time, port (C) is connected to port (B) and the pressure transmitted to the LS valve becomes pump pressure (PA). • When port (F) is connected to port (G) of the LS valve, the pressure in port (J) becomes pump pressure (PA) and servo piston (6) moves to the right. • Consequently, the pump discharge is decreased. • As servo piston (6) moves, lever (1) moves to the right and spring (2) is compressed and spring force is increased. Consequently, spool (3) moves to the right and port (C) is disconnected from port (B) and connected to drain pressure port (D). • As a result, the pressure in port (C) lowers and the piston pressure is decreased and servo piston (6) stops moving to the right. • Accordingly, the stop position (= pump discharge) of servo piston (6) is determined by the position where the thrust caused by pressure (PA) applied to piston (5) is balanced with the spring force of spring (2) acting through spool (3). (Fig. 3)

D61EM-23M0

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10 Structure and function Hydraulic system

When load is heavy (Fig. 2)

When balanced (Fig. 3)

10-92

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10 Structure and function Hydraulic system

Control valve a

This section describes only the 6-spool valve. 76

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D61EM-23M0

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10-93

10 Structure and function Hydraulic system

A1: Plug A2: To lift cylinder head A3: To side swing cylinder R.H. bottom A4: To side swing cylinder L.H. bottom A5: To planter unit A6: Plug B1: To cooling fan motor B2: To lift cylinder bottom B3: To side swing cylinder R.H. head B4: To side swing cylinder L.H. head B5: Plug B6: To water pump LS: To LS valve of work equipment and cooling fan pump P: From work equipment and cooling fan pump PP: To LS valve of work equipment and cooling fan pump PA1: Plug PA2: Plug PA3: Plug PA4: Plug PA5: Plug PA6: Plug PB1: Plug PB2: Plug PB3: Plug PB4: Plug PB5: Plug PB6: Plug PEPC1: From HST charge lamp PEPC2: From solenoid valve PI: Pump pressure pickup sensor port T: To hydraulic tank TS: To hydraulic tank CA2: Connector (from controller) CA3: Connector (from controller) CA4: Connector (from controller) CA5: Connector (from controller) CA6: Connector (from controller) CB1: Connector (from controller) CB2: Connector (from controller) CB3: Connector (from controller) CB4: Connector (from controller) CB5: Connector (from controller) CB6: Connector (from controller) 1. 6-spool valve 2. Cover 3. Block (pump/ tank port)

10-94

D61EM-23M0

10 Structure and function Hydraulic system

$ $

% %

D61EM-23M0

10-95

10 Structure and function Hydraulic system

1. Suction safety valve (cooling fan) 2. Suction valve (lift LOWER) 3. Suction valve (side swing R.H. LEFT) 4. Suction valve (side swing L.H. LEFT) 5. NO USE 6. Suction valve (planter unit) 7. Suction valve (side swing L.H. RIGHT) 8. Suction valve (side swing R.H. RIGHT) 9. Spool (cooling fan) 10. Spool (lift) 11. Spool (Side swing R.H.) 12. Spool (Side swing L.H.) 13. Spool (Planter unit) 14. Spool (Water pump)

10-96

D61EM-23M0

10 Structure and function Hydraulic system

& &

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D61EM-23M0

10-97

10 Structure and function Hydraulic system

1. Pressure compensation valve (cooling fan) (*1) 2. Pressure compensation valve (lift) (*1) 3. Pressure compensation valve (side swing R.H.) (*1) 4. Pressure compensation valve (side swing L.H.) (*1) 5. Pressure compensation valve (planter unit) (*1) 6. Pressure compensation valve (water pump) (*1) 7. Pressure compensation valve (water pump) (*2) 8. Pressure compensation valve (planter unit) (*2) 9. Pressure compensation valve (side swing L.H.) (*2) 10. Pressure compensation valve (side swing R.H.) (*2) 11. Pressure compensation valve (lift) (*2) 12. Pressure compensation valve (cooling fan) (*2) 13. Check valve (planter unit) 14. Check valve (side swing L.H.) 15. Check valve (side swing R.H.) *1: Flow control valve *2: Pressure reducing valve

10-98

D61EM-23M0

10 Structure and function Hydraulic system

D61EM-23M0

10-99

10 Structure and function Hydraulic system

1. Back pressure valve 2. Main relief valve 3. Unload valve 4. LS bypass valve Cooling fan valve 5. Pressure compensation valve (*1) 6. Spool 7. Suction safety valve 8. Pressure compensation valve (*2) Lift valve 9. Pressure compensation valve (*1) 10. Spool 11. Suction valve (LOWER) 12. Pressure compensation valve (*2) *1: Flow control valve *2: Pressure reducing valve

10-100

D61EM-23M0

10 Structure and function Hydraulic system

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D61EM-23M0

10-101

10 Structure and function Hydraulic system

Water pump valve 1. Pressure compensation valve (*1) 2. Spool 3. Pressure compensation valve (*2) Planter unit valve 4. Pressure compensation valve (*1) 5. Spool 6. NO USE 7. Suction valve (Planter unit) 8. Pressure compensation valve (*2) Side swing valve 9. Pressure compensation valve (*1) 10. Spool 11. Suction valve (LEFT) 12. Suction valve (RIGHT) 13. Pressure compensation valve (*2) 14. Centralized safety valve 15. Pressure relief plug *1: Flow control valve *2: Pressure reducing valve

10-102

D61EM-23M0

10 Structure and function Hydraulic system

Hydraulic circuit diagram and names of valves 3(3&

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D61EM-23M0

10-103

10 Structure and function Hydraulic system

1. Unload valve Set pressure: 3.4 MPa {34.5 kg/cm2} 2. Main relief valve Set pressure: 27.4 MPa {280 kg/cm2} 3. Pressure compensation valve 4. Suction valve 5. Fan port relief valve 6. Centralized safety valve (for work equipment valve) Set pressure: 31.4 MPa {320 kg/cm2} 7. Cooling fan valve 8. Lift valve 9. Side swing R.H. valve 10. Side swing L.H. valve 11. Planter unit valve 12. Water pump valve 12. Back pressure valve 14. LS bypass valve

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Unload valve

(D61-PQD0-040-K-00-A)

When control valve is in NEUTRAL position

PLS: LS circuit PP: Pump circuit T: Tank circuit 1. Sleeve 2. Spring 3. Spool Function • This valve releases discharge (Q) for the minimum pump swash plate angle into the tank circuit when the control valve is in neutral. At this time, pump discharge pressure (PP) is set to 3.4 MPa {34.5 kg/cm 2} by spring (2) in the valve. [LS pressure (PLS) is 0 MPa {0 kg/cm 2} Operation • Pump discharge pressure (PP) acts on the right end of spool (3), and LS pressure (PLS) acts on the right end of the spool. • LS pressure (PLS) is 0 MPa {0 kg/cm2}, so only pump discharge pressure (PP) acts, and (PP) is set only by the spring load of spring (2) when the control valve is in neutral. • When pump discharge pressure (PP) increases to the spring load 2.7 MPa {27.5 kg/cm 2} of spring (2), spool (3) moves to the left and pump circuit (PP) is connected to tank circuit (T) through hole (a) of sleeve (1). • Pump discharge pressure (PP) is set to 3.4 MPa {34.5 kg/cm2}.

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When control valve is in fine control range

Function • When the control valve is controlled finely, if the actuator demand flow is less than the discharge at the minimum swash plate angle of the pump, pump discharge pressure (PP) is set to LS pressure (PLS) + +2.7 MPa {27.5 kg/cm2}. When the differential pressure between discharge pressure (PP) and LS pressure (PLS) reaches the spring load 2.7 MPa {27.5 kg/cm2} of spring (2), the unload valve opens, thus LS differential pressure (dPLS) at this time is 2.7 MPa {27.5 kg/cm 2}. Operation • When the actuator is controlled at a flow less than the pump discharge with the swash plate at the minimum angle [below (Q) min. in the chart below], if the control valve spool is selected, the LS pressure [(PLS) = load pressure] is detected, and acts on the left end of spool (3). • As the system tries to let full flow of (Q) min. pass through the narrow opening of the control valve spool, the pump discharge pressure (PP) increases. As a result, the differential pressure between pump discharge pressure (PP) and LS pressure (PLS) becomes larger. • When the differential pressure between discharge pressure (PP) and LS pressure (PLS) reaches the spring load 2.7 MPa {27.5 kg/cm2} of spring (2), spool (3) moves to the left and pump circuit (PP) is connected to tank circuit (T). • Pump discharge pressure (PP) is set to pressure of spring force 2.7 MPa {27.5 kg/cm 2}＋LS pressure (PLS), and flow control differential pressure (dPLS) below the minimum swash plate angle is 2.7 MPa {27.5 kg/cm2}.

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When control valve is operated

Function • When the control valve is operated, if the actuator demand flow exceeds the pump discharge with the swash plate at the minimum angle, the unload valve blocks the flow to tank circuit (T) and allows all of pump discharge (Q) to flow to the actuator circuit. Operation • When the control valve is operated largely, LS pressure (PLS) is generated and applied to the left end of spool (3). LS differential pressure (dPLS) at this time is not so much different from pump discharge pressure (PP) because the opening area of control valve spool is wide. • Since the differential pressure between discharge pressure (PP) and LS pressure (PLS) does not reach the spring load 2.7 MPa {27.5 kg/cm2} of spring (2), spool (3) is pushed to the right by spring (2). • Pump circuit (PP) is disconnected from tank circuit (T) and all of pump discharge (Q) flows to the actuator circuit.

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Main relief valve, centralized safety valve

(D61-PQ90-042-K-00-A)

Function • If the oil pressure increases above the specified level, the oil is drained into the tank. Accordingly, the maximum pressure in the work equipment circuit is limited to protect the circuit.

Operation

(D65-C710-044-P-00-A)

• Port (A) is connected to the pump circuit, and port (B) is connected to the drain circuit. Pressurized oil flows through the diameter (d1) of main valve (2) and hole in the poppet (1) and acts on the diameter (d2) of main valve (2). Due to the difference in area (d1 < d2), main valve (2) is in contact with the sleeve.

• If the oil pressure in port (A) reaches the set pressure of spring (4), pilot poppet (3) opens and the oil flows around pilot poppet (3), through drilled hole (a), and then drains from port (B).

• As pilot poppet (3) opens, pressure in spring chamber (C) decreases. Poppet (1) moves to the right and comes in contact with the end of pilot poppet (3). The oil is drained through drilled hole (b).

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• As the pressure in spring chamber (C) is lower than the pressure in port (A), main vavle (2) opens and oil flows from port (A) to (B) to prevent abnormal pressure.

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Pressure compensation valve

(D61-C790-040-P-00-A)

Function • Oil flow rate to be supplied from pump to each actuators is equivalent when the load applied to actuators in operation is equivalent. • If pressure compensation valve is not equipped, operating speed of a certain actuator with smaller load becomes faster than it of other actuators with larger load. It is because oil supplied from pump flows more to actuators with lower load when load of a certain actuator increased. • Pressure compensation valve decreases flow rate going to actuator with smaller load so that LS pressure (PLS) of actuators is equalized at the value of the actuator with the largest load during combined

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operations. Thus, flow rate going to actuator with larger load is compensated to secure the operating speed not influenced by the load pressure. Operation • When the load pressure of the other actuator (below in the above figure) increases during combined operation, flow to the actuator circuit (A) on this side (top in the above figure) is going to increase. • In this case, LS pressure (PLS) of the other actuator side (below in the above figure) is applied to spring chamber (PLS1) on this side ((top in the above figure) and pushes pressure reducing valve (1) and flow control valve (2) to the left. • LS circuit (PLS) is connected to tank circuit (TS) from LS bypass valve (3). • Flow control valve (2) reduces the open area between pump circuit (PP) and spool upstream (PPA) to generate a pressure loss between (PP) and (PPA). • The flow control valve (2)and the pressure reducing valve (1) balance each other at the place where the pressure difference between (PA) and (PLS) which applies to the both end surfaces of the pressure reducing valve (1) becomes the same as the pressure loss between (PP) and (PPA) around the flow control valve. • The pressure differences between upstream pressure (PPA) and downstream pressure (PA) of both spools operated for combined operation becomes the same and the pump discharge is divided in proportion to the opening area of notch (a) of each spool.

Suction valve

(D65-C740-042-P-00-A)

Function • This valve prevents generation of negative pressure in the cylinder circuit.

Operation

(D65-C740-044-P-00-A)

• Port (A) is connected to the cylinder circuit and port (B) is connected to the drain circuit. When port (A) is loaded, the area difference between (d1) and (d2) causes main poppet (1) to open and lets oil to flow from port (B) to port (A) to prevent generation of negative pressure.

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Work equipment valve (lift, side swing L.H./R.H.) 1. When ZRUN HTXLSPHQW FRQWURO lever is set in the "LOWER" position

• When the lever is set in the "LOWER" position ( $ ' $ $ & $ $ $ $& ' 6 7 08 7 ), spool (2) is moved from the neutral position to the right by the pressurized oil from EPC valve (1) and the pressurized oil from the pump flows into the cylinder bottom through cylinder port (B). • The pressurized oil in the cylinder head is drained from drain port (T) through cylinder port (A).

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2. Work equipment valve (Planter unit, water pump)

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Spool (2) is moved from the neutral position to the right by the oil pressure from EPC valve (1) according to the command from the controller, and the pressurized oil from the pump flows in the actuator through port (B). The pressurized oil discharged from the actuator is directly drained in the tank.

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10 Structure and function Hydraulic system

Anti-drop valve

V T CY PI PCY

: From work equipment control valve : To hydraulic tank : To work equipment hydraulic cylinder : From PPC valve : For pressure pickup port and equalizer oil circuit

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1. Pilot spool 2. Spring (1st stage of spool) 3. Spring (2nd stage of spool) 4. Safety valve 5. Check valve 6. Spring

Unit: mm No.

Check item

Criteria

Remedy

Standard clearance

Repair limit

Load at installed length 15.1 N {1.54 kg}

Load at installed length 12.1 N {1.23 kg}

Free length × Outside diameter

Installed length

31.9 × 5.4

26.5

8 Spool return spring

19.1 × 8.0

14.0

22.6 N {2.3 kg}

18.0 N {1.84 kg}

9 Spool return spring

15.4 × 6

22.5

55.4 N {5.65 kg}

44.3 N {4.52 kg}

Check valve spring

D61EM-23M0

Free length

If spring is damaged or deformed, replace it

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10 Structure and function Hydraulic system

Function q

If the piping from the main valve to the work equipment hydraulic cylinder burst, this valve prevents the counter flow of the oil supplied from the work equipment hydraulic cylinder and protects the work equipment from sudden fall.

Operation 1.

When work equipment control lever is in neutral When piping is normal q The pressure maintained in the work equipment that is transmitted from port CY to chamber b closes check valve (5). This valve prevents the counter-flow of the oil supplied from the work equipment hydraulic cylinder if the piping from the main valve to the work equipment hydraulic cylinder bursts, protecting the work equipment from sudden fall. q Since the pilot pressure transmitted from PPC valve to port PI is 0 MPa {0 kg/cm2} when the control lever is in neutral, pilot spool (1) is moved to the far left by the forces of springs (2) and (3), and chambers a and b are disconnected. q As a result, the flow of oil from the main valve to the work equipment hydraulic cylinder is stopped, and the work equipment hydraulic cylinder is held in its position. q When extraordinarily high pressure exists in the work equipment hydraulic cylinder, safety valve (4) is actuated by pressure Pb maintained in the work equipment hydraulic cylinder. When piping bursts q If piping A between the main valve and the work equipment hydraulic cylinder bursts, chambers a and b are disconnected similarly to the case when the piping is normal. Therefore, the work equipment hydraulic cylinder is maintained in its position. q If the work equipment stops in an elevated position when the engine is stopped, you can lower the work equipment gradually by relieving port PCY and letting the pressurized oil in chamber b flow out of port PCY through orifice (7).

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When oil flows from the main valve to the work equipment cylinder When piping is normal q If pressure Pa of oil that is led from the main valve to chamber a exceeds the combined force of pressure Pb of chamber b, which is connected to the work equipment hydraulic cylinder, and spring (6), check valve (5) opens. As a result, chambers a and b are interconnected and oil flows from the main valve to the work equipment cylinder. When piping bursts If piping A between the main valve and the work equipment cylinder bursts, the oil in chamber a flows out of the burst location. Thus, pressure Pa in chamber a will be reduced. q If oil pressure Pa becomes lower than the combined forces of oil pressure Pb and of spring (6), check valve (5) closes, disconnecting chambers a and b. Therefore, oil pressure Pb in the cylinder is maintained and the work equipment is protected from sudden fall. q

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3. When oil flows from work equipment cylinder to main valve When piping is normal q The pressure maintained in the work equipment cylinder is transmitted to chamber b and check valve (5) closes. q The pilot pressure from PPC valve is transmitted to port PI, and spool (1) moves to the right up to a standby position when the pilot pressure becomes larger than the force of spring (2) (area with diameter d). (1st stage of travel) q At this point in time, chambers a and b are not interconnected. q If the pilot pressure is increased further until it becomes larger than the force of spring (3) (area with diameter d), spool (1) moves further to the right and chambers a and b are interconnected.(2nd stage of travel) q Therefore, the oil is returned from the work equipment cylinder to the main valve. When piping bursts If piping A between the main valve and the work equipment cylinder bursts, the oil in chamber a flows out of the burst location, but the oil in chamber b is supplied to chamber a through the opening of spool (1). Thus, the work equipment is protected from sudden fall and spool (1) returns to the left when the PPC valve is returned to the neutral position. As a result, chambers b and a are disconnected and the work equipment is stopped.

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Accumulator

For EPC circuit

1. Gas plug 2. Shell 3. Poppet 4. Holder 5. Bladder 6. Oil port

Specifications

(PC-PL40-030-K-00-A)

Gas to be used Volume of gas (cc) Charged pressure (MPa {kg/cm2}) Max. operating pressure (MPa {kg/cm2})

Function

Nitrogen gas 300 1.18 {12} (at 80°C) 6.86 {70}

(D65-PL40-042-K-01-A)

• If the engine is stopped with the work equipment raised (the starting switch must be at ON position), the pilot pressure is supplied to the control valve by the pressure of the compressed nitrogen gas in the accumulator. Therefore, the spool is operated to lower the work equipment by its own weight.

Operation

(D155-PL71-044-K-00-A)

• After the engine is stopped, when the work equipment lever is in NEUTRAL, chamber (A) inside the bladder is compressed by the oil pressure in chamber (B). • When the work equipment lever is operated, the oil pressure in chamber (B) goes 2.9 MPa {30 kg/cm 2} or less. Pressure of the nitrogen gas in chamber (A) expands the bladder and the oil in chamber (B) acts as the pilot pressure to actuate the control valve.

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10 Structure and function Work equipment

Work equipment

Planter unit

The figure shows D61EM-23M0.

1. Planter unit 2. Side swing cylinder 3. Lift cylinder 4. Main beam

D61EM-23M0

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10 Structure and function Cab and its attachments

Cab and its attachments

ROPS cab

a ROPS: Abbreviation for Roll-Over Protective Structure

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Cab and its attachments

1. Front window 2. Front wiper 3. Front light 4. KOMTRAX GPS antenna 5. Door glass wiper 6. Door 7. Rear window 8. Rear wiper 9. Camera 10. Rear light 11. KOMTRAX communication antenna 12. Radio antenna

Function

(D65-K000-042-K-00-A)

• ROPS cab is a structure which protects the operator fastening a seat belt not to be crushed when the machine tips over.

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10 Structure and function Cab and its attachments

Cab mount

1 (

)

1. Damper mount (front) 2. ROPS stopper (front) 3. ROPS stopper (rear) 4. Damper mount (rear) Structure • The mounts are installed at two places in the front section and at two places in the rear section to secure the floor frame and the cab. • Oil-filled damper mounts (1) and (4) are used to absorb vibration. • ROPS stoppers (2) and (3) are installed to two places each on the front and rear sides to fix the cab having the ROPS in it when the machine tips over.

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Engine control system

1. Battery disconnect switch 2. Battery 3. Starting switch 4. Engine shutdown secondary switch 5. Engine controller 6. HST controller D61EM-23M0

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10 Structure and function Electrical system

Machine monitor KOMTRAX terminal Fuel control dial

Decelerator and brake pedal Parking brake limit switch

Parking brake lever Work equipment lock limit switch

Work equipment lock lever Electric steering lever

Joystick (steering, directional, and gear shift lever) (PCCS lever)

Neutral safety relay Personal lock relay

Engine Starting motor

Safety relay

Engine speed sensor Coolant temperature sensor

Engine oil pressure switch Injector

Supply pump ^% $2*38 $ $

5 ' ! $

Input/output signal a. Battery power supply b. Engine start signal c. Neutral safety relay signal d. Personal lock relay signal e. Starting switch ACC signal (upstream) f. Starting switch ACC signal (downstream) g. Parking brake signal h. Work equipment lock signal i. Joystick (steering, directional and gear shift) signal j. 1st throttle signal (Decelerator and brake pedal) k. 2nd throttle signal (fuel control dial) l. 3rd throttle signal (controller control signal) m. Controller power supply n. Engine speed signal o. Engine coolant temperature signal p. Engine oil pressure signal q. Sensor signal r. Monitor display signal

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Function • The neutral safety circuit is employed to secure safety when the engine is started. a HST controller (6) controls neutral safety relay (17) to disable the engine from starting unless both the parking brake lever (12) and work equipment lock lever (14) are set in the "LOCK" position, and joystick (steering, directional and gear shift lever) (16) is set in "NEUTRAL"" position. • The HST controller (6) calculates a proper engine speed based on setting of the working mode, etc. and information on the speed range, fuel control dial signal, and decelerator/ brake pedal signal, and sends it as 3rd throttle signal (controller control signal) (l) to engine controller (5). • The information of engine controller (5) is shared by the other controllers through the network and used for the optimum control of engine (19) and machine. • When you cannot stop engine (19) due to stuck starting switch (3), engine shutdown secondary switch (4) is usable for stopping engine (19). Start engine • If starting switch (3) is turned to "ON" position, engine controller (5) sends a command current to supply pump (26). For this reason, a fail-safe mechanism is provided with the electrical system to stop engine (19) when an electrical failure occurs. • A neutral safety mechanism prevents engine (19) from starting when either parking brake lever (12) or work equipment lock lever (14) is set to "FREE" position, or steering, directional and gear shift lever (16) is not in "Neutral". In such conditions, neutral safety relay (17) cuts off the starting current to starting motor (20). • Upon receipt of the engine cut-off command from the external source, KOMTRAX terminal (8) sends the signal to machine monitor (7). Machine monitor (7) operates personal lock relay (18) to cut off the starting current to starting motor (20), therefore engine (19) does not start. Engine speed control • Engine controller (5) sends 1st throttle signal (fuel control dial) (j) to HST controller (6). The HST controller (6) calculates a proper engine speed based on 1st throttle signal (decelerator/brake pedal) (j), 2nd throttle signal (fuel control dial) (k), setting of working mode, speed range, pedal mode, etc., and turning condition, and sends it as 3rd throttle signal (controller control signal) (l) to engine controller (5). Engine controller (5) receives 3rd throttle signal (controller control signal) (l) and controls supply pump (26) and injector (25). Stop engine • If starting switch (3) is turned to "OFF" position, the starting switch ACC signal (downstream side) (f) from the ACC terminal of starting switch (3) to engine controller (5) is cut off, and consequently the command current to supply pump (26) is cut off. Supply pump (26) stops fuel feed, decreasing the engine speed until engine (19) stops. Stopping engine with engine shutdown secondary switch • If engine shutdown secondary switch (4) is turned to the "Stop Engine" position, the starting switch ACC signal (downstream side) (f) from the ACC terminal of starting switch (3) to engine controller (5) is forcibly cut off. Above induces the same state as when starting switch (3) is turned to the "OFF" position, stopping engine (19).

! • 3 ' $ ! ' ' ! $ ( ) 3 $ . ! $ ' % $ $ ! % $&& $ $ ^% $2*38 $ $ $ $ _ % $ $ $ !

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10 Structure and function Electrical system

Cooling system control system

1. Battery disconnect switch 2. Battery 3. HST controller 4. Engine controller 5. Machine monitor 6. Cooling fan motor 7. Work equipment and cooling fan pump 8. Control valve 9. Cooling fan EPC valve 10. Cooling fan speed sensor 11. HST oil temperature sensor 12. Engine 13. Engine speed sensor 14. Engine coolant temperature sensor 15. Boost temperature sensor 16. Intake air temperature sensor Input/output signal a. Controller power supply b. Cooling fan speed signal c. HST oil temperature signal d. Engine speed signal e. Engine coolant temperature signal f. Boost temperature signal g. Intake air temperature signal 10-128

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Electrical system

h. CAN signal i. Cooling fan speed control signal j. Cooling fan reverse signal

Function

(D61-B000-042-K-00-A)

• HST controller (3) monitors engine coolant temperature signal (e), HST oil temperature signal (c), and boost temperature signal (f) through each temperature sensor, and controls the cooling fan speed according to the temperatures. Cooling fan speed control • HST controller (3) outputs the largest value in the target cooling fan speeds obtained from the engine coolant temperature, HST oil temperature, and boost temperature as cooling fan speed signal (j) to cooling fan EPC valve (9). • Cooling fan EPC valve (9) changes the open area of the cooling fan spool in control valve (8) to control the oil flow to cooling fan motor (6). • HST controller (3) detects the actual cooling fan speed via cooling fan speed sensor (10) and controls the fan speed to be the target speed. Cooling fan mode selection • When the starting switch is at "ON" position and the engine is stopped, the operator can set the cooling fan mode by selecting "Fan Reverse Mode" on the User Menu of machine monitor (5). There are two cooling fan modes: 1. Normal rotation mode 2. Cleaning mode Depending on the selected mode, HST controller (3) energizes the reverse rotation solenoid valve of cooling fan motor (6) to switch the rotation direction of the cooling fan. 1) Normal rotation mode The reverse rotation solenoid valve is deenergized and the cooling fan operates in the normal direction and the fan speed varies according to the signals from the temperature sensor. It must usually be used in this mode. 2) Cleaning mode Regardless of temperature signals, the cooling fan rotates in reverse direction at high speed. In this mode, the dust in the radiator fins can be removed. Using this mode periodically can extend the radiator fin cleaning interval. In "Cleaning Mode", the machine will not move even when the joystick (steering, directional and gear shift lever) is set in FORWARD or REVERSE, in order to protect the radiator. The cooling fan mode returns to "Normal rotation mode" after the starting switch is turned OFF and then turned ON again. Interlock when mode is changed • The cooling fan drive circuit will be damaged if the rotation direction is switched during the rotation of cooling fan. • Even if the "Fan Reverse Mode" is selected in the "User menu" of the machine monitor while the engine is running, the signal is ignored to protect the cooling fan drive circuit. Machine monitor (5) displays "Cannot reverse fan." and the cooling fan does not rotate in reverse.

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10 Structure and function Electrical system

HST control system a

HST: Abbreviation for Hydrostatic Transmission

Battery disconnect switch Battery Engine controller HST controller Decelerator and brake potentiometer Joystick (steering, directional, and gear shift lever) (PCCS lever) Fuel control dial potentiometer Machine monitor Engine Engine speed sensor

L.H. HST pump forward EPC valve R.H. HST pump forward EPC valve

L.H. HST pump reverse EPC valve

R.H. HST pump reverse EPC valve L.H. forward HST circuit oil pressure sensor

L.H. reverse HST circuit oil pressure sensor R.H. forward HST circuit oil pressure sensor

R.H. reverse HST circuit oil pressure sensor

L.H. HST motor speed sensor R.H. HST motor speed sensor

L.H. HST motor EPC valve R.H. HST motor EPC valve !#

Input/output signal a. Controller power supply b. CAN signal

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c. Decelerator and brake pedal stroke signal d. Steering, directional and gear shift signal e. Fuel control dial stroke signal f. Engine speed signal g. HST circuit oil pressure signal h. HST motor speed signal j. HST pump EPC valve drive signal k. HST motor EPC valve drive signal

Function (D61-C7E0-042-K-00-A) Gear shift control system Speed range shift by operator

A: Reverse travel speed setting "-1" B: Forward and reverse travel speed setting "0" • Upon receiving the speed range shift signal of the upshift switch or downshift switch from the joystick (steering, directional and gear shift lever), HST controller decides the capacity of HST pump and HST motor, and shifts the speed range. • The operator can select the quick shift mode or variable shift mode by operating speed range shift mode switch (1) while the machine is stopped. • If the joystick (steering, directional and gear shift lever) is tilted "FORWARD", the set travel speed corresponding to the speed range on line (B) in the above figure is decided. • The operator can change the reverse travel speed setting to levels of (A) (`) by operating reverse travel speed set switch (2). • If the joystick (steering, directional and gear shift lever) is tilted "REVERSE", the set travel speed corresponding to the speed range of settings (A) $ (`) of the reverse travel speed set switch is decided according to the above figure. • When the joystick (steering, directional and gear shift lever) is in "NEUTRAL", the set travel speed is 0 km/ h.

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Variable shift mode

Set travel speed corresponding to the speed range Number of lighting segments of speed range gauge Quick shift Travel F R speed range gauge (reverse mode speed speed travel speed setting) setSpeed range ting range gaugA:j2 j B: "0" e 2 2 2 4 3 4 ― ― 5 6 6 8 7 8 –2 10 8 10 –1 12 10 12 1st 0 14 11 14

Set travel speed (km/h)

Forward 0.8 1.0 1.5 2.0 2.4 2.9 3.4

Reverse (reverse travel speed setting)

A:j2 j

B: "0"

0.8 0.9 1.2 1.6 2.0 2.3 2.7

0.8 1.0 1.5 2.0 2.4 2.9 3.4

a The values written in bold letters indicate the travel speed settings in the quick shift mode (default value).

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Screen display • The speed range shift mode is displayed on the speed range display part of the machine monitor as follows. Quick shift mode

G0089268

1. Current speed range 2. Quick shift mode symbol Variable shift mode

1. Current speed range 2. Variable shift mode symbol

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10 Structure and function Electrical system

HST pump and motor sequence control

(D61-C7H4-042-K-00-A)

a HST: Abbreviation for Hydrostatic Transmission

1. Joystick (steering, directional, and gear shift lever) (PCCS lever) 2. HST controller 3. EPC valve 4. Servo valve 5. Speed sensor 6. HST pump 7. HST motor

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• The command travel speed is converted into the pump capacity command and motor capacity command to control HST pump EPC valve command current and HST motor EPC valve command current according to the preceding figure. • When the command travel speed is low, the motor capacity is maximized to increase the pump capacity to increase the speed. • When the command travel speed is high, the pump capacity is maximized to decrease the motor capacity to increase the speed.

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Decelerator/brake pedal control

(D61-G4A1-042-K-00-A)

• When the decelerator/ brake pedal is operated, the pedal command is transmitted according to the above figure. a The pedal command means the ratio to the set travel speed. Examples) • When decelerator/ brake pedal is depressed halfway Command travel speed = Pedal command x set travel speed / 100 calculated as above, the travel speed is controlled.

• When the decelerator/brake pedal is operated while the pedal mode is set to decelerator mode (A), the engine speed decreases as shown in the above figure. • When the pedal mode is set to brake mode (B), the engine speed does not decrease even if the decelerator/brake pedal is operated. • Use the brake mode when controlling only the travel speed while keeping the work equipment speed constant in winch work, etc. • The operator can select the decelerator mode or brake mode by operating pedal mode switch (1).

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Electrical system

Screen display q The pedal mode is displayed on the speed range display portion of the machine monitor as shown below. Decelerator mode

G0089269

1. Decelerator mode symbol Brake mode

G0089270

1. Brake mode symbol

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Engine speed control in accordance with load

(D61-C7H5-042-K-00-A)

HST pump control (rated speed matching control) • When an external load is applied, the travel speed is lowered by reducing the HST pump capacity according to the engine speed and HST circuit pressure so that the engine speed is controlled not to be lowered.

A: HST absorption torque B: Engine torque C: Matching D: Low-speed matching engine speed • According to the above figure, from engine speed, HST absorption torque (A) is judged, and from HST absorption torque (A) and HST circuit pressure; HST pump capacity = HST absorption torque (A) ÷ HST circuit pressure x 200 x /2 Upper limit of HST pump capacity is judged by above. HST pump control (rated pressure control) • When an external load is applied, the travel speed is lowered by increasing the HST pump capacity according to the HST circuit pressure so that the HST circuit pressure is controlled to be constant.

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Steering control system

(D61-C7H6-001-K-00-A)

A: Normal B: Fine • The HST controller turns the machine by changing the capacities of the right and left HST pumps according to the steering stroke of the joystick (steering, directional and gear shift lever). • When the machine turns to the right during forward straight travel, the travel speed of the right track is lowered by the right HST pump capacity decreased . • During the turning operation, the engine speed is increased to prevent lowering of the travel speed of the outside track. • When the joystick (steering, directional and gear shift lever) is operated to the right, the "Right steering rate" is transmitted according to the above figure. a The right steering rate means the ratio of the right HST pump capacity to the HST pump capacity during straight travel. Right HST pump capacity = Right steering rate x HST pump capacity during straight travel / 100 When the right steering rate is 0%, if the right HST pump capacity is set in neutral, the right track stops and the machine makes a pivot turn.

• • • •

When the right steering rate is negative, if the right HST pump capacity is set in reverse, the right track turns in reverse and the machine makes a counter-rotation turn. NORMAL (A) or FINE (B) can be set by turning mode on the customize menu. If the turning mode is set to NORMAL (A), the machine makes a pivot turn when the steering lever is operated to 80% of the operation effort change point as shown in the above figure. If the turning mode is set to FINE (B), the inside track does not stop when the steering lever is operated to 80% of the operation effort change point, and the normal turning range extends as shown in the above figure. FINE (B) is used by an operator who is accustomed to the HSS machine (the inside track of which does not stop even at the stroke end) and feels something different about the turning pattern of the HST machine or when the operator must control a large turning radius finely.

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Deviation control system

(D61-C7H7-001-K-00-A)

• The HST controller monitors the operating condition of each lever and each pedal, and controls the swash plate angle, or the discharge, of the HST pump constantly so that the output speeds of the right and left HST pumps are the same. • During forward straight travel, if the right HST motor speed is higher than the left HST motor speed, the control signal of the right forward HST pump EPC valve is lowered so that the machine keeps traveling straight. Condition for canceling straight travel correction control system 1. When joystick (steering, directional and gear shift lever) is operated for "TURN TO LEFT" or "TURN TO RIGHT" 2. When joystick (steering, directional and gear shift lever) lever is in "NEUTRAL" in travel direction 3. When each pedal or fuel control dial is operated and signal of HST motor speed sensor is Max. 0.15 km/h. 4. When HST motor speed sensor is judged failed because of open circuit, etc. The straight travel performance is secured under conditions other than the above.

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Parking brake control system

Battery disconnect switch Battery HST controller Engine Engine controller HST pump Charge pump Decelerator and brake pedal Decelerator and brake potentiometer Pedal limit switch

Parking brake lever Parking brake limit switch 1

Parking brake limit switch 2

Joystick (steering, directional and gear shift lever) Fuel control dial

Slow brake solenoid valve Parking brake solenoid valve

Tow receiving valve

Brake oil pressure sensor HST motor 20a. Parking brake 20b. HST motor speed sensor ^% $2*38 $ $ #$ . 4% $ . , 8 $ !

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Input signal a. Controller power supply b. CAN signal c. Parking brake lever lock signal d. Decelerator and brake pedal stroke signal e. Solenoid valve drive signal f. Brake oil pressure signal g. Joystick (steering, directional and gear shift) signal h. Fuel control dial stroke signal j. HST motor speed signal k. Slow brake solenoid output current

Function q

q q

Parking brake lever (11) is equipped with interlock parking brake limit switches 1 (12) and 2 (13) so that parking brake (20a) is not released and the machine does not start unless parking brake lever (11) is raised to "FREE" position. By sifting work equipment lock lever into lock position, parking brake can be applied as same as operation of parking brake lever. Decelerator/brake pedal (8) is equipped with interlock decelerator/brake potentiometer (9) and pedal limit switch (10) so that parking brake (20a) operates when decelerator/brake pedal (8) is depressed to the stroke end. HST controller (3) turns ON/OFF the output to parking brake solenoid valve (17) according to the positions of parking brake limit switch (12), decelerator/brake potentiometer (9), joystick (steering, directional and gear shift lever) (14), and fuel control dial (15). If parking brake (20a) is operated during travel, the machine components may be damaged. To avoid this, HST controller (3) monitors the state of HST motor speed sensor (20b) and turns OFF the output to parking brake solenoid (17) after the machine stops. HST controller (3) keeps the output to slow brake solenoid valve (16) turned ON. However, when parking brake limit switch 2 (13) or pedal limit switch (10) is pressed, slow brake solenoid valve (16) is deenergized and parking brake (20a) operates. An orifice is installed in the hydraulic circuit on the drain side of slow brake solenoid valve (16) to mechanically delay operation of parking brake (20a) approximately 1 second. HST controller (3) monitors the output current to slow brake solenoid valve (16) to check for a mismatch.

Conditions for turning "OFF" parking brake solenoid valve (control by controller)

Operating condition

Operates

1. When one of the following conditions is established and travel speed is 0.6 km/h or less. 2. When one of the following conditions is established and kept for 1 second. Condition

Parking brake lever (11) is in "LOCK" position (Parking brake limit switch 1 (12) is "ON") $ $ . ' 4% $ . , $ . $ $ ( $ ! ( ) ~ ) Decelerator/brake pedal (8) is depressed to the stroke end (Decelerator/brake pedal travels 90% of stroke) Joystick (steering, directional and gear shift lever) (14) is in NEUTRAL position (*1) Fuel control dial (15) is in SLOW position (*1) No current flows in slow brake solenoid valve (16)

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Conditions for turning "OFF" slow brake solenoid valve (16) (operation without via controller) Operating condition

Operation

1. When one of the following conditions is established. Condition

Parking brake lever (11) is in "LOCK" position (Parking brake limit switch 2 (13) is "ON") $ $ . 4% $ . , $ . $ $ ( $ ! ( ) ~ ) Decelerator/brake pedal (8) is depressed to the stroke end (Pedal stroke limit switch (10) is "ON")

D61EM-23M0

Parking brake o operates about one second later

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System operating lamp function

1. Battery disconnect switch 2. Battery 3. System operating lamp 4. Machine monitor 5. Engine controller 6. HST controller 7. KOMTRAX terminal Function • You can prevent an abnormal end due to cut-off of the battery power supply circuit while the controllers are in operation by checking the operating status of machine monitor (4), controllers (5), (6), and (7) with system operating lamp (3). a Before cutting off the battery power supply circuit, turn the starting switch to "OFF" position, and check that system operating lamp (3) goes out, then turn battery disconnect switch (1) to "OFF" position. a If you turn battery disconnect switch (1) to "OFF" position (battery power supply circuit is cut off) while system operating lamp (3) is ON, data lost error of machine monitor (4), controllers (5), (6), and (7) can occur. Do not operate battery disconnect switch (1) while system operating lamp (3) is ON. a System operating lamp (3) goes out in 2 minutes after the starting switch is turned to "OFF" position. a System operating lamp (3) may sometimes light up while the starting switch is turned to "OFF" position because KOMTRAX terminal (7) may maintain its communication under this condition. Lighting up and going out of system operating lamp • Voltage of 24 V is always applied to one end of the system operating lamp (LED) (3). • When any of machine monitor (4), controllers (5), (6), and (7) is in operation, the controller outputs low voltage (0 V), and a current flows in the diode to turn ON system operating lamp (3). • When all of machine monitor (4), controllers (5), (6), and (7) are stopped, the controller outputs high voltage (24 V), and no current flows in the diode, thus system operating lamp (3) goes out. a System operating lamp (3) may look slightly luminous in the dark after it is turned out. It is due to the minute leakage of current and not an abnormal phenomenon. • KOMTRAX terminal (7) performs communication periodically even if the starting switch is kept in "OFF" position, thus it starts and stops repeatedly. • The start and stop cycle (sleep cycle) of KOMTRAX terminal (7) varies the conditions including the communication status and machine stop time, and the lamp may keep lighting for up to approximately one hour a When you want to cut off the battery circuit for maintenance but system operating lamp (3) keeps on lighting up, turn the starting switch to "ON" position, and then turn it to "OFF" position, and the lamp goes out in 2 minutes. After system operating lamp (3) goes out, turn battery disconnect switch (1) immediately to "OFF" position.

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Battery disconnect switch function

1. Battery disconnect switch 2. System operating lamp

(O): OFF position (I): ON position

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Function • Usually, battery disconnect switch (1) is used instead of disconnecting the cable from the negative terminal of the battery in the following cases. 1. When storing the machine for a long period (more than one month) 2. When servicing or repairing the electrical system 3. When performing electric welding 4. When handling the battery 5. When replacing a fuse, etc. • When battery disconnect switch (1) is turned to the OFF position (the contact is opened), all the continuous power supplies for the components, including the starting switch B terminal and controllers, are all cut out, and the condition is the same as the condition when the battery is not connected. Accordingly, all the electric system of the machine is disabled. • System operating lamp (2) lights up when the controller is turned ON. Even if the starting switch is in the OFF position, the lamp lights up while the KOMTRAX terminal is performing communication. Precautions for using battery disconnect switch • Do not turn OFF battery disconnect switch (1) while system operating lamp (2) is lighting up. • If battery disconnect switch (1) is turned OFF while system operating lamp (2) is lighting up, the data in the controller may be lost and the controller may be damaged seriously. • Do not turn OFF battery disconnect switch (1) while the engine is running or immediately after the engine is stopped. • If battery disconnect switch (1) is turned OFF while the alternator is generating power, the generated current has nowhere to go, leading to overvoltage in the electrical system of the machine, which may cause serious damage to the electrical system, including the electric devices and controllers. • If battery disconnect switch (1) is turned OFF for a long period, the machine monitor and the clock of the radio may be initialized. In this case, re-setting is required.

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Machine monitor system

1. Machine monitor 2. Battery 3. HST controller 4. Engine controller 5. KOMTRAX terminal 6. Sensors and switches 7. Camera (for machines equipped with camera) Input/output signal a: Power supply b. CAN signal c. Sensor signals and switch signals d. Camera signal (for machines equipped with camera) • This system monitors the machine condition by using the sensors and switches installed to various parts of the machine. This is the system which processes and displays the obtained information quickly on machine monitor (1) to notify the operator of the machine condition. The information displayed on machine monitor (1) falls into the following types: 1. Alarm when the machine has problem 2. Machine status display (coolant temperature, HST oil temperature, fuel level, etc.) 3. Failure code 4. Current and voltage values of sensors and solenoids D61EM-23M0

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5. Display of camera image Processing by machine monitor (all specifications) Display on machine monitor Contents and condition of processing 1. Display of travel direction and speed range • F1, R3, etc. are notified by CAN signal according to information of HST controller. 2. Display of gauges of fuel level, engine coolant temperature, etc. • Controller converts the sensor signals into gauge levels and sends them to the machine monitor by CAN signal. 3. Display of failure • When any failure occurs, the corresponding failure code is notified to the machine monitor by CAN signal. • The command to sound the buzzer or to light up the caution lamp is notified as well, according to the contents of failure. 1. When normal Action level and failure code 2. In abnormality record screen Failure codes and • service meter reading at the first occurrence, • service meter reading at the last occurrence, • number of occurrences, etc. are displayed on the machine monitor.

Method

Flow of signals

CAN signal

Sensors and solenoids O Controller O Machine monitor CAN signal

Monitoring display Contents and condition of processing 1. The communication conditions of each sensor, each solenoid, and CAN signals are displayed. • Item numbers and conditions of components are notified to the machine monitor by CAN signal. • The machine monitor displays each item and its value. 2. Each item is selected by by using the cursor switch and the enter switch.

Method

Flow of signals

CAN signal

Sensors O Controller O Machine monitor

Method

Flow of signals

―

CAN signal

Others Contents and condition of processing 1. Monitoring/Pre-defined 2. Monitoring 3. Abnormality Record 4. Maintenance Record 5. Maintenance Mode Setting 6. Phone Number Entry 7. Default 8. Diagnostic Tests 9. Adjustment 10. No-Injection 11. KOMTRAX Settings 12. Service Message 13. Screen Adjustment a 14. KOMTRAX Terminal Settings a

a For details of the operating method, see Testing and Adjusting, "Special functions of machine monitor (EMMS)". 10-148

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Machine monitor

(D61-Q180-042-K-00-A)

Function • The machine monitor has monitor display function, mode selection function and switch function for electrical parts etc. Also it has an alarm buzzer. • The machine monitor has a CPU (Central Processing Unit) in it to process, display, and output the information. • The machine monitor consists of a display and switches. The display is of LCD (liquid crystal display) type, and the switches are of flat sheet switch. • If there is trouble in the machine monitor, controller, or wiring between the machine monitor and controller, the display does not indicate normally. Precautions on the machine monitor display • One of the features of the liquid crystal of the display is that there may be black spots (spots that do not light up) or white spots (spots that stay lighting up) on the screen. When there are fewer than 11 black or white spots, this is not a failure or a defect. • When the engine is started, the battery voltage may lower suddenly, depending on the ambient temperature and the condition of the battery. In this case, the display may go out for a moment. However, this phenomenon is not a trouble. • When you use the machine monitor for a long time, blue bright spots may appear on the screen of black background. However, this phenomenon is not a failure or a defect of the machine monitor. Blue spots can never be a problem as the screen has usually blue or white background. (White in the LCD is made up of red, green and blue.)

Input and output signals of machine monitor

(D61-Q180-03C-K-00-A)

070-18P [CN-CM01] Pin No. 1 2 3 4 D61EM-23M0

Signal name Continuous power supply (24 V) Continuous power supply (24 V) GND (continuous power supply) GND (continuous power supply)

Input/output signal Input Input ― ― 10-149

10 Structure and function Electrical system

Pin No. 5 6 7 8 9 10 11 12 13 14 15 16 17 18

Signal name External starting signal Starting motor cut-off relay (*1) System operating lamp Lamp switch Starting switch ACC signal Starting switch C signal Preheating Engine shutdown secondary switch Analog GND Fuel level sensor Alternator R signal (*1) (*1)

Input/output signal Input Output ― Input Input Input Input Input Input ― Input Input ― ―

*1: Never connect these pins. Malfunctions or failures may occur. 070-12P [CN-CM02] Pin No. 1 2 3 4 5 6 7 8 9 10 11 12

Signal name Seat belt alarm switch (*1) (*1) Air cleaner clogging sensor (*1) (*1) CAN0 terminating resistor terminal CAN0_H (KOMNET/c) CAN0_L (KOMNET/c) CAN1 terminating resistor terminal CAN1_H (KOMNET/r) CAN1_L (KOMNET/r)

Input/output signal Input ― ― Input ― ― ― Input/Output Input/Output ― Input/Output Input/Output

*1: Never connect these pins. Malfunctions or failures may occur.

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070-20P [CN-CM03] Pin No. 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20

Signal name (*1) (*1) (*1) (*1) (*1) (*1) (*1) (*1) (*1) (*1) (*1) (*1) (*1) (*1) (*1) (*1) (*1) (*1) (*1) (*1)

Input/output signal ― ― ― ― ― ― ― ― ― ― ― ― ― ― ― ― ― ― ― ―

*1: Never connect these pins. Malfunctions or failures may occur. 070-8P [CN-CM04] Pin No. 1 2 3 4 5 6 7 8

Signal name Power supply for camera (8 V) Camera NTSC signal (*1) (*1) GND (power supply for camera) (*1) (*1) GND (shield)

Input/output signal Output Input ― ― ― ― ― ―

*1: Never connect these pins. Malfunctions or failures may occur.

D61EM-23M0

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10 Structure and function Electrical system

Display a

All caution monitor symbols are not shown in this figure.

G0089272

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A: Standard screen B: Standard screen (load graph display: ON) C: Check before starting screen D: Maintenance due time warning screen E: Warning screen F: Guidance screen G: Camera image screen (for machines equipped with camera) 1. Message monitor 3. Work equipment lock monitor 4. Parking brake monitor 5. Engine stop monitor 6. Seat belt monitor 7. Working mode monitor 8. Turning mode monitor 9. Preheating monitor 10. Fan reverse monitor 11. Speed range gauge 12. Service meter 13. Float mode monitor 14. Blade fine control monitor 15. Multi gauge q Engine tachometer q Speedometer q Hydraulic pump oil pressure gauge q Battery voltage gauge q Drawbar pull gauge q Clock 16. ECO gauge 17. Fuel consumption gauge 18. Fuel level monitor 19. Fuel level gauge 20. Speed range display 21. Engine coolant temperature monitor 22. Engine coolant temperature gauge 23. HST oil temperature monitor 24. HST oil temperature gauge 25. Load graph 26. Engine oil pressure monitor 27. Charge level monitor 28. Drawbar pull gauge 29. Clock 30. Maintenance due time warning monitor 31. HST system state monitor 32. Action level monitor 33. ECO guidance

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Gauges

(D61-Q1LA-042-K-01-A)

Gauge

Item displayed

Engine coolant temperature gauge (*1)

HST oil temperature gauge (*1)

Fuel level gauge (*1)

Description Range

Temperature (°C)

W1 W2 W3 W4 W5 W6

105 102 100 85 60 30

Range

Temperature (°C)

P1 P2 P3 P4 P5 P6

110 100 98 70 20 0

Range

Quantity (l)

F1 F2 F3 F4 F5 F6 Range

Engine tachometer (*1, *2)

M1 M2 M3 M4 M5 M6 Range

Speedometer (*1, *2)

M1 M2 M3 M4 Range

Hydraulic pump oil pressure gauge (*1, *2)

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M1 M2 M3 M4 M5 M6

335 267 199 132 74 63 Rotating speed (rpm) 3,000 2,750 2,000 1,500 1,000 500 Travel speed (km/ h) 15 10 5

Background color Red Red Blue Blue Blue White Background color Red Red Blue Blue Blue White Background color Blue Blue Blue Blue Blue Red Gauge range Red Red Green Green Green Green Gauge range

Remarks • Indicates corresponding temperature range. • Alarm buzzer sounds at 105°C or higher. • If background color is white, warm up engine.

• Indicates corresponding temperature range. • Alarm buzzer sounds at 110°C or higher. • If background color is white, warm up hydraulic components.

• Indicates corresponding level range.

• Indicates corresponding engine speed. • Engine overrun monitor lights up at 3,000 rpm or higher.

• Indicates corresponding travel speed.

Green Green Green

Green

Pressure (MPa) 50 40 30 20 10 0

Gauge range Green Green Green Green Green Green

• Indicates corresponding pump discharge pressure of work equipment

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10 Structure and function

Electrical system

Gauge

Item displayed

Battery voltage gauge (*1, *2)

Drawbar pull gauge (*1, *2)

Description Range

Voltage (V)

M1 M2 M3 M4 M5 M6

31 30 25 20 15 0

Range

Power (W)

M1 M2 M3 M4 M5 M6

1.0 0.8 0.6 0.4 0.2 0

Range

Power (W)

0.9

0.24

Load graph (*1, *4)

Segment Green

1 to 8

Orange

9, 10

ECO gauge (*3)

Segment Green

1 to 8

Orange

9, 10

Drawbar pull gauge (*3)

D61EM-23M0

Gauge range Red Red Green Green Green Red Gauge range Green Green Green Green Green Green Gauge range Red

Remarks • Indicates corresponding battery voltage.

• Indicates corresponding drawbar pull.

• Indicates drawbar pull by several seconds. • Horizontal axis indicates time and vertical axis indicates drawbar pull. (Indicates latest information on rightmost.) White (Indicated when "ON" is selected from items in "Load Display" of customize menu.) Fuel Rate • Indicates Fuel Rate (average of fuel consumption by 3 seconds) in Low to 10 steps. medium (Displays when "Fuel Consum" is selected from items in "ECO Guidance" o "Configurations" o High "ECO Gauge" on user menu.) Load level • Indicates Traction (average of drawbar pull by 1 second) in 10 Light to steps. medium (Displays when "Traction" is selected from items in ECO Guidance o "Configurations" o Heavy "ECO Gauge" on user menu.)

Service meter

00000.0 h to 99999.9 h

Clock

• 12-hour system display (AM/ PM) • 24-hour system display

• Indicates accumulated engine operating hours (alternator is generating). (Press F4 switch to change to clock display.) • Displays time. (Press F4 switch to change to service meter display.) (When clock is displayed on multi gauge, if F2 switch is pressed, clock changes to engine tachometer.)

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10 Structure and function Electrical system

Gauge

Item displayed

Description

Fuel consumption gauge (*3)

• 1 Day • Split Time • None

Speed range gauge (*1)

See "HST control system".

Remarks • Indicates average fuel consumption. (Display can be changed by selecting another item in "ECO Guidance" o "Configurations"o "Average Fuel Consumption Display" on user menu.)

*1: If the gauge signal is not available due to an open circuit in the CAN communication line, the gauge pointer disappears. *2: This item is classified into multi gauge, and the display changes every time the F2 switch is pressed. *3: The display setting can be changed by selecting another item in "ECO Guidance" o "Configurations". *4: The display setting can be changed by selecting another item in "Load Display" on the customize menu.

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Alarm monitor

Symbol

(D61-Q1LA-042-K-02-A)

Item displayed

Range

Description Monitor display (Background color) Lights up (Red)

L02

Min. 102°C

Lights up (Red)

―

Below 102°C

Lights up (Blue)

―

Min. 110°C

Lights up (Red)

L02

Min. 100°C

Lights up (Red)

―

Below 100°C

Lights up (Blue)

―

Min. 105°C Engine coolant temperature

HST oil temperature

Below 74 l Fuel level Min. 74 l When charge is defective (*1) (Charge voltage Battery < Battery charge voltage) When normal When abnormal (*1) (When below specified Engine oil pressure) pressure When normal When abnormal When air (When above cleaner is specified clogged pressure) When normal When abnormal (When below HST oil specified pressure pressure) When normal When abnormal (When above HST Oil Filter specified Clogging pressure) When normal

D61EM-23M0

Action level monitor

Lights up (Red) Lights up (Blue)

― ―

Lights up (Red)

L03

Goes out

―

Lights up (Red)

L03

Goes out

―

Lights up (Yellow)

(*3) L01

Goes out

―

Lights up (Red)

L02

Goes out

―

Lights up (Red)

L02

Goes out

―

Remarks

• Background color changes depending on the temperature detected. • Alarm buzzer sounds at 105 °C or higher.

• Background color changes depending on the temperature detected. • Alarm buzzer sounds at 110 °C or higher.

• Background color changes depending on the remaining fuel level. • Monitor lights up and alarm buzzer sounds when abnormality is detected while engine is running.

• Monitor lights up and alarm buzzer sounds when abnormality is detected while engine is running. • Monitor lights up when abnormality is detected while engine is running

• Monitor lights up and alarm buzzer sounds when abnormality is detected while engine is running. • Monitor lights up and alarm buzzer sounds when abnormality is detected while engine is running.

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Symbol

Item displayed

Water separator

Maintenance due time warning

State of system

State of engine system

State of hydraulic system

Range

Description Monitor display (Background color)

When abnormal (There is water collected above the specified amount.) When normal When maintenance due time is over (*2) When maintenance notice time is over When action level L04 or L03 is detected When action level L01 is detected When action level L04 or L03 is detected When action level L01 is detected When action level L04 or L03 is detected When action level L01 is detected

Lights up (Red)

―

Goes out

―

Lights up (Red)

Lights up (Yellow)

Lights up (Red) Lights up (Yellow) Lights up (Red) Lights up (Yellow) Lights up (Red) Lights up (Yellow) Lights up (Red) Lights up (Red)

L04 and L03

State of HST system

When action level L04 or L03 is detected When action level L01 is detected

Lights up (Yellow)

(*3) L01

Lights up (Red)

L03

Lights up (Red)

• Monitor lights up when abnormality is detected while engine is running

• The display changes depending on how long it has been since the maintenance due time was over • After starting switch is turned "ON", monitor lights ― up if condition for lighting it up is satisfied, and then goes out in 30 seconds. • Monitor lights up when abnormality is detected in L04 and L03 machine system. • When the background color (*3) is red, the alarm buzzer L01 sounds. • Monitor lights up when abnormality is detected in L04 and L03 engine system. • When the background color (*3) is red, the alarm buzzer L01 sounds. • Monitor lights up when abnormality is detected in L03 hydraulic system. • When the background color (*3) is red, the alarm buzzer L01 sounds. • Monitor lights up and alarm buzzer sounds when L04 and L03 abnormality is detected in steering system.

When action level L04 or L03 is detected

State of When action parking brake level L04 or L03 system is detected

Remarks

―

State of steering system

State of brake When action level L04 or L03 system is detected

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Action level monitor

• Monitor lights up when abnormality is detected in transmission system. • When the background color is red, the alarm buzzer sounds. • Monitor lights up and alarm buzzer sounds when abnormality is detected in brake system.

• Monitor lights up and alarm buzzer sounds when L04 and L03 abnormality is detected in parking brake system.

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Symbol

Item displayed

Range

Description Monitor display (Background color)

Action level monitor

State of fan control system

When action level L04 or L03 is detected When action level L01 is detected

Engine overspeed

When engine overspeed is detected

Lights up (Red)

L02

Lights up (Red)

L04

Lights up (Red)

L03

Action level

When action level L04 is detected When action level L03 is detected When action level L02 is detected When action level L01 is detected

Lights up (Red)

L02

Lights up (Yellow)

(*3) L01

Lights up (Red)

L03

Lights up (Yellow)

(*3) L01

Remarks

• Monitor lights up when abnormality is detected in fan control system. • When the background color is red, the alarm buzzer sounds. • Monitor lights up and alarm buzzer sounds when engine overspeed is detected. • Monitor lights up when abnormality is detected in machine. When the background color is red, the alarm buzzer sounds.

*1: This is included in the check before starting items. After the staring switch is turned "ON", the monitor lights up for 2 seconds, and changes to the standard screen if no failure is found. *2: The notice time is changeable from the items in "Maintenance Mode Setting" o "Maintenance Mode Change" o "Maintenance Notice Time Setting" of the service mode. *3: Lights up for 2 seconds, and then goes out.

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Pilot monitor Symbol

(D61-Q1LA-042-K-03-A)

Item displayed

Description • Operates automatically • at low temperature. (Lights up for Automatic approximately 45 preheating seconds at longest) • Goes off after engine is started. Elapsed time after turning Preheating Monitor starting display switch to HEAT (Preheating) Manual preheating 0 to 30 Lights up seconds 30 to 40 Flashes seconds 40 seconds Goes off or longer • Lights up: Lock Work Flashes: When it is necessary to release equipment lock the lock. Goes off: Free • Lights up: Lock Flashes: When it is necessary to release Parking brake the lock. Goes off: Free • Lights up: Not fastened Seat belt Goes off: Fastened

Engine stopped

Lights up: When engine is stopped Goes off: While engine is running

Fan rotating in Lights up: Cooling fan reverse rotation reverse Goes off: Cooling fan normal rotation

Message (Unread)

10-160

Lights up: There is unread message. Goes off: No message

Remarks Indicates the operation status of preheater.

Indicates the status of work equipment lock lever.

Indicates the status of parking brake lever.

Indicates whether seat belt is fastened.

• Indicates the operation status of engine.

• Indicates the rotating status of cooling fan.

• Indicates the status of message.

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Symbol

Item displayed Description Message Lights up: There is an already-read (No return message but return message for it is not message, sent yet. already-read Goes off: No message message) P: Heavy-duty operation Working mode E: Low-fuel consumption operation

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Remarks • Indicates the status of message.

• Indicates the status of working mode setting.

• Indicates the status of turning mode setting.

Turning mode

1: Normal 2: Fine

Blade float operation

Lights up: Blade float is operated. Goes off: Blade float is not operated.

• Indicates the operation status of blade float.

Blade fine control

Lights up: ON Goes off: OFF

• Indicates the status of blade fine control setting.

ECO guidance

• Guidance on excessive engine idling • Guidance on deterrence of hydraulic relief • Guidance on Economy Mode (recommended) • Guidance on deterrence of overload

• Indicates the guidance to support operation of the machine.

Speed range display

See "HST control system".

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Switches

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(D61-Q1C0-042-K-00-A)

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No. 1

Name Function Working mode selector Switches the working mode switch between P and E. [Numeral key pad: 1]

Operation P: Heavy-duty operation E: Low-fuel consumption operation • Changes the marks on speed range display. Quick shift mode

Gear shift mode selector switch [Numeral key pad: 2]

Switches the gear shift mode between quick shift and variable shift.

Reverse travel speed 3a setting (UP) switch [Numeral key pad: 3] Select reverse travel speed setting Reverse travel speed from 5 levels. 3b setting (DOWN) switch [Numeral key pad: 6] 4

Buzzer cancel switch [Numeral key pad: 4]

Stops the alarm buzzer. (Some alarm buzzer does not stop even if the switch is pressed.)

Pedal mode selector switch [Numeral key pad: 5]

Switches the pedal mode between brake mode and decelerator mode.

6a Guidance icon 6b Function switch

D61EM-23M0

Variable shift mode

• Set reverse travel speed to increase.

• Set reverse travel speed to decrease. • The alarm buzzer stops sounding. • When abnormality which turns on the alarm buzzer is detected again, the alarm buzzer sounds. • Mark on speed range display is changed. Decelerator mode

Brake mode

See "Guidance icon and function switch." section.

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Guidance icon and function switch

(D61-Q1C1-042-K-00-A)

• Functions available with the function switch vary depending on the guidance icon displayed above the switch. • No function is available if no guidance icon appears above the function switch. • The following is the list of guidance icons and the functions displayed above the function switches. Guidance icon

Item

Select user menu screen

Select clock or service meter

• Selects clock or service meter

Select camera image

• Selects camera image

Change multi gauge

• Changes gauge display of multi gauge display portion.

Select customize menu screen

Enter

Return

Move selected item

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Function • Selects user menu screen. • Information transmitted can be checked with background colors. Gray: When condition is normal Red: When soot accumulation abnormality (L03) is detected, or maintenance due time is over Yellow: When soot accumulation abnormality (L01) is detected, or maintenance notice time is over Green: When there is unread KOMTRAX message

• Displays customize menu screen to freely set and save working mode, gear shift mode, pedal mode, reverse travel speed setting, load graph display, blade fine control, swing mode, and travel speed in 1st, 2nd and 3rd gear speed. • Enters selected item or set item. • Information transmitted can be checked with background colors. Gray: When condition is normal Green: When ECO guidance is displayed • Returns to previous screen or status. • Moves selection to the above item. (Moves selection to the bottom item when at the top item) • Moves the point upward which is under adjustment in the item of "Default" o "Camera" o "Camera Setting Initialization" of service mode. • Moves selection to the below item. (Moves selection to the top item when at the bottom item) • Moves the point downward which is under adjustment in the item of "Default" o "Camera" o "Camera Setting Initialization" of service mode.

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Guidance icon

Item

Move selected item

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Function • Green arrow: Moves to the right tab. • White arrow: Moves to the right. (Moves selection to the leftmost item when at the rightmost item) • Moves the point rightward which is under adjustment in the item of "Default" o "Camera" o "Camera Setting Initialization" of service mode. • Green arrow: Moves to the left tab. • White arrow: Moves to the left. (Moves selection to the rightmost item when at the leftmost item) • Moves the point leftward which is under adjustment in the item of "Default" o "Camera" o "Camera Setting Initialization" of service mode.

Move selected item

• Moves selection to the above page. (Moves selection to the bottom page when at the top page)

Move selected item

• Moves selection to the below page. (Moves selection to the top page when at the bottom page)

Clear

• Clears selected item or displayed item.

Return to default setting

• Returns selected item to default value. (Used for screen adjustment.)

Set

• Executes setting.

Start

• Executes starting. (Used for starting split fuel consumption measurement for fuel consumption display)

Stop

• Executes stopping. (Used for stopping split fuel consumption measurement for fuel consumption display) • Stops fan rotation during reverse rotation of cooling fan.

Save

• Saves setting.

Select mode memory calling screen

• Selects "Memory Call" screen in customize mode.

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Guidance icon

Item

Function

Select mode memory storing screen

• Selects "Memory Store" screen in customize mode.

Hold

• Holds value of monitoring item. (Used during monitoring)

Cancel holding

• Cancels held value of monitoring item. (Used during monitoring)

Change "Average Fuel Consumption Logs" screen

• Changes graph on "Average Fuel Consumption Logs" screen.

Select "Error List" screen

• Selects "Error List" screen. • Information transmitted can be checked with background colors. Red: When action level of L02, L03, or L04 is displayed. Yellow: When action level of L01 is displayed.

Display image of camera No. 1

• Selects image of camera No. 1.

Display image of camera No. 2

• Selects image of camera No. 2.

Display image of camera No. 3

• Selects image of camera No. 3.

Display images of cameras No. 1 • Displays images of cameras No. 1 and No. 2 and No. 2 simultaneously simultaneously.

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Operator mode functions

(D61-Q193-042-K-00-A)

• The functions with which the operator can display or set by operating switches in normally displayed screen. Display and setting of some functions require special operation of the switch. • Items available in the operator mode are as follows: Category (*1)

Display order (*2) Item Display of KOMATSU logo Display of password input Display of Check before starting Display of warning after "Check before starting" Display of maintenance due time over Display of check of gear shift mode setting Display of standard screen Display of engine shutdown secondary switch screen Display of end screen Selection of working mode Selection of gear shift mode Selection of reverse travel speed setting Selection of pedal mode Operation to cancel alarm buzzer Operation of customizing Operation of customize memory Selection of multi gauge Operation of camera mode display (for machines equipped with camera) Operation of clock display and service meter display Check of maintenance information Setting and display of user menu • ECO Guidance • Machine Setting • Maintenance • Monitor Setting • Display of message (including KOMTRAX messages for user)

1 2 3 4 5

1 2 3 4

1 2 3 4 5

Display of ECO guidance Display of caution monitor Display of action level and failure code Checking function by LCD (Liquid Crystal Display) Function to check service meter Function of usage limitation setting/change password

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*1: The operator mode items are classified as follows. A: Display from the time when the starting switch is turned to "ON" position to the time when display changes to the standard screen, and display after starting switch is turned to "OFF" position B: Display when the machine monitor switch is operated C: Display when condition is satisfied D: Display that requires special operations of switches *2: Display sequence from the time when the starting switch is turned to the "ON" position to the time when the standard screen appears varies depending on the settings and conditions of the machine as follows: W: When the engine start lock is set ON X: When the engine start lock is set OFF Y: When any abnormality is detected by the check before starting Z: When any item is detected as the maintenance due time is over. a For how to operate the operator mode functions, see the Operation and Maintenance Manual or "Operator mode (Outline)" section in Testing and adjusting. a For the operating method of the engine start lock function, see "Password setting and canceling manual".

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Service mode functions

(D61-Q194-042-K-00-A)

• These functions are not displayed normally. A technician can display and set them special operation of switches. This function is used for special setting, testing, adjusting, or troubleshooting. • Items available in the service mode are as follows: Monitoring/Pre-defined Monitoring/Custom Mechanical Systems Abnormality Record Electrical Systems Maintenance Record Maintenance Mode Setting Phone Number Entry Key-on Mode Unit Default Camera Float Buzzer Cylinder Cut-out Diagnostic Tests Regeneration for Service KDPF Memory Reset Input ID Brake Pedal Potentio Initial Set Brake Pedal Potentio Detent Set Brake Pedal Potentio Full Set S/T Lever N Position Set S/T Lever Left Detent Set S/T Lever Left Full Set S/T Lever Right Detent Set S/T Lever Right Full Set Blade Lift Lever N Position Set Blade Lift Lever Up Full Set Adjustment Blade Lift Lever Down Full Set Blade Tilt Lever N Position Set ( $ ) Blade Tilt Lever Left Full Set ( $ ) Blade Tilt Lever Right Full Set ( $ ) F HST Pump Auto Set R HST Pump Auto Set HST Motor Auto Set Fan Auto Set Fan Test Mode Stall Pressure Test Mode Control Brake Release Mode No Injection Terminal Status KOMTRAX Settings GPS & Communication Status Modem Status Service Message a For operating method of the service mode functions, see "Service mode" section in Testing and adjusting.

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KOMTRAX system

• The KOMTRAX system consists of the KOMTRAX terminal, communication antenna and GPS antenna. • This system transmits various machine information by use of the radio communication. This system allows the KOMTRAX operator to reference the information and provide various services to the customers. • Information transmittable from the KOMTRAX system are as follows. 1. Operation map 2. Service meter reading 3. Location information 4. Abnormality record a To provide the services, you need to make an arrangement for starting the KOMTRAX service separately.

KOMTRAX terminal

(D65-Q220-042-K-00-A)

Type: TC330

1. GPS antenna connection 2. Machine harness connection (070-18P) 3. Machine harness connection (070-12P) 10-170

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4. Communication antenna connection

Input and output signals of KOMTRAX terminal

(D61-Q220-03C-K-00-A)

070-18P [CN-CK01] Signal name

Pin No. (*1) (*1) (*1) (*1) (*1) (*1) (*1) (*1) (*1) CAN_H (KOMNET/c) CAN_L (KOMNET/c) (*1) (*1) External starting signal System operation lamp (*1) (*1) (*1)

1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18

Input/Output Signal ― ― ― ― ― ― ― ― ― Input/Output Input/Output ― ― Input/Output Output ― ― ―

*1: Never connect these pins. Malfunctions or failures may occur. 070-12P [CN-CK02] Signal name

Pin No. 1 2 3 4 5 6 7 8 9 10 11 12

GND GND Starting switch ACC signal Alternator R signal (*1) Power supply Power supply (*1) (*1) (*1) Starting switch C signal (*1)

Input/Output Signal ― ― Input Input ― Input Input ― ― ― Input ―

*1: Never connect these pins. Malfunctions or failures may occur.

Function

(D65-Q220-042-K-01-A)

• This terminal utilizes satellite communications technology. • The terminal is an equipment which transmits various machine information obtained through network signals and input signals, as well as GPS positioning data. The terminal can transmit data via the communication antenna. • The status of the terminal can be checked by using the menu of "KOMTRAX setting" in the service mode of the machine monitor . • Use of KOMTRAX terminal must be limited for the countries in which such communication is allowed. • This terminal has LED lamps and 7-segment lamp indicator used for testing and troubleshooting on its display section.

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a When commencing operation of the KOMTRAX system or changing the country in which the system is used, you must give notice about the name of the country to Komatsu Ltd. a When operating the system in Japan, install a terminal dedicated for use in Japan.

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System component parts

Engine controller

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HST controller

Input and output signals of HST controller

(D61-C7W0-03C-K-00-A)

DRC26-24P [CN-ST1] Pin No. 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15

Signal name Travel lever potentiometer 2 (*1) Decelerator/ brake pedal potentiometer GND (analog) Downshift switch (NC) (*1) Swing lever position meter 2 Brake pressure sensor HST oil temperature sensor GND (signal) Downshift switch (NO) Starting switch C signal Travel lever position meter 1 Work equipment and cooling fan pump pressure sensor Alternator R signal

(*1)

17 18 19 20 21 22

Upshift switch (NC) Parking brake limit switch 2 (NO) Swing lever potentiometer 1 (*1) GND (analog) Sensor power supply 0 (5 V)

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Input/output signal Input Input Input Input Input Input Input Input Input Input Input Input Input Input Output

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Pin No. 23 24

Signal name Upshift switch (NO) (*1)

Input/output signal Input -

*1: Never connect these pins. Malfunctions or failures may occur. DRC26-40P (A) [CN-ST2] Pin No. 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30 31 32 33 34 35 36 37 38 39 40

Signal name Sensor power supply 1 (5 V) Auto switch (NC) Angle lever left 2 (NO) (*1) RR HST pressure sensor Blade tilt lever potentiometer 2 Angle lever right 2 (NO) Cooling fan reverse rotation solenoid valve (*1) Cooling fan speed sensor (*1) Auto switch (NO) Angle lever left 1 (NO) (*1) LR HST pressure sensor Blade tilt lever potentiometer 1 Angle lever right 1 (NO) Work equipment lock solenoid valve (*1) L.H. HST motor speed sensor (*1) CAN0_L CAN1_L External starting signal RF HST pressure sensor Blade lift lever potentiometer 2 FLOAT switch (NC) Backup alarm GND (pulse) R.H. HST motor speed sensor (*1) CAN0_H CAN1_H (*1) LF HST pressure sensor Blade lift lever potentiometer 1 FLOAT switch (NO) (*1) GND (pulse) (*1)

Input/output signal Output Input Input Input Input Input Input Output Input Input Input Input Input Output Input Input/Output Input/Output Input Input Input Input Output Input Input/Output Input/Output Input Input -

*1: Never connect these pins. Malfunctions or failures may occur. DRC26-40P (B) [CN-ST3] Pin No. 1 2 D61EM-23M0

Signal name Continuous power supply (24 V) Power supply (24 V)

Input/output signal Input Input

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3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30 31 32 33 34 35 36 37 38 39 40

GND (solenoid) Battery relay drive LF HST pump EPC valve LR HST pump EPC valve Blade angle left EPC valve Blade lift up EPC valve (*1) Parking brake limit switch 1 (NO) Continuous power supply (24 V) Power supply (24 V) GND (solenoids common) Starting switch ACC signal RF HST pump EPC valve RR HST pump EPC valve Blade angle right EPC valve Blade lift down EPC valve (*1) Parking brake limit switch 1 (NC) GND (power supply) Power supply (24 V) GND (solenoids common) Starting switch ACC signal Cooling fan EPC valve L.H. HST motor EPC valve Parking brake solenoid valve Blade tilt left EPC valve HST filter clogging switch Work equipment lock limit switch (NO) GND (power supply) GND (power supply) GND (power supply) System operating lamp Slow brake solenoid valve R.H. HST motor EPC valve Neutral safety relay Blade tilt right EPC valve (*1) Work equipment lock limit switch (NC)

Output Output Output Output Output Input Input Input Input Input Output Output Output Output Input Input Input Output Output Output Output Input Input Output Output Output Output Output Input

*1: Never connect these pins. Malfunctions or failures may occur.

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Electric blade control lever

(D155-PK80-041-K-00-A)

a Do not disassemble this lever since its output voltage characteristics and operating effort characteristics need to be adjusted after reassembly.

1. Boot 2. Nut 3. Connector

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Function

(D61-PK80-042-K-00-A)

Operating effort characteristics • The characteristics in all of the forward, reverse, rightward, and leftward directions are as follows. • Free return (operating effort characteristic curve)

Output voltage characteristics • This lever is installed to the right control stand and the control lever is fixed directly onto it. • The operating angle (stroke) of the control lever is detected with the potentiometer and signal voltages are output to the controller. • A potentiometer is installed to detect each of longitudinal displacement and lateral displacement. Each potentiometer outputs two signal voltages which are opposite in phase as shown in the figure on the right.

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Electric steering lever

(D155-F110-041-K-00-A)

a Do not disassemble this lever since its output voltage characteristics and operating effort characteristics need to be adjusted after reassembly.

1. Boot 2. Cover 3. O-ring 4. Bolt 5. Lever 6. Connector D61EM-23M0

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Function

(D61-F110-042-K-00-A)

Operating effort characteristics Operation for forward and reverse travel

• The control lever is held at 3 positions: "FORWARD", "NEUTRAL", and "REVERSE".

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Operation for right and left steering

• Free return Output voltage characteristics • The lever is installed to the left control stand and the control lever (knob) is fixed directly onto it. • The operating angle (travel) of the control levers is sensed with potentiometers and signal voltages are output to the power train controller. • A potentiometer is installed to detect each of longitudinal displacement and lateral displacement. Each potentiometer outputs two signal voltages which are opposite in phase as shown in the figure.

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Fuel control dial

(D65-AGJ7-041-K-00-A)

1. Knob 2. Dial 3. Spring 4. Ball 5. Potentiometer 6. Connector

Function

(D65-AGJ7-042-K-00-A)

• The fuel control dial is installed at the left side of the driver's seat. • When knob (1) is turned, potentiometer shaft (5) is turned and the resistance of the variable resistor changes to send variable throttle signals to the engine controller. • The hatched area in the following chart is the abnormality detection area and the engine speed is set to the medium (half) speed.

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Decelerator/ Brake potentiometer

(D61-G4E1-041-K-00-A)

1. Element 2. Contact 3. Shaft 4. Connector

Function

(D61-G4E1-042-K-00-A)

• The decelerator/ brake pedal potentiometer is installed to the front lower part of the floor and connected directly to the decelerator/ brake pedal. • When the pedal is depressed, shaft (3) of the potentiometer rotates to change the resistance of the variable resistor to send signals in voltages according to the pedal travel. Output characteristics

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CAN terminating resistor

(PC220-Q2V1-041-K-00-A)

a CAN: Abbreviation for Controller Area Network

1. Connector (with built-in resistor)

Specifications

(PC220-Q2V1-030-K-00-A)

Resistance: 120 z

Function

(PC220-Q2V1-042-K-00-A)

• This resistance controls the reflection of the high-frequency signals at the end of CAN communication line not to generate noise on the CAN communication signals sending and receiving between controllers. a If this resistance is missing, an error occurs on CAN communication and the machine cannot be operated.

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Engine oil pressure switch

(PC-ABK6-041-K-00-A)

1. Connector 2. Sensor 3. O-ring

Specifications

(PC220-ABK6-030-K-00-A)

Contact type: Normally closed

Function

(PC-ABK6-042-K-00-A)

• This oil pressure switch is installed to the cylinder block. It detects engine oil pressure, and turns the switch to "ON" position when the pressure goes below the specified value.

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Sensor

Ambient pressure sensor

(ENG-AAP2-041-K-00-A)

1. Connector 2. Sensor

Function

(ENG-AAP2-042-K-00-A)

• This sensor, installed to the air intake cover at the engine top side, detects the ambient pressure to output the corresponding variable voltage. Output characteristics

Charge (boost) pressure and temperature sensor

(ENG-AAM7-041-K-00-A)

1. Connector 2. Sensor 3. O-ring

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Function

(ENG-AAM7-042-K-00-A)

• This sensor is installed to the engine intake manifold. It detects the engine intake air pressure and its temperature, and outputs signals as a variable voltage for pressure, and as variable resistance for temperature. a "Charge pressure and temperature" are the engine intake air pressure and temperature of a turbocharged engine. These are also referred to as "boost pressure and temperature" or "intake air pressure and temperature". Output characteristics

Coolant temperature sensor

(ENG-BA87-041-K-00-A)

1. Connector 2. Sensor 3. O-ring

Function

(ENG-BA87-042-K-00-A)

• This sensor, installed on the cylinder head of the engine, converts the temperature variation into the resistance variation, and outputs the corresponding signals.

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Ne (crankshaft) speed sensor

(ENG-AG42-041-K-00-A)

1. O-ring 2. Sensor 3. Connector

Function

(ENG-AG42-042-K-00-A)

• This sensor, installed to the crankshaft pulley on the engine front cover, outputs the pulse voltage due to the gear rotation.

Bkup (camshaft) speed sensor

(ENG-AG62-041-K-00-A)

1. O-ring 2. Sensor 3. Connector

Function

(ENG-AG62-042-K-00-A)

• This sensor, installed to the ring of camshaft on the engine front cover, outputs the pulse voltage due to the gear rotation. 10-190

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Common rail pressure sensor

(ENG-AE28-041-K-00-A)

1. Connector 2. Sensor

Function

(ENG-AE28-042-K-00-A)

• This sensor, installed to the common rail in the engine, detects the fuel pressure to output the corresponding variable voltage.

Exhaust manifold pressure sensor

(ENG-AAN5-041-K-00-A)

1. O-ring 2. Sensor 3. Connector

Function

(ENG-AAN5-042-K-00-A)

• This sensor, installed to the pressure outlet tube installed to the exhaust manifold of the engine, detects the exhaust pressure to output the corresponding variable voltage.

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Crankcase pressure sensor

(ENG-A18C-041-K-00-A)

1. Connector 2. Sensor 3. O-ring

Function

(D61-A18C-042-K-00-A)

• This sensor, installed to the block part on the hose between engine and KCCV ventilator, detects the crankcase pressure (blowby pressure) to output the corresponding variable voltage.

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Hydraulic oil temperature sensor

(D65-PMT1-041-K-00-A)

1. Connector 2. Plug 3. Thermistor

Function

(D65-PMT1-042-K-00-A)

• This sensor is installed to the hydraulic tank. • This sensor detects the oil temperature and converts it into corresponding electric signals, and outputs the signals.

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HST circuit oil pressure sensor

(D61-C7Q1-041-K-00-A)

1. Sensor 2. Connector

Function

(D61-C7Q1-044-K-00-A)

• This sensor is installed to the HST pump. It senses the right and left HST circuit pressures as voltage changes by using the built-in semiconductors and generates signals according to the measured pressures. Output characteristics • The relationship between pressure (P) applied to the sensor and output voltage (E) is shown in the following graph.

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Work equipment and cooling fan pump circuit oil pressure sensor A)

(D61-C3WJ-041-K-00-

1. Sensor 2. Connector

Function

(D61-C3WJ-044-K-00-A)

• This sensor is installed to the work equipment/ cooling fan pump. It senses the work equipment/ cooling fan hydraulic circuit as a voltage change by using the built-in semiconductors and generates signals according to the measured pressure. Operation • The relationship between pressure (P) applied to the sensor and output voltage (E) is shown in the following graph.

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Brake circuit oil pressure sensor

(D61-G412-041-K-00-A)

1. Sensor 2. Connector

Function

(D61-G412-044-K-00-A)

• This sensor is installed to the central solenoid valve block. It senses the brake circuit pressure as a voltage change by using the built-in semiconductor and generates signals according to the measured pressure. Operation • The relationship between pressure (P) applied to the sensor and output voltage (E) is shown in the following graph.

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Cooling fan speed sensor

(D65-B750-041-K-00-A)

1. Sensor 2. Connector

Function

(D65-B750-042-K-00-A)

• This sensor is installed to the cooling fan motor. • This sensor detects the gear speed and outputs corresponding pulse signals.

Fuel level sensor

(D65-AD41-041-K-00-A)

1. Connector 2. Float 3. Arm 4. Body 5. Spring 6. Contact 7. Spacer D61EM-23M0

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Function

(D61-AD41-042-K-00-A)

• This sensor is installed on the rear surface of the fuel tank. • This sensor detects the fuel level and converts it into an electric signal, and outputs the corresponding signal. • The float (2) moves up and down according to the fuel level. • The movement of the float (2) activates the variable resistor through the arm (3).

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Water-in-fuel sensor

(PC-AEB3-041-K-00-A)

1. Connector 2. Tube 3. Sensor 4. O-ring

Function

(PC-AEB3-042-K-00-A)

• This sensor is installed to the cup of fuel prefilter. • This sensor outputs a signal when detecting water exists in the fuel beyond the specified level.

Air cleaner clogging sensor

(PC-A968-041-K-01-A)

1. Adapter 2. Hood 3. Indicator 4. Connector

Function

(PC-A968-042-K-00-A)

• This sensor is installed on the air cleaner outlet side. The switch is turned to "ON" position, if the air cleaner is clogged and the pressure level drops to the specified level (negative pressure).

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Charge filter clogging sensor

Function

(D61-C7Q4-041-K-00-A)

(D61-C7Q4-044-K-00-A)

• The charge filter clogging sensor is installed to the charge filter and its contacts detect the pressures before and after the filter. If the pressure difference between before and after exceeds the set level, the switch is turned ON.

Cleaning water line pressure switch

287387 &+$5$&7(5,67,& 35(6685( 5,6(

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Function q

The cleaning water line pressure switch drives the electric pump and pressurizes the accumulator until the pressure increases to Mh = 0.9 MPa in order to generate the source pressure of cleaning water. This switch stops the pump when the pressure increases to above Mh, and drives it again when the pressure decreases below MI = 0.7 MPa.

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Electrical system

Cleaning water pump

1. Water pump 2. Filter A: From water tank B: To water valve

Irrigation water valve

A: From water pump B: To work equipment

D61EM-23M0

10-201

10 Structure and function Electrical system

Refill cartridge rotation EPC

10-202

D61EM-23M0

SHOP MANUAL

D61E -23M0 Model

Serial Number

D61E -23M0

B 0001 and up

20 Standard value tables 4 20 Standard value tables

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20 Standard value tables Table of contents

Table of contents

20 Standard value tables- - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 20-1 Table of contents - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 20-2 Standard service value table- - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 20-3 Standard value table for engine - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 20-3 Standard value table for machine - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 20-4 Standard value table for electrical system - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 20-10

20-2

D61EM-23M0

20 Standard value tables Standard service value table

Standard service value table

Standard value table for engine

1 - 5 2 SAA6D107E-

Engine

Category

Machine model Engine Item

Standard value for new machine

Repair limit

rpm rpm

1,995 ± 50 1,670 ± 50 975 ± 25 2,200

1,995 ± 50 1,670 ± 50 975 ± 50 2,200

kPa {mmHg}

Min. 113 {Min. 850}

Min. 87 {Min. 650}

mm Intake valve mm Exhaust valve MPa Compression Engine oil temperature: pressure {kg/cm2} 40 to 60°C rpm Engine speed Coolant temperature: 30 to 102°C kPa Hydraulic oil temperature: 40 to 60°C HST stall (*1) and work equipment relief {mmH2O} KCCV circuit disconnected MPa High idle Coolant temperature: 30 to {kg/cm2} 102°C MPa EO15W40-LA Low idle {kg/cm2}

0.25 0.51 Min. 2.41 {Min. 24.6} 250 to 280

0.152 to 0.381 0.381 to 0.762 Min. 1.69 {Min. 17.2} 250 to 280

Max. 0.98 {Max. 100}

Max. 1.96 {Max. 200}

Min. 0.29 {Min. 3.0} Min. 0.10 {Min. 1.0}

Min. 0.25 {Min. 2.5} Min. 0.07 {Min. 0.7}

°C

80 to 110

120

Automatic adjustment (Autotensioner)

Measurement condition

Engine speed

• Coolant temperature: 30 to 102°C • Hydraulic oil temperature: 40 to 60°C

Boost pressure

• • • •

Valve clearance

• Coolant temperature: Normal temperature

Compression pressure Blowby pressure

Engine oil pressure Engine oil temperature Alternator belt tension

• • • • • • •

High P mode idle E mode Low idle Rated speed

Aftercooler inlet Coolant temperature: 30 to 102°C Hydraulic oil temperature: 40 to 60°C HST stall (*1) and work equipment relief

• Whole speed range (inside oil pan) —

Unit

rpm

(*1) Measure with "Stall pressure test mode" of the adjustment menu No. 21.

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20 Standard value tables Standard service value table

Standard value table for machine

Engine speed Machine model Engine Item

Decelerator pedal speed

Measurement condition

Unit

• Coolant temperature: 30 to 102°C • Hydraulic oil temperature: 40 to 60° C • Pedal-decelerated speed: Pedal depressed

rpm

- 5 2 SAA6D107E- Standard value Repair limit for new machine

975 ± 25

975 ± 50

Travel of control lever and pedal Machine model Engine Measurement condition

Forward and reverse

• Engine stopped • Center of lever knob Steering

NEUTRAL o FORWARD NEUTRAL o REVERSE NEUTRAL o Left counterrotation turn

NEUTRAL o Right counterrotation turn

Decelerator/brake pedal control

Half stroke (HST brake) • Engine stopped • Center of pedal (*1) Full stroke (mechanical brake)

` control lever

Joystick (steering, directional and gear shift lever)

Item

NEUTRAL o • Engine at low idle RAISE • Hydraulic oil temperature: 40 to NEUTRAL o 60°C • Center of lever knob LOWER

Unit

- 5 2 SAA6D107E- Standard value Repair limit for new machine 30 ± 10

30 ± 10

50 ± 10 (Play: Max. 3)

50 ± 10

59 ± 10

60 ± 10

(*1) When depressing the decelerator/brake pedal to full stroke, operating effort increases and the brake is applied mechanically.

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D61EM-23M0

20 Standard value tables Standard service value table

Control lever and pedal operating effort Machine model Engine

Joystick (steering, directional and gear shift lever)

Item

Unit

NEUTRAL o FORWARD/ REVERSE FORWARD/ REVERSE o NEUTRAL

Forward and reverse

55.9 ± 19.6 {5.7 ± 2.0}

Pivot turn

Steering

Decelerator/brake pedal control

` control lever

Measurement condition

• Engine stopped NEU• Center of lever TRAL o Counterknob LEFT rotation turn

Pivot turn NEUTRAL o CounterRIGHT rotation turn Half stroke • Engine stopped (HST brake) • Center of pedal Full stroke (*1) (mechanical brake) • Engine at low idle • Hydraulic oil temperature: 40 to 60°C • Center of lever knob

- 5 2 SAA6D107E- Standard value Repair limit for new machine 55.9 ± 19.6 55.9 ± 19.6 {5.7 ± 2.0} {5.7 ± 2.0}

N {kg}

55.9 ± 19.6 {5.7 ± 2.0}

20.6 ± 9.8 20.6 ± 9.8 {2.1 ± 1.0} {2.1 ± 1.0} 36.3(+14.7/36.3(+14.7/9.8) 9.8) {3.7(+1.5/-1.0)} {3.7(+1.5/-1.0)} 23.5 ± 9.8 23.5 ± 9.8 {2.4 ± 1.0} {2.4 ± 1.0} 39.2(+14.7/39.2(+14.7/9.8) 9.8) {4.0(+1.5/-1.0)} {4.0(+1.5/-1.0)} 62 ± 9.3 62 ± 9.3 {6.32 ± 0.95} {6.32 ± 0.95} 234.4 ± 46.9 310.0 > {23.9 ± 4.8} {31.6 >}

NEUTRAL o RAISE

24.5 ± 9.8 {2.5 ± 1.0}

NEUTRAL o LOWER

28.4 ± 9.8 {2.9 ± 1.0}

(*1) When depressing the decelerator/brake pedal to full stroke, operating effort increases and the brake is applied mechanically.

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20 Standard value tables Standard service value table

HST Machine model Engine

•

• • • • • • • Travel speed

• • • • • •

•

20-6

Reverse

Right Left Right

MPa Joystick {kg/cm2} (steering, directional and gear shift lever): P mode NEUTRAL Engine: High idle Hydraulic oil temperature: Joystick 40 to 60°C (steering, Control brake release mode directional and gear shift lever): FORWARD or REVERSE P mode Engine: High idle Quick shift mode 1st Reverse travel speed is the default value Hydraulic oil temperature: 40 to 60°C Measure on the level ground 1st " . ' . $ . , #05 $ . , 855 km/h P mode MIN. Engine: High idle position Variable shift mode Reverse travel speed is the MAX. default value position Hydraulic oil temperature: 40 to 60°C MIN. Measure on the level position ground MAX. " . ' . $ . , position #05 $ . , 855

3.23 ± 0.29 {33 ± 3.0}

3.04 ± 0.29 {31 ± 3.0}

3.04 ± 0.49 {31 ± 5.0}

Forward

• • •

Left

3.4 ± 0.2

3.4 ± 0.4

Reverse

Charge circuit pressure

P mode Engine: High idle Hydraulic oil temperature: 40 to 60°C Stall pressure test mode (*3)

Unit

4.1 ± 0.2

4.1 ± 0.4

Forward

• • Main circuit • pressure •

Forward

Measurement condition

0.8 ± 0.2

0.8 ± 0.3

Reverse

Hydraulic oil pressure

Item

- 5 2 SAA6D107E- Standard value Repair limit for new machine 40.2 to 44.1 39.2 to 45.1 {410 to 450} {400 to 460} 40.2 to 44.1 39.2 to 45.1 {410 to 450} {400 to 460} 40.2 to 44.1 39.2 to 45.1 {410 to 450} {400 to 460} 40.2 to 44.1 39.2 to 45.1 {410 to 450} {400 to 460}

0.8 ± 0.2

0.8 ± 0.3

D61EM-23M0

20 Standard value tables Standard service value table

Machine model Engine Item

Measurement condition • • • •

Travel deviation

• • • • • • •

Machine drift on a slope

• • • •

P mode Engine: High idle Hydraulic oil temperature: 40 to 60°C On a level ground (firm, flat and level ground such as concrete ground, etc.) Travel deviation in travel of 20 m after running-in 10 m and more Measure the travel deviation (x) For measuring posture, see "Travel 1" " . ' . $ . , #05 $ . , 855 Joystick (steering, directional and gear shift lever) position: N (neutral) position Stop the machine on the slope of 20 degrees Machine posture: Both front up and front down Machine drift on a slope for 1 minute (travel distance by hydraulic drift of travel) For measuring posture, see "Travel 2" Control Brake Release Mode " . ' . $ . , #05 $ . , 855

Unit

- 5 2 SAA6D107E- Standard value Repair limit for new machine

Max. 120

Max. 150

Max. 3.6

Max. 4.0

(*3) Measure with "Stall pressure test mode" of the adjustment menu No. 21.

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20 Standard value tables Standard service value table

Work equipment Machine model Engine Item Work equipment pump relief pressure

Cooling fan

Work equipment speed

Work equipment EPC valve output pressure

Measurement condition • Engine: High idle • Hydraulic oil temperature: 40 to 60°C NEUTRAL to RAISE

• Engine: High idle • Hydraulic oil temperature: 40 to NEUTRAL 60°C to LOWER • P mode • Engine: High idle RAISE • Hydraulic oil temperature: 40 to ` 60°C lifting • Between max. raise and speed ground level LOWER • For measuring posture, see "Work equipment 1" • Level and flat surface • Engine stopped • Lever in NEUTRAL Hydraulic • Hydraulic oil temperature: 40 to 60°C • Measure immediately after the setting drift of lifted • Measure the hydraulic drift (H) after 15 minutes elapsed • For measuring posture, see "Work equipment " • Engine at low idle • P mode • Coolant • Hydraulic oil Min. temperature: Max. temperaFan speed 80°C ture: 50 to 60°C • Engine: High idle • Fan normal Max. • Fan 100% speed rotation mode Work equipment • P mode • Fan 100% mode pump • Engine: High idle pressure • Hydraulic oil temperature: 50 to 60°C (fan drive pressure) • Fan normal rotation

20-8

Unit

MPa {kg/cm2}

- 5 2 SAA6D107E- Standard value Repair limit for new machine 27.44 ± 0.98 {280 ± 10}

24.5 {250}

Min. 1.65 {Min. 16.8}

Min. 1.37 {Min. 14.0}

2.2 ± 0.2

2.9

Max. 100

200 ± 50

200 ± 100

1,650 ± 50

1,650 ± 150

17.2 ± 1.5 {172 ± 15}

17.2 ± 2.5 {172 ± 25}

sec.

mm/15 min.

rpm

MPa {kg/cm2}

D61EM-23M0

20 Standard value tables Standard service value table

Machine posture and procedure for measuring performance

Work equipment : Hydraulic drift of lifted blade

Travel 1: Travel deviation

Travel 2: Machine drift on a slope

Work equipment 1: Blade lifting speed

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20 Standard value tables Standard service value table

Standard value table for electrical system Controller

(D61-RA1E-033-K-00-A)

Equipment name

Engine controller

20-10

Procedure, measuring location, criteria and remarks

a Check ground terminal T20 for looseness and corrosion. 1. Turn starting switch to OFF position. Continuous 2. Disconnect connector CE03, and connect T-adapter to female side. power 3. Turn starting switch to ON position. supply a If any trouble is found, perform troubleshooting for failure code [CA441]. voltage Between CE03 (female) (1) and (21) 20 to 30 V Voltage Between CE03 (female) (11) and (31) 20 to 30 V Continuous power supply voltage

1. Turn starting switch to OFF position. 2. Turn battery disconnect switch to OFF position. 3. Insert T-adapter into connector ST3. 4. Set battery disconnect switch to ON position. 5. Turn starting switch to ON position. Between ST3 (1) and each of (21) and (31) Voltage Between ST3 (11) and each of (32) and (33)

20 to 30 V 20 to 30 V

Solenoid power supply voltage

1. Turn starting switch to OFF position. 2. Turn the battery disconnect switch to OFF position. 3. Insert T-adapter into connector ST3. 4. Set battery disconnect switch to ON position. 5. Turn starting switch to ON position. Between ST3 (2) and (21) Voltage Between ST3 (12) and (31) Between ST3 (22) and (32)

20 to 30 V 20 to 30 V 20 to 30 V

Continuous power supply voltage

1. Turn starting switch to OFF position, and turn battery disconnect switch to OFF position. 2. Insert T-adapter into connector CM01. 3. Turn disconnect switch to ON position, and turn starting switch to ON position (connect ACC). Between CM01 (1) and (3) 20 to 30 V Voltage Between CM01 (2) and (4) 20 to 30 V Between CM01 (10) and (4) (ACC line) 20 to 30 V

HST controller

Machine monitor

D61EM-23M0

20 Standard value tables Standard service value table

Engine control

(D61-AG10-033-K-00-A)

Equipment name

Procedure, measuring location, criteria and remarks 1. Turn starting switch to OFF position. 2. Disconnect connector COOLANT TEMP, and connect socket to male side.

Coolant temperature sensor

a Regard coolant temperature sensor as normal if its resistance is 700 z to 37 kz when coolant temperature is min. 0°C. 0°C 30 to 37 kz Between COOLANT TEMP 25°C 9.3 to 10.7 kz (male) (A) and (B) 50°C 3.2 to 3.8 kz Resistance a Coolant temperature80°C 1.0 to 1.3 kz Resistance characteristics 95°C 700 to 800 z 1. Turn starting switch to OFF position. 2. Disconnect connector BOOST PRESS & IMT, and connect socket to male side.

Charge temperature sensor

a Regard charge temperature sensor as normal if its resistance is 80 z to 48 kz. -40°C 41 to 48 kz -20°C 14 to 16 kz Between BOOST PRESS & 0°C 5.4 to 6.1 kz IMT (male) (3) and (4) Resistance 30°C 1.6 to 1.8 kz a Charge temperature60°C 560 to 600 z Resistance characteristics 90°C 230 to 250 z 130°C 80 to 90 z

Intake air temperature sensor

1. Turn starting switch to OFF position. 2. Disconnect connector P55 and connect T-adapter to male side. -30°C 25 to 28 kz Between P55 (male) (3) and (4) 0°C 5.5 to 6.1 kz Resistance a Intake air temperature25°C 1.9 to 2.1 kz 40°C 1.1 to 1.2 kz Resistance characteristics 100°C 180 to 185 z

Charge (Boost) pressure sensor

1. Turn starting switch to OFF position. 2. Insert T-adapter into connector ECM J1. 3. Turn starting switch to ON position. Voltage Between ECM J1 (15) and (59)

Sensor output

0.3 to 4.7 V

1. Turn starting switch to OFF position. 2. Insert T-adapter into connector ECM J1. 3. Turn starting switch to ON position. Voltage Between ECM J1 (16) and (60)

Sensor output

0.5 to 4.5 V

1. Turn starting switch to OFF position. 2. Insert T-adapter into connector ECM J2. 3. Turn starting switch to ON position. Voltage Between ECM J2 (21) and (44)

Sensor output

0.2 to 4.8 V

Ambient pressure sensor

Common rail pressure sensor

Turbocharger speed sensor

1. Turn starting switch to OFF position. 2. Disconnect connector VGT REV and connect T-adapter to female side. Resistance Between VGT REV (female) (1) and (2) 600 to 1600 z

Throttle sensor (fuel dial)

1. Turn starting switch to OFF position. 2. Disconnect connector FP, and connect T-adapter to male side. Between FP (male) (A) and (C) 4.0 to 6.0 kz Resistance Between FP (male) (B) and (C) 3 to 7 kz Between FP (male) (A) and (B) 3 to 7 kz

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20 Standard value tables Standard service value table

Equipment name

Procedure, measuring location, criteria and remarks 1. Turn starting switch to OFF position. 2. Disconnect connector L28A, and connect T-adapter to female side.

Water-in-fuel sensor installed to fuel pre-filter

a If water is in fuel pre-filter, drain it. Between 28A (female) (1) and (2) Resistance Between 28A (female) (1) and ground

10 to 100 kz Min. 100 kz

1. Turn starting switch to OFF position. 2. Disconnect connector OIL PRESSURE SWITCH, and connect T-adapter to Engine oil pressure switch male side. Between OIL PRESSURE SWITCH (male) (1) Resistance and ground Max. 10 z

20-12

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20 Standard value tables Standard service value table

Machine control Equipment name

Parking brake solenoid

Procedure, measuring location, criteria and remarks 1. Turn starting switch to OFF position. 2. Disconnect S4, and connect T-adapter to male side. Between S4 (male) (1) and (2) Resistance Between ground and each of S4 (male) (1) and (2)

34 to 44 z Min. 1 Mz

Fan reverse solenoid

1. Turn starting switch to OFF position. 2. Disconnect connector FAR and connect T-adapter to male side of connector. Resistance Between FAR (male) (1) and (2) 34 to 44 z

Slow brake solenoid

1. Turn starting switch to OFF position. 2. Disconnect connector S3, and connect T-adapter to male side. Between S3 (male) (1) and (2) 34 to 44 z Resistance Between ground and each of S3 (male) (1) and Min. 1 Mz (2)

Fan EPC solenoid

1. Turn starting switch to OFF position. 2. Disconnect connector FAC, and connect T-adapter to male side. Resistance Between FAC (male) (1) and (2) 2 to 12 z

6eft forward HST pump EPC solenoid

1. Turn starting switch to OFF position. 2. Disconnect connector LF, and connect T-adapter to male side. Between LF (male) (1) and (2) Resistance Between ground and each of LF (male) (1) and (2)

Left reverse HST pump EPC solenoid

5 to 15 z Min. 1 Mz

1. Turn starting switch to OFF position. 2. Disconnect connector LR, and connect T-adapter to male side. Between LR (male) (1) and (2) 5 to 15 z Resistance Between ground and each of LR (male) (1) and Min. 1 Mz (2)

1. Turn starting switch to OFF position. 2. Disconnect connector RF, and connect T-adapter to male side. 8ight forward HST pump Between RF (male) (1) and (2) 5 to 15 z EPC solenoid Resistance Between ground and each of RF (male) (1) and Min. 1 Mz (2)

Right reverse HST pump EPC solenoid

1. Turn starting switch to OFF position. 2. Disconnect connector RR, and connect T-adapter to male side. Between RR (male) (1) and (2) 5 to 15 z Resistance Between ground and each of RR (male) (1) and Min. 1 Mz (2)

` lift RAISE EPC solenoid

Turn starting switch to OFF position. Disconnect connector 6 , and connect T-adapter to male side. Between 6 (male) (1) and (2) 2 to 12 z Resistance Between ground and each of 6 (male) (1) Min. 1 Mz and (2)

` lift LOWER EPC solenoid

Turn starting switch to OFF position. Disconnect connector 6- , and connect T-adapter to male side. Between 6- (male) (1) and (2) 3 to 13 z Resistance Between 6- (male) (1) and ground Min. 1 Mz

* * ' 67 ^ EPC solenoid

Turn starting switch to OFF position. Disconnect connector **6^, and connect T-adapter to male side. Between **6^ (male) (1) and (2) 2 to 12 z Resistance Between ground and each of **6^ (male) (1) Min. 1 Mz and (2)

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Equipment name

* * ' 67 ` EPC solenoid

* * ' 87 ^ EPC solenoid

Procedure, measuring location, criteria and remarks

Turn starting switch to OFF position. Disconnect connector **6`, and connect T-adapter to male side. Between **6` (male) (1) and (2) 2 to 12 z Resistance Between ground and each of **6` (male) (1) Min. 1 Mz and (2) Turn starting switch to OFF position. Disconnect connector **8^, and connect T-adapter to male side. Between **8^ (male) (1) and (2) 2 to 12 z Resistance Between ground and each of **8^ (male) (1) Min. 1 Mz and (2)

* * ' 87 ` EPC solenoid

Turn starting switch to OFF position. Disconnect connector **8`, and connect T-adapter to male side. Between **8` (male) (1) and (2) 2 to 12 z Resistance Between ground and each of **8` (male) (1) Min. 1 Mz and (2)

#ork equipment lock solenoid

1. Turn starting switch to OFF position. 2. Disconnect connector PSL, and connect T-adapter to male side. Between PSL (male) (1) and (2) 20 to 60 z Resistance Between ground and each of PSL (male) (1) Min. 1 Mz and (2)

~ EPC solenoid

Turn starting switch to OFF position. Disconnect connector `8 , and connect T-adapter to male side. Between `8 (male) (1) and (2) 2 to 12 z Resistance Between ground and each of `8 (male) (1) Min. 1 Mz and (2)

# EPC solenoid

Turn starting switch to OFF position. Disconnect connector #" , and connect T-adapter to male side. Between #" (male) (1) and (2) 2 to 12 z Resistance Between ground and each of #" (male) Min. 1 Mz (1) and (2)

Left HST motor EPC solenoid

1. Turn starting switch to OFF position. 2. Disconnect connector LME, and connect T-adapter to male side. Between LME (male) (1) and (2) 5 to 15 z Resistance Between ground and each of LME (male) (1) Min. 1 Mz and (2)

Right HST motor EPC solenoid

1. Turn starting switch to OFF position. 2. Disconnect connector RME, and connect T-adapter to male side. Between RME (male) (1) and (2) 5 to 15 z Resistance Between ground and each of RME (male) (1) Min. 1 Mz and (2)

HST oil temperature sensor

Brake pressure sensor

20-14

1. Turn starting switch to OFF position. 2. Disconnect connector 12, and connect T-adapter to male side. Between 12 (male) Approx. 90 kz 10°C (1) and (2) Approx. 35 kz 30°C Approx. 6.5 kz 80°C a TemperatureResistance resistance characteristics of Approx. 3.5 kz 100°C oil temperature sensor 1. Turn starting switch to OFF position. 2. Insert T-adapter into connector BS. 3. Turn starting switch to ON position. Between BS (2) and Voltage Sensor output 0.5 to 4.5 V (1) D61EM-23M0

20 Standard value tables Standard service value table

Equipment name Oil pressure sensor of work equipment pump

Procedure, measuring location, criteria and remarks 1. Turn starting switch to OFF position. 2. Insert T-adapter into connector WP. 3. Turn starting switch to ON position. Between WP (2) and Voltage Sensor output (1)

0.5 to 4.5 V

Fan speed sensor

1. Turn starting switch to OFF position. 2. Disconnect connector FRS, and connect T-adapter to male side. Between FRS (male) (1) and (2) 2 to 3 z Resistance Between FRS (male) (1) and ground Min. 1 Mz

` lift lever potentiometer 1

1. Turn starting switch to OFF position. 2. Insert T-adapter into connector WLV1. 3. Turn starting switch to ON position. 4. Operate blade control lever (in RAISE/LOWER direction) to perform troubleshooting. Voltage Between WLV1 (3) and (1) 0.96 to 4.04 V

` lift lever potentiometer 2

Blade tilt lever potentiometer 1 ( $ )

1. Turn starting switch to OFF position. 2. Insert T-adapter into connector WLV1. 3. Turn starting switch to ON position. 4. Operate blade control lever (in TILT direction) to perform troubleshooting. Voltage Between WLV1 (7) and (5) 0.96 to 4.04 V

Blade tilt lever potentiometer 2 ( $ )

Potentiometer 1for joystick (steering, directional, and gear shift lever)

Turn starting switch to OFF position. Insert T-adapter into connector 56 . Turn starting switch to ON position. Perform troubleshooting by operating joystick (steering, directional, and gear shift lever) . Voltage Between 56 (7) and (8) 0.5 to 4.5 V

Potentiometer 2 for joystick (steering, directional, and gear shift lever)

Decelerator/ brake pedal potentiometer

Turn starting switch to OFF position. Disconnect connector `" and connect T-adapter to male side. Turn starting switch to ON position. Perform troubleshooting by depressing the decelerator/ brake pedal. Between `" (male) (C) and (B) Approx. 2 kz Between `" (male) (A) and (C) 0.2 to 1.8 kz Resistance Between `" (male) (A) and (B) 0.2 to 1.8 kz Between `" (male) (A) and ground Min. 1 Mz

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Equipment name

Procedure, measuring location, criteria and remarks

Potentiometer 1 for joystick (steering, directional, and gear shift lever)

Potentiometer 2 for joystick (steering, directional, and gear shift lever)

Air cleaner clogging switch

1. Turn starting switch to OFF position. 2. Disconnect connector 116, and connect T-adapter to male side. 3. Start engine. Air cleaner: When normal Max. 1 z Between 116 (male) Resistance (1) and (2) Air cleaner: When Min. 1 Mz clogged

Shift up switch

1. Turn starting switch to OFF position. 2. Disconnect connector 38, and connect T-adapter to male side. 3. Turn shift down switch to ON or OFF position, and perform troubleshooting. Between 38 (male) Switch: OFF Max. 1 z (3) and (2) Switch: ON Min. 1 Mz Resistance Switch: OFF Between 38 (male) Min. 1 Mz (1) and (2) Switch: ON Max. 1 z

Downshift switch

1. Turn starting switch to OFF position. 2. Disconnect connector 39,and connect T-adapter to male side. 3. Turn downshift switch to ON or OFF position and perform troubleshooting. Between 39 (male) Switch: OFF Max. 1 z (3) and (2) Switch: ON Min. 1 Mz Resistance Between 39 (male) Switch: OFF Min. 1 Mz (1) and (2) Switch: ON Max. 1 z

Turn starting switch to OFF position. Disconnect connector , and connect T-adapter to male side. Operate parking break lever and perform troubleshooting. Parking brake lever switch Between (male) Lever: FREE Max. 1 z 1 (A) and (B) Lever: LOCK Min. 1 Mz Resistance Between 26 (male) Lever: FREE Min. 1 Mz (A) and (C) Lever: LOCK Max. 1 z Turn starting switch to OFF position. Disconnect connector 26B , and connect T-adapter to male side. Operate parking break lever, and perform troubleshooting. Parking brake lever switch Lever: FREE Max. 1 z Between 26B 2 (male) (A) and (B) Lever: LOCK Min. 1 Mz Resistance Lever: FREE Between 26B Min. 1 Mz (male) (A) and (C) Lever: LOCK Max. 1 z

" % switch harness

20-16

Turn starting switch to OFF position. Disconnect connector `6*#, and connect T-adapter to male side. Turn on and off blade float switch to perform troubleshooting. Between `6*# Switch: OFF Max. 1 z (male) (3) and (4) Switch: ON Min. 1 Mz Resistance Between `6*# Switch: OFF Min. 1 Mz (male) (3) and (5) Switch: ON Max. 1 z D61EM-23M0

20 Standard value tables Standard service value table

Equipment name

Procedure, measuring location, criteria and remarks

^% $ *

Turn starting switch to OFF position. Disconnect connector `6*#, and connect T-adapter to male side. Turn ^% $ switch ON and OFF, and perform troubleshooting. Between `6*# Switch: OFF Max. 1 z (male) (1) and (3) Switch: ON Min. 1 Mz Resistance Between `6*# Switch: OFF Min. 1 Mz (male) (2) and (3) Switch: ON Max. 1 z

Work equipment lock lever switch

Turn starting switch to OFF position. Disconnect connector "*# , and connect T-adapter to male side. Operate work equipment lock lever to perform troubleshooting. Lever: FREE Between "*# Max. 1 z (male) (A) and (B) Lever: LOCK Min. 1 Mz Resistance Between "*# Lever: FREE Min. 1 Mz (male) (A) and (C) Lever: LOCK Max. 1z

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Machine monitor

(D61-Q170-033-K-00-A)

Equipment name

"ower generation of alternator (when system is normal)

Procedure, measuring location, criteria and remarks 1. Turn starting switch to OFF position. 2. Remove T16 terminal cover. 3. Start engine. Voltage

Between T16 and ground

Engine speed: Medium or 27.5 to 29.5 V above

1. Turn starting switch to OFF position. 2. Insert T-adapter into connector CM01. 3. Disconnect heater relay terminal T6. Preheating

Fuel level sensor

a To prevent current from flowing through heater when starting switch is turned to HEAT position 4. Turn starting switch to HEAT position. Voltage Between CM01 (12) and (3) 20 to 30 V 1. Turn starting switch to OFF position. 2. Disconnect connector 13, and connect T-adapter to male side. Between 13 (male) (1) and (2) FULL Approx. 12 z Resistance

20-18

a Fuel level sensor EMPTY characteristics Between 13 (male) (2) and ground

Approx. 85 z Max. 1 z

D61EM-23M0

SHOP MANUAL

D61E -23M0 Model

Serial Number

D61E -23M0

B 0001 and up

30 Testing and adjusting 5 30 Testing and adjusting

D61EM-23M0

30-1

30 Testing and adjusting Table of contents

Table of contents

30 Testing and adjusting - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - Table of contents - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - Related information on testing and adjusting - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - Tools for testing and adjusting - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - Sketch of tools for testing and adjusting - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - Engine and cooling system- - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - Testing engine speed - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - Testing boost pressure - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - Testing exhaust gas color - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - Testing and adjusting valve clearance - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - Measuring compression pressure - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - Testing blowby pressure - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - Testing engine oil pressure - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - Testing fuel pressure- - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - Testing fuel discharge, return and leakage - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - Bleeding air from fuel system- - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - Testing fuel circuit for leakage - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - Handling cylinder cutout mode operation - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - Handling no-injection cranking operation - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - Testing of installed condition of cylinder heads and manifolds - - - - - - - - - - - - - - - - - - - - Testing engine piping for damage and looseness- - - - - - - - - - - - - - - - - - - - - - - - - - - - - Check alternator belt, replace - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - Power train - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - Testing and adjusting HST oil pressure- - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - Testing output pressure of solenoid valve - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - Testing if machine travels straight - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - Simple test procedure for brake performance - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - Adjusting deceleration/brake pedal- - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - Adjusting parking brake lever- - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - Move disabled machine urgently - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - Undercarriage and frame - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - Adjusting idler clearance - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - Checking sprocket wear - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - Testing and adjusting track tension- - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - Hydraulic system - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - Releasing remaining pressure in work equipment cylinder - - - - - - - - - - - - - - - - - - - - - - Testing and adjusting work equipment oil pressure - - - - - - - - - - - - - - - - - - - - - - - - - - - Testing source pressure of control circuit - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - Testing outlet pressure of work equipment EPC valve and fan EPC valve - - - - - - - - - - - Testing internal oil leakage of work equipment cylinder - - - - - - - - - - - - - - - - - - - - - - - - Testing fan speed - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - Testing fan circuit oil pressure - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - Bleeding air from hydraulic circuit- - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - Work equipment - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - Adjusting work equipment lock lever- - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - Electrical system - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - Special functions of machine monitor - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - Adjustment method when HST controller has been replaced - - - - - - - - - - - - - - - - - - - - Adjustment method when electric or hydraulic device has been replaced- - - - - - - - - - - - Adjusting rearview camera angle - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - Handling voltage circuit of engine controller - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - Handling battery disconnect switch - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - Testing diodes - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 30-2

30-1 30-2 30-4 30-4 30-7 30-9 30-9 30-11 30-13 30-15 30-18 30-21 30-22 30-23 30-28 30-33 30-35 30-36 30-37 30-38 30-39 30-40 30-42 30-42 30-47 30-51 30-52 30-53 30-56 30-58 30-61 30-61 30-62 30-63 30-64 30-64 30-65 30-67 30-68 30-70 30-71 30-72 30-73 30-74 30-74 30-76 30-76 30-146 30-149 30-150 30-151 30-152 30-153

D61EM-23M0

30 Testing and adjusting Table of contents

Pm clinic - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 30-154 Pm Clinic service - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 30-154 Pm Clinic check sheet - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 30-156

D61EM-23M0

30-3

30 Testing and adjusting

Related information on testing and adjusting

Tools for testing and adjusting

Testing and adjusting item Testing boost pressure Testing exhaust gas color Testing and adjusting valve clearance

Symbol 1 A 2 1 C

2 1 2 3

Testing compression E pressure

1 2 3 4 5 1

Testing blowby pressure

2 3

Part No.

Part name

799-201-2202 Boost gauge kit

-101 to 200 kPa {-760 to 1,500 1 mmHg}

799-201-9002 Handy smoke checker Commercially Smoke meter available 791T-601-1110 Plate 791T-601-1120 Bolt Commercially Feeler gauge available 795-502-1590 Gauge assembly 795-799-6700 Puller 795-790-4411 Adapter 6754-11-3130 Gasket Commercially Hose available 799-201-1504 Blowby checker Commercially Plug available Commercially Cap available

1 G

790-261-1204 Digital hydraulic tester 2

799-401-2320 Gauge 799-101-5002 Hydraulic tester

1 790-261-1204 Digital hydraulic tester

795-790-4430 Adapter 6215-81-9710 O-ring 795-790-5110 Screw

799-401-2320 Gauge

795-790-5120 Screw

799-401-2311 Gauge

2 Testing fuel pressure J

30-4

Remarks

790-301-1530 Elbow

799-101-5002 Hydraulic tester Testing engine oil pressure

Q'ty

Related information on testing and adjusting

1 1

Bosch index: 0 to 9

1 3 1 1 1 1 1 1 Inside diameter: approx. 15 mm 1 0 to 10 kPa {0 to 1,000 mmH2O} 1 Hose inside diameter: 24 mm 2 Pipe outside diameter: 25.4 mm Pressure gauge: 2.5, 6.0, 40, 60 1 MPa {25, 60, 400, 600 kg/cm2} Pressure gauge: 60 MPa {600 kg/ 1 cm2} Pressure gauge: 1.0 MPa {10 kg/ 1 cm2} Pressure gauge: 2.5, 6.0, 40, 60 1 MPa {25, 60, 400, 600 kg/cm2} Pressure gauge: 60 MPa {600 kg/ 1 cm2} 2 1 1 M12 x 1.5 o Rc1/8 Pressure gauge: 1.0 MPa {10 kg/ 1 cm2} 1 M14 x 1.5 o Rc1/8 Pressure gauge: -760 to 1,500 1 mmHg

D61EM-23M0

30 Testing and adjusting

Testing and adjusting item

Testing fuel discharge, return and leakage

Symbol 1 2 3 4 5 6

7 8 9 Adjusting decelerator/brake pedal Testing HST oil pressure Testing control oil pressure

Part No.

Part name

795-790-4700 Tester kit 6164-81-5790 Joint 07206-30812 Joint bolt 6745-71-1130 Seal washer 6151-51-8490 Spacer Commercially Stopwatch available Commercially Hose available Commercially Measuring cylinder available Commercially Hose available

1 1 1 1 1

79A-264-0021 Push-pull scale

799-101-5002 Hydraulic tester 1 M

790-261-1204 Digital hydraulic tester 2

799-101-5220 Nipple 07002-11023 O-ring 799-101-5002 Hydraulic tester

1 790-261-1204 Digital hydraulic tester Testing output pressure of solenoid N valve

2 3 4 5

Move disabled machine urgently

1 P

799-401-3100 Adapter 799-401-3200 Adapter 791T-640-1110 Nipple 07002-11423 O-ring 795-471-1450 Adapter 07002-10823 O-ring 799-101-5220 Nipple 07002-11023 O-ring 790-190-1601 Pump assembly 799-101-5220 Nipple 07002-11023 O-ring 799-101-5002 Hydraulic tester

Testing and adjusting work equipment oil pressure

1 790-261-1204 Digital hydraulic tester

Q 2 3

Testing work equipment EPC valve and fan EPC valve output pressure

799-101-5002 Hydraulic tester 790-261-1204 Digital hydraulic tester 2

D61EM-23M0

799-101-5220 Nipple 07002-11023 O-ring 799-401-3100 Adapter

1 R

Q'ty

Related information on testing and adjusting

799-101-5220 Nipple 07002-11023 O-ring

Remarks

1 1 Inside diameter: approx. 14 mm 1 1 Inside diameter: approx. 8 mm

Pressure gauge: 2.5, 6, 40, 60 1 MPa {25, 60, 400, 600 kg/cm2} Pressure gauge: 60 MPa {600 kg/ 1 cm2} 1 10 x 1.25 mm 1 Pressure gauge: 2.5, 6.0, 40, 60 1 MPa {25, 60, 400, 600 kg/cm2} Pressure gauge: 60 MPa {600 kg/ 1 cm2} 1 1 1 1 1 1 1 10 x 1.25 mm 1 1 1 10 x 1.25 mm 1 Pressure gauge: 2.5, 6, 40, 60 1 MPa {25, 60, 400, 600 kg/cm2} Pressure gauge: 60 MPa {600 kg/ 1 cm2} 1 10 x 1.25 mm 1 1 Pressure gauge: 2.5, 6, 40, 60 1 MPa {25, 60, 400, 600 kg/cm2} Pressure gauge: 60 MPa {600 kg/ 1 cm2} 1 10 x 1.25 mm 1 30-5

30 Testing and adjusting

Testing and adjusting item Testing internal oil leakage of work equipment cylinder Testing stroke and hydraulic drift Testing work equipment speed Testing voltage and resistance

Diagnosis for controller and actuator

Removal and installation of engine coolant temperature sensor Testing voltage and resistance Removal and installation of charge (boost) pressure and temperature sensor Removal and installation of engine oil pressure switch Removal and installation of engine coolant temperature sensor

30-6

Symbol S T U V

Part No.

Part name

Commercially Measuring cylinder available Commercially Ruler available Commercially Stopwatch available Commercially Multimeter available 799-601-7400 T-adapter assembly 799-601-7500 T-adapter assembly 799-601-9000 T-adapter assembly 799-601-9300 T-adapter assembly 799-601-7360 Adapter 799-601-7370 Adapter 799-601-4101 T-adapter assembly 795-799-5530 • Socket 799-601-4230 • Socket 799-601-4130 799-601-4160 799-601-4211 799-601-4220 799-601-4140 799-601-9020 799-601-4260 799-601-4190

• • • • • • • •

T-adapter assembly T-adapter assembly T-adapter assembly T-adapter assembly T-adapter assembly T-adapter assembly T-adapter assembly Socket

Q'ty

Related information on testing and adjusting

Remarks

1 1 1 1 1 AMP040 Connector 1 AMP070 Connector 1 DT, HD30 connector 1 DRC26-24 (40 pins) 1 Relay (5 pins) 1 Relay (6 pins) 1 Engine-related connectors 1 Engine coolant temperature Boost air temperature/pressure 1 sensor 1 Ne sensor, CAM sensor 1 Engine oil pressure sensor 1 Controller (50 poles) 1 Controller (60 poles) 1 Ambient pressure sensor 1 Pump actuator 1 Controller (4 poles) 1 Common rail pressure sensor 19 mm (width across flats) deep socket

795T-981-1010 Socket

Commercially Multimeter available

Commercially Torx wrench available

795-799-6210 Socket

1 27 mm deep socket

795T-981-1010 Socket

3.26 mm Torx wrench (KTC Q4T15 or equivalent)

19 mm deep socket (MITOLOY 4ML-19 or equivalent)

D61EM-23M0

30 Testing and adjusting

Related information on testing and adjusting

Sketch of tools for testing and adjusting

Note: Komatsu does not take any responsibility for special tools manufactured according to these sketches. D1: Plate

D2: Bolt

D61EM-23M0

30-7

30 Testing and adjusting

Related information on testing and adjusting

D3: Nipple

-: Socket

30-8

D61EM-23M0

30 Testing and adjusting Engine and cooling system

Engine and cooling system

Testing engine speed

k Place the machine on a level ground, lower

the work equipment to the ground, and stop the engine. Set the parking brake lever and work equipment lock lever to LOCK position.

a For the machine monitor operating method, see "Stall Pressure Test Mode" of "Special functions of machine monitor". a "Stall Pressure Test Mode" screen

a Check the engine speed with "Monitoring/Predefined" or "Monitoring/Custom" or "Stall Pressure Test Mode" function of the machine monitor. a Perform testing of the engine speed under the following conditions. • Coolant temperature: 60 to 100°C • HST oil temperature (hydraulic oil temperature): 40 to 60°C

Testing

(D61-A000-388-K-00-A)

Preparation Operate the machine monitor so that it can monitor the engine speed. a For the machine monitor operating method, see the section of "Special functions of machine monitor". a Monitoring code: 01002 "Engine Speed" a "Monitoring/Pre-defined" (01/14) screen

1. Check the engine speed when the joystick (steering, directional and gearshift lever), blade control lever, and ripper control lever are in NEUTRAL position. 2. Start the engine and check the engine speed when fuel control dial is set in high idle (MAX) position. a The parking brake lever and work equipment lock lever may be kept in LOCK position. a Check the engine speed at high idle with "Stall Pressure Test Mode" of the adjustment function of the machine monitor. Check it while the joystick (steering, directional and gearshift lever) is kept in NEUTRAL position.

Testing engine speed at low idle 1. Check the engine speed when the joystick (steering, directional and gearshift lever), blade control lever, and ripper control lever are in NEUTRAL position. 2. Start the engine and check the engine speed when fuel control dial is set in low idle (MIN) position. a The parking brake lever and work equipment lock lever may be kept in LOCK position. Testing engine speed at high idle Check it with "Stall Pressure Test Mode" of the adjustment function of the machine monitor.

D61EM-23M0

Testing maximum engine speed in P-mode or Emode 1. Check the engine speed when the joystick (steering, directional and gearshift lever), blade control lever, and ripper control lever are in NEUTRAL position. 2. Start the engine, and set the working mode to P or E mode. 3. Check the engine speed when fuel control dial is set in high idle (MAX) position. a The parking brake lever and work equipment lock lever may be kept in LOCK position. Testing decelerator pedal speed 1. Check the engine speed when the joystick (steering, directional and gearshift lever), blade control lever, and ripper control lever are in NEUTRAL position. 2. Start the engine and check the engine speed when the decelerator pedal is fully depressed to

30-9

30 Testing and adjusting Engine and cooling system

its stroke end while fuel control dial is set in high idle (MAX) position. a The parking brake lever and work equipment lock lever may be kept in LOCK position.

30-10

D61EM-23M0

30 Testing and adjusting Engine and cooling system

Testing boost pressure

a Testing tools Symbol 1 A 2

Part No.

Part name

790-301-1530 Elbow 799-201-2202 Boost gauge kit

k Place the machine on a level ground, lower

the work equipment to the ground, and stop the engine. Set the parking brake lever and work equipment lock lever to LOCK position. k When installing and removing testing tools,

take care not to touch a hot part of the engine. a Perform testing of the boost pressure under the following conditions. • Coolant temperature: 60 to 100°C • HST oil temperature (hydraulic oil temperature): 40 to 60°C • HST is stalled and work equipment circuit is relieved

Testing with machine monitor 362-K-01-A)

(D61-A900-

Check the boost pressure with the adjustment functions of machine monitor, "Stall Pressure Test Mode". a For the machine monitor operating method, see "Stall Pressure Test Mode" of "Special functions of machine monitor".

2. Install elbow A1. 3 Elbow A1: 2 to 3.9 Nm {0.2 to 0.4 kgm}

a "Stall Pressure Test Mode" screen

3. Install nipple [1] of boost gauge kit A2, and connect gauge [2] to the nipple.

Testing by use of testing tools 362-K-00-A)

(D61-A900-

1. Remove right side cover (1), and remove boost pressure pickup port plug (2).

D61EM-23M0

30-11

30 Testing and adjusting Engine and cooling system

4. Start the engine to increase the coolant temperature to 60 to 100°C. 5. Drain the oil in the hose with the engine running. a Repeat opening the self-sealing portion on the hose by inserting approximately half of the connection part of the gauge into the hose to drain oil. a When Pm kit A (799-401-2301) is available, you can use air bleeding coupling (790-2611130) in the kit. a If oil is left in the hose, the gauge does not work. Accordingly, be sure to drain the oil. 6. Measure the boost pressure while stalling HST. a For the HST stall method, see "Stall Pressure Test Mode" of "Special functions of machine monitor". a For standard values, see "Standard value table for engine". 7. After finishing test, remove the testing tools and restore the machine. 3 Pickup port plug (2): 2 to 3.9 Nm {0.2 to 0.4 kgm}

30-12

D61EM-23M0

30 Testing and adjusting Engine and cooling system

Testing exhaust gas color

a Testing tools Symbol 1 C 2

Part No.

Part name

799-201-9002 Handy smoke checker Commercially Smoke meter available

k Place the machine on a level ground, lower

the work equipment to the ground, stop the engine, and set the parking brake lever and work equipment lock lever in LOCK position. k Be careful not to touch any hot part when

installing or removing the testing tools. a Perform testing of the exhaust gas color under the following conditions. • Coolant temperature: 60 to 100°C • HST oil temperature (hydraulic oil temperature) 40 to 60°C • HST stall and work equipment relief a If an air source and a electric power source are not available in the field, use handy smoke checker C1. When recording official data, etc., use smoke meter C2.

Testing

Measuring by using handy smoke checker C1 ) Fit a sheet of filter paper to handy smoke checker C1. ) Insert the exhaust gas intake pipe into the tail pipe (4). ) Start the engine and be ready for HST stall. a For the method of performing HST stall, see "Stall Pressure Test Mode" of "Special functions of machine monitor". 4) Perform HST stall after relieving the work equipment circuit and operate the handle of handy smoke checker C1 to collect the exhaust gas on the filter paper. a In "Stall Pressure Test Mode", HST stall is performed only in 30 seconds. Be sure to collect it within this period. a Collecting time: 1.4 ± 0.2 second

D61EM-23M0

5) Remove the filter paper and compare it with the attached scale for judgment. 6) After finishing the test, remove the testing tools and restore the machine to its original condition. Testing with smoke meter C2 a For details of handling of smoke meter C2, see an instruction manual of the smoke meter. 1) Connect the probe hose, accelerator switch outlet and air hose to smoke meter C2. a The supplied air pressure must be 1.5 MPa {15 kg/cm2} or below. 2) Connect the power cable to an AC 100 V receptacle. a Before connecting the power cable, be sure that the power switch of the smoke meter is turned OFF. 3) Insert probe [1] of the smoke meter C2 into tail pipe (4).

30-13

30 Testing and adjusting Engine and cooling system

4) Loosen the cap nut of the suction pump and place the filter paper. a Place the filter paper securely so that the exhaust gas does not leak. 5) Turn the power switch of smoke meter C2 ON.

6) Start the engine and be ready for HST stall. a For the method of performing HST stall, see "Stall Pressure Test Mode" of "Special functions of machine monitor". 7) Perform HST stall after relieving the work equipment circuit, and then depress the accelerator pedal of smoke meter C2 to collect the exhaust gas on the filter paper. a In "Stall Pressure Test Mode", HST stall is performed only in 30 seconds. Be sure to collect it within this period. 8) Place the contaminated filter paper on the clean filter paper (at least 10 sheets) in the filter paper holder and read the indicated value. 9) After finishing the test, remove the testing tools and restore the machine.

30-14

D61EM-23M0

30 Testing and adjusting Engine and cooling system

Testing and adjusting valve clearance a Testing tools SymPart No. Part name bol 1 791T-601-1110 Plate D 2 791T-601-1120 Bolt Commercially Feeler gauge 3 available

1 a Since the O-ring is fitted to the flywheel housing side of blowby duct (13), blowby duct (13) may be removed together with cylinder head cover (12).

k Place the machine on a level ground, lower

the work equipment to the ground, and stop the engine. Set the parking brake lever and work equipment lock lever to the LOCK position. k Turn the battery disconnect switch to OFF

position, and remove the key. a Perform testing and adjusting of the valve clearance under the following condition.

4. Install testing tool D1 to vibration damper (14) with bolt D2.

• Coolant temperature: Normal temperature

Testing

(D61-A700-361-K-00-A)

1. Remove engine hood assembly (1). For details, see "Removal and installation of engine hood assembly".

2. Remove 3 bolts (6) and disconnect bracket (7).

5. Rotate the crankshaft forward by using testing tool D1 and align wide slit (b) in the speed sensor ring with projection top (a) of the front cover.

3. Remove cylinder head covers (12). a When removing blowby duct (13), be careful that the O-ring will not fall from it.

D61EM-23M0

a When seen from the air conditioner compressor side, top (a) of the projection must be within the range of wide slit (b). a If you can see the yellow marks of projection top (a) and wide slit (b), you may align them.

30-15

30 Testing and adjusting Engine and cooling system

k If this positioning is applied, note that the

No. 1 or No. 6 cylinder is not at the compression top dead center (TDC).

3 EGR circuit tube (5) (flange side): 24 ± 4 Nm {2.45 ± 0.41 kgm} 3 EGR circuit tube (5) (tube side): 10.5 ± 0.5 Nm {1.07 ± 0.05 kgm} 3 Hose (6): 25 ± 1.5 Nm {2.55 ± 0.15 kgm} 3 Hose (7): 15 ± 1 Nm {1.53 ± 0.10 kgm} 3 Cylinder head cover (12) mounting nut: 24 ± 4 Nm {2.45 ± 0.41 kgm}

Adjusting

(D61-A700-27D-K-00-A)

6. Check the movement of the rocker arm of the No. 1 cylinder to inspect the valve clearance.

After testing, adjust the valve clearance according to the following procedure, if necessary.

a For standard values, see "Standard value table for engine".

1. While fixing adjustment screw (4), loosen lock nut (5). 2. Insert feeler gauge D3 in the clearance between rocker arm (6) and crosshead (7) and adjust the valve clearance with adjustment screw (4).

a If you can move the rocker arm of air intake valves (IN) with the hand by the valve clearance amount, check the valves marked with Q in the valve arrangement drawing. a If you can move the rocker arm of exhaust valves (EX) with the hand by the valve clearance amount, check the valves marked with q in the valve arrangement drawing. a Valve arrangement drawing

a With feeler gauge D3 inserted, turn the adjustment screw (4) until the feeler gauge D3 can move lightly. a For standard values, see "Standard value table for engine". 3. With adjustment screw (4) fixed, tighten lock nut (5). 3 Lock nut (5): 24 ± 4 Nm {2.45 ± 0.41 kgm} a After tightening lock nut (5), check the valve clearance again.

7. If the valves marked with Q in the valve arrangement drawing are checked, rotate the crankshaft forward 1 turn and align wide slit (b) in the speed sensor ring with projection top (a) of the front cover according to the procedure in Step 10, and then adjust the valves marked with q in the valve arrangement drawing. a If the valves marked with q in the valve arrangement drawing are checked in Step 11, check the valves marked with Q. 8. After finishing the test, remove the testing tools and restore the machine.

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4. Rotate the crankshaft in the normal direction by one turn according to step 11 and align wide slit (b) with top (a) of the projection. 5. Adjust the clearances of the other valves according to Steps 1 to 3. a If the valves marked with Q in the valve arrangement drawing are adjusted in steps 1 through 3, adjust the valves marked with q. D61EM-23M0

30 Testing and adjusting Engine and cooling system

a If the valves marked with q in the valve arrangement drawing are adjusted in steps 1 through 3, adjust the valves marked with Q. 6. After finishing test, remove the testing tools and restore the machine. 3 Cylinder head cover mounting nut: 24 ± 4 Nm {2.45 ± 0.41 kgm}

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30 Testing and adjusting Engine and cooling system

Measuring compression pressure a Measuring tools for compression pressure SymPart No. Part name bol 1 795-502-1590 Gauge assembly 2 795-799-6700 Puller E 3 795-790-4410 Adapter 4 6754-11-3130 Gasket 5 795–799–8150 Remover

1 7. Remove retaining nut (9) and inlet connector (10). a Before removing the inlet connector, wash around it so that sticking mud will not enter its hole. a Tool E4 is set for removal of inlet connector

k Stop the machine on a level ground and

lower the work equipment to the ground. a Measure the compression pressure under the following condition. • Engine oil temperature: 40 – 60°C 1. Remove the engine hood assembly, aftercooler upper hose, muffler assembly and muffler bracket and disconnect the air conditioner hose clamp and corrosion resistor. For details, see “Adjusting valve clearance”, Steps 1 and 2. 2. Remove 4 bolts (1) and air intake elbow (2). 3. Remove 2 clamps (3) and move wiring harness (4) outward. 4. Disconnect 3 connectors (5). 5. Remove 6 high-pressure pipes (6). 6. Remove 6 nuts (7) and cylinder head cover (8).

a While pressing the lock of connector (5) with flat-head screwdriver [1], disconnect connector (5).

8. Remove the mounting bolts (11) of rocker arm assembly on the exhaust side, and then remove rocker arm assembly (2). a When removing the injector, you do not need to remove the rocker arm assembly on the intake side. 9. Disconnect injector wiring harness (13) and remove 2 injector holder mounting bolts (14).

10.Using tool E2, remove injector assembly (15).

11.Install adapter E3 to the injector assembly mounting part with the injector holder and connect compression gauge E1. 30-18

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30 Testing and adjusting Engine and cooling system

a Install the gasket to the adapter end without fail.

Compression pressure

a Tighten holder mounting bolts alternately

Engine speed

3 Injector holder mounting bolt: 8 ± 0.8 Nm {0.8 ± 0.08 kgm} a If a little quantity of engine oil is applied to the joint of the adapter and gauge, air does not leak easily. 12.Install rocker arm assembly (12) on the exhaust side and adjust the valve clearance. . 3 Rocker arm assembly mounting bolt: 36 ± 5 Nm {3.67 ± 0.5 kgm} a See “Adjusting valve clearance”.

1.69 MPa Min.{17.2 kg/cm2}. 250 to 280 rpm

15.After finishing measurement, remove the measuring tools and return the removed parts. a Install the injector assembly and inlet connector according to the following procedure. 1) Apply new engine oil (SAE15W-40) to the O-ring of injector assembly (15) and cylinder 2) Install injector assembly (15) with the fuel inlet hole directed to the air intake manifold. 3) Install injector holder (18) and tighten the mounting bolt by 3 – 4 threads. 4) Install inlet connector (10) and tighten retaining nut (9) temporarily. 3 Retaining nut: 15 ± 5 Nm {1.5 ± 0.5 kgm} 5) Tighten mounting bolt (14) of holder (18) securely. 3 Injector holder mounting bolt (14): 8 ± 0.8 Nm {0.8 ± 0.08 kgm} 6) Tighten retaining nut (9) securely.

13.Select the “No Injection” cranking mode by operating the machine monitor. a Turn the battery disconnect switch to ON position, then turn the starting switch to ON position.

3 Retaining nut: 50 ± 5 Nm {5.1 ± 0.5 kgm}

a To select the “No Injection cranking” see Special functions of machine monitor.

a Tighten the bolts and nuts other than the injector and inlet connector to the following torque. 3 Injector wiring harness nut: 1.5 ± 0.25 Nm {0.15 ± 0.026 kgm} 14.Rotate the crankshaft by the starting motor and measure the compression pressure. a Read the compression pressure when the gauge pointer stands still. a The compression pressure is normal when it is within the following standard value range.

3 Fuel tube sleeve nut: 35 ± 3.5 Nm {3.6 ± 0.4 kgm} 3 Rocker arm assembly mounting bolt: 36 ± 6 Nm {3.7 ± 0.6 kgm} a Adjust the valve clearance. For details, see “Adjusting valve clearance”.

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30 Testing and adjusting Engine and cooling system

3 Cylinder head cover mounting nut: 24 ± 4 Nm {2.45 ± 0.41 kgm}

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30 Testing and adjusting Engine and cooling system

Testing blowby pressure a Testing tools Symbol F 1

Part No.

Part name

799-201-1504 Blowby checker

k Place the machine on a level ground and

lower the work equipment to the ground. a Measure the blowby pressure under the following conditions. • Coolant temperature: 30 to 102°C • HST oil temperature (hydraulic oil temperature): 40 to 60°C • HST is stalled and work equipment circuit is relieved

Testing

(D61-A000-36C-K-00-A)

1 a Normally, the blowby pressure should be measured while the engine is operated at the rated horsepower. In the field, however, an approximate value can be obtained by performing HST stall. a Blowby pressure varies greatly with the condition of the engine. Therefore, if the value by the test is considered unusual, make a check for excessive oil consumption, bad color of exhaust gas, early oil deterioration, early oil contamination, etc., which are related to improper blowby pressure. a For standard values, see "Standard value table for engine".

1. Open left side cover.

4. After finishing the measurement, remove the measuring tools and restore the machine. 2. Install nozzle tool F2 to blow-by hose (1) and connect it to gauge (1) of blow-by checker F1

3. Run the engine at high idle and measure the blowby pressure when HST is stalled and work equipment circuit is relieved. a For the method of performing HST stall, see "Stall Pressure Test Mode" of "Special functions of machine monitor".

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30 Testing and adjusting Engine and cooling system

Testing engine oil pressure

a Testing tools Symbol G

1 2

Part No.

Part name

799-101-5002 Hydraulic tester 790-261-1204 Digital hydraulic tester 799-401-2320 Gauge

k Place the machine on a level ground, lower

the work equipment to the ground, and stop the engine. Set the parking brake lever and work equipment lock lever to the LOCK position. a Perform testing of the engine oil pressure under the following condition. • Coolant temperature: 60 to 100°C

Testing

(D61-AB00-362-K-00-A)

1. Remove right side cover. 2. Remove oil pressure pickup plug (1).

4. Start the engine and measure the oil pressure at low idle and high idle. a For standard values, see "Standard value table for engine". 5. After finishing the measurement, remove the measuring tools and restore the machine.

3. Install nipple [1] of hydraulic tester G1 to the plug mount, and then connect them to gauge G2.

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30 Testing and adjusting Engine and cooling system

Testing fuel pressure

1 k When removing or installing testing tools for

a Testing tools Symbol 1 2 J

3 4 5 6

Part No. 799-101-5002 790-261-1204 795-790-4430 6215-81-9710 795-790-5110 799-401-2320 795-790-5120 799-401-2311

Part name Hydraulic tester Digital hydraulic tester Adapter O-ring Screw Gauge Screw Gauge

the fuel system, stop the engine and wait for at least 30 seconds until the remaining pressure is released from the fuel circuit. (Do not start the work immediately after the engine is stopped since remaining pressure is still in the circuit.) k Place the machine on a level ground, lower

the work equipment to the ground, stop the engine, and set the parking brake lever and work equipment lock lever to the LOCK position. a Measure only the fuel pressure in the lowpressure circuit from the feed pump through the main fuel filter to the supply pump, and in the return circuit between the supply pump/common rail/ injector and fuel tank. k Since the pressure in the high-pressure

circuit from the supply pump through the common rail to the injector is very high and dangerous, do not measure it.

A: Low-pressure circuit measuring position (main fuel filter inlet side) B: Low-pressure circuit measuring position (main fuel filter outlet side) C: Return circuit measuring position (supply pump drain port) D: Negative pressure circuit measuring position (supply pump inlet)

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30 Testing and adjusting Engine and cooling system

Testing

(D61-AE20-362-K-00-A)

Testing low-pressure circuit (main fuel filter inlet side) $ ? @ \ ^ # ^ ? @@ ` | ~ @ \ ? ? ?

` \ @ @@ @@ ` ` \ ? ` @ \ @ ? @@ ` ` @ ` @ ` ^ @ ` \ ` ? @ \@ @ @ \ \ ^ @ @ \ \ ^ ? ` @@ @@ | ? ? ? @ \ ~ @ ? ` ` @ ` \

@ \ \ \ @ ? \ @ \ ` ` @ @ ` \ $ `

` `

@ @

3 Adapter J2: 32 ± 4 Nm {3.26 ± 0.41 kgm} @ ` ` ?

! \ @ ? \ ` \ @ @ @ \

? ? @ ` @ ^ @ ` @ \ @ 3 Fuel pressure pickup plug (1):

32 ± 4 Nm {3.26 ± 0.41 kgm}

30-24

D61EM-23M0

30 Testing and adjusting Engine and cooling system

Testing low-pressure circuit (pressure difference) # ^ ? @@ ` | ~ ? ? @ \ \ ? @@ ` | ~ @ \

@@ \ ?? @@ @@ \ ?? @@ @@ ? ? @ \ @@ ? ? @ \ @ \ @ ? @@ @ @ \ \ @ \ \ @ @ \ @ @ ? \ @ \ ` ` @ @ @ ` \ $ `

@ @

3 Adapter J2: 32 ± 4 Nm {3.26 ± 0.41 kgm} @ ` ` ?

! \ @ ? \ ` \ @ @ @ \

@@ \ ?? @@ @ ? ` @ \ \ ` @ ` \ ` `

? @@ \@ @ \ \ ^ ? ? `` \ @ @ ? ? \ @ @@ ` ? ? @ ` @ ^ @ ` @ \ @ 3 Fuel pressure pickup plugs (1), (2): 32 ± 4 Nm {3.26 ± 0.41 kgm} Testing return circuit $ ? @ \ ^ | ~ # ^ ? @ \ ^ | ~

` \ @ @@ @ \ \ @ \ ? @@ ` ` \ ? ` @ \ @ ? @@ ` ` @ ` @ ` ^ @ ` \ ` ? @ \@ @

D61EM-23M0

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30 Testing and adjusting Engine and cooling system

# ^ | ~ ? ? @ @ \ ?

` \ @ @@ ` ` \ ? ` @ \ @ ? @@ ` ` @ ` @ ` ^ @ ` \ ` ? @ \@ @ @ \ \ ^ @ @ \ \ ^ ? `

@ @ \ \ @ ? \ @ @ \ ? | ~ \ ` ` @ @ ` @ @ @

@ @

3 Screw J3: 24 ± 4 Nm {2.45 ± 0.41 kgm} ! \ @ ? \ ` \ @ @ @ \

? ? @ ` @ ^ @ ` @ \ @ 3 Joint bolt (2): 24 ± 4 Nm {2.45 ± 0.41 kgm} Testing negative-pressure circuit # ^ | ~ ? ? @ ? ? \ @

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30 Testing and adjusting Engine and cooling system

@ @ \ \ @ @ \ ? | ~ \ ` ` @ @ ` @ @ @ @ @ 3 Screw J5: 25.4 to 34.3 Nm {2.59 to 3.5 kgm} ! \ @ ? \ ` \ @ @ @ \

? ? @ ` @ ^ @ ` @ \ @ 3 Joint bolt (3): 25.4 to 34.3 Nm {2.59 to 3.5 kgm}

` \ @ @@ ` ^ @@ ` ` \

! @@ ` ^ @@ @ @ ? ` @ \ \ ^ ` ` \

? @@ @ ` @ \ \ ^ ? ? `` \ @ @ ? ? \ @ @@ `

D61EM-23M0

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30 Testing and adjusting Engine and cooling system

Testing fuel discharge, return and leakage k Place the machine on a level ground, lower

a Testing tools Symbol 1 2 3 4 5 K

6 7 8 9

Part No. 795-790-4700 6164-81-5790 07206-30812 6745-71-1130 6151-51-8490 Commercially available Commercially available Commercially available Commercially available

Part name Tester kit Joint Joint bolt Seal washer Spacer Stopwatch Hose (inside diameter: approximately 14 mm) Measuring cylinder Hose (inside diameter: approximately 8 mm)

the work equipment to the ground, stop the engine, and set the parking brake lever and work equipment lock lever to the LOCK position. a Since some fuel flows out during test, prepare a container of approximately 20 l. k When removing or installing testing tools for

A: Measuring position of supply pump discharge B: Measuring position of supply pump return rate C: Measuring position of leakage from pressure limiter D: Measuring position of injector return rate

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30 Testing and adjusting Engine and cooling system

Testing

(D61-AE20-363-K-00-A)

Testing supply pump discharge 1. Open left side cover (1).

2. Remove fuel spray prevention cap (2). 3. Loosen clamp (4) for high pressure tube (3) on the discharge side of the supply pump and disconnect the high pressure tube (3).

4. Install hose K7 to the connector on the discharge side of the supply pump. a Hose K7 may be clamped with a hose band to prevent it from coming off.

a Do not crank the engine for 20 seconds or longer continuously to protect the starting motor. In the measurement, repeat the steps of "cranking of 15 seconds, 15 seconds of rest and cranking of 15 seconds".

a $ , % j* , % &$ ' j

6. After finishing the test, remove the testing tools and restore the machine. 3 High-pressure pipe (2) mounting sleeve nut: 35 ± 3.5 Nm {3.57 ± 0.36 kgm} 3 Clamp (3) mounting bolt: 24 ± 4 Nm {2.45 ± 0.41 kgm} Testing supply pump return rate 1. Remove bracket mounting bolt (1) and remove the bracket. 3 Bracket mounting bolt (1): 24 ± 4 Nm {2.45 ± 0.4 kgm} 2. Remove joint bolt (2) of the fuel return hose from the supply pump, and then disconnect hose (3).

5. Crank the engine for 30 seconds and measure the discharge by using measuring cylinder K8.

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30 Testing and adjusting Engine and cooling system

3. Install cap nut [1] of tester kit K1 to fuel return hose (2) side to prevent the fuel from flowing out. a When installing cap nut [1], be sure to install the seal washer. 4. Install joint K2 to the supply pump side by using joint bolt K3. a When installing joint K2 and joint bolt K3, be sure to install the seal washer.

a ? @ @ ? ` ` @ At high idle | @ \@~

During cranking | @ \@~

3 Joint bolt K3: 24 ± 4 Nm {2.45 ± 0.41 kgm} 5. Install hose K9 to joint K2.

7. After finishing the test, remove the testing tools and restore the machine.

6. Start the engine and measure the fuel return rate in 30 seconds by using measuring cylinder K8 with the engine at low idle. a If the engine cannot be started, you can measure it while rotating the engine by using the starting motor. However, to protect the starting motor, do not rotate the engine for more than 20 seconds continuously. In the measurement, repeat the steps of "cranking of 15 seconds, 15 seconds of rest and cranking of 15 seconds".

30-30

3 Fuel return hose (3) mounting joint bolt (2): 24 ± 4 Nm {2.45 ± 0.41 kgm} Testing leakage from pressure limiter 1. Since pressure limiter is located behind fuel main filter, move fuel main filter in the following procedure. 1) Disconnect two wiring harnesses (1) from clamps, and remove bracket (2).

D61EM-23M0

30 Testing and adjusting Engine and cooling system

2) Remove fuel filter bracket (3) together with fuel filter cartridge. a Do not disconnect hoses. Leave them connected.

6. Start the engine and measure the fuel leakage rate for 30 seconds by using measuring cylinder K8 with the engine at low idle. a If the engine cannot be started, you can measure it while rotating the engine by using the starting motor. However, to protect the starting motor, do not rotate the engine for more than 20 seconds continuously. In the measurement, repeat the steps of "cranking of 15 seconds, 15 seconds of rest and cranking of 15 seconds".

2. Remove joint bolt (4) of the pressure limiter and disconnect spill tube (5).

a ` ? @@ @ @ ? ` @ \ \ ^ ` At high idle | @ \@~ During cranking | @ \@~

\ @

3. Install cap nut [1] of tester kit K1 to spill tube (5) to prevent outflow of fuel. a When installing cap nut [1], be sure to install the seal washer. 4. Install joint K2 to the pressure limiter side by using joint bolt K3. a When installing joint K2 and joint bolt K3, be sure to install the seal washer. 3 Joint bolt K3: 24 ± 4 Nm {2.45 ± 0.41 kgm} 5. Install hose K9 to joint K2. 7. After finishing the test, remove the testing tools and restore the machine. 3 Spill tube (5) mounting joint bolt (4): 24 ± 4 Nm {2.45 ± 0.41 kgm}

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30 Testing and adjusting Engine and cooling system

Testing fuel return rate from injector 1. Remove bracket mounting bolt (1) and remove the bracket. 3 Bracket mounting bolt (1):

3 Joint bolt (5): 24 ± 4 Nm {2.45 ± 0.41 kgm} 6. Hold measuring cylinder K8 at the pressure limiter side spill tube (6).

24 ± 4 Nm {2.45 ± 0.41 kgm} 2. Remove joint bolt (2) of the fuel return hose from the supply pump, and then disconnect hose (3).

7. Start the engine and measure the fuel return rate in 30 seconds by using measuring cylinder K8 with the engine at low idle. 3. Install cap nut [1] of tester kit K1 to spill tube (4) and tighten joint bolt K3 to prevent outflow of fuel. a When installing cap nut [1], be sure to install the seal washer. 4. Install spacer K5 to the supply pump side and install hose (3) by using joint bolt (2).

5. Remove joint bolt (5) of the pressure limiter and disconnect spill tube (6).

a If the engine cannot be started, you can measure it while rotating the engine by using the starting motor. However, to protect the starting motor, do not rotate the engine for more than 20 seconds continuously. In the measurement, repeat the steps of "cranking of 15 seconds, 15 seconds of rest and cranking of 15 seconds".

a ! ? ? @ @ ? ` @ \ \ ^ ` At high idle | @ \@~ During cranking | @ \@~

8. After finishing the test, remove the testing tools and restore the machine. 3 Spill tube (6) mounting joint bolt (5): 24 ± 4 Nm {2.45 ± 0.41 kgm}

30-32

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30 Testing and adjusting Engine and cooling system

Bleeding air from fuel system

a If fuel is used up or if a fuel circuit component is removed and installed, bleed air from the fuel circuit according to the following procedure. k Place the machine on a level ground, lower

the work equipment to the ground, and stop the engine. Set the parking brake lever and work equipment lock lever to the LOCK position.

Bleeding air

(D61-AD00-231-K-00-A)

1. Supply fuel to the fuel tank. a Continue the supply of fuel until the fuel gauge monitor turns to blue. (Check the fuel level with machine monitor after turning the starting switch to ON position.) 2. Open left side cover (1).

3. Loosen hand primer (2), pull it out, and move it back and forth. a Continue the above operation until the operation of hand primer (2) becomes heavy. a You may not remove the plug on the top surface of the main fuel filter.

4. After the air bleeding, push hand primer (2) in, and tighten it.

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30 Testing and adjusting Engine and cooling system

Route for bleeding air from fuel circuit Fuel tankoprefilterofeed pumpomain filterometering unitofuel tank

30-34

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30 Testing and adjusting Engine and cooling system

Testing fuel circuit for leakage k Very high pressure is generated in the high-

pressure circuit of the fuel system. If fuel leaks while the engine is running, it presents a serious danger that could result in a fire. After checking the fuel system and removing or installing its parts, check it for fuel leakage according to the following procedure.

1 a If any fuel leakage is detected, repair it and check again from Step 1. a If no fuel leakage is detected, check is complete.

k Place the machine on a level ground and

lower the work equipment to the ground. a Clean and degrease the engine and the parts around it in advance so that you can check it easily for fuel leakage.

Testing

(D61-AD00-364-K-00-A)

1. Spray color checker (developer) to the fuel supply pump, common rail, fuel injectors, and joints of the high-pressure fuel piping. 2. Start the engine, keep its speed at 1,000 rpm or below, and stop it when its speed is stabilized. 3. Check the fuel piping and devices for fuel leakage. a Check the high-pressure circuit for fuel leakage focusing on the area to which color checker is sprayed. a If any fuel leakage is detected, repair it and check again from Step 1. 4. Start the engine and keep it running at low idle. 5. Check the fuel piping and devices for fuel leakage. a Check the high-pressure circuit for fuel leakage focusing on the area to which color checker is sprayed. a If any fuel leakage is detected, repair it and check again from Step 1. 6. Start the engine and keep it running at high idle. 7. Check the fuel piping and devices for fuel leakage. a Check the high-pressure circuit for fuel leakage focusing on the area to which color checker is sprayed. a If any fuel leakage is detected, repair it and check again from Step 1. 8. Start the engine and keep it running at high idle, then load the engine. a Perform the torque converter stall or HST stall. 9. Check the fuel piping and devices for fuel leakage. a Check the high-pressure circuit for fuel leakage focusing on the area to which color checker is sprayed. D61EM-23M0

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30 Testing and adjusting Engine and cooling system

Handling cylinder cutout mode operation

a The cylinder cut-out test mode operation means to run the engine with the fuel injectors of one or more cylinders disabled electrically to reduce the number of active cylinders. The purposes and effects of this operation are as follows. 1. This mode is used to find out a cylinder which does not output power properly (or, combustion in it is abnormal). 2. When a cylinder is selected for the Cylinder Cutout Mode operation, if the engine speed and output do not change from the normal operation (all-cylinder operation), that cylinder has one or more defects. The following problems can be considered: • Compression leak from cylinder head gasket • Defective injection from injector • Defective piston or piston ring • Defective valve mechanism (valve operating system) • Defective electrical system 3. The injector of each cylinder is separately controlled electronically in the common rail fuel injection system, so the cylinder cut-out test can be performed easily by the simple operations of the switches compared with the mechanical fuel injection system. So, the defective cylinder can be found out easily.

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30 Testing and adjusting Engine and cooling system

Handling no-injection cranking operation

a No-injection cranking means to crank the engine by using the starting motor while all the injections are stopped electrically. The purpose and effect of this operation are as follows. No-injection cranking is performed to lubricate the engine parts and to protect them from seizure. It is performed before the engine is started, or after the machine has been stored for a long period. a When performing no-injection cranking operation, see "Special functions of machine monitor".

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30 Testing and adjusting Engine and cooling system

Testing of installed condition of cylinder heads and manifolds

Check the cylinder head and intake and exhaust manifold mountings for looseness. If any part is loosened, retighten it. a For the tightening torques, see the "Disassembly and assembly".

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30 Testing and adjusting Engine and cooling system

Testing engine piping for damage and looseness

Air intake and exhaust systems: Check the piping for damage, the mounting bolts and nuts for looseness, and the joints for air suction and exhaust gas leakage. If any part is loosened or damaged, retighten or repair it. Cooling system: Check the piping for damage, the mounting bolts and nuts for looseness, and the joints for water leakage. If any part is loosened or damaged, retighten or repair it. Fuel system: Check the piping for damage, the mounting bolts and nuts for looseness, and the joints for fuel leakage. If any part is loosened or damaged, retighten or repair it.

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30 Testing and adjusting Engine and cooling system

Check alternator belt, replace a Testing tools Symbol K

Part No.

a Possible causes of the damage on the belt Part name

Commercially Wrench available

k Place the machine on a level ground, lower

the work equipment to the ground, and stop the engine. Set the parking brake lever and work equipment lock lever to LOCK position. a Alternator belt is also used as air compressor belt. a The auto-tensioner is provided for the alternator belt. Thus, checking and adjusting the belt tension is usually not necessary.

Testing

(D61-AKM4-362-K-00-A)

1. Remove right cover (1).

• Improper tension has been applied. • Part whose size or length is wrong has been used. • Pulley is out of the position. • Pulley is damaged. • auto-tensioner is damaged. • Installation state is improper. • Severe operating environment • Oil and grease are attached to the side of the belt. a If the belt is obviously worn, there is a possibility that the auto-tensioner is also worn and the surface of the pulley is rough. In that case, the newly replaced belt may be worn early if the pulley is continuously used. Therefore, replacement of the belt and autotensioner as a set is recommended.

2. Remove cover (2).

Replace

(D61-AKM4-923-K-00-A)

1. Install the wrench (K) to the (g) part (width across flats: 12.7 mm) of the auto-tensioner (4). 3. Check the alternator belt (3). a Replace the alternator belt (3) in the following cases. • The alternator belt has a vertical scratch (b) which crosses the horizontal scratch (a). • The alternator belt has tears (c). Need not to be replaced if it has only a horizontal scratch (d). 30-40

a Check that the wrench (K) is securely installed. If the wrench (K) is loosely installed and rotated, it can accidentally come off and this is extremely dangerous because the spring force of the auto-tensioner (4) is strong. 2. Turn the wrench (K) in the direction of the arrow, and loosen the tension of the alternator belt (3).

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30 Testing and adjusting Engine and cooling system

7. After installing the alternator belt (3), return the auto-tensioner (4) slowly and carefully.

3. Remove the alternator belt (3). a Be careful not to get your fingers caught between the pulley and alternator belt (3) during work. 4. After removing the alternator belt (3), return the auto-tensioner (4) slowly and carefully.

8. Check that the groove of the alternator belt (3) fits in the each pulley groove (5) without any displacement.

5. Install the wrench (K) to the (g) part (width across flats: 12.7 mm) of the auto-tensioner (4). a Check that the wrench (K) is securely installed. If the wrench (K) is loosely installed and rotated, it can accidentally come off and this is extremely dangerous because the spring force of the auto-tensioner (4) is strong. 6. Turn the wrench (K) in the direction of the arrow, and install the alternator belt (3). a Be careful not to get your fingers caught between the pulley and alternator belt (3) during work.

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30 Testing and adjusting Power train

Power train

Testing and adjusting HST oil pressure

a Testing tools Symbol 1 M 2

Part No. 799-101-5002 790-261-1204 799-101-5220 07002-11023

Part name Hydraulic tester Digital hydraulic tester Nipple (M10 x 1.25) O-ring

k Place the machine on a level ground, and

lower the work equipment to the ground. k Be careful not to touch any hot parts when

installing or removing the testing tools.

Testing

(D61-C170-362-K-00-A)

Measuring a Perform testing of HST oil pressure under the following condition. • HST oil temperature (hydraulic oil temperature): 40 to 60°C 1. Measuring HST main circuit pressure a Measure HST main circuit pressure with the "Adjustment" mode in service mode of the machine monitor. k If HST is stalled while the bypass valve

(toe valve) of the parking brake circuit is tightened, HST device may be damaged or the machine may move unexpectedly. Therefore, do not stall HST with modes other than the "Adjustment" mode. 1) As preparation for HST stall, turn the starting switch to ON position, select P-mode, and switch to the display of the "Stall Pressure Test Mode" in the adjustment menu No.21 with the "Adjustment" of the machine monitor. a Place the parking brake lever to LOCK position and the joystick (steering, directional and gearshift lever) to NEUTRAL position. Then perform this operation. a For the operating method, see "Special functions of machine monitor". • "Adjustment" menu No.21: "Stall Pressure Test Mode"

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2) Start the engine and keep the parking brake lever in the LOCK position. a Stall HST when the parking brake lever is in the LOCK position. 3) Measure HST main circuit pressure when placing the joystick (steering, directional and gearshift lever) to FORWARD or REVERSE position, and stalling HST with P-mode and engine at high idle. a By operating the joystick (steering, directional and gear shift lever) to FORWARD or REVERSE position, HST is stalled. By returning it to NEUTRAL position, HST stalling is released. k Oil temperature rises partially and

suddenly during HST stall. Do not stall HST continuously for 30 seconds or longer. a For standard values, see "Standard value table for machine". 2. Measuring HST charge circuit pressure 2-1. Measuring method by using machine monitor a Measure HST charge circuit pressure with the "Adjustment" mode of the machine monitor. k Measure HST charge circuit pressure

when the machine stops and when it actually travels. So, measure the pressure on a level ground with no obstacles. 1) As preparation for brake pressure measurement, turn the starting switch to ON position, select P-mode, and switch the machine monitor to the display of the "Control Brake Release Mode" in the menu No.22 of the "Adjustment" mode.

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a For the operating method, see "Special functions of machine monitor". • "Adjustment" menu No.21: "Control Brake Release Mode" • Brake pressure is displayed in 0.01 MPa unit.

k Turn the starting switch to the ON

position, place the work equipment lock lever to the FREE position, and lower the blade to ground. Operate the blade control lever until it is not held in "FLOAT" position to release the remaining pressure in the accumulator. After releasing the remaining pressure, place the work equipment lock lever in the LOCK position, and then turn the starting switch to the OFF position. k Turn the oil filler cap of the hydraulic tank

to the left slowly to release the pressure in the hydraulic tank.

1) ~ , , $ $, 7*3 charge circuit pressure pickup plug (1) of solenoid valve. 2) Start engine and set the parking brake lever in FREE position. 3) Measure the brake pressure when placing the joystick (steering, directional and gearshift lever) to NEUTRAL position and traveling the machine forward or reverse with P-mode and engine at high idle. a When the machine stops, only the oil cooler bypass valve and charge safety valve on HST safety valve (integrated) side operate. When the machine travels, the charge relief valve on HST motor also operates. a For standard values, see "Standard value table for machine". 2-2. Measuring method by using oil pressure gauge If you measure HST charge circuit pressure directly for troubleshooting of the brake pressure sensor, parking brake solenoid and slow brake solenoid, perform it according to the following procedure.

2) Install nipple [1] of hydraulic tester M1 and connect them to oil pressure gauge [2]. • Use the oil pressure gauge of 6 MPa {60 kg/cm2}.

a HST charge circuit pressure is the same as the control circuit source pressure. k Measure HST charge circuit pressure

when the machine stops and when it actually travels. So, measure the pressure on a level ground with no obstacles.

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30 Testing and adjusting Power train

• Use the oil pressure gauge of 6 MPa {60 kg/cm2}.

3) Start the engine and set the parking brake in FREE position. 4) Measure HST charge circuit pressure when placing the joystick (steering, directional and gearshift lever) to NEUTRAL position and traveling the machine forward or reverse with engine at high idle. a For standard values, see "Standard value table for machine". 5) After finishing the measurement, remove the measuring tools and restore the machine. 3. Measuring EPC valve outlet pressure of HST pump k Measure EPC valve outlet pressure when

the machine stops and when it actually travels. So, measure the pressure on a level ground with no obstacles. k Turn the oil filler cap of the hydraulic tank

to the left slowly to release the pressure in the hydraulic tank. 1) Remove floor cover and remove EPC valve outlet pressure pickup plugs (2) to (5) on top of HST pump. • • • •

Plug (2) (CSA1): For LF EPC valve Plug (3) (CSB1): For LR EPC valve Plug (4) (CSA2): For RF EPC valve Plug (5) (CSB2): For RR EPC valve

3) Start the engine and set the parking brake lever in FREE position. 4) Select quick shift mode and set the speed range to the 1st. 5) Measure EPC valve outlet pressure when placing the joystick (steering, directional and gearshift lever) to NEUTRAL position and traveling the machine forward or reverse with engine at high idle. a For standard values, see "Standard value table for machine". 6) After finishing the measurement, remove the measuring tools and restore the machine.

Adjusting

(D61-C170-270-K-00-A)

a HST main circuit pressure and HST pump EPC valve outlet pressure cannot be adjusted. 1. Adjustment of HST charge circuit pressure (oil cooler bypass valve and HST charge safety valve (integrated) side) a If HST charge circuit pressure (only when HST is neutral) is not normal, adjust charge safety valve (6) of valves on the side of oil cooler bypass and HST charge safety valve (integrated).

2) Install nipple M2 and connect it to oil pressure gauge [2]. 30-44

a Remove undercover of cooling core to adjust charge safety valve (6) on the side of oil cooler bypass valve and HST charge safety valve (integrated). D61EM-23M0

30 Testing and adjusting

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4 Undercover of cooling core: 13 kg

a To adjust charge relief valve (9) of HST motor, remove cover (right and left) of HST motor.

1) While fixing adjustment screw (7), loosen lock nut (8). 2) Turn adjustment screw (7) to adjust the pressure.

1) While fixing adjustment screw (10), loosen lock nut (11). 2) Turn adjustment screw (10) to adjust the pressure.

a When the adjustment screw is: • turned clockwise, the pressure is increased. • turned counterclockwise, the pressure is decreased. a Quantity of pressure adjustment per turn of adjustment screw: 1.55 MPa {15.38 kg/cm2} 3) With adjustment screw (7) fixed, tighten lock nut (8).

a When the adjustment screw is: • turned clockwise, the pressure is increased. • turned counterclockwise, the pressure is decreased. a Quantity of pressure adjustment per turn of adjustment screw: 1.02 MPa {10.4 kg/cm2} 3) With adjustment screw (10) fixed, tighten lock nut (11).

3 Lock nut: 58.8 to 78.5 Nm {6 to 8 kgm}

4) After finishing the adjustment, check that oil pressure is normal according to the above measuring procedure. 2. Adjusting HST charge circuit pressure (motor side)

4) After finishing the adjustment, check that HST charge circuit pressure is normal according to the above measuring procedure. 3. Initial setting of HST pump EPC valve Adjustment of HST pump EPC valve itself is not required. But perform the related initial setting with the "Adjustment" mode of the machine monitor, when EPC valve is replaced.

a If HST charge circuit pressure (only in traveling) is not correct, adjust charge relief valve (9) of HST motor according to the following procedure.

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30 Testing and adjusting Power train

a For the operating method, see "Special functions of machine monitor". • "Adjustment mode" (adjusting by traveling the track idle) 1) "Adjustment" Menu No.16: "F HST Pump Auto Set" 2) "Adjustment" Menu No.17: "R HST Pump Auto Set" • "Adjustment mode" (adjusting by traveling actually) 1) ID code (3423) "F HST PUMP AUTO SET MODE RUN1" 2) ID code (3424) "R HST PUMP AUTO SET MODE RUN1" 3) ID code (3425) "F HST PUMP AUTO SET MODE RUN2" 4) ID code (3426) "R HST PUMP AUTO SET MODE RUN2"

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Testing output pressure of solenoid valve a Testing tools Symbol 1 2 N

3 4 5

Part No.

Part name

799-101-5002 Hydraulic tester 790-261-1204 Digital hydraulic tester 799-401-3100 Adapter 799-401-3200 Adapter 791T-640-1110 Nipple 07002-11423 O-ring 795-471-1450 Adapter 07002-10823 O-ring 799-101-5220 Nipple 07002-11023 O-ring

a The parking brake solenoid valve outlet pressure can be checked by using "Monitoring code" of machine monitor. (For the operating method, see "Special functions of machine monitor".)

k Place the machine on a level ground and

lower the work equipment to the ground. k Be careful not to touch any hot parts when

installing or removing the testing tools. k Before lifting the blade, check that the side

cover on the left side of engine and front cover are closed. a Perform testing of the solenoid valve outlet pressure under the following conditions: • HST oil temperature (hydraulic oil temperature): 40 to 60°C Preparation a Oil pressure of parking brake solenoid valve and slow brake solenoid valve must be measured simultaneously. Otherwise, operation of the slow brake solenoid valve cannot be checked. k Turn the starting switch to ON position, set

the work equipment lock lever to FREE position, and lower the blade to the ground. Operate the blade control lever to release the remaining pressure in the accumulator. After releasing the remaining pressure, place the work equipment lock lever in LOCK position, and then turn the starting switch to OFF position.

Testing

(D61-PQP1-362-K-00-A)

1. Work equipment lock solenoid valve outlet pressure 1) Disconnect work equipment lock solenoid valve outlet hose (7) to be measured from valve block (6).

k Turn the oil filler cap of the hydraulic tank to

the left slowly, and release the pressure in the hydraulic tank. Remove inspection cover of the floor. Pressure pickup ports • (1): Work equipment lock solenoid valve outlet pressure • (2): Right HST motor EPC valve outlet pressure • (3): Left HST motor EPC valve outlet pressure • (4): Parking brake solenoid valve outlet pressure • (5): Slow brake solenoid valve outlet pressure D61EM-23M0

2) Insert adapter N2, and connect the disconnected hose again. 3) Install nipple of hydraulic tester N1, and connect them to oil pressure gauge [2]. 30-47

30 Testing and adjusting Power train

• Use the oil pressure gauge of 6 MPa {60 kg/cm2}. 4) Start the engine. 5) Measure solenoid valve outlet pressure when operating the work equipment lock lever with engine at high idle.

k Measure outlet pressures of right HST

a Relationship between outlet pressure and operation condition of solenoid is as shown in Table 1. 6) After finishing the measurement, remove the mesuring tools and restore the machine to its original condition. Table 1. Work equipment lock solenoid valve outlet pressure (in normal)

1) Disconnect hose (8) at the bottom of valve block and remove nipple (9).

Condition (Work equipment lock lever position) LOCK FREE FREE: Turn starting switch to ON position right after stopping the engine

Work equipment lock solenoid valve outlet pressure [MPa {kg/cm2}] 0 {0} 3.23 ± 0.49 {33.0 ± 5.0} It lowers gradually from 3.23 {33.0}.

2. Outlet pressures of right HST motor EPC valve and left HST motor EPC valve

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motor EPC valve and left HST motor EPC valve when the machine stops and when it actually travels. So, measure the pressure on a level ground with no obstacles.

2) Install nipple N3 and nipple of hydraulic tester N1 and connect them to oil pressure gauge [2].

3) Start the engine, set travel mode to quick shift mode, and set reverse travel speed setting to (0). 4) Measure solenoid valve outlet pressure when switching travel speed with the engine at high idle. D61EM-23M0

30 Testing and adjusting

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a If the outlet pressure is as shown in Table 2, the operation of the solenoid valve is normal. 5) After finishing the measurement, remove the measuring tools and restore the machine to its original condition. Table 2. Outlet pressures of right HST motor EPC valve and left HST motor EPC valve (in normal) Gear shift mode

Quick shift mode

Travel speed and travel condition While stopping or traveling at 1st speed While traveling at 2nd speed While traveling at 3rd speed

2) Install adapter N4 and nipple of hydraulic tester N1 and connect them to oil pressure gauge [2].

Outlet pressure [MPa {kg/cm2}] 0 {0} 1.47 ± 0.49 {15 ± 5} 22 ± 0.49 {22 ± 5}

6) Initial adjustment setting of HST motor EPC valve Adjustment or HST motor EPC valve itself is not required. However, if EPC valve has been replaced, perform the related initial setting ("HST Motor Auto Set Mode") with the "Adjustment" mode of the machine monitor panel. a For the operating method, see "Special functions of machine monitor". • "Adjustment" mode 1) "Adjustment" Menu No.18: "HST Motor Auto Set Mode" 3. Slow brake solenoid outlet pressure and parking brake solenoid outlet pressure a At first, measure the slow brake solenoid outlet pressure, and check that the outlet pressure when not depressing brake pedal is "Normal" as shown in Table 3. Measure outlet pressure of parking brake solenoid valve afterward.

3) Remove parking brake solenoid valve outlet pressure pickup plug (11) (emergency escape hydraulic pump connection port).

4) Install nipple N5 and nipple of hydraulic tester N1, and connect them to oil pressure gauge [2].

1) Remove slow brake solenoid valve outlet pressure pickup plug (10).

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30 Testing and adjusting Power train

Table 4. Outlet pressure of parking brake solenoid valve (Measurement condition) Fuel control dial: MAX position Joystick (steering, directional and gear shift lever): NEUTRAL Parking brake lever: FREE

5) Start the engine. 6) Measure solenoid slow brake solenoid valve outlet pressure when operating the brake pedal with engine at high idle. a Relationship between outlet pressure and operation condition of solenoid is as shown in Table 3. 7) Switch to the display of "Control Brake Release Mode" of the "Adjustment" mode in service mode of the machine monitor, and switch ON/OFF of control brake release mode, and then measure parking brake solenoid valve output pressure. a Relationship between outlet pressure and operation condition of solenoid is as shown in Table 4. a For the machine monitor operating method, see menu No.22 in the "Adjustment" menu in "Special functions of machine monitor". "Adjustment" menu No.22: "Control Brake Release Mode" Table 3. Outlet pressure of slow brake solenoid valve (Measurement condition) Fuel control dial: MAX position Directional lever: NEUTRAL Parking brake lever: FREE

Condition of Control brake Output pressure parking brake release mode [MPa {kg/cm2}] solenoid valve 0 {0} OFF Normal 3.23 ± 0.49 ON {33.0 ± 5.0} 0 {0} Slow brake OFF solenoid error 0 {0} ON (sticking, etc.) 3.23 ± 0.49 OFF {33.0 ± 5.0} Slow brake solenoid error 3.23 ± 0.49 (sticking, etc.) ON {33.0 ± 5.0} a Preform after measuring slow brake solenoid valve outlet pressure. a You can check the operating condition (ON/ OFF) of parking brake solenoid valve and slow brake solenoid valve with the monitoring mode of the machine monitor (For details, see the section of "Special Functions of Machine Monitor"). • Controller: HST • Monitoring code: 40978 "HST SW Output" Reference: Output from HST controller to slow brake solenoid valve is always ON.

Output pressure Condition of slow brake [MPa {kg/cm2}] solenoid valve 3.23 ± 0.49 Not depressed {33.0 ± 5.0} Normal Depress (full) 0 {0} Not depressed 0 {0} Charge circuit error or slow brake solenoid Depress (full) 0 {0} error (sticking, etc.) 3.23 ± 0.49 Not depressed {33.0 ± 5.0} Slow brake solenoid error 3.23 ± 0.49 (sticking, etc.) Depress (full) {33.0 ± 5.0} Decelerator/ brake pedal

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Testing if machine travels straight

Testing

(D61-0000-347-K-00-A)

a Perform testing of the travel deviation under the following conditions. • HST oil temperature (hydraulic oil temperature): 40 to 60°C • Condition of ground: Firm and level ground such as concrete ground, etc.

a Measure the right and left HST main circuit pressures with the "Monitoring" mode in service mode of the machine monitor. • Controller: HST • Monitoring code: 52503 "LF HST Pressure" • Monitoring code: 52501 "RF HST Pressure"

1. Start engine and set the machine to the measuring posture by raising the blade approximately 300 mm off the ground. 2. Set travel speed to 1st speed of quick shift mode. 3. Run the engine at high idle and measure the travel deviation in travel of 20 m after running-in 10 m.

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30 Testing and adjusting Power train

Simple test procedure for brake performance

a Check this item under the following conditions. • HST oil temperature (hydraulic oil temperature): 40 to 60°C k Since the test is performed while traveling,

work in a large place just in case for the failure. 1. Start the engine, raise the blade "a" (approximately 300 mm) off the ground, and set the machine to the measuring posture.

2. Set parking brake lever to FREE position, and shift the speed range to 1st speed. 3. Run the engine at high idle, operate joystick (steering, directional and gear shift lever) to FORWARD position to travel forward. 4. Depress the brake pedal during traveling and check the stopping state of the machine. a Brake is normal when the machine stops securely.

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Adjusting deceleration/brake pedal

a Testing tools Symbol L

Part No.

Part name

79A-264-0021 Push-pull scale

k Place the machine on a level ground and

lower the work equipment to the ground.

a When adjusting the decelerator/brake pedal, remove 2 covers at dashboard, and remove pedal assembly. Place the removed pedal assembly on the upper surface of floor, and connect wiring harness connectors of pedal assembly.

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30 Testing and adjusting Power train

Adjusting

(D61-G4A1-270-K-01-A)

1. Adjusting decelerator/brake pedal 1) Turn starting switch to ON position and set the machine monitor to "Monitoring" of the service mode to display "Decel/Brake Pedal Potentio" and "Slow Brake Solenoid (F/B)". • Controller: HST • Monitoring code: 50400 "Decel/Brake Pedal Potentio" 31647 "Slow Brake Solenoid (F/B)" a For the operating method, see "Special functions of machine monitor". 2) Adjust stopper (1) so that the stroke dimension between the work position (g) of 2-stage spring and pedal at full stroke position (h) becomes (d) (= 10 ± 1 mm). a Stopper (1) standard dimension (b): 36 ± 3 mm 3) Adjust stopper (2) so that the stroke (distance) between operating position (g) of the 2-stage spring and pedal neutral position (f) becomes (e) (= 52.8 ± 2 mm). a Stopper (2) standard dimension (c): 36.0 ± 2.0 mm 4) Install potentiometer. 1] Install the potentiometer so that the voltage of "Decel/Brake Pedal Potentio" at pedal full stroke position (h) becomes 3,240 ± 100 mV (Set this value as X). a For adjustment, rotate the installed position of potentiometer (3). 2] Operate the pedal and check that the decelerator/brake pedal potentiometer voltage is 1,830 ± 100 mV (allowable value) at pedal neutral position (f). 3] Check that the decelerator/brake potentiometer voltage is 3,030 ± 180 mV at the work position (g) of 2-stage spring as well. a If the values of 2] and 3] are not within the range of allowable value, return to the adjustment on 1]. 5) Install limit switch (4). 1] Change the pedal position to the work position (g) of 2-stage spring. 2] Fix limit switch (4) without any stroke to surface (q) with bolt. Fit the cut out portion of limit switch protection stopper (5) to projection (j) of the limit switch to install. 3] Depress the pedal to full stroke position. 4] Check that the stroke of limit switch (4) becomes 3 to 3.5 mm. 30-54

5] Check that limit switch protection stopper (5) does not touch surface (a). 6] Set the parking brake lever to the Free position and check that voltage of "Decel Brake Pedal Potentio" at pedal full stroke position (h) is in the range of (-150 mV to -30 mV) against the voltage X measured in 4) - 1], and the value of "Slow Brake Solenoid (F/B)" changes 0 mA o 600 mA, or 600 mA o 0 mA. 2. Testing decelerator/brake pedal depressing effort 1) Operate the decelerator/brake pedal with your foot and check that it moves smoothly. 2) If it does not move smoothly, pump in grease to spring (7) through grease fitting (6). 2 Filling grease to grease fitting (6). Grease (G2-LI) 2 Spring (7): Grease (G2-LI) 3) Check the depressing effort of the pedal at work position (g) of 2-stage spring by using push-pull scale L. • Depressing effort of the pedal at work position (g) of 2-stage spring: 62 ± 9.3 N {6.32 ± 0.95 kg} 4) Check the depressing effort of pedal at full stroke by using push-pull scale L. • Depressing effort of pedal at full stroke: 310.0 N {32.6 kg} 3. Work after finishing adjustment When all the adjustment is finished, restore the machine and perform the following initial adjustment in the "Adjustment" mode of the service mode on the machine monitor. a For the operating method, see "Special functions of machine monitor". • "Adjustment" mode • "Adjustment" Menu No.02: "Brake Pedal Potentio Initial Set" • "Adjustment" Menu No.03: "Brake Pedal Potentio Detent Set" • "Adjustment" Menu No.04: "Brake Pedal Potentio Full Set" 4. Testing decelerator/brake pedal potentiometer and the limit switch for pedal 1) Turn starting switch to ON position and set the machine monitor to "Monitoring/Predefined" and display (13/14). a For the operating method, see "Special functions of machine monitor".

