SM D65ex, PX, WX-16 Komatsu PDF [PDF]
SEN04887-09 BULLDOZER D65EX -16 D65PX -16 D65WX -16 SERIAL NUMBERS D65EX- 80001 D65PX- 80001 D65WX- 80001 and up S
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SEN04887-09
BULLDOZER
D65EX -16 D65PX -16 D65WX -16 SERIAL NUMBERS
D65EX- 80001 D65PX- 80001 D65WX- 80001
and up
SEN04931-09
BULLDOZER D65EX-16 D65PX-16 D65WX-16 Machine model D65EX-16 D65PX-16 D65WX-16
Serial number 80001 and up 80001 and up 80001 and up
00 Index and foreword
00
100 Index Composition of shop manual..................................................................................................................................2 Table of contents .....................................................................................................................................................4
D65EX, PX, WX-16
00-100
1
SEN04931-09
100 Index Composition of shop manual
Composition of shop manual
1
The contents of this shop manual are shown together with Form No. in a list. Note 1: Always keep the latest version of this manual in accordance with this list and utilize accordingly. The marks shown to the right of Form No. denote the following: Q: New issue (to be filed additionally) q: Revision (to be replaced for each Form No.) Note 2: This shop manual can be supplied for each Form No. Note 3: To file this shop manual in the special binder for management, handle it as follows: • Place a divider on the top of each section in the file after matching the Tab No. with No. indicated next to each Section Name shown in the table below: • File overview and other materials in sections in the order shown below and utilize them accordingly. Section Title
Form Number
Shop Manual, contents binder, binder label and tabs ..................................................................... SEN04887-09 00 Index and foreword .................................................................................................................... SEN04923-09 100 Index .................................................................................................................................. SEN04931-09 q 200 Foreword and general information ..................................................................................... SEN04932-01 01 General ...................................................................................................................................... SEN04924-02 100 Specification and technical data......................................................................................... SEN04933-02 q 10 Structure, function and maintenance standard........................................................................... SEN04925-04 100 Engine and cooling system ................................................................................................ SEN04963-01 201 Power train, Part 1 ............................................................................................................. SEN04964-01 202 Power train, Part 2 ............................................................................................................. SEN04965-01 300 Undercarriage and frame ................................................................................................... SEN04966-02 401 Hydraulic system, Part 1 .................................................................................................... SEN04967-00 402 Hydraulic system, Part 2 .................................................................................................... SEN04968-01 403 Hydraulic system, Part 3 .................................................................................................... SEN04969-00 500 Work equipment................................................................................................................. SEN04970-01 600 Cab and its attachments .................................................................................................... SEN04971-02 700 Electrical system ................................................................................................................ SEN04972-02
q q
q q q
20 Standard value table................................................................................................................... SEN04926-01 100 Standard service value table.............................................................................................. SEN05118-01 30 Testing and adjusting ................................................................................................................. SEN04927-04 101 Testing and adjusting, Part 1.............................................................................................. SEN05119-02 102 Testing and adjusting, Part 2.............................................................................................. SEN05120-02 103 Testing and adjusting, Part 3.............................................................................................. SEN05121-02 104 Testing and adjusting, Part 4.............................................................................................. SEN05122-01 40 Troubleshooting.......................................................................................................................... SEN04928-03 100 Failure code table and fuse locations ................................................................................ SEN05029-01 200 General information on troubleshooting............................................................................. SEN05030-01 301 Troubleshooting by failure code (Display of code), Part 1 ................................................. SEN05031-00 302 Troubleshooting by failure code (Display of code), Part 2 ................................................. SEN05032-01 303 Troubleshooting by failure code (Display of code), Part 3 ................................................. SEN05033-01 304 Troubleshooting by failure code (Display of code), Part 4 ................................................. SEN05034-01
00-100
2
D65EX, PX, WX-16
100 Index Composition of shop manual
305 306 400 500 600
SEN04931-09
Troubleshooting by failure code (Display of code), Part 5..................................................SEN05035-01 Troubleshooting by failure code (Display of code), Part 6..................................................SEN05036-01 Troubleshooting of electrical system (E-mode) ..................................................................SEN05037-01 Troubleshooting of hydraulic and mechanical system (H-mode)........................................SEN05038-00 Troubleshooting of engine (S-mode) ..................................................................................SEN05039-00
50 Disassembly and assembly ........................................................................................................SEN04929-04 100 General information on disassembly and assembly........................................................... SEN05110-01 200 Engine and cooling system ................................................................................................ SEN05111-01 q 300 Power train .........................................................................................................................SEN05112-02 q 400 Undercarriage and frame ................................................................................................... SEN05113-02 500 Hydraulic system ................................................................................................................SEN05114-00 600 Work equipment .................................................................................................................SEN05115-00 700 Cab and its attachments.....................................................................................................SEN05116-01 800 Electrical system ................................................................................................................SEN05117-00 80 Appendix.....................................................................................................................................SEN05040-00 100 Air conditioner ....................................................................................................................SEN05041-00 90 Diagrams and drawings ..............................................................................................................SEN04930-03 100 Hydraulic diagrams and drawings ......................................................................................SEN04934-01 q 200 Electrical diagrams and drawings.......................................................................................SEN04935-03 q
D65EX, PX, WX-16
00-100
3
SEN04931-09
Table of contents
100 Index Table of contents
1
00 Index and foreword 100 Index ..........................................................................................................................................SEN04931-09 Composition of shop manual......................................................................................................................... 2 Table of contents ........................................................................................................................................... 4 200 Foreword and general information .............................................................................................SEN04932-01 Safety notice ................................................................................................................................................. 2 How to read the shop manual ....................................................................................................................... 7 Explanation of terms for maintenance standard............................................................................................ 9 Handling of electric equipment and hydraulic component............................................................................. 11 Handling of connectors newly used for engines............................................................................................ 20 How to read electric wire code ...................................................................................................................... 23 Precautions when carrying out operation...................................................................................................... 26 Method of disassembling and connecting push-pull type coupler................................................................. 29 Standard tightening torque table ................................................................................................................... 32 Conversion table ........................................................................................................................................... 36 01 General 100 Specification and technical data.................................................................................................SEN04933-02 Specification dimension drawing ................................................................................................................... 2 Specifications ................................................................................................................................................ 6 Weight table .................................................................................................................................................. 18 Table of fuel, coolant and lubricants.............................................................................................................. 22 10 Structure, function and maintenance standard 100 Engine and cooling system ........................................................................................................SEN04963-01 Engine mount ................................................................................................................................................ 3 Cooling system.............................................................................................................................................. 4 Cooling fan pump .......................................................................................................................................... 6 Cooling fan motor.......................................................................................................................................... 20 Coolant preheater (subextremely cold weather spec.).................................................................................. 26 201 Power train, Part 1 .....................................................................................................................SEN04964-01 Power train .................................................................................................................................................... 2 HSS system .................................................................................................................................................. 4 Overall view of power train unit ..................................................................................................................... 6 Power train hydraulic piping diagram ............................................................................................................ 10 Transmission, steering and brake control ..................................................................................................... 12 Damper ......................................................................................................................................................... 14 Universal joint................................................................................................................................................ 16 Torque converter and PTO ............................................................................................................................ 17 Transmission ................................................................................................................................................. 24 Transmission control valve............................................................................................................................ 42 ECMV............................................................................................................................................................ 46 Main relief and torque converter relief valve ................................................................................................. 54 Main relief and torque converter relief valve (subextremely cold weather spec.) ......................................... 56 Transmission lubrication relief valve ............................................................................................................. 58 202 Power train, Part 2 .....................................................................................................................SEN04965-01 Bevel gear shaft, HSS and brake.................................................................................................................. 2 Brake valve ................................................................................................................................................... 24 Final drive...................................................................................................................................................... 30 Final drive (Planetary gear installed inside of sprocket type) ........................................................................ 36 300 Undercarriage and frame ...........................................................................................................SEN04966-02 Main frame .................................................................................................................................................... 2 Suspension ................................................................................................................................................... 4 Track frame and idler cushion ....................................................................................................................... 14 Idler ............................................................................................................................................................... 18 00-100
4
D65EX, PX, WX-16
100 Index Table of contents
SEN04931-09
Idler (Without idler support automatic thrust adjustment) .............................................................................. 20 Carrier roller................................................................................................................................................... 26 Sprocket......................................................................................................................................................... 28 Track shoe ..................................................................................................................................................... 32 401 Hydraulic system, Part 1 ........................................................................................................... SEN04967-00 Work equipment hydraulic system layout drawing ........................................................................................ 2 Work equipment control................................................................................................................................. 6 Hydraulic tank and filter ................................................................................................................................. 8 Scavenging pump.......................................................................................................................................... 10 Power train and steering lubrication pump .................................................................................................... 11 HSS pump ..................................................................................................................................................... 12 HSS motor ..................................................................................................................................................... 31 402 Hydraulic system, Part 2 ........................................................................................................... SEN04968-01 Control valve.................................................................................................................................................. 2 CLSS ............................................................................................................................................................. 11 Function and operation of each valve............................................................................................................ 14 403 Hydraulic system, Part 3 ........................................................................................................... SEN04969-00 PPC valve (blade lift, blade tilt)...................................................................................................................... 2 PPC valve (ripper) ......................................................................................................................................... 8 Electric lever (steering).................................................................................................................................. 12 Quick drop valve............................................................................................................................................ 16 Work equipment lock solenoid valve ............................................................................................................. 18 Pitch selector solenoid valve ......................................................................................................................... 22 Hydraulic oil cooler bypass valve .................................................................................................................. 23 Accumulator................................................................................................................................................... 24 500 Work equipment ........................................................................................................................ SEN04970-01 Blade ............................................................................................................................................................. 2 Cutting edge and end bit ............................................................................................................................... 8 Ripper (Multi shank) ...................................................................................................................................... 10 Ripper (Single shank) .................................................................................................................................... 11 Hydraulic cylinder .......................................................................................................................................... 12 Piston valve ................................................................................................................................................... 15 600 Cab and its attachments............................................................................................................ SEN04971-02 Cab mount ..................................................................................................................................................... 2 Cab ................................................................................................................................................................ 3 Subextremely cold spec. cab (subextremely cold weather spec.)................................................................. 4 FRP canopy mount........................................................................................................................................ 5 FRP canopy................................................................................................................................................... 6 700 Electrical system ....................................................................................................................... SEN04972-02 Monitor system .............................................................................................................................................. 2 Engine control system ................................................................................................................................... 18 Cooling system control system...................................................................................................................... 21 Electronic steering control system................................................................................................................. 23 KOMTRAX system ........................................................................................................................................ 26 KOMTRAX terminal (for GPRS) .................................................................................................................... 28 System components ...................................................................................................................................... 29 Sensor ........................................................................................................................................................... 37 20 Standard value table 100 Standard service value table ..................................................................................................... SEN05118-01 Standard service value table for engine ........................................................................................................ 2 Standard service value table for chassis ....................................................................................................... 4 30 Testing and adjusting 101 Testing and adjusting, Part 1 ..................................................................................................... SEN05119-02 Tools for testing, adjusting, and troubleshooting ........................................................................................... 2
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00-100
5
SEN04931-09
100 Index Table of contents
Testing engine speed .................................................................................................................................... 5 Testing intake air pressure (boost pressure) ................................................................................................. 7 Testing exhaust temperature......................................................................................................................... 9 Testing exhaust gas color.............................................................................................................................. 11 Adjusting valve clearance ............................................................................................................................. 12 Testing compression pressure ...................................................................................................................... 14 Testing blow-by pressure .............................................................................................................................. 18 Testing engine oil pressure ........................................................................................................................... 19 Handling of fuel system devices.................................................................................................................... 20 Releasing residual pressure from fuel system .............................................................................................. 20 Testing fuel pressure ..................................................................................................................................... 21 Testing fuel return and leak amount .............................................................................................................. 26 Bleeding air from fuel circuit.......................................................................................................................... 28 Testing fuel circuit for leakage....................................................................................................................... 29 Handling of reduced cylinder mode operation............................................................................................... 30 Handling of no injection cranking operation .................................................................................................. 30 Testing and adjusting air conditioner compressor belt tension...................................................................... 31 Replacing alternator belt ............................................................................................................................... 32 Adjusting fuel control dial and decelerator pedal .......................................................................................... 33 Handling controller high-voltage circuit ......................................................................................................... 34 102 Testing and adjusting, Part 2......................................................................................................SEN05120-02 Testing power train oil pressure .................................................................................................................... 3 Adjusting transmission output shaft speed sensor (replacement procedure) ............................................... 8 Simple test procedure for brake performance............................................................................................... 9 Adjusting brake pedal.................................................................................................................................... 10 Adjusting parking brake lever........................................................................................................................ 12 Emergency escape method when power train has trouble ........................................................................... 14 Adjusting clearance of idler ........................................................................................................................... 17 Adjusting clearance of idler (without idler support automatic thrust adjustment) .......................................... 18 Inspecting wear of sprocket .......................................................................................................................... 19 Testing and adjusting track shoe tension ...................................................................................................... 20 Testing and adjusting work equipment and HSS oil pressure ....................................................................... 21 Testing control circuit basic pressure ............................................................................................................ 24 Testing PPC valve output pressure ............................................................................................................... 25 Adjusting work equipment PPC valve play.................................................................................................... 27 Testing internal leakage of work equipment cylinder..................................................................................... 31 Bleeding air from work equipment cylinder ................................................................................................... 32 Releasing residual pressure from work equipment cylinder.......................................................................... 32 Checking parts which caused hydraulic drift of blade or ripper ..................................................................... 33 Adjusting work equipment lock lever............................................................................................................. 34 Adjusting work equipment lock lever (FRP canopy specification)................................................................. 35 Testing fan speed .......................................................................................................................................... 37 Testing fan circuit oil pressure....................................................................................................................... 38 Bleeding air from fan pump ........................................................................................................................... 39 Bleeding air from HSS pump......................................................................................................................... 40 Adjusting straight tiltdozer ............................................................................................................................. 41 Adjusting play of blade center ball ................................................................................................................ 43 Adjusting operator's cab................................................................................................................................ 44 103 Testing and adjusting, Part 3......................................................................................................SEN05121-02 Special functions of machine monitor (EMMS) ............................................................................................. 2 104 Testing and adjusting, Part 4......................................................................................................SEN05122-01 Handling of voltage circuit of engine controller ............................................................................................. 2 Adjustment method when controller has been replaced ............................................................................... 3 Preparation work for troubleshooting of electrical system............................................................................. 5 Inspection procedure of diode....................................................................................................................... 9 Pm-Clinic service .......................................................................................................................................... 10
00-100
6
D65EX, PX, WX-16
100 Index Table of contents
SEN04931-09
40 Troubleshooting 100 Failure code table and fuse locations ........................................................................................ SEN05029-01 Failure codes table ........................................................................................................................................ 2 Fuse locations ............................................................................................................................................... 7 200General information on troubleshootingSEN05030-01 Points to remember when troubleshooting .................................................................................................... 2 How to proceed troubleshooting.................................................................................................................... 3 Checks before troubleshooting...................................................................................................................... 4 Classification and procedures for troubleshooting......................................................................................... 6 Symptom supposed to be failure and troubleshooting No............................................................................. 10 Information contained in troubleshooting table .............................................................................................. 12 Troubleshooting method for disconnecting wiring harness of pressure sensor system ................................ 14 Connector list and stereogram ...................................................................................................................... 16 Connection table for connector pin numbers................................................................................................. 30 T- branch box and T- branch adapter table ................................................................................................... 66 301 Troubleshooting by failure code (Display of code), Part 1......................................................... SEN05031-00 Failure code [1500L0] Transmission clutch: Abnormal.................................................................................. 3 Failure code [15SAL1] Forward clutch: Fill high ............................................................................................ 4 Failure code [15SALH] Forward clutch: Fill low............................................................................................. 6 Failure code [15SBL1] Reverse clutch: Fill high............................................................................................ 8 Failure code [15SBLH] Reverse clutch: Fill low............................................................................................. 10 Failure code [15SEL1] Speed 1st clutch: Fill high ......................................................................................... 12 Failure code [15SELH] Speed 1st clutch: Fill low .......................................................................................... 14 Failure code [15SFL1] Speed 2nd clutch: Fill high ........................................................................................ 16 Failure code [15SFLH] Speed 2nd clutch: Fill low ......................................................................................... 18 Failure code [15SGL1] Speed 3rd clutch: Fill high ........................................................................................ 20 Failure code [15SGLH] Speed 3rd clutch: Fill low ......................................................................................... 22 Failure code [15SJL1] L/U: Fill high............................................................................................................... 24 Failure code [15SJLH] L/U: Fill low ............................................................................................................... 26 Failure code [AB00MA] Battery Charge Abnormal ........................................................................................ 28 Failure code [B@BAZG] Eng Oil Press Low ................................................................................................. 30 Failure code [B@BCNS] Eng Water Overheat .............................................................................................. 30 Failure code [B@CENS] T/C Oil Overheat.................................................................................................... 31 Failure code [B@HANS] Hyd Oil Overheat ................................................................................................... 31 302 Troubleshooting by failure code (Display of code), Part 2......................................................... SEN05032-01 Failure code [CA111] ECM Critical Internal Failure ....................................................................................... 3 Failure code [CA115] Eng Ne and Bkup Speed Sens Error .......................................................................... 3 Failure code [CA122] Chg Air Press Sensor High Error................................................................................ 4 Failure code [CA123] Chg Air Press Sensor Low Error................................................................................. 6 Failure code [CA131] Throttle Sensor High Error.......................................................................................... 8 Failure code [CA132] Throttle Sensor Low Error........................................................................................... 10 Failure code [CA144] Coolant Temp Sens High Error ................................................................................... 12 Failure code [CA145] Coolant Temp Sens Low Error.................................................................................... 14 Failure code [CA153] Chg Air Temp Sensor High Error ................................................................................ 16 Failure code [CA154] Chg Air Temp Sensor Low Error ................................................................................. 18 Failure code [CA155] Chg Air Temp High Speed Derate............................................................................... 20 Failure code [CA187] Sens Supply 2 Volt Low Error ..................................................................................... 22 Failure code [CA221] Ambient Press Sens High Error.................................................................................. 24 Failure code [CA222] Ambient Press Sens Low Error................................................................................... 26 Failure code [CA227] Sens Supply 2 Volt High Error .................................................................................... 28 Failure code [CA234] Eng Overspeed........................................................................................................... 28 Failure code [CA238] Ne Speed Sens Supply Volt Error............................................................................... 29 Failure code [CA271] IMV/PCV1 Short Error ................................................................................................ 30 Failure code [CA272] IMV/PCV1 Open Error ................................................................................................ 32 Failure code [CA281] Abnormal supply pump pressure balance .................................................................. 34 Failure code [CA322] Inj #1(L#1) Open/Short Error ...................................................................................... 36
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00-100
7
SEN04931-09
100 Index Table of contents
Failure code [CA323] Inj #5(L#5) Open/Short Error...................................................................................... 38 Failure code [CA324] Inj #3(L#3) Open/Short Error...................................................................................... 40 Failure code [CA325] Inj #6(L#6) Open/Short Error...................................................................................... 42 Failure code [CA331] Inj #2(L#2) Open/Short Error...................................................................................... 44 Failure code [CA332] Inj #4(L#4) Open/Short Error...................................................................................... 46 303Troubleshooting by failure code (Display of code), Part 3 .............................................................SEN05033-01 Failure code [CA342] Calibration Code Incompatibility ................................................................................. 3 Failure code [CA351] Injectors Drive Circuit Error ........................................................................................ 3 Failure code [CA352] Sens Supply 1 Volt Low Error..................................................................................... 4 Failure code [CA386] Sens Supply 1 Volt High Error.................................................................................... 6 Failure code [CA428] Water in Fuel Sensor High Error ................................................................................ 8 Failure code [CA429] Water in Fuel Sensor Low Error ................................................................................. 10 Failure code [CA435] Eng Oil Press Sw Error .............................................................................................. 12 Failure code [CA441] Battery Voltage Low Error .......................................................................................... 14 Failure code [CA442] Battery Voltage High Error.......................................................................................... 16 Failure code [CA449] Rail Press Very High Error ......................................................................................... 18 Failure code [CA451] Rail Press Sensor High Error ..................................................................................... 20 Failure code [CA452] Rail Press Sensor Low Error ...................................................................................... 22 Failure code [CA488] Chg Air Temp High Torque Derate ............................................................................. 24 Failure code [CA553] Rail Press High Error.................................................................................................. 25 Failure code [CA559] Rail Press Low Error .................................................................................................. 26 Failure code [CA689] Eng Ne Speed Sensor Error....................................................................................... 28 Failure code [CA731] Eng Bkup Speed Sens Phase Error ........................................................................... 32 Failure code [CA757] All Continuous Data Lost Error................................................................................... 33 Failure code [CA778] Eng Bkup Speed Sensor Error ................................................................................... 34 Failure code [CA1633] KOMNET Datalink Timeout Error ............................................................................. 37 Failure code [CA2185] Throt Sens Sup Volt High Error ................................................................................ 38 Failure code [CA2186] Throt Sens Sup Volt Low Error................................................................................. 40 Failure code [CA2249] Rail Press Very Low Error ........................................................................................ 42 Failure code [CA2265] Fuel Feed Pump Open Error .................................................................................... 44 Failure code [CA2266] Fuel Feed Pump Short Error .................................................................................... 46 Failure code [CA2311] IMV Solenoid Error ................................................................................................... 47 Failure code [CA2555] Grid Htr Relay Volt High Error .................................................................................. 48 Failure code [CA2556] Grid Htr Relay Volt Low Error ................................................................................... 50 304 Troubleshooting by failure code (Display of code), Part 4 .........................................................SEN05034-01 Failure code [D110KB] Battery relay drive: Short circuit ............................................................................... 4 Failure code [D130KA] Neutral relay: Disconnection .................................................................................... 6 Failure code [D130KB] Neutral relay: Short circuit........................................................................................ 8 Failure code [D161KA] Back-up alarm relay: Disconnection ........................................................................ 10 Failure code [D161KB] Back-up alarm relay: Short circuit ............................................................................ 12 Failure code [D862KA] GPS Antenna Open Circuit ...................................................................................... 14 Failure code [DAFRKR] CAN Disconnection ................................................................................................ 15 Failure code [DAFRMC] CAN Discon (Monitor Detected)............................................................................. 16 Failure code [DB2RKR] CAN Disconnection................................................................................................. 19 Failure code [DBE0KT] PT controller: Abnormality in controller ................................................................... 24 Failure code [DBE1KK] Battery direct Source voltage reduction .................................................................. 26 Failure code [DBE2KK] Solenoid Source voltage reduction ......................................................................... 28 Failure code [DBE5KK] PT cont.: Sensor voltage 5V (1) reduction .............................................................. 30 Failure code [DBE6KK] PT cont.: Sensor voltage 24V reduction.................................................................. 32 Failure code [DBE7KK] PT cont.: Sensor voltage 5V (2) reduction .............................................................. 34 Failure code [DBE9KQ] PT controller: Type select signal ............................................................................. 36 Failure code [DD12KA] Shift up Sw: Disconnection...................................................................................... 38 Failure code [DD12KB] Shift up Sw: Short circuit ......................................................................................... 40 Failure code [DD13KA] Shift down Sw: Disconnection ................................................................................. 42 Failure code [DD13KB] Shift down Sw: Short circuit..................................................................................... 44 Failure code [DD14KA] Parking lever Sw: Disconnection............................................................................. 46 Failure code [DD14KB] Parking lever Sw: Short circuit ................................................................................ 48 305 Troubleshooting by failure code (Display of code), Part 5 .........................................................SEN05035-01 00-100
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D65EX, PX, WX-16
100 Index Table of contents
SEN04931-09
Failure code [DDN7KA] WEQ Knob Sw (down): Disconnection.................................................................... 4 Failure code [DDN7KB] WEQ Knob Sw (down): Short circuit ....................................................................... 6 Failure code [DDN8KA] WEQ Knob Sw (up): Disconnection ........................................................................ 8 Failure code [DDN8KB] WEQ Knob Sw (up): Short circuit............................................................................ 10 Failure code [DDNLKA] Weq lock Sw: Disconnection ................................................................................... 12 Failure code [DDNLKB] Weq lock Sw: Short circuit ...................................................................................... 14 Failure code [DGS1KX] Hyd oil temp sensor: Abnormal ............................................................................... 16 Failure code [DGT1KA] T/C oil temp sensor: Disconnection ......................................................................... 18 Failure code [DGT1KX] T/C oil temp sensor: Short circuit ............................................................................ 20 Failure code [DH21KA] Weq pressure sensor: Disconnection ...................................................................... 22 Failure code [DH21KB] Weq pressure sensor: Short circuit.......................................................................... 24 Failure code [DHT5KA] T/C pressure sensor: Disconnection ....................................................................... 26 Failure code [DHT5KB] T/C pressure sensor: Short circuit ........................................................................... 28 Failure code [DK10KA] Fuel control Dial: Disconnection .............................................................................. 30 Failure code [DK10KB] Fuel control Dial: Short circuit .................................................................................. 32 Failure code [DK30KA] ST lever 1: Disconnection ........................................................................................ 34 Failure code [DK30KB] ST lever 1: Short circuit............................................................................................ 36 Failure code [DK30KX] ST lever: Out of normal range.................................................................................. 38 Failure code [DK30KZ] ST lever: Disconnection or short circuit.................................................................... 38 Failure code [DK30L8] ST lever: Signal mismatch ........................................................................................ 39 Failure code [DK31KA] ST lever 2: Disconnection ........................................................................................ 40 Failure code [DK31KB] ST lever 2: Short circuit............................................................................................ 42 Failure code [DK40KA] Brake potentiometer: Disconnection ........................................................................ 44 Failure code [DK40KB] Brake potentiometer: Short circuit............................................................................ 46 Failure code [DK55KX] FR lever: Out of normal range ................................................................................. 48 Failure code [DK55KZ] FR lever: Disconnection or short circuit ................................................................... 48 Failure code [DK55L8] FR lever: Signal mismatch........................................................................................ 49 Failure code [DK56KA] FR lever 1: Disconnection........................................................................................ 50 Failure code [DK56KB] FR lever 1: Short circuit ........................................................................................... 52 Failure code [DK57KA] FR lever 2: Disconnection........................................................................................ 54 Failure code [DK57KB] FR lever 2: Short circuit ........................................................................................... 56 306 Troubleshooting by failure code (Display of code), Part 6......................................................... SEN05036-01 Failure code [DKH1KA] Pitch angle sensor: Disconnection .......................................................................... 4 Failure code [DKH1KB] Pitch angle sensor: Short circuit.............................................................................. 6 Failure code [DLT3KA] T/M out-speed sensor: Disconnection ...................................................................... 8 Failure code [DLT3KB] T/M out-speed sensor: Abnormal ............................................................................. 9 Failure code [DW5AKA] Pitch selector Sol.: Disconnection .......................................................................... 10 Failure code [DW5AKB] Pitch selector Sol.: Short circuit.............................................................................. 11 Failure code [DW5AKY] Pitch selector Sol.: Short circuit.............................................................................. 12 Failure code [DW7BKA] Fan rev EPC: Disconnection .................................................................................. 14 Failure code [DW7BKB] Fan rev EPC: Short circuit ...................................................................................... 15 Failure code [DWN1KA] Hss EPC1: Disconnection ...................................................................................... 16 Failure code [DWN1KB] Hss EPC1: Short circuit.......................................................................................... 17 Failure code [DWN1KY] Hss EPC1: Short circuit.......................................................................................... 18 Failure code [DWN2KA] Hss EPC2: Disconnection ...................................................................................... 19 Failure code [DWN2KB] Hss EPC2: Short circuit.......................................................................................... 20 Failure code [DWN2KY] Hss EPC2: Short circuit.......................................................................................... 21 Failure code [DWN5KA] Fan pump solenoid: Disconnection ........................................................................ 22 Failure code [DWN5KB] Fan pump solenoid: Short circuit............................................................................ 23 Failure code [DWN5KY] Fan control solenoid: Short circuit .......................................................................... 24 Failure code [DXA0KA] TVC Sol.: Disconnection.......................................................................................... 26 Failure code [DXA0KB] TVC Sol.: Short circuit ............................................................................................. 27 Failure code [DXA0KY] TVC Sol.: Short circuit ............................................................................................. 28 Failure code [DXH1KA] Lock-up ECMV: Disconnection................................................................................ 29 Failure code [DXH1KB] Lock-up ECMV: Short circuit ................................................................................... 30 Failure code [DXH1KY] Lock-up ECMV: Short circuit ................................................................................... 32 Failure code [DXH4KA] 1st clutch ECMV: Disconnection ............................................................................. 34 Failure code [DXH4KB] 1st clutch ECMV: Short circuit ................................................................................. 35 D65EX, PX, WX-16
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100 Index Table of contents
Failure code [DXH4KY] 1st clutch ECMV: Short circuit................................................................................. 36 Failure code [DXH5KA] 2nd clutch ECMV: Disconnection............................................................................ 37 Failure code [DXH5KB] 2nd clutch ECMV: Short circuit ............................................................................... 38 Failure code [DXH5KY] 2nd clutch ECMV: Short circuit ............................................................................... 39 Failure code [DXH6KA] 3rd clutch ECMV: Disconnection............................................................................. 40 Failure code [DXH6KB] 3rd clutch ECMV: Short circuit ................................................................................ 41 Failure code [DXH6KY] 3rd clutch ECMV: Short circuit ................................................................................ 42 Failure code [DXH7KA] R clutch ECMV: Disconnection ............................................................................... 43 Failure code [DXH7KB] R clutch ECMV: Short circuit................................................................................... 44 Failure code [DXH7KY] R clutch ECMV: Short circuit................................................................................... 46 Failure code [DXH8KA] F clutch ECMV: Disconnection................................................................................ 48 Failure code [DXH8KB] F clutch ECMV: Short circuit ................................................................................... 49 Failure code [DXH8KY] F clutch ECMV: Short circuit ................................................................................... 50 Failure code [DXJ4KA] Weq lock Sol.: Disconnection .................................................................................. 52 Failure code [DXJ4KB] Weq lock Sol.: Short circuit ...................................................................................... 53 400 Troubleshooting of electrical system (E-mode)..........................................................................SEN05037-01 Before troubleshooting of electrical system .................................................................................................. 3 Information in troubleshooting table .............................................................................................................. 5 E-1 Engine does not start (starting motor does not turn) .............................................................................. 7 E-2 Preheater does not operate.................................................................................................................... 10 E-3 When starting switch is turned ON, machine monitor displays nothing .................................................. 16 E-4 When starting switch is turned ON (before starting engine), basic check item lights up ........................ 18 E-5 Precaution item lights up while engine is running................................................................................... 20 E-6 Emergency stop item lights up while engine is running.......................................................................... 22 E-7 Engine coolant temperature gauge does not indicate normally.............................................................. 24 E-8 Fuel gauge does not indicate properly ................................................................................................... 26 E-9 Power train oil temperature gauge (multi-gauge) does not indicate normally ........................................ 29 E-10 Hydraulic temperature gauge (multi-gauge) does not indicate normally .............................................. 30 E-11 Contents of display by machine monitor are different from applicable machine................................... 31 E-12 Machine monitor does not display some items..................................................................................... 31 E-13 Function switch does not work ............................................................................................................. 31 E-14 Operation mode does not change ........................................................................................................ 32 E-15 Gearshift mode does not change ......................................................................................................... 32 E-16 Customize function does not operate normally .................................................................................... 33 E-17 Customize memory function does not operate normally ...................................................................... 33 E-18 Alarm buzzer does not sound or does not stop .................................................................................... 34 E-19 When starting switch is turned OFF, service meter is not displayed .................................................... 34 E-20 Machine monitor cannot be set in service mode .................................................................................. 34 E-21 Horn does not sound or does not stop ................................................................................................. 35 E-22 Back-up alarm does not sound or does not stop .................................................................................. 36 E-23 Head lamp or rear lamp does not light up ............................................................................................ 38 E-24 Windshield wiper does not operate ...................................................................................................... 42 E-25 Window washer does not operate ........................................................................................................ 56 E-26 KOMTRAX system does not operate correctly..................................................................................... 61 500 Troubleshooting of hydraulic and mechanical system (H-mode) ...............................................SEN05038-00 Failure mode and cause table....................................................................................................................... 2 Contents of troubleshooting table ................................................................................................................. 4 H-1 There is no travel power (no drawbar pull)............................................................................................. 5 H-2 Machine does not move (at 2nd or 3rd speed)....................................................................................... 6 H-3 Machine does not move at any gear speed ........................................................................................... 7 H-4 Machine travels only in one direction, forward or in reverse .................................................................. 8 H-5 When gear is shifted or travel direction is changed, large time lag is made .......................................... 9 H-6 Machine cannot be steered (Machine does not turn leftward or rightward) ........................................... 10 H-7 Steering speed or power is low .............................................................................................................. 10 H- 8 Brake does not work.............................................................................................................................. 11 H-9 Overheat of power train oil ..................................................................................................................... 12 H-10 Abnormal sound comes out from around HSS and work equipment pump or HSS motor................... 13 H-11 All work equipment speeds are slow .................................................................................................... 13 00-100
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SEN04931-09
H-12 Work equipment does not move ........................................................................................................... 14 H-13 Blade lift speed is slow or lacks power ................................................................................................. 14 H-14 Blade tilt speed is slow or lacks power ................................................................................................. 15 H-15 Ripper lift speed is slow or lacks power................................................................................................ 15 H-16 Excessive hydraulic drift of blade lift ..................................................................................................... 16 H-17 Excessive hydraulic drift of blade tilt..................................................................................................... 16 H-18 Excessive hydraulic drift of ripper lift..................................................................................................... 17 600 Troubleshooting of engine (S-mode) ......................................................................................... SEN05039-00 Method of using troubleshooting charts......................................................................................................... 3 S-1 Starting performance is poor. .................................................................................................................. 6 S-2 Engine does not start .............................................................................................................................. 7 S-3 Engine does not pick up smoothly .......................................................................................................... 10 S-4 Engine stops during operations .............................................................................................................. 11 S-5 Engine does not rotate smoothly ............................................................................................................ 12 S-6 Engine lacks output (or lacks power) ...................................................................................................... 13 S-7 Exhaust smoke is black (incomplete combustion) .................................................................................. 14 S-8 Oil consumption is excessive (or exhaust smoke is blue)....................................................................... 15 S-9 Oil becomes contaminated quickly ......................................................................................................... 16 S-10 Fuel consumption is excessive ............................................................................................................. 17 S-11 Oil is in coolant (or coolant spurts back, or coolant level goes down)................................................... 18 S-12 Oil pressure drops................................................................................................................................. 19 S-13 Oil level rises (water, fuel in oil) ............................................................................................................ 20 S-14 Coolant temperature becomes too high (overheating).......................................................................... 21 S-15 Abnormal noise is made ....................................................................................................................... 22 S-16 Vibration is excessive ........................................................................................................................... 23 50 Disassembly and assembly 100 General information on disassembly and assembly.................................................................. SEN05110-01 How to read this manual................................................................................................................................ 2 Coating materials list ..................................................................................................................................... 4 Special tool list............................................................................................................................................... 7 Sketches of special tools ............................................................................................................................... 17 200 Engine and cooling system ........................................................................................................SEN05111-01 Removal and installation of fuel supply pump assembly ............................................................................... 2 Removal and installation of fuel injector assembly ........................................................................................ 7 Removal and installation of cylinder head assembly..................................................................................... 17 Removal and installation of radiator assembly .............................................................................................. 32 Removal and installation of aftercooler assembly ......................................................................................... 35 Removal and installation of hydraulic oil cooler assembly ............................................................................ 37 Removal and installation of power train oil cooler assembly ......................................................................... 39 Removal and installation of cooling fan drive assembly ................................................................................ 42 Removal and installation of cooling fan motor assembly............................................................................... 44 Removal and installation of main body of coolant preheater (subextremely cold weather spec) .................. 46 Removal and installation of coolant preheater fuel tank (Subextremely cold weather spec.)........................ 50 Removal and installation of coolant preheater exhaust duct. (Subextremely cold weather spec.)................ 52 Removal and installation of oil pan cover of coolant preheater (subextremely cold weather spec.) ............. 56 Removal and installation of damper assembly .............................................................................................. 65 Removal and installation of engine front oil seal ........................................................................................... 68 Removal and installation of engine rear oil seal ............................................................................................ 72 Removal and installation of engine hood assembly ...................................................................................... 80 Removal and installation of fuel tank assembly............................................................................................. 82 300 Power train ................................................................................................................................ SEN05112-02 Removal and installation of power train unit assembly.................................................................................. 2 Separation and connection of power train unit assembly .............................................................................. 6 Disassembly and assembly of PTO assembly............................................................................................... 11 Disassembly and assembly of torque converter assembly............................................................................ 16 Disassembly and assembly of transmission assembly.................................................................................. 27
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Disassembly and assembly of HSS assembly .............................................................................................. 54 Removal and installation of final drive assembly .......................................................................................... 74 Removal and installation of final drive assembly (Planetary gear installed inside of sprocket type)............. 76 Disassembly and assembly of final drive assembly ...................................................................................... 78 Disassembly and assembly of final drive assembly (Planetary gear installed inside of sprocket type) ........ 86 400 Undercarriage and frame ...........................................................................................................SEN05113-02 Removal and installation of track frame assembly ........................................................................................ 2 Removal and installation of idler assembly ................................................................................................... 4 Removal and installation of idler assembly (Without idler support automatic thrust adjustment) ................. 6 Disassembly and assembly of idler assembly............................................................................................... 8 Disassembly and assembly of idler assembly (Without idler support automatic thrust adjustment) ............. 12 Removal and installation of recoil spring assembly ...................................................................................... 17 Disassembly and assembly of recoil spring assembly .................................................................................. 18 Removal and installation of track roller assembly ......................................................................................... 22 Disassembly and assembly of track roller assembly..................................................................................... 23 Removal and installation of carrier roller assembly....................................................................................... 27 Disassembly and assembly of carrier roller assembly .................................................................................. 28 Expansion and installation of track shoe assembly (Conventional type track shoe) ..................................... 31 Expansion and installation of track shoe assembly (PLUS type track shoe)................................................. 34 Whole disassembly and whole assembly of track shoe assembly (Conventional type track shoe) .............. 35 Whole disassembly and whole assembly of track shoe assembly (PLUS type track shoe).......................... 49 Field disassembly and assembly of one link (Conventional type track shoe) ............................................... 61 Field disassembly and assembly of one link (PLUS type track shoe)........................................................... 68 Removal and installation of pivot shaft assembly.......................................................................................... 73 Removal and installation of equalizer bar assembly ..................................................................................... 74 Disassembly and assembly of equalizer bar side bushing............................................................................ 76 500 Hydraulic system........................................................................................................................SEN05114-00 Removal and installation of hydraulic tank assembly.................................................................................... 2 Removal and installation of control valve assembly...................................................................................... 5 Disassembly and assembly of control valve assembly ................................................................................. 8 Disassembly and assembly of blade lift and tilt PPC valve assembly........................................................... 10 Disassembly and assembly of ripper PPC valve assembly .......................................................................... 11 Removal and installation of HSS and cooling fan pump assembly ............................................................... 12 Removal and installation of power train and lubrication pump assembly...................................................... 14 Removal and installation of scavenging pump assembly.............................................................................. 16 Removal and installation of HSS motor assembly ........................................................................................ 17 Disassembly and assembly of hydraulic cylinder assembly.......................................................................... 20 600 Work equipment .........................................................................................................................SEN05115-00 Removal and installation of blade assembly (ST-TPP dozer) ....................................................................... 2 Removal and installation of blade assembly (PAT dozer) ............................................................................. 5 Removal and installation of ripper assembly................................................................................................. 7 700 Cab and its attachments ............................................................................................................SEN05116-01 Removal and installation of ROPS cab assembly......................................................................................... 2 Removal and installation of FRP canopy (FRP canopy specification) .......................................................... 9 Removal and installation of floor frame assembly (FRP canopy specification)............................................. 10 Removal and installation of operator's cab glass (Stuck glass) .................................................................... 14 Removal and installation of air conditioner unit assembly ............................................................................ 20 Removal and installation of air conditioner compressor assembly ............................................................... 24 800 Electrical system ........................................................................................................................SEN05117-00 Removal and installation of monitor panel assembly .................................................................................... 2 Removal and installation of engine controller assembly ............................................................................... 4 Removal and installation of power train controller assembly ........................................................................ 6 Removal and installation of KOMTRAX terminal assembly .......................................................................... 8 80 Appendix 100 Air conditioner ............................................................................................................................SEN05041-00 Structure and function....................................................................................................................................... 4 00-100
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SEN04931-09
Air conditioner component............................................................................................................................. Configuration and function of refrigerating cycle ........................................................................................... Outline of refrigerating cycle.......................................................................................................................... Air conditioner unit......................................................................................................................................... Control plate .................................................................................................................................................. Compressor ................................................................................................................................................... Condenser ..................................................................................................................................................... Receiver drier ................................................................................................................................................ Testing, adjusting and troubleshooting.............................................................................................................. Caution about refrigerant............................................................................................................................... Troubleshooting procedure............................................................................................................................ Block diagram................................................................................................................................................ Circuit diagram and arrangement of connector pins...................................................................................... Detail of air conditioner unit ........................................................................................................................... Parts and connectors arrangement ............................................................................................................... Testing air leakage (duct) .............................................................................................................................. Testing with self-diagnosis function ............................................................................................................... Testing temperature control ........................................................................................................................... Testing vent (mode) changeover ................................................................................................................... Testing Recirc/Fresh changeover .................................................................................................................. Testing inner sensor ...................................................................................................................................... Testing evaporator temperature sensor......................................................................................................... Testing sunlight sensor .................................................................................................................................. Testing (dual) pressure switch for refrigerant ................................................................................................ Testing relays and diodes .............................................................................................................................. Troubleshooting chart 1 ................................................................................................................................. Troubleshooting chart 2 ................................................................................................................................. Troubleshooting for electrical system (E mode) ............................................................................................ E-1 Power supply system (Air conditioner does not operate)..................................................................... E-2 Compressor and refrigerant system (Air is not cooled)........................................................................ E-3 Blower motor system (No air comes out or air flow is abnormal)......................................................... E-4 Temperature cannot be controlled ....................................................................................................... E-5 Vent (mode) cannot be changed over.................................................................................................. E-6 Recirc/Fresh air cannot be changed over ............................................................................................ Troubleshooting with gauge pressure............................................................................................................ Connection of service tool ............................................................................................................................. Precautions for connecting air conditioner piping.......................................................................................... Handling of compressor oil ............................................................................................................................ 1. Control of compressor oil (Denso: ND-OIL8: For R134a)..................................................................... 2. Adding of compressor oil ...................................................................................................................... 3. Compressor replacement ..................................................................................................................... 4. Applying compressor oil for O-ring .......................................................................................................
4 6 7 10 14 15 16 17 18 18 19 20 22 24 26 32 34 37 39 42 43 44 47 48 50 52 53 56 57 60 63 66 68 70 72 75 76 77 77 77 78 78
90 Diagrams and drawings 100 Hydraulic diagrams and drawings ............................................................................................. SEN04934-01 Power train hydraulic circuit diagram............................................................................................................. 3 Work equipment hydraulic circuit diagram..................................................................................................... 7 200 Electrical diagrams and drawings.............................................................................................. SEN04935-03 Electrical circuit diagram................................................................................................................................ 3 Electrical circuit diagram (sand terrain specification) .................................................................................... 41 Electrical circuit diagram (FRP canopy specification).................................................................................... 47
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SEN04931-09
D65EX-16, D65PX-16, D65WX-16 Bulldozer Form No. SEN04931-09
©2012 KOMATSU All Rights Reserved Printed in Japan 02-12
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SEN04932-01
BULLDOZER D65EX-16 D65PX-16 D65WX-16 Machine model D65EX-16 D65PX-16 D65WX-16
Serial number 80001 and up 80001 and up 80001 and up
00 Index and foreword
00
200 Foreword and general information Safety notice ................................................................................................................................................... 2 How to read the shop manual ......................................................................................................................... 7 Explanation of terms for maintenance standard ............................................................................................. 9 Handling of electric equipment and hydraulic component .............................................................................11 Handling of connectors newly used for engines ........................................................................................... 20 How to read electric wire code...................................................................................................................... 23 Precautions when carrying out operation...................................................................................................... 26 Method of disassembling and connecting push-pull type coupler................................................................. 29 Standard tightening torque table ................................................................................................................... 32 Conversion table ........................................................................................................................................... 36
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200 Foreword and general information Safety notice
SEN04932-01
Safety notice
(Rev. 2008/08-a)1
Important safety notice Proper service and repair are extremely important for safe machine operation. The service and repair techniques recommended by Komatsu and described in this manual are both effective and safe. Some of these techniques require the use of tools specially designed by Komatsu for the specific purpose. To prevent injury to workers, the symbol k is used to mark safety precautions in this manual. The cautions accompanying these symbols should always be followed carefully. If any dangerous situation arises or may possibly arise, first consider safety, and take the necessary actions to deal with the situation. 1.
General precautions k Mistakes in operation are extremely dangerous. Read the Operation and Maintenance Manual carefully before operating the machine. In addition, read this manual and understand its contents before starting the work. 1) Before carrying out 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. 2) Decide a place in the repair workshop to keep tools and removed parts. Always keep the tools and parts in their correct places. Always keep the work area clean and make sure that there is no dirt, water, or oil on the floor. Smoke only in the areas provided for smoking. Never smoke while working. 3) When carrying out any operation, always wear safety shoes and helmet. Do not wear loose work clothes, or clothes with buttons missing. q Always wear safety glasses when hitting parts with a hammer. q Always wear safety glasses when grinding parts with a grinder, etc. 4) When carrying out any operation with 2 or more workers, always agree on the operating procedure before starting. Always inform your fellow workers before starting any step of the operation. Before starting work, hang UNDER REPAIR warning signs in the operator's compartment. 5) Only qualified workers must carry out work and operation which require license or qualification. 6) Keep all tools in good condition, learn the correct way to use them, and use the proper ones of them. Before starting work, thoroughly check the tools, machine, forklift, service car, etc.
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8)
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If welding repairs are needed, always have a trained and experienced welder carry out the work. When carrying out weld in g wo rk , al way s wear wel din g gloves, apron, shielding goggles, cap and other clothes suited for welding work. Before starting work, warm up your body thoroughly to start work under good condition. Avoid continuing work for long hours and take rests at proper intervals to keep your body in good condition. Take rests in specified safe places.
Safety points 1 Good arrangement 2 Correct work clothes 3 Following work standard 4 Making and checking signs 5
Prohibition of operation and handling by unlicensed workers
6 Safety check before starting work 7
Wearing protective goggles (for cleaning or grinding work)
8
Wearing shielding goggles and protectors (for welding work)
9 Good physical condition and preparation 10
Precautions against work which you are not used to or you are used to too much
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2.
3.
Preparations for work 1) Before adding oil or making any repairs, park the machine on a hard and level ground, and apply the parking brake and block the wheels or tracks to prevent the machine from moving. 2) Before starting work, lower the work equipment (blade, ripper, bucket, etc.) to the ground. If this is not possible, insert the lock pin or use blocks to prevent the work equipment from falling. In addition, be sure to lock all the control levers and hang warning signs on them. 3) When disassembling or assembling, support the machine with blocks, jacks, or stands before starting work. 4) Remove all mud and oil from the steps or other places used to get on and off the machine. Always use the handrails, ladders or steps when getting on or off the m a c h i n e . N e v e r j u m p o n o r o ff t h e machine. If it is impossible to use the handrails, ladders or steps, use a stand to provide safe footing. Precautions during work 1) Before disconnecting or removing components of the oil, water, or air circuits, first release the pressure completely from the circuit. When removing the oil filler cap, a drain plug, or an oil pressure pickup plug, loosen it slowly to prevent the oil from spurting out. 2) The coolant and oil in the circuits are hot when the engine is stopped, so be careful not to get scalded. Wait for the oil and coolant to cool before carrying out any work on the oil or water circuits. 3) Before starting work, stop the engine. When working on or around a rotating part, in particular, stop the engine. When checking the machine without stopping the engine (measuring oil pressure, revolving speed, temperature, etc.), take extreme care not to get rolled or caught in rotating parts or moving parts. 4) Before starting work, remove the leads from the battery. Always remove the lead from the negative (–) terminal first. 5) When raising a heavy component (heavier than 25 kg), use a hoist or crane. Before starting work, check that the slings (wire ropes, chains, and hooks) are free from damage. Always use slings which have ample capacity and install them to proper places. Operate the hoist or crane slowly to prevent the component from hitting any other part. Do not work with any part still raised by the hoist or crane.
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SEN04932-01 6)
7)
8)
9)
10)
11)
12)
13)
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When removing a cover which is under internal pressure or under pressure from a spring, always leave 2 bolts in diagonal positions. Loosen those bolts gradually and alternately to release the pressure, and then remove the cover. When removing components, be careful not to break or damage the electrical wiring. Damaged wiring may cause electrical fires. When removing piping, stop the fuel or oil from spilling out. If any fuel or oil drips onto the floor, wipe it up immediately. Fuel or oil on the floor can cause you to slip and can even start fires. As a general rule, do not use gasoline to wash parts. Do not use it to clean electrical parts, in particular. Be sure to assemble all parts again in their original places. Replace any damaged parts and parts which must not be reused with new parts. When installing hoses and wires, be sure that they will not be damaged by contact with other parts when the machine is operated. When installing high pressure hoses, make sure that they are not twisted. Damaged tubes are dangerous, so be extremely careful when installing tubes for high pressure circuits. In addition, check t h a t c o n n e c t i n g pa r ts a r e c o r r e c t l y installed. When assembling or installing parts, always tighten them to the specified torques. When installing protective parts such as guards, or parts which vibrate violently or rotate at high speed, be particul a r ly c a r e fu l t o c he c k t h a t t h e y ar e installed correctly. When aligning 2 holes, never insert your fingers or hand. Be careful not to get your fingers caught in a hole. When measuring hydraulic pressure, check that the measuring tools are correctly assembled. Take care when removing or installing the tracks of track-type machines. When removing the track, the track separates suddenly, so never let anyone stand at either end of the track. If the engine is operated for a long time in a place which is not ventilated well, you may suffer from gas poisoning. Accordingly, open the windows and doors to ventilate well.
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200 Foreword and general information Safety notice
SEN04932-01 4.
Precautions for sling work and making signs 1) Only one appointed worker must make signs and co-workers must communicate with each other frequently. The appointed sign maker must make specified signs clearly at a place where he is well seen from the operator's seat and where he can see the working condition easily. The sign maker must always stand in front of the load and guide the operator safely. q Do not stand under the load. q Do not step on the load. 2) Check the slings before starting sling work. 3) Keep putting on gloves during sling work. (Put on leather gloves, if available.) 4) Measure the weight of the load by the eye and check its center of gravity. 5) Use proper sling according to the weight of the load and method of slinging. If too thick wire ropes are used to sling a light load, the load may slip and fall. 6) Do not sling a load with 1 wire rope alone. If it is slung so, it may rotate and may slip out of the rope. Install 2 or more wire ropes symmetrically. k Slinging with 1 rope may cause turning of the load during hoisting, untwisting of the rope, or slipping of the rope from its original winding position on the load, which can result in a dangerous accident. 7) Limit the hanging angle to 60°, as a rule. Do not sling a heavy load with ropes forming a wide hanging angle from the hook. When hoisting a load with 2 or more ropes, the force subjected to each rope will increase with the hanging angle. The table below shows the variation of allowable load in kN {kg} when hoisting is made with 2 ropes, each of which is allowed to sling up to 9.8 kN {1,000 kg} vertically, at various hanging angles. When the 2 ropes sling a load vertically, up to 19.6 kN {2,000 kg} of total weight can be suspended. This weight is reduced to 9.8 kN {1,000 kg} when the 2 ropes make a hanging angle of 120°. If the 2 ropes sling a 19.6 kN {2,000 kg} load at a lifting angle of 150°, each of them is subjected to a force as large as 39.2 kN {4,000 kg}.
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8)
When installing wire ropes to an angular load, apply pads to protect the wire ropes. If the load is slippery, apply proper material to prevent the wire rope from slipping. 9) Use the specified eyebolts and fix wire ropes, chains, etc. to them with shackles, etc. 10) Apply wire ropes to the middle portion of the hook. q Slinging near the tip of the hook may cause the rope to slip off the hook during hoisting. The hook has the maximum strength at the middle portion.
11) Do not use twisted or kinked wire ropes. 12) When lifting up a load, observe the following. q Wind in the crane slowly until wire ropes are stretched. When settling the wire ropes with the hand, do not grasp them but press them from above. If you grasp them, your fingers may be caught. q After the wire ropes are stretched, stop the crane and check the condition of the slung load, wire ropes, and pads.
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If the load is unstable or the wire rope or chains are twisted, lower the load and lift it up again. q Do not lift up the load slantingly. 13) When lifting down a load, observe the following. q When lifting down a load, stop it temporarily at 30 cm above the floor, and then lower it slowly. q Check that the load is stable, and then remove the sling. q Remove kinks and dirt from the wire ropes and chains used for the sling work, and put them in the specified place.
SEN04932-01 13) If the hoist stops because of a power failure, turn the power switch OFF. When turning on a switch which was turned OFF by the electric shock prevention earth leakage breaker, check that the devices related to that switch are not in operation state. 14) If you find an obstacle around the hoist, stop the operation. 15) After finishing the work, stop the hoist at the specified position and raise the hook to at least 2 m above the floor. Do not leave the sling installed to the hook.
q
5.
6.
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 hoist crane k When raising a heavy part (heavier than 25 kg), use a hoist, etc. In Disassembly and assembly, the weight of a part heavier than 25 kg is indicated after the mark of 4. 1) Before starting work, inspect the wire ropes, brake, clutch, controller, rails, over wind stop device, electric shock prevention earth leakage breaker, crane collision prevention device, and power application warning lamp, and check safety. 2) Observe the signs for sling work. 3) Operate the hoist at a safe place. 4) Check the direction indicator plates (east, west, south, and north) and the directions of the control buttons without fail. 5) Do not sling a load slantingly. Do not move the crane while the slung load is swinging. 6) Do not raise or lower a load while the crane is moving longitudinally or laterally. 7) Do not drag a sling. 8) When lifting up a load, stop it just after it leaves the ground and check safety, and then lift it up. 9) Consider the travel route in advance and lift up a load to a safe height. 10) Place the control switch on a position where it will not be an obstacle to work and passage. 11) After operating the hoist, do not swing the control switch. 12) Remember the position of the main switch so that you can turn off the power immediately in an emergency.
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7.
Selecting wire ropes 1) Select adequate ropes depending on the weight of parts to be hoisted, referring to the table below.
Wire ropes (Standard “Z” twist ropes without galvanizing) (JIS G3525, No. 6, Type 6X37-A) Nominal Allowable load diameter of rope mm kN ton 10 8.8 0.9 12 12.7 1.3 14 17.3 1.7 16 22.6 2.3 18 28.6 2.9 20 35.3 3.6 25 55.3 5.6 30 79.6 8.1 40 141.6 14.4 50 221.6 22.6 60 318.3 32.4
a
The allowable load is one-sixth of the breaking strength of the rope used (Safety coefficient: 6).
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200 Foreword and general information Safety notice
SEN04932-01 8.
Precautions for disconnecting and connecting hoses and tubes in air conditioner circuit 1) Disconnection k For the environment, the air conditioner of this machine uses the refrigerant (air conditioner gas: R134a) which has fewer factors of the depletion of the ozone layer. However, it does not mean that you may discharge the refrigerant into the atmosphere as it is. Be sure to recover the refrigerant when disconnecting the refrigerant gas circuit and then reuse it. a Ask professional traders for collecting and filling operation of refrigerant (R134a). a Never release the refrigerant (R134a) to the atmosphere. k If the refrigerant gas gets in your eyes or contacts your skin, you may lose your sight and your skin may be frozen. Accordingly, put on safety glasses, safety gloves and safety clothes when recovering or adding the refrigerant. Refrigerant gas must be recovered and added by a qualified person. 2)
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Example of O-ring (Fitted to every joint of hoses and tubes)
a
For tightening torque, see the precautions for installation in each section of "Disassembly and assembly".
Connection 1] When installing the air conditioner circuit hoses and tubes, take care that dirt, dust, water, etc. will not enter them. 2] When connecting the air conditioner hoses and tubes, check that O-rings (1) are fitted to their joints. 3] Check that each O-ring is not damaged or deteriorated. 4] When connecting the refrigerant piping, apply compressor oil for refrigerant (R134a) (DENSO: ND-OIL8, VA L E O T H E R M A L S Y S T E M S : ZXL100PG (equivalent to PAG46)) to its O-rings.
6
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200 Foreword and general information How to read the shop manual
How to read the shop manual q q q
1.
SEN04932-01
1
Some attachments and optional parts in this shop manual may not be delivered to certain areas. If one of them is required, consult KOMATSU distributors. Materials and specifications are subject to change without notice. Shop manuals are divided into the “Chassis volume” and “Engine volume”. For the engine unit, see the engine volume of the engine model mounted on the machine.
Composition of shop manual This shop manual contains the necessary technical information for services performed in a workshop. For ease of understanding, the manual is divided into the following sections. 00. Index and foreword This section explains the shop manuals list, table of contents, safety, and basic information. 01. Specification This section explains the specifications of the machine. 10. Structure, function and maintenance standard This section explains the structure, function, and maintenance standard values of each component. The structure and function sub-section explains the structure and function of each component. It serves not only to give an understanding of the structure, but also serves as reference material for troubleshooting. The maintenance standard sub-section explains the criteria and remedies for disassembly and service. 20. Standard value table This section explains the standard values for new machine and judgement criteria for testing, adjusting, and troubleshooting. This standard value table is used to check the standard values in testing and adjusting and to judge parts in troubleshooting. 30. Testing and adjusting This section explains measuring instruments and measuring methods for testing and adjusting, and method of adjusting each part. The standard values and judgement criteria for testing and adjusting are explained in Testing and adjusting. 40. Troubleshooting This section explains how to find out failed parts and how to repair them. The troubleshooting is divided by failure modes. The “S mode” of the troubleshooting related to the engine may be also explained in the Chassis volume and Engine volume. In this case, see the Chassis volume. 50. Disassembly and assembly This section explains the special tools and procedures for removing, installing, disassembling, and assembling each component, as well as precautions for them. In addition, tightening torque and quantity and weight of coating material, oil, grease, and coolant necessary for the work are also explained. 80. Appendix This section explains the equipments which cannot be included in the other sections. This section explains the structure, function, testing, adjusting, and troubleshooting of the equipments. 90. Diagrams and drawings (chassis volume)/Repair and replacement of parts (engine volume) q Chassis volume This section gives hydraulic circuit diagrams and electrical circuit diagrams. q Engine volume This section explains the method of reproducing, repairing, and replacing parts.
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200 Foreword and general information How to read the shop manual
SEN04932-01 2.
Revision and distribution Any additions, revisions, or other change of notices will be sent to KOMATSU distributors. Get the most up-to-date information before you start any work.
3.
Filing method File by the brochures in the correct order of the form number printed in the shop manual composition table.
4.
q
Revised edition mark When a manual is revised, the ones and tens digits of the form number of each brochure is increased by 1. (Example: 00, 01, 02 …)
q
Revisions Revised brochures are shown in the shop manual composition table.
Symbols Important safety and quality portions are marked with the following symbols so that the shop manual will be used practically. Symbol
Item
k
Safety
a
Caution
Special technical precautions or other precautions for preserving standards are necessary when performing work.
4
Weight
Weight of parts of component or parts. Caution necessary when selecting hoisting wire, or when working posture is important, etc.
3
Tightening torque
2
5.
Coat
5
Oil, coolant
6
Drain
Remarks Special safety precautions are necessary when performing work.
Places that require special attention for tightening torque during assembly. Places to be coated with adhesives, etc. during assembly. Places where oil, etc. must be added, and capacity. Places where oil, etc. must be drained, and quantity to be drained.
Units In this shop manual, the units are indicated with International System of units (SI). For reference, conventionally used Gravitational System of units is indicated in parentheses { }.
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200 Foreword and general information Explanation of terms for maintenance standard
SEN04932-01
Explanation of terms for maintenance standard
1
The maintenance standard chapter explains the criteria for replacing or reusing products and parts in the machine maintenance work. The following terms are used to explain the criteria. 1.
Standard size and tolerance To be accurate, the finishing size of parts is a little different from one to another. q To specify a finishing size of a part, a temporary standard size is set and an allowable difference from that size is indicated. q The above size set temporarily is called the “standard size” and the range of difference from the standard size is called the “tolerance”. q The tolerance with the symbols of + or – is indicated on the right side of the standard size. q
Example: Standard size
Tolerance –0.022 –0.126
120 a
The tolerance may be indicated in the text and a table as [standard size (upper limit of tolerance/lower limit of tolerance)]. Example) 120 (–0.022/–0.126)
q
Usually, the size of a hole and the size of the shaft to be fitted to that hole are indicated by the same standard size and different tolerances of the hole and shaft. The tightness of fit is decided by the tolerance. Indication of size of rotating shaft and hole and relationship drawing of them
q
Example: Standard size 60
D65EX, PX, WX-16
Tolerance Shaft –0.030 –0.076
Hole +0.046 +0
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200 Foreword and general information Explanation of terms for maintenance standard
SEN04932-01 2.
Standard clearance and standard value The clearance made when new parts are assembled is called the “standard clearance“, which is indicated by the range from the minimum clearance to the maximum clearance. q When some parts are repaired, the clearance is generally adjusted to the standard clearance. q A value of performance and function of new products or equivalent is called the “standard value“, which is indicated by a range or a target value. q When some parts are repaired, the value of performance/function is set to the standard value.
5.
q
3.
Standard interference q When the diameter of a hole of a part shown in the given standard size and tolerance table is smaller than that of the mating shaft, the difference between those diameters is called the “interference”. q The range (A – B) from the difference (A) between the minimum size of the shaft and the maximum size of the hole to the difference (B) between the maximum size of the shaft and the minimum size of the hole is the “standard interference”. q After repairing or replacing some parts, measure the size of their hole and shaft and check that the interference is in the standard range.
4.
Repair limit and allowable value or allowable dimension q The size of a part changes because of wear and deformation while it is used. The limit of changed size is called the “repair limit”. q If a part is worn to the repair limit, it must be replaced or repaired. q The performance and function of a product lowers while it is used. A value which the product can be used without causing a problem is called the “allowable value” or “allowable dimension”. q If a product is worn to the allowable value, it must be checked or repaired. Since the permissible value is estimated from various tests or experiences in most cases, however, it must be judged after considering the operating condition and customer's requirement.
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10
Clearance limit Parts can be used until the clearance between them is increased to a certain limit. The limit at which those parts cannot be used is called the “clearance limit”. q If the clearance between the parts exceeds the clearance limit, they must be replaced or repaired. q
6.
Interference limit The allowable maximum interference between the hole of a part and the shaft of another part to be assembled is called the “interference limit”. q The interference limit shows the repair limit of the part of smaller tolerance. q If the interference between the parts exceeds the interference limit, they must be replaced or repaired. q
D65EX, PX, WX-16
200 Foreword and general information Handling of electric equipment and hydraulic component
SEN04932-01
Handling of electric equipment and hydraulic component
1
To maintain the performance of the machine over a long period, and to prevent failures or other troubles before they occur, correct “operation“, “maintenance and inspection“, “troubleshooting“, and “repairs” must be carried out. This section deals particularly with correct repair procedures for mechatronics and is aimed at improving the quality of repairs. For this purpose, it gives sections on “Handling electric equipment” and “Handling hydraulic equipment” (particularly gear oil and hydraulic oil).
Points to remember when handling electric equipment 1. Handling wiring harnesses and connectors Wiring harnesses consist of wiring connecting one component to another component, connectors used for connecting and disconnecting one wire from another wire, and protectors or tubes used for protecting the wiring. Compared with other electrical components fitted in boxes or cases, wiring harnesses are more likely to be affected by the direct effects of rain, water, heat, or vibration. Furthermore, during inspection and repair operations, they are frequently removed and installed again, so they are likely to suffer deformation or damage. For this reason, it is necessary to be extremely careful when handling wiring harnesses. 2.
Main failures occurring in wiring harness 1) Defective contact of connectors (defective contact between male and female) Problems with defective contact are likely to occur because the male connector is not properly inserted into the female connector, or because one or both of the connectors is deformed or the position is not correctly aligned, or because there is corrosion or oxidization of the contact surfaces. The corroded or oxidized contact surfaces may become shiny again (and contact may become normal) by connecting and disconnecting the connector about 10 times. 2)
Defective crimping or soldering of connectors The pins of the male and female connectors are in contact at the crimped terminal or soldered portion, but if there is excessive force brought to bear on the wiring, the plating at the joint will peel and cause improper connection or breakage.
D65EX, PX, WX-16
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SEN04932-01 3)
Disconnections in wiring If the wiring is held and the connectors are pulled apart, or components are lifted with a crane with the wiring still connected, or a heavy object hits the wiring, the crimping of the connector may separate, or the soldering may be damaged, or the wiring may be broken.
4)
High-pressure water entering connector The connector is designed to make it difficult for water to enter (drip-proof structure), but if high-pressure water is sprayed directly on the connector, water may enter the connector, depending on the direction of the water jet. Accordingly, take care not to splash water over the connector. The connector is designed to prevent water from entering, but at the same time, if water does enter, it is difficult for it to be drained. Therefore, if water should get into the connector, the pins will be shortcircuited by the water, so if any water gets in, immediately dry the connector or take other appropriate action before passing electricity through it.
5)
Oil or dirt stuck to connector If oil or grease are stuck to the connector and an oil film is formed on the mating surface between the male and female pins, the oil will not let the electricity pass, so there will be defective contact. If there is oil or grease stuck to the connector, wipe it off with a dry cloth or blow it dry with compressed air and spray it with a contact restorer. a When wiping the mating portion of the connector, be careful not to use excessive force or deform the pins. a If there is oil or water in the compressed air, the contacts will become even dirtier, so remove the oil and water from the compressed air completely before cleaning with compressed air.
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200 Foreword and general information Handling of electric equipment and hydraulic component
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200 Foreword and general information Handling of electric equipment and hydraulic component
3.
SEN04932-01
Removing, installing, and drying connectors and wiring harnesses 1) Disconnecting connectors 1] Hold the connectors when disconnecting. When disconnecting the connectors, hold the connectors. For connectors held by a screw, loosen the screw fully, then hold the male and female connectors in each hand and pull apart. For connectors which have a lock stopper, press down the stopper with your thumb and pull the connectors apart. a Never pull with one hand. 2] q
When removing from clips Both of the connector and clip have stoppers, which are engaged with each other when the connector is installed.
q
When removing a connector from a clip, pull the connector in a parallel direction to the clip for removing stoppers. a If the connector is twisted up and down or to the left or right, the housing may break.
3]
Action to take after removing connectors After removing any connector, cover it with a vinyl bag to prevent any dust, dirt, oil, or water from getting in the connector portion. a If the machine is left disassembled for a long time, it is particularly easy for improper contact to occur, so always cover the connector.
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SEN04932-01 2)
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200 Foreword and general information Handling of electric equipment and hydraulic component
Connecting connectors 1] Check the connector visually. Check that there is no oil, dirt, or water stuck to the connector pins (mating portion). Check that there is no deformation, defective contact, corrosion, or damage to the connector pins. Check that there is no damage or breakage to the outside of the connector. a If there is any oil, water, or dirt stuck to the connector, wipe it off with a dry cloth. If any water has got inside the connector, warm the inside of the wiring with a dryer, but be careful not to make it too hot as this will cause short circuits. a If there is any damage or breakage, replace the connector. 2] Fix the connector securely. Align the position of the connector correctly, and then insert it securely. For connectors with the lock stopper, push in the connector until the stopper clicks into position. 3] Correct any protrusion of the boot and any misalignment of the wiring harness. For connectors fitted with boots, correct any protrusion of the boot. In addition, if the wiring harness is misaligned, or the clamp is out of position, adjust it to its correct position. a If the connector cannot be corrected easily, remove the clamp and adjust the position. q If the connector clamp has been removed, be sure to return it to its original position. Check also that there are no loose clamps.
14
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200 Foreword and general information Handling of electric equipment and hydraulic component
3)
Heavy duty wire connector (DT 8-pole, 12pole) Disconnection (Left of figure) While pressing both sides of locks (a) and (b), pull out female connector (2). Connection (Right of figure) 1] Push in female connector (2) horizontally until the lock clicks. Arrow: 1) 2] Since locks (a) and (b) may not be set completely, push in female connector (2) while moving it up and down until the locks are set normally. Arrow: 1), 2), 3) a Right of figure: Lock (a) is pulled down (not set completely) and lock (b) is set completely. (1): Male connector (2): Female connector (a), (b): Locks
D65EX, PX, WX-16
SEN04932-01 q
Disconnection
q
Connection (Example of incomplete setting of (a))
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15
SEN04932-01 4)
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200 Foreword and general information Handling of electric equipment and hydraulic component
Drying wiring harness If there is any oil or dirt on the wiring harness, wipe it off with a dry cloth. Avoid washing it in water or using steam. If the connector must be washed in water, do not use high-pressure water or steam directly on the wiring harness. If water gets directly on the connector, do as follows. 1] Disconnect the connector and wipe off the water with a dry cloth. a If the connector is blown dry with compressed air, there is the risk that oil in the air may cause defective contact, so remove all oi l a nd wa ter fr om t he c ompressed air before blowing with air. 2] Dry the inside of the connector with a dryer. If water gets inside the connector, use a dryer to dry the connector. a Hot air from the dryer can be used, but regulate the time that the hot air is used in order not to make the connector or related parts too hot, as this will cause deformation or damage to the connector. 3] Carry out a continuity test on the connector. After drying, leave the wiring harness disconnected and carry out a continuity test to check for any short circuits between pins caused by water. a After completely drying the conn e c t o r, b l o w i t w i t h c o n ta c t restorer and reassemble.
16
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200 Foreword and general information Handling of electric equipment and hydraulic component
4.
Handling controller 1) The controller contains a microcomputer and electronic control circuits. These control all of the electronic circuits on the machine, so be extremely careful when handling the controller. 2) Do not place objects on top of the controller. 3) Cover the control connectors with tape or a vinyl bag. Never touch the connector contacts with your hand. 4) During rainy weather, do not leave the controller in a place where it is exposed to rain. 5) Do not place the controller on oil, water, or soil, or in any hot place, even for a short time. (Place it on a suitable dry stand). 6) Precautions when carrying out arc welding When carrying out arc welding on the body, disconnect all wiring harness connectors connected to the controller. Fit an arc welding ground close to the welding point.
5.
Points to remember when troubleshooting electric circuits 1) Always turn the power OFF before disconnecting or connecting connectors. 2) Before carrying out troubleshooting, check that all the related connectors are properly inserted. a Disconnect and connect the related connectors several times to check. 3) Always connect any disconnected connectors before going on to the next step. a If the power is turned ON with the connectors still disconnected, unnecessary abnormality displays will be generated. 4) When carrying out troubleshooting of circuits (measuring the voltage, resistance, continuity, or current), move the related wiring and connectors several times and check that there is no change in the reading of the tester. a If there is any change, there is probably defective contact in that circuit.
D65EX, PX, WX-16
SEN04932-01
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200 Foreword and general information Handling of electric equipment and hydraulic component
Points to remember when handling hydraulic equipment With the increase in pressure and precision of hydraulic equipment, the most common cause of failure is dirt (foreign material) in the hydraulic circuit. When adding hydraulic oil, or when disassembling or assembling hydraulic equipment, it is necessary to be particularly careful.
1.
Be careful of the operating environment. Avoid adding hydraulic oil, replacing filters, or repairing the machine in rain or high winds, or places where there is a lot of dust.
2.
Disassembly and maintenance work in the field If disassembly or maintenance work is carried out on hydraulic equipment in the field, there is danger of dust entering the equipment. It is also difficult to check the performance after repairs, so it is desirable to use unit exchange. Disassembly and maintenance of hydraulic equipment should be carried out in a specially prepared dustproof workshop, and the performance should be checked with special test equipment.
3.
Sealing openings After any piping or equipment is removed, the openings should be sealed with caps, tapes, or vinyl bags to prevent any dirt or dust from entering. If the opening is left open or is blocked with a rag, there is danger of dirt entering or of the surrounding area being made dirty by leaking oil so never do this. Do not simply drain oil out onto the ground, but collect it and ask the customer to dispose of it, or take it back with you for disposal.
4.
Do not let any dirt or dust get in during refilling operations Be careful not to let any dirt or dust get in when refilling with hydraulic oil. Always keep the oil filler and the area around it clean, and also use clean pumps and oil containers. If an oil cleaning device is used, it is possible to filter out the dirt that has collected during storage, so this is an even more effective method.
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200 Foreword and general information Handling of electric equipment and hydraulic component
5.
Change hydraulic oil when the temperature is high When hydraulic oil or other oil is warm, it flows easily. In addition, the sludge can also be drained out easily from the circuit together with the oil, so it is best to change the oil when it is still warm. When changing the oil, as much as possible of the old hydraulic oil must be drained out. (Drain the oil from the hydraulic tank; also drain the oil from the filter and from the drain plug in the circuit.) If any old oil is left, the contaminants and sludge in it will mix with the new oil and will shorten the life of the hydraulic oil.
6.
Flushing operations After disassembling and assembling the equipment, or changing the oil, use flushing oil to remove the contaminants, sludge, and old oil from the hydraulic circuit. Normally, flushing is carried out twice: primary flushing is carried out with flushing oil, and secondary flushing is carried out with the specified hydraulic oil.
7.
Cleaning operations After repairing the hydraulic equipment (pump, control valve, etc.) or when running the machine, carry out oil cleaning to remove the sludge or contaminants in the hydraulic oil circuit. The oil cleaning equipment is used to remove the ultra fine (about 3 m) particles that the filter built in the hydraulic equipment cannot remove, so it is an extremely effective device.
D65EX, PX, WX-16
SEN04932-01
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200 Foreword and general information Handling of connectors newly used for engines
SEN04932-01
Handling of connectors newly used for engines a
1.
Mainly, following engines are object for following connectors. q 95E-5 q 107E-1 q 114E-3 q 125E-5 q 140E-5 q 170E-5 q 12V140E-3 Slide lock type (FRAMATOME-3, FRAMATOME-2) q 95 – 170, 12V140 engines q Various pressure sensors and NE speed sensor Examples) Intake air pressure sensor in intake manifold: PIM (125, 170, 12V140 engines) Oil pressure sensor: POIL (125, 170, 12V140 engines) Oil pressure switch (95, 107, 114 engines) Ne speed sensor of flywheel housing: (95 – 170, 12V140 engines) NE Ambient pressure sensor: PAMB (125, 170, 12V140 engines)
2.
1
Pull lock type (PACKARD-2) 95 – 170, 12V140 engines q Various temperature sensors Example) Intake air temperature sensor in intake manifold: TIM Fuel temperature sensor: TFUEL Oil temperature sensor: TOIL Coolant temperature sensor: TWTR, etc. Disconnect the connector by pulling lock (B) (on the wiring harness side) of connector (2) outward.
q
Disconnect connector (1) according to the following procedure. 1) Slide lock (L1) to the right. 2) While pressing lock (L2), pull out connector (1) toward you. a Even if lock (L2) is pressed, connector (1) cannot be pulled out toward you, if part A does not float. In this case, float part A with a small screwdriver while press lock (L2), and then pull out connector (1) toward you.
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200 Foreword and general information Handling of connectors newly used for engines
3.
SEN04932-01
Push lock type q 95, 107, 114 engines Example) Fuel pressure sensor in common rail (BOSCH-03) Disconnect connector (3) according to the following procedure. 1) While pressing lock (C), pull out connector (3) in the direction of the arrow. q
q
114 engine
q
107, 114 engines Example) Intake air pressure/temperature sensor in intake manifold (SUMITOMO-04)
3)
While pressing lock (D), pull out connector (4) in the direction of the arrow.
107 engine
a
2)
If the lock is on the underside, use flat-head screwdriver [1] since you cannot insert your fingers. While pressing up lock (C) of the connector with flat-head screwdriver [1], pull out connector (3) in the direction of the arrow.
D65EX, PX, WX-16
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200 Foreword and general information Handling of connectors newly used for engines
SEN04932-01 q
4)
95, 125 – 170, 12V140 engines While pressing lock (E) of the connector, pull out connector (5) in the direction of the arrow. Example) Fuel pressure sensor in common rail: PFUEL etc. (AMP-3)
4.
Turn-housing type (Round green connector) 140 engine Example) Intake air pressure sensor in intake manifold (CANNON-04): PIM etc.
q
1)
Disconnect connector (6) according to the following procedure. 1] Turn housing (H1) in the direction of the arrow. a When connector is unlocked, housing (H1) becomes heavy to turn. 2] Pull out housing (H1) in the direction of the arrow. a Housing (H1) is left on the wiring harness side.
2)
Connect the connector according to the following procedure. 1] Insert the connector to the end, while setting its groove. 2] Turn housing (H1) in the direction of the arrow until it “clicks”.
Example) Injection pressure control valve of fuel supply pump: PCV (SUMITOMO-2)
Example) Speed sensor of fuel supply pump: G (SUMITOMO-3) a Pull the connector straight up.
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200 Foreword and general information How to read electric wire code
SEN04932-01
How to read electric wire code a
1
The information about the wires unique to each machine model is described in Troubleshooting section, Relational information of troubleshooting.
In the electric circuit diagram, the material, thickness, and color of each electric wire are indicated by symbols. The electric wire code is helpful in understanding the electric circuit diagram. Example: AEX
0.85
L - - - Indicates blue, heat-resistant, low-voltage wire for automobile, having nominal No. of 0.85 Indicates color of wire by color code. Color codes are shown in Table 3. Indicates size of wire by nominal No. Size (Nominal No.) is shown in Table 2. Indicates type of wire by symbol. Type, symbol, and material of wire are shown in Table 1. (Since AV and AVS are classified by size (nominal No.), they are not indicated.)
1.
Type, symbol, and material AV and AVS are different in only thickness and outside diameter of the cover. AEX is similar to AV in thickness and outside diameter of AEX and different from AV and AVS in material of the cover.
(Table 1) Type
Symbol
Low-voltage wire for automobile
AV
Thin-cover low-voltage wire for automobile
AVS
Heat-resistant low-voltAEX age wire for automobile
D65EX, PX, WX-16
Material Conductor Insulator Conductor
Annealed copper for electric appliance Soft polyvinyl chloride Annealed copper for electric appliance
Insulator
Soft polyvinyl chloride
Conductor
Annealed copper for electric appliance Heat-resistant crosslinked polyethylene
Insulator
Using temperature range (°C)
Example of use General wiring (Nominal No. 5 and above)
–30 to +60 General wiring (Nominal No. 3 and below) General wiring in extremely –50 to +110 cold district, wiring at high-temperature place
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200 Foreword and general information How to read electric wire code
SEN04932-01 2.
Dimensions
(Table 2) Nominal No. 0.5f (0.5) 0.75f (0.85) 1.25f (1.25) 2f 2 3f 3 5 Number of strands/Diam- 20/0.18 7/0.32 30/0.18 11/0.32 50/0.18 16/0.32 37/0.26 26/0.32 58/0.26 41/0.32 65/0.32 eter of strand Conductor Sectional 0.51 0.56 0.76 0.88 1.27 1.29 1.96 2.09 3.08 3.30 5.23 area (mm2) d (approx.) 1.0 1.2 1.5 1.9 1.9 2.3 2.4 3.0 3.6 – AVS Standard 2.0 2.2 2.5 2.9 2.9 3.5 CovAV Standard – – – – – – – 4.6 er D AEX Standard 2.0 2.2 2.7 3.0 3.1 – 3.8 4.6
Nominal No. Number of strands/Diameter of strand Conductor Sectional area (mm2) d (approx.) AVS Standard CovAV Standard er D AEX Standard
8
15
20
30
40
50
60
85
100
50/0.45
84/0.45
41/0.80
70/0.80
85/0.80
7.95
13.36
20.61
35.19
42.73
54.29
63.84
84.96
109.1
3.7 – 5.5 5.3
4.8 – 7.0 7.0
6.0 – 8.2 8.2
8.0 – 10.8 10.8
8.6 – 11.4 11.4
9.8 – 13.0 13.0
10.4 – 13.6 13.6
12.0 – 16.0 16.0
13.6 – 17.6 17.6
108/0.80 127/0.80 169/0.80 217/0.80
“f” of nominal No. denotes flexible”.
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3.
SEN04932-01
Color codes table
(Table 3) Color Code B Br BrB BrR BrW BrY Ch Dg G GB GL Gr GR GW GY L LB Lg LgB LgR
Color of wire Black Brown Brown & Black Brown & Red Brown & White Brown & Yellow Charcoal Dark green Green Green & Black Green & Blue Gray Green & Red Green & White Green & Yellow Blue Blue & Black Light green Light green & Black Light green & Red
Color Code LgW LgY LR LW LY O P R RB RG RL RW RY Sb Y YB YG YL YR YW
Color of wire Light green & White Light green & Yellow Blue & Red Blue & White Blue & Yellow Orange Pink Red Red & Black Red & Green Red & Blue Red & White Red & Yellow Sky Blue Yellow Yellow & Black Yellow &Green Yellow & Blue Yellow & Red Yellow & White
Remarks: In a color code consisting of 2 colors, the first color is the color of the background and the second color is the color of the marking. Example: “GW” means that the background is Green and marking is White.
4.
Types of circuits and color codes
(Table 4) Type of wire Charge Ground Start Light Instrument Signal Type of circuit
Others
D65EX, PX, WX-16
AVS or AV R B R RW Y G L Br Lg O Gr P Sb Dg Ch
AEX
WG
–
–
–
–
–
–
–
–
–
–
–
–
–
–
RB YR GW LW BrW LgR
RY YB GR LR BrR LgY
RG YG GY LY BrY LgB
RL YL GB LB BrB LgW
–
–
–
–
–
–
–
–
–
–
– –
–
R B R D Y G L
–
–
–
–
–
–
–
–
–
–
–
–
–
–
–
–
–
–
–
–
–
–
–
–
–
–
–
–
–
–
–
–
–
–
–
–
–
YW GL
– – – –
Gr Br –
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200 Foreword and general information Precautions when carrying out operation
SEN04932-01
Precautions when carrying out operation
1
[When carrying out removal or installation (disassembly or assembly) of units, be sure to follow the general precautions given below when carrying out the operation.] 1. q q q q q q q q q q
a
Precautions when carrying out removal work If the coolant contains antifreeze, dispose of it correctly. After disconnecting hoses or tubes, cover them or fit plugs to prevent dirt or dust from entering. When draining oil, prepare a container of adequate size to catch the oil. Confirm the match marks showing the installation position, and make match marks in the necessary places before removal to prevent any mistake when assembling. To prevent any excessive force from being applied to the wiring, always hold the connectors when disconnecting the connectors. Do not pull the wires. Fit wires and hoses with tags to show their installation position to prevent any mistake when installing. Check the number and thickness of the shims, and keep in a safe place. When raising components, be sure to use lifting equipment of ample strength. When using forcing screws to remove any components, tighten the forcing screws uniformly in turn. Before removing any unit, clean the surrounding area and fit a cover to prevent any dust or dirt from entering after removal. Precautions when handling piping during disassembly Fit the following plugs into the piping after disconnecting it during disassembly operations. 1) Face seal type hoses and tubes Nominal number 02 03 04 05 06 10 12 2)
00-200
Sleeve nut (elbow end)
07376-70210 07376-70315 07376-70422 07376-70522 07376-70628 07376-71034 07376-71234
02789-20210 02789-20315 02789-20422 02789-20522 02789-20628 07221-21034 07221-21234
Split flange type hoses and tubes Nominal number 04 05
3)
Plug (nut end)
Flange (hose end)
Sleeve head (tube end)
Split flange
07379-00400 07379-00500
07378-10400 07378-10500
07371-30400 07371-30500
If the part is not under hydraulic pressure, the following corks can be used. Nominal number
Part Number
06 08 10 12 14 16 18 20 22 24
07049-00608 07049-00811 07049-01012 07049-01215 07049-01418 07049-01620 07049-01822 07049-02025 07049-02228 07049-02430
D 6 8 10 12 14 16 18 20 22 24
27
07049-02734
27
26
Dimensions d L 5 8 6.5 11 8.5 12 10 15 11.5 18 13.5 20 15 22 17 25 18.5 28 20 30 22.5
34
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200 Foreword and general information Precautions when carrying out operation
2. q q q q q q q q q q q q q
a
a 3.
SEN04932-01
Precautions when carrying out installation work Tighten all bolts and nuts (sleeve nuts) to the specified (KES) torque. Install the hoses without twisting or interference and fix them with intermediate clamps, if there are any. Replace all gaskets, O-rings, cotter pins, and lock plates with new parts. Bend the cotter pins and lock plates securely. When coating with adhesive, clean the part and remove all oil and grease, then coat the threaded portion with 2 – 3 drops of adhesive. When coating with gasket sealant, clean the surface and remove all oil and grease, check that there is no dirt or damage, then coat uniformly with gasket sealant. Clean all parts, and correct any damage, dents, burrs, or rust. Coat rotating parts and sliding parts with engine oil. When press fitting parts, coat the surface with anti-friction compound (LM-P). After fitting snap rings, check that the snap ring is fitted securely in the ring groove. When connecting wiring connectors, clean the connector to remove all oil, dirt, or water, then connect securely. When using eyebolts, check that there is no deformation or deterioration, screw them in fully, and align the direction of the hook. When tightening split flanges, tighten uniformly in turn to prevent excessive tightening on one side. When operating the hydraulic cylinders for the first time after reassembling cylinders, pumps and other hydraulic equipment removed for repair, always bleed the air as follows: 1) Start the engine and run at low idle. 2) Operate the work equipment control lever to operate the hydraulic cylinder 4 – 5 times, stopping the cylinder 100 mm from the end of its stroke. 3) Next, operate the hydraulic cylinder 3 – 4 times to the end of its stroke. 4) After doing this, run the engine at normal speed. When using the machine for the first time after repair or long storage, follow the same procedure. Precautions when completing the operation 1) Refilling with coolant, oil and grease q If the coolant has been drained, tighten the drain valve, and add coolant to the specified level. Run the engine to circulate the coolant through the system. Then check the coolant level again. q If the hydraulic equipment has been removed and installed again, add engine oil to the specified level. Run the engine to circulate the oil through the system. Then check the oil level again. q If the piping or hydraulic equipment have been removed, always bleed the air from the system after reassembling the parts. a For details, see Testing and adjusting, “Bleeding air”. q Add the specified amount of grease (molybdenum disulphide grease) to the work equipment parts. 2) Checking cylinder head and manifolds for looseness Check the cylinder head and intake and exhaust manifold for looseness. If any part is loosened, retighten it. q For the tightening torque, see “Disassembly and assembly”. 3) Checking engine piping for damage and looseness Intake and exhaust system Check the piping for damage, the mounting bolts and nuts for looseness, and the joints for air suction and exhaust gas leakage. If any part is loosened or damaged, retighten or repair it. Cooling system Check the piping for damage, the mounting bolts and nuts for looseness, and the joints for coolant leakage. If any part is loosened or damaged, retighten or repair it. Fuel system Check the piping for damage, the mounting bolts and nuts for looseness, and the joints for fuel leakage. If any part is loosened or damaged, retighten or repair it.
D65EX, PX, WX-16
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SEN04932-01 4)
5)
00-200
200 Foreword and general information Precautions when carrying out operation
Checking muffler and exhaust pipe for damage and looseness 1] Visually check the muffler, exhaust pipe and their mounting parts for a crack and damage. If any part is damaged, replace it. 2] Check the mounting bolts and nuts of the muffler, exhaust pipe and their mounting parts for looseness. If any bolt or nut is loosened, retighten it. Checking muffler function Check the muffler for abnormal sound and sound different from that of a new muffler. If any abnormal sound is heard, repair the muffler, referring to “Troubleshooting” and “Disassembly and assembly”.
28
D65EX, PX, WX-16
200 Foreword and general information Method of disassembling and connecting push-pull type coupler
SEN04932-01
Method of disassembling and connecting push-pull type coupler k k
1
Before carrying out the following work, loosen the oil filler cap of the hydraulic tank gradually to release the residual pressure from the hydraulic tank. Even if the residual pressure is released from the hydraulic tank, some hydraulic oil flows out when the hose is disconnected. Accordingly, prepare an oil receiving container.
Type 1 1.
Disconnection 1) Hold adapter (1) and push hose joint (2) into mating adapter (3). (Fig. 1) a The adapter can be pushed in about 3.5 mm. a Do not hold rubber cap portion (4). 2) After hose joint (2) is pushed into adapter (3), press rubber cap portion (4) against adapter (3) until it clicks. (Fig. 2) 3) Hold hose adapter (1) or hose (5) and pull it out. (Fig. 3) a Since some hydraulic oil flows out, prepare an oil receiving container.
2.
Connection 1) Hold hose adapter (1) or hose (5) and insert it in mating adapter (3), aligning them with each other. (Fig. 4) a Do not hold rubber cap portion (4). 2) After inserting the hose in the mating adapter perfectly, pull it back to check its connecting condition. (Fig. 5) a When the hose is pulled back, the rubber cap portion moves toward the hose about 3.5 mm. This does not indicate abnormality, however.
D65EX, PX, WX-16
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SEN04932-01
200 Foreword and general information Method of disassembling and connecting push-pull type coupler
Type 2 1.
2.
Disconnection 1) Hold the tightening portion and push body (7) straight until sliding prevention ring (6) contacts contact surface (a) of the hexagonal portion at the male end. (Fig. 6) 2) While holding the condition of Step 1), turn lever (8) to the right (clockwise). (Fig. 7) 3) While holding the condition of Steps 1) and 2), pull out whole body (7) to disconnect it. (Fig. 8)
Connection Hold the tightening portion and push body (7) straight until sliding prevention ring (6) contacts contact surface (a) of the hexagonal portion at the male end. (Fig. 9)
q
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D65EX, PX, WX-16
200 Foreword and general information Method of disassembling and connecting push-pull type coupler
SEN04932-01
Type 3 1.
2.
Disconnection 1) Hold the tightening portion and push body (9) straight until sliding prevention ring (8) contacts contact surface (b) of the hexagonal portion at the male end. (Fig. 10) 2) While holding the condition of Step 1), push cover (10) straight until it contacts contact surface (b) of the hexagonal portion at the male end. (Fig. 11) 3) While holding the condition of Steps 1) and 2), pull out whole body (9) to disconnect it. (Fig. 12)
Connection Hold the tightening portion and push body (9) straight until the sliding prevention ring contacts contact surface (b) of the hexagonal portion at the male end. (Fig. 13)
q
D65EX, PX, WX-16
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200 Foreword and general information Standard tightening torque table
SEN04932-01
Standard tightening torque table 1.
1
Table of tightening torques for bolts and nuts a Unless there are special instructions, tighten metric nuts and bolts to the torque below. a
The following table applies to the bolts in Fig. A.
Thread diameter of bolt mm 6 8 10 12 14 16 18 20 22 24 27 30 33 36 39 a
Width across flats mm 10 13 17 19 22 24 27 30 32 36 41 46 50 55 60
Tightening torque Nm 11.8 – 14.7 27 – 34 59 – 74 98 – 123 157 – 196 245 – 309 343 – 427 490 – 608 662 – 829 824 – 1,030 1,180 – 1,470 1,520 – 1,910 1,960 – 2,450 2,450 – 3,040 2,890 – 3,630
kgm 1.2 – 1.5 2.8 – 3.5 6.0 – 7.5 10.0 – 12.5 16 – 20 25 – 31.5 35 – 43.5 50 – 62 67.5 – 84.5 84 – 105 120 – 150 155 – 195 200 – 250 250 – 310 295 – 370
The following table applies to the bolts in Fig. B.
Thread diameter of bolt mm 6 8 10 12 a Fig. A
Width across flats mm 10 12 14 17
Tightening torque Nm 5.9 – 9.8 13.7 – 23.5 34.3 – 46.1 74.5 – 90.2
kgm 0.6 – 1.0 1.4 – 2.4 3.5 – 4.7 7.6 – 9.2
a Fig. B
Remarks: The widths across flats against the thread diameters of flanged bolts (marks with "*") in Fig. A are the ones indicated in the table for bolts shown in Fig. B. (Values of tightening torques shown in the table for Fig. A are applied.)
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D65EX, PX, WX-16
200 Foreword and general information Standard tightening torque table
2.
Table of tightening torques for split flange bolts a Unless there are special instructions, tighten split flange bolts to the torque below.
Thread diameter of bolt mm 10 12 16
3.
Width across flats mm 14 17 22
Tightening torque Nm kgm 59 – 74 6.0 – 7.5 98 – 123 10.0 – 12.5 235 – 285 23.5 – 29.5
Table of tightening torques for O-ring boss piping joints a Unless there are special instructions, tighten O-ring boss piping joints to the torque below.
Nominal No. 02 03,04 05,06 10,12 14
4.
SEN04932-01
Thread diameter mm 14 20 24 33 42
Width across flats mm
Tightening torque Nm {kgm} Range Target 44 { 4.5} 35 – 63 { 3.5 – 6.5} 84 – 132 { 8.5 – 13.5} 103 {10.5} Varies depending 157 {16.0} on type of connec- 128 – 186 {13.0 – 19.0} tor. 363 – 480 {37.0 – 49.0} 422 {43.0} 746 – 1,010 {76.0 – 103} 883 {90.0}
Table of tightening torques for O-ring boss plugs a Unless there are special instructions, tighten O-ring boss plugs to the torque below. Nominal No. 08 10 12 14 16 18 20 24 30 33 36 42 52
Thread diameter mm 8 10 12 14 16 18 20 24 30 33 36 42 52
D65EX, PX, WX-16
Width across flats mm 14 17 19 22 24 27 30 32 32 – 36 – –
Tightening torque Nm {kgm} Range Target 5.88 – 8.82 {0.6 – 0.9} 7.35 {0.75} 9.81 – 12.74 {1.0 – 1.3} 11.27 {1.15} 14.7 – 19.6 {1.5 – 2.0} 17.64 {1.8} 19.6 – 24.5 {2.0 – 2.5} 22.54 {2.3} 24.5 – 34.3 {2.5 – 3.5} 29.4 {3.0} 34.3 – 44.1 {3.5 – 4.5} 39.2 {4.0} 44.1 – 53.9 {4.5 – 5.5} 49.0 {5.0} 58.8 – 78.4 {6.0 – 8.0} 68.6 {7.0} 93.1 – 122.5 { 9.5 – 12.5} 107.8 {11.0} 107.8 – 147.0 {11.0 – 15.0} 127.4 {13.0} 127.4 – 176.4 {13.0 – 18.0} 151.9 {15.5} 181.3 – 240.1 {18.5 – 24.5} 210.7 {21.5} 274.4 – 367.5 {28.0 – 37.5} 323.4 {33.0}
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200 Foreword and general information Standard tightening torque table
SEN04932-01 5.
Table of tightening torques for hoses (taper seal type and face seal type) a Unless there are special instructions, tighten the hoses (taper seal type and face seal type) to the torque below. a Apply the following torque when the threads are coated (wet) with engine oil. Tightening torque Nm {kgm}
Nominal No. of hose
Width across flats
02
19 22 24 27 32 36 41 46 55
03 04 05 06 (10) (12) (14)
6.
Range 34 – 54 { 3.5 – 5.5} 34 – 63 { 3.5 – 6.5} 54 – 93 { 5.5 – 9.5} 59 – 98 { 6.0 – 10.0} 84 – 132 { 8.5 – 13.5} 128 – 186 {13.0 – 19.0} 177 – 245 {18.0 – 25.0} 177 – 245 {18.0 – 25.0} 197 – 294 {20.0 – 30.0} 246 – 343 {25.0 – 35.0}
Target
44 { 4.5} 74 { 7.5} 78 { 8.0} 103 {10.5} 157 {16.0} 216 {22.0} 216 {22.0} 245 {25.0} 294 {30.0}
Taper seal Thread size (mm) – 14 – 18 22 24 30 33 36 42
Face seal Nominal No. – Thread Number of diameter (mm) threads, type of (Reference) 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 – – – – – –
Table of tightening torques for face seal joints a Tighten the face seal joints (sleeve nut type) made of plated steel pipes for low pressure service to be used for engines etc. to the torque shown in the following table. a Apply the following torque to the face seal joint while their threaded parts are coated with engine oil (wetted).
Outer diameter of pipe (mm)
Width across flats (mm)
8 10 12 15 (16) 22 (20)
19 22 24 (27) 30 (32) 36
Tightening torque Nm {kgm} Range
Target
14 – 16 {1.4 – 1.6} 24 – 27 {2.4 – 2.7} 43 – 47 {4.4 – 4.8} 60 – 68 {6.1 – 6.8} 90 – 95 {9.2 – 9.7}
15 {1.5} 25.5 {2.6} 45 {4.6} 64 {6.5} 92.5 {9.4}
Face seal Nominal No. – Thread diameter Number of threads, (mm) type of thread (Reference) 9/16-18UN 14.3 11/16-16UN 17.5 13/16-16UN 20.6 1-14UN 25.4 1-3/16-12UN 30.2
Reference: The face seal joints of the dimensions in ( ) are also used, depending on the specification.
7.
Table of tightening torques for 102, 107 and 114 engine series (Bolts and nuts) a Unless there are special instructions, tighten the metric bolts and nuts of the 102, 107 and 114 engine series to the torque below. Tightening torque Bolts and nuts
Thread size mm 6 8 10 12 14
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34
Nm 10 ± 2 24 ± 4 43 ± 6 77 ± 12 —
kgm 1.02 ± 0.20 2.45 ± 0.41 4.38 ± 0.61 7.85 ± 1.22 —
D65EX, PX, WX-16
200 Foreword and general information Standard tightening torque table
8.
Table of tightening torques for 102, 107 and 114 engine series (Eye joints) a Unless there are special instructions, tighten the metric eye joints of the 102, 107 and 114 engine series to the torque below. Thread size mm 6 8 10 12 14
9.
SEN04932-01
Tightening torque Nm 8±2 10 ± 2 12 ± 2 24 ± 4 36 ± 5
kgm 0.81 ± 0.20 1.02 ± 0.20 1.22 ± 0.20 2.45 ± 0.41 3.67 ± 0.51
Table of tightening torques for 102, 107 and 114 engine series (Taper screws) a Unless there are special instructions, tighten the taper screws (unit: inch) of the 102, 107 and 114 engine series to the torque below.
Material Thread size (inch) 1/16 1/8 1/4 3/8 1/2 3/4
D65EX, PX, WX-16
Tightening torque In aluminum In cast iron or steel Nm kgm Nm kgm 15 ± 2 1.53 ± 0.20 5±1 0.51 ± 0.10 20 ± 2 2.04 ± 0.20 15 ± 2 1.53 ± 0.20 25 ± 3 2.55 ± 0.31 20 ± 2 2.04 ± 0.20 35 ± 4 3.57 ± 0.41 25 ± 3 2.55 ± 0.31 55 ± 6 5.61 ± 0.61 35 ± 4 3.57 ± 0.41 75 ± 8 7.65 ± 0.82 45 ± 5 4.59 ± 0.51
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200 Foreword and general information Conversion table
SEN04932-01
Conversion table
1
Method of using the conversion table The conversion table in this section is provided to enable simple conversion of figures. For details of the method of using the conversion table, see the example given below. Example: Method of using the conversion table to convert from millimeters to inches 1.
Convert 55 mm into inches. 1) Locate the number 50 in the vertical column at the left side, take this as (A), and then draw a horizontal line from (A). 2) Locate the number 5 in the row across the top, take this as (B), then draw a perpendicular line down from (B). 3) Take the point where the 2 lines cross as (C). This point (C) gives the value when converting from millimeters to inches. Therefore, 55 mm = 2.165 inches.
2.
Convert 550 mm into inches. 1) The number 550 does not appear in the table, so divide it by 10 (move the decimal point one place to the left) to convert it to 55 mm. 2) Carry out the same procedure as above to convert 55 mm to 2.165 inches. 3) The original value (550 mm) was divided by 10, so multiply 2.165 inches by 10 (move the decimal point one place to the right) to return to the original value. This gives 550 mm = 21.65 inches.
Millimeters to inches
(A)
00-200
(B)
0 10 20 30 40
0 0 0.394 0.787 1.181 1.575
1 0.039 0.433 0.827 1.220 1.614
2 0.079 0.472 0.866 1.260 1.654
3 0.118 0.512 0.906 1.299 1.693
4 0.157 0.551 0.945 1.339 1.732
50 60 70 80 90
1.969 2.362 2.756 3.150 3.543
2.008 2.402 2.795 3.189 3.583
2.047 2.441 2.835 3.228 3.622
2.087 2.480 2.874 3.268 3.661
2.126 2.520 2.913 3.307 3.701
36
5 0.197 0.591 0.984 1.378 1.772 (C) 2.165 2.559 2.953 3.346 3.740
6 0.236 0.630 1.024 1.417 1.811
1 mm = 0.03937 in 7 8 9 0.276 0.315 0.354 0.669 0.709 0.748 1.063 1.102 1.142 1.457 1.496 1.536 1.850 1.890 1.929
2.205 2.598 2.992 3.386 3.780
2.244 2.638 3.032 3.425 3.819
2.283 2.677 3.071 3.465 3.858
2.323 2.717 3.110 3.504 3.898
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200 Foreword and general information Conversion table
SEN04932-01
Millimeters to inches 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
0 10 20 30 40
0 0 0.394 0.787 1.181 1.575
1 0.039 0.433 0.827 1.220 1.614
2 0.079 0.472 0.866 1.260 1.654
3 0.118 0.512 0.906 1.299 1.693
4 0.157 0.551 0.945 1.339 1.732
5 0.197 0.591 0.984 1.378 1.772
6 0.236 0.630 1.024 1.417 1.811
7 0.276 0.669 1.063 1.457 1.850
50 60 70 80 90
1.969 2.362 2.756 3.150 3.543
2.008 2.402 2.795 3.189 3.583
2.047 2.441 2.835 3.228 3.622
2.087 2.480 2.874 3.268 3.661
2.126 2.520 2.913 3.307 3.701
2.165 2.559 2.953 3.346 3.740
2.205 2.598 2.992 3.386 3.780
2.244 2.638 3.032 3.425 3.819
1 kg = 2.2046 lb 6 7 8 9 13.23 15.43 17.64 19.84 35.27 37.48 39.68 41.89 57.32 59.53 61.73 63.93 79.37 81.57 83.78 85.98 101.41 103.62 105.82 108.03
2.283 2.677 3.071 3.465 3.858
2.323 2.717 3.110 3.504 3.898
Kilogram to pound
0 10 20 30 40
0 0 22.05 44.09 66.14 88.18
1 2.20 24.25 46.30 68.34 90.39
2 4.41 26.46 48.50 70.55 92.59
3 6.61 28.66 50.71 72.75 94.80
4 8.82 30.86 51.91 74.96 97.00
5 11.02 33.07 55.12 77.16 99.21
50 60 70 80 90
110.23 132.28 154.32 176.37 198.42
112.44 134.48 156.53 178.57 200.62
114.64 136.69 158.73 180.78 202.83
116.85 138.89 160.94 182.98 205.03
119.05 141.10 163.14 185.19 207.24
121.25 143.30 165.35 187.39 209.44
0 10 20 30 40
0 1 2 0 0.264 0.528 2.642 2.906 3.170 5.283 5.548 5.812 7.925 8.189 8.454 10.567 10.831 11.095
3 0.793 3.434 6.076 8.718 11.359
4 1.057 3.698 6.340 8.982 11.624
1 l = 0.2642 U.S.Gal 5 6 7 8 9 1.321 1.585 1.849 2.113 2.378 3.963 4.227 4.491 4.755 5.019 6.604 6.869 7.133 7.397 7.661 9.246 9.510 9.774 10.039 10.303 11.888 12.152 12.416 12.680 12.944
50 60 70 80 90
13.209 15.850 18.492 21.134 23.775
14.001 16.643 19.285 21.926 24.568
14.265 16.907 19.549 22.190 24.832
14.529 17.171 19.813 22.455 25.096
123.46 145.51 167.55 189.60 211.64
125.66 147.71 169.76 191.80 213.85
127.87 149.91 171.96 194.01 216.05
130.07 152.12 174.17 196.21 218.26
Liters to U.S. Gallons
13.473 16.115 18.756 21.398 24.040
D65EX, PX, WX-16
13.737 16.379 19.020 21.662 24.304
14.795 17.435 20.077 22.719 25.361
15.058 17.700 20.341 22.983 25.625
15.322 17.964 20.605 23.247 25.889
15.586 18.228 20.870 23.511 26.153
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200 Foreword and general information Conversion table
SEN04932-01
Liters to U.K. Gallons 1 l = 0.21997 U.K.Gal 6 7 8 9 1.760 1.980 1.320 1.540 3.520 3.740 3.950 4.179 5.719 5.939 6.159 6.379 7.919 8.139 8.359 8.579 10.119 10.339 10.559 10.778
0 10 20 30 40
0 0 2.200 4.399 6.599 8.799
1 0.220 2.420 4.619 6.819 9.019
2 0.440 2.640 4.839 7.039 9.239
3 0.660 2.860 5.059 7.259 9.459
4 0.880 3.080 5.279 7.479 9.679
5 1.100 3.300 5.499 7.699 9.899
50 60 70 80 90
10.998 13.198 15.398 17.598 19.797
11.281 13.418 15.618 17.818 20.017
11.438 13.638 15.838 18.037 20.237
11.658 13.858 16.058 18.257 20.457
11.878 14.078 16.278 18.477 20.677
12.098 14.298 16.498 18.697 20.897
12.318 14.518 16.718 18.917 21.117
12.528 14.738 16.938 19.137 21.337
0 10 20 30 40
0 0 72.3 144.7 217.0 289.3
1 7.2 79.6 151.9 224.2 296.6
2 14.5 86.8 159.1 231.5 303.8
3 21.7 94.0 166.4 238.7 311.0
4 28.9 101.3 173.6 245.9 318.3
5 36.2 108.5 180.8 253.2 325.5
6 43.4 115.7 188.1 260.4 332.7
7 50.6 123.0 195.3 267.6 340.0
50 60 70 80 90
361.7 434.0 506.3 578.6 651.0
368.9 441.2 513.5 585.9 658.2
376.1 448.5 520.8 593.1 665.4
383.4 455.7 528.0 600.3 672.7
390.6 462.9 535.2 607.6 679.9
397.8 470.2 542.5 614.8 687.1
405.1 477.4 549.7 622.0 694.4
412.3 484.6 556.9 629.3 701.6
12.758 14.958 17.158 19.357 21.557
12.978 15.178 17.378 19.577 21.777
kgm to ft.lb 1 kgm = 7.233 ft.lb 8 9 57.9 65.1 130.2 137.4 202.5 209.8 274.9 282.1 347.2 354.4 419.5 491.8 564.2 636.5 708.8
426.8 499.1 571.4 643.7 716.1
100 110 120 130 140
723.3 730.5 737.8 745.0 752.2 759.5 766.7 773.9 781.2 788.4 795.6 802.9 810.1 817.3 824.6 831.8 839.0 846.3 853.5 860.7 875.2 882.4 889.7 896.9 904.1 911.4 918.6 925.8 933.1 868.0 940.3 947.5 954.8 962.0 969.2 976.5 983.7 990.9 998.2 1005.4 1012.6 1019.9 1027.1 1034.3 1041.5 1048.8 1056.0 1063.2 1070.5 1077.7
150 160 170 180 190
1084.9 1157.3 1129.6 1301.9 1374.3
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38
1092.2 1164.5 1236.8 1309.2 1381.5
1099.4 1171.7 1244.1 1316.4 1388.7
1106.6 1179.0 1251.3 1323.6 1396.0
1113.9 1186.2 1258.5 1330.9 1403.2
1121.1 1193.4 1265.8 1338.1 1410.4
1128.3 1200.7 1273.0 1345.3 1417.7
1135.6 1207.9 1280.1 1352.6 1424.9
1142.8 1215.1 1287.5 1359.8 1432.1
1150.0 1222.4 1294.7 1367.0 1439.4
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200 Foreword and general information Conversion table
SEN04932-01
kg/cm2 to lb/in2
0 10 20 30 40
0 0 142.2 284.5 426.7 568.9
1 14.2 156.5 298.7 440.9 583.2
2 28.4 170.7 312.9 455.1 597.4
3 42.7 184.9 327.1 469.4 611.6
4 56.9 199.1 341.4 483.6 625.8
5 71.1 213.4 355.6 497.8 640.1
6 85.3 227.6 369.8 512.0 654.3
1 kg/cm2 = 14.2233 lb/in2 7 8 9 99.6 113.8 128.0 241.8 256.0 270.2 384.0 398.3 412.5 526.3 540.5 554.7 668.5 682.7 696.9
50 60 70 80 90
711.2 853.4 995.6 1,138 1,280
725.4 867.6 1,010 1,152 1,294
739.6 881.8 1,024 1,166 1,309
753.8 896.1 1,038 1,181 1,323
768.1 910.3 1,053 1,195 1,337
782.3 924.5 1,067 1,209 1,351
796.5 938.7 1,081 1,223 1,365
810.7 953.0 1,095 1,237 1,380
825.0 967.2 1,109 1,252 1,394
839.2 981.4 1,124 1,266 1,408
100 110 120 130 140
1,422 1,565 1,707 1,849 1,991
1,437 1,579 1,721 1,863 2,005
1,451 1,593 1,735 1,877 2,020
1,465 1,607 1,749 1,892 2,034
1,479 1,621 1,764 1,906 2,048
1,493 1,636 1,778 1,920 2,062
1,508 1,650 1,792 1,934 2,077
1,522 1,664 1,806 1,949 2,091
1,536 1,678 1,821 1,963 2,105
1,550 1,693 1,835 1,977 2,119
150 160 170 180 190
2,134 2,276 2,418 2,560 2,702
2,148 2,290 2,432 2,574 2,717
2,162 2,304 2,446 2,589 2,731
2,176 2,318 2,460 2,603 2,745
2,190 2,333 2,475 2,617 2,759
2,205 2,347 2,489 2,631 2,773
2,219 2,361 2,503 2,646 2,788
2,233 2,375 2,518 2,660 2,802
2,247 2,389 2,532 2,674 2,816
2,262 2,404 2,546 2,688 2,830
200 210 220 230 240
2,845 2,987 3,129 3,271 3,414
2,859 3,001 3,143 3,286 3,428
2,873 3,015 3,158 3,300 3,442
2,887 3,030 3,172 3,314 3,456
2,901 3,044 3,186 3,328 3,470
2,916 3,058 3,200 3,343 3,485
2,930 3,072 3,214 3,357 3,499
2,944 3,086 3,229 3,371 3,513
2,958 3,101 3,243 3,385 3,527
2,973 3,115 3,257 3,399 3,542
D65EX, PX, WX-16
00-200
39
200 Foreword and general information Conversion table
SEN04932-01 Temperature
Fahrenheit-Centigrade conversion: A simple way to convert a Fahrenheit temperature reading into a Centigrade temperature reading or vice versa is to enter the accompanying table in the center (boldface column) of figures. These figures refer to the temperature in either Fahrenheit or Centigrade degrees. When convert from Fahrenheit to Centigrade degrees, consider the center column to be a table of Fahrenheit temperatures and read the corresponding Centigrade temperature in the column at the left. When convert from Centigrade to Fahrenheit degrees, consider the center column to be a table of Centigrade values, and read the corresponding Fahrenheit temperature on the right.
°C
°F
°C
°F
°C
°F
°C
1°C = 33.8°F °F
–40.4 –37.2 –34.4 –31.7 –28.9
–40 –35 –30 –25 –20
–40.0 –31.0 –22.0 –13.0 –4.0
–11.7 –11.1 –10.6 –10.0 –9.4
11 12 13 14 15
51.8 53.6 55.4 57.2 59.0
7.8 8.3 8.9 9.4 10.0
46 47 48 49 50
114.8 116.6 118.4 120.2 122.0
27.2 27.8 28.3 28.9 29.4
81 82 83 84 85
177.8 179.6 181.4 183.2 185.0
–28.3 –27.8 –27.2 –26.7 –26.1
–19 –18 –17 –16 –15
–2.2 –0.4 1.4 3.2 5.0
–8.9 –8.3 –7.8 –7.2 –6.7
16 17 18 19 20
60.8 62.6 64.4 66.2 68.0
10.6 11.1 11.7 12.2 12.8
51 52 53 54 55
123.8 125.6 127.4 129.2 131.0
30.0 30.6 31.1 31.7 32.2
86 87 88 89 90
186.8 188.6 190.4 192.2 194.0
–25.6 –25.0 –24.4 –23.9 –23.3
–14 –13 –12 –11 –10
6.8 8.6 10.4 12.2 14.0
–6.1 –5.6 –5.0 –4.4 –3.9
21 22 23 24 25
69.8 71.6 73.4 75.2 77.0
13.3 13.9 14.4 15.0 15.6
56 57 58 59 60
132.8 134.6 136.4 138.2 140.0
32.8 33.3 33.9 34.4 35.0
91 92 93 94 95
195.8 197.6 199.4 201.2 203.0
–22.8 –22.2 –21.7 –21.1 –20.6
–9 –8 –7 –6 –5
15.8 17.6 19.4 21.2 23.0
–3.3 –2.8 –2.2 –1.7 –1.1
26 27 28 29 30
78.8 80.6 82.4 84.2 86.0
16.1 16.7 17.2 17.8 18.3
61 62 63 64 65
141.8 143.6 145.4 147.2 149.0
35.6 36.1 36.7 37.2 37.8
96 97 98 99 100
204.8 206.6 208.4 210.2 212.0
–20.0 –19.4 –18.9 –18.3 –17.8
–4 –3 –2 –1 0
24.8 26.6 28.4 30.2 32.0
–0.6 0 0.6 1.1 1.7
31 32 33 34 35
87.8 89.6 91.4 93.2 95.0
18.9 19.4 20.0 20.6 21.1
66 67 68 69 70
150.8 152.6 154.4 156.2 158.0
40.6 43.3 46.1 48.9 51.7
105 110 115 120 125
221.0 230.0 239.0 248.0 257.0
–17.2 –16.7 –16.1 –15.6 –15.0
1 2 3 4 5
33.8 35.6 37.4 39.2 41.0
2.2 2.8 3.3 3.9 4.4
36 37 38 39 40
96.8 98.6 100.4 102.2 104.0
21.7 22.2 22.8 23.3 23.9
71 72 73 74 75
159.8 161.6 163.4 165.2 167.0
54.4 57.2 60.0 62.7 65.6
130 135 140 145 150
266.0 275.0 284.0 293.0 302.0
–14.4 –13.9 –13.3 –12.8 –12.2
6 7 8 9 10
42.8 44.6 46.4 48.2 50.0
5.0 5.6 6.1 6.7 7.2
41 42 43 44 45
105.8 107.6 109.4 111.2 113.0
24.4 25.0 25.6 26.1 26.7
76 77 78 79 80
168.8 170.6 172.4 174.2 176.0
68.3 71.1 73.9 76.7 79.4
155 160 165 170 175
311.0 320.0 329.0 338.0 347.0
00-200
40
D65EX, PX, WX-16
200 Foreword and general information Conversion table
D65EX, PX, WX-16
SEN04932-01
00-200
41
SEN04932-01
D65EX-16, D65PX-16, D65WX-16 Bulldozer Form No. SEN04932-01
©2009 KOMATSU All Rights Reserved Printed in Japan 07-09
00-200
42
SEN04933-02
BULLDOZER D65EX-16 D65PX-16 D65WX-16 Machine model D65EX-16 D65PX-16 D65WX-16
Serial number 80001 and up 80001 and up 80001 and up
01 General
1
100 Specification and technical data Specification dimension drawing..................................................................................................................... 2 Specifications .................................................................................................................................................. 6 Weight table .................................................................................................................................................. 18 Table of fuel, coolant and lubricants.............................................................................................................. 22
D65EX, PX, WX-16
01-100
1
100 Specification and technical data Specification dimension drawing
SEN04933-02
Specification dimension drawing
1
D65EX-16: With ROPS cab and air conditioner
Item
Unit
Machine weight
kg
Engine model
—
D65EX-16
D65EX-16
Sigma dozer
Power angle power tilt dozer
19,430 [19,750]
20,910 [21,230]
Komatsu SAA6D114E-3 diesel engine
Engine rated output • Net [ISO 9249/SAE J1349](*1) • Gross [SAE J1995](*2)
153 {205}/1,950
kW{HP}/rpm
154.5 {207}/1,950
A Overall length
mm
5,490
5,790
B Overall height (excluding antenna)
mm
3,155 [3,160]
3,155 [3,160]
C Overall width
mm
3,410
3,870
Travel speed [1st/2nd/3rd (Low)/3rd]
Forward
km/h
3.6/5.5/7.2/11.2
Reverse
km/h
4.4/6.6/8.6/13.4
Track shoe • Type
—
• Width
mm
510
560
—
Hitch
Counterweight
Rear work equipment
Single grouser
Single grouser
Values in [ ] are shown for machine equipped with PLUS type track shoe. *1: Indicates the value of minimum cooling fan speed. *2: Indicates the value of the stand-alone engine (without cooling fan). a The engine rated horsepower is displayed in the net value and gross value. Gross denotes the rated output measured of an independent engine. While, net denotes the value measured of an engine under the condition essentially the same as that when it is installed on machine. a Following shows the rated horsepower (net output power) at the maximum cooling fan speed. 139 kW {186 HP}/1,950 rpm a Following shows the maximum gross value of the engine output power. 163.7 kW {219 HP}/1,950 rpm
01-100
2
D65EX, PX, WX-16
100 Specification and technical data Specification dimension drawing
SEN04933-02
D65EX-16: With FRP canopy
Item
Unit
D65EX-16 Straight tilt dozer
Machine weight
kg
18,630
Engine model
—
Komatsu SAA6D114E-3 diesel engine
Engine rated output • Net [ISO 9249/SAE J1349](*1)
kW{HP}/rpm
• Gross [SAE J1995](*2)
153 {205}/1,950 154.5 {207}/1,950
A Overall length
mm
5,330
B Overall height (excluding antenna)
mm
3,125
C Overall width
mm
3,415
Forward
km/h
3.6/5.5/7.2/11.2
Reverse
km/h
4.4/6.6/8.6/13.4
• Type
—
Single grouser
• Width
mm
510
—
Hitch
Travel speed [1st/2nd/3rd (Low)/3rd] Track shoe
Rear work equipment
Values in [ ] are shown for machine equipped with PLUS type track shoe. *1: Indicates the value of minimum cooling fan speed. *2: Indicates the value of the stand-alone engine (without cooling fan). a The engine rated horsepower is displayed in the net value and gross value. Gross denotes the rated output measured of an independent engine. While, net denotes the value measured of an engine under the condition essentially the same as that when it is installed on machine. a Following shows the rated horsepower (net output power) at the maximum cooling fan speed. 139 kW {186 HP}/1,950 rpm a Following shows the maximum gross value of the engine output power. 163.7 kW {219 HP}/1,950 rpm
D65EX, PX, WX-16
01-100
3
100 Specification and technical data Specification dimension drawing
SEN04933-02 D65PX-16: With ROPS cab and air conditioner
Item
Unit
Machine weight
kg
Engine model
—
D65PX-16
D65PX-16
Straight tilt dozer
Power angle power tilt dozer
20,910 [21,230]
21,780 [22,120]
Komatsu SAA6D114E-3 diesel engine
Engine rated output • Net [ISO 9249/SAE J1349](*1) • Gross [SAE J1995](*2)
153 {205}/1,950
kW{HP}/rpm
154.5 {207}/1,950
A Overall length
mm
5,680
5,790
B Overall height (excluding antenna)
mm
3,155 [3,160]
3,155 [3,160]
C Overall width
mm
3,970
4,010
Travel speed [1st/2nd/3rd (Low)/3rd]
Forward
km/h
3.6/5.5/7.2/11.2
Reverse
km/h
4.4/6.6/8.6/13.4
Track shoe Type
—
Width
mm
915
760
—
Hitch
Hitch
Rear work equipment
Single grouser
Single grouser
Values in [ ] are shown for machine equipped with PLUS type track shoe. *1: Indicates the value of the minimum cooling fan speed. *2: Indicates the value of the stand-alone engine (without cooling fan). a The engine rated horsepower is displayed in the net value and gross value. Gross denotes the rated horsepower measured of stand-alone engine. While, net denotes the value measured of an engine under the condition essentially the same as that when it is installed on machine. a The rated horsepower (net output power) at the maximum cooling fan speed is as follows. 139 kW {186 HP}/1,950 rpm a The maximum gross value of the engine output is as follows. 163.7 kW {219 HP}/1,950 rpm
01-100
4
D65EX, PX, WX-16
100 Specification and technical data Specification dimension drawing
SEN04933-02
D65WX-16: With ROPS cab and air conditioner
Item
Unit
Machine weight
kg
Engine model
—
D65WX-16
D65WX-16
Sigma dozer
Power angle power tilt dozer
20,290 [20,610]
21,810 [22,130]
Komatsu SAA6D114E-3 diesel engine
Engine rated output • Net [ISO 9249/SAE J1349](*1) • Gross [SAE J1995](*2)
153 {205}/1,950
kW{HP}/rpm
154.5 {207}/1,950
A Overall length
mm
5,500
5,790
B Overall height (excluding antenna)
mm
3,155 [3,160]
3,155 [3,160]
C Overall width
mm
3,580
4,010
Travel speed [1st/2nd/3rd (Low)/3rd]
Forward
km/h
3.6/5.5/7.2/11.2
Reverse
km/h
4.4/6.6/8.6/13.4
Track shoe • Type
—
• Width
mm
760
760
—
Hitch
Counterweight
Rear work equipment
Single grouser
Single grouser
Values in [ ] are shown for machine equipped with PLUS type track shoe. *1: Indicates the value of the minimum cooling fan speed. *2: Indicates the value of stand-alone the engine (without cooling fan). a The engine rated horsepower is displayed in the net value and gross value. Gross denotes the rated horsepower measured of stand-alone engine. While, net denotes the value measured of an engine under the condition essentially the same as that when it is installed on machine. a The rated horsepower (net output power) at the maximum cooling fan speed is as follows. 139 kW {186 HP}/1,950 rpm a The maximum gross value of the engine output is as follows. 163.7 kW {219 HP}/1,950 rpm
D65EX, PX, WX-16
01-100
5
100 Specification and technical data Specifications
SEN04933-02
Specifications
1
D65EX-16 Machine model/type Serial No.
