D51 Manual de Serviço PDF

CEBM019109
Shop
Manual
D51EX-22
D51PX-22
CRAWLER DOZER
SERIAL NUMBERS D51EX-22 B10001 and up
D51PX-22 B10001 and up
ENGINE 6D107E-1
This material is proprietary to Komatsu America Corp. and is not to be reproduced, used, or disclosed except in
accordance with written authorization from Komatsu America Corp.
It is our policy to improve our products whenever it is possible and practical to do so. We reserve the right to
make changes or improvements at any time without incurring any obligation to install such changes on products
sold previously.
Due to this continuous program of research and development, revisions may be made to this publication. It is
recommended that customers contact their distributor for information on the latest revision.
Copyright 2013 Komatsu

Printed in U.S.A.
Komatsu America Corp.
March 2013
FOREWORD CONTENTS
12
CONTENTS 00
GENERAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 01-1
STRUCTURE, FUNCTION AND MAINTENANCE STANDARD . . . . . . . . . . . . . . . . . . . . 10-1
STANDARD VALUE TABLES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-1
TESTING AND ADJUSTING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-1
TROUBLESHOOTING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-1
DISASSEMBLY AND ASSEMBLY. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50-1
OTHER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 90-1
00-2 b
FOREWORD
The affected pages are indicated by using the following Mark Indication Action
marks. It is requested that necessary actions be taken to
these pages according to the table below. m New page to be added Add
l Page to be replaced Replace
( ) Page to be deleted Discard
Mark Page Rev Mark Page Rev Mark Page Rev Mark Page Rev
l 00-1 J 00-20 10-7 10-36 d
00-2 b 00-21 10-8 10-37 d
l 00-2-1 J 00-22 10-9 10-38 d
l 00-2-2 J 00-23 10-10 10-39 d
l 00-2-3 J 00-24 10-11 10-40 d
l 00-2-4 J 00-25 10-12 10-41 d
l 00-2-5 J 00-26 10-13 10-42 d
l 00-2-6 J 00-27 10-14 10-43 d
l 00-2-7 J 00-28 10-15 10-44 d
l 00-2-8 J 10-16 10-45 d
l 00-2-9 J 01-1 10-17 10-46 d
l 00-2-10 J 01-2 d 10-18 10-47 d
00-3 01-3 d 10-19 10-48 d
00-4 01-4 10-20 10-49 d
00-5 01-5 10-21 10-50 d
00-6 01-6 d 10-22 10-51 d
00-7 01-7 10-23 10-52 d
00-8 01-8 10-24 10-53 d
00-9 01-9 10-25 10-54 d
00-10 01-10 10-26 10-55 d
00-11 01-11 10-27 10-56 d
00-12 01-12 10-28 d 10-57 d
00-13 10-29 d 10-58 d
00-14 10-1 d 10-30 10-59 d
00-15 10-2 d 10-31 10-60 d
00-16 10-3 10-32 10-61 d
00-17 10-4 10-33 d 10-62 d
00-18 10-5 10-34 d 10-63 d
00-19 10-6 10-35 d 10-64 d
D51EX/PX-22 D51EX/PX-22 00-2-1 J

FOREWORD
10-65 d 10-98 d 10-131 d 10-164
10-66 d 10-99 d 10-132 d 10-165
10-67 d 10-100 d 10-133 d 10-166
10-68 d 10-101 d 10-134 d 10-167
10-69 d 10-102 d 10-135 d 10-168
10-70 d 10-103 d 10-136 d 10-169
10-71 d 10-104 d 10-137 d 10-170
10-72 d l 10-105 J 10-138 d 10-171
10-73 d 10-106 d 10-139 d 10-172
10-74 d 10-107 d 10-140 d 10-173
10-75 d 10-108 d 10-141 d 10-174
10-76 d 10-109 d 10-142 10-175
10-77 d 10-110 d 10-143 10-176
10-78 d 10-111 d 10-144 10-177
10-79 d 10-112 d 10-145 10-178
10-80 d 10-113 d 10-146 10-179
10-81 d 10-114 d 10-147 10-180
10-82 I 10-115 d 10-148 10-181
10-83 d 10-116 d 10-149 10-182
10-84 d 10-117 d 10-150 10-183
10-85 d l 10-118 J 10-151 10-184
10-86 d 10-119 d 10-152 10-185
l 10-87 J 10-120 d 10-153 10-186
10-88 d 10-121 d 10-154 10-187
10-89 d 10-122 d 10-155 10-188
10-90 d 10-123 d 10-156
10-91 d 10-124 d 10-157 20-1
10-92 d 10-125 d 10-158 20-2 e
10-93 d 10-126 d 10-159 20-3
10-94 d 10-127 d 10-160 20-4
10-95 d 10-128 d 10-161 20-5
10-96 d 10-129 d 10-162 20-6
10-97 d 10-130 d 10-163 20-7
00-2-2 J D51EX/PX-22
FOREWORD
20-8 30-30 l 30-63 J l 30-96 J
20-9 30-31 l 30-64 J l 30-97 J
20-10 30-32 l 30-65 J l 30-98 J
30-33 l 30-66 J l 30-99 J
30-1 30-34 l 30-67 J l 30-100 J
30-2 30-35 l 30-68 J l 30-101 J
30-3 30-36 l 30-69 J l 30-102 J
30-4 30-37 l 30-70 J l 30-103 J
30-5 30-38 l 30-71 J l 30-104 J
30-6 30-39 l 30-72 J l 30-105 J
30-7 30-40 l 30-73 J l 30-106 J
30-8 30-41 l 30-74 J l 30-107 J
30-9 30-42 l 30-75 J l 30-108 J
30-10 30-43 l 30-76 J l 30-109 J
30-11 30-44 l 30-77 J l 30-110 J
30-12 30-45 l 30-78 J l 30-111 J
30-13 30-46 l 30-79 J l 30-112 J
30-14 30-47 l 30-80 J l 30-113 J
30-15 30-48 l 30-81 J l 30-114 J
30-16 30-49 l 30-82 J l 30-115 J
30-17 30-50 l 30-83 J l 30-116 J
30-18 30-51 l 30-84 J l 30-117 J
30-19 30-52 l 30-85 J l 30-118 J
30-20 30-53 l 30-86 J l 30-119 J
30-21 30-54 l 30-87 J l 30-120 J
30-22 l 30-55 J l 30-88 J l 30-121 J
30-23 l 30-56 J l 30-89 J l 30-122 J
30-24 l 30-57 J l 30-90 J l 30-123 J
30-25 l 30-58 J l 30-91 J l 30-124 J
30-26 l 30-59 J l 30-92 J l 30-125 J
30-27 l 30-60 J l 30-93 J l 30-126 J
30-28 l 30-61 J l 30-94 J l 30-127 J
30-29 l 30-62 J l 30-95 J l 30-128 J
D51EX/PX-22 00-2-3 J
FOREWORD
l 30-129 J 40-115 40-148 40-229 b
l 30-130 J 40-116 40-149 40-230 b
l 30-131 J 40-117 40-150 40-231 b
l 30-132 J 40-118 40-151 40-232 b
l 30-133 J 40-119 40-233 b
l 30-134 J 40-120 40-201 b 40-234 b
l 30-135 J 40-121 40-202 b 40-235 b
l 30-136 J 40-122 40-203 b 40-236 b
l 30-137 J 40-123 40-204 b 40-237 b
l 30-138 J 40-124 40-205 b 40-238 b
l 30-139 J 40-125 40-206 b 40-239 b
l 30-140 J 40-126 40-207 b 40-240 b
l 30-141 J 40-127 40-208 b 40-241 b
l 30-142 J 40-128 40-209 b 40-242 b
l 30-143 J 40-129 40-210 b 40-243 b
l 30-144 J 40-130 40-211 b 40-244 b
m 30-145 J 40-131 40-212 b 40-245 b
m 30-146 J 40-132 40-213 b 40-246 b
40-133 40-214 b 40-247 b
40-101 40-134 40-215 b 40-248 b
40-102 40-135 40-216 b 40-249 b
40-103 40-136 40-217 b 40-250 b
40-104 40-137 40-218 b 40-251 b
40-105 40-138 40-219 b 40-252 b
40-106 40-139 40-220 b 40-253 b
40-107 40-140 40-221 b 40-254 b
40-108 40-141 40-222 b 40-255 b
40-109 40-142 40-223 b 40-256 b
40-110 40-143 40-224 b 40-257 b
40-111 40-144 40-225 b 40-258 b
40-112 40-145 40-226 b 40-259 b
40-113 40-146 40-227 b 40-260 b
40-114 40-147 40-228 b 40-261 b
00-2-4 J D51EX/PX-22
FOREWORD
40-262 b 40-295 b 40-328 b 40-361 b
40-263 b 40-296 b 40-329 b 40-362 b
40-264 b 40-297 b 40-330 b 40-363 b
40-265 b 40-298 b 40-331 b 40-364 b
40-266 b 40-299 b 40-332 b 40-365 b
40-267 b 40-300 b 40-333 b 40-366 b
40-268 b 40-301 b 40-334 b 40-367 b
40-269 b 40-302 b 40-335 b 40-368 b
40-270 b 40-303 b 40-336 b 40-369 b
40-271 b 40-304 b 40-337 b 40-370 b
40-272 b 40-305 b 40-338 b 40-371 b
40-273 b 40-306 b 40-339 b 40-372 b
40-274 e 40-307 b 40-340 b 40-373 b
40-275 b 40-308 b 40-341 b 40-374 b
40-276 b 40-309 b 40-342 b 40-375 b
40-277 b 40-310 b 40-343 b 40-376 b
40-278 b 40-311 b 40-344 b 40-377 b
40-279 b 40-312 b 40-345 b 40-378 b
40-280 b 40-313 b 40-346 b 40-379 b
40-281 b 40-314 b 40-347 b 40-380 b
40-282 b 40-315 b 40-348 b 40-381 b
40-283 b 40-316 b 40-349 b 40-382 b
40-284 b 40-317 b 40-350 b 40-383 b
40-285 b 40-318 b 40-351 b 40-384 b
40-286 b 40-319 b 40-352 b 40-385 b
40-287 b 40-320 b 40-353 b 40-386 b
40-288 b 40-321 b 40-354 b 40-387 b
40-289 b 40-322 b 40-355 b 40-388 b
40-290 b 40-323 b 40-356 b 40-389 b
40-291 b 40-324 b 40-357 b 40-390 b
40-292 b 40-325 b 40-358 b 40-391 b
40-293 b 40-326 b 40-359 b 40-392 b
40-294 b 40-327 b 40-360 b 40-393 b
D51EX/PX-22 00-2-5 J
FOREWORD
40-394 b 40-427 b 40-460 b 40-516 b
40-395 b 40-428 b 40-461 b 40-517 b
40-396 b 40-429 b 40-462 b 40-518 b
40-397 b 40-430 b 40-463 b 40-519 b
40-398 b 40-431 b 40-464 b 40-520 b
40-399 b 40-432 b 40-465 b 40-521 H
40-400 b 40-433 b 40-466 b 40-522 b
40-401 b 40-434 b 40-467 b 40-523 b
40-402 b 40-435 b 40-468 b 40-524 b
40-403 b 40-436 b 40-469 b 40-525 b
40-404 b 40-437 b 40-470 b 40-526 b
40-405 b 40-438 b 40-471 b 40-527 b
40-406 b 40-439 b 40-472 b 40-528 b
40-407 b 40-440 b 40-473 b 40-529 b
40-408 b 40-441 b 40-474 b 40-530 b
40-409 b 40-442 b 40-475 b 40-531 b
40-410 b 40-443 b 40-476 b 40-532 b
40-411 b 40-444 b 40-533 b
40-412 b 40-445 b 40-501 b 40-534 b
40-413 b 40-446 b 40-502 b 40-535 b
40-414 b 40-447 b 40-503 b 40-536 b
40-415 b 40-448 b 40-504 b 40-537 b
40-416 b l 40-449 J 40-505 b 40-538 b
40-417 b 40-450 b 40-506 b 40-539 b
40-418 b 40-451 b 40-507 b 40-540 b
40-419 b 40-452 b 40-508 b 40-541 b
40-420 b 40-453 b 40-509 b 40-542 b
40-421 b 40-454 b 40-510 b 40-543 b
40-422 b 40-455 b 40-511 b 40-544 b
40-423 b 40-456 b 40-512 b 40-545 b
40-424 b 40-457 b 40-513 b 40-546 b
40-425 b 40-458 b 40-514 b 40-547 b
40-426 b 40-459 b 40-515 b 40-548 b
00-2-6 J D51EX/PX-22
FOREWORD
40-549 b 40-607 b 40-715 b 50-23 H
40-550 b 40-608 b 40-716 b 50-24 H
40-551 b 40-609 b 40-717 b 50-25 H
40-552 b 40-610 b 40-718 b 50-26 H
40-553 b 40-611 b 40-719 b 50-27 H
40-554 b 40-612 b 40-720 b 50-28 H
40-555 b 40-613 b 40-721 b 50-29 H
40-556 b 40-614 b 40-722 b 50-30 H
40-557 b 40-615 b 40-723 b 50-31 H
40-558 b 40-616 b 40-724 b 50-32 H
40-559 b 40-617 b 50-33 H
40-560 b 40-618 b 50-1 H 50-34 H
40-561 b 40-619 b 50-2 I 50-35 H
40-562 b 40-620 b 50-3 I 50-36 H
40-563 b 40-621 b 50-4 b 50-37 H
40-564 b 40-622 b 50-5 b 50-38 H
40-565 b 40-623 b 50-6 b 50-39 H
40-566 b 40-624 b 50-7 b 50-40 H
40-567 b 50-8 H 50-41 H
40-568 b 40-701 b 50-9 H 50-42 H
40-569 b 40-702 b 50-10 H 50-43 H
40-570 b 40-703 b 50-11 H 50-44 H
40-571 b 40-704 b 50-12 H 50-45 H
40-572 b 40-705 b 50-13 H 50-46 H
40-573 b 40-706 b 50-14 H 50-47 H
40-574 b 40-707 b 50-15 H 50-48 H
40-708 b 50-16 H 50-49 H
40-601 b 40-709 b 50-17 H 50-50 H
40-602 b 40-710 b 50-18 H 50-51 H
40-603 b 40-711 b 50-19 H 50-52 H
40-604 b 40-712 b 50-20 H 50-53 H
40-605 b 40-713 b 50-21 H 50-54 H
40-606 b 40-714 b 50-22 H 50-55 H
D51EX/PX-22 00-2-7 J
FOREWORD
50-56 H 50-89 H 50-122 H 50-155 I
50-57 H 50-90 H 50-123 H 50-156 I
50-58 H 50-91 H 50-124 H 50-157 I
50-59 H 50-92 H 50-125 H 50-158 I
50-60 H 50-93 H 50-126 H 50-159 I
50-61 H 50-94 H 50-127 H 50-160 I
50-62 H 50-95 H 50-128 H 50-161 I
50-63 H 50-96 H 50-129 H 50-162 I
50-64 H 50-97 H 50-130 I 50-163 I
50-65 H 50-98 H 50-131 I 50-164 I
50-66 H 50-99 H 50-132 I 50-165 I
50-67 H 50-100 H 50-133 I 50-166 I
50-68 H 50-101 H 50-134 I 50-167 I
50-69 H 50-102 H 50-135 I 50-168 I
50-70 H 50-103 H 50-136 I 50-169 I
50-71 H 50-104 H 50-137 I 50-170 I
50-72 H 50-105 H 50-138 I 50-171 I
50-73 H 50-106 H 50-139 I 50-172 I
50-74 H 50-107 H 50-140 I 50-173 I
50-75 H 50-108 H 50-141 I 50-174 I
50-76 H 50-109 H 50-142 I 50-175 I
50-77 H 50-110 H 50-143 I 50-176 I
50-78 H 50-111 H 50-144 I 50-177 I
50-79 H 50-112 H 50-145 I 50-178 I
50-80 H 50-113 H 50-146 I 50-179 I
50-81 H 50-114 H 50-147 I 50-180 I
50-82 H 50-115 H 50-148 I 50-181 I
50-83 H 50-116 H 50-149 I 50-182 I
50-84 H 50-117 H 50-150 I 50-183 I
50-85 H 50-118 H 50-151 I 50-184 I
50-86 H 50-119 H 50-152 I 50-185 I
50-87 H 50-120 H 50-153 I 50-186 I
50-88 H 50-121 H 50-154 I 50-187 I
00-2-8 J D51EX/PX-22
FOREWORD
50-188 I 50-221 I 50-254 I 50-287 I
50-189 I 50-222 I 50-255 I 50-288 I
50-190 I 50-223 I 50-256 I 50-289 I
50-191 I 50-224 I 50-257 I 50-290 I
50-192 I 50-225 I 50-258 I 50-291 I
50-193 I 50-226 I 50-259 I 50-292 I
50-194 I 50-227 I 50-260 I 50-293 I
50-195 I 50-228 I 50-261 I l 50-294 J
50-196 I 50-229 I 50-262 I 50-295 I
50-197 I 50-230 I 50-263 I 50-296 I
50-198 I 50-231 I 50-264 I 50-297 I
50-199 I 50-232 I 50-265 I 50-298 I
50-200 I 50-233 I 50-266 I 50-299 I
50-201 I 50-234 I 50-267 I 50-300 I
50-202 I 50-235 I 50-268 I 50-301 I
50-203 I 50-236 I 50-269 I 50-302 I
50-204 I 50-237 I 50-270 I 50-303 I
50-205 I 50-238 I 50-271 I 50-304 I
50-206 I 50-239 I 50-272 I 50-305 I
50-207 I 50-240 I 50-273 I 50-306 I
50-208 I 50-241 I 50-274 I 50-307 I
50-209 I 50-242 I 50-275 I 50-308 I
50-210 I 50-243 I 50-276 I 50-309 I
50-211 I 50-244 I 50-277 I 50-310 I
50-212 I 50-245 I 50-278 I 50-311 I
50-213 I 50-246 I 50-279 I 50-312 I
50-214 I 50-247 I 50-280 I 50-313 I
50-215 I 50-248 I 50-281 I 50-314 I
50-216 I 50-249 I 50-282 I 50-315 I
50-217 I 50-250 I 50-283 I 50-316 I
50-218 I 50-251 I 50-284 I 50-317 I
50-219 I 50-252 I 50-285 I 50-318 I
50-220 I 50-253 I 50-286 I 50-319 I
D51EX/PX-22 00-2-9 J
FOREWORD
Mark Page Rev Mark Page Rev Mark Page Rev
50-320 I 50-353 I 90-7
50-321 I 50-354 I 90-9
50-322 I 50-355 I 90-11
50-323 I 50-356 I 90-13
50-324 I 50-357 I 90-15
50-325 I 50-358 I 90-17 e
50-326 I 50-359 I 90-19
50-327 I 50-360 I 90-21
50-328 I 50-361 I 90-23
50-329 I 50-362 I 90-25 d
50-330 I 50-363 I 90-27 d
50-331 I 50-364 I 90-29
50-332 I 50-365 I 90-31
50-333 I 50-366 I 90-33
50-334 I 50-367 I 90-35
50-335 I 50-368 I 90-37 d
50-336 I 50-369 I
50-337 I 50-370 I
50-338 I 50-371 I
50-339 I 50-372 I
50-340 I 50-373 I
50-341 I 50-374 I
50-342 I 50-375 I
50-343 I 50-376 I
50-344 I 50-377 I
50-345 I 50-378 I
50-346 I 50-379 I
50-347 I 50-380 I
50-348 I
50-349 I 90-1
50-350 I 90-3
50-351 I 90-4
50-352 I 90-5
00-2-10 J D51EX/PX-22
FOREWORD SAFETY
12
SAFETY 00
SAFETY NOTICE 00
IMPORTANT SAFETY NOTICE 00
Proper service and repair is extremely important for the safe operation of your machine. The service and repair techniques
recommended and described in this manual are both effective and safe methods of operation. Some of these operations
require the use of tools specially designed for the purpose.
To prevent injury to workers, the symbols and are used to mark safety precautions in this manual. The cautions
accompanying these symbols should always be followed carefully. If any dangerous situation arises or may possibly arise,
first consider safety, and take the necessary actions to deal with the situation.
GENERAL PRECAUTIONS 00 PREPARATIONS FOR WORK 00
Mistakes in operation are extremely dangerous. Read the 1. Before adding oil or making repairs, park the machine
OPERATION & MAINTENANCE MANUAL carefully on hard, level ground, and block the wheels or tracks to
BEFORE operating the machine. prevent the machine from moving.
1. Before carrying out any greasing or repairs, read all the 2. Before starting work, lower blade, ripper, bucket or any
precautions given on the decals which are fixed to the other work equipment to the ground. If this is not
machine. possible, insert the safety pin or use blocks to prevent
the work equipment from falling. In addition, be sure to
2. When carrying out any operation, always wear safety lock all the control levers and hang warning signs on
shoes and helmet. Do not wear loose work clothes, or them.
clothes with buttons missing.
• Always wear safety glasses when hitting parts with 3. When disassembling or assembling, support the
a hammer. machine with blocks, jacks or stands before starting
• Always wear safety glasses when grinding parts work.
with a grinder, etc.
4. Remove all mud and oil from the steps or other places
used to get on and off the machine. Always use the
3. If welding repairs are needed, always have a trained,
handrails, ladders or steps when getting on or off the
experienced welder carry out the work. When carrying
machine. Never jump on or off the machine. If it is
out welding work, always wear welding gloves, apron,
impossible to use the handrails, ladders or steps, use a
glasses, cap and other clothes suited for welding work.
stand to provide safe footing.
4. When carrying out any operation with two or more
workers, always agree on the operating procedure PRECAUTIONS DURING WORK 00
before starting. Always inform your fellow workers 1. When removing the oil filler cap, drain plug or
before starting any step of the operation. Before starting hydraulic pressure measuring plugs, loosen them slowly
work, hang UNDER REPAIR signs on the controls in to prevent the oil from spurting out. Before
the operator's compartment. disconnecting or removing components of the oil, water
or air circuits, first remove the pressure completely from
5. Keep all tools in good condition and learn the correct the circuit.
way to use them.
2. The water and oil in the circuits are hot when the engine
6. Decide a place in the repair workshop to keep tools and is stopped, so be careful not to get burned. Wait for the
removed parts. Always keep the tools and parts in their oil and water to cool before carrying out any work on
correct places. Always keep the work area clean and the oil or water circuits.
make sure that there is no dirt or oil on the floor. Smoke
only in the areas provided for smoking. Never smoke 3. Before starting work, remove the leads from the battery.
while working. ALWAYS remove the lead from the negative (-)
terminal first.
00-3
FOREWORD SAFETY
12
4. When raising heavy components, use a hoist or crane. Check that the wire rope, chains and hooks are free from damage.
Always use lifting equipment which has ample capacity. Install the lifting equipment at the correct places. Use a hoist or
crane and operate slowly to prevent the component from hitting any other part. Do not work with any part still raised by
the hoist or crane.
5. When removing covers which are under internal pressure or under pressure from a spring, always leave two bolts in
position on opposite sides. Slowly release the pressure, then slowly loosen the bolts to remove.
6. When removing components, be careful not to break or damage the wiring. Damaged wiring may cause electrical fires.
7. When removing piping, stop the fuel or oil from spilling out. If any fuel or oil drips on to the floor, wipe it up immediately.
Fuel or oil on the floor can cause you to slip, or can even start fires.
8. Never use flammable liquids to clean parts, use only non-flammable approved cleaning solutions to clean parts.
9. Be sure to assemble all parts again in their original places. Replace any damaged part with new parts.
• When installing hoses and wires, be sure that they will not be damaged by contact with other parts when the machine
is being operated.
10. When installing high pressure hoses, make sure that they are not twisted. Damaged tubes are dangerous, so be extremely
careful when installing tubes for high pressure circuits. Also check that connecting parts are correctly installed.
11. When assembling or installing parts, always use the specified tightening torques. When installing protective parts such as
guards, or parts which vibrate violently or rotate at high speed, be particularly careful to check that they are installed
correctly.
12. When aligning two holes, never insert your fingers or hand. Be careful not to get your fingers caught in a hole.
13. When measuring hydraulic pressure, check that the measuring tool is correctly assembled before taking any
measurements.
14. Take care when removing or installing the tracks of track-type machines. When removing the track, the track separates
suddenly, so never let anyone stand at either end of the track.
00-4
FOREWORD GENERAL
12
GENERAL 00
This shop manual has been prepared as an aid to improve the quality of repairs by giving the serviceman an accurate
understanding of the product and by showing him the correct way to perform repairs and make judgements. Make sure you
understand the contents of this manual and use it to full effect at every opportunity.
This shop manual mainly contains the necessary technical information for operations performed in a service workshop. For
ease of understanding, the manual is divided into the following sections. These sections are further divided into each main
group of components.
GENERAL
This section lists the general machine dimensions, performance specifications, component weights, and fuel, coolant and
lubricant specification charts.
STRUCTURE, FUNCTION AND MAINTENANCE STANDARD
This section explains the structure and function of each component. It serves not only to give an understanding of the
structure, but also serves as reference material for troubleshooting. In addition, this section gives the judgement standards
when inspecting disassembled parts.
TESTING AND ADJUSTING
This section explains checks to be made before and after performing repairs, as well as adjustments to be made at
completion of the checks and repairs.
TROUBLESHOOTING
Troubleshooting charts correlating “Problems” to “Causes” are also included in this section.
DISASSEMBLY AND ASSEMBLY
This section explains the order to be followed when removing, installing, disassembling or assembling each component,
as well as precautions to be taken for these operations.
OTHER
This section has the foldout drawings for the machine.
NOTICE
The specifications contained in this shop manual are subject to change at any time and without any advance notice. Contact
your distributor for the latest information.
00-5
FOREWORD HOW TO READ THE SHOP MANUAL
12
HOW TO READ THE SHOP MANUAL 00
VOLUMES 00
REVISIONS 00
Shop manuals are issued as a guide to carrying out repairs. Revised pages are shown at the LIST OF REVISED PAGES
They are divided as follows: between the title page and SAFETY page.
Chassis volume: Issued for every machine model
Engine volume: Issued for each engine series SYMBOLS 00
Electrical volume: Each issued as one to cover all models So that the shop manual can be of ample practical use,
Attachment volume: Each issued as one to cover all models important places for safety and quality are marked with the
following symbols.
These various volumes are designed to avoid duplication of
information. Therefore to deal with all repairs for any model, Symbol Item Remarks
it is necessary that chassis, engine, electrical and attachment
be available. Special safety precautions are
Safety necessary when performing the
work.
DISTRIBUTION AND UPDATING 00
Special technical precautions or

Any additions, amendments or other changes will be sent to other precautions for preserving
 Caution
your distributors. Get the most up-to-date information before standards are necessary when
you start any work. performing the work.
Weight of parts or systems.
FILING METHOD 00
Caution necessary when
Weight selecting hoisting wire or when
1. See the page number on the bottom of the page. File the working posture is important,
pages in correct order. etc.
2. Following examples show how to read the page number:
Example: Places that require special
Tightening
attention for tightening torque
torque
10 - 3 during assembly.
Places to be coated with
Item number (10. Structure and Function) Coat
adhesives and lubricants etc.
Consecutive page number for each item Places where oil, water or fuel
Fill
must be added, and the capacity.
3. Additional pages: Additional pages are indicated by a
hyphen (-) and numbered after the page number. File as Places where oil or water must
in the example. Drain be drained, and quantity to be
Example: drained.
10-4
10-4-1
Added pages
10-4-2
10-5
REVISED EDITION MARK 00
When a manual is revised, an edition mark (…) is

recorded on the bottom outside corner of the pages.
00-6
FOREWORD HOISTING INSTRUCTIONS
12
HOISTING INSTRUCTIONS 00
HOISTING 00
can result. Hooks have maximum strength at the middle
portion.
WARNING! Heavy parts (25 kg or more)
must be lifted with a hoist etc.
In the DISASSEMBLY AND
ASSEMBLY section, every
part weighing 25 kg or more is
indicated clearly with the
symbol.
l If a part cannot be smoothly removed from the machine

by hoisting, the following checks should be made: 3. Do not sling a heavy load with one rope alone, but sling
1. Check for removal of all bolts fastening the part to the with two or more ropes symmetrically wound on to the
relative parts. load.
2. Check for existence of another part causing interface
with the part to be removed. WARNING! Slinging with one rope may
cause turning of the load
WIRE ROPES 00
during hoisting, untwisting of

the rope, or slipping of the
1. Use adequate ropes depending on the weight of parts to rope from its original winding
be hoisted, referring to the table below: position on the load, which
Wire ropes can result in a dangerous
(Standard “Z” or “S” twist ropes without galvanizing) accident
Rope diameter Allowable load 4. Do not sling a heavy load with ropes forming a wide
hanging angle from the hook. When hoisting a load with
mm kN tons
two or more ropes, the force subjected to each rope will
10 9.8 1.0 increase with the hanging angles. The table below
shows the variation of allowable load (kg) when
11.2 13.7 1.4
hoisting is made with two ropes, each of which is
12.5 15.7 1.6 allowed to sling up to 1000 kg vertically, at various
hanging angles. When two ropes sling a load vertically,
14 21.6 2.2
up to 2000 kg of total weight can be suspended. This
16 27.5 2.8 weight becomes 1000 kg when two ropes make a 120°
hanging angle. On the other hand, two ropes are subject
18 35.3 3.6
to an excessive force as large as 4000 kg if they sling a
20 43.1 4.4 2000 kg load at a lifting angle of 150°.
22.4 54.9 5.6
30 98.1 10.0
40 176.5 18.0
50 274.6 28.0
60 392.2 40.0
H The allowable load value is estimated to be 1/6 or 1/7 of

the breaking strength of the rope used.Sling wire ropes
from the middle portion of the hook.
2. Slinging near the edge of the hook may cause the rope to
slip off the hook during hoisting, and a serious accident
00-7
FOREWORD PUSH PULL COUPLER
12
PUSH PULL COUPLER 00
WARNING! Before carrying out the following work,

release the residual pressure from the
hydraulic tank. For details, see TESTING
AND ADJUSTING, Releasing residual
pressure from hydraulic tank.
WARNING! 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 00
DISCONNECTION 00
1. Release the residual pressure from the hydraulic tank. For details,
see TESTING AND ADJUSTING, Releasing residual pressure
from hydraulic tank.
2. Hold the adapter (1) and push the hose joint (2) into the mating
adapter (3). The adapter can be pushed in about 3.5 mm. Do not
hold the rubber cap portion (4).
3. After the hose joint (2) is pushed into the adapter (3), press the
rubber cap portion (4) against the adapter until it clicks.
4. Hold the hose adapter (1) or hose (5) and pull it out. Since some
hydraulic oil flows out, prepare an oil receiving container.
CONNECTION 00
1. Hold the hose adapter (1) or hose (5) and insert it in the mating
adapter (3), aligning them with each other. Do not hold the rubber
cap portion (4).
2. After inserting the hose in the mating adapter, pull it back to check
its connecting condition. When the hose is pulled back, the rubber
cap portion moves toward the hose about 3.5 mm. This does not
indicate an abnormality.
00-8
TYPE 2 00
DISCONNECTION 00
1. Hold the mouthpiece of the tightening portion and push body (2) in
straight until sliding prevention ring (1) contacts contact surface a
of the hexagonal portion at the male end.
2. Hold in the condition in Step 1, and turn the lever (4) to the
right - clockwise.
3. Hold in the condition in Steps 1 and 2, and pull out the whole body
(2) to disconnect it.
CONNECTION 00
1. Hold the connector of the tightening portion and push body (2) in
straight until sliding prevention ring (1) contacts surface a of the
hexagonal portion at the male end to connect it.
00-9
12
TYPE 3 00
DISCONNECTION 00
1. Hold the connector of the tightening portion and push the body (2)
in straight until sliding prevention ring (1) contacts surface a of the
hexagonal portion at the male end.
2. Hold in the condition in Step 1, and push until the cover (3)
contacts surface a of the hexagonal portion at the male end.
3. Hold in the condition in Steps 1 and 2, and pull out the whole body
(2) to disconnect it.
CONNECTION 00
1. Hold the connector of the tightening portion and push the body (2)
in straight until the slide prevention ring (1) contacts surface a of
the hexagonal portion at the male end to connect it.
00-10
FOREWORD EXPLANATION OF MAINTENANCE STANDARD TERMS
12
EXPLANATION OF MAINTENANCE STANDARD TERMS 00
l The maintenance standard values necessary for judgment of

products and parts are described by the following terms.
1. Standard Size And Tolerance

• To be accurate, the finishing size of parts is a little different
from one to another.
• To specify a finishing size of a part, a temporary standard size
is set and an allowable difference from that size is indicated.
• The above size set temporarily is called the “standard size” and
the range of difference from the standard size is called the
“tolerance”.
• The tolerance with the symbols of + or – is indicated on the
right side of the standard size.
Example:
Standard size Tolerance
–0.022
120
–0.126
H The tolerance may be indicated in the text and a table as [standard size (upper limit of tolerance/lower limit of tolerance)].
Example) 120 (–0.022/–0.126)
• Usually, the size of a hole and the size of the shaft to be fitted to that hole are indicated by the same standard size and
different tolerances of the hole and shaft. The tightness of fit is decided by the tolerance.
• Indication of size of rotating shaft and hole and relationship drawing of them
Example:
Tolerance
Standard size
Shaft Hole
–0.030 +0.046
60
–0.076 +0
2. Standard Clearance And Standard Value

• The clearance made when new parts are assembled is called the “standard clearance“, which is indicated by the range
from the minimum clearance to the maximum clearance.
• When some parts are repaired, the clearance is generally adjusted to the standard clearance.
• A value of performance and function of new products or equivalent is called the “standard value“, which is indicated
by a range or a target value.
• When some parts are repaired, the value of performance/function is set to the standard value.
3. Standard Interference
• When the size of a hole is smaller than the size of a shaft because of the standard size and tolerance, the difference
between these sizes is called the “interference”.
• The range (A – B) from the difference (A) between the minimum size of the shaft and the maximum size of the shaft
to the difference (B) between the maximum size of the shaft and the minimum size of the hole is the “standard
interference”.
• After repairing or replacing some parts, measure the size of their hole and shaft and check that the interference is in
the standard range.
00-11
FOREWORD EXPLANATION OF MAINTENANCE STANDARD TERMS
12
4. Repair Limit And Allowable Value
• The size of a part changes because of wear and deformation while it is used. The limit of changed size is called the
“repair limit”.
• If a part is worn to the repair limit must be replaced or repaired.
• The performance and function of a product lowers while it is used. A value below which the product can be used
without causing a problem is called the “allowable value”.
• If a product is worn to the allowable value, it must be checked or repaired. Since the permissible value is estimated
from various tests or experiences in most cases, however, it must be judged after considering the operating condition
and customer's requirement.
5. Clearance Limit
• Parts can be used until the clearance between them is increased to a certain limit. The limit at which those parts
cannot be used is called the “clearance limit”.
• If the clearance between the parts exceeds the clearance limit, they must be replaced or repaired.
6. Interference Limit
• The allowable maximum interference between the hole of a part and the shaft of another part to be assembled is called
the “interference limit”.
• The interference limit shows the repair limit of the part of smaller tolerance.
• If the interference between the parts exceeds the interference limit, they must be replaced or repaired.
00-12
FOREWORD STANDARD TIGHTENING TORQUE
12
STANDARD TIGHTENING TORQUE 00
BOLTS AND NUTS 00
l Unless there are special instructions, tighten metric nuts and bolts to the torque below. (When using torque wrench)
H The following table corresponds to the bolts in Figure A.
Thread diameter of bolt Width across flats Tightning torque
mm mm Nm lbf ft
6 10 11.8 - 14.7 8.70 - 10.84
8 13 27 - 34 19.91 - 25.07
10 17 59 - 74 43.51 - 54.57
12 19 98 - 123 72.28 - 90.72
14 22 153 - 190 112.84 - 140.13
16 24 235 - 285 173.32 - 210.20
18 27 320 - 400 236.02 - 295.02
20 30 455 - 565 335.59 - 416.72
22 32 610 - 765 449.91 - 564.23
24 36 785 - 980 578.98 - 722.81
27 41 1150 - 1440 848.19 - 1062.09
30 46 1520 - 1910 1121.09 - 1408.74
33 50 1960 - 2450 1445.62 - 1807.02
36 55 2450 - 3040 1807.02 - 2242.19
39 60 2890 - 3630 2131.55 - 2677.35
H The following table corresponds to the bolts in Figure B.

Thread diameter of bolt Width across flats Tightning torque
mm mm Nm lbf ft
6 10 5.9 - 9.8 4.35 - 7.22
8 13 13.7 - 23.5 10.10 - 17.33
10 14 34.3 - 46.1 25.29 - 34.00
12 27 74.5 - 90.2 54.94 - 66.52
Figure A Figure B
00-13
12
TIGHTENING TORQUE OF HOSE NUTS 00
Use these torques for hose nuts.

Thread diameter Width across flat Tightening torque
Nominal No.
mm mm Nm lbf ft
02 14 19 19.6 - 29.4 14.5 - 21.7
03 18 24 29.4 - 68.6 21.7 - 50.6
04 22 27 58.9 - 98.1 44.4 - 72.4
05 24 32 107.9 - 166.7 79.6 - 123.0
06 30 36 147.1 - 205.9 108.5 - 151.9
10 33 41 147.1 - 245.1 108.5 - 180.8
12 36 46 196.2 - 294.2 144.7 - 217.0
14 42 55 245.2 - 343.2 180.9 - 253.1
TIGHTENING TORQUE OF SPLIT FLANGE BOLTS 00
Use these torques for split flange bolts.

mm mm Nm lbf ft
10 14 59 - 74 43.51 - 54.57
12 17 98 - 123 72.28 - 90.72
16 22 235 - 285 173.32 - 210.20
TIGHTENING TORQUE FOR FLARED NUTS 00
Use these torques for flared part of nut.

mm mm Nm lbf ft
14 19 24.5 ± 4.9 18.0 ± 3.6
18 24 49 ± 19.6 36.1 ± 14.4
22 27 78.5 ± 19.6 57.8 ± 14.4
24 32 137.3 ± 29.4 101.2 ± 21.6
30 36 176.5 ± 29.4 130.1 ± 21.6
33 41 196.1 ± 49 144.6 ± 36.1
36 46 245.2 ± 49 180.8 ± 36.1
42 55 294.2 ± 49 216.9 ± 36.1
00-14
12
TIGHTENING TORQUES FOR O-RING BOSS PIPING JOINTS 00
H Unless there are special instructions, tighten the O-ring boss piping joints to the torque below.
Thread diameter Width across flat Tightening torque Nm (lbf ft)

Norminal No.
mm mm Range Target
02 14 35 - 63 (25.81 - 46.46) 44 (32.45)
03, 04 20 84 - 132 (61.95 - 97.35) 103 (75.96)
Varies depending on
05, 06 24 128 - 186 (94.40 - 137.18) 157 (115.79)
type of connector.
10, 12 33 363 - 480 (267.73 - 354.02) 422 (311.25)
14 42 746 - 1010 (550.22 - 744.93) 883 (651.26)
TABLE OF TIGHTENING TORQUES FOR O-RING BOSS PLUGS 00
H Unless there are special instructions, tighten the O-ring boss plugs to the torque below.
Thread diameter Width across flat Tightening torque Nm (lbf lb)

Norminal No.
mm mm Range Target
08 08 14 5.88 - 8.82 (4.33 - 6.50) 7.35 (5.42)
10 10 17 9.8 - 12.74 (7.22 - 9.39) 11.27 (8.31)
12 12 19 14.7 - 19.6 (10.84 - 14.45) 17.64 (13.01)
14 14 22 19.6 - 24.5 (14.45 - 18.07) 22.54 (16.62)
16 16 24 24.5 - 34.3 (18.07 - 25.29) 29.4 (21.68)
18 18 27 34.3 - 44.1 (25.29 - 32.52) 39.2 (28.91)
20 20 30 44.1 - 53.9 (32.52 - 39.75) 49.0 (36.14)
24 24 32 58.8 - 78.4 (43.36 - 57.82) 68.6 (50.59)
30 30 32 93.1 - 122.5 (68.66 - 90.35) 107.8 (79.50)
33 33 _ 107.8 - 147.0 (79.50 - 108.42) 124.4 (91.75)
36 36 36 127.4 - 176.4 (93.96 - 130.10) 151.9 (112.03)
42 42 _ 181.3 - 240.1 (133.72 - 177.08) 210.7 (155.40)
52 52 _ 274.4 - 367.5 (202.38 - 271.05) 323.4 (238.52)
TORQUE TABLE FOR HOSES (TAPER SEAL TYPE AND FACE SEAL TYPE) 00
H Tighten the hoses (taper seal type and face seal type) to the following torque, unless otherwise specified.
H Apply the following torque when the threads are coated (wet) with engine oil.
Taper seal
Tightening torque (Nm (lbf ft)) Face seal type
type
Nominal Width Nominal thread
size of hose across flats Thread size size - Threads per Root diameter (mm)
Range Target
(mm) inch, Thread (Reference)
series
34 - 54 (25.0 - 39.8) 44 (32.4) - 9/16 - 18UN 14.3
02 19
34 - 63 (25.0 - 46.4) 44 (32.4) 14 - -
22 54 - 93 (39.8 - 68.5) 74 (54.5) - 11/16 -16UN 17.5
03
24 59 - 98 (43.5 - 72.2) 78 57.5) 18 - -
04 27 84 - 132 (61.9 - 97.3) 103 (75.9) 22 13/16 - 16UN 20.6
05 32 128 - 186 (94.4 - 137.1) 157 (115.7) 24 1 - 14UNS 25.4
06 36 177 - 245 (130.5 - 180.7) 216 (159.3) 30 1 3/16 - 12UN 30.2
(10) 41 177 - 245 (130.5 - 180.7) 216 (159.3) 33 - -
(12) 46 197 - 294 (145.3 - 216.8) 245 (180.7) 36 - -
(14) 55 246 - 343 (181.4 - 252.9) 294 (216.8) 42 - -
00-15
FOREWORD ELECTRIC WIRE CODE
12
ELECTRIC WIRE CODE 00
In the wiring diagrams, various colors and symbols are employed to indicate the thickness of wires. This wire code table will
help you understand WIRING DIAGRAMS.
Example: 05WB indicates a cable having a nominal number 05 and white coating with black stripe.
CLASSIFICATION BY THICKNESS 00
Copper wire
Nominal Cable O.D. Current
Number of Dia. Of strand Cross section Applicable circuit
number (mm) rating (A)
strands (mm) (mm)
0.85 11 0.32 0.88 2.4 12 Starting, lighting, signal etc.
2 26 0.32 2.09 3.1 20 Lighting, signal etc.
5 65 0.32 5.23 4.6 37 Charging and signal
15 84 0.45 13.36 7.0 59 Starting (Glow plug)
40 85 0.80 42.73 11.4 135 Starting
60 127 0.80 63.84 13.6 178 Starting
100 217 0.80 109.1 17.6 230 Starting
CLASSIFICATION BY COLOR AND CODE 00
Circuits
Priority Charging Ground Starting Lighting Instrument Signal Other
Classification
Primary
Code W B B R Y G L
1
Color White Black Black Red Yellow Green Blue
Code WR — BW RW YR GW LW
2 White & Black & Red & Yellow & Green & Blue &
Color —
Red White White Red White White
Code WB — BY RB YB GR LR
3 White & Black & Yellow & Green &
Color — Red & Black Blue & Red
Black Yellow Black Red
Code WL — BR RY YG GY LY
Auxiliary
4 White & Red & Yellow & Green & Blue &
Color — Black & Red
Blue Yellow Green Yellow Yellow
Code WG — — RG YL GB LB
Color — —
Green Green Blue Black Black
Code — — — RL YW GL —
6 Yellow & Green &
Color — — — Red & Blue —
White Blue
00-16
12
HOW TO READ ELECTRIC WIRE CODE 00
H 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)
Using
Type Symbol Material temperature Example of use
range °C (°F)
Low-voltage Annealed copper for electric
Conductor General wiring
wire for AV appliance
(Nominal No. 5 and above)
automobile Insulator Soft polyvinyl chloride
–30 to +60
Thin-cover Annealed copper for electric (-22 to +140)
Conductor
low-voltage appliance General wiring
AVS
wire for (Nominal No. 3 and below)
Insulator Soft polyvinyl chloride
automobile
Heat-resistant Annealed copper for electric
Conductor General wiring in extremely cold
low-voltage appliance –50 to +110
AEX district, wiring at high-temperature
wire for Heat-resistant crosslinked (-58 to +230)
Insulator place
automobile polyethylene
00-17
2. Dimensions
(Table 2)
Nominal No. 0.5f (0.5) 0.75f (0.85) 1.25f (1.25) 2f 2 3f 3 5
Number of
strands/
20/0.18 7/0.32 30/0.18 11/0.32 50/0.18 16/0.32 37/0.26 26/0.32 58/0.26 41/0.32 65/0.32
Diameter of
Conductor strand
Sectional area
0.51 0.56 0.76 0.88 1.27 1.29 1.96 2.09 3.08 3.30 5.23
(mm2)
d (approx.) 1.0 1.2 1.5 1.9 1.9 2.3 2.4 3.0
AVS Standard 2.0 2.2 2.5 2.9 2.9 3.5 3.6 –
Cover D
AV Standard – – – – – – – 4.6
AEX Standard 2.0 2.2 2.7 3.0 3.1 – 3.8 4.6
Nominal No. 8 15 20 30 40 50 60 85 100

Number of
strands/
50/0.45 84/0.45 41/0.80 70/0.80 85/0.80 108/0.80 127/0.80 169/0.80 217/0.80
Diameter of
Conductor strand
Sectional
7.95 13.36 20.61 35.19 42.73 54.29 63.84 84.96 109.1
area (mm2)
d (approx.) 3.7 4.8 6.0 8.0 8.6 9.8 10.4 12.0 13.6
AVS Standard – – – – – – – – –
Cover D
AV Standard 5.5 7.0 8.2 10.8 11.4 13.0 13.6 16.0 17.6
AEX Standard 5.3 7.0 8.2 10.8 11.4 13.0 13.6 16.0 17.6
H “f” of nominal No. denotes flexible”.
00-18
12
3. Color Codes Table
(Table 3)
Color Code Color of wire Color Code Color of wire
B Black LgW Light green & White
Br Brown LgY Light green & Yellow
BrB Brown & Black LR Blue & Red
BrR Brown & Red LW Blue & White
BrW Brown & White LY Blue & Yellow
BrY Brown & Yellow O Orange
Ch Charcoal P Pink
Dg Dark green R Red
G Green RB Red & Black
GB Green & Black RG Red & Green
GL Green & Blue RL Red & Blue
Gr Gray RW Red & White
GR Green & Red RY Red & Yellow
GW Green & White Sb Sky Blue
GY Green & Yellow Y Yellow
L Blue YB Yellow & Black
LB Blue & Black YG Yellow &Green
Lg Light green YL Yellow & Blue
LgB Light green & Black YR Yellow & Red
LgR Light green & Red YW Yellow & White
l 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.
H Types of circuits and color codes
(Table 4)
Type of wire AVS or AV AEX
Charge R WG – – – – R –
Ground B – – – – – B –
Start R – – – – – R –
Light RW RB RY RG RL – D –
Instrument Y YR YB YG YL YW Y Gr
Signal G GW GR GY GB GL G Br
L LW LR LY LB – L –
Type of
Br BrW BrR BrY BrB – – –
circuit
Lg LgR LgY LgB LgW – – –
O – – – – – – –
Others Gr – – – – – – –
P – – – – – – –
Sb – – – – – – –
Dg – – – – – – –
Ch – – – – – – –
00-19
FOREWORD CONVERSION TABLES
12
CONVERSION TABLES 00
METHOD OF USING THE CONVERSION TABLE 00
The Conversion Table in this section is provided to enable simple conversion of figures. For details of the method of using the
Conversion Table, see the example given below.
EXAMPLE
l Method of using the Conversion Table to convert from millimeters to inches.
1. Convert 55 mm into inches.
A. Locate the number 50 in the vertical column at the left side, take this as b, then draw a horizontal line from b.
B. Locate the number 5 in the row across the top, take this as c, then draw a perpendicular line down from c.
C. Take the point where the two lines cross as d. This point d gives the value when converting from millimeters to
inches. Therefore, 55 millimeters = 2.165 inches.
2. Convert 550 mm into inches.