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2) Set the parking brake lever to the Free position and check that the relationship between the decelerator/brake pedal position and "Decel/Brake Pedal Stroke" or "Slow Brake Solenoid (F/B)" is the same as indicated in the table 1. Table 1 Decelerator/brake pedal position Operating Stroke effort Monitoring code Neutral end change (f) point (h) (g) "Decel/ Brake 0% 73% 100% 50401 Pedal Stroke" "Slow brake 600 mA 600 mA 0 mA 31647 Solenoid (F/B)" • When "Decel/Brake Pedal Stroke" is NG, perform initial adjustment of pedal. • It is not a problem that the value of "Slow brake Solenoid (F/B)" changes. (Judge ON or OFF.) • When "Slow brake Solenoid (F/B)" is NG, perform adjustment of the limit switch for pedal. 3) When releasing the pedal gradually from the stroke end, check that "Slow brake Solenoid (F/B)" changes (0 o 600 mA) after "Decel/ Brake Pedal Stroke" changes (100 o 99.9%). a When it is NG, perform initial adjustment of pedal or adjust the installation of the limit switch for pedal.

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Adjusting parking brake lever

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Adjusting

(D61-GJX1-270-K-01-A)

a When the parts related to parking brake lever are removed and reinstalled or replaced, make adjustments according to the following procedures. 1. Set parking brake lever (1) to FREE position (A) and adjust installed dimension (b) of stopper bolt (2) so that dimension (a) of lever (1) becomes 30.7 mm. • Standard installed height (b) of stopper bolt: 4 mm 2. Set parking brake lever (1) to 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) to FREE position (A) and adjust clearance (d) between lever (4) and limit switches (5) (2 pieces). • Clearance (d) between the lever and limit switch: 0 mm • Do not move the limit switch during adjustment. 4. Check that limit switch (5) is moved 2.5 to 3 mm when parking brake lever (1) is operated. • Lever at LOCK position (B): Switch is ON • Lever at FREE position (A): Switch is OFF 5. Testing the limit switch for parking brake

Monitoring code Parking lock 1 NC Parking 40984 lock 1 NO Parking lock 2 NO

Parking brake lever position FREE LOCK (LOWER) (RAISE) (A) (B) OFF

OFF

Parking brake limit switch 1 (CN-26 )

Parking brake limit switch 2 (CN-26` )

a When it is NG, adjust the installation of the limit switches 1 and 2 for parking brake.

1) Turn starting switch to ON position and set the machine monitor to "Monitoring/Predefined" and display (13/14). a For the operating method, see "Special functions of machine monitor".

2) Check that the relationship between the parking brake lever position and ON/OFF state of "Parking lock 1 NC" or "Parking lock 2 NO" is the same as indicated in the table 1. Table 1

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Move disabled machine urgently a Testing tools Symbol 1 P 2

Part No.

Part name

790-190-1601 Pump assembly 799-101-5220 Nipple 07002-11023 O-ring

a If the engine cannot be started and the parking brake of HST motor cannot be released, perform the emergency escape according to the following procedure. a If the machine is on a slope, put blocks under the track before starting work. Move disabled machine by canceling parking brake 1. Testing of pump assembly P1 k If the work is performed when the

1 a After finishing the adjustment, remove plug (R1/4), and connect hose and quick coupler [5]. 2. Open the circuit of HST pump a If the machine is towed after parking brake is released, oil starts flowing because of the pumping action of HST motor. Open the forward circuit and reverse circuit of HST pump to prevent this. k Be sure to put the blocks under the track.

1) Remove inspection cover of the floor. 2) Loosen lock nuts (3) of tow receiving valve (1) of the pump for left and tow receiving valve (2) of the pump for right. Loosen plug (4) two turns. 3) Tighten lock nuts (3) lightly, and fix them not to be dropped when the machine is towed.

pressure of pump assembly is not within standard pressure, it may damage the brake piston of HST motor. Always check the pressure of the pump assembly before using. 1) Check that pump assembly P1 is connected as shown in the figure. [1]: Volume pump [2]: Relief valve [3]: Tee [4]: Oil pressure gauge (6 MPa {60 kg/cm2}) [5]: Hose and quick coupler

2) Remove hose and quick coupler [5] once, block the opening of its volume pump[1] side with plug (R1/4). 3) Close the valve of volume pump [1], operate the handle to adjust the relief valve [2] so that it relieves the oil at specified pressure. • Standard value of relief pressure: 2.7 to 3.1 MPa {28 to 32 kg/cm2} a After finishing the adjustment, open valve of volume pump, and release the pump internal pressure. 30-58

3. Connecting of pump assembly P1 k Turn the oil filler cap of the hydraulic tank

to the left slowly, and open it carefully to release the pressure in the hydraulic tank. 1) Install pump assembly P1 on the floor frame. 2) Loosen plug (5) and bolt (6) of solenoid valve, remove lock plate (7), and tighten plug (5) securely. Tighten bolt (6) lightly, and fix it not to be dropped when the machine is towed. 3) Remove plug (8), and install nipple P2. D61EM-23M0

30 Testing and adjusting

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4) Connect quick coupler at the top of pump assembly P1 to nipple P2.

2) Remove blocks put under the track shoe, tow the machine with maximum 2 km/h speed. k The pressure of oil supplied becomes

2.0 MPa {20 kg/cm2} or below, parking brake is not completely in released state (brake starts to work). Check oil pressure gauge [4] often during towing, and operate handle to keep oil pressure always within 2.1 to 3.1 MPa {20 to 32 kg/cm2} if the oil pressure dropped.

4. Releasing parking brake and towing the machine 1) Close the valve of volume pump [1], operate the handle to supply oil to parking brake circuit. a Increase the pressure of oil supplied until the relief valve [2] relieves the pressure once. a Check that the pressure of oil supplied is within specified value for the relieve pressure by using oil pressure gauge. • Standard value of relief pressure: 2.7 to 3.1 MPa {28 to 32 kg/cm2} k If the pressure of oil supplied exceeds

the standard value, it may damage brake piston of HST motor. Open the valve of volume pump immediately, and adjust relief pressure performed at Step 1) again. a The pressure of oil supplied becomes the standard value, parking brake is in released state.

D61EM-23M0

3) After the machine has been towed to a safe place, open the valve of volume pump [1] to open the parking brake circuit for oil to be supplied. 5. Treatment after towing the machine a After towing the machine and emergency escape are completed, always perform the following treatment to restore the machine to its original position. 1) Remove pump assembly P1 and nipple P2, and install plug (8). 2) Loosen plug (5) of solenoid valve, return lock plate (7) to its original position, and tighten and fix plug (5) and bolt (6) securely. 3 Plug (5): 34.5 to 63.7 Nm {3.5 to 6.5 kgm} 3) Return plugs (4) of tow receiving valve (1) and (2) of HST pump to their original positions, and fix them with lock nuts (3). 3 Plug (4) and locknut (3): 24.5 to 34.3 Nm {2.5 to 3.5 kgm} 4) Install inspection cover of the floor. Move disabled machine by removing final drive sun gear (drive shaft) 1. Drain oil in the final drive case. 2. Remove cover (1) of the final drive.

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30 Testing and adjusting Power train

3. Remove sun gear (drive shaft) (2). a Rotate the track by using a jack to find a position for sun gear to be removed smoothly. Then remove it.

4. Install cover (1) of the final drive. 5. Remove blocks put under the track shoe, tow the machine to a safe place. a After finishing towing, restore the machine.

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30 Testing and adjusting Undercarriage and frame

Undercarriage and frame

Adjusting idler clearance

a If runout or inclination occurs in the idler due to wear of the idler's guide plate, make adjustents according to the following procedure. k Place the machine on a level ground, lower

the work equipment to the ground, then set the parking brake lever and work equipment lock lever to LOCK position.

Adjusting

(D61-DT90-361-K-00-A)

Testing a When idler slides laterally or when track shoe comes off or is worn on only one side because of tilted idler, guide plate may be worn. Check it in the following procedure. 1. Travel forward 1 to 2 m slowly on a level ground, then stop the machine. 2. Measure the clearance (a) between track frame (1) and guide plate (2). a Measure clearance (a) at both inside and outside of the right and left idlers. • Allowable clearance (a): Max. 4 mm

Adjusting a If the clearance is improper, adjust it according to the following procedure. 1. Loosen mounting bolts (3) of guide plate (2). a Since the shims are half-split type, it is not necessary to remove guide plate. 2. Remove the shims from between idler support (4) and guide plate (2), then adjust clearance (a). • Target clearance (a): 0.2 to 1.2 mm • Shim thickness: 1.0 mm 3. Tighten mounting bolts (3) of guide plate (2).

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30 Testing and adjusting Undercarriage and frame

Checking sprocket wear Testing

(D65-DT60-389-K-00-A)

a Use the "Full-scale drawing of sprocket profile" in the section "Sprocket" in Structure, function and maintenance standard, "Sprocket" as a gauge for checking wear of the sprocket. a Make a copy of the "Full-scale drawing of sprocket profile" on a transparent paper or sheet and apply it directly to the sprocket to see if the sprocket can be used.

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30 Testing and adjusting Undercarriage and frame

Testing and adjusting track tension

k Place the machine on a level ground, lower

the work equipment to the ground, then set the parking lever and work equipment lock lever to LOCK position.

Testing

(D61-DTL0-285-K-01-A)

1. Move the machine forward slowly on a level ground, then stop it. a Do not apply the brake when stopping. 2. Place straight steel bar [1] between the idler and carrier roller, and measure the max. clearance (a) between the bottom of the steel bar and track shoe grouser. • Standard max. clearance (a): 20 to 30 mm

Adjusting

2. When the tension is low 1) Use the grease pump to pump in grease through grease fitting (2). 2) After the adjustment, recheck the tension according to the above checking procedure.

(D61-DTL0-27C-K-03-A)

a If the track tension is abnormal, adjust it according to the following procedure. a To adjust the track tension, remove the external cover from track frame. 1. When the tension is too high 1) Loosen valve (1) to discharge the grease. k Do not loosen the valve more than one

turn. If it is loosened more, it may jump out because of the internal highpressure grease. 2) If the grease is not discharged, slowly move the machine forward and backward. 3) Tighten valve (1). 3 Valve: 58.8 to 88.2 Nm {6 to 9 kgm} 4) After the adjustment, recheck the tension according to the above procedure.

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30 Testing and adjusting Hydraulic system

Hydraulic system

Releasing remaining pressure in work equipment cylinder

a When disconnecting the piping between the control valve and work equipment cylinder, release the remaining pressure in the circuit according to the following procedure. k Place the machine on a level ground, lower

the work equipment to the ground, and stop the engine. Set the parking brake lever and work equipment lock lever to the LOCK position. 1. Loosen hydraulic tank cap (1) gradually to release the remaining pressure in the tank.

2. Turn starting switch ON and place the work equipment lock lever in FREE position. 3. Operate the blade control lever and ripper control lever in all directions. a After the levers are operated 2 to 3 times, the remaining pressure in the accumulator is fully released. 4. Start the engine, run it at low idle for approximately 5 seconds, and then stop the engine. 5. Repeat above Steps 2 to 4 by 2 or 3 times.

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30 Testing and adjusting Hydraulic system

Testing and adjusting work equipment oil pressure a Testing tools Symbol 1 Q

2 3

Part No. 799-101-5002 799-261-1204 799-101-5220 07002-11023 799-401-3100

Part name Hydraulic tester Digital hydraulic tester Nipple O-ring Adapter

k Place the machine on a level ground and

lower the work equipment to the ground. k Be careful not to touch any hot parts when

installing or removing the testing tools.

Testing

a Angle cylinder includes piston valve. Therefore, relief pressure cannot be measured. 1-2. Measuring method by using oil pressure gauge k Turn the oil filler cap of the hydraulic tank to

the left slowly to release the pressure in the hydraulic tank. 1. Open the inspection cover at on the fuel tank side. 2. Disconnect hose (1) that connects to control valve Pp port, install adapter Q3 to it, and then connect the hose again.

(D61-D800-362-K-00-A)

a Perform testing of the work equipment oil pressure under the following condition. • HST oil temperature (hydraulic oil temperature): 40 to 60°C 1-1. Measuring method by using machine monitor a Measure the work equipment oil pressure with the "Monitoring" in service mode of the machine monitor. 1. Turn the starting switch to ON position and set the machine monitor to "Monitoring / Predefined"(3/14) or "Monitoring" of the service mode. • Monitoring code: 70700 "Hydraulic Pump Pressure"

3. Install nipple of hydraulic tester Q1 to adapter Q3, and connect them to oil pressure gauge [1]. a Use an oil pressure gauge of 40 MPa {400 kg/cm2}.

a For the operating method, see "Special functions of machine monitor".

2. Start the engine, and run it at high idle. Measure the work equipment oil pressure when each cylinder in blade lift and tilt is relieved at stroke end. a Relief pressure of control valve is displayed when the above operation are performed.

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4. Start the engine and run it at high idle, measure the work equipment oil pressure when each cylinder in blade lift and tilt is relieved at stroke end. a Relief pressure of main relief valve in control valve is displayed when the above operation are performed. a Angle cylinder includes piston valve. Therefore, relief pressure cannot be measured. 30-65

30 Testing and adjusting Hydraulic system

a Adjustment pressure per turn of adjustment screw: Approx. 19.6 MPa {200 kg/cm2} 4. With adjustment screw (2) fixed, tighten lock nut (3). 3 Locknut: 59 to 79 Nm (6 to 8 kgm) 5. After finishing the adjustment, measure the oil pressure again according to procedure of "Testing".

5. After finishing the test, remove the testing tools and restore the machine to its original condition.

Adjusting

(D61-D800-27B-K-00-A)

a If the oil pressure is not normal, adjust the main relief valve (1) of the control valve according to the following procedure. 1. Open the inspection cover on the fuel tank side. 2. While fixing adjustment screw (2) of the main relief valve (1), loosen lock nut (3).

3. Turn adjustment screw (2) to adjust the pressure. a When the adjustment screw is: • turned clockwise, the pressure is increased. • turned counterclockwise, the pressure is decreased. 30-66

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30 Testing and adjusting Hydraulic system

Testing source pressure of control circuit

a Control circuit source pressure is the same as HST charge circuit pressure while the machine is stopped. See "Testing and adjusting", "Measuring HST circuit pressure".

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30 Testing and adjusting Hydraulic system

Testing outlet pressure of work equipment EPC valve and fan EPC valve1 a Testing tools Symbol 1 R 2

Part No. 799-101-5002 790-261-1204 799-101-5220 07002-11023

Part name Hydraulic tester Digital hydraulic tester Nipple (M10 x 1.25) O-ring

a On the blade lowering side, operate the lever to FLOAT position. a When measuring fan EPC valve outlet pressure, select "Fan 100% mode" of "Fan Test Mode" of "Adjustment" on the machine monitor.

k Place the machine on a level ground, lower

the work equipment to the ground, stop the engine, and set the parking brake lever and work equipment lock lever in LOCK position. a Check that work equipment lock solenoid valve outlet pressure is normal, and measure each EPC valve outlet pressure. a Check this item under the following conditions. • Hydraulic oil temperature: 40 to 60°C

Testing

(D61-CW21-362-P-00-A)

1. Open the control valve cover from the right side of the operator's cab to measure. 2. Remove EPC valve outlet pressure pickup plug (1). (See Fig. 1.)

6. After finishing the measurement, remove the measuring tools and restore the machine.

3. Install nipple (R2) and connect oil pressure gauge [2] to the nipple. 4. Start the engine and set the work equipment lock lever in FREE position. 5. Run the engine at full speed, operate the control lever of the circuit to be tested, and measure the oil pressure. a Measurement should be performed while lever is at stroke end.

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Fig. 1 (measuring location) a Measuring locations are shown in following Fig. 1. PB6. Irrigation water pump PA6. (No use) PB5. (No use) PA5. Bracke Planter U oil PB4. Side Swing L cyl. R PA4. Side Swing L cyl. L PB3. Side Swing R cyl. L PA3. Side Swing R cyl. R PB2. Beam, Lift Lower PA2. Beam, Lift Raise PB1. Fan Motor

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30 Testing and adjusting Hydraulic system

Testing internal oil leakage of work equipment cylinder

a Testing tools Symbol S

Part No. Trade name

Part name Measuring cylinder

k Place the machine on a level ground and

lower the work equipment to the ground. a Check this item under the following condition. • HST oil temperature (hydraulic oil temperature): 40 to 60°C

Testing

(D61-PPZ0-364-K-00-A)

1. Testing oil leakage of blade lift cylinder 1) Start engine and travel the machine so that tracks (idler side) get onto the wooden blocks, etc. to raise the front side of machine. k Raise the front side of machine until

blade does not touch the ground even when the blade lift cylinder is extended to its LOWER stroke end. k Set parking brake lever to LOCK

position and put blocks under the rear of tracks. 2) Fully extend the lift cylinder to its LOWER stroke end and stop the engine. k Turn the starting switch to ON position,

set the work equipment lock lever to FREE position, operate the blade control lever to LOWER position, and then release the remaining pressure from the head side of lift cylinder. After releasing the remaining pressure, place the work equipment lock lever in LOCK position, and then turn the starting switch to OFF position. k Turn the oil filler cap of the hydraulic

tank counterclockwise slowly to release the pressure in the hydraulic tank. 3) Remove the cylinder cover on the measured side, disconnect hose (1) on the head side, and plug the hose side by using a plug.

4) Start engine and run it at high idle, operate the blade control lever to LOWER position to relieve lift cylinder circuit. k Be careful not to operate it to RAISE

side. 5) 30 seconds after starting relief, measure the amount of leakage for 1 minute. 6) After finishing the measurement, restore the machine. 2. Testing oil leakage of blade tilt cylinder 1) Start engine and raise the blade approximately 1 m off the ground. 2) Fully extend the tilt cylinder to the right TILT stroke end and stop the engine. k Turn the starting switch to ON position,

set the work equipment lock lever to FREE position, operate the blade control lever to right TILT position, and then release the remaining pressure from the head side of tilt cylinder. After releasing the remaining pressure, place the work equipment lock lever in LOCK position, and then turn the starting switch to OFF position. k Turn the oil filler cap of the hydraulic

tank counterclockwise slowly to release the pressure in the hydraulic tank. 3) Disconnect hose (2) on the head side, and plug the hose side by using a plug. a Plug to be used: 07376-70315 (for #03)

a Plug to be used: 07376-70422 (for #04)

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Testing fan speed

k Place the machine on a level ground, lower

the work equipment to the ground, and stop the engine. Set the parking brake lever and work equipment lock lever to LOCK position. a Check this item under the following condition. • HST oil temperature (hydraulic oil temperature): 50 to 60°C

Testing

(D61-B7P0-388-K-00-A)

1. Start the engine and switch the machine monitor to the "Adjustment" function display of the service mode. a Menu No.20: "FAN TEST MODE" "100 %" a For the operating method, see "Special functions of machine monitor". a If "Fan 100% mode" is selected (set (a) to "100%"), the fan speed is kept at 100% speed in accordance with the engine speed, regardless of the machine condition. a Be sure to keep the hydraulic oil temperature at 50°C or above when using this adjustment code. If the hydraulic oil temperature becomes 40°C or lower, the fan speed fluctuates.

2. While running the engine at low idle and high idle, measure the fan speed a For standard values, see "Standard value for machine". 3. After finishing test, remove the testing tools and restore the machine.

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Testing fan circuit oil pressure

a Testing tools Symbol 1 R 2

Part No. 799-101-5002 790-261-1204 799-101-5220 07002-11023

Part name Hydraulic tester Digital hydraulic tester Nipple (M10 x 1.25) O-ring

k Place the machine on a level ground, lower

the work equipment to the ground, and stop the engine. Set the parking brake lever and work equipment lock lever to LOCK position. a Perform testing of the fan circuit pressure under the following condition. • HST oil temperature (hydraulic oil temperature): 50 to 60°C

Testing

(D61-B441-362-K-00-A)

a Since the fan and the work equipment share a circuit, see "Testing oil pressure of work equipment circuit" for the fan circuit pressure. When oil pressure of work equipment circuit is normal, the fan circuit is normal. a When checking the oil pressure of fan circuit, check it with Menu No. 20 "Fan Test Mode" of "Adjustment" in "Special functions of machine monitor". a Set 100% in "Fan Test Mode", and read the value of "Hydraulic Pump Pressure" under P mode and running engine at high idle. a For standard values, see "Standard value table for machine".

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Bleeding air from hydraulic circuit k Place the machine on a level ground, and

lower the work equipment to the ground. a If hydraulic components of HST circuit and the work equipment circuit are removed and installed, or piping is disconnected and connected, bleed air from the circuit after those works according to the following procedure. a Check that oil level of hydraulic tank is at specified level and that there is no bubbles in the hydraulic tank before and after air bleeding.

Bleeding air

(D61-C000-231-P-02-A)

1. Bleeding air from HST pump, work equipment/ cooling fan pump 1) Remove inspection cover of the floor. 2) Remove oil filler cap of the hydraulic tank. k Turn the oil filler cap of the hydraulic

tank counterclockwise slowly, and open it carefully to release the pressure in the hydraulic tank, then remove it. 3) Loosen air bleeder (1) on top of HST pump, and check that oil oozes out. • When oil oozes out, air bleeding is completed. 4) Tighten air bleeder (1). 5) Loosen air bleeder (2) of work equipment/ cooling fan pump, and check that oil oozes out. • When oil oozes out, air bleeding is completed. 6) Tighten air bleeder (2). 7) Close oil filler cap of the hydraulic tank.

1 k Perform this work at a place where the

machine can travel, since the machine travels forward and in reverse during this work. 1) Perform warm-up operation to increase HST oil temperature (hydraulic oil temperature) to 80°C. a Air bleeding is effectively done when HST oil temperature (hydraulic oil temperature) is high. 2) Set gearshift mode selector switch to variable shift mode. 3) Press shift up switch twice at 1st speed. 4) Set the reverse travel speed setting to the same speed as the forward travel by operating shift down switch of reverse travel speed setting switch once. 5) Set the parking brake lever to FREE position, and travel forward and reverse repeatedly more than 20 times by operating the joystick (steering, directional and gearshift lever). • Forward o Neutral o Reverse o Neutral a Repeat more than 20 times of a cycle of one forward travel and one reverse travel. 4. Bleeding air from cylinder 1) Extract and retract each cylinder before the stroke end 4 or 5 times with engine running at low idle. a Stop the piston rod at approximately 100 mm before stroke end to avoid relieving. 2) Extract and retract each cylinder to the stroke end 3 or 4 times with engine running at low idle. 3) Extract and retract each cylinder to the stroke end four or five times with engine running at high idle. 5. Operation of the machine 1) After finishing air bleeding, stop the engine, and leave the machine in a stationary state for 5 minutes. a This is for bubbles in the oil in hydraulic tank to be released. 2) Check for oil leakage, and start operation if there is no abnormality.

2. Start the engine Start the engine, and run it at low idle for 10 minutes. 3. Air bleeding from servo portion of HST pump

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Work equipment

Adjusting work equipment lock lever

Adjusting

(D61-PK1G-270-K-00-A)

a When the parts related to work equipment lock lever are removed and reinstalled or replaced, perform adjustments according to the following procedures. 1. Set the work equipment lock lever (1) to LOCK position (B) and adjust clearance (b) between lever (2) and limit switches (3) (2 pieces). • Clearance (b) between the lever and limit switch: 0 mm • Do not move the limit switch during adjustment. 2. Check that limit switch (3) is moved 2.5 to 3.0 mm when work equipment lever (1) is operated. • Lever at LOCK position (B): Switch is OFF • Lever at LOCK position (A): Switch is ON 3. Testing the limit switch for work equipment lock 1) Turn starting switch to ON position and set the machine monitor to "Monitoring" function of the service mode and display "Blade Sw Input 1". • Controller: HST • Monitoring code: 70300 "Blade Sw Input 1"

2) Check that the relationship between work equipment lock lever position and ON/OFF of work equipment lock limit switch is the same as in the following table.

Monitoring code

a For the operating method, see "Special functions of machine monitor". 70300 30-74

"W/E Lock NC"

Work equipment lock lever position LOCK FREE (RAISE) (LOWER) (A) (B) OFF

ON D61EM-23M0

30 Testing and adjusting Work equipment

Monitoring code

"W/E Lock NO"

Work equipment lock lever position LOCK FREE (RAISE) (LOWER) (A) (B) ON

OFF

• When it is NG, perform adjustment of the limit switch for work equipment lock.

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Electrical system

Special functions of machine monitor

G0089279

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G0089280

Upper part of machine monitor (display portion)

Lower part of machine monitor (switch portion)

(a): Multi-information display

[1]: Numeral 1 input switch/Operation mode selector switch [2]: Numeral 2 input switch/Gearshift mode selector switch

a The figure shows an example of display of symbols and gauges in the ordinary display mode (The contents of display depend on the condition of the machine and operating method). a When the engine is started, the battery voltage may lower suddenly, depending on the ambient temperature and the condition of the battery. In this case, the display of the machine monitor goes out for a moment. This phenomenon is not a failure, however. Upper part of machine monitor (switch portion) [F1]: F1 function switch [F2]: F2 function switch [F3]: F3 function switch [F4]: F4 function switch [F5]: F5 function switch [F6]: F6 function switch a The function of each function switch is indicated by the icon in multi-information display (a) above each function switch.

[3]: Numeral 3 input switch/Reverse travel speed set switch (increase) [4]: Numeral 4 input switch/Buzzer cancel switch [5]: Numeral 5 input switch/Pedal mode selector switch [6]: Numeral 6 input switch/Reverse travel speed set switch (decrease) [7]: Numeral 7 input switch [8]: Numeral 8 input switch [9]: Numeral 9 input switch [0]: Numeral 0 input switch a Each switch has the function indicated by the icon on it and the function of inputting a numeral. a The machine monitor automatically judges which function of each switch is currently enabled according to the screen display of the multiinformation display (a).

a If the graphic mark of a function switch is not displayed, that function switch is not working.

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Ordinary functions and special functions of machine monitor

(D61-Q170-042-K-01-A)

The machine monitor has the ordinary functions and special functions to display the various types of information on the multi-display. Some items are displayed automatically according to the internal setting of the machine monitor and the others are displayed according to the operation of the switches. 1. Ordinary functions: Operator mode The information items in this mode are displayed ordinarily. The operator can display and set them by operating the switches. (Display and setting of some items need special operations of the switches.) 2. Special function: Service mode The information items in this mode are not displayed ordinarily. Each technician can display them by operating the switches specially. This function is used for special setting, testing, adjusting, or troubleshooting.

Operator mode (outline) Display of KOMATSU logo(PAGE 30- ) A A Password input(PAGE 30- )

Service mode Monitoring/ Pre-defined(PAGE 30- ) 01 02 Monitoring / Custom(PAGE 30- ) Abnormality record (mechanical systems) (PAGE 30- ) 03 Abnormality record (electrical systems)(PAGE 30- )

A Display of Check before starting(PAGE 30- )

B Selection of pedal mode(PAGE 30- )

Operation to cancel alarm buzzer(PAGE 30B ) B Operation of customizing(PAGE 30- ) B Operation of customize memory(PAGE 30- ) B Selection of multi gauge(PAGE 30- )

04 Maintenance Record(PAGE 30- ) 05 Maintenance mode setting(PAGE 30- ) 06 Phone number entry(PAGE 30- ) Default (Key-on Mode)(PAGE 30- ) 07 (Special operation) O

Display of warning after Check before starting A (PAGE 30- ) Display of maintenance time excess(PAGE A 30- ) Display of gear shift mode setting(PAGE 30A ) A Display of standard screen(PAGE 30- ) A Display of end screen(PAGE 30- ) Display of operation screen for engine A shutdown secondary switch(PAGE 30- ) B Selection of operation mode(PAGE 30- ) B Selection of gear shift mode(PAGE 30- ) Selection of reverse travel speed setting A (PAGE 30- )

Default (Unit)(PAGE 30- )

Default (Camera)(PAGE 30- ) Default (Float Buzzer)(PAGE 30- ) 0 Adjustment(PAGE 30- ) No-Injection(PAGE 30- ) KOMTRAX Settings (Terminal Status)(PAGE 30- ) KOMTRAX Settings (GPS and Communication Status)(PAGE 30- ) KOMTRAX Settings (Modem Information) (PAGE 30- ) Service Message(PAGE 30- )

Operation to display camera mode(PAGE 30B ) Operation to display clock and service meter B (PAGE 30- ) Checking maintenance information(PAGE 30B ) Setting and display of user mode (including B KOMTRAX messages for user)(PAGE 30- ) C Display of ECO guidance(PAGE 30- ) Display function of alarm monitor(PAGE 30C ) Display of action level and failure code(PAGE C 30- ) O (Special operation)

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Function of checking display of LCD (Liquid D Crystal Display)(PAGE 30- ) Function of checking service meter(PAGE 30D ) Function of Usage Limitation Setting/ Change D Password(PAGE 30- )

a Classification of operator mode A: Display or function that is indicated or enabled from the time when the starting switch is turned to the ON position to the time when display changes to the standard screen, and display after starting switch is turned to the OFF position B: Display/Function when machine monitor switch is operated C: Display/Function when certain condition is satisfied D: Display/Function that require special operations of switches

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Operator mode (outline)

(D61-Q193-042-K-01-A)

a Only outline of the operator mode is described in this section. For details of each function and display, and their operation, see "Structure and function ", or the "Operation and Maintenance Manual". a In this section, the following displays or functions of the operator mode are explained (including some items which need special operations). Operator mode (outline)

Display pattern a b c d

Display of KOMATSU logo(PAGE 1 1 1 1 30- ) Password input(PAGE 30- ) 2 ― ― ― Display of Check before starting 3 2 2 2 (PAGE 30- ) Display of warning after Check ― ― 3 ― before starting(PAGE 30- ) Display of maintenance time ― ― ― 3 excess(PAGE 30- ) Display of gear shift mode setting 4 3 4 4 (PAGE 30- ) Display of standard screen(PAGE 5 4 5 5 30- ) Display of end screen(PAGE 30- ) Display of operation screen for engine shutdown secondary switch(PAGE 30- ) Selection of operation mode(PAGE 30- ) Selection of gear shift mode(PAGE 30- ) Selection of reverse travel speed setting(PAGE 30) Selection of pedal mode(PAGE 30- ) Operation to cancel alarm buzzer(PAGE 30- ) Operation of customizing(PAGE 30- ) Operation of customize memory(PAGE 30- ) Selection of multi gauge(PAGE 30- ) Operation to display camera mode(PAGE 30- ) Operation to display clock and service meter (PAGE 30- ) Checking maintenance information(PAGE 30- ) Setting and display of user mode (including KOMTRAX messages for user)(PAGE 30- ) Display of ECO guidance(PAGE 30- ) Display function of alarm monitor(PAGE 30- ) Display of action level and failure code(PAGE 30 ) O (Special operation) Function of checking display of LCD (Liquid Crystal Display)(PAGE 30- ) Function of checking service meter(PAGE 30- ) Function of Usage Limitation Setting/ Change Password(PAGE 30- )

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a Display pattern of operator mode The contents of display from when the starting switch is turned to ON position to when the standard screen appears depend on the settings and conditions of the machine. a: When engine start lock is enabled b: When engine start lock is disabled c: When there is abnormal item in "Check before starting" items d: When there is maintenance item which is near specified time or excess User menu display switch If switch F6 is pressed on the standard screen, the user menu screen for setting various items of the machine is displayed on the monitor.

User menu The followings are menu screens in the user menu. Select each menu screen by switches F1 and F2. (a): "ECO Guidance" (b): "Machine Setting" (d): "Maintenance" (e): "Monitor Setting" (f): "Mail Checking"

Display of KOMATSU logo (PC220-Q180-044-K-01-A) When starting switch is turned to ON position, KOMATSU logo is displayed for 2 seconds.

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30 Testing and adjusting Electrical system

a After the KOMATSU logo screen is displayed for 2 seconds, the screen changes to "Password input" screen, or "Check before starting" screen.

a If this screen is displayed, call the person responsible for the operation of KOMTRAX in your Komatsu distributor and ask for remedy.

Password input (PC220-Q180-044-K-02-A) After the KOMATSU logo is displayed, the screen to input the engine start lock password is displayed.

Display of Check before starting

a This screen is displayed only when the engine start lock function is enabled. a When correct password is input, the screen changes to "Check before starting" screen. a The machine monitor has some password functions other than the engine start lock. Those functions are independent from one another.

06-A)

(D61-Q180-044-K-

When the screen changes to the "check before starting" screen, the check before starting is performed for 2 seconds. a If any abnormalities are detected by the check before starting, the screen changes to "Display of warning after Check before starting" or "Display of maintenance due time over". a If no abnormalities are detected by the check before starting, the screen changes to "Display of gear shift mode setting". a The monitors (2 monitors) on the screen shows the items currently subjected to the check before starting.

a The following screen may sometimes be displayed instead of the above "Password input" screen.

Display of warning after Check before starting (D61-Q180-044-K-07-A) If any abnormalities are detected in the "Check before starting", the alarm monitor is displayed on the screen.

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30 Testing and adjusting Electrical system

a The following figure shows that the HST oil filter clogging monitor (a) is warning that the HST oil filter is clogged.

Display of standard screen (D61-Q180-044-K-09-A) If the machine monitor starts normally, the standard screen is displayed. Display of maintenance time excess 044-K-08-A)

(D61-Q180-

If you find a maintenance item at check before starting that it is near or overdue the set interval, the maintenance monitor is displayed for 30 seconds to urge the operator to perform maintenance. a This screen is displayed only when the maintenance function is enabled. If the remaining time of any item is 30 hours or less, the yellow icon is displayed. If the remaining time of any item is 0 hour or less, the red icon is displayed.

a Service meter (a) or the clock is displayed at the center top of the screen (Switch between the service meter and clock with [F4]). a Engine speed (b) is displayed on the multigauge (The switching of the display is made with [F2]). a ECO gauge (c) is displayed at the right end of the screen (Switch the display in the user mode).

a Perform setting and changing of the maintenance function in the service mode. After the screen finishes this display, it changes to the "standard screen".

G0089281

Display of end screen (PC220-Q180-044-K-09-A) When starting switch is turned to OFF position, the end screen is displayed for 5 seconds. a Other messages may appear on the end screen due to KOMTRAX message display function.

Display of gear shift mode setting K-10-A)

(D61-Q180-044-

If the Check before starting is finished normally, the screen to check the gear shift mode setting is displayed for 2 seconds. a After the display of gear shift mode setting is finished, the screen changes to the ｄisplay of standard screen.

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30 Testing and adjusting Electrical system

a Each time the switch is pressed, the setting of the working mode changes to [P (Power)] o[E (Economy)] o [P (Power)] in order.

Display of operation screen for engine shutdown secondary switch (D61-AKHL-100-K-00-A) If you turn the engine shutdown secondary switch to ON position, "Engine Shutdown Secondary Switch Activated" screen is displayed on every screen except the end screen. a The engine shutdown secondary switch is installed to the right side of the monitor panel. This switch is used to stop the engine when it does not stop after the starting switch is turned to OFF position.

If you turn the engine shutdown secondary switch to OFF position, the KOMATSU logo appears once, and then the display changes to the standard screen.

Selection of operation mode (D61-Q1FR-100-K-00-A) When the working mode selector switch is pressed while the standard screen is displayed, the working mode monitor (a) changes.

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Selection of gear shift mode (D61-Q1G7-100-K-00-A) When the gear shift mode selector switch is pressed while the standard screen is displayed and while machine is stopped, the gear shift mode monitor (a) in the speed range display section changes. a Each time the switch is pressed, the gear shift mode changes to [Quick shift mode] o [Variable shift mode] o [Quick shift mode] in order.

Selection of reverse travel speed setting For selection of reverse travel speed setting, press the reverse travel speed setting switch (increase/ decrease) while the standard screen is displayed. Then gauge on the reverse side of the speed range gauge (a) increases or decreases. a The reverse travel speed setting consists of stages of -1 0, It is set to when the starting switch is in ON position.

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30 Testing and adjusting Electrical system

Load Display Blade Fine Control Steering Mode 1st Travel Speed Setting 2nd Travel Speed Setting 3rd Travel Speed Setting a Display pattern of operator mode The contents of display from when the starting switch is turned to ON position to when the standard screen appears depend on the settings and conditions of the machine.

Selection of pedal mode (D61-Q1CL-100-K-00-A) The pedal mode monitor (a) in the speed range display section changes by pressing the pedal mode switch while the standard screen is displayed, a Each time the switch is pressed, the pedal mode changes to [Deceleration mode] o [Brake mode] o [Deceleration mode] in order.

a: When engine start lock is enabled b: When engine start lock is disabled c: When there is abnormal item in "Check before starting" items d: When there is maintenance item which is near the due time or over the due time.

Operation of customize memory 00-A)

Operation to cancel alarm buzzer 00-A)

(D65-Q576-100-K-

While the alarm buzzer is sounding, When the buzzer cancel switch is pressed, the alarm buzzer stops.

(D61-Q1G9-100-K-

While the standard screen is displayed, select F1 "LOAD" by operating the customize switch, and you can select the recorded customized setting.

a Even if the buzzer cancel switch is pressed, the display on the screen does not change.

Operation of customizing (D61-Q1G8-100-K-00-A) While the standard screen is displayed, press the [F1] customize switch, and you can change the setting of the machine. a While this screen is displayed, press the F2 [SAVE] switch, and you can save the setting up to 5 contents. a There are following items in the customize mode. Working Mode Gear Shift Mode Pedal Mode Reverse Travel Speed Setting 30-84

Selection of multi gauge (D61-Q1LG-100-K-01-A) Display of the multi gauge (a) changes when [F2] is pressed while the standard screen is displayed.

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a Each time the switch is pressed, the multi gauge changes to [Engine tachometer] o [Machine temperature gauge] o [Work equipment pump oil pressure gauge] o [Battery voltage gauge] o [Drawbar pull gauge] o [Clock] o [Engine tachometer] in order.

Operation to display camera mode K-01-A)

(D61-Q16A-100-

a If any caution occurs while the camera mode is displayed, the corresponding alarm monitor is displayed at the left top of the screen.

a If an "action level present" error occurs while the camera mode is displayed, and the machine stops for more than 10 seconds, the screen returns to the standard screen and displays information about that error.

When a camera is installed, the screen of the multidisplay changes to the camera image by pressing [F3].

a When 2 or more cameras are connected, the image for display can be selected, or 2 images can be displayed at the same time.

a Set the connection of the camera in the service mode.

a When 2-camera image display is selected with [F4], the image of camera 1 is displayed on the left side of the screen, and the image of camera 2 is displayed on the right side. The image of camera 3 is displayed only singly. a If 2-camera image display operation is performed, the images are displayed frame by frame at intervals of approximately 1 second on the right and left side of the screen.

a Up to 3 cameras can be connected. However, if the camera mode is selected, only the image of camera 1 is always displayed.

Operation to display clock and service meter (D61-Q1MA-100-K-00-A) When [F4] is pressed while the standard screen is displayed, the display at section (a) is alternately switched between service meter display and clock display. a When selecting the clock display, perform the time adjustment, 12-hour or 24-hour display setting, and summer time setting by using the user mode functions. a Display of service meter

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a Display of clock

Setting and display of user mode (including KOMTRAX messages for user) (D65-Q1C3-100-K-03A)

To enter the user mode, press [F6] to display the "User Menu" screen while the standard screen is displayed.

Checking maintenance information 100-K-02-A)

(D65-Q1C2-

You can check the maintenance information on the maintenance screen by pressing [F6] while the maintenance monitor is displayed. When the maintenance monitor does not displayed, press [F6] and then press [F1] or [F2] to switch to the maintenance screen.

a There are following items in the user menu. ECO Guidance Machine setting KDPF regeneration Maintenance Monitor setting Mail Checking (Example of ECO guidance)

a To reset the time left after finishing maintenance, more operations are necessary.

[KOMTRAX message] 30-86

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• There are two types of KOMTRAX message; one is for the user and the other is for the technician. • For user: It denotes the messages transmitted from the KOMTRAX base station to users. Upon receiving a message, the message monitor is displayed on the standard screen. Operate this "Check mail" when viewing contents of a message. • For technician: It denotes the messages transmitted to the technicians from the KOMTRAX base station. Even if it is received, no sign is displayed in the standard screen. To view contents of a message, operate "Display service message" of the service menu in the service mode.

If relieving lasts for 10 or more seconds during operation, deterrence guidance of hydraulic relief is displayed on the monitor. a The lamp for the guidance on deterrence of hydraulic relief goes out automatically after 5 seconds has passed since it appeared, or if the function switch [F5] is pressed. a Deterrence guidance of hydraulic relief is displayed when the engine coolant temperature is 30°C or higher and the hydraulic oil temperature is 20°C or higher.

Display of ECO guidance (D61-Q1L3-100-K-01-A) When the machine remains in a certain operating condition, the "ECO Guidance" screen is displayed automatically to urge the operator to perform energy-saving operation. a The "ECO Guidance" screen is displayed when the following conditions are met while this display function setting is effective. Conditions for display • Idle stop guidance If the levers are not operated for more than 5 minutes with engine running at idle, the idling stop guidance is displayed on the monitor. Unnecessary fuel consumption can be reduced by stopping the engine when waiting for work or taking short break. a The lamp for the idle stop guidance goes out automatically when the lever operation is resumed, or if the function switch [F5] is pressed.

• Economy Mode (recommended) guidance If light-load work is continued for more than 10 minutes in P mode, Economy Mode (recommended) guidance is displayed. Unnecessary fuel consumption can be reduced by setting the working mode to E When working on light load. a The lamp for the Economy Mode (recommended) guidance goes out automatically after 5 seconds has passed since it appeared, or if the function switch [F5] is pressed.

a Idle stop guidance is displayed when the engine coolant temperature is 30°C or higher and the hydraulic oil temperature is 20°C or higher.

• Deterrence guidance of hydraulic relief D61EM-23M0

• Deterrence guidance on over load If too much load is applied to the machine during work, deterrence guidance on over load is displayed on the monitor. Fuel consumption can be reduced by operating the machine carefully to avoid shoe slipping, and keep operation within the green zone of eco-gauge. 30-87

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a The deterrence guidance on over load goes out automatically after 5 seconds has passed since it appeared, or if the function switch [F5] is pressed.

Display function of alarm monitor K-01-A)

(D61-Q1FC-044-

If an abnormality that displays the alarm monitor of action level "L01" occurs on the standard screen or camera mode screen, the alarm monitor is displayed in a large size for a while. Then it is kept displayed at (a) inside the screen. a When a caution occurs while the camera mode is displayed, the alarm monitor flashes at the upper left of the screen.

If an abnormality that displays an alarm monitor of action level "L02", "L03", or "L04" occurs, the alarm monitor is displayed at the center of the monitor. It keeps displayed until the abnormality is eliminated.

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Display of action level and failure code Q1FC-100-K-00-A)

(D61-

If an abnormality that displays an action level and a failure code occurs on the standard screen or camera mode screen, the alarm monitor lights up.

a Since "Error List" cannot be displayed from the screen on which the camera mode is displayed, move to "Occurred error list" from the standard screen side.

If the alarm monitor lights up, press function switch [F5] to display the "Error List". [F1]: Moves to next page (screen) (when displayed) [F2] Moves to previous page (screen) (when displayed) [F5]: Returns display to standard screen On the "Error List" screen, the following information is displayed. (a): Alarm monitor (b): Action level (3 digits) (c): Failure code (5 or 6 digits) (d): Failure code name (e): Message (f): Telephone No. (if registered) a This screen appears when trouble (failure code) occurs only if its action level is set. a The telephone number is displayed only when the telephone number is registered in the service mode. a If multiple troubles occur simultaneously, all the codes are displayed repeatedly in order. a As the information of the displayed failure code is recorded in the "Abnormality Record" in the service mode, check the details in the service mode. a "Error List" is replaced with the standard screen automatically after 30 seconds.

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Alarm monitor

Action level

Buzzer

Degree of emergency

Remedies that displayed action levels requires operator to do (The following table is an excerpt from the Operation and Maintenance Manual)

L04

Q (Continuous)

L03

Q (Intermittent)

High

I O

L02

L01 (For 2 seconds only) Low

Q (Intermittent)

―

If the number of the bright points and black points does not exceed 10, the LCD panel is not faulty or defective.

Remedy

Stop immediately and perform checking and maintenance. Ask your Komatsu distributor for testing and repair services. Stop the work, move machine to safe place, stop it, and perform checking and maintenance. Ask your Komatsu distributor for testing and repair services. Stop the work, and then run the engine at medium speed with no load, or stop it. If the condition is not improved, ask your Komatsu distributor for testing and repair services. Some functions are restricted, but the machine can operate. After finishing work, perform checking and maintenance. Ask your Komatsu distributor to perform testing or repairs as necessary.

Function of checking service meter 100-K-01-A)

(D65-Q1MB-

When checking the service meter with the starting switch in OFF position, operate the numeral input switches as follows to display only the service meter section. • Switch operations (simultaneous): [4] + [1] a There is some time lag in start of the LCD, so hold down the switches until the service meter is displayed. a If you release one of the switches, the monitor goes out. a After the machine monitor is used continuously over a long period of time, blue points (points that remain lit) may appear on this screen. It does not indicate that the LCD panel is faulty or defective.

Function of checking display of LCD (Liquid Crystal Display) (PC-Q1LE-100-K-00-A) While the standard screen is displayed, if the numeral input switches or function switches are operated in the following manner, the entire LCD screen turns white. • Switch operations (simultaneous): [4] + [F2] a When finishing the operation of the switches, release [F2] first. a If there is a display error in the LCD, only that part is indicated in black. a To return to the former screen, press any one of the function switches. Reference: An LCD panel, as one of its characteristics, sometimes shows black spots (spots that remain unlit) and bright spots (spots that do not go off). 30-90

Function of Usage Limitation Setting/ Change Password (D61-Q19X-100-K-00-A) By setting the usage limitation, the password input screen is displayed when you perform the maintenance resetting. Set the usage limitation according to the following procedure. 1. While the standard screen is displayed, perform the following operation by using the numeral input switches. D61EM-23M0

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• Switch operation (Press the switches in order while pressing [4]) [4]+[5]o[5]o[5] a This operation of the switches is not accepted until 10 minutes elapse after the starting switch is turned to ON position.

2. After the "Usage Limitation Password" screen is displayed, input the current password by using the numeral input switches and confirm it by using the function switch. • [F5]: Deletes input numbers/ Returns to standard screen • [F6]: Enters input password

Selection of use/ non-use of Usage Limitation After the "Usage Limitation ON/OFF" screen is displayed, select a setting by using the function switch. • Non-use: Password input screen is not displayed • Use: Displays the password input screen when you perform maintenance resetting. • [F3]: Moves selection downward • [F4]: Moves selection upward • [F5]: Cancels the selection and returns the display to the previous screen • [F6]: Enters selection

a Default password: [000000] a When the input password is correct, the screen changes to the next screen. a When the input password is incorrect, the screen displays message to request inputting the password again.

3. After the "Usage Limitation Setting" screen is displayed, select a setting by using the function switch. • [F3]: Moves selection downward • [F4]: Moves selection upward • [F5]: Cancels the selection and returns the display to the previous screen • [F6]: Enters selection D61EM-23M0

a The password for the Usage Limitation and the engine start lock password are not identical. 4. Changing a password After the "Usage Limitation New Password Input" screen is displayed, input the new password by using the numeral input switches and confirm it by using the function switch. • [F5]: Deletes input numbers/ Returns the display to the preceding screen • [F6]: Enters input password a Default password: [000000] a When the input password is correct, the screen changes to the next screen.

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a When the input password is incorrect, the screen displays message to request inputting the password again. a Set a new password of 4 to 6 digits (If it has only 3 or less digits or has seven or more digits, it is not accepted).

After the "Usage Limitation New Password Input" screen is displayed once more, input the new password for the second time by using the numeral input switches and confirm it by using the function switch. • [F5]: Deletes input numbers/ Returns to standard screen • [F6]: Enters input password a If the input password is different from the one input before, the screen displays message to request inputting again.

If the standard screen is displayed after the screen to notify completion of setting is displayed, the password is changed successfully.

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Service mode

(D61-Q194-100-K-00-A)

To change the operator mode to the service mode, perform the following operation. This operation is always required when you use the service mode. 1. Checking of display of screen, and switch operation While the standard screen is displayed, perform the following operation with the numeral input switches. • Switch operation (Press the switches in order while pressing [4]) [4] + [1] o [2] o [3] a This switch operation is accepted only while the standard screen is displayed.

a The items you can select in the service menu are as follows. 01 Monitoring/ Pre-defined(PAGE 30- ) 02 Monitoring / Custom(PAGE 30- ) Abnormality record (mechanical systems)(PAGE 30- ) 03 Abnormality record (electrical systems)(PAGE 30- ) 04 Maintenance Record(PAGE 30- ) 05 Maintenance mode setting(PAGE 30- ) 06 Phone number entry(PAGE 30- ) Default (Key-on Mode)(PAGE 30- ) Default (Unit)(PAGE 30- ) 07 Default (Camera)(PAGE 30- ) Default (Float Buzzer)(PAGE 30- ) 0 Adjustment(PAGE 30- ) No-Injection(PAGE 30- ) KOMTRAX Settings (Terminal Status)(PAGE 30- ) KOMTRAX Settings (GPS and Communication Status)(PAGE 30- ) KOMTRAX Settings (Modem Information) (PAGE 30- ) Service Message(PAGE 30- ) a The items written in ( ) are the menus on the next hierarchy to "Service Menu" screen.

2. Selecting the service menu When the "Service Menu" screen is displayed, the service mode is selected. Select a service menu you use by using the function switches or numeral input switches. • [F3]: Moves selection downward • [F4]: Moves selection upward • [F5]: Return the display to the standard screen (operator mode) • [F6]: Enters selection a If you input a 2-digit code by using the numeral input switches, the corresponding menu is directly selected. You do not need to enter it by using [F6].

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Monitoring/ Pre-defined (D61-Q1S1-100-K-00-A) The machine monitor can monitor the condition of the machine in real time by receiving signals from various switches, sensors, and actuators installed to various parts of the machine and the information from the controllers which is controlling switches, etc. In the "Monitoring/ Pre-defined", frequently used monitoring items in daily work are selected beforehand. 1. Selecting menu Select "Monitoring/Pre-defined" on "Service Menu" screen.

2. Checking Monitoring/Pre-defined information After the "Monitoring/Pre-defined" screen is displayed, you can check the items displayed in monitoring/pre-defined by using the function switches. • [F1]: Moves to next page (screen) • [F2]: Moves to previous page (screen) • [F4]: Selects hold or releasing hold (If Hold is selected, HOLD portion is hatched.) • [F5]: Returns to the "Service Menu" screen a For the items not displayed in "Monitoring/ Pre-defined", you can freely select and check from "Monitoring" items.

• See next page for list of Monitoring/Predefined items.

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Monitoring / Custom (D61-Q19L-100-K-00-A) The machine monitor can monitor the condition of the machine in real time by receiving signals from various switches, sensors, and actuators installed to various parts of the machine and the information from the controllers which is controlling switches, etc. The monitoring function allows you to select a desired monitoring item. 1. Selecting the menu Select "Monitoring/Custom" on Service Menu screen.

a Up to six monitoring items are selectable at a time. However, all of the 6 items may not be set up depending on the form of display of the selected item.

3. Deciding monitoring items After selecting monitoring items, execute monitoring with the function switch or numeral input switch. a Execution with function switch: Double click or keep pressing [F6] (for approximately 2 seconds). 2. Selecting a monitoring item After the "Monitoring Selection Menu" screen is displayed, select items to be monitored by using the function switches or numeral input switches. • [F1]: Moves selection leftward • [F2]: Moves selection rightward • [F3]: Moves selection downward • [F4]: Moves selection upward • [F5]: Deletes input numbers or returns to the "Service Menu" screen • [F6]: Enters selection

a Execution with numeral input switch: Input [99999] and press [F6]. a When monitoring only 2 items, for example, select them and enter them by using [F6]. If [F6] is pressed once more at this time, monitoring is executed. a If monitoring items are selected up to the limit number, monitoring is executed automatically.

a In setting of the monitoring, each time function switch [F1] is pressed, sequential switching among [ENG] o [KDPF] o [HST] o [MON] o [ENG] takes place in this order. (Press [F2] to switch in the reverse order.) a Selection with function switches: Select an applicable equipment by using [F1] or [F2], select an item by using [F3] or [F4], and then enter it by using [F6]. a Selection with numeral input switches: Enter a 5-digit code, and the item of that code is selected directly. Enter that item by using [F6]. a If the color of the selected box changes from yellow to red, the selection of the item of that box is entered.

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4. Executing monitoring After the "Monitoring" screen is displayed, perform the necessary operation of the machine, and check the monitoring information. a Monitoring information is indicated by value, ON/OFF, or special display.

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a The unit of display can be set to "SI unit", "Metric unit", or "Imperial unit" with the "Default" function in the service mode.

5. Holding monitoring information You can hold and release holding of the monitoring information by using the function switches. • [F4]: selects hold or releasing hold (If the Hold is selected, a diagonal line appears on the HOLD portion.) • [F5]: Returns the display to monitoring selection menu screen

7. Saving of monitoring item A function switch lets you save and delete the selected monitoring item. • [F1]: MEMORY • [F2]: CLEAR

a When a monitoring item is saved, a confirmation screen appears asking whether the saved item should be displayed or not, when "Monitoring" is selected again.

6. Changing machine setting mode To change the setting of the working mode or gear shift mode during monitoring, operate the corresponding switch under the current condition to turn on the applicable mode. a If the setting is changed during monitoring, the new setting is held even after the screen returns to the ordinary screen after monitoring is finished. a When you saved an item, you can display it as many times as you want until it is cleared. a In case you save an item when another item is saved already, the currently saved item is overwritten by the last one.

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Unit (Default: SI) Code No.

Monitoring item (Display on screen)

Monitor 3rd & 4th 04505 Row Switches

SW9 SW10 SW11 SW12 SW13 SW14 SW15

04506

Monitor 5th Row Switches

00500 20227 20402 20228 20221 20260 20418 20261

Monitor Model Code Monitor Ass'y P/N Monitor Serial No) Monitor Prog. P/N Monitor Prog. Version KOMTRAX Ass'y P/N KOMTRAX Serial No KOMTRAX Prog. P/N

Applicable Metric Imperial component ON/OFF MON ON/OFF MON ON/OFF MON ON/OFF MON ON/OFF MON ON/OFF MON ON/OFF MON ― MON ― MON ― MON ― MON ― MON ― MON ― MON ― MON

Remarks

a Listing order in the table of monitoring items The monitoring items are listed in the order of the display on the monitoring item selection menu screen. a Unit The display unit can be set to SI, Metric, or Imperial as required (select a desired unit from "Unit" of "Default"). "mg/st" in the display unit is an abbreviation for milligram/stroke. a Applicable component ENG: The engine controller is in charge of detecting the monitoring information. KDPF: KDPF detects monitoring information. HST: HST controller detects monitoring information. MON: The machine monitor detects monitoring information. *1: Instantaneous fuel consumption (Code No.: 37300) is the theoretical fuel consumption ratio. (Since it is a theoretical value, it is slightly different from the actual fuel consumption ratio.)

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Abnormality record (mechanical systems) (D61-Q1S2-100-K-00-A) The machine monitor classifies the failures which occurred in the past or which are occurring at present into the mechanical system abnormality, and electrical system abnormality, and logs them. To check the mechanical system abnormality record, perform the following procedures. a For the failure code list, see "40 Failure code list for troubleshooting". 1. Selecting a menu Select "Abnormality Record" on "Service Menu" screen.

(a) Occurrence order of abnormalities from latest one/ Total number of records (b): Failure code (c): Detail of failure (d): Number of occurrences (displayable range: 0 to 65,535 times) (e): Service meter reading at the first occurrence (f): Service meter reading at the last occurrence • [F1]: Moves to next page (screen) (when displayed) • [F2] Moves to previous page (screen) (when displayed) • [F5]: Returns the display to "Abnormality Record" screen a If no abnormality is recorded, "No Error" is displayed. a In the mechanical systems abnormality record screen, up to 50 cases currently stored are displayed.

2. Selecting a sub menu After the "Abnormality Record" screen is displayed, select "Mechanical System Abnormality Record" with the function switches or numeral input switches. • [F3]: Moves selection downward • [F4]: Moves selection upward • [F5]: Returns to the "Service Menu" screen • [F6]: Enters selection

a If the number of occurrence is 1 (first occurrence), the service meter reading at the first occurrence and that at the last occurrence are the same. When the latest service meter reading is recovered, the value at the recovery time is displayed, thus the above readings may not be the same. a If [E] is displayed on the left of a failure code, the abnormality is still occurring or correction of it is not confirmed. a For all of the failure codes that the machine monitor can record, see the failure code list.

a When you input a 2-digit code by using the numeral input switches, the corresponding item is directly selected. Accordingly, you may enter the selection by using [F6].

4. Deleting abnormality record The contents of an abnormality record of the mechanical system cannot be deleted.

3. Information displayed on "Abnormality Record" screen On the "Mechanical Systems" screen, the following information is displayed. 30-104

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Abnormality record (electrical systems) Q1S3-100-K-00-A)

(D65-

The machine monitor classifies the failures which occurred in the past or which are occurring at present into the mechanical system abnormality, and electrical system abnormality, and logs them. To check the electrical system abnormality record, perform the following procedures. a For the failure code list, see "40 Failure code list for troubleshooting". 1. Selecting a menu Select "Abnormality Record" on "Service Menu" screen.

(b): Failure code (c): Detail of failure (d): Number of occurrences (displayable range: 0 to 65,535 times) (e): Service meter reading at the first occurrence (f): Service meter reading at the last occurrence • [F1]: Moves to next page (screen) (when displayed) • [F2] Moves to previous page (screen) (when displayed) • [F3]: Moves selection downward • [F4]: Moves selection upward • [F5]: Returns the display to "Abnormality Record" screen a If no abnormality is recorded, "No Error" is displayed. a In the electrical systems abnormality record screen, up to 20 cases currently stored are displayed. a If the number of occurrence is 1 (first occurrence), the service meter reading at the first occurrence and that at the last occurrence are the same.

2. Selecting a sub menu After "Abnormality Record" screen is displayed, select "Electrical Systems" with the function switches or numeral input switches. • [F3]: Moves selection downward • [F4]: Moves selection upward • [F5]: Returns to "Service Menu" screen • [F6]: Enters selection

When the latest service meter reading is recovered, the value at the recovery time is displayed, thus the above readings may not be the same. a If [E] is displayed on the left of a failure code, the abnormality is still occurring or correction of it is not confirmed. a For all of the failure codes that the machine monitor can record, see the failure code list.

a When you input a 2-digit code by using the numeral input switches, the corresponding item is directly selected. Accordingly, you may enter the selection by using [F6].

4. Deleting abnormality record 1) While "Electrical Systems" screen is displayed, perform the following operation by using the numeral input switches. 3. Information displayed on "Abnormality Record" screen On "Electrical Systems" abnormality record screen, the following information is displayed. (a): Occurrence order from latest one/ Total number of records D61EM-23M0

• Switch operation (Press the switches in order while pressing [4]) [4] + [1] o [2] o [3]

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a Operate the switches similarly to the procedure for changing the ordinary display to the service mode.

2) Check that the display on the screen becomes the clear mode, then clear the individual information one by one or all together by using the function switches.

• [F6]: Executes clearing a The screens for clearing all information and clearing selected information slightly differ. (Deleting all information)

(Deleting selected information)

a If the screen is set in the clear mode, graphic mark [CLEAR] is indicated above [F2]. • • • •

[F2]: Clears all items [F3]: Moves selection downward [F4]: Moves selection upward [F5]: Returns the display to "Abnormality Record" screen • [F6]: Clears items one by one a To clear items one by one: Select the item to be cleared with [F3] or [F4] and press [F6]. a To clear all items together: Press [F2], and all the items are cleared, regardless of selection of the items. a If [E] is displayed on the left of a failure code, the clearing operation is accepted but the item is not cleared.

4) If the screen to notify completion of clearing is displayed and then the "Electrical System Abnormality Record" (clear mode) screen is displayed, the clearing of the abnormality record is complete. a After a while, the screen returns to "Electrical Systems" abnormality record screen.

3) After "Electrical Sys. Error Reset" screen is displayed, operate the function switches. • [F5]: Returns to "Electrical Systems" screen (clear mode) Return 30-106

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Maintenance Record (D61-Q19Z-100-K-00-A) The machine monitor records the maintenance information of the filters, oils, etc., which are displayed and checked by the following operations. When the maintenance is performed, if the data are reset in the operator mode, the number of the times of maintenance is recorded in this section. 1. Selecting the menu Select "Maintenance Record" on "Service Menu" screen.

a The following items can be selected in the maintenance record. 49 Air Cleaner Cleaning/ Change 01 Engine Oil Change Interval 02 Eng Oil Filter Change Interval 03 Fuel Main Filter Change Interval 41 Fuel Pre Filter Change Interval 04 Hyd Oil Filter Change Interval 08 Final Drive Oil Change Interval 05 H/Tank Breather Change Interval 44 F/Tank Breather Change Interval 10 Hydraulic Oil Change Interval 26 HST Oil Filter Change Interval 3. Items displayed on Maintenance Record screen (a): Maintenance items (b): Number of replacements up to now (c): Service meter reading (SMR) at the last replacement

2. Selecting a maintenance record item After the "Maintenance Record" screen is displayed, select an item of which the setting is to be checked by using the function switches or numeral input switches. • [F1]: Moves to next page (screen) • [F2]: Moves to previous page (screen) • [F3]: Moves selection downward • [F4]: Moves selection upward • [F5]: Returns to the "Service Menu" screen a You may enter a 2-digit code by using the numeral input switches to select the item of that code.

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Maintenance mode setting (D61-Q1F1-100-K-00-A) The actuating condition of the maintenance reminder function in the operator mode can be set and changed by using this menu. • To enable or disable the function • To change replacement interval setting (by item) • To initialize all of replacement interval setting 1. Selecting a menu Select "Maintenance Mode Setting" on "Service Menu" screen.

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a The following items can be selected on the "Maintenance Mode Setting" screen.

2. Selecting a sub menu After the "Maintenance Mode Setting" screen is displayed, select an item to change setting by using the function switches or numeral input switches. • [F1]: Moves to next page (screen) • [F2]: Moves to previous page (screen) • [F3]: Moves selection downward • [F4]: Moves selection upward • [F5]: Returns to the "Service Menu" screen • [F6]: Enters selection a When you input a 2-digit code by using the numeral input switches, the corresponding item is directly selected. Accordingly, you may enter the selection by using [F6].

00 Maintenance Mode Change 49 Air Cleaner Cleaning / Change Interval 01 Engine Oil Change Interval 02 Eng Oil Filter Change Interval 03 Fuel Main Filter Change Interval 41 Fuel Pre Filter Change Interval 04 Hyd Oil Filter Change Interval 07 Damper Case Service Interval 08 Final Drive Oil Change Interval 05 H/Tank Breather Change Interval 44 F/Tank Breather Change Interval 10 Hydraulic Oil Change Interval 26 HST Oil Filter Change Interval 99 All Default Value 3. Setting contents of "Maintenance Mode Change" After selecting "Maintenance Mode Change" and the screen is displayed, select the desired setting by using the function switches. • ON: All of functions of maintenance items become effective in operator mode. • OFF: All of functions of maintenance items becomes ineffective in operator mode. • [F3]: Moves selection downward • [F4]: Moves selection upward • [F5]: Cancels the selection and returns to the "Maintenance Mode Change" screen • [F6]: Enters selection and returns to the "Maintenance Mode Change" screen a Even if Use or Not use of each item has been set, if the above setting is changed, it overrides the individual setting.

4. Setting of Maintenance Notice Time Setting After selecting "Maintenance Notice Time Setting" and the screen is displayed, select the desired setting by using the function switches.

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• Default value: Maintenance notice time set on the machine monitor (Recommended by the manufacturer and not changeable). • Set value: Maintenance notice time which can be set freely between 10h and 200h. Operates on basis of this set time (which is increased or decreased by 10 hours). • [F3]: Decreases set value • [F4]: Increases set value • [F5]: Cancels contents of setting before entry and returns to "Maintenance Mode Change" screen • [F6]: Enters setting and returns to "Maintenance Mode Change" screen a When you enter by using [F6] and return to the "Maintenance Mode Setting" screen by using [F5] , your setting is validated.

• ON: All of functions of maintenance items become effective in operator mode. • OFF: All of functions of maintenance items becomes ineffective in operator mode. • [F3]: Moves selection downward • [F4]: Moves selection upward • [F5]: Cancels the selection and returns to the "Maintenance Mode Change" screen • [F6]: Enters selection and returns to the "Maintenance Mode Change" screen a Even if ON/OFF of each item has been set, if the above setting is changed, it overrides the individual setting. 6. Setting of set value of each maintenance item Select the set value of each maintenance item. After the screen is displayed, set the value by using the function switches.

a If the set value of an item of which maintenance reminder function is set to "ON" is changed after one operating hour or more from the setup, the change is recognized as a reset of the remaining time.

5. Setting of each maintenance item Select each maintenance item. After the screen is displayed, set the item by using the function switches.

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• Default value: Maintenance notice time set on the machine monitor (Recommended by the manufacturer and not changeable). • Set value: Maintenance interval that can be freely set. Maintenance reminder function works according to this set time in operator mode (the time increases or decreases in multiples of 25 hours). • [F3]: Decreases set value • [F4]: Increases set value • [F5] Cancels contents of setting before entry and returns to the "Maintenance Mode Change" screen

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• [F6]: Enters setting and returns to "Maintenance Mode Change" screen a When you enter by using [F6] and return to the "Maintenance Mode Setting" screen by using [F5] , your setting is validated.

a A while after [F6] is pressed, the initialization completion screen is displayed. Then, when the "Maintenance Mode Setting" screen is displayed, initialization is complete.

a If the set value of an item of which maintenance reminder function is set to "Enable" is changed after one operating hour or more from the setup, the change is recognized as a reset of the remaining time.

a Notice time can be set at Maintenance Notice Time Setting in "Air Cleaner Cleaning/ Change Interval". However, perform cleaning or replacement of the air cleaner element when the air cleaner clogging monitor of the monitor panel lights up. 7. Function to return all of the values to default values After selecting "All Default Value" and the screen is displayed, select the desired setting by using the function switches.

• If the operation for this function is executed, the set values of all the maintenance items are returned to the default values. • [F5]: Returns to the "Maintenance Mode Setting" screen • [F6]: Executes initialization

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Phone number entry (PC220-Q19A-110-K-00-A) The telephone number displayed together with the "Error List" in operator mode can be input and changed according to the following procedure. If no telephone number is inputted with this function, no telephone number is displayed in operator mode. 1. Selecting a menu Select "Phone Number Entry" on "Service Menu" screen.

2. Registering and changing phone number After the "Phone Number Entry" screen is displayed, register or change the phone number by using the function switch or numeral input switches. • [F2]: Deletes all input digits • [F3]: Moves the input position to the next left place (if not blank) • [F4]: Moves the input position to the next right place (if not blank) • [F5]: Deletes input numbers or returns the screen to the "Service Menu" screen • [F6]: Validates the entry

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2. Selecting a sub menu After the "Default" screen is displayed, select "Key-on Mode" by using the function switch or numeral input switches. a Selecting method is the same as on the "Service Menu" screen. a This function sets the following mode (these items are the same as the customize switch set in the operator mode). • Working mode: P/E • Load graph: ON/OFF • Blade fine control: ON/OFF a Up to 14 digits can be input from the left. Leave the surplus places without inputting. a If an input numeral is wrong, move the cursor (orange background) to that digit and overwrite it with the correct numeral. a If [F6] is pressed without inputting a digit, there is no information of telephone number for display in operator mode.

Default (Key-on Mode) (D61-Q1F2-100-K-00-A) Use the menu of "Default" to check or change various settings of the machine monitor and machine. The function of Key-on Mode is used to set the initial mode displayed on the machine monitor when the starting switch is turned to ON position. 1. Selecting a menu Select "Default" on "Service Menu" screen.

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3. Selecting a mode After the "Key-on Mode" screen is displayed, select the mode by using the function switches to set it. • "Mode at previous key-off": Displays final mode in previous operation when starting switch is turned ON. • "Default (All OFF)": Displays default mode settings (Working Mode P: P, other items: OFF) when starting switch is turned ON • [F3]: Moves selection downward • [F4]: Moves selection upward • [F5]: Cancels the selection and returns to the "Default" screen • [F6]: Enters selection and returns to the "Default "screen a Factory default is the "Mode at Previous Keyoff".

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Default (Unit) (D61-Q1F3-100-K-00-A) Use the menu of "Default" to check or change various settings of the machine monitor and machine. The unit selecting function is used to select the unit of the data to be displayed in monitoring, etc. 1. Selecting a menu Select "Default" on "Service Menu" screen.

2. Selecting a sub menu After the "Default" screen is displayed, select "Unit" by using the function switch or numeral input switches.

Default (Camera) (D155-Q1F6-100-K-00-A) Use the menu of "Default" to check or change various settings of the machine monitor and machine. Camera setting is for setting of camera when the camera is installed or removed. 1. Selecting a menu Select "Default" on "Service Menu" screen.

a Selecting a method is the same as on the "Service Menu" screen.

2. Selecting a sub menu After the "Default" screen is displayed, select "Camera" by using the function switch or numeral input switches.

3. Selecting a unit After the "Unit" screen is displayed, select the unit to be set by using the function switches. • [F3]: Moves selection downward • [F4]: Moves selection upward • [F5]: Cancels the selection and returns to the "Default" screen • [F6]: Enters selection and returns to the "Default "screen

a Select this item similarly to an item on the "Service Menu" screen.

a Factory default is the “SI Unit”.

3. Selecting a camera setting After the "Camera" screen is displayed, select a setting by using the function switch. 30-112

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• [F3]: Moves selection downward • [F4]: Moves selection upward • [F5] Cancels contents of setting before entry and returns to "Default" screen • [F6]: Enters selection in each line a Enter selection in each line with [F6], and return to the "Default" screen with [F5], and then your setting is validated. a Unless setting is normally set with this function when the camera is connected, the graphic mark of camera is not displayed at [F3] in the operator mode. Accordingly, the image of the camera cannot be used. a When the camera is installed, check that the right and left portions of the displayed image are correct.

In case of "Camera1" • "Not Use": Camera is not used • "Use": Image from connected camera is displayed as a normal image.

a If multiple cameras are connected, be sure to set them from camera 1 in order. a The simultaneous display function of 2 images becomes effective when camera 1 and camera 2 are set for use.

• "2 Cameras Display Setting"

a You cannot switch "Camera 1 "between [Я] and [R].

In cases of "Camera 2" and "Camera 3" • "—": Camera is not selected. • [Я]: Reverse images (mirror images, used for rearview monitor) are displayed. • [R]: Normal images (visual images, used for front monitor or side monitor) are displayed.

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4. Adjustment of guide line 1) After the "Guide Line Position Set" screen is displayed, select the item for adjustment. a The guide line is configured in the "Guide Line" mode of the operator mode. OFF, outline, center line, and outline plus center line are available. a Selecting method is the same as on the "Service Menu" screen. a The guide line is displayed only in the "Camera 1" screen. The guide line is not displayed in "Camera 2" and "Camera 3".

2) Adjusting point After the "Guide Line Position Set" screen is displayed, select the point or center line to be adjusted. • [F1]: Moves selected point downward • [F2]: Moves selected point upward • [F3]: Moves selected point or center line leftward • [F4]: Moves selected point or center line rightward • [F5]: Returns to "Guide Line Position Set" screen. • [F6]: Enters the position Selecting the point

a If it is not yet set, "Guide Line Position Setting Fix" items are displayed.

Selecting a center line

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5. Initializing camera setting a This screen is not displayed when cameras 1 to 3 are not installed. a If the camera setting is initialized, the cameras are returned to the Not Yet Set state.

3) Display of "Guide Line Position Setting Fix" screen When the "Guide Line Position Setting Fix" is displayed, you are asked if you want to fix the setting. Select with the function switch. • [F5]: Cancels setting and returns to the "Guide Line Position Set" screen • [F6]: Enters setting

1) Initializing camera setting When the "Camera Setting Initialization" is displayed, you are asked if you want to initialize. Select with the function switch. • [F5]: Cancels the setting and returns to the "Camera" screen • [F6]: Executes initialization

a If it is not yet set, you cannot set the guide line display in the user mode. a Since the guide line position is not set by default, set it after installing the camera.

a Press [F6], and the "Complete" screen is displayed, then initialization is complete.

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Default (Float Buzzer) (D61-Q1GF-100-K-00-A) Use the menu of "Default" to check or change various settings of the machine monitor and machine. Float Buzzer function is to set ON/OFF of buzzer sound when the blade is float or released. 1. Selecting a menu Select "Default" on "Service Menu" screen.

2. Selecting a sub menu After the "Default" screen is displayed, select "Float Buzzer" by using the function switch or numeral input switches. a Selecting method is the same as on the "Service Menu" screen.

3. Selecting a mode After the "Float Buzzer" screen is displayed, select the mode to be set by using the function switches. • [F3]: Moves selection downward • [F4]: Moves selection upward • [F5]: Cancels the selection and returns to the "Default" screen • [F6]: Enters selection and returns to the "Default "screen

Diagnostic tests (Cylinder cut-out mode operation) (D65-AD00-34F-K-00-A) The operator can perform "Cylinder Cut-out mode" operation and KDPF regeneration/ reset operation with the machine monitor. Cylinder Cut-out mode operation means to run the engine with one or more fuel injectors disabled electrically to reduce the number of effective cylinders. This operation is used to identify a cylinder that does not output power normally (combustion in it is abnormal). 1. Selecting the menu Select "Diagnostic Tests" on "Service Menu" screen.

2. Selecting the sub menu After the "Diagnostic Tests" screen is displayed, select "Cylinder Cut-out" using the function switch or numeral input switches.

a Factory default of the "Float Buzzer" selection is the "Use".

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Adjustment You can perform various adjustments related to the machine with the machine monitor. When using an adjustment item, select it according to the following procedure. 1. Selecting the menu Select "Adjustment" on "Service Menu" screen.

3. Displaying adjustment screen After the "Adjustment" screen for the adjustment ID is displayed, you can start adjustment. a In the figure, adjustment ID [0002] is selected and displayed as an example.

2. Selecting an adjustment items Input ID: After the "Adjustment" screen is displayed, input the 4-digit adjustment ID of the adjustment item to be used by using the numeral input switches. • [F5]: Cancels adjustment and returns to the "Service Menu" • [F6]: Enters input adjustment ID and moves the display to "Adjustment"

a "000", "00", and "0" on the left of the adjustment ID must be filled but they are not displayed on the "Adjustment" screen. a The functions given to function switches [F3] to [F6] vary depending on the adjustment item. a For the method of operating each adjustment item, see the explanation of its adjustment ID.

a For the adjustment ID and its adjustment items, see the adjustment items table. • For the adjustment items other than the input procedure of the ID, item selection method is the same as that of the "Service Menu" screen.

a If an improper adjustment ID is input, "Adjustment not allowed", is displayed and the screen does not move from the Input ID screen (ID can be re-entered by using numeral keys).

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Adjustment items table (D61-Q170-208-K-00-A) Items to be selected from the "Adjustment" menu Menu No.

Adjustment item

Remarks

02 03 04 05 06 07 08 09 10 11 12 16 17

Brake Pedal Potentio Initial Set Brake Pedal Potentio Detent Set Brake Pedal Potentio Full Set S/T Lever N Position Set S/T Lever Left Detent Set S/T Lever Left Full Set S/T Lever Right Detent Set S/T Lever Right Full Set Blade Lift Lever N Position Set Blade Lift Lever Up Full Set Blade Lift Lever Down Full Set F HST Pump Auto Set R HST Pump Auto Set

HST Motor Auto Set

Fan Auto Set

Saves relationship between EPC current of HST pump and the capacity. Saves relationship between EPC current of HST motor and the capacity. Saves relationship between EPC current of fan and the capacity.

20 21 22

Fan Test Mode Stall Pressure Test Mode Control Brake Release Mode

Switches 70%/100% mode of fan. Stalls HST. Always sets parking brake solenoid to ON.

Saves the relationship between positions of decelerator/brake pedal and potentiometer voltage.

Saves positions of potentiometer of steering lever and voltage.

Saves positions of blade lift lever and potentiometer voltage.

Disassembly and assembly q q q q q q q q q q q q q q q

Items to be selected by inputting ID ID code

Adjustment item

0002

MACHINE CODE SET MODE

3423 3424 3425

HST CONTROLLER UNSWITCHED POWER F HST PUMP AUTO SET MODE RUN1 R HST PUMP AUTO SET MODE RUN1 F HST PUMP AUTO SET MODE RUN2

3426

F HST PUMP AUTO SET MODE RUN2

3430 3431 3434

F HST PUMP MANUAL SET MODE R HST PUMP MANUAL SET MODE DEVIATION CONTROL

2021

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Remarks Saves model code in HST controller and model code. Displaying continuous power supply and switched power supply voltage Saves relationship between EPC current of HST pump and the capacity. (If the track idle cannot be operated and must be done by automatic run reluctantly)

Disassembly and assembly q

Manually corrects EPC current of ST pump at the beginning of running. Disables deviation control.

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Adjustment item

ID code 8020 8021 8022 8023

Current Offset LIFT UP CURRENT ADJUST BLADE UP EPC Current Offset LIFT DOWN CURRENT ADJUST BLADE DOWN EPC Current Offset LIFT-F UP CURRENT ADJUST BLADE UP EPC Current Offset LIFT-F DOWN CURRENT ADJUST BLADE DOWN EPC

Remarks

Disassembly and assembly

Manually corrects EPC current at the beginning of blade moving.

k After assembling the machine or replacing HST controller, be sure to adjust the items marked with

q in the column table "Disassembly and assembly" of the table (see "Adjustment method when HST controller has been replaced" for detail adjustment procedure).

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Adjustment (Brake Pedal Potentio Initial Set) (D61-G4E1-270-K-00-A) a Menu No.02

• This adjustment code is the function to save the voltage at NEUTRAL position of decelerator/ brake pedal potentiometer in HST controller. a When HST controller or decelerator/brake pedal potentiometer is replaced or the decelerator/ brake pedal linkage is adjusted, be sure to perform this adjustment once. • Functions of function switches: [F3]: No use [F4]: No use [F5]: Returns to adjustment item selection screen. [F6]: Saves adjustment value • Operating method: 1. Check that the decelerator/brake pedal is in NEUTRAL position (it is not depressed) and keep it in that position. 2. Press [F6] and check that the alarm buzzer sounds. a After this adjustment, HST controller saves the potentiometer voltage when [F6] is pressed as NEUTRAL position (decelerator/brake ratio = 0%) of the decelerator/brake pedal. a Even if the adjustment is performed, the displayed value of the potentiometer voltage does not change. a Even if this adjustment code is finished (starting switch is turned OFF), the adjustment is effective. a This adjustment code is the function to save the voltage at NEUTRAL position of decelerator/ brake pedal potentiometer in HST controller. It is not used to adjust brake pedal depressing effort.

• This adjustment code is the function to save the voltage of operating effort change point of decelerator/brake pedal potentiometer in HST controller. a After HST controller or decelerator/brake pedal potentiometer is replaced or the decelerator/ brake pedal linkage is adjusted, be sure to perform this adjustment once. • Functions of function switches [F3]: No use [F4]: No use [F5]: Returns to adjustment item selection screen [F6]: Saves adjustment value • Operating method: 1. Depress the decelerator/brake pedal to the operating effort change point, and keep it at the position. 2. Press [F6] and check that the alarm buzzer sounds. a After this adjustment, HST controller saves the potentiometer voltage when [F6] is pressed as the operating effort change point (decelerator/ brake ratio = 73%) of the decelerator/brake pedal. a Even if the adjustment is performed, the displayed value of the potentiometer voltage does not change. a Even after this adjustment code is finished (starting switch is turned OFF), the adjustment is effective. a This adjustment code is the function to save the voltage of operating effort change point of decelerator/brake pedal potentiometer in HST controller. It is not used to adjust brake pedal depressing effort.

Adjustment (Brake Pedal Potentio Detent Set) (D61-G4E1-270-K-01-A) a Menu No.03 30-120

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Adjustment (Brake Pedal Potentio Full Set) (D61-G4E1-270-K-02-A) a Menu No.04

• This adjustment code is the function to save the voltage at stroke end of decelerator/brake pedal potentiometer in HST controller. a When HST controller or decelerator/brake pedal potentiometer is replaced or the decelerator/ brake pedal linkage is adjusted, be sure to perform this adjustment once. • Functions of function switches [F3]: No use [F4]: No use [F5]: Returns to adjustment item selection screen [F6]: Saves adjustment value • Operating method: 1. Depress the decelerator/brake pedal to the stroke end, and hold it at the position. 2. Press [F6] and check that the alarm buzzer sounds. a After this adjustment, HST controller saves the potentiometer voltage when [F6] is pressed as the stroke end position (decelerator/brake ratio = 100%) of the decelerator/brake pedal. a Even if the adjustment is performed, the displayed value of the potentiometer voltage does not change. a After this adjustment code is finished (starting switch is turned OFF), the adjustment is effective. a This adjustment code is the function to save the voltage at the stroke end position of decelerator/ brake pedal potentiometer in HST controller. It is not used to adjust brake pedal depressing effort.

Adjustment (S/T Lever N Position Set) C8X6-270-K-00-A)

a Menu No.05

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• This adjustment code is the function to save the voltage at NEUTRAL position of the steering potentiometer of joystick (steering, directional and gearshift lever) in HST controller. a When HST controller or joystick (steering, directional and gearshift lever) is replaced, be sure to perform this adjustment once. • Functions of function switches [F3]: No use [F4]: No use [F5]: Returns to adjustment item selection screen [F6]: Saves adjustment value • Operating method: 1. Check that the joystick (steering, directional and gearshift lever) is in NEUTRAL position of the steering direction, and keep it in that position. 2. Press [F6] and check that the alarm buzzer sounds. a After this adjustment, HST controller saves the potentiometer voltage when [F6] is pressed as NEUTRAL position (S/T lever ratio = 0%) in the steering direction. a Even if the adjustment is performed, the displayed value of the potentiometer voltage does not change. a After this adjustment code is finished (starting switch is turned OFF), the adjustment is effective. a This adjustment code is the function to save the voltage at NEUTRAL position of the steering potentiometer of joystick (steering, directional and gearshift lever) in HST controller. It is not used to adjust the steering performance.

Adjustment (S/T Lever Left Detent Set) C8X6-270-K-01-A)

(D61-

a Menu No.06

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• This adjustment code is the function to save the voltage of left operating effort change point of the steering potentiometer of joystick (steering, directional and gearshift lever) in HST controller.

• This adjustment code is the function to save the voltage of left full set of the steering potentiometer of joystick (steering, directional and gearshift lever) in HST controller.

a When the HST controller or joystick (steering, directional and gearshift lever) is replaced, be sure to perform this adjustment once.

• Functions of function switches [F3]: No use [F4]: No use [F5]: Returns to adjustment item selection screen [F6]: Saves adjustment value • Operating method:

1. Operate the joystick (steering, directional and gearshift lever) to the operating effort change point (pivot turn) of left steering, and keep it in that position. 2. Press [F6] and check that the alarm buzzer sounds.

1. Operate the joystick (steering, directional and gearshift lever) to stroke end of left steering, and keep it in that position. 2. Press [F6] and check that the alarm buzzer sounds.

a After this adjustment, HST controller saves the potentiometer voltage when [F6] is pressed as the left operating effort change point (S/T lever ratio = -80%) in the steering direction. a Even if the adjustment is performed, the displayed value of the potentiometer voltage does not change. a After this adjustment code is finished (starting switch is turned OFF), the adjustment is effective. a This adjustment code is the function to save the voltage of left operating effort change point of the steering potentiometer of joystick (steering, directional and gearshift lever) in HST controller. It is not used to adjust the steering performance.

a After this adjustment, HST controller saves the potentiometer voltage when [F6] is pressed as the left operating effort change point (S/T lever ratio = -100%) in the steering direction. a Even if the adjustment is performed, the displayed value of the potentiometer voltage does not change. a After this adjustment code is finished (starting switch is turned OFF), the adjustment is effective. a This adjustment code is the function to save the voltage of left full set of the steering potentiometer of joystick (steering, directional and gearshift lever) in HST controller. It is not used to adjust the steering performance.

Adjustment (S/T Lever Right Detent Set) Adjustment (S/T Lever Left Full Set) 270-K-02-A)

(D61-C8X6-

C8X6-270-K-03-A)

(D61-

a Menu No.08

a Menu No.07

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• This adjustment code is the function to save the voltage of right operating effort change point of the steering potentiometer of joystick (steering, directional and gearshift lever) in HST controller.

• This adjustment code is the function to save the voltage of right full set of the steering potentiometer of joystick (steering, directional and gearshift lever) in HST controller.

a When the HST controller or joystick (steering, directional and gearshift lever) is replaced, be sure to perform this adjustment once.

• Functions of function switches: [F3]: No use [F4]: No use [F5]: Returns to adjustment item selection screen [F6]: Saves adjustment value • Operating method:

• Functions of function switches [F3]: No use [F4]: No use [F5]: Returns to adjustment item selection screen [F6]: Saves adjustment value • Operating method:

1. Operate the joystick (steering, directional and gearshift lever) to the operating effort change point (pivot turn) of right steering, and keep it in that position. 2. Press [F6] and check that the alarm buzzer sounds.

1. Operate the joystick (steering, directional and gearshift lever) to stroke end of right steering, and keep it in that position. 2. Press [F6] and check that the alarm buzzer sounds.

a After this adjustment, HST controller saves the potentiometer voltage when [F6] is pressed as the right operating effort change point (S/T lever ratio = 80%) in the steering direction. a Even if the adjustment is performed, the displayed value of the potentiometer voltage does not change. a After this adjustment code is finished (starting switch is turned OFF), the adjustment is effective. a This adjustment code is the function to save the voltage of right operating effort change point of the steering potentiometer of joystick (steering, directional and gearshift lever) in HST controller. It is not used to adjust the steering performance.

Adjustment (S/T Lever Right Full Set) 270-K-04-A)

a Menu No.09

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a After this adjustment, HST controller saves the potentiometer voltage when [F6] is pressed as the right operating effort change point (S/T lever ratio = 100%) in the steering direction. a Even if the adjustment is performed, the displayed value of the potentiometer voltage does not change. a After this adjustment code is finished (starting switch is turned OFF), the adjustment is effective. a This adjustment code is the function to save the voltage of right full set of the steering potentiometer of joystick (steering, directional and gearshift lever) in HST controller. It is not used to adjust the steering performance.

Adjustment (Blade Lift Lever N Position Set) (D61-LTL0-270-K-00-A) a Menu No.10

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• This adjustment code is the function to save the voltage at NEUTRAL position of blade control lever lift potentiometer in HST controller.

• This adjustment code is the function to save the voltage of RAISE stroke end of blade control lever lift potentiometer in HST controller.

a When HST controller or blade control lever is replaced, be sure to perform this adjustment once.

• Functions of function switches [F3]: No use [F4]: No use [F5]: Returns to adjustment item selection screen [F6]: Saves adjustment value • Operating method:

1. Check that the blade control lever is in NEUTRAL position of the lifting direction, and keep it in that position. 2. Press [F6] and check that the alarm buzzer sounds.

1. Operate the blade control lever to RAISE stroke end in the lifting direction, and keep it there. 2. Press [F6] and check that the alarm buzzer sounds.

a After this adjustment, HST controller saves the potentiometer voltage when [F6] is pressed as NEUTRAL position (blade lift lever ratio = 0%) in the lifting direction.

a After this adjustment, HST controller saves the potentiometer voltage when [F6] is pressed as RAISE stroke end (blade lift lever ratio = 100%) in the lifting direction.

a Even if the adjustment is performed, the displayed value of the potentiometer voltage does not change.

a After this adjustment code is finished (starting switch is turned OFF), the adjustment is effective.

a Even after this adjustment code is finished (starting switch is turned OFF), the adjustment is effective.

a This adjustment code is the function to save the voltage at NEUTRAL position of blade control lever lift potentiometer in HST controller. It is not used to adjust the sensitivity of the blade control lever (The sensitivity of the blade control lever in the lifting direction is adjusted with "Adjustment" ID: 8020 to 8023).

a This adjustment code is the function to save the voltage of RAISE stroke end of blade control lever lift potentiometer in HST controller. It is not used to adjust the sensitivity of the blade control lever (The sensitivity of the blade control lever in the lifting direction is adjusted with "Adjustment" ID: 8020 to 8023).

Adjustment (Blade Lift Lever Up Full Set) LTL0-270-K-01-A)

a Menu No.11

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Adjustment (Blade Lift Lever Down Full Set) (D61-LTL0-270-K-02-A) a Menu No.12

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• This adjustment code is the function to save the voltage of LOWER stroke end of blade control lever lift potentiometer in HST controller. a When HST controller or blade control lever is replaced, be sure to perform this adjustment once. • Functions of function switches [F3]: No use [F4]: No use [F5]: Returns to adjustment item selection screen [F6]: Saves adjustment value • Operating method: 1. Operate the blade control lever to LOWER stroke end in the lifting direction, and keep it there. 2. Press [F6] and check that the alarm buzzer sounds. a After this adjustment, HST controller saves the potentiometer voltage when [F6] is pressed as LOWER stroke end (blade lift lever ratio = -100%) in the lifting direction. a Even if the adjustment is performed, the displayed value of the potentiometer voltage does not change. a After this adjustment code is finished (starting switch is turned OFF), the adjustment is enabled. a This adjustment code is the function to save the voltage of LOWER stroke end of blade control lever lift potentiometer in HST controller. It is not used to adjust the sensitivity of the blade control lever (The sensitivity of the blade control lever in the lifting direction is adjusted with "Adjustment" ID: 8020 to 8023).

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Adjustment (F HST Pump Auto Set) a Menu No.16

The adjustment starts when placing the parking brake lever to FREE position and setting the joystick (steering, directional and gearshift lever) to FORWARD position. k Be careful of the track shoe since it

• This adjustment code is the function to save the relationship between the EPC current on the forward side of the HST (hydrostatic transmission) pump and the capacity of HST controller. • Perform the adjustment while running track idle off ground (If you cannot run it idle off ground, and perform adjustment by traveling actually, adjust by "Adjustment" ID: 3423 to 3426.) a When HST controller, HST pump assembly,or HST pump EPC valve is replaced, be sure to perform this adjustment once. • Functions of function switches [F3]: No use [F4]: No use [F5]: Returns to adjustment item selection screen [F3]: No use • Operating method: k Before switching to this adjustment code,

jack up bottom surface of frame at the rear of the machine. Then thrust blade to the LOWER side and lift the entire track shoe up from the ground in order to be ready for idle running. k Track

shoe runs at high speed during adjustment. Check that the track shoe is securely lifted from the ground, and stable during idle running.

Start the engine, and keep it running at high idle. Check that the fuel control dial is set to Max. position, parking brake lever is in LOCK position, the joystick (steering, directional and gear shift lever) is in NEUTRAL position, and [P] on the speed range display flashes.

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a When starting the adjustment, the progress display (a) of the adjustment automatically changes from [1/6] to [6/6]. a When the track shoe stops and [6/6] appears in the progress display (a) of the adjustment, the adjustment is complete. a To stop (interrupt) the track shoe during adjustment, return the joystick (steering, directional and gearshift lever) to the NEUTRAL position. (Be careful that you cannot operate the steering of the joystick (steering, directional and gearshift lever), decelerator/brake pedal and fuel control dial.) 4. When the adjustment is complete, place the joystick (steering, directional and gear shift lever) to NEUTRAL position, and the parking brake lever to LOCK position. a To interrupt and then resume the adjustment, start from step 2. a After this adjustment code is turned off (starting switch is turned OFF), the adjustment is effective. a The adjustment interrupts automatically and [ERR1] appears in the progress display (a), check the following devices. (If track shoe does not move even by raising HST pump EPC current, the error [ERR1] appears.) • When track shoe does not move: HST pump • When track shoe moves: HST motor speed sensor

Adjustment (R HST Pump Auto Set) 270-K-01-A)

(D61-C172-

a Menu No.17

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30 Testing and adjusting Electrical system

k Be careful of the track shoe since it

• This adjustment code is the function to save the relationship between EPC current on the reverse side of HST (hydrostatic transmission) pump and the capacity in the HST controller. • Perform the adjustment while running track idle off ground (If you cannot run it idle off ground, and perform adjustment by traveling actually, adjust by "Adjustment" ID: 3423 to 3426.)

a To stop (interrupt) the track shoe during adjustment, return the joystick (steering, directional and gearshift lever) to NEUTRAL position. (Be careful that you cannot operate the steering of the joystick (steering, directional and gearshift lever), decelerator/brake pedal and fuel control dial.) 4. When the adjustment is complete, return the joystick (steering, directional and gear shift lever) to NEUTRAL position and the parking brake lever to LOCK position.

a When the HST controller, HST pump assembly, or HST pump EPC valve is replaced, be sure to perform this adjustment once. • Functions of function switches [F3]: No use [F4]: No use [F5]: Returns to adjustment item selection screen [F3]: No use • Operating method:

a To interrupt and then resume the adjustment, start from step 2 again. a After this adjustment code is turned off (starting switch is turned OFF), the adjustment is effective.

k Before switching to this adjustment code,

jack up bottom surface of frame at the rear of the machine. Then thrust blade to the LOWER side and lift the entire track shoe up from the ground in order to be ready for idle running.

a The adjustment interrupts automatically and [ERR1] appears in the progress display (a), check the following devices. (If track shoe does not move even by raising the HST pump EPC current, the error [ERR1] appears.)

k Track

shoe runs at high speed during adjustment. Check that the track shoe is securely lifted from the ground, and stable during idle running.

1. Start the engine, and keep it running at high idle. 2. Check that the fuel control dial is set to Max. position, parking brake lever is in LOCK position, the joystick (steering, directional and gear shift lever) is in NEUTRAL position, and [P] on the speed range display flashes. 3. The adjustment starts when placing the parking brake lever to FREE position and setting the joystick (steering, directional and gearshift lever) to REVERSE position.

D61EM-23M0

• When track shoe does not move: HST pump • When track shoe moves: HST motor speed sensor

Adjustment (HST Motor Auto Set) 00-A)

(D61-C173-270-K-

a Menu No.18

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30 Testing and adjusting Electrical system

k Be careful of the track shoe since it

automatically starts moving when starting the adjustment. (Be careful of the track shoe since it stops moving after starts moving once, and starts moving again.) a The alarm buzzer continues to sound during adjustment. a When starting the adjustment, the progress display (a) of the adjustment automatically changes from [1/5] to [5/5]. • This adjustment code is the function to save the relationship between EPC current of HST motor and the capacity in the HST controller. • Perform the adjustment while running track idle off ground. (You cannot adjust HST motor while traveling actually.) a When the controller, HST motor assembly, or HST motor EPC valve is replaced, be sure to perform this adjustment once. • Functions of function switches [F3]: No use [F4]: No use [F5]: Returns to adjustment item selection screen [F3]: No use • Operating method: k Before switching to this adjustment code,

jack up bottom surface of frame at the rear of the machine. Then thrust blade to the LOWER side and lift the entire track shoe up from the ground in order to be ready for idle running. k Track

shoe runs at high speed during adjustment. Check that the track shoe is securely lifted from the ground, and stable during idle running.

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a When the track shoe stops and [5/5] appears in the progress display (a) of the adjustment , the adjustment is complete. a To stop (interrupt) the track shoe during adjustment, return the joystick (steering, directional and gearshift lever) to NEUTRAL position. (Be careful that you cannot operate the steering of the joystick (steering, directional and gearshift lever), decelerator/brake pedal and fuel control dial.) 4. When the adjustment is complete, return the joystick (steering, directional and gear shift lever) to EUTRAL position and the parking brake lever to LOCK position.

a To interrupt and then resume the adjustment, start from step 2 again. a After this adjustment code is turned off (starting switch is turned OFF), the adjustment is effective. a If the adjustment interrupts automatically and [ERR2] appears in the progress display (a), check the followings. (The error [ERR2] appears when the travel speed does not reach the specified speed even by raising the HST motor EPC current.) • When track shoe does not move: HST pump • When track shoe moves. 1) HST motor speed sensor 2) Hose between HST motor EPC and HST motor 3) (Whether engine is at high idle or not) 4) (Whether HST oil temperature is abnormally low or not) 5) Whether link of track shoe is too stiff or not (If it is too stiff despite new product, remove track shoe to check.)

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30 Testing and adjusting Electrical system

Adjustment (Fan Auto Set)

(D61-B711-270-K-00-A)

a Menu No.19

a After this adjustment code is turned off (starting switch is turned OFF), the adjustment is effective.

Adjustment (Fan Test Mode)

(D61-B711-270-K-01-A)

a Menu No.20

• This adjustment code is the function to save the relationship between the fan EPC current and the fan speed in the HST controller. a When the HST controller, fan and work equipment pumps, control valve, and fan EPC valve is replaced, be sure to perform this adjustment once.

• This adjustment code is the function to switch normal control mode/ fan 100% mode/ Fan 70% mode.

• Functions of function switches [F3]: No use [F4]: No use [F5]: Returns to adjustment item selection screen [F6]: Starts adjustment • Operating method:

a Use this adjustment code for testing, adjusting, or troubleshooting as needed.

k Before switching to this adjustment code,

adjust HST oil temperature (hydraulic oil temperature) to 50 to 60°C. k Before switching to this adjustment code,

set working mode to [P (power)] in the screen displaying working mode monitor. k Lower the work equipment to the ground,

and set the work equipment lock lever to LOCK position during this adjustment. 1. Start the engine, and run it at high idle. 2. When [F6] is pressed, this adjustment starts. a The alarm buzzer continues to sound during adjustment. a When starting the adjustment, the progress display (a) of the adjustment automatically changes from [1/21] to [21/ 21] and fan speed gradually increases.

• Functions of function switches [F3]: Switches "Fan Test Mode" [F4]: Switches "Fan Test Mode" [F5]: Returns to adjustment item selection screen [F6]: Enters selection • Operating method: 1. Press [F3] or [F4] to mode code to be selected in (a). Display (a) Mode OFF Normal control mode 100% Fan 100% mode 70% Fan 70% mode 2. The alarm buzzer sounds, and the settings are entered by pressing [F6]. a Mode to be displayed in (a) at first when switching to this adjustment code is currently selected. a In fan 100% or 70% mode, the cooling fan speed is forcibly set to 100% or 70% of the maximum speed regardless of temperature.

a When [21/21] is displayed, and then [0/ 21] appears in the progress display (a) of the adjustment , the adjustment is complete.

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30 Testing and adjusting Electrical system

a When HST oil temperature (hydraulic oil temperature) is 45°C or lower and engine coolant temperature is 60°C or lower, fan EPC current becomes 100mA and fan speed decreases to 200rpm or lower even when fan 100% or 70% mode is set. At this time, raise HST oil temperature (hydraulic oil temperature) to 55° C or higher and engine coolant temperature to 65°C or higher once before checking. a After this adjustment code is turned off, the settings are effective with the starting switch hold at ON position. Therefore, to return to normal control mode, set it to normal control mode again in this adjustment code or turn starting switch to OFF position.

Adjustment (Stall Pressure Test Mode) CDL4-270-K-00-A)

(D61-

a Menu No.21

• This adjustment code is the function to stall HST (hydrostatic transmission) and measure HST main circuit pressure, engine speed, engine boost pressure, and HST oil temperature (hydraulic oil temperature). a Use this adjustment code for testing, adjusting, or troubleshooting as needed. • Functions of function switches [F4]: Switches between Hold and Releasing hold (If Hold is selected, HOLD part is hatched) [F5]: Returns to adjustment item selection screen • Operating method: k Check

that the HST oil temperature (hydraulic oil temperature) is within the range from 40 to 60°C during stalling HST. (Do not stall HST unless the HST oil temperature is in the specified range.)

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k Before switching to this adjustment code,

check that the parking brake lever is in LOCK position and the joystick (steering, directional and gear shift lever) is in NEUTRAL position. a By switching to this adjustment code, the machine automatically enters the preparation condition for HST stalling. (However, HST is not stalled unless the joystick (steering, directional and gear shift lever) is in the FORWARD or REVERSE position.) • Travel speed range: 3rd (HST motor capacity: minimum) • Engine speed during high idle: 2,280 rpm (low speed matching released) • Parking brake solenoid valve: OFF • Slow brake solenoid valve: OFF a The following errors are set for the safety in this adjustment code. If an error occurs, display the following in the timer display (a), and stop the command current to the HST pump EPC valve. • ERROR No.1: The machine is moving or the joystick (steering, directional and gear shift lever) is not in NEUTRAL position when switching to this adjustment code. • ERROR No.2: The parking brake lever is not in LOCK position (check the control method and repeat the operation for Nos.1 and 2). • ERROR No.3: The machine moves after switching to this adjustment code. • ERROR No.4: The parking brake releasing pressure increases (for Nos.3 and 4, check it because an error may occur in the parking brake system). 1. Start the engine, and check for error display. 2. Set fuel control dial to Max. position, and check that the parking brake lever is in LOCK position. a Stall HST when the parking brake lever is in LOCK position. 3. Operate the joystick (steering, directional and gear shift lever) to FORWARD or REVERSE position, stall HST, and check the necessary items. a By operating the joystick (steering, directional and gear shift lever) to FORWARD or REVERSE position, HST is stalled. By returning it to NEUTRAL position, HST stalling is released. a Working Mode can be switched also when displaying this adjustment code.

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30 Testing and adjusting Electrical system

k Oil temperature rises partially and

suddenly during HST stall. Do not stall HST continuously for 30 seconds or longer. Accordingly, the following limitations are set. a When starting the HST stall, the countdown starts every 5 seconds in the timer display (a). When the countdown reaches 0, HST stall is released automatically. During release of the HST stall, the timer count increases up to 30 seconds. (Accordingly, HST can stall as long as the break time next time.) To resume the HST stall, return the joystick (steering, directional and gear shift lever) to NEUTRAL position once, and operate it to the FORWARD or REVERSE position again. a This setting is effective only when this adjustment code is displayed. This function becomes ineffective when this adjustment code is turned off.

Adjustment (Control Brake Release Mode) (D61-D8J2-270-K-00-A) a Menu No.22

a ON/OFF to be displayed in (a) when switching to this adjustment code is currently selected. a When the control brake release mode is turned ON, it cannot be returned to OFF until the starting switch is turned OFF. a When the control brake release mode is turned ON, the output to the parking brake solenoid is always ON (open). k Only slow brake solenoid operates parking

brake when the control brake release mode is turned ON, • Even if the joystick (steering, directional and gear shift lever) is in NEUTRAL position or the fuel control dial is in the low speed position, the parking brake does not operate. • By operating the parking brake lever to LOCK position or depressing the decelerator/brake pedal to the stroke end, the parking brake operates. But the time until the operation becomes longer. a After this adjustment code is finished, the settings are effective while the starting switch is ON. Accordingly, to return the control brake release mode to OFF, turn the starting switch OFF once.

Adjustment ID: 0002 (Machine Code Set Mode) (D61-C3V7-270-K-00-A)

• This adjustment code is the function to switch ON/OFF of the "Control Brake Release Mode". a Use this adjustment code for testing, adjusting, or troubleshooting as needed. • Functions of function switches [F3]: Switches between ON and OFF. [F4]: Switches between ON and OFF. [F5]: Returns to adjustment item selection screen. [F6]: Enters selection. • Operating method: 1. Press [F3] or [F4] to display ON/OFF condition to be selected in (a). Display (a) Mode ON Normal control mode OF Control brake release mode 2. The alarm buzzer sounds and the settings are entered by pressing [F6]. D61EM-23M0

• This adjustment code is the function to save the machine model code in HST controller and machine monitor. k If the actual machine model and HST

controller setting do not match, the machine may move unexpectedly and an error may occur. Be sure to set the HST controller for the machine.

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30 Testing and adjusting Electrical system

k If you enter this adjustment code carelessly,

memory saved in HST controller and machine monitor is initialized. Use this adjustment code only if necessary. a If the machine models different from the machines saved by HST controllers were used for entering, all initial adjustment works are required again. (Adjustment menu No. 02 to 19) a If the machine models different from the machines saved by HST controllers were used for entering, all the records other than monitor settings or service meter (SMR) are also initialized. Settings are required again. a When HST controller or machine monitor is replaced, be sure to perform this adjustment once. a Currently, the model code saved by HST controller or machine monitor is displayed in (b) and (c). (b): [HST CON MACHINE CODE] Model code saved by HST controller Display (b) DXX D61 D39 D37

Model Not yet set (*1) D61 D39 D37

*2: Does not appear when HST controller is not supported. 2. The alarm buzzer sounds, and the settings are entered by pressing [F6]. 3. Check that the selected model code is displayed in (b) and (c). 4. Turn the starting switch to OFF position and keep it for 15 seconds or longer. 5. Turn the starting switch to ON position again to check that the Model Selection Abnormality (DA29KQ) or HST controller: Type select signal (DAJ0KQ) is not displayed. 6. See "Monitoring/Pre-defined"(14/14) to check the model code of HST controller or machine monitor. a In HST controller and machine monitor, some model may not be compatible with others. If the incompatible models are selected, the settings may not be enabled. a After this adjustment code is finished (starting switch is turned OFF), the adjustment is effective.

Adjustment ID: 2021 (HST controller voltage check mode) (D61-C7W0-270-K-00-A)

*1: When HST controller is new one without any model settings performed (C): [MONITOR MACHINE CODE] Model code saved by machine monitor Display (c) D61-X D39-X D37-X

Model D61 (default) D39 D37

• Functions of function switches [F3]: Switches model code [F3]: Switches model code [F5]: Returns the display to the ID input screen [F6]: Enters selection • Operating method: 1. Press [F3] or [F4] to display model code to be selected in (a). Display (a) D61 D39 D37

Model Not to set (*1) D61 D39 (*2) D37 (*2)

*1: To prevent incorrect operation, nothing appears in (a) when switching this adjustment code. In this state, nothing occurs if [F6] is pressed. 30-132

• This adjustment code is the function to check the continuous power supply voltage and switched power supply voltage applied to HST controller. a Use this adjustment code for testing, adjusting, or troubleshooting as needed. • Functions of function switches [F3]: No use [F4]: No use [F5]: Returns the display to ID input screen [F6]: No use • Information displayed on screen [HST CONTROLLER UNSWITCHED POWER]: Continuous power supply [HST CONTROLLER SWITCHED POWER]: Switched power supply • Operating method: D61EM-23M0

30 Testing and adjusting Electrical system

When switching to this adjustment code, the function is enabled and the continuous power supply voltage and switched power supply voltage are displayed simultaneously. a This check is enabled only when this adjustment code is displayed. This function is disabled when this adjustment code is turned off.

Adjustment ID: 3423 (F HST Pump Auto Set Mode Run1) (D61-C172-270-K-02-A)

2. Check that the fuel control dial is set to Max. position, parking brake lever is in LOCK position, the joystick (steering, directional and gear shift lever) is in NEUTRAL position, and [P] on the speed range display flashes. 3. The adjustment starts when placing the parking brake lever to FREE position and setting the joystick (steering, directional and gearshift lever) to FORWARD position. k Be

careful of the machine since it starts forward travel automatically when starting the adjustment. (Be careful of the machine since the machine stops after starting forward travel once and then moves again.)

a The alarm buzzer continues to sound during adjustment. a When starting the adjustment, the progress display (a) of the adjustment automatically changes from [1/5] to [5/5]. • This adjustment code is the function to save the starting up position and maximum capacity position related to EPC current on the forward side of HST (hydrostatic transmission) pump and the capacity in HST controller during actually traveling. • This adjustment is used if you cannot run the track idle off the ground, and when adjustment is performed by traveling actually. If you can run the track idle off ground, this adjustment is not required by performing the adjustment menus Nos.16 and 17. a When HST controller, HST pump, or HST pump EPC valve is replaced, use this adjustment as needed. • Functions of function switches [F3]: No use [F4]: No use [F5]: Returns the display to ID input screen. [F6]: No use • Operating method: k Before switching to this adjustment code,

move the machine to spacious level ground where it can travel 30 meters or more. k The machine travels forward during

adjustment. Perform adjustment in spacious level ground where the machine can travel forward 30 meters or more without obstacles. 1. Start the engine and run it at high idle. D61EM-23M0

a When the machine stops and [5/5] appears in the progress display (a) of the adjustment, the adjustment is complete. a If operating the joystick (steering, directional and gear shift lever), decelerator/brake pedal, or fuel control dial, the machine operates according to the operation but the adjustment work is interrupted. a You can operate the machine as usual to move the machine after adjustment is interrupted. However, the travel speed range remains at the speed range when the adjustment is interrupted. 4. When the adjustment is complete, place the joystick (steering, directional and gear shift lever) to NEUTRAL position and the parking brake lever to LOCK position. a To resume the adjustment after adjustment is stopped, start from step 2. a After this adjustment code is finished (starting switch is turned OFF), the adjustment is effective. a The adjustment stops automatically and [ERR1] appears at the right top of the screen, check the following devices. (If track shoe does not move by raising the HST pump EPC current, an error appears.) • When track shoe does not move: HST pump • When track shoe moves: HST motor speed sensor 30-133

30 Testing and adjusting Electrical system

Adjustment ID: 3424 (R HST Pump Auto Set Mode Run1) (D61-C172-270-K-03-A)

setting the joystick (steering, directional and gearshift lever) to REVERSE position. k Be

careful of the machine since it starts reverse travel automatically when starting the adjustment. (Be careful of the machine since the machine stops after starting reverse travel once and then moves again.)

a The alarm buzzer continues to sound during adjustment. a When starting the adjustment, the progress display (a) of the adjustment automatically changes from [1/5] to [5/5]. • This adjustment code is the function to save the rising position and maximum capacity position related to EPC current on the reverse side of the HST (hydrostatic transmission) pump and the capacity in HST controller during actually traveling. • This adjustment is used if you cannot run the track idle off the ground, and when adjustment is performed by traveling actually. If you can run the track idle off ground, this adjustment is not required by performing the adjustment menus Nos.16 and 17. a When HST controller, HST pump, or HST pump EPC valve is replaced, use this adjustment as needed. • Functions of function switches [F3]: No use [F4]: No use [F5]: Returns the display to ID input screen [F6]: No use • Operating method: k Before switching to this adjustment code,

move the machine to spacious level ground where it can travel 30 meters or more. k The machine travels reverse during

adjustment. Perform adjustment in spacious level ground where the machine can travel 30 meters or more without obstacles. 1. Start the engine and keep it running at high idle. 2. Check that the fuel control dial is set to Max. position, parking brake lever is in LOCK position, the joystick (steering, directional and gear shift lever) is in NEUTRAL position, and [P] on the speed range display flashes. 3. The adjustment starts when placing the parking brake lever to FREE position and 30-134

a When the machine stops and [5/5] appears in the progress display (a) of the adjustment, the adjustment is complete. a If operating the joystick (steering, directional and gear shift lever), decelerator/brake pedal, or fuel control dial, the machine moves according to the operation but the adjustment work is interrupted. a The operation is done normally to move the machine after adjustment is interrupted. However, the travel speed range remains at the speed range when the adjustment is interrupted. 4. When the adjustment is complete, place the joystick (steering, directional and gear shift lever) to NEUTRAL position and the parking brake lever to LOCK position. a To resume the adjustment after adjustment is stopped, start from step 2. a After this adjustment code is finished (starting switch is turned OFF), the adjustment is effective. a The adjustment stops automatically and [ERR1] appears at the top right of the screen, check the following devices. (If track shoe does not move by raising the HST pump EPC current, an error appears.) • When track shoe does not move: HST pump • When track shoe moves: HST motor speed sensor

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30 Testing and adjusting Electrical system

Adjustment ID: 3425 (F HST Pump Auto Set Mode Run2) (D61-C172-270-K-04-A)

k Be

a The alarm buzzer continues to sound during adjustment. a When starting the adjustment, the progress display (a) of the adjustment automatically changes from [1/4] to [4/4]. a When the machine stops and [4/4] appears in the progress display (a) of the adjustment, the adjustment is complete. • This adjustment code is the function to save the intermediate capacity position related to EPC current on the forward side of HST (hydrostatic transmission) pump and the capacity in the HST controller during actually traveling. • This adjustment is used if you cannot run the track idle off the ground, and when adjustment is performed by traveling actually. If you can run the track idle off ground, this adjustment is not required by performing the adjustment menus Nos.16 and 17. a When HST controller, HST pump assembly, or HST pump EPC valve is replaced, use this adjustment as needed. • Functions of function switches [F3]: No use [F4]: No use [F5]: Returns the display to the ID input screen. [F6]: No use • Operating method:

a If operating the joystick (steering, directional and gear shift lever), decelerator/brake pedal, or fuel control dial, the machine moves according to the operation but the adjustment work is interrupted. a The operation is done normally to move the machine after adjustment is interrupted. However, the travel speed range remains at the speed range when the adjustment is interrupted. 4. When the adjustment is complete, place the joystick (steering, directional and gear shift lever) to NEUTRAL position and the parking brake lever to LOCK position. a To resume the adjustment after adjustment is stopped, start from step 2. a After this adjustment code is finished (starting switch is turned OFF), the adjustment is effective.

k Before switching to this adjustment code,

move the machine to spacious level ground where it can travel 30 meters or more.

Adjustment ID: 3426 (R HST Pump Auto Set Mode Run2) (D61-C172-270-K-05-A)

k The machine travels forward during

adjustment. Perform adjustment in spacious level ground where the machine can travel forward 30 meters or more without obstacles. 1. Start the engine and run it at high idle. 2. Check that the fuel control dial is set to Max. position, parking brake lever is in LOCK position, the joystick (steering, directional and gear shift lever) is in NEUTRAL position, and [P] on the speed range display flashes. 3. The adjustment starts when placing the parking brake lever to FREE position and setting the joystick (steering, directional and gearshift lever) to FORWARD position. D61EM-23M0

• This adjustment code is the function to save the intermediate capacity position related to EPC current on the reverse side of HST (hydrostatic transmission) pump and the capacity in the HST controller during actually traveling. 30-135

30 Testing and adjusting Electrical system

• This adjustment is used if you cannot run the track idle off the ground, and when adjustment is performed by traveling actually. If you can run the track idle off ground, this adjustment is not required by performing the adjustment menus Nos.16 and 17.

a When HST controller, HST pump, or HST pump EPC valve is replaced, enable this adjustment as needed.

a The operation is done normally to move the machine after adjustment is interrupted. However, the travel speed range remains at the speed range when the adjustment is interrupted. 4. When the adjustment is complete, place the joystick (steering, directional and gear shift lever) to NEUTRAL position and the parking brake lever to LOCK position.

• Functions of function switches [F3]: No use [F4]: No use [F5]: Returns the display to the ID input screen. [F6]: No use • Operating method: k BeBefore switching to this adjustment

code, move the machine to spacious level ground where it can travel 30 meters or more. k The machine travels reverse during

adjustment. Perform adjustment in spacious level ground where the machine can travel 30 meters or more without obstacles.

a To resume the adjustment after adjustment is stopped, start from step 2. a After this adjustment code is finished (starting switch is turned OFF), the adjustment is effective.

Adjustment ID: 3430 (F HST Pump Manual Set Mode) (D61-C172-270-K-06-A)

1. Start the engine and run it at high idle. 2. Check that the fuel control dial is set to Max. position, parking brake lever is in LOCK position, the joystick (steering, directional and gear shift lever) is in NEUTRAL position, and [P] on the speed range display flashes. 3. The adjustment starts when placing the parking brake lever to FREE position and setting the joystick (steering, directional and gearshift lever) to REVERSE position. k Be

careful of the machine since it starts reverse travel automatically when starting the adjustment. (Be careful of the machine since it stops after starting reverse travel once and then moves again.)

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• This adjustment code is the function to finely adjust the rising EPC current manually on the forward side of HST (hydrostatic transmission) pump. • Enable this adjustment if the following problems do not disappear on the forward side by the adjustment menu No.16. A) The one of tracks moves first when slowly releasing the decelerator/brake pedal and moving off. B) The machine starts with time lag after operation of move off. C) Large shock is made at the moment of moving off or stopping.

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30 Testing and adjusting Electrical system

a For the above problems, change the current value as following. In case of A), decrease the current value of the side that moves first. In case of B), increase the current value of the both sides. In case of C), decrease the current value of the both sides. • Functions of function switches [F3]: Switches between right and left, then decreases the current value by 1mA. [F4]: Switches between right and left, then increases the current value by 1mA. [F5]: Returns the display to the ID input screen. [F6]: Enters selection. • Operating method:

a To switch the direction before entering the changes, press [F5] once and then display this adjustment code again. 6. The alarm buzzer sounds, and the changes are entered by pressing [F6]. a Without the entering operation, the changes are disabled when the starting switch is OFF. a This adjustment is to adjust the shock at the moment of moving off or stopping. It is not to adjust the acceleration performance for moving off.

Adjustment ID: 3431 (R HST Pump Manual Set Mode) (D61-C172-270-K-07-A)

1. Record the rising current values (C) and (D) on the both sides. 2. Press [F3] or [F4] to display the direction to change to (a). Display (A) L&R EPC SELECTED L EPC SELECTED R EPC SELECTED

Content Change the current values on the both sides at the same time. Change the current value on the left side. Change the current value on the right side.

3. The direction to change enters by pressing [F6]. 4. After pressing [F3] or [F4] to increase or decrease the adjustment values (c) and (d), move the machine actually and check that the problem disappears. k If the value is largely changed, the

D61EM-23M0

• This adjustment code is the function to finely adjust the rising EPC current manually on the reverse side of HST (hydrostatic transmission) pump. • Enable this adjustment if the following problems do not disappear on the reverse side by the adjustment menu No.17. A) The one of tracks moves first when slowly releasing decelerator/brake pedal and moving off. B) The machine starts with time lag after operating to move off. C) Large shock is made at the moment of moving off or stopping. a For the above problems, change the current value as following. In case of A), decrease the current value of the side that moves first. In case of B), increase the current value of the both sides. In case of C), decrease the current value of the both sides. • Functions of function switches [F3]: Switches between right and left, then decreases the current value by 1mA. [F4]: Switches between right and left, then increases the current value by 1mA. [F5]: Returns the display to the ID input screen. 30-137

30 Testing and adjusting Electrical system

[F6]: Enters selection. • Operating method: 1. Record the rising current values (c) and (d) on the both sides. 2. Press [F3] or [F4] to display the direction to change to (a). Display (A) L&R EPC SELECTED L EPC SELECTED R EPC SELECTED

Content Change the current values on the both sides at the same time. Change the current value on the left side. Change the current value on the right side.

machine may move unexpectedly. Change the value gradually while checking the actual move. a The changes are enabled when the displays of the adjustment values (c) and (d) are changed. The changes remain enabled until the starting switch is OFF. a The changes remain enabled even if this adjustment code is turned off. To return to the condition before changing, turn starting switch OFF and repeat the operation. 5. Travel with very low speed of the variable shift mode. Check that the machine speed is in the range from 0.6 to 1.0 km/h. When the speed is too high, decrease the current value of the both sides. When the speed is too low, increase the current value of the both sides. a To switch the direction before entering the changes, press [F5] once and then display this adjustment code again. 6. The alarm buzzer sounds, and the changes are entered by pressing [F6]. a Without the entering operation, the changes are disabled when the starting switch is OFF. a This adjustment is to adjust the shock at the moment of moving off or stopping. It is not to adjust the acceleration performance for moving off.

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Adjustment ID: 3434 (Deviation Control OFF mode) (D61-C7W0-270-K-01-A)

• This adjustment code is the function to switch ON/OFF of the deviation control. a Use this adjustment code for testing, adjusting, or troubleshooting as needed. • Functions of function switches [F3]: Switches between ON and OFF. [F4]: Switches between ON and OFF. [F5]: Returns the display to the ID input screen. [F6]: Enters selection. • Operating method: 1. Press [F3] or [F4] to display ON/OFF condition to be selected in (a). Display (a)

Mode Deviation control ON (normal ON mode) OFF Deviation control OFF 2. The alarm buzzer sounds, and the settings are entered by pressing [F6]. a ON/OFF to be displayed in (a) at first when switching to this adjustment code is currently selected. a By setting the deviation control to OFF in this adjustment code, symptom canbe checked when the deviation control is not effective. Therefore, if a travel deviation failure occurs, use this function to specify the cause. a Even after this adjustment code is turned off, the settings are enabled if the starting switch is ON. Therefore, to return to normal control mode, set the display (a) to ON (deviation control ON) again in this adjustment code or turn starting switch to OFF position. (Once starting switch is turned to OFF position, normal control mode appears again.)

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30 Testing and adjusting Electrical system

Adjustment ID: 8020 (Blade lift RAISE current value correction) (D61-LTL0-270-K-03-A)

Adjustment ID: 8021 (Blade lift LOWER current value correction) (D61-LTL0-270-K-04-A)

• This adjustment code is used to adjust the sensitivity of blade movement at start when the blade control lever is operated in the lift RAISE direction with the blade fine control mode OFF.

• This adjustment code is used to adjust the sensitivity of blade movement at start when the blade control lever is operated in LOWER direction with the blade fine control mode OFF.

a Use this adjustment code for work as needed.

• Functions of function switches [F3]: Decreases adjustment value "Current offset" [F4]: Increases adjustment value "Current offset" [F5]: Returns the display to the ID input screen. [F6]: Saves adjustment value • Operating method:

• Functions of function switches [F3]: Decreases adjustment value "Current offset" [F4]: Increases adjustment value "Current offset" [F5]: Returns the display to the ID input screen [F6]: Saves adjustment value • Operating method:

1. Increase or decrease the adjustment value by operating [F3] or [F4]. 2. Press [F6] and check that the alarm buzzer sounds.

1. Increase or decrease the adjustment value by pressing [F3] or [F4]. 2. Press [F6] and check that the alarm buzzer sounds.

a If an adjustment has been performed, the adjustment value is displayed. However, it can be adjusted repeatedly.

a It is not necessary to move the blade during adjustment. After finishing adjustment, however, lift up the blade and check that there is no problem in the actual operation feeling (Check with the blade fine control mode OFF).

a It is not necessary to move the blade during adjustment. After finishing adjustment, however, lower the blade and check that there is no problem in the actual operation feeling (Check with the blade fine control mode OFF).

a Even if this adjustment code is turned off, the adjustment is effective.

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Adjustment ID: 8022 (Blade lift RAISE current value correction (fine control mode)) (D61-LTL0270-K-05-A)

Adjustment ID: 8023 (Blade lift LOWER current value correction (fine control mode)) (D61-LTL0-270-K-06-A)

• This adjustment code is used to adjust the sensitivity of blade movement at start when the blade control lever is operated in RAISE direction with the blade fine control mode ON.

• This adjustment code is used to adjust the sensitivity o blade movement at start when the blade control lever is operated in LOWER direction with the blade fine control mode ON.

a Use this adjustment code for work as needed.

a Use this adjustment code for work as needed. • Functions of function switches [F3]: Decreases adjustment value "Current offset" [F4]: Increases adjustment value "Current offset" [F5]: Returns the display to ID input screen [F6]: Saves adjustment value • Operating method: 1. Increase or decrease the adjustment value by pressing [F3] or [F4]. 2. Press [F6] and check that the alarm buzzer sounds.

• Functions of function switches [F3]: Decreases adjustment value "Current Offset" [F4]: Increases adjustment value "Current Offset" [F5]: Returns the display to ID input screen [F6]: Saves adjustment value • Operating method: 1. Increase or decrease the adjustment value by pressing [F3] or [F4]. 2. Press [F6] and check that the alarm buzzer sounds. a If an adjustment has been performed, the adjustment value is displayed. However, it can be adjusted repeatedly. a It is not necessary to move the blade during adjustment. After finishing adjustment, raise the blade and check that there is no problem in the actual operation feeling (Check with the blade fine control mode ON). a Even if this adjustment code is turned off, the adjustment is effective.

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a If an adjustment has been performed, the adjustment value is displayed. However, it can be adjusted repeatedly. a It is not necessary to move the blade during adjustment. After finishing adjustment, lower the blade and check that there is no problem in the actual operation feeling. (Check with the blade fine control mode ON.) a Even if this adjustment code is turned off, the adjustment is effective.

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Adjustment ID: 9998 (Max. speed range setting mode) (D61-CN10-270-K-00-A)

• This adjustment code is used to limit the maximum gear speed. • The limited gear speed is applied in both quick shift mode and variable shift mode.

a @ \ ? \ \ \ ` @ $! \ ^ @ $ @ ` \ \ `

2. Displaying check screen When the "No Injection" screen is displayed, the message to ask if "Begin Injectionless Cranking?" appears. Select the answer by using the function switch. • [F5]: Does not implement (returns the screen to "Service Menu") • [F6]: Executes

• Functions of function switches [F3]: Decreases the adjustment value [MAX SHIFT] [F4]: Increases the adjustment value [MAX SHIFT] [F5]: Returns the display to the ID input screen. [F6]: Saves adjustment value • Operating method: 1. Increase or decrease the adjustment value by pressing [F3] or [F4]. 2. Press [F6] and check that the alarm buzzer sounds. a When resetting the limitation of the maximum gear speed, set the adjustment value to the maximum gear speed (3rd) which is the initial setting at shipment. a Setting with this adjustment code becomes effective only after the starting switch is turned to OFF position and then to ON position again. (This setting is not enabled until starting switch is turned to OFF position.)

3. Starting no-injection cranking If no-injection cranking (no fuel injection to every cylinder) is enabled, a message "No-injection is possible" is displayed on the screen. Under this condition, crank the engine with the starting motor. a While the screen is changing to the following screen, the screen of "Getting Ready" is displayed.

No-Injection (PC220-AD00-25L-K-00-A) If the engine is operated after long storage of the machine, it may be worn or damaged because of insufficient lubrication with oil. To prevent this, the machine monitor has a function to crank the engine without injecting fuel to lubricate the engine before starting it. Set no-injection cranking while the engine is stopped. 1. Selecting a menu Select "No Injection" on "Service Menu" screen. D61EM-23M0

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30 Testing and adjusting Electrical system

a Do not crank the engine for 20 seconds or longer to protect the starting motor.

KOMTRAX Settings (Terminal Status) Q210-110-K-00-A)

(PC220-

4. Finishing no-injection cranking After the cranking is over, turn the starting switch to OFF position.

The setting and operating conditions of KOMTRAX can be checked on the display of KOMTRAX Settings.

a You cannot change the screen described above to another screen. 5. Prohibiting no-injection cranking Even if the operator tries to perform the noinjection cranking while the engine is running, the message "The engine is operating" is displayed and the no-injection cranking does not become effective.

Terminal setting status is used for checking the setting condition of the KOMTRAX terminal. 1. Selecting a menu Select "KOMTRAX Settings" on "Service Menu" screen.

a This function can be selected even when the engine is running. However, if you execute no-injection cranking, a message "The engine is operating. Please turn the key off once." is displayed on the screen.

2. Selecting a sub menu After the "KOMTRAX Settings" screen is displayed, select "Terminal Status" by using the function switch or numeral input switches. a Selecting method is the same as ot on the "Service Menu" screen.

Also, if no-injection cranking is operated when "Check" screen is displayed, the function does not become effective in the following case. • The communication between the monitor and engine controller is not normal. • Perform an engine start operation before the message "No injection is possible" is displayed.

3. Contents displayed on Terminal Status screen 30-142

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30 Testing and adjusting Electrical system

On "Terminal Status" screen, the following items of information are displayed. • "Terminal Type": Model name of the KOMTRAX communication modem • "KOMTRAX Communication": Status of radio station establishment underway • "GMT Time": Greenwich Mean Time (add 9 hours to it for Japan time) • [F5]: Returns the screen to "KOMTRAX Settings" screen

KOMTRAX Settings (GPS and Communication Status) (PC220-Q210-110-K-01-A) The setting and operating conditions of KOMTRAX can be checked on the display of KOMTRAX Settings. GPS & Communication Status is for checking the positioning and communication condition of the KOMTRAX terminal. 1. Selecting a menu Select "KOMTRAX Settings" on "Service Menu" screen.

3. Contents of display of GPS & Communication Status On "GPS & Communication Status" screen, the following items of information are displayed. • "Positioning": GPS positioning status • "Communication": Communication environment and connecting condition of the communication modem • "Number of message not yet sent": Number of message(s) not yet sent: Number of unsent mails existing in the machine monitor • [F5]: Returns the screen to "KOMTRAX Settings" screen

KOMTRAX Settings (Modem Information) Q210-110-K-02-A)

(D65-

The setting and operating status of KOMTRAX can be checked by using the menu of "KOMTRAX Settings". Modem status is used to check IP address of KOMTRAX communication modem. 2. Selecting a sub menu After the "KOMTRAX Settings" screen is displayed, select "GPS & Communication Status" by using the function switch or numeral input switches.

1. Selecting a menu Select "KOMTRAX Settings" on "Service Menu" screen.

a Selecting method is the same as it on the "Service Menu" screen.

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Service Message (D155-Q210-100-K-00-A) Special messages for the technician sent from KOMTRAX base station (a distributor, etc.) can be checked with this function. If a received message includes a setting operation, a return mail can be sent by using the numeral input switches as well. 1. Selecting the menu Select 12 "Service Message" on "Service Menu" screen.

2. Selecting a sub menu After "KOMTRAX Settings" screen is displayed, select "Modem Status" with the function switches or numeral input switches. a Select this sub menu as in the case of selecting a menu on "Service Menu" screen.

2. Display of message (read only) If there is a message, its contents are displayed. If there is no message, "No message." is displayed. • [F5]: Returns the display to Service Menu screen

3. Modem status displayed IP addresses (2 addresses) of the modem are displayed. • [F5]: Returns the display to KOMTRAX settings screen

a This message is different from that sent to the operator with the machine monitor in the operator mode. a Since this message is special for the technician, the message monitor is not displayed when it is received with the machine monitor in the operator mode.

a An IP address is a unique number assigned to each modem that is used when communication between the modem and server is turned on.

3. Display of message (with return mail function) If a message provides the Numeric Input line under the text, input a proper number by using the numeral input switches and enter it by using the function switch, and the information is returned to KOMTRAX base station.

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30 Testing and adjusting Electrical system

• [F5]: Returns the display to KOMTRAX settings screen • [F6]: Enters and returns input value a This message is different from that sent to the operator with the machine monitor in the operator mode. a Since this message is special for the technician, the message monitor is not displayed when it is received with the machine monitor in the operator mode.

• [F5]: Returns the display to previous screen • [F6]: Advances the display to next screen (after sending)

• [F5]: Returns the display to previous screen

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Adjustment method when HST controller has been replaced

a After the machine is assembled or HST controller is replaced, adjust the system according to the following procedure. k Be sure to adjust the system, otherwise the

machine may not operate normally or may move unexpectedly. a Precautions before replacing HST controller: Note down the values before replacement if necessary before HST controller is replaced, otherwise the value of the following adjustment items will be reset to the initial factory settings. • ID code (3430): F HST Pump Manual Set Mode • ID code (3431): R HST Pump Manual Set Mode • ID code (8020): Blade lift RAISE current value correction • ID code (8021): Blade lift LOWER current value correction • ID code (8022): Blade lift RAISE current value correction (fine control mode) • ID code (8023): Blade lift LOWER current value correction (fine control mode) • ID code (8024): Blade tilt LEFT current value correction • ID code (8025): Blade tilt RIGHT current value correction • ID code (9998): Max. speed range setting mode a Precautions for replacing HST controller: Before replacing HST controller, place the machine on a safe place, turn the starting switch to OFF position, and turn the battery disconnect switch to OFF position while system operating lamp is OFF. a For the machine monitor operating method, see the section of "Special functions of machine monitor". 1. Selecting the service mode Turn the battery disconnect switch to ON position, turn the starting switch to ON position, and operate machine monitor to select "Adjustment" screen in service mode.

2. Selecting the machine model 1) Select "Input ID", input ID code: 0002 (Machine code set mode), and implement adjustment.

2) Turn the starting switch to OFF position once. 3. Adjustment of decelerator/brake pedal, joystick (steering, directional and gear shift lever), and blade control lever potentiometer 1) Turn the starting switch to ON position again, and operate machine monitor to select "Adjustment" screen in service mode. 2) Select "Brake Pedal Potentio Initial Set", and perform adjustment. Press [F5] after adjustment to return to adjustment item selection screen

3) Select No. 03 "Brake Pedal Potentio Detent Set" on "Adjustment" menu, and perform 30-146

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30 Testing and adjusting Electrical system

adjustment. Press [F5] after adjustment to return to adjustment item selection screen 4) Select No. 04 for bake pedal maximum position set on "Adjustment" menu, and perform adjustment. Press [F5] after adjustment to return to adjustment item selection screen 5) Select No. 05 "S/T Lever N Position Set" on "Adjustment" menu, and perform adjustment. Press [F5] after adjustment to return to adjustment item selection screen 6) Select No. 06 "Steering Lever Left Operating Effort Change Point Set" on "Adjustment" menu, and perform adjustment. Press [F5] after adjustment to return to adjustment item selection screen 7) Select No. 07 "Steering Lever Left Maximum Position Set" on "Adjustment" menu, and perform adjustment. Press [F5] after adjustment to return to adjustment item selection screen 8) Select No. 08 "Steering Lever Right Operating Effort Change Point Set" on "Adjustment" menu, and perform adjustment. Press [F5] after adjustment to return to adjustment item selection screen 9) Select No. 09 "Steering Lever Right Maximum Position Set" on "Adjustment" menu, and perform adjustment. Press [F5] after adjustment to return to adjustment item selection screen 10)Select No. 10 "Blade Lift Lever N Position Set" on "Adjustment" menu, and perform adjustment. Press [F5] after adjustment to return to adjustment item selection screen 11)Select No. 11 "Blade Lift Lever RAISE Position Set" on "Adjustment" menu, and perform adjustment. Press [F5] after adjustment to return to adjustment item selection screen 12)Select No. 12 "Blade Lift Lever LOWER Position Set" on "Adjustment" menu, and perform adjustment. Press [F5] after adjustment to return to adjustment item selection screen 13)Select No. 13 "Blade Tilt Lever N Position Set" on "Adjustment" menu, and perform adjustment. Press [F5] after adjustment to return to adjustment item selection screen 14)Select No. 14 "Blade Tilt Lever Left Position Set" on "Adjustment" menu, and perform adjustment. Press [F5] after adjustment to return to adjustment item selection screen 15)Select No. 15 "Blade Tilt Lever Right Position Set" on "Adjustment" menu, and perform adjustment. Press [F5] after adjustment to return to adjustment item selection screen D61EM-23M0

16)Turn the starting switch to OFF position once. 4. Adjustment of HST pump and HST motor 1) Jack up bottom surface of frame at the rear of the machine, then thrust blade to the lower side, and lift the entire track shoe up from the ground in order to be ready for idle running. k Check that the track shoe is securely

lifted from the ground and stable during idle running since track shoe runs at high speed during adjustment. 2) Start the engine, and run it at high idle. 3) Operate machine monitor to select "Adjustment" of the service mode. 4) Select No.16 "F HST Pump Auto Set" on "Adjustment" menu, and perform adjustment. Press [F5] after adjustment to return to adjustment item selection screen

5) Select No. 17 "R HST Pump Auto Set" on "Adjustment" menu, and perform adjustment. Press [F5] after adjustment to return to adjustment item selection screen 6) Select No. 18 "HST Motor Auto Set" on "Adjustment" menu, and perform adjustment. Press [F5] after adjustment to return to adjustment item selection screen 7) Turn the starting switch to OFF position once. 5. Adjustment of fan 1) Adjust the HST oil temperature (hydraulic oil temperature) to 50 to 60°C. 2) Set the working mode to [P (Power Mode)]. 3) Start the engine, and run it at high idle. 4) Operate machine monitor to select "Adjustment" of the service mode. 5) Select "Fan Test Mode", and perform adjustment.

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6) Turn the starting switch to OFF position once. 6. Check of failure code 1) Turn the starting switch to ON position again, and operate machine monitor to select "Abnormality Record" screen in service mode. 2) Check to see if any failure code is occurring. If there is no failure code occurring, clear all the recorded failure codes. a If any failure code is occurring, eliminate the cause of the failure by troubleshooting, then perform Steps 1) and 2) again. a Precautions after replacing HST controller: Set the values noted down before replacement to the new HST controller, if necessary.

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Adjustment method when electric or hydraulic device has been replaced

System adjustment Adjustment menu No.

Component

• HST controller • Machine monitor

Adjustment item

See "Adjustment method when HST controller has been replaced"

See "Adjustment method when machine monitor has been replaced"

• Decelerator/brake pedal • Decelerator/brake pedal potentiometer

02 03 04

Brake pedal potentiometer initial setting Brake pedal detent set Brake pedal maximum position set

• PCCS lever

05 06 07 08 09

Steering lever neutral position set Steering lever left detent set Steering lever left maximum position set Steering lever right detent set Steering lever right maximum position set

• Blade control lever

10 11 12 13 14 15

Blade lift lever neutral position adjustment Blade lift lever maximum raise position set Blade lift lever maximum lower position set Blade tilt lever neutral position adjustment Blade tilt lever left maximum position set Blade tilt lever right maximum position set

• HST pump • HST pump EPC

16 17

HST pump forward adjustment HST pump reverse adjustment

• HST motor • Solenoid valve HST motor EPC

o 18

HST motor adjustment

• • • • •

o 19

Fan adjustment

Fan Fan motor Control valve Fan EPC Work equipment Cooling fan pump

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Adjusting rearview camera angle a A part of the machine is displayed on the monitor screen. Adjust the monitor screen so that 5 to 10% of the tank is displayed on it.

1 a Adjust the angle within the slot having mounting bolt (4) at center. Tighten mounting bolts (4) (both sides) and (5) (for slot).

If the image displayed on the monitor is out of position, adjust the installation angle (A) of the rear view camera. a Adjust angle (A) against the level surface as follows.

• D61E -23 : 38 deg.

Adjusting 1. Remove bolts (2) (2 pieces) of camera cover (1), and remove cover (1).

2. Loosen mounting bolts (4) (both sides) and (5) (for slot) of camera (3), and adjust angle (A). 30-150

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30 Testing and adjusting Electrical system

Handling voltage circuit of engine controller

1. Disconnecting or connecting work of the connector between the engine controller and the engine must be performed only when the starting switch and disconnect switch are in OFF position and the system operating lamp goes out. k Before connecting the wiring harness

connector, be sure to completely remove sand, dust, water, etc., inside the connector on the controller side. 2. If the T-adapter is inserted in or connected to the connector between the engine controller and engine harness for troubleshooting, do not start the engine. a You may turn the starting switch to OFF or ON position but must not turn it to START position.

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Handling battery disconnect switch

1. When you turn the battery disconnect switch to the OFF position, be sure to pull out switch key (1). k A serious accident can result if someone

turns switch key (1) ON inadvertently. 2. You can prevent an abnormal end of the operation due to cutoff of the battery power supply circuit while the controllers are in operation by checking the operating status of each controller with system operating lamp (2). 1) Before cutting off the battery power supply circuit, turn the starting switch to OFF position, and check that the system operating lamp (2) goes out, then turn the battery disconnect switch to OFF position. 2) If you turn the battery disconnect switch to OFF position (battery power supply circuit is cut off) while the system operating lamp (2) is lit, Controller Data Lost Error can occur. Do not operate the battery disconnect switch as long as the system operating lamp (2) is lit. 3) The system operating lamp (2) goes off in two minutes longest after the starting switch is turned to OFF position. 4) Even if the starting switch is in the OFF position, the system operating lamp (2) may light up since the KOMTRAX terminal may perform communication. 5) The system operating lamp (2) may look slightly luminous in the dark after it is turned off. It is due to the minute leakage of current and not an abnormal phenomenon. • After the starting switch is turned to OFF position, KOMTRAX terminal repeats the start and stop to maintain the periodic communication. • The start and stop cycle (sleep cycle) of KOMTRAX terminal varies depending on the factors including the communication status and machine stop time. So the lamp can be lit as long as approximately an hour. 6) When you want to cut off the battery circuit for maintenance but the operating lamp keeps on lighting up, turn the starting switch to OFF position once, then turn it to OFF position. The lamp will go out in two minutes maximum. After the system operating lamp (2) goes out, turn the battery disconnect switch to the OFF position immediately.

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Testing diodes

a Test the diode array (8-pin) and the single diode (2-pin) according to the following procedure. a The continuity directions of the diode array are as follows.

a The continuity direction of the single diode is indicated on the surface of the diode.

Testing

(PC220-E300-36J-P-00-A)

1. When using a digital tester 1) Select the diode range screen to check the displayed values. a When an ordinary circuit tester is used, the voltage of the internal battery is indicated. 2) Apply the red (+) lead of the multimeter to the anode (P) side of the diode and apply the black (-) lead to the cathode (N) side and check the indicated value. 3) Evaluate the condition of the diode by the indicated value. • Indicated value does not change: No continuity (defective) • Indicated value changes: Continuity (normal) (note) Note: In the case of a silicon diode, a value in the range from 460 to 600 mV is indicated. • The indicated value is 0 or approximate 0: The diode has internal short circuit (defective).

D61EM-23M0

2. When using analog tester 1) Selects the resistance range screen. 2) Check the movement of the pointer when performing the following connection. 1] Apply the red (+) lead of the multimeter to the anode (P) side of the diode and apply the black (-) lead to the cathode (N) side. 2] Apply the red (+) lead of the multimeter to the cathode (N) side of the diode and apply the black (-) lead to the anode (P) side. 3) Evaluate the condition of the diode by the movement of the pointer. • The pointer does not move by the above 1] connection, but it does by the 2] connection: Normal (however, the movement of the pointer (resistance) varies by type of tester, or selection of measuring range). • The pointer moves by either connection of the above 1], and 2]: Defective (internal short circuit) • The pointer moves by neither connection the above 1], nor 2]: Defective (internal open circuit)

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Pm clinic

Pm Clinic service (

)

Model T D61E -23

Serial No.

h Date of inspection / /

User name

Blade T PART blade (wide) T PAT blade (narrow)

Service meter

Inspector

Specification Attachment T Pitch drawbar

Shoe width T 600 mm (single) T 860 mm (single) T 680 mm (circular)

Operating conditions Type of soil (specific Construction gravity ) T Construction, civil T Rock engineering T Gravel T Road T Sand T Tunnel T Clay soil T

Quarry, mine T Coal T Gold T Limestone T

T Engine coolant level T Engine oil level T Hydraulic oil level

% % % %

Existence of abnormalities Check of oil and coolant levels When necessary T Final drive

Ambient temperature Max. Min.

Contents of work T Dozing/Digging T Side cutting T Leveling T Travel

Altitude °C Operator's comment Result of visual inspection

[ Details: [ Details:

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] ]

Failure code record [ h Details: [ h Details:

]

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30 Testing and adjusting

Pm clinic

a Max. range of engine coolant temperature gauge

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a Max. range of power train oil temperature gauge

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Pm Clinic check sheet

Machine serial T D61E -23 number Engine serial No. SAA6D107E- Time check Date of inspection Year Month Day

Work order

Service meter reading h

1. Engine

Item

Condition

Unit

• P mode Low idle • Coolant temperature: 30 to 102°C Engine rpm • HST oil speed (*1) High idle temperature (hydraulic oil temperature): 40 to 60°C • Coolant temperature: -30 to 102° C Pa Blowby • HST oil temperature (hydraulic oil {mmH2pressure temperature): 40 to 60°C O} • Stall pressure test mode + work equipment relief

Standard Repair value for new limit machine 950 to 1,000 950 to 1,000

Max. 980 {Max. 100}

1,960 {Max. 200}

MPa {kg/ cm2}

Min. 0.29 {Min. 3.0} Min. 0.10 {Min. 0.1}

Min. 0.25 {Min. 2.5} Min. 0.07 {Min. 0.7}

• Coolant temperature: -30 to 102° C kPa • HST oil temperature (hydraulic oil {mmHtemperature): 40 to 60°C g} • Stall pressure test mode + work equipment relief

Min. 113 {Min. 850}

Min. 87 {Min. 650}

Standard value for new machine

Repair limit

19.2 to 21.2 {196 to 216}

Min. 17.2 {Min. 175}

Engine oil SAE30 pressure SAE15W-40

Boost pressure (*1)

Inspector

High idle Low idle

>: Reference value Test results

No Gogood od

Test results

No Gogood od

2. Cooling fan Item Fan speed (*1) • Work • equipment • pump pressure • (fan drive pressure) (*1)

Condition

Unit rpm

P mode Fan 100% mode HST oil temperature (hydraulic oil temperature): 50 to 60°C Fuel control dial: MAX (High idle) position

MPa {kg/ cm2}

*1: Items to be inspected in "Special functions of monitor panel" a HST stall (stall pressure test mode) is within 30 seconds. HST oil temperature (hydraulic oil temperature) during HST stall is 40 to 60°C.

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Pm clinic

3. HST oil pressure Item

Main circuit pressure (*1)

Charge circuit pressure (*1)

Condition • HST oil Left Forward temperature Right (hydraulic oil Left temperature): 40 to 60°C • Fuel control dial: MAX (High idle) Reverse Right position • Stall Pressure Test Mode Joystick (steering, • HST oil directional and temperature gear shift (hydraulic oil lever): temperature): 40 NEUTRAL to 60°C Joystick • Fuel control dial: (steering, MAX (High idle) directional and position gear shift • Stall Pressure lever): Test Mode FORWARD or REVERSE

Unit

Standard value for new machine

Repair limit

MPa {kg/ cm2}

40.2 to 44.1 {410 to 450}

39.2 to 45.1 {400 to 460}

2.94 to 3.53 {30 to 36}

2.74 to 3.33 {28 to 34}

2.55 to 3.53 {26 to 36}

Test results

No Gogood od

MPa {kg/ cm2}

*1 Items to be inspected in "Special functions of monitor panel" a HST stall (stall pressure test mode) is within 30 seconds. HST oil temperature (hydraulic oil temperature) during HST stall is 40 to 60°C. a Inspect charge circuit pressure with adjustment menu No.22 "Control Brake Release Mode" in "Special functions of monitor panel". 4. Work equipment oil pressure Item

Condition

Work • HST oil temperature (hydraulic oil equipment temperature): 40 to 60 °C pump • Fuel control dial: MAX (High idle) relief oil position pressure • During work equipment relief (*1)

Unit

Standard value for new machine

Repair limit

MPa {kg/ cm2}

26.4 to 28.4 {270 to 290}

Min. 24.5 {Min. 250}

Test results

No Gogood od

*1 Items to be inspected in "Special functions of monitor panel"

D61EM-23M0

30-157

30 Testing and adjusting Pm clinic

5. Work equipment speed

lifting speed

• HST oil temperature (hydraulic oil Full temperaRAISE ture): 40 to ? 60°C ground • Fuel control dial: MAX (High idle) position

RAISE

2. 1

Max. 2.9

LOWER

Max.

Standard value for new machine

Repair limit

Max. 100

6. Hydraulic drift of work equipment Item Hydraulic drift of lifted

Condition • • • •

Unit

Level and flat ground Engine stopped mm/15 Lever in Neutral min. HST oil temperature (hydraulic oil temperature): 40 to 60°C

Test results

No Gogood od

a When changing oil 7. Final drive Visual check of drain plug • Engine stopped of final drive

There must be no excessive metal particles

Note: Write down the phenomena and information which draw your attention during today's checkup.

30-158

D61EM-23M0

30 Testing and adjusting

Pm clinic

Undercarriage check sheet

Machine serial number Date of inspection Year Month Day

Work instruction

T D61E -23

Service meter reading

Inspector

• Measure the bushing temperature immediately after the work. Left side of machine

Right side of machine

a Test results Good Left side of machine Right side of machine

No good

Left track Pin No.

A: Clearance between links 1.2

Right track Pin No.

A: Clearance between links 1.2

• Opening of track link

D61EM-23M0

30-159

30 Testing and adjusting Pm clinic

D61(0 0 (Normal, impact) (PLUS specification) (Program form No.: SELA195001)

D61EM-23M0

30-160

D61EM-23M0

SHOP MANUAL

D61E -23M0 Model

Serial Number

D61E -23M0

B 0001 and up

"# $% 5 30 Testing and adjusting

D61EM-23M0

40-1

40 Troubleshooting Table of contents

Table of contents

40 Troubleshooting - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - Table of contents - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - Related information on troubleshooting - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - Troubleshooting points - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - Sequence of events in troubleshooting - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - Checks before troubleshooting - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - Inspection procedure before troubleshooting- - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - Preparation for troubleshooting of electrical system - - - - - - - - - - - - - - - - - - - - - - - - - - - Classification and procedures for troubleshooting - - - - - - - - - - - - - - - - - - - - - - - - - - - - Symptom and troubleshooting numbers - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - Information in troubleshooting table - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - Procedure for troubleshooting wiring harness of pressure sensor system for open circuit Connector list and layout- - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - Connector contact identification - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - T-branch box and T-branch adapter table - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - Fuse location table - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - Failure codes table - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - Troubleshooting by failure code (Display of code)- - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - Failure code [6091NX] HST Oil Filter Clogging - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - Failure code [989L00] Engine Controller Lock Caution 1 - - - - - - - - - - - - - - - - - - - - - - - Failure code [989M00] Engine Controller Lock Caution 2 - - - - - - - - - - - - - - - - - - - - - - - Failure code [989N00] Engine Controller Lock Caution 3 - - - - - - - - - - - - - - - - - - - - - - - Failure code [AA10NX] Air Cleaner Clogging - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - Failure code [AB00KE] Charge Voltage Low - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - Failure code [B@BAZG] Eng Oil Press Low - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - Failure code [B@BCNS] Eng Water Overheat - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - Failure code [B@CRNS] HST Oil Overheat- - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - Failure code [B@CRZG] HST Charge Press Low - - - - - - - - - - - - - - - - - - - - - - - - - - - - Failure code [CA111] ECM Critical Internal Failure- - - - - - - - - - - - - - - - - - - - - - - - - - - - Failure code [CA115] Eng Ne and Bkup Speed Sens Error - - - - - - - - - - - - - - - - - - - - - - Failure code [CA122] Chg Air Press Sensor High Error - - - - - - - - - - - - - - - - - - - - - - - - Failure code [CA123] Chg Air Press Sensor Low Error- - - - - - - - - - - - - - - - - - - - - - - - - Failure code [CA131] Throttle Sensor High Error - - - - - - - - - - - - - - - - - - - - - - - - - - - - - Failure code [CA132] Throttle Sensor Low Error - - - - - - - - - - - - - - - - - - - - - - - - - - - - - Failure code [CA144] Coolant Temp Sens High Error- - - - - - - - - - - - - - - - - - - - - - - - - - Failure code [CA145] Coolant Temp Sens Low Error - - - - - - - - - - - - - - - - - - - - - - - - - - Failure code [CA153] Chg Air Temp Sensor High Error - - - - - - - - - - - - - - - - - - - - - - - - Failure code [CA154] Chg Air Temp Sensor Low Error - - - - - - - - - - - - - - - - - - - - - - - - - Failure code [CA187] Sensor 2 Supply Volt Low Error - - - - - - - - - - - - - - - - - - - - - - - - - Failure code [CA221] Ambient Press Sensor High Error- - - - - - - - - - - - - - - - - - - - - - - - Failure code [CA222] Ambient Press Sensor Low Error - - - - - - - - - - - - - - - - - - - - - - - - Failure code [CA227] Sensor 2 Supply Volt High Error - - - - - - - - - - - - - - - - - - - - - - - - - Failure code [CA234] Eng Overspeed - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - Failure code [CA238] Ne Speed Sensor Supply Volt Error - - - - - - - - - - - - - - - - - - - - - - Failure code [CA271] IMV/PCV1 Short Error - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - Failure code [CA272] IMV/PCV1 Open Error- - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - Failure code [CA322] Inj #1(L#1) Open/Short Error - - - - - - - - - - - - - - - - - - - - - - - - - - - Failure code [CA323] Inj #5(L#5) Open/Short Error - - - - - - - - - - - - - - - - - - - - - - - - - - - Failure code [CA324] Inj #3(L#3) Open/Short Error - - - - - - - - - - - - - - - - - - - - - - - - - - - Failure code [CA325] Inj #6(L#6) Open/Short Error - - - - - - - - - - - - - - - - - - - - - - - - - - - Failure code [CA331] Inj #2(L#2) Open/Short Error - - - - - - - - - - - - - - - - - - - - - - - - - - - Failure code [CA332] Inj #4(L#4) Open/Short Error - - - - - - - - - - - - - - - - - - - - - - - - - - - Failure code [CA342] Calibration Code Incompatibility - - - - - - - - - - - - - - - - - - - - - - - - - 40-2

40-1 40-2 40-8 40-8 40-10 40-12 40-14 40-31 40-35 40-37 40-39 40-41 40-44 40-58 40-97 40-102 40-107 40-115 40-115 40-117 40-118 40-119 40-120 40-122 40-124 40-125 40-126 40-127 40-128 40-129 40-130 40-132 40-134 40-136 40-138 40-140 40-142 40-144 40-146 40-148 40-150 40-152 40-153 40-154 40-155 40-157 40-159 40-161 40-163 40-165 40-167 40-169 40-171

D61EM-23M0

40 Troubleshooting Table of contents

Failure code [CA351] Injectors Drive Circuit Error - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 40-172 Failure code [CA352] Sensor 1 Supply Volt Low Error - - - - - - - - - - - - - - - - - - - - - - - - - - 40-173 Failure code [CA386] Sensor 1 Supply Volt High Error - - - - - - - - - - - - - - - - - - - - - - - - - - 40-175 Failure code [CA428] Water in Fuel Sensor High Error - - - - - - - - - - - - - - - - - - - - - - - - - - 40-176 Failure code [CA429] Water in Fuel Sensor Low Error - - - - - - - - - - - - - - - - - - - - - - - - - - 40-178 Failure code [CA435] Eng Oil Press Sw Error - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 40-180 Failure code [CA441] Battery Voltage Low Error - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 40-181 Failure code [CA442] Battery Voltage High Error - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 40-183 Failure code [CA449] Rail Press Very High Error - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 40-184 Failure code [CA451] Rail Press Sensor High Error - - - - - - - - - - - - - - - - - - - - - - - - - - - - 40-185 Failure code [CA452] Rail Press Sensor Low Error - - - - - - - - - - - - - - - - - - - - - - - - - - - - 40-187 Failure code [CA488] Chg Air Temp High Torque Derate- - - - - - - - - - - - - - - - - - - - - - - - - 40-189 Failure code [CA553] Rail Press High Error - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 40-190 Failure code [CA689] Eng Ne Speed Sensor Error - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 40-191 Failure code [CA731] Eng Bkup Speed Sens Phase Error- - - - - - - - - - - - - - - - - - - - - - - - 40-193 Failure code [CA757] All continuous Data Lost Error - - - - - - - - - - - - - - - - - - - - - - - - - - - 40-195 Failure code [CA778] Eng Bkup Speed Sensor Error - - - - - - - - - - - - - - - - - - - - - - - - - - - 40-196 Failure code [CA2185] Throt Sensor Sup Volt High Error - - - - - - - - - - - - - - - - - - - - - - - - 40-201 Failure code [CA2186] Throt Sensor Sup Volt Low Error- - - - - - - - - - - - - - - - - - - - - - - - - 40-202 Failure code [CA2249] Rail Press Very Low Error - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 40-203 Failure code [CA2311] IMV Solenoid Error - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 40-204 Failure code [CA2555] Grid Htr Relay Volt Low Error - - - - - - - - - - - - - - - - - - - - - - - - - - - 40-205 Failure code [CA2556] Grid Htr Relay Volt High Error - - - - - - - - - - - - - - - - - - - - - - - - - - - 40-207 Failure code [D130KA] Neutral relay Open - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 40-209 Failure code [D130KB] Neutral relay Short circuit- - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 40-211 Failure code [D130KY] Neutral relay: Hot Short - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 40-213 Failure code [D19JKZ] Personal Code Relay Abnormality- - - - - - - - - - - - - - - - - - - - - - - - 40-215 Failure code [D811MC] KOMTRAX Error- - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 40-218 Failure code [D862KA] GPS Antenna Open Circuit - - - - - - - - - - - - - - - - - - - - - - - - - - - - 40-219 Failure code [D8ALKA] Operating Lamp Open Circuit (KOMTRAX) - - - - - - - - - - - - - - - - - 40-220 Failure code [D8ALKB] Operating Lamp Short Circuit (KOMTRAX) - - - - - - - - - - - - - - - - - 40-222 Failure code [D8AQKR] CAN2 Discon (KOMTRAX) - - - - - - - - - - - - - - - - - - - - - - - - - - - - 40-223 Failure code [DAF0MB] Monitor ROM Abnormality- - - - - - - - - - - - - - - - - - - - - - - - - - - - - 40-224 Failure code [DAF0MC] Monitor Error - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 40-225 Failure code [DAF8KB] Camera Power Supply Short Circuit - - - - - - - - - - - - - - - - - - - - - - 40-226 Failure code [DAF9KQ] Model Selection Abnormality - - - - - - - - - - - - - - - - - - - - - - - - - - - 40-227 Failure code [DAFGMC] GPS Module Error- - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 40-228 Failure code [DAFLKA] Operating Lamp Open Circuit (Monitor) - - - - - - - - - - - - - - - - - - - 40-229 Failure code [DAFLKB] Operating Lamp Short Circuit (Monitor)- - - - - - - - - - - - - - - - - - - - 40-231 Failure code [DAFQKR] CAN2 Discon (Monitor) - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 40-232 Failure code [DAJ000] HST controller: Abnormality in controller - - - - - - - - - - - - - - - - - - - 40-233 Failure code [DAJ0KQ] HST controller: Type select signal - - - - - - - - - - - - - - - - - - - - - - - 40-234 Failure code [DAJ0KT] HST controller: Abnormality in controller - - - - - - - - - - - - - - - - - - - 40-235 Failure code [DAJ0MC] HST Con Error - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 40-236 Failure code [DAJ1KK] HST controller: Source voltage low - - - - - - - - - - - - - - - - - - - - - - - 40-237 Failure code [DAJ2KK] HST controller: Output voltage low - - - - - - - - - - - - - - - - - - - - - - - 40-239 Failure code [DAJ5KK] HST: Sensor volt 5V (0) Out of normal range - - - - - - - - - - - - - - - - 40-241 Failure code [DAJ6KK] HST: Sensor volt 5V (1) Out of normal range - - - - - - - - - - - - - - - - 40-244 Failure code [DAJLKA] Operating Lamp Open Circuit (HST Con) - - - - - - - - - - - - - - - - - - 40-246 Failure code [DAJLKB] Operating Lamp Short Circuit (HST Con) - - - - - - - - - - - - - - - - - - 40-248 Failure code [DAJPMA] Inconsistency of Option Selection (HST) - - - - - - - - - - - - - - - - - - 40-249 Failure code [DAJQKR] CAN2 Discon (HST Con) - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 40-250 Failure code [DAJRKR] CAN1 Discon (HST Con) - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 40-251 Failure code [DB2QKR] CAN2 Discon (Engine Con) - - - - - - - - - - - - - - - - - - - - - - - - - - - 40-252 Failure code [DD12KA] Shift up SW: Open - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 40-256 D61EM-23M0

40-3

40 Troubleshooting Table of contents

Failure code [DD12KB] Shift up SW: Short Circuit - - - - - - - - - - - - - - - - - - - - - - - - - - - - Failure code [DD13KA] Shift down SW: Open - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - Failure code [DD13KB] Shift down SW: Short Circuit - - - - - - - - - - - - - - - - - - - - - - - - - - Failure code [DD14KA] Parking lever SW: Open - - - - - - - - - - - - - - - - - - - - - - - - - - - - - Failure code [DD14KB] Parking lever SW: Short circuit - - - - - - - - - - - - - - - - - - - - - - - - Failure code [DDKAKA] Blade float Sw: Open - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - Failure code [DDKAKB] Blade float Sw: Short circuit - - - - - - - - - - - - - - - - - - - - - - - - - - Failure code [DDKFL4] Left Angle Sw: Signal mismatch- - - - - - - - - - - - - - - - - - - - - - - - Failure code [DDKGL4] Right Angle Sw: Signal mismatch - - - - - - - - - - - - - - - - - - - - - - Failure code [DDKHKA] iB Sw: Open - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - Failure code [DDKHKB] iB Sw: Short circuit - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - Failure code [DDNLKA] Weq lock Sw: Open - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - Failure code [DDNLKB] Weq lock Sw: Short circuit - - - - - - - - - - - - - - - - - - - - - - - - - - - Failure code [DDP6KA] Brake Pressure Sensor: Open - - - - - - - - - - - - - - - - - - - - - - - - Failure code [DDP6KB] Brake Pressure Sensor: Hot Short- - - - - - - - - - - - - - - - - - - - - - Failure code [DDP6MA] Brake pressure sensor: Malfunction - - - - - - - - - - - - - - - - - - - - Failure code [DDU1FS] Parking lever Switch 2: Signal mismatch - - - - - - - - - - - - - - - - - Failure code [DDU1KA] Parking lever Sw2: Open - - - - - - - - - - - - - - - - - - - - - - - - - - - - Failure code [DDU1KY] Parking lever Sw2: Hot Short - - - - - - - - - - - - - - - - - - - - - - - - - Failure code [DFA4KX] Blade lift lever: Main and Sub Error - - - - - - - - - - - - - - - - - - - - - Failure code [DFA4KZ] Blade lift lever: Main and Sub Error - - - - - - - - - - - - - - - - - - - - - Failure code [DFA4L8] Blade lift lever: Signal mismatch - - - - - - - - - - - - - - - - - - - - - - - - Failure code [DFA5KA] Blade lift lever1: Open - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - Failure code [DFA5KB] Blade lift lever1: Hot Short- - - - - - - - - - - - - - - - - - - - - - - - - - - - Failure code [DFA6KA] Blade lift lever2: Open - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - Failure code [DFA6KB] Blade lift lever2: Hot Short- - - - - - - - - - - - - - - - - - - - - - - - - - - - Failure code [DFA7KX] Blade tilt lever: Main and Sub Error - - - - - - - - - - - - - - - - - - - - - Failure code [DFA7KZ] Blade tilt lever: Main and Sub Error - - - - - - - - - - - - - - - - - - - - - Failure code [DFA7L8] Blade tilt lever: Signal mismatch - - - - - - - - - - - - - - - - - - - - - - - - Failure code [DFA8KA] Blade tilt lever1: Open - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - Failure code [DFA8KB] Blade tilt lever1: Hot Short- - - - - - - - - - - - - - - - - - - - - - - - - - - - Failure code [DFA9KA] Blade tilt lever2: Open - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - Failure code [DFA9KB] Blade tilt lever2: Hot Short- - - - - - - - - - - - - - - - - - - - - - - - - - - - Failure code [DGS1KA] HST oil temp sensor: Open - - - - - - - - - - - - - - - - - - - - - - - - - - Failure code [DGS1KX] HST oil temp sensor: Out of normal range - - - - - - - - - - - - - - - - Failure code [DH21KA] Weq pressure sensor: Open - - - - - - - - - - - - - - - - - - - - - - - - - - Failure code [DH21KB] Weq pressure sensor: Hot Short - - - - - - - - - - - - - - - - - - - - - - - Failure code [DHA4KA] Air Cleaner Clog Sensor Open Circuit - - - - - - - - - - - - - - - - - - - Failure code [DHH7KA] LF HST Pressure Sensor: Open - - - - - - - - - - - - - - - - - - - - - - - Failure code [DHH7KB] LF HST Pressure Sensor: Hot Short - - - - - - - - - - - - - - - - - - - - Failure code [DHH8KA] RF HST Pressure Sensor: Open - - - - - - - - - - - - - - - - - - - - - - - Failure code [DHH8KB] RF HST Pressure Sensor: Hot Short - - - - - - - - - - - - - - - - - - - - Failure code [DHH9KA] LR HST Pressure Sensor: Open - - - - - - - - - - - - - - - - - - - - - - - Failure code [DHH9KB] LR HST Pressure Sensor: Hot Short - - - - - - - - - - - - - - - - - - - - Failure code [DHHAKA] RR HST Pressure Sensor: Open - - - - - - - - - - - - - - - - - - - - - - Failure code [DHHAKB] RR HST Pressure Sensor: Hot Short - - - - - - - - - - - - - - - - - - - Failure code [DK30KA] ST lever1: Open- - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - Failure code [DK30KB] ST lever1: Hot Short - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - Failure code [DK30KX] ST lever: Main and Sub Error - - - - - - - - - - - - - - - - - - - - - - - - - Failure code [DK30KZ] ST lever: Main and Sub Error - - - - - - - - - - - - - - - - - - - - - - - - - Failure code [DK30L8] ST lever: Signal mismatch - - - - - - - - - - - - - - - - - - - - - - - - - - - - Failure code [DK31KA] ST lever2: Open- - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - Failure code [DK31KB] ST lever2: Hot Short - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - Failure code [DK40KA] Decel/Brake potentiometer: Open - - - - - - - - - - - - - - - - - - - - - - 40-4

40-258 40-260 40-262 40-264 40-267 40-271 40-273 40-275 40-277 40-279 40-281 40-283 40-286 40-289 40-291 40-293 40-295 40-298 40-301 40-303 40-304 40-305 40-306 40-309 40-311 40-313 40-315 40-316 40-317 40-318 40-321 40-323 40-326 40-328 40-330 40-331 40-333 40-335 40-337 40-339 40-341 40-343 40-345 40-347 40-349 40-351 40-353 40-356 40-358 40-359 40-360 40-361 40-364 40-366

D61EM-23M0

40 Troubleshooting Table of contents

Failure code [DK40KB] Decel/Brake potentiometer: Hot Short- - - - - - - - - - - - - - - - - - - - - 40-369 Failure code [DK55KX] FR lever: Main and Sub Error- - - - - - - - - - - - - - - - - - - - - - - - - - - 40-371 Failure code [DK55KZ] FR lever: Main and Sub Error- - - - - - - - - - - - - - - - - - - - - - - - - - - 40-372 Failure code [DK55L8] FR lever: Signal mismatch - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 40-373 Failure code [DK56KA] FR lever1: Open - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 40-374 Failure code [DK56KB] FR lever1: Hot Short - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 40-377 Failure code [DK57KA] FR lever2: Open - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 40-380 Failure code [DK57KB] FR lever2: Hot Short - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 40-383 Failure code [DLM0KX] HST Motor Speed Sensor: Left/Right Error - - - - - - - - - - - - - - - - - 40-385 Failure code [DLM1KA] Left HST motor speed sensor: Open - - - - - - - - - - - - - - - - - - - - - 40-386 Failure code [DLM1KB] Left HST motor speed sensor: Short circuit - - - - - - - - - - - - - - - - - 40-388 Failure code [DLM1MA] Left HST motor speed sensor: Malfunction - - - - - - - - - - - - - - - - - 40-390 Failure code [DLM2KA] Right HST motor speed sensor: Open - - - - - - - - - - - - - - - - - - - - 40-391 Failure code [DLM2KB] Right HST motor speed sensor: Short circuit- - - - - - - - - - - - - - - - 40-393 Failure code [DLM2MA] Right HST motor speed sensor: Malfunction- - - - - - - - - - - - - - - - 40-395 Failure code [DLM3KA] Fan rev. sensor: Open - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 40-396 Failure code [DLM3KB] Fan rev. sensor: Short circuit - - - - - - - - - - - - - - - - - - - - - - - - - - - 40-398 Failure code [DLM3MB] Fan control: Mismatch - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 40-400 Failure code [DN21FS] Decel/Brake pedal SW: Signal mismatch - - - - - - - - - - - - - - - - - - 40-401 Failure code [DR21KX] Camera 2 Picture Rev. Drive Abnormality - - - - - - - - - - - - - - - - - - 40-403 Failure code [DR31KX] Camera 3 Picture Rev. Drive Abnormality - - - - - - - - - - - - - - - - - - 40-404 Failure code [DV20KB] Back-up alarm: Short circuit - - - - - - - - - - - - - - - - - - - - - - - - - - - - 40-405 Failure code [DW4BKA] Parking brake solenoid: Open- - - - - - - - - - - - - - - - - - - - - - - - - - 40-407 Failure code [DW4BKB] Parking brake solenoid: Short circuit - - - - - - - - - - - - - - - - - - - - - 40-409 Failure code [DW4BKY] Parking brake solenoid: Hot Short - - - - - - - - - - - - - - - - - - - - - - - 40-411 Failure code [DW7BKA] Fan reverse solenoid: Open - - - - - - - - - - - - - - - - - - - - - - - - - - - 40-413 Failure code [DW7BKB] Fan reverse solenoid: Short circuit - - - - - - - - - - - - - - - - - - - - - - 40-415 Failure code [DW7EKA] Slow brake solenoid: Open- - - - - - - - - - - - - - - - - - - - - - - - - - - - 40-416 Failure code [DW7EKB] Slow brake solenoid: Short circuit - - - - - - - - - - - - - - - - - - - - - - - 40-418 Failure code [DW7EKY] Slow brake solenoid: Hot Short - - - - - - - - - - - - - - - - - - - - - - - - - 40-420 Failure code [DWN5KA] Fan EPC: Open- - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 40-422 Failure code [DWN5KB] Fan EPC: Short circuit - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 40-424 Failure code [DWN5KY] Fan EPC: Hot Short- - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 40-425 Failure code [DXA4KA] LF HST pump EPC: Open - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 40-427 Failure code [DXA4KB] LF HST pump EPC: Short circuit - - - - - - - - - - - - - - - - - - - - - - - - 40-429 Failure code [DXA4KY] LF HST pump EPC: Hot Short - - - - - - - - - - - - - - - - - - - - - - - - - - 40-430 Failure code [DXA5KA] LR HST pump EPC: Open- - - - - - - - - - - - - - - - - - - - - - - - - - - - - 40-432 Failure code [DXA5KB] LR HST pump EPC: Short circuit - - - - - - - - - - - - - - - - - - - - - - - - 40-434 Failure code [DXA5KY] LR HST pump EPC: Hot Short- - - - - - - - - - - - - - - - - - - - - - - - - - 40-436 Failure code [DXA6KA] RF HST pump EPC: Open - - - - - - - - - - - - - - - - - - - - - - - - - - - - 40-438 Failure code [DXA6KB] RF HST pump EPC: Short circuit - - - - - - - - - - - - - - - - - - - - - - - - 40-440 Failure code [DXA6KY] RF HST pump EPC: Hot Short- - - - - - - - - - - - - - - - - - - - - - - - - - 40-441 Failure code [DXA7KA] RR HST pump EPC: Open - - - - - - - - - - - - - - - - - - - - - - - - - - - - 40-443 Failure code [DXA7KB] RR HST pump EPC: Short circuit- - - - - - - - - - - - - - - - - - - - - - - - 40-445 Failure code [DXA7KY] RR HST pump EPC: Hot Short - - - - - - - - - - - - - - - - - - - - - - - - - 40-446 Failure code [DXHRKA] Blade lift up EPC: Open - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 40-448 Failure code [DXHRKB] Blade lift up EPC: Short circuit - - - - - - - - - - - - - - - - - - - - - - - - - 40-451 Failure code [DXHRKY] Blade lift up EPC: Hot short - - - - - - - - - - - - - - - - - - - - - - - - - - - 40-453 Failure code [DXHSKA] Blade lift down EPC: Open - - - - - - - - - - - - - - - - - - - - - - - - - - - - 40-455 Failure code [DXHSKB] Blade lift down EPC: Short circuit - - - - - - - - - - - - - - - - - - - - - - - 40-458 Failure code [DXHSKY] Blade lift down EPC: Hot short - - - - - - - - - - - - - - - - - - - - - - - - - 40-460 Failure code [DXHTKA] Blade tilt left EPC: Open - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 40-462 Failure code [DXHTKB] Blade tilt left EPC: Short circuit - - - - - - - - - - - - - - - - - - - - - - - - - 40-464 Failure code [DXHTKY] Blade tilt left EPC: Hot short - - - - - - - - - - - - - - - - - - - - - - - - - - - 40-465 Failure code [DXHUKA] Blade tilt right EPC: Open- - - - - - - - - - - - - - - - - - - - - - - - - - - - - 40-467 D61EM-23M0

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40 Troubleshooting Table of contents

Failure code [DXHUKB] Blade tilt right EPC: Short circuit - - - - - - - - - - - - - - - - - - - - - - - - 40-469 Failure code [DXHUKY] Blade tilt right EPC: Hot short - - - - - - - - - - - - - - - - - - - - - - - - - - 40-470 Failure code [DXJ4KA] Weq lock Sol.: Open - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 40-472 Failure code [DXJ4KB] Weq lock Sol.: Short circuit - - - - - - - - - - - - - - - - - - - - - - - - - - - - 40-474 Failure code [DXJCKA] Blade angle left EPC: Open - - - - - - - - - - - - - - - - - - - - - - - - - - - 40-476 Failure code [DXJCKB] Blade angle left EPC: Short circuit - - - - - - - - - - - - - - - - - - - - - - - 40-477 Failure code [DXJCKY] Blade angle left EPC: Hot short - - - - - - - - - - - - - - - - - - - - - - - - - 40-478 Failure code [DXJDKA] Blade angle right EPC: Open - - - - - - - - - - - - - - - - - - - - - - - - - - 40-480 Failure code [DXJDKB] Blade angle right EPC: Short circuit - - - - - - - - - - - - - - - - - - - - - - 40-481 Failure code [DXJDKY] Blade angle right EPC: Hot short - - - - - - - - - - - - - - - - - - - - - - - - 40-482 Failure code [DXK1KA] Left HST motor EPC: Open- - - - - - - - - - - - - - - - - - - - - - - - - - - - 40-484 Failure code [DXK1KB] Left HST motor EPC: Short circuit - - - - - - - - - - - - - - - - - - - - - - - 40-486 Failure code [DXK1KY] Left HST motor EPC: Hot Short- - - - - - - - - - - - - - - - - - - - - - - - - 40-487 Failure code [DXK2KA] Right HST motor EPC: Open - - - - - - - - - - - - - - - - - - - - - - - - - - 40-489 Failure code [DXK2KB] Right HST motor EPC: Short circuit - - - - - - - - - - - - - - - - - - - - - - 40-491 Failure code [DXK2KY] Right HST motor EPC: Hot Short- - - - - - - - - - - - - - - - - - - - - - - - 40-492 Troubleshooting of electrical system (E-mode) - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 40-494 E-1 Engine does not start (Engine does not crank) - - - - - - - - - - - - - - - - - - - - - - - - - - - - 40-494 E-2 Manual preheating system does not work - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 40-500 E-3 Automatic preheating system does not work - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 40-503 E-4 While preheating is working, preheating monitor does not light up- - - - - - - - - - - - - - - 40-505 E-5 When starting switch is turned to ON position, machine monitor displays nothing - - - - 40-507 E-6 When starting switch is turned to ON position (with engine stopped), basic check monitor lights up - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 40-510 E-7 Air cleaner clogging monitor lights up in yellow while engine is running - - - - - - - - - - - 40-511 E-8 Charge level monitor lights up in red while engine is running - - - - - - - - - - - - - - - - - - 40-512 E-9 Engine coolant temperature monitor lights up in red while engine is running - - - - - - - 40-513 E-10 Engine oil pressure monitor lights up in red while engine is running- - - - - - - - - - - - - 40-514 E-11 HST charge pressure monitor lights up in red while engine is running - - - - - - - - - - - 40-515 E-12 Hydraulic oil temperature monitor lights up in red while engine is running - - - - - - - - 40-516 E-13 HST oil filter clogging monitor lights up in red while engine is running - - - - - - - - - - - 40-517 E-14 Fuel level gauge does not indicate correct level- - - - - - - - - - - - - - - - - - - - - - - - - - - 40-518 E-15 Engine coolant temperature gauge does not indicate correct temperature - - - - - - - - 40-521 E-16 Hydraulic oil temperature gauge does not indicate correct temperature - - - - - - - - - - 40-522 E-17 Operation mode does not change - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 40-523 E-18 Service mode cannot be selected- - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 40-524 E-19 Operating customize switch does not display customize screen - - - - - - - - - - - - - - - 40-525 E-20 Modifying setting on customize screen does not change setting of machine - - - - - - - 40-526 E-21 Service meter is not displayed, while starting switch is in OFF position - - - - - - - - - - 40-527 E-22 Work equipment does not operate - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 40-528 E-23 Foot heater does not operate- - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 40-530 E-24 Horn does not sound- - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 40-535 E-25 Horn does not stop sounding - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 40-537 E-26 Backup alarm does not sound - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 40-538 E-27 Backup alarm does not stop sounding - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 40-539 E-28 Headlamp does not light up - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 40-540 E-29 Rear lamp does not light up - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 40-543 E-30 No wiper operates continuously or intermittently - - - - - - - - - - - - - - - - - - - - - - - - - - 40-546 E-31 Front wiper does not operate - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 40-548 E-32 Rear wiper does not operate - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 40-550 E-33 Left door wiper does not operate (failed in both continuous and intermittent operations) 40-552 E-34 Right door wiper does not operate (failed in both continuous and intermittent operations)- 40-556 E-35 Front washer does not operate - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 40-560 E-36 Rear washer does not operate - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 40-562 40-6

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40 Troubleshooting Table of contents

E-37 Left door washer does not operate - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 40-564 E-38 Right door washer does not operate - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 40-566 E-39 KOMTRAX system does not operate normally - - - - - - - - - - - - - - - - - - - - - - - - - - - - 40-568 Troubleshooting of hydraulic and mechanical system (H-mode) - - - - - - - - - - - - - - - - - - - - - - - 40-570 Information described in troubleshooting table (H-mode) - - - - - - - - - - - - - - - - - - - - - - - - 40-570 Failure mode and cause table - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 40-571 H-1 Neither RH nor LH of tracks does not travel forward nor reverse (None of the travel system operates) - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 40-574 H-2 Either RH or LH of track does not travel forward nor reverse (Only RH or LH of travel system operates) - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 40-576 H-3 Either RH or LH of track travel only forward or reverse (Only forward or reverse of RH or LH of travel system does not operate) - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 40-577 H-4 Travel speed or power is low - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 40-579 H-5 Shock is large when machine starts or stops - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 40-580 H-6 Machine deviates largely - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 40-581 H-7 Machine drift on a slope is large - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 40-583 H-8 Engine stalls during travel or engine speed drops significantly - - - - - - - - - - - - - - - - - 40-584 H-9 Unusual noise is heard from around HST pump or motor - - - - - - - - - - - - - - - - - - - - - 40-586 H-10 All work equipment do not operate - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 40-587 H-11 All work equipment operates slowly or lacks power - - - - - - - - - - - - - - - - - - - - - - - - 40-589 H-12 Front work equipment lift speed or power is low - - - - - - - - - - - - - - - - - - - - - - - - - - - 40-590 H-13 Front work equipment side swing speed or power is low - - - - - - - - - - - - - - - - - - - - - 40-591 H-14 Hydraulic drift of lifted front work equipment is large - - - - - - - - - - - - - - - - - - - - - - - - 40-592 H-15 Unusual noise is heard from around work equipment pump or control valve - - - - - - - 40-593 H-16 HST oil temperature (hydraulic oil temperature) rises too high- - - - - - - - - - - - - - - - - 40-594 H-17 Fan speed is abnormal (high, low, or no rotation) - - - - - - - - - - - - - - - - - - - - - - - - - - 40-596 H-18 Unusual noise is heard from around fan - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 40-598 Troubleshooting of engine (S-mode) - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 40-599 Method of using troubleshooting charts - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 40-599 S-1 Starting performance is poor - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 40-603 S-2 Engine does not start - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 40-604 S-3 Engine does not pick up smoothly - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 40-607 S-4 Engine stops during operations - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 40-608 S-5 Engine does not rotate smoothly - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 40-609 S-6 Engine lacks output (or lacks power)- - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 40-610 S-7 Exhaust smoke is black (incomplete combustion)- - - - - - - - - - - - - - - - - - - - - - - - - - - 40-611 S-8 Oil consumption is excessive (or exhaust smoke is blue) - - - - - - - - - - - - - - - - - - - - - 40-612 S-9 Oil becomes contaminated quickly - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 40-613 S-10 Fuel consumption is excessive - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 40-614 S-11 Oil is in coolant (or coolant spurts back or coolant level goes down) - - - - - - - - - - - - - 40-615 S-12 Oil pressure drops - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 40-616 S-13 Oil level rises (Entry of coolant or fuel) - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 40-617 S-14 Coolant temperature becomes too high (overheating)- - - - - - - - - - - - - - - - - - - - - - - 40-618 S-15 Abnormal noise is made - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 40-619 S-16 Vibration is excessive - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 40-620

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Related information on troubleshooting

Troubleshooting points

1 (Rev. 2012/11)

k Place the machine on a level ground, and make sure that the frame lock bar, chocks, and parking

brake are applied. k When performing the operation with two or more service technicians, keep strictly to the agreed

signals, and do not allow any unauthorized person to come near. k If the radiator cap is removed when the engine is hot, hot water may spurt out and cause burns, so

wait for the engine to cool down before starting troubleshooting. k Be extremely careful not to touch any hot parts or to get caught in any rotating parts. k Before disconnecting wiring, remove the key and turn the battery disconnect switch to OFF

position. k When removing the plug or cap from a component which is under pressure of oil, water, or air,

always release the internal pressure first. When installing measuring equipment, be sure to connect it properly. k Drain approximately 10l l of coolant beforehand, because you may get scalded by hot water

spurting out from mounting location of coolant temperature sensor when removing radiator cap during checking and replacing coolant temperature sensor. k When performing checking and replacement of engine oil pressure sensor (switch), open oil filler

port, and check that engine oil temperature cools down enough not to get scalded. k Loosen the oil filler cap of the hydraulic tank to release the pressure in the hydraulic tank. For

details, see Testing and adjusting "Releasing remaining pressure in hydraulic circuit" when checking and replacing oil temperature sensor and oil pressure sensor. Check the code with monitoring function and display the hydraulic oil temperature, then check that the temperature is 40°C or lower and cool enough not to burn. Troubleshooting denotes to locate the primary cause, fix the trouble without delay and prevent its recurrence. Despite the importance of understanding the structure and operation of the target system in troubleshooting, you should be aware how interviewing with the operator concerned can facilitate in roughly identifying the cause of the given undesirable symptom. 1. When performing troubleshooting, do not hurry to disassemble the components. If components are disassembled immediately after any failure occurs: • Parts that have no connection with the failure or other unnecessary parts will be disassembled. • It will become impossible to find the cause of the failure. It will also cause a waste of manhours, parts, or oil or grease, and at the same time, will also lose the confidence of the user or operator. For this reason, when performing troubleshooting, it is necessary to perform thorough prior investigation and to perform troubleshooting in accordance with the fixed procedure. 2. Points to ask the user or operator 1) Have any other problems occurred apart from the problem that has been reported? 2) Was there anything strange about the machine before the failure occurred? 3) Did the failure occur suddenly, or were there problems with the machine condition before the failure? 4) Under what conditions did the failure occur? 5) Had any repairs been performed before the failure? When were these repairs performed? 6) Has the same kind of failure occurred before? 3. Check before troubleshooting 1) Is there any sign of irregularities of the machine? 2) Make checks before starting day's work. 40-8

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Related information on troubleshooting

3) Make checks of other items. 4) Check other maintenance matters which can be checked externally and are considered to be necessary. 4. Checking failure Check the extent of the failure by yourself, and judge whether it is a real failure or a problem with the method of operation, etc. a When operating the machine to reenact the troubleshooting symptoms, do not perform any inspection or measurement that may make the problem worse. 5. Troubleshooting Use the results of the investigation and inspection in Items 2 to 4 to narrow down the probable causes of the failure, then use the troubleshooting flowchart to locate the failure exactly. a The basic procedure for troubleshooting is as follows. 1) Start from the simple points. 2) Start from the most likely points. 3) Investigate other related parts or information. 6. Measures to remove root cause of failure Fixing a trouble in hand does not necessarily prevents its recurrence unless the primary cause is eliminated. To that end, you must locate and eliminate the primary cause behind the given failure.