Sigma dozer
Power angle power tilt dozer
Straight tilt dozer (with FRP canopy)
80001 and up
80001 and up
80001 and up
Weight
Machine weight • Stand-alone tractor with ROPS cab
kg
17,230 [17,360]
18,140 [18,270]
—
• Stand-alone tractor with FRP canopy
kg
—
—
16,570
• With work equipment
kg
19,430 [19,750]
20,910 [21,230]
18,630
• With work equipment and ripper
kg
(21,390) [(21,520)]
(22,870) [(23,000)]
—
m
— [Counter-rotation] — [Counter-rotation] — [Counter-rotation]
deg.
30
30
30
Stability (front/rear/left/right)
deg.
35
35
35
Forward 1st
km/h
3.6
3.6
3.6
Forward 2nd
km/h
5.5
5.5
5.5
Forward 3rd (Low)
km/h
7.2
7.2
7.2
Forward 3rd
km/h
11.2
11.2
11.2
Reverse 1st
km/h
4.4
4.4
4.4
km/h
6.6
6.6
6.6
km/h
8.6
8.6
8.6
Reverse 3rd
km/h
13.4
13.4
13.4
Stand-alone tractor with ROPS cab
kPa {kg/cm2}
55.8 {0.57} [56.2 {0.57}]
53.5 {0.55} [53.8 {0.55}]
— —
Stand-alone tractor with FRP canopy
kPa {kg/cm2}
— —
— —
53.4 {0.55}
With work equipment
kPa {kg/cm2}
63.5 {0.65} [63.9 {0.65}]
62.2 {0.63} [62.6 {0.64}]
60.1 {0.61}
With work equipment and ripper
kPa {kg/cm2}
(69.2 {0.71}) [(69.6 {0.71})]
(67.4 {0.69}) [(67.8 {0.69})]
— —
Bare tractor
mm
4,250
4,250
4,250
With work equipment
mm
5,490
5,790
5,330
Bare tractor
mm
2,390
2,610
2,390
With work equipment
mm
3,410
3,870
3,415
To top of exhaust pipe
mm
3,080 [3,085]
3,080 [3,085]
3,080
When ROPS cab is installed (excluding antenna)
mm
3,155 [3,160]
3,155 [3,160]
—
When ROPS canopy is installed
mm
3,155 [3,160]
3,155 [3,160]
—
When FRP canopy is installed
mm
—
—
3,125
Track gauge
mm
1,880
2,050
1,880
Length of track on ground
mm
2,980 [2,970]
2,980 [2,970]
2,980
Ground pressure
Reverse 2nd Reverse 3rd (Low)
Overall length
Travel speed
Gradeability
Dimensions Overall Overall height width
Performance
Min. turning radius
Track width (Standard track shoe)
mm
510
560
510
Min. ground clearance
mm
410 [415]
410 [415]
410
Values in ( ) are shown for reference. Values in [ ] are shown for machine equipped with PLUS type track shoe.
01-100
6
D65EX, PX, WX-16
100 Specification and technical data Specifications
SEN04933-02
D65PX-16
D65WX-16
Straight tilt dozer
Power angle power tilt dozer
Sigma dozer
Power angle power tilt dozer
80001 and up
80001 and up
80001 and up
80001 and up
19,000 [19,130]
19,000 [19,130]
17,980 [18,110]
19,010 [19,140]
—
—
—
—
20,910 [21,230]
21,780 [22,120]
20,290 [20,610]
21,810 [22,130]
—
—
(22,250) [(22,380)]
(23,770) [(23,900)]
— [Counter-rotation]
– [Counter-rotation]
– [Counter-rotation]
– [Counter-rotation]
30
30
30
30
35
35
35
35
3.6
3.6
3.6
3.6
5.5
5.5
5.5
5.5
7.2
7.2
7.2
7.2
11.2
11.2
11.2
11.2
4.4
4.4
4.4
4.4
6.6
6.6
6.6
6.6
8.6
8.6
8.6
8.6
13.4
13.4
13.4
13.4
31.1 {0.32} [31.3 {0.32}]
37.4 {0.38} [37.7 {0.38}]
39.1 {0.40} [39.3 {0.40}]
41.3 {0.42} [41.6 {0.42}]
— —
— —
— —
— —
34.5 {0.35} [34.7 {0.35}]
43.3 {0.44} [43.6 {0.44}]
44.5 {0.45} [44.8 {0.46}]
47.8 {0.49} [48.1 {0.49}]
—
—
(48.3 {0.49}) [(48.6 {0.50})]
(51.6 {0.53}) [(51.9 {0.53})]
4,360 [4,370]
4,360 [4,370]
4,250
4,250
5,680
5,790
5,500
5,790
2,965
2,990
2,810
2,990
3,970
4,010
3,580
4,010
3,080 [3,085]
3,080 [3,085]
3,080 [3,085]
3,080 [3,085]
3,155 [3,160]
3,155 [3,160]
3,155 [3,160]
3,155 [3,160]
3,155 [3,160]
3,155 [3,160]
3,155 [3,160]
3,155 [3,160]
—
—
—
—
2,050
2,230
2,050
2,230
3,285 [3,275]
3,285 [3,275]
2,980 [2,970]
2,980 [2,970]
915
760
760
760
410 [415]
410 [415]
410 [415]
410 [415]
D65EX, PX, WX-16
01-100
7
100 Specification and technical data Specifications
SEN04933-02
D65EX-16 Machine model/type Serial No.
Power angle power tilt dozer
Straight tilt dozer
80001 and up
80001 and up
80001 and up
Model
SAA6D114E-3
Type
4-cycle, water-cooled, in-line vertical, direct injection type, with turbocharger and air-cooled aftercooler
No. of cylinders – bore x stroke Total piston displacement Rated horsepower • Net (*1) [ISO 9249/SAE J1349] • Gross (*2) [SAE J1995]
Performance
Engine
Sigma dozer
Max. torque (*2)
mm
6 – 114 x 135
l {cc}
8.27 {8,270} 153{205}/1,950
kW{HP}/rpm 154.5{207}/1,950 Nm{kgm}/rpm
1,012{103}/1,450
Max. speed at no load
rpm
2,070 ± 50
Min. speed at no load
rpm
825 ± 25
g/kWh {g/HPh}
227 {169}
Fuel consumption ratio at rated horsepower point Starting motor
24 V, 7.5 kW
Alternator
24 V, 60 A
Battery (*3)
12 V, 112 Ah x 2 pieces
Type of radiator core Torque converter
Planetary gear, multiple disc, hydraulic, gear pump pressure fed oil lubrication, 3 forward/reverse gear speeds, manual electronic type Spiral bevel gear, gear pump pressure fed oil lubrication type
HSS
Differential planetary gear, hydraulic motor drive, manual electronic, hydraulic type
Brake
Wet, multiple disc, spring-boosted, foot-operated, hydraulic type
Final drive Type of suspension Undercarriage
3-element, 1-stage, 2-phase
Bevel gear shaft HSS unit
Power train
Transmission
Corrugated aluminum
1-stage spur gear/1-stage planetary gear reduction, splash lubrication type Oscillation type, equlizer bar
Carrier roller
2 pieces on each side
Track roller
7 pieces on each side
Track shoe • Assembly-type single grouser shoe (PLUS type)
Width: 510 mm Each side: 42 pieces Pitch: 203.2 mm
Width: 510 mm Each side: 42 pieces Pitch: 203.2 mm
Width: 560 mm Each side: 42 pieces Pitch: 203.2 mm
*1: *2: *3: a
Indicates the value of minimum cooling fan speed. Indicates the value of the stand-alone engine (without cooling fan). The battery capacity (Ah) is the 5-hour rate value. The engine rated horsepower is displayed in the net value and gross value. Gross denotes the rated horsepower measured in stand-alone engine. While, net denotes the value measured in an engine under the condition essentially the same as that when it is installed on machine. a The rated horsepower (net output power) at the maximum cooling fan speed is as follows. 139 kW {186 HP}/1,950 rpm a The maximum gross value of the engine output is as follows. 163.7 kW {219 HP}/1,950 rpm
01-100
8
D65EX, PX, WX-16
100 Specification and technical data Specifications
SEN04933-02
D65PX-16
D65WX-16
Straight tilt dozer
Power angle power tilt dozer
Sigma dozer
Power angle power tilt dozer
80001 and up
80001 and up
80001 and up
80001 and up
SAA6D114E-3 4-cycle, water-cooled, in-line vertical, direct injection type, with turbocharger and air-cooled aftercooler 6 – 114 x 135 8.27 {8,270} 153{205}/1,950 154.5{207}/1,950 1,012{103}/1,450 2,070±50 825±25 227 {169} 24 V, 7.5 kW 24 V, 60 A 12 V, 112 Ah x 2 pieces Corrugated aluminum 3-element, 1-stage, 2-phase Planetary gear, multiple disc, hydraulic, gear pump pressure fed oil lubrication, 3 forward/reverse gear speeds, manual electronic type Spiral bevel gear, gear pump pressure fed oil lubrication type Differential planetary gear, hydraulic motor drive, manual electronic, hydraulic type Wet, multiple disc, spring-boosted, foot-operated, hydraulic type 1-stage spur gear/1-stage planetary gear reduction, splash lubrication type Oscillation type, equlizer bar 2 pieces on each side 8 pieces on each side Width: 915 mm Each side: 45 pieces Pitch: 203.2 mm
D65EX, PX, WX-16
Width: 760 mm Each side: 45 pieces Pitch: 203.2 mm
7 pieces on each side Width: 760 mm Each side: 42 pieces Pitch: 203.2 mm
Width: 760 mm Each side: 42 pieces Pitch: 203.2 mm
01-100
9
100 Specification and technical data Specifications
SEN04933-02
D65EX-16 Machine model/type Serial No.
Sigma dozer
Power angle power tilt dozer
Straight tilt dozer (with FRP canopy)
80001 and up
80001 and up
80001 and up
HSS pump Variable displacement swash plate type piston pump, load sensing type
Type Theoretical delivery
cm3/rev
112
Hydraulic pump
Cooling fan pump Type Theoretical delivery
Variable displacement swash plate type piston pump cm /rev
30
3
Power train and steering lubrication pump Type Theoretical delivery
Gear type (tandem) cm /rev 3
43.7 x 2
Type Theoretical delivery
Gear type cm /rev
61.2
3
HSS motor Hydraulic motor
Hydraulic system
Scavenging pump
Motor capacity
Control valve
cm3/rev
90
Cooling fan motor Type Motor capacity
Type and quantity
Control method Hydraulic tank Hydraulic oil filter Oil cooler
01-100
Fixed displacement swash plate type piston motor, with brake valve
Type
10
Fixed displacement swash plate type piston motor cm /rev
28
3
3-spool type, 1 piece 4-spool type, 1 piece (machine with ripper) 5-spool type, 1 piece (straight tilt power pitch dozer) (power angle power tilt dozer)
3-spool type, 1 piece 4-spool type, 1 piece (machine with ripper) — — —
Hydraulic assist type
Hydraulic assist type
Box type (external control valve type) Tank return side Corrugated aluminum
D65EX, PX, WX-16
100 Specification and technical data Specifications
SEN04933-02
D65PX-16
D65WX-16
Straight tilt dozer
Power angle power tilt dozer
Sigma dozer
Power angle power tilt dozer
80001 and up
80001 and up
80001 and up
80001 and up
Variable displacement swash plate type piston pump, load sensing type 112 Variable displacement swash plate type piston pump 30
Gear type (tandem) 43.7 x 2 Gear type 61.2 Fixed displacement swash plate type piston motor, with brake valve 90 Fixed displacement swash plate type piston motor 28 3-spool type, 1 piece 4-spool type, 1 piece (machine with ripper) 5-spool type, 1 piece (straight tilt power pitch dozer) (power angle power tilt dozer) Hydraulic assist type Box type (external control valve type) Tank return side Corrugated aluminum
D65EX, PX, WX-16
01-100
11
100 Specification and technical data Specifications
SEN04933-02
D65EX-16 Machine model/type
Sigma dozer
01-100
Lift cylinder Tilt cylinder Angle cylinder
Power angle power tilt dozer Ripper cylinder
Work equipment hydraulic system
Other than power angle power tilt dozer Tilt and pitch Lift cylinder cylinder
Serial No. Type Cylinder bore Piston rod diameter Stroke Max. distance between pins Min. distance between pins Type Cylinder bore Piston rod diameter Stroke Max. distance between pins Min. distance between pins Type Cylinder bore Piston rod diameter Stroke Max. distance between pins Min. distance between pins Type Cylinder bore Piston rod diameter Stroke Max. distance between pins Min. distance between pins Type Cylinder bore Piston rod diameter Stroke Max. distance between pins Min. distance between pins
Type Cylinder bore Piston rod diameter Stroke Max. distance between pins Min. distance between pins
12
80001 and up mm mm mm mm mm mm mm mm mm mm mm mm mm mm mm mm mm mm mm mm mm mm mm mm mm mm mm mm mm mm
Power angle power Straight tilt dozer tilt dozer (with FRP canopy) 80001 and up
80001 and up
Double acting piston — 85 — 60 — 1,145 — 1,695 — 550 — Double acting piston — 125 — 70 — 145 — 1,222 — 1,077 — — Double acting piston — 90 — 60 — 1,016 — 1,400 — 384 — Double acting piston — 130 — 70 — 160 — 1,200 — 1,040 — Double acting piston — 110 — 65 — 550 — 1,547 — 997 Double acting piston 125 70 330 1,080 750
Double acting 85 60 1,145 1,695 550 Double acting 125 70 145 1,222 1,077 — — — — — — — — — — — — — — — — — —
D65EX, PX, WX-16
100 Specification and technical data Specifications
SEN04933-02
D65PX-16
D65WX-16
Straight tilt dozer
Power angle power tilt dozer
Sigma dozer
Power angle power tilt dozer
80001 and up
80001 and up
80001 and up
80001 and up
Double acting piston 85 60 1,075 1,975 900 Double acting piston 125 70 145 1,222 1,077 — — — — — — — — — — — — — — — — — —
— — — — — — — — — — — — Double acting piston 90 60 1,016 1,400 384 Double acting piston 130 70 160 1,200 1,040 Double acting piston 110 65 550 1,547 997 — — — — — —
D65EX, PX, WX-16
Double acting piston — 85 — 60 — 1,145 — 1,695 — 550 — Double acting piston — 125 — 70 — 145 — 1,222 — 1,077 — — Double acting piston — 90 — 60 — 1,016 — 1,400 — 384 — Double acting piston — 130 — 70 — 160 — 1,200 — 1,040 — Double acting piston — 110 — 65 — 550 — 1,547 — 997 Double acting piston 125 70 330 1,080 750
01-100
13
100 Specification and technical data Specifications
SEN04933-02
D65EX-16 Machine model/type Serial No.
Sigma dozer
Power angle power tilt dozer
Straight tilt dozer (with FRP canopy)
80001 and up
80001 and up
80001 and up
Type
Straight tilt dozer
Performance
Left: brace, Right: tilt cylinder
Max. lift (above ground)
mm
1,100 [1,105]
—
1,100
Max. drop (below ground)
mm
435 [430]
—
435
Max. tilt
mm
870
—
870
Blade edge angle variable range
deg.
±7
—
±7
Dimensions
Blade supporting method
Blade width
mm
3,415
—
3,415
Blade height
mm
1,225
—
1,225
Tip angle of blade cutting edge
deg.
55
—
55
Type
Sigma dozer
Dimensions
Left: brace, Right: tilt cylinder
Max. lift (above ground)
mm
1,130 [1,135]
—
—
Max. drop (below ground)
mm
505 [500]
—
—
Max. tilt
mm
870
—
—
Blade edge angle variable range
deg.
±7
—
—
Blade width
mm
3,410
—
—
Blade height
mm
1,425
—
—
Tip angle of blade cutting edge
deg.
46
—
—
Type
Straight tilt power pitch dozer
Blade supporting method
Dimensions
Performance
Work equipment
Performance
Blade supporting method
Left: tilt cylinder, Right: pitch cylinder
Max. lift (above ground)
mm
1,100 [1,105]
—
—
Max. drop (below ground)
mm
435 [430]
—
—
Max. tilt
mm
870
—
—
Blade edge angle variable range
deg.
±7
—
—
Blade width
mm
3,415
—
—
Blade height
mm
1,225
—
—
Tip angle of blade cutting edge
deg.
55
—
—
Type
Sigma power pitch dozer
Dimensions
Performance
Blade supporting method
Left: tilt cylinder, Right: pitch cylinder
Max. lift (above ground)
mm
1,130 [1,135]
—
—
Max. drop (below ground)
mm
505 [500]
—
—
Max. tilt
mm
870
—
—
Blade edge angle variable range
deg.
±7
—
—
Blade width
mm
3,410
—
—
Blade height
mm
1,425
—
—
Tip angle of blade cutting edge
deg.
46
—
—
Values in [ ] are shown for machine equipped with PLUS type track shoe.
01-100
14
D65EX, PX, WX-16
100 Specification and technical data Specifications
SEN04933-02
D65PX-16
D65WX-16
Straight tilt dozer
Power angle power tilt dozer
Sigma dozer
Power angle power tilt dozer
80001 and up
80001 and up
80001 and up
80001 and up
Straight tilt dozer Left: brace, Right: tilt cylinder 1,125 [1,130]
—
—
540 [535]
—
—
890
—
—
±7
—
—
3,970
—
—
1,100
—
—
55
—
— Sigma dozer Left: brace, Right: tilt cylinder
—
1,130 [1,135]
—
—
505 [500]
—
—
820
—
—
±7
—
—
3,580
—
—
1,425
—
—
46
—
Straight tilt power pitch dozer Left: tilt cylinder, Right: pitch cylinder 1,125 [1,130]
—
—
540 [535]
—
—
890
—
—
±7
—
—
3,970
—
—
1,100
—
—
55
—
— Sigma power pitch dozer
Left: tilt cylinder, Right: pitch cylinder
D65EX, PX, WX-16
—
1,130 [1,135]
—
—
505 [500]
—
—
820
—
—
±7
—
—
3,580
—
—
1,425
—
—
46
—
01-100
15
100 Specification and technical data Specifications
SEN04933-02
D65EX-16 Machine model/type
Power angle power Straight tilt dozer tilt dozer (with FRP canopy)
Sigma dozer
Serial No.
80001 and up
Type
80001 and up
Power angle power tilt dozer
Dimensions
Both sides: angle cylinder
Max. lift (above ground)
mm
—
1,165 [1,170]
—
Max. drop (below ground)
mm
—
700 [695]
—
Max. tilt
mm
—
500
—
Blade edge angle variable range
deg.
—
25
—
Tip angle of blade cutting edge
deg.
—
±3
—
Blade width
mm
—
3,870
—
Blade height
mm
—
1,235
—
Tip angle of blade cutting edge
deg.
—
55
—
Type
Angle dozer Both sides: brace
Performance
Blade supporting method Max. lift (above ground)
mm
1,175 [1,180]
—
1,175
Max. drop (below ground)
mm
445 [440]
—
445
Max. tilt
mm
400
—
400
Blade edge angle variable range
deg.
25
—
25
Dimensions
Work equipment
Performance
Blade supporting method
Blade width
mm
3,970
—
3,970
Blade height
mm
1,100
—
1,100
Tip angle of blade cutting edge
deg.
55
—
55
Parallelogram
—
mm
2,170
—
Number of shanks
piece
3
—
Digging angle
deg.
55
—
Performance
Beam length
3-level variable
—
Max. digging depth
Digging depth mm
590 [585]
—
Max. lift
mm
640 [645]
—
Shank position (left/right)
mm
950/950
—
Type
Parallelogram
—
mm
2,170
—
Number of shanks
piece
1
—
Digging angle
deg.
55
—
Beam length Performance
Ripper (Multi shank)
Type
Ripper (Single shank)
80001 and up
3-stage variable
—
Max. digging depth
Digging depth adjustment mm
590 [585]
—
Max. lift above ground
mm
640 [645]
—
Values in [ ] are shown for machine equipped with PLUS type track shoe.
01-100
16
D65EX, PX, WX-16
100 Specification and technical data Specifications
SEN04933-02
D65PX-16
D65WX-16
Straight tilt dozer
Power angle power tilt dozer
Sigma dozer
Power angle power tilt dozer
80001 and up
80001 and up
80001 and up
80001 and up
Power angle power tilt dozer Both sides: angle cylinder —
1,165 [1,170]
—
1,165 [1,170]
—
700 [695]
—
700 [695]
—
520
—
520
—
25
—
25
—
±3
—
±3
—
4,010
—
4,010
—
1,235
—
1,235
—
55
—
55
Angle dozer Both sides: brace
D65EX, PX, WX-16
—
—
—
—
—
—
—
—
—
—
—
—
—
—
—
Parallelogram
—
2,170
—
3
—
55
—
3-level variable
—
590 [585]
—
640 [645]
—
950/950
—
—
—
—
—
—
—
—
—
—
—
—
—
—
01-100
17
100 Specification and technical data Weight table
SEN04933-02
Weight table k
1
This weight table is prepared for your reference when handling or transporting the components. Unit: kg Machine model/type
D65EX-16
D65EX-16 Straight tilt dozer (with FRP canopy)
D65PX-16
D65WX-16
Serial No.
80001 and up
80001 and up
80001 and up
80001 and up
Engine and damper assembly (excluding coolant and oil)
960
960
960
960
• Engine assembly
870
870
870
870
• Damper assembly
32
32
32
32
• Engine-related parts (wiring, mount)
59
59
59
59
Universal joint
23
23
23
23
Cooling assembly (excluding coolant)
110
110
110
110
• Radiator assembly
18
18
18
18
• Aftercooler assembly
22
22
22
22
Hydraulic oil cooler (excluding oil)
4
4
4
4
Power train oil cooler (excluding oil)
9
9
9
9
Cooling fan pump
30
30
30
30
Cooling fan motor
13
13
13
13
Fuel tank (excluding fuel)
290
290
290
290
1,460
1,460
1,460
1,460
• Torque converter and PTO assembly
340
340
340
340
• Transmission assembly
370
370
370
370
• Transmission control valve assembly
26
26
26
26
• Main relief and torque converter relief valve assembly
5
5
5
5
680
680
680
680
• Brake valve assembly
5
5
5
5
HSS motor
41
41
41
41
Power train unit assembly (excluding oil)
• HSS unit assembly
HSS pump
75
75
75
75
Power train and steering lubrication pump
14
14
14
14
Scavenging pump
5
5
5
5
Quick drop valve
7
7
7
7
Hydraulic tank (excluding oil)
85
85
85
85
45
45
45
45
(Straight tilt dozer with ripper) (Sigma dozer with ripper)
50
50
50
50
(Straight tilt power pitch dozer) (Sigma power pitch dozer) (Power angle power tilt dozer)
55
55
55
55
3
3
3
3
4
—
4
4
Control valve
Blade PPC valve
Ripper PPC valve
1
1
1
1
Steering electric lever
4
4
4
4
01-100
18
D65EX, PX, WX-16
100 Specification and technical data Weight table
SEN04933-02
Unit: kg Machine model/type
D65EX-16
D65EX-16 Straight tilt dozer (with FRP canopy)
D65PX-16
D65WX-16
Serial No.
80001 and up
80001 and up
80001 and up
80001 and up
Main frame assembly
2,710
2,710
2,710
2,710
2,870
2,870
3,060
3,060
Engine underguard
125
125
125
125
Transmission underguard
22
22
22
22
825
755 *1
850
850
835
—
860
860
850
—
850
850
860
—
860
860
8x9
8x9
8x9
8x9
9x9
—
9x9
9x9
1,580
1,580
1,730
1,600
1,640
—
1,790
1,690
1,560
1,560
1,690
1,560
1,620
—
1,750
1,620
• Track frame (each side)
685 660
685 660
755 710
705 660
• Idler assembly (each side)
200
200
200
200
• Idler cushion assembly (each side)
245
245
245
245
53 x 5 56 x 5
53 x 5 —
53 x 6 56 x 6
53 x 5 56 x 5
61 x 2 60 x 2
61 x 2 —
61 x 2 60 x 2
61 x 2 60 x 2
35 x 2 39 x 2
35 x 2 —
35 x 2 39 x 2
35 x 2 39 x 2
• Center roller guard (each side)
29 29
29 —
29 57
29 29
• Full roller guard (each side)
61 69
61 —
73 82
61 69
Final drive assembly (each side)
Sprocket teeth (each side)
Track frame assembly (each side)
• Single flange track roller assembly (each side)
• Double flange track roller assembly (each side)
• Carrier roller assembly (each side)
*1 : Values *1 are shown for Planetary gear installed inside of sprocket
D65EX, PX, WX-16
01-100
19
100 Specification and technical data Weight table
SEN04933-02
Unit: kg Machine model/type
D65EX-16
D65EX-16 Straight tilt dozer (with FRP canopy)
D65PX-16
D65WX-16
Serial No.
80001 and up
80001 and up
80001 and up
80001 and up
1,430
1,430
—
—
—
—
2,120
—
1,495
1,495
—
—
1,555
1,555
—
—
1,620
1,620
—
—
—
—
1,880
1,755
—
—
2,105
—
1,535
1,535
—
—
1,525
—
—
—
1,590
—
—
—
1,655
—
—
—
1,720
—
—
—
—
—
1,985
1,850
—
—
2,200
—
85
85
97
97
97
97
97
97
120
120
140
140
140
140
225
225
ROPS cab assembly (including floor, operator seat and air conditioner unit)
1,140
1,140
1,140
1,140
ROPS cab assembly with subextremely cold weather spec. (including double window glass, floor, operator's seat, and air conditioner)
1,207
1,207
—
—
ROPS canopy assembly (including floor and operator seat mount)
1,000
1,000
1,000
1,000
Floor frame Ass'y (including operator seat and FRP canopy)
—
560
—
—
FRP canopy
—
105
—
—
Operator seat
59
59
59
—
Air conditioner unit
10
10
10
10
Track shoe assembly (each side)
Pivot shaft (each side)
Equalizer bar
Compressor
7
7
7
7
Condenser
2
2
2
2
Receiver
1
1
1
1
2,060 1,200 300 62 2,390 1,525 300 62
2,060 1,200 300 62 — — — —
2,100 1,250 300 62 — — — —
— — — — 2,500 1,585 325 62
Straight tilt dozer assembly • Blade • Straight frame (each side) • Tilt cylinder assembly Sigma dozer assembly • Blade • Straight frame (each side) • Tilt cylinder assembly
01-100
20
D65EX, PX, WX-16
100 Specification and technical data Weight table
SEN04933-02
Unit: kg Machine model/type
D65EX-16
D65EX-16 Straight tilt dozer (with FRP canopy)
D65PX-16
D65WX-16
Serial No.
80001 and up
80001 and up
80001 and up
80001 and up
Straight tilt power pitch dozer assembly
2,110
—
2,160
—
• Blade
1,200
—
1,250
—
• Straight frame (each side)
300
—
300
—
• Tilt cylinder assembly
62
—
62
—
• Pitch cylinder assembly
62
—
62
—
Sigma power pitch dozer assembly
2,440
—
—
2,550
• Blade
1,525
—
—
1,585
• Straight frame (each side)
300
—
—
325
• Tilt cylinder assembly
62
—
—
62
62
—
—
62
Power angle power tilt dozer assembly
• Pitch cylinder assembly
2,960
—
2,990
2,990
• Blade
1,510
—
1,540
1,540
• U-frame
1,110
—
1,110
1,110
• Tilt cylinder assembly
80
—
80
80
• Angle cylinder assembly
80 x 2
—
80 x 2
80 x 2
Angle dozer assembly
2,200
2,200
—
—
• Blade
1,030
1,030
—
—
• C-frame
850
850
—
—
Lift cylinder assembly
85 x 2
85 x 2
85 x 2
85 x 2
Ripper assembly (Multi shank)
1,770
—
—
1,770
70
—
—
70
1,300
—
—
—
70
—
—
—
Ripper cylinder assembly Ripper assembly (Single shank) Ripper cylinder assembly
D65EX, PX, WX-16
01-100
21
SEN04933-02
100 Specification and technical data Table of fuel, coolant and lubricants
Table of fuel, coolant and lubricants a
1
For details of notes (Notes 1 and 2…) in the table, see Operation and Maintenance Manual.
01-100
22
D65EX, PX, WX-16
100 Specification and technical data Table of fuel, coolant and lubricants
q
SEN04933-02
ASTM: American Society of Testing and Material
Supply point Engine oil pan Damper case Idler (each of right and left) Power train case Final drive case (each of right and left) Hydraulic oil system Cooling system (including sub-tank) Cooling system (including sub-tank) (subextremely cold weather spec.) Fuel tank Fuel tank for coolant preheat (subextremely cold weather spec.)
D65EX, PX, WX-16
Specified capacity 33 1.7 0.25 53 EX: 24 PX: 27 WX: 27 82 36
Unit: l Refill capacity 28 1.7 0.25 48 EX: 24 PX: 27 WX: 27 55 —
37
—
415
—
4
—
01-100
23
SEN04933-02
D65EX-16, D65PX-16, D65WX-16 Bulldozer Form No. SEN04933-02
© 2012 KOMATSU All Rights Reserved Printed in Japan 02-12
01-100
24
SEN04963-01
BULLDOZER D65EX-16 D65PX-16 D65WX-16 Machine model D65EX-16 D65PX-16 D65WX-16
Serial number 80001 and up 80001 and up 80001 and up
10 Structure, function and maintenance standard
10
100 Engine and cooling system Engine mount.................................................................................................................................................. 3 Cooling system ............................................................................................................................................... 4 Cooling fan pump............................................................................................................................................ 6 Cooling fan motor.......................................................................................................................................... 20 Coolant preheater (subextremely cold weather spec.) ................................................................................. 26
D65EX, PX, WX-16
10-100
1
SEN04963-01
10-100
2
100 Engine and cooling system
D65EX, PX, WX-16
100 Engine and cooling system Engine mount
SEN04963-01
Engine mount
D65EX, PX, WX-16
1
10-100
3
SEN04963-01
100 Engine and cooling system Cooling system
Cooling system
1. Aftercooler inlet port hose 2. Radiator inlet port hose 3. Reservoir tank 4. Aftercooler outlet port hose 5. Radiator outlet port hose 6. Power train oil cooler 7. Cooling fan
10-100
4
1
8. Cooling fan motor 9. Drain valve 10. Aftercooler 11. Radiator cap 12. Radiator 13. Hydraulic oil cooler bypass valve 14. Hydraulic oil cooler
D65EX, PX, WX-16
100 Engine and cooling system Cooling system
SEN04963-01
A: Power train oil cooler inlet port B: Power train oil cooler outlet port C: Hydraulic oil cooler inlet port D: Hydraulic oil cooler outlet port Specifications Radiator
Power train oil cooler
Core type
Corrugated aluminum
PTO-OL
Fin pitch (mm)
8.0/2
—
8.0/2
8.0/2
Total heat dissipation surface (m2)
46.62
1.722
2.74
20.75
Pressure valve cracking pressure (kPa {kg/cm2})
88.3 ± 14.7 {0.9 ± 0.15}
—
—
—
Vacuum valve cracking pressure (kPa {kg/cm2})
0 – 4.9 {0 – 0.05}
—
—
—
D65EX, PX, WX-16
Hydraulic oil cooler
Aftercooler
Corrugated aluminum Corrugated aluminum
10-100
5
SEN04963-01
100 Engine and cooling system Cooling fan pump
Cooling fan pump
1
Model: LPV30
P1: Pump discharge port PCEPC: EPC output pressure pickup plug PEPC: EPC valve basic pressure pickup plug PR1: Self-pressure reducing valve output port PS: Pump suction port T0: Drain port T1: Drain plug
10-100
6
1. Servo valve 2. EPC valve 3. Self-pressure reducing valve 4. Air bleeder
D65EX, PX, WX-16
100 Engine and cooling system Cooling fan pump
SEN04963-01
1. Shaft 2. Oil seal 3. Case 4. Rocker cam 5. Shoe 6. Piston 7. Cylinder block 8. Valve plate 9. Spring 10. Servo piston 11. Valve 12. Spring
D65EX, PX, WX-16
10-100
7
SEN04963-01
Function q The pump converts the engine rotation and torque transmitted to its shaft to oil pressure and delivers pressurized oil corresponding to the load. q It is possible to change the delivery by changing the swash plate angle.
10-100
8
100 Engine and cooling system Cooling fan pump
Structure q Cylinder block (7) is supported to shaft (1) by spline (a), and shaft (1) is supported by the front and rear bearings. q The tip of piston (6) is a concave ball, and shoe (5) is caulked to it to form one unit. Piston (6) and shoe (5) form a spherical bearing. q Rocker cam (4) has flat surface (A). It slides in a circle pressing shoe (5) constantly to this surface. q Rocker cam (4) slides around ball retainer (11) using it as fulcrum. q Piston (6) performs relative movement in the axial direction inside each cylinder chamber of cylinder block (7). q Cylinder block (7) carries out rotation relative to valve plate (8) while sealing the pressurized oil, and this surface ensures that the hydraulic balance is maintained correctly. q The oil inside each cylinder chamber of cylinder block (7) is suctioned and discharged through valve plate (8).
D65EX, PX, WX-16
100 Engine and cooling system Cooling fan pump
SEN04963-01
Operation Operation of pump
q q
q q
q
q
Cylinder block (7) rotates together with shaft (1), and shoe (5) slides on flat surface (A). Tilting of rocker cam (4) around ball retainer (11) changes inclination (a) of the center line (X) of rocker cam (4) and cylinder block (7) in the axial direction. Angle (a) is called the swash plate angle. With the condition of center line (X) of rocker cam (4) has swash plate angle (a) to axial direction of cylinder block (7), flat surface (A) functions as cam against shoe (5). Piston (6) slides inside cylinder block (7) and, by this movement, a difference is made between volumes (E) and (F) in cylinder block (7). As a result, suction and discharge of oil by (F) – (E) is carried out for each piston (6). Rotation of cylinder block (7) reduces the volume of chamber (E) and the oil is discharged in this process. At the same time, the volume of chamber (F) becomes larger and the oil is sucked in this process. [In the figure, chamber (F) is at the end of the suction stroke and chamber (E) is at the end of the discharge stroke.]
D65EX, PX, WX-16
q
q
When center line (X) of rocker cam (4) is the same as the axial direction of cylinder block (7) [ s w a s h p l at e a n gl e = 0] , t he d i ff er e nc e between volumes (E) and (F) inside cylinder block (7) is 0, so pump does not suck and discharge, and no pumping is carried out. (Actually, however, the swash plate angle is not set to 0) Swash plate angle (a) is in proportion to the delivery.
10-100
9
SEN04963-01
100 Engine and cooling system Cooling fan pump
Control of delivery
q
q
The discharge amount is increased by the increase of capacity difference of (E) and (F) as swash plate angle (a) is increased. Swash plate angle (a) is changed with servo piston (10). Servo piston (10) reciprocates straight according to the signal pressure of the servo valve. This straight line movement is transmitted to rocker cam (4), and rocker cam (4) supported on ball retainer (11) starts oscillating around ball retainer (11).
10-100
10
D65EX, PX, WX-16
100 Engine and cooling system Cooling fan pump
SEN04963-01
Servo valve
1
P: EPC valve basic pressure PE: Control piston pressure PH: Pump discharge pressure T: Drain 1. Plug 2. Lever 3. Retainer 4. Seat 5. Spool 6. Piston 7. Sleeve
D65EX, PX, WX-16
10-100
11
SEN04963-01
100 Engine and cooling system Cooling fan pump
A: Drain side B: Pump discharge pressure input side C: EPC output pressure received D: EPC output pressure
10-100
12
D65EX, PX, WX-16
100 Engine and cooling system Cooling fan pump
Function q The servo valve controls the current input to the EPC valve and the swash plate angle (a) of the pump so that they will be related as shown in the diagram.
q
The relationship between the input current (i) to the EPC valve and output pressure (F) of EPC valve is as follows.
D65EX, PX, WX-16
SEN04963-01 Operation q The output pressure of EPC valve is applied to piston chamber (C) to push piston (6). Piston (6) pushes spool (5) until it is balanced with the spring. q Then, the land (PE) of the servo piston pressure passage is connected to the pump discharge passage (PH) by the notch of spool (5) and the discharge pressure is led to the servo piston. q The servo piston is raised by the rocker cam. Then, the position feedback is applied and the lever moves to compress the spring. q If spool (5) is pushed back, the pump discharge circuit and the servo piston circuit are shut off. The pressure in the servo piston chamber lowers and the rocker cam returns toward the maximum swash plate angle. q These processes are repeated until the swash plate is fixed to a position where the EPC output is balanced with the spring force. q The greater the EPC output pressure, the smaller the swash plate angle. Conversely, the smaller the EPC output pressure, the greater the swash plate angle.
10-100
13
100 Engine and cooling system Cooling fan pump
SEN04963-01
Self-pressure reducing valve
P: From fan pump discharge port P1: Fan pump inside pressure PR1: To PPC valve PS: To sequence valve TS2: To fan pump drain
1
Cooling fan pump 1. Body 2. Sequence valve 3. Spring Self-pressure reducing valve 4. Valve (pressure reducing valve) 5. Spring (pressure reducing valve main) 6. Poppet 7. Spring (pressure reducing valve pilot) 8. Screw 9. Spring (safety valve) 10. Ball
10-100
14
D65EX, PX, WX-16
100 Engine and cooling system Cooling fan pump
Function
SEN04963-01 Operation At engine stop (total low pressure)
q
The self-pressure reducing valve reduces the discharge pressure of the fan pump and supplies it to the PPC valve, the EPC valve, etc. as the control pressure.
q
q q
D65EX, PX, WX-16
Since spring (7) pushes the poppet (6) against the seat, the circuit between port (PR1) and (TS2) is closed. Since spring (5) pushes valve (4) leftward, the circuit between port (P) and (PR1) is open. Since spring (3) pushes valve (2) downward, the circuit between ports (P) and (P1) is closed.
10-100
15
SEN04963-01
100 Engine and cooling system Cooling fan pump
When load pressure (P1) is lower than output pressure (PR1) of self-pressure reducing valve q Spring (3) and pressure (PS) [0 MPa {0 kg/cm2} when the engine is stopped] push valve (2) in the direction to close the circuit between ports (P) and (P1). However, inflow of the hydraulic oil from port (P) balances the pressure at [Pressure (P) C Spring (3) force + (area (d) x pressure (PR))] and the valve adjusts the opening from port (P) to port (P1) in order to maintain pressure (P) at a level higher than pressure (PS). q When pressure (PR1) rises above set pressure, poppet (6) opens and hydraulic oil flows through the route, from port (PR1), through hole (a) in spool (4), through poppet (6) opening to the tank port (TS2). q Therefore, differential pressure is generated around (a) inside spool (4), and spool (4) is moved to close the opening from port (P) to port (PR1) area. Using the amount of opening at this point, the valve decreases pressure (P) to the constant pressure [set pressure] and supplies it as pressure (PR1).
10-100
16
D65EX, PX, WX-16
100 Engine and cooling system Cooling fan pump
SEN04963-01
At raise of load pressure (P1) q In this case, load pressure (P1) of the fan m o t o r i n c r e a s e s a n d p r e s s u r e ( P) a l s o increases to [Pressure (P) > Spring (3) force + ((d) area x pressure (PR))] accompanying increase in pump delivery. Thus, valve (2) moves up to the stroke end. q The amount of opening from ports (P) to (P1) increases and the passage resistance is reduced. As a result, engine horsepower loss is reduced. q When pressure (PR1) rises above set pressure, poppet (6) opens and hydraulic oil flows through the route, from port (PR1), through hole (a) in spool (4), through poppet (6) opening to the tank port (TS2). q Therefore, differential pressure is generated around (a) inside spool (4), and spool (4) is moved to close the opening from port (P) to port (PR1) area. Using the amount of opening at this point, the valve decreases pressure (P) to the constant pressure [set pressure] and supplies it as pressure (PR1).
D65EX, PX, WX-16
10-100
17
SEN04963-01
100 Engine and cooling system Cooling fan pump
In the case of abnormal high pressure q If pressure (PR1) of the self-pressure reducing valve goes abnormally high, ball (10) comes off the seat resisting spring (9) force. This move of ball (10) reduces pressure (PR1) by conducting the hydraulic oil from output port (PR1) to (TS2). As a result, the equipment [PPC valve, EPC valve, etc.], to which the oil pressure is supplied, is protected from the abnormal high pressure.
10-100
18
D65EX, PX, WX-16
100 Engine and cooling system Cooling fan pump
D65EX, PX, WX-16
SEN04963-01
10-100
19
100 Engine and cooling system Cooling fan motor
SEN04963-01
Cooling fan motor
1
Model: LMF28
P: From fan pump T: From cooler to tank TC: To tank
Specifications Capacity (cc/rev)
1,850
Rated flow (l/min)
51.8
Check valve crack pressure (MPa {kg/cm2})
10-100
20
28
Rated speed (rpm)
0.044 {0.45}
D65EX, PX, WX-16
100 Engine and cooling system Cooling fan motor
SEN04963-01
1. Output shaft 2. Case 3. Thrust plate 4. Piston assembly 5. Cylinder block 6. Valve plate
7. End cover 8. Center spring 9. Check valve 10. Pilot valve 11. Spool (for reversible valve) 12. Safety valve Unit: mm
No.
Check item
Criteria Standard size
13 Spool return spring
14 Check valve spring
D65EX, PX, WX-16
Remedy Repair limit
Free length x outside diameter
Installed length
Installed load
Free length
Installed load
44.84 x 12
33
58.8 N {6 kg}
—
47.1 N {4.8 kg}
13.0 x 6.5
9.5
1.96 N {0.2 kg}
—
1.57 N {0.16 kg}
Replace spring if damaged or deformed.
10-100
21
SEN04963-01
Hydraulic motor portion
100 Engine and cooling system Cooling fan motor
1
Function q This hydraulic motor is called a swash platetype axial piston motor. It converts the energy of the pressurized oil sent from the hydraulic pump into rotary motion. Principle of operation The pressurized oil sent from the pump flows through valve plate (7) into cylinder block (5). This oil can flow on only one side of the (Y-Y) line connecting the top dead center and bottom dead center of the stroke of piston (4). q The pressurized oil sent to one side of cylinder block (5) pushes each piston (4) [2 or 3 pistons in total] to generate the force (F1) [F1 = P x xD2/4]. q This force is applied to thrust plate (2). Since thrust plate (2) is fixed to the angle of (a°) to output shaft (1), the force is divided into components (F2) and (F3). q Among them, radial component (F3) respectively generates torque (T = F3 x ri) against the (Y-Y) line connecting the top dead center and bottom dead center. q The combined force of these torques [T = s (F3 x ri)] rotates cylinder block (5) through the piston (4). q Since this cylinder block (5) is splined to the output shaft, the output shaft revolves to transmit the torque. q
10-100
22
D65EX, PX, WX-16
100 Engine and cooling system Cooling fan motor
SEN04963-01
Suction valve Function q If the fan pump stops, the pressurized oil does not flow into the motor. Since the motor continues revolution because of the force of inertia, however, the pressure on the outlet side of the motor rises. q When the oil stops flowing in from inlet port (P), the suction valve sucks in the oil on the outlet side and supplies it to port (MA) where there is not sufficient oil to prevent cavitation.
1
When stopped
Operation When started
q
q
q
When the engine is stopped and the input rotation of the fan pump lowers to 0 rpm, the pressurized oil from the pump is not supplied to port (P) any more. Since the pressurized oil is not supplied to (MA) side of the motor, the motor speed lowers gradually to stop. If the motor shaft is rotated by the force of inertia while the oil flow to the port (P) is reducing, the pressurized oil in port (T) on the outlet side is sent by the suction valve (1) to the (MA) side to prevent cavitation.
If the pressurized oil from the pump is supplied to port (P) and the pressure on (MA) side rises and starting torque is generated in the motor, the motor starts revolution. The pressurized oil on the motor outlet (MB) side returns through port (T) to the tank.
D65EX, PX, WX-16
10-100
23
100 Engine and cooling system Cooling fan motor
SEN04963-01
Reversible valve
1
Operation When ON/OFF solenoid is "de-energized"
q
q
If ON/OFF solenoid (1) is "de-energized", the pressurized oil from the pump is blocked by ON/OFF selector valve (2) and port (C) opens to the tank circuit. Spool (3) is pushed by spring (4) to the right to open motor port (MA). As a result, the pressurized oil flows in to cause the positive rotation (clockwise rotation) of the motor.
10-100
24
When ON/OFF solenoid is "energized"
q
q q
If ON/OFF solenoid (1) is "energized", ON/OFF selector valve (2) is switched to allow the pressurized oil from the pump flow through port (C) into spool chamber (D). The pressurized oil in chamber (D) pushes valve spool (3) to the left resisting spring (4). As a result, motor port (MB) opens and pressurized oil flows in to cause reverse rotation (counterclockwise rotation) of the motor.
D65EX, PX, WX-16
100 Engine and cooling system Cooling fan motor
SEN04963-01
Safety valve
1
Function q When the engine is started, the pressure in port (P) of the fan motor is heightened in some cases. q Safety valve (1) is installed to protect the fan system circuit. Operation If the pressure in port (P) rises above the cracking pressure of safety valve (1), valve (2) of safety valve (1) opens to release the pressurized oil into port (T). q In this way, the safety valve prevents generation of an abnormal pressure in port (P). q
D65EX, PX, WX-16
10-100
25
SEN04963-01
100 Engine and cooling system Coolant preheater (subextremely cold weather spec.)
Coolant preheater (subextremely cold weather spec.) a
subextremely cold weather specification machine only
1. 2. 3. 4.
Coolant preheater Oil pan cover for coolant preheater Exhaust duct for coolant preheater Coolant preheater fuel tank
10-100
26
1
D65EX, PX, WX-16
100 Engine and cooling system Coolant preheater (subextremely cold weather spec.)
SEN04963-01
Function Subextremely cold weather specification machines are equipped with coolant preheater (1) to warm up engine coolant and engine oil when starting engine at minus 25°C or low. Coolant preheater includes fuel tank for coolant preheater (4), exhaust duct (3) which leads the exhaust heat of coolant preheater to engine oil pan, oil pan cover(2) which transmits the exhaust heat to engine oil pan.
1.
Preheater timing chart 1) Normal ignition and normal combustion
2)
When abnormal
D65EX, PX, WX-16
10-100
27
SEN04963-01
3)
10-100
100 Engine and cooling system Coolant preheater (subextremely cold weather spec.)
Normal operation
28
D65EX, PX, WX-16
100 Engine and cooling system Coolant preheater (subextremely cold weather spec.)
2.
SEN04963-01
Electrical circuit diagram of preheater
D65EX, PX, WX-16
10-100
29
SEN04963-01
D65EX-16, D65PX-16, D65WX-16 Bulldozer Form No. SEN04963-01
© 2012 KOMATSU All Rights Reserved Printed in Japan 02-12
10-100
30
SEN04964-01
BULLDOZER D65EX-16 D65PX-16 D65WX-16 Machine model D65EX-16 D65PX-16 D65WX-16
Serial number 80001 and up 80001 and up 80001 and up
10 Structure, function and maintenance standard
10
201 Power train, Part 1 Power train...................................................................................................................................................... 2 HSS system .................................................................................................................................................... 4 Overall view of power train unit....................................................................................................................... 6 Power train hydraulic piping diagram............................................................................................................ 10 Transmission, steering and brake control ..................................................................................................... 12 Damper ......................................................................................................................................................... 14 Universal joint ............................................................................................................................................... 16 Torque converter and PTO............................................................................................................................ 17 Transmission................................................................................................................................................. 24 Transmission control valve............................................................................................................................ 42 ECMV............................................................................................................................................................ 46 Main relief and torque converter relief valve ................................................................................................. 54 Main relief and torque converter relief valve (subextremely cold weather spec.) ......................................... 56 Transmission lubrication relief valve ............................................................................................................. 58
D65EX, PX, WX-16
10-201
1
201 Power train, Part 1 Power train
SEN04964-01
Power train
Outline q The power generated by engine (1) has its torsional vibration dampened by damper (2), and then passes through universal joint (3) and is transmitted to torque converter (7). q The power from the engine is transmitted through the oil by torque converter (7) to the transmission input shaft in accordance with the change in load. q Transmission (8) uses a combination of a planetary gear system and hydraulic clutches to reduce the speed and shift the gears (3 forward speeds and 3 reverse speeds). It connects 2 sets of clutches selected according to the change in load and transmits the power to bevel gear (9) from the bevel pinion at the rear end of the transmission.
1
q
q
q
q
10-201
2
The power transmitted to the bevel gear shaft is transmitted to HSS unit (10). HSS pump (4) is driven by PTO (5), and discharged oil of the HSS pump drives HSS motor (11). The rotation of the pair of the HSS gears on the right and left is controlled by HSS motor (11). The steering direction is controlled by generating a difference in speed on the right and left. It is also possible to use the HSS mechanism to rotate the right and left sides in opposite directions to carry out counter-rotation. Brake (12) built in HSS unit (10) is used for braking the machine. Brake (12) is a wet, multiple disc clutch and spring boosted type. The power sent from brake (12) is transmitted to final drive (13). Final drive (13) consists of a single-stage spur gear and a single-stage planetary gear system. It reduces the speed and rotates sprocket (14) to drive track shoe (15) and moves the machine. Cooling fan motor (19) is rotated with the oil discharged from cooling fan pump (6) driven by PTO (5).
D65EX, PX, WX-16
201 Power train, Part 1 Power train
1. Engine 2. Damper 3. Universal joint 4. HSS pump 5. PTO 6. Cooling fan pump 7. Torque converter 8. Transmission 9. Bevel gear 10. HSS unit
D65EX, PX, WX-16
SEN04964-01
11. HSS motor 12. Brake 13. Final drive 14. Sprocket 15. Track shoe 16. Power train pump 17. Steering lubrication pump 18. Scavenging pump 19. Cooling fan motor
10-201
3
SEN04964-01
HSS system a
201 Power train, Part 1 HSS system
1
HSS: Abbreviation for Hydrostatic Steering System
10-201
4
D65EX, PX, WX-16
201 Power train, Part 1 HSS system
1. Steering, directional, gear shift lever (PCCS lever) 2. Power train controller 3. Engine controller 4. Control valve 5. EPC valve 6. HSS pump 7. Servo valve 8. HSS motor 9. HSS circuit 10. Engine 11. Final drive 12. Sprocket 13. Hydraulic tank Input and output signals a. Forward and reverse signals b. Steering signal c. Engine control information d. Work equipment oil pressure signal e. CAN communication network
D65EX, PX, WX-16
SEN04964-01 Outline q The HSS system consists of control valve (4), HSS pump (6) and HSS motor (8). It turns the machine continuously without lowering the traveling speed by making a difference in speed between both track shoes. q Power train controller (2) controls the rotating direction and the rotating speed of HSS motor (8) according to the tilting direction and angle of steering, directional, gear shift lever (1) with EPC valve (5) of control valve (4). HSS motor (8) acts on the planetary gear mechanism of the bevel gear shaft making a difference in speed between both sprockets (12) to turn the machine. q Power train controller (2) senses the engine speed and the oil pressure at each part, and controls HSS pump (6) and control valve (4) so that engine (10) will not stall. q The engine speed signal and other engine control information are sent and received through the CAN communication network which connects engine controller (3) and power train controller (2).
10-201
5
SEN04964-01
Overall view of power train unit
10-201
6
201 Power train, Part 1 Overall view of power train unit
1
D65EX, PX, WX-16
201 Power train, Part 1 Overall view of power train unit
SEN04964-01
1. HSS motor 2. Transmission 3. Transmission ECMV 4. Torque converter and PTO 5. Scavenging pump 6. Power train oil strainer 7. Power train pump 8. Lubrication pump 9. HSS pump 10. Cooling fan pump 11. Brake valve 12. HSS unit 13. Main relief valve 14. Power train filter relief valve (subextremely cold weather spec.) Outline q The power train unit broadly consists of torque converter and PTO (4), transmission (2), and HSS unit (12). Therefore, after the power train unit is removed, it can be divided into torque converter and PTO (4), transmission (2), and HSS unit (12). q HSS unit (12) consists of the bevel gear unit, bevel gear, HSS motor (1), planetary gear mechanism and brake.
D65EX, PX, WX-16
10-201
7
SEN04964-01
201 Power train, Part 1 Overall view of power train unit
*1: Shows other than the power angle power tilt dozer. *2: Shows the power angle power tilt dozer.
10-201
8
D65EX, PX, WX-16
201 Power train, Part 1 Overall view of power train unit
SEN04964-01
Unit: mm
No.
1
2
Check item Clearance between steering case cover and bushing
Free height of rear mount rubber
D65EX, PX, WX-16
Criteria Tolerance Standard size Shaft Hole +0.096 +0.046 204 +0.050 0 Standard size 43
Remedy Standard clearance
Clearance limit
–0.096 – Max. 0 –0.004 Repair limit
Replace
41
10-201
9
SEN04964-01
201 Power train, Part 1 Power train hydraulic piping diagram
Power train hydraulic piping diagram
A: Transmission oil pressure pick-up port B: Torque converter outlet oil pressure pick-up port C: Torque converter inlet oil pressure pick-up port D: Brake oil pressure pick-up port
10-201
10
1
1. HSS pump 2. HSS motor 3. Brake valve 4. Power train oil filter 5. Main relief, torque converter relief valve 6. Scavenging pump 7. Lubrication pump 8. Power train pump 9. Power train oil cooler 10. Central pressure detection port
D65EX, PX, WX-16
201 Power train, Part 1 Power train hydraulic piping diagram
D65EX, PX, WX-16
SEN04964-01
10-201
11
SEN04964-01
Transmission, steering and brake control a
201 Power train, Part 1 Transmission, steering and brake control
1
PCCS: Abbreviation for Palm Command Control System
10-201
12
D65EX, PX, WX-16
201 Power train, Part 1 Transmission, steering and brake control
SEN04964-01
1. Decelerator pedal 2. Brake pedal 3. Parking brake lever 4. Steering, directional, gear shift lever (PCCS lever) 5. Fuel control dial 6. Parking brake limit switch 7. Brake valve 8. Power train controller 9. Cable 10. Transmission control valve 11. Rod 12. Brake pedal potentiometer 13. Decelerator pedal potentiometer 14. UP switch 15. DOWN switch
Outline q The transmission, steering, and brake are controlled with operation of steering, directional, gear shift lever (PCCS lever) (4). q Upon receiving the electric signal from steering, directional, gear shift lever (4), power train controller (8) transmits the signal to the EPC valve of the control valve according to the tilting angle of steering, directional, gear shift lever (4) to change the oil flow of the HST pump and thereby controls the HST motor. q Brake pedal (2) operates brake valve (7) using rod (11) to operate the brake. q Parking brake lever (3) doubles as the parking brake since it operates brake valve (7) using cable (9). q The safety mechanism employed does not allow parking brake limit switch (6) to operate unless parking brake lever (3) is set to the "LOCK" position. In this case, therefore, the engine does not start.
D65EX, PX, WX-16
10-201
13
SEN04964-01
Damper
10-201
14
201 Power train, Part 1 Damper
1
D65EX, PX, WX-16
201 Power train, Part 1 Damper
SEN04964-01
Unit: mm
No.
Check item
diameter of oil seal 1 Outside contact surface of coupling and radial runout of — Facial coupling
2. Breather 3. Oil filler plug 4. Inspection plug 5. Drain plug 6. Damper case 7. Coupling 8. Shaft 9. Bearing 10. Drive plate 11. Friction plate 12. Friction spring 13. Stopper pin 14. Hub 15. Cover
D65EX, PX, WX-16
Criteria
Remedy
Tolerance Repair limit 0 85 84.8 –0.087 Facial runout: Max 1.0 (at ø148.38), Radial runout: Max.: 1.5 [When the damper shaft and transmission input shaft are rotated at the same time.]
Repair by hard chrome plating or replace
Standard size
Adjust
Outline q The damper is a wet friction spring type. Stopper angle: 4° Stopper torque: 2,685 Nm {274 kgm} q The damper dampens the torsional vibration caused by the engine torque fluctuation and the impact torque generated when accelerating suddenly or carrying out heavy-duty operation mode. In this way it acts to protect the torque converter, transmission, and other parts of the power train.
10-201
15
SEN04964-01
Universal joint
201 Power train, Part 1 Universal joint
1
1. Spider 2. Yoke
10-201
16
D65EX, PX, WX-16
201 Power train, Part 1 Torque converter and PTO
SEN04964-01
Torque converter and PTO a
1
PTO: Abbreviation for Power Take Off
D65EX, PX, WX-16
10-201
17
SEN04964-01
10-201
18
201 Power train, Part 1 Torque converter and PTO
D65EX, PX, WX-16
201 Power train, Part 1 Torque converter and PTO
A: From transmission case (To power train and lubrication pump) B: To transmission case (Drain) C: From transmission case (To scavenging pump) D: From transmission case (To torque converter) E: Torque converter outlet pressure pick-up port F: Torque converter inlet pressure pick-up port G: To oil cooler
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.
PTO lubrication tube HSS pump and cooling fan pump mounting port Torque converter oil temperature sensor mounting port Torque converter oil pressure sensor mounting port Power train and steering lubrication pump mounting port Scavenging pump mounting port Coupling Input shaft (PTO drive gear portion number of teeth: 62) PTO idler gear shaft PTO idler gear (number of teeth: 63) PTO case Drive case Turbine Stator Pump Stator shaft Housing Retainer Transmission input shaft Free wheel Outer race Boss Lockup clutch disc Lockup clutch piston Lockup clutch housing HSS pump, cooling fan pump, power train and steering lubrication pump drive gear (number of teeth: 53) Sleeve Scavenging pump drive gear (number of teeth: 56) Scavenging pump strainer Power train strainer
D65EX, PX, WX-16
SEN04964-01 Outline q The torque converter is a 3-element, 1-stage, and 2-phase type, which is integral with the transmission. q Pump (15) is integrated with coupling (7), input shaft (8) and drive case (12), and rotated by the power from the engine. q Turbine (13) is integrated with transmission input shaft (19), and rotated by the oil from pump (15) as medium. q Stator (14), which is installed to stator shaft (16) through outer race (21) and free wheel (20), is fixed to PTO case (11). q Each pump installed to the PTO case is driven with the power transmitted from input shaft (8) to pump drive gears (26) and (28) through PTO idler gear (10).
10-201
19
SEN04964-01
10-201
20
201 Power train, Part 1 Torque converter and PTO
D65EX, PX, WX-16
201 Power train, Part 1 Torque converter and PTO
SEN04964-01
Unit: mm
No.
Check item
Criteria
1
Outside diameter of oil seal contact surface of input coupling
2
Inside diameter of retainer seal ring contact surface Backlash between PTO drive gear and PTO idler gear Backlash of PTO idler gear and HSS pump, cooling fan pump, power train and steering lubrication pump drive gear Backlash between PTO drive gear and scavenging pump drive gear
3 4
5
Standard size 95 140
6
7
8
Fit tolerance of HSS pump, cooling fan pump, power train and steering lubrication pump drive gear bearing
Fit tolerance of scavenging pump drive gear bearing
D65EX, PX, WX-16
Repair by hard chrome plating or replace
140.5
Replace
0.17 – 0.46
110
Inside diameter
60
Outside diameter (On the case side)
94.8
0.16 – 0.42
Outside diameter
Outside diameter (On the cover side)
Remedy Repair limit
0.17 – 0.46
Standard size Fit tolerance of PTO idler gear bearing
Tolerance 0 –0.087 +0.040 0
Tolerance Shaft 0 –0.015 0 –0.019
Hole –0.024 –0.049 0 –0.015 +0.035 0
120
0 –0.015
— +0.022 –0.013
Inside diameter
55
Outside diameter
72
Inside diameter
35
+0.030 +0.011 0 –0.013 +0.025 +0.009
0 –0.015 +0.030 0 0 –0.010
10-201
21
SEN04964-01
201 Power train, Part 1 Torque converter and PTO
Power transmitting route When the lockup clutch is set to "DISENGAGED"
When the lockup clutch is set to "ENGAGED"
Drive case (4) is disconnected from turbine (6) and works as an ordinary torque converter.
Drive case (4) is connected to turbine (6) to perform the lockup function.
The power from engine O Coupling (1) O Input shaft (2), clutch housing (3), drive case (4) and pump (5) rotate together O Oil is used as medium O Turbine (6) and boss (7) O Transmission input shaft (8)
The power from engine O Coupling (1) O Input shaft (2), clutch housing (3), drive case (4) and pump (5) rotate together O Lockup clutch (9) O Turbine (6) and boss (7) O Transmission input shaft (8)
10-201
22
D65EX, PX, WX-16
201 Power train, Part 1 Torque converter and PTO
SEN04964-01
Oil flow
q
q
q
The oil flows through the main relief valve and its pressure is regulated to below the set pressure at the torque converter relief valve. It then flows into inlet port (A), goes through the oil passages of housing (1) and retainer (2) and then flows into pump (3). The oil is given centrifugal force by pump (3) and flows in turbine (4) to transfer its energy to turbine (4). The oil from turbine (4) is sent to stator (5) and flows into pump (3) again. And part of the oil flows through the space between turbine (4) and stator (5) to outlet port (B). The oil is then conducted to the oil cooler for cooling and used for lubricating the transmission.
D65EX, PX, WX-16
10-201
23
SEN04964-01
Transmission
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24
201 Power train, Part 1 Transmission
1
D65EX, PX, WX-16
201 Power train, Part 1 Transmission
A: B: C: D: E: F: G: H: J: K:
To steering control valve Transmission lubrication oil pressure pick-up port Main relief pressure pick-up port From power train pump From oil cooler To torque converter To PTO case (to scavenging pump) From PTO case (drain) To PTO case (to power train and steering lubrication pump) From steering case
1. 2. 3. 4. 5.
Transmission control valve Transmission case Main relief and torque converter relief valve Transmission lubrication relief valve Sleeve
D65EX, PX, WX-16
SEN04964-01
10-201
25
SEN04964-01
10-201
26
201 Power train, Part 1 Transmission
D65EX, PX, WX-16
201 Power train, Part 1 Transmission
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.
SEN04964-01
Transmission input shaft R sun gear (number of teeth: 26) Tie bolt R planetary pinion (number of teeth: 22) R ring gear (number of teeth: 70) Disc Plate F planetary pinion (number of teeth: 21) 3rd planetary pinion (number of teeth: 28) 3rd ring gear (number of internal teeth: 75) 2nd planetary pinion (number of teeth: 23) 2nd sun gear (number of teeth: 29) 1st planetary pinion (number of teeth: 18) 1st sun gear (number of teeth: 39) Output shaft (3rd sun gear number of teeth: 17) Rear housing 1st clutch piston 1st carrier 1st ring gear (number of internal teeth: 75) 2nd clutch housing 2nd clutch piston 2nd carrier 2nd ring gear (number of internal teeth: 75) 3rd clutch housing 3rd clutch piston 3rd carrier F and 3rd clutch housing F sun gear (number of teeth: 34) F ring gear (number of internal teeth: 76) F clutch piston F carrier R and F clutch housing R clutch piston Return spring R ring gear (hub) (number of internal teeth: 75) R carrier Front housing
D65EX, PX, WX-16
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27
201 Power train, Part 1 Transmission
SEN04964-01 Outline q The transmission uses a combination of the planetary gear system and disc clutches to shift the gears in "3-forward and 3-reverse speeds". q The transmission selects a single steering direction and gear speed by hydraulically fixing the planetary gear mechanism and 2 of the 5 sets of disc clutches by use of ECMV. q The transmission transfers the power received by the transmission input shaft to the output shaft while changing the gear speed (forward 1st-3rd or reverse 1st-3rd) by any combination of the F, R clutches and 3 speed clutches.
Number of plates and discs used Clutch No.
Number of plates
Number of discs
R clutch
6
5
F clutch
8
7
3rd clutch
5
4
2nd clutch
5
4
1st clutch
5
4
Gear speeds and operated clutches Gear speed
Operated clutches
Reduction ratio
Forward 1st
F x 1st
2.020
Forward 2nd
F x 2nd
1.388
Forward 3rd
F x 3rd
0.674
Neutral
(*1)
—
Reverse 1st
R x 1st
1.681
Reverse 2nd
R x 2nd
1.155
Reverse 3rd
R x 3rd
0.561
*1: Either of the 1st, 2nd or 3rd clutch is filled with oil at low pressure.
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28
D65EX, PX, WX-16
201 Power train, Part 1 Transmission
D65EX, PX, WX-16
SEN04964-01
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SEN04964-01
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201 Power train, Part 1 Transmission
D65EX, PX, WX-16
201 Power train, Part 1 Transmission
SEN04964-01
Unit: mm
No.
Check item
Criteria Standard size Installed Installed Free length length load 190.2 N 69.5 60.7 {19.4 kg} 95.2 N 77.0 63.6 {9.7 kg} 141.2 N 59.0 44.6 {14.4 kg} 141.2 N 59.0 44.6 {14.4 kg} 114.7 N 59.0 47.3 {11.7 kg}
1
R clutch spring (5 pcs.)
2
F clutch spring (5 pcs.)
3
3rd clutch spring (5 pcs.)
4
2nd clutch spring (5 pcs.)
5
1st clutch spring (5 pcs.)
6
Total thickness of R clutch assembly consisting of 5 discs and 6 plates
Remedy Repair limit Installed Free length load 161.7 N 65.3 {16.5 kg} 81 N 72.4 {8.2 kg} 120.0 N 55.5 {12.2 kg} 120.0 N 55.5 {12.2 kg} 97.5 N 55.5 {9.9 kg}
Standard size
Tolerance
Repair limit
36.2
±0.33
32.2
49.4
±0.39
43.8
29.6
±0.30
26.4
29.6
±0.30
26.4
29.6
±0.30
26.4
11 Thickness of clutch disc
3.4
±0.1
2.6
12 Thickness of clutch plate
3.2
±0.1
2.9
Width
4
–0.01 –0.03
3.6
Thickness
5
±0.15
4.85
Total thickness of F clutch assembly consisting of 7 discs and 8 plates Total thickness of 3rd clutch 8 assembly consisting of 4 discs and 5 plates Total thickness of 2nd clutch 9 assembly consisting of 4 discs and 5 plates Total thickness of 1st clutch 10 assembly consisting of 4 discs and 5 plates
7
Wear on 3rd speed
13 and 1st speed carrier cover seal rings
Replace
Backlash between R, F, 3rd and
14 1st speed sun gears and 15 16 17 18 19 20 21
planetary pinion Backlash between 2nd speed sun gear and planetary pinion Backlash of R planetary pinion and ring gear Backlash of F, 3rd and 1st planetary pinion and ring gear Backlash of 2nd planetary pinion and ring gear Backlash between R carrier and internal teeth of ring gear Backlash between F carrier and internal teeth of ring gear Backlash between 1st carrier and internal teeth of ring gear
D65EX, PX, WX-16
0.11 – 0.30 0.12 – 0.33 0.13 – 0.41 0.12 – 0.33 0.13 – 0.36 0.14 – 0.44 0.14 – 0.38 0.14 – 0.39
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SEN04964-01
201 Power train, Part 1 Transmission
Disc clutch Structure q The disc clutch consists of piston (2), plates (3), discs (4), pin (5), return spring (6) etc. to fix ring gear (1). q Inside teeth of disc (4) are engaged with outside teeth of ring gear (1). q Plate (3) is assembled to clutch housing (7) with pin (5).
Operation When clutch is "ENGAGED" (fixed) q The oil from ECMV passes through the oil passage of clutch housing (7) and then sent with pressure to the back of piston (2) to push piston (2) leftward. q Piston (2) contacts plate (3) closely against disc (4) to stop rotation of disc (4) by use of the friction force generated between them. q Since the internal teeth of disc (4) are engaged with the external teeth of ring gear (1), move of ring gear (1) is stopped.
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When clutch is "DISENGAGED" (released) q As the oil from ECMV is stopped, piston (2) is pushed back rightward by return spring (6). q Plates (3) and discs (4) are free from the frictional force and thus ring gear (1) is released.
Oil passage in speed clutch q When the steering, directional, gear shift lever is set to the "NEUTRAL" position, the 1st, 2nd, or 3rd speed is selected. q The piston chamber of the clutch corresponding to the selected gear speed is filled with oil by electronically controlling the hydraulic circuit of each clutch. q When the steering, directional, gear shift lever is shifted from the "NEUTRAL" position to the "FORWARD" or "REVERSE" position, the amount of oil from the pump must be sufficient to fill up the piston chamber of the F clutch or R clutch. q When the gear speed is changed from "FORWARD 1ST" to "FORWARD 2ND", only the amount of oil enough to press-fitting the plate and disc of the 2nd clutch is required since the F clutch has been filled with the oil. q The time lag in the gear shifting operation is reduced by controlling the oil in the clutch circuit as explained above.
D65EX, PX, WX-16
201 Power train, Part 1 Transmission
D65EX, PX, WX-16
SEN04964-01
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SEN04964-01
201 Power train, Part 1 Transmission
Power transmitting route Forward 1st
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D65EX, PX, WX-16
201 Power train, Part 1 Transmission
SEN04964-01
F ring gear (4) of F clutch and 1st ring gear (19) of 1st clutch are fixed hydraulically. The power from torque converter O Input shaft (1) O F sun gear (2) O F planetary pinion (3) O F carrier (10) O 3rd carrier (11) O 3rd planetary pinion (12) O 3rd ring gear (13) O 2nd carrier (14) O 2nd planetary pinion (15) O 2nd ring gear (16) O 1st carrier (17) O 1st planetary pinion (18) O 1st sun gear (20) O Output shaft (22)
D65EX, PX, WX-16
o
o
o
O O
O o
O O O O O
i
O 2nd sun gear (21) O i
i
O i
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SEN04964-01
201 Power train, Part 1 Transmission
Forward 2nd
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D65EX, PX, WX-16
201 Power train, Part 1 Transmission
SEN04964-01
F ring gear (4) of F clutch and 2nd ring gear (16) of 2nd clutch are fixed hydraulically. The power from torque converter O Input shaft (1) O F sun gear (2) O F planetary pinion (3) O F carrier (10) O 3rd carrier (11) O 3rd planetary pinion (12) O 3rd ring gear (13) O 2nd carrier (14) O 2nd planetary pinion (15) O 2nd sun gear (21) O Output shaft (22)
D65EX, PX, WX-16
o
O O O O O
i
O i
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SEN04964-01
201 Power train, Part 1 Transmission
Forward 3rd
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D65EX, PX, WX-16
201 Power train, Part 1 Transmission
SEN04964-01
F ring gear (4) of F clutch and 3rd ring gear (13) of 3rd clutch are fixed hydraulically. The power from torque converter O Input shaft (1) O F sun gear (2) O F planetary pinion (3) O F carrier (10) O 3rd carrier (11) O 3rd planetary pinion (12) O Output shaft (22)
D65EX, PX, WX-16
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SEN04964-01
201 Power train, Part 1 Transmission
Reverse 1st
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D65EX, PX, WX-16
201 Power train, Part 1 Transmission
SEN04964-01
R ring gear (7) of R clutch and 1st ring gear (19) of 1st clutch are fixed hydraulically. The power from torque converter O Input shaft (1) O R sun gear (5) O R planetary pinion (6) O R ring gear(9) (R carrier (8) is fixed with R ring gear (7)) = Rotation direction of R ring gear (9) is opposite to input shaft (1)) O F carrier (10) O 3rd carrier (11) O 3rd planetary pinion (12) O 3rd ring gear (13) O 2nd carrier (14) O 2nd planetary pinion (15) O 2nd ring gear (16) O 1st carrier (17) O 1st planetary pinion (18) O 1st sun gear (20) O Output shaft (22)
D65EX, PX, WX-16
o
o
o
O O O O
o
i
O O
O
O
O
O
O
O 2nd sun gear (21) O i
O
i
O i
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SEN04964-01
Transmission control valve
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42
201 Power train, Part 1 Transmission control valve
1
D65EX, PX, WX-16
201 Power train, Part 1 Transmission control valve
SEN04964-01
A: B: C: D: E: F:
Lockup clutch oil pressure pick-up port R clutch oil pressure pick-up port 3rd clutch oil pressure pick-up port 1st clutch oil pressure pick-up port F clutch oil pressure pick-up port 2nd clutch oil pressure pick-up port
1. 2. 3. 4. 5. 6. 7.
Lockup clutch ECMV R clutch ECMV 3rd clutch ECMV 1st clutch ECMV F clutch ECMV 2nd clutch ECMV Last chance filter
Operation table of ECMV ECMV
F
R
1st
2nd
3rd
L/U
Gear speed
F1
Q
F2
Q
F3
Q
Q Q
Q Q
R1
Q
R2
Q
R3
Q
N (*1)
Q
Q
Q Q
Q Q
(Q)
Q
(Q)
Q
(Q)
*1: Either of 1st, 2nd or 3rd clutch operates depending on the preset value. L/U: Indicates the lockup clutch ECMV.
D65EX, PX, WX-16
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201 Power train, Part 1 Transmission control valve
SEN04964-01
Outline q The oil from the pump flows to the transmission case through the power train oil filter and then the flow is divided to the one toward the main relief circuit and the other toward the clutch operating circuit. q The oil, which has flown to the clutch operation circuit after being regulated at the main relief valve, then flows through the last chance filter to operate the clutch, parking brake and main brake. The oil fed by the main relief valve is supplied to the torque converter. q At a gear shift, ECMV smoothly increases the clutch oil pressure responding to the command current from the power train controller in order to alleviate the impacts resulting from the gear shift. And during travel, the clutch oil pressure is kept at a constant level. q Switching between the F and R as well as 1st, 2nd and 3rd clutch ECMVs supplies pressure-regulated oil to the selected clutch to secure the desired speed. q While traveling at the 1st, 2nd or 3rd speed, the lockup ECMV operates at a speed higher than the one set on the transmission controller. q 2 types of ECMVs are used. The following shows how to identify them as well as the difference between them. Printing on the nameplate (A)
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Color for Pressure control identification valve (B)
L*******
—
No slit
E*******
Pink
With slit
44
Fill switch (operating pressure: MPa {kg/cm2}) Provided (0.19 {2.0}) Provided (0.26 {2.7})
Operated clutches F, R, 1st, 2nd and 3rd L/U
D65EX, PX, WX-16
201 Power train, Part 1 Transmission control valve
D65EX, PX, WX-16
SEN04964-01
10-201
45
SEN04964-01
201 Power train, Part 1 ECMV
ECMV a
1
ECMV: Abbreviation for Electronic Control Modulation Valve
For F, R, 1st, 2nd and 3rd clutches a Don't try to disassemble it since adjustment for maintaining the performance will be needed.
A: To clutch P: From pump T: Drain DR: Drain P1: Clutch oil pressure pick-up port 1. Fill switch connector 2. Proportional solenoid connector 3. Oil pressure detection valve 4. Fill switch 5. Proportional solenoid 6. Pressure control valve 7. Nameplate
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D65EX, PX, WX-16
201 Power train, Part 1 ECMV
Outline of ECMV q The ECMV consists of 1 pressure control valve and 1 fill switch. q
Pressure control valve
This valve receives the current from the power train controller with the proportional solenoid, and then converts it into oil pressure. q
1.
2.
Fill switch
This switch detects that the clutch is filled with oil and has the following functions. Outputs a signal (a fill signal) to the controller to notify that filling is completed when the clutch is filled with oil. As long as oil pressure is needed for the clutch, it keeps on transmitting the signals (fill signals) to the controller to notify whether oil pressure is actually applied.
SEN04964-01 ECMV and proportional solenoid q One proportional solenoid is mounted for each ECMV. The proportional solenoid generates thrust shown below according to the command current from the controller. The thrust generated by the proportional solenoid is applied to the pressure control valve spool to generate oil pressure as shown in the figure below. Therefore, modifying the amount of the command current changes the thrust and turns on the operation of the pressure control valve for controlling the oil flow and oil pressure. Current – Thrust characteristics of proportional solenoid
Thrust – Pressure characteristics of proportional solenoid
Range A: Before shifting gear (when draining) Range B: During filling Range C: Pressure adjustment Range D: During filling (during triggering) Point E: Start of filling Point F: Finish of filling a The logic employed for the controller does not recognize the filling is over even if the fill switch is turned "ON" as long as the triggering is taking place (range D).
D65EX, PX, WX-16
ECMV and fill switch For each ECMV, 1 fill switch is installed. As the clutch is filled up, the fill switch is turned "ON" by the pressure of the clutch. The oil pressure is built up according to this signal.
q
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47
201 Power train, Part 1 ECMV
SEN04964-01 Operation of ECMV q The ECMV is controlled by the command current from the controller to the proportional solenoid and the fill switch output signal. The relationship between the proportional solenoid command current of ECMV, clutch input pressure, and fill switch output signal is shown below.
Before shifting gear (when draining) (Range A in chart)
q
Range A: Range B: Range C: Range D: Point E: Point F: a
Before shifting gear (when draining) During filling Pressure adjustment During filling (during triggering) Start of filling Finish of filling
Under the condition where any current is not sent to the proportional solenoid (1), pressure control valve (3) drains the oil from clutch port (A) through drain port (T). Also at this time, fill switch (5) is turned "OFF" because oil pressure is not applied to oil pressure detection valve (4).
The logic employed for the controller does not recognize the filling is over even if the fill switch is turned "ON" as long as the triggering is taking place (range D).
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48
D65EX, PX, WX-16
201 Power train, Part 1 ECMV
During filling (Range B in chart)
q
If current is supplied to proportional solenoid (1) when there is no oil in the clutch, the oil pressure force balanced with the solenoid force is applied to chamber (B) and pushes pressure control valve (3) to the left. As a result, pump port (P) and clutch port (A) are opened and oil starts filling the clutch. As the clutch is filled with oil, oil pressure detection valve (4) operates to turn fill switch (5) "ON".
D65EX, PX, WX-16
SEN04964-01 Pressure adjustment (Range C in chart)
q
If current is supplied to proportional solenoid (1), the solenoid generates thrust in proportion to the current. This thrust of the solenoid is balanced with the sum of the thrust generated by the oil pressure in clutch port and the reaction force of pressure control valve spring (2), and then the pressure is settled.
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49
SEN04964-01
201 Power train, Part 1 ECMV
ECMV for lockup clutch a Don't try to disassemble it since adjustment for maintaining the performance will be needed.
A: To clutch P: From pump T: Drain DR: Drain P1: Clutch oil pressure pick-up port 1. Fill switch connector 2. Proportional solenoid connector 3. Oil pressure detection valve 4. Fill switch 5. Proportional solenoid 6. Pressure control valve 7. Nameplate
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D65EX, PX, WX-16
201 Power train, Part 1 ECMV
Outline q In addition to regulate the lockup clutch oil pressure, this valve is used to switch the lockup clutch, too. Since the modulation waveform is used for the pressure application characteristics to the clutch, ECMV is capable of connecting the lockup clutch smoothly, thereby reducing shocks resulting from gear shift. In addition, it prevents generation of peak torque in the power train. As a result, it provides a comfortable ride for the operator and increases the durability of the power train.
SEN04964-01
Operation When traveling in torque converter range
When changing from torque converter travel to direct travel
q
D65EX, PX, WX-16
When traveling in torque converter range, current is not supplied to proportional solenoid (1). Since pressure control valve (3) drains the oil from clutch port (A) through drain port (T), the lockup clutch is "RELEASED". Also at this time, fill switch (5) is turned "OFF" because oil pressure force is not applied to oil pressure detection valve (4).
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51
201 Power train, Part 1 ECMV
SEN04964-01 When traveling in direct range (torque converter travel to direct travel) During filling
q
When traveling in direct (lockup) range, current is supplied to proportional solenoid (1), the oil pressure force balanced with the solenoid force is applied to chamber (B) and pushes pressure control valve (3) to the left. As a result, pump port (P) and clutch port (A) are opened and oil starts filling the clutch. As the clutch is filled with oil, oil pressure detection valve (4) turns fill switch (5) "ON".
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52
Pressure regulation
q
If current is supplied to proportional solenoid (1), the solenoid generates thrust in proportion to the current. This thrust of the solenoid is balanced with the sum of the thrust generated by the oil pressure in clutch port and the reaction force of pressure control valve spring (2), and then the pressure is settled.
D65EX, PX, WX-16
201 Power train, Part 1 ECMV
D65EX, PX, WX-16
SEN04964-01
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53
201 Power train, Part 1 Main relief and torque converter relief valve
SEN04964-01
Main relief and torque converter relief valve
1
Unit: mm
No.
1
Check item Clearance between main relief valve and valve body
Criteria Standard size 28
2
Clearance between torque converter relief valve and valve body
3
Main relief valve spring (outside)
4
Main relief valve spring (inside)
5
Torque converter relief valve spring
6. Body 7. Piston 8. Torque converter relief valve 9. Piston 10. Main relief valve
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54
22
Tolerance Shaft Hole –0.035 +0.013 –0.045 0 –0.035 –0.045
+0.013 0
Standard size Installed Installed Free length length load 479.1 N 128 78.3 {48.9 kg} 365.5 N 108 78.3 {37.3 kg} 162.5 N 50 41.5 {16.5 kg}
Remedy Standard clearance
Clearance limit
0.035 – 0.058
0.078
0.035 – 0.058
0.078
Repair limit Installed Free length load 456 N 124.2 {46.5 kg} 347 N 104.8 {35.4 kg} 154 N 48.5 {15.7 kg}
Replace
A: Drain (torque converter relief) B: Drain C: From pump D: Drain E: To torque converter P1: Main relief oil pressure pick-up port P2: Torque converter relief oil pressure pick-up port
D65EX, PX, WX-16
201 Power train, Part 1 Main relief and torque converter relief valve
Outline
SEN04964-01 Operation of main relief valve
Torque converter relief valve q The torque converter relief valve maintains the oil pressure in the torque converter inlet circuit always below the set pressure in order to protect the torque converter from abnormally high pressure. Set pressure: 1.02 MPa {10.4 kg/cm2} (cracking pressure) Main relief valve q The main relief valve maintains the hydraulic circuit of the transmission, parking brake and main brake at the set pressure. Set pressure: 3.58 MPa {36.5 kg/cm2} (when engine is run at rated speed)
q
The oil from the hydraulic pump flows to chamber (F) through the filter, port (C) of the relief valve and orifice (a) of main relief valve (1).
q
As the oil pressure in the circuit goes beyond the set pressure, the oil conducted to chamber (F) pushes piston (2) and the resulting reaction force pushes main relief valve (1) leftward, opening ports (C) and (E). Above operation conducts the oil from port (E) to the torque converter.
Operation Operation of torque converter relief valve
q
q
The oil from the main relief valve is conducted to the torque converter through port (E) and, at the same time, also conducted to chamber (G) through orifice (b) of torque converter relief valve (3). As the oil pressure to the torque converter rises beyond the set pressure, the oil conducted to chamber (G) pushes piston (4) and the resulting reaction force pushes torque converter relief valve (3) rightward, opening ports (E) and (A). As a result, the oil in port (E) is drained through port (A).
D65EX, PX, WX-16
10-201
55
SEN04964-01
201 Power train, Part 1 Main relief and torque converter relief valve (subextremely cold weather spec.)
Main relief and torque converter relief valve (subextremely cold weather spec.) 1 a
subextremely cold weather specification machine only
Unit: mm
No.
1
2
Check item Clearance between relief valve and valve body
Relief valve spring (outside)
Criteria Tolerance Shaft Hole –0.035 +0.013 28 –0.045 0 Standard size Installed Installed Free length length load 1,066 N 125 102.3 {108.8 kg} Standard size
Remedy Standard clearance
Clearance limit
0.035 – 0.078 0.058 Repair limit Installed Free length load 1,010 N 123.8 {103.1 kg}
Replace
3. Body 4. Piston 5. Relief valve A: From pump B: To power line fillter C: Drain
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56
D65EX, PX, WX-16
201 Power train, Part 1 Main relief and torque converter relief valve (subextremely cold weather spec.)
SEN04964-01
Outline q
Power train filter relief valve always keeps the oil pressure of power train filter inlet circuit lower than set pressure to protect power train filter from abnormal high pressure when starting the engine at low temperature under subextremely cold weather.
Set pressure: 4.07 MPa ± 0.2 MPa (41.5 kg/cm2 ± 2 kg/cm2) (cracking pressure)
Operation Operation of power train filter valve
q
The oil from power train pump flows to power train filter of port (B) through port (A), at the same time it flows to chamber (D) through orifice (a).
q
When the oil pressure in the port (B) flowing to power train filter exceeds the set pressure, the oil in chamber (D) pushes piston (4) and the reaction force pushes relief valve (5) rightward. This connects ports (E) and (C). Then, the oil in port (E) is drained through port (A).
D65EX, PX, WX-16
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57
201 Power train, Part 1 Transmission lubrication relief valve
SEN04964-01
Transmission lubrication relief valve
1
Unit: mm
No.
1
Check item
Transmission lubrication relief valve spring
2. Piston 3. Spring 4. Forward clutch housing A: From oil cooler B: Drain C: Drain
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58
Criteria Standard size Installed Installed Free length length load 12.0 N 26 23.7 {1.22 kg}
Remedy Repair limit Installed Free length load 11.4 N 25.2 {1.16 kg}
Replace
Outline q The oil leaving the torque converter passes through the oil cooler built in the radiator lower tank. It then goes through the lubrication relief valve and lubricates the transmission and PTO. q The transmission lubrication relief valve is installed to the left side face of the forward clutch housing. It maintains the lubricating oil pressure below the set pressure. Set pressure: 0.05 – 0.15 MPa {0.5 – 1.5 kg/cm2} Cracking pressure: 0.29 MPa {3.0 kg/cm2}
D65EX, PX, WX-16
201 Power train, Part 1 Transmission lubrication relief valve
D65EX, PX, WX-16
SEN04964-01
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SEN04964-01
D65EX-16, D65PX-16, D65WX-16 Bulldozer Form No. SEN04964-01
© 2012 KOMATSU All Rights Reserved Printed in Japan 02-12
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60
SEN04965-01
BULLDOZER D65EX-16 D65PX-16 D65WX-16 Machine model D65EX-16 D65PX-16 D65WX-16
Serial number 80001 and up 80001 and up 80001 and up
10 Structure, function and maintenance standard
10
202 Power train, Part 2 Bevel gear shaft, HSS and brake.................................................................................................................... 2 Brake valve ................................................................................................................................................... 24 Final drive ..................................................................................................................................................... 30 Final drive (Planetary gear installed inside of sprocket type)........................................................................ 36
D65EX, PX, WX-16
10-202
1
SEN04965-01
Bevel gear shaft, HSS and brake a
202 Power train, Part 2 Bevel gear shaft, HSS and brake
1
HSS: Abbreviation for Hydrostatic Steering System
A: To transmission case (to power train and steering lubrication pump) B: Brake oil pressure pick-up port
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2
D65EX, PX, WX-16
202 Power train, Part 2 Bevel gear shaft, HSS and brake
D65EX, PX, WX-16
SEN04965-01
10-202
3
SEN04965-01
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4
202 Power train, Part 2 Bevel gear shaft, HSS and brake
D65EX, PX, WX-16
202 Power train, Part 2 Bevel gear shaft, HSS and brake
SEN04965-01
1. Brake valve 2. HSS motor 3. Output shaft 4. Brake spring (large) 5. Brake spring (small) 6. Spacer 7. Hub 8. Cage 9. Piston 10. Cover 11. Plate (one side: 4 pcs.) 12. Disc (one side: 5 pcs.) 13. Brake drum 14. Brake hub 15. Gear A (number of teeth: 38/55) 16. Cage 17. Gear B (number of teeth: 32) 18. Bevel gear shaft 19. Bevel gear (number of teeth: 34) 20. Bearing 21. Shaft 22. Gear C (number of teeth: 32) 23. Planetary pinion (number of teeth: 26) 24. Ring gear (number of teeth: 91) 25. Pinion shaft 26. Hub 27. Carrier 28. Gear D shaft 29. Gear D (number of teeth: 48) 30. HSS motor drive gear (number of teeth: 25) 31. Bevel pinion (number of teeth: 25) 32. Cage
D65EX, PX, WX-16
10-202
5
SEN04965-01
10-202
6
202 Power train, Part 2 Bevel gear shaft, HSS and brake
D65EX, PX, WX-16
202 Power train, Part 2 Bevel gear shaft, HSS and brake
SEN04965-01
Unit: mm
No.
1
2
Check item
Brake plate
Criteria Tolerance
Repair limit
Thickness
5.0
± 0.1
4.7
Strain
—
Max 0.15
0.3
Repair or replace
Thickness
5.2
± 0.1
4.7
Replace
Strain
—
Max 0.25
0.4
Repair or replace
46.0
± 0.3
43.3
Total assembled thickness of 4 brake plates and 5 discs
4
Backlash between gear A and gear B
5
Backlash between gear A and planetary pinion Backlash between planetary pinion and ring gear
7
Replace
Brake disc
3
6
Remedy
Standard size
Standard clearance
Clearance limit
0.06 – 0.65
—
0.14 – 0.35
—
0.15 – 0.38
—
If the starting torque is less than 9.8 Nm {1.0 kgm}, preload Preload of taper roller bearing for adjustment must be done. bevel gear shaft Starting torque after adjustment 10.3 – 14.7 Nm {1.05 – 1.50 kgm}
D65EX, PX, WX-16
Replace
Adjust
10-202
7
SEN04965-01
10-202
8
202 Power train, Part 2 Bevel gear shaft, HSS and brake
D65EX, PX, WX-16
202 Power train, Part 2 Bevel gear shaft, HSS and brake
SEN04965-01
Unit: mm
No.
Check item
1
Backlash between gear A and gear D
2
Backlash between gear C and gear D Backlash between gear D and HSS motor drive gear Backlash between bevel pinion and bevel gear
3 4
D65EX, PX, WX-16
Criteria
Remedy
Standard clearance
Clearance limit
0.09 – 0.64
—
0.15 – 0.49
—
0.10 – 0.40
—
0.20 – 0.28
—
Replace
Adjust
10-202
9
SEN04965-01
202 Power train, Part 2 Bevel gear shaft, HSS and brake
Outline Bevel gear shaft q Bevel gear shaft converts power sideways at a right angle, which is transmitted from engine to torque converter and transmission through mesh of bevel pinion (31) and bevel gear (19). It also reduces the rotation speed. q Bevel gear shaft adopts spiral bevel gear at bevel pinion (31) and bevel gear (19), and it adopts splash lubrication with oil from scavenging pump and lubrication pump for lubrication. q Bevel gear shaft consists of bevel gear (19) which meshes with bevel pinion (31), bevel gear shaft (18) and bearing (20) which supports bevel gear shaft and cage (16). HSS q HSS is constructed from transfer area which transmits rotation of HSS motor (2) by turning it in reverse direction, and the planet area which adjusts inputs to ring gear (24) and gear A (15) and then outputs to carrier (27). It changes the turning direction of the machine by turning off the rotation of HSS motor (2), or by making it move in normal rotation or reverse rotation. q The transfer unit employs a spur gear speed reduction mechanism and is lubricated with oil splashed by the scavenging pump and lubrication pump. q Planet area adopts forced lubrication with oil from scavenging pump and lubrication pump for lubrication. q Transfer portion is constructed from HSS motor drive gear (30) connected with HSS motor (2) with spline, gear D (29) meshed with HSS motor drive gear, gear C (22) meshed with gear D, gear B (17) attached to shaft (21), gear A (15) retained on bevel gear shaft with bearing, gear A (15) meshed with gear D (29) and the case which supports them all. q Planet area is constructed from gear A (15), planetary pinion (23), pinion shaft (25), hub (26) attached to bevel gear shaft (18) and ring gear (24) with gear, and carrier (27) attached to brake hub (14).
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10
Brake q Brake is established to control the movement of the machine, and is attached to brake hub (14). q Brake adopts wet multiple disc type and spring-boosted type, and it is hydraulic actuated type which activates brake valve (1) by the operation of brake pedal. q It adopts forced lubrication which sends oil from scavenging pump and lubrication pump to cover (10) and cage (8) through passage inside steering case, and then to disc (12) and plate (11). q When the engine is stopped, back pressure of brake piston (9) decreases even if the brake pedal is not depressed. As a result, the brake is set to "operated" state. However, when the engine is started, the parking brake lever must be set to "LOCK" state since the brake is "released" as the oil pressure within the circuit increases when the engine is restarted. q Brake is constructed from carrier (27), brake hub (14) attached to hub (7), disc (12) meshed with brake hub, plate (11) whose outside perimeter is attached to brake drum (13) with gear, piston (9) and springs (4) and (5) which brings disc and plate together, and cage (8), cover (10) and output shaft (3) which supports all of them. Brake drum (13) and cover (10) are fixed to the steering case. Also, output shaft (3) is connected to the hub (7) by spline and held by spacer (6) in the axial direction.
D65EX, PX, WX-16
202 Power train, Part 2 Bevel gear shaft, HSS and brake
D65EX, PX, WX-16
SEN04965-01
10-202
11
202 Power train, Part 2 Bevel gear shaft, HSS and brake
SEN04965-01 HSS operation When steering is at "NEUTRAL" (straight travel)
Rotation direction of HSS motor PCCS lever steering operation
Neutral
Left turn
Right turn
PCCS lever Free, not Neutral Neutral forward and reverse specified Forward Reverse Forward Reverse (*) (*) switching operation Rotation direction of HSS motor viewed from left side of machine
Stop
Right
Right
Left
Left
Left
Right
*: Counter-rotation
10-202
12
D65EX, PX, WX-16
202 Power train, Part 2 Bevel gear shaft, HSS and brake
SEN04965-01
When the PCCS lever is steered to "NEUTRAL", HSS motor (7) is stopped. The power from transmission O Bevel pinion (1) O Bevel gear (2) O Bevel gear shaft (3) O Hub (4) O Ring gear (5) O Planetary pinion (6) O Carrier (14) O Brake hub (15) O Hub (16) O Output shaft (17) O To final drive
D65EX, PX, WX-16
10-202
13
SEN04965-01
202 Power train, Part 2 Bevel gear shaft, HSS and brake
When steered to "LEFT TURN" (forward)
*A: Transmission output *B: HSS motor output *C: Combined output *1. Transmission output speed *2. HSS motor output speed *3. Left bevel gear shaft output speed (*1 – *2) *4. Right bevel gear shaft output speed (*1 + *2)
10-202
14
D65EX, PX, WX-16
202 Power train, Part 2 Bevel gear shaft, HSS and brake
SEN04965-01
If the PCCS lever is steered to "LEFT TURN" during forward travel, HSS motor (7) rotates clockwise viewed from the left side of the machine body. Power from transmission (forward) O Bevel pinion (1) O Bevel gear (2) O Bevel gear shaft (3) O Hub (4) O Ring gear (5) O O O Planetary pinion (6) O Carrier (14) O Brake hub (15) O Hub (16) O Output shaft (17) O To final drive
D65EX, PX, WX-16
i
i
Power from HST motor (7) (clockwise viewed from left side of the machine) O Drive gear (8) O Gear D (9) O Gear C (10) O Shaft (11) O Gear B (12) O Left gear A (13) (counterclockwise viewed from left side of the machine) O i
o
O O O O
i
O Right gear A (13) (clockwise viewed from left side of the machine) O i
10-202
15
SEN04965-01
202 Power train, Part 2 Bevel gear shaft, HSS and brake
When steered to "LEFT TURN" (reverse)
*A: Transmission output *B: HSS motor output *C: Combined output *1. Transmission output speed *2. HSS motor output speed *3. Left bevel gear shaft output speed (*1 – *2) *4. Right bevel gear shaft output speed (*1 + *2)
10-202
16
D65EX, PX, WX-16
202 Power train, Part 2 Bevel gear shaft, HSS and brake
SEN04965-01
If PCCS lever is steered to "LEFT TURN" during reverse travel, HSS motor (7) rotates counterclockwise viewed from the left side of the machine body. Power from transmission (reverse) O Bevel pinion (1) O Bevel gear (2) O Bevel gear shaft (3) O Hub (4) O Ring gear (5) O O O Planetary pinion (6) O Carrier (14) O Brake hub (15) O Hub (16) O Output shaft (17) O To final drive
D65EX, PX, WX-16
i
i
Power from HST motor (7) (counterclockwise viewed from left side of the machine body) O Drive gear (8) O Gear D (9) O Gear C (10) O Shaft (11) O Gear B (12) O Left gear A (13) (clockwise viewed from left side of the machine body) O i
o
O O O O
O Right gear A (13) (counterclockwise viewed from left side of the machine body) O i i
10-202
17
SEN04965-01
202 Power train, Part 2 Bevel gear shaft, HSS and brake
When steered to "RIGHT TURN" (forward)
*A: Transmission output *B: HSS motor output *C: Combined output *1. Transmission output speed *2. HSS motor output speed *3. Left bevel gear shaft output speed (*1 + *2) *4. Right bevel gear shaft output speed (*1 – *2)
10-202
18
D65EX, PX, WX-16
202 Power train, Part 2 Bevel gear shaft, HSS and brake
SEN04965-01
If PCCS lever is steered to "RIGHT TURN" during forward travel, HSS motor (7) rotates counterclockwise viewed from the left side of the machine body. Power from transmission (forward) O Bevel pinion (1) O Bevel gear (2) O Bevel gear shaft (3) O Hub (4) O Ring gear (5) O O O Planetary pinion (6) O Carrier (14) O Brake hub (15) O Hub (16) O Output shaft (17) O To final drive
D65EX, PX, WX-16
i
i
Power from HST motor (7) (counterclockwise viewed from left side of the machine body) O Drive gear (8) O Gear D (9) o O O O Gear C (10) O O Shaft (11) O O Gear B (12) O O Left gear A (13) Right gear A (13) (clockwise viewed from left (counterclockwise viewed from left side of the machine body) side of the machine body) O O i i i
10-202
19
SEN04965-01
202 Power train, Part 2 Bevel gear shaft, HSS and brake
When steered to "RIGHT TURN" (reverse)
*A: Transmission output *B: HSS motor output *C: Combined output *1. Transmission output speed *2. HSS motor output speed *3. Left bevel gear shaft output speed (*1 + *2) *4. Right bevel gear shaft output speed (*1 – *2)
10-202
20
D65EX, PX, WX-16
202 Power train, Part 2 Bevel gear shaft, HSS and brake
SEN04965-01
If PCCS lever is steered to "RIGHT TURN" during reverse travel, HSS motor (7) rotates clockwise viewed from the left side of the machine body. Power from transmission (reverse) O Bevel pinion (1) O Bevel gear (2) O Bevel gear shaft (3) O Hub (4) O Ring gear (5) O O O Planetary pinion (6) O Carrier (14) O Brake hub (15) O Hub (16) O Output shaft (17) O To final drive
D65EX, PX, WX-16
i
Power from HST motor (7) (clockwise viewed from left side of the machine body) O Drive gear (8) O Gear D (9) O Gear C (10) O Shaft (11) O Gear B (12) O Left gear A (13) (counterclockwise viewed from left side of the machine body) O i i
o
O O O O
i
O Right gear A (13) (clockwise viewed from left side of the machine body) O i
10-202
21
202 Power train, Part 2 Bevel gear shaft, HSS and brake
SEN04965-01 Brake operation When brake is "released"
q
q
q
When the brake pedal is released, the brake valve is at "NEUTRAL" position, and the back pressure port of piston (1) is filled with oil. Rising of oil pressure makes piston (1) push down springs (2) and (3) and move towards left direction, and releases disc (4) and plate (5). Power transmitted from bevel gear shaft via HSS to brake hub (7) is transmitted from hub (8) to output shaft (9) and then to final drive.
When brake is "operated" (when brake pedal "depressed"
q
q
q
q
10-202
22
When brake pedal is depressed, brake valve is switched and the oil of back pressure port of piston (1) is drained. By reducing the oil pressure of back pressure port, piston (1) moves to the right direction using reaction force of springs (2) and (3), and makes disc (4) and plate (5) crimped to brake drum (6). Brake drum (6) is connected and fixed to steering case. Power to brake hub (7), namely to output shaft (9), is stopped by crimping disc (4) and plate (5). By adjusting the depression power of the brake pedal and controlling the oil pressure given to piston (1), brake pedal can adjust the braking power.
D65EX, PX, WX-16
202 Power train, Part 2 Bevel gear shaft, HSS and brake
D65EX, PX, WX-16
SEN04965-01
10-202
23
SEN04965-01
Brake valve
P: From power train pump T1: To steering case T2: To steering case Br (R): To right brake Br (L): To left brake 1. Parking brake valve 2. Body 3. Main brake valve 4. Piston 5. Shaft 6. Guide
10-202
24
202 Power train, Part 2 Brake valve
1
Outline q Brake valve is located in the circuit between power train pump and brake piston within HSS unit, and is installed to the upper surface of HSS unit. q Depressing the brake pedal actuates main brake valve (3) and setting the parking brake lever to "LOCK" operates parking brake valve (1). q Actuating each valve stops the oil flow to the back pressure port of the brake piston and sets the brake "operated" state. q In case of HSS, since brake is for braking power control [not involved in steering operation], both left and right brake operate concurrently.
D65EX, PX, WX-16
202 Power train, Part 2 Brake valve
SEN04965-01
Unit: mm
No.
Check item
Criteria
Tolerance Standard size between main brake Shaft Hole 7 Clearance valve and body –0.020 +0.013 19 –0.030 0 Clearance between main brake –0.030 +0.015 9 8 valve and piston –0.040 0 Clearance between parking brake –0.034 +0.013 19 9 valve and body –0.043 0 Standard size Installed Installed Free length length load 10 Main brake modulating spring 75.3 N 48 36 {7.68 kg} 157.9 N 52 38 11 Main brake valve return spring {16.11 kg} 16.7 N 36.5 28.5 12 Parking brake valve return spring {1.7 kg}
D65EX, PX, WX-16
Remedy Standard clearance
Clearance limit
0.020 – 0.07 0.043 0.030 – 0.08 0.055 0.034 – 0.08 0.056 Repair limit Installed Free length load 71.6 N 46.6 {7.3 kg} 150 N 50.4 {15.3 kg} 15.7 N 35.4 {1.6 kg}
Replace
10-202
25
SEN04965-01
202 Power train, Part 2 Brake valve
Operation When brake is "released" (brake pedal "RELEASED", parking brake lever "FREE")
q
q
q
q
q
When the brake pedal is "released" [not depressed], parking brake valve (1) opens port (P) and chamber (A) by the reaction force of return spring (2). Main brake valve (3) opens chamber (B) and port (Br) by the reaction force of return spring (4). The oil pressure from the power train pump is regulated at the main relief valve, flows from port (P) through chambers (A) and (B) and port (Br) to the brake piston back pressure port. The brake piston moves to the left and compresses the brake spring to "RELEASE" the brake. At this time, the oil pressure is balanced at 2.84 MPa {29.0 kg/cm 2}. Its measurement is available at pressure detection port (Q).
10-202
26
D65EX, PX, WX-16
202 Power train, Part 2 Brake valve
SEN04965-01
When brake is "operated" (brake pedal "DEPRESSED", parking beake lever "FREE")
q q
q
q
q
q
q
As the brake pedal is depressed, guide (5) and shaft (6) is pushed to the right. As shaft (6) is pushed, it compresses modulating spring (7), and its reaction force moves main brake valve (3) to the right. Then port (Br) and chamber (B) close while port (Br) and port (T2) open. The oil from the power train pump enters chamber (A) through port (P) and blocked by chamber (B). A portion of the oil which had flown into the brake piston back pressure port is drained from port (Br) to port (T2). The other portion of oil flows through port (Br) and orifice (a) to chamber (D). When the oil behind port (Br) is drained to port (T2) and the oil pressure is reduced, the oil in chamber (D) pushes piston (8). Then the force pushing main brake valve (3) to the right is reduced, and main brake valve (3) moves to the left by the reaction force of return spring (4). Port (Br) and port (T2) are closed by the movement of main brake valve (3) to the left, and the oil pressure behind port (Br) is maintained not to be further reduced. If the brake pedal is depressed further, the operation described above is repeated until main brake valve (3) reaches the stroke end, setting the brake to fully "operated" state.
D65EX, PX, WX-16
q
q
The oil pressure behind port (Br) is determined by the reaction force of return spring (4) of which the load varies in accordance with the brake pedal travel. If the brake pedal stroke is small, the oil pressure after port (Br) increases and the brake is set to "semi-applied" state. And when the stroke is large, the oil pressure decreases and the brake is "applied".
10-202
27
SEN04965-01
202 Power train, Part 2 Brake valve
When brake is set to "parking" (brake pedal "RELEASED", parking brake lever "LOCK")
q
q q
q
q
When the parking brake lever is set to "LOCK" position, parking brake valve (1) is pulled to the left. Then port (P) and chamber (A) are closed while chamber (A) and chamber (C) are open. The oil from the power train pump is blocked by port (P). The oil which had flown into the brake piston back pressure port flows from port (Br) through chambers (B), (A), and (C) and is drained through port (T1). The oil pressure at the brake piston back pressure port continues to be reduced because parking brake valve (1) is held to the left. As a result, the brake is fully set to "operated" and this state is maintained. This condition is maintained while engine is restarted.
10-202
28
D65EX, PX, WX-16
202 Power train, Part 2 Brake valve
D65EX, PX, WX-16
SEN04965-01
10-202
29
SEN04965-01
202 Power train, Part 2 Final drive
Final drive
1
Outline q The final drive uses a single-stage spur gear and a single-stage planetary gear reduction system. q The lubrication is the splash type utilizing the gear rotation. q The final drive can be removed and installed as a single unit. q Floating seal is installed to the rotating and sliding portion of the sprocket to prevent entry of dirt or sand from the outside and the lubrication oil leakage.
10-202
30
D65EX, PX, WX-16
202 Power train, Part 2 Final drive
a
SEN04965-01
The figure shows D65EX-16.
1. Sun gear (number of teeth: 13) 2. Carrier 3. Ring gear (number of teeth: 68) 4. Floating seal 5. Cover 6. Pinion cover 7. Final drive case 8. Bearing cage
D65EX, PX, WX-16
9. Pinion (number of teeth: 21) 10. Gear (number of teeth: 78) 11. Sprocket hub 12. Sprocket teeth 13. Hub 14. Planetary pinion (number of teeth: 27) 15. Pinion shaft
10-202
31
SEN04965-01 a
202 Power train, Part 2 Final drive
The figure shows D65EX-16.
10-202
32
D65EX, PX, WX-16
202 Power train, Part 2 Final drive
SEN04965-01
Unit: mm
No.
Check item
1
Backlash between pinion and gear
2 3
Backlash between sun gear and planetary pinion Backlash between planetary pinion and ring gear
4
Outside diameter of oil seal contact surface of pinion (large)
5
Outside diameter of oil seal contact surface of pinion (small)
6
Interference between pinion shaft and carrier
Criteria Clearance limit
0.23 – 0.61
1.0
0.18 – 0.45
1.0
0.23 – 0.67
1.0
Standard size
Repair limit
80
79.9
70 Standard size 56
7
Axial clearance of pinion bearing
8
Standard shim thickness for pinion bearing cage
9
Projection of ball from pinion cover
of wear of sprocket tooth 10 Amount surface
D65EX, PX, WX-16
Remedy
Standard clearance
Tolerance 0 –0.074 0 –0.074 Tolerance Shaft Hole +0.051 +0.030 +0.032 0
Replace
69.9 Standard Interference interference limit 0.002 – 0.051
0.002
0 – 0.1 Adjust 1.5 Standard size
Repair limit
5.2
1.5
317
299
Replace Rebuild or replace
10-202
33
SEN04965-01
202 Power train, Part 2 Final drive
Power transmitting route a The figure shows D65EX-16.
10-202
34
D65EX, PX, WX-16
202 Power train, Part 2 Final drive
SEN04965-01
The power from HSS O Pinion (1) O Gear (2) O Sun gear (3) O Planetary pinion (4) O Pinion shaft (5) O Carrier (6) O Sprocket hub (7) O Sprocket teeth (8)
D65EX, PX, WX-16
10-202
35
SEN04965-01
202 Power train, Part 2 Final drive (Planetary gear installed inside of sprocket type)
Final drive (Planetary gear installed inside of sprocket type)
1
Structure q The final drive uses a single stage spur gear and single stage planetary gear reduction system. q The lubrication is of splash type using the rotation of the gears. q The final drive can be removed and installed in a single unit. q A floating seal is installed to the rotating portion of the sprocket to prevent the entry of dirt or sand and to prevent leakage of lubricating oil.
10-202
36
D65EX, PX, WX-16
202 Power train, Part 2 Final drive (Planetary gear installed inside of sprocket type)
1. Oil filler plug 2. Oil level plug 3. Drain plug 4. Cover 5. Pinion cover 6. Pinion (number of teeth: 19) 7. Bearing cage 8. Planetary gear shaft 9. Planetary gear (number of teeth: 27) 10. Final drive case
D65EX, PX, WX-16
SEN04965-01
11. Sun gear (number of teeth: 17) 12. Gear hub 13. Carrier 14. Gear (number of teeth: 82) 15. Ring gear (number of teeth: 73) 16. Floating seal 17. Shaft 18. Sprocket hub 19. Sprocket teeth
10-202
37
SEN04965-01
10-202
38
202 Power train, Part 2 Final drive (Planetary gear installed inside of sprocket type)
D65EX, PX, WX-16
202 Power train, Part 2 Final drive (Planetary gear installed inside of sprocket type)
SEN04965-01
Unit: mm
No.
Check item
1
Backlash between pinion and gear
2 3
Backlash between sun gear and planetary gear Backlash between planetary gear and ring gear
4
Outside diameter of oil seal contact surface of pinion
5
Interference between planetary gear shaft and carrier
Criteria Standard clearance
Allowable clearance
0.23 to 0.70
1.0
0.17 to 0.47
1.0
0.20 to 0.66
1.0
Standard dimension 80 Standard dimension 84
Tolerance 0 -0.074 Tolerance Shaft Hole +0.059 +0.035 +0.037 0
6
Axial clearance of pinion bearing
0 to 0.1
7
Standard shim thickness of pinion bearing cage
1.5
8
Pinion cover ball projection
9
Wear of sprocket teeth
D65EX, PX, WX-16
Remedy
Repair limit
Replace
79.9 Standard Allowable interference interference 0.002 to 0.059
0.002
Adjust Standard dimension
Repair limit
5.2
1.5
317
299
Replace Build-up welding for rebuilding or replace
10-202
39
SEN04965-01
202 Power train, Part 2 Final drive (Planetary gear installed inside of sprocket type)
Power transmitting route
10-202
40
D65EX, PX, WX-16
202 Power train, Part 2 Final drive (Planetary gear installed inside of sprocket type)
SEN04965-01
The power from HSS O Pinion (1) O Gear (2) O Gear hub (3) O Sun gear (4) O Planetary gear (5) O Planetary gear shaft (6) O Carrier (7) O Shaft (8) O Sprocket hub (9) O Sprocket teeth (10)
D65EX, PX, WX-16
10-202
41
SEN04965-01
D65EX-16, D65PX-16, D65WX-16 Bulldozer Form No. SEN04965-01
©2011 KOMATSU All Rights Reserved Printed in Japan 09-11
10-202
42
SEN04966-02
BULLDOZER D65EX-16 D65PX-16 D65WX-16 Machine model D65EX-16 D65PX-16 D65WX-16
Serial number 80001 and up 80001 and up 80001 and up
10 Structure, function and maintenance standard
10
300 Undercarriage and frame Main frame ...................................................................................................................................................... 2 Suspension ..................................................................................................................................................... 4 Track frame and idler cushion....................................................................................................................... 14 Idler ............................................................................................................................................................... 18 Idler (Without idler support automatic thrust adjustment) ............................................................................. 20 Carrier roller .................................................................................................................................................. 26 Sprocket ........................................................................................................................................................ 28 Track shoe .................................................................................................................................................... 32
D65EX, PX, WX-16
10-300
1
SEN04966-02
Main frame a
300 Undercarriage and frame Main frame
1
The figure shows other than the power angle power tilt dozer.
10-300
2
D65EX, PX, WX-16
300 Undercarriage and frame Main frame
SEN04966-02
Unit: mm
No.
1
2
Check item Clearance between cylinder yoke and bushing (large) Clearance between cylinder yoke and bushing (small)
Criteria Standard size 85 65
Tolerance Shaft Hole –0.036 +0.207 –0.090 +0.120 –0.030 –0.076
+0.174 +0.100
Remedy Standard clearance
Clearance limit
0.156 – 0.297
0.5
0.130 – 0.250
0.5
Replace bushing
3. Frame assembly 4. Undercover 5. Engine mount 6. Power train unit mount 7. Cooling assembly mount
Outline q Frame assembly (3) has a hull-frame structure, on which the radiator guard, main frame, steering case, transmission underguard, fender and cab mount are assembled into one unit.
D65EX, PX, WX-16
10-300
3
SEN04966-02
Suspension
300 Undercarriage and frame Suspension
1
D65EX-16
10-300
4
D65EX, PX, WX-16
300 Undercarriage and frame Suspension
1. Equalizer bar 2. Pivot shaft 3. Side pin grease fitting 4. Center pin grease fitting 5. Track frame 6. Center pin 7. Side pin 8. Seal 9. Bushing 10. Bushing 11. Seal 12. Bushing (large) 13. Oil filler plug 14. Bushing (small) 15. Cover 16. Seal
D65EX, PX, WX-16
SEN04966-02
Outline q Track frame (5) moves the front part of the track frame up and down around pivot shaft (2) in its rear side. q Equalizer bar (1) vibrates around center pin (6) and is connected to the right and left track frames by side pin (7). D65EX-16 Upward Displacement at center of equalizer bar side pin (mm) Downward
67.6 67.6
10-300
5
300 Undercarriage and frame Suspension
SEN04966-02
Unit: mm
No.
Check item
between pivot shaft 17 Clearance and bushing (large)
Criteria Standard size 148
between pivot shaft 18 Clearance and bushing (small)
105
between center pin 19 Clearance and bushing
70
between side pin and 20 Clearance bushing
60
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
Remedy Standard clearance 0.145 – 0.271 0.120 – 0.228 0.200 – 0.320 0.010 – 0.070
force of pivot shaft 21 Press-fitting bushing (large)
0.98 – 22.6 kN {0.1 – 2.3 tons}
force of pivot shaft 22 Press-fitting bushing (small)
0.98 – 36.3 kN {0.1 – 3.7 tons}
of oil in pivot shaft — Quantity section
10-300
6
Clearance limit 1.0 1.0
Replace bushing
0.5 0.5
—
4.5 l (power line oil: TO30)
D65EX, PX, WX-16
300 Undercarriage and frame Suspension
SEN04966-02
D65EX-16 (power angle power tilt dozer) D65PX-16 D65WX-16
D65EX, PX, WX-16
10-300
7
SEN04966-02
1. Equalizer bar 2. Pivot shaft 3. Side pin grease fitting 4. Center pin grease fitting 5. Track frame 6. Center pin 7. Side pin 8. Seal 9. Bushing 10. Bushing 11. Seal 12. Bushing (large) 13. Oil filler plug 14. Bushing (small) 15. Cover 16. Seal
10-300
8
300 Undercarriage and frame Suspension
Outline q Track frame (5) moves the front part of the track frame up and down around pivot shaft (2) in its rear side. q Equalizer bar (1) vibrates around center pin (6) and is connected to the right and left track frames by side pin (7). D65EX-16 (PAT) D65PX-16 D65WX-16 Upward Displacement at center of equalizer bar side pin (mm) Downward
76.3 76.3
PAT: Power Angle power Tilt dozer
D65EX, PX, WX-16
300 Undercarriage and frame Suspension
SEN04966-02
Unit: mm
No.