A. The number 550 does not appear in the table, so divide by 10 (move the decimal one place to the left) to convert it to
55 mm.
B. Carry out the same procedure as above to convert 55 mm to 2.165 inches.
C. The original value (550 mm) was divided by 10, so multiply 2.165 inches by 10 (move the decimal one place to the
right) to return to the original value. This gives 550 mm = 21.65 inches.
c
Millimeters to inches 1 mm = 0.03937 in
0 1 2 3 4 5 6 7 8 9
0 0 0.039 0.079 0.118 0.157 0.197 0.236 0.276 0.315 0.354
10 0.394 0.433 0.472 0.512 0.551 0.591 0.630 0.669 0.709 0.748
20 0.787 0.827 0.866 0.906 0.945 0.984 1.024 1.063 1.102 1.142
30 1.181 1.220 1.260 1.299 1.339 1.378 1.417 1.457 1.496 1.536
40 1.575 1.614 1.654 1.693 1.732 1.772 1.811 1.850 1.890 1.929
d
50 1.969 2.008 2.047 2.087 2.126 2.165 2.205 2.244 2.283 2.323
b
60 2.362 2.402 2.441 2.480 2.520 2.559 2.598 2.638 2.677 2.717
70 2.756 2.795 2.835 2.874 2.913 2.953 2.992 3.032 3.071 3.110
80 3.150 3.189 3.228 3.268 3.307 3.346 3.386 3.425 3.465 3.504
90 3.543 3.583 3.622 3.661 3.701 3.740 3.780 3.819 3.858 3.898
00-20
12
Millimeters to Inches 1 mm = 0.03937 in

0 1 2 3 4 5 6 7 8 9
0 0 0.039 0.079 0.118 0.157 0.197 0.236 0.276 0.315 0.354
10 0.394 0.433 0.472 0.512 0.551 0.591 0.630 0.669 0.709 0.748
20 0.787 0.827 0.866 0.906 0.945 0.984 1.024 1.063 1.102 1.142
30 1.181 1.220 1.260 1.299 1.339 1.378 1.417 1.457 1.496 1.536
40 1.575 1.614 1.654 1.693 1.732 1.772 1.811 1.850 1.890 1.929
50 1.969 2.008 2.047 2.087 2.126 2.165 2.205 2.244 2.283 2.323
60 2.362 2.402 2.441 2.480 2.520 2.559 2.598 2.638 2.677 2.717
70 2.756 2.795 2.835 2.874 2.913 2.953 2.992 3.032 3.071 3.110
80 3.150 3.189 3.228 3.268 3.307 3.346 3.386 3.425 3.465 3.504
90 3.543 3.583 3.622 3.661 3.701 3.740 3.780 3.819 3.858 3.898
Kilogram to Pound 1 kg = 2.2046 lb

0 1 2 3 4 5 6 7 8 9
0 0 2.20 4.41 6.61 8.82 11.02 13.23 15.43 17.64 19.84
10 22.05 24.25 26.46 28.66 30.86 33.07 35.27 37.48 39.68 41.89
20 44.09 46.30 48.50 50.71 51.91 55.12 57.32 59.53 61.73 63.93
30 66.14 68.34 70.55 72.75 74.96 77.16 79.37 81.57 83.78 85.98
40 88.18 90.39 92.59 94.80 97.00 99.21 101.41 103.62 105.82 108.03
50 110.23 112.44 114.64 116.85 119.05 121.25 123.46 125.66 127.87 130.07
60 132.28 134.48 136.69 138.89 141.10 143.30 145.51 147.71 149.91 152.12
70 154.32 156.53 158.73 160.94 163.14 165.35 167.55 169.76 171.96 174.17
80 176.37 178.57 180.78 182.98 185.19 187.39 189.60 191.80 194.01 196.21
90 198.42 200.62 202.83 205.03 207.24 209.44 211.64 213.85 216.05 218.26
00-21
12
Liter to U.S. Gallon 1 L = 0.2642 U.S. Gal

0 1 2 3 4 5 6 7 8 9
0 0 0.264 0.528 0.793 1.057 1.321 1.585 1.849 2.113 2.378
10 2.642 2.906 3.170 3.434 3.698 3.963 4.227 4.491 4.755 5.019
20 5.283 5.548 5.812 6.076 6.340 6.604 6.869 7.133 7.397 7.661
30 7.925 8.189 8.454 8.718 8.982 9.246 9.510 9.774 10.039 10.303
40 10.567 10.831 11.095 11.359 11.624 11.888 12.152 12.416 12.680 12.944
50 13.209 13.473 13.737 14.001 14.265 14.529 14.795 15.058 15.322 15.586
60 15.850 16.115 16.379 16.643 16.907 17.171 17.435 17.700 17.964 18.228
70 18.492 18.756 19.020 19.285 19.549 19.813 20.077 20.341 20.605 20.870
80 21.134 21.398 21.662 21.926 22.190 22.455 22.719 22.983 23.247 23.511
90 23.775 24.040 24.304 24.568 24.832 25.096 25.361 25.625 25.889 26.153
Liter to U.K. Gallon 1 L = 0.21997 U.K. Gal

0 1 2 3 4 5 6 7 8 9
0 0 0.220 0.440 0.660 0.880 1.100 1.320 1.540 1.760 1.980
10 2.200 2.420 2.640 2.860 3.080 3.300 3.520 3.740 3.950 4.179
20 4.399 4.619 4.839 5.059 5.279 5.499 5.719 5.939 6.159 6.379
30 6.599 6.819 7.039 7.259 7.479 7.699 7.919 8.139 8.359 8.579
40 8.799 9.019 9.239 9.459 9.679 9.899 10.119 10.339 10.559 10.778
50 10.998 11.281 11.438 11.658 11.878 12.098 12.318 12.528 12.758 12.978
60 13.198 13.418 13.638 13.858 14.078 14.298 14.518 14.738 14.958 15.178
70 15.398 15.618 15.838 16.058 16.278 16.498 16.718 16.938 17.158 17.378
80 17.598 17.818 18.037 18.257 18.477 18.697 18.917 19.137 19.357 19.577
90 19.797 20.017 20.237 20.457 20.677 20.897 21.117 21.337 21.557 21.777
00-22
12
kgm to ft. lb. 1 kgm = 7.233 ft. lb.

0 1 2 3 4 5 6 7 8 9
0 0 7.2 14.5 21.7 28.9 36.2 43.4 50.6 57.9 65.1
10 72.3 79.6 86.8 94.0 101.3 108.5 115.7 123.0 130.2 137.4
20 144.7 151.9 159.1 166.4 173.6 180.8 188.1 195.3 202.5 209.8
30 217.0 224.2 231.5 238.7 245.9 253.2 260.4 267.6 274.9 282.1
40 289.3 296.6 303.8 311.0 318.3 325.5 332.7 340.0 347.2 354.4
50 361.7 368.9 376.1 383.4 390.6 397.8 405.1 412.3 419.5 426.8
60 434.0 441.2 448.5 455.7 462.9 470.2 477.4 484.6 491.8 499.1
70 506.3 513.5 520.8 528.0 535.2 542.5 549.7 556.9 564.2 571.4
80 578.6 585.9 593.1 600.3 607.6 614.8 622.0 629.3 636.5 643.7
90 651.0 658.2 665.4 672.7 679.9 687.1 694.4 701.6 708.8 716.1
100 723.3 730.5 737.8 745.0 752.2 759.5 766.7 773.9 781.2 788.4
110 795.6 802.9 810.1 817.3 824.6 831.8 839.0 846.3 853.5 860.7
120 868.0 875.2 882.4 889.7 896.9 904.1 911.4 918.6 925.8 933.1
130 940.3 947.5 954.8 962.0 969.2 976.5 983.7 990.9 998.2 1005.4
140 1012.6 1019.9 1027.1 1034.3 1041.5 1048.8 1056.0 1063.2 1070.5 1077.7
150 1084.9 1092.2 1099.4 1106.6 1113.9 1121.1 1128.3 1135.6 1142.8 1150.0
160 1157.3 1164.5 1171.7 1179.0 1186.2 1193.4 1200.7 1207.9 1215.1 1222.4
170 1129.6 1236.8 1244.1 1251.3 1258.5 1265.8 1273.0 1280.1 1287.5 1294.7
180 1301.9 1309.2 1316.4 1323.6 1330.9 1338.1 1345.3 1352.63 1359.8 1367.0
190 1374.3 1381.5 1388.7 1396.0 1403.2 1410.4 1417.7 1424.9 1432.1 1439.4
00-23
12
kg/cm2 to lb/in2 1 kg/cm2 = 14.2233lb/in2

0 1 2 3 4 5 6 7 8 9
0 0 14.2 28.4 42.7 56.9 71.1 85.3 99.6 113.8 128.0
10 142.2 156.5 170.7 184.9 199.1 213.4 227.6 241.8 256.0 270.2
20 284.5 298.7 312.9 327.1 341.4 355.6 369.8 384.0 398.3 412.5
30 426.7 440.9 455.1 469.4 483.6 497.8 512.0 526.3 540.5 554.7
40 568.9 583.2 597.4 611.6 625.8 640.1 654.3 668.5 682.7 696.9
50 711.2 725.4 739.6 753.8 768.1 782.3 796.5 810.7 825.0 839.2
60 853.4 867.6 881.8 896.1 910.3 924.5 938.7 953.0 967.2 981.4
70 995.6 1010 1024 1038 1053 1067 1081 1095 1109 1124
80 1138 1152 1166 1181 1195 1209 1223 1237 1252 1266
90 1280 1294 1309 1323 1337 1351 1365 1380 1394 1408
100 1422 1437 1451 1465 1479 1493 1508 1522 1536 1550
110 1565 1579 1593 1607 1621 1636 1650 1664 1678 1693
120 1707 1721 1735 1749 1764 1778 1792 1806 1821 1835
130 1849 1863 1877 1892 1906 1920 19324 1949 1963 1977
140 1991 2005 2034 2048 2062 2077 2091 2105 2119
150 2134 2148 2162 2176 2190 2205 2219 2233 2247 2262
160 2276 2290 2304 2318 2333 2347 2361 2375 2389 2404
170 2418 2432 2446 2460 2475 2489 2503 2518 2532 2546
180 2560 2574 2589 2603 2617 2631 2646 2660 2674 2688
190 2702 2717 2731 2745 2759 2773 2788 2802 2816 2830
200 2845 2859 2873 2887 2901 2916 2930 2944 2958 2973
210 2987 3001 3015 3030 3044 3058 3072 3086 3101 3115
220 3129 3143 3158 3172 3186 3200 3214 3229 3243 3257
230 3271 3286 3300 3314 3328 3343 3357 3371 3385 3399
240 3414 3428 3442 3456 3470 3485 3499 3513 3527 3542
00-24
12
Temperature
Fahrenheit Centigrade Conversion; a simple way to convert a Fahrenheit temperature reading into a Centigrade temperature
reading or vise versa is to enter the accompanying table in the center or boldface column of figures. These figures refer to the
temperature in either Fahrenheit or Centigrade degrees. If it is desired to convert from Fahrenheit to Centigrade degrees,
consider the center column as a table of Fahrenheit temperatures and read the corresponding Centigrade temperature in the
column at the left. If it is desired to convert from Centigrade to Fahrenheit degrees, consider the center column as a table of
Centigrade values, and read the corresponding Fahrenheit temperature on the right.
°C °F °C °F °C °F °C °F
-40.4 -40 -40.0 -11.7 11 51.8 7.8 46 114.8 27.2 81 117.8
-37.2 .35 -31.0 -11.1 12 53.6 8.3 47 116.6 27.8 82 179.6
-34.4 -30 -22.0 -10.6 13 55.4 8.9 48 118.4 28.3 83 181.4
-31.7 -25 -13.0 -10.0 14 57.2 9.4 49 120.2 28.9 84 183.2
-28.9 -20 -4.0 -9.4 15 59.0 10.0 50 122.0 29.4 85 185.0
-28.3 -19 -2.2 -8.9 16 60.8 10.6 51 123.8 30.0 86 186.8

-27.8 -18 -0.4 -8.3 17 62.6 11.1 52 125.6 30.6 87 188.6
-27.2 -17 1.4 -7.8 18 64.4 11.7 53 127.4 31.1 88 190.4
-26.7 -16 3.2 -7.2 19 66.2 12.2 54 129.2 31.7 89 192.2
-26.1 -15 5.0 -6.7 20 68.0 12.8 55 131.0 32.2 90 194.0
-25.6 -14 6.8 -6.1 21 69.8 13.3 56 132.8 32.8 91 195.8

-25.0 -13 8.6 -5.6 22 71.6 13.9 57 134.6 33.3 92 197.6
-24.4 -12 10.4 -5.0 23 73.4 14.4 58 136.4 33.9 93 199.4
-23.9 -11 12.2 -4.4 24 75.2 15.0 59 138.2 34.4 94 201.2
-23.3 -10 14.0 -3.9 25 77.0 15.6 60 140.0 35.0 95 203.0
-22.8 -9 15.8 -3.3 26 78.8 16.1 61 141.8 35.6 96 204.8

-22.2 -8 17.6 -2.8 27 80.6 16.7 62 143.6 36.1 97 206.6
-21.7 -7 19.4 -2.2 28 82.4 17.2 63 145.4 36.7 98 208.4
-21.1 -6 21.2 -1.7 29 84.2 17.8 64 147.2 37.2 99 210.2
-20.6 -5 23.0 -1.1 30 86.0 18.3 65 149.0 37.8 100 212.0
-20.0 -4 24.8 -0.6 31 87.8 18.9 66 150.8 40.6 105 221.0

-19.4 -3 26.6 0 32 89.6 19.4 67 152.6 43.3 110 230.0
-18.9 -2 28.4 0.6 33 91.4 20.0 68 154.4 46.1 115 239.0
-18.3 -1 30.2 1.1 34 93.2 20.6 69 156.2 48.9 120 248.0
-17.8 0 32.0 1.7 35 95.0 21.1 70 158.0 51.7 125 257.0
-17.2 1 33.8 2.2 36 96.8 21.7 71 159.8 54.4 130 266.0

-16.7 2 35.6 2.8 37 98.6 22.2 72 161.6 57.2 135 275.0
-16.1 3 37.4 3.3 38 100.4 22.8 73 163.4 60.0 140 284.0
-15.6 4 39.2 3.9 39 102.2 23.3 74 165.2 62.7 145 293.0
-15.0 5 41.0 4.4 40 104.0 23.9 75 167.0 65.6 150 302.0
-14.4 6 42.8 5.0 41 105.8 24.4 76 168.8 68.3 155 311.0

-13.9 7 44.6 5.6 42 107.6 25.0 77 170.6 71.1 160 320.0
-13.3 8 46.4 6.1 43 109.4 25.6 78 172.4 73.9 165 329.0
-12.8 9 48.2 6.7 44 111.2 26.1 79 174.2 76.7 170 338.0
-12.2 10 50.0 7.2 45 113.0 26.7 80 176.0 79.4 175 347.0
00-25
FOREWORD COATING MATERIALS
12
COATING MATERIALS 00
H The recommended coating materials prescribed in the shop manuals are listed below.
Category Code Part No. Quantity Container Main applications, features
l Used to prevent rubber gaskets, rubber cushions
LT-1A 790-129-9030 150 g Tube
and cork plugs from coming out
l Used in places requiring an immediately
effective, strong adhesive.
20 g Polyethylene
LT-1B 790-129-9050 l Used for plastics (except polyethylene,
(2 pes.) container
polypropylene, tetrafluoroethylene, and vinyl
chloride), rubber, metal and non-metal.
l Features: Resistance to heat, chemicals
Polyethylene
LT-2 09940-00030 50 g l Used for anti-loosening and sealant
container
purposes for bolts and plugs.
Adhesive:
790-129-9060
1 kg
(Set of adhesive l Used as adhesive or sealant for metal, glass or
LT-3 Hardening Can
and hardening plastic.
agent:
agent)
Adhesives
500 g
Polyethylene
LT-4 790-129-9040 250 g l Used as sealant for machined holes.
container
Holtz l Used as heat-resisting sealant for repairing
790-126-9120 75 g Tube
MH 705 engine.
l Quick hardening type adhesive.
Three bond Polyethylene l Cure time: within 5 sec. to 3 min.
179-129-9140 2g
1735 container l Used mainly for adhesion of metals, rubbers,
plastics and woods.
l Quick hardening type adhesive.
Aron-alpha Polyethylene l Quick cure type (max. strength after 30 minutes).
790-129-9130 50 g
201 container l Used mainly for adhesion of rubbers, plastics
and metals.
l Features: Resistance to heat, chemicals
Loctite Polyethylene
79A-129-9110 50 cc l Used at joint portions subject to high tempera-
648-50 container
ture.
l Used as adhesive or sealant for gaskets and
LG-1 790-129-9010 200 g Tube
packing of power train case, etc.
Gasket sealant
l Features: Resistance to heat

l Used as sealant for flange surfaces and bolts at
high temperature locations; used to prevent
LG-3 790-129-9070 1 kg Can seizure.
l Used as sealant for heat resistant gasket for at
high temperature locations such as engine
pre-combustion chamber, exhaust pipe.
00-26
Category Code Part No. Quantity Container Main applications, features

l Features: Resistance to water, oil
l Used as sealant for flange surface, thread.
l Also possible to use as sealant for flanges with
LG-4 790-129-9020 200 g Tube
large clearance.
l Used as sealant for mating surfaces of final drive
case, transmission case.
l Used as sealant for various threads, pipe joints,
Polyethylene con- flanges.
Gasket sealant
LG-5 790-129-9080 1 kg
tainer l Used as sealant for tapered plugs, elbows,
nipples of hydraulic piping.
l Features: Silicon based, resistant to heat, cold.
LG-6 09940-00011 250 g Tube l Used as sealant for flange surface, thread.
l Used as sealant for oil pan, final drive case, etc.
l Features: Silicon based, quick hardening type.
LG-7 09920-00150 150 g Tube l Used as sealant for flywheel housing, intake
manifold, oil pan, thermostat housing, etc.
Three bond l Used as heat-resisting sealant for repairing
790-129-9090 100 g Tube
1211 engines.
l Used as lubricant for sliding parts (to prevent
LM-G 09940-00051 60 g Can
Molybdenum
squeaking).
disulphide
lubricant
l Used to prevent seizure or scuffing of the thread

LM-P 09940-00040 200 g Tube when press fitting or shrink fitting.
l Used as lubricant for linkage, bearings, etc.
SYG2-400LI
SYG2-350LI
G2-LI SYG2-400LI-A Various Various l General purpose type
SYG2-160LI
SYGA160CNLI
SYG2-400CA
SYG2-350CA
l Used for normal temperature, light load bearing
Grease
G2-CA SYG2-400CA-A Various Various

at places in contact with water or steam.
SYG2-160CA
SYG2-160CNCA
disulphide lubricant
Molybdenum
400 g (10 per

SYG2-400M Belows type l Used for places with heavy load.
case)
00-27
12
MEMORANDUM
00-28
01 GENERAL
SPECIFICATION DRAWING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 01-2

D51EX, PX-22 POWER ANGLE, POWER TILT DOZER WITH ROPS CAB . . . . . . . . . . . . . . . . . . . . . . 01-2
SPECIFICATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 01-3
WEIGHT TABLE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 01-7
TABLE OF FUEL, COOLANT AND LUBRICANTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 01-10
RECOMMENDED PRODUCTS OTHER THAN KOMATSU GENUINE OILS . . . . . . . . . . . . . . . . . . . . 01-12
D51EX/PX-22 01-1
GENERAL SPECIFICATION DRAWING
12
SPECIFICATION DRAWING
D51EX, PX-22 POWER ANGLE, POWER TILT DOZER WITH ROPS CAB
D51EX-22 D51PX-22
Item Unit 510 mm 710 mm 720 mm
Single shoe Single shoe Swamp shoe
12,600
Machine weight kg 13,100 13,000
(12,695)
Engine model --- Komatsu SAA6D107E-1 diesel engine
Engine rated horsepower kW {HP} /rpm 97 {130} / 2,200
A Overall length mm 4,800 4,820
B Overall height (not including antenna) 2,997 3,015

mm
(to tip of antenna pipe) 3,177 3,195
3,045
C Overall width mm 3,350
(3,350)
FORWARD km/h 3.4/5.6/9.0
Travel speed (1st/2nd/3rd)
(Quick shift mode) REVERSE km/h 4.1/6.5/9.0
(1st/2nd/3rd)
Travel speed FORWARD km/h 0 - 9.0

(Variable shift mode) REVERSE km/h 0 - 9.0
Values in (_) are for the machines equipped with wide blade.
01-2 d D51EX/PX-22
GENERAL SPECIFICATION
12
SPECIFICATION
D51EX-22 D51PX-22
Machine model 510 mm 710 mm 720 mm
Serial No. B10001 and up
Operating weight
l Bare tractor with ROPS cab 11,100 11,500 11,400
12,600 13,100 13,000
Weight
l With power angle tilt dozer + ROPS cab

kg (12,695)
l With power angle totalizer + ROPS canopy 12,240 12,740 12,640

(12,335)
Min. turning radius (bare tractor,counter-rotation) m 2.4 2.6 2.6
Gradeability deg 30 30 30
Stability (front, rear, left, right) deg 35 35 35
Quick shift mode
Forward (1st/2nd/3rd) km/h 3.4/5.6/9.0 3.4/5.6/9.0 3.4/5.6/9.0
Performance
Reverse (1st/2nd/3rd) 4.1/6.5/9.0 4.1/6.5/9.0 4.1/6.5/9.0

Travel
speed
Variable shift mode

Forward km/h 0 - 9.0 0 - 9.0 0 - 9.0
Reverse 0 - 9.0 0 - 9.0 0 - 9.0
Bare tractor with ROPS cab 38.9 28.9 28.3
(0.40) (0.30) (0.29)
pressure
Ground
With power angle tiltdozer + kPa 44.1 32.9 32.2

ROPS cab {kg/cm2} (0.45) (0.34) (0.33)
With power angle tiltdozer + 42.8 32.0 31.3
ROPS canopy (0.44) (0.43) (0.32)
Bare tractor 3,660 3,660 3,700
Overall
length
With power angle tiltdozer + mm 4,800 4,800 4,820

ROPS cab
With power angle tiltdozer + 4,800 4,800 4,820
ROPS canopy
Bare tractor 2,300 2,590 2,610
Overall
width
mm
Power angle tiltdozer 3,045 3,350 3,350
Dimensions
(3,350)
To tip of exhaust pipe 2,885 2,885 2,905
To top of operator's compartment with ROPS
Overall
height
cab/canopy mm
(not including antenna) 2,997 2,997 3,015
(including antenna) 3,177 3,177 3195
Track gauge 1,790 1,880 1,880
Length of track on ground 2,745 2,745 2,745
Width of track mm 510 710 720

(standard track shoe)
Min. ground clearance 385 385 455
D51EX/PX-22 01-3 d
12
D51EX-22 D51PX-22
--- SAA6D107E-1
Model --- 4-cycle, water-cooled, in-line vertical type, 6 cylinders,
Type direct injection, with turbocharger, air-cooled after cooler
No. of cylinders - bore x stroke mm 6-107x124
Piston displacement L {cc} 6.69 {6,690}
Rated horsepower kW {HP}/rpm 99 {133}

Performance
Engine
Max. torque Nm {kgm}/rpm 585.5 {59.7}

High idling rpm 2,270
Low idling rpm 850
Min. fuel consumption ratio g/kWh {g/HPh} 242 {181}
Starting motor --- 24 V, 5.5 kW
Alternator --- 24 V, 25 A
Battery (*1) --- 12 V, 140 Ah x 2
Radiator core type --- Aluminium bar plate 5.1/2
Type, number Variable displacement swash-plate piston type x 2
(main pump) --- Fix displacement gear type x 1
(charge pump)
HST pump
Discharge amount
(main pump) cm3/rev 95
Power train system
(charge pump) 55
Set pressure MPa
(main pump) {kg/cm2} 41.2 {420}
(charge pump) 3.6 {35}
Type, number --- Variable displacement angled piston type
HST motor
(with parking brake) x 2

Discharge amount cm3/rev 160
Planetary gear, 2-stage reduction type,

Final drive --- splash type lubrication
Suspension --- Semi-rigid, equalizer beam type
Carrier roller --- 2 on each side
Track roller --- 7 on each side
Undercarriage
Track shoe Width: 510 mm Width: 710 mm

l Assembly-type single grouser Q'ty on each side: Q'ty on each side: ---
44 pieces 44 pieces
Pitch: 175 mm Pitch: 175 mm
--- Width: 720 mm
l Assembly-type special swamp shoe --- --- Q'ty on each side:
44 pieces
Pitch: 175 mm
*1: The battery capacity (Ah) is the 5-hour rate valve.
01-4 D51EX/PX-22
12
D51EX-22 D51PX-22
control Hydraulic
Type, number --- Variable displacement swash-plate piston type x 1

pump
Discharge amount cm3/rev 45

Max. discharge pressure MPa {kg/cm2} 27.4 {280}
valve
Main
Type, number --- 4-spool valve x 1

Operating method --- Hydraulic pilot type
Type --- Double-acting piston type

Cylinder bore mm 90
cylinder
Outside diameter of piston rod mm 50

Lift
Work equipment hydraulic system
Piston stroke mm 425

Max. distance between pins mm 1,165
Min. distance between pins mm 740
Cylinder bore mm 
cylinder
Outside diameter of piston rod mm 

Tilt

Max. distance between pins mm 675
Cylinder bore mm 
cylinder

Angle
Outside diameter of piston rod mm

Max. distance between pins mm 1,265
Type --- Double-acting
piston type

cylinder
Cylinder bore mm
Ripper
Outside diameter of piston rod mm  --- ---

Max. distance between pins mm 994
Hydraulic tank --- Box type (externally mounted control valve type)
Hydraulic filter --- Tank return side
Oil cooler --- Air-cooled type (Aluminium bar-plate 5.1/2)
D51EX/PX-22 01-5
12
D51EX-22 D51PX-22
Type --- Hydraulic type angle tilt dozer
Blade support method --- Hydraulic cylinder type
Dimensions Performance
Max. lifting height (from ground) mm 1107 1107 1180

Work equipment
Max. lowering depth (from ground) mm 461 461 338

Max. tilt mm 459 (505) 505 505
Max. angle deg 28.5 28.5 28.5
Blade width mm 3045 (3350) 3350 3350

Blade height mm 1110 1110 1110
Blade cutting angle deg 57 57 59
Type Parallelogram
Beam length mm 700
Number of shanks 3
Ripper
Digging angle (at on the ground/at max. digging deg 53.5/53.5

Performance
depth)
Adjustment of digging depth Changeable for 2 level
Max. digging depth mm 430
Max. lift mm 375
Shank interval mm 700
01-6 d D51EX/PX-22
GENERAL WEIGHT TABLE
12
WEIGHT TABLE
H This Weight Table is for reference when handling components or when transporting the machine.
Unit: kg (lb)
Machine model D51EX-22 D51PX-22
Serial Number B10001 and up
Machine weight
with ROPS cab 12,600 (27,800) 13,100 (28,900)
with ROPS Canopy 12,240 (26,985) 12,740 (28,087)
Engine, damper assembly (not including water or oil) 585 (1,290) 585 (1,290)
l Engine assembly (including mount bracket, starter, alternator etc.) 548 (1,210) 548 (1,210)
l Damper assembly 37 (81.6) 37 (81.6)
Fan support bracket assembly (include fan, motor, guard and bracket) 67 (148) 67 (148)
Cooling core
l Radiator 36 (79.4) 36 (79.4)
l Oil cooler 25 (55.1) 25 (55.1)
l Charge air cooler 25 (55.1) 25 (55.1)
Fuel tank (not including fuel) 216 (476) 216 (476)
Hydraulic pump assembly (including fittings on pumps) 193 (425) 193 (425)
l HST pump 160 (353) 160 (353)
l Work equipment pump 26 (57.3) 26 (57.3)
Final drive assembly (including motor and sprockets) 496 (1,090) 496 (1,090)
l HST motor (each side) 180 (397) 180 (397)
l Final drive (each side) (including sprocket, bolts and nuts) 316 (697) 316 (697)
l Sprocket (each side) 5.6 (12.3) x9 5.6 (12.3) x9
Frame assembly (including plumbing mount brackets 1,498 (3,300) 1,498 (3,300)
l Main frame 1439 (3,170) 1439 (3,170)
l Underguard (inspection covers) 48 (106) 48 (106)
Track frame assembly (each side) 1473 (3,250) 1477 (3,260)

l Track frame (each side) (include guards and covers) 709 (1,560) 713 (1,570)
l Idler assembly (each side) 219 (483) 219 (483)
l Recoil spring assembly (each side) 221 (487) 221 (487)
l Track roller (each side)
39 (86) x 4, 44 (97) x 3 39 (86) x 4, 44 (97) x 3
18 (39.7) x 2 18 (39.7) x 2
l Carrier roller (each side)
Track shoe assembly

l Single grouser shoe (510 mm) 1,041 (2,300) x 2 ---
l Single grouser shoe (560 mm) 1,095 (2,410) x 2 ---
l Single grouser shoe (710 mm) --- 1,260 (2,780) x 2
l Swamp shoe (720 mm)
--- 1,065 (2,350) x 2
Hydraulic tank (not including hydraulic oil) (include washer tank) 173 (381) 173 (381)
Charge pump 15 (33.1) 15 (33.1)
Control valve
l 4-spool valve (including fittings and mount plate) 25 (55.1) 25 (55.1)
l 5-spool valve (with ripper) (include fittings and mount plate) 28 (61.7) ---
D51EX/PX-22 01-7
Unit: kg (lb)
Machine model D51EX-22 D51PX-22
Serial Number B10001 and up
Power angle tilt dozer assembly (include center ball, pitch link and pins) 1,415 (3,120) 1,513 (3,340)
l Blade 713 (1,570) 811 (1,790)
l Dozer frame 464 (1,020) 464 (1,020)
l Tilt cylinder assembly 37 (81.6) 37 (81.6)
l Angle cylinder assembly 32 (70.5) x 2 32 (70.5) x 2
Lift cylinder assembly 32 (70.5) x 2 32 (70.5) x 2
Ripper assembly (include ripper cylinder) 842 (1,860) ---
Ripper cylinder assembly 47 (104) ---
ROPS cab assembly (Include floor, seat, air conditioner) 1,176 ( (2,590) 1,176 ( (2,590)
ROPS canopy assembly (Include floor, seat) 814 (1,790) 814 (1,790)
Operator’s seat
l Standard seat 64 (141) 64 (141)
l Hi-back seat 67 (148) 67 (148)
74 (163) 74 (163)
l Air suspension seat
Rear mask assembly (include linkage) 78 (172) 78 (172)
Engine hood assembly (include doors, muffler, pre-cleaner, exhaust tubes) 252 (556) 252 (556)
Pivot shaft (each side) 150 (331) 162 (357)
Equalizer bar 89 (196) 93 (205)
01-8 D51EX/PX-22
12
MEMORANDUM
D51EX/PX-22 01-9
GENERAL TABLE OF FUEL, COOLANT AND LUBRICANTS
12
TABLE OF FUEL, COOLANT AND LUBRICANTS
Ambient Temperature Recommended
Fluid
Reservoir -22 -4 14 32 50 68 86 140 122 °F Komatsu
Type
-30 -20 -10 0 10 20 30 40 50 °C Fluids
Komatsu
SAE 0W30EOS and HTHS 3.5min. (Note 1) EOS0W30
Komatsu
SAE 5W40EOS and HTHS 3.5min. (Note 1) EOS5W40
Engine oil pan
Engine oil
Komatsu
SAE 10W30DH EO10W30DH
Komatsu
SAE 15W40DH EO15W40DH
SAE 30DH Komatsu EO30DH
Power
Final drive case train oil TO 30 (SEA30) TO30
(Note 2)
Idler Engine SAE 30 EO30DH

oil
Hydraulic
oil TOS5W30 (SEA5W30) TOS5W30
(synthetic
type oil)
Power
train TO 10 TO10
Hydraulic system oil
SAE10W30DH EO10W30DH
Engine SAE15W40DH EO15W40DH
oil
SAE10WDH EO10DH
Hyper GO-T (NLGI NO. 0) GO-T

white grease
(Note 4) G2-T (NLGI NO. 2) G2-T
Moly disul. LM-G (NLGI NO. 2) LM-G

grease
Grease
LM-G (NLGI NO. 2) GO-L1
Lithium LM-G (NLGI NO. 2) G2-L1
grease
LM-G (NLGI NO. 2) G2-L1-S
Bio grease G2-BT (NLGI NO.2) G2-BT
Engine Cooling Super

AF-NAC (Note 5) AF-NAC
system coolant
No.2-D ASTM N0. 2-D

Fuel tank Diesel fuel
No. 1-D ASTM No. 1-D
l API: American Petroleum Institute

l SAE: Society of Automotive Engineers
l ASTM: American Society of Testing and Material
01-10 D51EX/PX-22
Final drive case Cooling

Engine oil pan Hydraulic system Idler (each) Fuel tank
(each) system
Specified liter 23 4.4 123 0.21 270 35
capacity US gal 6.08 1.16 32.5 --- 71.3 9.25
Refill liter 20 4.0 63 0.21 --- ---
capacity US gal 5.28 1.06 16.64 --- --- ---
REMARK
Always use diesel oil for the fuel.
To ensure good fuel consumption characteristics and exhaust gas characteristics, the engine
mounted on this machine uses an electronically controlled high-pressure fuel injection device.
This device requires high precision parts and lubrication, so if low viscosity fuel with low
lubricating ability is used, the durability may drop markedly.
Note 1: SAE0W30EOS and SAE5W40EOS must be fully synthetic and HTHS (High-Temperature High-Shear Viscosity
150°C [302°F]) must be equal to or higher than 3.5 cP. Komatsu EOS0W30 and EOS5W40 are the most suitable oils.
If these oils are not available, contact your Komatsu Distributor.
Note 2: Power train oil has different properties from engine oil. Be sure to use the recommended oils.
Note 3: Hyper white grease (G2-TE) has a high performance.

When it is necessary to improve the lubricating ability of the grease in order to prevent squeaking of pins and
bushings, the use of G2-TE is recommended.
Note 4: Hyper white grease (G2-TE) is a high performance white grease.

When it is necessary to improve the lubricating ability of the grease in order to prevent squeaking of pins and
bushings, the use of G2-TE is recommended.
When it is desired to preserve the external appearance of the machine and prevent it from becoming to dirty due to
black grease.
Load Friction Heat Water Biodegrad

Type of grease Remarks
performance resistance resistance resistance ability
Hyper white grease e e e e R Non-black high load
Moly. disul. grease q e q q R Molybdenum grease
Lithium grease Q q q q R 
Biodegradable grease Q e q e Synthetic grease
e: Excellent q: Good Q: Normal R: Poor
Note. 5: Supercoolant (AF-NAC)
1) The coolant has the important function of preventing corrosion as well as preventing freezing.
Even in the areas where freezing is not an issue, the use of antifreeze coolant is essential.
Komatsu machines are supplied with Komatsu Supercoolant (AF-NAC). Komatsu Supercoolant (AF-NAC) has
excellent anticorrosion, antifreeze and cooling properties and can be used continuously for 2 years or 4000 hours.
Komatsu Supercoolant (AF-NAC) is strongly recommended wherever available.
2) For details of the ratio when diluting super coolant with water, see "CLEAN INSIDE OF COOLING SYSTEM (4-
26)" of your Operation and Maintenance Manual.
When the machine is shipped from the factory, it may be filled with coolant containing 30% or more Supercoolant
(AF-NAC). In this case, no adjustment is needed for temperatures down to -10°C (14°F). (never dilute with water)
3) To maintain the anticorrosion properties of Supercoolant (AF-NAC), always keep the density of Supercoolant
between 30% and 68%.
D51EX/PX-22 01-11
RECOMMENDED PRODUCTS OTHER THAN KOMATSU GENUINE OILS

When using commercially available oils other than Komatsu genuine oil, or when checking the latest specifications, refer to
the Komatsu web page or consult your Komatsu distributor.
01-12 D51EX/PX-22
10 STRUCTURE, FUNCTION AND
MAINTENANCE STANDARD
12
ENGINE AND COOLING SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-3
ENGINE RELATED PARTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-3
COOLING SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-5
COOLING FAN PUMP - SEE HYDRAULIC SYSTEM 2 (WORK EQUIPMENT AND FAN PUMP) . . . 10-8
COOLING FAN MOTOR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-9
OIL COOLER BYPASS VALVE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-15
CHARGE SAFETY VALVE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-18
POWER TRAIN . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-20
POWER TRAIN . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-20
POWER TRAIN SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-21
DAMPER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-22
FINAL DRIVE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-23
PATH OF POWER TRANSMISSION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-26
UNDER CARRIAGE AND FRAME . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-27
MAIN FRAME . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-27
TRACK FRAME AND RECOIL SPRING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-28
SUSPENSION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-30
IDLER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-33
TRACK ROLLER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-35
CARRIER ROLLER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-39
TRACK SHOE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-45
HYDRAULIC SYSTEM 1 (HST) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-50
HST HYDRAULIC EQUIPMENT ARRANGEMENT DIAGRAM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-50
HST PUMP . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-51
SAFETY-SUCTION VALVE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-59
TOWING VALVE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-62
HST MOTOR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-63
MOTOR CONTROL VALVE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-75
SOLENOID VALVE (3-SPOOL), EPC VALVE (2-SPOOL) AND TOWING VALVE . . . . . . . . . . . 10-75
SOLENOID VALVE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-77
EPC VALVE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-78
CHARGE PUMP . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-82
HYDRAULIC SYSTEM 2 (WORK EQUIPMENT) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-84
CLSS (CLOSED CENTER LOAD SENSING SYSTEM) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-84
UNLOAD VALVE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-88
PRESSURE COMPENSATION VALVE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-94
LS BYPASS VALVE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-95
WORK EQUIPMENT HYDRAULIC ARRANGEMENT DIAGRAM . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-96
WORK EQUIPMENT AND FAN PUMP . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-97
SERVO VALVE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-102
CONTROL VALVE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-104
QUICK DROP VALVE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-116
BLADE PPC VALVE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-118
RIPPER/WINCH PPC VALVE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-124
HYDRAULIC TANK, FILTER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-128
ACCUMULATOR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-129
WORK EQUIPMENT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-130
D51EX/PX-22 10-1 d
STRUCTURE, FUNCTION AND
MAINTENANCE STANDARD
WORK EQUIPMENT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-130
CUTTING EDGE AND END BIT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-135
RIPPER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-136
WORK EQUIPMENT CYLINDER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-137
LIFT CYLINDER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-137
TILT CYLINDER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-137
ANGLE CYLINDER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-138
RIPPER CYLINDER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-138
PISTON VALVE FOR ANGLE CYLINDER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-140
CAB AND ITS ATTACHMENTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-141
ROPS CAB . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-141
STEERING AND BRAKE CONTROL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-142
WORK EQUIPMENT CONTROL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-144
CAB DAMPER MOUNT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-146
AIR CONDITIONER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-147
AIR CONDITIONER AND FLOOR HEATER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-147
AIR CONDITIONER PIPING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-148
ELECTRICAL SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-149
MONITOR SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-149
ENGINE CONTROL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-151
ENGINE CONTROL SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-152
COOLING CONTROL SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-154
HST CONTROL SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-156
GEAR SHIFT CONTROL SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-157
GEAR SHIFTING BY OPERATOR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-157
SET TRAVEL SPEEDS CORRESPONDING TO GEAR SPEEDS . . . . . . . . . . . . . . . . . . . . . . . . . . 10-158
CHANGING TRAVEL SPEED ACCORDING TO CHANGE OF ENGINE SPEED . . . . . . . . . . . . 10-160
STRAIGHT TRAVEL CORRECTION CONTROL SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-161
PARKING BRAKE CONTROL SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-162
KOMTRAX SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-164
SYSTEM COMPONENTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-166
MONITOR PANEL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-166
ENGINE CONTROLLER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-170
HST CONTROLLER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-172
ELECTRIC LEVER (FOR TRAVEL) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-174
KOMTRAX TERMINAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-176
SENSORS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-177
BRAKE OIL PRESSURE SENSOR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-178
HYDRAULIC OIL TEMPERATURE SENSOR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-179
HST CIRCUIT OIL PRESSURE SENSOR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-180
AIR CLEANER CLOGGING SENSOR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-181
DECELERATOR PEDAL POTENTIOMETER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-182
BRAKE PEDAL POTENTIOMETER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-182
FUEL CONTROL DIAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-183
FUEL LEVEL SENSOR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-184
CHARGE FILTER CLOGGING SENSOR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-185
COOLANT TEMPERATURE SENSOR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-185
ENGINE OIL PRESSURE SWITCH . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-186
ENGINE ROTATION SENSOR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-186
BOOST PRESSURE AND TEMPERATURE SENSOR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-187
WIF SENSOR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-187
HST MOTOR SPEED SENSOR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-188
10-2 d D51EX/PX-22
MAINTENANCE STANDARD ENGINE AND COOLING SYSTEM
ENGINE AND COOLING SYSTEM
ENGINE RELATED PARTS
1. Rear engine mount 5. Belt tensioner 9. HST charge pump
2. Front engine mount 6. Alternator 10. Fuel pump
7. Air conditioner compressor

3. Vibration damper 11. Engine controller
(Idler pulley for canopy spec.)
4. Water pump 8. Turbocharger
D51EX/PX-22 10-3
12
Outline
1. Cooling cores and fan located at rear end of machine. Charged air and coolant water are directed to the rear of the machine
through pipes.
2. Compressor for air conditioner is located at the front of the engine and is driven by the alternator belt.
3. The air cleaner, pre-cleaner, muffler and exhaust pipe are located on or near the engine hood.
10-4 D51EX/PX-22
12
COOLING SYSTEM
13. Oil cooler bypass valve

1. Radiator 7. Coolant drain valve
assembly
2. Radiator cap 8. After cooler outlet port 14. Cooler fan motor
3. Oil cooler 9. Radiator inlet port hose 15. Air bleeder of engine block
4. After cooler 10. Reservoir tank 16. Water bypass line
5. Shroud 11. After cooler inlet port
6. Fan 12. Radiator outlet port hose
Item Unit Radiator Oil cooler After cooler
Aluminium brazed Aluminium brazed Aluminium brazed

Core type ---
bar-plate bar-plate bar-plate
Fin pitch mm/2p 5.08 5.08 5.08
Total heat dissipation area m2 (ft2) 27.9 (300) 18.6 (200) 14.0 (151)
kPa 110 °15 490 °50

Pressure valve cracking pressure kg/cm2 1.12 ± 0.15 5 ± 0.5 ---
(psi) (16 ± 2.18) (71.1 ± 16.7)
kPa 4.8 - 10.3

Vacuum valve cracking pressure kg/cm2 0.05 - 0.1 --- ---
(psi) (0.69 - 1.49)
D51EX/PX-22 10-5
12
10-6 D51EX/PX-22
12
1. Coolant inlet 7. Coolant flow to thermostat housing
2. Pump impeller 8. Coolant by-pass passage
3. Coolant flow past lubricating oil cooler 9. Coolant flow back to radiator
4. Coolant flow past cylinders 10. Bypass open
5. Coolant flow from cylinder block to cylinder head 11. Coolant bypass in cylinder head
6. Coolant flow between cylinders 12. Coolant flow to water pump inlet
During normal operating temperature.
1. The coolant flow thermostat opens and coolant flows through the return line to the radiator.
2. Coolant temperature deceases as coolant passes through radiator.
3. Coolant is returned to the pump inlet through the supply line.
During cold engine operating temperature.
1. The coolant flow thermostat is closed.
2. Coolant flows through coolant bypass in cylinder head back to water pump inlet.
D51EX/PX-22 10-7
12
COOLING FAN PUMP - SEE HYDRAULIC SYSTEM 2 (WORK EQUIPMENT
AND FAN PUMP)
10-8 D51EX/PX-22
12
COOLING FAN MOTOR
Type: LMF16
1. Torque . . . . . . . . . . . . . . . . . . . . . . . . . . . 59 - 74 Nm (43.5 - 54.5 lbf ft)

P: From fan pump
T: From cooler to tank
TC: To Tank
Specifications
Type . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . LMF16
Capacity. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16.0 cc/rev
Rated speed . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1,500 rpm
Rated flow rate . . . . . . . . . . . . . . . . . . . . . . . . . . . .24 L/min (6.3 gal/min)
Cracking pressure of check valve . . . . . . . . . . . . . . 0.13 kg/cm2 (1.84 psi)
D51EX/PX-22 10-9
12
1. Output shaft 7. End cover

2. Case 8. Center spring
3. Thrust plate 9. Check valve
4. Piston assembly 10. Pilot valve
5. Cylinder block 11. Spool
6. Valve plate
Unit: mm
No. Check item Criteria Remedy
Standard size Repair limit
Installation Installation
Free length × Installation
load Free length load
12 Spool return spring Outside diameter length
(N {kg}) (N {kg}) If damaged or
deformed, replace
58.8 N 47.1 N spring.
44.84 × 12 33 —
{6 kg} {4.8 kg}
3.04 N 2.45 N
13 Check valve spring 29.27 × 6.5 19.1 —
{0.31 kg} {0.25 kg}
14. Torque . . . . . . . . . . . . . . . . . . . . . . . . . . 9.8 - 12.7 Nm (7.2 - 9.3 lbf ft)
10-10 D51EX/PX-22
12
1. Hydraulic motor
Function
l This hydraulic motor is called a swash plate-type axial piston motor. It
converts the energy of the pressurized oil sent from the hydraulic
pump into rotary motion.
Principle of operation
l The oil sent from the hydraulic pump flows through valve plate (7)
into cylinder block (5).
l This oil can flow on only one side of the (Y – Y) line connecting the
top dead center of the stroke of piston (4).
l The oil sent to one side of cylinder block (5) presses piston (4) and
generates force (F1) [F1 = P × xD2/4].
l This force is applied to thrust plate (2). Since thrust plate (2) is fixed to
the angle of (a°) to the output shaft (1), the force is divided into com-
ponents (F2) and (F3).
l The radial component (F3) generates torque [T = F3 × ri] against the
(Y-Y) line connecting the top dead center and bottom dead center.
l The result of this torque [T = (F3 × ri)] rotates cylinder block (5)
through the piston.
l Since this cylinder block (5) is splined to the output shaft, the output
shaft revolves to transmit the torque.
D51EX/PX-22 10-11
12
2. Suction valve
Function
l 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.
l When the oil stops flowing in from inlet port (P), the suction valve sucks in the oil on the outlet side and supplies it to port
(MA) where there is not sufficient oil to prevent cavitation.
Operation
A. When starting
l If the pressurized oil from the pump is supplied to port (P)
and the pressure on (MA) side rises and starting torque is
generated in the motor, the motor starts revolution. The oil on
motor outlet (MB) side of the motor returns through port (T)
to the tank.
B. When stopping
l If the engine is stopped and the input revolution of the fan
pump lowers to 0 rpm, the pressurized oil from the pump is
not supplied to port (P) any more. As the pressurized oil is
not supplied to (MA) side of the motor, the motor speed
lowers gradually to stop.
l If the motor shaft is revolved by the force of inertia while the
oil flow in port (P) is reducing, the oil in port (T) on the outlet
side is sent by suction valve (1) to (MA) side to prevent
cavitation.
10-12 D51EX/PX-22
12
3. Operation of reversible valve
A. When the ON-OFF solenoid for the reversible valve is

de-energized
l If ON-OFF solenoid (1) for the reversible valve is
“de-energized“, the pressurized oil from the pump is blocked
by ON-OFF selector valve (2), and port (C) opens for the
tank circuit.
l Accordingly, reversible valve spool (3) is pushed by
reversible valve spring (4) to the right to open motor port
(MA) and then the pressurized oil flows in to revolve the
motor forward (clockwise).
B. When ON-OFF solenoid for reversible valve is energized

l If ON-OFF solenoid (1) for reversible valve is "energized",
ON-OFF selector valve (2) changes to let the pressurized oil
from the pump flow through port (C) into spool chamber (D).
l The pressurized oil in chamber (D) pushes reversible valve
spool (3) to the left against reversible valve spring (4). As a
result, motor port (MB) opens and pressurized oil flows in to
revolve the motor in reverse (counterclockwise).
D51EX/PX-22 10-13
12
MEMORANDUM
10-14 D51EX/PX-22
12
OIL COOLER BYPASS VALVE
H This valve consists of oil cooler bypass valve and charge safety valve
.
P1: From charge filter 1. Oil cooler bypass valve
P2: From fan motor 2. Charge safety valve
C1: To oil cooler inlet 3. Torque ........................ 147 - 186.3 Nm (108 - 137 lbf ft)
C2: From oil cooler outlet 4. Torque ........................ 49 - 59 Nm (36.0 - 43.5 lbf ft)
T: To hydraulic tank
Ts: To HST pump T1
D51EX/PX-22 10-15
12
Oil cooler bypass valve
1. Charge pump 4. Oil cooler bypass valve

2. HST pump 4A. Poppet
3. Charge safety valve 4B. Ring
4C. Plug
5. Oil cooler
10-16 D51EX/PX-22
12
Function
l The oil cooler bypass valve controls the maximum pressure in the oil cooler to protect the oil cooler.
Unit: mm
Installed Installed
Free length × Installed Free
load load Replace spring if damaged or
6 Cooler bypass valve spring Outside diameter length length
N {kg} N {kg} deformed
86.1 N 68.9 N
43.8 × 13.2 30.8 —
{8.78 kg} {7.0 kg}
D51EX/PX-22 10-17
12
CHARGE SAFETY VALVE
1. Charge pump 3C. Valve seat

2. HST pump 3D. Poppet
3. Charge safety valve 3E Spring
3A. Valve 3F. Adjustment screw
3B. Spring
10-18 D51EX/PX-22
12
Function
l The charge safety valve is installed to the oil cooler bypass valve and controls the maximum pressure in the charge circuit
to protect the charge circuit.
Operation
l Port (A) is connected to the charge circuit, port (B) to the drain circuit,
and port (C) to the tank drain circuit through the oil cooler. The oil
also fills chamber (D) through orifice (a) of valve (3A). Poppet (3D) is
fitted to valve seat (3C).
l When abnormal pressure is generated in the circuit or the shuttle valve

of the HST motor is in neutral, if the oil in port (A) and chamber (C)
rises to the pressure set with spring (3E), poppet (3D) is pushed to the
right and the oil in chamber (D) is relieved to port (B) and the oil
pressure in chamber (D) lowers.
l If the oil pressure in port (D) lowers, differential pressure is generated

between ports (A) and (D) by orifice (a) of valve (3A) and then valve
(3A) is pushed to the right by the oil pressure in port (A) and the oil in
port (A) is relieved. As a result, the pressure in the charge circuit does
not rise any more.
D51EX/PX-22 10-19
MAINTENANCE STANDARD POWER TRAIN
12
POWER TRAIN
POWER TRAIN
Outline
l The power generated by engine (1) has its torsional vibration reduced by damper (2), and is then transmitted to the input
shaft of the HST pump.
l HST pump (3) consists of swash plate type piston pumps for the left travel and right travel joined in tandem. The
hydraulic power passes from each pump through high-pressure hoses (4) and is transmitted to left and right HST motors
(5).
l HST pump (3) changes the discharge direction and discharge amount continuously in accordance with the movement of
the swash plate of each pump to match the movement of the steering, direction, and speed lever. This changes the
direction of rotation and speed of the left and right HST motors and controls the forward and reverse travel and turning of
the machine.
l The hydraulic power transmitted to HST motor (5) is output from the motor output shaft as mechanical power, and is
transmitted to final drive (6).
l Final drive (6) is a 2-stage planetary gear mechanism. It reduces the speed and rotates sprocket (7) to drive track shoe (8).
REMARK
HST is an abbreviation for Hydrostatic Transmission.
10-20 D51EX/PX-22
12
POWER TRAIN SYSTEM
1. Engine 6. HST motor
2. Damper 7. Final drive
3. HST pump 8. Sprocket
4. Charge pump 9. Track shoe
5. High pressure hose 10. Work equipment pump
D51EX/PX-22 10-21
12
DAMPER
Unit: mm
Distance between HST pump Standard size Repair limit

1. Adjust
mounting surface and tip of boss 82.5 ±0.5
Wear of inner teeth of coupling
2. Repair limit: 1.0 Replace
(resin)
Coupling
3.
4. Boss
5. HST pump input shaft
6. Cover
7. Flywheel
8. Torque . . . . . . . . . . . . . . . . . . . . . . . . 55.8 - 73.5 Nm (41.1 - 54.2 lbf ft)

9. Torque . . . . . . . . . . . . . . . . . . . . . . . . 44.1 - 53.9 Nm (32.5 - 39.7 lbf ft)
10. Torque . . . . . . . . . . . . . . . . . . . . . . . . . 98 - 123 Nm (72.2 - 90.7 lbf ft)
11. Torque . . . . . . . . . . . . . . . . . . . . . . 490 - 608 Nm (361.4 - 448.4 lbf ft)
Outline
l The damper reduces the torsional vibration caused by variations in the engine torque, and acts to protect the engine and
downstream drive system from the torsional vibration.
l The power from the engine is transmitted from flywheel (7) to coupling (3). Coupling (3) absorbs the torsional vibration
and transmits the power through boss (4) to the HST pump.
10-22 D51EX/PX-22
FINAL DRIVE
1. Oil level plug