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Related information on troubleshooting

Sequence of events in troubleshooting

1 (Rev. 2011. 7)

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Related information on troubleshooting

D61EM-23M0

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Related information on troubleshooting

Checks before troubleshooting

a: Engine, lubricating oil, and coolant

NItem o. 1 Check of unusual noise and smell 2 Check of engine for dirt 3 Check of engine for water leakage 4 Check of engine for oil leakage

Criteria

Remedy

Repair Remove Repair Repair

5 Check of fuel line for leakage

Repair

6 Check of radiator for clogging 7 Check of fuel level and type 8 Check of foreign material in fuel 9 Check of fuel pre-filter 10 Check of fuel main filter

Between H and L Between H and L No clogging indication on monitor Between H and L Between H and L

Remove Refilling with fuel Clean and drain Replace Replace

Air bleeding

11 Check of engine oil level (in oil pan) and type 12 Check of coolant level (in sub tank)

c: Electrical equipment

b: Hydraulic and mechanical equipment

13 Check of air cleaner for clogging 1 Check of unusual noise and smell 2 Check for oil leakage 3 Check of hydraulic oil 4 Check of hydraulic oil strainer and hydraulic oil filter 5 Check of hydraulic oil filter 6 Check of final drive case oil level

7 Performing air bleeding operation

Check of battery terminals for looseness and corrosion

Check of alternator terminals for looseness and corrosion

Check of starting motor terminals for looseness and corrosion

Check of battery voltage (with engine stopped)

Check of battery electrolyte level

6 7 8 9

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Check of wiring harness for discoloration, burnt areas and cover peeling Check for coming off of wiring harness clamp and sagging of wiring harness Check of grounding Check for loose connector and damaged lock

Refilling with oil Refilling with coolant Clean or replace Repair Repair Refilling with oil Clean and drain Replace Refilling with oil

Retighten or replace Retighten or replace Retighten or replace

20 to 30 V Between H and L

Charge or replace

Repair or replace

Repair

Repair Repair or replace

Add or replace

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Related information on troubleshooting

10 Check of connector pin for corrosion, bends and deformation

11 Check for water and foreign matter in connector

12 Check of wiring harness for open or short circuit 13 Check of fuse for breakage and corrosion

27.5 to 29.5 V after few minutes operation

e: Interior parts

d: Exterior parts

Check of alternator voltage (when engine speed is medium or 14 higher) Check of battery relay operation sound (when starting switch is 15 turned to ON or OFF position) 1 Check of undercarriage

Repair or replace Dry, clean or replace Repair or replace Replace

Replace

Repair

Check of handrails and steps

Repair

Check of gauges and monitors

Clean or replace

Check of seat belt

Repair

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Inspection procedure before troubleshooting Walk-around check

(D65-5150-289-A-00-A)

Before starting the engine, look around and under the machine to check for any loose nuts or bolts, leakages of oil, fuel or coolant, and check the condition of the work equipment and hydraulic system. Check the connectors for looseness, the wiring harnesses for play, and the hot parts for accumulated dust. k Accumulated combustibles around hot

engine parts such as the engine, muffler, and turbocharger, etc. and fuel or oil leakages may cause a machine fire. Be sure to check thoroughly and repair any failures. a1. and b1. Check for unusual sounds and smells Check for unusual sounds and smells. Some causes of unusual sounds and smells can damage the machine if they are left as they are. Therefore, stop the machine immediately when you find any unusual sounds and smells. a2. Check around engine and dirt removal Check and remove any accumulated dirt around the engine and any combustibles (dead leaves, twigs, etc.) on hot engine parts such as the muffler, turbocharger, etc. a3. Check for water leakage around muffler a4. Check for oil leakage around engine Check any oil leaks from the engine and any water leaks from the coolant system. If any of them is unusual, perform a repair. a5. Check for leakage from fuel line

b3. Check of hydraulic equipment, hydraulic tank, hoses and joints for oil leakage Check and repair any oil leaks. c1. Check around battery and dirt removal Check and remove any accumulated dirt and combustibles (dead leaves, twigs, etc.) around the battery. d1. Check of undercarriage (tracks, sprockets, idlers and guards) for defect, wear, loose bolts and oil leakage from roller Repair any unusual parts. d2. Check of handrails and steps for unusual conditions and loose bolts Repair any unusual conditions and retighten any loose bolts. d3. Check and cleaning of rear view mirrors Check and repair any unusual conditions and breakage of the rear view mirrors. Clean the mirror surfaces and adjust their angles so that the operator can see the area behind him at the operator's seat. e1. Check of gauges and monitors for unusual conditions Check the gauges and monitors inside the operator cab. If any of them is unusual, replace it. Clean up the surfaces. e2. Check of seat belt and mounting hardware Check the hooks, locks and hook fittings for damage. If any of them has a problem, repair the damage.

Check the hoses and tubes for any fuel leaks and damages. If any of them is abnormal, perform a repair. a6. Check of radiator and dirt removal Check and remove any accumulated dirt and combustibles (dead leaves, twigs, etc.) around the radiator. For removal of dirt from the radiator, see the Operation and Maintenance Manual, "Cleaning and testing of radiator fins, oil cooler fins, aftercooler fins, fuel cooler fins and air conditioner condenser fins (machine with the air conditioner)". b2. Check of work equipment, cylinders, linkage and hoses for breakage, wear and clearance Check the work equipment, cylinders, linkage and hoses for cracks and excessive wear, check that each clearance is within the normal range, and then repair any unusual parts.

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Testing in accordance with testing procedure a: Engine, lubricating oil, and coolant a7. Check of fuel level and type k Fuel is highly flammable and dangerous.

Never bring flames near fuel.

(D61-5150-280-A-00-A)

3. Turn drain valve (2) to "Open" position O to drain all the sediment and water accumulated at the bottom together with fuel. 4. When clean fuel flows out, set drain valve (2) to "Close" position C. 5. Close fuel tank inspection cover.

k When adding fuel, never spill it or let it

overflow. k Wipe off any spilled fuel. If fuel spills over

soil or sand, remove all the fuel and soil or sand together. 1. Turn the engine starting switch to ON position and check fuel level with fuel gauge G on monitor panel. After checking, turn the switch back to the OFF position.

a9. Check of fuel pre-filter (water separator) k Immediately after the engine is stopped, its

parts and oil are still very hot, and may cause burn injury. Accordingly, wait until all parts have cooled down before starting the work. k High pressure is generated inside the engine

2. If fuel level is low, open fuel filler cap F of fuel tank, and add fuel through filler port to the level enough for checking. • Clean filter of breather (1) since its clogging can reduce pressure in tank, and blocks supply of fuel.

fuel piping system when the engine is running. Stop the engine and wait at least 30 seconds until the inner pressure is released and then replace the filter. k Never bring flames near fuel.

a A special filter with high-efficiency filtering properties is adopted for Komatsu genuine fuel pre-filter cartridges. Be sure to use Komatsu genuine parts when replacing. a The common rail fuel injection system used on this machine consists of more precise parts than those in the conventional injection pump and nozzles. If any cartridge other than a Komatsu genuine fuel pre-filter cartridge is used, foreign materials may enter and problem may occur in the injection system. Do no use substitute parts.

a8. Check of foreign material in fuel 1. Open fuel tank inspection cover on the right side of machine. 2. Prepare a container below drain hose (1) to receive the fuel.

D61EM-23M0

a During testing or maintenance of the fuel system, take extreme care not to allow any foreign material to enter the fuel system. If any dust or other material sticks to any part, wash the part thoroughly with clean fuel. • Prepare a container to receive drained oil. • Prepare a filter wrench. 1. Set supply valve (1) of the fuel tank to "Close" position C.

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a After adding fuel, remove cap (B) and install the fuel filter. a Always fill with clean fuel. Be careful not to let any dirt or dust get into the fuel. In particular, center portion is the clean side, so do not remove cap (B) when adding fuel. Be careful not to let dirt or dust get into the center clean side part.

2. Open L.H. engine side cover. a Check that the drain plug on the bottom of the transparent cup is tightened securely. 3. Pull drain hose (2) to your side, and place a container under the hose to receive fuel. 4. Loosen drain valve (3) to drain water and sediments in transparent cap (4) and also drain all the fuel in filter cartridge (5). 5. Remove connector (6) of water separator. Wrap the removed connector with a plastic bag to protect it from fuel, oil and water. 6. Using the filter wrench, turn transparent cap (4) counterclockwise to remove it. (If damaged, replace it with a new one.) 7. By using the filter wrench, turn filter cartridge (5) counterclockwise to remove it.

10.When installing the cartridge, tighten it until the packing surface contacts the sealing surface of the filter holder, then tighten it 3/4 of a turn. If the filter cartridge is fastened too much, the packing will be damaged and this leads to leakage of fuel. If the filter cartridge is too loose, fuel will also leak from gaps of the packing. Therefore, be sure to observe the fastening angle. • When tightening the filter cartridge with a filter wrench, be careful not to dent or damage the filter. 11.Remove the plastic bag wrapping connector (6), then connect connector (6). 12.Set fuel supply valve (1) to "Open" position (O). 13.Then proceed to "a10. Check of fuel filter." a10. Check of fuel filter k Immediately after the engine is stopped, its

8. When installing the transparent cap, apply thin film of clean fuel to O-ring, contact it to the sealing surface of filter cartridge (5), and then tighten it by 1/4 to 1/2 turn. If the transparent cap is fastened too much, the O-ring will be damaged and this leads to leakage of fuel. If it is too loose, fuel will also leak from gaps of the O-ring. Therefore, be sure to observe the fastening angle. 9. Clean the filter bracket, fill the filter cartridge with clean fuel, apply thin film of oil to the packing surface, then install it to the filter bracket. a When adding fuel, do not remove cap (B) at the center. Always fill the fuel from the dirty side of eight small holes (A). 40-16

parts and oil are still very hot, and may cause burn injury. Accordingly, wait until all parts have cooled down before starting the work. k High pressure is generated inside the engine

fuel piping system when the engine is running. Stop the engine and wait at least 30 seconds until the inner pressure is released and then replace the filter . k Never bring flames near fuel.

a A special filter with high-efficiency filtering properties is adopted for Komatsu genuine fuel filter cartridges. Be sure to use Komatsu genuine parts when replacing.

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a The common rail fuel injection system used on this machine consists of more precise parts than those in the conventional injection pump and nozzles. If any cartridge other than a Komatsu genuine fuel filter cartridge is used, foreign material may enter and it may cause problems in the injection system. Do no use substitute parts. a During testing or maintenance of the fuel system, take extreme care not to allow any foreign material to enter the fuel system. If any dust or other material sticks to any part, wash the part thoroughly with clean fuel. • Prepare a container to receive drained oil. • Prepare a filter wrench. 1. Set supply valve (1) of the fuel tank to "Close" position C.

6. Install the filter cartridge. a When installing the filter cartridge, tighten it by 3/4 turns after the O-ring came in touch with the sealing surface of filter bracket. a If the filter cartridge is fastened too much, the O-ring will be damaged and this leads to leakage of fuel. If the filter cartridge is too loose, fuel will also leak from gaps of the packing. Therefore, be sure to observe the fastening angle. 7. Set supply valve (1) at the bottom of the fuel tank to "Open" position O. 8. Bleed air from the fuel line. For details, see Testing and adjusting, "Bleeding air from fuel circuit". a11. Check of engine oil level (in oil pan) and type

2. Open the side cover and remove the mudguard cover. 3. By using the filter wrench, turn filter cartridge (2) counterclockwise to remove it.

k Immediately after the engine is stopped, its

parts and oil are still very hot, and may cause burn injury. Accordingly, wait until all parts have cooled down before starting the work. a When checking the oil level after the engine has been operated, wait for at least 15 minutes after stopping the engine. a If the machine is at an angle, make it level before checking. 1. Stop the engine. 2. Open L.H. engine side cover. 3. Pull out dipstick G and wipe the oil off with a cloth. 4. Fully insert dipstick G into the dipstick pipe and pull it out.

4. Clean the filter bracket and apply a thin film of oil to the packing surface of the filter cartridge. a Do not fill the filter cartridge with fuel. 5. Remove cap B in the center, and then install it to the filter bracket.

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5. Check the oil level using the side with the stamped mark "ENGINE STOPPED" of the dipstick G. The level is appropriate if it is between the marking H and L. f the oil level is below L mark, add oil through oil filler port F.

a12. Check of coolant level (in sub tank) k The radiator cap does not need to be opened

for standard checks. When checking the coolant level, check it in the sub-tank when the engine is cooled down. k Immediately after the engine is stopped, the

coolant is still very hot and the pressure is accumulated in the radiator. If the cap is opened under these conditions, you may be scalded. If you need to remove the radiator cap, wait until the temperature drops before you do. Then turn the cap slowly to release the pressure and remove it with care.

6. When the oil level is above H mark: 1) Remove cover (1) in the front lower side and place a container for drained oil right below it.

1. Open the hydraulic oil inspection cover on the left side of machine and check that coolant level is between the FULL and LOW marks of reservoir tank (1). 2. If the reservoir tank is empty, leakage of coolant is suspected. If any abnormality is found in the check for leakage, repair it immediately. If no abnormality is found, check the level of the coolant in the radiator. If it is low, add coolant through radiator filler port (2). 3. Add coolant to the reservoir tank through the filler port up to the FULL level.

2) Take a hose out. 3) Loosen drain plug P gradually to drain oil, be careful not to get splashed with drained oil. 4) Check the oil level again.

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a Inspection, cleaning or servicing while the engine is running allows entry of dusts and can damage the engine since dusts attached to the element drop into the inner cylinder element more frequently during the cleaning process. Be sure to stop the engine before cleaning. Cleaning of outer element a Before and after cleaning, be careful not to leave or store the element being exposed to the direct sunlight.

a.13 Check of air cleaner for clogging k When using compressed air for cleaning, put

on personal protective items such as protective eyeglasses, gloves, dust mask, etc. to protect yourself from dirt that will fly out. k When removing the outer element from the

air cleaner body, do not forcibly pull it out, otherwise it can be dangerous. Be careful not to fall from a high location on unsafe scaffolding as a reaction when pulling out the outer element.

a Replace the outer element after you have cleaned six times or it has been used for a year. When replacing it, replace the inner element at the same time, too. a Even when the number of cleanings of the outer element is less than six times, it must be replaced along with the inner element if dust indicator (1) indicates the red zone immediately after cleaning. 1. Open the door on the left side of the engine and disengage hook (2) at six positions to remove cover (3).

Testing If the internal yellow piston is overlapped with the outer red zone (A) of dust indicator (1), clean the air cleaner element. After the cleaning, press the reset button to release the cleaning.

2. When removing outer element (4), hold it and pull it out while gently moving it up and down, right and left. a Be sure not to remove inner element (5). Removing the inner element allows entry of dusts, leading to failure of the engine. a Do not use tools like a screwdriver. a Do not clean the element until the yellow piston of dust indicator (1) overlaps with the outer red zone A. If you clean the element frequently before the yellow piston of dust indicator (1) overlaps with the outer red zone A, the air cleaner will not deliver optimum performance and the cleaning efficiency will be reduced.

D61EM-23M0

a After removing outer element (4), check the inner element for disengagement and tilting. If tilted, push it back fully with your hands. 3. After removing outer element (4), cover inner element (5) with a clean cloth or tape to protect from dusts. 4. Clean dusts in inside and on cover (3) of air cleaner body (6) using a clean cloth or brush. a Do not hit the element or bump it against nearby things when cleaning it.

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a Do not use the element if its folds or gasket or seal are damaged. 9. Push the outer element straight backward into the air cleaner body with your hands while moving it up and down, right and left. a When installing the air cleaner elements, set it in such that their cylinder bottoms (side without a hole) B and C come to cover (3) side. Installing them in an opposite direction can induce serious troubles including damage on the air cleaner elements and engine. 5. Blow dry compressed air (Max. 196 kPa {Max. 2 kg/cm2}) from the inside of the outer element along the folds. 6. Then blow it from outside along the folds, and finally blow it from the inside again.

10.Install cover (3) according to the following procedure. 1) Align cover (3) with the element.

a After clearing the element, throw light on its inside using a light bulb to check it. If it has a small hole or thin part, replace it.

2) Lock the tip of hook (2) on the protrusion of the air cleaner body. a Lock the tip of hooks (2) diagonally (top and bottom, and right and left). 7. Remove the cover of cloth or tape attached to inner element (6). 8. Check the seal of the cleaned or new element for adhesion of dusts and oil and wipe them of, if any.

a After installing cover (3), check presence of clearance between the air cleaner body and cover (3). If any, install the cover again.

a Do not use an element or O-ring that has been in service for a year since trying to use them after cleaning most probably induces troubles. 40-20

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Replacement of element 1. Referring to "Cleaning of outer element", remove outer element (4). 2. Remove inner element (5), and immediately install inner element (5) to air cleaner body (6). a Do not clean or reuse the inner element. Replace the inner element with a new one when replacing the outer element.

a When installing the air cleaner element, set it in such that its cylinder bottom (side without a hole) B comes to cover (3) side. Installing it in an opposite direction can induce serious troubles including damage on the air cleaner elements and engine. a If the outer element and cover are installed when the inner element is securely installed, the outer element can be damaged. Be sure to install it securely.

3. Push the outer element straight backward into the air cleaner body with your hands while moving it up and down, right and left. a When installing the air cleaner element, set it in such that its cylinder bottom (side without a hole) C comes to cover (3) side. Installing it in an opposite direction can induce serious troubles including damage on the air cleaner elements and engine. 4. Replace O-ring (7) of cover (3) with a new one.

5. Referring to "Cleaning of outer element", install cover (3). 6. Replace the seal of cover (3) with a new one. b. Hydraulic and mechanical equipment b3. Check of hydraulic oil level k Immediately after the engine is stopped, its

parts and oil are still very hot, and may cause burn injury. Accordingly, wait until all parts have cooled down before starting the work. k When removing the oil filler cap, the oil may

spout out. Turn it slowly to release the internal pressure, then remove it. 1. Lower the work equipment to the ground completely, stop the engine. Check oil level and refill it. 2. Turn the starting switch to ON position within 15 seconds from the engine stop and operate control levers (work equipment and travel) to the D61EM-23M0

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travel end in each direction to release internal pressure. 3. Check the oil level through sight gauge G on the left side of the machine. The oil level is normal if it is between H and L marks of sight gauge G.

2. Release inner pressure by turning gradually the cap of oil filler port (F) at the top of the hydraulic oil tank, the remove the cap.

a If the oil level is below the L mark, add oil through oil filler port F. a Do not add oil above the H mark since it can damage the hydraulic circuit or allow spurt of oil.

3. Remove bolt (1) and open the rear mask.

4. Bring out drain hose (2). 5. Loosen drain valve (P) to drain oil. After draining oil, tighten drain valve (P).

Since the oil level varies according to the oil temperature, use the followings as a guide. • Between of H and L before start of operation (oil temperature 10 to 30°C) • In vicinity of H level after operation is started (oil temperature 50 to 80°C) b4. Check of hydraulic oil strainer and hydraulic oil filter k Immediately after the engine is stopped, its

parts and oil are still very hot, and may cause burn injury. Accordingly, wait until all parts have cooled down before starting the work. k When you remove the oil filler cap, oil may

spurt out. Be careful to rotate it slowly, and release inner pressure gradually. 1. Lower the work equipment to the ground, and stop the engine.

40-22

6. Open the hydraulic oil tank inspection cover on the left side the machine and remove bolt (3). 7. Loosen the clamp of hose (4), and slide flange (5) and the hose as a unit toward front side of the machine. 8. Bend hose (4) to your side to remove flange (5) from the hose and then remove hose (4) from the piping.

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Related information on troubleshooting

and threads of the filter cartridge with oil (or apply a thin film of grease), then install it. 16.When installing the filter cartridge, tighten it until the packing surface contacts the sealing surface of the filter bracket, then tighten it 2/3 of a turn. Be sure to use the Komatsu genuine cartridge. 17.By using the filter wrench, turn HST oil filter cartridge (11) counterclockwise to remove it.

9. Remove bolt (6) and remove strainer (7). 10.Remove all dirt from strainer (7), then wash it in clean diesel oil or flushing oil. 11.Assemble strainer (7) and tighten it with bolt (6). At this time, replace O-ring (8) (on the strainer side) with a new one and install it. 12.Install hose (4) to the piping and install flange (5) to it. 13.Tighten flange (5) using bolt (3) and tighten the clamp (on both sides) of hose (4). At this point, replace O-ring (9) (on the strainer side) with a new one and install it.

14.Prepare a container for receiving oil below the filter. Then, by using the filter wrench, turn the hydraulic oil filter (return filter) (10) counterclockwise to remove it.

18.Clean the filter bracket, fill the new filter cartridge with clean oil, coat the sealing surface and threads of the filter cartridge with oil (or apply a thin film of grease), then install it. 19.When installing the filter cartridge, tighten it until the packing surface contacts the sealing surface of the filter bracket, then tighten it 2/3 of a turn. Be sure to use the Komatsu genuine cartridge. 20.Add oil through oil filler port (F). 21.After adding oil, make sure the oil level is appropriate referring to "Check of hydraulic oil level". 22.After replacing the hydraulic oil and filter element and cleaning the strainer, bleed air in the circuit. b5. Check of final drive case oil level k Since oil is heated high immediately after the

move, wait until it is cooled before starting your work. 1. Set the TOP mark at the top, and the line running on TOP mark and plug (P) perpendicular to the ground. 2. Remove plug (F) by using a handle. Make sure oil level reaches the bottom end of the plug hole. 3. If the oil is insufficient, add oil through plug (F) hole. 4. After the inspection, install plug (F). 3 Plug F: 58.8 to 78.4 Nm { 6 to 8 kgm }

15.Clean the filter bracket, fill the new filter cartridge with clean oil, coat the sealing surface D61EM-23M0

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c3. Check of starting motor terminal for looseness and corrosion • Check starting motor terminal B (T1) and connector (T4) for open circuit, looseness, or corrosion.

b6. Bleeding air • For the bleeding air from the fuel system, see Testing and adjusting, "Bleeding air from fuel circuit". • For bleeding air from the hydraulic system, see Testing and adjusting, "Bleeding air from hydraulic circuit". c. Electric equipment c1. Check of battery terminal for looseness and corrosion 1. Open the battery cover. 2. Check the battery cable terminals for looseness and corrosion. c2. Check of alternator terminal for looseness and corrosion • Open the right engine hood. • Check alternator terminals B (T15), ground (T17) and R (T16) for open circuit, loosening and corrosion.

c4. Check of battery voltage (with engine stopped) Check the battery voltage by using the battery tester while the engine is stopped. c5. Check of battery electrolyte level Check before operating the machine. k Do not use the battery if the battery

electrolyte level is below the LOWER LEVEL line. This will accelerate deterioration of the inside of the battery and reduce the service life of the battery. In addition, it may cause an explosion. k Since the battery produces combustible gas

that can explode, do not bring any open flame near it. k Battery electrolyte is dangerous. Take care

that it does not come in contact with your eyes or skin. If it does, wash it away with water and contact your doctor. a Do not add the battery fluid above the UPPER LEVEL line. If done, the fluid may leak and the coating surface may be damaged or the parts may be corroded.

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a To avoid freezing, add the purified water (such as a commercial battery fluid) before starting the work in the next day. • When checking the electrolyte level through the side face of the battery 1. Wipe and clean the battery surface, especially around the battery level lines with a wet cloth, and check to see that the battery fluid is between the UPPER LEVEL and LOWER LEVEL lines. a Do not clean the battery with a dry cloth since static electricity may cause an explosion.

a If the fluid exceeds the UPPER LEVEL, remove the fluid using a dropping pipette or others until the fluid drops to the UPPER LEVEL. When you have removed the fluid from the battery, neutralize it with the baking soda (sodium bicarbonate) and wash it away with a large quantity of water. c6. Check of wiring harness for discoloration, burn and cover peeling • Check the wiring harness and cables for discoloration and burn.

2. If the battery fluid drops below the center position between the upper level (U.L.) and lower level (L.L.) lines, remove cap (2) and add fluid (such as a commercial battery fluid) immediately until the fluid reaches the upper level (U.L.). 3. After adding the refined water, tighten the cap securely. a If the fluid exceeds the UPPER LEVEL, remove the fluid using a dropping pipette or others until the fluid drops to the UPPER LEVEL. When you have removed the fluid from the battery, neutralize it with the baking soda (sodium bicarbonate) and wash it away with a large quantity of water. • When electrolyte level cannot be checked through the side face of the battery 1. Remove the cap from the top of battery. (As mentioned before) 2. Observe fluid level port (3), and check the fluid level. If the fluid level is below sleeve (4), always add the fluid (such as a commercial battery fluid) until it reaches the bottom of sleeve (the UPPER LEVEL). • (A) Correct level: Since the electrolyte level reaches to the sleeve bottom, the shape of the electrode plates will appear distorted due to the surface tension. • (B) Low: Since the electrolyte level does not reach the sleeve bottom, the shape of the electrode plates will appear straight. 3. After adding the refined water, tighten the cap. D61EM-23M0

a If discolored or burnt, the circuit may be shorted or grounded. • Check the wiring harnesses and cables for damage and peeling of the covers. • If any abnormality is found, repair or replace the wiring harness or cables. c7. Check for coming off of wiring harness clamp and sagging of wiring harness • Check wiring harness for sagging and looseness due to coming off of harness clamp a In particular, carefully check the wiring harness around the hot and movable parts. • If removed from the clamp, secure it with the clamp.

c8. Check of grounding a Take special care not to cause a loose cable connection and corrosion. • Open left engine hood. 40-25

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• Check the connection of ground strap (1) of the engine.

• Cab ground a Back side of cab left ladder • Check connection of ground (4).

• Check connection of ground terminal (T20B). • Remove the bottom monitor cover. • Check connection of ground (T36).

• Check the connection of ground terminals (3) of the engine controller. • Remove the floor mat. • Remove the inspection cover (on the cab floor). • Check connection of ground (T35).

• Open the right engine hood. • Check connection of ground (T126).

a Reference (GND7 and GND6 are not visible until the cab is removed.) • Open the right side cover. • (GND7) is provided in the back side of section P.

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c9. Check for loose connector and damaged lock. • Check the connection of male and female connectors by pulling them by hand. • If the connection is loose, secure it.

• Open the left side cover. • (GND6) is provided in the back side of section Q. • Check connection of (GND8) from section R. • Check the connectors for unlocking, and check the lock and connector housing for cracking. • Check lock screws (L1) and (L2) of engine controller for looseness. a Use a hexagonal wrench with 4 mm width across flats. 3 Lock screw: 3 ± 1 Nm {0.3 ± 0.1 kgm}

• Check lock screw (L3) of HST controller for looseness. a Use a hexagonal wrench with 4 mm width across flats.

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3 Lock screw: 3 ± 1 Nm {0.3 ± 0.1 kgm}

c10. Check the connector pins for corrosion, bending and deformation.

• Wipe and remove any foreign material with a cloth or others, and blow the air to clean the connector.

• Disconnect the connectors, and check their pins for corrosion, bending, sinking than other pins, and extension of female pins. • If pins are defective, repair or replace them. a If the pins are not shiny, apply contact restorer to them and connect and disconnect the connectors several times to shine them. (If the pins do not become shiny, connect and disconnect the connectors 10 times) c11. Check of connector for water and foreign material insertion. • Disconnect the connector and check it for intrusion of water, dirt or dusts.

c12. Check of wiring harness for open or short circuit • Check the connection (crimped part) between connector pins and wiring harness. • If the line is open as shown as (A), repair or replace the wiring harness or cables.

a If found, the seals may be damaged. Check the seals for damage. • If the seal is defective, repair or replace it. • Dry the inside of the connector with a dryer.

• Visually check wiring harnesses for peeling of harness covers and the pins for contact with adjacent pins due to defective crimping. c13. Check of fuse for breakage and corrosion a When replacing a fuse, be sure to turn off the power (turn the starting switch to OFF position) and turn the battery disconnect switch to OFF position.

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• A fusible link is a large-capacity fuse. • If a fuse is corroded and coated with white powder, or there is any play between the fuse and fuse holder, replace the fuse. • Replace each fuse with the one of the same capacity. • Open the left side cover and you will see fuse box (5) and the fusible link in section S.

• Open the engine hood right cover. • Two fusible links (120A) are provided in section T.

• Open cover (6). a Descriptions of each fuse are provided on the back face of cover (6).

• Fusible links (120A) and (50A) provided in section S.

• Fuse box (7) contains the fuses exclusively use for the wipers, radio, etc.

D61EM-23M0

c14. Check of alternator voltage (when engine speed is medium or higher) 1. Open the engine hood. 2. Connect the positive (+) lead of the multimeter to alternator terminal (B) and connect the negative (-) lead to the chassis ground. 3. Start and warm up the engine and measure the voltage while running the engine at a medium or a higher speed. • If the voltage is abnormal, repair or replace the alternator. c15. Check of battery relay operation sound 1. Open the battery cover. 2. Turn the starting switch to the ON and OFF positions, and check whether the battery relay operation sound is heard or not. 40-29

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• If the operation sound is not heard, check the related circuits, referring to the description of troubleshooting for E-1 described in the E mode troubleshooting. • If the relating circuit is normal, replace the battery relay.

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Preparation for troubleshooting of electrical system

a When performing troubleshooting of electric circuits of HST controller, engine controller, machine monitor and KOMTRAX terminal, expose the applicable connector portion according to the following procedure. a For connectors whose lock method is special, perform disconnection and connection. Preparation 1. HST controller 1) Remove operator's seat. 2) Remove cover (1). 3) Disconnect machine monitor (5) connectors CM01, CM02 and CM04, and connect or insert T-adapter for troubleshooting to them.

3) Disconnect connectors ST1, ST2 and ST3 of HST controller (2), and insert or connect Tadapter for troubleshooting. a Use a hexagonal wrench with 4 mm width across flats for lock screw (L3). 3 Lock screw: 3 ± 1 Nm {0.3 ± 0.1 kgm}

2. Machine monitor and KOMTRAX terminal 1) Remove cover (4). 2) Remove machine monitor (5).

a KOMTRAX terminal (6) is located behind the machine monitor. 4) Connect or insert T-adapter for troubleshooting to KOMTRAX terminal (6) connectors CK01 and CK02.

3. Engine controller 1) Open the engine hood on the left side of the machine. 2) Connect or insert T-adapter for troubleshooting to engine controller (3) connectors CE01, CE02 and CE03. a Use a hexagonal wrench with 4 mm width across flats for lock screws (L1) and (L2).

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3 Lock screw: 3 ± 1 Nm {0.3 ± 0.1 kgm}

a Disconnection and connection of connectors Since connectors of the boost pressure and temperature have a special lock mechanism, disconnect them in the order of (a) and (b) and connect them in the order of (c) and (d) as shown in the figure below. Disconnection: (a) Unlock and (b) disconnect the connectors. Connection: (c) Connect the connectors and (d) engage the lock.

4. Engine-related connectors 1) Ambient pressure sensor (C29) Engine Ne speed sensor (C15) Engine Bkup speed sensor (C13) 2) Disconnection and connection of connectors Since the connectors of the ambient pressure sensor, engine Ne speed sensor, engine Bkup speed sensor and engine oil pressure switch have a special lock mechanism, disconnect them in the order of (a) to (c), and connect them in the order of (d) to (f) as shown in the following figure. Disconnection: (a) Slide the lever, (b) unlock, and (c) disconnect the connectors. Connection: (d) Connect the connectors, (e) engage the lock, and (f) slide the lever.

a Removal and installation of sensor body Since a torque wrench is necessary when removing and installing the charge (boost) pressure and temperature sensor, see "Tools for testing, adjusting, and troubleshooting". 4) Supply pump IMV solenoid (C17) a Disconnection and connection of connectors Since connectors of the supply pump IMV solenoid have a special lock mechanism, disconnect them in the order of (a) and (b) and connect them in the order of (c) and (d) as shown in the figure below. Disconnection: (a) Unlock disconnect the connectors.

a Removal and installation of sensor body Since a deep socket is necessary when performing removal and installation of engine oil pressure switch, see "Tools for testing, adjusting, and troubleshooting". 3) Boost pressure and temperature sensor (C4)

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and

(b)

Connection: (c) Connect the connectors and (d) engage the lock.

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5) Common rail pressure sensor (C8) a Disconnection and connection of connectors Since the connectors of common rail pressure sensor have a special lock mechanism, disconnect them in the order of (a) to (b), and connect them in the order of (c) to (d) as shown in the following figure. Disconnection: (a) Unlock and (b) disconnect the connectors.

a Precautions for connecting connectors When connecting connectors, pay attention not to connect the connectors reverse. Engage lock portion (e) on the harness side to triangle notch portion (f). (Pay attention not to take square guide portion (g) on the opposite side of triangle notch portion (f) by mistake.)

Connection: (c) Connect the connectors and (d) engage the lock.

6) Engine coolant temperature sensor (C16)

a Precautions for disconnection of connectors The direction of the lock for connector may be changed toward the difficult direction (facing to the bottom or to the engine side) for unlocking depending on the position where the sensor is screwed in. In such a case, turn the lock to the direction (a) by using the needle nose pliers with curved tip (commercially available) [1], then the lock can be canceled easily.

a Disconnection and connection of connectors Since the connectors of engine coolant temperature sensor have a special lock mechanism, disconnect them in the order of (a) to (b), and connect them in the order of (c) to (d) as shown in the following figure. Disconnection: (a) Unlock disconnect the connectors.

and

(b)

Connection: (c) Connect the connectors and (d) engage the lock.

Since the lock is canceled with "click" sound, listen the sound and disconnect the connectors. D61EM-23M0

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a Removal and installation of sensor body Since a deep socket is necessary when removing and installing the engine coolant temperature sensor, see "Tools for testing, adjusting, and troubleshooting".

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Classification and procedures for troubleshooting Classification of troubleshooting Mode Content Display of Troubleshooting by failure code code E mode Troubleshooting of electrical system Troubleshooting of hydraulic and H-mode mechanical systems S-mode Troubleshooting of engine

3. Action to take after failure is eliminated Clear all the failure codes in the electrical system abnormality record, referring to the next page. [*1], [*2] 1. While pressing numerical key [4] on the panel switch at the normal screen, press [1], [2], and [3] in order to enter to service menu screen.

Procedure for troubleshooting If a phenomenon which appears a source of a trouble occurs on the machine, go to the corresponding troubleshooting section according to the following procedure. 1. Procedure for troubleshooting when action level and failure code are displayed on machine monitor: If a action level and a failure code are displayed on the standard screen of the machine monitor, perform the troubleshooting for the corresponding "Display of code" according to the displayed failure code. a If multiple failures occur simultaneously, all failure codes are displayed repeatedly in order. Record all failure codes on a paper. 2. Procedure for troubleshooting when action level and failure code are not displayed on machine monitor: Check a mechanical system failure code and an electrical system failure code with the abnormality record function of the machine monitor. (See [*1].) 1) If a failure code is displayed, perform troubleshooting for the corresponding "Display of code" according to the failure code. a If an electrical system failure code is displayed, delete all the codes once and reproduce them, and then see if the failure is still detected. (See [*2].)

2. On the service menu screen, press switch [F3] (R) twice in the panel switch section, and select 03 "Abnormality Record". 3. Press the [F6] key (check mark) on the panel switch to validate it, and go to the "Abnormality Record" screen.

a A failure code of the mechanical system cannot be deleted. 2) If no failure code is found in the abnormality record, a failure that the machine cannot find out by itself may have occurred in the electrical system or hydraulic and mechanical system. In this case, check the phenomenon which is assumed to show the failure again and select the same phenomenon from the table of "Phenomenon to be assumed a failure and troubleshooting number", and then perform troubleshooting corresponding to that phenomenon in the "E-mode" or "H-mode" or "S-mode". D61EM-23M0

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4. Press the [F6] key (check mark) on the panel switch to validate it, and go to the "Mechanical Systems" screen.

5. Press the [F3] switch (R) on the panel switch to see if the next failure code is displayed and note down all of the failure codes. a A failure code of the mechanical system cannot be deleted. 6. Press [F5] switch (RETURN) on the panel switch to return to the "Abnormality Record" screen. 7. Go to the "Electrical Systems" similarly to steps 2 and 3.

11.Press the [F6] key (check mark) on the panel switch to clear all failure codes. 12.Press the [F5] switch (RETURN) on the panel switch to return to the "Electrical Systems" screen. Check if a failure code is still displayed or not, and record it on a paper. 13.Press [F5] switch (RETURN) on the panel switch to return to the "Abnormality Record" screen.

8. Press the [F3] switch (R) on the panel switch to see if the next failure code is displayed and note down all of the failure codes. a If "E" is displayed at the left to the failure code, this code is "active" (that is, this failure still continues or its recovery is not verified yet). If "E" is not displayed, the failure code is "inactive" and the code will be cleared in the subsequent clearing step. Be sure to record this failure code on a paper. 9. While pressing numerical key [4] on the panel switch, press [1], [2], and [3] in this order to go to the "Clear mode". (Same as 1) 10.Press [F2] switch (CLEAR) on the panel switch.

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Related information on troubleshooting

Symptom and troubleshooting numbers No.

1 2 3

Symptom of failure User code, failure code Action level is displayed on the machine monitor. Press function switch [F5] to display the "Occurred error list". Failure code is displayed on mechanical system abnormality record. Failure code is displayed on electrical system abnormality record.

No. 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 31 32 33 34 35 36 37 38 39 40 41 42 43 44 45 46

1 Troubleshooting Index Perform troubleshooting for failure code.

Symptom of failure Symptom related to engine Engine does not crank when starting switch is turned to "START" position. Engine does not crank Engine does not start Engine cranks but exhaust smoke does not come out. Exhaust smoke comes out but engine does not start Engine speed does not rise sharply (Follow-up performance is low) Engine stops during operation Engine rotation is abnormal (Hunting) Output is insufficient (Power is low) Exhaust gas color is bad (Incomplete combustion) Oil is consumed much (or exhaust gas color is bad). Oil becomes dirty quickly. Fuel is consumed much Coolant contains oil (or it blows back or reduces) Engine oil pressure warning lamp lights up (Oil pressure lowers). Oil level rises (Water or fuel is mixed in oil). Water temperature rises too high (Overheat). Abnormal sound comes out. Vibration is excessive. Manual preheating system does not work. Automatic preheating system does not work. While preheating is working, preheating monitor does not light up. Symptom related to HST Neither RH nor LH of tracks does not travel forward nor reverse (None of the travel system operates). Either RH or LH of track does not travel forward nor reverse (Only RH or LH of travel system operates). Either RH or LH of track travel only forward or reverse (Only forward or reverse of RH or LH of travel system does not operate). Travel speed or power is low. Shock is large when machine starts or stops. Machine deviates largely Machine drift on a slope is large. Engine stalls during travel or engine speed drops significantly. Unusual noise is heard from around HST pump or motor. HST oil temperature (hydraulic oil temperature) rises too high. Symptom related to work equipment All work equipment do not operate. All work equipment operates slowly or lacks power. Front work equipment lift speed or power is low. Front work equipment side swing speed or power is low. Hydraulic drift of lifted front work equipment is large. Unusual noise is heard from around work equipment pump or control valve.

D61EM-23M0

Troubleshooting Index S-1 E-1, S-2 S-2 S-2 S-3 H-8, S-4 S-5 S-6 S-7 S-8 S-9 S-10 S-11 S-12 S-13 S-14 S-15 S-16 E-2 E-3 E-4 H-1 H-2 H-3 H-4 H-5 H-6 H-7 H-8 H-9 H-16 H-10, E-22 H-11 H-12 H-13 H-14 H-15 40-37

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No. 47 48 49 50 51 52 53 54 55 56 57 58 59 60 61 62 63 64

65 66 67 68 69 70 71 72 73 74 75 76 77 78 79 80 81 82 83

40-38

Symptom of failure Symptom related to machine monitor When starting switch is turned to ON position, machine monitor displays nothing. When starting switch is turned to ON position (with engine stopped), basic check monitor lights up. Air cleaner clogging monitor lights up in yellow while engine is running Charge level monitor lights up in red while engine is running. Engine coolant temperature monitor lights up in red while engine is running. Engine oil pressure monitor lights up in red while engine is running. HST charge pressure monitor lights up in red while engine is running. Hydraulic oil temperature monitor lights up in red while engine is running. HST oil filter clogging monitor lights up in red while engine is running. Fuel level gauge does not indicate correct level. Engine coolant temperature gauge does not indicate correct temperature. Hydraulic oil temperature gauge does not indicate correct temperature. Working mode does not change. Service mode cannot be selected. When customize switch is operated, customize screen is not displayed When setting is changed on customize screen, setting of machine is not changed Service meter is not displayed while starting switch is in OFF position.

Troubleshooting Index E-5 E-6

E-7 E-8 E-9 E-10 E-11 E-12 E-13 E-14 E-15 E-16 E-17 E-18 E-19 E-20 E-21 "Procedure for Air conditioner does not operate normally (including failure codes related to air contesting and troubleshooting" ditioner). in Chapter 80 Others Foot heater does not operate. E-23 Horn does not sound. E-24 Horn does not stop sounding. E-25 Backup alarm does not sound. E-26 Backup alarm does not stop sounding. E-27 Headlamp does not light up. E-28 Rear lamp does not light up. E-29 No wiper operates continuously or intermittently. E-30 Front wiper does not operate. E-31 Rear wiper does not operate. E-32 Left door wiper does not operate (failed continuous and intermittent operations). E-33 Right door wiper does not operate (failed continuous and intermittent operations). E-34 Front washer does not operate. E-35 Rear washer does not operate. E-36 Left door washer does not operate. E-37 Right door washer does not operate. E-38 KOMTRAX system does not work properly. E-39 Fan speed is abnormal (too high or low or fan does not rotate). H-17 Unusual noise is heard from around fan. H-18

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Related information on troubleshooting

Information in troubleshooting table

1 (Rev. 2011/12)

a The following information is summarized in the troubleshooting table. Before performing troubleshooting, understand that information fully. Action level Display on machine monitor Detail of failure Action of controller Problem on machine Related information

Failure code Display on machine monitor

Failure

Failure name displayed on the Abnormality Record screen of the machine monitor

Description of the failure detected by the machine monitor or controller An action that is performed to protect the system and devices when a failure is detected by the machine monitor or controller A problem that appears as a failure on the machine as a result of an action (above) that is performed by the machine monitor or controller. Information on occurred failure or troubleshooting

Procedure, measuring location, criteria and remarks No. Cause <Contents of description> 1 Defective — Open or short circuit in wiring • Procedure 2 harness • Measuring location Open circuit in wiring harness a "Between A and B" denotes measuring values such as voltage 3 (wire breakage or defective and resistance between A and B. contact of connector) a "Between A and ground" means the measurement of voltage, Ground fault in wiring harness resistance or others between terminal A and the place which has 4 (contact with ground circuit) a continuity with chassis frame such as unpainted hexagonal 5 Hot short circuit head bolt or bolt hole which has no rust, etc. • Criteria to judge probable causes (standard value), remarks <How to use troubleshooting sheet> • Perform troubleshooting procedures in numerical order. • If the check result does not meet the criteria, the probable cause described on the left column is the actual cause of the failure. • If the check result meet the criteria and there is no specific instruction, proceed to the next step (cause). • If a defect is found and repaired, check that the defect has been corrected. <Failures in wiring harness> Short circuit in wiring harness • Open circuit 6 Connection of connector is defective or wiring harness is broken. • Ground fault A harness not to be connected to the ground (earth) circuit comes into contact with the ground (earth) circuit or chassis accidentally. • Hot short circuit A harness not to be connected to the power circuit comes into contact with the power circuit accidentally. • Short circuit An independent wire in the harness erroneously comes into contact with another independent wire. (poor insulation at connector and others)

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No.

Cause

Defective controller

Procedure, measuring location, criteria and remarks <Precautions for troubleshooting> (1) Connector number indication method and handling of T-adapter For troubleshooting, insert or connect T-adapters as follows unless otherwise specified. • When "male" or "female" is not indicated with a connector number, disconnect the connector, and insert T-adapter between the male and female connectors. • When "male" or "female" is indicated with a connector number, disconnect the connector, and connect T-adapter to the male or female connector. • "Male and female" means male and female of connector pins, not connector housings. • Male and female of connector pins and housing in DT series, etc, are opposite to those described in this manual. Take care. (2) Pin number description sequence and tester lead handling For troubleshooting, connect the positive (+) and negative (-) leads as shown below unless otherwise specified. • Connect the positive (+) lead to pin or wire indicated first. • Connect the negative (-) lead to a pin or wire indicated second.

Related circuit diagram This is the excerpted circuit diagram related to troubleshooting • The circuit diagram contains the connector Nos., pin Nos., and connector colors related to the failure. • The "/" in a connector number is either: 1) An abbreviation (of more than three letters) Example: T/C (Torque Converter) 2) Different connector number at male and female sides Example: BREAK OUT/E24 • The circuit diagram contains the destination or source of the branch line in a wiring harness. • The arrow (io) indicates a rough installation position on the given machine. • NO: Normally Open • NC: Normally Closed • Signal names such as GND and 24 V are included in addition to connector numbers at junctions, etc. in circuit diagrams. • Except for GND and 24 V, a signal name indicated at a junction, etc. shows that the wire is connected to another junction or controller at where the same signal name is indicated.

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Procedure for troubleshooting wiring harness of pressure sensor system for open circuit

a Pressure sensors consist not only of resistors but also of electronic circuit components such as amplifiers. Therefore, troubleshooting must be performed carefully taking into consideration of their individual variability and polarities. Failure codes applicable to this diagnosis • CA123: Charge air pressure sensor low error • CA451: Rail pressure sensor high error Procedure 1. Measure and record resistance of pressure sensor unit. 1) Disconnect pressure sensor connector (1) and connect socket (2) to the sensor side connector. 2) Measure resistance R1 and R2 between pins. a If the polarities of multimeter probes are reversed, measured value may change. Therefore, when measuring the resistance, apply the multimeter probes to the pins without changing their polarities to the pressure sensor between measurements in steps 1 and 2. a When a measured value is infinite, reverse the polarity and try measurement again. If you obtained a non-infinity value in this manner, use it as the measurement value. a Since the measured values may be dispersed, take several measurements. Above is considered due to electric charge applied to inside of the sensor. Measurement must be repeated several times similarly in steps 1 and 2. In step 3, you must determine whether the wiring harness is open-circuited taking this dispersion into consideration.

2. Measure and record resistance of the pressure sensor to which the wiring harness between the engine controller and pressure sensor is connected. 1) Since 5 V power supply to the pressure sensor is connected to other sensors, disconnect other sensor connectors first.(*) 2) While the connector of the target pressure sensor of measurement is connected, disconnect connector (3) of the engine controller and connect T-adapter (4) to the wiring harness side. 3) Connect T-box (5) to T-adapter (4) and measure resistance R1' and R2' between respective pins. 3. Judging open circuit If there is an "apparent difference" between resistance R1 and R2 measured in step 1 and resistance R1' and R2' measured in step 2, you may judge that the wiring harness is open-circuited. a "Apparent difference" means here that there exists a difference of 10-fold or greater between the two.

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Related information on troubleshooting

List of pressure sensor measuring locations and reference values

Sensors

Boost pressure sensor

Common rail pressure sensor

Measuring location at sensor pin R2: between (2) and (4) R1: between (1) and (4) R2: Between (3) and (1) R1: Between (1) (+) and (2) (-)

Inside of sensor Measured internal resistance of sensor (reference) Approx. 100 z Approx. 200 z

Remarks

Sensor is common to engine models 107 and 114

Approx. 23 kz Approx. 10 Mz

If the polarity is reversed, the resistance becomes infinite.

*: The following lists the connector to be disconnected when measuring R2'. (See related circuit diagram listed in troubleshooting section of each failure code.) • When measuring R2' of boost pressure sensor (CA123): Connectors of ambient pressure sensor, CAM sensor and crankcase pressure sensor (KCCV) • When measuring R2' of common rail pressure sensor (CA451): Since 5 V power supply is used independently, there is no connector to be disconnected. Measurement record (For measuring locations, see related circuit diagram listed in troubleshooting section of each failure code.)

Sensors

Boost pressure sensor 40-42

Sensor unit (Measuring location at sensor pin) R2: between (2) and (4) R1: between (1) and (4)

Measured value

Sensor with wiring harness connected (Measuring location on harness connector of engine controller) R2': Between (37) and (47) (*) R1': Between (44) and (47)

Measured value

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Sensors

Common rail pressure sensor

D61EM-23M0

Sensor unit (Measuring location at sensor pin) R2: Between (3) and (1) R1: Between (1) (+) and (2) (-)

Measured value

Sensor with wiring harness connected (Measuring location on harness connector of engine controller) R2': Between (37) and (47) (*) R1': Between (47) (+) and (25) (-)

Measured value

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Connector list and layout

D61EM-23M0 Connector No.

Connector type

2 3 4 5 11 12 13 14 17 20 21 23 26 26B 26B1 26R 26BR 27 28A 38 39 54 54B 92 102 104 106 107 116 119 120 261 361 362 363 364 A A AC/AC1 AC2 AC3 AC4 AC5 AC6 AC7 AC8 AC9

DT DT DT DT SHINAGAWA DT DT DT DTHD #12 DT Yazaki 090 DT DT DT DT SHINAGAWA SHINAGAWA DT DT C03 C03 SHINAGAWA SHINAGAWA DT DT DT Terminal Terminal DT DT DT DT M M M M DT DT DT DT DT DT DT DT DT DT DT

40-44

Number of pins 8 12 2 8 6 2 2 2 1 3 2 2 3 3 3 5 5 6 2 3 3 6 6 4 12 12 4 4 2 3 3 3 2 2 2 2 4 4 6 4 3 8 4 12 2 2 2

Location Intermediate connector Intermediate connector Safety relay Intermediate connector Relay for neutral safety Hydraulic oil temperature sensor Fuel gauge sensor Backup alarm ACC power reserved Intermediate connector Horn Compressor Intermediate connector Intermediate connector Travel lock switch 2 Travel lock interlock relay 1 Travel lock interlock relay 2 Travel speed shift switch Water-in-fuel sensor Travel speed shift switch Travel speed shift switch Relay for front lamp Relay for rear lamp Foot heater Intermediate connector Intermediate connector Fuse holder Fusible link Dust indicator CAN resistor CAN resistor Travel lock switch 1 Window washer tank LH Window washer tank F Window washer tank RH Window washer tank R Wiper motor Wiper motor Intermediate connector Hot water valve Temperature adjustment switch Blower selector switch Mode selector switch Intermediate connector Diode for foot heater Hi Diode for foot heater Lo Diode for A/C mode

Address AK-8 AL-8 C-2 AL-8 U-2 AO-6 J-9 L-9 T-1 Y-3 G-9 AF-4 U-2 U-2 S-1 W-5 W-6 U-3 H-9 U-3 U-4 T-2 T-1 R-1 E-9 AK-8 C-2 L-7 J-4 AJ-6 AI-6 S-1 L-6 L-6 L-5 L-6 Y-4 Y-2 Y-3 Z-1 AC-3 AD-3 AC-3 AD-7 AB-1 AA-1 AA-1 D61EM-23M0

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Connector No.

Connector type

ACC1 ACC2 AL AR ASUS B BNSW BLR BLSW BML BMR BNSW BP1 BP2 BR1 BR2 BR3 BRC1 BRC2 BRC3 BRCG BRM1 BRM2 BRR1 BRR2 BRV BS

DT DT DT DT DT Terminal DT SHINAGAWA DT DT DT DT DT DT DTHD #4 DTHD #8 DT M12 M12 DRC16 Terminal M12 M12 SHINAGAWA SHINAGAWA DT AMP

Number of pins 2 2 2 2 2 1 12 6 12 4 4 12 3 3 1 1 4 5 5 24 1 5 5 5 5 2 3

SUMITOMO

C5 C8 C9 C10 C11 C12 C13 C15 C16 C17 C28 C29 CB00 CB01 CB02 CB04 CB07 CB08 CB10 CB11 CB12

FRAMATOME FRAMATOME DT DT DT DT FRAMATOME FRAMATOME DELPHI DT DT FRAMATOME DT DT DT DT YAZAKI PA DT SWP SWP SWP

2 3 4 4 4 3 3 3 2 2 2 3 2 2 2 2 9 2 6 6 6

D61EM-23M0

Location

Address

Void Intermediate connector Void Void Void Fuse box Intermediate connector Interlock relay lift Work equipment lever switch Intermediate connector Intermediate connector Intermediate connector Intermediate connector Decel & brake potentiometer Intermediate connector Intermediate connector Intermediate connector Bracke junction box cab Bracke junction box cab Bracke junction box cab GND, Bracke controller Bracke monitor Bracke monitor Emergency stop switch interlock1 Emergency stop switch interlock2 Bracke oil EPC Brake pressure sensor Boost pressure and intake manifold temperature sensor Engine oil pressure switch Common rail pressure sensor Intermediate connector Intermediate connector Intermediate connector CAN_C CAM sensor (Bkup) Ne sensor (Crank) Coolant temperature sensor Inlet measuring valve Intermediate connector Ambient pressure sensor Intermediate connector Intermediate connector Rear speaker (left) Rear speaker (right) Radio Void Cleaning water pump switch Wiper intermittent switch Rear wiper switch

AC-2 AD-3 F-9 F-7 M-7 AA-9 N-6 D-7 N-6 G-1 C-4 N-6 O-1 N-1 K-9 K-9 L-6 S-9 S-9 R-9 Q-8 P-7 P-7 W-6 W-7 F-7 J-4 AG-6 AI-2 AJ-4 AG-5 AG-6 AI-6 AF-3 AF-2 AG-1 AF-4 AJ-3 AH-1 AF-3 U-3 AB-9 AD-7 AB-9 AA-9 AA-9 Z-8 Z-8 Z-8 40-45

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Connector No.

Connector type

CB13 CB14 CB15 CB16 CB17/B CB19 CB23 CB24/B CB25 CB27 CB28 CB32 CB35 CB37 CBL1 CBL2/CBLS CBL3/CBLR CBL4/CBLR CBL5/CBLS CBLMP CE01 CE02 CE03 CFS CIG CK01 CK02 CLG CM01 CM02 CM03 CM04 CV1 CWP D1 D2 D4 D20 DAC DT12 EL EL1 ESS1 ESS2 ESS3 ESS4 F F01 FAC

SWP SWP SWP YAZAKI DT DT DT DT SHINAGAWA YAZAKI SHINAGAWA SHINAGAWA DT DT DT DT DT DT DT DT DRC 26 DRC 26 DTP DT YAZAKI 070 070 DT 070 070 070 070 DT DT DT DT SWP DT DT DT DT DT Terminal Terminal Terminal Terminal Terminal Terminal DT

40-46

Number of pins 6 6 6 2 4 6 4 4 5 11 5 5 2 4 2 2 2 2 2 8 60 50 4 2 2 18 12 6 18 12 20 8 6 2 2 2 8 2 2 12 8 8 1 1 1 1 1 20 2

Location Right wiper switch Front wiper switch Left wiper switch Room lamp R.H. door wiper motor Intermediate connector (washer tank) Front wiper motor L.H. door wiper motor Cleaning water pump relay R.H. and L.H. wiper intermittent relay unit Front wiper selector relay Rear wiper selector relay Void Rear wiper motor Intermediate connector Intermediate connector Intermediate connector Intermediate connector Intermediate connector Intermediate connector Engine controller Engine controller Engine controller HST charge filter clogging switch Power supply outlet for lighter KOMTRAX KOMTRAX Intermediate connector Monitor panel Monitor panel Monitor panel Monitor panel DC-DC Converter Cleaning water pump Diode Diode Diode Diode Diode Service connector Intermediate connector Travel lever Emergency stop switch 1 Emergency stop switch 2 Emergency stop switch 3 Emergency stop switch 4 Fuse box Fuse box Fan EPC solenoid

Address Z-8 Z-8 Y-8 Y-7 Y-4 Z-2 Y-6 AB-2 AD-5 AD-4 AD-5 AD-5 Y-5 AD-3 Y-5 Y-6 AD-6 AC-9 Y-5 Y-3 AI-2 AI-2 AH-1 L-8 AC-2 N-2 N-3 J-9 V-3 V-2 W-4 AB-2 L-7 S-1 S-1 J-4 AJ-6 AI-6 O-1 U-3 U-3 O-7 O-7 P-8 O-7 AA-9 T-2 D-8 D61EM-23M0

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Connector No.

Connector type

FAR FG FL1 FL1 FL2 FL2 FLC1 FLC2 FLC3 FLSW FM1 FP FRS FUSE GND1 GND3 GND4 GND5 GND6 GND7 GND8 HC1A HC1B HC2A HC2B HC3A HC3B HC4A HC4B HCR HCR2 HEAT1 HEAT2 HEAT2 HET HNSW HM0 HMA HMB HRH HRL HS/HEAT1 HSW HXR INJECTOR #1 INJECTOR #2 INJECTOR #3 INJECTOR #4 INJECTOR #5

DT DTHD #8 DT DT DT DT DT DT DT SWP DT DT DT Terminal Terminal Terminal Terminal Terminal Terminal Terminal Terminal DTM DTM DTM DTM DTM DTM DTM DTM DT DT YAZAKI YAZAKI DT SWP DT DT DTM DTM SHINAGAWA SHINAGAWA DT SWP SHINAGAWA DT DT DT DT DT

D61EM-23M0

Number of pins 2 1 2 2 2 2 2 2 2 6 12 3 2 6 1 1 1 1 1 1 1 12 12 12 12 12 12 12 12 3 3 3 3 2 6 2 2 12 12 5 5 2 6 5 2 2 2 2 2

Location Fan reverse solenoid Intermediate connector LED light LED light LED light LED light LED light LED light LED light Front lamp switch Intermediate connector Fuel dial potentiometer Fan motor speed sensor Fuse box GND GND GND GND GND GND GND Hexagon controller Steering Hexagon controller Steering Hexagon controller Side swing L Hexagon controller Side swing L Hexagon controller Side swing R Hexagon controller Side swing R Hexagon controllor Oil & Water Hexagon controllor Oil & Water CAN terminal resistor CAN terminal resistor Foot heater Foot heater Seat heater Heater switch Horn switch Hexagon monitor Hexagon monitor Hexagon monitor Heater relay (Hi) Heater relay (Lo) Intermediate connector Planter system switch Hexagon system power relay Injector #1 Injector #2 Injector #3 Injector #4 Injector #5

Address L-9 I-9 Y-8 AD-8 Y-7 AD-8 Y-6 Y-5 Y-4 V-3 J-9 U-3 L-9 AA-9 AA-9 AD-6 AD-4 AC-2 AB-2 Y-4 Z-1 U-8 V-8 U-8 V-7 T-9 V-7 T-9 W-7 X-2 S-9 R-1 S-1 O-7 X-3 N-6 X-4 X-4 W-4 N-1 N-1 N-7 X-4 W-5 AE-8 AE-8 AF-9 AF-9 AG-9 40-47

40 Troubleshooting

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Connector No.

Connector type

INJECTOR #6 KEY KEY0 KOM2 KOM3 KOM4 LBU LD LD1 LF LMD1 LMD2 LME LPF LPR LR LRS2 LU LU1 MC MFG/T36 NC1 NC2 NG1 NG2 NM1 PB PLR PSL PSW PSW1 PU1 PU2 PU3 RCW RF RH RH RHR RL1 RL2 RL1 RL2 RLSW RME RPF RPR RR RRS2

DT DT 070 GT5-1PP-HU BNCP MLJ DT DT DT DT DT DT DT AMP AMP DT DT DT DT DT Terminal DT DT DT DT DT DT SHINAGAWA DT DT DT DT DT DT SHINAGAWA DT Terminal DT SHINAGAWA DT DT DT DT SWP DT AMP AMP DT DT

40-48

Number of pins 2 6 14 1 1 1 2 2 2 2 2 2 2 3 3 2 3 2 2 12 1 12 12 12 8 4 3 6 2 3 3 6 6 6 6 2 1 4 6 2 2 2 2 6 2 3 3 2 3

Location Injector #6 Starting switch Intermediate connector GPS antenna ORBCOMM antenna Antenna System operating lamp Intermediate connector Lift down EPC solenoid HST pump EPC solenoid Diode Diode L.H. motor EPC solenoid L.H. front pressure sensor L.H. rear pressure sensor HST pump EPC solenoid L.H. motor speed sensor Intermediate connector Lift up EPC solenoid Intermediate connector M/F GND Intermediate connector Intermediate connector Intermediate connector Intermediate connector Intermediate connector Limit switch for brake Personal lock relay PPC lock solenoid Intermediate connector Work equipment lock switch Planter head unit LH Planter head unit CTR Planter head unit RH Interlock relay cleaning water HST pump EPC solenoid Electrical intake air heater (ribbon heater) Intermediate connector Preheating relay LED light LED light LED light LED light Rear lamp switch R.H. motor EPC solenoid R.H. front pressure sensor R.H. rear pressure sensor HST pump EPC solenoid R.H. motor speed sensor

Address AG-9 X-2 N-3 N-2 N-3 W-9 K-9 D-8 F-8 A-2 Q-1 Q-1 K-5 AL-4 B-1 AM-5 K-5 E-7 F-7 H-9 P-1 I-9 K-5 G-9 G-9 AJ-6 O-1 T-2 K-5 F-8 D-8 G-2 F-2 C-4 D-8 A-1 AJ-3 I-9 U-2 AC-9 AC-8 AD-6 AD-6 V-3 K-5 A-1 AL-4 AM-4 I-9 D61EM-23M0

40 Troubleshooting

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Connector No.

Connector type

RS RVC S3 S4 SBC SES1 SESW SSEL SSEL SSLA SSLB SSRA SSRB SSLR SSRR ST1 ST2 ST3 T1 T2 T3 T4 T4 T5 T6 T7 T8 T9 T12 T13 T15 T16 T17 T20 T20A T20B T35 T36 T50 T126 TG1 TL TPS TR TSR VH1 VH2 WE

DT DT DT DT DT SWP SWP DT DT DT DT DT DT SHINAGAWA SHINAGAWA DRC26 DRC26 DRC26 Terminal Terminal Terminal Terminal Terminal Terminal Terminal Terminal Terminal Terminal Terminal Terminal Terminal Terminal Terminal Terminal Terminal Terminal Terminal Terminal Terminal Terminal Terminal DT DT DT Terminal DT DT DT

Number of pins 8 4 2 2 2 6 6 4 4 2 2 2 2 6 6 24 40 40 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 2 12 2 1 12 12 12

WELR

SHINAGAWA

D61EM-23M0

Location

Address

Intermediate connector Rearview camera Slow brake solenoid Parking brake solenoid Seat belt caution switch Engine shut down secondary Intermediate connector Hexagon encoder Hexagon encoder Side swing L EPC A Side swing L EPC B Side swing R EPC A Side swing R EPC B Interlock relay side swing L Interlock relay side swing R HST controller HST controller HST controller Starter (terminal B) Starting motor (terminal C) Safety relay Safety relay GND disconnected Electrical intake air heater relay Electrical intake air heater relay Battery relay Battery relay Battery relay Electrical intake air heater relay Battery relay Alternator (terminal B) Alternator (terminal R) Alternator (terminal E) Engine GND Engine GND Engine GND GND Floor GND GND GND GND Bracke oil EPC solenoid Intermediate connector Irrigation water EPC solenoid GND Intermediate connector Intermediate connector Intermediate connector Interlock relay work equipment lever & irrigation water

E-9 AD-8 J-4 J-4 U-4 X-3 X-3 C-8 J-1 F-7 D-9 F-7 D-8 D-7 D-7 N-4 N-4 N-4 C-1 C-1 C-2 B-2 AH-6 AI-6 L-7 L-7 L-7 AH-6 L-8 C-3 C-3 C-3 AH-1 B-2 AJ-4 H-9 P-1 I-4 L-7 F-9 P-1 F-7 B-2 F-9 F-9 D-9 D-7 40-49

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Connector No.

Connector type

WEP

WEP2

WLD1 WLD2 WLD3 WLV1 WP WPC WPCD WPCR WPS WPV WS WVC WVL WVR

DT DT DT DT AMP DT DT SHINAGAWA FRAMATOME DT DT DT DT DT

40-50

Number of Location pins 3 Intermediate connector Switch harness for emergency operation of work 3 equipment 2 Diode 2 Diode 2 Diode 8 Work equipment control lever 3 Work equipment pump pressure sensor 2 Refill rotation EPC solenoid 2 Diode 5 Refill rotation relay 3 Cleaning water pressure switch 2 Irrigation water pump EPC 2 Void 2 Irrigation water valve 2 Irrigation water valve 2 Irrigation water valve

Address E-9 F-8 F-8 F-8 F-8 N-5 E-7 D-9 F-9 E-7 L-8 D-9 N-6 D-4 D-4 E-3

D61EM-23M0

40 Troubleshooting

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Layout of connectors (1/7)

D61EM-23M0

40-51

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(2/7)

40-52

D61EM-23M0

40 Troubleshooting

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(3/7)

D61EM-23M0

40-53

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(4/7)

40-54

D61EM-23M0

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(5/7)

D61EM-23M0

40-55

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(6/7)

40-56

D61EM-23M0

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(7/7)

D61EM-23M0

40-57

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Connector contact identification

1 (Rev. 2014. 08)

a The terms of male and female refer to the pins, while the terms of male housing and female housing refer to the mating portion of the housing.

40-58

D61EM-23M0

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D61EM-23M0

40-59

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40-60

D61EM-23M0

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D61EM-23M0

40-61

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40-62

D61EM-23M0

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D61EM-23M0

40-63

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40-64

D61EM-23M0

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D61EM-23M0

40-65

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40-66

D61EM-23M0

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D61EM-23M0

40-67

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40-68

D61EM-23M0

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D61EM-23M0

40-69

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40-70

D61EM-23M0

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D61EM-23M0

40-71

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40-72

D61EM-23M0

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D61EM-23M0

40-73

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40-74

D61EM-23M0

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D61EM-23M0

40-75

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40-76

D61EM-23M0

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D61EM-23M0

40-77

40 Troubleshooting

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40-78

D61EM-23M0

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D61EM-23M0

40-79

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40-80

D61EM-23M0

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D61EM-23M0

40-81

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40-82

D61EM-23M0

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D61EM-23M0

40-83

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40-84

D61EM-23M0

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D61EM-23M0

40-85

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40-86

D61EM-23M0

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D61EM-23M0

40-87

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40-88

D61EM-23M0

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D61EM-23M0

40-89

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40-90

D61EM-23M0

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D61EM-23M0

40-91

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40-92

D61EM-23M0

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D61EM-23M0

40-93

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40-94

D61EM-23M0

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D61EM-23M0

40-95

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40-96

D61EM-23M0

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D61EM-23M0

40-96-1

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40-96-2

D61EM-23M0

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T-branch box and T-branch adapter table

1 (Rev. 2014. 05)

799-601-2750 Adapter for ECONO 799-601-2760 Adapter for ECONO 799-601-2770 Adapter for ECONO 799-601-2780 Adapter for ECONO 799-601-2790 Adapter for ECONO 799-601-2810 Adapter for DLI 799-601-2820 Adapter for DLI 799-601-2830 Adapter for DLI Extension cable (ECONO 799-601-2840 type) 799-601-2850 Case T-box (for DRC60, 799-601-4350 ECONO) 799-601-4360 Case 799-601-7010 Adapter for X (T-adapter) 799-601-7020 Adapter for X 799-601-7030 Adapter for X D61EM-23M0

21 37 37 24 24 17 17 5 10 5 17 19 14

q q

Not included in kit

799-601-4201

799-601-4101

799-601-9300

799-601-9200

799-601-9100

799-601-9000

799-601-8000

799-601-7500

799-601-7400

799-601-7100

799-601-7000

T-box (for ECONO) T-box (for MS) T-box (for MS) Plate for MS (14 pins) Adapter for BENDIX (MS) Adapter for BENDIX (MS) Adapter for BENDIX (MS) Adapter for BENDIX (MS) Adapter for BENDIX (MS) Adapter for BENDIX (MS) Adapter for BENDIX (MS) Adapter for BENDIX (MS) Adapter for BENDIX (MS) Adapter for BENDIX (MS) Case Adapter for MIC Adapter for MIC Adapter for MIC Adapter for MIC Adapter for MIC

799-601-2800

799-601-2600 799-601-3100 799-601-3200 799-601-3380 799-601-3410 799-601-3420 799-601-3430 799-601-3440 799-601-3450 799-601-3460 799-601-3510 799-601-3520 799-601-3530 799-601-2910 799-601-3470 799-601-2710 799-601-2720 799-601-2730 799-601-2740 799-601-2950

799-601-2700

Part name

Identification Symbol

799-601-2500

Part No.

Number of pins

a The part numbers of the T-boxes and T-adapters are listed in the vertical column, and the part numbers of harness checker assemblies are listed in the horizontal line. T-adapter kit

q q q q q q q q q q q q q q q

MS-24P MS-24P MS-17P MS-17P MS-5P MS-10P MS-5P MS-17P MS-19P MS-14P

q 5 MIC-5P q q q 13 MIC-13P q q q q 17 MIC-17P q q q q q 21 MIC-21P q q q q q q 9 MIC-9P ECONq q 2 O2P ECONq q 3 O3P ECONq q 4 O4P ECONq q 8 O8P ECONq q 12 O12P 8 DLI-8P q q 12 DLI-12P q q 16 DLI-16P q q ECONq q q 12 O12P q

q q q

q q

1 2 3

X2P X3P

q q q q q q q

q q q 40-97

40 Troubleshooting

Related information on troubleshooting

40-98

4 6 8 12 14 16 1 2 3 4 6 8 8 10 12 16 16 12 8 12 16 20 2

X4P SW6P SW8P SW12P SW14P SW16P M2P M3P M4P M6P M8P S8P S10P S12P S16P S16PW S12PW A8P A12P A16P A20P

10 07-10 12 07-12 14 07-14 18 07-18 20 07-20 5 REL-5P 6 REL-6P 2 2 DTM2 2 DT2 3 DT3 4 DT4 6 DT6 8 DT8GR 8 DT8B 8 DT8G 8 DT8BR 12 DT12GR 12 DT12B 12 DT12G

q q q q q q q q q

Not included in kit

799-601-4201

799-601-4101

799-601-9300

799-601-9200

799-601-9100

799-601-9000

799-601-8000

799-601-7500

799-601-7400

799-601-7100

799-601-7000

Adapter for X Adapter for SWP Adapter for SWP Adapter for SWP Adapter for SWP Adapter for SWP Adapter for M (T-adapter) Adapter for M Adapter for M Adapter for M Adapter for M Adapter for M Adapter for S Adapter for S (white) Adapter for S (blue) Adapter for S (blue) Adapter for S (white) Adapter for S (white) Adapter for AMP040 Adapter for AMP040 Adapter for AMP040 Adapter for AMP040 Short socket adapter for X Case Case Adapter for 070 Adapter for 070 Adapter for 070 Adapter for 070 Adapter for 070 Adapter for relay Adapter for relay Adapter for JFC Adapter for DTM Adapter for DT Adapter for DT Adapter for DT Adapter for DT Adapter for DT (gray) Adapter for DT (black) Adapter for DT (green) Adapter for DT (brown) Adapter for DT (gray) Adapter for DT (black) Adapter for DT (green)

799-601-2800

799-601-7040 799-601-7050 799-601-7060 799-601-7310 799-601-7070 799-601-7320 799-601-7080 799-601-7090 799-601-7110 799-601-7120 799-601-7130 799-601-7340 799-601-7140 799-601-7150 799-601-7160 799-601-7170 799-601-7330 799-601-7350 799-601-7180 799-601-7190 799-601-7210 799-601-7220 799-601-7230 799-601-7240 799-601-7270 799-601-7510 799-601-7520 799-601-7530 799-601-7540 799-601-7550 799-601-7360 799-601-7370 799-601-7380 799-601-9010 799-601-9020 799-601-9030 799-601-9040 799-601-9050 799-601-9060 799-601-9070 799-601-9080 799-601-9090 799-601-9110 799-601-9120 799-601-9130

Identification Symbol

799-601-2700

Part name

799-601-2500

Part No.

Number of pins

T-adapter kit

q q

q q q q q q q q q q q q q

q q q q q

q q q q q q q q q q q q

q q

q q q

q q q q q q q q q q q q q q

q q q q

q q q q q q q q q q q q q q q q q q q q

q q q q q q q q q q q q

q q q q

D61EM-23M0

40 Troubleshooting

Related information on troubleshooting

799-601-9140 Adapter for DT (brown) 799-601-9210 Adapter for HD30-18 799-601-9220 Adapter for HD30-18 799-601-9230 Adapter for HD30-18 799-601-9240 Adapter for HD30-18 799-601-9250 Adapter for HD30-24 799-601-9260 Adapter for HD30-24 799-601-9270 Adapter for HD30-24 799-601-9280 Adapter for HD30-24 799-601-9290 Adapter for HD30-24 799-601-9310 Plate for HD30 (24 pins) 799-601-9320 T-box (for ECONO) 799-601-9330 Case 799-601-9340 Case 799-601-9350 Adapter for DRC 799-601-9360 Adapter for DRC 799-601-9410* Socket for engine (CRI-T2) Adapter for engine (CRIT2) 799-601-9420 Adapter PFUEL for engine (CRI-T3) Oil pressure sensor Socket for engine (CRI-T2) 799-601-9430* Socket PCV for engine (CRI-T3) 799-601-9440* Socket for engine (CRI-T2) 795-799-5520* Socket for engine (HPI-T2) Socket for engine (HPI-T2) 795-799-5530* Socket for engine (CRI-T3) Temperature sensor Socket for engine (HPI-T2) 795-799-5540* Socket TIM for engine (CRI-T3) 795-799-5460 Cable for engine (HPI-T2) 795-799-5470 Cable for engine (HPI-T2) 795-799-5480 Cable for engine (HPI-T2) Adapter PIM for engine 799-601-4110 (140-T3) Adapter NE, CAM for 799-601-4130 engine (CRI-T3) Adapter for engine (CRI799-601-4140 T3) Ambient pressure Adapter POIL for engine 799-601-4150 (CRI-T3) Adapter for engine (CRI799-601-4160 T3) D61EM-23M0

12 DT12BR 8 D18-8 14 D18-14 20 D18-20 21 D18-21 9 D24-9 16 D24-16 21 D24-21 23 D24-23 31 D24-31 24

40 DRC-40 24 DRC-24 2 G

Not included in kit

799-601-4201

799-601-4101

799-601-9300

799-601-9200

799-601-9100

799-601-9000

799-601-8000

799-601-7500

799-601-7400

799-601-7100

799-601-7000

799-601-2800

Identification Symbol

799-601-2700

Part name

799-601-2500

Part No.

Number of pins

T-adapter kit

q q q q q q q q q q q q q q q q q q q q q q q q q q q q q q q

q q

3 2

1,2,3 S

q q

3 3 3

q q q

ITT3N

q q

FCIN

q q

FCIG

q q

FCIB

q q

4160

q q 40-99

40 Troubleshooting

Related information on troubleshooting

Oil pressure switch Adapter PEVA for engine 799-601-4180 (CRI-T3) Socket for engine (CRI-T3) 799-601-4190* Common rail pressure Socket for engine (CRI-T3) 799-601-4230* Intake pressure/ temperature Socket PAMB for engine 799-601-4240* (CRI-T3) Socket PIM for engine 799-601-4250* (CRI-T3) Socket G for engine (CRI799-601-4330* T3) Socket for engine (CRI-T3) 799-601-4340* Pump actuator Socket for engine (CRI-T3) (95) 799-601-4380* Intake pressure/ temperature Adapter for controller 799-601-4260 (ENG) Adapter for controller 799-601-4211 (ENG) Adapter for controller 799-601-4220 (ENG) Socket for controller 799-601-4390* (95ENG)

1, 2, 3B

q q

1, 2, 3, G

q q

2, PA

q q

1, 2, 3, 4T

DTP4

q q

50 DRC50

60 DRC60

121 Adapter for controller (HST) 16 HST16A Adapter for controller (HST) 16 HST16B Adapter for controller (HST) 26 HST26A 2, Multi-adapter for DT 2 to 4, 3, DTM 2 pins 4 T-adapter for ICT control 26 box T-box 26

Not included in kit

q q

799-601-4201

1, 2, 3A

799-601-4101

799-601-9300

q q

799-601-9200

1, 2, 3, 4 C

799-601-9100

799-601-9000

q q

799-601-8000

1, 2, 3 L

799-601-7500

799-601-7400

q q

799-601-7100

4180

799-601-7000

799-601-2800

Identification Symbol

799-601-2700

Part name

799-601-2500

Part No.

Number of pins

T-adapter kit

799-601-4280* Box for controller (PUMP)

799-601-9720 799-601-9710 799-601-9730

q q q

799-601-9890 799-902-9600 799-902-9700

q q q

*: These are not T-adapters but sockets.

40-100

D61EM-23M0

40 Troubleshooting

Related information on troubleshooting

Adapter for controller (ENG-T4) 4 Adapter for controller (ENG-T4) 2 Adapter for controller (ENG-T4) 2 Adapter for controller (ENG-T4) 24 Adapter for controller (ENG-T4) 3 Adapter for control box 19 Adapter for IMU 10 Adapter for MS cylinder 6 KDPF differential pressure sensor 799T-601-4611 short socket adapter 4 KDPF outlet pressure sensor short 799T-601-4670 socket adapter 4 799T-601-4680 KDPF dummy temperature sensor 4 799-601-4620 799-601-4630 799-601-4640 799-601-4651 799-601-4660 799-902-9310 799-902-9320 799-902-9330

D61EM-23M0

799-601-4620 799-601-4630 799-601-4640 799-601-4651 799-601-4660 799-902-9310 799-902-9320 799-902-9330

Not included in kit

Identification Symbol

799-A65-4600

Part name

799-902-9300

Part No.

Number of pins

T-adapter kit

q q q q q q q q

799T-601-4611

799T-601-4670

799T-601-4680

40-101

40 Troubleshooting

Related information on troubleshooting

Fuse location table

Connection table of fusible links and fuse boxes a This connection table shows the devices to which each power supply of the fusible links and fuse boxes supplies power. a The switched power supply is the power (battery relay output) which is supplied while the stating switch is in ON position. The continuous power supply is the power (battery direct output) which is supplied while the starting switch is in OFF and ON positions. a When performing the troubleshooting related to the electrical system, check the fusible links and fuses to see if the power is supplied properly. 1. Fuse box (F01) Type of power supply (Supply source)

Fuse No.

1 (Between terminals 1 and 1A) 2 (Between terminals 2 and 2A) 3 (Between terminals 3 and 3A) 4 (Between terminal 4 Switched power supply and 4A) (Battery relay terminal M, 5 fusible link 120 A*) (Between terminals 5 and 5B) 6 (Between terminals 6 and 6B) 7 (Between terminals 7 and 7B) 8 (Between terminals 8 and 8B) 9 (Between terminals 9 Continuous power supply and 9C) 10 (Battery relay terminal B, fusible link 50 A*) (Between terminals 10 and 10C)

40-102

Fuse capacity

Destination of power

30 A

Head lamp and rear lamp

10 A

Horn, preheater

15 A

Foot heater

30 A

Air conditioner components

10 A

HST controller 1

15 A

Air suspension seat, winch

30 A

Cab power supply 1

30 A

Cab power supply 2

15 A

Starting switch

30 A

Engine controller 1

D61EM-23M0

40 Troubleshooting

Related information on troubleshooting

Type of power supply (Supply source)

Fuse No.

11 (Between terminals 11 and 11D) 12 (Between terminals 12 and Switched power supply 12D) (Battery relay terminal M, 13 fusible link 120 A*) (Between terminals 13 and 13D) 14 (Between terminals 14 and 14D) 15 (Between terminals 15 and 15E) 16 (Between terminals 16 and 16E) 17 Continuous power supply (Between (Battery relay terminal B, terminals 17 and fusible link 50 A*) 17E) 18 (Between terminals 18 and 18E) 19 (Between terminals 19 and 19E) 20 Switched power supply (Between (Starting switch terminal terminals 20 and ACC) 20F)

Fuse capacity

Destination of power

20 A

8 , "$ 0 ` . "$

Spare

Key ACC

10 A

HST controller 2

10 A

Monitor panel

System operating lamp

Service connector / Hexagon Power

10 A

Cab continuous power supply

10 A

Key ACC

*: See "4. Fusible link (battery room)" for fusible link 50 A and 120 A.

D61EM-23M0

40-103

40 Troubleshooting

Related information on troubleshooting

2. Fuse box A (FUSE) Type of power supply (Supply source)

Fuse No.

1 Continuous power supply (Between (Fuse box CN-F01 (19)) terminals 1 and F) 2 (Between terminals 2 and B) 3 (Between terminals 3 and B) 4 Switched power supply (Between (Fuse boxes CN-F01 (7), terminals 4 (8)) and B) 5 (Between terminals 5 and B) 6 (Between terminals 6 and B)

40-104

Fuse capacity 10 A

Destination of power

Radio (continuous power supply)

20 A

' # "%

20 A

12V, Hexagon Power

10 A

Room lamp, radio

10 A

Front wiper and front wiper washer, rear wiper and rear wiper washer

10 A

R.H. and L.H. door wipers and R.H. and L.H. door wiper washers

D61EM-23M0

40 Troubleshooting

Related information on troubleshooting

3. Fuse installation positions and fuse No.

4. Fusible link (battery room) Fusible link (Section S) 50 A 120 A

D61EM-23M0

Power supply Continuous power supply Switched power supply

Terminal No.

Destination of power

107-3

Fuse boxes F01-9, 10, 15 to 19

107-4

Fuse boxed F01-1 to 8, 11 to 14

40-105

40 Troubleshooting

Related information on troubleshooting

5. Fusible link (engine room) Fusible link (Section T) 120 A 120 A

40-106

Power supply Switched power supply Switched power supply

Terminal No.

Destination of power

106-3

Power supply for intake air heater

106-4

Alternator

D61EM-23M0

40 Troubleshooting

Related information on troubleshooting

Failure codes table Failure code

Failure (Displayed on screen)

Failure code [6091NX] HST Oil Filter Clogging (PAGE 40-115) Failure code [989L00] Engine Controller Lock 989L00 Caution 1 (PAGE 40-117) Failure code [989M00] Engine Controller Lock 989M00 Caution 2 (PAGE 40-118) Failure code [989N00] Engine Controller Lock 989N00 Caution 3 (PAGE 40-119) Failure code [AA10NX] Air Cleaner Clogging AA10NX (PAGE 40-120) Failure code [AB00KE] Charge Voltage Low AB00KE (PAGE 40-122) Failure code [B@BAZG] Eng Oil Press Low B@BAZG (PAGE 40-124) Failure code [B@BCNS] Eng Water Overheat B@BCNS (PAGE 40-125) Failure code [B@CRNS] HST Oil Overheat B@CRNS (PAGE 40-126) Failure code [B@CRZG] HST Charge Press B@CRZG Low (PAGE 40-127) Failure code [CA111] ECM Critical Internal CA111 Failure (PAGE 40-128) Failure code [CA115] Eng Ne and Bkup Speed CA115 Sens Error (PAGE 40-129) Failure code [CA122] Chg Air Press Sensor High CA122 Error (PAGE 40-130) Failure code [CA123] Chg Air Press Sensor Low CA123 Error (PAGE 40-132) Failure code [CA131] Throttle Sensor High Error CA131 (PAGE 40-134) Failure code [CA132] Throttle Sensor Low Error CA132 (PAGE 40-136) Failure code [CA144] Coolant Temp Sens High CA144 Error (PAGE 40-138) Failure code [CA145] Coolant Temp Sens Low CA145 Error (PAGE 40-140) Failure code [CA153] Chg Air Temp Sensor High CA153 Error (PAGE 40-142) Failure code [CA154] Chg Air Temp Sensor Low CA154 Error (PAGE 40-144) Failure code [CA187] Sensor 2 Supply Volt Low CA187 Error (PAGE 40-146) Failure code [CA221] Ambient Press Sensor CA221 High Error (PAGE 40-148) Failure code [CA222] Ambient Press Sensor Low CA222 Error (PAGE 40-150) Failure code [CA227] Sensor 2 Supply Volt High CA227 Error (PAGE 40-152) Failure code [CA234] Eng Overspeed (PAGE 40CA234 153) Failure code [CA238] Ne Speed Sensor Supply CA238 Volt Error (PAGE 40-154) Failure code [CA271] IMV/PCV1 Short Error CA271 (PAGE 40-155) 6091NX

D61EM-23M0

1 Controller

Action level

HST

—

MON

—

MON

—

MON

—

MON

L01

MON

L03

ENG

L03

ENG

L02

HST

L02

HST

L02

ENG

L04

ENG

L04

ENG

L03

ENG

L03

ENG

L03

ENG

L03

ENG

L01

ENG

L01

ENG

L03

ENG

L03

ENG

L03

ENG

L03

ENG

L03

ENG

L03

ENG

L02

ENG

L01

ENG

L03

Category Remarks history Mechanical system Electrical system Electrical system Electrical system Mechanical system Mechanical system Mechanical system Mechanical system Mechanical system Mechanical system Electrical system Electrical system Electrical system Electrical system Electrical system Electrical system Electrical system Electrical system Electrical system Electrical system Electrical system Electrical system Electrical system Electrical system Mechanical system Electrical system Electrical system 40-107

40 Troubleshooting

Related information on troubleshooting

Failure code CA272 CA322 CA323 CA324 CA325 CA331 CA332 CA342 CA351 CA352 CA386 CA428 CA429 CA435 CA441 CA442 CA449 CA451 CA452 CA488 CA553 CA689 CA731 CA757 CA778 CA2185 CA2186 CA2249 40-108

Failure (Displayed on screen) Failure code [CA272] IMV/PCV1 Open Error (PAGE 40-157) Failure code [CA322] Inj #1(L#1) Open/Short Error (PAGE 40-159) Failure code [CA323] Inj #5(L#5) Open/Short Error (PAGE 40-161) Failure code [CA324] Inj #3(L#3) Open/Short Error (PAGE 40-163) Failure code [CA325] Inj #6(L#6) Open/Short Error (PAGE 40-165) Failure code [CA331] Inj #2(L#2) Open/Short Error (PAGE 40-167) Failure code [CA332] Inj #4(L#4) Open/Short Error (PAGE 40-169) Failure code [CA342] Calibration Code Incompatibility (PAGE 40-171) Failure code [CA351] Injectors Drive Circuit Error (PAGE 40-172) Failure code [CA352] Sensor 1 Supply Volt Low Error (PAGE 40-173) Failure code [CA386] Sensor 1 Supply Volt High Error (PAGE 40-175) Failure code [CA428] Water in Fuel Sensor High Error (PAGE 40-176) Failure code [CA429] Water in Fuel Sensor Low Error (PAGE 40-178) Failure code [CA435] Eng Oil Press Sw Error (PAGE 40-180) Failure code [CA441] Battery Voltage Low Error (PAGE 40-181) Failure code [CA442] Battery Voltage High Error (PAGE 40-183) Failure code [CA449] Rail Press Very High Error (PAGE 40-184) Failure code [CA451] Rail Press Sensor High Error (PAGE 40-185) Failure code [CA452] Rail Press Sensor Low Error (PAGE 40-187) Failure code [CA488] Chg Air Temp High Torque Derate (PAGE 40-189) Failure code [CA553] Rail Press High Error (PAGE 40-190) Failure code [CA689] Eng Ne Speed Sensor Error (PAGE 40-191) Failure code [CA731] Eng Bkup Speed Sens Phase Error (PAGE 40-193) Failure code [CA757] All continuous Data Lost Error (PAGE 40-195) Failure code [CA778] Eng Bkup Speed Sensor Error (PAGE 40-196) Failure code [CA2185] Throt Sensor Sup Volt High Error (PAGE 40-201) Failure code [CA2186] Throt Sensor Sup Volt Low Error (PAGE 40-202) Failure code [CA2249] Rail Press Very Low Error (PAGE 40-203)

Controller

Action level

ENG

L03

ENG

L03

ENG

L03

ENG

L03

ENG

L03

ENG

L03

ENG

L03

ENG

L04

ENG

L03

ENG

L03

ENG

L03

ENG

L01

ENG

L01

ENG

L01

ENG

L04

ENG

L04

ENG

L03

ENG

L03

ENG

L03

ENG

L03

ENG

L01

ENG

L01

ENG

L01

ENG

L04

ENG

L01

ENG

L03

ENG

L03

ENG

L03

Category history Electrical system Electrical system Electrical system Electrical system Electrical system Electrical system Electrical system Electrical system Electrical system Electrical system Electrical system Electrical system Electrical system Electrical system Electrical system Electrical system Electrical system Electrical system Electrical system Electrical system Electrical system Electrical system Electrical system Electrical system Electrical system Electrical system Electrical system Electrical system

Remarks

D61EM-23M0

40 Troubleshooting

Related information on troubleshooting

Failure code

Failure (Displayed on screen)

Failure code [CA2311] IMV Solenoid Error (PAGE 40-204) Failure code [CA2555] Grid Htr Relay Volt Low CA2555 Error (PAGE 40-205) Failure code [CA2556] Grid Htr Relay Volt High CA2556 Error (PAGE 40-207) Failure code [D130KA] Neutral relay Open D130KA (PAGE 40-209) Failure code [D130KB] Neutral relay Short circuit D130KB (PAGE 40-211) Failure code [D130KY] Neutral relay: Hot Short D130KY (PAGE 40-213) Failure code [D19JKZ] Personal Code Relay D19JKZ Abnormality (PAGE 40-215) Failure code [D811MC] KOMTRAX Error (PAGE D811MC 40-218) Failure code [D862KA] GPS Antenna Open D862KA Circuit (PAGE 40-219) Failure code [D8ALKA] Operating Lamp Open D8ALKA Circuit (KOMTRAX) (PAGE 40-220) Failure code [D8ALKB] Operating Lamp Short D8ALKB Circuit (KOMTRAX) (PAGE 40-222) Failure code [D8AQKR] CAN2 Discon D8AQKR (KOMTRAX) (PAGE 40-223) Failure code [DAF0MB] Monitor ROM DAF0MB Abnormality (PAGE 40-224) Failure code [DAF0MC] Monitor Error (PAGE 40DAF0MC 225) Failure code [DAF8KB] Camera Power Supply DAF8KB Short Circuit (PAGE 40-226) Failure code [DAF9KQ] Model Selection DAF9KQ Abnormality (PAGE 40-227) Failure code [DAFGMC] GPS Module Error DAFGMC (PAGE 40-228) Failure code [DAFLKA] Operating Lamp Open DAFLKA Circuit (Monitor) (PAGE 40-229) Failure code [DAFLKB] Operating Lamp Short DAFLKB Circuit (Monitor) (PAGE 40-231) Failure code [DAFQKR] CAN2 Discon (Monitor) DAFQKR (PAGE 40-232) Failure code [DAJ000] HST controller: DAJ000 Abnormality in controller (PAGE 40-233) Failure code [DAJ0KQ] HST controller: Type DAJ0KQ select signal (PAGE 40-234) Failure code [DAJ0KT] HST controller: DAJ0KT Abnormality in controller (PAGE 40-235) Failure code [DAJ0MC] HST Con Error DAJ0MC (PAGE 40-236) Failure code [DAJ1KK] HST controller: Source DAJ1KK voltage low (PAGE 40-237) Failure code [DAJ2KK] HST controller: Output DAJ2KK voltage low (PAGE 40-239) Failure code [DAJ5KK] HST: Sensor volt 5V (0) DAJ5KK Out of normal range (PAGE 40-241) Failure code [DAJ6KK] HST: Sensor volt 5V (1) DAJ6KK Out of normal range (PAGE 40-244) CA2311

D61EM-23M0

Controller

Action level

ENG

L03

ENG

L01

ENG

L01

HST

L01

HST

L01

HST

L01

MON

L03

KOMTRAX KOMTRAX KOMTRAX KOMTRAX

— — — —

MON

—

MON

—

MON

—

MON

L03

MON

L03

KOMTRAX

—

MON

—

MON

—

KOMTRAX

—

HST

—

HST

L03

HST

L03

HST

—

HST

L04

HST

L04

HST

L04

HST

L03

Remarks

40-109

40 Troubleshooting

Related information on troubleshooting

Failure code DAJLKA DAJLKB DAJPMA DAJQKR DAJRKR DB2QKR DD12KA DD12KB DD13KA DD13KB DD14KA DD14KB DDKAKA DDKAKB DDKFL4 DDKGL4 DDKHKA DDKHKB DDNLKA DDNLKB DDP6KA DDP6KB DDP6MA DDU1FS DDU1KA DDU1KY DFA4KX DFA4KZ 40-110

Failure (Displayed on screen) Failure code [DAJLKA] Operating Lamp Open Circuit (HST Con) (PAGE 40-246) Failure code [DAJLKB] Operating Lamp Short Circuit (HST Con) (PAGE 40-248) Failure code [DAJPMA] Inconsistency of Option Selection (HST) (PAGE 40-249) Failure code [DAJQKR] CAN2 Discon (HST Con) (PAGE 40-250) Failure code [DAJRKR] CAN1 Discon (HST Con) (PAGE 40-251) Failure code [DB2QKR] CAN2 Discon (Engine Con) (PAGE 40-252) Failure code [DD12KA] Shift up SW: Open (PAGE 40-256) Failure code [DD12KB] Shift up SW: Short Circuit (PAGE 40-258) Failure code [DD13KA] Shift down SW: Open (PAGE 40-260) Failure code [DD13KB] Shift down SW: Short Circuit (PAGE 40-262) Failure code [DD14KA] Parking lever SW: Open (PAGE 40-264) Failure code [DD14KB] Parking lever SW: Short circuit (PAGE 40-267) Failure code [DDKAKA] Blade float Sw: Open (PAGE 40-271) Failure code [DDKAKB] Blade float Sw: Short circuit (PAGE 40-273) Failure code [DDKFL4] Left Angle Sw: Signal mismatch (PAGE 40-275) Failure code [DDKGL4] Right Angle Sw: Signal mismatch (PAGE 40-277) Failure code [DDKHKA] iB Sw: Open (PAGE 40279) Failure code [DDKHKB] iB Sw: Short circuit (PAGE 40-281) Failure code [DDNLKA] Weq lock Sw: Open (PAGE 40-283) Failure code [DDNLKB] Weq lock Sw: Short circuit (PAGE 40-286) Failure code [DDP6KA] Brake Pressure Sensor: Open (PAGE 40-289) Failure code [DDP6KB] Brake Pressure Sensor: Hot Short (PAGE 40-291) Failure code [DDP6MA] Brake pressure sensor: Malfunction (PAGE 40-293) Failure code [DDU1FS] Parking lever Switch 2: Signal mismatch (PAGE 40-295) Failure code [DDU1KA] Parking lever Sw2: Open (PAGE 40-298) Failure code [DDU1KY] Parking lever Sw2: Hot Short (PAGE 40-301) Failure code [DFA4KX] Blade lift lever: Main and Sub Error (PAGE 40-303) Failure code [DFA4KZ] Blade lift lever: Main and Sub Error (PAGE 40-304)

Controller

Action level

HST

—

HST

—

HST

L01

MON

L03

MON

L03

MON

L03

HST

L03

HST

L03

HST

L03

HST

L03

HST

L03

HST

L03

HST

L01

HST

L01

HST

L01

HST

L01

HST

L01

HST

L01

HST

L03

HST

L03

HST

L03

HST

L03

HST

L03

HST

L03

HST

L03

HST

L03

HST

L01

HST

L01

Remarks

D61EM-23M0

40 Troubleshooting

Related information on troubleshooting

Failure code DFA4L8 DFA5KA DFA5KB DFA6KA DFA6KB DFA7KX DFA7KZ DFA7L8 DFA8KA DFA8KB DFA9KA DFA9KB DGS1KA DGS1KX DH21KA DH21KB DHA4KA DHH7KA DHH7KB DHH8KA DHH8KB DHH9KA DHH9KB DHHAKA DHHAKB DK30KA DK30KB DK30KX D61EM-23M0

Failure (Displayed on screen) Failure code [DFA4L8] Blade lift lever: Signal mismatch (PAGE 40-305) Failure code [DFA5KA] Blade lift lever1: Open (PAGE 40-306) Failure code [DFA5KB] Blade lift lever1: Hot Short (PAGE 40-309) Failure code [DFA6KA] Blade lift lever2: Open (PAGE 40-311) Failure code [DFA6KB] Blade lift lever2: Hot Short (PAGE 40-313) Failure code [DFA7KX] Blade tilt lever: Main and Sub Error (PAGE 40-315) Failure code [DFA7KZ] Blade tilt lever: Main and Sub Error (PAGE 40-316) Failure code [DFA7L8] Blade tilt lever: Signal mismatch (PAGE 40-317) Failure code [DFA8KA] Blade tilt lever1: Open (PAGE 40-318) Failure code [DFA8KB] Blade tilt lever1: Hot Short (PAGE 40-321) Failure code [DFA9KA] Blade tilt lever2: Open (PAGE 40-323) Failure code [DFA9KB] Blade tilt lever2: Hot Short (PAGE 40-326) Failure code [DGS1KA] HST oil temp sensor: Open (PAGE 40-328) Failure code [DGS1KX] HST oil temp sensor: Out of normal range (PAGE 40-330) Failure code [DH21KA] Weq pressure sensor: Open (PAGE 40-331) Failure code [DH21KB] Weq pressure sensor: Hot Short (PAGE 40-333) Failure code [DHA4KA] Air Cleaner Clog Sensor Open Circuit (PAGE 40-335) Failure code [DHH7KA] LF HST Pressure Sensor: Open (PAGE 40-337) Failure code [DHH7KB] LF HST Pressure Sensor: Hot Short (PAGE 40-339) Failure code [DHH8KA] RF HST Pressure Sensor: Open (PAGE 40-341) Failure code [DHH8KB] RF HST Pressure Sensor: Hot Short (PAGE 40-343) Failure code [DHH9KA] LR HST Pressure Sensor: Open (PAGE 40-345) Failure code [DHH9KB] LR HST Pressure Sensor: Hot Short (PAGE 40-347) Failure code [DHHAKA] RR HST Pressure Sensor: Open (PAGE 40-349) Failure code [DHHAKB] RR HST Pressure Sensor: Hot Short (PAGE 40-351) Failure code [DK30KA] ST lever1: Open (PAGE 40-353) Failure code [DK30KB] ST lever1: Hot Short (PAGE 40-356) Failure code [DK30KX] ST lever: Main and Sub Error (PAGE 40-358)

Controller

Action level

HST

L01

HST

L01

HST

L01

HST

L01

HST

L01

HST

L01

HST

L01

HST

L01

HST

L01

HST

L01

HST

L01

HST

L01

HST

L01

HST

L01

HST

L01

HST

L01

MON

L01

HST

L03

HST

L03

HST

L03

HST

L03

HST

L03

HST

L03

HST

L03

HST

L03

HST

L03

HST

L03

HST

L04

Remarks

40-111

40 Troubleshooting

Related information on troubleshooting

Failure code DK30KZ DK30L8 DK31KA DK31KB DK40KA DK40KB DK55KX DK55KZ DK55L8 DK56KA DK56KB DK57KA DK57KB DLM0KX DLM1KA DLM1KB DLM1MA DLM2KA DLM2KB DLM2MA DLM3KA DLM3KB DLM3MB DN21FS DR21KX DR31KX DV20KB DW4BKA 40-112

Failure (Displayed on screen) Failure code [DK30KZ] ST lever: Main and Sub Error (PAGE 40-359) Failure code [DK30L8] ST lever: Signal mismatch (PAGE 40-360) Failure code [DK31KA] ST lever2: Open (PAGE 40-361) Failure code [DK31KB] ST lever2: Hot Short (PAGE 40-364) Failure code [DK40KA] Decel/Brake potentiometer: Open (PAGE 40-366) Failure code [DK40KB] Decel/Brake potentiometer: Hot Short (PAGE 40-369) Failure code [DK55KX] FR lever: Main and Sub Error (PAGE 40-371) Failure code [DK55KZ] FR lever: Main and Sub Error (PAGE 40-372) Failure code [DK55L8] FR lever: Signal mismatch (PAGE 40-373) Failure code [DK56KA] FR lever1: Open (PAGE 40-374) Failure code [DK56KB] FR lever1: Hot Short (PAGE 40-377) Failure code [DK57KA] FR lever2: Open (PAGE 40-380) Failure code [DK57KB] FR lever2: Hot Short (PAGE 40-383) Failure code [DLM0KX] HST Motor Speed Sensor: Left/Right Error (PAGE 40-385) Failure code [DLM1KA] Left HST motor speed sensor: Open (PAGE 40-386) Failure code [DLM1KB] Left HST motor speed sensor: Short circuit (PAGE 40-388) Failure code [DLM1MA] Left HST motor speed sensor: Malfunction (PAGE 40-390) Failure code [DLM2KA] Right HST motor speed sensor: Open (PAGE 40-391) Failure code [DLM2KB] Right HST motor speed sensor: Short circuit (PAGE 40-393) Failure code [DLM2MA] Right HST motor speed sensor: Malfunction (PAGE 40-395) Failure code [DLM3KA] Fan rev. sensor: Open (PAGE 40-396) Failure code [DLM3KB] Fan rev. sensor: Short circuit (PAGE 40-398) Failure code [DLM3MB] Fan control: Mismatch (PAGE 40-400) Failure code [DN21FS] Decel/Brake pedal SW: Signal mismatch (PAGE 40-401) Failure code [DR21KX] Camera 2 Picture Rev. Drive Abnormality (PAGE 40-403) Failure code [DR31KX] Camera 3 Picture Rev. Drive Abnormality (PAGE 40-404) Failure code [DV20KB] Back-up alarm: Short circuit (PAGE 40-405) Failure code [DW4BKA] Parking brake solenoid: Open (PAGE 40-407)

Controller

Action level

HST

L04

HST

L03

HST

L03

HST

L03

HST

L03

HST

L03

HST

L04

HST

L04

HST

L03

HST

L03

HST

L03

HST

L03

HST

L03

HST

L03

HST

L01

HST

—

HST

—

HST

L01

HST

—

HST

—

HST

L01

HST

L01

HST

L01

HST

L03

MON

L01

MON

L01

HST

L01

HST

L04

Remarks

D61EM-23M0

40 Troubleshooting

Related information on troubleshooting

Failure code

Failure (Displayed on screen)

Failure code [DW4BKB] Parking brake solenoid: Short circuit (PAGE 40-409) Failure code [DW4BKY] Parking brake solenoid: DW4BKY Hot Short (PAGE 40-411) Failure code [DW7BKA] Fan reverse solenoid: DW7BKA Open (PAGE 40-413) Failure code [DW7BKB] Fan reverse solenoid: DW7BKB Short circuit (PAGE 40-415) Failure code [DW7EKA] Slow brake solenoid: DW7EKA Open (PAGE 40-416) Failure code [DW7EKB] Slow brake solenoid: DW7EKB Short circuit (PAGE 40-418) Failure code [DW7EKY] Slow brake solenoid: DW7EKY Hot Short (PAGE 40-420) Failure code [DWN5KA] Fan EPC: Open (PAGE DWN5KA 40-422) Failure code [DWN5KB] Fan EPC: Short circuit DWN5KB (PAGE 40-424) Failure code [DWN5KY] Fan EPC: Hot Short DWN5KY (PAGE 40-425) Failure code [DXA4KA] LF HST pump EPC: DXA4KA Open (PAGE 40-427) Failure code [DXA4KB] LF HST pump EPC: DXA4KB Short circuit (PAGE 40-429) Failure code [DXA4KY] LF HST pump EPC: Hot DXA4KY Short (PAGE 40-430) Failure code [DXA5KA] LR HST pump EPC: DXA5KA Open (PAGE 40-432) Failure code [DXA5KB] LR HST pump EPC: DXA5KB Short circuit (PAGE 40-434) Failure code [DXA5KY] LR HST pump EPC: Hot DXA5KY Short (PAGE 40-436) Failure code [DXA6KA] RF HST pump EPC: DXA6KA Open (PAGE 40-438) Failure code [DXA6KB] RF HST pump EPC: DXA6KB Short circuit (PAGE 40-440) Failure code [DXA6KY] RF HST pump EPC: Hot DXA6KY Short (PAGE 40-441) Failure code [DXA7KA] RR HST pump EPC: DXA7KA Open (PAGE 40-443) Failure code [DXA7KB] RR HST pump EPC: DXA7KB Short circuit (PAGE 40-445) Failure code [DXA7KY] RR HST pump EPC: Hot DXA7KY Short (PAGE 40-446) Failure code [DXHRKA] Blade lift up EPC: Open DXHRKA (PAGE 40-448) Failure code [DXHRKB] Blade lift up EPC: Short DXHRKB circuit (PAGE 40-451) Failure code [DXHRKY] Blade lift up EPC: Hot DXHRKY short (PAGE 40-453) Failure code [DXHSKA] Blade lift down EPC: DXHSKA Open (PAGE 40-455) Failure code [DXHSKB] Blade lift down EPC: DXHSKB Short circuit (PAGE 40-458) Failure code [DXHSKY] Blade lift down EPC: DXHSKY Hot short (PAGE 40-460) DW4BKB

D61EM-23M0

Controller

Action level

HST

L04

HST

L03

HST

L01

HST

L01

HST

L04

HST

L04

HST

L03

HST

L03

HST

L03

HST

L01

HST

L03

HST

L03

HST

L04

HST

L03

HST

L03

HST

L04

HST

L03

HST

L03

HST

L04

HST

L03

HST

L03

HST

L04

HST

L01

HST

L01

HST

L03

HST

L01

HST

L01

HST

L03

Remarks

40-113

40 Troubleshooting

Related information on troubleshooting

Failure code DXHTKA DXHTKB DXHTKY DXHUKA DXHUKB DXHUKY DXJ4KA DXJ4KB DXJCKA DXJCKB DXJCKY DXJDKA DXJDKB DXJDKY DXK1KA DXK1KB DXK1KY DXK2KA DXK2KB DXK2KY

Failure (Displayed on screen) Failure code [DXHTKA] Blade tilt left EPC: Open (PAGE 40-462) Failure code [DXHTKB] Blade tilt left EPC: Short circuit (PAGE 40-464) Failure code [DXHTKY] Blade tilt left EPC: Hot short (PAGE 40-465) Failure code [DXHUKA] Blade tilt right EPC: Open (PAGE 40-467) Failure code [DXHUKB] Blade tilt right EPC: Short circuit (PAGE 40-469) Failure code [DXHUKY] Blade tilt right EPC: Hot short (PAGE 40-470) Failure code [DXJ4KA] Weq lock Sol.: Open (PAGE 40-472) Failure code [DXJ4KB] Weq lock Sol.: Short circuit (PAGE 40-474) Failure code [DXJCKA] Blade angle left EPC: Open (PAGE 40-476) Failure code [DXJCKB] Blade angle left EPC: Short circuit (PAGE 40-477) Failure code [DXJCKY] Blade angle left EPC: Hot short (PAGE 40-478) Failure code [DXJDKA] Blade angle right EPC: Open (PAGE 40-480) Failure code [DXJDKB] Blade angle right EPC: Short circuit (PAGE 40-481) Failure code [DXJDKY] Blade angle right EPC: Hot short (PAGE 40-482) Failure code [DXK1KA] Left HST motor EPC: Open (PAGE 40-484) Failure code [DXK1KB] Left HST motor EPC: Short circuit (PAGE 40-486) Failure code [DXK1KY] Left HST motor EPC: Hot Short (PAGE 40-487) Failure code [DXK2KA] Right HST motor EPC: Open (PAGE 40-489) Failure code [DXK2KB] Right HST motor EPC: Short circuit (PAGE 40-491) Failure code [DXK2KY] Right HST motor EPC: Hot Short (PAGE 40-492)

Controller

Action level

HST

L01

HST

L01

HST

L03

HST

L01

HST

L01

HST

L03

HST

L03

HST

L03

HST

L01

HST

L01

HST

L03

HST

L01

HST

L01

HST

L03

HST

L03

HST

L03

HST

L04

HST

L03

HST

L03

HST

L04

Remarks

In this table, failure codes are arranged in the order of characters from numeric to alphabetic character.

A component in charge is a controller or the machine monitor in charge of the system check. MON: Machine monitor ENG: Engine controller HST: HST controller KOMTRAX: KOMTAX terminal

The failure codes that do not have numbers in the action level columns are not displayed on the standard screen even when a failure related to them occurs. They are simply recorded in the abnormality record (electrical system or mechanical system) of the service menu.

The history classification column shows in which system each failure is classified, the electrical system or mechanical system, when it is recorded in the abnormality record. For details, see "Troubleshooting by failure code (Display of code)".

40-114

D61EM-23M0

40 Troubleshooting

Troubleshooting by failure code (Display of code)

Failure code [6091NX] HST Oil Filter Clogging

Action level Detail of failure Action of controller Problem on machine

HST Oil Filter Clogging Failure code Failure (Mechanical system) 6091NX • When HST oil temperature reaches 50°C or above, HST oil filter clogging switch is activated. • Flashes "HST Oil Filter Clogging" caution lamp on machine monitor. • If cause of failure disappears, machine becomes normal by itself. • If machine is used as it is, hydraulic component may be damaged.

Related information

• Input signal (ON/OFF) from HST oil filter clogging switch can be checked with monitoring function (Code: 40912: "HST SW Input 2") • Method of reproducing failure code: Start engine and increase HST oil temperature to 50° C or above.

No.

Cause

HST oil filter clogging (when system is normal)

1. Turn starting switch to OFF position. 2. Disconnect connector CFS and connect T-adapter to male side. Defective HST oil filter 3. Start engine. clogging switch (internal open HST oil filter: When Min. 1 Mz circuit) normal *1 Resis- Between CFS (male) (1) and (2) HST oil filter: When tance Max. 1 z clogged *2

1. Turn starting switch to OFF position. 2. Disconnect connectors ST2, ST3, and CFS, and insert T-adapters to Open circuit in wiring harness each female side. Between ST3 (female) (29) and CFS (female) (wire breakage or defective Max. 1 z contact of connector) Resis- (1) tance Between ST2 (female) (29) and CFS (female) Max. 1 z (2)

Defective HST controller

Defective machine monitor

Procedure, measuring location, criteria and remarks Since a phenomenon leading to HST oil filter clogging may have occurred in the past or occurs currently, check cause of clogging and condition of machine damage, then repair machine.

1. Turn starting switch to OFF position. 2. Insert T-adapter to connectors ST2 and ST3. 3. Start engine. HST oil filter: When 7 to 11 V normal Between ST3 (29) and Voltage ST2 (29) HST oil filter: When Max. 1 V clogged If no failure is found by check on causes 1 to 4, machine monitor may be defective. (Since this is an internal defect, troubleshooting cannot be performed.)

• Differential pressure between inlet and outlet of HST oil filter *1: Max. 0.2 MPa {Max. 2 kg/cm2} *2: Max. 0.2 MPa {Max. 2 kg/cm2}

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Circuit diagram related to HST oil filter clogging sensor

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Failure code [989L00] Engine Controller Lock Caution 1 Action level – Detail of failure Action of machine monitor Problem on machine Related information No. 1

Failure code 989L00

Engine Controller Lock Caution 1 (Machine monitor system)

• Engine controller lock up is detected (Factor 1). • None in particular • If cause of failure disappears, machine becomes normal by itself. • Engine cannot be started. • If this failure code is generated after machine monitor is replaced, user password must be changed to one before replacement. • Method of reproducing failure code: Turn starting switch to ON position.

Cause Replacement of machine monitor

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Failure

Procedure, measuring location, criteria and remarks This problem may be caused by replacement of machine monitor.

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Failure code [989M00] Engine Controller Lock Caution 2 Action level – Detail of failure Action of machine monitor Problem on machine Related information No. 1 2

Failure code 989M00

Engine Controller Lock Caution 2 (Machine monitor system)

• Engine controller lock up is detected (Factor 2). • None in particular • If cause of failure disappears, machine becomes normal by itself. • Engine cannot be started. • If this failure code is generated after machine monitor is replaced, user password must be changed to one before replacement. • Method of reproducing failure code: Turn starting switch to ON position.

Cause Replacement of machine monitor Defective machine monitor

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Failure

Procedure, measuring location, criteria and remarks This problem may be caused by replacement of machine monitor. If this failure code is displayed while machine monitor is not replaced, machine monitor may be defective. (Since this is an internal defect, troubleshooting cannot be performed.)

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Failure code [989N00] Engine Controller Lock Caution 3 Engine Controller Lock Caution 3 (Machine monitor system)

Action level – Detail of failure Action of machine monitor Problem on machine Related information

• Tries automatic recovery. • If cause of failure disappears, machine becomes normal by itself.

No.

Cause

Defective engine controller

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Failure code 989N00

Failure

• Engine controller lock up is detected (Factor 3).

• Method of reproducing failure code: Failure code cannot be reproduced since machine recovers when cause of failure disappears. Procedure, measuring location, criteria and remarks If this failure code is generated repeatedly, engine controller may be defective. (Since this is an internal defect, troubleshooting cannot be performed.)

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Failure code [AA10NX] Air Cleaner Clogging Action level L01 Detail of failure Action of controller Problem on machine Related information No. 1

Air Cleaner Clogging Failure code Failure (Machine monitor system) AA10NX • Signal voltage of air cleaner clogging switch became not 1 V or less while engine was running, and machine monitor detected clogging of air cleaner (open of sensor contacts). • Displays air cleaner clogging monitor in yellow on machine monitor. • If machine is used as it is, engine may be damaged. • Input signal (ON/OFF) from air cleaner clogging switch can be checked with monitoring function. (Code: 04501" Monitor input 2") • Method of reproducing failure code: Start engine.

Cause Air Cleaner Clogging (When system works properly)

Procedure, measuring location, criteria and remarks Air cleaner may be clogged. Check it for clogging. If clogged, clean or replace it.

1. Turn starting switch to OFF position. 2. Disconnect connector 116 and connect T-adapter to male side. 3. Start engine. Defective air cleaner clogging Air cleaner: When Max. 1 z switch (internal open circuit) normal*1 Resis- Between 116 (male) (1) Air cleaner: When and (2) tance clogged *2 Min. 1 Mz

1. Turn starting switch to OFF position. Open circuit in wiring harness 2. Disconnect connectors CM02 and 116, and insert T-adapters to each female side. (wire breakage or defective Between CM02 (female) (4) and 116 (female) Max. 1 z contact of connector) Resis- (1) tance Between 116 (female) (2) and ground Max. 1 z

Defective machine monitor

1. Turn starting switch to OFF position. 2. Insert T-adapters into connectors CM01 and CM02. 3. Start engine. Air cleaner: When normal Between CM02 (4) and Voltage CM01 (3) Air cleaner: When clogged

Max. 1 V Min. 10 V

• Air cleaner suction resistance *1: Max. -3,430 Pa {-350 mmH2O} *2: -7,470 ± 490 Pa {-762 ± 50 mmH2O}

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Circuit diagram related to air cleaner clogging sensor

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Failure code [AB00KE] Charge Voltage Low Action level L03 Detail of failure Action of machine monitor Problem on machine

Charge Voltage Low Failure code Failure (Machine monitor system) AB00KE • While engine is running, voltage from alternator lowers, and machine monitor detects that battery charge voltage is low. • Displays the charge level monitor in red on machine monitor. • If machine continues to be operated, battery may not be charged.

Related information

• Battery voltage can be checked with monitoring function. (Code: 04300" Battery Charge Volt") • Method of reproducing failure code: Start engine.

No.

Cause

Procedure, measuring location, criteria and remarks

Defective power generation of 1. Turn starting switch to OFF position. 2. Remove T16 terminal cover. alternator 3. Start engine. (When system works Between T16 (2) and Engine speed: Medium properly) Voltage ground or above

27.5 to 29.5 V

1. Turn starting switch to OFF position. 2. Disconnect diodes D1 and D2, and connect T-adapters to each male side. a Measure by using diode range. 2

Defective diode

Between D1(male) (1) (+) and (2) (-) Continuity

Between D1 (male) (2) (+) and (1) (-) Between D2 (male) (1) (+) and (2) (-) Between D2 (male) (2) (+) and (1) (-)

Defective wiring harness or machine monitor

1. Turn starting switch to OFF position. 2. Insert T-adapter into connector CM01. 3. Start engine. Voltage Between CM01 (16) and ground

No continuity Continuity No continuity Continuity

20 to 30 V

a If no failure is found by check on cause 2, this check is not required. Open circuit in wiring harness 1. Turn starting switch to OFF position. 2. Disconnect connector CM01, and connect T-adapter to female side. (wire breakage or defective 3. Remove T16 terminal cover. contact of connector) Resis- Between CM01 (female) (16) and T16 Max. 1 z tance a If no failure is found by check on cause 2, this check is not required. Ground fault in wiring harness 1. Turn starting switch to OFF position. 2. Disconnect connector CM01, and connect T-adapter to female side. (contact with ground circuit) 3. Remove T16 terminal cover. Resis- Between ground and CM01 (female) (16) or Min. 1 Mz tance T16 If no failure is found by above checks, machine monitor is defective. Defective machine monitor (Since this is an internal defect, troubleshooting cannot be performed.)

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Circuit diagram related to alternator

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Failure code [B@BAZG] Eng Oil Press Low Action level L03 Detail of failure Action of machine monitor Problem on machine Related information

No. 1

Engine Oil Pressure Low Failure code Failure B@BAZG (Engine controller system) • Engine controller determines that engine oil pressure drops abnormally because signal voltage from engine oil pressure switch drops to ground level while engine is running. • Lights up engine oil pressure monitor in red on machine monitor. • If machine is used as it is, engine may be seized. • Engine oil pressure switch signal is input to engine controller that transmits information to machine monitor through CAN communication system. • For troubleshooting of engine oil pressure switch while engine is not running, see failure code [CA435]. • Method of reproducing failure code: Start engine.

Cause Drop of engine oil pressure (When system works properly)

Procedure, measuring location, criteria, and remarks Engine oil pressure may drops. Check it and remove cause of failure if oil pressure is low.

If no failure is found by check on cause 1, engine oil pressure sensor Defective engine oil pressure system may be defective. Perform troubleshooting for failure code sensor system [CA435].

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Failure code [B@BCNS] Eng Water Overheat Action level L02 Detail of failure Action of controller Problem on machine Related information

No. 1

Engine Water Overheat Failure code Failure B@BCNS (Engine controller system) • While engine is running, voltage from engine coolant temperature sensor drops, so engine controller determines that engine coolant is overheated. • Displays engine coolant temperature monitor red on machine monitor. • If machine is operated as it is, engine may seize up. • Signal voltage of engine coolant temperature sensor is input to engine controller that transmits information to machine monitor through CAN communication system. • Engine coolant temperature can be checked with monitoring function (Code: 04107 Engine coolant temperature) • Method of reproducing failure code: Start engine.

Cause Overheating of engine coolant (when system is normal) Defective engine coolant temperature sensor system

D61EM-23M0

Procedure, measuring location, criteria and remarks Engine coolant may overheat. Check it and remove cause if it overheats. If no failure is found by checks on cause 1, engine coolant temperature sensor system may be defective. Carry out troubleshooting for failure codes [CA144] and [CA145].

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Failure code [B@CRNS] HST Oil Overheat Action level L02 Detail of failure Action of controller Problem on machine

Related information

Failure code B@CRNS

Failure

HST Oil Overheat (Mechanical system)

• "HST oil temperature" is indicated while engine is running. • Displays HST oil temperature gauge monitor on machine monitor in red. • If cause of failure disappears, machine becomes normal by itself. • If machine is used as it is, hydraulic component of HST or that of work equipment may be damaged. • HST oil temperature from HST oil temperature sensor and HST oil temperature sensor voltage can be checked with monitoring function. (Code: 04401 "HST Oil Temperature", Code: 04402 "HST Temp. Sens Volt") • Method of reproducing failure code: Start engine. a What is implied is the same since the identical sensor is used for measuring HST oil temperature and hydraulic oil temperature.

No. 1

Procedure, measuring location, criteria and remarks Cause HST oil temperature overheat Since a phenomenon leading to HST oil overheat may have occurred in the past or occurs currently, check cause of overheat and condition of (When system works machine damage, then repair machine. properly) If no failure is found by check on cause 1, HST (hydraulic) oil temperature gauge system may be defective. Perform troubleshooting Defective HST oil for failure codes [DGS1KA] and [DGS1KX] or "E-16 Hydraulic oil temperature gauge system temperature gauge does not indicate correct temperature" in E mode.

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Failure code [B@CRZG] HST Charge Press Low

HST Charge Pressure Low Action level Failure code Failure B@CRZG (Mechanical system) L02 Detail of Brake pressure (charge pressure) lowers with parking brake released while engine is running. failure • Displays "HST Charge Press Low" monitor on machine monitor. Action of • If cause of failure disappears, machine becomes normal by itself. controller Problem on • If machine is used as it is, hydraulic component of HST or that of work equipment may be damaged. machine • Brake pressure from brake pressure sensor and L.H. brake sensor voltage can be checked with monitoring function. General (Code: 91902 "Brake Pressure", Code 91903 "Brake Pressure Sensor") information • Method of reproducing failure code: Start engine, operate parking brake lever (to FREE position) and operate brake pedal (to RELEASE position). No. 1

Cause HST charge pressure low (When system works properly) Defective brake oil pressure sensor system Defective parking brake solenoid system (electrical system) Defective slow brake solenoid system (electrical system) Defective parking brake solenoid system or slow brake solenoid system (sticking, etc.)

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Procedure, measuring location, criteria and remarks Since a phenomenon leading to low HST charge pressure may have occurred in the past or occurs currently, check cause of low pressure and condition of machine damage, then repair machine. If no failure is found by check of cause 1, brake oil pressure sensor system may be defective. Perform troubleshooting for "Failure codes [DDP6KA], [DDP6KB], and [DDP6MA] Brake oil pressure sensor error". If no failure is found by check of cause 2, parking brake solenoid system may be defective. Perform troubleshooting for "Failure codes [DW4BKA] and [DW4BKB] Parking brake solenoid error". If no failure is found by check of cause 3, slow brake solenoid system may be defective. Perform troubleshooting for "Failure codes [DW7EKA] and [DW7EKB] Slow brake solenoid error". If no failure is found by check of cause 4, measure the output pressures of slow brake solenoid and parking brake solenoid. For details, see Testing and adjusting "Testing output pressure of solenoid valve". If any failure is found, solenoid valve is defective.

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Failure code [CA111] ECM Critical Internal Failure Action level L04 Detail of failure Action of controller Problem on machine Related information No. 1

Failure code CA111

ECM Critical Internal Failure (Engine controller system)

• Engine controller has internal defect. • None in particular • Engine continues to run normally, but it may stop during running or may not be able to start if it is stopped. • Power supply voltage of engine controller can be checked with monitoring function. (Code: 03203) • Method of reproducing failure code: Turn starting switch to ON position

Cause Defective engine controller system

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Failure

Procedure, measuring location, criteria and remarks Perform troubleshooting for failure code [CA757].

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Failure code [CA115] Eng Ne and Bkup Speed Sens Error Action level L04 Detail of failure Action of controller Problem on machine Related information No. 1 2 3 4

Failure code CA115

Failure

Engine Ne and Bkup Speed Sensor Error (Engine controller system)

• Both signals from engine Ne speed sensor and engine Bkup speed sensor are unusual. • None in particular. • Engine stops. • Engine does not start. • Method of reproducing failure code: Start engine.

Procedure, measuring location, criteria and remarks Cause Connectors of engine Ne speed sensor and Bkup sensor may be poorly Poor connection of sensor (incorrectly) connected. Check their connection. connector Defective Ne speed sensor Perform troubleshooting for failure code [CA689]. system Defective Bkup speed sensor Perform troubleshooting for failure code [CA778]. system If no failure is found by above checks, engine controller is defective. Defective engine controller (Since this is an internal defect, troubleshooting cannot be performed.)

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Failure code [CA122] Chg Air Press Sensor High Error Action level L03 Detail of failure Action of controller Problem on machine

Failure code

Failure

Charge Air pressure sensor high error (Engine controller system)

CA122 • High voltage is detected in pressure signal circuit of charge (boost) pressure & temperature sensor. • Takes it that charge (boost) pressure is at calculated value and allows engine to run. • Restricts engine output and allows engine to run. • Closes EGR valve. • Stops regeneration control by KDPF. • Engine output lowers.

Related information

• Input voltage from charge (boost) pressure sensor can be checked with monitoring function. (Code: 36501 (V)) • Charge (boost) pressure sensed by charge (boost) pressure sensor can be checked with monitoring function. (Code: 36500 (kPa)) • Method of reproducing failure code: Turn starting switch to ON position. • Since troubleshooting "socket" for this sensor features female connector only, it is not usable for checking open circuit in wiring harness and voltage at sensor connector (not designed for T-adapter). • If sensor connector is disconnected, code [CA123] for "Low Error" is displayed, even in normal condition.

No.

Cause

Defective wiring harness connector

Defective sensor power source 2 circuit

Procedure, measuring location, criteria and remarks 1. See descriptions of wiring harness and connectors in "c: Electrical equipment" in "Checks before troubleshooting" of "General information on troubleshooting", and check it. 2. Turn starting switch to ON position. If this failure code does not appear, wiring harness connector is defective. a If this failure code appears, perform the following. If failure code [CA187] or [ CA227] is also displayed, perform troubleshooting for it first. 1. Turn starting switch to OFF position. 2. Disconnect connector BOOST PRESS & IMT. 3. Turn starting switch to ON position. If failure code changes from [CA122] to [CA123] ,boost pressure sensor is defective. a Failure code [CA153] for temperature sensor is displayed at the same time. Ignore this failure code since it appears because of disconnection of sensor. • Reference 1. Turn starting switch to OFF position. 2. Insert T-adapter in connector ECM J1. 3. Turn starting switch to ON position. Sensor 0.3 to 4.7 Voltage Between ECM J1 (15) and (59) output V

Defective boost pressure & temperature sensor

1. Turn starting switch to OFF position. 2. Disconnect connectors ECM J1 and BOOST PRESS & IMT, and connect T-adapter to female side of ECM J1. Short circuit in wiring harness Min. 100 Resis- Between ECM J1 (female) (15) and (60) kz tance

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No.

Cause

Hot short circuit in wiring harness

Defective engine controller

Procedure, measuring location, criteria and remarks 1. Turn starting switch to OFF position. 2. Disconnect connector BOOST PRESS & IMT, and connect Tadapter to connector ECM J1. 3. Turn starting switch to ON position (with connector BOOST PRESS & IMT disconnected). Voltage Between ECM J1 (15) and (59) Max. 1 V If no failure is found by above checks, engine controller is defective. (Since this is internal defect, troubleshooting cannot be performed.)

Circuit diagram related to boost pressure sensor

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Failure code [CA123] Chg Air Press Sensor Low Error Action level 6 Detail of failure Action of controller Problem on machine

Failure code

Failure

Charge air pressure sensor low error (Engine controller system)

CA123 • Low voltage is detected in pressure signal circuit of charge (boost) pressure & temperature sensor. • Takes it that charge (boost) pressure is at calculated value and allows engine to run. • Restricts engine output and allows engine to run. • Closes EGR valve. • Stops regeneration control by KDPF. • Engine output lowers.

Related information

No.

Cause

Defective wiring harness connector

Defective power supply system of charge pressure sensor (boost pressure sensor)

If failure code [CA187] or [CA227] is also displayed, perform troubleshooting for it first.

1. Turn starting switch to OFF position. 2. Disconnect connectors CAM SENSOR, AMB. AIR PRESSURE, BOOST PRESS & IMT, and ECM J1. Short circuit in wiring harness 3. Connect T-adapter to female side of ECM J1. Resis- Between ECM J1 (female) (15) and (59) Min. 100 kz tance 1. Turn starting switch to OFF position. Ground fault of wiring 2. Disconnect connectors ECM J1 and BOOST PRESS & IMT, and harness (contact with ground connect T-adapter to female side of ECM J1. circuit) Resis- Between ECM J1 (female) (15) and ground Min. 100 kz tance If no failure is found by the above checks, there may be open circuit in Open circuit in wiring harness wiring harness. (*) a If causes 1 to 5 are not cause for failure and check result of cause 6 is abnormal, sensor is defective. Defective boost pressure and 1. Turn starting switch to OFF position. temperature sensor 2. Insert T-adapter in connector ECM J1. (improper input voltage to 3. Turn starting switch to ON position. engine controller) Sensor Voltage Between ECM J1 (15) and (59) 0.3 to 4.7 V output If no failure is found by above checks, engine controller is defective. Defective engine controller (Since this is internal defect, troubleshooting cannot be performed.)

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*: See "Troubleshooting method for open circuit in wiring harness of pressure sensor system" of "General information on troubleshooting". Circuit diagram related to boost pressure sensor

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Failure code [CA131] Throttle Sensor High Error Action level L03 Detail of failure Action of controller Problem on machine

Failure code CA131

Failure

Throttle Sensor High Error (Engine controller system)

• High voltage appears in signal circuit of fuel dial sensor. • Runs engine with signal voltage of fuel dial as fixed value (as if fuel dial is at the half position) • Engine speed cannot be controlled by using fuel control dial.

Related information

• Signal voltage from fuel control dial can be checked with monitoring function. (Code: 03000 "Fuel Dial Sensor Volt") • Method of reproducing failure code: Turn starting switch to ON position.

No.

Cause

Defective wiring harness connector

Defective throttle sensor power supply system

1. Turn starting switch to OFF position. 2. Disconnect connector FP, and connect T-adapter to male side. Defective throttle sensor (fuel Between FP (male) (A) and (C) 4.0 to 6.0 kz dial) Resis- Between FP (male) (B) and (C) 3 to 7 kz tance Between FP (male) (A) and (B) 3 to 7 kz

Open or short circuit in wiring harness

a If no failure is found by check on cause 4, this check is not required. 1. Turn starting switch to OFF position. Short circuit in wiring harness 2. Disconnect connectors CE03 and FP, and connect T-adapter to either female side. Resis- Between CE03 (female) (51) and (42), or Min. 1 Mz tance between FP (female) (A) and (B)

Hot short circuit in wiring harness

Defective engine controller

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a If this failure code is displayed, perform following checks. If failure code [CA2185] is also displayed, perform troubleshooting for it first.

1. Turn starting switch to OFF position. 2. Disconnect connector CE03, and connect T-adapter to female side. 4.0 to 6.0 kz Resis- Between CE03 (female) (41) and (42) tance Between CE03 (female) (51) and (42) 3 to 7 kz

1. Turn starting switch to OFF position. 2. Disconnect connector FP and connect T-adapter to female side. 3. Turn starting switch to ON position. Voltage Between FP (female) (B) and ground Max 1 V If no failure is found by above checks, engine controller is defective. (Since this is an internal defect, troubleshooting cannot be performed.) • Reference 1. Turn starting switch to OFF position. 2. Insert T-adapter into connector CE03. 3. Turn starting switch to ON position. 4. Operate fuel dial and perform troubleshooting. Power Between CE03 (42) and (41) 4.75 to 5.25 V supply Voltage Sensor Between CE03 (51) and (41) 0.5 to 4.5 V output

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Circuit diagram related to throttle sensor

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Failure code [CA132] Throttle Sensor Low Error Action level L03 Detail of failure Action of controller Problem on machine

Failure code CA132

Failure

Throttle Sensor Low Error (Engine controller system)

• Low voltage appears in signal circuit of fuel dial sensor. • Runs engine with signal voltage of fuel dial as fixed value (as if fuel dial is at the half position) • Engine speed cannot be controlled by using fuel control dial.

Related information

• Signal voltage from fuel control dial can be checked with monitoring function. (Code: 03000 "Fuel Dial Sensor Volt") • Method of reproducing failure code: Turn starting switch to ON position.

No.

Cause

Defective wiring harness connector

Defective throttle sensor power supply system

1. Turn starting switch to OFF position. 2. Disconnect connector FP, and connect T-adapter to male side. Defective throttle sensor (fuel Between FP (male) (A) and (C) 4.0 to 6.0 kz dial) Between FP (male) (B) and (C) Resistance 3 to 7 kz Between FP (male) (A) and (B) 3 to 7 kz

Open or short circuit in wiring harness

a If no failure is found by check on cause 4, this check is not required. 1. Turn starting switch to OFF position. 2. Disconnect connector CE03 and FP, and connect T-adapter to each female side. Open circuit in wiring harness Between CE03 (female) (42) and FP (wire breakage or defective Max. 1 z (female) (A) contact of connector) Between CE03 (female) (51) and FP Resistance (female) (B) Max. 1 z Between CE03 (female) (41) and FP Max. 1 z (female) (C)

a If no failure is found by check on cause 4, this check is not required. 1. Turn starting switch to OFF position. Short circuit in wiring harness 2. Disconnect connectors CE03 and FP, and connect T-adapter to either female side. Between CE03 (female) (51) and (41), or Resistance between FP (female) (B) and (C) Min. 1 Mz

1. Turn starting switch to OFF position. Ground fault in wiring harness 2. Disconnect connectors CE03 and FP, and connect T-adapter to either female side. (contact with ground circuit) Between ground and CE03 (female) (51) or Resistance FP (female) (B) Min. 1 Mz

Defective engine controller

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a If this failure code is displayed, perform following checks. If failure code [CA2186] is also displayed, perform troubleshooting for it first.

1. Turn starting switch to OFF position. 2. Disconnect connector CE03, and connect T-adapter to female side. Between CE03 (female) (41) and (42) 4.0 to 6.0 kz Resistance Between CE03 (female) (41) and (51) 3 to 7 kz

If no failure is found by above checks, engine controller is defective. (Since this is an internal defect, troubleshooting cannot be performed.) • Reference D61EM-23M0

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No.

Procedure, measuring location, criteria and remarks

Cause

1. Turn starting switch to OFF position. 2. Insert T-adapter into connector CE03. 3. Turn starting switch to ON position. 4. Operate fuel dial and perform troubleshooting. Between CE03 (42) and (41) Power supply 4.75 to 5.25 V Voltage Between CE03 (51) and (41) Sensor output 0.4 to 4.5 V Circuit diagram related to throttle sensor

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Failure code [CA144] Coolant Temp Sens High Error Action level L01 Detail of failure Action of controller Problem on machine

Related information

No.

Failure code CA144

Failure

Coolant temperature sensor high error (Engine controller system)

• High voltage is detected in engine coolant temperature sensor signal circuit. • Sets coolant temperature to fixed temperature (100 °C ),and allows engine to run. • Engine does not start easily at low temperature. • Overheat prevention function does not work. • Signal voltage from engine coolant temperature sensor can be checked with monitoring function (Code: 04105 (V)). • Temperature sensed by engine coolant temperature sensor can be checked with monitoring function. (Code: 04107 (°C)) • Method of reproducing failure code: Turn starting switch to ON position. • This failure code is displayed if temperature sensor connector is disconnected. • Because troubleshooting "socket" for this sensor features female connector only, it is not connectable to female connector of sensor wiring harness, and thus not usable for checking open circuit (not designed for T-adapter). Cause

Defective wiring harness connector

Defective coolant temperature sensor

1. Turn starting switch to OFF position. 2. Disconnect connector ECM J1 and connect T-adapter to female side of connector. Between ECM J1 (female) (14) and (13) Open or short circuit in wiring (coolant temperature: Min. 0 °C ) harness Resis700 z to 37 a Resistance is the same as that shown in tance kz resistance characteristics table of coolant temperature sensor of cause 2. If no failure is found in above checks, engine controller is defective. Defective engine controller (Since this is internal defect, troubleshooting cannot be performed.)

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Circuit diagram related to coolant temperature sensor

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Failure code [CA145] Coolant Temp Sens Low Error Action level 6 Detail of failure Action of controller Problem on machine

Related information

No.

Failure code CA145

Failure

Coolant temperature sensor low error (Engine controller system)

• Low voltage is detected in engine coolant temperature sensor signal circuit. • Sets coolant temperature to fixed temperature (100 °C ),and allows engine to run. • Engine does not start easily at low temperature. • Overheat prevention function does not work. • Signal voltage from engine coolant temperature sensor can be checked with monitoring function (Code: 04105 (V)). • Temperature sensed by engine coolant temperature sensor can be checked with monitoring function. (Code: 04107 (°C)) • Method of reproducing failure code: Turn starting switch to ON position. • If temperature sensor connector is disconnected, this failure code is not displayed but failure code [CA144] for "High Error" is displayed. Cause

Defective wiring harness connector

Defective coolant temperature sensor

Short circuit in wiring harness

a If coolant temperature sensor has resistance of 700 z to 37 kz with coolant temperature above 0 °C , regard coolant temperature sensor as normal. 0 °C 30 to 37 kz Between COOLANT TEMP (male) 9.3 to 10.7 25 °C (A) and (B) kz 50 °C 3.2 to 3.8 kz Resis- a Coolant temperature 80 °C 1.0 to 1.3 kz -Resistance characteristics tance 95 °C 700 to 800 z All coolant tempera- Min. 100 kz Between (B) and ground ture range 1. Turn starting switch to OFF position. 2. Disconnect connector ECM J1 and connect T-adapter to female side of connector. Between ECM J1 (female) (14) and (13) (coolant temperature: Min. 0 °C ) Resis700 z to 37 a Resistance is the same as that shown in tance kz resistance characteristics table of coolant temperature sensor of cause 2.

1. Turn starting switch to OFF position. Ground fault in wiring 2. Disconnect connectors ECM J1 and COOLANT TEMP, and connect harness (contact with ground T-adapters to female side of ECM J1. circuit) Resis- Between ECM J1 (female) (14) and ground Min. 100 kz tance If no failure is found in above checks, engine controller is defective. Defective engine controller (Since this is internal defect, troubleshooting cannot be performed.)

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Troubleshooting by failure code (Display of code)

Circuit diagram related to coolant temperature sensor

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Failure code [CA153] Chg Air Temp Sensor High Error Action level L03 Detail of failure Action of controller Problem on machine

Related information

No.

Failure code CA153

Failure

Charge Air Temperature sensor High Error. (Engine controller system)

• High voltage is detected in charge (boost) temperature sensor signal circuit. • Takes it that charge temperature (boost temperature) is at calculated value and allows engine to run. • Closes EGR valve. • Restricls engine output and allows engine to run. • Stops KDPF regeneration control. • Engine does not start easily at low temperature. • Engine output lowers. • Signal voltage from charge temperature sensor (boost temperature sensor) can be checked with monitoring function (Code: 18501 (V)). • Temperature sensed by charge temperature sensor (boost temperature sensor) can be checked with monitoring function. (Code: 18500 ( °C )) • Method of reproducing failure code: Turn starting switch to ON position. • Because troubleshooting "socket" for this sensor features female connector only, it is not connectable to female connector of sensor wiring harness, and thus not usable for checking open circuit (not designed for T-adapter). • This failure code is displayed if temperature sensor connector is disconnected. Cause

Defective wiring harness connector

Defective charge temperature sensor

a If temperature sensor has resistance of 80 z to 48 kz , regard charge temperature sensor as normal. -40 °C 41 to 48 kz -20 °C 14 to 16 kz Between BOOST PRESS & IMT 0 °C 5.4 to 6.1 kz Resis- (male) (3) and (4) 30 °C 1.6 to 1.8 kz tance a Charge temperature 60 °C 560 to 600 z -Resistance characteristics 90 °C 230 to 250 z 130 °C 80 to 90 z

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Circuit diagram related to boost temperature sensor

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Failure code [CA154] Chg Air Temp Sensor Low Error Action level L03 Detail of failure Action of controller Problem on machine

Related information

No.

Failure code CA154

Failure

Charge Air Temperature sensor Low Error. (Engine controller system)

• Low voltage is detected in charge (boost) temperature sensor signal circuit. • Takes it that charge temperature (boost temperature) is at calculated value and allows engine to run. • Closes EGR valve. • Restricts engine output and allows engine to run. • Stops KDPF regeneration control. • Engine does not start easily at low temperature. • Engine output lowers. • Signal voltage from charge temperature sensor (boost temperature sensor) can be checked with monitoring function (Code: 18501 (V)). • Temperature sensed by charge temperature sensor (boost temperature sensor) can be checked with monitoring function. (Code: 18500 ( °C )) • Method of reproducing failure code: Turn starting switch to ON position. • If temperature sensor connector is disconnected, this failure code is not displayed but failure code [CA153] for "High Error" is displayed. Cause

Defective wiring harness connector

Defective charge temperature sensor

a If charge temperature sensor has resistance of 80 z to 48 kz , regard charge temperature sensor as normal. -40 °C 41 to 48 kz -20 °C 14 to 16 kz Between BOOST PRESS & IMT 0 °C 5.4 to 6.1 kz (male) (3) and (4) 30 °C 1.6 to 1.8 kz Resis- a Charge temperature 60 °C 560 to 600 z tance -Resistance characteristics 90 °C 230 to 250 z 130 °C 80 to 90 z Whole Between BOOST PRESS & IMT Min. 100 kz range (male) (3) and ground

1. Turn starting switch to OFF position. 2. Disconnect connector ECM J1 and connect T-adapter to female side of connector. Open or short circuit in wiring Between ECM J1 (female) (5) and (59) harness Resis- a Use Temperature-Resistance 80 z to 48 tance kz characteristics table for troubleshooting on cause 2. 1. Turn starting switch to OFF position. Ground fault in wiring 2. Disconnect connectors ECM J1 and BOOST PRESS & IMT, and harness (contact with ground connect T-adapter to female side of ECM J1. circuit) Resis- Between ECM J1 (female) (5) and ground Min. 100 kz tance If no failure is found in above checks, engine controller is defective. Defective engine controller (Since this is internal defect, troubleshooting cannot be performed.)

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Troubleshooting by failure code (Display of code)

Circuit diagram related to boost temperature sensor

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Failure code [CA187] Sensor 2 Supply Volt Low Error Action level L03 Detail of failure

Action of controller

Failure code CA187

Failure

Sensor 2 Supply Voltage Low Error (Engine controller system)

• Low voltage appears in sensor power supply 2 (5 V) circuit. • Ignores signals from Bkup speed sensor and controls engine by using Ne speed sensor signals. • Ignores signals from ambient pressure sensor and allows engine to run taking it that ambient pressure is at fixed value (52.44 kPa {0.53 kg/cm2}). • Ignores signals from boost pressure sensor and allows engine to run taking it that boost pressure is at calculated value. • Ignores signals from crankcase pressure sensor and allows engine to run taking it that crankcase pressure is at fixed value (0 kPa). • Closes EGR valve. • Limits engine output and allows engine to run. • Stops KDPF regeneration control.

Problem on machine Related information

• Engine output decreases.

No.

Cause

• Method of reproducing failure code: Turn starting switch to ON position.

Defective wiring harness connector

Defective sensor or wiring harness

Defective relevant system

Defective engine controller

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a Other failure codes (many codes) are also displayed. They are generated because of disconnection of connector. Ignore failure codes other than [CA187]. Sensor and wiring Connector harness Cam (Bkup speed) CAM SENSOR sensor Boost pressure sensor BOOST PRESS & IMT Connector Ambient pressure AMB. AIR PRESSURE sensor Crankcase pressure P57 sensor Engine harness ECM J1 If failure codes other than this code are displayed, perform troubleshooting for them. 1. Turn starting switch to OFF position. 2. Disconnect connector ECM J1 and connect T-adapters to male side. 3. Turn starting switch to ON position with connector ECM J1 disconnected. 4.75 to 5.25 Voltage Between ECM J1 (male) (60) and (59) V

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Circuit diagram related to sensor power supply 2 circuit

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Failure code [CA221] Ambient Press Sensor High Error Action level L03 Detail of failure

Failure code

Failure

CA221

Ambient Pressure Sensor High Error (Engine controller system)

• High voltage appears in signal circuit of ambient pressure sensor.

Action of controller

• Takes it that ambient pressure is at fixed value of 52.44 kPa (0.53 kg/cm 2) and allows engine to run. • Limits engine output and allows engine to run. • Closes EGR valve. • Stops KDPF regeneration control.

Problem on machine

• Engine output decreases.

Related information

• Input voltage from ambient pressure sensor can be checked with monitoring function. (Code: 37401 (V)) • Ambient pressure sensed by ambient pressure sensor can be checked with monitoring function. (Code: 37400 (kPa)) • Method of reproducing failure code: Turn starting switch to ON position.

No.

Cause

Procedure, measuring location, criteria and remarks

a If this failure code appears, perform following checks. If failure code [CA187] or [ CA227] is also displayed, perform troubleshooting for it first. 1. Turn starting switch to OFF position. 2. Disconnect connector AMB. AIR PRESSURE. 3. Turn starting switch to ON position. If failure code [CA221] changes to [CA222], sensor is defective. • Reference 1. Turn starting switch to OFF position. 2. Insert T-adapters in connector ECM J1. 3. Turn starting switch to ON position. Sensor 0.5 to 4.5 Voltage Between ECM J1 (16) and (59) output V

Defective ambient pressure sensor

1. Turn starting switch to OFF position. 2. Disconnect connectors AMB AIR PRESSURE and ECM J1, and Open circuit in wiring harness connect T-adapters to either female side. (wire breakage or defective a Open circuit in GND line contact of connector) Between ECM J1 (female) (59) and AMB. AIR PRESSURE Max. 10 z (female) (2)

1. Turn starting switch to OFF position. 2. Disconnect connectors ECM J1 and AMB AIR PRESSURE, and Short circuit in wiring harness connect T-adapters to either female side. Resis- Between ECM J1 (60) and (16), or between Min. 100 AMB. AIR PRESSURE (female) (1) and (3) tance kz

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No.

Cause

Hot short circuit in wiring harness

Defective engine controller

Procedure, measuring location, criteria and remarks 1. Turn starting switch to OFF position. 2. Disconnect connector AMB. AIR PRESSURE. 3. Connect T-adapters to female side of connector AMB. AIR PRESSURE or insert T-adapters into connector ECM J1. 4. Turn starting switch to ON position with connector AMB AIR PRESSURE disconnected. Between ECM J1 (16) and (59), or between Voltage Max. 1 V AMB. AIR PRESSURE (female) (3) and (2) If no failure is found by above checks, engine controller is defective. (Since this is an internal defect, troubleshooting cannot be performed.)

Circuit diagram related to ambient pressure sensor

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Failure code [CA222] Ambient Press Sensor Low Error Action level L03 Detail of failure

Failure code CA222

Failure

Ambient Pressure Sensor Low Error (Engine controller system)

• Low voltage appears in signal circuit of ambient pressure sensor.

Action of controller

• Takes it that ambient pressure is at fixed value of 52.44 kPa (0.53 kg/cm2) and allows engine to run. • Limits engine output and allows engine to run. • Closes EGR valve. • Stops KDPF regeneration control.

Problem on machine

• Engine output decreases.

Related information

No.

• Input voltage from ambient pressure sensor can be checked with monitoring function. (Code: 37401 (V)) • Ambient pressure sensed by ambient pressure sensor can be checked with monitoring function. (Code: 37400 (kPa)) • This failure code appears if sensor connector is disconnected. • Method of reproducing failure code: Turn starting switch to ON position. Procedure, measuring location, criteria and remarks

Cause

1. See descriptions of wiring harness and connectors in "c: Electrical equipment" in "Checks before troubleshooting" of "General information on troubleshooting", and check it. Defective harness connector 2. Turn starting switch to ON position. If this failure code disappears, harness connector is defective. a If this failure code appears, perform following checks. If failure code [CA187] or [ CA227] is also displayed, perform troubleshooting for it first.

Defective ambient pressure sensor power supply circuit

1. Turn starting switch to OFF position. 2. Disconnect connector AMB. AIR PRESSURE and connect Tadapters to female side. 3. Turn starting switch to ON position. Power Between AMB. AIR PRESSURE 4.75 to Voltage supply (female) (1) and (2) 5.25 V input 1. Turn starting switch to OFF position. 2. Disconnect connectors AMB AIR PRESSURE and ECM J1, and connect T-adapters to either female side.

Open circuit in wiring harness (wire breakage or defective contact of connector)

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a If power supply input is normal in check on cause 2, this check is not required. Max. 10 z Between ECM J1 (female) (60) and AMB. AIR PRESSURE (female) (1) Resistance

a If power supply input is normal in check on cause 2, this check is not required. Max. 10 z Between ECM J1 (female) (59) and AMB. AIR PRESSURE (female) (2) Between ECM J1 (female) (16) and AMB. AIR Max. 10 z PRESSURE (female) (3) (sensor output)

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No.

Procedure, measuring location, criteria and remarks

Cause

1. Turn starting switch to OFF position. Ground fault in wiring harness 2. Disconnect connectors ECM J1 and AMB. AIR PRESSURE, and connect T-adapters to either female side. (contact with ground circuit) Resis- Between ground and ECM J1 (female) (16) or Min. 100 AMB. AIR PRESSURE (female) (3) tance kz

1. Turn starting switch to OFF position. 2. Disconnect connectors ECM J1 and AMB. AIR PRESSURE, and Short circuit in wiring harness connect T-adapters to either female side. Resis- Between ECM J1 (16) and (59), or between Min. 100 AMB. AIR PRESSURE (female) (2) and (3) tance kz

Defective ambient pressure sensor

1. Turn starting switch to OFF position. 2. Insert T-adapters in connector ECM J1. 3. Turn starting switch to ON position. Sensor 0.5 to 4.5 output V If no failure is found by above checks, engine controller is defective. (Since this is an internal defect, troubleshooting cannot be performed.) Voltage

Defective engine controller

Between ECM J1 (16) and (59)

Circuit diagram related to ambient pressure sensor

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Failure code [CA227] Sensor 2 Supply Volt High Error Action level L03 Detail of failure

Action of controller

Problem on machine Related information No. 1

Failure code CA227

Sensor 2 Supply Voltage High Error (Engine controller system)

• High voltage appears in sensor power supply 2 circuit. • Ignores signals from Bkup speed sensor and controls engine by using Ne speed sensor signals. • Ignores signals from ambient pressure sensor and allows engine to run taking it that ambient pressure is at fixed value (52.44 kPa {0.53 kg/cm2}). • Ignores signals from boost pressure sensor and allows engine to run taking it that boost pressure is at calculated value. • Ignores signals from crankcase pressure sensor and allows engine to run taking it that crankcase pressure is at fixed value (0 kPa). • Closes EGR valve. • Limits engine output and allows engine to run. • Stops KDPF regeneration control. • Engine output decreases. • Method of reproducing failure code: Turn starting switch to ON position.

Cause Abnormally high sensor power supply 2 voltage

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Failure

Procedure, measuring location, criteria and remarks Perform same troubleshooting as that for failure code [CA187].

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Failure code [CA234] Eng Overspeed Action level L02 Detail of failure Action of controller Problem on machine Related information

Failure code CA234

Engine Overspeed (Engine controller system)

• Engine speed exceeds its operating range. • Regulates fuel injection rate so that engine speed lowers within operating range. • Engine speed fluctuates. • Engine speed can be checked with monitoring function. (Code: 01002 (rpm)) • Method of reproducing failure code: Start engine and run at high idle.

No. Cause 1 Improper fuel is used. 2

Defective relevant system

Improper machine usage

Defective engine controller

D61EM-23M0

Failure

Procedure, measuring location, criteria, and remarks Fuel used may be improper. Check it. If other failure codes are also displayed, perform troubleshooting for them. Method of using machine may be improper, so instruct operator on how to use machine properly. If no failure is found by above checks, engine controller is defective. (Since this is an internal defect, troubleshooting cannot be performed.)

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Failure code [CA238] Ne Speed Sensor Supply Volt Error Action level L01 Detail of failure Action of controller

Failure code

Failure

CA238

Ne Speed Sensor Supply Voltage Error (Engine controller system)

• Low voltage appears in power supply circuit of engine Ne speed sensor. • Controls engine by using signals from engine Bkup speed sensor.

Problem on machine

• • • •

Related information

• Method of reproducing failure code: Turn starting switch to ON position.

No.

Cause

Procedure, measuring location, criteria and remarks

Defective sensor

1. Turn starting switch to OFF position. 2. Disconnect connector CRANK SENSOR, and turn starting switch to ON position. If this failure code is not displayed, crank sensor is defective. a Other failure codes (many codes) are also displayed. They are generated because of disconnection of connector. Ignore failure codes other than [CA238].

Defective wiring harness

1. Turn starting switch to OFF position. 2. Disconnect harness connector ECM J1 and turn starting switch to ON position. If this failure code is not displayed, engine wiring harness is defective. a Other failure codes (many codes) are also displayed. They are generated because of disconnection of connector. Ignore failure codes other than [CA238].

Defective engine controller

1. Turn starting switch to OFF position. 2. Disconnect connector ECM J1 and connect T-adapters to male side. 3. Turn starting switch to ON position with engine wiring harness disconnected. 4.75 to 5.25 Voltage Between ECM J1 (male) (36) and (37) V

Circuit diagram related to Ne speed sensor

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Failure code [CA271] IMV/PCV1 Short Error Action level L03 Detail of failure Action of controller

Failure code CA271

Failure

IMV/PCV1 Short Error (Engine controller system)

• Short circuit is detected in drive circuit of supply pump actuator (IMV). • None in particular.

Problem on machine

• Engine speed does not increase from low idle speed. • Engine output decreases. • Common rail fuel pressure rises above command value.

Related information

• Method of reproducing failure code: Turn starting switch to ON position.

No.

Cause

Procedure, measuring location, criteria and remarks

1. Turn starting switch to OFF position. 2. Disconnect connector INLET METERING VALVE. Defective supply pump 3. Turn starting switch to ON position. actuator If failure code changes from [CA271] to [CA272] , supply pump actuator is defective. 1. Turn starting switch to OFF position. 2. Disconnect connector ECM J1 and connect T-adapters to female Short circuit or ground fault in side. wiring harness Between ECM J1 (female) (30) and (40) 1 to 5 z ResisMin. 100 tance Between ECM J1 (female) (30) and ground kz a If no failure is found by check on cause 3, this check is not required. 1. Turn starting switch to OFF position. Short circuit in wiring harness 2. Disconnect connectors ECM J1 and INLET METERING VALVE, and connect T-adapters to female side of ECM J1. Resis- Between ECM J1 (female) (30) and (40) Min. 100 tance kz a If no failure is found by check on cause 3, this check is not required. 1. Turn starting switch to OFF position. 2. Disconnect connectors ECM J1 and INLET METERING VALVE, and Ground fault in wiring harness connect T-adapters to female side of ECM J1. (contact with ground circuit) Min. 100 Between ECM J1 (female) (30) and ground kz Resistance Min. 100 Between ECM J1 (female) (40) and ground kz If no failure is found by above checks, engine controller is defective. Defective engine controller (Since this is an internal defect, troubleshooting cannot be performed.)

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Circuit diagram related to IMV/PCV1

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Failure code [CA272] IMV/PCV1 Open Error

IMV/PCV1 Open Error Action level Failure code Failure (Engine controller system) L03 CA272 Detail of • Open circuit is detected in drive circuit of supply pump actuator. failure Action of None in particular. controller Problem on • Engine runs but its speed does not stabilize. • Common rail fuel pressure rises above command value. machine • Method of reproducing failure code: Turn starting switch to ON position. • Since female connector alone is provided for "socket" used for troubleshooting of this Related sensor, it is not connectable to female connector on sensor wiring harness side and thus information not usable for check of open circuit (not designed as T-adapter). No.

Cause

Procedure, measuring location, criteria and remarks

1. See descriptions of wiring harness and connectors in "c: Electrical equipment" in "Checks before troubleshooting" of "General information on troubleshooting", and check it. Defective harness connector 2. Turn starting switch to ON position. If this failure code disappears, harness connector is defective. a If this failure code appears, perform following checks. 1. Turn starting switch to OFF position. 2. Disconnect connector INLET METERING VALVE. Between INLET METERING VALVE (male) (1) 1 to 5 z Resis- and (2) tance Between INLET METERING VALVE (male) (1) Min. 100 kz and ground

Defective supply pump actuator

1. Turn starting switch to OFF position. Open circuit or short circuit in 2. Disconnect connector ECM J1 and connect T-adapters to female side. wiring harness Resis- Between ECM J1 (female) (30) and (40) 1 to 5 z tance

Ground fault in wiring harness (contact with ground circuit)

Hot short circuit in wiring harness

Defective engine controller

D61EM-23M0

a If no failure is found by check on cause 3, this check is not required. 1. Turn starting switch to OFF position. 2. Disconnect connectors ECM J1 and INLET METERING VALVE, and connect T-adapters to female side of ECM J1. Min. 100 kz Resis- Between ECM J1 (female) (30) and ground tance Between ECM J1 (female) (40) and ground Min. 100 kz 1. Turn starting switch to OFF position. 2. Disconnect connector INLET METERING VALVE. 3. Insert T-adapters into connector ECM J1. 4. Turn starting switch to ON position (with connector INLET METERING VALVE connected) and start measurement after at least one minute. a Average voltage is displayed because of PWM control. Voltage Between ECM J1 (30) and (40) Max. 3 V If no failure is found by above checks, engine controller is defective. (Since this is an internal defect, troubleshooting cannot be performed.)

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Circuit diagram related to IMV/PCV1

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Failure code [CA322] Inj #1(L#1) Open/Short Error Action level L03 Detail of failure Action of controller Problem on machine Related information No.

Failure code CA322

Failure

Injector #1(L#1) Open/Short Error (Engine controller system)

• Open or short circuit is detected in drive circuit of No. 1 injector. • None in particular. • • • •

Engine runs with poor combustion or hunts. Engine output decreases. Method of reproducing failure code: Start engine. While engine is running normally, approx. 65 V of pulse voltage is supplied to injector (+) side. Because it is pulse voltage, it cannot be measured by using multimeter.

Cause

Procedure, measuring location, criteria and remarks

1. See descriptions of wiring harness and connectors in "c: Electrical equipment" in "Checks before troubleshooting" of "General information on troubleshooting", and check it. Defective harness connector 2. Turn starting switch to ON position. If this failure code disappears, harness connector is defective. a If this failure code appears, perform following checks. 1. Turn starting switch to OFF position. 2. Disconnect connector INJECTOR CYL 1 & 2 and connect T-adapters to male side. Between INJECTOR CYL 1 & 2 (male) (3) Max. 2 z Resis- and (4) tance Between INJECTOR CYL 1 & 2 (male) (3) Min. 100 kz and ground

Defective No. 1 injector

1. Turn starting switch to OFF position. 2. Disconnect connector ECM J1 and connect T-adapters to female Open circuit or ground fault in side. wiring harness Max. 2 z Resis- Between ECM J1 (female) (48) and (58) tance Between ECM J1 (female) (48) and ground Min. 100 kz

a If no failure is found by check on cause 3, this check is not required. 1. Turn starting switch to OFF position. Open circuit in wiring harness 2. Disconnect connectors ECM J1 and INJECTOR CYL 1 & 2, and connect T-adapters to each female side. (wire breakage or defective Between ECM J1 (female) (48) and contact of connector) Max. 2 z Resis- INJECTOR CYL 1 & 2 (female) (3) tance Between ECM J1 (female) (58) and Max. 2 z INJECTOR CYL 1 & 2 (female) (4)

a If no failure is found by check on cause 3, this check is not required. 1. Turn starting switch to OFF position. 2. Disconnect connectors ECM J1 and INJECTOR CYL 1 & 2, and connect T-adapters to either female side. Resis- Between ground and ECM J1 (female) (48) Min. 100 kz or INJECTOR CYL 1 & 2 (female) (3) tance

Ground fault in wiring harness (contact with ground circuit)

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No.

Procedure, measuring location, criteria and remarks

Cause

1. Turn starting switch to OFF position. 2. Disconnect connectors ECM J1 and INJECTOR CYL1 & 2, and connect T-adapters to female side of ECM J1. a Check by using multimeter in continuity mode. 6

7 8 9

No continuity Between ECM J1 (female) (48) and each pin (No sound is other than pin (48) heard) Continuity No continuity Between ECM J1 (female) (58) and each pin (No sound is other than pin (58) heard) Defective injector of other If failure codes of other injectors are displayed, perform troubleshooting cylinder for them first. Defective injector harness of If failure codes of other injectors are displayed, perform troubleshooting other cylinder for them first. If no failure is found by above checks, engine controller is defective. Defective engine controller (Since this is an internal defect, troubleshooting cannot be performed.) Short circuit in wiring harness

Circuit diagram related to injector #1

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Failure code [CA323] Inj #5(L#5) Open/Short Error Action level L03 Detail of failure Action of controller Problem on machine Related information No.

Failure code CA323

Failure

Injector #5(L#5) Open /Short Error (Engine controller system)

• Open or short circuit is detected in drive circuit of No. 5 injector. • None in particular. • • • •

Cause

Procedure, measuring location, criteria and remarks

1. See descriptions of wiring harness and connectors in "c: Electrical equipment" in "Checks before troubleshooting" of "General information on troubleshooting", and check it. Defective harness connector 2. Turn starting switch to ON position. If this failure code disappears, harness connector is defective. a If this failure code appears, perform following checks. 1. Turn starting switch to OFF position. 2. Disconnect connector INJECTOR CYL 5 & 6 and connect T-adapters to male side. Between INJECTOR CYL 5 & 6 (male) (3) Max. 2 z Resis- and (4) tance Between INJECTOR CYL 5 & 6 (male) (3) Min. 100 kz and ground

Defective No. 5 injector

1. Turn starting switch to OFF position. 2. Disconnect connector ECM J1 and connect T-adapters to female Open circuit or ground fault in side. wiring harness Max. 2 z Resis- Between ECM J1 (female) (44) and (54) tance Between ECM J1 (female) (44) and ground Min. 100 kz

a If no failure is found by check on cause 3, this check is not required. 1. Turn starting switch to OFF position. Open circuit in wiring harness 2. Disconnect connectors ECM J1 and INJECTOR CYL 5 & 6, and connect T-adapters to either female side. (wire breakage or defective Between ECM J1 (female) (44) and contact of connector) Max. 2 z Resis- INJECTOR CYL 5 & 6 (female) (3) tance Between ECM J1 (female) (54) and Max. 2 z INJECTOR CYL 5 & 6 (female) (4)

a If no failure is found by check on cause 3, this check is not required. 1. Turn starting switch to OFF position. 2. Disconnect connectors ECM J1 and INJECTOR CYL 5 & 6, and connect T-adapters to either female side. Resis- Between ground and ECM J1 (female) (44) Min. 100 kz or INJECTOR CYL 5 & 6 (female) (3) tance

Ground fault in wiring harness (contact with ground circuit)

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Troubleshooting by failure code (Display of code)

No.

Procedure, measuring location, criteria and remarks

Cause

1. Turn starting switch to OFF position. 2. Disconnect connectors ECM J1 and INJECTOR CYL 5 & 6, and connect T-adapters to female side of ECM J1. a Check by using multimeter in continuity mode. 6

Short circuit in wiring harness

No continuity Between ECM J1 (female) (44) and each pin (No sound is other than pin (44) heard) Continuity No continuity Between ECM J1 (female) (54) and each pin (No sound is other than pin (54) heard)

Defective injector of other cylinder

If failure codes of other injectors are displayed, perform troubleshooting for them first.

8 9

Defective injector harness of If failure codes of other injectors are displayed, perform troubleshooting other cylinder for them first. If no failure is found by above checks, engine controller is defective. Defective engine controller (Since this is an internal defect, troubleshooting cannot be performed.)

Circuit diagram related to injector #5

40-162

D61EM-23M0

40 Troubleshooting

Troubleshooting by failure code (Display of code)

Failure code [CA324] Inj #3(L#3) Open/Short Error Action level L03 Detail of failure Action of controller Problem on machine Related information No.

Failure code CA324

Failure

Injector #3(L#3) Open/Short Error (Engine controller system)

• Open or short circuit is detected in drive circuit of No. 3 injector. • None in particular. • • • •

Cause

Procedure, measuring location, criteria and remarks

1. See descriptions of wiring harness and connectors in "c: Electrical equipment" in "Checks before troubleshooting" of "General information on troubleshooting", and check it. Defective harness connector 2. Turn starting switch to ON position. If this failure code disappears, harness connector is defective. a If this failure code appears, perform following checks. 1. Turn starting switch to OFF position. 2. Disconnect connector INJECTOR CYL 3 & 4 and connect T-adapters to male side. Between INJECTOR CYL 3 & 4 (male) (3) Max. 2 z Resis- and (4) tance Between INJECTOR CYL 3 & 4 (male) (3) Min. 100 kz and ground

Defective No. 3 injector

1. Turn starting switch to OFF position. 2. Disconnect connector ECM J1 and connect T-adapters to female Open circuit or ground fault in side. wiring harness Max. 2 z Resis- Between ECM J1 (female) (46) and (56) tance Between ECM J1 (female) (46) and ground Min. 100 kz

a If no failure is found by check on cause 3, this check is not required. 1. Turn starting switch to OFF position. Open circuit in wiring harness 2. Disconnect connectors ECM J1 and INJECTOR CYL 3 & 4, and connect T-adapters to each female side. (wire breakage or defective Between ECM J1 (female) (46) and contact of connector) Max. 2 z Resis- INJECTOR CYL 3 & 4 (female) (3) tance Between ECM J1 (female) (56) and Max. 2 z INJECTOR CYL 3 & 4 (female) (4)

a If no failure is found by check on cause 3, this check is not required. 1. Turn starting switch to OFF position. 2. Disconnect connectors ECM J1 and INJECTOR CYL 3 & 4, and connect T-adapters to either female side. Resis- Between ground and ECM J1 (female) (46) Min. 100 kz or INJECTOR CYL 3 & 4 (female) (3) tance

Ground fault in wiring harness (contact with ground circuit)

D61EM-23M0

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40 Troubleshooting

Troubleshooting by failure code (Display of code)

No.

Procedure, measuring location, criteria and remarks

Cause

1. Turn starting switch to OFF position. 2. Disconnect connectors ECM J1 and INJECTOR CYL 3 & 4, and connect T-adapters to female side of ECM J1. a Check by using multimeter in continuity mode. 6

7 8 9

No continuity Between ECM J1 (female) (46) and each pin (No sound is other than pin (46) heard) Continuity No continuity Between ECM J1 (female) (56) and each pin (No sound is other than pin (56) heard) Defective injector of other If failure codes of other injectors are displayed, perform troubleshooting cylinder for them first. Defective injector harness of If failure codes of other injectors are displayed, perform troubleshooting other cylinder for them first. If no failure is found by above checks, engine controller is defective. Defective engine controller (Since this is an internal defect, troubleshooting cannot be performed.) Short circuit in wiring harness

Circuit diagram related to injector #3

40-164

D61EM-23M0

40 Troubleshooting

Troubleshooting by failure code (Display of code)

Failure code [CA325] Inj #6(L#6) Open/Short Error Action level L03 Detail of failure Action of controller Problem on machine Related information No.

Failure code CA325

Failure

Injector #6(#6) Open/Short Error (Engine controller system)

• Open or short circuit is detected in drive circuit of No. 6 injector. • None in particular. • • • •

Cause

Procedure, measuring location, criteria and remarks

1. See descriptions of wiring harness and connectors in "c: Electrical equipment" in "Checks before troubleshooting" of "General information on troubleshooting", and check it. Defective harness connector 2. Turn starting switch to ON position. If this failure code disappears, harness connector is defective. a If this failure code appears, perform following checks. 1. Turn starting switch to OFF position. 2. Disconnect connector INJECTOR CYL 5 & 6 and connect T-adapters to male side. Between INJECTOR CYL 5 & 6 (male) (1) Max. 2 z Resis- and (2) tance Between INJECTOR CYL 5 & 6 (male) (1) Min. 100 kz and ground

Defective No. 6 injector

1. Turn starting switch to OFF position. 2. Disconnect connector ECM J1 and connect T-adapters to female Open circuit or ground fault in side. wiring harness Max. 2 z Resis- Between ECM J1 (female) (45) and (55) tance Between ECM J1 (female) (45) and ground Min. 100 kz

a If no failure is found by check on cause 3, this check is not required. 1. Turn starting switch to OFF position. Open circuit in wiring harness 2. Disconnect connectors ECM J1 and INJECTOR CYL 5 & 6, and connect T-adapters to each female side. (wire breakage or defective Between ECM J1 (female) (45) and contact of connector) Max. 2 z Resis- INJECTOR CYL 5 & 6 (female) (1) tance Between ECM J1 (female) (55) and Max. 2 z INJECTOR CYL 5 & 6 (female) (2)

a If no failure is found by check on cause 3, this check is not required. 1. Turn starting switch to OFF position. 2. Disconnect connectors ECM J1 and INJECTOR CYL 5 & 6, and connect T-adapters to either female side. Resis- Between ground and ECM J1 (female) (45) Min. 100 kz or INJECTOR CYL 5 & 6 (female) (1) tance

Ground fault in wiring harness (contact with ground circuit)

D61EM-23M0

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40 Troubleshooting

Troubleshooting by failure code (Display of code)

No.

Procedure, measuring location, criteria and remarks

Cause

1. Turn starting switch to OFF position. 2. Disconnect connectors ECM J1 and INJECTOR CYL 5 & 6, and connect T-adapters to female side of ECM J1. a Check by using multimeter in continuity mode. 6

7 8 9

No continuity Between ECM J1 (female) (45) and each pin (No sound is other than pin (45) heard) Continuity No continuity Between ECM J1 (female) (55) and each pin (No sound is other than pin (55) heard) Defective injector of other If failure codes of other injectors are displayed, perform troubleshooting cylinder for them first. Defective injector harness of If failure codes of other injectors are displayed, perform troubleshooting other cylinder for them first. If no failure is found by above checks, engine controller is defective. Defective engine controller (Since this is an internal defect, troubleshooting cannot be performed.) Short circuit in wiring harness

Circuit diagram related to injector #6

40-166

D61EM-23M0

40 Troubleshooting

Troubleshooting by failure code (Display of code)

Failure code [CA331] Inj #2(L#2) Open/Short Error Action level L03 Detail of failure Action of controller Problem on machine Related information No.

Failure code CA331

Failure

Injector #2(L#2) Open/Short Error (Engine controller system)

• Open or short circuit is detected in drive circuit of No. 2 injector. • None in particular. • • • •

Cause

Procedure, measuring location, criteria and remarks

1. See descriptions of wiring harness and connectors in "c: Electrical equipment" in "Checks before troubleshooting" of "General information on troubleshooting", and check it. Defective harness connector 2. Turn starting switch to ON position. If this failure code disappears, harness connector is defective. a If this failure code appears, perform following checks. 1. Turn starting switch to OFF position. 2. Disconnect connector INJECTOR CYL 1 & 2 and connect T-adapters to male side. Between INJECTOR CYL 1 & 2 (male) (1) Max. 2 z Resis- and (2) tance Between INJECTOR CYL 1 & 2 (male) (2) Min. 100 kz and ground

Defective No. 2 injector

1. Turn starting switch to OFF position. 2. Disconnect connector ECM J1 and connect T-adapters to female Open circuit or ground fault in side. wiring harness Max. 2 z Resis- Between ECM J1 (female) (47) and (57) tance Between ECM J1 (female) (47) and ground Min. 100 kz

a If no failure is found by check on cause 3, this check is not required. 1. Turn starting switch to OFF position. Open circuit in wiring harness 2. Disconnect connectors ECM J1 and INJECTOR CYL1 & 2, and connect T-adapters to each female side. (wire breakage or defective Between ECM J1 (female) (47) and contact of connector) Max. 2 z Resis- INJECTOR CYL 1 & 2 (female) (2) tance Between ECM J1 (female) (57) and Max. 2 z INJECTOR CYL 1 & 2 (female) (1)

a If no failure is found by check on cause 3, this check is not required. 1. Turn starting switch to OFF position. 2. Disconnect connectors ECM J1 and INJECTOR CYL 1 & 2, and connect T-adapters to either female side. Resis- Between ground and ECM J1 (female) (47) Min. 100 kz or INJECTOR CYL 1 & 2 (female) (2) tance

Ground fault in wiring harness (contact with ground circuit)

D61EM-23M0

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40 Troubleshooting

Troubleshooting by failure code (Display of code)

No.

Procedure, measuring location, criteria and remarks

Cause

1. Turn starting switch to OFF position. 2. Disconnect connectors ECM J1 and INJECTOR CYL1 & 2, and connect T-adapters to female side of ECM J1. a Check by using multimeter in continuity mode. 6

7 8 9

No continuity Between ECM J1 (female) (47) and each pin (No sound is other than pin (47) heard) Continuity No continuity Between ECM J1 (female) (57) and each pin (No sound is other than pin (57) heard) Defective injector of other If failure codes of other injectors are displayed, perform troubleshooting cylinder for them first. Defective injector harness of If failure codes of other injectors are displayed, perform troubleshooting other cylinder for them first. If no failure is found by above checks, engine controller is defective. Defective engine controller (Since this is an internal defect, troubleshooting cannot be performed.) Short circuit in wiring harness

Circuit diagram related to injector #2

40-168

D61EM-23M0

40 Troubleshooting

Troubleshooting by failure code (Display of code)

Failure code [CA332] Inj #4(L#4) Open/Short Error Action level L03 Detail of failure Action of controller Problem on machine Related information No.

Failure code CA332

Failure

Injector #4(L#4) Open/Short Error (Engine controller system)

• Open or short circuit is detected in drive circuit of No. 4 injector. • None in particular. • • • •

Cause

Procedure, measuring location, criteria and remarks

1. See descriptions of wiring harness and connectors in "c: Electrical equipment" in "Checks before troubleshooting" of "General information on troubleshooting", and check it. Defective harness connector 2. Turn starting switch to ON position. If this failure code disappears, harness connector is defective. a If this failure code appears, perform following checks. 1. Turn starting switch to OFF position. 2. Disconnect connector INJECTOR CYL 3 & 4 and connect T-adapters to male side. Between INJECTOR CYL 3 & 4 (male) (1) Max. 2 z Resis- and (2) tance Between INJECTOR CYL 3 & 4 (male) (2) Min. 100 kz and ground

Defective No. 4 injector

1. Turn starting switch to OFF position. 2. Disconnect connector ECM J1 and connect T-adapters to female Open circuit or ground fault in side. wiring harness Max. 2 z Resis- Between ECM J1 (female) (43) and (53) tance Between ECM J1 (female) (43) and ground Min. 100 kz

a If no failure is found by check on cause 3, this check is not required. 1. Turn starting switch to OFF position. Open circuit in wiring harness 2. Disconnect connectors ECM J1 and INJECTOR CYL 3 & 4, and connect T-adapters to each female side. (wire breakage or defective Between ECM J1 (female) (43) and contact of connector) Max. 2 z Resis- INJECTOR CYL 3 & 4 (female) (2) tance Between ECM J1 (female) (53) and Max. 2 z INJECTOR CYL 3 & 4 (female) (1)

a If no failure is found by check on cause 3, this check is not required. 1. Turn starting switch to OFF position. 2. Disconnect connectors ECM J1 and INJECTOR CYL 3 & 4, and connect T-adapters to either female side. Resis- Between ground and ECM J1 (female) (43) Min. 100 kz or INJECTOR CYL 3 & 4 (female) (2) tance

Ground fault in wiring harness (contact with ground circuit)

D61EM-23M0

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40 Troubleshooting

Troubleshooting by failure code (Display of code)

No.

Procedure, measuring location, criteria and remarks

Cause

1. Turn starting switch to OFF position. 2. Disconnect connectors ECM J1 and INJECTOR CYL 3 & 4, and connect T-adapters to female side of ECM J1. a Check by using multimeter in continuity mode. 6

7 8 9

No continuity Between ECM J1 (female) (43) and each pin (No sound is other than pin (43) heard) Continuity No continuity Between ECM J1 (female) (53) and each pin (No sound is other than pin (53) heard) Defective injector of other If failure codes of other injectors are displayed, perform troubleshooting cylinder for them first. Defective injector harness of If failure codes of other injectors are displayed, perform troubleshooting other cylinder for them first. If no failure is found by above checks, engine controller is defective. Defective engine controller (Since this is an internal defect, troubleshooting cannot be performed.) Short circuit in wiring harness

Circuit diagram related to injector #4

40-170

D61EM-23M0

40 Troubleshooting

Troubleshooting by failure code (Display of code)

Failure code [CA342] Calibration Code Incompatibility Action level L04 Detail of failure Action of controller Problem on machine Related information No. 1

Failure code CA342

Calibration Code Incompatibility (Engine controller system)

• Calibration Code Incompatibility. • None in particular. • Engine continues to run normally, but it may stop during running or may not be able to start if it is stopped. • Method of reproducing failure code: Turn starting switch to ON position.

Cause Defective engine controller system

D61EM-23M0

Failure

Procedure, measuring location, criteria and remarks Perform troubleshooting for failure code [CA757].