Check item
between pivot shaft 17 Clearance and bushing (large)
Criteria Standard size 148
between pivot shaft 18 Clearance and bushing (small)
105
between center pin 19 Clearance and bushing
70
between side pin and 20 Clearance bushing
60
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
Remedy Standard clearance 0.145 – 0.271 0.120 – 0.228 0.200 – 0.320 0.010 – 0.070
force of pivot shaft 21 Press-fitting bushing (large)
0.98 – 22.6 kN {0.1 – 2.3 tons}
force of pivot shaft 22 Press-fitting bushing (small)
0.98 – 36.3 kN {0.1 – 3.7 tons}
of oil in pivot shaft — Quantity section
D65EX, PX, WX-16
Clearance limit 1.0 1.0
Replace bushing
0.5 0.5
—
4.5 l (power line oil: TO30)
10-300
9
SEN04966-02
300 Undercarriage and frame Suspension
D65PX-16 (Power angle power tilt dozer) D65WX-16 (Power angle power tilt dozer)
10-300
10
D65EX, PX, WX-16
300 Undercarriage and frame Suspension
1. Equalizer bar 2. Pivot shaft 3. Side pin grease fitting 4. Center pin grease fitting 5. Track frame 6. Center pin 7. Side pin 8. Seal 9. Bushing 10. Bushing 11. Seal 12. Bushing (large) 13. Oil filler plug 14. Bushing (small) 15. Cover 16. Seal
D65EX, PX, WX-16
SEN04966-02
Outline q Track frame (5) moves the front part of the track frame up and down around pivot shaft (2) in its rear side. q Equalizer bar (1) vibrates around center pin (6) and is connected to the right and left track frames by side pin (7). D65PX-16 (PAT) D65WX-16 (PAT) Upward Displacement at center of equalizer bar side pin (mm) Downward
65.9 65.9
PAT: Power Angle power Tilt dozer
10-300
11
300 Undercarriage and frame Suspension
SEN04966-02
Unit: mm
No.
Check item
between pivot shaft 17 Clearance and bushing (large)
Criteria Standard size 148
between pivot shaft 18 Clearance and bushing (small)
105
between center pin 19 Clearance and bushing
70
between side pin and 20 Clearance bushing
60
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
Remedy Standard clearance 0.145 – 0.271 0.120 – 0.228 0.200 – 0.320 0.010 – 0.070
force of pivot shaft 21 Press-fitting bushing (large)
0.98 – 22.6 kN {0.1 – 2.3 tons}
force of pivot shaft 22 Press-fitting bushing (small)
0.98 – 36.3 kN {0.1 – 3.7 tons}
of oil in pivot shaft — Quantity section
10-300
12
Clearance limit 1.0 1.0
Replace bushing
0.5 0.5
—
4.5 l (power line oil: TO30)
D65EX, PX, WX-16
300 Undercarriage and frame Suspension
D65EX, PX, WX-16
SEN04966-02
10-300
13
SEN04966-02
Track frame and idler cushion
300 Undercarriage and frame Track frame and idler cushion
1
D65EX-16 D65WX-16
*1: Shows the machine equipped with the conventional type track shoe. *2: Shows the machine equipped with the PLUS type track shoe. a PLUS: Abbreviation for Parallel Link Undercarriage System
10-300
14
D65EX, PX, WX-16
300 Undercarriage and frame Track frame and idler cushion
SEN04966-02
1. Idler 2. Carrier roller (*3) 3. Track frame 4. Sprocket teeth (*3) 5. Track roller guard (*3) 6. Track roller (*3) 7. Center roller guard (*3) 8. Yoke 9. Seal 10. Piston
11. Recoil spring 12. Wear ring 13. U-packing 14. Cabin 15. Nut 16. Lubricator 17. Cylinder 18. Bushing 19. Holder
*3: Exclusive parts are used for the machine equipped with the PLUS type track shoe. a
Using the parts for the machine equipped with the conventional type track shoe shortens the life of this machine. The parts indicated with *3 must be exclusive ones. Unit: mm
No.
Check item
Criteria
20 Deformation of track frame
21 Recoil spring
between piston and 22 Clearance bushing
Remedy
Check item Repair limit Bend 7 (in length of 3,000) Distortion 3 (in length of 300) Unclosed idler portion 5 Standard size Repair limit Free length Installed Installed Installed x outside Free length length load load diameter 193.2 kN 171.9 kN 723 x 239 580 705 {19,700 kg} {17,533 kg} Tolerance Standard Standard Clearance size clearance limit Shaft Hole –0.036 +0.270 0.097 – 90 1.0 –0.090 +0.061 0.360
23 Press-fitting force of idler yoke
392 kN {40 ton} Repair limit
27
16
— Quantity of grease
140 cc (Grease: G2-LI)
Replace
Replace bushing
Adjust
Standard size
24 Height of track roller guard guide
Repair
Rebuild or replace —
Outline The idler cushion moves piston (10) back and forth by filling or draining grease from lubricator (16) and adjusts tension of the track shoe. Recoil spring (11) also dampens sudden shock forced on idler (1).
q
Quantity for one Flange type and arrangement side D65EX-16 D65WX-16
7 pieces
S, S, D, S, D, S, S
S: single flange D: double flange
D65EX, PX, WX-16
10-300
15
SEN04966-02
300 Undercarriage and frame Track frame and idler cushion
D65PX-16
*1: Shows the machine equipped with the conventional type track shoe. *2: Shows the machine equipped with the PLUS type track shoe. a PLUS: Abbreviation for Parallel Link Undercarriage System
10-300
16
D65EX, PX, WX-16
300 Undercarriage and frame Track frame and idler cushion
SEN04966-02
1. Idler 2. Carrier roller (*3) 3. Track frame 4. Sprocket teeth (*3) 5. Track roller guard (*3) 6. Track roller (*3) 7. Center roller guard (*3) 8. Yoke 9. Seal 10. Piston
11. Recoil spring 12. Wear ring 13. U-packing 14. Cabin 15. Nut 16. Lubricator 17. Cylinder 18. Bushing 19. Holder
*3: Exclusive parts are used for the machine equipped with the PLUS type track shoe. a
Using the parts for the machine equipped with the conventional type track shoe shortens the life of this machine. The parts indicated with *3 must be exclusive ones. Unit: mm
No.
Check item
Criteria
20 Deformation of track frame
21 Recoil spring
between piston and 22 Clearance bushing
Remedy
Check item Repair limit Bend 7 (in length of 3,000) Distortion 3 (in length of 300) Unclosed idler portion 5 Standard size Repair limit Free length Installed Installed Installed x outside Free length length load load diameter 193.2 kN 171.9 kN 723 x 239 580 705 {19,700 kg} {17,533 kg} Tolerance Standard Standard Clearance size clearance limit Shaft Hole –0.036 +0.270 0.097 – 90 1.0 –0.090 +0.061 0.360
23 Press-fitting force of idler yoke
392 kN {40 ton} Repair limit
27
16
— Quantity of grease
140 cc (Grease: G2-LI)
Replace
Replace bushing
Adjust
Standard size
24 Height of track roller guard guide
Repair
Rebuild or replace —
Outline The idler cushion moves piston (10) back and forth by filling or draining grease from lubricator (16) and adjusts tension of the track shoe. Recoil spring (11) also dampens sudden shock forced on idler (1).
q
Quantity for one Flange type and arrangement side D65PX-16
8 pieces
S, S, D, S, S, D, S, S
S: single flange D: double flange
D65EX, PX, WX-16
10-300
17
SEN04966-02
Idler
10-300
300 Undercarriage and frame Idler
1
18
D65EX, PX, WX-16
300 Undercarriage and frame Idler
SEN04966-02
Unit: mm
No.
Check item
Criteria
Remedy
Standard size
Repair limit
630
—
1
Outside diameter of protruding portion
2
Outside diameter of tread
590
570
3
Depth of tread
20
30
4
Thickness of tread
15
5
5
Width of tread
44.5
48.5
6
Overall width
190
—
7
Clearance between shaft and bushing
8
Clearance between shaft and support
9
Axial play of idler
between guide plate 10 Clearance and side plate shim thickness at side 11 Standard plate installation part
D65EX, PX, WX-16
Tolerance Shaft Hole –0.250 +0.142 65 –0.350 –0.008 –0.250 +0.090 64.7 –0.350 0 Standard clearance
Standard size
Standard clearance
Clearance limit
0.242 – — 0.492 0.250 – — 0.440 Clearance limit
0.26 – 0.66
—
0.9
— 4.0
Rebuild or replace
Replace
Adjust shim or replace plate
10-300
19
SEN04966-02
300 Undercarriage and frame Idler (Without idler support automatic thrust adjustment)
Idler (Without idler support automatic thrust adjustment)
10-300
20
1
D65EX, PX, WX-16
300 Undercarriage and frame Idler (Without idler support automatic thrust adjustment)
SEN04966-02
Unit: mm No.
Check item
1
Outer diameter of projection
2
Criteria Standard size
Remedy Repair limit
630
—
Outer diameter of tread
590
570
3
Depth of tread
20
30
4
Thickness of tread
15
5
5
Width of tread
44.5
48.5
6
Overall width
190
—
7
Clearance between shaft and bushing
8
Clearance between shaft and support
9
Axial play of idler
10 11
Standard size
Tolerance
Build-up welding or replace
Shaft
Hole
Standard clearance
Clearance limit
65
–0.250 –0.350
+0.142 –0.008
0.242 – 0.492
—
64.7
–0.250 –0.350
+0.090 +0.090
0.250 – 0.440
—
Replace
Standard clearance
Clearance limit
0.26 – 0.66
—
Clearance between guide plate and support
2.0
—
Clearance between guide plate and side plate
1.0
—
Standard shim thickness at 12 side plate installation part
D65EX, PX, WX-16
4.0
Build-up welding or replace Adjust shim or replace plate
10-300
21
300 Undercarriage and frame Track roller
SEN04966-02
Track roller
1
For conventional type track shoe Single flange type
Unit: mm
No.
Check item
Criteria
Remedy
Standard size
Repair limit
240
—
2 Outside diameter of tread
210
174
3 Thickness of tread
69
51
19.5
13.5
5 Width of tread
47
—
6 Overall width
235
—
diameter of flange 1 Outside (outside)
4 Width of flange (outside)
7
Clearance between shaft and bushing
between shaft and 8 Clearance collar
9 Play of roller in axial direction
10-300
22
Tolerance Shaft Hole –0.250 +0.143 65 –0.350 –0.007 –0.250 –0.100 64.7 –0.350 –0.150 Standard clearance
Standard size
0.26 – 0.66
Standard clearance
Rebuild or replace
Clearance limit
0.243 – — 0.493 0.100 – — 0.250 Clearance limit
Replace
—
D65EX, PX, WX-16
300 Undercarriage and frame Track roller
SEN04966-02
For conventional type track shoe Double flange type
Unit: mm
No.
Check item
Criteria
Remedy
Standard size
Repair limit
240
—
Outside diameter of flange (inside)
236
—
3
Outside diameter of tread
210
174
4
Thickness of tread
69
51
5
Width of flange (outside)
19.5
13.5
6
Width of flange (inside)
19.5
13.5
7
Width of tread
47.7
—
8
Overall width
235
—
9
Clearance between shaft and bushing
1
Outside diameter of flange (outside)
2
between shaft and 10 Clearance collar
11 Play of roller in axial direction
D65EX, PX, WX-16
Tolerance Shaft Hole –0.250 +0.143 65 –0.350 –0.007 –0.250 –0.100 64.7 –0.350 –0.150 Standard clearance
Standard size
0.26 – 0.66
Standard clearance
Rebuild or replace
Clearance limit
0.243 – — 0.493 0.100 – — 0.250 Clearance limit
Replace
—
10-300
23
300 Undercarriage and frame Track roller
SEN04966-02 For PLUS type track shoe Single flange type a PLUS: Abbreviation for Parallel Link Undercarriage System
Unit: mm
No.
Check item
Criteria
Remedy
Standard size
Repair limit
250
—
1
Outside diameter of flange (outside)
2
Outside diameter of tread
210
174
3
Thickness of tread
69
51
4
Width of flange (outside)
24
13.5
5
Width of tread
47
—
6
Overall width
244
—
7
Clearance between shaft and bushing
8
Clearance between shaft and collar
9
Play of roller in axial direction
10-300
24
Tolerance Shaft Hole –0.250 +0.143 65 –0.350 –0.007 –0.250 –0.100 64.7 –0.350 –0.150 Standard clearance
Standard size
0.26 – 0.66
Standard clearance
Rebuild or replace
Clearance limit
0.243 – — 0.493 0.100 – — 0.250 Clearance limit
Replace
—
D65EX, PX, WX-16
300 Undercarriage and frame Track roller
SEN04966-02
For PLUS type track shoe Double flange type a PLUS: Abbreviation for Parallel Link Undercarriage System
Unit: mm
No.
Check item
Criteria
Remedy
Standard size
Repair limit
240
—
1
Outside diameter of flange (outside)
2
Outside diameter of flange (inside)
236
—
3
Outside diameter of tread
210
174
4
Thickness of tread
69
51
5
Width of flange (outside)
19.5
13.5
6
Width of flange (inside)
19.5
13.5
7
Width of tread
47.7
—
8
Overall width
235
—
9
Clearance between shaft and bushing
between shaft and 10 Clearance collar
11 Play of roller in axial direction
D65EX, PX, WX-16
Tolerance Shaft Hole –0.250 +0.143 65 –0.350 –0.007 –0.250 –0.100 64.7 –0.350 –0.150 Standard clearance
Standard size
0.26 – 0.66
Standard clearance
Rebuild or replace
Clearance limit
0.243 – — 0.493 0.100 – — 0.250 Clearance limit
Replace
—
10-300
25
300 Undercarriage and frame Carrier roller
SEN04966-02
Carrier roller
1
For conventional type track shoe
Unit: mm
No.
Check item
Criteria
Remedy
Standard size
Repair limit
215
—
1
Outside diameter of flange
2
Outside diameter of tread
185
163
3
Thickness of tread
37.5
26.5
4
Width of tread
49.5
—
5
Width of flange
21
15
6
Clearance between shaft and support
7
8
Interference between shaft and seal guard
Play of roller in axial direction
10-300
26
Tolerance Shaft Hole –0.100 +0.300 61 –0.200 0 Tolerance Standard size Shaft Hole +0.150 +0.030 61.5 +0.130 0 Standard clearance Standard size
0 – 0.32
Rebuild or replace
Standard clearance
Clearance limit
0.100 – 0.500
—
Standard Interference interference limit
Replace
0.100 – — 0.150 Clearance limit —
D65EX, PX, WX-16
300 Undercarriage and frame Carrier roller
SEN04966-02
For PLUS type track shoe a PLUS: Abbreviation for Parallel Link Undercarriage System
Unit: mm
No.
Check item
Criteria
Remedy
Standard size
Repair limit
224
—
Outside diameter of tread
200
160
3
Thickness of tread
37.5
25
4
Width of tread
49.5
55.5
5
Width of flange
21
15
6
Clearance between shaft and support
1
Outside diameter of flange
2
7
8
Interference between shaft and seal guard
Play of roller in axial direction
D65EX, PX, WX-16
Tolerance Shaft Hole –0.100 +0.300 61 –0.200 0 Tolerance Standard size Shaft Hole +0.150 +0.030 61.5 +0.130 0 Standard clearance Standard size
0 – 0.32
Rebuild or replace
Standard clearance
Clearance limit
0.100 – 0.500
—
Standard Interference interference limit
Replace
0.100 – — 0.150 Clearance limit —
10-300
27
300 Undercarriage and frame Sprocket
SEN04966-02
Sprocket
1
For conventional type track shoe
Unit: mm
No. 1 2
Check item Width of tooth bottom Thickness of tooth bottom
10-300
28
Criteria
Remedy
Standard size
Repair limit
87
77
26
17
Rebuild or replace
D65EX, PX, WX-16
300 Undercarriage and frame Sprocket
SEN04966-02
Full-size drawing of sprocket tooth shape a Set the rule to the full-scale size, and then copy the whole drawing to an OHP sheet.
D65EX, PX, WX-16
10-300
29
300 Undercarriage and frame Sprocket
SEN04966-02 For PLUS type track shoe a PLUS: Abbreviation for Parallel Link Undercarriage System
Unit: mm
No. 1 2
Check item Width of tooth bottom Thickness of tooth bottom
10-300
30
Criteria
Remedy
Standard size
Repair limit
87
78
26
17
Rebuild or replace
D65EX, PX, WX-16
300 Undercarriage and frame Sprocket
SEN04966-02
Full-size drawing of sprocket tooth shape a Set the rule to the full-scale size, and then copy the whole drawing to an OHP sheet.
D65EX, PX, WX-16
10-300
31
SEN04966-02
Track shoe
300 Undercarriage and frame Track shoe
1
Conventional type track shoe
*1. Single shoe *2. Swamp shoe a
P portion shows the link of bushing press fitting end.
10-300
32
D65EX, PX, WX-16
300 Undercarriage and frame Track shoe
SEN04966-02
Unit: mm
No. 1
Check item Link pitch
Criteria Repair limit
203.45
206.45
Standard size
2
Thickness of bushing
4
Link height
5
Thickness of link (bushing press fitted portion) a. Regular link
6
Shoe bolt b. Master link
7
Interference between bushing and link
8
Interference between regular pin and link
9
Clearance between regular pin and bushing
D65EX, PX, WX-16
Reverse Light load
Heavy load
73
62.8
65.4
13.9
3.7
6.3
Outside diameter of bushing
3
Remedy
Standard size
Standard size
Repair limit
132
119.5
44.8
32.3
Tightening torque (Nm {kgm})
Retightening angle (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 size interference Shaft Hole +0.404 +0.074 66.5 0.230 – 0.404 +0.304 0 +0.435 +0.086 44.4 0.199 – 0.411 +0.285 +0.024 Tolerance Standard Standard size clearance Shaft Hole +0.235 +0.915 44.6 0.180 – 0.830 +0.085 +0.415
Reverse or replace
Repair or replace Replace
Retighten
Adjust or replace
10-300
33
SEN04966-02
300 Undercarriage and frame Track shoe
PLUS type track shoe a PLUS: Abbreviation for Parallel Link Undercarriage System
a
P portion shows the link of bushing press fitting end.
10-300
34
D65EX, PX, WX-16
300 Undercarriage and frame Track shoe
SEN04966-02
Unit: mm
No. 1
Check item Link pitch
Criteria Repair limit
203.45
206.45
Standard size
2
Thickness of bushing
4
Link height
5
Thickness of link (bushing press-fitting portion) a. Regular link
6
Shoe bolt b. Master link
7
8
Interference between regular pin and link
Clearance between links
D65EX, PX, WX-16
Reverse Light load
Heavy load
73
62.8
65.4
13.9
3.7
6.3
Outside diameter of bushing
3
Remedy
Standard size
Standard size
Repair limit
132
119.5
44.8
32.3
Tightening torque (Nm {kgm})
Retightening angle (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 size interference Shaft Hole +0.435 +0.086 44.4 0.199 – 0.411 +0.285 +0.024 Standard clearance One side
Both side
1.4
2.8
Reverse or replace
Repair or replace Replace
Retighten
Adjust or replace
10-300
35
300 Undercarriage and frame Track shoe
SEN04966-02 Single shoe
Unit: mm
No. 1 2
Check item Height of grouser Thickness of grouser
Criteria
Remedy
Standard size
Repair limit
65
25
77
37
Rebuild or replace
Swamp shoe
Unit: mm
No. 1 2
Check item Height of grouser Thickness of grouser
10-300
36
Criteria
Remedy
Standard size
Repair limit
109.5
94.5
20
5
Rebuild or replace
D65EX, PX, WX-16
300 Undercarriage and frame Track shoe
D65EX, PX, WX-16
SEN04966-02
10-300
37
SEN04966-02
D65EX-16, D65PX-16, D65WX-16 Bulldozer Form No. SEN04966-02
©2011 KOMATSU All Rights Reserved Printed in Japan 09-11
10-300
38
SEN04967-00
BULLDOZER D65EX-16 D65PX-16 D65WX-16 Machine model D65EX-16 D65PX-16 D65WX-16
Serial number 80001 and up 80001 and up 80001 and up
10 Structure, function and maintenance standard
10
401 Hydraulic system, Part 1 Work equipment hydraulic system layout drawing .......................................................................................... 2 Work equipment control .................................................................................................................................. 6 Hydraulic tank and filter .................................................................................................................................. 8 Scavenging pump ......................................................................................................................................... 10 Power train and steering lubrication pump.....................................................................................................11 HSS pump..................................................................................................................................................... 12 HSS motor .................................................................................................................................................... 31
D65EX, PX, WX-16
10-401
1
SEN04967-00
401 Hydraulic system, Part 1 Work equipment hydraulic system layout drawing
Work equipment hydraulic system layout drawing
1
Straight tilt dozer (ST-T) Sigma dozer (SGM) Straight tilt power pitch dozer (ST-TPP) Sigma power pitch dozer (SGM-PP) Angle dozer (A) a The figure shows the straight tilt power pitch dozer.
10-401
2
D65EX, PX, WX-16
401 Hydraulic system, Part 1 Work equipment hydraulic system layout drawing
SEN04967-00
1. Tilt cylinder (ST-T, SGM) Pitch cylinder (ST-TPP, SGM-PP) 2. Quick drop valve 3. Cooling fan motor 4. Lift cylinder 5. Control valve 6. Work equipment lock solenoid valve (ST-TPP, SGM-PP) 7. Accumulator 8. Blade pitch selector solenoid valve (ST-TPP, SGM-PP) 9. Blade PPC valve 10. Hydraulic tank 11. Ripper PPC valve (if equipped) 12. HSS motor 13. Ripper cylinder (if equipped) 14. Self-pressure reducing valve 15. Cooling fan pump 16. HSS pump 17. Hydraulic oil cooler 18. Tilt cylinder (ST-TPP, SGM-PP) 19. Hydraulic oil cooler bypass valve
D65EX, PX, WX-16
10-401
3
SEN04967-00
401 Hydraulic system, Part 1 Work equipment hydraulic system layout drawing
Power angle power tilt dozer (PAT)
10-401
4
D65EX, PX, WX-16
401 Hydraulic system, Part 1 Work equipment hydraulic system layout drawing
SEN04967-00
1.Tilt cylinder 2. Quick drop valve 3. Cooling fan motor 4. Lift cylinder 5. Control valve 6. Work equipment lock solenoid valve 7. Accumulator 8. Blade PPC valve 9. Hydraulic tank 10. Ripper PPC valve (if equipped) 11. HSS motor 12. Ripper cylinder (if equipped) 13. Self-pressure reducing valve 14. Cooling fan pump 15. HSS pump 16. Hydraulic oil cooler 17. Hydraulic oil cooler bypass valve 18. Angle cylinder
D65EX, PX, WX-16
10-401
5
SEN04967-00
Work equipment control
10-401
6
401 Hydraulic system, Part 1 Work equipment control
1
D65EX, PX, WX-16
401 Hydraulic system, Part 1 Work equipment control
SEN04967-00
1. Ripper control lever (if equipped) 2. Blade control lever 3. Work equipment lock lever 4. Blade PPC valve 5. Ripper PPC valve (if equipped) 6. Work equipment lock limit switch 7. PITCH switch (if equipped)
Outline q The work equipment control system is a PPC system that operates each spool of the control valves by operating blade PPC valve (4) with blade control lever (2) or operating ripper PPC valve (5) with ripper control lever (1). q Work equipment lock lever (3) is interlocked with work equipment lock limit switch (6). When work equipment lock lever (3) is set to "FREE"position, work equipment lock limit switch is turned "ON". Turning on of the lever opens the work equipment control circuit and it enables operating the work equipment. q When blade control lever (2) is set to the "FLOAT" position, the hydraulic detent of blade PPC valve (4) works, and blade control lever (2) is set to self-holding at the "FLOAT" position. q When work equipment lock lever (3) is set to the "LOCK" position, the hydraulic detent of blade PPC valve (4) is reset and blade control lever (2) returns to the "HOLD" position by itself. q While the engine is stopped, the hydraulic detent does not work even when blade control lever (2) is set to the "FLOAT" position. Thus, blade control lever (2) returns to "HOLD" position by itself.
D65EX, PX, WX-16
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7
401 Hydraulic system, Part 1 Hydraulic tank and filter
SEN04967-00
Hydraulic tank and filter
1. Hydraulic tank 2. Sight gauge 3. Hydraulic oil temperature sensor 4. Hydraulic filter element 5. Spring 6. Bypass valve 7. Oil filler cap 8. Breather 9. Strainer 10. Drain plug
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8
1
Specifications Tank capacity (l)
80
Oil level in tank (l)
55
Bypass valve set pressure (kPa {kg/cm2})
147 ± 29.4 {1.5 ± 0.3}
D65EX, PX, WX-16
401 Hydraulic system, Part 1 Hydraulic tank and filter
Breather
SEN04967-00
1
1. Nut 2. Cover 3. Filter element 4. Case 5. Valve assembly 6. Body
Prevention of negative pressure in tank q The hydraulic tank is enclosed and pressurized. When the oil level in the hydraulic tank drops, negative pressure is generated in the tank. To prevent this negative pressure generation, valve assembly (5) is opened to draw the atmosphere to the tank. (Intake valve set pressure: 1.96 ± 0.29 kPa {0.02 ± 0.003 kg/cm2}) Prevention of pressure buildup in tank When the hydraulic circuit is operating, the pressure in the hydraulic tank increases as the hydraulic cylinder operates and the oil level and temperature increase in the tank. If the pressure in the tank rises above the set value, valve assembly (5) is pushed up to release the pressure in the tank. (Exhaust valve set pressure: 38.2 ± 5.69 kPa {0.39 ± 0.058 kg/cm2})
q
D65EX, PX, WX-16
10-401
9
401 Hydraulic system, Part 1 Scavenging pump
SEN04967-00
Scavenging pump
1
Outline q The scavenging pump is installed to the lower part of the PTO case and is driven with the power from the engine. q The scavenging pump sucks oil collected in the transmission case bottom through a strainer and returns it to the steering case.
Specifications Type
Gear pump
Theoretical capacity (cc/rev)
61.2
Maximum delivery pressure (MPa {kg/cm2})
0.29{3.0}
Maximum speed (rpm)
2,500
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10
D65EX, PX, WX-16
401 Hydraulic system, Part 1 Power train and steering lubrication pump
SEN04967-00
Power train and steering lubrication pump
1
Model: SAL (2) 45 + 45
Unit: mm
No.
Check item
1
Side clearance
2
Clearance between plain bearing inner diameter and gear shaft outer diameter
3
Pin driving depth
4
Rotating torque of spline shaft
Delivery — Oil: SAE10W Oil temperature: 45 – 55°C
D65EX, PX, WX-16
Criteria
Remedy
Type
Standard clearance
Clearance limit
SAL(2)45
0.10 – 0.15
0.19
SAL(2)45
0.067 – 0.125
0.20
Type
Standard size
SAL(2)45
12
Tolerance 0 –0.5
Replace
Repair limit —
5.8 – 13.8 Nm {0.6 – 1.4 kgm} Type
Speed (rpm)
Discharge pressure (MPa{kg/cm2})
Standard delivery (l/min)
Delivery limit (l/min)
SAL(2)45
3,000
2.9{30}
125
111
—
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SEN04967-00
401 Hydraulic system, Part 1 HSS pump
HSS pump
1
Model: HPV95(112)
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12
D65EX, PX, WX-16
401 Hydraulic system, Part 1 HSS pump
IM: PC mode selector current connector PA: Pump discharge port PB: Pump pressure input port PC: Pump discharge pressure pickup port PD1: Case drain port PD2: Drain plug PEN: Control pressure pickup port PEPB: EPC source pressure pickup port PEPC: EPC source pressure port PLS: Load pressure input port PLSC: Load pressure pickup port PM: PC mode selector pressure pickup port PS: Pump suction port
SEN04967-00 Outline q This pump consists of a variable-displacement swash plate type piston pump, PC valve, LS valve and EPC valve.
1. Main pump 2. LS valve 3. PC valve 4. PC-EPC valve
D65EX, PX, WX-16
10-401
13
SEN04967-00
401 Hydraulic system, Part 1 HSS pump
1. Shaft 2. Cradle 3. Front case 4. Rocker cam 5. Shoe 6. Piston 7. Cylinder block 8. Valve plate 9. End cap 10. Servo piston 11. PC valve
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14
D65EX, PX, WX-16
401 Hydraulic system, Part 1 HSS pump
Function q The pump converts the engine rotation transmitted to its shaft to oil pressure and delivers pressurized oil corresponding to the load. q It is possible to change the delivery by changing the swash plate angle.
D65EX, PX, WX-16
SEN04967-00
Structure q Cylinder block (7) is supported to shaft (1) by spline (12). q Shaft (1) is supported by each bearing (13). q The end of piston (6) has a spherical hollow and is combined with shoe (5). q Piston (6) and shoe (5) form a spherical bearing. q Shoe (5) slides in circle being constantly pushed against plane (A) of rocker cam (4). q Rocker cam (4) conducts high pressure oil to cylinder surface (B) with cradle (2), which is secured to the case, and forms a static pressure bearing when it slides. q Piston (6) performs relative movement in the axial direction inside each cylinder chamber of cylinder block (7). q Cylinder block (7) seals the pressurized oil to valve plate (8) and carries out relative rotation. q This surface is designed so that the oil pressure balance is maintained at a suitable level. q The oil inside each cylinder chamber of cylinder block (7) is suctioned and discharged through valve plate (8). 10-401
15
401 Hydraulic system, Part 1 HSS pump
SEN04967-00 Operation of pump
q q
q
q
q
q q
q
Cylinder block (7) rotates together with shaft (1), and shoe (5) slides on flat surface (A). When this happens, rocker cam (4) moves along cylindrical surface (B), so angle (a) between center line (X) of rocker cam (4) and the ax ial di rec tio n of cy li nder b loc k (7) changes. Angle (a) is called the swash plate angle.
q
q
As center line (X) of rocker cam (4) matches the axial direction of cylinder block (7) (swash plate angle (a) = 0), the difference between volumes (E) and (F) inside cylinder block (7) becomes 0. Suction and discharge of pressurized oil is not carried out in this state. Namely pumping action is not performed. (Actually, however, the swash plate angle is not set to 0)
When center line (X) of rocker cam (4) has swash plate angle (a) to axial direction of cylinder block (7), flat surface (A) functions as cam to shoe (5). Piston (6) slides on the inside of cylinder block (7), so a difference between volumes (E) and (F) is created inside cylinder block (7). A single piston (6) sucks and discharges the oil by the amount (F) – (E). As cylinder block (7) rotates and the volume of chamber (E) becomes smaller, the pressurized oil is discharged. The volume of chamber (F) grows larger and, in this process, the oil is suctioned.
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16
D65EX, PX, WX-16
401 Hydraulic system, Part 1 HSS pump
SEN04967-00
Control of delivery q If the swash plate angle (a) becomes larger, the difference between volumes (E) and (F) b ec o me s l ar g er a nd pu m p d el i v e r y ( Q ) increases. q Swash plate angle (a) is changed with servo piston (10). q Servo piston (10) reciprocates straight according to the signal pressure of the PC and the LS valve. q This straight line movement is transmitted to rocker cam (4) through slider (14). q Being supported by cradle (2) on the cylindrical surface, rocker cam (4) slides on the surface while continuing revolving movement. q The area receiving the pressure is different at the left and right sides of servo piston (10), and the receiving pressure at the small diameter piston end is always connected with the main pump discharge pressure (self pressure) (PP). q Output pressure (PEN) of the LS valve is brought to the chamber receiving the pressure at the large diameter piston end. q The movement of servo piston (10) is controlled by the relationship of the size of the pressure (PP) at the small diameter piston end and the pressure (PEN) at the large diameter piston end, and the comparative size of the ratio of the area receiving the pressure at the small diameter piston end and large diameter piston end.
D65EX, PX, WX-16
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SEN04967-00
LS valve
PA: Pump port PDP: Drain port PLP: LS control pressure output port PLS: LS pressure input port PP: Pump port PPL: Control pressure input port PSIG: Drain port 1. Sleeve 2. Piston 3. Spool 4. Spring 5. Seat 6. Sleeve 7. Plug 8. Locknut
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401 Hydraulic system, Part 1 HSS pump
1
Function q The LS (load sensing) valve detects the load and controls the delivery. q This valve controls pump delivery (Q) according to differential pressure ( d PLS [= (PP) – (P LS) ] (c alle d LS differ ential pr ess ure) between pump delivery pressure (PP) and control valve outlet port pressure (PLS). q Pump discharge pressure (PP), pressure (PLS) [called LS pressure] coming from the control valve output enter this valve.
D65EX, PX, WX-16
401 Hydraulic system, Part 1 HSS pump
SEN04967-00
Operation When control valve is at neutral position
q
q
q q
q q
The LS valve is a three-way selector valve, with pressure (PLS) (LS pressure) from the inlet port of the control valve brought to spring chamber (B), and pump discharge pressure (PP) brought to port (H) of sleeve (1). Magnitude of the force resulting from this LS pressure (PLS), force of spring (4) and the pump delivery pressure (self pressure) (PP) determine the position of spool (3). Before the engine is started, servo piston (10) is pressed to the left. (See right drawing) If the control lever is at the neutral position when the engine is started, LS pressure (PLS) is set to 0 MPa {0 kg/cm2}. (It is interconnected to the drain circuit through the control valve spool) Spool (3) is pushed to the right, and port (C) and port (D) will be connected. Pump discharge pressure (PP) enters the large diameter end of piston from port (K).
D65EX, PX, WX-16
q q
Pump discharge pressure (PP) is present in the small diameter end of piston port (J). Because of the difference in area of servo piston (10), it moves in the direction to make the swash plate angle smaller.
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SEN04967-00
401 Hydraulic system, Part 1 HSS pump
Action for the direction of maximizing the pump delivery
q
q
q
q
When the difference between pump discharge pressure (PP) and LS pressure (PLS), namely LS differential pressure (dPLS) becomes smaller (for example, when opening area of the control valve becomes larger and pump delivery pressure (PP) drops), spool (3) is pushed to the left by the combined force of LS pressure (PLS) and the force of spring (4). When spool (3) moves, port (D) and port (E) are interconnected and connected to the PC valve. The PC valve is connected to the drain port, so the pressure across circuits (D) and (K) becomes drain pressure (PT). (The operation of the PC valve is explained later.) The pressure at the large piston diameter end of servo piston (10) becomes drain pressure (PT), and pump discharge pressure (PP) always enters the small diameter end port (J), so servo piston (10) is pushed to the left, and moves the swash plate in the direction to make the delivery larger.
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D65EX, PX, WX-16
401 Hydraulic system, Part 1 HSS pump
SEN04967-00
Action for the direction of minimizing the pump delivery
q
q
q
When LS differential pressure (dPLS) becomes larger [for example, when the area of opening of the control valve becomes smaller and pump pressure (PP) rises], pump pressure (PP) pushes spool (3) to the right. When spool (3) moves, pump discharge pressure (PP) flows from port (C) to port (D), and from port (K), it enters the large piston diameter end. Although main pump pressure (PP) is present in the small diameter end port (J) of piston, servo piston (10) is pushed to the right due to the difference in area between the large and small piston diameter ends of servo piston (10). As a result, it moves in the direction to make the swash plate angle smaller.
D65EX, PX, WX-16
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401 Hydraulic system, Part 1 HSS pump
SEN04967-00 When servo piston is balanced
q
q
q
q
Let us take the area receiving the pressure at the large diameter end of the piston as (A1), the area receiving the pressure at the small diameter end as (A0), and the pressure flowing into the large diameter end of the piston as (PEN). If pump discharge pressure (PP) of the LS valve and the combined force of spring (4) and LS pressure (PLS) are balanced, and the relationship becomes (A0) x (PP) = (A1) x (PEN), servo piston (10) stops at that position. And the swash plate of the pump will be held in an intermediate position. [Spool (3) will be stopped at a position where the distance of the opening from port (D) to port (E) and the distance from port (C) to port (D) is almost the same.] The relationship between the area receiving the pressure on both ends of servo piston (10) is (A0) : (A1) = 3 : 5, so the pressure applied to both ends of the piston when it is balanced becomes (PP) : (PEN) C 5 : 3.
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q
Force of spring (4) is adjusted in such that the position of the balanced stop of this spool (3) may be determined when (PP) – (PLS) = 1.9 MPa {19 kg/cm2} at the median of the specified value.
D65EX, PX, WX-16
401 Hydraulic system, Part 1 HSS pump
SEN04967-00
PC valve
PA: Pump port PDP: Drain port PM: Mode selector pressure pilot port PPL: Control pressure output port (to LS valve) 1. Plug 2. Servo piston assembly 3. Pin 4. Spool 5. Retainer 6. Seat 7. Seat 8. Plug 9. Cover 10. Wiring
D65EX, PX, WX-16
1
Function q When the pump discharge pressure (PP) is high, the PC valve controls flow to a constant level corresponding to the discharge pressure independent of increase in stroke of the control valve. q If the load during the operation becomes larger and the pump discharge pressure rises, it reduces the delivery from the pump. q If the pump discharge pressure drops, it increases the delivery from the pump. q In this case, the relationship between pump discharge pressure (PP) and pump delivery (Q) may be represented like shown in the figure below if the relationship is expressed as the parameter of current value (X) given to PCEPC valve solenoid. q The controller counts the actual engine speed. q At a low engine speed, the controller sends the command current to PC-EPC valve solenoid to reduce the pump delivery corresponding to the engine speed.
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SEN04967-00
401 Hydraulic system, Part 1 HSS pump
Operation When the load on the actuator is small and the pump pressure (PP) is low
Action of PC-EPC valve solenoid (1) q Command current (X) is being sent to PC-EPC valve solenoid (1) from the pump controller. q This command current (X) works on PC-EPC valve and output the signal pressure to change the force of pushing piston (2). q Spool (3) stops at a position where the combined force for pushing spool (3) is balanced by the spring set pressure of spring (4) and spring (5) and pump discharge pressure (PP). q The pressure [port (C) pressure] output from PC valve is changed depending on the above position. q The size of command current (X) is determined by the nature of the operation (lever operation), the selected working mode, and the set value and actual value of the engine speed.
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D65EX, PX, WX-16
401 Hydraulic system, Part 1 HSS pump
Action of spring q The load of spring (4) and spring (5) on the PC valve is determined by the swash plate position. q Spring load changes as servo piston (9) elongates and contracts spring (4) and spring (5). q If the command current (X) to PC-EPC valve solenoid (1) changes, so does the force pushing piston (2). q The load of spring (4) and spring (5) also changes according to the command current (X) to the PC-EPC valve solenoid. q Port (C) of the PC valve is connected to port (E) of the LS valve. q Pump pressure (PP) is applied to the small piston diameter end of servo piston (9), port (A) and port (B). q As long as pump pressure (PP) is low, spool (3) is on the left. q Ports (C) and (D) are connected, and the pressure entering the LS valve becomes drain pressure (PT).
D65EX, PX, WX-16
SEN04967-00
q
q q q
q
q
If port (E) and port (G) of the LS valve are connected, the pressure entering the large diameter end of the piston from port (J) becomes drain pressure (PT), and servo piston (9) moves to the left side. The pump delivery will be set to the increasing trend. Spring (4) extends as servo piston (9) moves and weakens the spring force. As the spring force is weakened, spool (3) moves to the right, the connecting between port (C) and port (D) is shut off and the pump discharge pressure ports (B) and (C) are connected. The pressure on port (C) rises and the pressure on the large diameter end of the piston also rises. Thus, the leftward move of servo piston (9) is stopped. The stop position for servo piston (9) [ = pump delivery] is decided at the point where the force of spring (4) and the pushing force of PC-EPC valve by solenoid and the pushing force created by pressure (PP) acting on spool (3) are in balance. 10-401
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SEN04967-00
401 Hydraulic system, Part 1 HSS pump
When load on actuator is large and pump pressure is high
Outline q When the load is large and pump discharge pressure (PP) is high, the force pushing spool (3) to the right becomes larger and spool (3) moves to the position shown in the diagram above. q As shown in the diagram above, part of the pressurized oil from port (B) flows out to port (D) from port (C) through the LS valve, and the pressure oil flowing from port (C) to the LS valve becomes approximately half of pump discharge pressure (PP).
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26
D65EX, PX, WX-16
401 Hydraulic system, Part 1 HSS pump
Operation q When port (E) and port (G) of the LS valve are connected, this pressure from port (J) enters the large diameter end of servo piston (9), stopping servo piston (9). q If pump discharge pressure (PP) increases further and spool (3) moves further to the right, pump discharge pressure (PP) flows to port (C) and acts to make the delivery the minimum. q If servo piston (9) moves to the right, spring (4) and spring (5) contract and push back spool (3). q When spool (3) moves to the left, the openings of port (C) and port (D) become larger. q The pressure on port (C) (= J) is decreased and the rightward move of servo piston (9) is stopped. q Stop position of servo piston (9) moves further rightward compared when pump discharge pressure (PP) is low. q The relationship between pump discharge pressure (PP) and pump delivery (Q) is as shown in the following figure.
D65EX, PX, WX-16
SEN04967-00
q
q
If command current (X) sent to PC-EPC valve solenoid (1) increases, the relationship between pump discharge pressure (PP) and pump delivery (Q) moves parallel in proportion to the pushing force of PC-EPC valve solenoid. Because the pushing force of PC-EPC valve solenoid (1) is added to the rightward pushing force applied to spool (3) by the pump discharge pressure, the relationship between pump discharge pressure (PP) and pump delivery (Q) moves from (A) to (B) in accordance with the increase of command current (X).
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SEN04967-00
PC-EPC valve
401 Hydraulic system, Part 1 HSS pump
1
C: To PC valve P: From pilot pump T: To tank 1. Connector 2. Coil 3. Body 4. Spring 5. Spool 6. Rod 7. Plunger
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D65EX, PX, WX-16
401 Hydraulic system, Part 1 HSS pump
Function q The EPC valve consists of the proportional solenoid portion and the hydraulic valve portion. q On receiving signal current (i) from the controller, the EPC valve generates EPC output pressure in proportion to the signal current and outputs it to the PC valve.
SEN04967-00 Operation When the signal current 0 (coil de-energized)
q
q q q
D65EX, PX, WX-16
When there is no signal current flowing from the controller to coil (2), coil (2) is de-energized. Spool (5) is pushed to the left by spring (4). Port (P) is closed and the pressurized oil from the pilot pump does not flow to the PC valve. The oil from the PC valve is drained through ports (C) and (T) to the tank.
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401 Hydraulic system, Part 1 HSS pump
SEN04967-00 When the signal current minute (coil energized)
q
q q
q q q
q
When a very small signal current flows to coil (2), coil (2) is energized, and a propulsion force is generated on the right side of plunger (7). Rod (6) pushes spool (5) to the right, and pressurized oil flows from port (P) to port (C). Pressures on port (C) increases and the force to act on spool (5) surface and the spring load on spring (4) become larger than the propulsion force of plunger (7). Spool (5) is pushed to the left, and port (P) is shut off from port (C). Port (C) and port (T) are connected. Spool (5) moves in such that the thrust of plunger (7) and pressure of port (C) + spring load of spring (4) balance to each other. Circuit pressure between the EPC valve and PC valve is controlled in proportion to the size of the signal current.
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When the signal current maximum (coil energized)
q q
q q
q
As the signal current flows to coil (2), coil (2) is energized. When this happens, the signal current is at its maximum, so the propulsion force of plunger (7) is also at its maximum. Spool (5) is pushed toward the right side by rod (6). Hydraulic oil from port (P) flows to port (C) with maximum flow rate. As the result, the circuit pressure between the EPC and PC valves becomes maximum. Since port (T) is closed, pressurized oil does not flow to the tank.
D65EX, PX, WX-16
401 Hydraulic system, Part 1 HSS motor
SEN04967-00
HSS motor
1
Model: HMF95(90)
PA: From control valve PB: From control valve T2: To hydraulic tank 1. HSS motor 2. Counterbalance valve 3. Safety valve 4. Check valve
Outline q This motor is composed of the fixed capacity swash plate type piston motor, flashing shuttle valve, bypass valve and charge relief valve. Specifications Theoretical delivery (cc/rev)
81.79
Rated speed (rpm)
2,597
Rated output pressure (MPa {kg/cm2})
D65EX, PX, WX-16
38.2 {390}
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401 Hydraulic system, Part 1 HSS motor
SEN04967-00
1. Output shaft 2. Motor case 3. Thrust plate 4. Piston 5. Cylinder block 6. Valve plate 7. End cover 8. Brake valve assembly
9. Counterbalance valve 10. Safety valve 11. Check valve 12. Sub bearing 13. Spline 14. Shoe 15. Main bearing
Unit: mm
No.
Check item
Criteria Standard size
16 Spool return spring
17 Check valve spring
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Free length x outside diameter
Installed length
42.7 x 30.0
40.5
43 x 13.8
32.9
Remedy Repair limit
Installed load 192 N {19.6 kg} 1.27 N {0.13 kg}
Free length — —
Installed load 154 N {15.7 kg} 0.98 N {0.10 kg}
Replace spring if damaged or deformed.
D65EX, PX, WX-16
401 Hydraulic system, Part 1 HSS motor
SEN04967-00
Outline q Pressurized oil sent from pump is converted to rotating torque and is transmitted to output shaft. Structure Cylinder block (5) is supported by output shaft (1) on spline (13), and output shaft (1) is supported by main bearing (15) and sub bearing (12). q The end of piston (4) has a concave ball shape, and shoe (14) is caulked to it to form one unit. Piston (4) and shoe (14) form a spherical bearing. q Piston (4) performs relative movement in the axial direction inside each cylinder chamber of cylinder block (5). q Cylinder block (5) carries out rotation relative to valve plate (6) while sealing the pressurized oil. q This surface ensures that the hydraulic balance is maintained correctly. q The oil inside each cylinder chamber on the rotating side [cylinder block] flows in and out of the port area on the stationary side [valve plate]. q
D65EX, PX, WX-16
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401 Hydraulic system, Part 1 HSS motor
SEN04967-00 Operation Operation of motor q The pressurized oil sent from the pump enters cylinder block (5) and pushes piston (4) from the back face. q In the case of the motor, the center line of plate (3) is constantly tilted at a certain degree [swash plate angle (a)] to the axial direction of cylinder block (5). q If we take the example of a piston (4), the oil pressure applied to the back face of the piston generates the piston axial force (FO) as shown in the figure below. q With shoe (14), which is joined to piston (4) by the spherical surface, reaction force (FR) in a direction at right angles to flat surface (A) is generated. The combined force of (FO) and (FR) is (FP) and this becomes the force to rotate cylinder block (5).
q
q
q
Rotation speed and torque control q As flow (Q) from the HSS pump is increased, motor speed (N) is heightened. q Since the swash plate angle of the HSS motor is fixed ((a) is constant), rotating torque (T) is proportional to pressure (P). q Swash plate angle (a) is approx. 15°. Q = qN (q = E – F) T = Pq/2x Q: Total flow q: Flow per rotation N: Rotation speed P: Pressure T: Rotating torque
Shaft (1), which is meshed to cylinder block (5) by spline (13) transfers this rotating torque to the output side. Cylinder block (5) rotates, and while the condition changes from volume (E) to volume (F), pressurized oil from the pump flows into the cylinder chamber, and pressure (P) is generated according to the load. On the other hand, when the condition goes beyond volume (F) and changes to volume (E), the oil is pushed out and returned to the pump.
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D65EX, PX, WX-16
401 Hydraulic system, Part 1 HSS motor
SEN04967-00
Brake valve operation q The brake valve consists of check valve (11), counterbalance valve (9), and safety valve (10), and the circuit is configured as shown in the following figure. q The function and the operation of each component is as given below.
D65EX, PX, WX-16
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401 Hydraulic system, Part 1 HSS motor
SEN04967-00
Counterbalance valve and check valve Function q When the steering is operated on a downhill slopes, the weight on the machine produces a force in the downward direction which makes the machine try to turn faster than the speed of the HSS motor. q If the engine is run at low speed and the steering is operated, the HSS motor will overrun, and this may cause an extremely dangerous condition. q To prevent this, this valve is installed to carry out the steering in accordance with the engine speed [pump discharge amount].
1
q
q
The pressurized oil at the side where the oil is being supplied flows from orifice (E1) of spool (9) into chamber (S1). And when the pressure in chamber (S1) becomes greater than the spool switching pressure, spool (9) is pushed to the right. In this way, port (MB) and port (PB) are connected. As a result, the outlet port side of the HSS motor is opened and the HSS motor starts to run.
Operation when pressurized oil is supplied When the steering lever is operated, the pressurized oil from the control valve is supplied to port (PA). It pushes open check valve (11a), and flows from HSS motor inlet port (MA) to HSS motor outlet port (MB). q However, the outlet port side of the HSS motor is closed with check valve (11b) and counterbalance valve (9), so the pressure at the supply side increases. q
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D65EX, PX, WX-16
401 Hydraulic system, Part 1 HSS motor
SEN04967-00
Action of brakes when operating steering on downhill slopes q When the steering is operated on a downhill slopes, if the machine attempts to run away, the HSS motor will rotate under no load, and the oil pressure at the inlet port of the HSS motor will drop. This drop in the pressure will pass through orifice (E1), so the pressure in chamber (S1) will also drop. q If the pressure in chamber (S1) drops below the spool switching pressure, spool (9) is pushed to the left by spring (16) and outlet port (MB) is throttled. q The pressure on the outlet side increases to generate rotational resistance on the HSS motor. In this way, the machine runaway is prevented. q The spool moves to a position where the pressure of the outlet side port (MB) is balanced with the machine weight and the inlet side pressure to throttle the outlet port circuit and control the speed corresponding the pump delivery.
D65EX, PX, WX-16
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SEN04967-00
401 Hydraulic system, Part 1 HSS motor
Safety valve
1
Function q When the operation of the steering stops, counterbalance valve (9) closes the circuit at the inlet and outlet ports of the HSS motor. q Since the inertial force keeps the HSS motor running, the pressure on the outlet port of the HSS motor becomes abnormally high, resulting in damaging the HSS motor and the piping. q The safety valve releases this abnormal pressure to the inlet port side of the HSS motor to protect the equipment from damage. Operation
q
When the operation of the steering is stopped, the check valve of the counterbalance valve (9) closes chamber (E) (or chamber (F)) in the outlet port circuit, but the pressure at the outlet port side continues to rise because of inertia.
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q
If the pressure in chamber (E) [or chamber (F)] goes above the set pressure, x(D12 – D22)/4 x pressure resulting from the difference in area between (D1) and (D2) [or x (D3 2 – D1 2 )/4 x pressure resulting from the difference in area between (D3) and (D1)] moves the poppet rightward overcoming the spring force. Thus, the oil flows to the circuit on the opposite side chamber (F) [or chamber (E)].
D65EX, PX, WX-16
401 Hydraulic system, Part 1 HSS motor
D65EX, PX, WX-16
SEN04967-00
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39
SEN04967-00
D65EX-16, D65PX-16, D65WX-16 Bulldozer Form No. SEN04967-00
©2009 KOMATSU All Rights Reserved Printed in Japan 02-09 (01)
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SEN04968-01
BULLDOZER D65EX-16 D65PX-16 D65WX-16 Machine model D65EX-16 D65PX-16 D65WX-16
Serial number 80001 and up 80001 and up 80001 and up
10 Structure, function and maintenance standard
1
402 Hydraulic system, Part 2 Control valve ................................................................................................................................................... 2 CLSS..............................................................................................................................................................11 Function and operation of each valve ........................................................................................................... 14
D65EX, PX, WX-16
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1
SEN04968-01
Control valve
402 Hydraulic system, Part 2 Control valve
1
Outline The control valves of the following 4 types are set. q 4-spool valve (lift + tilt + angle + steering) q 4-spool valve (lift + tilt + ripper + steering) q 5-spool valve (lift + tilt + angle + ripper + steering) [for power angle power tilt dozer] q 5-spool valve (lift + tilt + pitch + ripper + steering) [for straight tilt power pitch dozer] [for sigma power pitch dozer] As for outside view and sectional view, only the 5-spool valves (for straight tilt power pitch dozer and for sigma power pitch dozer) are shown. A1: To HSS motor A2: To lift cylinder head A3: To pitch cylinder bottom A4: To angle cylinder bottom A5: To ripper cylinder bottom B1: To HSS motor B2: To lift cylinder bottom B3: To pitch cylinder head B4: To angle cylinder head B5: To ripper cylinder head CA1: Connector (from controller) CB1: Connector (from controller) LS: To pump (port LS) P: From pump PA2: From blade PPC valve PA3: From blade PPC valve PA4: From blade PPC valve PA5: From ripper PPC valve PB2: From blade PPC valve PB3: From blade PPC valve PB4: From blade PPC valve PB5: From ripper PPC valve PEPC: From self-pressure reducing valve PI: Pump pressure pickup port PP: To pump LS valve SI: Steering LS pressure pickup port T: To tank TS: To tank
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D65EX, PX, WX-16
402 Hydraulic system, Part 2 Control valve
SEN04968-01
Outside view
D65EX, PX, WX-16
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SEN04968-01
402 Hydraulic system, Part 2 Control valve
Sectional view (1/5)
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D65EX, PX, WX-16
402 Hydraulic system, Part 2 Control valve
SEN04968-01
1. Suction valve 2. Back pressure valve 3. Steering spool 4. Lift spool 5. Tilt spool 6. Pitch spool 7. Ripper spool 8. Cover (work equipment valve side) 9. Ripper valve 10. Pitch valve 11.Tilt valve 12. Lift valve 13. Block (pump port) 14. Steering valve 15. Cover (steering valve side) Unit: mm
No.
Check item
16 Suction valve spring
17 Back pressure valve spring 18 Suction valve spring 19 20 21 22 23
Spool return spring (steering) Spool return spring (lift ripper) Spool return spring (tilt pitch) Spool return spring (lift) Spool return spring (lift)
D65EX, PX, WX-16
Criteria Standard size Free length x Installed outside diameter length 46.8 x 7.5
40.6
67.7 x 20
42.5
39.2 x 4.45
33.5
45.7 x 28
43
41.1 x 19.3
40.5
41.9 x 18.6
39
37.3 x 19.4
17
40.5 x 24.6
37.5
Installed load 5.49 N {0.56 kg} 67.7 N {6.9 kg} 5.10 N {0.52 kg} 221 N {22.55 kg} 34.3 N {3.5 kg} 108 N {11 kg} 51.4 N {5.24 kg} 81.4 N {8.3 kg}
Remedy Repair limit Installed Free length load 4.41 N — {0.45 kg} 54.1 N — {5.52 kg} 4.12 N — {0.42 kg} 177 N — {18.0 kg} 27.5 N — {2.8 kg} 86.3 N — {8.8 kg} 41.1 N — {4.19 kg} 65.1 N — {6.64 kg}
Replace spring if damaged or deformed.
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402 Hydraulic system, Part 2 Control valve
(2/5)
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D65EX, PX, WX-16
402 Hydraulic system, Part 2 Control valve
SEN04968-01
1. LS relief valve (for steering valve) 2. Pressure compensation valve R 3. Pressure compensation valve F 4. Pressure reducing valve (for work equipment valve) 5. Steering priority valve 6. Check valve (centralized safety valve) R: Pressure reducing valve F: Flow control valve Unit: mm
No.
Check item
Criteria
7
Standard size Free length x Installed Pressure compensation valve outside diameter length F 36.2 x 5.3 32
8
Pressure compensation valve R spring
27.5 x 14.2
18
9
Steering priority valve spring
106.5 x 20
82
10
Pressure reducing valve spring Pressure compensation valve F spring Pressure compensation valve R spring Pressure compensation valve R spring
51.6 x 10.5
44.5
30.85 x 5.2
27
31.9 x 14.4
21.5
33.4 x 14.4
21.5
27.2 x 6.9
22
11 12 13
14 Check valve spring
D65EX, PX, WX-16
Installed load 9.81 N {1 kg} 17.7 N {1.8 kg} 473 N {48.2 kg} 125 N {12.7 kg} 9.81 N {1.0 kg} 34.3 N {3.5 kg} 55.9 N {5.7 kg} 3.92 N {0.4 kg}
Remedy Repair limit Installed Free length load 7.85 N — {0.80 kg} 14.1 N — {1.44 kg} 379 N — {38.6 kg} 100 N — {10.2 kg} 7.85 N — {0.80 kg} 27.5 N — {2.8 kg} 44.7 N — {4.56 kg} 3.14 N — {0.32 kg}
Replace spring if damaged or deformed.
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402 Hydraulic system, Part 2 Control valve
(3/5)
1. Main relief valve
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D65EX, PX, WX-16
402 Hydraulic system, Part 2 Control valve
SEN04968-01
(4/5)
1. Unload valve
D65EX, PX, WX-16
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402 Hydraulic system, Part 2 Control valve
(5/5)
1. Centralized safety valve (for work equipment valve) 2. Pressure release plug 3. Main relief valve (for work equipment valve)
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D65EX, PX, WX-16
402 Hydraulic system, Part 2 CLSS
SEN04968-01
CLSS a
1
CLSS: Abbreviation for Closed center Load Sensing System
Outline of CLSS
Features CLSS has the following features. q Fine control performance free from influence of load q Control performance which enables digging even in fine control mode q Flow distribution decided by spool opening area during compound operation q Energy saved by variable pump control
D65EX, PX, WX-16
1
Configuration q CLSS consists of the variable displacement type piston pump, control valve and actuators. q The pump unit consists of the main pump, fixed choke valve, PC valve and LS valve.
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402 Hydraulic system, Part 2 CLSS
SEN04968-01
Basic principle Control of pump swash plate q The pump swash plate (pump delivery) is controlled so that the LS differential pressure (dPLS) which is the differential pressure between pump discharge pressure (PP) and control valve outlet LS pressure (PLS) (actuator load pressure) may become constant. [LS differential pressure (dPLS) = Pump discharge pressure (PP) – LS pressure (PLS)]
1
q
If the LS differential pressure (dPLS) lowers below the LS valve set pressure (when the actuator load pressure is high), the pump swash plate angle increases. If the LS differential pressure rises higher than the set pressure (the actuator load pressure is low), the pump swash plate angle decreases.
[LS differential pressure (dPLS) and pump swash plate
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402 Hydraulic system, Part 2 CLSS
SEN04968-01
Pressure compensation control
q
The valve which balances the load (pressure compensation valve) is installed to the outlet side of the control valve. When the actuators are operated simultaneously, this valve keeps the pressure difference between the upstream (inlet) side of each valve spool and downstream (outlet) side (dP) constant, regardless of the load (pressure). By this operation, the oil flow from the pump is divided (compensated)
D65EX, PX, WX-16
in proportion to open area (S1) and (S2) of each operated valve.
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402 Hydraulic system, Part 2 Function and operation of each valve
Function and operation of each valve
1
Hydraulic circuit diagram and valve names
1
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D65EX, PX, WX-16
402 Hydraulic system, Part 2 Function and operation of each valve
1. 2. 3. 4. 5. 6. 7. 8. 9. 10. 11. 12. 13. 14. 15. 16.
SEN04968-01
Unload valve Set pressure: 3.4 MPa {35 kg/cm2} Main relief valve Set pressure: 40.2 MPa {410 kg/cm2} Steering priority valve Pressure reducing valve (for work equipment valve) Set pressure: 28.1 MPa {287 kg/cm2} Pressure compensation valve Suction valve LS shuttle valve LS relief valve (for steering valve) Set pressure: 37.2 MPa {379 kg/cm2} Centralized safety valve (for work equipment valve) Set pressure: 34.0 MPa {347 kg/cm2} Main relief valve (for work equipment valve) Set pressure: 30.1 MPa {307 kg/cm2} Steering valve Lift valve Tilt valve Pitch valve Ripper valve Back pressure valve
D65EX, PX, WX-16
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Unload valve
402 Hydraulic system, Part 2 Function and operation of each valve
1
When control valve is in neutral
PLS: LS circuit PP: Pump circuit T: Tank circuit 1. Sleeve 2. Spring 3. Spool
Function q When the control valve is in neutral, the valve releases delivery (Q) for the pump minimum swash plate angle into the tank circuit. At this time, pump discharge pressure (PP) is set to 3.4 MPa {35 kg/cm2} by spring (2) in the valve. [LS pressure (PLS) is 0 MPa {0 kg/cm2}] Operation q Pump discharge pressure (PP) is applied to the right end of spool (3) and LS pressure (PLS) is applied to the left end. q While the control valve is in neutral, only pump discharge pressure (PP) is applied and it is set with only the spring load of spring (2) since LS pressure (PLS) is 0 MPa {0 kg/cm2}. q If pump discharge pressure (PP) increases to the 3.4 MPa {35 kg/cm2} spring load of spring (2), spool (3) moves to the left and pump circuit (PP) is connected to the tank circuit (T) through hole (a) of sleeve (1). q Pump discharge pressure (PP) is set to 3.4 MPa {35 kg/cm2}.
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D65EX, PX, WX-16
402 Hydraulic system, Part 2 Function and operation of each valve
SEN04968-01
When control valve is set fine control
Function q When the control valve is set fine control, if the actuator demand flow is below the delivery at the pump minimum swash plate angle, pump discharge pressure (PP) is set to LS pressure (PLS) + 3.4 MPa {35 kg/cm2}. If the differential pressure between discharge pressure (PP) and LS pressure (PLS) reaches the 3.4 MPa {35 kg/cm 2 } spring load of spring (2), the unload valve opens and LS differential pressure (dPLS) becomes 3.4 MPa {35 kg/cm2}.
q
q
If the differential pressure between pump discharge pressure (PP) and LS pressure (PLS) reaches 3.4 MPa {35 kg/cm 2 } spring load of spring (2), spool (3) moves to the left and pump circuit (PP) is connected to the tank circuit (T). The pump discharge pressure (PP) is set to pressure of 3.4 MPa {35 kg/cm2} + LS pressure (PLS) and flow control differential pressure ( d P L S ) a t b e l o w m i n i m um s wa s h p l a t e becomes 3.4 MPa {35 kg/cm2}.
Operation q When the actuators are controlled with flow of below the pump minimum swash plate angle [flow below (Q) min. in the figure at right], if the control valve spool is changed, LS pressure [PLS = Load pressure] is detected and applied to the left end of spool (3). q Since pump discharge pressure (PP) increases to pass all of (Q) min. through the narrow opening of the control valve spool, the differential pressure between pump discharge pressure (PP) and LS pressure (PLS) increases.
D65EX, PX, WX-16
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402 Hydraulic system, Part 2 Function and operation of each valve
When control valve is operated
Function q When the control valve is operated, if the actuator demand flow exceeds the flow at the pump minimum swash plate angle, the flow to the tank circuit (T) is stopped and all of pump delivery (Q) is supplied to the actuator circuit. Operation If the control valve is operated far, LS pressure (PLS) is generated and applied to the left end of spool (3). At this time, LS differential pressure (dPLS) not much different from pump discharge pressure (PP), since the open area of control valve spool is wide. q Since the differential pressure between pump discharge pressure (PP) and LS pressure (PLS) does not reach the 3.4 MPa {35 kg/cm2} spring load of spring (2), spool (3) is pushed to the right by spring (2). q Pump circuit (PP) is disconnected from tank circuit (T) and all of pump delivery (Q) flows to the actuator circuit. q
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D65EX, PX, WX-16
402 Hydraulic system, Part 2 Function and operation of each valve
SEN04968-01
Main relief valve (steering and work equipment)
1
Centralized safety valve Function q If the oil pressure exceeds a set pressure, this valve drains the oil into the tank. The maximum pressure in the work equipment circuit is limited by this operation to protect the circuit. Operation
q
q
q
Since pilot poppet (3) opens, the pressure in spring chamber (C) decreases and poppet (1) moves to the right until it touches the end of pilot poppet (3) and then oil is drained through throttle (b) and the drilled hole.
q
Since the pressure in spring chamber (C) is lower than that in port (A), main valve (2) opens and the oil flows from port (A) to (B) to prevent abnormal pressure rise.
Port (A) is connected to the pump circuit and port (B) is connected to the drain circuit. The pressurized oil acts on diameter (d2) of main valve (2) through diameter (d1) of main valve (2) and the hole of poppet (1). Main valve (2) is in contact with the sleeve because of the area difference (d1 < d2).
If the pressure in port (A) reaches the set pressure of spring (4), pilot poppet (3) opens and the oil flows around pilot poppet (3) and then is drained through drilled hole (a) and port (B).
D65EX, PX, WX-16
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Steering priority valve
402 Hydraulic system, Part 2 Function and operation of each valve
1
Compound operations
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D65EX, PX, WX-16
402 Hydraulic system, Part 2 Function and operation of each valve
SEN04968-01
a: Pump circuit b: Steering pump circuit c: Work equipment pump circuit d: Spring chamber e: Pressure chamber 1. Steering priority valve spool 2. Priority valve spring 3. Steering spool 4. Work equipment spool Function q If the steering valve and the work equipment valve on the downstream side of the steering priority valve are operated at the same time, priority is given to the flow of oil to the steering valve, and the rest of the oil discharged from the pump goes to the work equipment valve. Operation When steering spool (3) is operated and the oil flows, differential pressure occurs between pump discharge pressure (PP) and LS pressure (PLS). Steering priority valve (1) is controlled by this differential pressure, and at the same time, the pump swash plate angle is controlled by (dPLS) [(PP) – (PLS)] = 1.96 MPa {20 kg/cm2}, and the flow of oil to the steering valve is fixed. q The (PP) pressure is applied to right end (e) of priority valve spool (1) and the (PLS) pressure is applied to spring chamber (d) on the left side. Priority valve spool (1) is pushed to the right by spring (2). q When the differential pressure between the (PP) pressure and (PLS) pressure is below the set pressure, the opening between chamber (a) and chamber (b) becomes maximum. If the differential pressure increases, spool (1) moves to the left to throttle the opening for the steering and increase the opening for the work equipment. q If work equipment spool (4) is operated while steering spool (3) is operated, pump pressure (PP) momentarily drops. q The differential pressure between (PP) and (PLS) decreases and priority valve (1) is moved by the pressure in chamber (d) in the direction to throttle the opening to the [right]. q At the same time, (dPLS) becomes smaller, so the pump swash plate angle increases to supply an oil flow to make up the amount that the pressures drops. q
D65EX, PX, WX-16
When pump swash plate does not reach maximum angle q When the maximum oil flow from the pump is greater than the sum of the flow demanded by the steering valve and work equipment valve, an amount of oil that matches the opening of steering spool (3) flows to the steering valve and the amount of oil decided by the pump pressure, load pressure and spool opening area flows to the work equipment valve. When pump swash plate is at maximum angle When the maximum flow of oil from the pump is smaller than the sum of the oil flow demanded by the steering valve and work equipment valve.
q
1.
When steering valve load Z work equipment valve load q An amount of oil that matches the opening of steering spool (3) flows to the steering valve, and the remaining oil flows to work equipment valve.
2.
When steering valve load > work equipment valve load q Pump pressure (PP) is determined by the steering valve load, but in this condition, if the downstream work equipment valve where the load is smaller is operated, the differential pressure causes the oil to flow to the work equipment valve, so the pump pressure drops. q Steering priority valve (1) increases the size of the opening to the steering, while at the same time reducing the size of the opening to the work equipment in order to ensure the flow of oil to the steering. q In this condition, the flow of oil is divided in proportion to the ratio of (PP) – (P1) differential pressure to (PP) – (P2) differential pressure. The bigger (P1) – (P2) is, the smaller the flow of oil to the steering system becomes.
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402 Hydraulic system, Part 2 Function and operation of each valve
SEN04968-01
Pressure reducing valve for work equipment
1
When work equipment valve is operated singly
a: Work equipment pump circuit b: Orifice c: Spring chamber d: Valve pressure receiving chamber e: Notch f: Orifice g: Pressure chamber h: Notch i: Notch PP: Pump circuit T: Tank circuit 1. 2. 3. 4. 5. 6. 7.
Function q This valve controls the pump circuit pressure on the work equipment side to a maximum of 28.1 MPa {287 kg/cm2} and secures the pump cir cui t pres sur e on the s teeri ng sid e at 40.2 MPa {410 kg/cm2} during compound operation (work equipment + steering).
Pressure reducing valve Poppet Spring Valve Spring Steering priority valve spool Spring
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D65EX, PX, WX-16
402 Hydraulic system, Part 2 Function and operation of each valve
SEN04968-01
Operation q If the work equipment valve (lift, tilt, angle, etc.) is operated, pressurized oil (PP) in the pump circuit flows through notch (e) and orifice (f) of spool (6) to right end chamber (g) and pushes spring (7) to the left, and notch open area (h) becomes maximum. The pressurized oil is supplied through notch (i) of valve (4) to work equipment pump circuit (a). q If the pressure in work equipment pump circuit (a) reaches 28.1 MPa {287 kg/cm2} set pressure of pressure reducing valve (1), poppet (2) pushes spring (3) to the right to release the pressurized oil in spring chamber (c) into tank circuit (T). Accordingly, the pressurized oil in pressure chamber (d) flows through orifice (b) and spring chamber (c) to tank circuit (T). A pressure difference is generated between pressure chamber (d) and spring chamber (c) and then valve (4) moves to the right to close notch (i). As a result, pump circuit (PP) and work equipment pump circuit (a) are disconnected. q Even if the steering is operated and the pump c ir cu it pr es su re in cr ea se s to 40.2 MP a {410 kg/cm2}, the work equipment pump circuit pressure does not exceed 28.1 MPa {287 kg/ cm2}.
D65EX, PX, WX-16
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Pressure compensation valve
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402 Hydraulic system, Part 2 Function and operation of each valve
1
D65EX, PX, WX-16
402 Hydraulic system, Part 2 Function and operation of each valve
Function q When the load pressure of an actuator is lower than the other actuator and the oil flow is about start increasing during compound operation, the pressure compensation valve compensates for the pressure. [At this time, the load pressure on the other actuator side (upper side) in the compound operation is higher than the actuator on this side (lower side).] Operation Load pressure (Ab) on the other actuator side (upper side) increases during compound operation, the flow in the actuator circuit (Aa) on this side (lower side) starts increasing. q In this case, LS pressure (PLS) of the other actuator acts on spring chamber (PLS1) and pushes pressure reducing valve (1) and flow control valve (2) to the left. q Flow control valve (2) throttles the open area between pump circuit (PP) and spool upstream (PPA) to generate a pressure loss between (PP) and (PPA). q Flow control valve (2) and pressure reducing valve (1) are balanced at a position where the pressure difference between (PA) and (PLS) applied to both sides of pressure reducing valve (1) is the same as the pressure loss between (PP) and (PPA) at the front and rear of flow control valve (2). q The pressure differences between upstream pressure (PPA) and downstream pressure (PA) of both spools operated for compound operation become the same and the pump delivery is divided in proportion to the open area of notch (a) of each spool.
SEN04968-01
Suction valve
1
Function q This valve prevents generation of negative pressure in the cylinder circuit. Operation
q
D65EX, PX, WX-16
q
Port (A) is connected to the cylinder circuit and port (B) is connected to the drain circuit. If load is applied to port (A), main poppet (1) opens because of the area difference between (d1) and (d2) and then the oil flows through port (B) to port (A) to prevent generation of negative pressure.
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402 Hydraulic system, Part 2 Function and operation of each valve
SEN04968-01
Suction safety valve
1
Function q When an impact is applied to the cylinder and abnormal pressure is generated, this valve releases the abnormal pressure to protect the cylinder and other hydraulic devices. q If negative pressure is generated in the cylinder circuit, this valve functions as a suction valve. Operation as safety valve
q
q
Since pilot poppet (4) opens, the pressure in chamber (C) drops and poppet (3) moves to the right. Poppet (3) is seated to the end of pilot poppet (4) and the oil is drained through throttle (b) and chamber (D).
q
Since the pressure in chamber (C) is lower than that in port (A), safety valve (2) moves to the right and the oil flows from port (A) to port (B) to prevent abnormal pressure generation. Even if abnormal pressure is generated, suction valve (1) having large sectional area does not operate since (d1) < (d4).
Port (A) is connected to the cylinder circuit and port (B) is connected to the drain circuit. The hydraulic pressure in port (A) passes through the hole of poppet (3) and port (C), and safety valve (2) is seated to the left side because of the relationship of (d2) < (d3). The relationship between the sectional diameters (sectional areas) is (d4) > (d1) > (d3) > (d2).
q
q
If abnormal pressure is generated in port (A) and it reaches the set pressure of spring (5), pilot poppet (4) opens and the oil in chamber (C) is drained through chamber (D) and periphery (a) of suction valve (1).
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402 Hydraulic system, Part 2 Function and operation of each valve
SEN04968-01
Operation as suction valve
q
If negative pressure is generated in the cylinder circuit, the pressures in port (A) and chamber (C) become negative since those are connected to each other. Since the tank pressure of port (B) is applied to port (E), the hydraulic pressure on suction valv e ( 1) increases by the area difference between (d4) and (d3) and moves suction valve (1) to the right against the reaction force of spring (6). As a result, the oil flows through port (B) to port (A) to prevent negative pressure generation in port (A).
D65EX, PX, WX-16
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SEN04968-01
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402 Hydraulic system, Part 2 Function and operation of each valve
D65EX, PX, WX-16
402 Hydraulic system, Part 2 Function and operation of each valve
SEN04968-01
LS shuttle valve
a: LS bypass orifice (steering) b: LS bypass orifice (work equipment side) 1. LS shuttle valve 2. Ball shuttle valve Function q This valve releases residual LS pressure (PLS). q This valve lowers the increasing speed of LS pressure (PLS) and generates a pressure loss in the throttle between (P) and (LS) of the pressure compensation valve with the discarded throttled flow to lower the effective LS differential pressure to increase the stability. q This valve selects and outputs the higher one of LS pressure on the steering side or on the work equipment side.
D65EX, PX, WX-16
1
Operation q Circuit pressure (PLS) on the steering side presses ball shuttle valve (2) to the right and is led to upper output port (PLS). [When steering is operated singly or together with another actuator and steering (PLS) > work equipment PLS)] q Pressurized oil (PLS) on the steering side flows through orifice (a) to the tank circuit. q The pressure in the PLS circuit on the work equipment side presses ball shuttle valve (2) to the left and is led to upper (PLS) output port. [When work equipment is operated singly or together with another actuator and work equipment (PLS) > steering (PLS)] q Pressurized oil (PLS) on the work equipment side flows through orifice (b) to the tank circuit.
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402 Hydraulic system, Part 2 Function and operation of each valve
SEN04968-01 Operations of steering LS relief valve and main relief valve
a: Pump primary circuit b: Pump secondary circuit c: LS circuit
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1. Steering spool 2. Steering LS relief valve 3. Main relief valve 4. HSS motor 5. Priority valve spool 6. Priority valve spring 7. Unload valve
D65EX, PX, WX-16
402 Hydraulic system, Part 2 Function and operation of each valve
SEN04968-01
Function q It sets the maximum pressure when the HSS motor is operated. q The pump LS valve senses the differential pressure (PP) – (PLS) generated by the operation of the LS relief valve and reduces the pump swash plate angle. The pump delivery is balanced at the minimum point. As a result, the relief flow decreases. q The main relief valve cuts the peak pressure generated by a sudden outside load (e.g., operation of the LS relief valve) which the pump swash plate control cannot follow. Operation If steering spool (1) is moved and HSS motor drive pressure (4) increases, steering LS relief valve (2) operates and the oil in pump circuit (b) is drained. As a result, the pressure difference between pump circuit (b) and LS circuit (c) increases. q For the same reason, if the pressure in LS circuit (c) decreases, priority valve spool (5) moves to the left against spring (6) to throttle the open area between pump primary circuit (a) and secondary circuit (b), and the pressure difference between (a) and (b) increases. q The pump LS valve senses LS differential pressure (PP) – (PLS) generated by LS relief valve (2) and reduces the pump swash plate angle. The pump swash plate is balanced at the minimum delivery point when LS differential pressure X 2.0 MPa {20 kg/cm 2 }. (See "Control of pump swash plate") q When the pump swash plate is at the minimum angle (minimum flow position), if pump circuit pressure (PP) – LS circuit pressure (PLS) X 3.4 MPa {35 kg/cm2}, unload valve (7) operates to relieve the excessive oil to balance the swash plate. q
LS relief valve set pressure (MPa {kg/cm2})
37.2 {379}
Main relief valve set pressure (MPa {kg/cm2})
40.2 {410}
D65EX, PX, WX-16
10-402
31
SEN04968-01
402 Hydraulic system, Part 2 Function and operation of each valve
Operation of work equipment relief valve
1. Work equipment spool 2. Pressure reducing valve 3. Main relief valve (work equipment) 4. Main relief valve (steering) 5. Pressure reducing valve spool 6. Unload valve
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32
D65EX, PX, WX-16
402 Hydraulic system, Part 2 Function and operation of each valve
SEN04968-01
Function q This valve sets the maximum pressure when the work equipment operates. q The pump LS valve senses differential pressure (PP1) – (PP2) C (PLS) generated by the operation of the reducing valve and relief pressure on the work equipment side, and reduces the pump swash plate angle. The pump delivery is balanced at the minimum point. As a result, the relief flow decreases. Operation If work equipment spool (1) is moved and work equipment operating pressure (PP2) increases, pressure reducing valve (2) operates and pressure reducing valve spool (5) closes to reduce the opening between (PP1) and (PP2) (1.1 mm2). Work equipment pump circuit pressure (PP2) becomes 28.1 MPa {287 kg/cm 2 } of the pressure reducing valve set pressure. q Work equipment operating pressure (PP2) is decided by the pressure reducing valve set pressure and (PP1) is decided by the pressure reducing valve set pressure + unload valve set pressure since excessive oil is drained through the unload valve. q The work equipment relief valve cuts the peak pressure generated by a sudden outside load (e.g., operation of the pressure reducing valve) which the pump swash plate control cannot follow. q
Pressure reducing valve set pressure (MPa {kg/cm2})
28.1 {287}
Relief valve set pressure (MPa {kg/cm2})
30.1 {307}
Unload valve set pressure (MPa {kg/cm2})
D65EX, PX, WX-16
3.4 {35}
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33
402 Hydraulic system, Part 2 Function and operation of each valve
SEN04968-01
Introduction of LS pressure
1
Steering valve
Function q The LS pressure means the actuator load pressure on the control valve outlet side. q In the work equipment valve, actually, pump discharge pressure (PP) is reduced by pressure reducing valve (3) of the pressure compensation valve to the level of actuator circuit pressure (A) and then introduced into LS circuit (PLS). Orifice (c) is made in piston (5) between pump circuit (PP) and pressure reducing valve (3), and it works as a damper. Operation If spool (1) is operated, pump discharge pressure (PP) flows through flow control valve (2), spool notch (a) and bridge passage (b) to actuator circuit (A).
q
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34
q
q q
q
Since pressure reducing valve (3) moves to the left at the same time, pump discharge pressure (PP) led through orifice (c) is led into LS circuit (PLS) while it is pressure-reduced by the pressure loss of throttle (d) and further led to spring chamber (PLS1). LS circuit (PLS) is connected to tank circuit (T) through LS bypass plug (4). The areas on both sides of pressure reducing valve (3) are the same (SA) = (SLS), and actuator circuit pressure (PA) = (A) is applied to the (SA) side and reduced pump discharge pressure (PP) is applied to the opposite (SLS) side. Pressure reducing valve (3) is balanced at a position where actuator circuit pressure (PA) and the pressure in spring chamber (PLS1) are the same, and pump discharge pressure (PP) reduced by notch (d) is led as actuator circuit pressure (A) to LS circuit (PLS).
D65EX, PX, WX-16
402 Hydraulic system, Part 2 Function and operation of each valve
SEN04968-01
Work equipment valve (lift, tilt, angle, ripper) When blade is lifted "RAISE"
Operation q If spool (1) is operated, pump discharge pressure (PP) flows through flow control valve (2), spool notch (a) and bridge passage (b) to actuator circuit (A). q Since pressure reducing valve (3) moves to the right at the same time, pump discharge pressure (PP) led through passage (c) is led into LS circuit (PLS) while it is pressurereduced by the pressure loss of notch (d) and further led to spring chamber (PLS1). q LS circuit (PLS) is connected to tank circuit (T) through LS bypass plug (4). q The areas on both sides of pressure reducing valve (3) are the same (SA) = (SLS), and actuator circuit pressure (PA) = (A) is applied to the (SA) side and reduced pump discharge pressure (PP) is applied to the opposite (SLS) side.
D65EX, PX, WX-16
q
Pressure reducing valve (3) is balanced at a position where actuator circuit pressure (PA) and the pressure in spring chamber (PLS1) are the same, and pump discharge pressure (PP) reduced by notch (d) is led as actuator circuit pressure (A) to LS circuit (PLS).
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35
SEN04968-01
402 Hydraulic system, Part 2 Function and operation of each valve
When blade is operated in "FLOAT" position
Operation q When the lift valve is in the "FLOAT" position, the cylinder port and drain port (T) are connected and no load is applied. q Even while the lift valve is in the "FLOAT" position, the pump circuit and the cylinder circuit are separated so that the other work equipment control valves (e.g., tilt, angle) can be operated. q If the work equipment control lever is set in the "FLOAT" position, spool (1) is set to the maximum stroke position, port (B) is connected to port (A) through bridge passage (b), and port (A) is connected to (T) circuit. q If the blade is loaded, it moves in either direction. q While the work equipment control lever is in the "FLOAT" position, part (a) of spool (1) is closed. Accordingly, another work equipment valve (e.g., tilt, angle) is operated, the pump pressure increases and compound operation becomes possible.
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36
D65EX, PX, WX-16
402 Hydraulic system, Part 2 Function and operation of each valve
SEN04968-01
Back pressure valve
Function q When the steering is operated or stopped, the steering drain circuit pressure is increased to improve the effect of suction valve (3) and prevent cavitation in the HSS motor.
D65EX, PX, WX-16
1
Operation q The steering circuit drain pressure is increased with back pressure valve (1) and spring (2).
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37
SEN04968-01
D65EX-16, D65PX-16, D65WX-16 Bulldozer Form No. SEN04968-01
©2010 KOMATSU All Rights Reserved Printed in Japan 02-10 (01)
10-402
38
SEN04969-00
BULLDOZER D65EX-16 D65PX-16 D65WX-16 Machine model D65EX-16 D65PX-16 D65WX-16
Serial number 80001 and up 80001 and up 80001 and up
10 Structure, function and maintenance standard
1
403 Hydraulic system, Part 3 PPC valve (blade lift, blade tilt) ....................................................................................................................... 2 PPC valve (ripper)........................................................................................................................................... 8 Electric lever (steering) ................................................................................................................................. 12 Quick drop valve ........................................................................................................................................... 16 Work equipment lock solenoid valve............................................................................................................. 18 Pitch selector solenoid valve......................................................................................................................... 22 Hydraulic oil cooler bypass valve .................................................................................................................. 23 Accumulator .................................................................................................................................................. 24
D65EX, PX, WX-16
10-403
1
SEN04969-00
PPC valve (blade lift, blade tilt) a
403 Hydraulic system, Part 3 PPC valve (blade lift, blade tilt)
1
PPC: Abbreviation for Proportional Pressure Control
10-403
2
D65EX, PX, WX-16
403 Hydraulic system, Part 3 PPC valve (blade lift, blade tilt)
P: From self-pressure reducing valve P1: To blade lift valve (port PA3) P2: To blade lift valve (port PB3) P3: To blade tilt valve (port PA2) P4: To blade tilt valve (port PB2) T: To hydraulic tank
D65EX, PX, WX-16
SEN04969-00
1. Disc 2. Plate 3. Body
10-403
3
403 Hydraulic system, Part 3 PPC valve (blade lift, blade tilt)
SEN04969-00 Operation When in neutral For blade lift
q
Ports (PA3) and (PB3) of the blade lift control valve and ports (P1) and (P2) of the PPC valve are connected to drain chamber (D) through fine control hole (f) of spool (1).
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4
For blade tilt
q
Ports (PA2) and (PB2) of the blade tilt control valve and ports (P3) and (P4) of the PPC valve are connected to drain chamber (D) through fine control hole (f) of spool (1).
D65EX, PX, WX-16
403 Hydraulic system, Part 3 PPC valve (blade lift, blade tilt)
SEN04969-00
During fine control (neutral o fine control) q
q
q
q
q
q
In this way, the control valve spool moves to a position where the pressure of chamber (PA3) [same as pressure at port (P1)] and the force of the return spring of the control valve spool are balanced.
When piston (4) is pushed by disc (5), retainer (9) is pushed, spool (1) is also pushed by metering spring (2), and moves down. Fine control hole (f) is shut off from drain chamber (D) and almost simultaneously it is connected to pump pressure chamber (PP). The pilot pressure oil passes through fine control hole (f) and is conducted from port (P1) to port (PA3). When the pressure at port (P1) becomes higher, spool (1) is pushed back and fine control hole (f) is shut off from pump pressure chamber (PP). At almost the same time, it is connected to drain chamber (D) to release the pressure at port (P1). As a result, spool (1) moves up and down until the force of metering spring (2) is balanced with the pressure at port (P1). The relation between the positions of spool (1) and body (10) [fine control hole (f) is at the midpoint between drain chamber (D) and pump pressure chamber (PP)] does not change until retainer (9) contacts spool (1). Metering spring (2) is compressed in proportion to the strokes of the control lever. Thus, the pressure at port (P1) increases in proportion to the strokes of the control lever.
D65EX, PX, WX-16
10-403
5
403 Hydraulic system, Part 3 PPC valve (blade lift, blade tilt)
SEN04969-00 During fine control (when control lever is returned)
During full stroke
q q
q
q
q
When disc (5) starts to be returned, spool (1) is pushed up by the force of centering spring (3) and the pressure at port (P1). Because of this, fine control hole (f) is connected to drain chamber (D), and the pressurized oil at port (P1) is released. If the pressure at port (P1) goes down too far, spool (1) is pushed down by metering spring (2). Fine control hole (f) is shut off from drain chamber (D), and almost simultaneously, it is connected to pump pressure chamber (PP). Pump pressure is supplied until the pressure at port (P1) recovers to a pressure equivalent to the position of the lever. When the control valve spool returns, the oil at drain chamber (D) flows from fine control hole (f') in the valve on the side that is not moving. Oil passed through port (P2) is taken to chamber (PB3), and fills the chamber.
10-403
6
q
q
When disc (5) pushes down piston (4) and retainer (9) pushes down spool (1), fine control hole (f) is shut off from drain chamber (D) and is connected to pump pressure chamber (PP). The pilot pressure oil passed through fine control hole (f), is taken from port (P1) to chamber (PA3), and pushes the control valve spool. The return oil from chamber (PB3) passes from port (P2) through fine control hole (f'), and then flows to drain chamber (D).
D65EX, PX, WX-16
403 Hydraulic system, Part 3 PPC valve (blade lift, blade tilt)
When blade is operated in "FLOAT" position q When piston (4) at port (P1) "LOWER" side is pushed by disc (5) and moves down, ball (11) contacts protrusion (a) of the piston during the stroke. [Detent starts to act] q When piston (4) is pushed in, ball (11) pushes up collar (12), which is being held by detent spring (13). While pushing up collar (12), it escapes to the outside and passes over protrusion (a) of the piston. q Piston (4') on the opposite side is pushed up by spring (14). q The oil inside chamber (F) passes through (b) and (c), and flows to chamber (E), and piston (4') follows disc (5). Passage (d) is connected to port (P1), so more or less the same pressure is applied as is applied to port (P1). q Chamber (E) is normally connected to drain chamber (D), but if ball (11) passes over protrusion (a) of the piston, passage (d) and chamber (E) which were shut off, are connected and the pressure oil flows. q At the same time, the control valve also moves to "FLOAT" position and the circuit is set to the "FLOAT" condition. q Piston (4') is being pushed up by the oil pressure inside chamber (E), so even if the lever is released, it is held at the "FLOAT" position.
D65EX, PX, WX-16
SEN04969-00 When "FLOAT" position of blade is released q When disc (5) is returned from the "FLOAT" position, it is pushed down by a force greater than the hydraulic force in chamber (E). q As a result, chamber (E) is shut off from passage (d) and is connected to the drain chamber. Therefore, the oil pressure inside chamber (E) is los t, and the "F LOAT " position is released.
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7
SEN04969-00
PPC valve (ripper)
403 Hydraulic system, Part 3 PPC valve (ripper)
1
(if equipped) a
PPC: Abbreviation for Proportional Pressure Control
10-403
8
D65EX, PX, WX-16
403 Hydraulic system, Part 3 PPC valve (ripper)
SEN04969-00
P: From self-pressure reducing valve P1: To ripper valve (port PA4) P2: To ripper valve (port PB4) T: To tank 1. Spool 2. Piston 3. Lever 4. Plate 5. Retainer 6. Body Unit: mm
No.
Check item
Criteria Standard size
7
8
Centering spring
Metering spring
D65EX, PX, WX-16
Free length x outside diameter
Installed length
33.9 x 15.3
28.4
22.7 x 8.10
22.0
Remedy Repair limit
Installed load 125 N {12.7 kg} 16.7 N {1.70 kg}
Free length — —
Installed load 100 N {10.2 kg} 13.3 N {1.36 kg}
Replace spring if damaged or deformed.
10-403
9
403 Hydraulic system, Part 3 PPC valve (ripper)
SEN04969-00 Operation When in neutral
q
q
q
q
The relation between the positions of spool (1) and body (8) [fine control hole (f) is at the midpoint between drain chamber (D) and pump pressure chamber (PP)] does not change until retainer (7) contacts spool (1). Metering spring (2) is compressed in proportion to the strokes of the control lever. Thus, the pressure at port (P1) increases in proportion to the strokes of the control lever. In this way, the control valve spool moves to a position where the pressure of chamber (A) [same as pressure at port (P1)] and the force of the return spring of the control valve spool are balanced.
Ports (A) and (B) of the control valve and ports (P1) and (P2) of the PPC valve are connected to drain chamber (D) via fine control hole (f) in spool (1).
During fine control (neutral o fine control) q As piston (4) is pushed by lever (5), retainer (7) is pushed too. At the same time, spool (1) is also pushed down via metering spring (2). q Fine control hole (f) is shut off from drain chamber (D) and almost simultaneously it is connected to pump pressure chamber (PP). The pilot pressure oil passes through fine control hole (f) and is conducted from port (P1) to port (A). q When the pressure at port (P1) becomes higher, spool (1) is pushed back and fine control hole (f) is shut off from pump pressure chamber (PP). At almost the same time, it is connected to drain chamber (D) to release the pressure at port (P1). q As a result, spool (1) moves up and down until the force of metering spring (2) is balanced with the pressure at port (P1).
10-403
10
D65EX, PX, WX-16
403 Hydraulic system, Part 3 PPC valve (ripper)
During fine control (when control lever is returned)
SEN04969-00 During full stroke
q q
q
q
When lever (5) starts to be returned, spool (1) is pushed up by the force of centering spring (3) and the pressure at port (P1). Because of this, fine control hole (f) is connected to drain chamber (D), and the pressurized oil at port (P1) is released. If the pressure at port (P1) goes down too far, spool (1) is pushed down by metering spring (2). Fine control hole (f) is shut off from drain chamber (D), and almost simultaneously, it is connected to pump pressure chamber (PP). Pump pressure is supplied until the pressure at port (P1) recovers to a pressure equivalent to the position of the lever. When the spool of the control valve returns, the oil in drain chamber (D) flows from fine control hole (f') in the valve on the side that is not working. The oil passes through port (P2) and enters chamber (B) to replenish the chamber with pressurized oil.
D65EX, PX, WX-16
q
q
When lever (5) pushes down piston (4) and retainer (7) pushes down spool (1), fine control hole (f) is shut off from drain chamber (D) and is connected to pump pressure chamber (PP). The pilot pressure oil passes through fine control hole (f), is taken from port (P1) to chamber (A), and pushes the control valve spool. The return oil from chamber (B) passes from port (P2) through fine control hole (f'), and then flows to drain chamber (D).
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11
403 Hydraulic system, Part 3 Electric lever (steering)
SEN04969-00
Electric lever (steering) a
1
Don't try to disassemble it since adjustment for maintaining the performance will be needed.
1. Boot 2. Bracket 3. Plate 4. Bolt
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12
5. Screw 6. Lever 7. Connector
D65EX, PX, WX-16
403 Hydraulic system, Part 3 Electric lever (steering)
SEN04969-00
Function Operating effort characteristics Operation for forward and reverse travel
q
The control lever is held at 3 positions: "FORWARD", "NEUTRAL" and "REVERSE".
D65EX, PX, WX-16
Operation for left and right steering
q
Free return
10-403
13
SEN04969-00
403 Hydraulic system, Part 3 Electric lever (steering)
Output voltage characteristics q The control unit is installed to the left control stand and the control lever is installed directly onto it. q The operating angle (stroke) of the control levers is detected with potentiometers and it is output to the transmission, steering controller as signal voltage. q A potentiometer is installed in each of longitudinal direction and lateral direction. Each potentiometer outputs 2 signal voltages which are opposite to each other as shown in the figure at right.
10-403
14
D65EX, PX, WX-16
403 Hydraulic system, Part 3 Electric lever (steering)
D65EX, PX, WX-16
SEN04969-00
10-403
15
SEN04969-00
403 Hydraulic system, Part 3 Quick drop valve
Quick drop valve
CB1: To right lift cylinder bottom CB2: To left lift cylinder bottom CH1: To right lift cylinder head CH2: To left lift cylinder head VB: From control valve, blade "LOWER" VH: From control valve, blade "RAISE"
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16
1
1. Plug 2. Piston 3. Retainer 4. Valve 5. Body 6. Plug 7. Plug 8. Plug with operating orifice
D65EX, PX, WX-16
403 Hydraulic system, Part 3 Quick drop valve
SEN04969-00
Unit: mm
No.
Check item
Criteria
Remedy
Standard size Free length x outside diameter
Installed length
27.3 x 12
20
10 Valve spring
53.24 x 34.8
18
11 Valve spring
26.35 x 23
25
9
Piston spring
Outline q The quick drop valve is installed between control valve and lift cylinder. When blade control lever is set in "LOWER" position, the quick drop valve prevents a vacuum on cylinder bottom side and shortens time lag in starting digging. q The blade "lowering" speed is mostly decided by the pump discharge. However, it can be heightened by installing the quick drop valve.
Repair limit Installed load Free length Installed load 25.5 N {2.6 kg} 46.1 N {4.7 kg} 52.5 N {5.35 kg}
— — —
20.4 N {2.08 kg} 36.9 N {3.76 kg} 42.0 N {4.28 kg}
Replace spring if damaged or deformed.
While lowering blade
Operation Start of lowering blade q
q
q
q
q
If the blade control lever is set in "LOWER" position, pressurized oil from the control valve flows into port (VB) and further flows through ports (CB1) and (CB2) to the cylinder bottom and pushes the cylinder piston to the left. The pressurized oil in the cylinder head side is pushed out by the cylinder piston into ports (CH1) and (CH2), and flows through port (VH) and control valve into the hydraulic tank.
D65EX, PX, WX-16
q
The pressurized oil pushed out of cylinder head side flows through ports (CH1) and (CH2) to port (VH). At this time, the oil flow rate is reduced by orifice (a) and pressure difference is made before and after the orifice. If oil pressure in ports (CH1) and (CH2) rises higher than the reaction force of springs (1) and (2), valve (3) and piston (4) move to the right. A part of the pressurized oil which has been flowing from ports (CH1) and (CH2) to port (VH) opens valve (3) and flows into ports (VB), (CH1) and (CH2), and then merges with the pressurized oil from control valve and flows into cylinder bottom side. The blade lowering speed is increased by the quantity of oil flowing into cylinder bottom side and prevents on the bottom side being vacuum.
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17
SEN04969-00
Work equipment lock solenoid valve
403 Hydraulic system, Part 3 Work equipment lock solenoid valve
1
Straight tilt dozer (ST-T) Sigma dozer (SGM) Power angle power tilt dozer (PAT) Angle dozer (A)
10-403
18
D65EX, PX, WX-16
403 Hydraulic system, Part 3 Work equipment lock solenoid valve
SEN04969-00
P:
From cooling fan pump (from self-pressure reducing valve) P1: To PPC valve P2: To control valve PEPC port ACC: To accumulator T: From blade PPC valve T port T1: To hydraulic tank 1. Solenoid 2. Accumulator check valve 3. Block Outline q The work equipment lock solenoid valve is installed to the work equipment control circuit between the self-pressure reducing valve and PPC valve. q If the work equipment lock lever is set in the "FREE" position, the work equipment lock limit switch operates and the work equipment lock solenoid valve opens the work equipment control circuit so that the operator can operate the work equipment. Operation Solenoid (1) is "energized" by the electric signal and operates the spool to open ports (P) and (P1) and the source pressure is supplied to the PPC valve.
q
D65EX, PX, WX-16
10-403
19
SEN04969-00
403 Hydraulic system, Part 3 Work equipment lock solenoid valve
Straight tilt power pitch dozer (ST-TPP) Sigma power pitch dozer (SGM-PP)
10-403
20
D65EX, PX, WX-16
403 Hydraulic system, Part 3 Work equipment lock solenoid valve
SEN04969-00
P:
From cooling fan pump (from self-pressure reducing valve) P1: To PPC valve P2: To control valve PEPC port P4: To control valve PA3 port A1: From blade PPC valve P4 port A2: To control valve PA4 port B1: From blade PPC valve P3 port B2: To control valve PB4 port ACC: To accumulator T: From blade PPC valve T port T1: To hydraulic tank T2: To control valve PB3 port PS: To pitch selector solenoid valve P port AS: To pitch selector solenoid valve A port BS: To pitch selector solenoid valve B port TS: To pitch selector solenoid valve T port 1. Solenoid 2. Accumulator check valve 3. Block Outline q The work equipment lock solenoid valve is installed to the work equipment control circuit between the self-pressure reducing valve and PPC valve. q If the work equipment lock lever is set in the "FREE" position, the work equipment lock limit switch operates and the work equipment lock solenoid valve opens the work equipment control circuit so that the operator can operate the work equipment. Operation Solenoid (1) is "energized" by the electric signal and operates the spool to open ports (P) and (P1) and the source pressure is supplied to the PPC valve.
q
D65EX, PX, WX-16
10-403
21
SEN04969-00
Pitch selector solenoid valve
403 Hydraulic system, Part 3 Pitch selector solenoid valve
1
Straight tilt power pitch dozer (ST-TPP) Sigma power pitch dozer (SGM-PP)
P: From port A: From port B: From port T: From port
work equipment lock solenoid valve PS work equipment lock solenoid valve AS work equipment lock solenoid valve BS work equipment lock solenoid valve TS
Outline q The pitch selector solenoid valve is installed to the tilt circuit between the blade PPC valve and control valve. q Solenoid (2) is "energized" to connect the tilt and pitch pilot circuits while the PITCH switch on the blade control lever head is depressed.
1. Block 2. Solenoid
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22
D65EX, PX, WX-16
403 Hydraulic system, Part 3 Hydraulic oil cooler bypass valve
SEN04969-00
Hydraulic oil cooler bypass valve
M: From cooling fan motor C: From hydraulic oil cooler outlet T: To hydraulic tank 1. 2. 3. 4.
Block Poppet Spring Plug
1
Outline q This valve is installed on the oil cooler outlet side and pushes open poppet (2) to return the oil to the hydraulic tank directly when the press ur e o f t he oi l fl o wi n g to th e o i l c o o l er increases abnormally.
Cracking pressure (MPa {kg/cm2})
D65EX, PX, WX-16
Specified value 0.78 ± 0.05 {8 ± 0.5}
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23
403 Hydraulic system, Part 3 Accumulator
SEN04969-00
Accumulator
1
(for PPC circuit) 1. Gas plug 2. Shell 3. Poppet 4. Holder 5. Bladder 6. Oil port
Outline q The accumulator is installed between the selfpressure reducing valve and PPC valve. When the engine is stopped with the work equipment raised, the operator can send pilot oil pressure to the control valve to have the work equipment lower with its own weight by using nitrogen gas pressure in the accumulator.
Specifications
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24
Gas used
Nitrogen gas
Amount of gas (cc)
300
Charged pressure (MPa {kg/cm2})
1.18 {12} (at 80°C)
Max. pressure used (MPa {kg/cm2})
6.86 {70}
D65EX, PX, WX-16
403 Hydraulic system, Part 3 Accumulator
D65EX, PX, WX-16
SEN04969-00
10-403
25
SEN04969-00
D65EX-16, D65PX-16, D65WX-16 Bulldozer Form No. SEN04969-00
©2009 KOMATSU All Rights Reserved Printed in Japan 02-09 (01)
10-403
26
SEN04970-01
BULLDOZER D65EX-16 D65PX-16 D65WX-16 Machine model D65EX-16 D65PX-16 D65WX-16
Serial number 80001 and up 80001 and up 80001 and up
10 Structure, operation and maintenance standard
10
500 Work equipment Blade............................................................................................................................................................... 2 Cutting edge and end bit................................................................................................................................. 8 Ripper (Multi shank)...................................................................................................................................... 10 Ripper (Single shank) ....................................................................................................................................11 Hydraulic cylinder.......................................................................................................................................... 12 Piston valve................................................................................................................................................... 15
D65EX, PX, WX-16
10-500
1
SEN04970-01
Blade
500 Work equipment Blade
1
Straight tilt dozer (ST-T) Sigma dozer (SGM) Straight tilt power pitch dozer (ST-TPP) Sigma power pitch dozer (SGM-PP)
*1: Shows the sigma dozer. 1. 2. 3. 4. 5. 6. 7.
Cutting edge Center brace End bit Straight frame Trunnion Blade Left side: Brace (ST-T, SGM) Tilt cylinder (ST-TPP, SGM-PP) Right side: Tilt cylinder (ST-T, SGM) Pitch cylinder (ST-TPP, SGM-PP)
10-500
2
D65EX, PX, WX-16
500 Work equipment Blade
SEN04970-01
Unit: mm
No.
1
Check item Spherical clearance between trunnion and cap
Criteria Standard size S140
Clearance between brace mounting pin and bracket between brace 3 Clearance mounting pin and brace clearance between 4 Spherical bracket and brace clearance between 5 Spherical bearing and bushing between frame 6 Clearance mounting pin and bracket between frame 7 Clearance mounting pin and bearing between center brace 8 Clearance mounting pin and bracket between center brace 9 Clearance mounting pin and brace clearance between 10 Spherical bracket and center brace
2
D65EX, PX, WX-16
50 50 S90 (shaft) S91 (hole) S90 55 55 50 50 S90 (shaft) S91 (hole)
Tolerance Shaft Hole –0.1 +1.5 –0.5 0 –0.2 +0.2 –0.4 0 –0.2 +0.2 –0.4 0 –0.1 +1.0 –0.3 0 –0.1 +0.5 –0.5 0 0 +0.6 –0.3 +0.2 +0.5 0 –0.3 +0.2 +0.2 –0.2 –0.4 0 +0.2 –0.2 –0.4 0 –0.1 +1.0 –0.3 0
Remedy Standard clearance
Clearance limit
0.1 – 2.0
5.0
0.2 – 0.6
2.0
0.2 – 0.6
2.0
1.1 – 2.3
2.0
0.1 – 1.0
2.0
0.2 – 0.9
2.0
0.2 – 0.8
2.0
0.2 – 0.6
2.0
0.2 – 0.6
2.0
1.1 – 2.3
2.0
Adjust shim or replace
Replace Adjust shim or replace
Replace
Adjust shim or replace
10-500
3
SEN04970-01
500 Work equipment Blade
Power angle power tilt dozer (PAT)
1. Tilt cylinder 2. Cutting edge 3. End bit 4. Pitch rod 5. Blade 6. Angle cylinder 7. U-frame 8. Trunnion
10-500
4
D65EX, PX, WX-16
500 Work equipment Blade
SEN04970-01
Unit: mm
No.
1
Check item Spherical clearance between trunnion and cap
Criteria Standard size S140
2 3 4 5 6 7 8
Clearance between angle cylinder bottom pin and U-frame bracket Clearance between angle cylinder head pin and blade bracket Clearance between U-frame center spherical surface and blade cap Clearance between pitch rod pin and bushing Clearance between tilt cylinder bottom pin and U-frame bracket Clearance between tilt cylinder head pin and blade bracket Standard shim thickness between U-frame center spherical surface and blade cap
D65EX, PX, WX-16
50 50 S177.5 60 50 50
Tolerance Shaft Hole –0.1 +1.5 –0.5 0 –0.025 +0.3 –0.064 +0.1 –0.025 +0.3 –0.064 +0.1 –0.25 +0.5 –0.75 0 –0.030 +0.004 –0.076 –0.019 –0.025 +0.3 –0.064 +0.1 –0.025 +0.3 –0.064 +0.1 8.0
Remedy Standard clearance
Clearance limit
0.1 – 2.0
5.0
0.125 – 0.364 0.125 – 0.364 0.25 – 1.25 0.011 – 0.080 0.125 – 0.364 0.125 – 0.364
Adjust shim or replace
1.0 Replace 1.0 5.0
Adjust shim or replace
0.5 1.0
Replace
1.0 Adjust shim or replace
10-500
5
SEN04970-01
500 Work equipment Blade
Angle dozer (A)
1. Center shaft 2. Cutting edge 3. C-frame 4. End bit 5. Trunnion 6. Joint 7. Blade 8. Arm 9. Brace
10-500
6
D65EX, PX, WX-16
500 Work equipment Blade
SEN04970-01
Unit: mm
No.
1
Check item Spherical clearance between trunnion and cap
Criteria Standard size S140
Clearance between arm mounting 100 pin and bracket (large) between arm mounting 80 3 Clearance pin and bracket (small) between brace 50 4 Clearance mounting pin and arm bracket between brace 50 5 Clearance mounting pin and brace between brace 50 6 Clearance mounting pin and joint between brace 50 7 Clearance mounting pin and bearing between joint mounting 50 8 Clearance pin and bracket between joint mounting 50 9 Clearance pin and joint between center shaft 79.5 (shaft) 10 Clearance and frame 80 (hole) Clearance between center shaft 55 11 mounting pin and bracket between center shaft 55 (shaft) 12 Clearance mounting pin and center shaft 60 (hole)
2
D65EX, PX, WX-16
Tolerance Shaft Hole –0.1 +1.5 –0.5 0 –0.6 +1.5 -1.0 +1.0 –0.6 +1.5 –1.0 +1.0 –0.3 +0.7 –0.6 0 –0.3 +0.2 –0.6 0 0 +0.2 –0.3 0 0 +0.5 –0.3 0 –0.1 +0.3 –0.3 0 –0.1 +0.2 –0.3 0 –0.2 +0.5 –0.5 –0.5 –0.1 +0.3 –0.3 0 –0.1 +0.5 –0.3 +0.1
Remedy Standard clearance
Clearance limit
0.1 – 2.0
8.0
1.6 – 2.5
3.5
1.6 – 2.5
3.5
0.3 – 1.3
2.0
0.3 – 0.8
2.0
0 – 0.5
2.0
0 – 0.8
2.0
0.1 – 0.6
2.0
0.1 – 0.5
2.0
0.2 – 1.5
2.0
0.1 – 0.6
2.0
5.2 – 5.8
7.0
Replace
10-500
7
SEN04970-01
Cutting edge and end bit
10-500
8
500 Work equipment Cutting edge and end bit
1
D65EX, PX, WX-16
500 Work equipment Cutting edge and end bit
SEN04970-01
Unit: mm
No.
1
2
3
Check item
End bit height (outside)
Width of end bit
End bit height (inside)
Cutting edge height
4
Criteria Repair limit
ST-T(EX) ST-TPP(EX)
242
187
ST-T(PX) ST-TPP(PX)
204
187
SGM(EX,WX) SGM-PP(EX,WX)
225
198
A(EX)
242
187
PAT(EX,PX,WX)
242
187
ST-T(EX) ST-TPP(EX)
330
300
ST-T(PX) ST-TPP(PX)
325
300
SGM(EX,WX) SGM-PP(EX,WX)
511
440
A(EX)
330
300
PAT(EX,PX,WX)
330
300
ST-T(EX) ST-TPP(EX)
204
187
ST-T(PX) ST-TPP(PX)
204
187
SGM(EX,WX) SGM-PP(EX,WX)
205
198
A(EX)
204
187
PAT(EX,PX,WX)
204
187
ST-T(EX) ST-TPP(EX)
102
85
ST-T(PX) ST-TPP(PX)
102
85
SGM(EX,WX)
102
85
102
85
102
85
(from center of bolt SGM-PP(EX,WX) mounting hole to A(EX) end face) PAT(EX,PX,WX)
5
Remedy
Standard size
ST-T(EX) ST-TPP(EX)
392 – 530 Nm {40 – 54 kgm}
ST-T(PX) ST-TPP(PX)
392 – 530 Nm {40 – 54 kgm}
Tightening torque SGM(EX,WX) of end bit and SGM-PP(EX,WX) cutting edge
392 – 530 Nm {40 – 54 kgm}
A(EX)
392 – 490 Nm {40 – 50 kgm}
PAT(EX,PX,WX)
392 – 530 Nm {40 – 54 kgm}
Replace
Replace or reverse
Retighten
ST-T: Shows values for straight tilt dozer. ST-TPP: Shows values for straight tilt power pitch dozer. SGM: Shows values for sigma dozer. SGM-PP: Shows values for sigma power pitch dozer. PAT: Shows values for power angle power tilt dozer. A: Shows values for angle dozer.
D65EX, PX, WX-16
10-500
9
500 Work equipment Ripper (Multi shank)
SEN04970-01
Ripper (Multi shank)
1
(if equipped) D65EX-16, D65WX-16
Unit: mm
No.
1
2
Check item Clearance between pin and bushing
Wear of point
Criteria Tolerance Standard size Shaft Hole –0.030 +0.299 56 –0.076 +0.169 Standard size 222
Remedy Standard clearance
Clearance limit
0.199 – 0.375 Repair limit
1.0
Replace
152
3. Bracket 4. Upper link 5. Ripper cylinder 6. Beam 7. Shank 8. Point 9. Lower link
10-500
10
D65EX, PX, WX-16
500 Work equipment Ripper (Single shank)
SEN04970-01
Ripper (Single shank)
1
(if equipped) D65EX-16, D65WX-16
Unit: mm
No.
1
2
Check item Clearance between pin and bushing
Wear of point
Criteria Tolerance Shaft Hole –0.030 +0.299 56 –0.076 +0.169 Standard size
Standard size
222
Remedy Standard clearance
Clearance limit
0.199 – 0.375 Repair limit
1.0
Replace
152
3. Bracket 4. Upper link 5. Ripper cylinder 6. Beam 7. Shank 8. Point 9. Lower link
D65EX, PX, WX-16
10-500
11
SEN04970-01
Hydraulic cylinder
500 Work equipment Hydraulic cylinder
1
Lift cylinder D65EX-16, D65WX-16 (for other than power angle power tilt dozer)
D65PX-16 (for other than power angle power tilt dozer)
D65EX-16, D65PX-16, D65WX-16 (for power angle power tilt dozer)
10-500
12
D65EX, PX, WX-16
500 Work equipment Hydraulic cylinder
SEN04970-01
Tilt cylinder Pitch cylinder (for other than power angle power tilt dozer)
Tilt cylinder (for power angle power tilt dozer)
Angle cylinder (for power angle power tilt dozer)
D65EX, PX, WX-16
10-500
13
500 Work equipment Hydraulic cylinder
SEN04970-01 Ripper cylinder D65EX-16, D65WX-16
Unit: mm
No.
1
2
Check item
Clearance between piston rod and bushing
Spherical clearance between piston rod and trunnion Clearance between cylinder rod support shaft and bushing Spherical clearance between piston rod and bracket Clearance between cylinder rod support shaft and bushing Clearance between cylinder rod support shaft and bushing Clearance between cylinder boss and bushing
3 Clearance between cylinder bottom support shaft and bushing
Criteria Cylinder name
Standard size
Lift
60
Lift (PAT) Tilt Pitch Tilt (PAT) Angle (PAT)
60 70 70 65
Tolerance Shaft Hole –0.030 +0.151 –0.076 +0.006 –0.030 +0.151 –0.076 +0.006 –0.030 +0.259 –0.076 +0.063 –0.030 +0.259 –0.076 +0.063 –0.030 +0.250 –0.076 +0.055 –0.030 +0.259 –0.076 +0.063
Remedy Standard clearance 0.036 – 0.227 0.036 – 0.227 0.093 – 0.335 0.093 – 0.335 0.085 – 0.326 0.093 – 0.335
Clearance limit 0.527 0.527 0.635
Replace bushing
0.635 0.626
Ripper
70
Lift
S85
–0.2 –0.3
+0.3 0
0.2 – 0.5
1.0
Adjust shim or replace
Lift (PAT)
50
–0.025 –0.064
+0.003 –0.015
0.010 – 0.067
1.0
Replace bushing
Tilt Pitch
S90 (shaft) S91 (hole)
–0.1 –0.3
+1.0 0
0.2 – 0.5
2.0
Adjust shim or replace
Tilt (PAT)
50
–0.025 –0.064
+0.039 0
0.025 – 0.103
1.0
Angle (PAT)
50
Ripper
75
Lift
55
–0.025 –0.064 –0.030 –0.076 –0.100 –0.174 –0.100 –0.174 –0.200 –0.400 –0.025 –0.064 –0.025 –0.064 –0.030 –0.076
+0.039 0 +0.174 +0.100 +0.116 0 +0.118 0 +0.142 +0.080 +0.039 0 +0.039 0 +0.174 +0.100
0.025 – 0.103 0.130 – 0.250 0.100 – 0.290 0.100 – 0.292 0.280 – 0.542 0.025 – 0.103 0.025 – 0.103 0.130 – 0.250
Lift (PAT) Tilt Pitch Tilt (PAT) Angle (PAT) Ripper
55 50 50 50 75
0.635
1.0 1.0 1.0 1.0
Replace pin and bushing
1.0 1.0 1.0 1.0
PAT: Shows values for power angle power tilt dozer.
10-500
14
D65EX, PX, WX-16
500 Work equipment Piston valve
SEN04970-01
Piston valve
1
For lift cylinder Outline q The piston valve is installed to the piston of the lift cylinder. q When the piston rod is at the stroke end, oil from the pump is released to the port on the opposite side to lower the oil pressure applied to the piston. Oil is also released to the port on the opposite side before the piston rod reaches the stroke end to lower the surge pressure and reduce the shock made when the piston rod reaches the stroke end. Operation Piston valve "closed"
q
The pressurized oil from the pump acts on piston (3) and piston valve (1). Then, piston valve (1) is pushed to the right to seal tapered part (a) of piston valve seat (2). As a result, the oil pressure in the cylinder rises to move piston (3) to the right.
D65EX, PX, WX-16
Piston valve "opened"
q
q q
Slider (5) touches cylinder bottom (b) and stops moving before piston rod (4) reaches the stroke end. Slider (5) touches the end of piston valve (1), and then only piston (3) continues moving. The pressurized oil which has been stopped by piston valve (1) is released through piston valve seat (2) to the bottom side, thus the oil pressure in the cylinder lowers.
10-500
15
500 Work equipment Piston valve
SEN04970-01 For angle cylinder (for power angle power tilt dozer) Outline q The piston valve is installed to the piston of the angle cylinder. q When the piston rod is at the stroke end, pressurized oil from the pump is released to the port on the opposite side to lower the oil pressure applied to the piston. Operation Piston valve "closed"
q
q
q
The pressurized oil from the pump pushes piston (2) open against the force of spring (4) and flows to chamber (A). The pressurized oil fills chamber (A) and pushes piston valve (5) to the right to seal the tapered part of piston valve seat (a). As a result, the oil pressure in the cylinder rises and piston (3) moves to the right.
10-500
16
Piston valve "opened"
q
q q
Slider (6) touches cylinder bottom (b) and stops moving before piston rod (1) reaches the stroke end. Slider (6) touches the end of piston valve (5), and then only piston (3) continues moving. The pressurized oil which has been stopped in chamber (A) by piston valve (5) is released through piston valve seat (a) to the bottom side, thus the oil pressure in the cylinder lowers.
D65EX, PX, WX-16
500 Work equipment Piston valve
D65EX, PX, WX-16
SEN04970-01
10-500
17
SEN04970-01
D65EX-16, D65PX-16, D65WX-16 Bulldozer Form No. SEN04970-01
© 2012 KOMATSU All Rights Reserved Printed in Japan 02-12
10-500
18
SEN04971-02
BULLDOZER D65EX-16 D65PX-16 D65WX-16 Machine model D65EX-16 D65PX-16 D65WX-16
Serial number 80001 and up 80001 and up 80001 and up
10 Structure, function and maintenance standard
1
600 Cab and its attachments Cab mount ...................................................................................................................................................... 2 Cab ................................................................................................................................................................. 3 Subextremely cold spec. cab (subextremely cold weather spec.) .................................................................. 4 FRP canopy mount ......................................................................................................................................... 5 FRP canopy .................................................................................................................................................... 6
D65EX, PX, WX-16
10-600
1
SEN04971-02
Cab mount
1. Damper mount (front) 2. Damper mount (rear)
10-600
2
600 Cab and its attachments Cab mount
1
Outline q Mounts are installed at two places in front and at two places in the rear to secure the floor frame and cab. q An oil-filled damper mount is used to absorb the vibration.
D65EX, PX, WX-16
600 Cab and its attachments Cab
SEN04971-02
Cab a
1
ROPS: Abbreviation for RollOver Protective Structure
1. Front window 2. Front wiper 3. Door 4. Radio antenna 5. Rear wiper 6. ROPS cab
D65EX, PX, WX-16
10-600
3
SEN04971-02
600 Cab and its attachments Subextremely cold spec. cab (subextremely cold weather spec.)
Subextremely cold spec. cab (subextremely cold weather spec.)
1
(if equipped) a ROPS: Abbreviation for RollOver Protective Structure
1. Front window 2. Front wiper 3. Door 4. Radio antenna 5. Rear wiper 6. ROPS cab
Outline q q
The window is a double glass window. Window washer is not equipped to.
10-600
4
D65EX, PX, WX-16
600 Cab and its attachments FRP canopy mount
SEN04971-02
FRP canopy mount
1.
Damper mount
D65EX, PX, WX-16
1
Outline q Mounts are installed at two places in front and at two places in the rear to secure the floor frame and cab. q An oil-filled damper mount is used to absorb the vibration.
10-600
5
SEN04971-02
FRP canopy
1. 2. 3.
600 Cab and its attachments FRP canopy
1
Roof Bracket Pole
10-600
6
D65EX, PX, WX-16
600 Cab and its attachments FRP canopy
D65EX, PX, WX-16
SEN04971-02
10-600
7
SEN04971-02
D65EX-16, D65PX-16, D65WX-16 Bulldozer Form No. SEN04971-02
© 2012 KOMATSU All Rights Reserved Printed in Japan 02-12
10-600
8
SEN04972-02
BULLDOZER D65EX-16 D65PX-16 D65WX-16 Machine model D65EX-16 D65PX-16 D65WX-16
Serial number 80001 and up 80001 and up 80001 and up
10 Structure, operation and maintenance standard
10
700 Electrical system Monitor system................................................................................................................................................ 2 Engine control system................................................................................................................................... 18 Cooling system control system ..................................................................................................................... 21 Electronic steering control system ................................................................................................................ 23 KOMTRAX system........................................................................................................................................ 26 KOMTRAX terminal (for GPRS).................................................................................................................... 28 System components ..................................................................................................................................... 29 Sensor........................................................................................................................................................... 37
D65EX, PX, WX-16
10-700
1
700 Electrical system Monitor system
SEN04972-02
Monitor system
1. Machine monitor 2. Battery 3. Power train controller 4. Engine controller 5. Air conditioner controller 6. KOMTRAX terminal 7. Sensors, switches Input and output signals a. Power supply b. CAN signal c. Sensor and switch signals
1
Outline q The monitor system keeps the operator informed of all machine functions, by monitoring the machine conditions using the sensors and switches installed in various parts of the machine and processing them instantly to display on the machine monitor. The contents displayed on the machine monitor falls into the following types: 1. Alarm buzzer when any abnormality occurs in the machine 2. Machine status display (including engine coolant temperature, power train oil temperature, hydraulic oil temperature and fuel level, etc.) 3. Action code and failure code 4. Current values and voltage values displayed on the sensors and solenoids, etc. q
10-700
2
The switches on the machine monitor controls the machine.