2. Drain plug
Outline
l The final drive is a planetary gear, 2-stage reduction type. It provides splash lubrication when the gear rotates.
l It is also possible to remove or install the final drive as a single unit.
l A floating seal is installed to the rotating and sliding portion of the sprocket to prevent the entry of sand or soil from
outside and to prevent leakage of lubricating oil.
Specifications
Reduction ratio: . . . . . . – ((14 + 97) / 14) × ((20 + 97) / 20) + 1 = –45.382
D51EX/PX-22 10-23
12
3. No. 1 sun gear (No. of teeth: 14) 9. Floating seal

4. No. 2 sun gear (No. of teeth: 20) 10. HST motor
5. No. 1 planetary carrier 11. Hub
6. Cover 12. No. 2 planetary pinion (No. of teeth: 37)
7. Sprocket 13. Ring gear (No. of teeth: 97)
8. No. 2 planetary carrier 14. No. 1 planetary pinion (No. of teeth: 41)
10-24 D51EX/PX-22
12
Unit: mm
Backlash of No. 1 sun gear and No. Standard clearance Clearance limit
15
1 planetary pinion 0.13 – 0.35 1.00
Backlash of No. 1 planetary pinion
16 0.17 – 0.53 1.10
and ring gear
Backlash of No. 1 planetary carrier Replace
17 0.27 – 0.49 1.00
and No. 2 sun gear
Backlash of No. 2 sun gear and No.
18 0.14 – 0.38 1.00
2 planetary pinion
Backlash of No. 2 planetary pinion
19 0.17 – 0.53 1.10
and ring gear
20. Torque . . . . . . . . . . . . . . . . . . . . . . . . . 461 - 559 Nm (340 - 412 lbf ft)

21. Torque . . . . . . . . . . . . . . . . . . . . . . . 245 - 308.7 Nm (181 - 228 lbf ft)
22. Torque . . . . . . . . . . . . . . . . . . . . . . . 58.8 - 73.5 Nm (43.4 - 54.2 lbf ft)
23. Torque . . . . . . . . . . . . . . . . . . . . . . . 98 - 122.5 Nm (72.3 - 90.4 lbf ft)
24. Torque . . . . . . . . . . . . . . . . . . . . . . . 58.5 - 78.4 Nm (43.1 - 57.8 lbf ft)
D51EX/PX-22 10-25
12
PATH OF POWER TRANSMISSION
l The power from the HST motor goes from No. 1 sun gear (1) through No. 1 planetary pinion (2), is reduced and rotates in
the opposite direction from the rotation of the HST motor, and is then transmitted to ring gear (6).
l When this happens, No. 1 planetary pinion (2) forms one unit with No. 1 planetary carrier (3), and the power from No. 1
planetary carrier (3) is transmitted to No. 2 sun gear (4).
l The power transmitted to No. 2 sun gear (4) passes through No. 2 planetary pinion (5), has its speed reduced, and is
transmitted to ring gear (6).
l The rotating power undergoes two-stage reduction, is transmitted to ring gear (6), passes through hub (7), and is
transmitted to sprocket (8).
10-26 D51EX/PX-22
MAINTENANCE STANDARD UNDER CARRIAGE AND FRAME
12
UNDER CARRIAGE AND FRAME
MAIN FRAME
1. Engine mount
2. Frame assembly
3. Rear underguard
4. Middle underguard
5. Engine underguard
6. Oil drain guard
Outline
l A hull frame structure with the main frame, track frame, and underguard forming one unit is used.
D51EX/PX-22 10-27
12
TRACK FRAME AND RECOIL SPRING
H 1: Machines equipped with conventional type track shoe

H 2: Machines equipped with PLUS type track shoe
10-28 d D51EX/PX-22
1. Idler 9. Rod
2. Carrier roller 10.Recoil spring
3. Track frame 11. Wear ring
4. Sprocket teeth 12. U-packing
5. Track roller end guard 13. Nut
6. Track roller center guard (if equipped) 14. Lubricator
7. Track roller 15. Cylinder
8. Seal 16. Bushing
*3: Machines equipped with the PLUS type track shoe use special parts.
H If the standard type track shoe parts are used to the PLUS type track shoe, the life span of the track shoe will be shortened.
Accordingly, use only the special parts to the PLUS type track shoe.
Unit: mm
Check item Repair limit
17 Deformation of track frame 7(in length of 3,000) Repair
Bend, twist, opening of idler section 3(in length of 300)
5
Free length x Installed Installed Free Installed
18 Recoil spring O.D. length load length load
Replace
110.2 kN 99.2 kN
563 x 196 438 551
11,238 kg 10,114 kg
Standard Tolerance Standard Clearance

Clearance between piston size Shaft Hole clearance limit
19 Replace bushing
and bushing
-0.030 +0.262 0.097
65 1.0
-0.078 +0.067 0.340
Guideheight of track roller Standard size Repair limit Build-up welding

20 guard 20.3 11 or replace
- Quantity of grease 270cc(grease: G2-LI) ---
21. Torque . . . . . . . . . . . . . . . . . . . . . . 235 - 285 Nm (173.3 - 210.2 lbf ft)

22. Torque . . . . . . . . . . . . . . . . . . . . . . . 58.8 - 88.2 Nm (43.3 - 65.2 lbf ft)
23. Min. Torque . . . . . . . . . . . . . . . . . . . . . . . . . . . 147.1 Nm (108.4 lbf ft)
Outline
l Recoil spring (10) is used to adjust the track shoe tension by supplying grease through lubricator (14) or discharge
existing grease and moving rod (9) forward or in reverse. It also damps sudden shocks applied to idler (1)
Q'ty on each Flange type and arrangement

side
D51EX-22, D51PX-22 7 pcs. S, D, S, D, S, D, S
S: Single flange
D: Double flange
D51EX/PX-22 10-29 d
12
SUSPENSION
10-30 D51EX/PX-22
12
1. Equalizer bar 5. Bushing 9. Bushing (large)
2. Center pin 6. Seal 10. Plug (oil filler)
3. Side pin 7. Seal 11. Bushing (small)
4. Pivot shaft 8. Bushing 12. Cover
13. Seal
Outline
l The track frame moves the front part of the track frame up and down around pivot shaft (4) in its rear.
l Equalizer bar (1) rocks around center pin (2) and is connected to both track frames by side pin (3).
D51EX-22 D51PX-22
Displacement at center Upward 46.1 49.4
of equalizer bar side pin
(mm) Downward 46.1 49.4
D51EX/PX-22 10-31
12
Unit: mm

Clearance between pivot shaft size Shaft Hole clearance limit
14 and bushing (large)
-0.145 +0.063 0.145-
123 1.0
-0.208 0 0.271
Clearance between pivot shaft -0.120 +0.054 0.120- Replace
15 85 1.0 bushing
and bushing (small) -0.174 0 0.228
Clearance between center pin -0.100 +0.174 0.200-
16 0 0.5
and bushing -0.146 +0.100 0.320
Clearance between side pin and -0.100 +0.010 0.080-
17 50 0.5
bushing -0.146 -0.020 0.156
Press-fitting force of pivot shaft
18 48.0kN {4.9ton}
bushing (large)
Press-fitting force of pivot shaft
19 33.3kN {3.4ton}
bushing (small)
Quantity of oil in pivot shaft
- 4.0 L (enging oil: SAE30)
section
20. Torque . . . . . . . . . . . . . . . . . . . . 490 - 607.6 Nm (361.4 - 448.1 lbf ft)

21. Torque . . . . . . . . . . . . . . . . . . . . 245 - 308.4 Nm (180.7 - 227.4 lbf ft)
22. Torque . . . . . . . . . . . . . . . . . . . 2245 - 308.7 Nm (180.9 - 227.6 lbf ft)
10-32 D51EX/PX-22
12
IDLER
D51EX/PX-22 10-33 d
12
Unit: mm
No Check Item Criteria Remedy

1 Guide rib outer diameter
541 ---
2 Idler tread outer diameter 505 487

Build-up
3 Guide rib height 18 27 welding or
replace
4 Idler tread thickness 21 12
5 Tread section width 42 ---
6 Idler over width 167 ---

Clearance between shaft size Shaft Hole clearance limit
7
and bushing
-0.250 +0.074 0.250
54 ---
-0.280 -0 0.354 Replace
Clearance between shaft -0.250 +0.046 0.250

8 54 ---
and support -0.280 -0 0.326
9 Axial play of idler 0.26 ~ 0.66
Clearance between guide

10 2 6 Shim
plate and side plate adjustment or
plate
Clearance between guide
11 1 replacement
plate and side plate
Thickness of guide plate

12 2
shim pack

13 4 Adjust
shim pack

14 4
shim pack
15 Thickness of guide plate 9 6
16 Thickness of support plate 6 3
17 Thickness off support plate 6 3

Replace
18 Thickness off guide plate 6 3
19 Thickness off guide plate 6 3
20 Thickness of side plate 6 3
10-34 d D51EX/PX-22
12
TRACK ROLLER
D51EX/PX-22
For conventional type track shoe
Single flange type
Double flange type (If equipped)
D51EX/PX-22 10-35 d
12
Unit: mm
1 Outside diameter of flange (outside)
ø213 —
2 Outside diameter of flange (inside) ø205 —
3 Outside diameter of tread ø185 ø160
4 Thickness of tread ø42.5 30
Repair by
5 Width of flange (outside) 18 13 buildup weld-
6 Width of flange (inside) 15 10 ing or replace
Width of tread
7 42 —
(Single-flange type)
Width of tread
8 44.5 —
(Double-flange type)
9 Overall width 208 —
Tolerance Standard Clearance
Standard size
Clearance between shaft and Shaft Hole clearance limit
10
bushing –0.250 +0.074 0.250 –
ø54 —
–0.280 0 0.344
Replace
–0.250 –0.160 0.044 –
11 Clearance between shaft and collar ø53.7 —
–0.300 –0.206 0.140
Standard clearance Clearance limit
12 Axial play of roller
0.43 – 0.72 —
13. Torque . . . . . . . . . . . . . . . . . . . . . . . . . 245 - 309 Nm (181 - 227 lbf ft)
10-36 d D51EX/PX-22
12
D51EX/PX-22
For PLUS type track shoe
Single flange type
Unit: mm
ø219 —
Repair by
3 Thickness of tread ø42.5 30
buildup weld-
4 Width of flange (outside) 22 13 ing or replace
Width of tread
5 42 —
(Single-flange type)
Standard size
7
bushing –0.250 +0.074 0.250 –
ø54 —
–0.280 0 0.344
Replace
–0.250 –0.160 0.044 –
–0.300 –0.206 0.140
0.43 – 0.72 —
10. Torque . . . . . . . . . . . . . . . . . . . . . . . . . 245 - 309 Nm (181 - 227 lbf ft)
D51EX/PX-22 10-37 d
D51EX/PX-22
Double flange type (If equipped)
Unit: mm
ø213 —
2 Outside diameter of flange (inside) ø205 —
Repair by
4 Thickness of tread 42.5 30
buildup weld-
5 Width of flange (outside) 18 13 ing or replace
6 Width of flange (inside) 15 10
Width of tread
7 44.5 —
(Double-flange type)
Standard size
9
bushing –0.250 +0.074 0.250 –
ø54 —
–0.280 0 0.344
Replace
–0.250 –0.160 0.044 –
–0.300 –0.206 0.140
0.43 – 0.72 —
12. Torque . . . . . . . . . . . . . . . . . . . . . . . . . 245 - 309 Nm (181 - 227 lbf ft)
10-38 d D51EX/PX-22
CARRIER ROLLER
Unit: mm
1 Outside diameter of flange
ø170 —
2 Outside diameter of tread ø150 ø126 Rebuild or
3 Thickness of tread 20 8 replace
4 Width of tread 42 —
5 Width of flange 15 10
Standard size
6
support –0.100 +0.250 0.100 –
ø41 —
–0.200 0 0.450
Standard size Replace
Interference between shaft and seal Shaft Hole clearance limit
7
guard +0.170 +0.025 0.115 –
ø41.5 —
+0.140 0 0.170
8 Play in axial direction of shaft
0 – 0.50 —
9. Torque . . . . . . . . . . . . . . . . . . . . . . . . . . 245 - 309 Nm (181 - 227 lbf ft)
D51EX/PX-22 10-39 d
12
Unit: mm
1 Outside diameter of flange
ø185 —
2 Outside diameter of tread ø167 ø135 Rebuild or
3 Thickness of tread 28.5 12.5 replace
4 Width of tread 42 —
5 Width of flange 15 10
Standard size
6
support –0.100 +0.250 0.100 –
ø41 —
–0.200 0 0.450
Standard size Replace
Interference between shaft and seal Shaft Hole clearance limit
7
guard +0.170 +0.025 0.115 –
ø41.5 —
+0.140 0 0.170
8 Play in axial direction of shaft
0 – 0.50 —
9. Torque . . . . . . . . . . . . . . . . . . . . . . . . . . 245 - 309 Nm (181 - 227 lbf ft)
10-40 d D51EX/PX-22
SPROCKET
Unit: mm
1 Wear of tooth root Rebuild or
74 65
replace
2 Thickness of tooth root 22.7 13.7
D51EX/PX-22 10-41 d
12
Full-scale drawing of sprocket tooth profile
H Set the rule to the full-scale size, and then copy the whole drawing to an OHP sheet.
10-42 d D51EX/PX-22
12
Unit: mm
1 Wear of tooth root Rebuild or
74 65
replace
2 Thickness of tooth root 22.7 13.7
D51EX/PX-22 10-43 d
Full-scale drawing of sprocket tooth profile
H Set the rule to the full-scale size, and then copy the whole drawing to an OHP sheet.
10-44 d D51EX/PX-22
TRACK SHOE
D51EX/PX-22
Conventional type track shoe
*1. Single shoe

*2. Swamp shoe
H Port (P) is the link on the bushing fitting side.
D51EX/PX-22 10-45 d

1 Link pitch
175.3 178.3
Turning over Turn over or
Standard size
2 Outside diameter of bushing Light load Heavy load replace
63 52.8 55.4
3 Thickness of bushing 13.1 2.9 5.5
4 Height of link
106 95 Repair or
Thickness of link replace
5 32 21
(Bushing fitting part)
a. Tightening torque (Nm {kgm}) Retightening angle (deg.)
Shoe bolt Regular link 196 ± 20 {20 ± 2} 120 ± 10
6 (Single shoe) Retighten
(Swamp shoe) b. Tightening torque (Nm {kgm}) Retightening angle (deg.)
Master link 196 ± 20 {20 ± 2} 180 ± 10
Tolerance
Standard size Standard clearance
Interference between bushing and Shaft Hole
7
link +0.304 +0.074
ø59 0.190 – 0.304
+0.264 0
Adjust or
Interference between regular pin +0.372 +0.062
8 ø36.2 0.210 – 0.372 replace
and link +0.272 0
Standard clearance
9 Clearance of link mating face Each side Both sides
1.2 2.4
10-46 d D51EX/PX-22
12
PLUS type track shoe
H PLUS:Abbreviation for Parallel Link Undercarriage System
H Port (P) is the link on the bushing fitting side.
D51EX/PX-22 10-47 d
Unit: mm
1 Link pitch
175.3 178.5
Replace
2 Outside diameter of bushing 63 54
3 Thickness of bushing 12.1 7.6
4 Height of link
111 97 Reverse or
Thickness of link replace
5 34.3 20.3
(Bushing fitting part)
a. Tightening torque (Nm {kgm}) Retightening angle (deg.)
Shoe bolt Regular link 245 ± 29 {25 ± 3} 120 ± 10
6 (Single shoe) Retighten
(Swamp shoe) b. Tightening torque (Nm {kgm}) Retightening angle (deg.)
Master link 294 ± 29 {30 ± 3} 180 (0/-20)
Tolerance Standard interfer-
Standard size
Interference between regular pin Shaft Hole ence
7
and link +0.372 +0.062
ø36 0.250 – 0.372 Adjust or
+0.312 0
replace
Standard clearance
8 Clearance of link mating face Each side Both sides
1.2 2.4
10-48 d D51EX/PX-22
Single shoe
D51EX/PX-22
Unit: mm
1 Height of grouser Rebuild or
55 25
replace
2 Thickness of grouser 67 37
D51PX-22
Swap shoe
Unit: mm
1 Height of grouser Rebuild or
83 70
replace
2 Thickness of grouser 20 7
D51EX/PX-22 10-49 d
MAINTENANCE STANDARD HYDRAULIC SYSTEM 1 (HST)
12
HYDRAULIC SYSTEM 1 (HST)
HST HYDRAULIC EQUIPMENT ARRANGEMENT DIAGRAM

H HST: Abbreviation for Hydrostatic Transmission
1. HST pump 4. L.H. HST motor
2. R.H. HST motor 5. Motor control solenoid valve
3. HST charge filter 6. Charge pump
10-50 d D51EX/PX-22
12
HST PUMP
H HST: Abbreviation for HydroStatic Transmission
Type: HPV95 + 95
D51EX/PX-22 10-51 d
Outline
This pump consists of a variable displacement swash plate tandem piston pump, servo valve, EPC valve and safety-suction
valve.
A1: . . . . . . . . . . . . . Max. displacement adjustment screw (Forward L.H.)

A2: . . . . . . . . . . . . . Max. displacement adjustment screw (Forward R.H.)
B1: . . . . . . . . . . . . . . Max. displacement adjustment screw (Reverse L.H.)
B2: . . . . . . . . . . . . . .Max. displacement adjustment screw (Reverse R.H.)
CPA: . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Charge pressure input port
CSA1: . . . . . . . . . . . . Pressure pickup port (Forward L.H. EPC pressure)
CSA2: . . . . . . . . . . . . Pressure pickup port (Forward R.H. EPC pressure)
CSB1: . . . . . . . . . . . . .Pressure pickup port (Reverse L.H. EPC pressure)
CSB2: . . . . . . . . . . . . .Pressure pickup port (Reverse R.H. EPC pressure)
ESA1: . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Pilot current (Forward L.H.)
ESA2: . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Pilot current (Forward R.H.)
ESB1: . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Pilot current (Reverse L.H.)
ESB2: . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Pilot current (Reverse R.H.)
PA1: . . . . . . . . . . . . . . . . . . . . . . . . . .Pump discharge port (Forward L.H.)
PA2: . . . . . . . . . . . . . . . . . . . . . . . . . Pump discharge port (Forward R.H.)
PB1:. . . . . . . . . . . . . . . . . . . . . . . . . . Pump discharge port (Reverse L.H.)
PB2:. . . . . . . . . . . . . . . . . . . . . . . . . . Pump discharge port (Reverse R.H.)
PH1:. . . . . . . . . . . . . Pressure pickup port (L.H. pump high pressure side)
PH2:. . . . . . . . . . . . . Pressure pickup port (R.H. pump high pressure side)
RP1:. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Towing valve
T3: . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Drain port
T4: . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Oil cooler return port
TS1: . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Drain port
TS2: . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Drain port
1. EPC valve
2. Piston pump
3. Servo valve
4. Safety-suction valve
5. Torque . . . . . . . . . . . . . . . . . . . . . . . . 19.6 - 27.4 Nm (14.4 - 20.2 lbf ft)

6. Torque . . . . . . . . . . . . . . . . . . . . . . . . . . . 27 - 34 Nm (19.9 - 25.0 lbf ft)
7. Torque . . . . . . . . . . . . . . . . . . . . . . . . . 49 - 58.8 Nm (36.1 - 43.3 lbf ft)
8. Torque . . . . . . . . . . . . . . . . . . . . . . . . . . 98 - 123 Nm (72.2 - 90.7 lbf ft)
10-52 d D51EX/PX-22
12
1. Front shaft 7. Cylinder block 13. Piston
2. Cradle bearing 8. Valve plate 14. Spline
3. Rocker cam 9. End cap 15. Shoe
4. Front case 10. Rear case 16. Bearing
5. Servo piston 11. Rear Shaft
6. Slider 12. Bearing
D51EX/PX-22 10-53 d
12
Outline
l The rotation and torque transmitted to the pump shaft is converted into hydraulic energy, and pressurized oil is discharged
according to the load.
l It is possible to change the delivery by changing the swash plate angle (normal  0  reverse discharge).
Structure
l Cylinder block (7) is supported to front shaft (1) by spline (15). Front shaft (1) is supported by front and rear bearings (12)
and (16).
l The tip of piston (13) is a concave ball, and shoe (14) is caulked to it to form one unit. Piston (13) and shoe (14) form a
spherical bearing.
l Rocker cam (3) has flat surface (A), and shoe (14) is always pressed against this surface while sliding in a circular
movement. Rocker cam (3) positions cradle bearing (2) between front case (4) and cylindrical surface (B), and rocks.
l Piston (13) carries out relative movement in the axial direction inside each cylinder chamber of cylinder block (7).
l Cylinder block (7) seals the pressure oil to valve plate (8) and carries out relative rotation. This surface is designed so that
the oil pressure balance is maintained at a suitable level. The oil inside each cylinder chamber of cylinder block (7) is
sucked in and discharged through valve plate (8).
10-54 d D51EX/PX-22
12
Operation
1. Operation of pump
l Cylinder block (7) rotates together with shaft (1), and shoe (5)
slides on flat surface (A).
l When this happens, rocker cam (4) moves along cylindrical
surface (B), so angle (a) between center line (X) of rocker cam (4)
and the axial direction of cylinder block (7) changes.
l (a) is named the swash plate angle.
l With center line (X) of rocker cam (4) at a swash plate angle (a) in
relation to the axial direction of cylinder block (7), flat surface
(A) acts as a cam in relation to shoe (5).
l In this way, piston (6) slides on the inside of cylinder block (7), so
a difference between volumes (E) and (F) is created inside
cylinder block (7).
l A single piston suctions and discharges the oil by the amount
(F) – (E).
l As cylinder block (7) rotates and the volume of chamber (E)
becomes smaller, the pressurized oil is discharged.
l On the other hand, the volume of chamber (F) grows larger and,
in this process, the oil is suctioned.
l 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.
l 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)
D51EX/PX-22 10-55 d
12
2. Control of delivery
l If swash plate angle (a) becomes larger, the difference between
volumes (E) and (F) becomes larger and delivery (Q) increases.
Swash plate angle (a) is changed by servo piston (5).
l Servo spool (7) moves according to the command of the EPC
valve. Servo piston (5) is reciprocated by the command pressure
output from servo spool (7).
l This straight line movement is transmitted through slider (6) to
rocker cam (4). Rocker cam (4), which is supported by the
cylindrical surface to cradle bearing (3), then rocks on the
cylindrical surface.
l For the pump, swash plate angle (a) is a maximum of ± 16°.
10-56 d D51EX/PX-22
12
3. Operation of servo valve
D51EX/PX-22 10-57 d
12
A. When lever is operated
i. Operation of servo spool

l The command current from the pump controller flows in the EPC valve solenoids (ESA and ESB).
l This command current works on the EPC valve to output signal pressure. The signal pressure is applied
through port (SA) (SB) to chamber (sa) (sb) and used to change the pressing force on servo spool (1).
l The servo spool (1) stops at a point where the pressing force on servo spool (1) is balanced with the force of
spring (3).
l The strength of the command current is decided by the software of the controller on the basis of the stroke
of the steering lever, pump pressure, etc.
ii. Operation of servo piston

l If servo spool (1) moves to the left, port (CP) is connected to port (A) and pressure is applied to chamber
(a). At the same time, port (B) is connected to port (T) and the oil in chamber (b) is drained. As a result,
servo piston (2) moves to the left.
l If servo piston (2) moves to the left and port (CP) is disconnected from port (A), servo piston (2) stops.
l In short, servo spool (1) and servo piston (2) move by the same distance.
l Similarly, if servo spool (1) moves to the right, port (CP) is connected to port (B) and pressure is applied to
chamber (b). At the same time, port (A) is connected to port (T) and the oil in chamber (a) is drained. As a
result, servo piston (2) moves to the right until port (CP) is disconnected from port (B).
B. When lever is in neutral

l If oil does not flow from the EPC valve, servo spool (1) does not move. Servo piston (2) is kept at the neutral
position by the force of spring (4) and the main pump is kept in neutral.
10-58 d D51EX/PX-22
SAFETY-SUCTION VALVE
1. Charge pump 2C. Sleeve
2. Safety-suction valve 2D. Spring
2A. Valve 2E. Spring
2B. Rod 2F. Plug
3. Torque . . . . . . . . . . . . . . . . . . . . . . . . 147 - 186.2 Nm (108 - 137 lbf ft)
D51EX/PX-22 10-59 d
12
1. When it is high-pressure relief valve
Function
It restricts the maximum pressure inside the HST circuit to protect the
circuit.
Operation
(valve at piston pump discharge side)

l Port (A) is connected to the pump circuit and port (B) is connected to
the charge circuit. The pressure oil passes through drill hole (a) in
piston (2A) and also fills port (C).
l The oil at high-pressure port (A) passes through passage groove (b) in
the body and also fills port (D).
l Poppet (2A) is in tight contact with valve seat (2C).
l If abnormal pressure is generated in the circuit and the oil pressure at
ports (A) and (D) reaches the pressure set by spring (2D), poppet (2A)
is pushed to the right, and the oil at port (A) is relieved to port (B), so
the oil pressure at port (A) goes down.
2. When it is safety-suction valve
Function
l This ensures the oil flow in the HST closed circuit. It prevents the
charge oil flow from flowing to the pump high-pressure side
(discharge side).
Operation
A. When HST pump delivery is 0

l The HST closed circuit is sealed, so the charge pressure oil
does not flow into the HST circuit.
10-60 d D51EX/PX-22
12
B. When HST pump delivery is being discharged from port (PA)
i. Valve at piston pump discharge side

l If pressure oil is being discharged from port (PA) of
HST pump (3), port (PA) becomes the high-pressure
side.
l This pressure oil at port (PA) passes through passage (b)
in the body and flows into port (D).
l When this happens, sleeve (2C) is pushed fully to the
left because of the relationship of the difference in area
[(A1)>(A2)].
l Therefore, the pressure oil from charge pump (1) is
prevented from flowing in.
3. Valve at piston pump suction side
Operation
l Port (PB) becomes the suction side, so it is at low-pressure. Sleeve

(2C) is pushed to the right by the charge pressure oil from the
relationship of the difference in area [(A1)<(A2)], and the seat of
sleeve (2C) opens.
l As a result, the charge pressure oil at port (B) passes through this gap,
flows to port (PB), and carries out the charge action in the HST circuit.
D51EX/PX-22 10-61 d
12
TOWING VALVE
1. Torque . . . . . . . . . . . . . . . . . . . . . . . . 24.5 - 34.3 Nm (18.0 - 25.2 lbf ft)
Function
l These valves are built into the top surface of the pump. There are two valves: the F valve (for the left track) and the R
valve (for the right track).
l If there is a failure on the machine, it is possible to tow the machine by connecting the HST circuit.
l However, it is necessary to cancel the shaft brake of the motor at the same time.
Operation
l To actuate the towing valves, loosen the two valves a maximum of 4.5 mm (3 turns).
10-62 d D51EX/PX-22
12
HST MOTOR
l HST: Abbreviation for HydroStatic Transmission
Type: KMV160
1. Left HST motor

Direction of rotation (as seen facing drive shaft)
Flows in from (MA): Counterclockwise rotation
Flows in from (MB): Clockwise rotation
H Sections C-C and E-E of the illustration are shown in "Shuttle valve".
D51EX/PX-22 10-63 d
12
1. Drive shaft MA: (High pressure when traveling in reverse) Discharge port
2. Variable bent axis piston motor (L.H.) MB: (High pressure when traveling forward) Discharge port
3. Speed sensor PB: Parking brake cancel signal port
4. Charge relief valve P: Displacement control signal pressure port
T: Drain
5. Torque . . . . . . . . . . . . . . . . . . . . . . . . . . 157 - 196 Nm (116 - 144 lbf ft)

6. Torque . . . . . . . . . . . . . . . . . . . . . . . . . . . . 98 - 123 Nm (72 - 90.7 lbf ft
7. Torque . . . . . . . . . . . . . . . . . . . . . . . . 78.5 - 76.0 Nm (57.9 - 76.0 lbf ft)
8. Torque . . . . . . . . . . . . . . . . . . . . . . . . 34.3 - 44.1 Nm (25.3 - 32.5 lbf ft)
9. Torque . . . . . . . . . . . . . . . . . . . . . . . . . . . 27 - 34 Nm (19.9 - 25.1 lbf ft)
10. Torque . . . . . . . . . . . . . . . . . . . . . . . . . 343 - 427 Nm (253 - 315 lbf ft)
11. Torque . . . . . . . . . . . . . . . . . . . . . . . . . . 49 - 59 Nm (36.1 - 43.5 lbf ft)
12. Torque . . . . . . . . . . . . . . . . . . . . . . . . . 147 - 186 Nm (108 - 137 lbf ft)
13. Torque . . . . . . . . . . . . . . . . . . . . . . . 19.6 - 27.5 Nm (14.5 - 20.3 lbf ft)
10-64 d D51EX/PX-22
12
2. Right HST motor
Direction of rotation (as seen facing drive shaft)
Flows in from (MA): Clockwise rotation
Flows in from (MB): Counterclockwise rotation
H Sections C-C and E-E of the illustration are shown in "Shuttle valve".
D51EX/PX-22 10-65 d
12
1. Drive shaft MA: (High pressure when traveling in reverse) Discharge port
2. Variable bent axis piston motor (R.H.) MB: (High pressure when traveling forward) Discharge port
3. Speed sensor PB: Parking brake cancel signal port
4. Charge relief valve P: Displacement control signal pressure port
T: Drain
5. Torque . . . . . . . . . . . . . . . . . . . . . . . . . . 157 - 196 Nm (116 - 144 lbf ft)

6. Torque . . . . . . . . . . . . . . . . . . . . . . . . . . . 98 - 123 Nm (72 - 90.7 lbf ft)
7. Torque . . . . . . . . . . . . . . . . . . . . . . . . 78.5 - 76.0 Nm (57.9 - 76.0 lbf ft)
8. Torque . . . . . . . . . . . . . . . . . . . . . . . . 34.3 - 44.1 Nm (25.3 - 32.5 lbf ft)
9. Torque . . . . . . . . . . . . . . . . . . . . . . . . . . . 27 - 34 Nm (19.9 - 25.1 lbf ft)
10. Torque . . . . . . . . . . . . . . . . . . . . . . . . . 343 - 427 Nm (253 - 315 lbf ft)
11. Torque . . . . . . . . . . . . . . . . . . . . . . . . . . 49 - 59 Nm (36.1 - 43.5 lbf ft)
12. Torque . . . . . . . . . . . . . . . . . . . . . . . . . 147 - 186 Nm (108 - 137 lbf ft)
13. Torque . . . . . . . . . . . . . . . . . . . . . . . 19.6 - 27.5 Nm (14.5 - 20.3 lbf ft)
10-66 d D51EX/PX-22
12
3. Operation of piston motor
Principle
l Let us assume that the shaft of a disc is supported to allow the disc to
rotate freely. If force (F) is applied to this disc at an angle, this force
(F) can be divided into force (F1) applied at a right angle to the face of
the disc and force (F2) applied in the direction of the circumference of
the disc. Force (F1) pushes the disc in the axial direction, and force
(F2) rotates the disc in a clockwise direction.
l If force (F') is applied to the disc instead of force (F), the force can be
divided in the same way into forces (F'1) and (F'2), and force (F'2) will
rotate the disc in a counterclockwise direction.
Structure
l Seven pistons (2) are installed with a spherical connection to the disc
portion of output shaft (1). Pistons (2) are at a certain angle to drive
shaft (1) and are fitted inside cylinder block (3).
l The angle of cylinder block (3) and piston (2) is determined by the
displacement control signal pressure to port (P). The relationship
between the signal pressure and displacement is shown in the
following figure.
Operation
l The oil sent under pressure from the main piston pump enters from the
piston motor inlet port. Oil pressure is formed at the rear face of piston
(2), and drive shaft (1) is rotated by angle (Q) of piston (2) and the
cylinder block.
D51EX/PX-22 10-67 d
12
4. Change of displacement of continuous variable displacement motor
1. Chamber (A) (Self pressure) 4. Displacement selector valve spool

2. Displacement control spring 5. Chamber (C) (Displacement control signal pressure)
3. Main piston 6. Chamber (B) (Drain)
Function
l When the main piston is at the bottom, the motor displacement

becomes maximum.
l When the main piston is at the top, the motor displacement becomes
minimum.
l When the main piston is between the top and bottom, the motor
displacement is determined by the displacement control signal
pressure.
Operation
l The servo mechanism section has chambers (A), (B) and (C).
l The self-pressures on the chamber (A) side and chamber (C) side are
applied to their respective pressure receiving areas and the main piston is operated by the load balance on those areas.
l When the EPC pressure is 0 kg/cm2, the main piston is on the maximum side.
l If some EPC pressure is supplied, it is supplied to chamber (C) to push out the displacement selector valve spool. The
displacement selector valve spool supplies the self-pressure to chamber (C) according to the balance between the load
generated by the pressure supplied by the EPC and the load received from the displacement control spring until the set
displacement is obtained.
10-68 d D51EX/PX-22
12
1. Variable shaft piston motor

2. Angled main piston
3. Shuttle valve
4. Charge relief valve
5. Displacement selector valve
6. Parking brake
7. Speed sensor
8. Tank
Specifications
Type: . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . KMV160
Type: . . . . . . . . . . . . . .Variable displacement, bent axis type piston pump
Charge relief valve set pressure: . . . . . . . . . 25 - 26 kg/cm2 (355 - 370 psi)
Parking brake release pressure: . . . . . . . . . .11 – 18 kg/cm2 (157 - 257 psi)
Theoretical capacity: . . . . . . . . . . . . . . . . . . . . . . . . . . . . .70 - 160 cm3/rev
D51EX/PX-22 10-69 d
12
5. Shuttle valve
H For sections C-C and E-E of the illustration, see the general view.
1. Check valve
2. Shuttle valve
3. Main piston
Function
l The pressure at the high-pressure side is selected at HST main pressures (MA) and (MB), and is supplied to main piston
(3).
l A shuttle valve is provided to select the pressure from the low-pressure side and supply it to the charge relief valve.
Operation
l The higher one of pressures (MA) and (MB) is supplied to chamber (A) of the main piston by 2 check valves (1).
l In section E-E, when (MA) > (MB), the shuttle valve leans to the right and (MB) is selected as the low-pressure side and
supplied to the charge relief valve.
l When (MB) > (MA), the shuttle valve leans to the left and (MA) is selected as the low-pressure side and supplied to the
charge relief valve.
10-70 d D51EX/PX-22
12
6. Charge relief valve
1. Valve 4. Poppet
2. Spring 5. Spring
3. Valve seat 6. Adjustment screw
Function
l The charge relief valve is installed inside the motor end cover. It prevents the pressure at the HST main low-pressure side
(charge pressure) selected by the shuttle valve from going above the set pressure. At the same time, it relieves the
determined oil flow inside the motor case and prevents the motor from overheating.
l In addition, it discharges the dirtiest oil inside the HST main circuit to the outside and acts to keep the inside of the HST
main circuit clean.
Operation
l Port (A) connects the pressure at the HST main low-pressure side
(charge circuit) selected by the shuttle valve.
l In addition, ports (B) and (D) are connected to the tank drain circuit
through the HST motor case.
l The pressure oil passes through orifice (g) in valve (1) and fills
chamber (C). Poppet (4) is fitted tightly to valve seat (5).
D51EX/PX-22 10-71 d
12
l If abnormal pressure is generated inside the circuit, and the oil
pressure in port (A) and chamber (C) rises to the pressure set by spring
(5), poppet (4) is pushed to the right, and the oil in chamber (C) is
relieved to port (D), so the oil pressure in chamber (C) goes down.
l When the oil pressure in chamber (C) goes down, a difference in

pressure between ports (A) and (C) is generated by orifice (g) of valve
(1).
l Valve (1) is pushed to the right by the oil pressure at port (A), and the
oil at port (A) is relieved to port (B).
l As a result, the pressure in the charge circuit is prevented from rising
any further.
10-72 d D51EX/PX-22
12
7. Actuation of parking brake
A. When parking brake valve is de-energized

l If the parking brake valve is de-energized, the pressure oil of
the control pump is shut off and port (B) is connected to the
tank.
l As a result, brake piston (2) is pushed down by brake spring
(1), disc (3) and plate (4) are pushed together, and the brake
is applied.
B. When parking brake valve is energized

l If the parking brake valve is energized, the valve is switched,
the pressure oil from the control pump enters port (B), and
flows into brake chamber (A).
l The oil entering chamber (A) overcomes brake spring (1) and
pushes brake piston (2) up. As a result, disc (3) and plate (4)
separate, and the brake is released.
D51EX/PX-22 10-73 d
12
8. Speed sensor
1. Hall IC (with magnet) 6. Shrinkable tube

2. P.C.B 7. Wire protection hose
3. Housing 8. Rubber cap
4. Wire 9. Connector
5. O-ring
Function
l The speed sensor is installed to the end cover of the motor. It senses revolution pulses from the drive shaft spline in the
motor and transmits electric signals to the HST controller.
l This sensor is of Hall IC type. Unlike a common speed sensor of coil type, the specified gap and angle between this sensor
and spline are maintained.
10-74 d D51EX/PX-22
12
MOTOR CONTROL VALVE
SOLENOID VALVE (3-SPOOL), EPC VALVE (2-SPOOL) AND TOWING VALVE
D51EX/PX-22 10-75 d
P: From HST pump CPA
T: To hydraulic tank
A1: To work equipment PPC valve
A2: To accumulator
A3: To right HST motor P
A4: To left HST motor P
A5: Plug
A6: To right and left HST motor B
1. Work equipment lock solenoid valve Solenoid valve EPC valve
2. Right HST motor gear shift EPC valve 12. Nut 20. Block
3. Left HST motor gear shift EPC valve 13. Plunger 21. Body
4. Slow brake solenoid valve 14. Coil 22. Spool
5. Parking brake solenoid valve 15. Connector 23. Spring
6. Brake pressure sensor 16. Push pin 24. Rod
7. Towing valve 17. Spring 25. Coil
8. Oil pressure pickup plug 18. Spool 26. Plunger
9. Towing plate 19. Block 27. Connector
10. Towing plate fixing bolt
11. Block
Outline
l In block (11), 3 solenoid valves, 2 EPC valves, towing valve and brake
pressure sensor are installed.
l Parking brake solenoid valve (5) transmits a signal generated by the
potentiometer which operates when the brake pedal is pressed or a
signal of the limit switch connected to the parking brake lever through
the HST controller to drain the changeover oil and operate the parking
brakes built in the HST motors.
l Upon receiving a signal generated by the limit switch which operates
when the brake pedal is pressed fully or a signal from the limit switch
connected to the parking brake lever, slow brake solenoid valve (4)
drains the changeover oil slowly through the orifice in it to operate the
parking brakes built in the HST motors.
l Right HST motor gear shift EPC valve (2) and left HST motor gear shift EPC valve (3) transmit the shift switch signals of
the steering/directional/gear shift lever through the HST controller and output the oil pressure according to the signals to
change the HST motor capacity.
l Work equipment lock solenoid valve (1) is installed between HST pump CPA and control valve. If the work equipment
lock lever is set in the "Free" position, the work equipment lock solenoid is linked with the work equipment lock switch
and opens the work equipment control circuit, and then the work equipment can be operated.
l Towing valve (7) is installed between the parking brake solenoid valve and HST motor. When the parking brake cannot be
released because of an engine trouble, etc., the parking brake can be released by removing towing plate (9) and tightening
towing valve (7) to apply parking brake release pressure from outside.
H For the procedure of releasing the parking brake, see Testing and adjusting, Procedure for releasing parking brake.
10-76 d D51EX/PX-22
12
SOLENOID VALVE
P: From HST pump CPA 1. Nut 5. Push pin
T: To hydraulic tank 2. Plunger 6. Spring
C: To work equipment PPC valve 3. Coil 7. Spool
4. Connector 8. Block
Operation
When solenoid is de-energized
l The signal current does not flow from the controller, so coil (3) is
de-energized.
l For this reason, spool (7) is pushed fully to the left by spring (6).
l As a result, port (A) closes and the flow of pressurized oil from the
pump does not flow to actuator (9).
l At the same time, the oil from actuator (9) flows from port (B) to port
(C) and then, it is drained.
When solenoid is energized
l When the signal current flows to the solenoid valve, coil (3) is
energized, and propulsion force to the right is generated in plunger (2).
l For this reason, spool (7) is pushed to the right by push pin (5).
l As a result, the pressurized oil from the pump flows from port (A)
through port (B), and goes to actuator (9).
l At the same time, port (C) closes, so the oil is not drained.
D51EX/PX-22 10-77 d
12
EPC VALVE
1. Body 4. Coil C: To HST motor

2. Spool 5. Plunger P: From HST pump CPA
3. Push pin 6. Connector T: To hydraulic tank
10-78 d D51EX/PX-22
12
Unit: mm
Free length × Installed Installed Free Installed Replace EPC valve assembly
7 Return spring Outside diameter length load length load if there is damage or deforma-
3.14 N 2.55 N tion
9.0 8.4 —
{0.32 kg} {0.26 kg}
8. Torque . . . . . . . . . . . . . . . . . . . . . . . . . . . 9.8 - 12.7 Nm (7.3 - 9.3 lbf ft)

9. Torque . . . . . . . . . . . . . . . . . . . . . . . . . . 0.98 - 1.96 Nm (0.7 - 1.4 lbf ft)
10. Torque . . . . . . . . . . . . . . . . . . . . . . . . . 7.84 - 11.8 Nm (5.8 - 8.7 lbf ft)
Function
l The EPC valve consists of the proportional solenoid section and

hydraulic valve section.
l Upon receiving signal current (i) from the controller, the EPC valve
generates EPC output pressure in proportion to the signal current and
output it to the control valve.
D51EX/PX-22 10-79 d
12
Operation
1. When signal current is 0 (When coil is de-energized)

l While the signal current from the controller is not flowing in coil
(14), coil (14) is de-energized.
l Spool (11) is pushed by spring (12) to the right.
l Port (P) is closed and the oil from the self pressure reducing valve
does not flow in the control valve.
l The oil from the control valve is drained through ports (C) and (T)
to the tank.
2. When signal current is "small" (Coil is energized)

l If a small signal current flows in coil (5), coil (5) is energized and
a thrust to the left is generated in plunger (6).
l Rod (4) pushes spool (2) to the left and the oil from port (P) flows
in port (C).
l The pressure in port (C) rises and the total of the force applied to
face (a) of spool (2) and the load of spring (3) exceeds the thrust
of plunger (6).
l Spool (2) is pushed to the right and ports (P) and (C) are
disconnected from each other.
l Ports (C) and (T) are connected to each other.
l Spool (2) moves until the thrust of plunger (6) is balanced with
the total of the pressure in port (C) and the load of spring (3).
l The pressure in the circuit between the EPC valve and control
valve is controlled in proportion to the signal current.
10-80 d D51EX/PX-22
12
3. When signal current is maximum (When coil is energized)
l If the signal current flows in coil (5), coil (5) is energized.
l Since the signal current at this time is maximum, the thrust of
plunger (6) becomes maximum.
l Rod (4) presses spool (2) to the left.
l The maximum oil flows from port (P) to port (C) and the pressure
in the circuit between the EPC valve and control valve becomes
maximum.
l Since port (T) is closed, the oil does not flow to the tank.
D51EX/PX-22 10-81 d
12
CHARGE PUMP
1. Front cover 7. Rear cover 13. Square section O-ring
2. Stud 8. Drive gear 14. Center section
3. Nut 9. Inverted shaft seal 15. Driven gear
4. Lock washer 10. Snap ring 16. Plug
5. Seal gland and retainer 11. Inverted shaft seal
6. Wear Plate 12. Wear plate
10-82 I D51EX/PX-22
Outline
l The HST charge pump is attached to the engine flywheel housing and is driven by the pump drive assembly.
l The HST charge pump supplies pilot pressure oil to the low pressure side of the HST main circuit, charge safety valve,
motor control solenoid valve, and work equipment PPC valve.
l The charge pump sucks in the oil from the hydraulic tank.
Specifications
Type . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Gear pump
Theoretical discharge amount . . . . . . . . . . . . . . . . . . . . . . . . . . . 55 cc/rev
Operation
l The charge pump is connected to the drive assembly by coupling and rotates the drive gear. The drive gear then rotates the
driven gear.
D51EX/PX-22 10-83 d
MAINTENANCE STANDARD HYDRAULIC SYSTEM 2 (WORK EQUIPMENT)
12
HYDRAULIC SYSTEM 2 (WORK EQUIPMENT)
CLSS (CLOSED CENTER LOAD SENSING SYSTEM)

Outline of CLSS
Feature
CLSS stands for Closed center Load Sensing System, and has the following features.
l Fine control not influenced by load.
l Control enabling digging even with fine control.
l Ease of compound operation ensured by flow divider function using area of opening of spool during compound
operations.
l Energy saving using variable pump control.
Structure
l The CLSS consists of a variable capacity single piston pump, control valve, and actuator.
l The pump body consists of the main pump, PC valve and LS valve.
10-84 d D51EX/PX-22
12
Basic principle
1. Control of pump swash plate angle

l The pump swash plate angle (pump delivery) is controlled so that
LS differential pressure (PLS) [the difference between pump
discharge pressure (PP) and control valve outlet port LS pressure
(PLS) (load pressure of actuator)] is constant.
(LS pressure (PLS) = Pump discharge pressure (PP) – LS
pressure (PLS))
l If LS differential pressure (PLS) becomes lower than the set

pressure of the LS valve (when the actuator load pressure is high),
the pump swash plate moves towards the maximum position; if
the set pressure becomes higher than the set pressure of the LS
valve (when the actuator load pressure is low), the pump swash
plate moves towards the minimum position.
H For details of the operation, see "HST pump".
D51EX/PX-22 10-85 d
12
2. Pressure compensation control
l A pressure compensation valve is installed to the outlet port side of the control valve spool to balance the load.
When two actuators are operated together, this valve acts to make pressure difference (P) between the upstream
(inlet port) and downstream (outlet port) the same, regardless of the size of the load (pressure). In this way, the flow
of oil from the pump is divided (compensated) in proportion to the area of opening (S1) and (S2) of each valve when
it is operated.
10-86 d D51EX/PX-22
12
Hydraulic circuit diagram and the name of valves
1. Unload valve 7. Check valve

2. Safety valve (Set pressure: 310 kg/cm2 [4409 psi]) 8. Fan spool
3. Pressure compensation valve 9. Lift spool
4. Suction valve 10. Tilt spool
5. Main relief valve (Set pressure: 280 kg/cm2 [3982 psi]) 11. Angle spool
6. Fan relief valve (Set pressure: 230 kg/cm2 [3271 psi]) 12. Ripper spool
D51EX/PX-22 10-87 J
12
UNLOAD VALVE
1. When control valve is at neutral
PP : Pump circuit (pressure)

PLS : LS circuit (pressure)
T : Tank circuit (pressure)
1. Spool
2. Spring
Function
l When the control valve is at neutral, pump delivery (Q) discharged by the minimum swash plate angle is released to the
tank circuit. When this happens, pump discharge pressure (PP) is set at 22 kg/cm2 (312 psi) by spring (2) inside the valve:
[LS pressure (PLS): 0 kg/cm2 (0 psi)].
Operation
l Pump discharge pressure (PP) is acting on the left end of spool, and LS pressure (PLS) is acting on the right end.
l When the control valve is at neutral, LS pressure (PLS) is 0, so only pump discharge pressure (PP) has any effect, and
(PP) is set only by the load of spring (2).
l As pump discharge pressure (PP) rises, and reaches the load of spring (2) (22 kg/cm2 [312 psi]), spool (1) is moved to the
right in the direction of the arrow. Pump discharge pressure (PP) then passes through the notch (a) of spool (1) and is
connected to tank circuit (T).
l In this way, pump discharge pressure (PP) is set to 22 kg/cm2 [312 psi]
10-88 d D51EX/PX-22
12
2. When control valve is in fine control

1. Spool
2. Spring
Function
l When the control valve is in the fine control mode, if the demand flow for actuator is less than the value corresponding to
the minimum swash plate angle of the pump, pump pressure (PP) is set to LS pressure (PLS) + 22 kg/cm2 (312 psi). If the
differential pressure between pump pressure (PP) and LS pressure (PLS) becomes equal to the load of spring (2)
22 kg/cm2 (312 psi), the unload valve opens. Accordingly, LS differential pressure (PLS) is 22 kg/cm2 (312 psi) at this
time.
Operation
When fine control is carried out on the control valve, LS pressure (PLS) is generated and acts on the right end of spool (1).
l When this happens, the area of the opening of the control valve spool is small, so there is a big difference between LS
pressure (PLS) and pump discharge pressure (PP).
l When the differential pressure between pump discharge pressure (PP) and LS pressure (PLS) reaches the load of spring
(2) 22 kg/cm2 (312 psi), spool (1) moves to the right in the direction of the arrow, and pump circuit (PP) and tank circuit
(T) are connected.
l In other words, pump discharge pressure (PP) is set to a pressure equal to the spring force 35 kg/cm2 (497 psi) + LS
pressure (PLS), and LS differential pressure (PLS) becomes 22 kg/cm2 (312 psi).
D51EX/PX-22 10-89 d
12
3. When control valve is being operated (work equipment)