40-171

40 Troubleshooting

Troubleshooting by failure code (Display of code)

Failure code [CA351] Injectors Drive Circuit Error Action level L03 Detail of failure Action of controller Problem on machine Related information No.

Failure code CA351

Injectors Drive Circuit Error (Engine controller system)

• Error occurs in injector drive power supply circuit. • Limits engine output and allows engine to run. • • • • • •

Exhaust gas color becomes black. Engine runs with poor combustion. Engine output decreases. Engine does not start Method of reproducing failure code: Start engine. Power supply voltage of engine controller can be checked with monitoring function. (Code: 03203(V)) Cause

Defective relevant system

Defective power supply voltage circuit

40-172

Failure

Procedure, measuring location, criteria and remarks If other failure codes are also displayed, perform troubleshooting for them. Perform troubleshooting for failure code [CA441].

D61EM-23M0

40 Troubleshooting

Troubleshooting by failure code (Display of code)

Failure code [CA352] Sensor 1 Supply Volt Low Error Action level L03 Detail of failure Action of controller Problem on machine Related information No.

Failure code CA352

Failure

Sensor 1 Supply Voltage Low Error (Engine controller system)

• Low voltage appears in sensor power supply 1 (5 V) circuit. • Ignores signals from exhaust manifold pressure sensor, closes EGR valve, and limits engine output. • Ignores signals from EGR valve lift sensor and KVGT position sensor, runs engine by setting boost pressure to calculated value. • Engine output lowers. • Method of reproducing failure code: Turn starting switch to ON position. Cause

Procedure, measuring location, criteria and remarks

1. See descriptions of wiring harness and connectors in "c: Electrical equipment" in "Checks before troubleshooting" of "General information on troubleshooting", and check it. Defective harness connector 2. Turn starting switch to ON position. If this failure code disappears, harness connector is defective. a If this failure code appears, perform following checks. 1. Turn starting switch to OFF position. 2. Disconnect following connectors one by one and turn starting switch to ON position each time. 3. Each time troubleshooting is finished, return to step 1. If this failure code is not displayed, disconnected sensor or engine harness is defective.

Defective sensor or wiring harness

Defective relevant system

Defective engine controller

D61EM-23M0

a Other failure codes (many codes) are also displayed. They are generated because of disconnection of connector. Ignore failure codes other than [CA352]. Exhaust manifold pressure sensor EXHAUST PRESSURE EGR valve lift sensor SEGR Connector KVGT position sensor SVGT Engine harness ECM J2 If failure codes other than this code are displayed, perform troubleshooting for them. 1. Turn starting switch to OFF position. 2. Disconnect connector ECM J2 and connect T-adapters to male side. 3. Turn starting switch to ON position with connector ECM J2 disconnected. 4.75 to 5.25 Voltage Between ECM J2 (male) (30) and (47) V

40-173

40 Troubleshooting

Troubleshooting by failure code (Display of code)

Circuit diagram related to sensor power supply 1 circuit

40-174

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40 Troubleshooting

Troubleshooting by failure code (Display of code)

Failure code [CA386] Sensor 1 Supply Volt High Error Action level L03 Detail of failure Action of controller Problem on machine Related information No. 1

Failure code CA386

Sensor 1 Supply Voltage High Error (Engine controller system)

• High voltage appears in sensor power supply 1 circuit. • Ignores signals from exhaust manifold pressure sensor, closes EGR valve, and limits engine output. • Ignores signals from EGR valve lift sensor and KVGT position sensor, takes it that they remain at values before failure detection, and allows engine to run.. • Engine output lowers. • Method of reproducing failure code: Turn starting switch to ON position.

Cause Abnormally high sensor supply voltage

D61EM-23M0

Failure

Procedure, measuring location, criteria and remarks Perform troubleshooting for failure code [CA352].

40-175

40 Troubleshooting

Troubleshooting by failure code (Display of code)

Failure code [CA428] Water in Fuel Sensor High Error Action level L01 Detail of failure Action of controller Problem on machine

Failure code CA428

Water-in-fuel sensor high error (Engine controller system)

Failure

• High voltage appears in signal circuit of water-in-fuel sensor installed to fuel pre-filter. • None in particular • Water separator monitor is not displayed correctly.

Related information

• Signal (ON/OFF) from water-in-fuel sensor of fuel pre-filter can be checked with monitoring function. (Code: 18800) • Method of reproducing failure code: Turn starting switch to ON position.

No.

Cause

Defective wiring harness connector

1. Turn starting switch to OFF position. Defective water-in-fuel sensor 2. Disconnect connector 28A and connect T-adapters to male side. installed to fuel pre-filter a If water is in water separator, drain it. Resistance Between 28A (male) (1) and (2)

10 to100 kz

1. Turn starting switch to OFF position. Short circuit or ground fault in 2. Disconnect connector ECM J1 and connect T-adapter to female side of connector. wiring harness Between ECM J1 (female) (24) and (32) Resistance (Water sensor resistance) 10 to100 kz

a If no failure is found in checks on cause 3, this check is not required. 1. Be ready with starting switch to OFF position. Open circuit in wiring harness 2. Disconnect connectors ECM J1 and 28A, and connect T-adapters to each female side. (wire breakage or defective Between ECM J1 (female) (32) and 28A contact of connector) Max. 10 z (female) (1) Resistance Between ECM J1 (female) (24) and 28A Max. 10 z (female) (2) 1. Turn starting switch to OFF position. 2. Disconnect connectors ECM J1 and 28A, and connect T-adapters to female side of ECM J1.

Short circuit in wiring harness a Check with multimeter in continuity mode. No continuity (no sound is heard.) If no failure is found in above checks, engine controller is defective. (Since this is internal defect, troubleshooting cannot be performed.) Continuity

Defective engine controller

40-176

Between ECM J1 (female) (24) and every pin other than (24)

D61EM-23M0

40 Troubleshooting

Troubleshooting by failure code (Display of code)

Circuit diagram related to water-in-fuel sensor

D61EM-23M0

40-177

40 Troubleshooting

Troubleshooting by failure code (Display of code)

Failure code [CA429] Water in Fuel Sensor Low Error Action level L01 Detail of failure Action of controller Problem on machine

Failure code CA429

Failure

Water-in-fuel sensor low error (Engine controller system)

• Low voltage appears in signal circuit of water-in-fuel sensor installed to fuel pre-filter. • None in particular • Water separator monitor is not displayed correctly.

Related information

• Signal (ON/OFF) from water-in-fuel sensor of fuel pre-filter can be checked with monitoring function. (Code: 18800) • Method of reproducing failure code: Turn starting switch to ON position.

No.

Cause

Defective wiring harness connector

Defective water-in-fuel sensor installed to fuel prefilter

1. Turn starting switch to OFF position. 2. Disconnect connector 28A and connect T-adapters to male side. a If water is in water separator, drain it. Resistance

Between 28A (male) (1) and (2) Between 28A (male) (1) and ground

10 to100 kz Min. 100 kz

1. Turn starting switch to OFF position. 2. Disconnect connector ECM J1 and connect T-adapter to female side Short circuit or ground fault in of connector. wiring harness Between ECM J1 (female) (24) and (32) 10 to100 Resis- (water-in-fuel sensor resistance) kz tance Between ECM J1 (female) (32) and ground Min. 100 kz 1. Be ready with starting switch to OFF position. 2. Disconnect connectors ECM J1 and 28A, and connect T-adapters to female side of ECM J1.

Short circuit in wiring harness a Check with multimeter in continuity mode. Between ECM J1 (female) (24) and every pin Continuity other than (24)

No continuity (no sound is heard.)

a If no failure is found in checks on cause 3, this check is not required. 1. Turn starting switch to OFF position. Ground fault in wiring harness (contact with ground 2. Disconnect connectors ECM J1 and 28A, and connect T-adapters to either female side. circuit) Resis- Between ground and ECM J1 (female) (32) or Min. 100 kz 28A (female) (1) tance If no failure is found in above checks, engine controller is defective. Defective engine controller (Since this is internal defect, troubleshooting cannot be performed.)

40-178

D61EM-23M0

40 Troubleshooting

Troubleshooting by failure code (Display of code)

Circuit diagram related to water-in-fuel sensor

D61EM-23M0

40-179

40 Troubleshooting

Troubleshooting by failure code (Display of code)

Failure code [CA435] Eng Oil Press Sw Error Action level L01 Detail of failure Action of controller Problem on machine

Related information

Failure code CA435

Failure

Engine Oil Pressure Switch Error (Engine controller system)

• Failure occurs in engine oil pressure switch signal circuit. • None in particular. • • • •

Protection function based on engine oil pressure does not work. Engine oil pressure monitor is not displayed normally. Method of reproducing failure code: Turn starting switch to ON position or start engine. Engine oil pressure switch is in CLOSED (ON) when oil pressure is low (when engine is stopped), but is in OPEN (OFF) when oil pressure is high (when engine is running). • To generate this failure code, engine controller checks whether engine oil pressure switch is in CLOSED (ON) only when engine is stopped, that is, whether signal voltage is zero or not. • Failure of engine oil pressure switch when engine is running is indicated by failure code [B@BAZG].

k When performing checking and replacement of engine oil pressure switch, open oil

filler port, and check that engine oil temperature cools down enough not to get scalded. No.

Cause

Procedure, measuring location, criteria and remarks

Defective engine oil pressure switch

Open circuit or ground fault in wiring harness

Defective engine controller

1. Turn starting switch to OFF position. 2. Disconnect connector OIL PRESSURE SWITCH and connect Tadapters to male side. Resis- Between OIL PRESSURE SWITCH (male) (1) Max. 10 z and ground tance 1. Turn starting switch to OFF position. 2. Disconnect connector ECM J1 and connect T-adapters to female side. Resis- Between ECM J1 (female) (31) and ground Max. 10 z tance If no failure is found by above checks, engine controller is defective. (Since this is an internal defect, troubleshooting cannot be performed.)

Circuit diagram related to engine oil pressure switch

40-180

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40 Troubleshooting

Troubleshooting by failure code (Display of code)

Failure code [CA441] Battery Voltage Low Error Action level L04 Detail of failure Action of controller Problem on machine Related information No. 1 2 3

Failure code CA441

Failure

• Takes power voltage to be at fixed value (24 V) and allows engine to run. • • • •

Engine stops. Engine startability is poor. Method of reproducing failure code: Starting switch: ON Power supply voltage of engine controller can be checked with moniitoring funtion. (Code: 03203(V))

Cause Loose or corroded battery terminal Loose terminal or partial open circuit at terminal Defective wiring harness connector

Improper battery voltage

Defective alternator

Defective engine controller

D61EM-23M0

Battery voltage low error (Engine controller system)

• Low voltage appears in controller power supply circuit.

Procedure, measuring location, criteria and remarks Battery cable terminal may be loose or corroded. Check it. 1. Starting switch: OFF Check terminals of alternator, battery relay, ground terminal (T20), etc. See descriptions of wirings harness and connectors in "c: Electrical equipment" in "Checks before troubleshooting" of "General information on troubleshooting", and check them. 1. Starting switch: OFF 2. Perform troubleshooting with starting switch at OFF position and at engine cranking. Voltage Between battery terminals (+) and (-). 20 to30 V 1. Starting switch: OFF 2. Insert T-adapter into connector E12. 3. Start engine (Engine speed: Middle or faster). 27.5 to 29.5 V If no failure is found by above checks, engine controller is defective. (Since this is an internal defect, troubleshooting cannot be performed.) Voltage

Between E12 (1) and ground

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40 Troubleshooting

Troubleshooting by failure code (Display of code)

Circuit diagram related to engine controller power supply

40-182

D61EM-23M0

40 Troubleshooting

Troubleshooting by failure code (Display of code)

Failure code [CA442] Battery Voltage High Error Action level L04 Detail of failure Action of controller Problem on machine Related information No. 1

Failure code CA442

Battery Voltage High Error (Engine controller system)

• High voltage (approximately 36 V or higher) appears in controller power supply circuit. • Takes it that power supply voltage is at fixed value (24 V) and allows engine to run. • Engine continues to run normally, but it may stop during running or may not be able to restart if it is stopped. • Method of reproducing failure code: Turn starting switch to ON position. • Power supply voltage of engine controller can be checked with monitoring function. (Code: 03204 (V))

Cause Abnormally high power supply voltage

D61EM-23M0

Failure

Procedure, measuring location, criteria and remarks Perform troubleshooting for failure code [CA441].

40-183

40 Troubleshooting

Troubleshooting by failure code (Display of code)

Failure code [CA449] Rail Press Very High Error Action level L03 Detail of failure Action of controller Problem on machine Related information No.

Failure code CA449

Failure

Rail Pressure Very High Error (Engine controller system)

• Excessively high pressure is developed in common rail circuit. • Limits engine output and allows engine to run. • Engine sounds become louder under no load or light load. • Engine output decreases. • Common rail pressure can be checked with monitoring function. (Code: (36400 Common rail pressure) • Method of reproducing failure code: Start engine. Cause

Defective relevant system

Air in low-pressure circuit

Procedure, measuring location, criteria and remarks If other failure codes are also displayed, perform troubleshooting for them. Air may be in low-pressure circuit. Check it according to following procedure. 1. Remove pressure pickup plug (outlet side) of fuel main filter. 2. Operate feed pump of fuel pre-filter. 3. Check leaking level of fuel and air from pressure pickup plug hole.

Defective fuel return circuit equipment

a For check of pressure in fuel return circuit, see Testing and adjusting, "Testing fuel pressure". Max. 18.6 kPa Pressure in {max. 0.19 kg/ fuel return At low idle or during cranking cm2} circuit

Defective common rail pressure sensor system

Perform troubleshooting for failure codes [CA451] and [CA452].

Defective pressure limiter

Defective supply pump

40-184

a For check of fuel leakage from pressure limiter, see Testing and adjusting, "Testing fuel delivery rate, return rate and leakage". Leakage from At low idle (for 30 seconds) Max. 8 ml pressure limiter If no failure is found by above checks, supply pump may be defective.

D61EM-23M0

40 Troubleshooting

Troubleshooting by failure code (Display of code)

Failure code [CA451] Rail Press Sensor High Error Action level L03 Detail of failure Action of controller Problem on machine

Failure code CA451

Failure

Rail Pressure Sensor High Error (Engine controller system)

• High voltage appears in signal circuit of common rail pressure sensor. • Limits engine output and allows engine to run. • Engine speed or output decreases. • Engine does not start.

Related information

• Signal voltage from common rail pressure sensor can be checked with monitoring function. (Code: 36401 Common rail pressure sensor voltage) • Pressure sensed by common rail pressure sensor can be checked with monitoring function. (Code: 36400 (MPa)) • Method of reproducing failure code: Turn starting switch to ON position. • This failure code appears if common rail pressure sensor connector is disconnected. • Since female connector alone is provided for "socket" used for troubleshooting of this sensor, it is not usable for check of open circuit in wiring harness and voltage at sensor connector (.not designed as T-adapter).

No.

Cause

Procedure, measuring location, criteria and remarks

Defective common rail pressure sensor power supply system

If failure code [CA515] or [CA516] is also displayed, perform troubleshooting for it first.

1. Turn starting switch to OFF position. 2. Disconnect connectors FUEL RAIL PRESS and ECM J2. Short circuit in wiring harness 3. Connect T-adapters to female side of ECM J2. Resis- Between ECM J2 (female) (31) and (44) Min. 100 kz tance 1. Turn starting switch to OFF position. 2. Disconnect connector FUEL RAIL PRESS and insert T-adapters into connector ECM J2. 3. Turn starting switch to ON position (with connector FUEL RAIL Hot short circuit in wiring PRESS disconnected). harness a Pin (31) of ECM J2 is connected to 5 V circuit via resistor inside engine controller. 4.75 to 5.25 Voltage Between ECM J2 (21) and (44) V If no failure is found by above checks, wiring harness probably has open Open circuit in wiring harness circuit. (*)

Defective common rail pressure sensor (defective input voltage to engine controller)

D61EM-23M0

a If no failure is found by checks on cases 1 to 5 and failure is found by check on cause 6, sensor is defective. 1. Turn starting switch to OFF position. 2. Insert T-adapters in connector ECM J2. 3. Turn starting switch to ON position. Sensor 0.2 to 4.8 V Voltage Between ECM J2 (21) and (44) output

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No. 7

Cause Defective engine controller

Procedure, measuring location, criteria and remarks If no failure is found by above checks, engine controller is defective. (Since this is an internal defect, troubleshooting cannot be performed.)

*: See "Troubleshooting method for open circuit in wiring harness of pressure sensor system" of "General information on troubleshooting". Circuit diagram related to common rail pressure sensor

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40 Troubleshooting

Troubleshooting by failure code (Display of code)

Failure code [CA452] Rail Press Sensor Low Error Action level L03 Detail of failure Action of controller Problem on machine

Related information

No.

Failure code CA452

Failure

Rail Pressure Sensor Low Error (Engine controller system)

• Low voltage appears in signal circuit of common rail pressure sensor. • Limits engine output and allows engine to run. • Engine speed or output decreases. • Engine does not start. • Signal voltage from common rail pressure sensor can be checked with monitoring function. (Code: 36401 Common rail pressure sensor voltage) • Pressure sensed by common rail pressure sensor can be checked with monitoring function. (Code: 36400 (MPa)) • Method of reproducing failure code: Turn starting switch to ON position. • If sensor connector is disconnected even in normal condition, failure code [CA451] for "High Error" is generated instead of this code. Cause

Defective harness connector

a If this failure code appears, perform following checks. Defective common rail If failure code [CA515] or [CA516] is also displayed, perform pressure sensor power supply troubleshooting for it first. system 1. Turn starting switch to OFF position. 2. Disconnect connector FUEL RAIL PRESS. 3. Turn starting switch to ON position. If failure code [CA452] changes to [CA451], sensor is defective. • Reference 1. Turn starting switch to OFF position. 2. Insert T-adapters in connector ECM J2. 3. Turn starting switch to ON position. Sensor Voltage Between ECM J2 (21) and (44) output 0.2 to 4.8 V

Defective common rail pressure sensor

1. Turn starting switch to OFF position. Ground fault in wiring harness 2. Disconnect connectors ECM J2 and FUEL RAIL PRESS, and (contact with ground circuit) connect T-adapters to female side of ECM J2. Resistance Between ECM J2 (female) (44) and ground Min. 100 kz

1. Turn starting switch to OFF position. 2. Disconnect connectors FUEL RAIL PRESS and ECM J2. Short circuit in wiring harness 3. Connect T-adapters to female side of ECM J2. Resistance Between ECM J2 (female) (21) and (44) Min. 100 kz If no failure is found by above checks, engine controller is defective. Defective engine controller (Since this is an internal defect, troubleshooting cannot be performed.)

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Circuit diagram related to common rail pressure sensor

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Failure code [CA488] Chg Air Temp High Torque Derate Action level L03 Detail of failure Action of controller Problem on machine

Charge air Temperature High Torque Derate Failure code Failure (Engine controller system) CA488 • Temperature signal from boost pressure & temperature sensor exceeds upper limit of control temperature. • Restricts engine output and allows engine to run. • Engine output lowers.

Related information

• Boost temperature can be checked with monitoring function. (Code: 18500) • Method of reproducing failure code: Start engine.

No.

Cause

Drop of cooling performance of aftercooler

2 3

Unusual rise of turbocharger outlet temperature Defective boost temperature sensor system

D61EM-23M0

Procedure, measuring location, criteria and remarks Aftercooler cooling performance may be degraded. Check for following points: • Defective fan rotation • Insufficient cooling air • Clogged aftercooler fins Outlet temperature of turbocharger may be unusually high. Check related parts. Perform troubleshooting for failure codes [CA153] and [CA154].

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Failure code [CA553] Rail Press High Error Action level L01 Detail of failure Action of controller Problem on machine Related information

Failure code CA553

Rail Pressure High Error (Engine controller system)

• Excessively high pressure trouble (1) has occurred in the common rail circuit. • None in particular • Engine noise becomes louder at no or light load. • Engine output lowers. • Common rail pressure can be checked with monitoring function. (Code: 36400) • Method of reproducing failure code: Start engine.

No. Cause 1 Defect in related system

Defective connection of ground terminal

Defective common rail pressure sensor system

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Failure

Procedure, measuring location, criteria and remarks If another failure code is displayed, perform troubleshooting for it. Connection of ground terminals may be defective. Check the following terminals. • Ground terminal of machine ((-) terminal of battery) • Ground terminal of engine • Ground terminal of engine controller • Ground terminal of starting motor Perform troubleshooting for failure code [CA451], [CA452]

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Failure code [CA689] Eng Ne Speed Sensor Error Action level L01 Detail of failure Action of controller Problem on machine

Related information

No.

2 3

Failure code CA689

Failure

Engine Ne Speed Sensor Error (Engine controller system)

• Engine Ne speed sensor signal is abnormal. • Runs engine by using signals from engine Bkup speed sensor. • • • • • •

Running engine stops (when Bkup (CAM) speed sensor is also defective). Stopped engine cannot be started (when Bkup (CAM) speed sensor is also defective). Engine starting performance becomes deteriorated Engine hunts. Method of reproducing failure code: Start engine. Since interior portion of speed sensor is configured with hall sensor and electronic circuit rather than coil, measurements of speed sensor resistance by using mulitimeter cannot be used to determine whether sensor is normal or not. • Since speed sensor output is pulse voltage of 5 V in normal state, multimeter is not usable for measurement. • Speed sensor detects passing of slot on speed sensing wheel, which is installed to inner surface on vibration damper, to measure crankshaft speed. Procedure, measuring location, criteria and remarks

Cause

Defective Ne speed sensor power supply input

a If this failure code appears, perform following checks. If failure code [CA238] or [CA239] is also displayed, perform troubleshooting for it first. Engine Ne speed sensor may be broken or installed improperly (loosened). Check it. 1. Turn starting switch to OFF position. 2. Disconnect connector CRANK SENSOR and connect T-adapters to female side. 3. Turn starting switch to ON position. Power Between CRANK SENSOR Voltage supply 4.75 to 5.25 (female) (1) and (2) V input 1. Turn starting switch to OFF position. 2. Disconnect connectors ECM J1 and CRANK SENSOR and connect T-adapters to each female side.

Open circuit in wiring harness (wire breakage or defective contact of connector)

D61EM-23M0

a If no failure is found by check on cause 4, this check is not required. Between ECM J1 (female) (36) and CRANK SENSOR (female) (1) Resistance

a If no failure is found by check on cause 4, this check is not required. Between ECM J1 (female) (37) and CRANK SENSOR (female) (2) Between ECM J1 (female) (26) and CRANK SENSOR (female) (3)

Max. 10 z

Max. 10 z Max. 10 z

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No.

Cause

Procedure, measuring location, criteria and remarks

1. Turn starting switch to OFF position. 2. Disconnect connectors ECM J1 and CRANK SENSOR and connect T-adapters to each female side. Short circuit in wiring harness Between ECM J1 (female) (26) and (36) or Min. 100 kz Resis- CRANK SENSOR (female) (1) and (3) tance Between ECM J1 (female) (26) and (37) or Min. 100 kz CRANK SENSOR (female) (2) and (3)

Ground fault in wiring harness (contact with ground circuit)

1. Turn starting switch to OFF position. 2. Disconnect connectors ECM J1 and CRANK SENSOR and connect T-adapters to female side of ECM J1 or CRANK SENSOR. Resis- Between ground and ECM J1 (female) (26) or Min. 100 kz CRANK SENSOR (female) (3) tance

Hot short circuit in wiring harness

1. Turn starting switch to OFF position. 2. Disconnect connector CRANK SENSOR and connect T-adapters to female side of CRANK SENSOR. 3. Turn starting switch to ON position. Between CRANK SENSOR (female) (3) and Voltage Max. 1 V ground

Damage or loose mounting of Check speed sensing wheel. speed sensing wheel If no failure is found by above checks, Ne speed sensor is defective. 10 Defective Ne speed sensor (Since this is an internal defect, troubleshooting cannot be performed.) If no failure is found by above checks, engine controller is defective. 11 Defective engine controller (Since this is an internal defect, troubleshooting cannot be performed.) 9

Circuit diagram related to engine Ne speed sensor

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Failure code [CA731] Eng Bkup Speed Sens Phase Error Action level L01 Detail of failure Action of controller

Engine Bkup Speed Sensor Phase Error Failure code Failure (Engine controller system) CA731 • Phase error occurs between signals of engine Ne speed sensor and engine Bkup speed sensor. • Continues to control engine by using engine Ne speed sensor signal.

Problem on machine

• Engine stops during operation (when Ne speed sensor is also defective at the same time). • Engine can not start or engine is hard to start. • Idle speed is unstable. • Exhaust gas color becomes black.

Related information

• Method of reproducing failure code: Start engine.

No. 1 2

Cause Damaged engine Ne speed sensor Damaged engine Bkup speed sensor

Improper installation or damage of speed sensing wheel on crankshaft side

Procedure, measuring location, criteria and remarks Engine Ne speed sensor may be damaged. Check it. Engine Bkup speed sensor may be damaged. Check it. Speed sensing wheel on crankshaft side may be installed improperly or damaged. Check it according to following procedure. 1. Align paint mark (M1) of damper with mounting bolt (M2) of damper.

a No.1 cylinder is not at its compression top dead center with damper at that position (approximately 76 to 88 degrees before to compression top dead center). 2. Installation is correct if center of slot (WS) of speed sensing wheel is positioned under top surface (M2) of Ne speed sensor. Speed detection ring on camshaft side may be installed improperly or damaged. Check it according to following procedure. Improper installation or 1. Set No. 1 cylinder to compression top dead center (align stamping damage of speed sensing ring mark). on camshaft side 2. Remove Bkup speed sensor. 3. Installation is correct if twin groove (single rib) (B) of speed sensing ring is visible through sensor mounting hole (H). Defective timing adjustment of Timings of crankshaft and camshaft may not be matched each other. crankshaft and camshaft Check them. Ground terminals may be connected defectively. Check following terminals : Defective connection of ground • Ground terminal of machine ((-) terminal of battery) terminal • Ground terminal of engine • Ground terminal of engine controller • Ground terminal of starting motor

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Failure code [CA757] All continuous Data Lost Error Action level L04 Detail of failure Action of controller

Failure code CA757

Failure

All continuous Data Lost Error (Engine controller system)

• Internal defect occurred in controller. • None in particular.

Problem on machine

• Engine continues to run normally, but it may stop during running or may not be able to start if it is stopped. • Engine controller cannot store internal data correctly.

Related information

• Method of reproducing failure code: Turn starting switch to ON position.

No. 1 2

Procedure, measuring location, criteria and remarks Since the power supply circuit may be defective, carry out Defective power supply circuit troubleshooting for failure code [CA441]. Improper operation of battery Battery disconnect switch may have been operated improperly. disconnect switch

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Cause

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Failure code [CA778] Eng Bkup Speed Sensor Error Action level L01 Detail of failure Action of controller Problem on machine

Related information

No.

Failure code CA778

Engine Bkup Speed Sensor Error (Engine controller system)

• Engine Bkup speed (cam) sensor signal is abnormal. • Continues to control engine by using engine Ne speed sensor signal. • • • •

Engine starting performance becomes deteriorated Engine output decreases. Method of reproducing failure code: Start engine. Since interior portion of speed sensor is configured with hall sensor and electronic circuit rather than coil, measurements of speed sensor resistance by using mulitimeter cannot be used to determine whether sensor is normal or not. • Since speed sensor output is pulse voltage of 5 V in normal state, multimeter is not usable for measurement. • This speed sensor detects groove in speed sensing ring, which is installed to camshaft, to measure camshaft speed.

Cause

Defective harness connector

Defective sensor power supply 2 circuit Breakage or improper installation (loosened) of Engine Bkup speed sensor may be broken or installed improperly (loosened). Check it engine Bkup speed (cam) sensor

Defective engine Bkup speed sensor power supply input

Open circuit in wiring harness (wire breakage or defective contact of connector)

Failure

Short circuit in wiring harness

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1. Turn starting switch to OFF position. 2. Disconnect connector CAM SENSOR , and connect T-adapters to female side. 3. Turn starting switch to ON position. Power 4.75 to 5.25 Between CAM SENSOR (female) (1) and (2) supply V 4.75 to 5.25 Voltage Between CAM SENSOR (female) (1) and (2) V 1. Turn starting switch to OFF position. 2. Disconnect connectors ECM J1 and CAM SENSOR, and connect Tadapters to each female side. Between ECM J1 (female) (60) and CAM SENSOR Max. 10 z (female) (1) Resis- Between ECM J1 (female) (59) and CAM SENSOR Max. 10 z tance (female) (2) Between ECM J1 (female) (9) and CAM SENSOR Max. 10 z (female) (3) 1. Turn starting switch to OFF position. 2. Disconnect connectors ECM J1 and CAM SENSOR, and connect Tadapters to either female side. Between ECM J1 (female) (9) and (60) or between Min. 100 kz Resis- CAM SENSOR (female) (1) and (3) tance Between ECM J1 (female) (9) and (59) or between Min. 100 kz CAM SENSOR (female) (2) and (3)

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No.

Cause Ground fault in wiring harness (contact with ground circuit)

1. Turn starting switch to OFF position. 2. Disconnect connectors ECM J1 and CAM SENSOR, and connect Tadapters to either female side. Resis- Between ground and ECM J1 (female) (9) or CAM Min. 100 kz tance SENSOR (female) (3)

1. Turn starting switch to OFF position. 2. Disconnect connector CAM SENSOR , and connect T-adapters to Hot short circuit in wiring female side. harness 3. Turn starting switch to ON position. Voltage Between CAM SENSOR (female) (3) and ground Max. 1 V Remove engine Bkup speed (cam) sensor, and check ring through hole (H). Loosened camshaft speed sensing ring a If speed sensing ring (B) is loosened, see "Reference".

Defective engine Bkup 10 speed (cam) sensor 11

Procedure, measuring location, criteria and remarks

Defective engine controller

If no failure is found by above checks, engine Bkup speed (cam) sensor is defective. (Since this is an internal defect, troubleshooting cannot be performed.) If no failure is found by above checks, engine controller is defective. (Since this is an internal defect, troubleshooting cannot be performed.)

Circuit diagram related to engine Bkup speed sensor

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• Reference Check of camshaft ring for looseness Remove front cover and check camshaft ring for looseness. a See Disassembly and assembly, "Removal and installation of engine front seal". a Prepare front seal, liquid gasket LG-7 and front seal tool (795-799-6400)) beforehand. Removal 1. Remove fan and fan belt, For details, see Disassembly and assembly, "Removal and installation of engine front seal". 2. Remove damper assembly (1). (DP): Dowel pin

3. Remove front cover (2). 4. Remove front seal (3). (RING): Ring

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5. Check that mounting bolt (4) of camshaft ring (5) is not loosened. 3 Mounting bolt (4): 10 ± 2 Nm {0.98 ± 0.2 kgm} (DP): Dowel pin

Installation a See figures shown in removal procedure section. 1. Install front cover (2). 2 Front cover: Liquid gasket (LG-7) 2. See Disassembly and assembly, "Removal and installation of engine front seal". 1) install front cover (3). 2) Install dowel pin (DP), and install damper assembly. 3) Install fan belt, and install the fan. 4) Install the cooling system assembly.

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Failure code [CA2185] Throt Sensor Sup Volt High Error Throttle Sensor Supply Voltage High Error (Engine controller system)

Action level L03 Detail of failure Action of controller Problem on machine Related information

• Runs engine as if fuel dial is at half position.

No.

Cause

Failure code CA2185

Failure

• A high voltage was detected in throttle sensor power supply (5 V) circuit.

• Engine speed cannot be controlled by fuel dial. • Method of reproducing failure code: Turn starting switch to ON position.

Defective wiring harness connector

1. Turn starting switch to OFF position. 2. Disconnect connector FP and turn starting switch to ON position. Defective throttle sensor (fuel If this failure code disappears, throttle sensor is defective. dial) a Other failure codes are also displayed. They are generated because of disconnection of connector. Ignore failure codes other than [CA2185].

1. Turn starting switch to OFF position. 2. Disconnect connectors CE03 and FP, and connect T-adapter to Short circuit in wiring harness female side of CE03. Resis- Between CE03 (female) (42) and each pin Min. 1 Mz other than CE03 (female) (42) pin. tance

Hot short circuit in wiring harness

Defective engine controller

1. Turn starting switch to OFF position. 2. Disconnect connector FP and connect T-adapter to female side. 3. Turn starting switch to ON position. 4.75 to 5.25 Voltage Between FP (female) (A) and (C) V 1. Turn starting switch to OFF position. 2. Disconnect connector CE03 and connect T-adapter to male side. 3. Turn starting switch to ON position with connector CE03 disconnected. 4.75 to 5.25 Voltage Between CE03 (male) (42) and (41) V

Circuit diagram related to throttle sensor

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Failure code [CA2186] Throt Sensor Sup Volt Low Error Action level L03 Detail of failure Action of controller Problem on machine Related information No.

Failure code CA2186

Failure

Throttle Sensor Supply Voltage Low Error (Engine controller system)

• A low voltage is detected in throttle sensor power supply (5 V) circuit. • Runs engine as if fuel dial is at half position. • Engine speed cannot be controlled by fuel dial. • Method of reproducing failure code: Turn starting switch to ON position. Procedure, measuring location, criteria and remarks

Cause

Defective wiring harness connector

1. See descriptions of wiring harness and connectors in "c: Electrical equipment" in "Checks before troubleshooting" of "Related information on troubleshooting", and check it. 2. Turn starting switch to ON position. If this failure code is not displayed, wiring harness connector is defective. a If this failure code is displayed, perform following checks.

Ground fault in wiring harness (contact with ground circuit)

1. Turn starting switch to OFF position. 2. Disconnect connectors CE03 and FP, and connect T-adapter to female side of CE03. Short circuit in wiring harness 3. Turn starting switch to ON position. Resis- Between CE03 (female) (42) and each pin Min. 1 Mz other than CE03 (female) (42) pin. tance

1. Turn starting switch to OFF position. 2. Disconnect connector CE03 and connect T-adapter to male side. 3. Turn starting switch to ON position with connector CE03 disconnected. 4.75 to 5.25 Voltage Between CE03 (male) (42) and (41) V

Defective engine controller

1. Turn starting switch to OFF position. 2. Disconnect connectors CE03 and FP, and connect T-adapter to either female side. Resis- Between ground and CE03 (female) (42) or Min. 1 Mz FP (female) (A) tance

Circuit diagram related to throttle sensor

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Failure code [CA2249] Rail Press Very Low Error Action level L03 Detail of failure Action of controller Problem on machine Related information

No. 1

Failure code CA2249

Rail Pressure Very Low Error (Engine controller system)

• Supply pump does not feed fuel (level 2). • Limits engine output and allows engine to run. • Engine output lowers. • Signal voltage from common rail pressure sensor can be checked by using monitoring function. (Code: 36401 (V)) • Common rail pressure sensed by common rail pressure sensor can be checked with monitoring function. (Code: 36400 (MPa)) • Method of reproducing failure code: Start engine.

Cause Supply pump pressure low error

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Failure

Procedure, measuring location, criteria and remarks Perform troubleshooting for failure code [CA559].

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Failure code [CA2311] IMV Solenoid Error Action level L03 Detail of failure Action of controller Problem on machine Related information

Defective IMV solenoid Failure code Failure (Engine controller system) CA2311 • Resistance value of supply pump actuator circuit is unusually high or low. Or rail pressure error. • None in particular • Engine output lowers. • Method of reproducing failure code: Start engine.

No. Cause 1 Defective IMV solenoid 2 Rail pressure error

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Procedure, measuring location, criteria, and remarks Perform troubleshooting for failure codes [CA271] and [CA272]. Perform troubleshooting for failure code [CA449].

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Failure code [CA2555] Grid Htr Relay Volt Low Error Action level L01 Detail of failure Action of controller Problem on machine

Related information

No.

Failure code CA2555

Failure

Grid Heater Relay Voltage Low Error (Engine controller system)

• Open circuit is in preheat relay drive circuit (primary circuit). • None in particular • Intake air heater does not work in auto preheating mode (resulting in degraded startability and emission of white smoke at low temperatures). • Temperature sensed by charge temperature sensor (boost temperature sensor) can be checked with monitoring function. (Code: 18500 (°C)) • Method of reproducing failure code: Turn starting switch to ON position (boost temperature: Max. -4 °C). • Troubleshooting of this failure code covers circuits from engine controller to primary circuit (coil) of preheat relay RHR. • For troubleshooting of heater relay and secondary circuit of preheat relay RHR, see following E-mode troubleshooting. • E-2 Manual preheating system does not work • E-3 Automatic preheating system does not work • E-4 While preheating is working, preheating monitor does not light up Cause

Defective wiring harness connector

1. Turn starting switch to OFF position. 2. Disconnect relay RHR, and connect T-adapter to male side. Resis- Between RHR (male) (1) and (2) 200 to 400 z tance Defective preheat relay RHR 1. Turn starting switch to OFF position. 2. Replace relay RHR with another one. 3. Turn starting switch to ON position. If this failure code disappears, original preheat relay RHR is defective.

Open or short circuit in wiring harness

1. Turn starting switch to OFF position. 2. Disconnect connector CE03, and connect T-adapter to female side. Resis- Between CE03 (female) (4) and (13) 200 to 400 z tance a Coil resistance of relay RHR

a If no failure is found by check on cause 3, this check is not required. 1. Turn starting switch to OFF position. 2. Disconnect connector CE03 and relay RHR, and connect T-adapter to each female side. Open circuit in wiring harness Between CE03 (female) (4) and RHR Max. 10 z Resis- (female) (1) tance Between CE03 (female) (13) and RHR Max. 10 z (female) (2) If no failure is found by above checks, engine controller is defective. Defective engine controller (Since this is an internal defect, troubleshooting cannot be performed.)

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Circuit diagram related to intake air heater relay

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Failure code [CA2556] Grid Htr Relay Volt High Error Action level L01 Detail of failure Action of controller Problem on machine

Related information

No.

Failure code CA2556

Grid Heater Relay Voltage High Error (Engine controller system)

Failure

• Short circuit is in preheat relay drive circuit (primary circuit). • None in particular • Intake air heater does not work in auto preheating mode (resulting in degraded startability and emission of white smoke at low temperatures). • Temperature sensed by charge temperature sensor (boost temperature sensor) can be checked with monitoring function. (Code: 18500 (°C)) • Method of reproducing failure code: Turn starting switch to ON position (boost temperature: Max. -4 °C). • Troubleshooting of this failure code covers circuits from engine controller to primary circuit (coil) of preheat relay RHR. • For troubleshooting of heater relay and secondary circuit of preheat relay RHR, see following E-mode troubleshooting. • E-2 Manual preheating system does not work • E-3 Automatic preheating system does not work • E-4 While preheating is working, preheating monitor does not light up Cause

Defective wiring harness connector

1. Turn starting switch to OFF position. 2. Disconnect connector CE03 and relay RHR, and connect T-adapter Ground fault in wiring harness to either female side. Resis- Between ground and CE03 (female) (4) or Min. 100 kz RHR (female) (1) tance 1. Turn starting switch to OFF position. 2. Disconnect connector CE03 and relay RHR, and connect T-adapter to female side of CE03.

Short circuit in wiring harness a Check by using multimeter in continuity mode. No continuity (No sound is heard) If no failure is found by above checks, engine controller is defective. (Since this is an internal defect, troubleshooting cannot be performed.) Continuity

Defective engine controller

D61EM-23M0

Between CE03 (female) (4) and each pin other than pin (4)

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Circuit diagram related to intake air heater relay

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Failure code [D130KA] Neutral relay Open Action level L01 Detail of failure Action of controller Problem on machine

Neutral relay: Open Failure code Failure (Defective HST controller) D130KA • No current flows when primary (coil) circuit of neutral safety relay is grounded, or no voltage is supplied when circuit is disconnected from ground terminal. • Stops grounding to neutral safety relay primary circuit (coil side). • Engine does not start.

Related information

• Output to primary (coil) circuit of neutral safety relay can be checked with monitoring function. (Code 40979: "HST SW Output") • Method of reproducing failure code: Turn starting switch to ON position and operate parking brake lever to FREE position. • This failure code indicates failure on primary circuit (coil side) of neutral safety relay, but not on secondary circuit (contact side). • When ST3 (37) pin is shorted to ground, engine starts in any gear speed including neutral gear speed.

No.

Cause

Procedure, measuring location, criteria and remarks

1. Turn starting switch to OFF position. Defective neutral safety relay 2. Disconnect connector 11 and connect T-adapter to male side. (internal open or short circuit) Resis- Between 11 (male) (1) and (2) 200 to 600 tance z 1. Turn starting switch to OFF position. 2. Disconnect connector ST3 and connect T-adapter to female side. Open or short circuit in wiring a If resistance is 1 Mz or higher, harness has open circuit. If it is 1 z or harness below, harness has short circuit. Resis- Between ST3 (female) (37) and (23) 200 to 600 tance z a If no failure is found by check on cause 2, this check is not required. Open circuit in wiring harness 1. Turn starting switch to OFF position. 2. Disconnect connectors ST3 and 11, and connect T-adapters to each (wire breakage or defective female side. contact of connector) Resis- Between ST3 (female) (37) and 11 (female) (1) Max. 1 z tance Between ST3 (female) (23) and 11 (female) (2) Max. 1 z 1. Turn starting switch to OFF position. Ground fault in wiring harness 2. Disconnect connectors ST3 and 11, and connect T-adapter to either female side. (contact with ground circuit) Resis- Between ground and either 11 (female) (1) or Min. 1 Mz ST3 (female) (37) tance If no failure is found by above checks, HST controller is defective. • Reference 1. Turn starting switch to OFF position. 2. Insert T-adapter into connector ST3. Defective HST controller 3. Turn starting switch to ON position. 4. Operate parking brake lever and perform troubleshooting. Between ST3 (37) and Parking brake: FREE 20 to 30 V Voltage (23) Parking brake: LOCK Max. 4.5 V

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Circuit diagram related to neutral safety relay

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40 Troubleshooting

Troubleshooting by failure code (Display of code)

Failure code [D130KB] Neutral relay Short circuit Action level L01 Detail of failure Action of controller Problem on machine

Neutral relay: Short circuit Failure code Failure (Defective HST controller) D130KB • Abnormal current flows in neutral safety relay primary circuit (coil side) when neutral safety relay is grounded . • Stops grounding to neutral safety relay primary circuit (coil side). • Engine does not start.

Related information

• Output to primary (coil) circuit of neutral safety relay can be checked with monitoring function. (Code 40979: "HST SW Output") • Method of reproducing failure code: Turn starting switch to ON position and operate parking brake lever to LOCK position. • This failure code indicates failure on primary circuit (coil side) of neutral safety relay, but not on secondary circuit (contact side).

No.

Cause

Procedure, measuring location, criteria and remarks

1. Turn starting switch to OFF position. Defective neutral safety relay 2. Disconnect connector 11 and connect T-adapter to male side. (internal open or short circuit) Resis- Between 11 (male) (1) and (2) 300 to 600 tance z 1. Turn starting switch to OFF position. 2. Disconnect connector ST3 and connect T-adapter to female side. Open or short circuit in wiring a If resistance is 1 Mz or higher, harness has open circuit. If it is 1 z or harness below, harness has short circuit. Resis- Between ST3 (female) (37) and (23) 300 to 600 tance z 1. Turn starting switch to OFF position. 2. Disconnect connectors ST3 and 11, and connect T-adapter to Hot short circuit in wiring female side of ST3. harness 3. Turn starting switch to ON position. Voltage Between ST3 (female) (37) and (23) Max. 1 V If no failure is found by above checks, HST controller is defective. • Reference 1. Turn starting switch to OFF position. 2. Insert T-adapter into connector ST3. Defective HST controller 3. Turn starting switch to ON position. 4. Operate parking brake lever and perform troubleshooting. Between ST3 (37) and Parking brake: FREE 20 to 30 V Voltage (23) Parking brake: LOCK Max. 4.5

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Troubleshooting by failure code (Display of code)

Circuit diagram related to neutral safety relay

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40 Troubleshooting

Troubleshooting by failure code (Display of code)

Failure code [D130KY] Neutral relay: Hot Short Action level L01 Detail of failure Action of controller Problem on machine

Related information

No.

Neutral relay: Hot short Failure code Failure (Defective HST controller) D130KY • When controller does not drive primary circuit (coil) of neutral safety relay, current flows through circuit. • None in particular • Engine is allowed to start even when gear shift lever is in a position other that N (NEUTRAL). • Output to primary (coil) circuit of neutral safety relay can be checked with monitoring function. (Code 40979: "HST SW Output") • Method of reproducing failure code: Turn starting switch to ON position and move directional lever to any position other than N (NEUTRAL). • This failure code indicates failure on primary circuit (coil side) of neutral safety relay, but not on secondary circuit (contact side). Cause

Procedure, measuring location, criteria and remarks 1. Turn starting switch to OFF position.

Defective neutral safety relay 2. Disconnect connector 11 and connect T-adapter to male side. Resis- Between connector 11 (male) (1) and (2) 200 to 600 z tance 1. Turn starting switch to OFF position. 2. Disconnect connector 11 and connect T-adapter to female side. Hot short circuit in wiring 3. Turn starting switch to ON position. harness 4. Move directional lever to position other than N (NEUTRAL). Voltage Between 11 (female) (1) and (2) Max. 4.5 V If no failure is found by above checks, HST controller is defective. • Reference 1. Turn starting switch to OFF position. 2. Insert T-adapter into connector ST3. 3. Turn starting switch to ON position. Defective HST controller 4. Operate work equipment lock lever to perform troubleshooting. Parking brake lever: 20 to 30 V Between ST3 (37) FREE Voltage and (23) Parking brake lever: Max. 4.5 V LOCK

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Troubleshooting by failure code (Display of code)

Circuit diagram related to neutral safety relay

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D61EM-23M0

40 Troubleshooting

Troubleshooting by failure code (Display of code)

Failure code [D19JKZ] Personal Code Relay Abnormality Action level L03 Detail of failure Action of machine monitor Problem on machine

Related information

No. 1

Failure code D19JKZ

Failure

Personal Code Relay Abnormality (Machine monitor system)

• Open error or short circuit occurs in primary (coil) circuit of personal code relay. • None in particular (when open error occurred) • Stops driving personal code relay (when short circuit occurred). • If cause of failure disappears, machine becomes normal by itself (when open error occurred). • Even if cause of failure disappears, machine does not become normal until starting switch is turned to OFF position (when short circuit occurred). • This failure code is displayed only when engine lock function is enabled. • Method of reproducing failure code: Turn starting switch to ON position (when open circuit occurred). Failure code cannot be reproduced on the machine (when short circuit occurred). • Troubleshooting for this failure code covers circuits from fuse No. 5 in fuse box F01 through primary (coil) circuit of personal code relay PLR to machine monitor.

Cause Defective No.5 in fuse box F01

Procedure, measuring location, criteria and remarks If fuse is blown, circuit may have ground fault.

1. Turn starting switch to OFF position. 2. Disconnect relay PLR and connect T-adapter to male side. Resis- Between PLR (male) (1) and (2) 200 to 600 z tance Defective personal code relay 1. Turn starting switch to OFF position. PLR 2. Replace relay PLR with preheating relay RHR. 3. Turn starting switch to ON position. If this failure code disappears, original personal code relay PLR is defective. 1. Turn starting switch to OFF position. 2. Remove fuse No. 5 in fuse box F01. 3. Disconnect connector CM01, and connect T-adapter to female side. Open circuit, short circuit, or ground fault in wiring harness Between F01-5 and CM01 (female) (6) 200 to 600 z ResisBetween ground and F01-5 or CM01 (female) tance Min. 1 Mz (6)

a If no failure is found by check on cause 3, this check is not required. 1. Turn starting switch to OFF position. 2. Remove fuse No. 5 in fuse box F01. Open circuit in wiring harness 3. Remove connector CM01 and relay PLR, and connect T-adapter to each female side. Between F01-5 and PLR (female) (1) Max. 1 z ResisBetween PLR (female) (2) and CM01 tance Max. 1 z (female) (6)

a If no failure is found by check on cause 3, this check is not required. 1. Turn starting switch to OFF position. 2. Remove fuse No. 5 in fuse box F01. 3. Remove connector CM01 and relay PLR, and connect T-adapter to Ground fault in wiring harness either female side. Between ground and F01-5 or PLR (female) Min. 1 Mz Resis- (1) tance Between ground and PLR (female) (2) or Min. 1 Mz CM01 (female) (6)

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Troubleshooting by failure code (Display of code)

No.

Procedure, measuring location, criteria and remarks

Cause

1. Turn starting switch to OFF position. 2. Remove fuse No. 5 in fuse box F01. 3. Disconnect connectors CM01 and relay PLR, and connect T-adapter to female side of CM01. 6

Short circuit in wiring harness

a Check by using multimeter in continuity mode. No continuity (No sound is heard) If no failure is found by above checks, machine monitor is defective. (Since this is an internal defect, troubleshooting cannot be performed.) Continuity

Defective machine monitor

40-216

Between CM01 (female) (6) and each pin other than (6)

D61EM-23M0

40 Troubleshooting

Troubleshooting by failure code (Display of code)

Circuit diagram related to personal code relay

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Troubleshooting by failure code (Display of code)

Failure code [D811MC] KOMTRAX Error Action level – Detail of failure Action of controller Problem on machine Related information No. 1

Failure code D811MC

KOMTRAX Error (KOMTRAX system)

• KOMTRAX malfunctions.

• KOMTRAX system does not operate properly. • Method of reproducing failure code: Turn starting switch to ON position. Cause

Malfunction of KOMTRAX

40-218

Failure

Procedure, measuring location, criteria and remarks KOMTRAX is defective. (Since this is an internal defect, troubleshooting cannot be performed.)

D61EM-23M0

40 Troubleshooting

Troubleshooting by failure code (Display of code)

Failure code [D862KA] GPS Antenna Open Circuit Action level Detail of failure Action of machine monitor Problem on machine Related information No. 1

Failure code D862KA

Failure

GPS Antenna Open Circuit (KOMTRAX system)

• Open circuit occurs in GPS antenna circuit. • None in particular • If cause of failure disappears, machine becomes normal by itself. • GPS positioning system does not work. • Method of reproducing failure code: Turn starting switch to ON position.

Cause Defective GPS antenna or antenna cable

Procedure, measuring location, criteria, and remarks GPS antenna may be defective, or antenna cable may have open or short circuit, or poor contact at terminal area (GPS).

Figure of structure

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Troubleshooting by failure code (Display of code)

Failure code [D8ALKA] Operating Lamp Open Circuit (KOMTRAX) Action level — Detail of failure Action of controller Problem on machine

Related information

No. 1

Operating Lamp Open Circuit (KOMTRAX) Failure code Failure (KOMTRAX system) D8ALKA • KOMTRAX determines that system operating lamp circuit is open because voltage of output circuit remains at approximately 5 V or less for approximately 3 seconds after starting switch is turned to the ON position, during which KOMTRAX outputs no current to system operating lamp. • None in particular • While system operating lamp lights up, battery disconnect switch must not be turned to OFF position. Turning battery disconnect switch to OFF position may destroy data stored in KOMTRAX memory. • Method of reproducing failure code: Turn starting switch to the ON position. • Although KOMTRAX is not able to light up system operating lamp, no trouble will result unless battery disconnect switch is turned to OFF position. • When controller lights up system operating lamp, output circuit voltage is at low level. • Since no controller drives system operating lamp for approximately 3 seconds after starting switch is turned to ON position, open circuit can be detected.

Cause Defective fuse No.17 in fuse box F01

Procedure, measuring location, criteria and remarks If fuse is blown, circuit probably has ground fault.

1. Turn starting switch to OFF position. 2. Remove fuse No. 17 in fuse box F01. Open circuit in wiring harness 3. Disconnect connector CK01and LBU and connect T-adapter to each female side. (wire breakage or defective Between CK01 (female) (15) and LBU (female) contact of connector) Max. 1 z Resis- (2) tance Between LBU (female) (1) and F01-17 Max. 1 z If no failure is found by above checks, KOMTRAX terminal is defective. Defective KOMTRAX terminal (Since this is an internal defect, troubleshooting cannot be performed.)

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40 Troubleshooting

Troubleshooting by failure code (Display of code)

Circuit diagram related to system operating lamp

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Troubleshooting by failure code (Display of code)

Failure code [D8ALKB] Operating Lamp Short Circuit (KOMTRAX) Action level — Detail of failure Action of controller Problem on machine Related information No.

Operating Lamp Short Circuit (KOMTRAX) Failure code Failure (KOMTRAX system) D8ALKB • KOMTRAX determines that system operating lamp circuit shorts because voltage of output circuit does not become low level while KOMTRAX outputs current to system operating lamp. • None in particular • While system operating lamp lights up, battery disconnect switch must not be turned to OFF position. Turning battery disconnect switch to OFF position may destroy data stored in KOMTRAX memory. • Method of reproducing failure code: Turn starting switch to the ON position. • Although KOMTRAX is not able to light up system operating lamp, no trouble will result unless battery disconnect switch is turned to OFF position. • When controller lights up system operating lamp, output circuit voltage is at low level. Cause

Procedure, measuring location, criteria and remarks

1. Turn starting switch to OFF position. 2. Remove fuse No. 17 in fuse box F01. Short circuit in wiring harness 3. Disconnect connectors CM01, ST3, CK01, CE03, and LBU, and connect T-adapter to female side of LBU. Resis- Between LBU (female) (1) and (2) Min. 1 Mz tance If no failure is found by above checks, KOMTRAX terminal is defective. Defective KOMTRAX terminal (Since this is an internal defect, troubleshooting cannot be performed.)

Circuit diagram related to system operating lamp

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D61EM-23M0

40 Troubleshooting

Troubleshooting by failure code (Display of code)

Failure code [D8AQKR] CAN2 Discon (KOMTRAX) Action level — Detail of failure Action of machine monitor Problem on machine

Related information

CAN2 Disconnection (KOMTRAX) Failure code Failure (Detected by machine monitor) (Machine monitor system) D8AQKR • Machine monitor does not recognize KOMTRAX over CAN communication-2 line (KOMNET/c). • None • None • Method of reproducing failure code: Turn starting switch to ON position. • Start of CAN communication is recognized by each controller when ACC signal of starting switch is received. • Four different failure codes, [DBEQKR], [DB2QKR], [D8AQKR], and [DAZQKR], are used for defective CAN communication by CAN2, which are detected by machine monitor. When all of these four failure codes are displayed, ground fault, short circuit or hot short in wiring harness (CAN communication circuit) can be suspected. In this case, check whether air conditioner is operated (ON/OFF and air flow adjustment) from air conditioner operation screen since air conditioner is also controlled over CAN communication line. a Air conditioner can be controlled even when failure code is displayed on screen. If air conditioner is controlled, wiring harness (CAN communication line) does not have ground fault, short circuit, or hot short circuit. • Since each controller and machine monitor are connected directly to battery, they are supplied with power even after starting switch is turned to OFF position. • Since signal of active CAN communication line is pulse voltage, it cannot be measured by using multimeter.

No.

Cause

Defective fuse No.20 in fuse box F01

2 3 4 5

Defective power supply to KOMTRAX terminal Defective CAN communication 2 system

Procedure, measuring location, criteria and remarks 1. Turn starting switch to OFF position. 2. Remove fuse No. 20 in fuse box F01. If fuse is blown, circuit probably has ground fault. Perform troubleshooting for "E-39" of E mode.

Perform checks on causes 4 to 9 in troubleshooting for failure code [DB2QKR]. If no failure is found by above checks, KOMTRAX terminal is defective. Defective KOMTRAX terminal (Since this is an internal defect, troubleshooting cannot be performed.) If no failure is found by above checks, machine monitor is defective. Defective machine monitor (Since this is an internal defect, troubleshooting cannot be performed.)

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Troubleshooting by failure code (Display of code)

Failure code [DAF0MB] Monitor ROM Abnormality Action level – Detail of failure Action of controller Problem on machine Related information No. 1

Failure code DAF0MB

Monitor ROM Abnormality (Machine monitor system)

• Program of machine monitor is rewritten (program error).

• Indication of machine monitor is unreliable. • Machine monitor is incapable of normally exchanging data with controllers. • Method of reproducing failure code: Turn starting switch to ON position. Cause

Defective machine monitor

40-224

Failure

Procedure, measuring location, criteria and remarks Machine monitor is defective. (Since this is an internal defect, troubleshooting cannot be performed.)

D61EM-23M0

40 Troubleshooting

Troubleshooting by failure code (Display of code)

Failure code [DAF0MC] Monitor Error Action level – Detail of failure Action of controller Problem on machine Related information No. 1

Failure code DAF0MC

Monitor Error (Machine monitor system)

• Machine monitor malfunctions.

Defective machine monitor

D61EM-23M0

Failure

Procedure, measuring location, criteria and remarks Machine monitor is defective. (Since this is an internal defect, troubleshooting cannot be performed.)

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Troubleshooting by failure code (Display of code)

Failure code [DAF8KB] Camera Power Supply Short Circuit Action level L03 Detail of failure Action of machine monitor Problem on machine Related information No.

Camera Power Supply Short Circuit Failure code Failure (Machine monitor system) DAF8KB • Output power supply voltage from machine monitor to camera (rated voltage is 8 V) drops to 6.0 V or less or increases to 10 V or more. • Stops output power supply voltage to camera (rated voltage is 8 V). • Even if cause of failure disappears, machine does not become normal until starting switch is turned to OFF position. • Camera image is not displayed on monitor screen. • Method of reproducing failure code: Turn starting switch to ON position. Cause

Defective camera (internal short circuit)

Defective machine monitor

Procedure, measuring location, criteria and remarks 1. Turn starting switch to OFF position. 2. Disconnect connector RVC of camera and turn starting switch to ON position. After disconnecting camera connector and performing failure code reproducing procedure, if failure code disappears, camera has internal defect. 1. Turn starting switch to OFF position. 2. Disconnect connector CM04. 3. Connect T-adapter to male side of connector CM04. 4. Turn starting switch to ON position. Voltage Between CM04 (male) (1) and ground 6 to 10 V

1. Turn starting switch to OFF position. Ground fault in wiring harness 2. Disconnect connector CM04 and camera connector RVC. 3. Connect T-adapter to female side of connector CM04. (contact with ground circuit) Resis- Between CM04 (female) (1) and ground Min. 1 Mz tance 1. Turn starting switch to OFF position. 2. Disconnect camera connector RVC. 3. Insert T-adapter into connector CM04. Hot short circuit in wiring 4. Turn starting switch to ON position. harness (Disconnect camera and check that camera is not defective in advance.) Voltage Between CM04 (1) and (5) Max. 10 V

Circuit diagram related to camera power supply

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40 Troubleshooting

Troubleshooting by failure code (Display of code)

Failure code [DAF9KQ] Model Selection Abnormality Action level L03 Detail of failure Action of controller Problem on machine

Model Selection Abnormality Failure code Failure (Machine monitor system) DAF9KQ • Machine model in machine monitor program differs from that in HST controller program. (Replaced machine monitor or HST controller has wrong part No.)

• Machine does not operate normally.

Related information

• Assembly part number of HST controller program can be checked with monitoring function. (Code: 20237 "HST Con Ass'y P/N") • Assembly part number of machine monitor program can be checked with monitoring function. (Code: 20227" Monitor Ass'y P/N") • Method of reproducing failure code: Turn starting switch to ON position.

No.

Cause

Procedure, measuring location, criteria and remarks

Defective machine monitor

1. Display assembly part number with monitoring function, and check that it is the same as part number in Parts Catalog. Defective machine monitor (Wrong machine model is programmed.)

Defective HST controller

1. Display assembly part number with monitoring function, and check that it is the same as part number in Parts Catalog. Defective HST controller (Wrong machine model is programmed.)

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Troubleshooting by failure code (Display of code)

Failure code [DAFGMC] GPS Module Error Action level Detail of failure Action of machine monitor Problem on machine Related information No. 1

GPS Module Error Failure code Failure (KOMTRAX system) DAFGMC • Position data is not sent from GPS module (in machine monitor) to KOMTRAX communication modem in 50 seconds after KOMTRAX started. • None in particular • If cause of failure disappears, machine becomes normal by itself.

• Method of reproducing failure code: Turn starting switch to ON position (at least 50 seconds after starting switch is turned to ON position). Cause

Defective machine monitor

40-228

Procedure, measuring location, criteria, and remarks GPS module in machine monitor may be defective. (Since this is an internal defect, troubleshooting cannot be performed.)

D61EM-23M0

40 Troubleshooting

Troubleshooting by failure code (Display of code)

Failure code [DAFLKA] Operating Lamp Open Circuit (Monitor) Action level — Detail of failure Action of controller Problem on machine

Related information

No. 1

Operating Lamp Open Circuit (Monitor) Failure code Failure (Machine monitor system) DAFLKA • Machine monitor determines that system operating lamp circuit is open because voltage of output circuit remains at approximately 5 V or less for approximately 3 seconds after starting switch is turned to ON position, during which machine monitor outputs no current to system operating lamp. • None in particular • While system operating lamp lights up, battery disconnect switch must not be turned to OFF position. Setting battery disconnect switch to OFF position may destroy data stored in machine monitor terminal memory. • Method of reproducing failure code: Turn starting switch to ON position. • Although machine monitor is not able to light system operating lamp, no trouble will result unless battery disconnect switch is turned to OFF position. • When controller lights up system operating lamp, output circuit voltage is at low level. • Since no controller drives system operating lamp for approximately 3 seconds after starting switch is turned to ON position, open circuit can be detected.

Cause Defective fuse No.17 in fuse box F01

Procedure, measuring location, criteria and remarks If fuse is blown, circuit probably has ground fault.

1. Turn starting switch to OFF position. 2. Remove fuse No. 17 in fuse box F01. Open circuit in wiring harness 3. Disconnect connector CM01,and LBU and connect T-adapter to each female side. (wire breakage or defective Between CK01 (female) (15) and LBU (female) contact of connector) Max. 1 z Resis- (2) tance Between LBU (female) (1) and F01-17 Max. 1 z If no failure is found by above checks, machine monitor is defective. Defective machine monitor (Since this is an internal defect, troubleshooting cannot be performed.)

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Troubleshooting by failure code (Display of code)

Circuit diagram related to system operating lamp

40-230

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40 Troubleshooting

Troubleshooting by failure code (Display of code)

Failure code [DAFLKB] Operating Lamp Short Circuit (Monitor) Action level — Detail of failure Action of controller Problem on machine Related information No.

Operating Lamp Short Circuit (Monitor) Failure code Failure (Machine monitor system) DAFLKB • Machine monitor determines that system operating lamp circuit shorts because voltage of output circuit does not become low level while machine monitor outputs current to system operating lamp. • None in particular • While system operating lamp lights up, battery disconnect switch must not be turned to OFF position. Setting battery disconnect switch to OFF position may destroy data stored in machine monitor terminal memory. • Method of reproducing failure code: Turn starting switch to the ON position. • Although machine monitor is not able to light system operating lamp, no trouble will result unless battery disconnect switch is turned to OFF position. • When controller lights up system operating lamp, output circuit voltage is at low level. Cause

Procedure, measuring location, criteria and remarks

1. Turn starting switch to OFF position. 2. Remove fuse No. 17 in fuse box F01. Short circuit in wiring harness 3. Disconnect connectors CM01, ST3, CK01, CE03, and LBU, and connect T-adapter to female side of LBU. Resis- Between LBU (female) (1) and (2) Min. 1 Mz tance If no failure is found by above checks, machine monitor is defective. Defective machine monitor (Since this is an internal defect, troubleshooting cannot be performed.)

Circuit diagram related to system operating lamp

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Troubleshooting by failure code (Display of code)

Failure code [DAFQKR] CAN2 Discon (Monitor) Action level ― Detail of failure Action of controller Problem on machine

Related information

No. 1 2

CAN2 Disconnection (Monitor) Failure code Failure (detected by KOMTRAX terminal)(KOMTRAX system) DAFQKR • KOMTRAX terminal does not recognize machine monitor through CAN communication 2 line.

• KOMTRAX system may not function normally. • Method of reproducing failure code: Turn starting switch to ON position. • Start of CAN communication is recognized by each controller when ACC signal of starting switch is received. • Failure code is transmitted to and displayed on machine monitor by CAN communication. Accordingly, if CAN communication with machine monitor fails, failure code [DAFQKR] is not displayed on machine monitor and it can be observed only through KOMTRAX system. • Since each controller and machine monitor are connected directly to battery, they are supplied with power even after starting switch is turned to OFF position. • Since signal of active CAN communication line is pulse voltage, it cannot be measured by using multimeter.

Cause Defective power supply to machine monitor

Procedure, measuring location, criteria and remarks Perform troubleshooting for "E-5" in E mode troubleshooting.

Perform checks on causes 5 and after in troubleshooting for failure Defective CAN communication code [DB2QKR]

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Troubleshooting by failure code (Display of code)

Failure code [DAJ000] HST controller: Abnormality in controller Action level — Detail of failure Action of controller Problem on machine Related information No.

Failure code DAJ000

HST controller: Abnormality in controller (Defective HST controller)

• Information in ROM (non-volatile memory) of HST controller is abnormal. • Uses the normal data of either the main area or backup area.

Cause

Defective HST controller

Open circuit or ground fault in wiring harness

D61EM-23M0

Failure

Procedure, measuring location, criteria and remarks Since this is internal defect, troubleshooting cannot be performed. (If there is no visible failure on machine, controller may be used as it is.) Since the power voltage (VB) of HST controller may drop during data writing in memory, perform troubleshooting for failure code [DAJ1KK].

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Troubleshooting by failure code (Display of code)

Failure code [DAJ0KQ] HST controller: Type select signal Action level L03 Detail of failure Action of controller Problem on machine Related information No.

• • • • • • • •

HST controller: Type select signal Failure code Failure (HST controller system) DAJ000 The machine model which is selected and stored in memory does not match between the HST controller and monitor panel. No machine model is selected. Partially limits the functions. Even if cause of failure disappears, machine does not become normal until starting switch is turned to OFF position. System may not function normally. Once machine stops, engine speed is restricted to medium (half) speed. Once machine stops, travel speed is restricted to 50% after restart. The machine code recognized by the HST controller and the one recognized by the machine monitor can be checked with the monitoring function. (Code: 00204 "HST Con Model Code"; Code: 00500 "Monitor Model Code") Cause

Incorrect machine model selection

40-234

Procedure, measuring location, criteria and remarks • Check and record the machine model which has been recognized by HST controller and by machine monitor with the monitoring function. • In the machine model selection mode, select the correct machine model. • If a machine model not recognized by the HST controller was selected, initialize the entire memory data.

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Troubleshooting by failure code (Display of code)

Failure code [DAJ0KT] HST controller: Abnormality in controller Action level L03 Detail of failure Action of controller

Problem on machine

• • • • • • • • • • •

HST controller: Abnormality in controller Failure code Failure (HST controller system) DAJ000 Information in ROM (non-volatile memory) of HST controller is abnormal. (Both of main area memory and backup area data are abnormal.) Displays the system abnormality on the machine monitor. Restrict the throttle to the 50% upper limit. Restrict the gear speed to the second gear. Clears the entire memory, and uses the default values. System may not function normally. The machine may not reach the top speed. The straight movement may fail when the machine starts. When steered, the pivot turn and counter-rotation turn may have a displacement. When breaking, the breaking start point and the breaking pedal position may differ from each other. Since the machine model setting is also cleared, failure code [DAJ0KQ] is also generated.

Related information

• Method of reproducing failure code: Turn starting switch to ON position.

No.

Cause

Defective HST controller

Open circuit or ground fault in wiring harness

D61EM-23M0

Procedure, measuring location, criteria and remarks Since this is internal defect, troubleshooting cannot be performed. (If there is no visible failure on machine after machine model setting and initial adjustment, controller may be used as it is.) Since the power voltage (VB) of HST controller may drop during data writing in memory, perform troubleshooting for failure code [DAJ1KK].

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Troubleshooting by failure code (Display of code)

Failure code [DAJ0MC] HST Con Error Action level — Detail of failure Action of controller

Failure code DAJ0MC

Failure

HST controller error (HST controller system)

• A runtime error generated by the OS • Resets the CPU, restarts the system, and sends a failure code after restarting.

Problem on machine

• Since the HST pump and motor stop, machine cannot travel. • The parking brake is locked. • An output to the work equipment stops (but when the work equipment lever is returned to the neutral position, work equipment can be operated).

Related information

• Method of reproducing failure code: Turn starting switch to ON position.

No.

Cause

Defective HST controller

40-236

Procedure, measuring location, criteria and remarks Since this is internal defect, troubleshooting cannot be performed. (If there is no visible failure on machine, controller may be used as it is.)

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40 Troubleshooting

Troubleshooting by failure code (Display of code)

Failure code [DAJ1KK] HST controller: Source voltage low Action level L04 Detail of failure Action of controller Problem on machine Related information No. 1

Failure code DAJ1KK

Failure

HST controller: Source voltage low (HST controller system)

• Main power supply voltage of HST controller drops to below 17 V. • Displays the system abnormality on the machine monitor. • Restricts the engine speed to 50%. • The normal operation fails due to unstable input and output signals. • Power supply voltage of HST controller can be checked with the adjusting function. (Adjustment ID: 2021 "HST controller voltage check mode") • Method of reproducing failure code: Turn starting switch to ON position.

Procedure, measuring location, criteria and remarks Cause Defective fuse No. 15 in fuse If fuse F01-15 is blown out, circuit probably has ground fault. In this case, perform check on cause 6 first. box F01

Loose terminal or open circuit at terminal

1. Turn starting switch to OFF position. Check terminals of battery, battery relay, etc.

Improper battery voltage

1. Perform troubleshooting with starting switch at OFF position and when starting engine. Voltage Between battery terminals (+) and (-) 20 to 30 V

Open and short circuit in wiring harness

1. Turn starting switch to OFF position. 2. Turn battery disconnect switch to OFF position. 3. Insert T-adapter into connector ST3. 4. Turn battery disconnect switch to ON position. a If voltage is 0 V, it has open-cricuit or ground fault. Between ST3 (1) and each of (21) and (31) Voltage Between ST3 (11) and each of (32) and (33)

20 to 30 V 20 to 30 V

Open circuit in wiring harness (wire breakage or defective contact of connector)

a If no failure is found by check on cause 4, this check is not required. 1. Turn starting switch to OFF position. 2. Turn battery disconnect switch to OFF position. 3. If fuse is blown out, replace it. 4. Disconnect connector ST3 and connect T-adapter to female side. Between ground and each of ST3 (female) (21), (31), (32) and (33) Max. 1 z Resistance a Check terminal T36 for looseness and rust. Between each of ST3 (female) (1) and (11) Max. 1 z and battery positive terminal (+)

Ground fault in wiring harness (contact with ground circuit)

a If no failure is found by check on cause 4, this check is not required. 1. Turn starting switch to OFF position. 2. Turn battery disconnect switch to OFF position. 3. If fuse is blown out, replace it. 4. Disconnect connector ST3 and connect T-adapter to female side. Between ST3 (female) (1) and each of (21) Max. 1 Mz and (31) Resistance Between ST3 (female) (11) and each of (32) Max. 1 Mz and (33)

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No.

Cause

Defective HST controller

Procedure, measuring location, criteria and remarks If no failure is found by above checks, HST controller is defective. • Reference 1. Turn starting switch to OFF position. 2. Turn battery disconnect switch to OFF position. 3. Insert T-adapter into connector ST3. 4. Turn battery disconnect switch to ON position. 5. Turn starting switch to ON position. Between ST3 (1) and each of (21) and (31) 20 to 30 V Voltage Between ST3 (11) and each of (32) and (33) 20 to 30 V

Circuit diagram related to HST controller battery direct power supply

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Failure code [DAJ2KK] HST controller: Output voltage low Action level L04 Detail of failure Action of controller Problem on machine Related information

Failure code DAJ2KK

Failure

HST controller: Output voltage low (HST controller system)

• Power voltage for HST controller loads (relays and solenoids) drops below 17 V. • Displays the system abnormality on the machine monitor. • Restricts the engine speed to 50%. • Since the relays, solenoids and others cannot drive, the normal operation cannot be performed. • Power supply voltage of HST controller can be checked with the adjusting function. (Adjustment ID: 2021 "HST controller voltage check mode") • If battery relay does not turn ON, see E-1 in E-mode. • Method of reproducing failure code: Turn starting switch to ON position.

Cause Defective fuse No. 5 in fuse box F01

Procedure, measuring location, criteria and remarks If fuse F01-15 is blown out, circuit probably has ground fault. In this case, perform check on cause 6 first.

Loose terminal or open circuit at terminal

1. Turn starting switch to OFF position. Check terminals of battery, battery relay, etc.

Improper battery voltage

1. Perform troubleshooting with starting switch at OFF position and when starting engine. Voltage Between battery terminals (+) and (-) 20 to 30 V

Defective wiring harness or HST controller

1. Turn starting switch to OFF position. 2. Turn battery disconnect switch to OFF position. 3. Insert T-adapter into connector ST3. 4. Turn battery disconnect switch to ON position. 5. Turn starting switch to ON position. Between ST3 (2) and (21) Voltage Between ST3 (12) and (31) Between ST3 (22) and (32)

No. 1

Open circuit in wiring harness (wire breakage or defective contact of connector)

Ground fault in wiring harness (contact with ground circuit)

Defective HST controller

D61EM-23M0

20 to 30 V 20 to 30 V 20 to 30 V

a If no failure is found by check on cause 4, this check is not required. 1. Turn starting switch to OFF position. 2. Turn battery disconnect switch to OFF position (to prevent short circuit during work). 3. Disconnect connector ST3 and connect T-adapter to female side. Between ground and each of ST3 (female) (21), (31), (32) and (33) Max. 1 z Resistance a Check terminal T36 for looseness and rust. Between each of ST3 (female) (2), (12) and Max. 1 z (22) and terminal M a If no failure is found by check on cause 4, this check is not required. 1. Turn starting switch to OFF position. 2. Turn battery disconnect switch to OFF position (to prevent short circuit during work). 3. If fuse is blown out, replace it. 4. Disconnect connector ST3. Resistance Between terminal M and ground Max. 1 Mz If no failure is found by above checks, HST controller is defective.

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Circuit diagram related to HST controller solenoid power supply

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Troubleshooting by failure code (Display of code)

Failure code [DAJ5KK] HST: Sensor volt 5V (0) Out of normal range Action level L04 Detail of failure Action of controller

• • • • • •

Failure code HST: Sensor voltage 5 V (0) Out of normal range Failure (HST controller system) DAJ5KK Voltage of 5 V power supply (0) from HST controller to sensors is below 4.5 V or above 5.5 V. Unusual current flows in 5 V power supply (0) circuit for HST controller sensors. Stops driving 5 V power supply (0) circuit. Displays the system state on the machine monitor. Holds each sensor value. Restricts the engine speed to 50%.

Problem on machine Related information

• The normal operation fails due to unstable input and output signals.

No.

Cause

• Method of reproducing failure code: Turn starting switch to ON position.

Defective fuel control dial, or defective joystick (steering, directional, and gear shift lever) (internal defect)

Procedure, measuring location, criteria and remarks

& & % $ ! $ 2 7*# % ~ % & , + '$ ' $ $ 2 2 & & % $ $ $ ! $ 27*# % ~ - $ 5 56 $ 56 (& ) 56 ( ) . & & % $ - $ `" `" $ `" (& ) `" ( ) . & & % $ & & % $ $, &$ % & , 7 + '$ ' $ $ 2 2 $ & , ' 7 ^ 56056 $ 7 ^ `"0`" $ . $& ' % $ & & % $ ! $ 56 56 &$ $ $ Turn starting switch to OFF position. Disconnect following connectors one by one and turn starting switch to ON position each time. Each time troubleshooting is finished, return to step . • If this code is not displayed when sensor or device is disconnected, that sensor or device is defective. a Other failure codes (many codes) are also displayed. They are generated because of disconnection of connector. Ignore failure codes other than [DAJ5KK]. Joystick (steering, directional, and gear shift 56 lever) Left Forward HST pressure sensor LPF Right Forward HST pressure sensor RPF Connector Brake pressure sensor BS Oil pressure sensor of work equipment WP pump Decelerator/ brake pedal potentiometer `"

Defective HST controller

D61EM-23M0

1. Turn starting switch to OFF position. 2. Disconnect connector ST1 and connect T-adapter to male side. 3. Turn starting switch to ON position. Voltage Between ST1 (male) (22) and (21) 4.5 to 5.5 V

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Cause

Procedure, measuring location, criteria and remarks

Ground fault in wiring harness (contact with ground circuit)

Turn starting switch to OFF position. Disconnect all of connectors ST1, 56 , LPF, RPF, BS, WP and `" , and connect T-adapter to female side of either connector. Between ground and either of ST1 (female) (22), 56 (female) (4) and (5), LPF Resistance (female) (3), RPF (female) (3), BS (female) Min. 1 Mz (3), WP (female) (3), and `" (female) (C)

Hot short circuit in wiring harness

Turn starting switch to OFF position. Disconnect all of connectors 56 , LPF, RPF, BS, WP and `" , and connect T-adapter to female side of either connector. Turn starting switch to ON position. Between 56 (female) (4) and (1), between (5) and (8), between LPF (female) (3) and (1), between RPF Voltage 4.5 to 5.5 V (female) (3) and (1), between BS (female) (3) and (1), between WP (female) (3) and (1), or between `" (female) (C) and (B)

No.

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Circuit diagram related to HST controller 5 V power supply (0)

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Failure code [DAJ6KK] HST: Sensor volt 5V (1) Out of normal range Action level L03 Detail of failure Action of controller

• • • • •

HST: Sensor voltage 5 V (1) Out of normal range Failure code Failure (HST controller system) DAJ6KK Voltage of 5 V power supply (1) from HST controller to sensors is below 4.5 V or above 5.5 V. Unusual current flows in 5 V power supply (1) circuit for HST controller sensors. Stops driving 5 V power supply (1) circuit. Stops traveling. Disables deviation control.

Problem on machine

• Machine does not travel straight. • After stopping, the engine speed is restricted to 50%.

Related information

• Method of reproducing failure code: Turn starting switch to ON position.

No.

Cause

Defective R.H. motor speed sensor or L.H. motor speed sensor (internal defect)

Procedure, measuring location, criteria and remarks 1. Turn starting switch to OFF position. 2. Disconnect following connectors one by one and turn starting switch to ON position each time. 3. Each time troubleshooting is finished, return to step 1. • If this code is not displayed when sensor or device is disconnected, that sensor or device is defective. a Other failure codes (many codes) are also displayed. They are generated because of disconnection of connector. Ignore failure codes other than [DAJ6KK]. R.H. motor speed sensor RRS2 Connector L.H. motor speed sensor LRS2

Defective HST controller

1. Turn starting switch to OFF position. 2. Disconnect connector ST2 and connect T-adapter to male side. 3. Each time troubleshooting is finished, return to step 1. Voltage Between ST2 (male) (1) and (39) 4.5 to 5.5 V

Ground fault in wiring harness (contact with ground circuit)

1. Turn starting switch to OFF position. 2. Disconnect all of connectors ST2, RRS2 and LRS2, and connect Tadapter to female side of either connector. Between ground and either of ST2 (female) Resistance (1), RRS2 (female) (A) and LRS2 (female) Min. 1 Mz (A)

Hot short circuit in wiring harness

1. Turn starting switch to OFF position. 2. Disconnect connectors RRS2 and LRS2, and connect T-adapter to female side of either connector. 3. Turn starting switch to ON position. Between RRS2 (female) (A) and (B), or Voltage 4.5 to 5.5 V between LRS2 (female) (A) and (B)

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Circuit diagram related to HST controller 5 V power supply for work equipment controller sensor

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Failure code [DAJLKA] Operating Lamp Open Circuit (HST Con) Action level — Detail of failure Action of controller Problem on machine

Related information

No. 1

Open circuit of system operating lamp (HST controller) Failure code Failure (HST controller system) DAJLKA • HST controller has detected an open circuit because the output line voltage of system operating lamp is approximately 5 V or less when the HST controller does not output the voltage for approximately 3 seconds after the starting switch has turned ON. • None in particular • While system operating lamp lights up, battery disconnect switch must not be turned to OFF position. If the battery disconnect switch is turned OFF, the memory data of HST controller may be destroyed. • Method of reproducing failure code: Turn starting switch to ON position. • Although HST controller is not able to light up system operating lamp, no trouble will result unless battery disconnect switch is turned to OFF position. • When controller lights up system operating lamp, output circuit voltage is at low level. • Since no controller drives system operating lamp for approximately 3 seconds after starting switch is turned to ON position, open circuit can be detected.

Procedure, measuring location, criteria and remarks Cause Defective fuse No.17 in fuse If fuse is blown, circuit probably has ground fault. box F01 1. Turn starting switch to OFF position. 2. Remove fuse No. 17 from fuse box F01. Open circuit in wiring 3. Disconnect connectors ST3 and LBU, and connect T-adapters to harness each female side. Between ST3 (female) (34) and LBU (wire breakage or defective Max. 1 z (female) (2) contact of connector) Resistance Between LBU (female) (1) and fuse terminal Max. 1 z 17 of F01 If no failure is found by above checks, HST controller is defective. Defective HST controller (Since this is an internal defect, troubleshooting cannot be performed.)

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Circuit diagram related to system operating lamp

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Failure code [DAJLKB] Operating Lamp Short Circuit (HST Con) Action level — Detail of failure Action of controller Problem on machine Related information No.

Operating Lamp Short Circuit (HST Controller) Failure code Failure (HST controller system) DAJLKB • HST controller determines that output circuit to system operating lamp shorts because voltage of output circuit does not become Low level while HST controller drives system operating lamp. • None in particular • While system operating lamp lights up, battery disconnect switch must not be turned to OFF position. If the battery disconnect switch is turned OFF, the memory data of HST controller may be destroyed. • Method of reproducing failure code: Turn starting switch to ON position. • Although HST controller is not able to light up system operating lamp, no trouble will result unless battery disconnect switch is turned to OFF position. • When controller lights up system operating lamp, output circuit voltage is at low level. Cause

Short circuit in wiring harness

Defective HST controller

Procedure, measuring location, criteria and remarks 1. Turn starting switch to OFF position. 2. Remove fuse No. 17 from fuse box F01. 3. Disconnect connectors CM01, ST3, CK01, CE03, and LBU, and connect T-adapter to female side of LBU. Resistance Between LBU (female) (1) and (2) Min. 1 Mz If no failure is found by above checks, HST controller is defective. (Since this is an internal defect, troubleshooting cannot be performed.)

Circuit diagram related to system operating lamp

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Failure code [DAJPMA] Inconsistency of Option Selection (HST) Action level L01 Detail of failure Action of controller Problem on machine

Inconsistency of Option Selection (HST Controller) Failure code Failure (HST controller system) DAJPMA • When the starting switch is set to ON position, the option setting information sent from the monitor controller differs from that stored in the HST controller memory. • Starts operation by considering no option setting. • Displays the system state monitor on the machine monitor. • The option setting does not work normally.

Related information

• Perform initial setting and initial adjustment similar to those required when the HST controller is replaced. • Method of reproducing failure code: Turn starting switch to ON position.

No.

Cause

Improper option setting of machine monitor

Defective monitor controller

Defective HST controller

D61EM-23M0

Procedure, measuring location, criteria and remarks Option setting of machine monitor is probably incorrect. Perform correct setting referring to Testing and adjustment, "Special functions of machine monitor". Monitor controller may be defective. (Since this is an internal defect, troubleshooting cannot be performed.) If no failure is found by above checks, HST controller may be defective. (Since this is an internal defect, troubleshooting cannot be performed.)

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Failure code [DAJQKR] CAN2 Discon (HST Con) Action level L03 Detail of failure Action of controller Problem on machine

Related information

No.

CAN2 Disconnection (HST Controller) Failure code Failure (Machine monitor system) DAJQKR • Machine monitor cannot recognize HST controller over CAN communication-2 line (KOMNET/c). • None • None • Method of reproducing failure code: Turn starting switch to ON position. • Start of CAN communication is recognized by each controller when ACC signal of starting switch is received. • Three different failure codes, [DAJQKR], [DB2QKR], and [D8AQKR] are used for defective CAN communication by CAN2, which are detected by machine monitor. When all of these three failure codes are displayed simultaneously on screen, ground fault, short circuit, or hot short circuit may occur in wiring harness (CAN communication line). • Since each controller and machine monitor are connected directly to battery, they are supplied with power even after starting switch is turned to OFF position. • Since signal of active CAN communication line is pulse voltage, it cannot be measured by using multimeter.

Cause Defective power supply to HST controller Defective CAN communication 2 system

Defective HST controller

Defective machine monitor

40-250

Procedure, measuring location, criteria and remarks Perform troubleshooting for failure code [DAJ1KK]. Perform checks on causes 4 to 9 in troubleshooting for failure code [DB2QKR]. If no failure is found by above checks, HST controller is defective. (Since this is an internal defect, troubleshooting cannot be performed.) If no failure is found by above checks, machine monitor is defective. (Since this is an internal defect, troubleshooting cannot be performed.)

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Troubleshooting by failure code (Display of code)

Failure code [DAJRKR] CAN1 Discon (HST Con) Action level L03 Detail of failure Action of controller

Problem on machine

• • • • • • • • • • • • • •

Related information

•

• • No.

CAN1 Disconnection ( HST Controller) Failure code Failure (Machine monitor system) DAJRKR Machine monitor cannot recognize HST controller over CAN communication-1 line (KOMNET/r). Retains current working mode. Retains current selection of auto-deceleration. Retains current setting (Hi/Lo) of travel speed. Retains information at time of occurrence of failure. Information to be obtained from HST controller is not displayed and special functions that need information do not work. Or received data are not updated. Pump control is disabled. Hydraulic oil temperature gauge pointer disappears on machine monitor screen. Wiper operation is disabled. Washer operation is disabled. Flow rate of attachment oil pressure line cannot be controlled. Method of reproducing failure code: Turn starting switch to ON position. Start of CAN communication is recognized by each controller when ACC signal of starting switch is received. Machine monitor uses failure code [DAJRKR] to indicate failure in CAN communication over CAN 1 line. . When failure code [DAJRKR] is displayed simultaneously on screen, ground fault, short circuit, or hot short circuit may occur in wiring harness (CAN communication line). Terminal resistor of CAN1 on cab side is provided in machine monitor and connector "RES2" is used as terminal resistor on engine side. (It is not provided for CAN communication-1 line (KOMNET/r) and the line is connected to it via connector "ECM J2".) Since each controller and machine monitor are connected directly to battery, they are supplied with power even after starting switch is turned to OFF position. Since signal of active CAN communication line is pulse voltage, it cannot be measured by using multimeter.

Cause Defective power supply system to HST controller Defective CAN communication 1 system

Defective HST controller

Defective machine monitor

D61EM-23M0

Procedure, measuring location, criteria and remarks Perform troubleshooting for failure code [DAJ1KK]. Perform checks on causes 2 to 8 in troubleshooting for failure code [DAJRKR]. If no failure is found by above checks, HST controller is defective. (Since this is an internal defect, troubleshooting cannot be performed.) If no failure is found by above checks, machine monitor is defective. (Since this is an internal defect, troubleshooting cannot be performed.)

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Failure code [DB2QKR] CAN2 Discon (Engine Con) Action level L03 Detail of failure Action of controller Problem on machine

Related information

No.

CAN2 Disconnection (Engine Controller) Failure code Failure (Machine monitor system) DB2QKR • Machine monitor cannot recognize engine controller over CAN communication-2 line (KOMNET/c). • Retains information at time of occurrence of failure. • Information to be obtained from engine controller is not displayed and special functions that need information from engine controller do not work. Or received data are not updated. (Failure codes and monitoring codes that are sent by engine controller) • Method of reproducing failure code: Turn starting switch to the ON position. • Start of CAN communication is recognized by each controller when ACC signal of starting switch is received. • If failure code [DB2RKR] is also displayed, engine controller may be defective (cause 2). • Three different failure codes, [DAJQKR], [DB2QKR], and [D8AQKR] are used for defective CAN communication by CAN2, which are detected by machine monitor. When all of these three failure codes are displayed simultaneously on screen, ground fault, short circuit, or hot short circuit may occur in wiring harness (CAN communication line). • Since each controller and machine monitor are connected directly to battery, they are supplied with power even after starting switch is turned to OFF position. • Since signal of active CAN communication line is pulse voltage, it cannot be measured by using multimeter. Cause

Procedure, measuring location, criteria and remarks

Defective fuse No. 10 or No.13 in fuse box F01.

1. Turn starting switch to OFF position. 2. Remove fuse No. 10 in fuse box F01. • When fuse is blown, engine controller may have internal short circuit. • If fuse (No. 13 in F01) is blown, wiring harness may have ground fault.

Defective engine controller

a If fuse is not blown, this check is not required. 1. Turn starting switch to OFF position. 2. Disconnect connector CE03 and connect T-adapter to male side. Min. 10 z Resis- Between CE03 (male) (1) and (21) tance Between CE03 (male) (11) and (31) Min. 10 z

Defective power supply to engine controller

a Check ground terminal T20 for looseness and corrosion. 1. Turn starting switch to OFF position. 2. Disconnect connector CE03, and connect T-adapter to female side. 3. Turn starting switch to ON position. a If any trouble is found, perform troubleshooting for failure code [CA441]. Between CE03 (female) (1) and (21) 20 to 30 V Voltage Between CE03 (female) (11) and (31) 20 to 30 V

1. Turn starting switch to OFF position. 2. Disconnect connectors CM02 and 119, and connect T-adapters to Defective CAN terminating each male side. resistor Between 119 (male) (A) and (B) 120 ± 12 z (internal open or short circuit) Resis120 ± 12 z tance Between CM02 (male) (7) and (9)

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No.

Cause

Procedure, measuring location, criteria and remarks • CAN communication line a CAN terminating resistor of 120 z is also located in machine monitor. That is, two CAN terminating resistors of 120 z are connected in parallel. When circuit resistance is measured at connector of controller other than machine monitor, if combined resistance is 60 z, wiring harness does not have open circuit. 1. Turn starting switch to OFF position, and turn battery disconnect switch to OFF position. 2. Disconnect related connectors and connect T-adapters to connectors to be measured.

Open or short circuit in wiring a If short circuit is found (resistance between two terminals is 1z or less), disconnect all CAN communication connectors of every harness controller and check whether short circuit occurs between wiring harnesses or inside controller. Approx. Between CM02 (female) (8) and (9) 120 z Approx. 60 Between CE03 (female) (17) and (18) z Resis- Between ST2 (female) (32) and (22) Approx. 60 tance z Approx. 60 Between CK01 (female) (10) and (11) z Approx. Between 119 (female) (A) and (B) 120 z • ACC signal of starting switch (start of CAN communication is not recognized) 1. Turn starting switch to OFF position, and set battery disconnect switch to OFF position. 2. Disconnect connectors to be measured and insert T-adapters into them. 3. Turn battery disconnect switch to ON position, and turn starting switch to ON position. Between CM01 (10) and (3) 20 to 30 V 20 to 30 V Resis- Between CE03 (3) and (21) tance Between ST2 (14) (24) and (31) 20 to 30 V Between CK02 (3) and (1) 20 to 30 V a If no failure is found by check on cause 5, this check is not required. 1. Turn starting switch to OFF position, and set battery disconnect switch to OFF position. Open circuit in wiring harness 2. Disconnect related connectors and connect T-adapters to female (wire breakage or defective side of connectors to be measured. contact of connector) Between CM02 (female) (8) and ST2 (male) Max. 1 z (32) Between CM02 (female) (9) and ST2 (female) Max. 1 z (22) Between CM02 (female) (8) and CE03 (female) Max. 1 z (17) Between CM02 (female) (9) and CE03 (female) Max. 1 z Resis- (18) tance Between CM02 (female) (8) and CK01 (female) Max. 1 z (10) Between CM02 (female) (9) and CK01 (female) Max. 1 z (11) Between CE03 (female) (17) and 119 (female) Max. 1 z (A) Between CE03 (female) (18) and 119 (female) Max. 1 z (B)

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No.

Cause

Procedure, measuring location, criteria and remarks

a If no failure (open circuit) is found by check on cause 5, measure resistance at any one place in each case. 1. Turn starting switch to OFF position, and set battery disconnect switch to OFF position. 2. Disconnect related connectors and connect T-adapters to female Ground fault in wiring harness side of connectors to be measured. (contact with ground circuit) Between ground and either of ST2 (female) (32), CM02 (female) (7), (8), and CE03 (female) Min. 1 Mz Resis- (17) tance Between ground and either of ST2 (female) (22), CM02 (female) (9), and CE03 (female) Min. 1 Mz (18).

Open circuit or hot short circuit in wiring harness

Defective engine controller, HST controller, machine monitor, or KOMTRAX terminal

10 Defective engine controller 11 Defective machine monitor

40-254

a If no failure (open circuit) is found by check on cause 5, measure voltage at any one place in each case. 1. Turn starting switch to OFF position, and set battery disconnect switch to OFF position. 2. Disconnect connectors to be measured and insert T-adapters into them. 3. Set battery disconnect switch to ON position. 4. Turn starting switch to ON position. a Voltage of CAN H and CAN L is 2.5 ± 1 V including during communication, so regard wiring harness as normal if measured voltage is 1 to 4 V. Between ground and either of CM02 (female) (8), ST2 (female) (32), CK01 (female) (10), and 1 to 4 V CE03 (female) (17). Voltage Between ground and either of CM02 (female) (9), ST2 (female) (22), CK01 (female) (11), and 1 to 4 V CE03 (female) (18). • If all three failure codes of [DAJQKR], [DB2QKR], and [D8AQKR] are displayed a Identify which controller is defective by disconnecting them one by one from CAN communication line by repeating the following steps 1 to 3. 1. Turn starting switch to OFF position, and set battery disconnect switch to OFF position. 2. Disconnect CAN communication connector of engine controller (connector CE03), HST controller (connector ST2), machine monitor (connector CM02), and KOMTRAX terminal (connector CK01) one by one in turn. 3. Turn battery disconnect switch to ON position, turn starting switch to ON position, then perform troubleshooting. 4. Return to step 1 to check next connector. Has the number of displayed failure codes If YES, disconnected decreased from three? controller is defective. If no failure is found by above checks, engine controller is defective. (Since this is an internal defect, troubleshooting cannot be performed.) If no failure is found by above checks, machine monitor is defective. (Since this is an internal defect, troubleshooting cannot be performed.)

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40 Troubleshooting

Troubleshooting by failure code (Display of code)

Circuit diagram related CAN2 communication

D61EM-23M0

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Failure code [DD12KA] Shift up SW: Open Action level L03 Detail of failure Action of controller Problem on machine

Related information

No.

Shift up Switch: Open Failure code Failure (HST controller system) DD12KA • Both lines of NO* and NC* for shift up switch circuit are OPEN (switch: OFF) at the same time. • Recognizes that shift up switch is not pressed. • • • • •

Shift up of transmission gear is unavailable. Auto-downshift function does not operator. Once machine stops, engine speed is restricted to medium (half) speed. Once machine stops, travel is restricted to F1 and R1. "NO*" circuit is used for detecting switch operation and "NC*" circuit is used for detecting error. • Condition of shift up switch signal can be checked with monitoring function. (Code: 40905 "HST SW Input 1") • Method of reproducing failure code: Turn starting switch to ON position and operate shift up switch Cause

Defective shift up switch (internal open circuit)

Procedure, measuring location, criteria and remarks 1. Turn starting switch to OFF position. 2. Disconnect connector 38 and connect T-adapter to male side. 3. Turn shift up switch to ON or OFF position and perform troubleshooting. a "Switch: OFF": Released, "Switch: ON": Pressed Between 38 (male) (3) Switch: OFF and (2) Switch: ON Resistance Between 38 (male) (1) Switch: OFF and (2) Switch: ON

Max. 1 z Min. 1 Mz Min. 1 Mz Max. 1 z

1. Turn starting switch to OFF position. 2. Disconnect connector 38 and connect T-adapter to female side. 3. Turn starting switch to ON position. 2

Open circuit or hot short circuit in wiring harness

a When voltage is 0 V, it shows open circuit, and when voltage is 24 V, it shows hot short circuit. a Voltage of approximately 9 V is applied to "NO" and "NC" signal circuits through resistor in the HST controller. Between 38 (female) (1) and (2) 7 to 11 V Voltage Between 38 (female) (3) and (2) 7 to 11 V

a If no failure is found by check on cause 2, this check is not required. 1. Turn starting switch to OFF position. Open circuit in wiring harness 2. Disconnect connectors ST1, 38 and ST2, and connect T-adapters to each female side. (wire breakage or defective Between ST1 (female) (23) and 38 (female) (1) Max. 1 z contact of connector) Resis- Between ST2 (female) (29) and 38 (female) (2) Max. 1 z tance Between ST1 (female) (17) and 38 (female) (3) Max. 1 z

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No.

Cause

Defective HST controller

Procedure, measuring location, criteria and remarks If no failure is found by above checks, HST controller is defective. • Reference 1. Turn starting switch to OFF position. 2. Insert T-adapters into connectors ST1 and ST2. 3. Turn starting switch to ON position. 4. Turn shift up switch to ON or OFF position and perform troubleshooting. a Voltage of approximately 9 V is applied to ST1 (23) pin and (17) pin through resistor in HST controller. Between ST1 (23) and Switch: OFF 7 to 11 V ST2 (29) Switch: ON Max. 1 V Voltage Switch: OFF Max. 1 V Between ST1 (17) and ST2 (29) Switch: ON 7 to 11 V

*NO: Normally Open *NC: Normally Closed Circuit diagram related to shift up switch

D61EM-23M0

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40 Troubleshooting

Troubleshooting by failure code (Display of code)

Failure code [DD12KB] Shift up SW: Short Circuit Action level L03 Detail of failure Action of controller Problem on machine

Related information

No.

Failure code DD12KB

Failure

Shift up Switch: Short circuit (HST controller system)

• Both lines of NO* and NC* for shift up switch circuit are 0 V (switch: ON) at the same time. • Recognizes that shift up switch is not pressed. • • • • •

Shift up of transmission gear is unavailable. Auto-downshift function does not operate. Once machine stops, engine speed is restricted to medium (half) speed. Once machine stops, travel is restricted to F1 and R1. "NO*" circuit is used for detecting switch operation and "NC*" circuit is used for detecting error. • Condition of shift up switch signal can be checked with monitoring function. (Code: 40905 "HST SW Input 1") • Method of reproducing failure code: Turn starting switch to ON position and operate shift up switch Procedure, measuring location, criteria and remarks

Cause

Defective shift up switch (internal open circuit)

1. Turn starting switch to OFF position. 2. Disconnect connector 38 and connect T-adapter to male side. 3. Turn shift up switch to ON or OFF position and perform troubleshooting. a "Switch: OFF": Released, "Switch: ON": Pressed Between 38 (male) (3) Switch: OFF and (2) Switch: ON Resistance Between 38 (male) (1) Switch: OFF and (2) Switch: ON

Max. 1 z Min. 1 Mz Min. 1 Mz Max. 1 z

1. Turn starting switch to OFF position. 2. Disconnect connectors ST1 and SFTU, and connect T-adapter to female side of either connector. Ground fault in wiring harness Between ground and either 38 (female) (1) or (contact with ground circuit) Min. 1 Mz Resis- ST1 (female) (23) tance Between ground and either 38 (female) (3) or Min. 1 Mz ST1 (female) (17) 1. Turn starting switch to OFF position. 2. Disconnect connectors ST1 and 38, and connect T-adapter to female side of connector ST1. a Check by using multimeter in continuity mode.

Between ST1 (female) (23) and each pin other than pin (23)

Short circuit in wiring harness Continuity

Between ST1 (female) (17) and each pin other than pin (17)

40-258

No continuity (No sound is heard) No continuity (No sound is heard)

D61EM-23M0

40 Troubleshooting

Troubleshooting by failure code (Display of code)

No.

Cause

Defective HST controller

*NO: Normally Open *NC: Normally Closed Circuit diagram related to shift up switch

D61EM-23M0

40-259

40 Troubleshooting

Troubleshooting by failure code (Display of code)

Failure code [DD13KA] Shift down SW: Open Action level L03 Detail of failure Action of controller Problem on machine

Related information

No.

Shift down Switch: Open Failure code Failure (HST controller system) DD13KA • Both linens of NO* and NC* for downshift switch circuit are OPEN (switch: OFF) at the same time. • Recognizes that downshift switch is not pressed. • • • • •

Downshift is not possible. Auto-downshift function does not operate. Once machine stops, engine speed is restricted to medium (half) speed. Once machine stops, travel is restricted to F1 and R1. "NO*" circuit is used for detecting switch operation and "NC*" circuit is used for detecting error. • Condition of downshift switch signal can be checked with monitoring function. (Code: 40905 "HST SW Input 1") • Method of reproducing failure code: Turn starting switch to ON position and operate downshift switch. Cause

Defective downshift switch (internal open circuit)

Procedure, measuring location, criteria and remarks 1. Turn starting switch to OFF position. 2. Disconnect connector 39 and connect T-adapter to male side. 3. Turn downshift switch to ON or OFF position and perform troubleshooting. a "Switch: OFF": Released, "Switch: ON": Pressed Between 39 (male) (3) Switch: OFF Switch: ON Resis- and (2) tance Between 39 (male) (1) Switch: OFF and (2) Switch: ON

Max. 1 z Min. 1 Mz Min. 1 Mz Max. 1 z

1. Turn starting switch to OFF position. 2. Disconnect connector 39 and connect T-adapter to female side. 3. Turn starting switch to ON position. 2

Open circuit or hot short circuit in wiring harness

a When voltage is 0 V, it shows open circuit, and when voltage is 24 V, it shows hot short circuit. a Voltage of approximately 9 V is applied to "NO" and "NC" signal circuits through resistor in the HST controller. Between 39 (female) (1) and (2) 7 to 11 V Voltage Between 39 (female) (3) and (2) 7 to 11 V

a If no failure is found by check on cause 2, this check is not required. 1. Turn starting switch to OFF position. Open circuit in wiring harness 2. Disconnect connectors ST1, 39 and ST2, and connect T-adapters to each female side. (wire breakage or defective Between ST1 (female) (5) and 39 (female) (1) Max. 1 z contact of connector) Resis- Between ST2 (female) (29) and 39 (female) (2) Max. 1 z tance Between ST1 (female) (11) and 39 (female) (3) Max. 1 z

40-260

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40 Troubleshooting

Troubleshooting by failure code (Display of code)

No.

Cause

Defective HST controller

Procedure, measuring location, criteria and remarks If no failure is found by above checks, HST controller is defective. • Reference 1. Turn starting switch to OFF position. 2. Insert T-adapter into connectors ST1 and ST2. 3. Turn starting switch to ON position. 4. Turn downshift switch to ON or OFF position and perform troubleshooting. a Voltage of approximately 9 V is applied to ST1 (5) pin and (11) pin through resistor in HST controller. Between ST1 (5) and Switch: OFF 7 to 11 V ST2 (29) Switch: ON Max. 1 V Voltage Switch: OFF Max. 1 V Between ST1 (11) and ST2 (29) Switch: ON 7 to 11 V

*NO: Normally Open *NC: Normally Closed Circuit diagram related to downshift switch

D61EM-23M0

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40 Troubleshooting

Troubleshooting by failure code (Display of code)

Failure code [DD13KB] Shift down SW: Short Circuit Action level L03 Detail of failure Action of controller Problem on machine

Related information

No.

Shift down Switch: Short circuit Failure code Failure (HST controller system) DD13KB • Both lines of NO* and NC* for downshift switch circuit are 0 V (switch: ON) at the same time. • Recognizes that downshift switch is not pressed. • • • • •

Cause

Defective downshift switch (internal open circuit)

1. Turn starting switch to OFF position. 2. Disconnect connector 39 and connect T-adapter to male side. 3. Turn downshift switch to ON or OFF position and perform troubleshooting. a "Switch: OFF": Released, "Switch: ON": Pressed Between 39 (male) (3) Switch: OFF Switch: ON Resis- and (2) tance Between 39 (male) (1) Switch: OFF and (2) Switch: ON

Max. 1 z Min. 1 Mz Min. 1 Mz Max. 1 z

1. Turn starting switch to OFF position. 2. Disconnect connectors ST1 and 39, and connect T-adapter to female side of either connector. Ground fault in wiring harness Between ground and either 39 (female) (1) or (contact with ground circuit) Min. 1 Mz Resis- ST1 (female) (11) tance Between ground and either 39 (female) (3) or Min. 1 Mz ST1 (female) (5) 1. Turn starting switch to OFF position. 2. Disconnect connectors ST1 and 39, and connect T-adapter to female side of connector ST1. a Check by using multimeter in continuity mode.

Between ST1 (female) (11) and each pin other than (11)

Short circuit in wiring harness Continuity

Between ST1 (female) (5) and each pin other than (5)

40-262

No continuity (No sound is heard) No continuity (No sound is heard)

D61EM-23M0

40 Troubleshooting

Troubleshooting by failure code (Display of code)

No.

Cause

Defective HST controller

Procedure, measuring location, criteria and remarks If no failure is found by above checks, HST controller is defective. • Reference 1. Turn starting switch to OFF position. 2. Insert T-adapter into connectors ST1 and ST2. 3. Turn starting switch to ON position. 4. Turn downshift switch to ON or OFF position and perform troubleshooting. a Voltage of approximately 9 V is applied to ST1 (5) pin and (11) pin through resistor in HST controller. Between ST1 (5) and Switch: OFF 7 to 11 V ST2 (29) Switch: ON Max. 1 V Voltage Switch: OFF Max. 1 V Between ST1 (11) and ST2 (29) Switch: ON 7 to 11 V

*NO: Normally Open *NC: Normally Closed Circuit diagram related to downshift switch

D61EM-23M0

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40 Troubleshooting

Troubleshooting by failure code (Display of code)

Failure code [DD14KA] Parking lever SW: Open Action level L03 Detail of failure Action of controller Problem on machine

Related information

• • • • • • • •

• • • •

No.

Parking lever Switch: Open Failure code Failure (HST controller system) DD14KA Both lines of NO* and NC* for parking brake lever switch circuit are OPEN (switch: OFF) at the same time. Recognizes parking brake lever is in Free position. Restricts engine operation. Once machine stops, engine speed is restricted to medium (half) speed. Once machine stops, travel is restricted to F1 and R1. Engine cannot start. NC* circuit is used for detecting operation and NO* circuit is used for detecting error. Condition of parking brake lever switch signal can be checked with monitoring function. (Code: 40984 HST SW Input 3) Method of reproducing failure code:Turn starting switch to ON position and operate parking brake lever. When parking brake lever is in FREE, parking brake lever switch is turned off. When operating parking brake lever, parking brake lever switches 1 and 2 are operated at the same time. & & % $ $ $ . 4% $ . , ! &$ $% $$ ' &$ &

Cause

Procedure, measuring location, criteria and remarks 1. Turn starting switch to OFF position. 2. Disconnect connector 261 and connect T-adapter to male side. 3. Operate parking brake lever and perform troubleshooting.

Defective parking brake lever switch (internal open circuit) Resistance

Open circuit or hot short circuit in wiring harness

Between 261 (male) (A) and (C)

Lever: FREE

Max. 1 z

Lever: LOCK

Min. 1 Mz

Lever: FREE

Min. 1 Mz

Lever: LOCK

Max. 1 z

1. Turn starting switch to OFF position. 2. Disconnect connector 261 and connect T-adapter to female side. 3. Turn starting switch to ON position. 4. Keep work equipment lock lever in FREE. a When voltage is 0 V, it shows open circuit, and when voltage is 24 V,it shows hot short circuit. a Voltage of approximately 9 V is applied to "NO" and "NC" signal circuits through resistor in the HSTcontroller. Voltage

Open circuit in wiring harness 3 (wire breakage or defective contact of connector)

Between 261 (male) (A) and (B)

Between 261 (female) (A) and (B)

7 to 11 V

Between 261 (female) (A) and (C)

7 to 11 V

a If no failure is found by check on cause 2, this check is not required. 1. Turn starting switch to OFF position. 2. Disconnect connectors ST1, ST3 and 261, and connect T-adapters to each female side. Between ST1 (female) (10) and 261 (female) (A)

Max. 1 z

Resistance Between ST3 (female) (20) and 261 (female) (B)

Min. 1 Mz

Between ST3 (female) (10) and 261 (female) (C)

Max. 1 z

1. Turn starting switch to OFF position. 2. Disconnect relay 26R and connect T-adapter to male side. Resistance Between 26R (male) (1) and (2) 4 Defective travel lock relay 1, 26R

200 to 400 Ω

1. Turn starting switch to OFF position. 2. Replace relay 26R with another one. For example, cleaning water pump relay RCW 3. Turn starting switch to ON position. If this failure code disappears, original travel lock relay 1, 26R is defective.

40-264

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40 Troubleshooting

Troubleshooting by failure code (Display of code)

No.

Cause

Procedure, measuring location, criteria and remarks 1. Turn starting switch to OFF position. 2. Disconnect relay WELR and connect T-adapter to male side. Resistance Between WELR (male) (1) and (2)

Defective work equipment lock relay 1 WELR

200 to 400 Ω

1. Turn starting switch to OFF position. 2. Replace relay WELR with another one. For example, cleaning water pump relay RCW. 3. Turn starting switch to ON position. If this failure code disappears, original work equipment lock relay 1 WELR is defective.

Defective diode WLD3 (internal open or short circuit)

1. Turn starting switch to OFF position. 2. Remove connectors WLD3 and D2, and connect T-adapter to male side. a Measure it with diode range of multimeter. Continuity

Open circuit in wiring harness 7 (Wire breakage or defective contact)

Open circuit in wiring harness 8 (Wire breakage or defective contact)

Between WLD3 (male) (1) (+) and (2) (-)

No continuity

Between WLD3 (male) (2) (+) and (1) (-)

Continuity

a Following checks are unnecessary if no abnormality is detected by above checks. 1. Turn starting switch to OFF position. 2. Disconnect connectors ST3, 26R, and 261, and connect T-adapter to each female side. Between ST3 (female) (20) and 26R (female) (5)

Max. 1 z

Resistance Between ST3 (female) (10) and 26R (female) (6)

Max. 1 z

Between 261 (female) (C) and 26R (female) (6)

Max. 1 z

a Following checks are unnecessary if no abnormality is detected by above checks. 1. Turn starting switch to OFF position. 2. Connect T-adapter to each female side of connectors 26R, 261, WELR, and fuse No. 11. Between 26R (female) (2) and ground

Max. 1 z

Resistance Between 26R (female) (1) and WELR (female) (2)

Max. 1 z

Between WELR (female) (1) and F01-11

Open circuit in wiring harness 9 (Wire breakage or defective contact)

Max. 1 z

a Following checks are unnecessary if no abnormality is detected by above checks. 1. Turn starting switch to OFF position. 2. Disconnect connectors WELR, PSW1, and WLD3, and connect T-adapter to each female side. Resistance

Between PSW1 (female) (B) and WLD3 (female) (1)

Max. 1 z

Between WELR (female) (6) and WLD3 (female) (2)

Max. 1 z

If no failure is found by above checks, HST controller is defective. Reference 1. Turn starting switch to OFF position. 2. Insert T-adapter into connectors ST1 and ST3. 3. Turn starting switch to ON position. 4. Operate parking brake lever and perform troubleshooting. a Voltage of approximately 9 V is applied to ST3 (20) pin and (10) pin through resistor in HST controller.

10 Defective HST controller

Voltage

Between ST3 (20) and ST1 (10) Between ST3 (10) and ST1 (10)

Lever: FREE

Max. 1 V

Lever: LOCK

7 to 11 V

Lever: FREE

7 to 11 V

Lever: LOCK

Max. 1 V

*NO: Normally Open *NC: Normally Closed D61EM-23M0

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40 Troubleshooting

Troubleshooting by failure code (Display of code)

Circuit diagram related to parking brake lever switch

40-266

D61EM-23M0

40 Troubleshooting

Troubleshooting by failure code (Display of code)

Failure code [DD14KB] Parking lever SW: Short circuit Action level L03 Detail of failure Action of controller Problem on machine

Related information

No.

• • • • • • • • • • •

Parking Lever Switch: Short Circuit Failure code Failure (HST controller system) DD14KB Both lines of NO* and NC* for parking brake lever switch circuit are 0 V (switch: ON) at the same time. Recognizes parking brake lever is in Free position. Restricts engine operation. Once machine stops, engine speed is restricted to medium (half) speed. Once machine stops, travel is restricted to F1 and R1. Engine cannot start. NC* circuit is used for detecting operation and NO* circuit is used for detecting error. Condition of parking brake lever switch signal can be checked with monitoring function. (Code: 40984 HST SW Input 3) Method of reproducing failure code:Turn starting switch to ON position and operate parking brake lever. When parking brake lever is in FREE, parking brake lever switch is turned off. When operating parking brake lever, parking brake lever switches 1 and 2 are operated at the same time. Cause

Procedure, measuring location, criteria and remarks

Turn starting switch to OFF position. Disconnect connector 26 and connect T-adapter to male side. Operate parking brake lever to ON and OFF positions and perform troubleshooting. Defective parking brake lever switch (internal open circuit) Lever: FREE Between 26 (male) Max. 1 z (A) and (B) Lever: LOCK Min. 1 Mz Resistance Lever: FREE Between 26 (male) Min. 1 Mz (A) and (C) Lever: LOCK Max. 1 z Turn starting switch to OFF position. Disconnect connectors ST and 26 , and connect T-adapter to Ground fault in wiring & side of either connector. harness Between ground and 26 (female) (B) or ST Min. 1 Mz (contact with ground circuit) Resis- (female) (20) tance Between ground and 26 (female) (C) or ST Min. 1 Mz (female) (10) Turn starting switch to OFF position. Disconnect connectors ST and 26 , and connect T-adapter to female side of ST . a Check by using multimeter in continuity mode.

No Between ST (female) (20) and each pin other continuity Short circuit in wiring harness than pin (20) (No sound is heard) Continuity No continuity Between ST (female) (10) and each pin other (No sound than pin (10) is heard)

D61EM-23M0

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40 Troubleshooting

Troubleshooting by failure code (Display of code)

No.

Cause

Procedure, measuring location, criteria and remarks 1. Turn starting switch to OFF position. 2. Disconnect relay 26R and connect T-adapter to male side. Resistance Between 26R (male) (1) and (2)

4 Defective travel lock relay 1, 26R

200 to 400 Ω

1. Turn starting switch to OFF position. 2. Replace relay 26R with another one. For example, cleaning water pump relay RCW. 3. Turn starting switch to ON position. If this failure code disappears, original travel lock relay 1, 26R is defective. 1. Turn starting switch to OFF position. 2. Disconnect relay WELR and connect T-adapter to male side. Resistance Between WELR (male) (1) and (2)

Defective work equipment lock relay 1 WELR

200 to 400 Ω

Defective diode WLD3 (internal open or short circuit)

1. Turn starting switch to OFF position. 2. Remove connectors WLD3 and D2, and connect T-adapter to male side. a Measure it with diode range of multimeter. Continuity

Open circuit in wiring harness 7 (Wire breakage or defective contact)

Open circuit in wiring harness 8 (Wire breakage or defective contact)

Between WLD3 (male) (1) (+) and (2) (-)

No continuity

Between WLD3 (male) (2) (+) and (1) (-)

Continuity

Max. 1 z

Resistance Between ST3 (female) (10) and 26R (female) (6)

Max. 1 z

Between 261 (female) (C) and 26R (female) (6)

Max. 1 z

Resistance Between 26R (female) (1) and WELR (female) (2)

Max. 1 z

Between WELR (female) (1) and F01-11

Open circuit in wiring harness 9 (Wire breakage or defective contact)

Resistance

40-268

Max. 1 z

Between WELR (female) (6) and WLD3 (female) (2)

Max. 1 z

D61EM-23M0

40 Troubleshooting

Troubleshooting by failure code (Display of code)

No.

Cause

Defective HST controller

Procedure, measuring location, criteria and remarks If no failure is found by above checks, HST controller is defective. • Reference Turn starting switch to OFF position. Insert T-adapter into connectors ST1 and ST . Turn starting switch to ON position. Operate parking brake lever to ON and OFF positions and perform troubleshooting.

a Voltage of approximately 9 V is applied to ST (20) pin and (10) pin through resistor in HST controller. Lever: FREE Max. 1 V Between ST (20) and ST1 (10) Lever: LOCK 7 to 11 V Voltage Lever: FREE 7 to 11 V Between ST (10) and ST1 (10) Lever: LOCK Max. 1 V *NO: Normally Open *NC: Normally Closed

D61EM-23M0

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40 Troubleshooting

Troubleshooting by failure code (Display of code)

Circuit diagram related to parking brake lever switch

40-270

D61EM-23M0

40 Troubleshooting

Troubleshooting by failure code (Display of code)

Failure code [DDKAKA] Blade float Sw: Open Action level L01 Detail of failure Action of controller Problem on machine

Blade Float Switch: Open Failure code Failure (HST controller system) DDKAKA • Both lines of NO* and NC* for blade float switch circuit are OPEN (switch: OFF) at the same time. • Recognizes that blade float switch is not pressed.

• $

Related information

• * & $ &% $ $ $ % . ~ & $, & % $ ! ' ! & , • "NO*" circuit is used for detecting switch operation and "NC*" circuit is used for detecting error. • Signal from blade float switch can be checked with monitoring function. (Code: 70300 "Blade SW Input 1") • Method of reproducing failure code: Turn starting switch to ON position.

No.

Cause

Defective wiring harness of blade float switch (internal open circuit)

Procedure, measuring location, criteria and remarks

Turn starting switch to OFF position. Disconnect connector BNSW and connect T-adapter to male side. Resistance

Between BNSW (male) (3) and (4)

Switch: OFF

Max. 1 z

Between BNSW (male) (3) and (5)

Switch: OFF

Min. 1 Mz

1. Turn starting switch to OFF position. 2. Connect T-adapter into connector BNSW. 3. Turn starting switch to ON position.

Open circuit or hot short circuit in wiring harness

a When voltage is 0 V, it shows open circuit, and when voltage is 24 V, it shows hot short circuit. a Voltage of approximately 9 V is applied to "NO" and "NC" signal circuits through resistor in the HST controller. a Ignore other failure codes displayed than DDKAKA. Between BNSW (3) and (4) Voltage Between BNSW (3) and (5)

7 to 11 V 7 to 11 V

Turn starting switch to OFF position. Open circuit in wiring harness Disconnect connector ST2, and connect T-adapter to female side. (wire breakage or defective Resiscontact of connector) Max. 1 z Between ST2 (female) (27) and (29) tance If no failure is found by above checks, HST controller is defective. • Reference Turn starting switch to OFF position. Insert T-adapter into connector ST2. Turn starting switch to ON position. Defective HST controller a Voltage of approximately 9 V is applied to ST2 (27) pin and (37) pin through resistor in HST controller. Between ST2 (27) and (29) Max. 1 V Voltage Between ST2 (37) and (29) 7 to 11 V

*NO: Normally Open *NC: Normally Closed

D61EM-23M0

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40 Troubleshooting

Troubleshooting by failure code (Display of code)

Circuit diagram related to blade float switch

40-272

D61EM-23M0

40 Troubleshooting

Troubleshooting by failure code (Display of code)

Failure code [DDKAKB] Blade float Sw: Short circuit Action level L01 Detail of failure Action of controller Problem on machine Related information

Blade float Switch: Short circuit Failure code Failure (HST controller system) DDKAKB • Both lines of NO* and NC* for blade float switch circuit are 0 V (switch: ON) at the same time.

• 8 $' & $ $ • $ •

\ ? ? @ @ \ @ @ $ ? ^ ? \ @ \ @ \ ` \ ? ^ • "NO*" circuit is used for detecting switch operation and "NC*" circuit is used for detecting error. • Signal from blade float switch can be checked with monitoring function. (Code: 70300 "Blade Sw Input") • Method of reproducing failure code: Turn starting switch to ON position

No.

Cause

Procedure, measuring location, criteria and remarks

Defective wiring harness of blade float switch (internal open circuit)

Turn starting switch to OFF position. Disconnect connector BNSW and connect T-adapter to male side. Between BNSW (male) (3) and (4) Max. 1 z Resistance Between BNSW (male) (3) and (5) Min. 1 Mz

1. Turn starting switch to OFF position. Ground fault in wiring harness 2. Disconnect connectors ST2 and BNSW, and connect T-adapter to female side of ST2. (contact with ground circuit) Min. 1 Mz Resis- Between ST2 (female) (27) and ground tance Between ST2 (female) (37) and ground Min. 1 Mz 1. Turn starting switch to OFF position. 2. Disconnect connectors ST2 and BNSW, and connect T-adapter to female side of ST2.

Short circuit in wiring harness a Check by using multimeter in continuity mode. Between ST2 (female) (27) and No continuity (no each pin other than pin (27) sound is heard) Continuity Between ST2 (female) (37) and No continuity (no each pin other than pin (37) sound is heard) If no failure is found by above checks, HST controller is defective. • Reference Turn starting switch to OFF position. Insert T-adapter into connector ST2. Turn starting switch to ON position. Defective HST controller a Voltage of approximately 9 V is applied to ST2 (27) pin and (37) pin through resistor in HST controller. Between ST2 (27) and (29) Max. 1 V Voltage $ Between ST2 (37) and (29)

*NO: Normally Open *NC: Normally Closed

D61EM-23M0

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40 Troubleshooting

Troubleshooting by failure code (Display of code)

Circuit diagram related to blade float switch

40-274

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40 Troubleshooting

Troubleshooting by failure code (Display of code)

Failure code [DDKFL4] Left Angle Sw: Signal mismatch Action level L01 Detail of failure Action of controller Problem on machine

Failure code DDKFL4

Failure

Left Angle Switch: Signal mismatch (HST controller system)

• There is inconsistency of two lines of NO* for SW1 and SW2 in left angle lever circuit. • Recognizes that left angle lever is not pressed.

• •

Related information

` ? @ @ \ @ @ @ @ \ \ @ |$ ~ ? ^ ? \ @ \ @ \ ` ^ @ • Condition of left angle lever signal can be checked with monitoring function. (Code: 70306 "Blade Sw Input 2") • Method of reproducing failure code: Turn starting switch to ON position

No.

Cause

Procedure, measuring location, criteria and remarks 1. Turn starting switch to OFF position. 2. Disconnect connector BNSW and connect T-adapter to female side of connector. 3. Turn starting switch to ON position.

ot short circuit in wiring harness

Defective HST controller

a When voltage is 0 V, it shows open circuit, and when voltage is 24 V, it shows hot short circuit. a Voltage of approximately 9 V is applied to two "NO" signal circuits through resistor in HST controller. Between BNSW (female) (10) and (9) 7 to 11 V Voltage Between BNSW (female) (11) and (9) 7 to 11 V If no failure is found by above checks, HST controller is defective. • Reference Turn starting switch to OFF position. Insert T-adapter into connector ST2. Turn starting switch to ON position. a Voltage of approximately 9 V is applied to ST2 (13) pin and (3) pin through resistor in HST controller. Between ST2 (13) and (29) 7 to 11 V Voltage Between ST2 (3) and (29) 7 to 11 V

*NO: Normally Open *NC: Normally Closed

D61EM-23M0

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40 Troubleshooting

Troubleshooting by failure code (Display of code)

Circuit diagram related to right and left angle levers

40-276

D61EM-23M0

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Troubleshooting by failure code (Display of code)

Failure code [DDKGL4] Right Angle Sw: Signal mismatch Action level L01 Detail of failure Action of controller Problem on machine

Failure code DDKGL4

Failure

Right Angle Switch :Signal mismatch (HST controller system)

• There is inconsistency of two lines of NO* for SW1 and SW2 of right angle lever circuit. • Recognizes that right angle lever is not pressed.

• •

Related information

` ? @ @ \ @ @ @ @ \ \ @ $ | ~ ? ^ ? \ @ \ @ \ ` ^ @ • Condition of right angle lever signal can be checked with monitoring function. (Code: 70306 "Blade Sw Input 2") • Method of reproducing failure code: Turn starting switch to ON position

No.

Cause

ot short circuit in wiring harness

Defective HST controller

a When voltage is 0 V, it shows open circuit, and when voltage is 24 V, it shows hot short circuit. a Voltage of approximately 9 V is applied to "NO" signal circuit through resistor in the HST controller. Between BNSW (female) (7) and (9) 7 to 11 V Voltage Between BNSW (female) (8) and (9) 7 to 11 V If no failure is found by above checks, HST controller is defective. • Reference Turn starting switch to OFF position. Insert T-adapter into connector ST2. Turn starting switch to ON position. a Voltage of approximately 9 V is applied to ST2 (7) pin and (17) pin through resistor in HST controller. Between ST2 (7) and (29) 7 to 11 V Voltage 7 to 11 V Between ST2 (17) and (29)

*NO: Normally Open *NC: Normally Closed

D61EM-23M0

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40 Troubleshooting

Troubleshooting by failure code (Display of code)

Circuit diagram related to right and left angle levers

40-278

D61EM-23M0

40 Troubleshooting

Troubleshooting by failure code (Display of code)

Failure code [DDKHKA] iB Sw: Open Action level L01 Detail of failure Action of controller Problem on machine

Failure code DDKHKA

Failure

iB Switch: Open (HST controller system)

• Both lines of NO* and NC* for iB switch circuit are OPEN (switch: OFF) at the same time. • Recognizes that iB switch is not pressed. •

•

Related information

@ @ @ \ @ @ $ | ~ ? ^ ? \ @ \ @ \ ` \ ? ^ • "NO*" circuit is used for detecting switch operation and "NC*" circuit is used for detecting error. • Condition of iB switch signal can be checked with monitoring function. (Code: 70306 "Blade Sw Input 2")

No.

Cause

Procedure, measuring location, criteria and remarks

Turn starting switch to OFF position. Disconnect connector BNSW and connect T-adapter to male side 1

Defective iB switch (wiring harness) (internal open circuit)

a "Switch: OFF": Released, "Switch: ON": Pressed Resistance

Between BNSW (male) (1) and (3) Between BNSW (male) (2) and (3)

Max. 1 z Min. 1 Mz

1. Turn starting switch to OFF position. 2. Disconnect connector BNSW and connect T-adapter to female side of connector. 3. Turn starting switch to ON position. 2

Open circuit or hot short circuit in wiring harness

a When voltage is 0 V, it shows open circuit, and when voltage is 24 V, it shows hot short circuit. a Voltage of approximately 9 V is applied to "NO" and "NC" signal circuits through resistor in the HST controller. a Ignore displayed failure codes other than DDKHKA. Between BNSW (female) (1) and (3) Voltage Between BNSW (female) (2) and (3)

7 to 11 V 7 to 11 V

a If no failure is found by check on cause 2, this check is not required. 1. Turn starting switch to OFF position. 2. Disconnect connectors ST2 and BNSW, and connect T-adapter to female side of each connector. Open circuit in wiring harness Between ST2 (female) (2) and BNSW (female) (wire breakage or defective Max. 1 z (1) contact of connector) Resis- Between ST2 (female) (12) and BNSW Max. 1 z (female) (2) tance Between ST2 (female) (29) and BNSW Max. 1 z (female) (3)

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40 Troubleshooting

Troubleshooting by failure code (Display of code)

No.

Cause

Defective HST controller

Procedure, measuring location, criteria and remarks If no failure is found by above checks, HST controller is defective. • Reference Turn starting switch to OFF position. Insert T-adapter into connector ST2. Turn starting switch to ON position. a Voltage of approximately 9 V is applied to ST2 (12) pin and (2) pin through resistor in HST controller.

Between ST2 (12) and (29) Voltage

Between ST2 (2) and (29)

7 to 11 V Max. 1 V

*NO: Normally Open *NC: Normally Closed Circuit diagram related to iB switch

40-280

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40 Troubleshooting

Troubleshooting by failure code (Display of code)

Failure code [DDKHKB] iB Sw: Short circuit Action level L01 Detail of failure Action of controller Problem on machine

Failure code DDKHKB

Failure

iB Switch: Short circuit (HST controller system)

• Both lines of NO* and NC* for iB switch circuit are 0 V (switch: ON) at the same time. • Recognizes that iB switch is not pressed. •

•

Related information

No.

Cause

Defective iB switch (wiring harness) (internal open circuit)

Ground fault in wiring harness (contact with ground circuit)

Procedure, measuring location, criteria and remarks

Turn starting switch to OFF position. Disconnect connector BNSW and connect T-adapter to male side. a "Switch: OFF": Released, "Switch: ON": Pressed Resis- Between BNSW (male) (1) and (3) Between BNSW (male) (2) and (3) tance

Max. 1 z Min. 1 Mz

1. Turn starting switch to OFF position. 2. Disconnect connectors ST2 and BNSW, and connect T-adapters to female side of either connector. Between ground and BNSW (female) (1) or Min. 1 Mz Resis- ST2 (female) (2) tance Between ground and BNSW (female) (2) or Min. 1 Mz ST2 (female) (12) 1. Turn starting switch to OFF position. 2. Disconnect connectors ST2 and BNSW, and connect T-adapter to female side of ST2. a Check by using multimeter in continuity mode.

No continuity Short circuit in wiring harness (No sound is heard) Continuity No continuity Between ST2 (female) (2) and each pin other than pin (2) (No sound is heard) If no failure is found by above checks, HST controller is defective. • Reference Turn starting switch to OFF position. Insert T-adapter into connector ST2. Turn starting switch to ON position. Defective HST controller a Voltage of approximately 9 V is applied to ST2 (12) pin and (2) pin through resistor in HST controller. 7 to 11 V Between ST2 (12) and (29) Voltage Between ST2 (2) and (29) Max. 1 V Between ST2 (female) (12) and each pin other than pin (12)

*NO: Normally Open *NC: Normally Closed

D61EM-23M0

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40 Troubleshooting

Troubleshooting by failure code (Display of code)

Circuit diagram related to iB switch

40-282

D61EM-23M0

40 Troubleshooting

Troubleshooting by failure code (Display of code)

Failure code [DDNLKA] Weq lock Sw: Open Action level L03 Detail of failure Action of controller Problem on machine

Related information

No.

• • • • • • • • • •

Work equipment lock Switch: Open Failure code Failure (HST controller system) DDNLKA Both lines of NO* and NC* for work equipment lock lever switch circuit are OPEN (switch: OFF) at the same time. Recognizes that work equipment lock lever is in LOCK position. Restricts engine operations. Once machine stops, engine speed is restricted to medium (half) speed. Once machine stops, travel is restricted to F1 and R1. Work equipment cannot be operated. NC* circuit is used for detecting operation and NO* circuit is used for detecting error. Signal from work equipment lock lever switch can be checked with monitoring function. (Code: 70300 "Blade SW Input 1") Method of reproducing failure code: Turn starting switch to ON position and operate work equipment lock lever. When work equipment lock lever is in free, work equipment lock lever switch becomes "OFF". (Lever is in FREE position in illustration.) Cause

Defective work equipment lock lever switch (internal open circuit)

Open circuit or hot short circuit in wiring harness

Procedure, measuring location, criteria and remarks

Turn starting switch to OFF position. Disconnect connector and connect T-adapter to male side. Operate work equipment lock lever to perform troubleshooting. Work equipment lock Max. 1 z Between (male) lever: Free (A) and (B) Work equipment lock Min. 1 Mz lever: Locked Resistance Work equipment lock Min. 1 Mz Between (male) lever: Free (A) and (C) Work equipment lock Max. 1 z lever: Locked Turn starting switch to OFF position. Disconnect connector PSW and connect T-adapter to female side. Turn starting switch to ON position. a When voltage is 0 V, it shows open circuit, and when voltage is 24 V, it shows hot short circuit. a Voltage of approximately 9 V is applied to "NO" and "NC" signal circuits through resistor in power train controller. Between (female) (B) and (A) $ Voltage Between (female) (C) and (A) 7 to 11 V

a If no failure is found by check on cause 2, this check is not required. Turn starting switch to OFF position. Disconnect connectors ST1, ! , and , and connect T-adapter Open circuit in wiring harness to female side of each connector. (wire breakage or defective Between ST1 (female) (10) and (female) contact of connector) Max. 1 z Resis- (A) Between ! (female) (30) and (female) tance Max. 1 z (B)

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No.

Cause

Defective diode WLD1 (internal open or short circuit)

Procedure, measuring location, criteria and remarks 1. Turn starting switch to OFF position. 2. Remove connector WLD1, and connect T-adapter to male side. a Measure it with diode range of multimeter. Continuity

Open circuit in wiring harness 5 (Wire breakage or defective contact)

Between WLD1 (male) (1) (+) and (2) (-)

No continuity

Between WLD1 (male) (2) (+) and (1) (-)

Continuity

a Following checks are unnecessary if no abnormality is detected by above checks. 1. Turn starting switch to OFF position. 2. Disconnect connectors PSW, PSW1, and WLD1, and connect T-adapter to each female side. Resistance

Between PSW1 (female) (B) and WLD1 (female) (1)

Max. 1 z

Between PSW (female) (B) and WLD1 (female) (2)

Max. 1 z

If no failure is found by above checks, HST controller is defective. q Reference 1. Turn starting switch to OFF position. 2. Insert T-adapter into connectors ST1 and ST3. 3. Turn starting switch to ON position. 4. Operate work equipment lock lever to perform troubleshooting. a Voltage of approximately 9 V is applied to ST3 (30) pin and (40) pin through resistor in HST controller. 6 Defective HST controller Between ST3 (30) and ST1 (10) Voltage Between ST3 (40) and ST1 (10)

Work equipment lock lever: Free

Max. 1 V

Work equipment lock lever: Locked

7 to 11 V

Work equipment lock lever: Free

7 to 11 V

Work equipment lock lever: Locked

Max. 1 V

*NO: Normally Open *NC: Normally Closed

40-284

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40 Troubleshooting

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Circuit diagram related to work equipment lock switch

D61EM-23M0

40-285

40 Troubleshooting

Troubleshooting by failure code (Display of code)

Failure code [DDNLKB] Weq lock Sw: Short circuit Action level L03 Detail of failure Action of controller Problem on machine

Related information

No.

Work equipment lock Switch: Short circuit Failure code Failure (HST controller system) DDNLKB • Both lines of NO* and NC* for work equipment lock lever switch circuit are 0 V (switch: ON) at the same time. • Recognizes that work equipment lock lever is in LOCK position. • Restricts engine operations. • Once machine stops, engine speed is restricted to medium (half) speed. • Once machine stops, travel is restricted to F1 and R1. • Work equipment cannot be operated. • NC* circuit is used for detecting operation and NO* circuit is used for detecting error. • Signal from work equipment lock lever switch can be checked with monitoring function. (Code: 70300 "Blade SW Input 1") • Method of reproducing failure code: Turn starting switch to ON position and operate work equipment lock lever. • When work equipment lock lever is in free, work equipment lock lever switch becomes OFF. (Lever is in FREE position in illustration.) Cause

Procedure, measuring location, criteria and remarks

Turn starting switch to OFF position. Disconnect connector and connect T-adapter to male side. Operate work equipment lock lever to perform troubleshooting. Work equipment lock Max. 1 z Defective work equipment Between (male) lever: Free lock lever switch (internal (A) and (B) Work equipment lock Min. 1 Mz open circuit) lever: Locked Resistance Work equipment lock Min. 1 Mz Between (male) lever: Free (A) and (C) Work equipment lock Max. 1 z lever: Locked Turn starting switch to OFF position. Disconnect connectors ! and , and connect T-adapter to female side of either connector. Ground fault in wiring harness Between ground | ~ and (female) (B) or (contact with ground circuit) Min. 1 Mz ! (female) (30) (+) Resistance Between ground | ~ and either (female) Min. 1 Mz (C) or ! (female) (40) | ~ Turn starting switch to OFF position. Disconnect connectors ! and , and connect T-adapter to female side of ! . a Check by using multimeter in continuity mode.

No Between ! (female) (30) and each pin other continuity Short circuit in wiring harness than pin (30) (No sound is heard) Continuity No continuity Between ! (female) (40) and each pin other (No sound than pin (40) is heard)

40-286

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Troubleshooting by failure code (Display of code)

No.

Cause

Defective diode WLD1 (internal open or short circuit)

Defective diode WLD2 (internal open or short circuit)

Defective diode WLD3 (internal open or short circuit)

Between WLD1 (male) (2) (+) and (1) (-)

Continuity

Between WLD2 (male) (1) (+) and (2) (-)

No continuity

Between WLD2 (male) (2) (+) and (1) (-)

Continuity

1. Turn starting switch to OFF position. 2. Remove connector WLD3, and connect T-adapter to male side. a Measure it with diode range of multimeter. Continuity

Open circuit in wiring harness 7 (Wire breakage or defective contact)

No continuity

1. Turn starting switch to OFF position. 2. Remove connector WLD2, and connect T-adapter to male side. a Measure it with diode range of multimeter. Continuity

Between WLD1 (male) (1) (+) and (2) (-)

Between WLD3 (male) (1) (+) and (2) (-)

No continuity

Between WLD3 (male) (2) (+) and (1) (-)

Continuity

Between PSW1 (female) (B) and WLD1 (female) (1)

Max. 1 z

Between PSW (female) (B) and WLD1 (female) (2)

Max. 1 z

If no failure is found by above checks, HST controller is defective. q Reference 1. Turn starting switch to OFF position. 2. Insert T-adapter into connectors ST1 and ST3. 3. Turn starting switch to ON position. 4. Operate work equipment lock lever to perform troubleshooting. a Voltage of approximately 9 V is applied to ST3 (30) pin and ST3 (40) pin through resistor in HST controller. 8 Defective HST controller Between ST3 (30) and ST1 (10) Voltage Between ST3 (40) and ST1 (10)

Work equipment lock lever: Free

Max. 1 V

Work equipment lock lever: Locked

7 to 11 V

Work equipment lock lever: Free

7 to 11 V

Work equipment lock lever: Locked

Max. 1 V

*NO: Normally Open *NC: Normally Closed

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Circuit diagram related to work equipment lock switch

40-288

D61EM-23M0

40 Troubleshooting

Troubleshooting by failure code (Display of code)

Failure code [DDP6KA] Brake Pressure Sensor: Open Action level

Failure code

L03 Detail of failure

DDP6KA

Failure

Brake Pressure Sensor: Open (HST controller system)

• Signal voltage from brake pressure sensor is 0.3 V or lower.

Action of controller

• Determines that the brake pressure is 3 MPa {30 kg/cm2} if the machine stops. • Even if cause of failure disappears, machine does not become normal until starting switch is turned to OFF position.

Problem on machine

• HST charge pressure monitor does not light up even when the brake pressure lowers.

Related information

• When checking, be extremely careful not to connect the 5V circuit (3) and GND circuit (1) reversely to prevent the pressure sensor from being damaged. • Input pressure and voltage from brake pressure sensor can be checked with monitoring function. (Code: 91902 "Brake pressure"; Code: 91903 "Brake pressure sensor voltage") • Method of reproducing failure code: Turn starting switch to ON position.

No.

Cause

Defective 5 V sensor power supply system

Procedure, measuring location, criteria and remarks If failure code [DAJ6KK] is also displayed, perform troubleshooting for it first. 1. Turn starting switch to OFF position. 2. Disconnect connector BS, and connect T-adapter to female side. 3. Turn starting switch to ON position. a If power supply voltage is abnormal, go to check on cause 3 and after. Power 4.5 to 5.5 Voltage Between BS (female) (3) and (1) supply V 1. Turn starting switch to OFF position. 2. Insert T-adapter into connector BS. 3. Turn starting switch to ON position. a If power supply voltage is normal and sensor output voltage is abnormal (0.5 V or lower), it cannot be determined whether ground fault or defective sensor is the cause. In this case, go to check on cause 4. If no failure is found in check on cause 4, brake pressure sensor is defective. Sensor 0.5 to 4.5 Voltage Between BS (2) and (1) output V

Defective brake pressure sensor (internal defect) or ground fault

1. Turn starting switch to OFF position. 2. Disconnect connectors ST1 and BS, and connect T-adapter to female side of each connector. Open circuit in wiring harness (wire breakage or defective a If power supply voltage in check on cause 1 contact of connector) Max. 1 z Resisis normal, this check is not required. tance Between ST1 (female) (21) and BS (female) (1) Between ST1 (female) (8) and BS (female) (2) Max. 1 z

a If no failure is found by check on cause 2, this check is not required. 1. Turn starting switch to OFF position. 2. Disconnect connectors ST1 and BS, and connect T-adapter to Ground fault in wiring harness female side of either connector. (contact with ground circuit) Between ST1 (female) (8) and (21), or between Min. 1 Mz Resis- BS (female) (1) and (2) tance Between ST1 (female) (8) and ground, or Min. 1 Mz between BS (female) (2) and ground

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No.

Cause

Defective HST controller

Circuit diagram related to brake pressure sensor

40-290

D61EM-23M0

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Troubleshooting by failure code (Display of code)

Failure code [DDP6KB] Brake Pressure Sensor: Hot Short Action level L03 Detail of failure

Failure code DDP6KB

Failure

Brake Pressure Sensor: Hot short (HST controller system)

• Signal voltage from brake pressure sensor is 4.7 V or above.

Action of controller

Problem on machine

• HST charge pressure monitor does not light up even when the brake pressure lowers.

Related information

• When checking, be extremely careful not to connect the 5V circuit (3) and GND circuit (1) of the pressure sensor reversely to prevent the pressure sensor from being damaged. • Input pressure and voltage from brake pressure sensor can be checked with monitoring function. (Code: 91902 "Brake pressure"; Code: 91903 "Brake pressure sensor voltage") • Method of reproducing failure code: Turn starting switch to ON position.

No.

Cause

Defective 5 V sensor power supply system

Defective brake pressure sensor (internal defect) or ground fault

1. Turn starting switch to OFF position. 2. Disconnect connector BS. 3. Turn starting switch to ON position. If failure code [DDP6KB] disappears, brake pressure sensor is defective. (If failure code [DDP6KB] is still displayed, it shows that wiring harness or HST controller is defective.)

Hot short circuit in wiring harness

1. Turn starting switch to OFF position. 2. Disconnect connector BS, and connect T-adapter to female side. 3. Turn starting switch to ON position. Between ground and either BS (female) (2) and Voltage Max. 1 V (1) 1. Turn starting switch to OFF position. 2. Disconnect connectors ST1 and BS, and connect T-adapter to female side of ST1.

Short circuit in wiring harness

Defective HST controller

D61EM-23M0

a Check by using multimeter in continuity mode. No continuity Between ST1 (female) (8) and Continuity each pin other than pin (8) (No sound is heard) If no failure is found by above checks, HST controller is defective. • Reference 1. Turn starting switch to OFF position. 2. Insert T-adapter into connector ST1. 3. Turn starting switch to ON position. 0.5 to 4.5 Voltage Between ST1 (8) and (21) V

40-291

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Circuit diagram related to brake oil pressure sensor

40-292

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Failure code [DDP6MA] Brake pressure sensor: Malfunction Action level L03 Detail of failure Action of controller Problem on machine

Failure code DDP6MA

Failure

Brake Pressure Sensor: Malfunction (HST controller system)

• Abnormality (sensor failure) is found in the signal voltage from brake pressure sensor. • Even if cause of failure disappears, machine does not become normal until starting switch is turned to OFF position. • HST charge pressure monitor does not light up even when the brake pressure lowers.

Related information

• Input pressure and voltage from brake pressure sensor can be checked with monitoring function. (Code: 91902 "Brake pressure"; Code: 91903 "Brake pressure sensor voltage") • Method of reproducing failure code: Turn starting switch to ON position.

No.

Cause

Defective brake pressure sensor (internal defect)

Procedure, measuring location, criteria and remarks 1. Turn starting switch to OFF position. 2. Insert T-adapter into connector BS. 3. Turn starting switch to ON position. Sensor 0.5 to 4.5 output V If no failure is found by above checks, HST controller is defective. • Reference 1. Turn starting switch to OFF position. 2. Insert T-adapter into connector ST1. 3. Turn starting switch to ON position. 0.5 to 4.5 Voltage Between ST1 (8) and (21) V Voltage

Defective HST controller

D61EM-23M0

Between BS (2) and (1)

40-293

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Circuit diagram related to brake oil pressure sensor

40-294

D61EM-23M0

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Troubleshooting by failure code (Display of code)

Failure code [DDU1FS] Parking lever Switch 2: Signal mismatch Action level L03 Detail of failure Action of controller Problem on machine

Related information

• • • • • • •

• • •

No.

Parking lever Switch 2: Signal mismatch Failure code Failure (HST controller system) DDU1FS The parking brake lever switch 1 signal shows the lock position, but the power is supplied to the slow brake solenoid valve. Displays the parking brake abnormality monitor on the machine monitor. Partially limits the functions. Even if cause of failure disappears, machine does not become normal until starting switch is turned to the OFF position. Once machine stops, engine speed is restricted to medium (half) speed. Once machine stops, travel speed is restricted to 50% after restart. ? ? \ \ ^ ^ @ $ . 4% ^ @ \ @ \ @ ? @ ` ? ? @ @ ` ` . ^ ^ $ . 4% ^ # @ Input condition (ON/OFF) from parking brake lever switches 1 and 2 can be checked with $ $ ' &% $ ( $ j7*3 *# % j) Method of reproducing failure code: Turn starting switch to ON position and operate the parking brake lever. When operating parking brake lever, parking brake lever switches 1 and 2 are operated at the same time. Cause

Procedure, measuring location, criteria and remarks

Turn starting switch to OFF position. Disconnect connector and connect T-adapter to male side. Operate parking brake lever to ON and OFF positions and perform troubleshooting. Defective parking brake lever switch 1 (internal open circuit) Lever: FREE Max. 1 z Between (male) Lever: LOCK Min. 1 Mz Resis- (A) and (B) tance Lever: FREE Between (male) Min. 1 Mz (A) and (C) Lever: LOCK Max. 1 z

Turn starting switch to OFF position. Disconnect connector and connect T-adapter to male side. Operate parking brake lever to ON and OFF positions and perform troubleshooting. Defective parking brake lever switch 2 (internal open circuit) Between (male) Lever: FREE Max. 1 z (A) and (B) Lever: LOCK Min. 1 Mz Resistance Between (male) Lever: FREE Min. 1 Mz (A) and (C) Lever: LOCK Max. 1 z

1. Turn starting switch to OFF position. 2. Disconnect connector S3 and connect T-adapter to female side. 3. Turn starting switch to ON position. Between ground and either S3 (female) (1) or Voltage Max. 4.5 V (2)

Hot short circuit in wiring harness

D61EM-23M0

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No.

Cause

Procedure, measuring location, criteria and remarks 1. Turn starting switch to OFF position. 2. Disconnect relay 26BR and connect T-adapter to male side. Resistance Between 26BR (male) (1) (+) and (2) (-)

Defective work equipment lock lever interlock relay 26BR

200 to 400 Ω

1. Turn starting switch to OFF position. 2. Replace relay 26BR with another one such as cleaning water pump relay (RCW). 3. Turn starting switch to ON position. If this failure code disappears, original work equipment lock lever interlock relay 26BR is defective. 1. Turn starting switch to OFF position. 2. Disconnect relay 26R and connect T-adapter to male side. Resistance Between 26R (male) (1) (+) and (2) (-)

Defective work equipment lock lever interlock relay 26R

200 to 400 Ω

1. Turn starting switch to OFF position. 2. Replace relay 26R with another one such as cleaning water pump relay (RCW). 3. Turn starting switch to ON position. If this failure code disappears, original work equipment lock lever interlock relay 26R is defective.

Open circuit in wiring harness 6 (wire breakage or defective contact of connector) Defective installation of parking 7 brake lever switches 1 and 2

40-296

1. Turn starting switch to OFF position 2. Disconnect connectors 26R and 26BR, and connect T-adapter to female side of each connector. Resistance

Between 26R (female) (1) and 26BR (female) (1)

Max. 1 z

Between 26R (female) (2) and 26BR (female) (2)

Max. 1 z

Since parking brake lever switches 1 and 2 may be improperly installed, check their installation (see Testing and adjusting).

D61EM-23M0

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Troubleshooting by failure code (Display of code)

Circuit diagram related to parking brake lever switch

D61EM-23M0

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Failure code [DDU1KA] Parking lever Sw2: Open Action level L03 Detail of failure Action of controller Problem on machine

Related information

• • • • • • •

• • • •

No.

Parking lever Switch 2: Open Failure code Failure (HST controller system) DDU1KA Even if the signal of parking brake lever switch 1 shows the lock position and no current flows through the output circuit to slow brake solenoid valve, the signal of parking brake lever switch 2 (NO) is OFF (free). Displays the parking brake abnormality monitor on the machine monitor. Partially limits the functions. Even if cause of failure disappears, machine does not become normal until starting switch is turned to the OFF position. Once machine stops, engine speed is restricted to medium (half) speed. Once machine stops, travel speed is restricted to 50% after restart. ? ? \ \ ^ ^ @ $ . 4% ^ @ \ @ \ @ ? @ ` ? ? @ @ ` ` . ^ ^ $ . 4% ^ # @ Input condition (ON/OFF) from parking . lever switches 1 and 2 can be checked with monitoring function. (Code: 40984 HST SW Input 3) Method of reproducing failure code: Turn starting switch to ON position and operate the parking brake lever. If failure code [DW7EKA] is also displayed, perform troubleshooting for it first. When operating parking brake lever, parking brake lever switches 1 and 2 are operated at the same time. Cause

Procedure, measuring location, criteria and remarks

Turn starting switch to OFF position. Disconnect connector and connect T-adapter to male side. Operate parking brake lever and perform troubleshooting. Defective parking brake lever Lever: FREE Max. 1 z Between (male) switch 2 (internal open circuit) Lever: LOCK Min. 1 Mz Resis- (A) and (B) tance Lever: FREE Between (male) Min. 1 Mz (A) and (C) Lever: LOCK Max. 1 z Turn starting switch to OFF position. Disconnect connector and connect T-adapter to female side. Turn starting switch to ON position. $ . 4% $ . , 855

Open circuit or hot short circuit in wiring harness

a When voltage is 0 V, it shows open circuit, and when voltage is 24 V, it shows hot short circuit. a Voltage of approximately 9 V is applied to "NO" and "NC" signal circuits through resistor in the HST controller. Between (female) (A) and (B) 7 to 11 V Voltage Between (female) (A) and (C) 7 to 11 V

a If no failure is found by check on cause 2, this check is not required. Turn starting switch to OFF position. Disconnect connectors ST1, ST3, # and PB, and connect ! adapters to female side of each connector. Between ST3 (female) (35) and (female) Open circuit in wiring harness Max. 1 z (A) (wire breakage or defective Between PB (female) (A) and 8 (female) ( ) Max. 1 z contact of connector) Resis- Between 26BR (female) (3) and 26B1 (female) Max. 1 z (B~ tance

Between ST1 (female) (18) and (female) (C) ! |? ~ | ~ \ # |? ~ ( ~ 40-298

Max. 1 z Max. 1 z

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40 Troubleshooting

Troubleshooting by failure code (Display of code)

No.

Cause

Defective work equipment lock lever interlock relay 26BR

200 to 400 Ω

Open circuit in wiring harness 5 (wire breakage or defective contact of connector)

a Following checks are unnecessary if no abnormality is detected by above checks. 1. Turn starting switch to OFF position. 2. Disconnect connectors 26BR and 26B1, and connect T-adapter to female side of each connector. Resistance

6 Defective HST controller

Between 26BR (female) (2) and ground

Max. 1 z

Between 26BR (female) (1) and 26R (female) (1)

Max. 1 z

If no failure is found by above checks, HST controller is defective. q Reference 1. Turn starting switch to OFF position. 2. Insert T-adapter into connectors ST1 and ST3. 3. Turn starting switch to ON position. 4. Operate parking brake lever and perform troubleshooting. a Voltage of approximately 9 V is applied to ST3 (35) pin and ST1 (18) pin through resistor in HST controller.

Voltage

Between ST3 (35) and ST1 (10) Between ST1 (18) and ST1 (10)

Lever: FREE

Max. 1 V

Lever: LOCK

7 to 11 V

Lever: FREE

7 to 11 V

Lever: LOCK

Max. 1 V

*NO: Normally Open *NC: Normally Closed

D61EM-23M0

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Troubleshooting by failure code (Display of code)

Circuit diagram related to parking brake lever switch

40-300

D61EM-23M0

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Troubleshooting by failure code (Display of code)

Failure code [DDU1KY] Parking lever Sw2: Hot Short Action level L03 Detail of failure

• • •

Action of controller

Problem on machine

Related information

• • • • •

• • •

No.

Parking lever Switch 2: Hot short Failure code Failure (HST controller system) DDU1KY Even if the signal of parking brake lever switch 1 shows the free position and the signal is normal from output circuit to slow brake solenoid valve, the signal of parking brake lever switch 2 (NO) is ON (locked). Displays the parking brake abnormality monitor on the machine monitor. When the parking brake lever switch is in lock position, an open circuit of slow brake solenoid may be detected. Partially limits the functions. Even if cause of failure disappears, machine does not become normal until starting switch is turned to OFF position. Once machine stops, engine speed is restricted to medium (half) speed. Once machine stops, travel speed is restricted to 50% after restart. & & % $ $ , $ . , $ $ . 4% $ . , ! &$ $% $$ ' &$ & # $% $$ ' . ' . , $, $ . 4% $ . , $ 855 $ $ Input condition (ON/OFF) from parking brake lever switches 1 and 2 can be checked with monitoring function. (Code: 40984 "HST SW Input 3") Method of reproducing failure code: Turn starting switch to ON position and operate the parking brake lever (Free). When operating parking brake lever, parking brake lever switches 1 and 2 are operated at the same time. Cause

Procedure, measuring location, criteria and remarks 1. Turn starting switch to OFF position. 2. Disconnect connector 26B1 and connect T-adapter to male side. 3. Operate parking brake lever and perform troubleshooting.

Defective parking brake lever switch 2 (internal open circuit) Resistance

2 Hot short circuit in wiring harness

1. 2. 3. 4.

Between 26B1 (male) (A) and (B) Between 26B1 (male) (A) and (C)

Lever: FREE

Max. 1 z

Lever: LOCK

Min. 1 Mz

Lever: FREE

Min. 1 Mz

Lever: LOCK

Max. 1 z

Turn starting switch to OFF position. Disconnect connector 26B1 and connect T-adapter to female side. Turn starting switch to ON position. Keep work equipment lock lever in FREE. Voltage

Between 26B1 (female) (C) and ground

7 to 11 V

1. Turn starting switch to OFF position. 2. Disconnect relay 26BR and connect T-adapter to male side. Resistance Between 26BR (male) (1) (+) and (2) (-) 3

Defective work equipment lock lever interlock relay 26BR

200 to 400 Ω

Open circuit in wiring harness 4 (wire breakage or defective contact of connector)

D61EM-23M0

Between 26BR (female) (2) and ground

Max. 1 z

Between 26BR (female) (1) and 26R (female) (1)

Max. 1 z

40-301

40 Troubleshooting

Troubleshooting by failure code (Display of code)

No.

Cause

5 Defective HST controller

Procedure, measuring location, criteria and remarks If no failure is found by above checks, HST controller may be defective. (Since this is an internal defect, troubleshooting cannot be performed.)

Circuit diagram related to parking brake lever switch

40-302

D61EM-23M0

40 Troubleshooting

Troubleshooting by failure code (Display of code)

Failure code [DFA4KX] Blade lift lever: Main and Sub Error Action level L01 Detail of failure Action of controller Problem on machine Related information

No. 1

Blade lift lever: Main and Sub Error Failure code Failure (HST controller system) DFA4KX • In blade lift lever potentiometer systems 1 and 2, either failure code [DFA5KA] or [DFA5KB] and either failure code [DFA6KA] or [DFA6KB] are generated at the same time. • Recognizes that blade lift lever is in neutral position. • Blade cannot be raised and lowered. • Signal from blade lift lever potentiometer can be checked with monitoring function. (Code: 73400 "Blade Lift Lever 1 Potentio") (Code: 73401 "Blade Lift Lever 2 Potentio") • Method of reproducing failure code: Turn starting switch to ON position and operate blade lever (lifting).

Cause Defective blade lift lever potentiometer

D61EM-23M0

Procedure, measuring location, criteria and remarks Perform troubleshooting for failure codes [DFA5KA], [DFA5KB], [DFA6KA], and [DFA6KB].

40-303

40 Troubleshooting

Troubleshooting by failure code (Display of code)

Failure code [DFA4KZ] Blade lift lever: Main and Sub Error Action level L01 Detail of failure Action of controller Problem on machine Related information

No. 1

Blade lift lever: Main and Sub Error Failure code Failure (HST controller system) DFA4KZ • Either system 1 or 2 of blade lift lever potentiometer is abnormal when starting switch is turned to ON position. Then either failure code [DFA5KA] or [DFA5KB] and either failure code [DFA6KA] or [DFA6KB] are generated simultaneously in systems 1 and 2 respectively. • Recognizes that blade lift lever is in neutral position. • Blade cannot be raised and lowered. • Signal from blade lift lever potentiometer can be checked with monitoring function. (Code: 73400 "Blade Lift Lever 1 Potentio") (Code: 73401 "Blade Lift Lever 2 Potentio") • Method of reproducing failure code: Turn starting switch to ON position and operate blade lever (lifting).

Cause Defective blade lift lever potentiometer

40-304

Procedure, measuring location, criteria and remarks Perform troubleshooting for failure codes [DFA5KA], [DFA5KB], [DFA6KA], and [DFA6KB].

D61EM-23M0

40 Troubleshooting

Troubleshooting by failure code (Display of code)

Failure code [DFA4L8] Blade lift lever: Signal mismatch Action level L01 Detail of failure Action of controller Problem on machine Related information

No. 1

Blade lift lever: Signal Mismatch Failure code Failure (HST controller system) DFA4L8 • Sum of signal voltages of blade lift lever potentiometer systems 1 and 2 is 4.41 V or below, or 5.59 V or above. • Continues blade control with signal from blade lift lever potentiometer system 1 or 2 whichever is normal. • Not installed • Signal from blade lift lever potentiometer can be checked with monitoring function. (Code: 73400 "Blade Lift Lever 1 Potentio") (Code: 73401 "Blade Lift Lever 2 Potentio") • Method of reproducing failure code: Turn starting switch to ON position and operate blade lever (lifting).

Cause Defective blade lift lever potentiometer

D61EM-23M0

Procedure, measuring location, criteria and remarks Perform troubleshooting for failure codes [DFA5KA], [DFA5KB], [DFA6KA], and [DFA6KB].

40-305

40 Troubleshooting

Troubleshooting by failure code (Display of code)

Failure code [DFA5KA] Blade lift lever1: Open Action level L01 Detail of failure Action of controller Problem on machine

Failure code DFA5KA

Failure

Blade lift lever 1: Open (HST controller system)

• Signal voltage of blade lift lever potentiometer system 1 is 0.5 V or lower. • Continues blade control with signal from blade lift lever potentiometer system 2. • None

Related information

• Signal voltage of blade lift lever potentiometer 1 can be checked with monitoring function. (Code: 73400 Blade Lift Lever 1 Potentio) • Method of reproducing failure code: Turn starting switch to ON position and operate blade lever (lifting).

No.

Cause

Defective 5 V sensor power supply system

Procedure, measuring location, criteria and remarks If failure code [DAJ6KK] is also displayed, perform troubleshooting for it first. 1. Turn starting switch to OFF position. 2. Disconnect connector WLV1 and connect T-adapter to female side. 3. Turn starting switch to ON position. a If power supply voltage is abnormal, go to check on cause 3 and after. Power Voltage Between WLV1 (female) (4) and (1) supply 4.5 to 5.5 V 1. Turn starting switch to OFF position. 2. Insert T-adapter into connector WLV1. 3. Turn starting switch to ON position. 4. Operate blade control lever (in RAISE/LOWER direction) to perform troubleshooting.

Defective blade lift lever potentiometer 1 (internal open circuit or ground fault)

Open circuit in wiring harness (wire breakage or defective contact of connector)

40-306

a If power supply voltage is normal and potentiometer output voltage is abnormal (0.5 V or lower), it cannot be determined whether ground fault or defective potentiometer is the cause. In this case, go to check on cause 4. If no failure is found by check on cause 4, blade lift lever potentiometer 1 is defective. 0.96 to 4.04 Voltage Between WLV1 (3) and (1) V 1. Turn starting switch to OFF position. 2. Disconnect connectors ST1, ST2 and WLV1, and connect T-adapters to each female side. a If power supply voltage in check on cause 1 is normal, this check is not required. Between ST1 (female) (22) and WLV1 (female) (4) Resistance

a If power supply voltage in check on cause 1 is normal, this check is not required. Between ST1 (female) (4) and WLV1 (female) (1) Between ST2 (female) (36) and WLV1 (female) (3)

Max. 1 z

Max. 1 z Max. 1 z

D61EM-23M0

40 Troubleshooting

Troubleshooting by failure code (Display of code)

No.

Cause

Ground fault in wiring harness (contact with ground circuit)

Defective HST controller

D61EM-23M0

Procedure, measuring location, criteria and remarks a If no failure is found by check on cause 2, this check is not required. 1. Turn starting switch to OFF position. 2. Disconnect connectors ST1, ST2 and WLV1, and connect T-adapter to either female side. Between ST2 (female) (36) and ST1 (4), or Min. 1 Mz Resis- between WLV1 (female) (1) and (8) tance Between ST2 (female) (36) and ground, or Min. 1 Mz between WLV1 (female) (3) and ground If no failure is found by above checks, HST controller is defective. • Reference 1. Turn starting switch to OFF position. 2. Insert T-adapters into connectors ST1 and ST2. 3. Turn starting switch to ON position. 4. Operate blade control lever (in RAISE/LOWER direction) to perform troubleshooting. 0.96 to 4.04 Voltage Between ST2 (36) and ST1 (4) V

40-307

40 Troubleshooting

Troubleshooting by failure code (Display of code)

Circuit diagram related to blade lift lever potentiometer

40-308

D61EM-23M0

40 Troubleshooting

Troubleshooting by failure code (Display of code)

Failure code [DFA5KB] Blade lift lever1: Hot Short Action level L01 Detail of failure Action of controller Problem on machine Related information No. 1

Failure code DFA5KB

Failure

Blade lift lever 1: Hot Short (HST controller system)

• Signal voltage of blade lift lever potentiometer system 1 is 4.5 V or above. • Continues blade control with signal from blade lift lever potentiometer system 2. • None • Signal voltage of blade lift lever potentiometer 1 can be checked with monitoring function. (Code: 73400 "Blade Lift Lever 1 Potentio") • Method of reproducing failure code: Turn starting switch to ON position.

Cause Defective 5 V sensor power supply system

Defective blade lift lever potentiometer 1 (internal short circuit or ground fault)

Procedure, measuring location, criteria and remarks If failure code [DAJ6KK] is also displayed, perform troubleshooting for it first. 1. Turn starting switch to OFF position. 2. Disconnect connector WLV1. 3. Turn starting switch to ON position. If failure code [DFA5KB] disappears, blade lift lever potentiometer is defective. (If failure code is still displayed, wiring harness or HST controller is defective.) a Since connector WLV1 is disconnected, many failure codes appear. Ignore failure codes other than [DFA5KB].

Hot short circuit in wiring harness

Short circuit in wiring harness

Defective HST controller

D61EM-23M0

1. Turn starting switch to OFF position. 2. Disconnect connector WLV1 and connect T-adapter to female side. 3. Turn starting switch to ON position. Voltage Between WLV1 (female) (3) and (4) or ground 7 to 11 V 1. Turn starting switch to OFF position. 2. Disconnect connectors ST2 and WLV1, and connect T-adapter to female side of ST2. a Check by using multimeter in continuity mode. Between ST2 (female) (36) and each No continuity (no Continuity pin other than pin (36) sound is heard) If no failure is found by above checks, HST controller is defective. • Reference 1. Turn starting switch to OFF position. 2. Insert T-adapters into connectors ST1 and ST2. 3. Turn starting switch to ON position. 4. Operate blade control lever (in RAISE/LOWER direction) to perform troubleshooting. 0.96 to 4.04 Voltage Between ST2 (36) and ST1 (4) V

40-309

40 Troubleshooting

Troubleshooting by failure code (Display of code)

Circuit diagram related to blade lift lever

40-310

D61EM-23M0

40 Troubleshooting

Troubleshooting by failure code (Display of code)

Failure code [DFA6KA] Blade lift lever2: Open Action level L01 Detail of failure Action of controller Problem on machine

Failure code DFA6KA

Failure

Blade lift lever 2: Open (HST controller system)

• Signal voltage of blade lift lever potentiometer 2 is 0.5 V or lower. • Continues blade control with signal from blade lift lever potentiometer 1. • None

Related information

• Signal voltage of blade lift lever potentiometer 2 can be checked with monitoring function. (Code: 73401 "Blade Lift Lever 2 Potentio") • Method of reproducing failure code: Turn starting switch to ON position and operate blade lever (lifting).

No.

Cause

Defective 5 V sensor power supply system

Procedure, measuring location, criteria and remarks If failure code [DAJ6KK] is also displayed, perform troubleshooting for it first. 1. Turn starting switch to OFF position. 2. Disconnect connector WLV1 and connect T-adapter to female side. 3. Turn starting switch to ON position. a If power supply voltage is abnormal, go to check on cause 3 and after. Power Voltage Between WLV1 (female) (4) and (1) supply 4.5 to 5.5 V 1. Turn starting switch to OFF position. 2. Insert T-adapter into connector WLV1. 3. Turn starting switch to ON position. 4. Operate blade control lever (in RAISE/LOWER direction) to perform troubleshooting.

Defective blade lift lever potentiometer 2 (internal open circuit or ground fault)

Open circuit in wiring harness (wire breakage or defective contact of connector)

Ground fault in wiring harness (contact with ground circuit)

D61EM-23M0

a If power supply voltage is normal and potentiometer output voltage is abnormal (0.5 V or lower), it cannot be determined whether ground fault or defective potentiometer is the cause. In this case, go to check on cause 4. If no failure is found by check on cause 4, blade lift lever potentiometer 2 is defective. 0.96 to 4.04 Voltage Between WLV1 (2) and (1) V 1. Turn starting switch to OFF position. 2. Disconnect connectors ST1, ST2 and WLV1, and connect T-adapters to each female side. a If power supply voltage in check on cause 1 is normal, this check is not required. Between ST1 (female) (22) and WLV1 (female) (4) Resistance

a If power supply voltage in check on cause 1 is normal, this check is not required. Between ST1 (female) (4) and WLV1 (female) (1) Between ST2 (female) (26) and WLV1 (female) (2)

Max. 1 z

a If no failure is found by check on cause 2, this check is not required. 1. Turn starting switch to OFF position. 2. Disconnect connectors ST1, ST2 and WLV1, and connect T-adapter to either female side. Between ST1 (female) (26) and ST1 (4), or Min. 1 Mz Resis- between WLV1 (female) (1) and (2) tance Between ST1 (female) (26) and ground, or Min. 1 Mz between WLV1 (female) (2) and ground 40-311

40 Troubleshooting

Troubleshooting by failure code (Display of code)

No.

Cause

Defective HST controller

Circuit diagram related to blade lift potentiometer

40-312

D61EM-23M0

40 Troubleshooting

Troubleshooting by failure code (Display of code)

Failure code [DFA6KB] Blade lift lever2: Hot Short Action level L01 Detail of failure Action of controller Problem on machine Related information No. 1

Failure code DFA6KB

Failure

Blade lift lever2:Hot Short (HST controller system)

• Signal voltage of blade lift lever potentiometer system 2 is 4.5 V or above. • Continues blade control with signal from blade lift lever potentiometer 1. • None • Signal voltage of blade lift lever potentiometer 2 can be checked with monitoring function. (Code: 73401 "Blade Lift Lever 2 Potentio") • Method of reproducing failure code: Turn starting switch to ON position.

Cause Defective 5 V sensor power supply system

Procedure, measuring location, criteria and remarks If failure code [DAJ6KK] is also displayed, perform troubleshooting for it first.

1. Turn starting switch to OFF position. 2. Disconnect connector WLV1. 3. Turn starting switch to ON position. Defective blade lift lever If failure code [DFA6KB] disappears, blade lift lever potentiometer is potentiometer 2 (internal short defective. (If failure code is still displayed, wiring harness or HST circuit or ground fault) controller is defective.) a Since connector WLV1 is disconnected, many failure codes appear. Ignore failure codes other than [DFA6KB]]

Hot short circuit in wiring harness

Short circuit in wiring harness

Defective HST controller

D61EM-23M0

1. Turn starting switch to OFF position. 2. Disconnect connector WLV1 and connect T-adapter to female side. 3. Turn starting switch to ON position. Between WLV1 (female) (1) and (2) or Voltage 7 to 11 V ground 1. Turn starting switch to OFF position. 2. Disconnect connectors ST2 and WLV1, and connect T-adapter to female side of ST2. a Check by using multimeter in continuity mode. Between ST2 (female) (26) and No continuity (no Continuity each pin other than pin (26) sound is heard) If no failure is found by above checks, HST controller is defective. • Reference 1. Turn starting switch to OFF position. 2. Insert T-adapter into connectors ST1 and ST2. 3. Turn starting switch to ON position. 4. Operate blade control lever (in RAISE/LOWER direction) to perform troubleshooting. 0.96 to 4.04 Voltage Between ST2 (26) and ST1 (4) V

40-313

40 Troubleshooting

Troubleshooting by failure code (Display of code)

Circuit diagram related to blade lift lever potentiometer

40-314

D61EM-23M0

40 Troubleshooting

Troubleshooting by failure code (Display of code)

Failure code [DFA7KX] Blade tilt lever: Main and Sub Error Action level L01 Detail of failure Action of controller Problem on machine Related information

No. 1

Blade tilt lever: Main and Sub Error Failure code Failure (HST controller system) DFA7KX • In blade tilt lever potentiometer systems 1 and 2, either failure code [DFA8KA] or [DFA8KB] and either failure code [DFA9KA] or [DFA9KB] are displayed at the same time. • Recognizes that blade tilt lever is in neutral position. • Blade cannot be tilted. • Signal from blade tilt lever potentiometer can be checked with monitoring function. (Code: 73500 "Blade Tilt Lever 1 Potentio") (Code: 73501 "Blade Tilt Lever 2 Potentio") • Method of reproducing failure code: Turn starting switch to ON position and operate blade lever (tilting).

Cause Defective blade tilt lever potentiometer

D61EM-23M0

Procedure, measuring location, criteria and remarks Perform troubleshooting for failure codes [DFA8KA], [DFA8KB], [DFA9KA], and [DFA9KB].

40-315

40 Troubleshooting

Troubleshooting by failure code (Display of code)

Failure code [DFA7KZ] Blade tilt lever: Main and Sub Error Action level L01 Detail of failure Action of controller Problem on machine Related information

No. 1

Blade tilt lever: Main and Sub Error Failure code Failure (HST controller system) DFA7KZ • Either system 1 or 2 of blade tilt lever potentiometer is abnormal when starting switch is turned to ON position. Then either failure code [DFA8KA] or [DFA8KB] and either failure code [DFA9KA] or [DFA9KB] are generated simultaneously in systems 1 and 2. • Recognizes that blade tilt lever is in neutral position. • Blade cannot be tilted. • Signal from blade tilt lever potentiometer can be checked with monitoring function. (Code: 73500 "Blade Tilt Lever 1 Potentio") (Code: 73501 "Blade Tilt Lever 2 Potentio") • Method of reproducing failure code: Turn starting switch to ON position and operate blade lever (tilting).

Cause Defective blade tilt lever potentiometer

40-316

Procedure, measuring location, criteria and remarks Perform troubleshooting for failure codes [DFA8KA], [DFA8KB], [DFA9KA], and [DFA9KB].

D61EM-23M0

40 Troubleshooting

Troubleshooting by failure code (Display of code)

Failure code [DFA7L8] Blade tilt lever: Signal mismatch Action level L01 Detail of failure Action of controller Problem on machine Related information

No. 1

Blade tilt lever: Signal mismatch Failure code Failure (HST controller system) DFA7L8 • Sum of signal voltages of blade tilt lever potentiometer systems 1 and 2 is 4.41 V or below, or 5.59 V or above. • Continues blade control with signal from blade tilt lever potentiometer system 1 or 2 whichever is normal. • None • Signal from blade tilt lever potentiometer can be checked with monitoring function. (Code: 73500 "Blade Tilt Lever 1 Potentio") (Code: 73501 "Blade Tilt Lever 2 Potentio") • Method of reproducing failure code: Turn starting switch to ON position and operate blade lever (tilting).

Cause Defective blade tilt lever potentiometer

D61EM-23M0

Procedure, measuring location, criteria and remarks Perform troubleshooting for failure codes [DFA8KA], [DFA8KB], [DFA9KA], and [DFA9KB].

40-317

40 Troubleshooting

Troubleshooting by failure code (Display of code)

Failure code [DFA8KA] Blade tilt lever1: Open Action level L01 Detail of failure Action of controller Problem on machine

Failure code DFA8KA

Failure

Blade tilt lever 1: Open (HST controller system)

• Signal voltage of blade tilt lever potentiometer system 1 is 0.5 V or lower. • Continues blade control with signal from blade tilt lever potentiometer system 2. • None

Related information

• ^ $%' $ $ , &% $ % &$ $ $ &% $ $ $ ^ $, & % $ ! ! % $ . ' $& $ $ , ! ' $ $ $ • Signal voltage of blade tilt lever potentiometer 1 can be checked with monitoring function. (Code: 73500 "Blade Tilt Lever 1 Potentio") • Method of reproducing failure code: Turn starting switch to ON position and operate blade lever (tilting).

No.

Cause

Defective 5 V sensor power supply system

Turn starting switch to OFF position. Insert T-adapter into connector WLV1. Turn starting switch to ON position. 2

Defective blade tilt lever potentiometer 1 (internal open circuit or ground fault)

Open circuit in wiring harness (wire breakage or defective contact of connector)

40-318

a If power supply voltage is normal and potentiometer output voltage is abnormal (0.5 V or lower), it cannot be determined whether ground fault or defective potentiometer is the cause. In this case, go to check on cause 4. If no failure is found by check on cause 4, blade tilt lever potentiometer 1 is defective. 0.96 to 4.04 Voltage Between WLV1 (7) and (5) V 1. Turn starting switch to OFF position. 2. Disconnect connectors ST1, ST2 and WLV1, and connect T-adapters to each female side. a If power supply voltage in check on cause 1 is normal, this check is not required. Between ST1 (female) (22) and WLV1 (female) (8) Resistance

a If power supply voltage in check on cause 1 is normal, this check is not required. Between ST1 (female) (4) and WLV1 (female) (5) Between ST2 (female) (16) and WLV1 (female) (7)

Max. 1 z

Max. 1 z Max. 1 z

D61EM-23M0

40 Troubleshooting

Troubleshooting by failure code (Display of code)

No.

Cause

Ground fault in wiring harness (contact with ground circuit)

Defective HST controller

D61EM-23M0

Procedure, measuring location, criteria and remarks a If no failure is found by check on cause 2, this check is not required. 1. Turn starting switch to OFF position. 2. Disconnect connectors ST1, ST2 and WLV1, and connect T-adapter to either female side. Between ST2 (female) (16) and ST1 (4), or Min. 1 Mz Resis- between WLV1 (female) (7) and (8) tance Between ST2 (female) (16) and ground, or Min. 1 Mz between WLV1 (female) (7) and ground If no failure is found by above checks, HST controller is defective. • Reference Turn starting switch to OFF position. Insert T-adapter into connector ST2. Turn starting switch to ON position. 0.96 to 4.04 Voltage Between ST2 (16) and ST1 (4) V

40-319

40 Troubleshooting

Troubleshooting by failure code (Display of code)

Circuit diagram related to blade tilt lever potentiometer

40-320

D61EM-23M0

40 Troubleshooting

Troubleshooting by failure code (Display of code)

Failure code [DFA8KB] Blade tilt lever1: Hot Short Action level L01 Detail of failure Action of controller Problem on machine Related information

No. 1

Failure code DFA8KB

Failure

Blade tilt lever 1: Hot Short (HST controller system)

• Signal voltage of blade tilt lever potentiometer system 1 is 4.5 V or above. • Continues blade control with signal from blade tilt lever potentiometer system 2. • None

Cause Defective 5 V sensor power supply system

Procedure, measuring location, criteria and remarks If failure code [DAJ6KK] is also displayed, perform troubleshooting for it first.

1. Turn starting switch to OFF position. 2. Disconnect connector WLV1. 3. Turn starting switch to ON position. Defective blade tilt lever If failure code [DFA8KB] disappears, blade tilt lever potentiometer is potentiometer 1 (internal short defective. (If failure code is still displayed, wiring harness or work circuit or ground fault) equipment controller is defective.) a Since connector WLV1 is disconnected, many failure codes appear. Ignore all of displayed failure codes other than [DFA8KB]]

Hot short circuit in wiring harness

Short circuit in wiring harness

Defective HST controller

D61EM-23M0

1. Turn starting switch to OFF position. 2. Disconnect connector WLV1 and connect T-adapter to female side. 3. Turn starting switch to ON position. Between WLV1 (female) (7) and (8) or Voltage 7 to 11 V ground 1. Turn starting switch to OFF position. 2. Disconnect connectors ST2 and WLV1, and connect T-adapter to female side of ST2. a Check by using multimeter in continuity mode. Between ST2 (female) (16) and No continuity (no Continuity each pin other than pin (16) sound is heard) If no failure is found by above checks, HST controller is defective. • Reference Turn starting switch to OFF position. Insert T-adapters into connectors ST1 and ST2. Turn starting switch to ON position. Voltage Between ST2 (16) and ST1 (4) 0.96 to 4.04 V

40-321

40 Troubleshooting

Troubleshooting by failure code (Display of code)

Circuit diagram related to blade lever tilt potentiometer

40-322

D61EM-23M0

40 Troubleshooting

Troubleshooting by failure code (Display of code)

Failure code [DFA9KA] Blade tilt lever2: Open Action level L01 Detail of failure Action of controller Problem on machine

Failure code DFA9KA

Failure

Blade tilt lever 2: Open (HST controller system)

• Signal voltage of blade tilt lever potentiometer system 2 is 0.5 V or lower. • Continues blade control with signal from blade tilt lever potentiometer system 1. • None

Related information

• ^ $%' $ $ , &% $ % &$ $ $ &% $ $ $ ^ $, & % $ ! ! % $ . ' $& $ $ , ! ' $ $ $ • Signal voltage of blade tilt lever potentiometer 2 can be checked with monitoring function. (Code: 73501 "Blade Tilt Lever 2 Potentio") • Method of reproducing failure code: Turn starting switch to ON position and operate blade lever (tilting).

No.

Cause

Defective 5 V sensor power supply system

Turn starting switch to OFF position. Insert T-adapter into connector WLV1. Turn starting switch to ON position. 2

Defective blade tilt lever a If power supply voltage is normal and potentiometer output voltage potentiometer 2 (internal open is abnormal (0.5 V or lower), it cannot be determined whether circuit or ground fault) ground fault or defective potentiometer is the cause. In this case, go to check on cause 4. If no failure is found by check on cause 4, blade tilt lever potentiometer 2 is defective. 0.96 to 4.04 Voltage Between WLV1 (6) and (5) V 1. Turn starting switch to OFF position. 2. Disconnect connectors ST1, ST2 and WLV1, and connect Tadapters to each female side.

Open circuit in wiring harness (wire breakage or defective contact of connector)

D61EM-23M0

a If power supply voltage in check on cause 1 is normal, this check is not required. Between ST1 (female) (22) and WLV1 (female) (8) Resistance a If power supply voltage in check on cause 1 is normal, this check is not required. Between ST1 (female) (4) and WLV1 (female) (5) Between ST2 (female) (6) and WLV1 (female) (6)

Max. 1 z

40-323

40 Troubleshooting

Troubleshooting by failure code (Display of code)

No.