D65EX, PX, WX-16
700 Electrical system Monitor system
SEN04972-02
Processing on machine monitor (common to all specifications) Display of machine monitor Contents and conditions of processing 1. Display of direction of travel and gear speed • Based on the information from the power train controller, F1, R3, etc. are transmitted to the machine monitor in CAN signal. 2. Display of gauge such as fuel level, engine coolant temperature, etc. • The controller converts the sensor signals into gauge numbers and sends them to the machine monitor by CAN signal. 3. Display of failure • If the machine failure occurs, the controller transmits the corresponding failure code to the machine monitor in CAN signal. • Depending on the content of failure, the controller transmits information whether the alarm buzzer should be sounded. • The following information is displayed on the machine monitor: 1) In the normal state • Action code (3-digit code) • Failure code (6-digit code) 2) In the abnormality record display mode • Failure code (6-digit code) • Service meter hours when the failure occurred for the first time • Service meter hours when it occurred the last time • Frequency of occurrence
Method
Flow of signals
CAN signal
CAN signal
Sensors and solenoids O Controller O Machine monitor CAN signal
Display of monitoring Contents and conditions of processing 1. Display of sensors, solenoids and communicating state of CAN signal • The monitoring system transmits the item No.and equipment status to the machine monitor in CAN signal. • The machine monitor displays the items and values. 2. Items are selected by using the function switch.
Method
Flow of signals
CAN signal
Sensors O Controller O Machine monitor
Method
Flow of signals
—
—
CAN signal
Other items Contents and conditions of processing 1. Monitoring 2. Abnormality record 3. Maintenance record 4. Maintenance mode change 5. Phone number entry 6. Default 7. Adjustment 8. PM clinic 9. Cylinder cut-out 10. No injection 11. Fuel consumption 12. KOMTRAX settings 13. Service message
a
For details of the operating method, see "Special functions of monitor panel (EMMS)" in "Testing and adjusting".
D65EX, PX, WX-16
10-700
3
SEN04972-02
Machine monitor
Outline q The machine monitor provides monitor display function, mode selection function and switch function of the electrical equipment etc. Also it provides an alarm buzzer. q The machine monitor has a CPU (Central Processing Unit) in it to process, display, and output the information. q The machine monitor consists of display and switches: the display is of LCD type, and the switches are of flat sheet switch. q If an error occurs in the machine monitor itself, controller or wiring circuit between monitor and controller, the monitor does not display properly.
10-700
4
700 Electrical system Monitor system
1
Precautions on the machine monitor display q The LCD panel may have black points (points which are not lighted) and bright points (points which do not go off) for the reason of its characteristics. It is not failure occurrence as long as the number of black or bright spots are 10 or less. q Battery voltage may suddenly drop at enginestart due to ambient temperature or the condition of the battery. In this case, the machine monitor may go off for a moment. However, this phenomenon is not a failure. q Continuous operation of the machine monitor may display blue bright spots on the screen with black background. It, however, is not failure occurrence on the monitor. Blue points can never be a problem as the screen has blue or white background. (White in the LCD is made up of red, green and blue.)
D65EX, PX, WX-16
700 Electrical system Monitor system
SEN04972-02
Input and output signals 070-18P(1) [CN-CM01] Pin No.
Signal name
Input/Output signal
Pin No.
Signal name
1
Constant power supply (24 V)
Input
10
NC
2
Constant power supply (24 V)
Input
11
Charge level
— Input
3
GND (constant power supply)
—
12
GND (machine analog signal)
4
GND (constant power supply)
—
13
Lamp switch
5
Wake-up
6
NC
7
NC
—
8
Hydraulic oil temperature
Input
9
Fuel level
Input
18
Input/Output signal
Pin No.
Input/Output signal
— Input
Input/output
14
Starting switch ACC signal
Input
—
15
Starting switch C signal
Input
16
Preheating
Input
17
NC
—
NC
—
070-12P(1) [CN-CM02] Pin No.
Signal name
Signal name
Input/Output signal
1
NC
—
7
NC
—
2
NC
—
8
CAN terminal signal
—
3
NC
4
Air cleaner clogging sensor
5
NC
6
NC
—
9
CAN_H
Input/output
Input
10
CAN_L
Input/output
—
11
NC
—
—
12
NC
—
Input/Output signal
Pin No.
070-18P(2) [CN-CM03] Pin No.
Signal name
Signal name
Input/Output signal
1
RS232C CD for communication terminal
Input
10
NC
—
2
RS232C RXD for communication terminal
Input
11
NC
—
3
RS232C SG for communication terminal
—
12
GND (communication terminal power supply)
—
4
GND (communication terminal control signal)
—
13
NC
—
5
Communication terminal selection signal
Input
14
NC
—
6
NC
—
15
NC
—
7
For communication terminal, RS232C TXD
Output
16
NC
—
8
For communication terminal, RS232C DTR
Output
17
NC
9
For communication terminal, RS232C DSR
Input
18
Communication terminal power supply (12 V)
Output
Input/Output signal
Pin No.
Signal name
Input/Output signal
—
070-12P(2) [CN-CM04] Pin No.
Signal name
1
NC
—
7
NC
—
2
NC
—
8
NC
—
3
NC
—
9
NC
—
4
NC
—
10
NC
—
5
NC
—
11
NC
—
6
NC
—
12
NC
—
Input/Output signal
Pin No.
B60-8P [CN-CM05] Pin No.
Signal name
Signal name
Input/Output signal
1
Camera power supply (8 V)
Output
5
GND (Camera power supply)
—
2
Camera NTSC signal 1
Input
6
GND (Camera signal 1)
—
3
Camera NTSC signal 2
Input
7
GND (Camera signal 2)
—
4
Camera NTSC signal 3
Input
8
GND (Camera signal 3)
—
D65EX, PX, WX-16
10-700
5
SEN04972-02
Display
700 Electrical system Monitor system
1
A: Check before starting screen q If troubles that turn monitors (13) – (15) ON occur after the starting switch is turned "ON", the corresponding monitors are displayed from the left top in the order of the occurrence time. q If trouble of monitors (13) – (15) occur during working, the corresponding monitors are displayed in large size for 2 seconds and then displayed in small size. q If power train oil temperature or hydraulic oil temperature rises while any monitoring item is displayed at the center portion (multi gauge portion), monitor (3b) alone is displayed. B: Standard screen C: Maintenance interval warning screen 10-700
6
D65EX, PX, WX-16
700 Electrical system Monitor system
No.
Display classification
SEN04972-02
Display item
Description
Temperature Background (°C) color W1 105 Red W2 102 Red (*1) W3 100 Blue Engine coolant temperature W4 85 Blue W5 60 Blue W6 30 Blue See the "Background color" of the gauge. Background Range Quantity (l) color F1 376 Blue F2 297 Blue (*1) F3 219 Blue Fuel level F4 140 Blue F5 100 Blue F6 61 Blue See the "Background color" of the gauge. Temperature Background Range (°C) color M1 130 Red M2 120 Red (*1) M3 118 Blue Power train oil temperature M4 90 Blue M5 50 Blue M6 0 Blue See the "Background color" of the gauge. Temperature Background Range (°C) color M1 105 Red M2 102 Red (*1) M3 98 Blue Hydraulic oil temperature M4 70 Blue M5 20 Blue M6 0 Blue See the "Background color" of the gauge. Background Range Speed (km/h) color M1 15 Blue (*1) M2 10 Blue Travel speed M3 5 Blue M4 0 Blue See the "Background color" of the gauge. Range
1a
Gauge
1b
Caution
2a
Gauge
2b
Caution
3a-1
Gauge
3b-1
Caution
3a-2
Gauge
3b-2
Caution
3a-3
Gauge
3b-3
Caution
Remarks • Indicates the corresponding temperature range. • If the temperature goes beyond 105°C, the alarm buzzer is sounded. • When the background color is white, warming-up run of the engine must be done.
• Indicates the corresponding range of the remaining fuel level.
• Indicates the corresponding temperature range. • If the temperature goes beyond 130°C, the alarm buzzer is sounded. • When the background color is white, warming-up run of the hydraulic equipment must be done. (Press switch F2 to switch the display of gauge.)
• Indicates the corresponding temperature range. • If the temperature goes beyond 105°C, the alarm buzzer is sounded. • When the background color is white, warming-up run of the hydraulic equipment must be done. (Press switch F2 to switch the display of gauge.)
• Indicates the corresponding speed range. (Press switch F2 to switch the display of gauge.)
*1: If the gauge signal is not received due to disconnection of CAN communication line, the gauge pointer is out of the screen.
D65EX, PX, WX-16
10-700
7
700 Electrical system Monitor system
SEN04972-02
No.
Display classification
Display item
Description
Remarks
Pressure Background (MPa) color M1 50 Blue M2 40 Blue M3 30 Blue M4 20 Blue M5 10 Blue M6 0 Blue See the "Background color" of the gauge. Background Range Voltage (V) color M1 31 Blue M2 30 Blue M3 25 Blue M4 20 Blue M5 17 Blue M6 0 Blue See the "Background color" of the gauge. Rotation Background Range speed color (n/min) M1 3,000 Blue M2 2,500 Blue M3 2,000 Blue M4 1,500 Blue M5 1,000 Blue M6 500 Blue See the "Background color" of the gauge. Traction Background Range force (W) color M1 1.0 Blue M2 0.8 Blue M3 0.6 Blue M4 0.4 Blue M5 0.2 Blue M6 0 Blue See the "Background color" of the gauge. Segment Load level Light to Green 1–8 medium Orange 9,10 Heavy
• Indicates the corresponding pressure range. (Press switch F2 to switch the display of gauge.)
Range
3a-4
Gauge
3b-4
Caution
3a-5
Gauge
3b-5
Caution
3a-6
Gauge
3b-6
Caution
3a-7
Gauge
3b-7
Caution
4
(*1) HSS pump oil pressure
(*1) Battery voltage
(*1) Engine speed
(*1) Traction force
ECO gauge
Service meter
00000 h – 99999 h
5 Clock
• 12-hour display (AM/PM) • 24-hour display
• Indicates the corresponding voltage range. (Press switch F2 to switch the display of gauge.)
• Indicates the corresponding rotation speed range. (Press switch F2 to switch the display of gauge.)
• Indicates the corresponding traction force range. (Press switch F2 to switch the display of gauge.)
• Displays the mean of the load level in 10 levels on a second-by-second basis. (It is displayed when "ON" is selected for the "Default (setting of ECO display)".) • Counts the engine operation hours (when power is generated by the alternator). (Press switch F4 to switch to the clock display.) • Displays the time. (Press switch F4 to switch to the service meter display)
*1: If the gauge signal is not received due to disconnection of CAN communication line, the gauge pointer is out of the screen.
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D65EX, PX, WX-16
700 Electrical system Monitor system
No. 6
Display classification
Display item
8 9 Pilot 10
11 12 13
• Displays the present gear speed and gear shift mode. Background State color Message Green There is unread message. Blue There is unsent message. Operation P: Heavy-duty operation mode E: Low-fuel consumption operation Light ON: ON Air conditioner Light OFF: OFF Ambient Monitor light ON duration temperature (seconds) (°C) Preheating -3 – -10 5 – 15 -10 – -20 15 – 32 -20 – -30 32 – 45 Fan in reverse Light ON: Cooling fan in reverse rotation rotation Light OFF: Cooling fan in normal rotation Reverse slow Light ON: ON (decelerates reverse travel) mode Light OFF: OFF (*2) Light ON: When abnormal (water settles Water in the water separator) separator Light OFF: When normal Light ON: Defective battery charge (*2) (charge voltage is below Charge level specified value) Light Off: Normal state
Caution
(*2) Engine oil pressure
15
16
Remarks
Pilot
Caution
Light ON: Abnormal state (below the specified pressure) Light OFF: Normal state
(KOMTRAX-equipped machine) • Displays the state of messages. (Background color goes out when there is no message) • Displays the operation mode. • Indicates the operating state of the air conditioner and air blower. • Displays the operating state of preheating.
• Displays the rotating state of the cooling fan. • Displays the operating state of reverse slow mode. • The monitor is lit if any abnormality is detected while the starting switch is at "ON" position. • The monitor is lit if any abnormality is detected while the engine is in operation. • If any abnormality is detected while the engine is in operation, the monitor lamp is lit and the alarm buzzer is sounded at the same time. • Displays the operating state of the parking brake lever. • Displays the operating state of the work equipment lock lever.
Light ON: Lock Light OFF: Free Work Light ON: Lock equipment lock Light OFF: Free Background • The display switches as course of State color maintenance time. There is a maintenance item • When the starting switch is turned "ON" Maintenance position, the lamp is lit if the monitor Yellow which is 30 hours or less left interval lamp turning-on requirements are met. before next maintenance. The lamp goes out in 30 seconds. There is a maintenance Red overdue item. Parking brake
17
18
Description
Gear speed display
7
14
SEN04972-02
*2: These items are included in the check before starting. After the staring switch is turned "ON", the monitor is lit for 2 seconds, and switching to the standard screen if no abnormality is detected.
D65EX, PX, WX-16
10-700
9
700 Electrical system Monitor system
SEN04972-02
Switch part
1
For the air conditioner specification
No.
Name
Function
1
Operation mode selector switch Switches the engine operation mode. [Numeric keypad: 1]
2
Gear shift mode selector switch Switches the gear shift mode. [Numeric keypad: 2]
3 4 5 6
7a
Customize switch [Numeric keypad: 3] Buzzer cancel switch [Numeric keypad: 4]
8b
Stops the alarm buzzer. (Some alarm buzzer does not stop even if the switch is pressed.)
P: Heavy-duty operation E: Low-fuel consumption operation Automatic gear shift mode I O Manual gear shift mode • The screen allows setting the operation mode and the reverse slow mode. • The alarm buzzer stops. • If any abnormality is detected again, the alarm buzzer is sounded.
[Numeric keypad: 5] Customize memory switch [Numeric keypad: 6] Fan switch (Increase) [Numeric keypad: 7] Fan switch (Decrease)
7b
8a
Displays the customize mode screen.
Operation
Temperature control switch (Raise) [Numeric keypad: 8] Temperature control switch (Lower) [Numeric keypad: 0]
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Saves and calls of data to and from the memory.
• This switch allows data store up to 5.
• The fan speed increases concurrently with the switching to the air conditioner control Adjusts the fan speed of the air conditioner screen. in 6 levels. (Low, Middle 1, Middle 2, Middle 3, Middle • The fan speed decreases concurrently with 4, High) the switching to the air conditioner control screen. • The set temperature rises concurrently with the switching to the air conditioner control Controls the temperature in the cab. screen. (18.0°C – 32.0°C: Allows controlling the temperature in 0.5°C steps between • The set temperature lowers concurrently 18.0°C – 32.0°C.) with the switching to the air conditioner control screen.
D65EX, PX, WX-16
700 Electrical system Monitor system
No.
Name
SEN04972-02
Function
9
Operates the air conditioner and air blower (*1) in automatic operation mode. Auto switch [Numeric keypad: 9] AUTO light ON: Auto run
10
Turns the air conditioner ON/OFF. (*2) AC ON light ON: Manual operation Air conditioner switch Light OFF: Stop
11
12
FRESH/RECIRC selector switch
Changes the FRESH/RECIRC.
Selects the air vent mode from 5 types. 1. Front and rear 2. Front and rear-foot Vent selector switch 3. Foot 4. Foot and defroster 5. Defroster
13
OFF switch
14a
Guidance icon
14b
Function switch
Turns the fan and air conditioner OFF. Light OFF: OFF
Operation • In parallel with the switching to the air conditioner control screen, switching of the fan speed, vent and FRESH/RECIRC takes place automatically according to the set temperature. • The air conditioner control screen appears. Pressing this switch again to switch ON to OFF and vice versa. OFF io ON • The air conditioner control screen appears. Pressing this switch again causes switching between FRESH and RECIRC. FRESH io RECIRC • The air conditioner control screen appears. Pressing this switch again switches the vent mode. • In the auto mode, vent modes 4 and 5 are not selectable. o1o2o3o4o5o I O i i i i i • Operation of the fan and air conditioner is stopped.
a See "Guidance icon and function switch." *1: When the temperature is set at 18.0°C or 32.0°C, the fan speed is kept at "High". In this case, the fan speed remains the same even if the set temperature is reached. *2: When the fan is not in operation, the air conditioner is not operated even if the switch is pressed.
D65EX, PX, WX-16
10-700
11
700 Electrical system Monitor system
SEN04972-02 For the non air conditioner specification
No.
Name
Function
1
Operation mode selector switch Switches the engine operation mode. [Numeric keypad: 1]
2
Gear shift mode selector switch Switches the gear shift mode. [Numeric keypad: 2]
3 4
Customize switch Displays the customize mode screen. [Numeric keypad: 3] Stops the alarm buzzer. Buzzer cancel switch (Some alarm buzzer does not stop even if [Numeric keypad: 4] the switch is pressed.)
Operation P: Heavy-duty operation E: Low-fuel consumption operation Automatic gear shift mode I O Manual gear shift mode • This screen allows setting the operation mode and the reverse slow mode. • The alarm buzzer stops. • If any abnormality is detected again, the alarm buzzer is sounded.
5
[Numeric keypad: 5]
6
Customize memory switch Saves and calls data to and from memory. [Numeric keypad: 6]
7
[Numeric keypad: 7]
—
—
8
[Numeric keypad: 8]
—
—
9
[Numeric keypad: 9]
—
—
10
[Numeric keypad: 0]
—
—
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—
—
• This switch allows data store up to 5.
D65EX, PX, WX-16
700 Electrical system Monitor system
D65EX, PX, WX-16
SEN04972-02
10-700
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700 Electrical system Monitor system
SEN04972-02
Guidance icon and function switch q Functions of the function switch depend on the guidance icon displayed above the switch. q No function is available if no guidance icon appears above the function switch. q The following is the list of guidance icons and the functions displayed above the function switches.
Function switch
F1
Guidance icon
Item
1
Clear
Clears selected/displayed item.
2
Move selection
Moves selection down one page. (To the top page from the bottom page.)
3
Set
Sets function.
4
Start
5
Stop
1
Selecting multi gauge
Selects the display item of the multi gauge.
2
Move selection
Moves selection up one page. (To the bottom page from the top page.)
3
Clear
Clears selected/displayed item.
4
Default
1
Camera image
2
Move selection
3
Move selection
F2
F3
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14
Function
Starts function. (Used for starting measurement of split fuel consumption.) Stops function. (Used for stopping measurement of split fuel consumption.)
Sets selected item back to default. (Used for screen adjustment.) Switches to camera image. (machines equipped with camera) Moves selection down one item. (To the top item from the bottom item.) Cancels hold function in the monitoring. Moves selection to the left. (To the rightmost item from the leftmost item.)
D65EX, PX, WX-16
700 Electrical system Monitor system
Function switch
SEN04972-02
Guidance icon
F4
Function
1
Switching clock/ service meter
2
Move selection
3
Move selection
1
Selecting maintenance screen
Selects maintenance screen.
2
Return
Returns to the previous screen or condition.
1
Selecting user mode screen
Selects user mode screen.
2
Fix
Fixes selected/displayed item.
F5
F6
D65EX, PX, WX-16
Item
Switches clock/service meter display. Moves selection up one item. (To the bottom item from the top item.) Starts hold function in the monitoring. Moves selection to the right. (To the leftmost item from the rightmost item.)
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700 Electrical system Monitor system
SEN04972-02
Operator mode function q
q
1
When the standard screen is displayed, display and setting of these functions are available from the operator's switch operations. Display and setting of some functions require special operation of the switch. Items available in the operator mode are as follows:
Category (*1)
A
B
C
D
Item Display of KOMATSU logo Display of inputting password Display of check before starting Display of warning after check before starting Display of overdue maintenance Display of preset confirmation Display of standard screen Display of end screen Selection of operation mode Selection of gear shift mode Operation of customize Operation of customize memory Operation to stop alarm buzzer Operation of air conditioner Selection of multi gauge Operation to display camera mode (machines equipped with camera) Operation to display clock/service meter Check of maintenance information Setting and display of user mode • Utility Screen Select • Multi Gauge Select • Screen Adjustment • Clock Adjustment • Language • User Message (including KOMTRAX messages for user) • Fan Reverse Mode Display of caution monitor Display of action code and failure code Function of checking display of LCD (Liquid Crystal Display) Function of checking service meter Function of changing maintenance password
Display order (*2) W X Y Z 1 1 1 1 2 — — — 3 2 2 2 — — 3 — — — — 3 4 3 4 4 5 4 5 5
*1: The items available in the operator mode fall into the following categories. A: The items displayed from turning "ON" of the starting switch up to switching to the standard screen and the item displayed after the starting switch is turned "OFF" B: The items displayed when the machine monitor switch is operated C: The items displayed when the requirements are met D: The items that require special switch operation to display *2: The sequence of display from turning "ON" of the starting switch up to switching to the standard screen varies depending on the setting and conditions of the machine as described below. W: When the engine start lock is effective X: When the engine start lock is ineffective Y: When a trouble is detected in any of the check before starting items Z: When a maintenance overdue item is detected
a a
For how to operate the operator mode functions, see the Operation and Maintenance Manual or "Special functions of machine monitor" in "Testing and adjusting". For how to set the engine start lock on/off, see "Password setting/cancel manual".
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D65EX, PX, WX-16
700 Electrical system Monitor system
SEN04972-02
Service mode function q
q
1
When the standard screen is displayed, display and setting of these functions are available by the serviceman's special operations of the switch. This mode is used for special setting, testing, adjusting or troubleshooting. Items available in the service mode are as follows:
Monitoring Abnormality Record
Mechanical Systems Electrical Systems Air-conditioning System
Maintenance Record Maintenance Mode Change Phone Number Entry Key-on Mode Unit Default Maintenance Password Camera ECO Display Adjustment PM CLINIC Cylinder Cut-Out No Injection Fuel Consumption Terminal Status KOMTRAX Settings GPS & Communication Status Modem S/N Service Message
a
For how to operate the service mode functions, see "Special functions of machine monitor" in "Testing and adjusting".
D65EX, PX, WX-16
10-700
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SEN04972-02
Engine control system
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700 Electrical system Engine control system
1
D65EX, PX, WX-16
700 Electrical system Engine control system
SEN04972-02
1. Battery 2. Starting switch 3. Engine controller 4. Power train controller 5. Machine monitor 6. Fuel control dial 7. Decelerator pedal 8. Parking limit switch 9. Parking brake lever 10. Work equipment lock limit switch 11. Work equipment lock lever 12. Electric lever 13. Steering, directional, gear shift lever (PCCS lever) 14. Neutral safety relay 15. Engine 16. Starting motor 17. Engine speed sensor 18. Coolant temperature sensor 19. Engine oil pressure switch 20. Injector 21. Fuel supply pump valve Input and output signals a. Battery power source b. Engine start signal c. Neutral safety relay signal d. Starting switch ACC signal e. Parking brake signal f. Work equipment lock signal g. Neutral signal h. No.1 throttle signal (fuel control dial signal) i. No.2 throttle signal (decelerator pedal signal) j. No.3 throttle signal (controller control signal) k. Controller power supply l. Engine speed signal m. Coolant temperature signal n. Engine oil pressure signal o. Sensor signal p. Monitor display signal
D65EX, PX, WX-16
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SEN04972-02 Engine start mechanism q The power train controller controls the neutral safety relation operation in such that the engine is not started unless both the parking brake lever and work equipment lock lever are set to "LOCK" and the steering, directional, gear shift lever is set to "NEUTRAL".
700 Electrical system Engine control system
Engine stop mechanism q Setting the starting switch to "OFF" turns off the starting switch ACC signal to the engine controller. q The engine controller stops supplying fuel to the engine to stop the engine.
Engine speed control mechanism The engine controller receives the No.1 throttle signal (fuel dial signal), No.2 throttle signal (decelerator pedal signal) and No.3 throttle signal (controller control signal) from the power train controller. The engine controller selects the lowest command signal among the above three to control the fuel supply pump and injector. The No.3 throttle signal has the following types: 1) Auto-decelerator (F3, R3) The auto-decelerator is the function of lowering the engine speed temporarily when the travel direction is changed from F3 or R3. (Above is intended to protect the transmission clutch.)
q
2)
q
q
Momentary engine speed-up (directional change on downhill) When travel direction is changed while running down a hill, this function increases the minimum engine speed momentarily depending on the given conditions of the machine. (This function secures safety by preventing slipping down of the machine body.)
The power train controller calculates a proper engine speed based on the information from the auto-decelerator and momentary engine speed-up, and transmits it to the engine controller as the No.3 throttle signal. The information from the engine controller is owned jointly by the other controllers and transmitted so that the relationship between the engine and chassis will be optimized.
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D65EX, PX, WX-16
700 Electrical system Cooling system control system
SEN04972-02
Cooling system control system
1. Battery 2. Battery relay 3. Power train controller 4. Engine controller 5. Machine monitor 6. Cooling fan motor 7. Cooling fan pump 8. Power train oil temperature sensor 9. Hydraulic oil temperature sensor 10. Engine 11. Engine speed sensor 12. Coolant temperature sensor
D65EX, PX, WX-16
1
Input and output signals a. Controller power supply b. Power train oil temperature signal c. Hydraulic oil temperature signal d. Engine speed signal e. Coolant temperature signal f. CAN signal g. Pump control signal h. Fan reverse signal
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700 Electrical system Cooling system control system
SEN04972-02 Outline q The power train controller monitors the coolant, power train oil and hydraulic oil temperatures and controls the fan speed according to those temperatures. Function Fan speed control q The power train controller selects the maximum target fan speed obtained from the coolant, power train oil, and hydraulic oil temperatures and outputs it as the pump control signal to the cooling fan pump. q The cooling fan pump changes its swash plate angle to control its oil discharge for the cooling fan motor.
Selection of fan rotation mode q When the starting switch is set to "ON" and the engine is stopped, selecting the "fan reverse mode" in the "user menu" of the machine monitor allows setting the fan rotation mode. Fan rotation mode includes; 1) Forward rotation mode 2) Cleaning mode According to the selected mode, the power train controller operates the reverse solenoid valve of the cooling fan motor to change the rotational direction of the fan. 1)
Forward rotation mode In this mode, the reverse solenoid valve does not operate and the fan rotates forward. The fan speed varies with the temperature sensor signal. This mode is selected normally.
2)
Cleaning mode In this mode, the fan rotates in reverse at high speed to blow off dirt from the radiator fins, regardless of the temperature sensor signals. If this mode is used periodically, the cleaning interval of the radiator fins can be expanded. As long as the "cleaning mode" is turned on, setting the steering, directional, gear shift lever to "FORWARD" or "REVERSE" does not start the machine operation. This arrangement is intended for protecting the radiator. Set the starting switch to "OFF" once and then set it to "ON" again to restore the "forward rotation mode".
Interlock for changing rotation mode If the rotation direction of the fan is changed while the fan is rotating, the fan drive circuit is broken. q In order to protect the fan drive circuit, this system ignores the signal generated from selecting the "fan reverse mode" in the "user menu" of the machine as long as the engine is run. In this case, the machine monitor displays "Denied" and the fan does not rotate reverse. q
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22
D65EX, PX, WX-16
700 Electrical system Electronic steering control system
SEN04972-02
Electronic steering control system
1. Machine monitor 2. Steering, directional, gear shift lever (PCCS lever) 3. Engine controller 4. Power train controller 5. Engine speed sensor 6. Torque converter oil pressure sensor 7. Transmission output speed sensor
D65EX, PX, WX-16
1
8. Engine 9. Torque converter 10. Transmission 11. Transmission control valve 12. HSS unit 13. Control valve 13a. Steering control valve 14. HSS motor
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SEN04972-02
700 Electrical system Electronic steering control system
Gear shift mode function Outline q There are the auto gear shift mode and manual gear shift mode in the gear shift mode. These modes are changed to each other each time gear shift mode switch (1) is pressed.
1
Screen display q The gear shift mode is displayed on the gear speed display of the machine monitor as shown below. Auto gear shift mode
Auto gear shift mode If a load is applied, the gear is shifted down automatically. And if the load is reduced, the gear is automatically shifted up to the set maximum gear speed. q This mode excels in the fuel consumption and working efficiency since the torque converter locks up according to the given load, enabling to select the set maximum gear speed automatically. q
1. Currently used gear speed 2. "AUTO" mark representing the auto gear shift mode 3. The symbol representing the auto gear shift mode 4. Preset (gear speed at start) and maximum gear speed during travel Manual gear shift mode
Manual gear shift mode q If a load is applied, the gear is shifted down automatically. However, reducing the load does not automatic induce the shift up.
Gear shift operation Pressing UP switch (1) or DOWN switch (2) of the steering, directional, gear shift lever enables the gear shift operation and specifying a preset speed.
q
1. Currently used gear speed 2. "MAN" mark representing the manual gear shift mode 3. The symbol representing the manual gear shift mode 4. Preset (gear speed at start)
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D65EX, PX, WX-16
700 Electrical system Electronic steering control system
Setting preset with shift switch operation at NEUTRAL q Set the preset (gear speed at start) and the maximum gear speed during travel (for only the auto gear shift mode) with the gear shift switches in neutral. Auto gear shift mode Setting the preset (gear speed at start) and the maximum gear speed during travel
SEN04972-02 Shifting speed range by operating shift switch when traveling q While the machine is traveling, operating UP switch and DOWN switch allows changing the maximum gear speed when the auto gear shift mode is turned on and changing the gear speed currently used when the manual gear shift mode is turned on. Auto gear shift mode Changing maximum gear speed during travel During forward travel During reverse travel
The maximum gear speed can be set to F1–F3. The maximum gear speed can be set to R1–R3. Each time operator presses this switch, UP switch the maximum gear speed is sequentially increased to the next higher range. Each time operator presses this switch, DOWN switch the maximum gear speed is sequentially decreased to the next lower range.
Manual gear shift mode Setting the preset (gear speed at start)
a a
Turning the starting switch to "ON" sets the preset to "F1–R1" of the automatic gear shift mode. When the gear shift mode is changed, "F1–R1" is selected as the initial state.
D65EX, PX, WX-16
Manual gear shift mode Changing the currently used gear speed during travel During forward travel During reverse travel
The maximum gear speed can be set to F1–F3. The maximum gear speed can be set to R1–R3. Each time operator presses this switch, UP switch the maximum gear speed is sequentially increased to the next higher range. Each time operator presses this switch, DOWN switch the maximum gear speed is sequentially decreased to the next lower range.
Gear speed at start or travel direction change on a slope q In order to secure safety, this function may switch an uphill travel started at 3rd speed (Low) "3L" to 2nd speed "2" depending on the given condition of the machine. q When travel direction is changed while the machine is running a downhill, this function may start the travel at 1st speed "1" and increase the engine minimum speed momentarily in order to secure safety under the given condition of the machine.
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SEN04972-02
KOMTRAX system
q
q
q
a
700 Electrical system KOMTRAX system
1
The KOMTRAX system consists of the KOMTRAX terminal, communication antenna, machine monitor and GPS antenna. This system sends various information of the machine via wireless communication. It allows operators of the KOMTRAX to obtain the machine information from the office and to provide various services with the customers. Information transmittable from the KOMTRAX system includes the following. 1. Operation map 2. Service meter 3. Location information 4. Error history and others. To provide the services, you need to make an arrangement for starting the KOMTRAX service separately.
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D65EX, PX, WX-16
700 Electrical system KOMTRAX system
SEN04972-02
KOMTRAX terminal
1
Model: TH300 q The KOMTRAX system uses satellite communication technology.
1. Communication antenna connection 2. Machine harness connection (AMP-14P) 3. Machine harness connection (AMP-10P)
Input and output signals AMP-14P [CN-CK01] Pin No.
Outline q The KOMTRAX terminal sends various machine information based on the network signals and input signals obtained through the machine monitor, as well as GPS position d a ta , v ia w i r e l e s s c o m m u n ic a t i o n . T h e KOMTRAX terminal can transmit information via the communication antenna. q Conditions of the KOMTRAX terminal can be checked with the "Display of KOMTRAX setting" in the service mode of the machine monitor. q Use of KOMTRAX terminal must be limited to the countries where such communication is allowed.
Signal name
Input/Output signal
A1
Power supply (12 V)
A2
NC
Input
A3
NC
A4
Switching of power supply voltage
A5
NC
—
A6
NC
—
A7
GND
—
A8
GND
—
A9
NC
—
A10
NC
—
A11
NC
—
A12
NC
—
A13
NC
—
A14
NC
—
— — Output
AMP-10P [CN-CK02] Pin No.
D65EX, PX, WX-16
Signal name
Input/Output signal
B1
RS232C DCD
Output
B2
RS232C RXD
Output
B3
RS232C TXD
Input
B4
RS232C DTR
Input
B5
RS232C SGND
B6
RS232C DSR
B7
NC
—
B8
NC
—
B9
NC
—
B10
NC
—
Input Output
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700 Electrical system KOMTRAX terminal (for GPRS)
SEN04972-02
KOMTRAX terminal (for GPRS)
1
Model: TC530 q The KOMTRAX system uses Terrestrial transmission.
1. Communication antenna connection 2. Machine harness connection (AMP-14P) 3. Machine harness connection (AMP-10P)
Input and output signals AMP-14P [CN-CK01] Pin No.
Outline The KOMTRAX terminal sends various machine information based on the network signals and input signals obtained through the machine monitor, as well as GPS position d a ta , v ia w i r e l e s s c o m m u n ic a t i o n . T h e KOMTRAX terminal can transmit information via the communication antenna. q Conditions of the KOMTRAX terminal can be checked with the "Display of KOMTRAX setting" in the service mode of the machine monitor. q Use of KOMTRAX terminal must be limited to the countries where such communication is allowed. q
Input/Output signal
Signal name
A1
Power supply output (5 V)
A2
GND
Output
A3
RS232C (extend) RXD
A4
RS232C (extend) RXD
Input
A5
ON/OFF contact input 3 (low side)
Input
A6
ON/OFF contact input 6 (low side, startable by terminal)
Input
A7
ON/OFF contact input 2 (low side)
Input
A8
ON/OFF contact input 1 (low side)
A9
ON/OFF output 0
A10
CAN
Input/Output
A11
CAN
Input/Output
A12
ON/OFF contact input 5 (high side)
Input
A13
ON/OFF contact input 4 (high side)
Input
A14
Outside input/output to cancel sleep mode
Input/Output
Output
Input Output
A15
Busy lamp output
A16
Analog input 3 (0 to 5 V)
Output Input
A17
Analog input 4 (0 to 5 V)
Input
A18
Analog input 5 (0 to 5 V)
Input
AMP-10P [CN-CK02] Pin No. B1
10-700
28
Input/Output signal
Signal name GND
B2
GND
B3
ACC signal input (high side)
Input
B4
Analog input 2 (0 to 30 V)
Input
B5
Analog input 2 (0 to 5 V)
Input
B6
Power supply input (10 to 30 V)
Input
B7
Power supply input (10 to 30 V)
B8
Output of prohibition of starting engine
B9
Inspection mode switch signal (low side)
Input
B10
Inspection mode switch signal (low side)
Input
B11
ON/OFF contact input 0 (high side)
Input
Input Output
D65EX, PX, WX-16
700 Electrical system System components
B12
Analog input 2 (0 to 30 V)
SEN04972-02
Input
System components
1
Engine controller
Input and output signals q The following is the list of the symbols used for signal classification in the input/output signal chart. A: Power supply B: Input C: Ground/shield/return D: Output E: Communication DTP06-4P [CN-CE03] Pin No.
Signal name
Signal classification
1
GND
C
2
GND
C
3
Constant power supply (+24 V)
A
4
Constant power supply (+24 V)
A
D65EX, PX, WX-16
10-700
29
700 Electrical system System components
SEN04972-02
DRC26-60P [CN-CE01] 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
Signal classification Fuel electrical lift pump (+) D Inlet metering valve (+) D Atmospheric pressure sensor B NC — NC — CAN_L E NC — CAN_H E NC — NC — Fuel electrical lift pump (–) C NC — NC — Water-in-fuel sensor (+) B Coolant temperature sensor B Crank shaft angle sensor power supply (+5V) A Engine oil pressure switch B NC — NC — NC — NC — NC — Boost temperature sensor B NC — Common rail pressure sensor B Camshaft speed sensor (+) B Crankshaft angle sensor (+) B NC — NC — NC — Signal name
Pin No. 31 32 33 34 35 36 37 38 39 40 41 42 43 44 45 46 47 48 49 50 51 52 53 54 55 56 57 58 59 60
Signal classification NC — Inlet metering valve (–) C Atmospheric pressure sensor power supply (+5V) A NC — NC — NC — Sensor power supply (+5 V) A Sensor GND C NC — NC — NC — NC — NC — Boost pressure sensor B Injector #1 (+) D Injector #5 (+) D Sensor GND C Crankshaft angle sensor GND C NC — NC — Injector #2 (–) C Injector #3 (–) C Injector #1 (–) C Injector #2 (+) D Injector #3 (+) D Injector #4 (+) D Injector #6 (+) D Injector #4 (–) C Injector #6 (–) C Injector #5 (–) C Signal name
DRC26-50P [CN-CE02] 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
Signal name NC NC NC NC NC NC NC NC Decelerator potentiometer signal NC NC NC NC NC NC NC NC NC NC NC NC Decelerator potentiometer power supply (+5 V) Decelerator potentiometer (–) NC NC
10-700
30
Signal classification — — — — — — — — B — — — — — — — — — — — —
Pin No. 26 27 28 29 30 31 32 33 34 35 36 37 38 39 40 41 42 43 44 45 46
Signal classification — — — — — — — — — — — — — B D — — — — — E
NC NC NC NC NC NC NC NC NC NC NC NC NC Starting switch ACC signal Intake air heater drive signal NC NC NC NC NC CAN_H
A
47
CAN_L
E
C — —
48 49 50
NC Engine power supply relay drive signal NC
— D —
Signal name
D65EX, PX, WX-16
700 Electrical system System components
SEN04972-02
Power train controller
D65EX, PX, WX-16
10-700
31
700 Electrical system System components
SEN04972-02 Input and output signals DRC26-24P [CN-STC1] Pin No. 1 2 3 4 5 6 7 8 9 10 11 12
Signal name Fuel control dial Steering lever potentiometer 1 Brake pedal potentiometer GND (signal) NC NC Directional lever position meter 4 Pitch angle sensor Torque converter oil temperature sensor GND (signal) Air compressor drive signal UP switch (NC)
Input/Output signal Input Input Input — — — Input Input Input — Input Input
Pin No. 13 14 15 16 17 18 19 20 21 22 23 24
Input/Output signal — Input Input Input Input Input — Output — — — — Input Output Input Input — Output Output —
Pin No. 21 22 23 24 25 26 27 28 29 30 31 32 33 34 35 36 37 38 39 40
Input/Output signal Input Input Input Output — Output Output Output Input Input Input Input Input Input — Output Output Output Input Input
Pin No. 21 22 23 24 25 26 27 28 29 30 31 32 33 34 35 36 37 38 39 40
Signal name Directional lever position meter 3 Hydraulic oil pressure sensor Alternator R signal Sensor power supply (+24 V) Starting switch C signal DOWN switch (NO) Steering lever potentiometer 2 Torque converter oil pressure sensor GND (analog) Sensor power supply (+5 V) NC DOWN switch (NC)
Input/Output signal Input Input Input Output Input Input Input Input — Output — Input
DRC26-40P(A) [CN-STC2] Pin No. 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20
Signal name NC Left tilt oil pressure switch Blade lower oil pressure sensor RS232C RXD Parking brake limit switch (NC) Work equipment lock limit switch (NC) NC Neutral safety relay NC NC NC NC Blade raise oil pressure switch RS232C TXD Parking brake limit switch (NO) Work equipment lock limit switch (NO) NC Backup alarm relay Beacon lamp relay NC
Signal name NC CAN0_L CAN1_L Service connector signal Transmission R clutch fill switch NC Blade control lever lower switch (NC) NC GND (Pulse) Transmission output speed sensor NC CAN0_H CAN1_H RS232C GND Transmission F clutch fill switch Torque converter lockup clutch fill switch Blade control lever lower switch (NO) Right tilt oil pressure switch NC NC
Input/Output signal — Input/output Input/output Input Input — Input — — Input — Input/output Input/output — Input Input Input Input — —
DRC26-40P(B) [CN-STC3] Pin No. 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20
Signal name Power supply (Controller) Power supply (Solenoid) GND (Solenoid, common) For activating battery relay NC Transmission 1st clutch ECMV HSS pump TVC solenoid Work equipment lock solenoid UP switch (NO) Blade control lever upper switch (NO) Power supply (Controller) Power supply (Solenoid) GND (Solenoid, common) Starting switch ACC signal NC Transmission 2nd clutch ECMV Torque converter lockup clutch ECMV Cooling fan reverse solenoid Transmission 1st clutch fill switch Blade control lever upper switch (NC)
10-700
32
Signal name GND (Power supply) Power supply (Solenoid) GND (Solenoid, common) Starting switch ACC signal HSS left EPC valve Transmission 3rd clutch ECMV Transmission F clutch ECMV Pitch selecting solenoid Transmission 2nd clutch fill switch NC GND (Power supply) GND (Power supply) GND (Power supply) Sensor power supply 2 (+5 V) HSS right EPC valve Fan pump solenoid Transmission R clutch ECMV NC Transmission 3rd clutch fill switch NC
Input/Output signal — Input — Input Output Output Output Output Input — — — — Output Output Output Output — Input —
D65EX, PX, WX-16
700 Electrical system System components
SEN04972-02
Engine oil pressure switch
1. Connector 2. Sensor 3. O-ring
Coolant temperature sensor
1. Connector 2. Sensor 3. O-ring
D65EX, PX, WX-16
10-700
33
SEN04972-02
700 Electrical system System components
Crankshaft angle sensor (Ne sensor)
1. Connector 2. Sensor 3. O-ring
Boost pressure, temperature sensor
1. Connector 2. Sensor 3. O-ring
10-700
34
D65EX, PX, WX-16
700 Electrical system System components
SEN04972-02
Fuel control dial
1. Knob 2. Dial 3. Spring 4. Ball 5. Potentiometer 6. Connector
D65EX, PX, WX-16
Function q The fuel control dial is installed to the left side of the operator's seat. q If knob (1) is turned, the shaft of potentiometer (5) is turned to change the resistance of the variable resistor and send a throttle signal to the engine controller. q The hatched areas in the following graph is the abnormality detection areas. In those areas, the engine speed is reduced to a half.
10-700
35
700 Electrical system System components
SEN04972-02 Decelerator pedal potentiometer Brake pedal potentiometer
1. Element 2. Contact 3. Shaft 4. Connector
Output characteristics
Function q The decelerator pedal potentiometer is installed at the bottom of the front part of the floor and directly connected to the decelerator pedal. q The brake pedal potentiometer is installed at the bottom of the front part of the floor and directly connected to the brake pedal. q Potentiometer shaft (3) starts rotation when the pedal is operated. It outputs the signal voltage after converting the power supply voltage to signal voltage according to the angle of pedal operation based on the resistance value of the variable resistor.
10-700
36
D65EX, PX, WX-16
700 Electrical system Sensor
SEN04972-02
Sensor
1
Power train oil temperature sensor Hydraulic oil temperature sensor
1. Connector
2. Plug
3. Thermistor
Function q The power train oil temperature sensor is installed on the left side face block of the torque converter and the hydraulic oil temperature sensor is installed in the hydraulic tank. q This sensor senses the oil temperature and converts it into an electric signal and then outputs that signal.
Hydraulic oil pressure sensor
1. O-ring 2. Sensor 3. Connector
Output characteristics
Function This sensor is installed in the discharge side block of the HSS pump. q This sensor detects pressure of hydraulic oil. It converts the pressure to an electric signal and then outputs that signal. q
D65EX, PX, WX-16
10-700
37
700 Electrical system Sensor
SEN04972-02 Torque converter oil pressure sensor
1. O-ring 2. Sensor 3. Connector
Output characteristics
Function q This sensor is installed on the left side block of the torque converter. q This sensor detects the torque converter oil pressure. It converts the pressure to an electric signal and then outputs that signal.
10-700
38
D65EX, PX, WX-16
700 Electrical system Sensor
SEN04972-02
Transmission output speed sensor
1. Pole piece 2. Magnet wire 3. Bobbin
4. Magnet 5. Housing 6. Grommet
7. Connector
Function q This sensor is installed on the bevel gear area situated in the rear side of the steering case. q These sensors detect the gear shift speed. It converts speed to the corresponding pulse signals and then outputs the signals.
Pitch angle sensor
1. Body 2. Tube 3. Tube
4. Ring 5. Wire 6. Connector
Function This sensor is installed in the engine room on the right side of the machine body. q There are multiple electrodes and oil in this sensor. The changes of the oil level made by inclination of the machine are sensed by the differences in electrostatic capacity between the electrodes, and then those differences are converted into voltage signals. q
D65EX, PX, WX-16
10-700
39
700 Electrical system Sensor
SEN04972-02 Fuel level sensor
1. Connector 2. Float 3. Arm
4. Body 5. Spring 6. Contact
7. Spacer
Function q This sensor is installed on the front of the fuel tank. q This sensor senses the fuel level and converts it into an electric signal and then outputs that signal. q The float moves up and down according to the fuel level. q The movement of the float operates the variable resistor through the arm.
10-700
40
D65EX, PX, WX-16
700 Electrical system Sensor
SEN04972-02
Water-in-fuel sensor
1. Connector 2. Tube
3. Sensor 4. O-ring
Function q This sensor is installed in the cup of the fuel pre-filter. q This sensor outputs the signal upon sensing water in fuel.
D65EX, PX, WX-16
10-700
41
SEN04972-02
700 Electrical system Sensor
Air cleaner clogging sensor (sand terrain specification)
1. Adapter 2. Hood 3. Indicator 4. Connector Function q The air cleaner clogging sensor is installed to the air cleaner outlet. If the air cleaner is clogged and the pressure reaches the specified level (negative pressure), caution lamp on the machine monitor lights up to output a warning.
10-700
42
D65EX, PX, WX-16
700 Electrical system Sensor
D65EX, PX, WX-16
SEN04972-02
10-700
43
SEN04972-02
D65EX-16, D65PX-16, D65WX-16 Bulldozer Form No. SEN04972-02
© 2012 KOMATSU All Rights Reserved Printed in Japan 02-12
10-700
44
SEN05118-01
BULLDOZER D65EX-16 D65PX-16 D65WX-16 Machine model D65EX-16 D65PX-16 D65WX-16
Serial number 80001 and up 80001 and up 80001 and up
20 Standard value table
20
100 Standard service value table Standard service value table for engine .......................................................................................................... 2 Standard service value table for chassis......................................................................................................... 4
D65EX, PX, WX-16
20-100
1
100 Standard service value table Standard service value table for engine
SEN05118-01
Standard service value table for engine
Check item
1
Machine model
D65EX, PX, WX-16
Engine
SAA6D114E-3
Measurement conditions
Standard value for new machine
Permissible value
2,070 ± 50
2,070 ± 50
825 ± 25
825 ± 25
1,950
—
kPa {mmHg}
151 – 177 {1,130 – 1,330}
120 {900}
Bosch index
Max. 2.5 Max. 1.0
3.5 2.0
°C
Max. 600
Max. 650
0.305
0.152 – 0.559
0.559
0.381 – 0.813
Unit
High idle Rotation speed
Low idle
rpm
Rated speed Air boost pressure (boost pressure) (Aftercooler outlet)
At rated horsepower
Exhaust gas color
At sudden acceleration (LooHi) At high idle
Exhaust temperature Whole speed range (Turbine inlet temperature) (Ambient temperature 20°C) Intake valve
Valve clearance
(Normal temperature)
Compression pressure
Oil temperature: 40 – 60°C (SAE30 or SAE15W-40) (Engine speed: Min. 170 rpm)
MPa {kg/cm2}
Min. 2.6 {Min. 26.5}
2.1 {21.4}
Blow-by pressure
(SAE30 or SAE15W-40) kPa (Coolant temperature: Operating range) {mmH2O} At rated horsepower
Max. 1.96 {Max. 200}
Max. 2.94 {Max. 300}
0.34 – 0.59 {3.5 – 6.0}
0.21 {2.1}
Min. 0.15 {Min. 1.5}
0.08 {0.8}
80 – 110
Min. 120
Auto-tensioner
—
15 – 18
—
Exhaust valve
mm
(Coolant temperature: Operating range)
Oil pressure
When torque converter is stalling (SAE30 or SAE15W-40)
MPa {kg/cm2}
At low idle (SAE30 or SAE15W-40) Oil temperature
Belt tension
20-100
2
Whole speed range (Inside oil pan)
Deflection when pressed with finger force of approx. 98 N {approx. 10 kg}
°C
Alternator – crankshaft pulley Air conditioner compressor – crankshaft pulley
mm
D65EX, PX, WX-16
100 Standard service value table Standard service value table for engine
D65EX, PX, WX-16
SEN05118-01
20-100
3
100 Standard service value table Standard service value table for chassis
SEN05118-01
Standard service value table for chassis
1
Engine speed
Classification
Machine model
Check item
Decelerator pedal speed
Torque converter stall speed
PCCS lever
• Stop engine. • Center of lever knob.
• Stop engine. • Center of pedal.
Brake pedal
• Engine: Low idle • Center of pedal.
• Straight tilt dozer • Sigma dozer
Power angle power tilt dozer
Permissible value
1,000 ± 25
1,000 ± 25
1,770 ± 100
1,650
Neutral o Forward
30 ± 10
30 ± 10
Neutral o Reverse
30 ± 10
30 ± 10
• Coolant temperature: Within operating range • Power train oil temperature: Within operating range • Hydraulic oil temperature: Within operating range • Engine: High idle • Operation mode: P-mode • Decelerator pedal speed: Press pedal. • Torque converter stall speed: F3
Decelerator pedal
Blade control lever
Stroke of control lever and pedal
Steering
Standard value for new machine
Measurement conditions
Forward and reverse
D65EX, WX-16
Unit
rpm
Neutral o Left
40 ± 15 40 ± 15 (Play: Max. 3) (Play: Max. 3)
Neutral o Right
40 ± 15 40 ± 15 (Play: Max. 3) (Play: Max. 3) 55 ± 11
55 ± 11
All stroke
68 ± 11
68 ± 11
Neutral o Raise or Lower
63 ± 10
63 ± 10
Neutral o Float
88 ± 13
88 ± 13
53 ± 8
53 ± 8
51 ± 10
51 ± 10
77 ± 13
77 ± 13
57 ± 8
57 ± 8
15 ± 3
15 ± 3
54 ± 8
54 ± 8
46.1 ± 19.6 {4.7 ± 2.0}
46.1 ± 19.6 {4.7 ± 2.0}
46.1 ± 19.6 {4.7 ± 2.0}
46.1 ± 19.6 {4.7 ± 2.0}
24.5 ± 9.8 {2.5 ± 1.0}
24.5 ± 9.8 {2.5 ± 1.0}
24.5 ± 9.8 {2.5 ± 1.0}
24.5 ± 9.8 {2.5 ± 1.0}
mm
• Engine: Low idle Neutral o Left or Right tilt • Hydraulic oil temperature: 45 – 55°C Neutral o Raise or Lower • Center of lever Neutral o Float knob. Neutral o Left or Right tilt Neutral o Left or Right angle ° (degree)
Operating effort of control lever and pedal
• Engine: Low idle • Hydraulic oil temRipper control lever perature: 45 – 55°C Neutral o Raise or Lower (If equipped) • Center of lever knob. Neutral o Forward or Reverse
Forward and reverse • Stop engine. • Center of lever knob.
PCCS lever
20-100
Forward or Reverse o Neutral Neutral o Left
Steering Neutral o Right
4
mm
N {kg}
D65EX, PX, WX-16
100 Standard service value table Standard service value table for chassis
SEN05118-01
D65PX-16 Standard value for new machine
Permissible value
1,000 ± 25
1,000 ± 25
1,770 ± 100
1,650
30 ± 10
30 ± 10
30 ± 10
30 ± 10
40 ± 15 (Play: Max. 3)
40 ± 15 (Play: Max. 3)
40 ± 15 (Play: Max. 3)
40 ± 15 (Play: Max. 3)
55 ± 11
55 ± 11
68 ± 11
68 ± 11
63 ± 10
63 ± 10
88 ± 13
88 ± 13
53 ± 8
53 ± 8
51 ± 10
51 ± 10
77 ± 13
77 ± 13
57 ± 8
57 ± 8
15 ± 3
15 ± 3
—
—
46.1 ± 19.6 {4.7 ± 2.0}
46.1 ± 19.6 {4.7 ± 2.0}
46.1 ± 19.6 {4.7 ± 2.0}
46.1 ± 19.6 {4.7 ± 2.0}
24.5 ± 9.8 {2.5 ± 1.0}
24.5 ± 9.8 {2.5 ± 1.0}
24.5 ± 9.8 {2.5 ± 1.0}
24.5 ± 9.8 {2.5 ± 1.0}
D65EX, PX, WX-16
20-100
5
100 Standard service value table Standard service value table for chassis
SEN05118-01
Check item
Measurement conditions
Unit
Standard value for new machine
Permissible value
• Engine: Low idle • Center of pedal.
62.7 ± 19.6 {6.4 ± 2.0}
62.7 ± 19.6 {6.4 ± 2.0}
Brake pedal
• Engine: Low idle • Center of pedal.
392 ± 39 {40 ± 4.0}
510 {52}
29.4 ± 9.8 {3.0 ± 1.0}
29.4 ± 9.8 {3.0 ± 1.0}
74.5 ± 19.6 {7.6 ± 2.0}
74.5 ± 19.6 {7.6 ± 2.0}
25.5 ± 9.8 {2.6 ± 1.0}
25.5 ± 9.8 {2.6 ± 1.0}
Neutral o Raise or Lower
29.4 ± 9.8 {3.0 ± 1.0}
29.4 ± 9.8 {3.0 ± 1.0}
Neutral o Float
74.5 ± 19.6 {7.6 ± 2.0}
74.5 ± 19.6 {7.6 ± 2.0}
Neutral o Left or Right tilt
25.5 ± 9.8 {2.6 ± 1.0}
25.5 ± 9.8 {2.6 ± 1.0}
3.9 ± 1.0 {0.4 ± 0.1}
3.9 ± 1.0 {0.4 ± 0.1}
25.5 ± 9.8 {2.6 ± 1.0}
25.5 ± 9.8 {2.6 ± 1.0}
25.5 ± 9.8 {2.6 ± 1.0}
25.5 ± 9.8 {2.6 ± 1.0}
Engine: Low idle
0.03 – 0.49 {0.3 – 5.0}
0.03 – 0.49 {0.3 – 5.0}
Engine: High idle
Max. 0.98 {Max. 10}
Max. 0.98 {Max. 10}
Engine: Low idle
0.02 – 0.29 {0.2 – 3.0}
0.02 – 0.29 {0.2 – 3.0}
Engine: High idle
0.39 – 0.89 {4.0 – 9.0}
0.39 – 0.89 {4.0 – 9.0}
Engine: Low idle
3.3 ± 0.2 {33.7 ± 2.0}
Min. 3.01 {Min. 30.7}
3.45 ± 0.2 {35.3 ± 2.0}
Min. 3.17 {Min. 32.3}
1.42 ± 0.15 {14.5 ± 1.5}
1.42 ± 0.15 {14.5 ± 1.5}
Engine: High idle
1.42 ± 0.15 {14.5 ± 1.5}
1.42 ± 0.15 {14.5 ± 1.5}
Engine: Low idle
2.89 ± 0.15 {29.5 ± 1.5}
Min. 2.60 {Min. 26.5}
Engine: High idle
2.89 ± 0.15 {29.5 ± 1.5}
Min. 2.60 {Min. 26.5}
Engine: Low idle
3.28 ± 0.15 {33.5 ± 1.5}
Min. 2.99 {Min. 30.5}
Engine: High idle
3.28 ± 0.15 {33.5 ± 1.5}
Min. 2.99 {Min. 30.5}
Neutral o Raise or Lower • Straight tilt dozer • Sigma dozer
Power angle power tilt dozer
Neutral o Float • Engine: Low idle • Hydraulic oil temperature: 45 – 55°C • Center of lever knob.
Neutral o Left or Right tilt
Neutral o Left or Right angle Ripper control lever (If equipped)
• Engine: Low idle • Hydraulic oil temperature: 45 – 55°C • Center of lever knob.
Torque converter inlet pressure
Torque converter outlet pressure Power train oil pressure
D65EX, WX-16
Decelerator pedal
Blade control lever
Operating effort of control lever and pedal
Classification
Machine model
Transmission main relief pressure
Torque converter lock-up clutch pressure
Transmission F clutch pressure
Transmission R clutch pressure
20-100
6
• Power train oil temperature: Within operating range
Neutral o Raise Neutral o Lower
Engine: High idle Engine: Low idle
N {kg}
Nm {kgm} N {kg}
MPa {kg/cm2}
D65EX, PX, WX-16
100 Standard service value table Standard service value table for chassis
SEN05118-01
D65PX-16 Standard value for new machine
Permissible value
62.7 ± 19.6 {6.4 ± 2.0}
62.7 ± 19.6 {6.4 ± 2.0}
392 ± 39 {40 ± 4.0}
510 {52}
29.4 ± 9.8 {3.0 ± 1.0}
29.4 ± 9.8 {3.0 ± 1.0}
74.5 ± 19.6 {7.6 ± 2.0}
74.5 ± 19.6 {7.6 ± 2.0}
25.5 ± 9.8 {2.6 ± 1.0}
25.5 ± 9.8 {2.6 ± 1.0}
29.4 ± 9.8 {3.0 ± 1.0}
29.4 ± 9.8 {3.0 ± 1.0}
74.5 ± 19.6 {7.6 ± 2.0}
74.5 ± 19.6 {7.6 ± 2.0}
25.5 ± 9.8 {2.6 ± 1.0}
25.5 ± 9.8 {2.6 ± 1.0}
3.9 ± 1.0 {0.4 ± 0.1}
3.9 ± 1.0 {0.4 ± 0.1}
—
—
—
—
0.03 – 0.49 {0.3 – 5.0}
0.03 – 0.49 {0.3 – 5.0}
Max. 0.98 {Max. 10}
Max. 0.98 {Max. 10}
0.02 – 0.29 {0.2 – 3.0}
0.02 – 0.29 {0.2 – 3.0}
0.39 – 0.89 {4.0 – 9.0}
0.39 – 0.89 {4.0 – 9.0}
3.3 ± 0.2 {33.7 ± 2.0}
Min. 3.01 {Min. 30.7}
3.45 ± 0.2 {35.3 ± 2.0}
Min. 3.17 {Min. 32.3}
1.42 ± 0.15 {14.5 ± 1.5}
1.42 ± 0.15 {14.5 ± 1.5}
1.42 ± 0.15 {14.5 ± 1.5}
1.42 ± 0.15 {14.5 ± 1.5}
2.89 ± 0.15 {29.5 ± 1.5}
Min. 2.60 {Min. 26.5}
2.89 ± 0.15 {29.5 ± 1.5}
Min. 2.60 {Min. 26.5}
3.28 ± 0.15 {33.5 ± 1.5}
Min. 2.99 {Min. 30.5}
3.28 ± 0.15 {33.5 ± 1.5}
Min. 2.99 {Min. 30.5}
D65EX, PX, WX-16
20-100
7
100 Standard service value table Standard service value table for chassis
SEN05118-01
Classification
Machine model
Check item
Power train oil pressure
Transmission 2nd clutch pressure • Power train oil temperature: Within operating range
Transmission lubricating oil pressure (For reference)
Power train performance
HSS pressure
Brake pressure
Work equipment oil pressure
Standard value for new machine
Permissible value
Engine: Low idle
3.23 ± 0.15 {33.0 ± 1.5}
Min. 2.94 {Min. 30.0}
Engine: High idle
3.23 ± 0.15 {33.0 ± 1.5}
Min. 2.94 {Min. 30.0}
Engine: Low idle
24.5 ± 0.15 {25.0 ± 1.5
Min. 2.16 {Min. 22.0}
Engine: High idle
24.5 ± 0.15 {25.0 ± 1.5
Min. 2.16 {Min. 22.0}
Engine: Low idle
3.28 ± 0.15 {33.5 ± 1.5}
Min. 2.99 {Min. 20.5}
3.28 ± 0.15 {33.5 ± 1.5}
Min. 2.99 {Min. 20.5}
Engine: High idle
0.05 – 0.25 {0.5 – 2.5}
0.05 – 0.25 {0.5 – 2.5}
Engine: Low idle
2.55 – 2.94 {26 – 30}
2.55 – 2.94 {26 – 30}
Engine: High idle
2.55 – 2.94 {26 – 30}
2.55 – 2.94 {26 – 30}
37.1 – 40.1 {379 – 409}
Min. 34.8 {Min. 355}
35.2 – 38.1 {359 – 389}
Min. 32.8 {Min. 335}
3.6 ± 0.2
3.6 ± 0.2
5.5 ± 0.3
5.5 ± 0.3
7.2 ± 0.4
7.2 ± 0.4
11.2 ± 0.6
11.2 ± 0.6
4.4 ± 0.3
4.4 ± 0.3
6.6 ± 0.3
6.6 ± 0.3
8.6 ± 0.4
8.6 ± 0.4
13.4 ± 0.7
13.4 ± 0.7
3.23 – 4.9 {33 – 50}
3.23 – 4.9 {33 – 50}
Min. 28.4 {Min. 290}
Min. 27.4 {Min. 280}
29.4 – 32.8 {300 – 335}
Min. 28.4 {Min. 290}
Measurement conditions
Transmission 1st clutch pressure
Transmission 3rd clutch pressure
D65EX, WX-16
Engine: High idle
Unit
MPa {kg/cm2}
Relief pressure
• Hydraulic oil temperature: 45 – 55°C • Engine: High idle LS pressure (Load sensing pressure)
Travel speed
F1 • Flat road F2 • Coolant temperature: Within operating F3L range • Power train oil temperature: Within F3 operating range R1 • Engine: High idle • Before measuring, run machine 10 – R2 30 m. R3L • Measuring distance: 20 m R3
• Hydraulic oil temperature: 45 – 55°C • Unload pressure: Set all equipment in neutral. • Relief pressure: Set tilt or ripper cylinder to stroke end. Blade tilt relief pressure • LS pressure: Set tilt or ripper cylinder to stroke end.
Unload pressure
20-100
8
km/h
Engine: High idle Engine: Low idle Engine: High idle
MPa {kg/cm2}
D65EX, PX, WX-16
100 Standard service value table Standard service value table for chassis
SEN05118-01
D65PX-16 Standard value for new machine
Permissible value
3.23 ± 0.15 {33.0 ± 1.5}
Min. 2.94 {Min. 30.0}
3.23 ± 0.15 {33.0 ± 1.5}
Min. 2.94 {Min. 30.0}
24.5 ± 0.15 {25.0 ± 1.5
Min. 2.16 {Min. 22.0}
24.5 ± 0.15 {25.0 ± 1.5
Min. 2.16 {Min. 22.0}
3.28 ± 0.15 {23.5 ± 1.5
Min. 2.99 {Min. 30.5}
3.28 ± 0.15 {23.5 ± 1.5
Min. 2.99 {Min. 30.5}
0.05 – 0.25 {0.5 – 2.5}
0.05 – 0.25 {0.5 – 2.5}
2.55 – 2.94 {26 – 30}
2.55 – 2.94 {26 – 30}
2.55 – 2.94 {26 – 30}
2.55 – 2.94 {26 – 30}
37.1 – 40.1 {379 – 409}
Min. 34.8 {Min. 355}
35.2 – 38.1 {359 – 389}
Min. 32.8 {Min. 335}
3.6 ± 0.2
3.6 ± 0.2
5.5 ± 0.3
5.5 ± 0.3
7.2 ± 0.4
7.2 ± 0.4
11.2 ± 0.6
11.2 ± 0.6
4.4 ± 0.3
4.4 ± 0.3
6.6 ± 0.3
6.6 ± 0.3
8.6 ± 0.4
8.6 ± 0.4
13.4 ± 0.7
13.4 ± 0.7
3.23 – 4.9 {33 – 50}
3.23 – 4.9 {33 – 50}
Min. 28.4 {Min. 290}
Min. 27.4 {Min. 280}
29.4 – 32.8 {300 – 335}
Min. 28.4 {Min. 290}
D65EX, PX, WX-16
20-100
9
100 Standard service value table Standard service value table for chassis
SEN05118-01
Work equipment oil pressure
Classification
Machine model
Check item
Ripper lift relief pressure
LS pressure (Load sensing pressure) Control circuit main pressure (HSS, PPC, fan) PPC valve output pressure
Blade lift
Work equipment speed
Work equipment
Blade tilt
Blade angle
Ripper lift (If equipped)
Pitch speed (If equipped)
20-100
10
D65EX, WX-16 Standard value for new machine
Permissible value
Engine: Low idle
Min. 2.84 {Min. 290}
Min. 27.4 {Min. 280}
Engine: High idle
29.4 – 32.8 {300 – 335}
Min. 28.4 {Min. 290}
Engine: Low idle
Min. 26.5 {Min. 270}
Min. 25.5 {Min. 260}
Measurement conditions
• Hydraulic oil temperature: 45 – 55°C • Unload pressure: Set all equipment in neutral. • Relief pressure: Set cylinder to stroke end. LS pressure: Set cylinder to stroke end.
Unit
Engine: High idle
MPa {kg/cm2} 27.4 – 30.9 {280 – 315} 3.97 ± 0.29 {40.5 ± 3.0}
3.97 ± 0.29 {40.5 ± 3.0}
3.19 – 4.17 {32.5 – 42.5}
3.19 – 4.17 {32.5 – 42.5}
2.5 ± 0.3
3.1
2.5 ± 0.3
3.1
1.9 ± 0.2
2.3
1.6 ± 0.2
2.0
Straight tilt dozer Sigma dozer
1.6 ± 0.3
2.1
Power angle power tilt dozer
1.7 ± 0.3
2.2
Straight tilt dozer Sigma dozer
1.6 ± 0.3
2.1
Power angle power tilt dozer
1.7 ± 0.3
2.2
4.0 ± 0.5
5.0
4.0 ± 0.5
5.0
1.5 ± 0.5
2.5
1.5 ± 0.5
2.5
1.6 ± 0.3
2.1
1.6 ± 0.3
2.1
• Hydraulic oil temperature: 45 – 55°C • Engine: High idle a See figure A Straight tilt dozer Sigma dozer • Hydraulic oil temperaRaise ture: 45 – 55°C Power angle • Apply no load to blade. power tilt dozer • Between ground level Straight tilt dozer and rising end of blade Sigma dozer • Engine: High idle Lower Power angle power tilt dozer a See figure B • Hydraulic oil temperaLeft ture: 45 – 55°C tilt • Apply no load to blade. • Between left tilt end and right tilt end Right • Engine: High idle tilt
Min. 26.5 {Min. 270}
a See figure C • Hydraulic oil tempera- Left angle ture: 45 – 55°C • Apply no load to blade. • Between left angle end and right angle end Right angle • Engine: High idle a See figure D • Hydraulic oil tempera- Raise ture: 45 – 55°C • Apply no load to ripper. • Between ground level and rising end of rip- Lower per. a See figure E • Hydraulic oil tempera- Pitch in ture: 45 – 55°C • Apply no load to blade. • Pitch in – pitch back Pitch back • Engine: High idle
Second
D65EX, PX, WX-16
100 Standard service value table Standard service value table for chassis
SEN05118-01
D65PX-16 Standard value for new machine
Permissible value
— — — — Min. 26.5 {Min. 270}
— — — — Min. 26.5 {Min. 270}
27.4 – 30.9 {280 – 315}
Min. 26.5 {Min. 270}
3.97 ± 0.29 {40.5 ± 3.0}
3.97 ± 0.29 {40.5 ± 3.0}
3.19 – 4.17 {32.5 – 42.5}
3.19 – 4.17 {32.5 – 42.5}
2.4 ± 0.3
3.0
2.5 ± 0.3
3.1
1.7 ± 0.2
2.1
1.6 ± 0.2
2.0
1.6 ± 0.3
2.1
1.7 ± 0.3
2.2
1.6 ± 0.3
2.1
1.7 ± 0.3
2.2
4.0 ± 0.5
5.0
4.0 ± 0.5
5.0
—
—
—
—
1.6 ± 0.3
2.1
1.6 ± 0.3
2.1
D65EX, PX, WX-16
20-100
11
100 Standard service value table Standard service value table for chassis
SEN05118-01
Classification
Machine model
Hydraulic drift
Work equipment
Time lag
Check item
Leakage from cylinder
Work equipment Cooling fan
Measurement conditions
Blade
• Hydraulic oil temperature: 45 – 55°C • Move lever to stroke end. • Lower blade from max. rising position and measure time after blade comes in contact with ground until idler is lifted. • High idle
Hydraulic drift of lifted blade
a See figure F • Hydraulic oil temperature: 45 – 55°C • Stop engine.
Hydraulic drift of machine when blade is titled
Hydraulic drift of lifted ripper Blade tilt cylinder Ripper lift cylinder
Fan speed
Fan pump pressure
20-100
D65EX, WX-16
12
a See figure G • Hydraulic oil temperature: 45 – 55°C • Stop engine. • Hydraulic drift of tip of blade cutting edge
Unit
Standard value for new machine
Permissible value
Second
Max. 1.0
Max. 1.5
Max. 35
Max. 35
Max. 70
Max. 70
Max. 70
Max. 70
Max. 35
Max. 35
5
20
5
20
600 ± 50
500
1,700 (+100/0)
1,600
14.2 – 17.2 {145 – 175}
13.2 {135}
Left tilt mm/ 5 min Right tilt
a See figure H • Hydraulic oil temperature: 45 – 55°C • Stop engine.
• Engine: High idle • Hydraulic oil temperature: 45 – 55°C • Relieve cylinder and measure leakage for 1 minute.
• Hydraulic oil temperature: 45 – 55°C • Fan: Normal rotation
cc/min
• Engine: Low idle • Coolant temperature, Min. power train oil tem- speed perature: Max. 80°C rpm • Engine: High idle • Fan 100% speed mode
• Hydraulic oil temperature: 45 – 55°C • Fan: Normal rotation
Max. speed
MPa {kg/cm2}
D65EX, PX, WX-16
100 Standard service value table Standard service value table for chassis
SEN05118-01
D65PX-16 Standard value for new machine
Permissible value
Max. 1.0
Max. 1.5
Max. 35
Max. 35
Max. 70
Max. 70
Max. 70
Max. 70
—
—
5
20
5
20
600 ± 50
500
1,700 (+100/0)
1,600
14.2 – 17.2 {145 – 175}
13.2 {135}
D65EX, PX, WX-16
20-100
13
100 Standard service value table Standard service value table for chassis
SEN05118-01 Illustrations related to standard value table Figure A
Figure D
Figure B
Figure E
Figure C
Figure F
20-100
14
D65EX, PX, WX-16
100 Standard service value table Standard service value table for chassis
SEN05118-01
Figure G
Figure H
D65EX, PX, WX-16
20-100
15
SEN05118-01
D65EX, PX, WX-16 Bulldozer Form No. SEN05118-01
©2010 KOMATSU All Rights Reserved Printed in Japan 02-10 (01)
20-100
16
SEN05119-02
BULLDOZER D65EX-16 D65PX-16 D65WX-16 Machine model D65EX-16 D65PX-16 D65WX-16
Serial number 80001 and up 80001 and up 80001 and up
30 Testing and adjusting
30
101 Testing and adjusting, Part 1 Tools for testing, adjusting, and troubleshooting............................................................................................. 2 Testing engine speed ...................................................................................................................................... 5 Testing intake air pressure (boost pressure) ................................................................................................... 7 Testing exhaust temperature........................................................................................................................... 9 Testing exhaust gas color ..............................................................................................................................11 Adjusting valve clearance ............................................................................................................................. 12 Testing compression pressure ...................................................................................................................... 14 Testing blow-by pressure .............................................................................................................................. 18 Testing engine oil pressure ........................................................................................................................... 19 Handling of fuel system devices ................................................................................................................... 20 Releasing residual pressure from fuel system .............................................................................................. 20 Testing fuel pressure..................................................................................................................................... 21 Testing fuel return and leak amount.............................................................................................................. 26 Bleeding air from fuel circuit.......................................................................................................................... 28 Testing fuel circuit for leakage....................................................................................................................... 29 Handling of reduced cylinder mode operation .............................................................................................. 30 Handling of no injection cranking operation .................................................................................................. 30 Testing and adjusting air conditioner compressor belt tension ..................................................................... 31 Replacing alternator belt ............................................................................................................................... 32 Adjusting fuel control dial and decelerator pedal .......................................................................................... 33 Handling controller high-voltage circuit ......................................................................................................... 34
D65EX, PX, WX-16
30-101
1
101 Testing and adjusting, Part 1 Tools for testing, adjusting, and troubleshooting
SEN05119-02
Tools for testing, adjusting, and troubleshooting Symbol
Part No.
Part name
Quantity
Testing or adjusting item
1
Remarks
Air boost pressure (boost pressure)
A
799-201-2202 Boost gauge kit
1 –101 – 200 kPa {–760 – 1,500 mmHg}
Water temperature, oil temperature and exhaust temperature
B
799-101-1502 Digital temperature gauge
1 –99.9 – 1,299°C
1 799-201-9001 Handy smoke checker Exhaust gas color
C
Valve clearance
D
2 1 2
Commercial item
Smoke meter
795-799-1131 Gear Commercial item
Clearance gauge
1 795-799-6700 Puller 2 795-502-1590 Gauge assembly Compression pressure
E 3 4
Blow-by pressure
F
G
6754-11-3130 Gasket
2
1 1 1 For 114E-3 1
795-790-3300 or Blow-by tool 799-201-1511
1
799-101-5002 Hydraulic tester
1
790-261-1204 Digital hydraulic tester
1 Pressure gauge: 60 MPa {600 kg/cm2}
2 799-401-2320 Gauge
Pressure gauge: 2.5, 6, 40, 60 MPa {25, 60, 400, 600 kg/cm2}
1 Pressure gauge: 1 MPa {10 kg/cm2}
6732-81-3170 Adapter
1 10 x 1.0 mm o R1/8
6215-81-9710 O-ring
1
799-101-5002 Hydraulic tester
1
790-261-1204 Digital hydraulic tester
1
6732-81-3170 Adapter
1 10 x 1.0 mm o R1/8
6215-81-9710 O-ring
1
3 799-401-2320 Gauge
*As common as G1
1 *As common as G2
H 4 795-790-6210 M10 computer check fitting 1 795-790-1500 1 (0 – 30 inHg) 5 or Vacuum gauge 1 –107 – 0 kPa {–800 – 0 mmHg} 799-201-1201
J
6 795-790-4900 Adapter kit
1
7 795-790-5010 Fitting
1
8
1 (0 – 75 inHg)
795-790-1150 Pressure gauge
1 795-790-4800 Hose kit
1
2 795-790-6700 Adapter
1
4
2
1
1 0 – 5 kPa {0 – 500 mmH20}
2
30-101
1
1 799-201-1504 Blow-by checker
1
Quantity of fuel return and leakage
Bosch index: 0 – 9
1
3
Fuel pressure
1
5 795-799-8150 Remover
1 Engine oil pressure
795-790-6110 Adapter
1
Commercial item
Measuring cylinder
1
D65EX, PX, WX-16
101 Testing and adjusting, Part 1 Tools for testing, adjusting, and troubleshooting
Symbol 1
Power train oil pressure
1 2
L
1
790-261-1204 Digital hydraulic tester
1 1
07002-11023
1
19M-06-32820 Switch assembly
1
14X-06-52930 Wiring harness
1
7824-66-6430 Prolix resistance
1 1 1
M 2 1
N
799-101-5220 Nipple (10 x 1.25 mm) O-ring
799-101-5220 Nipple (10 x 1.25 mm)
1
07002-11023
1
O-ring
795-101-5002 Hydraulic tester
1
Digital hydraulic tester
1
790-261-1204
799-101-5220 Nipple (10 x 1.25 mm)
1
07002-11023
1
O-ring
799-101-5002 Hydraulic tester
1
790-261-1204 Digital hydraulic tester
1
2 799-401-3100 Adapter (size 02) PPC valve output pressure
O
1
1
790-261-1204 Digital hydraulic tester
1
P
Fan motor speed
Q
Commercial item
1 Fan pump circuit pressure
Measuring cylinder
3
799-205-2200 Tachometer
1 1
790-261-1204 Digital hydraulic tester
1
799-101-5220 Nipple (10 x 1.25 mm)
1
07002-11023
O-ring
1
79A-264-0021 0 – 294 N {0 – 30 kg}
1
79A-264-0091 0 – 490 N {0 – 50 kg}
1
Stroke and hydraulic drift
T
Commercial item
Scale
1
Work equipment speed
U
Commercial item
Stopwatch
1
Voltage and resistance
V
Commercial item
Tester
1
D65EX, PX, WX-16
*As common as K3 *As common as G1
*As common as G1
*As common as G1
1
S
—
*As common as G1
1
Operating effort
Troubleshooting sensors and wiring harnesses
*As common as K3
1
799-101-5002 Hydraulic tester
R 2 799-401-3400 Adapter (size 05)
*As common as G1
1
799-101-5002 Hydraulic tester
2 799-401-3100 Adapter (size 02) Internal leakage of work equipment cylinder
Remarks
1 *As common as G2
7827-10-1520 Prolix resistance
1
Control circuit basic pressure
799-101-5002 Hydraulic tester
3 790-190-1601 Pump assembly 4
Work equipment and HSS oil pressure
Part name
K 2 799-401-2320 Gauge 3
Emergency escape method when power train has trouble
Part No.
Quantity
Testing or adjusting item
SEN05119-02
*As common as K3
799-601-7400 T-adapter assembly
1 AMP40 connector
799-601-7500 T-adapter assembly
1 AMP070 connector
799-601-9000 T-adapter assembly
2 DT, HD30 connector
799-601-9300 T-adapter assembly
1 DRC26-24, 40-pin
799-601-7360 Adapter
1 Relay (5-pin)
799-601-7370 Adapter
1 Relay (6-pin)
30-101
3
Testing or adjusting item
Symbol
Troubleshooting sensors and wiring harnesses —
Removal and installation of engine coolant temperature sensor
30-101
4
Part No.
Part name
Quantity
101 Testing and adjusting, Part 1 Tools for testing, adjusting, and troubleshooting
SEN05119-02
Remarks
799-601-4101 T-adapter assembly
1 Engine-related connector
799-601-4130 • T-adapter
1 Ne sensor, CAM sensor
799-601-9020 • Socket
1 Pump actuator
799-601-4140 • T-adapter
1 Ambient pressure sensor
799-601-4230 • Socket
1
799-601-4190 • Socket
1 Common rail pressure sensor
799-601-4160 • T-adapter
1 Oil pressure sensor
Boost pressure and temperature sensor
795-799-5530 • Socket
1 Coolant temperature sensor
799-601-4260 • T-adapter
1 Controller (4-pole)
799-601-4211 • T-adapter
1 Controller (50-pole)
799-601-4220 • T-adapter
1 Controller (60-pole)
795T-981-1010 Socket
1 19mm (width across flats) deep socket
D65EX, PX, WX-16
101 Testing and adjusting, Part 1 Testing engine speed
Testing engine speed k
a
1.
SEN05119-02
1
Stop the machine on level ground, lower the work equipment to the ground, stop the engine, and set the parking brake lever and work equipment lock lever in the lock position. Measure the engine speed under the following conditions. q Engine coolant temperature: Within operating range q Power train oil temperature: Within operating range q Hydraulic oil temperature: Within operating range q Working mode: P mode q Gearshift mode: Either Auto or Manual Preparation work Measure the engine speed with the Adjustment function in the service mode of the machine monitor. a For the operating method of the machine monitor, see Special functions of machine monitor (EMMS). q Measuring low idle speed, high idle speed, decelerator pedal speed, torque converter stall speed, and torque converter stall speed + work equipment relief speed (full stall speed): q Adjustment code: 0530 (Stall mode) a When stalling the torque converter for a purpose other than measuring the engine speed, be sure to use this adjustment code, too.
D65EX, PX, WX-16
2.
Measuring low idle speed 1) Start the engine and set the fuel control dial in the low idle (MIN) position. 2) Set the PCCS lever, blade control lever, and ripper control lever in neutral and measure the engine speed. a The parking brake lever and work equipment lock lever may be kept in the LOCK position.
3.
Measuring high idle speed 1) Start the engine and set the fuel control dial in the high idle (MAX) position. 2) Set the PCCS lever, blade control lever, and ripper control lever in neutral and measure the engine speed. a The parking brake lever and work equipment lock lever may be kept in the LOCK position.
4.
Measuring decelerator pedal speed 1) Start the engine and set the fuel control dial in the high idle (MAX) position. 2) Set the PCCS lever, blade control lever, and ripper control lever in neutral, press the decelerator pedal to the stroke end, and measure the engine speed. a The parking brake lever and work equipment lock lever may be kept in the LOCK position.
5.
Measuring torque converter stall speed a Relieve the work equipment frequently during measurement to keep the hydraulic oil temperature above 50°C. If the hydraulic oil temperature lowers below 40°C, the fan speed fluctuates and t h e a c c u r a t e s ta l l s p e e d c a n n o t b e obtained. 1) Start the engine and set the fuel control dial in the low idle (MIN) position. 2) Operate the shiftup (UP) switch of the PCCS lever and set the preset mode display section to [F3-R3]. a The preset mode display section (at the right bottom of the screen) can be set to [F3-R3] only while the Adjustment function is selected. 3) While pressing the brake pedal securely, set the parking brake lever in the free position and set the direction of PCCS lever in the forward position. a Before going to the next step, check that [F3] is displayed in the gear speed display section (at the right bottom of the screen). a Keep the steering system in neutral.
30-101
5
SEN05119-02 4)
5) k
6)
7) 8)
30-101
101 Testing and adjusting, Part 1 Testing engine speed
Press the decelerator pedal and set the fuel control dial in the high idle (MAX) position. Return the decelerator pedal slowly to stall the torque converter with the engine at high idle. Keep pressing the brake pedal securely and keep your right foot on the decelerator pedal for safety until the work is finished. Just after the power train oil temperature gauge (T/C TEMPERATURE) indicates 118 – 120°C, return the direction of PCCS lever to neutral. a The top of the green range of the power train oil temperature gauge indicates about 118 – 120°C. Repeat above steps 3) – 6) 3 times. Perform steps 3) – 5) again and measure the engine speed about 5 seconds after the power train oil temperature gauge (T/C TEMPERATURE) indicates 118 – 120°C. a Immediately after finishing measurement, return the direction of PCCS lever to neutral and lower the power train oil temperature with the engine at high idle.
6
D65EX, PX, WX-16
101 Testing and adjusting, Part 1 Testing intake air pressure (boost pressure)
SEN05119-02
Testing intake air pressure (boost pressure) 1 a
Testing instruments for intake air pressure (boost pressure)
Symbol A k
Part No. 799-201-2202 799-401-2220
Part name Boost gauge kit Hose
a
Stop the machine on level ground, lower the work equipment to the ground, stop the engine, and set the parking brake lever and work equipment lock lever in the lock position. Be careful not to touch any hot part of the engine when removing or installing the measuring tools. Measure the intake air pressure (boost pressure) under the following conditions. q Engine coolant temperature: Within operating range q Power train oil temperature: Within operating range q Hydraulic oil temperature: Within operating range
1.
Open the top left side engine cover.
2.
Remove intake air pressure pickup plug (1) from the air intake connector.
3.
Install nipple [1] of boost gauge kit A and connect gauge [2].
k
D65EX, PX, WX-16
4.
Run the engine at a medium or higher speed and drain the oil from the test hose. a Insert the connecting parts of the gauge and hose about a half and open the selfseal on the hose side repeatedly, and the oil will be drained. a If Pm kit (A) is available, you may drain the oil by using the oil draining coupling (790-261-1130) in that kit. a If oil is left in the hose, the gauge does not work. Accordingly, be sure to drain the oil.
5.
Turn the starting switch ON and set the machine monitor to Adjustment function of the service mode. q Adjustment code: 0530 (Stall mode) a For the operating method, see “Special functions of machine monitor (EMMS)”.
30-101
7
SEN05119-02 6.
While running the engine at high idle, stall the torque converter and measure the intake air pressure (boost pressure). a For the procedure for stalling the torque converter, see Measuring engine speed. a Normally, the intake air pressure (boost pressure) should be measured while the engine is operated at the rated output. In the field, however, an approximate value can be obtained by stalling the torque converter.
7.
After finishing measurement, remove the measuring instruments and return the removed parts. a The boost pressure can also be checked with the “PM clinic” function in the Service mode of the machine monitor. a For the operation procedure, see “Special functions of machine monitor (EMMS)”. a Since the boost pressure displayed on the machine monitor is an absolute pressure value (including the atmospheric pressure), measure the atmospheric pressure simultaneously and calculate its difference from the displayed boost pressure to obtain the actual boost pressure. q Example If the value measured by the monitor is 247 kPa; 247 kPa – 101 kPa (Atmospheric pressure) = 146 kPa (Actual boost pressure)
30-101
8
101 Testing and adjusting, Part 1 Testing intake air pressure (boost pressure)
D65EX, PX, WX-16
101 Testing and adjusting, Part 1 Testing exhaust temperature
SEN05119-02
Testing exhaust temperature a
Part No.
B
799-101-1502
k
k
1.
2.
Install sensor [1] of digital thermometer B and connect them to thermometer B. a Clamp the wiring harness of the digital thermometer so that it will not touch a hot part during measurement.
3.
When measuring maximum exhaust temperature for troubleshooting Operate the machine actually and measure the maximum exhaust temperature. a Use the PEAK mode of the thermometer. a The exhaust temperature largely depends on the outside air temperature (intake air temperature of the engine). Accordingly, if any abnormal value is obtained, correct it by the following calculation. q Corrected value [°C] = Measured value + 2 × (20 – Outside air temperature)
Testing instruments for exhaust temperature
Symbol
a
1
Part name Digital thermometer
Stop the machine on level ground, lower the work equipment to the ground, stop the engine, and set the parking brake lever and work equipment lock lever in the lock position. Install and remove the measuring instruments after the exhaust manifold is cooled. Measure the exhaust temperature under the following conditions. q Engine coolant temperature: Within operating range q Power train oil temperature: Within operating range q Hydraulic oil temperature: Within operating range Open the right engine side cover and remove heat insulation cover (1) and exhaust gas temperature pickup plug (2).
D65EX, PX, WX-16
30-101
9
101 Testing and adjusting, Part 1 Testing exhaust temperature
SEN05119-02 4.
Procedure for measuring exhaust temperature periodically for preventive maintenance (Pm clinic) a If the torque converter is stalled simply, the torque converter oil is overheated before the exhaust temperature is stabilized. Accordingly, measure according to the following procedure. 1) Turn the starting switch ON and set the machine monitor to Adjustment function of the service mode. q Adjustment code: 0530 (Stall mode) a For the operating method, see “Special functions of machine monitor (EMMS)”.
7)
k
8)
2) 3)
4)
5)
6)
30-101
Start the engine and set the fuel control dial in the low idle (MIN) position. Operate the shiftup (UP) switch of the PCCS lever and set the preset mode display section to [F3-R3]. a The preset mode display section (at the right bottom of the screen) can be set to [F3-R3] only while the Adjustment function is selected. Set the work equipment lock lever in the free position and operate the blade control lever to set the blade tilt cylinder to the maximum extend. While pressing the brake pedal securely, set the parking brake lever in the free position and set the direction of PCCS lever in the forward position. a Before going to the next step, check that [F3] is displayed in the gear speed display section (at the right bottom of the screen). a Keep the steering system in neutral. Press the decelerator pedal and set the fuel control dial in the high idle (MAX) position.
10
Return the decelerator pedal slowly to stall the torque converter and relieve the blade tilt system to raise the exhaust temperature to about 450°C (Condition (a) in the figure) with the engine at high idle.
9)
Under the condition of step 7), stop relieving the blade tilt system and lower the exhaust temperature by only stalling the torque converter (Condition (b) in the figure). a If the exhaust temperature does not lower but rises, set the temperature high in step 7). After the exhaust temperature is lowered and stabilized, measure the exhaust temperature (Condition (c) in the figure). k
a
5.
Keep pressing the brake pedal securely and keep your right foot on the decelerator pedal for safety until the work is finished.
Just after the power train oil temperature (T/C TEMPERATURE) reaches about 120°C, return the direction of PCCS lever to neutral and lower the power train oil temperature with the engine at high idle. The border between the green range and red range of the power train oil temperature gauge indicates about 120°C.
After finishing measurement, remove the measuring instruments and return the removed parts.
D65EX, PX, WX-16
101 Testing and adjusting, Part 1 Testing exhaust gas color
SEN05119-02
Testing exhaust gas color a
Testing instruments for exhaust gas color
Symbol C k
k
a
a
1.
1
Part No.
Part name
1
799-201-9001
Handy smoke checker
2
Commercially available
Smoke meter
Stop the machine on level ground, lower the work equipment to the ground, stop the engine, and set the parking brake lever and work equipment lock lever in the lock position. Be careful not to touch any hot part of the engine when removing or installing the measuring tools. If an air source and an electric power source are not available in the field, use handy smoke checker C1. When recording official data, use smoke meter C2. Measure the exhaust gas color under the following condition. q Engine coolant temperature: Within operating range Measuring with handy smoke checker C1 1) Stick a sheet of filter paper to smoke checker C1. 2) Insert the exhaust gas intake pipe in exhaust pipe. 3) Start the engine. 4) Accelerate the engine suddenly or run it at high idle and operate the handle of smoke checker C1 so that the filter paper will absorb the exhaust gas.
2.
Measuring with smoke meter C2 1) Insert probe [1] of smoke meter C2 in the outlet of exhaust pipe and fix it to the exhaust pipe with a clip.
2)
3)
4)
5)
6) 7) 5) 6)
Remove the filter paper and compare it with the attached scale. After finishing measurement, remove the measuring instrument and return the removed parts.
8)
9)
D65EX, PX, WX-16
Connect the probe hose, receptacle of the accelerator switch, and air hose to smoke meter C2. a Limit the supplied air pressure to 1.5 MPa {15 kg/cm²}. Connect the power cable to a receptacle of AC 100 V. a Before connecting the cable, check that the power switch of the smoke meter is turned OFF. Loosen the cap nut of the suction pump and fit the filter paper. a Fit the filter paper securely so that the exhaust gas will not leak. Turn power switch of smoke meter C2 ON.
Start the engine. Accelerate the engine suddenly or run it at high idle and press the accelerator switch of smoke meter C2 and collect the exhaust gas into the filter paper. Place the contaminated filter paper on the clean filter paper (at least 10 sheets) in the filter paper holder and read the indicated value. After finishing measurement, remove the measuring instrument and return the removed parts.
30-101
11
101 Testing and adjusting, Part 1 Adjusting valve clearance
SEN05119-02
Adjusting valve clearance a
k
1.
4.
Adjusting instrument for valve clearance
Symbol D
1
Part No.
1
795-799-1131
2
Commercial item
Part name
Set the No.1 cylinder to the compression top dead center. 1) Remove cap (5) of flywheel housing, insert gear D1 to rotate forward.
Gear Clearance gauge
Stop the machine on level ground, lower the work equipment to the ground, stop the engine, and set the parking brake lever and work equipment lock lever in the lock position. Remove and install the engine hood assembly and muffler assembly. For detail, see Disassembly and assembly, “Removal and installation of cylinder head assembly”.
2.
Disconnect breather tube (1) and blow-by tube (2) and remove cylinder head cover (3). [*1]
3.
Remove cap (4) of the front gear cover.
2)
5.
30-101
12
Align the TDC stamp line (a) of the front gear cover and supply pump gear stamp line (b). a The No.1 cylinder comes to the compression top dead center position.
While the No.1 cylinder is at the compression top dead center, adjust the clearance of valve marked with q in the valve arrangement figure.
D65EX, PX, WX-16
101 Testing and adjusting, Part 1 Adjusting valve clearance
6.
Adjust the valve clearance in the following procedure. 1) Insert clearance gauge D2 into the clearance between rocker lever (6) and crosshead (7). 2) Loosen locknut (8) and adjust valve clearance with adjustment screw (9). a With the clearance gauge inserted, turn the adjustment screw so that you can move clearance gauge D2 lightly. 3) Fix adjustment screw (9) and tighten locknut (8). 3 Locknut: 24 ± 4 Nm {2.4 ± 0.4 kgm} a After tightening the locknut, check the valve clearance again.
4)
SEN05119-02 5)
7.
While the No. 6 cylinder is at the compression top dead center, adjust the clearance of valves marked with Q in the valve arrangement figure. a Procedure for the adjustment is as same as 1) – 3).
After finishing adjustment, reinstall the removed parts. [*1]
3
Cylinder head cover mounting bolt: 12 ± 2 Nm {1.2 ± 0.2 kgm}
After finishing the adjustment of all valves marked with q, turn the crankshaft 360° forward and align stamp line (c) of the front gear cover and stamp line (b) of supply pump gear. a The No.6 cylinder comes to the compression top dead center position.
D65EX, PX, WX-16
30-101
13
101 Testing and adjusting, Part 1 Testing compression pressure
SEN05119-02
Testing compression pressure a
Testing instruments for compression pressure
Symbol
E
k
k
a
1
Part No.
Part name
1
795-799-6700
Puller
2
795-502-1590
Gauge assembly
3
795-790-6110
Adapter
4
6754-11-3130
Gasket
5
795-799-8150
Remover
Stop the machine on level ground, lower the work equipment to the ground, stop the engine, and set the parking brake lever and work equipment lock lever in the lock position. When measuring the compression pressure, take care not to burn yourself on the exhaust manifold, muffler, etc. or get caught in a rotating part. Measure the compression pressure after the engine is warmed up. (Engine oil temperature: 40 – 60°C)
1.
Remove and install the engine hood assembly and muffler assembly. For detail, see Disassembly and assembly, “Removal and installation of cylinder head assembly”.
2.
Disconnect breather tube (1) and blow-by tube (2) and remove cylinder head cover (3).
3.
Disconnect injector harness (4). (3 places)
5.
Loosen injector harness terminal nuts (7) and disconnect the terminal from the injector.
6.
Set the cylinder to be inspected to the compression top dead center. a Refer to “Adjusting valve clearance”.
7.
Remove rocker arm assembly (8).
8.
Remove crossheads (9).
a
4.
Make notes of the installation positions and hole shapes of (a) and (b) sections. (So that the removed parts can be reinstalled to their original positions later.)
Disconnect fuel high-pressure pipe (5). a Before disconnecting pipes No.1, 3, and 5, disconnect harness connector (6) from the block.
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14
D65EX, PX, WX-16
101 Testing and adjusting, Part 1 Testing compression pressure
9.
Remove retainer (10) to dismount inlet connector (11). k Remove the dusts around the inlet connector thoroughly in advance to prevent them from entering the cylinder head hole or the inlet connector during the removal operations. q Use remover E5 to remove the inlet connectors.
10. Unscrew bolt (12) to remove holder (13).
SEN05119-02 12. Install gasket E4 to the top of adapter E3 and insert adapter into mounting section of the injector.
13. Fix adapter E3 with holder (13). a Tighten bolts (12) diagonally so that the upper surface of holder (13) becomes parallel to the upper surface of the cylinder head. q Maximum angle limit: 2.4° 3 Bolt: 1st time: 10 ± 2.0 Nm {1.0 ± 0.2 kgm} 2nd time: 41 ± 4.0 Nm {4.1 ± 0.4 kgm} 14. Connect gauge assembly E2 to adapter E3. a Leakage can be prevented by applying a little amount of engine oil to the fitting faces of the adapter and gauge.
11. Remove injector (14) with puller E1. a Do not ply the upper part of the injector to remove it without using puller E1.
15. Install rocker arm assembly (8). 3 Rocker arm assembly mounting bolts: 64.7 ± 4.9 Nm {6.6 ± 0.5 kgm} 16. Install crossheads (9). 17. Adjust valve clearance. a Refer to “Adjusting valve clearance”.
D65EX, PX, WX-16
30-101
15
101 Testing and adjusting, Part 1 Testing compression pressure
SEN05119-02 18. Turn the starting switch to the ON position and set the machine monitor in the service mode. q Select 09 “Cylinder cutout mode operation” and set all the cylinders in the cylinder cutout mode. a Depress “F6” and check background (a) of the cylinder No. If the background is white, the corresponding cylinder is set in the cylinder cutout mode. a For the operation procedure, see “Special functions of machine monitor (EMMS)”. k If all the cylinders are not set in the cylinder cutout mode, the engine starts during testing and that is dangerous. Accordingly, be sure to set in the cylinder cutout mode.
6)
Tighten bolts (12) to the specified torque. a Tighten bolts diagonally so that the upper surface of holder (13) becomes parallel to the upper surface of the cylinder head. q Maximum angle limit: 2.4° 3 Bolt: 10 ± 2.0 Nm {1.0 ± 0.2 kgm}
7)
Tighten inlet connector (11) to the specified torque. 3 Retainer (10): 41 ± 4 Nm {4.1 ± 0.4 kgm} Apply the caulking compound (e) (hatched section) to retainer (10) and the cylinder head. 2 Caulking compound: GE TOSHIBA SILICON TOSSEAL 381
19. Crank the engine with the starting motor and measure the compression pressure. a Read the pressure when the gauge pointer is stabilized. a Check the engine speed with the monitor. 20. When the checking is completed, remove the instruments and reinstall the removed parts. a Install the injector and the inlet connector according to the following procedure. 1) Coat the O-ring of injector (14) and the mounting hole on the head with engine oil (EO15W-40). 2) Assemble holder (13) on injector (14) then insert the assembly into the cylinder head with the fuel inlet hole of injector (14) on the intake manifold side. 3) Tighten bolt (12) by three or four threads with hands. 4) Coat the O-ring of inlet connector (11) and the mounting hole on the head with engine oil (EO15W-40). 5) Install inlet connector (11) temporarily with retainer (10). 3 Retainer: 14.7 ± 5.0 Nm {1.5 ± 0.5 kgm}
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16
a
Rocker arm assembly 1) Tighten the mounting bolt after checking that the ball portion of adjustment screw is well seated in the push rod socket. 3 Bolts: 65 ± 5 Nm {6.6 ± 0.5 kgm} 2) After installing the rocker arm assembly, adjust the valve clearance referring to “Adjusting valve clearance”.
D65EX, PX, WX-16
101 Testing and adjusting, Part 1 Testing compression pressure
a
a a
a
SEN05119-02
Fuel high-pressure piping When assembling the pipe, tighten the mounting nuts in the injector side first, then tighten nuts in the common rail side. 3 Nuts: 37 ± 4 Nm {3.8 ± 0.4 kgm} Tightening torque of the injector harness terminal nut 3 Nut: 1.25 ± 0.25 Nm {0.13 ± 0.03 kgm} When installing, secure clearance between injector wiring harnesses (15), rocker arm (16) and rocker housing (17) so that they will not interfere with each other. q Clearance (f): Min. 3 mm q Clearance (g): Min. 3 mm
Tightening torque of the head cover mounting nuts 3 Nut: 11.8 ± 1.96 Nm {1.2 ± 0.2 kgm}
D65EX, PX, WX-16
30-101
17
101 Testing and adjusting, Part 1 Testing blow-by pressure
SEN05119-02
Testing blow-by pressure a
Testing instrument for blow-by pressure
Symbol
F
k
a
1
Part No.
Part name
1
799-201-1504
Blow-by checker
2
795-790-3300 or 799-201-1511
Blow-by tool
Stop the machine on level ground, lower the work equipment to the ground, stop the engine, and set the parking brake lever and work equipment lock lever in the lock position. Measure the blow-by pressure under the following condition. q Coolant temperature: Within operating range q Hydraulic oil temperature: Within operating range q Power train oil temperature: Within operating range
1.
Open the left side cover (1) of engine hood and remove side cover (2).
2.
Remove the mounting clamp of blow-by hose (3) on the engine side and pull out the hose to the left outer side of the engine.
3.
Install blow-by tool F2 to blow-by hose (3).
4.
Install hose [1] of blow-by checker F1 to blowby tool F2 and connect them to gauge [2].
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18
5.
Measure the blow-by pressure while the engine is running at high idle and the torque converter is stalling. a For the procedure for stalling the torque converter, see “Measuring engine speed”. a Normally, the blow-by pressure should be measured while the engine is operated at the rated output. In the field, however, an approximate value can be obtained by stalling the torque converter. a If it is impossible to run the engine at the rated output or stall the torque converter, measure while the engine is running at high idle. The value obtained in this case is about 80% of the blow-by pressure at the rated output. a The blow-by pressure may vary largely with the engine condition. If the measured value is judged abnormal, check for increase of oil consumption, bad exhaust gas color, premature deterioration or contamination of oil, etc. which are related to the abnormal blow-by pressure.
6.
After finishing measurement, remove the measuring instrument and reinstall the removed parts.
D65EX, PX, WX-16
101 Testing and adjusting, Part 1 Testing engine oil pressure
SEN05119-02
Testing engine oil pressure a
1 2 3 k
a
3.
Install adapter G3 and nipple [1] of hydraulic tester G1 to the plug installation portion and connect to gauge G2.
4.
Start the engine and measure the engine oil pressure when the engine is running at low idle and when the torque converter is stalling. a For the procedure for stalling the torque converter, see “Measuring engine speed”.
5.
After finishing measurement, remove the measuring instrument and reinstall the removed parts.
Testing instruments for engine oil pressure
Symbol
G
1
Part No. 799-101-5002
Part name Hydraulic tester
790-261-1204
Digital hydraulic tester
799-401-2320
Gauge: 1 MPa {10 kg/cm2}
6732-81-3170
Adapter (10 x 1.0 mm o R1/8)
6215-81-9710
O-ring
Stop the machine on level ground, lower the work equipment to the ground, stop the engine, and set the parking brake lever and work equipment lock lever in the lock position. Measure the engine oil pressure under the following condition. q Coolant temperature: Within operating range
1.
Open left side cover (1) of engine hood and remove side cover (2).
2.
Remove oil pressure inspection plug (3).
D65EX, PX, WX-16
30-101
19
101 Testing and adjusting, Part 1 Handling of fuel system devices
SEN05119-02
Handling of fuel system devices a
a
1
Precautions for testing and maintaining fuel system The common rail fuel injection system (CRI) consists of more precise parts than the conventional fuel injection pump and nozzle. If foreign matter enters this system, it can cause a trouble. When testing and maintaining the fuel system, take care more than the past. If dust, etc. sticks to any part, wash that part thoroughly with clean fuel. Precautions for replacing fuel filter cartridge Be sure to use Komatsu genuine fuel filter cartridge. Since the common rail fuel injection system (CRI) consists of more precise parts than the conventional fuel injection pump and nozzle, it employs a high-efficiency special filter to prevent foreign matter from entering it. If a filter other than the genuine one is used, the fuel system may have a trouble. Accordingly, never use such a filter.
30-101
20
Releasing residual pressure from fuel system 1 a
a
a
k
Pressure is generated in the low-pressure circuit and high-pressure circuit of the fuel system while the engine is running. Low-pressure circuit: Fuel pre-filter – Lift pump – Fuel main filter – Fuel supply pump High-pressure circuit: Fuel supply pump – Common rail – Fuel injector The pressure in both low-pressure circuit and high-pressure circuit lowers to a safety level automatically 30 seconds after the engine is stopped. Before the fuel circuit is tested and its parts are removed, the residual pressure in the fuel circuit must be released completely. Accordingly, observe the following. Before testing the fuel system or removing its parts, wait at least 30 seconds after stopping the engine until the residual pressure in the fuel circuit is released. (Do not start the work just after stopping the engine since there is residual pressure.)
D65EX, PX, WX-16
101 Testing and adjusting, Part 1 Testing fuel pressure
SEN05119-02
Testing fuel pressure a
Testing tools for fuel pressure
Symbol
a
k
1.
Part name Hydraulic tester
790-261-1204
Digital hydraulic tester
6732-81-3170
Adapter (10 x 1.0 mm o PT1/8)
6215-81-9710
O-ring
3
799-401-2320
Gauge: 1 MPa {10 kg/cm2}
4
795-790-6210
M10 computer check fitting
5
795-790-1500 or 799-201-1201
Vacuum gauge
6
795-790-4900
Adapter kit
7
795-790-5010
Fitting
8
795-790-1150
Pressure gauge
2
k
Part No. 799-101-5002
1
H
1
2.
Testing fuel negative pressure circuit pressure (fuel supply connector) 1) Remove fuel pressure pickup plug (3) from the fuel supply connector.
2)
Connect M10 computer check fitting H4 to vacuum gauge H5.
3)
Run the engine at high idle and test the fuel negative pressure circuit pressure. a If the fuel negative pressure circuit pressure is in the following range, it is normal. q Standard value of fuel negative pressure circuit pressure (fuel supply connector): –27.1 – 0 kPa {–203 – 0 mmHg}
4)
After finishing testing, remove the testing tools and return the removed parts. 3 Fuel pressure pickup plug: 20 – 22 Nm {2.0 – 2.2 kgm}
Stop the machine on level ground, lower the work equipment to the ground, stop the engine, and set the parking brake lever and work equipment lock lever in the lock position. Tests only the fuel pressure in negative pressure circuit from fuel supply connector to lift pump inlet, and in low-pressure circuit from lift pump to fuel main filter and supply pump. Since the pressure in the high-pressure circuit from fuel supply pump to common rail and fuel injector is very high, it cannot be measured. Open left side cover (1) of engine hood and remove side cover (2).
D65EX, PX, WX-16
30-101
21
101 Testing and adjusting, Part 1 Testing fuel pressure
SEN05119-02 3.
Testing fuel negative pressure circuit pressure (supply pump section) 1) Disconnect intake hose (4) from the engine. a Make a mark at the hose end of the tube to indicate the original connection point.
2) 3)
4)
5) 6) 7)
30-101
Disconnect fuel tube (5) from supply pump (6). Remove fitting (7) installed to supply pump (6).
8)
Start the engine and measure the fuel negative pressure circuit pressure at high idle. a If the fuel negative pressure circuit pressure is in the following standard range, it is normal. q Standard fuel negative pressure circuit pressure (supply pump section): –33.9 – 0 kPa {–254 – 0 mmHg}
9)
After finishing testing, remove the testing tools and return the removed parts. 3 Fitting (7): 24 ± 4 Nm {2.4 ± 0.4 kgm} q When assembling, replace fuel tube (5) with new one. 3 Intake hose clamp: 10.5 ± 0.5 Nm {107 ± 5 kgcm}
Install hose assembly [1] of adapter kit H6 to fitting H7 and install them to supply pump (6). 3 Fitting H7: 24 ± 4 Nm {2.4 ± 0.4 kgm} Connect fuel tube (5) again. Connect fuel vacuum gauge H5 to hose assembly [1]. Install intake hose (4). 3 Intake hose clamp: 10.5 ± 0.5 Nm {107 ± 5 kgcm}
22
D65EX, PX, WX-16
101 Testing and adjusting, Part 1 Testing fuel pressure
4.
SEN05119-02
Testing fuel low-pressure circuit pressure (fuel filter inlet side) 1) Remove fuel pressure pickup plug (8) from the fuel main filter inlet side.
4)
2)
3)
Install adapter H2 and nipple [1] of hydraulic tester H1 to plug hole, and connect hydraulic tester H3.
Measure fuel low-pressure circuit pressure when cranking the engine. a If the fuel low-pressure circuit pressure (at the fuel filter inlet side) is in the following range, it is normal. q Standard value of fuel low-pressure circuit pressure (fuel filter inlet side): Min. 0.14 MPa {1.4 kg/cm2} k For protection of the starting motor, do not continue cranking for 30 seconds or more.
D65EX, PX, WX-16
5.
After finishing testing, remove the testing tools and return the removed parts. 3 Fuel pressure pickup plug: 20 – 22 Nm {2.0 – 2.2 kgm}
Testing fuel low-pressure circuit pressure (fuel filter outlet side) 1) Remove fuel pressure pickup plug (9) from the fuel main filter outlet side.
2)
Install adapter H2 and nipple [1] of hydraulic tester H1 to plug hole, and connect hydraulic tester H3.
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23
101 Testing and adjusting, Part 1 Testing fuel pressure
SEN05119-02 3)
4)
6.
Run the engine at high idle and measure the fuel low-pressure circuit pressure. a If the fuel low-pressure circuit pressure (at the fuel filter outlet side) is in the following range, it is normal. q Standard value of fuel low-pressure circuit pressure (fuel filter outlet side): Min. 0.48 MPa {Min. 4.9 kg/cm2}
2)
Install adapter H2 and nipple [1] of hydraulic tester H1 to plug hole, and connect hydraulic tester H3.
3)
Run the engine at high idle and measure the fuel filter front and rear differential pressure. q Fuel filter front and rear differential pressure = Fuel filter inlet pressure – Fuel filter outlet pressure a If the fuel filter front and rear differential pressure is in the following range, it is normal. q Standard value of fuel filter front and rear differential pressure: Max. 0.14 MPa {Max. 1.4 kg/cm2} a If the drop exceeds the standard value, clogging of the fuel filter is suspected.
4)
After finishing testing, remove the testing tools and return the removed parts. 3 Fuel pressure pickup plug: 20 – 22 Nm {2.0 – 2.2 kgm}
After finishing testing, remove the testing tools and return the removed parts. 3 Fuel pressure pickup plug: 20 – 22 Nm {2.0 – 2.2 kgm}
Testing fuel filter front and rear differential pressure 1) Remove fuel pressure pickup plug (8) from the fuel main filter inlet side and fuel pressure pickup plug (9) from the outlet side.
30-101
24
D65EX, PX, WX-16
101 Testing and adjusting, Part 1 Testing fuel pressure
7.
Testing fuel lift pump outlet pressure (supply pump section) 1) The testing position is the same as that for fuel negative circuit pressure and only gauge H8 of the testing tool is different.
2)
a
a
SEN05119-02 a
If the fuel lift pump outlet pressure is not in the standard range, perform the following checks. q Check that fuel is in the fuel lift pump. q If fuel is not in the fuel lift pump just after the fuel filter is replaced or a fuel system part is removed and returned, operate the fuel lift pump 3 – 4 times with the starting switch to bleed air from the fuel circuit and fill the pump with fuel and then measure the outlet pressure again. q If the fuel lift pump outlet pressure is not in the standard range while fuel is in the fuel lift pump, remove check valve (13) of engine controller cooling plate (12) and check to see if the valve is seized.
3)
After finishing measurement, remove the measuring instruments and return the removed parts. 3 Fitting (7): 24 ± 4 Nm {2.4 ± 0.4 kgm} q When assembling, replace fuel tube (5) with new one 3 Intake hose clamp: 10.5 ± 0.5 Nm {107 ± 5 kgcm}
Turn the starting switch ON, operate fuel lift pump (10), and measure the fuel lift pump outlet pressure. Reference: Fuel lift pump (10) is installed to cooling plate (12) on the back side of engine controller (11).
The fuel lift pump operates for 30 seconds after the starting switch is turned ON and then stops. Measure the pressure while the pump is operating. If the fuel lift pump outlet pressure is in the following standard range, it is normal. q Standard fuel lift pump outlet pressure (supply pump section): Min. 34 kPa {10.0 in Hg}
D65EX, PX, WX-16
30-101
25
101 Testing and adjusting, Part 1 Testing fuel return and leak amount
SEN05119-02
Testing fuel return and leak amount a
1.
1
Testing tools for leakage from pressure limiter and return rate from injector
Symbol
J
3)
Part No.
Part name
1
795-790-4800
Hose kit
2
795-790-6700
Adapter
4
Commercial item
4) 5)
Measuring cylinder
Testing supply pump return rate 1) Remove air conditioner compressor (4) and its bracket together. a For the removal procedure, see Disassembly and assembly, “Removal and installation of fuel supply pump assembly”.
2)
30-101
Remove tube installation bolt, and disconnect return tube (1).
26
Connect hose kit J1 on supply pump side, and insert the tip into measuring cylinder J4. Connect adapter J2 to fuel return connector side, and block fuel leak. Run the engine at low idle and test the return rate from the supply pump. a If the return rate from the supply pump is in the following range, it is normal.
k
6)
Low idle
Max. 300 cc/30 sec.
Cranking
Max. 200 cc/30 sec.
When the engine cannot run, you may test it by cranking the engine with the starting motor. To protect the starting motor, do not continuously crank the engine 30 seconds or more.
After finishing testing, remove the testing tools and return the removed parts. 3 Joint bolt (M14): 36 ± 5 Nm {3.7 ± 0.5 kgm}
D65EX, PX, WX-16
101 Testing and adjusting, Part 1 Testing fuel return and leak amount
2.
SEN05119-02
Testing leakage from pressure limiter a When displaying failure code [CA559] or [CA2249], implement troubleshooting beforehand. 1) Remove return tube (2) of the pressure limiter.
3.
Testing return rate from injector 1) Remove return tube (3) of the injector.
2)
3) 2)
3)
4)
Connect hose kit J1 on pressure limiter side, and insert the tip into measuring cylinder J4. Connect adapter J2 to return tube joint connector on cylinder block side, and block fuel leak. Run the engine at low idle and test the return rate from the pressure limiter. a If the leakage from the pressure limiter is in the following range, it is normal. Low idle
5)
k
Below 30 drops/min.
After finishing testing, remove the testing tools and return the removed parts. 3 Joint bolt: 24 ± 4 Nm {2.4 ± 0.4 kgm}
D65EX, PX, WX-16
4)
Connect hose kit J1 on cylinder head side, and insert the tip into measuring cylinder J4. Connect adapter J2 to return tube joint connector on cylinder block side, and block fuel leak. Run the engine at low idle and test the return rate from the injector. a If the return rate from the injector is in the following range, it is normal.
5)
Low idle
Max. 300 cc/45 sec.
Cranking
Max. 100 cc/30 sec.
When the engine cannot run, you may test it by cranking the engine with the starting motor. To protect the starting motor, do not continuously crank the engine for 30 seconds or more.
After finishing testing, remove the testing tools and return the removed parts. 3 Joint bolt: 24 ± 4 Nm {2.4 ± 0.4 kgm}
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27
101 Testing and adjusting, Part 1 Bleeding air from fuel circuit
SEN05119-02
Bleeding air from fuel circuit a
1.
1
Bleed the air by electric lift pump as follows if the engine has run out of fuel or the fuel circuit equipment has been removed and installed. The installation procedures for fuel main filter (1) and fuel pre-filter (2) after their removal, installation or replacement are as follows.
1) 2)
Do not fill fuel into fuel main filter (1). Fill up fuel into fuel pre-filter (2). q When filling, use clean fuel and be careful not to let dirt get in. q Add fuel through inlet port (a) areas (8 places) of the filter.
2. 3.
Fill up the fuel tank with fuel. Turn the starting switch ON. The lift pump is operated for 30 seconds automatically. k Do not turn the starting switch to start position.
q
4.
Return the starting switch to OFF position, and keep it for 10 seconds.
5.
Repeat the above 3 and 4 operation 4 times.
6.
Crank the engine with the starting motor and start the engine. a The air in the high-pressure circuit is bled automatically if the engine is cranked. a If the engine does not start, there may be still air in the low-pressure circuit. In this case, repeat the above procedure from step 2. a If the engine is run when there is still air in the fuel circuit, fuel circuit errors (CA559, CA2249) may occur. In this case, start the engine after the procedure above, and continue to drive the engine for about 3 minutes at low idle. When air is bleed from fuel circuit, engine speed is stabilized and error display will disappear.
Area (b) is the outlet port (clean side) after the fuel has been filtered, so never add fuel from here.
3)
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Apply a thin coat of oil on the packing surface of the filter and install it to filter head until it touches the sealing surface, then tighten 3/4 rotation. (For the procedure to replace fuel filter cartridge, see the Operation and Maintenance Manual.)
28
D65EX, PX, WX-16
101 Testing and adjusting, Part 1 Testing fuel circuit for leakage
Testing fuel circuit for leakage k
a
SEN05119-02
1
Very high pressure is generated in the highpressure circuit of the fuel system. If fuel leaks while the engine is running, it is dangerous since it can catch fire. After testing the fuel system or removing its components, inspect it for fuel leakage according to the following procedure. Clean and degrease the engine and the parts around it in advance so that you can inspect it easily for fuel leakage.
1.
Spray color checker (developer) over the fuel supply pump, common rail, fuel injector, and joints of the high-pressure piping.
2.
Run the engine at a speed less than 1,000 rpm and stop it after its rotation is stabilized.
3.
Inspect the fuel piping and the devices for fuel leakage. a Inspect the high-pressure circuit parts concentration on the areas coated with the color checker, for fuel leakage. a If any fuel leakage is detected, repair it and inspect again from step 1.
4.
Run the engine at low idle.
5.
Inspect the fuel piping and the devices for fuel leakage. a Inspect the high-pressure circuit parts concentration on the areas coated with the color checker, for fuel leakage. a If any fuel leakage is detected, repair it and inspect again from step 1.
6.
Run the engine at high idle.
7.
Inspect the fuel piping and the devices for fuel leakage. a Inspect the high-pressure circuit parts concentration on the areas coated with the color checker, for fuel leakage. a If any fuel leakage is detected, repair it and inspect again from step 1.
8.
Run the engine at high idle to apply load to the engine. a Relieve by tilting the blade or raising the ripper.
D65EX, PX, WX-16
9.
Inspect the fuel piping and the devices for fuel leakage. a Inspect the high-pressure circuit parts concentration on the areas coated with the color checker, for fuel leakage. a If any fuel leakage is detected, repair it and inspect again from step 1. a If any fuel leakage is not detected, inspection is completed.
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29
101 Testing and adjusting, Part 1 Handling of reduced cylinder mode operation
SEN05119-02
Handling of reduced cylinder mode operation a
1.
2.
1
Reduced cylinder mode operation means to run the engine with the fuel injectors of 1 or more cylinders disabled electrically to reduce the number of effective cylinders. The purposes and effects of this operation are as follows. This operation is used to find out a cylinder which does not output power normally (or, combustion in it is abnormal). When a cylinder is selected for the reduced cylinder mode operation, if the engine speed and output do not change from the normal operation (all-cylinder operation), that cylinder has 1 or more defects. The possible defects are as follows. q Leakage through cylinder head gasket q Defective injection q Defective piston, piston ring, and cylinder liner q Defective valve mechanism (Moving valve system) q Defect in electrical system Since the common rail fuel injection system controls the injector of each cylinder electronically, the operator can perform the reduced cylinder mode operation easily with switches to find out a defective cylinder. a The reduced cylinder mode operation is carried out by using the special functions of machine monitor. a For the operation method, see Testing and adjusting, “Special functions of machine monitor”.