1. Spool
2. Spring
3. Actuator circuit
Function
l When the control valve is operated, if the demand flow for actuator exceeds the value corresponding to the minimum
swash plate angle of the pump, the outflow to tank circuit (T) is shut off and all of pump delivery (Q) is sent to the
actuator circuit.
Operation
l When the control valve is operated to a bigger stroke, LS pressure (PLS) is generated and acts on the right end of spool
(1). When this happens, the area of the opening of the control valve spool is large, so the difference between LS pressure
(PLS) and pump discharge pressure (PP) is small.
l For this reason, the differential pressure between pump discharge pressure (PP) and LS pressure (PLS) does not reach the
load of spring (2) 22 kg/cm2 (312 psi), so spool (1) is pushed to the left by spring (2).
l As a result, pump circuit (PP) and tank circuit (T) are shut off, and all the pump delivery (Q) flows to the actuator circuit
(3).
10-90 d D51EX/PX-22
12
Work equipment operated
1. When lift is operated to LOWER
l When the lift is operated to LOWER, spool (1) moves to the right from the HOLD position, and the oil from the
pump enters bridge circuit (C), passes through cylinder port (B), and enters the cylinder bottom.
l When this happens, the oil at the cylinder head passes through cylinder port (A) and is drained.
D51EX/PX-22 10-91 d
12
2. When lift is operated to FLOAT
l When the lift is operated to FLOAT, spool (1) moves further to the right. The oil from the pump does not enter bridge
circuit (C).
l The oil at cylinder port (B) is connected to the drain circuit through bridge circuit (C), opening (a), and cylinder port
(A).
10-92 d D51EX/PX-22
12
Introduction of LS pressure
For lift, tilt, angle, ripper valve
Function
l The LS pressure is the actuator load pressure at the outlet port end of the control valve.
l It actually reduces pump pressure (PP) at pressure reducing valve (3) of the pressure compensation valve to the same
pressure as actuation circuit pressure (A), and sends it to the LS circuit (PLS).
Operation
l When spool (1) is operated, pump discharge pressure (PP) flows from flow control valve (2) and notch (a) in spool (1)
through bridge passage (b) to actuator circuit (A).
l At the same time, pressure reducing valve (3) also moves to the right, so pump pressure (PP) has its pressure reduced by
the pressure loss at notch (C). It is introduced to LS circuit (PLS), and then goes to spring chamber (PLS1).
l When this happens, LS circuit (PLS) is connected to tank circuit (TS) from LS bypass plug (4). (See the section on the LS
bypass plug).
l Actuator circuit pressure (PA) [(=(A)] acts on the left end of pressure reducing valve (3); the reduced pump discharge
pressure (PP) acts on the other end.
l As a result, pressure reducing valve (3) is balanced at a position where actuator circuit pressure (PA) and the pressure of
spring chamber (PLS1) are the same. Pump discharge pressure (PP) is reduced at notch (C), becomes actuator circuit
pressure (A), and is taken to LS circuit (PLS).
D51EX/PX-22 10-93 d
12
PRESSURE COMPENSATION VALVE
Function
l During compound operations, if the load pressure becomes lower than the other actuator and the oil flow tries to increase,
compensation is received. [When this happens, the other actuator being used for compound operation (right side) is at a
higher load than the actuator on this side (left side).]
Operation
l If the load pressure of the other actuator (right side) becomes higher during compound operations, the oil flow in actuator
circuit (A) on this side (left side) tries to increase.
l If this happens, the LS pressure (PLS) of the other actuator acts on spring chamber (PLS1), and pressure reducing valve
(1) and flow control valve (2) are pushed to the left.
l Flow control valve (2) throttles the area of opening between pump circuit (PP) and spool upstream (PPA), and pressure
loss is generated between (PP) and (PPA).
l Flow control valve (2) and pressure reducing valve (1) are balanced in position where the difference in pressure between
(PLS) and (PA) acting on both ends of pressure reducing valve (2) and the pressure loss between (PP) and (PPA) on both
sides of flow control valve (2) are the same.
l In this way, the pressure difference between upstream pressure (PPA) and downstream pressure (PA) of both spools used
during compound operations is the same, so the pump flow is divided in proportion to the area of opening of notch (a) of
each spool.
10-94 d D51EX/PX-22
12
LS BYPASS VALVE

1. LS bypass valve
2. Valve cover
Function
l This releases the residual pressure of LS pressure (PLS).
l It makes the speed of the rise in pressure of LS pressure (PLS) more gentle. In addition, with this discarded throttled flow,
it creates a pressure loss in the throttled flow of the spool or shuttle valve, and increases the stability by lowering the effec-
tive LS differential pressure.
Operation
l The pressurized oil for LS circuit (PLS) passes from filter (a) of bypass plug (1) through orifice (b) and flows to the tank
circuit (T).
D51EX/PX-22 10-95 d
12
WORK EQUIPMENT HYDRAULIC ARRANGEMENT DIAGRAM
1. Title cylinder 5. Blade PPC Valve 9. Ripper cylinder (If equipped)
6. Ripper/Winch PPC valve (If

2. Angle cylinder 10. Control valve
equipped)
3. Oil cooler 7. Hydraulic tank 11. Accumulator
4. Lift cylinder 8. Oil filter 12. Work equipment and fan pump
10-96 d D51EX/PX-22
12
WORK EQUIPMENT AND FAN PUMP
Type: LPV45
P1: Pump discharge port 1. Pump unit

PS: Pump suction port 2. Servo valve
3. Air breather
4. Torque . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7.8 - 9.8 Nm (5.7 - 7.2 lbf ft)
5. Torque . . . . . . . . . . . . . . . . . . . . . . . . . . 8.7 - 10.8 Nm (8.7 - 10.8 lbf ft)
6. Torque . . . . . . . . . . . . . . . . . . . . . . . . 68.6 - 83.4 Nm (50.5 - 61.5 lbf ft)
D51EX/PX-22 10-97 d
12
1. Shaft 7. Cylinder block

2. Oil seal 8. Valve plate
3. Case 9. Spring
4. Rocker cam 10. Servo piston
5. Shoe 11. Ball
6. Piston
12. Torque . . . . . . . . . . . . . . . . . . . . . . . 58.8 - 78.4 Nm (43.3 - 57.8 lbf ft)
10-98 d D51EX/PX-22
12
Function
l The engine rotation and torque transmitted to the pump shaft is converted into hydraulic energy, and pressurized oil is
discharged according to the load.
l It is possible to change the delivery amount by changing the swash plate angle.
Structure
l Cylinder block (7) is supported to shaft (1) by spline (a), and shaft (1) is supported by the front and rear bearings.
l 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.
l Rocker cam (4) has flat surface (A). Shoe (5) is kept pressed against the flat surface (A) and it slides circularly on flat
surface (A). Rocker cam (4) slides around ball (11).
l Piston (6) carries out relative movement in the axial direction inside each cylinder chamber or cylinder block (7).
l Cylinder block (7) seals the pressure oil to valve plate (8) and carries out relative rotation. This surface is designed so that
the oil pressure balance is maintained at a suitable level. The oil inside each cylinder chamber of cylinder block (7) is
sucked in and discharged through valve plate (8).
l Hole number of cylinder block (7) is an odd number. So, it is suited to groove of valve plate (8).
D51EX/PX-22 10-99 d
12
Operations
l Shaft (1) and cylinder block (7) rotate together and shoe (5) slides on
the flat surface (A). Since the rocker cam (4) leans around ball (11) at
this time, the angle (a) between the center line (X) of rocker cam (4)
and axis of cylinder block (7) changes. The angle (a) is called the
swash plate angle.
l When the center line (X) of the rocker cam (4) maintains the swash
plate angle (a) in relation to the axial direction of the cylinder block
(7), the flat surface (A) acts as a cam for the shoe (5).
l By this, the piston (6) slides on the inside of the cylinder block (7),
creates a difference between capacities (E) and (F), then suction and
discharge of oil for the amount of this difference (F) – (E) will be
carried out.
l In other words, oil is discharged as the capacity of the chamber (E)
decreases when the cylinder block (7) rotates.
l In the mean time, the capacity of the chamber (F) increases, and the oil
is sucked at this process. (The figure shows the state of the pump when
suction of the chamber (F) and discharge of the chamber (E) have
completed.)
l When the center line (X) of the rocker cam (4) becomes in line with
the axial direction of the cylinder block (7) (swash plate angle = 0), the
difference between capacities of (E) and (F) inside the cylinder block
(7) becomes 0, so the pump does not carry out any suction or
discharge action of oil. (In actual fact, the swash plate angle never
becomes 0.)
l In other words, delivery of the pump is directly proportional to the
swash plate angle (a).
10-100 d D51EX/PX-22
l As the swash plate angle (a) becomes larger, difference between the
capacities (E) and (F) becomes larger, so the pump delivery (Q)
increases.
l The swash plate angle (a) is changed by the servo piston (10).
l Servo piston (10) is reciprocated straight by the signal pressure of the
PC and LS valves. This reciprocation is transferred to rocker cam (4).
Rocker cam (4) supported on ball (11) rocks around ball (11).
l The output pressure (PE) of the LS valve is applied to the pressure
chamber of servo piston (10).
l As output pressure (PE) rises, rocker cam (4) moves to reduce the
swash plate angle (a), so the pump delivery (Q) decreases.
D51EX/PX-22 10-101 d
12
SERVO VALVE
P1L : Pump pressure input port 1. Locknut

PE : Control pressure output port 2. Plug
PH : Pump pressure port 3. Spring
PLS : LS pressure input port 4. Spool
T : Drain port 5. Plug
6. Seat
7. Piston
8. Sleeve
9. Lever
10. Spool
11. PC valve
12. LS valve
13. Torque . . . . . . . . . . . . . . . . . . . . . . . 27.4 - 34.3 Nm (20.2 - 25.2 lbf ft)
10-102 d D51EX/PX-22
12
Function
1. LS valve
l The LS valve controls the discharge of the pump according to the
stroke of the control lever, or the demand flow for the actuator.
l The LS valve calculates the demand flow for the actuator from
differential pressure (PLS) between pump discharge pressure
(P1L) and control valve outlet pressure (PLS) and controls pump
delivery (Q).
l [(P1L) is called the pump discharge pressure, (PLS) called the LS
pressure, and (PLS) called the LS differential pressure.]
l That is, the pump discharge is controlled according to the demand
flow for the actuator by the following method; The pressure loss
made when the oil flows through the opening of the control valve
spool [LS differential pressure (PLS)] is sensed and pump
delivery (Q) is so controlled that the pressure loss will be
constant.
2. PC valve
l When pump discharge pressure (P1L) rises, the stroke of the
control valve spool is increased and the opening area is increased
and pump delivery (Q) is increased. At this time, the PC valve
limits pump delivery (Q) according to discharge pressure (P1L) so
that the pump absorption horsepower will not exceed the engine
horsepower. In other words, the PC valve performs approximate
constant-horsepower control.
l That is, if the load on the actuator is increased and pump
discharge pressure (P1L) rises during operation, the PC valve
reduces pump delivery (Q). If the pump discharge pressure
lowers, the PC valve increases pump delivery (Q).
l The relationship between pump discharge pressure (P1L) and
pump delivery (Q) is shown below.
D51EX/PX-22 10-103 d
12
CONTROL VALVE
General view
10-104 d D51EX/PX-22
12
Outline
l This external view diagram shows the ripper valve.
l The standard valve does not have the ripper section.
A1 : To fan pump
A2 : To lift cylinder head
A3 : To tilt cylinder head
A4 : To angle cylinder
A5 : To ripper cylinder bottom
B1 : To fan pump
B2 : To lift cylinder bottom
B3 : To tilt cylinder bottom
B4 : To angle cylinder
B5 : To ripper cylinder head
LS : To LS valve of hydraulic pump
P : From work equipment pump
PA2 : From lift raise PPC valve
PA3 : From tilt left PPC valve
PA4 : From angle right PPC valve
PA5 : From ripper lower PPC valve
PB1 : —
PB2 : From lift lower PPC valve
PB3 : From tilt right PPC valve
PB4 : From angle left PPC valve
PB5 : From ripper raise PPC valve
PEPC : From solenoid valve
PP : To LS valve of hydraulic pump
T : To tank
TS : To tank
1. Torque . . . . . . . . . . . . . . . . . . . . . . . . . . . 9.8 - 12.7 Nm (7.2 - 9.3 lbf ft)

2. Torque . . . . . . . . . . . . . . . . . . . . . . . . 29.4 - 34.3 Nm (21.6 - 25.2 lbf ft)
D51EX/PX-22 10-105 J
12
Sectional view (1/5)
10-106 d D51EX/PX-22
12
1. Fan relief valve

2. Suction valve (Lift bottom)
3. Suction valve (Angle)
4. Suction valve (Ripper bottom)
5. Safety valve
6. Suction valve (Ripper head)
7. Suction valve (Angle)
Unit: mm
Free length × Installation Installation Installation
Free length
8 Suction valve spring Outside diameter length load load If damaged or
2.65 N 2.16 N deformed,
36.3 × 4.45 33.3 —
{0.27 kg} {0.22 kg} replace spring.
5.1 N 4.12 N
9 Check valve spring 39.2 × 4.45 33.5 —
{0.52 kg} {0.42 kg}
10. Torque . . . . . . . . . . . . . . . . . . . . . . . . . 137 - 157 Nm (101 - 115 lbf ft)

11. Torque . . . . . . . . . . . . . . . . . . . . . . . 39.2 - 49.0 Nm (28.9 - 36.1 lbf ft)
D51EX/PX-22 10-107 d
12
(2/5)
10-108 d D51EX/PX-22
12
1. Spool (Fan)
2. Spool (Lift)
3. Spool (Tilt)
4. Spool (Angle)
5. Spool (Ripper)
Unit: mm
Free length
6 Spool return spring Outside diameter length load load
180 N 144 N
29 × 17.5 25 —
{18.4 kg} {14.7 kg}
50 N 40.0 N
7 Spool return spring 19.92 × 16.8 18.2 —
{5.1 kg} {4.08 kg}
39.2 N 31.4 N
{4 kg} {3.2 kg} If damaged or
55.9 N 44.7 N deformed,
9 Spool return spring 31.98 × 17.4 28.5 — replace spring.
{5.7 kg} {4.56 kg}
77.5 N 62.0 N
{7.9 kg} {6.32 kg}
75.4 N 60.0 N
{7.69 kg} {6.12 kg}
45.9 N 36.7 N
{4.68 kg} {3.74 kg}
189 N 151 N
{19.25 kg} {15.4 kg}
14. Torque . . . . . . . . . . . . . . . . . . . . . . . . . . 35 - 63 Nm (25.8 - 46.4 lbf ft)
D51EX/PX-22 10-109 d
12
(3/5)
10-110 d D51EX/PX-22
12
1. Unload valve 8. Pressure compensation valve R (Angle)
2. Pressure compensation valve F (Fan) 9. Pressure compensation valve R (Tilt)
3. Pressure compensation valve F (Lift) 10. Pressure compensation valve R (Lift)
4. Pressure compensation valve F (Tilt) 11. Pressure compensation valve R (Fan)
5. Pressure compensation valve F (Angle)
6. Pressure compensation valve F (Ripper) F: Flow control valve
7. Pressure compensation valve R (Ripper) R: Pressure reducing valve
Unit: mm
Free length × Installation Installation Installation If damaged or
Free length
12 Unload valve spring Outside diameter length load load deformed,
91.2 N 73.0 N replace spring.
28.64 × 18.6 18 —
{9.3 kg} {7.44 kg}
13. Torque . . . . . . . . . . . . . . . . . . . . . . . 14.7 - 19.6 Nm (10.8 - 14.4 lbf ft)

14. Torque . . . . . . . . . . . . . . . . . . . . 117.6 - 161.8 Nm (86.7 - 119.3 lbf ft)
D51EX/PX-22 10-111 d
12
(4/5)
10-112 d D51EX/PX-22
12
1. Unload valve 9. Pressure compensation valve R (Lift)
2. Main relief valve 10. Pressure compensation valve F (Lift)
3. Fan relief valve 11. Spool (Tilt)
4. Spool (Fan) 12. Pressure compensation valve R (Tilt)
5. Pressure compensation valve R (Fan) 13. Pressure compensation valve F (Tilt)
6. Pressure compensation valve F (Fan)
7. Suction valve (Lift) F: Flow control valve
8. Spool (Lift) R: Pressure reducing valve
14. Torque . . . . . . . . . . . . . . . . . . . . . . . 137 - 157 Nm (101.0-115.7 lbf ft)

15. Torque . . . . . . . . . . . . . . . . . . . . . . . 49.0 - 58.8 Nm (36.0 - 43.3 lbf ft)
16. Torque . . . . . . . . . . . . . . . . . . . . . . . 29.4 - 39.2 Nm (21.6 - 28.9 lbf ft)
D51EX/PX-22 10-113 d
12
(5/5)
10-114 d D51EX/PX-22
12
1. Suction valve 8. Spool (Ripper)
2. Suction valve 9. Pressure compensation valve R (Ripper)
3. Spool (Angle) 10. Pressure compensation valve F (Ripper)
4. Pressure compensation valve R (Angle) 11. Safety valve
5. Pressure compensation valve F (Angle) 12. Pressure bleed plug
6. Suction valve
7. Suction valve F: Flow control valve
R: Pressure reducing valve
Unit: mm
Free length × Installation Installation Installation If damaged or
Free length
13 Check valve spring Outside diameter length load load deformed,
1.98 N 1.57 N replace spring.
21.9 × 5 15.8 —
{0.2 kg} {0.16 kg}
14. Torque . . . . . . . . . . . . . . . . . . . . . . . 15.6 - 20.6 Nm (11.5 - 15.1 lbf ft)

15. Torque . . . . . . . . . . . . . . . . . . . . . . 137 - 157 Nm (101.0 - 115.7 lbf ft)
16. Torque . . . . . . . . . . . . . . . . . . . . . . . 19.6 - 24.5 Nm (14.4 - 18.0 lbf ft)
17. Torque . . . . . . . . . . . . . . . . . . . . 117.6 - 161.8 Nm (86.7 - 119.3 lbf ft)
D51EX/PX-22 10-115 d
12
QUICK DROP VALVE
CB1 : To right lift cylinder bottom 1. Plug

CB2 : To left lift cylinder bottom 2. Piston
CH1 : To right lift cylinder head 3. Retainer
CH2 : To left lift cylinder head 4. Valve
VB : From control valve blade "LOWER" 5. Body
VH : From control valve blade "RAISE" 6. Plug
7. Plug
10-116 d D51EX/PX-22
12
Unit: mm
Free length × Installation Installation Free Installation
8 Piston spring Outside diameter length load length load
25.5 N 20.4 N If damaged or
27.3 × 12 20 —
{2.6 kg} {2.08 kg} deformed, replace
46.1 N 36.9 N spring.
9 Valve spring 53.24 × 34.8 18 —
{4.7 kg} {3.76 kg}
52.5 N 42.0 N
10 Valve spring 26.35 × 23 25 —
{5.35 kg} {4.28 kg}
11. Torque . . . . . . . . . . . . . . . . . . . . . . . . . 98.122.5 Nm 72.2 - 90.3 lbf ft)

12. Torque . . . . . . . . . . . . . . . . . . . . . . . 15.7 - 20.6 Nm (11.5 - 15.1 lbf ft)
13. Torque . . . . . . . . . . . . . . . . . . . 578.2 - 725.2 Nm (426.4 - 534.8 lbf ft)
Outline
l The quick drop valve is installed between the control valve and lift cylinder. When the control lever is operated to
"LOWER" the blade, this device prevents a vacuum in the cylinder bottom and shortens the time lag in starting digging.
l The blade lowering speed is almost decided by the pump discharge. It can be heightened, however, by installing the quick
drop valve.
Operation
Start of lowering blade
l If the blade control lever is set in the "LOWER" position, the oil from
the control valve flows in port (VB), and then flows through ports
(CB1) and (CB2) to the cylinder bottom side and pushes the piston to
the left.
l The oil on the cylinder head side is pushed out by the piston, and then
it enters ports (CH1) and (CH2) and flows through port (VH) and
control valve to the hydraulic tank.
While lowering blade

l The oil pushed out of the 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 a pressure difference is made between before and
behind the orifice.
l If the oil pressure in ports (CH1) and (CH2) becomes higher than the
tension of springs (1) and (2), valve (3) and piston (4) move to the
right.
l Since ports (VB), (CH1), and (CH2) are opened, a part of the oil
flowing from ports (CH1) and (CH2) to port (VH) merges with the oil
from the control valve and then flows to the cylinder bottom side.
l Accordingly, the blade lowering speed is increased by the quantity of
the oil flowing into the cylinder bottom side and a vacuum on the
bottom side is prevented.
D51EX/PX-22 10-117 d
12
BLADE PPC VALVE
H PPC: Abbreviation for Proportional Pressure Control
For blade lift, tilt, angle
10-118 J D51EX/PX-22
P : From control pump 1. Spool

P1 : To blade tilt valve (LEFT tilt) 2. Metering spring
P2 : To blade tilt valve (RIGHT tilt) 3. Centering spring
P3 : To blade lift valve (RAISE) 4. Piston
P4 : To blade lift valve (LOWER) 5. Disc
P5 : To blade angle valve (RIGHT angle) 6. Cap (for connecting lever)
P6 : To blade angle valve (LEFT angle) 7. Joint
T : To hydraulic tank 8. Plate
9. Retainer
10. Body
11. Torque . . . . . . . . . . . . . . . . . . . . . . . . . . 39 - 49 Nm (28.7 - 36.1 lbf ft)

12. Torque . . . . . . . . . . . . . . . . . . . . . . . . . 98 - 127 Nm (72.2 - 93.6 lbf ft)
13. Torque . . . . . . . . . . . . . . . . . . . . . . . . 11.8 - 14.7 Nm (8.7 - 10.8 lbf ft)
D51EX/PX-22 10-119 d
12
Operation
1. At neutral
A. For blade lift

l Ports (PA) and (PB) of the blade lift 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).
B. For blade tilt

l Ports (PA) and (PB) of the blade tilt control valve and ports
(P1) and (P2) of the PPC valve are connected to drain
10-120 d D51EX/PX-22
12
C. For blade angle
l Ports (PA) and (PB) of the blade angle control valve and
ports (P5) and (P6) of the PPC valve are connected to drain
2. During fine control (Neutral  fine control)

l When piston (4) is pushed by disc (5), retainer (9) is pushed, and
spool (1) is also pushed through metering spring (2), and moves
down.
l As a result, if fine control hole (f) is shut off from drain chamber
(D), at almost the same time, it is connected with pump pressure
chamber (PP), and the pilot pressure oil from the control pump
passes through fine control hole (f) and flows from port (P4) to
port (PB).
l When the pressure at port (P4) becomes high, if spool (1) is
pushed back and fine control hole (f) is shut off from pump
pressure chamber (PP), at almost the same time, it is connected
with drain chamber (D) and releases the pressure at port (P4).
l As a result, spool (1) moves up and down so that the force of
metering spring (2) is balanced with the pressure at port (P4). 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).
l Therefore, metering spring (2) is compressed an amount
proportional to the movement of the control lever, so the pressure
at port (P4) also rises in proportion to the movement of the control
lever.
l The control valve spool moves to a position where the pressure in
chamber (PB) [same as pressure at port (P4)] is balanced with the force of the return spring.
D51EX/PX-22 10-121 d
12
3. During fine control
(when control lever is returned)
l When disc (5) starts to be returned, spool (1) is pushed up by the
pressure at port (P4) and the force of centering spring (3).
l As a result, fine control hole (f) is connected to drain chamber
(D), so the pressure oil at port (P4) is relieved.
l If the pressure at port (P4) goes down too far, spool (1) is pushed
down by metering spring (2). Fine control hole (f) is shut off from
drain chamber (D), and at almost the same time, it is connected to
pump pressure chamber (PP). Pump pressure is supplied until the
pressure at port (P4) recovers to a pressure equivalent to the
position of the lever.
l When the control valve spool returns, the oil at drain chamber (D)
flows in from fine control hole (f') in the valve on the side that is
not moving. It passes through port (P3), is taken to chamber (PA),
and the oil fills the chamber.
4. When lever is operated fully

l 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).
l Therefore, the pilot pressure oil from the control pump passes
through fine control hole (f), is taken from port (P4) to chamber
(PB), and pushes the control valve spool.
l The return oil from chamber (PA) passes from port (P3) through
fine control hole (f'), and then flows to drain chamber (D).
10-122 d D51EX/PX-22
12
5. When blade is operated to FLOAT
l When piston (4) at the port (P4) LOWER side is pushed by disc
(5) and moves down, ball (11) contacts protrusion (a) of the piston
during the stroke. (Detente starts to act.)
l When piston (4) pushed in further, ball (11) pushes up collar (12),
which is being held by detente spring (13). While pushing up col-
lar (12), it escapes to the outside and passes over protrusion (a) of
the piston.
l When this happens, piston (4') on the opposite side is pushed up
by spring (14).
l As a result, the oil inside chamber (F) passes through (b) and (c),
and flows to chamber (E), and piston (4') follows disc (5). Passage
(d) is connected to port (P4), so more or less the same pressure is
applied as is applied to port (P4).
l 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.
l At the same time, the control valve also moves to the FLOAT
position and the circuit is set to the FLOAT condition.
l 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.
6. When blade is released from FLOAT

l When disc (5) is returned from the FLOAT position, it is pushed down by a force greater than the hydraulic force in
chamber (E).
l As a result, chamber (E) is shut off from passage (d) and is connected to the drain chamber. Therefore, the oil
pressure inside chamber (E) is lost, and the FLOAT position is canceled.
D51EX/PX-22 10-123 d
12
RIPPER/WINCH PPC VALVE
(If equipped)
10-124 d D51EX/PX-22
12
P : From charge pump 1. Spool
P1 : To ripper valve 2. Piston
P2 : To ripper valve 3. Lever
T : To tank 4. Plate
5. Retainer
6. Body
7. Filter
Unit: mm
Free length
8 Centering spring Outside diameter length load load If damaged or
125 N 100 N deformed,
33.9 × 15.3 28.4 —
{12.7 kg} {10.2 kg} replace spring.
16.7 N 13.3 N
9 Metering spring 22.9 × 8.10 22.0 —
{1.70 kg} {1.36 kg}
10. Torque . . . . . . . . . . . . . . . . . . . . . . . 11.76 - 14.7 Nm (8.6 - 10.8 lbf ft)
D51EX/PX-22 10-125 d
12
Operation
1. At neutral
l Ports (A) and (B) of the control valve and ports (P1) and (P2) of
the PPC valve are connected to drain chamber (D) through fine
control hole (f) on spool (1).
2. During fine control (Neutral  fine control)

l As piston (4) is pushed by disc (5), retainer (7) is pushed too. At
the same time, spool (1) is also pushed down through metering
spring (2).
l By this move, connection of fine control hole (f) is switched from
drain chamber (D) to pump pressure chamber (PP), and pilot
pressure oil of control pump is conducted from port (P1) to port
(A).
l As port (P1) pressure increases, spool (1) is pushed back. By this
move, connection of fine control hole (f) is switched from pump
pressure chamber (PP) to drain chamber (D), thereby relieving
port (P1) pressure.
l As the result, spool (1) moves up and down so that force of
metering spring (2) and port (P1) pressure may be balanced.
l Positional relationship between spool (1) and body (8) [fine
control hole (f) is situated at mid point between drain chamber
(D) and pump pressure chamber (PP)] remains unchanged until
retainer (7) is contacted against spool (1).
l Metering spring (2) is, therefore, compressed in proportion to
strokes of the control lever. Thus, port (P1) pressure too, increases
in proportion to strokes of the control lever.
l As the result, the control valve spool moves to the position where
the pressure of chamber (A) [the same as port (P1) pressure] is
balanced against force of the control valve spool return spring.
10-126 d D51EX/PX-22
12
3. During fine control
(when control lever is returned)
l As lever (5) starts returning, spool (1) is pushed up by force of
centering spring (3) and port (P1) pressure. By this move, fine
control hole (f) is connected to drain chamber (D) and relieves
pressurized oil of port (P1) to it.
l If port (P1) pressure goes excessively low, spool (1) is pushed
down by metering spring (2), and passage between fine control
hole (f) and drain chamber (D) is shut down. And, almost at the
same time, the hole is connected to pump pressure chamber (PP)
and starts supplying pump the pressure. This supply continues
until port (P1) pressure is recovered to the level equivalent to the
lever position.
l When the control valve spool returns, oil in drain chamber (D)
flows in through fine control hole (f') on the not moving side
valve. Oil is then conducted via port (P2) to chamber (B) to fill it
up.
4. At full stroke
l When disc (5) pushes down piston (4) and retainer (7) pushes
down spool (1), connection of fine control hole (f) is switched
from drain chamber (D), to pump pressure chamber (PP).
l Thus, pilot pressurized oil from the control pump passes through
fine control hole (f) and conducted to chamber (A) through port
(P1) to push the control valve spool.
l Return oil from chamber (B) is conducted from port (P2) to drain
chamber (D) through fine control hole (f').
D51EX/PX-22 10-127 d
12
HYDRAULIC TANK, FILTER
1. Hydraulic tank
2. Hydraulic oil filter
3. Oil filler cap
4. Sight gauge
5. Strainer
6. Drain plug
7. Bypass valve
Specifications
Tank capacity. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 93.1 L (24.6 gal US)

Quantity of oil in tank . . . . . . . . . . . . . . . . . . . . . . . . . . 68.2 L (18 gal US)
Set pressure of bypass valve . . . . . . . . . . 1.5 ± 0.3 kg/cm2 (21.7 ± 4.3 psi)
Cracking pressure of pressure valve . . 0.39 ± 0.15 kg/cm2 (5.54 ± 2.1 psi)
Actuating pressure of vacuum valve . . . . . . 0 - 0.046 kg/cm2 (0 - 0.65 psi)
10-128 d D51EX/PX-22
12
ACCUMULATOR
(for PPC circuit)
1. Gas plug
2. Shell
3. Poppet
4. Holder
5. Bladder
6. Oil port
Specifications
Type of gas . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Nitrogen gas
Amount of gas . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .500 cc
Max. operating pressure . . . . . . . . . . . . . . . . . . . . . .70 kg/cm2 (995.6 psi)
Charge pressure . . . . . . . . . . . . . . . . . . . . . . 12 kg/cm2 (170.6 psi) at 80°C
Outline
l A accumulator is installed between the charge valve and the work
equipment valve. In the case the engine is stopped with the work
equipment raised, the compressed nitrogen gas pressure in the
accumulator feeds the pilot oil pressure to the work equipment control
valve so that the work equipment will lower by its weigh.
D51EX/PX-22 10-129 d
MAINTENANCE STANDARD WORK EQUIPMENT
12
WORK EQUIPMENT
WORK EQUIPMENT
a. Title cylinder e. Pitching rod
b. Cutting edge f. Angle cylinder
c. End bit g. U-frame
d. Blade h. Lift cylinder
10-130 d D51EX/PX-22
12
D51EX/PX-22 10-131 d
12
10-132 d D51EX/PX-22
12
D51EX/PX-22 10-133 d
12
Unit: mm

Clearance between frame size Shaft Hole clearance limit
1 connecting pin and bushing
+0.207 0.15 ~ 0.283 0.5
+0.120
-0.030
Clearance between frame 75 -0.076 +0.3
2 connecting pin and U-frame 0.13 ~ 0.516 1.0
+0.1
bracket
Clearance between lift cylinder -0.025 +0.046
3 50 0.025 ~ 0.11 1.0
bottom pin and frame bracket -0.064 0
Clearance between lift cylinder -0.025 +0.3
4 50 0.125 ~ 0.364 1.0
head pin and U-frame bracket -0.064 +0.1
Clearance between angle -0.025 +0.3 Replace
5 cylinder bottom pin and 40 0.125 ~ 0.364 1.0
-0.064 +0.1
U-frame bracket
Clearance between angle -0.025 +0.3
6 cylinder head pin and blade 40 0.125 ~ 0.364 1.0
-0.064 +0.1
bracket
Clearance between tilt cylinder -0.025 +0.3
7 40 0.125 ~ 0.364 1.0
bottom pin and U-frame bracket -0.064 +0.1
Clearance between tilt cylinder -0.025 +0.3
8 40 0.125 ~ 0.364 1.0
head pin and blade bracket -0.064 +0.1
Clearance between pitching rod +0.039
9 0.025 ~ 0.103 0.5
pin and bushing -0.025 0
0
Clearance between pitching rod -0.064 +0.164
10 0.145 ~ 0.228 1.0
pin and U-frame bracket +0.120
-0.5
Clearance between blade S 114 ---
0
11 spherical portion and pitching 0.5 - 1.5 3.0
rod cap -0.5
S  --- 0
Clearance between blade -0.25 -0.5
12 center spherical portion and S 160 0.25 - 1.25 5.0
-0.75 0 Adjust
U-frame cap shim
Standard shim thickness at
13 main blade spherical portion 8.0
and U-frame cap
Standard shim thickness at
14 blade pitching spherical portion 4.0
end cap
10-134 d D51EX/PX-22
12
CUTTING EDGE AND END BIT
Unit: mm
1 Height of cutting edge
204 110
2 Height of end bit 204 110 Replace
D51EX-22 379.6 ---
3 Width of end pit
D51PX-22 379.6 ---
4. Torque . . . . . . . . . . . . . . . . . . . . 225.4 - 294.0 Nm (166.2 - 216.8 lbf ft)
D51EX/PX-22 10-135 d
12
RIPPER
(If equipped)
Unit: mm
Clearance between pin and size Shaft Hole clearance limit
1 bushing
-0.025 +0.142 0.105 -
50 1.0 Replace
-0.064 +0.080 0.206
2 Wear of point
222 114
3. Support
4. Ripper cylinder
5. Shank
6. Point
7. Beam
10-136 d D51EX/PX-22
12
WORK EQUIPMENT CYLINDER
LIFT CYLINDER
TILT CYLINDER
D51EX/PX-22 10-137 d
12
ANGLE CYLINDER
RIPPER CYLINDER
(If equipped)
10-138 d D51EX/PX-22
12
Unit: mm
Cylinder Standard Tolerance Standard Clearance
name size Shaft Hole clearance limit
–0.025 +0.152 0.020 –
Lift ø50 0.516
–0.064 –0.005 0.216
Clearance between piston rod and –0.030 +0.151 0.024 –
1 Tilt ø55 0.527
bushing –0.076 –0.006 0.227
–0.025 +0.152 0.020 –
Angle ø50 0.516
–0.064 –0.005 0.216
–0.030 +0.151 0.024 –
Ripper ø60 0.527
–0.076 –0.006 0.227
–0.025 +0.142 0.105 –
Lift ø50 1.0
–0.064 +0.080 0.206
–0.025 +0.039 0.025 – Replace
Tilt ø40 1.0 bushing
Clearance between piston rod –0.064 0 0.103
2
support shaft and bushing –0.025 +0.039 0.025 –
Angle ø40 1.0
–0.064 0 0.103
–0.030 +0.174 0.130 –
Ripper ø70 1.0
–0.076 +0.100 0.250
–0.025 +0.142 0.105 –
Lift ø50 1.0
–0.064 +0.080 0.206
–0.025 +0.039 0.025 –
Tilt ø40 1.0
Clearance between cylinder bottom –0.064 0 0.103
3
support shaft and bushing –0.025 +0.025 0.025 –
Angle ø40 1.0
–0.064 0 0.089
–0.030 +0.174 0.130 –
Ripper ø70 1.0
–0.076 +0.100 0.250
4. Torque . . . . . . . . . . . . . . . . . . . . . . . . . 677 ±67.5 Nm (499 ±49.7 lbf ft)

5. Torque . . . . . . . . . . . . . . . . . . . . . . . . . 1.42 ±0.14 Nm (1.0 ±0.10 lbf ft)
6. Torque . . . . . . . . . . . . . . . . . . . . . . . . . 785 ±78.5 Nm (578 ±57.8 lbf ft)
7. Torque . . . . . . . . . . . . . . . . . . . . . . . . . 1.67 ±0.17 Nm (1.2 ±0.12 lbf ft)
8. Torque . . . . . . . . . . . . . . . . . . . . . . . . . 1.39 ±0.14 Nm (1.0 ±0.10 lbf ft)
9. Torque . . . . . . . . . . . . . . . . . . . . . . . . . 923 ±93.0 Nm (680 ±68.5 lbf ft)
10. Torque . . . . . . . . . . . . . . . . . . . . . . . . . 2.6 ±0.26 Nm (1.9 ±0.19 lbf ft)
D51EX/PX-22 10-139 d
12
PISTON VALVE FOR ANGLE CYLINDER
Outline
l The piston valve is installed to the piston section of the angle cylinder.
l When the piston rod is at the stroke end, the oil from the pump is sent to the port on the opposite side to lower the oil
pressure applied to the piston.
The oil is also sent to the port on the opposite side before the piston rod reaches the stroke end to lower the surge pressure
and reduce the shock made when the piston rod reaches the stroke end.
Operation
Piston valve is "Open"
The oil from the pump acts on piston (2) and piston valve (3).
Then, piston valve (3) is pushed to the right to seal the tapered part of
piston valve seat (4).
As a result, the oil pressure in the cylinder rises to move piston (2) to the
right.
Piston valve is "Closed"
The end of piston valve (3) touches cylinder bottom (a) before piston rod
(1) reaches the stroke end, and then only piston (2) continues moving.
At this time, the oil which has been stopped by piston valve (3) is sent
through piston valve seats (4) and (5) to the bottom side, thus the oil
pressure in the cylinder lowers.
10-140 d D51EX/PX-22
MAINTENANCE STANDARD CAB AND ITS ATTACHMENTS
12
CAB AND ITS ATTACHMENTS
ROPS CAB
1. ROPS cab
2. Door
3. Front wiper
4. Rear wiper
5. Door wiper
D51EX/PX-22 10-141 d
12
STEERING AND BRAKE CONTROL
H PCCS: Abbreviation for Palm Command Control System
10-142 D51EX/PX-22
1. Parking brake lever
2. Joystick (PCCS lever)
3. Electric lever
4. Parking brake limit switch 1
6. HST controller
7. Center brake proximity switch
8. Brake pedal potentiometer
9. Brake pedal
Outline
l Electric lever (3) sends electric signals to HST controller (6) according to the stroke of joystick (PCCS lever) (2). Upon
receiving these signals, HST controller (6) sends signals to the EPC valve of HST pump to change the flow in HST pump
and control the HST motor.
l If the joystick (PCCS lever) (2) is leaned to the left a little while it is leaned to the forward position, the machine turns to
the left gradually. If it is leaned to the left stroke end, the machine makes a counter-rotation.
l Brake pedal potentiometer (8) sends electric signals to HST controller (6) according to the stroke of brake pedal (9). Upon
receiving these signals, HST controller (6) sends signals to the EPC valve of HST pump to decelerate the right and left
HST motors simultaneously.
l If brake pedal (9) is pressed fully while parking brake lever (1) is in the FREE position, HST controller (6) receives
electric signals from brake pedal potentiometer (8) and operates the right and left HST brakes simultaneously. After the
machine stops, HST controller (6) stops sending signals to the parking brake solenoid valve. At this time, the signal of
center brake proximity switch (7) operates the relay to stop the signal to the slow brake solenoid valve. If the signal to the
parking brake solenoid valve or slow brake solenoid valve is stopped, the parking brakes built in the right and left HST
motors operate.
l If the parking brake lever (1) is set in the LOCK position, the HST controller receives electric signals from parking brake
limit switch 1 (4) and stops sending signals to the parking brake solenoid valve. At this time, parking brake limit switch 2
(5) stops sending signals to the slow brake solenoid valve. If the signal to the parking brake solenoid valve or slow brake
solenoid valve is stopped, the parking brakes built in the right and left HST motors operate.
D51EX/PX-22 10-143
12
WORK EQUIPMENT CONTROL
10-144 D51EX/PX-22
12
1. Work equipment lock lever
2. Blade PPC valve
3. Blade control lever
4. Ripper control lever (If equipped)
5. Ripper PPC valve (If equipped)
6. PPC lock limit switch
Outline
l The work equipment control system is a PPC system, which moves each spool of the control valves through blade control
lever (3) and blade PPC valve (2) and through ripper control lever (4) and ripper PPC valve (5).
l If work equipment lock lever (1) is set in the LOCK position, the PPC lock limit switch stops the signal to the PPC lock
solenoid valve and the operator can move blade control lever (3) and ripper control lever (4) but cannot operate the work
equipment.
l If blade control lever (3) is set in the FLOAT position, the hydraulic detent of blade PPC valve (2) works so that blade
control lever (3) will hold itself.
l If work equipment lock lever (1) is set in the LOCK position, the hydraulic detent is reset and blade control lever (3)
returns to the HOLD position automatically.
l While the engine is stopped, the hydraulic detent does not work even, if blade control lever (3) is in the FLOAT position,
and blade control lever (3) returns to the HOLD position automatically.
D51EX/PX-22 10-145
12
CAB DAMPER MOUNT
Cab mount and ROPS stopper
1. Damper mount (Front)

2. Damper mount (Rear)
3. ROPS stopper (Front)
4. ROPS stopper (Rear)
Outline
l The mounts are installed to 2 places on each of the front side and rear side to fix the cab (with the floor frame).
l The oil-filled damper mounts absorb vibrations.
l The ROPS stoppers are installed 2 places on each of the front side and rear side to fix the cab (having the ROPS in it)
when the machine overturns.
10-146 D51EX/PX-22
12
AIR CONDITIONER
AIR CONDITIONER AND FLOOR HEATER
1. Air conditioner unit

2. Heater unit (Floor)
3. Condenser
4. Receiver tank
5. Water valve
6. Refrigerant liquid piping
7. Front window defroster
8. Side window defroster
9. Rear window defroster
10. Face air outlet
11. Foot air outlet
A External air inlet (Bottom of unit)

B Internal air circulation opening
D51EX/PX-22 10-147
12
AIR CONDITIONER PIPING
1. Compressor
2. Refrigerant discharge piping
3. Refrigerant suction piping
4. Hot water outlet
5. Hot water return piping
10-148 D51EX/PX-22
MAINTENANCE STANDARD ELECTRICAL SYSTEM
12
ELECTRICAL SYSTEM
MONITOR SYSTEM
a. Each sensor f. KOMTRAX

b. Sensor signal g. Battery
c. HST controller h. Power source
d. CAN signal i. Alarm buzzer
e. Engine controller j. Alarm buzzer signal
l The monitor system notifies the operator of the machine condition. It monitors the machine condition with the sensors
installed to the machine and processes and displays the obtained information on the monitor panel immediately.
The contents displayed on the panel are roughly classified as shown below.
l Travel direction, gear speed, shift mode (Display panel A)
l Coolant temperature, HST oil temperature, and fuel level (Gauge section)
l Machine trouble alarm (Monitor section)
l Current, voltage, error code, of each sensor and solenoid (Display panel B)
l The monitor system consists of the monitor panel, controller, sensors, alarm buzzer, and power supply.
l The component parts are connected by wiring harnesses and the monitor panel is powered by the battery.
l If the machine has any trouble (and a sensor detects it), the monitor and alarm lamp flash and the alarm buzzer sounds to
protect the machine. The alarm buzzer can be turned OFF temporarily with the buzzer cancel switch.
D51EX/PX-22 10-149
12
Processing in monitor panel (Common to all specifications)
Display of monitor panel

Contents and conditions of processing Method Flow of signals
1. Display of travel direction and gear speed
l Signals (F1, R3, etc.) are sent to the monitor panel according to the information of the CAN signal
HST controller.
2. Display of coolant temperature, HST oil temperature, and fuel level by gauge
l The controller processes the sensor signals and sends the result to the CAN signal
monitor panel.
3. Display of trouble
l If there is any trouble, its failure code signal is sent to the monitor panel. Each sensor/solenoid

l Information about sounding the buzzer and flashing the caution lamp is sent,
Controller
according to the contents of the trouble.

1) In normal state Monitor panel
An action code and a failure code are displayed.
2) In failure history display mode CAN signal
l A failure code (6-characteristics code) and the following are displayed.
l Elapsed time after first occurrence (When trouble is in electrical system)
l Elapsed time after latest occurrence (When trouble is in electrical
system)
l Number of occurrences
Display of monitor panel

1. Display of each sensor, each solenoid, communicating state of CAN signal, etc. Each sensor/solenoid
CAN signal 
l The signals of condition of each device are sent to the monitor panel.
Controller
2. Selection of each item with buzzer cancel switches (U, t) and cursor switches (>, <).
CAN signal 
Monitor panel
H For details of the operating method, see Testing and adjusting, "Special functions of monitor panel (EMMS)".
Other items
1. Filter and oil maintenance mode (User)
2. Maintenance interval change mode (Service)
3. Electric system failure code display mode
4. Mechanical system failure code display mode
5. Adjustment mode (Service) Each sensor/solenoid
6. Real-time monitoring mode 
7. Reduced cylinder mode (Service) CAM signal Controller
8. No-injection cranking mode (Service) 
9. Phone No. setting mode (Service) Monitor panel
10. Machine model selection mode (Service)
11. Option selection mode (Service)
12. Initialization mode (Service)
13. Luminance and brightness adjustment mode (User)
H For details of the operating method, see Testing and adjusting, "Special functions of monitor panel (EMMS)".
10-150 D51EX/PX-22
12
ENGINE CONTROL
1. Battery 5. Monitor panel 9. Limit switch
2. Starting switch 6. HST controller 10. Parking brake lever
3. Engine 7. Neutral safety relay 11. Electric lever
12. Steering/directional/gear shift

4. Starting motor 8. Safety relay
lever (PCCS) lever)
Input and output signals
a. Battery power source
b. Engine start signal
c. Starting switch ACC signal
d. Parking brake signal
e. Neutral signal
Function
l A limit switch is installed to the linkage of the parking brake. HST controller permits the engine to start only when the
parking brake is in the “lock” position and the steering/directional/gear shift lever is in the “N (Neutral)” position.
D51EX/PX-22 10-151
12
ENGINE CONTROL SYSTEM
1. Battery 6. Fuel control dial 11. Engine oil pressure switch
2. Starting switch 7. Decelerator pedal 12. Injector
3. Engine controller 8. Engine 13. Fuel supply pump valve
4. HST controller 9. Engine speed sensor
5. Monitor panel 10. Coolant temperature
a. No. 1 throttle signal (fuel control dial signal) f. Engine speed signal
b. No. 2 throttle signal (decelerator pedal signal) g. Coolant temperature signal
c. N0. 3 throttle signal (controller control signal) h. Engine oil pressure signal
d. Starting switch ACC signal i. Sensor signal
e. Controller power source j. Monitor display signal
10-152 D51EX/PX-22
12
ENGINE SPEED CONTROL MECHANISM
l The engine controller receives the No. 1 throttle signal (fuel control dial signal) and No. 2 throttle signal (decelerator
pedal signal) and then selects the lower command signal and controls the fuel supply pump and injector.
l 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.
ENGINE STOP MECHANISM
l If the starting switch is set in the OFF position, the starting switch ACC signal to the engine controller is turned OFF.
l The engine controller stops supplying fuel to the engine to stop the engine.
D51EX/PX-22 10-153
12
COOLING CONTROL SYSTEM
1. Battery 6. Cooling fan motor 11. Fan speed sensor
2. Battery relay 7. Work equipment and cooling fan pump 12. Hydraulic oil temperature sensor
3. HST controller 8. Fan rotation selector switch 13. Engine
4. Engine controller 9. Work equipment valve 14. Engine speed sensor
5. Monitor panel 10. Fan EPC valve 15. Coolant temperature sensor
a. Controller power source f. Coolant temperature signal
b. Fan rotation selector signal g. CAN signal
c. Fan speed signal h. Fan speed control signal
d. Hydraulic oil temperature signal i. Fan reverse signal
e. Engine speed signal
10-154 D51EX/PX-22
12
Outline
The HST controller monitors the coolant and hydraulic oil temperatures and controls the fan speed according to those
temperatures.
Function
Fan speed control
l The HST controller controls the oil flow to the cooling fan motor to set the fan speed properly according to the informa-
tion from the coolant and hydraulic oil temperature sensors.
l The HST controller selects the maximum target fan speed obtained from the coolant and hydraulic oil temperatures and
output it as the fan speed control signal to the fan EPC valve.
l The fan EPC valve changes the open area of the fan spool in the work equipment valve to control the oil flow to the cool-
ing fan motor.
l The HST controller monitors the actual fan speed with the fan speed sensor and controls it to the target fan speed.
Selection of fan rotation mode
While the starting switch is in the “on” position and the engine is stopped, one of the following fan rotation modes can be
selected with the fan rotation selector switch.
Fan rotation mode includes;
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.
While in the “Cleaning mode”, the machine does not move for the radiator protection even if the PCCS lever is shifted to
“forward” or “reverse” position. The starting switch needs to be turned from “off” to “on” to restart the machine under the
“forward rotation mode”.
According to the selected mode, HST controller operates the reverse solenoid valve of the cooling fan motor to change the
rotation direction of the fan.
Interlock for changing rotation mode
If the rotation direction of the fan is changed while the fan is rotating, the fan drive circuit is broken. To prevent this, the fan
rotation selector switch signal is ignored while the engine is running. In this case, the fan operation pilot lamp on the monitor
panel flashes for 3 seconds.
D51EX/PX-22 10-155
12
HST CONTROL SYSTEM
H HST: Abbreviation for HydroStatic Transmission
1. Battery 9. Fuel control dial potentiometer 17. RH HST pump reverse EPC valve
2. Battery relay 10. Monitor panel 18. LH HST circuit oil pressure sensor
3. Engine controller 11. Reverse travel speed setting switch 19. RH HST circuit oil pressure sensor
4. Fuse box 12. Shift mode switch 20. LH HST motor speed sensor
5. HST controller 13. Engine speed sensor 21. RH HST motor speed sensor
6. Decelerator pedal potentiometer 14. LH HST pump forward EPC valve 22. LH HST motor EPC valve
7. Brake pedal potentiometer 15. RH HST pump forward EPC valve 23. RH HST motor EPC valve
8. Electric lever (for steering) 16. LH HST pump reverse EPC valve
a. Controller power supply

b. CAN signal
c. Reverse travel speed setting signal
d. Shift mode signal
e. Decelerator pedal stroke signal
f. Brake pedal stroke signal
g. Steering/directional/gear shift signal
h. Fuel control dial stroke signal
j. Engine speed signal
k. HST circuit oil pressure signal
m. HST motor speed signal
n. HST pump EPC valve drive signal
p. HST motor EPC drive signal
10-156 D51EX/PX-22
12
GEAR SHIFT CONTROL SYSTEM
GEAR SHIFTING BY OPERATOR
Function
l Upon receiving the gear shift signal from the shift-up or shift-down switch of the steering/directional/gear shift lever, the
HST controller decides the capacity of the HST pump and HST motor and shift the gear.
l The operator can select the quick shift mode or the variable shift mode with the shift mode switch.
l If the steering/directional/gear shift lever is leaned forward (for forward travel), a set travel speed is decided according to
the gear speed of broken line (B) in the above graph.
l If the steering/directional/gear shift lever is leaned backward (for reverse travel), a set travel speed corresponding to the
gear speed of settings (A) – (E) of the reverse travel speed setting switch is decided according to the above graph.
l When the steering/directional/gear shift lever is in the neutral position, the set travel speed is 0 km/h.
The figure to the right shows setting of reverse travel speed (C) in the 1st
gear speed (default).
D51EX/PX-22 10-157
12
SET TRAVEL SPEEDS CORRESPONDING TO GEAR SPEEDS
Bar graph gauge No. Set travel speed (km/h)

Gear
F shift R shift gauge Reverse
speed Forward
gauge A B C D E A B C D E
2 2 2 2 2 2 0.8 0.8 0.8 0.8 0.8 0.8
4 3 4 4 5 5 1.0 0.9 1.0 1.1 1.2 1.3
6 5 6 7 8 9 1.5 1.2 1.5 1.7 1.9 2.2
8 7 8 9 11 12 2.0 1.6 2.0 2.3 2.7 3.0
10 8 10 12 14 16 2.4 2.0 2.4 2.9 3.4 3.8
12 10 12 14 17 19 2.9 2.3 2.9 3.5 4.1 4.7
1 14 11 14 17 20 23 3.4 2.7 3.4 4.1 4.8 5.5
16 13 16 19 22 25 3.8 3.0 3.8 4.5 5.2 6.0
18 15 18 21 25 28 4.1 3.4 4.1 4.9 5.7 6.4
20 16 20 24 27 31 4.5 3.7 4.5 5.3 6.1 6.9
22 18 22 26 30 33 4.9 4.0 4.9 5.7 6.5 7.4
24 20 24 28 32 36 5.2 4.4 5.2 6.1 7.0 7.8
2 26 22 26 30 34 38 5.6 4.7 5.6 6.5 7.4 8.3
28 24 28 32 36 40 6.1 5.2 6.1 7.0 7.9 8.8
30 26 30 34 38 40 6.6 5.7 6.6 7.5 8.4 9.0
32 28 32 36 40 40 7.1 6.2 7.1 8.0 8.9 9.0
34 30 34 38 40 40 7.5 6.6 7.5 8.4 9.0 9.0
36 32 36 40 40 40 8.0 7.1 8.0 8.9 9.0 9.0
38 34 38 40 40 40 8.5 7.6 8.5 9.0 9.0 9.0
3 40 36 40 40 40 40 9.0 8.1 9.0 9.9 10.8 11.7
H The values of bold-face type are for the quick shift mode.
10-158 D51EX/PX-22
12
l If the fuel control dial or decelerator pedal is operated, a deceleration command is lowered according to the deceleration
command map.
l The deceleration command of fuel control dial is higher than that of the decelerator pedal. Accordingly, even if the fuel
control dial is returned from the "FULL SPEED" position, higher output is secured.
l The deceleration command means the ratio to the set travel speed.
Example:
l When the fuel control dial is at the "FULL SPEED" position and the decelerator pedal is not pressed:
l The deceleration command is 100%, and the command travel speed is equal to the set travel speed.
l When the fuel control dial or the decelerator pedal is set in the "MEDIUM SPEED" position:
l The travel speed is limited according to the formula of Command travel speed = Deceleration command x Set travel speed
/ 100.
<Deceleration command map>
<Brake command map>

l If the brake pedal is operated, a brake command is lowered according
to the brake command map.
l The brake command means the ratio to the set travel speed.
Example:
l When the brake pedal is pressed halfway:
l The travel speed is limited according to the formula of Command
travel speed = Brake command x Set travel speed / 100.
D51EX/PX-22 10-159
12
CHANGING TRAVEL SPEED ACCORDING TO CHANGE OF ENGINE SPEED
When external load increases and engine speed lowers

The HST controller lowers the command travel speed according to command travel speed map (A).
In addition, the HST controller decides the HST pump EPC valve control signal and HST motor EPC valve control signal to
lower the travel speed according to the HST pump capacity command map and the HST motor capacity command map.
When external load decreases and engine speed rises

The HST controller raises the command travel speed according to command travel speed map (A).
In addition, the HST controller decides the HST pump EPC valve control signal and HST motor EPC valve control signal to
raise the travel speed according to the HST pump capacity command map and the HST motor capacity command map.
<Command travel speed map>
<HST pump capacity command map>
<HST motor capacity command map>
10-160 D51EX/PX-22
12
STRAIGHT TRAVEL CORRECTION CONTROL SYSTEM
Function
l The HST controller monitors the operating conditions of each lever and each pedal and constantly controls the swash plate
angle of the HST pump, or the delivery of the HST pump, so that the output speed of the right and left HST motors will be
the same.
l While the machine is traveling straight forward, if the right HST motor speed is higher than the left HST motor speed, the
HST controller lowers the control signal of the right HST motor forward EPC valve so that the machine will always travel
straight.
l Conditions for resetting straight travel correction control system
A. The steering/directional/gear shift lever is set in the RIGHT or LEFT steering position.
B. The steering/directional/gear shift lever is set in the NEUTRAL travel direction position.
C. A pedal or the fuel control lever is operated and the travel speed sensed by the HST motor speed sensor is 0.15 km/h
or lower.
D. The HST motor speed sensor is judged defective because of disconnection, etc.
Straight travel is secured when none of the above condition is satisfied.
D51EX/PX-22 10-161
12
PARKING BRAKE CONTROL SYSTEM
1. Battery
2. Battery relay
3. Fuse box
4. HST controller
5. Engine
6. HST pump
7. Brake pedal
8. Brake pedal potentiometer
9. Center brake proximity switch
10. Parking brake lever
13. Center brake relay
14. Slow brake solenoid valve
15. Parking brake solenoid valve
16. Towing valve
17 Brake oil pressure sensor
18. HST motor
18a. Parking brake
a. Controller power supply

b. Parking brake lever LOCK signal
c. Brake pedal stroke signal
d. Solenoid valve drive signal
e. Brake oil pressure signal
10-162 D51EX/PX-22
12
Function
l Parking brake limit switches 1 (11) and 2 (12) are installed and connected to parking brake lever (10) so that parking brake
(18a) will be released only when parking brake lever (10) is in the FREE position.
l Center brake proximity switch (9) is installed and connected to brake pedal (7) so that slow brake solenoid valve (14) will
be de-energized and parking brake (18a) will be applied when brake pedal (7) is pressed fully.
Conditions for turning parking brake solenoid valve OFF

Operating condition Operation
1. (a) or (b) shown below is satisfied and travel speed is 0.6 km/h or lower.
2. (a) or (b) shown below is satisfied for 1 second continuously.
(a) Parking brake lever is in LOCK position.  Parking brake operates.