Cause

Procedure, measuring location, criteria and remarks

a If no failure is found by check on cause 2, this check is not required. 1. Turn starting switch to OFF position. 2. Disconnect connectors ST1, ST2 and WLV1, and connect T-adapter Ground fault in wiring harness to either female side. (contact with ground circuit) Between ST2 (female) (6) and ST1 (female) Min. 1 Mz (4), or between WLV1 (female) (5) and (6) Resistance Between ST2 (female) (6) and ground, or Min. 1 Mz between WLV1 (female) (6) and ground If no failure is found by above checks, HST controller is defective. • Reference Turn starting switch to OFF position. Defective HST controller Insert T-adapters into connectors ST1 and ST2. 3% ' $ ~ $ $ 0.96 to 4.04 Voltage Between ST2 (6) and ST1 (4) V

40-324

D61EM-23M0

40 Troubleshooting

Troubleshooting by failure code (Display of code)

Circuit diagram related to blade tilt lever potentiometer

D61EM-23M0

40-325

40 Troubleshooting

Troubleshooting by failure code (Display of code)

Failure code [DFA9KB] Blade tilt lever2: Hot Short Action level L01 Detail of failure Action of controller Problem on machine Related information

No. 1

Failure code DFA9KB

Failure

Blade tilt lever 2: Hot Short (HST controller system)

• Signal voltage of blade tilt lever potentiometer system 2 is 4.5 V or above. • Continues blade control with signal from blade tilt lever potentiometer system 1. • None

Cause Defective 5 V sensor power supply system

Defective blade tilt lever potentiometer 2 (internal short circuit or ground fault)

Procedure, measuring location, criteria and remarks If failure code [DAJ6KK] is also displayed, perform troubleshooting for it first. 1. Turn starting switch to OFF position. 2. Disconnect connector WLV1. 3. Turn starting switch to ON position. If failure code [DFA9KB] disappears, blade tilt lever potentiometer is defective. (If failure code is still displayed, wiring harness or HST controller is defective.) a Since connector WLV1 is disconnected, many failure codes appear. Ignore all of displayed failure codes other than [DFA9KB].

Hot short circuit in wiring harness

Short circuit in wiring harness

Defective HST controller

40-326

1. Turn starting switch to OFF position. 2. Disconnect connector WLV1 and connect T-adapter to female side. 3. Turn starting switch to ON position. Voltage Between WLV1 (female) (6) and (5) or ground 7 to 11 V 1. Turn starting switch to OFF position. 2. Disconnect connectors ST2 and WLV1, and connect T-adapter to female side of ST2. a Check by using multimeter in continuity mode. Between ST2 (female) (6) and each No continuity (no Continuity pin other than pin (6) sound is heard) If no failure is found by above checks, HST controller is defective. • Reference Turn starting switch to OFF position. Insert T-adapters into connectors ST1 and ST2. Turn starting switch to ON position. 0.96 to 4.04 Voltage Between ST2 (6) and ST1 (4) V

D61EM-23M0

40 Troubleshooting

Troubleshooting by failure code (Display of code)

Circuit diagram related to blade tilt lever potentiometer

D61EM-23M0

40-327

40 Troubleshooting

Troubleshooting by failure code (Display of code)

Failure code [DGS1KA] HST oil temp sensor: Open Action level L01 Detail of failure

•

HST oil temperature sensor: Open Failure code Failure (HST controller system) DGS1KA As the HST oil temperature sensor signal circuit is open, the HST oil temperature signal exceeds the normal range. (HST oil temperature sensor signal voltage: 4.6 V or more (15° C or less) and water temperature: 85°C or more) Recognizes that HST oil temperature is 85°C. Controls fan speed to approximately 70%. If cause of failure disappears, machine becomes normal by itself.

Action of controller

• • •

Problem on machine

• Hydraulic oil temperature gauge points to MIN position.

Related information

• Input voltage from HST oil temperature sensor can be checked with monitoring function. (Code: 04402 "HST Temp. Sens Volt") • Oil temperature detected by HST oil temperature sensor can be checked with monitoring function. (Code: 04401 "HST Oil Temperature") • Input voltage from engine water temperature sensor can be checked with monitoring function. (Code: 30101 "Coolant Temp Sens Volt") • Water temperature detected by engine water temperature sensor can be checked with monitoring function. (Code: 30100 "Coolant Temperature") • The HST oil temperature sensor and controller can be accessed only after removing the seats. First, check the intermediate connector. • Method of reproducing failure code: Start engine (and raise engine water temperature above 85°C). • HST oil temperature is actually the same as the operating oil temperature.

No.

Cause

Procedure, measuring location, criteria and remarks

Defective HST oil temperature sensor system

1. Turn starting switch to OFF position. 2. Disconnect connector 104 and connect T-adapter to male side. Between HST oil temperature (100 to Approx. 3.1 to Resis- 104 (male) 10°C) 90kz tance (1) and (12) Between 102 (male) (1) and ground Min. 1 Mz

1. Turn starting switch to OFF position. 2. Disconnect connector 104 and connect T-adapter to female side. 3. Turn starting switch to ON position.

Open circuit, short circuit, ground fault, hot short circuit a If voltage is 0 V, wiring harness has open circuit, ground fault, or short circuit, and if voltage is 24 V, wiring harness has hot short circuit. of wiring harness, or defective HST controller a Voltage of approximately 5 V is applied to temperature sensor signal circuits through resistance in pump controller. Voltage Between 104 (female) (1) and (12) Approx. 5 V a If no failure is found by check on cause 1, this check is not required. 1. Turn starting switch to OFF position. 2. Disconnect connector 12 and connect T-adapter to male side. Defective HST oil 10°C Approx. 90 kz Between 12 (male) (1) and (2) temperature sensor 30°C Approx. 35 kz a Temperature-resistance (internal open or short circuit) Resischaracteristics of oil temperature 80°C Approx. 6.5 kz tance sensor 100°C Approx. 3.5 kz Min. 1 Mz Between 12 (male) (2) and ground

40-328

D61EM-23M0

40 Troubleshooting

Troubleshooting by failure code (Display of code)

Cause

Procedure, measuring location, criteria and remarks

Open circuit in wiring harness (wire breakage or defective contact of connector)

a If no failure is found by check on causes 1 and 2, this check is not required. 1. Turn starting switch to OFF position. 2. Disconnect connectors ST1 and 12, and connect T-adapter to female side of each connector. Between ST1 (female) (21) and 12 (female) Max. 1 z Resis- (2) tance Between ST1 (female) (9) and 12 (female) Max. 1 z (1)

a If no failure is found by check on causes 1 and 2, this check is not required. 1. Turn starting switch to OFF position. Short circuit in wiring harness 2. Disconnect connectors ST1 and 12, and connect T-adapter to female side of either connector. Resis- Between ST1 (female) (9) and (21), or Min. 1 Mz tance between 12 (female) (1) and (2)

No.

Ground fault in wiring harness (contact with ground circuit)

Defective HST controller

a If no failure is found by check on causes 1 and 2, this check is not required. 1. Turn starting switch to OFF position. 2. Disconnect connectors ST1 and 12, and connect T-adapter to female side of either connector. Resis- Between ground and either ST1 (female) (9) Min. 1 Mz tance or 12 (female) (1) If no failure is found by above checks, HST controller is defective. (Since this is an internal defect, troubleshooting cannot be performed.)

Circuit diagram related to HST oil temperature sensor

D61EM-23M0

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40 Troubleshooting

Troubleshooting by failure code (Display of code)

Failure code [DGS1KX] HST oil temp sensor: Out of normal range Action level L01 Detail of failure

•

HST oil temperature sensor: Out of normal range Failure code Failure (Transmission controller system) DGS1KX Due to ground fault in signal circuit of HST oil temperature sensor, oil temperature signal voltage is lower than normal range. (HST oil temperature sensor signal voltage: 0.97 V or less (150°C or more)) Cannot determine hydraulic oil temperature correctly. Generates a hydraulic oil temperature overheat caution. Sets the fan speed to 100%. If cause of failure disappears, machine becomes normal by itself.

Action of controller

• • • •

Problem on machine

• Hydraulic oil temperature gauge points MAX position.

Related information

No. 1

• Input voltage from HST oil temperature sensor can be checked with monitoring function. (Code: 04402 "HST Temp. Sens Volt") • Oil temperature of HST oil temperature sensor can be checked with monitoring function. (Code: 04401 "HST Oil Temperature") • Method of reproducing failure code: Turn starting switch to ON position. • HST oil temperature is actually the same as the operating oil temperature.

Cause Defective HST oil temperature sensor system

40-330

Procedure, measuring location, criteria and remarks Perform troubleshooting for failure codes [DGS1KA].

D61EM-23M0

40 Troubleshooting

Troubleshooting by failure code (Display of code)

Failure code [DH21KA] Weq pressure sensor: Open Action level L01 Detail of failure Action of controller Problem on machine

Failure code DH21KA

Failure

Work equipment pressure sensor: Open (HST controller)

• Signal voltage of work equipment pump pressure sensor is 0.2 V or lower. • None in particular • Oil pressure of work equipment pump cannot be monitored.

Related information

No.

Cause

Defective 5 V sensor power supply system

Procedure, measuring location, criteria and remarks If failure code [DBJ6KK] is also displayed, perform troubleshooting for it first. 1. Turn starting switch to OFF position. 2. Disconnect connector WP and connect T-adapter to female side. 3. Turn starting switch to ON position. a If power supply voltage is abnormal, go to check on cause 3 and after. Power 4.5 to 5.5 Voltage Between WP (female) (3) and (1) supply V 1. Turn starting switch to OFF position. 2. Insert T-adapter into connector WP. 3. Turn starting switch to ON position.

Defective work equipment pump pressure sensor (internal defect) or ground fault

a If power supply voltage is normal and sensor output voltage is abnormal (0.5 V or lower), it cannot be determined whether ground fault or defective sensor is the cause. In this case, go to check on cause 4. If no failure is found by check on cause 4, work equipment pump pressure sensor is defective. Sensor 0.5 to 4.5 Voltage Between WP (2) and (1) output V 1. Turn starting switch to OFF position. 2. Disconnect connectors ST1 and WP, and connect T-adapter to female side of each connector.

Open circuit in wiring harness (wire breakage or defective contact of connector)

a If power supply voltage in check on cause 1 is normal, this check is not required. Between ST1 (female) (22) and WP (female) (3) Resistance

a If power supply voltage in check on cause 1 is normal, this check is not required. Between ST1 (female) (13) and WP (female) (1) Between ST1 (female) (14) and WP (female) (2)

Max. 1 z

a If no failure is found by check on cause 2, this check is not required. 1. Turn starting switch to OFF position. 2. Disconnect connectors ST1 and WP, and connect T-adapter to Ground fault in wiring harness female side of either connector. (contact with ground circuit) Between ST1 (female) (14) and (13), or Min. 1 Mz Resis- between WP (female) (2) and (1) tance Between ST1 (female) (14) and ground, or Min. 1 Mz between WP (female) (2) and ground

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40 Troubleshooting

Troubleshooting by failure code (Display of code)

No.

Cause

Defective HST controller

Circuit diagram related to work equipment pump oil pressure sensor

40-332

D61EM-23M0

40 Troubleshooting

Troubleshooting by failure code (Display of code)

Failure code [DH21KB] Weq pressure sensor: Hot Short Action level L01 Detail of failure Action of controller Problem on machine

Failure code DH21KB

Failure

Work equipment pressure sensor: Hot Short (HST controller)

• Signal voltage of work equipment pump pressure sensor is 4.8 V or above. • None in particular • Oil pressure of work equipment pump cannot be monitored.

Related information

• Signal voltage of work equipment pump pressure sensor can be checked with monitoring function. (Code: 70701 "Hydraulic Pressure Sensor") • Method of reproducing failure code: Turn starting switch to ON position. • Even when system works properly, failure code [DH21KA] appears if sensor connector is disconnected and starting switch is turned to ON position.

No.

Cause

Defective 5 V sensor power supply system

Procedure, measuring location, criteria and remarks If failure code [DBJ6KK] is also displayed, perform troubleshooting for it first. 1. Turn starting switch to OFF position. 2. Disconnect connector WP and connect T-adapter to female side. 3. Turn starting switch to ON position. a If power supply voltage is unusual, go to cause 3 and after. Power 4.5 to 5.5 Voltage Between WP (female) (3) and (1) supply V

Defective work equipment pump pressure sensor (internal defect) or ground fault

1. Turn starting switch to OFF position. 2. Disconnect connector WP. 3. Turn starting switch to ON position. If failure code [DH21KB] disappears and [DH21KA] for open circuit appears, work equipment pump oil pressure sensor is defective. (If failure code [DH21KB] is still displayed, wiring harness or HST controller is defective.)

Hot short circuit in wiring harness

1. Turn starting switch to OFF position. 2. Disconnect connector WP and connect T-adapter to female side. 3. Turn starting switch to ON position. Voltage Between WP (female) (2) and (1) or ground Max. 1 V 1. Turn starting switch to OFF position. 2. Disconnect connectors ST1 and WP, and connect T-adapter to female side of ST1.

Short circuit in wiring harness

Defective HST controller

D61EM-23M0

a Check by using multimeter in continuity mode. No continuity Between ST1 (female) (14) and Continuity each pin other than (14) (No sound is heard) If no failure is found by above checks, HST controller is defective. • Reference 1. Turn starting switch to OFF position. 2. Insert T-adapter into connector ST1. 3. Turn starting switch to ON position. 0.5 to 4.5 Voltage Between ST1 (14) and (13) V

40-333

40 Troubleshooting

Troubleshooting by failure code (Display of code)

Circuit diagram related to work equipment pump oil pressure sensor

40-334

D61EM-23M0

40 Troubleshooting

Troubleshooting by failure code (Display of code)

Failure code [DHA4KA] Air Cleaner Clog Sensor Open Circuit Action level L01 Detail of failure Action of controller Problem on machine Related information No. 1

Air Cleaner Clogging Sensor Open Circuit Failure code Failure (Machine monitor system) DHA4KA • Air cleaner clogging switch signal voltage became not below 1 V when starting switch is turned to the ON position, and machine monitor determines that air cleaner clogging sensor circuit is open (open of sensor contacts). • Displays air cleaner clogging monitor in yellow on machine monitor. • If machine is used as it is, engine may be damaged. • Input signal (ON/OFF) from air cleaner clogging switch can be checked with monitoring function. (Code: 04501" Monitor input 2"） • Method of reproducing failure code: Turn starting switch to ON position.

Cause When air cleaner is clogged (When system works properly)

Procedure, measuring location, criteria and remarks Air cleaner may be clogged. Check it for clogging and then clean or replace if clogged.

1. Turn starting switch to OFF position. 2. Disconnect connector 116 and connect T-adapter to male side. 3. Turn starting switch to ON position. Defective air cleaner clogging Air cleaner: When switch (internal open circuit) Max. 1 z normal *1 Resis- Between 116 (male) (1) Air cleaner: When and (2) tance Min. 1 Mz clogged *2

1. Turn starting switch to OFF position. Open circuit in wiring harness 2. Disconnect connectors CM02 and 116, and insert T-adapters to each female side. (wire breakage or defective contact of connector) Resis- Between CM02 (female) (4) and 116 (female) Max. 1 z (1) tance

Defective machine monitor

1. Turn starting switch to OFF position. 2. Insert T-adapters into connectors CM01 and CM02. 3. Turn starting switch to ON position. Air cleaner: When Between CM02 (4) and normal Voltage CM01 (3) Air cleaner: When clogged

Max. 1 V 10 V

• Air cleaner suction resistance *1: Max. -3,430 Pa {-350 mmH2O} *2: -7,470 ± 490 Pa {-762 ± 50 mmH2O}

D61EM-23M0

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40 Troubleshooting

Troubleshooting by failure code (Display of code)

Circuit diagram related to air cleaner clogging sensor

40-336

D61EM-23M0

40 Troubleshooting

Troubleshooting by failure code (Display of code)

Failure code [DHH7KA] LF HST Pressure Sensor: Open Action level L03 Detail of failure

Action of controller

Problem on machine

Related information

Failure code DHH7KA

Failure

LF HST pressure sensor: Open (HST controller system)

• Signal voltage from left HST pump pressure sensor is 0.3 V or less. • Displays the HST system status on the machine monitor. • Uses the pressure signal received before failure occurrence to control the machine until machine stops. • Determines that the pump pressure is 3.0 MPa {30 kg/cm2} once after the machine stops. • Even if cause of failure disappears, machine does not become normal until starting switch is turned to the OFF position. • Once the machine stops, engine speed is restricted to medium (half) speed. • The straight travel correction does not work normally. • The engine stops or stalls easily when loaded. • The electronic cut-off does not work. • Be extremely careful not to connect the 5V circuit (3) and GND circuit (1) reversely to prevent pressure sensor from being damaged when checking. • The input pressure and voltage from left HST pump pressure sensor can be checked with the monitoring function. (Code: 52503 "LF HST Pressure", Code: 52502 "LF HST Pressure Sensor") • Method of reproducing failure code: Turn starting switch to the ON position or start engine.

No.

Cause

Defective 5 V sensor power supply system

Defective left forward HST pressure sensor (internal defect) or ground fault

a If power supply voltage is normal and sensor output voltage is abnormal (0.5 V or lower), it cannot be determined whether internal open circuit or ground fault is the cause. In this case, go to cause 4. If no failure is found in check on cause 4, left forward HST pressure sensor is defective. Sensor 0.4 to 4.5 Voltage Between LPF (female) (2) and (1) output V 1. Turn starting switch to OFF position. 2. Disconnect connectors ST1, ST2 and LPF, and connect T-adapter to each female side.

Open circuit in wiring harness (wire breakage or defective contact of connector)

D61EM-23M0

a If power supply voltage in check on cause 1 is normal, this check is not required. Between ST1 (female) (22) and LPF (female) (3) Resistance

a If power supply voltage in check on cause 1 is normal, this check is not required. Between ST1 (female) (21) and LPF (female) (1) Between ST2 (female) (35) and LPF (female) (2)

Max. 1 z

Max. 1 z Max. 1 z

40-337

40 Troubleshooting

Troubleshooting by failure code (Display of code)

No.

Cause

Procedure, measuring location, criteria and remarks

a If no failure is found by check on cause 2, this check is not required. 1. Turn starting switch to OFF position. 2. Disconnect connectors ST1, ST2 and LPF, and connect T-adapter to Ground fault in wiring harness each female side. (contact with ground circuit) Between ST2 (female) (35) and ST1 (female) Min. 1 Mz Resis- (21), or between LPF (female) (2) and (1) tance Between ST1 (female) (35) and ground, or Min. 1 Mz between LPF (female) (2) and ground If no failure is found by above checks, HST controller is defective. • Reference 1. Turn starting switch to OFF position. Defective HST controller 2. Insert T-adapter into connectors ST1 and ST2. 3. Turn starting switch to ON position. 0.5 to 4.5 Voltage Between ST2 (35) and ST1 (21) V

Circuit diagram related to left forward HST pressure sensor

40-338

D61EM-23M0

40 Troubleshooting

Troubleshooting by failure code (Display of code)

Failure code [DHH7KB] LF HST Pressure Sensor: Hot Short Action level L03 Detail of failure

Action of controller

Problem on machine

Related information

Failure code DHH7KB

Failure

LF HST pressure sensor: Hot short (HST controller)

• Signal voltage from left HST pump pressure sensor is 4.7 V or above. • Displays the HST system status on the machine monitor. • Uses the pressure signal received before failure occurrence to control the machine until machine stops. • Determines that the pump pressure is 3.0 MPa {30 kg/cm2} once after the machine stops. • Even if cause of failure disappears, machine does not become normal until starting switch is turned to the OFF position. • Once machine stops, engine speed is restricted to medium (half) speed. • The straight travel correction does not work normally. • The engine stops or stalls easily when loaded. • The electronic cut-off does not work. • Be extremely careful not to connect the 5V circuit (3) and GND circuit (1) reversely to prevent sensor from being damaged when checking. • The input pressure and voltage from left HST pump pressure sensor can be checked with the monitoring function. (Code: 52503 "LF HST Pressure", Code: 52502 "LF HST Pressure Sensor") • Method of reproducing failure code: Turn starting switch to the ON position or start engine.

No.

Cause

Defective 5 V sensor power supply system

Defective left forward HST pressure sensor (internal defect) or ground fault

1. Turn starting switch to OFF position. 2. Disconnect connector LPF. 3. Turn starting switch to ON position. If failure code [DHH7KB] disappears and [DHH7KA] for open circuit appears, left forward HST pressure sensor is defective. (If failure code [DHH7KB] is still displayed, wiring harness or HST controller is defective.)

Hot short circuit in wiring harness

1. Turn starting switch to OFF position. 2. Disconnect connector LPF and connect T-adapter to female side. 3. Turn starting switch to ON position. Voltage Between LPF (female) (2) and (1) or ground Max. 1 V 1. Turn starting switch to OFF position. 2. Disconnect connectors ST2 and LPF, and connect T-adapter to female side of ST2.

Short circuit in wiring harness

Defective HST controller

D61EM-23M0

a Check by using multimeter in continuity mode. No continuity Between ST2 (female) (35) and Continuity each pin other than pin (35) (No sound is heard) If no failure is found by above checks, HST controller is defective. • Reference 1. Turn starting switch to OFF position. 2. Insert T-adapter into connectors ST1 and ST2. 3. Turn starting switch to ON position. 0.5 to 4.5 Voltage Between ST2 (35) and ST1 (21) V

40-339

40 Troubleshooting

Troubleshooting by failure code (Display of code)

Circuit diagram related to left forward HST pressure sensor

40-340

D61EM-23M0

40 Troubleshooting

Troubleshooting by failure code (Display of code)

Failure code [DHH8KA] RF HST Pressure Sensor: Open Action level L03 Detail of failure

Action of controller

Problem on machine

Related information

Failure code DHH8KA

Failure

RF HST pressure sensor: Open (HST controller system)

• Signal voltage from right HST pump pressure sensor is 0.3 V or less. • Displays the HST system status on the machine monitor. • Uses the pressure signal received before failure occurrence to control the machine until machine stops. • Determines that the pump pressure is 3.0 MPa {30 kg/cm2} once after the machine stops. • Even if cause of failure disappears, machine does not become normal until starting switch is turned to the OFF position. • Once machine stops, engine speed is restricted to medium (half) speed. • The straight travel correction does not work normally. • The engine stops or stalls easily when loaded. • The electronic cut-off does not work. • Be extremely careful not to connect the 5V circuit (3) and GND circuit (1) reversely to prevent pressure sensor from being damaged when checking. • The input pressure and voltage from right HST pump pressure sensor can be checked with the monitoring function. (Code: 52501 "RF HST Pressure", Code: 52500 "RF HST Pressure Sensor") • Method of reproducing failure code: Turn starting switch to the ON position or start engine.

No.

Cause

Defective 5 V sensor power supply system

Defective right forward HST circuit pressure sensor (internal defect) or ground fault

a If power supply voltage is normal and sensor output voltage is abnormal (0.5 V or lower), it cannot be determined whether internal open circuit or ground fault is the cause. In this case, go to cause 4. If no failure is found in check on cause 4, the right forward HST circuit pressure sensor is defective. Sensor 0.4 to 4.5 Voltage Between RPF (2) and (1) output V 1. Turn starting switch to OFF position. 2. Disconnect connectors ST1, ST2 and RPF, and connect T-adapter to each female side.

Open circuit in wiring harness (wire breakage or defective contact of connector)

D61EM-23M0

a If power supply voltage in check on cause 1 is normal, this check is not required. Between ST1 (female) (22) and RPF (female) (3) Resistance

a If power supply voltage in check on cause 1 is normal, this check is not required. Between ST1 (female) (21) and RPF (female) (1) Between ST2 (female) (25) and RPF (female) (2)

Max. 1 z

Max. 1 z Max. 1 z

40-341

40 Troubleshooting

Troubleshooting by failure code (Display of code)

No.

Cause

Procedure, measuring location, criteria and remarks

a If no failure is found by check on cause 2, this check is not required. 1. Turn starting switch to OFF position. 2. Disconnect connectors ST1 and RPF, and Insert T-adapter to either Ground fault in wiring harness female side. (contact with ground circuit) Between ST2 (female) (25) and ST1 (female) Min. 1 Mz Resis- (21), or between RPF (female) (1) and (2) tance Between ST2 (female) (25) and ground, or Min. 1 Mz between RPF (female) (2) and ground If no failure is found by above checks, HST controller is defective. • Reference 1. Turn starting switch to OFF position. Defective HST controller 2. Insert T-adapter into connectors ST1 and ST2. 3. Turn starting switch to ON position. 0.5 to 4.5 Voltage Between ST2 (25) and ST1 (21) V

Circuit diagram related to right forward HST circuit pressure sensor

40-342

D61EM-23M0

40 Troubleshooting

Troubleshooting by failure code (Display of code)

Failure code [DHH8KB] RF HST Pressure Sensor: Hot Short Action level L03 Detail of failure Action of controller

Problem on machine

Related information

Failure code DHH8KB

Failure

RF HST pressure sensor: Hot short (HST controller)

• Signal voltage from right HST pump pressure sensor is 4.7 V or above. • Displays the HST system status on the machine monitor. • Uses the pressure signal received before failure occurrence to control the machine until machine stops. • Determines that the pump pressure is 3.0 MPa {30 kg/cm2} once after the machine stops. • Even if cause of failure disappears, machine does not become normal until starting switch is turned to the OFF position. • Once machine stops, engine speed is restricted to medium (half) speed. • The straight travel correction does not work normally. • The engine stops or stalls easily when loaded. • The electronic cut-off does not work. • Be extremely careful not to connect 5V circuit (3) and GND circuit (1) reversely to prevent pressure sensor from being damaged when checking. • The input pressure and voltage from right HST pump pressure sensor can be checked with the monitoring function. (Code: 52501 "RF HST Pressure", Code: 52500 "RF HST Pressure Sensor") • Method of reproducing failure code: Turn starting switch to the ON position or start engine.

No.

Cause

Defective 5 V sensor power supply system

Defective right forward HST circuit pressure sensor (internal defect) or ground fault

1. Turn starting switch to OFF position. 2. Disconnect connector RPF. 3. Turn starting switch to ON position. If failure code [DHH8KB] disappears and [DHH8KA] for open circuit appears, right forward HST pressure sensor is defective. (If failure code [DHH8KB] is still displayed, wiring harness or HST controller is defective.)

Hot short circuit in wiring harness

1. Turn starting switch to OFF position. 2. Disconnect connector RPF and connect T-adapter to female side. 3. Turn starting switch to ON position. Voltage Between RPF (female) (2) and (1) or ground Max. 1 V 1. Turn starting switch to OFF position. 2. Disconnect connectors ST1 and RPF, and connect T-adapter to female side of ST1.

Short circuit in wiring harness

Defective HST controller

D61EM-23M0

a Check by using multimeter in continuity mode. No continuity Between ST1 (female) (25) and Continuity each pin other than (25) (No sound is heard) If no failure is found by above checks, HST controller is defective. • Reference 1. Turn starting switch to OFF position. 2. Insert T-adapter into connectors ST1 and ST2. 3. Turn starting switch to ON position. 0.5 to 4.5 Voltage Between ST2 (25) and ST1 (21) V

40-343

40 Troubleshooting

Troubleshooting by failure code (Display of code)

Circuit diagram related to right forward HST circuit pressure sensor

40-344

D61EM-23M0

40 Troubleshooting

Troubleshooting by failure code (Display of code)

Failure code [DHH9KA] LR HST Pressure Sensor: Open Action level L03 Detail of failure

Action of controller

Problem on machine

Related information

Failure code DHH9KA

Failure

LR HST pressure sensor: Open (HST controller)

• Signal voltage from left HST pump pressure sensor is 0.3 V or less. • Displays the HST system status on the machine monitor. • Uses the pressure signal received before failure occurrence to control the machine until machine stops. • Determines that the pump pressure is 3.0 MPa {30 kg/cm2} once after the machine stops. • Even if cause of failure disappears, machine does not become normal until starting switch is turned to the OFF position. • Once machine stops, engine speed is restricted to medium (half) speed. • The straight travel correction does not work normally. • The engine stops or stalls easily when loaded. • The electronic cut-off does not work. • Be extremely careful not to connect 5V circuit (3) and GND circuit (1) reversely to prevent pressure sensor from being damaged when checking. • The input pressure and voltage from left HST pump pressure sensor can be checked with the monitoring function. (Code: 52507 "LR HST Pressure", Code: 52506 "LR HST Pressure Sensor") • Method of reproducing failure code: Turn starting switch to the ON position or start engine.

No.

Cause

Defective 5 V sensor power supply system

Defective left reverse HST circuit pressure sensor (internal defect) or ground fault

a If power supply voltage is normal and sensor output voltage is abnormal (0.5 V or lower), it cannot be determined whether internal open circuit or ground fault is the cause. In this case, go to cause 4. If no failure is found in check on cause 4, the left reverse HST circuit pressure sensor is defective. Sensor 0.4 to 4.5 Voltage Between LPR (female) (2) and (1) output V 1. Turn starting switch to OFF position. 2. Disconnect connectors ST1, ST2 and LPR, and connect T-adapter to each female side.

Open circuit in wiring harness (wire breakage or defective contact of connector)

D61EM-23M0

a If power supply voltage in check on cause 1 is normal, this check is not required. Between ST1 (female) (22) and LPR (female) (3) Resistance

a If power supply voltage in check on cause 1 is normal, this check is not required. Between ST1 (female) (21) and LPR (female) (1) Between ST2 (female) (15) and LPR (female) (2)

Max. 1 z

Max. 1 z Max. 1 z

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40 Troubleshooting

Troubleshooting by failure code (Display of code)

No.

Cause

Procedure, measuring location, criteria and remarks

a If no failure is found by check on cause 2, this check is not required. 1. Turn starting switch to OFF position. 2. Disconnect connectors ST1, ST2 and LPR, and connect T-adapter Ground fault in wiring harness to female side of either connector. (contact with ground circuit) Between ST2 (female) (15) and ST1 (female) Min. 1 Mz Resis- (21), or between LPR (female) (2) and (1) tance Between ST2 (female) (15) and ground, or Min. 1 Mz between LPR (female) (2) and ground If no failure is found by above checks, HST controller is defective. • Reference 1. Turn starting switch to OFF position. Defective HST controller 2. Insert T-adapter into connectors ST1 and ST2. 3. Turn starting switch to ON position. 0.5 to 4.5 Voltage Between ST2 (15) and ST1 (21) V

Circuit diagram related to left reverse HST circuit pressure sensor

40-346

D61EM-23M0

40 Troubleshooting

Troubleshooting by failure code (Display of code)

Failure code [DHH9KB] LR HST Pressure Sensor: Hot Short Action level L03 Detail of failure Action of controller

Problem on machine

Related information

Failure code DHH9KB

Failure

LR HST pressure sensor: Hot short (HST controller)

• Signal voltage from left HST pump pressure sensor is 4.7 V or above. • Displays the HST system status on the machine monitor. • Uses the pressure signal received before failure occurrence to control the machine until machine stops. • Determines that the pump pressure is 3.0 MPa {30 kg/cm2} once after the machine stops. • Even if cause of failure disappears, machine does not become normal until starting switch is turned to the OFF position. • Once machine stops, engine speed is restricted to medium (half) speed. • The straight travel correction does not work normally. • The engine stops or stalls easily when loaded. • The electronic cut-off does not work. • Be extremely careful not to connect 5V circuit (3) and GND circuit (1) reversely to prevent pressure sensor from being damaged when checking. • The input pressure and voltage from left HST pump pressure sensor can be checked with the monitoring function. (Code: 52507 "LR HST Pressure", Code: 52506 "LR HST Pressure Sensor") • Method of reproducing failure code: Turn starting switch to the ON position or start engine.

No.

Cause

Defective 5 V sensor power supply system

Defective left reverse HST circuit pressure sensor (internal defect) or ground fault

1. Turn starting switch to OFF position. 2. Disconnect connector LPR. 3. Turn starting switch to ON position. If failure code [DHH9KB] disappears and [DHH9KA] for open circuit appears, right forward HST pressure sensor is defective. (If failure code [DHH9KB] is still displayed, wiring harness or HST controller is defective.)

Hot short circuit in wiring harness

1. Turn starting switch to OFF position. 2. Disconnect connector LPR and connect T-adapter to female side. 3. Turn starting switch to ON position. Voltage Between LPR (female) (2) and (1) or ground Max. 1 V 1. Turn starting switch to OFF position. 2. Disconnect connectors ST2 and LPR, and connect T-adapter to female side of ST2.

Short circuit in wiring harness

Defective HST controller

D61EM-23M0

a Check by using multimeter in continuity mode. No continuity Between ST2 (female) (15) and Continuity each pin other than pin (15) (No sound is heard) If no failure is found by above checks, HST controller is defective. • Reference 1. Turn starting switch to OFF position. 2. Insert T-adapter into connectors ST1 and ST2. 3. Turn starting switch to ON position. 0.5 to 4.5 Voltage Between ST2 (15) and ST1 (21) V

40-347

40 Troubleshooting

Troubleshooting by failure code (Display of code)

Circuit diagram related to left reverse HST circuit pressure sensor

40-348

D61EM-23M0

40 Troubleshooting

Troubleshooting by failure code (Display of code)

Failure code [DHHAKA] RR HST Pressure Sensor: Open Action level L03 Detail of failure

Action of controller

Problem on machine

Related information

Failure code DHHAKA

Failure

RR HST pressure sensor: Open (HST controller)

• Signal voltage from right HST pump pressure sensor is 0.3 V or above. • Displays the HST system status on the machine monitor. • Uses the pressure signal, received before failure occurrence, to control the machine until machine stops. • Determines that the pump pressure is 3.0 MPa {30 kg/cm2} once after the machine stops. • Even if cause of failure disappears, machine does not become normal until starting switch is turned to the OFF position. • Once machine stops, engine speed is restricted to medium (half) speed. • The straight travel correction does not work normally. • The engine stops or stalls easily when loaded. • The electronic cut-off does not work. • Be extremely careful not to connect 5V circuit (3) and GND circuit (1) reversely to prevent pressure sensor from being damaged when checking. • The input pressure and voltage from right HST pump pressure sensor can be checked with the monitoring function. (Code: 52505 "RR HST Pressure", Code: 52504 "RR HST Pressure Sensor") • Method of reproducing failure code: Turn starting switch to the ON position or start engine.

No.

Cause

Defective 5 V sensor power supply system

Defective right reverse HST circuit pressure sensor (internal defect) or ground fault

a If power supply voltage is normal and sensor output voltage is abnormal (0.5 V or lower), it cannot be determined whether internal open circuit or ground fault is the cause. In this case, go to cause 4. If no failure is found in check on cause 4, the right reverse HST circuit pressure sensor is defective. Sensor 0.5 to 4.5 Voltage Between RPR (2) and (1) output V 1. Turn starting switch to OFF position. 2. Disconnect connectors ST1, ST2 and RPR, and connect T-adapter to each female side.

Open circuit in wiring harness (wire breakage or defective contact of connector)

D61EM-23M0

a If power supply voltage in check on cause 1 is normal, this check is not required. Between ST1 (female) (22) and RPR (female) (3) Resistance

a If power supply voltage in check on cause 1 is normal, this check is not required. Between ST1 (female) (21) and RPR (female) (1) Between ST2 (female) (5) and RPR (female) (2)

Max. 1 z

Max. 1 z Max. 1 z

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40 Troubleshooting

Troubleshooting by failure code (Display of code)

No.

Cause

Procedure, measuring location, criteria and remarks

a If no failure is found by check on cause 2, this check is not required. 1. Turn starting switch to OFF position. 2. Disconnect connectors ST1, ST2 and RPR, and connect T-adapter Ground fault in wiring harness to female side of either connector. (contact with ground circuit) Between ST2 (female) (5) and ST1 (female) Min. 1 Mz Resis- (21), or between RPR (female) (1) and (2) tance Between ST2 (female) (5) and ground, or Min. 1 Mz between RPR (female) (2) and ground If no failure is found by above checks, HST controller is defective. • Reference 1. Turn starting switch to OFF position. Defective HST controller 2. Insert T-adapter into connectors ST1 and ST2. 3. Turn starting switch to ON position. 0.5 to 4.5 Voltage Between ST2 (5) and ST1 (21) V

Circuit diagram related to right reverse HST pressure sensor

40-350

D61EM-23M0

40 Troubleshooting

Troubleshooting by failure code (Display of code)

Failure code [DHHAKB] RR HST Pressure Sensor: Hot Short Action level L03 Detail of failure Action of controller

Problem on machine

Related information

Failure code DHHAKB

Failure

RR HST Pressure Sensor: Hot Short (HST controller)

• Signal voltage from right HST pump pressure sensor is 4.7 V or above. • Displays the HST system status on the machine monitor. • Uses the pressure signal, received before failure occurrence, to control the machine until machine stops. • Determines that the pump pressure is 3.0 MPa {30 kg/cm2} once after the machine stops. • Even if cause of failure disappears, machine does not become normal until starting switch is turned to the OFF position. • Once machine stops, engine speed is restricted to medium (half) speed. • The straight travel correction does not work normally. • The engine stops or stalls easily when loaded. • The electronic cut-off does not work. • Be extremely careful not to connect 5V circuit (3) and GND circuit (1) reversely to prevent pressure sensor from being damaged when checking. • The input pressure and voltage from right HST pump pressure sensor can be checked with the monitoring function. (Code: 52505 "RR HST Pressure", Code: 52504 "RR HST Pressure Sensor") • Method of reproducing failure code: Turn starting switch to the ON position or start engine.

No.

Cause

Defective 5 V sensor power supply system

Defective right reverse HST circuit pressure sensor (internal defect) or ground fault

1. Turn starting switch to OFF position. 2. Disconnect connector RPR. 3. Turn starting switch to ON position. If failure code [DHHAKB] disappears and [DHHAKA] for open circuit appears, right forward HST pressure sensor is defective. (If failure code [DHHAKB] is still displayed, wiring harness or HST controller is defective.)

Hot short circuit in wiring harness

1. Turn starting switch to OFF position. 2. Disconnect connector RPR and connect T-adapter to female side. 3. Turn starting switch to ON position. Voltage Between RPR (female) (2) and (1) or ground Max. 1 V 1. Turn starting switch to OFF position. 2. Disconnect connectors ST2 and RPR, and connect T-adapter to female side of ST2.

Short circuit in wiring harness

Defective HST controller

D61EM-23M0

a Check by using multimeter in continuity mode. No continuity Between ST2 (female) (5) and Continuity each pin other than pin (5) (No sound is heard) If no failure is found by above checks, HST controller is defective. • Reference 1. Turn starting switch to OFF position. 2. Insert T-adapter into connectors ST1 and ST2. 3. Turn starting switch to ON position. 0.5 to 4.5 Voltage Between ST2 (5) and ST1 (21) V

40-351

40 Troubleshooting

Troubleshooting by failure code (Display of code)

Circuit diagram related to right reverse HST circuit pressure sensor

40-352

D61EM-23M0

40 Troubleshooting

Troubleshooting by failure code (Display of code)

Failure code [DK30KA] ST lever1: Open Action level L03 Detail of failure Action of controller

Steering lever 1: Open Failure code Failure (HST controller system) DK30KA • Signal voltage of joystick (steering, directional, and gear shift lever) steering potentiometer 1 (ST lever 1) is 0.5 V or lower. • Continues to control with signal of joystick (steering, directional, and gear shift lever) steering potentiometer 2 (ST lever 2). • Restricts engine operation.

Problem on machine

• Once machine stops, engine speed is restricted to medium (half) speed.

Related information

• Signal voltage of joystick (steering, directional, and gear shift lever) steering potentiometer 1 can be checked with monitoring function. (Code: 50300"S/T Lever1 Potentio") • Method of reproducing failure code: Turn starting switch to ON position and operate joystick (steering, directional, and gear shift lever) (for steering).

No.

Cause

Procedure, measuring location, criteria and remarks If failure code [DAJ6KK] is also displayed, perform troubleshooting for it first.

1. Turn starting switch to OFF position. 2. Disconnect connector EL1 and connect T-adapter to female side. Defective 5 V sensor power supply 1 3. Turn starting switch to ON position. system a If power supply voltage is abnormal, go to check on cause 3 and after. Voltage

Between EL1 (female) (5) and (1)

Power supply

4.5 to 5.5 V

1. 2. 3. 4.

Turn starting switch to OFF position. Insert T-adapter into connector EL1. Turn starting switch to ON position. Perform troubleshooting by operating joystick (steering, directional). Check with planter system power switch HSW in ON and OFF position. Defective joystick (steering, direc- a If measured value varies with position of this switch, Hexagon controller tional, and gear shift lever) steer13Y-06-17540 is defective. 2 ing potentiometer 1 (internal open a If power supply voltage is normal and potentiometer output voltage is circuit) or ground fault abnormal (0.5 V or lower), it cannot be determined whether ground fault or defective potentiometer is the cause. In this case, go to check on cause 4. If no failure is found by check on cause 4, joystick (steering, directional, and gear shift lever) steering potentiometer 1 is defective. Voltage

Between EL1 (7) and (8)

0.5 to 4.5 V

1. Turn starting switch to OFF position. 2. Disconnect connectors ST1 and EL1, and connect T-adapters to female side of each connector. Open circuit in wiring harness 3 (wire breakage or defective contact of connector)

a If power supply voltage in check on cause 1 is normal, this check is not required. Between ST1 (female) (22) and EL1 (female) (5)

Max. 1 z

Resistance a If power supply voltage in check on cause 1 is normal, this check is not required. Between ST1 (female) (4) and EL1 (female) (8)

Max. 1 z

Between ST1 (female) (19) and EL1 (female) (7)

Ground fault in wiring harness (contact with ground circuit)

a If no failure is found by check on cause 2, this check is not required. 1. Turn starting switch to OFF position. 2. Disconnect connectors ST1 and EL1, and connect T-adapter to female side of either connector.

Resistance

D61EM-23M0

Max. 1 z

Between ST1 (female) (19) and (4), or between EL1 (female) (7) and (8)

Min. 1 Mz

Between ST1 (female) (19) and ground, or between EL1 (female) (7) and ground

Min. 1 Mz

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40 Troubleshooting

Troubleshooting by failure code (Display of code)

No.

Cause

5 Defective Hexagon controller

Procedure, measuring location, criteria and remarks If no abnormality is detected by above diagnosis, Hexagon controller 13Y-0617540 may be defective. q Reference 1. Turn starting switch to OFF position. 2. Disconnect connector HC1B and connect T-adapter to male of connector on controller. Resistance Between connector HC1B (male) (4) and (8)

Max.1Ω

If no failure is found by above checks, HST controller is defective. Reference 1. Turn starting switch to OFF position. 2. Insert T-adapter into connector ST1 . 3. Turn starting switch to ON position. 4. Perform troubleshooting by operating joystick (steering, directional, and gear shift lever) (steering).

6 Defective HST controller

Voltage

40-354

Between ST1 (19) and (4)

0.5 to 4.5 V

D61EM-23M0

40 Troubleshooting

Troubleshooting by failure code (Display of code)

Circuit diagram related to steering lever

D61EM-23M0

40-355

40 Troubleshooting

Troubleshooting by failure code (Display of code)

Failure code [DK30KB] ST lever1: Hot Short Action level L03 Detail of failure Action of controller

Steering lever 1: Hot Short Failure code Failure (HST controller) DK30KB • Signal voltage of joystick (steering, directional, and gear shift lever steering) potentiometer 1 (ST lever 1) is 4.5 V or more. • Continues to control with signals of joystick (steering, directional, and gear shift leer) steering potentiometer 2 (ST lever 2). • Restricts engine operations.

Problem on machine

• Once machine stops, engine speed is restricted to medium (half) speed.

Related information

No. 1

Cause Defective 5 V sensor power supply system

Procedure, measuring location, criteria and remarks If failure code [DAJ6KK] is also displayed, perform troubleshooting for it first.

Defective 7 + '$ ^% $2 *38 $ $

Turn starting switch to OFF position. Disconnect connector EL 56 . 8 2 $ 56 ( ) $ 56 (& ) Turn starting switch to ON position. Perform troubleshooting by operating joystick (steering). If failure code [DK30KB] disappear , 7 + '$ ^% $2*38 $ $ & , ^ & ~3 &$ $ ' . % $ $ $ $ $ ' $ $

Turn starting switch to OFF position. Disconnect connector EL . Turn starting switch to ON position. Defective joystick (steering, Perform troubleshooting by operating joystick (steering, directional, directional, and gear shift and gear shift levers) (steering). lever) steering potentiometer If failure code [DK30KB] disappears, joystick (steering, directional, and 1 (internal short circuit) or gear shift lever) steering potentiometer is defective. (If failure code is still ground fault displayed, wiring harness or HST controller is defective.) a Since connector EL1 is disconnected, many failure codes appear. Ignore all of displayed failure codes other than [DK30KB]. Hot short circuit in wiring harness

Turn starting switch to OFF position. Disconnect connector EL and connect T-adapter to female side. Turn starting switch to ON position. Voltage Between EL (female) (7) and (8) or ground 7 to 11 V Turn starting switch to OFF position. Disconnect connectors ST1 and EL , and connect T-adapter to female side of ST1.

Short circuit in wiring harness a Check by using multimeter in continuity mode. No continuity (No sound is heard) If no failure is found by above checks, HST controller is defective. • Reference Turn starting switch to OFF position. Insert T-adapter into connector ST1. Turn starting switch to ON position. Perform troubleshooting by operating joystick (steering, directional, and gear shift lever) (steering). Voltage Between ST1 (19) and (4) 0.5 to 4.5 V

Between ST1 (female) (19) and each pin other Continuity than (19)

Defective HST controller

40-356

D61EM-23M0

40 Troubleshooting

Troubleshooting by failure code (Display of code)

Circuit diagram related to steering lever potentiometer

D61EM-23M0

40-357

40 Troubleshooting

Troubleshooting by failure code (Display of code)

Failure code [DK30KX] ST lever: Main and Sub Error Action level L04 Detail of failure Action of controller Problem on machine

Related information

Steering lever: Main and Sub Error Failure code Failure (Defective HST controller) DK30KX • In joystick (steering, directional, and gear shift lever) potentiometers 1 (ST lever 1) and 2 (ST lever 2), either of failure codes [DK30KA] and [DK30KB], and either of failure codes [DK31KA] and [DK31KB] are displayed at the same time. • Restricts engine operations. • Once machine stops, engine speed is restricted to medium (half) speed. • Once machine stops, it cannot travel at all. • Signal voltage of joystick (steering, directional, and gear shift lever) potentiometers can be checked with monitoring function. (Code: 50300"S/T Lever1 Potentio") (Code: 50301"S/T Lever2 Potentio") • Method of reproducing failure code: Turn starting switch to ON position and operate joystick (steering, directional, and gear shift levers) (for steering).

Procedure, measuring location, criteria and remarks Cause Perform troubleshoot for failure codes [DK30KA], [DK30KB], [DK31KA] and [DK31KB].

40-358

D61EM-23M0

40 Troubleshooting

Troubleshooting by failure code (Display of code)

Failure code [DK30KZ] ST lever: Main and Sub Error Action level L04 Detail of failure Action of controller Problem on machine

Related information

Steering lever: Main and Sub Error Failure code Failure (HST controller) DK30KZ • In joystick (steering, directional, and gear shift lever) potentiometers 1 (ST lever 1) or 2 (ST lever 2), starting switch is turned to ON position, only one side malfunctions and then either of failure codes [DK30KA] and [DK30KB], and either of failure codes [DK31KA] and [DK31KB] are displayed at the same time. • Restricts the engine brake operation. • Once machine stops, engine speed is restricted to medium (half) speed. • Once machine stops, it cannot travel at all. • Signal voltage of joystick (steering, directional, and gear shift lever) potentiometers can be checked with monitoring function. (Code: 50300"S/T Lever1 Potentio") (Code: 50301"S/T Lever2 Potentio") • Method of reproducing failure code: Turn starting switch to ON position and operate joystick (steering, directional, and gear shift levers) (for steering).

Procedure, measuring location, criteria and remarks Cause Perform troubleshoot for failure codes [DK30KA], [DK30KB], [DK31KA] and [DK31KB].

D61EM-23M0

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40 Troubleshooting

Troubleshooting by failure code (Display of code)

Failure code [DK30L8] ST lever: Signal mismatch Action level L03 Detail of failure Action of controller Problem on machine

Related information

• • • • • •

•

Steering lever: Signal mismatch Failure code Failure (HST controller) DK30L8 Total voltage of signals from joystick (steering, directional, and gear shift lever) potentiometers 1 (ST lever 1) and 2 (ST lever 2) is 4.41 V or less or 5.59 V or more. Continues control with signal of normal one of joystick (steering, directional, and gear shift lever) potentiometers 1 (ST lever 1) and 2 (ST lever 2). Restricts engine operations. Once machine stops, engine speed is restricted to medium (half) speed. Once machine stops, travel is restricted to F1 and R1. Signal voltage of joystick (steering, directional, and gear shift lever) potentiometers can be checked with monitoring function. (Code: 50300"S/T Lever1 Potentio") (Code: 50301"S/T Lever2 Potentio") Method of reproducing failure code: Turn starting switch to ON position and operate joystick (steering, directional, and gear shift levers) (for steering).

Procedure, measuring location, criteria and remarks Cause Perform troubleshoot for failure codes [DK30KA], [DK30KB], [DK31KA] and [DK31KB].

40-360

D61EM-23M0

40 Troubleshooting

Troubleshooting by failure code (Display of code)

Failure code [DK31KA] ST lever2: Open Action level L03 Detail of failure Action of controller

Steering lever 2: Open Failure code Failure (HST controller system) DK31KA • Signal voltage of joystick (steering, directional, and gear shift lever) steering potentiometer 2 (ST lever 2) is 0.5 V or lower. • Continues to control with signal of joystick (steering, directional, and gear shift lever) steering potentiometer 1 (ST lever 1). • Restricts engine operation.

Problem on machine

• Once machine stops, engine speed is restricted to medium (half) speed.

Related information

• Signal voltage of joystick (steering, directional, and gear shift lever) steering potentiometer 2 can be checked with monitoring function. (Code: 50301"S/T Lever2 Potentio") • Method of reproducing failure code: Turn starting switch to ON position and operate joystick (steering, directional, and gear shift lever) (for steering).

No.

Cause

Defective 5 V sensor power supply system

Defective potentiometer 2 for joystick (steering, directional, and gear shift lever) steering (internal open circuit) or ground fault

Open circuit in wiring harness (wire breakage or defective contact of connector)

Procedure, measuring location, criteria and remarks If failure code [DAJ6KK] is also displayed, perform troubleshooting for it first.

Turn starting switch to OFF position. Disconnect connector EL and connect T-adapter to female side. Turn starting switch to ON position. a If power supply voltage is abnormal, go to check on cause 3 and & Power 4.5 to 5.5 Voltage Between EL (female) (5) and (8) supply V Turn starting switch to OFF position. Insert T-adapter into connector EL . Turn starting switch to ON position. Perform troubleshooting by operating joystick (steering, directional) . ! $ 7*# ~ ~ $ $ & % , % , $ $ $& 7 + '$ $ $ 2 2 & , & $ % ! ,$ ' $ $ $ $% % ,$ ' abnormal (0.5 V or lower), it cannot be determined whether ground fault or defective potentiometer is the cause. In this case, go to check on cause 4. If no failure is found by check on cause 4, joystick (steering, directional, and gear shift lever) steering potentiometer 2 is defective. 0.5 to 4.5 Voltage Between EL (6) and (8) V Turn starting switch to OFF position. Disconnect connectors ST1 and EL , and connect T-adapters to female side of each connector.

Resistance

a If power supply voltage in check on cause 1 is normal, this check is not required. Between ST1 (female) (22) and EL (female) (5)

Max. 1 z

a If power supply voltage in check on cause 1 is normal, this check is not required. Between ST1 (female) (4) and EL (female) (8)

Max. 1 z

Between ST1 (female) (7) and EL (female) (6)

Max. 1 z

a If no failure is found by check on cause 2, this check is not required. Turn starting switch to OFF position. Disconnect connectors ST1 and EL , and connect T-adapter to Ground fault in wiring harness female side of either connector. (contact with ground circuit) Between ST1 (female) (7) and (4), or between Min. 1 Mz EL (female) (6) and (8) Resistance Between ST1 (female) (7) and ground, or Min. 1 Mz between EL (female) (6) and ground

D61EM-23M0

40-361

40 Troubleshooting

Troubleshooting by failure code (Display of code)

No.

Cause

5 Defective Hexagon controller

Max.1Ω

If no failure is found by above checks, HST controller is defective. Reference 1. Turn starting switch to OFF position. 2. Insert T-adapter into connector ST1. 3. Turn starting switch to ON position. 4. Perform troubleshooting by operating joystick (steering, directional, and gear shift lever) (steering).

6 Defective HST controller

Voltage

40-362

Between ST1 (19) and (4)

0.5 to 4.5 V

D61EM-23M0

40 Troubleshooting

Troubleshooting by failure code (Display of code)

Circuit diagram related to steering lever potentiometer

D61EM-23M0

40-363

40 Troubleshooting

Troubleshooting by failure code (Display of code)

Failure code [DK31KB] ST lever2: Hot Short Action level L03 Detail of failure Action of controller

Steering lever 2: Hot Short Failure code Failure (HST controller system) DK31KB • Signal voltage of joystick (steering, directional, and gear shift lever) steering potentiometer 2 (ST lever 2) is 4.5 V or more. • Continues to control with signals of joystick (steering, directional, and gear shift lever) steering potentiometer 1 (ST lever 1). • Restricts engine operations.

Problem on machine

• Once machine stops, engine speed is restricted to medium (half) speed.

Related information

No. 1

Cause Defective 5 V sensor power supply system

Procedure, measuring location, criteria and remarks If failure code [DAJ6KK] is also displayed, perform troubleshooting for it first.

Defective 7 + '$ ^% $2 *38 $ $

Turn starting switch to OFF position. Disconnect connector EL 56 . 8 2 $ 56 ( ) $ 56 (& ) Turn starting switch to ON position. Perform troubleshooting by operating joystick (steering). If failure code [DK KB] disappear , 7 + '$ ^% $2*38 $ $ & , ^ & ~3 &$ $ ' . % $ $ $ $ $ ' $ $

Turn starting switch to OFF position. Disconnect connector EL . Turn starting switch to ON position. Defective joystick (steering, Perform troubleshooting by operating joystick (steering, directional, directional, and gear shift and gear shift levers) (steering). lever steering) potentiometer If failure code DK31KB] disappears, joystick (steering, directional, 2 (internal short circuit) or and gear shift lever) potentiometer is defective. (If failure code is still ground fault displayed, wiring harness or HST controller is defective.) a Since connector EL1 is disconnected, many failure codes appear. Ignore all of displayed failure codes other than [DK31KB]. Hot short circuit in wiring harness

Turn starting switch to OFF position. Disconnect connector EL and connect T-adapter to female side. Turn starting switch to ON position. Voltage Between EL (female) (6) and (8) or ground 7 to 11 V

Turn starting switch to OFF position. Disconnect connectors ST1 and EL , and connect T-adapter to female side of ST1. a Check by using multimeter in continuity mode. Short circuit in wiring harness No continuity Between ST1 (female) (7) and each pin other Continuity than (7) (No sound is heard) If no failure is found by above checks, HST controller is defective. • Reference Turn starting switch to OFF position. Insert T-adapter into connector ST1. Defective HST controller Turn starting switch to ON position. Perform troubleshooting by operating joystick (steering, directional, and gear shift lever) (steering). 0.5 to 4.5 Voltage Between ST1 (7) and (4)

40-364

D61EM-23M0

40 Troubleshooting

Troubleshooting by failure code (Display of code)

Circuit diagram related to steering lever potentiometer

D61EM-23M0

40-365

40 Troubleshooting

Troubleshooting by failure code (Display of code)

Failure code [DK40KA] Decel/Brake potentiometer: Open Action level L03 Detail of failure Action of controller Problem on machine Related information No.

Failure code DK40KA

Failure

Decel/Brake potentiometer: Open (HST controller system)

• Signal voltage of brake pedal potentiometer is 0.3 V or lower. • • • • • •

Holds the previously entered signals until the machine stops. Recognizes that the pedal is not depressed after stopping. Pedal is in the state not depressed until it comes at half stroke (deceleration). The brake can be controlled when the pedal is depressed to the full stroke (brake). The machine does not start even when the pedal is released. Signal voltage of brake pedal potentiometer can be checked with monitoring function. (Code: 50400 "Decel/Brake Pedal Potentio") • Method of reproducing failure code: Turn starting switch to ON position and operate brake pedal. Cause

Procedure, measuring location, criteria and remarks If failure code [DAJ6KK] is also displayed, perform troubleshooting for it first.

1. Turn starting switch to OFF position. 2. Disconnect connector BP2 and connect T-adapter to female side. 3. Turn starting switch to ON position. Defective 5 V sensor power supply a Check with planter system power switch HSW in ON and OFF positions. If 1 system measured value varies with position of this switch, Hexagon controller 13Y06-17540 is defective. a If power supply voltage is unusual, go to check on cause 3 and after. Voltage

Between BP2 (female) (C) and (B)

Power supply

4.5 to 5.5 V

1. Turn starting switch to OFF position. 2. Disconnect connector BP2 and connect T-adapter to male side. 3. Perform troubleshooting by depressing the decelerator/ brake pedal. Defective decelerator/ brake pedal 2 potentiometer (internal open circuit or ground fault)

Open or short circuit in wiring harness

40-366

Resistance

Between BP2 (male) (C) and (B)

Approx. 2 kz

Between BP2 (male) (A) and (C)

0.2 to 1.8 kz

Between BP2 (male) (A) and (B)

0.2 to 1.8 kz

Between BP2 (male) (A) and ground

Min. 1 Mz

1. Turn starting switch to OFF position. 2. Disconnect connectors ST1 and BP2, and connect T-adapter to each female side. a Use resistance table for check on cause 2 as resistance criteria. a If resistance is 1 Mz or higher, wiring harness has open circuit. If resistance is 1 z or below, wiring harness has short circuit. Between ST1 (female) (22) and ST1 (female) (21)

Approx. 2 kz

Resistance Between ST1 (female) (3) and (21)

0.2 to 1.8 kz

Between BP2 (female) (A) and (B)

0.2 to 1.8 kz

D61EM-23M0

40 Troubleshooting

Troubleshooting by failure code (Display of code)

No.

Cause

Procedure, measuring location, criteria and remarks 1. Turn starting switch to OFF position. 2. Disconnect connectors ST1 and BP2, and connect T-adapter to each female side.

Open circuit in wiring harness 4 (wire breakage or defective contact of connector)

Ground fault in wiring harness (contact with ground circuit)

Resistance

D61EM-23M0

a If power supply voltage in cause 1 or check result of cause 3 is normal, this check is not required. Between ST1 (female) (21) and BP2 (female) (B)

Max. 1 z

a If no failure is found by check on cause 3, this check is not required. Between ST1 (female) (3) and BP2 (female) (A)

Max. 1 z

Between ST1 (female) (3) and (21), or between BP2 (female) (A) and (B)

Min. 1 Mz

Between ST1 (female) (3) and ground, or between BP2 (female) (A) and ground

Min. 1 Mz

1. Turn starting switch to OFF position. 2. Insert T-adapter into connector ST1. 3. Turn starting switch to ON position. Check with planter system power switch HSW in ON and OFF position. 4. Perform troubleshooting by depressing the decelerator/ brake pedal. a If measured value varies with position of this switch, Hexagon controller 13Y-06-17540 is defective. Voltage

7 Defective Hexagon controller

Max. 1 z

a If no failure is found by check on cause 2, this check is not required. 1. Turn starting switch to OFF position. 2. Disconnect connectors ST1 and BP2, and connect T-adapter to female side of either connector.

Resistance

6 Defective HST controller

a If power supply voltage in cause 1 or check result of cause 3 is normal, this check is not required. Between ST1 (female) (22) and BP2 (female) (C)

Between ST1 (3) and (21)

0.5 to 4.5 V

If no abnormality is detected by above diagnosis, 1. Turn starting switch to OFF position 2. Put T-adapter to HC4H. If there is no continuity between HC1A (5) and (6), Hexagon controller 13Y-0617540 is defective.

40-367

40 Troubleshooting

Troubleshooting by failure code (Display of code)

Circuit diagram related to decel/brake pedal potentiometer

40-368

D61EM-23M0

40 Troubleshooting

Troubleshooting by failure code (Display of code)

Failure code [DK40KB] Decel/Brake potentiometer: Hot Short Action level L03 Detail of failure Action of controller Problem on machine Related information No.

Failure code DK40KB

Failure

Decelerator/Brake potentiometer: Hot Short (HST controller system)

• Signal voltage of brake pedal potentiometer is 4.5 V or higher. • • • • • •

Procedure, measuring location, criteria and remarks If failure code [DAJ6KK] is also displayed, perform troubleshooting for it first.

1. Turn starting switch to OFF position. 2. Disconnect connector BP2 and connect T-adapter to female side. Defective 5 V sensor power supply 1 3. Turn starting switch to ON position. system a If power supply voltage is unusual, go to check on cause 4 and after. Voltage 1. 2. 3. Defective Hexagon Auto-STR con- 4. 2 5. troller

Between BP2 (female) (C) and (B)

Power supply

4.5 to 5.5 V

Turn starting switch to OFF position. Disconnect connectors BP1, BP2. Re-connect BP2 (male) into BP1 (female). Turn starting switch to ON position. Perform troubleshooting by operating joystick (steering).

If failure code [DK40KB] disappeared, Hexagon Auto-STR controller is defective. And if NOT disappeared, following checks must be done, in condition restored connecting connectors. 1. Turn starting switch to OFF position. 2. Disconnect connector BP2 and connect T-adapter to male side. 3. Perform troubleshooting by depressing the decelerator/ brake pedal. Defective decelerator/ brake pedal 3 potentiometer (internal open circuit or ground fault)

Between BP2 (male) (C) and (B)

Approx. 2 kz

Resistance Between BP2 (male) (A) and (C)

0.2 to 1.8 kz

Between BP2 (male) (A) and (B)

0.2 to 1.8 kz

4 Hot short circuit in wiring harness

1. Turn starting switch to OFF position. 2. Disconnect connector BP2 and connect T-adapter to female side. 3. Turn starting switch to ON position.

5 Short circuit in wiring harness

1. Turn starting switch to OFF position. 2. Disconnect connectors ST1 and BP2, and connect T-adapter to female side of ST1. a Check by using multimeter in continuity mode.

Voltage

Continuity

Between BP2 (female) (A) and (B) or ground

Between ST1 (female) (3) and each pin other than (3)

7 to 11 V

No continuity (No sound is heard)

If no failure is found by above checks, HST controller is defective. Reference 1. Turn starting switch to OFF position. 2. Insert T-adapter into connector ST1. 3. Turn starting switch to ON position. 4. Perform troubleshooting by depressing the decelerator/ brake pedal.

6 Defective HST controller

Voltage D61EM-23M0

Between ST1 (3) and (21)

0.5 to 4.5 V

40-369

40 Troubleshooting

Troubleshooting by failure code (Display of code)

Circuit diagram related to decel/brake pedal potentiometer

40-370

D61EM-23M0

40 Troubleshooting

Troubleshooting by failure code (Display of code)

Failure code [DK55KX] FR lever: Main and Sub Error Action level L04 Detail of failure Action of controller Problem on machine

Related information

FR lever: Main and Sub Error Failure code Failure (HST controller system) DK55KX • In joystick (steering, directional, and gear shift lever) potentiometers 1 (FR1) and 2 (FR2), either failure code [DK56KA] or [DK56KB], and either failure code [DK57KA] or [DK57KB] are displayed at the same time. • Restricts engine operation. • Once machine stops, engine speed is restricted to medium (half) speed. • Once machine stops, it cannot travel at all. • Signal voltage of joystick (steering, directional, and gear shift lever) potentiometers can be checked with monitoring function. (Code: 50202 "FR Lever1 Potentio") (Code: 50203 "FR Lever2 Potentio") • Method of reproducing failure code: Turn starting switch to ON position and operate joystick (steering, directional, and gear shift lever) (directional shifting).

Procedure, measuring location, criteria and remarks Cause Perform troubleshooting for failure codes [DK56KA], [DK56KB], [DK57KA], and [DK57KB].

D61EM-23M0

40-371

40 Troubleshooting

Troubleshooting by failure code (Display of code)

Failure code [DK55KZ] FR lever: Main and Sub Error Action level L04 Detail of failure Action of controller Problem on machine

Related information

FR lever: Main and Sub Error Failure code Failure (HST controller system) DK55KZ • In joystick (steering, directional, and gear shift lever) potentiometer 1 (FR1) or 2 (FR2), starting switch is turned to ON position, only one side malfunctions and then either failure code [DK56KA] or [DK56KB], and either failure code [DK57KA] or [DK57KB] are displayed at the same time. • Restricts engine operation. • Once machine stops, engine speed is restricted to medium (half) speed. • Once machine stops, it cannot travel at all. • Signal voltage of joystick (steering, directional, and gear shift lever) potentiometers can be checked with monitoring function. (Code: 50202 "FR Lever1 Potentio") (Code: 50203 "FR Lever2 Potentio") • Method of reproducing failure code: Turn starting switch to ON position and operate joystick (steering, directional, and gear shift lever) (directional shifting).

Procedure, measuring location, criteria and remarks Cause Perform troubleshooting for failure codes [DK56KA], [DK56KB], [DK57KA], and [DK57KB].

40-372

D61EM-23M0

40 Troubleshooting

Troubleshooting by failure code (Display of code)

Failure code [DK55L8] FR lever: Signal mismatch Action level L03 Detail of failure Action of controller Problem on machine

Related information

• • • • • •

•

FR lever: Signal mismatch Failure code Failure (HST controller system) DK55L8 Sum of signal voltages of joystick (steering, directional, and gear shift lever) potentiometers 1 (FR1) and 2 (FR2) is 4.41 V or less, or 5.59 V or more. Continues control with signal from joystick (steering, directional, and gear shift lever) potentiometer 1 (FR1) or 2 (FR2) whichever is normal. Restricts engine operation. Once machine stops, engine speed is restricted to medium (half) speed. Once machine stops, travel is restricted to F1 and R1. Signal voltage of joystick (steering, directional, and gear shift lever) potentiometers can be checked with monitoring function. (Code: 50202 "FR Lever1 Potentio") (Code: 50203 "FR Lever2 Potentio") Method of reproducing failure code: Turn starting switch to ON position and operate joystick (steering, directional, and gear shift lever) (directional shifting).

Procedure, measuring location, criteria and remarks Cause Perform troubleshooting for failure codes [DK56KA], [DK56KB], [DK57KA], and [DK57KB].

D61EM-23M0

40-373

40 Troubleshooting

Troubleshooting by failure code (Display of code)

Failure code [DK56KA] FR lever1: Open Action level L03 Detail of failure Action of controller

FR lever 1: Open Failure code Failure (HST controller system) DK56KA • Signal voltage of joystick (steering, directional, and gear shift lever) potentiometer 1 (FR1) is 0.5 V or lower. • Continues to control with signal of joystick (steering, directional, and gear shift lever) potentiometer 2 (FR2). • Restricts engine operation.

Problem on machine

• Once machine stops, engine speed is restricted to medium (half) speed.

Related information

• Signal voltage of joystick (steering, directional, and gear shift lever) potentiometer 1 can be checked with monitoring function. (Code: 50202 "FR Lever1 Potentio") • Method of reproducing failure code: Turn starting switch to ON position and operate joystick (steering, directional, and gear shift lever) (directional shifting).

No.

Cause

Procedure, measuring location, criteria and remarks If failure code [DAJ6KK] is also displayed, perform troubleshooting for it first.

Between EL1 (female) (4) and (1)

Power supply

4.5 to 5.5 V

1. 2. 3. 4.

Turn starting switch to OFF position. Insert T-adapter into connector EL1. Turn starting switch to ON position. Perform troubleshooting by operating joystick (steering, directional). Check with planter system power switch HSW in ON and OFF position. Defective joystick (steering, direc- a If measured value varies with position of this switch, Hexagon controller tional, and gear shift lever) potenti13Y-06-17540 is defective. 2 ometer 1 (internal open circuit or a If power supply voltage is normal and potentiometer output voltage is ground fault) abnormal (0.5 V or lower), it cannot be determined whether ground fault or defective potentiometer is the cause. In this case, go to check on cause 4. If no failure is found by check on cause 4, joystick (steering, directional, and gear shift lever) potentiometer 1 is defective. Voltage

Between EL1 (3) and (1)

0.5 to 4.5 V

a If power supply voltage in check on cause 1 is normal, this check is not required. Between ST1 (female) (22) and EL1 (female) (4)

Max. 1 z

Resistance a If power supply voltage in check on cause 1 is normal, this check is not required. Between ST1 (female) (4) and EL1 (female) (1)

Max. 1 z

Between ST1 (female) (13) and EL1 (female) (3)

Ground fault in wiring harness (contact with ground circuit)

Resistance

40-374

Max. 1 z

Between ST1 (female) (13) and (4), or between EL1 (female) (3) and (1)

Min. 1 Mz

Between ST1 (female) (13) and ground, or between EL1 (female) (3) and ground

Min. 1 Mz

D61EM-23M0

40 Troubleshooting

Troubleshooting by failure code (Display of code)

No.

Cause

5 Defective Hexagon controller

Max.1 Ω

If no failure is found by above checks, HST controller is defective. Reference 1. Turn starting switch to OFF position. 2. Insert T-adapter into connector ST1. 3. Turn starting switch to ON position. 4. Perform troubleshooting by operating joystick (steering, directional, and gear shift lever) (steering).

6 Defective HST controller

Voltage

D61EM-23M0

Between ST1 (19) and (4)

0.5 to 4.5 V

40-375

40 Troubleshooting

Troubleshooting by failure code (Display of code)

Circuit diagram related to travel lever potentiometer

40-376

D61EM-23M0

40 Troubleshooting

Troubleshooting by failure code (Display of code)

Failure code [DK56KB] FR lever1: Hot Short Action level L03 Detail of failure Action of controller

FR lever 1: Hot Short Failure code Failure (HST controller system) DK56KB • Signal voltage of joystick (steering, directional, and gear shift lever) potentiometer 1 (FR1) is 4.5 V or more. • Continues to control with signal of joystick (steering, directional, and gear shift lever) potentiometer 2 (FR2). • Restricts engine operation.

Problem on machine

• Once machine stops, engine speed is restricted to medium (half) speed.

Related information

No. 1

Cause Defective 5 V sensor power supply system

Procedure, measuring location, criteria and remarks If failure code [DAJ6KK] is also displayed, perform troubleshooting for it first.

Defective 7 + '$ ^% $2 *38 $ $

Turn starting switch to OFF position. Disconnect connector EL 56. 8 2 $ 56 ( ) $ 56 (& ) Turn starting switch to ON position. Perform troubleshooting by operating joystick (steering). If failure code [DK KB] disappear , 7 + '$ ^% $2*38 $ $ & , ^ & ~3 &$ $ ' . % $ $ $ $ $ ' $ $

Defective joystick (steering, directional, and gear shift lever) potentiometer 1 (internal short circuit) or ground fault

Turn starting switch to OFF position. Disconnect connector EL . Turn starting switch to ON position. Perform troubleshooting by operating joystick (steering, directional, and gear shift lever) (directional). If failure code [DK56KB] disappears, joystick (steering, directional, and gear shift lever) potentiometer is defective. (If failure code is still displayed, wiring harness or HST controller is defective.) a Since connector EL is disconnected, many failure codes appear. Ignore failure codes other than [DK56KB].

Hot short circuit in wiring harness

Turn starting switch to OFF position. Disconnect connector EL and connect T-adapter to female side. Turn starting switch to ON position. Voltage Between EL (female) (3) and (1) or ground 7 to 11 V Turn starting switch to OFF position. Disconnect connectors ST1 and EL , and connect T-adapter to female side of ST1.

Short circuit in wiring harness a Check by using multimeter in continuity mode. Between ST1 (female) (13) and each pin other Continuity than pin (13)

D61EM-23M0

No continuity (No sound is heard)

40-377

40 Troubleshooting

Troubleshooting by failure code (Display of code)

No.

Cause

Defective HST controller

40-378

Procedure, measuring location, criteria and remarks If no failure is found by above checks, HST controller is defective. • Reference 1. Turn starting switch to OFF position. 2. Insert T-adapter into connector ST1. 3. Turn starting switch to ON position. 4. Perform troubleshooting by operating joystick (steering, directional, and gear shift lever) (directional). Voltage Between ST1 (13) and (4) 0.5 to 4.5 V

D61EM-23M0

40 Troubleshooting

Troubleshooting by failure code (Display of code)

Circuit diagram related to travel lever potentiometer

D61EM-23M0

40-379

40 Troubleshooting

Troubleshooting by failure code (Display of code)

Failure code [DK57KA] FR lever2: Open Action level L03 Detail of failure Action of controller

FR lever 2: Open Failure code Failure (HST controller system) DK57KA • Signal voltage of joystick (steering, directional, and gear shift lever) potentiometer 2 (FR2) is 0.5 V or lower. • Continues to control with signals of joystick (steering, directional, and gear shift lever) potentiometer 1 (FR1). • Restricts engine operation.

Problem on machine

• Once machine stops, engine speed is restricted to medium (half) speed.

Related information

• Signal voltage of joystick (steering, directional, and gear shift lever) potentiometer 2 can be checked with monitoring function. (Code: 50203 "FR Lever2 Potentio") • Method of reproducing failure code: Turn starting switch to ON position and operate joystick (steering, directional, and gear shift lever) (directional shifting).

No.

Cause

Procedure, measuring location, criteria and remarks If failure code [DAJ6KK] is also displayed, perform troubleshooting for it first.

Between EL1 (female) (4) and (1)

Power supply

4.5 to 5.5 V

1. 2. 3. 4.

Defective joystick (steering, directional, and gear shift 2 lever) potentiometer 2 (internal open circuit or ground fault)

Turn starting switch to OFF position. Insert T-adapter into connector EL1. Turn starting switch to ON position. Perform troubleshooting by operating joystick (steering, directional). Check with planter system power switch HSW in ON and OFF position. a If measured value varies with position of this switch, Hexagon controller 13Y-06-17540 is defective. a If power supply voltage is normal and potentiometer output voltage is abnormal (0.5 V or lower), it cannot be determined whether ground fault or defective potentiometer is the cause. In this case, go to check on cause 4. If no failure is found by check on cause 4, joystick (steering, directional, and gear shift lever) potentiometer 2 is defective. Voltage

Between EL1 (2) and (1)

0.5 to 4.5 V

a If power supply voltage in check on cause 1 is normal, this check is not required. Between ST1 (female) (22) and EL1 (female) (4)

Max. 1 z

Resistance a If power supply voltage in check on cause 1 is normal, this check is not required. Between ST1 (female) (4) and EL1 (female) (1)

Max. 1 z

Between ST1 (female) (1) and EL1 (female) (2)

Ground fault in wiring harness (contact with ground circuit)

Resistance

40-380

Max. 1 z

Between ST1 (female) (1) and (4), or between EL1 (female) (2) and (1)

Min. 1 Mz

Between ST1 (female) (1) and ground, or between EL1 (female) (2) and ground

Min. 1 Mz

D61EM-23M0

40 Troubleshooting

Troubleshooting by failure code (Display of code)

No.

Cause

5 Defective Hexagon controller

Max.1 Ω

If no failure is found by above checks, HST controller is defective. Reference 1. Turn starting switch to OFF position. 2. Insert T-adapter into connector ST1. 3. Turn starting switch to ON position. 4. Perform troubleshooting by operating joystick (steering, directional, and gear shift lever) (steering).

6 Defective HST controller

Voltage

D61EM-23M0

Between ST1 (19) and (4)

0.5 to 4.5 V

40-381

40 Troubleshooting

Troubleshooting by failure code (Display of code)

Circuit diagram related to travel lever potentiometer

40-382

D61EM-23M0

40 Troubleshooting

Troubleshooting by failure code (Display of code)

Failure code [DK57KB] FR lever2: Hot Short Action level L03 Detail of failure Action of controller

FR lever 2: Hot Short Failure code Failure (HST controller system) DK57KB • Signal voltage of joystick (steering, directional, and gear shift lever) potentiometer 2 (FR2) is 4.5 V or more. • Continues to control with signals of joystick (steering, directional, and gear shift lever) potentiometer 1 (FR1). • Restricts engine operation.

Problem on machine

• Once machine stops, engine speed is restricted to medium (half) speed.

Related information

No. 1

Cause Defective 5 V sensor power supply system

Defective 7 + '$ ^% $2 *38 $ $

Defective joystick (steering, directional, and gear shift lever) potentiometer 2 (internal short circuit) or ground fault

Procedure, measuring location, criteria and remarks If failure code [DAJ6KK] is also displayed, perform troubleshooting for it first. Turn starting switch to OFF position. Disconnect connector EL 56. 8 2 $ 56 ( ) $ 56 (& ) Turn starting switch to ON position. Perform troubleshooting by operating joystick (steering). If failure code [DK KB] disappear , 7 + '$ ^% $2*38 $ $ & , ^ & ~3 &$ $ ' . % $ $ $ $ $ ' $ $

Turn starting switch to OFF position. Disconnect connector EL . Turn starting switch to ON position. Perform troubleshooting by operating joystick (steering, directional, and gear shift lever) (directional). If failure code [DK57KB] disappears, joystick (steering, directional, and gear shift lever) potentiometer is defective. (If failure code is still displayed, wiring harness or HST controller is defective.) a Since connector EL is disconnected, many failure codes appear. Ignore failure codes other than [DK57KB].

Hot short circuit in wiring harness

Turn starting switch to OFF position. Disconnect connector EL and connect T-adapter to female side. Turn starting switch to ON position. Voltage Between EL (female) (2) and (1) or ground 7 to 11 V Turn starting switch to OFF position. Disconnect connectors ST1 and EL , and connect T-adapter to female side of ST1.

Short circuit in wiring harness a Check by using multimeter in continuity mode. Between ST1 (female) (1) and each pin other Continuity than pin (1)

D61EM-23M0

No continuity (No sound is heard)

40-383

40 Troubleshooting

Troubleshooting by failure code (Display of code)

No.

Cause

Defective HST controller

Procedure, measuring location, criteria and remarks If no failure is found by above checks, HST controller is defective. • Reference 1. Turn starting switch to OFF position. 2. Insert T-adapter into connector ST1. 3. Turn starting switch to ON position. 4. Perform troubleshooting by operating joystick (steering, directional, and gear shift lever) (directional). Voltage Between ST1 (1) and (4) 0.5 to 4.5 V

Circuit diagram related to travel lever potentiometer

40-384

D61EM-23M0

40 Troubleshooting

Troubleshooting by failure code (Display of code)

Failure code [DLM0KX] HST Motor Speed Sensor: Left/Right Error Action level L03 •

Detail of failure Action of controller Problem on machine

Related information

No. 1

D61EM-23M0

• • • • • • •

•

HST Motor Speed Sensor: Left/Right Error Failure code Failure (HST controller system) DLM0KX Either failure code [DLM1KA] or [DLM1KB] and either failure code [DLM2KA] or [DLM2KB] are generated simultaneously in the left HST motor speed sensor system and right HST motor speed sensor system. Displays the HST system state monitor on the machine monitor. Partially limits the functions. Even if cause of failure disappears, machine does not become normal until starting switch is turned to the OFF position. Once machine stops, engine speed is restricted to medium (half) speed. Once machine stops, travel speed is restricted to 50% after restart. Travel deviation occurs. The input speed and voltage from left HST motor speed sensor and right HST motor speed sensor can be checked with monitoring function. (Code: 40002 "Right Vehicle Speed"; Code: 40003 "Left Vehicle Speed"; Code: 40963 "Right Vehicle Speed Sensor"; Code: 40964 "Left Vehicle Speed Sensor") Method of reproducing failure code: Start the engine, and operate joystick (steering, directional, and gear shift lever) (forwarding).

Procedure, measuring location, criteria and remarks Cause Perform troubleshooting for failure codes [DLM1KA], [DLM1KB], [DLM2KA] and [DLM2KB].

40-385

40 Troubleshooting

Troubleshooting by failure code (Display of code)

Failure code [DLM1KA] Left HST motor speed sensor: Open Action level L01 Detail of failure

Failure code DLM1KA

Failure

Left HST motor speed sensor: Open (HST controller system)

• Open circuit occurs in the left HST motor speed sensor circuit.

Action of controller

• Stops deviation control. • Even if cause of failure disappears, machine does not become normal until starting switch is turned to the OFF position.

Problem on machine

• Travel deviation occurs.

Related information

No.

Cause

Defective 5 V sensor power supply system

Open circuit in wiring harness (wire breakage or defective contact of connector)

Resistance

a If power supply voltage in check on cause 1 is normal, this check is not required. Between ST2 (female) (1) and LRS2 (female) (A)

Max. 1 z

a If power supply voltage in check on cause 1 is normal, this check is not required. Between ST2 (female) (39) and LRS2 (female) (B)

Max. 1 z

a If power supply voltage in check on cause 2 is normal, this check is not required. Between ST2 (female) (20) and LRS2 (female) (C)

Max. 1 z

1. Turn starting switch to OFF position. 2. Disconnect connectors ST2 and LRS2, and connect T-adapter to female side of either connector. Ground fault in wiring harness Between ST2 (female) (20) and (39), or (contact with ground circuit) Max. 1 z Resis- between LRS2 (female) (C) and (B) tance Between ST2 (female) (20) and ground, or Max. 1 z between LRS2 (female) (C) and ground

40-386

D61EM-23M0

40 Troubleshooting

Troubleshooting by failure code (Display of code)

No. 5 6

Cause Defective left HST motor speed sensor (internal defect) Defective HST controller

Procedure, measuring location, criteria and remarks If no failure is found by above checks, the left HST motor speed sensor is defective. If no failure is found by above checks, HST controller is defective. (Since this is an internal defect, troubleshooting cannot be performed.)

Circuit diagram related to left HST motor speed sensor

D61EM-23M0

40-387

40 Troubleshooting

Troubleshooting by failure code (Display of code)

Failure code [DLM1KB] Left HST motor speed sensor: Short circuit

Action of controller

Left HST motor speed sensor: Short circuit Failure code Failure (HST controller system) DLM1KB • Even if the travel command is issued, no signal is input from the left HST motor speed sensor. • Stops deviation control. • Even if cause of failure disappears, machine does not become normal until starting switch is turned to the OFF position.

Problem on machine

• Travel deviation occurs.

Action level — Detail of failure

Related information

• The input speed and voltage from left HST motor speed sensor can be checked with monitoring function. (Code: 40003 "Left Vehicle Speed"; Code: 40964 "Left Vehicle Speed Sensor") • Method of reproducing failure code: Start the engine, and operate joystick (steering, directional, and gear shift lever) (forwarding). • If error is not reproduced, sensor is normal. Air bleeding after reassembling or modification is defective. Or an error is detected incorrectly due to startup in low temperature. No part replacement is required.

No.

Cause

Defective 5 V sensor power supply system

4 5

Open or short circuit in wiring a If resistance is 1 Mz or higher, wiring harness has open circuit. If harness resistance is 1z or below, wiring harness has short circuit. Resis- Between ST2 (female) (20) and (1) Approx. tance 620 z 1. Turn starting switch to OFF position. Ground fault in wiring harness 2. Disconnect connectors ST2 and LRS2, and connect T-adapter to female side of either connector. (contact with ground circuit) Resis- Between ground and either ST2 (female) (20) Min. 1 Mz and LRS2 (female) (C) tance Defective left HST motor If no failure is found by above checks, the left HST motor speed sensor speed sensor is defective. (internal defect) If no failure is found by above checks, HST controller may be defective. Defective HST controller (Since this is an internal defect, troubleshooting cannot be performed.)

40-388

D61EM-23M0

40 Troubleshooting

Troubleshooting by failure code (Display of code)

Circuit diagram related to turbocharger speed sensor

D61EM-23M0

40-389

40 Troubleshooting

Troubleshooting by failure code (Display of code)

Failure code [DLM1MA] Left HST motor speed sensor: Malfunction

Action of controller

Left HST motor speed sensor: Malfunction Failure code Failure (HST controller system) DLM1MA • Although signals are entered from left HST motor speed sensor, but many signal pulses are lost. • Stops the straight travel correction. • Even if cause of failure disappears, machine does not become normal until starting switch is turned to OFF position.

Problem on machine

• Travel deviation occurs.

Action level — Detail of failure

Related information

• The input speed and voltage from left HST motor speed sensor can be checked with monitoring function. (Code: 40003 "Left Vehicle Speed", Code: 40002 "Right Vehicle Speed", Code: 40010 "Vehicle Speed") • Method of reproducing failure code: Start the engine, and operate joystick (steering, directional, and gear shift lever)(forward) • If error does not occur again, replacement is not required because sensor is normal but air still remains in circuit after assembling or modification, or error may be detected incorrectly due to startup in low temperature.

No.

Cause

Defective left HST motor speed sensor

Defective left HST motor (internal defect)

40-390

Procedure, measuring location, criteria and remarks 1. Turn starting switch to OFF position. 2. Using the monitoring function, display the "Vehicle Speed", "Left Vehicle Speed", and "Right Vehicle Speed". 3. Start the engine, travel machine, and check the travel speed, then perform troubleshooting. If "Left Vehicle Speed" is abnormal when compared with other speed, the left HST motor speed sensor is defective. Left HST motor may have internal defect (such as damaged speed sensor). Check it.

D61EM-23M0

40 Troubleshooting

Troubleshooting by failure code (Display of code)

Failure code [DLM2KA] Right HST motor speed sensor: Open Action level L01 Detail of failure

Failure code DLM2KA

Failure

Right HST motor speed sensor: Open (HST controller system)

• Open circuit occurs in the right HST motor speed sensor circuit.

Action of controller

• Stops deviation control. • Even if cause of failure disappears, machine does not become normal until starting switch is turned to the OFF position.

Problem on machine

• Travel deviation occurs.

Related information

No.

Cause

Defective 5 V sensor power supply system

Open circuit in wiring harness (wire breakage or defective contact of connector)

Resistance

a If power supply voltage in check on cause 1 is normal, this check is not required. Between ST2 (female) (1) and RRS2 (female) (A)

Max. 1 z

a If power supply voltage in check on cause 1 is normal, this check is not required. Between ST2 (female) (39) and RRS2 (female) (B)

Max. 1 z

a If no failure is found by check on cause 2, this check is not required. Between ST2 (female) (30) and RRS2 (female) (C)

Max. 1 z

a If no failure is found by check on cause 2, this check is not required. 1. Turn starting switch to OFF position. 2. Disconnect connectors ST2 and RRS2, and connect T-adapter to Ground fault in wiring harness female side of either connector. (contact with ground circuit) Between ST2 (female) (30) and (39), or Max. 1 z Resis- between RRS2 (female) (C) and (B) tance Between ST2 (female) (30) and ground, or Max. 1 z between RRS2 (female) (C) and ground

D61EM-23M0

40-391

40 Troubleshooting

Troubleshooting by failure code (Display of code)

No. 5 6

Cause Defective right HST motor speed sensor (internal defect) Defective HST controller

Procedure, measuring location, criteria and remarks If no failure is found by above checks, the right HST motor speed sensor is defective. If no failure is found by above checks, HST controller may be defective. (Since this is an internal defect, troubleshooting cannot be performed.)

Circuit diagram related to right HST motor speed sensor

40-392

D61EM-23M0

40 Troubleshooting

Troubleshooting by failure code (Display of code)

Failure code [DLM2KB] Right HST motor speed sensor: Short circuit

Action of controller

Right HST motor speed sensor: Short circuit Failure code Failure (HST controller system) DLM2KB • Even if the travel command is issued, no signal is input from the right HST motor speed sensor. • Stops deviation control. • Even if cause of failure disappears, machine does not become normal until starting switch is turned to OFF position.

Problem on machine

• Travel deviation occurs.

Action level — Detail of failure

Related information

• The input speed and voltage from right HST motor speed sensor can be checked with monitoring function. (Code: 40002 "Right Vehicle Speed"; Code: 40963 "Right Vehicle Speed Sensor") • Method of reproducing failure code: Start the engine, and operate joystick (steering, directional, and gear shift lever) (forwarding). • If error is not reproduced, sensor is normal. Replacement is not required since air may remain in circuit after reassembling or modification, or error may be detected incorrectly due to startup in low temperature.

No.

Cause

Defective 5 V sensor power supply system

4 5

Open or short circuit in wiring a If resistance is 1 Mz or higher, wiring harness has open circuit. If harness resistance is 1z or below, wiring harness has short circuit. Resis- Between ST2 (female) (30) and (1) Approx. tance 620 z 1. Turn starting switch to OFF position. Ground fault in wiring harness 2. Disconnect connectors ST2 and RRS2, and connect T-adapter to female side of either connector. (contact with ground circuit) Resis- Between ground and either ST2 (female) (30) Min. 1 Mz and RRS2 (female) (C) tance Defective right HST motor If no failure is found by above checks, the right HST motor speed sensor speed sensor is defective. (internal defect) If no failure is found by above checks, HST controller may be defective. Defective HST controller (Since this is an internal defect, troubleshooting cannot be performed.)

D61EM-23M0

40-393

40 Troubleshooting

Troubleshooting by failure code (Display of code)

Circuit diagram related to right HST motor speed sensor

40-394

D61EM-23M0

40 Troubleshooting

Troubleshooting by failure code (Display of code)

Failure code [DLM2MA] Right HST motor speed sensor: Malfunction

Action of controller

Right HST motor speed sensor: Malfunction Failure code Failure (HST controller system) DLM2MA • Although signals are entered from right HST motor speed sensor, but many signal pulses are lost. • Stops the travel deviation control. • Even if cause of failure disappears, machine does not become normal until starting switch is turned to OFF position.

Problem on machine

• Travel deviation occurs.

Action level — Detail of failure

Related information

• The input speed and voltage from right HST motor speed sensor can be checked with monitoring function. (Code: 40003 "Left Vehicle Speed", Code: 40002 "Right Vehicle Speed", Code: 40010 "Vehicle Speed") • Method of reproducing failure code: Start the engine, and operate joystick (steering, directional, and gear shift lever) (forward). • If error does not occur again, replacement is not required because sensor is normal but air still remains in circuit after assembling or modification, or error may be detected incorrectly due to startup in low temperature.

No.

Cause

Defective right HST motor speed sensor

Defective right HST motor (internal defect)

D61EM-23M0

Procedure, measuring location, criteria and remarks 1. Turn starting switch to OFF position. 2. Using the monitoring function, display the "Vehicle Speed", "Left Vehicle Speed", and "Right Vehicle Speed". 3. Start the engine, travel machine, and check the travel speed, then perform troubleshooting. If the "Right Vehicle Speed" is abnormal when compared with other speed, the right HST motor speed sensor is defective. Right HST motor may have internal defect (such as damaged speed sensor). Check it.

40-395

40 Troubleshooting

Troubleshooting by failure code (Display of code)

Failure code [DLM3KA] Fan rev. sensor: Open Action level L01 • Detail of failure

•

Action of controller Problem on machine

• •

Related information No.

Fan revolution sensor: Open Failure code Failure (HST controller system) DLM3KA Due to open circuit in fan speed sensor system, no pulse voltage is input from fan speed sensor. This failure code appears if following conditions are met. 1. Pulse feedback input voltage is 2.2 V or more. 2. No pulse voltage is input. 3. Engine is running. HST controller does not control PID on fan. Recognizes that fan speed is 0 rpm.

• Fan rotates at the maximum speed. • Fan speed input by fan speed sensor can be checked with monitoring function. (Code: 10007 "Fan Speed") • Method of reproducing failure code: Turn starting switch to ON position.

Procedure, measuring location, criteria and remarks If failure code [DAJ6KK] is also displayed, perform troubleshooting for it first. 1. Turn starting switch to OFF position. Defective fan speed sensor 2. Disconnect connector FRS and connect T-adapter to male side of (internal open or short circuit) connector. 2 to 3 kz Resis- Between FRS (male) (1) and (2) tance Between FRS (male) (1) and ground Min. 1 Mz Cause

1. Turn starting switch to OFF position. 2. Disconnect connector FRS and connect T-adapter to female side of connector. 3. Turn starting switch to ON position.

Open circuit, short circuit, ground fault, hot short circuit of wiring harness, or defective a If measured voltage is 0 V or more, wiring harness has open circuit, HST controller ground fault, or short circuit. Voltage Between FRS (female) (1) and (2) 3 to 4 V

a If no failure is found by check on cause 2, this check is not required. 1. Turn starting switch to OFF position. 2. Disconnect connector ST2, and connect T-adapter to female side.

Open or short circuit in wiring harness a If resistance is 1 Mz or higher, wiring harness has open circuit. If resistance is 1z or below, wiring harness has short circuit. Resis- Between ST2 (female) (10) and (39) 2 to 3 kz tance a If no failure is found by check on cause 2, this check is not required. 1. Turn starting switch to OFF position. Open circuit in wiring harness 2. Disconnect connectors ST2 and FRS, and connect T-adapters to each female side. (wire breakage or defective Between ST2 (female) (39) and FRS (female) contact of connector) Max. 1z Resis- (1) tance Between ST2 (female) (10) and FRS (female) Max. 1z (2) If no failure is found by above checks, HST controller may be defective. Defective HST controller (Since this is an internal defect, troubleshooting cannot be performed.)

40-396

D61EM-23M0

40 Troubleshooting

Troubleshooting by failure code (Display of code)

Circuit diagram related to fan speed sensor

D61EM-23M0

40-397

40 Troubleshooting

Troubleshooting by failure code (Display of code)

Failure code [DLM3KB] Fan rev. sensor: Short circuit Action level L01 Detail of failure Action of controller Problem on machine

Failure code DLM3KB

Failure

Fan revolving sensor: Short circuit (HST controller system)

• Engine speed is 800 rpm or more, and fan speed is 10 Hz or less. • Stops feedback control of fan. • Fan rotates at the maximum speed.

Related information

• Fan speed can be checked with monitoring function. (Code: 10007 "Fan Speed") • Method of reproducing failure code: Start engine.

No.

Cause

Procedure, measuring location, criteria and remarks

1. Turn starting switch to OFF position. 2. Disconnect connector FRS and connect T-adapter to male side of Defective fan speed sensor connector. (internal open or short circuit) 2 to 3 kz Resis- Between FRS (male) (1) and (2) tance Between FRS (male) (1) and ground Min. 1 Mz

1. Turn starting switch to OFF position. Ground fault in wiring harness 2. Disconnect connectors ST2 and FRS, and connect T-adapter to female side of either connector. (contact with ground circuit) Resis- Between ground and either ST2 (female) (10) Min. 1 Mz or FRS (female) (2) tance

1. Turn starting switch to OFF position. 2. Disconnect connectors ST2 and FRS, and connect T-adapter to Short circuit in wiring harness female side of either connector. Resis- Between ST2 (female) (10) and (39), or Min. 1 Mz between FRS (female) (1) and (2) tance

1. Start engine. 2. Check the fan speed by reading monitoring code 10007. If no failure is found by above checks and monitored fan speed is zero (0), the HST controller may be defective. (Since this is an internal defect, troubleshooting cannot be performed).

Defective HST controller

40-398

D61EM-23M0

40 Troubleshooting

Troubleshooting by failure code (Display of code)

Circuit diagram related to fan speed sensor

D61EM-23M0

40-399

40 Troubleshooting

Troubleshooting by failure code (Display of code)

Failure code [DLM3MB] Fan control: Mismatch Action level L01 Detail of failure Action of controller Problem on machine Related information

No. 1

Fan control: Mismatch Failure code Failure (HST controller system) DLM3MB • Difference between fan speed value specified by HST controller and actual speed sensed by fan speed sensor exceeds 100 rpm. • HST controller does not perform PID control on fan. • Fan speed control does not function properly. • The fan speed detected by fan speed sensor can be checked with monitoring function. (Code: 10007 "Fan Speed") • This failure code can be generated under conditions that fan solenoid system is normal and fan speed sensor is also normal (they are electrically normal). • Method of reproducing failure code: Start engine.

Cause Defective hydraulic circuit of hydraulic fan

Defective adjustment of fan speed

40-400

Procedure, measuring location, criteria and remarks Perform test and adjustment. For details, see Testing and adjusting, "Testing fan hydraulic circuit". Refer to the "Fan test mode" of "Adjustment" menu of Testing and adjusting, set "100% mode" and "70% mode", and check each fan speed. a If the fan speed does not match, follow the "Fan Auto Set" of "Special functions of machine monitor" of Testing and adjusting. Fan test mode: 100% mode 1650 ± 50 a Engine at high idle, hydraulic temperature rpm 50 to 60°C Fan speed Fan test mode: 70% mode (1650 x 0.7 = 1155) 1155 ± 50 a Engine at high idle, hydraulic temperature rpm 50 to 60°C

D61EM-23M0

40 Troubleshooting

Troubleshooting by failure code (Display of code)

Failure code [DN21FS] Decel/Brake pedal SW: Signal mismatch Action level L03 Detail of failure Action of controller

• • • •

Problem on machine

• • •

Related information

• •

No.

2 3

Decelerator/ brake pedal switch: Signal mismatch Failure code Failure (HST controller system) DN21FS Even if the signal for travel lock switch 1 is recognized at FREE position, the signal for travel lock switch 2 (NO) is as locked, and the brake pedal stroke is recognized as depressed fully, controller drives slow brake solenoid normally. Displays the parking brake system state monitor on the machine monitor. Partially limits the functions. Even if cause of failure disappears, machine does not become normal until starting switch is turned to the OFF position. Once machine stops, engine speed is restricted to medium (half) speed. Once machine stops, travel speed is restricted to 50% after restart. Input condition (ON/OFF) from travel lock switches 1 and 2 can be checked with monitoring function. (Code: 40984 "HST SW Input 3") The input stroke and voltage from brake pedal sensor can be checked with the monitoring function. (Code: 50401 "Decel/Brake Pedal Storoke"; Code: 50400 "Decel/Brake Pedal Potentio") Method of reproducing failure code: Set the starting switch to ON position, and operate parking brake lever (free position) and operate decelerator/ brake pedal (fully depressing). Cause

Procedure, measuring location, criteria and remarks

1. Turn starting switch to OFF position. 2. Disconnect connector PB and connect T-adapter to male side. 3. Release the travel lock switch. Limit switch for braking 4. Perform troubleshooting by depressing the decelerator/ brake pedal. (internal defect) Decelerator/ brake pedal: Max. 1 Mz Fully depressed Resis- Between PB (male) (A) and (B) Decelerator/ brake pedal: tance Min. 1 z Free Defective limit switch for Since limit switch for braking may be improperly installed, check it by braking referring to Testing and adjusting, "Adjusting decelerator/ brake pedal". Improper installation of brake Since the brake potentiometer may be improperly installed, check it by referring to Testing and adjusting, "Adjusting decelerator/ brake pedal". potentiometer

D61EM-23M0

40-401

40 Troubleshooting

Troubleshooting by failure code (Display of code)

Circuit diagram related to decelerator/brake pedal control

40-402

D61EM-23M0

40 Troubleshooting

Troubleshooting by failure code (Display of code)

Failure code [DR21KX] Camera 2 Picture Rev. Drive Abnormality

a This failure code does not relate to this machine because it is not equipped with camera 2. This failure code is provided in case where camera 2 is installed in future. a If this failure code appears, clear failure code by referring to "Classification and procedures for troubleshooting".

D61EM-23M0

40-403

40 Troubleshooting

Troubleshooting by failure code (Display of code)

Failure code [DR31KX] Camera 3 Picture Rev. Drive Abnormality

a This failure code does not relate to this machine because it is not equipped with camera 3. This failure code is provided in case where camera 3 is installed in future. a If this failure code appears, clear failure code by referring to "Classification and procedures for troubleshooting".

40-404

D61EM-23M0

40 Troubleshooting

Troubleshooting by failure code (Display of code)

Failure code [DV20KB] Back-up alarm: Short circuit Action level L01 Detail of failure

Failure code DV20KB

Failure

Back-up alarm: Short circuit (HST controller system)

• When controller drives backup alarm, abnormal current flows through circuit.

Action of controller

• Stops driving backup alarm. • Even if cause of failure disappears, machine does not become normal until starting switch is set to OFF position.

Problem on machine

• Backup alarm does not sound.

Related information

• Operating condition of backup alarm (ON or OFF) can be checked with monitoring function. (Code: 40979 "HST SW Output") • Method of reproducing failure code: Turn starting switch to ON position and set travel lever to reverse position.

No.

Cause

Procedure, measuring location, criteria and remarks 1. Turn starting switch to OFF position. 2. Disconnect connector 14 and connect T-adapter to female side. 3. Turn starting switch to ON position. 4. Perform troubleshooting by operating the travel lever.

Defective backup alarm (internal defect)

a If voltage described as follows is normal and backup alarm does not operate, backup alarm may be defective. k Never enter under the machine when operating travel lever.

Between 14 (female) (1) Voltage and (2)

Travel lever: NEUTRAL Travel lever: REVERSE

Max. 4.5 V 20 to 30 V

1. Turn starting switch to OFF position. 2. Disconnect connectors ST2 and ST3, and connect T-adapters to each female side.

Open or short circuit in wiring a If resistance is 1 Mz or higher, harness has open circuit. If it is 1 z or harness below, harness has short circuit. Resis- Between ST2 (female) (28) and ST3 (female) Approx. 40 tance (13) z Ground fault in wiring harness (contact with ground circuit)

1. Turn starting switch to OFF position. 2. Disconnect connectors ST2 and 14, and connect T-adapter to female side of either connector. Resis- Between ground and either ST2 (female) (28) or Min. 1 Mz tance 14 (female) (1) 1. Turn starting switch to OFF position. 2. Insert T-adapter into connector 14. 3. Turn starting switch to ON position. 4. Perform troubleshooting by operating the travel lever.

Defective HST controller

k Never enter under the machine when operating travel lever.

Voltage Between 14 (1) and (2)

D61EM-23M0

Travel lever: NEUTRAL Travel lever: REVERSE

Max. 4.5 V 20 to 30 V

40-405

40 Troubleshooting

Troubleshooting by failure code (Display of code)

Circuit diagram related to backup alarm

40-406

D61EM-23M0

40 Troubleshooting

Troubleshooting by failure code (Display of code)

Failure code [DW4BKA] Parking brake solenoid: Open Action level L04 Detail of failure Action of controller Problem on machine

Related information

No. 1

Failure code DW4BKA

Failure

Parking brake solenoid: Open (HST controller system)

• When controller drives parking brake solenoid valve, no current flows through circuit. • Stops driving parking brake solenoid valve. • Partially limits the functions. • Even if cause of failure disappears, machine does not become normal until starting switch is turned to the OFF position. • The machine stops during travel. • The machine cannot start after stopping. • Once machine stops, engine speed is restricted to medium (half) speed. • The output (ON/OFF) state to the parking brake solenoid valve can be checked with monitoring function. (Code: 40978 "Parking brake Solenoid") • Method of reproducing failure code: Turn starting switch to the ON position and operate parking brake lever (Free). Cause

Defective parking brake solenoid

Procedure, measuring location, criteria and remarks 1. Turn starting switch to OFF position. 2. Disconnect S4 and connect T-adapter to male side. Resis- Between S4 (male) (1) and (2) 34 to 44 z tance 1. Turn starting switch to OFF position. 2. Disconnect connector S4 and connect T-adapter to female side. 3. Turn starting switch to ON position.

Open circuit, short circuit, ground fault, hot short circuit of wiring harness, or defective a Shake the wiring harness by hand while measuring the voltage. If the voltage drops to approximately 0 V during shaking, circuit is HST controller open around this point. Voltage Between S4 (female) (1) and (2) 1 to 4.5 V

Open circuit in wiring harness (wire breakage or defective contact of connector)

Defective HST controller

D61EM-23M0

a If no failure is found by check on cause 2, this check is not required. 1. Turn starting switch to OFF position. 2. Disconnect connectors ST3 and S4, and connect T-adapters to each female side. Resis- Between ST3 (female) (27) and S4 (female) (1) Max. 1 z tance Between ST3 (female) (3) and S4 (female) (2) Max. 1 z If no failure is found by above checks, HST controller may be defective. (Since this is an internal defect, troubleshooting cannot be performed.)

40-407

40 Troubleshooting

Troubleshooting by failure code (Display of code)

Circuit diagram related to parking brake solenoid

40-408

D61EM-23M0

40 Troubleshooting

Troubleshooting by failure code (Display of code)

Failure code [DW4BKB] Parking brake solenoid: Short circuit Action level L04 Detail of failure Action of controller Problem on machine

Related information

No.

Failure code DW4B `

Failure

Parking brake solenoid: Short circuit (HST controller system)

• When controller drives parking brake solenoid, abnormal current flows through circuit. • Stops driving parking brake solenoid valve. • Partially limits the functions. • Even if cause of failure disappears, machine does not become normal until starting switch is turned to OFF position. • The machine stops during travel. • The machine cannot start after stopping. • Once machine stops, engine speed is restricted to medium (half) speed. • The output (ON/OFF) state to the parking brake solenoid valve can be checked with monitoring function. (Code: 40978 "Parking brake Solenoid") • Method of reproducing failure code: Turn starting switch to the ON position and operate parking brake lever (Free). Cause

Defective parking brake solenoid

Defective diode D4

Procedure, measuring location, criteria and remarks 1. Turn starting switch to OFF position. 2. Disconnect S4 and connect T-adapter to male side. Between S4 (male) (1) and (2) 34 to 44 z ResisBetween ground and each of S4 (male) (1) and tance Min. 1 Mz (2) 1. Turn starting switch to OFF position. 2. Disconnect connector D4. 3. Turn starting switch to ON position. 4. Perform troubleshooting by operating parking brake lever (free). a Ignore any failure code other than this code. If this failure code does not appear, diode D4 is defective.

1. Turn starting switch to OFF position. Ground fault in wiring harness 2. Disconnect connectors ST3 and S4, and connect T-adapter to either female side. (contact with ground circuit) Resis- Between ground and either ST3 (female) (27) Min. 1 Mz or S4 (female) (1) tance 1. Turn starting switch to OFF position. 2. Disconnect connectors ST3 and S4, and connect T-adapter to either Short circuit in wiring harness female side. Resis- Between ST3 (female) (27) and (3), or between Min. 1 Mz S4 (female) (1) and (2) tance If no failure is found by above checks, HST controller may be defective. Defective HST controller (Since this is an internal defect, troubleshooting cannot be performed.)

D61EM-23M0

40-409

40 Troubleshooting

Troubleshooting by failure code (Display of code)

Circuit diagram related to parking brake solenoid

40-410

D61EM-23M0

40 Troubleshooting

Troubleshooting by failure code (Display of code)

Failure code [DW4BKY] Parking brake solenoid: Hot Short Action level L03 Detail of failure Action of controller Problem on machine Related information No.

Failure code DW4B

Failure

Parking brake solenoid: Hot Short (HST controller system)

• When controller does not drive parking brake solenoid, abnormal voltage appears. • Even if cause of failure disappears, machine does not become normal until starting switch is turned to OFF position. • The parking brake solenoid is kept energized (and the parking brake does not function). • The output (ON/OFF) state to parking brake solenoid can be checked with monitoring function. (Code: 40978 "Parking brake Solenoid") • Method of reproducing failure code: Turn starting switch to ON position. Cause

Procedure, measuring location, criteria and remarks

Defective parking brake solenoid

1. Turn starting switch to OFF position. 2. Disconnect S4 and connect T-adapter to male side. Between S4 (male) (1) and (2) 34 to 44 z ResisBetween ground and each of S4 (male) (1) and tance Min. 1 Mz (2)

Hot short circuit in wiring harness

1. Turn starting switch to OFF position. 2. Disconnect connector S4 and connect T-adapter to female side. 3. Turn starting switch to ON position. Voltage Between S4 (female) (1) and (2) Max. 4.5 V 1. Turn starting switch to OFF position. 2. Disconnect connectors ST3 and S4, and connect T-adapter to female side of ST3. a Check by using multimeter in continuity mode. No Between ST3 (female) (27) and each pin other continuity Continuity than pin (27) (No sound is heard)

Short circuit in wiring harness

1. Turn starting switch to OFF position. 2. Disconnect connectors ST1, ST2 ST3, MC and S4, and connect Tadapter to either female side of MC or male side of MC. a Check by using multimeter in continuity mode. No continuity (No sound is heard) Continuity No continuity Between MC (male) (7) and each pin other than pin (7) (No sound is heard) If no failure is found by above checks, HST controller may be defective. (Since this is an internal defect, troubleshooting cannot be performed.) Between MC (female) (7) and each pin other than pin (7)

Defective HST controller

D61EM-23M0

40-411

40 Troubleshooting

Troubleshooting by failure code (Display of code)

Circuit diagram related to parking brake solenoid

40-412

D61EM-23M0

40 Troubleshooting

Troubleshooting by failure code (Display of code)

Failure code [DW7BKA] Fan reverse solenoid: Open Action level L01 Detail of failure Action of controller Problem on machine

Failure code DW7BKA

Failure

Fan reverse solenoid: Open (HST controller system)

• When controller drives fan reverse solenoid, no current flows through circuit. • Stops driving fan reverse solenoid. • Fan reverse function cannot be used.

Related information

• Output condition to fan reverse solenoid can be checked with monitoring function. (Code: 40979 "HST SW Output", "Fan Reverse Solenoid") • Method of reproducing failure code: Turn starting switch to ON position and select fan reverse mode.

No.

Cause

Defective fan reverse solenoid (internal open circuit)

Procedure, measuring location, criteria and remarks 1. Turn starting switch to OFF position. 2. Disconnect connector FAR and connect T-adapter to male side of connector. Resis- Between FAR (male) (1) and (2) 34 to 44 z tance 1. Turn starting switch to OFF position. 2. Disconnect connector FAR and connect T-adapter to female side of connector. 3. Turn starting switch to ON position.

Open circuit, short circuit, ground fault, hot short circuit of wiring harness, or a Shake the wiring harness by hand while measuring the voltage. If the defective HST controller voltage drops to approximately 0 V during shaking, circuit is open around this point. Voltage Between FAR (female) (1) and (2) 1 to 4.5 V a If no failure is found by check on cause 2, this check is not required. 1. Turn starting switch to OFF position. 2. Disconnect connectors ST2 and ST3, and connect T-adapter to each female side. Open or short circuit in wiring harness a If resistance is 1 Mz or higher, wiring harness has open circuit. If resistance is 1 z or below, wiring harness has short circuit. Resis- Between ST2 (female) (8) and ST3 (female) 34 to 44 z (13) tance

Open circuit in wiring harness (wire breakage or defective contact of connector)

Defective HST controller

D61EM-23M0

a If no failure is found by check on cause 2, this check is not required. 1. Turn starting switch to OFF position. 2. Disconnect connectors ST2, ST3 and FAR, and connect T-adapters to each female side. Between ST2 (female) (8) and FAR (female) Max. 1 z Resis- (1) tance Between ST3 (female) (13) and FAR (female) Max. 1 z (2) If no failure is found by above checks, HST controller may be defective. (Since this is an internal defect, troubleshooting cannot be performed.)

40-413

40 Troubleshooting

Troubleshooting by failure code (Display of code)

Circuit diagram related to fan reverse solenoid

40-414

D61EM-23M0

40 Troubleshooting

Troubleshooting by failure code (Display of code)

Failure code [DW7BKB] Fan reverse solenoid: Short circuit Action level L01 Detail of failure Action of controller Problem on machine

Failure code DW7BKB

Failure

Fan reverse solenoid: Short circuit (HST controller system)

• When controller drives fan reverse solenoid, abnormal current flows through circuit. • Stops driving fan reverse solenoid. • Fan reverse function cannot be used.

Related information

No.

Cause

Procedure, measuring location, criteria and remarks

Defective fan reverse solenoid (internal open circuit)

1. Turn starting switch to OFF position. 2. Disconnect connector FAR and connect T-adapter to male side of connector. 34 to 44 z Resis- Between FAR (male) (1) and (2) tance Between FAR (female) (1) and ground Min. 1 Mz

Ground fault in wiring harness (contact with ground circuit)

1. Turn starting switch to OFF position. 2. Disconnect connectors ST2 and FAR, and connect T-adapter to female side of either connector. Resis- Between ground and ST2 (female) (8) or FAR Min. 1 Mz (female) (1) tance

Short circuit in wiring harness

Defective HST controller

1. Turn starting switch to OFF position. 2. Disconnect connectors ST2, ST3 and FAR, and connect T-adapter to female side of either connector. Resis- Between ST2 (female) (8) and ST3 (female) Min. 1 Mz (13), or between FAR (female) (1) and (2) tance If no failure is found by above checks, HST controller may be defective. (Since this is an internal defect, troubleshooting cannot be performed.)

Circuit diagram related to fan reverse solenoid

D61EM-23M0

40-415

40 Troubleshooting

Troubleshooting by failure code (Display of code)

Failure code [DW7EKA] Slow brake solenoid: Open Action level L04 Detail of failure Action of controller

Problem on machine

Related information

• • • • • • • • • • •

No. 1

Slow brake solenoid: Open Failure code Failure (HST controller system) DW7EKA Even if travel lock switch 1 is in free position, and decelerator/ brake pedal is depressed, no current flows through slow brake solenoid valve circuit. Displays parking brake system state monitor on the machine monitor. Stops driving slow brake solenoid valve. Partially limits the functions. Even if cause of failure disappears, machine does not become normal until starting switch is turned to OFF position. The machine stops during travel. Once machine stops, it cannot restart. Once machine stops, engine speed is restricted to medium (half) speed. Input condition (ON/OFF) from travel lock switches 1 and 2 can be checked with monitoring function. (Code: 40984 "HST SW Input 3") The input stroke and voltage from brake pedal can be checked with monitoring function. (Code: 50401 "Decel/Brake Pedal Stroke"; Code: 50400 "Decel/Brake Pedal Potentio") Method of reproducing failure code: Turn starting switch to ON position, operate parking brake lever (Free position), and operate brake pedal (Release position). Cause

Procedure, measuring location, criteria and remarks

1. Turn starting switch to OFF position. 2. Disconnect connector S3 and connect T-adapter to male side. Defective slow brake solenoid Resis- Between S3 (male) (1) and (2) 34 to 44 z tance 1. Turn starting switch to OFF position. 2. Disconnect connector S3 and connect T-adapter to female side. Open circuit, short circuit, 3. Turn starting switch to ON position. ground fault, hot short circuit of wiring harness, or defective a Shake the wiring harness by hand while measuring the voltage. If the voltage drops to approximately 0 V during shaking, circuit is HST controller open around this point. Voltage Between S3 (female) (1) and (2) 1 to 4.5 V a If no failure is found by check on cause 2, this check is not required. Open or short circuit in wiring 1. Turn starting switch to OFF position. 2. Disconnect connector ST3 and connect T-adapter to female side. harness Resis- Between ST3 (female) (35) and (3) 34 to 44 z tance a If no failure is found by check on cause 2, this check is not required. Open circuit in wiring harness 1. Turn starting switch to OFF position. 2. Disconnect connectors ST3 and S3, and connect T-adapter to each (wire breakage or defective female side. contact of connector) Resis- Between ST3 (female) (35) and S3 (female) (1) Max. 1 z tance Between ST3 (female) (3) and S3 (female) (2) Max. 1 z If no failure is found by above checks, HST controller may be defective. Defective HST controller (Since this is an internal defect, troubleshooting cannot be performed.)

40-416

D61EM-23M0

40 Troubleshooting

Troubleshooting by failure code (Display of code)

Circuit diagram related to swing slow brake solenoid

D61EM-23M0

40-417

40 Troubleshooting

Troubleshooting by failure code (Display of code)

Failure code [DW7EKB] Slow brake solenoid: Short circuit Action level L04 Detail of failure Action of controller

Problem on machine

Related information

Failure code DW7EKB

Slow brake solenoid: Short circuit (HST controller system)

• When controller drives slow brake solenoid valve, unusual current flows through circuit. • • • • • • • • • •

No.

Failure

Displays parking brake system state monitor on the machine monitor. Stops driving slow brake solenoid valve. Partially limits the functions. Even if cause of failure disappears, machine does not become normal until starting switch is turned to OFF position. The machine stops during travel. The machine cannot start after stopping. Once machine stops, engine speed is restricted to medium (half) speed. Input condition (ON/OFF) from travel lock switches 1 and 2 can be checked with monitoring function. (Code: 40984 "HST SW Input 3") The input stroke and voltage from brake pedal can be checked with monitoring function. (Code: 50401 "Decel/Brake Pedal Stroke"; Code: 50400 "Decel/Brake Pedal Potentio") Method of reproducing failure code: Turn starting switch to ON position, operate parking brake lever (Free position), and operate brake pedal (Release position). Cause

Procedure, measuring location, criteria and remarks

1. Turn starting switch to OFF position. Defective slow brake solenoid 2. Disconnect connector S3 and connect T-adapter to male side. Between S3 (male) (1) and (2) 34 to 44 z (internal defect) ResisBetween ground and each of S3 (male) (1) and tance Min. 1 Mz (2)

Defective diode D4

1. Turn starting switch to OFF position. 2. Disconnect connector D4. 3. Turn starting switch to ON position. 4. Perform troubleshooting by operating the parking brake lever (free). a Ignore any failure code other than this code. If this failure code does not appear, diode D4 is defective.

1. Turn starting switch to OFF position. Ground fault in wiring harness 2. Disconnect connectors ST3 and S3, and connect T-adapter to either female side. (contact with ground circuit) Resis- Between ground and either ST3 (female) (35) Min. 1 Mz or S3 (female) (1) tance

1. Turn starting switch to OFF position. 2. Disconnect connectors ST3,D4 and S3, and connect T-adapter to Short circuit in wiring harness either female side. Resis- Between ST3 (female) (35) and (3), or between Min. 1 Mz S3 (female) (1) and (2) tance

Defective HST controller

40-418

If no failure is found by above checks, HST controller may be defective. (Since this is an internal defect, troubleshooting cannot be performed.)

D61EM-23M0

40 Troubleshooting

Troubleshooting by failure code (Display of code)

Circuit diagram related to slow brake solenoid

D61EM-23M0

40-419

40 Troubleshooting

Troubleshooting by failure code (Display of code)

Failure code [DW7EKY] Slow brake solenoid: Hot Short Action level L03 Detail of failure Action of controller Problem on machine Related information No.

Failure code DW7EKY

Slow brake solenoid: Hot short (HST controller system)

Failure

• Current always flows through slow brake solenoid valve circuit. • Displays parking brake system state monitor on the machine monitor. • Partially limits the functions. • Even if cause of failure disappears, machine does not become normal until starting switch is turned to the OFF position. • Once machine stops, engine speed is restricted to medium (half) speed. • Once machine stops, travel speed is restricted to 50% after restart. • Method of reproducing failure code: Turn starting switch to ON position, operate parking brake lever (Free position), and operate decelerator/ brake pedal (Release position). Cause

Procedure, measuring location, criteria and remarks

1. Turn starting switch to OFF position. Defective slow brake solenoid 2. Disconnect connector S3 and connect T-adapter to male side. (internal defect) 34 to 44 z Resis- Between S3 (male) (1) and (2) tance Between S3 (male) (1) and ground Min. 1 Mz

Hot short circuit in wiring harness

1. Turn starting switch to OFF position. 2. Disconnect connector S3 and connect T-adapter to female side. 3. Turn starting switch to ON position. Voltage Between S3 (female) (1) and (2) Max. 4.5 V 1. Turn starting switch to OFF position. 2. Disconnect connectors ST3,D4, and S3, and connect T-adapter to female side of ST3. a Check by using multimeter in continuity mode. Continuity

Between ST3 (female) (35) and each pin other than pin (35)

No continuity (No sound is heard)

1. Turn starting switch to OFF position. Short circuit in wiring harness 2. Disconnect connectors ST1, ST2, ST3, MC, D4, and S3, and connect T-adapter to either female side of MC or male side of MC. a Check by using multimeter in continuity mode. No continuity Between MC (female) (5) and each pin other than pin (5) (No sound is heard) Continuity No Between MC (male) (5) and each pin other than continuity pin (5) (No sound is heard)

Defective HST controller

40-420

If no failure is found by above checks, HST controller may be defective. (Since this is an internal defect, troubleshooting cannot be performed.)

D61EM-23M0

40 Troubleshooting

Troubleshooting by failure code (Display of code)

Circuit diagram related to slow brake solenoid

D61EM-23M0

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40 Troubleshooting

Troubleshooting by failure code (Display of code)

Failure code [DWN5KA] Fan EPC: Open Action level L03 Detail of failure Action of controller Problem on machine Related information

Failure code DWN5KA

• Stops driving fan EPC solenoid. • • • •

Fan speed is always maximum. Once machine stops, engine speed is restricted to medium (half) speed. Once machine stops, travel is restricted to F1 and R1. Output condition to fan EPC solenoid can be checked with monitoring function. (Code: 31624 "FAN EPC(F/B)") • Method of reproducing failure code: Turn starting switch to ON position. Cause

Defective fan EPC solenoid (internal open circuit)

Fan EPC: Open (HST controller system)

• When controller drives fan EPC solenoid, no current flows through circuit.

No.

Failure

Procedure, measuring location, criteria and remarks 1. Turn starting switch to OFF position. 2. Disconnect connector FAC and connect T-adapter to male side. Resis- Between FAC (male) (1) and (2) 2 to 12 z tance 1. Turn starting switch to OFF position. 2. Disconnect connector FAC and connect T-adapter to female side. 3. Turn starting switch to ON position.

Open circuit, short circuit, a Shake the wiring harness by hand while measuring the voltage. If ground fault, hot short circuit the voltage drops to approximately 0 V during shaking, circuit is of wiring harness, or defective open around this point. HST controller a Voltage becomes approximately 24 V for approximately 0.5 sec. immediately after the starting switch is turned to ON position. Voltage Between FAC (female) (1) and (2) 1 to 4.5 V a If no failure is found by check on cause 2, this check is not required. 1. Turn starting switch to OFF position. Open or short circuit in wiring 2. Disconnect connector ST3 and connect T-adapter to female side. harness a Solenoid coil resistance Resis- Between ST3 (female) (25) and (23) 2 to 12 z tance a If no failure is found by check on cause 2, this check is not required. 1. Turn starting switch to OFF position. Open circuit in wiring harness 2. Disconnect connectors ST3 and FAC, and connect T-adapter to each female side. (wire breakage or defective Between ST3 (female) (25) and FAC (female) contact of connector) Max. 1 z Resis- (1) tance Between ST3 (female) (23) and FAC (female) Max. 1 z (2) If no failure is found by above checks, HST controller may be defective. Defective HST controller (Since this is an internal defect, troubleshooting cannot be performed.)

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Troubleshooting by failure code (Display of code)

Circuit diagram related to fan EPC solenoid

D61EM-23M0

40-423

40 Troubleshooting

Troubleshooting by failure code (Display of code)

Failure code [DWN5KB] Fan EPC: Short circuit Action level L03 Detail of failure Action of controller Problem on machine Related information

Failure code DWN5KB

Failure

Fan EPC: Short circuit (HST controller system)

• When controller drives fan EPC solenoid, abnormal current flows through circuit. • Stops driving fan EPC solenoid. • • • •

No.

Cause

Procedure, measuring location, criteria and remarks

Defective fan EPC solenoid (internal open circuit)

1. Turn starting switch to OFF position. 2. Disconnect connector FAC and connect T-adapter to male side. 2 to 12 z Resis- Between FAC (male) (1) and (2) tance Between FAC (male) (1) and ground Min. 1 Mz

Ground fault in wiring harness (contact with ground circuit)

1. Turn starting switch to OFF position. 2. Disconnect connectors ST3 and FAC, and connect T-adapter to female side of either connector. Resis- Between ground and either ST3 (female) (25) Min. 1 Mz or FAC (female) (1) tance

Short circuit in wiring harness

Defective HST controller

1. Turn starting switch to OFF position. 2. Disconnect connectors ST3 and FAC, and connect T-adapter to female side of either connector. Resis- Between ST3 (female) (25) and (23), or Min. 1 Mz between FAC (female) (1) and (2) tance If no failure is found by above checks, HST controller may be defective. (Since this is an internal defect, troubleshooting cannot be performed.)

Circuit diagram related to fan EPC solenoid

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40 Troubleshooting

Troubleshooting by failure code (Display of code)

Failure code [DWN5KY] Fan EPC: Hot Short Action level L01 Detail of failure Action of controller Problem on machine Related information

Failure code DWN5KY

Fan EPC: Hot Short (HST controller system)

Failure

• Current flows constantly to fan EPC solenoid circuit. • Stops driving fan EPC solenoid. • Fan speed is always minimum. • Machine easily overheats. • Output condition to fan EPC solenoid can be checked with monitoring function. (Code: 31624 "FAN EPC(F/B)") • Method of reproducing failure code: Turn starting switch to ON position.

No.

Cause

Procedure, measuring location, criteria and remarks

Defective fan EPC solenoid (internal open circuit)

Hot short circuit in wiring harness

1. Turn starting switch to OFF position. 2. Disconnect connector FAC and connect T-adapter to female side. 3. Turn starting switch to ON position. a Voltage becomes approximately 24 V for approximately 0.5 sec. immediately after the starting switch is turned to ON position. Voltage Between FAC (female) (1) and (2) Max. 4.5 V 1. Turn starting switch to OFF position. 2. Disconnect connectors ST3 and FAC, and connect T-adapter to female side of ST3. a Check by using multimeter in continuity mode. Continuity

Short circuit in wiring harness

No continuity Between ST3 (female) (25) and each pin other (No sound is than pin (25) heard)

1. Turn starting switch to OFF position. 2. Disconnect connectors ST1, ST2, ST3, 102 and FAC, and connect Tadapter to either female or male side of 102. a Check by using multimeter in continuity mode. Between 102 (female) (7) and each pin other than pin (7) Continuity Between 102 (male) (7) and each pin other than pin (7)

No continuity (No sound is heard) No continuity (No sound is heard)

a If no failure is found by check on cause 2, this check is not required. Open or short circuit in wiring 1. Turn starting switch to OFF position. 2. Disconnect connector ST3 and connect T-adapter to female side. harness Resis- Between ST3 (female) (25) and (23) 2 to 12 z tance If no failure is found by above checks, HST controller may be defective. Defective HST controller (Since this is an internal defect, troubleshooting cannot be performed.)

D61EM-23M0

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40 Troubleshooting

Troubleshooting by failure code (Display of code)

Circuit diagram related to fan EPC solenoid

40-426

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40 Troubleshooting

Troubleshooting by failure code (Display of code)

Failure code [DXA4KA] LF HST pump EPC: Open Action level L03 Detail of failure Action of controller

Problem on machine

Related information

No. 1

• • • • • • • • • • •

LF HST pump EPC: Open Failure code Failure (HST controller system) DXA4KA When controller drives left forward HST pump EPC solenoid valve, no current flows through circuit. Stops driving left forward HST pump EPC solenoid valve. Stops driving right forward HST pump EPC solenoid valve as well. Partially limits the functions. Even if cause of failure disappears, machine does not become normal until starting switch is turned to OFF position. The machine stops during forward travel. The machine cannot start forward after stopping. Once machine stops, engine speed is restricted to medium (half) speed. Once machine stops, travel speed is restricted to 50% after restart. Output current to left forward HST pump EPC solenoid valve can be checked with monitoring function. (Code: 42409 "LF HST Pump EPC(F/B)") Method of reproducing failure code: Start the engine, and operate joystick (steering, directional, and gear shift lever) (forwarding). Cause

Defective left forward HST pump EPC solenoid

Procedure, measuring location, criteria and remarks 1. Turn starting switch to OFF position. 2. Disconnect connector LF and connect T-adapter to male side. Resis- Between LF (male) (1) and (2) 5 to 15 z tance 1. Turn starting switch to OFF position. 2. Disconnect connector LF and connect T-adapter to female side. 3. Turn starting switch to ON position.

Open or short circuit in wiring a Solenoid coil resistance harness Resis- Between ST3 (female) (5) and (3) tance

5 to 15 z

a If no failure is found by check on cause 2, this check is not required. Open circuit in wiring harness 1. Turn starting switch to OFF position. 2. Disconnect connectors ST3 and LF, and connect T-adapters to each (wire breakage or defective female side. contact of connector) Max. 1 z Resis- Between ST3 (female) (5) and LF (female) (1) tance Between ST3 (female) (3) and LF (female) (2) Max. 1 z If no failure is found by above checks, HST controller may be defective. Defective HST controller (Since this is an internal defect, troubleshooting cannot be performed.)

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40 Troubleshooting

Troubleshooting by failure code (Display of code)

Circuit diagram related to left forward HST pump EPC solenoid

40-428

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40 Troubleshooting

Troubleshooting by failure code (Display of code)

Failure code [DXA4KB] LF HST pump EPC: Short circuit Action level L03 Detail of failure Action of controller

Problem on machine

Related information

• • • • • • • • • • •

LF HST pump EPC: Short circuit Failure code Failure (HST controller system) DXA4KB When controller drives left forward HST pump EPC solenoid valve, unusual current flows through circuit. Stops driving left forward HST pump EPC solenoid valve. Stops driving right forward HST pump EPC solenoid valve as well. Partially limits the functions. Even if cause of failure disappears, machine does not become normal until starting switch is turned to the OFF position. The machine stops during forward travel. The machine cannot start forward after stopping. Once machine stops, engine speed is restricted to medium (half) speed. Once machine stops, travel speed is restricted to 50% after restart. Output current to left forward HST pump EPC solenoid valve can be checked with monitoring function. (Code: 42409 "LF HST Pump EPC(F/B)") Method of reproducing failure code: Start the engine, and operate joystick (steering, directional, and gear shift lever) (forwarding).

No.

Cause

Procedure, measuring location, criteria and remarks

Defective left forward HST pump EPC solenoid (internal open circuit)

1. Turn starting switch to OFF position. 2. Disconnect connector LF and connect T-adapter to male side. 5 to 15 z Resis- Between LF (male) (1) and (2) tance Between LF (male) (1) and ground Min. 1 Mz

1. Turn starting switch to OFF position. Ground fault in wiring harness 2. Disconnect connectors ST3 and LF, and connect T-adapter to female side of either connector. (contact with ground circuit) Resis- Between ground and either ST3 (female) (5) or Min. 1 Mz LF (female) (1) tance

1. Turn starting switch to OFF position. 2. Disconnect connectors ST3 and LF, and connect T-adapter to Short circuit in wiring harness female side of either connector. Resis- Between ST3 (female) (5) and (3), or between Min. 1 Mz LF (female) (1) and (2) tance If no failure is found by above checks, HST controller may be defective. Defective HST controller (Since this is an internal defect, troubleshooting cannot be performed.)

Circuit diagram related to left forward HST pump EPC solenoid

D61EM-23M0

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40 Troubleshooting

Troubleshooting by failure code (Display of code)

Failure code [DXA4KY] LF HST pump EPC: Hot Short Action level L04 Detail of failure Action of controller Problem on machine

Related information

No.

• • • • • • • •

LF HST pump EPC:Hot Short Failure code Failure (HST controller system) DXA4KY When controller does not drive left forward HST pump EPC solenoid valve, unusual current flows through circuit. Partially limits the functions. Even if cause of failure disappears, machine does not become normal until starting switch is turned to the OFF position. Left track continues to rotate forward. Once machine stops, engine speed is restricted to medium (half) speed. Once machine stops, it cannot restart. Output current to left forward HST pump EPC solenoid valve can be checked with monitoring function. (Code: 42409 "LF HST Pump EPC(F/B)") Method of reproducing failure code: Start the engine, and operate joystick (steering, directional, and gear shift lever) (forwarding). Cause

Procedure, measuring location, criteria and remarks

Defective left forward HST pump EPC solenoid

1. Turn starting switch to OFF position. 2. Disconnect connector LF and connect T-adapter to male side. Between LF (male) (1) and (2) 5 to 15 z ResisBetween ground and each of LF (male) (1) and tance Min. 1 Mz (2)

Hot short circuit in wiring harness

1. Turn starting switch to OFF position. 2. Disconnect connector LF and connect T-adapter to female side. 3. Turn starting switch to ON position. Voltage Between LF (female) (1) and (2) Max. 4.5 V 1. Turn starting switch to OFF position. 2. Disconnect connectors ST3 and LF, and connect T-adapter to female side of ST3. a Check by using multimeter in continuity mode. Between ST3 (female) (5) and each pin other Continuity than pin (5)

No continuity (No sound is heard)

1. Turn starting switch to OFF position. Short circuit in wiring harness 2. Disconnect connectors ST1, ST2, ST3, 3 and LF, and connect Tadapter to either female or male side of 3. a Check by using multimeter in continuity mode. No continuity (No sound is heard) Continuity No Between 3 (male) (10) and each pin other than continuity pin (10) (No sound is heard) If no failure is found by above checks, HST controller may be defective. (Since this is an internal defect, troubleshooting cannot be performed.) Between 3 (female) (10) and each pin other than pin (10)

Defective HST controller

40-430

D61EM-23M0

40 Troubleshooting

Troubleshooting by failure code (Display of code)

Circuit diagram related to left forward HST pump EPC solenoid

D61EM-23M0

40-431

40 Troubleshooting

Troubleshooting by failure code (Display of code)

Failure code [DXA5KA] LR HST pump EPC: Open Action level L03 Detail of failure Action of controller

Problem on machine

Related information

No. 1

• • • • • • • • • • •

LR HST pump EPC: Open Failure code Failure (HST controller system) DXA5KA When controller drives left reverse HST pump EPC solenoid valve, no current flows through circuit. Stops driving left reverse HST pump EPC solenoid valve. Stops driving right reverse HST pump EPC solenoid valve as well. Partially limits the functions. Even if cause of failure disappears, machine does not become normal until starting switch is turned to the OFF position. The machine stops during reverse travel. The machine cannot start in reverse after stopping. Once machine stops, engine speed is restricted to medium (half) speed. Once machine stops, travel speed is restricted to 50% after restart. Output current to left reverse HST pump EPC solenoid valve can be checked with monitoring function. (Code: 42411 "LR HST Pump EPC(F/B)") Method of reproducing failure code: Start the engine, and operate joystick (steering, directional, and gear shift lever) (reversing). Cause

Defective left reverse HST pump EPC solenoid

Procedure, measuring location, criteria and remarks 1. Turn starting switch to OFF position. 2. Disconnect connector LR and connect T-adapter to male side. Resis- Between LR (male) (1) and (2) 5 to 15 z tance 1. Turn starting switch to OFF position. 2. Disconnect connector LR and connect T-adapter to female side. 3. Turn starting switch to ON position.

Open or short circuit in wiring a Solenoid coil resistance harness Resis- Between ST3 (female) (6) and (3) tance

5 to 15 z

a If no failure is found by check on cause 2, this check is not required. Open circuit in wiring harness 1. Turn starting switch to OFF position. 2. Disconnect connectors ST3 and LR, and connect T-adapter to each (wire breakage or defective female side. contact of connector) Max. 1 z Resis- Between ST3 (female) (6) and LR (female) (1) tance Between ST3 (female) (3) and LR (female) (2) Max. 1 z If no failure is found by above checks, HST controller may be defective. Defective HST controller (Since this is an internal defect, troubleshooting cannot be performed.)

40-432

D61EM-23M0

40 Troubleshooting

Troubleshooting by failure code (Display of code)

Circuit diagram related to reft reverse HST pump EPC solenoid

D61EM-23M0

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40 Troubleshooting

Troubleshooting by failure code (Display of code)

Failure code [DXA5KB] LR HST pump EPC: Short circuit Action level L03 Detail of failure Action of controller

Problem on machine

Related information

• • • • • • • • • • •

LR HST pump EPC: Short circuit Failure code Failure (HST controller system) DXA5KB When controller drives left reverse HST pump EPC solenoid valve, unusual current flows through circuit. Stops driving left reverse HST pump EPC solenoid valve. Stops driving right reverse HST pump EPC solenoid valve as well. Partially limits the functions. Even if cause of failure disappears, machine does not become normal until starting switch is turned to OFF position. The machine stops during reverse travel. The machine cannot start in reverse after stopping. Once machine stops, engine speed is restricted to medium (half) speed. Once machine stops, travel speed is restricted to 50% after restart. Output current to left reverse HST pump EPC solenoid valve can be checked with monitoring function. (Code: 52411 "LR HST Pump EPC(F/B)") Method of reproducing failure code: Start the engine, and operate joystick (steering, directional, and gear shift lever) (reversing).

No.

Cause

Procedure, measuring location, criteria and remarks

Defective left reverse HST pump EPC solenoid (internal open circuit)

1. Turn starting switch to OFF position. 2. Disconnect connector LR and connect T-adapter to male side. Between LR (male) (1) and (2) 5 to 15 z ResisBetween ground and each of LR (male) (1) and tance Min. 1 Mz (2)

1. Turn starting switch to OFF position. Ground fault in wiring harness 2. Disconnect connectors ST3 and LR, and connect T-adapter to female side of either connector. (contact with ground circuit) Resis- Between ground and either ST3 (female) (6) or Min. 1 Mz LR (female) (1) tance

1. Turn starting switch to OFF position. 2. Disconnect connectors ST3 and LR, and connect T-adapter to Short circuit in wiring harness female side of either connector. Resis- Between ST3 (female) (6) and (3), or between Min. 1 Mz LR (female) (1) and (2) tance If no failure is found by above checks, HST controller may be defective. Defective HST controller (Since this is an internal defect, troubleshooting cannot be performed.)

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40 Troubleshooting

Troubleshooting by failure code (Display of code)

Circuit diagram related to left reverse HST pump EPC solenoid

D61EM-23M0

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40 Troubleshooting

Troubleshooting by failure code (Display of code)

Failure code [DXA5KY] LR HST pump EPC: Hot Short Action level L04 Detail of failure Action of controller Problem on machine

Related information

No.

• • • • • • • •

LR HST pump EPC: Hot short Failure code Failure (HST controller system) DXA5KY When controller does not drive left reverse HST pump EPC solenoid valve, unusual current flows through circuit. Partially limits the functions. Even if cause of failure disappears, machine does not become normal until starting switch is turned to OFF position. Left track continues to rotate reversely. Once machine stops, engine speed is restricted to medium (half) speed. Once machine stops, it cannot restart. Output current to left reverse HST pump EPC solenoid valve can be checked with monitoring function. (Code: 52411 "LR HST Pump EPC(F/B)") Method of reproducing failure code: Start the engine, and operate joystick (steering, directional, and gear shift lever) (reversing). Cause

Procedure, measuring location, criteria and remarks

Defective left reverse HST pump EPC solenoid

Hot short circuit in wiring harness

1. Turn starting switch to OFF position. 2. Disconnect connector LR and connect T-adapter to female side. 3. Turn starting switch to ON position. Voltage Between LR (female) (1) and (2) Max. 4.5 V 1. Turn starting switch to OFF position. 2. Disconnect connectors ST3 and LR, and connect T-adapter to female side of ST3. a Check by using multimeter in continuity mode. Between ST3 (female) (6) and each pin other Continuity than pin (6)

No continuity (No sound is heard)

1. Turn starting switch to OFF position. Short circuit in wiring harness 2. Disconnect connectors ST1, ST2, ST3, 3 and LR, and connect Tadapter to either female or male side of 3. a Check by using multimeter in continuity mode. No continuity (No sound is heard) Continuity No Between 3 (male) (11) and each pin other than continuity pin (11) (No sound is heard) If no failure is found by above checks, HST controller may be defective. (Since this is an internal defect, troubleshooting cannot be performed.) Between 3 (female) (11) and each pin other than pin (11)

Defective HST controller

40-436

D61EM-23M0

40 Troubleshooting

Troubleshooting by failure code (Display of code)

Circuit diagram related to left reverse HST pump EPC solenoid

D61EM-23M0

40-437

40 Troubleshooting

Troubleshooting by failure code (Display of code)

Failure code [DXA6KA] RF HST pump EPC: Open Action level L03 Detail of failure Action of controller

Problem on machine

Related information

• • • • • • • • • • •

RF HST pump EPC: Open Failure code Failure (HST controller system) DXA KA When controller drives right forward HST pump EPC solenoid valve, no current flows through circuit. Stops driving right forward HST pump EPC solenoid valve. Stops driving left forward HST pump EPC solenoid valve as well. Partially limits the functions. Even if cause of failure disappears, machine does not become normal until starting switch is turned to the OFF position. The machine stops during forward travel. The machine cannot start forward after stopping. Once machine stops, engine speed is restricted to medium (half) speed. Once machine stops, travel speed is restricted to 50% after restart. Output current to right forward HST pump EPC solenoid valve can be checked with monitoring function. (Code: 52408 "RF HST Pump EPC(F/B)") Method of reproducing failure code: Start the engine, and operate joystick (steering, directional, and gear shift lever) (forwarding).

No.

Cause

Defective right forward HST pump EPC solenoid

Procedure, measuring location, criteria and remarks 1. Turn starting switch to OFF position. 2. Disconnect connector RF and connect T-adapter to male side. Resis- Between RF (male) (1) and (2) 5 to 15 z tance 1. Turn starting switch to OFF position. 2. Disconnect connector RF and connect T-adapter to female side. 3. Turn starting switch to ON position.

Open or short circuit in wiring a Solenoid coil resistance harness Resis- Between ST3 (female) (15) and (23) tance

5 to 15 z

a If no failure is found by check on cause 2, this check is not required. Open circuit in wiring harness 1. Turn starting switch to OFF position. 2. Disconnect connectors ST3 and RF, and connect T-adapter to each (wire breakage or defective female side. contact of connector) Resis- Between ST3 (female) (15) and RF (female) (1) Max. 1 z tance Between ST3 (female) (23) and RF (female) (2) Max. 1 z If no failure is found by above checks, HST controller may be defective. Defective HST controller (Since this is an internal defect, troubleshooting cannot be performed.)

40-438

D61EM-23M0

40 Troubleshooting

Troubleshooting by failure code (Display of code)

Circuit diagram related to right forward HST pump EPC solenoid

D61EM-23M0

40-439

40 Troubleshooting

Troubleshooting by failure code (Display of code)

Failure code [DXA6KB] RF HST pump EPC: Short circuit Action level L03 Detail of failure Action of controller

Problem on machine

Related information

• • • • • • • • • • •

RF HST pump EPC: Short circuit Failure code Failure (HST controller system) DXA6KB When controller drives right forward HST pump EPC solenoid valve, unusual current flows through circuit. Stops driving right forward HST pump EPC solenoid valve. Stops driving left forward HST pump EPC solenoid valve as well. Partially limits the functions. Even if cause of failure disappears, machine does not become normal until starting switch is turned to OFF position. The machine stops during forward travel. The machine cannot start forward after stopping. Once machine stops, engine speed is restricted to medium (half) speed. Once machine stops, travel speed is restricted to 50% after restart. Output current to right forward HST pump EPC solenoid valve can be checked with monitoring function. (Code: 42408 "RF HST Pump EPC(F/B)") Method of reproducing failure code: Start the engine, and operate joystick (steering, directional, and gear shift lever) (forwarding).

No.

Cause

Procedure, measuring location, criteria and remarks

Defective right forward HST pump EPC solenoid (internal open circuit)

1. Turn starting switch to OFF position. 2. Disconnect connector RF and connect T-adapter to male side. 5 to 15 z Resis- Between RF (male) (1) and (2) tance Between RF (male) (1) and ground Min. 1 Mz

1. Turn starting switch to OFF position. Ground fault in wiring harness 2. Disconnect connectors ST3 and RF, and connect T-adapter to female side of either connector. (contact with ground circuit) Resis- Between ground and either ST3 (female) (15) Min. 1 Mz or RF (female) (1) tance

1. Turn starting switch to OFF position. 2. Disconnect connectors ST3 and RF, and connect T-adapter to Short circuit in wiring harness female side of either connector. Resis- Between ST3 (female) (15) and (23), or Min. 1 Mz between RF (female) (1) and (2) tance If no failure is found by above checks, HST controller may be defective. Defective HST controller (Since this is an internal defect, troubleshooting cannot be performed.)

Circuit diagram related to right forward HST pump EPC solenoid

40-440

D61EM-23M0

40 Troubleshooting

Troubleshooting by failure code (Display of code)

Failure code [DXA6KY] RF HST pump EPC: Hot Short Action level L04 Detail of failure Action of controller Problem on machine Related information

• • • • • • • •

RF HST pump EPC: Hot Short Failure code Failure (HST controller system) DXA6KY When controller does not drive right forward HST pump EPC solenoid valve, unusual current flows through circuit. Partially limits the functions. Even if cause of failure disappears, machine does not become normal until starting switch is turned to OFF position. Right track continues to rotate forward. Once machine stops, engine speed is restricted to medium (half) speed. Once machine stops, it cannot restart. Output current to right forward HST pump EPC solenoid valve can be checked with monitoring function. (Code: 52408 "RF HST Pump EPC(F/B)") Method of reproducing failure code: Start engine. Cause

Procedure, measuring location, criteria and remarks

Defective right forward HST pump EPC solenoid

1. Turn starting switch to OFF position. 2. Disconnect connector RF and connect T-adapter to male side. Between RF (male) (1) and (2) 5 to 15 z ResisBetween ground and each of RF (male) (1) and tance Min. 1 Mz (2)

Hot short circuit in wiring harness

1. Turn starting switch to OFF position. 2. Disconnect connector RF and connect T-adapter to female side. 3. Turn starting switch to ON position. Voltage Between RF (female) (1) and (2) Max. 4.5 V

No.

1. Turn starting switch to OFF position. 2. Disconnect connectors ST3 and RF, and connect T-adapter to female side of ST3. a Check by using multimeter in continuity mode. Between ST3 (female) (15) and each pin other Continuity than pin (15)

No continuity (No sound is heard)

1. Turn starting switch to OFF position. Short circuit in wiring harness 2. Disconnect connectors ST1, ST2, ST3, 3 and RF, and connect Tadapter to either female or male side of 3. a Check by using multimeter in continuity mode.

Defective HST controller

D61EM-23M0

No Between 3 (female) (6) and each pin other than continuity pin (6) (No sound is heard) Continuity No continuity Between 3 (male) (6) and each pin other than pin (6) (No sound is heard) If no failure is found by above checks, HST controller may be defective. (Since this is an internal defect, troubleshooting cannot be performed.)

40-441

40 Troubleshooting

Troubleshooting by failure code (Display of code)

Circuit diagram related to right forward HST pump EPC solenoid

40-442

D61EM-23M0

40 Troubleshooting

Troubleshooting by failure code (Display of code)

Failure code [DXA7KA] RR HST pump EPC: Open Action level L03 Detail of failure Action of controller

Problem on machine

Related information

• • • • • • • • • • •

RR HST pump EPC: Open Failure code Failure (HST controller system) DXA7KA When controller drives right reverse HST pump EPC solenoid valve, no current flows through circuit. Stops driving right reverse HST pump EPC solenoid valve. Stops driving left reverse HST pump EPC solenoid valve as well. Partially limits the functions. Even if cause of failure disappears, machine does not become normal until starting switch is turned to OFF position. The machine stops during reverse travel. The machine cannot start in reverse after stopping. Once machine stops, engine speed is restricted to medium (half) speed. Once machine stops, travel speed is restricted to 50% after restart. Output current to right reverse HST pump EPC solenoid valve can be checked with monitoring function. (Code: 52410 "RR HST Pump EPC(F/B)") Method of reproducing failure code: Start the engine, and operate joystick (steering, directional, and gear shift lever) (reversing).

No.

Cause

Defective right reverse HST pump EPC solenoid

Procedure, measuring location, criteria and remarks 1. Turn starting switch to OFF position. 2. Disconnect connector RR and connect T-adapter to male side. Resis- Between RR (male) (1) and (2) 5 to 15 z tance 1. Turn starting switch to OFF position. 2. Disconnect connector RR and connect T-terminal to female side. 3. Turn starting switch to ON position.

Open or short circuit in wiring a Solenoid coil resistance harness Resis- Between ST3 (female) (16) and (23) tance

5 to 15 z

a If no failure is found by check on cause 2, this check is not required. Open circuit in wiring harness 1. Turn starting switch to OFF position. 2. Disconnect connectors ST3 and RR, and connect T-adapters to (wire breakage or defective each female side. contact of connector) Resis- Between ST3 (female) (16) and RR (female) (1) Max. 1 z tance Between ST3 (female) (23) and RR (female) (2) Max. 1 z If no failure is found by above checks, HST controller may be defective. Defective HST controller (Since this is an internal defect, troubleshooting cannot be performed.)

D61EM-23M0

40-443

40 Troubleshooting

Troubleshooting by failure code (Display of code)

Circuit diagram related to right reverse HST pump EPC solenoid

40-444

D61EM-23M0

40 Troubleshooting

Troubleshooting by failure code (Display of code)

Failure code [DXA7KB] RR HST pump EPC: Short circuit Action level L03 Detail of failure Action of controller

Problem on machine

Related information

• • • • • • • • • • •

RR HST pump EPC: Short circuit Failure code Failure (HST controller system) DXA7KB When controller drives right reverse HST pump EPC solenoid valve, unusual current flows through circuit. Stops driving right reverse HST pump EPC solenoid valve. Stops driving left reverse HST pump EPC solenoid valve as well. Partially limits the functions. Even if cause of failure disappears, machine does not become normal until starting switch is turned to the OFF position. The machine stops during reverse travel. The machine cannot start in reverse after stopping. Once machine stops, engine speed is restricted to medium (half) speed. Once machine stops, travel speed is restricted to 50% after restart. Output current to right reverse HST pump EPC solenoid valve can be checked with monitoring function. (Code: 52410 "RR HST Pump EPC(F/B)") Method of reproducing failure code: Start the engine, and operate joystick (steering, directional, and gear shift lever) (reversing).

No.

Cause

Procedure, measuring location, criteria and remarks

Defective right reverse HST pump EPC solenoid (internal open circuit)

1. Turn starting switch to OFF position. 2. Disconnect connector RR and connect T-adapter to male side. 5 to 15 z Resis- Between RR (male) (1) and (2) tance Between RR (male) (1) and ground Min. 1 Mz

1. Turn starting switch to OFF position. Ground fault in wiring harness 2. Disconnect connectors ST3 and RR, and connect T-adapter to female side of either connector. (contact with ground circuit) Resis- Between ground and either ST3 (female) (16) Min. 1 Mz or RR (female) (1) tance

1. Turn starting switch to OFF position. 2. Disconnect connectors ST3 and RR, and connect T-adapter to Short circuit in wiring harness female side of either connector. Resis- Between ST3 (female) (16) and (23), or Min. 1 Mz between RR (female) (1) and (2) tance If no failure is found by above checks, HST controller may be defective. Defective HST controller (Since this is an internal defect, troubleshooting cannot be performed.)

Circuit diagram related to right reverse HST pump EPC solenoid

D61EM-23M0

40-445

40 Troubleshooting

Troubleshooting by failure code (Display of code)

Failure code [DXA7KY] RR HST pump EPC: Hot Short Action level L04 Detail of failure Action of controller Problem on machine

Related information

• • • • • • • •

RR HST pump EPC: Hot Short Failure code Failure (HST controller system) DXA7KY When controller does not drive right reverse HST pump EPC solenoid valve, unusual current flows through circuit. Partially limits the functions. Even if cause of failure disappears, machine does not become normal until starting switch is turned to the OFF position. Right track continues to rotate reversely. Once machine stops, engine speed is restricted to medium (half) speed. Once machine stops, it cannot restart. Output current to right reverse EPC solenoid valve can be checked with monitoring function. (Code: 52410 "RR HST Pump EPC(F/B)") Method of reproducing failure code: Start the engine, and operate joystick (steering, directional, and gear shift lever) (reversing).

No.

Cause

Procedure, measuring location, criteria and remarks

Defective right reverse HST pump EPC solenoid (internal open circuit)

1. Turn starting switch to OFF position. 2. Disconnect connector RR and connect T-adapter to male side. Between RR (male) (1) and (2) 5 to 15 z ResisBetween ground and each of RR (male) (1) and tance Min. 1 Mz (2)

Hot short circuit in wiring harness

1. Turn starting switch to OFF position. 2. Disconnect connector RR and connect T-terminal to female side. 3. Turn starting switch to ON position. Voltage Between RR (female) (1) and (2) Max. 4.5 V 1. Turn starting switch to OFF position. 2. Disconnect connectors ST3 and RR, and connect T-adapter to female side of ST3. a Check by using multimeter in continuity mode. Between ST3 (female) (16) and each pin other Continuity than pin (16)

No continuity (No sound is heard)

1. Turn starting switch to OFF position. Short circuit in wiring harness 2. Disconnect connectors ST1, ST2, ST3, 3 and RR, and connect Tadapters to either female or male side of 3. a Check by using multimeter in continuity mode.

Defective HST controller

40-446

No Between 3 (female) (5) and each pin other than continuity pin (5) (No sound is heard) Continuity No continuity Between 3 (male) (5) and each pin other than pin (5) (No sound is heard) If no failure is found by above checks, HST controller may be defective. (Since this is an internal defect, troubleshooting cannot be performed.)

D61EM-23M0

40 Troubleshooting

Troubleshooting by failure code (Display of code)

Circuit diagram related to right reverse HST pump EPC solenoid

D61EM-23M0

40-447

40 Troubleshooting

Troubleshooting by failure code (Display of code)

Failure code [DXHRKA] Blade lift up EPC: Open Action level L01 Detail of failure Action of controller Problem on machine Related information

No. 1

Failure code DXHRKA

Failure

Blade lift up EPC: Open (HST controller system)

• When controller drives blade RAISE EPC solenoid, no current flows through circuit. • Stops driving blade RAISE EPC solenoid. • Blade cannot be raised.

• Output condition to blade RAISE EPC solenoid can be checked with monitoring function. (Code: 71001 "Blade Raise EPC(F/B)") • Method of reproducing failure code: Turn starting switch to ON position, and operate blade control lever (raising). • & & % $ -- 6 ^ -- 6 ` $ $ . 4% $ . ! &$ $% $$ ' &$ & Cause

Procedure, measuring location, criteria and remarks

1. Turn starting switch to OFF position. Defective blade RAISE EPC sole- 2. Disconnect connector LU1 and connect T-adapter to male side. noid (internal open circuit) Resistance Between LU1 (male) (1) and (2) 2 to 12 Ω

1. Turn starting switch to OFF position. 2. Disconnect connector LU1, and connect T-adapter to female side. 3. Turn starting switch to ON position with work equipment lock in FREE. Open circuit, short circuit, ground a Shake the wiring harness by hand while measuring the voltage. If the voltage drops to approximately 0 V during shaking, circuit is open around this 2 fault, hot short circuit of wiring harpoint. ness, or defective HST controller a Voltage becomes approximately 25 V for approximately 0.5 sec. immediately after the starting switch is turned to ON position. Voltage

Between LU1 (female) (1) and (2)

1 to 4.5 V

1. Turn starting switch to OFF position. 2. Disconnect connector ST3 and connect T-adapter to female side. Open or short circuit in wiring har- 3. Turn starting switch to ON position with work equipment lock in FREE. 3 ness a Solenoid coil resistance Resistance Between ST3 (female) (8) and (3)

Open circuit in wiring harness 4 (wire breakage or defective contact of connector)

2 to 12 Ω

a If no failure is found by check on cause 2, this check is not required. 1. Turn starting switch to OFF position. 2. Disconnect connectors ST3, BLR, and LU1, and connect T-adapter to each female side. Between ST3 (female) (8) and BLR (female) (1)

Max. 1 Ω

Resistance Between BLR (female) (2) and LU1 (female) (1)

Max. 1 Ω

Between ST3 (female) (3) and LU1 (female) (2)

Max. 1 Ω

1. Turn starting switch to OFF position. 2. Disconnect relay BLR and connect T-adapter to male side. Resistance Between BLR (male) (1) and (2) 5

200 to 400 Ω

Defective work equipment lift relay 1. Turn starting switch to OFF position. (BLR) 2. Replace relay BLR with another one such as cleaning water pump relay (RCW). 3. Turn starting switch to ON position. If this failure code disappears, original work equipment lift relay (BLR) is defective.

40-448

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40 Troubleshooting

Troubleshooting by failure code (Display of code)

No.

Cause

Open circuit in wiring harness 6 (wire breakage or defective contact of connector)

Procedure, measuring location, criteria and remarks a Following checks are unnecessary if no abnormality is detected by above checks. 1. Turn starting switch to OFF position. 2. Disconnect connectors BLR, WELR and PSW1, and connect T-adapter to female side of each connector.

Resistance

Between BLR (female) (6) and ground

Max. 1 Ω

Between BLR (female) (5) and WELR (female) (2)

Max. 1 Ω

Between WELR (female) (6) (+) and PSW1 (female) (B) (-)

Max. 1 Ω

1. Turn starting switch to OFF position. 2. Disconnect relay WELR and connect T-adapter to male side. Resistance Between WELR (male) (1) and (2) 7

200 to 400 Ω

Defective work equipment lift relay 1. Turn starting switch to OFF position. 2 (WELR) 2. Replace relay WELR with another one such as cleaning water pump relay (RCW). 3. Turn starting switch to ON position. If this failure code disappears, original work equipment lift relay 2 (WELR) is defective.

Open circuit in wiring harness 8 (wire breakage or defective contact of connector)

a Following checks are unnecessary if no abnormality is detected by above checks. 1. Turn starting switch to OFF position. 2. Disconnect connectors WELR and PSW1, and connect T-adapter to female side of each connector. 3. Turn starting switch to ON position. Voltage

9 Defective HST controller

D61EM-23M0

WELR (female) (5)

Min. 17 V

WELR (female) (1)

Min. 17 V

If no failure is found by above checks, HST controller may be defective. (Since this is an internal defect, troubleshooting cannot be performed.)

40-449

40 Troubleshooting

Troubleshooting by failure code (Display of code)

Circuit diagram related to blade RAISE EPC solenoid

40-450

D61EM-23M0

40 Troubleshooting

Troubleshooting by failure code (Display of code)

Failure code [DXHRKB] Blade lift up EPC: Short circuit Action level L01 Detail of failure Action of controller Problem on machine

Failure code DXHRKB

Failure

Blade lift up EPC: Short circuit (HST controller system)

• When controller drives blade RAISE EPC solenoid, unusual current flows through circuit. • Stops driving blade RAISE EPC solenoid. • Blade cannot be raised.

Related information

No.

Cause

Procedure, measuring location, criteria and remarks

Defective blade RAISE EPC solenoid (internal open circuit)

Turn starting switch to OFF position. Disconnect connector 6 and connect T-adapter to male side. 2 to 12z Resis- Between 6 (male) (1) and (2) tance Between ground and 6 (male) (1) and (2) Min. 1 Mz

Turn starting switch to OFF position. Ground fault in wiring harness Disconnect connectors ST3 and LU , and connect T-adapter to female $& $ $ (contact with ground circuit) Min. 1 Mz Resis- ` *3 (& ) ( ) ' $% tance ` 6 (& ) ( ) ' $% Min. 1 Mz Turn starting switch to OFF position. Disconnect connectors ST3 and 6 , and connect T-adapter to female side of either connector. *hort circuit in wiring harness Min. 1 Mz Resis- ` *3 (& ) ( ) ( ) tance Min. 1 Mz ` 6 (& ) ( ) ( ) If no failure is found by above checks, HST controller may be defective. Defective HST controller (Since this is an internal defect, troubleshooting cannot be performed.)

D61EM-23M0

40-451

40 Troubleshooting

Troubleshooting by failure code (Display of code)

Circuit diagram related to blade RAISE EPC solenoid

40-452

D61EM-23M0

40 Troubleshooting

Troubleshooting by failure code (Display of code)

Failure code [DXHRKY] Blade lift up EPC: Hot short Action level L03 Detail of failure Action of controller Problem on machine Related information No. 1

Failure code DXHRKY

Failure

Blade lift up EPC: Hot short (HST controller system)

• Current always flows to blade RAISE EPC solenoid circuit. • • • • • • •

Stops driving blade RAISE EPC solenoid. Restricts engine operation. Blade continues to be raised. Once machine stops, engine speed is restricted to medium (half) speed. Once machine stops, travel is restricted to F1 and R1. Automatic gear shift function does not work. Output condition to blade RAISE EPC solenoid can be checked with monitoring function. (Code: 71001 "Blade Raise EPC(F/B)") • Method of reproducing failure code: Turn starting switch to ON position. Cause

Procedure, measuring location, criteria and remarks

Turn starting switch to OFF position. Defective blade RAISE EPC Disconnect connector 6 and connect T-adapter to male side. solenoid (internal open Between 6 (male) (1) and (2) 2 to 12 z circuit) Resistance Between 6 (male) (1) and ground Min. 1 Mz

Hot short circuit in wiring harness

Turn starting switch to OFF position. Disconnect connector 6 , and connect T-adapter to female side. 3% ' $ ~ $ $ $ . 4% $ . 855 a Voltage becomes approximately 25 V for approximately 0.5 sec. immediately after the starting switch is turned to ON position. Voltage Between 6 (female) (1) and (2) Max. 4.5 V Turn starting switch to OFF position. Disconnect connector ST3, and connect T-adapter to female side of ST3. a Check by using multimeter in continuity mode. Between ST3 (female) (8) and each pin other Continuity than pin (8)

No continuity (No sound is heard)

Turn starting switch to OFF position. Disconnect connectors ST1, ST2, ST3 WE, and connect TShort circuit in wiring harness adapter to either female or male side of WE. a Check by using multimeter in continuity mode. No continuity (No sound is heard) Continuity No continuity Between WE (male) (12) and each pin other than pin (12) (No sound is heard) If no failure is found by above checks, HST controller may be defective. (Since this is an internal defect, troubleshooting cannot be performed.) Between WE (female) (12) and each pin other than pin (12)

Defective HST controller

D61EM-23M0

40-453

40 Troubleshooting

Troubleshooting by failure code (Display of code)

Circuit diagram related to blade RAISE EPC solenoid

40-454

D61EM-23M0

40 Troubleshooting

Troubleshooting by failure code (Display of code)

Failure code [DXHSKA] Blade lift down EPC: Open Action level L01 Detail of failure Action of controller Problem on machine

Related information

No.

Failure code DXHSKA

Failure

Blade lift down EPC: Open (HST controller system)

• When controller drives blade LOWER EPC solenoid, no current flows through circuit. • Stops driving blade LOWER EPC solenoid. • Blade cannot be lowered.

• Output condition to blade LOWER EPC solenoid can be checked with monitoring function. (Code: 71003 "Blade Down EPC(F/B)") • Method of reproducing failure code: Turn starting switch to ON position, and operate blade control lever (lowering down). • & & % $ -- 6 ^ -- 6 ` $ $ . 4% $ . ! &$ $% $$ ' &$ & Cause

Defective blade LOWER EPC 1 solenoid (internal open circuit)

Open circuit, short circuit, ground fault, hot short circuit 2 of wiring harness, or defective HSTcontroller

Procedure, measuring location, criteria and remarks 1. Turn starting switch to OFF position. 2. Disconnect connector LD1 and connect T-adapter to male side. Resistance Between LD1 (male) (1) and (2)

2 to 12 Ω

1. Turn starting switch to OFF position. 2. Disconnect connector LD1, and connect T-adapter to female side. 3. Turn starting switch to ON position with work equipment lock in FREE. a Shake the wiring harness by hand while measuring the voltage. If the voltage drops to approximately 0 V during shaking, circuit is open around this point. a Voltage becomes approximately 25 V for approximately 0.5 sec. immediately after the starting switch is turned to ON position. Voltage

Between LD1 (female) (1) and (2)

1 to 4.5 V

Open circuit in wiring harness 4 (wire breakage or defective contact of connector)

2 to 12 Ω

a If no failure is found by check on cause 2, this check is not required. 1. Turn starting switch to OFF position. 2. Disconnect connectors ST3, BLR, and LD1, and connect T-adapters to each female side. Between ST3 (female) (18) and BLR (female) (1)

Max. 1 Ω

Resistance Between BLR (female) (4) and LD1 (female) (1)

Max. 1 Ω

Between ST3 (female) (13) and LD1 (female) (2)

Max. 1 Ω

1. Turn starting switch to OFF position. 2. Disconnect relay BLR and connect T-adapter to male side. Resistance Between BLR (male) (1) and (2) 5

200 to 400 Ω

D61EM-23M0

40-455

40 Troubleshooting

Troubleshooting by failure code (Display of code)

No.

Cause

Open circuit in wiring harness 6 (wire breakage or defective contact of connector)

Resistance

Between BLR (female) (6) and ground

Max. 1 Ω

Between BLR (female) (5) and WELR (female) (2)

Max. 1 Ω

Between WELR (female) (6) (+) and PSW1 (female) (B) (-)

Max. 1 Ω

1. Turn starting switch to OFF position. 2. Disconnect relay WELR and connect T-adapter to male side. Resistance Between WELR (male) (1) and (2) 7

200 to 400 Ω

Open circuit in wiring harness 8 (wire breakage or defective contact of connector)

9 Defective HST controller

40-456

WELR (female) (5)

Min. 17 V

WELR (female) (1)

Min. 17 V

If no failure is found by above checks, HST controller may be defective. (Since this is an internal defect, troubleshooting cannot be performed.)

D61EM-23M0

40 Troubleshooting

Troubleshooting by failure code (Display of code)

Circuit diagram related to blade LOWER EPC solenoid

D61EM-23M0

40-457

40 Troubleshooting

Troubleshooting by failure code (Display of code)

Failure code [DXHSKB] Blade lift down EPC: Short circuit Action level L01 Detail of failure Action of controller Problem on machine

Blade lift down EPC: Short circuit Failure code Failure (HST controller system) DXHSKB • When controller drives blade LOWER EPC solenoid, unusual current flows through circuit. • Stops driving blade LOWER EPC solenoid. • Blade cannot be lowered.

Related information

No.

Cause

Procedure, measuring location, criteria and remarks

Turn starting switch to OFF position. Defective blade LOWER EPC Disconnect connector 6- and connect T-adapter to male side. solenoid (internal open 2 to 12 z Resis- Between 6- (male) (1) and (2) circuit) tance Between 6- (male) (1) and ground Min. 1 Mz Turn starting switch to OFF position. Ground fault in wiring harness Disconnect connectors ST3 and 6- , and connect T-adapter to female $& $ $ . (contact with ground circuit) Min. 1 Mz Resis- ` *3 (& ) ( ) ' $% tance ` 6- (& ) ( ) ' $% Min. 1 Mz Turn starting switch to OFF position. Disconnect connectors ST3 and 6- , and connect T-adapter to Short circuit in wiring harness female side of either connector. Min. 1 Mz Resis- ` *3 (& ) ( ) ( ) tance Min. 1 Mz ` 6 (& ) ( ) ( ) If no failure is found by above checks, HST controller may be defective. Defective HST controller (Since this is an internal defect, troubleshooting cannot be performed.)

40-458

D61EM-23M0

40 Troubleshooting

Troubleshooting by failure code (Display of code)

Circuit diagram related to blade LOWER EPC solenoid

D61EM-23M0

40-459

40 Troubleshooting

Troubleshooting by failure code (Display of code)

Failure code [DXHSKY] Blade lift down EPC: Hot short Action level L03 Detail of failure Action of controller Problem on machine Related information

Failure code DXHSKY

Failure

Blade lift down EPC: Hot short (HST controller system)

• Current always flows to blade LOWER EPC solenoid circuit. • • • • • • •

Stops driving blade LOWER EPC solenoid. Restricts engine operation. Blade continues to be lowered. Once machine stops, engine speed is restricted to medium (half) speed. Once machine stops, travel is restricted to F1 and R1. Automatic gear shift function does not work. Output condition to blade LOWER EPC solenoid can be checked with monitoring function. (Code: 71003 "Blade Down EPC(F/B)") • Method of reproducing failure code: Turn starting switch to ON position.

No.

Cause

Procedure, measuring location, criteria and remarks

Defective blade LOWER EPC solenoid (internal open circuit)

Turn starting switch to OFF position. Disconnect connector 6 and connect T-adapter to male side. Between 6 (male) (1) and (2) 2 to 12 z Resistance Between 6 (male) (1) and ground Min. 1 Mz

Hot short circuit in wiring harness

Turn starting switch to OFF position. Disconnect connector 6 , and connect T-adapter to female side. Turn starting switch to ON position $ . 4% $ . 855 a Voltage becomes approximately 25 V for approximately 0.5 sec. immediately after the starting switch is turned to ON position. Voltage Between 6 (female) (1) and (2) Max. 4.5 V Turn starting switch to OFF position. Disconnect connector LD, and connect T-adapter to female side a Check by using multimeter in continuity mode. Between ST3 (female) (18) and each pin other Continuity than pin (18)

No continuity (No sound is heard)

Turn starting switch to OFF position. Disconnect connectors ST1, ST2, ST3 WE and connect Short circuit in wiring harness T-adapter to either female or male side of WE. a Check by using multimeter in continuity mode. No continuity (No sound is heard) Continuity No continuity Between WE (male) (10) and each pin other than pin (10) (No sound is heard) If no failure is found by above checks, HST controller may be defective. (Since this is an internal defect, troubleshooting cannot be performed.) Between WE (female) (10) and each pin other than pin (10)

Defective HST controller

40-460

D61EM-23M0

40 Troubleshooting

Troubleshooting by failure code (Display of code)

Circuit diagram related to blade LOWER EPC solenoid

D61EM-23M0

40-461

40 Troubleshooting

Troubleshooting by failure code (Display of code)

Failure code [DXHTKA] Blade tilt left EPC: Open Action level L01 Detail of failure Action of controller Problem on machine

Failure code DXHTKA

Failure

Blade tilt left EPC: Open (` . $ % ! 5" ~ ) (HST controller system)

• 3 $ $ , &% $ 5" % % $ $ $ ` . $ % ! , , 7$ , $ $ ! ` & 5" ~ ' &$ % $ • When controller drives ` . $ % ! EPC solenoid, no current flows through circuit. • Stops driving ` . $ % ! EPC solenoid. • 7! % $ $ % $ ` . !

Related information

• The output condition to ` . $ % ! EPC solenoid can be checked with monitoring function. (Code: 71005 "Blade Tilt LH EPC(F/B)") • Method of reproducing failure code: Turn starting switch to ON position, and operate ` . !

No.

Cause

Procedure, measuring location, criteria and remarks

Defective ` . $ % ! EPC solenoid (internal open circuit)

1. Turn starting switch to OFF position. 2. Disconnect connector TL and connect T-adapter to male side. Resis- Between TL (male) (1) and (2) 2 to 12 z tance 1. Turn starting switch to OFF position. 2. Disconnect connector TL, and connect T-adapter to female side. 3. Turn starting switch to ON position.

Open or short circuit in wiring a Solenoid coil resistance harness Resis- Between ST3 (female) (28) and (13) tance

2 to 12 z

a If no failure is found by check on cause 2, this check is not required. Open circuit in wiring harness 1. Turn starting switch to OFF position. 2. Disconnect connectors ST3 and TL, and connect T-adapter to each (wire breakage or defective female side. contact of connector) Resis- Between ST3 (female) (28) and TL (female) (1) Max. 1 z tance Between ST3 (female) (13) and TL (female) (2) Max. 1 z If no failure is found by above checks, HST controller may be defective. Defective HST controller (Since this is an internal defect, troubleshooting cannot be performed.)

40-462

D61EM-23M0

40 Troubleshooting

Troubleshooting by failure code (Display of code)

Circuit diagram related to Bracke oil supply EPC solenoid

D61EM-23M0

40-463

40 Troubleshooting

Troubleshooting by failure code (Display of code)

Failure code [DXHTKB] Blade tilt left EPC: Short circuit Action level L01 Detail of failure Action of controller Problem on machine

Failure code DXHTKB

Failure

Blade tilt left EPC: Short circuit (` . $ % ! 5" * $ % ) (HST controller system)

• 3 $ $ , &% $ 5" % % $ $ $ ` . $ % ! , , 7$ , $ $ ! ` & 5" * $ % ' &$ % $ • When controller drives ` . $ % ! EPC solenoid, unusual current flows through circuit. • Stops driving ` . $ % ! EPC solenoid. • 7! % $ $ % $ ` . !

Related information

No.

Cause

Procedure, measuring location, criteria and remarks

Defective ` . $ % ! EPC solenoid (internal open circuit)

1. Turn starting switch to OFF position. 2. Disconnect connector TL and connect T-adapter to male side. 2 to 12 z Resis- Between TL (male) (1) and (2) tance Between TL (male) (1) and ground Min. 1 Mz

1. Turn starting switch to OFF position. Ground fault in wiring harness 2. Disconnect connectors ST3 and TL, and connect T-adapter to female side of either connector. (contact with ground circuit) Resis- Between ground and ST3 (female) (28) or TL Min. 1 Mz (female) (1) tance

1. Turn starting switch to OFF position. 2. Disconnect connectors ST3 and TL, and connect T-adapter to Short circuit in wiring harness female side of either connector. Resis- Between ST3 (female) (28) and (13), or Min. 1 Mz between TL (female) (1) and (2) tance If no failure is found by above checks, HST controller may be defective. Defective HST controller (Since this is an internal defect, troubleshooting cannot be performed.)

Circuit diagram related to & ' * $ ! EPC solenoid

40-464

D61EM-23M0

40 Troubleshooting

Troubleshooting by failure code (Display of code)

Failure code [DXHTKY] Blade tilt left EPC: Hot short Action level L03 Detail of failure Action of controller Problem on machine

Failure code DXHTKY

Failure

Blade tilt left EPC: Hot short (` . $ % ! 5" 7$ $ ) (7*3 $ $ ! )

• 3 $ $ , &% $ 5" % % $ $ $ ` . $ % ! , , 7$ , $ $ ! ` & 5" 7$ $ ' &$ % $ • Current always flows to ` . $ % ! EPC solenoid circuit. • Stops driving ` . $ % ! EPC solenoid. • Restricts engine operation. • 7! % $ $ % $ % $ ` . ! • Once machine stops, engine speed is restricted to medium (half) speed. • Automatic gear shift function does not work.

Related information

• The output status to ` . $ % ! EPC solenoid can be checked with monitoring function.(Code: 71005 "Blade Tilt LH EPC(F/B)") • Method of reproducing failure code: Turn starting switch to ON position.

No.

Cause

Procedure, measuring location, criteria and remarks

1. Turn starting switch to OFF position. Defective ` . $ % ! 2. Disconnect connector TL and connect T-adapter to male side. EPC solenoid (internal open Between TL (male) (1) and (2) 2 to 12 z circuit) Resistance Between ground and each of TL (male) (1) and Min. 1 Mz (2)

Hot short circuit in wiring harness

1. Turn starting switch to OFF position. 2. Disconnect connector TL, and connect T-adapter to female side. 3. Turn starting switch to ON position. Voltage Between TL (female) (1) and (2) Max. 4.5 V 1. Turn starting switch to OFF position. 2. Disconnect connectors ST3 and TL, and connect T-adapter to female side of ST3. a Check by using multimeter in continuity mode. Between ST3 (female) (28) and each pin other Continuity than pin (28)

No continuity (No sound is heard)

1. Turn starting switch to OFF position. Short circuit in wiring harness 2. Disconnect connectors ST1, ST2, ST3, WE and TL, and connect Tadapter to either female or male side of WE. a Check by using multimeter in continuity mode. No continuity (No sound is heard) Continuity No Between WE (male) (8) and each pin other than continuity pin (8) (No sound is heard) If no failure is found by above checks, HST controller may be defective. (Since this is an internal defect, troubleshooting cannot be performed.) Between WE (female) (8) and each pin other than pin (8)

Defective HST controller

D61EM-23M0

40-465

40 Troubleshooting

Troubleshooting by failure code (Display of code)

Circuit diagram related to Bracke oil supply EPC solenoid

40-466

D61EM-23M0

40 Troubleshooting

Troubleshooting by failure code (Display of code)

Failure code [DXHUKA] Blade tilt right EPC: Open Action level L01 Detail of failure Action of controller Problem on machine

Failure code DXHUKA

Failure

` ' 5" ~ ( ' $ % $ % ! 5" ~ ) (7*3 $ $ ! )

• 3 $ $ , &% $ 5" % % $ $ $ ' $ % $ % ! , , 7$ , $ $ ! ` ' 5" ~ ' &$ % $ • When controller drives ' $ % $ % ! EPC solenoid, no current flows through circuit. • Stops driving ' $ % $ % ! EPC solenoid. • 7! % $ $ % $ ` . !

Related information

• Output condition to ' $ % $ % ! EPC solenoid can be checked with monitoring function. (Code: 71007 "Blade Tilt RH EPC(F/B)") • Method of reproducing failure code: Turn starting switch to ON position, and operate ^% $ $ ^% $ *38 $ $ !

No.

Cause

Procedure, measuring location, criteria and remarks

Defective ' $ % $ 1. Turn starting switch to OFF position. % ! EPC solenoid (internal 2. Disconnect connector TR and connect T-adapter to male side. Resis- Between TR (male) (1) and (2) open circuit) 2 to 12 z tance 1. Turn starting switch to OFF position. 2. Disconnect connector TR, and connect T-adapter to female side. 3. Turn starting switch to ON position. Open circuit, short circuit, a Shake the wiring harness by hand while measuring the voltage. If ground fault, hot short circuit the voltage drops to approximately 0 V during shaking, circuit is of wiring harness, or defective open around this point. HST controller a Voltage becomes approximately 25 V for approximately 0.5 sec. immediately after the starting switch is turned to ON position. Voltage Between TR (female) (1) and (2) 1 to 4.5 V 1. Turn starting switch to OFF position. 2. Disconnect connector ST3 and connect T-adapter to female side.

Open or short circuit in wiring a Solenoid coil resistance harness Resis- Between ST3 (female) (38) and (23) tance

2 to 12 z

a If no failure is found by check on cause 2, this check is not required. Open circuit in wiring harness 1. Turn starting switch to OFF position. 2. Disconnect connectors ST3 and TR, and connect T-adapter to each (wire breakage or defective female side. contact of connector) Resis- Between ST3 (female) (38) and TR (female) (1) Max. 1 z tance Between ST3 (female) (23) and TR (female) (2) Max. 1 z If no failure is found by above checks, HST controller may be defective. Defective HST controller (Since this is an internal defect, troubleshooting cannot be performed.)

D61EM-23M0

40-467

40 Troubleshooting

Troubleshooting by failure code (Display of code)

Circuit diagram related to Irrigation pump oil supply EPC solenoid

40-468

D61EM-23M0

40 Troubleshooting

Troubleshooting by failure code (Display of code)

Failure code [DXHUKB] Blade tilt right EPC: Short circuit Action level L01 Detail of failure Action of controller Problem on machine

Failure code DXHUKB

Failure

Blade tilt right EPC: Short circuit ( ' $ % $ % ! 5" * $ % ) (HST controller system)

• 3 $ $ , &% $ 5" % % $ $ $ ' $ % $ % ! , , 7$ , $ $ ! ` ' 5" * $ % ' &$ % $ • When controller drives ' $ % $ % ! EPC solenoid, unusual current flows through circuit. • Stops driving ' $ % $ % ! EPC solenoid circuit. • 7! % $ $ % $ ' $ %

Related information

No.

Cause

Procedure, measuring location, criteria and remarks

1. Turn starting switch to OFF position. Defective ' $ % $ 2. Disconnect connector TR and connect T-adapter to male side. % ! EPC solenoid (internal 2 to 12 z Resis- Between TR (male) (1) and (2) open circuit) tance Between TR (male) (1) and ground Min. 1 Mz

1. Turn starting switch to OFF position. Ground fault in wiring harness 2. Disconnect connectors ST3 and TR, and connect T-adapter to female side of either connector. (contact with ground circuit) Resis- Between ground and either ST3 (female) (38) Min. 1 Mz or TR (female) (1) tance

1. Turn starting switch to OFF position. 2. Disconnect connectors ST3 and TR, and connect T-adapter to Short circuit in wiring harness female side of either connector. Resis- Between ST3 (female) (38) and (23), or Min. 1 Mz between TR (female) (1) and (2) tance If no failure is found by above checks, HST controller may be defective. Defective HST controller (Since this is an internal defect, troubleshooting cannot be performed.)

Circuit diagram related to + ' $ $ ! EPC solenoid

D61EM-23M0

40-469

40 Troubleshooting

Troubleshooting by failure code (Display of code)

Failure code [DXHUKY] Blade tilt right EPC: Hot short Action level L03 Detail of failure Action of controller Problem on machine Related information No.

Failure code DXH KY

Failure

Blade tilt right EPC: Hot short | ` @ ~ (HST controller system)

• ! @ \ @ ^ ? \ @ @ @ \ ` @ ^ ^ ^ @ \ @ @ \ ` @ @ @@ ` ? @ \ • Current always flows to ` @ EPC solenoid circuit. • Stops driving ` @ EPC solenoid. • Restricts engine operation. • \ @ @ \ ` • Once machine stops, engine speed is restricted to medium (half) speed. • Automatic gear shift function does not work. • Output condition to ` @ EPC solenoid can be checked with monitoring function. (Code: 71007 "Blade Tilt RH EPC(F/B)") • Method of reproducing failure code: Turn starting switch to ON position. Cause

Procedure, measuring location, criteria and remarks

1. Turn starting switch to OFF position. Defective ' $ % $ 2. Disconnect connector TR and connect T-adapter to male side. % ! EPC solenoid Between TR (male) (1) and (2) 2 to 12 z (internal open circuit) Resistance Between ground and each of TR (male) (1) and Min. 1 Mz (2)

Hot short circuit in wiring harness

1. Turn starting switch to OFF position. 2. Disconnect connector TR, and connect T-adapter to female side. 3. Turn starting switch to ON position. a Voltage becomes approximately 25 V for approximately 0.5 sec. immediately after the starting switch is turned to ON position. Voltage Between TR (female) (1) and (2) Max. 4.5 V 1. Turn starting switch to OFF position. 2. Disconnect connectors ST3 and WE, and connect T-adapter to female side of ST3. a Check by using multimeter in continuity mode. Between ST3 (female) (38) and each pin other Continuity than pin (38)

No continuity (No sound is heard)

1. Turn starting switch to OFF position. Short circuit in wiring harness 2. Disconnect connectors ST1, ST2, ST3, WE and TR, and connect Tadapter to either female or male side of WE. a Check by using multimeter in continuity mode. No continuity (No sound is heard) Continuity No Between WE (male) (6) and each pin other than continuity pin (6) (No sound is heard) Between WE (female) (6) and each pin other than pin (6)

a If no failure is found by check on cause 2, this check is not required. Open or short circuit in wiring 1. Turn starting switch to OFF position. harness 2. Disconnect connector ST3 and connect T-adapter to female side. Resistance Between ST3 (female) (38) and (23) 2 to 12 z If no failure is found by above checks, HST controller may be defective. Defective HST controller (Since this is an internal defect, troubleshooting cannot be performed.)