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30
Handling of no injection cranking operation 1 a
q
a a
No injection cranking means to crank the engine with the starting motor while all the injections are stopped electrically. The purpose and effect of this operation are as follows. Before the engine is started after it or the engine unit has been stored for a long period, the no injection cranking is performed to lubricate the engine parts and protect them from seizure. Use the no-injection cranking function for only the above purposes while the engine is mounted on the machine. To implement no injection cranking operation, see “Special functions of machine monitor (EMMS)”.
D65EX, PX, WX-16
101 Testing and adjusting, Part 1 Testing and adjusting air conditioner compressor belt tension
Testing and adjusting air conditioner compressor belt tension k
1
Stop the machine on level ground, lower the work equipment to the ground, stop the engine, and set the parking brake lever and work equipment lock lever in the lock position. Testing q Press the intermediate point between air conditioner pulley and drive pulley with a finger and measure deflection (a). a Pressing force: Approx. 98 N {Approx. 10 kg} a Defection (a): 15 – 18 mm
D65EX, PX, WX-16
SEN05119-02 Adjusting a If the deflection is out of range, adjust it according to the following procedure. 1.
Loosen 4 compressor bracket mounting bolts (1).
2.
Loosen locknut (2), turn adjustment nut (3) and adjust the belt tension.
3.
After adjusting the belt tension to the standard value, tighten locknut (2), then tighten 4 compressor bracket mounting bolts (1).
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31
101 Testing and adjusting, Part 1 Replacing alternator belt
SEN05119-02
Replacing alternator belt a a k
1.
2.
1
The auto-tensioner is provided for the alternator belt. Thus, testing and adjustment of the belt is usually not necessary. Disconnect air conditioner compressor belt before replacing the alternator belt. Stop the machine on level ground, lower the work equipment to the ground, stop the engine, and set the parking brake lever and work equipment lock lever in the lock position. Open engine hood right cover (1) and remove side cover (2).
3.
Replace the alternator belt (4). q Check each pulley for breakage and crack.
Insert a wrench [1] to the portion (A) (width across flats T12.7 mm) of the tensioner assembly (3), and rotate it to the opposite to the winding-up direction to decrease the alternator belt (4) tension. k Make sure that the wrench [1] is secured at the portion (A) of the tensioner assembly (3) before rotating it. (The spring of the tensioner assembly (3) is strong. If the wrench [1] is loosely inserted, the wrench [1] may accidentally come off while being rotated and it is extremely dangerous.) k After removing the alternator belt (4), return the tensioner assembly (3) slowly with care. k Be careful not to get your fingers caught between the pulley and alternator belt (4) during work.
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32
D65EX, PX, WX-16
101 Testing and adjusting, Part 1 Adjusting fuel control dial and decelerator pedal
SEN05119-02
Adjusting fuel control dial and decelerator pedal
k
1.
1
Stop the machine on level ground, lower the work equipment to the ground, stop the engine, and set the parking brake lever and work equipment lock lever in the lock position. Outline of fuel control system q The following signals are inputted as rotation command signals to the engine controller. q Decelerator pedal potentiometer signal q 3rd throttle signal q The engine controller controls the fuel control system of the engine (CRI system) according to the lowest engine speed signal among those input signals. q Adjust the deceleration slow speed by adjusting the decelerator pedal stopper bolt.
D65EX, PX, WX-16
[1] Fuel control dial [2] Engine controller [3] Power train controller [4] Decelerator pedal [5] Decelerator potentiometer [6] Engine (CRI system) [7] 3rd throttle signal
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33
101 Testing and adjusting, Part 1 Handling controller high-voltage circuit
SEN05119-02 2.
Preparation work Test the engine speed with the "Adjustment" function in the service mode of the machine monitor. q Adjustment code: 0530 (Stall mode) a For the operating method, see "Special functions of machine monitor (EMMS)".
3.
Adjusting decelerator pedal speed With the fuel control dial in the high idle position (MAX), press decelerator pedal (1) to stopper bolt (2) and check that the decelerator pedal speed is normal. q Decelerator pedal speed: 1,000 ± 25 rpm a If the decelerator pedal speed is abnormal, adjust installed dimension (a) of stopper bolt (2). q Standard installed dimension (a) of stopper bolt: 22.0 mm
4.
Adjusting high idle speed With the fuel control dial in the high idle position (MAX), release decelerator pedal (1) and check that the high idle speed is normal. q High idle speed: 2,100 ± 50 rpm a If the high idle speed is abnormal, adjust it according to the following procedure. q When the engine speed is above 2,000 rpm: Lower the engine speed below 1,950 rpm temporarily with stopper bolt (3) to eliminate the play of the decelerator pedal, and then adjust the engine speed to the high idle. q When the engine speed is below 2,000 rpm: Adjust the engine speed to the high idle speed with stopper bolt (3). q Standard installed dimension (b) of stopper bolt: 28.0 mm
5.
Work after adjustment After finishing all adjustment, return the removed parts.
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34
Handling controller high-voltage circuit
1
1.
Disconnection or connection of the connector between the engine controller and engine must be done after turning off the starting switch.
2.
It is prohibited to start the engine when Tadapter is inserted or connected, for troubleshooting purpose, to the connector between the engine controller and engine. a You may turn the starting switch to the OFF or ON position but must not turn it to the START position.
D65EX, PX, WX-16
101 Testing and adjusting, Part 1 Handling controller high-voltage circuit
D65EX, PX, WX-16
SEN05119-02
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35
SEN05119-02
D65EX, PX, WX-16 Bulldozer Form No. SEN05119-02
©2011 KOMATSU All Rights Reserved Printed in Japan 01-11
30-101
36
SEN05120-02
BULLDOZER D65EX-16 D65PX-16 D65WX-16 Machine model D65EX-16 D65PX-16 D65WX-16
Serial number 80001 and up 80001 and up 80001 and up
30 Testing and adjusting
30
102 Testing and adjusting, Part 2 Testing power train oil pressure ...................................................................................................................... 3 Adjusting transmission output shaft speed sensor (replacement procedure) ................................................. 8 Simple test procedure for brake performance................................................................................................. 9 Adjusting brake pedal ................................................................................................................................... 10 Adjusting parking brake lever........................................................................................................................ 12 Emergency escape method when power train has trouble ........................................................................... 14 Adjusting clearance of idler........................................................................................................................... 17 Adjusting clearance of idler (without idler support automatic thrust adjustment) .......................................... 18 Inspecting wear of sprocket .......................................................................................................................... 19 Testing and adjusting track shoe tension ...................................................................................................... 20 Testing and adjusting work equipment and HSS oil pressure ....................................................................... 21 Testing control circuit basic pressure ............................................................................................................ 24 Testing PPC valve output pressure............................................................................................................... 25 Adjusting work equipment PPC valve play ................................................................................................... 27 Testing internal leakage of work equipment cylinder .................................................................................... 31 Bleeding air from work equipment cylinder ................................................................................................... 32 Releasing residual pressure from work equipment cylinder ......................................................................... 32 Checking parts which caused hydraulic drift of blade or ripper..................................................................... 33 Adjusting work equipment lock lever............................................................................................................. 34 Adjusting work equipment lock lever (FRP canopy specification)................................................................. 35 Testing fan speed.......................................................................................................................................... 37 Testing fan circuit oil pressure....................................................................................................................... 38 Bleeding air from fan pump........................................................................................................................... 39 D65EX, PX, WX-16
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1
SEN05120-02
102 Testing and adjusting, Part 2
Bleeding air from HSS pump......................................................................................................................... 40 Adjusting straight tiltdozer ............................................................................................................................. 41 Adjusting play of blade center ball ................................................................................................................ 43 Adjusting operator’s cab................................................................................................................................ 44
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2
D65EX, PX, WX-16
102 Testing and adjusting, Part 2 Testing power train oil pressure
SEN05120-02
Testing power train oil pressure a
Testing tools for power train oil pressure
Symbol 1 K
2 3
k
a
a
1
Part No.
Part name
799-101-5002
Hydraulic tester
790-261-1204
Digital hydraulic tester
799-401-2320
Hydraulic tester (1 MPa {10 kg/cm2})
799-101-5220
Nipple (10 x 1.25 mm)
07002-11023
O-ring
Stop the machine on a level place, lower the work equipment to the ground, and set the parking brake lever and work equipment lock lever in the lock position. Measure the power train oil pressure under the following condition. q Power train oil temperature: Within operating range The centralized power train oil pressure pickup ports are installed inside the inspection cover (1) on the right side of the operator cab.
1.
Measuring brake pressure (BR) 1) Remove oil pressure pickup plug (1) and attach nipple K3, and connect oil pressure gauge [1] of hydraulic tester K1. a Use an oil pressure gauge of 6 MPa {60 kg/cm2}.
2) a
List of oil pressure measuring points and gauges to be used.
No. Stamp
Oil pressure reading
Gauge (MPa {kg/cm2})
1
BR
Brake pressure
6.0 {60}
2
IN
Torque converter inlet pressure
2.5 {25}
3
OUT
Torque converter outlet pressure
1.0 {10}
4
MAIN
Transmission main relief pressure
6.0 {60}
D65EX, PX, WX-16
3)
Run the engine and set the parking brake lever in free position. Measure the oil pressure while the engine is running at low idle and high idle. a Check that the oil pressure lowers to 0 when the brake pedal is depressed or the parking brake lever is set in the lock position.
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3
102 Testing and adjusting, Part 2 Testing power train oil pressure
SEN05120-02 4)
2.
After finishing measurement, remove the measuring instrument and reinstall the removed parts.
Measuring torque converter inlet pressure (IN) 1) Remove oil pressure pickup plug (2) and attach nipple K3, and connect oil pressure gauge [1] of hydraulic tester K1. a Use an oil pressure gauge of 2.5 MPa {25 kg/cm2}.
3.
Measuring torque converter outlet pressure (OUT) 1) Remove oil pressure pickup plug (3) and attach nipple K3, and connect hydraulic tester K1. a Use an oil pressure gauge of 1 MPa {10 kg/cm2}.
2) 3) 2) 3)
Run the engine and set the PCCS lever in the full neutral position. Measure the oil pressure while the engine is running at low idle and high idle.
4)
4)
30-102
Run the engine and set the PCCS lever in the full neutral position. Measure the oil pressure while the engine is running at low idle and high idle.
After finishing measurement, remove the measuring instrument and reinstall the removed parts.
After finishing measurement, remove the measuring instrument and reinstall the removed parts.
4
D65EX, PX, WX-16
102 Testing and adjusting, Part 2 Testing power train oil pressure
4.
Measuring transmission main relief pressure (MAIN) 1) Remove oil pressure pickup plug (4) and attach nipple K3, and connect oil pressure gauge [1] of hydraulic tester K1. a Use an oil pressure gauge of 6 MPa {60 kg/cm2}.
2) 3)
4)
SEN05120-02 5.
Measuring clutch pressure q Remove the operator seat assembly and measure the clutch pressure from the top of the floor frame. a List of oil pressure measuring points and gauges to be used.
No.
Measuring point
Gauge (MPa {kg/cm2})
5
Transmission forward clutch pressure
6 {60}
6
Transmission reverse clutch pressure
6 {60}
7
Transmission 1st clutch pressure
6 {60}
8
Transmission 2nd clutch pressure
6 {60}
9
Transmission 3rd clutch pressure
6 {60}
10
Torque converter lockup clutch pressure
2.5 {25}
Run the engine and set the PCCS lever in the full neutral position. Measure the oil pressure while the engine is running at low idle and high idle.
After finishing measurement, remove the measuring instrument and reinstall the removed parts.
D65EX, PX, WX-16
30-102
5
102 Testing and adjusting, Part 2 Testing power train oil pressure
SEN05120-02 1)
2)
3)
30-102
Measuring transmission forward clutch pressure 1] Remove oil pressure pickup plug (5) and attach nipple K3, and connect oil pressure gauge [1] of hydraulic tester K1. a Use an oil pressure gauge of 6 MPa {60 kg/cm2}. 2] Run the engine and set the parking brake lever in free position. 3] With the brake pedal depressed, set the PCCS lever in the “forward” and 3rd gear speed position. 4] Measure the oil pressure while the engine is running at high idle. k Since the torque converter is stalled, keep pressing the brake pedal securely. 5] After finishing measurement, remove the measuring instrument and reinstall the removed parts. Measuring transmission reverse clutch pressure 1] Remove oil pressure pickup plug (6) and attach nipple K3, and connect oil pressure gauge [1] of hydraulic tester K1. a Use an oil pressure gauge of 6 MPa {60 kg/cm2}. 2] Run the engine and set the parking brake lever in free position. 3] With the brake pedal depressed, set the PCCS lever in the “forward” and 3rd gear speed position. 4] Measure the oil pressure while the engine is running at high idle. k Since the torque converter is stalled, keep pressing the brake pedal securely. 5] After finishing measurement, remove the measuring instrument and reinstall the removed parts. Measuring transmission 1st clutch pressure 1] Remove oil pressure pickup plug (7) and attach nipple K3, and connect oil pressure gauge [1] of hydraulic tester K1. a Use an oil pressure gauge of 6 MPa {60 kg/cm2}. 2] Run the engine and set the parking brake lever in free position. 3] With the brake pedal depressed, set the PCCS lever in the “forward” and 1st gear speed position. 4] Measure the oil pressure while the engine is running at low idle.
6
k
4)
5)
Since the torque converter is stalled, keep pressing the brake pedal securely. k Do not run the engine at high idle while measuring. 5] After finishing measurement, remove the measuring instrument and reinstall the removed parts. Measuring transmission 2nd clutch pressure 1] Remove oil pressure pickup plug (8) and attach nipple K3, and connect oil pressure gauge [1] of hydraulic tester K1. a Use an oil pressure gauge of 6 MPa {60 kg/cm2}. 2] Run the engine and set the parking brake lever in free position. 3] With the brake pedal depressed, set the PCCS lever in the “forward” and 2nd gear speed position. 4] Measure the oil pressure while the engine is running at low idle. k Since the torque converter is stalled, keep pressing the brake pedal securely. k Do not run the engine at high idle while measuring. 5] After finishing measurement, remove the measuring instrument and reinstall the removed parts. Measuring transmission 3rd clutch pressure 1] Remove oil pressure pickup plug (9) and attach nipple K3, and connect oil pressure gauge [1] of hydraulic tester K1. a Use an oil pressure gauge of 6 MPa {60 kg/cm2}. 2] Run the engine and set the parking brake lever in free position. 3] With the brake pedal depressed, set the PCCS lever in the “forward” and 3rd gear speed position. 4] Measure the oil pressure while the engine is running at low idle. k Since the torque converter is stalled, keep pressing the brake pedal securely. k Do not run the engine at high idle while measuring. 5] After finishing measurement, remove the measuring instrument and reinstall the removed parts.
D65EX, PX, WX-16
102 Testing and adjusting, Part 2 Testing power train oil pressure
6)
Measuring torque converter lockup clutch pressure 1] Remove oil pressure pickup plug (10) and attach nipple K3, and connect oil pressure gauge [1] of hydraulic tester K1. a Use an oil pressure gauge of 2.5 MPa {25 kg/cm2}. 2] Start the engine and raise the machine with the blade and ripper to a height where you can run the track shoe idle. k After raising the machine, set the work equipment lock lever in the LOCK position.
SEN05120-02 3]
4]
5] k
6]
7]
D65EX, PX, WX-16
Set the gearshift mode and preset range as follows with the gearshift mode selector switch and shiftup or shiftdown switch. q Gearshift mode: Auto gearshift (Dozing) q Preset range: F1-R1 Set the machine monitor to Monitoring function of the service mode. q Monitoring code: 31520 T/M Fill Sw Input 2 a For the operating method, see “Special functions of machine monitor (EMMS)”.
Set the PCCS lever in the reverse position to run the track shoe idle. Take care not to get caught in a rotating part of the track shoe during measurement. a Keep the steering system in neutral. While running the engine at high idle, when L/U Fill Sw in the monitoring item is turned ON, measure the lockup clutch pressure. After finishing measurement, remove the measuring instruments and return the removed parts.
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7
SEN05120-02
102 Testing and adjusting, Part 2 Adjusting transmission output shaft speed sensor (replacement procedure)
Adjusting transmission output shaft speed sensor (replacement procedure) k
1.
2.
3. 1
Stop the machine on level ground, lower the work equipment to the ground, stop the engine, and set the parking brake lever and work equipment lock lever in the LOCK position. Remove the cover of the main frame rear, then remove transmission speed sensor assembly (1) from steering case (2). a Before adjusting the transmission output shaft speed sensor, remove it and check that its tip is free from steel chips and flaws, and then reinstall it.
Measure installation dimension (L) of removed sensor (3). a When replacing the sensor, be sure to measure dimension (L).
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8
Assembly procedure for sensor assembly 1) Install sensor (3) to bracket (4). 3 Locknut (5): 39.2 – 49.1 Nm {4 – 5 kgm} a Installed dimension of sensor: Dimension (L) measured at removal ± 0.2 mm 2) Pull out the sensor (3) connector through the flange hole of bracket (4) and insert it in connector assembly (6). (Push in the connector securely until it clicks.) 3) Install connector assembly (6) to bracket (4). 3 Bolt (7): 4.9 – 6.9 Nm {0.5 – 0.7 kgm} 4) Install sensor assembly (1) to steering case (2). 2 O-ring: Grease (G2-LI) q Standard clearance between bevel gear and sensor end (x): 0.84 – 1.76 mm 5) After finishing adjustment, return the removed parts. 6) Start the engine, set the machine monitor to the “Monitoring” function display in the service mode, and check that the transmission speed is displayed normally. a Monitoring code: 31400 (T/M Out Speed) a For the operation procedure, see “Special functions of machine monitor (EMMS)”. a To rotate the transmission output shaft, travel actually or travel with no load.
D65EX, PX, WX-16
102 Testing and adjusting, Part 2 Simple test procedure for brake performance
Simple test procedure for brake performance k
a
SEN05120-02 6. 1
Stop the machine on a level place, lower the work equipment to the ground, and set the parking brake lever and work equipment lock lever in the lock position. Carry out the simple performance test of the brake under the following condition. q Power train oil temperature: Within operating range
1.
Set the blade and ripper in the travel position on a level place.
2.
Run the engine and set the parking brake lever in the FREE position.
3.
Set the gearshift mode and preset range as follows with the gearshift mode selector switch and shiftup or shiftdown switch. q Gearshift mode: Manual gearshift q Preset range: F2-R2
4.
With the engine at low idle and the brake pedal depressed securely, set the direction of PCCS lever in the forward position. k If this test is carried out in the 1st gear position, the brake will be overloaded. Accordingly, be sure to carry out in the 2nd gear speed. a Check that [F2] is displayed in the gear speed display section. a Keep the steering system in neutral.
5.
Press the decelerator pedal and set the fuel control dial in the high idle (MAX) position.
D65EX, PX, WX-16
Return the decelerator pedal slowly and check that the machine does not start when the engine speed reaches the high idle level. k Since the torque converter is stalled, keep pressing the brake pedal securely and keep your right foot on the decelerator pedal for safety until the work is finished.
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9
SEN05120-02
Adjusting brake pedal
k
a 1.
102 Testing and adjusting, Part 2 Adjusting brake pedal
1
Stop the machine on level ground, lower the work equipment to the ground, stop the engine, and set the parking brake lever and work equipment lock lever in the lock position. Tighten the locknuts of the rods and cables securely, and bend the cotter pins securely. Adjust the stroke (a) of brake pedal (1) with the installation dimension (b) of bumper (2). q Pedal stroke (a): 68 mm q Installation dimension (b) of bumper: 23 mm
2.
Adjust installation dimension (c) of rod (3) on the valve side, then connect to brake valve lever (4). q Rod installation dimension (c): 938 mm a Fully screw in joint (5) to the valve side.
3.
Adjust installation dimension (d) of rod (6) on the pedal side, then connect to brake pedal (1). q Rod installation dimension (d): 175 mm
4.
Lightly push rod (3) on the valve side toward the rear of the machine, and turn only joint (7) to connect rods (3) and (6). a Push rod (3) with a force of about 9.8 – 19.6 N {1 – 2 kg}. 3 Joint: 34.3 – 58.8 Nm {3.5 – 6.0 kgm}
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10
D65EX, PX, WX-16
102 Testing and adjusting, Part 2 Adjusting brake pedal
SEN05120-02
5.
With brake pedal (1) released, adjust its play with dimension (e) between the pins of rod assembly (8). q Play of pedal: 3 – 8 mm (center of pedal) q Dimension (e) between pins of rod assembly: 1,143 mm a Adjust by turning joints (5) and (7) in the same direction at the same time.
6.
With brake pedal (1) released, check that brake pedal (1) is in contact with damper (2).
7.
Checking brake oil pressure
8.
Oil pressure MPa {kg/cm2}
Remarks
Brake released
Min. 2.55 {Min. 26}
Engine at full throttle
Brake applied
0
After adjusting the pedal, turn the starting switch to the ON position, set the machine monitor to “ADJUSTMENT” function in the service mode, and perform adjustment. a Adjustment code: 0005 (Brake pedal potentiometer initial correction) a For the operating method, see “Special functions of machine monitor (EMMS)”.
D65EX, PX, WX-16
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11
102 Testing and adjusting, Part 2 Adjusting parking brake lever
SEN05120-02
Adjusting parking brake lever
k
1.
2.
Stop the machine on level ground, lower the work equipment to the ground, stop the engine, and set the parking brake lever and work equipment lock lever in the lock position. Assembling and installing lever assembly 1) Assemble lever assembly (1) and adjust the operation of limit switch (2). a When assembling the lever assembly, disconnect the parking brake cable from the lever. q When lever is pulled up: OFF, lowered: ON q Operation stroke of limit switch: 3 mm 2) Install lever assembly (1).
1
3.
Checking brake oil pressure Check that the brake oil pressure is as follows when the parking brake lever is set in free and lock positions. a For the method of measuring the brake oil pressure, see “Measuring power train oil pressure”. q Lock position: 0, Free position: Specified pressure
Adjusting installation length of parking brake cable 1) Connect parking brake cable (3) to the lever side and valve side, and adjust installation dimensions (a) and (b). q Cable installation dimension (a): 148.5 mm q Cable installation dimension (b): 166 mm 2) Operate parking brake lever (4) between the free and lock positions, and adjust rod end (6) so that spool stroke (h) of brake valve (5) is normal. q Spool stroke (h): 13.3 mm
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D65EX, PX, WX-16
102 Testing and adjusting, Part 2 Adjusting parking brake lever
4.
SEN05120-02
Checking limit switch 1) Turn the starting switch ON and set the machine monitor to Monitoring function of the service mode. a Monitoring code: 40905 T/M Sw Input 1 a For the operating method, see “Special functions of machine monitor (EMMS)”.
2)
Check that the limit switch signal is input normally when parking brake lever (4) is set in the FREE position and LOCK position. q FREE position: Travel lock NC OFF, Travel lock NO ON q LOCK position: Travel lock NC ON, Travel lock NO OFF
D65EX, PX, WX-16
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102 Testing and adjusting, Part 2 Emergency escape method when power train has trouble
SEN05120-02
Emergency escape method when power train has trouble 1 a
1 2 3 4
1.
Open the battery cover of the machine left and connect wiring harness [2] to connector PL1 (1). a The male housing and female housing of connector PL1 are fixed with screws. a Connect the wiring harness to both male side and female side of connector PL1.
3)
Remove the cover (2) on the front of the left console box.
Devices used for emergency escape
Symbol
L
2)
Part No.
Part name
19M-06-32820 Switch assembly 14X-06-52930 Wiring harness 7824-66-6430
Prolix resistance
7827-10-1520
Prolix resistance
790-190-1601
Pump assembly
799-101-5220
Nipple (10 x 1.25 mm)
07002-11023
O-ring
Emergency escape method by the switch box (Use L1) a If the machine cannot be moved because of a trouble in the electric system of the power train control unit (travel direction, gear speed, steering), carry out the emergency escape according to the following procedure. a The engine must be able to start during implementing this procedure. a If the engine cannot be started, see “Emergency escape method with brake releasing device”. 1) Connect switch assembly [1] and L2 to wiring harness [2] of emergency escape device L1. k To prevent the machine from starting suddenly, set all the gear speed switches of switch assembly [1] to OFF position and the direction switch in P position.
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D65EX, PX, WX-16
102 Testing and adjusting, Part 2 Emergency escape method when power train has trouble
4)
Disconnect neutral safety relay NSF (3) and connect pins [3] and [5] of the connector on the wiring harness side (female). k If the engine is started by this method, the neutral safety function does not work. Accordingly, before starting the engine, set the parking brake lever in lock position and set the PCCS lever in full neutral position. k Start the engine by this method only in an emergency. If the engine does not start in other cases, be sure to carry out troubleshooting and repair the trouble.
SEN05120-02 5) 6)
7)
D65EX, PX, WX-16
Run the engine and set the parking brake lever in free position. Operate switch assembly [1] and move the machine to a safe place. a The electrical circuit of the gear speed switches is configured so that the switch on the lower gear speed is operated first. k Take care that the L.H. and R.H. steering directions are opposite when reverse.
After moving the machine, remove the instruments used and return the removed parts. a Check that the seal at the joint of connector PL1 is not projected or removed and then tighten the screws to the specified torque. 3 Screw of connector PL1: 2.83 ± 0.28 Nm {0.288 ± 0.028 kgm}
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SEN05120-02 2.
Emergency escape method with brake releasing device (Use L3) a If the engine cannot be started and the parking brake cannot be released, carry out the emergency escape according to the following procedure. a Operate after putting a block, etc. on the crawler as a lock so that machine cannot move on a downhill slope. 1) Assemble pump assembly L3. 2) Install volume pump [1] of pump assembly L3 to the left outside of the operator cab.
102 Testing and adjusting, Part 2 Emergency escape method when power train has trouble
3)
4)
5) 6)
7)
8)
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16
Remove inspection plug for brake oil pressure which is located within the inspection cover on the right outer side of the operator cab. Install nipple L4 and connect hose [2] of pump assembly L3.
Turn the starting switch on and set the parking brake lever in free position. Operate the vacuum pump to raise the brake releasing oil pressure to the initial pressure. q Initial pressure: Approx. 2.74 MPa {Approx. 28 kg/cm2} a Since an accumulator is installed in the circuit, the handle must be operated 30 – 50 times to raise the oil pressure. a If the oil pressure does not rise above a certain level, the relief valve may be set to low pressure. In this case, adjust the set pressure of the relief valve. Tow the machine to a safe place. a The brake releasing oil pressure lowers gradually because of internal leakage and the brake is applied again about 1 minute after. Therefore, work immediately. a If the brake releasing pressure lowers to about 1.57 MPa {16 kg/cm 2 }, the brake is applied. In this case, operate the volume pump again to raise the brake releasing pressure to the initial pressure. When disconnecting the hose after finishing the work, loosen the screw slowly and do not stand in the spouting direction of the oil.
D65EX, PX, WX-16
102 Testing and adjusting, Part 2 Adjusting clearance of idler
Adjusting clearance of idler a
k
SEN05120-02
1
If the lateral guide plates of the idler have worn excessively and the idler ran out slants, adjust the clearance of the idler according to the following procedure. Stop the machine on level ground, lower the work equipment to the ground, stop the engine, and set the parking brake lever and work equipment lock lever in the lock position.
Adjustment procedure 1) Drive the machine 1 – 2 m on flat ground, then measure clearance (a) between the track frame and guide plate (4 places; left, right, inner and outer sides). 2) If clearance (a) is larger than 4 mm, loosen bolt (1) and reduce shim (2). q Standard clearance (a) on each side: 0.5 – 1.0 mm q Shim thickness: 1.0 mm
D65EX, PX, WX-16
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17
SEN05120-02
102 Testing and adjusting, Part 2 Adjusting clearance of idler (without idler support automatic thrust adjustment)
Adjusting clearance of idler (without idler support automatic thrust adjustment) a
k
1
If the lateral guide plates of the idler have worn excessively and the idler ran out slants, adjust the clearance of the idler according to the following procedure. Stop the machine on level ground, lower the work equipment to the ground, stop the engine, and set the parking brake lever and work equipment lock lever in the lock position.
Adjustment procedure 1) Drive the machine 1 – 2 m on flat ground, then measure clearance (a) between the track frame and guide plate (4 places; left, right, inner and outer sides). 2) If clearance (a) is larger than 4 mm, loosen bolt (1) and reduce shim (2). q Standard clearance (a) on each side: 0.5 – 1.0 mm q Shim thickness: 1.0 mm
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18
D65EX, PX, WX-16
102 Testing and adjusting, Part 2 Inspecting wear of sprocket
Inspecting wear of sprocket a
a
SEN05120-02
1
Use the “Full-scale dimensions drawing of sprocket profile” in the topic “Sprocket” in the chapter “Structure, function and maintenance standard” as a gauge for measuring wear of the sprocket. Make a copy of the “Full-scale dimensions drawing of sprocket profile” on a transparent paper or sheet and apply it directly to the sprocket to see if the sprocket can be used.
D65EX, PX, WX-16
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19
102 Testing and adjusting, Part 2 Testing and adjusting track shoe tension
SEN05120-02
Testing and adjusting track shoe tension k
Adjusting 1
Stop the machine on level ground, lower the work equipment to the ground, stop the engine, and set the parking brake lever and work equipment lock lever in the lock position.
a 1. 2.
When the tension is too high Loosen plug (2) to discharge the grease. k Since the high-pressure grease may spout out, do not loosen the plug more than 1 turn. 3 Plug: 59 – 88 Nm {6 – 9 kgm}
3.
When tension is low Add grease through grease fitting (3). a If the track shoe is not tensed well, drive the machine forward and in reverse slowly.
4.
After finishing adjustment, return the removed parts.
Testing 1.
2.
Drive the machine slowly on a level place, then stop it. a Do not apply the brake when stopping. Place straight steel bar [1] between the idler and front carrier roller and measure clearance (a) between the bottom of the steel bar and shoe grouser. q Standard clearance (a): 20 – 30 mm
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20
If the track shoe tension is abnormal, adjust it according to the following procedure. Remove cover (1).
D65EX, PX, WX-16
102 Testing and adjusting, Part 2 Testing and adjusting work equipment and HSS oil pressure
Testing and adjusting work equipment and HSS oil pressure a
1 M 2
a
2.
Testing main valve LS pressure Remove pressure pickup plug (1) on the machine center side of the main valve and measure the oil pressure. a Use the following pressure gauge. Work equipment oil pressure: 60 MPa {600 kg/cm2} HSS oil pressure: 60 MPa {600 kg/cm2}
3.
Testing unload pressure Run the engine at high idle and measure the unload pressure with the blade control lever and ripper control lever in neutral. a The unload pressure may be measured with the work equipment control lever in the lock position. a Check unload pressure with machine monitor.
1
Testing and adjusting instruments for work equipment and HSS oil pressure
Symbol
k
SEN05120-02
Part No.
Part name
795-101-5002
Hydraulic tester
790-261-1204
Digital hydraulic tester
799-101-5220
Nipple (10 x 1.25 mm)
07002-11023
O-ring
Stop the machine on level ground, lower the work equipment to the ground, stop the engine, and set the parking brake lever and work equipment lock lever in the LOCK position. When measuring and adjusting the work equipment and HSS oil pressure, remove the control valve cover.
Testing a
a
a
1.
Test the work equipment and HSS oil pressure under the following condition. q Hydraulic oil temperature: Within operating range The unload pressure, work equipment oil pressure, and HSS oil pressure can be checked with the monitoring function of the service mode of the machine monitor. Measure the LS pressure directly through the pressure pickup port of the device. Measuring with machine monitor Turn the starting switch ON and set the machine monitor to Monitoring function of the service mode. q Monitoring code: 70700 Hydraulic Pump Pressure 1 a For the operating method, see “Special functions of machine monitor (EMMS)”.
D65EX, PX, WX-16
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21
SEN05120-02 4.
Testing work equipment oil pressure 1) Install nipple M2 to the LS pressure pickup port and connect it to oil pressure gauge [1] of hydraulic tester M1. 2) Start the engine and set the work equipment lock lever in the FREE position. 3) Run the engine at high idle, operate the blade control lever and ripper control lever to relieve each cylinder at a stroke end, and measure the work equipment oil pressure and work equipment LS oil pressure. a Check work equipment oil pressure with machine monitor.
102 Testing and adjusting, Part 2 Testing and adjusting work equipment and HSS oil pressure
5.
Testing HSS oil pressure 1) Install nipple M2 to the LS pressure pickup port and connect it to oil pressure gauge [1] of hydraulic tester M1. a Measuring points of the HSS oil pressure are the same as those of the work equipment oil pressure. 2) Start the engine, set the parking brake lever in the FREE position, and keep pressing the brake pedal. 3) Run the engine at high idle, set the PCCS lever in the right or left steering position to oil the steering circuit, and measure the HSS oil pressure and HSS LS oil pressure. k
a
4)
After finishing measurement, remove the measuring instrument and return the removed parts.
4)
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Since the steering circuit is relieved, keep pressing the brake pedal securely and keep your right foot on the decelerator pedal for safety until the work is finished. Check HSS oil pressure with machine monitor.
22
After finishing measurement, remove the measuring instruments and return the removed parts.
D65EX, PX, WX-16
102 Testing and adjusting, Part 2 Testing and adjusting work equipment and HSS oil pressure
Adjusting 1.
Adjusting unload pressure a The unload pressure cannot be adjusted.
2.
Adjusting work equipment oil pressure a Work equipment oil pressure cannot be adjusted.
3.
Adjusting HSS oil pressure a If the HSS oil pressure is abnormal, adjust it with HSS LS relief valve (2) according to the following procedure.
1) 2)
3)
SEN05120-02 4)
After finishing measurement, check the HSS oil pressure according to the above measuring method.
While fixing adjustment screw (6), loosen locknut (7). Adjust the pressure by rotating adjustment screw (6). a If the adjustment screw is q rotated to the right, the pressure is heightened. q rotated to the left, the pressure is lowered. a Quantity of adjustment per turn of adjustment screw: Approx. 15.1 MPa {Approx. 154 kg/cm2} While fixing adjustment screw (6), tighten locknut (7). 3 Locknut: 68.6 – 78.5 Nm {7 – 8 kgm}
D65EX, PX, WX-16
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23
102 Testing and adjusting, Part 2 Testing control circuit basic pressure
SEN05120-02
Testing control circuit basic pressure a
N
1 2
a
Part No.
Install oil pressure pickup adapter N2 and connect the disconnected hose again.
4.
Install nipple [1] of hydraulic tester N1 and connect oil pressure gauge [2]. a Use an oil pressure gauge of 6 MPa {60 kg/cm2}.
5.
Run the engine at high idle and set the blade lever and ripper lever in neutral and measure the oil pressure.
6.
After finishing measurement, remove the measuring instrument and reinstall the removed parts.
1
Instruments for testing and adjusting control circuit basic pressure
Symbol
3.
Part name
799-101-5002
Hydraulic tester
790-261-1204
Digital type hydraulic tester
799-401-3100
Adapter (size 02)
The control circuit main pressure is the pressure lowered by the self pressure reducing valve. It is used commonly for blade PPC, HSS pump control, fan pump control, steering EPC and ripper PPC (if equipped).
Measuring k Stop the machine on level ground, lower the work equipment to the ground, stop the engine, and set the parking brake lever and work equipment lock lever in the lock position. a Measure the control circuit basic pressure under the following condition. q Hydraulic oil temperature: Within operating range 1.
Remove the control valve cover at the right side of the operator cab.
2.
Disconnect hose (1).
Adjusting a
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24
The self pressure reducing valve cannot be adjusted.
D65EX, PX, WX-16
102 Testing and adjusting, Part 2 Testing PPC valve output pressure
SEN05120-02
Testing PPC valve output pressure a
O
1 2
k
a a
Part No.
Install oil pressure pickup adapter O2 and connect the disconnected hose again.
4.
Install nipple [1] of hydraulic tester O1 and connect oil pressure gauge [2].
5.
Run the engine and set the work equipment lock lever in the free position.
6.
Run the engine at high idle and operate the control lever of the circuit to be measured and measure the oil pressure. a Measure the oil pressure with the lever at a stroke end. a When measuring the blade circuit, operate the lever until the blade floats.
7.
After finishing measurement, remove the measuring instrument and reinstall the removed parts.
1
Testing instruments for PPC valve output pressure
Symbol
3.
Part name
799-101-5002
Hydraulic tester
790-261-1204
Digital type hydraulic tester
799-401-3100
Adapter (size 02)
Stop the machine on level ground, lower the work equipment to the ground, stop the engine, and set the parking brake lever and work equipment lock lever in the lock position. Before measuring the PPC valve output pressure, check that the control circuit basic pressure is normal. Measure the PPC valve output pressure under the following condition. q Hydraulic oil temperature: Within operating range
1.
Remove the control valve cover at the right side of the operator cab.
2.
Disconnect PPC valve output pressure hose (1). a For the circuits to be measured, see the drawing on the next page.
D65EX, PX, WX-16
30-102
25
SEN05120-02
1. Main valve 2. Self pressure reducing valve 3. PPC lock valve 4. Blade PPC valve 5. Ripper PPC valve (If equipped)
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26
102 Testing and adjusting, Part 2 Testing PPC valve output pressure
A. Blade LEFT TILT B: Blade LOWER C. Ripper RAISE D. Ripper LOWER E. Blade RAISE F. Blade RIGHT TILT
D65EX, PX, WX-16
102 Testing and adjusting, Part 2 Adjusting work equipment PPC valve play
SEN05120-02
Adjusting work equipment PPC valve play
1
2-axis PPC valve (Part R in hatched area must not be disassembled)
k
a a
Stop the machine on level ground, lower the work equipment to the ground, stop the engine, and set the parking brake lever and work equipment lock lever in the lock positions. If the blade lever end play is large, adjust the PPC valve according to the following procedure. The ripper valve cannot be adjusted.
D65EX, PX, WX-16
1.
Measuring play in directions of ports P3 and P4 Measure play (x) in the neutral position of the lever at 240 mm from the turn center of the lever. (x): Max. 24 mm a If the play is out of the above range, joint (1) may be worn. In this case, replace joint (1).
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27
102 Testing and adjusting, Part 2 Adjusting work equipment PPC valve play
SEN05120-02 Replacement procedure for joint (1) 1) Remove boot (2), nut (3), disc (4) and nut (5). 2) Replace joint (1). a Install joint (1) to valve body (7) according to the following procedure. 1] Thoroughly degrease and dry the threaded portion and body of the joint. 2] Apply a drop (about 0.02 g) of LOCTITE (No. 262) each to 2 places at dimension (a) from the threaded portion of the body end. q Dimension (a): 5 – 7 mm
3)
4) 2.
3.
Applying grease 1) Apply grease to the sliding part of joint (1) and contact parts of disc (4) and piston (6). 2 Grease (G2-LI) 2) Quantity of grease to be applied 1] Sliding part of joint (1): 7 – 10 ml/ periphery 2] Contact parts of disc (4) and piston (6) (4 places): 0.3 – 0.8 ml/place
4.
Install boot (2).
3 Joint (1): 39 – 49 Nm {4 – 5 kgm} Install nut (5) and disc (4). a Take care of the installed direction of disc (4). (Take care of the shape of part Q.) Install nut (3).
Adjusting lever end play 1) Remove boot (2) and nut (3). 2) Tighten disc (4) and tighten nut (3) temporarily. a Take care of the installed direction of disc (4). (Take care of the shape of part Q.) 3) Measure the lever end play. q Measuring play in directions of ports P3 and P4 Measure play (x) in the neutral position of the lever at 240 mm from the turn center of the lever. (x): 0.6 – 3.6 mm q Measuring play in direction of port P1 (Full stroke) (y): 0.03 – 0.3 mm 4) Tighten nut (3). a Fix disc (4) and tighten nut (3). 3 Nut (3): 93.1 – 112.7 Nm {9.5 – 11.5 kgm}
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28
D65EX, PX, WX-16
102 Testing and adjusting, Part 2 Adjusting work equipment PPC valve play
SEN05120-02
3-axis PPC valve (For power angle tiltdozer) (Part R in hatched area must not be disassembled)
1.
Measuring play in directions of ports P1 and P2 Measure play (x) in the neutral position of the lever at 240 mm from the turn center of the lever. (x): Max. 24 mm a If the play is out of the above range, joint (1) may be worn. In this case, replace joint (1).
Replacement procedure for joint (1) 1) Remove boot (2), nut (3) and disc assembly (4). 2) Replace joint (1). a Install joint (1) to valve body (6) according to the following procedure. 1] Thoroughly degrease and dry the threaded portion and body of the joint. 2] Apply a drop (about 0.02 g) of LOCTITE (No. 262) each to 2 places at dimension (a) from the threaded portion of the body end. D65EX, PX, WX-16
3
3)
Joint (1): 39 – 49 Nm {4 – 5 kgm}
Install nut (3) and disc assembly (4).
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29
SEN05120-02 2.
Adjusting lever end play 1) Remove boot (2) and nut (3). 2) Tighten disc assembly (4) and tighten nut (3) temporarily. 3) Measure the lever end play. q Measuring play in directions of ports P1 and P2 Measure play (x) in the neutral position of the lever at 240 mm from the turn center of the lever. (x): Max. 2.4 mm 4) Tighten nut (3). 3 Nut (3): 98 – 127 Nm {10 – 13 kgm}
3.
Applying grease 1) Apply grease to the sliding part of joint (1) and contact parts of disc (4) and piston (5). 2 Grease (G2-LI) 2) Quantity of grease to be applied 1] Sliding part of joint (1): 7 – 10 ml/ periphery 2] Contact parts of disc (4) and piston (5) (4 places): 0.3 – 0.8 ml/place
4.
Install boot (2).
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30
102 Testing and adjusting, Part 2 Adjusting work equipment PPC valve play
D65EX, PX, WX-16
102 Testing and adjusting, Part 2 Testing internal leakage of work equipment cylinder
Testing internal leakage of work equipment cylinder a
Part No.
P
Commercially available
k
a
1.
2.
q 1
Hose (2): Ripper lift cylinder Plug: 07376-70522 (Size #05) O-ring: 02896-11015 (Size #05)
Testing instruments for leakage of work equipment cylinder
Symbol
a
SEN05120-02
Part name Measuring cylinder
Stop the machine on level ground, lower the work equipment to the ground, stop the engine, and set the parking brake lever and work equipment lock lever in the LOCK position. Measure the internal leakage of work equipment cylinder under the following condition. q Hydraulic oil temperature: 45 – 55°C Since the blade lift cylinder and blade angle cylinder (for power angle tilt dozer) is equipped with a piston valve, its internal leakage cannot be measured. Extend the cylinder to be measured to the stroke end and set the machine in the measuring position. 1) Blade tilt cylinder Lower the blade tip to the ground. 2) Ripper lift cylinder Pull out the shank pin and lower the ripper to the end. Disconnect hoses (1), (2) on the head side of the tested cylinder and stop the control valve side with a plug. a When working on the blade tilt cylinder hoses, remove the hose cover (3) of the frame. k Take care not to disconnect the hoses on the bottom side. q Hose (1): Blade tilt cylinder Plug: 07376-70315 (Size #03) O-ring: 02896-11009 (Size #03)
D65EX, PX, WX-16
3.
Run the engine at high idle and apply the relief pressure to the cylinder bottom side. q Blade tilt cylinder: Operate to tilt blade to left. q Ripper lift cylinder: Operate to lower ripper.
4.
After 30 second, measure leakage in 1 minute with measuring cylinder P.
5.
After finishing measurement, return the removed parts. a Bleed air from the cylinder circuit. For details, see “Bleeding air from work equipment cylinder”.
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31
102 Testing and adjusting, Part 2 Bleeding air from work equipment cylinder
SEN05120-02
Bleeding air from work equipment cylinder 1
Releasing residual pressure from work equipment cylinder 1
a
a
a
If the work equipment cylinder is removed and installed or its piping is disconnected and connected, bleed air from its circuit according to the following procedure. Before performing the following operation, check that the hydraulic oil level is normal.
1.
Run the engine at low idle for about 5 minutes.
2.
While running the engine at low idle, extend and retract the cylinder to be bled 4 – 5 times. a Move the piston rod to about 100 mm before the stroke end and never relieve the oil.
3.
While running the engine at high idle, carry out the operation in step 2.
4.
While running the engine at low idle, move the cylinder to the stroke end to relieve the oil.
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32
k
When disconnecting the piping between the control valve and work equipment cylinder, release the residual pressure from the circuit according to the following procedure. Stop the machine on level ground, lower the work equipment to the ground, stop the engine, and set the parking brake lever and work equipment lock lever in the LOCK position.
1.
Loosen oil filler cap (1) of the hydraulic tank gradually to release the residual pressure from the tank.
2.
Turn the starting switch ON and set the work equipment lock lever in the FREE position.
3.
Operate the blade control lever and ripper control lever to each direction. a If the control lever is operated 2 – 3 times, the residual pressure in the accumulator is released.
4.
Run the engine at low idle for about 10 seconds to increase the pressure in the accumulator, then stop it.
5.
Repeat steps 2 – 4 above 2 – 3 times.
D65EX, PX, WX-16
102 Testing and adjusting, Part 2 Checking parts which caused hydraulic drift of blade or ripper
Checking parts which caused hydraulic drift of blade or ripper
3) 1
a
When a hydraulic drift of blade or ripper occurred, check if the parts causing the drift is located in cylinder packing side or in control valve side according to the following procedure.
1.
Stop the engine with the cylinder at the following positions. 1) Blade lift cylinder Tense the blade to push up the front of the machine. a Do not extend the blade lift cylinder to the stroke end since it is equipped with the piston valve.
2)
Blade tilt cylinder Retract the tilt cylinder to the stroke end and tense blade further to push up the right side of the machine.
D65EX, PX, WX-16
SEN05120-02 Ripper lift cylinder Tense the ripper to push up the rear of the machine.
2.
Turn the starting switch ON and set the work equipment lock lever in the FREE position.
3.
Move the control lever of cylinder to be checked to the direction of extending cylinder and validate the movement of cylinder. q If the drift speed becomes faster, a cylinder packing is defective. q If the speed does not change, an control valve is defective. a If the pressure in the accumulator is lost, run the engine for about 10 seconds to heighten the pressure in the accumulator.
[Reference] In case of the hydraulic drift is caused by defective cylinder packing, the reason why the drift speed becomes faster by above mentioned operation is as follows: 1) When work equipment is set in the above mentioned position, where the holding pressure is applied to the bottom side, the oil leaks from bottom side to head side. Since the volume of head side is smaller than that of bottom side by the volume of the rod, the inner pressure of head side rises by the oil leak from bottom side. 2) If the inner pressure of head side rises, cylinder is balanced at certain pressure (depending on the amount of leakage) which is in proportion to the inner pressure. Therefore, the drifting speed becomes slower. 3) At this time, if the circuit in the head side is opened (bottom side is closed by check valve) to drain circuit by above mentioned lever operation, the oil in the head side flows into the drain circuit causing the lost of the pressure balance. Then the drift speed becomes faster.
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33
102 Testing and adjusting, Part 2 Adjusting work equipment lock lever
SEN05120-02
Adjusting work equipment lock lever
k
a a
1
a a
Stop the machine on level ground, lower the work equipment to the ground, stop the engine, and set the parking brake lever and work equipment lock lever in the LOCK position. Tighten the locknut of the rod securely and bend the cotter pin securely. When adjusting the work equipment lock lever, remove the control valve cover.
1.
Set work equipment lock lever (1) in the LOCK position.
2.
Set and install limit switch (2) to sliding surface (a) of lever (3). a Just set the roller of the limit switch to the sliding surface. Do not move it.
3.
Set work equipment lock lever (1) in the FREE position and check that limit switch (2) operates normally. q Stroke of limit switch: 2.5 – 3 mm
4.
Turn the starting switch ON and set the machine monitor to Monitoring function of the service mode.
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34
5.
Monitoring code: 70300 Blade Sw Input For the operating method, see “Special functions of machine monitor (EMMS)”.
Check that the limit switch signal is input normally when work equipment lock lever (1) is set in the FREE position and LOCK position. q FREE position: Work equipment lock NC OFF, Work equipment lock NO ON q LOCK position: Work equipment lock NC ON, Work equipment lock NO OFF
D65EX, PX, WX-16
102 Testing and adjusting, Part 2 Adjusting work equipment lock lever (FRP canopy specification)
SEN05120-02
Adjusting work equipment lock lever (FRP canopy specification)
k
a a
q
1. 2. 3. 4.
q
1. 2.
3. 4.
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 the LOCK position. Tighten the locknut of the rod securely and bend the cotter pin securely. When adjusting the work equipment lock lever, remove the control valve cover.
1
5.
Turn the starting switch to the ON position and set the machine monitor to "Monitoring" function of the service mode. a Monitoring code: 70300 Blade knob switch input a For the operation procedure of the machine monitor, see "Special functions of machine monitor (EMMS)".
6.
Check that the limit switch signal is input normally when work equipment lock lever (1) is set in the FREE position and LOCK position. q FREE position: Work equipment lock NC OFF, Work equipment lock NO ON q LOCK position:
Adjustment procedure for lock lever Set lever (1) in FREE position (b). At this time, adjust angle "a" to 66 degrees with bolt (2). In addition, adjust dimension B to 118.4 mm with rod (5). Set lever (1) in LOCK position (c) and adjust dimension C to 114.5 mm with bolt (3). Adjustment procedure for limit switch Set lever (1) in FREE position (b). Touch limit switch (4) to sliding surface (A) and fix it with bolt (6). a Just set the roller of the limit switch to the sliding surface. Do not move it. Set lever (1) in FREE position (b). Check that limit switch (4) moves by 2.5 to 3 mm.
D65EX, PX, WX-16
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35
SEN05120-02
102 Testing and adjusting, Part 2 Adjusting work equipment lock lever (FRP canopy specification)
Work equipment lock NC ON, Work equipment lock NO OFF
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36
D65EX, PX, WX-16
102 Testing and adjusting, Part 2 Testing fan speed
SEN05120-02
Testing fan speed a
Part No.
Q
799-205-2200
k
a 1.
2.
Start the engine and set the machine monitor to Adjusting function of the service mode. a Adjustment code: 1005 (Fan 100% mode) a For the operation method, see “Special functions of machine monitor (EMMS)”. a If this adjustment code is displayed, the fan speed is kept at 100% speed in accordance wit the engine speed, regardless of the state of the machine. a When using this adjustment code, keep the hydraulic oil temperature above 50°C. If the hydraulic oil temperature lowers below 40°C, the fan speed fluctuates. a “FAN SPEED” of adjustment code is different from the actual fan speed.
3.
While running the engine at low idle and high idle, measure the fan speed.
4.
After finishing measurement, remove the measuring instrument and reinstall the removed parts.
Testing instrument for fan speed
Symbol
a
1
Part name Tachometer
Stop the machine on level ground, lower the work equipment to the ground, stop the engine, and set the parking brake lever and work equipment lock lever in the lock position. Measure the fan motor speed under the following condition. q Hydraulic oil temperature: Min. 50°C Avoid measuring in direct sunlight. Set tachometer Q with stand [2], matching it to reflective tape [1] stuck to fan (1).
D65EX, PX, WX-16
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37
102 Testing and adjusting, Part 2 Testing fan circuit oil pressure
SEN05120-02
Testing fan circuit oil pressure a
Testing instruments for fan circuit oil pressure
Symbol 1 R
2 3
k
1
Part No.
Part name
799-101-5002
Hydraulic tester
790-261-1204
Digital hydraulic tester
799-401-3400
Adapter (size 05)
799-101-5220
Nipple (10 x 1.25 mm)
07002-11023
O-ring
Stop the machine on level ground, lower the work equipment to the ground, stop the engine, and set the parking brake lever and work equipment lock lever in the lock position. Measure the fan circuit oil pressure under the following condition. q Hydraulic oil temperature: Min. 50°C
5.
Close the radiator mask. k Before starting the engine, be sure to close the radiator mask. Do not start the engine while the radiator mask is open.
1.
Open the radiator mask and remove the fan net.
6.
2.
Disconnect supply hose (1) of the fan motor.
Start the engine and set the machine monitor to Adjusting function of the service mode. a Adjustment code: 1005 (Fan 100% mode) a For the operation method, see “Special functions of machine monitor (EMMS)”. a If this adjustment code is displayed, the fan speed is kept at 100% speed in accordance wit the engine speed, regardless of the state of the machine. a “FAN SPEED” of adjustment code is different from the actual fan speed. a When using this adjustment code, keep the hydraulic oil temperature above 50°C. If the hydraulic oil temperature lowers below 40°C, the fan speed fluctuates.
3.
Install adapter R2 and connect the disconnected hose again.
4.
Install nipple R3 and connect it to oil pressure gauge [2]. a When using an analog oil pressure gauge, use one of 40 MPa {400 kg/cm2}.
a
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38
D65EX, PX, WX-16
102 Testing and adjusting, Part 2 Bleeding air from fan pump
7.
While running the engine at high idle, measure the fan circuit oil pressure.
SEN05120-02
Bleeding air from fan pump a
a a
8.
1
If the fan pump was removed and installed or its piping was disconnected and connected, bleed air from the pump case according to the following procedure. Before performing the following procedure, check that the hydraulic oil is at the specified level. Remove operator seat (1) and move it toward the dashboard.
1.
Remove the cover under the operator seat.
2.
Loosen air bleeder (3) of fan pump (2) and leave it for 15 minutes.
3.
After 15 minutes, run the engine at low idle.
4.
When oil flows out of air bleeder (3), tighten air bleeder (3). 3 Bleeder: 8.8 ± 1.0 Nm {0.9 ± 0.1 kgm}
After finishing measurement, remove the measuring instrument and reinstall the removed parts.
D65EX, PX, WX-16
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39
102 Testing and adjusting, Part 2 Bleeding air from HSS pump
SEN05120-02
Bleeding air from HSS pump a
a a
1
If the HSS pump was removed and installed or its piping was disconnected and connected, bleed air from the pump case according to the following procedure. Before performing the following procedure, check that the hydraulic oil is at the specified level. Remove operator seat (1) and move it toward the dashboard.
1.
Remove the cover under the operator seat.
2.
Loosen air bleeder (3) of HSS pump (2) and leave it for 15 minutes.
3.
After 15 minutes, run the engine at low idle.
4.
Steer to the right and left alternately 2 – 3 times each.
5.
When oil flows out of air bleeder (3), tighten air bleeder (3). 3 Bleeder: 8.8 ± 1.0 Nm {0.9 ± 0.1 kgm}
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102 Testing and adjusting, Part 2 Adjusting straight tiltdozer
SEN05120-02
Adjusting straight tiltdozer
1
a
If the blade was removed and installed or disassembled and assembled, adjust it according to the following procedure.
1.
Adjusting blade tilting distance 1) After installing the blade, adjust installation dimension (A) of brace (1) by handle (2). q Installation dimension (A) of brace A (mm)
PX
EX
1,150
1,150
2.
Adjusting shims for blade assembly 1) After assembling the blade, adjust the shims of tilt section (3), center section (4), lift section (5), and trunnion section (6).
Center section (4)
Lift section (5)
Trunnion section (6)
Unit: mm
Tilt section (3)
Adjustment of shims
a
b
c
d
Adjustment sections
Check item Clearance Standard clearance (Note) Standard thickness of shim
2)
Measure right and left tilting distances (B1) and (B2).
3)
EX
Right tilting distance B1 (mm)
Approx. 430
Approx. 440
Left tilting distance B2 (mm)
Approx. 430
Approx. 440
5
5
4
10
Note: Play of spherical part in axial direction
2) PX
0.2 – 0.7 0.2 – 0.7 0.2 – 0.7 0.2 – 1.2
Supply grease to each adjustment section and check that each part rotates smoothly. 2 Adjustment sections (3), (4), (5): Grease (G2-T)
If the tilting distances are different remarkably, adjust installation dimension (A) of brace (1) according to the following procedure. q (B1) > (B2): Increase installation dimension (A) finely. q (B1) > (B2): Decrease installation dimension (A) finely.
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102 Testing and adjusting, Part 2 Adjusting straight tiltdozer
SEN05120-02 3.
Adjusting center brace a Adjust the center brace tension according to the following procedure. 1) Adjust clearance (b) of ball joint (7) with shim (8). q Clearance (b): 0.2 – 0.5 mm 2) Loosen bolt (9). 3) Operate the blade control lever to float the blade. k After operating the blade control lever, lock it with the safety lever securely. 4) Insert a bar in the hole of center brace (10) and turn it in the tensing direction. a Tension adjustment torque of center brace (10) 3 Center brace: 24.5 – 49 Nm {2.5 – 5 kgm}
5)
Installation dimension of center brace (10) Standard dimension (C) C (mm)
a
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EX
991.5
990.5
Adjust center brace so that clearances (e) between the track and frame on both sides will be the same.
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102 Testing and adjusting, Part 2 Adjusting play of blade center ball
Adjusting play of blade center ball1 a
After the blade is disassembled and assembled or transported, adjust the play of the center ball according to the following procedure.
1.
Install cap (1) and tighten mounting bolts (2) and (3) without inserting any shim.
2.
Measure clearance (a) between cap (1) and blade (4).
3.
Calculate the thickness of shims (5) to be inserted from measured clearance (a), and then select shims to be used. q Thickness of shims to be inserted = (Measured clearance (a)) + (0.5 mm) q Thickness of provide shims: 0.5 mm, 1.0 mm q Standard shim thickness (Reference): 8 mm (2 pieces of 0.5 mm shim and 7 pieces of 1.0 mm shim)
4.
Loosen mounting bolts (2) and remove mounting bolts (3).
5.
Insert selected shims (5).
6.
Tighten the mounting bolts (2) and (3) temporarily.
D65EX, PX, WX-16
SEN05120-02 7.
Angle and tilt the blade and check that no abnormal noise is heard and the blade moves smoothly. a If the blade does not move smoothly or abnormal noise is heard, return to step 2 and select shims (5) again.
8.
Tighten mounting bolts (2) and (3). 3 Cap mounting bolt: 785 – 980 Nm {80 – 100 kgm}
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102 Testing and adjusting, Part 2 Adjusting operator’s cab
SEN05120-02
Adjusting operator’s cab
1
a
If the operator's cab is removed and installed or disassembled and transported and assembled in the field, test and adjust it according to the following procedure.
1.
Measuring internal pressure of cab a Criterion Criterion: Measured value X 68.6 Pa {7 mmH2O} a Measurement condition q Engine speed: High idle q Fan speed: Fan 100% mode q EXTERNAL/INTERNAL air changeover switch: EXTERNAL position q Air conditioner fan switch: High (FULL) 1) Prepare a transparent vinyl hose. q Outside diameter: 6 mm, Length: 3,000 mm 2) Secure the inside end of the hose to the top of the back seat with a tape. 3) Remove bolt (2) (for grounding the wiring harness) at the rear of left console box (1), insert the opposite end of the hose in the bolt hole, and pull it out of the battery cover on the left side of the cab.
4) 5) 6)
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Seal the clearance between the hole of bolt (2) and hose [1] with tape (3). Pour water in the hose up to about half and bend the hose in a U-shape. Secure hose [1] to the outside of the cab and set the water level in the vinyl hose out of the cab to that in the cab.
44
7)
Start the engine and set the machine monitor to Adjusting function of the service mode. a Adjustment code: 1005 (Fan 100% mode) a For the operation method, see “Special functions of machine monitor (EMMS)”.
8)
Run the engine at high idle and measure water level difference (c) in hose [1]. q (a): Inside of cab (Pressurized) q (b): Out of cab (Ambient pressure) q (c): Measured value (Internal pressure of cab) a If the measured value (internal pressure of the cab) is lower than the standard value, check the seals of the holes for wiring harnesses and optional parts in the cab.
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102 Testing and adjusting, Part 2 Adjusting operator’s cab
2.
SEN05120-02
Testing and adjusting door lock (damper rubber) a Close the door and check the relationship between the operator ’s cab and door (damper rubber portions). If there is any abnormality, adjust it. Testing 1) Stick adhesive tape [2] to the contact face of damper rubber (6) of door (5). a Check both sides, 2 pieces on each side. 2) Open and close the door (5) 2 – 3 times. 3) Check the contact portions of adhesive tape [2] and operator’s cab. q Normal: When the door is closed, the damper rubber comes in contact lightly (No adjustment is required). q Abnormal: When the door is closed, the damper rubber does not come in contact or comes in contact so strongly that the adhesive tape is removed (Adjustment is required).
Adjusting 1) Loosen the mounting bolts of damper rubber (6). a You can remove and install the shims without removing the mounting bolts. 2) Increase or decrease shims (7) under damper rubber (6) to adjust the height of damper rubber (6) properly.
3.
Testing and adjusting door lock (latch and striker) a Close the door and check the relationship between the operator ’s cab and door (latch and striker). If there is any abnormality, adjust it. Testing 1) Move door (5) in the closing direction and check the engaging condition of latch (8) and striker (9). a Check quantity of misalignment (f) between center of latch (d) and center of striker (e). q Normal: Quantity of misalignment (f) is 0.5 mm or less.
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102 Testing and adjusting, Part 2 Adjusting operator’s cab
SEN05120-02 Adjusting 1) Tighten the mounting bolts of striker (9) temporarily. Then, open and close door (5) 2 – 3 times to align latch (8) with striker (9). 2) Check the engaging of latch (8) and striker (9). 3) Tighten the mounting bolts of striker (9) securely. 4) Open and close door (5) and check that it is locked and unlocked smoothly. a If the door is not locked or unlocked smoothly (the operating effort of the knob is large), repeat adjustment from the first. a Operating effort of door knob: 58.8 ± 19.6 N {6 ± 2 kg} 5) Apply grease to latch (8). a If the latch dries up, the operating e ff o r t o f t h e k n o b i s i n c r e a s e d . Accordingly, apply sufficient grease to the latch. 2 Latch: Grease (G2-LI)
4.
Testing and adjusting open lock (latch and striker) a Check the relationship between the operator’s cab and door (latch and striker) while the door is locked open. If there is any fault, adjust the open lock. Testing 1) Check the relationship between the open lock latch and striker from the direction of (B). a Move the door in the opening direction to check the engagement of the latch and striker.
2) 3)
Check that striker (10) is not leaning against or from center of latch (11). Check that striker (10) is aligned with center of latch (11). q Normal: Quantity of misalignment is 0.5 mm or less.
Adjusting 1) Loosen the mounting bolts of striker (10). 2) While setting striker (10) upright, tighten the mounting bolts.
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102 Testing and adjusting, Part 2 Adjusting operator’s cab
5.
SEN05120-02
Testing and adjusting open lock (stopper rubber) a Check the relationship between the operator's cab and door (stopper rubber) while the door is locked open. If there is any fault, adjust the open lock. 1) Lock the door open and move it in the forward and reverse directions to check that it does not have play. a Check both sides, 2 places on each side. 2) Check that the operating effort of the unlock lever is not large. 3) Loosen the locknut of stopper rubber (12) (upper one). 4) Loosen the locknut of stopper rubber (13) (lower one).
5)
6)
Adjust the height of stopper rubbers (12) and (13) according to the trouble. a If there is play, project (heighten) the stopper rubber until the play is eliminated. a If the door is not locked easily or the unlock lever is heavy, return (lower) the stopper rubber in the range that the door does not have play. While fixing stopper rubbers (12) and (13), tighten the locknuts.
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SEN05120-02
D65EX, PX, WX-16 Bulldozer Form No. SEN05120-02
©2011 KOMATSU All Rights Reserved Printed in Japan 09-11
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SEN05121-02
BULLDOZER D65EX-16 D65PX-16 D65WX-16 Machine model
Serial number
D65EX-16 D65PX-16 D65WX-16
80001 and up 80001 and up 80001 and up
30 Testing and adjusting
30
103 Testing and adjusting, Part 3 Special functions of machine monitor (EMMS) ............................................................................................... 2
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SEN05121-02
103 Testing and adjusting, Part 3 Special functions of machine monitor (EMMS)
Special functions of machine monitor (EMMS)
1
Air conditioner specification
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103 Testing and adjusting, Part 3 Special functions of machine monitor (EMMS)
Heater specification
D65EX, PX, WX-16
SEN05121-02 Upper section of machine monitor (Display section) (a): Multi-display 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 oper ating 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 machine monitor goes off for a moment. This phenomenon is not a failure, however. Upper section of machine monitor (Switch section) [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 graphic mark in the multi-display (a) above that function switch. a If the graphic mark of a function switch is not displayed, that function switch is not working. Lower section of machine monitor (Switch section) [1]: Numeral 1 input switch/Operation mode selector switch [2]: Numeral 2 input switch/Gearshift mode selector switch [3]: Numeral 3 input switch/Customize switch [4]: Numeral 4 input switch/Buzzer cancel switch [5]: Numeral 5 input switch [6]: Numeral 6 input switch/Customize memory switch [7]: Numeral 7 input switch/Air conditioner or heater switch [8]: Numeral 8 input switch/Air conditioner or heater switch [9]: Numeral 9 input switch/Air conditioner or heater switch [0]: Numeral 0 input switch/Air conditioner or heater switch Switch having no numerals: Air conditioner or heater switch a Each switch has the function indicated by graphic mark and the function of inputting a numeral. a The machine monitor automatically judges which function of each switch is currently effective, according to the display condition of multidisplay (a). a The difference between the air conditioner specification and heater specification is only the functions of the switches in this section. 30-103
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103 Testing and adjusting, Part 3 Special functions of machine monitor (EMMS)
SEN05121-02 t
Ordinary functions and special functions of machine monitor
The machine monitor has the ordinary functions and special functions and displays information of various types 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 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 functions: Service mode The items in this mode are not displayed ordinarily. Each serviceman can display them by operating the switches specially. This mode is used for special setting, testing, adjusting, or troubleshooting. Page
Page
Service mode
5p
16 p
A Display of KOMATSU logo
5p
A Display of screen to input password
6p
A Display of check before starting
6p
A Display of warning after check before starting
6p
A Display of ending of maintenance interval
6p
03 Maintenance Record
26 p
A Display of check of preset
7p
04 Maintenance Mode Change
27 p
A Display of ordinary screen
7p
05 Phone Number Entry
29 p
A Display of end screen
7p
B Selection of operation mode
7p
B Selection of gearshift mode
8p
o 06 Default
B Customizing operation
8p
B Operation of customize memory
8p
Special operations
Operator mode (Outline)
B Operation to cancel alarm buzzer
8p
B Operation of air conditioner/heater
9p
Operation to display camera mode (if camera is installed)
9p
B
01 Monitoring
17 p Mechanical system "Abnormality Record"
02 Abnormal- Electrical system "Abnormality ity Record Record"
22 p 23 p
Air conditioner "Abnormality Record"/ 25 p Heater "Abnormality Record"
Key-on Mode
30 p
Selecting of unit
31 p
Setting of maintenance password
32 p
Setting of camera
33 p
Setting of ECO display
34 p
07 Adjustment
35 p
08 PM CLINIC
49 p
09 Cylinder Cut-Out
50 p
B Operation to display clock and service meter
10 p
10 No Injection
51 p
B Check of maintenance information
10 p
11 Fuel Consumption
53 p
11 p
Terminal Status 12 KOMTRAX GPS & Communication Status Settings
54 p
B
Setting and display of user mode (including KOMTRAX messages for user)
C Display of caution monitor
12 p
C Display of action code and failure code
12 p
O (Special operations) D
Function of checking display of LCD (Liquid Crystal Display)
56 p 57 p
14 p
D Function of checking service meter
14 p
D Function of changing maintenance password
14 p
a
Modem S/N 13 Service Message
55 p
Classification of operator mode A: Display/Function from time when starting switch is turned ON to time when screen changes to ordinary screen and display after starting switch is turned OFF B: Display/Function when switch of machine monitor is operated C: Display/Function when certain condition is satisfied D: Display/Function which needs special operation of switch
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103 Testing and adjusting, Part 3 Special functions of machine monitor (EMMS)
t
a
a
SEN05121-02 a
Operator mode (Outline) Only outline of the operator mode is described in this section. For details of contents/operation of each function/display, see the "Structure, function and maintenance standard, or Operation and Maintenance Manual". The followings are the displays or functions of the operator mode explained in this section (including some items which need special operations).
Display pattern of operator mode The contents of display from the time when starting switch is turned ON to the time when screen changes to ordinary screen depends on the setting and condition of the machine. a: When engine start lock is set effective b: When engine start lock is set ineffective c: When there is abnormal item in checkbefore-starting items d: When there is maintenance item which is not maintained after specified interval
Display pattern a
b
c
d
Display of KOMATSU logo
1
1
1
1
Display of screen to input password
2
–
–
–
Display of check before starting
3
2
2
2
Display of warning after check before starting
–
–
3
–
Display of ending of maintenance inter– val
–
–
3
Display of check of preset
4
4
4
4
Display of ordinary screen
5
4
5
5
Display of KOMATSU logo When the starting switch is turned ON, the KOMATSU logo is displayed for 2 seconds. After the KOMATSU logo is displayed for 2 seconds, the screen changes to "Display of screen to input password" or "Display of check before starting".
Display of end screen Selection of operation mode Selection of gearshift mode Customizing operation Operation of customize memory Operation to cancel alarm buzzer Operation of air conditioner/heater Operation to display camera mode (if camera is installed) Operation to display clock and service meter Check of maintenance information Setting and display of user mode (including KOMTRAX messages for user)
a a
The following screen may be displayed instead of the above "Display of screen to input password screen". If this screen is displayed, call the person responsible to operation of KOMTRAX in your Komatsu distributor and ask for remedy.
Display of caution monitor Display of action code and failure code O (Special operations) Function of checking display of LCD (Liquid Crystal Display) Function of checking service meter Function of changing maintenance password
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SEN05121-02 Display of screen to input password After the KOMATSU logo is displayed, the screen to input the engine start lock password is displayed. a This screen is displayed only when the engine start lock function is set effective. a If the password is input normally, the screen changes to "Display of check before starting". a The machine monitor has some password functions other than the engine start lock. Those functions are independent from one another.
Display of check before starting When the screen changes to the check-beforestarting screen, the check before starting is carried out for 2 seconds. a If any abnormality is detected by the check before starting, the screen changes to "Display of warning after check before starting" or "Display of ending of maintenance interval". a If no abnormality is detected by the check before starting, the screen changes to "Display of check of preset". a The monitors (3 pieces) displayed on the screen are the items under the check before starting.
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103 Testing and adjusting, Part 3 Special functions of machine monitor (EMMS)
Display of warning after check before starting If any abnormality is detected by the check before starting, the warning monitor is displayed on the screen. a The following figure shows that the water separator monitor (a) is warning of water collected in water separator.
Display of ending of maintenance interval When the check before starting is carried out, if a maintenance item is near or after the end of the set interval, the maintenance monitor is displayed for 30 seconds to urge the operator to maintenance. a This screen is displayed only when the maintenance function is effective. The color of the maintenance monitor (yellow or red) indicates the length of the time after the maintenance interval. a Set or change the maintenance function in the service mode.
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103 Testing and adjusting, Part 3 Special functions of machine monitor (EMMS)
SEN05121-02
Display of check of preset If the check before starting is finished normally, the screen to check the preset (gear speed at start) is displayed for 2 seconds. a After display of check of preset is finished, the screen changes to "Display of ordinary screen".
Display of end screen When the starting switch is turned OFF, the end screen is displayed for 5 seconds. a Another message may be displayed on the end screen, depending on the message display function of KOMTRAX.
Display of ordinary screen If the machine monitor starts normally, the ordinary screen is displayed. a Service meter (a) or a clock is displayed at the center upper section of the screen (The service meter or clock is selected with [F4]). a Power train oil temperature gauge (b) is displayed on the multi-gauge section (It is turned ON and OFF with the user mode function or [F2]). a ECO gauge (c) is displayed at the right end of the screen (It is turned ON and OFF in the service mode).
Selection of operation mode While the ordinary screen is displayed, press the operation mode selector switch, and the operation mode monitor (a) changes. a Each time the switch is pressed, the operation mode changes between [P (Power)] and [E (Economy)].
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SEN05121-02 Selection of gearshift mode While the ordinary screen is displayed, press the gearshift mode selector switch, and the gearshift mode monitor (a) in the gear speed display section changes. a Each time the switch is pressed, the gearshift mode changes between [Automatic gearshift] and [Manual gearshift]. a If dozing (automatic gearshift) is selected, AUTO symbol (b) is displayed in the gear speed display section.
103 Testing and adjusting, Part 3 Special functions of machine monitor (EMMS)
Operation of customize memory While the ordinary screen is displayed, press the customize memory switch, and you can select the recorded setting of customization.
Operation to cancel alarm buzzer While the alarm buzzer is sounding, if the buzzer cancel switch is pressed, the alarm buzzer stops. a Even if the buzzer cancel switch is pressed, the screen does not change. Customizing operation While the ordinary screen is displayed, press the customize switch, and you can change the setting of the machine. a If the customize memory switch is operated while the above screen is displayed, up to 5 settings can be saved.
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Operation of air conditioner/heater While the ordinary screen is displayed, press the air conditioner switch or heater switch, and the Airconditioner Adjustment screen or Heater Adjustment screen is displayed. a While the Air-conditioner Adjustment screen or Heater Adjustment screen is displayed, if you do not touch any switch for 5 seconds, the screen changes to the ordinary screen. a Air conditioner specification
a
SEN05121-02 Operation to display camera mode (if camera is installed) When a camera is installed, if [F3] is pressed, the multi-display changes to the camera image. a Set the connection of the camera in the service mode.
a
Up to 3 cameras can be connected. If the camera mode is selected, however, only the image of camera 1 is always displayed.
a
If a caution is generated in the camera mode, the caution monitor is displayed at the left upper of the screen. When an error that there is a action code occurs in the camera mode, if the machine stops for 10 seconds, the screen changes to the ordinary screen and displays the error information. When 2 or more cameras are connected, the image of one of them or the images of 2 of them can be displayed. If 2-camera image display [F4] is selected, 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. If the images of 2 cameras are displayed simultaneously, images are displayed at intervals of 1 second on the right and left screen.
Heater specification
a
a a
a
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SEN05121-02 Operation to display clock and service meter While the ordinary screen is displayed, press [F4], and section (a) changes to the service meter and clock alternately. a When the clock is selected, adjust the time, set 12-hour or 24-hour display, and set the summer time with the user mode function. a Display of service meter
Check of maintenance information While the maintenance monitor or ordinary screen is displayed, press [F5], and the maintenance table screen is displayed.
a
a
To reset the time left after finishing maintenance, more operations are necessary.
Display of clock
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Setting and display of user mode (including KOMTRAX messages for user) While the ordinary screen is displayed, press [F6], and the user menu screen is displayed.
SEN05121-02 [KOMTRAX message] q There are 2 types of KOMTRAX message; one is for the user and the other is for the service. q For user: A message transmitted from the KOMTRAX base station for the user. If it is received, the message monitor is displayed on the ordinary screen. To see the contents of the message, operate "Message display" in the above user menu. q
a
There are following items in the user menu.
For service: A message transmitted from the KOMTRAX base station for the service. Even if it is received, nothing is displayed on the ordinary screen. To see the contents of the message, operate "KOMTRAX message display" in the service menu.
Utility Screen Select Multi Gage Select Screen Adjustment Clock Adjustment Language Message display Hydraulic fan reversing
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SEN05121-02 Display of caution monitor If an abnormality which displays a caution monitor occurs on the ordinary screen or camera mode screen, the caution monitor is displayed large for a moment and then displayed at (a) in the screen. a On the camera mode screen, the caution monitor blinks at the left upper of the screen when the caution is generated.
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103 Testing and adjusting, Part 3 Special functions of machine monitor (EMMS)
Display of action code and failure code If an abnormality which displays an action code and a failure code occurs on the ordinary screen or camera mode screen, all the information of the abnormality is displayed. (a) : Action code (3 digits) (b) : Failure code (5 or 6 digits) (c) : Telephone mark (d) : Telephone No. a This screen is displayed only when an abnormality (failure code) for which an action code is set occurs. a The telephone mark and telephone No. are displayed only when the telephone No. is registered in the service mode. a If multiple abnormalities occur simultaneously, all the codes are displayed repeatedly in order. a Since the information of the displayed failure code is recorded in the fault history in the service mode, check the details in the service mode.
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a
SEN05121-02
Remedies given by displayed action codes to operator to take (The following table is an excerpt from the Operation and Maintenance Manual)
Action code
Method of indicating trouble
Examples of trouble
Remedy given to operator to take
• Action code and failure code are • Backup alarm does not sound. displayed. • Fan speed is kept at maximum.
• Although all or a part of automatic function stops, machine can be operated. • Ask your Komatsu distributor for repair.
E02
• Action code and failure code are • Gear is not shifted up or down. displayed. • Exhaust gas color is bad when • Alarm buzzer sounds. temperature is low.
• If operator stops and restarts engine, machine can be operated without limiting any function. Operator must take care, however. • Ask your Komatsu distributor for repair.
E03
• Action code and failure code are displayed. • Telephone No. is displayed (if set). • Alarm buzzer sounds.
• Move machine to safe place. • Ask your Komatsu distributor for repair.
E04
• Action code and failure code are displayed. • Engine cannot be controlled. • Telephone No. is displayed (if • Machine cannot travel. set). • Machine stops. • Alarm buzzer sounds.
E01
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• Usable gear speeds are limited. • Engine speed does not rise to maximum. • Gearshift shock is increased. • Steering performance lowers.
• Stop machine immediately. • Ask your Komatsu distributor for repair.
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SEN05121-02 Function of checking display of LCD (Liquid Crystal Display) While the ordinary screen is displayed, if the following numeral input switch and function switch are operated as follows, all the LCD (Liquid Crystal Display) lights up in white. q Operation of switches (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 The LCD panel sometimes has black points (points which are not lighted) and bright points (points which do not go off) for the reason of its characteristics. If the number of the bright points and black points does not exceed 10, those points are not a failure or a defect. a To return to the former screen, press the function switch.
Function of checking service meter To check the service meter while the starting switch is turned OFF, operate the numeral input switches as follows. At this time, only the service meter section displays. q Operation of switches (simultaneous): [4] + [1] a Since there is some time lag in start of the LCD, hold down the switches until the LCD displays normally. a After the machine monitor is used continuously, blue points (points which do not go off) may be seen on this screen. This phenomenon does not indicate a failure or a defect.
Function of changing maintenance password When changing the maintenance password used for the maintenance setting function, follow these procedures. a To use this function, the machine monitor must be set to "Use maintenance password setting" in the service mode. a See "Initialize (Set maintenance password)". 1.
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While the ordinary screen is displayed, perform the following operation with the numeral input switches. q Operation of switches (While pressing [4], perform the operation in order): [4] + [5] o [5] o [5] a This operation of the switches is not accepted until 10 minutes pass after the starting switch is turned on.
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103 Testing and adjusting, Part 3 Special functions of machine monitor (EMMS)
2.
3.
After the "Password" screen is displayed, input the current password with the numeral input switches and confirm it with the function switch. q [F5]: Delete input numeral/Return to ordinary screen q [F6]: Confirm input numeral a Default password: [000000] a If the input password is correct, the screen changes to the next screen. a If the input password is incorrect, the message to input the password again is displayed.
SEN05121-02
4.
After the "New Password" screen is displayed again, input a new password again with the numeral input switches and confirm it with the function switch. q [F5]: Delete input numeral/Return to ordinary screen q [F6]: Confirm input numeral a If a password different from the password input before is input, the message to input again is displayed.
5.
If the screen to notify completion of setting is displayed and then the ordinary screen is displayed, the password is changed successfully.
After the "New Password" screen is displayed, input a new password with the numeral input switches and confirm it with the function switch. a Set a new password of 4 – 6 digits (If it has only 3 or less digits or has 7 or more digits, it is not accepted). q [F5]: Delete input numeral/Return to ordinary screen q [F6]: Confirm input numeral
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103 Testing and adjusting, Part 3 Special functions of machine monitor (EMMS)
SEN05121-02 t
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.
a
Service mode
Check of display of screen and operation of switches While the ordinary screen is displayed, perform the following operation with the numeral input switches. q Operation of switches (While pressing [4], perform the operation in order): [4] + [1] o [2] o [3] a This operation of the switches is accepted only while the ordinary screen is displayed.
The items which can be selected in the service menu are as follows.
01 Monitoring Mechanical system "Abnormality Record" 02 Abnormality Record
Electrical system "Abnormality Record" Air conditioner "Abnormality Record"/ Heater "Abnormality Record"
03 Maintenance Record 04 Maintenance Mode Change 05 Phone Number Entry Key-on Mode Selecting of unit 06 Default
Setting of maintenance password Setting of camera Setting of ECO display
07 Adjustment 08 PM CLINIC 09 Cylinder Cut-Out 10 No Injection 11 Fuel Consumption Terminal Status 12 KOMTRAX Settings
GPS & Communication Status Modem S/N
2.
Selection of service menu When the "Service Menu" screen is displayed, the service mode is selected. Select a service menu you use with the function switches or numeral input switches. q [F3]: Move to lower menu q [F4]: Move to upper menu q [F5]: Return to ordinary screen (operator mode) q [F6]: Confirm selection a You may enter a 2-digit code with the numeral input switches to select the menu of that code and confirm it with [F6].
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13 Service Message
a
Items with 2-digit codes are the menus displayed on the Service menu screen. The items on their right are the menus on the next hierarchy.
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103 Testing and adjusting, Part 3 Special functions of machine monitor (EMMS)
Monitoring The machine monitor can monitor the condition of the machine in real time by receiving signals from various switches, sensors, and actuators installed to many parts of the machine and the information from the controllers which are controlling switches, etc. 1.
Selecting menu Select "01 Monitoring" on the "Service Menu" screen.
D65EX, PX, WX-16
SEN05121-02 2.
Selecting monitoring items After the "Monitoring" screen is displayed, select items to be monitored with the function switches or numeral input switches. q [F1]: Move to next page (screen) q [F2]: Move to previous page (screen) q [F3]: Move to lower item q [F4]: Move to upper item q [F5]: Delete input numeral/Return to service menu screen q [F6]: Confirm selection a Selection with function switches: Select an item with [F3] or [F4] and confirm it with [F6]. a Selection with numeral input switches: Enter a 5-digit code, and the item of that code is selected directly. Confirm that item with [F6]. a If the color of the selected box changes from yellow to red, selection of the item of that box is confirmed. a Up to 6 monitoring items can be selected at a time. You may not able to set up to 6 items, however, depending on the display form of those items.
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103 Testing and adjusting, Part 3 Special functions of machine monitor (EMMS)
SEN05121-02 3.
4.
Deciding monitoring items After selecting monitoring items, execute monitoring with the function switch or numeral input switch. a Execution with function switch: Doubleclick or hold down [F6] (about 2 seconds). a Execution with numeral input switch: Input [99999] and press [F6]. a When monitoring only 2 items, for example, select them and confirm with [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.
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. a The unit of display can be set to SI unit, metric unit, or inch unit with the Default function in the service mode.
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5.
Holding monitoring information The monitoring information can be held and holding is reset with the function switches. q [F3]: Reset holding q [F4]: Hold information (displayed data) q [F5]: Return to monitoring selection menu screen
6.
Changing machine setting mode To change the setting of the "Operation Mode" or "Gearshift Mode" during monitoring, operate the corresponding switch under the current condition, and the mode setting screen is displayed. While this screen is displayed, if the corresponding switch is operated further, the corresponding mode is changed. a After finishing changing the setting, press [F6] to return to the monitoring information screen. 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.
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103 Testing and adjusting, Part 3 Special functions of machine monitor (EMMS)
SEN05121-02 Monitoring items list Unit (Initial setting: ISO) ISO
meter
inch
Component in charge
50300 S/T Lever 1 Potentio
mV
mV
mV
P/T
50301 S/T Lever 2 Potentio
mV
mV
mV
P/T
50400 Brake Pedal Potentio
mV
mV
mV
P/T
50600 HSS Solenoid LH (F/B)
mA
mA
mA
P/T
50601 HSS Solenoid RH (F/B)
mA
mA
mA
P/T
°
°
°
P/T
mV
mV
mV
P/T
Code No.
Monitoring item (Display on screen)
32900 Pitch Angle 60100 Pitch Angle Sensor 18800 Water in Fuel
WIF sensor
60600 BR Hold Relay
ON • OFF
ENG
mV
mV
mV
P/T
03001 Fuel Dial Throttle
%
%
%
P/T
03000 Fuel Dial Sensor
mV
mV
mV
P/T
50200 T/M Lever 1 Potentio
mV
mV
mV
P/T
50201 T/M Lever 2 Potentio
mV
mV
mV
P/T
31622 T/M Clutch F ECMV (F/B)
mA
mA
mA
P/T
31616 T/M Clutch R ECMV (F/B)
mA
mA
mA
P/T
31612 T/M Clutch 1st ECMV (F/B)
mA
mA
mA
P/T
31613 T/M Clutch 2nd ECMV (F/B)
mA
mA
mA
P/T
31614 T/M Clutch 3rd ECMV (F/B)
mA
mA
mA
P/T
30100 T/C Oil Temperature
C
C
F
P/T
30101 T/C oil temp sensor
mV
mV
mV
P/T
31400 T/M Out Speed
r/min
rpm
rpm
P/T
32600 T/C AVR Pressure
MPa
kg/cm²
psi
P/T
32605 T/C AVR Pressure Sensor
mV
mV
mV
P/T
31642 L/U ECMV (F/B)
mA
mA
mA
P/T
km/h
km/h
MPh
P/T
60000 Traction
W
W
W
P/T
70200 T/M Out Speed Sensor
mV
mV
mV
P/T
31624 Fan Pump Solenoid (F/B)
mA
mA
mA
P/T
r/min
rpm
rpm
P/T
40001 Vehicle Speed
10000 Fan Speed
40905 T/M Sw Input 1
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Remarks
SUNC (Gear shift up sw)
ON • OFF
P/T
SUNO (Gear shift up sw)
ON • OFF
P/T
SDNC (Gear shift down sw)
ON • OFF
P/T
SDNO (Gear shift down sw)
ON • OFF
P/T
PNC (Parking brake lever sw)
ON • OFF
P/T
PNO (Parking brake lever sw)
ON • OFF
P/T
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103 Testing and adjusting, Part 3 Special functions of machine monitor (EMMS)
SEN05121-02
Code No.
Monitoring item (Display on screen)
T/M Fill Sw 40906 Input 1
31520
T/M Fill Sw Input 2
40909 T/M Output 1
Unit (Initial setting: ISO) ISO
meter
inch
Component in charge
F (F clutch fill sw)
ON • OFF
P/T
R (R clutch fill sw)
ON • OFF
P/T
1st (1st clutch fill sw)
ON • OFF
P/T
2nd (2nd clutch fill sw)
ON • OFF
P/T
3rd (3rd clutch fill sw)
ON • OFF
P/T
L/U (Lock-up clutch fill sw)
ON • OFF
P/T
Brly (Back Alarm relay)
ON • OFF
P/T
Prly (Parking lock relay)
ON • OFF
P/T
Fres (Fan reverse solenoid)
ON • OFF
P/T
70700 Hydraulic Pump Pressure 1
MPa
kg/cm²
psi
P/T
70701 Hydraulic Pressure Sensor 1
mV
mV
mV
P/T
01300 TVC Solenoid (F/B)
mA
mA
mA
P/T
KUNC (Knob raise sw)
ON • OFF
P/T
KUNO (Knob raise sw)
ON • OFF
P/T
KLNC (Knob down sw)
ON • OFF
P/T
KLNO (Knob down sw)
ON • OFF
P/T
WLNC (Work equipment lock sw)
ON • OFF
P/T
WLNO (Work equipment lock sw)
ON • OFF
P/T
WE lock sol.
ON • OFF
P/T
Pitch selector sol.
ON • OFF
P/T
Amber light relay
ON • OFF
P/T
20227 Monitor Ass’y P/N
—
MON
20402 Monitor Serial No
—
MON
20228 Monitor Prog P/N
—
MON
20242 P/T Con Ass’y P/N
—
P/T
20404 P/T Con Serial No
—
P/T
20243 P/T Con Prog P/N
—
P/T
70300 Blade Sw Input
90803 Blade Output 1
04200 Fuel Level Sensor Volt
V
V
V
MON
04300 Battery Charge Volt
V
V
V
MON
04401 Hyd Oil Temperature
C
C
F
MON
04402 Hyd Temp Sens Volt
V
V
V
MON
18900 ECM Internal Temp
C
C
F
ENG
00201 Machine ID
—
ENG
20216 ECM Build Version
—
ENG
20217 ECM Calibration Data Ver
—
ENG
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Remarks
Current to PC-EPC valve is displayed
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103 Testing and adjusting, Part 3 Special functions of machine monitor (EMMS)
Code No.
Monitoring item (Display on screen)
SEN05121-02
Unit (Initial setting: ISO) ISO
20400 ECM Serial No
meter
inch
—
01002 Engine Speed
Component in charge ENG
r/min
rpm
rpm
ENG
36700 Engine Torque Ratio
%
%
%
ENG
31701 Decel Pedal Position
%
%
%
ENG
31703 Decel pedal pos sens volt
V
V
V
ENG
17500 Engine Power Mode 36400 Rail Pressure
—
ENG
MPa
kg/cm²
psi
ENG
V
V
V
ENG
MPa
kg/cm²
psi
ENG
CA
CA
CA
ENG
04107 Coolant Temperature
C
C
F
ENG
04105 Coolant Temp Sens Volt
V
V
V
ENG
kPa
kg/cm²
psi
ENG
V
V
V
ENG
kPa
kg/cm²
psi
ENG
36501 Charge Press Sens Volt
V
V
V
ENG
03203 Battery Power Supply (ENG)
V
V
V
ENG
37300 Fuel Rate
l/h
l/h
gal/h
ENG
31706 Final Throttle Position
%
%
%
ENG
18500 Charge Temperature
C
C
F
ENG
18501 Charge Temp Sens Volt
V
V
V
ENG
18600 Inject Fueling Command
mg/st
mg/st
mg/st
ENG
Nm
kgm
lbft
ENG
36401 Rail Pressure Sens Volt 36200 Rail Press Command 36300 Injection Timing Command
37400 Ambient Pressure 37401 Ambient Press Sens Volt 36500 Charge Pressure-Abs
18700 Engine Output Torque
40912 P/T Sw Input
a a
a
Remarks
C-sig
ON • OFF
P/T
R-sig
ON • OFF
P/T
ACC
ON • OFF
P/T
Indication by absolute value
Indication by absolute value (including ambient pressure)
Entry order of items in table The items are entered in the order of display on the monitoring selection menu screen. Unit The display unit can be set to ISO, meter, or inch freely (Set it with Unit in "Default" of the service menu). "CA" in the display unit is an abbreviation for crankshaft angle. "mg/st" in the display unit is an abbreviation for milligram/stroke. Components in charge MON : The machine monitor is in charge of detection of monitoring information. ENG : The engine controller is in charge of detection of monitoring information. P/T : The power train controller is in charge of detection of monitoring information.
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103 Testing and adjusting, Part 3 Special functions of machine monitor (EMMS)
SEN05121-02 "Abnormality Record" (Mechanical system "Abnormality Record") The machine monitor classifies and records the abnormality which occurred in the past or which are occurring at present into the mechanical system abnormality, electrical system abnormality, and air conditioner abnormality or heater abnormality. To check the mechanical system "Abnormality Record", perform the following procedures. a See section "Failure code table and fuse locations" for the list of failure codes. 1.
Selecting menu Select "02 Abnormality Record" on the "Service Menu" screen.
2.
Selecting sub menu After the "Abnormality Record" screen is displayed, select "01 Mechanical Systems" with the function switches or numeral input switches. q [F3]: Move to lower record q [F4]: Move to upper record q [F5]: Return to service menu screen q [F6]: Confirm selection a You may enter a 2-digit code with the numeral input switches to select the record of that code and confirm it with [F6]. a The following figure shows the display of the air conditioner specification. If the heater specification is selected, "03 Heater Abnormality Record" is displayed.
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3.
Information displayed on "Abnormality Record" screen On the "Mechanical Systems" screen, the following information is displayed. (a): Occurrence order of abnormality from latest one/Total number of records (b): Failure code (c): Contents of trouble (d): Number of occurrence time (e): Service meter reading at first occurrence (f): Service meter reading at last occurrence q [F1]: Move to next page (screen) (if displayed) q [F2]: Move to previous page (screen) (if displayed) q [F5]: Return to "Abnormality Record" screen a If no "Abnormality Record" is recorded, "No Abnormality Record" is displayed. a If the number of occurrence time is 1 (first occurrence), the service meter reading at the first occurrence and that at the last occurrence are the same. a If [E] is displayed on the left of a failure code, the abnormality is still occurring or resetting of it has not been confirmed.
4.
Deleting "Abnormality Record" The contents of the mechanical system "Abnormality Record" cannot be deleted.
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103 Testing and adjusting, Part 3 Special functions of machine monitor (EMMS)
"Ab normality Reco rd" (Electrical system "Abnormality Record") The machine monitor classifies and records the abnormality which occurred in the past or which are occurring at present into the mechanical system abnormality, electrical system abnormality, and air conditioner abnormality or heater abnormality. To check the electrical system "Abnormality Record", perform the following procedures. a See section "Failure code table and fuse locations" for the list of failure codes. 1.
Selecting menu Select "02 Abnormality Record" on the "Service Menu" screen.
2.
Selecting sub menu After the "Abnormality Record" screen is displayed, select "02 Electrical Systems" with the function switches or numeral input switches. q [F3]: Move to lower record q [F4]: Move to upper record q [F5]: Return to service menu screen q [F6]: Confirm selection a You may enter a 2-digit code with the numeral input switches to select the record of that code and confirm it with [F6]. a The following figure shows the display of the air conditioner specification. If the heater specification is selected, "03 Heater Abnormality Record" is displayed.
D65EX, PX, WX-16
SEN05121-02 3.
Information displayed on "Abnormality Record" screen On the "Electrical Systems" screen, the following information is displayed. (a):Occurrence order of abnormality from latest one/Total number of records (b):Failure code (c): Contents of trouble (d):Number of occurrence time (e):Service meter reading at first occurrence (f): Service meter reading at last occurrence q [F1]: Move to next page (screen) (if displayed) q [F2]: Move to previous page (screen) (if displayed) q [F3]: Move to lower record q [F4]: Move to upper record q [F5]: Return to "Abnormality Record" screen a If no "Abnormality Record" is recorded, "No Abnormality Record" is displayed. a If the number of occurrence time is 1 (first occurrence), the service meter reading at the first occurrence and that at the last occurrence are the same. a If [E] is displayed on the left of a failure code, the abnormality is still occurring or resetting of it has not been confirmed.
4.
Deleting "Abnormality Record" 1) While the "Electrical Systems" screen is displayed, perform the following operation with the numeral input switches. q Operation of switches (While pressing [4], perform the operation in order): [4] + [1] o [2] o [3] a Operate the switches similarly to the procedure for changing the ordinary display to the service mode.
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103 Testing and adjusting, Part 3 Special functions of machine monitor (EMMS)
SEN05121-02
2)
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Check that the screen is set in the delete mode, and then delete the items one by one or together with the function switches. a If the screen is set in the delete mode, [CLEAR] graphic mark is indicated at [F2]. q [F2]: Delete all items q [F3]: Move to lower item q [F4]: Move to upper item q [F5]: Return to "Abnormality Record" screen q [F6]: Delete selected item a To delete items one by one: Select the item to be deleted with [F3] or [F4] and press [F6]. a To delete all items together: Press [F2], and all the items are deleted, regardless of selection of the items. a If [E] is displayed on the left of a failure code, the deleting operation is accepted but the information is not deleted.
24
3)
After the "Electrical Sys. Error Reset" screen is displayed, operate the function switches. q [F5]: Return to "Electrical Sys. Error Reset" screen (Delete mode) q [F6]: Execute deletion a The following figure shows the screen displayed when the items are deleted one by one (which is a little different from the screen displayed when all the items are deleted together).
4)
If the screen to notify completion of deletion is displayed and then the "Electrical Sys. Error Reset" (delete mode) screen is displayed, the deletion of the "Abnormality Record" is completed. a After a while, the screen returns to the "Electrical Sys. Error Reset" screen.
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103 Testing and adjusting, Part 3 Special functions of machine monitor (EMMS)
"Abnormality Record" (Air conditioner "Abnormality Record"/Heater "Abnormality Record") The machine monitor classifies and records the abnormality which occurred in the past or which are occurring at present into the mechanical system abnormality, electrical system abnormality, and air conditioner abnormality or heater abnormality. To check the air conditioner "Abnormality Record" or heater "Abnormality Record", perform the following procedures. a All the following figures show the air conditioner specification. 1.
Selecting menu Select "02 Abnormality Record" on the Service menu screen.
2.
Selecting sub menu After the "Abnormality Record" screen is displayed, select "03 Air-conditioning System" or "03 Heater Abnormality Record" with the function switches or numeral input switches. q [F3]: Move to lower record q [F4]: Move to upper record q [F5]: Return to service menu screen q [F6]: Confirm selection a You may enter a 2-digit code with the numeral input switches to select the record of that code and confirm it with [F6].
D65EX, PX, WX-16
SEN05121-02 3.
Information displayed on "Abnormality Record" screen On the air conditioner "Abnormality Record" or heater "Abnormality Record" screen, the following information is displayed. (a): System/Component name (b): Number of occurrence time (c): Condition (Normal or abnormal) q [F2]: Delete "Abnormality Record" q [F5]: Return to "Abnormality Record" screen a If [E] is displayed on the left of a condition, the abnormality is still occurring or resetting of it has not been confirmed. a If "CAN Status" is displayed in Communication condition, communication cannot be carried out normally. Accordingly, the conditions of other items are turned OFF.
4.
Deleting "Abnormality Record" While the "Abnormality Record" screen is displayed, press [F2], and the number of occurrence time of fault is deleted. If it is confirmed at this time that the abnormality has been reset, the display changes to Normal.
a
Heater specification In the heater specification, the display of "Air conditioner" is replaced with "Heater" and the items which are not related to the heater are not displayed.
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103 Testing and adjusting, Part 3 Special functions of machine monitor (EMMS)
SEN05121-02 a
Maintenance Record The machine monitor records the maintenance information of the filters, oils, etc., which the operator can display and check by the following operations. When maintenance is carried out, if the data are reset in the operator mode, the number of the times of maintenance is recorded in this section. 1.
The following items can be selected in the maintenance record. 01 Engine Oil Change 02 Eng Oil Filter Change 03 Fuel Main Filter Change 41 Fuel Pre Filter Change
Selecting menu Select "03 Maintenance Record" on the "Service Menu" screen.
04 Hyd Oil Filter Change 06 Corrosion Resistor Change 07 Check and addition of damper case oil 08 Replacement interval of final drive case oil 10 Replacement of hydraulic oil 19 Replacement of power train oil 20 Replacement of power train oil filter
3.
2.
Items displayed on “Maintenance Record” screen. The following items are displayed. (a): Maintenance items (b): Number of times of change up to now (c): Service meter reading (SMR) at previous change
Selecting maintenance record item After the "Maintenance Record" screen is displayed, select an item to be checked with the function switches or numeral input switches. q [F1]: Move to next page (screen) q [F2]: Move to previous page (screen) q [F3]: Move to lower item q [F4]: Move to upper item q [F5]: Return to service menu screen a You may enter a 2-digit code with the numeral input switches to select the item of that code.
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103 Testing and adjusting, Part 3 Special functions of machine monitor (EMMS)
SEN05121-02 a
Maintenance Mode Change The operating condition for maintenance function in the operation mode can be set and changed with this menu. q Set function effective or ineffective q Change set change interval (by items) q Initialize all set change intervals
00 Maintenance Mode On/Off
1.
41 Fuel Pre Filter Change Int
Selecting menu Select "04 Maintenance Mode Change" on the Service menu screen.
The following items can be selected on the "Maintenance Mode On/Off" screen.
01 Engine Oil Change Int 02 Eng Oil Filter Change Int 03 Fuel Main Filter Change Int 04 Hyd Oil Filter Change Int 06 Replacement interval of corrosion resistor 07 Check and replacement interval of damper case oil 08 Replacement interval of final drive case oil 10 Replacement interval of hydraulic oil 19 Replacement interval of power train oil 20 Replacement interval of power train oil filter 99 Use Default Value
3.
2.
Selecting sub menu After the "Maintenance Mode On/Off" screen is displayed, select an item to be monitored with t he f u nc t i o n s wi t c h e s or nu m e r a l i np u t switches. q [F1]: Move to next page (screen) q [F2]: Move to previous page (screen) q [F3]: Move to lower item q [F4]: Move to upper item q [F5]: Return to service menu screen q [F6]: Confirm selection a You may enter a 2-digit code with the numeral input switches to select the item of that code and confirm it with [F6].
D65EX, PX, WX-16
Contents of setting of ON/OFF of maintenance mode After selecting "00 Maintenance Mode On/Off", if the screen is displayed, set ON or OFF with the function switches. q ON: Functions of all maintenance items are set effective in operator mode q OFF: Functions of all maintenance items are set ineffective in operator mode q [F3]: Move to lower item q [F4]: Move to upper item q [F5]: Cancel selection and return to Maintenance mode screen q [F6]: Confirm selection and return to Maintenance mode screen a Even if ON/OFF of each item has been set, if the above setting is changed, it is applied.
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103 Testing and adjusting, Part 3 Special functions of machine monitor (EMMS)
SEN05121-02 4.
Contents of setting of each maintenance item After selecting each maintenance item, if the screen is displayed, set the item with the function switches.
q
q
q q q q q
q
a
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Default: Maintenance interval set in machine monitor (Recommended by manufacturer and not changeable). Set: Maintenance interval which can be set freely. Maintenance functions in operator mode operate on basis of this set time (which is increased or decreased by 25 hours). ON: Maintenance function of this item is set effective in operator mode. OFF: Maintenance function of this item is set ineffective in operator mode. [F3]: Select Reduce set value (Upper) or OFF (Lower). [F4]: Select Increase set value (Upper) or ON (Lower). [F5]: Cancel setting before confirmation and return to “Maintenance Mode Change” screen. [F6]: Confirm setting of upper or lower line. After the setting of the upper and lower lines is confirmed with [F6] and the screen chang es to the “ Maintena nce M ode Change” screen with [F5], the setting is effective.
28
5.
Function of “All Default Value” After selecting “99 Use Default Value”, if the screen is displayed, set with the function switches.
a
q q
a
a
If this operation is executed, the set values of all the maintenance items are set to default values. [F5]: Return to “Maintenance Mode Change” screen [F6]: Execute default setting A while after [F6] is pressed, the default setting completion screen is displayed. Then, if the "Maintenance Mode Change" screen is displayed, default setting is completed. The default setting of the corrosion resistor is “OFF”.
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103 Testing and adjusting, Part 3 Special functions of machine monitor (EMMS)
Phone Number Entry The phone No. displayed when the action code/failure code is displayed in the operator mode can be input and changed according to the following procedure. If a phone No. is not input with this function, no phone No. is displayed in the operator mode. 1.
Selecting menu Select "05 Phone Number Entry" on the "Service Menu" screen.
2.
Registering and changing telephone No. After the "Phone Number Entry" screen is displayed, register or change the phone No. q [F2]: Delete all input No. q [F3]: Move to left position (if not blank) q [F4]: Move to right position (if not blank) q [F5]: Delete input digit/Return to service menu q [F6]: Confirm input
a a
SEN05121-02 a
If [F6] is pressed without inputting a digit, there is not information of phone No. Accordingly, no phone No. is displayed in the operator mode.
Up to 14 digits can be input from the left. Input nothing in the surplus positions. If one of the input digits is wrong, move to that digit (and its background changes to orange) and overwrite it with the correct digit.
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103 Testing and adjusting, Part 3 Special functions of machine monitor (EMMS)
SEN05121-02 Default setting (Key-on Mode) Check or change various settings related to the machine monitor and machine by default setting. The function of Key-on Mode is used to set the initial mode displayed on the machine monitor when the starting switch is turned ON. 1.
Selecting menu Select "06 Default" on the "Service Menu" screen.
2.
Selecting sub menu After the "Default" screen is displayed, select "01 Key-on Mode" with the function switches or numeral input switches. a Select this item similarly to an item on the "Service Menu" screen. a This function sets the following 2 mode items (which are the items set with the customize switch in the operator mode). q Operation mode: P/E q Reverse slow mode: ON/OFF
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3.
Selecting mode After the "Key-on Mode" screen is displayed, select the mode to be set with the function switches. q Mode at Previous Key-off: Final mode in previous operation is displayed when starting switch is turned ON q Default Value (ALL OFF): Default setting of all mode items (Operation mode: P, other item: OFF) is displayed when starting switch is turned ON q [F3]: Move to lower item q [F4]: Move to upper item q [F5]: Cancel selection and return to default screen q [F6]: Confirm selection and return to default screen a When the machine is delivered, “Mode at Previous Key-off”.
D65EX, PX, WX-16
103 Testing and adjusting, Part 3 Special functions of machine monitor (EMMS)
Default setting (Selecting of unit) Check or change various settings related to the machine monitor and machine by default setting. The unit selecting function is used to select the unit of the data displayed for monitoring, etc. 1.
Selecting menu Select "06 Default" on the "Service Menu" screen.
2.
Selecting sub menu After the "Default" screen is displayed, select "02 Unit" with the function switches or numeral input switches. a Select this item similarly to an item on the "Service Menu" screen.
D65EX, PX, WX-16
SEN05121-02 3.
Selecting unit After the "Unit" screen is displayed, select the unit to be set with the function switches. q [F3]: Move to lower unit q [F4]: Move to upper unit q [F5]: Cancel selection and return to default screen q [F6]: Confirm selection and return to default screen a When the machine is delivered, the SI unit system is set.
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103 Testing and adjusting, Part 3 Special functions of machine monitor (EMMS)
SEN05121-02 Default setting (Setting of maintenance password) Check or change various settings related to the machine monitor and machine by default setting. The function of setting maintenance password is used to set the display of the password screen when the functions related to the maintenance are used in the operator mode. 1.
Selecting menu Select "06 Default" on the "Service Menu" screen.
2.
Selecting sub menu After the "Default" screen is displayed, select "03 Maintenance Password" with the function switches or numeral input switches. a Select this item similarly to an item on the Service menu screen.
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3.
Selecting Enable/Disable After the "Maintenance Password" screen is displayed, select the setting with the function switches. q Disable: Password screen is not displayed q Enable: Password screen is displayed q [F3]: Move to lower item q [F4]: Move to upper item q [F5]: Cancel selection and return to Initialization screen q [F6]: Confirm selection and return to default screen
4.
Displaying maintenance password screen When the following operation is performed, the password screen is displayed in the operator mode. q The ordinary screen is changed to the maintenance mode (with [F5]) and then the "Maintenance table" screen is changed to the "Maintenance interval reset" screen.
5.
Changing maintenance password The password can be changed by operating the switches specially in the operator mode. a See "Function of changing maintenance password" in the operator mode. a Default password: [000000] a If the password setting is changed from "Enable" to "Disable", the password is reset to the default. a When "Enable" is set again, be sure to set a new password. a The maintenance password is different from the engine start lock password.
D65EX, PX, WX-16
103 Testing and adjusting, Part 3 Special functions of machine monitor (EMMS)
Default setting (Setting of camera) Check or change various settings related to the machine monitor and machine by default setting. The camera setting function is used to set default setting and removal of a camera. 1.
Selecting menu Select "06 Default" on the "Service Menu" screen.
2.
Selecting sub menu After the "Default" screen is displayed, select "04 Camera" with the function switches or numeral input switches. a Select this item similarly to an item on the "Service Menu" screen.
D65EX, PX, WX-16
SEN05121-02 3.
Selecting camera setting After the "Camera" screen is displayed, select the setting with the function switches. q OFF: Camera is not connected q Original image: Image of connected camera is displayed in original position (as in mirror, used as back monitor) q Reverse image: Image of connected camera is displayed in reverse position (as seen directly, used as front or side monitor) q [F3]: Move to left item q [F4]: Move to right item q [F5]: Cancel setting before confirmation and return to “Default” screen q [F6]: Confirm selection in each line a After "Camera" screen is displayed, camera 1 can be always set. When 2 or more cameras are connected, if camera 1 is set, the screen changes to setting of camera 2 automatically. a After confirming the setting of each line with [F6], return to the “Default” screen with [F5], and the setting is effective. a If a camera is connected but not set normally with this function, the graphic mark of camera is not displayed at [F3] in the operator mode. Accordingly, the image of the camera cannot be used. a If 2 or more cameras are connected, be sure to set the use of them from camera 1 in order. a The function of displaying 2 images simultaneously is effective when use of camera 1 and camera 2 is set. a When a camera is installed, check that the displayed image is not inverted horizontally in the operator mode.
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103 Testing and adjusting, Part 3 Special functions of machine monitor (EMMS)
SEN05121-02 Default setting (Setting of ECO display) Check or change various settings related to the machine monitor and machine by initialization. The ECO display setting function is used to set the display of the ECO gauge. 1.
Selecting menu Select "06 Default" on the "Service Menu" screen.
2.
Selecting sub menu After the "Default" screen is displayed, select "05 ECO Display" with the function switches or numeral input switches. a Select this item similarly to an item on the "Service Menu" screen.
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3.
Selecting display setting After the "ECO Display" screen is displayed, select the setting with the function switches. q ON: Display ECO q OFF: Do not display ECO q [F3]: Move to left item q [F4]: Move to right item q [F5]: Cancel selection and return to default screen q [F6]: Confirm selection and return to default screen a If ECO display is turned ON, ECO is displayed when the screen changes to the ordinary screen.
a
Display of ECO gauge (a)
D65EX, PX, WX-16
103 Testing and adjusting, Part 3 Special functions of machine monitor (EMMS)
SEN05121-02 a
Adjustment The operator can adjust various items related to the machine with the machine monitor. When using an adjustment item, select it according to the following procedure. 1.
Selecting menu Select "07 Adjustment" on the "Service Menu" screen.
3.
2.
If the input adjustment ID is incorrect, the message of "No ready Adjustment" is displayed and the ID input screen does not change (Another ID can be input again with the numeral input switches while this screen is displayed).
Selecting adjustment item After the "Adjustment" screen is displayed, input the 4-digit adjustment ID of the adjustment item to be used with the numeral input switches. q [F5]: Cancel adjustment and return to “Service menu” screen q [F6]: Confirm input adjustment ID and go to “Adjustment” screen a For the adjustment ID's and their adjustment items, see the “Adjustment items table”.
D65EX, PX, WX-16
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. 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] – [F6] depend on the adjustment item. a For the method of operating each adjustment item, see the explanation of its adjustment ID.
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103 Testing and adjusting, Part 3 Special functions of machine monitor (EMMS)
SEN05121-02 Adjustment items table Adjustment ID
Adjustment item
Remarks
0002
Power train controller initialization
0004
Work equipment specification setting
0005
Brake pedal potentiometer initial correction
0007
Engine decelerator cutting
0009
Pitch angle sensor initial correction
0010
Fan 70% mode
0530
Stall mode
0910
Load record check mode
1005
Fan 100% mode
1012
Steering lever neutral position adjustment
1013
Steering lever leftmost position adjustment
1014
Steering lever rightmost position adjustment
2021
Power train controller voltage check mode
2222
HSS min. current setting mode
6001
R1 reverse slow set speed
Fine adjustment of reverse slow mode
6002
R2 reverse slow set speed
Fine adjustment of reverse slow mode
6003
R3 reverse slow set speed
Fine adjustment of reverse slow mode
7842
Transmission clutch IP and fill time automatic initial correction
7843
Transmission clutch IP manual initial correction
7845
Transmission clutch IP learning display
7847
Transmission clutch fill time manual initial correction
9997
High idle cut mode
9998
Max. gear speed setting mode
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Recommended mode of torque converter stall
D65EX, PX, WX-16
103 Testing and adjusting, Part 3 Special functions of machine monitor (EMMS)
Adjustment ID: 0002 (Power train controller initialization)
q
a
This adjustment code is used to initialize the specification code recognized by the power train controller and the set values of the memory in the controller. After the power train controller is replaced, be sure to carry out this adjustment once.
q
Functions of function switches [F3]: Unused [F4]: Unused [F5]: Return to adjustment item selecting screen (ID inputting screen) [F6]: Save setting
q
Operating method: 1) Press [F6] and check that the alarm buzzer sounds. 2) Check that the displayed specification code [CODE] has changed from [5x5] to [555]. a If specification code [555] is not displayed, the controller unit may be defective. a Even if this adjustment code is turned off, the setting is effective.
SEN05121-02 Adjustment ID: 0004 (Work equipment specification setting)
q
a
This adjustment code is used to make the work equipment controller recognize the type of the work equipment. After the power train controller is replaced, be sure to carry out this adjustment once.
q
Functions of function switches [F3]: Increase specification value [CODE] [F4]: Decrease specification value [CODE] [F5]: Return to adjustment item selecting screen (ID inputting screen) [F6]: Save setting
q
Operating method: 1) Press [F3] or [F4] to select the specification value [CODE] of the work equipment concerned.
2) k
a
D65EX, PX, WX-16
CODE
Type of work equipment
0
Standard dozer (including PAT dozer)
2
Power pitch dozer
Press [F6] and check that the alarm buzzer sounds. If the specification of the work equipment is different from the setting in the controller, the work equipment may move unexpectedly or an error may be made. Accordingly, be sure to match the controller to the work equipment. Even if this adjustment code is turned off, the setting is effective.
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103 Testing and adjusting, Part 3 Special functions of machine monitor (EMMS)
SEN05121-02 Adjustment ID: 0005 (Brake pedal potentiometer initial correction)
q
a
q
q
This adjustment code is used to make the power train controller recognize the zero point of the brake pedal potentiometer. After the power train controller or brake pedal potentiometer is replaced or the brake pedal linkage is disconnected and connected, be sure to carry out this adjustment once. Functions of function switches [F3]: Unused [F4]: Unused [F5]: Return to adjustment item selecting screen (ID inputting screen) [F6]: Save corrected value Operating method: 1) Check that the brake pedal is in the neutral position (it is not pressed at all) and keep it in that position. 2) Press [F6] and check that the alarm buzzer sounds. a Even if the adjustment is carried out, the displayed value does not change. a Even if this adjustment code is turned off, the correction is effective. a This adjustment code is used to make the controller recognize the zero point of the potentiometer. It is not used to adjust the braking force.
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Adjustment ID: 0007 (Engine decelerator cutting)
q
a
a
This adjustment code is used to stop the autodeceleration function of the engine and check the high idle speed of the engine unit. Since this machine does not use the autodeceleration function in neutral, the high idle speed can be checked without using this adjustment code. Use this adjustment code for testing, adjusting, or troubleshooting when necessary.
q
Functions of function switches [F3]: Unused [F4]: Unused [F5]: Return to adjustment item selecting screen (ID inputting screen) [F6]: Unused
q
Operating method: When this adjustment code is displayed, its function is effective and the auto-deceleration function is stopped. a After this adjustment code is turned OFF, its function is ineffective.
D65EX, PX, WX-16
103 Testing and adjusting, Part 3 Special functions of machine monitor (EMMS)
Adjustment ID: 0009 (Pitch angle sensor initial correction)
q
a
q
q
This adjustment code is used to make the power train controller recognize the zero point of the pitch angle sensor and to correct the installation error. After the power train controller is replaced or the pitch angle sensor is removed and installed or replaced, be sure to carry out this adjustment once. Functions of function switches [F3]: Unused [F4]: Unused [F5]: Return to adjustment item selecting screen (ID inputting screen) [F6]: Save corrected value Operating method: 1) Check that the machine is level. 2) Press [F6] and check that the alarm buzzer sounds. a If adjustment is carried out, displayed item [BODY PITCH ANGLE] changes to [0.0°] (The other displayed items do not change). a Even if this adjustment code is turned off, the correction is effective.
D65EX, PX, WX-16
SEN05121-02 Adjustment ID: 0010 (Fan 70% mode)
q
a
This adjustment code is used to set the cooling fan speed to about 70% forcibly. Use this adjustment code for testing, adjusting, or troubleshooting when necessary.
q
Functions of function switches [F3]: Increase adjustment value [FAN 70% SPEED MODE] [F4]: Decrease adjustment value [FAN 70% SPEED MODE] [F5]: Return to adjustment item selecting screen (ID inputting screen) [F6]: Unused
q
Operating method: When this adjustment code is displayed, its function is effective and the cooling fan speed is controlled to about 70% of the maximum speed. a Since [FAN SPEED] of this adjustment code is different from the actual fan speed, see Testing and adjusting, "Testing fan speed", for the fan speed testing method. a After this adjustment code is turned OFF, its function is ineffective.
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103 Testing and adjusting, Part 3 Special functions of machine monitor (EMMS)
SEN05121-02 Adjustment ID: 0530 (Stall mode)
a
a
q
This adjustment code is used to set the fan speed in the 100% mode automatically and make it possible to set the preset (gear speed at start) to [F3-R3] to stall the torque converter. a The preset (gear speed at start) can be set to [F3-R3] only while this adjustment code is selected. a Use this adjustment code for testing, adjusting, or troubleshooting when necessary.
q
Functions of function switches [F3]: Unused [F4]: Unused [F5]: Return to adjustment item selecting screen (ID inputting screen) [F6]: Unused
q
Mode setting information within screen [P-AUTO SFT MODE]: Automatic gearshift in P mode [E-AUTO SFT MODE]: Automatic gearshift in E mode [P-MANUAL SFT MODE]: Manual gearshift in P mode [E-MANUAL SFT MODE]: Manual gearshift in E mode
q
Operating method: When this adjustment code is displayed, its function is effective and the preset (gear speed at start) is set to [F3-R3]. k
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When using this adjustment code, keep the hydraulic oil temperature above 50°C. (If the hydraulic oil temperature lowers below 40°C, the fan speed fluctuates.) After this adjustment code is turned OFF, its function is ineffective.
This adjustment code does not stall the t o r q u e c o n v e r t e r a u t o m a t i c a l l y. Accordingly, operate the levers and pedals securely when stalling the torque converter (For the procedure for stalling the torque converter, see "Measuring engine speed").
40
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103 Testing and adjusting, Part 3 Special functions of machine monitor (EMMS)
Adjustment ID: 0910 (Load record check mode)
q
a
q
q
q
This adjustment code is used to check the load on the machine, odometer, and reverse odometer. Use this adjustment code for testing, adjusting, or troubleshooting when necessary. Functions of function switches [F3]: Unused [F4]: Unused [F5]: Return to adjustment item selecting screen (ID inputting screen) [F6]: Unused Mode setting information within screen [1000 rpm SMR]: Time displayed by service meter in which engine speed was above 1,000 rpm [ODO METER FORWARD]: Total forward travel distance [ODO METER REVERSE]: Total reverse travel distance Operating method: When this adjustment code is displayed, its function is effective and the load on the machine, odometer, and reverse odometer are displayed simultaneously. a The data cannot be reset. a After this adjustment code is turned OFF, its function is ineffective.