(Parking brake limit switch 1 is ON.)
(b) Brake pedal is pressed fully.
(Pedal stroke is 90% or more.)
Conditions for turning slow brake solenoid valve OFF

Operating condition Operation
1. (a) or (b) shown below is satisfied.
(a) Parking brake lever is in LOCK position.

 Parking brake operates.
(Parking brake limit switch 2 is ON.)
(b) Brake pedal is pressed fully.
(Center brake proximity switch is ON.)
D51EX/PX-22 10-163
12
KOMTRAX SYSTEM
KOMTRAX terminal system
l The KOMTRAX terminal sends various information on the machine by a wireless communication.The KOMTRAX
operator refers to this information in the office, and various services can be provided for the customer.
H To be provided with the KOMTRAX terminal service, it is necessary to sign up separately.
Information that can be sent from the KOMTRAX terminal is as follows:

1. Traveling map
2. Service meter
3. Location information
4. Error history
10-164 D51EX/PX-22
12
MEMORANDUM
D51EX/PX-22 10-165
12
SYSTEM COMPONENTS
MONITOR PANEL
Outline
The monitor panel consists of the monitor section which outputs an alarm when the machine has any trouble and the gauge
section and display panel which display the machine condition constantly.
The monitor panel has a microcomputer, which processes and displays the signals from the sensors, solenoids, and controllers.
The items displayed on the monitor section and gauge section are shown in DISPLAY OF MONITOR PANEL.
Operation
When power is turned ON

(When starting switch is turned to ON position)
All the LC segments and lamps of the monitor panel light up for 2 seconds (the LC gauges move up and down between MIN
and MAX) and the alarm buzzer sounds for 2 seconds.
Check before starting
After the operation performed when the power is turned ON, if there is any abnormal one in the check-before-starting items,
the lamp of that item flashes or the contents of the abnormality are displayed on display panel B.
Caution items
The caution items are checked constantly while the engine is running.
If any item is abnormal, it and alarm lamp flash synchronously. The alarm buzzer may sound at this time.
10-166 D51EX/PX-22
12
Buzzer cancel switch
l If this switch is operated while the alarm buzzer is sounding, the buzzer is turned OFF temporarily.
While the buzzer is turned OFF, if a new trouble which turns on the buzzer is detected, the buzzer sounds again.
l The lamp lights up and goes off at the intervals of about 0.8 seconds.
l The flashing intervals of the lamp may change a little when the temperature is low (below about –10°C). This does not
indicate a trouble.
AMP070-20P [CN-1] AMP070-12P [CN-2]

Input/Output Input/Output
Pin No. Signal name Pin No. Signal name
signal signal
1 ACC terminal Input 1 CAN (0) H Input/Output
2 ACC terminal Input 2 NC Input/Output
3 GND Input 3 CAN (0) L Input/Output
4 GND Input 4 NC Input/Output
5 +24V, unswitched Input 5 NC Input/Output
6 +24V, unswitched Input CAN (0) (Built-in terminal
6 Input
7 Key C Input resistor)
8 Lighting signal Input 7 NC Input
9 Preheating pilot Input 8 NC —
10 NC Input 9 Alternator Input
11 NC Input 10 Fuel level Input
12 NC Input 11 NC Input
13 Air cleaner clogging Input 12 NC Input
14 Mode selector switch (<) Input
15 Mode selector switch (>) Input
16 Mode selector switch (U) Input
17 Mode selector switch (t) Input
18 Caution buzzer Output
19 NC Output
20 WAKE UP signal Input/Output
D51EX/PX-22 10-167
Monitor panel display
H The following figure shows an example of display in the quick shift mode.
To the right is an example of display panel A in the variable shift mode.
10-168 D51EX/PX-22
12
Alarm Alarm Dis-
Display
No. Display item Display range Display method lamp buzzer play Remarks
section
output output color
Below corresponding segment
1a Gauge See figure at left — — Black LCD
All light up
Coolant
Below 102°C OFF OFF OFF
temperature
1b Caution 102°C – 105°C Flashing Flashing OFF Red LED
Above 105°C Flashing Flashing ON
2a Gauge See figure at left — — Black LCD
All light up
HST oil
Below 100°C OFF OFF OFF Red LED
temperature
2b Caution 100°C – 110°C Flashing Flashing OFF
Above 110°C Flashing Flashing ON
3 Gauge Fuel level See figure at left — —
All light up
P: Parking brake lever in LOCK
Travel direction N: Joystick in NEUTRAL
4a
(P, N, F, R) F: Joystick in FORWARD
Indicator R: Joystick in REVERSE OFF OFF
1: Joystick gear shift switch in 1st
[*3]
4b 2: Joystick gear shift switch in 2nd
Display panel A Gear speed (1, 2, 3) 3: Joystick gear shift switch in 3rd
(Travel direction,
[*1]
gear speed, shift
4c Forward gear speed Black LCD
mode)
(See figure at left) Below corresponding segment
Gauge — —
[*1] All light up
4d Reverse gear speed
(See figure at left)
4e Variable shift mode ON — —
Pilot
4f Quick shift mode ON — —
[*2]
Character Display panel B 0 – 99999.9 h/ Time is counted while engine is running
5 — —
display (Service meter/ 0 – 9999 rpm (alternator is generating)
Engine speed)
When charge is OFF (While engine is stopped) OFF OFF
6 Charge level
defective (Below 12 V) Flashing (While engine is running) Flashing OFF
Engine oil Below specified value OFF (While engine is stopped) OFF OFF
7
pressure (49 kPa {0.5 kg/cm2}) Flashing (While engine is running) Flashing ON
Caution Red
Charge filter Above specified value OFF (While engine is stopped) OFF OFF
8
clogging (200 kPa {2.0 kg/cm2}) Flashing (While engine is running) Flashing ON
HST charge oil Below specified value OFF (While engine is stopped) OFF OFF
9
pressure (785 kPa {8.0 kg/cm2}) Flashing (While engine is running) Flashing ON
10 Pilot Preheating In preheating mode ON OFF OFF Green
Before 30 h or more OFF
11 Maintenance Before 30 h – Replace- ON for 30 seconds after starting switch is OFF OFF Red
ment time turned ON LED
12 Warning lamp See the “warning lamp output” column of this table — — Red
Air cleaner Below specified value
13 Flashing OFF OFF Red
clogging (–7.47 kPa)
When fan speed selec-
Caution
tor switch is operated Flashing (several times)
Fan operation while engine is running
14 OFF OFF Orange
check In fan cleaning
ON
(reverse) mode
In fan forward mode OFF
Coolant level in When coolant level in
15 Flashing OFF OFF Red
fuel filter water separator rises
*1: For details, see "Hst control system".

*2: For details in the service mode, see Testing and adjusting, "Special functions of monitor panel (EMMS)".
*3: Displayed only in the quick shift mode.
D51EX/PX-22 10-169
12
ENGINE CONTROLLER
CN-CE01 CN-CE01
Input/
Pin No. Signal name Pin No. Signal name Title panel
output
1 Electric power supply for lift pump 18 NC(*)
2 Electric power supply for IMA 19 NC(*)
3 Atmosphere sensor 20 NC(*)
4 NC(*) 21 NC(*)
5 NC(*) 22 Engine brake drive D
6 CAN(?) 23 Boost temperature sensor B
7 NC(*) 24 NC(*)
8 CAN(+) 25 Common rail pressure sensor B
9 NC(*) 26 G sensor (+) B
10 NC(*) 27 NE sensor (+) B
11 Lift pump return 28 Engine brake return
12 NC(*) 29 NC(*)
13 NC(*) 30 NC(*)
14 NC(*) 31 NC(*) D
15 Coolant temperature sensor 32 IMA return C
16 5V electric power supply for sensor 33 5V electric power supply for sensor
17 Oil pressure switch 34 NC(*)
*: Never connect to NC or malfunctions or failures will occur. *: Never connect to NC or malfunctions or failures will occur.
10-170 D51EX/PX-22
12
CN-CE01 CN-CE02
Pin No. Signal name Title panel Pin No. Signal name Input/output
35 NC(*) A 20 NC(*)
36 NC(*) 21 NC(*)
37 5V electric power supply for sensor A 22 Fuel control dial (+5V)
38 GND C 23 Fuel control dial (?)
39 NC(*) 24 NC(*)
40 NC(*) 25 NC(*)
41 NC(*) 26 NC(*)
42 NC(*) C 27 NC(*)
43 NC(*) 28 NC(*)
44 Boost pressure sensor B 29 NC(*)
45 Injector #1 (+) D 30 NC(*)
46 Injector #5 (+) D 31 NC(*)
47 G sensor (?) C 32 NC(*)
48 Ne sensor (?) C 33 GND
49 NC(*) 34 NC(*)
50 NC(*) 35 NC(*)
51 Injector #2 (?) C 36 NC(*)
52 Injector #3 (?) C 37 NC(*)
53 Injector #1 (?) C 38 NC(*)
54 Injector #2 (+) D 39 Key switch (ACC)
55 Injector #3 (+) D 40 Electrical intake air heater relay drive
56 Injector #4 (+) D 41 NC(*)
57 Injector #6 (+) D 42 Electrical intake air heater relay return
58 Injector #4 (?) C 43 NC(*)
59 Injector #6 (?) C 44 NC(*)
60 Injector #5 (?) C 45 NC(*)
*: Never connect to NC or malfunctions or failures will occur. 46 CAN(+)
47 CAN(?)
CN-CE02 48 NC(*)
Pin No. Signal name Input/output 49 PWM OUTPUT
1 NC(*) 50 NC(*)
2 NC(*) *: Never connect to NC or malfunctions or failures will occur.
3 NC(*)
4 NC(*) CN-CE03
5 NC(*) Pin No. Signal name Input/output
6 NC(*) 1 GND
7 NC(*) 2 NC(*)
8 NC(*) 3 Electric power supply (+24V constantly)
9 Fuel control dial (+) 4 NC(*)
10 NC(*) *: Never connect to NC or malfunctions or failures will occur.
11 NC(*)
12 NC(*)
13 NC(*)
14 NC(*)
15 NC(*)
16 NC(*)
17 NC(*)
18 NC(*)
19 NC(*)
*: Never connect to NC or malfunctions or failures will occur.
D51EX/PX-22 10-171
HST CONTROLLER
10-172 D51EX/PX-22
DEUTSCH-24P [CN-ST1] DEUTSCH-40P (1) [CN-ST2] DEUTSCH-40P (2) [CN-ST3]
Pin Input/Output Pin Input/Output Pin Input/Output
Signal name Signal name Signal name
No. signal No. signal No. signal
1 Joystick position FR4 Input 1 NC — Power source
1 Input
Fuel control dial 2 NC — (Controller)
2 Input
potentiometer 3 NC — 2 Power source (Solenoid) Input
Brake pedal 4 NC — GND
3 Input 3 —
potentiometer Parking brake limit (Solenoid, common)
5 Input
4 GND (Signal) — switch 1 (NC) 4 For driving battery relay Output
Charge filter clogging 6 NC — Left HST pump forward
5 Input 5 Output
sensor 7 Fan forward switch Input EPC valve
6 NC — 8 Neutral safety relay Output Left HST pump reverse
6 Output
7 Joystick position ST2 Input 9 NC — EPC valve
Brake oil pressure 10 Fan speed sensor Input 7 Fan reverse solenoid Output
8 Input
sensor 11 NC — 8 NC —
HST oil temperature 12 NC — Parking brake limit
9 Input 9 Input
sensor 13 Immobilize signal Input switch 2 (NO)
10 GND (Signal) — 14 NC — 10 Key cylinder C signal Input
11 NC — Parking brake limit Power source
15 Input 11 Input
12 Shift-up switch (NC) Input switch 1 (NO) (Controller)
13 Joystick position FR3 Input 16 NC — 12 Power source (Solenoid) Input
L.H. HST circuit oil Fan cleaning reverse GND
14 Input 17 Input 13 —
pressure sensor switch (Solenoid, common)
15 Alternator (R) Input 18 NC — 14 Starting switch (ACC) Input
16 NC — 19 NC — Right HST motor
15 Output
17 NC — L.H. HST motor speed forward EPC valve
20 Input
18 Shift-down switch (NO) Input sensor Right HST motor
16 Output
19 Joystick position ST1 Input 21 NC — reverse EPC valve
R.H. HST circuit oil 22 CAN0 (L) Input/Output 17 NC —
20 Input
pressure sensor 23 NC — 18 Back-up alarm Output
21 GND (Analog) — Flash ROM write 19 NC —
24 Input
Sensor power source permission signal 20 NC —
22 Output
(+5 V) Reverse travel speed 21 GND (Power source) —
25 Input
23 Shift-up switch (NO) Input setting switch (Up) 22 Power source (Solenoid) Input
24 Shift-down switch (NC) Input 26 NC — GND
23 —
Mode selector switch (Solenoid, common)
27 Input
(VARIABLE) 24 Starting switch (ACC) Input
28 NC — 25 Fan control EPC Output
29 GND (Pulse) — Left HST motor EPC
26 Output
R.H. HST motor speed valve
30 Input
sensor Parking brake solenoid
27 Output
31 GND (Communication) — valve
32 CAN0 (H) Input/Output 28 NC —
33 NC — 29 NC —
34 GND (Communication) — 30 NC —
Reverse travel speed 31 GND (Power source) —
35 Input
setting switch (Down) 32 GND (Power source) —
36 NC — 33 GND (Power source) —
Mode selector switch Sensor power source 1
37 Input 34 Output
(QUICK) (+5V)
38 NC — 35 NC —
39 GND (Pulse) — Right HST motor EPC
36 Output
40 NC — valve
Slow brake solenoid
37 Output
valve
38 NC —
39 NC —
40 NC —
D51EX/PX-22 10-173
12
ELECTRIC LEVER (FOR TRAVEL)
H Do not disassemble the electric lever. If it is disassembled, the output voltage characteristics and operating effort
characteristics will need to be adjusted.
10-174 D51EX/PX-22
12
1. Boot 5. Screw
2. Bracket 6. Lever
3. Plate 7. Connector
4. Bolt
8. Torque . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6.9 - 9.8 Nm (5.1 - 7.2 lbf ft)

9. Torque . . . . . . . . . . . . . . . . . . . . . . . . . 11.8 - 14.7 Nm (8.7 - 10.8 lbf ft)
10. Torque . . . . . . . . . . . . . . . . . . . . . . . . . . 8.8 - 10.8 Nm (6.5 - 7.9 lbf ft)
11. Torque . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.4 - 4.4 Nm (2.6 - 3.2 lbf ft)
D51EX/PX-22 10-175
12
KOMTRAX TERMINAL
1. Communication antenna connector

2. GPS antenna connector
3. Machine harness connector (DEUTSCH-40P)

DEUTSCH-40P [CN-G01]
Input/Output Input/Output
Pin No. Signal name Pin No. Signal name
signal signal
1 NC — 21 Operation mode selection 1 Input
2 NC — 22 Operation mode selection 2 Input
3 NC — 23 NC —
4 NC — 24 NC —
5 NC — 25 NC —
6 CAN shield GND — 26 NC —
7 CAN signal (L) Input/Output 27 Starting switch (C) Input
8 CAN signal (H) Input/Output 28 Alternator (R) Input
9 NC — 29 NC —
10 NC — 30 NC —
11 NC — 31 NC —
12 NC — 32 NC —
13 NC — 33 NC —
14 NC — 34 NC —
15 NC — 35 NC —
16 NC — 36 Starting switch (ACC) Input
17 NC — 37 Power source GND —
18 NC — 38 Power source GND —
19 NC — 39 Constant power source (24V) Input
20 Immobilizing signal Output 40 Constant power source (24V) Input
Outline
l The KOMTRAX controller can send information via wireless communication antenna, acquiring various information of
the machine from the network signal in the machine and the input signal. Also, the controller incorporates CPU (Central
Processing Unit) and provide the wireless communication function and the GPS function.
l There are the LED lamp and the 7-segment indicator lamp in the display area, and these lamps are used for the testing and
the troubleshooting.
l The information of the LED lamp and the 7-segment indicator lamp can be checked on the monitor panel by EMMS.
10-176 D51EX/PX-22
12
SENSORS
The signals from the sensors are input through the controllers to the monitor panel.
Category of When
Sensor method When normal
display abnormal
Caution Brake oil pressure sensor Resistance --- ---
Gauge Hydraulic oil temperature sensor Resistance --- ---
--- HST circuit oil pressure sensor Semiconductor --- ---
Caution Air cleaner clogging sensor Contact Closed Open
--- Decelerator and brake pedal potentiometer Resistance --- ---
--- Fuel control dial Resistance --- ---
Gauge Fuel level sensor Resistance --- ---
Caution Charge filter clogging sensor Contact Open Closed
Gauge Coolant temperature sensor Resistance --- ---
Caution Engine oil pressure switch Contact Closed Open
--- Engine rotation sensor Electromagnetic --- ---
--- boost pressure and temperature sensor Resistance --- ---
Caution WIF sensor
--- HST motor speed sensor HaII IC --- ---
D51EX/PX-22 10-177
12
BRAKE OIL PRESSURE SENSOR
(HST charge oil pressure sensor)
A. Sensor
B. Connector
Function
This sensor is installed to the parking brake solenoid valve piping. It senses
the changes of the brake circuit pressure as the changes of voltage with the
semiconductor in it, and then generates signals according to the measured
pressure.
Operation
l The oil pressure is applied to the diaphragm of the oil pressure sensor
from the pressure intake part, the diaphragm is deformed.
l The deformation in the diaphragm causes the resistance of the gauge
to change. This causes a change in the output voltage, which is
transmitted to the amplifier (voltage amplifier).
l The relationship between the pressure applied to sensors (P) and

output voltage (E) is shown at right.
l The amplifier magnifies output voltage (E) and transmits it to HST
controller.
10-178 D51EX/PX-22
12
HYDRAULIC OIL TEMPERATURE SENSOR
1. Thermistor
2. Plug
3. Connector
Function
This sensor is installed to the pump suction piping. It senses the changes of the temperature as the changes of the resistance of
thermistor in it, and then generates signals according to the measured temperature.
D51EX/PX-22 10-179
12
HST CIRCUIT OIL PRESSURE SENSOR
1. Sensor
2. Connector
Function
This sensor is installed to the HST pump. It senses the changes of the right and left HST circuit pressures as the changes of
voltage with the semiconductor in it, and then generates signals according to the measured pressure.
Operation
The relationship between the pressure applied to sensor (P) and output
voltage (E).
10-180 D51EX/PX-22
12
AIR CLEANER CLOGGING SENSOR
1. Boss
2. Switch
3. Conduit
4. Wire
5. Connector
D51EX/PX-22 10-181
12
DECELERATOR PEDAL POTENTIOMETER
BRAKE PEDAL POTENTIOMETER
1. Potentiometer
2. Connector
Function
l The potentiometer is connected to the decelerator pedal, brake pedal,
and fuel control lever and its shaft is rotated according to the operating
angle of the pedal and lever.
l The movement of the shaft operates the internal variable resistor,
which generates a signal voltage by changing the source voltage of 5
V according to the operating angle.
10-182 D51EX/PX-22
12
FUEL CONTROL DIAL
1. Knob
2. Dial
3. Spring
4. Ball
5. Potentiometer
6. Connector
Function
l The fuel control dial is installed to the left side of the operator's seat.
l 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.
l The hatched areas in the following graph is the abnormality detection
areas. In those areas, the engine speed is reduced to a half.
D51EX/PX-22 10-183
12
FUEL LEVEL SENSOR
1. Connector 5. Spring
2. Float 6. Contact
3. Arm 7. Spacer
4. Body
Function
The fuel level sensor is installed to the side of the fuel tank. Its float moves up and down according to the fuel level.
The movement of the float operates the variable resistor through the arm. As a result, signals of change in resistance are
generated.
10-184 D51EX/PX-22
12
CHARGE FILTER CLOGGING SENSOR
Function
The charge filter clogging sensor is installed to the charge filter and its contact senses the pressures before and after the filter.
If the difference between those pressures exceeds the set level, the switch is turned ON.
COOLANT TEMPERATURE SENSOR
1. Sensor
2. O-ring
3. Connector
D51EX/PX-22 10-185
12
ENGINE OIL PRESSURE SWITCH
1. Connector
2. Sensor
3. O-ring
ENGINE ROTATION SENSOR
1. Connector
2. Sensor
3. O-ring
10-186 D51EX/PX-22
12
BOOST PRESSURE AND TEMPERATURE SENSOR
1. Connector
2. Sensor
3. O-ring
WIF SENSOR
(WATER-IN-FUEL)
1. Connector
2. Tube
3. Sensor
4. O-ring
D51EX/PX-22 10-187
12
HST MOTOR SPEED SENSOR
See HST motor, this section page 10-70.
10-188 D51EX/PX-22
20 STANDARD VALUE TABLES
STANDARD VALUE TABLE FOR ENGINE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-2

STANDARD VALUE TABLE FOR CHASSIS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-3
PERFORMANCE MEASURING POSTURE AND METHOD . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-8
H Note the following when making judgements using the standard value tables for testing, adjusting, or
troubleshooting.
1. The standard value for a new machine given in the table is the value used when shipping the machine from the
factory and is given for reference. It is used as a guideline for judging the progress of wear after the machine has
been operated, and as a reference value when carrying out repairs.
2. The service limit value given in the tables is the estimated value for the shipped machine based on the results of
various tests. It is used for reference together with the state of repair and the history of operation to judge if there
is a failure.
3. These standard values are not the standards used in dealing with claims.
WARNING! When carrying out testing, adjusting, or troubleshooting, park the machine on
level ground, insert the safety pins, and use blocks to prevent the machine from
moving.
WARNING! When carrying out work together with other workers, always use signals and do
not let unauthorized people near the machine.
WARNING! When checking the water level, always wait for the water to cool down. If the
radiator cap is removed when the water is still hot, the water will spurt out and
cause burns.
WARNING! Be careful not to get caught in the fan, fan belt or other rotating parts.
D51EX/PX-22 20-1
STANDARD VALUE TABLES STANDARD VALUE TABLE FOR ENGINE
12
STANDARD VALUE TABLE FOR ENGINE
Machine model D51EX-22, D51PX-22

Engine SAA6D107E-1
Standard
Cate- Service limit
gory Item Measurement conditions Unit value for new value
machine
l Engine coolant High idling 2270 ±50 2270 ±50
temperature: Within
operating range
Engine speed l HST oil temperature rpm
(hydraulic oil temperature): Low idling 850 ±25 850 ±25
Within operating range (40
- 60°C)
l Engine coolant temperature: Within operating
range
l HST oil temperature (hydraulic oil
Intake air pressure kPa Min. 131 106
temperature): Within operating range (40 -
(Boost pressure) (mmHg) (Min. 983) (795)
60°C)
l Stall pressure test mode + Work equipment
relief
range
Exhaust temperature temperature): Within operating range (40 - °C Max. 650 700
60°C)
l All speed range (Outside temperature: 20°C)
l Stall pressure test mode
l Engine coolant At sharp Max. 25 35
acceleration
Engine
Exhaust gas color temperature: Within %

operating range At high idling Max. 120 22
Intake valve 0.25 0.152 ~ 0.381
Valve clearance l Normal temperature mm
Exhaust valve 0.51 0.381 ~ 0.762
l SAE30 or SAE15W-40 oil Compression MPa Min. 2.41 1.69
Compression pressure (kg/cm2) (Min. 24.6) (17.2)
pressure l Engine oil
temperature: 40 - 60°C Engine speed rpm 250 ~ 280 250 ~ 280
range
l HST oil temperature (hydraulic oil Pa Max. 980 1.960
Blow-by pressure (mmH O)
temperature): Within operating range 2 (Max. 100) (200)
l Stall pressure test mode + Work
equipment relief
Min. 0.29 0.25
Oil pressure l SAE30 or SAE15W-40 oil At high idling (Min. 3.0) (2.5)
MPa
l Engine coolant temperature:
(kg/cm2) Min. 0.10 0.07
Within operating range At low idling
(Min. 1.0) (0.7)
Oil temperature l All speed range (In oil pan) °C 80 - 110 120
Oil consumption ratio l At continuous rated (ratio to fuel consumption) % Max. 0.15 0.3
Fan speed l At rated engine speed rpm Hydraulic driven fan
Air compressor belt l Deflection under pressing force of about 98 N (10
tension mm 15 - 18 15 - 18
kg)
20-2 e D51EX/PX-22
STANDARD VALUE TABLES STANDARD VALUE TABLE FOR CHASSIS
12
STANDARD VALUE TABLE FOR CHASSIS

Cate- Standard value Service limit

Item Measurement conditions Unit for new
gory machine value
Forward and l Engine: Stopped

PCCS lever
N  Forward/Reverse 29 ± 6 29 ± 6
reverse l Center of lever grip
l Engine: Stopped
Steering N - Sharp turn to right/left 50 ± 10 50 ± 10
l Center of lever knob
l Engine: stopped 1st stage 52 ±10 52 ±10
Brake pedal
l Center of pedal 2nd stage 75 ± 10 75 ± 10
mm
Stroke
l Engine: Stopped
Decelerator pedal 50 ±10 50 ±10
l Center of pedal
Neutral - Raise 47 ± 10 47 ± 20
l Engine: Stopped Neutral - Lower 46 ± 10 46 ± 20
Work equipment l Center of lever knob
Neutral - Float 71 ± 10 71 ± 20
control lever l Angle: Twisting angle of
lever Neutral - Left/Right tilt 52 ± 10 52 ± 20
Neutral - Left/Right angle ° 15 ± 3 15 ± 6
Forward and 55.9 ±9.8 55.9 ±11.8
N - Forward/Reverse
reverse (5.7 ±1.0) (5.7 ±1.2)
PCCS lever
44.1 ±8.8 44.1 ±9.8

Steering l Engine: Stopped N - Sharp turn to right/left (4.5 ±6.8) (4.5 ±1.0)
Operating effort
l Center of lever knob

l Button switch Shift-up 6.9 - 12.7 147.7
Shift-up/down N (0.7 - 1.3) (1.5)
switch (kg) 6.9 - 12.7 147.7
Shift-down
(0.7 - 1.3) (1.5)
142 ±28 199
1st stage (14.5 ±2.9) (20)
l Engine: stopped
Brake pedal
l Center of pedal 230 ±46 322
2nd stage
(23.5 ±4.7) (33)
D51EX/PX-22 20-3
12
Cate- Standard
Item Measurement conditions Unit value for new Service limit value
gory machine
l Engine: Stopped 70 ± 14 9.8
Decelerator pedal
l Center of pedal (7.1 ±1.4 (10)
22.5 ± 10 39.2
Neutral - Raise
(2.3 ± 1.0) (4.0)
Operating effort
N 25.5 ± 10 39.2
Neutral - Lower (kg) (2.6 ± 1.0) (4.0)
Work equipment l Engine: Low idling 70 ± 22 118
Neutral - Float
control lever l Center of lever knob (7.1 ± 2.2) (12.0)
25.5 ± 10 39.2
Neutral - Left/Right tilt
(2.6 ± 1.0) (4.0)
Neutral - Left/Right Nm 2.9 - 5.4 8.3
angle (kgm) (0.3 - 0.55) (0.9)
l Engine: High idling Forward - Left 40.2 - 44.1 39.2 - 45.1
(410 - 450) (400 - 460)
l HST oil temperature
(hydraulic oil 40.2 - 44.1 39.2 - 45.1
Forward - Right
Main circuit temperature): Within (410 - 450) (400 - 460)
pressure operating range (40 - 40.2 - 44.1 39.2 - 45.1
60°C) Reverse - Left (410 - 450) (400 - 460)
HST oil pressure
l Stall pressure test 40.2 - 44.1 39.2 - 45.1

mode Reverse - Right (410 - 450) (400 - 460)
MPa
HST
l Engine: High idling (kg/cm2) 3.23 ± 0.29 3.23 ± 0.29

PCCS lever: Neutral
l HST oil temperature (33 ± 3.0) (33 ± 3.0)
(hydraulic oil
Charge circuit temperature): Within
pressure operating range (40 - PCCS lever: Forward or 3.04 ± 0.29 3.04 ± 0.49
60°C) reverse (31 ± 3.0) (31 ± 5.0)
l Stall pressure test
mode
20-4 D51EX/PX-22
12
Cate- Standard
gory machine
l Engine: High idling 1st 3.4 ± 0.2 3.4 ± 0.4
l Quick shift mode Forward 2nd 5.6 ± 0.3 5.6 ± 0.6
l Reverse travel speed: Set to
3rd 9.0 ± 0.5 9.0 ± 0.8
center
l HST oil temperature 1st 4.1 ± 0.2 4.1 ± 0.4
(hydraulic oil temperature): 2nd 6.5 ± 0.3 6.5 ± 0.6
Within operating range (40 - Reverse
60°C)
3rd 9.0 ± 0.5 9.0 ± 0.8
l Measure on flat place.
Travel speed km/h
l Engine: High idling MIN 0.8 ±0.2 0.8 ±0.3
l Variable shift mode Forward
MAX 8.5 ± 0.5 8.5 ± 0.8
l Reverse travel speed: Set to
center MIN 0.8 ±0.2 0.8 ±0.3
(hydraulic oil temperature): Reverse
Within operating range (40 - MAX 9.0 ± 0.5 9.0 ± 0.8
60°C)
l Measure on flat place.
HST
l Engine: High idling

(hydraulic oil temperature): Within operating range
(40 - 60°C)
l Flat place (Hard and level place such as concrete
Travel deviation mm Max. 120 Max. 150
floor)
l After approach run of at least 10 m, measure
deviation in travel of 20 m.
l Measure deviation (x).
l For measuring posture, see "Travel 1".
l HST oil temperature (hydraulic oil temperature):
Within operating range (40 - 60°C)
l Travel lever: N (Neutral)
Hydraulic drift of travel l Travel lock lever: Free m Max. 3.6 Max. 4.0
l Stop machine on slope of 20°
l Posture of machine: With front side up and down
l Hydraulic drift (Hydraulic travel distance) in 1 minute
l For measuring posture, see "Travel 2".
Work equipment relief 27.44 ±0.98 24.5
pressure l HST oil temperature (hydraulic oil temperature): (280 ±10) (250)
Within operating range (40 - 60°C)
Min. 1.65 Min. 1.65
Neutral - Raise
Work equipment
(Min. 16.8) (Min. 16.8)
Neutral - Lower MPa Min. 1.37 Min. 1.37

l Engine: High idling (Min. 14.0) (Min. 14.0)
(kg/cm2)
Work equipment PPC l HST oil temperature (hydrau- Min. 2.01 Min. 2.01
Neutral - Float
valve output pressure lic oil temperature): Within (Min. 21.0) (Min. 21.0)
operating range (40 - 60±C) Min. 1.72 Min. 1.72
Neutral - Left/Right tilt (Min. 17.5) (Min. 17.5)
Neutral - Left/Right Min. 1.96 Min. 1.96
angle (Min. 20.0) (Min. 20.0)
D51EX/PX-22 20-5
12
Cate- Standard
gory machine
l (hydraulic oil temperature):
Raise 2.5 ± 0.2 3.0
l Within operating range(40 -
Blade lifting 60°C)
speed l Between max. lifting height
l and ground
Lower 1.9 ± 0.2 2.3
l For measuring posture, see
"Work equipment 1".
Work equipment speed

Left tilt 1.7 ± 0.2 2.1
(hydraulic oil temperature):
Within operating range(40 -
Blade tilting 60°C)
speed
l Between max. left and right
tilting positions
Right tilt 1.7 ± 0.2 2.1
"Work equipment 2". sec.
Left angle 4.5 ± 0.2 5.2
(hydraulic oil temperature):
Within operating range(40 -
Blade angling 60°C)
speed
l Between max. left and right
angling positions Right angle 4.5 ± 0.2 5.2
Work equipment
"Work equipment 3".

Time lag

Blade lifting time 60°C) 1.0 Max. 1.5
lag
l Lower blade from max. lifting height and
measure time after blade comes in contact
with ground until starts rising.
l Measure on level and flat place.
l Engine: Stopped
l Lever: Neutral
Hydraulic drift of
lifted blade 60°C) Max. 50 Max. 50
Hydraulic drift of work equipment
l Start measurement just after setting.

l Measure lowering distance (h) after 15
minutes.
l For measuring posture, see "Work equipment
4". mm/15
l Measure on level and flat place. min.
l Engine: Stopped
l Lever: Neutral
Hydraulic drift
of tilted blade 60°C) Max. 100 Max. 100
l Start measurement just after setting.
l Measure lowering distance (h) after 15
minutes.
l For measuring posture, see "Work equipment
5".
20-6 D51EX/PX-22

Standard
Cate-
gory Item Measurement conditions Unit value for new Service limit value
machine

Leakage from cylinder
Blade lift cylinder 1.6 6.5

l HST oil temperature (
Work equipment
hydraulic oil temperature): Within operating

range (40 - 60°C)
Blade tilt cylinder cc/min 1.6 6.5
l Fully extend piston rod of cylinder to be
measured and disconnect hose on head side.
Blade angle l Relieve circuit and measure leakage for 1 min- 1.6 6.5
cylinder ute. (Lift and tilt only)
Fan speed l Fan 100% mode rpm 1485 - 1515 1450 - 1550
Cooling
l Engine: High idle

fan
Work equipment pump MPa 18.6 - 20.6 17.6 - 21.6

l HST oil temperature (Hydraulic oil tempera-
pressure
ture): 50 - 60°C (kg/cm2) (190 - 210) (180 - 220)
 = Angle cylinder should be measured on a test stand.
D51EX/PX-22 20-7
STANDARD VALUE TABLES PERFORMANCE MEASURING POSTURE AND METHOD
12
PERFORMANCE MEASURING POSTURE AND METHOD
Travel 1: Travel deviation
Travel 2: Hydraulic drift travel
Work equipment 1: Blade lifting speed
Work equipment 2: Blade tilting speed
20-8 D51EX/PX-22
12
Work equipment 3: Blade angling speed
Work equipment 4: Hydraulic drift of lifted blade
Work equipment 5: Hydraulic drift of tilted blade
D51EX/PX-22 20-9
12
MEMORANDUM
20-10 D51EX/PX-22
30 TESTING AND ADJUSTING
LIST OF TOOLS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-3

ENGINE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-6
ENGINE SPEED . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-6
AIR INTAKE BOOST PRESSURE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-7
EXHAUST TEMPERATURE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-8
EXHAUST GAS COLOR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-10
VALVE CLEARANCE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-11
COMPRESSION PRESSURE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-14
BLOW-BY PRESSURE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-16
ENGINE OIL PRESSURE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-17
HANDLING CONTROLLER HIGH-VOLTAGE CIRCUIT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-18
FUEL SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-19
HANDLING FUEL SYSTEM PARTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-19
RELEASING RESIDUAL PRESSURE FROM FUEL SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-19
BLEEDING AIR FROM FUEL CIRCUIT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-20
FUEL PRESSURE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-22
FUEL RETURN RATE AND LEAKAGE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-24
FUEL CIRCUIT FOR LEAKAGE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-27
FAN (WORK EQUIPMENT) PUMP PRESSURE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-28
FAN SPEED . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-28
FAN SPEED SENSOR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-29
DECELERATOR PEDAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-31
HST OIL PRESSURE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-33
MOTOR CONTROL VALVE OUTLET PRESSURE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-38
TRAVEL DEVIATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-41
PARKING BRAKE LEVER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-42
BRAKE PERFORMANCE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-44
BRAKE PEDAL LINKAGE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-45
EMERGENCY RELEASE OF PARKING BRAKE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-47
IDLER CLEARANCE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-50
TRACK SHOE TENSION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-52
WORK EQUIPMENT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-53
OIL PRESSURE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-53
WORK EQUIPMENT PPC VALVE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-55
OIL PRESSURE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-55
ADJUSTING PLAY OF WORK EQUIPMENT PPC VALVE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-57
LOCK LEVER ADJUSTMENT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-58
CYLINDER LEAKAGE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-59
HYDRAULIC CIRCUIT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-61
RELEASING RESIDUAL PRESSURE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-61
BLEEDING AIR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-62
BLADE CENTER BALL ADJUSTMENT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-63
BLADE PITCH BALL ADJUSTMENT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-63
DIODES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-64
PROCEDURE FOR TESTING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-64
MONITOR PANEL (EMMS) - SPECIAL FUNCTIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-66
PREPARATION WORK FOR TROUBLESHOOTING FOR ELECTRICAL SYSTEM . . . . . . . . . . . . . . . . . 30-127
D51EX/PX-22 30-1
TESTING AND ADJUSTING
ELECTRIC/HYDRAULIC DEVICES ARE ADJUSTED/REPLACED . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-129
ITEMS TO BE ADJUSTED . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-129
HST CONTROLLER ADJUSTMENT AFTER REPLACEMENT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-130
MONITOR PANEL ADJUSTMENT AFTER REPLACEMENT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-133
PM-CLINIC . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-135
PM-CLINIC SERVICE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-135
PM-CLINIC INSPECTION SHEET (1/2) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-138
PM-CLINIC INSPECTION SHEET (2/2) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-139
PM-CLINIC UNDERCARRIAGE CHECK SHEET . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-140
UNDERCARRIAGE TROUBLESHOOTING REPORT (NORMAL) . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-141
UNDERCARRIAGE TROUBLESHOOTING REPORT (IMPACT) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-142
PM-CLINIC UNDERCARRIAGE CHECK SHEET . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-143
UNDERCARRIAGE TROUBLESHOOTING REPORT (NORMAL) . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-144
UNDERCARRIAGE TROUBLESHOOTING REPORT (IMPACT) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-145
30-2 D51EX/PX-22
TESTING AND ADJUSTING LIST OF TOOLS
12
LIST OF TOOLS
Testing and adjusting item Symbol Part No. Part name Q'ty Remarks
-101 - 200 kPa
Measuring intake air pressure 799-201-2202 Boost gauge kit 1
A (-760 - 1,500 Hg)
(boost pressure)
799-401-2220 Hose 1 I-coupler type (if necessary)
Measuring exhaust
B 799-101-1502 Digital thermometer 1 -99.9 - 1,299°C
temperature
Handy smoke
1 799-201-9001 1
checker
Measuring exhaust gas color C Bosch index: 0 - 9
Commercially
2 Smoke meter 1
available
1 795-799-1131 Gear 1 For 107 Series engine
Adjusting valve clearance D Commercially
2 Feeler gauge 1
available
1 795-502-1590 Compression gauge 1
Measuring compression 2 795-799-6700 Puller 1

E
pressure 795-502-4410 Adapter 1 For 107 Series engine
3
6754-11-3130 Gasket 1
1 799-201-1504 Blow-by checker 1 0 - 5 kPa (0 - 500 mmH2O)
Measuring blow-by pressure F
2 799-201-1411 Adapter 1
Pressure gauge: 2.5, 6.0, 40,
1 799-101-5002 Hydraulic tester 1
58.8 MPa (25, 60, 400, 600 kg/cm2)
2 790-301-1220 Nipple 1
Measuring engine oil pressure G
3 799-101-5160 Nipple 1
Pressure gage:
4 799-401-2320 Gauge 1
1.0 MPa (10 kg/cm2)
Pressure gauge: 6.0, 40, 60 MPa
799-101-5002 Hydraulic tester 1
(25, 60, 400, 600 kg/cm2)
1
Pressure gage:
790-261-1204 Digital hydraulic tester 1
60 MPa (600 kg/cm2)
Measuring fuel pressure H
6732-81-3170 Adapter 1 10 x 1.0 mm ï PT1/8
2
6215-81-9710 O-ring 1
Pressure gauge:
3 795 - 790 - 1470 Pressure gauge 1 0 ~ 254 kPa (0 ~ 75 in/Hg)
1 795-790-4700 Tester kit 1
2 799-401-3200 Adapter 1
6754-71-5340 Connector 1
3
Measuring fuel return rate and 6754-71-5350 Washer 1
I
leakage
Commercially
4 Measuring cylinder 1
available
Commercially
5 Stopwatch 1
available
799-101-5002 Hydraulic tester 1 h Same as G1
1 Pressure gage:
Testing and adjusting HST oil 790-261-1204 Digital hydraulic tester 1
J 60 MPa (600 kg/cm2)
pressure
799-101-5220 Nipple 4 Size: 10 x 1.25 mm
2
07002-11023 O-ring 4
D51EX/PX-22 30-3
Testing and adjusting item Symbol Part No. Part name Q'ty Remarks
1 Digital hydraulic h Same as G1
790-261-1203 1
tester
Measuring motor control 799-401-3100 Adapter 1 Size: 02
K
valve output pressure for HST 2
799-401-3200 Adapter 1 Size: 03
799-101-5230 Nipple 1
3 Size: 14 x 1.5 mm
07002-11423 O-ring 1
1 790-190-1500 Pump assembly 1 ---
Method of releasing parking
brake (Procedure for M 799-101-5220 Nipple 4
emergency escape) 2 Size: 10 x 1.25 mm
07002-11023 O-ring 4
Testing and adjusting work 799-101-5002 Hydraulic tester 1

N 1 h Same as J
equipment oil pressure 790-261-1203 Digital hydraulic tester 1
Measuring work equipment 1 h Same as G1
P 790-261-1203 Digital hydraulic tester 1
PPC valve output pressure
2 799-401-3100 Adapter 1 Size: 02
Measuring leakage in work Commercially
Q Measuring cylinder 1
equipment cylinder available
Measuring water temperature --- 799-101-1502 Digital thermometer 1 h Same as B
and oil temperature
Adjusting decelerator pedal & --- 79A-264-0091 Push-pull scale 1 0 - 490 N {0 - 50 kg}
brake pedal
Measuring stroke and Commercially
--- Scale 1 ---
hydraulic drift available
Measuring work equipment Commercially
--- Stopwatch 1 ---
speed available
Measuring voltage and Commercially
--- Circuit tester 1 ---
resistance available
30-4 D51EX/PX-22
12
MEMORANDUM
D51EX/PX-22 30-5
TESTING AND ADJUSTING ENGINE
12
ENGINE
ENGINE SPEED
H Measure the engine speed under the following condition.
• Engine coolant temperature: Within operating range
• HST oil (Hydraulic oil) temperature: Within operating range (40 – 60°C)
1. Preparation work
Turn the starting switch ON and set the monitor panel in the "Real-time monitoring mode" to prepare for measurement of
the engine speed.
H For the operating method, see "Special functions of monitor panel
(EMMS)".
• Controller: ENGINE
• Monitoring code: 01002-ENG SPEED
• The engine speed is displayed in rpm.
2. Measuring low idle speed

A. Start the engine and set the fuel control dial in the low idle
position.
B. Set the PCCS lever and blade control lever in neutral and measure
the engine speed.
3. Measuring high idle speed

A. Start the engine and set the fuel control dial in the high idle position.
B. Set the PCCS lever and blade control lever in neutral and measure the engine speed.
4. Measuring decelerator pedal speed

A. Start the engine and set the fuel control dial in the high idle position.
B. Set the PCCS lever and work equipment control lever in neutral and press the decelerator pedal and measure the
engine speed.
H The engine speed when the decelerator pedal is pressed to the stroke end is the same as the low idle speed.
30-6 D51EX/PX-22
12
AIR INTAKE BOOST PRESSURE
H Testing air boost pressure
WARNING! Be careful not to touch any hot part when

removing or installing the testing tools.
1. Remove air boost pressure pickup plug (1).
2. Install nipple (1) of boost gauge kit A and connect it to gauge [2].
3. Run the engine at the rated output and test the air boost pressure.
• When testing with the engine mounted on the machine, test on the
condition described in the shop manual for the machine.
4. After finishing testing, remove the measuring tools and return the
removed parts.
D51EX/PX-22 30-7
12
EXHAUST TEMPERATURE
WARNING! Install and remove the measuring

instrument after the exhaust manifold is
cooled.
H Measure the exhaust temperature under the following condition.

• HST oil (Hydraulic oil) temperature: Within operating range (40 - 60°C)
1. Open the right engine side cover and remove exhaust temperature pickup plug (1) from the exhaust pipe.
2. Install sensor [1] of digital thermometer B and connect them to meter

[2].
H Clamp the wiring harness of the digital thermometer so that it will
not touch a hot part during measurement.
Remark
(1)is exhaust port measurement point.
3. When measuring the maximum exhaust temperature for

troubleshooting, observe the following procedure.
Operate the machine actually and measure the maximum exhaust
temperature.
H Set the digital thermometer in the PEAK mode.
H The exhaust temperature largely depends on the ambient
temperature (intake air temperature of the engine). Accordingly, if
any abnormal value is obtained, correct it by the following
calculation.
• Corrected value [°C] = Measured value + 2 x (20 - Ambient
temperature)
4. When measuring the exhaust temperature periodically for preventive

maintenance (Pm Clinic), observe the following procedure.
A. Turn the starting switch ON, set the monitor panel in the
"Adjustment mode", and prepare for stalling the HST.
H When performing this operation, set the parking brake lever
in the LOCK position and the PCCS lever in the neutral
position.
H For the operating method, see "Special functions of monitor
panel (EMMS)".
• Adjustment code: 3016-STALL CHECK
B. Start the engine and keep the parking brake lever in the LOCK
position.
H Stall the HST with the parking brake lever in the LOCK posi-
tion.
30-8 D51EX/PX-22
12
C. While running the engine at high idle, operate PCCS lever in the
forward or reverse position to stall the HST and measure the
exhaust temperature.
H If the PCCS lever is set in the forward or reverse position, the
HST stalls. If the PCCS lever is returned, stalling of the HST
stops.
WARNING! While the HST is stalled, the oil

temperature rises sharply and locally.
Accordingly, do not stall the HST
continuously for more than 30 seconds.
5. After finishing measurement, remove the measuring instruments and

return the removed parts.
D51EX/PX-22 30-9
12
EXHAUST GAS COLOR
WARNING! When installing and removing the

measuring instruments, take care not to
touch a hot part.
H 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.
H Measure the exhaust gas color under the following condition.
1. Measuring with handy smoke checker C1.