40-470

D61EM-23M0

40 Troubleshooting

Troubleshooting by failure code (Display of code)

Circuit diagram related to Irrigation pump oil supply EPC solenoid

D61EM-23M0

40-471

40 Troubleshooting

Troubleshooting by failure code (Display of code)

Failure code [DXJ4KA] Weq lock Sol.: Open Action level L03 Detail of failure Action of controller Problem on machine Related information

Failure code DXJ4KA

Failure

Work equipment lock Solenoid: Open (HST controller system)

• When controller drives work equipment lock solenoid, no current flows through circuit. • • • • • •

Stops driving work equipment lock solenoid. Restricts engine operation. Blade and ripper cannot be operated. Once machine stops, engine speed is restricted to medium (half) speed. Once machine stops, travel is restricted to F1 and R1. Method of reproducing failure code: Turn starting switch to ON position and operate work equipment lock lever (FREE).

No.

Cause

Procedure, measuring location, criteria and remarks

Defective work equipment lock solenoid (internal open circuit)

1. Turn starting switch to OFF position. 2. Disconnect connector PSL and connect T-adapter to male side. Resis- Between PSL (male) (1) and (2) 20 to 60 z tance 1. Turn starting switch to OFF position. 2. Disconnect connector PSL, and connect T-adapter to female side. 3. Turn starting switch to ON position.

Open or short circuit in wiring harness a Solenoid coil resistance Resis- Between ST2 (female) (18) and ST3 (3) tance

20 to 60 z

a If no failure is found by check on cause 2, this check is not required. 1. Turn starting switch to OFF position. Open circuit in wiring harness 2. Disconnect connectors ST2, ST3 and PSL, and connect T-adapters (wire breakage or defective to each female side. contact of connector) Between ST2 (female) (18) and PSL (female) Max. 1 z Resis- (1) tance Between ST3 (female) (3) and PSL (female) (2) Max. 1 z If no failure is found by above checks, HST controller may be defective. Defective HST controller (Since this is an internal defect, troubleshooting cannot be performed.)

40-472

D61EM-23M0

40 Troubleshooting

Troubleshooting by failure code (Display of code)

Circuit diagram related to work equipment lock solenoid

D61EM-23M0

40-473

40 Troubleshooting

Troubleshooting by failure code (Display of code)

Failure code [DXJ4KB] Weq lock Sol.: Short circuit Action level L03 Detail of failure Action of controller Problem on machine Related information

• • • • • • •

Work equipment lock Solenoid: Short circuit Failure code Failure (HST controller system) DXJ4KB When controller drives work equipment lock solenoid, unusual current flows through circuit. Stops driving work equipment lock solenoid. Restricts engine operation. Blade and ripper cannot be operated. Once machine stops, engine speed is restricted to medium (half) speed. Once machine stops, travel is restricted to F1 and R1. Method of reproducing failure code: Turn starting switch to ON position and operate work equipment lock lever (FREE).

No.

Cause

Procedure, measuring location, criteria and remarks

Defective work equipment lock solenoid (internal open circuit)

1. Turn starting switch to OFF position. 2. Disconnect connector PSL and connect T-adapter to male side. 20 to 60 z Resis- Between PSL (male) (1) and (2) tance Between PSL (male) (1) and ground Min. 1 Mz

Defective diode D4

1. Turn starting switch to OFF position. 2. Disconnect connector D4. 3. Turn starting switch to ON position. 4. Operate work equipment lock lever (free) to perform troubleshooting. a Ignore any failure code other than this code. If this failure code does not appear, diode D4 is defective.

1. Turn starting switch to OFF position. Ground fault in wiring harness 2. Disconnect connectors ST2, D4 and PSL, and connect T-adapter to female side of either connector. (contact with ground circuit) Resis- Between ground and either ST2 (female) (18) Min. 1 Mz or PSL (female) (1) tance 1. Turn starting switch to OFF position. 2. Disconnect connectors ST2, ST3, D4 and PSL, and connect TShort circuit in wiring harness adapter to female side of either connector. Resis- Between ST2 (female) (18) and ST3 (female) Min. 1 Mz (3), or between PSL (female) (1) and (2) tance If no failure is found by above checks, HST controller may be defective. Defective HST controller (Since this is an internal defect, troubleshooting cannot be performed.)

40-474

D61EM-23M0

40 Troubleshooting

Troubleshooting by failure code (Display of code)

Circuit diagram related to work equipment lock solenoid

D61EM-23M0

40-475

40 Troubleshooting

Troubleshooting by failure code (Display of code)

Failure code [DXJCKA] Blade angle left EPC: Open Action level L01 Detail of failure

Action of controller Problem on machine

Failure code DXJCKA

Failure

Blade angle left EPC: Open (HST controller system)

• 3 $ $ , ' &% $ % $ $ $ 5" $ $ % . $ $ ^ $ ' ! % $% % $ ' $, & % $ $ ! % % ! • $ $ ! ` ' & 5" ~ ' &$ % $ • When controller drives blade angle left EPC solenoid, no current flows through circuit. • Stops driving blade angle left EPC solenoid. •

Related information

• Output condition to blade angle left EPC solenoid can be checked with monitoring function. (Code: 71013 "Blade Angle LH EPC(F/B)")

No.

Cause

Defective HST controller

Procedure, measuring location, criteria and remarks HST controller may be defective. (Since this is an internal defect, troubleshooting cannot be performed.)

Circuit diagram related to blade angle left EPC solenoid

40-476

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40 Troubleshooting

Troubleshooting by failure code (Display of code)

Failure code [DXJCKB] Blade angle left EPC: Short circuit Action level L01

Detail of failure

Action of controller Problem on machine

Blade angle left EPC: Short circuit Failure code Failure (HST controller system) DXJCKB • 3 $ $ , ' &% $ % $ $ $ 5" $ $ % . $ $ ^ $ ' ! % $% % $ ' $, & % $ $ ! % % ! • $ $ ! ` ' & 5" * $ % ' &$ % $ • When controller drives blade angle left EPC solenoid, unusual current flows through circuit.

• * $ , ' ' & 5" $ $ •

Related information

• Output condition to blade angle left EPC solenoid can be checked with monitoring function. (Code: 71013 "Blade Angle LH EPC(F/B)")

No.

Cause

Procedure, measuring location, criteria and remarks

1. Turn starting switch to OFF position. Ground fault in wiring harness 2. Disconnect connectors ST3 and AL, and connect T-adapter to female side of either connector. (contact with ground circuit) Resis- Between ground and either ST3 (female) (7) or Min. 1 Mz AL (female) (1) tance 1. Turn starting switch to OFF position. 2. Disconnect connectors ST3 and AL, and connect T-adapter to Short circuit in wiring harness female side of either connector. Resis- Between ST3 (female) (7) and (3), or between Min. 1 Mz AL (female) (1) and (2) tance If no failure is found by above checks, HST controller may be defective. Defective HST controller (Since this is an internal defect, troubleshooting cannot be performed.)

Circuit diagram related to blade angle left EPC solenoid

D61EM-23M0

40-477

40 Troubleshooting

Troubleshooting by failure code (Display of code)

Failure code [DXJCKY] Blade angle left EPC: Hot short Action level L03

Detail of failure

Action of controller Problem on machine

Failure code DXJCKY

Blade angle left EPC: Hot short (HST controller system)

Failure

• 3 $ $ , ' &% $ % $ $ $ 5" $ $ % . $ $ ^ $ ' ! % $% % $ ' $, & % $ $ ! % % ! • $ $ ! ` ' & 5" 7$ $ ' &$ % $ • Current always flows to blade angle left EPC solenoid circuit. • Stops driving blade angle left EPC solenoid. • Restricts engine operation. • Once machine stops, engine speed is restricted to medium (half) speed.

Related information

• Output condition to blade angle left EPC solenoid can be checked with monitoring function. (Code: 71013 "Blade Angle LH EPC(F/B)")

No.

Cause

Hot short circuit in wiring harness

Procedure, measuring location, criteria and remarks 1. Turn starting switch to OFF position. 2. Disconnect connector AL, and connect T-adapter to female side. 3. Turn starting switch to ON position. Voltage Between AL (female) (1) and (2) Max. 4.5 V 1. Turn starting switch to OFF position. 2. Disconnect connectors ST3 and AL, and connect T-adapter to female side of ST3. a Check by using multimeter in continuity mode. Continuity

Between ST3 (female) (7) and each pin other than pin (7)

No continuity (No sound is heard)

1. Turn starting switch to OFF position. Short circuit in wiring harness 2. Disconnect connectors ST1, ST2, ST3, WE and AL, and connect Tadapter to either female or male side of WE. a Check by using multimeter in continuity mode.

Defective HST controller

40-478

No continuity Between WE (female) (3) and each pin other than pin (3) (No sound is heard) Continuity No Between WE (male) (3) and each pin other than continuity pin (3) (No sound is heard) If no failure is found by above checks, HST controller may be defective. (Since this is an internal defect, troubleshooting cannot be performed.)

D61EM-23M0

40 Troubleshooting

Troubleshooting by failure code (Display of code)

Circuit diagram related to blade angle left EPC solenoid

D61EM-23M0

40-479

40 Troubleshooting

Troubleshooting by failure code (Display of code)

Failure code [DXJDKA] Blade angle right EPC: Open Action level L01 Detail of failure Action of controller Problem on machine

Blade angle right EPC: Open Failure code Failure (HST controller system) DXJDKA • ! @ \ @ ^ ` ? \ @ @ \ @ \ \ @ @ @ \ \ ` @ @ @ ` \ ^ ? \ @ \ @ \ @ • @ \ @ @ \ ` ` $ @ @@ ` ? @ \ • When controller drives blade angle right EPC solenoid, no current flows through circuit.

• Stops driving blade angle right EPC solenoid. •

Related information

• Output condition to blade angle right EPC solenoid can be checked with monitoring function. (Code: 71011 "Blade Angle RH EPC(F/B)")

No.

Cause

Defective HST controller

Procedure, measuring location, criteria and remarks HST controller may be defective. (Since this is an internal defect, troubleshooting cannot be performed.)

Circuit diagram related to blade angle right EPC solenoid

40-480

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40 Troubleshooting

Troubleshooting by failure code (Display of code)

Failure code [DXJDKB] Blade angle right EPC: Short circuit Action level L01

Detail of failure

Action of controller Problem on machine

Blade angle right EPC: Short circuit Failure code Failure (HST controller system) DXJDKB • ! @ \ @ ^ ` ? \ @ @ \ @ \ \ @ @ @ \ \ ` @ @ @ ` \ ^ ? \ @ \ @ \ @ • @ \ @ @ \ ` ` @ @@ ` ? @ \ • When controller drives blade angle right EPC solenoid, unusual current flows through circuit.

• Stops driving blade angle right EPC solenoid. •

Related information

• Output condition to blade angle right EPC solenoid can be checked with monitoring function. (Code: 71011 "Blade Angle RH EPC(F/B)")

No.

Cause

Procedure, measuring location, criteria and remarks

1. Turn starting switch to OFF position. Ground fault in wiring harness 2. Disconnect connectors ST3 and AR, and connect T-adapter to female side of either connector. (contact with ground circuit) Resis- Between ground and either ST3 (female) (17) Min. 1 Mz or AR (female) (1) tance 1. Turn starting switch to OFF position. 2. Disconnect connectors ST3 and AR, and connect T-adapter to Open or short circuit in wiring female side of either connector. harness Resis- Between ST3 (female) (17) and (13), or Min. 1 Mz between AR (female) (1) and (2) tance If no failure is found by above checks, HST controller may be defective. Defective HST controller (Since this is an internal defect, troubleshooting cannot be performed.)

Circuit diagram related to blade angle right EPC solenoid

D61EM-23M0

40-481

40 Troubleshooting

Troubleshooting by failure code (Display of code)

Failure code [DXJDKY] Blade angle right EPC: Hot short Action level L03

Detail of failure

Failure code DXJ-KY

Failure

Blade angle right EPC: Hot short (HST controller system)

• ! @ \ @ ^ ` ? \ @ @ \ @ \ \ @ @ @ \ \ ` @ @ @ ` \ ^ ? \ @ \ @ \ @ • @ \ @ @ \ ` ? @ @ @@ ` ? @ \ • Current always flows to blade angle right EPC solenoid circuit. • Stops driving blade angle right EPC solenoid. • Restricts engine operation.

Action of controller Problem on machine

• Once machine stops, engine speed is restricted to medium (half) speed.

Related information

• Output condition to blade angle right EPC solenoid can be checked with monitoring function. (Code: 71011 "Blade Angle RH EPC(F/B)")

No.

Cause

Hot short circuit in wiring harness

Procedure, measuring location, criteria and remarks 1. Turn starting switch to OFF position. 2. Disconnect connector AR, and connect T-adapter to female side. 3. Turn starting switch to ON position. Voltage Between AR (female) (1) and (2) Max. 4.5 V 1. Turn starting switch to OFF position. 2. Disconnect connectors ST3 and AR, and connect T-adapter to female side of ST3. a Check by using multimeter in continuity mode. Between ST3 (female) (17) and each pin other Continuity than pin (17)

No continuity (No sound is heard)

1. Turn starting switch to OFF position. Short circuit in wiring harness 2. Disconnect connectors ST1, ST2, ST3, WE and AR, and connect Tadapter to either female or male side of WE. a Check by using multimeter in continuity mode. No continuity (No sound is heard) Continuity No continuity Between WE (male) (2) and each pin other than pin (2) (No sound is heard) If no failure is found by above checks, HST controller may be defective. (Since this is an internal defect, troubleshooting cannot be performed.) Between WE (female) (2) and each pin other than pin (2)

Defective HST controller

40-482

D61EM-23M0

40 Troubleshooting

Troubleshooting by failure code (Display of code)

Circuit diagram related to blade angle right EPC solenoid

D61EM-23M0

40-483

40 Troubleshooting

Troubleshooting by failure code (Display of code)

Failure code [DXK1KA] Left HST motor EPC: Open Action level L03 Detail of failure Action of controller Problem on machine Related information

No. 1

• • • • • • • •

Left HST motor EPC: Open Failure code Failure (HST controller system) DXK1KA When controller drives left HST motor EPC solenoid valve, no current flows through circuit. Stops driving left HST motor EPC solenoid valve. Stops driving right HST motor EPC solenoid valve as well. Even if cause of failure disappears, machine does not become normal until starting switch is turned to the OFF position. Machine decelerates during traveling at high speed. Machine cannot travel at high speed. The output current to left HST motor EPC solenoid valve can be checked with monitoring function. (Code: 52304 "Left Motor EPC(F/B)") Method of reproducing failure code: Turn starting switch to ON position and run the machine at high speed. Cause

Procedure, measuring location, criteria and remarks

1. Turn starting switch to OFF position. Defective left HST motor EPC 2. Disconnect connector LME and connect T-adapter to male side. solenoid Resis- Between LME (male) (1) and (2) 5 to 15 z tance 1. Turn starting switch to OFF position. 2. Disconnect connector LME, and connect T-adapter to female side. Open circuit, short circuit, 3. Turn starting switch to ON position. ground fault, hot short circuit of wiring harness, or defective a Shake the wiring harness by hand while measuring the voltage. If the voltage drops to approximately 0 V during shaking, circuit is HST controller open around this point. Voltage Between LME (female) (1) and (2) 1 to 4.5 V 1. Turn starting switch to OFF position. 2. Disconnect connector ST3 and connect T-adapter to female side.

Open or short circuit in wiring a Solenoid coil resistance harness Resis- Between ST3 (female) (26) and (3) tance

5 to 15 z

a If no failure is found by check on cause 2, this check is not required. 1. Turn starting switch to OFF position. Open circuit in wiring harness 2. Disconnect connectors ST3 and LME, and connect T-adapter to (wire breakage or defective each female side. contact of connector) Between ST3 (female) (26) and LME (female) Max. 1 z Resis- (1) tance Between ST3 (female) (3) and LME (female) (2) Max. 1 z If no failure is found by above checks, HST controller may be defective. Defective HST controller (Since this is an internal defect, troubleshooting cannot be performed.)

40-484

D61EM-23M0

40 Troubleshooting

Troubleshooting by failure code (Display of code)

Circuit diagram related to left HST motor EPC solenoid

D61EM-23M0

40-485

40 Troubleshooting

Troubleshooting by failure code (Display of code)

Failure code [DXK1KB] Left HST motor EPC: Short circuit Action level L03 Detail of failure Action of controller Problem on machine Related information

No.

• • • • • • • •

Left HST motor EPC: Short circuit Failure code Failure (HST controller system) DXK1KB When controller drives left HST motor EPC solenoid valve, unusual current flows through circuit. Stops driving left HST motor EPC solenoid valve. Stops driving right HST motor EPC solenoid valve as well. Even if cause of failure disappears, machine does not become normal until starting switch is turned to the OFF position. Machine decelerates during traveling. Machine cannot travel at high speed. Output current to left HST motor EPC solenoid valve can be checked with monitoring function. (Code: 52304 "Left Motor EPC(F/B)") Method of reproducing failure code: Turn starting switch to ON position and run the machine at high speed. Cause

Procedure, measuring location, criteria and remarks

1. Turn starting switch to OFF position. Defective left HST motor EPC 2. Disconnect connector LME and connect T-adapter to male side. solenoid (internal open 5 to 15 z Resis- Between LME (male) (1) and (2) circuit) tance Between LME (male) (1) and ground Min. 1 Mz

1. Turn starting switch to OFF position. Ground fault in wiring harness 2. Disconnect connectors ST3 and LME, and connect T-adapter to female side of either connector. (contact with ground circuit) Resis- Between ground and either ST3 (female) (26) Min. 1 Mz or LME (female) (1) tance

1. Turn starting switch to OFF position. 2. Disconnect connectors ST3 and LME, and connect T-adapter to Short circuit in wiring harness female side of either connector. Resis- Between ST3 (female) (26) and (3), or between Min. 1 Mz LME (female) (1) and (2) tance If no failure is found by above checks, HST controller may be defective. Defective HST controller (Since this is an internal defect, troubleshooting cannot be performed.)

Circuit diagram related to left HST motor EPC solenoid

40-486

D61EM-23M0

40 Troubleshooting

Troubleshooting by failure code (Display of code)

Failure code [DXK1KY] Left HST motor EPC: Hot Short Action level L04 Detail of failure Action of controller Problem on machine Related information No.

• • • • • • • •

Left HST motor EPC: Hot Short Failure code Failure (HST controller system) DXK1KY When controller does not drive left HST motor EPC solenoid valve, unusual current flows through circuit. Partially limits the functions. Even if cause of failure disappears, machine does not become normal until starting switch is turned to the OFF position. Left track speed increases during traveling. Once machine stops, engine speed is restricted to medium (half) speed. Once machine stops, it cannot restart. Output current to left HST motor EPC solenoid valve can be checked with monitoring function. (Code: 52304 "Left Motor EPC(F/B)") Method of reproducing failure code: Turn starting switch to ON position. Cause

Procedure, measuring location, criteria and remarks

1. Turn starting switch to OFF position. Defective left HST motor EPC 2. Disconnect connector LME and connect T-adapter to male side. solenoid (internal open Between LME (male) (1) and (2) 5 to 15 z Resiscircuit) Between ground and each of LME (male) (1) tance Min. 1 Mz and (2)

Hot short circuit in wiring harness

1. Turn starting switch to OFF position. 2. Disconnect connector LME, and connect T-adapter to female side. 3. Turn starting switch to ON position. Voltage Between LME (female) (1) and (2) Max. 4.5 V 1. Turn starting switch to OFF position. 2. Disconnect connectors ST3 and LME, and connect T-adapter to female side of ST3. a Check by using multimeter in continuity mode. Between ST3 (female) (26) and each pin other Continuity than pin (26)

No continuity (No sound is heard)

1. Turn starting switch to OFF position. Short circuit in wiring harness 2. Disconnect connectors ST1, ST2, ST3, MC and LME, and connect T-adapter to either female or male side of MC. a Check by using multimeter in continuity mode. No continuity (No sound is heard) Continuity No continuity Between MC (male) (3) and each pin other than pin (3) (No sound is heard) If no failure is found by above checks, HST controller may be defective. (Since this is an internal defect, troubleshooting cannot be performed.) Between MC (female) (3) and each pin other than pin (3)

Defective HST controller

D61EM-23M0

40-487

40 Troubleshooting

Troubleshooting by failure code (Display of code)

Circuit diagram related to left HST motor EPC solenoid

40-488

D61EM-23M0

40 Troubleshooting

Troubleshooting by failure code (Display of code)

Failure code [DXK2KA] Right HST motor EPC: Open Action level L03 Detail of failure Action of controller Problem on machine Related information

No. 1

• • • • • • • •

Right HST motor EPC: Open Failure code Failure (HST controller system) DXK2KA When controller drives right HST motor EPC solenoid valve, no current flows through circuit. Stops driving right HST motor EPC solenoid valve. Stops driving left HST motor EPC solenoid valve as well. Even if cause of failure disappears, machine does not become normal until starting switch is turned to OFF position. Machine decelerates during traveling. Machine cannot travel at high speed. The output current to right HST motor EPC solenoid valve can be checked with monitoring function. (Code: 52303 "Right Motor EPC(F/B)") Method of reproducing failure code: Turn starting switch to ON position and travel the machine at high speed. Cause

Defective right HST motor EPC solenoid

Procedure, measuring location, criteria and remarks 1. Turn starting switch to OFF position. 2. Disconnect connector RME and connect T-adapter to male side. Resis- Between RME (male) (1) and (2) 5 to 15 z tance 1. Turn starting switch to OFF position. 2. Disconnect connector RME, and connect T-adapter to female side. 3. Turn starting switch to ON position.

Open circuit, short circuit, ground fault, hot short circuit of wiring harness, or defective a Shake the wiring harness by hand while measuring the voltage. If the voltage drops to approximately 0 V during shaking, wiring HST controller harness is open at this point. Voltage Between RME (female) (1) and (2) 1 to 4.5 V 1. Turn starting switch to OFF position. 2. Disconnect connector ST3 and connect T-adapter to female side.

Open or short circuit in wiring a Solenoid coil resistance harness Resis- Between ST3 (female) (36) and (3) tance

5 to 15 z

a If no failure is found by check on cause 2, this check is not required. 1. Turn starting switch to OFF position. Open circuit in wiring harness 2. Disconnect connectors ST3 and RME, and connect T-adapter to each female side. (wire breakage or defective Between ST3 (female) (36) and RME (female) contact of connector) Max. 1 z Resis- (1) tance Between ST3 (female) (3) and RME (female) Max. 1 z (2) If no failure is found by above checks, HST controller may be defective. Defective HST controller (Since this is an internal defect, troubleshooting cannot be performed.)

D61EM-23M0

40-489

40 Troubleshooting

Troubleshooting by failure code (Display of code)

Circuit diagram related to right HST motor EPC solenoid

40-490

D61EM-23M0

40 Troubleshooting

Troubleshooting by failure code (Display of code)

Failure code [DXK2KB] Right HST motor EPC: Short circuit Action level L03 Detail of failure Action of controller Problem on machine Related information

• • • • • • • •

Right HST motor EPC: Short circuit Failure code Failure (HST controller system) DXK2KB When controller drives right HST motor EPC solenoid valve, unusual current flows through circuit. Stops driving right HST motor EPC solenoid valve. Stops driving left HST motor EPC solenoid valve as well. Even if cause of failure disappears, machine does not become normal until starting switch is turned to OFF position. Machine decelerates during traveling. Machine cannot travel at high speed. The output current to right HST motor EPC solenoid valve can be checked with monitoring function. (Code: 52303 "Right Motor EPC(F/B)") Method of reproducing failure code: Turn starting switch to ON position and travel the machine at high speed.

No.

Cause

Procedure, measuring location, criteria and remarks

Defective right HST motor EPC solenoid (internal open circuit)

1. Turn starting switch to OFF position. 2. Disconnect connector RME and connect T-adapter to male side. 5 to 15 z Resis- Between RME (male) (1) and (2) tance Between RME (male) (1) and ground Min. 1 Mz

1. Turn starting switch to OFF position. Ground fault in wiring harness 2. Disconnect connectors ST3 and RME, and connect T-adapter to female side of either connector. (contact with ground circuit) Resis- Between ground and either ST3 (female) (36) Min. 1 Mz or RME (female) (1) tance

1. Turn starting switch to OFF position. 2. Disconnect connectors ST3 and RME, and connect T-adapter to Short circuit in wiring harness female side of either connector. Resis- Between ST3 (female) (36) and (3), or between Min. 1 Mz RME (female) (1) and (2) tance If no failure is found by above checks, HST controller may be defective. Defective HST controller (Since this is an internal defect, troubleshooting cannot be performed.)

Circuit diagram related to right HST motor EPC solenoid

D61EM-23M0

40-491

40 Troubleshooting

Troubleshooting by failure code (Display of code)

Failure code [DXK2KY] Right HST motor EPC: Hot Short Action level L04 Detail of failure Action of controller Problem on machine Related information

• • • • • • • •

Right HST motor EPC: Hot Short Failure code Failure (HST controller system) DXK2KY When controller drives right HST motor EPC solenoid valve, unusual current flows through circuit. Partially limits the functions. Even if cause of failure disappears, machine does not become normal until starting switch is turned to OFF position. Right track accelerates during traveling. Once machine stops, engine speed is restricted to medium (half) speed. Once machine stops, it cannot restart. Output current to right HST motor EPC solenoid valve can be checked with monitoring function. (Code: 52303 "Right Motor EPC(F/B)") Method of reproducing failure code: Turn starting switch to ON position.

No.

Cause

Procedure, measuring location, criteria and remarks

Defective right HST motor EPC solenoid (internal open circuit)

1. Turn starting switch to OFF position. 2. Disconnect connector RME and connect T-adapter to male side. Between RME (male) (1) and (2) 5 to 15 z ResisBetween ground and each of RME (male) (1) tance Min. 1 Mz and (2)

Hot short circuit in wiring harness

1. Turn starting switch to OFF position. 2. Disconnect connector RME, and connect T-adapter to female side. 3. Turn starting switch to ON position. Voltage Between RME (female) (1) and (2) Max. 4.5 V 1. Turn starting switch to OFF position. 2. Disconnect connectors ST3 and RME, and connect T-adapter to female side of ST3. a Check by using multimeter in continuity mode. Between ST3 (female) (36) and each pin other Continuity than pin (36)

No continuity (No sound is heard)

1. Turn starting switch to OFF position. Short circuit in wiring harness 2. Disconnect connectors ST1, ST2 ST3, MC and RME, and connect T-adapter to either female or male side of MC. a Check by using multimeter in continuity mode. No continuity (No sound is heard) Continuity No continuity Between MC (male) (1) and each pin other than pin (1) (No sound is heard) Between MC (female) (1) and each pin other than pin (1)

Open or short circuit in wiring harness

Defective HST controller

40-492

1. Turn starting switch to OFF position. 2. Disconnect connector ST3 and connect T-adapter to female side. Resis- Between ST3 (female) (36) and (3) 5 to 15 z tance If no failure is found by above checks, HST controller may be defective. (Since this is an internal defect, troubleshooting cannot be performed.)

D61EM-23M0

40 Troubleshooting

Troubleshooting by failure code (Display of code)

Circuit diagram related to right HST motor EPC solenoid

D61EM-23M0

40-493

40 Troubleshooting

Troubleshooting of electrical system (E-mode)

E-1 Engine does not start (Engine does not crank)

• Engine does not start (engine does not crank). • Since engine start circuit has neutral safety function, engine does not start unless work equipment lock lever and parking brake lever are in LOCK position and travel lever is in NEUTRAL position. • KOMTRAX has start lock function. Engine does not start unless start lock is released. • Before performing troubleshooting, check that no related failure code is displayed.(If failure code [D19JKZ], [D130KA], [D130KB], [DD14KA], or [DD14KB] is Related information displayed, perform troubleshooting for the displayed code first.) • If failure symptom "Battery relay operation sound is not heard" appears when starting switch is turned to ON position, perform troubleshooting for E-1 as well. • If failure symptom "Machine monitor does not light up" appears when starting switch is turned to ON position, there must be a failure in main power supply system. In this case, perform troubleshooting for E-5 (lines of 50 A of fusible link 107, and fuses 9 and 20 of fuse box F01). • ? \ @ @ ? @@ ` ` @ @ @ $ @ ` @ $ @ ` @ @ @ $ @ @ ? @@ ` ` @ @ @ $ @ \ @ \ @ ` @ @ @ $ ? ` @ @ @ $ | @@ \~ Failure

No. 1

Cause

Procedure, measuring location, criteria and remarks

1. Turn starting switch to OFF position. Loose terminal or open circuit Check terminals of starting motor, alternator, battery relay, and ground at terminal terminals T35, T20, etc. 1. Turn starting switch to OFF position.

Defective battery relay ground

a Use machine frame as grounding point for measurement. a Check terminal T35 for looseness or gathering of rusts. Resis- Between battery relay terminal T9 and ground tance

Max. 1 z

a Be ready with starting switch at OFF position, then perform troubleshooting without turning starting switch to ON position. Battery voltage (two batteries) Min. 24 V Specific gravity of electrolyte (each Min. 1.26 battery) Defects of engine controller power supply and ACC signal are indicated with failure codes [DB2QKR] and [DB2RKR]. If these codes appear, perform troubleshooting for causes 1 to 3 of [DB2QKR] first.

Insufficient battery capacity

Defective engine controller system

Defective power supply to HST controller

If -2 of fusible link 106 is blown, the circuit probably has ground fault. Defective -2 of fusible link 106 Perform troubleshooting for cause 14 first

Defective parking brake lever switch (internal defect or defective adjustment)

Defective work equipment lock 1. Turn starting switch to ON position. 2. Operate work equipment lock lever to perform troubleshooting. lever switch Lever position: Free Symbol: OFF Display of symbol of (internal defect or defective "work equipment lock" adjustment) Symbol: ON Lever position: Lock on monitor panel

40-494

Perform troubleshooting for failure code [DAJ2KK].

1. Turn starting switch to ON position. 2. Operate parking brake lever to perform troubleshooting. Lever position: Free Other than "P" Display of "P" on monitor panel Lever position: Lock "P"

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40 Troubleshooting

Troubleshooting of electrical system (E-mode)

No.

Cause

Procedure, measuring location, criteria and remarks

1. Turn starting switch to ON position. 2. Perform troubleshooting using monitoring function. Controller: HST Monitoring code: 50303 "S/T Lever Stroke" Defective joystick (steering, Joystick (steering, directional and gear shift lever) directional and gear 0 ± 10% Stroke shift lever): Neutral If any trouble is found, perform initial adjustment of joystick (steering, directional and gear shift levers). For detail, see Testing and adjusting.

1. Turn starting switch to ON position (to connect ACC). Defective battery relay system 10 a If battery relay operation sound is not heard, go to checks on causes 21 and after. 1. Turn starting switch to ON position. Defective fusible link 106-2 or Voltage Between alternator terminal T15 and ground 20 to 30 V 11 wiring harness a If voltage is abnormal, go to check on cause 13. 1. Turn starting switch to OFF position. 2. Remove fuse -10 (30 A) in fuse box F01. (To prevent engine from Defective starting switch, starting during troubleshooting) neutral safety relay 11, 3. Insert T-adapter into connector 4. 12 personal lock relay PLR, 4. Hold starting switch at START (two persons required for this check). battery relay, or wiring harness Voltage Between 4 (1) and ground 20 to 30 V a If voltage is abnormal, go to check on cause 15 and after. Open circuit 1 in wiring harness 13 (wire breakage or defective contact of connector)

a If no failure is found by check on cause 11, this check is not required. 1. Turn starting switch to OFF position, and turn battery disconnect switch to OFF position. (To prevent short circuit during troubleshooting) Resis- Between battery relay terminal T8 and Max. 1 z tance aternator terminal T15

Ground fault 1 in wiring 14 harness (contact with ground circuit)

a If no failure is found by check on cause 10, this check is not required. 1. Turn starting switch to OFF position, and turn battery disconnect switch to OFF position. 2. Disconnect fusible link 106-2 and alternator terminal T15. Resis- Between ground and terminal T15 (wiring Min. 1 Mz harness side) or 106-4 tance

Defective starting switch (internal open circuit)

a If no failure is found by check on cause 11, this check is not required. 1. Turn starting switch to OFF position. 2. Disconnect connector KEY and connect T-adapter to male side. 3. After troubleshooting, turn starting switch to ON and START positions to perform troubleshooting again. Turn starting switch to Min. 1 Mz Between KEY (male) OFF position. (1) and (5) Turn starting switch to Max. 1 z ON position. Turn starting switch to Min. 1 Mz Resis- Between KEY (male) OFF position. (4) and (5) tance Turn starting switch to Max. 1 z ON position. Turn starting switch to Min. 1 Mz Between KEY (male) OFF position. (3) and (5) Starting switch START Max. 1 z

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40 Troubleshooting

Troubleshooting of electrical system (E-mode)

No.

Procedure, measuring location, criteria and remarks

Cause

Defective neutral safety relay 16 (internal open circuit)

a If no failure is found by check on cause 11, this check is not required. 1. Turn starting switch to OFF position. 2. Replace neutral safety relay (11) with another relay. 3. Start engine. If engine starts, original neutral safety relay (11) is defective.

Defective personal lock relay (internal open or short circuit)

a If no failure is found by check on cause 11, this check is not required. 1. Turn starting switch to OFF position. 2. Replace personal lock relay (PLR) with another relay. 3. Start engine. If engine starts, original personal lock relay is defective.

1. Turn starting switch to OFF position. 18

Defective alternator (internal short circuit)

a Terminal should be connected. 2. Turn starting switch to ON position. Voltage

Between terminal T16 and ground

Input from alternator Max. 1 V generation

1. Turn starting switch to OFF position. 2. Insert T-adapter into connector 4. 3. Turn starting switch to START position and perform troubleshooting. Between starting motor terminal B Power 20 to 30 V (T1) and ground supply Defective starting motor safety Starting 19 relay input to Voltage Between 4 (1) and ground 20 to 30 V (internal defect) starting motor Charge Between 4 (2) and ground Max. 1 V input If power supply and starting input to starting motor are normal but starting motor does not rotate, starting motor is defective. 1. Turn starting switch to OFF position. 2. Remove connectors D1 and D2, and connect T-adapter to male side.

Defective diode D1 or D2 (internal open or short circuit)

40-496

a Measure it with diode range of multimeter. Between D1 (male) (1) (+) and (2) (-) Between D1 (male) (2) (+) and (1) (-) Continuity Between D2 (male) (1) (+) and (2) (-) Between D2 (male) (2) (+) and (1) (-)

No continuity Continuity No continuity Continuity

D61EM-23M0

40 Troubleshooting

Troubleshooting of electrical system (E-mode)

No.

Cause

Procedure, measuring location, criteria and remarks • Battery relay 1. Turn starting switch to OFF position. 2. Disconnect connector D1, and connect T-adapter to female side. Resis- Between KEY (female) (4) and D1 (female) (2) Max. 1 z tance Between D1 (female) (1) and terminal T13 Max. 1 z • Battery relay 1. Turn starting switch to OFF position. 2. Turn starting switch to ON position. a Check where 24 V power is reached to, and locate open section. Between terminals T7 and T9 20 to 30 V Between terminals T13 and T9 20 to 30 V Voltage Between treminals T8 and T9 20 to 30 V Between terminal T9 and ground Max. 1 V • Alternator and starting motor 1. Turn starting switch to OFF position. 2. Turn battery disconnect switch to OFF position. 3. Insert T-adapter into connectors KEY, 11, PLR and 4. 4. Turn battery disconnect switch to ON position. 5. Turn starting switch to START position to perform troubleshooting.

a Check where 24 V power is reached to, and locate open section. Between KEY (3) and ground 20 to 30 V Between 11 (3) and ground 20 to 30 V Open circuit in wiring harness Between 11 (5) and ground 20 to 30 V 21 (wire breakage or defective Voltage Between PLR (3) and ground 20 to 30 V contact of connector) Between 4(1) and ground 20 to 30 V Between alternator terminal B and ground 20 to 30 V Between starting motor terminal B and ground 20 to 30 V • If fuse or fusible link is blown, replace it with new one. 1. Turn starting switch to OFF position. 2. Disconnect connectors KEY, 11, PLR, CM01, D1, D2, and 4. 3. Connect T-adapter to female side of KEY, 11, PLR, D1, D2, and CM01. 4. Remove fuse FS22-1. Between KEY (female) (3) and 11 (female) (3) Max. 1 z Between 11 (female) (5) and PLR (female) (3) Max. 1 z Between PLR (female) (1) and F01-5 Max. 1 z Between PLR (female) (2) and CM01 (female) Max. 1 z (6) Between PLR (female) (6) and 4 (female) (1) Max. 1 z ResisBetween alternator terminal B and starting tance Max. 1 z motor terminal B Between starting motor B and battery relay T8 Max. 1 z Between alternator T16 (terminal R) and Max. 1 z starting motor terminal R Between alternator T16 and D2 (female) (2) Max. 1 z Between D2 (female) (1) and D1 (female) (1) Max. 1 z If only terminal T8 voltage is abnormal in check on cause 21 for battery Defective battery relay 22 relay, battery relay is defective. (does not turn ON)

D61EM-23M0

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40 Troubleshooting

Troubleshooting of electrical system (E-mode)

Cause

Procedure, measuring location, criteria and remarks

Ground fault in wiring harness (contact with ground circuit)

1. Turn starting switch to OFF position. 2. Disconnect connectors KEY, 11, PLR, 4, CM01, ST1, and CK02. 3. Connect T-adapter to female side of KEY, 11,4, and PLR. 4. Remove No. 1 of fuse FS22. Between ground and KEY (female) (3) or 11 Min. 1 Mz (female) (3). Between ground and 11 (female) (5) or PLR Min. 1 Mz Resis- (female) (3) tance Between ground and PLR (female) (6) or 4 Min. 1 Mz (female) (1) Between PLR (female) (2) and ground Min. 1 Mz

Hot short circuit in wiring harness

1. Turn starting switch to OFF position. 2. Turn starting switch to ON position. Voltage Between terminal T16 and ground

No.

40-498

Max. 1 V

D61EM-23M0

40 Troubleshooting

Troubleshooting of electrical system (E-mode)

Circuit diagram related to engine starting circuit

D61EM-23M0

40-499

40 Troubleshooting

Troubleshooting of electrical system (E-mode)

E-2 Manual preheating system does not work Failure

Manual preheating system does not work.

a This troubleshooting describes procedures to be followed when manual preheating does not function to heat electrical intake air heater (ribbon heater) mounting portion. • This machine has "Automatic preheating" and "Manual preheating" functions. When either preheating works, preheating monitor lights up. (When only preheating monitor does not light up, perform troubleshooting for failure symptom "While Related information preheating is working, preheating monitor does not light up"). • If failure symptom "Machine monitor displays nothing" or "Battery relay does not make operating sound" appears when starting switch is turned to ON position, main electric power supply system may be defective. In these cases, perform troubleshooting for E-5 and E-1 respectively. • Before performing troubleshooting, check that no related failure code is displayed. No.

Cause

Loose terminal or open circuit at terminal

Procedure, measuring location, criteria and remarks 1. Turn starting switch to OFF position. Check terminals of heater relay, battery relay, electrical intake air heater (ribbon heater), etc.

Defective fuse 120 A in fusible If fuse is blown, circuit may have ground fault. (See check on cause 8.) link 106 1. Turn starting switch to OFF position. 2. Disconnect connectors CM01 and Key, and connect T-adapter to female side of Key. Resis- Between Key (female) (2) and ground (coil Approx. 20 resistance of heater relay) tance z • Secondary side 1. Turn starting switch to OFF position. 2. Turn starting switch to ON position. Voltage Between terminal T12 and ground 20 to 30 V • Primary side Open and short circuit in wiring 1. Turn starting switch to OFF position. harness 2. Disconnect terminal T6 of heater relay. a To prevent current from flowing through heater when starting switch is turned to HEAT position 3. Turn starting switch to the HEAT position (connect R1). Voltage Between heater relay terminal T5 and ground 20 to 30 V 1. Turn starting switch to OFF position. 2. Disconnect terminal T6 of heater relay. Between T6 (wiring harness side) Continuity and ground

Defective diode D20 (internal open or short circuit)

40-500

Continuity

a If no failure is found in primary side by check on cause 3, this check is not required. 1. Turn starting switch to OFF position. 2. Disconnect connector D20 and connect T-adapter to diode. a Measure it with diode range of multimeter. Between D20 (male) (1) (+) and Continuity (2) (-) Between D20 (male) (2) (+) and Continuity (1) (-)

No continuity Continuity

D61EM-23M0

40 Troubleshooting

Troubleshooting of electrical system (E-mode)

No.

Cause

Defective starting switch

Defective electrical intake air heater (ribbon heater) (internal open circuit) Defective heater relay (Does not turn ON) (Terminal T6)

Ground fault in wiring harness (contact with ground circuit)

D61EM-23M0

Procedure, measuring location, criteria and remarks a If no failure is found in primary side by check on cause 3, this check is not required. 1. Turn starting switch to OFF position. 2. Turn battery disconnect switch to OFF position. 3. Disconnect connector KEY and connect T-adapter to male side. 4. Turn starting switch to OFF and the HEAT positions to perform troubleshooting. OFF Min. 1 Mz Resis- Between Key (male) (2) and (5) tance HEAT Max. 1 z 1. Turn starting switch to OFF position. 2. Disconnect cable terminal RH. Continuity Between terminal RH and ground

Continuity

If no failure is found by check on cause 3 and heater relay operation sound is not heard, heater relay is defective. a If no failure is found by check on cause 2, this check is not required. 1. Turn starting switch to OFF position. 2. Disconnect connectors Key, CM01, D20, terminal T5, RH and starting motor terminal B terminal. Between heater terminal T5 (wiring harness Min. 1 Mz side) and ground Resis- Between heater relay T12 (contact side input Min. 1 Mz terminal) and ground tance Between heater relay terminal RH (wiring Min. 1 Mz harness side) and ground

40-501

40 Troubleshooting

Troubleshooting of electrical system (E-mode)

Circuit diagram related to engine preheating system

40-502

D61EM-23M0

40 Troubleshooting

Troubleshooting of electrical system (E-mode)

E-3 Automatic preheating system does not work Failure

Related information

No. 1

Automatic preheating system does not work. • Automatic preheating starts when charge (boost) temperature sensor sensed below -4° C. • Engine controller generates failure code [CA2555] or [CA2556] if primary (coil) side of preheat relay (connector RHR) is defective. • Engine controller generates failure code [CA153] or [CA154] if charge (boost) temperature sensor is defective. • Temperature sensed by charge (boost) temperature sensor sensor can be checked with monitoring function. (Code: 18500 (°C)) • Method of reproducing failure code: Turn starting switch to ON position (charge (boost) temperature: Max. -4°C). • If automatic preheating function does not work, check whether manual preheating function works first. • If fuse 120 A of fusible link 107 is broken, "machine monitor does not light up".

Cause Defective fuse -2 in fuse box F01.

Procedure, measuring location, criteria and remarks If fuse -2 in fuse box F01 is blown, circuit probably has ground fault. In this case, perform check on cause 5 first.

Defective preheater relay RHR (internal open or short circuit)

1. Turn starting switch to OFF position. 2. Replace preheater relay (connector RHR) with another relay, for instance, neutral safety relay (connector: 11). 3. Turn starting switch to ON position. If automatic preheating functions when charge (boost) temperature is below -4°C, original preheater relay is defective. 1. Turn starting switch to OFF position. 2. Disconnect connectors CM01, RHR and D20, and connect T-adapter to female side of RHR.

Open circuit or ground fault in wiring harness

a If resistance is 1 Mz or higher, harness has open circuit. If it is 1 z or below, harness has short circuit. a Heater relay coil resistance Resistance Between RHR (female) (3) and ground

Open circuit in wiring harness (wire breakage or defective contact of connector)

Ground fault in wiring harness (contact with ground circuit)

D61EM-23M0

Approx. 20 z

1. Turn starting switch to OFF position. 2. Disconnect connectors RHR and CM01, and connect T-adapter to female side of RHR. 3. Remove fuse 120 A of fusible link 107. Between RHR (female) (5) and 107-4 Max. 1 z Resistance Between RHR (female) (3) and heater relay Max. 1 z terminal T5 If fuse is not blown, this check is not required. 1. Turn starting switch to OFF position. 2. Disconnect connector RHR and connect T-terminal to female side. 3. Remove fuse 120 A of fusible link 107. Resistance Between RHR (female) (5) and ground Min. 1 Mz

40-503

40 Troubleshooting

Troubleshooting of electrical system (E-mode)

Circuit diagram related to engine preheating system

40-504

D61EM-23M0

40 Troubleshooting

Troubleshooting of electrical system (E-mode)

E-4 While preheating is working, preheating monitor does not light up 1 Failure Related information No.

While preheating is working, preheating monitor does not light up. • This machine has "Automatic preheating" and "Manual preheating" functions. When either preheating works, preheating monitor lights up. • Check whether manual preheating function works first. Cause

Open circuit in wiring harness (wire breakage or defective contact of connector)

Defective machine monitor

D61EM-23M0

Procedure, measuring location, criteria and remarks 1. Turn starting switch to OFF position. 2. Disconnect connectors KEY, CM01 and RHR, and connect T-adapters to each female side Between Key (female) (2) and CM01 (female) (12) Max. 1 z Resistance Between RHR (female) (3) and CM01 (female) Max. 1 z (12) If no failure is found by above checks, machine monitor is defective. • Reference 1. Turn starting switch to OFF position. 2. Insert T-adapter into connector CM01. 3. Disconnect terminal T6 of heater relay. a To prevent current from flowing through heater when starting switch is turned to HEAT position for checking. 4. Turn starting switch to HEAT. Resistance Between CM01 (12) and (3) 20 to 30 V

40-505

40 Troubleshooting

Troubleshooting of electrical system (E-mode)

Circuit diagram related to engine preheating system

40-506

D61EM-23M0

40 Troubleshooting

Troubleshooting of electrical system (E-mode)

E-5 When starting switch is turned to ON position, machine monitor displays nothing

• When starting switch is turned to ON position, machine monitor displays nothing. • When starting switch is turned to ON position, machine monitor displays KOMATSU logo screen, password input screen (if password protection is enabled), preset setting confirmation screen, and standard screen in order. Related information • Depending on ambient temperature and condition of battery, battery voltage may lower suddenly and machine monitor displays nothing temporarily when engine is started. But this phenomenon does not mean that machine monitor is defective. • Check that battery disconnect switch is in ON position. Failure

No. 1 2 3

Cause Battery disconnect switch left in OFF position

Procedure, measuring location, criteria and remarks Turn starting switch to OFF position and check that battery disconnect switch is in ON position.

Loose terminal or open circuit 1. Turn starting switch to OFF position. at terminal Check terminals of battery relay, etc. Defective fuse -9, -16 or -20 in If fuse is blown, circuit probably has ground fault (see causes 8 and 12). fuse box F01

Defective fuse 50 A in fusible link 107, defective wiring harness or defective battery

1. Turn starting switch to OFF position, and turn battery disconnect switch to OFF position. 2. Remove fuses -9 and -16 in fuse box F01. 3. Turn battery disconnect switch to ON position. Between fuse box F01-9C and ground 20 to 30 V Voltage Between fuse box F01-16F and ground 20 to 30 V a If voltage is normal, proceed to check on cause 8.

Insufficient battery capacity

Defective fuse 50 A in fusible link 107

Open circuit 1 in wiring harness (wire breakage or defective contact of connector)

Ground fault 1 in wiring harness (contact with ground circuit)

D61EM-23M0

a Be ready with starting switch at OFF position, then perform troubleshooting without turning starting switch to ON position. Battery voltage (two batteries) Min. 24 V Specific gravity of electrolyte (each Min. 1.26 battery) If fusible link 50 A is broken, circuit probably has ground fault. (See Cause 12.) a If no failure is found by check on cause 3, this check is not required. 1. Turn starting switch to OFF position, and turn battery disconnect switch to OFF position. 2. Disconnect 50 A of fusible link 107 and -9, -16 and -20 of fuse F01. 3. Turn starting switch to ON position with battery disconnect switch at OFF position. Between battery (-) terminal and ground Max. 1 z Between battery (+) and 107-1 Max. 1 z ResisBetween 107-3 and F01-9C Max. 1 z tance Between 107-3 and F01-16F Max. 1 z Between F01-9 and F01-20G Max. 1 z If no failure is found by check on causes 3 and 4, this check is not required. 1. Turn starting switch to OFF position, and turn battery disconnect switch to OFF position. 2. Disconnect 50 A of fusible link 107, fuses F01-9 and F01-16, and battery (+) terminal. Between ground and battery (+) or 107-1 Min. 1 Mz ResisBetween ground and 107-3, F01-9C or F01Min. 1 Mz tance 16F

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No.

Cause

Defective wiring harness, starting switch, or machine monitor

Defective starting switch (internal open circuit)

Open circuit 2 in wiring harness 11 (wire breakage or defective contact of connector)

Ground fault 2 in wiring 12 harness (contact with ground circuit)

13 Defective machine monitor

40-508

Procedure, measuring location, criteria and remarks 1. Turn starting switch to OFF position, and turn battery disconnect switch to OFF position. 2. Insert T-adapter into connector CM01. 3. Turn battery disconnect switch to ON position, and turn starting switch to ON position (connect ACC). Between CM01 (1) and (3) 20 to 30 V Voltage Between CM01 (2) and (4) 20 to 30 V Between CM01 (10) and (4) (ACC line) 20 to 30 V a If ACC line is found normal by check on cause 9, this check is not required. 1. Turn starting switch to OFF position. 2. Disconnect connector KEY and connect T-adapter to male side. 3. Turn starting switch to ON position and perform troubleshooting again. Turn starting switch to Min. 1 Mz OFF position. Resis- Between KEY (male) (1) and (5) tance Turn starting switch to Max. 1 z ON position. If no failure is found by check on cause 9, this check is not required. 1. Turn starting switch to OFF position, and turn battery disconnect switch to OFF position. 2. Disconnect fuses F01-9 and F01-16 and connectors KEY and CM01. 3. Connect T-adapters to each female side of connectors KEY and CM01. Between F01-16 and CM01 (female) (1) and Max. 1 z (2) Between ground (T36) and CM01 (female) (3) Max. 1 z Resis- and (4) tance Between F01-9 and KEY (female) (5) Max. 1 z Between KEY (female) (1) and CM01 (female) Max. 1 z (10) If no failure is found by check on cause 9, this check is not required. 1. Turn starting switch to OFF position, and turn battery disconnect switch to OFF position. 2. Disconnect fuses F01-9, F01-16 and F01-20, and connectors KEY, CM01 and 3. 3. Connect T-adapters to female side of connectors KEY and CM01. Between ground and F01-16 or CM01 (female) Min. 1 Mz Resis- (1) and (2) tance Between ground and F01-20 or CM01 (female) Min. 1 Mz (10) If no failure is found by above checks, machine monitor is defective. (Since this is an internal defect, troubleshooting cannot be performed.)

D61EM-23M0

40 Troubleshooting

Troubleshooting of electrical system (E-mode)

Circuit diagram related to machine monitor power supply

D61EM-23M0

40-509

40 Troubleshooting

Troubleshooting of electrical system (E-mode)

E-6 When starting switch is turned to ON position (with engine stopped), basic check monitor lights up

When starting switch is turned to ON position (with engine stopped), water separator monitor (increase of water level in pre-filter) lights up. • Condition of water in pre-filter detected by water-in-fuel sensor can be checked with monitoring function. Related information (Code: 18800 "Water in Fuel") Failure

No. 1 2

Cause Increase of water level in prefilter (when system is normal)

Procedure, measuring location, criteria and remarks Since water is detected in pre-filter, check pre-filter and drain water in it.

If no failure is found by check on cause 1, water-in-fuel sensor system Defective water-in-fuel sensor may be defective. Perform troubleshooting for failure codes [CA428] system and [CA429]. If no failure is found by check on causes 1 to 2, machine monitor may be defective. Defective machine monitor (Since this is an internal defect, troubleshooting cannot be performed.)

40-510

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40 Troubleshooting

Troubleshooting of electrical system (E-mode)

E-7 Air cleaner clogging monitor lights up in yellow while engine is running

Air cleaner clogging monitor lights up in yellow while engine is running. • Signal from air cleaner clogging switch can be checked with monitoring function. Related information (Code: 04501 "Monitor Input 2") Failure

No. 1 2

Procedure, measuring location, criteria and remarks Cause Clogged air cleaner Air cleaner may be clogged. Check it for clogging, and clean or replace (When system works properly) it if it is clogged. Defective air cleaner clogging Perform troubleshooting for failure code [AA10NX]. switch system

D61EM-23M0

40-511

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Troubleshooting of electrical system (E-mode)

E-8 Charge level monitor lights up in red while engine is running

Charge level monitor lights up in red while engine is running. • Power-generation signal from alternator can be checked with monitoring function. Related information (Code: 04300 "Battery Charge Volt") Failure

No. Cause 1 Defective alternator system

40-512

Procedure, measuring location, criteria and remarks Perform troubleshooting for failure code [AB00KE].

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Troubleshooting of electrical system (E-mode)

E-9 Engine coolant temperature monitor lights up in red while engine is running 1 Engine coolant temperature monitor lights up in red while engine is running. • Signal voltage of engine coolant temperature sensor is input to engine controller, and then it is transmitted to machine monitor through CAN communication system. Related information • Engine coolant temperature can be checked with monitoring function. (Code: 04107 "Coolant Temperature") Failure

No. 1 2

Procedure, measuring location, criteria and remarks Cause Overheating of engine coolant Engine coolant may overheat. Check coolant temperature and remove (When system works properly) cause of failure if coolant overheats. If no failure is found by check on cause 1, engine coolant temperature Defective engine coolant sensor system may be defective. Perform troubleshooting for failure temperature sensor system codes [CA144] and [CA145]. If no failure is found by checks on causes 1 and 2, machine monitor may be defective. (Since this is an internal defect, troubleshooting Defective machine monitor cannot be performed.)

D61EM-23M0

40-513

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E-10 Engine oil pressure monitor lights up in red while engine is running

Engine oil pressure monitor lights up while engine is running. • Controller does not monitor signal (ON/OFF) from engine oil pressure switch. Related information • If engine oil pressure switch turns ON while engine is running, failure code [B@BAZG] is transmitted from engine controller to machine monitor through CAN. Failure

No. 1

Procedure, measuring location, criteria and remarks Cause Check the engine oil pressure as the drop of engine oil pressure is Reduction of engine oil detected. pressure (when system works properly) • Perform troubleshooting for "S-12 Oil pressure drops". If no failure is found by check on cause 1, engine oil pressure switch Defective engine oil pressure system may be defective. Perform troubleshooting for failure code system [CA435] Engine oil pressure error. If no failure is found by checks on causes 1 and 2, machine monitor may be defective. Defective machine monitor (Since this is an internal defect, troubleshooting cannot be performed.)

40-514

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Troubleshooting of electrical system (E-mode)

E-11 HST charge pressure monitor lights up in red while engine is running

HST charge pressure monitor lights up in red while engine is running. • Signal voltage and brake pressure from brake pressure sensor can be checked with monitoring function. Related information (Code: 91903 "Brake Pressure Sensor", 91902 "Brake Pressure") Failure

No. 1 2

Procedure, measuring location, criteria and remarks Cause Decrease in brake pressure Brake pressure may be low. Check the brake pressure and if it is the (When system works properly) case, examine the cause and damage, and repair machine. If no failure is found by above checks, brake pressure sensor system Defective brake pressure may be defective. Perform troubleshooting for failure codes [ DDP6KA system ], [ DDP6KB ] and [ DDB6MA ].

D61EM-23M0

40-515

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E-12 Hydraulic oil temperature monitor lights up in red while engine is running 1 Hydraulic oil temperature monitor lights up in red while engine is running. • Signal voltage of hydraulic oil temperature sensor is input to work equipment controller that transmits information to machine monitor through CAN communication system. Related information • Hydraulic oil temperature can be checked with monitoring function. • (Code: 04401 "Hyd Oil Temperature") Failure

No. 1 2

Procedure, measuring location, criteria and remarks Cause Overheating of hydraulic oil Hydraulic oil may overheat. Check hydraulic oil temperature, and (When system works properly) remove cause of failure if hydraulic oil overheats. If no failure is found by check on cause 1, hydraulic oil temperature Defective hydraulic oil sensor system or machine monitor may be defective. Perform temperature sensor system troubleshooting for failure codes [DGS1KA] and [DGS1KX]. If no failure is found by checks on causes 1 and 2, machine monitor may be defective. (Since this is an internal defect, troubleshooting Defective machine monitor cannot be performed.)

40-516

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Troubleshooting of electrical system (E-mode)

E-13 HST oil filter clogging monitor lights up in red while engine is running

HST oil filter clogging monitor lights up in red while engine is running. • Signal from HST clogging switch can be checked with monitoring function. Related information (Code: 40912 "HST Oil Filter") Failure

No. 1 2

Procedure, measuring location, criteria and remarks Cause Clogging of HST oil filter HST oil filter may be clogged. Check it for clogging, and clean or (When system works properly) replace it if it is clogged. Defective HST oil filter clogging Perform troubleshooting for failure code [6091NX]. switch system

D61EM-23M0

40-517

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E-14 Fuel level gauge does not indicate correct level

1) Fuel gauge does not indicate correct fuel level. 2) Display of fuel level gauge is different from actual fuel level. Failure 3) Indication of fuel level gauge does not accord with indication of fuel level monitor. • Check intermediate connector first, since seat must be removed before checking fuel level sensor. Related information • Input voltage from fuel level sensor can be checked with monitoring function. (Code: 04200 "Fuel Level Sensor Volt") No.

Cause

Procedure, measuring location, criteria and remarks 1. Turn starting switch to OFF position. 2. Disconnect connector 102, and connect T-adapter to male side.

Defective fuel level sensor, open circuit, or short circuit in wiring harness

Open circuit, short circuit, or ground fault in wiring harness

a Use fuel level sensor characteristics table for check on cause 3 as resistance criteria. a If resistance 1 Mz or higher, wiring harness has open circuit. If resistance is below 1 z, oil level sensor is defective. Resis- Between 102 (male) (11) and ground Approx. 10 tance to 85 z 1. Turn starting switch to OFF position. 2. Disconnect connector 102, and connect T-adapter to female side. 3. Turn starting switch to ON position. a If voltage is 0 V, wiring harness has open circuit, ground fault, or short circuit, and if voltage is 24 V, wiring harness has hot short circuit. a Voltage of approximately 3.3 V is applied to fuel level sensor signal lines through resistor inside machine monitor. Approx. Voltage Between 102 (female) (11) and ground 3.3 V a If no failure is found by check on cause 1, this check is not required. 1. Turn starting switch to OFF position. 2. Disconnect connector 13 and connect T-adapter to male side. Approx. 10 Between 13 (male) (1) and (2) FULL z Resis- a Fuel level sensor Approx. 85 EMPTY tance characteristics z Between 13 (male) (2) and ground Max. 1 z

Defective fuel level sensor (internal open or short circuit)

a If no failure is found by check on cause 1, this check is not required. 1. Turn starting switch to OFF position. 2. Disconnect connectors 102 and 13, and connect T-adapter to male side of 102 and female side of 13. Between 102 (male) (11) and 13 (female) (1) Max. 1 z ResisOpen circuit in wiring harness tance Between 13 (male) (2) and ground Max. 1 z (wire breakage or defective contact of connector) a If no failure is found by check on cause 2, this check is not required. 1. Turn starting switch to OFF position. 2. Disconnect connectors CM01 and 12, and connect T-adapter to each female side. Resis- Between CM01 (female) (15) and 102 (female) Max. 1 z (11) tance

40-518

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No.

Procedure, measuring location, criteria and remarks

Cause

a If no failure is found by check on cause 1, this check is not required. 1. Turn starting switch to OFF position. 2. Disconnect connectors 102 and 13, and connect T-adapter to male side of 102 or female side of 13. Resis- Between ground and 102 (male) (11) or 13 Min. 1 Mz Ground fault in wiring harness (female) (1) tance (contact with ground circuit) a If no failure is found by check on cause 2, this check is not required. 1. Turn starting switch to OFF position. 2. Disconnect connectors CM01 and 102, and connect T-adapter to either female side. Resis- Between ground and CM01 (female) (15) or Min. 1 Mz 102 (female) (11) tance 1. Turn starting switch to OFF position. 2. Disconnect connectors CM01 and 13, and connect T-adapter to female side of CM01.

Short circuit in wiring harness

Defective machine monitor

a Check by using multimeter in continuity mode. No continuity Between CM01 (female) (15) and Continuity each pin other than (15) (No sound is heard) If no failure is found by above checks, machine monitor is defective. • Reference a Turn starting switch to ON position or start engine to perform troubleshooting. Fuel gauge level: 6 Fuel level: 335 l Fuel gauge level: 5 Fuel level: 267 l Blue Color of Fuel gauge level: 4 Fuel level: 199 l monitor Fuel gauge level: 3 Fuel level: 132 l light Fuel gauge level: 2 Fuel level: 74 l Red Fuel gauge level: 1 Fuel level: Min. 63 l

Circuit diagram related to fuel level sensor

D61EM-23M0

40-519

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Troubleshooting of electrical system (E-mode)

Fuel level gauge and fuel level monitor

40-520

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Troubleshooting of electrical system (E-mode)

E-15 Engine coolant temperature gauge does not indicate correct temperature

1) While engine coolant temperature is rising normally, it does not rise from white range (C). 2) While engine coolant temperature is stabilized normally, it rises to red range (H). Failure 3) Engine coolant temperature is different from indication of coolant temperature gauge. 4) Indication of engine coolant temperature gauge is different from indication of engine coolant temperature monitor. • Signal voltage of engine coolant temperature sensor is input to engine controller and then the data is transmitted to machine monitor through CAN communication system. Related information • Engine coolant temperature can be checked with monitoring function. (Code: 04107 "Coolant Temperature") No. 1

Cause Defective engine coolant temperature sensor system

Procedure, measuring location, criteria and remarks Engine coolant temperature sensor system may be defective. Perform troubleshooting for failure codes [CA144] and [CA145]. If no failure is found by check on cause 1, machine monitor may be defective. (Since this is an internal defect, troubleshooting cannot be performed.) • Reference

Defective machine monitor

a Turn starting switch to ON position or start engine to perform troubleshooting. Engine coolant Coolant temperature temperature: 105°C gauge level: 6 Red Engine coolant Coolant temperature temperature: 102°C gauge level: 5 Engine coolant Coolant temperature Color of temperature: 100°C gauge level: 4 monitor Engine coolant Coolant temperature light temperature: 85°C gauge level: 3 Blue Engine coolant Coolant temperature temperature: 60°C gauge level: 2 Engine coolant Coolant temperature temperature: 30°C gauge level: 1

Engine coolant temperature gauge and coolant temperature monitor

D61EM-23M0

40-521

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Troubleshooting of electrical system (E-mode)

E-16 Hydraulic oil temperature gauge does not indicate correct temperature

1) While hydraulic oil temperature is rising normally, it does not rise from white range (C). 2) While hydraulic oil temperature is stabilized normally, it rises to red range (H). Failure 3) Hydraulic oil temperature is different from indication of hydraulic oil temperature gauge. 4) Indication of hydraulic oil temperature gauge is different from indication of hydraulic oil temperature monitor. • Signal voltage of hydraulic oil temperature sensor is inputted to work equipment controller which transmits information to the machine monitor through CAN communication system. Related information • Hydraulic oil temperature can be checked with monitoring function. (Code: 04401 "Hyd. Oil Temperature") No. 1

Cause Defective hydraulic oil temperature sensor system

Defective machine monitor

Procedure, measuring location, criteria and remarks Hydraulic oil temperature sensor system may be defective. Perform troubleshooting for failure codes [DGS1KA] and [DGS1KX]. If no failure is found by check on cause 1, machine monitor may be defective. (Since this is an internal defect, troubleshooting cannot be performed.) • Reference a Turn starting switch to ON position or start engine to perform troubleshooting. Hydraulic oil Hydraulic oil temperature gauge temperature: 105°C level: 6 Red Hydraulic oil Hydraulic oil temperature gauge temperature: 102°C level: 5 Hydraulic oil Hydraulic oil temperature gauge temperature: 98°C Color of level: 4 monitor Hydraulic oil light Hydraulic oil temperature gauge temperature: 70°C level: 3 Blue Hydraulic oil Hydraulic oil temperature gauge temperature: 20°C level: 2 Hydraulic oil Hydraulic oil temperature gauge temperature: 0°C level: 1

Hydraulic oil temperature gauge and hydraulic oil temperature monitor

40-522

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Troubleshooting of electrical system (E-mode)

E-17 Operation mode does not change

1) When working mode switch is operated, display of working mode monitor does not change. 2) When working mode is changed, engine output is not changed. • Engine output mode recognized by engine controller can be checked with monitoring function. (Code: 17500 Engine Power Mode) Related information • Before performing troubleshooting, check that no related failure code is displayed. (When failure code [DB2QKR] or [DB2RKR] is displayed, perform troubleshooting for it first.) Failure

No.

Cause

Defective machine monitor

Defective engine controller

D61EM-23M0

Procedure, measuring location, criteria and remarks Machine monitor may be defective. (Since this is an internal defect, troubleshooting cannot be performed.) a If engine output is varied by operating working mode switch, engine controller is normal. Engine controller may be defective. (Since this is an internal defect, troubleshooting cannot be performed.)

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E-18 Service mode cannot be selected

Failure

Service mode cannot be selected. • Operate the following switch operations, then service mode is displayed. Switch operations: [4]＋[1]o[2]o[3] (While pressing [4], press [1], [2] and [3] in this Related information order.) No. 1

Cause Defective machine monitor

40-524

Procedure, measuring location, criteria and remarks Machine monitor may be defective. (Since this is an internal defect, troubleshooting cannot be performed.)

D61EM-23M0

40 Troubleshooting

Troubleshooting of electrical system (E-mode)

E-19 Operating customize switch does not display customize screen 1 Failure Related information

Operating customize switch does not display customize screen.

No.

Cause

Defective machine monitor

D61EM-23M0

Procedure, measuring location, criteria and remarks Machine monitor may be defective. (Since this is an internal defect, troubleshooting cannot be performed.)

40-525

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Troubleshooting of electrical system (E-mode)

E-20 Modifying setting on customize screen does not change setting of machine 1 Failure Related information

When setting is changed on customize screen, setting of machine is not changed

No.

Cause

Defective machine monitor

Defective engine controller or defective HST controller

40-526

Procedure, measuring location, criteria and remarks Machine monitor may be defective. (Since this is an internal defect, troubleshooting cannot be performed.) Engine controller or HST controller may be defective. (Since this is an internal defect, troubleshooting cannot be performed.)

D61EM-23M0

40 Troubleshooting

Troubleshooting of electrical system (E-mode)

E-21 Service meter is not displayed, while starting switch is in OFF position

Service meter is not displayed while starting switch is in OFF position. • When following switches are operated while stating switch is in OFF position, service meter appears at top center of screen. Related information Switch operations: [4] ＋ [1] (simultaneously) Failure

No.

Procedure, measuring location, criteria and remarks When starting switch is turned to ON position, if machine monitor displays nothing, backup power supply system may be defective. In Defective backup power supply this case, perform the following troubleshooting. system • E-5 When starting switch is turned to ON position, machine monitor displays nothing If no failure is found by check on cause 1, machine monitor may be defective. Defective machine monitor (Since this is an internal defect, troubleshooting cannot be performed.)

D61EM-23M0

Cause

40-527

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Troubleshooting of electrical system (E-mode)

E-22 Work equipment does not operate Failure

Related information

No. 1

Work equipment does not operate. • This troubleshooting describes procedures to be followed when turning work equipment lock lever to FREE position does not energize work equipment lock solenoid valve (if work equipment does not operate when work equipment solenoid valve is energized, perform troubleshooting for [H-11 All work equipment do not operate]). • Signal from work equipment lock switch can be checked with monitoring function. (HST controller system code: 70300 "Blade knob Sw Input1")

Procedure, measuring location, criteria and remarks Cause Defective work equipment lock When failure code [DXJ4KA] or [DXJ4KB] is displayed, perform troubleshooting [DXJ4KA] or [DXJ4KB] first. solenoid 1. Turn starting switch to OFF position. 2. Disconnect connector PSW, and connect T-adapter to male side. Work equipment lock Defective work equipment lock lever: LOCK (bottom Min. 1 Mz lever (internal short circuit) Resis- Between PSW (male) side) (A) and (B) tance Work equipment lock lever: FREE (top side) Max. 1 z Since work equipment lock switch may be improperly installed, check Defective installation of work its installation (see "Testing and adjusting"). equipment lock switch 1. Turn starting switch to OFF position. 2. Disconnect diode array D4, and connect T-adapter to male side.

Defective diode array D4 (internal short circuit)

a Measure it with diode range of multimeter. Continuity Between D4 (male) (5) (+) and (1) (-) Continuity Between D4 (male) (1) (+) and (5) (-)

Continuity No continuity

Defective wiring harness or controller

1. Turn starting switch to OFF position. 2. Disconnect connectors PSL and PSW, and connect T-adapters to each female side. 3. Turn starting switch to ON position. Between PSL (female) (1) and (2) 1 to 4.5 V Work equipment lock lever: LOCK (bottom 7 to 11 V Between PSW side) (female) (B) and (A) Work equipment lock Voltage lever: FREE (top side) Max. 1 V Work equipment lock lever: LOCK (bottom Max. 1 V Between PSW side) (female) (C) and (A) Work equipment lock lever: FREE (top side) 7 to 11 V

Open circuit in wiring harness (wire breakage or defective contact of connector)

a If no failure is found by check on cause 5, this check is not required. 1. Turn starting switch to OFF position. 2. Disconnect connectors PSL, PSW, ST1, ST2 and ST3, and connect T-adapters to each female side. Between PSL (female) (1) and ST2 (female) Max. 1 z (18) Between PSL (female) (2) and ST3 (female) Max. 1 z (3) Resis- Between ST1 (female) (10) and PSW (female) Max. 1 z (A) tance Between PSW (female) (C) and ST3 (female) Max. 1 z (30) Between PSW (female) (B) and ST3 (female) Max. 1 z (40)

40-528

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Troubleshooting of electrical system (E-mode)

Cause

Procedure, measuring location, criteria and remarks

Ground fault in wiring harness (contact with ground circuit)

a If no failure is found by check on cause 5, this check is not required. 1. Turn starting switch to OFF position. 2. Disconnect connectors PSL, ST2, ST3, D4 and PSW, and connect T-adapter to female side of PSL and PSW. Between PSL (female) (1) and ground Min. 1 Mz Resis- Between PSW (female) (B) and ground Min. 1 Mz tance Between PSW (female) (C) and ground Min. 1 Mz

No.

Circuit diagram related to PPC lock solenoid

D61EM-23M0

40-529

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Troubleshooting of electrical system (E-mode)

E-23 Foot heater does not operate Failure

Related information

No. 1

Foot heater does not operate. • Trouble shooting for blower motor not rotating and failed hot water valve are described. • When blower motor rotates but air is not warmed up, hot water may be not supplied from engine. Check hot water valve system (cause 11 and after). • Air is not warmed up or temperature cannot be controlled until engine coolant is heated. • Temperature is controlled by changing volume of hot water entering into foot heater by using hot water valve under the floor. • When foot heater does not operate normally, check whether temperature control is available when turning air conditioner mode switch to HEAT position. When temperature control starts operating normally after air conditioner mode switch is turned to HEAT position, hot water valve body and diode AC9 are normal. • Start troubleshooting of blower motor from intermediate connector 92. Cause

Defective fuse F01-3 or -4

Defective relay for foot heater HI

Defective relay for foot heater LO

Defective diode AC7 or AC8

Procedure, measuring location, criteria and remarks If fuse is blown, circuit may have ground fault. (See check on cause 16.) a Make sure beforehand that air comes out when foot heater is set to LO. 1. Turn starting switch to OFF position. 2. Interchange connectors HRH and HRL. (Interchange relay for foot heater HI and relay for foot heater LO) 3. Turn starting switch to ON position. 4. Set foot heater to HI. If air comes out of foot heater, original relay for foot heater HI is defective. a Make sure beforehand that air comes out when foot heater is set to HI. 1. Turn starting switch to OFF position. 2. Interchange connectors HRH and HRL. (Interchange relay for foot heater HI and relay for foot heater LO) 3. Turn starting switch to ON position. 4. Set foot heater to LO. If air comes out of foot heater, original relay for foot heater LO is defective. 1. Turn starting switch to OFF position. 2. Disconnect connectors AC7 and AC8. 3. Turn starting switch to ON position. 4. Shift foot heater switch HI and LO repeatedly. a If air comes out of foot heater, diode AC7 or AC8 is defective. 1. Turn starting switch to OFF position. 2. Disconnect connector 92, and connect T-adapter to male side.

Defective blower motor system

Defective hoot heater switch, or open circuit in wiring harness

40-530

a If check result is unusual, go to check on causes 8 and 9. 1 to 5 z Resis- Between 92 (male) (1) and (3) tance Between 92 (male) (2) and (3) 1 to 5 z 1. Turn starting switch to OFF position. 2. Disconnect connector 92, and connect T-adapter to female side. 3. Turn starting switch to ON position. 4. Shift foot heater switch HI and LO repeatedly. Between 92 (female) (3) and ground 20 to 30 V Between 92 (female) Foot heater switch: HI 20 to 30 V Voltage (3) and (1) Between 92 (female) 20 to 30 V Foot heater switch: LO (3) and (2)

D61EM-23M0

40 Troubleshooting

Troubleshooting of electrical system (E-mode)

No.

Cause

Procedure, measuring location, criteria and remarks

Defective foot heater switch (internal defect)

a If no failure is found by check on cause 6, this check is not required. 1. Turn starting switch to OFF position. 2. Disconnect connector HET and connect T-adapter to male side. 3. Shift foot heater switch HI and LO repeatedly. Foot heater switch: HI Max. 1 z Between HET (male) (5) and (6) Foot heater switch: LO Min. 1 Mz Resistance Foot heater switch: HI Min. 1 Mz Between HET (male) (5) and (4) Foot heater switch: LO Max. 1 z

Defective blower motor

a If no failure is found by check on cause 5, this check is not required. 1. Turn starting switch to OFF position. 2. Disconnect connectors HEAT1 and HEAT2, and connect Tadapters to each male side. Between HEAT1 (male) (A) and (C) 1 to 5 z 1 to 5 z Resis- Between HEAT1 (male) (B) and (C) tance Between HEAT2 (male) (A) and (C) 1 to 5 z Between HEAT2 (male) (B) and (C) 1 to 5 z

a If no failure is found by check on cause 6, this check is not required. 1. Turn starting switch to OFF position. 2. Remove fuse -3 (15 A) in fuse box F01. 3. Disconnect connectors HET, HRH, HRL and 92, and connect Tadapter to each female side. 4. Disconnect connector 92 and connect T-adapter to male side. Between F01-3 and HET (female) (5) Max. 1 z Between F01-3 and 92 (female) (3) Max. 1 z Between ground (T35) and HRH (female) (2) Max. 1 z and (5) Between HRH (female) (1) and HET (female) Max. 1 z Resis- (6) tance Between HRH (female) (3) and 92 (female) (1) Max. 1 z Between ground (T35) and HRL (female) (2) Open circuit 1 in wiring harness Max. 1 z and (5) (wire breakage or defective Between HRL (female) (1) and HET (female) Max. 1 z contact of connector) (4) Between HRL (female) (3) and 92 (female) (2) Max. 1 z a If no failure is found by check on cause 5, this check is not required. 1. Turn starting switch to OFF position. 2. Disconnect connector 92, and connect T-adapter to male side. 3. Disconnect connectors HEAT1 and HEAT2. Between 92 (male) (1) and HEAT1 (female) (A) Max. 1 z Between 92 (male) (1) and HEAT2 (female) (A) Max. 1 z Between 92 (male) (2) and HEAT1 (female) (B) Max. 1 z Resis- Between 92 (male) (2) and HEAT2 (female) (B) Max. 1 z tance Between 92 (male) (3) and HEAT1 (female) Max. 1 z (C) Between 92 (male) (3) and HEAT2 (female) Max. 1 z (C)

D61EM-23M0

40-531

40 Troubleshooting

Troubleshooting of electrical system (E-mode)

No.

Cause

Procedure, measuring location, criteria and remarks 1. Turn starting switch to OFF position. 2. Disconnect connector AC2, and connect T-adapter to female side. 3. Turn starting switch to ON position. 4. Check foot heater switch at both settings of HI and LO. 5. Turn temperature adjustment switch from C to H. Between AC2 (female) (1) and (4) 20 to 30 V 0 (C) to Voltage Between AC2 (female) (2) and (4) approx. 25 (H) V

Defective temperature adjustment switch, defective 10 diode, or open circuit in wiring harness

a If no failure is found by above checks, this check is not required. 1. Turn starting switch to OFF position. 2. Disconnect connector AC7 and connect T-adapter to female side. 3. Turn starting switch to ON position. 4. Set foot heater switch to HI. Voltage Between AC7 (female) (2) and ground 20 to 30 V a If no failure is found by above checks, this check is not required. 1. Turn starting switch to OFF position. 2. Disconnect connector AC8 and connect T-adapter to female side. 3. Turn starting switch to ON position. 4. Set foot heater switch to LO. Voltage Between AC8 (female) (2) and ground 20 to 30 V

11 Defective hot water valve

12 Defective diode AC9

a If no failure is found in check on cause 10 and temperature control remains still unavailable, hot water valve is defective. a If no failure is found by check on cause 10, this check is not required. 1. Turn starting switch to OFF position. 2. Disconnect connector AC9. 3. Turn starting switch to ON position. 4. Check foot heater switch at both settings of HI and LO. 5. Turn temperature adjustment switch from C to H. a If temperature control becomes operable, diode AC9 is defective. a If no failure is found by check on cause 10, this check is not required. 1. Turn starting switch to OFF position. 2. Disconnect connectors AC7 and AC8, and connect T-adapters to each female side.

13 Defective diode AC7 or AC8

a Measure it with diode range of multimeter. Between AC7 (male) (1) (+) and (2) Continuity

Between AC7 (male) (2) (+) and (1) Between AC8 (male) (1) (+) and (2) Between AC8 (male) (2) (+) and (1)

Defective temperature control switch

40-532

No continuity Continuity No continuity Continuity

a If no failure is found by check on cause 10, this check is not required. 1. Turn starting switch to OFF position. 2. Disconnect connector AC3 and connect T-adapter to male side, or disconnect connector AC2 and connect T-adapter to female side. 3. Turn temperature adjustment switch from C to H. Approx. Between AC3 (male) (A) and (B), or between 1.5 (C) to ResisAC2 (female) (2) and (4) tance 5.2 (H) k z

D61EM-23M0

40 Troubleshooting

Troubleshooting of electrical system (E-mode)

No.

Cause

Procedure, measuring location, criteria and remarks

a If no failure is found by check on cause 10, this check is not required. 1. Turn starting switch to OFF position. 2. Remove fuse -4 (30 A) in fuse box F01. 3. Disconnect connector ACR1. 4. Disconnect connectors AC2, AC3, AC4, AC5 and AC7, and connect T-adapter to each female side. Open circuit 2 in wiring harness Between F01-4 and AC2 (female) (1) Max. 1 z 15 (wire breakage or defective Between AC2 (female) (2) and AC3 (female) contact of connector) Max. 1 z (B) Between AC2 (female) (4) and ground Max. 1 z ResisBetween AC3 (female) (A) and ground Max. 1 z tance Between AC7 (female) (1) and AC3 (female) Max. 1 z (C) Between AC8 (female) (1) and AC3 (female) Max. 1 z (C) 1. Turn starting switch to OFF position. 2. Remove fuses -3 (15 A) and -4 (30 A) in fuse box F01. 3. Disconnect connectors 92, AC2, AC3 and AC4, and connect Tadapter to each female side. 16

Ground fault in wiring harness (contact with ground circuit)

D61EM-23M0

a If check result is unusual, go to check on causes 8 and 9. Between ground and F01-3 or 92 (female) (3) Min. 1 Mz Between ground and F01-4 or AC2 (female) Resis- (1) Min. 1 Mz tance Between ground and AC2 (female) (2) or AC3 Min. 1 Mz (female) (B)

40-533

40 Troubleshooting

Troubleshooting of electrical system (E-mode)

Circuit diagram related to foot heater

40-534

D61EM-23M0

40 Troubleshooting

Troubleshooting of electrical system (E-mode)

E-24 Horn does not sound

Failure Horn does not sound. Related information No. 1

Cause Defective fuse F01-2

Defective horn switch

Defective wiring harness

Open circuit in wiring harness or horn

Procedure, measuring location, criteria and remarks If fuse F01-2 is blown out, circuit probably has ground fault. In this case, perform check on cause 6 first. 1. Turn starting switch to OFF position. 2. Disconnect horn switch terminals (No polarity). 3. Turn horn switch on and off to perform troubleshooting. OFF ResisBetween horn switch terminals tance ON

Min. 1 Mz Max. 1 z

1. Turn starting switch to OFF position. 2. Disconnect terminal 21. 3. Turn starting switch to ON position. 4. Turn horn switch to ON position. Between wiring harness side terminal 21 and Voltage ground

20 to 30 V

1. Turn starting switch to OFF position. 2. Remove fuse F01-2. 3. Turn horn switch to ON position. Continuity Between F01-2 and ground

Continuity

a If no failure is found by check on cause 4, this check is not required. 1. Turn starting switch to OFF position. 2. Disconnect terminal 21. Between terminal 21 (horn side) Continuity Continuity and ground

Open circuit in horn

Open circuit in wiring harness If any failure is found by check on cause 4 and no failure is found by (wire breakage or defective check on cause 5, wiring harness has open circuit. contact of connector)

a If fuse is not blown, this check is not required. 1. Turn starting switch to OFF position. Ground fault in wiring harness 2. Disconnect terminal 21. 3. Remove fuse F01-2. (contact with ground circuit) 4. Turn horn switch to ON position. Resis- Between terminal 21 (wiring harness side) and Min. 1 Mz ground tance Defective horn (internal If no failure is found by above checks, horn may be defective. defect)

D61EM-23M0

40-535

40 Troubleshooting

Troubleshooting of electrical system (E-mode)

Circuit diagram related to horn

40-536

D61EM-23M0

40 Troubleshooting

Troubleshooting of electrical system (E-mode)

E-25 Horn does not stop sounding

Horn does not stop sounding. Failure Related information No.

Cause

Defective horn switch

Hot short circuit in wiring harness Defective horn (internal defect)

Procedure, measuring location, criteria and remarks 1. Turn starting switch to OFF position. 2. Disconnect horn switch terminals (No polarity). 3. Turn horn switch on and off to perform troubleshooting. OFF ResisBetween horn switch terminals tance ON

Min. 1 Mz Max. 1 z

1. Turn starting switch to OFF position. 2. Disconnect terminal 21. 3. Turn starting switch to ON position. Between terminal 21 (wiring harness side) and Voltage ground

Max. 1 V

If no failure is found by above checks, horn may be defective.

Circuit diagram related to horn

D61EM-23M0

40-537

40 Troubleshooting

Troubleshooting of electrical system (E-mode)

E-26 Backup alarm does not sound Failure Related information No.

Backup alarm does not sound. • If ground fault occurs in backup alarm circuit, failure code [DV20KB] is displayed. k Depress brake pedal securely so that machine does not move and it does not hurt

people around the machine. Procedure, measuring location, criteria and remarks

Cause

1. Turn starting switch to OFF position. 2. Disconnect connector 14, and connect T-adapter to female side. 3. Turn starting switch to ON position. 4. Perform reverse traveling. Voltage Between 14 (female) (1) and (2) 20 to 30 V

Defective wiring harness or HST controller

a If no failure is found by check on cause 1, this check is not required. 1. Turn starting switch to OFF position. Open circuit in wiring harness 2. Disconnect connectors STC2, STC3 and 14, and connect Tadapters to female side of each connector. (wire breakage or defective Between STC2 (female) (28) and 14 (female) contact of connector) Max. 1 z Resis- (1) tance Between 14 (female) (2) and STC3 (female) Max. 1 z (13)

4 5

a If no failure is found by check on cause 1, this check is not required. 1. Turn starting switch to OFF position. Ground fault in wiring harness 2. Disconnect connectors STC2 and 14, and connect T-adapter to (contact with ground circuit) female side of either connector. Resis- Between ground and either 14 (female) (1) or Min. 1 Mz STC2 (female) (28) tance Defective backup alarm If no failure is found by above checks, backup alarm may be defective. (internal defect) If any failure is found by check on cause 1 and no failure is found by Defective HST controller check on cause 2 and 3, HST controller may be defective.

Circuit diagram related to backup alarm

40-538

D61EM-23M0

40 Troubleshooting

Troubleshooting of electrical system (E-mode)

E-27 Backup alarm does not stop sounding Failure Related information No.

Backup alarm does not stop sounding.

Procedure, measuring location, criteria and remarks

Cause

Hot short circuit in wiring harness

1. Turn starting switch to OFF position. 2. Disconnect connector 14, and connect T-adapter to female side. 3. Turn starting switch to ON position. Voltage

Defective backup alarm (internal defect)

Between 14 (female) (1) and (2)

Max. 4.5 V

Between 14 (female) (1) and ground

Max. 4.5 V

If no failure is found by above checks, backup alarm may be defective.

Circuit diagram related to backup alarm

D61EM-23M0

40-539

40 Troubleshooting

Troubleshooting of electrical system (E-mode)

E-28 Headlamp does not light up

Headlamp does not light up. • ! @ @ @ ` @ \ ` \ ` Related information • If headlamp relay, headlamp switch, diode and common wiring harness for R.H. and H headlamps are defective, R.H, L.H. and center headlamps do not light up (If either of headlamps lights up, these checks for the cause are not required). Failure

No.

Cause

Procedure, measuring location, criteria and remarks

1 Defective headlamp

Since headlamp may be defective, check it for breakage.

2 Defective fuse F01-1

If fuse is blown, circuit may have ground fault.

Defective headlamp relay (internal open or short circuit)

1. Turn starting switch to OFF position. 2. Replace headlamp relay (connector: 54) with rear lamp relay (connector: 54B). 3. Turn starting switch to ON position. 4. Turn on headlamp switch. If headlamp lights up, original headlamp relay is defective. 1. Turn starting switch to OFF position. 2. Disconnect connector FLSW, and connect T-adapter to male side. 3. Turn on and off headlamp switch to perform troubleshooting. a Head lamp switch has two ON positions in both sides.

4 Defective headlamp switch

Between FLSW (male) (5) and (6) Resistance Between FLSW (male) (5) and (4)

OFF

Min. 1 Mz

Max. 1 z

OFF

Min. 1 Mz

Max. 1 z

1. Turn starting switch to OFF position. 2. Remove connectors LMD1 and LMD2, and connect T-adapter to male side. a Measure it with diode range of multimeter. 5

Defective diode LMD1 or LMD2 (internal open or short circuit) Continuity

Open and short circuit in wiring harness

No continuity

Between LMD1 (male) (2) (+) and (1) (-)

Continuity

Between LMD2 (male) (1) (+) and (2) (-)

No continuity

Between LMD2 (male) (2) (+) and (1) (-)

Continuity

a To check location where voltage abnormality occurs, and roughly locate defective point of wiring harness 1. Turn starting switch to OFF position. 2. Disconnect connectors FL1 (2 places), FL2 (2 places), FLC1, FLC2 and FLC3, and connect T-adapter to each female side. 3. Turn starting switch to ON position. 4. Turn on headlamp switch.

Voltage

40-540

Between LMD1 (male) (1) (+) and (2) (-)

Between FL1 (2 places) (female) (1) (+) and (2) (-)

20 to 30 V

Between FL2 (2 places) (female) (1) (+) and (2) (-)

20 to 30 V

Between FLC1 (female) (1) (+) and (2) (-)

20 to 30 V

Between FLC2 (female) (1) (+) and (2) (-)

20 to 30 V

Between FLC3 (female) (1) (+) and (2) (-)

20 to 30 V

D61EM-23M0

40 Troubleshooting

Troubleshooting of electrical system (E-mode)

No.

Cause

Procedure, measuring location, criteria and remarks a If no failure is found by above checks, this check is not required. 1. Turn starting switch to OFF position. 2. Disconnect connector 54, and connect T-adapter to female side. 3. Turn starting switch to ON position. 4. Turn on headlamp switch.

Open and short circuit in wiring harness

Voltage

Between 54 (female) (5) and (6)

20 to 30 V

Between 54 (female) (1) and (6)

20 to 30 V

Between 54 (female) (3) and (6)

20 to 30 V

a If no failure is found by above checks, this check is not required. 1. Turn starting switch to OFF position. 2. Disconnect connector FLSW and connect T-adapter to female side. 3. Turn starting switch to ON position. Voltage

Between FLSW (female) (5) and (2)

20 to 30 V

a If no failure is found by check on cause 6, this check is not required. 1. Turn starting switch to OFF position. 2. Remove fuse F01-1. 3. Disconnect connectors FLSW, LMD1. LMD2, FL1 (2 places), FL2 (2 places), FLC1, FLC2, FLC3 and 54, and connect T-adapter to each female side.

Open circuit in wiring harness 7 (wire breakage or defective contact of connector)

Ground fault in wiring harness (contact with ground circuit)

D61EM-23M0

Between FL1 (2 places) (female) (2) and ground

Max. 1 Ω

Between FL2 (2 places) (female) (2) and ground

Max. 1 Ω

Between FLC1 (female) (2) and ground

Max. 1 Ω

Between FLC2 (female) (2) and ground

Max. 1 Ω

Between FLC3 (female) (2) and ground

Max. 1 Ω

Between FL1 (2 places) (female) (1) and 54 (female) (2), (4)

Max. 1 Ω

Between FL2 (2 places) (female) (1) and 54 (female) (2), (4)

Max. 1 Ω

Between FLC1 (female) (2) and 54 (female) (2), (4) Resistance Between FLC2 (female) (2) and 54 (female) (2), (4)

Max. 1 Ω

Between FLC3 (female) (2) and 54 (female) (2), (4)

Max. 1 Ω

Between 54 (female) (5) and LMD1 (female) (1)

Max. 1 Ω

Between 54 (female) (5) and LMD2 (female) (1)

Max. 1 Ω

Between 54 (female) (6) and ground

Max. 1 Ω

Between F01-1 and each of 54 (female) (1) and (3)

Max. 1 Ω

Between FLSW (female) (6) and LMD2 (female) (2)

Max. 1 Ω

Between FLSW (female) (4) and LMD1 (female) (2)

Max. 1 Ω

Between FLSW (female) (5) and F01-1

Max. 1 Ω

Between FLSW (female) (2) and ground

Max. 1 Ω

a If no failure is found by check on cause 6, this check is not required. 1. Turn starting switch to OFF position. 2. Remove fuse F01-1. 3. Disconnect connectors LMD1, LMD2, FL1 (2 places), FL2 (2 places), FLC1, FLC2, FLC3 and 54, and connect T-adapter to female side of 54. Between 54 (female) (1) and ground

Min. 1 MΩ

Resistanc Between 54 (female) (2) and ground

Min. 1 MΩ

Between 54 (female) (5) and ground

Min. 1 MΩ

40-541

40 Troubleshooting

Troubleshooting of electrical system (E-mode)

Circuit diagram related to headlamp

40-542

D61EM-23M0

40 Troubleshooting

Troubleshooting of electrical system (E-mode)

E-29 Rear lamp does not light up

Rear lamp does not light up. • If rear lamp relay, rear lamp switch and common wiring harness for R.H. and L.H rear lamps are defective, both R.H. and L.H. rear lamps do not light up (If either of Related information rear lamps lights up, these checks for the cause are not required). Failure

No. 1 2

Procedure, measuring location, criteria and remarks

Cause Defective rear lamp (burnedout bulb) Defective fuse F01-1

Since the rear lamp may be defective, check its bulb for breakage.

Defective rear lamp relay (internal open or short circuit)

1. Turn starting switch to OFF position. 2. Replace headlamp relay (connector: 54) with rear lamp relay (connector: 54B). 3. Turn starting switch to ON position. 4. Turn on rear lamp switch. If rear lamp lights up, original rear lamp relay is defective.

Defective rear lamp switch

1. Turn starting switch to OFF position. 2. Disconnect connector RLSW and connect T-adapter to male side. 3. Turn on and off rear lamp switch to perform troubleshooting. OFF Min. 1 Mz Resis- Between RLSW (female) (5) and (6) tance ON Max. 1 z

If fuse is blown, circuit may have ground fault.

a To check location where voltage abnormality occurs and roughly locate defective point of wiring harness Turn starting switch to OFF position. Disconnect connectors # | @~ \ # | @~, connect T-adapters to each female side. Turn starting switch to ON position. Turn on rear lamp switch. # | @~ |? ~ | ~ | ~ \ | ~ | ~ 20 to 30 V Voltage # | @~ |? ~ | ~ | ~ \ | ~ | ~ 20 to 30 V

a If no failure is found by above checks, this check is not required. Open circuit or ground fault in 1. Turn starting switch to OFF position. 2. Disconnect connector 54B and connect T-adapter to female side. wiring harness 3. Turn starting switch to ON position. 4. Turn on rear lamp switch. Between 54B (female) (5) and (6) 20 to 30 V Voltage Between 54B (female) (1) and (6) 20 to 30 V Between 54B (female) (3) and (6) 20 to 30 V a If no failure is found by above checks, this check is not required. 1. Turn starting switch to OFF position. 2. Disconnect connector RLSW and connect T-adapter to female side. 3. Turn starting switch to ON position. 20 to 30 V Voltage Between RLSW (female) (5) and (2)

D61EM-23M0

40-543

40 Troubleshooting

Troubleshooting of electrical system (E-mode)

No.

Cause

Procedure, measuring location, criteria and remarks

a If no failure is found by check on cause 6, this check is not required. Turn starting switch to OFF position. Remove fuse F01-1. Disconnect connectors RLSW, # | @~ # | @~ and 54B, and connect ! adapter to each female side. Between # | @~ (female) ( ) and ground Max. 1 z # | @~ |? ~ | ~ \ ` \ Max. 1 z # | @~ |? ~ | ~ \ Max. 1 z |? ~ | ~ | ~ Open circuit in wiring harness # | @~ |? ~ | ~ \ (wire breakage or defective Max. 1 z |? ~ | ~ | ~ contact of connector) Between 54B (female) (5) and RLSW (female) Max. 1 z Resis- (1) tance Between 54B (female) (5) and RLSW (female) Max. 1 z (6) Between 54B (female) (6) and ground Max. 1 z Between F01-1 and each of 54B (female) (1) Max. 1 z and (3) Between RLSW (female) (5) and F01-1 Max. 1 z Between RLSW (female) (2) and ground Max. 1 z

a If no failure is found by check on cause 6, this check is not required. Turn starting switch to OFF position. Remove fuse F01-1. Ground fault in wiring harness Disconnect connectors # | @~ # | @~ and 54B, and connect T-adapter to female side of 54B. (contact with ground circuit) Between 54B (female) (1) and ground Min. 1 Mz Resis- Between 54B (female) (2) and ground Min. 1 Mz tance Between 54B (female) (5) and ground Min. 1 Mz

40-544

D61EM-23M0

40 Troubleshooting

Troubleshooting of electrical system (E-mode)

Circuit diagram related to rear lamps

D61EM-23M0

40-545

40 Troubleshooting

Troubleshooting of electrical system (E-mode)

E-30 No wiper operates continuously or intermittently

No wiper operates continuously or intermittently.

Failure

a If fuse -5 of fuse box (in cab) is defective, front and rear wipers do not operate. Related information

a If fuse -6 of fuse box (in cab) is defective, right door and left door wipers do not operate. Procedure, measuring location, criteria and remarks If fuse shown at left is broken, the circuit probably has ground fault. In this case, perform check on cause 3 first. • If both fuses -7 and -8 in fuse box F01 are defective, no wiper operates.

No.

Cause

Defective fuse -7 or -8 in fuse box F01

Open circuit in wiring harness (wire breakage or defective contact of connector)

1. Turn starting switch to OFF position. 2. Remove fuses -7 and -8 in fuse box F01. 3. Remove fuse -5 in fuse box (in cab). Resis- Between F01-7 and FUSE box-B tance Between F01-8 and FUSE box -B

Ground fault in wiring harness (contact with ground circuit)

1. Turn starting switch to OFF position. 2. Remove fuses -7 and -8 in fuse box F01. 3. Remove fuse -5 in fuse box (in cab). ResisBetween FUSE box -B and F01-7 or F01-8 tance

40-546

Max. 1 z Max. 1 z

Min. 1 Mz

D61EM-23M0

40 Troubleshooting

Troubleshooting of electrical system (E-mode)

Circuit diagram related to wiper

D61EM-23M0

40-547

40 Troubleshooting

Troubleshooting of electrical system (E-mode)

E-31 Front wiper does not operate

Front wiper does not operate. Failure Related information • If fuse -5 in fuse box (in cab) is blown, both front and rear wipers do not operate. No. 1

Cause Defective fuse -5 in fuse box (in cab)

Procedure, measuring location, criteria and remarks If fuse is blown, circuit probably has ground fault, etc. (See check on cause 6.)

Defective front wiper motor (internal open circuit)

1. Turn starting switch to OFF position. 2. Disconnect connector CB23 and connect T-adapter to female side. 3. Turn starting switch to ON position. 4. Turn on front wiper switch. Voltage Between CB23 (female) (3) and (1) 20 to 30 V If voltage is normal and wiper does not operate, wiper motor may be defective.

a Check beforehand that rear wiper operates normally. 1. Turn starting switch to OFF position. Defective front wiper ON-OFF 2. Disconnect connectors CB28 and CB32, and interchange relays relay with each other. 3. Turn starting switch to ON position. (internal defect) 4. Turn on front wiper switch. If front wiper operates normally, original front wiper ON-OFF relay is defective. 1. Turn starting switch to OFF position. 2. Disconnect connector CB14 and connect T-adapter to male side. 3. Turn front wiper switch ON and OFF, and perform troubleshooting. Defective front wiper switch OFF Min. 1 Mz Resis- Between CB14 (female) (2) and (3) tance ON Max. 1 z

Open circuit in wiring harness (wire breakage or defective contact of connector)

1. Turn starting switch to OFF position. 2. Remove fuse -5 in fuse box (in cab). 3. Disconnect connectors CB14, CB28 and CB23, and connect Tconnector to each female side. Between fuse terminal -5 in fuse box and CB14 Max. 1 z (female) (3) Between CB28 (female) (1) and CB14 (female) Max. 1 z (2) Between CB28 (female) (2) and ground Max. 1 z Resis- (GND3) tance Between CB28 (female) (3) and CB23 (female) Max. 1 z (3) Between fuse terminal -5 in fuse box and CB23 Max. 1 z (female) (4) Between CB23 (female) (1) and ground Max. 1 z (GND1)

Ground fault in wiring harness (contact with ground circuit)

1. Turn starting switch to OFF position. 2. Remove fuse -5 in fuse box (in cab). 3. Disconnect connectors CB23 and CB37, and connect T-adapter to female side of either connector. 4. Turn front wiper switch and rear wiper switch to OFF position. Resis- Between ground and fuse terminal -5 in fuse Min. 1 Mz box, CB23 (female) (4) or CB37 (female) (4) tance

40-548

D61EM-23M0

40 Troubleshooting

Troubleshooting of electrical system (E-mode)

Circuit diagram related to wiper

D61EM-23M0

40-549

40 Troubleshooting

Troubleshooting of electrical system (E-mode)

E-32 Rear wiper does not operate

Rear wiper does not operate. Failure Related information • If fuse -5 in fuse box (in cab) is blown, both front and rear wipers do not operate. No. 1

Cause Defective fuse -5 in fuse box (in cab)

Procedure, measuring location, criteria and remarks If fuse is blown, circuit probably has ground fault, etc. (See check on cause 6.)

Defective rear wiper motor (internal open circuit)

1. Turn starting switch to OFF position. 2. Disconnect connector CB37, and connect T-adapter to female side. 3. Turn starting switch to ON position. 4. Turn on rear wiper switch. Voltage Between CB37 (female) (3) and (1) 20 to 30 V If voltage is normal and wiper does not operate, wiper motor may be defective.

Defective rear wiper ON-OFF relay (internal defect)

Defective rear wiper switch

a Check beforehand that front wiper operates normally. 1. Turn starting switch to OFF position. 2. Disconnect connectors CB28 and CB32, and interchange relays with each other. 3. Turn starting switch to ON position. 4. Turn on rear wiper switch. If rear wiper operates normally, original rear wiper ON-OFF relay is defective 1. Turn starting switch to OFF position. 2. Disconnect connector CB12 and connect T-adapter to male side. 3. Turn rear wiper switch ON and OFF, and perform troubleshooting. OFF Min. 1 Mz Resis- Between CB12 (female) (2) and (3) tance ON Max. 1 z

Open circuit in wiring harness (wire breakage or defective contact of connector)

1. Turn starting switch to OFF position. 2. Remove fuse -5 in fuse box (in cab). 3. Disconnect connectors CB12, CB32 and CB37, and connect Tadapter to each female side. Between fuse terminal -5 in fuse box and CB12 Max. 1 z (female) (3) Between CB32 (female) (1) and CB12 (female) Max. 1 z (2) Between CB32 (female) (2) and ground Max. 1 z Resis- (GND3) tance Between CB32 (female) (3) and CB37 (female) Max. 1 z (3) Between fuse terminal -5 in fuse box and CB37 Max. 1 z (female) (4) Between CB37 (female) (1) and ground Max. 1 z (GND1)

Ground fault in wiring harness (contact with ground circuit)

40-550

D61EM-23M0

40 Troubleshooting

Troubleshooting of electrical system (E-mode)

Circuit diagram related to wiper

D61EM-23M0

40-551

40 Troubleshooting

Troubleshooting of electrical system (E-mode)

E-33 Left door wiper does not operate (failed in both continuous and intermittent operations)

Left door wiper does not operate (failure continuous and intermittent operations). • If fuse -6 in fuse box (in cab) is blown, both right and left door wipers malfunction. • If front door wiper does not operate either, see troubleshooting for E-30. • Left door wiper motor is driven by power supplied from L.H. and R.H. door wiper intermittent unit CB27 even in continuous operation mode. • Wiper motor detects stop position, and converts 24 V voltage supplied from fuse into pulse voltage. • In intermittent operation mode, wiper motor operates while exchanging 24 V pulses with L.H. and R.H. door wiper intermittent unit CB27. Related information • Following pins on wiper intermittent unit CB27 are associated with this troubleshooting. GND1 (2): Relay output 1 (power supply 1 to wiper motor) (3): Continuous (24 V) input (4): Intermittent (24 V) input (6): Common 24 V input (8): 24 V pulse input 1 from wiper motor Failure

No. 1

Cause Defective fuse -6 in fuse box (in cab)

Procedure, measuring location, criteria and remarks If fuse is blown, circuit probably has ground fault, etc. (See check on cause 6.)

1. Turn starting switch to OFF position. Defective left door wiper motor 2. Disconnect connector CB24, and connect T-adapter to female side. 3. Turn starting switch to ON position. (internal open circuit) 4. Turn on left door wiper switch. Voltage Between CB24 (female) (3) and (1) 20 to 30 V

Defective L.H. and R.H. door wiper intermittent unit (internal defect)

1. Turn starting switch to OFF position. 2. Disconnect connector CB27. Resis- Between CB27 (male) (2) and (8) tance Between CB27 (male) (2) and (6)

Defective left door wiper switch

1. Turn starting switch to OFF position. 2. Disconnect connector CB15, and connect T-adapter to male side. 3. Turn L.H. door wiper switch ON and OFF, and perform troubleshooting. OFF Min. 1 Mz Resis- Between CB15 (female) (2) and (3) tance ON Max. 1 z

a If R.H. door wiper operates, this check is not required. 1. Turn starting switch to OFF position. 2. Remove fuse -6 in fuse box (in cab). 3. Turn starting switch to ON position. Between terminal of fuse -6 of fuse box and Voltage ground

Open circuit in wiring harness (wire breakage or defective contact of connector)

Max. 1 z Min. 1 Mz

20 to 30 V

a If R.H. door wiper operates, this check is not required. 1. Turn starting switch to OFF position. 2. Disconnect connector CB11, and connect T-adapter to female side. 3. Remove fuse -6 in fuse box (in cab). Resis- Between fuse terminal 4 of fuse box and each Max. 1 z of CB11 (female) (-6) and (5) tance • Wiper intermittent unit 1. Turn starting switch to OFF position. 2. Disconnect connectors CB11 and CB15, and connect T-adapter to each female side. a The internal circuit has many diodes, so be careful of the polarity of multimeter when performing measurement with it.

40-552

D61EM-23M0

40 Troubleshooting

Troubleshooting of electrical system (E-mode)

No.

Procedure, measuring location, criteria and remarks

Cause

a If multimeter does not indicate "OFF" as resistance, it is considered that wiring harness has no open circuit. • Check pins 1 and 3 of CB27 for open circuit Between CB11 (female) (3) (+) and CB15 1 to 50 Mz (female) (3) (-) Resistance • Check pins 4 and 1 of CB27 for open circuit Between CB11 (female) (6) (+) and CB15 1 to 50 Mz (female) (3) (-) • Wiper intermittent unit 1. Turn starting switch to OFF position. 2. Insert T-adapter into connector CB24. 3. Turn starting switch to ON position. 4. Turn L.H. wiper switch to ON position 5. Turn off intermittent switch. • Check pins 6 and 2 of CB27 for open circuit Voltage 20 to 30 V Between CB24 (3) and ground • Ground 1. Turn starting switch to OFF position. 2. Disconnect connector CB15 and connect T-adapter to female side. Resis- Between CB15 (female) (2) and ground Max. 1 z tance • Wiper motor power from fuse 1. Turn starting switch to OFF position. 2. Disconnect connector CB24 and connect T-adapter to female side. 3. Turn starting switch to ON position. Voltage Between CB24 (4) and (1) 20 to 30 V 1. Turn starting switch to OFF position. 2. Remove fuse terminal -6 in fuse box (in cab). 3. Disconnect connector CB24 and connect T-adapter to female side. a If no failure is found by check on wiper motor power, this check is not required. Max. 1 z Between CB24 (female) (4) and fuse terminal -6 of fuse box Resistance

Ground fault in wiring harness (contact with ground circuit)

D61EM-23M0

a If no failure is found by check on wiper motor power, this check is not required. Between CB24 (female) (1) and ground • Check of open circuit in wiring harness connecting pins 2 and 8 on CB27 between CB24 (female) (2) and (3)

Max. 1 z

1. Turn starting switch to OFF position. 2. Disconnect connectors CB11, CB13, CB15, CB17, CB24 and CB27, and connect T-adapter to each female side. Between CB24 (female) (2) and ground Min. 1 Mz Between CB24 (female) (3) and ground Min. 1 Mz Between ground and fuse terminal -6 in fuse ResisMin. 1 Mz box or CB24 (female) (4) tance Between CB11 (female) (3) and ground Min. 1 Mz Min. 1 Mz Between CB11 (female) (6) and ground

40-553

40 Troubleshooting

Troubleshooting of electrical system (E-mode)

No.

Procedure, measuring location, criteria and remarks If no failure is found by above checks, left door wiper motor is defective. • Reference 1. Turn starting switch to OFF position. 2. Insert T-adapter into connector CB24. Defective left door wiper motor 3. Turn starting switch to ON position. (Defective stop position 4. Turn on left door wiper switch. detection) a Voltage is applied when wiper operates (voltage is at GND level when wiper is at stop position and is resting in intermittent operation). Between CB24 (2) and (1) 20 to 30 V Voltage Between CB24 (3) and (1) 20 to 30 V

40-554

Cause

D61EM-23M0

40 Troubleshooting

Troubleshooting of electrical system (E-mode)

Circuit diagram related to wiper

D61EM-23M0

40-555

40 Troubleshooting

Troubleshooting of electrical system (E-mode)

E-34 Right door wiper does not operate (failed in both continuous and intermittent operations) 1 Right door wiper does not operate (failure of continuous and intermittent operations). • If fuse -6 in fuse box (in cab) is blown, both right and left door wipers do not operate. • If front windshield wiper does not operate either, see troubleshooting for E-30. • Left door wiper motor is driven by power supplied from L.H. and R.H. door wiper intermittent unit CB27 even in continuous operation mode. • Wiper motor detects stop position, and converts 24 V voltage supplied from fuse into pulse voltage. • In intermittent operation mode, wiper motor operates while exchanging 24 V pulses with L.H. and R.H. door wiper intermittent unit CB27. Related information • Following pins on wiper intermittent unit CB27 are associated with this troubleshooting. (3): Continuous (24 V) input (4): Intermittent (24 V) input (5): Relay output 2 (power supply 2 to wiper motor) (6): Common 24 V input (7): 24 V pulse input 2 from wiper motor (9): GRD2 Failure

Cause Defective fuse -6 in fuse box (in cab)

Procedure, measuring location, criteria and remarks If fuse is blown, circuit probably has ground fault, etc. (See check on cause 6.)

Defective right door wiper motor (internal open circuit)

1. Turn starting switch to OFF position. 2. Disconnect connector CB17, and connect T-adapter to female side. 3. Turn starting switch to ON position. 4. Turn on right door wiper switch. Voltage Between CB17 (female) (3) and (1) 20 to 30 V

Defective L.H. and R.H. door wiper intermittent unit (internal defect)

1. Turn starting switch to OFF position. 2. Disconnect connector CB27. Resis- Between CB27 (male) (5) and (7) tance Between CB27 (male) (5) and (6)

Defective right door wiper switch

1. Turn starting switch to OFF position. 2. Disconnect connector CB13, and connect T-adapter to male side. 3. Turn R.H. door wiper switch ON and OFF, and perform troubleshooting. OFF Min. 1 Mz Resis- Between CB13 (male) (2) and (3) tance ON Max. 1 z

No. 1

a If L.H. door wiper operates, this check is not required. 1. Turn starting switch to OFF position. 2. Remove fuse terminal -6 in fuse box (in cab). 3. Turn starting switch to ON position. Between terminal of fuse -6 of fuse box and Voltage ground

Open circuit in wiring harness (wire breakage or defective contact of connector)

Max. 1 z Min. 1 Mz

20 to 30 V

a If L.H. door wiper operates, this check is not required. 1. Turn starting switch to OFF position. 2. Disconnect connector CB11, and connect T-adapter to female side. 3. Remove fuse terminal -6 in fuse box (in cab). Resis- Between fuse terminal -6 in fuse box and each Max. 1 z of CB11 (female) (4) and (5) tance • Wiper intermittent unit 1. Turn starting switch to OFF position. 2. Disconnect connectors CB11 and CB13, and connect T-adapters to each female side. a The internal circuit has many diodes, so be careful of the polarity of multimeter when performing measurement with it.

40-556

D61EM-23M0

40 Troubleshooting

Troubleshooting of electrical system (E-mode)

No.

Procedure, measuring location, criteria and remarks

Cause

a If multimeter does not indicate "OFF" as resistance, it is considered that wiring harness has no open circuit. • Check pins 9 and 3 of CB27 for open circuit Between CB11 (female) (3) (+) and CB13 1 to 50 Mz (female) (3) (-) Resistance • Check pins 4 and 9 of CB27 for open circuit Between CB11 (female) (6) (+) and CB13 1 to 50 Mz (female) (3) (-) • Wiper intermittent unit 1. Turn starting switch to OFF position. 2. Insert T-adapter into connector CB17. 3. Turn starting switch to ON position. 4. Turn right door switch to ON position. 5. Turn off intermittent switch. • Check pins 6 and 5 of CB27 for open circuit Voltage 20 to 30 V Between CB17 (3) and ground • Ground 1. Turn starting switch to OFF position. 2. Disconnect connector CB13, and connect T-adapter to female side. Resis- Between CB13 (female) (2) and ground Max. 1 z tance • Wiper motor power from fuse 1. Turn starting switch to OFF position. 2. Disconnect connector CB17, and connect T-adapter to female side. 3. Turn starting switch to ON position. Voltage Between CB17 (4) and (1) 20 to 30 V 1. Turn starting switch to OFF position. 2. Remove fuse terminal -6 in fuse box (in cab). 3. Disconnect connector CB17, and connect T-adapter to female side. a If no failure is found by check on wiper motor power, this check is not required. Max. 1 z Between CB17 (female) (4) and fuse terminal -6 of fuse box Resistance

Ground fault in wiring harness (contact with ground circuit)

D61EM-23M0

a If no failure is found by check on wiper motor power, this check is not required. Between CB17 (female) (1) and ground • Check of open circuit in wiring harness connecting pins 5 and 8 on CB27 between CB17 (female) (2) and (3)

Max. 1 z

1. Turn starting switch to OFF position. 2. Disconnect connectors CB11, CB13, CB13, CB17, CB17 and CB27, and connect T-adapter to each female side. Between CB17 (female) (2) and ground Min. 1 Mz Between CB17 (female) (3) and ground Min. 1 Mz Between ground and fuse terminal 6 in fuse ResisMin. 1 Mz box or CB17 (female) (4) tance Between CB11 (female) (3) and ground Min. 1 Mz Min. 1 Mz Between CB11 (female) (6) and ground

40-557

40 Troubleshooting

Troubleshooting of electrical system (E-mode)

No.

Cause

Defective right door wiper motor (Defective stop position detection)

40-558

Procedure, measuring location, criteria and remarks If no failure is found by above checks, right door wiper motor is defective. • Reference 1. Turn starting switch to OFF position. 2. Insert T-adapter into connector CB17. 3. Turn starting switch to ON position. 4. Turn on right door wiper switch. a Voltage is applied when wiper operates (voltage is at GND level when wiper is at stop position and is resting in intermittent operation). Between CB17 (2) and (1) 20 to 30 V Voltage Between CB17 (3) and (1) 20 to 30 V

D61EM-23M0

40 Troubleshooting

Troubleshooting of electrical system (E-mode)

Circuit diagram related to wiper

D61EM-23M0

40-559

40 Troubleshooting

Troubleshooting of electrical system (E-mode)

E-35 Front washer does not operate Failure Related information

No.

Front washer does not operate. • If fuse -5 in fuse box (in cab) is blown, all of front wiper, rear wiper, front washer and rear washer do not operate. • If wiper does not operate either, see troubleshooting for E-31. • T-adapter is not provided for connectors of washer motor (troubleshooting is performed without using T-adapter). Cause

Defective front washer motor (internal open circuit)

Procedure, measuring location, criteria and remarks a Check that rear washer fluid flows. 1. Turn starting switch to OFF position. 2. Interchange connectors 362 and 364 with each other. 3. Turn starting switch to ON position. 4. Turn front washer switch to ON position. If fluid of rear washer flows, original front washer motor is defective. 1. Turn starting switch to OFF position. 2. Disconnect connector CB14, and connect T-adapter to male side. 3. Turn front wiper switch ON and OFF, and perform troubleshooting.

Defective front wiper switch

Open circuit in wiring harness (wire breakage or defective contact of connector)

Ground fault in wiring harness (contact with ground circuit)

40-560

a Measure it with diode range of multimeter. Front wiper switch: OFF Resis- Between CB14 (female) (5) and (6) Front wiper switch: tance WASH position

Min. 1 Mz Max. 1 z

1. Turn starting switch to OFF position. 2. Disconnect connector CB14, and connect T-adapter to female side. Continuity Between CB14 (female) (6) and ground Continuity 1. Turn starting switch to OFF position. 2. Remove fuse -5 of fuse box. 3. Disconnect connector CB14, and connect T-adapter to female side. Resis- Between CB14 (female) (5) and fuse terminal Max. 1 z tance 5 of fuse box 1. Turn starting switch to OFF position. 2. Remove fuse -5 of fuse box. 3. Disconnect connectors 362 and CB14, and connect T-adapter to each female side. Resis- Between CB14 (female) (6) and ground Min. 1 Mz tance

D61EM-23M0

40 Troubleshooting

Troubleshooting of electrical system (E-mode)

Circuit diagram related to windshield washer

D61EM-23M0

40-561

40 Troubleshooting

Troubleshooting of electrical system (E-mode)

E-36 Rear washer does not operate Failure Related information

No.

Rear washer does not operate. • If fuse -5 in fuse box (in cab) is blown, all of front wiper, rear wiper, front washer and rear washer do not operate. • If wiper does not operate either, see troubleshooting for E-32. • T-adapter is not provided for connectors of washer motor (troubleshooting is performed without using T-adapter). Cause

Defective rear washer motor (internal open circuit)

Procedure, measuring location, criteria and remarks a Check that front washer fluid flows. 1. Turn starting switch to OFF position. 2. Interchange connectors 362 and 364 with each other. 3. Turn starting switch to ON position. 4. Turn rear washer switch to ON position. If fluid of front washer flows, original rear washer motor is defective. 1. Turn starting switch to OFF position. 2. Disconnect connector CB12 and connect T-adapter to male side. 3. Turn rear wiper switch ON and OFF, and perform troubleshooting.

Defective rear wiper switch

Open circuit in wiring harness (wire breakage or defective contact of connector)

Ground fault in wiring harness (contact with ground circuit)

40-562

a Measure it with diode range of multimeter. Rear wiper switch: OFF Resis- Between CB12 (female) (5) and (6) Rear wiper switch: tance WASH position

Min. 1 Mz Max. 1 z

1. Turn starting switch to OFF position. 2. Disconnect connector CB12, and connect T-adapter to female side. Continuity Between CB12 (female) (6) and ground Continuity 1. Turn starting switch to OFF position. 2. Remove fuse -5 of fuse box. 3. Disconnect connector CB12, and connect T-adapter to female side. Resis- Between CB12 (female) (5) and fuse terminal Max. 1 z tance 5 of fuse box 1. Turn starting switch to OFF position. 2. Remove fuse -5 of fuse box. 3. Disconnect connectors 364 and CB12, and connect T-adapter to each female side. Resis- Between CB12 (female) (6) and ground Min. 1 Mz tance

D61EM-23M0

40 Troubleshooting

Troubleshooting of electrical system (E-mode)

Circuit diagram related to windshield washer

D61EM-23M0

40-563

40 Troubleshooting

Troubleshooting of electrical system (E-mode)

E-37 Left door washer does not operate Failure Related information

No.

Left door washer does not operate. • If fuse -6 in fuse box (in cab) is blown, all of left door wiper, right door wiper, left door washer and right door washer do not operate. • If wiper does not operate either, see troubleshooting for E-33. • T-adapter is not provided for connectors of washer motor (troubleshooting is performed without using T-adapter). Procedure, measuring location, criteria and remarks

Cause

a Check that right door washer fluid flows. 1. Turn starting switch to OFF position. 2. Interchange connectors 361 and 363 with each other. 3. Turn starting switch to ON position. 4. Turn left door washer switch to ON position. If fluid of right door washer flows, original left door washer motor is defective. 1. Turn starting switch to OFF position. 2. Disconnect connector CB15, and connect T-adapter to male side. 3. Turn L.H. door wiper switch ON and OFF, and perform troubleshooting.

Defective left door washer motor (internal open circuit)

Defective left door wiper switch a Measure it with diode range of multimeter. Resistance

Open circuit in wiring harness (wire breakage or defective contact of connector)

Ground fault in wiring harness (contact with ground circuit)

40-564

Between CB15 (female) (5) and (6)

L.H. door wiper switch: Min. 1 Mz OFF L.H. door wiper switch: Max. 1 z WASH position

1. Turn starting switch to OFF position. 2. Disconnect connector CB15, and connect T-adapter to female side. Continuity Between CB15 (female) (6) and ground Continuity 1. Turn starting switch to OFF position. 2. Remove fuse -6 of fuse box. 3. Disconnect connector CB15, and connect T-adapter to female side. Resis- Between CB15 (female) (5) and fuse terminal Max. 1 z tance 6 of fuse box 1. Turn starting switch to OFF position. 2. Remove fuse -6 of fuse box. 3. Disconnect connectors 361 and CB15, and connect T-adapter to each female side. Resis- Between CB15 (female) (6) and ground Min. 1 Mz tance

D61EM-23M0

40 Troubleshooting

Troubleshooting of electrical system (E-mode)

Circuit diagram related to windshield washer

D61EM-23M0

40-565

40 Troubleshooting

Troubleshooting of electrical system (E-mode)

E-38 Right door washer does not operate Failure Related information

No.

Right door washer does not operate. • If fuse -6 in fuse box (in cab) is blown, all of right door wiper, left door wiper, right door washer and left door washer do not operate. • If wiper does not operate either, see troubleshooting for E-34. • T-adapter is not provided for connectors of washer motor (troubleshooting is performed without using T-adapter). Cause

Defective right door washer motor (internal open circuit)

Defective right door wiper switch

Open circuit in wiring harness (wire breakage or defective contact of connector)

Ground fault in wiring harness (contact with ground circuit)

40-566

Procedure, measuring location, criteria and remarks a Check that left door washer fluid flows. 1. Turn starting switch to OFF position. 2. Interchange connectors 361 and 363 with each other. 3. Turn starting switch to ON position. 4. Turn right door washer switch to ON position. If fluid of left door washer flows, original right door washer motor is defective. 1. Turn starting switch to OFF position. 2. Disconnect connector CB13, and connect T-adapter to male side. 3. Turn R.H. door wiper switch ON and OFF, and perform troubleshooting. a Measure it with diode range of multimeter. R.H. door wiper Min. 1 Mz switch: OFF Resis- Between CB13 (male) (5) and (6) R.H. door wiper tance switch: WASH position Max. 1 z 1. Turn starting switch to OFF position. 2. Disconnect connector CB13, and connect T-adapter to female side. Continuity Between CB13 (female) (6) and ground Continuity 1. Turn starting switch to OFF position. 2. Remove fuse -6 of fuse box. 3. Disconnect connector CB13, and connect T-adapter to female side. Resis- Between CB13 (female) (5) and fuse terminal Max. 1 z tance -6 of fuse box 1. Turn starting switch to OFF position. 2. Remove fuse -6 of fuse box. 3. Disconnect connectors 363 and CB13, and connect T-adapter to each female side. Resis- Between CB13 (female) (6) and ground Min. 1 Mz tance

D61EM-23M0

40 Troubleshooting

Troubleshooting of electrical system (E-mode)

Circuit diagram related to windshield washer

D61EM-23M0

40-567

40 Troubleshooting

Troubleshooting of electrical system (E-mode)

E-39 KOMTRAX system does not operate normally Failure Related information No. 1

• KOMTRAX system does not operate normally. • Perform following troubleshooting if administrator of KOMTRAX system requests to check whether failure is occurring in system on machine. • Even when KOMTRAX system is defective, no problem appears on machine. • Check all of results of troubleshooting on service menu display of machine monitor. Cause

Defective communication 1

Procedure, measuring location, criteria and remarks 1. Turn starting switch to ON position. 2. Display "Terminal status" screen. Monitoring Checkpoints: display Station setup check

To be completed

1. Turn starting switch to ON position. 2. Display "GPS & Communication Status" screen. N ###.##.## (Latitude) Monitoring Checkpoints: E ###.##.## (Longitude) Defective positioning by GPS display Positioning In positioning If latitude and longitude are not displayed within 5 minutes with machine stayed outdoor where opens clearly for sky, contact KOMTRAX service hot line. 1. Turn starting switch to ON position. 2. Display "GPS & Communication Status" screen. Monitoring Checkpoints: Satellite in View or No Satellite in Defective communication display Communication View environment If Communication Status does never display "Satellite in View" within 15 minutes with machine stayed outdoor where opens clearly for sky, check if connector of TC330 or antenna on top of cab are properly connected. 1. Turn starting switch to ON position. 2. Display "GPS & Communication Status" screen. Defective communication 2 Checkpoints: Monitoring 0 to 60 (normally 0) display Number of message not yet sent

a Select “01 Terminal Status” from “KOMTRAX settings” in service menu of machine monitor.

40-568

D61EM-23M0

40 Troubleshooting

Troubleshooting of electrical system (E-mode)

a Select "02 GPS & Communication Status" from "11 KOMTRAX settings" in service menu of machine monitor.

D61EM-23M0

40-569

40 Troubleshooting

Troubleshooting of hydraulic and mechanical system (H-mode)

Troubleshooting of hydraulic and mechanical system (H-mode)1 Information described in troubleshooting table (H-mode)

1 (Rev. 2011/03)

a The following information is summarized in the troubleshooting table. Before performing troubleshooting, understand that information fully. Failure Related information

Failure symptom that appears on machine Information on occurred failure or troubleshooting

No. Cause 1 2 Probable cause of failure (Each number is serial 3 number, not priority 4 sequence.) 5

40-570

Procedure, measuring location, criteria and remarks <Contents of description> • Criteria to determine probable causes • Remarks for determination of probable cause

D61EM-23M0

40 Troubleshooting

Troubleshooting of hydraulic and mechanical system (H-mode)

Failure mode and cause table

Troubleshooting No.

Work equipment pump LS valve

Work equipment pump PC valve

Work equipment (fan) pump (body)

HST pump safety valve with suction

HST pump servo valve

HST pump EPC valve (including incorrect connection of connectors)

HST pump (initial adjustment) HST pump (air bleeding)

HST pump (pump body)

Hydraulic oil (oil temperature and oil type)

Piping between pump and motor

Hydraulic oil cooler (including bypass valve)

Pump suction piping (ECMV)

Charge filter

Hydraulic tank strainer

Rear damper

Air leakage from air supply pipe

Pump suction piping (air suction)

Pump and motor

Engine system

Component causing failure

Failure Directional travel is not available for both L.H. and R.H. systems (both systems do not work for travel).

H-1

Directional travel is not available for L.H. or R.H. system (travel is available only for L.H. or R.H. system).

H-2

Power train system

Forward or reverse travel is not available for L.H. or R.H. system (travel is available only for a single system). Travel speed or power is low.

Travel deviation is large.

Machine drift on a slope is large.

Engine to stall or engine speed to lower significantly during travel.

q q

All work equipment do not operate.

All work equipment speed or power is low. Work equipment system

H-3

H-4

H-

q q

Unusual noise is heard from around HST pump or motor.

Fan system

Large shocks are made when work equipment starts or stops.

H-

H- H-1

H-1

speed or power is low.

H-1

@ \ @ ` @ \ @

H-1

Hydraulic drift of & ? is large.

H-1

Unusual noise is heard from around work equipment pump and

control valve. HST oil temperature (hydraulic oil temperature) rises too high

Fan speed is abnormal (too high or low, or fan does not rotate).

Unusual noise is heard from around fan.

D61EM-23M0

q q

H-1 H- H-

H-

40-571

40 Troubleshooting

Troubleshooting of hydraulic and mechanical system (H-mode)

Troubleshooting No.

Fan control valve (spool, pressure compensation valve)

Safety valve

Suction valve

Fan EPC valve

Work equipment lock solenoid valve

Work equipment EPC valve

Work equipment (fan) main relief valve

Unload valve

Fan motor (initial adjustment)

Fan motor (suction valve)

Fan motor (motor body)

Control valve and cylinder

Fan motor (reverse spool)

HST motor charge relief valve

HST motor shaft speed sensor

HST motor parking brake (disc and plate)

HST motor EPC valve

HST motor (motor body)

HST motor (initial adjustment)

Pump and motor

Charge pump

Component causing failure

Failure Directional travel is not available for both L.H. and R.H. systems (both systems do not work for travel).

H-1

Directional travel is not available for L.H. or R.H. system (travel is

available only for L.H. or R.H. system).

H-2

Work equipment system

Power train system

Forward or reverse travel is not available for L.H. or R.H. system

! ^ $ $ $

H-

Large shocks are made when work equipment starts or stops.

H-

Travel deviation is large.

Machine drift on a slope is large.

Engine to stall or engine speed to lower significantly during travel.

Unusual noise is heard from around HST pump or motor.

H-

All work equipment do not operate.

All work equipment speed or power is low.

H-1 H-1

@ \ @

@ \ @ ` @ \ @

H-1 H-1

\ \ ? ? & ? @ `

H-1

Unusual noise is heard from around work equipment pump and

control valve. HST oil temperature (hydraulic oil temperature) rises too high

Fan system

H-3

(travel is available only for a single system).

Fan speed is abnormal (too high or low, or fan does not rotate).

Unusual noise is heard from around fan.

40-572

H-1

H-

D61EM-23M0

40 Troubleshooting

Troubleshooting of hydraulic and mechanical system (H-mode)

Troubleshooting No.

Fan exterior

Final drive

Steering lever (stroke adjustment)

Work equipment lever (stroke adjustment)

Parking brake lever linkage

Slow brake solenoid valve

Brake pedal linkage

Brake (inappropriate operation of tow receiving valve)

* ' control valve (spool, pressure compensation valve)

Brake

* ' cylinder

Blade lift cylinder

Quick drop valve for blade lift

Control valve and cylinder

Blade lift control valve (spool, pressure compensation valve)

Component causing failure

Failure Directional travel is not available for both L.H. and R.H. systems (both systems do not work for travel).

H-1

Directional travel is not available for L.H. or R.H. system (travel is available

only for L.H. or R.H. system).

H-2

Power train system

Forward or reverse travel is not available for L.H. or R.H. system (travel is H-3

available only for a single system). Travel speed or power is low.

H-4

Large shocks are made when work equipment starts or stops.

H-

Travel deviation is large.

Machine drift on a slope is large.

q q

H-

Engine to stall or engine speed to lower significantly during travel.

H-

Unusual noise is heard from around HST pump or motor.

H-

All work equipment do not operate.

H-1

Fan system

Work equipment system

All work equipment speed or power is low.

@ \ @

H-1

@ \ @ ` @ \ @ \ \ ? ? & ? @ `

q q

H-1

H-13

H-1

Unusual noise is heard from around work equipment pump and control

H-1

valve. HST oil temperature (hydraulic oil temperature) rises too high

H-

Fan speed is abnormal (too high or low, or fan does not rotate).

H-

Unusual noise is heard from around fan.

D61EM-23M0

H-

40-573

40 Troubleshooting

Troubleshooting of hydraulic and mechanical system (H-mode)

H-1 Neither RH nor LH of tracks does not travel forward nor reverse (None of the travel system operates) Failure

Related information

• Neither R.H. nor L.H. of tracks does not travel forward nor reverse. (None of the travel system operates.) • Check that oil level in hydraulic tank is normal before performing troubleshooting. • If any failure code is displayed, perform troubleshooting for that failure code first (6091NX, DW7EKA, DW7EKB, DW4BKA, or DW4BKB). • When fan cleaning mode is turned on, when turbo protection function is in operation, or when error of action code [E04] is detected, [N flashing] is indicated in the gear speed display, and machine cannot travel. • Oil pressure of HST circuit (pump outlet) can also be checked on monitor (monitoring code: 52501 "RF HST Pressure", 52503 "LF HST Pressure", 52505 "RR HST Pressure", and 52507 "LR HST Pressure"). Testing method 1. If charge pressure low caution is generated and work equipment does not work and fan is rotated at high speed when you turned parking brake lever to FREE position, charge pressure may be low. Perform checks on causes 2, 3, 4, and 5. 2. If HST pump generates relieving sounds and engine speed is reduced when you drive machine, parking brake in HST motor may not be released. Perform checks on causes 6 and 7.

No.

Cause Internal defect of rear 1 damper

2 Clogged charge filter

Defective adjustment or malfunction of oil cooler bypass valve (charge 3 safety valve) and malfunction of parking brake solenoid valve.

Defective adjustment or 4 malfunction of HST motor (charge relief valve)

Internal defect of charge 5 pump

Malfunction of slow brake solenoid valve

40-574

Procedure, measuring location, criteria and remarks When both work equipment and fan do not work, HST pump may not be rotating. Check rear damper connection to pump for any abnormalities. Check charge filter for clogging. Clogging of charge filter can be checked with monitoring function. (Controller: HST, Monitoring code: 40912 "HST Oil Filter") a Be ready with engine stopped. Then run engine at high idle and set monitor panel to 22 "Control Brake Release Mode" in "Adjustment mode" to perform troubleshooting. 3.23 ± 0.29 MPa HST charge PCCS lever At NEUTRAL circuit pressure {33 ± 3 kg/cm2} If pressure cannot be adjusted to normal level, charge safety valve of HST motor charge relief valve may malfunction or has internal defect. Or parking brake solenoid valve may malfunction. Check valve for sticking and spring for deterioration. a Be ready with engine stopped. Then run engine at high idle and set monitor panel to (Code 91902: "Brake pressure") in "Real monitoring mode", and travel the machine to perform troubleshooting. 3.04 ± 0.49 MPa HST charge FORWARD or PCCS lever circuit pressure REVERSE {31 ± 5 kg/cm2} If oil pressure cannot be adjusted to normal level, charge relieve valve of HST motor may malfunction or has internal defect. Check spring for deterioration and valve seat for any defect. If no failure is found by check on cause 4, charge pump may have internal defect. a Be ready with engine stopped, then perform troubleshooting with engine at high idle. Parking brake lever in FREE position 3.23 ± 0.29 MPa Brake pedal at release position {33 ± 3 kg/cm2} Outlet pressure of slow brake Parking brake lever in FREE position 0 MPa solenoid valve Brake pedal at full depressing {0 kg/cm2} position If oil pressure is low when brake pedal is at release position, spool of solenoid valve may be locked.

D61EM-23M0

40 Troubleshooting

Troubleshooting of hydraulic and mechanical system (H-mode)

No. 7 8 9

Procedure, measuring location, criteria and remarks Cause Check TOW valve for inappropriate operation (wrong selection). Inappropriate operation of TOW valve (towed) (Brake is kept applied because valve is screwed in.) Internal defect of HST HST pump body of HST pump system may have internal defect. Loosen pump (pump body) bleeder and check oil for contamination of metal particles. Inappropriate connection of Since RF and LR or LF and RR of EPC connector are connected reversely, check color bands of connector for matching. EPC connector of HST pump LF: Yellow, RF: Green, LR: Red, RR: Blue . $ % $ & $& $ . $ . , , $ . $ $ . , # , ' % $ . $ . , $ . & $ $ ! ! $, ' $ 7 + '$ $ $ 2 2 ! & , (* & - & , 7 + '$ $% $$ ' $ &$ ) $ $ 5, & ! $ 7*# ~ $ $ ! $ $ , % $ & , 7 + '$ $ $

D61EM-23M0

40-575

40 Troubleshooting

Troubleshooting of hydraulic and mechanical system (H-mode)

H-2 Either RH or LH of track does not travel forward nor reverse (Only RH or LH of travel system operates) 1 Failure

• Either R.H. or L.H. of track does not travel forward nor reverse. (Only R.H. or L.H. of travel system operates.)

Related information No.

Cause

Malfunction of HST pump 1 (EPC valve)

Malfunction of HST pump 2 (servo valve) Inappropriate operation of 3 TOW valve (towing)

Internal defect of HST 4 pump (pump body)

Procedure, measuring location, criteria and remarks a Be ready with engine stopped, then perform troubleshooting with engine at high idle. 1.0 MPa At F1 (travel) {10 kg/cm2} 0 MPa Outlet pressure of When in N (NEUTRAL) EPC valve {0 kg/cm2} 1.0 MPa At R1 (travel) {10 kg/cm2} If no failure is found by check on cause 1, servo valve of HST pump (on one side) may be defective. Replace assembly because internal inspection (disassembly) is not available. Check TOW valve for inappropriate operation (wrong selection). (Brake is kept on by screwed in valve.) a Be ready with engine stopped, then perform troubleshooting with engine at high idle. Set monitor panel to "3450 Stall Pressure Test Mode" of "Adjustment mode". 3.0 to 3.6 MPa At NEUTRAL {30 to 37 kg/cm2} HST main circuit PCSS lever In forward or 40.2 to 44.1 MPa pressure reverse travel {410 to 450 kg/ cm2} When HST main circuit pressures both for forward and reverse, on notraveling side, are both similarly low, pump body may be failed. Loosen bleeder and check oil for contamination of metallic dusts.

a If machine does not move when engine is at low idle and gear shift lever is set to F2, brake is dragging. Move machine to a level ground and be ready with engine stopped, then run engine at high idle to perform troubleshooting. Parking brake lever in FREE position 3.23 ± 0.29 MPa Internal defect of HST 5 motor (parking brake) {33 ± 3 kg/cm2} Outlet pressure of Brake pedal in RELEASE position slow brake Parking brake lever in FREE position 0 MPa solenoid valve Brake pedal in full depressing {0 kg/cm2} position If above oil pressure is normal, brake may be sticked. Internal defect of HST • If no failure is found by checks on causes 1 to 5, motor body may have 6 motor (motor body) internal defect. • If no failure is found by checks on causes 1 to 6, final drive may have 7 Internal defect of final drive internal defect. Check magnet plug for metal particles.

- & , 7 + '$ $ $

40-576

& $ $ ! ! $, ' $ 7 + '$ $ $ 2 2 ! & , (* & $% $$ ' $ &$ ) 5, & ! $ 7*# ~ $ $ ! $ $ , % $ & , 7 + '$ $ $

D61EM-23M0

40 Troubleshooting

Troubleshooting of hydraulic and mechanical system (H-mode)

H-3 Either RH or LH of track travel only forward or reverse (Only forward or reverse of RH or LH of travel system does not operate) 1 Failure

Related information

No.

• Either R.H. or L.H. of track travel only forward or reverse. (Only forward or reverse of R.H. or L.H. of travel system does not operate.) • If any failure code is displayed, perform troubleshooting for that failure code first. DXA4KA or DXA4KB: When machine is moving forward, HST brake will be applied without modulation and machine will be stopped suddenly. After that, only reverse travel is available (selector lever of front left side pump is set to N). DXA5KA or DXA5KB: When machine is moving reverse, HST brake will be applied without modulation and machine will be stopped suddenly. After that, only forward travel is available (selector lever of rear left pump is set to N). DXA6KA or DXA6KB: When machine is moving forward, HST brake will be applied without modulation and machine will be stopped suddenly. After that, only reverse travel is available (selector lever of front right pump is set to N). DXA7KA or DXA7KB: When machine is moving reverse, HST brake will be applied without modulation and machine will be stopped suddenly. After that, only reverse travel is available (selector lever of rear right pump is set to N). • If machine cannot travel immediately after initial adjustment of pump, initial adjustment may be failed. Select the applicable item from monitor panel in adjustment mode and repeat initial adjustment of pump again. (When tracks are run idle: 20 "F HST Pump Auto Set", 21 "R HST Pump Auto Set") or (When machine is traveled actually: ID code 3423 "F HST Pump Auto Set Run1", 3424 "R HST Pump Auto Set Run1", 3425 "F HST Pump Auto Set Run" 2, 3426 "R HST Pump Auto Set Run2") • Capacity command value and EPC current command value of HST pump can be checked in monitoring mode. Current Capacity command command value value Right forward 52404 52408 RF PUMP Left forward 52405 52409 LF PUMP Right reverse 52406 52410 RR PUMP Left reverse 52407 52411 LR PUMP Cause

Procedure, measuring location, criteria and remarks

Malfunction of HST pump (safety valve with suction)

a Be ready with starting switch ON, and run engine at high idle to perform troubleshooting. Set monitor panel to 3450: "Stall Pressure Test Mode" of "Adjustment mode". 3.0 to 3.6 MPa At NEUTRAL {30 to 37 kg/cm2} HST main circuit PCSS lever pressure In forward or 40.2 to 44.1 MPa reverse travel {410 to 450 kg/cm2} When above oil pressure is low, check suction valve for sticking (kept open).

Malfunction of HST pump (EPC valve)

a Be ready with engine stopped, then perform troubleshooting with engine at high idle. Min. 1.0 MPa At F1 (travel) {Min. 10.0 kg/cm2} 0 MPa When in N Outlet pressure of PCSS lever (NEUTRAL) EPC valve {0 kg/cm2} Min. 1.0 MPa At R1 (travel) {Min. 10.0 kg/cm2} If EPC current command is normal and outlet pressure is low,EPC valve may be sticked.

D61EM-23M0

40-577

40 Troubleshooting

Troubleshooting of hydraulic and mechanical system (H-mode)

No. 3 4

Cause Malfunction of HST pump (servo valve) Malfunction of HST pump (pump body)

- & , 7 + '$ $ $

40-578

Procedure, measuring location, criteria and remarks • If no failure is found by check on causes 1 and 2, servo valve of HST pump (on one side) may malfunction. • If no failure is found by check on causes 1 to 3, HST pump system (on one side) in pump body may have internal defect. & $ $ ! ! $, ' $ 7 + '$ $ $ 2 2 ! & , (* & $% $$ ' $ &$ ) 5, & ! $ 7*# ~ $ $ ! $ $ , % $ & , 7 + '$ $ $

D61EM-23M0

40 Troubleshooting

Troubleshooting of hydraulic and mechanical system (H-mode)

H-4 Travel speed or power is low Failure

Related information

No.

• Travel speed or power is low. • Check that oil level in hydraulic tank is normal before performing troubleshooting. • If any failure code is displayed, perform troubleshooting for that failure code first (DHH7KB, DHH8KB, DHH9KB, DHHAKB, or 6091NX). • If travel speed or power became low immediately after initial adjustment of pump or motor, initial adjustment may be defective. Carry out initial adjustment of pump or motor again. (3420 F HST Pump Auto Set, 3421 R HST Pump Auto Set, 3422 HST Motor Auto Set) • HST Motor Volume and HST motor current can be checked in monitoring mode. Controller: HST Motor capacity command value: 52300 "HST Motor Volume" EPC current command value of R.H. motor: 52303 "Right Motor EPC" EPC current command value of L.H. motor: 52304 "Left Motor EPC"

Cause Air leakage from air supply pipe

Defective rear damper

Clogged charge filter

Defective adjustment or malfunction of oil cooler bypass valve (charge safety valve)

Defective adjustment or malfunction of HST motor (charge relief valve)

Internal defect of charge pump

Procedure, measuring location, criteria and remarks Check air supply pipe for air leakage due to loosened clamps. If travel speed, work equipment speed or fan speed is low, engine rear damper may be defective. Check joint part of pump shaft for wear. Clogging of charge filter can be checked in monitoring mode. (Controller: HST, Code: 40912 "HST Oil Filter") a Be ready with engine stopped. Then run engine at high idle and set monitor panel to 22 "Control Brake Release Mode" in "Adjustment mode" to perform troubleshooting. 3.23 ± 0.29 MPa HST main circuit PCSS lever At NEUTRAL pressure {33 ± 3 kg/cm2} If oil pressure cannot be adjusted to normal level, charge safety valve of oil cooler bypass valve may be defective. Check spring for deterioration and valve for sticking. a Be ready with engine stopped. Then run engine at high idle and set monitor panel to "91902: Brake Pressure" in "Monitoring mode" to perform troubleshooting while traveling machine. 3.04 ± 0.49 MPa HST charge circuit In forward or PCCS lever {31 ± Min. 5 kg/ pressure reverse travel cm2} If oil pressure cannot be adjusted to normal level, charge relief valve of HST motor may be defective. Check spring for deterioration and valve for sticking. If no failure is found by checks on causes 1 to 5, charge pump may be defective.

a Be ready with starting switch ON. Then run engine at high idle and set monitor panel to 3450: "Stall pressure test mode" in "Adjustment mode"to perform troubleshooting. 3.0 to 3.6 MPa At NEUTRAL {Min. 30 to 37 kg/ Malfunction of HST pump cm2} HST main circuit (safety valve with suction) PCCS lever Min. 40.2 to 44.1 pressure MPa In forward or reverse travel {Min. 410 to 450 kg/ cm2} When above oil pressure is low, check suction valve for sticking (kept open). & $ $ ! ! $, ' $ 7 + '$ $ $ 2 2 ! & , (* & - & , 7 + '$ $ $ $% $$ ' $ &$ ) 5, & ! $ 7*# ~ $ $ ! $ $ , % $ & , 7 + '$ $ $

D61EM-23M0

40-579

40 Troubleshooting

Troubleshooting of hydraulic and mechanical system (H-mode)

H-5 Shock is large when machine starts or stops Failure Related information No. 1 2

• Shock is large when machine starts or stops.

Procedure, measuring location, criteria and remarks Cause Lack of bleeding air from HST Since air is possibly remaining in servo valve of HST pump, perform bleeding air again. pump Perform warm up operation (until pointer reaches green range of HST oil HST oil temperature is low. temperature gauge) and check whether shocks are reduced. If now failure is found by check of causes 1 and 2, initial adjustment of pump may be defective. Repeat adjustment again (see Testing and adjusting, "Adjustment" in "Special functions of machine monitor" for procedure.) Defective initial adjustment of a If the failure is not removed, adjust it in fine adjustment mode. pump Modification of adjusted starting time of pump for forward travel 3430 "R HST Pump Manual Set" Modification of adjusted starting time of pump for reverse travel 3431 "R HST Pump Manual Set" & $ $ ! ! $, ' $ 7 + '$ $ $ - & , 7 + '$ $ $ 2 2 ! & , (* & $% $$ ' $ &$ )

40-580

D61EM-23M0

40 Troubleshooting

Troubleshooting of hydraulic and mechanical system (H-mode)

H-6 Machine deviates largely Failure

Related information

No.

4 5

• Machine deviates largely. • If any failure code is displayed, perform troubleshooting for that failure code first. Testing method 1. If machine deviates in the same direction both in traveling forward and in traveling reverse, or deviates in the equivalent turning radius even if travel speed changes, the adjustment of steering lever may be defective. Perform check on cause 1. 2. If machine travels straight or deviates in the opposite direction when the travel deviation control is set to OFF (adjustment mode: 3434), the travel speed sensor may be defective. Perform check on cause 2. 3. If machine deviates only in either direction of forward or reverse, HST pump may be defective. Perform check on causes 3 to 7. 4. If machine deviates only when traveling at high speed, HST motor may be defective. Perform check on causes 8 to 12. • EPC output current of HST pump can be checked on monitor (monitoring code: 52408 "RF HST Pump EPC(F/B)", 52409 "LF HST Pump EPC(F/B)", 52410 "RR HST Pump EPC(F/B)", 52411 "LR HST Pump EPC(F/B)"). • EPC output current of HST motor can be checked on monitor (monitoring code: 52303 "Right Motor EPC(F/B)", 52304 "Left Motor EPC(F/B)"). • Right and left side travel speeds (motor speeds) can be checked on monitor (monitoring code: 40002 "Right Vehicle Speed", 40003 "Left Vehicle Speed"). • Brake pressure can be checked on monitor (monitoring code: 91902 "Brake Pressure"). Cause

Defective adjustment of steering lever

HST motor shaft speed sensor

Procedure, measuring location, criteria and remarks a Be ready with starting switch ON, and select the following settings in monitoring mode to perform troubleshooting. Controller: HST, Monitoring code: 50303 "S/T Lever Stroke" Joystick (steering, Steering lever directional and NEUTRAL 0 ± 10% stroke gear shift lever) If any failure is found, make initial adjustment referring Testing and adjusting, "S/T Lever N Position Set", "Difference in Level Position Detection Set", and "Maximum Position Set" for right and left sides. a Be ready with starting switch ON, and select the following settings by monitoring code to perform troubleshooting. Controller: HST, Monitoring code: 40002 "Right Vehicle Speed", 40003 "Left Vehicle Speed" Travel speed sensor whose actual travel speed differs from the displayed travel speed may be defective. Since initial adjustment of pump may be defective, perform adjustment again. (For adjustment procedure, see Testing and adjusting, "Adjustment" in "Special functions of machine monitor".)

Defective initial adjustment of a If failure still persists, adjust it in fine adjustment mode. Modification of adjusted starting time of pump for forward travel HST pump 3430 "F HST Pump Manual Set" Modification of adjusted starting time of pump for reverse travel 3431 "R HST Pump Manual Set" Tow receiving valve may be operated inappropriately (wrong shifting). Inappropriate operation of Check it. TST pump (tow receiving valve) (If the valve is screwed in, it is proper.) Since air is possibly remaining in servo valve of HST pump, perform air Insufficient bleeding of air bleeding again. from HST pump See "3. Measuring outlet pressure of HST pump EPC valve" "Testing Malfunction of HST pump and adjusting of HST oil pressure" "Power train" "Adjustment" in 30. Testing and adjusting. EPC valve

D61EM-23M0

40-581

40 Troubleshooting

Troubleshooting of hydraulic and mechanical system (H-mode)

No.

Cause

Procedure, measuring location, criteria and remarks

a Be ready with engine stopped, then perform troubleshooting with engine at high idle. Set monitor panel to "Stall Pressure Test Mode" of "Adjustment mode". Joystick 3.0 to 3.6 MPa At NEUTRAL (steering, {30 to 37 kg/cm2} HST main circuit directional and Internal defect of HST pump pressure 40.2 to 44.1 MPa In forward or gear shift (pump body) reverse travel {410 to 450 kg/cm2} lever) When no failure is found by check on causes 1 to 6, equivalent level of turning was observed both in forward and reverse travels, and HST main circuit pressure for forward and reverse on turning side (slower side) are both similarly low, pump body may have failure. Loosen bleeder, and check oil for contamination of metal particles. Defective initial adjustment of Perform adjustment again. For details, see Testing and adjusting, "HST motor adjustment". HST motor a Be ready with engine stopped, then perform troubleshooting with engine at high idle. While stopped or 0 MPa traveling at {0 kg/cm2} 1st speed range While Set travel Malfunction of solenoid valve Outlet pressure of 1.47 ± 0.49 MPa R.H. and L.H. HST mode to quick traveling at (HST motor EPC valve) 2nd speed motor EPC valves shift mode. {15 ± 5 kg/cm2} range While 2.16 ± 0.49 MPa traveling at 3rd speed {22 ± 5 kg/cm2} range If EPC current command is normal and outlet pressure is low, check EPC valve for sticking.

a Be ready with engine stopped. Then run engine at high idle and set monitor panel to 91902 "Brake pressure" in "Monitoring mode" to perform troubleshooting while traveling machine. Joystick 3.04 ± 0.49 MPa Defective adjustment or (steering, HST charge circuit 10 malfunction of HST motor directional and In forward or {31 ± Min. 5 kg/ pressure reverse travel (charge relief valve) gear shift cm2} lever) If oil pressure cannot be adjusted to normal level, charge relieve valve of HST motor may malfunction or has internal defect. Check spring for deterioration and valve seat for any defect. When travel speed of turning side is slow in a pivot turn, motor parking Internal defect of HST motor brake may be dragged. 11 (parking brake) Check that brake pressure is normal in monitoring mode in advance. Internal defect of HST motor If no failure is found by check on causes 8 to 11, HST motor may have 12 (motor body) internal defect. & $ $ ! ! $, ' $ 7 + '$ $ $ 1 - & , 7 + '$ $ $ 2 2 ! & , (* & $% $$ ' $ &$ )

40-582

D61EM-23M0

40 Troubleshooting

Troubleshooting of hydraulic and mechanical system (H-mode)

H-7 Machine drift on a slope is large Failure

Related information

No.

2 3

6 7

• Machine drift on a slope is large. • Brake pressure can be checked in monitoring mode (Monitoring code: 91902 "Brake Pressure"). • Oil pressure of HST circuit (pump outlet) can also be checked on monitor (monitoring code: 52501 "RF HST Pressure, 52503 "LF HST Pressure", 52505 "RR HST Pressure", and 52507 "LR HST Pressure"). • Capacity command value and EPC current command value of HST pump can be checked in monitoring mode. Capacity Current command command value value Right forward 52404 52408 RF PUMP Left forward 52405 52409 LF PUMP Right reverse 52406 52410 RR PUMP Left reverse 52407 52411 LR PUMP Cause

Procedure, measuring location, criteria and remarks

a Be ready with engine stopped, then perform troubleshooting with engine at high idle. Parking brake lever in FREE 3.23 ± 0.29 MPa position {33 ± 3 kg/cm2} Brake pedal in RELEASE Outlet pressure of Malfunction of slow brake position slow brake solenoid solenoid valve Parking brake lever in FREE valve 0 MPa position {0 kg/cm2} Brake pedal in full-pressing distance If brake pressure remains as is at brake pedal position, check around disc for sticking of solenoid valve spool. Check TOW valve for inappropriate operation (wrong selection). Inappropriate operation of TOW valve (towed) (Brake is kept on by screwed in valve) Defective HST motor (parking If no failure is found by check on causes 1 and 2, check brake disc and brake) plate for slip and wear. a Be ready with starting switch at ON. Then run engine at high idle and set monitor panel to 3450: "Stall Pressure Test Mode" in "Adjustment mode" to perform troubleshooting. 3.0 to 3.6 MPa Malfunction of HST pump NEUTRAL {30 to 37 kg/cm2} HST main circuit (safety valve with suction) PCCS lever pressure 40.2 to 44.1 MPa In forward or reverse travel {410 to 450 kg/cm2} When above oil pressure is low, check suction valve for locking (kept open). Check HST pump current command value while setting it in NEUTRAL position in monitoring mode (approximately 0 mA). Malfunction of HST pump (servo valve) If current value is normal, NEUTRAL position of servo valves (on both sides) of HST pump may be inappropriate. Internal leakage from HST If no failure is found by check on causes 1 to 5, there may be internal pump (pump body) leakage from pump body of HST pump (both side). Internal defect of HST motor If no failure is found by check on causes 1 to 6, there may be internal (motor body) leakage from motor body of HST motor (both side). & $ $ ! ! $, ' $ 7 + '$ $ $ - & , 7 + '$ $ $ 2 2 ! & , (* & $% $$ ' $ &$ )

D61EM-23M0

40-583

40 Troubleshooting

Troubleshooting of hydraulic and mechanical system (H-mode)

H-8 Engine stalls during travel or engine speed drops significantly Failure

Related information

No.

• Engine stalls during travel or engine speed drops significantly. • Check that power train oil level is normal before performing troubleshooting. • If any failure code is displayed, perform troubleshooting for it first. (DHH7KA, DHH7KB, DHH8KA, DHH8KB, DHHAKA, or DHHAKB). • Oil pressure of HST circuit (pump outlet) can also be checked on monitor (monitoring code: 52501 "RF HST Pressure", 52503 "LF HST Pressure", 52505 "RR HST Pressure", and 52507 "LR HST Pressure"). • Capacity command value and current command value of HST motor can be checked in real monitoring mode. Controller HST Motor capacity command value: 52300 "HST Motor Volume" EPC current command value of R.H. motor: 52303 "Right Motor EPC" EPC current command value of L.H. motor: 52304 "Left Motor EPC" Cause

Malfunction of HST pump (EPC valve)

Malfunction of HST pump (servo valve)

Malfunction of HST pump (safety valve with suction)

Procedure, measuring location, criteria and remarks a Be ready with engine stopped, then perform troubleshooting with engine at high idle. Min. 1.0 MPa At F1 (travel) {Min. 10.0 kg/cm2} 0 MPa When in N Outlet pressure of PCSS lever (NEUTRAL) EPC valve {0 kg/cm2} Min. 1.0 MPa At R1 (travel) {Min. 10.0 kg/cm2} If EPC current command is normal and outlet pressure is low, check EPC valve for sticking. If no failure is found by check on cause 1, servo valve of HST pump (on one side) may malfunction. a Be ready with starting switch at ON. Then run engine at high idle and set monitor panel to 3450: "Stall Pressure Test Mode" in "Adjustment mode" to perform troubleshooting. 3.0 to 3.6 MPa At NEUTRAL {30 to 37 kg/cm2} HST main circuit PCSS lever pressure In forward or 40.2 to 44.1 MPa reverse travel {410 to 450 kg/cm2} When above oil pressure is low, check suction valve for locking (kept open).

a Be ready with engine stopped, then perform troubleshooting with engine at high idle. While stopped or 0 MPa traveling at {0 kg/cm2} 1st speed range While Set travel 1.47 ± Min. 0.49 Malfunction of solenoid valve Outlet pressure of R.H. and L.H. HST mode to quick traveling at MPa (HST motor EPC valve) 2nd speed shift mode. motor EPC valves {15 ± 5 kg/cm2} range 2.16 ± Min. 0.49 While MPa traveling at 3rd speed {22 ± Min. 5 kg/ range cm2} If EPC current command is normal and outlet pressure is low, check EPC valve for sticking. Internal defect of HST motor If no failure is found by check on cause 4, HST motor body (on one (motor body) side) may have internal defect.

40-584

D61EM-23M0

40 Troubleshooting

Troubleshooting of hydraulic and mechanical system (H-mode)

No.

Procedure, measuring location, criteria and remarks & $ $ ! ! $, ' $ 7 + '$ $ $ - & , 7 + '$ $ $ 2 2 ! & , (* & $% $$ ' $ &$ )

D61EM-23M0

Cause

40-585

40 Troubleshooting

Troubleshooting of hydraulic and mechanical system (H-mode)

H-9 Unusual noise is heard from around HST pump or motor Failure General information

No. 1 2 3 4 5

• Unusual noise is heard from around HST pump or motor. • Check that oil level in hydraulic tank is normal. • If any failure code is displayed, perform troubleshooting for that failure code first. (6091NX) • Charge circuit pressure can be checked with monitoring function (Monitoring code: 91902 "Brake Pressure"). Cause

Inappropriate oil

Procedure, measuring location, criteria and remarks Perform oil analysis to check for inappropriate oil used. (Check whether an oil of recommended grade and brand is used.)

Clogged charge pump suction Check strainer for clogging. strainer Check suction piping of charge pump for looseness, cracks, etc. Air sucked in suction circuit Looseness of piping between Check piping for looseness, cracks, etc. HST pump and HST motor Check clogging of charge filter with monitoring function. Clogging of charge filter (Controller: HST, Monitoring code: 40912 "HST Oil Filter")

Defective adjustment or malfunction of oil cooler bypass valve (charge safety valve)

a Be ready with engine stopped. Then run engine at high idle and set monitor panel to 22 "Control Brake Release Mode" in "Adjustment mode" to perform troubleshooting. 3.23 ± 0.29 MPa HST charge circuit PCSS lever At NEUTRAL pressure {33 ± 3 kg/cm2} If oil pressure cannot be adjusted to normal level, charge safety valve of oil cooler bypass valve may be defective. Check spring for deterioration and valve for sticking.

a Be ready with engine stopped. Then run engine at high idle and set monitor panel to 91902: "Brake Pressure" in "Monitoring" to perform troubleshooting while traveling machine. 3.04 ± Min. 0.49 Defective adjustment or MPa HST charge circuit FORWARD 7 malfunction of HST motor PCCS lever pressure or REVERSE {31 ± Min. 5 kg/ (charge relief valve) cm2} If oil pressure cannot be adjusted to normal level, charge relief valve of HST motor may be defective. Check spring for deterioration and valve for sticking. Since air may remain in servo valve of HST pump, perform air bleeding 8 Bleeding air from HST pump again. Internal defect of HST pump If no failure is found by check on causes 1 to 8, HST motor body may 9 (pump body) have internal defect. Internal defect of HST motor If no failure is found by check on causes 1 to 9, HST motor body may 10 (motor body) have internal defect. & $ $ ! ! $, ' $ 7 + '$ $ $ 1 - & , 7 + '$ $ $ 2 2 ! & , (* & $% $$ ' $ &$ )

40-586

D61EM-23M0

40 Troubleshooting

Troubleshooting of hydraulic and mechanical system (H-mode)

H-10 All work equipment do not operate Failure

Related information

No. 1

• All work equipment do not operate. • Check that oil level in hydraulic tank is normal before performing troubleshooting. • If any failure code is displayed, perform troubleshooting for that failure code first. (6091NX) Testing method 1. If fan rotates at high speed after engine is started, charge pressure itself may be low. Check on causes 2 to 4. When fan speed is normal, check on cause 5. 2. When machine cannot travel and fan stops, HST pump may not be rotating. Check on cause 1. 3. When machine can travel but fan stops, check on causes 6 to 8. 4. When work equipment lock solenoid valve is not energized even after work equipment lock lever is turned to FREE position, perform troubleshooting for "Work equipment does not operate" of E mode. • If any failure code is displayed, perform troubleshooting for that failure code first (DDNLKA or DDNLKB). • Work equipment pump pressure can be checked on monitor (monitoring code: 70700).

Procedure, measuring location, criteria and remarks When both work equipment and fan does not move, HST pump may not Internal defect of rear damper be rotating. Check rear damper connection to pump for any abnormalities. Check charge filter for clogging. Clogged charge filter Clogging of charge filter can be checked in monitoring mode. (Controller: HST, Monitoring code 40912: "HST Oil Filter") Cause

Defective adjustment or malfunction of oil cooler bypass valve (charge safety valve)

Internal defect of charge pump

a Be ready with engine stopped, then perform troubleshooting with engine at high idle. 0 MPa When locked {0 kg/cm2} Work Outlet pressure of Malfunction of work equipment lock work equipment equipment lock solenoid valve When in 3.23 ± 0.29 MPa lever lock solenoid valve FREE {33 ± 3 kg/cm2} position If oil pressure is low when in FREE position, spool of solenoid valve may be sticked. If hydraulic relief of work equipment does not increase work equipment pump pressure much beyond set pressure of unload valve, unload valve may remain opened. Replace valve assembly because unload valve cannot be adjusted. (Reference) Malfunction of control valve Normally, set work equipment lock lever to NEUTRAL position before (unload valve) set pressure of unload valve is measured. In this circuit, however, open type circuit is used for fan motor main spool in NEUTRAL position. Therefore, starting engine rotates fan and generates drive pressure. Because of above, pump pressure of work equipment is increased beyond unload valve set pressure, (2.6 MPa {27 kg/cm2}), but it is not error.

D61EM-23M0

40-587

40 Troubleshooting

Troubleshooting of hydraulic and mechanical system (H-mode)

No.

Cause

Procedure, measuring location, criteria and remarks

a Be ready with engine stopped, then perform troubleshooting with engine at high idle. Min. 27.5 MPa $ $ . During Defective adjustment or Work equipment 4% & $ hydraulic {280 ± Min. 10 kg/ 7 malfunction of control valve relief pressure ' cylinder relief cm2} (main relief valve) When oil pressure cannot be adjusted to normal level, main relief valve may malfunction or has internal defect. Check spring for deterioration and valve for sticking. • If measured pressure by check on cause 7 is unusual and main relief Internal defect of work valve is normal, disconnect work equipment pump outlet hose, crank 8 equipment pump (pump body) engine, and check whether oil flows out. If oil does not flow out, replace work equipment pump. & $ $ ! ! $, ' $ 7 + '$ $ $ - & , 7 + '$ $ $ 2 2 2 2 $ 2 2 ! & , (* & $% $$ ' $ &$ ) & $ $ ! ! $, ' $ ` . $ $ - & , ` . $ $ 2 2 ! & , (* & $% $$ ' $ &$ )

40-588

D61EM-23M0

40 Troubleshooting

Troubleshooting of hydraulic and mechanical system (H-mode)

H-11 All work equipment operates slowly or lacks power Failure Related information

No. 1

• All work equipment operates slowly or lacks power. • Check that oil level in hydraulic tank is normal before performing troubleshooting. • If any failure code is displayed, perform troubleshooting for that failure code first. (6091NX) • Check that engine high idle speed is normal on monitor (monitoring code: 01002). • Work equipment pump pressure can be checked on monitor (monitoring code: 70700). Cause

Clogged charge filter

Defective adjustment or malfunction of oil cooler bypass valve (charge safety valve)

Internal defect of charge pump

Malfunction of control valve (unload valve)

6 7

Procedure, measuring location, criteria and remarks Check charge filter for clogging. Clogging of charge filter can be checked in monitoring mode. (Controller: HST, Monitoring code: 40912 ”HST Oil Filter") a Be ready with engine stopped. Then run engine at high idle and set monitor panel to "22 Control Brake Release Mode" in "Adjustment mode" to perform troubleshooting. 3.23 ± 0.29 MPa HST charge circuit PCSS lever At NEUTRAL pressure {33 ± 3 kg/cm2} If oil pressure cannot be adjusted to normal level, charge safety valve of oil cooler bypass valve may be defective. Check spring for deterioration and valve for sticking. If no failure is found by check on cause 2, charge pump may have internal defect. If hydraulic relief of work equipment does not increase work equipment pump pressure much beyond set pressure of unload valve, unload valve may be left open. Replace assembly since unload valve cannot be adjusted.

a Be ready with engine stopped, then perform troubleshooting with engine at high idle. Min. 27.5 MPa $ $ . Work equipment Defective adjustment or During relief pump relief 4% & $ {280 ± Min. 10 kg/ malfunction of control valve pressure cm2} ' ! (main relief valve) # $ % $ /% $ $ , & , , may malfunction or has internal defect. Check spring for deterioration and valve for sticking. Check PC valve for sticking of spool and setting of spring. If any failure Malfunction of PC valve is found, replace it. Check LS valve for sticking of spool and setting of spring. If any failure Malfunction of LS valve is found, replace it. If measured pressure by check on cause 5 is unusual and main relief valve is normal, disconnect work equipment pump outlet hose, crank Internal defect of work equipment pump (pump body) engine, and check whether oil flows out. If oil does not flow out, replace work equipment pump.

& $ $ ! ! $, ' $ 7 + '$ $ $ - & , 7 + '$ $ $ 2 2 2 2 $ 2 2 ! & , (* & $% $$ ' $ &$ ) & $ $ ! ! $, ' $ ` . $ $ 2 2 ! & , (* & - & , ` . $ $ $% $$ ' $ &$ )

D61EM-23M0

40-589

40 Troubleshooting

Troubleshooting of hydraulic and mechanical system (H-mode)

H-12 Front work equipment lift speed or power is low Failure Related information

No. 1

• • • •

$ $ . 4% lift speed or power is low. Check that oil level in hydraulic tank is normal before performing troubleshooting. Check that blade is not modified before starting troubleshooting. $ $ . 4% RAISE EPC current can also be checked on monitor (monitoring code: 71001). • Work equipment pump pressure can be checked on monitor (monitoring code: 94700).

Cause Defective strainer of work equipment pump Air sucked in on suction side of work equipment pump

Malfunction of & $ $ . 4% LIFT EPC valve

Defective work equipment main relief valve

Malfunction of & $ $ . 4% lift control valve spool

Malfunction of pressure compensation valve of & $ $ . 4% lift control valve

Procedure, measuring location, criteria and remarks Check strainer for clogging. Check suction piping for cracks, etc. a Be ready with engine stopped, then perform troubleshooting with engine at high idle. $ $ . Output pressure of 3.23 MPa EPC valve (For 4% lift LIFT {33 g/cm2} reference) $ $ , If EPC current command is normal and outlet pressure is low, check EPC valve for sticking. a Be ready with engine stopped, then perform troubleshooting with engine at high idle. 27.5 MPa Work equipment $ $ . 4% During main relief pressure relief lift ! {280 ± 10 kg/cm2} If relief pressure is not increased to normal level after main relief valve is adjusted, unload valve or safety valve may be defective. Replace defective unload or safety valve since they cannot be adjusted. When no failure is found by checks on causes 3 and 4 but main circuit pressure in boom RAISE operation does not rise beyond set pressure of unload valve, work equipment valve spool may malfunction. Check spool for sticking. When tilt moves normally and & $ $ . 4% can rise while tilt is not operated but cannot rise while tilt is operated, pressure compensation valve of ? control valve may be defective.

Suction valve of & $ $ . 4% control valve may malfunction. Check brake for defective sealing. Judgment may be made by checking a change of phenomenon after exchanging suction valves of angle circuit.

Malfunction of & $ $ . 4% lift control valve (suction valve)

a Be ready with engine stopped, then perform troubleshooting with engine at high idle. Cylinder internal oil $ $ . 4% LOWER to 8 cc/min Internal defect of work leakage lift ! relief equipment pump (pump body) If measured relief pressure is low, disconnect hydraulic hose from & $ $ . 4% lift cylinder head end, and relieve & $ $ . 4% lift cylinder at its stroke end. If oil flows out from cylinder, cylinder piston ring is defective.

40-590

D61EM-23M0

40 Troubleshooting

Troubleshooting of hydraulic and mechanical system (H-mode)

H-13 Front work equipment side swing speed or power is low Failure Related information No. 1 2

• @ \ @ ` speed or power is low. • Check that oil level in hydraulic tank is normal before performing troubleshooting. • Check that & $ $ . 4% is not modified before starting troubleshooting. • Work equipment pump pressure can be checked on monitor (monitoring code: 94700).

Cause Defective strainer of work equipment pump Air sucked in on suction side of work equipment pump

Malfunction of ? ' EPC valve

a Be ready with engine stopped, then perform troubleshooting with engine at full speed. 27.5 MPa $ $ . 4% Work equipment Defective work equipment Relief main relief pressure ' ! {280 ± 10 kg/cm2} main relief valve If relief pressure is not increased to normal level after main relief valve is adjusted, unload valve or safety valve may be defective. Replace defective unload or safety valve since they cannot be adjusted. When no failure is found by checks on causes 3 and 4 and main circuit Malfunction of ? pressure in ' operation does not rise beyond set pressure of ' control unload valve, work equipment valve spool may malfunction. valve spool Check spool for sticking. When lift moves normally and ' can operate while ' Malfunction of pressure compensation valve of & $ is not operated but cannot operate while ' is operated, $ . 4% ' pressure compensation valve of ' control valve may be defective. control valve

Internal defect of & $ $ . 4% ' cylinder

D61EM-23M0

a Be ready with engine stopped, then perform troubleshooting with engine at high idle. $ $ . 4% Cylinder internal oil During relief 8 cc/min leakage ' ! If measured relief pressure is low, disconnect hydraulic hose from ? ' cylinder head end, and relieve ? ' cylinder hydraulically at its stroke end. If oil flows out from cylinder, cylinder piston ring is defective.

40-591

40 Troubleshooting

Troubleshooting of hydraulic and mechanical system (H-mode)

H-14 Hydraulic drift of lifted front work equipment is large

Failure Related information

• Hydraulic drift of lifted & $ $ . 4% is large. • Check that blade is not modified before starting troubleshooting. • Check that oil leak is not in work equipment circuit before performing troubleshooting.

No.

Cause

Procedure, measuring location, criteria and remarks

Defective sealing of & $ $ . 4% lift control valve (spool)

a Be ready with engine stopped, then perform troubleshooting with engine at high idle. Perform troubleshooting in the following procedures. If hydraulic drift speed is increased, sealing of & $ $ . 4% lift control valve spool is defective. Thrust ? against ground with & $ $ . 4% lift function to raise front of machine off ground. Stop engine and turn starting switch to ON position. Check phenomena when ? control lever is operated to "? LOWER" position.

Internal defect of & $ $ . 4% lift cylinder

a Be ready with engine stopped, then perform troubleshooting with engine at high idle. Cylinder internal oil $ $ . 4% During relief 8 cc/min leakage lift ! If measured relief pressure is low, disconnect hydraulic hose from & $ $ . 4% lift cylinder head end, and relieve & $ $ . 4% lift cylinder at its stroke end. If oil flows out from cylinder, cylinder piston ring is defective.

- & , ? \ ^ , ,

40-592

\ ^ , , ! & , . &$ `

D61EM-23M0

40 Troubleshooting

Troubleshooting of hydraulic and mechanical system (H-mode)

H-15 Unusual noise is heard from around work equipment pump or control valve Failure Related information No. 1 2 3 4

• • • •

Unusual noise is heard from around work equipment pump or control valve. Check that oil level in hydraulic tank is normal before performing troubleshooting. Work equipment pump serves as fan circuit. Work equipment pump oil pressure can be checked on monitor (monitoring code: 70700). Cause

Inappropriate oil

Procedure, measuring location, criteria and remarks Check for inappropriate oil used and perform oil analysis. (Check whether an oil of recommended grade and brand is used.)

Clogged hydraulic oil tank Check strainer for clogging. strainer Check pump suction circuit piping for cracks, looseness, etc. Air sucked in suction circuit Looseness of piping between Check piping between pump and motor for cracks, looseness, etc. HST pump and HST motor

Defective adjustment or malfunction of control valve (main relief valve)

Defective work equipment pump (pump body)

D61EM-23M0

a Be ready with engine stopped, then perform troubleshooting with engine at high idle. 27.5 MPa Work equipment Blade lift Relief main relief pressure cylinder {280 ± 10 kg/cm2} When oil pressure cannot be adjusted to normal level, check main relief valve for malfunction or internal defect. If no failure is found by check on causes 1 to 5, work equipment pump may be defective.

40-593

40 Troubleshooting

Troubleshooting of hydraulic and mechanical system (H-mode)

H-16 HST oil temperature (hydraulic oil temperature) rises too high Failure Related information No. 1 2

• HST oil temperature (hydraulic oil temperature) rises too high. • Check that oil level in hydraulic tank is normal before performing troubleshooting. • If any failure code is displayed, perform troubleshooting for it first. (DHH7KA, DHH7KB, DHH8KA, DHH8KB, DHH9KA, DHH9KB, DHHAKA, or DHHAKB). • Fan speed can also be checked in monitoring mode (monitoring code: 10007).

Cause Insufficient oil level in hydraulic tank or use of inappropriate oil Clogged hydraulic oil cooler

Defective adjustment or malfunction of HST motor (charge relief valve)

Malfunction of HST pump (safety valve with suction)

Internal defect of HST pump (pump body)

Improper adjustment of work equipment main relief valve (set pressure is too high)

Defective work equipment pump (pump body)

40-594

Procedure, measuring location, criteria and remarks Check for inappropriate oil used and perform oil analysis. (Check whether an oil of recommended grade and brand is used.) Check fin and core of hydraulic oil cooler for clogging. a Be ready with engine stopped. Then run engine at high idle and set monitor panel to 91902: "Brake Pressure" in "Monitoring mode" to perform troubleshooting while traveling machine. HST charge circuit In forward or 3.04 ± 0.49 MPa PCCS lever pressure reverse travel {31 ±Min. 5 kg/cm2} If oil pressure cannot be adjusted to normal level, charge relief valve of HST motor may be defective. Check spring for deterioration and valve for sticking. a Be ready with starting switch ON, and run engine at high idle to perform troubleshooting. Set monitor panel to 3450: "Stall Pressure Test Mode" of "Adjustment mode". 3.0 to 3.6 MPa At NEUTRAL {30 to 37 kg/cm2} HST main circuit PCSS lever pressure In forward or 40.2 to 44.1 MPa reverse travel {410 to 450 kg/cm2} When above oil pressure is low, check suction valve for sticking (kept open). If no failure is found by check on causes 1 to 4, HST pump (pump body) may have internal defect. a Be ready with engine stopped, then perform troubleshooting with engine at high idle. 27.5 MPa Work equipment Blade lift Relief relief pressure cylinder {280 ± 10 kg/cm2} When oil pressure cannot be adjusted to normal level, main relief valve may malfunction or has internal defect. Check spring for deterioration and valve for sticking. If measured pressure by check on cause 7 is unusual and main relief valve is normal, disconnect work equipment pump outlet hose, crank engine, and check whether oil flows out.

D61EM-23M0

40 Troubleshooting

Troubleshooting of hydraulic and mechanical system (H-mode)

No.

Cause

Decrease in fan speed

Oil cooler bypass valve

D61EM-23M0

Procedure, measuring location, criteria and remarks If no failure is found by check on causes 1 and 2, servo valve of HST pump (on one side) may malfunction. Heat oil temperature to 50°C or above and run 1,650 rpm engine at high idle to check fan speed in fan 100% mode. a If oil temperature reads 45°C or below and engine coolant temperature reads 60°C or below, fan EPC command current becomes 1000 mA and fan speed decreases to 200 rpm or below even when fan 100% mode is selected. In such case, heat oil temperature to 55°C or more and engine coolant temperature to 65° C or more before starting troubleshooting. Select 100% by using adjustment code: 3441 "Fan Fan 100% mode Test Mode". If fan speed does not return to standard value in one minute, carry out initial adjustment of fan. Engine speed High idle Adjustment code: Initial adjustment of 3440 "Fan Auto Oil fan Set" temperature 50 to 60°C a If fan speed does not reach standard value after repeated initial adjustments, perform troubleshooting for "H-21". Oil cooler bypass valve may malfunction. Check valve for sticking (left opened) and spring for deterioration.

40-595

40 Troubleshooting

Troubleshooting of hydraulic and mechanical system (H-mode)

H-17 Fan speed is abnormal (high, low, or no rotation) Failure

Related information

No.

• Fan speed is abnormally high. • Fan speed in fan 100% mode does not conform to standard value in one minute. Standard value: 1,650 rpm (Oil temperature: Min. 50°C, Engine: High idle) • Fan stops while engine is running. • If machine travel and work equipment operation are abnormal, troubleshoot them first. • When engine is started for first time after hydraulic oil replacement, fan may temporarily rotates at higher speed but this is normal. • Check that oil level in hydraulic tank is normal before performing troubleshooting. • If any failure code is displayed, perform troubleshooting for that failure code first. (DLM3KA, DLM3KB, or DLM3MB) • Select 100% by using fan 100% adjustment code: 3441 "Fan Test Mode". • Fan speed controller: HST monitoring mode: 1007-FAN SPEED Cause

Procedure, measuring location, criteria and remarks

Defective engine speed

a Start engine and perform check. Engine low idle 925 to 1025 rpm Engine speed Engine high idle 1,945 to 2,045 rpm If engine speed is not increased to specification, perform troubleshooting for "S-5 Engine runs rough or is unstable".

Clogged hydraulic oil cooler

a Perform troubleshooting with engine at high idle. • Hydraulic oil temperature: Fan speed 1,600 to 1,700 rpm Within operating range • Fan 100% mode

Initial adjustment of fan

a Initial fan adjustment may be defective. Repeat adjustment again. Engine speed High idle Adjustment code: HST charge circuit 3440 ”Fan Auto Oil pressure 50 to 60°C Set" temperature

Malfunction of fan control valve (fan EPC valve)

a Be ready with engine stopped, then perform troubleshooting with engine at high idle. Output pressure of 3.23 MPa Blade lift EPC valve (For LIFT control lever {33 kg/cm2} reference) If EPC current command is normal and outlet pressure is low, check EPC valve for sticking.

5 6

Malfunction of fan control Check main spool of fan control valve for sticking to body. valve (main spool) Malfunction of fan control valve (pressure compensation Pressure compensation valve of fan control valve may malfunction. Check valve for deterioration. valve) If no failure is found by check on causes 5 and 6, safety valve may be Malfunction of fan control defective. valve spool (safety valve) Replace assembly since safety valve cannot be adjusted.

Malfunction of fan motor (reverse spool)

Check fan motor reverse spool for sticking to valve body.

Malfunction of fan motor (suction valve)

Check fan motor suction valve for sticking to valve body.

40-596

D61EM-23M0

40 Troubleshooting

Troubleshooting of hydraulic and mechanical system (H-mode)

No.

Cause

10 Decrease in fan speed

11 Oil cooler bypass valve

D61EM-23M0

Procedure, measuring location, criteria and remarks a Be ready with engine stopped, then run engine at high idle and rotate fan in normal direction to perform troubleshooting . Hydraulic oil temperature: 40 14.2 MPa Fan motor drive to 60°C pressure (P mode) {145 kg/cm2} Fan adjustment mode: 100% If fan speed does not reach standard value after repeated initial adjustments, perform troubleshooting for "H-21". If work equipment pump pressure is normal, fan motor drive pressure is low and no failure is found by checks on causes 3 to 8, fan motor may have internal defect.

40-597

40 Troubleshooting

Troubleshooting of hydraulic and mechanical system (H-mode)

H-18 Unusual noise is heard from around fan

(

)

Failure Related information

• Unusual noise is heard from around fan. • You may hear a clicking sound after operating work equipment. It is a sound generated when suction valve in fan motor closes and it is normal.

No.