D65EX, PX, WX-16
SEN05121-02 Adjustment ID: 1005 (Fan 100% mode)
q
a
This adjustment code is used to set the cooling fan speed to about 100% forcibly. It is also used to set the adjustment value of the maximum speed. Use this adjustment code for testing, adjusting, or troubleshooting when necessary.
q
Functions of function switches [F3]: Increase adjustment value [FAN 100% SPEED MODE] [F4]: Decrease adjustment value [FAN 100% SPEED MODE] [F5]: Return to adjustment item selecting screen (ID inputting screen) [F6]: Save adjustment value
q
Operating method: a When this adjustment code is displayed, its function is effective and the cooling fan speed is controlled to about 100% of the maximum speed. 1) Increase or decrease the adjustment value by pressing [F3] or [F4]. 2) When confirming the adjustment value, press [F6] and check that the alarm buzzer sounds. a Since [FAN SPEED] of this adjustment code is different from the actual fan speed, see Testing and adjusting, "Testing fan speed", for the fan speed testing method. a When using this adjustment code, keep the hydraulic oil temperature above 50°C. (If the hydraulic oil temperature lowers below 40°C, the fan speed fluctuates.) a After this adjustment code is turned OFF, its function is ineffective but the set adjustment value is effective.
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103 Testing and adjusting, Part 3 Special functions of machine monitor (EMMS)
SEN05121-02 Adjustment ID: 1012 (Steering lever neutral position adjustment)
Adjustment ID: 1013 (Steering lever leftmost position adjustment)
This adjustment code is used to make the power train controller recognize the neutral position of the steering potentiometer of the PCCS lever. After the power train controller or PCCS lever is replaced, be sure to carry out this adjustment once.
q
q
Functions of function switches [F3]: Unused [F4]: Unused [F5]: Return to adjustment item selecting screen (ID inputting screen) [F6]: Save adjustment value
q
Functions of function switches [F3]: Unused [F4]: Unused [F5]: Return to adjustment item selecting screen (ID inputting screen) [F6]: Save adjustment value
q
Operating method: 1) Check that the PCCS lever is in the neutral position of the steering direction and keep it in that position. 2) Press [F6] and check that the alarm buzzer sounds. a Even if this adjustment code is turned off, the adjustment is effective. a This adjustment code is used to make the controller recognize the neutral position of the potentiometer. It is not used to adjust the steering force.
q
Operating method: 1) Operate the PCCS lever to the left stroke end of the steering direction and keep it in that position. 2) Press [F6] and check that the alarm buzzer sounds. a Even if this adjustment code is turned off, the adjustment is effective. a This adjustment code is used to make the controller recognize the leftmost position of the potentiometer. It is not used to adjust the steering force.
q
a
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a
This adjustment code is used to make the power train controller recognize the leftmost position of the steering potentiometer of the PCCS lever. After the power train controller or PCCS lever is replaced, be sure to carry out this adjustment once.
D65EX, PX, WX-16
103 Testing and adjusting, Part 3 Special functions of machine monitor (EMMS)
Adjustment ID: 1014 (Steering lever rightmost position adjustment)
q
a
This adjustment code is used to make the power train controller recognize the rightmost position of the steering potentiometer of the PCCS lever. After the power train controller or PCCS lever is replaced, be sure to carry out this adjustment once.
q
Functions of function switches [F3]: Unused [F4]: Unused [F5]: Return to adjustment item selecting screen (ID inputting screen) [F6]: Save adjustment value
q
Operating method: 1) Operate the PCCS lever to the right stroke end of the steering direction and keep it in that position. 2) Press [F6] and check that the alarm buzzer sounds. a Even if this adjustment code is turned off, the adjustment is effective. a This adjustment code is used to make the controller recognize the rightmost position of the potentiometer. It is not used to adjust the steering force.
D65EX, PX, WX-16
SEN05121-02 Adjustment ID: 2021 (Power train controller voltage check mode)
q
a
This adjustment code is used to check the constant power supply voltage and switch power supply voltage applied to the power train controller. Use this adjustment code for testing, adjusting, or troubleshooting when necessary.
q
Functions of function switches [F3]: Unused [F4]: Unused [F5]: Return to adjustment item selecting screen (ID inputting screen) [F6]: Unused
q
Information displayed on screen [PT CONTROLLER UNSWITCH POWER]: Constant power supply voltage [PT CONTROLLER ACC POWER]: Switch power supply voltage
q
Operating method: When this adjustment code is displayed, its function is effective and the constant power supply voltage and switch power supply voltage are displayed simultaneously. a After this adjustment code is turned OFF, its function is ineffective.
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103 Testing and adjusting, Part 3 Special functions of machine monitor (EMMS)
SEN05121-02 a
Adjustment ID: 2222 (HSS min. current setting mode)
q
a
This adjustment code is used to adjust the turning radius to start steering the machine when the steering feel is different by the steering direction. Use this adjustment code for work when necessary.
q
Functions of function switches [F3]: Unused [F4]: Unused [F5]: Return to adjustment item selecting screen (ID inputting screen) [F6]: Save adjustment value
q
Operating method 1) Set the parking brake lever in the free position. 2) Tilt the PCCS lever to a right or left position at which the current to be set is indicated and hold it at that position. q If the lever is tilted to the left, the current becomes negative. q If the lever is tilted to the right, the current becomes positive. 3) Press [F6] and check that the alarm buzzer sounds. 4) Set the PCCS lever in neutral and depress [F6], and the values are set to the initial setting at the delivery time. a The current (mA) varies in the range from -395 (left end) to 395 (right end). a As the set current is increased in the positive or negative direction, the turning radius to start steering is reduced more (the machine is steered more quickly). a It is not necessary to steer the machine during adjustment. After finishing adjustment, however, steer the machine and check that there is not a problem in the actual steering feel.
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a
The following figure shows an example of reducing the set current for the left steering to increase the turning radius.
Even if this adjustment code is turned off, the adjustment is effective.
D65EX, PX, WX-16
103 Testing and adjusting, Part 3 Special functions of machine monitor (EMMS)
Adjustment ID: 6001 (R1 reverse slow set speed)
SEN05121-02 Adjustment ID: 6002 (R2 reverse slow set speed)
This adjustment code is used to adjust the engine speed applied to travel at gear speed R1 with the reverse slow mode ON. Use this adjustment code for work when necessary.
q
q
Functions of function switches [F3]: Increase adjustment value [F4]: Decrease adjustment value [F5]: Return to adjustment item selecting screen (ID inputting screen) [F6]: Save adjustment value
q
Functions of function switches [F3]: Increase adjustment value [F4]: Decrease adjustment value [F5]: Return to adjustment item selecting screen (ID inputting screen) [F6]: Save adjustment value
q
Information displayed on screen The speed reduced from the high idle speed (2,100 rpm) is displayed and the adjustment value is increased or decreased by 50 rpm a The adjustment value at the time of the factory shipment is 300 rpm. (Setting at factory shipment: 2,100 – 300 = 1,800 rpm)
q
Information displayed on screen The speed reduced from the high idle speed (2,100 rpm) is displayed and the adjustment value is increased or decreased by 50 rpm a The adjustment value at the time of the factory shipment is 300 rpm. (Setting at factory shipment: 2,100 – 300 = 1,800 rpm)
q
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 the engine speed has been adjusted, it is displayed. It can be adjusted again within the adjustment range, however. a It is not necessary to drive the machine during adjustment. After finishing adjustment, however, drive the machine at R1 with the reverse slow mode ON and check that there is not a problem in the actual travel speed. a Even if this adjustment code is turned off, the adjustment is effective.
q
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 the engine speed has been adjusted, it is displayed. It can be adjusted again within the adjustment range, however. a It is not necessary to drive the machine during adjustment. After finishing adjustment, however, drive the machine at R2 with the reverse slow mode ON and check that there is not a problem in the actual travel speed. a Even if this adjustment code is turned off, the adjustment is effective.
q
a
D65EX, PX, WX-16
a
This adjustment code is used to adjust the engine speed applied to travel at gear speed R2 with the reverse slow mode ON. Use this adjustment code for work when necessary.
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103 Testing and adjusting, Part 3 Special functions of machine monitor (EMMS)
SEN05121-02 Adjustment ID: 6003 (R3 reverse slow set speed)
q
a
q
q
q
This adjustment code is used to adjust the engine speed applied to travel at gear speed R3 with the reverse slow mode ON. Use this adjustment code for work when necessary. Functions of function switches [F3]: Increase adjustment value [F4]: Decrease adjustment value [F5]: Return to adjustment item selecting screen (ID inputting screen) [F6]: Save adjustment value Information displayed on screen The speed reduced from the high idle speed (2,100 rpm) is displayed and the adjustment value is increased or decreased by 50 rpm a The adjustment value at the time of the factory shipment is 300 rpm. (Setting at factory shipment: 2,100 – 300 = 1,800 rpm) 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 the engine speed has been adjusted, it is displayed. It can be adjusted again within the adjustment range, however. a It is not necessary to drive the machine during adjustment. After finishing adjustment, however, drive the machine at R3 with the reverse slow mode ON and check that there is not a problem in the actual travel speed. a Even if this adjustment code is turned off, the adjustment is effective.
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Adjustment ID: 7842 (Transmission clutch IP and fill time automatic initial correction)
q
a
This adjustment code is used to make the power train controller recognize the mechanical condition of the transmission. After the power train controller or transmission is replaced, be sure to carry out this adjustment once.
q
Functions of function switches [F3]: Unused [F4]: Unused [F5]: Return to adjustment item selecting screen (ID inputting screen) [F6]: Save adjustment value
q
Conditions for correction work 1) [ENGINE SPEED]: 1,800 – 2,100 rpm 2) [T/C TEMPERATURE]: 65 – 85°C 3) Parking brake lever: LOCK position 4) PCCS lever: NEUTRAL position a When using this adjustment code, keep the abo ve c ond iti ons ( In pa rti c ula r, increase the power train oil temperature sufficiently before starting adjustment).
q
Operating method: 1) Start the engine and keep its speed in the specified range of condition with the fuel control dial. 2) Press [F6] and start the correction work and check that [I/P AUTO CHECK F CLUTCH] is displayed newly on the screen. 3) If [End of teaching. Press F6] is displayed on the screen, press [F6]. If the alarm buzzer sounds at this time, correction work is completed. a The machine does not move during the correction work. a Even if this adjustment code is turned off, the correction is effective.
D65EX, PX, WX-16
103 Testing and adjusting, Part 3 Special functions of machine monitor (EMMS)
Adjustment ID: 7843 (Transmission clutch IP manual initial correction)
q
a
q
This adjustment code is used to carry out correction manually when the correction is not carried out normally by the operation of IP automatic correction (Adjustment ID: 7842). Use this adjustment code after the IP correction work, if necessary. Functions of function switches [F3]: Increase adjustment value [F4]: Decrease adjustment value [F5]: Return to adjustment item selecting screen (ID inputting screen) [F6]: Save adjustment value a If [F2] is pressed while [F1] is pressed, all the correction values are set to 0.
q
Functions of shift-up and shift-down switches You can select a clutch to be corrected manually with the shift-up and shift-down switches.
q
Conditions for correction work Same as the conditions for IP automatic correction (Adjustment ID: 7842).
q
Operating method: 1) Start the engine and keep its speed in the specified range of condition with the fuel control dial. 2) Select a clutch to be corrected manually with the shift-up or shift-down switches. 3) Increase or decrease the adjustment value by pressing [F3] or [F4]. 4) Press [F6] and check that the alarm buzzer sounds. a The machine does not move during the correction work. a Even if this adjustment code is turned off, the correction is effective.
D65EX, PX, WX-16
SEN05121-02 Adjustment ID: 7845 (Transmission clutch IP learning display)
q
a
This adjustment code is used to check the information of correction made by the operation of IP automatic correction (Adjustment ID: 7842) or IP manual correction (Adjustment ID: 7843). Use this adjustment code for testing, adjusting, or troubleshooting when necessary.
q
Functions of function switches [F3]: Change display [F4]: Change display [F5]: Return to adjustment item selecting screen (ID inputting screen) [F6]: Unused
q
Operating method When this adjustment code is displayed, its function is effective and the correction information is displayed. a After this adjustment code is turned OFF, its function is ineffective.
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103 Testing and adjusting, Part 3 Special functions of machine monitor (EMMS)
SEN05121-02 Adjustment ID: 7847 (Transmission clutch fill time manual initial correction)
q
a
q
q
a
q
q
This adjustment code is used to carry out correction manually when the correction is not carried out normally by the operation of fill time automatic correction (Adjustment ID: 7842). Use this adjustment code after the fill time correction work, if necessary. Functions of function switches [F3]: Increase adjustment value [F4]: Decrease adjustment value [F5]: Return to adjustment item selecting screen (ID inputting screen) [F6]: Save adjustment value a If [F2] is pressed while [F1] is pressed, all the correction values are set to 0. Functions of shift-up and shift-down switches You can select a clutch to be corrected manually with the shift-up and shift-down switches. The value displayed when the clutch is selected is correction information set automatically or manually before. Conditions for correction work Same as the conditions for fill time automatic correction (Adjustment ID: 7842).
Adjustment ID: 9997 (High idle cut mode)
q
a
This adjustment code is used to limit the high idle speed. Use this adjustment code for work when necessary.
q
Functions of function switches [F3]: Increase adjustment value [HI IDLE RPM SET MODE] [F4]: Decrease adjustment value [HI IDLE RPM SET MODE] [F5]: Return to adjustment item selecting screen (ID inputting screen) [F6]: Save adjustment value
q
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 high idle speed, set the adjustment value which is the initial setting at factory shipment to the original high idle speed (2,100 rpm). a Even if this adjustment code is turned off, the adjustment is effective.
Operating method: 1) Start the engine and keep its speed in the specified range of condition with the fuel control dial. 2) Select a clutch to be corrected manually with the shift-up or shift-down switches. 3) Increase or decrease the adjustment value by pressing [F3] or [F4]. 4) Press [F6] and check that the alarm buzzer sounds. a The machine does not move during the correction work. a Even if this adjustment code is turned off, the correction is effective.
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103 Testing and adjusting, Part 3 Special functions of machine monitor (EMMS)
Adjustment ID: 9998 (Max. gear speed setting mode)
q q
a
SEN05121-02 Pm Clinic The machine monitor can check the condition of the machine without connecting testing tools to assist the Pm Clinic and other periodic inspections. 1.
Selecting menu Select "08 PM CLINIC" on the Service menu screen.
2.
Information displayed on Pm Clinic screen The Pm Clinic function displays the following information on 2 pages. q 1st screen
This adjustment code is used to limit the maximum transmission gear speed. The limited gear speed is applied in both automatic gearshift mode and manual gearshift mode. Use this adjustment code for work when necessary.
q
Functions of function switches [F3]: Increase adjustment value [MAX SHIFT] [F4]: Decrease adjustment value [MAX SHIFT] [F5]: Return to adjustment item selecting screen (ID inputting screen) [F6]: Save adjustment value
q
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 maximum gear speed limit, set the adjustment value to the maximum gear speed (3RD) that is the initial set value at delivery. a The setting with this adjustment code becomes effective after the starting switch is turned to the OFF position and turned to the ON position again.
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103 Testing and adjusting, Part 3 Special functions of machine monitor (EMMS)
SEN05121-02 q
q q q q q
3.
2nd screen
Cylinder Cut-Out operation The operator can perform Cylinder Cut-Out operation with the machine monitor. Cylinder cut-out operation means to run the engine with 1 or more fuel injectors disabled electrically to reduce the number of effective cylinders. This operation is used to find out a cylinder which does not output power normally (combustion in it is abnormal). 1.
Selecting menu Select "09 Cylinder Cut-Out" on the "Service Menu" screen.
2.
Selecting cylinder to be disabled After the "Cylinder Cut-Out" screen is displayed, select a cylinder to be disabled with the function switches. q [F1]: Move selection mark (R) to left q [F2]: Move selection mark (R) to right q [F3]: Reset holding q [F4]: Hold q [F5]: Return to service menu screen q [F6]: Confirm selection a This operation may be performed while the engine is running. a When [F6] is pressed, if background (a) of the selected cylinder No. becomes white, the cylinder is disabled. a If the machine monitor disables a cylinder but the engine controller cannot disable that cylinder, the background of the cylinder No. becomes yellow. a One or more cylinders can be disabled.
[F1]: Change screen [F2]: Change screen [F3]: Reset holding [F4]: Hold (displayed data) [F5]: Return to service menu screen
Holding displayed information The displayed information can be held and released with [F3] and [F4].
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3.
4.
Resetting disabled cylinder When changing a cylinder to be disabled or when cylinder cut-out operation is finished, select a disabled cylinder to be reset with the function switches. a This operation may be performed while the engine is running. a When [F6] is pressed, if background (a) of the selected cylinder No. becomes light blue, the cylinder is reset. a If the machine monitor resets a cut-out cylinder but the engine controller cannot reset that cut-out cylinder, the background (a) of the cylinder No. becomes red. a The cylinder cut-out operation is not automatically reset after the screen returns to the operator mode. Accordingly, be sure to perform the resetting operation after the cylinder cut-out operation is finished. Function of holding displayed information If [F4] is pressed during the reduced cylinder mode operation, the displayed information is newly held (b) (The real-time information is kept displayed on the left side). a While the information is held, if [F3] is pressed, the holding function is reset. a The holding function is effective, regardless of setting of the cylinder cut-out operation.
SEN05121-02 Display of No Injection 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 function to lubricate the engine before starting it by cranking it without injecting fuel is installed. Set the No Injection while the engine is stopped. 1.
Selecting menu Select "10 No Injection" on the "Service Menu" screen.
2.
Preparation for no injection cranking When the “No injection” screen is displayed, the machine monitor checks automatically if no injection cranking can be performed. If no injection cranking can be performed, the screen changes to the next screen automatically. a If no injection cranking cannot be performed because the engine is running or the communication is abnormal, the screen does not change from the following screen. In this case, depress [F5] to return to the "Service Menu" screen and solve the problem.
[Reference] q If a normally operating cylinder is disabled, the following phenomena occur. 1) Lowering of engine speed 2) Increase of final injection rate command (quantity) q If the engine is running near the high idle, however, the engine speed may not lower for the reason of engine control. q In this case, lower the engine speed with the fuel control dial and judge by increase of the injection rate command.
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103 Testing and adjusting, Part 3 Special functions of machine monitor (EMMS)
SEN05121-02 3.
Display of confirmation screen The confirmation screen for no injection cranking is displayed. Select with the function switch. q [F5]: Do not perform (Return to Service menu screen) q [F6]: Perform
4.
Starting no injection cranking If no injection cranking (Fuel injection in no cylinders) becomes effective, that 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 "Being prepared" is displayed. a Limit the cranking time to 20 seconds to protect the starting motor.
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5.
Finishing no injection cranking After completing the no injection cranking operation, press [F6], and finish of no injection cranking is displayed and the screen returns to the "2. Preparation of No Injection cranking" screen automatically.
6.
Prohibiting no injection cranking If the operator tries to perform the no injection cranking while the engine is running, the message that the engine is running is displayed and the no injection cranking is not set effective. a Depress [F5] to return to the "Service Menu" screen, stop the engine, and select no injection cranking again.
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103 Testing and adjusting, Part 3 Special functions of machine monitor (EMMS)
Display of Fuel Consumption This function calculates the hourly fuel consumption from the actual fuel consumption in a measuring period and indicates it. 1.
Selecting menu Select "11 Fuel Consumption" on the "Service Menu" screen.
2.
Starting measurement After the screen of "Fuel Consumption" is displayed, start measurement with the function switches. q [F1]: Start q [F2]: Clear q [F5]: Return to “Service Menu” screen a When the screen of "Fuel Consumption" is displayed, if a data is indicated, it is the data of the previous measurement. This data is not an obstacle to new measurement and can be deleted by pressing [F2]. a If [F1] is pressed, the data is displayed on the starting date and time side and measurement starts. a The display unit of the fuel changes according to the unit set with the initialization (unit setting) function. SI and meter: l/h, inch: gal/h
D65EX, PX, WX-16
SEN05121-02 3.
Display and function during measurement Clock mark (a) flashes during measurement. a While the fuel consumption is being measured, the operator can work with the operator mode and other functions. Measurement is not finished until this screen is displayed again and [F1] is pressed (Even if the starting switch is turned OFF, this function is kept effective, although fuel consumption is measured only while the engine is running).
4.
Finishing measurement Press [F1], and measurement is finished and the data are displayed on the finishing date and time side.
5.
Displaying fuel consumption If the measurement is finished, the hourly fuel consumption calculated from the fuel consumption calculated by the engine controller and the elapsed time are displayed.
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103 Testing and adjusting, Part 3 Special functions of machine monitor (EMMS)
SEN05121-02 Display of KOMTRAX Settings (Terminal Status) The setting condition and operating condition of KOMTRAX can be checked with "KOMTRAX Settings". Terminal Status is used to check the setting condition of the KOMTRAX terminal. 1.
Selecting menu Select "12 KOMTRAX Settings" on the "Service Menu" screen.
2.
Selecting sub menu After the "KOMTRAX Settings" screen is displayed, select "01 Terminal Status" with the function switches or numeral input switches. a Select this item similarly to an item on the "Service Menu" screen.
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3.
Contents of Terminal Status On the "Terminal Status" screen, the following items are displayed. q Terminal Type: model name of KOMTRAX communication modem q KOMTRAX communication: Executing condition of KOMTRAX communication q GMT time: Greenwich Meant Time (+ 9 hours in Japan) q [F5]: Return to “KOMTRAX Settings” screen
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103 Testing and adjusting, Part 3 Special functions of machine monitor (EMMS)
Display of KOMTRAX Settings (GPS & Communication Status) The setting condition and operating condition of KOMTRAX can be checked with KOMTRAX Settings. Condition of positioning and communication is used to check the condition of positioning and communication of the KOMTRAX terminal. 1.
Selecting menu Select "12 KOMTRAX Settings" on the "Service Menu" screen.
2.
Selecting sub menu After the display of "KOMTRAX Settings" screen is displayed, select "02 GPS & Communication Status" with the function switches or numeral input switches. a Select this item similarly to an item on the "Service Menu" screen.
D65EX, PX, WX-16
SEN05121-02 3.
Contents of display of condition of positioning and communication On the screen of "GPS & Communication Status", the following items are displayed. q Positioning: Positioning condition of GPS q Communication: Communication environment of communication modem and connecting condition of c ommunication modem q Number of message not yet sent: Number of mails in machine monitor not yet sent q [F5]: Return to “KOMTRAX Settings” screen
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103 Testing and adjusting, Part 3 Special functions of machine monitor (EMMS)
SEN05121-02 Display of KOMTRAX Settings (Modem S/N) The setting condition and operating condition of KOMTRAX can be checked with “KOMTRAX Settings”. Modem S/N is used to check the serial No. of the KOMTRAX communication modem. 1.
Selecting menu Select "12 KOMTRAX Settings" on the "Service Menu" screen.
2.
Selecting sub menu After the display of "KOMTRAX Settings" screen is displayed, select "03 Modem S/N" with the function switches or numeral input switches. a Select this item similarly to an item on the "Service Menu" screen.
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3.
Contents of display of modem S/N The serial No. of KOMTRAX communication modem is displayed. q [F5]: Return to “KOMTRAX Settings” screen
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103 Testing and adjusting, Part 3 Special functions of machine monitor (EMMS)
Display of Service Message Special messages for the serviceman sent from the KOMTRAX base station (a distributor, etc.) can be checked with this function. If there is setting in a message, a return mail can be sent by using numeral input switches. 1.
Operation to display menu Select "13 Service Message" on the "Service Menu" screen.
2.
Display of message (Read-only) If there is a message, its contents are displayed. If there is not a message, "No message" is displayed. q [F5]: Return to service menu screen a This message is different from a message transmitted to the operator in the operator mode. a Since this message is special for the serviceman, the message monitor is not displayed when it is received as in the operator mode.
D65EX, PX, WX-16
SEN05121-02 3.
Display of message (with return mail function) If a box to enter a value with the numeral keys is displayed under the message, enter a proper number with the numeral input switches and function switches and confirm it, and the information is returned to the KOMTRAX base station. q [F5]: Return to service menu screen q [F6]: Confirm and return input value a This message is different from a message transmitted to the operator in the operator mode. a Since this message is special for the serviceman, the message monitor is not displayed when it is received as in the operator mode.
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SEN05121-02
D65EX, PX, WX-16 Bulldozer Form No. SEN05121-02
©2010 KOMATSU All Rights Reserved Printed in Japan 02-10 (01)
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SEN05122-01
BULLDOZER D65EX-16 D65PX-16 D65WX-16 Machine model D65EX-16 D65PX-16 D65WX-16
Serial number 80001 and up 80001 and up 80001 and up
30 Testing and adjusting
30
104 Testing and adjusting, Part 4 Handling of voltage circuit of engine controller ............................................................................................... 2 Adjustment method when controller has been replaced ................................................................................. 3 Preparation work for troubleshooting of electrical system .............................................................................. 5 Inspection procedure of diode......................................................................................................................... 9 Pm-Clinic service .......................................................................................................................................... 10
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104 Testing and adjusting, Part 4 Handling of voltage circuit of engine controller
SEN05122-01
Handling of voltage circuit of engine controller
1
1.
When disconnecting or connecting a connector between engine controller and engine, be sure to turn off the starting switch. k Before connecting the harness connector, be sure to completely remove sand, dust, water, etc., from inside of controller side connector.
2.
Do not start the engine with T-adapter inserted in or connected to a connector between engine controller and engine for troubleshooting. a You may turn the starting switch to the OFF or ON position but must not turn it to the START position.
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104 Testing and adjusting, Part 4 Adjustment method when controller has been replaced
Adjustment method when controller has been replaced a k
a
a
1.
SEN05122-01 2.
Adjusting power train controller Select “power train controller initialization (0002)” and adjust the power train controller.
3.
Turning power on again Turn the starting switch OFF then ON, and set the machine monitor in the “07 Adjustment” of the service mode again.
4.
Adjusting work equipment specification Select “work equipment specification setting (0004)” and adjust the machine specification.
5.
Adjusting brake pedal potentiometer Select “brake pedal potentiometer initial correction (0005)” and adjust the brake potentiometer.
1
After the machine is assembled or power train controller is replaced, adjust the system according to the following procedure. If the system is not adjusted, the machine may not operate normally and may move suddenly. Accordingly, be sure to adjust it. Precautions for replacing a controller: If a controller is replaced, the following adjustment values are reset to the initial set values at factory shipment. Accordingly, take a record of the set values before replacement, if necessary. q Load record check mode: (0910) q Fan 100% mode (1005) q HSS min. current setting mode (2222) q R1 reverse slow set speed (6001) q R2 reverse slow set speed (6002) q R3 reverse slow set speed (6003) q High idle cut mode (9997) q Max. gear speed setting mode (9998) Precautions for replacing a controller: When replacing a controller, stop the machine in a safe place and turn the starting switch off. Setting system in service mode. Turn the starting switch ON and set the machine monitor in the “07 Adjustment” of the service mode.
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104 Testing and adjusting, Part 4 Adjustment method when controller has been replaced
SEN05122-01 6.
Adjusting pitch angle sensor Select “pitch angle sensor initial correction (0009)” and adjust the pitch angle sensor.
7.
Adjustment of steering lever neutral position Select “steering lever neutral position adjustment (1012)” and perform adjustment.
8.
Adjustment of steering lever left maximum position Select “steering lever leftmost position adjustment (1013)” and perform adjustment.
9.
Adjustment of steering lever right maximum position Select “steering lever rightmost position adjustment (1014)” and perform adjustment.
10. Adjustment of transmission clutch IP and fill time Select “transmission clutch IP and fill time automatic initial correction (7842)” and perform adjustment.
11. Turning on power again Turn the starting switch to the OFF position and to the ON position again. 12. Confirmation of failure code 1) Set the machine monitor to “Abnormality Record” in the service mode. 2) Check for a failure code occurring currently. If no failure code is occurring currently, delete all the recorded failure codes. a If any failure code is occurring currently, remove the cause of the trouble by troubleshooting, and then perform steps 11 and 12 again. a Precautions after replacing controller Re-set the adjustment values recorded before replacing the controller, if necessary.
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Preparation work for troubleshooting of electrical system
SEN05122-01 a
1
a
When carrying out troubleshooting of an electric circuit related to the machine monitor, engine controller, or power train controller, expose the related connectors according to the following procedure.
1.
Machine monitor 1) Remove cover (1). 2) Remove the mounting bolts (2) and remove cover (3). 2.
3)
Engine controller 1) Open the left engine side cover (1) and remove lower cover (2).
Remove the mounting bolts (4) of machine monitor (5) bracket and pull out machine monitor (5) and switch together toward the operator's seat. 2)
4)
If a camera is installed, CM05 is also wired.
Insert or connect troubleshooting T-adapters in or to connectors (4) (ECM), (5) (CE02) and (6) (CE03) of engine controller (3). a Since connectors ECM and CE02 are fixed with screws, loosen those screws before disconnecting. a When returning connectors ECM and CE02, tighten the screws to the specified torque. 3 Screw: 2.83 ± 0.28 Nm {0.28 ± 0.03 kgm}
Insert or connect troubleshooting T-adapters in or to connectors CM01, CM02, and CM03 of machine monitor (5). a AT11 is for the GPS antenna.
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SEN05122-01 k
104 Testing and adjusting, Part 4 Preparation work for troubleshooting of electrical system
a
In order to prevent malfunction and mistaken system error warning, be sure to completely remove foreign object (b) such as sand, dust, water, etc., from inside of controller side connector (a) with air blow etc., before connecting to harness connector.
If the removal and installation of the connector is difficult, remove the connector from the console box and perform the work. a Since the connectors are fixed with screws, loosen those screws before disconnecting. a When returning the connectors, tighten the screws to the specified torque. 3 Screw: 2.83 ± 0.28 Nm {0.28 ± 0.03 kgm}
4.
3.
KOMTRAX terminal 1) Remove covers (1), (2) and (3) of the right console box.
Power train controller 1) Slide the operator’s seat (1) rearward and remove the inside lower cover (2) of the left console.
2)
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Insert or connect troubleshooting T-adapters in or to connectors (4) (STC1), (5) (STC2), and (6) (STC3) of power train controller (3).
6
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104 Testing and adjusting, Part 4 Preparation work for troubleshooting of electrical system
2)
5.
Insert or connect the troubleshooting Tadapters in or to connectors (5) (CK01) and (6) (CK02) of KOMTRAX terminal (4). a Connector (7) (AT21) is for the communication antenna.
Air pressure sensor (AIR PRESSURE SENSOR) Engine Ne speed sensor (CRANK SENSOR) Engine Bkup speed sensor (CAM SENSOR) Engine oil pressure switch (OIL PRESSURE SWITCH) a Disconnecting and connecting connectors Since the connectors of air pressure sensor, engine Ne speed sensor, engine Bkup speed sensor and engine oil pressure switch have special lock mechanism, disconnect in the order of (a) – (c) and connect in the order of (d) – (f) as shown in the below figure. Disconnect: (a) slide lever – (b) release lock – (c) disconnect connector Connect: (d) connect connector – (e) mesh lock – (f) slide lever
a
SEN05122-01 6.
Boost pressure sensor and intake manifold temperature sensor (BOOST PRES & IMT) a Disconnecting and connecting connectors Since the connectors of boost pressure and temperature sensor have special lock mechanism, disconnect in the order of (a) – (b) and connect in the order of (c) – (d) as shown in the below figure. Disconnect: (a) release lock – (b) disconnect connector Connect: (c) connect connector – (d) mesh lock
a
7.
Removal and installation of sensor When removing and installing boost pressure and intake manifold temperature sensor, use T type torque wrench [bearing number : T15].
Fuel supply pump IMV solenoid (FUEL REGULATOR) a Disconnecting and connecting connectors Since the connector of fuel supply pump IMV solenoid has special lock mechanism, disconnect in the order of (a) – (b) and connect in the order of (c) – (d) as shown in the below figure. Disconnect: (a) release lock – (b) disconnect connector Connect: (c) connect connector – (d) mesh lock
Removal and installation of sensor When removing and installing engine oil pressure switch, use deep sockets with 27 mm width across flats and φ22mm center hole diameter.
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104 Testing and adjusting, Part 4 Preparation work for troubleshooting of electrical system
8.
9.
Common rail pressure sensor (FUEL RAIL PRESS) a Disconnecting and connecting connectors Since the connector of common rail pressure sensor has special lock mechanism, disconnect in the order of (a) – (b) and connect in the order of (c) – (d) as shown in the below figure. Disconnect: (a) release lock – (b) disconnect connector Connect: (c) connect connector – (d) mesh lock
Engine coolant temperature sensor (COOLANT TEMP) a Disconnecting and connecting connectors Since the connector of engine coolant temperature sensor has special lock mechanism, disconnect in the order of (a) – (b) and connect in the order of (c) – (d) as shown in the below figure. Disconnect: (a) release lock – (b) disconnect connector Connect: (c) connect connector – (d) mesh lock
a
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Removal and installation of sensor When removing and installing engine coolant temperature sensor, use deep sockets with 19 mm width across flats and φ18 mm center hole diameter.
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104 Testing and adjusting, Part 4 Inspection procedure of diode
Inspection procedure of diode
SEN05122-01
1
a
The direction of continuity of diode is marked on the surface of the diode.
1.
When using digital tester 1) Switch to diode range and check displayed value. a Voltage of internal battery is displayed by normal tester. 2) Set red (+) test lead to diode anode (P) side and black (–) test lead to cathode (N) side. Check displayed value. 3) Judge quality of diode from displayed value. q Displayed value does not change: No continuity (defect) q Displayed value changes: Continue (normal) (note) Note: In the case of silicon diode, the value between 460 – 600 mV is displayed. q Displayed value becomes 0 or near 0 : Short-circuiting of diode internal part (defect)
D65EX, PX, WX-16
2.
When using analog tester 1) Switch to resistance range. 2) Check the deflection of needle while connecting as follows. i) Set red (+) test lead to diode anode (P) side and black (–) test lead to cathode (N) side. ii) Set red (+) test lead to diode cathode (N) side and black (–) test lead to anode (P) side. 3) Based on the deflection of needle, judge the quality of diode. q Needle does not deflect with connection i) but deflects with connection ii): Normal. (however deflection range (resistance value) varies depending on the type of tester and measuring range. q Needle deflects with both connection i) and ii): Defective (internal short circuit) q Needle does not deflect with either connection i) or ii): Defective (internal disconnection)
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104 Testing and adjusting, Part 4 Pm-Clinic service
SEN05122-01
Pm-Clinic service
1
Model T D65EX-16 T D65PX-16
Serial No.
Service meter
TD65WX-16
h
User name
Date of clinic /
Serviceman
/
Specifications Blade
Attachment
T Sigma blade T Angle blade T Straight tilt blade T Power angle power tilt blade
T Multi-shank ripper T Towing winch T Drawbar T Long drawbar T Counterweight
Shoe width T 510 mm T 560 mm T 610 mm T 660 mm
T 760 mm T 940 mm T 940 mm
Operating conditions Quarry, mine
Construction
Type of soil (specific gravity)
Type of work
T Coal T Gold T Limestone T
T Construction, civil engineering T Roads T Tunnels T
T Rock T Gravel T Sand T Clay
T Dozing, digging T Side cutting T Grading T Travel
% % % %
Existence of abnormalities Oil, water level check T Engine coolant level
When necessary
T Engine oil level
T Power train
T Damper case
T Hydraulic oil level
T Final drive
T(
Ambient temperature Max. Min.
)
Height above sea level °C
Operator's opinion
Visual check results
Failure code history [
]
h
Content: [
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]
h
]
h
Content: ]
Content:
[
h
[ Content:
D65EX, PX, WX-16
104 Testing and adjusting, Part 4 Pm-Clinic service
a
Engine coolant temperature: Max. range
D65EX, PX, WX-16
SEN05122-01 a
Power train oil temperature: Max. range
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104 Testing and adjusting, Part 4 Pm-Clinic service
Pm-clinic measuring points (1/2)
Reference pages for measurement procedure designated *1. Engine speed: Testing and adjusting, No. 1 pages 5 – 6 *2. Blow-by pressure: Testing and adjusting, No. 1 page 18 *3. Engine oil pressure: Testing and adjusting, No. 1 page 19 *4. Boost pressure: Testing and adjusting, No. 1 pages 7 – 8 *5. Exhaust temperature: Testing and adjusting, No. 1 pages 9 – 10
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SEN05122-01
Pm-clinic measuring points for D65EX, PX, WX-15E0 (2/2)
Reference pages for measurement procedure designated *6. Torque converter related: Testing and adjusting, No. 2 page 4 *7. Transmission related: Testing and adjusting, No. 2 pages 5 – 7 *8. Steering brake related: Testing and adjusting, No. 2 page 3 *9. Work equipment and HSS related: Testing and adjusting, No. 2 page 20 – 22
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104 Testing and adjusting, Part 4 Pm-Clinic service
SEN05122-01
Serial number
Pm-clinic check sheet Work order
Date /
Check item
Service meter /
Measurement conditions
High idle
Deceleration pedal depressed
Unit
rpm
High idle
Engine
Engine oil pressure
Torque converter
SAE15W-40, SAE30
Torque converter stall
Exhaust temperature
Torque converter stall
Inlet oil pressure Outlet oil pressure
Check item Cooling fan Transmission
Engine at high idle
Boost pressure
Check item
kPa {mmAq}
Torque converter stall Engine at low idle
MPa {kg/cm2}
Engine at high idle
Measurement conditions
Fan speed
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Transmission: Neutral
800 – 850
800 – 850
975 – 1,025
975 – 1,025
1,670 – 1,870
1,650
Max. 1.96 {Max. 200}
2.94 {300}
Min. 0.15 {Min. 1.5}
0.08 {0.8}
0.34 – 0.59 {3.5 – 6.0}
0.21 {2.1}
Measurement Pass Fail results
Engine at high idle
• Fan 100% speed mode • Engine: Low idle
Min. speed
• Fan 100% speed mode • Engine: High idle
Max. speed
120 {900}
°C
Max. 600
Max. 650
Unit
Standard value for new machine
Service limit value
Max. 0.98 {Max. 10}
Max. 0.98 {Max. 10}
0.39 – 0.88 {4 – 9}
0.39 – 0.88 {4 – 9}
Standard value for new machine
Service limit value
3.10 – 3.50 {31.7 – 35.7}
Min. 3.01 {Min. 30.7}
3.25 – 3.65 {33.3 – 37.3}
Min. 3.17 {Min. 32.3}
550 – 650
500
1,700 – 1,800
1,600
MPa {kg/cm2}
Unit
Engine at low idle Main relief pressure
Service limit value
kPa 151 – 171 {mmHg} {1,130 – 1,330}
Measurement conditions
Transmission: Neutral Oil temperature: 70 – 90°C
Standard value for new machine
2,020 – 2,120 2,020 – 2,120
Torque converter stall (P mode) Blow-by pressure
Serviceman h
Low idle Engine speed
T D65EX-16 # T D65PX-16 # T D65WX-16 #
MPa {kg/cm2}
Measurement Pass Fail results
Measurement Pass Fail results
rpm
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104 Testing and adjusting, Part 4 Pm-Clinic service
SEN05122-01
Serial number
Pm-clinic check sheet Work order
Date /
Brake
Steering
Check item
Service meter /
Measurement conditions
h Standard value for new Service limit Measurement Pass Fail value results machine
Unit
Engine at high idle
Measurement conditions
Standard value for new Service limit Measurement Pass Fail value results machine
Unit
Hydraulic system
Work equipment load sensing Engine at high idle pressure Ripper lift relief Blade tilt relief HSS and work equipment pump Ripper lift relief Blade tilt relief
27.4 – 30.9 {280 – 315} Engine at low idle
Engine at high idle
PPC valve Blade tilt relief output pressure Check item
Work equipment speed
Serviceman
35.2 – 38.1 Min. 32.8 {359 – 389} {Min. 335} 37.1 – 40.1 Min. 34.8 MPa HSS oil pressure when relieved {kg/cm2} {379 – 409} {Min. 355} Engine at high 2.55 – 2.94 Min. 2.55 Brake actuating pressure idle {26 – 30} {Min. 26.0} Brake Apply brake and run engine at high idle with Machine must not move performance transmission gear in F2. HSS LS oil pressure when relieved
Check item
Blade RAISE
Measurement conditions
Measurement conditions
Hydraulic oil temperature Blade lift cylinder
Standard value for new Service limit Measurement Pass Fail value results machine
Unit
EX/WX: 2.2 – 2.8 PX: 2.1 – 2.7
Power angle power tilt dozer Straight tilt dozer High idle Sigma dozer Tilt (left o right) Power angle power tilt dozer Angle (left o right) Ripper RAISE
Engine stopped
Blade tilt cylinder
second
Max. 3.1 Max. 3.0
2.2 – 2.8
Max. 3.1
1.3 – 1.9
Max. 2.1
1.4 – 2.0
Max. 2.2
3.5 – 4.5 1.0 – 2.0
Max. 5.0 Max. 2.5
Standard value for new Service limit Measurement Pass Fail value results machine
Unit °C
45 – 55
—
mm/ 5 min.
Max. 35
Max. 35
Max. 70
Max. 70
Check item
Measurement conditions
Unit
Visual inspection of final drive drain plug
Engine stopped
—
Standard value for new Service limit Measurement Pass Fail value results machine
There must be no excessive metal particles
Always fill in the record when repairing, adjusting, or replacing main parts. Date Service meter Repair record Date
D65EX, PX, WX-16
Min. 26.4 {Min. 270}
Min. 28.4 Min. 27.4 {Min. 290} {Min. 280} Min. 28.4 Min. 27.4 MPa {Min. 290} {Min. 280} 2 {kg/cm } 29.4 – 32.9 Min. 28.4 {300 – 335} {Min. 290} 29.4 – 32.9 Min. 28.4 {300 – 335} {Min. 290} 3.19 – 4.17 3.19 – 4.17 {32.5 – 42.5} {32.5 – 42.5}
Straight tilt dozer Sigma dozer
Check item Hydraulic drift
T D65EX-16 # T D65PX-16 # T D65WX-16 #
Service meter
Repair record
30-104
15
104 Testing and adjusting, Part 4 Pm-Clinic service
SEN05122-01
Pm-clinic undercarriage check sheet
Serial number
Work order
Date /
T D65EX-16 # T D65WX-16 #
Service meter /
Serviceman h
Measure the bushing temperature immediately after operations Left side of machine
q
Right side of machine
a
Measurement results Pass
Left side of machine Right side of machine q
Fail
Left track
A: Clearance between links
Right track
A: Clearance between links
Pin No.
1.4
Pin No.
1.4
Opening of track link
30-104
16
D65EX, PX, WX-16
104 Testing and adjusting, Part 4 Pm-Clinic service
SEN05122-01
Pm-clinic undercarriage check sheet Work order
Serial number Date /
T D65PX-16 #
Service meter
/
Serviceman h
Measure the bushing temperature immediately after operations Left side of machine
q
Right side of machine
a
Measurement results Pass
Left side of machine Right side of machine q
Fail
Left track
A: Clearance between links
Right track
A: Clearance between links
Pin No.
1.4
Pin No.
1.4
Opening of track link
D65EX, PX, WX-16
30-104
17
SEN05122-01 Undercarriage troubleshooting report (Normal)
30-104
18
104 Testing and adjusting, Part 4 Pm-Clinic service
(Program form No.: SELA195001)
D65EX, PX, WX-16
104 Testing and adjusting, Part 4 Pm-Clinic service
Undercarriage troubleshooting report (Impact)
D65EX, PX, WX-16
SEN05122-01 (Program form No.: SELA195001)
30-104
19
104 Testing and adjusting, Part 4 Pm-Clinic service
SEN05122-01
Pm-clinic undercarriage check sheet (PLUS specification) Work order
Serial number
Date /
T D65EX-16 # T D65WX-16 #
Service meter /
Serviceman h
Measure the bushing temperature immediately after operations Left side of machine
q
Right side of machine
a
Measurement results Pass
Left side of machine Right side of machine q
Fail
Left track
A: Clearance between links
Right track
A: Clearance between links
Pin No.
1.4
Pin No.
1.4
Opening of track link
30-104
20
D65EX, PX, WX-16
104 Testing and adjusting, Part 4 Pm-Clinic service
SEN05122-01
Pm-clinic undercarriage check sheet (PLUS specification) Work order
Serial number
Date /
T D65PX-16 #
Service meter
/
Serviceman h
Measure the bushing temperature immediately after operations Left side of machine
q
Right side of machine
a
Measurement results Pass
Left side of machine Right side of machine q
Fail
Left track
A: Clearance between links
Right track
A: Clearance between links
Pin No.
1.4
Pin No.
1.4
Opening of track link
D65EX, PX, WX-16
30-104
21
SEN05122-01
104 Testing and adjusting, Part 4 Pm-Clinic service
Undercarriage troubleshooting report (Normal, impact) (PLUS specification) (Program form No.: SELA195001)
30-104
22
D65EX, PX, WX-16
104 Testing and adjusting, Part 4 Pm-Clinic service
D65EX, PX, WX-16
SEN05122-01
30-104
23
SEN05122-01
D65EX, PX, WX-16 Bulldozer Form No. SEN05122-01
©2011 KOMATSU All Rights Reserved Printed in Japan 01-11
30-104
24
SEN05029-01
BULLDOZER D65EX-16 D65PX-16 D65WX-16 Machine model D65EX-16 D65PX-16 D65WX-16
Serial number 80001 and up 80001 and up 80001 and up
40 Troubleshooting
40
100 Failure code table and fuse locations Failure codes table.......................................................................................................................................... 2 Fuse locations................................................................................................................................................. 7
D65EX, PX, WX-16
40-100
1
100 Failure code table and fuse locations Failure codes table
SEN05029-01
Failure codes table Action code
Failure code
E03
1500L0
E03
1
Component in charge
Category of history
P/T
Electrical system
15SAL1 Forward clutch: Fill high
P/T
Electrical system
E03
15SALH Forward clutch: Fill low
P/T
Electrical system
E03
15SBL1 Reverse clutch: Fill high
P/T
Electrical system
E03
15SBLH Reverse clutch: Fill low
P/T
Electrical system
E03
15SEL1 Speed 1st clutch: Fill high
P/T
Electrical system
E03
15SELH Speed 1st clutch: Fill low
P/T
Electrical system
E03
15SFL1 Speed 2nd clutch: Fill high
P/T
Electrical system
E03
15SFLH Speed 2nd clutch: Fill low
P/T
Electrical system
E03
15SGL1 Speed 3rd clutch: Fill high
P/T
Electrical system
E03
15SGLH Speed 3rd clutch: Fill low
P/T
Electrical system
E02
15SJL1
P/T
Electrical system
E02
15SJLH L/U: Fill low
P/T
Electrical system
Trouble (Displayed on screen) Transmission clutch: Abnormal
L/U: Fill high
Reference manual No.
—
AB00MA Battery Charge Abnormal
MON
Mechanical system
—
B@BAZG Eng Oil Press Low
ENG
Mechanical system
—
B@BCNS Eng Water Overheat
ENG
Mechanical system
—
B@CENS T/C Oil Overheat
P/T
Mechanical system
—
B@HANS Hyd Oil Overheat
P/T
Mechanical system
E04
CA111
EMC Critical Internal Failure
ENG
Electrical system
E04
CA115
Eng Ne and Bkup Speed Sens Error
ENG
Electrical system
E03
CA122
Chg Air Press Sensor High Error
ENG
Electrical system
E03
CA123
Chg Air Press Sensor Low Error
ENG
Electrical system
E03
CA131
Throttle Sensor High Error
ENG
Electrical system
E03
CA132
Throttle Sensor Low Error
ENG
Electrical system
E02
CA144
Coolant Temp Sens High Error
ENG
Electrical system
E02
CA145
Coolant Temp Sens Low Error
ENG
Electrical system
E01
CA153
Chg Air Temp Sensor High Error
ENG
Electrical system
E01
CA154
Chg Air Temp Sensor Low Error
ENG
Electrical system
E03
CA155
Chg Air Temp High Speed Derate
ENG
Electrical system
E03
CA187
Sens Supply 2 Volt Low Error
ENG
Electrical system
E03
CA221
Ambient Press Sens High Error
ENG
Electrical system
E03
CA222
Ambient Press Sens Low Error
ENG
Electrical system
E03
CA227
Sens Supply 2 Volt High Error
ENG
Electrical system
—
CA234
Eng Overspeed
ENG
Mechanical system
E03
CA238
Ne Speed Sens Supply Volt Error
ENG
Electrical system
E03
CA271
IMV/PCV1 Short Error
ENG
Electrical system
E03
CA272
IMV/PCV1 Open Error
ENG
Electrical system
E03
CA281
Pump Press Balance Error
ENG
Electrical system
E03
CA322
Inj #1 (L#1) Open/Short Error
ENG
Electrical system
40-100
2
Troubleshooting by failure code, Part 1 SEN05031-00
Troubleshooting by failure code, Part 2 SEN05032-01
D65EX, PX, WX-16
100 Failure code table and fuse locations Failure codes table
Action code
Failure code
E03
CA323
E03
SEN05029-01
Component in charge
Category of history
Inj #5 (L#5) Open/Short Error
ENG
Electrical system
CA324
Inj #3 (L#3) Open/Short Error
ENG
Electrical system
E03
CA325
Inj #6 (L#6) Open/Short Error
ENG
Electrical system
E03
CA331
Inj #2 (L#2) Open/Short Error
ENG
Electrical system
E03
CA332
Inj #4 (L#4) Open/Short Error
ENG
Electrical system
E04
CA342
Calibration Code Incompatibility
ENG
Electrical system
E03
CA351
Injectors Drive Circuit Error
ENG
Electrical system
E03
CA352
Sens Supply 1 Volt Low Error
ENG
Electrical system
E03
CA386
Sens Supply 1 Volt High Error
ENG
Electrical system
E01
CA428
Water in Fuel Sensor High Error
ENG
Electrical system
E01
CA429
Water in Fuel Sensor Low Error
ENG
Electrical system
E02
CA435
Eng Oil Press Sw Error
ENG
Electrical system
E04
CA441
Battery Voltage Low Error
ENG
Electrical system
E04
CA442
Battery Voltage High Error
ENG
Electrical system
E03
CA449
Rail Press Very High Error
ENG
Electrical system
E03
CA451
Rail Press Sensor High Error
ENG
Electrical system
E03
CA452
Rail Press Sensor Low Error
ENG
Electrical system
E03
CA488
Chg Air Temp High Torque Derate
ENG
Electrical system
E02
CA553
Rail Press High Error
ENG
Electrical system
E02
CA559
Rail Press Low Error
ENG
Electrical system
E03
CA689
Eng Ne Speed Sensor Error
ENG
Electrical system
E03
CA731
Eng Bkup Speed Sens Phase Error
ENG
Electrical system
E04
CA757
All Continuous Data Lost Error
ENG
Electrical system
E03
CA778
Eng Bkup Speed Sensor Error
ENG
Electrical system
E03
CA1633 KOMNET Datalink Timeout Error
ENG
Electrical system
E03
CA2185 Throt Sens Sup Volt High Error
ENG
Electrical system
E03
CA2186 Throt Sens Sup Volt Low Error
ENG
Electrical system
E03
CA2249 Rail Press Very Low Error
ENG
Electrical system
E01
CA2265 Fuel Feed Pump Open Error
ENG
Electrical system
E01
CA2266 Fuel Feed Pump Short Error
ENG
Electrical system
E03
CA2311 IMV Solenoid Error
ENG
Electrical system
E01
CA2555 Grid Htr Relay Volt Low Error
ENG
Electrical system
E01
CA2556 Grid Htr Relay Volt High Error
ENG
Electrical system
D110KB Battery Relay: Drive Short Circuit
P/T
Electrical system
E02
D130KA Neutral relay: Disconnection
P/T
Electrical system
E02
D130KB Neutral relay: Short circuit
P/T
Electrical system
E01
D161KA Back-up alarm relay: Disconnection
P/T
Electrical system
E01
D161KB Back-up alarm relay: Short circuit
P/T
Electrical system
E01
D862KA GPS Antenna Open Circuit
MON
Electrical system
E03
DAFRKR CAN Disconnection
P/T
Electrical system
E03
DAFRMC CAN Discon (Monitor Detected)
MON
Electrical system
—
Trouble (Displayed on screen)
D65EX, PX, WX-16
Reference manual No.
Troubleshooting by failure code, Part 2 SEN05032-01
Troubleshooting by failure code, Part 3 SEN05033-01
Troubleshooting by failure code, Part 4 SEN05034-01
40-100
3
100 Failure code table and fuse locations Failure codes table
SEN05029-01
Action code
Failure code
Trouble (Displayed on screen)
Component in charge
Category of history
ENG
Electrical system
Reference manual No.
E03
DB2RKR CAN Disconnection
E01
DBE0KT PT controller: Abnormality in controller
P/T
Electrical system
E04
DBE1KK Battery direct Source voltage reduction
P/T
Electrical system
E04
DBE2KK Solenoid Source voltage reduction
P/T
Electrical system
E03
DBE5KK PT cont.: Sensor voltage 5 V (1) reduction
P/T
Electrical system
E03
DBE6KK PT cont.: Sensor voltage 24 V reduction
P/T
Electrical system
E02
DBE7KK PT cont.: Sensor voltage 5 V (2) reduction
P/T
Electrical system
E04
DBE9KQ PT controller: Type select signal
P/T
Electrical system
E02
DD12KA Shift up Sw: Disconnection
P/T
Electrical system
E02
DD12KB Shift up Sw: Short circuit
P/T
Electrical system
E02
DD13KA Shift down Sw: Disconnection
P/T
Electrical system
E02
DD13KB Shift down Sw: Short circuit
P/T
Electrical system
E03
DD14KA Parking lever Sw: Disconnection
P/T
Electrical system
E03
DD14KB Parking lever Sw: Short circuit
P/T
Electrical system
E02
DDN7KA WEQ Knob Sw (down): Disconnection
P/T
Electrical system
E02
DDN7KB WEQ Knob Sw (down): Short circuit
P/T
Electrical system
E02
DDN8KA WEQ Knob Sw (up): Disconnection
P/T
Electrical system
E02
DDN8KB WEQ Knob Sw (up): Short circuit
P/T
Electrical system
E03
DDNLKA Weq lock Sw: Disconnection
P/T
Electrical system
E03
DDNLKB Weq lock Sw: Short circuit
P/T
Electrical system
E01
DGS1KX Hyd oil temp sensor: Abnormal
P/T
Electrical system
E01
DGT1KA T/C oil temp sensor: Disconnection
P/T
Electrical system
E01
DGT1KX T/C oil temp sensor Short circuit
P/T
Electrical system
E01
DH21KA WEQ pressure sensor: Disconnection
P/T
Electrical system
E01
DH21KB WEQ pressure sensor: Short circuit
P/T
Electrical system
E02
DHT5KA T/C pressure sensor: Disconnection
P/T
Electrical system
E02
DHT5KB T/C pressure sensor: Short circuit
P/T
Electrical system
E03
DK10KA Fuel control Dial: Disconnection
P/T
Electrical system
E03
DK10KB Fuel control Dial: Short circuit
P/T
Electrical system
E03
DK30KA ST lever 1: Disconnection
P/T
Electrical system
E03
DK30KB ST lever 1: Short circuit
P/T
Electrical system
E04
DK30KX ST lever 1: Out of normal range
P/T
Electrical system
E04
DK30KZ ST lever: Disconnection or short circuit
P/T
Electrical system
E03
DK30L8 ST lever: Signal mismatch
P/T
Electrical system
E03
DK31KA ST lever 2: Disconnection
P/T
Electrical system
E03
DK31KB ST lever 2: Short circuit
P/T
Electrical system
E02
DK40KA Brake potentiometer: Disconnection
P/T
Electrical system
E02
DK40KB Brake potentiometer: Short circuit
P/T
Electrical system
E04
DK55KX FR lever: Out of normal range
P/T
Electrical system
E04
DK55KZ FR lever: Disconnection or short circuit
P/T
Electrical system
E03
DK55L8 FR lever: Signal mismatch
P/T
Electrical system
40-100
4
Troubleshooting by failure code, Part 4 SEN05034-01
Troubleshooting by failure code, Part 5 SEN05035-00
D65EX, PX, WX-16
100 Failure code table and fuse locations Failure codes table
Action code
Failure code
Trouble (Displayed on screen)
SEN05029-01
Component in charge
Category of history
E03
DK56KA FR lever 1: Disconnection
P/T
Electrical system
E03
DK56KB FR lever 1: Short circuit
P/T
Electrical system
E03
DK57KA FR lever 2: Disconnection
P/T
Electrical system
E03
DK57KB FR lever 2: Short circuit
P/T
Electrical system
E03
DKH1KA Pitch angle sensor: Disconnection
P/T
Electrical system
E03
DKH1KB Pitch angle sensor: Short circuit
P/T
Electrical system
E02
DLT3KA T/M out-speed sensor: Disconnection
P/T
Electrical system
E02
DLT3KB T/M out-speed sensor: Abnormal
P/T
Electrical system
E02
DW5AKA Pitch selector Sol.: Disconnection
P/T
Electrical system
E02
DW5AKB Pitch selector Sol.: Short circuit
P/T
Electrical system
E02
DW5AKY Pitch selector Sol.: Hot Short
P/T
Electrical system
E02
DW7BKA Fan rev EPC: Disconnection
P/T
Electrical system
E01
DW7BKB Fan rev EPC: Short circuit
P/T
Electrical system
E03
DWN1KA Hss EPC1: Disconnection
P/T
Electrical system
E03
DWN1KB Hss EPC1: Short circuit
P/T
Electrical system
E04
DWN1KY Hss EPC1: Short circuit
P/T
Electrical system
E03
DWN2KA Hss EPC2: Disconnection
P/T
Electrical system
E03
DWN2KB Hss EPC2: Short circuit
P/T
Electrical system
E04
DWN2KY Hss EPC2: Short circuit
P/T
Electrical system
E01
DWN5KA Fan pump solenoid: Disconnection
P/T
Electrical system
E01
DWN5KB Fan pump solenoid: Short circuit
P/T
Electrical system
E02
DWN5KY Fan control solenoid.: Short circuit
P/T
Electrical system
E01
DXA0KA TVC Sol.: Disconnection (*)
P/T
Electrical system
E01
DXA0KB TVC Sol.: Short circuit (*)
P/T
Electrical system
E01
DXA0KY TVC Sol.: Short circuit (*)
P/T
Electrical system
E02
DXH1KA Lock-up ECMV: Disconnection
P/T
Electrical system
E02
DXH1KB Lock-up ECMV: Short circuit
P/T
Electrical system
E03
DXH1KY Lock-up ECMV: Short circuit
P/T
Electrical system
E03
DXH4KA 1st clutch ECMV: Disconnection
P/T
Electrical system
E03
DXH4KB 1st clutch ECMV: Short circuit
P/T
Electrical system
E03
DXH4KY 1st clutch ECMV: Short circuit
P/T
Electrical system
E03
DXH5KA 2nd clutch ECMV: Disconnection
P/T
Electrical system
E03
DXH5KB 2nd clutch ECMV: Short circuit
P/T
Electrical system
E03
DXH5KY 2nd clutch ECMV: Short circuit
P/T
Electrical system
E03
DXH6KA 3rd clutch ECMV: Disconnection
P/T
Electrical system
E03
DXH6KB 3rd clutch ECMV: Short circuit
P/T
Electrical system
E03
DXH6KY 3rd clutch ECMV: Short circuit
P/T
Electrical system
E03
DXH7KA R clutch ECMV: Disconnection
P/T
Electrical system
E03
DXH7KB R clutch ECMV: Short circuit
P/T
Electrical system
E04
DXH7KY R clutch ECMV: Short circuit
P/T
Electrical system
Reference manual No. Troubleshooting by failure code, Part 5 SEN05035-00
Troubleshooting by failure code, Part 6 SEN05036-01
(*): TVC solenoid means PC-EPC valve.
D65EX, PX, WX-16
40-100
5
100 Failure code table and fuse locations Failure codes table
SEN05029-01
Action code
a a
a
a
Failure code
Trouble (Displayed on screen)
Component in charge
Category of history
Reference manual No.
E03
DXH8KA F clutch ECMV: Disconnection
P/T
Electrical system
E03
DXH8KB F clutch ECMV: Short circuit
P/T
Electrical system
E04
DXH8KY F clutch ECMV: Short circuit
P/T
Electrical system
E03
DXJ4KA WEQ lock Sol.: Disconnection
P/T
Electrical system
E03
DXJ4KB WEQ lock Sol.: Short circuit
P/T
Electrical system
Troubleshooting by failure code, Part 6 SEN05036-01
Entry order of items in table The items are entered in the order of their failure codes (incremental order). Action code Attached: If a failure code is detected, the action code, failure code, and telephone No. (if registered) are displayed on the ordinary screen to notify the operator of the fault. Not attached: Even if a failure code is detected, the machine monitor does not notify the operator of the fault. Component in charge MON: The machine monitor is in charge of detection of fault. ENG: The engine controller is in charge of detection of fault. P/T: The power train controller is in charge of detection of fault. Category of history Mechanical system: Fault information is recorded in the mechanical system fault history. Electrical system: Fault information is recorded in the electrical system fault history.
40-100
6
D65EX, PX, WX-16
100 Failure code table and fuse locations Fuse locations
SEN05029-01
Fuse locations
1
Connection table of fusible link and fuse box a This connection table shows the devices to which each power supply of fusible link and the fuse box supplies power (An accessory power supply is a device which supplies power while the starting switch is in the ON position and an unswitched power supply is a device which supplies power while the starting switch is in the OFF and ON positions). a When carrying out troubleshooting related to the electrical system, you should check the fusible link and and fuses to see if the power is supplied normally. Fuse box (A) Fusible link (Connector No.)
Fuse No.
Fuse capacity (A)
1
20
Starting switch (B terminal)
2
15
Monitor, power train controller
3
30
Engine controller
4
15
Cab main circuit
5
15
Power train controller
7
5
Horn
8
5
Backup alarm
9
20
Electrical intake air heater, air suspension seat
10
20
Spare
11
20
Head lamp
12
20
Rear lamp
13
20
Air conditioner
ACC power supply
6
5
Engine controller (ACC signal)
Fusible link (Connector No.)
Power supply
Fuse No.
Fuse capacity (A)
—
Unswitched power supply
1
10
Radio memory
2
20
Additional lamp, rotation lamp
3
20
12 V converter
4
20
Radio, room lamp, cigarettelighter, intermittent wipper
5
10
Front wiper, rear wiper
6
10
LH and RH door wiper
FL2 [50 A] (FL2-4)
FL1 [120 A] (FL1-4)
—
Power supply
Unswitched power supply
Accessory power supply
Destination of power
Fuse box (B)
FL1 [50 A] (FL1-3)
Accessory power supply
Destination of power
Location of fusible link (FL1, FL2)
D65EX, PX, WX-16
40-100
7
SEN05029-01
100 Failure code table and fuse locations Fuse locations
Location of fuse and fuse No.
40-100
8
D65EX, PX, WX-16
100 Failure code table and fuse locations Fuse locations
D65EX, PX, WX-16
SEN05029-01
40-100
9
SEN05029-01
D65EX-16, D65PX-16, D65WX-16 Bulldozer Form No. SEN05029-01
©2010 KOMATSU All Rights Reserved Printed in Japan 02-10 (01)
40-100
10
SEN05030-01
BULLDOZER D65EX-16 D65PX-16 D65WX-16 Machine model D65EX-16 D65PX-16 D65WX-16
Serial number 80001 and up 80001 and up 80001 and up
40 Troubleshooting
1
200 General information on troubleshooting Points to remember when troubleshooting ..................................................................................................... 2 How to proceed troubleshooting ..................................................................................................................... 3 Checks before troubleshooting ....................................................................................................................... 4 Classification and procedures for troubleshooting .......................................................................................... 6 Symptom supposed to be failure and troubleshooting No. ........................................................................... 10 Information contained in troubleshooting table ............................................................................................. 12 Troubleshooting method for disconnecting wiring harness of pressure sensor system................................ 14 Connector list and stereogram...................................................................................................................... 16 Connection table for connector pin numbers ................................................................................................ 30 T- branch box and T- branch adapter table ................................................................................................... 66
D65EX, PX, WX-16
40-200
1
SEN05030-01
Points to remember when troubleshooting k k k k k k
200 General information on troubleshooting Points to remember when troubleshooting
1
Stop the machine on a level place, and check that the lock pin, blocks, and parking brake are securely fitted. When carrying out the operation with 2 or more workers, keep strictly to the agreed signals, and do not allow any unauthorized person to come near. If the radiator cap is removed when the engine is hot, hot coolant may spurt out and cause burns, so wait for the engine to cool down before starting troubleshooting. Be extremely careful not to touch any hot parts or to get caught in any rotating parts. When disconnecting wiring, always disconnect the negative (–) terminal of the battery first. When removing the plug or cap from a location which is under pressure from oil, water, or air, always release the internal pressure first. When installing measuring equipment, be sure to connect it properly.
The aim of troubleshooting is to pinpoint the basic cause of the failure, to carry out repairs swiftly, and to prevent reoccurrence of the failure. When carrying out troubleshooting, an important point is of course to understand the structure and function. However, a short cut to effective troubleshooting is to ask the operator various questions to form some idea of possible causes of the failure that would produce the reported symptoms. 1.
2.
3.
4.
5.
6.
When carrying out troubleshooting, do not hurry to disassemble the components. If components are disassembled in confusion immediately after any failure occurs: q Parts that have no connection with the failure or other unnecessary parts will be disassembled. q It will become impossible to find the cause of the failure. It will also cause a waste of manhours, parts, or oil or grease, and at the same time, will also lose the confidence of the user or operator. For this reason, when carrying out troubleshooting, it is necessary to carry out thorough prior investigation and to carry out troubleshooting in accordance with the fixed procedure. Points to ask user or operator 1) Have any other problems occurred apart from the problem that has been reported? 2) Was there anything strange about the machine before the failure occurred? 3) Did the failure occur suddenly, or were there problems with the machine condition before this? 4) Under what conditions did the failure occur? 5) Had any repairs been carried out before the failure? When were these repairs carried out? 6) Has the same kind of failure occurred before? Check before troubleshooting 1) Check for any sign of abnormality on the machine. 2) Make checks before starting day's work. 3) Make checks of other items. 4) Check other maintenance items which can be visually checked and are considered necessary. Confirming failure Confirm the extent of the failure by yourself, and judge whether to treat it as a real failure or as a problem of handling, operation, etc. a When operating a machine to reproduce the symptom of failure for troubleshooting, do not carry out any investigation or measurement that may make the problem worse. Troubleshooting Use the results of the investigation and inspection in items 2 – 4 to narrow down the causes of failure, then use the troubleshooting table or flowchart (matrix) to find out the failure part 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. Measures to remove root cause of failure Even if the immediate failure is repaired, the same failure may occur again, unless the root cause of the failure is repaired. To prevent this, always investigate why the cause of the failure occurred. Then, remove the root cause.
40-200
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D65EX, PX, WX-16
200 General information on troubleshooting How to proceed troubleshooting
How to proceed troubleshooting
D65EX, PX, WX-16
SEN05030-01
1
40-200
3
200 General information on troubleshooting Checks before troubleshooting
SEN05030-01
Checks before troubleshooting
b. Hydraulic and mechanical equipment
a. Engine, Lubricating oil, Coolant
No.
40-200
1
Check item
Judgement value
Action
1
Check for abnormal noise and smell
—
Repair
2
Garabage check around engine
—
Removal
3
Water leak check around engine
—
Repair
4
Oil leak check around engine
—
Repair
5
Check fuel line leakl
—
Repair
6
Check radiator for clogging
—
Removal
7
Check fuel level and type
—
Add fuel
8
Check for impurities in fuel
—
Clean and drain
9
Check fuel filter
—
Replace
10
Check engine oil level (engine oilpan level) and type
Between H and L
Add oil
11
Check coolant level (sub-tank level)
Between H and L
Add coolant
12
Check dustindicator for clogging
No red color
Clean or replace
1
Check for abnormal noise and smell
—
Repair
2
Check for oil leakage
—
Repair
3
Check hydraulic oil level
Between H and L
Add oil
4
Check oil level in damper case
—
Add oil
5
Check hydraulic oil strainer
—
Clean and drain
6
Check power train oil level
Between H and L
Add oil
7
Check hydraulic oil filter
—
Replace
8
Carry out bleeding
—
Bleed air
4
D65EX, PX, WX-16
200 General information on troubleshooting Checks before troubleshooting
e. Interior
d. EXterior
c. Electrical equipment
No.
Check item
SEN05030-01
Judgement value
Action
1
Check for looseness and corrosion of battery terminals
—
Retighten or replace
2
Check for looseness and corrosion of alternator terminals
—
Retighten or replace
3
Check for looseness and corrosion of starting motor terminals
—
Retighten or replace
4
Check battery voltage (engine stopped)
20 – 30 V
Charge or replace
5
Check battery electrolyte level
Between H and L
Add or replace
6
Check for discoloration, burnout of wiring, and peeling of harness coating
—
Repair or replace
7
Check for missing wiring clamps and a slack of wire.
—
Repair
8
Check for water leaking on wiring (pay particularly careful attention to water leaking on connectors or terminals)
—
Dry
9
Check for loose connector and damage to connector lock
Repair or replace
10
Check connector pins for corrosion, bent ot deformation
Repair or replace
11
Check for dirt or debris in the connector
Clean or replace
12
Check the continuity and insulation of the harness
Repair or replace
13
Check for blown or corroded fuse
—
Replace
After running for several minutes: 27.5 – 29.5 V
Replace
14
Check alternator voltage (engine running at half speed or above)
15
Check operating sound of battery relay (when turning starting switch ON or OFF)
—
Replace
1
Check for undercarriage
—
Repair
2
Check for handrail and step
—
Repair
3
Check for mirror
—
Repair
1
Check for gauge and monitor
—
Replace
2
Check for seat belt
—
Repair
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200 General information on troubleshooting Classification and procedures for troubleshooting
SEN05030-01
Classification and procedures for troubleshooting
1
Classification of troubleshooting Mode
Contents
Display of code Troubleshooting by failure code E-mode
Troubleshooting of electrical system
H-mode
Troubleshooting of hydraulic and mechanical system
S-mode
Troubleshooting of engine
Procedure for troubleshooting If a phenomenon which appears a source of a trouble occurs on the machine, select a proper troubleshooting No. according to the following procedure, and then go to the corresponding troubleshooting section. 1. Procedure for troubleshooting when action code and failure code are displayed on machine monitor: If an action code and a failure code are displayed on the machine monitor, perform the troubleshooting for the corresponding "Display of code". a If multiple failure codes are displayed simultaneously, all the codes are displayed repeatedly in order. Note down all the codes. 2.
Procedure for troubleshooting when an action code and a 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 dispayed after having noted down all the codes, delete all the codes and reproduce them, and then see if the trouble is still detected. (See [*2].) a A failure code of the mechanical system cannot be deleted. a If a trouble is displayed in the air conditioner system by the abnormality record function, perform "Inspection with self-diagnosis function" in "Air conditioner". (See [*3].) 2) If no failure code is found in the abnormality record, a trouble that the machine cannot find out by itself may have occurred in the electrical system or hydraulic and mechanical system. In this case, check the phenomenon which is assumed to show a trouble again and select the same phenomenon from the list on the next page, and then perform troubleshooting corresponding to that phenomenon in the "E-mode", "H-mode", or "S-mode".
3.
Action to take after trouble is eliminated Referring to the next page, clear all the failure codes in the electrical system abnormality record.
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6
D65EX, PX, WX-16
200 General information on troubleshooting Classification and procedures for troubleshooting
[*1], [*2] 1. While pressing numerical key [4] on the panel switch at the normal screen, press [1], [2] and [3] in order.
SEN05030-01 5.
6. 7. 8.
2.
3.
On the service menu screen, press [F3] switch (R) on the panel switch once to select “02 Abnormality Record”. Press [F6] switch (3) on the panel switch to confirm and go to “Abnormality Record” screen.
9.
10. 11. 12.
13.
4.
Press the [F3] switch (R) on the panel switch to see if the next failure code is displayed and note down all the failure codes. a A mechanical system failure code cannot be cleared. Press [F5] switch (Return) on the panel switch to return to the “Abnormality record” screen. Enter the “Electrical system abnormality record” similarly to steps 2 and 3. 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 “E” on the left of a failure code indicates that the failure code is “active” (the failure remains or restoration to normal has not been checked). A failure code having no “E” on its left is a “non-active” one. Since it disappears at the following clear step, be sure to note it down. While pressing numerical key [4] on the panel switch, press [1], [2] and [3] in this order to enter the “Clear mode”. (Same as 1) Press [F2] switch(CLEAR) on the panel switch. Press [F6] switch (3) on the panel switch to clear all the failure codes temporarily. Press [F5] switch (Return) on the panel switch to return to the “Electrical system abnormality record” screen. See if any failure code is still displayed and note down displayed ones. Press [F5] switch (Return) on the panel switch to return to the “Abnormality record” screen.
Press [F6] switch (3) on the panel switch to confirm and go to “Mechanical system” screen.
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7
SEN05030-01
200 General information on troubleshooting Classification and procedures for troubleshooting
[*3] a For how to enter the “Abnormality record” screen, see steps 1 – 3 in [*1] and [*2]. 1. On the “Abnormality Record” screen, press [F3] switch (R) on the panel switch twice to select “03 Air-conditioning System”. 2. Press [F6] switch (3) on the panel switch to confirm and enter the “Air conditioner abnormality record” screen.
3.
4.
5.
Note down of information in all the columns. a “E” on the left of a failure code (same as electrical abnormality record) indicates that the failure code is “active” (the failure remains or its elimination has not been confirmed). Press [F2] switch (CLEAR) on the panel switch section to clear all the codes temporarily. See if “Abnormality” is still displayed and take a note. (Same as 10 of [*1] and [*2]) Press [F5] switch (Return) on the panel switch section to return to the “Abnormality record” screen.
40-200
8
D65EX, PX, WX-16
200 General information on troubleshooting Classification and procedures for troubleshooting
D65EX, PX, WX-16
SEN05030-01
40-200
9
200 General information on troubleshooting Symptom supposed to be failure and troubleshooting No.
SEN05030-01
Symptom supposed to be failure and troubleshooting No.
1
Troubleshooting No.
Symptom supposed to be failure
Code display
E-mode
H-mode
S-mode
Symptom related to action code and failure code Check failure code.
1 Display action code on monitor panel. 2 Display failure code in failure code display mode.
q
Engine related 3 Engine is hard to start. (Engine starting always takes time.) 4 5
Engine does not crank. Engine does not start.
6
S-1 E-1
S-2a)
Engine cranks but no exhaust smoke comes out.
S-2b)
Exhaust smoke comes out but engine does not start.
S-2c)
7 Engine does not pick-up smoothly. (Poor follow-up performance)
S-3
8 Engine stops during operation.
S-4
9 Engine does not rotate smoothly (hunting).
S-5
10 Engine lacks in output or power.
S-6
11 Exhaust smoke is black (incomplete combustion).
S-7
12 Oil consumption is excessive or exhaust smoke is blue.
S-8
13 Oil gets contaminated quickly.
S-9
14 Fuel consumption is excessive.
S-10
15
Oil mixes in coolant or coolant spurts back or coolant level goes down.
S-11
16 Engine oil pressure drops.
S-12
17 Oil level rises (water or fuel mixes).
S-13
18 Coolant temperature rises too high. (overheat)
S-14
19 Abnormal noise occurs.
S-15
20 Vibration is excessive.
S-16
21 Preheater does not operate.
E-2 Power train related
22 There is no travel power. (no drawbar pull)
H-1
23 Machine does not travel (at 2nd or 3rd speed)
H-2
24 Machine does not start at any gear speed.
H-3
25 Machine travels only in one direction, forward or reverse.
H-4
26
Time lag is excessive at shifting gear speed or shifting forwardreverse.
H-5
27
Machine cannot be steered. (Machine does not turn leftward or rightward.)
H-6
28 Steering speed or power is insufficient.
H-7
29 Brake does not work.
H-8
30 Power train oil overheats.
H-9
31
Abnormal sound comes out around HSS and hydraulic pump or HSS motor.
40-200
10
S-6
H-10
D65EX, PX, WX-16
200 General information on troubleshooting Symptom supposed to be failure and troubleshooting No.
SEN05030-01
Troubleshooting No.
Symptom supposed to be failure
Code display
E-mode
H-mode
S-mode
Work equipment related 32 Speed of all work equipments is slow.
H-11
33 All work equipments do not move.
H-12
34 Blade lift moves slowly or lacks power.
H-13
35 Blade tilt moves slowly or lacks power.
H-14
36 Ripper lift moves slowly or lacks power.
H-15
37 Hydraulic drift of blade lift is excessive.
H-16
38 Hydraulic drift of blade tilt is excessive.
H-17
39 Hydraulic drift of ripper lift is excessive.
H-18
Machine monitor related (operator mode: normal screen) 40 When starting switch turned ON, machine monitor displays nothing.
E-3
When starting switch turned ON (before starting engine), basic check item lights up.
E-4
41
42 Precaution item lights up while engine is running.
E-5
43 Emergency stop item lights up while engine is running.
E-6
44 Engine coolant temperature gauge does not indicate normally.
E-7
45 Fuel gauge does not indicate properly.
E-8
Power train oil temperature gauge (multi-gauge) does not indicate 46 normally.
E-9
47
Hydraulic temperature gauge (multi-gauge) does not indicate normally.
E-10
48
Contents of display by machine monitor are different from applicable machine.
E-11
49 Machine monitor does not display some items.
E-12
50 Function switch does not work.
E-13
51 Operation mode does not change.
E-14
52 Gearshift mode does not change.
E-15
53 Customize function does not operate normally.
E-16
54 Customize memory function does not operate normally.
E-17
55 Alarm buzzer cannot be stopped.
E-18
56 When starting switch is turned OFF, service meter is not displayed.
E-19
Machine monitor related (service mode: special function screen) 57 Machine monitor cannot be set in service mode.
E-20 Other items
58 The horn does not sound or does not stop.
E-21
59 The back-up alarm does not sound or does not stop.
E-22
60 The head lamp and rear lamp do not light up.
E-23
61 Windshield wiper does not operate.
E-24
62 Window washer does not operate.
E-25
63 KOMTRAX system does not operate correctly.
E-26
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200 General information on troubleshooting Information contained in troubleshooting table
SEN05030-01
Information contained in troubleshooting table a
1
The following information is summarized in the troubleshooting table and the related electrical circuit diagram. Before performing troubleshooting, understand that information fully. Action code
Failure code
Monitor display
Monitor display
Failure description
Trouble
Problem that appears on machine
Description of the trouble detected by the machine monitor or controller
Action of controller
Action taken by machine monitor or controller to protect system or devices when machine monitor or controller detects trouble
Indication of problem on machine
Problem that appears on machine as result of action taken by machine monitor or controller (shown above)
Related information
Information related to detected trouble or troubleshooting
Cause
Procedure, measuring location, standard (value) and remarks
• Procedure • Measuring location a “Between A – B” means A and B “Measure voltage or resistance and so on between A and B.” • Standard value in normal condition to evaluate assumed cause if it is good condition or not. • Remarks required to evaluate the cause is correct
1
• Disconnection in wiring The connector connection is defective or the wiring harness is disconnected. 2 • Grounding fault A harness not connected to ground (earth) circuit contacts the ground (earth) circuit or machine. • Hot short circuit Possible causes of trouble A harness not connected to the power (24 V) circuit contacts the power (24 V) is assumed to be detected circuit. • Short circuit An independent wire in the harness abnormally contact another wire.
(1) How to indicate connector number and handle T-branch For troubleshooting, insert or connect T-branch adapter as follows unless especially specified. • When “male” or “female” is not indicated with a connector number, disconnect the connector, and insert T-branch adapter in both male and female. • When “male” or “female” is indicated with a connector number, disconnect the connector, and connect T-branch adapter only to either male or female end. (2) Description sequence of pin number and handling of tester lead For troubleshooting, connect plus (+) and minus (–) leads as follows unless especially 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.
3
4
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12
D65EX, PX, WX-16
200 General information on troubleshooting Information contained in troubleshooting table
SEN05030-01
Related circuit diagram
This drawing is a part of the circuit diagram related to troubleshooting. • Connector No.: Indicates (Model – Number of pins) and (Color). • "Connector No. and pin No." from each branching/ merging point: Shows the ends of branch or source of merging within the parts of the same wiring harness. • Arrow (io): Roughly shows the location on the machine. • NO: Normally open • NC: Normally closed a See “Electrical circuit diagram” in chapter 90 for branch label in wiring harness.
D65EX, PX, WX-16
40-200
13
SEN05030-01
200 General information on troubleshooting Troubleshooting method for disconnecting wiring harness of pressure sensor system
Troubleshooting method for disconnecting wiring harness of pressure sensor system a
1
Since pressure sensor consists not only of resistors but also electronic circuits such as amplifiers, it may have the deferences among the registances measured and its own polarities. So troubleshoting must be performed carefully.
Failure codes applicable to this diagnosis q CA123: Charge air pressure sensor low error q 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. 2) Measure resistances R1 and R2 between pins. a If tester probes polarities to apply are reversed, measured values may change. Therefore, when measuring resistances, apply the same tester probe polarities to the pressure sensor in steps 1 and 2. a If measured value is infinite, take measurements with tester probes polarities exchanged each other and record the finite value obtained as a measured value. a Since measured values may be diferent from each other, take several measurements. Cause of the diferences appears to be that the sensor may be charged by the tester. Take several measurement in both steps 1 and 2. Take the fact into consideration this diferences when determining whether the wiring harness is disconnected in step 3.
2.
Measure and record resistance with wiring harness between pressure sensor and engine controller connected. 1) Since 5 V power supply to pressure sensor is supplied to other sensors, disconnect the other sensor connectors first.(*) 2) Connect the pressure sensor to be measured, disconnect connector (3) on engine controller side, and connect T-adapter (4) to wiring harness side. 3) Connect T-box (5) to T-adapter (4) and measure respective pins for resistances R1' and R2'.
3.
Judging disconnection If there is an "apparent difference" between resistances R1 and R2 measured in step 1 and resistances R1' and R2' measured in step 2, "wiring harness is disconnected". a "Apparent difference" means a difference of 10 or more times.
40-200
14
D65EX, PX, WX-16
200 General information on troubleshooting Troubleshooting method for disconnecting wiring harness of pressure sensor system
SEN05030-01
List of pressure sensor measuring locations and reference values Sensor
Charge pressure sensor
Common rail pressure sensor
Sensor pin measuring location
Internal resistance of measured Remarks sensor (reference value)
R2: Between (2) and (4)
Approx. 5.5 kz
R1: Between (1) and (4)
Approx. 7 kz
R2: Between (3) and (1)
Approx. 23 kz
R1: Between (2) (+) and (1) (-) Approx. 17 Mz
Sensor is common to engine models 107 and 114 Sensor is common to engine models 107 and 114 If polarities are reversed, resistance is infinite
*: When measuring R2', disconnect the following connectors.(See circuit diagram related to each code) q When measuring R2' of charge pressure sensor (CA123) Connectors of common rail pressure sensor, CAM sensor and water-in-fuel sensor (water separator) q When measuring R2' of common rail pressure sensor (CA451) Connectors of charge pressure sensor, CAM sensor and water-in-fuel sensor (water separator) Measurement record (For measuring locations, see circuit diagram related to each code) Sensor
Charge pressure sensor
Common rail pressure sensor
Sensor unit (Measuring location on sensor pin side)
Measured value
Sensor + Wiring harness (Measuring location on wiring harness side of engine controller)
R2: Between (2) and (4)
R2': Between (37) and (47) (*)
R1: Between (1) and (4)
R1': Between (44) and (47)
R2: Between (3) and (1)
SR2': Between (37) and (47) (*)
R1: Between (2) (+) and (1) (-)
R1': Between (25) (+) and (47) (-)
D65EX, PX, WX-16
Measured value
40-200
15
200 General information on troubleshooting Connector list and stereogram
SEN05030-01
Connector list and stereogram
1
D65EX-16, D65PX-16, D65WX-16 Connector No.
Model
Number of pins
250
Terminal
1
Starting switch (Terminal B)
O-3
255
Terminal
1
Starting switch (Terminal R1)
O-2
256
Terminal
1
Starting switch (Terminal R2)
N-2
260
Terminal
1
Starting switch (Terminal BR)
N-2
270
Terminal
1
Starting switch (Terminal ACC)
N-3
280
Terminal
1
Starting switch (Terminal C)
N-3
1 SOL
DT
2
Transmission 1st clutch ECMV (Solenoid)
AL-6
1 SW
DT
2
Transmission 1st clutch ECMV (Fill switch)
AL-6
2 SOL
DT
2
Transmission 2nd clutch ECMV (Solenoid)
AN-4
2 SW
DT
2
Transmission 2nd clutch ECMV (Fill switch)
AN-4
3 SOL
DT
2
Transmission 3rd clutch ECMV (Solenoid)
AK-6
3 SW
DT
2
Transmission 3rd clutch ECMV (Fill switch)
AK-6
3DMC
DT-A
12
Intermediate connector (3D-MC select switch)
S-9
A
DT
2
Air suspension seat (If equipped)
S-8
A/C
DT
2
Intermediate connector (Air conditioner compressor)
AC01
YAZAKI
8
Intermediate connector (Air conditioner controller)
X-8
AC02
SUMITOMO
4
Intermediate connector (Air conditioner controller)
W-8
AC03
—
5
Blower relay (Air conditioner)
X-3
AC04
—
4
Compressor relay (Air conditioner)
X-3
AC05
S090
2
A/C refrigerant pressure switch (Air conditioner)
H-1
ACB1
—
7
Blow off motor 1 (Air conditioner)
—
ACB2
—
7
Blow off motor 2 (Air conditioner)
—
ACBM
—
2
Blower motor (Air conditioner)
—
ACCN
040
36
Air conditioner controller
—
ACD
SWP
8
Diode (Air conditioner)
ACFS
—
2
Frost sensor (Air conditioner)
ACG
DT
2
Diode (Air compressor)
ACIS
—
7
Inside-outside servo motor (Air conditioner)
—
ACPS
—
2
Inside temperature sensor (Air conditioner)
—
ACPT
—
4
Power transistor (Air conditioner)
—
ACSM
—
7
A/C servo motor (Air conditioner)
—
AL/B
Terminal
1
Alternator terminal B
AC-5
AL/E
Terminal
1
Alternator terminal E
AC-5
AL/R
Terminal
1
Alternator terminal R
AC-4
3
Air pressure sensor
AH-6
2
Intermediate connector (Air suspension seat)
AMB. AIR PRESSURE FRAMATOME [C29] ASUS
40-200
16
DT
Component name
Address
AC-6
W-2 — AC-8
T-9
D65EX, PX, WX-16
200 General information on troubleshooting Connector list and stereogram
SEN05030-01
Connector No.
Model
Number of pins
AT11
—
1
Monitor panel
O-4
AT12
—
1
GPS antenna
T-1
AT21
—
1
KOMTRAX modem
T-9
AT22
—
1
ORBCOMM antenna
J-9
AUXO
DTHD#12
1
Device drive (If equipped)
E-8
BCV
DT
6
Intermediate connector (Backup lamp, washer motor)
L-5
BKA
SUMITOMO
5
Backup alarm relay
S-1
BKAL
DT
2
Backup alarm
L-5
BNSW
DT
6
Intermediate connector (Blade pitch switch)
S-8
4
Boost pressure & Intake manifold temperature sensor AH-5
BOOST PRESS & IMT SUMITOMO [C4]
Component name
Address
BRB
Terminal
1
Battery relay (Terminal B)
E-7
BRC
Terminal
1
Battery relay (Terminal M)
E-7
BRE
Terminal
1
Battery relay (Terminal E)
E-6
BRK
DT
3
Brake pedal potentiometer
S-1
BRSW
Terminal
1
Battery relay (Terminal BR)
E-6
BVRV
DT
2
Transmission bevel speed sensor
AN-5
C28
DT
2
Intermediate connector (Water-In-Fuel sensor)
AE-1
CA1
DT
3
CAN terminal resistance
AF-2
CA3
DT
3
CAN terminal resistance
W-2
CA4
DT
3
CAN terminal resistance (If equipped)
CAM SENSOR [C13]
FRAMATOME
3
CAM sensor (G)
CB01
DT
4
Intermediate connector (Rear lamp)
K-8
CB02
M
2
Rear speaker (R.H.)
K-8
CB04
M
2
Rear speaker (L.H.)
J-9
CB07
PA
9
Radio
J-9
CB08
M
3
Accessory (12 V output)
B-8
CB10
SWP
6
Additional lamp switch
B-8
CB11
SWP
6
Wiper intermittent switch
B-8
CB12
SWP
6
Rear wiper switch
A-7
CB13
SWP
6
R.H. wiper switch
A-7
CB14
SWP
6
Front wiper switch
A-7
CB15
SWP
6
L.H. wiper switch
A-7
CB16
KES-1
2
Room lamp
H-9
CB17
DT
4
Intermediate connector (Wiper motor for right door)
G-8
CB18
DT
4
Intermediate connector (Front lamp)
G-8
CB23
DT
6
Front wiper motor
G-8
CB24
DT
4
Intermediate connector (Wiper motor for left door)
K-1
CB25
YAZAKI
4
Lamp relay
L-8
D65EX, PX, WX-16
— AC-2
40-200
17
200 General information on troubleshooting Connector list and stereogram
SEN05030-01
Connector No.
Model
Number of pins
CB26
YAZAKI
11
F, R wiper intermittent unit
L-8
CB27
YAZAKI
11
LH, RH wiper intermittent unit
L-7
CB34
SWP
6
Rotary lamp switch
B-8
CB35
DT
2
Intermediate connector (Rotary lamp)
G-8
CB37
DT
6
Rear wiper motor
K-9
CBACC
—
2
Accessory socket
X-7
CBBCN
DT
2
Rotary lamp
H-9
CBCIG
—
2
Cigarette lighter
X-7
CBCV1
DT
6
DC converter
L-8
CBFB1
Terminal
1
Fuse box
C-8
CBFB2
Terminal
1
Fuse box
C-8
CBFB3
Terminal
1
Fuse box
C-8
CBFL
DT
2
Front lamp (L.H.)
H-9
CBFR
DT
2
Front lamp (R.H.)
H-8
CBRL
DT
2
Rear lamp (L.H.)
K-8
CBRR
DT
2
Rear lamp (R.H.)
J-9
CE02
DRC26
50
Engine controller CM850
AG-3
CE03
DTP
4
Engine controller CM850
AF-2
Ck01
070
14
KOMTRAX modem
S-9
CK02
070
10
KOMTRAX modem
T-9
CLP
SUMITOMO
5
Rotary lamp relay
U-1
CM01
070
18
Monitor panel
O-9
CM02
070
12
Monitor panel
P-7
CM03
070
18
Monitor panel
M-8
COOLANT TEMP [C5]
PACKARD
2
Coolant temperature sensor
AD-9
CRANK SENSOR [C15]
FRAMATOME
3
Crank sensor (Ne)
AH-4
DCL
DT
3
Decelerator pedal potentiometer
S-2
DIA2
DT
3
Fuel control dial
V-9
DIAL
DT
3
Intermediate connector (Fuel control dial)
S-5
DPNL
DT
2
Diode (Emergency switch)
DSH
DRC
40
Intermediate connector
M-5
ECM [CE01]
DRC26
60
Engine controller CM850
AF-2
EG1
DTP
2
Intermediate connector (Engine harness from left fender harness)
AH-6
EG2
DT-A
12
Intermediate connector (Left fender harness from engine harness)
AH-6
EP1
SHINAGAWA
5
Engine power relay 1
V-1
EP2
SHINAGAWA
5
Engine power relay 2
U-1
40-200
18
Component name
Address
AM-9
D65EX, PX, WX-16
200 General information on troubleshooting Connector list and stereogram
SEN05030-01
Connector No.
Model
Number of pins
F SOL
DT
2
Transmission F clutch ECMV (Solenoid)
AN-3
F SW
DT
2
Transmission F clutch ECMV (Fill switch)
AN-3
F50
DTP
4
Intermediate connector (Cab power and engine controller power)
E-7
F120
DTHD#4
1
Intermediate connector (Main power 24 V)
E-7
FAC
DT
2
Fan pump control valve
AI-4
FAR
DT
2
Fan reverse solenoid valve
C-2
FAR_OPT
DT
2
Fan reverse solenoid valve (If equipped)
—
FD1
DRC
40
Intermediate connector
FL1
—
—
Fusible link
E-9
FL2
—
—
Fusible link
E-9
FLP1
SUMITOMO
5
Front lamp relay
U-1
FLP2
SUMITOMO
5
Front lamp relay (If equipped)
FLSW
SWP
6
Front lamp switch
M-8
FLV
DT
2
Fuel level sensor
L-1
FS11
—
—
Fuse box
S-2
FS12
—
—
Fuse box
S-2
FTK
DT
4
Intermediate connector (Fuel level sensor and backup alarm)
L-7
FUEL LIFT PUMP [C18]
DT
2
Lift pump valve
AD-2
FUEL RAIL PRESS. [C8]
BOSCH
3
Common rail pressure sensor
AH-3
GND
Terminal
1
GND (ROPS)
K-1
GND03
Terminal
1
GND (Fame R.H.)
E-5
GND1
Terminal
1
GND (Engine body)
AF-2
GND2
Terminal
1
GND (Engine body)
AD-8
GND3
Terminal
1
GND (Engine body)
AC-3
GND4
Terminal
1
GND (Engine body)
AC-7
GND11
Terminal
1
GND (Engine connector) (floor)
X-4
GND12
Terminal
1
GND (Air conditioner) (floor)
X-4
GNDC1
Terminal
1
GND (Cab)
I-9
GNDC2
Terminal
1
GND (Cab)
I-9
GNDC3
Terminal
1
GND (Cab)
K-8
GNDC4
Terminal
1
GND (Cab)
J-9
GNDC5
Terminal
1
GND (Cab)
X-5
HDT
DT
2
Hydraulic oil temperature sensor
A-2
HHP
AMP
3
Hydraulic oil pump pressure sensor
AJ-5
HNSW
—
2
Horn switch
S-7
HRN
—
1
Horn
C-3
D65EX, PX, WX-16
Component name
Address
D-8, X-2
—
40-200
19
200 General information on troubleshooting Connector list and stereogram
SEN05030-01
Connector No.
Model
Number of pins
HRN_OPT
—
1
Horn (If equipped)
—
HSL
DT
2
HSS left EPC valve
C-3
HSR
DT
2
HSS right EPC valve
A-2
HT/A
Terminal
1
Heater relay (Terminal A)
AF-9
HT/B
Terminal
1
Heater relay (Terminal B)
AG-8
HT/C
Terminal
1
Heater relay (Terminal C)
AE-9
HTD
DT
2
Diode
AE-9
INJECTOR CYL 1&2 [C9]
DTP
4
Intermediate connector (Injector #1and #2)
AC-7
INJECTOR CYL 3&4 [C10]
DTP
4
Intermediate connector (Injector #3 and #4)
AC-8
INJECTOR CYL 5&6 [C11]
DTP
4
Intermediate connector (Injector #5 and #6)
AH-7
INLET METERING VALVE [C17]
DT
2
Inlet metering valve
AC-4
KEY
DT
6
Starting switch
P-8
L SOL
DT
2
Torque converter lockup clutch ECMV (Solenoid)
AJ-5
L SW
DT
2
Torque converter lockup clutch ECMV (Fill switch)
AJ-5
LDNE
DT
2
Lift down EPC valve (If equipped)
—
LDNS
DT
2
Lift down EPC switch (If equipped)
—
LHDL
DT
2
Front lamp (L.H.)
C-4
LHDL1
DT
2
Front lamp (L.H.) (If equipped)
—
LHDL2
DT
2
Front lamp (L.H.) (If equipped)
—
LHDR
DT
2
Front lamp (R.H.)
LHDR1
DT
2
Front lamp (R.H.) (If equipped)
—
LHDR2
DT
2
Front lamp (R.H.) (If equipped)
—
LMD
SWP
8
Diode
N-9
LREL
DT
2
Rear lamp
L-6
LRSE
DT
2
Lift raise EPC valve (If equipped)
—
LRSS
DT
2
Lift raise EPC switch (If equipped)
—
NSF
SUMITOMO
5
Neutral safety relay
T-1
OIL PRESSURE SWITCH [C2]
FRAMATOME
2
Engine oil pressure switch
AG-2
OPPW
DT
2
Device power (If equipped)
T-1
PAC
DT
6
Intermediate connector (Brake and decelerator pedal potentiometer)
S-1
PHR
SUMITOMO
5
Preheater relay
U-1
PKSW
DT
3
Parking brake lock switch
X-4
PL1
DRC
70
Intermediate connector (Power train controller)
X-3
PL1F
DRC
70
Intermediate connector (Emergency switch)
40-200
20
Component name
Address
C-4
AM-9
D65EX, PX, WX-16
200 General information on troubleshooting Connector list and stereogram
SEN05030-01
Connector No.
Model
Number of pins
PL1M
DRC
70
Intermediate connector (Emergency switch)
AN-9
PNL
HD-24
31
Intermediate connector (Emergency switch)
AL-9
POA
—
3
3D-MC select switch (If equipped)
—
POB
—
3
Blade pitch select switch (If equipped)
S-6
POB
—
3
3D-MC select switch (If equipped)
—
PRT
DT-A
8
Intermediate connector (Front lamp, horn and fan reverse solenoid valve)
D-5
PT1
DT
3
Pitch angle sensor
D-5
PTF
X
4
Intermediate connector (Flash power train controller)
W-2
PTP
DT
2
Blade pitch select solenoid (If equipped)
C-5
R SOL
DT
2
Transmission R clutch ECMV (Solenoid)
AK-5
R SW
DT
2
Transmission R clutch ECMV (Fill switch)
AJ-5
RFD
DT-A
12
Intermediate connector (HSS EPC solenoid and hydraulic oil temperature sensor)
C-3, AI-5
RLP
SUMITOMO
5
Rear lamp relay
V-1
RLSW
SWP
6
Rear lamp switch
M-7
RSD
SWP
8
Diode
W-2
SFTD
—
3
Shift-down switch
U-9
SFTU
—
3
Shift-up switch
V-9
SLS
YAZAKI
2
Daylight sensor
M-9
SRV
DT-A
12
Intermediate connector (Service connector)
S-5
ST
DT
2
Intermediate connector (Starting motor)
AH-8
ST/B
Terminal
1
Starting motor (Terminal B)
AG-8
STC1
DRC26
24
Power train controller
V-1
STC2
DRC26
40
Power train controller
V-2
STC3
DRC26
40
Power train controller
W-2
STRG
X
2
Resistor (Emergency switch)
AN-8
TCT
DT
2
Torque converter oil temperature sensor
AM-2
TIP
AMP
3
Torque converter oil pressure sensor
AL-1
TLHE
DT
2
Blade left tilt EPC valve (If equipped)
—
TLHS
DT
2
Blade left tilt switch (If equipped)
—
TLV1
DT-B
8
Lever assembly
W-8
TLV2
DT
6
Intermediate connector (Shift switch)
S-6
TMRG
M
2
Resistor (Emergency switch)
AM-7
TOOL PORT [C12]
DT
3
CAN
AE-1
TRHE
DT
2
Blade right tilt EPC valve (If equipped)
—
TRHS
DT
2
Blade right tilt switch (If equipped)
—
TVC
DT
2
Pump TVC solenoid valve
AI-4
WELK
DT
3
Work equipment lock lever switch
S-8
D65EX, PX, WX-16
Component name
Address
40-200
21
200 General information on troubleshooting Connector list and stereogram
SEN05030-01
a
Connector No.
Model
Number of pins
W.I.F. [WIF]
DT
2
Water-In-Fuel sensor
WLK
DT
2
Work equipment lock lever solenoid
C-2
WSFR
—
2
Window washer motor (Front)
K-1
WSLH
—
2
Window washer motor (Left)
L-2
WSRH
—
2
Window washer motor (Right)
L-1
WSRR
—
2
Window washer motor (Rear)
L-1
Component name
Address AG-8
The color symbols of the bodies of the heavy duty wire connectors (DT-8 poles, 12 poles) are as follows. DT-A = Gray, DT-B = Black, DT-C = Green, DT-D = Brown
40-200
22
D65EX, PX, WX-16
200 General information on troubleshooting Connector list and stereogram
D65EX, PX, WX-16
SEN05030-01
40-200
23
SEN05030-01
200 General information on troubleshooting Connector list and stereogram
Connector arrangement diagram (1/6)
40-200
24
D65EX, PX, WX-16
200 General information on troubleshooting Connector list and stereogram
SEN05030-01
(2/6)
D65EX, PX, WX-16
40-200
25
SEN05030-01
200 General information on troubleshooting Connector list and stereogram
(3/6)
40-200
26
D65EX, PX, WX-16
200 General information on troubleshooting Connector list and stereogram
SEN05030-01
(4/6)
D65EX, PX, WX-16
40-200
27
SEN05030-01
200 General information on troubleshooting Connector list and stereogram
(5/6)
40-200
28
D65EX, PX, WX-16
200 General information on troubleshooting Connector list and stereogram
SEN05030-01
(6/6)
D65EX, PX, WX-16
40-200
29
SEN05030-01
Connection table for connector pin numbers a
200 General information on troubleshooting Connection table for connector pin numbers
(Rev. 2009.04)
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.
40-200
30
D65EX, PX, WX-16
200 General information on troubleshooting Connection table for connector pin numbers
D65EX, PX, WX-16
SEN05030-01
40-200
31
SEN05030-01
40-200
32
200 General information on troubleshooting Connection table for connector pin numbers
D65EX, PX, WX-16
200 General information on troubleshooting Connection table for connector pin numbers
D65EX, PX, WX-16
SEN05030-01
40-200
33
SEN05030-01
40-200
34
200 General information on troubleshooting Connection table for connector pin numbers
D65EX, PX, WX-16
200 General information on troubleshooting Connection table for connector pin numbers
D65EX, PX, WX-16
SEN05030-01
40-200
35
SEN05030-01
40-200
36
200 General information on troubleshooting Connection table for connector pin numbers
D65EX, PX, WX-16
200 General information on troubleshooting Connection table for connector pin numbers
D65EX, PX, WX-16
SEN05030-01
40-200
37
SEN05030-01
40-200
38
200 General information on troubleshooting Connection table for connector pin numbers
D65EX, PX, WX-16
200 General information on troubleshooting Connection table for connector pin numbers
D65EX, PX, WX-16
SEN05030-01
40-200
39
SEN05030-01
40-200
40
200 General information on troubleshooting Connection table for connector pin numbers
D65EX, PX, WX-16
200 General information on troubleshooting Connection table for connector pin numbers
D65EX, PX, WX-16
SEN05030-01
40-200
41
SEN05030-01
40-200
42
200 General information on troubleshooting Connection table for connector pin numbers
D65EX, PX, WX-16
200 General information on troubleshooting Connection table for connector pin numbers
D65EX, PX, WX-16
SEN05030-01
40-200
43
SEN05030-01
40-200
44
200 General information on troubleshooting Connection table for connector pin numbers
D65EX, PX, WX-16
200 General information on troubleshooting Connection table for connector pin numbers
D65EX, PX, WX-16
SEN05030-01
40-200
45
SEN05030-01
40-200
46
200 General information on troubleshooting Connection table for connector pin numbers
D65EX, PX, WX-16
200 General information on troubleshooting Connection table for connector pin numbers
D65EX, PX, WX-16
SEN05030-01
40-200
47
SEN05030-01
40-200
48
200 General information on troubleshooting Connection table for connector pin numbers
D65EX, PX, WX-16
200 General information on troubleshooting Connection table for connector pin numbers
D65EX, PX, WX-16
SEN05030-01
40-200
49
SEN05030-01
40-200
50
200 General information on troubleshooting Connection table for connector pin numbers
D65EX, PX, WX-16
200 General information on troubleshooting Connection table for connector pin numbers
D65EX, PX, WX-16
SEN05030-01
40-200
51
SEN05030-01
40-200
52
200 General information on troubleshooting Connection table for connector pin numbers
D65EX, PX, WX-16
200 General information on troubleshooting Connection table for connector pin numbers
D65EX, PX, WX-16
SEN05030-01
40-200
53
SEN05030-01
40-200
54
200 General information on troubleshooting Connection table for connector pin numbers
D65EX, PX, WX-16
200 General information on troubleshooting Connection table for connector pin numbers
D65EX, PX, WX-16
SEN05030-01
40-200
55
SEN05030-01
40-200
56
200 General information on troubleshooting Connection table for connector pin numbers
D65EX, PX, WX-16
200 General information on troubleshooting Connection table for connector pin numbers
D65EX, PX, WX-16
SEN05030-01
40-200
57
SEN05030-01
40-200
58
200 General information on troubleshooting Connection table for connector pin numbers
D65EX, PX, WX-16
200 General information on troubleshooting Connection table for connector pin numbers
D65EX, PX, WX-16
SEN05030-01
40-200
59
SEN05030-01
40-200
60
200 General information on troubleshooting Connection table for connector pin numbers
D65EX, PX, WX-16
200 General information on troubleshooting Connection table for connector pin numbers
D65EX, PX, WX-16
SEN05030-01
40-200
61
SEN05030-01
40-200
62
200 General information on troubleshooting Connection table for connector pin numbers
D65EX, PX, WX-16
200 General information on troubleshooting Connection table for connector pin numbers
D65EX, PX, WX-16
SEN05030-01
40-200
63
SEN05030-01
40-200
64
200 General information on troubleshooting Connection table for connector pin numbers
D65EX, PX, WX-16
200 General information on troubleshooting Connection table for connector pin numbers
D65EX, PX, WX-16
SEN05030-01
40-200
65
200 General information on troubleshooting T- branch box and T- branch adapter table
SEN05030-01
T- branch box and T- branch adapter table
The vertical column indicates a part number of T-branch box or T-branch adapter while the horizontal column indicates a part number of harness checker assembly.
q
q
q q
Out of kit
799-601-4201
799-601-4101
799-601-9300
799-601-9200
799-601-9100
799-601-9000
799-601-8000
799-601-7500
799-601-7400
799-601-7100
799-601-7000
799-601-2800
Identification symbol
799-601-2700
Part name
T-adapter kit 799-601-2500
Part No.
Number of pins
a
(Rev. 2009.03)1
q
799-601-2600 T-box (for ECONO)
21
799-601-3100 T-box (for MS)
37
q
799-601-3200 T-box (for MS)
37
q q
799-601-3380 Plate for MS (14-pin) 799-601-3410 Adapter for BENDIX (MS)
24
MS-24P
q
799-601-3420 Adapter for BENDIX (MS)
24
MS-24P
q
799-601-3430 Adapter for BENDIX (MS)
17
MS-17P
q
799-601-3440 Adapter for BENDIX (MS)
17
MS-17P
q
799-601-3450 Adapter for BENDIX (MS)
5
MS-5P
q
799-601-3460 Adapter for BENDIX (MS)
10
MS-10P
q
799-601-3510 Adapter for BENDIX (MS)
5
MS-5P
q
799-601-3520 Adapter for BENDIX (MS)
17
MS-17P
q
799-601-3530 Adapter for BENDIX (MS)
19
MS-19P
q
799-601-2910 Adapter for BENDIX (MS)
14
MS-14P
q
799-601-2710 Adapter for MIC
5
MIC-5P
q q
799-601-2720 Adapter for MIC
13
MIC-13P
q q
799-601-2730 Adapter for MIC
17
MIC-17P
q q q
q q
799-601-2740 Adapter for MIC
21
MIC-21P
q q q
q q
q
799-601-2950 Adapter for MIC
9
MIC-9P
q q q
q
799-601-2750 Adapter for ECONO
2
ECONO2P
q q
799-601-2760 Adapter for ECONO
3
ECONO3P
q q
799-601-2770 Adapter for ECONO
4
ECONO4P
q q
799-601-2780 Adapter for ECONO
8
ECONO8P
q q
799-601-2790 Adapter for ECONO
12 ECONO12P q q
q
799-601-3470 Case
799-601-2810 Adapter for DLI
8
DLI-8P
q q
799-601-2820 Adapter for DLI
12
DLI-12P
q q
799-601-2830 Adapter for DLI
16
DLI-16P
q q
799-601-2840 Extension cable (ECONO type)
12 ECONO12P q q
q q
q
q
799-601-2850 Case 799-601-4350 T-box (for DRC 60, ECONO)
q
q
60
q
799-601-4360 Case 799-601-7010 Adapter for X (T-adapter)
1
799-601-7020 Adapter for X
2
799-601-7030 Adapter for X
3
q
q
X2P
q q q
q
X3P
q q q
q q
799-601-7040 Adapter for X
4
X4P
q q q
799-601-7050 Adapter for SWP
6
SW6P
q q q
799-601-7060 Adapter for SWP
8
SW8P
q q q
799-601-7310 Adapter for SWP
12
SW12P
799-601-7070 Adapter for SWP
14
SW14P
799-601-7320 Adapter for SWP
16
SW16P
799-601-7080 Adapter for M (T-adapter)
1
799-601-7090 Adapter for M
2
799-601-7110 Adapter for M
3
40-200
66
q q
q
q
q
M2P
q q q
q
M3P
q q q
q
q
D65EX, PX, WX-16
200 General information on troubleshooting T- branch box and T- branch adapter table
SEN05030-01
Out of kit
799-601-4201
799-601-4101
799-601-9300
799-601-9200
799-601-9100
M8P
799-601-9000
8
799-601-8000 q
799-601-7340 Adapter for M
799-601-7500
q
q q q
799-601-7400
q q q
M6P
799-601-7100
M4P
6
799-601-7000
4
799-601-7130 Adapter for M
799-601-2800
799-601-7120 Adapter for M
Part name
799-601-2700
Identification symbol
Part No.
799-601-2500
Number of pins
T-adapter kit
q
799-601-7140 Adapter for S
8
S8P
q q q
q
799-601-7150 Adapter for S (White)
10
S10P
q q q
q
799-601-7160 Adapter for S (Blue)
12
S12P
q q q
799-601-7170 Adapter for S (Blue)
16
S16P
q q q
799-601-7330 Adapter for S (White)
16
S16PW
799-601-7350 Adapter for S (White)
12
S12PW
799-601-7180 Adapter for AMP040
8
A8P
q
799-601-7190 Adapter for AMP040
12
A12P
q
q
799-601-7210 Adapter for AMP040
16
A16P
q q q
q
799-601-7220 Adapter for AMP040
20
A20P
q q q
q
799-601-7230 Short connector for X
2
—
q q q
q
q q q
q q
799-601-7240 Case
q
799-601-7270 Case 799-601-7510 Adapter for 070
10
07-10
q
799-601-7520 Adapter for 070
12
07-12
q
799-601-7530 Adapter for 070
14
07-14
q
799-601-7540 Adapter for 070
18
07-18
q
799-601-7550 Adapter for 070
20
07-20
q
799-601-7360 Adapter for relay
5
REL-5P
q
799-601-7370 Adapter for relay
6
REL-6P
q
799-601-7380 Adapter for JFC
2
—
799-601-9010 Adapter for DTM
2
DTM2
q
q
q
799-601-9020 Adapter for DT
2
DT2
q
q
799-601-9030 Adapter for DT
3
DT3
q
q
799-601-9040 Adapter for DT
4
DT4
q
q
799-601-9050 Adapter for DT
6
DT6
q
q
799-601-9060 Adapter for DT (Gray)
8
DT8GR
q
q
799-601-9070 Adapter for DT (Black)
8
DT8B
q
q
799-601-9080 Adapter for DT (Green)
8
DT8G
q
q
799-601-9090 Adapter for DT (Brown)
8
DT8BR
q
q
799-601-9110 Adapter for DT (Gray)
12
DT12GR
q
q
799-601-9120 Adapter for DT (Black)
12
DT12B
q
q
799-601-9130 Adapter for DT (Green)
12
DT12G
q
q
799-601-9140 Adapter for DT (Brown)
12
DT12BR
q
q
799-601-9210 Adapter for HD30-18
8
D18-8
q q
799-601-9220 Adapter for HD30-18
14
D18-14
q q
799-601-9230 Adapter for HD30-18
20
D18-20
q q
799-601-9240 Adapter for HD30-18
21
D18-21
q q
799-601-9250 Adapter for HD30-24
9
D24-9
q q
799-601-9260 Adapter for HD30-24
16
D24-16
q q
799-601-9270 Adapter for HD30-24
21
D24-21
q q
799-601-9280 Adapter for HD30-24
23
D24-23
q q
799-601-9290 Adapter for HD30-24
31
D24-31
q q
799-601-9310 Plate for HD30 (24-pin) 799-601-9320 T-box (for ECONO)
D65EX, PX, WX-16
24
q q q q
q q
q
q q
q
40-200
67
200 General information on troubleshooting T- branch box and T- branch adapter table
q
799-601-9330 Case
q
799-601-9340 Case 799-601-9350 Adapter for DRC
40
DRC-40
q q
799-601-9360 Adapter for DRC
24
DRC-24
799-601-9410* Socket for engine (CRI-T2)
2
G
Adapter for engine (CRI-T2) 799-601-9420 Adapter for engine (CRI-T3) PFUEL Oil pressure sensor
3
A3
q q
2
P
q q
799-601-9430*
Socket for engine (CRI-T2) Socket for engine (CRI-T3) PCV
Out of kit
799-601-4201
799-601-4101
799-601-9300
799-601-9200
799-601-9100
799-601-9000
799-601-8000
799-601-7500
799-601-7400
799-601-7100
799-601-7000
799-601-2800
Identification symbol
799-601-2700
Part name
T-adapter kit 799-601-2500
Part No.
Number of pins
SEN05030-01
q
799-601-9440* Socket for engine (CRI-T2)
3
1,2,3
q
795-799-5520* Socket for engine (HPI-T2)
2
S
q
Socket for engine (HPI-T2) 795-799-5530* Socket for engine (CRI-T3) Temperature sensor
2
C
q q
2
A
q q
795-799-5460 Cable for engine (HPI-T2)
3
—
q
795-799-5470 Cable for engine (HPI-T2)
3
—
q
795-799-5480 Cable for engine (HPI-T2)
3
—
q
795-799-5540*
Socket for engine (HPI-T2) Socket for engine (CRI-T3) TIM
799-601-4110 Adapter for engine (140-T3) PIM
4
ITT3N
q q
799-601-4130 Adapter for engine (CRI-T3) NE, CAM
3
FCIN
q q
Adapter for engine (CRI-T3) 799-601-4140 Atomosphere pressure
3
FCIG
q q
799-601-4150 Adapter for engine (CRI-T3) POIL
3
FCIB
q q
Adapter for engine (CRI-T3) 799-601-4160 Oil pressure switch
2
4160
q q
799-601-4180 Adapter for engine (CRI-T3) PEVA
3
4180
q q
Socket for engine (CRI-T3) 799-601-4190* Commonrail pressure
3
1,2,3L
q q
4
1,2,3,4C
q q
799-601-4230*
Socket for engine (CRI-T3) Air intake pressure/temperature
799-601-4240* Socket for engine (CRI-T3) PAMB
3
1,2,3A
q q
799-601-4250* Socket for engine (CRI-T3) PIM
3
1,2,3B
q q
799-601-4330* Socket for engine (CRI-T3) G
3
1,2,3,G
q q q q
799-601-4340*
Socket for engine (CRI-T3) Pump actuator
2
2,PA
799-601-4380*
Socket for engine (CRI-T3)(95) Air intake pressure/temperature
4
1,2,3,4T
q q q
799-601-4260 Adapter for controller (ENG)
4
DTP4
799-601-4211 Adapter for controller (ENG)
50
DRC50
q q
799-601-4220 Adapter for controller (ENG)
60
DRC60
799-601-4390* Socket for controller (95 ENG)
60
—
q
799-601-4280* Box for controller (PUMP)
121
—
q
799-601-9720 Adapter for controller (HST)
16
HST16A
q
799-601-9710 Adapter for controller (HST)
16
HST16B
q
799-601-9730 Adapter for controller (HST)
26
HST26A
q
2, 3, 4,
—
q
799-601-9890
Multi-adapter for DT2 – 4 and DTM2
“*” Shows not T-adapter but socket. 40-200
68
D65EX, PX, WX-16
200 General information on troubleshooting T- branch box and T- branch adapter table
D65EX, PX, WX-16
SEN05030-01
40-200
69
SEN05030-01
D65EX-16, D65PX-16, D65WX-16 Bulldozer Form No. SEN05030-01
©2009 KOMATSU All Rights Reserved Printed in Japan 07-09
40-200
70
SEN05031-00
BULLDOZER D65EX-16 D65PX-16 D65WX-16 Machine model D65EX-16 D65PX-16 D65WX-16
Serial number 80001 and up 80001 and up 80001 and up
40 Troubleshooting
40
301 Troubleshooting by failure code (Display of code), Part 1 Failure code [1500L0] Transmission clutch: Abnormal ................................................................................... 3 Failure code [15SAL1] Forward clutch: Fill high ............................................................................................. 4 Failure code [15SALH] Forward clutch: Fill low .............................................................................................. 6 Failure code [15SBL1] Reverse clutch: Fill high ............................................................................................. 8 Failure code [15SBLH] Reverse clutch: Fill low ............................................................................................ 10 Failure code [15SEL1] Speed 1st clutch: Fill high......................................................................................... 12 Failure code [15SELH] Speed 1st clutch: Fill low ......................................................................................... 14 Failure code [15SFL1] Speed 2nd clutch: Fill high........................................................................................ 16 Failure code [15SFLH] Speed 2nd clutch: Fill low ........................................................................................ 18 Failure code [15SGL1] Speed 3rd clutch: Fill high........................................................................................ 20 Failure code [15SGLH] Speed 3rd clutch: Fill low......................................................................................... 22 Failure code [15SJL1] L/U: Fill high .............................................................................................................. 24 Failure code [15SJLH] L/U: Fill low............................................................................................................... 26 Failure code [AB00MA] Battery Charge Abnormal ....................................................................................... 28 Failure code [B@BAZG] Eng Oil Press Low................................................................................................. 30 Failure code [B@BCNS] Eng Water Overheat.............................................................................................. 30 Failure code [B@CENS] T/C Oil Overheat ................................................................................................... 31 Failure code [B@HANS] Hyd Oil Overheat................................................................................................... 31
D65EX, PX, WX-16
40-301
1
SEN05031-00
40-301
2
301 Troubleshooting by failure code (Display of code), Part 1
D65EX, PX, WX-16
301 Troubleshooting by failure code (Display of code), Part 1 Failure code [1500L0] Transmission clutch: Abnormal
SEN05031-00
Failure code [1500L0] Transmission clutch: Abnormal Action code
Failure code
E03
1500L0
Failure description
Action of controller
Trouble
1
Transmission clutch: Abnormal (Power train controller system)
• Of the failure codes related to the transmission clutch, the following codes were displayed at the same time. (Gear speed is limited.) (1) Either [DXH4KA] or [DXH4KB] and either [DXH5KA] or [DXH5KB] • Of the failure codes related to the transmission clutch, the following codes were displayed at the same time. (Machine can not travel.) (2) Either [DXH8KA] or [DXH8KB] and either [DXH7KA] or [DXH7KB] (3) Either of [DXH6KA] or [DXH6KB] and (1) above (4) [15SALH] and [15SBLH] (5) Either [15SAL1] or [DXH8KY] and either [15SBL1] or [DXH7KY] (6) [15SELH], [15SFLH], and [15SGLH] (7) Either [15SEL1] or [DXH4KY] and either [15SFL1] or [DXH5KY] (8) Either [15SEL1] or [DXH4KY] and either [15SGL1] or [DXH6KY] (9) Either [15SFL1] or [DXH5KY] and either [15SGL1] or [DXH6KY] • Limits operation of engine and transmission.