A. Stick a sheet of filter paper to smoke checker C1.
B. Insert the exhaust gas intake pipe in exhaust pipe (1).
C. Run the engine.
D. Accelerate the engine suddenly or run it at high idling and operate
the handle of smoke checker C1 so that the filter paper will
absorb the exhaust gas.
E. Remove the filter paper and compare it with the attached scale.
F. After finishing measurement, remove the measuring instrument
and return the removed parts.
2. Measuring with smoke meter C2.

A. Insert probe [1] of smoke meter C2 in the outlet of exhaust pipe
(1) and fix it to the exhaust pipe with a clip.
B. Connect the probe hose, receptacle of the accelerator switch, and
air hose to smoke meter C2.
H Limit the supplied air pressure to 1.5 MPa {15 kg/cm2} (213
psi).
C. Connect the power cable to a receptacle of AC socket.
H Before connecting the cable, check that the power switch of
the smoke meter is turned OFF.
D. Loosen the cap nut of the suction pump and fit the filter paper.
H Fit the filter paper securely so that the exhaust gas will not
leak.
E. Turn on the power switch of smoke meter C2.
F. Start the engine.
G. Accelerate the engine suddenly or run it at high idling and press
the accelerator pedal of smoke meter C2 and collect the exhaust
gas into the filter paper.
H. Place the contaminated filter paper on the clean filter paper (at
least 10 sheets) in the filter paper holder and read the indicated
value.
I. After finishing measurement, remove the measuring instrument
30-10 D51EX/PX-22
12
VALVE CLEARANCE
1. Remove cylinder head cover (1).
2. Remove cap (2) from flywheel housing and install barring tool D1.
3. Rotate the crankshaft forward using barring tool D1 until the stamped
“1.6TOP” line (a) of the crankshaft pulley faces upward and set the
No. 1 cylinder to the compression top dead center.
H When the No. 1 cylinder is at the compression top dead center, the
rocker arm of the No. 1 cylinder can be moved by the valve
clearance with the hand. If the rocker arm cannot be moved, rotate
the crankshaft one more turn. (Alternatively, adjust the valve
clearance indicated by m of the valve layout plan in the next
section without rotating the crankshaft.)
D51EX/PX-22 30-11
12
4. Adjust the valve clearance of No. 1 cylinder according to the
following procedure.
valve clearance indicated by l of the valve layout plan can be
adjusted.
• Valve layout plan
A. Insert clearance gauge D2 into the clearance between rocker arm
(3) and crosshead (4).
B. Loosen locknut (5) and adjust valve clearance using adjustment
screw (6).
H With the filler gauge inserted, turn the adjustment screw to a
degree that you can move the filler gauge lightly.
C. Fix adjustment screw (6) and tighten locknut (5). 3Locknut:
Locknut: 24 ± 4 Nm (17.7 ± 2.9 lbf ft)
H After tightening the locknut, check the valve clearance again.
5. In the same manner as step 3, rotate the crankshaft forward using

barring tool D1 until the stamped "1.6TOP" line (a) of the crankshaft
pulley faces upward.
6. Adjust the valve clearance of No. 6 cylinder.

H The adjustment method is the same as step 4.
valve clearance indicated by m of the valve layout plan can be
adjusted.
7. After finishing adjustment, return the removed parts.
Cylinder head cover mounting bolt:

24 ± 4 Nm (17.7 ± 2.9 lbf ft)
8. Remove barring tool before operating engine.
30-12 D51EX/PX-22
12
MEMORANDUM
D51EX/PX-22 30-13
12
COMPRESSION PRESSURE
WARNING! Stop the machine on a level ground and

lower the work equipment to the ground.
H Measure the compression pressure under the following condition.

• Engine oil temperature: 40 – 60°C
1. Remove the engine hood and remove cylinder head cover (1).
H Since the breather connector on the rear side of the cylinder head
cover is connected to the flywheel housing through the O-ring,
pull it together with the cylinder head cover.
2. Remove the mounting bolts of rocker arm assembly (2) on the exhaust
side, and then remove rocker arm assembly (2).
H When removing the injector, you do not need to remove the
rocker arm assembly on the intake side.
3. Remove fuel tube (3), and then remove inlet connector (7) in the
cylinder head.
H The inlet connector is connecting the fuel tube to the injector.
4. Disconnect injector wiring harness. Using tool E2, remove injector

(4).
5. Install adapter E3 to the injector mounting part with the injector clamp
and connect compression gauge E1.
H Install the gasket to the adapter end without fail.
Injector clamp mounting bolt:

1st time: 3.5 ± 0.35 Nm (2.5 ± 0.25 lbf ft)
2nd time: 75 ± 5 ° (Angle tightening)
H If a little quantity of engine oil is applied the joint of the adapter

and gauge, air does not leak easily.
6. Install rocker arm assembly (2) on the exhaust side and adjust the
valve clearance.
H See “Adjusting valve clearance”.
30-14 D51EX/PX-22
12
7. Disconnect CN-117 connector (5) of the engine controller.
WARNING! If the connector is not disconnected, the

engine will start during measurement
which will be dangerous.
WARNING! Since the CN-117 connector is a part of

the power supply circuit of the engine
controller, cover the connector on the
machine side with electrical tape, etc. to
prevent sparking and a ground fault.
8. Rotate the engine with the starting motor and measure the
compression pressure.
H Read the gauge when the pointer is stabilized.
9. After finishing measurement, remove the measuring tools and return

the removed parts.
H Install the injector and inlet connector according to the following
procedure.
A. Apply new engine oil (SAE15W-40) to the O-ring of injector (4)
and cylinder head.
B. Install injector (4) with the fuel inlet hole directed to the air intake
manifold.
C. Install injector clamp (6) and tighten the mounting bolt by 3 – 4
threads.
D. Install inlet connector (7) and tighten inlet connector retainer
temporarily.
E. Tighten the mounting bolt of injector clamp (6) securely.
Injector clamp mounting bolt:

8 ± 0.8 Nm (5.9 ± 0.59 lbf ft)
F. Tighten inlet connector retainer (8) securely.
Inlet connector retainer: 50 ± 5 Nm (36.8 ± 3.6 lbf ft)
H Tighten the bolts and nuts other than the injector and inlet connector to the following torque.
Injector wiring harness nut:

1.5 ± 0.25 Nm (1.1 ± 0.18 lbf ft)
Fuel tube sleeve nut: 35 ± 3.5 Nm 25.8 ± 2.58 lbf ft)
Rocker arm assembly mounting bolt:

36 ± 6 Nm (26.5 ± 4.4 lbf ft)
H Adjust the valve clearance. For details, see “Adjusting valve clearance”.
Cylinder head cover mounting nut:

24 ± 4 Nm 17.7 ±2.9 lbf ft)
D51EX/PX-22 30-15
12
BLOW-BY PRESSURE
H Measure the blow-by pressure under the following condition.
• HST oil (Hydraulic oil) temperature: Within operating range (40 -
60°C)
1. Open the left engine side cover and pull out blow-by hose (1).
2. Install nozzle tool F2 to blow-by hose (1) and connect it to gauge [1]
of blow-by checker F1.
3. Turn the starting switch ON, set the monitor panel in the "Adjustment
mode", and prepare for stalling the HST.
H When performing this operation, set the parking brake lever in the
LOCK position and the PCCS lever in the neutral position.
H For the operating method, see "Special functions of monitor panel
(EMMS)".
H Adjustment code: 3016-STALL CHECK
4. While keeping the parking brake lever in the LOCK position, set the
work equipment lock lever in the FREE position and raise the blade to
the stroke end.
H Stall the HST with the parking brake lever in the LOCK position.
5. While running the engine at high idle, operate PCCS lever in the
forward or reverse position to stall the HST and relieve the blade
circuit by raising the blade, and then measure the blow-by pressure.
H If the PCCS lever is set in the forward or reverse position, the
HST stalls. If the PCCS lever is returned, stalling of the HST
stops.
WARNING! While the HST is stalled, the oil

temperature rises sharply and locally.
Accordingly, do not stall the HST
continuously for more than 30 seconds.

30-16 D51EX/PX-22
12
ENGINE OIL PRESSURE
1. Remove right engine side covers.
2. Remove oil pressure pickup plug (1).
3. Install the nipples to the plug mount in order of G2 and G3.

• Test the engine at standard operating conditions.
4. Connect the hose of the hydraulic tester G1 to the nipples and gauge
G4.
5. Run the engine at the rated output and low idle and test the oil
pressure.
H When testing with the engine mounted on the machine, test on the
condition described in the shop manual for the machine.
6. After finishing testing, remove the measuring tools and return the
removed parts.
D51EX/PX-22 30-17
TESTING AND ADJUSTING HANDLING CONTROLLER HIGH-VOLTAGE
12
HANDLING CONTROLLER HIGH-VOLTAGE CIRCUIT
WARNING! The engine controller uses a high-voltage

circuit to drive the fuel injector.
Accordingly, the high-voltage circuit is
connected to the wiring harnesses and
connectors between the engine controller
and injector.
H Normally, the engine controller keeps outputting the high voltage to

the injector only while the engine is running and quits outputting when
the engine stops.
WARNING! If you touch the high-voltage circuit

directly, you may get an electric shock. To
avoid this, observe the following
precautions when testing.
1. The following connectors are used in the high voltage circuit.

• Engine controller connector: C1
• Injector intermediate connector: C3 = INJ CYL 1&2,
C4 = INJ CYL 3&4,
C5 = INJ CYL 5&6
• Injector head terminal (in head cover)
2. When disconnecting or connecting a connector related to the high-voltage circuit, be sure to turn the starting switch OFF.
3. If a T-adapter is inserted in or connected to a connector related to the high-voltage circuit for troubleshooting, do not start
the engine.
H You may turn the starting switch to the OFF or ON position but must not turn it to the START position.
30-18 D51EX/PX-22
TESTING AND ADJUSTING FUEL SYSTEM
12
FUEL SYSTEM
HANDLING FUEL SYSTEM PARTS

H Precautions for checking and maintaining fuel system
The common rail fuel injection system (CRIS) consists of more precise parts than the conventional fuel injection pump
and nozzle. If foreign matter enters this system, it can cause trouble. When checking 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.
H Precautions for replacing fuel filter cartridge
Be sure to use the Komatsu genuine fuel filter cartridge.
Since the common rail fuel injection system (CRIS) consists of more precise parts than the conventional fuel injection
pump and nozzle, it employs a high-efficiency special filter to prevent foreign matter from entering it. If a filter other than
the genuine one is used, the fuel system may have a trouble. Accordingly, never use such a filter.
RELEASING RESIDUAL PRESSURE FROM FUEL SYSTEM

H Pressure is generated in the low-pressure circuit and high-pressure circuit of the fuel system while the engine is running.
Low-pressure circuit: Feed pump – Fuel main filter – Supply pump
High-pressure circuit: Supply pump – Common rail – Injector
H The pressure in both low-pressure circuit and high-pressure circuit lowers to a safety level automatically 30 seconds after
the engine is stopped.
H Before the fuel circuit is checked and its parts are removed, the residual pressure in the fuel circuit must be released
completely. Accordingly, observe the following.
WARNING! Before checking the fuel system or removing its parts, wait at least 30 seconds after
stopping the engine until the residual pressure in the fuel circuit is released. (Do not start
the work just after stopping the engine since there is residual pressure.)
D51EX/PX-22 30-19
12
BLEEDING AIR FROM FUEL CIRCUIT
H If fuel is used up or if a fuel circuit part is removed and installed, bleed air from the fuel circuit according to the following
procedure.

1. Fill the fuel tank with fuel.
2. Open the front cover of the engine hood.
Remark
Item 2 is the water separator.
3. Loosen knob (1) of the feed pump and pull it out, and then operate it
forward and backward.
H Move the knob until it becomes stiff.
H The plug at the top of the fuel main filter does not need to be
removed.
4. After bleeding air, push in and tighten knob (1).
30-20 D51EX/PX-22
12
H Air bleeding route of fuel circuit
Fuel tank ß Pre-filter ß Feed pump ß Main filter ß Metering unit ß Fuel tank
D51EX/PX-22 30-21
12
FUEL PRESSURE
WARNING! Stop the machine on a level ground and lower the work equipment to the ground.
H Measure only the fuel pressure in the low-pressure circuit from the feed pump through the fuel main filter to the supply
pump and the return circuit from the supply pump/common rail/injector to fuel tank.
WARNING! Since the pressure in the high-pressure circuit from the supply pump through the
common rail to the injector is very high, it cannot be measured.
1. Measuring pressure in fuel low-pressure circuit.

A. Open the engine hood and remove fuel pressure pickup plug (1)
from the fuel main filter.
B. Install adapter H2 and nipple [1] of hydraulic tester H1 and

connect them to oil pressure gauge [2].
H Use the oil pressure gauge of 2.5 MPa {25 kg/cm2}.
C. Run the engine at low idle and measure the pressure in the fuel
low-pressure circuit.
H If the pressure in the fuel low-pressure circuit is in the
following range, it is normal.
At low idle 0.5 - 1.3 MPa (5.1 - 13.3 kg/cm2)

During cranking 0.3 - 1.1 MPa (3.1 - 11.3 kg/cm2)
WARNING! If the engine cannot be started, you may

measure the fuel pressure while rotating
the engine with the starting motor. Do not
rotate for more than 20 seconds continu-
ously, however, for protection of the start-
ing motor.
D. After finishing measurement, remove the measuring tools and

Fuel pressure pickup plug: 10 ± 2 Nm (7.3 ± 1.4 lbf ft)
30-22 D51EX/PX-22
12
2. Measuring pressure in fuel return circuit.
A. Disconnect the fuel return elbow (2) from the check valve at the
rear of the head.
B. Install adapter [F4] between fuel return hose and check valve.
C. Install nipple [1] of hydraulic tester F1 and connect to pressure
gauge.
Nipple [3]: . . . . . . . . . . . . . . . . . . . . . . 790-301-1181, 07002-11223
D. Run the engine at low idle and measure the pressure in the fuel
return circuit.
H If the pressure in the fuel return circuit is in the following
range, it is normal.
At low idle Max. 0.02 MPa

During cranking (Max. 0.19 kg/cm2)

measure the fuel pressure while rotating
rotate for more than 20 seconds continu-
ously, however, for protection of the start-
ing motor.
E. After finishing measurement, remove the measuring tools and return the removed parts.
Fuel pressure pickup plug: 24 ± 4 Nm (17.7 ± 2.9 lbf ft)
D51EX/PX-22 30-23
12
FUEL RETURN RATE AND LEAKAGE
H Since some fuel flows out during check, prepare an oil (receiving) pan of about 20 liters.

1. Measuring return rate from supply pump.

A. Open the engine hood and disconnect return hose (1) of the
supply pump.
H The return hose is connected by a quick coupler.
B. Install connector I3 and cap nut [1] of tester kit I1 to the return
hose to stop the fuel from flowing out.
C. Connect test hose [2] of tester kit I1 to the supply pump.
H Lay the test hose so that it will not slacken and put its end in
the oil (receiving) pan.
D. Run the engine at low idle and measure the return rate in 1 minute
with measuring cylinder I4.
H If the return rate from the supply pump is in the following
At low idle 1,000 cc/min
During cranking 140 cc/min

measure the fuel return rate while rotating
rotate for more than 20 seconds
continuously, however, for protection of
the starting motor.
H When measuring the leakage from the pressure limiter or finishing the measurement: Return the removed parts to
their original positions.
H When measuring the leakage from the injector: Leave the removed parts as they are and keep the hose end in the
oil pan.
30-24 D51EX/PX-22
12
2. Measuring leakage from pressure limiter.
A. Open the engine hood and disconnect return hose (2) of the
pressure limiter.
H Install the seal washer to the connector bolt.
B. Install removed connector bolt -3 and cap nut [I1] of tester kit I1
to the return hose to stop the fuel from flowing out.
C. Install connector I3 to the common rail and connect test hose [2]
of tester kit I1.
H If the leakage from the pressure limiter is in the following
At low idle 0 cc (No leakage)
E. After finishing measurement, remove the measuring tools and

Joint bolt: 24 ± 4 Nm (17.7 ± 2.9 lbf ft)
3. Measuring return rate from injector.

H The leakage from the injector is measured while the return hose of
the pressure limiter is connected. Accordingly, before measuring the leakage from the injector, check that the leakage
from the pressure limiter is normal.
A. Referring to Measuring return rate from supply pump, set the supply pump for testing.
WARNING! The fuel returning from the supply pump flows out during measurement of the return rate
from the injector. Accordingly, keep the test hose end in the oil pan.
D51EX/PX-22 30-25
B. Disconnect return hose (4) of the return block.
H Install the seal washer to the return hose.
C. Install connector bolt [3] of adapter I2 instead of the removed

connector bolt, and connect test hose [4].
H If the return rate from the injector is in the following range, it
is normal.
At low idle 180 cc/min
During cranking 90 cc/min

measure the fuel return rate while rotating
rotate for more than 20 seconds
continuously, however, for protection of
the starting motor.
Joint bolt: 24 ± 4 Nm (17.7 ± 2.9 lbf ft)
30-26 D51EX/PX-22
12
FUEL CIRCUIT FOR LEAKAGE
WARNING! Very high pressure is generated in the high-pressure circuit of the fuel system. If fuel
leaks while the engine is running, it is dangerous since it can catch fire.
After checking the fuel system or removing its parts, check it for fuel leakage according to
the following procedure.
WARNING! Stop the machine on a level ground and lower the work equipment to the ground.
H Clean and degrease the engine and the parts around it in advance so that you can check it easily for fuel leakage.
1. Spray color checker (developer) over the fuel supply pump, common rail, fuel injector, and joints of the high-pressure
piping.
2. Run the engine at speed below 1,000 rpm and stop it after its speed is stabilized.
3. Check the fuel piping and devices for fuel leakage.

H Check mainly around the high-pressure circuit parts coated with the color checker for fuel leakage.
H If any fuel leakage is detected, repair it and check again from step 2.
4. Run the engine at low idle.

6. Run the engine at high idle.

H Check around the high-pressure circuit parts coated with the color checker for fuel leakage.
8. Run the engine at high idle and load it.

H Relieve the blade lift circuit at the IN stroke end.

H If no fuel leakage is detected, check is completed.
D51EX/PX-22 30-27
TESTING AND ADJUSTING FAN (WORK EQUIPMENT) PUMP PRES-
12
FAN (WORK EQUIPMENT) PUMP PRESSURE
Remark
If the HST oil temperature is below 45°C and the engine coolant temperature is below 60°C, the fan EPC
command current is set to 1,000 mA and the fan speed lowers below 200 rpm even in the fan 100% mode.
In this case, increase the oil temperature to above 55°C and the coolant temperature to above 65°C and
then check again.
• HST oil (Hydraulic oil) temperature: 50 - 60°C.
1. Measuring fan motor pressure.

A. The fan motor is common with the work equipment pump.
B. Measure the oil pressure at the same port as for the work equipment pump.
See "Testing and adjusting work equipment oil pressure".
FAN SPEED
MEASURING FAN SPEED
Remark
If the HST oil temperature is below 45°C and the engine coolant temperature is below 60°C, the fan EPC
command current is set to 1,000 mA and the fan speed lowers below 200 rpm even in the fan 100% mode.
In this case, increase the oil temperature to above 55°C and the coolant temperature to above 65°C and
then check again.
H Measure the fan speed under the following conditions.
• HST oil (Hydraulic oil) temperature: 50 - 60°C.
1. Preparation work
H Measure the fan speed in the "Fan 100% mode".
A. Turn the starting switch ON and set monitor panel in the "Tuning mode" and select the "Fan 100% mode".
H For operation method, see "Special functions of monitor panel (EMMS)".
• Tuning code: 3022 FAN MODE
B. Set monitor panel in the: Real time monitoring mode" to prepare
for measurement of the fan speed.
H For operation method, see "Special functions of monitor
panel (EMMS)".
• Controller: HST
• Monitor code: 10007 FAN SPEED
• The fan speed is displayed in rpm.
2. Measuring fan speed

A. Start the engine and set the fuel control dial in the high idle posi-
tion.
B. Set the PCCS lever and blade control lever in neutral and measure
the fan speed.
30-28 D51EX/PX-22
TESTING AND ADJUSTING FAN SPEED
12
FAN SPEED SENSOR
ADJUSTING
H If the fan speed sensor has been removed and installed or its signal
contains an error, adjust it according to the following procedure.
H Remove fan speed sensor (1) before adjusting it and check that its tip
is free from steel chips.
The fan speed sensor is installed to the left top of the fan motor.
To install sensor:
1. Position indicator (2) on fan assembly in order to have a bar in front of

the threaded indicator hole.
2. Install sensor (1) by threading in until stopped by the indicator plate

(2).
3. Rotate out two full turns.
4. If sensor wire lies in "Zone A" after adjustment, rotate sensor counterclockwise until wire is in the "Required position
range".
5. If sensor wire lies in "Zone B" after adjustment, rotate sensor clockwise until wire is in the "Required position range".
D51EX/PX-22 30-29
TESTING AND ADJUSTING FAN SPEED
6. If sensor wire lies in "Zone C" after adjustment, no further rotation is required.
Jam nut: 49 ~ 68.7 Nm (36.1 ~ 50.6 lbf ft)
7. After finishing adjustment, check that the monitor panel displays the fan speed normally in the "Real-time monitoring
mode".
H For the operating method, see "Special functions of the monitor panel (EMMS)".
• Controller: HST
• Monitoring code: 10007-FAN SPEED
30-30 D51EX/PX-22
TESTING AND ADJUSTING DECELERATOR PEDAL
12
DECELERATOR PEDAL
ADJUSTING
H When adjusting the decelerator pedal, remove the dashboard cover, dashboard undercover and pedal assembly.
Place the removed pedal assembly on the floor and connect the wiring harness connector between floor and pedal.
1. Adjusting decelerator pedal potentiometer

A. Turn the starting switch ON and change the monitor for display of the decelerator pedal potentiometer voltage in the
"real-time monitoring mode".
• Monitoring code: 31702-DECEL PEDAL
• For the operating method, see "Special functions of monitor panel (EMMS)".
B. Adjust installed dimension (b) of stopper (2) so that pedal height (a) will be 209 mm when decelerator pedal (1) is in
neutral.
• Dimension (b) = 33.1 mm (Reference value)
C. Adjust (Rotate) the installed position of the potentiometer so that the decelerator pedal potentiometer voltage will be
the specified voltage when decelerator pedal (1) is in neutral.
DECEL PEDAL VOLTAGE: . . . . . . . . . . . . . . . . . . . . 1.23 ± 0.10 V
D. Adjust stopper (3) temporarily so that pedal height (c) will be 159 mm when decelerator pedal (1) is pressed to the
stroke end.
E. Adjust installed dimension (d) of stopper (3) so that decelerator pedal potentiometer voltage will be the specified
voltage when decelerator pedal (1) is pressed to the stroke end.
DECEL PEDAL VOLTAGE: . . . . . . . . . . . . . . . . . . . . 2.59 ± 0.10 V
• Dimension (d) = 22.3 mm (Reference value)
D51EX/PX-22 30-31
TESTING AND ADJUSTING DECELERATOR PEDAL
12
2. Measuring decelerator pedal pressing effort
A. Press the decelerator pedal with the foot to check that it operates smoothly.
B. If the decelerator pedal does not operate smoothly, supply grease through grease fitting (4) and apply grease to spring
(5).
Grease fitting (4): . . . . . . . . . . . . . . . . . . . . . . . . . . . Grease (G2-LI)
Spring (5): . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Grease (G2-LI)
C. Using push-pull scale, measure the full-stroke pressing effort of the decelerator pedal.
Full-stroke pressing effort: . . . . . . . . . . . . . . . . . . . . . 71 N {7.3 kg}
3. Work after finishing measurement

After finishing all adjustment, return the removed parts.
4. Testing decelerator pedal potentiometer

A. Turn the starting switch ON and change the monitor for display of the decelerator pedal operating degree in the
• Monitoring code: 31701-DECEL PEDAL
B. The relationship between the position and operating degree of the decelerator pedal is shown below.
Decelerator pedal
Decelerator pedal
operating degree
Released 100%
Pressed (Fully) 0%
30-32 D51EX/PX-22
TESTING AND ADJUSTING HST OIL PRESSURE
12
HST OIL PRESSURE
MEASURING
H Measure the HST oil pressure under the following condition.

1. Measuring HST main circuit pressure.

H Measure the HST main circuit pressure in the "Tuning mode" of the monitor panel.
WARNING! If the HST is stalled while the bypass valve (tow valve) of the parking brake circuit is
closed, the HST equipment may be damaged or it may move beyond your expectations.
Accordingly, do not stall the HST out of the "Tuning mode".
A. Turn the starting switch ON, set the monitor panel in the "Tuning mode", and prepare for stalling the HST.
• When performing this operation, set the parking brake lever in the LOCK position and the PCCS lever in the
neutral position.
• Tuning code: 3016-STALL CHECK
• If the HST main circuit pressure is selected in the tuning
mode, it is displayed in 0.1 MPa.
(The figure shows the item displayed first (engine speed)
when the mode is selected.)
B. Start the engine and keep the parking brake lever in the LOCK
position.
• Stall the HST with the parking brake lever in the LOCK
position.
C. While running the engine at high idle, operate PCCS lever in the
forward or reverse position to stall the HST and measure the HST
main circuit pressure.
• If the PCCS lever is set in the forward or reverse position, the
HST stalls. If the PCCS lever is returned, stalling of the HST stops.
WARNING! While the HST is stalled, the oil temperature rises sharply and locally. Accordingly, do not
stall the HST continuously for more than 30 seconds.
2. Measuring HST charge circuit pressure

A. Measure the HST charge circuit pressure with the "Real-time monitoring mode" of the monitor panel.
• If the parking brake is released (the parking brake lever is in the FREE position and the brake pedal is released),
the HST charge circuit pressure and the brake pressure are the same. Measure the brake pressure in this case.
WARNING! The HST charge circuit pressure needs to be measured while the machine is stopped
and while the machine is actually traveling. Accordingly, measure it on a level ground
where there are no obstacles.
i. Turn the starting switch ON and display the "Real-time monitoring mode" on the monitor panel to prepare for
measuring the brake pressure.
• Controller: HST
• Monitoring code: 91902-BRAKE PRESS
D51EX/PX-22 30-33
12 • The brake pressure is displayed in 0.01 MPa.
ii. Start the engine and set the parking brake lever in the FREE
position.
iii. While running the engine at high idle, measure the brake
pressure with the PCCS lever in the neutral position and in
the forward or reverse position.
• While the machine is stopped, only the charge safety valve
on the oil cooler bypass valve side operates. While the
machine is traveling, the charge relief valve on the HST
motor side operates, also.
B. When measuring the HST charge circuit pressure directly for troubleshooting of the brake pressure sensor, parking
brake solenoid or slow brake solenoid, apply the following method.
WARNING! The HST charge circuit pressure needs to be measured while the machine is stopped
and while the machine is traveling actually. Accordingly, measure it on a level ground
where there are no obstacles.
WARNING! Loosen the oil filler cap of the hydraulic tank slowly to release the internal pressure of the
tank.
WARNING! Turn the starting switch ON, set the work equipment lock lever in the FREE position, and
lower the blade to the ground. Move the work equipment control lever until it is not held in
the FLOAT position to release the residual pressure in the accumulator. After the residual
pressure is released, set the work equipment lock lever in the LOCK position and turn
starting switch OFF.
i. Remove the inspection cover of the floor and remove HST

charge circuit pressure pickup plug (1) on the 5-spool
solenoid valve.
30-34 D51EX/PX-22
ii. Install nipple [1] of hydraulic tester J1 and connect it to oil
pressure gauge [2].
• Use the oil pressure gauge of 5.9 MPa {60 kg/cm2}.
iii. Start the engine and set the parking brake lever in the FREE
position.
iv. While running the engine at high idle, measure the HST
charge circuit pressure with the PCCS lever in the neutral
position and in the forward or reverse position.
v. After finishing measurement, remove the measuring

instruments and return the removed parts.
3. Measuring HST pump EPC valve output pressure
WARNING! Since the machine will be stopped and driven actually to measure the EPC valve output
pressure, work on a flat place where there is not an obstacle.
WARNING! Loosen the oil filler cap of the hydraulic tank slowly to release the residual pressure in the
hydraulic tank.
A. Remove the cover at the floor, and then remove EPC valve output
pressure pickup plugs (2) – (5) at the top of the HST pump.
Plug (2): For left forward EPC valve
Plug (3): For left reverse EPC valve
Plug (4): For right forward EPC valve
Plug (5): For right reverse EPC valve
B. Install nipple J2 and connect it to oil pressure gauge [2].

C. Start the engine and set the parking brake lever in the FREE
position.
D. Select the quick shift mode and set the gear speed to the 1st.
E. While the engine is running at high idle, set the PCCS lever in the
neutral position and forward or reverse position and measure the
EPC valve output pressure.
• If the EPC valve output pressure is as follows, it is normal.
EPC valve output

During travel
pressure
Neutral 0 MPa {0 kg/cm2}
Travel in F1 Min. 1.0 MPa
Travel in R1 {Min. 10 kg/cm2}
D51EX/PX-22 30-35
After finishing measurement, remove the measuring instruments and return the removed parts.
ADJUSTING
H The HST main circuit pressure and the HST pump EPC valve output
pressure cannot be adjusted.
1. Adjusting HST charge circuit pressure (on oil cooler bypass valve
side)
H If the HST charge circuit pressure (only when the HST is in
neutral) is abnormal, adjust charge safety valve (6) of the oil
cooler bypass valve according to the following procedure.
H When adjusting charge safety valve (6) of the oil cooler bypass
valve, remove the cooling core undercover.
Undercover of cooling core: 15 kg (33 lb)
A. Fixing tuning screw (7), loosen locknut (8).

B. Turn tuning screw (7) to adjust the pressure.
H If the adjustment screw is
• turned to the right, the pressure rises.
• turned to the left, the pressure lowers.
H Quantity of tuning per turn of adjustment screw:
Approximately 1.55 MPa {15.38 kg/cm2}
C. Fixing adjustment screw (7), tighten locknut (8).
Locknut: 58.8 – 78.5 Nm {6 – 8 kgm} (43.3 - 57.8 lbf ft)
D. After finishing adjustment, check that the HST charge circuit

pressure is normal according to the measurement procedure
described above.
30-36 D51EX/PX-22
12
2. Adjusting HST charge circuit pressure (on motor side)
H If the HST charge circuit pressure (only when traveling) is
abnormal, adjust charge relief valve (9) of the HST motor
according to the following procedure.
H When adjusting charge relief valve (9) of the HST pump, remove
the HST motor covers (right and left).
A. Fixing adjustment screw (10), loosen locknut (11).

B. Turn adjustment screw (10) to adjust the pressure.
H If the adjustment screw is
H Quantity of adjustment per turn of adjustment screw:
Approximately 1.02 MPa {10.4 kg/cm2}
C. Fixing adjustment screw (10), tighten locknut (11).
Locknut: 58.8 – 78.5 Nm {6 – 8 kgm} (43.3 - 57.8 lbf ft)
D. After finishing adjustment, check that the HST charge circuit

pressure is normal according to the measurement procedure
described above.
3. Initializing HST pump EPC valve

The HST pump EPC valve does not need to be adjusted. If it is replaced, however, initialize the related items in the tuning
mode of the monitor panel.
H For the operating method, see "Special functions of monitor panel (EMMS)".
• Tuning code (When adjusting while track shoe is driven idle)
i. 3001: F-PUMP LINE
ii. 3002: R-PUMP LINE

• Tuning code (When adjusting while machine is actually traveling )
i. 3003: F-PUMP RUN1
ii. 3004: R-PUMP RUN1
iii. 3005: F-PUMP RUN2
iv. 3006: R-PUMP RUN2
D51EX/PX-22 30-37
TESTING AND ADJUSTING MOTOR CONTROL VALVE OUTLET PRES-
12
MOTOR CONTROL VALVE OUTLET PRESSURE
H Measure the solenoid valve outlet pressure under the following
condition.
• HST oil (Hydraulic oil) temperature: Within operating range (40 –
60°C)
1. Preparation work
H If the pressures in the parking brake solenoid valve and slow
brake solenoid valve are not measured simultaneously, the
operation cannot be checked.
WARNING! Loosen the oil filler cap of the hydraulic

tank slowly to release the residual
pressure in the hydraulic tank.
WARNING! Turn the starting switch ON, set the work

equipment lock lever in the FREE
position, and lower the blade to the
ground. Move the work equipment control
lever until it is not held in the FLOAT
position to release the residual pressure
in the accumulator. After the residual
pressure is released, set the work
equipment lock lever in the LOCK position
and turn starting switch OFF.
A. Remove the inspection cover at the floor.

B. Disconnect solenoid valve outlet hoses (2), (3), (4) and (5) of the
circuit to be measured or remove oil pressure pickup plug (6)
from the valve block (1).
• Hose (2): Right HST motor EPC valve
• Hose (3): Left HST motor EPC valve
• Hose (4): Parking brake solenoid valve
• Hose (5): Work equipment lock solenoid valve
• Plug (6): Slow brake solenoid valve
H The output pressure of the parking brake solenoid valve can
be measured with the "Real-time monitoring mode" of the
monitor panel.
30-38 D51EX/PX-22
H For the operating method, see "Special functions of monitor
panel (EMMS)".
• Controller: HST
• Monitoring code: 91902-BRAKE PRESS
C. If the hoses are disconnected, insert adapters K2 and connect the

hoses again.
D. Install nipple [1] or nipple M2 of hydraulic tester K1 to the plug
hole and connect it to oil pressure gauge [2].
• The figure shows the measuring instruments installed to the
outlet hose of the solenoid valve.
2. Measuring Right HST motor EPC valve and Left HST motor EPC
valve
WARNING! Since the machine will be stopped and driven actually to measure the right HST motor
EPC valve and left HST motor EPC valves, work on a flat place where there is no
obstacles.
A. Start the engine and set the travel mode in the quick shift mode, then set the reverse speed setting "B".
B. While running the engine at high idle, change the travel speed and measure the solenoid valve output pressure.
H If the output pressure is as shown in Table 1, the solenoid valve is normal.
C. After finishing measurement, remove the measuring instruments and return the removed parts.
D. Initialization of HST motor EPC valve
If the EPC valve is replaced, initialize the items related to it in the tuning mode of the monitor panel. The EPC valve
does not need to be adjusted, however, in this case.
• Tuning code: 3024-MOTOR LINE
3. Measuring parking brake solenoid and slow brake solenoid

A. Start the engine.
B. While running the engine at high idle, operate the parking brake lever and brake pedal and measure the solenoid valve
output pressure.
H The relationship between the output pressure and operating states of the solenoids is shown in Table 2.
C. After finishing measurement, remove the measuring instruments and return the removed parts.
D51EX/PX-22 30-39
Table 1. Output pressures of right HST motor EPC valve and left HST motor EPC valve (when normal)
Travel speed and Output pressure of right HST motor EPC valve
Travel mode
travel condition and left HST motor EPC valve
Stopped or traveling 1st 0 MPa {0 kg/cm2}
Quick shift mode Traveling in 2nd 1.47 ± 0.49 MPa {15 ± 5 kg/cm2}
Traveling in 3rd 2.16 ± 0.49 MPa {22 ± 5 kg/cm2}
Table 2. Output pressures of parking brake solenoid valve and slow brake solenoid valve
(when normal and abnormal)
Parking brake Output pressure of parking Output pressure of slow
Brake pedal Condition of each solenoid
lever brake solenoid valve brake solenoid valve
3.23 ± 0.49 MPa 3.23 ± 0.49 MPa
Both are normal
{33 ± 5 kg/cm2} {33 ± 5 kg/cm2}
0 MPa 3.23 ± 0.49 MPa Parking brake has trouble
{0 kg/cm2} {33 ± 5 kg/cm2} (Sticking, etc.)
FREE Released
Slow brake has trouble
0 MPa 0 MPa (Sticking, etc.).
{0 kg/cm2} {0 kg/cm2} or charge pressure is
abnormal
0 MPa 0 MPa
Both are normal
{0 kg/cm2} {0 kg/cm2}
LOCK Pressed (fully)
0 MPa 3.23 ± 0.49 MPa Slow brake has trouble
{0 kg/cm2} {33 ± 5 kg/cm2} (Sticking, etc.)
H The operation state (ON/OFF) of the solenoid valve can be checked in the monitoring mode of the monitor panel (For the
operating method, see “Special functions of monitor panel (EMMS)”).
• Controller: HST
• Monitoring code: 40914 D-OUT
[10]: Parking brake solenoid valve
[11]: Slow brake solenoid valve
Remark
Output from HST controller to the slow brake solenoid is always "ON".
4. Measuring work equipment lock solenoid

1) Start the engine.
2) While running the engine at high idle, operate the work equipment lock lever and measure the output pressure of the
solenoid valve.
a) The relationship between the output pressure and operation of the solenoid valve is shown in Table 3.
3) After finishing measurement, remove the measuring instruments and return the removed parts.
Table 3. Output pressure of work equipment lock solenoid valve (Normal values)
Work equipment lock lever Output pressure of work equipment lock solenoid valve
Lock 0 MPa {0 kg/cm2}
Free 3.23 ± 0.49 MPa {33 ± 5 kg/cm2}
Stop engine with lever in free position and
turn starting switch ON immediately Decreases gradually from 3.23 MPa {33 kg/cm2}.
30-40 D51EX/PX-22
12
TRAVEL DEVIATION
H Test the travel deviation under the following condition.

• Test place: Hard and even ground.
1. Start the engine and raise the blade to about 300 mm above the ground
and set the machine in the measuring posture.
2. Set the travel speed to the 1st in the quick shift mode.
3. After running up for 10 m with the engine speed at high idle, measure
the deviation in the travel of 20 m.
H While measuring the travel deviation, check the HST main circuit
pressures on the right and left sides.
• Controller: HST
• Monitoring code: 52503-HST L PRESS
• Monitoring code: 52501-HST R PRESS
D51EX/PX-22 30-41
TESTING AND ADJUSTING PARKING BRAKE LEVER
12
PARKING BRAKE LEVER
H If any part related to the parking brake lever was removed and installed or replaced, adjust the parking brake lever
1. Set parking brake lever (1) in free position (A) and adjust installed height (b) of stopper bolt (2) so that dimension (a) of
lever (1) will be 30.7 mm.
• Standard installed height (b) of stopper bolt = 4 mm
2. Set parking brake lever (1) in lock position (B) and adjust installed height (c) of stopper bolt (3).
• Standard installed height (c) of stopper bolt: 4 mm
3. Set parking brake lever (1) in free position (A) and adjust clearance (d) between lever (4) and 2 limit switches (5).
• Clearance (d) between lever and limit switch = 0 mm
• When adjusting, do not operate the limit switch.
4.Check that limit switch (5) operates 2.5 – 3 mm when parking brake lever (1) is operated.
• When lever is lock position (B): Switch is ON
• When lever is free position (A): Switch is OFF
H The operating condition (ON/OFF) of limit switch (5) can be checked in the "real-time monitoring mode" of the monitor.
H Controller: HST
H Real-time monitoring code:
40911-D-IN--8-----15
40912-D-IN-16-----22
30-42 D51EX/PX-22
TESTING AND ADJUSTING PARKING BRAKE LEVER
12
If the parking brake lever is adjusted normally, the following is displayed.
D51EX/PX-22 30-43
TESTING AND ADJUSTING BRAKE PERFORMANCE
12
BRAKE PERFORMANCE
H Carry out the simple test of the brake performance under the following condition.
• Check point:
Since the test will be carried out while the machine is traveling, work on a sufficiently wide place so that you can
avoid an accident even if there is a trouble.
1. Start the engine and raise the blade to about 300 mm above the ground
and set the machine in the measuring posture.
2. Set the parking brake lever in the FREE position and set the gear speed
to the 1st.
3. Run the engine at high idle and set the PCCS lever in the forward
travel position to drive the machine forward straight.
4. While the machine is traveling, press the brake pedal and check the
stopping condition of the machine.
H If the machine stops securely, the brake is normal.
30-44 D51EX/PX-22
TESTING AND ADJUSTING BRAKE PEDAL LINKAGE
12
BRAKE PEDAL LINKAGE
H When adjusting the brake pedal, remove the dashboard cover, dashboard undercover and pedal assembly.
Place the removed pedal assembly on the floor and connect the wiring harness connector between floor and pedal.
1. Adjusting brake pedal potentiometer

A. Turn the starting switch ON and change the monitor for display of the brake pedal potentiometer voltage in the
• Controller: HST
• Monitoring code: 50400-BRAKE PEDAL
B. Adjust stopper (2) temporarily so that pedal height (a) will be 258 mm when brake pedal (1) is in neutral.
C. Adjust (Rotate) the installed position of the potentiometer so that the brake pedal potentiometer voltage will be the
specified voltage when brake pedal (1) is pressed to the stroke end.
• BRAKE PEDAL VOLTAGE: 3.87 ± 0.10 V
D. Adjust installed dimension (b) of stopper (2) so that brake pedal potentiometer voltage will be the specified voltage
when brake pedal (1) is in neutral
• Dimension (b) = 37.0 mm (Reference value)
E. Check that the brake pedal potentiometer voltage is the specified voltage when brake pedal (1) is at 2-stage spring
operating point (d). If not, return to adjustment step B).
H 2-stage spring operating point (3) is the position where effort of a brake pedal increases (148N{15.1kg} ß 211N
{21.5kg} [Reference value]) at the time of operation greatly.
D51EX/PX-22 30-45
TESTING AND ADJUSTING BRAKE PEDAL LINKAGE
12
2. Adjusting proximity switch
A. Adjust clearance (c) between proximity switch (3) and brake pedal (1).
• Clearance (c) = 2 ± 0.5 mm
B. Check that the lamp in proximity switch (3) lights up when brake pedal (1) is between the neutral position and 2-stage
spring operating point (d).
C. Check that the lamp in proximity switch (3) does not light up when brake pedal (1) is pressed to the stroke end.
3. Measuring brake pedal pressing effort

A. Press the brake pedal with the foot to check that it operates smoothly.
B. If the brake pedal does not operate smoothly, supply grease through grease fitting (4) and apply grease to large spring
(5) and small spring (6).
Grease fitting (4): Grease (G2-LI)
Large spring (5) and small spring (6): Grease (G2-LI)
C. Using push-pull scale, measure the pressing effort of the brake pedal at 2-stage spring operating point (d).
• Pressing effort at 2-stage spring operating point (d): 148 N {15.1 kg}
D. Using push-pull scale, measure the full-stroke pressing effort of the brake pedal.
• Full-stroke pressing effort: 234 N {23.8 kg}
4. Work after finishing measurement

After finishing all adjustment, return the removed parts and perform the related initial tuning in the "Tuning mode" of the
monitor panel.
• Tuning code: 0005-BRAKE N-SET
• Tuning code: 3007-BRAKE END
5. Testing brake pedal potentiometer

(If the initial adjustment was performed, turn the starting switch OFF before starting the measurement.)
A. Turn the starting switch ON and change the monitor for display of the brake pedal stroke in the "real-time monitoring
mode".
• Controller: HST
• Monitoring code: 50401-BRAKE PEDAL
B. The relationship between the position and stroke of the brake pedal is shown in the table.
Brake pedal Brake pedal stroke

Released 0 – 10%
2-stage spring operating point (d) 60 – 90%
Pressed (Fully) 90 – 100%
30-46 D51EX/PX-22
TESTING AND ADJUSTING EMERGENCY RELEASE OF PARKING
12
EMERGENCY RELEASE OF PARKING BRAKE
H If the engine cannot be started and the parking brake of the HST motor cannot be released, release it according to the
1. Testing pump assembly M1
WARNING! If the following work is performed while the pressure of the pump assembly is abnormal,
the brake piston of the HST motor may be damaged. Accordingly, be sure to test the
pump assembly.
A. Check that pump assembly M1 is connected in the following

order.
[1] Volume pump
[2] Relief valve
[3] T-piece
[4]Oil pressure gauge (5.9 MPa {60 kg/cm2})
[5] Hose and quick coupler
B. Remove the hose and quick coupler [5] and block the volume
pump [1] side with a plug (R1/4).
C. Close the valve of volume pump [1] and operate the handle to
adjust relief valve [2] so that it will relieve at the specified
pressure.
Specified relief pressure: . . . . . . . . 2.7 – 3.1 MPa {28 – 32 kg/cm2}
H After finishing adjustment, open the valve of the volume pump to release the residual pressure in the pump.
H After finishing adjustment, remove the plug (R1/4) and connect the hose and quick coupler [5].
2. Opening HST pump

H If the machine is towed after the parking brake is released, the HST motor works as a pump to make the oil flow.
Accordingly, open the forward travel circuit and reverse travel circuit of the HST pump.
WARNING! Fit a block to the track shoe securely.
A. Remove the inspection cover of the floor.

B. Loosen locknuts (6) of towed valve (5) for the left pump towed
valve (2) for the right pump, and then loosen plugs (4) by 2 turns.
C. Tighten locknuts lightly and secure them so that they will not
come off when the machine is towed.
D51EX/PX-22 30-47
3. Connecting pump assembly M1

A. Install pump assembly M1 onto the floor frame.

B. Loosen plug (5) and bolt (6) of the 5-spool valve and remove lock
plate (7) and then tighten plug (5) to the end. Tighten bolt (6)
lightly so that it will not come off when the machine is towed.
C. Remove plug (8) and install nipple M2.
D. Connect the quick coupler at the end of pump assembly M1 to

nipple M2.
4. Releasing parking brake and towing machine

A. Close the valve of volume pump [1] and operate the handle to
supply oil to the parking brake circuit.
H Increase the supply pressure until relief valve [2] relieves
once.
H Check that the supply pressure is lower than the specified
relief pressure with oil pressure gauge [4].
Specified relief pressure: . . . . . . . . 2.7 – 3.1 MPa {28 – 32 kg/cm2}
WARNING! If the supply pressure rises above the

specified relief pressure, the brake piston
of the HST motor may be damaged.
Accordingly, if the supply pressure
exceeds the specified relief pressure,
open the valve of the volume pump
immediately and adjust the relief pressure
by the method in 1.
H If the supply pressure becomes the specified relief pressure, the parking brake is released.
B. Remove the block of the track shoe and tow the machine at speed lower than 2 km/h.
WARNING! If the supply pressure lowers below 1.5 MPa {15 kg/cm2}, the parking brake is not
released completely (it works partially). Accordingly, keep checking oil pressure gauge [4]
while towing the machine. If the oil pressure lowers, operate the handle to maintain the oil
pressure in the range of 1.5 – 3.1 MPa {15 – 32 kg/cm2}.
C. After towing the machine to a safe place, open the valve of volume pump [1] to release the pressure supplied to the
parking brake circuit.
30-48 D51EX/PX-22
12
5. Remedy to take after towing machine
H After towing the machine to a safe place, take the following remedy without fail to return the machine to the
condition before towing.
A. Remove pump assembly M1 and nipple M2 and install plug (8).
B. Loosen plug (5) of the 5-spool valve and return lock plate (7) and
then tighten plug (5) and bolt (6) to fix lock plate (7).
C. Install the inspection cover to the right of the floor.
D. Return plugs (4) of towed valves (1) and (2) of the HST pump and
secure them with locknuts (3).
Plug and locknut: 24.5 – 34.3 Nm {2.5 – 3.5 kgm}
D51EX/PX-22 30-49
TESTING AND ADJUSTING IDLER CLEARANCE
12
IDLER CLEARANCE
TESTING
H If the lateral guide and vertical guide of the idler are so worn that the idler runs out or slants, adjust the clearance of the
idler according to the following procedure.
1. Lateral adjustment
A. Drive the machine forward slowly by 1 - 2 m onto flat ground, and then stop it.
B. Measure clearance (a) between track frame (1) and guide plate (2).
H Measure clearance (a) on inside and outside of the right and left idlers.
Clearance limit (a): . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Max. 4 mm
ADJUSTING
H If the clearance exceeds the limit, adjust it according to the following procedure.
A. Loosen mounting bolt (3) of guide plate (2).
H Since 2-piece shims are used, the guide plate does not need to be removed.
B. Remove the shims between guide plate (2) and support (4) and
adjust clearance (a).
Adjusted clearance (a): . . . . . . . . . . . . . . . . . . . . . . . 0.5 - 1.0 mm
Thickness shim x quantity for new machine: . . . . . . . . . . . . . . . . . .
. . . . . . . . . . . . . . . . . . . . . . . . . 1.0 mm x 4 pieces (for each place)
C. Tighten mount bolt (3) of guide plate (2).
Bolts: 245 - 309 Nm [25 - 31.5 kgm] (180.7 - 227.9 lbf ft)
30-50 D51EX/PX-22
TESTING AND ADJUSTING IDLER CLEARANCE
12
2. Vertical adjustment
A. Measure clearance b, subtract 2 mm from it, and record the result (quantity of adjustment).
• Example: When clearance b is 5 mm. The quantity of adjustment is 5 -2 = 3 mm.
B. Loosen bolts (5) (4 pieces on inside and outside) until the reaction force of the spring is lost.
C. Loosen bolt (6). Do not loosen more than 3 turns.
D. Pull up vertical guide (7) with a bar and pull out shim (8) by quantity of adjustment obtained in step A.
E. Add shim (8) pulled out onto shim (9).
Remark
8 pieces in total on both sides, inside and outside.
Remark
The total number of shims (5) and (6) before adjustment must be the same as that after adjustment.
Shim thickness: . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 mm
F. Tighten bolts (5) of spring set.
G. Tighten bolts (6) of guide plate.
D51EX/PX-22 30-51
TESTING AND ADJUSTING TRACK SHOE TENSION
12
TRACK SHOE TENSION
TESTING
1. Drive the machine forward slowly on a level place, and then stop it.
H Do not apply the brake when stopping.
2. Place straight steel bar (1) between the idler and carrier roller and
measure clearance (a) between the bottom of the steel bar and shoe
grouser.
H As the steel bar, use an L-shape steel, etc. which will be deflected
less.
Standard clearance (a): . . . . . . . . . . . . . . . . . . . . . . . . . 20 - 30 mm
ADJUSTING
H If the track shoe tension is abnormal, adjust it according to the

H When adjusting the track shoe tension, remove the outer covers from
the track frames.
1. When tension is too high.

A. Loosen valve (1) slowly to discharge the grease.
WARNING! Since the valve may jump out because of

the high-pressure grease, do not loosen it
more than 1 turn.
B. If the grease does not come out, move the machine forward and in
reverse slowly.
C. Tighten valve (1).
Valve: 58.8 - 88.2 Nm {6 - 9 kgm} (43.3 - 65.0 lbf ft)
D. After adjusting, check the tension again according to the

procedure described above.
2. When tension is low.