Cause

1 2 3 4

Vibration of fan Loosened mounting of fan and fan motor Interference to fan speed sensor and shroud Internal defect of fan motor

40-598

Procedure, measuring location, criteria and remarks Vibrations can be due to imbalance of fan. Check fan for adhesion of dirt and such and, if any, remove them. Vibrations may also be due to play. Check fan and fan motor for loose installation. Check interference between fan speed sensor and speed detecting plate, or between shroud and fan. If no failure is found by checks on causes 1 to 3, fan motor body may have internal defect.

D61EM-23M0

40 Troubleshooting

Troubleshooting of engine (S-mode)

Method of using troubleshooting charts

The troubleshooting chart consists of the jquestionsj, jcheck itemsj, jcausesj, and jtroubleshootingj blocks. The questions and check items are used to pinpoint high probability causes by simple inspection or from phenomena without using troubleshooting tools. Next, troubleshooting tools or direct inspection are applied to check the narrowed causes in order from the most probable one to make final confirmation according to the troubleshooting procedure. [Questions]: Items to be drawn from the user or operator. They correspond to A and B in the chart on the right. The items in A are basic ones. The items in B can be drawn from the user or operator, depending on their level. [Check items]: Items to be simply checked by the serviceman to narrow down causes. They correspond to C in the chart on the right. [Causes]: Items to be narrowed from the questions and check items. The serviceman narrows down the probable causes from A, B, and C. [Troubleshooting]: Items to finally verify whether the narrowed down causes are undoubtedly the real causes using the troubleshooting tools and direct inspections.

D61EM-23M0

40-599

40 Troubleshooting

Troubleshooting of engine (S-mode)

Items listed in the [Questions] and [Check items] and related to the [Causes] are marked with E, Q, or w. E: Causes to be referred to for questions and check items Q: Causes related to questions and check items w: Causes highly probable among ones marked with Q a When narrowing the “causes”, apply the items marked with w before those marked with Q. When narrowing the causes, do not apply the items marked with E. (If no items have other marks and the causes cannot be narrowed, however, you may apply them.)

40-600

D61EM-23M0

40 Troubleshooting

Troubleshooting of engine (S-mode)

<Example of troubleshooting> Exhaust gas is black Let us assume that a trouble of "Exhaust gas is black" occurred and we checked the [Question] and [Check items] and found the following 3 items to be the causal symptoms; [Exhaust gas slowly became black], [Power slowly became weaker], and [Dust indicator is lighting red].

D61EM-23M0

40-601

40 Troubleshooting

Troubleshooting of engine (S-mode)

There is a causal relationship between 3 items in the [Questions] and [Check items] sections and 5 items in the [Causes] section. The method of pinpointing the "cause" from the causal relationship and approaching the "troubleshooting" is explained according to Step 1 2 Step 3 shown below.

40-602

D61EM-23M0

40 Troubleshooting

Troubleshooting of engine (S-mode)

S-1 Starting performance is poor

D61EM-23M0

40-603

40 Troubleshooting

Troubleshooting of engine (S-mode)

S-2 Engine does not start

40-604

D61EM-23M0

40 Troubleshooting

Troubleshooting of engine (S-mode)

D61EM-23M0

40-605

40 Troubleshooting

Troubleshooting of engine (S-mode)

40-606

D61EM-23M0

40 Troubleshooting

Troubleshooting of engine (S-mode)

S-3 Engine does not pick up smoothly

D61EM-23M0

40-607

40 Troubleshooting

Troubleshooting of engine (S-mode)

S-4 Engine stops during operations

40-608

D61EM-23M0

40 Troubleshooting

Troubleshooting of engine (S-mode)

S-5 Engine does not rotate smoothly

D61EM-23M0

40-609

40 Troubleshooting

Troubleshooting of engine (S-mode)

S-6 Engine lacks output (or lacks power)

40-610

D61EM-23M0

40 Troubleshooting

Troubleshooting of engine (S-mode)

S-7 Exhaust smoke is black (incomplete combustion)

D61EM-23M0

40-611

40 Troubleshooting

Troubleshooting of engine (S-mode)

S-8 Oil consumption is excessive (or exhaust smoke is blue)

40-612

D61EM-23M0

40 Troubleshooting

Troubleshooting of engine (S-mode)

S-9 Oil becomes contaminated quickly

D61EM-23M0

40-613

40 Troubleshooting

Troubleshooting of engine (S-mode)

S-10 Fuel consumption is excessive

40-614

D61EM-23M0

40 Troubleshooting

Troubleshooting of engine (S-mode)

S-11 Oil is in coolant (or coolant spurts back or coolant level goes down)

D61EM-23M0

40-615

40 Troubleshooting

Troubleshooting of engine (S-mode)

S-12 Oil pressure drops

40-616

D61EM-23M0

40 Troubleshooting

Troubleshooting of engine (S-mode)

S-13 Oil level rises (Entry of coolant or fuel)

D61EM-23M0

40-617

40 Troubleshooting

Troubleshooting of engine (S-mode)

S-14 Coolant temperature becomes too high (overheating)

40-618

D61EM-23M0

40 Troubleshooting

Troubleshooting of engine (S-mode)

S-15 Abnormal noise is made

D61EM-23M0

40-619

40 Troubleshooting

Troubleshooting of engine (S-mode)

S-16 Vibration is excessive

40-620

D61EM-23M0

SHOP MANUAL

D61E -23M0 Model

Serial Number

D61E -23M0

B 0001 and up

50 Disassembly and assembly 7 50 Disassembly and assembly

D61EM-23M0

50-1

50 Disassembly and assembly Table of contents

Table of contents

50 Disassembly and assembly- - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 50-1 Table of contents - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 50-2 Related information on disassembly and assembly- - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 50-4 How to read this manual - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 50-4 Coating materials list - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 50-6 Special tools list - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 50-10 Sketches of special tools- - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 50-16 Engine and cooling system- - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 50-29 Removal and installation of supply pump assembly - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 50-29 Removal and installation of fuel injector assembly - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 50-33 Removal and installation of cylinder head assembly - - - - - - - - - - - - - - - - - - - - - - - - - - - - 50-40 Removal and installation of radiator assembly- - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 50-54 Removal and installation of aftercooler assembly - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 50-58 Removal and installation of hydraulic oil cooler assembly- - - - - - - - - - - - - - - - - - - - - - - - - 50-61 Removal and installation of cooling fan drive assembly - - - - - - - - - - - - - - - - - - - - - - - - - - 50-64 Removal and installation of cooling fan motor assembly- - - - - - - - - - - - - - - - - - - - - - - - - - 50-67 Removal and installation of engine assembly - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 50-69 Disassembly and assembly of damper assembly- - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 50-76 Removal and installation of engine front oil seal - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 50-77 Removal and installation of engine rear oil seal - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 50-79 Removal and installation of engine hood assembly - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 50-82 Removal and installation of fuel tank assembly - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 50-85 Removal and installation of muffler- - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 50-90 Removal and installation of belt for alternator and air conditioner compressor - - - - - - - - - - 50-92 Removal and installation of air cleaner assembly- - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 50-93 Power train - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 50-95 Removal and installation of HST pump assembly - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 50-95 Removal and installation of HST motor and final drive assembly- - - - - - - - - - - - - - - - - - - - 50-97 Disassembly and assembly of final drive- - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 50-100 Undercarriage and frame - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 50-110 Removal and installation of track frame assembly - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 50-110 Removal and installation of idler assembly - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 50-114 Disassembly and assembly of idler - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 50-116 Removal and installation of recoil spring assembly - - - - - - - - - - - - - - - - - - - - - - - - - - - - 50-120 Disassembly and assembly of recoil spring - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 50-121 Removal and installation of track roller assembly- - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 50-125 Disassembly and assembly of track roller assembly- - - - - - - - - - - - - - - - - - - - - - - - - - - - 50-127 Removal and installation of carrier roller assembly - - - - - - - - - - - - - - - - - - - - - - - - - - - - 50-130 Disassembly and assembly of carrier roller assembly - - - - - - - - - - - - - - - - - - - - - - - - - - 50-132 Removal and installation of segment teeth - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 50-134 Separation and connection of track shoe assembly (Standard type track shoe) - - - - - - - - 50-135 Overall disassembly and assembly of track shoe assembly (Standard type track shoe)- - - 50-138 Disassembly and assembly of one track link assembly in field (Standard type track shoe) - 50-154 Removal and installation of pivot shaft assembly - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 50-160 Removal and installation of equalizer bar assembly - - - - - - - - - - - - - - - - - - - - - - - - - - - - 50-162 Removal and installation of equalizer bar side bushing - - - - - - - - - - - - - - - - - - - - - - - - - 50-164 Hydraulic system - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 50-165 Removal and installation of hydraulic tank assembly - - - - - - - - - - - - - - - - - - - - - - - - - - - 50-165 Removal and installation of control valve assembly - - - - - - - - - - - - - - - - - - - - - - - - - - - - 50-169 Disassembly and assembly of hydraulic cylinder assembly- - - - - - - - - - - - - - - - - - - - - - - 50-172 Work equipment - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 50-175 Removal and installation of planter unit assembly - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 50-175 Removal and installation of center frame assembly - - - - - - - - - - - - - - - - - - - - - - - - - - - - 50-177 50-2

D61EM-23M0

50 Disassembly and assembly

Table of contents

Cab and its attachments - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 50-179 Removal and installation of ROPS cab assembly - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 50-179 Removal and installation of operator's cab glass (adhesion glass) - - - - - - - - - - - - - - - - - - 50-183 Removal and installation of operator's seat - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 50-189 Removal and installation of seat belt - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 50-190 Removal and installation of foot heater assembly - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 50-191 Disassembly and assembly of foot heater assembly- - - - - - - - - - - - - - - - - - - - - - - - - - - - 50-193 Removal and installation of air conditioner unit assembly - - - - - - - - - - - - - - - - - - - - - - - - 50-194 Removal and installation of air conditioner compressor assembly - - - - - - - - - - - - - - - - - - 50-198 Electrical system - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 50-200 Removal and installation of machine monitor assembly - - - - - - - - - - - - - - - - - - - - - - - - - 50-200 Removal and installation of engine controller assembly - - - - - - - - - - - - - - - - - - - - - - - - - 50-201 Removal and installation of HST controller assembly - - - - - - - - - - - - - - - - - - - - - - - - - - - 50-203 Removal and installation of KOMTRAX terminal - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 50-204

D61EM-23M0

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50 Disassembly and assembly

Related information on disassembly and assembly

How to read this manual (

)

(Rev.2013.05) Removal and installation of TTTT assembly Special tools • The special tools required for removal and installation work are described in the list as symbols such as A1, ..., X1. Part number, part name, necessity, and quantity are described. • Mark used in the column of necessity are explained below. t: Tools are not substituted, must always be equipped (used). q: Tools extremely useful if available or tools that can be substituted with commercially available tools. • For details and the sketches of the special tools, see "Special tool list" and "Sketches of special tools." Removal • In "Removal" section, the work procedures, precautions and know-how to do the work, and the amount of oil and coolant to be drained are described. • The general tools required for "Removal" are listed as [1], [2], ..., without description of part number, part name, and quantity. • Marks used in "Removal" section are explained below. k : This mark shows safety-related precautions

which must be followed when performing the work.

• The general tools required for "Installation" are listed as [1], [2], ..., without description of part number, part name, and quantity. • Marks used in "Installation" section are explained below. k : This mark shows safety-related precautions

which must be followed when performing the work. a : This mark gives knowledge or precautions when performing the work. 4 : This mark shows the weight of the part or equipment. 2 : This mark shows a specific coating agent to be used. 3 : This mark shows the specified tightening torque. 5 : This mark shows the amount of oil or coolant to be added. • For details of oil or coolant to be added after installation, see Specification "Table of fuel, coolant and lubricants". Disassembly and assembly of TTTT assembly Special tools

Installation

• The special tools required for disassembly and assembly work are described in the list as symbols such as A1, ..., X1. Part number, part name, necessity, and quantity are described. • Mark used in the column of necessity are explained below. t: Tools are not substituted, must always be equipped (used). q: Tools extremely useful if available or tools that can be substituted with commercially available tools. • For details and the sketches of the special tools, see "Special tool list" and "Sketches of special tools."

• The work procedure of "Installation" is in the reversed order to removal unless otherwise specified. • For knowledge and precautions required for "Installation", a [*1] mark is assigned to the "Removal" work procedure to indicate the work item of the installation knowledge or precaution.

Disassembly • "Disassembly" describes the work procedure as well as the precautions, knowledge, and drain amounts of oil and coolant required for the work. • The general tools required for "Disassembly" are listed as [1], [2], ..., without description of part number, part name, and quantity.

a : This mark gives knowledge or precautions when performing the work. [*1]: This mark indicates that knowledge or precautions for the assembly installation work are given in the "Installation" section. 6 : This mark shows the amount of oil or coolant to be drained. 4 : This mark shows the weight of the part or equipment.

50-4

D61EM-23M0

50 Disassembly and assembly

Related information on disassembly and assembly

• Marks used in the section of "Disassembly" are explained below. k : This mark shows safety-related precautions

which must be followed when performing the work. a : This mark gives knowledge or precautions when performing the work. 6 : This mark shows the amount of oil or coolant to be drained. 4 : This mark shows the weight of the part or equipment. Assembly • "Assembly" describes the work procedure as well as the precautions, knowledge, and drain amounts of oil and water required for the work. • The general tools required for "Assembly" are listed as [1], [2], ..., without description of part number, part name, and quantity. • Marks used in the section of "Assembly" are explained below. k : This mark shows safety-related precautions

D61EM-23M0

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50 Disassembly and assembly

Related information on disassembly and assembly

Coating materials list

1 (Rev.2012.11)

a The coating materials such as adhesives, liquid gasket, and grease used for disassembly and assembly are listed below. a For coating materials not listed below, use the equivalent of products shown in this manual. Adhesive Komatsu code

Part No.

Capacity

Container

LT-1A

790-129-9030

150 g

Tube

LT-1B

790-129-9050

20 g (contained 2 pieces)

Polyethylene container

LT-2

790-129–9180

50 g

Polyethylene container

Main features and applications • Use to prevent rubber gaskets, rubber cushions, and cork plugs from coming out. • Use for plastic (except polyethylene, polypropylene, tetrafluoroethylene and vinyl chloride), rubber, metal, and nonmetal parts which require immediate and strong adhesion. • Features: Resistance to heat and chemicals • Use to prevent bolts and plugs from coming loose and as sealant.

LT-3

790-129-9060 Set of adhesive and hardener

Adhesive: 1 kg Hardener: 500 g

Can

• Use to bond and seal metal, glass and plastics.

LT-4

790-129-9040

250 g

Polyethylene container

Holts MH705

790-129-9120

75 g

Tube

ThreeBond 1735

790-129-9140

50 g

Polyethylene container

Aron Alpha 201

790-129-9130

2g (contained 5 pieces)

Polyethylene container

Loctite 499

428-99-80070

20 cc

Tube

Loctite 648-50

79A-129-9110

50 cc

Polyethylene container

50-6

• Use to seal plugs for blank holes. • Heat-resistant seal used to repair engines • Instantaneous adhesive • Curing time: From 5 sec. to 3 min. • Use mainly to bond metals, rubbers, plastics, and woods. • Instantaneous adhesive • Quick-curing type (max. strength is obtained after 30 minutes) • Use mainly to bond rubbers, plastics, and metals. • General-purpose instantaneous adhesive with excellent resistance to heat and impact • Use on the bushing mounting faces of axle supports. • Features: Resistance to heat and chemicals • Use to bond high-temperature fit parts.

D61EM-23M0

50 Disassembly and assembly

Related information on disassembly and assembly

Liquid gasket Komatsu code

Part No.

Capacity

Container

LG-5 ThreeBond 1110F

790-129-9080

1 kg

Polyethylene container

LG-6 ThreeBond 1215

790-129-9160

250 g

Tube

LG-7 ThreeBond 1207C

790-129-9170

150 g

Tube

LG-8 ThreeBond 1207B

419-15-18131

100 g

Tube

LG-9 ThreeBond 1206D

790-129-9310

200 g

Tube

LG-10 ThreeBond 1206E

790-129-9320

200 g

Tube

LG-11 ThreeBond 1121

790-129-9330

200 g

Tube

ThreeBond 1211

790-129-9090

100 g

Tube

Capacity

Container

Main features and applications • Use to seal various threaded parts, pipe joints, and flanges. • Use to seal taper plugs, elbows, and nipples for hydraulic piping. • Features: Silicon-based heat and coldresistant sealant. • Use to seal flange surface and threaded parts. • Use to seal oil pan, final drive case, etc. • Features: Silicon-based quick-curing sealant • Use to seal flywheel housing, intake manifold, oil pan, thermostat housing, etc. • Features: Silicon-based heat, vibration, and shock-resistant sealant. • Use to seal transfer case, etc. • Use for rough surfaces such as the circle gear top seal which is not clamped by bolts, gaps in the weld which must be caulked, etc. • Can be coated with paint. • Use as lubricant or sealant when the radiator hoses are put on. • Can be coated with paint. • Feature: Can be used together with solid gaskets. • Use for covers of the transmission case and steering case etc. • Liquid gasket used to repair engine

Molybdenum disulfide lubricant Komatsu code

Part No.

• LM-P

09940-00040

200 g

Tube • • •

LM-S

09995-00250

190 g

Can •

D61EM-23M0

Main features and applications Use to prevent galling and seizure of press-fitted parts, shrinkage-fitted parts, and threaded parts. Use to lubricate linkages, bearings, etc. Spray type Thin molybdenum disulfide films are made on metal surfaces to prevent the metals from galling. Use for the drive shaft splines, needle bearings, various link pins, bolts, etc.

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50 Disassembly and assembly

Related information on disassembly and assembly

Seizure prevention compound Komatsu code

Part No.

Capacity

Container

LC-G NEVER-SEEZ

—

Can

Capacity

Container

Main features and applications

Various

• Lithium grease with extreme pressure lubrication performance, general purpose type.

400 g x 10 400 g x 20 16 kg

Bellowstype container Can

• Use for parts under heavy load. Caution: • Do not use this grease for rolling bearings like swing circle bearings, etc. and spline. • Use this grease for work equipment pins only when installing them, but do not use it afterward.

400 g 16 kg

Bellowstype container Can

• Higher seizure resistance, heat resistance, and waterproof than molybdenum disulfide grease • Not conspicuous on machine since color is white.

400 g 16 kg

Bellowstype container Can

• Since this grease is biodegradable in short period, it has less impact on microorganisms, animals, and plants.

Main features and applications • Feature: Seizure and galling prevention compound with metallic super-finegrain, etc. • Use for the mounting bolt in the high temperature area of the exhaust manifold and the turbocharger, etc.

Grease Komatsu code

Part No. SYG2-400LI-A G2-LI SYGA-16CNLI G0-LI(*) SYG0-400LI-A *: For cold districts (*) SYG0-16CNLI (*)

Molybdenum disulfide grease LM-G(G2-M)

SYG2-400M SYG2-400M-A SYGA-16CNM

Hyper white SYG2-400T grease SYG2-16CNT G2-T SYG0-400T(*) G0-T(*) SYG0-16CNT(*) *: For cold districts Biogrease SYG2-400B G2-B SYGA-16CNB G2-BT(*) SYG2-400BT(*) *: For use at high SYGA-16CNBT temperature and (*) under high load

G2-S ThreeBond 1855

—

200 g

Tube

G2-U-S ENS grease

427-12-11871

2 kg

Can

50-8

• Feature: Silicon-based grease with wider operating temperature range and superior thermal oxidative stability to prevent deterioration of rubber and plastic. • Use for oil seals of the transmission, etc. • Feature: Urea (organic) grease with heat resistance and long life, inclusion type. • Use for rubber, bearing and oil seal in damper. Caution: Do not mix with lithium grease.

D61EM-23M0

50 Disassembly and assembly

Related information on disassembly and assembly

Primer Loctite 712

Part No.

Capacity

428-99-80080

100 ml

SUNSTAR Paint Surface Primer 580 SUPER SUNSTAR Glass Primer 580 SUPER

417-926-3910

SUNSTAR Paint Surface Primer 435-95

Container Glass container

20 ml

Glass container

20 ml

Glass container

22M-54-27230

20 ml

Glass container

SUNSTAR PRIMER 435-41 for glass

22M-54-27240

150 ml

Steel can

SUNSTAR sash primer GP-402

22M-54-27250

20 ml

Glass container

Komatsu code

Part No.

Capacity

Container

SUNSTAR Penguin Seal 580 SUPER "S" or "W"

417-926-3910

320 ml

Polyethylene container

Sika Japan Sikaflex 256HV

20Y-54-39850

310 ml

Cartridge

SUNSTAR Penguin Super 560

22M-54-27210

320 ml

Ecocart (special container)

Part No.

Capacity

Container

417-926-3920

330 ml

Cartridge

20Y-54-55130

333 ml

Cartridge

Main features and applications • Use to accelerate hardening of instantaneous adhesive. • Use as primer for cab side. (Effective period: 4 months after manufacture) • Use as primer for glass side. (Effective period: 4 months after manufacture) • Use as primer for painted cab sheet metal surface. (Effective period: 4 months after manufacture) • Use as primer for black ceramiccoated glass surface and for hard polycarbonate-coated surface. (Effective period: 4 months after manufacture) • Use as primer for sash (alumite surface treatment). (Effective period: 4 months after manufacture)

For adhered window glass

Komatsu code

For adhered window glass

Adhesive Main features and applications • Use "S" as adhesive for glass in high temperature months (during summer) and "W" in low temperature months (during winter). (Effective period: 4 months after manufacture) • Use as adhesive for glass. (Effective period: 6 months after manufacture) • Use as adhesive for glass. (Effective period: 6 months after manufacture)

Komatsu code SUNSTAR Penguin Seal No.2505 SEKISUI Silicone Sealant 83

GE TOSHIBA SILICONES TOSSEAL381

D61EM-23M0

22M-54-27220

333 ml

Cartridge

For adhered window glass

Caulking material Main features and applications • Use to seal glass-to-glass joint. (Effective period: 4 months after manufacture) • Use to seal front window. (Effective period: 6 months after manufacture) • Translucent white seal used for joint seals between glasses (Effective period: 12 months after manufacture)

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50 Disassembly and assembly

Related information on disassembly and assembly

Special tools list

a Tools with part number 79*T-***-**** are not supplied (to be locally manufactured). a Necessity t: Tools are not substituted, must always be equipped (used). q: Tools extremely useful if available or tools that can be substituted with commercially available tool. a New/Redesign N: Tools with new part numbers, newly developed for this model. R: Tools, with advanced part numbers, developed by improving existing tools for other models. Blankl: Tools already available for other models that can be used without any modification.

Symbol

Removal and installation of supply pump assembly Removal and installation of fuel injector assembly and cylinder head assembly Removal and installation of cylinder head assembly and engine front oil seal Removal and installation of cylinder head assembly A Removal and installation of engine front oil seal Removal and installation of engine rear oil seal Disassembly and assembly of KDPF assembly Removal, installation, disassembly and assembly of cylinder head assembly and KDPF assembly

50-10

Part No.

Part name

Sketch

Work

Necessity Q'ty New/Redesign

a Tools marked with Q in the Sketch column have the sketches. (See "Sketches of special tools")

Details of work and remarks

795-799-6130 Support

t 1

Fixing supply pump gear

795-799-6700 Puller

t 1

Removal of fuel injector assembly

795-799-8150 Remover

q 1

Removal of inlet connector

790-331-1120 Wrench (angle)

q 1

Angle tightening of bolts

795-790-4510 Gauge

q 1

Judgment of mounting bolt length for cylinder head

795-799-6400 Seal puller

t 1

Installation of engine front oil seal

795-799-6500 Seal puller

t 1

Installation of engine rear oil seal

Commercially Long socket (1/2 inches) available

q 1

Removal and installation of V-clamp

Commercially Long socket (7/16 inches) available

q 1

Removal and installation of V-clamp and band

D61EM-23M0

50 Disassembly and assembly

Symbol

Removal and installation of HST motor, final drive assembly, and track frame assembly

Disassembly and assembly of final C drive

Part No.

Part name

Disassembly and assembly of track roller assembly

790-337-1001 Lifting tool

t 1

1 2 3 4 1 5 6 7

790-434-1050 01580-12419 01643-32460 790-101-2540 790-101-2102 790-201-2850 790-101-1102

t t t t t t t

Removal of planetary pinion shaft

Installer Nut Washer Washer Puller assembly Spacer Hydraulic pump

Disassembly and assembly of recoil M spring

Removal and installation of round nut N Q Installation of seal Adjust the bearing preload N Q Press fit of bearing N Q

791T-627-2210 Wrench

t 1 N Q

791T-627-2240 Installer

t 1

79A-264-0091 Ruler

q 1 t t t t t t q t

1 1 1 1 1 1 1 1

q 1 t 1 t 1 t 1

796T-267-1180 Push tool

t 1

796T-667-1120 Push tool

t 1

9 10 1

t 1 796-230-1110 Installer t 1 790-201-2730 Spacer t 1 791T-B30-1110 Sleeve Compressor (B) t 1 791-685-8006 t 1 791-635-3160 Extension t 1 790-201-2770 Spacer Pump assembly t 790-101-1102 1 Cylinder (686 kN {70 t 1 790-101-1600 ton})

D61EM-23M0

1 1 1 1 1 1 1

791T-627-2220 Spacer 791T-627-2230 Spacer 1 790-201-1990 Plate 7 2 790-101-5021 Grip 3 01010-50816 Bolt 1 791-515-1520 Installer 2 791-601-1000 Oil pump 3 791-126-0211 Adapter Commercially available or Puller 4 790-101-3501 790-201-1420 Spacer 5 790-201-2650 Plate L 6 791-515-1520 Installer

Disassembly and assembly of carrier roller

Details of work and remarks

Removal and installation of HST motor, final drive assembly, and track frame assembly

5 6

Disassembly and assembly of idler

Sketch

Work

Necessity Q'ty New/Redesign

Related information on disassembly and assembly

796T-467-2160 Push tool

t 1

Press fit of outer race Press fit of floating seal Oil refilling Press fit of bushing Removal of collar Press fit of bushing Press fit of floating seal Removal of shaft Q assembly Assembly of shaft Q assembly Press fit of floating seal Press fit of bearing Q Removal of piston

Disassembly, assembly of recoil spring

Assembly of yoke and Q piston assembly

50-11

50 Disassembly and assembly

Removal and installation of equalizer bar assembly

Symbol

Removal and installation of pivot P shaft assembly

Disassembly and assembly of track shoe assembly (standard type track shoe)

Disassembly and assembly of one link in field (standard type track shoe)

50-12

Details of work and remarks

t 1

t t t t t

792T-413-1120 Push tool

Press fit of spherical t 1 N Q bushing

791-430-1200 Installer assembly Puller (294 kN {30 790-101-2102 ton}) 790-101-1102 Pump assembly

t 1

790-337-1001 Lifting tool

t 1

791-646-7531 Remover

t 1

791-660-7460 Pin brush

t 1

3 4

791-432-1110 Plug push tool 791-932-1110 Plug push tool

t 1 t 1

790-701-3000 Seal checker

t 1 t 1

9 10

790-101-1102 Pump assembly Cylinder (980 kN 790-101-1300 {100 ton}) 791-101-1102 Pump assembly Jack (294 kN {30 790-105-2300 ton}) 791-635-3110 Frame 791-635-3160 Extension 791-635-3170 Nut 791-635-3180 Screw 791-635-3190 Screw 791-645-3510 Adapter 791-646-3260 Pusher 791-630-3560 Pusher 791-432-1110 Push tool

t t t t t t t t t

791T-630-3570 Guide

t 1

Part name

791-450-1100 Remover Puller (294 kN {30 790-101-2102 ton}) 790-101-1102 Pump assembly 790-101-2420 Adapter 790-101-2520 Screw 791-112-1180 Nut 790-101-2540 Washer

Removal and installation of equalizer bar side bushing

Part No.

Sketch

Work

Necessity Q'ty New/Redesign

Related information on disassembly and assembly

t 1 1 1 1 1 1

Removal of equalizer bar center pin

t 1 Press fit of pivot shaft ring

t 1

Removal and installation of pivot shaft Removal of pin plug Cleaning of sealed and lubricated track pins Driving in pin plug (large) Driving in pin plug (small) Sealing check and refilling of sealed and lubricated track link Removal of pin

t 1 t 1

Disconnecting link

t 1 1 1 4 2 1 1 1 1 1

Removal of pin

Installation of bushing Driving in pin plug (large) Installation of link

D61EM-23M0

50 Disassembly and assembly

Symbol

17 18 4 5

790-701-3000 Seal checker

t 1

793T-B32-1200 Push tool assembly 793T-B32-1230 • Adapter 793T-B32-1240 • Ring 793T-B32-1250 • Plate 793T-B32-1260 • Plate 793T-B32-1210 • Push tool 793T-B32-1220 • Adapter 793T-B32-1280 • Spring 793T-B32-1270 • Bolt 793T-B32-1030 • Bar 01580-11210 • Nut 01252-10612 • Bolt

t 1 1 1 1 1 1 1 1 1 1 1 4

D61EM-23M0

t t t t t t t t t t t t t t t t t

t t t t t t t t t t

Disassembly and assembly of track shoe assembly (PLUS type track shoe)

Part name

791-635-3110 Frame 791-635-3160 Extension 791-635-3170 Nut 791-635-3180 Screw 791-635-3190 Screw 791-645-3510 Adapter 791-645-3520 Adapter 791-645-3530 Pusher 791-635-3110 Frame 791-635-3160 Extension 791-635-3170 Nut 791-635-3180 Screw 791-635-3190 Screw 791-645-3520 Adapter 791T-630-3570 Guide 791-630-3560 Pusher 790-101-1102 Pump assembly Jack (294 kN {30 790-105-2300 ton}) 791-646-3270 Guide 791-635-3110 Frame 791-635-3160 Extension 791-635-3170 Nut 791-635-3180 Screw 791-635-3190 Screw 791-645-3510 Adapter 791-646-8002 Lubricator 791-932-1110 Plug push tool 791-932-1110 Plug push tool

Disassembly and assembly of one link in field R (standard type track shoe)

Part No.

1 1 4 2 1 1 1 1 1 1 4 2 1 1 1 1 1

t 1 1 1 1 4 2 1 1 1 1 1

Sketch

Work

Necessity Q'ty New/Redesign

Related information on disassembly and assembly

Details of work and remarks

Installation of pin

Installation of bushing Q

Installation of link Installation of pin

Installation of pin

Adding oil Driving in pin plug (small) Driving in pin plug (small) Sealing check and refilling of sealed and lubricated track link Q Q Q Q Q Q Installation of wedge ring Q (for large plug side) Q Q Q

50-13

50 Disassembly and assembly

Disassembly and assembly of track shoe assembly (PLUS type track shoe)

Disassembly and assembly of one link in field (PLUS type track shoe)

Symbol

Part name

793T-B32-1300 Push tool assembly 793T-B32-1310 • Adapter 793T-B32-1240 • Ring 793T-B32-1250 • Plate 793T-B32-1260 • Plate 793T-B32-1210 • Push tool 21 793T-B32-1220 • Adapter 793T-B32-1280 • Spring 793T-B32-1270 • Bolt R 793T-B32-1030 • Bar 01580-11210 • Nut 01252-10612 • Bolt 791T-B32-1100 Push tool assembly 793T-B32-1010 • Holder 22 791T-B32-1110 • Push tool 793T-B32-1030 • Bar 01580-11210 • Nut 23 791T-B32-1030 Push tool Remover and 1 791-532-2201 installer assembly Cylinder (980 kN 2 790-101-1300 {100 ton}) Puller (294 kN {30 3 790-105-2300 ton}) 4 790-532-2210 Plate 5 791-532-2220 Plate 6 791-532-2230 Block 7 791-532-2240 Stud bolt 8 791-532-2390 Rod 19 9 791-532-2260 Plate R 10 791-532-2270 Boss 11 791-532-2280 Boss 12 791-532-2310 Plate 13 01582-12722 Nut 14 791-532-2380 Washer 15 01252-61645 Bolt 16 02205-12437 Nut 17 791-532-2370 Plate 18 791-532-2350 Push tool 20

50-14

Part No.

790-101-1102 Pump assembly

t 1 1 1 1 1 1 1 1 1 1 1 4 t 2 1 2 2 2 t 1

Sketch

Work

Necessity Q'ty New/Redesign

Related information on disassembly and assembly

Details of work and remarks

Q Q Q Q Q Q Q Q Installation of wedge ring Q (for small plug side) Q

Q Q Q Q Q Press fit of oil seal

t 1 t 1 t 1 t t t t t t t t t t t t t t t

1 1 1 2 2 1 2 2 1 4 2 2 4 1 2

t 1

Disassembly and assembly of link

Press fit of wedge ring Disassembly and assembly of link

D61EM-23M0

50 Disassembly and assembly

Symbol

3 1 Disassembly and assembly of hydraulic cylinder assembly

Removal and installation of operator's cab glass (adhered window glass)

D61EM-23M0

Part No.

Part name

790-502-1003 Repair stand

t 1

790-101-1102 Pump assembly

t 1

Wrench assembly t 790-330-1100 ( & ') *$ . ( $ t 2 2 & ) Socket (width across t 790-302-1290 flats: 60 mm) q 790-720-1000 Expander q 2 2 8 ' ( ') ( ') q 2 q 796-720-1660 Ring (lift) q 07281-01159 Clamp (lift) t 790-201-1702 Push tool kit 790-101-5021 • Grip 01010-50816 • Bolt • Push tool kit 2 2 ( ') • Push tool kit (lift) 790-201-1771 t 790-201-1500 Push tool kit 790-101-5021 • Grip 01010-50816 • Bolt 2 2 • " ( ') 790-201-1580 • Plate (lift) 793-498-1210 Lifter (suction cup)

1 1 1 1 1 1 1 1 1 1 1

Sketch

Work

Necessity Q'ty New/Redesign

Related information on disassembly and assembly

Details of work and remarks

Disassembly and assembly of hydraulic cylinder Removal and installation of round head Removal and installation of piston nut Expansion of piston ring Installation of piston ring Installation of piston ring

Press fit of roll bushing

1 1 1 1 1 1 1

t 2

Press fit of dust seal

Installation of window glass

50-15

50 Disassembly and assembly

Related information on disassembly and assembly

Sketches of special tools

Note: Komatsu does not take any responsibility for special tools manufactured according to these sketches. C2: Wrench

C3: Installer

50-16

D61EM-23M0

50 Disassembly and assembly

Related information on disassembly and assembly

Note: Komatsu does not take any responsibility for special tools manufactured according to these sketches. C5: Spacer

C6: Spacer

D61EM-23M0

50-17

50 Disassembly and assembly

Related information on disassembly and assembly

Note: Komatsu does not take any responsibility for special tools manufactured according to these sketches. L7: Push tool

L8: Push tool

50-18

D61EM-23M0

50 Disassembly and assembly

Related information on disassembly and assembly

Note: Komatsu does not take any responsibility for special tools manufactured according to these sketches. M1: Sleeve

M3: Push tool

D61EM-23M0

50-19

50 Disassembly and assembly

Related information on disassembly and assembly

Note: Komatsu does not take any responsibility for special tools manufactured according to these sketches. N2: Push tool

R11 and R13: Guides

50-20

D61EM-23M0

50 Disassembly and assembly

Related information on disassembly and assembly

Note: Komatsu does not take any responsibility for special tools manufactured according to these sketches. R20: Push tool assembly

R20: Adapter

D61EM-23M0

50-21

50 Disassembly and assembly

Related information on disassembly and assembly

Note: Komatsu does not take any responsibility for special tools manufactured according to these sketches. R20 and R21: Rings

R20 and R21: Plates

50-22

D61EM-23M0

50 Disassembly and assembly

Related information on disassembly and assembly

Note: Komatsu does not take any responsibility for special tools manufactured according to these sketches. R20 and R21: Plates

R20 and R21: Push tools

D61EM-23M0

50-23

50 Disassembly and assembly

Related information on disassembly and assembly

Note: Komatsu does not take any responsibility for special tools manufactured according to these sketches. R20 and R21: Adapters

R20 and R21: Springs

50-24

D61EM-23M0

50 Disassembly and assembly

Related information on disassembly and assembly

Note: Komatsu does not take any responsibility for special tools manufactured according to these sketches. R20 and R21: Bolts

R20, R21, R22: Bars

D61EM-23M0

50-25

50 Disassembly and assembly

Related information on disassembly and assembly

Note: Komatsu does not take any responsibility for special tools manufactured according to these sketches. R21: Push tool assembly

R21: Adapter

50-26

D61EM-23M0

50 Disassembly and assembly

Related information on disassembly and assembly

Note: Komatsu does not take any responsibility for special tools manufactured according to these sketches. R22: Push tool assembly

R22: Holder

D61EM-23M0

50-27

50 Disassembly and assembly

Related information on disassembly and assembly

Note: Komatsu does not take any responsibility for special tools manufactured according to these sketches. R22: Posh tool

R23: Push tool

50-28

D61EM-23M0

50 Disassembly and assembly

Engine and cooling system

Removal and installation of supply pump assembly

Symbol

Part No.

A 1 795-799-6130

Part name Support

Necessity Q'ty

a Special tools

t 1

k Place machine on a level ground, and set

parking brake lever to LOCK position. k Lower the work equipment to the ground,

and set the work equipment lock lever to LOCK position. k Turn the starting switch to OFF position, and

stop the engine.

5. Sling blade lift cylinder assembly (5) and remove pin (6). 6. Sling blade lift cylinder assembly (5), reverse it to the blade side, and fix it in that position.

k Turn the battery disconnect switch to OFF

position, and remove the key. (For details, see Testing and adjusting, "Handling of battery disconnect switch".) k If you drain the coolant when it is still hot,

you may be scalded. Wait until the coolant temperature drops before starting the work.

Removal

(D61-AD70-520-K-00-A)

1. Remove engine hood assembly. For details, see "Removal and installation of engine hood assembly". 2. Remove left blade lift cylinder cover (1).

7. Open the right side cover, and disconnect fuel return hose (7). a Place an oil container under the hose. a Plug the disconnected hose and the mounting port to prevent oil leakage.

3. Remove hose clamp (2), and disconnect hydraulic hose (3). a Place an oil container under the hose. a Plug the disconnected hose and the mounting port to prevent oil leakage. 4. Remove lock plate (4) from the blade lift cylinder.

D61EM-23M0

8. Remove oil filler (8). 9. Remove hose clamp (10), and disconnect fuel hose (11). [*1]

50-29

50 Disassembly and assembly Engine and cooling system

10.Remove bracket (13). 11.Disconnect fuel hoses (14) and (15). 12.Remove fuel filter and bracket (16).

13.Remove tube clamps (17) (3 pieces). [*3] 14.Disconnect harness connector (18). 15.Disconnect fuel supply hose (19). [*4] 16.Disconnect fuel return tube (20). [*5] 17.Remove the fuel spray prevention cap, and remove the fuel high-pressure pipe (21). [*6]

20.Remove mounting nuts (A) (3 pieces), and remove supply pump assembly (22). [*8] a Pull supply pump assembly (22) sideways straight when removing it. Otherwise the pump assembly may interfere with the top of boost pump (26).

a Supply pump assembly (22) comes off with the gear. The gear is not worked on its teeth (no missing tooth) to show the mark for 1, 6 TDC adjustment.

18.Disconnect fuel filter hoses (23) and (24) from supply pump assembly (22). [*7] a Pull out hose to the direction of (a) while pressing lock (L) on the both sides. 19.Remove bracket (25).

21.Remove the gear from the supply pump assembly according to the following procedure. [*9] 1) While locking the gear by using tool A1 and 1/2-inch spin handle [1], loosen mounting nut (27). a Remove mounting nut (27) from the shaft.

50-30

D61EM-23M0

50 Disassembly and assembly

Engine and cooling system

2) Install puller [2] between the flange and gear (28).

Installation

(D61-AD70-720-K-00-A)

• Perform installation in the reverse order to removal. [*1] 3 Fuel hose (11) mounting bolt: 19.6 to 29.4 Nm {2.0 to 3.0 kgm} [*3] 3 Tube clamp (17): 24 ± 4 Nm {2.45 ± 0.41 kgm} [*4]

3) Install puller [3] on puller [2] and the shaft. 4) Turn center bolt [4] until the gear is disengaged from the shaft. 5) Remove pullers [2] and [3].

3 Fuel supply hose (19) mounting bolt: 25.4 to 34.3 Nm {2.6 to 3.5 kgm} [*5] 3 Fuel return tube (20) joint bolt: 24 ± 4 Nm {2.5 ± 0.4 kgm} [*6] • How to install fuel high-pressure pipe (21) 1. Finger-tighten sleeve nuts of fuel highpressure fuel pipe (21). (both ends) 2. Tighten the sleeve nuts on supply pump first, and then tighten the sleeve nuts on common rail side. 3 Sleeve nut: 35 ± 3.5 Nm {3.57 ± 0.36 kgm} • Install fuel spray prevention caps. a Direct slits of fuel spray prevention caps outward and downward.

6) Remove mounting nut (27), lock washer (29) and gear (28) from shaft (30).

a The fuel spray prevention caps are installed so that fuel will not spout over the hot part of the engine and catch fire when it leaks by any chance. [*7] • When installing a connector of quick coupler type, observe the following points. a The internal parts of the fitting of the hose or tube may be damaged when it is once disconnected . Do not reuse them. a For installation, replace it with a new one.

D61EM-23M0

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50 Disassembly and assembly Engine and cooling system

a Ensure that mud or dirt is not sticking to the hose joint portions in advance. a Push and insert the connector straight (in the direction of (b)) without prying or shaking it. If it is difficult to insert it, do not push it in forcibly but pull it out once. Then, check concave and convex portion for damage and dirt.

3 Supply pump assembly mounting nut (33): 24 ± 4 Nm {2.45 ± 0.41 kgm}

[*9] • Procedure for installing gear (28)

[*8] • Install supply pump assembly (22). a If grease is applied too much to O-ring (31), it will ooze out. Do not apply grease too much. (Apply grease to the O-ring groove area of part B.)

a Before installation, clean dusts and foreign substances on the mating surfaces of shaft (30) and gear (28), and keep the mating surfaces dry. 1. Install gear (28) to shaft (30). 2. Install lock nuts (27) with washer (29), and finger-tighten the nut lightly.

a When installing new fuel supply pump mounting stud bolts (32) to replace the existing ones, apply Loctite to them when mounting. 3 Stud bolt (32): 12 ± 2 Nm {1.2 ± 0.2 kgm}

3. While locking the gear by using tool A1 and 1/2-inch spin handle [1], tighten nut (27) to the specified torque.

a Since it is difficult to install the cylinder block side nuts when installing supply pump assembly mounting nuts (33), be sure to use a new socket for their installation. a If an old socket is used, the nut may fall off or be damaged due to excess clearance between the socket and mounting nut (33). 50-32

3 Supply pump gear mounting nut (27): 105 ± 5 Nm {10.7 ± 0.51 kgm} • Checking for fuel leakage (fuel system) Check the fuel system for leakage. For details, see Testing and adjusting, "Checking fuel circuit for leakage". • Bleeding air (fuel system) Bleed air from the fuel circuit. For details, see Testing and adjusting, "Bleeding air from fuel circuit".

D61EM-23M0

50 Disassembly and assembly

Engine and cooling system

Removal and installation of fuel injector assembly

Symbol A

2 4

Part No.

Part name

795-799-6700 Puller 795-799-8150 Remover

Necessity Q'ty

a Special tools

t 1 q 1

k Place machine on a level ground, and set

parking brake lever to LOCK position. k Lower the work equipment to the ground,

and set the work equipment lock lever to LOCK position.

7. Remove tube clamp (26). [*4] 8. Disconnect fuel return tube (27). [*5] 9. Remove bracket (28).

k Turn the starting switch to OFF position, and

stop the engine. k Turn the battery disconnect switch to OFF

position, and remove the key. (For details, see Testing and adjusting, "Handling of battery disconnect switch".) k If you drain the coolant when it is still hot,

you may be scalded. Wait until the coolant temperature drops before starting the work.

Removal

(D61-AE60-520-K-00-A)

1. Remove engine hood assembly. For details, see "Removal and installation of engine hood assembly". 2. Remove wiring harness clamps (3) (5 pieces), and disconnect the following wiring harness connectors. • Connector 23 (4) • Terminal T6 (5) • Terminal T12 (6) • Terminal T5 (7) • Ground (8)

10.Remove bracket (29).

11.Disconnect wiring harness connector RH (30). 12.Disconnect air connector (31). [*6] 13.Remove air inlet connector (32). [*7] a When removing mounting bolt from part (a) of air inlet connector (32), disconnect front side connector (33) to prevent interference with the tool.

3. Disconnect fuel hoses (21) and (22). 4. Remove fuel filter and bracket (23). 5. Remove oil level gauge (24). 6. Remove bracket (25). D61EM-23M0

50-33

50 Disassembly and assembly Engine and cooling system

22.Loosen common rail mounting nuts and bolts (39a) (4 pieces).

23.Remove blowby duct (41) from rear of the engine. 24.Remove mounting nuts (42) (6 pieces), and remove cylinder head cover (43).

14.Disconnect wiring harness cable ties (34) (2 pieces). 15.Disconnect fuel injector connectors (35) (3 pieces). 16.Disconnect common rail pressure sensor wiring harness connector (36). 17.Disconnect boost temperature and pressure sensor wiring harness connector (37).

25.Remove wiring harness nut (45) from the fuel injector assembly. Color of wiring harness White Black

Cylinder No. 1, 3, 5 2, 4, 6

a Remove fuel injector wiring harness connector (60) from the rocker housing only when required. 26.Remove mounting bolts (46) (12 pieces), then remove rocker arm assembly (47), crosshead (48), and the rocker arm support.

18.Remove mounting bolts and leave fuel injector wiring harness connectors (60) (3 pieces) free. [*8] a This is to prevent interference of the fuel high-pressure pipe sleeve nut tool. 19.Remove fuel spray prevention caps (39) (14 pieces). 20.Remove fuel high-pressure pipes (40) (6 pieces). 21.Remove tube clamp, and disconnect fuel highpressure pipe (38). 50-34

a Loosen lock nuts (49), and then loosen adjustment screws (50) a few turns each so that excessive force does not apply to the push rods when the rocker arms are installed. a Record the installed positions and directions of the crossheads (shapes of holes at portions (a) and (b)). (This is necessary to reinstall them in the original directions.)

D61EM-23M0

50 Disassembly and assembly

Engine and cooling system

Installation

(D61-AE60-720-K-00-A)

1. Fuel injector assembly a When the fuel injector assembly is replaced with a new one, the inlet connector also should be replaced with a new one. a Check that fuel injector mounting sleeve (56) is free from dirt or other particles.

27.Remove retaining nuts (51), then remove inlet connectors (52) (6 pieces). a Clean the surrounding area to remove mud and other contamination in advance to prevent them from entering the connector hole. a Use tool A4 to remove inlet connector (52). 28.Remove mounting bolts (53) of fuel injector assembly (55), then remove holder (54). 29.Remove fuel injector assembly (55) by using tool A2. a Be careful that dirt and foreign material do not enter the fuel injector assembly mounting area.

1) Install O-ring (58) and gasket (59) to fuel injector (57). a Replace O-rings and gasket with new ones. 2) Apply engine oil to O-ring (58) of fuel injector (57) and the cylinder head side surface. 2 O-ring (58) of fuel injector (57) and head side of mounting hole: Engine oil (EO15W-40) 3) While aligning convex and concave shapes at (A), install holder (54) to fuel injector (57).

D61EM-23M0

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50 Disassembly and assembly Engine and cooling system

4) Install fuel injector assembly (55) into the cylinder head with the fuel inlet hole toward the air intake manifold. 5) Tighten holder mounting bolt (53) by 3 to 4 threads. 6) Check inlet connector on the following points. If any abnormality is found, replace it. 1] When there are burrs or wear on top-end part (a) or rear-end part (b) of inlet connector. 2] When there is foreign matter on edge filer at rear-end part (c) of inlet connector. 3] Cracks or deterioration are recognizable on the O-ring of the inlet connector upper (d) portion.

7) Apply engine oil to O-ring (part C) and head side (part B) of inlet connector (52). 2 O-ring of inlet connector and head side of mounting hole: Engine oil (EO15W-40) 8) Insert inlet connector (52) to the mounting hole of fuel injector assembly (55) and tighten retaining nut (51) lightly. a After tightening lightly, it is tightened to the specified torque. Be sure to tighten it to the specified torque in both steps. If a bolt or a nut is tightened insufficiently or too strongly, fuel may leak into the engine. a Install inlet connector so that its positioning ball (part D) fits in guide groove part on head side. 3 Retaining nut (51) (tightening lightly): 15 ± 5 Nm {1.53 ± 0.51 kgm}

4] When there is a worn part or an uneven seat contact mark on seat surface (e) at front-end of inlet connector. a If high-pressure fuel leaks through the inlet connector, seat surface has fine streaks or cracks. 9) Tighten mounting bolts (53) of holder (54) alternately. 3 Holder mounting bolt (53): 8 ± 0.8 Nm {0.82 ± 0.08 kgm} 10)Tighten retaining nut (51) of inlet connector (52).

50-36

D61EM-23M0

50 Disassembly and assembly

Engine and cooling system

3 Retaining nut (51) (tightening to the specified torque): 50 ± 5 Nm {5.1 ± 0.5 kgm}

3 Mounting bolt (46): 36 ± 5 Nm {3.7 ± 0.5 kgm} 2) Adjust the valve clearance. a See Testing and adjusting, "Testing and adjusting valve clearance". 3) After adjusting valve clearance, check that lock nut (49) is tightened to the specified torque. 3 Lock nut: 24 ± 4 Nm {2.45 ± 0.41 kgm} 4) Install harness mounting nuts (45) of fuel injector assembly (55). a Check that wiring harness does interfere with rocker arm. a Wiring harness mounting position Color of wiring harness White Black

Cylinder No. 1, 3, 5 2, 4, 6

3 Mounting nut: 1.5 ± 0.25 Nm {0.15 ± 0.03 kgm} a When installing the currently removed fuel injector wiring harness connector (60), apply liquid gasket to O-ring (61) and flange surface (62) of connector. 2. Rocker arm and crosshead assembly 1) Install rocker arm assembly (47), crosshead (48), and the rocker arm support. a Shape of hole in (a) and (b) portions of cross head is not identical. So when reusing them for the same intake or exhaust valve, be sure to install them in the same direction.

a As for O-ring, apply liquid gasket (f:3 mm in diameter) until O-ring groove is completely hidden. a When O-ring is damaged, replace an entire wiring harness assembly. 2 O-ring and flange surface of connector: Liquid gasket (LG-7) 3 Connector flange mounting bolt (63): 10 ± 2 Nm {1 ± 0.2 kgm}

a Check that spherical portion of adjustment screw (50) is fitted securely to socket of push rod, and then tighten the mounting bolt (46).

D61EM-23M0

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50 Disassembly and assembly Engine and cooling system

3. Cylinder head cover 1) Fit the gasket and install cylinder head cover (43). 2) Tighten mounting nut (42). 3 Mounting nut (42): 24 ± 4 Nm {2.45 ± 0.41 kgm} 3) Install the O-ring and blowby duct (41). 3 Mounting bolt: 7 ± 2 Nm {0.7 ± 0.2 kgm}

4. Fuel high-pressure pipe k Do not bend the fuel high-pressure pipe

to correct before installing. k Be sure to use the genuine fuel high-

pressure pipe clamp and strictly observe the specified tightening torque. k Install each fuel high-pressure pipe and

wiring harness at least 10 mm apart from each other. a A fuel high-pressure pipe may cause fuel leakage if visible lengthwise streaks (b) or spots (c) are found at the joint's taper seal at part (a) (within 2 mm from the end), or the stepped wear at part (d) (2 mm from the end of taper seal) is as severe as it can be felt with a fingernail. If there is any of those defects, replace the fuel high-pressure pipe. 50-38

1) Tighten common rail mounting nut, bolt (39a), and fuel high-pressure pipes (40a) to (40f) lightly. 3 Mounting nut, bolt, and sleeve nut (lightly tightening): 0.2 to 0.8 Nm {0.02 to 0.08 kgm} 2) Tighten fuel high-pressure pipes (40a) to (40f) to the specified torque according to the following procedure. 1] Fuel high-pressure pipes (40a) to (40c): In the order from (40a) to (40c), inlet connector side o common rail side 2] Fuel high-pressure pipes (40d) to (40f): In the order from (40d) to (40f), inlet connector side o common rail side 3 Sleeve nut: 35 ± 3.5 Nm {3.57 ± 0.36 kgm} 3) Lightly tighten fuel high-pressure pipe (38) and tube clamp. 4) Tighten fuel high-pressure pipe (38) in the order of supply pump side o common rail side. 3 Sleeve nut: 35 ± 3.5 Nm {3.57 ± 0.36 kgm} 5) Tighten common rail mounting nuts and bolts (39a) (4 pieces). a Apply liquid gasket to threaded portion of bolts (P) (2 pieces) inside engine. 2 Threaded portion of bolt (P): Liquid gasket (LG-7) 3 Mounting nut and bolt: 24 ± 4 Nm {2.45 ± 0.41 kgm} 6) Fasten tube clamp to the specified torque. 3 Mounting bolt: 24 ± 4 Nm {2.45 ± 0.41 kgm} 7) Install fuel spray prevention cap (39). k When installing the fuel spray

prevention caps, direct their slits outward or downward. D61EM-23M0

50 Disassembly and assembly

Engine and cooling system

[*8] 3 Fuel injector harness connector (60) mounting bolt:

• Perform subsequent installation in the reverse order to removal. [*4]

10 ± 2 Nm {1.0 ± 0.2 kgm} • Checking for fuel leakage (fuel system) Check the fuel system for leakage. For details, see Testing and adjusting, "Checking fuel circuit for leakage". • Bleeding air (fuel system) Bleed air from the fuel circuit. For details, see Testing and adjusting, "Bleeding air from fuel circuit".

3 Tube clamp (26) mounting bolt: 24 ± 4 Nm {2.5 ± 0.4 kgm} [*5] 3 Fuel return tube (27) joint bolt: 24 ± 4 Nm {2.5 ± 0.4 kgm} [*6] 3 Air connector (31) mounting bolt: 24 ± 4 Nm {2.5 ± 0.4 kgm} a Replace the gasket with a new one. [*7] 3 Air inlet connector (32) mounting bolt: 24 ± 4 Nm {2.5 ± 0.4 kgm} a Replace the gasket with a new one. a When installing the gasket, the part No. tag position (b) must be placed at the rear of the engine.

D61EM-23M0

50-39

50 Disassembly and assembly Engine and cooling system

Removal and installation of cylinder head assembly

Symbol

Part No.

2 4 5 A 6

795-799-6700 795-799-8150 790-331-1120 795-790-4510 Commercially 12 available

Part name Puller Remover Wrench (angle) Gauge Long socket (7/16 inches)

Necessity Q'ty

a Special tools

t q q q

4. Loosen coolant drain valve (2) to drain the coolant. 6 Radiator: 45 l

1 1 1 1

q 1

k Place machine on a level ground, and set

parking brake lever to LOCK position. k Lower the work equipment to the ground,

and set the work equipment lock lever to LOCK position. k Turn the starting switch to OFF position, and

stop the engine. k Turn the battery disconnect switch to OFF

position, and remove the key. (For details, see Testing and adjusting, "Handling of battery disconnect switch".) k If you drain the coolant when it is still hot,

you may be scalded. Wait until the coolant temperature drops before starting the work.

Removal

(D61-A100-520-K-00-A)

1. Remove engine hood assembly. For details, see "Removal and installation of engine hood assembly". 2. Collect refrigerant (R134a) from the air conditioner circuit. For details, see "Removal and installation of air conditioner compressor assembly". [*1]

5. Remove wiring harness clamps (3) (5 pieces) and disconnect the following wiring harness connectors. • • • • •

Connector 23 (4) Terminal T6 (5) Terminal T12 (6) Terminal T5 (7) Ground (8)

6. Disconnect fuel hoses (21) and (22). 7. Remove fuel filter and bracket (23). 8. Remove oil level gauge (24). 9. Remove bracket (25).

D61EM-23M0

50 Disassembly and assembly

Engine and cooling system

10.Remove tube clamp (26). [*5] 11.Disconnect fuel return tube (27). [*6] 12.Remove bracket (28).

13.Remove bracket (29).

17.Disconnect wiring harness cable ties (34) (2 pieces). 18.Disconnect fuel injector connectors (35) (3 pieces). 19.Disconnect common rail pressure sensor wiring harness connector (36). 20.Disconnect boost temperature and pressure sensor wiring harness connector (37).

14.Disconnect wiring harness connector RH (30). 15.Disconnect air connector (31). [*7] 16.Remove air inlet connector (32). [*8] a When removing mounting bolt from part (a) of air inlet connector (32), disconnect front side connector (33) to prevent interference with the tool.

21.Remove mounting bolts and leave fuel injector wiring harness connectors (60) (3 pieces) free. [*9] a This is to prevent interference of the fuel high-pressure pipe sleeve nut tool. 22.Remove fuel spray prevention caps (39) (14 pieces). 23.Remove fuel high-pressure pipes (40) (6 pieces). 24.Remove tube clamp, and disconnect fuel highpressure pipe (38).

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50 Disassembly and assembly Engine and cooling system

25.Loosen common rail mounting nuts and bolts (39a) (4 pieces).

26.Remove alternator and air conditioner compressor belt (42). For details, see "Removal and installation of alternator and air conditioner compressor belt". [*10] 27.Remove air conditioner compressor assembly (43). For details, see "Removal and installation of air conditioner compressor assembly". [*11] 28.Remove bracket (44).

31.Remove wiring harness bracket (48) and the bracket spacer (50). 32.Disconnect the wire harness connector (49).

33.Remove bracket (51). 34.Disconnect water hoses (52) and (53). [*13]

29.Remove oil filler tube (45).

35.Disconnect air tube (56a). 36.Disconnect drain tube (57). [*15]

30.Remove fuel return hose joint bolt (47). [*12]

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Engine and cooling system

37. 38.Remove wiring harness clamps (58) (2 pieces), and remove bracket (59).

39.Remove right blade lift cylinder cover (59a).

44.Remove the U-bolt, from bracket (72). [*21] and remove the bracket (72). 45.Remove the V-clamp (73) to disconnect the pipe from the muffler [22]. a Note the position of the V-clamp. 46.Remove V-clamp (74), and disconnect the exhaust tube. a Note the end of the tube holds a slip joint, be carefull in handling tube. 47.Remove exhaust tube (75).

40.Remove Heat Shield (67). 41.Disconnect water hose (68).

48.Remove brackets (77), (77a), (77b), (78), (78a), (78b) and (78c). [*23]

42.Remove U-bolt (69). [*19] 43.Remove V-clamp (70) by using tool A12 (long socket), and disconnect exhaust tube (71). [*20] a Place marks before removal to indicate the direction of V-clamp (70). – 49.Disconnect the following wiring harness connectors from the alternator. [*24] • Terminal T17 (79a) • Terminal T15 (79b) • Terminal T16 (79c)

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50 Disassembly and assembly Engine and cooling system

50.Remove cover (79d). 51.Remove mounting bolts (79e) and (79f), and remove alternator assembly (79g).

52.Sling the turbo and exhaust manifold assembly. 53.Remove mounting bolts (81) (12 pieces).

54.Sling the turbo and exhaust manifold assembly (83), and remove them. a When disconnecting , be careful that the gasket does not fall off. 4 Turbo and exhaust manifold assembly (83): 40 kg

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55.Remove bracket (84), heat insulation plate (84b), and bracket (84c). [*26]

56.Remove blowby duct (76) from rear of the engine. 57.Remove mounting nuts (82) (6 pieces) and cylinder head cover (85).

58.Remove wiring harness nut (86) from the fuel injector assembly. Color of wiring harness White Black

Cylinder No. 1, 3, 5 2, 4, 6

a Remove fuel injector wiring harness connector (97) from the rocker housing only when required. 59.Remove mounting bolts (87) (12 pieces), then remove rocker arm assembly (88), crosshead (89), and the rocker arm support.

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Engine and cooling system

a Loosen lock nuts (90) and then loosen adjustment screws (91) a few turns each to prevent excessive forces from working on the push rods when the rocker arms are installed. a Record the installed positions and directions of the crossheads (shapes of holes at portions (a) and (b)). (This is necessary to reinstall them in the original directions.)

63.Remove push rod (98). 64.Remove mounting bolt (99), then remove rocker housing assembly (100).

60.Remove retaining nuts (92), then remove inlet connectors (93) (6 pieces). a Clean the surrounding area to remove mud and other contamination in advance to prevent them from entering the connector hole. a Use tool A4 to remove inlet connector (93). 61.Remove mounting bolts (94) of fuel injector assembly (96), then remove holder (95). 62.Remove fuel injector assembly (96) by using tool A2.

65.Remove mounting bolts (101) (26 pieces), then remove cylinder head assembly (102). 4 Cylinder head assembly (102): 75 kg 66.Remove cylinder head gasket (103).

a Be careful that dirt and foreign material do not enter the fuel injector assembly mounting area.

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50 Disassembly and assembly Engine and cooling system

a Apply engine oil to mounting bolt threads and bolt head seat surface. 2 Threaded portion and seat surface of head of mounting bolt: Engine oil (EO15W-40) 3 Mounting bolt: 1] 90 ± 3 Nm {9.2 ± 0.3 kgm} 2] 90 ± 3 Nm {9.2 ± 0.3 kgm} 3] 90 ± 5 degrees. (Use tool A5 to angle tighten)

Installation

(D61-A100-720-K-00-A)

1. Cylinder head assembly 1) Measure stem length "a" of every cylinder head mounting bolt and check that it is within the using limit. • Using limit length of bolt: less than 132.1 mm a If a bolt is longer than the using limit, do not reuse it but replace it. a Use tool A6 for measurement.

2) Install cylinder head gasket (103) to cylinder block. a Check that cylinder head mounting surface and inside of cylinders are free from dirt or foreign matter.

• When not using an angle tightening tool, put a mark on cylinder head and bolt using a felt-tip pen and retighten bolt to 90 ± 5 degrees.

a Check that the holes in cylinder head gasket (103) are aligned with the holes in the cylinder head. 3) Install cylinder head assembly (102) in position on the cylinder block, and fingertighten mounting bolts (101) more than 2 to 3 turns. 4 Cylinder head assembly (102): 75 kg 4) Tighten mounting bolts (101) in the order shown in the figure as follows.

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2. Install rocker housing assembly (100) with mounting bolt (99). D61EM-23M0

50 Disassembly and assembly

Engine and cooling system

Note: Komatsu does not take any responsibility for special tools manufactured according to these sketches. 3 Mounting bolt: M1: Sleeve 24 ± 4 Nm {2.45 ± 0.41 kgm} 3. Install push rods (98). a Check that push rod is fitted to tappet. a Pour engine oil to push rod socket. 2 Push rod socket: Engine oil (EO15W-40)

4) Install fuel injector assembly (96) into the cylinder head with the fuel inlet hole toward the air intake manifold. 5) Tighten holder mounting bolt (94) by 3 to 4 threads. 6) Check inlet connector on the following points. If any abnormality is found, replace it.

4. Fuel injector assembly a When the fuel injector assembly is replaced with a new one, the inlet connector also should be replaced with a new one. Check M3:aPush toolthat fuel injector mounting sleeve (104) is free from dirt or other particles.

1) Install O-ring (106) and gasket (107) to fuel injector (105). a Replace O-rings and gasket with new ones. 2) Apply engine oil to O-ring (106) of fuel injector (105) and the cylinder head side surface.

1] When there are burrs or wear on top-end part (a) or rear-end part (b) of inlet connector. 2] When there is foreign matter on edge filer at rear-end part (c) of inlet connector. 3] Cracks or deterioration are recognizable on the O-ring of the inlet connector upper (d) portion.

2 Mounting holes of O-ring (106) and the head side of fuel injector (105): Engine oil (EO15W-40) 3) While aligning convex and concave shapes at (A), install holder (95) to fuel injector (105).

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50 Disassembly and assembly Engine and cooling system

7) Apply engine oil to O-ring (part C) and head side (part B) of inlet connector (93). 2 O-ring and head side of inlet connector: Engine oil (EO15W-40) 8) Tighten retaining nut (92) lightly. a After tightening lightly, it is tightened to the specified torque in the next step. Be sure to tighten it to the specified torque in both steps. If a bolt or a nut is tightened insufficiently or too strongly, fuel may leak into the engine. a Install inlet connector so that its positioning ball (part D) fits in guide groove part on head side. 3 Retaining nut (92) (tightening lightly): 15 ± 5 Nm {1.53 ± 0.51 kgm}

5. Rocker arm and crosshead assembly 1) Install rocker arm assembly (88), crosshead (89), and the rocker arm support. a Shape of hole in (a) and (b) portions of cross head is not identical. So when reusing them for the same intake or exhaust valve, be sure to install them in the same direction.

9) Tighten mounting bolts (94) of holder (95) alternately. 3 Holder mounting bolt (94): 8 ± 0.8 Nm {0.82 ± 0.08 kgm} 10)Tighten retaining nut (92) of inlet connector (93). 3 Retaining nut (92) (tightening to the specified torque): 50 ± 5 Nm {5.1 ± 0.5 kgm}

50-48

a Check that spherical portion of adjustment screw (91) is fitted securely to socket of push rod, and then tighten the mounting bolt (87). 3 Mounting bolt (87): 36 ± 5 Nm {3.7 ± 0.5 kgm} 2) Adjust the valve clearance. a See Testing and adjusting, "Testing and adjusting valve clearance". D61EM-23M0

50 Disassembly and assembly

Engine and cooling system

3) After adjusting valve clearance, check that lock nut (90) is tightened to the specified torque. 3 Lock nut: 24 ± 4 Nm {2.45 ± 0.41 kgm} 4) Install harness mounting nuts (86) of fuel injector assembly (96). a Check that wiring harness does interfere with rocker arm. a Wiring harness mounting position Color of wiring harness White Black

Cylinder No. 1, 3, 5 2, 4, 6

3 Mounting nut: 1.5 ± 0.25 Nm {0.15 ± 0.03 kgm} a When installing the fuel injector wiring harness connector (97) having been removed, apply liquid gasket to O-ring (108) and flange surface (109) of connector.

6. Cylinder head cover 1) Fit the gasket and install cylinder head cover (85). 2) Tighten mounting nut (82). 3 Mounting nut (82): 24 ± 4 Nm {2.45 ± 0.41 kgm} 3) Install the O-ring and blowby duct (76). 3 Mounting bolt: 7 ± 2 Nm {0.7 ± 0.2 kgm}

7. Fuel high-pressure pipe k Do not bend the fuel high-pressure pipe

to correct before installing. k Be sure to use the genuine fuel high-

pressure pipe clamp and strictly observe the specified tightening torque. k Install each fuel high-pressure pipe and

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50 Disassembly and assembly Engine and cooling system

• Perform subsequent installation in the reverse order to removal. [*1] a When installing the hose for the air conditioner circuit, be careful not to allow any invasion of dirt, dusts and water into the hose. a When installing the air conditioner hoses, check that O-rings (70) are fitted to each of their fittings. a Check that O-ring (70) is free from flaws and deterioration. a When connecting refrigerant piping, apply compressor oil (Denso: ND-OIL8) for the new refrigerant (R134a). Apply compressor oil (SANDEN: SP-20 PAG oil) for (R134a). Table of tightening torque for refrigerant pipe joint. Thread size 5/8 -18UNF 3/4 -16UNF 7/8 -14UNF

Tightening torque: Nm {kgm} 14.9 to 17.6 {1.6 to 1.8} 20.3 to 27.1 {2.1 to 2.7} 28.4 to 36.6 {2.9 to 3.7}

3 Mounting bolt: 24 ± 4 Nm {2.45 ± 0.41 kgm} 7) Install fuel spray prevention cap (39). k When installing the fuel spray

prevention caps, direct their slits outward or downward. 50-50

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50 Disassembly and assembly

Engine and cooling system

a Install alternator and air conditioner compressor belt. For details, see "Removal and installation of alternator and air conditioner compressor belt". [*11] a Install air conditioner compressor assembly (43). For details, see"Removal and installation of air conditioner compressor assembly". [*12] 3 Fuel return hose joint bolt (47): 24 ± 4 Nm {2.5 ± 0.4 kgm} [*5]

[*13]

3 Tube clamp (26) mounting bolt: 24 ± 4 Nm {2.5 ± 0.4 kgm}

• Installed dimensions of water hose (53) are shown in the following figure. Dimension (a): 46 mm Dimension (b): 15 mm

[*6] 3 Fuel return tube (27) joint bolt: 24 ± 4 Nm {2.5 ± 0.4 kgm}

3 Water hose (53) mounting clamp: 8.8 ± 0.5 Nm {0.9 ± 0.05 kgm}

[*7] 3 Air connector (31) mounting bolt: 24 ± 4 Nm {2.5 ± 0.4 kgm} a Replace the gasket with a new one. [*8] 3 Air inlet connector (32) mounting bolt: 24 ± 4 Nm {2.5 ± 0.4 kgm} a Replace the gasket with a new one. a When installing the gasket, the part No. tag position (b) must be placed at the rear of the engine.

3 Tube (55): 12 ± 2 Nm {1.2 ± 0.2 kgm} 3 Tube (56): 40 ± 5 Nm {4 ± 0.5 kgm} [*15] a Replace the gasket with a new one. 3 Drain tube (57): 24 ± 4 Nm {2.5 ± 0.4 kgm} [*19]

[*9] 3 Fuel injector harness connector (60) mounting bolt: 10 ± 2 Nm {1.0 ± 0.2 kgm} [*10]

a Temporarily install and adjust the position of all U-bolts before tightening to the specified torque. 3 U-bolt (69): 14.7 to 44.1 Nm {1.5 to 4.5 kgm} [*20], [*21], [*22] a Tighten V-clamps (70) and (73) by using tool A12 (long socket). a V-clamps (70) and (73) must be oriented so that the marks placed before removal are aligned.

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50 Disassembly and assembly Engine and cooling system

a Width across flats of V-clamp fastening nut: 7/16 in. (11.1 mm) a After fastening V-clamps (70) and (73), make sure trunnions and bands are not contacting each other. 3 V-clamps (70) and (73): 6.3 to 8.3 Nm {0.64 to 0.84 kgm} 3 Bracket (72) mounting U-bolt: 14.7 to 44.1 Nm {1.5 to 4.5 kgm}

[*23] • Install brackets according to the following procedure. 1. Install brackets (78c) and (77a) to bracket (77). 2. Adjust the direction and position of brackets (78a) and (77b). 3. Tighten the mounting bolts according to the following procedure. (A) o (B) o (C) o (A)

[*24] a Tightening torques are common for 60A and 90A alternators. 3 Terminal T17 (79a) mounting U-bolt: 2.4 to 3.0 Nm {0.24 to 0.30 kgm} 3 Terminal T15 (79b) mounting U-bolt: 4.6 to 6.9 Nm {0.47 to 0.70 kgm} 3 Terminal T16 (79c) mounting U-bolt: 2.4 to 3.0 Nm {0.24 to 0.30 kgm} [*26] 3 Bracket (84a) mounting bolt: a Although V-clamp can be reused, replace it with a new one when it is under the following condition. • V-clamp is deformed • Threads of T-bolt are crushed • V-groove is cracked • V-groove is flaking

24 ± 4 Nm {2.5 ± 0.4 kgm} 3 Heat insulation plate (84b) mounting bolt: 24 ± 4 Nm {2.5 ± 0.4 kgm} • Handling of common rail pressure sensor and pressure limiter 1. If necessary, replace common rail pressure sensor (112) according to the following procedure. a Do not remove common rail pressure sensor (112) from common rail (111) for a purpose other than replacement. a Be sure to replace the sensor removed from the common rail with a new sensor. 1) Before removing the common rail pressure sensor, clean the area around it to remove dirt, etc. throughly. 2) Remove the common rail pressure sensor.

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Engine and cooling system

3) Check the common rail pressure sensor connector for crack, breakage, damage of the seal, foreign matter on the pin and corrosion, bend and breakage of the pin. 4) Install a new common rail pressure sensor. 2 Thread portion of common rail pressure sensor: Gear oil (#90): 3 Common rail pressure sensor: 70 ± 5 Nm {7.1 ± 0.5 kgm} 5) Connect engine wiring harness. At this time, be careful not to connect the connector in reverse. 6) Start the engine and check for fuel leakage. a See "Checking fuel circuit for leakage" in Testing and adjusting for the testing procedure. 2. If necessary, replace pressure limiter (113) according to the following procedure. 1) Before removing pressure limiter, remove dirt and dusts on and around it. 2) Remove pressure limiter. a If leakage is beyond the specified value, pressure limiter concerned must not be used. 3) Check that there is no damage on highpressure fuel sealing surfaces (A) on the pressure limiter and common rail. 4) Install a new pressure limiter. 2 Pressure limiter: Gear oil (#90): 3 Pressure limiter:

100 ± 4 Nm {10.2 ± 0.4 kgm} a Excessive tightening can cause leakage. Be careful not to tighten too strongly. 5) Start the engine and check for fuel leakage. a See "Checking fuel circuit for leakage" in Testing and adjusting for the testing procedure.

D61EM-23M0

5 Radiator (engine coolant): 45 l (For details, see "Table of fuel, coolant and lubricants") • Checking for fuel leakage (fuel system) Check the fuel system for leakage. For details, see Testing and adjusting, "Checking fuel circuit for leakage". • Bleeding air (fuel system) Bleed air from the fuel circuit. For details, see Testing and adjusting, "Bleeding air from fuel circuit".

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50 Disassembly and assembly Engine and cooling system

Removal and installation of radiator assembly

k Place machine on a level ground, and set

parking brake lever to LOCK position. k Lower the work equipment to the ground,

and set the work equipment lock lever to LOCK position. k Turn the starting switch to OFF position, and

stop the engine. k Turn the battery disconnect switch to OFF

position, and remove the key. (For details, see Testing and adjusting, "Handling of battery disconnect switch".) k Loosen the cap of the hydraulic tank

gradually to release the pressure remaining inside the hydraulic tank. k If you drain the coolant when it is still hot,

you may be scalded. Wait until the coolant temperature drops before starting the work.

Removal

(D61-B220-520-K-00-A)

1. Collect refrigerant (R134a) from the air conditioner circuit. For details, see "Removal and installation of air conditioner compressor assembly". [*1] a Ask a qualified person for collecting, adding and filling operations of the refrigerant. (Only registered persons can work.) a Never release the refrigerant to the atmosphere. k If refrigerant gets in your eyes, you may

4. Remove the ROPS cab assembly. For details, see "Removal and installation of ROPS cab assembly." 5. Remove the cooling fan drive assembly. For details, see "Removal and installation of cooling fan drive assembly". 6. Remove mounting bolts (3) (3 pieces) and remove upper plate (4).

6 Radiator: 45 l

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Engine and cooling system

7. Remove mounting bolts (5) ( 2 pieces) and remove lower plate (6).

8. Remove mounting bolts (7) (2 pieces) and mounting bolts (8) ( 2 pieces). 9. Pull upward to remove L.H. shroud (9) and R.H. shroud (10).

12.Disconnect radiator lower hose (13). [*4]

13.Disconnect radiator overflow hose (14). 14.Remove brackets (15)

a Remove garbage, etc. from the lower insert part of shrouds (9) and (10) before pulling them out.

15.Sling radiator assembly (17), and remove it. [*5] 4 Radiator assembly (17): 44.3 kg

10.Disconnect radiator air bleeding hose (11). [*2] 11.Disconnect radiator upper hose (12). [*3]

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50 Disassembly and assembly Engine and cooling system

3 Radiator air bleeder hose (11) mounting clamp: 4.4 ± 0.5 Nm {0.45 ± 0.05 kgm}

Installation

(D61-B220-720-K-00-A)

[*3] • Installed dimensions of radiator upper hose (12) are shown in the following figure. Dimension (c): 62.8 mm Dimension (d): 15 mm 3 Radiator upper hose (12) mounting clamp: 8.8 ± 0.5 Nm {0.9 ± 0.05 kgm}

a When connecting the refrigerant pipes, apply compressor oil for new refrigerant (R134a) (SANDEN: SP-20 PAG oil) to O-ring (70). Table of tightening torque for refrigerant pipe joint. Thread size 5/8 -18UNF 3/4 -16UNF 7/8 -14UNF

Tightening torque: Nm {kgm} 14.9 to 17.6 {1.6 to 1.8} 20.3 to 27.1 {2.1 to 2.7} 28.4 to 36.6 {2.9 to 3.7}

[*4] • Installed dimensions of radiator lower hose (13) are shown in the following figure. Dimension (e): 50.7 mm Dimension (f): 15 mm 3 Radiator lower hose (13) mounting clamp: 8.8 ± 0.5 Nm {0.9 ± 0.05 kgm}

[*2] • Installed dimensions of radiator air bleeder hose (11) are shown in the following figure. Dimension (a): 10 mm Dimension (b): 37 mm

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5 Hydraulic tank (hydraulic oil): Only necessary quantity (For details, see "Table of fuel, coolant and lubricants") • Bleeding air (hydraulic system) Bleed air from the hydraulic pump circuit. For details, see Testing and adjusting, "Bleeding air from hydraulic system".

[*5] • Check that the projection (a) under the radiator gets securely into the mount rubber and mount rubber gets securely into the mount rubber receiving (b).

• Filling of refrigerant (R134) Refill the air conditioner circuit with refrigerant. a Filling quantity: 900 ± 50 g • Refilling of air conditioner compressor oil See Air conditioner, "Handling of compressor oil". • Refilling of coolant (radiator) Refill with coolant to the specified level through the coolant filler port. Run the engine to circulate the coolant through the system. Then check the coolant level again. 5 Radiator (engine coolant): 45 l (For details, see "Table of fuel, coolant and lubricants") • Refilling of oil (hydraulic tank) Refill with oil to the specified level through the oil filler port. Run the engine to circulate the oil through the piping. Then check the oil level again.

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50 Disassembly and assembly Engine and cooling system

Removal and installation of aftercooler assembly

k Place machine on a level ground and set

parking brake lever to LOCK position. k Lower the work equipment to the ground and

set the work equipment lock lever to LOCK position. k Turn the starting switch to OFF position and

stop the engine. k Turn the battery disconnect switch to OFF

position and remove the key. (For details, see Testing and adjusting, "Handling of battery disconnect switch".)

5. Remove mounting bolts (5) (2 pieces), and remove lower plate (6).

k Loosen the cap of the hydraulic tank

gradually to release the pressure remaining inside the hydraulic tank. k If you drain the coolant when it is still hot,

you may be scalded. Wait until the coolant temperature drops before starting the work.

Removal

(D61-A9A0-520-K-00-A)

6. Remove mounting bolts (7) (2 pieces) and mounting bolts (8) (2 pieces) 7. Pull upward to remove L.H. shroud (9) and R.H. shroud (10). a Remove garbage, etc. from the lower insert part of shrouds (9) and (10) before pulling them out.

k If refrigerant gets in your eyes, you may

lose your sight. And if it touches your skin, you may suffer from frostbite. Accordingly, put on the protective eyeglasses, gloves and working suits with long sleeves while you are collecting or filling the refrigerant. • Refrigerant to be collected: 900 ± 50 g 2. Remove the ROPS cab assembly. For details, see "Removal and installation of ROPS cab assembly." 3. Remove the cooling fan drive assembly. For details, see "Removal and installation of cooling fan drive assembly". 4. Remove mounting bolts (3) (3 pieces), and remove upper plate (4).

50-58

8. Remove the hydraulic oil cooler assembly. For details, see "Removal and installation of hydraulic oil cooler assembly". 9. Disconnect aftercooler upper hose (11). [*2]

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50 Disassembly and assembly

Engine and cooling system

10.Disconnect aftercooler lower hose (12). [*3]

Installation

(D61-A9A0-720-K-00-A)

11.Remove bracket (13).

a Check that O-ring (70) is free from flaws and deterioration. a When connecting the refrigerant pipes, apply compressor oil for new refrigerant (R134a) (SANDEN: SP-20 PAG oil) to O-ring (70). Table of tightening torque for refrigerant pipe joint. Thread size 5/8 -18UNF 3/4 -16UNF 7/8 -14UNF

Tightening torque: Nm {kgm} 14.9 to 17.6 {1.6 to 1.8} 20.3 to 27.1 {2.1 to 2.7} 28.4 to 36.6 {2.9 to 3.7}

12.Sling aftercooler assembly (14), and remove it. [*4] 4 Aftercooler assembly (14): 27 kg

[*2] • Installed dimensions of aftercooler upper hose (11) are shown in the following figure. Dimension (a): 69.2 mm Dimension (b): 22 mm Dimension (c): 10 mm

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50 Disassembly and assembly Engine and cooling system

a For the double clamps, slide the location of installation of 2 clamps as shown in the figure. 3 Aftercooler upper hose (11) mounting clamp: 10.5 ± 0.5 Nm {1.0 ± 0.05 kgm}

• Filling of refrigerant (R134) Refill the air conditioner circuit with refrigerant. a Filling quantity: 900 ± 50 g

[*3] • Installed dimensions of aftercooler lower hose (12) are shown in the following figure. Dimension (d): 22 mm Dimension (e): 67.8 mm Dimension (f): 10 mm a For the double clamps, slide the location of installation of 2 clamps as shown in the figure. 3 Aftercooler lower hose (12) mounting clamp: 10.5 ± 0.5 Nm {1.0 ± 0.05 kgm}

• Refilling of air conditioner compressor oil See Air conditioner, "Handling of compressor oil". • Refilling of coolant (radiator) Refill with coolant to the specified level through the coolant filler port. Run the engine to circulate the coolant through the system. Then check the coolant level again. 5 Radiator (engine coolant): Only necessary quantity (For details, see "Table of fuel, coolant and lubricants") • Refilling of oil (hydraulic tank) Refill with oil to the specified level through the oil filler port. Run the engine to circulate the oil through the piping. Then check the oil level again. 5 Hydraulic tank (hydraulic oil): Only necessary quantity (For details, see "Table of fuel, coolant and lubricants") • Bleeding air (hydraulic system) Bleed air from the hydraulic pump circuit. For details, see Testing and adjusting, "Bleeding air from hydraulic system".

[*4] • Check that the projection (a) under the aftercooler gets securely into the mount rubber and mount rubber gets securely into the mount rubber receiving (b).

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Engine and cooling system

Removal and installation of hydraulic oil cooler assembly

k Place machine on a level ground, and set

parking brake lever to LOCK position. k Lower the work equipment to the ground,

and set the work equipment lock lever to LOCK position. k Turn the starting switch to OFF position, and

stop the engine. k Turn the battery disconnect switch to OFF

position, and remove the key. (For details, see Testing and adjusting, "Handling of battery disconnect switch".)

5. Remove mounting bolts (5) (2 pieces) to remove lower plate (6).

k Loosen the cap of the hydraulic tank

gradually to release the pressure remaining inside the hydraulic tank. k If you drain the coolant when it is still hot,

you may be scalded. Wait until the coolant temperature drops before starting the work.

Removal

(D61-B8P0-520-K-00-A)

6. Remove mounting bolts (7) (2 pieces) and mounting bolts (8) (2 pieces). 7. Pull upward to remove L.H. shroud (9) and R.H. shroud (10). a Remove garbage, etc. from the lower insert part of shrouds (9) and (10) before pulling them out.

k If refrigerant gets in your eyes, you may

8. Disconnect oil hoses (11), (12), and (13). 9. Remove mounting bolts (14) (4 pieces), and remove oil cooler bypass valve (15). [*2] a Place an oil container under the oil cooler bypass valve (15). a Plug the disconnected hose and the mounting port to prevent oil leakage.

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50 Disassembly and assembly Engine and cooling system

Tightening torque: Nm {kgm} 14.9 to 17.6 {1.6 to 1.8} 20.3 to 27.1 {2.1 to 2.7} 28.4 to 36.6 {2.9 to 3.7}

10.Remove brackets (16) and (17).

11.Sling and remove hydraulic oil cooler assembly (18). [*3]

[*2] • Replace the O-rings on oil cooler bypass valve (15) with new ones.

4 Hydraulic oil cooler assembly (18):

3 Mounting bolt (14):

39.5 kg

39 ± 5 Nm {4 ± 0.5 kgm} [*3] • Check that the projection (a) under the hydraulic oil cooler gets securely into the mount rubber and mount rubber gets securely into the mount rubber receiving (b).

Installation

(D61-B8P0-720-K-00-A)

• Perform installation in the reverse order to removal. [*1] a When installing the hose for the air conditioner circuit, be careful not to allow any invasion of dirt, dusts and water into the hose.

• Filling of refrigerant (R134) Refill the air conditioner circuit with refrigerant.

a When installing the air conditioner hoses, check that O-rings (70) are fitted to each of their fittings.

a Filling quantity: 900 ± 50 g • Refilling of air conditioner compressor oil See Air conditioner, "Handling of compressor oil". • Refilling of coolant (radiator)

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Engine and cooling system

Refill with coolant to the specified level through the coolant filler port. Run the engine to circulate the coolant through the system. Then check the coolant level again. 5 Radiator (engine coolant): Only necessary quantity (For details, see "Table of fuel, coolant and lubricants") • Refilling of oil (hydraulic tank) Refill with oil to the specified level through the oil filler port. Run the engine to circulate the oil through the piping. Then check the oil level again. 5 Hydraulic tank (hydraulic oil): Only necessary quantity (For details, see "Table of fuel, coolant and lubricants") • Bleeding air (hydraulic system) Bleed air from the hydraulic pump circuit. For details, see Testing and adjusting, "Bleeding air from hydraulic system".

D61EM-23M0

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50 Disassembly and assembly Engine and cooling system

Removal and installation of cooling fan drive assembly

k Place machine on a level ground, and set

parking brake lever to LOCK position. k Lower the work equipment to the ground,

and set the work equipment lock lever to LOCK position. k Turn the starting switch to OFF position, and

stop the engine. k Turn the battery disconnect switch to OFF

position, and remove the key. (For details, see Testing and adjusting, "Handling of battery disconnect switch".) k Loosen the cap of the hydraulic tank

gradually to release the pressure remaining inside the hydraulic tank.

Removal

(D61-B400-520-K-00-A)

1. Remove top rubber cover (1).

5. Open the cooling fan drive assembly upward. a Lift up the cooling fan drive assembly to the maximum open position, and make sure it is locked. 6. Sling cooling fan guard (5) and remove it. 4 Cooling fan guard (5): 65 kg

2. Remove top cover (2).

7. Remove cooling fan net (6).

3. Remove cooling fan motor cover (3). 4. Remove cooling fan drive mounting bolts (4) (2 pieces) from the rear of the machine.

8. Remove wiring harness clamp (7), and disconnect harness connector CLG (8).

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Engine and cooling system

9. Remove hose clamp (9), and disconnect hose (10).

14.With gas cylinders (16) hanged, remove right and left link mounting pins (18).

a Plug the disconnected hose and the mounting port to prevent oil leakage. 10.Remove hose clamp (11), and disconnect hoses (12) and (13). a Plug the disconnected hose and the mounting port to prevent oil leakage.

15.Remove rubber cushion (19). a This is because it may interfere with pin when removing it.

11.Sling cooling fan drive assembly (14) at its fully raised position. 12.Remove covers (15) on right and left sides.

16.Remove right and left cooling fan drive assembly mounting pins (20). [*1]

13.Remove right and left gas cylinder (16) mounting pins (17).

D61EM-23M0

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50 Disassembly and assembly Engine and cooling system

17.Sling cooling fan drive assembly (14), and remove it. 4 Cooling fan drive assembly (14): 130 kg

Installation

(D61-B400-720-K-00-A)

• Perform installation in the reverse order to removal. [*1] • Securely install cotter pins to right and left mounting pins (20). • Refilling with oil (hydraulic tank) 5 Hydraulic tank (hydraulic oil): Only necessary quantity (For details, see "Table coolant and lubricants") • Air bleeding (fan pump circuit)

fuel,

a Bleed air from the circuit. For details, see Testing and adjusting "Bleeding air from fan pump".

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50 Disassembly and assembly

Engine and cooling system

Removal and installation of cooling fan motor assembly

k Place machine on a level ground, and set

parking brake lever to LOCK position. k Lower the work equipment to ground, and

set the work equipment lock lever to LOCK position. k Turn the starting switch to OFF position, and

stop the engine. k Turn the battery disconnect switch to OFF

position and remove the key. (For details, see Testing and adjusting, "Handling of battery disconnect switch".)

Removal

7. Reverse the cooling fan drive assembly. 8. Remove cooling fan net (8).

(D61-B5L0-520-K-00-A)

1. Remove the cooling fan drive assembly. For details, see "Removal and installation of cooling fan drive assembly". 2. Disconnect wiring harness connectors 14 (1) and FRS (2). 3. Remove backup alarm buzzer (3) mounting bolts (4) (3 pieces). 4. Disconnect wiring harness connector FAR (5). 5. Remove backup alarm buzzer (3) together with the bracket. 9. Remove mounting bolt (9) and lock plate (10). [*1]

10.Loosen mounting nuts (11). [*2] a Screw in mounting nuts (11) 2 or 3 turns to prevent the cooling fan from popping out. 11.Disconnect cooling fan (12) from the motor shaft by using puller [1]. 12.Remove nut (11) to remove cooling fan (12). [*3]

6. Remove mounting bolts (6) (2 pieces), and remove bracket (7).

D61EM-23M0

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50 Disassembly and assembly Engine and cooling system

16.Remove key (15) from the motor shaft. [*4]

13.Loosen mounting bolts (13) (4 pieces). 14.Reverse the cooling fan drive assembly. 15.Remove mounting bolts (13), and remove cooling-in fan motor assembly (14).

Installation

(D61-B5L0-720-K-00-A)

• Perform installation in the reverse order to removal. [*1], [*2] 1. Tighten mounting nut (11). 3 Mounting nut (11): 142 Nm {14.5 kgm} 2. Perform position alignment of lock plate (10). a Select either the front or rear side of lock plate (10) which can be used with less adjustment. Retighten mounting nut (11) until it reaches the mounting bolt hole. 3. Install mounting bolt (9). 2 Mounting bolt (9): Adhesive (LT-2) 3 Mounting bolt (9): 59 to 74 Nm {6.0 to 7.5 kgm} [*3] • Thoroughly remove dirt and degrease the fitting part of fan motor shaft and fan boss. [*4] • Securely install key (15) after confirming its direction.

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50 Disassembly and assembly

Engine and cooling system

Removal and installation of engine assembly

k Place machine on a level ground and set

parking brake lever to LOCK position. k Lower the work equipment to the ground,

and set the work equipment lock lever to LOCK position. k Turn the starting switch to OFF position,and

stop the engine. k Turn the battery disconnect switch to OFF

position, and remove the key. (For details, see Testing and adjusting, "Handling of battery disconnect switch".) k Loosen the cap of the hydraulic tank

gradually to release the pressure remaining inside the hydraulic tank. k If you drain the coolant when it is still hot,

you may be scalded. Wait until the coolant temperature drops before starting the work.

Removal

(D61-A000-520-K-00-A)

4. Remove mounting bolts (2a) (2 pieces), and open cooling fan drive assembly (2b) upward. a Lift up the cooling fan drive assembly (2b) to the maximum open position, and make sure it is locked.

2. Remove engine hood right side cover (1). 3. Loosen coolant drain valve (2) and (2a), and drain the coolant. 6 Radiator: 45 l

D61EM-23M0

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50 Disassembly and assembly Engine and cooling system

5. Open drain valve (3) at the rear of the hydraulic tank, and drain the hydraulic oil. 6 Hydraulic tank: 195 l

10.Remove wiring harness clamps (9) (4 pieces).

6. Remove engine hood assembly. For details, see "Removal and installation of engine hood assembly". 7. Remove the ROPS cab assembly. For details, see "Removal and installation of ROPS cab assembly." 8. Remove undercover (4) from the bottom of the HST pump. a Remove undercover (4) by using a transmission jack.

9. Disconnect the following hoses from the bottom of the HST Pump. [*2] • • • •

Hose PB1 green (5) Hose PA1 yellow (6) Hose PB2 blue (7) Hose PA2 red (8)

11.Open left side cover (10) from the left side of the machine, and disconnect wiring harness terminal TB (11).

12.Disconnect hydraulic hoses (12) and (13) from the left side of the HST Pump. [*3] a Place an oil container under the hose.

a Place an oil container under the hose. a Plug the disconnected hose and the mounting port to prevent oil leakage.

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Engine and cooling system

• Hose (25) • Hose (26) • Hose (27) a Plug the disconnected hose and the mounting port to prevent oil leakage.

13.Remove hose clamps (14) (2 pieces), and remove bracket (15). 14.Disconnect the following hydraulic hoses. • Hose (16) • Hose (17) • Hose (18) a Plug the disconnected hose and the mounting port to prevent oil leakage.

17.Disconnect the following wiring harness connectors. • Connector PSL (28) • Connector RME (29) • Connector LME (30) 18.Remove bracket (31), and fix it to the HST Pump side together with the wiring harness. 19.Remove mounting bolts (32) (2 pieces), and leave heater pipe (33) free.

15.Disconnect the following hydraulic hoses. • Hose (19) • Hose (20) • Hose (21) a Plug the disconnected hose and the mounting port to prevent oil leakage.

20.Disconnect hydraulic hose (34). a Plug the disconnected hose and the mounting port to prevent oil leakage.

16.Remove hose clamp (22), and disconnect the following hoses. • Hose (23) • Hose (24) D61EM-23M0

21.Close fuel valves (34a) and (34b). 50-71

50 Disassembly and assembly Engine and cooling system

22.Disconnect ground terminal (35) from the left side of the engine. 23.Disconnect fuel supply hose (36). a Plug the disconnected hose and the mounting port to prevent oil leakage.

25.Disconnect the following air hoses from the left side of the engine. [*5] • Intake manifold side hose (39) • Turbo side hose (40)

24.Disconnect the following water hoses from the right side of the engine. [*4] • Cylinder head side hose (37): • Cylinder block side hose (38):

26.Remove front ROPS cab mount cushion mounting bolts (41) (4 pieces), and then remove 50-72

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Engine and cooling system

right and left plates (42) together with the cushion.

30.Sling engine assembly (46), and remove it. 27.Remove engine mount bolts (43) (2 pieces). [*6]

a Ensure that all the wiring, piping, clamps, etc. are disconnected before removing. 4 Engine assembly (46): 1,235 kg

28.Remove front engine mount bolts (44) (2 pieces) from the right and left sides. [*7]

Installation

(D61-A000-720-K-00-A)

• Perform installation in the reverse order to removal. [*1] a When installing the hose for the air conditioner circuit, be careful not to allow any invasion of dirt, dusts and water into the hose.

29.Remove bracket (45). a Remove bracket (45). This is because the bracket (45) may interfere the sling wire.

a When installing the air conditioner hoses, check that O-rings (70) are fitted to each of their fittings. a Check that O-ring (70) is free from flaws and deterioration. a When connecting the refrigerant pipes, apply compressor oil for new refrigerant (R134a) (SANDEN: SP-20 PAG oil) to O-ring (70). Table of tightening torque for refrigerant pipe joint. Thread size 5/8 -18UNF 3/4 -16UNF 7/8 -14UNF

D61EM-23M0

Tightening torque: Nm {kgm} 14.9 to 17.6 {1.6 to 1.8} 20.3 to 27.1 {2.1 to 2.7} 28.4 to 36.6 {2.9 to 3.7}

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50 Disassembly and assembly Engine and cooling system

[*2]

[*4]

a Replace the O-ring with a new one. 3 Hoses (5), (6), (7), (8) mounting bolts: 98 to 123 Nm {10.0 to 12.5 kgm} [*3] • Installed dimensions of hoses (12) and (13) are shown in the following figure. Dimension (a): 5 mm Dimension (b): 8 mm Dimension (c): 62 mm Dimension (d): 10 mm Dimension (e): 13 mm Dimension (f): 70 mm a For the double clamps, slide the location of installation of 2 clamps as shown in the figure.

• Installed dimensions of cylinder head side hose (37) and cylinder block side hose (38) are shown in the following figure. Dimension (g): 15 mm Dimension (h): 55 mm Dimension (j): 45 mm Dimension (k): 15 mm Dimension (m): 15 degrees 3 Cylinder head side hose (37) mounting clamp: 8.8 ± 0.5 Nm {0.9 ± 0.05 kgm} 3 Cylinder block side hose (38) mounting clamp: 8.8 ± 0.5 Nm {0.9 ± 0.05 kgm}

3 Hoses (12) and (13) mounting clamps: 8.8 ± 0.5 Nm {0.9 ± 0.05 kgm}

[*5] 50-74

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Engine and cooling system

• Installed dimensions of intake manifold side hose (39) and turbo side hose (40) are shown in the following figure. Dimension (n): 24 mm Dimension (p): 10 mm Dimension (q): 60.5 mm Dimension (r): 63 mm Dimension (s): 22 mm Dimension (t): 5 mm Dimension (u): 2 degrees 5 minutes a For the double clamps, slide the location of installation of 2 clamps as shown in the figure. 3 Intake manifold side hose (39) mounting clamp: 10.5 ± 0.5 Nm {1.0 ± 0.05 kgm} 3 Turbo side hose (40) mounting clamp: 10.5 ± 0.5 Nm {1.0 ± 0.05 kgm}

• Refilling of coolant (radiator) Refill with coolant to the specified level through the coolant filler port. Run the engine to circulate the coolant through the system. Then check the coolant level again. 5 Radiator (engine coolant): 45 l (For details, see "Table of fuel, coolant and lubricants") • Refilling with oil (hydraulic tank) Refill with oil to the specified level through the oil filler port. Run the engine to circulate the oil through the piping. Then check the oil level again. 5 Hydraulic tank (hydraulic oil): 195 l (For details, see "Table of fuel, coolant and lubricants") • Bleeding air (hydraulic system) Bleed air from the hydraulic pump circuit. For details, see Testing and adjusting, "Bleeding air from hydraulic system". • Checking for fuel leakage (fuel system) Check the fuel system for leakage. For details, see Testing and adjusting, "Checking fuel circuit for leakage". • Bleeding air (fuel system) Bleed air from the fuel circuit. For details, see Testing and adjusting, "Bleeding air from fuel circuit".

[*6] 3 Rear engine mounting bolt (43): 784 to 980 Nm {80 to 100 kgm} [*7] 3 Front engine mounting bolt (44): 490 to 608 Nm {50 to 62 kgm} • Filling of refrigerant (R134) Refill the air conditioner circuit with refrigerant. a Filling quantity: 900 ± 50 g D61EM-23M0

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50 Disassembly and assembly Engine and cooling system

Disassembly and assembly of damper assembly

k Place machine on a level ground, and set

parking brake lever to LOCK position. k Lower the work equipment to the ground,

and set the work equipment lock lever to LOCK position. k Turn the starting switch to OFF position, and

stop the engine. k Turn the battery disconnect switch to OFF

position, and remove the key. (For details, see Testing and adjusting, "Handling of battery disconnect switch".)

Removal

(D61-CB00-520-K-00-A)

8. Remove damper mounting bolts (6) (8 pieces). [*2] 9. Remove damper (7).

5. Sling the damper case. 6. Remove mounting bolts (4) (12 pieces).

Installation

(D61-CB00-720-K-00-A)

• Perform installation in the reverse order to removal. [*1] 2 Mating face of damper case (5) Adhesive (LG-5) [*2] 7. Sling damper case (5) and remove it. [*1] 4 Damper case (5): 90 kg

50-76

2 Damper mounting bolt (6): Adhesive (LT-2) 3 Damper mounting bolt (6): 44.1 to 53.9 Nm {4.5 to 5.5 kgm}

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50 Disassembly and assembly

Engine and cooling system

Removal and installation of engine front oil seal

Symbol A

Part No.

5 790-331-1120 7 795-799-6400

Part name

Necessity Q'ty

a Special tools

Wrench (angle) Seal puller

q 1 t 1

a Be careful not to damage the oil seal contact surface of the crankshaft during removal.

k Place machine on a level ground and set

parking brake lever to LOCK position. k Lower the work equipment to the ground,

and set the work equipment lock lever to LOCK position. k Turn the starting switch to OFF position, and

stop the engine. k Turn the battery disconnect switch to OFF

position, and remove the key. (For details, see Testing and adjusting, "Handling of battery disconnect switch".)

Removal

(D61-A350-520-K-00-A)

1. Remove engine hood assembly. For details, see "Removal and installation of engine hood assembly". 2. Remove alternator and air conditioner compressor belt. For details, see "Removal and installation of alternator and air conditioner compressor belt". [*1] 3. Remove mounting bolts (22) (6 pieces), and then remove vibration damper (20).

Installation

(D61-A350-720-K-00-A)

1. Use tool A7 to install engine front oil seal (21). a Before installing the seal, check that the housing in the crank end face corner and lip sliding surface is free from flaws, burrs, sharp edges and rusts. a When installing the seal, do not apply oil or grease to the shaft and seal lip. Also, wipe away oil or grease thoroughly from the shaft. a Dimension from cover (c) of engine front oil seal (21) • Protrusion (x): Max. 0.38 mm • Facial runout (y): Max. 0.25 mm

4. Remove engine front oil seal (21) according to the following procedure. 1) Install tool A7 to the crankshaft. 2) Screw in tapping screw [1] of tool A7 to the seal carrier section of engine front oil seal (21). 3) Turn the handle clockwise to remove engine front oil seal (21).

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50 Disassembly and assembly Engine and cooling system

2. Install vibration damper (20). 1) Install vibration damper (20) while aligning its dowel hole to dowel pin (a) of the crankshaft. 2) Tighten vibration damper mounting bolts (22). 3 Vibration damper mounting bolt: 1) Tighten the bolts diagonally with a torque of 55 ± 5 Nm {5.6 ± 0.5 kgm}. 2) Loosen the bolts 180 degrees. 3) Tighten the bolts diagonally with a torque of 55 ± 5 Nm {5.6 ± 0.5 kgm}. 4) Retighten 90 ± 5 degrees. in a diagonal order.

• Perform subsequent installation in the reverse order to removal. [*1] Install alternator and air conditioner compressor belt. For details, see "Removal and installation of alternator and air conditioner compressor belt". a Adjust the belt tension. For details, see Testing and adjusting, "Testing and adjusting air conditioner compressor belt tension".

a Use tool A5 to angle tighten.

• When an angle tightening tool is not used Put marks on the vibration damper and bolts with a felt-tip pen and retighten the bolts to 90 ± 5 degrees.

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Engine and cooling system

Removal and installation of engine rear oil seal Removal

(D61-A510-520-K-00-A)

1. Remove the engine assembly. For details, see "Removal and installation of engine assembly". 2. Remove the HST pump assembly. For details, see "Removal and installation of HST pump assembly". 3. Remove the damper assembly. For details, see "Removal and installation of damper assembly". 4. Remove mounting bolts (4), and set guide bolts [1] (2 pieces) in the bolt holes. 5. Sling flywheel assembly (4a) and pull it out. 6. Sling flywheel assembly (4a) and remove it 4 Flywheel assembly (4a): 35 kg

Installation

(D61-A510-720-K-00-A)

1. Install the engine rear oil seal (5) according to the following procedure. a Do not remove pilot [4] attached to engine rear oil seal (5) until it is inserted into the crankshaft. a Before installing the engine rear oil seal, degrease, clean and dry the crankshaft sealing face and the seal lip face to prevent oil leakage.

7. Remove engine rear oil seal (5) according to the following procedure. 1) Install tool A8 to the crankshaft. 2) Screw tapping screw [3] of tool A8 into the seal carrier of engine rear oil seal (5). 3) Turn the handle clockwise to remove rear oil seal (5). a Be careful not to damage the oil seal contact surface of the crankshaft during removal.

D61EM-23M0

2. Install pilot [4] to crankshaft (6), and insert engine rear oil seal (5) into flywheel housing (7). 3. Push in engine rear oil seal (5) further, and then remove pilot [4].

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50 Disassembly and assembly Engine and cooling system

4. Install engine rear oil seal (5) to the proper depth in flywheel housing (7) by using tool A8.

a Hold flywheel assembly (4a) by using plate [5] and tighten it.

a When inserting engine rear oil seal (5), be careful that there are no bend etc. on it. a Flywheel of engine rear oil seal (5) Protrusion from housing (7) X: Max. 0.38 mm

[*2] • Measurement of radial runout a Radial runout: Max. 0.13 mm 1. Install dial gauge [6] on the stand, and set it to flywheel housing (7). 2. Make the probe of dial gauge contact with spigot joint portion (a) or outer circumference of the flywheel at a right angle. 3. Rotate the flywheel 1 turn, and measure the values of the dial gauge pointer (the maximum and minimum readings). a When the flywheel rotated 1 turn, check that the dial gauge indicates the same value as it of the starting rotation. • Measurement of facial runout a Facial runout: Max. 0.20 mm • Perform subsequent installation in the reverse order to removal. [*1] a Tighten flywheel assembly mounting bolts (4) (8 pieces) in the order shown in the figure. 3 Flywheel assembly mounting bolt (4): 137 ± 7 Nm {13.97 ± 0.71 kgm}

50-80

1. Similarly to the measurement of radial runout, set the dial gauge so that its probe is at a right angle with the end face (b) near the outer circumference of the flywheel. a Perform the measurement with the crankshaft pulled to either the front or rear side of the engine to prevent errors caused by backlash.

D61EM-23M0

50 Disassembly and assembly

Engine and cooling system

2. Rotate the flywheel 1 turn, and measure the values of the dial gauge pointer (the maximum and minimum readings).

D61EM-23M0

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50 Disassembly and assembly Engine and cooling system

Removal and installation of engine hood assembly

k Place the machine on a level ground, and set

the parking brake lever to the LOCK position. k Lower the work equipment to the ground,

and set the work equipment lock lever to LOCK position. k Turn the starting switch OFF position, and

stop the engine. k Turn the battery disconnect switch to OFF

position, and remove the key. (For details, see Testing and adjusting, "Handling of battery disconnect switch".)

Removal

6. Disconnect air duct (8). [*1]

(D61-H500-520-K-00-A)

1. Remove exhaust pipe (1). 4 Exhaust pipe (1): 25 kg 2. Remove pre-cleaner (2). 3. Remove covers (3) and (4). 4. Open cover (5). 5. Remove covers (6) and (7).

7. Disconnect hose (10).

8. Disconnect connector NM1 (11).

9. Disconnect hoses (17) and (18) on the left side of the engine. 50-82

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Engine and cooling system

a Remove clamps (2 pieces). 10.Remove mounting bolts (19).

14.Remove engine hood mounting bolts (25) (2 pieces each on right and left sides). [*3] 11.Remove clamp (20)

15.Sling engine hood assembly (26), and remove it. a Be careful that it does not interfere with the engine and peripheral parts during removal.

12.Remove cover (22), and remove engine hood mounting bolt (23). [*3] a Remove the cover and mounting bolt on the right side of the machine in the same way.

13.Remove the undercover, and remove engine hood mounting bolt (24). [*3]

4 Engine hood assembly (26): 330 kg

Installation

(D61-H500-720-K-00-A)

• Perform installation in the reverse order to removal. [*1] 3 Clamp of air duct (8): 10.5 ± 0.5 Nm {1.07 ± 0.05 kgm} [*3]

D61EM-23M0

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50 Disassembly and assembly Engine and cooling system

3 Engine hood mounting bolts (23), (24), and (25): 235 to 285 Nm {23.5 to 29.5 kgm}

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50 Disassembly and assembly

Engine and cooling system

Removal and installation of fuel tank assembly k Place the machine on a level ground, and set

the parking brake lever to LOCK position. k Lower the work equipment to the ground,

and set the work equipment lock lever to LOCK position. k Turn the starting switch to OFF position, and

stop the engine.

2. Remove the ROPS cab assembly. For details, see "Removal and installation of ROPS cab assembly." 3. Remove the gas cylinder. For details, see "Removal and installation of cooling fan drive assembly". 1) Sling cooling fan guard (1) and remove it. 4 Cooling fan guard (1): 65kg

k Turn the battery disconnect switch to OFF

position, and remove the key. (For details, see Testing and adjusting, "Handling of battery disconnect switch".) k Loosen the cap of the hydraulic tank

gradually to release the pressure remaining inside the hydraulic tank. k If you drain the coolant when it is still hot,

you may be scalded. Wait until the coolant temperature drops before starting the work.

Removal

(D61-AD10-520-K-00-A)

1. Collect refrigerant (R134a) from the air conditioner circuit. For details, see "Removal and installation of air conditioner compressor assembly". [*1]

2) Sling cooling fan drive assembly (2) at its fully raised position. 3) Remove covers (2a) on right and left sides.

a Ask a qualified person for collecting, adding and filling operations of the refrigerant. (Only registered persons can work.) a Never release the refrigerant to the atmosphere. If refrigerant gets in your eyes, you may lose your sight. And if it touches your skin, you may suffer from frostbite. Accordingly, put on the protective eyeglasses, gloves and working suits with long sleeves while you are collecting or filling the refrigerant.

4) Remove gas cylinder (2b) mounting pins (2c) on right and left sides.

k If refrigerant gets in your eyes, you may

lose your sight. And if it touches your skin, you may suffer from frostbite. Accordingly, put on the protective eyeglasses, gloves and working suits with long sleeves while you are collecting or filling the refrigerant. If refrigerant gets in your eyes, you may lose your sight. And if it touches your skin, you may suffer from frostbite. Accordingly, put on the protective eyeglasses, gloves and working suits with long sleeves while you are collecting or filling the refrigerant. • Refrigerant to be collected: 900 ± 50 g

D61EM-23M0

5) With gas cylinders (2b) hanged, remove link mounting pins (2d) on right and left sides.

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50 Disassembly and assembly Engine and cooling system

4. Open drain valve (3) of the fuel tank, and drain the fuel.

Remove cover (4).

Remove harness clamps (5) (3 pieces), and disconnect the following harness connectors. q Connector LD1 (6) q Connector WPCR (7) q Connector RCW (8) q Connector WELR (9) q Connector BLR (10) q Connector SSRR (11) q Connector SSLR (12) q Connector WPV (13) q Connector SSLB (14) q Connector SSRB (15) q Connector LD (16) q Connector BRV (17) q Connector SSLA (18) q Connector SSRA (19) q Connector LU (20) Remove brackets (21) and (22).

Remove harness clamps (23) (3 pieces), and disconnect the following harness connectors. q Connector AL (24) q Connector TL (25) q Connector FAC (26) q Connector AR (27) q Connector TR (28) q Connector WP (29) Disconnect hose (30). a Plug the disconnected hose and its connection port in order to prevent oil from flowing out.

6 Fuel tank: 372 l 5. Close fuel valve (3a), and disconnect fuel supply hose (3b). 6. Close fuel valve (4), and disconnect fuel supply hose (4a).

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Engine and cooling system

14. Disconnect hose (38). a Plug the disconnected hose and the mounting port to prevent oil leakage.

10. Disconnect hoses (31), (32), and (33) from the inside. 11. Remove hose clamps (33a) (2 pieces), and disconnect fuel return hose (33b). 12. Disconnect accumulator hose (33c). a Plug the disconnected hose and the mounting port to prevent oil leakage.

13. Disconnect the following hoses. q Hose (34) q Hose (35) q Hose (36) q Hose (37) (8 pieces) a Plug the disconnected hose and the mounting port to prevent oil leakage.

D61EM-23M0

15. Remove wiring harness clamps (39) (4 pieces), and disconnect the following wiring harness connectors. q Connector FM1 (40) q Connector 13 (41) (fuel level sensor)

16. Remove upper mounting bolts (42) (4 pieces). [*2]

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50 Disassembly and assembly Engine and cooling system

17. Sling the fuel tank assembly. 18. Remove lower mounting bolts (43) (4 pieces) and mounting bolts (44) (6 pieces). [*3]

[* ] 19. Sling fuel tank assembly (45), and remove it. 4

Fuel tank assembly (45): 350 kg

3 Upper part mounting bolt ("/): 490 to 565 Nm {50 to 58 kgm} [*3] 3 Lower part mounting bolts ("9) and (""): 490 to 565 Nm {50 to 58 kgm} • Filling of refrigerant (R134) Refill the air conditioner circuit with refrigerant. a Filling quantity: 900 ± 50 g • Refilling of air conditioner compressor oil See Air conditioner, "Handling of compressor oil". • Refilling of coolant (radiator) Refill with coolant to the specified level through the coolant filler port. Run the engine to circulate the coolant through the system. Then check the coolant level again. 5 Radiator (engine coolant):

Installation

(D61-AD10-720-K-00-A)

• Perform installation in the reverse order to removal. [*1] a When installing the hose for the air conditioner circuit, be careful not to allow any invasion of dirt, dusts and water into the hose. a When installing the air conditioner hoses, check that O-rings (70) are fitted to each of their fittings. a Check that O-ring (70) is free from flaws and deterioration. a When connecting the refrigerant pipes, apply compressor oil for new refrigerant (R134a) (SANDEN: SP-20 PAG oil) to O-ring (70). Table of tightening torque for refrigerant pipe joint. Thread size 5/8 -18UNF 3/4 -16UNF 7/8 -14UNF 50-88

Tightening torque: Nm {kgm} 14.9 to 17.6 {1.6 to 1.8} 20.3 to 27.1 {2.1 to 2.7} 28.4 to 36.6 {2.9 to 3.7}

Only necessary quantity (For details, see "Table of fuel, coolant and lubricants") • Refilling of oil (hydraulic tank) Refill with oil to the specified level through the oil filler port. Run the engine to circulate the oil through the piping. Then check the oil level again. 5 Hydraulic tank (hydraulic oil): Only necessary quantity (For details, see "Table of fuel, coolant and lubricants") • Bleeding air (hydraulic system) Bleed air from the hydraulic pump circuit. For details, see Testing and adjusting, "Bleeding air from hydraulic system". • Refilling of fuel (fuel tank) 5 Fuel tank (diesel fuel): 372 l (For details, see "Table coolant and lubricants")

fuel,

D61EM-23M0

50 Disassembly and assembly

Engine and cooling system

• Checking for fuel leakage (fuel system) Check the fuel system for leakage. For details, see Testing and adjusting, "Checking fuel circuit for leakage". • Bleeding air (fuel system) Bleed air from the fuel circuit. For details, see Testing and adjusting, "Bleeding air from fuel circuit".

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50 Disassembly and assembly Engine and cooling system

Removal and installation of muffler

Symbol A 12

Part No.

Part name

Commercially Long socket (7/16 inches) available

Necessity Q'ty

a Special tools

1 a Width across flats of V-clamp fastening nut: 7/16 in. (11.1 mm) a Be careful to the gasket at the tube connection that may fall off during the removal.

q 1

k Place machine on a level ground and set

parking brake lever to LOCK position. k Lower the work equipment to the ground and

set the work equipment lock lever to LOCK position. k Turn the starting switch to OFF position and

stop the engine. k Turn the battery disconnect switch to OFF

position and remove the key. (For details, see Testing and adjusting, "Handling of battery disconnect switch".) k The temperature of muffler is very high. Wait

5. Remove bracket (12) and U-bolt (13). 6. Remove V-clamp (14) and disconnect tube (15). a Remove tube (15). This is because the tube (15) may interfere the muffler assembly when slinging it.

until the piping around the engine cools down after the engine is stopped, and then start the removal work. k Check for any accumulated dirt and

combustibles (dead leaves, twigs, etc.) on the muffler, and remove them.

Removal

(D61-A9H0-520-K-00-A)

1. Remove engine hood assembly. For details, see "Removal and installation of engine hood assembly". 2. Remove insulator (6).

3. Remove U-bolts (8) and (9). [*2] 4. Remove V-clamps (10) and (11) by using tool A12 (long socket), and disconnect tube. [*3] a Place marks before removal to indicate the direction of V-clamps (10) and (11).

50-90

7. Remove double nuts (16) (4 places), then remove U-bolts (17) (2 pieces). [*4]

Installation

(D61-A9H0-720-K-00-A)

• Perform installation in the reverse order to removal. [*2], [*3] D61EM-23M0

50 Disassembly and assembly

Engine and cooling system

a Replace the gasket on the joint portion of the tube with a new one.

3 Double nut (16): 9.8 to 14.7 Nm {1.0 to 1.5 kgm}

a Temporarily install U-bolts (8) and (9) ,adjust the position of them, and tighten them to the specified torque. a Fasten V-clamps (10) and (11) by using tool A12 (long socket). a V-clamps (10) and (11) must be placed to match to the marks put before removal. a Width across flats of V-clamp fastening nut: 7/16 in. (11.1 mm) a After fastening V-clamps (10) and (11), make sure trunnions and bands are not contacting each other. 3 V-clamps (10) and (11): 6.3 to 8.3 Nm {0.64 to 0.84 kgm}

a Although V-clamp can be reused, replace it with a new one when it is under the following condition. • V-clamp is deformed • Threads of T-bolt are crushed • V-groove is cracked • V-groove is flaking

[*4] a Tighten nuts (16) according to the following procedure. 1. Tighten double nuts (16) at 4 places alternately. D61EM-23M0

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50 Disassembly and assembly Engine and cooling system

Removal and installation of belt for alternator and air conditioner compressor k Place machine on a level ground and set

parking brake lever to LOCK position. k Lower the work equipment to the ground,

k Be careful not to get your fingers caught

between the pulley and alternator and air conditioner compressor belt (4) during work.

and set the work equipment lock lever to LOCK position. k Turn the starting switch to OFF position, and

stop the engine. k Turn the battery disconnect switch to OFF

position, and remove the key. (For details, see Testing and adjusting, "Handling of battery disconnect switch".)

Removal

(D61-AT50-520-K-00-A)

1. Remove side cover (1) on the the right side of engine.

Installation

(D61-AT50-720-K-00-A)

• Perform installation in the reverse order to removal.

2. Remove alternator and air conditioner compressor belt (4) according to the following procedure. 1) Set wrench [1] to part A (width across flats: 12.7 mm) of the tensioner assembly. 2) Turn wrench [1] in the direction (R) to your side to decrease the alternator and air conditioner compressor belt (4) tension. 3) Remove alternator and air conditioner compressor belt (4). k Make sure before turning the wrench that

it is positively inserted into part A of the tensioner assembly. (Since the spring force of tensioner assembly (1) is strong, wrench [1] might come off and induce personal injury if it is turned when not securely attached.) k After removing alternator and air

conditioner compressor belt (4), slowly and carefully restore the tensioner assembly.

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50 Disassembly and assembly

Engine and cooling system

Removal and installation of air cleaner assembly

k Place machine on a level ground and set

parking brake lever to LOCK position. k Lower the work equipment to the ground,

and set the work equipment lock lever to LOCK position. k Turn the starting switch to OFF position, and

stop the engine. k Turn the battery disconnect switch to OFF

positio,n and remove the key. (For details, see Testing and adjusting, "Handling of battery disconnect switch".)

Removal

(D61-A910-520-K-00-A)

1. Remove engine hood right side cover (1).

4. Open the left side inspection window in the engine hood. 5. Remove bands (5) (2 pieces) and lower air cleaner assembly (6). [*2] a This is to loosen the mounting bolts of bracket (7).

2. Remove band (3). [*1] 6. Loosen mounting bolts of bracket (7), and remove bracket (7) and air cleaner (6) together.

3. Remove inside cover (4). a This is because the cover may interfere with the air cleaner when removing it.

Installation

(D61-A910-720-K-00-A)

• Perform installation in the reverse order to removal. [*1] 3 Band (3) mounting clamp: 10.5 ± 0.5 Nm {1.07 ± 0.05 kgm} [*2]

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50 Disassembly and assembly Engine and cooling system

• Installed position of air cleaner assembly (6) is shown in the following figure. Dimension (a): 153 mm Dimension (b): 198.5 mm Dimension (c):7 mm Dimension (d): 30 mm 3 Band (5) mounting clamp: 9.8 ± 1.0 Nm {1.0 ± 0.1 kgm}

• Check that bolt anchor part (e) of band (5) is on the top of bracket (7).

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50 Disassembly and assembly

Power train

Removal and installation of HST pump assembly

Removal

(D61-C172-520-K-00-A)

1. Remove the engine assembly. For details, see "Removal and installation of engine assembly". 2. Place engine assembly (1) on blocks [1]. 4 Engine assembly (1): 1,235 kg

3. Remove tube clamps (2) (2 pieces), and disconnect tubes (3) (2 pieces) from the HST Pump.

6. Sling the HST pump assembly. 7. Remove mounting bolts (10) (3 pieces) from each of the right and left sides. [*1]

4. Remove wiring harness clamps (4) (5 pieces) and wiring harness clamps (4a) (2 pieces). 5. Disconnect the following wiring harness connectors. • • • • •

Connector 12 (5) Connector LPR (6) Connector RF (7) Connector RPF (8) Connector LF (9)

D61EM-23M0

8. Sling HST pump assembly (11) and remove it. 4 HST pump assembly (11): 300 kg

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50 Disassembly and assembly Power train

Installation

(D61-C172-720-K-00-A)

• Perform installation in the reverse order to removal. [*1] 2 Mounting bolt (10): Adhesive (LG-5) 3 Mounting bolt (10): 490.3 to 608.9 Nm {50.0 to 62.0 kgm}

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50 Disassembly and assembly

Power train

Removal and installation of HST motor and final drive assembly

Symbol B

Part No.

3. Remove covers (1) to (3).

Part name

Necessity Q'ty

a Special tools

790-337-1001 Lifting tool

Removal

t 1

(D61-DF10-520-K-00-A)

1. Separate the track shoe assembly. For details, see "Separation and connection of track shoe assembly". k Loosen the cap of the hydraulic tank

gradually to release the pressure remaining inside the hydraulic tank. k Turn the starting switch to OFF position,

and stop the engine. k Turn the battery disconnect switch to OFF

position, and remove the key. (For details, see Testing and adjusting, "Handling of battery disconnect switch".) 2. Lift the machine by using a jack, and support the front and rear of the frame by placing blocks [1] and [2] under them. k Place blocks [1] and [2] securely.

4. Disconnect hoses (4) to (8). [*1] 5. Disconnect sensor (9). [*2] 6. Remove elbows (10) to (12). [*3]

7. Remove guard (13). [*4] a Sling it and remove it by using eyebolts (M12 x 1.75). 4 Guard (13): 30 kg

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50 Disassembly and assembly Power train

8. Remove sprocket teeth (14). [*5]

Installation

(D61-DF10-720-K-00-A)

• Perform installation in the reverse order to removal. [*1] 3 Hoses (7) and (8) flange bolts: 98 to 123 Nm {10 to 12.5 kgm} [*2] 3 Sensor (9) mounting bolt: 27 to 34 Nm {2.8 to 3.5 kgm} [*3] 9. Sling final drive assembly (15) by using tool B. 10.Remove mounting bolts (16) (26 pieces), and then remove the HST motor and final drive assembly (15) together. [*6] 4 Final drive assembly (15): 800 kg

3 Elbows (11) and (12) mounting bolts: 98 to 123 Nm {10 to 12.5 kgm} [*4] 2 Guard (13) mounting bolt: Adhesive (LT-2) 3 Guard (13) mounting bolt: 245 to 309 Nm {25 to 31.5 kgm} [*5] 2 Sprocket teeth (14) mounting bolt: Adhesive (LT-2) 3 Sprocket teeth (14) mounting bolt: 461 to 565 Nm {47 to 57 kgm} [*6] 2 Final drive assembly mounting bolt (16): Adhesive (LT-2) 3 Final drive assembly mounting bolt (16): 490 to 608 Nm {50 to 62 kgm} • Refilling of oil (hydraulic tank) Refill with oil to the specified level through the oil filler port. Run the engine to circulate the oil through the system. Then check the oil level again.

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5 Hydraulic tank: Only necessary quantity (For details, see "Table coolant and lubricants") • Bleeding air

fuel,

a Bleed air from the hydraulic circuit. For details, see Testing and adjusting, "Bleeding air from hydraulic system".

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50 Disassembly and assembly Power train

Disassembly and assembly of final drive

Part name

Necessity Q'ty

a Special tools

1 790-434-1050 Installer 2 01580-12419 Nut 3 01643-32460 Washer 1 4 790-101-2540 Washer 5 790-101-2102 Puller assembly 6 790-201-2850 Spacer 7 790-101-1102 Hydraulic pump C 2 791T-627-2210 Wrench 3 791T-627-2240 Installer 4 79A-264-0091 Ruler 5 791T-627-2220 Spacer 6 791T-627-2230 Spacer 1 790-201-1990 Plate 7 2 790-101-5021 Grip 3 01010-50816 Bolt

t 1 t 1 t 1 t 1 t 1 t 1 t 1 t 1 t 1 q 1 t 1 t 1 t 1 t 1 t 1

Symbol

Part No.

Disassembly

4. Cover 1) Remove mounting bolts (6) (20 pieces)

(D61-DF10-530-K-00-A)

1. Draining oil Remove the drain plug to drain the oil in the final drive case. 6 Final drive case: 8.3 l 2. Final drive assembly Place the final drive assembly on the block so that its HST motor side is down.

2) Disconnect cover (7) from the ring gear by using forcing screws [1].

a When turning over the final drive assembly, be careful not to damage speed sensor (1).

3) Remove cover (7) by using eyebolts [2] (2 pieces).

3. Segment teeth 1) Set the final drive assembly on the block with the cover side facing up. 2) Remove mounting nuts (4) (27 pieces), and remove segment teeth (5) (9 pieces).

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50 Disassembly and assembly

Power train

2) Install No. 1 planetary carrier assembly (11) by using eyebolts [4] (2 pieces).

5. Ring gear 1) Remove mounting bolts (8) (36 pieces) 3) Assemble No. 1 planetary carrier assembly according to the following procedure. 1] Drive pin (12) into shaft (13). 2] Remove shaft (13) from No. 1 planetary carrier assembly. 3] Remove pin (12) from shaft (13). 4] Remove thrust washers (14) (2 pieces), gear (15), and bearing (16) (1 pieces).

2) Install ring gear (9) by using eyebolts [3] (2 pieces).

7. No. 1 sun gear Remove No. 1 sun gear (17).

6. No. 1 planetary carrier assembly 1) Remove thrust washer (10).

8. No. 2 sun gear 1) Remove No. 2 sun gear (18).

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50 Disassembly and assembly Power train

2) Remove thrust washer (19) from No. 2 sun gear (18).

3) Remove ball (23). 4) Remove gear (24) from No. 2 planetary carrier assembly. 5) Remove bearings (25) (2 pieces) from gear (24).

9. O-ring Remove O-ring (20). 10.No. 2 planetary carrier assembly 1) Remove mounting bolts (21) (3 pieces)

6) Remove outer races (26) (2 pieces) from the gear.

2) Pull shaft (22) out of No. 2 planetary carrier assembly by using tool C1.

7) Remove thrust washer (27).

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50 Disassembly and assembly

Power train

4) Disassemble hub assembly (30) according to the following procedure. 1] Remove floating seal (31). 2] Remove mounting bolts (32) (18 pieces) 3] Remove retainer (33). 4] Remove bearing (34).

11.Hub assembly 1) Remove lock plate (28).

12.Floating seal Remove floating seal (35) from the HST motor case.

2) Remove nut (29) by using tool C2.

Assembly

(D61-DF10-710-K-00-A)

a Clean all parts ,and check them for dirt or damage before installation. a Apply power train oil (TO30) to the sliding surfaces of each part and install them. 3) Remove hub assembly (30) from the HST motor assembly by using eyebolts [5] (2 pieces).

1. Floating seal 1) Use tool C3 to install floating seal (35) to the HST motor case. a Install the floating seal after degreasing and drying the O-ring and O-ring contacting surface completely. a Push in the O-ring by using tool C3. a After inserting the floating seal, check its protrusion at αA to αD (4 places). a Check that the difference between maximum value and minimum value of protrusion α is 1 mm or less. a After installing the floating seal, apply oil (TO30) to the sliding surface lightly.

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50 Disassembly and assembly Power train

3 Mounting bolt: 98 to 123 Nm {10 to 12.5 kgm} 3] Install floating seal (31) to the retainer by sing tool C3. a For installation procedures, refer to Step 1.

2) Place hub assembly (30) on the HST motor assembly by using eyebolts [5] (2 pieces).

2. Hub assembly 1) Assemble the hub assembly according to the following procedure. 1] Press fit bearing (34) to the hub by using tool C5. a Press-fit the bearing until its outer race end comes in full contact with the hub. a After press fitting the bearing, check that a thickness gauge of 0.03 mm cannot go through the clearance between the outer race end and hub.

3) Tighten the nut and adjust the pre-load on the bearing according to the following procedure. a Adjust the pre-load under the condition that the temperature differences between each of HST motor case, bearing, hub, and nut are 3°C or lower. 1] Press-fit the inner race of the nut side bearing by using tool C6 and a press. a Pressing force on inner race: 12.7 to 16.7 kN {1.3 to 1.7 ton} a After installing hub assembly (30), rotate the hub 2 or 3 times on the HST motor case to settle the roller bearings.

2] Install retainer (33) with 18 mounting bolts (32). 2 Retainer mating face: Liquid gasket (LG-8) 50-104

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50 Disassembly and assembly

Power train

2] Tighten nut (29) to 500 Nm {51 kgm} by using tool C2. 1] Rotate the hub 3 turns clockwise and 3 turns counterclockwise against the HST motor case. 2] Tighten nut (29) again to 500 Nm {51 kgm}. 3] Loosen nut (29) to 353 Nm {36 kgm} or less. Do not loosen to a torque of 0 Nm. If loosened to 0 Nm, repeat the procedure from 2]. 4] Tighten nut (29) to 441 Nm {45 kgm}. 5] Rotate the hub 3 turns clockwise and 3 turns counterclockwise on the HST motor case. 6] Tighten nut (29) again to 441 Nm {45 kgm}.

5) Install lock plate (28). a If lock plate (28) is turned over, it deviates by 1/2 notch. Accordingly, install it so that its claws will be fitted to the notches of nut (29). 2 Mounting bolt threads: Adhesive (LT-2) 3 Mounting bolt: 58.8 to 73.5 Nm {6.0 to 7.5 kgm}

2 Nut (Contact surface of bearing): Molybdenum lubricant (LM-S)

disulfide

4) Make match marks (a) between nut (29) and the HST motor case. a If the lock plate claws do not engage with the notches of the nut, rotate the nut in the tightening direction within the torque range of 441 to 500 Nm {45 to 51 kgm}. Make sure that tightening angle of the nut is within 0 to 1/2 notches from the match marks.

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50 Disassembly and assembly Power train

6) Check that the tangential force of the hub is as follows by using tool C4.

3) Install bearings (25) (2 pieces) to gear (24).

a Tangential force at bolt hole on periphery of hub: 200 to 249 N {20.4 to 25.4 kg}

3. No. 2 planetary carrier assembly 1) Install thrust washer (27).

4) Insert gear (24) into the No. 2 planetary carrier assembly, and rotate gear (24) to settle the roller bearings. 5) Align the bearing and carrier holes and rotate gear (24) in both directions for more than 3 turns to settle the roller bearings further. Check that gear (24) can be rotated easily. 6) Install shaft (22) and ball (23) to the No. 2 planetary carrier assembly. a Install the shaft by expansion fit. k Do not touch the shaft by bare hands.

a When installing, apply grease to ball (23) and be careful not to let it come off.

2) Press-fit outer races (26) (2 pieces) into gear by using tool C7. a Press-fit until the outer race end comes in full contact with the gear. a After press fitting the outer races, check that a thickness gauge of 0.03 mm cannot go through the clearance between the outer race end and gear.

7) Tighten mounting bolts (21) (3 pieces). 2 Mounting bolt threads: Adhesive (LT-2)

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50 Disassembly and assembly

Power train

3 Mounting bolt: 490 to 608 Nm {50.0 to 62.0 kgm} a Check that gear (24) rotates smoothly. 4. O-ring Install O-ring (20).

7. No. 1 planetary carrier assembly 1) Assemble No. 1 planetary carrier assembly according to the following procedure.

5. No. 2 sun gear 1) Install thrust washer (19) to No. 2 sun gear (18).

a Replace the thrust washers and pin with new ones. 1] Install bearing (16) to gear (15). 2] Attach thrust washers (14) to the top and bottom of gear (15) and set them on the No. 1 planetary carrier assembly. 3] Align the pin hole in shaft (13) with the hole in the carrier, and tap shaft (13) with a plastic hammer to install the shaft. a Be careful not to damage thrust washer (14). 4] Drive in pin (12). a Remove burrs from the edges on the intersection of the pin (12) insertion hole and shaft (13) insertion hole in the No. 1 planetary carrier by using sandpaper

2) Install No. 2 sun gear (18).

a After driving in pin (12), swage part (a). (3 places) a When driving in pin (12), be careful that the claws (b) (3 places) on the periphery of the pin will not be placed on the thin-wall parts of No. 1 planetary carrier. 5] After assembling No. 1 planetary carrier assembly, check that gear (15) rotates smoothly.

6. No. 1 sun gear Install No. 1 sun gear (17).

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50 Disassembly and assembly Power train

2) Tighten mounting bolts (8) (36 pieces). 3 Mounting bolt: 245 to 309 Nm {25.0 to 31.5 kgm}

2) Install No. 1 planetary carrier assembly (11) by using eyebolts [4] (2 pieces). 9. Cover 1) Install cover (7) by using eyebolts [2] (2 pieces). a Degrease the mating faces of the cover and the ring gear. 2 Cover fitting face: Liquid gasket (LG-8)

3) Install thrust washer (10).

a Do not apply liquid gasket to the following places. • Tap holes in the cover and ring gear • Ring gear wheel • Magnet mounting part of cover

8. Ring gear 1) Install ring gear (9) by using eyebolts [3] (2 pieces).

2) Tighten mounting bolts (6) (20 pieces). 3 Mounting bolt: 157 to 196 Nm {16.0 to 20.0 kgm}

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50 Disassembly and assembly

Power train

1) Tighten the drain plug and supply oil through the oil filler port. 3 Drain plug: 58.5 to 78.4 Nm {6.0 to 8.0 kgm} 2) Tighten the oil filler plug. 3 Oil filler plug: 58.5 to 78.4 Nm {6.0 to 8.0 kgm} 5 Final drive case: 8.3l l 10.Segment teeth 1) Set segment teeth (5) (9 pieces) on the hub, and tighten mounting nuts (4) (27 pieces).

a After installing the final drive assembly to the chassis, check the oil level again.

2 Threaded portion of bolts: Adhesive (LT-2) 3 Mounting nut: 461 to 565 Nm {47 to 57 kgm}

2) Place the final drive assembly on the block so that its HST motor side is up. a Check that clearances (a) between the segment teeth are 0 to 2 mm. a Check that the radial clearance between the segment teeth and hub is 0 mm at both ends (b) and 0 to 0.5 mm at the center (c).

11.Refilling of oil

D61EM-23M0

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50 Disassembly and assembly Undercarriage and frame

Undercarriage and frame

Removal and installation of track frame assembly

Symbol

Part No.

790-337-1001

Removal

Part name

Necessity Q'ty

a Special tools

Lifting tool

t 1

(D61-DT20-520-K-00-A)

1. Separate the track shoe assembly. For details, see "Separation and connection of track shoe assembly". k Loosen the cap of the hydraulic tank

3. Remove covers (1) to (4).

gradually to release the pressure remaining inside the hydraulic tank. k Turn the starting switch to OFF position,

and stop the engine. k Turn the battery disconnect switch to OFF

position, and remove the key. (For details, see Testing and adjusting, "Handling of battery disconnect switch".) 2. Lift the machine by using a jack and support with blocks [1] and [2] placed under the front and rear of the frame. k Blocks [1] and [2] must be placed

securely.

4. Disconnect hoses (5) to (9). [*1] 5. Disconnect sensor (10). [*2]

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50 Disassembly and assembly

Undercarriage and frame

6. Remove brackets (11) and (12) in front of the HST motor.

10.Remove cover (16). [*4] 7. Remove bracket mounting bolts (13) in front of the pivot shaft.

11.Remove cover (17) of the equalizer bar end. [*5] a Remove oil refilling nipple (18) from inside cover (17). 8. Remove cover (14).

9. Remove guard (15). [*3] a Lift and remove by using eyebolts (M12 x 1.75). 4 Guard (15): 30 kg

12.Sling track frame assembly (19) by using tool B.

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50 Disassembly and assembly Undercarriage and frame

13.Remove plate (20), and pull off pin (21). [*6]

Installation

(D61-DT20-720-K-00-A)

• Perform installation in the reverse order to removal. [*1] 3 Hoses (8) and (9) flange bolts: 98 to 123 Nm {10 to 12.5 kgm} [*2] 3 Sensor (10) mounting bolt: 27 to 34 Nm {2.8 to 3.5 kgm} [*3] 14.Remove plate (22). [*7]

2 Guard (15) mounting bolt: Adhesive (LT-2) 3 Guard (15) mounting bolt: 245 to 309 Nm {25 to 31.5 kgm} [*4] 3 Cover (16) mounting bolt: 455 to 565 Nm {46.5 to 58 kgm} [*5] 3 Cover (15) mounting bolt (equalizer bar): 455 to 565 Nm {46.5 to 58 kgm} [*6]

15.Remove track frame assembly (19). [*8] a Place an oil container since oil flows out from the pivot shaft case. 4 Track frame assembly: 2,600 kg 6 Pivot shaft case: 4.5 l

2 Frame side boss portion: Molybdenum disulfide lubricant (LM-P) k When aligning the mounting holes pin, never

insert your fingers in the holes. [*7] 3 Plate (22) mounting bolt: 455 to 565 Nm {46.5 to 58 kgm} [*8] a Apply power train oil (TO30) to (a) surface of track frame (9) when installing the track frame assembly. a When installing seal (23), see "Removal and installation of pivot shaft assembly".

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50 Disassembly and assembly

Undercarriage and frame

• Refilling with oil (pivot shaft case) 5 Pivot shaft case: 4.5 l (power line oil: TO30) • Refilling with oil (hydraulic tank) Refill with oil to the specified level through the oil filler port. Run the engine to circulate the oil through the system. Then check the oil level again. 5 Hydraulic tank: Only necessary quantity (For details, see "Table coolant and lubricants") • Bleeding air

fuel,

a Bleed air from the hydraulic circuit. For details, see Testing and adjusting, "Bleeding air from hydraulic system".

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50 Disassembly and assembly Undercarriage and frame

Removal and installation of idler assembly Removal

(D61-DT90-520-K-00-A)

1. Separate the track shoe assembly. For details, see "Separation and connection of track shoe assembly".

5. Sling idler assembly (6), and pull it out forwards by using chain block [1]. 6. Remove right and left yoke mounting bolts (7) (3 pieces) and remove yoke (8). [*3]

k Turn the starting switch to OFF position,

and stop the engine. k Turn the battery disconnect switch to OFF

position, and remove the key. (For details, see Testing and adjusting, "Handling of battery disconnect switch".) 2. Loosen lubricator (2) to discharge the grease. k This is because the yoke will not be able

to remove when the pressure inside the cylinder for the recoil spring becomes negative. k Do not allow anyone to stay in front of the

idler during the work for safety.

7. Pull out idler assembly (6) to the position shown in the figure. Remove right and left sliders (9), springs (10) (2 pieces each), and plates (11) (2 pieces each). 8. Sling idler assembly (6), and remove it. 3. Remove right and left top support mounting bolts (3) (2 pieces). [*1] 4. Remove right and left side support mounting bolts (4) (4 pieces), and remove side support (5). [*2]

4 Idler assembly (6): 210 kg

a Since shims are used under side support (5), check and note the number and thickness of the shims.

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Undercarriage and frame

Installation

(D61-DT90-720-K-00-A)

• Perform installation in the reverse order to removal. [*1] 3 Top support mounting bolt (3): 98 to 123 Nm {10.0 to 12.5 kgm} [*2] • Adjust clearance (a) at side supports (5) to the dimension shown below by using shims (5a). Clearance (a) at side supports (5): 0.2 to 1.2 mm 2 Side support (5) mounting bolt: Adhesive (LT-2)

[*3] 3 Yoke mounting bolt (7): 235 to 285 Nm {23.5 to 29.5 kgm}

D61EM-23M0

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50 Disassembly and assembly Undercarriage and frame

Disassembly and assembly of idler

Symbol 1 L 2 3

Part No.

Part name

Necessity Q'ty

a Special tools

791-515-1520 Installer 791-601-1000 Oil pump 791-126-0211 Adapter

Disassembly

t 1 q 1 t 1

(D61-DT90-530-K-00-A)

1. Remove oil filler plug (1), and drain oil. 6 Idler: 0.21 to 0.23 l

2. Support 1) Remove nut (3), and remove bolt (4) by driving it out from the nut side.

3. Floating seal 1) Remove floating seal (7) from support (6).

2) Sling idler (5), and remove it from shaft and support assembly (8). a Use wire or rope to prevent sling rope [2] from fanning out. (part A) 3) Remove floating seals (9) and (10) from idler (5).

2) Remove support (6) from idler (5) by using push puller tool [1].

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4) Remove floating seal (11) from the shaft and support assembly. 4. Shaft 1) Remove nut (12) and remove bolt (13) by driving it out from the nut side. 2) Pull out shaft (15) from support (14). a O-rings are installed on both ends of shaft (15).

2. Idler 1) Fit the O-ring to shaft (15) and install the shaft to support (14). a When installing the shaft, align the groove in the shaft with the one in the support. 2) Drive in bolt (13) and tighten nut (12). 3 Nut (12): 230.4 to 308.9 Nm {23.5 to 31.5 kgm}

5. Remove bushings (16) (2 pieces) from idler (5). 3) Install floating seal (11) to shaft and support assembly (8) by using tool L1, and then install the O-ring to the shaft. a When installing the floating seal, degrease and dry the parts indicated with thick lines (O-ring and mating face of the O-ring). a Check that the leaning is less than 1 mm after the seal is inserted. a Check that the projection (a) of the seal is 7 to 11 mm after the seal is inserted.

Assembly

(D61-DT90-710-K-00-A)

1. Press-fit bushing (16) to idler by using tool L3.

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50 Disassembly and assembly Undercarriage and frame

4) Install floating seal (10) to idler (5) by using tool L1.

6) Install floating seal (9) to idler (5) by using tool L1.

a When installing the floating seal, degrease and dry the parts indicated with thick lines (O-ring and mating face of the O-ring).

a When installing the floating seal, degrease and dry the parts indicated with thick lines (O-ring and mating face of the O-ring). (See the figure)

a Check that the inclination is less than 1 mm and projection (a) is 7 to 11 mm after the seal is inserted. (See 3) above)

a Make sure that the inclination is less than 1 mm and projection (a) is 7 to 11 mm after the seal is inserted. (See 3) above)

5) Sling and install idler (3) to install it to shaft and support assembly (6). a Use wire or rope to prevent sling rope [2] from fanning out as shown in (A).

3. Refilling of oil Add power train oil to the idler. 6 Idler: 0.21 to 0.23 l 4. Support 1) Install floating seal (7) to support (6) by using tool L1.

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a When installing the floating seal, degrease and dry the parts indicated with thick lines (O-ring and mating face of the O-ring). a Check that the leaning is less than 1 mm after the seal is inserted. a Check that the projection (a) of the seal is 7 to 11 mm after the seal is inserted.

1) Normal method of refilling 1] Remove plug (1) from the shaft. 2] Add power train oil through the oil filler port up to the specified level. 6 Idler: 0.21 to 0.23 l 3] Install plug (1) to the the shaft after refilling with oil. 3 Plug (1): 156.8 to 254.8 Nm {16 to 26 kgm}

2) Filling by evacuation 1] Remove plug (1) from the shaft. 2] Fill the idler assembly with power train oil by using tool L2.

2) Install support (6) to idler (5). 3) Install bolt (4), and tighten nut (3). 3 Nut (3): 230.4 to 308.9 Nm {23.5 to 31.5 kgm}

6 Idler: 0.21 to 0.23 l 3] Install plug (1) to the the shaft after refilling with oil. 3 Plug (1): 156.8 to 254.8 Nm {16 to 26 kgm}

5. Fill the idler assembly with power train oil. a If refilling with oil is not performed in above Step 3, refill it in the following procedure. D61EM-23M0

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50 Disassembly and assembly Undercarriage and frame

Removal and installation of recoil spring assembly Removal

(D61-DTBP-520-K-00-A)

1. Separate the track shoe assembly. For details, see "Separation and connection of track shoe assembly". 2. Remove the idler assembly. For details see "Removal and installation of idler assembly". k Turn the starting switch to OFF position,

and stop the engine. k Turn the battery disconnect switch to OFF

position, and remove the key. (For details, see Testing and adjusting, "Handling of battery disconnect switch".) 3. Sling yoke and piston assembly (1), and remove them. 4 Yoke and piston assembly (1): 45 kg

4. Pull out recoil spring assembly (2), and sling it to remove. 4 Recoil spring assembly (2): 160 kg

Installation

(D61-DTBP-720-K-00-A)

• Perform installation in the reverse order to removal.

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Disassembly and assembly of recoil spring

Symbol

Part No.

Part name

1 791T-B30-1110 Sleeve 791-685-8006 Compressor (B) 791-635-3160 Extension 790-201-2770 Spacer M 2 790-101-1102 Pump assembly Cylinder (686 kN {70 790-101-1600 ton}) 3 796T-467-2160 Push tool

Disassembly

Necessity Q'ty

a Special tools

t t t t t

1 1 1 1 1

t 1 t 1

(D61-DTBP-530-K-00-A)

1. Remove yoke and piston assembly (2) from recoil spring assembly (1).

3. Remove mounting bolts (21) (4 pieces), and remove holder (13) from recoil spring case (12). k For safety reasons, no one is allowed to

2. Disassembly of yoke and piston assembly

be in front and back of the recoil spring assembly during the work.

1) Remove snap ring (3), then remove Upacking (4) and wear ring (5). 2) Remove bolt (7), and remove plate (8) and washer (9).

4. Disassembly of holder 1) Remove snap ring (14) from holder (13). 2) Remove spacer (15) and seal (15a) from holder (13). 3) Remove piston (11) from yoke (10) by using a press and tool M1. a If cylinder (19) is not broken and shaft end nut (16) is not fallen out, disassemble the yoke and piston as follows:

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50 Disassembly and assembly Undercarriage and frame

a There is a step (a) in case (12). Therefore, loosen the recoil spring tension while adjusting so that part (b) and part (c) of cylinder (19) do not come in contact.

5. Set recoil spring assembly (1) to tool M2. k Since the load at installed length of the

spring is large and dangerous, set the recoil spring assembly securely to the tool. a Load at installed length of spring:

9. Remove spring (18) and cylinder (19) from case (12). 10.Remove bushing (20) from cylinder (19).

163.6 kN {16,692 kg}

6. Apply hydraulic pressure slowly to compress the spring. 7. Tighten nut (16) until spacer (17) comes off, and remove spacer (17) and nut (16).

k If mounting bolt (21) is removed from

holder (13) when there are broken cylinder (19) and fallen out shaft end nut (16), the recoil spring fly off to the front of the machine. Thus, disassemble the yoke and position as follows: k Do not allow anyone to remain in front of

and at the back of the recoil spring assembly until the holder (13) is separated from case (12), the recoil spring is removed and safety is confirmed. 1) Set recoil spring assembly (1) to tool M2. k Since the load at installed length of the

8. Release hydraulic pressure gradually and relieve tension of the spring.

spring is large and dangerous, set recoil spring assembly securely to tool M2. a Load at installed length of spring: 163.6 kN {16,692 kg}

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2) Apply hydraulic pressure slowly to secure recoil spring assembly (1). 3) Under the condition of Step 2) above, remove mounting bolt (21) from holder (13). 4) Release hydraulic pressure gradually and relieve tension of the recoil spring.

4. Apply hydraulic pressure slowly to compress the recoil spring so that the installed length of the spring becomes specified value. a To protect the threaded portion when the spring is compressed, use lever block [2], etc. to center the recoil spring and compress it. a Installed length of recoil spring: 593 mm

Assembly

(D61-DTBP-710-K-00-A)

1. Press fit bushing (20) to cylinder (19). 2. Temporarily assemble case (12), spring (18), and cylinder (19). 3. Set temporarily assembled recoil spring assembly (1) to tool M2.

5. Install nut (16) and install spacer (17).

k Since the load at installed length of the

spring is large and dangerous, set recoil spring assembly securely to tool M2.

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50 Disassembly and assembly Undercarriage and frame

6. Release hydraulic pressure gradually to relieve tension of spring, then remove recoil spring assembly (1) from tool M2. 7. Install seal (15a) and spacer (15) to holder (13), and install snap ring (14).

2) Install washer (9) and plate (8), and tighten bolt (7).

2 Seal lip: Grease (G2-L1) 8. Install holder (13) to case (12) of the recoil spring.

a Bend plate (8) securely. 3) Install U-packing (4) and wear ring (5), and install snap ring (3).

3 Bolt (7): 455 to 565 Nm {46.5 to 58.0 kgm}

2 Holder (13) mating face: Liquid gasket (LG-5)

10.Assemble yoke and piston assembly (2) to recoil spring assembly (1).

9. Assembly of yoke and piston assembly 1) Press fit piston (11) to yoke (10) by using tool M3. a Yoke (10) press-fitting force: 294 kN {30 ton} 50-124

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50 Disassembly and assembly

Undercarriage and frame

Removal and installation of track roller assembly Removal

(D61-DTD0-520-K-00-A)

1. Remove plate (1). 2. Loosening lubricator (2), and slacken the track tension. [*1] k Never loosen lubricator (2) more than 1

turn. a If the track tension is not decreased even when the lubricator is loosened, move the machine backwards and forwards. k Turn the starting switch to OFF position,

and stop the engine. k Turn the battery disconnect switch to OFF

position, and remove the key. (For details, see Testing and adjusting, "Handling of battery disconnect switch".)

4. Remove the mounting bolts of track roller guard (5). [*3] 5. Remove the mounting bolts of track roller assembly (6). [*4]

6. Start the engine, and raise the machine by operating the blade and ripper or hydraulic jack. k When the machine has been raised, place

a block on the track shoe, and lock the work equipment lock lever and brake lock lever. 7. Remove track roller assembly (6). 4 Track roller assembly (6): 46 kg (single flange 1 piece) 51 kg (double flange 1 piece) a The following figure shows the right side. 3. Remove mounting bolt (3), and remove guard (4). [*2]

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50 Disassembly and assembly Undercarriage and frame

Installation

(D61-DTD0-720-K-00-A)

• Perform installation in the reverse order to removal. [*1] a Adjust the track tension. For details, see Testing and adjusting, "Checking and adjusting track tension". [*2] 2 Threaded portion of guard (4) mounting bolt: Adhesive (LT-2) 3 Guard (4) mounting bolt: 245 to 309 Nm {25.0 to 31.5 kgm} [*3] 2 Threaded portion of track roller guard (5) mounting bolt: Adhesive (LT-2) 3 Track roller guard (5) mounting bolt: 245 to 309 Nm {25.0 to 31.5 kgm} [*4] 2 Threaded portion of track roller assembly (6) mounting bolt: Adhesive (LT-2) 3 Track roller assembly (6) mounting bolt: 245 to 309 Nm {25.0 to 31.5 kgm} a Install the oil plug so that it faces outside of the machine.

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50 Disassembly and assembly

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Disassembly and assembly of track roller assembly

Symbol

4 L 5 6

Part No.

Part name

Commercially available or 790-101-3501 790-201-1420 790-201-2650 791-515-1520

Disassembly

Necessity Q'ty

a Special tools

Puller

q 1

Spacer Plate Installer

t 1 t 1 t 1

(D61-DTD0-530-K-00-A)

1. Remove plug (2) from roller assembly (1) to drain the oil. 6 Track roller: 0.25 l 2. Place roller assembly (1) on block [1]. 3. Push in collar (3) by using tool L4, then remove lock (4) to remove collar (3).

4. Remove floating seal (5) from collar (3). 5. Remove floating seal (6) from roller assembly (1).

8. Remove floating seal (10) from shaft assembly (8). 9. Remove lock pin (11), then remove collar (13) from shaft (12). a O-rings are installed on both ends of shaft (12).

10.Remove floating seal (14) from collar (13). 11.Remove bushing (15) from roller (7). Turn over roller (7) and remove bushing (16).

Assembly 6. Sling roller (7), and remove it from shaft assembly (8). 7. Remove floating seal (9) from roller (7).

D61EM-23M0

(D61-DTD0-710-K-00-A)

1. Press-fit bushings (16) and (15) to roller (7) by using tool L5.

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50 Disassembly and assembly Undercarriage and frame

a Check that the leaning is less than 1 mm, and projection (a) is 7 to 11 mm after the seal is inserted. (See step 2. of previous section.)

2. Install floating seal (14) to collar (13) by using tool L6. a When installing the floating seal, degrease and dry the parts indicated with thick line (Oring and mating face of the O-ring). a Check that the leaning of seal is less than 1 mm. a Check that the projection (a) of the inserted seal is 7 to 11 mm.

5. Install floating seal (9) to roller (7) by using tool L6. a When installing the floating seal, degrease and dry the parts indicated with thick line (Oring and mating face of the O-ring). (See step 2. of previous section.) a Check that the leaning is less than 1 mm, and projection (a) is 7 to 11 mm after the seal is inserted. (See step 2. of previous section.)

6. Sling roller (7), and install it to shaft assembly (8).

3. Install O-ring and collar (13) to shaft (12), and install lock pin (11). 4. Install floating seal (10) to shaft assembly (8) by using tool L6. a When installing the floating seal, degrease and dry the parts indicated with thick line (Oring and mating face of the O-ring). (See step 2. of previous section.) 50-128

7. Install floating seal (6) by using tool L6.

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50 Disassembly and assembly

Undercarriage and frame

a When installing the floating seal, degrease and dry the parts indicated with thick line (Oring and mating face of the O-ring). (See step 2. of previous section.) a Check that the leaning is less than 1 mm, and projection (a) is 7 to 11 mm after the seal is inserted. (See step 2. of previous section.)

13.Check the oil level, and tighten plug (2) on roller assembly (1). 3 Plug: 98.0 to 137.2 Nm {10 to 14 kgm}

8. Install floating seal (5) to collar (3) by using tool L6. a When installing the floating seal, degrease and dry the parts indicated with thick line (Oring and mating face of the O-ring). (See step 2. of previous section.) a Check that the leaning is less than 1 mm, and projection (a) is 7 to 11 mm after the seal is inserted. (See step 2. of previous section.)

9. Add gear oil to the roller. 5 Track roller: 0.25 l (GO140) 10.Fit the O-ring to the shaft and install collar (3) to the shaft. 11.Place roller assembly (1) on block [1]. 12.Push in collar (3) by using tool L4, then install lock (4).

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50 Disassembly and assembly Undercarriage and frame

Removal and installation of carrier roller assembly Removal

(D61-DTJ0-520-K-01-A)

1. Remove plate (1). 2. Loosening lubricator (2) and slacken the track tension. [*1] k Never loosen lubricator (2) more than 1

turn. a If the track tension is not decreased even when the lubricator is loosened, move the machine backwards and forwards. k Turn the starting switch to OFF position,

and stop the engine. k Turn the battery disconnect switch to OFF

4. Remove mounting bolts (3). 5. Sling carrier roller assembly (4) and pull it out of support (5). [*2]

position, and remove the key. (For details, see Testing and adjusting, "Handling of battery disconnect switch".)

4 Carrier roller assembly (4): 25 kg (1 piece)

Installation

(D61-DTJ0-720-K-00-A)

• Perform installation in the reverse order to removal. [*1] a Adjust the track tension. For details, see Testing and adjusting, "Checking and adjusting track tension". [*2] a Adjust clearance (a) between the carrier roller and support as follows before installation. Clearance (a): 3 mm 3. Raise the track shoe by using hydraulic jack [1].

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D61EM-23M0

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Disassembly and assembly of carrier roller assembly

Symbol

Part No.

Part name

7 796T-267-1180 Push tool 8 796T-667-1120 Push tool L 9 796-230-1110 Installer 10 790-201-2730 Spacer

Disassembly

Necessity Q'ty

a Special tools

t t t t

1 1 1 1

(D61-DTJ0-530-K-00-A)

1. Remove plug (1) and drain oil. 6 Carrier roller: 0.22 l 2. Remove snap ring (2), then remove cover (3). 3. Remove bolt (4) to remove spacer (5).

4) Remove bearing (12) from shaft (11). 8. Remove outer race (14) from roller (13). Turn over roller (13) and remove outer race (15).

Assembly 4. Set the carrier roller assembly on block [1]. 5. Remove shaft assembly (6) by using press and tool L7. 6. Remove bearing (7).

7. Disassemble the shaft assembly according to the following procedure. 1) Remove collar (8) from shaft assembly (6). 2) Remove floating seal (9). 3) Remove floating seal (10) from collar (8).

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(D61-DTJ0-710-K-00-A)

1. Press fit outer races (15) and (14) to roller (13). 2. Assemble the shaft assembly according to the following procedure. 1) Press fit collar (8) to shaft (11) by using tool L8.

2) Install floating seal (10) by using tool L6. a When installing the floating seal, degrease and dry the parts indicated with thick line (O-ring and mating face of the O-ring).

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50 Disassembly and assembly

Undercarriage and frame

3) Install floating seal (9), and press fit bearing (12) with tool L10.

5. Install spacer (5) with bolt (4). 3 Bolt:

a When installing the floating seal, degrease and dry the parts indicated with thick line (O-ring and mating face of the O-ring).

245 to 309 Nm {25.0 to 31.5 kgm} 6. Add gear oil to the carrier roller.

a Make sure that the seal is inclined less than 1 mm.

0.22 l (GO140) 7. Fit the O-ring to cover (3) and install it to the roller, then install snap ring (2) . 8. Check the oil level and tighten plug (1).

a Make sure that the projection (a) of the inserted seal is 7 to 11 mm.

5 Carrier roller:

3. Set shaft assembly (6) to block [2] and install roller (13). 4. Press fit bearing (7) with tool L10. a Press-fit the bearing while rotating the roller, until the roller becomes heavy a little to rotate.

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50 Disassembly and assembly Undercarriage and frame

Removal and installation of segment teeth k Place machine on a level ground, and set

parking brake lever to LOCK position. k Lower the work equipment to the ground,

and set the work equipment lock lever to LOCK position.

Removal

a Clearance (a) between the teeth segments must be equal all around when assembled. Clearance (a): 0 to 2 mm Difference in level (b): Max. 0.5 mm

(D61-LR89-520-K-00-A)

1. Stop the machine when the teeth segment comes to a position convenient for removing (between the shoe and track frame). 2. Remove mounting bolt (1), and remove guard (2). [*1]

3. Remove mounting nuts (3) (3 pieces), and remove teeth (4). [*2]

Installation

(D61-LR89-720-K-00-A)

• Perform installation in the reverse order to removal. [*1] 2 Threaded portion of guard mounting bolt (1): Adhesive (LT-2) 3 Guard mounting bolt (1): 245 to 309 Nm {25.0 to 31.5 kgm} [*2] 3 Teeth mounting nut (3): 461 to 559 Nm {47 to 57 kgm} 50-134

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50 Disassembly and assembly

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Separation and connection of track shoe assembly (Standard type track shoe) 1 Checking before separation of the track shoe assembly (D61-DTL0-520-K-00-A) k In some cases, it may be extremely

dangerous to separate the track shoe assembly. To prevent danger, perform the following checks before separation of the track shoe assembly. k Do not loosen the lubricator more than 1 turn.

If the grease does not come out sufficiently, move the machine backwards and forwards. 1. Remove cover (1), loosen lubricator (2) of the adjustment cylinder to discharge the grease.

Separation of track shoe assembly (normal) (D61-DTL0-520-K-01-A) a If no abnormality is detected by "Checking before separation of track shoe assembly", perform the following procedure. 1. Start the engine and Locate master link (3) above the idler (a little backward from the center). a Place block [1] between the carrier rollers and place block [2] under the front track so that the mating faces of master link do not open until the master bolts are removed.

k Do not loosen the lubricator more than 1

turn.

2. Loosen the track tension. [*1] k Do not loosen lubricator (2) more than 1

turn. a If the track tension is not decreased even when the lubricator is loosened, move the machine backwards and forwards.

2. After the track tension is decreased, follow the procedure in the "Separation of track shoe assembly (normal)". 3. If the track tension is not decreased after the above work is performed, follow the procedure in the "Separation of track shoe assembly (when track frame has internal defect)". a A problem may have occurred inside the track frame (such as damaged recoil spring case, broken recoil spring set bolt, coming off of shaft end nut, etc.).

D61EM-23M0

3. Remove track shoe (4). [*2] a Loosen each of the 4 mounting bolts (5) by 1 or 2 turns. Do not remove only 1 bolt without loosening the other 3 bolts. Check that they can be unscrewed smoothly, and then remove them.

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50 Disassembly and assembly Undercarriage and frame

a If a bolt does not turn smoothly and it is unscrewed forcibly, the threads of the bolt and master link (3) may be damaged.

4. Sling the front end of master link (3), move the machine backward slowly to spread track shoe assembly (5).

2. Move the machine forward slowly to press the track shoes on the idler side against large block [3] or a wall (or a blade of another machine of same size). When the recoil spring and the track shoe assembly sags, stop the machine and apply the brake. a Locate master link (3) between the idler and front carrier roller.

a Length of track: Approx. 9.5 m

a Apply lever block [4] between the carrier roller support and link to assure safety. 3. Remove track shoe (4) and disconnect master link (3). [*2] a Loosen each of the 4 bolts by 1 or 2 turns. Do not remove only 1 bolt without loosening the other 3 bolts. Check that they can be unscrewed smoothly, and then remove them.

Separation of track shoe assembly (when track frame has internal defect) (D61-DTL0-520-K-02-A)

a If a bolt does not turn smoothly and it is unscrewed forcibly, the threads of the bolt and master link (3) may be damaged. 4. Move the machine slowly in reverse to separate the track shoe assembly.

a If any abnormality is detected by "Checking before separation of track shoe assembly", perform the following procedure. k If a problem has occurred inside the track

frame, the track shoe may spring back when the assembly is separated. Also, the idler may fly out when the track shoe assembly is separated. This is potentially very dangerous. Be sure to separate the track shoe assembly as follows. 1. Loosen the track tension. [*1] k Do not loosen lubricator (2) more than 1

turn.

Installation

(D61-DTL0-720-K-00-A)

• Perform connection in the reverse to separation (normally). [*1]

a If the track tension is not decreased even when the lubricator is loosened, move the machine backwards and forwards.

a Adjust the track tension. For details, see Testing and adjusting, "Testing and adjusting track tension".

a Check that all the grease is discharged.

[*2]

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a Tighten the shoe mounting bolts for the master link in the order shown in the following figure. a Finger-tighten the bolts (4 pieces) until the mating faces of the master links are fitted. a If the bolts are tightened forcibly before the master link mating faces are fitted, the threads of bolts and master link may be damaged. 2 Shoe bolt (master link): Molybdenum disulfide lubricant (LM-P) 3 Shoe mounting bolt: 1st time: 343 ± 39 Nm {35 ± 4 kgm} 2nd time: 180 degrees. (0/-20 degrees.) (angle tightening)

D61EM-23M0

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50 Disassembly and assembly Undercarriage and frame

Overall disassembly and assembly of track shoe assembly (Standard type track shoe) 1

Symbol

Part No.

1 2 R 3 4 5

791-646-7531 791-660-7460 791-432-1110 791-932-1110 790-701-3000

Part name Remover Pin brush Plug push tool Plug push tool Seal checker

Overall disassembly

Necessity Q'ty

a Special tools

t t t t t

1 1 1 1 1

(D61-DTL0-530-K-00-A)

a This section describes the lubricated track. 1. Place the track shoe assembly on a flat floor with the shoes facing up. Remove the track shoe bolt from the master link and remove the shoe. a Loosen master link bolts without using an impact wrench.

4. Draining oil Before disassembling the link assembly, drain oil from inside the pin to prevent the link press being smeared with oil.

2. If a half assembly (in mass and length) is too large for disassembly and assembly, divide the track shoe assembly into quarter assemblies. 3. Sling the track shoe assembly, and place the assembly on the floor with the shoes up. Remove the track shoe from the regular link by using an impact wrench. a When repositioning the track shoe assembly, be careful not to damage the master links. a If the shoe nut needs to be removed by gas cut, keep the temperature in the seal section below 80°C to prevent thermal deterioration of the seals. Take measures to prevent the spatters from entering through the clearances between the links.

50-138

a If it is decided that the track should be rebuilt as a dry type track before starting the disassembly, the following work is not necessary to perform. 1) Place the link assembly on a flat floor with the large plug side facing up and chamfer the pin end to remove burrs by using a grinder, etc. a If the track shoe is disassembled with burrs remaining on the pin end faces, the pin press-fitting hole in the link will be damaged and result in oil leaks from the press-fitting portion after the track is rebuilt.

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50 Disassembly and assembly

Undercarriage and frame

a If the small plug hole is clogged with burrs, use a grinder to remove it until the hole becomes completely visible. 5) Chamfer the small plug holesing a drill by using drill (f 10 mm), . 6) Blow with compressed air to remove oil or iron particles in the pin caused by removing burrs, and then wash the link assembly by using pressurized water or steam.

2) Make a hole in the large plug to remove the plug by using a drill (f 10 mm). a If foreign material or deteriorated oil is sticking to the pin hole, pass a long drill through the hole to remove it. Be careful not to damage the oil hole in the pin when doing this.

5. Disassembly of link 1) Place the link assembly on the link press and hit it with a hammer to fit the bushing to jaw [1] firmly.

3) After removing the large plug, chamfer the pin hole by using a small-sized grinder (grindstone end angle: 45 to 60 degrees) so that the plug will not be damaged when it is driven in.

4) Reverse the link assembly so that the small plug side faces up. Remove burrs from the pin end face by using a grinder, etc., and then drive out the small plug toward the inside by using tool R1.

D61EM-23M0

a If the link tread or outer periphery of the bushing is worn, adjust the height of jaw [1] or guide plate to align the pin or bushing with disassembly jigs [2] and [3] in the lateral direction so that the pin-bore or bushing-bore in the link is not damaged during disassembly. a If the pin or bushing is not aligned with the jig, the bore in the link may be damaged or the pin or bushing may be broken during disassembly.

2) Operate the left cylinder to pull out the left link and the press fit portion of the pin and bushing at the same time.

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50 Disassembly and assembly Undercarriage and frame

a Check the pulling-out force of the pin and bushing to see if the press-fitting force is obtained, that is required when they are reused by being turned 180 degrees. a Avoid extending the disassembly jig more than necessary toward the inside to avoid damage to the spacer.

6. Checking Check the removed parts for following items, then determine to reuse them for a lubricated track or grease-lubricated track, depending on the check results.

3) Return the left cylinder and operate the right cylinder to pull out the right link and the press fit portion of the pin and bushing at the same time.

4) Return the right cylinder, take out the right and left links, pins, bushings and spacers, and feed the next set of the link assembly to the jaw. a Seals are inspected whether they can be reused or not while they are installed on the link. Therefore, do not remove the seal from the link.

a For judgment of reuse of the parts, see "Parts judgment guide, Undercarriage, Lubricated track". 1) Visually check the pin, bushing, link, and spacer for damage. If any part seems to be damaged, check it by dye penetrant test or magnaflux inspection. A cracked part cannot be reused. Discard it. 2) Visually check the appearance of the seals and bushing end faces to judge if they are reusable or not. a Replacing the bushing only may cause the worn or damaged seal lips to come in direct contact with the bushing end faces, resulting in poor sealing. Replace the seals at the same time, or rebuild the track as a grease sealed track. 3) Measure spacer thickness (a) and the overall length (b) of bushing to confirm by using vernier calipers whether the specified seal installing dimension can be obtained at assembly. a If the wear of the spacer and bushing exceeds the specified limit, the accuracy at the sealed portion will not be attained. Replace parts with new ones or rebuild the track as a grease sealed track.

a Remaining oil is a rough indication to judge if they are reusable or not. Place a mark on the link or seal. a If the bushing end faces and its sealing surface are damaged, oil will leak. Accordingly, handle them carefully.

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4) Measure the pin outside diameter and bushing inside diameter at the worn portions to judge by using vernier calipers, micrometer, and a cylinder gauge whether the parts are reusable or not. a If the wear exceeds the specified limit, backlash may occur during travel and oil may leak. Replace parts with new ones or rebuild the track as a grease sealed track. a For the dimensional criteria, see "Maintenance standard".

5) Measure the outside diameter of the pin and bushing at the press-fitting portions and measure the inside diameter of the pin and bushing press-fitting portions in the link by using a micrometer and cylinder gauge. Determine whether the specified interference can be obtained. If the track is reused as a lubricated track, a standard interference must be obtained between the pin and link. a If the allowable interference is not obtained, replace the parts with new ones or over sized parts. a For the dimensional criteria, see "Maintenance standard".

D61EM-23M0

a Precautions for storage 1) Store the seal without removing it from the link so that the counterbore portion of the link does not rust, and be careful not to damage the seal lip. 2) Apply rust-preventive oil to the pin and bushing press-fitting bores, shoe mounting surface of the link, and mating face of the master link. 3) Apply rust-preventive oil to the all surfaces of the pin, bushing, and spacer prior to storage. Be careful not to damage the bushing end faces.

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50 Disassembly and assembly Undercarriage and frame

Overall assembly

(D61-DTL0-710-K-00-A)

1. Rebuilding for lubricated track 1) Preparation 1] Cleaning of seal assembly a F5 type seal Do not clean seals to be reused, leave them installed to the link. 2] When reusing the pin, chamfer the edges of its end corners faces with a grinder. Remove the protruding nodules formed on its press-fitting portions with the grinder as well.

a Clean the parts immediately before the assembly because they easily rust. a Clean the pin hole by using tool R2. a Do not grind the bushing end faces because doing so may cause oil leak.

a If the edge of its end face is worn and sharpened, the press-fitting portion of the pin may cause galling, resulting in oil leak.

5] Drive in large plug (3) by using tool R3.

3] Place a mark (*) on the small plug side end surface to indicate the direction of the cross (radial) hole in the pin for assembly purposes. a Install the pin, even it is reused, with its cross hole facing the link tread as in the case of a new one.

a Apply oil (G090) to the outside periphery of large plug (3), and install it from the small diameter end first. 1] Insert large plug (3) in the hole of the guide through the plug inserting window. 2] Press the bar of tool R3 with the hand until large plug (3) stops. 3] Press large plug (3) with the bar of tool R3 until the guide touches the pin. 4] Hit the bar with a hammer to drive in the plug. a Driving distance (a) from pin end: 6 ± 2 mm a If chamfered face of the pin hole is lost due to wear, chamfer it by using a small-sized grinder (grindstone end angle: 45 to 60 degrees.) so that the plug is not damaged.

4] Clean any dirty links, pins, bushings, and spacers. Remove the protruding nodules formed on the rings and bushings by using a grinder.

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6] Installation of seal assembly • F5 type seal When the link is reused and the seal is replaced with a new one, clean the counterbore (portion A) in the link, and push the seal completely until it reaches the bottom. a Do not apply oil to the counterbore portion of the link and the seal assembly (portion A). It is because any adhered oil causes the seal to turn, and its sealing performance is lowered. Be careful not to let oil adhere when inserting the seal into the counterbore.

8] Adjust the relief pressure of the link press so that the pressing force of the press does not exceed the standard value. 7] Adjust the installed dimensions of the link press press-fitting jigs to keep the protrusion of the pin and bushing constant and to keep the installed dimensions of the seal within the standard range.

a If the pressing force is excessive, the spacer is pressed against the bushing excessively. As a result, the spacer may be broken or abnormal wear may occur between the spacer and bushing end face.

a For the standard dimensions of the link press press-fitting jigs, see "Link press press-fitting jig dimensions." a Ensure an extra dimension (a') rather than dimension (a) at the pin pushing portion of the left side press-fitting jig to provide clearance for the pin during assembly. When assembling in the order of [1] press-fitting of LH link and then [2] press fitting of RH link, provide clearance for the pin at the right side press-fitting jig. a If the pin end face (portion P) or link side faces (portions Q and R) are worn, add the wear reduction to the standard installed dimensions of the press-fitting jigs so that the right and left projections of the pins and bushings on both sides are even.

D61EM-23M0

a If the interference at the press-fitting portions is not the same as new parts, as in the case of reusing pins and bushings, take measurements at some press-fitting portions and calculate the average interference to determine the pushing pressure.

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50 Disassembly and assembly Undercarriage and frame

a Pin and bushing pushing pressure: 588 kN {60 ton} Pushing pressure C 1.8 x Average press-fitting force (pushing pressure is set by adjusting the relief pressure of the link press) 2) Assembly of link

a Remove all steel chips generated by the press-fitting process completely with compressed air.

1] Apply oil (GO90) on the mating faces of pin and bushing with a clean brush and assemble them, then set them on the bushing jaw of the link press. a When reusing the bushing (by turning it 180 degree), set it with the worn outside surface facing the shoe mounting face of the link (set the bushing on the link press with the face up).

4] Turn over the master links and check that the right and left master links are pressfitted in parallel. 5] Measure the right and left projections of the bushing with a depth gauge. a Adjust the link press press-fitting jigs so that the right and left protrusions of the bushing are even.

2] Set the right and left master links having bushing-bore with their shoe mounting faces up, and press fit them to the bushing. a At this time, use the master links having pin-bore as supports. a Bushing press-fitting force: 49 to 196 kN {5 to 20 ton}

6] Send out the master link portion, and then set the next pins and bushings. a Install the pin with its cross hole facing the link tread as in the case of new one even it is reused. If it is not installed as specified, the strength of the assembly may be lowered. Indicate the direction of the cross hole (i) on the end face to prevent wrong installation. a When assembled, the large plug must be at the left side when facing the link press.

3] While checking the distance between the shoe bolt holes of the right and left master links by using the shoe bolt pitch gage, press fit the master links to the bushing until the distance is the standard value. 50-144

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a Press fit them smoothly because bumpy press-fitting may cause the seal to come off the link. When the seal comes off the link, stop the press-fitting and set the seal to the link correctly, then restart the pressfitting. a Press-fitting force for pin and bushing: 196 to 392 kN {20 to 40 ton}

7] To prevent oil from oozing through the scuff marks at the pin press-fitting portions, apply liquid gasket (198-3219890) to the link at the pin press-fitting hole and to the outside perimeter of the pin press-fitting portion.

10]Use minor adjustment spacer [6] to press fit the pin until its end face reaches the bottom of the receiver jig. a Adjust the depth of the receiver jig hole so that the right and left protrusions of the pin are even.

8] Set the right link and install the spacer to the pin. a Check that the seal surfaces and bushing end faces are free from dirt, then apply oil (G090) on them using a clean cloth or brush. a Wipe the spacer with a clean cloth before installing.

11]Set the left link and install the spacer to the pin. a Apply oil similarly to the right link.

9] Press fit the pin and bushing at the same time by using the right jig as receiver jig and the left jig as pusher jig. D61EM-23M0

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50 Disassembly and assembly Undercarriage and frame

12]Press fit the left link by using the left jig as receiver jig and the right jig as pusher jig. a When press fitting, be careful that the right and left seals and spacers do not come off. a At the left jig, a clearance must be provided to avoid interference between the pin end surface and the bottom of the jig. a Press-fitting force for pin and bushing: 196 to 392 kN {20 to 40 ton}

13]Perform the press fitting until the link, spacers, and bushing are mutually fitted. a You cannot see if the above parts are fitted from outside. Set the relief pressure to a proper level, and raise the pressure to that level while performing the press fitting by controlling the hydraulic pressure of the link press. a For the relief pressure settings, see "Preparatory work." a Check that adjacent two sets of links pivot on the pin.

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14]After assembly of each link, measured the end play between the previous link by using a dial gauge and a pinch bar, etc. to check if the link is assembled as specified. a If the end play exceeds 0 to 0.13 mm after pressed until the relief valve opens, gradually increase the relief pressure setting to adjust the pushing pressure. a Set the relief pressure carefully so as not to increase the pushing pressure of the link press more than necessary.

15]heck that the distance between the shoe bolt holes is within the standard range by using the shoe bolt pitch gage. a If the distance between the shoe bolt holes is longer than the standard range, disassemble and check for abnormality, then assemble them again if no abnormality is found. a If the distance between the shoe bolt holes is less than the standard range and the track shoe cannot be installed, then wear of the spacer or bushing end face may be exceeding the allowable limit. In this case, disassemble it and replace the relevant part.

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50 Disassembly and assembly

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a The end play must be set small because a large end play results in poor sealing.

a For cold or extremely cold districts, supply Komatsu genuine engine oil (150-09-19270), which has excellent low-temperature characteristics, instead of oil (GO90). a If the charged oil pressure is increased too much, it has bad effects on the seals.

16]Use tool R5 for each link assembly to remove air from inside the pin, and check the sealing performance. a Keep the degree of vacuum inside the pin at 92.7 ± 2.0 kPa {695 ± 15 mmHg} for 5 seconds to check that the pressure does not change. If the pressure changes, disassemble the link assembly to check the seals. If no abnormality is found, assemble them.

a Add oil up to the level where depth (j) of the pin hole space is in the following range when the pin is left with the large plug (B) side down (the link assembly placed on its side) for 30 minutes. Dimension (j): 30 to 50 mm

17]Install the master links having pin-bore at last. a Check that the right and left master links are press fitted in parallel. 3) Adding oil When the link assembly is assembled, fill oil through the pin hole. 1] Extract air from inside the pin through the small plug hole by using tool R5 until the vacuum reaches 92.7 ± 2.0 kPa {695 ± 15 mmHg}, and then fill oil (GO90) until the charged pressure reaches 0.2 to 0.3 MPa {2 to 3 kg/cm2}.

D61EM-23M0

2] After supplying oil, drive in the small plug to the specified position by using tool R4. a Apply oil (GO90) on the outside periphery of the small plug. a Drive in the plug to the following depth. Driving depth from end face: 2.5 ± 1 mm

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50 Disassembly and assembly Undercarriage and frame

3 Shoe bolt (master link): Initial torque: 343 ± 39 Nm {35 ± 4 kgm} Retightening angle: 180 (+0/-20) degrees.

4) Place the link assembly on the bed, and install the track shoe for the regular link part by using in impact wrench and torque wrench on the shoe bolt. 2 Shoe bolt (regular link): Molybdenum disulfide (LM-P)

lubricant

3 Shoe bolt (regular link):

a Tighten the shoe bolts in the order shown in the following figure.

Initial torque: 539 ± 49 Nm {55 ± 5 kgm} Retightening angle: 120 ± 10 degrees.

a Do not use an impact wrench on the master link.

5) Connection of track consisting of 2 track shoe assemblies Place the 2 track shoe assemblies on a level place in a line with the track shoes up. Pull master links with pin-bore (5) and master links with bushing-bore (6) together to contact their mating faces each other. Place track shoe (7) on the master links, confirm that shoe bolts (8) can be easily inserted with the hand, and then tighten the bolts to complete the connection. 2 Shoe bolt (master link): Molybdenum (LM-P)

50-148

disulfide

lubricant

2. Reusing the link assembly for grease sealed track 1) Preparation 1] Cleaning of seal assembly

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a F5 type seal Leave seals to be reused on the link and do not clean them.

• Tool R3 (large plug) • Tool R4 (small plug) 1] Insert plug (3) in the hole of the guide through the plug inserting window. (Apply oil to plug (3).) 2] Press the bar of tools R3 and R4 with the hand until plug (3) can be inserted. 3] Press plug (3) with the bar of tools R3 and R4, and push the guide against pin (4). 4] Drive in the bar of tools R3 and R4 with a hammer. a Driving distance (a) from pin end face:

2] When reusing the pin, chamfer the edges of its end surface corners with a grinder to allow for smooth press-fitting. a Be sure to wear the protective eyeglasses when using a grinder.

Small plug: 2.5 ± 1 mm Large plug: 6 ± 2 mm a If the plugs were not pulled out from the pin when disassembling, reuse them as they are. 5] Clean any dirty surfaces among the outside periphery of the pin, spacer surface, and end faces and inside surface of the bushing. 6] Apply grease on the outside periphery of the pin and surfaces of the spacer.

7] Installation of seal assembly F5 type seal When the link is reused and the seal is replaced with a new one, clean the counterbore (part A) in the link and push the seal completely until it reaches the bottom. a Do not apply grease to the link bores and the seal assembly (part A) because any adhered grease causes the seal to turn and its sealing performance is lowered.

4] Drive in the large and small plugs by using tools R3 and R4. D61EM-23M0

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50 Disassembly and assembly Undercarriage and frame

8] Adjust the installed dimensions of the link press press-fitting jigs to keep the protrusion of the pin and bushing constant and to keep the installed dimensions of the seal within the standard range. a For the standard dimensions of the link press press-fitting jigs, see "Link press press-fitting jig dimensions."

a If the pin end face (portion P) or link side faces (portions Q and R) are worn, add the wear reduction to the standard installed dimensions of the press-fitting jigs so that the right and left projections of the pins and bushings on both sides are even.