Indication of problem on machine
• • • •
The auto shift down function does not work. Once machine is stopped, engine speed is limited to medium (half). Once machine is stopped, traveling is limited to specific gear speeds. Machine cannot travel.
Related information
• Duplication of failure code: Engine start and travel
Cause Procedure, measuring location, standard (value) and remarks Confirm the failure codes displayed at the same time, then perform troubleshooting for the codes. [15SAL1], [15SALH], [15SBL1], [15SBLH], [15SEL1], [15SELH], [15SFL1], [15SFLH], [15SGL1], [15SGLH] [DXH4KA], [DXH4KB], [DXH4KY], [DXH5KA], [DXH5KB], [DXH5KY], [DXH6KA], [DXH6KB], [DXH6KY], [DXH7KA], [DXH7KB], [DXH7KY], [DXH8KA], [DXH8KB], [DXH8KY]
D65EX, PX, WX-16
40-301
3
301 Troubleshooting by failure code (Display of code), Part 1 Failure code [15SAL1] Forward clutch: Fill high
SEN05031-00
Failure code [15SAL1] Forward clutch: Fill high Action code
Failure code
E03
15SAL1
Failure description
Trouble
1
Forward clutch: Fill high (Power train controller system)
• Nevertheless controller does not output to transmission F clutch ECMV solenoid circuit, fill switch signal is turned ON. • Sets transmission in neutral when operator sets it in reverse position (Prevention of double engagement). • Limits operation of engine and transmission.
Action of controller Indication of problem on machine
• Once machine is stopped, engine speed is limited to medium (half). • Once machine is stopped, travel is limited to F1.
Related information
• State of F clutch ECMV fill switch signal can be checked with monitoring function. (Code: 40906 T/M Fill Sw Input 1) • Method of reproducing failure code: Start engine and set transmission in neutral. • Remove seat (approx. 50 kg) and seat bottom cover. • First, check the power train oil filter for clogging etc. • Next, check that clutch pressure is normal with reference to the troubleshooting (H mode), “H-1”.
Cause
1
2
3
4
Procedure, measuring location, standard (value) and remarks 1. Turn starting switch to OFF position. Defective F clutch ECMV fill 2. Disconnect connector F SW and connect T-adapter to male side. switch (Internal short circuit) Between F SW (female) (1) and ground Resistance Min. 1 Mz (Fill switch OFF) 1. Turn starting switch to OFF position. 2. Disconnect connector F SW. Ground fault of wiring 3. Start engine. harness or defective If failure code [15SAL1] is still displayed, there is ground fault of wiring harness or power train controller power train controller is defective. (If failure code [15SAL1] is not displayed, F clutch fill switch is defective) a If cause 2 is not the cause for the trouble, this check is not required. 1. Turn starting switch to OFF position. Ground fault of wiring 2. Disconnect connectors STC2 and F SW and connect T-adapter to female side of harness (Contact with either of them. ground circuit) Between STC2 (female) (35) or F SW (female) (1) and Resistance Min. 1 Mz ground If “check result of cause 2 is abnormal” and “check result of cause 3 is normal”, power train controller is defective. • Reference; the followings are standard values in normal condition. 1. Turn starting switch to OFF position. 2. Insert T-adapter into connector STC2. 3. Start engine. Defective power train a Keep PCCS lever in N position. controller Between STC2 (35) and ground Voltage 7 – 11 V 1. – 3. are same as above. 4. While depressing brake pedal, operate PCCS lever (travel gear speed) and perform troubleshooting. Between STC2 (35) and ground F1/F2/F3 Voltage Max. 1 V
40-301
4
D65EX, PX, WX-16
301 Troubleshooting by failure code (Display of code), Part 1 Failure code [15SAL1] Forward clutch: Fill high
SEN05031-00
Related circuit diagram
D65EX, PX, WX-16
40-301
5
301 Troubleshooting by failure code (Display of code), Part 1 Failure code [15SALH] Forward clutch: Fill low
SEN05031-00
Failure code [15SALH] Forward clutch: Fill low Action code
Failure code
E03
15SALH
Failure description
Trouble
1
Forward clutch: Fill low (Power train controller system)
• Nevertheless controller outputs to transmission F clutch ECMV solenoid circuit, fill switch signal is turned OFF. • Sets transmission in neutral when operator sets it in forward position (Prevention of defective engagement). • Limits operation of engine and transmission.
Action of controller Indication of problem on machine
• Once machine is stopped, engine speed is limited to medium (half). • Once machine is stopped, travel is limited to R1.
Related information
• State of F clutch ECMV fill switch signal can be checked with monitoring function. (Code: 40906 T/M Fill Sw Input 1) • Method of reproducing failure code: Start engine and set transmission in forward position. • Remove seat (approx. 50 kg) and seat bottom cover. • First, check the power train oil filter for clogging etc. • Next, check that clutch pressure is normal with reference to the troubleshooting (H mode), “H-1”.
Cause
Procedure, measuring location, standard (value) and remarks 1. Turn starting switch to OFF position. 2. Disconnect connector F SW and connect T-adapter to male side. 3. Start engine. a Keep PCCS lever in N position. Defective F clutch ECMV fill Between F SW (male) (1) and ground Resistance Min. 1 Mz 1 switch (It does not turn ON) 1. – 3. are same as above. 4. While depressing brake pedal, operate PCCS lever (travel gear speed) and perform troubleshooting. Between F SW (male) (1) and ground F1/F2/F3 Resistance Max. 1 z 1. Turn starting switch to OFF position. Disconnection in wiring 2. Disconnect connectors STC2 and F SW and connect T-adapters to female side of 2 harness (Disconnection or them. defective contact) Between STC2 (female) (35) and F SW (female) (1) Resistance Max. 1 z 1. Turn starting switch to OFF position. 2. Insert T-adapter into connector STC2. 3. Start engine. a Keep PCCS lever in N position. Defective power train Between STC2 (35) and ground Voltage 7 – 11 V 3 controller 1. – 3. are same as above. 4. While depressing brake pedal, operate PCCS lever (travel gear speed) and perform troubleshooting. Between STC2 (35) and ground F1/F2/F3 Voltage Max. 1 V
40-301
6
D65EX, PX, WX-16
301 Troubleshooting by failure code (Display of code), Part 1 Failure code [15SALH] Forward clutch: Fill low
SEN05031-00
Related circuit diagram
D65EX, PX, WX-16
40-301
7
301 Troubleshooting by failure code (Display of code), Part 1 Failure code [15SBL1] Reverse clutch: Fill high
SEN05031-00
Failure code [15SBL1] Reverse clutch: Fill high Action code
Failure code
E03
15SBL1
Failure description
Trouble
1
Reverse clutch: Fill high (Power train controller system)
• Nevertheless controller does not output to transmission R clutch ECMV solenoid circuit, fill switch signal is turned ON. • Sets transmission in neutral when operator sets it in forward position (Prevention of double engagement). • Limits operation of engine and transmission.
Action of controller Indication of problem on machine
• Once machine is stopped, engine speed is limited to medium (half). • Once machine is stopped, travel is limited to R1.
Related information
• State of R clutch ECMV fill switch signal can be checked with monitoring function. (Code: 40906 T/M Fill Sw Input 1) • Method of reproducing failure code: Start engine and set transmission in neutral. • Remove seat (approx. 50 kg) and seat bottom cover. • First, check the power train oil filter for clogging etc. • Next, check that clutch pressure is normal with reference to the troubleshooting (H mode), “H-1”.
Cause
1
2
3
4
Procedure, measuring location, standard (value) and remarks 1. Turn starting switch to OFF position. Defective R clutch ECMV fill 2. Disconnect connector R SW and connect T-adapter to male side. switch (Internal short circuit) Between R SW (female) (1) and ground Resistance Min. 1 Mz (Fill switch OFF) 1. Turn starting switch to OFF position. 2. Disconnect connector R SW. Ground fault of wiring 3. Start engine. harness or defective If failure code [15SBL1] is still displayed, there is ground fault of wiring harness or power train controller power train controller is defective. (If failure code [15SBL1] is not displayed, R clutch fill switch is defective) a If cause 2 is not the cause for the trouble, this check is not required. 1. Turn starting switch to OFF position. Ground fault of wiring 2. Disconnect connectors STC2 and R SW and connect T-adapter to female side of harness (Contact with either of them. ground circuit) Between STC2 (female) (25) or R SW (female) (1) and Resistance Min. 1 Mz ground If “check result of cause 2 is abnormal” and “check result of cause 3 is normal”, power train controller is defective. • Reference; the followings are standard values in normal condition. 1. Turn starting switch to OFF position. 2. Insert T-adapter into connector STC2. 3. Start engine. Defective power train a Keep PCCS lever in N position. controller Between STC2 (25) and ground Voltage 7 – 11 V 1. – 3. are same as above. 4. While depressing brake pedal, operate PCCS lever (travel gear speed) and perform troubleshooting. Between STC2 (25) and ground R1/R2/R3 Voltage Max. 1 V
40-301
8
D65EX, PX, WX-16
301 Troubleshooting by failure code (Display of code), Part 1 Failure code [15SBL1] Reverse clutch: Fill high
SEN05031-00
Related circuit diagram
D65EX, PX, WX-16
40-301
9
301 Troubleshooting by failure code (Display of code), Part 1 Failure code [15SBLH] Reverse clutch: Fill low
SEN05031-00
Failure code [15SBLH] Reverse clutch: Fill low Action code
Failure code
E03
15SBLH
Failure description
Trouble
1
Reverse clutch: Fill low (Power train controller system)
• Nevertheless controller outputs to transmission R clutch ECMV solenoid circuit, fill switch signal is turned OFF. • Sets transmission in neutral when operator sets it in reverse position (Prevention of defective engagement). • Limits operation of engine and transmission.
Action of controller Indication of problem on machine
• Once machine is stopped, engine speed is limited to medium (half). • Once machine is stopped, travel is limited to F1.
Related information
• State of R clutch ECMV fill switch signal can be checked with monitoring function. (Code: 40906 T/M Fill Sw Input 1) • Method of reproducing failure code: Start engine and set transmission in reverse position. • Remove seat (approx. 50 kg) and seat bottom cover. • First, check the power train oil filter for clogging etc. • Next, check that clutch pressure is normal with reference to the troubleshooting (H mode), “H-1”.
Cause
Procedure, measuring location, standard (value) and remarks 1. Turn starting switch to OFF position. 2. Disconnect connector R SW and connect T-adapter to male side. 3. Start engine. a Keep PCCS lever in N position. Defective R clutch ECMV fill Between R SW (male) (1) and ground Resistance Min. 1 Mz 1 switch (It does not turn ON) 1. – 3. are same as above. 4. While depressing brake pedal, operate PCCS lever (travel gear speed) and perform troubleshooting. Between R SW (male) (1) and ground R1/R2/R3 Resistance Max. 1 z 1. Turn starting switch to OFF position. Disconnection in wiring 2. Disconnect connectors STC2 and R SW and connect T-adapters to female side of 2 harness (Disconnection or them. defective contact) Between STC2 (female) (25) and R SW (female) (1) Resistance Max. 1 z 1. Turn starting switch to OFF position. 2. Insert T-adapter into connector STC2. 3. Start engine. a Keep PCCS lever in N position. Defective power train Between STC2 (25) and ground Voltage 7 – 11 V 3 controller 1. – 3. are same as above. 4. While depressing brake pedal, operate PCCS lever (travel gear speed) and perform troubleshooting. Between STC2 (25) and ground R1/R2/R3 Voltage Max. 1 V
40-301
10
D65EX, PX, WX-16
301 Troubleshooting by failure code (Display of code), Part 1 Failure code [15SBLH] Reverse clutch: Fill low
SEN05031-00
Related circuit diagram
D65EX, PX, WX-16
40-301
11
301 Troubleshooting by failure code (Display of code), Part 1 Failure code [15SEL1] Speed 1st clutch: Fill high
SEN05031-00
Failure code [15SEL1] Speed 1st clutch: Fill high Action code
Failure code
E03
15SEL1
Failure description Action of controller
Trouble
1
Speed 1st clutch: Fill high (Power train controller system)
• Nevertheless controller does not output to transmission 1st clutch ECMV solenoid circuit, fill switch signal is turned ON. • Limits operation of engine and transmission.
Indication of problem on machine
• Once machine is stopped, engine speed is limited to medium (half). • Once machine is stopped, travel is limited to F1 and R1.
Related information
• State of 1st clutch ECMV fill switch signal can be checked with monitoring function. (Code: 40906 T/M Fill Sw Input 1) • Method of reproducing failure code: Start engine and set transmission in neutral. • Remove seat (approx. 50 kg) and seat bottom cover. • First, check the power train oil filter for clogging etc. • Next, check that clutch pressure is normal with reference to the troubleshooting (H mode), “H-1”.
Cause Defective 1st clutch ECMV 1 fill switch (Internal short circuit)
Ground fault of wiring 2 harness or defective power train controller
Ground fault of wiring 3 harness (Contact with ground circuit)
4
Defective power train controller
40-301
12
Procedure, measuring location, standard (value) and remarks 1. Turn starting switch to OFF position. 2. Disconnect connector 1 SW and connect T-adapter to male side. Between 1 SW (female) (1) and ground Resistance Min. 1 Mz (Fill switch OFF) 1. Turn starting switch to OFF position. 2. Disconnect connector 1 SW. 3. Start engine. If failure code [15SEL1] is still displayed, there is ground fault of wiring harness or power train controller is defective. (If failure code [15SEL1] is not displayed, 1st clutch fill switch is defective) a If cause 2 is not the cause for the trouble, this check is not required. 1. Turn starting switch to OFF position. 2. Disconnect connectors STC3 and 1 SW and connect T-adapter to female side of either of them. Between STC3 (female) (19) or 1 SW (female) (1) and Resistance Min. 1 Mz ground If “check result of cause 2 is abnormal” and “check result of cause 3 is normal”, power train controller is defective. • Reference; the followings are standard values in normal condition. 1. Turn starting switch to OFF position. 2. Insert T-adapter into connector STC3. 3. Start engine. a Keep PCCS lever in N position. Between STC3 (19) and ground Voltage 7 – 11 V 1. – 3. are same as above. 4. While depressing brake pedal, operate PCCS lever (travel gear speed) and perform troubleshooting. Between STC3 (19) and ground F1/R1 Voltage Max. 1 V
D65EX, PX, WX-16
301 Troubleshooting by failure code (Display of code), Part 1 Failure code [15SEL1] Speed 1st clutch: Fill high
SEN05031-00
Related circuit diagram
D65EX, PX, WX-16
40-301
13
301 Troubleshooting by failure code (Display of code), Part 1 Failure code [15SELH] Speed 1st clutch: Fill low
SEN05031-00
Failure code [15SELH] Speed 1st clutch: Fill low Action code
Failure code
E03
15SELH
Failure description Action of controller
Trouble
1
Speed 1st clutch: Fill low (Power train controller system)
• Nevertheless controller outputs to transmission 1st clutch ECMV solenoid circuit, fill switch signal is turned OFF. • Limits operation of engine and transmission.
Indication of problem on machine
• Once machine is stopped, engine speed is limited to medium (half). • Once machine is stopped, travel is limited to F2 and R2.
Related information
• State of 1st clutch ECMV fill switch signal can be checked with monitoring function. (Code: 40906 T/M Fill Sw Input 1) • Method of reproducing failure code: Start engine and set transmission in F1 or R1 position. • Remove seat (approx. 50 kg) and seat bottom cover. • First, check the power train oil filter for clogging etc. • Next, check that clutch pressure is normal with reference to the troubleshooting (H mode), “H-1”.
Cause
Defective 1st clutch ECMV 1 fill switch (It does not turn ON)
Disconnection in wiring 2 harness (Disconnection or defective contact)
3
Defective power train controller
40-301
14
Procedure, measuring location, standard (value) and remarks 1. Turn starting switch to OFF position. 2. Disconnect connector 1 SW and connect T-adapter to male side. 3. Start engine. a Keep PCCS lever in N position. Between 1 SW (male) (1) and ground Resistance Min. 1 Mz 1. – 3. are same as above. 4. While depressing brake pedal, operate PCCS lever (travel gear speed) and perform troubleshooting. Between 1 SW (male) (1) and ground F1/R1 Resistance Max. 1 z 1. Turn starting switch to OFF position. 2. Disconnect connectors STC3 and 1 SW and connect T-adapters to female side of them. Between STC3 (female) (19) and 1 SW (female) (1) Resistance Max. 1 z 1. Turn starting switch to OFF position. 2. Insert T-adapter into connector STC3. 3. Start engine. a Keep PCCS lever in N position. Between STC3 (19) and ground Voltage 7 – 11 V 1. – 3. are same as above. 4. While depressing brake pedal, operate PCCS lever (travel gear speed) and perform troubleshooting. Between STC3 (19) and ground F1/R1 Voltage Max. 1 V
D65EX, PX, WX-16
301 Troubleshooting by failure code (Display of code), Part 1 Failure code [15SELH] Speed 1st clutch: Fill low
SEN05031-00
Related circuit diagram
D65EX, PX, WX-16
40-301
15
301 Troubleshooting by failure code (Display of code), Part 1 Failure code [15SFL1] Speed 2nd clutch: Fill high
SEN05031-00
Failure code [15SFL1] Speed 2nd clutch: Fill high Action code
Failure code
E03
15SFL1
Failure description Action of controller
Trouble
1
Speed 2nd clutch: Fill high (Power train controller system)
• Nevertheless controller does not output to transmission 2nd clutch ECMV solenoid circuit, fill switch signal is turned ON. • Limits operation of engine and transmission.
Indication of problem on machine
• Once machine is stopped, engine speed is limited to medium (half). • Once machine is stopped, travel is limited to F2 and R2.
Related information
• State of 2nd clutch ECMV fill switch signal can be checked with monitoring function. (Code: 40906 T/M Fill Sw Input 1) • Method of reproducing failure code: Start engine and set transmission in neutral. • Remove seat (approx. 50 kg) and seat bottom cover. • First, check the power train oil filter for clogging etc. • Next, check that clutch pressure is normal with reference to the troubleshooting (H mode), “H-1”.
Cause Defective 2nd clutch ECMV 1 fill switch (Internal short circuit)
Ground fault of wiring 2 harness or defective power train controller
Ground fault of wiring 3 harness (Contact with ground circuit)
4
Defective power train controller
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16
Procedure, measuring location, standard (value) and remarks 1. Turn starting switch to OFF position. 2. Disconnect connector 2 SW and connect T-adapter to male side. Between 2 SW (female) (1) and ground Resistance Min. 1 Mz (Fill switch OFF) 1. Turn starting switch to OFF position. 2. Disconnect connector 2 SW. 3. Start engine. If failure code [15SFL1] is still displayed, there is ground fault of wiring harness or power train controller is defective. (If failure code [15SFL1] is not displayed, 2nd clutch fill switch is defective) a If cause 2 is not the cause for the trouble, this check is not required. 1. Turn starting switch to OFF position. 2. Disconnect connectors STC3 and 2 SW and connect T-adapter to female side of either of them. Between STC3 (female) (29) or 2 SW (female) (1) and Resistance Min. 1 Mz ground If “check result of cause 2 is abnormal” and “check result of cause 3 is normal”, power train controller is defective. • Reference; the followings are standard values in normal condition. 1. Turn starting switch to OFF position. 2. Insert T-adapter into connector STC3. 3. Start engine. a Keep PCCS lever in N position. Between STC3 (29) and ground Voltage 7 – 11 V 1. – 3. are same as above. 4. While depressing brake pedal, operate PCCS lever (travel gear speed) and perform troubleshooting. Between STC3 (29) and ground F2/R2 Voltage Max. 1 V
D65EX, PX, WX-16
301 Troubleshooting by failure code (Display of code), Part 1 Failure code [15SFL1] Speed 2nd clutch: Fill high
SEN05031-00
Related circuit diagram
D65EX, PX, WX-16
40-301
17
301 Troubleshooting by failure code (Display of code), Part 1 Failure code [15SFLH] Speed 2nd clutch: Fill low
SEN05031-00
Failure code [15SFLH] Speed 2nd clutch: Fill low Action code
Failure code
E03
15SFLH
Failure description Action of controller
Trouble
1
Speed 2nd clutch: Fill low (Power train controller system)
• Nevertheless controller outputs to transmission 2nd clutch ECMV solenoid circuit, fill switch signal is turned OFF. • Limits operation of engine and transmission.
Indication of problem on machine
• Once machine is stopped, engine speed is limited to medium (half). • Once machine is stopped, travel is limited to F1 and R1.
Related information
• State of 2nd clutch ECMV fill switch signal can be checked with monitoring function. (Code: 40906 T/M Fill Sw Input 1) • Method of reproducing failure code: Start engine and set transmission in F2 or R2 position. • Remove seat (approx. 50 kg) and seat bottom cover. • First, check the power train oil filter for clogging etc. • Next, check that clutch pressure is normal with reference to the troubleshooting (H mode), “H-1”.
Cause
Defective 2nd clutch ECMV 1 fill switch (It does not turn ON)
Disconnection in wiring 2 harness (Disconnection or defective contact)
3
Defective power train controller
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18
Procedure, measuring location, standard (value) and remarks 1. Turn starting switch to OFF position. 2. Disconnect connector 2 SW and connect T-adapter to male side. 3. Start engine. a Keep PCCS lever in N position. Between 2 SW (male) (1) and ground Resistance Min. 1 Mz 1. – 3. are same as above. 4. While depressing brake pedal, operate PCCS lever (travel gear speed) and perform troubleshooting. Between 2 SW (male) (1) and ground F2/R2 Resistance Max. 1 z 1. Turn starting switch to OFF position. 2. Disconnect connectors STC3 and 2 SW and connect T-adapters to female side of them. Between STC3 (female) (29) and 2 SW (female) (1) Resistance Max. 1 z 1. Turn starting switch to OFF position. 2. Insert T-adapter into connector STC3. 3. Start engine. a Keep PCCS lever in N position. Between STC3 (29) and ground Voltage 7 – 11 V 1. – 3. are same as above. 4. While depressing brake pedal, operate PCCS lever (travel gear speed) and perform troubleshooting. Between STC3 (29) and ground F2/R2 Voltage Max. 1 V
D65EX, PX, WX-16
301 Troubleshooting by failure code (Display of code), Part 1 Failure code [15SFLH] Speed 2nd clutch: Fill low
SEN05031-00
Related circuit diagram
D65EX, PX, WX-16
40-301
19
301 Troubleshooting by failure code (Display of code), Part 1 Failure code [15SGL1] Speed 3rd clutch: Fill high
SEN05031-00
Failure code [15SGL1] Speed 3rd clutch: Fill high Action code
Failure code
E03
15SGL1
Failure description Action of controller
Trouble
1
Speed 3rd clutch: Fill high (Power train controller system)
• Nevertheless controller does not output to transmission 3rd clutch ECMV solenoid circuit, fill switch signal is turned ON. • Limits operation of engine and transmission.
Indication of problem on machine
• Once machine is stopped, engine speed is limited to medium (half). • Once machine is stopped, travel is limited to F3 and R3.
Related information
• State of 3rd clutch ECMV fill switch signal can be checked with monitoring function. (Code: 40906 T/M Fill Sw Input 1) • Method of reproducing failure code: Start engine and set transmission in neutral. • Remove seat (approx. 50 kg) and seat bottom cover. • First, check the power train oil filter for clogging etc. • Next, check that clutch pressure is normal with reference to the troubleshooting (H mode), “H-1”.
Cause Defective 3rd clutch ECMV 1 fill switch (Internal short circuit)
Ground fault of wiring 2 harness or defective power train controller
Ground fault of wiring 3 harness (Contact with ground circuit)
4
Defective power train controller
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Procedure, measuring location, standard (value) and remarks 1. Turn starting switch to OFF position. 2. Disconnect connector 3 SW and connect T-adapter to male side. Between 3 SW (female) (1) and ground Resistance Min. 1 Mz (Fill switch OFF) 1. Turn starting switch to OFF position. 2. Disconnect connector 3 SW. 3. Start engine. If failure code [15SGL1] is still displayed, there is ground fault of wiring harness or power train controller is defective. (If failure code [15SGL1] is not displayed, 3rd clutch fill switch is defective) a If cause 2 is not the cause for the trouble, this check is not required. 1. Turn starting switch to OFF position. 2. Disconnect connectors STC3 and 3 SW and connect T-adapter to female side of either of them. Between STC3 (female) (39) or 3 SW (female) (1) and Resistance Min. 1 Mz ground If “check result of cause 2 is abnormal” and “check result of cause 3 is normal”, power train controller is defective. • Reference; the followings are standard values in normal condition. 1. Turn starting switch to OFF position. 2. Insert T-adapter into connector STC3. 3. Start engine. a Keep PCCS lever in N position. Between STC3 (39) and ground Voltage 7 – 11 V 1. – 3. are same as above. 4. While depressing brake pedal, operate PCCS lever (travel gear speed) and perform troubleshooting. Between STC3 (39) and ground F3/R3 Voltage Max. 1 V
D65EX, PX, WX-16
301 Troubleshooting by failure code (Display of code), Part 1 Failure code [15SGL1] Speed 3rd clutch: Fill high
SEN05031-00
Related circuit diagram
D65EX, PX, WX-16
40-301
21
301 Troubleshooting by failure code (Display of code), Part 1 Failure code [15SGLH] Speed 3rd clutch: Fill low
SEN05031-00
Failure code [15SGLH] Speed 3rd clutch: Fill low Action code
Failure code
E03
15SGLH
Failure description Action of controller
Trouble
1
Speed 3rd clutch: Fill low (Power train controller system)
• Nevertheless controller outputs to transmission 3rd clutch ECMV solenoid circuit, fill switch signal is turned OFF. • Limits operation of engine and transmission.
Indication of problem on machine
• Once machine is stopped, engine speed is limited to medium (half). • Once machine is stopped, travel is limited to F1 and R1.
Related information
• State of 3rd clutch ECMV fill switch signal can be checked with monitoring function. (Code: 40906 T/M Fill Sw Input 1) • Method of reproducing failure code: Start engine and set transmission in F3 or R3 position. • Remove seat (approx. 50 kg) and seat bottom cover. • First, check the power train oil filter for clogging etc. • Next, check that clutch pressure is normal with reference to the troubleshooting (H mode), “H-1”.
Cause
Defective 3rd clutch ECMV 1 fill switch (It does not turn ON)
Disconnection in wiring 2 harness (Disconnection or defective contact)
3
Defective power train controller
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Procedure, measuring location, standard (value) and remarks 1. Turn starting switch to OFF position. 2. Disconnect connector 3 SW and connect T-adapter to male side. 3. Start engine. a Keep PCCS lever in N position. Between 3 SW (male) (1) and ground Resistance Min. 1 Mz 1. – 3. are same as above. 4. While depressing brake pedal, operate PCCS lever (travel gear speed) and perform troubleshooting. Between 3 SW (male) (1) and ground F3/R3 Resistance Max. 1 z 1. Turn starting switch to OFF position. 2. Disconnect connectors STC3 and 3 SW and connect T-adapters to female side of them. Between STC3 (female) (39) and 3 SW (female) (1) Resistance Max. 1 z 1. Turn starting switch to OFF position. 2. Insert T-adapter into connector STC3. 3. Start engine. a Keep PCCS lever in N position. Between STC3 (39) and ground Voltage 7 – 11 V 1. – 3. are same as above. 4. While depressing brake pedal, operate PCCS lever (travel gear speed) and perform troubleshooting. Between STC3 (39) and ground F3/R3 Voltage Max. 1 V
D65EX, PX, WX-16
301 Troubleshooting by failure code (Display of code), Part 1 Failure code [15SGLH] Speed 3rd clutch: Fill low
SEN05031-00
Related circuit diagram
D65EX, PX, WX-16
40-301
23
301 Troubleshooting by failure code (Display of code), Part 1 Failure code [15SJL1] L/U: Fill high
SEN05031-00
Failure code [15SJL1] L/U: Fill high Action code
Failure code
E02
15SJL1
Failure description Action of controller
Trouble
1
L/U: Fill high (Power train controller system)
• Nevertheless controller does not output to torque converter lockup clutch ECMV solenoid circuit, fill switch signal is turned ON. • Prohibits lockup.
Indication of problem on machine
• Engine may stall during travel.
Related information
• State of lockup clutch ECMV fill switch signal can be checked with monitoring function. (Code: 31520 T/M Fill Sw Input 2) • Method of reproducing failure code: Start engine and set transmission in R (reverse) position (in automatic gearshift mode). • Remove seat (approx. 50 kg) and seat bottom cover. • First, check the power train oil filter for clogging etc. • Next, check that clutch pressure is normal in lockup operation with reference to the troubleshooting (H mode), “H-1”.
Cause Defective lockup clutch 1 ECMV fill switch (Internal short circuit)
Ground fault of wiring 2 harness or defective power train controller
Ground fault of wiring 3 harness (Contact with ground circuit)
4
Defective power train controller
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Procedure, measuring location, standard (value) and remarks 1. Turn starting switch to OFF position. 2. Disconnect connector L SW and connect T-adapter to male side. Between L SW (female) (1) and ground Resistance Min. 1 Mz (Fill switch OFF) 1. Turn starting switch to OFF position. 2. Disconnect connector L SW. 3. Start engine. a Keep PCCS lever in N position. If failure code [15SJL1] is still displayed, there is ground fault of wiring harness or power train controller is defective. (If failure code [15SJL1] is not displayed, lockup clutch fill switch is defective) a If cause 2 is not the cause for the trouble, this check is not required. 1. Turn starting switch to OFF position. 2. Disconnect connectors STC2 and L SW and connect T-adapter to female side of either of them. Between STC2 (female) (36) or L SW (female) (1) and Resistance Min. 1 Mz ground If “check result of cause 2 is abnormal” and “check result of cause 3 is normal”, power train controller is defective. • Reference; the followings are standard values in normal condition. 1. Turn starting switch to OFF position. 2. Insert T-adapter into connector STC2. 3. Start engine. a Keep PCCS lever in N position. Between STC2 (36) and ground Voltage 7 – 11 V 1. – 3. are same as above. 4. Put machine on the stands and keep all the track shoe in the air. 5. Travel machine in R1 (automatic gearshift mode), and troubleshoot with lockup in operation. a See “Testing torque converter lockup clutch” in “Testing and adjusting”. Between STC2 (36) and ground R1 Voltage Max. 1 V
D65EX, PX, WX-16
301 Troubleshooting by failure code (Display of code), Part 1 Failure code [15SJL1] L/U: Fill high
SEN05031-00
Related circuit diagram
D65EX, PX, WX-16
40-301
25
301 Troubleshooting by failure code (Display of code), Part 1 Failure code [15SJLH] L/U: Fill low
SEN05031-00
Failure code [15SJLH] L/U: Fill low Action code
Failure code
E02
15SJLH
Failure description Action of controller
Trouble
1
L/U: Fill low (Power train controller system)
• Nevertheless controller outputs to torque converter lockup clutch ECMV solenoid circuit, fill switch signal is turned OFF. • Prohibits lockup.
Indication of problem on machine
• It is impossible to lockup.
Related information
• State of lockup clutch ECMV fill switch signal can be checked with monitoring function. (Code: 31520 T/M Fill Sw Input 2) • Method of reproducing failure code: Start engine and set transmission in R (reverse) position (in automatic gearshift mode). • Remove seat (approx. 50 kg) and seat bottom cover. • First, check the power train oil filter for clogging etc. • Next, check that clutch pressure is normal in lockup operation with reference to the troubleshooting (H mode), “H-1”.
Cause
Procedure, measuring location, standard (value) and remarks 1. Turn starting switch to OFF position. 2. Disconnect connector L SW, and connect T-adapter to male side. 3. Start engine. Defective lockup clutch 4. Put machine on the stands and keep all the track shoe in the air. 1 ECMV fill switch (It does not 5. Travel machine in R1 (automatic gearshift mode), and troubleshoot with lockup in turn ON) operation. a See “Testing torque converter lockup clutch” in “Testing and adjusting”. Between L SW (female) (1) and ground (Fill switch ON) Resistance Max. 1 z 1. Turn starting switch to OFF position. Disconnection in wiring 2. Disconnect connectors STC2 and L SW and connect T-adapters to female side of 2 harness (Disconnection or them. defective contact) Between STC2 (female) (36) and L SW (female) (1) Resistance Max. 1 z If no abnormality is found by the above checks, power train controller is defective. • Reference; the followings are standard values in normal condition. 1. Turn starting switch to OFF position. 2. Insert T-adapter into connector STC2. 3. Start engine. a Keep PCCS lever in N position. Defective power train Between STC2 (36) and ground Voltage 7 – 11 V 3 controller 1. – 3. are same as above. 4. Put machine on the stands and keep all the track shoe in the air. 5. Travel machine in R1 (automatic gearshift mode), and troubleshoot with lockup in operation. a See “Testing torque converter lockup clutch” in “Testing and adjusting”. Between STC2 (36) and ground R1 Voltage Max. 1 V
40-301
26
D65EX, PX, WX-16
301 Troubleshooting by failure code (Display of code), Part 1 Failure code [15SJLH] L/U: Fill low
SEN05031-00
Related circuit diagram
D65EX, PX, WX-16
40-301
27
301 Troubleshooting by failure code (Display of code), Part 1 Failure code [AB00MA] Battery Charge Abnormal
SEN05031-00
Failure code [AB00MA] Battery Charge Abnormal Action code
Failure code
—
AB00MA
Failure description
Trouble
Battery Charge Abnormal (Machine monitor system)
• While engine was running, voltage from alternator lowered, and machine monitor detected that battery charge voltage was low.
Action of controller
• Displays charge level monitor red on machine monitor.
Indication of problem on machine
• If machine is used as it is, battery may not be charged.
Related information
• Battery voltage can be checked with monitoring function. (Code: 04300 Charge voltage) • Method of reproducing failure code: Start engine.
Cause Defective charge by 1 alternator (When system is normal) 2
Defective charge level monitor system
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1
Procedure, measuring location, standard (value) and remarks 1. Turn starting switch to OFF position. 2. Inert T-adapter into connector CM01. 3. Start engine and troubleshoot above medium of engine speed. Between CM01 (11) and (3) Voltage 26 – 30.5 V If cause 1 is not detected, charge level monitor system may be defective. Perform “E-5 Caution item lights up while engine is running” in E mode.
D65EX, PX, WX-16
301 Troubleshooting by failure code (Display of code), Part 1 Failure code [AB00MA] Battery Charge Abnormal
SEN05031-00
Related circuit diagram
D65EX, PX, WX-16
40-301
29
301 Troubleshooting by failure code (Display of code), Part 1 Failure code [B@BAZG] Eng Oil Press Low
SEN05031-00
Failure code [B@BAZG] Eng Oil Press Low Action code
Failure code
—
B@BAZG
Failure description Action of controller
Trouble
1
Eng Oil Press Low (Engine controller system)
• While engine was running, voltage from engine oil pressure switch became GND level, and engine controller detected that engine oil pressure was abnormally low. • Displays engine oil pressure monitor red on machine monitor.
Indication of problem on machine
• If machine is used as it is, engine may be seized.
Related information
• Engine controller inputs engine oil pressure switch signal and then transmits the data to machine monitor through CAN communication system. • See failure code [CA435] for troubleshooting about engine oil pressure switch in engine stop. • Method of reproducing failure code: Start engine.
Cause Low engine oil pressure 1 (When system is normal) Defective engine oil 2 pressure sensor system
Procedure, measuring location, standard (value) and remarks Check engine oil pressure. If it is low, remove cause. If cause 1 is not detected, engine oil pressure sensor may be defective. Perform troubleshooting for failure code [CA435].
Failure code [B@BCNS] Eng Water Overheat Action code
Failure code
—
B@BCNS
Failure description Action of controller
Trouble
1
Eng Water Overheat (Engine controller system)
• While engine was running, voltage from engine coolant temperature sensor lowered, and engine controller detected that engine coolant was overheated. • Displays engine coolant temperature monitor red on machine monitor.
Indication of problem on machine
• If machine is used as it is, engine may be seized.
Related information
• Engine controller inputs voltage of engine coolant temperature sensor signal and then transmits the data to machine monitor through CAN communication system. • Engine coolant temperature can be checked with monitoring function. (Code: 04107 Coolant Temperature) • Method of reproducing failure code: Start engine.
Cause Overheated engine coolant 1 (When system is normal) Defective engine coolant 2 temperature sensor system
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30
Procedure, measuring location, standard (value) and remarks Check engine coolant for overheating. If it is overheated, remove cause. If cause 1 is not detected, engine coolant temperature sensor may be defective. Perform troubleshooting for failure codes [CA144] and [CA145].
D65EX, PX, WX-16
301 Troubleshooting by failure code (Display of code), Part 1 Failure code [B@CENS] T/C Oil Overheat
SEN05031-00
Failure code [B@CENS] T/C Oil Overheat Action code
Failure code
—
B@CENS
Failure description
Trouble
1
T/C Oil Overheat (Power train controller system)
• While engine was running, voltage from torque converter oil temperature sensor lowered, and power train controller detected that power train oil was overheated.
Action of controller
• Displays power train oil temperature monitor red on machine monitor.
Indication of problem on machine
• If machine is used as it is, power train components may be damaged.
Related information
• Torque converter oil temperature is considered as power train oil temperature. • Power train controller inputs voltage of torque converter oil temperature sensor signal and then transmits the data to machine monitor through CAN communication system. • Torque converter oil temperature can be checked with monitoring function. (Code: 30100 T/C Oil Temperature) • Method of reproducing failure code: Start engine.
Cause Overheated torque converter 1 (power train) oil (When system is normal) Defective torque converter 2 oil temperature sensor system
Procedure, measuring location, standard (value) and remarks Check torque converter (power train) oil for overheating. If it is overheated, remove cause. If cause 1 is not detected, torque converter oil temperature sensor system may be defective. Perform troubleshooting for failure code [DGT1KA] or [DGT1KX].
Failure code [B@HANS] Hyd Oil Overheat Action code
Failure code
—
B@HANS
Failure description Action of controller
Trouble
1
Hyd Oil Overheat (Machine monitor system)
• While engine was running, voltage from hydraulic oil temperature sensor lowered, and power train controller detected that hydraulic oil was overheated. • Displays hydraulic oil temperature monitor red on machine monitor.
Indication of problem on machine
• If machine is used as it is, work equipment and HSS circuit components may be damaged.
Related information
• Signal voltage of hydraulic oil temperature sensor is input to machine monitor and then the data is transmitted to power train controller through CAN communication system. • Hydraulic oil temperature can be checked with monitoring function. (Code: 04401 Hyd Oil Temperature) • Method of reproducing failure code: Start engine.
Cause Overheated hydraulic oil 1 (When system is normal) 2
Defective hydraulic oil temperature gauge system
D65EX, PX, WX-16
Procedure, measuring location, standard (value) and remarks Check hydraulic oil for overheating. If it is overheated, remove cause. If cause 1 is not detected, hydraulic oil temperature gauge system may be defective. Perform troubleshooting for failure code [DGS1KX] or “E-10 Hydraulic oil temperature gauge (Multi-gauge) does not indicated normally” in E mode.
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31
SEN05031-00
D65EX, PX, WX-16 Bulldozer Form No. SEN05031-00
©2009 KOMATSU All Rights Reserved Printed in Japan 04-09 (01)
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SEN05032-01
BULLDOZER D65EX-16 D65PX-16 D65WX-16 Machine model D65EX-16 D65PX-16 D65WX-16
Serial number 80001 and up 80001 and up 80001 and up
40 Troubleshooting
40
302 Troubleshooting by failure code (Display of code), Part 2 Failure code [CA111] ECM Critical Internal Failure......................................................................................... 3 Failure code [CA115] Eng Ne and Bkup Speed Sens Error ............................................................................ 3 Failure code [CA122] Chg Air Press Sensor High Error ................................................................................. 4 Failure code [CA123] Chg Air Press Sensor Low Error .................................................................................. 6 Failure code [CA131] Throttle Sensor High Error ........................................................................................... 8 Failure code [CA132] Throttle Sensor Low Error .......................................................................................... 10 Failure code [CA144] Coolant Temp Sens High Error .................................................................................. 12 Failure code [CA145] Coolant Temp Sens Low Error ................................................................................... 14 Failure code [CA153] Chg Air Temp Sensor High Error................................................................................ 16 Failure code [CA154] Chg Air Temp Sensor Low Error ................................................................................ 18 Failure code [CA155] Chg Air Temp High Speed Derate .............................................................................. 20 Failure code [CA187] Sens Supply 2 Volt Low Error .................................................................................... 22 Failure code [CA221] Ambient Press Sens High Error ................................................................................. 24 Failure code [CA222] Ambient Press Sens Low Error .................................................................................. 26 Failure code [CA227] Sens Supply 2 Volt High Error.................................................................................... 28 Failure code [CA234] Eng Overspeed .......................................................................................................... 28 Failure code [CA238] Ne Speed Sens Supply Volt Error .............................................................................. 29 Failure code [CA271] IMV/PCV1 Short Error................................................................................................ 30 Failure code [CA272] IMV/PCV1 Open Error................................................................................................ 32 Failure code [CA281] Abnormal supply pump pressure balance.................................................................. 34 Failure code [CA322] Inj #1(L#1) Open/Short Error...................................................................................... 36 D65EX, PX, WX-16
40-302
1
SEN05032-01
302 Troubleshooting by failure code (Display of code), Part 2
Failure code [CA323] Inj #5(L#5) Open/Short Error...................................................................................... 38 Failure code [CA324] Inj #3(L#3) Open/Short Error...................................................................................... 40 Failure code [CA325] Inj #6(L#6) Open/Short Error...................................................................................... 42 Failure code [CA331] Inj #2(L#2) Open/Short Error...................................................................................... 44 Failure code [CA332] Inj #4(L#4) Open/Short Error...................................................................................... 46
40-302
2
D65EX, PX, WX-16
302 Troubleshooting by failure code (Display of code), Part 2 Failure code [CA111] ECM Critical Internal Failure
SEN05032-01
Failure code [CA111] ECM Critical Internal Failure Action code
Failure code
E04
CA111
Failure description Action of controller
Trouble
1
ECM critical internal failure (Engine controller system)
• Memory or power supply circuit in engine controller is defective. • None in particular.
Indication of problem on machine
• Engine stops. • Engine does not start.
Related information Cause
Procedure, measuring location, standard (value) and remarks
1 Related defective system
Check another failure code displayed simultaneously. If another failure code is also displayed, perform troubleshooting for it first.
2
Perform troubleshooting for failure code [CA441].
Failure code [CA115] Eng Ne and Bkup Speed Sens Error Action code
Failure code
E04
CA115
Failure description Action of controller
Trouble
1
Engine Ne and Bkup speed sensor error (Engine controller system)
• Both signals of engine Ne speed sensor and engine Bkup speed sensor are abnormal. • None in particular.
Indication of problem on machine
• Engine stops. • Engine does not start.
Related information
• Method of reproducing failure code: Start engine
Cause
Procedure, measuring location, standard (value) and remarks
1
Connector of Ne speed sensor or Bkup speed sensor may be connected defectively Defective connection of sen(or wrong connection - Ne speed sensor harness is connected to Bkup speed sensor, sor connector and Bkup speed sensor harness to Ne speed sensor). Check them directly.
2
Defective Ne speed sensor system
Perform troubleshooting for causes 1 –10 in failure code CA689.
3
Defective Bkup speed sensor system
Perform troubleshooting for failure code CA778.
4 Defective engine controller
D65EX, PX, WX-16
If no abnormality is found by the above checks, the engine controller is defective. (Since the trouble is in system, troubleshooting cannot be performed.)
40-302
3
302 Troubleshooting by failure code (Display of code), Part 2 Failure code [CA122] Chg Air Press Sensor High Error
SEN05032-01
Failure code [CA122] Chg Air Press Sensor High Error Action code
Failure code
E03
CA122
Failure description Action of controller
Trouble
1
Charge air pressure sensor high error (Engine controller system)
• High voltage was detected in pressure signal circuit of charge (boost) pressure/temperature sensor. • Fixes charge pressure value and continues operation.
Indication of problem on machine
• Engine output lowers.
Related information
• Signal voltage on boost pressure side of boost pressure/temperature sensor can be checked with monitoring function. (Code: 36501 Boost pressure sensor voltage) • Method of reproducing failure code: Turn starting switch to ON position. • Even under normal condition if sensor connector is disconnected, failure code of “low error”, that is [CA123] is displayed.
Cause
Procedure, measuring location, standard (value) and remarks See the items related to wiring harness and connectors in "c: Electric and electrical equipment" in "Checks before troubleshooting" in "General information on troubleshooting" section, and check them directly.
1
Defective wiring harness connector
2
Defective sensor power supIf failure code [CA227] is also indicated, perform troubleshooting for it first. ply 2 system
3
Defective boost pressure/ temperature sensor
Short circuit in wiring har4 ness
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], the sensor is defective. a Failure code [CA153] is displayed together with [CA123]. This is because that the sensor connector is disconnected. So, it can be ignored. 1. Turn starting switch to OFF position. 2. Disconnect connectors ECM and BOOST PRESS & IMT, and connect T-adapter to female side of ECM. Between ECM (female) (37) and (44)
5
Hot short in wiring harness (Contact with 24 V circuit)
40-302
4
Min. 100 kz
1. Turn starting switch to OFF position. 2. Disconnect connector BOOST PRESS & IMT, and insert T-adapter into connector ECM. 3. Turn starting switch to ON position (with connector BOOST PRESS & IMT disconnected). Between ECM (44) and (47)
6 Defective engine controller
Resistance
Voltage
Max. 1 V
If no abnormality is found by the above checks, the engine controller is defective. (Since the trouble is in system, troubleshooting cannot be performed.)
D65EX, PX, WX-16
302 Troubleshooting by failure code (Display of code), Part 2 Failure code [CA122] Chg Air Press Sensor High Error
SEN05032-01
Related circuit diagram
D65EX, PX, WX-16
40-302
5
302 Troubleshooting by failure code (Display of code), Part 2 Failure code [CA123] Chg Air Press Sensor Low Error
SEN05032-01
Failure code [CA123] Chg Air Press Sensor Low Error Action code
Failure code
E03
CA123
Failure description Action of controller
Trouble
1
Charge air pressure sensor low error (Engine controller system)
• Low voltage was detected in pressure signal circuit of boost pressure/temperature sensor. • Fixes charge pressure value and continues operation.
Indication of problem on machine
• Engine output lowers.
Related information
• Signal voltage on boost pressure side of boost pressure/temperature sensor can be checked with monitoring function. (Code: 36501 Boost pressure sensor voltage) • Method of reproducing failure code: Turn starting switch to ON position. • Disconnection in wiring harness and voltage at sensor connector cannot be checked, because that T-adapter for sensor connector is socket type. • This failure code is displayed if the sensor connector or harness is disconnected.
Cause
Procedure, measuring location, standard (value) and remarks See the items related to wiring harness and connectors in "c: Electric and electrical equipment" in "Checks before troubleshooting" in "General information on troubleshooting" section, and check them directly.
1
Defective wiring harness connector
2
Defective power supply sys- If failure code [CA187] (ground fault of sensor power supply line) or [CA227] is indicated, perform troubleshooting for it first. tem of sensor
3
Short circuit in wiring harness
1. Turn starting switch to OFF position. 2. Disconnect connectors CAM SENSOR, FUEL RAIL PRESS, BOOST PRESS & IMT and ECM. 3. Connect T-adapter to female side of connector ECM. Between ECM (female) (37) and (47)
Resistance
Min. 100 kz
Between ECM (female) (44) and (47)
Resistance
Min. 100 kz
1. Turn starting switch to OFF position. Ground fault of wiring har2. Disconnect connectors ECM and BOOST PRESS & IMT, and connect T-adapter to 4 ness female side of ECM. (Contact with ground circuit) Between ECM (female) (44) and ground Resistance Min. 100 kz Disconnection in wiring harness If no abnormality is found by the above checks, disconnection in wiring harness is 5 (Disconnection or defective considered. (*) contact in connector)
Defective boost pressure/ temperature sensor 6 (Improper input voltage to engine controller)
a If causes 1 – 5 are not the cause of the trouble and the check result of cause 6 is abnormal, sensor is defective. 1. Turn starting switch to OFF position. 2. Insert T-adapter between male and female sides of connector ECM. 3. Turn starting switch to ON position. Between ECM (44) and (47)
7 Defective engine controller
Sensor output
Voltage
Min. 0.2 V
If no abnormality is found by the above checks, the engine controller is defective. (Since trouble is in system, troubleshooting cannot be performed.)
*: See "Troubleshooting for disconnection in wiring harness of pressure sensor system" in "General information on troubleshooting" section.
40-302
6
D65EX, PX, WX-16
302 Troubleshooting by failure code (Display of code), Part 2 Failure code [CA123] Chg Air Press Sensor Low Error
SEN05032-01
Related circuit diagram
D65EX, PX, WX-16
40-302
7
302 Troubleshooting by failure code (Display of code), Part 2 Failure code [CA131] Throttle Sensor High Error
SEN05032-01
Failure code [CA131] Throttle Sensor High Error Action code
Failure code
E03
CA131
Failure description Action of controller
Trouble
1
Throttle sensor high error (Engine controller system)
• High voltage was detected in signal circuit of decelerator pedal (throttle sensor). • Controller considers decelerator pedal (throttle) sensor voltage as a fixed value and continues operation.
Indication of problem on machine
• Engine speed cannot be controlled with decelerator pedal (throttle sensor).
Related information
• Signal voltage of decelerator pedal (throttle sensor) can be checked with monitoring function. (Code: 31703 Decelerator pedal sensor voltage) • Method of reproducing failure code: Turn starting switch to ON position and depress decelerator pedal.
Cause 1
Defective wiring harness connector
2
Defective throttle sensor power supply system
3
4
5
6
7
Procedure, measuring location, standard (value) and remarks See the items related to wiring harness and connectors in "c: Electric and electrical equipment" in "Checks before troubleshooting" in "General information on troubleshooting" section, and check them directly. If failure code [CA2185] is also indicated, perform troubleshooting for it first.
1. Turn starting switch to OFF position. 2. Disconnect connector DCL and connect T-adapter to male side. Defective decelerator pedal Between DCL (male) (B) and (C) Resistance Approx. 2 kz (throttle sensor) Between DCL (male) (A) and (C) Resistance 0.2 – 1.8 kz Between DCL (male) (B) and (A) Resistance 0.2 – 1.8 kz 1. Turn starting switch to OFF position. Disconnection or short circuit 2. Disconnect connector CE02 and connect T-adapter to female side. Between CE02 (female) (22) and (23) Resistance Approx. 2 kz in wiring harness Between CE02 (female) (9) and (23) Resistance 0.2 – 1.8 kz a If cause 4 is not the cause for the trouble, this check is not required. 1. Turn starting switch to OFF position. 2. Disconnect connector CE02 and DCL and connect T-adapter to female side of Short circuit in wiring either one of them. harness Between CE02 (female) (9) and (22), or between DCL Resistance Min. 1 Mz (female) (A) and (B) 1. Turn starting switch to OFF position. Hot short in wiring harness 2. Disconnect connector DCL and connect T-adapter to female side. 3. Turn starting switch to ON position. (Contact with 24 V circuit) Between DCL (female) (A) and ground Voltage Max. 1 V a If no abnormality is found by the above checks, the engine controller is defective. (Since trouble is in system, troubleshooting cannot be performed.) • Reference; The following is standard value in normal condition. 1. Turn starting switch to OFF position. 2. Insert T-adapter between male and female sides of CE02. 3. Turn starting switch to ON position. Defective engine controller 4. Troubleshoot with decelerator pedal operation. Between CE02 (22) and (23) Voltage 4.75 – 5.25 V With decelerator pedal Between CE02 (9) and (23) Voltage Approx. 3.5 V stamping Away from decelerator Between CE02 (9) and (23) Voltage Approx. 2 V pedal
40-302
8
D65EX, PX, WX-16
302 Troubleshooting by failure code (Display of code), Part 2 Failure code [CA131] Throttle Sensor High Error
SEN05032-01
Related circuit diagram
D65EX, PX, WX-16
40-302
9
302 Troubleshooting by failure code (Display of code), Part 2 Failure code [CA132] Throttle Sensor Low Error
SEN05032-01
Failure code [CA132] Throttle Sensor Low Error Action code
Failure code
E03
CA132
Failure description Action of controller
Trouble
1
Throttle sensor low error (Engine controller system)
• Low voltage was detected in signal circuit of decelerator pedal (throttle sensor). • Controller considers decelerator pedal (throttle) sensor voltage as a fixed value and continues operation.
Indication of problem on machine
• Engine speed cannot be controlled with decelerator pedal (throttle sensor).
Related information
• Signal voltage of decelerator pedal (throttle sensor) can be checked with monitoring function. (Code: 31703 Decelerator pedal sensor voltage) • Method of reproducing failure code: Turn starting switch to ON position and depress decelerator pedal.
Cause 1
Defective wiring harness connector
2
Defective throttle sensor power supply system
Procedure, measuring location, standard (value) and remarks See the items related to wiring harness and connectors in "c: Electric and electrical equipment" in "Checks before troubleshooting" in "General information on troubleshooting" section, and check them directly. If failure code [CA2186] is also indicated, perform troubleshooting for it first.
1. Turn starting switch to OFF position. 2. Disconnect connector DCL and connect T-adapter to male side. Defective decelerator pedal Between DCL (male) (B) and (C) Resistance Approx. 2 kz 3 (throttle sensor) Between DCL (male) (A) and (C) Resistance 0.2 – 1.8 kz Between DCL (male) (B) and (A) Resistance 0.2 – 1.8 kz 1. Turn starting switch to OFF position. Disconnection or short circuit 2. Disconnect connector CE02 and connect T-adapter to female side. 4 Between CE02 (female) (22) and (23) Resistance Approx. 2 kz in wiring harness Between CE02 (female) (9) and (23) Resistance 0.2 – 1.8 kz a If cause 4 is not the cause for the trouble, this check is not required. 1. Turn starting switch to OFF position. Disconnection in wiring har- 2. Disconnect connectors CE02 and DCL and connect T-adapter to each female ness side. 5 (Disconnection or defective Between CE02 (female) (22) and DCL (female) (B) Resistance Max. 1 z contact in connector) Between CE02 (female) (9) and DCL (female) (A) Resistance Max. 1 z Between CE02 (female) (23) and DCL (female) (C) Resistance Max. 1 z a If cause 4 is not the cause for the trouble, this check is not required. 1. Turn starting switch to OFF position. 2. Disconnect connectors CE02 and DCL and connect T-adapter to female side of Short circuit in wiring 6 either one of them. harness Between CE02 (female) (9) and (23), or between DCL Min. 1 Mz Resistance (female) (A) and (C) 1. Turn starting switch to OFF position. 2. Disconnect connectors CE02 and DCL and connect T-adapter to female side of Ground fault of wiring either one of them. 7 harness (Contact with ground circuit) Between CE02 (female) (9) or DCL (female) (A) and Resistance Min. 1 Mz ground
40-302
10
D65EX, PX, WX-16
302 Troubleshooting by failure code (Display of code), Part 2 Failure code [CA132] Throttle Sensor Low Error
Cause
8 Defective engine controller
SEN05032-01
Procedure, measuring location, standard (value) and remarks a If no abnormality is found by the above checks, the engine controller is defective. (Since trouble is in system, troubleshooting cannot be performed.) • Reference; The following is standard value in normal condition. 1. Turn starting switch to OFF position. 2. Insert T-adapter between male and female sides of CE02. 3. Turn starting switch to ON position. 4. Troubleshoot with decelerator pedal operation. Between CE02 (22) and (23) Voltage 4.75 – 5.25 V With decelerator pedal Between CE02 (9) and (23) Voltage Approx. 3.5 V stamping Away from decelerator Between CE02 (9) and (23) Voltage Approx. 2 V pedal
Related circuit diagram
D65EX, PX, WX-16
40-302
11
302 Troubleshooting by failure code (Display of code), Part 2 Failure code [CA144] Coolant Temp Sens High Error
SEN05032-01
Failure code [CA144] Coolant Temp Sens High Error Action code
Failure code
E02
CA144
Failure description Action of controller
Trouble
1
Coolant temperature sensor high error (Engine controller system)
• High voltage was detected in signal circuit of coolant temperature sensor. • Fixes coolant temperature value and continues operation.
Indication of problem on machine
• Engine is hard to start at low temperature. • Exhaust gas becomes white. • Overheat prevention function does not work.
Related information
• Signal voltage of coolant temperature sensor can be checked with monitoring function. (Code: 04105 Coolant temperature sensor voltage) • Method of reproducing failure code: Turn starting switch to ON position. • This failure code is displayed if temperature sensor connector or harness is disconnected. • Because that T-adapter for sensor connector is socket type, it cannot be connected to wiring harness.
Cause
1
2
3
4
Procedure, measuring location, standard (value) and remarks See the items related to wiring harness and connectors in "c: Electric and electrical Defective wiring harness equipment" in "Checks before troubleshooting" in "General information on connector troubleshooting" section, and check them directly. 1. Turn starting switch to OFF position. 2. Disconnect connector COOLANT TEMP and connect socket to male side. a When coolant temperature is above 0°C, if coolant temperature sensor resistance is 700 z – 37 kz, coolant temperature sensor is regarded as normal. 0°C Resistance 30 – 37 kz Defective coolant tempera9.3 – ture sensor Resistance 25°C COOLANT TEMP (male) between (A) 10.7 kz and (B) 50°C Resistance 3.2 – 3.8 kz a Coolant temperature characteristic 80°C Resistance 1.0 – 1.3 kz 95°C Resistance 700 – 800 z 1. Turn starting switch to OFF position. 2. Disconnect connector ECM and connect T-adapter to female side. Disconnection or short circuit Between ECM (female) (15) and (38) (Coolant temperature is above 0°C) in wiring harness 700 z – a Resistance value is the same as the one on “coolant Resistance 37 kz temperature – resistance characteristics table” for coolant temperature sensor in cause 2. If no abnormality is found by the above checks, the engine controller is defective. Defective engine controller (Since trouble is in system, troubleshooting cannot be performed.)
40-302
12
D65EX, PX, WX-16
302 Troubleshooting by failure code (Display of code), Part 2 Failure code [CA144] Coolant Temp Sens High Error
SEN05032-01
Related circuit diagram
D65EX, PX, WX-16
40-302
13
302 Troubleshooting by failure code (Display of code), Part 2 Failure code [CA145] Coolant Temp Sens Low Error
SEN05032-01
Failure code [CA145] Coolant Temp Sens Low Error Action code
Failure code
E02
CA145
Failure description Action of controller
Trouble
1
Coolant temperature sensor low error (Engine controller system)
• Low voltage was detected in signal circuit of coolant temperature sensor. • Fixes coolant temperature value and continues operation.
Indication of problem on machine
• Engine is hard to start at low temperature. • Exhaust gas becomes white. • Overheat prevention function does not work.
Related information
• Signal voltage of coolant temperature sensor can be checked with monitoring function. (Code: 04105 Coolant temperature sensor voltage) • Method of reproducing failure code: Turn starting switch to ON position. • This code is not displayed but High Error failure code is displayed, if sensor connector or harness is disconnected.
Cause
1
2
3
4
5
Procedure, measuring location, standard (value) and remarks See the items related to wiring harness and connectors in "c: Electric and electrical Defective wiring harness equipment" in "Checks before troubleshooting" in "General information on connector troubleshooting" section, and check them directly. 1. Turn starting switch to OFF position. 2. Disconnect connector COOLANT TEMP and connect socket to male side. a When coolant temperature is above 0°C, if coolant temperature sensor resistance is 700 z – 37 kz, coolant temperature sensor is regarded as normal. 0°C Resistance 30 – 37 kz Defective coolant tempera9.3 – ture sensor Resistance 25°C COOLANT TEMP (male) between (A) 10.7 kz and (B) 50°C Resistance 3.2 – 3.8 kz a Coolant temperature characteristic 80°C Resistance 1.0 – 1.3 kz 95°C Resistance 700 – 800 z 1. Turn starting switch to OFF position. 2. Disconnect connector ECM and connect T-adapter to female side. Between ECM (female) (15) and (38) (Coolant temperaShort circuit in wiring harture is above 0°C) ness 700 z – a Resistance value is the same as the one on “coolant Resistance 37 kz temperature – resistance characteristics table” for coolant temperature sensor in cause 2. 1. Turn starting switch to OFF position. Ground fault of wiring har2. Disconnect connectors ECM and COOLANT TEMP, and connect T-adapter to ness female side of ECM. (Contact with ground circuit) Between ECM (female) (15) and ground Resistance Min. 100 kz If no abnormality is found by the above checks, the engine controller is defective. Defective engine controller (Since trouble is in system, troubleshooting cannot be performed.)
40-302
14
D65EX, PX, WX-16
302 Troubleshooting by failure code (Display of code), Part 2 Failure code [CA145] Coolant Temp Sens Low Error
SEN05032-01
Related circuit diagram
D65EX, PX, WX-16
40-302
15
302 Troubleshooting by failure code (Display of code), Part 2 Failure code [CA153] Chg Air Temp Sensor High Error
SEN05032-01
Failure code [CA153] Chg Air Temp Sensor High Error Action code
Failure code
E01
CA153
Failure description Action of controller
Trouble
1
Charge air temperature sensor high error (Engine controller system)
• High voltage was detected in temperature signal circuit of charge (boost) pressure/temperature sensor. • Fixes charge air temperature value and continues operation.
Indication of problem on machine
• Exhaust gas becomes white. • Engine protection function based on boost temperature does not work.
Related information
• Signal voltage on boost temperature side of boost pressure/temperature sensor can be checked with monitoring function. (Code: 18501 Boost temperature sensor voltage) • Method of reproducing failure code: Turn starting switch to ON position. • This failure code is displayed if temperature sensor connector or harness is disconnected.
Cause
1
2
3
4
Procedure, measuring location, standard (value) and remarks See the items related to wiring harness and connectors in "c: Electric and electrical Defective wiring harness equipment" in "Checks before troubleshooting" in "General information on connector troubleshooting" section, and check them directly. 1. Turn starting switch to OFF position. 2. Disconnect connector BOOST PRESS & IMT and connect socket to male side. a If charge temperature sensor resistance is 80 z – 48 kz, regard charge temperature sensor as normal. –40°C Resistance 41 – 48 kz Defective charge –20°C Resistance 14 – 16 kz temperature sensor 0°C Resistance 5.4 – 6.1 kz BOOST PRESS & IMT (male) between 30°C Resistance 1.6 – 1.8 kz (3) and (4) a Charge temperature characteristic 60°C Resistance 560 – 600 z 90°C Resistance 230 – 250 z 130°C Resistance 80 – 90 z 1. Turn starting switch to OFF position. 2. Disconnect connector ECM and connect T-adapter to female side. Disconnection or short circuit Between ECM (female) (23) and (47) in wiring harness a Resistance value is the same as the one on “charge Resistance 80 z – 48 kz temperature – resistance characteristics table” for charge temperature sensor in cause 2. If no abnormality is found by the above checks, the engine controller is defective. Defective engine controller (Since trouble is in system, troubleshooting cannot be performed.)
40-302
16
D65EX, PX, WX-16
302 Troubleshooting by failure code (Display of code), Part 2 Failure code [CA153] Chg Air Temp Sensor High Error
SEN05032-01
Related circuit diagram
D65EX, PX, WX-16
40-302
17
302 Troubleshooting by failure code (Display of code), Part 2 Failure code [CA154] Chg Air Temp Sensor Low Error
SEN05032-01
Failure code [CA154] Chg Air Temp Sensor Low Error Action code
Failure code
E01
CA154
Failure description Action of controller
Trouble
1
Charge air temperature sensor low error (Engine controller system)
• Low voltage was detected in temperature signal circuit of charge (boost) pressure/temperature sensor. • Fixes charge temperature value and continues operation.
Indication of problem on machine
• Exhaust gas becomes white. • Engine protection function based on boost temperature does not work.
Related information
• Signal voltage on boost temperature side of boost pressure/temperature sensor can be checked with monitoring function. (Code: 18501 Boost temperature sensor voltage) • Method of reproducing failure code: Turn starting switch to ON position. • This failure code is displayed if temperature sensor connector or harness is disconnected.
Cause
1
2
3
4
5
Procedure, measuring location, standard (value) and remarks See the items related to wiring harness and connectors in "c: Electric and electrical Defective wiring harness equipment" in "Checks before troubleshooting" in "General information on connector troubleshooting" section, and check them directly. 1. Turn starting switch to OFF position. 2. Disconnect connector BOOST PRESS & IMT and connect socket to male side. a If charge temperature sensor resistance is 80 z – 48 kz, regard charge temperature sensor as normal. –40°C Resistance 41 – 48 kz Defective charge –20°C Resistance 14 – 16 kz temperature sensor 0°C Resistance 5.4 – 6.1 kz BOOST PRESS & IMT (male) between 30°C Resistance 1.6 – 1.8 kz (3) and (4) a Charge temperature characteristic 60°C Resistance 560 – 600 z 90°C Resistance 230 – 250 z 130°C Resistance 80 – 90 z 1. Turn starting switch to OFF position. 2. Disconnect connector ECM and connect T-adapter to female side. Short circuit in wiring Between ECM (female) (23) and (47) harness a Resistance value is the same as the one on “charge Resistance 80 z – 48 kz temperature – resistance characteristics table” for charge temperature sensor in cause 2. 1. Turn starting switch to OFF position. 2. Disconnect connectors ECM and BOOST PRESS & IMT and connect T-adapter to Ground fault of wiring female side of ECM. harness (Contact with ground circuit) Between ECM (female) (23) or BOOST PRESS & IMT Resistance Min. 100 kz (female) (3) and ground If no abnormality is found by the above checks, the engine controller is defective. Defective engine controller (Since the trouble is in system, troubleshooting cannot be performed.)
40-302
18
D65EX, PX, WX-16
302 Troubleshooting by failure code (Display of code), Part 2 Failure code [CA154] Chg Air Temp Sensor Low Error
SEN05032-01
Related circuit diagram
D65EX, PX, WX-16
40-302
19
302 Troubleshooting by failure code (Display of code), Part 2 Failure code [CA155] Chg Air Temp High Speed Derate
SEN05032-01
Failure code [CA155] Chg Air Temp High Speed Derate Action code
Failure code
E03
CA155
Failure description Action of controller
Trouble
Charge air temperature high speed derate (Engine controller system)
• Temperature signal from charge (boost) pressure/temperature sensor exceeded temperature upper control limit. • Limits output and continues operation.
Indication of problem on machine
• Engine output lowers. • Engine stops.
Related information
• Boost temperature can be checked with monitoring function. (Code: 18500 Boost temperature) • Method of reproducing failure code: Start engine.
Cause 1
Lowering of cooling performance of aftercooler
Abnormal rise of 2 turbocharger outlet temperature 3
Defective charge air temperature sensor system
40-302
20
1
Procedure, measuring location, standard (value) and remarks Cooling performance of aftercooler may be low. Check following points directly. • Looseness and breakage of fan belt • Insufficiency of cooling air • Clogging of aftercooler fins Outlet temperature of turbocharger may be abnormally high. Check related parts directly. If no abnormality is found by the above checks, charge air temperature sensor system is defective. Perform troubleshooting for failure codes [CA153] and [CA154]
D65EX, PX, WX-16
302 Troubleshooting by failure code (Display of code), Part 2 Failure code [CA155] Chg Air Temp High Speed Derate
D65EX, PX, WX-16
SEN05032-01
40-302
21
302 Troubleshooting by failure code (Display of code), Part 2 Failure code [CA187] Sens Supply 2 Volt Low Error
SEN05032-01
Failure code [CA187] Sens Supply 2 Volt Low Error Action code
Failure code
E03
CA187
Failure description
Trouble
Sensor power supply 2 voltage low error (Engine controller system)
• Low voltage was detected in sensor power supply 2 circuit. • Fixes charge (boost) pressure value and continues operation. • Fixes charge (boost) air temperature value and continues operation. • Limits output and continues operation.
Action of controller Indication of problem on machine
• Engine output lowers. • Engine does not start easily.
Related information
• Method of reproducing failure code: Turn starting switch to ON position.
Cause 1
Defective wiring harness connector
2
Defective sensor or wiring harness
3 Defective engine controller
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22
1
Procedure, measuring location, standard (value) and remarks See the items related to wiring harness and connectors in "c: Electric and electrical equipment" in "Checks before troubleshooting" in "General information on troubleshooting" section, and check them directly. 1. Turn starting switch to OFF position. 2. Disconnect following connectors one by one and turn starting switch to ON position each time. 3. After troubleshooting, return to 1. If this failure code is not displayed when a sensor is disconnected, that sensor or engine wiring harness is defective. a Other failure code(s) is(are) displayed together. This is because that the sensor connector is disconnected. So, code(s) can be ignored except the failure code [CA187]. Sensor or harness Connector Boost pressure/temperature sensor BOOST PRESS & IMT Common rail pressure sensor FUEL RAIL PRESS Bkup sensor CAM SENSOR Engine wiring harness ECM 1. Turn starting switch to OFF position. 2. Disconnect connector ECM and connect T-adapter to male side. 3. Turn starting switch to ON position without connecting engine wiring harness. 4.75 – Between ECM (male) (37) and (47) Voltage 5.25 V
D65EX, PX, WX-16
302 Troubleshooting by failure code (Display of code), Part 2 Failure code [CA187] Sens Supply 2 Volt Low Error
SEN05032-01
Related circuit diagram
D65EX, PX, WX-16
40-302
23
302 Troubleshooting by failure code (Display of code), Part 2 Failure code [CA221] Ambient Press Sens High Error
SEN05032-01
Failure code [CA221] Ambient Press Sens High Error Action code
Failure code
E03
CA221
Failure description Action of controller
Trouble
1
Ambient pressure sensor high error (Engine controller system)
• High voltage was detected in signal circuit of ambient pressure sensor. • Fixes ambient pressure value and continues operation.
Indication of problem on machine
• Engine output lowers. • Engine does not start easily.
Related information
• Signal voltage of ambient pressure sensor can be checked with monitoring function. (Code: 37401 Ambient pressure sensor voltage) • Method of reproducing failure code: Turn starting switch to ON position.
Cause 1
Defective wiring harness connector
2
Defective sensor power supply 1 system
Defective ambient pressure 3 sensor
4
Short circuit in wiring harness
5
Hot short in wiring harness (Contact with 24 V circuit)
6 Defective engine controller
40-302
24
Procedure, measuring location, standard (value) and remarks See the items related to wiring harness and connectors in "c: Electric and electrical equipment" in "Checks before troubleshooting" in "General information on troubleshooting" section, and check them directly. If failure code [CA386] is also indicated, 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 changes from [CA221] to [CA222], sensor is defective. 1. Turn starting switch to OFF position. 2. Disconnect connectors ECM and AMB. AIR PRESSURE, and connect T-adapter to female side of either one of them. Between ECM (female) (33) and (3) or between AMB. Resistance Min. 100 kz AIR PRESSURE (female) (1) and (3) 1. Turn starting switch to OFF position. 2. Disconnect connector AMB. AIR PRESSURE. 3. Connect T-adapter to female side of connector AMB. AIR PRESSURE or insert Tadapter in connector ECM. 4. Turn starting switch to ON position (with connector AMB. AIR PRESSURE disconnected). Between ECM (3) and (38), or between AMB. AIR Voltage Max. 1 V PRESSURE (female) (3) and (2) If no abnormality is found by the above checks, the engine controller is defective. (Since trouble is in system, troubleshooting cannot be performed.)
D65EX, PX, WX-16
302 Troubleshooting by failure code (Display of code), Part 2 Failure code [CA221] Ambient Press Sens High Error
SEN05032-01
Related circuit diagram
D65EX, PX, WX-16
40-302
25
302 Troubleshooting by failure code (Display of code), Part 2 Failure code [CA222] Ambient Press Sens Low Error
SEN05032-01
Failure code [CA222] Ambient Press Sens Low Error Action code
Failure code
E03
CA222
Failure description Action of controller
Trouble
1
Ambient pressure sensor low error (Engine controller system)
• Low voltage was detected in signal circuit of ambient pressure sensor. • Fixes ambient pressure value and continues operation.
Indication of problem on machine
• Engine does not start easily. • Engine output lowers.
Related information
• Signal voltage of ambient pressure sensor can be checked with monitoring function. (Code: 37401 Ambient pressure sensor voltage) • Method of reproducing failure code: Turn starting switch to ON position.
Cause
1
2
3
4
5
6
Procedure, measuring location, standard (value) and remarks See the items related to wiring harness and connectors in "c: Electric and electrical Defective wiring harness equipment" in "Checks before troubleshooting" in "General information on connector troubleshooting" section, and check them directly. If failure code [CA352] (Ground fault in sensor power supply line) or [CA386] is displayed, perform troubleshooting for it first. 1. Turn starting switch to OFF position. Defective power supply 2. Disconnect connector AMB. AIR PRESSURE and connect T-adapter to female system of ambient pressure side. sensor 3. Turn starting switch to ON position. Between AMB. AIR PRESSURE (female) Power 4.75 – Voltage (1) and (2) supply input 5.25 V 1. Turn starting switch to OFF position. 2. Disconnect connectors ECM and AMB. AIR PRESSURE and connect T-adapters to each female side. a If power supply in checks on cause 2 is normal, this check is not required. Resistance Max. 10 z Disconnection in wiring Between ECM (female) (33) and AMB. AIR PRESharness SURE (female) (1) (Disconnection or defective a If power supply in checks on cause 2 is normal, this contact in connector) check is not required. Resistance Max. 10 z Between ECM (female) (38) and AMB. AIR PRESSURE (female) (2) Between ECM (female) (3) and AMB. AIR PRESSURE Resistance Max. 10 z (female) (3) (Sensor output) 1. Turn starting switch to OFF position. 2. Disconnect connectors ECM and AMB. AIR PRESSURE, and connect T-adapter Ground fault of wiring to female side of either one of them. harness (Contact with ground circuit) Between ECM (female) (3) and ground, or between Resistance Min. 100 kz AMB. AIR PRESSURE (female) (3) and ground 1. Turn starting switch to OFF position. 2. Disconnect connectors ECM and AMB. AIR PRESSURE, and connect T-adapter Short circuit in wiring to female side of either one of them. harness Between ECM (female) (3) and (38), or between AMB. Resistance Min. 100 kz AIR PRESSURE (female) (2) and (3) a If causes 1 – 5 are not the cause for the trouble and check result of cause 6 is abnormal, sensor is defective. Defective ambient pressure 1. Turn starting switch to OFF position. 2. Insert T-adapter between male and female sides of connector ECM. sensor (Improper input voltage to engine controller) 3. Turn starting switch to ON position. Sensor Voltage 0.5 – 4.5 V Between ECM (3) and (38) output
40-302
26
D65EX, PX, WX-16
302 Troubleshooting by failure code (Display of code), Part 2 Failure code [CA222] Ambient Press Sens Low Error
Cause 7 Defective engine controller
SEN05032-01
Procedure, measuring location, standard (value) and remarks If no abnormality is found by the above checks, the engine controller is defective. (Since trouble is in system, troubleshooting cannot be performed.)
Related circuit diagram
D65EX, PX, WX-16
40-302
27
302 Troubleshooting by failure code (Display of code), Part 2 Failure code [CA227] Sens Supply 2 Volt High Error
SEN05032-01
Failure code [CA227] Sens Supply 2 Volt High Error Action code
Failure code
E03
CA227
Failure description
Trouble
1
Sensor power supply 2 voltage high error (Engine controller system)
• High voltage was detected in sensor power supply No.2 circuit. • Fixes boost pressure value and continues operation. • Fixes charge air temperature value and continues operation. • Limits output and continues operation.
Action of controller Indication of problem on machine
• Engine output lowers. • Engine does not start easily.
Related information
• Method of reproducing failure code: Turn starting switch to ON position.
Cause
Procedure, measuring location, standard (value) and remarks Perform troubleshooting for failure code [CA187].
Failure code [CA234] Eng Overspeed Action code
Failure code
—
CA234
Failure description Action of controller
Trouble
Engine overspeed (Engine controller system)
• Engine speed exceeded upper limit. • Stops injection until engine speed lowers to normal level.
Indication of problem on machine
• Engine speed fluctuates.
Related information
• Engine speed can be checked with monitoring function. (Code: 01002 Engine speed) • Method of reproducing failure code: Run engine at high idle.
Cause 1 Use of improper fuel 2 Improper use 3 Defective engine controller
40-302
28
1
Procedure, measuring location, standard (value) and remarks Improper fuel may be used. Check it directly. Machine may be used improperly. Instruct operator proper way of use. If no abnormality is found by the above checks, the engine controller is defective. (Since trouble is in system, troubleshooting cannot be performed.)
D65EX, PX, WX-16
302 Troubleshooting by failure code (Display of code), Part 2 Failure code [CA238] Ne Speed Sens Supply Volt Error
SEN05032-01
Failure code [CA238] Ne Speed Sens Supply Volt Error Action code
Failure code
E03
CA238
Failure description Action of controller
Trouble
1
Ne speed sensor power supply voltage error (Engine controller system)
• Low voltage was detected in power supply circuit for engine Ne speed sensor. • Continues control with signal from engine Bkup speed sensor.
Indication of problem on machine
• Engine does not start easily. • Engine hunts.
Related information
• Method of reproducing failure code: Turn starting switch to ON position.
Cause 1
Defective wiring harness connector
2
Defective sensor or wiring harness
3 Defective engine controller
Procedure, measuring location, standard (value) and remarks See the items related to wiring harness and connectors in "c: Electric and electrical equipment" in "Checks before troubleshooting" in "General information on troubleshooting" section, and check them directly. 1. Turn starting switch to OFF position. 2. Disconnect following connectors one by one and turn starting switch to ON position each time. 3. After troubleshooting, return to 1. If this failure code is not displayed when a sensor is disconnected, sensor or engine wiring harness is defective. a Other failure code(s) is(are) displayed at the same time. This is because the sensor connector is disconnected. Therefore, code(s) can be ignored except the failure code [CA238]. Sensor or harness Connector Ne speed sensor CRANK SENSOR Engine wiring harness ECM 1. Turn starting switch to OFF position. 2. Disconnect connector ECM and connect T-adapter to male side. 3. Turn starting switch to ON position without connecting engine wiring harness. 4.75 – Between ECM (male) (16) and (48) Voltage 5.25 V
Related circuit diagram
D65EX, PX, WX-16
40-302
29
302 Troubleshooting by failure code (Display of code), Part 2 Failure code [CA271] IMV/PCV1 Short Error
SEN05032-01
Failure code [CA271] IMV/PCV1 Short Error Action code
Failure code
E03
CA271
Failure description Action of controller
Trouble
1
IMV/PCV1 short circuit error (Engine controller system)
• Short circuit was detected in drive circuit for supply pump actuator. • None in particular.
Indication of problem on machine
• Engine speed does not rise from low idle. • Engine output lowers. • Common rail fuel pressure rises above command value.
Related information
• Method of reproducing failure code: Turn starting switch to ON position.
Cause
1
2
3
4
5
6
Procedure, measuring location, standard (value) and remarks See the items related to wiring harness and connectors in "c: Electric and electrical Defective wiring harness equipment" in "Checks before troubleshooting" in "General information on connector troubleshooting" section, and check them directly. 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 and connect T-adapter to female side. Short circuit in, or ground fault of wiring harness Between ECM (female) (2) and (32) Resistance 1–5z Between ECM (female) (2) and ground Resistance Min. 100 kz a If cause 3 is not the cause for the trouble, this check is not required. 1. Turn starting switch to OFF position. 2. Disconnect connectors ECM and INLET METERING VALVE, and connect TShort circuit in wiring adapter to female side of ECM. harness Between ECM (female) (2) and (32), or between INLET Resistance Min. 100 kz METERING VALVE (female) (1) and (2) a If cause 3 is not the cause for the trouble, this check is not required. 1. Turn starting switch to OFF position. Ground fault of wiring 2. Disconnect connectors ECM and INLET METERING VALVE, and connect Tharness adapter to female side of ECM. (Contact with ground circuit) Between ECM (female) (2) and ground, or between Resistance Min. 100 kz INLET METERING VALVE (female) (1) and ground If no abnormality is found by the above checks, the engine controller is defective. Defective engine controller (Since trouble is in system, troubleshooting cannot be performed.)
Related circuit diagram
40-302
30
D65EX, PX, WX-16
302 Troubleshooting by failure code (Display of code), Part 2 Failure code [CA271] IMV/PCV1 Short Error
D65EX, PX, WX-16
SEN05032-01
40-302
31
302 Troubleshooting by failure code (Display of code), Part 2 Failure code [CA272] IMV/PCV1 Open Error
SEN05032-01
Failure code [CA272] IMV/PCV1 Open Error Action code
Failure code
E03
CA272
Failure description Action of controller
Trouble
1
IMV/PCV1 open error (Engine controller system)
• Disconnection was detected in drive circuit for supply pump actuator. • None in particular.
Indication of problem on machine
• Engine runs but its operation is unstable. • Common rail fuel pressure rises above command value.
Related information
• Method of reproducing failure code: Turn starting switch to ON position.
Cause
1
2
3
4
5
6
Procedure, measuring location, standard (value) and remarks See the items related to wiring harness and connectors in "c: Electric and electrical Defective wiring harness equipment" in "Checks before troubleshooting" in "General information on connector troubleshooting" section, and check them directly. 1. Turn starting switch to OFF position. Defective supply pump 2. Disconnect connector INLET METERING VALVE. actuator Between INLET METERING VALVE (male) (1) and (2) Resistance Max. 5 z 1. Turn starting switch to OFF position. Disconnection or short circuit 2. Disconnect connector ECM and connect T-adapter to female side. in wiring harness Between ECM (female) (2) and (32) Resistance Max. 5 z a If no abnormality is found in checks on cause 3, this check is not required. 1. Turn starting switch to OFF position. Disconnection in wiring 2. Disconnect connectors ECM and INLET METERING VALVE and connect Tharness adapters to each female side. (Disconnection in wiring or Between ECM (female) (2) and INLET METERING defective contact in Resistance Max. 10 z VALVE (1) connector) Between ECM (female) (32) and INLET METERING Resistance Max. 10 z VALVE (2) 1. Turn starting switch to OFF position. 2. Disconnect connector INLET METERING VALVE. 3. Insert T-adapter into connector ECM or connect female side of INLET METERING VALVE. Hot short in wiring harness 4. Turn starting switch to ON position and perform troubleshooting after one minute (Contact with 24 V circuit) or longer (with connector INLET METERING VALVE disconnected). a Average voltage is displayed because of PWM. Between ECM (2) and (32), or between INLET Voltage Max. 3 V METERING VALVE (female) (1) and (2) If no abnormality is found by the above checks, the engine controller is defective. Defective engine controller (Since the trouble is in system, troubleshooting cannot be performed.)
40-302
32
D65EX, PX, WX-16
302 Troubleshooting by failure code (Display of code), Part 2 Failure code [CA272] IMV/PCV1 Open Error
SEN05032-01
Related circuit diagram
D65EX, PX, WX-16
40-302
33
302 Troubleshooting by failure code (Display of code), Part 2 Failure code [CA281] Abnormal supply pump pressure balance
SEN05032-01
Failure code [CA281] Abnormal supply pump pressure balance Action code
Failure code
E03
CA281
Failure description Action of controller
Trouble
1
Abnormal supply pump pressure balance (Engine controller system)
• Due to the abnormality in supply pump mechanical system, response of fuel pressure feed is not appropriate, that is abnormal. • No particular action
Indication of problem on machine
• Engine does not start. Or it starts, but it does not stabilize. • The pressure of high-pressure fuel is different in front side and rear side of supply pump.
Related information
• Method of reproducing failure code: Start the engine.
Cause
Procedure, measuring location, standard (value) and remarks Refer to “Bleeding air from fuel circuit” in Testing and adjusting, and bleed air from 1 Residual air in the fuel circuit the fuel circuit. See the items related to wiring harness and connectors in "c: Electric and electrical Defective wiring harness 2 equipment" in "Checks before troubleshooting" in "General information on connector troubleshooting" section, and check them directly. Engine controller is possibly defective if no problem is found in causes 1 – 2. 3 Defective engine controller (Since the trouble is in system, troubleshooting cannot be performed.)
40-302
34
D65EX, PX, WX-16
302 Troubleshooting by failure code (Display of code), Part 2 Failure code [CA281] Abnormal supply pump pressure balance
D65EX, PX, WX-16
SEN05032-01
40-302
35
302 Troubleshooting by failure code (Display of code), Part 2 Failure code [CA322] Inj #1(L#1) Open/Short Error
SEN05032-01
Failure code [CA322] Inj #1(L#1) Open/Short Error Action code
Failure code
E03
CA322
Failure description Action of controller
Trouble
1
Injector #1(L#1) open/short circuit error (Engine controller system)
• Open or short circuit was detected in drive circuit of No. 1 injector. • None in particular.
Indication of problem on machine
• Combustion becomes irregular or engine hunts. • Engine output lowers.
Related information
• Method of reproducing failure code: Run engine. • While engine is running normally, pulse voltage of about 65 V is supplied to injector (+) side but it cannot be measured with tester since tester cannot measure pulse voltages.
Cause
1
2
3
4
5
6
7 8
Procedure, measuring location, standard (value) and remarks See the items related to wiring harness and connectors in "c: Electric and electrical Defective wiring harness equipment" in "Checks before troubleshooting" in "General information on connector troubleshooting" section, and check them directly. 1. Turn starting switch to OFF position. 2. Disconnect connector INJECTOR CYL 1&2, and connect T-adapter to male side. Defective No. 1 injector Between INJECTOR CYL 1&2 (male) (3) and (4) Resistance Max. 2 z Between INJECTOR CYL 1&2 (male) (3) and ground Resistance Min. 100 kz 1. Turn starting switch to OFF position. Disconnection in, or ground 2. Disconnect connector ECM and connect T-adapter to female side. Between ECM (female) (45) and (53) Resistance Max. 2 z fault of wiring harness Between ECM (female) (45) and ground Resistance Min. 100 kz a If cause 3 is not the cause of the trouble, this check is not required. 1. Turn starting switch to OFF position. Disconnection in wiring 2. Disconnect connectors ECM and INJECTOR CYL 1&2, and connect T-adapters to harness each female side. (Disconnection in wiring or Between ECM (female) (45) and INJECTOR CYL 1&2 Max. 2 z Resistance defective contact in (female) (3) connector) Between ECM (female) (53) and INJECTOR CYL 1&2 Max. 2 z Resistance (female) (4) a If cause 3 is not the cause of the trouble, this check is not required. 1. Turn starting switch to OFF position. Ground fault of wiring 2. Disconnect connectors ECM and INJECTOR CYL 1&2, and connect T-adapter to harness female side of either one of them. (Contact with ground circuit) Between ECM (female) (45) or INJECTOR CYL 1&2 Resistance Min. 100 kz (female) (3), and ground 1. Turn starting switch to OFF position. 2. Disconnect connectors ECM and INJECTOR CYL 1&2, and connect T-adapter to female side of ECM. a Check with tester in continuity mode. Short circuit in wiring Between ECM (female) (45) and each pin other than pin No continuity harness (No sound is heard) (45) Between ECM (female) (53) and each pin other than pin No continuity (No sound is heard) (53) If the failure codes of other injectors are displayed, perform troubleshooting of them, Defective other cylinder too. injectors or wiring harness If causes 1 – 7 are not the cause for the trouble, the engine controller is defective. Defective engine controller (Since trouble is in system, troubleshooting cannot be performed.)
40-302
36
D65EX, PX, WX-16
302 Troubleshooting by failure code (Display of code), Part 2 Failure code [CA322] Inj #1(L#1) Open/Short Error
SEN05032-01
Related circuit diagram
D65EX, PX, WX-16
40-302
37
302 Troubleshooting by failure code (Display of code), Part 2 Failure code [CA323] Inj #5(L#5) Open/Short Error
SEN05032-01
Failure code [CA323] Inj #5(L#5) Open/Short Error Action code
Failure code
E03
CA323
Failure description Action of controller
Trouble
1
Injector #5(L#5) open/short circuit error (Engine controller system)
• Open or short circuit was detected in drive circuit of No. 5 injector. • None in particular.
Indication of problem on machine
• Combustion becomes irregular or engine hunts. • Engine output lowers.
Related information
• Method of reproducing failure code: Run engine. a While engine is running normally, pulse voltage of about 65 V is supplied to injector (+) side but it cannot be measured with tester since tester cannot measure pulse voltages.
Cause
1
2
3
4
5
6
7 8
Procedure, measuring location, standard (value) and remarks See the items related to wiring harness and connectors in "c: Electric and electrical Defective wiring harness equipment" in "Checks before troubleshooting" in "General information on connector troubleshooting" section, and check them directly. 1. Turn starting switch to OFF position. 2. Disconnect connector INJECTOR CYL 5&6, and connect T-adapter to male side. Defective No. 5 injector Between INJECTOR CYL 5&6 (male) (3) and (4) Resistance Max. 2 z Between INJECTOR CYL 5&6 (male) (3) and ground Resistance Min. 100 kz 1. Turn starting switch to OFF position. Disconnection in, or ground 2. Disconnect connector ECM and connect T-adapter to female side. Between ECM (female) (46) and (60) Resistance Max. 2 z fault of wiring harness Between ECM (female) (46) and ground Resistance Min. 100 kz a If no abnormality is found in checks on cause 3, this check is not required. 1. Turn starting switch to OFF position. Disconnection in wiring 2. Disconnect connectors ECM and INJECTOR CYL 5&6, and connect T-adapters to harness each female side. (Disconnection in wiring or Between ECM (female) (46) and INJECTOR CYL 5&6 Max. 2 z Resistance defective contact in (female) (3) connector) Between ECM (female) (60) and INJECTOR CYL 5&6 Max. 2 z Resistance (female) (4) a If no abnormality is found in checks on cause 3, this check is not required. 1. Turn starting switch to OFF position. Ground fault of wiring 2. Disconnect connectors ECM and INJECTOR CYL 5&6, and connect T-adapter to harness female side of either one of them. (Contact with ground circuit) Between ECM (female) (46) or INJECTOR CYL 5&6 Resistance Min. 100 kz (female) (3), and ground 1. Turn starting switch to OFF position. 2. Disconnect connectors ECM and INJECTOR CYL 5&6, and connect T-adapter to female side of ECM. a Check with tester in continuity mode. Short circuit in wiring Between ECM (female) (46) and each pin other than pin No continuity harness (No sound is heard) (46) Between ECM (female) (60) and each pin other than pin No continuity (No sound is heard) (60) If the failure codes of other injectors are displayed, perform troubleshooting for them, Defective other cylinder too. injectors or wiring harness If no abnormality is found by the above checks, the engine controller is defective. Defective engine controller (Since trouble is in system, troubleshooting cannot be performed.)
40-302
38
D65EX, PX, WX-16
302 Troubleshooting by failure code (Display of code), Part 2 Failure code [CA323] Inj #5(L#5) Open/Short Error
SEN05032-01
Related circuit diagram
D65EX, PX, WX-16
40-302
39
302 Troubleshooting by failure code (Display of code), Part 2 Failure code [CA324] Inj #3(L#3) Open/Short Error
SEN05032-01
Failure code [CA324] Inj #3(L#3) Open/Short Error Action code
Failure code
E03
CA324
Failure description Action of controller
Trouble
1
Injector #3(L#3) open /short circuit error (Engine controller system)
• Open or short circuit was detected in drive circuit of No. 3 injector. • None in particular.
Indication of problem on machine
• Combustion becomes irregular or engine hunts. • Engine output lowers.
Related information
• Method of reproducing failure code: Run engine. a While engine is running normally, pulse voltage of about 65 V is supplied to injector (+) side but it cannot be measured with tester since tester cannot measure pulse voltages.
Cause
1
2
3
4
5
6
7 8
Procedure, measuring location, standard (value) and remarks See the items related to wiring harness and connectors in "c: Electric and electrical Defective wiring harness equipment" in "Checks before troubleshooting" in "General information on connector troubleshooting" section, and check them directly. 1. Turn starting switch to OFF position. 2. Disconnect connector INJECTOR CYL 3&4, and connect T-adapter to male side. Defective No. 3 injector Between INJECTOR CYL 3&4 (male) (3) and (4) Resistance Max. 2 z Between INJECTOR CYL 3&4 (male) (3) and ground Resistance Min. 100 kz 1. Turn starting switch to OFF position. Disconnection in, or ground 2. Disconnect connector ECM and connect T-adapter to female side. Between ECM (female) (55) and (52) Resistance Max. 2 z fault of wiring harness Between ECM (female) (55) and ground Resistance Min. 100 kz a If no abnormality is found in checks on cause 3, this check is not required. 1. Turn starting switch to OFF position. Disconnection in wiring 2. Disconnect connectors ECM and INJECTOR CYL 3&4, and connect T-adapters to harness each female side. (Disconnection in wiring or Between ECM (female) (55) and INJECTOR CYL 3&4 Max. 2 z Resistance defective contact in (female) (3) connector) Between ECM (female) (52) and INJECTOR CYL 3&4 Max. 2 z Resistance (female) (4) a If no abnormality is found in checks on cause 3, this check is not required. 1. Turn starting switch to OFF position. Ground fault of wiring 2. Disconnect connectors ECM and INJECTOR CYL 3&4, and connect T-adapter to harness female side of either one of them. (Contact with ground circuit) Between ECM (female) (55) or INJECTOR CYL 3&4 Resistance Min. 100 kz (female) (3), and ground 1. Turn starting switch to OFF position. 2. Disconnect connectors ECM and INJECTOR CYL 3&4, and connect T-adapter to female side of ECM. a Check with tester in continuity mode. Short circuit in wiring Between ECM (female) (55) and each pin other than pin No continuity harness (No sound is heard) (55) Between ECM (female) (52) and each pin other than pin No continuity (No sound is heard) (52) If the failure codes of other injectors are displayed, perform troubleshooting for them, Defective other cylinder too. injectors or wiring harness If no abnormality is found by the above checks, the engine controller is defective. Defective engine controller (Since trouble is in system, troubleshooting cannot be performed.)
40-302
40
D65EX, PX, WX-16
302 Troubleshooting by failure code (Display of code), Part 2 Failure code [CA324] Inj #3(L#3) Open/Short Error
SEN05032-01
Related circuit diagram
D65EX, PX, WX-16
40-302
41
302 Troubleshooting by failure code (Display of code), Part 2 Failure code [CA325] Inj #6(L#6) Open/Short Error
SEN05032-01
Failure code [CA325] Inj #6(L#6) Open/Short Error Action code
Failure code
E03
CA325
Failure description Action of controller
Trouble
1
Injector #6 (L#6) open / short circuit error (Engine controller system)
• Open or short circuit was detected in drive circuit of No. 6 injector. • None in particular.
Indication of problem on machine
• Combustion becomes irregular or engine hunts. • Engine output lowers.
Related information
• Method of reproducing failure code: Run engine. a While engine is running normally, pulse voltage of about 65 V is supplied to injector (+) side but it cannot be measured with tester since tester cannot measure pulse voltages.
Cause
1
2
3
4
5
6
7 8
Procedure, measuring location, standard (value) and remarks See the items related to wiring harness and connectors in "c: Electric and electrical Defective wiring harness equipment" in "Checks before troubleshooting" in "General information on connector troubleshooting" section, and check them directly. 1. Turn starting switch to OFF position. 2. Disconnect connector INJECTOR CYL 5&6, and connect T-adapter to male side. Defective No. 6 injector Between INJECTOR CYL 5&6 (male) (1) and (2) Resistance Max. 2 z Between INJECTOR CYL 5&6 (male) (1) and ground Resistance Min. 100 kz 1. Turn starting switch to OFF position. Disconnection in, or ground 2. Disconnect connector ECM and connect T-adapter to female side. Between ECM (female) (57) and (59) Resistance Max. 2 z fault of wiring harness Between ECM (female) (57) and ground Resistance Min. 100 kz a If no abnormality is found in checks on cause 3, this check is not required. 1. Turn starting switch to OFF position. Disconnection in wiring 2. Disconnect connectors ECM and INJECTOR CYL 5&6, and connect T-adapters to harness each female side. (Disconnection in wiring or Between ECM (female) (57) and INJECTOR CYL 5&6 Max. 2 z Resistance defective contact in (female) (1) connector) Between ECM (female) (59) and INJECTOR CYL 5&6 Max. 2 z Resistance (female) (2) a If no abnormality is found in checks on cause 3, this check is not required. 1. Turn starting switch to OFF position. Ground fault of wiring 2. Disconnect connectors ECM and INJECTOR CYL 5&6, and connect T-adapter to harness female side of either one of them. (Contact with ground circuit) Between ECM (female) (57) or INJECTOR CYL 5&6 Resistance Min. 100 kz (female) (1), and ground 1. Turn starting switch to OFF position. 2. Disconnect connectors ECM and INJECTOR CYL 5&6, and connect T-adapter to female side of ECM. a Check with tester in continuity mode. Short circuit in wiring Between ECM (female) (57) and each pin other than pin No continuity harness (No sound is heard) (57) Between ECM (female) (59) and each pin other than pin No continuity (No sound is heard) (59) If the failure codes of other injectors are displayed, perform troubleshooting of them, Defective other cylinder too. injectors or wiring harness If no abnormality is found by the above checks, the engine controller is defective. Defective engine controller (Since trouble is in system, troubleshooting cannot be performed.)
40-302
42
D65EX, PX, WX-16
302 Troubleshooting by failure code (Display of code), Part 2 Failure code [CA325] Inj #6(L#6) Open/Short Error
SEN05032-01
Related circuit diagram
D65EX, PX, WX-16
40-302
43
302 Troubleshooting by failure code (Display of code), Part 2 Failure code [CA331] Inj #2(L#2) Open/Short Error
SEN05032-01
Failure code [CA331] Inj #2(L#2) Open/Short Error Action code
Failure code
E03
CA331
Failure description Action of controller
Trouble
1
Injector #2(L#2) open /short circuit error (Engine controller system)
• Open or short circuit was detected in drive circuit of No. 2 injector. • None in particular.
Indication of problem on machine
• Combustion becomes irregular or engine hunts. • Engine output lowers.
Related information
• Method of reproducing failure code: Run engine. a While engine is running normally, pulse voltage of about 65 V is supplied to injector (+) side but it cannot be measured with tester since tester cannot measure pulse voltages.
Cause
1
2
3
4
5
6
7 8
Procedure, measuring location, standard (value) and remarks See the items related to wiring harness and connectors in "c: Electric and electrical Defective wiring harness equipment" in "Checks before troubleshooting" in "General information on connector troubleshooting" section, and check them directly. 1. Turn starting switch to OFF position. 2. Disconnect connector INJECTOR CYL 1&2, and connect T-adapter to male side. Defective No. 2 injector Between INJECTOR CYL 1&2 (male) (1) and (2) Resistance Max. 2 z Between INJECTOR CYL 1&2 (male) (2) and ground Resistance Min. 100 kz 1. Turn starting switch to OFF position. Disconnection in, or ground 2. Disconnect connector ECM and connect T-adapter to female side. Between ECM (female) (54) and (51) Resistance Max. 2 z fault of wiring harness Between ECM (female) (54) and ground Resistance Min. 100 kz a If no abnormality is found in checks on cause 3, this check is not required. 1. Turn starting switch to OFF position. Disconnection in wiring 2. Disconnect connectors ECM and INJECTOR CYL 1&2, and connect T-adapters to harness each female side. (Disconnection in wiring or Between ECM (female) (54) and INJECTOR CYL 1&2 Max. 2 z Resistance defective contact in (female) (2) connector) Between ECM (female) (51) and INJECTOR CYL 1&2 Max. 2 z Resistance (female) (1) a If no abnormality is found in checks on cause 3, this check is not required. 1. Turn starting switch to OFF position. Ground fault of wiring 2. Disconnect connectors ECM and INJECTOR CYL 1&2, and connect T-adapter to harness female side of either one of them. (Contact with ground circuit) Between ECM (female) (54) or INJECTOR CYL 1&2 Resistance Min. 100 kz (female) (2), and ground 1. Turn starting switch to OFF position. 2. Disconnect connectors ECM and INJECTOR CYL 1&2, and connect T-adapter to female side of ECM. a Check with tester in continuity mode. Short circuit in wiring Between ECM (female) (54) and each pin other than pin No continuity harness (No sound is heard) (54) Between ECM (female) (51) and each pin other than pin No continuity (No sound is heard) (51) If the failure codes of other injectors are displayed, perform troubleshooting for them, Defective other cylinder too. injectors or wiring harness If no abnormality is found by the above checks, the engine controller is defective. Defective engine controller (Since trouble is in system, troubleshooting cannot be performed.)
40-302
44
D65EX, PX, WX-16
302 Troubleshooting by failure code (Display of code), Part 2 Failure code [CA331] Inj #2(L#2) Open/Short Error
SEN05032-01
Related circuit diagram
D65EX, PX, WX-16
40-302
45
302 Troubleshooting by failure code (Display of code), Part 2 Failure code [CA332] Inj #4(L#4) Open/Short Error
SEN05032-01
Failure code [CA332] Inj #4(L#4) Open/Short Error Action code
Failure code
E03
CA332
Failure description Action of controller
Trouble
1
Injector #4 (L#4) open / short circuit error (Engine controller system)
• Open or short circuit was detected in drive circuit of No. 4 injector. • None in particular.
Indication of problem on machine
• Combustion becomes irregular or engine hunts. • Engine output lowers.
Related information
• Method of reproducing failure code: Run engine. a While engine is running normally, pulse voltage of about 65 V is supplied to injector (+) side but it cannot be measured with tester since tester cannot measure pulse voltages.
Cause
1
2
3
4
5
6
7 8
Procedure, measuring location, standard (value) and remarks See the items related to wiring harness and connectors in "c: Electric and electrical Defective wiring harness equipment" in "Checks before troubleshooting" in "General information on connector troubleshooting" section, and check them directly. 1. Turn starting switch to OFF position. 2. Disconnect connector INJECTOR CYL 3&4, and connect T-adapter to male side. Defective No. 4 injector Between INJECTOR CYL 3&4 (male) (1) and (2) Resistance Max. 2 z Between INJECTOR CYL 3&4 (male) (2) and ground Resistance Min. 100 kz 1. Turn starting switch to OFF position. Disconnection in, or ground 2. Disconnect connector ECM and connect T-adapter to female side. Between ECM (female) (56) and (58) Resistance Max. 2 z fault of wiring harness Between ECM (female) (56) and ground Resistance Min. 100 kz a If no abnormality is found in checks on cause 3, this check is not required. 1. Turn starting switch to OFF position. Disconnection in wiring 2. Disconnect connectors ECM and INJECTOR CYL 3&4, and connect T-adapters to harness each female side. (Disconnection in wiring or Between ECM (female) (56) and INJECTOR CYL 3&4 Max. 2 z Resistance defective contact in (female) (2) connector) Between ECM (female) (58) and INJECTOR CYL 3&4 Max. 2 z Resistance (female) (1) a If no abnormality is found in checks on cause 3, this check is not required. 1. Turn starting switch to OFF position. Ground fault of wiring 2. Disconnect connectors ECM and INJECTOR CYL 3&4, and connect T-adapter to harness female side of either one of them. (Contact with ground circuit) Between ECM (female) (56) or INJECTOR CYL 3&4 Resistance Min. 100 kz (female) (2), and ground 1. Turn starting switch to OFF position. 2. Disconnect connectors ECM and INJECTOR CYL 3&4, and connect T-adapter to female side of ECM. a Check with tester in continuity mode. Short circuit in wiring Between ECM (female) (56) and each pin other than pin No continuity harness (No sound is heard) (56) Between ECM (female) (58) and each pin other than pin No continuity (No sound is heard) (58) If the failure codes of other injectors are displayed, perform troubleshooting for them, Defective other cylinder too. injectors or wiring harness If no abnormality is found by the above checks, the engine controller is defective. Defective engine controller (Since trouble is in system, troubleshooting cannot be performed.)
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46
D65EX, PX, WX-16
302 Troubleshooting by failure code (Display of code), Part 2 Failure code [CA332] Inj #4(L#4) Open/Short Error
SEN05032-01
Related circuit diagram
D65EX, PX, WX-16
40-302
47
SEN05032-01
D65EX, PX, WX-16 Bulldozer Form No. SEN05032-01
©2009 KOMATSU All Rights Reserved Printed in Japan 07-09
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SEN05033-01
BULLDOZER D65EX-16 D65PX-16 D65WX-16 Machine model D65EX-16 D65PX-16 D65WX-16
Serial number 80001 and up 80001 and up 80001 and up
40 Troubleshooting
40
303 Troubleshooting by failure code (Display of code), Part 3 Failure code [CA342] Calibration Code Incompatibility................................................................................... 3 Failure code [CA351] Injectors Drive Circuit Error .......................................................................................... 3 Failure code [CA352] Sens Supply 1 Volt Low Error ...................................................................................... 4 Failure code [CA386] Sens Supply 1 Volt High Error...................................................................................... 6 Failure code [CA428] Water in Fuel Sensor High Error .................................................................................. 8 Failure code [CA429] Water in Fuel Sensor Low Error ................................................................................. 10 Failure code [CA435] Eng Oil Press Sw Error .............................................................................................. 12 Failure code [CA441] Battery Voltage Low Error .......................................................................................... 14 Failure code [CA442] Battery Voltage High Error ......................................................................................... 16 Failure code [CA449] Rail Press Very High Error ......................................................................................... 18 Failure code [CA451] Rail Press Sensor High Error ..................................................................................... 20 Failure code [CA452] Rail Press Sensor Low Error...................................................................................... 22 Failure code [CA488] Chg Air Temp High Torque Derate ............................................................................. 24 Failure code [CA553] Rail Press High Error ................................................................................................. 25 Failure code [CA559] Rail Press Low Error .................................................................................................. 26 Failure code [CA689] Eng Ne Speed Sensor Error....................................................................................... 28 Failure code [CA731] Eng Bkup Speed Sens Phase Error ........................................................................... 32 Failure code [CA757] All Continuous Data Lost Error................................................................................... 33 Failure code [CA778] Eng Bkup Speed Sensor Error ................................................................................... 34 Failure code [CA1633] KOMNET Datalink Timeout Error ............................................................................. 37 Failure code [CA2185] Throt Sens Sup Volt High Error................................................................................ 38 D65EX, PX, WX-16
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SEN05033-01
303 Troubleshooting by failure code (Display of code), Part 3
Failure code [CA2186] Throt Sens Sup Volt Low Error................................................................................. 40 Failure code [CA2249] Rail Press Very Low Error ........................................................................................ 42 Failure code [CA2265] Fuel Feed Pump Open Error .................................................................................... 44 Failure code [CA2266] Fuel Feed Pump Short Error .................................................................................... 46 Failure code [CA2311] IMV Solenoid Error ................................................................................................... 47 Failure code [CA2555] Grid Htr Relay Volt High Error .................................................................................. 48 Failure code [CA2556] Grid Htr Relay Volt Low Error ................................................................................... 50
40-303
2
D65EX, PX, WX-16
303 Troubleshooting by failure code (Display of code), Part 3 Failure code [CA342] Calibration Code Incompatibility
SEN05033-01
Failure code [CA342] Calibration Code Incompatibility Action code
Failure code
E04
CA342
Failure description Action of controller
Trouble
Calibration code incompatibility (Engine controller system)
• Calibration code incompatibility occurred in engine controller. • None in particular.
Indication of problem on machine
• Continues normal operation.
Related information
• Method of reproducing failure code: Turn starting switch to ON position.
Cause 1 Related defective system 2
1
Abnormal power supply voltage
Procedure, measuring location, standard (value) and remarks Check another failure code displayed simultaneously. If another failure code is also displayed, perform troubleshooting for it first. Perform troubleshooting for failure code [CA441].
Failure code [CA351] Injectors Drive Circuit Error Action code
Failure code
E03
CA351
Failure description Action of controller
Trouble
Injector drive circuit error (Engine controller system)
• Power supply circuit to drive injectors is defective. • Limits engine output and continues operation.
Indication of problem on machine
• • • •
Related information
• Method of reproducing failure code: Start engine. a If it outputs failure code, power supply to engine controller is normal.
Exhaust gas becomes black. Combustion becomes irregular. Engine output lowers. Engine cannot be started.
Cause 1 Related defective system 2
1
Abnormal power supply voltage
D65EX, PX, WX-16
Procedure, measuring location, standard (value) and remarks Check another failure code displayed simultaneously. If another failure code is displayed, perform troubleshooting for it first. Perform troubleshooting for failure code [CA441].
40-303
3
303 Troubleshooting by failure code (Display of code), Part 3 Failure code [CA352] Sens Supply 1 Volt Low Error
SEN05033-01
Failure code [CA352] Sens Supply 1 Volt Low Error Action code
Failure code
E03
CA352
Failure description Action of controller
Trouble
Sensor power supply 1 voltage low error (Engine controller system)
• Low voltage was detected in sensor power supply No.1 circuit. • Fixes ambient pressure value and continues operation.
Indication of problem on machine
• Engine does not start easily. • Engine output lowers.
Related information
• Method of reproducing failure code: Turn starting switch to ON position.
Cause 1
Defective wiring harness connector
2
Defective sensor or wiring harness
3 Defective engine controller
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1
Procedure, measuring location, standard (value) and remarks See the items related to wiring harness and connectors in "c: Electric and electrical equipment" in "Checks before troubleshooting" in "General information on troubleshooting" section, and check them directly. 1. Turn starting switch to OFF position. 2. Disconnect following connectors one by one and turn starting switch to ON position to check whether the failure code is displayed or not. 3. After troubleshooting, return to 1. If this failure code is not displayed when a sensor is disconnected, that sensor or engine wiring harness is defective. a Other failure code(s) is(are) displayed at the same time. This is because the sensor connector is disconnected. Therefore, code(s) may be ignored except for the failure code [CA352]. Sensor or harness Connector Ambient pressure sensor AMB. AIR PRESSURE Engine wiring harness ECM 1. Turn starting switch to OFF position. 2. Disconnect connector ECM and connect T-adapter to male side. 3. Turn starting switch to ON position without connecting engine wiring harness. 4.75 – Between ECM (male) (33) and (38) Voltage 5.25 V
D65EX, PX, WX-16
303 Troubleshooting by failure code (Display of code), Part 3 Failure code [CA352] Sens Supply 1 Volt Low Error
SEN05033-01
Related circuit diagram
D65EX, PX, WX-16
40-303
5
303 Troubleshooting by failure code (Display of code), Part 3 Failure code [CA386] Sens Supply 1 Volt High Error
SEN05033-01
Failure code [CA386] Sens Supply 1 Volt High Error Action code
Failure code
E03
CA386
Trouble
Sensor power supply 1 voltage high error (Engine controller system)
Failure description
• High voltage was detected in sensor power supply No.1 circuit.
Action of controller
• Sets ambient pressure at a fixed value and continues operation.
Indication of problem on machine
• Engine does not start easily. • Engine output lowers.
Related information
• Method of reproducing failure code: Turn starting switch to ON position.
Cause
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1
Procedure, measuring location, standard (value) and remarks Perform troubleshooting for failure code [CA352].
D65EX, PX, WX-16
303 Troubleshooting by failure code (Display of code), Part 3 Failure code [CA386] Sens Supply 1 Volt High Error
D65EX, PX, WX-16
SEN05033-01
40-303
7
303 Troubleshooting by failure code (Display of code), Part 3 Failure code [CA428] Water in Fuel Sensor High Error
SEN05033-01
Failure code [CA428] Water in Fuel Sensor High Error Action code
Failure code
E01
CA428
Failure description Action of controller
Trouble
1
Water-in-fuel sensor high error (Engine controller system)
• High voltage was detected in signal circuit of water-in-fuel sensor. • None in particular.
Indication of problem on machine
• Water separator monitor is not displayed properly.
Related information
• Condition of water-in-fuel sensor signal can be checked with monitoring function. (Code: 18800 Condition of WIF sensor) • Method of reproducing failure code: Turn starting switch to ON position.
Cause
1
2
3
4
5
6
Procedure, measuring location, standard (value) and remarks See the items related to wiring harness and connectors in "c: Electric and electrical Defective wiring harness equipment" in "Checks before troubleshooting" in "General information on connector troubleshooting" section, and check them directly. 1. Turn starting switch to OFF position. 2. Disconnect connector WIF and connect T-adapter to female side. Defective water-in-fuel a If water is in water separator, drain it. sensor Between WIF (female) (1) and (2) Resistance Max. 100 kz 1. Turn starting switch to OFF position. Disconnection or short circuit 2. Disconnect connector ECM and connect T-adapter to female side. in wiring harness Between ECM (female) (14) and (47) Resistance Max. 100 kz (resistance in water-in-fuel sensor) a If no abnormality is found in checks on cause 3, this check is not required. 1. Turn starting switch to OFF position. Disconnection in wiring 2. Disconnect connectors ECM and WIF, and connect T-adapters to each female harness side. (Disconnection in wiring or Between connector ECM (female) (14) and WIF defective contact in Max. 10 z Resistance (female) (1) connector) Between connector ECM (female) (47) and WIF Max. 10 z Resistance (female) (2) 1. Turn starting switch to OFF position. 2. Disconnect connectors ECM and WIF, and connect T-adapters to each female side. Short circuit in wiring a Check with tester in continuity mode. harness Between ECM (female) (14) and each pin other than No continuity (14) pin (No sound is heard) If no abnormality is found by the above checks, the engine controller is defective. Defective engine controller (Since the trouble is in system, troubleshooting cannot be performed.)
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D65EX, PX, WX-16
303 Troubleshooting by failure code (Display of code), Part 3 Failure code [CA428] Water in Fuel Sensor High Error
SEN05033-01
Related circuit diagram
D65EX, PX, WX-16
40-303
9
303 Troubleshooting by failure code (Display of code), Part 3 Failure code [CA429] Water in Fuel Sensor Low Error
SEN05033-01
Failure code [CA429] Water in Fuel Sensor Low Error Action code
Failure code
E01
CA429
Failure description Action of controller
Trouble
1
Water-in-fuel sensor low error (Engine controller system)
• Low voltage was detected in signal circuit of water-in-fuel sensor. • None in particular.
Indication of problem on machine
• Water separator monitor is not displayed properly.
Related information
• Condition of water-in-fuel sensor signal can be checked with monitoring function. (Code: 18800 Condition of WIF sensor) • Method of reproducing failure code: Turn starting switch to ON position.
Cause
1
2
3
4
5
6
Procedure, measuring location, standard (value) and remarks See the items related to wiring harness and connectors in "c: Electric and electrical Defective wiring harness equipment" in "Checks before troubleshooting" in "General information on connector troubleshooting" section, and check them directly. 1. Turn starting switch to OFF position. 2. Disconnect connector WIF and connect T-adapter to female side. Defective water-in-fuel a If water is in water separator, drain it. sensor Between WIF (female) (1) and (2) Resistance Max.100 kz Between WIF (female) (1) and ground Resistance Min. 100 kz 1. Turn starting switch to OFF position. 2. Disconnect connector ECM and connect T-adapter to female side. Short circuit in, or ground Between ECM (female) (14) and (47) (Water-in-fuel fault of wiring harness Resistance Max.100 kz sensor resistance) Between ECM (female) (14) and ground Resistance Min. 100 kz 1. Turn starting switch to OFF position. 2. Disconnect connectors ECM and WIF, and connect T-adapter to female side of either one of them. Short circuit in wiring a Check with tester in continuity mode. harness Between ECM (female) (14) and each pin other than No continuity (14) pin (No sound is heard) a If cause 3 is not the cause for the trouble, this check is not required. 1. Turn starting switch to OFF position. Ground fault of wiring 2. Disconnect connectors ECM and WIF and connect T-adapter to female side of harness either one of them. (Contact with ground circuit) Between ECM (female) (14) or WIF (female) (1) and Resistance Min. 100 kz ground If no abnormality is found by the above checks, the engine controller is defective. Defective engine controller (Since trouble is in system, troubleshooting cannot be performed.)
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D65EX, PX, WX-16
303 Troubleshooting by failure code (Display of code), Part 3 Failure code [CA429] Water in Fuel Sensor Low Error
SEN05033-01
Related circuit diagram
D65EX, PX, WX-16
40-303
11
303 Troubleshooting by failure code (Display of code), Part 3 Failure code [CA435] Eng Oil Press Sw Error
SEN05033-01
Failure code [CA435] Eng Oil Press Sw Error Action code
Failure code
E02
CA435
Failure description Action of controller
Trouble
1
Engine oil pressure switch error (Engine controller system)
• Abnormality is detected in signal circuit of engine oil pressure switch. • None in particular.
Indication of problem on machine
• Engine protection function based on engine oil pressure does not work. • Engine oil pressure monitor is not displayed properly.
Related information
• Method of reproducing failure code: Turn starting switch to ON position or start engine. • Engine oil pressure switch closes (ON) with starting switch at OFF position and opens (OFF) with engine running. • In this failure code, engine controller checks whether oil pressure switch is closed (ON), that is “GND level” only with engine stopped. • With engine running, failure code [B@BAZG] applies to engine oil pressure switch abnormality.
Cause
1
2
3 4
Procedure, measuring location, standard (value) and remarks See the items related to wiring harness and connectors in "c: Electric and electrical Defective wiring harness equipment" in "Checks before troubleshooting" in "General information on connector troubleshooting" section, and check them directly. 1. Turn starting switch to OFF position. 2. Disconnect connector OIL PRESSURE SWITCH and connect T-adapter to male Defective engine oil side. pressure switch Between OIL PRESSURE SWITCH (male) (1) and Resistance Max. 10 z ground 1. Turn starting switch to OFF position. Disconnection or short circuit 2. Disconnect connector ECM and connect T-adapter to female side. in wiring harness Between ECM (female) (17) and ground Resistance Max. 10 z If no abnormality is found by the above checks, the engine controller is defective. Defective engine controller (Since the trouble is in system, troubleshooting cannot be performed.)
Related circuit diagram
40-303
12
D65EX, PX, WX-16
303 Troubleshooting by failure code (Display of code), Part 3 Failure code [CA435] Eng Oil Press Sw Error
D65EX, PX, WX-16
SEN05033-01
40-303
13
303 Troubleshooting by failure code (Display of code), Part 3 Failure code [CA441] Battery Voltage Low Error
SEN05033-01
Failure code [CA441] Battery Voltage Low Error Action code
Failure code
E04
CA441
Failure description Action of controller
Trouble
1
Battery voltage low error (Engine controller system)
• Low voltage was detected in voltage source circuit of controller. • None in particular.
Indication of problem on machine
• Engine stops. • Engine does not start easily.
Related information
• Method of reproducing failure code: Turn starting switch to ON position.