A. Using a grease pump, add grease through grease fitting (2).
B. After adjusting, check the tension again according to the
procedure described above.
H You may supply grease until distance (b) between the idler
guide and frame end is 20 mm. If the tension is still low, the
pins and bushings are worn excessively. In this case, turn
over or replace the pin and bushing.
30-52 D51EX/PX-22
TESTING AND ADJUSTING WORK EQUIPMENT
12
WORK EQUIPMENT
OIL PRESSURE
MEASURING
H Measure the work equipment oil pressure under the following

condition.
• HST oil (Hydraulic oil) temperature: Within operating range
(40 - 60°C)

1. A pressure check fitting (1) is standard in the work equipment circuit.

The fitting (1) is located at the top section of the control valve.
2. Connect the oil pressure gauge [1] of hydraulic tester N1 to pressure

check fitting.
H Use the oil pressure gauge of 39.2 MPa {400 kg/cm2}.
3. Run the engine at high idle and relieve the blade lift and tilt cylinders
one by one at the stroke end and measure the work equipment oil
pressure.
H The relief pressure of the main relief valve of the control valve is
indicated when each of the above operation is performed. The oil
pressure in the angle circuit is low at the stroke end, because it has
piston valves.
4. After finishing measurement, remove the measuring instruments.
D51EX/PX-22 30-53
TESTING AND ADJUSTING WORK EQUIPMENT
12
ADJUSTING
H If the oil pressure is abnormal, adjust main relief valve (2) of the
control valve according to the following procedure.
H Remove the panel on the right hand side of the operator’s seat.
1. Fixing adjustment nut (3), loosen locknut (4).
2. Turn adjustment nut (3) to adjust the pressure.
WARNING! Do not remove the adjustment nut. If it is

removed, the internal parts may fall.
H If the adjustment nut is:

Quantity of adjustment per turn of adjustment nut: . . . . . . . . . . . . .
. . . . . . . . . . . . . . . . . . . . . . . Approximately 19.6 MPa {200 kg/cm2}
3. Fixing adjustment nut (3), tighten locknut (4).
Locknut: 39 - 49 Nm {4 - 5 kgm} (28.7 - 36.1 lbf ft)
4. After finishing adjustment, check the oil pressure again according to

the measurement procedure described above.
30-54 D51EX/PX-22
TESTING AND ADJUSTING WORK EQUIPMENT PPC VALVE
12
WORK EQUIPMENT PPC VALVE
OIL PRESSURE
WARNING! Stop the machine on a flat place and lower the work equipment to the ground.
WARNING! Take care not to touch a hot part when installing or removing a testing tool.
WARNING! Before raising the blade, check that the side cover on the left side of the engine and front
cover are closed.
WARNING! Turn the starting switch ON, set the work equipment lock lever in the Free position, and
lower the blade to the ground. Move the blade control lever until it is not held in the Float
position to release the residual pressure in the accumulator. After the residual pressure is
released, set the work equipment lock lever in the Lock position and turn starting switch
OFF.
hydraulic tank.
H Before measuring the output pressure of the work equipment PPC valve, check that the output pressure of the work
equipment lock solenoid valve is normal.
H Test the output pressure of the work equipment PPC valve under the following condition.
• HST oil temperature (Hydraulic oil temperature):
Within operating range (40 – 60°C)
1. Open the inspection cover on the fuel tank side.
2. Disconnect PPC valve output hose (1) to be measured.

H For the circuit to be measured, see “PPC circuit connection
diagram” on the following page.
H Since the adapter cannot be connected to the quick coupler on the
control valve (2) side, disconnect the PPC valve (3) side.
D51EX/PX-22 30-55 j
3. Install adapter P2 to the disconnected hose and connect again.
4. Install nipple (2) of hydraulic tester P1 to adapter P2 and connect oil

pressure gauge [1].
H Use the oil pressure gauge of 6 MPa {60 kg/cm2}.
5. Start the engine and set the work equipment lock lever in the Free
position.
6. While running the engine at high idle, operate the circuit to be mea-
sured and measure the oil pressure.
H When measuring, set the lever to the stroke end.
H Measure at the Lower position and Float position on the lowering
side of the blade.

PPC circuit connection diagram

a The position of PPC valve ports are shown from the bottom.
30-56 j D51EX/PX-22
ADJUSTING PLAY OF WORK EQUIPMENT PPC VALVE 1

H If the play of the blade control lever in the lifting and tilting directions is large, adjust it according to the following
procedure.
WARNING! Turn the starting switch ON, set the work equipment lock lever in the Free position, an
lower the blade to the ground. Move the blade control lever until it is not held in the Float
position to release the residual pressure in the accumulator. After the residual pressure is
released, set the work equipment lock lever in the Lock position and turn starting switch
OFF.
hydraulic tank.
1. Remove the work equipment PPC valve from the machine.
2. 2. Remove bellows (1).
3. 3. Fixing plug (2), loosen cap (3).
4. 4. Tighten plug (2) to adjust the play of the lever.

H At this time, take care not to move piston (4).
H Play of lever:
Max. 3 mm (at center of lever knob)
H When cap (3) is tightened, the play of the lever is reduced a little.
Count in this reduction, when adjusting.
5. 5. Fixing plug (2), tighten cap (3).

3Cap: 98 – 127 Nm {10 – 13 kgm}
6. Install bellows (1).
7. Install the work equipment PPC valve to the machine.

H After installing the blade control lever, check that its play is
proper.
D51EX/PX-22 30-57 j
TESTING AND ADJUSTING LOCK LEVER ADJUSTMENT
12
LOCK LEVER ADJUSTMENT
H If any part related to the work equipment lock lever was removed and installed or replaced, adjust the work equipment
lock lever according to the following procedure.
1. Adjust rod (1) to standard dimension (a).

• Standard dimension (a) between rod pins:195 mm (Reference value)
2. Set work equipment lock lever (2) in lock position (B) and adjust clearance (b) between lever (3) and limit switch (4).
• Clearance (b) between lever and limit switch = 0 mm
• When adjusting, do not operate the limit switch.
3. Check that limit switch (4) operates 2.5 – 3 mm when work equipment lock lever (1) is operated.
• When lever is lock position (B): Switch is OFF
• When lever is free position (A): Switch is ON
30-58 j D51EX/PX-22
TESTING AND ADJUSTING CYLINDER LEAKAGE
12
CYLINDER LEAKAGE
H Measure the leakage in the work equipment cylinder under the following condition.
1. Measuring leakage in blade lift cylinder.

A. Start the engine and put the front part of the track shoe (idler side) on a wood block, etc. to raise the front part of the
machine.
WARNING! Raise the front part of the machine to a height where the blade will not touch the ground
when the blade lift cylinder is extended to the lowering stroke end.
WARNING! Set the parking brake lever in the LOCK position and put a block to the rear of the track
shoe.
B. Extend the lift cylinder to the lowering stroke end and stop the engine.
WARNING! Operate the blade control lever in the lifting direction several times within 15 seconds
after stopping the engine, and then loosen the oil filler cap of the hydraulic tank slowly to
release the residual pressure in the cylinder and tank.
C. Remove the cylinder cover on the side to be measured, disconnect

hose (1) on the head side, and block the hose side with a plug.
H Plug used to block hose: 07376-70422 (# 04).
D. Run the engine at high idle and move the blade control lever to
the lowering position to relieve the lift cylinder.
WARNING! Do not move the blade control lever to the

raising position.
E. Start measuring the oil leakage 30 seconds after the relief is

started and measure the leakage in 1 minute.
F. After finishing measurement, remove the measuring instruments
D51EX/PX-22 30-59 j
TESTING AND ADJUSTING CYLINDER LEAKAGE
12
2. Measuring leakage in blade tilt cylinder.
A. Remove guard on blade above tilt cylinder and cylinder cover.
B. Start the engine and raise the blade to about 1 m above the ground.
C. Fully extend the tilt cylinder to the stroke end and stop the engine.
WARNING! Operate the blade control lever in the

tilting direction several times within 15
seconds after stopping the engine, and
then loosen the oil filler cap of the
hydraulic tank slowly to release the
residual pressure in the cylinder and tank.
D. Disconnect hose (2) on the head side, and block the hose side with
a plug.
H Plug used to block hose: 07376-70210 (# 02)
E. Run the engine at high idle and move the blade control lever to
the right position and hold the tilt cylinder at relief.
WARNING! Do not move the blade control lever to the

left tilting position.
F. Continuing to hold the blade control lever at relief, wait 30

seconds and then measure amount of fluid coming out of cylinder
for one minute (60 seconds).
G. After finishing measurement, remove the measuring instruments
3. Measuring leakage in blade angle cylinder.

• Since the angle cylinder is equipped with piston valves, its internal leakage cannot be measured on the machine.
• Send the angle cylinder to a test stand for measuring.
30-60 j D51EX/PX-22
TESTING AND ADJUSTING HYDRAULIC CIRCUIT
12
HYDRAULIC CIRCUIT
RELEASING RESIDUAL PRESSURE

H When removing any hydraulic equipment or disconnecting any piping
from the HST circuit or work equipment circuit, release the residual
pressure according to the following procedure.
1. Stop the machine on a hard and level place.
2. Lower the blade to the ground and stop the engine.
3. Operate the blade control lever in each direction to the stroke end
several times within 15 seconds after stopping the engine to release the
residual pressure in the circuit.
4. Loosen oil filler cap (1) of the hydraulic tank slowly to release the
residual pressure in the tank.
WARNING! Since the oil may spout out, depending on

the condition in the tank, loosen the oil
filler cap slowly.
H Once the residual pressure is released, tighten the oil filler cap to
prevent dirt from entering the tank.
D51EX/PX-22 30-61 j
TESTING AND ADJUSTING HYDRAULIC CIRCUIT
12
BLEEDING AIR
H If any hydraulic equipment/piping of the HST circuit or work equipment circuit was removed/disconnected and installed/
connected, bleed air according to the following procedure after finishing the work.
H Before and after bleeding air, check that the oil level in the hydraulic tank is normal and no bubbles are contained in the
oil.
1. Bleeding air from HST pump.

A. Remove the floor mat and floor plate in front of the seat.
B. Loosen air bleeder (1) at the top of the HST pump and check that
oil oozes out.
• If oil with out bubbles oozes out, the pump has been bled.
C. Tighten air bleeder (1).
D. Tighten the filler cap of hydraulic oil tank.
2. Starting engine.
Start the engine and run it at low idle for 10 minutes.
3. Bleeding air from HST pump servo section.
WARNING! Since the machine will travel forward and

in reverse during the following work, stop
the machine in a place where it can travel.
A. Warm up the engine until the HST oil temperature (hydraulic oil temperature) reaches 80°C.
H Air is bled more effectively when the HST oil temperature (hydraulic oil temperature) is high.
B. Set the shift mode switch in the variable shift mode position.
C. While the 1st gear speed is selected, press the shift-up switch twice.
D. Set the reverse travel speed set switch to the left once to set the reverse travel speed equal -to the forward travel
speed.
E. Set the parking brake lever in the FREE position and set the PCCS lever in the forward and reverse travel positions at
least 20 times.
• Forward ß Neutral ß Reverse ß Neutral
H Repeat the operation cycle of setting the PCCS lever in the forward and reverse positions at least 20 times.
4. Bleeding air from cylinders.

A. While running the engine at low idle, extend and retract each cylinder to before each stroke end 4 – 5 times.
H Stop the piston rod of each cylinder about 100 mm before the stroke end to avoid relieving.
B. Keep running the engine at low idle and extend and retract each cylinder to each stroke end 3 – 4 times.
C. Keep running the engine at high idle and extend and retract each cylinder to each stroke end 4 – 5 times.
5. Operating machine.
A. After bleeding air, stop the engine and leave it for 5 minutes.
H By this operation, the bubbles in the oil in the hydraulic tank are discharged.
B. Check for oil leakage. If no oil is leaking, operate the machine.
30-62 j D51EX/PX-22
TESTING AND ADJUSTING BLADE CENTER BALL ADJUSTMENT
12
BLADE CENTER BALL ADJUSTMENT
H If the blade was disassembled and assembled or transported, adjust the play of the center ball according to the following
procedure.
1. Tentatively assemble trunnion and cap (1) to bearing attached to the blade using bolts (2) without shims and tighten.
2. Set clearance a equal around the entire rim and measure value a.
3. Install 0.5 mm shim and 1.0 mm shim so that the total thickness of
shims equals the value of a+0.5 mm.
H Include at least one pair of 0.5 mm shims.
4. Tighten bolts to full torque.
Bolt: 608 ~ 726 Nm {62 ~ 74 kgm} (448 ~ 535 lbf ft)
BLADE PITCH BALL ADJUSTMENT

H If the blade was disassembled and assembled or transported, adjust the play of the center ball according to the following
procedure.
1. Tentatively assemble trunnion and cap to bearing attached to the blade

using bolts (2) without shims and tighten.
2. Set clearance b equal around the entire rim and measure value b.
3. Install minimum of one set of shims so that the total thickness of

shims equals the value of b+0.5 mm.
4. Tighten bolts to full torque.
Bolt: 823 ~ 1029 Nm {84 ~ 105 kgm} (607 ~ 758 lbf ft)
D51EX/PX-22 30-63 j
TESTING AND ADJUSTING DIODES
12
DIODES
PROCEDURE FOR TESTING

H Test the assembled-type diode (8-pin) and the single diode (2-pin) according to the following procedure.
H The conductive directions of the assembled-type diode are shown to
the right.
H The conductive direction of the single diode is indicated on the surface

of the diode.
1. When using digital circuit tester.

A. Set the tester in the diode range and check the indicated value.
H When an ordinary circuit tester is used, the voltage of the
internal battery is indicated.
B. Apply the red (+) lead of the tester to the anode (P) side of the
diode and apply the black (-) lead to the cathode (N) side and
check the indicated value.
C. Judge the condition of the diode by the indicated value.
• The indicated value does not change: The diode do not have
conductivity (Defective).
• The indicated value changes: The diode has conductivity
(Normal).
Remark
In the case of a silicon diode, a value in the range from 460 to 600 is indicated.
30-64 j D51EX/PX-22
TESTING AND ADJUSTING DIODES
12
2. When using analog circuit tester.
A. Set the tester in the resistance range.
B. Apply the leads of the tester as shown below and check the movement of the pointer.
i. Apply the red (+) lead of the tester to the anode (P) side of the diode and apply the black (-) lead to the cathode
(N) side.
ii. Apply the red (+) lead of the tester to the cathode (N) side of the diode and apply the black (-) lead to the anode
(P) side.
C. Judge the condition of the diode by the movement of the pointer.
• The pointer does not move in i) but moves in ii): The diode is normal (The moving range (resistance) depends on
the type and selected range of the tester, however).
• The pointer moves in both i) and ii): The diode is defective (Internal short circuit).
• The pointer moves in neither of i) and ii): The diode is defective (Internal disconnection).
D51EX/PX-22 30-65 j
TESTING AND ADJUSTING MONITOR PANEL (EMMS) - SPECIAL FUNC-
12
MONITOR PANEL (EMMS) - SPECIAL FUNCTIONS
H EMMS: Equipment Management Monitoring System
1. Buzzer cancel switch (Used to change, select or confirm modes in this chapter)
2. Information switch (Used to move the cursor or input values in this chapter)
3. Character display (Used to display information in this chapter)
Normal functions and the special functions of monitor panel (EMMS)

The monitor panel is equipped with normal functions and special functions. Various items of data are displayed on the
character display in the middle of the monitor panel. The display items are divided by the internal setting of the monitor panel
(EMMS), into automatic display items and items displayed when the monitor panel switches are operated.
A. Normal functions: Operator mode.
Functions for which the content is normally displayed or which can be displayed and operated by the operator
operating the switches.
B. Special functions: Service mode.
Functions which the serviceman can display and operate with the special switches to carry out inspection,
maintenance, and troubleshooting.
30-66 j D51EX/PX-22
12
Operator mode Ö Service mode

1 Operating mode 6 Electrical system failure history display mode
2 Action code display mode 7 Mechanical system failure history display mode
3 Error code display mode 8 Real-time monitoring mode
4 Oil/Filter maintenance mode 9 Cylinder cut-out mode
5 Brightness adjustment mode 10 No-injection cranking mode
11 Tuning mode
12 Maintenance interval change mode
13 Telephone number input mode
14 Model selection mode
15 Option selection mode
16 Initialize mode (factory use only)
D51EX/PX-22 30-67 j
12
30-68 j D51EX/PX-22
12
Remark
The following Nos. correspond to those in the table on the previous page. Each No. in the table is put in [_]
in the title of each item in the text.
Operator mode
H No. 4 – No. 5 is displayed endlessly by following the switch operation.

H When a failure occurs, the screen changes automatically to No. 2 regardless of the displayed screen.
H If the switch is not operated for over 30 seconds regardless of the display screen, the screen automatically;
• Changes to No. 1. (If malfunction has not occurred.)
• Changes to No. 2. (If malfunction has occurred.)
H After moving from No. 3 to No. 1 by the switch operation, if no switch operation is performed for longer than 10 seconds,
then it automatically moves to No. 2.
Service mode
H No. 6 – No. 16 is displayed endlessly by following the switch operation.

H By inputting and determining the ID once, it will be effective until the starting switch is turned off.
Character display portion
16 characters can be displayed on each upper and lower row of the

character display section, and depending on the contents displays the
combination of the next figures, letters, and symbols.
A. Arabic numbers: 1, 2, 3...
B. Small letters: a, b, c...
C. Capital letters: A, B, C...
D. Symbols: @,?, $...
E. Special letters:
Control switch section
All the display operation of the monitor panel is operated by the buzzer
cancel switch (1) and information switch (2).
Each switch of [], [n], [>], [<] is assigned to the following function.
: Determine and execute
n To cancel, release, and determine (only YES and NO screen)
>: To right, to next, to proceed, to increase (only when inputting Arabic
numbers)
<: To left, to previous, to return, to decrease (only when inputting Arabic
numbers)
D51EX/PX-22 30-69 j
12
n Operator mode (Outline)
[1] Operating mode (Default)

When turning the starting switch ON, the service meter is displayed in
the upper row.
If this function is selected, the engine speed is displayed in the lower
row.
• Turn ON and OFF the display with the [>] and [<] switches.
• For details, see Operation and maintenance manual.
[2] Action code display mode

When abnormal situations occur, the monitor panel automatically
displays the action code depending on the extent of the abnormality in
order to remind the operator of proper remedy.
H When action code [E03] or [E04] is displayed, it and "CALL +
phone No." are displayed alternately.
H When action code [E01] or [E02] is displayed, "CALL + phone
No." is not displayed.
H The phone No. is displayed only when it is set.
Remark
An action code is displayed only when a serious fault occurs.
Even if an action code is not displayed, a fault may have
occurred. If you feel any abnormality, be sure to check for an
failure history in the “Electrical system failure history
display mode” and “Mechanical system error code display mode” of the service mode.
Action codes table

Action code Indication method of fault Contents of fault Remedy notified to operator
• Only action code is displayed. • Backup alarm does not sound. • Functions are defective or they stop
• Fan speed is kept at maximum. partially, but operator can work
E01 safely.
• After finishing work, however, call
your Komatsu distributor for repair.
• Action code is displayed. • Gear is not shifted up or down. • Important functions are defective or
• Caution lamp flashes. • Engine rotated irregularly. they stop partially.
• Caution buzzer sounds. • When continuing work, take care
E02
extremely.
• After finishing work, call your
Komatsu distributor for repair.
• Action code is displayed. • Usable gear speeds are limited. • Move machine to safe place and
E03 • Caution lamp flashes. • Engine speed does not rise fully. stop it immediately.
CALL • Caution buzzer sounds. • Call your Komatsu distributor for
repair.
• Action code is displayed. • Engine can not be controlled. • Stop machine immediately.
E04
• Caution lamp flashes. • Machine can not travel. • Call your Komatsu distributor for
CALL
• Caution buzzer sounds. repair.
30-70 j D51EX/PX-22
12
[3] Error code display mode
By pressing the [>] switch once while the action code is displayed on
the monitor panel, the present error code is displayed.
• [>]: To display error code.
H The error codes which have been detected in the past are
separated into electrical and mechanical systems and recorded as
failure history (refer to service mode for a detail).
H If there are several failures, other error codes are displayed by
pressing the [>] switch.
H After displaying all the error codes by pressing the [>] switch,
press [>] switch further to return to the service meter display
screen.
H Press the [>] switch again, and the error code is displayed from
the beginning.
H If there is no switch operation for longer than 10 seconds in the
service meter display screen, it automatically switches to the
action code display screen.
H The following information is displayed in the service code display
function.
A: Error code
B: Controller code
MON:Monitor panel
ENG:Engine controller
HST:HST controller
C: Trouble occurring system
H Refer to "Error code table" for details of displayed error codes.
H Be careful of the partial difference in the displayed information for the error code display mode and the failure history
display mode (service mode).
D51EX/PX-22 30-71 j
12
Error code table
Error Applicable Action Caution Caution History
Defective part Trouble Message lamp buzzer
codes equipment code classification
Mechanical
6091NX HST charge filter element Clogging HST – – l l
system
Mechanical
AA10NX Air cleaner Clogging MON – – – –
system
Mechanical
AB00MA Alternator Malfunction MON – – l –
system
Mechanical
B@BAZG Engine oil Lowering of oil pressure ENG – – l l
system
Mechanical
B@BCNS Coolant Overheating ENG – – l l
system
Mechanical
B@CRNS HST oil Overheating HST – – l l
system
Mechanical
B@CRZG HST oil Lowering of oil pressure HST – – l l
system
CONTROLLER Electrical
CA111 Engine controller Internal defect ENG E04 l l
R system
Engine Ne/Bkup speed Electrical
CA115 Abnormal ENG E04 ENG SPEED l l
sensor system
Excessively high voltage Electrical
CA122 Charge pressure sensor ENG E03 ENGINE l l
detected system
Electrical
CA123 Charge pressure sensor Excessively low voltage detected ENG E03 ENGINE l l
system
CA131 Throttle sensor ENG E03 DECEL PEDAL l l
detected system
Electrical
CA132 Throttle sensor Excessively low voltage detected ENG E03 DECEL PEDAL l l
system
CA144 Coolant temperature sensor ENG E02 WATER TEMP l l
detected system
Electrical
CA145 Coolant temperature sensor Excessively low voltage detected ENG E02 WATER TEMP l l
system
CA153 Charge temperature sensor ENG E01 ENGINE – –
detected system
Electrical
CA154 Charge temperature sensor Excessively low voltage detected ENG E01 ENGINE – –
system
SENSOR Electrical
CA187 Sensor power supply 2 Excessively low voltage detected ENG E03 l l
VOLTAGE system
Atmospheric pressure Excessively high voltage Electrical
CA221 ENG E03 ENGINE l l
sensor detected system
Atmospheric pressure Electrical
CA222 Excessively low voltage detected ENG E03 ENGINE l l
sensor system
Excessively high voltage SENSOR Electrical
CA227 Sensor power supply 2 ENG E03 l l
detected VOLTAGE system
Mechanical
CA234 Engine Excessively high speed ENG – – l l
system
Ne speed sensor power Electrical
CA238 Excessively low voltage detected ENG E03 ENG SPEED l l
supply system
Electrical
CA271 IMV/PCV1 Short circuit ENG E03 ENGINE l l
system
Electrical
CA272 IMV/PCV1 Disconnection ENG E03 ENGINE l l
system
Electrical
CA322 Injector # 1 Disconnection or short circuit ENG E03 ENGINE l l
system
30-72 j D51EX/PX-22
Error code table (Continued)
Electrical
system
Electrical
system
Electrical
system
Electrical
system
Electrical
system
Electrical
CA342 Engine controller Defective matching of data ENG E04 ENGINE l l
system
Electrical
CA351 Injector system Abnormal circuit ENG E03 ENGINE l l
system
SENSOR Electrical
CA352 Sensor power source 1 Excessively low voltage detected ENG E03 l l
VOLTAGE system
Excessively high voltage SENSOR Electrical
CA386 Sensor power source 1 ENG E03 l l
CA428 Coolant sensor ENG E01 FUEL FILTER – –
detected system
Electrical
CA429 Coolant sensor Excessively low voltage detected ENG E01 FUEL FILTER – –
system
ENG OIL Electrical
CA435 Engine oil pressure switch Abnormal signal circuit ENG E02 l l
PRESS SW system
BATTERY Electrical
CA441 Power supply voltage Excessively low voltage detected ENG E04 l l
VOLTAGE system
Excessively high voltage BATTERY Electrical
CA442 Power supply voltage ENG E04 l l
Excessively high pressure Electrical
CA449 Common rail pressure 2 ENG E03 ENGINE l l
detected system
Common rail pressure Excessively high voltage Electrical
CA451 ENG E03 ENGINE l l
sensor detected system
Common rail pressure Electrical
CA452 Excessively low voltage detected ENG E03 ENGINE l l
sensor system
Exceeded upper control limit of CAC Electrical
CA488 Charge temperature ENG E03 l l
temperature OVERHEAT system
Excessively high pressure Electrical
CA553 Common rail pressure 1 ENG E02 ENGINE l l
detected system
Electrical
CA559 Supply pump 1 No pressure feeding detected ENG E02 ENGINE l l
system
Electrical
CA689 Engine Ne speed sensor Abnormality in signal ENG E03 ENG SPEED l l
system
Electrical
CA731 Engine Bkup speed sensor Abnormal phase ENG E03 ENG SPEED l l
system
CA757 Engine controller Loss of data ENG E04 l l
R system
Electrical
CA778 Engine Bkup speed sensor Abnormal signal ENG E03 ENG SPEED l l
system
CAN communication
Electrical
CA1633 (Engine controller - HST Abnormal communication ENG E03 DATA LINK l l
system
controller)
CA2185 Decelerator pedal sensor ENG E03 DECEL PEDAL l l
detected system
D51EX/PX-22 30-73 j
Electrical
CA2186 Decelerator pedal sensor Excessively low voltage detected ENG E03 DECEL PEDAL l l
system
Electrical
CA2249 Supply pump 2 No pressure feeding detected ENG E03 ENGINE l l
system
Electrical
CA2311 IMV solenoid Abnormal resistance ENG E03 ENGINE l l
system
HEATER Electrical
CA2555 Air intake heater relay Disconnection ENG E01 – –
RELAY system
HEATER Electrical
CA2556 Air intake heater relay Short circuit ENG E01 – –
RELAY system
N SAFETY Electrical
D130KA Neutral safety relay Disconnection HST E02 l l
RELAY system
N SAFETY Electrical
D130KB Neutral safety relay Short circuit HST E02 l l
RELAY system
CAN communication Defective communication
Electrical
DAFRKR (Monitor panel - HST (Abnormality in objective MON E03 DATA LINK l l
system
controller) component system)
CAN communication Defective communication
Electrical
DAFRMC (Monitor panel - Engine (Abnormality in objective MON E03 DATA LINK l l
system
Electrical
DAJ000 HST controller Memory error HST – – – –
system
BATTERY Electrical
DAJ0KK HST controller Lowering of source voltage HST E04 l l
VOLTAGE system
MACHINE Electrical
DAJ0KQ HST controller Machine code error HST E03 l l
CODE system
DAJ0KT HST controller Memory error HST E03 l l
R system
HST controller sensor 5V SENSOR Electrical
DAJ5KK Lowering of source voltage/Input HST E04 l l
power supply No.1 VOLTAGE system
HST controller sensor 5V SENSOR Electrical
DAJ6KK Lowering of source voltage/Input HST E03 l l
power supply No.2 VOLTAGE system
Defective communication
CAN communication (HST Electrical
DAJRKR (Abnormality in objective HST E03 DATA LINK l l
controller - Monitor panel) system
component system)
CAN communication (HST Defective communication
Electrical
DB2RKR controller - Engine (Abnormality in objective HST E03 DATA LINK l l
system
Electrical
DD12KA Shift up switch Disconnection HST E02 SHIFT UP SW l l
system
Electrical
DD12KB Shift up switch Short circuit HST E02 SHIFT UP SW l l
system
SHIFT DOWN Electrical
DD13KA Shift down switch Disconnection HST E02 l l
SW system
SHIFT DOWN Electrical
DD13KB Shift down switch Short circuit HST E02 l l
SW system
Electrical
DD14KB Travel lock SW 1 Short circuit HST E03 TRAVEL LOCK l l
system
Disagreement of ON/OFF Electrical
DD1NL4 Fan rotation selector switch HST E01 FAN SW – –
signals system
Reverse travel speed Electrical
DDDCKB Short circuit HST E01 R SPEED SW – –
switch system
Electrical
DDP6KA Brake oil pressure sensor Disconnection HST E02 BRAKE PRESS l l
system
30-74 j D51EX/PX-22
Electrical
DDP6KB Brake oil pressure sensor Short circuit HST E02 BRAKE PRESS l l
system
Electrical
DDP6MA Brake oil pressure sensor Malfunction HST E02 BRAKE PRESS l l
system
Electrical
DDQ2KA Travel lock SW 1 Disconnection HST E03 TRAVEL LOCK l l
system
Disagreement of ON/OFF SHIFT MODE Electrical
DDT0L4 Shift mode SW HST E01 – –
signals SW system
Travel lock limit switches 1 Electrical
DDU1FS Fixing HST E03 TRAVEL LOCK l l
and 2 system
Electrical
DDU1KA Travel lock limit switch 2 Disconnection HST E03 TRAVEL LOCK l l
system
Short circuit with power supply Electrical
DDU1KY Travel lock limit switch 2 HST E03 TRAVEL LOCK l l
line system
Hydraulic tank oil Electrical
DGS1KA Disconnection HST E01 OIL TEMP – –
temperature sensor system
Hydraulic tank oil Electrical
DGS1KX Out of input signal range HST E01 OIL TEMP – –
temperature sensor system
Electrical
DHH5KA LH pump pressure sensor Disconnection HST E02 HST PRESS l l
system
Electrical
DHH5KB LH pump pressure sensor Short circuit HST E02 HST PRESS l l
system
Electrical
DHH6KA RH pump pressure sensor Disconnection HST E02 HST PRESS l l
system
Electrical
DHH6KB RH pump pressure sensor Short circuit HST E02 HST PRESS l l
system
Electrical
DK10KA Fuel dial sensor Disconnection HST E03 FUEL DIAL l l
system
Electrical
DK10KB Fuel dial sensor Short circuit HST E03 FUEL DIAL l l
system
Electrical
DK30KA Steering angle sensor 1 Disconnection HST E03 ST LEVER l l
system
Electrical
DK30KB Steering angle sensor 1 Short circuit HST E03 ST LEVER l l
system
Electrical
DK30KX Steering angle sensor Out of input signal range HST E04 ST LEVER l l
system
Electrical
DK30KZ Steering angle sensor Disconnection or short circuit HST E04 ST LEVER l l
system
Electrical
DK30L8 Steering angle sensor Disagreement of analog signals HST E03 ST LEVER l l
system
Electrical
DK31KA Steering angle sensor 2 Disconnection HST E03 ST LEVER l l
system
Electrical
DK31KB Steering angle sensor 2 Short circuit HST E03 ST LEVER l l
system
Electrical
DK40KA Brake pedal sensor Disconnection HST E03 BRAKE PEDAL l l
system
Electrical
DK40KB Brake pedal sensor Short circuit HST E03 BRAKE PEDAL l l
system
Electrical
DK55KX Directional potentiometer Out of input signal range HST E04 FR LEVER l l
system
Electrical
DK55KZ Directional potentiometer Disconnection or short circuit HST E04 FR LEVER l l
system
Electrical
DK55L8 Directional potentiometer Disagreement of analog signals HST E03 FR LEVER l l
system
D51EX/PX-22 30-75 j
Electrical
DK56KA Directional potentiometer 1 Disconnection HST E03 FR LEVER l l
system
Electrical
DK56KB Directional potentiometer 1 Short circuit HST E03 FR LEVER l l
system
Electrical
DK57KA Directional potentiometer 2 Disconnection HST E03 FR LEVER l l
system
Electrical
DK57KB Directional potentiometer 2 Short circuit HST E03 FR LEVER l l
system
TRAVEL Electrical
DLM0KX HST motor speed sensor Out of input signal range HST E03 l l
SPEED system
Left HST motor speed TRAVEL Electrical
DLM1KA Disconnection HST E01 – –
sensor SPEED system
Left HST motor speed TRAVEL Electrical
DLM1KB Short circuit HST – – –
sensor SPEED system
Left HST motor speed Electrical
DLM1MA Malfunction HST – – – –
sensor system
Right HST motor speed TRAVEL Electrical
DLM2KA Disconnection HST E01 – –
sensor SPEED system
Right HST motor speed TRAVEL Electrical
DLM2KB Short circuit HST – – –
sensor SPEED system
Right HST motor speed Electrical
DLM2MA Malfunction HST – – – –
sensor system
Electrical
DLM3KA Fan speed sensor Disconnection HST E01 FAN SPEED – –
system
Electrical
DLM3KB Fan speed sensor Short circuit HST E02 FAN SPEED l l
system
Brake pedal and proximity Electrical
DN21FS Fixing HST E03 BRAKE PEDAL l l
switch system
Electrical
DV00KB Caution buzzer: Short circuit MOM E01 BUZZER – –
system
Electrical
DV20KB Back alarm buzzer Short circuit HST E01 BACK ALARM – –
system
Parking brake solenoid Electrical
DW4BKA Disconnection HST E04 P BRAKE SOL l l
valve system
Parking brake solenoid Electrical
DW4BKB Short circuit HST E04 P BRAKE SOL l l
valve system
Parking brake solenoid Short circuit with power supply Electrical
DW4BKY HST E03 P BRAKE SOL l l
valve line system
Electrical
DW7BKA Fan reverse solenoid valve Disconnection HST E01 FAN CLN SOL – –
system
Electrical
DW7BKB Fan reverse solenoid valve Short circuit HST E01 FAN CLN SOL – –
system
Short circuit with power supply Electrical
DW7BKY Fan reverse solenoid valve HST E03 FAN CLN SOL l l
line system
SLOW BRAKE Electrical
DW7EKA Slow brake solenoid valve Disconnection HST E04 l l
SOL system
SLOW BRAKE Electrical
DW7EKB Slow brake solenoid valve Short circuit HST E04 l l
SOL system
Short circuit with power supply SLOW BRAKE Electrical
DW7EKY Slow brake solenoid valve HST E03 l l
line SOL system
Fan pump EPC solenoid Electrical
DWN5KA Disconnection HST E01 FAN EPC – –
valve system
Fan pump EPC solenoid Electrical
DWN5KB Short circuit HST E01 FAN EPC – –
valve system
30-76 j D51EX/PX-22
Fan pump EPC solenoid Short circuit with power supply Electrical
DWN5KY HST E02 FAN EPC l l
valve line system
LF HST pump EPC HST PUMP Electrical
DXA4KA Disconnection HST E03 l l
solenoid valve EPC system
LF HST pump EPC HST PUMP Electrical
DXA4KB Short circuit HST E03 l l
LF HST pump EPC Short circuit with power supply HST PUMP Electrical
DXA4KY HST E04 l l
solenoid valve line EPC system
LR HST pump EPC HST PUMP Electrical
LR HST pump EPC HST PUMP Electrical
LR HST pump EPC Short circuit with power supply HST PUMP Electrical
DXA5KY HST E04 l l
RF HST pump EPC HST PUMP Electrical
RF HST pump EPC HST PUMP Electrical
RF HST pump EPC Short circuit with power supply HST PUMP Electrical
DXA6KY HST E04 l l
RR HST pump EPC HST PUMP Electrical
RR HST pump EPC HST PUMP Electrical
RR HST pump EPC Short circuit with power supply HST PUMP Electrical
DXA7KY HST E04 l l
Left HST motor EPC HST MOTOR Electrical
DXK1KA Disconnection HST E02 l l
Left HST motor EPC HST MOTOR Electrical
DXK1KB Short circuit HST E02 l l
Left HST motor EPC Short circuit with power supply HST MOTOR Electrical
DXK1KY HST E04 l l
Right HST motor EPC HST MOTOR Electrical
DXK2KA Disconnection HST E02 l l
Right HST motor EPC HST MOTOR Electrical
DXK2KB Short circuit HST E02 l l
Right HST motor EPC Short circuit with power supply HST MOTOR Electrical
DXK2KY HST E04 l l
H Error codes:
The error code table is written in alphabetical order and also starting from small number.
The error code in parentheses is not recorded in the failure history for both electrical system and mechanical system.
H Applicable equipment:
Applicable equipment indicates in which controller system the failure has occurred.
MON: Monitor panel system
ENG: Engine controller system
HST: HST controller system
H Action codes:
Action codes indicate what is displayed in the operator mode when a failure is detected.
H History classification:
History classification indicates in which system, either electrical system or mechanical system in the failure history
display function, a failure has been recorded.
D51EX/PX-22 30-77 j
12
[4] Oil/filter maintenance mode (MAINTENANCE MONITOR)
1. If buzzer cancel switch [] is pressed on the normal display screen, the
maintenance mode is selected and the filter/oil maintenance mode
screen is displayed first.
2. Replacement time display of filter and oil (displayed automatically).

When the replacement interval for the various filters or oils
approaches, the monitor panel automatically displays the information
to remind an operator of maintenance.
• Table of maintenance items

Code Display Maintenance items
01 01: ENG OIL Engine oil
02 02: ENG FILT Engine oil filter
03 03: FUEL FILT Fuel main filter
41 41: FUEL P FILT Fuel pre filter
04 04: HYD FILT Hydraulic oil filter
06 06: CORR RES Corrosion resistor (*)
18 18: BYPS FILT Bypass filter (*)
07 07: DAMP OIL Damper filter (*)
08 08: FNL OIL Final drive oil
10 10: HYD OIL Hydraulic oil
19 19: POWL OIL Power train oil (*)
20 20: POWL FILT Power train oil filter (*)
21 21: HST FILT HST charge filter
* Unused on D51.
3. Reset of replacement time (selection menu)

The monitor panel can reset the interval time by operating the switch,
if various filters and oils maintenances are finished.
• For details, see Operation and Maintenance Manual.
• Replacement interval time setting can be operated by the
maintenance interval change mode in the service mode.
30-78 j D51EX/PX-22
12
[5] Brightness adjustment mode (BRIGHTNESS)
In this mode, the display condition of the monitor panel can be
adjusted on the character display portion.
The following items are displayed in the brightness adjustment mode.
Order Display Item
1 BRIGHTNESS GAUGE Adjustment of back light of LCD gauge
BRIGHTNESS Adjustment of back light of character display

2
CHARACTER DISP portion.
CONTRAST Adjustment of LCD contrast of character display

3
CHARACTER DISP portion.
• Screen during adjustment

• [>]: To increase adjustment value
• [<]: To decrease adjustment value
• []: To determine and return to previous screen
H The state when [] is pressed is recorded.
D51EX/PX-22 30-79 j
12
n Service mode
Procedure for switching to service mode and screen display

H When using the service mode, change the screen by the following special operation.
1. Confirming the screen display.

Check that the monitor panel is in operator mode and the screen is displaying either of the "service meter, "action code",
or "error code".
2. Displaying ID input initial screen.

Press the following 2 switches at the same time for longer than 5
seconds to display the ID input screen.
• [n] switch and [<] switch
H If the switch is pressed for longer than 5 seconds, the character
display section becomes blank. After confirming this condition,
release the switch.
3. Input and determination of ID.

After displaying ID input screen, operate [>], [<], [], and [n] switch
and input 4 digits ID.
H ID: 6491
• [>]: Number at the cursor increases.
• [<]: Number at the cursor decreases
• []: Number at the cursor is determined
• [n]:Cursor moves to left end or the display returns to operator
mode screen.
H If the ID input screen is left without switch operation for longer
than 60 seconds, it automatically returns to the operator mode
screen.
4. Displaying service menu selection screen.

After confirming all 4 digits of ID, display the service menu selection
screen in the service mode.
H By inputting and determining the ID once, it will be effective until
the starting switch is turned off.
30-80 j D51EX/PX-22
12
5. Selection of the service menu.
If the [>] switch or [<] switch is pressed on the service menu selection screen, the service menu is displayed endlessly in
the order of the following table, then select the menu that is used.
• [>]: To proceed to next service menu.
• [<]: To return to previous service menu.
H Displayed service menu:

Remark
No. 1 - 5 are used in the operator mode.
Order Display Function
6 ELECTRIC FAULT Electrical system failure history display mode
7 MACHINE FAULT Mechanical system failure history display mode
8 REAL-TIME MONITOR Real-time monitoring mode
9 CYLINDER CUT-OUT Cylinder cut-out mode
10 NO INJECTION No injection cranking mode
11 TUNING Tuning mode
12 MAINTENANCE MONITOR Maintenance interval change mode
13 TEL Phone No. input mode
14 MACHINE Model selection mode
15 OPTIONAL SELECT Option selection mode
16 INITIALIZE Initialize mode (exclusive function for factory)
H The service menu is displayed in the places marked with [*].
6. Finishing mode and function.

The current mode and function can be finished by either of the
following method, regardless of the current function and hierarchy.
• When continuing operations in another mode or function:
Press the [n] switch and return to the mode screen to be used or menu screen to be used.
H Note that if the [] switch is pressed on the YES/NO screen, the function will be executed.
H If you return to the operator mode screen by mistake, repeat the procedure from step 1 above (however there is
no need to input the ID again).
• When completing all operations: Turn the starting switch OFF.
D51EX/PX-22 30-81 j
12
[6] Electrical system failure history display mode (ELECTRIC FAULT)
The monitor panel retains the data for problems that occurred in the electrical system in the past as failure history. They
can be displayed as follows.

Select electrical system failure history display mode (ELECTRIC
FAULT) in the service menu selection screen.
H The total number of failure history data items recorded in memory
is displayed in the [* *] portion.
2. Failure history data display.

With the service menu selected, press the [] switch and display the
failure history data recorded in memory.
• []: Conduct the service menu.
3. Displayed failure history data.

With the electrical system failure history display mode, the following
data can be displayed.
1: Record number (recorded up to a maximum of 20 items)
A: Error code (4-digits device code + 2-digits symptom code)
2: Number of occurrences (number of occurrences of same code in
the past)
3: Elapsed time 1 (time elapsed on service meter since first
occurrence)
4: Elapsed time 2 (time elapsed on service meter since last
occurrence)
H Error codes for problems that are still existing are shown on a
flashing display.
H Refer to error code table of operator mode for details of displayed
error codes.
H Note that with the electrical system failure history display mode and error code display mode (operator mode), the
displayed data are partially different.
H If the fault history is not recorded, "–" is displayed on the display section of 1/A/2/3/4.
4. Switching failure history display.

If the [>] switch or [<] switch is pressed during the display of failure history, the display switches to another failure
history data recorded.
• [>]: To proceed to data for next record number
• [<]: Go back to data for previous record number
30-82 j D51EX/PX-22
12
5. Deleting individual failure history data.
A. With the failure history data to be deleted displayed, press the []
switch and display the individual deletion screen.
• []: Display the deletion screen
B. When the individual deletion screen is displayed, operate each
switch of [<], [>] and [].
• [<]: Select YES (move cursor)
• [>]: Select NO (move cursor)
• []: Execute YES or NO
• An information which is active currently (display is flashing)
cannot be deleted.
6. Deletion of all the failure history information.

A. With the failure history data displayed, press the [>] switch or [<]
switch and display ALL CLEAR menu screen.
• The ALL CLEAR menu is displayed at the end of failure
history data.
B. When the ALL CLEAR menu is displayed, press the [] switch
and display the ALL CLEAR execution screen.
• []: Execute ALL CLEAR menu
C. When the ALL CLEAR execution screen is displayed, operate

each switch of [<], [>] and [].
H An information which is active currently (display is flashing)
cannot be deleted.
D. The screen changes to the fault history screen. Check that the
number of records in ** is "0".
D51EX/PX-22 30-83 j
12
[7] Mechanical system failure history display mode (MACHINE
FAULT)
The monitor panel retains the data for problems that occurred in the
mechanical system in the past as failure history. They can be displayed
as follows.

Select mechanical system failure history display mode (MACHINE
FAULT) in the service menu selection screen.
H The total number of failure history data items recorded in memory
is displayed in the [* *] portion.
2. Failure history data display.

With the service menu selected, press the [] switch and display the
failure history data recorded in memory.
3. Displayed failure history data.

With the mechanical system failure history display mode, the
following data can be displayed.
1: Record number
A: Error code (4-digits device code + 2-digits symptom code)
2: Number of occurrences (number of occurrences of same code in
the past)
3: Service meter at first occurrence)
4: Service meter at last occurrence)
H Error codes for problems that are still existing are shown on a
flashing display.
H Refer to error code table of operator mode for details of displayed
error codes.
H Note that with the mechanical system failure history display mode
and error code display mode (operator mode), the displayed data are partially different.
H If the fault history is not recorded, "–" is displayed on the display section of 1/A/2/3/4.
4. Switching failure history display.

If the [>] switch or [<] switch is pressed during the display of failure history, the display switches to another failure
history data recorded.
• [>]: To proceed to data for next record number
• [<]: Go back to data for previous record number
5. Deleting failure history data (not permitted).

The failure history data for the mechanical system cannot be deleted.
30-84 j D51EX/PX-22
12
[8] Real time monitoring mode (REAL-TIME MONITOR)
The monitor panel can monitor the condition of the machine in real
time through the signals from the sensors installed to various parts of
the machine. In the real time monitoring mode, the following 2 types
of display can be shown.
• 1 item independent display (for each controller)
• 2 items simultaneous display (code input)

Select real time monitoring mode (REAL-TIME MONITOR) in the
service menu selection screen.
2. Display and selection of monitoring system and mode.

A. With the service menu selected, press the [] switch to display the
monitoring system and mode selection screen.
• []: Execute the service menu.
B. If the [>] switch or [<] switch is pressed on the monitoring system
and mode selection screen, the monitoring system and device is
displayed endlessly in the following order, then select the system
or mode that is used.
• [>]: To proceed to next monitoring system and mode
• [<]: Go back to data for previous monitoring system and
mode
H Monitoring system and mode to be displayed:
No. Display System and function
1 MONITOR PANEL Monitor panel system
2 HST HST controller system
3 ENGINE Engine controller system
4 KOMTRAX KOMTRAX controller system
5 2 ITEMS 2 items simultaneous monitoring
H Monitoring system and mode is displayed in the "*" section.
D51EX/PX-22 30-85 j
12
3. Setting 1 item individual monitoring.
A. In the monitoring system and mode selection screen, select the
monitoring system (example: ENGINE) to be used.
B. With the monitoring system selected, press the [] switch and
display the monitoring display and item selection screen.
• []: Implement 1 system individual monitoring
C. With the monitoring display and item selection screen displayed,

press the [>] switch or [<] switch and select items to monitor.
• [>]: To proceed to the next monitoring item
• [<]: Return to the previous monitoring item
H The monitored items are scroll-displayed due to internal
setting.
H If the switch is kept pressed, the monitoring items scroll at
high speed.
H In the monitoring display and item selection screen, the
information of the monitored items are displayed on real
time.
D. To hold or cancel monitoring data display: If the [] switch is
pressed during monitoring, the monitoring data display is held
and the [] mark flashes. If the [] switch is pressed again, hold is canceled and it becomes active again.
• []: Hold and release of data display
4. Display data for 1 item individual monitoring.

On the 1 item individual monitoring display screen, the following data
are displayed.
A: Item display
B: Monitoring code (5-digit)
1: Monitoring data (including unit)
H For details, see "Monitoring code table".
30-86 j D51EX/PX-22
5. Setting 2 items simultaneous monitoring
A. Select 2 items simultaneous monitoring (2 ITEMS) in the
monitoring system and function selection screen.
B. With 2 items simultaneous monitoring selected, press the []
switch to display the monitoring code input screen.
• []: Implement 2 system individual monitoring
C. In the monitoring code input screen, operate the switches [>], [<],
[] and [n], to input two monitoring codes directly.
• [<]: Number at the cursor decreases
• []: Number at the cursor is determined
• [n]:Cursor moves to the left end / To return to the monitoring
system and function selection screen.
D. When both of the monitoring codes have been confirmed, the

screen switches to the 2 items simultaneous monitoring display
screen.
E. To hold or cancel monitoring data display:
If the [] switch is pressed during monitoring, the monitor data is
held and the [] mark flashes.
If the [] switch is pressed again, hold is canceled and it becomes
active again.
• []: Hold and release of data
6. Display data for 2 items simultaneous monitoring.