2) Assembly of link 1] Apply lithium grease (G2-LI) to the mating surfaces of the pin and bushing and assemble them, then set them on the bushing jaw of the link press.

a Remove all steel chips generated by the press-fitting process completely with compressed air.

a When reusing the bushing (by turning it 180 degree), set it with the worn outside surface facing the shoe mounting face of the link (set the bushing on the link press with the face up).

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a Press fit them smoothly because bumpy press-fitting may cause the seal to come off the link. When the seal comes off the link, stop the press-fitting and set the seal to the link correctly, then restart the pressfitting. a Pin and bushing pushing pressure: 588 kN {60 ton} Pushing pressure C 1.8 x Average press-fitting force (pushing pressure is set by adjusting the relief pressure of the link press)

6] Send out the master link portion, and then set the next pins and bushings. a Install the pin with its cross hole facing the link tread as in the case of new one even it is reused. If it is not installed as specified, the strength of the assembly may be lowered. Accordingly, indicate the direction of the cross hole on the end face to prevent wrong installation. a If the outside of the pin is worn, assemble it with the un-worn portion facing the traction side. Even in this case, assemble it with its cross hole facing the link tread.

7] Set the right and left links, and operate the right and left press-fitting jigs to press fit the pin and bushing at the same time.

D61EM-23M0

8] Check the distance between the shoe bolt holes by using the shoe bolt pitch gage, and when it reaches the standard range, stop the press-fitting. 9] Install the master links having pin-bore at last. a Check that the right and left master links are press fitted in parallel.

3) Installation of track shoe (to regular links) Place the link assembly on the bed, and install the track shoe by using the shoe bolt impact wrench and torque wrench. 2 Shoe bolt (regular link): Molybdenum (LM-P)

disulfide

lubricant

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50 Disassembly and assembly Undercarriage and frame

3 Shoe bolt (regular link): Initial torque: 539 ± 49 Nm {55 ± 5 kgm} Retightening degrees.

angle:

120

a Do not use an impact wrench on the master link.

4) Connection of track consisting of 2 track shoe assemblies Place the 2 track shoe assemblies on a level place in a line with the track shoes up. Pull master links with pin-bore (5) and master links with bushing-bore (6) together to contact their mating faces each other. Place track shoe (7) on the master links, confirm that shoe bolts (8) can be easily inserted with the hand, and then tighten the bolts to complete the connection. 2 Shoe bolt (master link): Molybdenum (LM-P)

disulfide

lubricant

3 Shoe bolt (master link): Initial torque: 343 ± 39 Nm {35 ± 4 kgm} Retightening angle: 180 (+0/-20) degrees.

a Tighten the shoe bolts in the order shown in the following figure.

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Link press press-fitting jig dimensions

a b c

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Jig dimensions (mm) 4.0 ± 2 3.05 ± 0.13 45.8

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Disassembly and assembly of one track link assembly in field (Standard type track shoe) 1 a Special tools

Part No.

Part name

790-101-1102 Pump assembly 6 Cylinder (980 kN 790-101-1300 {100 ton}) 791-101-1102 Pump assembly 7 Jack (294 kN {30 790-105-2300 ton}) 791-635-3110 Frame 791-635-3160 Extension 791-635-3170 Nut 8 791-635-3180 Screw 791-635-3190 Screw 791-645-3510 Adapter 791-646-3260 Pusher 9 791-630-3560 Pusher 10 791-432-1110 Push tool 11 791T-630-3570 Guide 791-635-3110 Frame 791-635-3160 Extension 791-635-3170 Nut 791-635-3180 Screw 12 791-635-3190 Screw 791-645-3510 Adapter R 791-645-3520 Adapter 791-645-3530 Pusher 791-635-3110 Frame 791-635-3160 Extension 791-635-3170 Nut 791-635-3180 Screw 13 791-635-3190 Screw 791-645-3520 Adapter 791T-630-3570 Guide 791-630-3560 Pusher 790-101-1102 Pump assembly 14 Jack (294 kN {30 790-105-2300 ton}) 15 791-646-3270 Guide 791-635-3110 Frame 791-635-3160 Extension 791-635-3170 Nut 16 791-635-3180 Screw 791-635-3190 Screw 791-645-3510 Adapter 17 791-646-8002 Lubricator 18 791-932-1110 Plug push tool

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Necessity Q'ty

Symbol

Disassembly

(D61-DTL0-530-K-02-A)

1. Positioning of track shoe assembly Place the track shoe assembly on blocks [1] (approximately 300 mm in height).

t 1 t 1 t 1 t 1 t t t t t t t t t t t t t t t t t t t t t t t t t t t

1 1 4 2 1 1 1 1 1 1 1 1 4 2 1 1 1 1 1 1 4 2 1 1 1 1 1

t 1 t t t t t t t t t

1 1 1 4 2 1 1 1 1

2. Pin Pull out pins (1) and (2) by using tool R8 (frame, extension, nut, screw, screw, adapter and pusher) and tool R6 (pump and cylinder). a If the pin end surface or the sides of the link are worn unevenly, correct the surface with a grinder to ensure that tool R8 is applied at right angle.

3. Link 1) Set tool R7 and spacer [2] to the tread side of links (3) and (4). a Set tool R7 to the link tip end as far as possible.

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2) Apply hydraulic pressure to the puller slowly, and disconnect the links until the link tip opens for 6 to 8 mm. a Be careful not to apply excess hydraulic pressure as the bushing may be pulled out.

2. Pin 1) Drive in the large plug into the oil hole of pin (1) by using tool R10. a Be sure to use a new pin.

a Always use manual pump. Do not use an electric pump because it may apply excess hydraulic pressure. 3) Separate links (5) and (6) similarly. Spacer [2] dimensions: Outside diameter 55 mm x Thickness 47 mm

2) To determine the pushing pressure in final assembly, measure the outside diameter of the pin with a micrometer.

Assembly

(D61-DTL0-710-K-02-A)

1. Bushing Set tool R9 to the end face of link (4), and pressfit bushing (7) by using a press or a remover. a Bushing press-fitting force: 49 to 147 kN {5 to 15 ton} a Be sure to use a new bushing.

3) Apply liquid gasket (198-32-19890) to the pin press-fitting hole in link (4). a When reusing the removed link, finish the pin press-fitting hole smoothly with sandpaper etc.

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50 Disassembly and assembly Undercarriage and frame

a Check that the seal surfaces and bushing end faces are free from dirt, then apply oil (G090) on them using a clean cloth or brush.

4) Set tool R9 to the end face of link (4), and press-fit pin (1) by using a press or a remover. a Press fit the pin with the cross hole (b) facing the link tread. a Press-fitting force for pin: 147 to 245 kN {15 to 25 ton}

2) Install tool R11 (guide for press fitting the link) to bushing (7).

a Be sure to use a new pin.

5. Link

3. Seal Install seal (8).

1) To determine the pushing pressure in the final assembly, measure the dimension of pin press-fitting hole in link (3) with a cylinder gauge.

a Make sure the contact faces of link and seal are free from oil. a Work described in 1 to 3 should be performed in advance.

2) Apply liquid gasket (198-32-19890) to the pin press-fitting hole in link (4).

4. Link sub assembly

a When reusing the removed link, finish the pin press-fitting hole smoothly with sandpaper etc.

1) Install link sub assembly (10). 50-156

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a Press fit the pin and bushing alternately so that excessive force is not applied to the press-fitting portion. a Pin and bushing press-fitting force: 196 to 392 kN {20 to 40 ton}

3) Install seal (8). a Make sure the contact faces of link and seal are free from oil. a Check that the seal surfaces and bushing end faces are free from dirt, then apply oil (G090) on them using a clean cloth or brush.

6. Connection of link 1) Finish the inner surface of the pin pressfitting hole of links (5) and (6) to be connected smoothly with sandpaper, etc.

4) Press fit the pin portion of link (3) to link sub assembly (10) by using tool R12. a Press-fitting force for pin: 294 to 490 kN {30 to 50 ton} a (G): Guide

2) Remove blocks [1], and lay the track shoe assembly on the ground. 3) Set lever blocks [3] to the right and left link assemblies as shown in the figure. Set tool R14 and spacer [2] to the tread side of links (5) and (6). a Set tool R14 to the link tip end as far as possible.

5) Press fit the bushing portion of link (3) to link sub assembly (10) by using tool R13.

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4) Install seals (13) and (14) to links (5) and (6). a Be sure to use a new seal. a Make sure the contact faces of link and seal are free from oil. a Check that the seal surfaces and bushing (7) end faces are free from dirt, then apply oil (G090) on them using a clean cloth or brush.

2) To determine the pushing pressure, measure the outside diameter of pin (2) with a micrometer. 3) Place again the track shoe assembly on blocks [1]. 4) Press fit pin (2) to links (5) and (6) by using tool R16. a Install the pin with the cross hole facing the link tread. 5) Apply hydraulic pressure to the puller until the tips of links (5) and (6) open for 6 to 8 mm. a Be careful not to apply excessive hydraulic pressure as the bushing may be pulled out.

a Bushing press-fitting force: 49 to 147 kN {5 to 15 ton} 5) Stop press fitting temporarily when the remaining dimension of pin (2) reaches 15 to 20 mm.

a An electric pump is not allowed to use because it may apply excessive hydraulic pressure. Always use manual pump. 6) Operate chain block [3] to align the link hole with the center of the bushing hole, and connect the links to tool R15 (guide pin). a Operate chain block [3] slowly, and be careful not to damage the seal and that dirt does not stick to the seal.

6) Apply liquid gasket (198-32-19890) to the remaining press-fitting part in link (2). 7) Apply liquid gasket (198-32-19890) to the pin press-fitting hole in link (6), and press fit pin (2) again.

7. Pin 1) Drive in the large plug into the oil hole of pin (2) by using tool R10. a Be sure to use a new pin. 50-158

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1) Add oil (G090) from the small plug hole of the pin by using tool R17. a If the charged oil pressure is increased too much, it has bad effects on the seals. a Do not add oil excessively by taking thermal expansion etc. of oil into consideration.

8) Apply the standard pushing pressure to links (3) and (4), and to links (5) and (6) by using tool R12. a Pin and bushing pushing pressure: 588 kN {60 ton} Pushing pressure C 1.8 x Average press-fitting force (pushing pressure is set by adjusting the relief pressure of the link press) 2) Drive in the small plug quickly by using tool R18. a Apply oil (GO90) on the outside periphery of the small plug. a Drive in the plug to the following depth. Driving depth from end face: 2.5 ± 1 mm

8. Vacuum test Remove air from the small plug hole at pins (1) and (2) end surfaces by using hand vacuum pump [4], and check the sealing performance. a Keep the degree of vacuum at 92.7 ± 2.0 kPa {695 ± 15 mmHg} for 5 seconds and check if the airtightness is maintained.

9. Adding oil

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Removal and installation of pivot shaft assembly

Symbol

Part No.

Part name

791-430-1200 Installer assembly Puller (294 kN {30 790-101-2102 ton}) 790-101-1102 Pump assembly 790-337-1001 Lifting tool

1 2

Removal

Necessity Q'ty

a Special tools

t 1 t 1 t 1 t 1

(D61-E3E1-520-K-00-A)

1. Remove the track frame assembly. For details, see "Removal and installation of track frame assembly." k Turn the starting switch to OFF position,

and stop the engine.

Installation

(D61-E3E1-720-K-00-A)

• Perform installation in the reverse order to removal. [*1] • Install seal (1) according to the following procedure. 1. Reverse seal (1) so that the embossed character (a) of the seal faces inside. 2. With seal (1) reversed, insert it to pivot shaft (5).

k Turn the battery disconnect switch to OFF

position, and remove the key. (For details, see Testing and adjusting, "Handling of battery disconnect switch".)

a When inserting seal (1), be careful not to damage the surface.

2. Remove seal (1). [*1] 3. Remove bushing (2). [*2] 4. Remove ring (3). [*3]

[*2] 5. Sling pivot shaft assembly (5) by using tool P2. 6. Remove mounting bolts (4) (16 pieces) 7. Sling pivot shaft assembly (5), and remove it by using tool P2. [*4] a If pivot shaft assembly (5) cannot be removed, use forcing screws.

2 Bushing (2) press fit surface: Molybdenum disulfide lubricant (LM-P) [*3] a Use tool P1 to press fit ring (3). a Ring (3) press-fitting force: 18.6 kN (1.9 ton)

4 Pivot shaft assembly (5): D61E -23 #: 97 kg

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50 Disassembly and assembly

Undercarriage and frame

[*4] 3 Pivot shaft mounting bolt (4): 455 to 565 Nm {46.5 to 58.0 kgm}

D61EM-23M0

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50 Disassembly and assembly Undercarriage and frame

Removal and installation of equalizer bar assembly

Symbol

Part No.

Part name

Necessity Q'ty

a Special tools

791-450-1100 Remover Puller (294 kN {30 790-101-2102 ton}) 790-101-1102 Pump assembly 790-101-2420 Adapter 790-101-2520 Screw 791-112-1180 Nut 790-101-2540 Washer

N 1

Removal

t 1 t 1 t t t t t

1 1 1 1 1

(D61-E3A2-520-K-00-A)

4. Disconnect grease hose (5). a Remove the elbow as well.

1. Remove undercover (1) from the bottom of the HST pump. a Remove undercover (1) by using a transmission jack.

5. Remove lock plate (6), and remove side pin (7). [*2] k Support the track shoes by placing

blocks under it before removing side pin. 2. Remove the track frame assembly from one side. For details, see "Removal and installation of track frame assembly." k Turn the starting switch to OFF position

and stop the engine. k Turn the battery disconnect switch to OFF

position, and remove the key. (For details, see Testing and adjusting, "Handling of battery disconnect switch".) k Loosen the cap of the hydraulic tank

gradually, and release the pressure remaining inside the hydraulic tank.

6. Remove seal (8) from the side pin mounting part. [*3]

3. Remove mounting bolts (4a) (2 pieces) from the equalizer bar side pin part opposite of the removed track frame side, and remove cover (4). [*1]

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50 Disassembly and assembly

Undercarriage and frame

7. Disconnect grease hose (9) from center pin (11).

Installation

a Remove the elbow, too. 8. Remove lock plate (10) and center pin (11). 9. Remove center pin (11) by using tool N1. [*4]

• Perform installation in the reverse order to removal. [*1]

(D61-E3A2-720-K-00-A)

3 Mounting bolt (4a): 455 to 565 Nm {46.5 to 58.0 kgm} [*2] 2 Between seal and bushing: Fill grease (G2-L1) [*3], [*4] 2 Joint between pin and bushing: Grease (G2-LI) 2 Between bushing and bushing: Fill grease (G2-L1) 2 Frame boss portion: Molybdenum disulfide lubricant (LM-P) • Refilling of oil (hydraulic tank) Refill with oil to the specified level through the oil filler port. Run the engine to circulate the oil through the piping. Then check the oil level again. 5 Hydraulic tank (hydraulic oil): Only necessary quantity 10.Pull wire (1) by using a forklift truck, etc. to remove equalizer bar assembly (12) from the frame. 11.Sling equalizer bar assembly (12), and remove it.

(For details, see "Table of fuel, coolant and lubricants") • Bleeding air (hydraulic system) Bleed air from the hydraulic pump circuit. For details, see Testing and adjusting, "Bleeding air from hydraulic system".

4 Equalizer bar assembly (12):

D61E -23 #: 153 kg

D61EM-23M0

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50 Disassembly and assembly Undercarriage and frame

Removal and installation of equalizer bar side bushing

Symbol

4. Install seal (1).

Part No.

Part name

N 2 792T-413-1120 Push tool

Removal

Necessity Q'ty

a Special tools

t 1

2 Between bushing and seal: Fill grease (G2-L1) 5. Install the equalizer bar assembly. For details see "Removal and installation of equalizer bar assembly".

(D61-E3AB-520-K-00-A)

1. Remove the equalizer bar assembly. For details see "Removal and installation of equalizer bar assembly". k Turn the starting switch to OFF position,

and stop the engine. k Turn the battery disconnect switch to OFF

position, and remove the key. (For details, see Testing and adjusting, "Handling of battery disconnect switch".) 2. Remove seals (1) (2 pieces). 3. Remove snap rings (2) (2 pieces). 4. Remove spherical bushing (3).

Installation

(D61-E3AB-720-K-00-A)

1. Install snap ring (2) on one side. 2. Press fit spherical bushing (3) by using tool N2. a Press-fitting force: 15.68 kN (1.6 ton) 3. Install snap ring (2) on the other side.

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Hydraulic system

Removal and installation of hydraulic tank assembly

k Place machine on a level ground, and set

parking brake lever to LOCK position. k Lower the work equipment to the ground,

and set the work equipment lock lever to LOCK position. k Turn the starting switch to OFF position, and

stop the engine. k Turn the battery disconnect switch to OFF

position, and remove the key. (For details, see Testing and adjusting, "Handling of battery disconnect switch".) k Loosen the cap of the hydraulic tank

2) Sling cooling fan drive assembly (2) at its fully raised position. 3) Remove covers (2a) on right and left sides.

gradually to release the pressure remaining inside the hydraulic tank. k If you drain the coolant when it is still hot,

you may be scalded. Wait until the coolant temperature drops before starting the work.

Removal

(D61-PM30-520-K-00-A)

4) Remove gas cylinder (2b) mounting pins (2c) on right and left sides.

a Never release the refrigerant to the atmosphere. k If refrigerant gets in your eyes, you may

lose your sight. And if it touches your skin, you may suffer from frostbite. Accordingly, put on the protective eyeglasses, gloves and working suits with long sleeves while you are collecting or filling the refrigerant. • Refrigerant to be collected: 900 ± 50 g 2. Remove the ROPS cab assembly. For details, see "Removal and installation of ROPS cab assembly." 3. Remove the gas cylinder. For details, see "Removal and installation of cooling fan drive assembly".

5) With gas cylinders (2b) are hung, remove link mounting pins (2d) on right and left sides.

1) Sling cooling fan guard (1) and remove it. 4 Cooling fan guard (5): 65kg

D61EM-23M0

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50 Disassembly and assembly Hydraulic system

4. Open drain valve (3) at the rear of the hydraulic tank, and drain the hydraulic oil.

8. Open left side cover (7) from the left side of the machine, and disconnect wiring harness terminal TB (8).

6 Hydraulic tank: 195 l

9. Disconnect hydraulic hoses (9) and (10). 5. Disconnect ground terminal (4). 6. Remove harness clamp (5).

7. Remove wiring harness clamps (6) (4 pieces).

a Plug the disconnected hose and the mounting port to prevent oil leakage.

10.Remove hose clamp (11), and disconnect hydraulic hose (12). a Plug the disconnected hose and the mounting port to prevent oil leakage.

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Hydraulic system

11.Remove hose clamp (13), and disconnect the following hoses. • • • • •

Hose (14) Hose (15) (disconnect at the HST pump side) Hose (16) Hose (17) Hose (18)

15.Sling hydraulic tank assembly (22), and remove it. 4 Hydraulic tank assembly (22): 350 kg

a Place an oil container under hoses (16), (17), and (18). a Plug the disconnected hose and the mounting port to prevent oil leakage.

Installation

(D61-PM30-720-K-01-A)

• Perform installation in the reverse order to removal. [*1]

12.Remove upper mounting bolts (19) (4 pieces). [*2]

a When installing the hose for the air conditioner circuit, be careful not to allow any invasion of dirt, dusts and water into the hose. a When installing the air conditioner hoses, check that O-rings (70) are fitted to each of their fittings. a Check that O-ring (70) is free from flaws and deterioration. a When connecting the refrigerant pipes, apply compressor oil for new refrigerant (R134a) (SANDEN: SP-20 PAG oil) to O-ring (70). Table of tightening torque for refrigerant pipe joint. Thread size

13.Sling the hydraulic tank assembly. 14.Remove lower mounting bolts (20) (4 pieces) and mounting bolts (21) (6 pieces). [*3]

D61EM-23M0

5/8 -18UNF 3/4 -16UNF 7/8 -14UNF

Tightening torque: Nm {kgm} 14.9 to 17.6 {1.6 to 1.8} 20.3 to 27.1 {2.1 to 2.7} 28.4 to 36.6 {2.9 to 3.7}

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50 Disassembly and assembly Hydraulic system

[*2] 3 Upper part mounting bolt (19): 490 to 565 Nm {50 to 58 kgm} [*3] 3 Lower part mounting bolts (20) and (21): 490 to 565 Nm {50 to 58 kgm} • Filling of refrigerant (R134) Refill the air conditioner circuit with refrigerant. a Filling quantity: 900 ± 50 g • Refilling of air conditioner compressor oil See Air conditioner, "Handling of compressor oil". • Refilling of coolant (radiator) Refill with coolant to the specified level through the coolant filler port. Run the engine to circulate the coolant through the system. Then check the coolant level again. 5 Radiator (engine coolant): Only necessary quantity (For details, see "Table of fuel, coolant and lubricants") • Refilling of oil (hydraulic tank) Refill with oil to the specified level through the oil filler port. Run the engine to circulate the oil through the piping. Then check the oil level again. 5 Hydraulic tank (hydraulic oil): 195 l (For details, see "Table of fuel, coolant and lubricants") • Bleeding air (hydraulic system) Bleed air from the hydraulic pump circuit. For details, see Testing and adjusting, "Bleeding air from hydraulic system".

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50 Disassembly and assembly

Hydraulic system

Removal and installation of control valve assembly

k Place machine on a level ground, and set

parking brake lever to LOCK position. k Lower the work equipment to the ground,

and set the work equipment lock lever to LOCK position. k Turn the starting switch to OFF position, and

stop the engine. k Turn the battery disconnect switch to OFF

position, and remove the key. (For details, see Testing and adjusting, "Handling of battery disconnect switch".)

Remove cover (4).

k Loosen the cap of the hydraulic tank

gradually to release the pressure remaining inside the hydraulic tank. k If you drain the coolant when it is still hot,

you may be scalded. Wait until the coolant temperature drops before starting the work.

Removal

(D61-R404-520-K-00-A)

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50 Disassembly and assembly Hydraulic system

Disconnect hose (39). a Plug the disconnected hose and the mounting port to prevent oil leakage.

Disconnect hoses (31), (32), (33), and (34) from inside. a Plug the disconnected hoses and their connection ports in order to prevent oil from flowing out. 10. Set slings to the control valve assembly. 11. Remove mounting bolts (40) (4 pieces).

Disconnect the following hoses. q Hose (35) q Hose (36) q Hose (37) q Hose (38) (8 pieces) a Plug the disconnected hose and the mounting port to prevent oil leakage.

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Hydraulic system

12. Sling control valve assembly (41) and remove it. 4

Control valve assembly (41): 70 kg

Installation

(D61-R404-720-K-00-A)

D61EM-23M0

Tightening torque: Nm {kgm} 14.9 to 17.6 {1.6 to 1.8} 20.3 to 27.1 {2.1 to 2.7} 28.4 to 36.6 {2.9 to 3.7}

• Refilling of coolant (radiator) Refill with coolant to the specified level through the coolant filler port. Run the engine to circulate the coolant through the system. Then check the coolant level again. 5 Radiator (engine coolant): Only necessary quantity (For details, see "Table of fuel, coolant and lubricants") • Refilling of oil (hydraulic tank) Refill with oil to the specified level through the oil filler port. Run the engine to circulate the oil through the piping. Then check the oil level again. 5 Hydraulic tank (hydraulic oil): Only necessary quantity (For details, see "Table of fuel, coolant and lubricants") • Bleeding air (hydraulic system) Bleed air from the hydraulic pump circuit. For details, see Testing and adjusting, "Bleeding air from hydraulic system".

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50 Disassembly and assembly Hydraulic system

Disassembly and assembly of hydraulic cylinder assembly

Symbol 1

Part No.

Part name

790-502-1003 Repair stand 790-101-1102 Pump assembly Wrench assembly 790-330-1100 ( & ')

2 2 3

Necessity Q'ty

a Special tools

3) Pull out piston rod assembly (3) from cylinder (4). a Place a container under the cylinder to receive oil.

t 1 t 1 t 1

Socket (width t 1 across flats: 0 mm)

Socket (width across flats: 60 mm) t q 1 790-720-1000 Expander q 2 2 8 ' ( ') ( ') q 2 4 2 U q 796-720-1660 Ring (lift) q 07281-01159 Clamp (lift) t 790-201-1702 Push tool kit 790-101-5021 • Grip 01010-50816 • Bolt 5 • Push tool kit 2 2 ( ') 790-201-1771 • Push tool kit (lift) t 790-201-1500 Push tool kit • Grip 790-101-5021 01010-50816 • Bolt 6 2 2 • " ( ') 790-201-1580 • Plate (lift) 790-302-1290

1 1 1 1 1 1 1 1 1

1 1 1 1 1 1 1

2. Piston assembly and head assembly 1) Set piston rod assembly (3) to tool U1. 2) By using tool U3, loosen and remove nut (5). Cylinder name

* ' &

Width across flats of nut (mm)

3) Remove piston assembly (6) and head assembly (2).

Disassembly Piston rod assembly ~ Set cylinder assembly (1) to tool U1. ~ Disconnect cylinder head assembly (2) by using a hydraulic pump or a torque multiplier wrench, and tool U2. a lift cylinder, ' !

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Hydraulic system

Disassembly of piston assembly ~ Remove wear ring (7). ~ Remove piston ring (8). a lift cylinder, ' !

Assembly

(D61-PPZ0-710-K-00-A)

a Apply engine oil to the sliding surfaces of each part, and be careful not to damage the rod, packing, dust seals, and O-rings when assembling. a When installing the backup ring, do not install it forcibly. Warm it in hot water (temperature is approximately 50 to 60°C), and then install it. 1. Assembly of head assembly 1) Press-fit bushing (23) by using tool U5. 2) By using tool U6, press-fit dust seal (21). 3) Install snap rings (20) and (22). 4) Install buffer ring (19). 5) Install packing (18). 6) Install O-ring (17). 7) Install backup ring (15) and O-ring (16).

Disassembly of head assembly ) Remove backup ring (15) and O-ring (16). 2) Remove O-ring (17). 3) Remove packing (18). 4) Remove buffer ring (19). 5) Remove snap ring (20), then remove dust seal (21). 6) Remove snap ring (22), then remove bushing (23).

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50 Disassembly and assembly Hydraulic system

2. Assembly of piston assembly 1) Set piston ring (8) to tool U4-1 and rotate the handle 8 to 10 turns to expand the piston ring. 2) Remove piston ring (8) from tool U4-1, and install it to piston (6). 3) Compress piston ring (8) by using tool U4-2. 4) Install wear ring (7).

3 Piston nut: Width across flats of nut (mm)

Tightening torque (kNm {kgm})

* '

1 1

Cylinder name

a and degrease the threaded portion of the piston rod thoroughly before installing the nut. 2 Threaded portion of rod: Adhesive (Loctite 262 or equivalent) 2) Set cylinder (4) to tool U1, and install piston rod assembly (3) to cylinder (4).

3. Piston rod assembly 1) Set the piston rod to tool U1, install head assembly (2) and piston assembly (6), and then tighten nut (5) by using tool U3.

50-174

3) Set cylinder (1) to tool U1. 4) Tighten cylinder head assembly (2) by using tool U2, a pump or a torque multiplier wrench. 3 Cylinder head: Cylinder name Cylinder head tightening torque 1 . 1 .' Side swing & 1 1 .'

D61EM-23M0

50 Disassembly and assembly

Work equipment

Removal and installation of planter unit assembly k Stop the machine on a level surface, and

move the parking brake to LOCK position. the starting switch to OFF position and stop the engine. k Turn the battery disconnect switch to OFF position, and remove the key. (For details, see “Testing and adjusting”, “Handle battery disconnect switch”.) k Gradually loosen the hydraulic tank cap and release the tank internal pressure. k Turn

6. 7.

Remove cover (9). Remove brackets (10) and (11).

Removal 1.

Lower planter unit assembly (1) and parking leg (2) to a level surface. 8.

Remove mounting bolts (12) and (13), and remove side swing cylinder (14). 9. Remove mounting bolts (15), and remove rods (16). 10. Remove mounting bolts (17), and remove cover (18).

2. 3. 4. 5.

Remove clamp (3) and disconnect irrigation water hose (4). Remove clamp (5) and disconnect the harness connector. Disconnect the hydraulic hoses (2 pieces). q (7): Planter unit return (OUT) hose q (8): Planter unit feed (IN) hose Disconnect the cleaning water hose. a Plug the disconnected hydraulic hoses and their connection ports in order to prevent oil from flowing out.

D61EM-23M0

11. Sling planter unit assembly (1), remove mounting bolts (19), and remove planter unit mounting bolt pin (20).

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50 Disassembly and assembly Work equipment

12. Gradually move forward and remove planter unit assembly (1). 4

Planter unit assembly: 875 kg

13. Work on the center and right planter unit assemblies according to the above procedure as well.

Installation q q

Install in the reverse order of removal. Add oil (Hydraulic tank) Add oil through the oil filler port to the specified level. Run the engine to circulate the oil. Then, check the oil level again. 5

Hydraulic tank (Hydraulic oil) Addition only (For details, see “Table of fuel, coolant, and lubricants”)

Apply grease a After completing installation, securely apply grease to the removed mounting pin. a Before installing the removed mounting pin, apply grease to the inside of mating hole.

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Work equipment

Removal and installation of center frame assembly

k Place machine on a level ground, and set

parking brake lever to LOCK position. k Turn the starting switch to OFF position, and

stop the engine. k Turn the battery disconnect switch to OFF

position, and remove the key. (For details, see Testing and adjusting, "Handling of battery disconnect switch".) k Loosen the cap of the hydraulic tank

gradually, and release the pressure remaining inside the hydraulic tank.

Removal 8 $, 8 7 6 7 % $ ~ $ % - % 8 $, % ! $ 8 $, % Sling the head side of lift cylinder assembly (1) by using rope, etc., and remove piston rod mounting pin (2). • Both right and left sides

Sling center frame assembly (5). a Sling by the right and left ends of frame on the front side and by the work equipment frame (lift cylinder head pin mounting portions) on the rear side, 4 points in total. a Install chain blocks as slings to the rear sling points in order to adjust the weight balance. Remove right and left center frame mounting pins (6). Move the center frame assembly forward to remove it. 4

Center frame assembly: 870 kg

a Do not use metal slinging tools at the cylinder head side of the piston rod.

Disconnect hoses (6 pieces). • ( ) " & % $ ( $ ' $ & ) • ( ) * ' ! $ ( $ ' $ & ) a Plug the disconnected hose and the mounting port to prevent oil leakage.

D61EM-23M0

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50 Disassembly and assembly Work equipment

Installation

(D61-LL00-720-K-00-A)

• Perform installation in the reverse order to removal. • Refilling of oil (hydraulic tank) Refill with oil to the specified level through the oi filler port. Run the engine to circulate the oi through the system. Then check the oil leve again. 5 Hydraulic tank (hydraulic oil): Only necessary quantity (For details, see "Table coolant and lubricants") • Greasing

fue

a Be sure to grease the removed and reinstalled mounting pins when the installation is complete.

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Cab and its attachments

Removal and installation of ROPS cab assembly

k Place machine on a level ground and set

parking brake lever to LOCK position. k Lower the work equipment to the ground and

set the work equipment lock lever to LOCK position. k Turn the starting switch to OFF position, and

stop the engine. k Turn the battery disconnect switch to OFF

position, and remove the key. (For details, see Testing and adjusting, "Handling of battery disconnect switch".) k If you drain the coolant when it is still hot,

you may be scalded. Wait until the coolant temperature drops before starting the work.

Removal

4. Close valve (8) at the heater inlet. 5. Disconnect wiring harness connectors FG (9) and MC (10). 6. Remove bracket (11), and leave it free. 7. Disconnect heater inlet hose (12) and outlet hose (13).

(D61-K000-520-K-01-A)

8. Remove wiring harness clamp (17), and disconnect the following wiring harness connectors. • Connector 5 (18) • Connector 3 (19) • Connector 2 (20) • Connector 104 (21)

9. Remove bracket (22) ,and disconnect air conditioner refrigerant tubes (23) and (24). 3. Remove floor plate (7). D61EM-23M0

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50 Disassembly and assembly Cab and its attachments

• ROPS stopper mounting bolt (31):

10.Remove cover (25) on the left side of the machine. 11.Disconnect ground terminal (26).

14.Remove mounting bolts (32) (2 pieces). 15.Remove ROPS stopper mounting bolts (33) (2 pieces).

16.Remove mounting bolts (34) (3 pieces) from each of the right and left sides.

12.Remove covers (27) and (28) from the rear of the cab. 17.Open machine left side cover (35).

13.Remove the following right and left bolts. • Mounting bolt (29): 4 pieces each 50-180

D61EM-23M0

50 Disassembly and assembly

Cab and its attachments

18.Disconnect harness connector CB19 (36).

19.Disconnect washer hoses (38) (4 pieces). a Check the installed position of each of the disconnected hoses, and note it.

21.Open machine right side cover (43).

22.Disconnect ripper PPC hoses (44) (3 pieces). (if equipped) 23.Remove wiring harness clamp (45), and disconnect the following wiring harness connectors. • Connector 102 (46) • Connector RS (47) • Connector WE (48)

20.Remove wiring harness clamp (39), and disconnect the following wiring harness connectors. • Connector BR1 (40) • Connector BR2 (41) • Connector BR3 (42)

24.Sling ROPS cab assembly (49), and remove it. a Ensure that all the wiring, piping, clamps, etc. are disconnected before removing. 4 ROPS cab assembly (49): 1,150 kg

D61EM-23M0

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50 Disassembly and assembly Cab and its attachments

Installation

(D61-K000-720-K-00-A)

• Perform installation in the reverse order to removal. [*1] a When installing cab, check that the directions of ROPS stopper tabs (50) and (51) are the same as shown in the figure.

50-182

Tightening torque: Nm {kgm} 14.9 to 17.6 {1.6 to 1.8} 20.3 to 27.1 {2.1 to 2.7} 28.4 to 36.6 {2.9 to 3.7}

D61EM-23M0

50 Disassembly and assembly

Cab and its attachments

Removal and installation of operator's cab glass (adhesion glass)

(1): Front window glass (2): Left door window glass/ right door window glass

a Special tools Symbol X 1

Part No.

Part name

793-498-1210 Lifter (suction cup)

Necessity Q'ty

a Among the window glasses of the operator's cab, 6 pieces of window glasses (1), (2) (RH and LH), (3) (RH and LH) and (4) are of the adhesion type. This section describes only the replacement procedure of the adhesion type glass.

t 2

(3): Left sash window glass/ right sash window glass (4): Rear window glass (5): Dam rubber

D61EM-23M0

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50 Disassembly and assembly Cab and its attachments

Removal

(D61-K183-520-K-00-A)

a Remove the window glass to be replaced according to the following procedure. 1. Cut the adhesive between broken window glass (6) and operator's cab (metal sheet) (7) by using seal cutter [1].

2. Remove the window glass.

a When a seal cutter is not available, drill a hole in the adhesive and dam rubber with a gimlet, then pass one end of an ultrafine wire (such as piano wire) [2] through the hole. Clip both ends of the ultrafine wire passed through the hole with pliers [3] (or wind the wire around pliers), then cut off the adhesive and dam rubber by shuttling the wire. Since the wire may be broken by the frictional heat, apply lubricant to it. (Figure shows the operator's cab on a wheel loader.)

a If the window glass is broken in small pieces, it may be removed with knife [4] and a flathead screwdriver. a While widening the cut with a flat-head screwdriver, cut the adhesive and dam rubber with knife [4]. (The following figure shows the operator's cab for a wheel loader.)

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Cab and its attachments

Installation

(D61-K183-720-K-00-A)

1. Remove the remaining adhesive and dam rubber from the sheet metal (adhesion surfaces) of the operator's cab by using a knife and scraper [5]. a Remove the adhesive and dam rubber to a degree that they will not affect adhesion of the new adhesive. Be careful not to scratch the painted surfaces. (If the painted surfaces are damaged, adhesion will be lowered.) (The following figure shows the operator's cab for a wheel loader.)

a Do not remove the release tape on glassadhering side of the dam rubber until installation of the window glass is started. a When sticking the dam rubber, do not touch the cleaned surface. a Care should be taken not to float the dam rubber in each sticking corner. a Be careful not to overlap the beginning and end portions of dam rubber (3). Contact mating ends (a) with each other.

2. Remove oil, dusts and stains from bonding surfaces on operator's cab (7) and window glass (8) by using white gasoline. a Clean them thoroughly since insufficient cleaning induces defective adhesion. a Clean all the black part on the back of the window glass. a After cleaning, leave them as is 5 minutes for natural drying. 4. Position the new window glass. 1) Position the window glass by using tool X1, and make the clearances between the window glass and the operator's cab on the right, left, upper, and lower sides even.

3. Adhere dam rubber (double-sided adhesive tape) (3) along the inside edge of the glass adhering section of the front window glass and right and left door window glasses.

D61EM-23M0

a Adjust the position of front window glass (1) from the inside of operator's cab (7). Adjust the position of the front window glass so that the distance between the black coating portion (black ceramic) and the metal sheet of operator's cab (7) becomes even at the right and left and top and bottom positions. a Adjust the position of right and left door window glasses (2) so that the clearance becomes even between glasses and metal plate of the door. 50-185

50 Disassembly and assembly Cab and its attachments

2) After the positioning, stick tape [6] between front window glass (1) and operator's cab (7), and between right and left door window glasses (2) and the right, left and bottom portions of right and left doors (9). Then, mark line (e) on these tapes for positioning. 3) Cut the tape between window glasses (1) and (2) and operator's cab (7) with a utility knife or others, and remove the window glasses. a Do not remove the tapes left on the window glass and the operator's cab before installing the window glass.

2) Cut the tip of adhesive nozzle (12) to dimensions (f) and (g) shown in the figure. • Dimension "f": 10 mm • Dimension "g": 15 mm

5. Apply adhesive. 2 Adhesive: Sika Japan Sikaflex 256HV a Do not use a primer. a The use limit of adhesive is 6 months after its production. Do not use the adhesive after this limit.

3) Set adhesive cartridge (10) on caulking gun [7]. a A better workability is obtainable from a power caulking gun.

a Adhesives must be stored at 25°C or lower in a dark and cool place. a Never heat an adhesive beyond 30°C. a When reusing the adhesive, remove hardened adhesive at the nozzle tip completely. 1) Break aluminum dehumidification membrane (11) at the mouth of adhesive cartridge (10) and attach there the dedicated nozzle. 4) Remove tape (3a) on glass adhesion side of the dam rubber.

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Cab and its attachments

5) Apply adhesive (13) to outside portion of dam rubber (3) on the operator's cab.

6. Install the front window glass. 1) Install front window glass (1) to operator's cab (7) by using tool X1 while aligning lines (e) of positioning tapes [6] attached in Step 5. a Since the window glass cannot be removed and adhered again, adhere it with utmost care. a Adhere the glass within 5 minutes after applying the adhesive. 2) After installation of the window glass, press its periphery until it is adhered to the dam rubber. a Press the corners of the window glass firmly.

a Apply adhesive (13) to dam rubber (3) of operator's cab (7) with dimensions (h) and (j) shown in the figure . • Dimension "h": 10 mm • Dimension "j": 15 mm a Height of applied adhesive (13) must be higher than that of dam rubber (3). a Height of applied adhesive must be uniform.

D61EM-23M0

7. Install right and left door window glasses. 1) Install right and left door window glasses (2) to doors (9) by using tool X1 while aligning lines (e) of positioning tapes [6] attached in Step 5. a Since the window glass cannot be removed and adhered again, adhere it with utmost care. a Adhere the glass within 5 minutes after applying the adhesive. 2) After installation of the window glass, press its periphery until it is adhered to the dam rubber.

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50 Disassembly and assembly Cab and its attachments

a Press the corners of the window glass firmly.

8. Fix window glass (9). 1) Fix the front window glass securely to cure it by using styrene foam blocks [10] and rubber bands [11]. a Or secure it with adhesive tapes. (The figure shows the operator's cab for a hydraulic excavator.)

9. Clean the remaining primer and adhesive on the window glass and operator's cab after completing the installation of the window glass. a Wipe off adhesives before it is dried up by using white gasoline. a When cleaning the glass, do not give an impact to it. 10.Cure the adhered window glass. 1) Keep the stopper rubbers, styrene foam blocks, and rubber bands installed for 10 hours of curing period. (Ambient temperature 20°C/ Humidity 65 %) 2) After applying adhesives, cure the windows for 24 hours. Then, start the machine.

50-188

D61EM-23M0

50 Disassembly and assembly

Cab and its attachments

Removal and installation of operator's seat

k Place machine on a level ground and set

parking brake lever to LOCK position. k Lower the work equipment to the ground,

and set the work equipment lock lever to LOCK position. k Turn the starting switch to OFF position, and

stop the engine. k Turn the battery disconnect switch to OFF

position, and remove the key. (For details, see Testing and adjusting, "Handling of battery disconnect switch".)

Removal

(D61-K2Q0-520-K-00-A)

Installation

(D61-K2Q0-720-K-00-A)

• Perform installation in the reverse order to removal.

1. Move the operator's seat forward ,and disconnect wiring harness connectors SBC (1) and HS (1a). 2. Remove mounting bolts (2). 3. Disconnect harness connector ASUS (1b). 4. Remove operator's seat assembly (3). 4 Operator's seat assembly (3): 30 kg

5. Remove mounting bolts (4), and remove suspension assembly (5). 4 Suspension assembly (5): 35 kg

D61EM-23M0

50-189

50 Disassembly and assembly Cab and its attachments

Removal and installation of seat belt k Place machine on a level ground and set

parking brake lever to LOCK position.

1 3 Mounting bolt (4): 19.6 to 29.4 Nm {2.0 to 3.0 kgm}

k Lower the work equipment to the ground,

and set the work equipment lock lever to LOCK position. k Turn the starting switch to OFF position, and

stop the engine. k Turn the battery disconnect switch to OFF

position, and remove the key. (For details, see Testing and adjusting, "Handling of battery disconnect switch".)

Removal

(D61-K2Q3-520-K-00-A)

1. Move the operator's seat to the rear, and disconnect wiring harness connector SBC (1). 2. Remove mounting bolt (2), and remove left seat belt catch (3). [*1]

3. Remove mounting bolt (4) , and remove right seat belt reel (5). [*2]

Installation

(D61-K2Q3-720-K-00-A)

• Perform installation in the reverse order to removal. [*1] 3 Mounting bolt (2): 19.6 to 29.4 Nm {2.0 to 3.0 kgm} [*2] 50-190

D61EM-23M0

50 Disassembly and assembly

Cab and its attachments

Removal and installation of foot heater assembly

k Place machine on a level ground, and set

parking brake lever to LOCK position. k Lower the work equipment to the ground,

and set the work equipment lock lever to LOCK position. k Turn the starting switch to OFF position, and

stop the engine. k Turn the battery disconnect switch to OFF

position, and remove the key. (For details, see Testing and adjusting, "Handling of battery disconnect switch".) k If you drain the coolant when it is still hot,

you may be scalded. Wait until the coolant temperature drops before starting the work.

Removal

(D61-K310-520-K-00-A)

1. Remove operator's seat assembly (2). For details, see "Removal and installation of operator's seat assembly." 2. Remove floor mat (3).

5. Close valve (6) at the heater inlet. 6. Remove bracket (7), and leave it free. 7. Disconnect heater inlet hose (8) and outlet hose (9). a Heater inlet hose (8) is disconnected to disconnect heater inlet hose (10) easily. 8. Disconnect heater inlet hose (10). 9. Remove clamp (11) ,and disconnect wiring harness connector 92 (12).

3. Remove floor plate (4).

10.Remove mounting bolts (13) (4 pieces), and remove foot heater assembly (14). 4. Remove foot heater cover (5).

D61EM-23M0

4 Foot heater assembly (14): 25 kg

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50 Disassembly and assembly Cab and its attachments

Installation

(D61-K310-720-K-00-A)

• Perform installation in the reverse order to removal. • Refilling of coolant (radiator) Refill with coolant to the specified level through the coolant filler port. Run the engine to circulate the coolant through the system. Then check the coolant level again. 5 Radiator (engine coolant): Only necessary quantity (For details, see "Table coolant and lubricants")

50-192

fuel,

D61EM-23M0

50 Disassembly and assembly

Cab and its attachments

Disassembly and assembly of foot heater assembly Disassembly

(D61-K310-530-K-00-A)

1. Remove harness clamp (1). 2. Disconnect hoses (2) and (3). 3. Remove grommet (4).

Assembly

(D61-K310-710-K-00-A)

• Assemble in the reverse order of disassembly.

4. Reverse the foot heater assembly. 5. Disconnect wiring harness connector AC2 (5).

6. Remove mounting bolts (6) (4 pieces), and remove foot heater assembly (8) from frame (7).

7. Disconnect hoses (9) and (10). 8. Remove mounting bolts, and remove foot heater assembly (8) from frame (11).

D61EM-23M0

50-193

50 Disassembly and assembly Cab and its attachments

Removal and installation of air conditioner unit assembly k Place machine on a level ground and set

parking brake lever to LOCK position.

a Remove cover (3) according to the following procedure.

k Lower the work equipment to the ground,

and set the work equipment lock lever to LOCK position. k Turn the starting switch to OFF position, and

stop the engine. k Turn the battery disconnect switch to OFF

position, and remove the key. (For details, see Testing and adjusting, "Handling of battery disconnect switch".) k If you drain the coolant when it is still hot,

you may be scalded. Wait until the coolant temperature drops before starting the work.

1) Remove cover (4).

your sight. And if it touches your skin, you may suffer from frostbite. Accordingly, put on the protective eyeglasses, gloves and working suits with long sleeves while you are collecting or filling the refrigerant.

2) Disconnect connector RVC (5).

a Note connector numbers and installed positions before disconnecting wiring and hoses.

Removal

(D61-K540-520-K-00-A)

1. Collect the refrigerant (air conditioner gas: R134a) from the air conditioner circuit. [*1] a Remove left side cover of engine hood, and collect refrigerant from port (1). a Refrigerant to be collected: 900 ± 50 g

3) Remove mounting bolts (7) of bracket (6).

2. Remove covers (2) and (3) on the upper side of the operator’s cab.

50-194

D61EM-23M0

50 Disassembly and assembly

Cab and its attachments

4) Remove KOMTRAX antenna (8) and bracket (6). Pull wiring harness (9) from inside of cover (3) to remove it from the cover. 5) Remove cover (3).

2) Remove plate (13). 3) Remove bracket (14) mounting bolts (15) to (18), and remove bracket (14). 4) When removing the fan or fan motor, disconnect connector (19), and remove mounting bolts (20) (4 pieces each on the right and left sides). 5) Remove mounting bolts (21). a It is not necessary to remove bracket (22).

3. Disconnect tubes (10) and (11). [*1]

4. Remove the condenser according to the following procedure. 1) Disconnect connector (12).

D61EM-23M0

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50 Disassembly and assembly Cab and its attachments

6) Remove mounting bolts (23).

8. Remove plug (38).

7) Remove fan shroud (24) by moving it together with the condenser to the right.

9. Remove mounting bolts (39).

10.Loosen knob (40), and open cover (41). 5. Remove caps (34) (12 pieces).

11.Remove mounting bolts (42). 6. Remove mounting bolts (35) (12 pieces). 7. Loosen knob (36), and remove trim (37). 50-196

D61EM-23M0

50 Disassembly and assembly

Cab and its attachments

a When connecting the refrigerant pipes, apply compressor oil for new refrigerant (R134a) (SANDEN: SP-20 PAG oil) to O-ring (70). [*1] a Tighten the sleeve nuts on tubes (10) and (11) to the following torque. 3 Sleeve nut: 14.9 to 17.6 Nm {1.6 to 1.8 kgm} [*2] 12.Remove brackets (25) and (26). 13.Disconnect connectors (27) and (28). 14.Disconnect hoses (29) and (30). 15.Disconnect tubes (31) and (32). [*2] 16.Remove air conditioner unit assembly (33). [*3]

a Tighten the sleeve nuts on tubes (31) and (32) to the following torque. 3 Sleeve nut (31): 28.4 to 36.6 Nm {2.9 to 3.7 kgm} 3 Sleeve nut (32): 14.9 to 17.6 Nm {1.6 to 1.8 kgm} [*3] a Before installing, apply liquid gasket to both ends (hatched area) of the air conditioner unit and to the front surface of air conditioner unit (contact surface with cab).

• Filling of refrigerant (R134) Refill the air conditioner circuit with refrigerant. a Filling quantity: 900 ± 50 g

Installation

(D61-K540-720-K-00-A)

• Refilling of air conditioner compressor oil See Air conditioner, "Handling of compressor oil".

• Perform installation in the reverse order to removal. a When installing the hose for the air conditioner circuit, be careful not to allow any invasion of dirt, dusts and water into the hose. a When installing the air conditioner hoses, check that O-rings (70) are fitted to each of their fittings. a Check that O-ring (70) is free from flaws and deterioration.

D61EM-23M0

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50 Disassembly and assembly Cab and its attachments

Removal and installation of air conditioner compressor assembly ) k Place machine on a level ground and set

parking brake lever to LOCK position. k Lower the work equipment to the ground,

and set the work equipment lock lever to LOCK position. k Turn the starting switch to OFF position, and

1) Set wrench [1] to part A (width across flats: 12.7 mm) of the tensioner assembly. 2) Turn wrench [1] in the direction opposite (R) to the winding-up direction to decrease the alternator and air conditioner compressor belt (4) tension. 3) Remove alternator and air conditioner compressor belt (4).

stop the engine. k Turn the battery disconnect switch to OFF

position, and remove the key. (For details, see Testing and adjusting, "Handling of battery disconnect switch".)

Removal

(D61-K590-520-K-00-A)

1. Remove engine hood assembly. For details, see "Removal and installation of engine hood assembly". 2. Collect refrigerant (air conditioner gas: R134a) from valve (1). [*1] 3. Remove tube clamps (2) (2 pieces) and disconnect air conditioner tubes (3) (2 pieces).

k Make sure before turning the wrench that

conditioner compressor belt (4), slowly and carefully restore the tensioner assembly. k Be careful not to get your fingers caught

between the pulley and alternator and air conditioner compressor belt (4) during work.

a Ask a qualified person for collecting, adding and filling operations of the refrigerant. (Only registered persons can work.) a Never release the refrigerant to the atmosphere.

5. Remove the wiring harness clamp (5), and disconnect wiring harness 23 (6).

k If refrigerant gets in your eyes, you may

50-198

6. Remove cover (7).

D61EM-23M0

50 Disassembly and assembly

Cab and its attachments

7. Remove mounting bolts (8) (3 pieces), and remove air conditioner compressor assembly (9).

Installation

(D61-K590-720-K-00-A)

• Perform installation in the reverse order to removal. [*1], [*2] a When installing the hose for the air conditioner circuit, be careful not to allow any invasion of dirt, dusts and water into the hose. a When installing the air conditioner hoses, check that O-rings (70) are fitted to each of their fittings. a Check that O-ring (70) is free from flaws and deterioration. a When connecting the refrigerant pipes, apply compressor oil for new refrigerant (R134a) (SANDEN: SP-20 PAG oil) to O-ring (70). Table of tightening torque for refrigerant pipe joint. Thread size 5/8 -18UNF 3/4 -16UNF 7/8 -14UNF

D61EM-23M0

Tightening torque: Nm {kgm} 14.9 to 17.6 {1.6 to 1.8} 20.3 to 27.1 {2.1 to 2.7} 28.4 to 36.6 {2.9 to 3.7}

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50 Disassembly and assembly Electrical system

Electrical system

Removal and installation of machine monitor assembly

k Place machine on a level ground, and set

parking brake lever to LOCK position. k Lower the work equipment to the ground,

and set the work equipment lock lever to LOCK position. k Turn the starting switch to OFF position, and

stop the engine. k Turn the battery disconnect switch to OFF

position, and remove the key. (For details, see Testing and adjusting, "Handling of battery disconnect switch".)

Removal

(D61-Q180-520-K-00-A)

1. Remove mounting bolts (1) (4 pieces).

4. Pull out machine monitor assembly (7), and disconnect clamps (8) and (9). 5. Disconnect harness connectors CM04 (10), CM01 (11), CM02 (12), and KEY (13). 6. Remove machine monitor assembly (7).

2. Pull out machine monitor cover (2) and disconnect wiring harness connectors HET (3), FLSW (4), and RLSW (5).

Installation 3. Remove mounting bolts (6 (4 pieces).

50-200

(D61-Q180-720-K-00-A)

• Perform installation in the reverse order to removal.

D61EM-23M0

50 Disassembly and assembly

Electrical system

Removal and installation of engine controller assembly

k Place machine on a level ground and set

parking brake lever to LOCK position. k Lower the work equipment to the ground and

set the work equipment lock lever to LOCK position. k Turn the starting switch to OFF position and

stop the engine. k Turn the battery disconnect switch to OFF

position and remove the key. (For details, see Testing and adjusting, "Handling of battery disconnect switch".)

Removal

(D61-AP70-520-K-00-A)

1. Remove engine hood assembly. For details, see "Removal and installation of engine hood assembly". 2. Collect refrigerant (air conditioner gas: R134a) from valve (1). [*1] 3. Remove tube clamps (2) (2 pieces), and disconnect air conditioner tubes (3) (2 pieces). [*2]

5. Remove the wiring harness clamp (5) and disconnect the harness connector (6). 6. Remove mounting nuts (8) (3 pieces) [*3] wiring harness cable tie clamps (7) (3 pieces). 7. Disconnect wiring harness connector (11).

8. Disconnect wiring harness connector (12) from the controller. a Remove dirt, etc. sticking to each wiring harness connector before removing them. 9. Remove mounting bolts (14) (12 pieces) [6]* a Ask a qualified person for collecting, adding and filling operations of the refrigerant. (Only registered persons can work.)

a Mounting bolt (front) is tightened with the ground terminal. 10.Remove engine controller (16).

a Never release the refrigerant to the atmosphere. k If refrigerant gets in your eyes, you may

Installation

(D61-AP70-720-K-00-A)

• Perform installation in the reverse order to removal.

D61EM-23M0

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50 Disassembly and assembly Electrical system

[*1], [*2] a When installing the hose for the air conditioner circuit, be careful not to allow any invasion of dirt, dusts and water into the hose.

• Refilling of air conditioner compressor oil See Air conditioner, "Handling of compressor oil".

Tightening torque: Nm {kgm} 14.9 to 17.6 {1.6 to 1.8} 20.3 to 27.1 {2.1 to 2.7} 28.4 to 36.6 {2.9 to 3.7}

[*3] 3 Mounting nut (8): 10 ± 2 Nm {1.0 ± 0.2 kgm} [*4] 3 Hexagonal socket head bolt (4 mm) (10) at center of wiring harness connector: 3 ± 1 Nm {0.3 ± 0.1 kgm} [*5] a Remove dirt, etc. sticking to wiring harness connectors CE03 (11), (12), and (13) before connecting them. [*6] 3 Mounting bolt (14): 24 ± 4 Nm {2.4 ± 0.4 kgm} a Tighten stud bolt (15) together with the ground terminal. • Filling of refrigerant (R134) Refill the air conditioner circuit with refrigerant. a Filling quantity: 900 ± 50 g 50-202

D61EM-23M0

50 Disassembly and assembly

Electrical system

Removal and installation of HST controller assembly

k Place machine on a level ground and set

parking brake lever to LOCK position. k Lower the work equipment to the ground and

set the work equipment lock lever to LOCK position. k Turn the starting switch to OFF position and

stop the engine. k Turn the battery disconnect switch to OFF

position and remove the key. (For details, see Testing and adjusting, "Handling of battery disconnect switch".)

Removal

(D61-C7W0-520-K-00-A)

1. Remove operator's seat assembly (2). For details, see "Removal and installation of operator's seat assembly." 2. Remove right side cover (1) of the operator seat.

Installation

(D61-C7W0-720-K-00-A)

• Perform installation in the reverse order to removal. [*1] • Remove dirt, etc. sticking to each wiring harness connector before connecting them. 3 Hexagonal socket head bolt (4 mm) at center of each wiring harness connector: 2.82 Nm {0.288 kgm}

3. Disconnect wiring harness connectors ST-3 (2), ST-2 (3), and ST-1 (4). [*1] a Remove dirt, etc. sticking to each wiring harness connector before removing them. a Remove hexagonal socket head bolt (4 mm) at the center of each wiring harness connector. 4. Remove mounting bolts (5) ( 4 pieces), and remove HST controller assembly (6).

D61EM-23M0

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50 Disassembly and assembly Electrical system

Removal and installation of KOMTRAX terminal

k Place machine on a level ground, and set

parking brake lever to LOCK position. k Lower the work equipment to the ground,

and set the work equipment lock lever to LOCK position. k Turn the starting switch to OFF position, and

stop the engine. k Turn the battery disconnect switch to OFF

position, and remove the key. (For details, see Testing and adjusting, "Handling of battery disconnect switch".)

Removal

(D61-Q210-520-K-00-A)

1. Remove the machine monitor assembly. For details, see "Removal and installation of machine monitor assembly". 2. Wiring harness connector Disconnect COMMUNICATION (1), CK02 (2), CK01 (3), and GPS (4). 3. Remove mounting bolts (5) (4 pieces). 4. Remove KOMTRAX terminal (6).

Installation

(D61-Q210-720-K-00-A)

• Perform installation in the reverse order to removal.

50-204

D61EM-23M0

SHOP MANUAL

D61E -23M0 Model

Serial Number

D61E -23M0

B 0001 and up

60 Maintenance standard 8 60 Maintenance standard

D61EM-23M0

60-1

60 Maintenance standard Table of contents

Table of contents

60 Maintenance standard - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 60-1 Table of contents - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 60-2 Engine and cooling system- - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 60-3 Engine mount- - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 60-3 Cooling fan motor - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 60-4 Oil cooler bypass and HST charge safety valve- - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 60-6 Power train - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 60-7 Damper - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 60-7 HST pump - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 60-8 HST motor - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 60-10 Charge pump - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 60-11 Solenoid valve - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 60-12 Final drive - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 60-13 Sprocket - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 60-14 Full-scale drawing of sprocket tooth profile - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 60-15 Undercarriage and frame - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 60-16 Suspension - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 60-16 Track frame and idler cushion - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 60-18 Idler - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 60-20 Track roller- - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 60-22 Carrier roller- - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 60-24 Track shoe- - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 60-25 Hydraulic system - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 60-28 Hydraulic tank - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 60-28 Work equipment and cooling fan pump - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 60-29 Control valve - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 60-32 Anti-drop valve - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 60-39 Work equipment - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 60-41 Planter unit - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 60-41 Lift cylinder - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 60-44 Swing cylinder - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 60-45 Cab and its attachments- - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 60-46 Cab mount- - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 60-46 Electrical system - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 60-47 Electric steering lever - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 60-47

60-2

D61EM-23M0

60 Maintenance standard Engine and cooling system

Engine and cooling system

Engine mount

D61EM-23M0

60-3

60 Maintenance standard Engine and cooling system

Cooling fan motor

60-4

D61EM-23M0

60 Maintenance standard Engine and cooling system

No.

Item

Spool return spring

Check valve spring

D61EM-23M0

Criteria Standard dimension Free Load at Installed length x installed length Outside length diameter 58.8 N 44.84 x 12 33 {6 kg} 3.33 N 13.0 x 6.5 7.1 {0.34 kg}

Unit: mm Remedy Repair limit Free length — —

Load at installed length 47.1 N {4.8 kg} 2.66 N {0.27 kg}

If damaged or deformed, replace spring

60-5

60 Maintenance standard Engine and cooling system

Oil cooler bypass and HST charge safety valve

a HST: Abbreviation for Hydrostatic Transmission

Oil cooler bypass valve

No.

60-6

Item

Oil cooler bypass valve spring

(D61-B8PB-034-K-01-A)

Criteria Standard dimension Free Load at Installed length x installed length Outside length diameter 153.9 N 56.9 x 23.6 43.6 {15.7 kg}

Unit: mm Remedy Repair limit Free length

Load at installed length

—

123.1 N {12.6 kg}

If damaged or deformed, replace spring

D61EM-23M0

60 Maintenance standard

Power train

Damper

No. 1 2

Item Distance between HST pump shaft end surface and boss end tip Wear of internal teeth of coupling (plastic)

D61EM-23M0

Unit: mm Remedy

Criteria Standard dimension

Tolerance

± 0.5 Repair limit: 1.3

Adjustment Replacement

60-7

60 Maintenance standard Power train

HST pump

a HST: Abbreviation for Hydrostatic Transmission

60-8

D61EM-23M0

60 Maintenance standard

Power train

Towing valve

D61EM-23M0

(D61-C2VF-034-K-00-A)

60-9

60 Maintenance standard Power train

HST motor

a HST: Abbreviation for Hydrostatic Transmission

60-10

D61EM-23M0

60 Maintenance standard

Power train

Charge pump

No.

Item

1 Side clearance

Type SAR (2) 56

Criteria Standard clearance 0.100 to 0.150

Clearance between plain bearing inside 2 circumference and gear shaft outside circumference

SAR (2) 56

0.067 to 0.125

Torque of splined shaft

0.200

Replacement

Standard dimension

Tolerance

Repair limit

SAR (2) 56

120

0 -0.5

—

2.9 to 6.9 Nm {0.3 to 0.7 kgm}

Discharge Rotating Type speed (rpm) — Oil: EO10-CD Oil temperature: 45 to 55°C SAR (2) 56 2,500

D61EM-23M0

Allowable clearance 0.190

Type 3 Driving depth of pin

Unit: mm Remedy

Discharge pressure MPa {kg/ cm2} 3.2 {33}

Standard discharge (l/min)

Allowable discharge (l/min)

135.6

120.1

—

60-11

60 Maintenance standard Power train

Solenoid valve EPC valve

No.

(D61-C4E9-034-K-00-A)

Item

Return spring

60-12

Criteria Standard dimension Free Load at Installed length x installed length Outside length diameter 3.1N 9.5 8.4 {0.32 kg}

Unit: mm Remedy Repair limit Free length

Load at installed length

—

2.5N {0.26 kg}

Replace EPC valve assembly if damaged or deformed

D61EM-23M0

60 Maintenance standard

Power train

Final drive

a Figure shows D61E -23 equipped with PLUS type track shoes.

No. 1

Item Backlash between No. 1 sun gear and No. 1 planetary pinion Backlash between No. 1 planetary carrier and No. 2 sun gear Backlash between No. 2 sun gear and No. 2 planetary pinion Backlash between No. 2 planetary pinion and ring gear Backlash between No.1 planetary pinion and ring gear

D61EM-23M0

Unit: mm Remedy

Criteria Standard clearance

Allowable clearance

0.14 to 0.39

1.00

0.27 to 0.46

1.00

0.14 to 0.39

1.00

0.17 to 0.55

1.10

0.17 to 0.55

1.10

Replace

60-13

60 Maintenance standard Power train

Sprocket

For conventional type track shoes

No.

Item

Criteria

Wear of tooth tip width

Standard dimension 77

Repair limit 68

Tooth bottom thickness

29.25

60-14

Unit: mm Remedy Rebuild by build-up welding or replace

D61EM-23M0

60 Maintenance standard

Power train

Full-scale drawing of sprocket tooth profile

For conventional type track shoes a Duplicate the full-scale drawing onto an OHP sheet.

D61EM-23M0

60-15

60 Maintenance standard Undercarriage and frame

Undercarriage and frame Suspension a

1 1

The figure shows D61EM-23M0

60-16

D61EM-23M0

60 Maintenance standard Undercarriage and frame

The figure shows D61EM-23M0

No.

Item

Clearance between pivot shaft and bushing (large)

Clearance between pivot shaft and bushing (small) Clearance between 3 center pin and bushing Clearance between side 4 pin and bushing Press fit force of pivot 5 shaft bushing (large) Press fit force of pivot 6 shaft bushing (small) — Oil quantity at pivot shaft 2

D61EM-23M0

Standard dimension 148 105 70 60

Criteria Tolerance Shaft Hole -0.145 +0.063 -0.208 0 -0.120 +0.054 -0.174 0 -0.100 +0.174 -0.146 +0.100 -0.030 +0.010 -0.060 -0.020

Unit: mm Remedy Standard clearance 0.145 to 0.271 0.120 to 0.228 0.200 to 0.320 0.010 – 0.070

Allowable clearance 1.0 1.0

Replace bushing

0.5 0.5

0.98 to 22.6 kN {0.1 to 2.3 ton} 0.98 to 36.3 kN {0.1 to 3.7 ton}

—

4.5 l (power line oil: TO30)

60-17

60 Maintenance standard Undercarriage and frame

Track frame and idler cushion a

The figure shows D61EM-23M0

60-18

D61EM-23M0

60 Maintenance standard Undercarriage and frame

The figure shows D61EM-23M0

No. 1

Item Deformation of track frame

Recoil spring

Criteria Item Straightening Torsion Opening at idler Tolerance Free Installed length x length Outside diameter 755 x 212

Clearance between piston and bushing

Press fit force of idler yoke — Amount of filled grease 4

D61EM-23M0

Unit: mm Remedy

Standard dimension 75

Repair limit 7 (in length of 3,000) 3 (in length of 300) 5 Repair limit Load at installed length

163.6 kN 593 {16,692 kg} Tolerance Shaft Hole -0.030 +0.291 -0.076 +0.077

Free length

Load at installed length

736

145.7 kN {14,856 kg}

Standard clearance 0.107 to 0.367

Allowable clearance 1.0

Repair

Replace bushing

294 kN {30 ton}

Adjustment

140 cc (grease: G2-LI)

—

60-19

60 Maintenance standard Undercarriage and frame

Idler

60-20

D61EM-23M0

60 Maintenance standard Undercarriage and frame

No.

Item Outside diameter of protrusion

Criteria

Repair limit Standard dimension — 588 2 Outside diameter of tread 550 530 3 Depth of tread 19 29 4 Thickness of tread 24.5 14.5 5 Width of tread 39.5 43.5 — 6 Overall width 164 Tolerance Standard Standard Allowable clearance clearance Clearance between shaft dimension Shaft Hole 7 and bushing -0.215 +0.195 0.215 to — 60 0.510 -0.315 0 -0.215 +0.046 Clearance between shaft 0.215 to — 8 and support 60 0.361 -0.315 0 Standard clearance Allowable clearance 9 Axial play of idler — 0.26 to 0.66 Clearance between guide — 10 plate and side plate 0.2 to 1.2 Standard shim thickness 4.0 11 for side plate mount 1

D61EM-23M0

Unit: mm Remedy

Rebuild by build-up welding or replace

Replace

Adjust shims or replace plate

60-21

60 Maintenance standard Undercarriage and frame

Track roller

For conventional type track shoes (single flange type)

No. 1 2 3 4 5 6 7

8 9

60-22

Item Outer diameter of flange (outside)

(D61-DTD0-034-K-00-A)

Criteria

Repair limit Standard dimension — 233 Outside diameter of tread 200 164 Thickness of tread 66.5 48.5 Width of flange (outside) 19.5 13.5 — Width of tread 44.5 — Overall width 212 Tolerance Standard Standard Allowable clearance clearance Clearance between shaft dimension Shaft Hole and bushing -0.244 +0.208 0.207 to — 60 0.498 -0.290 -0.037 -0.250 -0.160 0.020 to Clearance between shaft — 59.7 0.140 and collar -0.300 -0.230 Standard clearance Allowable clearance Axial play of roller — 0.26 to 0.66

Unit: mm Remedy

Rebuild by build-up welding or replace

Replace

D61EM-23M0

60 Maintenance standard Undercarriage and frame

For conventional type track shoes (double flange type)

No. 1 2 3 4 5 6 7 8

Item Outer diameter of flange (outside) Outer diameter of flange (inside) Outside diameter of tread Thickness of tread Width of flange (outside) Width of flange (inside) Width of tread Overall width

Standard dimension 233

Repair limit —

227

—

200 66.5 19.5 18 43.5 212 Tolerance Shaft Hole -0.244 +0.208 -0.290 -0.037 -0.250 -0.160 59.7 -0.300 -0.230 Standard clearance 0.26 to 0.66

Clearance between shaft and collar

D61EM-23M0

Unit: mm Remedy

Criteria

Standard Clearance between shaft dimension and bushing 60

11 Axial play of roller

(D61-DTD0-034-K-01-A)

Rebuild by 164 build-up welding or 48.5 replace 13.5 12 — — Standard Allowable clearance clearance 0.207 to — 0.498 Replace 0.020 to — 0.140 Allowable clearance —

60-23

60 Maintenance standard Undercarriage and frame

Carrier roller

For conventional type track shoes

(D61-DTJ0-034-K-00-A)

No. 1 2 3 4 5 6

Item Outside diameter of flange

Repair limit — 143 16.5 — 11 Standard Allowable clearance clearance 0.100 to — 0.500 Standard Allowable interferinterferdimension Shaft Hole ence ence +0.150 +0.030 0.100 to — 61.5 0.150 +0.130 0 Standard clearance Allowable clearance — 0 to 0.32

Standard dimension 190 Outside diameter of tread 165 Thickness of tread 27.5 Width of tread 45.5 Width of flange 17 Tolerance Standard Clearance between shaft dimension Shaft Hole and support -0.100 +0.300 61 -0.200 0 Tolerance Standard

Interference between shaft and seal guard

Axial play of roller

60-24

Criteria

Unit: mm Remedy Rebuild by build-up welding or replace

Replace

D61EM-23M0

60 Maintenance standard Undercarriage and frame

Track shoe Conventional type track shoe

1 (D61-DTL0-034-K-01-A)

*1. Single grouser shoe *2. Swamp shoe a Portion P shows the link in which the bushing is press-fitted.

D61EM-23M0

60-25

60 Maintenance standard Undercarriage and frame

No.

Item

Unit: mm Remedy

Criteria

Outside diameter of bushing Thickness of bushing

13.2

Repair limit 193.3 Light load Heavy load 54.8 57.4 3.0 5.6

Link height

119

108

Repair or replacement

42.5

31.5

Replace

1 2

Standard dimension 190.3

Link pitch

Thickness of link (bushing press-fit part) a. Regular link

Shoe bolt

Interference between bushing and link

Interference between regular pin and link

Clearance between regular pin and link

60-26

b. Master link

Tightening torque Retightening angle (Nm {kgm}) (deg.) 539 ± 49 {55 ± 5} 120 ± 10 Tightening torque Retightening angle Lower limit torque (Nm {kgm}) (deg.) (Nm {kgm}) 343 ± 39 180 (0 / -20) 784 {80} {35 ± 4} Tolerance Standard Standard interference dimension Shaft Hole +0.264 +0.074 0.160 to 59 0.264 +0.234 0 +0.372 +0.062 0.210 to 37.8 0.372 +0.272 0 Standard clearance One side Both side 1.2 2.4

Turn 180 deg. or replace

Retighten

Adjustment or replacement

D61EM-23M0

60 Maintenance standard Undercarriage and frame

Single grouser shoe

No.

(D61-DTL0-034-K-00-A)

Item

Height of grouser

Thickness of grouser

D61EM-23M0

Criteria Standard dimension 57.5

Repair limit 25

38.5

Unit: mm Remedy Rebuild by build-up welding or replace

60-27

60 Maintenance standard Hydraulic system

Hydraulic system Hydraulic tank

60-28

1 1

D61EM-23M0

60 Maintenance standard Hydraulic system

Work equipment and cooling fan pump

D61EM-23M0

60-29

60 Maintenance standard Hydraulic system

Servo valve

60-30

(D61-B4H0-034-K-00-A)

D61EM-23M0

60 Maintenance standard Hydraulic system

D61EM-23M0

60-31

60 Maintenance standard Hydraulic system

Control valve

1P ^ NJP`

; 1P ^ NJP`

+ *

1P ^ NJP`

* )

1P ^ NJP`

) '

; &

1P ^ NJP`

1P ^ NJP` 1P ^ NJP`

& =

60-32

< *

D61EM-23M0

60 Maintenance standard Hydraulic system

1P ^ NJP`

$ $

1P ^ NJP`

% %

D61EM-23M0

60-33

60 Maintenance standard Hydraulic system

Unit: mm

No.

Item

Suction valve spring

Spool return spring (fan)

Spool return spring (lift)

60-34

Spool return spring ( `, $ ) Back pressure valve spring

Criteria Standard dimension Free Load at Installed length x installed length Outside length diameter 5.10 N 39.2 x 4.45 33.5 {0.52 kg} 34.3 N 41.1 x 19.3 40.5 {3.50 kg} 44.2 N 41.5 x 19.3 40.5 {4.51 kg} 80.4 N 35.2 x 17.4 32.3 {8.20 kg} 41.9 x 18.6

40.5

58.3 x 17

52.9 N {5.39 kg} 56.9 N {5.80 kg}

Repair limit Free length — — — — — —

Load at installed length 4.12 N {0.42 kg} 27.4 N {2.80 kg} 35.4 N {3.61 kg} 64.3 N {6.56 kg}

Remedy

If damaged or deformed, replace spring

42.3 N {4.31 kg} 45.5 N {4.64 kg}

D61EM-23M0

60 Maintenance standard Hydraulic system

1P ^ NJP`

& & 1P ^ NJP`

' ' *

D61EM-23M0

60-35

60 Maintenance standard Hydraulic system

Unit: mm

No.

1 2 3

Item

Pressure compensation valve F spring (lift) Pressure compensation valve R spring )DQ 6ZLQJ / 5 2LO :DWHU Pressure compensation valve R spring (lift)

60-36

Criteria Standard dimension Free Load at Installed length x installed length Outside length diameter 27.6 N 30.85 x 5.2 20 {2.82 kg}

Repair limit Free length

Load at installed length

—

22.1 N {2.26 kg}

31.9 x 14.4

21.5

34.3 N {3.50 kg}

—

27.4 N {2.80 kg}

33.4 x 14.4

21.5

55.9 N {5.7 kg}

—

44.7 N {4.56 kg}

Remedy

If damaged or deformed, replace spring

D61EM-23M0

60 Maintenance standard Hydraulic system

1P ^ NJP`

+ +

1P ^ NJP`

) )

1P ^ NJP` 1P ^ NJP`

1P ^ NJP`

* *

D61EM-23M0

1P ^ NJP`

- *

60-37

60 Maintenance standard Hydraulic system

1P ^ NJP`

. .

0 0

1P ^ NJP`

/ /

1P ^ NJP`

1 1 *

60-38

D61EM-23M0

60 Maintenance standard Hydraulic system

Anti-drop valve

1P ^ NJP`

D61EM-23M0

$ $

60-39

60 Maintenance standard Hydraulic system

Unit: mm

No.

Item

^ ^ @ `

# @ `

60-40

Criteria Standard dimension Free Load at Installed length x installed length Outside length diameter ` ` `

Repair limit Free length — — —

Load at installed length

Remedy

` If damaged or deformed, ` replace spring `

D61EM-23M0

60 Maintenance standard Work equipment

Work equipment Planter unit

D61EM-23M0

1 1

60-41

60 Maintenance standard Work equipment

60-42

D61EM-23M0

60 Maintenance standard Work equipment

Unit: mm No.

Item

Clearance between planter unit connecting pin and bushing Clearance between planter 2 unit connecting pin and swing bracket Clearance between frame 3 connecting pin and bushing Clearance between frame 4 connecting pin and center frame bracket Clearance between lift cyl5 inder bottom pin and frame bracket Clearance between lift cyl6 inder head pin and center beam bracket Clearance between beam 7 connecting pin and parking foot Clearance between side 8 swing cylinder pin and swing bracket Clearance between fixing 9 rod and bushing Standard shim thickness between planter unit con10 necting pin and swing bracket 1

D61EM-23M0

Criteria Tolerance Shaft Hole

Standard Allowable clearance clearance

-0.025 -0.064

+0.219 +0.180

0.205 to 0.283

1.0

-0.025 -0.064

+0.039 0

0.025 to 0.103

1.0

-0.036 -0.090

+0.207 +0.120

0.156 to 0.297

5.0

-0.036 -0.090

+0.300 +0.100

0.136 to 0.390

1.0

-0.030 -0.076

+0.046 0

0.030 to 0.122

2.0

-0.030 -0.076

+0.300 +0.100

0.13 to 0.376

2.0

-0.020 -0.053

+0.033 0

0.02 to 0.086

2.0

-0.025 -0.064

+0.039 0

0.025 to 0.103

1.0

-0.025 -0.064

+0.039 0

0.025 to 0.103

2.0

Standard dimension

1.0

Remedy

Replace

Adjust shim

60-43

60 Maintenance standard Work equipment

Lift cylinder

No.

Item

Clearance between piston rod and bushing

60-44

Clearance between piston rod support shaft and bushing Clearance between cylinder bottom support shaft and bushing Tightening torque of cylinder head Tightening torque of cylinder piston fixing nut

Unit: mm Remedy

Criteria Tolerance Shaft Hole -0.030 +0.151 -0.076 -0.006

Standard clearance 0.036 to 0.227

-0.030 -0.076

+0.174 +0.100

0.130 to 0.250

1.0

-0.030 -0.076

+0.174 +0.100

0.130 to 0.250

1.0

Standard dimension 55

Allowable clearance 0.527

Replace bushing

785 ± 78.5 Nm {80 ± 8.0 kgm} Retighten 1,770 ± 177 Nm {180 ± 18 kgm} (width across flats: 60 mm)

D61EM-23M0

60 Maintenance standard Work equipment

Swing cylinder

No.

Item

Clearance between piston rod and bushing

Clearance between piston rod support shaft and bushing Clearance between cylinder bottom support shaft and bushing Tightening torque of cylinder head Tightening torque of cylinder piston fixing nut

D61EM-23M0

Unit: mm Remedy

Criteria Tolerance Shaft Hole -0.0 +0. -0.0 +0.0

Standard clearance 0.0 to 0.

-0.025 -0.064

+0.039 0

0.025 to 0.103

0.5

-0.025 -0.064

+0.039 0

0.025 to 0.103

0.5

Standard dimension

Allowable clearance

Replace bushing

1 .' Retighten

1 1 .'

60-45

60 Maintenance standard Cab and its attachments

Cab and its attachments Cab mount

60-46

1 1

D61EM-23M0

60 Maintenance standard Electrical system

Electrical system Electric steering lever a

1 1

Do not disassemble this lever since its output voltage characteristics and operating effort characteristics need to be adjusted after reassembly.

D61EM-23M0

60-47

60 Maintenance standard Electrical system

60-48

D61EM-23M0

SHOP MANUAL

D61E -23M0 Model

Serial Number

D61E -23M0

B 0001 and up

80 Appendix 9 80 Appendix

D61EM-23M0

80-1

80 Appendix

Table of contents

80 Appendix- - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 80-1 Table of contents - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 80-2 Air conditioner components - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 80-3 Precautions for refrigerant - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 80-3 Air conditioner component- - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 80-4 Configuration and function of refrigeration cycle - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 80-7 Outline of refrigeration cycle - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 80-8 Air conditioner unit - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 80-10 Dual pressure switch - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 80-14 Pressure switch - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 80-15 Compressor - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 80-16 Condenser- - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 80-17 Receiver drier - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 80-19 Procedure for testing and troubleshooting- - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 80-20 Electrical circuit diagram - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 80-23 System diagram - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 80-24 Parts and connectors layout - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 80-26 Testing relays- - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 80-31 Troubleshooting chart 1- - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 80-33 Troubleshooting chart 2- - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 80-34 Information described in troubleshooting table- - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 80-36 A-1 Troubleshooting for condenser fan - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 80-37 A-2 Troubleshooting for compressor and refrigerant system (Air is not cooled) - - - - - - - - - - 80-40 A-3 Troubleshooting for blower motor system (No air comes out or air flow is abnormal) - - - 80-44 A-4 Troubleshooting for temperature control - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 80-46 Troubleshooting with gauge pressure - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 80-49 Connection of service tool - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 80-52 Precautions for disconnecting and connecting hoses and tubes in air conditioner circuit - - - 80-54 Handling of compressor oil - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 80-56

80-2

D61EM-23M0

80 Appendix

Air conditioner components

Precautions for refrigerant

D61E -23M0 k Collect the refrigerant (air conditioner gas: R134a) from the air conditioner circuit before 600 or mmcondenser, the air disconnecting theItem air conditioner hoses toUnit replace the air conditioner unit single grouser shoe conditioner compressor, receiver drier, etc. Machine weight kg a Ask a qualified of theSAA6D107E-1 refrigerant (airdiesel conditioner Engine model person for collecting, adding and Komatsu enginegas: — filling operations R134a). (Onlyhorsepower registered person can work.) Engine rated • SAE J1995the (gross) (*1) (R134a) to thekW 127 {170} / 2,200 {2,200} a Never release refrigerant atmosphere. {HP}/ min-1 126 {169} / 2,200 {2,200} • ISO 14396 k If refrigerant gas (R134a) gets in your eyes, you may lose your sight. And if it touches your skin, {rpm} • ISO 9249/SAE J1349 (net) (*2) 125 {168} / 2,200 {2,200} you may suffer from frostbite. Put on protective eyeglasses, gloves and working clothes with long Overall length mm A sleeves while collecting the refrigerant or filling the air conditioner circuit with the refrigerant. Overall height (including KOMTRAX mm B antenna) mm C Overall width Forward km/h 3.4 Travel speed (1st) Reverse (Quick shift mode) km/h 4.1 (1st) Travel speed Forward km/h 0.8 to (Variable shift mode) Reverse km/h 0.8 to *1: Indicates the value of the basic engine (without cooling fan). *2: Indicates the value at the minimum cooling fan speed. a The engine rated horsepower is indicated in the net value and gross value. The gross denotes the flywheel horsepower measured on the basic engine unit, while the net denotes the value measured of an engine under the condition essentially the same as that when it is installed on a machine. a Following shows the rated horsepower (net) at the maximum cooling fan speed. 113 kW {152 HP}/2,200 min-1 {2,200 rpm}

D61EX-23M0

01-3

D61EM-23M0

80-3

80 Appendix

Air conditioner components

Air conditioner component

80-4

D61EM-23M0

80 Appendix

Air conditioner components

1. Compressor 2. Air conditioner unit 3. Condenser 4. Receiver drier 5. Refrigerant discharge piping 6. Refrigerant suction piping 7. Heater unit (floor) 8. Hot water valve 9. Hot water piping 10.Hot water return piping 11.Dual pressure switch 12.Pressure switch 13.Recirculation air filter 14.Fresh air filter 15.Sight glass

D61EM-23M0

80-5

80 Appendix

Air conditioner components

A. Vents for front window defroster B. Vents for side window defroster C. Vents for face D. Rear vents E. Fresh air inlet F. Recirculation air inlet

Specifications

(D61-K500-030-K-00-A)

Refrigerant Refrigerant refill amount (g)

80-6

R134a 900 ± 50

D61EM-23M0

80 Appendix

Air conditioner components

Configuration and function of refrigeration cycle Cycle (Component) Location

Function

State of refrigerant

D61EM-23M0

Compression (Compressor) Engine compartment Circulates refrigerant gas and increases its temperature and pressure so that it can be liquefied easily in condenser. (Compression of refrigerant) Gas o gas Adiabatic compression

Condensation (Condenser) Front of radiator

Condenses refrigerant to discharge heat absorbed in evaporator. (condensation of refrigerant) Gas o liquid Constant pressure change

Expansion (Expansion valve) In operator's cab (Built in air conditioner unit) Lowers temperature and pressure of refrigerant liquid and gas for easy evaporation with throttle. Controls flow rate, too. (Throttle action of refrigerant) Liquid o liquid, gas Adiabatic expansion

1 Evaporation (Evaporator) In operator's cab (Built into air conditioner unit) By evaporating refrigerant, absorb heat from the air around the evaporator, and cools the surrounding air. (Evaporation of refrigerant) Liquid, gas o gas Constant pressure change

80-7

80 Appendix

Air conditioner components

Outline of refrigeration cycle

• The refrigerating cycle performs the following four processes. The refrigerant is liquefied and gasified repeatedly while it is circulated in the cycle. Compression (Compressor) • The compressor sucks in the refrigerant that has been vaporized in the evaporator and compresses it into a state where it can be easily liquefied at the ambient temperature. • The gaseous refrigerant sucked into the compressor cylinder is compressed to a temperature and pressure at which it can be easily liquefied when cooled to the ambient temperature. Condensation (Condenser) • The condenser cools and liquefies the high pressure and high-temperature gaseous refrigerant sent from the compressor. • The heat released to the outside from the condenser is called condensation heat. • The amount of condensation heat is the sum total of the heat absorbed by the evaporator from the air in the cab and the quantity of the work applied (the value converted into a heat quantity) by compression of the compressor. • The refrigerant liquefied in the condenser is dehydrated in the modulator and cooled further in the sub-cool section to increase the cooling efficiency. • In the compression cycle, the gaseous refrigerant and liquid refrigerant coexist. • The temperature (condensation temperature) and the pressure (condensation pressure) at which the gaseous refrigerant is liquefied are proportional to each other. (The condensation pressure varies depending on the condensation temperature of the refrigerant) Expansion (Expansion valve) • The expansion valve reduces the liquid refrigerant pressure to a level where liquid refrigerant can be easily evaporated by the throttle action (*1). • The action of reducing the liquid refrigerant pressure to a level where it can be easily evaporated before it is sent to the evaporator is called expansion. • The expansion valve, which reduces the refrigerant pressure, also adjusts the refrigerant flow rate simultaneously. • The quantity of the liquid refrigerant that can be evaporated in the evaporator depends on the amount of heat (refrigeration load) to be removed under the specific evaporation temperature (evaporation pressure). • The expansion valve controls the refrigerant feed rate so that the optimum quantity of liquid refrigerant is supplied to the evaporator. *1: Throttle action • If there is a narrow section in the passage through which liquid is flowing at a constant rate, a resistance to the flow will be generated. The liquid expands when it passes through the narrow section and rushes into the passage where the sectional area is larger, and consequently, its pressure and temperature are reduced. • No heat is transferred from or to the outside during the throttle action. Evaporation (Evaporator) • The evaporator evaporates the liquid refrigerant (superheated vapor). • The refrigerant evaporates, while absorbing an amount of heat necessary for evaporation (evaporation heat) from the air around the cooling fins (air in the cab). • After the heat has been removed, the cooled air is sent into the cab by the blower fan, reducing the temperature inside the cab. • The mist refrigerant that has been sent from the expansion valve coexists with the evaporated refrigerant in the evaporator • The temperature (evaporation temperature) and the pressure (evaporation pressure) at which the liquid refrigerant is evaporated are proportional to each other. • The compressor sucks in the evaporated refrigerant in order to keep the pressure level in the evaporator as low as possible so that the liquid refrigerant can be evaporated at a much lower temperature. Relationship between refrigerant and defective air conditioning • The refrigerant circulates in the refrigeration circuit while repeating the refrigeration cycle to expel the heat from inside the cab. 80-8

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• If there is an insufficient quantity of refrigerant, all of it will be evaporated while it is passing through the evaporator. This causes evaporator efficiency to deteriorate, which will result in defective air conditioning. • If there is excessive refrigerant, not all of it will be evaporated and part of it will be sucked into the compressor in liquid form, which will cause the compressor to compress the liquid and may damage the components. • If water gets into the refrigeration circuit, it will freeze at a small hole in the expansion valve, lower the refrigerant flow, and may result in defective air conditioning.

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Air conditioner unit

A. Refrigerant inlet (from compressor) B. Refrigerant outlet (to condenser) C. Hot water inlet D. Hot water outlet 1. Evaporator 2. Heater core 3. Expansion valve 4. Blower fan and blower motor 5. Resistance 80-10

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6. For thermostat (6), see the following description 7. Compressor clutch relay 8. Heater mode relay

Function

(D61-K540-042-K-00-A)

• The air conditioner unit consists of evaporator (1) and heater core (2), and is used to cool down or warm up the air in the cab. Temperature control • The temperature adjustment switch controls the opening of hot water valve (locating under the floor), changes the flow rate of hot water to heater core (2), and adjusts the temperature. Over-cooling (Freezing) prevention • Thermostat (6) is turned ON or OFF according to the temperature.* • In order to prevent freezing of evaporator (1), thermostat (6) turns OFF compressor clutch relay (8) and stops the compressor. * For thermostat (6), see the following description. Air flow adjustment • By operating the air flow control switch, the current passing through blower motor (4) is changed with resistance (5) and the air flow rate is controlled.

Functions of major components

(ALL-K540-001-K-00-A)

a For details of the numbers in the following sentence, see “Air conditioner unit”.

Evaporator

(ALL-K549-042-K-00-A)

• Evaporator (1) is cooled by the low-pressure, low-temperature refrigerant gas being sent from expansion valve (3). • Air from blower motor (4) is cooled and dehumidified when passing through the evaporator fins.

Heater core

(ALL-K547-042-K-00-A)

• Heater core (2) is warmed by the hot water (engine coolant) being sent from the engine. Air from blower motor (4) is warmed when passing through fins of the heater core (2).

Thermostat

(D61-BA30-041-K-00-A)

• Tip (A) of thermostat (6) is attached to evaporator (1) to detect evaporator (1) temperature in order to protect it from freezing. • Compressor clutch turns on or off in accordance with turning on or off of thermostat (6) to control compressor and, thereby, protect freezing of evaporator (1). • Temperature characteristics of thermostat 1. Turned-on temperature: 4.2°C 2. Turned-off temperature: -0.6°C

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Expansion valve

(ALL-K548-041-K-00-A)

A: When evaporator outlet temperature is high B: When evaporator outlet temperature is low C: From capacitor (high-pressure refrigerant) D: To compressor (low-pressure refrigerant) 1. Expansion valve 1a. Needle valve 1a-1. Diaphragm 1a-2. Thermoprobe 1b. Spring 2. Refrigerant gas 3. Evaporator Structure • Box-type expansion valve (1) consists of needle valve (1a), spring (1b), etc. • Refrigerant gas (2) is sealed in the diaphragm chamber (hatched area) outside diaphragm (1a-1) of needle valve (1a).

Function (ALL-K548-042-K-00-A) • The expansion valve (1) converts high-pressure and high-temperature liquid refrigerant from the receiver drier to low-pressure, low-temperature misty refrigerant through the throttle action. • It controls the flow rate of refrigerant by changing the level of throttling depending on the temperature in the cab. • The temperature of the air blown out of the air vent is adjusted depending on the flow rate of refrigerant circulating in the evaporator (3). Operation (ALL-K548-044-K-00-A) • Thermoprobe (1a-2) senses the refrigerant temperature after it passes through the evaporator (3). 80-12

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• After the refrigerant passes through evaporator (3), its temperature is transferred to the refrigerant gas (2) in the diaphragm chamber (hatched area) through the thermoprobe (1a-2). • The pressure of the refrigerant gas (2) sealed in the diaphragm chamber (hatched area) changes in response to the temperature change of the thermoprobe (1a-2), which therefore changes the force (Fg) pushing the needle valve (1a). • The opening level of the needle valve (1a) is determined based on the balance between the reaction force exerted by the spring (1b) in a rightward direction, and the force (Fg) of the refrigerant gas (2) pushing the needle valve (1a) through the diaphragm (1a-1) in a leftward direction. • The refrigerant flow rate flowing from the receiver drier to evaporator (3) is determined based on the opening level of needle valve (1a). When evaporator (3) outlet temperature is high: [When not cooled yet: Condition (A) in the figure] • The pressure of the refrigerant gas (2) in the diaphragm chamber is high and the volume is increased. • The force (Fg) of the refrigerant gas (2) pushing the needle valve (1a) is increased, and the needle valve (1a) moves leftward. • As a result, the opening level of the needle valve (1a) is increased and the refrigerant flow rate to the evaporator (3) is increased to improve cooling capacity. (Condition (A) in previous figure) When evaporator (3) outlet temperature is low: [When cooled already: Condition (B) in the figure] • The pressure of the refrigerant gas (2) in the diaphragm chamber is low and the volume is decreased. • The force (Fg) of the refrigerant gas (2) pushing the needle valve (1a) is reduced, and the needle valve (1a) is moved rightward by the reaction force of spring (1b). • The opening level of the needle valve (1a) is reduced and the refrigerant flow rate to the evaporator (3) is reduced to lower the cooling capacity. (Condition (B) in previous figure)

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Dual pressure switch

a The dual pressure switch is installed to the air conditioner hose near the air conditioner unit. • The dual pressure switch turns "OFF" when it detects abnormally low refrigerant pressure in low pressure line or abnormally high refrigerant pressure in high pressure line. • When the dual pressure switch turns "OFF", compressor clutch relay disengages. Thus, the electromagnetic clutch if the compressor is disengaged and air conditioner components are protected. Function

a LA or lower: Abnormally low pressure in low-pressure line a HA or higher: Abnormally high pressure in high-pressure line LA: 0.14 to 0.23 MPa {1.4 to 2.3 kg/cm2} LB: 0.16 to 0.25 MPa {1.6 to 2.5 kg/cm2} HA: 2.62 to 2.89 MPa {26.2 to 28.9 kg/cm2} HB: 1.38 to 2.07 MPa {13.8 to 20.7 kg/cm2}

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Pressure switch

a The pressure switch is installed to the air conditioner hose near the air conditioner unit. • The pressure switch turns OFF when it detects abnormally low refrigerant pressure in the refrigerant circulation circuit. • When the pressure switch turns OFF, the condenser fan relay turns OFF and the condenser fan does not operate. Function

OFF pressure (A): 1.24 to 1.38 MPa {12.4 to 13.8 kg/cm2 } ON pressure (B): 1.65 to 1.79 MPa {16.5 to 17.9 kg/cm2}

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Compressor

A: Refrigerant inlet (from air conditioner unit) B: Refrigerant outlet (to condenser) 1. Pulley 2. Electromagnetic clutch

Specifications

(D61-K590-044-K-00-A)

Number of cylinders - Bore x Stroke (mm) Piston capacity (cc/rev) Max. allowable speed (rpm) Compressor oil Compressor oil refill capacity (cc)

Function

5-3528.6 138 4,000 (SANDEN: SP-20 for use with R134a) 175

(D61-K590-042-K-00-A)

• The compressor circulates the refrigerant and compresses the gaseous refrigerant from the evaporator into a misty refrigerant at high pressure and high temperature so that it will be easily regenerated (liquefied) at the normal temperature. • Calling into account of the evaporator temperature and refrigerant pressure, the air conditioner controller activates magnetic clutch (2) built in the compressor. • When magnet clutch (2) is engaged, the power of engine rotates the compressor shaft along with pulley (1) to drive the compressor.

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Condenser

1. Condenser 2. Fan A: Refrigerant inlet (from condenser) B: Refrigerant outlet (to receiver dryer)

Specifications

(D61-K580-030-K-00-A)

Fin pitch (mm) Height x Width x Thickness (mm) Max. operating pressure: (MPa {kg/cm2}) D61EM-23M0

1.8 283 x 790 x 18 3.45 {34.5} 80-17

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Function

(D61-K580-042-K-00-A)

• Condenser (1) cools and liquefies the high-pressure and high-temperature misty refrigerant sent from the compressor by using fan (2). a If its cooling fins are crushed or clogged with dirt and dust, heat exchange efficiency lowers. Accordingly, the condenser cannot liquefy the refrigerant entirely. If heat exchange efficiency deteriorates, pressure in the refrigerant cycle increases, resulting in unnecessary load on the engine or poor cooling effect. Accordingly, take care not to crush the fins in handling and daily maintenance of the condenser.

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Receiver drier

A: Refrigerant inlet (from condenser) B: Refrigerant outlet (to air conditioner unit) Function • The receiver drier temporarily stores the high pressure and high temperature liquid refrigerant sent from the condenser so that it can be supplied to the evaporator according to the need of cooling. • It sends the stored refrigerant from its bottom to the evaporator, allowing the refrigerant to be liquefied completely even when it contains bubbles due to the lower heat dissipation of the condenser. • The built-in filter and desiccating agent eliminate foreign substances in the circulation circuit and water content in the refrigerant. Specifications Capacity (cc)

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Procedure for testing and troubleshooting

If a troubled section is detected , every part of that section must be inspected. 1. After basic test, find the troubled section according to the detected trouble of the air conditioner. 2. Find the troubled section through operating the relevant switches. a The troubleshooting chart is also used to find the troubled section. 3. After finding out the troubled section, inspect its components, identify the failed section and repair the failure.

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Basic flow of testing and troubleshooting

*1 Simple checking of refrigerant volume through sight glass. Start the engine, turn the air conditioner switch ON, and check after 5 minutes. A) When bubbles are continuously seen, the quantity of refrigerant is insufficient D61EM-23M0

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B) When bubbles are seen intermittently, the quantity of refrigerant is proper C) When no bubble is seen (i.e., the liquid is clear), the system has too much refrigerant or no refrigerant The above is general description for reference but there are exceptions. See "Troubleshooting with gauge pressure" and judge it by the gauge pressure. S: Condition viewed through sight glass R: Receiver drier internal condition LR: Liquid refrigerant

*2 If the refrigerant leaks from somewhere, so does the compressor oil circulating in the air conditioner circuit from the the same place. In such a case, retighten according to the tightening torque table in "Precautions for disconnecting and connecting air conditioner piping." *3 Start the engine, then turn the fan switch to any of 1 to 4 positions and turn the air conditioner mode selector switch to AIR CONDITIONER to start troubleshooting.

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Electrical circuit diagram

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System diagram

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Control method of air conditioner a Self-diagnosis function is not provided. 1. Air conditioner unit is controlled by respective switches input. 2. Operation of fan switch varies air flow by switching the terminal connected to resistor. 3. Fan switch functions as ON/OFF switch of air conditioner as well. Setting fan switch to any position other than OFF (1 to 4) starts supplying power to mode selector switch and relays (ACR1 to ACR3). 4. Turning fan switch to any position other than OFF (1 to 4), and mode selector switch to AIR CONDITIONING (A) normally turns compressor clutch relay (ACR2) and condenser fan relay (ACR3) to ON. Thermostat and dual pressure switch are provided in primary side of compressor clutch relay (ACR2). They controls compressor to be turned OFF when freezing evaporator is frozen or abnormality in refrigerant pressure (abnormally high or low) is detected. Pressure switch is provided in primary side of condenser fan relay (ACR3). It controls condenser fan to be turned OFF if abnormality in refrigerant pressure (abnormally high or low) is detected. 5. By turning mode selector switch to AIR CONDITIONER (A), power is supplied to temperature adjustment switch (potentiometer) through diode (AC9). By operating temperature adjustment switch, volume of hot water supplied from hot water valve to air conditioner varies and temperature is adjusted. a Temperature adjustment switch is operable even after foot heater switch is turned on. 6. By turning mode selector switch to HEATER (B), heater mode relay (ACR1) is actuated and compressor clutch relay (ACR2) and condenser fan relay (ACR3) are turned OFF. As a result, operation of compressor and condenser fan is stopped. • Mode selector switch

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Parts and connectors layout

• Air conditioner unit, fan, condenser, relays and blower are provided in the rear outside of the cab. • Hot water valve is located below the seat. 1. Open left side cover and open fuse box cover. • Fuses for air conditioner (every fuse related to air conditioner): F01-4 30A

2. Remove cover (1). For details, see "Removal and installation of engine rear seal" in "Disassembly and assembly.

(2): Condenser fan a Condenser is located inside fan. [1], [2], and [3]: Fan connectors

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a Remove fan condenser unit and you will find air conditioner unit (3). [4]: Pressure switch connector [5]: Dual pressure switch connector

AC6: Intermediate connector

a Lower left side of air conditioner unit (4): Blower motor ACR: Resistor ACR1 (without label): Relay for heater mode ACR2 (without label): Relay for compressor clutch

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a Lower right side of air conditioner unit (5): Thermostat ACR3 (without label): Relay for condenser fan

3. Open left side cover. a On front side wall face of battery room AC7, AC8, and AC9: Diode connectors

4. Remove floor mat. 5. Remove inspection cover underneath floor mat. (6): Hot water valve AC2: Hot water valve connector

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6. Open engine hood left cover. a Photo shows the state after engine hood is removed. (23): Connector for compressor clutch

DAC: Diode connector for compressor clutch

7. Open right side cover. AC1/AC: Intermediate connector

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8. Ground (T35) associated with air conditioner is provided under floor.

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Testing relays

There are following three relays. • Relay for heater mode: ACR1 (for turning OFF air conditioner control) • Compressor clutch relay: ACR2 (for turning ON or OFF air compressor (clutch)) • Relay for condenser fan: ACR3 a This check is not necessary when air comes from condenser fan, mode selection between HEATER and AIR CONDITIONER is performed normally and air compressor operation is normal (cools air). a Listen closely to the relay to check if it is defective. (Two persons are required for this check.) a A connector label (ACR1 or ACR2 or ACR3) is not attached to each relay. 1. Remove fresh air filter cover (1) provided at bottom of air conditioner unit.

2. Check connectors ACR1, ACR2, and ACR3 for normal contact. (Check whether it is securely in place.)

3. Turn starting switch to ON position (engine is stopped), turn fan switch to any position other than OFF (1 to 4) and turn mode selector switch to dehumidification (C) and HEAT (B). If it is normal, relay (ACR1) for heater mode is turned ON or OFF at this point. Check its clicking sound. 4. Turn starting switch to ON position (engine is stopped), turn fan switch to any position other than OFF (1 to 4) and turn mode selector switch to air conditioner (A) and HEAT (B). If normal, compressor clutch relay (ACR2) and condenser fan relay (ACR3) are turned ON or OFF at this point. Check their clicking sounds. D61EM-23M0

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a As long as an abnormality in refrigerant pressure is detected by pressure switch (pressure switch is turned OFF), relay for condenser fan remains not turned ON. a In the following cases, compressor clutch relay does not turn ON. • When evaporator temperature is 4.2°C or below (when thermostat is turned OFF). • When an abnormality in refrigerant pressure is detected by dual pressure switch (when dual pressure switch is turned OFF). a If sounds of condenser fan are too large to hear sounds of compressor relay, turn starting switch to OFF position and disconnect connector [3] before starting your check. (See "Parts and connectors layout") 5. Checking relay unit a Since T-adapter is not available, it is actually impossible to check relay while voltage is applied to coil. a Turn starting switch to OFF position and remove relay. a Common to respective relays a In the following cases, relay is normal. • Coil resistance between terminals (85) and (86) is approximately 360 z. • When voltage (20 to 30 VDC) is not applied across terminals (85) and (86), terminals (30) and (87) remain unconnected from each other and terminals (30) and (87a) are connected.

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Troubleshooting chart 1

Numbers in T represent the item numbers in the troubleshooting quick reference table. 1. Lowered cooling performance

2. Lowered heating performance

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Troubleshooting chart 2

1. During cooling, the blower fan motor does not rotate or the rotation speed does not match the air flow setting. Remedy Repair open section. Connect connector correctly.

Probable cause

Check method

Wire breakage or defective contact of connector

Check for coming off of connector, etc. See "Parts and connectors layout".

Defective blower fan motor

Operate fan switches in order and check fan speed. See "A-3 Troubleshooting for blower motor system".

Replace

Defective fan switch

Operate the fan switches in order and check the fan speed.

Replace

2. During cooling, the blower fan motor is normal but the flow of air is insufficient. Probable cause Large duct resistance Obstruction on evaporator suction side Defective thermostat, defective thermostat contact, or defective expansion valve*

Check method Check filter for clogging Check evaporator for stain and obstruction Evaporator is frozen. Check thermostat fixing clip for any trouble and thermostat for adherence of dusts. Check air conditioner hose near pressure switch for frost (when freezing advanced further).

Remedy Repair Remove obstruction and clean.

Replace or repair.

*Thermostat and expansion valve are located outside air conditioner unit body. 3. Pressure abnormality (low pressure / high pressure) during cooling Probable cause

Check method

Insufficient refrigerant Check the refrigerant volume through sight glass. Specifically, perform checking with the gauge manifold connected. Overcharge with refrigerant

Failure judgment from refrigerant pressures at compressor inlet and outlet

80-34

Normal refrigerant pressure range Pressure of low pressure line: Approx. 0.13 to 0.2 MPa {1.3 to 2.0 kg/cm2} Pressure of high pressure line: Approx. 1.5 to 1.7 MPa {15 to 17 kg/cm2} Temperature in operator's cab: 30 to 35 °C, Engine speed: Approx. 1,500 rpm

Remedy Repair leaking part, then fill with proper quantity of refrigerant again Collect refrigerant, then fill up with proper quantity of refrigerant again.

See Troubleshooting with gauge pressure.

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4. During cooling, compressor does not rotate or does not rotate smoothly. a See "A-2 Troubleshooting for compressor and refrigerant system (Air is not cooled)". Failed part Compressor belt

Compressor

Electromagnetic clutch

Relay Refrigerant pressure

Dual pressure switch

Probable cause Slack of belt Internal defect of compressor Insufficient compressor oil Seizure of compressor Drop of battery voltage Open or short circuit in coil Open circuit in wiring harness or defective connection of ground cable Defective compressor clutch relay Abnormal refrigerant pressure (pressure switch is actuated)

Defective dual pressure switch

Check method Deflection of belt is large.

Remedy Adjust belt tension.

Check belt for slipping.

Repair or replace

Check compressor for overheating.

See "Handling of compressor oil."

Check clutch for slipping. Check by using multimeter (10 to 20 z) Check ground cable and its connection. See "A-2 Troubleshooting for compressor and refrigerant system (Air is not cooled)".

Charge battery.

See "Testing relays".

Replace

Repair

Replace

See "Troubleshooting with gauge pressure".

See "A-2 Troubleshooting for compressor and refrigerant system (Air is not cooled)". See "Testing (dual) pressure switch for refrigerant".

Replace

5. During heating, blower fan motor is normal but air flow is insufficient. Probable cause Check method Large duct resistance Check filter for clogging. Clogging of heater core fins Check heater core fins for clogging.

Remedy Repair Clean

6. Engine coolant temperature or volume abnormalities during heating or cooling Probable cause Check method Low engine coolant Warm up engine, and then check engine coolant temperature temperature. Low engine coolant level Check coolant level in radiator. Check engine coolant piping for clogging. Insufficient circulation of engine coolant (Hose, pipe, and core) Reversed connection of IN Check destination of heater hoses. and OUT heater hoses 7. Fan speed abnormalities during cooling Probable cause Condenser fan does not operate.

Check method See "A-1 Troubleshooting for condenser fan".

Remedy Find out cause. Add coolant. Bleed air and repair Repair

Remedy Repair

8. Other abnormalities Probable cause Temperature control does not work. Excessive compressor oil Water leakage into the cab

D61EM-23M0

Check method See "A-4 Troubleshooting for temperature control". See "Handling of compressor oil". Clogging of drain hole

Remedy Common to cooling and heating Cooling only

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Information described in troubleshooting table

Information in troubleshooting table a The following information is summarized in the troubleshooting table. Before performing troubleshooting, understand that information fully. Failure Related information

Failure symptom that appears on machine Information on occurred failure or troubleshooting

Cause

Procedure, measuring location, criteria and remarks [Information described] • Procedure • Measuring location

a "Between A and B" denotes measuring voltage or resistance, etc. between A and B. Probable cause of failure (Perform troubleshooting • Criteria to determine probable causes • Remarks for judgment of Good or No good according to these.) [Notes on troubleshooting] (1) pin number description sequence and tester lead handling For troubleshooting, connect the plus (+) and minus (-) tester leads as shown below unless otherwise specified. • Connect the plus (+) lead to a pin or harness indicated in the front. • Connect the minus (-) lead to a pin or harness indicated in the rear. Defective — (2) Example of troubleshooting done by testing multiple items a Normal in 1 but abnormal in 2 At this time, "Defective component" shown at left 3 is applied.

a If a wiring harness is burnt, replace it. [Defective wiring harness] • Open circuit Connection of connector is defective or wiring harness is broken. • Ground fault A harness not to be connected to the ground (earth) circuit comes into contact with the ground (earth) circuit or chassis accidentally. • Hot short circuit A harness not to be connected to the power (24V) circuit comes into contact with the power (24V) circuit accidentally. • Short circuit An independent wire in the harness abnormally comes into contact with another independent wire. (poor insulation at connector and others) Related circuit diagram This is the extracted circuit diagram related to failure • Indicates connector No., and pin No. • See "Electrical circuit diagram " and "Parts and connectors layout" for connector location • The circuit diagram shows the size and colors of wires. W: White, B: Black, R: Red, G: Green, Y: Yellow, L: Blue, V: Purple, P: Pink, O: Orange, Br: Brown, Gr: Gray, Sb: Sky blue, Lg: Light green, Dg: Dark green, Ch: Dark brown a When there are two colors Example: WY: Yellow line on white background a The number before the wire color indicates the wire size. • N.C.: Normally closed (Normally ON) • [1], [2], ... are numbers of unlabeled connectors. • The arrow (io) indicates their rough installation position on the machine.

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A-1 Troubleshooting for condenser fan Detail of failure

Related information

No.

• Condenser fan does not rotate • When air does not come out after turning starting switch to ON position and fan switch to any position other than OFF (1 to 4), perform troubleshooting for A-3 first. • When refrigerant pressure is abnormal (such as when refrigerant is not provided), condenser fan relay is not turned ON by pressure switch. (Condenser fan does not rotate.) • A connector label is not attached to relay connector. • A T-adapter is not provided for relay and pressure switch connectors. Cause

Procedure, measuring location, criteria and remarks 1. Turn starting switch to OFF position. 2. Disconnect connector [4].

a When an abnormality is detected, attach a pressure gauge to air conditioner compressor, and measure refrigerant pressure. (See "Troubleshooting with gauge pressure".) Resis- Between connector [4] (male) (A) and (B) Max. 1z tance 1. Turn starting switch to OFF position. 2. Disconnect connector ACR3. 3. Turn fan switch to any position other than OFF (1 to 4). Between ACR3 (female) (85) (black) and Max. 1z ground ResisBetween ACR3 (female) (87) (orange) and tance Approx. ground Defective condenser fan, or 1z ★ Parallel connector of condenser fan resistors defective fan switch, or open circuit in wiring harness 1. Turn starting switch to OFF position. 2. Disconnect connector ACR3. 3. Turn starting switch to ON position. 4. Turn fan switch to any position other than OFF (1 to 4). 20 to 30 Between ACR3 (female) (30) and (85) V Voltage 20 to 30 Between ACR3 (female) (87) and (85) V Referring to ”Testing relays”, check sounds when heater mode Defective relay ACR1 or ACR3 relay ACR1 and condenser fan relay ACR3 are turned ON. Defective pressure switch

Defective condenser fan

a If no failure is found by check on cause 2, this check is not required. 1. Turn starting switch to OFF position. 2. Disconnect connector [3] and connect T-adapter to male side. Approx. 2 Between connector [3] (male) (1) and (3) Resisz tance Between connector [3] (male) (3) and (4) Approx. 2 z

Defective fan switch (internal defect)

a If no failure is found by check on cause 2, this check is not required. 1. Turn starting switch to OFF position. 2. Disconnect connector AC4 and connect T-adapter to male side. Fan switch: OFF Min. 1Mz Between AC4 (male) (4) Fan switch: Other and (5) Max. 1z than OFF (1 to 4) Resistance Fan switch: OFF Min. 1Mz Between AC4 (male) (5) Fan switch: Other Max. 1z and (7) than OFF (1 to 4)

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No.

Cause

Procedure, measuring location, criteria and remarks a If no failure is found by check on cause 2, this check is not required. 1. Turn starting switch to OFF position. 2. Disconnect connector AC6 and connect T-adpater to female side. 3. Turn starting switch to ON position. 4. Turn fan switch to any position other than OFF (1 to 4). 20 to 30 Voltage Between AC6 (female) (4) and (8) V

a If no failure is found by above checks, this check is not required. 1. Turn starting switch to OFF position. 2. Remove fuse 30 A in fuse box F01-4. 3. Disconnect connectors AC4 and AC6, and connect T-adapters to each female side. Between F01-4 and AC4 (female) (4) Max. 1z Open circuit in wiring harness (wire Max. 1z Resis- Between F01-4 and AC4 (female) (7) breakage or defective contact of tance Between AC6 (female) (8) and ground Max. 1z connector) Between AC4 (female) (5) and AC6 (4) Max. 1z a If no failure is found by check on cause 2, this check is not required. 1. Turn starting switch to OFF position. 2. Disconnect connector AC6 and connect T-adapter to male side. 3. Disconnect connector ACR3. 4. Disconnect connector [3] and connect T-adapter to female side. Between AC6 (male) (4) and ACR3 (female) Max. 1z (30) (red) Between AC6 (male) (4) and ACR3 (female) Max. 1z (86) (a white line on black background) Resis- Between ACR3 (female) (87) (orange) and [3] tance (female) (1) Max. 1z Between ACR3 (female) (87) (orange) and [3] Max. 1z (female) (4) Between AC6 (male) (8) and [3] (female) (3) Max. 1z

80-38

D61EM-23M0

80 Appendix

Air conditioner components

Circuit diagram related to condenser fan

D61EM-23M0

80-39

80 Appendix

Air conditioner components

A-2 Troubleshooting for compressor and refrigerant system (Air is not cooled) 1 Failure Problem on machine

• Air is not cooled due to compressor or refrigerant system failure. • Air is not cooled despite the screen indication even when engine is started, air conditioner mode switch is turned to air conditioner, fan switch is turned to 1 and temperature control switch is turned to COOL. • Air conditioner compressor does not operate. a When condenser fan does not rotate, perform troubleshooting for A-1 first. • If the refrigerant pressure is abnormal, the compressor will not be turned on, and air will not be cooled.

Related information

a Abnormal refrigerant pressure indicates that the dual pressure switch is OFF, i.e. switch side terminals of connector [5] are not ON. • When ambient air temperature or evaporator temperature is max. 0°C, air conditioner is not turned ON as it is prevented by thermostat (normal). • When fuse 30 A of F01-4 is blown, air does not come out. (See "Troubleshooting of blower motor system".) • For each connector and fuse, see "Parts and connectors layout". • For pin location of each connector, see "Electric circuit diagram". a A connector label is not attached to relay connectors ACR1 to ACR3.

No. 1

Procedure, measuring location, criteria and remarks Cause Defective fuse 30A in fuse box If fuse is blown, circuit probably has ground fault. F01-4

Defective thermostat

Defective dual pressure switch

a Check that ambient air temperature is not 4°C or below, and evaporator is not frozen. 1. Turn starting switch to OFF position. 2. Disconnect wiring harness from thermostat. ResisBetween thermostat terminals Max. 1z tance 1. Turn starting switch to OFF position. 2. Turn the battery disconnect switch to the OFF position. 3. Disconnect connector [5] of dual pressure switch. a There are some cases that dual pressure switch is operating normally and the switch is in the OFF position. If the following abnormality is indicated (i.e., switch in the OFF position), attach a pressure gauge to the air conditioner compressor and check the refrigerant pressure. (See "Troubleshooting with gauge pressure".) Resis- Between [5] (male) (1) and (2) Max. 1 z tance k When replacing the dual pressure switch, refrigerant must be

Defective air conditioner compressor

Defective diode

80-40

collected in advance. 1. Turn starting switch to OFF position. 2. Disconnect connector 23 from air conditioner compressor and connect T-adapter to male side. Resis- Between 23 (male) (1) and ground Approx. 15 tance z 1. Turn starting switch to OFF position. 2. Disconnect connector DAC. a Measure by using diode range. Between DAC (male) (1) and (2) Continuity Between DAC (male) (2) and (1)

No continuity Continuity

D61EM-23M0

80 Appendix

Air conditioner components

No.

Cause

Procedure, measuring location, criteria and remarks • Referring to "Testing relays", check sounds when compressor clutch relay and heater mode relay are turned ON. a If sounds of condenser fan are too large to hear sounds of compressor clutch relay being turned ON, turn starting switch to OFF position and disconnect connector [3]. Clicking sound is heard: A a When A above is abnormal and B below is normal and C below is abnormal (if the relay is normal), go to cause 6.

Defective compressor clutch relay (does not turn ON)

1. Turn starting switch to OFF position. 2. Disconnect connector ACR2 and troubleshoot in that condition. ApproxiResis- Between ACR2 (male) (85) and (86) (coil mately 360 resistance) tance z: B 1. Turn starting switch to OFF position. 2. Disconnect connector ACR2. 3. Use a wire to short-circuit (87) (green) and (30) (white line on black base) of connector ACR2 (wiring harness side). (This forces the compressor to operate without using relay.) 4. Turn starting switch to ON position. Air is cooled: C

Defective mode selector switch (internal open or short circuit)

1. Turn starting switch to OFF position. 2. Disconnect connector AC5 and connect T-adapter to male side. Mode selector switch: Min. 1Mz Resis- Between AC5 (male) COOL or HEAT (1) and (3) tance Mode selector switch: Max. 1z A/C 1. Turn starting switch to OFF position. 2. Disconnect connector ACR2. Between ACR2 (female) (85) (black) and Max. 1z ground Between ACR2 (female) (30) (a white line on black background) and (86) (brown) Max. 1z Resis- a Turn dual pressure switch and thermostat tance to ON position. Between ACR2 (female) (87) (green) and ground

Open circuit in wiring harness (wire breakage or defective contact of connector)

a Air conditioner compressor coil resistance

Approx. 15 z

1. Turn starting switch to OFF position. 2. Disconnect connector ACR2. 3. Turn starting switch to ON position. 4. Turn fan switch to any position other than OFF (1 to 4). Between ACR3 (female) (30) (a white line on Voltage 20 to 30 V black background) and (85) (black) a If no failure is found by above checks, this check is not required. 1. Turn starting switch to OFF position. 2. Disconnect connectors AC6 and 23, and connect T-adapter to male side. Resis- Between AC6 (female) (7) and 23 (female) Max. 1z (1) tance

D61EM-23M0

80-41

80 Appendix

Air conditioner components

No.

Cause

1. Turn starting switch to OFF position. Ground fault in wiring harness 2. Disconnect connectors 23 and [5], and connect T-adapter to female side of 23. (contact with ground circuit) Min. 1 Mz Resis- Between [5] (female) (B) (brown) and ground tance Between 23 (female) (1) and ground Min. 1 Mz

Short circuit in wiring harness 10 (contact with 24 V circuit)

80-42

Procedure, measuring location, criteria and remarks

1. Turn starting switch to OFF position. 2. Insert T-adapter into connector AC6. Voltage Between AC6 (9) and (8)

Max. 1V

D61EM-23M0

80 Appendix

Air conditioner components

Circuit diagram related to compressor and refrigerant system

D61EM-23M0

80-43

80 Appendix

Air conditioner components

A-3 Troubleshooting for blower motor system (No air comes out or air flow is abnormal) 1 Failure Problem on machine

Related information

No. 1 2

80-44

• • • •

No air comes out or air flow is abnormal due to blower motor system failure. Air does not come out even when fan switch is turned to any of 1 to 4 positions. Air flow does not match fan switch setting on air conditioner operation screen. During cooling, if the air flow becomes abnormal after a certain time, the evaporator may be frozen. This may be due to the followings. 1. Defective compressor clutch relay (remains turned ON) (see Item A of cause 6 of "Troubleshooting for compressor and refrigerant system") 2. Tip of thermostat has come off evaporator (Since air conditioner unit must be removed and disassembled to check thermostat, replace air conditioner unit with new one.) 3. Improper adjustment of expansion valve (replace expansion valve) • If air comes out of air conditioner, fuse is normal. • For each connector, relay and resistor, see "Parts and connectors layout". • For pin location of each connector, see "Electric circuit diagram".

Procedure, measuring location, criteria and remarks Cause Defective fuses in fuse box If fuse is blown, circuit probably has ground fault. F01-4. Defective fuse 120 A of If fuse is blown, circuit probably has ground fault. fusible link 1. Turn starting switch to OFF position. 2. Disconnect connector AC6 and connect T-adpater to female side. 3. Turn starting switch to ON position. Between AC6 20 to 30 V (female) (2) and (8) Fan switch: 1 Open circuit in wiring harness or defective fan Between AC6 20 to 30 V switch (female) (3) and (8) Fan switch: 2 Voltage Between AC6 20 to 30 V (female) (5) and (8) Fan switch: 3 Between AC6 20 to 30 V (female) (6) and (8) Fan switch: 4 Defective blower motor

1. Turn starting switch to OFF position. 2. Disconnect wiring harness from blower motor. ResisBetween blower motor terminals tance

Continuity

Defective fan switch (internal open circuit or short circuit)

a If no failure is found by check on cause 3, this check is not required. 1. Turn starting switch to OFF position. Between AC4 (male) Fan switch: OFF Min. 1M z (2) and (4) Fan switch: HI Max. 1 z Between AC4 (male) Fan switch: OFF Min. 1M z (1) and (4) Fan switch: MID2 Max. 1 z Min. 1M z Resis- Between AC4 (male) Fan switch: OFF tance (6) and (4) Fan switch: MID1 Max. 1 z Between AC4 (male) Fan switch: OFF Min. 1M z (3) and (4) Fan switch: LO Max. 1 z Between AC4 (male) Fan switch: OFF Min. 1M z (4) and (5) Fan switch: LO to HI Max. 1 z

Defective resistor

a If no failure is found by check on cause 3, this check is not required. 1. Turn starting switch to OFF position. Approx. 1.5 Between ACR (male) (1) and (2) z Resis- Between ACR (male) (1) and (3) Approx. 3.8 tance z Approx. 5.7 Between ACR (male) (1) and (4) z D61EM-23M0

80 Appendix

Air conditioner components

Cause

Procedure, measuring location, criteria and remarks

Open circuit in wiring harness (wire breakage or defective contact of connector)

a If no failure is found by check on cause 3, this check is not required. 1. Turn starting switch to OFF position. 2. Remove fuse F01-4. 3. Disconnect connectors AC4 and AC6, and connect T-adapters to each female side. Between F01 (4) and AC4 (female) (4) Max. 1 z Between F01 (4) and AC4 (female) (7) Max. 1 z Between AC4 (female) (2) and AC6 (female) (6) Max. 1 z Resis- Between AC4 (female) (1) and AC6 (female) (5) Max. 1 z tance Between AC4 (female) (6) and AC6 (female) (3) Max. 1 z Between AC4 (female) (3) and AC6 (female) (2) Max. 1 z Between AC6 (female) (1) and ground Max. 1 z

No.

1. Turn starting switch to OFF position. 2. Disconnect connector AC6 and connect T-adapter to male side. 8

Short circuit in wiring harness

a Since above is to measure resistance of resistor, value does not exceed 1Mz Between AC6 (male) (1) and (2) 1 to 20 z 1 to 20 z Resis- Between AC6 (male) (1) and (3) tance Between AC6 (male) (1) and (5) 1 to 20 z Between AC6 (male) (1) and (6) 1 to 20 z

Circuit diagram related to blower motor

D61EM-23M0

80-45

80 Appendix

Air conditioner components

A-4 Troubleshooting for temperature control Detail of failure

Related information

No.

• Air is not warmed up. • Temperature control does not work. • Air is not warmed up or temperature cannot be regulated until coolant temperature is increased. • When air does not come out after turning starting switch to ON position and fan switch to any position other than OFF (1 to 4), perform troubleshooting for A-3 first. • When condenser fan does not rotate, perform troubleshooting for A-1 first. • When air is not cooled down, perform troubleshooting for A-2 first. • When air conditioner mode switch is turned to HEATER position, relay ACR1 is actuated. Relays ACR2 and ACR3 are turned to OFF position, and power is not supplied to air compressor and condenser fan. (Air is not warmed unless relay ACR1 is actuated.) • Temperature is controlled by changing volume of hot water entering into heater core of air conditioner by using hot water valve under the floor. • When temperature control of air conditioner does not work, check that foot heater normally operates. As long as foot heater normally operates, power is supplied to hot water valve. • A connector label is not attached to a relay connector. • T-adapter is not prepared for a relay connector. Procedure, measuring location, criteria and remarks

Cause

1. Turn starting switch to OFF position. 2. Disconnect connector ACR1. Resis- Between ACR1 (female) (85) (black) and ground tance 1. Turn starting switch to OFF position. 2. Disconnect connector ACR1. 3. Turn starting switch to ON position. 4. Turn fan switch to any position other than OFF (1 to 4). 5. Turn air conditioner mode switch to HEATER. Between ACR3 (female) (30) (red) and (85) (black) Between ACR3 Defective mode selector Air conditioner mode switch: (female) (86) (white) switch, defective HEATER temperature adjustment Voltage and (85) (black) Between ACR3 switch, defective diode, Air conditioner mode switch: (female) (86) (white) or open circuit in wiring AIR CONDITIONER and (85) (black) harness

Max. 1 Ω

20 to 30 V 20 to 30 V

Max. 1 V

1. Turn starting switch to OFF position. 2. Disconnect connector AC2 and connect T-adapter to female side. 3. Turn starting switch to ON position. 4. Turn fan switch to any position other than OFF (1 to 4). 5. Turn air conditioner mode switch to AIR CONDITIONER. 6. Turn temperature adjustment switch from C to H. Between AC2 (female) (1) and (4) 20 to 30 V 0 (C) to Voltage Between AC2 (female) (2) and (4) approx. 25 (H) V 2

Defective hot water valve

Defective relay ACR1

a If no failure is found in above check and temperature control remains still unavailable, hot water valve is defective. Referring to "Testing relays", check sounds when heater mode relay ACR1 is turned ON. a If no failure is found by check on cause 1, this check is not required. 1. Turn starting switch to OFF position. 2. Disconnect connectors AC9 and connect T-adapter to male side.

Defective diode AC9

a Measure by using diode range. Continuity

80-46

Between AC9 (male) (1) (+) and (2) Between AC9 (male) (2) (+) and (1)

No continuity Continuity

D61EM-23M0

80 Appendix

Air conditioner components

No.

Cause

Defective diode AC7 or AC8

Procedure, measuring location, criteria and remarks a Following is implemented only when failure is found between AC2 (female) (2) and (4) by check on cause 1. 1. Turn starting switch to OFF position. 2. Disconnect connectors AC7 and AC8. 3. Start engine. 4. Turn fan switch to any position other than OFF (1 to 4). 5. Turn air conditioner mode switch to AIR CONDITIONER. 6. Turn temperature adjustment switch from C to H. a If temperature control becomes operable, diode AC7 or AC8 is defective. a If no failure is found by check on cause 1, this check is not required. 1. Turn starting switch to OFF position. 2. Disconnect connector AC3 and connect T-adapter to male side, or disconnect connector AC2 and connect T-adapter to female side. 3. Turn temperature adjustment switch from C to H (resistance is variable). Approx. 1.5 Resis- Between AC3 (male) (A) and (B), or between AC2 (C) to 5.2 tance (female) (2) and (4) (H) kΩ

Defective temperature control switch

a If no failure is found by check on cause 1, this check is not required. 1. Turn starting switch to OFF position. 2. Disconnect connector AC5 and connect T-adapter to male side. Mode selector switch: Any Min. 1 MΩ Between AC5 (male) position other than AIR Defective mode selector CONDITIONER (1) and (3) switch (internal defect) Mode selector switch: AIR Max. 1 Ω ResisCONDITIONER tance Mode selector switch: Any Min. 1 MΩ Between AC5 (male) position other than HEATER (1) and (4) Mode selector switch: Max. 1 Ω HEATER

a If no failure is found by check on cause 1, this check is not required. 1. Turn starting switch to OFF position. 2. Remove fuse -4 (30 A) in fuse box F01. 3. Disconnect connector ACR1. 4. Disconnect connectors AC2, AC4 and AC5, and connect T-adapter to each female side. Between AC4 (female) (5) and ACR1 (female) (30) Max. 1 Ω (red) Between AC4 (female) (5) and AC5 (female) (1) Max. 1 Ω Open circuit in wiring Between AC5 (female) (3) and ACR1 (female) (87) harness (wire breakage Max. 1 Ω (green) or defective contact of connector) Between AC5 (female) (4) and ACR1 (female) (86) Max. 1 Ω (white) ResisMax. 1 Ω tance Between F01-4 and AC2 (female) (1) Between AC2 (female) (2) and AC3 (female) (B) Max. 1 Ω Between AC2 (female) (4) and ground Max. 1 Ω Between AC3 (female) (A) and ground Max. 1 Ω Between AC9 (female) (1) and AC3 (female) (C) Max. 1 Ω Between AC5 (female) (3) and AC9 (female) (2) Max. 1 Ω Between AC9 (female) (1) and AC3 (female) (C) Max. 1 Ω

D61EM-23M0

80-47

80 Appendix

Air conditioner components

Circuit diagram related to temperature control

80-48

D61EM-23M0

80 Appendix

Air conditioner components

Troubleshooting with gauge pressure

Perform troubleshooting according to the indicator of gauge pressures of high-pressure and low-pressure lines of the cooling cycle. For details, see "Connection of service tool". a Note that the gauge pressure changes significantly depending on weather and operating condition of the machine. • Pressure of high-pressure line is too high: Min. approximately 2.5 MPa {25 kg/cm 2 } • Pressure of high-pressure line is too low: Max. approximately 1 MPa {10 kg/cm 2 } • Pressure of low-pressure line is too high: Min. approximately 0.3 MPa {3 kg/cm 2 } • Pressure of low-pressure line is too low: Max. approximately 0.05 MPa {0.5 kg/cm 2 } a Dual pressure switch installed in the high-pressure line turns "OFF" to protect the air conditioner circuit if the pressure of the high-pressure or low-pressure line is abnormal. <Measurement condition for pressure> Item Ambient temperature Engine speed Air conditioner switch Fan switch Set temperature

Condition value 20 to 50°C Low idle ON HI Cool-Max

• Dual pressure switch a The switch outputs "ON" signal when the pressures are normal, and "OFF" signal when it detects an abnormal pressure for compressor operation.

LA: 0.14 to 0.23 MPa {1.4 to 2.3 kg/cm2} LB: 0.16 to 0.25 MPa {1.6 to 2.5 kg/cm2} HA: 2.62 to 2.89 MPa {26.2 to 28.9 kg/cm2} HB: 1.38 to 2.07 MPa {13.8 to 20.7 kg/cm2}

D61EM-23M0

80-49

80 Appendix

Air conditioner components

Indicated gauge pressure

<Pressure of both highpressure and low-pressure lines are too low> Low-pressure line gauge reads vacuum

<Pressure of high-pressure line is too high and that of lowpressure line is too low> <Pressure of high-pressure line is too low and that of lowpressure line is too high> 80-50

Cause

Check method

Remedy

Air conditioner cycle is operating normally. If any cooling trouble (poor cooling) is recognized, the cause is in other system. Pressure of high-pressure line: approximately 1.5 to 1.7 MPa {15 to 17 kg/cm2} Pressure of low-pressure line: approximately 0.13 to 0.2 MPa {1.3 to 2.0 kg/cm2 } Collect refrigerant, Bubbles can be seen through sight then fill up with Insufficient refrigerant glass. *1, *3 proper quantity of refrigerant again. *2 Temperature difference is recognized between inlet and Clogging of receiver drier Replace *2 outlet pipes of receiver drier. Tank is frosty. Clogging of expansion valve Expansion valve is frosty. Clean or replace *2 Gas leakage at thermoprobe of Low-pressure line gauge reads Replace *2 expansion valve vacuum. Repair or replace Evaporator is frozen. Flow rate of refrigerant is reduced Replace receiver drier. Defective thermostat or defective due to freezing. contact of sensor (coming off of Collect refrigerant, (If air conditioner is set to Cool mounting clip) then fill up with Max. and HI fan speed modes, proper quantity of later its cooling performance refrigerant again. *2 lowers.) Piping between receiver drier and compressor is clogged or crushed. Clogging or crushing of piping Clean or replace *2 If clogged completely, lowpressure line gauge reads vacuum Collect refrigerant, then fill up with Filling of too much refrigerant Connect gauge manifold. proper quantity of refrigerant again. *2 Clean condenser, Check condenser for dirt, fins for repair fins, or repair Defective cooling of condenser clogging or crushing, and cooling or replace cooling fan for defective rotation. fan *2 Improper adjustment of Bubbles can be seen through sight expansion valve (valve is opened Replace *2 glass. *3 too wide) Evacuate air from air conditioner and Bubbles can be seen through sight Air sucked in cooling cycle parts then fill up with glass. *3 proper quantity of refrigerant again. *2 Remarkable temperature Piping between compressor and difference is recognized across condenser is Clogged or crushed. clogged part.

Defective compressor (compression trouble of compressor)

Clean inside of cooling cycle parts or replace them.*2

Pressures of high-pressure and low-pressure lines are almost the same while compressor is running. Replace *2 Compressor has seized and is extremely hot. D61EM-23M0

80 Appendix

Air conditioner components

*1: If refrigerant leaks, compressor oil in the air conditioner circuit always leaks, too. So perform the check mainly on pipe joints and dirty parts with oil. *2: k When replacing cooling cycle parts, be sure to collect refrigerant. For details, see "Precautions for

refrigerant". After replacing parts, fill the air conditioner circuit with refrigerant. *3: Sight glass is provided in rear left corner of cab.

D61EM-23M0

80-51

80 Appendix

Air conditioner components

Connection of service tool

k Place the machine on a level ground, turn parking brake switch to the PARK position, and stop the

engine. k Turn the battery disconnect switch to the OFF position, and remove the key.

a Following service tool kit is used for work with refrigerant R134a. Symbol X

Part No. 799-703-1200

Part name Service tool kit

Service tool kit X (1): Gauge manifold (2): Red high-pressure line charging hose (3): Blue low-pressure line charging hose (4): Large diameter quick joint (for high-pressure line) (5): Small diameter quick joint (for low-pressure line) (a): Note that the threads are coarse and the hoses are relatively easy to loosen. Connect the gauge manifold, hoses and other service tools according to the following procedure. 1. Close high-pressure line valve (6) and low-pressure line valve (7) of gauge manifold (1). 2. Connect red high-pressure line charging hose (2) to the gauge manifold (1) (HI side) and blue lowpressure line charging hose (3) to the gauge manifold (LO side). 3. Connect quick joints (4) and (5) to each hose. 4. Connect quick joints (4) and (5) to service valves (8) and (9) of high- and low-pressure piping respectively.

80-52

D61EM-23M0

80 Appendix

Air conditioner components

D61EM-23M0

80-53

80 Appendix

Air conditioner components

Precautions for disconnecting and connecting hoses and tubes in air conditioner circuit 1 Precautions for disconnection k When replacing air conditioner unit, condenser, receiver drier, etc., collect refrigerant (air

conditioner gas: R134a) from air conditioner circuit before disconnecting air conditioner hoses. a Ask a qualified person for collecting, adding and filling operations of the refrigerant (air conditioner gas: R134a). (Only registered persons can work.) a Never release refrigerant (air conditioner gas: R134a) to atmosphere. k If refrigerant gas (air conditioner gas: R134a) gets in your eyes, you may lose your sight. And if it

touches your skin, you may suffer from frostbite. Put on protective eyeglasses, gloves and working clothes with long sleeves while collecting the refrigerant or filling the air conditioner circuit with the refrigerant. • When loosening the air conditioner hose nut after collecting the refrigerant, be sure to use two wrenches. Use one wrench to fix one nut and the other wrench to loosen the other nut. • For the disconnected air conditioner piping, take measures to prevent dirt, dust, and water from entering the hose. Precautions for connection • When connecting piping, apply compressor oil (SP-20) for R134a to the O-ring. (See Item 4 of "Handling of compressor oil".) Do not apply oil to threads of a bolt, nut and union. a An O-ring is fitted to every joint of the air conditioner piping. • A once used O-ring is deformed and deteriorated. Do not reuse it. When removing it, use a soft tool (such as a toothpick) so that the piping will not be damaged. • When connecting the piping, press the pipe until it is seated and finger-tighten the bolt or nut fully. • Be sure to use two wrenches to tighten each nut. Use one wrench to fix one nut and the other wrench (torque wrench) to tighten the other nut to the specified torque. a Example of fitting of O-ring

Table of tightening torque for refrigerant pipe joint. Thread size 5/8 -18UNF 3/4 -16UNF 7/8 -14UNF

80-54

Tightening torque: Nm {kgm} 14.9 to 17.6 {1.6 to 1.8} 20.3 to 27.1 {2.1 to 2.7} 28.4 to 36.6 {2.9 to 3.7}

D61EM-23M0

80 Appendix

Air conditioner components

1. Engine 2. Compressor 3. Condenser 4. Receiver drier 5. Air conditioner unit 6. Sight glass

D61EM-23M0

80-55

80 Appendix

Air conditioner components

Handling of compressor oil

1. Compressor oil management (SANDEN: SP-20 for use with R134a) Although compressor oil differs from engine oil in that it does not need regular checking or filling, the following types of problem can occur if the amount in the system is excessive or too insufficient. Condition Insufficient oil Excess oil

Content Lubrication trouble and seizure of compressor Cooling trouble (Excess oil sticks to parts and lowers heat exchange performance)

Accordingly, compressor oil must be filled to the specified level, similarly to refrigerant. 2. Filling of compressor oil k Refrigerant is potentially hazardous to health and environment. Before disconnecting air

conditioner hoses, collect refrigerant in accordance with "Precautions for connecting and disconnecting hoses and tubes in air conditioner circuit". a Using oil for CFC-12 (R-12) may cause lubrication trouble, leading to damage or seizure of compressor. Be sure to use the oil for R134a (SANDEN: SP-20). a Oil for use with R134a is extremely hygroscopic, and therefore, put the cap the to oil container immediately after use to limit contact with air. Store it in a dry and well-ventilated place. a Precautions for using oil Do not allow oil for use with R134a to come into contact with acrylic resin or polystyrene surfaces (except a baked finish) since it may dissolve these plastics. Check compressor oil in the following cases, and then add new oil if necessary. • When much refrigerant is discharged because of leakage. • When the compressor has trouble and is replaced (See 3 below) • When a cycle part such as condenser, receiver drier, evaporator unit, etc. is replaced Quantity of oil to be added when cycle part is replaced Air conditioner part Air conditioner unit, evaporator Condenser Receiver drier A hose A tube

Quantity to be added (cc) Approx. 40 Approx. 40 Approx. 20 Approx. 5 Approx. 10

3. Replacement of compressor • When compressor is damaged due to seizure, etc. Metal chips may circulate through air conditioner circuit and seriously contaminate compressor oil. In this case, flush the air conditioner circuit and replace the compressor and receiver drier. The compressor oil is removed from the air conditioner circuit by flushing. Accordingly, install a new compressor with the oil of the specified quantity (175 cc) filled in it. • Other cases 80-56

D61EM-23M0

80 Appendix

Air conditioner components

a Compressor oil of 175 cc is charged beforehand to a new compressor. 1. Prepare an oil container and drain oil from the old compressor. 2. Measure the quantity of the drained oil with a measuring cylinder, and note the quantity.

3. Drain below-mentioned quantity of oil from the new compressor. Quantity to be drained= 175 cc - "Noted quantity" Example: If 30 cc was drained from the removed compressor, the quantity to be drained from the new compressor would be 145 cc (i.e., 175 - 30 cc). 4. Applying compressor oil to O-rings When connecting piping or hoses, apply the compressor oil for R134a (SP-20) to O-rings in order to prevent the leakage of refrigerant.

D61EM-23M0

80-57

80 Appendix

Air conditioner components

80-58

D61EM-23M0

SHOP MANUAL

D61E -23M0 Model

Serial Number

D615 -23M0

B 0001 and up

90 Diagrams and drawings 10 90 Diagrams and drawings

D61EM-23M0

90-1

90 Diagrams and drawings Table of contents

Table of contents

90 Diagrams and drawings - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 90-1 Table of contents - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 90-2 Hydraulic circuit diagram - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 90-3 Symbols in hydraulic circuit diagram- - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 90-3 Hydraulic circuit diagram - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 90-7 Electric circuit diagram - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 90-9 Symbols in electric circuit diagram - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 90-9 Electric circuit diagram - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 90-13

90-2

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90 Diagrams and drawings Hydraulic circuit diagram

Hydraulic circuit diagram

Symbols in hydraulic circuit diagram

1 (Rev. 2013/09)

Symbols

Substances Main piping line

Pilot or drain line

Flexible pipe (hose etc.)

Lines intersecting without jointing

Lines jointing (junction with a black dot)

Direction of flow

Throttle in passage

Variable

Electricity

Spring

Take-off port

Take-off port and pressure gauge

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90 Diagrams and drawings Hydraulic circuit diagram

Symbols

Substances Check valve

Suction (with strainer)

Tank and return pipe

Filter

Oil cooler

Stop valve

Drive shaft (unidirectional)

Drive shaft (bidirectional)

Hydraulic pump Note: Black triangle shows outlet port

Variable capacity hydraulic pump

Hydraulic motor Note: Two black triangles in the figure show direction of oil entering hydraulic motor depending on the oil entry port, the direction of rotation is reversed. Servo piston

PPC valve

90-4

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90 Diagrams and drawings Hydraulic circuit diagram

Symbols

Substances Control valve

Single-acting solenoid valve

Single-acting proportional solenoid valve

Hydraulic pilot valve

Hydraulic two-stage pilot valve

Lock valve

Drain valve

Pressure regulator valve, Safety valve, Abnormal pressure prevention valve Pressure regulator valve, Safety valve, Abnormal pressure prevention valve (when the figure shows air pressure, being released to atmosphere)

Bypass valve

Accumulator

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90-5

90 Diagrams and drawings Hydraulic circuit diagram

Symbols

Substances

Cylinder

Component group

90-6

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Hydraulic circuit diagram D61EM-23M0 a This diagram covers optional components that are unavailable in some areas.

Hydraulic circuit diagram D61EM-23M0

* D61EM-23M0

90-7

90 Diagrams and drawings

Electric circuit diagram

Symbols in electric circuit diagram

1 (Rev. 2013/09)

Symbols

Substances Electric wire

Electric wire (wires intersecting without connecting)

Electric wire (wires intersecting and connecting (junction) with a black dot)

Electric wire (bundled drawing style)

Terminal

Chassis ground

Chassis ground using terminal

Contact, Switch

Push-button type switch (N.O. type) N.O.: Normally Open

Push-button type switch (N.C. type) N.C.: Normally Close

Pull-button type switch (N.O. type) N.O.: Normally Open

Pull-button type switch (N.C. type) N.C.: Normally Close

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90-9

90 Diagrams and drawings Electric circuit diagram

Symbols

Substances Variable

Resistor

Variable resistor

Diode

Light emitting diode (LED)

Photo diode

Constant voltage diode (zener diode)

Transistor (PNP type)

Transistor (NPN type)

Coil

Battery

Fuse Connector Note: • Concave side of connecting portion (left in figure): female • Convex side of connecting portion (right in figure): male a Figure shows a line disconnection status 90-10

D61EM-23M0

90 Diagrams and drawings

Electric circuit diagram

Symbols

Substances Plug and receptacle type connector (left: male, right: female) a Figure shows a line connection status

Solenoid

Motor

Lamp

Pressure switch (N.O. type) N.O.: Normally Open

Pressure switch (N.C. type) N.C.: Normally Close

Potentiometer, Fuel control dial

Temperature sensor

Starting switch

Back up alarm

Horn

Buzzer

Antenna

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90-11

90 Diagrams and drawings Electric circuit diagram

90-12

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Electrical circuit diagram (1/12) D61EM-23M0 a This diagram covers optional components that are unavailable in some areas.

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Electrical circuit diagram (1/12) D61EM-23M0

90-13

Electrical circuit diagram (2/12) D61EM-23M0 a This diagram covers optional components that are unavailable in some areas.

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Electrical circuit diagram (2/12) D61EM-23M0

90-15

Electrical circuit diagram (3/12) D61EM-23M0 a This diagram covers optional components that are unavailable in some areas.

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Electrical circuit diagram (3/12) D61EM-23M0

90-17

Electrical circuit diagram (4/12) D61EM-23M0 a This diagram covers optional components that are unavailable in some areas.

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Electrical circuit diagram (4/12) D61EM-23M0

90-19

Electrical circuit diagram (5/12) D61EM-23M0 a This diagram covers optional components that are unavailable in some areas.

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Electrical circuit diagram (5/12) D61EM-23M0

90-21

Electrical circuit diagram (6/12) D61EM-23M0 a This diagram covers optional components that are unavailable in some areas.

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Electrical circuit diagram (6/12) D61EM-23M0

90-23

Electrical circuit diagram (7/12) D61EM-23M0 a This diagram covers optional components that are unavailable in some areas.

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Electrical circuit diagram (7/12) D61EM-23M0

90-25

Electrical circuit diagram (8/12) D61EM-23M0 a This diagram covers optional components that are unavailable in some areas.

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Electrical circuit diagram (8/12) D61EM-23M0

90-27

Electrical circuit diagram (9/12) D61EM-23M0 a This diagram covers optional components that are unavailable in some areas.

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Electrical circuit diagram (9/12) D61EM-23M0

90-29

Electrical circuit diagram (10/12) D61EM-23M0 a This diagram covers optional components that are unavailable in some areas.

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Electrical circuit diagram (10/12) D61EM-23M0

90-31

Electrical circuit diagram (11/12) D61EM-23M0 a This diagram covers optional components that are unavailable in some areas.

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Electrical circuit diagram (11/12) D61EM-23M0

90-33

Electrical circuit diagram (12/12) D61EM-23M0 a This diagram covers optional components that are unavailable in some areas.

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Electrical circuit diagram (12/12) D61EM-23M0

90-35

INDEX

INDEX A A-1 Troubleshooting for condenser fan................... 80-37 A-2 Troubleshooting for compressor and refrigerant system (Air is not cooled) .................................. 80-40 A-3 Troubleshooting for blower motor system (No air comes out or air flow is abnormal) .................... 80-44 A-4 Troubleshooting for temperature control .......... 80-46 Accumulator .......................................................... 10-119 Adjusting deceleration/brake pedal ......................... 30-53 Adjusting idler clearance ......................................... 30-61 Adjusting parking brake lever.................................. 30-56 Adjusting rearview camera angle .......................... 30-150 Adjusting work equipment lock lever....................... 30-74 Adjustment method when electric or hydraulic device has been replaced.................................................. 30-149 Adjustment method when HST controller has been replaced........................................................... 30-146 Air conditioner component ........................................ 80-4 Air conditioner components....................................... 80-3 Air conditioner unit .................................................. 80-10 Anti-drop valve ........................................................ 60-39

B Battery disconnect switch function ........................ 10-145 Bleeding air from fuel system.................................. 30-33 Bleeding air from hydraulic circuit ........................... 30-73

C Cab and its attachments ................. 10-122,50-179,60-46 Cab mount................................................... 10-124,60-46 Carrier roller ............................................................ 60-24 Charge pump ................................................ 10-56,60-11 Check alternator belt, replace ................................. 30-40 Checking sprocket wear.......................................... 30-62 Checks before troubleshooting ............................... 40-12 Classification and procedures for troubleshooting .. 40-35 CLSS....................................................................... 10-79 Coating materials list................................................. 50-6 Compressor............................................................. 80-16 Condenser............................................................... 80-17 Configuration and function of refrigeration cycle....... 80-7 Connection of service tool....................................... 80-52 Connector contact identification .............................. 40-58 Connector list and layout......................................... 40-44 Control valve ................................................. 10-93,60-32 Conversion table ..................................................... 00-59 Cooling fan motor.............................................. 10-7,60-4 Cooling system.......................................................... 10-5 Cooling system control system ............................. 10-128

D Damper ........................................................... 10-22,60-7 Disassembly and assembly of carrier roller assembly ......................................................... 50-132 Disassembly and assembly of damper assembly ... 50-76 Disassembly and assembly of final drive .............. 50-100 Disassembly and assembly of foot heater assembly ......................................................... 50-193 Disassembly and assembly of hydraulic cylinder assembly ......................................................... 50-172 Disassembly and assembly of idler....................... 50-116 D61EM-23M0

Disassembly and assembly of one track link assembly in field (Standard type track shoe)....................... 50-154 Disassembly and assembly of recoil spring .......... 50-121 Disassembly and assembly of track roller assembly ......................................................... 50-127 Dual pressure switch ............................................... 80-14

E E-1 Engine does not start (Engine does not crank) .................................. 40-494 E-2 Manual preheating system does not work ...... 40-500 E-3 Automatic preheating system does not work .. 40-503 E-4 While preheating is working, preheating monitor does not light up ....................................................... 40-505 E-5 When starting switch is turned to ON position, machine monitor displays nothing ................... 40-507 E-6 When starting switch is turned to ON position (with engine stopped), basic check monitor lights up ........................................................... 40-510 E-7 Air cleaner clogging monitor lights up in yellow while engine is running ............................................. 40-511 E-8 Charge level monitor lights up in red while engine is running............................................................. 40-512 E-9 Engine coolant temperature monitor lights up in red while engine is running .................................... 40-513 E-10 Engine oil pressure monitor lights up in red while engine is running ............................................. 40-514 E-11 HST charge pressure monitor lights up in red while engine is running ............................................. 40-515 E-12 Hydraulic oil temperature monitor lights up in red while engine is running .................................... 40-516 E-13 HST oil filter clogging monitor lights up in red while engine is running ............................................. 40-517 E-14 Fuel level gauge does not indicate correct level ................................................................. 40-518 E-15 Engine coolant temperature gauge does not indicate correct temperature ......................................... 40-521 E-16 Hydraulic oil temperature gauge does not indicate correct temperature ......................................... 40-522 E-17 Operation mode does not change ................ 40-523 E-18 Service mode cannot be selected................. 40-524 E-19 Operating customize switch does not display customize screen............................................. 40-525 E-20 Modifying setting on customize screen does not change setting of machine............................... 40-526 E-21 Service meter is not displayed, while starting switch is in OFF position............................................. 40-527 E-22 Work equipment does not operate................ 40-528 E-23 Foot heater does not operate ....................... 40-530 E-24 Horn does not sound .................................... 40-535 E-25 Horn does not stop sounding........................ 40-537 E-26 Backup alarm does not sound ...................... 40-538 E-27 Backup alarm does not stop sounding.......... 40-539 E-28 Headlamp does not light up .......................... 40-540 E-29 Rear lamp does not light up.......................... 40-543 E-30 No wiper operates continuously or intermittently .................................................... 40-546 E-31 Front wiper does not operate........................ 40-548 E-32 Rear wiper does not operate ........................ 40-550 E-33 Left door wiper does not operate (failed in both continuous and intermittent operations) .......... 40-552

INDEX

E-34 Right door wiper does not operate (failed in both continuous and intermittent operations) .......... 40-556 E-35 Front washer does not operate..................... 40-560 E-36 Rear washer does not operate ..................... 40-562 E-37 Left door washer does not operate............... 40-564 E-38 Right door washer does not operate ............ 40-566 E-39 KOMTRAX system does not operate normally ........................................................... 40-568 Electric circuit diagram .................................... 90-9,90-13 Electric steering lever.............................................. 60-47 Electrical circuit diagram ......................................... 80-23 Electrical system ...................10-125,30-76,50-200,60-47 Engine and cooling system .............10-3,30-9,50-29,60-3 Engine control system........................................... 10-125 Engine mount ............................................................ 60-3 Engine related parts .................................................. 10-3 Explanation of terms for maintenance standard...... 00-22

F Failure code [6091NX] HST Oil Filter Clogging..... 40-115 Failure code [989L00] Engine Controller Lock Caution 1 ......................................................... 40-117 Failure code [989M00] Engine Controller Lock Caution 2 ......................................................... 40-118 Failure code [989N00] Engine Controller Lock Caution 3 ......................................................... 40-119 Failure code [AA10NX] Air Cleaner Clogging ....... 40-120 Failure code [AB00KE] Charge Voltage Low ........ 40-122 Failure code [B@BAZG] Eng Oil Press Low ......... 40-124 Failure code [B@BCNS] Eng Water Overheat...... 40-125 Failure code [B@CRNS] HST Oil Overheat.......... 40-126 Failure code [B@CRZG] HST Charge Press Low 40-127 Failure code [CA111] ECM Critical Internal Failure.............................................................. 40-128 Failure code [CA115] Eng Ne and Bkup Speed Sens Error................................................................. 40-129 Failure code [CA122] Chg Air Press Sensor High Error................................................................. 40-130 Failure code [CA123] Chg Air Press Sensor Low Error................................................................. 40-132 Failure code [CA131] Throttle Sensor High Error . 40-134 Failure code [CA132] Throttle Sensor Low Error .. 40-136 Failure code [CA144] Coolant Temp Sens High Error................................................................. 40-138 Failure code [CA145] Coolant Temp Sens Low Error................................................................. 40-140 Failure code [CA153] Chg Air Temp Sensor High Error................................................................. 40-142 Failure code [CA154] Chg Air Temp Sensor Low Error................................................................. 40-144 Failure code [CA187] Sensor 2 Supply Volt Low Error................................................................. 40-146 Failure code [CA2185] Throt Sensor Sup Volt High Error................................................................. 40-201 Failure code [CA2186] Throt Sensor Sup Volt Low Error................................................................. 40-202 Failure code [CA221] Ambient Press Sensor High Error................................................................. 40-148 Failure code [CA222] Ambient Press Sensor Low Error................................................................. 40-150 Failure code [CA2249] Rail Press Very Low Error 40-203 Failure code [CA227] Sensor 2 Supply Volt High Error................................................................. 40-152 Failure code [CA2311] IMV Solenoid Error ........... 40-204

Failure code [CA234] Eng Overspeed................... 40-153 Failure code [CA238] Ne Speed Sensor Supply Volt Error................................................................. 40-154 Failure code [CA2555] Grid Htr Relay Volt Low Error................................................................. 40-205 Failure code [CA2556] Grid Htr Relay Volt High Error................................................................. 40-207 Failure code [CA271] IMV/PCV1 Short Error ........ 40-155 Failure code [CA272] IMV/PCV1 Open Error ........ 40-157 Failure code [CA322] Inj #1(L#1) Open/Short Error................................................................. 40-159 Failure code [CA323] Inj #5(L#5) Open/Short Error................................................................. 40-161 Failure code [CA324] Inj #3(L#3) Open/Short Error................................................................. 40-163 Failure code [CA325] Inj #6(L#6) Open/Short Error................................................................. 40-165 Failure code [CA331] Inj #2(L#2) Open/Short Error................................................................. 40-167 Failure code [CA332] Inj #4(L#4) Open/Short Error................................................................. 40-169 Failure code [CA342] Calibration Code Incompatibility .................................................. 40-171 Failure code [CA351] Injectors Drive Circuit Error................................................................. 40-172 Failure code [CA352] Sensor 1 Supply Volt Low Error................................................................. 40-173 Failure code [CA386] Sensor 1 Supply Volt High Error................................................................. 40-175 Failure code [CA428] Water in Fuel Sensor High Error................................................................. 40-176 Failure code [CA429] Water in Fuel Sensor Low Error................................................................. 40-178 Failure code [CA435] Eng Oil Press Sw Error....... 40-180 Failure code [CA441] Battery Voltage Low Error .. 40-181 Failure code [CA442] Battery Voltage High Error.. 40-183 Failure code [CA449] Rail Press Very High Error . 40-184 Failure code [CA451] Rail Press Sensor High Error................................................................. 40-185 Failure code [CA452] Rail Press Sensor Low Error................................................................. 40-187 Failure code [CA488] Chg Air Temp High Torque Derate .............................................................. 40-189 Failure code [CA553] Rail Press High Error.......... 40-190 Failure code [CA689] Eng Ne Speed Sensor Error................................................................. 40-191 Failure code [CA731] Eng Bkup Speed Sens Phase Error................................................................. 40-193 Failure code [CA757] All continuous Data Lost Error................................................................. 40-195 Failure code [CA778] Eng Bkup Speed Sensor Error................................................................. 40-196 Failure code [D130KA] Neutral relay Open ........... 40-209 Failure code [D130KB] Neutral relay Short circuit. 40-211 Failure code [D130KY] Neutral relay Hot Short..... 40-213 Failure code [D19JKZ] Personal Code Relay Abnormality...................................................... 40-215 Failure code [D811MC] KOMTRAX Error.............. 40-218 Failure code [D862KA] GPS Antenna Open Circuit............................................................... 40-219 Failure code [D8ALKA] Operating Lamp Open Circuit (KOMTRAX)..................................................... 40-220 Failure code [D8ALKB] Operating Lamp Short Circuit (KOMTRAX)..................................................... 40-222 D61EM-23M0

INDEX

Failure code [D8AQKR] CAN2 Discon (KOMTRAX) .................................................... 40-223 Failure code [DAF0MB] Monitor ROM Abnormality ..................................................... 40-224 Failure code [DAF0MC] Monitor Error................... 40-225 Failure code [DAF8KB] Camera Power Supply Short Circuit..................................................... 40-226 Failure code [DAF9KQ] Model Selection Abnormality ..................................................... 40-227 Failure code [DAFGMC] GPS Module Error ......... 40-228 Failure code [DAFLKA] Operating Lamp Open Circuit (Monitor) .......................................................... 40-229 Failure code [DAFLKB] Operating Lamp Short Circuit (Monitor) .......................................................... 40-231 Failure code [DAFQKR] CAN2 Discon (Monitor) .. 40-232 Failure code [DAJ000] HST controller: Abnormality in controller.......................................................... 40-233 Failure code [DAJ0KQ] HST controller: Type select signal ............................................................... 40-234 Failure code [DAJ0KT] HST controller: Abnormality in controller.......................................................... 40-235 Failure code [DAJ0MC] HST Con Error ................ 40-236 Failure code [DAJ1KK] HST controller: Source voltage low ................................................................... 40-237 Failure code [DAJ2KK] HST controller: Output voltage low ................................................................... 40-239 Failure code [DAJ5KK] HST: Sensor volt 5V (0) Out of normal range ................................................... 40-241 Failure code [DAJ6KK] HST: Sensor volt 5V (1) Out of normal range ................................................... 40-244 Failure code [DAJLKA] Operating Lamp Open Circuit (HST Con) ....................................................... 40-246 Failure code [DAJLKB] Operating Lamp Short Circuit (HST Con) ....................................................... 40-248 Failure code [DAJPMA] Inconsistency of Option Selection (HST)............................................................... 40-249 Failure code [DAJQKR] CAN2 Discon (HST Con) ....................................................... 40-250 Failure code [DAJRKR] CAN1 Discon (HST Con) ....................................................... 40-251 Failure code [DB2QKR] CAN2 Discon (Engine Con) ................................................... 40-252 Failure code [DD12KA] Shift up SW: Open................................................................ 40-256 Failure code [DD12KB] Shift up SW: Short Circuit..................................................... 40-258 Failure code [DD13KA] Shift down SW: Open................................................................ 40-260 Failure code [DD13KB] Shift down SW: Short Circuit..................................................... 40-262 Failure code [DD14KA] Parking lever SW: Open................................................................ 40-264 Failure code [DD14KB] Parking lever SW: Short circuit ..................................................... 40-267 Failure code [DDKAKA] Blade float Sw: Open................................................................ 40-271 Failure code [DDKAKB] Blade float Sw: Short circuit ..................................................... 40-273 Failure code [DDKFL4] Left Angle Sw: Signal mismatch .............................................. 40-275 Failure code [DDKGL4] Right Angle Sw: Signal mismatch .............................................. 40-277 Failure code [DDKHKA] iB Sw: Open ................... 40-279 Failure code [DDKHKB] iB Sw: Short circuit ......... 40-281 D61EM-23M0

Failure code [DDNLKA] Weq lock Sw: Open................................................................ 40-283 Failure code [DDNLKB] Weq lock Sw: Short circuit...................................................... 40-286 Failure code [DDP6KA] Brake Pressure Sensor: Open................................................................ 40-289 Failure code [DDP6KB] Brake Pressure Sensor: Hot Short ......................................................... 40-291 Failure code [DDP6MA] Brake pressure sensor: Malfunction ...................................................... 40-293 Failure code [DDU1FS] Parking lever Switch 2: Signal mismatch .............................................. 40-295 Failure code [DDU1KA] Parking lever Sw2: Open................................................................ 40-298 Failure code [DDU1KY] Parking lever Sw2: Hot Short ......................................................... 40-301 Failure code [DFA4KX] Blade lift lever: Main and Sub Error ......................................... 40-303 Failure code [DFA4KZ] Blade lift lever: Main and Sub Error ......................................... 40-304 Failure code [DFA4L8] Blade lift lever: Signal mismatch .............................................. 40-305 Failure code [DFA5KA] Blade lift lever1: Open................................................................ 40-306 Failure code [DFA5KB] Blade lift lever1: Hot Short ......................................................... 40-309 Failure code [DFA6KA] Blade lift lever2: Open................................................................ 40-311 Failure code [DFA6KB] Blade lift lever2: Hot Short ......................................................... 40-313 Failure code [DFA7KX] Blade tilt lever: Main and Sub Error ......................................... 40-315 Failure code [DFA7KZ] Blade tilt lever: Main and Sub Error ......................................... 40-316 Failure code [DFA7L8] Blade tilt lever: Signal mismatch .............................................. 40-317 Failure code [DFA8KA] Blade tilt lever1: Open................................................................ 40-318 Failure code [DFA8KB] Blade tilt lever1: Hot Short ......................................................... 40-321 Failure code [DFA9KA] Blade tilt lever2: Open................................................................ 40-323 Failure code [DFA9KB] Blade tilt lever2: Hot Short ......................................................... 40-326 Failure code [DGS1KA] HST oil temp sensor: Open................................................................ 40-328 Failure code [DGS1KX] HST oil temp sensor: Out of normal range......................................... 40-330 Failure code [DH21KA] Weq pressure sensor: Open................................................................ 40-331 Failure code [DH21KB] Weq pressure sensor: Hot Short ......................................................... 40-333 Failure code [DHA4KA] Air Cleaner Clog Sensor Open Circuit .............................................................. 40-335 Failure code [DHH7KA] LF HST Pressure Sensor: Open................................................................ 40-337 Failure code [DHH7KB] LF HST Pressure Sensor: Hot Short ......................................................... 40-339 Failure code [DHH8KA] RF HST Pressure Sensor: Open................................................................ 40-341 Failure code [DHH8KB] RF HST Pressure Sensor: Hot Short ......................................................... 40-343 Failure code [DHH9KA] LR HST Pressure Sensor: Open................................................................ 40-345

INDEX

Failure code [DHH9KB] LR HST Pressure Sensor: Hot Short ......................................................... 40-347 Failure code [DHHAKA] RR HST Pressure Sensor: Open................................................................ 40-349 Failure code [DHHAKB] RR HST Pressure Sensor: Hot Short ......................................................... 40-351 Failure code [DK30KA] ST lever1: Open .............. 40-353 Failure code [DK30KB] ST lever1: Hot Short ........ 40-356 Failure code [DK30KX] ST lever: Main and Sub Error ......................................... 40-358 Failure code [DK30KZ] ST lever: Main and Sub Error ......................................... 40-359 Failure code [DK30L8] ST lever: Signal mismatch .............................................. 40-360 Failure code [DK31KA] ST lever2: Open .............. 40-361 Failure code [DK31KB] ST lever2: Hot Short ........ 40-364 Failure code [DK40KA] Decel/Brake potentiometer: Open................................................................ 40-366 Failure code [DK40KB] Decel/Brake potentiometer: Hot Short ......................................................... 40-369 Failure code [DK55KX] FR lever: Main and Sub Error ......................................... 40-371 Failure code [DK55KZ] FR lever: Main and Sub Error ......................................... 40-372 Failure code [DK55L8] FR lever: Signal mismatch .............................................. 40-373 Failure code [DK56KA] FR lever1: Open .............. 40-374 Failure code [DK56KB] FR lever1: Hot Short........ 40-377 Failure code [DK57KA] FR lever2: Open .............. 40-380 Failure code [DK57KB] FR lever2: Hot Short........ 40-383 Failure code [DLM0KX] HST Motor Speed Sensor: Left/Right Error ................................................ 40-385 Failure code [DLM1KA] Left HST motor speed sensor: Open................................................................ 40-386 Failure code [DLM1KB] Left HST motor speed sensor: Short circuit...................................................... 40-388 Failure code [DLM1MA] Left HST motor speed sensor: Malfunction ...................................................... 40-390 Failure code [DLM2KA] Right HST motor speed sensor: Open................................................................ 40-391 Failure code [DLM2KB] Right HST motor speed sensor: Short circuit...................................................... 40-393 Failure code [DLM2MA] Right HST motor speed sensor: Malfunction ...................................................... 40-395 Failure code [DLM3KA] Fan rev. sensor: Open................................................................ 40-396 Failure code [DLM3KB] Fan rev. sensor: Short circuit...................................................... 40-398 Failure code [DLM3MB] Fan control: Mismatch .... 40-400 Failure code [DN21FS] Decel/Brake pedal SW: Signal mismatch .............................................. 40-401 Failure code [DR21KX] Camera 2 Picture Rev. Drive Abnormality...................................................... 40-403 Failure code [DR31KX] Camera 3 Picture Rev. Drive Abnormality...................................................... 40-404 Failure code [DV20KB] Back-up alarm: Short circuit...................................................... 40-405 Failure code [DW4BKA] Parking brake solenoid: Open................................................................ 40-407 Failure code [DW4BKB] Parking brake solenoid: Short circuit...................................................... 40-409 Failure code [DW4BKY] Parking brake solenoid: Hot Short ......................................................... 40-411

Failure code [DW7BKA] Fan reverse solenoid: Open ................................................................ 40-413 Failure code [DW7BKB] Fan reverse solenoid: Short circuit...................................................... 40-415 Failure code [DW7EKA] Slow brake solenoid: Open ................................................................ 40-416 Failure code [DW7EKB] Slow brake solenoid: Short circuit...................................................... 40-418 Failure code [DW7EKY] Slow brake solenoid: Hot Short.......................................................... 40-420 Failure code [DWN5KA] Fan EPC: Open.............. 40-422 Failure code [DWN5KB] Fan EPC: Short circuit.... 40-424 Failure code [DWN5KY] Fan EPC: Hot Short ....... 40-425 Failure code [DXA4KA] LF HST pump EPC: Open ................................................................ 40-427 Failure code [DXA4KB] LF HST pump EPC: Short circuit...................................................... 40-429 Failure code [DXA4KY] LF HST pump EPC: Hot Short.......................................................... 40-430 Failure code [DXA5KA] LR HST pump EPC: Open ................................................................ 40-432 Failure code [DXA5KB] LR HST pump EPC: Short circuit...................................................... 40-434 Failure code [DXA5KY] LR HST pump EPC: Hot Short.......................................................... 40-436 Failure code [DXA6KA] RF HST pump EPC: Open ................................................................ 40-438 Failure code [DXA6KB] RF HST pump EPC: Short circuit...................................................... 40-440 Failure code [DXA6KY] RF HST pump EPC: Hot Short.......................................................... 40-441 Failure code [DXA7KA] RR HST pump EPC: Open ................................................................ 40-443 Failure code [DXA7KB] RR HST pump EPC: Short circuit...................................................... 40-445 Failure code [DXA7KY] RR HST pump EPC: Hot Short.......................................................... 40-446 Failure code [DXHRKA] Blade lift up EPC: Open ................................................................ 40-448 Failure code [DXHRKB] Blade lift up EPC: Short circuit...................................................... 40-451 Failure code [DXHRKY] Blade lift up EPC: Hot short .......................................................... 40-453 Failure code [DXHSKA] Blade lift down EPC: Open ................................................................ 40-455 Failure code [DXHSKB] Blade lift down EPC: Short circuit...................................................... 40-458 Failure code [DXHSKY] Blade lift down EPC: Hot short .......................................................... 40-460 Failure code [DXHTKA] Blade tilt left EPC: Open ................................................................ 40-462 Failure code [DXHTKB] Blade tilt left EPC: Short circuit...................................................... 40-464 Failure code [DXHTKY] Blade tilt left EPC: Hot short .......................................................... 40-465 Failure code [DXHUKA] Blade tilt right EPC: Open ................................................................ 40-467 Failure code [DXHUKB] Blade tilt right EPC: Short circuit...................................................... 40-469 Failure code [DXHUKY] Blade tilt right EPC: Hot short .......................................................... 40-470 Failure code [DXJ4KA] Weq lock Sol.: Open ................................................................ 40-472

D61EM-23M0

INDEX

Failure code [DXJ4KB] Weq lock Sol.: Short circuit ..................................................... 40-474 Failure code [DXJCKA] Blade angle left EPC: Open................................................................ 40-476 Failure code [DXJCKB] Blade angle left EPC: Short circuit ..................................................... 40-477 Failure code [DXJCKY] Blade angle left EPC: Hot short .......................................................... 40-478 Failure code [DXJDKA] Blade angle right EPC: Open................................................................ 40-480 Failure code [DXJDKB] Blade angle right EPC: Short circuit ..................................................... 40-481 Failure code [DXJDKY] Blade angle right EPC: Hot short .......................................................... 40-482 Failure code [DXK1KA] Left HST motor EPC: Open................................................................ 40-484 Failure code [DXK1KB] Left HST motor EPC: Short circuit ..................................................... 40-486 Failure code [DXK1KY] Left HST motor EPC: Hot Short ......................................................... 40-487 Failure code [DXK2KA] Right HST motor EPC: Open................................................................ 40-489 Failure code [DXK2KB] Right HST motor EPC: Short circuit ..................................................... 40-491 Failure code [DXK2KY] Right HST motor EPC: Hot Short ......................................................... 40-492 Failure codes table................................................ 40-107 Failure mode and cause table............................... 40-571 Final drive...................................................... 10-66,60-13 Foreword, safety and general information............... 00-13 Full-scale drawing of sprocket tooth profile............. 60-15 Fuse location table ................................................ 40-102

H H-1 Neither RH nor LH of tracks does not travel forward nor reverse (None of the travel system operates) ......................................................... 40-574 H-2 Either RH or LH of track does not travel forward nor reverse (Only RH or LH of travel system operates) ......................................................... 40-576 H-3 Either RH or LH of track travel only forward or reverse (Only forward or reverse of RH or LH of travel system does not operate) ............................................ 40-577 H-4 Travel speed or power is low.......................... 40-579 H-5 Shock is large when machine starts or stops . 40-580 H-6 Machine deviates largely................................ 40-581 H-7 Machine drift on a slope is large..................... 40-583 H-8 Engine stalls during travel or engine speed drops significantly ...................................................... 40-584 H-9 Unusual noise is heard from around HST pump or motor ............................................................... 40-586 H-10 All work equipment do not operate............... 40-587 H-11 All work equipment operates slowly or lacks power............................................................... 40-589 H-12 Front work equipment lift speed or power is low ................................................................... 40-590 H-13 Front work equipment side swing speed or power is low ................................................................... 40-591 H-14 Hydraulic drift of lifted front work equipment is large ................................................................ 40-592 H-15 Unusual noise is heard from around work equipment pump or control valve ...................................... 40-593 H-16 HST oil temperature (hydraulic oil temperature) rises too high ................................................... 40-594 D61EM-23M0

H-17 Fan speed is abnormal (high, low, or no rotation)................................. 40-596 H-18 Unusual noise is heard from around fan....... 40-598 Handling battery disconnect switch ....................... 30-152 Handling cylinder cutout mode operation ................ 30-36 Handling equipment of fuel system devices ............ 00-24 Handling no-injection cranking operation ................ 30-37 Handling of compressor oil...................................... 80-56 Handling of electrical equipment ............................. 00-31 Handling of hydraulic equipment ............................. 00-26 Handling of intake system parts .............................. 00-25 Handling voltage circuit of engine controller.......... 30-151 How to read electric wire code ................................ 00-39 How to read the shop manual ................................. 00-20 How to read this manual............................................ 50-4 HST control system ............................................... 10-130 HST controller ....................................................... 10-176 HST motor ..................................................... 10-41,60-10 HST pump ....................................................... 10-26,60-8 Hydraulic circuit diagram ................................... 90-3,90-7 Hydraulic component layout of HST........................ 10-23 Hydraulic component layout of work equipment...... 10-75 Hydraulic system .....................10-75,30-64,50-165,60-28 Hydraulic tank................................................ 10-77,60-28

I Idler ......................................................................... 60-20 Important safety notice ............................................ 00-13 Information described in troubleshooting table........ 80-36 Information described in troubleshooting table (H-mode) ......................................................... 40-570 Information in troubleshooting table ........................ 40-39 Inspection procedure before troubleshooting .......... 40-14

K KOMTRAX system ................................................ 10-170

L Lift cylinder .............................................................. 60-44 List of abbreviation .................................................. 00-54

M Machine monitor system ....................................... 10-147 Main frame .............................................................. 10-70 Measuring compression pressure ........................... 30-18 Method of disconnecting and connecting of push-pull type coupler............................................................... 00-28 Method of using troubleshooting charts ................ 40-599 Move disabled machine urgently............................. 30-58

O Oil cooler bypass and HST charge safety valve .......................................................... 10-13,60-6 Outline of refrigeration cycle...................................... 80-8 Overall disassembly and assembly of track shoe assembly (Standard type track shoe) .............. 50-138

P Parking brake control system ................................ 10-141 Parts and connectors layout.................................... 80-26 Planter unit .................................................. 10-121,60-41 Pm clinic ................................................................ 30-154

INDEX

Pm Clinic check sheet........................................... 30-156 Pm Clinic service................................................... 30-154 Power train ............................................10-19,50-95,60-7 Power train system.................................................. 10-19 Practical use of KOMTRAX..................................... 00-47 Precautions for disconnecting and connecting hoses and tubes in air conditioner circuit ............................ 80-54 Precautions for refrigerant......................................... 80-3 Precautions to prevent fire ...................................... 00-18 Precautions when performing operation ................. 00-42 Preparation for troubleshooting of electrical system ............................................................... 40-31 Pressure switch....................................................... 80-15 Procedure for testing and troubleshooting .............. 80-20 Procedure for troubleshooting wiring harness of pressure sensor system for open circuit........................... 40-41

R Receiver drier.......................................................... 80-19 Related information on disassembly and assembly .. 50-4 Related information on testing and adjusting ............ 30-4 Related information on troubleshooting .................... 40-8 Releasing remaining pressure in work equipment cylinder .............................................................. 30-64 Removal and installation of aftercooler assembly ... 50-58 Removal and installation of air cleaner assembly ... 50-93 Removal and installation of air conditioner compressor assembly ......................................................... 50-198 Removal and installation of air conditioner unit assembly ......................................................... 50-194 Removal and installation of belt for alternator and air conditioner compressor ..................................... 50-92 Removal and installation of carrier roller assembly ......................................................... 50-130 Removal and installation of center frame assembly ......................................................... 50-177 Removal and installation of control valve assembly ......................................................... 50-169 Removal and installation of cooling fan drive assembly ........................................................... 50-64 Removal and installation of cooling fan motor assembly ........................................................... 50-67 Removal and installation of cylinder head assembly ........................................................... 50-40 Removal and installation of engine assembly ......... 50-69 Removal and installation of engine controller assembly ......................................................... 50-201 Removal and installation of engine front oil seal..... 50-77 Removal and installation of engine hood assembly ........................................................... 50-82 Removal and installation of engine rear oil seal...... 50-79 Removal and installation of equalizer bar assembly ......................................................... 50-162 Removal and installation of equalizer bar side bushing ............................................................ 50-164 Removal and installation of foot heater assembly ......................................................... 50-191 Removal and installation of fuel injector assembly . 50-33 Removal and installation of fuel tank assembly ...... 50-85 Removal and installation of HST controller assembly ......................................................... 50-203 Removal and installation of HST motor and final drive assembly ........................................................... 50-97 Removal and installation of HST pump assembly... 50-95

Removal and installation of hydraulic oil cooler assembly............................................................ 50-61 Removal and installation of hydraulic tank assembly.......................................................... 50-165 Removal and installation of idler assembly ........... 50-114 Removal and installation of KOMTRAX terminal... 50-204 Removal and installation of machine monitor assembly.......................................................... 50-200 Removal and installation of muffler ......................... 50-90 Removal and installation of operator’s cab glass (adhesion glass) .............................................. 50-183 Removal and installation of operator’s seat .......... 50-189 Removal and installation of pivot shaft assembly.. 50-160 Removal and installation of planter unit assembly.......................................................... 50-175 Removal and installation of radiator assembly........ 50-54 Removal and installation of recoil spring assembly.......................................................... 50-120 Removal and installation of ROPS cab assembly.......................................................... 50-179 Removal and installation of seat belt..................... 50-190 Removal and installation of segment teeth ........... 50-134 Removal and installation of supply pump assembly............................................................ 50-29 Removal and installation of track frame assembly.......................................................... 50-110 Removal and installation of track roller assembly.......................................................... 50-125 ROPS cab ............................................................. 10-122

S S-1 Starting performance is poor .......................... 40-603 S-2 Engine does not start...................................... 40-604 S-3 Engine does not pick up smoothly .................. 40-607 S-4 Engine stops during operations ...................... 40-608 S-5 Engine does not rotate smoothly .................... 40-609 S-6 Engine lacks output (or lacks power).............. 40-610 S-7 Exhaust smoke is black (incomplete combustion).................................. 40-611 S-8 Oil consumption is excessive (or exhaust smoke is blue)............................... 40-612 S-9 Oil becomes contaminated quickly ................. 40-613 S-10 Fuel consumption is excessive ..................... 40-614 S-11 Oil is in coolant (or coolant spurts back or coolant level goes down).............................................. 40-615 S-12 Oil pressure drops ........................................ 40-616 S-13 Oil level rises (Entry of coolant or fuel) ......... 40-617 S-14 Coolant temperature becomes too high (overheating).................................................... 40-618 S-15 Abnormal noise is made ............................... 40-619 S-16 Vibration is excessive ................................... 40-620 Sensor ................................................................... 10-188 Separation and connection of track shoe assembly (Standard type track shoe) .............................. 50-135 Sequence of events in troubleshooting ................... 40-10 Simple test procedure for brake performance ......... 30-52 Sketch of tools for testing and adjusting.................... 30-7 Sketches of special tools......................................... 50-16 Solenoid valve ............................................... 10-57,60-12 Special functions of machine monitor...................... 30-76 Special tools list....................................................... 50-10 Specification drawing ................................................ 01-3 Specifications .................................................... 01-3,01-4 Sprocket .................................................................. 60-14 D61EM-23M0

INDEX

Standard service value table..................................... 20-3 Standard tightening torque table ............................. 00-48 Standard value table for electrical system .............. 20-10 Standard value table for engine ................................ 20-3 Standard value table for machine ............................. 20-4 Steering and brake control ...................................... 10-24 Suspension ................................................... 10-71,60-16 Swing cylinder ......................................................... 60-45 Symbols in electric circuit diagram............................ 90-9 Symbols in hydraulic circuit diagram......................... 90-3 Symptom and troubleshooting numbers ................. 40-37 System component parts ...................................... 10-173 System diagram ...................................................... 80-24 System operating lamp function............................ 10-144

W Weight table .............................................................. 01-9 Work equipment ....................10-121,30-74,50-175,60-41 Work equipment and cooling fan pump......... 10-82,60-29 Work equipment control system .............................. 10-76

T Table of fuel, coolant, and lubricants ...................... 01-11 T-branch box and T-branch adapter table............... 40-97 Testing and adjusting HST oil pressure .................. 30-42 Testing and adjusting track tension......................... 30-63 Testing and adjusting valve clearance .................... 30-15 Testing and adjusting work equipment oil pressure ............................................................ 30-65 Testing blowby pressure ......................................... 30-21 Testing boost pressure............................................ 30-11 Testing diodes....................................................... 30-153 Testing engine oil pressure ..................................... 30-22 Testing engine piping for damage and looseness... 30-39 Testing engine speed................................................ 30-9 Testing exhaust gas color ....................................... 30-13 Testing fan circuit oil pressure ................................ 30-72 Testing fan speed.................................................... 30-71 Testing fuel circuit for leakage ................................ 30-35 Testing fuel discharge, return and leakage ............. 30-28 Testing fuel pressure............................................... 30-23 Testing if machine travels straight........................... 30-51 Testing internal oil leakage of work equipment cylinder .............................................................. 30-70 Testing of installed condition of cylinder heads and manifolds ........................................................... 30-38 Testing outlet pressure of work equipment EPC valve and fan EPC valve.................................................... 30-68 Testing output pressure of solenoid valve............... 30-47 Testing relays.......................................................... 80-31 Testing source pressure of control circuit ............... 30-67 Tools for testing and adjusting .................................. 30-4 Track frame and idler cushion....................... 10-73,60-18 Track roller .............................................................. 60-22 Track shoe .............................................................. 60-25 Troubleshooting by failure code (Display of code) 40-115 Troubleshooting chart 1 .......................................... 80-33 Troubleshooting chart 2 .......................................... 80-34 Troubleshooting of electrical system (E-mode)..... 40-494 Troubleshooting of engine (S-mode)..................... 40-599 Troubleshooting of hydraulic and mechanical system (H-mode) ......................................................... 40-570 Troubleshooting points.............................................. 40-8 Troubleshooting with gauge pressure ..................... 80-49

U Undercarriage and frame ........10-70,30-61,50-110,60-16

D61EM-23M0

D61E -23M0 3/$17(5 Form No.