Cause Looseness or corrosion of 1 battery terminal 2 3
4
5
6
Procedure, measuring location, standard (value) and remarks Looseness or corrosion of battery terminal may be cause of failure. Check them directly. Loosened terminal or partial 1. Turn starting switch to OFF position. disconnection at terminal Check terminals of alternator, battery relay, ground (GND1) etc. for looseness. See the items related to wiring harness and connectors in "c: Electric and electrical Defective wiring harness equipment" in "Checks before troubleshooting" in "General information on connector troubleshooting" section, and check them directly. 1. Turn starting switch to OFF position. 2. Measure voltage with starting switch at OFF and when starting engine. Improper battery voltage Between battery terminal (+) and (–). Voltage 20 – 30 V 1. Turn starting switch to OFF position. 2. Insert T-adapter between male and female side of connector EG2. Defective alternator 3. Start engine (Engine speed: Middle or faster) Between EG2 (7) and ground Voltage 26 – 30.5 V If no abnormality is found by the above checks, the engine controller is defective. (Since the trouble is in system, troubleshooting cannot be performed.) • Reference: The followings are standard value in normal condition. 1. Turn starting switch to OFF position and disconnect ground cable. Defective engine controller 2. Insert T-adapter between male and female sides of CE03. 3. Connect ground cable. 4. Measure voltage with starting switch at OFF and when starting engine. Between CE03 (3) and (1) Voltage 20 – 30 V Between CE03 (4) and (2) Voltage 20 – 30 V
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D65EX, PX, WX-16
303 Troubleshooting by failure code (Display of code), Part 3 Failure code [CA441] Battery Voltage Low Error
SEN05033-01
Related circuit diagram
D65EX, PX, WX-16
40-303
15
303 Troubleshooting by failure code (Display of code), Part 3 Failure code [CA442] Battery Voltage High Error
SEN05033-01
Failure code [CA442] Battery Voltage High Error Action code
Failure code
E04
CA442
Failure description
Trouble
Battery voltage high error (Engine controller system)
• High voltage (36 V or higher) was detected in voltage source circuit of controller.
Action of controller
• None in particular.
Indication of problem on machine
• Engine may stop.
Related information
• Method of reproducing failure code: Turn starting switch to ON position.
Cause
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1
Procedure, measuring location, standard (value) and remarks Perform troubleshooting for failure code [CA441].
D65EX, PX, WX-16
303 Troubleshooting by failure code (Display of code), Part 3 Failure code [CA442] Battery Voltage High Error
D65EX, PX, WX-16
SEN05033-01
40-303
17
303 Troubleshooting by failure code (Display of code), Part 3 Failure code [CA449] Rail Press Very High Error
SEN05033-01
Failure code [CA449] Rail Press Very High Error Action code
Failure code
E03
CA449
Failure description Action of controller
Trouble
Common rail pressure very high error (Engine controller system)
• There is high pressure error (2) in common rail circuit. • Limits output and continues operation.
Indication of problem on machine
• Engine sound becomes large when no or light load is applied. • Engine output lowers.
Related information
• Common rail pressure can be checked with monitoring function. (Code: 36400 Common rail pressure) • Method of reproducing failure code: Start engine.
Cause 1 Defect in related system
2 Air in low pressure circuit
3
Defect in fuel low pressure circuit parts
4 Defective fuel cooler
5
Defective common rail pressure sensor
6
Defective O-ring of supply pump actuator
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1
Procedure, measuring location, standard (value) and remarks If another failure code is displayed, perform troubleshooting for it, too. There may be air in low pressure circuit. Check it directly according to the following procedure. 1. Remove pressure pickup plug (outlet side) of fuel main filter. 2. Operate feed pump of fuel pre-filter. 3. Check pressure pickup plug for leakage of fuel and air. • If this failure occurs during air bleeding after the fuel filter was replaced, air may remain in the fuel circuit. Keep running the engine at low idle for about three minutes. As air is bled from the fuel circuit, the engine speed will be stabilized, erasing the failure indication. a For check of pressure in fuel low pressure circuit, see Testing and adjusting, “Checking fuel pressure”. • Measured in fuel filter outlet side. Pressure in fuel During high idle Max. 0.48 MPa low-pressure circuit (if engine can be started) {Max. 4.9 kg/cm2} a For check of pressure in fuel low pressure circuit, see Testing and adjusting, “Checking fuel pressure”. • Measured in fuel filter inlet and outlet sides. • Pressure drop in fuel low-pressure circuit = Fuel filter inlet pressure – Fuel filter outlet pressure Pressure drop in fuel Max. 0.14 MPa During high idle low-pressure circuit {Max. 1.4 kg/cm2} a For check of fuel suction pressure, see Testing and adjusting, “Checking fuel pressure”. • Measured in gear pump fuel inlet side of supply pump. Fuel suction circuit Max. 33.9 kPa pressure During high idle {Max. 254 mmHg} (gear pump side) a For check of fuel return circuit pressure, see Testing and adjusting, “Checking fuel pressure”. Fuel suction circuit Max. 27.1 kPa pressure During high idle {Max. 203 mmHg} (fuel connector side) a Directly check for fuel leakage from fuel tube of fuel cooler, O-ring, seal washer damage, and check valve clogging or damage. 1. Turn starting switch to OFF position 2. Display monitoring code: 36400 with monitoring function of machine monitor. Common rail pressure: 0 ± 0.39 MPa While engine is stopped 36400 {0 ± 4 kg/cm2} a Directly check that O-ring of supply pump actuator is not damaged.
D65EX, PX, WX-16
303 Troubleshooting by failure code (Display of code), Part 3 Failure code [CA449] Rail Press Very High Error
Cause
7
Defective supply pump actuator
8
Defective wiring harness connector
9
Defective engine controller ground wiring harness
10 Defective supply pump
SEN05033-01
Procedure, measuring location, standard (value) and remarks 1. Turn starting switch to OFF position 2. Display monitoring code: 36400 with monitoring function of machine monitor. Common rail pressure: 0 ± 0.39 MPa While engine is stopped 36400 {0 ± 4 kg/cm2} 1. Turn starting switch to OFF position 2. Display monitoring code: 36400 with monitoring function of machine monitor. 3. Start engine. • Measured after one minute or more lapsed at idle. Common rail pressure: 1.96 MPa During low idle 36400 {20 kg/cm2} See the items related to wiring harness and connectors in "c: Electric and electrical equipment" in "Checks before troubleshooting" in "General information on troubleshooting" section, and check them directly. 1. Turn starting switch to OFF position. 2. Disconnect connector CE03, and connect T-adapter to female side. a Check looseness and corrosion of GND1 terminal. Between CE03 (female) (1) and ground Resistance Max. 10 z If causes 1 – 9 are not detected, supply pump may be defective.
Related circuit diagram
D65EX, PX, WX-16
40-303
19
303 Troubleshooting by failure code (Display of code), Part 3 Failure code [CA451] Rail Press Sensor High Error
SEN05033-01
Failure code [CA451] Rail Press Sensor High Error Action code
Failure code
E03
CA451
Failure description Action of controller
Trouble
1
Common rail pressure sensor high error (Engine controller system)
• High voltage was detected in signal circuit of common rail pressure sensor. • Limits engine output and continues operation.
Indication of problem on machine
• Engine does not start. • Engine speed or output lowers.
Related information
• Signal voltage of common rail pressure sensor can be checked with monitoring function. (Code: 36401 Common rail pressure sensor voltage) • Method of reproducing failure code: Turn starting switch to ON position. • This code is displayed if common rail pressure sensor connector or harness is disconnected. • Disconnection in wiring harness and voltage at sensor connector cannot be checked, because that T-adapter for sensor connector is socket type.
Cause 1
Defective wiring harness connector
Defective common rail 2 pressure sensor power supply line
3
Short circuit in wiring harness
4
Hot short in wiring harness (Contact with 24 V circuit)
Disconnection in wiring harness 5 (Disconnection or defective contact in connector) Defective common rail pressure sensor 6 (Improper input voltage to engine controller)
7 Defective engine controller
Procedure, measuring location, standard (value) and remarks See the items related to wiring harness and connectors in "c: Electric and electrical equipment" in "Checks before troubleshooting" in "General information on troubleshooting" section, and check them directly. If failure code [CA227] or [CA187] is displayed, perform troubleshooting for it first. 1. Turn starting switch to OFF position. 2. Disconnect connectors CAM SENSOR, FUEL RAIL PRESS, BOOST PRESS & IMT and ECM. 3. Connect T-adapter to female side of ECM. Between ECM (female) (25) and (37) Resistance Min. 100 kz 1. Turn starting switch to OFF position. 2. Disconnect connector FUEL RAIL PRESS and insert T-adapter in connector ECM. 3. Turn starting switch to ON position (with connector FUEL RAIL PRESS disconnected). a ECM (25) pin is connected to 5 V source through resistor in engine controller. Between ECM (25) and (47) Voltage Approx. 5 V If no abnormality is found by the above checks, disconnection in wiring harness is considered. (*) a If causes 1 – 5 are not the cause of the trouble and check result of cause 6 is abnormal, sensor is defective. 1. Turn starting switch to OFF position. 2. Insert T-adapter in connector ECM. 3. Turn starting switch to ON position. Sensor Between ECM (25) and (47) Voltage 0.2 – 4.6 V output If no abnormality is found by the above checks, the engine controller is defective. (Since trouble is in system, troubleshooting cannot be performed.)
*: See "Troubleshooting for disconnection in wiring harness of pressure sensor system" in "General information on troubleshooting" section.
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D65EX, PX, WX-16
303 Troubleshooting by failure code (Display of code), Part 3 Failure code [CA451] Rail Press Sensor High Error
SEN05033-01
Related circuit diagram
D65EX, PX, WX-16
40-303
21
303 Troubleshooting by failure code (Display of code), Part 3 Failure code [CA452] Rail Press Sensor Low Error
SEN05033-01
Failure code [CA452] Rail Press Sensor Low Error Action code
Failure code
E03
CA452
Failure description Action of controller
Trouble
1
Common rail pressure sensor low error (Engine controller system)
• Low voltage was detected in signal circuit of common rail pressure sensor. • Limits engine output and continues operation.
Indication of problem on machine
• Engine does not start. • Engine speed or output lowers.
Related information
• Signal voltage of common rail pressure sensor can be checked with monitoring function. (Code: 36401 Common rail pressure sensor voltage) • Method of reproducing failure code: Turn starting switch to ON position. • This code is not displayed but “High Error” failure code, that is [CA451] is displayed if sensor connector is disconnected even under normal condition.
Cause 1
Defective wiring harness connector
Defective common rail 2 pressure sensor power supply line
3
4
5
6
Procedure, measuring location, standard (value) and remarks See the items related to wiring harness and connectors in "c: Electric and electrical equipment" in "Checks before troubleshooting" in "General information on troubleshooting" section, and check them directly. If failure code [CA187] (Ground fault of sensor power supply line) or [CA227] is displayed, perform troubleshooting for it first.
a Check that failure code [CA187] (Ground fault of sensor power supply line) is not displayed. 1. Turn starting switch to OFF position. Defective common rail 2. Disconnect connector FUEL RAIL PRESS. pressure sensor 3. Turn starting switch to ON position. If failure code changes from [CA452] to [CA451], sensor is defective. 1. Turn starting switch to OFF position. Ground fault of wiring 2. Disconnect connectors ECM and FUEL RAIL PRESS, and connect T-adapter to harness female side of ECM. (Contact with ground circuit) Between ECM (female) (25) and ground Resistance Min. 100 kz 1. Turn starting switch to OFF position. 2. Disconnect connectors ECM and FUEL RAIL PRESS, and connect T-adapter to Short circuit in wiring female side of ECM. harness Between ECM (female) (25) and (47) Resistance Min. 100 kz If no abnormality is found by the above checks, the engine controller is defective. Defective engine controller (Since trouble is in system, troubleshooting cannot be performed.)
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D65EX, PX, WX-16
303 Troubleshooting by failure code (Display of code), Part 3 Failure code [CA452] Rail Press Sensor Low Error
SEN05033-01
Related circuit diagram
D65EX, PX, WX-16
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23
303 Troubleshooting by failure code (Display of code), Part 3 Failure code [CA488] Chg Air Temp High Torque Derate
SEN05033-01
Failure code [CA488] Chg Air Temp High Torque Derate Action code
Failure code
E03
CA488
Failure description Action of controller
Trouble
Charge air temperature high torque derate (Engine controller system)
• Temperature signal of boost pressure/temperature sensor exceeded control upper temperature limit. • Limits engine output and continues operation.
Indication of problem on machine
• Engine output lowers.
Related information
• Boost temperature can be checked with monitoring function. (Code: 18500 Boost temperature) • Method of reproducing failure code: Start engine.
Cause 1
Lowering of cooling performance of aftercooler
Abnormal rise of 2 turbocharger outlet temperature Defective charge 3 temperature sensor
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1
Procedure, measuring location, standard (value) and remarks Cooling performance of aftercooler may be low. Check following points directly. • Looseness and breakage of fan belt • Insufficiency of cooling air • Clogging of aftercooler fins Outlet temperature of turbocharger may be abnormally high. Check related parts directly. Perform troubleshooting for failure codes [CA153] and [CA154].
D65EX, PX, WX-16
303 Troubleshooting by failure code (Display of code), Part 3 Failure code [CA553] Rail Press High Error
SEN05033-01
Failure code [CA553] Rail Press High Error Action code
Failure code
E02
CA553
Failure description Action of controller
Trouble
Common rail pressure high error (Engine controller system)
• High voltage (1) was detected in common rail circuit. • None in particular.
Indication of problem on machine
• Engine sound becomes large when no or light load is applied. • Engine output lowers.
Related information
• Common rail pressure can be checked with monitoring function. (Code: 36400 Common rail pressure) • Method of reproducing failure code: Start engine.
Cause 1 Related defective system
2
1
Defective connection of ground terminal
Procedure, measuring location, standard (value) and remarks Check another failure code displayed simultaneously. If another failure code is also indicated, perform troubleshooting for it first. Ground terminal may be connected defectively. Check following terminals directly. • Ground terminal of chassis ((–) terminal of battery) • Ground terminal of engine • Ground terminal of engine controller • Ground terminal of starting motor
Breakage of O-ring of supply O-ring of supply pump may be broken. Check it directly. pump Defective common rail 4 Perform troubleshooting for failure codes [CA451] and [CA452]. pressure sensor
3
D65EX, PX, WX-16
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25
303 Troubleshooting by failure code (Display of code), Part 3 Failure code [CA559] Rail Press Low Error
SEN05033-01
Failure code [CA559] Rail Press Low Error Action code
Failure code
E02
CA559
Failure description Action of controller
Trouble
1
Common rail pressure low error (Engine controller system)
• There is low pressure error (1) in common rail circuit. • None in particular.
Indication of problem on machine
• Engine does not start at all or does not start easily. • Exhaust gas becomes black. • Engine output lowers.
Related information
• Common rail pressure can be checked with monitoring function. (Code: 36400 Common rail pressure) • Method of reproducing failure code: Start engine.
Cause 1 Non-fuel 2 Defective fuel tank breather
Procedure, measuring location, standard (value) and remarks Check fuel remain. Fuel tank breather may be clogged. Check it directly. Fuel may be leaking to outside. Check it directly (Check visually while running engine 3 Fuel leakage to outside at low idle). a For check of pressure in fuel low pressure circuit, see Testing and adjusting, “Checking fuel pressure”. • Measured in fuel filter inlet side. • Cranking speed: Min. 150 rpm Pressure in fuel Min. 0.14 MPa During cranking low-pressure circuit {Min. 1.4 kg/cm2} a For check of pressure in fuel low pressure circuit, see Testing and adjusting, “Checking fuel pressure”. • Measured in fuel filter outlet side. Pressure in fuel Min. 0.48 MPa During high idle low-pressure circuit {Min. 4.9 kg/cm2} a For check of pressure in fuel low pressure circuit, see Testing and adjusting, “Checking fuel pressure”. • Measured in fuel filter inlet and outlet sides. Defect in low pressure circuit • Pressure drop in fuel low-pressure circuit = Fuel filter inlet pressure – Fuel filter 4 parts (Note 1) outlet pressure Pressure drop in fuel Max. 0.14 MPa During high idle low-pressure circuit {Max. 1.4 kg/cm2} a For check of fuel suction pressure, see Testing and adjusting, “Checking fuel pressure”. • Measured in gear pump fuel inlet side of supply pump. Fuel suction circuit Max. 33.9 kPa During high idle pressure (gear pump side) {Max. 254 mmHg} a For check of fuel suction pressure, see Testing and adjusting, “Checking fuel pressure”. • Measured in fuel connector side. Fuel suction circuit Max. 27.1 kPa pressure During high idle {Max. 203 mmHg} (fuel connector side) a For check of return rate from injector, see Testing and adjusting, “Checking fuel return rate and leakage”. Defective injector During cranking 5 (including high pressure (if engine cannot be Max. 100 cc/30 sec. piping in head) started) Return rate from injector During low idle Max. 300 cc/45 sec. (if engine can be started)
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D65EX, PX, WX-16
303 Troubleshooting by failure code (Display of code), Part 3 Failure code [CA559] Rail Press Low Error
Cause
6 Defective supply pump
7 Defective pressure limiter
8
Defective supply pump plunger
9 Air in low pressure circuit
SEN05033-01
Procedure, measuring location, standard (value) and remarks a For check of return rate from supply pump, see Testing and adjusting, “Checking fuel return rate and leakage”. During cranking (if engine cannot be Max. 200 cc/30 sec. Return rate from supply started) pump During low idle Max. 300 cc/30 sec. (if engine can be started) a For check of leakage through pressure limiter, see Testing and adjusting, “Checking fuel return rate and leakage”. Leakage through pressure At low idle Below 30 drops/60 sec. limiter a Remove the supply pump head, and directly check that the plunger is not damaged. There may be air in low pressure circuit. Check it directly according to the following procedure. 1. Remove pressure pickup plug (outlet side) of fuel main filter. 2. Operate feed pump of fuel pre-filter. 3. Check pressure pickup plug for leakage of fuel and air. • If this failure occurs during air bleeding after the fuel filter was replaced, air may remain in the fuel circuit. Keep running the engine at low idle for about three minutes. As air is bled from the fuel circuit, the engine speed will be stabilized, erasing the failure indication.
Note 1: When low-pressure circuit equipment is detective, check the following: 1) Clogged fuel tank breather 2) Clogged check valve (3) installed cooling plate (2) on engine controller (1). 3) Leaked or clogged low-pressure fuel pipe 4) Clogging in fuel pre-filter 5) Clogging in fuel main filter a Replace fuel main filter if cause of failure is not detected with checking clogging.
D65EX, PX, WX-16
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303 Troubleshooting by failure code (Display of code), Part 3 Failure code [CA689] Eng Ne Speed Sensor Error
SEN05033-01
Failure code [CA689] Eng Ne Speed Sensor Error Action code
Failure code
E03
CA689
Failure description Action of controller
Trouble
1
Engine Ne speed sensor error (Engine controller system)
• Signals from engine Ne speed sensor are abnormal. • Continues engine control with signal from engine Bkup speed sensor.
Indication of problem on machine
• Engine hunts. • Engine does not start easily. • Engine output lowers.
Related information
• Method of reproducing failure code: Start engine. • Since inside of speed sensor is not composed of coil but Hall sensor and electronic circuit, speed sensor cannot be determined to be normal by measuring its resistance with tester. • Since output of normal speed sensor is 5 V pulse voltage, it cannot be measured with tester. • Speed sensor senses tooth missing part of rotating speed-sensed ring installed on crankshaft.
Cause 1
Defective wiring harness connector
Defective Ne speed sensor power supply line Breakage or improper 3 installation (looseness) of engine Ne speed sensor 2
4
5
6
7
8
Procedure, measuring location, standard (value) and remarks See the items related to wiring harness and connectors in "c: Electric and electrical equipment" in "Checks before troubleshooting" in "General information on troubleshooting" section, and check them directly. If failure code [CA238] is also indicated, perform troubleshooting for it first. Engine Ne speed sensor may be broken or may have improper installation (looseness). Check it directly.
1. Turn starting switch to OFF position. 2. Disconnect connector CRANK SENSOR and connect T-adapter to female side. Defective Ne speed sensor 3. Turn starting switch to ON position. power supply input Between CRANK SENSOR (female) (1) Power 4.75 – Voltage and (2) supply input 5.25 V 1. Turn starting switch to OFF position. 2. Disconnect connectors ECM and CRANK SENSOR. a If no abnormality is found in checks on cause 4, this check is not required. Max. 10 z Resistance Disconnection in wiring Between ECM (female) (16) and CRANK SENSOR harness (female) (1) (Disconnection in wiring or a If no abnormality is found in checks on cause 4, this defective contact in check is not required. connector) Resistance Max. 10 z Between ECM (female) (48) and CRANK SENSOR (female) (2) Between ECM (female) (27) and CRANK SENSOR Max. 10 z Resistance (female) (3) 1. Turn starting switch to OFF position. 2. Disconnect connectors ECM and CRANK SENSOR. Between ECM (female) (16) and (27) or between Short circuit in wiring Resistance Min. 100 kz CRANK SENSOR (female) (1) and (3) harness Between ECM (female) (27) and (48) or between Resistance Min. 100 kz CRANK SENSOR (female) (2) and (3) 1. Turn starting switch to OFF position. Ground fault of wiring 2. Disconnect connectors ECM and CRANK SENSOR. harness Between ECM (female) (27) or CRANK SENSOR (Contact with ground circuit) Resistance Min. 100 kz (female) (3) and ground 1. Turn starting switch to OFF position. Hot short in wiring harness 2. Disconnect connector CRANK SENSOR. 3. Turn starting switch to ON position. (Contact with 24 V circuit) Between CRANK SENSOR (female) (3) and ground Voltage Max. 1 V
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303 Troubleshooting by failure code (Display of code), Part 3 Failure code [CA689] Eng Ne Speed Sensor Error
Cause Breakage or improper 9 installation (looseness) of speed-sensed ring 10 Defective Ne speed sensor 11 Defective engine controller
SEN05033-01
Procedure, measuring location, standard (value) and remarks 1. Remove Ne speed sensor (CRANK SENSOR). 2. Check speed sensing wheel (R) from sensor mounting hole directly. a Speed sensing wheel (R) has tooth missing part (A) to sense rotation. a When speed sensing wheel (R) is loose, see “Reference”. If no abnormality is found by the above checks, the Ne speed sensor is defective. (Since trouble is in system, troubleshooting cannot be performed.) If no abnormality is found by the above checks, the engine controller is defective. (Since the trouble is in system, troubleshooting cannot be performed.)
Related circuit diagram
D65EX, PX, WX-16
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SEN05033-01 Reference Check of crankshaft speed sensing wheel for loose installation (Engine Model 114) Remove the damper, flywheel, flywheel housing and outer main cap and check the crankshaft speed sensing wheel for loose installation. a When replacing the crankshaft speed sensing wheel, the crankshaft must be removed. a Keep the rear seal, gasket and gasket sealants LG-6 and LG-7 on hand.
303 Troubleshooting by failure code (Display of code), Part 3 Failure code [CA689] Eng Ne Speed Sensor Error
6.
Check that mounting bolts (4) of Ne speed (crank) sensing wheel (3) are not loose. a If the bolts are loose, replace them with new ones. a Tighten all the bolts evenly. 3 Mounting bolt (4): 8 ± 2 Nm {0.8 ± 0.2 kgm} (5): Crankshaft
Removal 1.
Remove the engine. For details, see Disassembly and assembly, "Removal and installation of engine assembly".
2.
Remove the following parts. For details, see Disassembly and assembly, "Removal and installation of engine rear seal". 1) Damper 2) Flywheel 3) Flywheel housing 4) Rear seal housing
3.
Remove the oil pan.
4.
Remove mounting bolts (2) of main cap (1).
5.
Insert mounting bolts (2) into the bolt holes of main cap (1) and remove main cap (1) while shaking it. a Check that embossed letters "BACK" on side (A) of main cap (1) face the rear of the cylinder block. (3): Speed sensing wheel
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D65EX, PX, WX-16
303 Troubleshooting by failure code (Display of code), Part 3 Failure code [CA689] Eng Ne Speed Sensor Error
SEN05033-01
Installation a 1.
For drawings, see the “Removal”. Install main cap (1) with the embossed letters “BACK” facing toward the rear of the cylinder block. 2
Crankshaft journal surface: Engine oil (EO15W-40)
a 2.
Tap the main cap lightly with a plastic or rubber hammer to install. Install main cap (1) with mounting bolts (2). 2 3
Mounting bolt: Engine oil (EO15W-40) Main cap mounting bolt: 1]: 167 ± 8 Nm {17.0 ± 0.8 kgm} 2]: Loosen 360° 3]: 30.4 ± 3.0 Nm {3.1 ± 0.3 kgm} 4]: 50 ± 4.9 Nm {5.1 ± 0.5 kgm} 5]: 120° ± 5°
3.
Install the oil pan. Tighten the mounting bolts in the order of [1] to [32]. 3 Mounting bolt: 24 ± 4 Nm {2.4 ± 0.4 kgm}
4.
Install the engine rear seal and engine assembly. For details, see Disassembly and assembly, "Removal and installation of engine rear seal" and "Removal and installation of engine assembly".
D65EX, PX, WX-16
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303 Troubleshooting by failure code (Display of code), Part 3 Failure code [CA731] Eng Bkup Speed Sens Phase Error
SEN05033-01
Failure code [CA731] Eng Bkup Speed Sens Phase Error Action code
Failure code
E03
CA731
Failure description Action of controller
Trouble
1
Engine Bkup speed sensor phase error (Engine controller system)
• Phase error was detected in signals from engine Ne speed sensor and engine Bkup speed sensor. • Continues engine control with signal from engine Ne speed sensor.
Indication of problem on machine
• Engine does not start at all or does not start easily. • Idle speed is unstable. • Exhaust gas becomes black.
Related information
• Method of reproducing failure code: Start engine.
Cause Breakage of engine Ne 1 speed (CRANK) sensor Breakage of engine Bkup 2 speed (CAM) sensor
Procedure, measuring location, standard (value) and remarks Engine Ne speed sensor (CRANK SENSOR) may be broken. Check it directly. Engine Bkup speed sensor (CAM SENSOR) may be broken. Check it directly.
Rotation sensor ring on crankshaft side may be installed defectively or broken. Check it according to the following procedure. Defective installation or 1. Set No. 1 cylinder at compression top dead center (Match stamped mark). 3 breakage of rotation sensing 2. Remove Ne speed sensor (CRANK SENSOR). wheel on crankshaft 3. If tooth missing part (A) of rotation speed sensing wheel (R) can be seen through mounting hole of Ne speed sensor, the wheel is installed normally. Rotation sensing wheel on camshaft is camshaft gear (CAMG) itself, and it may be installed defectively or broken. Check it according to the following procedure. Defective installation or 1. Set No. 1 cylinder at compression top dead center (Match stamped mark). 4 breakage of camshaft gear 2. Remove Bkup speed sensor (CAM SENSOR). on camshaft 3. If two ribs (B) of camshaft gear (CAMG) can be seen through sensor mounting hole, the gear is installed normally. Defective timing of 5 Timing of crankshaft and camshaft may be defective. Check it directly. crankshaft and camshaft Ground terminal may be connected defectively. Check following terminals directly. • Ground terminal of machine ((–) terminal of battery) Defective connection of 6 • Ground terminal of engine ground terminal • Ground terminal of engine controller • Ground terminal of starting motor
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D65EX, PX, WX-16
303 Troubleshooting by failure code (Display of code), Part 3 Failure code [CA757] All Continuous Data Lost Error
SEN05033-01
Failure code [CA757] All Continuous Data Lost Error Action code
Failure code
E04
CA757
Failure description Action of controller
Trouble
1
All continuous data lost error (Engine controller system)
• All data in engine controller are lost. • None in particular.
Indication of problem on machine
• Engine may stop and may not be restarted. • Monitoring function of machine monitor (engine controller system) may not work normally.
Related information
• Method of reproducing failure code: Turn starting switch to ON position.
Cause 1 Related defective system 2
D65EX, PX, WX-16
Procedure, measuring location, standard (value) and remarks Check another failure code displayed simultaneously. If another failure code is also displayed, perform troubleshooting for it first. Perform troubleshooting for failure code [CA441].
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33
303 Troubleshooting by failure code (Display of code), Part 3 Failure code [CA778] Eng Bkup Speed Sensor Error
SEN05033-01
Failure code [CA778] Eng Bkup Speed Sensor Error Action code
Failure code
E03
CA778
Failure description Action of controller
Trouble
1
Engine Bkup speed (CAM) sensor error (Engine controller system)
• Abnormality was detected in signal from engine Bkup speed (CAM) sensor. • Continues engine control with signal from engine Ne speed sensor.
Indication of problem on machine
• Engine does not start. • Engine output lowers.
Related information
• Method of reproducing failure code: Start engine. • Since inside of speed sensor is not composed of coil but Hall sensor and electronic circuit, speed sensor cannot be determined to be normal by measuring its resistance with tester. • Since output of normal speed sensor is 5 V pulse voltage, it cannot be measured with tester. • Speed sensor senses rotation with two ribs on camshaft gear.
Cause 1
Defective wiring harness connector
Defective sensor power supply line 2 Breakage or improper installation (looseness) of 3 engine Bkup speed (CAM) sensor 2
Procedure, measuring location, standard (value) and remarks See the items related to wiring harness and connectors in "c: Electric and electrical equipment" in "Checks before troubleshooting" in "General information on troubleshooting" section, and check them directly. If failure code [CA187] or [CA227] is also displayed, perform troubleshooting for it first. Engine Bkup speed (CAM) sensor may be broken or may have improper installation (looseness). Check it directly.
1. Turn starting switch to OFF position. Defective power supply input 2. Disconnect connector CAM SENSOR and connect T-adapter to female side. 3. Turn starting switch to ON position. 4 of engine Bkup speed sensor Between CAM SENSOR (female) (1) and Power 4.75 – Voltage (2) supply input 5.25 V 1. Turn starting switch to OFF position. 2. Disconnect connectors ECM and CAM SENSOR, and connect T-adapters to each female side. Disconnection in wiring Between ECM (female) (37) and CAM SENSOR Resistance Max. 10 z harness (female) (1) 5 (Disconnection or defective Between ECM (female) (47) and CAM SENSOR contact in connector) Max. 10 z Resistance (female) (2) Between ECM (female) (26) and CAM SENSOR Max. 10 z Resistance (female) (3) 1. Turn starting switch to OFF position. 2. Disconnect connectors ECM and CAM SENSOR, and connect T-adapter to female side of either one of them. Short circuit in wiring Between ECM (female) (26) and (37) or between CAM 6 Resistance Min. 100 kz harness SENSOR (female) (1) and (3) Between ECM (female) (26) and (47) or between CAM Resistance Min. 100 kz SENSOR (female) (2) and (3) 1. Turn starting switch to OFF position. 2. Disconnect connectors ECM and CAM SENSOR, and connect T-adapter to Ground fault of wiring female side of either one of them. 7 harness (Contact with ground circuit) Between ECM (female) (26) or CAM SENSOR (female) Resistance Min. 100 kz (3) and ground 1. Turn starting switch to OFF position. Hot short in wiring harness 2. Disconnect connector CAM SENSOR and connect T-adapter to female side. 8 3. Turn starting switch to ON position. (Contact with 24 V circuit) Between CAM SENSOR (female) (3) and ground Voltage Max. 1 V
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D65EX, PX, WX-16
303 Troubleshooting by failure code (Display of code), Part 3 Failure code [CA778] Eng Bkup Speed Sensor Error
Cause 9 Loosened camshaft gear
10
Defective engine Bkup speed (CAM) sensor
11 Defective engine controller
SEN05033-01
Procedure, measuring location, standard (value) and remarks Remove engine Bkup speed (CAM) sensor and check from sensor mounting hole directly. a If camshaft gear (CAMG) is loosened, see “Reference.” If no abnormality is found by the above checks, the engine Bkup speed (CAM) sensor is defective. (Since trouble is in system, troubleshooting cannot be performed.) If no abnormality is found by the above checks, the engine controller is defective. (Since trouble is in system, troubleshooting cannot be performed.)
Related circuit diagram
q
D65EX, PX, WX-16
(B): Speed sensor senses rotation with two ribs on camshaft gear.
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SEN05033-01 Reference Checking camshaft gear for loose installation (114 engine) Remove the pulley, damper, front seal, front cover and housing, and check the camshaft gear for looseness. a Prepare the front seal, gasket, liquid gasket LG-7 and front seal installation tool (795-7998120) on hand.
303 Troubleshooting by failure code (Display of code), Part 3 Failure code [CA778] Eng Bkup Speed Sensor Error
4.
Check mounting bolt (10) of gear (9) on camshaft (11) for looseness. 3 Mounting bolt (10): 24 ± 4 Nm {2.4 ± 0.4 kgm}
Removal 1.
Remove followings, see Disassembly and assembly, “Removal and installation of engine front seal”. 1) Remove the fan and fan belt. 2) Remove pulley (1). 3) Remove damper assembly (2). (DP): Dowel pin
Installation
4) 5)
Remove carrier assembly (3). Remove dust seal (4) and front seal (5) from carrier assembly (3).
2.
Remove front cover (6).
3.
Remove housing (7). (8): gasket
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a 1.
For figures, see “Removal”. Install gasket (8) to housing (7) and install front cover (6) to housing (7). 2 Housing: Liquid gasket LG-7
2.
See Disassembly and assembly, “Removal and installation of engine front seal” and, 1) Install front seal (5) and dust seal (4) to carrier (3). 2) Install carrier assembly to front cover (6). 3) Install dowel pin (DP) and damper (2). 4) Install pulley (1). 5) Install the fan belt and fan. 6) Install the cooling assembly.
D65EX, PX, WX-16
303 Troubleshooting by failure code (Display of code), Part 3 Failure code [CA1633] KOMNET Datalink Timeout Error
SEN05033-01
Failure code [CA1633] KOMNET Datalink Timeout Error Action code
Failure code
E03
CA1633
Failure description Action of controller
Trouble
1
KOMNET Datalink timeout error (Engine controller system)
• Engine controller detected communication error in CAN (KOMNET) communication circuit between engine controller and power train controller or machine monitor. • Continues operation in default mode. • If cause of failure disappears, system resets itself.
Indication of problem on machine
• Information may not be transmitted normally by CAN (KOMNET) communication and machine may not operate normally. (Trouble phenomenon depends on failed section.)
Related information
• Method of reproducing failure code: Turn starting switch to ON position.
Cause
D65EX, PX, WX-16
Procedure, measuring location, standard (value) and remarks Perform troubleshooting for failure code [DB2RKR].
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303 Troubleshooting by failure code (Display of code), Part 3 Failure code [CA2185] Throt Sens Sup Volt High Error
SEN05033-01
Failure code [CA2185] Throt Sens Sup Volt High Error Action code
Failure code
E03
CA2185
Failure description
Trouble
Throttle sensor supply voltage high error (Engine controller system)
• High voltage (5.25 V or higher) was detected in throttle sensor power supply circuit. • If trouble occurs while starting switch is in ON position, controller fixes voltage value to level just before detection of trouble and continues operation. • If starting switch is turned from OFF to ON position while voltage is abnormally high, controller continues operation with voltage at 100% value.
Action of controller Indication of problem on machine
• Engine speed cannot be controlled with decelerator pedal.
Related information
• Method of reproducing failure code: Turn starting switch to ON position.
Cause 1
Defective wiring harness connector
2
Short circuit in wiring harness
3
Hot short in wiring harness (Contact with 24 V circuit)
4 Defective engine controller
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1
Procedure, measuring location, standard (value) and remarks See the items related to wiring harness and connectors in "c: Electric and electrical equipment" in "Checks before troubleshooting" in "General information on troubleshooting" section, and check them directly. 1. Turn starting switch to OFF position. 2. Disconnect connectors CE02, CE03 and DCL and connect T-adapters to female sides of CE02 and CE03. Between CE02 (female) (22) and each pin other than Resistance Min. 100 kz CE02 (female) (22) pin Between CE02 (female) (22) and CE03 (female) (3) Resistance Min. 100 kz 1. Turn starting switch to OFF position. 2. Disconnect connector DCL and connect T-adapter to female side. 3. Turn starting switch to ON position. 4.75 – Between DCL (female) (B) and ground Voltage 5.25 V 1. Turn starting switch to OFF position. 2. Disconnect connector CE02 and connect T-adapter to male side. 3. Turn starting switch to ON position without connecting engine wiring harness. 4.75 – Between CE02 (male) (22) and (23) Voltage 5.25 V
D65EX, PX, WX-16
303 Troubleshooting by failure code (Display of code), Part 3 Failure code [CA2185] Throt Sens Sup Volt High Error
SEN05033-01
Related circuit diagram
D65EX, PX, WX-16
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303 Troubleshooting by failure code (Display of code), Part 3 Failure code [CA2186] Throt Sens Sup Volt Low Error
SEN05033-01
Failure code [CA2186] Throt Sens Sup Volt Low Error Action code
Failure code
E03
CA2186
Failure description
Trouble
1
Throttle sensor supply voltage low error (Engine controller system)
• Low voltage was detected in throttle sensor power supply circuit. • If trouble occurs while starting switch is in ON position, controller fixes voltage value to level just before detection of trouble and continues operation. • If starting switch is turned from OFF to ON position while abnormal voltage is detected, controller continues operation with voltage at 100% value.
Action of controller Indication of problem on machine
• Engine speed cannot be controlled with decelerator pedal.
Related information
• Method of reproducing failure code: Turn starting switch to ON position.
Cause
1
2
3
4
5
Procedure, measuring location, standard (value) and remarks See the items related to wiring harness and connectors in "c: Electric and electrical Defective wiring harness equipment" in "Checks before troubleshooting" in "General information on connector troubleshooting" section, and check them directly. 1. Turn starting switch to OFF position. 2. Disconnect connector DCL and turn starting switch to ON position. If this failure code is not displayed when a sensor is disconnected, throttle sensor is Defective throttle sensor defective. a Other failure code is displayed together. This is because that the sensor connector is disconnected. So, code can be ignored except the failure code [CA2186]. 1. Turn starting switch to OFF position. 2. Disconnect connectors CE02 and DCL and connect T-adapter to female side of Ground fault of wiring either one of them. harness (Contact with ground circuit) Between CE02 (female) (22) or DCL (female) (B) and Resistance Min. 100 kz ground 1. Turn starting switch to OFF position. 2. Disconnect connectors CE02 and DCL and connect T-adapter to female side of CE02. Short circuit in wiring 3. Turn starting switch to ON position. harness Between CE02 (female) (22) and each pin other than Resistance Min. 100 kz CE02 (female) (22) pin 1. Turn starting switch to OFF position. 2. Disconnect connector CE02 and connect T-adapter to male side. Defective engine controller 3. Turn starting switch to ON position without connecting engine wiring harness. 4.75 – Between CE02 (male) (22) and (23) Voltage 5.25 V
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D65EX, PX, WX-16
303 Troubleshooting by failure code (Display of code), Part 3 Failure code [CA2186] Throt Sens Sup Volt Low Error
SEN05033-01
Related circuit diagram
D65EX, PX, WX-16
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41
303 Troubleshooting by failure code (Display of code), Part 3 Failure code [CA2249] Rail Press Very Low Error
SEN05033-01
Failure code [CA2249] Rail Press Very Low Error Action code
Failure code
E03
CA2249
Failure description Action of controller
Trouble
Common rail pressure very low error (Engine controller system)
• Low pressure was detected in common rail circuit. • Limits engine output and continues operation.
Indication of problem on machine
• Engine does not start easily. • Exhaust gas becomes black. • Engine output lowers.
Related information
• Common rail pressure can be checked with monitoring function. (Code: 36400 Common rail pressure) • Method of reproducing failure code: Start engine.
Cause
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42
1
Procedure, measuring location, standard (value) and remarks Perform troubleshooting for failure code [CA559].
D65EX, PX, WX-16
303 Troubleshooting by failure code (Display of code), Part 3 Failure code [CA2249] Rail Press Very Low Error
D65EX, PX, WX-16
SEN05033-01
40-303
43
303 Troubleshooting by failure code (Display of code), Part 3 Failure code [CA2265] Fuel Feed Pump Open Error
SEN05033-01
Failure code [CA2265] Fuel Feed Pump Open Error Action code
Failure code
E01
CA2265
Failure description Action of controller
Trouble
Fuel feed pump open error (Engine controller system)
• Opening was detected in drive circuit of electric fuel feed pump actuator. • None in particular.
Indication of problem on machine
• Engine does not start easily.
Related information
• Method of reproducing failure code: Turn starting switch to ON position.
Cause 1
Defective wiring harness connector
Defective electric fuel feed pump 2 (Internal disconnection or short circuit) 3
4
5
6
7
1
Procedure, measuring location, standard (value) and remarks See the items related to wiring harness and connectors in "c: Electric and electrical equipment" in "Checks before troubleshooting" in "General information on troubleshooting" section, and check them directly. 1. Turn starting switch to OFF position. 2. Disconnect connector FUEL LIFT PUMP. Between FUEL LIFT PUMP (male) (1) and (2)
Resistance
Max. 20 z
1. Turn starting switch to OFF position. Disconnection or short circuit 2. Disconnect connector ECM and connect T-adapter to female side. in wiring harness Between ECM (female) (1) and (11) Resistance Max. 20 z a If no abnormality is found in checks on cause 3, this check is not required. Disconnection in wiring 1. Turn starting switch to OFF position. harness 2. Disconnect connectors ECM and FUEL LIFT PUMP and connect T-adapters to (Disconnection in wiring or each female side. defective contact in Between ECM (female) (1) and FUEL LIFT PUMP (1) Resistance Max. 10 z connector) Between ECM (female) (11) and FUEL LIFT PUMP (2) Resistance Max. 10 z 1. Turn starting switch to OFF position. 2. Disconnect connectors ECM and FUEL LIFT PUMP, and connect T-adapter to female side of ECM. Short circuit in wiring a Check with tester in continuity mode. harness Between ECM (female) (1) and each pin other than (1) No continuity pin (No sound is heard) 1. Turn starting switch to OFF position. 2. Disconnect connector FUEL LIFT PUMP. 3. Insert T-adapter between male and female sides of connector ECM or connect Tadapter to female side of FUEL LIFT PUMP. Hot short in wiring harness 4. Turn starting switch to ON position and perform troubleshooting after one minute (Contact with 24 V circuit) or longer (with connector FUEL LIFT PUMP disconnected). a Average voltage is displayed because of PWM. Between ECM (female) (1) and (11), or between FUEL Max. 6 V Voltage LIFT PUMP (female) (1) and (2) If no abnormality is found by the above checks, the engine controller is defective. Defective engine controller (Since the trouble is in system, troubleshooting cannot be performed.)
40-303
44
D65EX, PX, WX-16
303 Troubleshooting by failure code (Display of code), Part 3 Failure code [CA2265] Fuel Feed Pump Open Error
SEN05033-01
Related circuit diagram
D65EX, PX, WX-16
40-303
45
303 Troubleshooting by failure code (Display of code), Part 3 Failure code [CA2266] Fuel Feed Pump Short Error
SEN05033-01
Failure code [CA2266] Fuel Feed Pump Short Error Action code
Failure code
E01
CA2266
Failure description Action of controller
Trouble
1
Fuel feed pump short error (Engine controller system)
• Short circuit was detected in electric fuel feed pump actuator. • None in particular.
Indication of problem on machine
• Engine does not start easily.
Related information
• Method of reproducing failure code: Turn starting switch to ON position.
Cause
1
2
3
4
5
6
Procedure, measuring location, standard (value) and remarks See the items related to wiring harness and connectors in "c: Electric and electrical Defective wiring harness equipment" in "Checks before troubleshooting" in "General information on connector troubleshooting" section, and check them directly. 1. Turn starting switch to OFF position. 2. Disconnect connector FUEL LIFT PUMP. Defective electric fuel feed 3. Turn starting switch to ON position. pump (Internal short circuit) If failure code changes from [CA2266] to [CA2265], electric fuel feed pump is defective. 1. Turn starting switch to OFF position. 2. Disconnect connector ECM and connect T-adapter to female side. Short circuit in, or ground Between ECM (female) (1) and (11) Resistance 1 – 20 z fault of wiring harness Between ECM (female) (1) and ground Resistance Min. 100 kz a If cause 3 is not the cause for the trouble, this check is not required. 1. Turn starting switch to OFF position. 2. Disconnect connectors ECM and FUEL LIFT PUMP, and connect T-adapter to Short circuit in wiring female side of ECM. harness Between ECM (female) (1) and (11), or between FUEL Resistance Min. 100 kz LIFT PUMP (female) (1) and (2) a If cause 3 is not the cause for the trouble, this check is not required. 1. Turn starting switch to OFF position. Ground fault of wiring 2. Disconnect connectors ECM and FUEL LIFT PUMP, and connect T-adapter to harness female side of ECM. (Contact with ground circuit) Between ECM (female) (1) and ground, or between Resistance Min. 100 kz FUEL LIFT PUMP (female) (1) and ground If no abnormality is found by the above checks, the engine controller is defective. Defective engine controller (Since trouble is in system, troubleshooting cannot be performed.)
Related circuit diagram
40-303
46
D65EX, PX, WX-16
303 Troubleshooting by failure code (Display of code), Part 3 Failure code [CA2311] IMV Solenoid Error
SEN05033-01
Failure code [CA2311] IMV Solenoid Error Action code
Failure code
E03
CA2311
Failure description Action of controller
Trouble
1
IMV solenoid error (Engine controller system)
• Resistance of supply pump actuator circuit is abnormally high or low. • None in particular.
Indication of problem on machine
• Engine output lowers.
Related information
• Method of reproducing failure code: Start engine.
Cause
D65EX, PX, WX-16
Procedure, measuring location, standard (value) and remarks Perform troubleshooting for failure codes [CA271] and [CA272].
40-303
47
303 Troubleshooting by failure code (Display of code), Part 3 Failure code [CA2555] Grid Htr Relay Volt High Error
SEN05033-01
Failure code [CA2555] Grid Htr Relay Volt High Error Action code
Failure code
E01
CA2555
Failure description Action of controller
Trouble
1
Auto pre-heater relay voltage high error (Engine controller system)
• Disconnection was detected in drive circuit (primary coil side) of auto pre-heater relay. • None in particular.
Indication of problem on machine
• Intake air heater does not work (Engine does not start easily and exhaust gas becomes white at low temperature).
Related information
• Method of reproducing failure code: Turn starting switch to ON position. • The troubleshooting for this failure code covers defect between engine controller and primary coil side of auto pre-heater relay PHR. See E-mode E-2 for troubleshooting for intake air heater relay and secondary coil side of auto pre-heater replay PHR.
Cause
1
2
3
4
5
6
Procedure, measuring location, standard (value) and remarks See the items related to wiring harness and connectors in "c: Electric and electrical Defective wiring harness equipment" in "Checks before troubleshooting" in "General information on connector troubleshooting" section, and check them directly. 1. Turn starting switch to OFF position. 2. Disconnect relay PHR and connect T-adapter to male side. Between PHR (male) (1) and (2) Resistance 300 – 600 z Defective auto pre-heater 1. OFF position. Turn starting switch to relay PHR 2. Replace relay PHR with other relay. 3. Turn starting switch to ON position. If this failure code disappears, auto pre-heater relay PHR is defective. 1. Turn starting switch to OFF position. Disconnection or short circuit 2. Disconnect connector CE02 and connect T-adapter to female side. in wiring harness Between CE02 (female) (40) and ground Resistance 300 – 600 z a Relay PHR coil resistance a If no abnormality is found in checks on cause 3, this check is not required. 1. Turn starting switch to OFF position. 2. Disconnect connector CE02 and relay PHR and connect T-adapters to female Disconnection in wiring side. harness Between CE02 (female) (40) and PHR (female) (1) Resistance Max. 10 z Between PHR (female) (2) and ground Resistance Max. 10 z 1. Turn starting switch to OFF position. 2. Disconnect connector CE02 and relay PHR and connect T-adapter to female side of CE02. Short circuit in wiring a Check with tester in continuity mode. harness Between CE02 (female) (40) and each pin other than No continuity (40) pin. (No sound is heard) If no abnormality is found by the above checks, the engine controller is defective. Defective engine controller (Since the trouble is in system, troubleshooting cannot be performed.)
40-303
48
D65EX, PX, WX-16
303 Troubleshooting by failure code (Display of code), Part 3 Failure code [CA2555] Grid Htr Relay Volt High Error
SEN05033-01
Related circuit diagram
D65EX, PX, WX-16
40-303
49
303 Troubleshooting by failure code (Display of code), Part 3 Failure code [CA2556] Grid Htr Relay Volt Low Error
SEN05033-01
Failure code [CA2556] Grid Htr Relay Volt Low Error Action code
Failure code
E01
CA2556
Failure description Action of controller
Trouble
1
Auto pre-heater relay voltage low error (Engine controller system)
• Short circuit was detected in drive circuit (primary coil side) of auto pre-heater relay. • None in particular.
Indication of problem on machine
• Intake air heater does not work (Engine does not start easily and exhaust gas becomes white at low temperature).
Related information
• Method of reproducing failure code: Turn starting switch ON. • The troubleshooting for this failure code covers defect between engine controller and primary coil side of auto pre-heater relay PHR. See E-2 for troubleshooting for intake air heater relay and secondary coil side of auto pre-heater replay PHR.
Cause 1
Defective wiring harness connector
2
Defective auto pre-heater relay PHR
3
Ground fault of wiring harness
4
Short circuit in wiring harness
5 Defective engine controller
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Procedure, measuring location, standard (value) and remarks See the items related to wiring harness and connectors in "c: Electric and electrical equipment" in "Checks before troubleshooting" in "General information on troubleshooting" section, and check them directly. 1. Turn starting switch to OFF position. 2. Disconnect relay PHR and connect T-adapter to male side. Between PHR (male) (1) and (2) Resistance 300 – 600 z 3. Turn starting switch to OFF position. 4. Replace relay PHR with other relay. 5. Turn starting switch to ON position. If this failure code disappears, auto pre-heater relay PHR is defective. 1. Turn starting switch to OFF position. 2. Disconnect connector CE02 and relay PHR and connect T-adapter to female side of either one of them. Between CE02 (female) (40) or PHR (female) (1) and Resistance Max. 100 kz ground 1. Turn starting switch to OFF position. 2. Disconnect connector CE02 and relay PHR and connect T-adapter to female side of CE02. a Check with tester in continuity mode. Between CE02 (female) (40) and each pin other than No continuity (40) pin (No sound is heard) If no abnormality is found by the above checks, the engine controller is defective. (Since the trouble is in system, troubleshooting cannot be performed.)
D65EX, PX, WX-16
303 Troubleshooting by failure code (Display of code), Part 3 Failure code [CA2556] Grid Htr Relay Volt Low Error
SEN05033-01
Related circuit diagram
D65EX, PX, WX-16
40-303
51
SEN05033-01
D65EX, PX, WX-16 Bulldozer Form No. SEN05033-01
©2009 KOMATSU All Rights Reserved Printed in Japan 07-09
40-303
52
SEN05034-01
BULLDOZER D65EX-16 D65PX-16 D65WX-16 Machine model D65EX-16 D65PX-16 D65WX-16
Serial number 80001 and up 80001 and up 80001 and up
40 Troubleshooting
40
304 Troubleshooting by failure code (Display of code), Part 4 Failure code [D110KB] Battery relay drive: Short circuit ................................................................................. 4 Failure code [D130KA] Neutral relay: Disconnection...................................................................................... 6 Failure code [D130KB] Neutral relay: Short circuit ......................................................................................... 8 Failure code [D161KA] Back-up alarm relay: Disconnection ........................................................................ 10 Failure code [D161KB] Back-up alarm relay: Short circuit............................................................................ 12 Failure code [D862KA] GPS Antenna Open Circuit...................................................................................... 14 Failure code [DAFRKR] CAN Disconnection ................................................................................................ 15 Failure code [DAFRMC] CAN Discon (Monitor Detected) ............................................................................ 16 Failure code [DB2RKR] CAN Disconnection ................................................................................................ 19 Failure code [DBE0KT] PT controller: Abnormality in controller ................................................................... 24 Failure code [DBE1KK] Battery direct Source voltage reduction .................................................................. 26 Failure code [DBE2KK] Solenoid Source voltage reduction ......................................................................... 28 Failure code [DBE5KK] PT cont.: Sensor voltage 5V (1) reduction .............................................................. 30 Failure code [DBE6KK] PT cont.: Sensor voltage 24V reduction ................................................................. 32 Failure code [DBE7KK] PT cont.: Sensor voltage 5V (2) reduction .............................................................. 34 Failure code [DBE9KQ] PT controller: Type select signal............................................................................. 36 Failure code [DD12KA] Shift up Sw: Disconnection ..................................................................................... 38 Failure code [DD12KB] Shift up Sw: Short circuit ......................................................................................... 40 Failure code [DD13KA] Shift down Sw: Disconnection ................................................................................. 42 Failure code [DD13KB] Shift down Sw: Short circuit .................................................................................... 44 Failure code [DD14KA] Parking lever Sw: Disconnection............................................................................. 46 D65EX, PX, WX-16
40-304
1
SEN05034-01
304 Troubleshooting by failure code (Display of code), Part 4
Failure code [DD14KB] Parking lever Sw: Short circuit ................................................................................ 48
40-304
2
D65EX, PX, WX-16
304 Troubleshooting by failure code (Display of code), Part 4
D65EX, PX, WX-16
SEN05034-01
40-304
3
304 Troubleshooting by failure code (Display of code), Part 4 Failure code [D110KB] Battery relay drive: Short circuit
SEN05034-01
Failure code [D110KB] Battery relay drive: Short circuit Action code
Failure code
E00
D110KB
Failure description Action of controller
Trouble
1
Battery relay drive: Short circuit (Power train controller system)
• Abnormal current flowed when outputting 24 V to battery relay primary (coil side) circuit. • Stops 24 V output to battery relay primary (coil side) circuit.
Indication of problem on machine
• Problem may occur in data writing to ROM (nonvolatile memory) of each controller.
Related information
• Output condition (voltage) to battery relay primary (coil side) circuit can be checked in monitoring function. (Code 60600: Battery relay drive voltage) • Method of reproducing failure code: Switch starting switch from ON to OFF.
Cause Defective battery relay 1 (Internal short circuit) Ground fault of wiring 2 harness (Contact with ground circuit)
3
Defective power train controller
40-304
4
Procedure, measuring location, standard (value) and remarks 1. Turn starting switch to OFF position. Between terminals BRSW and BRE Continuity 1. Turn starting switch to OFF position. 2. Disconnect ground cable (Not to make short circuit). 3. Disconnect terminal BRE and connector STC3. Between terminal BRSW and ground Resistance Min. 1 Mz If cause is not found by the above checks, power train controller is defective. • Reference: the followings are standard values in normal condition. 1. Turn starting switch to OFF position. 2. Insert T-adapter into connector STC3. 3. Turn starting switch to ON position. Between STC3 (4) and (21) Voltage 20 – 30 V
D65EX, PX, WX-16
304 Troubleshooting by failure code (Display of code), Part 4 Failure code [D110KB] Battery relay drive: Short circuit
SEN05034-01
Related circuit diagram
D65EX, PX, WX-16
40-304
5
304 Troubleshooting by failure code (Display of code), Part 4 Failure code [D130KA] Neutral relay: Disconnection
SEN05034-01
Failure code [D130KA] Neutral relay: Disconnection Action code
Failure code
E02
D130KA
Failure description Action of controller
Trouble
1
Neutral safety relay: Disconnection (Power train controller system)
• No current flows when grounding to neutral safety relay primary (coil side) circuit or no voltage is applied when no grounding. • Stops grounding to neutral safety relay primary (coil side) circuit.
Indication of problem on machine
• Engine does not start.
Related information
• Output condition to neutral safety relay primary (coil side) circuit can be checked in monitoring function. (Code 40909: T/M Output1) • Method of reproducing failure code: Turn starting switch ON and operate parking brake lever (to free position). • This failure code detects failure on primary side (coil side) of neutral safety relay, but not on secondary side (contact side). • If STC2 (8) has ground fault, engine can start even if PCCS lever is set to any gear speed except for “Neutral”.
Cause Procedure, measuring location, standard (value) and remarks 1. Turn starting switch to OFF position. Defective neutral safety 1 relay (Internal disconnection 2. Disconnect connector NSF and connect T-adapter to male side. or short circuit) Between NSF (male) (1) and (2) Resistance 300 – 600 z 1. Turn starting switch to OFF position. 2. Disconnect connectors STC2 and KEY and connect T-adapters to female side of them. Disconnection or short circuit 2 a If resistance is above 1 Mz, wiring harness has disconnection. If resistance is in wiring harness below 1 z, wiring harness has short circuit. Between KEY (male) (1) and STC2 (female) (8) Resistance 300 – 600 z a If cause 2 is not the cause for the trouble, this check is not required. 1. Turn starting switch to OFF position. Disconnection in wiring 2. Disconnect connectors STC2, NSF and KEY, and connect T-adapters to female 3 harness (Disconnection or side of them. defective contact) Between STC2 (female) (8) and NSF (female) (2) Resistance Max. 1 z Between KEY (male) (1) and NSF (female) (1) Resistance Max. 1 z 1. Turn starting switch to OFF position. 2. Disconnect connectors STC2 and NSF and connect T-adapters to female side of Ground fault of wiring them. 4 harness (Contact with ground circuit) Between NSF (female) (2) or STC2 (female) (8) and Resistance Min. 1 Mz ground If cause is not found by the above checks, power train controller is defective. • Reference: the followings are standard values in normal condition. 1. Turn starting switch to OFF position. 2. Insert T-adapter into connector STC2. Defective power train 5 3. Turn starting switch to ON position. controller 4. Operate parking brake lever and perform troubleshooting. Free Voltage 20 – 30 V Between STC2 (8) and ground Max. 1 V Voltage Lock
40-304
6
D65EX, PX, WX-16
304 Troubleshooting by failure code (Display of code), Part 4 Failure code [D130KA] Neutral relay: Disconnection
SEN05034-01
Related circuit diagram
D65EX, PX, WX-16
40-304
7
304 Troubleshooting by failure code (Display of code), Part 4 Failure code [D130KB] Neutral relay: Short circuit
SEN05034-01
Failure code [D130KB] Neutral relay: Short circuit Action code
Failure code
E02
D130KB
Failure description Action of controller
Trouble
1
Neutral safety relay: Short circuit (Power train controller system)
• Abnormal current flowed in neutral safety relay primary (coil side) circuit when grounding. • Stops grounding to neutral safety relay primary (coil side) circuit.
Indication of problem on machine
• Engine does not start.
Related information
• Output condition to neutral safety relay primary (coil side) circuit can be checked in monitoring function. (Code 40909: T/M Output1) • Method of reproducing failure code: Turn starting switch ON and operate parking brake lever (to free position). • This failure code detects failure on primary side (coil side) of neutral safety relay, but not on secondary side (contact side).
Cause
Procedure, measuring location, standard (value) and remarks 1. Turn starting switch to OFF position. Defective neutral safety 1 relay (Internal disconnection 2. Disconnect connector NSF and connect T-adapter to male side. or short circuit) Between NSF (male) (1) and (2) Resistance 300 – 600 z 1. Turn starting switch to OFF position. 2. Disconnect connectors STC2 and STC3 and connect T-adapters to female side of them. Disconnection or short circuit a If resistance is above 1 Mz, wiring harness has disconnection. If resistance is 2 in wiring harness below 1 z, wiring harness has short circuit. Between STC2 (female) (8) and STC3 (female) (14) or Resistance 300 – 600 z (24) 1. Turn starting switch to OFF position. 2. Disconnect connectors STC2 and NSF, and connect T-adapter to female side of Hot short circuit in wiring STC2. 3 harness 3. Turn starting switch to ON position. (Contact with 24 V circuit) Between STC2 (female) (8) and ground Voltage Max. 1 V If cause is not found by the above checks, power train controller is defective. • Reference: the followings are standard values in normal condition. 1. Turn starting switch to OFF position. 2. Insert T-adapter into connector STC2. Defective power train 4 3. Turn starting switch to ON position. controller 4. Operate parking brake lever and perform troubleshooting. Free Voltage 20 – 30 V Between STC2 (8) and ground Max. 1 V Lock Voltage
40-304
8
D65EX, PX, WX-16
304 Troubleshooting by failure code (Display of code), Part 4 Failure code [D130KB] Neutral relay: Short circuit
SEN05034-01
Related circuit diagram
D65EX, PX, WX-16
40-304
9
304 Troubleshooting by failure code (Display of code), Part 4 Failure code [D161KA] Back-up alarm relay: Disconnection
SEN05034-01
Failure code [D161KA] Back-up alarm relay: Disconnection Action code
Failure code
E01
D161KA
Failure description Action of controller
Trouble
1
Back-up alarm relay: Disconnection (Power train controller system)
• Current does not flow to back-up alarm relay primary (coil side) circuit when grounding or voltage is applied when no grounding. • Stops grounding to back-up alarm relay primary (coil side) circuit.
Indication of problem on machine
• Back-up alarm does not sound.
Related information
• Output condition to back-up alarm relay primary (coil side) circuit can be checked in monitoring function. (Code 40909: T/M Output1) • Method of reproducing failure code: Turn starting switch ON and operate PCCS lever to neutral. • This failure code detects failure on primary side (coil side) of back-up alarm relay, but not in secondary side (contact side). • If pin STC2 (18) has ground fault, back-up alarm keeps sounding.
Cause
Procedure, measuring location, standard (value) and remarks If fuse FS12-8 is broken, circuit probably has ground fault. In this case, perform 1 Defective fuse FS12-8 troubleshooting for cause 5 first. 1. Turn starting switch to OFF position. Defective back-up alarm 2 relay (Internal disconnection 2. Disconnect connector BKA and connect T-adapter to male side. or short circuit) Between BKA (male) (1) and (2) Resistance 300 – 600 z 1. Turn starting switch to OFF position. 2. Disconnect fuse FS12-8. Disconnection or short circuit 3. Disconnect connector STC2 and connect T-adapter to female side. 3 a If resistance is above 1 Mz, wiring harness has disconnection. If resistance is in wiring harness below 1 z, wiring harness has short circuit. Between STC2 (female) (18) and FS12-8 Resistance 300 – 600 z a If cause 3 is not the cause for the trouble, this check is not required. 1. Turn starting switch to OFF position. Disconnection in wiring 2. Disconnect connectors STC2 and BKA and connect T-adapters to female side of 4 harness (Disconnection or them. defective contact) Between STC2 (female) (18) and BKA (female) (2) Resistance Max. 1 z Between FS12-8 and BKA (female) (1) Resistance Max. 1 z 1. Turn starting switch to OFF position. 2. Disconnect fuse FS12-8. Ground fault of wiring 3. Disconnect connectors BKA and STC2, and connect T-adapters to female side of 5 harness (Contact with them. ground circuit) Between BKA (female) (1) and ground Resistance Min. 1 Mz Between BKA (female) (2) or STC2 (18) and ground Resistance Min. 1 Mz If cause is not found by the above checks, power train controller is defective. • Reference: the followings are standard values in normal condition. 1. Turn starting switch to OFF position. 2. Insert T-adapter into connector STC2. Defective power train 6 3. Turn starting switch to ON position. controller 4. Operate PCCS lever and perform troubleshooting. N Voltage 20 – 30 V Between STC2 (18) and ground Voltage Max. 1 V R (Reverse)
40-304
10
D65EX, PX, WX-16
304 Troubleshooting by failure code (Display of code), Part 4 Failure code [D161KA] Back-up alarm relay: Disconnection
SEN05034-01
Related circuit diagram
D65EX, PX, WX-16
40-304
11
304 Troubleshooting by failure code (Display of code), Part 4 Failure code [D161KB] Back-up alarm relay: Short circuit
SEN05034-01
Failure code [D161KB] Back-up alarm relay: Short circuit Action code
Failure code
E01
D161KB
Failure description Action of controller
Trouble
1
Back-up alarm relay: Short circuit (Power train controller system)
• Abnormal current flowed in back-up alarm relay circuit when grounding. • Stops grounding to back-up alarm relay primary circuit.
Indication of problem on machine
• Back-up alarm does not turn on.
Related information
• Output condition to back-up alarm relay can be checked in monitoring function. (Code 40909: T/M Output1) • Method of reproducing failure code: Turn starting switch ON and operate PCCS lever (to reverse). • This failure code detects failure on primary side (coil side) of back-up alarm relay, but not in secondary side (contact side).
Cause Procedure, measuring location, standard (value) and remarks 1. Turn starting switch to OFF position. Defective back-up alarm 1 relay (Internal disconnection 2. Disconnect connector BKA and connect T-adapter to male side. or short circuit) Between BKA (male) (1) and (2) Resistance 300 – 600 z 1. Turn starting switch to OFF position. 2. Disconnect fuse FS12-8. Disconnection or short circuit 3. Disconnect connector STC2 and connect T-adapter to female side. 2 a If resistance is above 1 Mz, wiring harness has disconnection. If resistance is in wiring harness below 1 z, wiring harness has short circuit. Between STC2 (female) (18) and FS12-8 Resistance 300 – 600 z 1. Turn starting switch to OFF position. Hot short circuit in wiring 2. Disconnect connector STC2 and connect T-adapter to female side. 3 harness (Contact with 24 V circuit) Between STC2 (female) (18) and ground Voltage Max. 1 V If cause is not found by the above checks, power train controller is defective. • Reference: the followings are standard values in normal condition. 1. Turn starting switch to OFF position. 2. Insert T-adapter into connector STC2. Defective power train 4 3. Turn starting switch to ON position. controller 4. Operate PCCS lever and perform troubleshooting. N Voltage 20 – 30 V Between STC2 (18) and ground Voltage Max. 1 V R (Reverse)
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12
D65EX, PX, WX-16
304 Troubleshooting by failure code (Display of code), Part 4 Failure code [D161KB] Back-up alarm relay: Short circuit
SEN05034-01
Related circuit diagram
D65EX, PX, WX-16
40-304
13
304 Troubleshooting by failure code (Display of code), Part 4 Failure code [D862KA] GPS Antenna Open Circuit
SEN05034-01
Failure code [D862KA] GPS Antenna Open Circuit Action code
Failure code
—
D862KA
Failure description Action of controller
Trouble
1
GPS antenna disconnection (KOMTRAX system in machine monitor)
• Disconnection was detected in GPS antenna circuit. • None in particular. • If cause of failure disappears, system resets itself.
Indication of problem on machine
• GPS cannot locate position.
Related information
• Method of reproducing failure code: Turn starting switch to ON position.
Cause Defective GPS antenna or 1 antenna cable
Procedure, measuring location, standard (value) and remarks Possible causes are defective GPS antenna, disconnection or short circuit in antenna cable, and defective connection of antenna cable connector (GPS).
Configuration drawing
40-304
14
D65EX, PX, WX-16
304 Troubleshooting by failure code (Display of code), Part 4 Failure code [DAFRKR] CAN Disconnection
SEN05034-01
Failure code [DAFRKR] CAN Disconnection Action code
Failure code
E03
DAFRKR
Failure description Action of controller
Trouble
1
CAN disconnection (Power train controller system)
• Power train controller cannot recognize machine monitor with CAN communication circuit. • Limits operation of engine and transmission.
Indication of problem on machine
• System may not operate normally. • Once machine stops, engine speed is limited to medium (half). • Once machine stops, travel is limited to F1 and R1.
Related information
• Method of reproducing failure code: Turn the starting switch to ON position. • Start of CAN communication is notified to each controller by ACC signal of starting switch. • Since air conditioner also uses CAN communication, ensure that air conditioner can be operated (turned ON/OFF and air flow can be adjusted) on air conditioner screen. (Air conditioner can be operated even while failure code is displayed on the monitor screen.) If air conditioner can be operated, there is no ground fault, short circuit or hot short in wiring harness (CAN communication line) • Failure code is displayed on machine monitor by CAN communication. Accordingly, if CAN communication of machine monitor has error, code [DAFRKR] is not displayed on machine monitor and can be confirmed only through KOMTRAX system. • Since each controller and machine monitor receive power from battery directly, they have power even while starting switch is OFF. • Since CAN communication line signal in operation is pulse voltage, it cannot be measured with multimeter.
Cause Defective power supply to 1 machine monitor Defective CAN 2 communication
D65EX, PX, WX-16
Procedure, measuring location, standard (value) and remarks Perform troubleshooting for E-mode, “E-3”. Perform troubleshooting for failure code [DAFRMC], cause 4 and after.
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304 Troubleshooting by failure code (Display of code), Part 4 Failure code [DAFRMC] CAN Discon (Monitor Detected)
SEN05034-01
Failure code [DAFRMC] CAN Discon (Monitor Detected) Action code
Failure code
E03
DAFRMC
Failure description Action of controller
Trouble
1
CAN disconnection (Machine monitor detected) (Machine monitor system)
• Machine monitor cannot recognize engine controller or power train controller with CAN communication circuit. • Limits operation of engine and transmission.
Indication of problem on machine
• System may not operate normally. • Once machine stops, engine speed is limited to medium (half). • Once machine stops, travel is limited to F1 and R1.
Related information
• Method of reproducing failure code: Turn the starting switch to ON position. • Start of CAN communication is notified to each controller by ACC signal of starting switch. • Since air conditioner also uses CAN communication, ensure that air conditioner can be operated (turned ON/OFF and air flow can be adjusted) on air conditioner screen. (Air conditioner can be operated even while failure code is displayed on the monitor screen.) If air conditioner can be operated, there is no ground fault, short circuit or hot short in wiring harness (CAN communication line) • If failure code [DB2RKR] is also displayed, cause of this trouble is probably engine controller problem in causes 1 – 3. • Since each controller and machine monitor receive power from battery directly, they have power even while starting switch is OFF. • Since CAN communication line signal in operation is pulse voltage, it cannot be measured with multimeter.
Cause 1
Broken engine controller fuse
2
Defective engine controller (Internal short circuit)
3
Defective power supply to engine controller
4
Defective CAN terminal resistor (Internal disconnection or short circuit)
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Procedure, measuring location, standard (value) and remarks 1. Turn starting switch to OFF position. 2. Remove fuses in fuse boxes F12-3 and F12-6. a If fuse is broken, controller probably has short circuit in it. a If fuse is not broken, this check is not required. 1. Turn starting switch to OFF position. 2. Disconnect connector CE03 and connect T-adapter to male side. a Measured value: approx. 9 – 20 kz. a If measured value is below 10 z, engine controller is defective (Internal short circuit). Between CE03 (male) (3) and (1) Resistance Min. 10 z 1. Turn starting switch to OFF position. 2. Disconnect connector CE03 and connect T-adapter to female side. 3. If fuse is broken, replace it. a If result is abnormal, perform troubleshooting for [DB2RKR], Failure description 2) Defective power supply circuit to engine controller. Between CE03 (female) (3) and (1) or ground Voltage 20 – 30 V Between CE03 (female) (4) and (2) or ground Voltage 20 – 30 V 1. Turn starting switch to OFF position. 2. Disconnect connectors CA1 and CM02 and connect T-adapters to male sides of them. Between CA1 (male) (A) and (B) Resistance 120 ± 12 z Between CM02 (male) (8) and (10) Resistance 120 ± 12 z
D65EX, PX, WX-16
304 Troubleshooting by failure code (Display of code), Part 4 Failure code [DAFRMC] CAN Discon (Monitor Detected)
SEN05034-01
Procedure, measuring location, standard (value) and remarks • CAN communication line a There is 120 z CAN terminal resistor inside machine monitor, too. Since 120 z resistor is connected in parallel, if resistance measured at connector of controller other than machine monitor is 60 z which is combined resistance, wiring harness is not disconnected. 1. Turn starting switch to OFF position and disconnect ground cable. 2. Disconnect one of following connectors CE02, STC2, AC02, CA1 and CM02 and connect T-adapter to female side of that connector. a If connector has short circuit (Resistance between terminals is 1 z or less), disDisconnection or short circuit connect all of CE02, STC2, AC02, CA1 and CM02 and check again to see if there in wiring harness is short circuit between wiring harnesses or in controller. Between CE02 (female) (46) and (47) Resistance Approx. 60 z Between STC2 (female) (32) and (22) Resistance Approx. 60 z Between AC02 (female) (1) and (2) Resistance Approx. 60 z Approx. Between CA1 (female) (A) and (B) Resistance 120 z Approx. Resistance Between CM02 (female) (9) and (10) 120 z a If check result of cause 5 is normal, this check is not required. 1. Turn starting switch to OFF position and disconnect ground cable. 2. Disconnect connectors CE02, C01, N10, K02 and CM02 and connect T-adapters to female side of them. Between STC2 (female) (32) and CM02 (female) (9), (8) Resistance Max. 1 z Disconnection in wiring Between STC2 (female) (22) and CM02 (female) (10) Resistance Max. 1 z harness (Disconnection or Between STC2 (female) (32) and CE02 (female) (46) Resistance Max. 1 z defective contact in connector) Between STC2 (female) (22) and CE02 (female) (47) Resistance Max. 1 z Between STC2 (female) (32) and AC02 (female) (1) Resistance Max. 1 z Between STC2 (female) (22) and AC02 (female) (2) Resistance Max. 1 z Between CE02 (female) (46) and K02 (female) (A) Resistance Max. 1 z Between CE02 (female) (47) and K02 (female) (B) Resistance Max. 1 z • Signal ACC of starting switch 1. Turn starting switch to OFF position and disconnect ground cable. Disconnection in wiring 2. Insert T-adapters into connectors CE02, STC3 and CM01. harness (Disconnection or 3. Connect ground cable and turn starting switch to ON position. defective contact in Between CE02 (39) and ground Voltage 20 – 30 V connector) Between STC3 (14) or (24) and (31) Voltage 20 – 30 V Between CM01 (14) and (3) Voltage 20 – 30 V a If air conditioner can be operated, this check is not required. a If check result of cause 5 is normal (there is no disconnection), measure at only 1 place. 1. Turn starting switch to OFF position and disconnect ground cable. Ground fault of wiring 2. Disconnect connectors CE02, STC2, CM02 and AC02, and connect T-adapter to harness (Contact with female side of one of them. ground circuit) Between STC2 (female) (32), CM02 (female) (8), (9) or Min. 1 Mz Resistance CE02 (female) (46) and ground Between STC2 (female) (22), CM02 (female) (10) or Min. 1 Mz Resistance CE02 (female) (47) and ground a If air conditioner can be operated, this check is not required. a If check result of cause 5 is normal (there is no disconnection), measure at only 1 place each. 1. Turn starting switch to OFF position and disconnect ground cable. 2. Insert T-adapter into connector CE02, STC2 or CM02. 3. Connect ground cable. Short circuit or hot short (contact with 24 V circuit) in 4. Turn starting switch to ON position. a Since voltages of CAN H and CAN L are 2.5 ± 1 V even while communication is wiring harness continued, they are judged to be normal if they are 1 – 4 V. Between STC2 (32), CM02 (8), (9) or CE02 (46) and Voltage 1–4V ground Between STC2 (22), CM02 (10) or CE02 (47) and Voltage 1–4V ground Cause
5
6
7
8
9
D65EX, PX, WX-16
40-304
17
SEN05034-01
Cause
Defective engine controller, 10 power train controller or air conditioner unit
11
Defective machine monitor
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18
304 Troubleshooting by failure code (Display of code), Part 4 Failure code [DAFRMC] CAN Discon (Monitor Detected)
Procedure, measuring location, standard (value) and remarks If cause is not found by above checks and failure code [DB2RKR] is not displayed or air conditioner cannot be operated, identify which controller is defective according to following procedure. A. Procedure for judging by operating air conditioner • Step 1 1. Turn starting switch to OFF position and disconnect ground cable. 2. Disconnect engine controller (connector CE02) and power train controller (connector STC2). 3. Connect ground cable and turn starting switch to ON position. 4. Operate air conditioner. a If air conditioner can be operated, go to step 2. Air conditioner unit is NO defective Can air conditioner be operated? Any one of removed YES controllers is defective • Step 2 1. Turn starting switch to OFF position and disconnect ground cable. 2. Disconnect either engine controller (connector CE02) or power train controller (connector STC2). 3. Connect ground cable, turn starting switch to ON position and perform troubleshooting. 4. Return to 1. and perform troubleshooting on next controller. Removed controller is Can air conditioner be operated? YES defective B. Procedure for judging from failure code [DB2RKR] (When there is no air conditioner unit) 1. Turn starting switch to OFF position and disconnect ground cable. 2. Disconnect engine controller (connector CE03). 3. Connect ground cable and turn starting switch to ON position. Defective power NO train controller Is failure code [DB2RKR] displayed? YES Defective engine controller a If no failure is detected by above checks, machine monitor is defective. (Since trouble is in monitor system, troubleshooting cannot be performed.)
D65EX, PX, WX-16
304 Troubleshooting by failure code (Display of code), Part 4 Failure code [DB2RKR] CAN Disconnection
SEN05034-01
Failure code [DB2RKR] CAN Disconnection Action code
Failure code
E03
DB2RKR
Failure description Action of controller
Trouble
1
CAN disconnection (Engine controller is disconnected) (Power train controller system)
• Power train controller cannot recognize engine controller with CAN communication circuit. 1) Except for power supply circuit to engine controller • Limits operation of engine and transmission.
Indication of problem on machine
• • • •
System may not operate normally. When machine is traveling, engine speed is limited up to medium (half) at a certain rate. Once machine stops, engine speed is limited to medium (half). Once machine stops, travel is limited to F1 and R1.
Related information
• Method of reproducing failure code: Turn the starting switch to ON position. • Start of CAN communication is notified to each controller by ACC signal of starting switch. • Failure code is sent to machine monitor by CAN communication. Accordingly, if failure code [DB2RKR] is displayed on the machine monitor, CAN communication between power train controller and machine monitor is normal. That is, there cannot be short circuit, ground fault or hot short in CAN communication line. • Since air conditioner also uses CAN communication, ensure that air conditioner can be operated (turned ON/OFF and air flow can be adjusted) on air conditioner screen. (Air conditioner can be operated even while failure code [DB2RKR] is displayed on the monitor screen.) • If failure code [DAFRMC] is also displayed, cause of this trouble is probably engine controller problem in cause 2. • Since each controller and machine monitor receive power from battery directly, they have power even while starting switch is OFF. • Since CAN communication line signal in operation is pulse voltage, it cannot be measured with multimeter.
Cause 1 Broken fuse
2
Defective engine controller (Internal short circuit)
3
Defective power supply to engine controller
4
Defective CAN terminal resistor (Internal disconnection or short circuit)
D65EX, PX, WX-16
Procedure, measuring location, standard (value) and remarks 1. Turn starting switch to OFF position. 2. Remove fuses in fuse boxes F12-3 and F12-6. a If fuse is broken, controller probably has short circuit in it. a If fuse is not broken, this check is not required. 1. Turn starting switch to OFF position. 2. Disconnect connector CE03 and connect T-adapter to male side. a Measured value: approx. 9 – 20 kz. a If measured value is below 10 z, engine controller is defective (Internal short circuit). Between CE03 (male) (3) and (1) Resistance Min. 10 z 1. Turn starting switch to OFF position. 2. Disconnect connector CE03 and connect T-adapter to female side. 3. If fuse is broken, replace it. a If result is abnormal, perform troubleshooting for [DB2RKR], Failure description 2) Defective power supply circuit to engine controller. Between CE03 (female) (3) and (1) or ground Voltage 20 – 30 V Between CE03 (female) (4) and (2) or ground Voltage 20 – 30 V 1. Turn starting switch to OFF position. 2. Disconnect connectors CA1 and CM02 and connect T-adapters to male side of them. Between CA1 (male) (A) and (B) Resistance 120 ± 12 z Between CM02 (male) (8) and (10) Resistance 120 ± 12 z
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19
SEN05034-01
304 Troubleshooting by failure code (Display of code), Part 4 Failure code [DB2RKR] CAN Disconnection
Cause
5
6
7
8 9
Procedure, measuring location, standard (value) and remarks • CAN communication line a There is 120 z CAN terminal resistor inside machine monitor, too. Since 120 z resistor is connected in parallel, if resistance measured at connector of controller other than machine monitor is 60 z which is combined resistance, wiring harness is not disconnected. 1. Turn starting switch to OFF position and disconnect ground cable. 2. Disconnect one of following connectors CE02, STC2, AC02, CA1 and CM02 and connect T-adapter to female side of that connector. a If connector has short circuit (resistance between terminals is 1 z or less), disconDisconnection or short circuit nect all of CE02, STC2, AC02, CA1 and CM02 and check again to see if there is in wiring harness short circuit between wiring harnesses or in controller. Between CE02 (female) (46) and (47) Resistance Approx. 60 z Between STC2 (female) (32) and (22) Resistance Approx. 60 z Between AC02 (female) (1) and (2) Resistance Approx. 60 z Approx. Between CA1 (female) (A) and (B) Resistance 120 z Approx. Resistance Between CM02 (female) (9) and (10) 120 z a If check result of cause 5 is normal, this check is not required. 1. Turn starting switch to OFF position and disconnect ground cable. 2. Disconnect connectors CE02, C01, N10, K02 and CM02 and connect T-adapters to female side of them. Between STC2 (female) (32) and CM02 (female) (9), (8) Resistance Max. 1 z Disconnection in wiring Between STC2 (female) (22) and CM02 (female) (10) Resistance Max. 1 z harness (Disconnection or Between STC2 (female) (32) and CE02 (female) (46) Resistance Max. 1 z defective contact in connector) Between STC2 (female) (22) and CE02 (female) (47) Resistance Max. 1 z Between STC2 (female) (32) and AC02 (female) (1) Resistance Max. 1 z Between STC2 (female) (22) and AC02 (female) (2) Resistance Max. 1 z Between CE02 (female) (46) and K02 (female) (A) Resistance Max. 1 z Between CE02 (female) (47) and K02 (female) (B) Resistance Max. 1 z • Signal ACC of starting switch 1. Turn starting switch to OFF position and disconnect ground cable. Disconnection in wiring 2. Insert T-adapters into connectors CE02, STC3 and CM01. harness (Disconnection or 3. Connect ground cable and turn starting switch to ON position. defective contact in Between CE02 (39) and ground Voltage 20 – 30 V connector) Between STC3 (14) or (24) and (31) Voltage 20 – 30 V Between CM01 (14) and (3) Voltage 20 – 30 V If cause is not found by the above checks and failure code [DAFRMC] is displayed, Defective engine controller engine controller is defective. (Since trouble is in controller system, troubleshooting cannot be performed.) Defective power train If cause is not found by the above checks, power train controller is defective. (Since controller trouble is in controller system, troubleshooting cannot be performed.)
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D65EX, PX, WX-16
304 Troubleshooting by failure code (Display of code), Part 4 Failure code [DB2RKR] CAN Disconnection
SEN05034-01
Related circuit diagram
D65EX, PX, WX-16
40-304
21
SEN05034-01
Failure description
304 Troubleshooting by failure code (Display of code), Part 4 Failure code [DB2RKR] CAN Disconnection
2) Defective power supply circuit to engine controller
Cause Procedure, measuring location, standard (value) and remarks Loose or corroded battery 1 Check battery terminals and ground (GND1) terminal directly for loose and corrosion. terminals or ground terminal See the items related to wiring harness and connectors in "c: Electric and electrical Defective wiring harness equipment" in "Checks before troubleshooting" in "General information on 2 connector troubleshooting" section, and check them directly. 1. Turn starting switch to OFF position and troubleshoot. 2. Starting engine and troubleshoot. 3 Defective battery voltage Between (+) and (–) terminals of battery (2 pieces) Voltage 20 – 30 V 1. Turn starting switch to OFF position. Defective engine controller 2. Replace engine controller power supply relay (EP1, EP2) with another relay. 4 3. Turn starting switch to ON position. power supply relay If this failure code goes off, the relay is defective. 1. Turn starting switch to OFF position. 2. Remove diode RSD and connect T-adapter to male side. a Measure in diode range. Between RSD (male) (6) (+) and (2) (–) Continuity 5 Defective diode RSD Between RSD (male) (2) (+) and (6) (–) No continuity Between RSD (male) (8) (+) and (4) (–) Continuity Between RSD (male) (4) (+) and (8) (–) No continuity • Ground circuit 1. Turn starting switch to OFF position and disconnect ground cable. 2. Disconnect connectors CE03, EP1 and EP2 and connect T-adapters to female side of them. Between EP1 (female) (2) and ground Resistance Max. 1 z a Rusted or loose ground terminal (GND03) Between EP2 (female) (2) and ground Resistance Max. 1 z a Rusted or loose ground terminal (GND03) Between CE03 (female) (1), (2) and ground Resistance Max. 1 z a Rusted or loose ground terminal (GND1) • Primary circuit of relay 1. Turn starting switch to OFF position and disconnect ground cable. Disconnection in wiring 2. Disconnect connector RSD and connect T-adapter to female side. harness (Disconnection or a Coil resistance of a relay is 260 – 320 z, so it is reduced to half since two relays 6 defective contact in are connected in parallel. connector) Between RSD (female) (2) and ground Resistance 130 – 160 z 1. Turn starting switch to OFF position and disconnect ground cable. 2. Insert T-adapters into connectors RSD, EP1 and EP2. 3. Connect ground cable and turn starting switch to ON position. a Check to where 24 V is supplied to identify disconnected place. Between RSD (6) and ground Voltage 20 – 30 V Between EP1 (1) and (2) Voltage 20 – 30 V Between EP1 (3) and (2) Voltage 20 – 30 V Between EP2 (1) and (2) Voltage 20 – 30 V Between EP2 (3) and (2) Voltage 20 – 30 V Between CE03 (3), (4) and (1), (2) Voltage 20 – 30 V 1. Turn starting switch to OFF position and disconnect ground cable. 2. Disconnect connectors RSD, CE03, EP1 and EP2 and connect T-adapters to female side of them. Between RSD (female) (2) and ground Resistance Min. 1 Mz Ground fault of wiring Between CE03 (female) (3) and ground Resistance Min. 1 Mz 7 harness (Contact with ground circuit) Between CE03 (female) (4) and ground Resistance Min. 1 Mz Between RSD (6) and ground Resistance Min. 1 Mz Between EP1 (1), (3) and ground Resistance Min. 1 Mz Between EP2 (1), (3) and ground Resistance Min. 1 Mz
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D65EX, PX, WX-16
304 Troubleshooting by failure code (Display of code), Part 4 Failure code [DB2RKR] CAN Disconnection
Cause 8 Defective engine controller
SEN05034-01
Procedure, measuring location, standard (value) and remarks If cause is not found by the above checks, engine controller is defective. (Since trouble is in controller system, troubleshooting cannot be performed.)
Related circuit diagram
D65EX, PX, WX-16
40-304
23
304 Troubleshooting by failure code (Display of code), Part 4 Failure code [DBE0KT] PT controller: Abnormality in controller
SEN05034-01
Failure code [DBE0KT] PT controller: Abnormality in controller Action code
Failure code
E01
DBE0KT
Failure description Action of controller
Trouble
PT controller: Failure in controller (Power train controller system)
• Information in ROM (non-volatile memory) of power train controller is abnormal. • Sets internal adjustment values to default values.
Indication of problem on machine
• Shift feeling of transmission may become bad. • Adjusting function may not operate normally.
Related information
• Method of reproducing failure code: Turn starting switch to ON position.
Cause 1
Defective adjustment of power train controller
2
Defective power train controller
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1
Procedure, measuring location, standard (value) and remarks Turn adjustment function in service mode ON and perform operation of reproducing trouble. If “E” of failure code disappears at this time, system is normal. • Adjustment code: 0002 (Initialization of power train controller) Troubleshooting cannot be performed since defect is in power train controller. (If there is not any visible trouble in machine, controller may be used as it is.)
D65EX, PX, WX-16
304 Troubleshooting by failure code (Display of code), Part 4 Failure code [DBE0KT] PT controller: Abnormality in controller
D65EX, PX, WX-16
SEN05034-01
40-304
25
304 Troubleshooting by failure code (Display of code), Part 4 Failure code [DBE1KK] Battery direct Source voltage reduction
SEN05034-01
Failure code [DBE1KK] Battery direct Source voltage reduction Action code
Failure code
E04
DBE1KK
Failure description Action of controller
Trouble
Battery direct source voltage drop (Power train controller system)
• Main power source voltage of power train controller is less than 17 V. • Limits operation of engine and transmission.
Indication of problem on machine
• • • •
Related information
• Main power source voltage of power train controller can be checked in adjusting function. (Code 2021: Power train controller voltage check mode) • Power train controller power supply voltage can be checked with adjustment function.
Machine monitor may not display normally. Relay and solenoid may not drive and therefore, system may not operate normally. Once machine is stopped, engine speed is limited to medium (half). Once machine is stopped, it becomes impossible to travel.
Cause Defective fuse FL2-4 or 1 FS12-2 2
Loose terminal or disconnection at terminal
3 Defective battery voltage
4
Disconnection in or ground fault of wiring harness
Disconnection in wiring 5 harness (Disconnection or defective contact)
Ground fault of wiring 6 harness (Contact with ground circuit)
7
Defective power train controller
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1
Procedure, measuring location, standard (value) and remarks If fuse FL2-4 or FS12-2 is broken, circuit probably has ground fault. In this case, perform troubleshooting for cause 6 first. 1. Turn starting switch to OFF position. Check terminals of battery, battery relay, etc. for looseness or disconnection. 1. Turn starting switch to OFF position. After starting engine, troubleshoot. Between battery (+) and (–) Voltage 20 – 30 V 1. Turn starting switch to OFF position. 2. Disconnect ground cable. 3. Disconnect connector STC3 and connect T-adapter to female side. 4. Connect ground cable. a If voltage is 0 V, wiring harness has disconnection or ground fault. Between STC3 (female) (1) and (21), (31) Voltage 20 – 30 V Between STC3 (female) (11) and (32), (33) Voltage 20 – 30 V a If cause 4 is not the cause for the trouble, this check is not required. 1. Turn starting switch to OFF position. 2. Disconnect ground cable. 3. If fuse is broken, replace it. 4. Disconnect connector STC3 and connect T-adapter to female side. Between STC3 (female) (21), (31), (32), (33) and ground Resistance Max. 1 z a Check terminal GND11 for looseness and rust. Resistance Max. 1 z Between STC3 (female) (1), (2) and battery (+) a If cause 4 is not the cause for the trouble, this check is not required. 1. Turn starting switch to OFF position. 2. Disconnect ground cable. 3. If fuse is broken, replace it. 4. Disconnect connector STC3 and connect T-adapter to female side. Between STC3 (female) (1) and (21), (31) Resistance Min. 1 Mz Between STC3 (female) (11) and (32), (33) Resistance Min. 1 Mz If cause is not found by the above checks, power train controller is defective. • Reference: the followings are standard values in normal condition. 1. Turn starting switch to OFF position. 2. Disconnect ground cable. 3. Insert T-adapter into connector STC3. 4. Connect ground cable. Between STC3 (1) and (21), (31) Voltage 20 – 30 V Between STC3 (11) and (32), (33) Voltage 20 – 30 V
D65EX, PX, WX-16
304 Troubleshooting by failure code (Display of code), Part 4 Failure code [DBE1KK] Battery direct Source voltage reduction
SEN05034-01
Related circuit diagram
D65EX, PX, WX-16
40-304
27
304 Troubleshooting by failure code (Display of code), Part 4 Failure code [DBE2KK] Solenoid Source voltage reduction
SEN05034-01
Failure code [DBE2KK] Solenoid Source voltage reduction Action code
Failure code
E04
DBE2KK
Failure description Action of controller
Trouble
1
Load power source voltage drop of power train controller (Power train controller system)
• Power source voltage for load (relay, solenoid and etc,) on power train controller is less than 17 V. • Limits operation of engine and transmission.
Indication of problem on machine
• Relay and solenoid may not drive and therefore, system may not operate normally. • Once machine is stopped, engine speed is limited to medium (half). • Once machine is stopped, it becomes impossible to travel.
Related information
• Main power source voltage of power train controller can be checked in adjusting function. (Code 2021: Power train controller voltage check mode) • Power train controller power supply voltage can be checked with adjustment function. • If battery relay is not turned ON, see E-mode, E-1.
Cause Defective fuse FL1-4 or 1 FS12-5 2
Loose terminal or disconnection at terminal
3 Defective battery voltage
4
Defective wiring harness or power train controller
Disconnection in wiring 5 harness (Disconnection or defective contact)
Ground fault of wiring 6 harness (Contact with ground circuit)
7
Defective power train controller
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Procedure, measuring location, standard (value) and remarks If fuse FL2-4 or FS12-2 is broken, circuit probably has ground fault. In this case, perform troubleshooting for cause 6 first. 1. Turn starting switch to OFF position. Check terminals of battery, battery relay, etc. for looseness or disconnection. 1. Turn starting switch to OFF position. After starting engine, troubleshoot. Between battery (+) and (–) Voltage 20 – 30 V 1. Turn starting switch to OFF position. 2. Disconnect ground cable. 3. Insert T-adapter into connector STC3. 4. Connect ground cable. 5. Turn starting switch to ON position. Between STC3 (2) and (21) Voltage 20 – 30 V Between STC3 (12) and (31) Voltage 20 – 30 V Between STC3 (22) and (32) Voltage 20 – 30 V a If cause 4 is not the cause for the trouble, this check is not required. 1. Turn starting switch to OFF position. 2. Disconnect ground cable (not to make short circuit). 3. Disconnect connector STC3 and connect T-adapter to female side. Between STC3 (female) (21), (31), (32), (33) and ground Resistance Max. 1 z a Check terminal GND11 for looseness and rust. Between STC3 (female) (2), (12), (22) and terminal Resistance Max. 1 z BRC a If cause 4 is not the cause for the trouble, this check is not required. 1. Turn starting switch to OFF position. 2. Disconnect ground cable (not to make short circuit). 3. If fuse is broken, replace it. 4. Disconnect connector STC3. Between terminal BRC and ground Resistance Min. 1 Mz If cause is not found by the above checks, power train controller is defective.
D65EX, PX, WX-16
304 Troubleshooting by failure code (Display of code), Part 4 Failure code [DBE2KK] Solenoid Source voltage reduction
SEN05034-01
Related circuit diagram
D65EX, PX, WX-16
40-304
29
304 Troubleshooting by failure code (Display of code), Part 4 Failure code [DBE5KK] PT cont.: Sensor voltage 5V (1) reduction
SEN05034-01
Failure code [DBE5KK] PT cont.: Sensor voltage 5V (1) reduction Action code
Failure code
E03
DBE5KK
Failure description Action of controller
Trouble
1
PT controller: Sensor voltage 5V (1) drop (Power train controller system)
• Voltage of 5 V power supply (1) circuit for power train controller sensors is below 4.5 V or above 5.5 V. • Abnormal current flowed in 5 V power supply (1) circuit for power train controller sensors. • Stops to output 5 V power supply (1) circuit, if abnormal current flows. • Limits operation of engine and transmission.
Indication of problem on machine
• System may not operate normally. • Once machine is stopped, engine speed is limited to medium (half). • Once machine is stopped, travel is limited to F1 and R1.
Related information
• Method of reproducing failure code: Turn starting switch to ON position.
Cause
1
2
3
4
Procedure, measuring location, standard (value) 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. After troubleshooting, return to 1. • If this code is not displayed when a sensor is disconnected, that sensor is defective. Defective fuel control dial or PCCS lever (Internal defect) a Other failure codes are displayed at the same time. This is because the connector is disconnected. Ignore failure codes other than [DBE5KK]. Device Connector Fuel control dial DIA2 PCCS lever TLV1 1. Turn starting switch to OFF position. 2. Disconnect connector STC1 and connect T-adapter to male side. Defective power train 3. Turn starting switch to ON position. controller Between STC1 (male) (22) and (21) Voltage 4.5 – 5.5 V 1. Turn starting switch to OFF position. 2. Disconnect connectors STC1, DIA2 and TLV1, and connect T-adapter to female Ground fault of wiring side of one of them. harness (Contact with ground circuit) Between STC1 (female) (22), TLV1 (female) (4), (5) or Min. 1 Mz Resistance DIA2 (female) (A) and ground 1. Turn starting switch to OFF position. 2. Disconnect connectors DIA2 and TLV1, and connect T-adapter to female side of either of them. Hot short in wiring harness 3. Turn starting switch to ON position. (Contact with 24 V circuit) Between TLV1 (female) (4) or (5) and (8), or between Voltage 4.5 – 5.5 V DIA2 (female) (A) and (C)
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D65EX, PX, WX-16
304 Troubleshooting by failure code (Display of code), Part 4 Failure code [DBE5KK] PT cont.: Sensor voltage 5V (1) reduction
SEN05034-01
Related circuit diagram
D65EX, PX, WX-16
40-304
31
304 Troubleshooting by failure code (Display of code), Part 4 Failure code [DBE6KK] PT cont.: Sensor voltage 24V reduction
SEN05034-01
Failure code [DBE6KK] PT cont.: Sensor voltage 24V reduction Action code
Failure code
E03
DBE6KK
Failure description
Trouble
PT controller: Sensor voltage 24V drop (Power train controller system)
• Voltage of 24 V power supply circuit for power train controller sensor is below 17 V or above 30 V. • Abnormal current flowed in 24 V power supply circuit for power train controller sensor.
Action of controller
• Stops to output 24 V power supply circuit, if abnormal current flows. • Limits operation of engine and transmission.
Indication of problem on machine
• System may not operate normally. • Once machine is stopped, engine speed is limited to medium (half). • Once machine is stopped, travel is limited to F1 and R1.
Related information
• Method of reproducing failure code: Turn starting switch to ON position.
Cause
1
Defective inclination angle sensor (Internal defect)
2
Defective power train controller
Ground fault of wiring 3 harness (Contact with ground circuit)
4
Short circuit in wiring harness
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32
1
Procedure, measuring location, standard (value) and remarks 1. Turn starting switch to OFF position. 2. Disconnect connector PT1. 3. Turn starting switch to ON position. • If this code is not displayed when a inclination angle sensor is disconnected, that sensor is defective. a Other failure codes are displayed at the same time. This is because the connector is disconnected. Ignore failure codes other than [DBE6KK]. 1. Turn starting switch to OFF position. 2. Disconnect connector STC1 and connect T-adapter to male side. 3. Turn starting switch to ON position. Between STC1 (male) (16) and (21) Voltage 20 – 30 V 1. Turn starting switch to OFF position. 2. Disconnect connectors STC1 and PT1, and connect T-adapter to female side of either of them. Between STC1 (female) (16) or PT1 (female) (C) and Resistance Min. 1 Mz ground 1. Turn starting switch to OFF position. 2. Disconnect connector PT1 and connect T-adapter to female side. 3. Turn starting switch to ON position. Between PT1 (female) (C) and (A) Voltage 20 – 30 V
D65EX, PX, WX-16
304 Troubleshooting by failure code (Display of code), Part 4 Failure code [DBE6KK] PT cont.: Sensor voltage 24V reduction
SEN05034-01
Related circuit diagram
D65EX, PX, WX-16
40-304
33
304 Troubleshooting by failure code (Display of code), Part 4 Failure code [DBE7KK] PT cont.: Sensor voltage 5V (2) reduction
SEN05034-01
Failure code [DBE7KK] PT cont.: Sensor voltage 5V (2) reduction Action code
Failure code
E02
DBE7KK
Failure description Action of controller
Trouble
1
PT controller: Sensor voltage 5V (2) drop (Power train controller system)
• Voltage of 5 V power supply (2) circuit for power train controller sensors is below 4.5 V or above 5.5 V. • Abnormal current flowed in 5 V power supply (2) circuit for power train controller sensors. • Stops to output 5 V power supply (2) circuit, if abnormal current flows.
Indication of problem on machine
• None in particular.
Related information
• Method of reproducing failure code: Turn starting switch to ON position.
Cause
1
2
3
4
Procedure, measuring location, standard (value) 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. After troubleshooting, return to 1. • If this code is not displayed when a sensor or a device is disconnected, that senDefective brake pedal sor or device is defective. potentiometer, torque converter pressure sensor or a Other failure codes are displayed at the same time. This is because the connector work equipment pump oil is disconnected. Ignore failure codes other than [DBE5KK]. pressure sensor (Internal Device or sensor Connector defect) Brake pedal potentiometer BRK Torque converter pressure sensor TIP Work equipment pump HHP oil pressure sensor 1. Turn starting switch to OFF position. 2. Disconnect connectors STC3, BRK, TIP and HHP, and connect T-adapter to Ground fault of wiring female side of one of them. harness (Contact with ground circuit) Between STC3 (female) (34), BRK (female) (B), TIP Resistance Min. 1 Mz (female) (3) or HHP (female) (3) and ground 1. Turn starting switch to OFF position. 2. Disconnect connectors BRK, TIP and HHP, and connect T-adapter to female side of one of them. Hot short in wiring harness 3. Turn starting switch to ON position. (Contact with 24 V circuit) Between BRK (female) (B) and (C), between TIP (female) (3) and (1), or between HHP (female) (3) and Voltage 4.5 – 5.5 V (1) If cause is not found by the above checks, power train controller is defective. • Reference: the followings are standard values in normal condition. 1. Turn starting switch to OFF position. 2. Insert T-adapter into connector STC3. Defective power train 3. Turn starting switch to ON position. controller a Since connector STC3 has 24 V power supply, 5 V output cannot be checked with connector STC3 disconnected. Between STC3 (34) and ground Voltage 4.5 – 5.5 V
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34
D65EX, PX, WX-16
304 Troubleshooting by failure code (Display of code), Part 4 Failure code [DBE7KK] PT cont.: Sensor voltage 5V (2) reduction
SEN05034-01
Related circuit diagram
D65EX, PX, WX-16
40-304
35
304 Troubleshooting by failure code (Display of code), Part 4 Failure code [DBE9KQ] PT controller: Type select signal
SEN05034-01
Failure code [DBE9KQ] PT controller: Type select signal Action code
Failure code
E04
DBE9KQ
Failure description Action of controller
Trouble
PT controller: Type select signal (Power train controller system)
• Specification setting in power train controller does not match specification setting memory (Initialization of power train controller is not performed). • Turns all outputs of power train controller OFF. • Limits operation of engine and transmission.
Indication of problem on machine
• Machine does not move at all. • Once machine stops, engine speed is limited to medium (half). • Once machine stops, it cannot travel at all.
Related information
• Method of reproducing failure code: Turn starting switch to ON position.
Cause 1
Defective adjustment of power train controller
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1
Procedure, measuring location, standard (value) and remarks Display adjustment function in service mode and perform operation of reproducing trouble. If “E” of failure code disappears at this time, system is normal. • Adjustment code: 0002 (Initialization of power train controller)
D65EX, PX, WX-16
304 Troubleshooting by failure code (Display of code), Part 4 Failure code [DBE9KQ] PT controller: Type select signal
D65EX, PX, WX-16
SEN05034-01
40-304
37
304 Troubleshooting by failure code (Display of code), Part 4 Failure code [DD12KA] Shift up Sw: Disconnection
SEN05034-01
Failure code [DD12KA] Shift up Sw: Disconnection Action code
Failure code
E02
DD12KA
Failure description Action of controller
Trouble
1
Shift up switch: Disconnection (Power train controller system)
• 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.
Indication of problem on machine
• Transmission gear cannot be shifted up. • Auto shift down function does not operate.
Related information
• “NO*” line is used for sensing operation and “NC*” line is used for detecting error. • Condition of shift up switch signal can be checked with monitoring function. (Code: 40905 T/M Sw Input 1) • Method of reproducing failure code: Turn starting switch to ON position and operate shift up switch.
Cause
1
2
3
4
Procedure, measuring location, standard (value) and remarks 1. Turn starting switch to OFF position. 2. Disconnect connector SFTU and connect T-adapter to male side. 3. Turn shift up switch ON/OFF and troubleshoot. a “Switch OFF”: Release, “Switch ON”: Press Defective shift up switch Resistance Max. 1 z Between SFTU (male) (3) Switch: OFF (Internal disconnection) and (2) Switch: ON Resistance Min. 1 Mz Resistance Min. 1 Mz Between SFTU (male) (1) Switch: OFF and (2) Switch: ON Resistance Max. 1 z 1. Turn starting switch to OFF position. 2. Disconnect connector SFTU and connect T-adapter to female side. 3. Turn starting switch to ON position. a If voltage is 0 V, it shows disconnection in wiring harness, and if voltage is 24 V, it Disconnection or hot short in shows hot short in wiring harness. wiring harness a Voltage of about 9 V is applied to signal lines of “NO” and “NC” through resistor in power train controller. Between SFTU (female) (1) and (2) Voltage 7 – 11 V Between SFTU (female) (3) and (2) Voltage 7 – 11 V a If cause 2 is not the cause for the trouble, this check is not required. 1. Turn starting switch to OFF position. Disconnection in wiring 2. Disconnect connectors STC1, STC3 and SFTU and connect T-adapters to female harness side of them. (Disconnection or defective Between STC3 (female) (9) and SFTU (female) (1) Resistance Max. 1 z contact) Between STC1 (female) (4) and SFTU (female) (2) Resistance Max. 1 z Between STC1 (female) (12) and SFTU (female) (3) Resistance Max. 1 z If cause is not found by the above checks, power train controller is defective. • Reference; the followings are standard values in normal condition. 1. Turn starting switch to OFF position. 2. Insert T-adapters into connectors STC1 and STC3. 3. Turn starting switch to ON position. 4. Turn shift up switch ON/OFF and troubleshoot. Defective power train a Voltage of about 9 V is applied to STC1 pin (12) and STC3 pin (9) through resistor controller in power train controller. Switch: OFF Voltage Max. 1 V Between STC1 (12) and (4) Switch: ON Voltage 7 – 11 V OFF Voltage 7 – 11 V Switch: Between STC3 (9) and STC1 (4) Switch: ON Voltage Max. 1 V
*NO: Normally Open *NC: Normally Closed
40-304
38
D65EX, PX, WX-16
304 Troubleshooting by failure code (Display of code), Part 4 Failure code [DD12KA] Shift up Sw: Disconnection
SEN05034-01
Related circuit diagram
D65EX, PX, WX-16
40-304
39
304 Troubleshooting by failure code (Display of code), Part 4 Failure code [DD12KB] Shift up Sw: Short circuit
SEN05034-01
Failure code [DD12KB] Shift up Sw: Short circuit Action code
Failure code
E02
DD12KB
Failure description Action of controller
Trouble
1
Shift up switch: Short circuit (Power train 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.
Indication of problem on machine
• Transmission gear cannot be shifted up. • Auto shift down function does not operate.
Related information
• “NO*” line is used for sensing operation and “NC*” line is used for detecting error. • Condition of shift up switch signal can be checked with monitoring function. (Code: 40905 T/M Sw Input 1) • Method of reproducing failure code: Turn starting switch to ON position and operate shift up switch.
Cause
1
2
3
4
Procedure, measuring location, standard (value) and remarks 1. Turn starting switch to OFF position. 2. Disconnect connector SFTU and connect T-adapter to male side. 3. Turn shift up switch ON/OFF and troubleshoot. a “Switch OFF”: Release, “Switch ON”: Press Defective shift up switch Resistance Max. 1 z Between SFTU (male) (3) Switch: OFF (Internal disconnection) and (2) Switch: ON Resistance Min. 1 Mz Resistance Min. 1 Mz Between SFTU (male) (1) Switch: OFF and (2) Switch: ON Resistance Max. 1 z 1. Turn starting switch to OFF position. 2. Disconnect connectors STC1, STC3 and SFTU and connect T-adapter to female side of one of them. Ground fault of wiring Between SFTU (female) (1) or STC3 (female) (9) and harness Resistance Min. 1 Mz (Contact with ground circuit) ground Between SFTU (female) (3) or STC1 (female) (12) and Resistance Min. 1 Mz ground 1. Turn starting switch to OFF position. 2. Disconnect connectors STC1, STC3 and SFTU and connect T-adapters to female side of STC1 and STC3. a Check with tester in continuity mode. Short circuit in wiring Between STC1 (female) (12) and each pin other than No continuity harness (12) (No sound is heard) No continuity Between STC3 (female) (9) and each pin other than (9) (No sound is heard) If cause is not found by the above checks, power train controller is defective. • Reference; the followings are standard values in normal condition. 1. Turn starting switch to OFF position. 2. Insert T-adapters into connectors STC1 and STC3. 3. Turn starting switch to ON position. 4. Turn shift up switch ON/OFF and troubleshoot. Defective power train a Voltage of about 9 V is applied to STC1 pin (12) and STC3 pin (9) through resistor controller in power train controller. Switch: OFF Voltage Max. 1 V Between STC1 (12) and (4) Switch: ON Voltage 7 – 11 V Switch: OFF Voltage 7 – 11 V Between STC3 (9) and STC1 (4) Switch: ON Voltage Max. 1 V
*NO: Normally Open *NC: Normally Closed
40-304
40
D65EX, PX, WX-16
304 Troubleshooting by failure code (Display of code), Part 4 Failure code [DD12KB] Shift up Sw: Short circuit
SEN05034-01
Related circuit diagram
D65EX, PX, WX-16
40-304
41
304 Troubleshooting by failure code (Display of code), Part 4 Failure code [DD13KA] Shift down Sw: Disconnection
SEN05034-01
Failure code [DD13KA] Shift down Sw: Disconnection Action code
Failure code
E02
DD13KA
Failure description Action of controller
Trouble
1
Shift down switch: Disconnection (Power train controller system)
• Both lines of NO* and NC* for shift down switch circuit are OPEN (switch: OFF) at the same time. • Recognizes that shift down switch is not pressed.
Indication of problem on machine
• Transmission gear cannot be shifted down. • Auto shift down function does not operate.
Related information
• “NO*” line is used for sensing operation and “NC*” line is used for detecting error. • Condition of shift down switch signal can be checked with monitoring function. (Code: 40905 T/M Sw Input 1) • Method of reproducing failure code: Turn starting switch to ON position and operate shift down switch.
Cause
1
2
3
4
Procedure, measuring location, standard (value) and remarks 1. Turn starting switch to OFF position. 2. Disconnect connector SFTD and connect T-adapter to male side. 3. Turn shift up switch ON/OFF and troubleshoot. a “Switch OFF”: Release, “Switch ON”: Press Defective shift down switch Resistance Max. 1 z Between SFTD (male) (3) Switch: OFF (Internal disconnection) and (2) Switch: ON Resistance Min. 1 Mz Resistance Min. 1 Mz Between SFTD (male) (1) Switch: OFF and (2) Switch: ON Resistance Max. 1 z 1. Turn starting switch to OFF position. 2. Disconnect connector SFTD and connect T-adapter to female side. 3. Turn starting switch to ON position. a If voltage is 0 V, it shows disconnection in wiring harness, and if voltage is 24 V, it Disconnection or hot short in shows hot short in wiring harness. wiring harness a Voltage of about 9 V is applied to signal lines of “NO” and “NC” through resistor in power train controller. Between SFTD (female) (1) and (2) Voltage 7 – 11 V Between SFTD (female) (3) and (2) Voltage 7 – 11 V a If cause 2 is not the cause for the trouble, this check is not required. 1. Turn starting switch to OFF position. Disconnection in wiring 2. Disconnect connectors STC1 and SFTD and connect T-adapters to female side of harness them. (Disconnection or defective Between STC1 (female) (18) and SFTD (female) (1) Resistance Max. 1 z contact) Between STC1 (female) (4) and SFTD (female) (2) Resistance Max. 1 z Between STC1 (female) (24) and SFTD (female) (3) Resistance Max. 1 z If cause is not found by the above checks, power train controller is defective. • Reference; the followings are standard values in normal condition. 1. Turn starting switch to OFF position. 2. Insert T-adapter into connector STC1. 3. Turn starting switch to ON position. 4. Turn shift down switch ON/OFF and troubleshoot. Defective power train a Voltage of about 9 V is applied to STC1 pin (18) and pin (24) through resistor in controller power train controller. Switch: OFF Voltage 7 – 11 V Between STC1 (18) and (4) Switch: ON Voltage Max. 1 V Switch: OFF Voltage Max. 1 V Between STC1 (24) and (4) Switch: ON Voltage 7 – 11 V
*NO: Normally Open *NC: Normally Closed
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42
D65EX, PX, WX-16
304 Troubleshooting by failure code (Display of code), Part 4 Failure code [DD13KA] Shift down Sw: Disconnection
SEN05034-01
Related circuit diagram
D65EX, PX, WX-16
40-304
43
304 Troubleshooting by failure code (Display of code), Part 4 Failure code [DD13KB] Shift down Sw: Short circuit
SEN05034-01
Failure code [DD13KB] Shift down Sw: Short circuit Action code
Failure code
E02
DD13KB
Failure description Action of controller
Trouble
1
Shift down switch: Short circuit (Power train controller system)
• Both lines of NO* and NC* for shift down switch circuit are 0 V (switch: ON) at the same time. • Recognizes that shift down switch is not pressed.
Indication of problem on machine
• Transmission gear cannot be shifted down. • Auto shift down function does not operate.
Related information
• “NO*” line is used for sensing operation and “NC*” line is used for detecting error. • Condition of shift down switch signal can be checked with monitoring function. (Code: 40905 T/M Sw Input 1) • Method of reproducing failure code: Turn starting switch to ON position and operate shift down switch.
Cause
1
2
3
4
Procedure, measuring location, standard (value) and remarks 1. Turn starting switch to OFF position. 2. Disconnect connector SFTD and connect T-adapter to male side. 3. Turn shift down switch ON/OFF and troubleshoot. a “Switch OFF”: Release, “Switch ON”: Press Defective shift down switch Resistance Max. 1 z Between SFTD (male) (3) Switch: OFF (Internal disconnection) and (2) Switch: ON Resistance Min. 1 Mz Resistance Min. 1 Mz Between SFTD (male) (1) Switch: OFF and (2) Switch: ON Resistance Max. 1 z 1. Turn starting switch to OFF position. 2. Disconnect connectors STC1 and SFTD and connect T-adapter to female side of one of them. Ground fault of wiring Between SFTD (female) (1) or STC1 (female) (18) and harness Resistance Min. 1 Mz (Contact with ground circuit) ground Between SFTD (female) (3) or STC1 (female) (24) and Resistance Min. 1 Mz ground 1. Turn starting switch to OFF position. 2. Disconnect connectors STC1 and SFTD and connect T-adapter to female side of STC1. a Check with tester in continuity mode. Short circuit in wiring harness Between STC1 (female) (18) and each pin other than No continuity (18) (No sound is heard) Between STC1 (female) (24) and each pin other than No continuity (24) (No sound is heard) If cause is not found by the above checks, power train controller is defective. • Reference; the followings are standard values in normal condition. 1. Turn starting switch to OFF position. 2. Insert T-adapter into connector STC1. 3. Turn starting switch to ON position. 4. Turn shift down switch ON/OFF and troubleshoot. Defective power train a Voltage of about 9 V is applied to STC1 pin (18) and pin (24) through resistor in controller power train controller. Switch: OFF Voltage 7 – 11 V Between STC1 (18) and (4) Switch: ON Voltage Max. 1 V Voltage Max. 1 V Switch: OFF Between STC1 (24) and (4) Switch: ON Voltage 7 – 11 V
*NO: Normally Open *NC: Normally Closed
40-304
44
D65EX, PX, WX-16
304 Troubleshooting by failure code (Display of code), Part 4 Failure code [DD13KB] Shift down Sw: Short circuit
SEN05034-01
Related circuit diagram
D65EX, PX, WX-16
40-304
45
304 Troubleshooting by failure code (Display of code), Part 4 Failure code [DD14KA] Parking lever Sw: Disconnection
SEN05034-01
Failure code [DD14KA] Parking lever Sw: Disconnection Action code
Failure code
E03
DD14KA
Failure description Action of controller
Trouble
1
Parking lever switch: Disconnection (Power train controller system)
• Both lines of NO* and NC* for parking brake lever switch circuit are OPEN (switch: OFF) at the same time. • Recognizes that parking brake lever is in FREE position. • Limits operation of engine and transmission.
Indication of problem on machine
• Once machine stops, engine speed is limited to medium (half). • Once machine stops, travel is limited to F1 and R1. • Engine cannot start.
Related information
• “NO*” line is used for sensing operation and “NC” line is used for detecting error. • Condition of parking brake lever switch signal can be checked with monitoring function. (Code: 40905 T/M Sw Input 1) • Method of reproducing failure code: Turn starting switch to ON position and operate parking brake lever. • When parking brake lever is free, parking brake lever switch becomes “ON”.
Cause
1
2
3
4
Procedure, measuring location, standard (value) and remarks 1. Turn starting switch to OFF position. 2. Disconnect connector PKSW and connect T-adapter to male side. 3. Operate parking brake lever and troubleshoot. a “Switch OFF”: Release, “Switch ON”: Press Defective parking brake lever switch (Internal Resistance Min. 1 Mz Between PKSW (male) (A) Lever: free disconnection) and (B) Lever: lock Resistance Max. 1 z Lever: free Resistance Max. 1 z Between PKSW (male) (A) and (C) Lever: lock Resistance Min. 1 Mz 1. Turn starting switch to OFF position. 2. Disconnect connector PKSW and connect T-adapter to female side. 3. Turn starting switch to ON position. a If voltage is 0 V, it shows disconnection in wiring harness, and if voltage is 24 V, it Disconnection or hot short in shows hot short in wiring harness. wiring harness a Voltage of about 9 V is applied to signal lines of “NO” and “NC” through resistor in power train controller. Between PKSW (female) (A) and (B) Voltage 7 – 11 V Between PKSW (female) (A) and (C) Voltage 7 – 11 V a If cause 2 is not the cause for the trouble, this check is not required. 1. Turn starting switch to OFF position. Disconnection in wiring 2. Disconnect connectors STC1, STC2 and PKSW and connect T-adapters to female harness side of them. (Disconnection or defective Between STC1 (female) (4) and PKSW (female) (A) Resistance Max. 1 z contact) Between STC2 (female) (5) and PKSW (female) (B) Resistance Max. 1 z Between STC2 (female) (15) and PKSW (female) (C) Resistance Max. 1 z If cause is not found by the above checks, power train controller is defective. • Reference; the followings are standard values in normal condition. 1. Turn starting switch to OFF position. 2. Insert T-adapters into connectors STC1 and STC2. 3. Turn starting switch to ON position. 4. Operate parking brake lever and troubleshoot. Defective power train a Voltage of about 9 V is applied to STC2 pin (5) and pin (15) through resistor in controller power train controller. Lever: free Voltage 7 – 11 V Between STC2 (5) and STC1 (4) Lever: lock Voltage Max. 1 V Voltage Max. 1 V Lever: free Between STC2 (15) and STC1 (4) Lever: lock Voltage 7 – 11 V
*NO: Normally Open *NC: Normally Closed
40-304
46
D65EX, PX, WX-16
304 Troubleshooting by failure code (Display of code), Part 4 Failure code [DD14KA] Parking lever Sw: Disconnection
SEN05034-01
Related circuit diagram
D65EX, PX, WX-16
40-304
47
304 Troubleshooting by failure code (Display of code), Part 4 Failure code [DD14KB] Parking lever Sw: Short circuit
SEN05034-01
Failure code [DD14KB] Parking lever Sw: Short circuit Action code
Failure code
E03
DD14KB
Failure description Action of controller
Trouble
1
Parking lever switch: Short circuit (Power train controller system)
• Both lines of NO* and NC* for parking brake lever switch circuit are 0 V (switch: ON) at the same time. • Recognizes that parking brake lever is in FREE position. • Limits operation of engine and transmission.
Indication of problem on machine
• Once machine stops, engine speed is limited to medium (half). • Once machine stops, travel is limited to F1 and R1. • Engine cannot start.
Related information
• “NO*” line is used for sensing operation and “NC” line is used for detecting error. • Condition of parking brake lever switch signal can be checked with monitoring function. (Code: 40905 T/M Sw Input 1)