On the 2 item simultaneous monitoring display screen, the following
data are displayed.
A : Monitoring code 1
1 : Monitoring data 1 (including unit)
B : Monitoring code 2
2 : Monitoring data 2 (including unit)
H For details, see "Monitoring code table".
D51EX/PX-22 30-87 j
12
Monitoring code table
MONITOR PANEL [Monitor panel system]
Display Monitoring
Monitoring item Item display Data display range Unit
order code
D51
1 Machine model code MACHINE CODE 00205 –
(Example of display)
01010101
2 Monitor panel input signal 1 D–IN––0––––––7 40921 (8 digits of 0/1. 0: OFF/1: ON
See detail.)
01010101
3 Monitor panel input signal 2 D–IN––8–10 40922 (8 digits of 0/1. 0: OFF/1: ON
See detail.)
4 Fuel sensor voltage FUEL SENSOR 04200 0 – 500 mV
5 Alternator R signal input voltage R SIGNAL 04303 0 – 500 mV
****
6 Application ver. 1 VERSION (APP) 20221 –
(8 digits/symbols)
****
7 Application data ver. 1 VERSION (DATA) 20222 –
(8 digits/symbols)
****
8 Program No. VERSION 20228 –
(8 digits/symbols)
****
9 Assembly No. PART NUMBER 20227 –
(8 digits/symbols)
*******
10 Serial No. SERIAL NUMBER 20402
(7 digits)
Display example of bit information
H Bit information is displayed in parts [0] – [10] and "OFF" is indicated

with "0" and "ON" with "1".
H In case of no use, displayed "0".
H The state of each item described in this section indicates the condition
for turning on the bit.
Detailed information of 40921 (D–IN––0––––––7)

[0] Staring switch C signal: Start position
[1] Front lamp and rear lamp: ON
[2] Preheater: ON
[3] (Unused)
[4] (Unused)
[5] (Unused)
[6] Air cleaner clogging sensor: ON (Clogged)
[7] Information switch: < (Left)
Detailed information of 40922 (D–IN––8–10)

[8] Information switch: > (Right)
[9] Buzzer cancel switch: U (Left)
[10] Buzzer cancel switch: t (Right)
30-88 j D51EX/PX-22
12
HST CONTROLLER [HST controller system]
Display Monitoring
order code
D51
1 Machine model code MACHINE CODE 00204 –
(Example of display)
2 HST oil temperature HST TEMP 04401 -99.9 – 999.9 °C
3 HST oil temperature sensor voltage HST TEMP 04402 0 – 5.00 V
4 Travel speed (Faster one of right and left) VEHICLE SPEED 40010 0 – 99.9 km/h
5 Right travel speed R SPEED 40002 0 – 99.9 km/h
6 Left travel speed L SPEED 40003 0 – 99.9 km/h
7 Right travel speed R SPEED 40963 0 – 9999 Hz
8 Left travel speed L SPEED 40964 0 – 9999 Hz
9 HST right circuit pressure HST R PRESS 52501 0 – 99.9 MPa
10 HST left circuit pressure HST L PRESS 52503 0 – 99.9 MPa
11 HST right circuit pressure sensor voltage HST R PRESS 52500 0 – 5.00 V
12 HST left circuit pressure sensor voltage HST L PRESS 52502 0 – 5.00 V
13 Brake pressure BRAKE PRESS 91902 0.00 – 9.99 MPa
14 Brake pressure sensor voltage BRAKE PRESS 91903 0 – 5000 mV
15 FR lever stroke FR LEVER 50204 -100.0 – 100.0 %
16 FR potentiometer 1 voltage FR LEVER 1 50202 0 – 5.00 V
17 FR potentiometer 2 voltage FR LEVER 2 50203 0 – 5.00 V
18 Steering stroke S/T LEVER 50303 -100.0 – 100.0 %
19 Steering potentiometer 1 voltage S/T LEVER 1 50300 0 – 5.00 V
20 Steering potentiometer 2 voltage S/T LEVER 2 50301 0 – 5.00 V
21 Brake pedal stroke BREAK PEDAL 50401 0.0 – 100.0 %
22 Brake potentiometer voltage BREAK PEDAL 50400 0 – 5.00 V
23 Throttle dial command speed FUEL DIAL 03003 0 – 9999 rpm
24 Throttle dial voltage FUEL DIAL 03002 0 – 5.00 V
25 Right forward pump capacity command value RF PUMP 52404 0.0 – 95.0 CC/r
26 Left forward pump capacity command value LF PUMP 52405 0.0 – 95.0 CC/r
27 Right reverse pump capacity command value RR PUMP 52406 0.0 – 95.0 CC/r
28 Left reverse pump capacity command value LR PUMP 52407 0.0 – 95.0 CC/r
Right forward pump output current command
29 RF PUMP 52400 0 – 9999 mA
value
30 Left forward pump output current command value LF PUMP 52401 0 – 9999 mA
Right reverse pump output current command
31 RR PUMP 52402 0 – 9999 mA
value
32 Left reverse pump output current command value LR PUMP 52403 0 – 9999 mA
33 Right forward pump output current sensed value RF PUMP FB 52408 0 – 9999 mA
34 Left forward pump output current sensed value LF PUMP FB 52409 0 – 9999 mA
35 Right reverse pump output current sensed value RR PUMP FB 42410 0 – 9999 mA
36 Left reverse pump output current sensed value LR PUMP FB 52411 0 – 9999 mA
37 Motor capacity command value MOTOR 52300 0 – 160 CC/r
38 Right motor output current command value R MOTOR 52301 0 – 9999 mA
39 Left motor output current command value L MOTOR 52302 0 – 9999 mA
40 Right motor output current sensed value R MOTOR FB 52303 0 – 9999 mA
41 Left motor output current sensed value L MOTOR FB 52304 0 – 9999 mA
42 Theoretical traction force TRACTION 60000 0 – 99.9 ton
43 Fan speed FAN SPEED 10007 0 – 9999 rpm
D51EX/PX-22 30-89 j
HST CONTROLLER [HST controller system]

Display Monitoring
order code
44 Fan speed FAN SPEED 40965 0 – 9999 Hz
45 Fan EPC output current command value FAN EPC 31623 0 – 9999 rpm
46 Fan EPC output current sensed value FAN EPC FB 31624 0 – 9999 mA
47 R signal input voltage R SIGNAL 04303 0 – 50.0 V
48 Battery relay drive voltage BR HOLD 60600 0 – 50.0 V
49 Neutral safety relay drive voltage N-SAFETY 50901 0 – 50.0 V
50 Backup alarm drive voltage BACK ALARM 70401 0 – 50.0 V
51 Controller unswitched power supply voltage (VB) PWR IN BATT 03207 0 – 50.0 V
52 Controller load drive power supply voltage (VIS) PWR IN BRY 03202 0 – 50.0 V
53 Key ACC input voltage PWR CNT KEY 03201 0 – 50.0 V
01010101
54 Machine controller switch input 1 D–IN––0––––––7 40910 (8 digits of 0/1. 0: OFF/1: ON
See detail.)
01010101
55 Machine controller switch input 2 D–IN––8––––––15 40911 (8 digits of 0/1. 0: OFF/1: ON
See detail.)
01010101
56 Machine controller switch input 3 D–IN––16–––––23 40912 (8 digits of 0/1. 0: OFF/1: ON
See detail.)
01010101
57 Machine controller switch input 4 D–IN––23–––––31 40913 (8 digits of 0/1. 0: OFF/1: ON
See detail.)
01010101
58 Machine controller D-OUT output D–OUT–0–––––7 40918 (8 digits of 0/1. 0: OFF/1: ON
See detail.)
01010101
59 Machine controller SOL OUT output D–OUT–8–––––15 40914 (8 digits of 0/1. 0: OFF/1: ON
See detail.)
60 Forward odometer FORWARD ODO M 53501 0 – 9999999 m
61 Reverse odometer BACKWARD ODO M 53502 0 – 9999999 m
62 1000 rpm service meter 1000rpm SMR 31105 0 – 9999999 h
********
63 Application ver. 1 VERSION (APP) 20235 –
(8 digits/symbols)
********
64 Application data ver. 1 VERSION (DATA) 20236 –
(8 digits/symbols)
********
65 Program No. VERSION 20238 –
(8 digits/symbols)
********
66 Assembly No. PART NUMBER 20237 –
(8 digits/symbols)
*******
67 Serial No. SERIAL NUMBER 20406 –
(7 digits/symbols)
30-90 j D51EX/PX-22
12
Detailed information of 40910 (D–IN––0 –––––– 7)
[0] Travel lever shift-up switch (NO): ON
[1] (Unused)
[2] (Unused)
[3] HST filter switch: ON (Filter is clogged)
[4] Travel lever shift-down switch (NC): OFF
[5] Travel lever shift-down switch (NO): ON
[6] Travel lever shift-up switch (NC): OFF
[7] (Unused)
Examples of display of bit information
H The bit information is displayed by "0" for OFF and "1" for ON in the
place [_].
Detailed information of 40911 (D–IN––8 ––––– 15)

[8] Starting switch C signal: Start position
[9] (Unused)
[10] (Unused)
[11] (Unused)
[12] Travel lock switch 2 (NO): Lock
[13] (Unused)
[14] (Unused)
[15] (Unused)
place [_].
Detailed information of 40912 (D–IN–16 ––––– 23)

[16] Reverse travel speed set switch: Deceleration (Left)
[17] Reverse travel speed set switch: Acceleration (Right)
[18] Travel lock switch (NO): Lock
[19] Travel lock switch (NC): Free
[20] (Unused)
[21] (Unused)
[22] (Unused)
[23] (Unused)
place [_].
D51EX/PX-22 30-91 j
12
Detailed information of 40913 (D–IN–24 ––––– 31)
[24] Shift mode switch: Quick shift mode (Right)
[25] Shift mode switch: Variable shift mode (Left)
[26] Fan rotation selector switch: Reverse (Right)
[27] Fan rotation selector switch: Forward (Left)
[28] (Unused)
[29] (Unused)
[30] (Unused)
[31] (Unused)
place [_].
Detailed information of 40918 (D–OUT–0 ––––– 7)

[0] (Unused)
[1] (Unused)
[2] (Unused)
[3] Neutral safety relay: ON
[4] (Unused)
[5] Backup alarm: ON
[6] (Unused)
[7] Battery relay: ON
place [_].
Detailed information of 40914 (D–OUT–8 –––– 15)

[8] Fan reverse solenoid valve: ON
[9] (Unused)
[10] Parking brake solenoid valve: ON
[11] Slow brake solenoid valve: ON
[12] (Unused)
[13] (Unused)
[14] (Unused)
[15] (Unused)
place [_].
30-92 j D51EX/PX-22
12
ENGINE [Engine controller system]
Display Monitoring
order code
1 Engine speed 1 ENG SPEED 01002 0 – 4000 rpm
2 Engine coolant temperature COOLANT TEMP 04107 -40 – 210 °C
3 Engine coolant temperature sensor voltage COOLANT TEMP 04105 0.00 – 5.00 V
4 Decelerator pedal operating degree DECEL PEDAL 31701 0 – 100 %
5 Decelerator pedal sensor voltage DECEL PEDAL 31702 0.00 – 5.00 V
6 Selected machine model name MACHINE ID 00201 – –
7 Build version BUILD VER 20216 – –
8 Calibration data version CAL VER 20217 – –
9 Controller internal temperature ECMINT TEMP 18900 -40 – 210 °C
10 Hardware serial No. ECM S/N 20400 0 – 49999999 –
11 Converted torque TORQUE RATIO 36700 0 – 100 %
12 Engine mode selection POWER MODE 17500 0–4 –
13 Common rail pressure RAIL PRESS 36400 0 – 400 MPa
14 Common rail pressure sensor voltage RAIL PRESS 36401 0.00 – 5.00 V
15 Final common rail pressure command PFIN PRESS COMMAND 36200 0 – 400 MPa
16 Final injection timing command TFIN INJECT TIMING 36300 -180.0 – 180.0 CA
17 Ambient pressure AMBIENT PRESS 37400 -99.9 – 999.9 kPa
18 Ambient pressure sensor voltage AMBIENT PRESS 37401 0.00 – 5.00 V
19 Boost pressure 1 CHG PRESS-A 36500 -99.9 – 99.9 kPa
20 Boost pressure sensor voltage 1 CHG PRESS-A 36501 0.00 – 5.00 V
21 Battery voltage POWER PATE 03203 0.0 – 480.0 V
22 Momentary fuel consumption FUEL RATE 37300 0.0 – 999.9 L/h
23 Final accelerator pedal operating degree FINAL THROTTLE 31706 0 – 100 %
24 Intake air temperature INTAKE TEMP 18400 -50 – 200 °C
25 Intake air temperature sensor voltage INTAKE TEMP 18401 0.00 – 5.00 V
26 Boost temperature CHG TEMP 18500 -50 – 200 °C
27 Boost temperature sensor voltage CHG TEMP 18501 0.00 – 5.00 V
28 Idle validation switch 1 IVS 1 18300 0 or 1 –
29 Idle validation switch 2 IVS 2 18301 0 or 1 –
30 Final injection command (Weight unit) INJECT COMMAND 18600 0 – 1000 mg
31 Engine output torque OUTPUT TORQUE 18700 -24000 – 24000 Nm
32 WIF sensor state WATER IN FUEL 18800 0 or 1 –
KOMTRAX [KOMTRAX controller system]

Display Monitoring
order code
1 LED display LED STATUS 20300 0_00_ 7 (Example) –
D51EX/PX-22 30-93 j
12
[9] Cylinder cut-out mode (CYLINDER CUT-OUT)
As one method of troubleshooting for the engine, the monitor panel
has a reduced cylinder mode that can set the desired cylinder to the no
injection condition.
1. Starting engine.
Use this function while the engine is running, because a defective
cylinder is determined depending on the engine speed in the reduced
cylinder mode.
2. Selection in the service menu.

A. Select the reduced cylinder mode (CYLINDER CUT-OUT) in the
service menu selection screen.
B. With the cylinder cut-out mode selected, press the [] switch and
display the reduced cylinder mode execution screen.
H The cylinder No. and the engine speed are displayed on the
upper line, and the final injection amount command is
displayed on the lower line.
H When being switched to the reduced cylinder mode execution
screen, the cursor of cylinder selection is always displayed
under the No.1 cylinder.
3. Setting cut-out cylinder.

In the reduced cylinder mode execution screen, operate the switches
[>], [<], [] and [n] to select the cut-out cylinder.
• [>]: Selector cursor moves to the right.
• [<]: Selector cursor moves to the left.
• []: Determine the cylinder.
• [n]:To return to the service menu selection screen.
H When the [] switch is used to confirm the cut-out cylinder,
communication is carried out between the monitor panel and
engine controller. During this time, the cylinder No. flashes.
After completion of the communication, the segment under
the cylinder No. becomes black to show that the cylinder has
been cut out.
H A single cylinder or multiple cylinders can be cut out.
4. Canceling cylinder cut-out.

Cancellation of cylinder cut-out is done by the same procedure as
setting cut-out cylinder.
H When the [] switch is used to confirm the cancellation of the
cut-out cylinder, communication is carried out between the
monitor panel and engine controller. During this time, the
cylinder No. flashes.
After completion of the communication, the segment under the
cylinder No. becomes white to show that the cylinder cut-out has
been canceled.
30-94 j D51EX/PX-22
12
[10] No injection cranking mode
(NO INJECTION)
The monitor panel has the mode of no injection cranking, which is used for cranking after long-term storage, stopping fuel
injection of all the cylinders without starting the engine.
H The mode of no injection cranking must be operated under the condition that the engine is stopped.
1. Selection in the service menu.

In the service menu selection screen, select no injection cranking
mode (NO INJECTION).
2. Establishment of no injection cranking.

With the no injection cranking selected, press the [] switch to display
no injection cranking execution screen.
H If "CRANKING READY" is displayed on the lower line, the
none injection cranking is set.
H If the starting switch is operated to the START position under this
condition, the engine cranks but will not start.
3. Setting is rejected during engine running.

During engine running, if the setting of no injection cranking is
attempted, "STOP ENGINE" is displayed with blinking in the lower
line, and setting is rejected.
H No injection cranking mode cannot be used during engine
running.
4. Canceling no injection cranking.

If the [n] switch is pressed on the no injection cranking execution
screen, the screen returns to the service menu selection screen and the
no injection cranking is cancelled.
D51EX/PX-22 30-95 j
12
[11] Tuning mode (TUNING)
Various devices can be set and tuned with this mode. The changes of the screen in this mode are outlined below.
1. Selecting service menu.

A. Select the tuning mode (TUNING) on the service menu selection
screen.
30-96 j D51EX/PX-22
12
B. While the tuning mode (TUNING) screen is displayed, press the
[] switch to display the ID input (ID INPUT) screen.
• []: Display ID input (ID INPUT) screen.
C. If the [n] switch is pressed on the screen, the screen returns to the
tuning mode (TUNING) screen.
• [n]: Return to tuning mode (TUNING) screen.
2. Selecting display pattern.

A. Select a pattern of displaying desired items on the ID input (ID
INPUT) screen by pressing the [], [>] or [<] switch.
• []: Go to tuning item ID input (ID = 0000) screen.
On this screen, all the tuning items can be called up by input-
ting the ID.
H For the selectable tuning items, see "Tuning mode table".
• [>]: Go to tuning 1 (TUNING 1) screen.
On this screen, the set tuning items can be called up in order.
• [<]: Go to tuning 2 (TUNING 2) screen.
On this screen, the set tuning items can be called up in order.
H For the selectable tuning items, see "Tuning mode table".
H The following figure shows the display of tuning 1 (TUNING
1) as an example.
D51EX/PX-22 30-97 j
3. Changing display pattern.
A. When changing the display pattern on the ID input (ID INPUT),
tuning 1 (TUNING 1) or tuning 2 (TUNING 2) screen, press the
[>] or [<] switch, and the 3 patterns are selected in order.
H For the switches to be pressed and the changing order, see the
figure.
4. Selecting tuning item.

A. When selecting a tuning item on tuning item ID input (ID = 0000)
screen.
i. Input the tuning item ID to be selected to the position of

"0000" on the following screen with the [>], [<], [] and [n]
switches.
• [>]: Increase value.
• [<]: Decrease value.
• []: Confirm value. After value is confirmed, cursor
moves to right next position.
• [n]: Move cursor to left most position from right most
position.
ii. After inputting tuning item ID, press the [] switch, and the
ID is confirmed and the selected item screen appears.
H The displayed contents of the tuning screen are as
follows.
a: Tuning item ID
b: Tuning item name
c: Value
30-98 j D51EX/PX-22
H If a tuning item ID which has not been set is input, the
message is displayed. In this case, input another tuning
item ID.
iii. If the [n] switch is pressed on each tuning item screen, the screen returns to the tuning item ID input (ID = 0000)
screen.
• [n] Return to tuning item ID input (ID = 0000) screen.
B. When selecting a tuning item on tuning 1 (TUNING 1) or tuning 2 (TUNING 2) screen.
H The selecting procedure is the same on the tuning 1 (TUNING 1) and tuning 2 (TUNING 2) screens, but
selectable items on those screens are different.
H An example of display in tuning 1 (TUNING 1) is shown below.
i.Press the [] switch on the tuning 1 (TUNING 1) or tuning 2 (TUNING 2) screen, and the top item of the set
tuning items is displayed.
• []: Display top item of set tuning items.
H In tuning 2 (TUNING 2), "ID: 3001 F-PUMP LINE" is
displayed.
ii.
Press the [>] or [<] switch, and the set items are displayed in order.
• [>]: Display set items in normal order.
• [<]: Display set items in reverse order.
H For the displayable items, see "Tuning mode table".
• <Normal display order> (For the symbols, see "Tuning mode table") Tuning 1 (TUNING 1): A1 A2  A3
 A4  A5  A6  A7  A1 --- (Repeated continuously).
• Tuning 2 (TUNING 2): B1 B2  B3  B1 --- (Repeated continuously).
iii. If the [n] switch is pressed on each tuning screen, the screen returns to the tuning 1 (TUNING 1) or tuning 2
(TUNING 2) screen.
• [n]: Return to tuning 1 (TUNING 1) or tuning 2 (TUNING 2) screen.
D51EX/PX-22 30-99 j
12
5. Tuning mode table and adjustment procedure
Tuning Automatic selection
No. Display Item Related information
item ID TUNING1 TUNING2
1 0005 BRAKE N-SET Brake potentiometer neutral set Potentiometer voltage A6
Steering lever left counter-rotation set
2 1010 S/T H.L-SET Potentiometer voltage A2
(Operating effort difference)
Steering lever right counter-rotation set
3 1011 S/T H.R-SET Potentiometer voltage A4
(Operating effort difference)
4 1012 S/T N-SET Steering lever neutral set Potentiometer voltage A1
5 1013 S/T M.L-SET Steering lever left max. set Potentiometer voltage A3
6 1014 S/T M.R-SET Steering lever right max. set Potentiometer voltage A5
Forward pump set
7 3001 F-PUMP LINE Command current B1
(For running track shoe idle)
Reverse pump set
8 3002 R-PUMP LINE Command current B2
(For running track shoe idle)
Forward pump start/max. capacity set
9 3003 F-PUMP RUN1 Command current
(For travel)
Reverse pump start/max. capacity set
10 3004 R-PUMP RUN1 Command current
(For travel)
11 3005 F-PUMP RUN2 Forward pump medium capacity set (For travel) Command current
12 3006 R-PUMP RUN2 Reverse pump medium capacity set (For travel) Command current
13 3007 BRAK END Brake potentiometer max. set Potentiometer voltage A7
Engine speed
EST oil temperature
14 3016 STALL CHECK Stall pressure test mode (Hydraulic oil temperature)
Right HST main circuit pressure
Left HST main circuit pressure
15 3019 SHIFT LIMIT Gear speed limit mode Limit gear speed
16 3024 MOTOR LINE Motor set (For running track shoe idle) Command current B3
17 3032 FAN MODE Fan test mode selection Mode name
18 3033 FAN AMP SET Fan set Command current
Forward pump start adjustment value change Adjustment direction
19 3035 F-PUMP MAP1
(For right and left separately) adjustment value
Reverse pump start adjustment value change Adjustment direction
20 3036 R-PUMP MAP1
(For right and left separately) adjustment value
Forward pump start adjustment value change
21 3037 F-PUMP MAP2 Travel speed adjustment value
(For right and left simultaneously)
Reverse pump start adjustment value change
22 3038 R-PUMP MAP2 Travel speed adjustment value
(For right and left simultaneously)
23 -- -- Service meter set (*) Service meter value
*: Refer to Parts and Service News (PSN) AA07100.

<Automatic selection of adjustment item>
H For items having numbers in the "Automatic selection" column of the above table, once TUNING 1 or TUNING 2 is
selected on the ID INPUT/TUNING 1/TUNING 2 selection screen, those items can be selected automatically in the order
within the group by operating the information switch.
<Items to be adjusted after disassembly and assembly>
• When HST controller assembly is replaced (Either of the following):
H Perform the following adjustment after selecting the machine model.
A. TUNING 1: [A1] [A2] [A3] [A4] [A5] [A6] [A7] and TUNING 2: [B1] [B2] [B3] and ID INPUT: [3033]
B. TUNING 1: [A1] [A2] [A3] [A4] [A5] [A6] [A7] and ID INPUT: [3003] [3005] [3004] [3006] [3024] [3033]
H When HST pump assembly or HST pump EPC valve is replaced (Either of the following)
A. ID INPUT: [3001] [3002]
B. ID INPUT: [3003] [3005] [3004] [3006]
• When HST motor assembly or HST motor EPC valve is replaced: ID INPUT: [3024]
30-100 j D51EX/PX-22
• When hydraulic fan, fan motor, work equipment valve, fan EPC or work equipment pump is replaced: ID INPUT: Items
of [3033]
• When PCCS lever assembly is replaced: ID INPUT: [1012] [1010] [1013] [1011] [1014]
• When brake linkage is adjusted or brake potentiometer is replaced: ID INPUT [0005] [3007]
n Details of each item
H The 4-digit number in [_] is the adjustment item ID.

[0005]: Brake potentiometer neutral set (Changed in normal order: A6)
• This code is used to adjust the neutral position of the brake pedal
potentiometer.
• The signal output of the brake pedal potentiometer is displayed by
voltage on the lower line. (Display range: 0 – 5000)
• Adjustment method:
i. Check that the brake pedal is in neutral (it is not pressed).
ii.
Set buzzer cancel switch in the [] position and check that the
caution buzzer sounds.
H The display of the lower line does not change after
adjustment.
H Even if this code is turned OFF, the setting is effective.
H This adjustment is performed to make the HST controller recognize the neutral position of the brake pedal
potentiometer. It is not performed to adjust the effect of the brake.
[1010] Steering lever left counter-rotation set

(Operating effort difference) (Changed in normal order: A2)
• This code is used to adjust the left counter-rotation (operating effort
difference) position of the steering potentiometer of the PCCS lever.
• The signal output of the steering potentiometer is displayed by voltage
on the lower line (Display range: 0 – 5000).
i. Set the PCCS lever in the left counter-rotation (operating

effort difference) position.
ii. Set buzzer cancel switch in the [] position and check that the
adjustment.
H This code is not used to adjust the steering performance, etc.
H The adjustment value cannot be adjusted higher than 2,000 mV to prevent wrong setting (The caution buzzer
does not sound).
D51EX/PX-22 30-101 j
12
[1011] Steering lever right counter-rotation set
(Operating effort difference) (Changed in normal order: A4)
• This code is used to adjust the right counter-rotation (operating effort
difference) position of the steering potentiometer of the PCCS lever.
i. Set the PCCS lever in the right counter-rotation (operating

effort difference) position.
adjustment.
H The adjustment value cannot be adjusted lower than 3,000 mV to prevent wrong setting (The caution buzzer does
not sound).
[1012] Steering lever neutral set

(Changed in normal order: A1)
H This code is used to adjust the neutral position of the steering
potentiometer of the PCCS lever.
H The signal output of the steering potentiometer is displayed by voltage
i. Set the PCCS lever in the neutral position.
H The display of the lower line does not change after adjust-
ment.
H The adjustment value cannot be adjusted lower than 2,000 mV or higher than 3,000 mV to prevent wrong setting
(The caution buzzer does not sound).
30-102 j D51EX/PX-22
12
[1013] Steering lever left max. set
• This code is used to adjust the left maximum position of the steering
i. Set the PCCS lever to the left steering stroke end.
adjustment.
H The adjustment value cannot be adjusted higher than 2,000 mV to prevent wrong setting (The caution buzzer
does not sound).
[1014] Steering lever right max. set

• This code is used to adjust the right maximum position of the steering
i. Set the PCCS lever to the right steering stroke end.
adjustment.
H The adjustment value cannot be adjusted lower than 3,000 mV to prevent wrong setting (The caution buzzer does
not sound).
D51EX/PX-22 30-103 j
12
[3001] Forward pump set
(For running track shoe idle) (Changed in normal order: B1)
• This code is used to adjust the command current of the forward pump
while the track shoe is running idle.
• The command current of the forward pump is displayed on the lower
line.
i. Jack up the rear frame bottom of the machine and brace the
blade in the lowering direction to float the whole track shoe
so that it can run idle.
WARNING! Since the track shoe will run idle during

adjustment, check that it is floated
securely above the ground.
ii. Run the engine at high idle.
iii. Check that the parking brake lever is in the LOCK position and the PCCS lever is in the neutral position and [P]
is flashing in the gear speed/set travel speed/shift mode indicator section.
iv. Set the parking brake lever in the FREE position and set the PCCS lever in the forward travel position, and
adjustment starts.
WARNING! If adjustment starts, the pump command current increases and the track shoe starts
running automatically. (The track shoe starts running idle, then stops and starts again.
Take care.)
WARNING! The caution buzzer keeps sounding during adjustment.
WARNING! The command current of the forward pump increases to 805 mA, then the track shoe
stops.
H When adjustment is finished, [SETTING NOW!!] is displayed on the lower line.
WARNING! When stopping (interrupting) the track shoe during adjustment, return the PCCS lever to
the neutral position. (Operations of steering with the PCCS lever, brake pedal, fuel
control dial, and decelerator pedal are not accepted during adjustment. Take care.)
v. After adjustment is finished, set the PCCS lever in the neutral

position and set the parking brake lever in the LOCK
position.
H When starting adjustment again after interrupting it, perform
the procedures from ii).
H If adjustment is interrupted and an error is displayed, check
the following devices.
• When the track shoe does not move: HST pump
• When the track shoe moves: HST motor speed sensor
• Display example of error
H The arrowed letters indicate the abnormal sides.
• R: Right side
• L: Left side
• LR: Both right and left sides
30-104 j D51EX/PX-22
12
[3002] Reverse pump set (For running track shoe idle) (Changed in normal
order: B2)
• This code is used to adjust the command current of the reverse pump
while the track shoe is running idle.
• The command current of the reverse pump is displayed on the lower
line.

iv. Set the parking brake lever in the FREE position and set the PCCS lever in the reverse travel position, and adjust-
ment starts.
WARNING! If adjustment starts, the pump command current increases and the track shoe starts
running automatically. (The track shoe starts running idle, then stops and starts again.
Take care.)
WARNING! The command current of the reverse pump increases to 805 mA, then the track shoe
stops.
WARNING! When stopping (interrupting) the track shoe during adjustment, return the PCCS lever to
the neutral position. (Operations of steering with the PCCS lever, brake pedal, fuel
control dial, and decelerator pedal are not accepted during adjustment. Take care.)

position.
the procedures from ii).
H If adjustment is interrupted and an error is displayed, check
the following devices.
• When the track shoe does not move: HST pump
• When the track shoe moves: HST motor speed sensor
• R: Right side
• L: Left side
D51EX/PX-22 30-105 j
12
[3003] Forward pump start/maximum capacity set (For travel)
• This code is used to adjust the command current of the start and
maximum capacity of the forward pump while the machine is
traveling.
line.
i. Move the machine to a wide and flat place where it can travel
straight for at least 30 m.
WARNING! Since the machine will travel straight

forward during adjustment, work in a
place where there is not an obstacle
through length of at least 30 m.
adjustment starts.
WARNING! If adjustment starts, the pump command current increases and the machine starts
traveling forward automatically. (The machine starts traveling forward, then stops and
starts again. Take care.)
WARNING! The command current of the forward pump increases to 805 mA, then the machine stops.
WARNING! If the PCCS lever, fuel control dial, decelerator pedal, or brake pedal is operated during
adjustment, the machine moves as operated. In this case, however, adjustment is
interrupted, the caution buzzer stops sounding, and gear speed/set travel speed/shift
mode indicator section stops flashing and lights up.
H When moving the machine after interrupting adjustment,

operate it as usually. The travel speed at the time of
interruption is kept, however.

position.
the procedures from i).
H If adjustment is interrupted and an error is displayed, adjust
the following parts.
• When machine does not move: HST pump
• When machine moves: HST motor speed sensor
• R: Right side
• L: Left side
30-106 j D51EX/PX-22
[3004] Reverse pump start/maximum capacity set (For travel)
• This code is used to adjust the command current of the start and
maximum capacity of the forward pump while the machine is
traveling.
line.

ment starts.
H When moving the machine after interrupting adjustment,

operate it as usually. The travel speed at the time of

position.
the procedures from i).
H If adjustment is interrupted and an error is displayed, adjust
the following parts.
• When machine does not move: HST pump
• When machine moves: HST motor speed sensor
• R: Right side
• L: Left side
D51EX/PX-22 30-107 j
[3005] Forward pump medium capacity set (For travel)
• This code is used to adjust the command current of the medium
capacity of the forward pump while the machine is traveling.
line.

adjustment starts.
H When moving the machine after interrupting adjustment, operate it as usually. The travel speed at the time of
v.After adjustment is finished, set the PCCS lever in the neutral position and set the parking brake lever in the
LOCK position.
H When starting adjustment again after interrupting it, perform the procedures from i).
30-108 j D51EX/PX-22
12
[3006] Reverse pump medium capacity set (For travel)
• This code is used to adjust the command current of the medium
capacity of the forward pump while the machine is traveling.
line.

ment starts.
H When moving the machine after interrupting adjustment, operate it as usually. The travel speed at the time of
v.After adjustment is finished, set the PCCS lever in the neutral position and set the parking brake lever in the
LOCK position.
H When starting adjustment again after interrupting it, perform the procedures from i).
D51EX/PX-22 30-109 j
12
[3007] Brake potentiometer maximum set (Changed in normal order: A7)
• This code is used to adjust the maximum position of the brake pedal
potentiometer.
• The signal output of the brake pedal potentiometer is displayed by
voltage on the lower line.
(Display range: 0 – 5000)
i. Press and hold the brake pedal at the stroke end.
ii.
Set buzzer cancel switch in the [] position and check that the
adjustment.
H This code is used to make the HST controller recognize the maximum position of the brake pedal potentiometer.
It is not used to adjust the brake performance.
30-110 j D51EX/PX-22
12
[3016] Stall pressure test mode
• This code is used to test the engine speed, HST oil temperature
(hydraulic oil temperature), and right and left HST main circuit
pressures while the HST is stalled.
• The engine speed, HST oil temperature, right HST main circuit
pressure, or left HST main circuit pressure is displayed on the lower
line.
• How to use:
WARNING! Check that the HST oil temperature

(hydraulic oil temperature) is in the range
from 40 to 60ºC while the HST is stalled.
(Do not stall the HST while the oil
temperature is out of the specified range.)
WARNING! Before selecting this code, check that the parking brake lever is in the LOCK position and
the PCCS lever is in the neutral position.
H If this code is selected, the HST is stalled automatically. (The HST is stalled only when the PCCS lever is set in the
FORWARD or REVERSE position, however.)
• Travel speed: 3rd (Min. delivery of HST motor)
• Parking brake solenoid valve: OFF
• Slow brake solenoid valve: OFF
WARNING! The following errors are set in this code for safety. If one of them is turned ON, the
command current to the HST pump EPC valve is stopped.
No. 1: When the machine is set in this mode, it is moving.
No. 2: The parking brake lever is not in the LOCK position.
No. 3: After the machine is set in this mode, it is moving.
No. 4: The parking brake release pressure is increased.
No. 0: The above errors are reset.
i. While the engine is running, select an item to be displayed by operating information switch (5).
• [>]: Next code
• [<]: Previous code
H The following items can be displayed.
No. Display Item Unit
1 ENG-REV Engine speed rpm
2 HST TEMP HST oil temperature °C
3 R PRESS Right HST main circuit pressure MPa
4 L PRESS Left HST main circuit pressure MPa
ii. Check that the parking brake lever is in the LOCK position.
H Stall the HST while the parking brake lever is in the LOCK position.
iii. Set the PCCS lever in the FORWARD or REVERSE position to stall the HST and test the necessary items.
• If the PCCS lever is set in the FORWARD or REVERSE position, the HST stalls. If the PCCS lever is
returned, stalling of the HST stops.
• The displayed item can be changed even while the HST is stalled.
WARNING! While the HST is stalled, the oil temperature rises sharply and locally. Accordingly, do not
stall the HST continuously for more than 30 seconds. Accordingly, the following restric-
tion function is installed.
D51EX/PX-22 30-111 j
H If stalling of the HST starts, the gauge displays gear speed, set travel speed and the shift indicator section
cycles one cell at a time. If stalling is stopped, the gauges are lit one cell at a time.
If all the gauges are out, stalling of the HST is stopped automatically. When you start the stalling again,
return the PCCS lever to the neutral position once. Then start the stalling again.
[3019] Gear speed limit mode

• This code is used to prevent shifting the gear to the 3rd position.
• The usable gear speeds are displayed on the lower line.
• Using method:
i. Select use of the highest gear speed by operating shift-up

switch.
• [3RD]: Permit use of 3rd gear speed.
• [2ND]: Limit use of 3rd gear speed.
ii.
Set the buzzer cancel switch in the [] position to enter the
setting.
H If the gear speed is limited, it is not shifted to the 3rd
position, even if the shift-up switch is operated.
H The setting becomes effective when the starting switch is turned OFF and ON.
H The setting is effective in both quick shift mode and variable shift mode.
30-112 j D51EX/PX-22
12
[3024] Motor set (For running track shoe idle) (Changed in normal order:
B3)
• This code is used to adjust the command current of the motor while
the track shoe is running idle.
• The command current of the motor is displayed on the lower line.

adjustment starts.
WARNING! If adjustment starts, the motor command current increases and the track shoe starts
running automatically. Take care.
WARNING! The motor command current changes from 248 mA ß 448 mA ß 605 mA ß.... and the
track shoe stops finally.
H If adjustment stops automatically and an error is displayed, check the following items.
• When track shoe does not move: HST pump
• When track shoe moves:
1) HST motor speed sensor
2) Hose between motor EPC of 5-spool valve and motor
3) Connector between motor EPC of 5-spool valve and wiring harness
4) Is hydraulic oil temperature abnormally low?
R: Right side
L: Left side
LR: Both right and left sides
D51EX/PX-22 30-113 j
12
[3032] Fan test mode selection
• This code is used to select the normal control mode, fan 100% mode
or fan 70% mode.
• The mode to be selected is displayed on the lower line.
• How to select
i. Start the engine, set the fuel control dial to the high idle
position, and set the decelerator pedal in neutral (release it).
ii. Operate the information switch to select a mode.
iii. Set buzzer cancel switch in the [] position to settle the
setting.
• The following modes can be selected.
Order Display Item
1 OFF Normal control mode
2 100% Fan 100% operation mode
3 70% Fan 70% operation mode
• Use this code while the engine coolant temperature is above 65°C and the HST oil temperature is above 55°C.
• Even if this code is turned OFF, the setting is effective as long as the starting switch is in the ON position.
• Accordingly, set the fan in the normal control mode before turning this code OFF.
[3033] Fan set

• This code is used to adjust the fan command current while the fan is
running.
• The fan command current is displayed on the lower line.
• Adjustment method
WARNING! Before selecting this code, adjust the HST

oil temperature (hydraulic oil temperature)
to 50 – 60°C.
WARNING! Keep the work equipment lowered to the

ground and set the work equipment lock
lever in the LOCK position during this
adjustment.
i. Start the engine, set the fuel control dial in the high idle position, and set the decelerator pedal in neutral (release
it).
ii. Set the buzzer cancel switch in the [] position, and adjustment starts.
iii. The fan command current changes from 800 mA to 300 mA and adjustment is finished.
30-114 j D51EX/PX-22
12
[3035] Forward pump start adjustment value change (For right and left
separately)
• This code is used to adjust the forward pump command value finely
when the right and left track shoes do not start forward simultaneously
(the machine swings in either direction) after performing adjustments
of [B1], or [3003] and [3005].
• The correction value of the right or left side to be adjusted is displayed
on the lower line.
i. Operate the information switch to select the side which starts

earlier (RIGHT/LEFT).
• Press the [>] or [<] button to select [RIGHT] or [LEFT].
ii. Set the buzzer cancel switch in the [] position to settle the selected correction direction.
If the selection is settled, [AD:***] is added next to [RIGHT/LEFT] on the lower line.
Once adjustment is completed, it cannot be returned. Accordingly, be sure to record the value on the right side of
[DA:***] before starting iii).
iii. Operate the information switch to decrease the value by 1. (Decrease the value by 1)
• [>]: Increase value (Start earlier)
• [<]: Decrease value (Start later)
WARNING! If the value is increased, the machine starts sharply. Take care.
WARNING! If you changed the value largely by mistake at a time, turn the starting switch OFF and
then start adjustment again.
iv. Check that the right and left track shoes start forward simultaneously.
v. Repeat steps iii) and iv) until the right and left track shoes start simultaneously.
vi. Set the buzzer cancel switch in the [] position and check that the caution buzzer sounds and [SETTING NOW!!]
is displayed on the lower line.
D51EX/PX-22 30-115 j
12
[3036] Reverse pump start adjustment value change (For right and left
separately)
• This code is used to adjust the reverse pump command value finely
when the right and left track shoes do not start reverse simultaneously
(the machine swings in either direction) after performing adjustments
of [B2], or [3004] and [3006].
• The correction value of the right or left side to be adjusted is displayed
on the lower line.
i. Operate the information switch to select the side which starts

earlier (RIGHT/LEFT).
• Press the [>] or [<] button to select [RIGHT] or [LEFT].
ii.
Set the buzzer cancel switch in the [] position to settle the selected side.
If the selection is settled, [AD:***] is added next to [RIGHT/LEFT] on the lower line.
H Once adjustment is completed, it cannot be returned. Accordingly, be sure to record the value on the right side of
[DA:***] before starting iii).
iii. Operate the information switch to decrease the value by 1.

WARNING! If the value is changed largely, the track shoe starts sharply. Take care.
iv. Check that the right and left track shoes start reverse simultaneously.
v. Repeat steps iii) and iv) until the right and left track shoes start simultaneously.
vi. Set the buzzer cancel switch in the [] position and check that the caution buzzer sounds and [SETTING NOW!!]
30-116 j D51EX/PX-22
12
[3037] Forward pump start adjustment value change (For right and left
simultaneously)
when remarkably large shocks are made at the starting and stopping
moments of forward travel after performing adjustments of [B1], or
[3003] and [3005].
• The travel speed and correction value are displayed on the lower line.
WARNING! Once adjustment is completed, it cannot

be returned. Accordingly, be sure to
record the value on the right side of
[DA:****] before starting adjustment.
i. Operate the information switch to decrease the value by 1.

ii. Check that shocks are not made at the moments when the machine starts and stops forward travel.
iii. Repeat i) and ii) until shocks are not made.
iv. Select the variable gear shift mode, set the gear speed display to the minimum (2 gauge segments), drive the
machine, and check that the travel speed is "0.6 km/h" or higher (the value on the right of [SPD:1] on the lower
line, is 600 or higher).
If the travel speed is below "0.6 km/h", time lag in start and other negative effects are made. Accordingly, return
the adjusted value until the travel speed lowers below "0.6 km/h".
v. Set the buzzer cancel switch in the [] position and check that the caution buzzer sounds and [SETTING NOW!!]
H This code is not used to adjust the starting acceleration performance but used to adjust the shocks made at the
moments when the machine starts and stops.
[_-_] Service meter set: Refer to Parts and Service News (PSN) AA07100.
D51EX/PX-22 30-117 j
12
[3038] Reverse pump start adjustment value change (For right and left
simultaneously)
when remarkably large shocks are made at the starting and stopping
moments of forward travel after performing adjustments of [B2], or
[3004] and [3006].
• The travel speed and correction value are displayed on the lower line.
WARNING! Once adjustment is completed, it cannot

be returned. Accordingly, be sure to
record the value on the right side of
[DA:****] before starting adjustment.
i. Operate the information switch to decrease the value by 1.

ii. Check that shocks are not made at the moments when the machine starts and stops forward travel.
iii. Repeat i) and ii) until shocks are not made.
iv. Select the variable gear shift mode, set the gear speed display to the minimum (2 gauge segments), drive the
machine, and check that the travel speed is "0.6 km/h" or higher (the value on the right of [SPD:1] on the lower
line, is 600 or higher).
If the travel speed is below "0.6 km/h", time lag in start and other negative effects are made. Accordingly, return
the adjusted value until the travel speed lowers below "0.6 km/h".
v. Set the buzzer cancel switch in the [] position and check that the caution buzzer sounds and [SETTING NOW!!]
H This code is not used to adjust the starting acceleration performance but used to adjust the shocks made at the
moments when the machine starts and stops.
[_-_] Service meter set: Refer to Parts and Service News (PSN) AA07100.
30-118 j D51EX/PX-22
12
[12] Maintenance interval change mode (MAINTENANCE
MONITOR)
Monitor panel can set the maintenance intervals for various filters and
oil which become the base of replacement time display for filter and
oil. Also the monitor panel can activate or deactivate the display
function.

Select the filter and oil replacement time setting function
(MAINTENANCE MONITOR) in the service menu selection screen.
2. Displaying and selecting the maintenance item and function

A. With the service menu selected, press the [] switch to display the
maintenance item and function selection screen.
B. If [>] switch or [<] switch is pushed while the maintenance item
and function selection screen is displayed, the maintenance item
and function will be displayed endlessly in the order shown by the
below table. Select the item or the function which will be used.
• [>]: To proceed to next maintenance item and function.
• [<]: To return to the previous maintenance item and function.
H Displayed maintenance item and function:
Maintenance items
Code Display
and functions
01 01: ENG OIL Engine oil
02 02: ENG FILT Engine oil filter
03 03: FUEL FILT Fuel main filter
41 41: FUEL P FILT Fuel pre-filter
04 04: HYD FILT Hydraulic oil filter
06 06: CORR RES Corrosion resistor (*)
18 18: BYPS FILT Bypass filter (*)
07 07: DAMP OIL Damper filter (*)
08 08: FNL OIL Final drive oil
10 10: HYD OIL Hydraulic oil
19 19: POWL OIL Power train oil (*)
20 20: POWL FILT Power train oil filter (*)
21 21: HST FILT HST charge filter
– INITIALIZE Setting default value for all items
Setting validity or invalidity for all
– ALL ITEMS
items
* Unused on D51.
H The maintenance items which have their respective codes
are changed separately and the functions which have no
codes are used to change all the items simultaneously.
H The item and function is displayed in the [*] section.
D51EX/PX-22 30-119 j
12
3. Display contents of the maintenance item (Items with code No.)
If the maintenance item for filter or oil is selected, the following
contents are displayed.
1: Code (2 digits)
A: Filter and oil replacement time set item
2: Remaining time to set replacement time
3: Number of times of replacement up to present
4. Changing the interval time by maintenance item (Items with code No.)
A. With the item to change the interval time (ex: P FUEL FILT)
selected on the maintenance item and the function selection
screen, press the [] switch to display the interval change screen.
• []: Execute the function to change maintenance item.
H The current set interval is displayed on the screen.
H With this screen displayed, if the [>] switch or the [<] switch is
operated, the screen switches to the setting screen for enable or
disable the maintenance item.
B. On the interval change screen, operate the switches [>], [<], []
and [n] to input the interval time.
• [<]: Number at the cursor decreases.
• []: Number at the cursor is determined.
H The time must always be input with 4 digits. For the time
with less than 4 digits, input 0s in place of the vacant number.
C. When the interval time is completely determined, the screen to
confirm the changes is displayed. Then, operate the switches [<],
[>] and [].
5. Set the function activation or deactivation by maintenance item (items

with code No.).
A. With the item (ex: 41: FUEL P FILT) to change the enable or
disable of the function selected on the maintenance item and
function selection screen, press the [] switch to display the
interval input screen.
• []: Execute the function to change maintenance item.
30-120 j D51EX/PX-22
12
B. After the screen to input intervals is displayed, press the [>]
switch or the [<] switch to display the activation or deactivation
setting screen.
• [>]: Switch the setting screen.
• [<]: Switch the setting screen
H If the function is activated, it is displayed like the upper line.
And if it is deactivated, it is displayed like the lower line.
C. After the activate or deactivate setting screen is displayed, check
the present setting status and the contents of change. Then operate
the switches [] or [n].
• []: Switch to the change confirmation screen
• [n]:To return to the maintenance item and function selection
screen.
• [<]: Switch to the interval change screen.
D. When the change confirmation screen is displayed, operate each
[<], [>] and [] switches.
H If the timer which has been OFF is turned ON, the interval is
set to the value before it was turned OFF and the rest of set
time of the timer is reset. The number of resetting times is set
to the value before it was turned OFF.
6. Setting default values of interval time for all items (INITIALIZE)

A. With all item default value setting (INITIALIZE) selected on the
maintenance item and function selection screen, press the []
switch to display the all item default value setting screen.
• []: Execute the function to set the default values of all the
items.
B. After the all item default value setting screen is displayed operate
H All the items are set to their respective default values,
regardless of the ON or OFF state of each item.
H The rest of the set time of the timer is set to the [default
value/elapsed time after the previous replacement].
H The number of resetting times is kept at the value before the
default was set.
H Each item is set turned ON.
D51EX/PX-22 30-121 j
12
7. Setting the function activation or deactivation for all the items (ALL
ITEMS).
A. With the activation or deactivation setting for all items selected
(ALL ITEMS) on the maintenance item and function selection
screen, press the [] switch to display the all items activation or
deactivation setting screen.
• []: Implement the function to set activation or deactivation
of all the items.
B. After the all items activation or deactivation setting screen is
displayed, press the [>] switch or the [<] switch to display the
activation setting or deactivation setting screen.
• [>]: Switch the setting screen.
• [<]: Switch the setting screen
H To deactivate all the items, display the upper line setting screen (OFF), and to activate all the items, display the
lower line setting screen (ON).
C. Confirm the setting screen, press the [] switch or the [n] switch
to display the change confirmation screen.
• []: To switch to the change confirmation screen.
• [n]:To return to the maintenance item and function selection
screen.
H If deactivation of all the items (OFF) is set, it will stop the
maintenance function of all the items, regardless of the
setting of each maintenance item.
H If activation of all the items (ON) is set, the maintenance
function of all the items starts to work regardless of the
setting of each maintenance item and the interval is set to the
previous time before the interval has been deactivated.
H The timer is reset simultaneously and it restarts to count from
0 h.
The number of resetting times is set to the value before it was turned OFF.
D. When the change confirmation screen is displayed, operate each
30-122 j D51EX/PX-22
12
Table of filter and oil replacement time set items

Replacement frequency
Order System and function Code Display Remarks
(Default value)
1 Engine oil 01 ENG OIL 0500h
2 Engine oil filter 02 ENG FILT 0500h
3 Fuel main filter 03 FUEL FILT 1000h
4 Fuel pre filter 41 FUEL P FILT 0500h
5 Hydraulic oil filter 04 HYD FILT 2000h
6 Corrosion resistor 06 CORR RES — Unused
7 Bypass filter 18 BYPS FILT — Unused
8 Damper filter 07 DAMP OIL — Unused
9 Final drive oil 08 FNL OIL 1000h
10 Hydraulic oil 10 HYD OIL 2000h
11 Power train oil 19 POWL OIL — Unused
12 Power train oil filter 20 POWL FILT — Unused
13 HST charge filter 21 HST FILT 2000h
All item simultaneous
14 Setting default value for all items (None) INITIALIZE —
setting function
All item simultaneous
15 Setting enable or disable for all items (None) ALL ITEMS —
setting function
D51EX/PX-22 30-123 j
12
[13] Telephone number input function (TEL)
The phone No. set in the monitor panel can be input, corrected or reset
with switches.
• When action code "E03" or "E04" is displayed, the phone No. is
displayed together with "CALL".
A. Press buzzer cancel switch [] on the above screen to display the
phone No. input screen.
• Once the phone No. is input, it is displayed after next time.
• Up to 12 digits can be input as the phone No. Input them in
order from the left most one.
B. The cursor is displayed on the position to input the next digit.
Select the next digit with information switches [>] and [<]. To
leave a position blank, select "*".
C. After inputting the digit, press the [] switch to move the cursor to
the next position.
• Repeat steps B and C until the right most digit is input.
• To change an input digit, press the [n] switch, and the screen
returns to the previous screen.
D. To finish the inputting operation, press the [n] switch twice.
• The inputting operation can be also finished by turning the starting switch OFF.
30-124 j D51EX/PX-22
12
[14] Model selection mode (MACHINE).
This mode is used to make the monitor panel and HST controller recognize a machine model.
WARNING! If an input is settled carelessly in this mode, the memory in the controller is initialized.
Accordingly, use this mode only when it is necessary.
H If a machine model different from the one which the HST controller has recognized is settled, perform all the
initialization work again.
WARNING! If the actual machine model is different from that set in the controller, the machine may
move unexpectedly or an error may be made. Accordingly, be sure to set the correct
machine model in the controller.
H The machine model currently recognized by the monitor panel and HST controller can be checked in the real-time
monitoring mode.
Controller: MONITOR PANEL
Code: 00204 MACHINE CODE
Controller: HST
Code: 00205 MACHINE CODE
1. Selecting and setting of model

A. To enter the machine model selection mode, hold down the [] switch (for 3 seconds).
B. When pressing the [>] switch or [<] switch in the model selection setting screen, the model which can be set is
displayed endlessly in the order shown in the below table, so select the applied model.
• [>] switch:To proceed to next model
• [<] switch:To return to previous model
H Displayed model:
Display Model
D51 D51 (Default)
D39 D39
D37 D37
D31 D31
C. After selecting the model in the model selecting screen, determine

the model by pressing the [] switch.
• []: Determine the setting.
• [n]: To cancel the setting
H The below figure shows the example that D51 has been
selected.
D51EX/PX-22 30-125 j
2. Storing data in controller
A. After determining the model selection setting, check that the
display automatically returned to the service menu screen and the
selected model is surely displayed.
B. Turn the starting switch OFF and keep that condition for longer
than 15 seconds.
H Unless the starting switch is turned off for longer than 15
seconds, the new data is not memorized in the controller.
C. Turn the starting switch ON again.
H After this operation, the model setting becomes effective.
[15] Optional selection mode (OPTIONAL SELECT)

H Do not use this mode.
[16] Initializing mode (INITIALIZE)

H This mode is exclusive for the plant, and is not used for field
service.
30-126 j D51EX/PX-22
TESTING AND ADJUSTING PREPARATION WORK FOR TROUBLE-
12
PREPARATION WORK FOR TROUBLESHOOTING FOR ELECTRI-
CAL SYSTEM
H When carrying out troubleshooting for an electric circuit related to the
monitor panel and HST controller, expose the related connectors
1. Monitor panel
A. Pull out the starting key (1), remove the 4 mounting bolts (3) of
each side of plastic panel (2), and move plastic panel (2) toward
the operator's seat.
B. Remove the 7 connectors of panel switches (4) and remove the
plastic panel (2).
C. Remove 7 panel switches (4) from the plastic panel (2) and insert
them in their respective connectors correctly.
D. Remove 6 mounting bolts (6) of monitor panel mounting bracket
(5) and move the bracket toward the operator's seat.
E. Remove connectors CN-P1, CN-P2 and CN-P3 and remove the
monitor panel mounting bracket (5).
F. Insert the diagnostic T-adapters in connectors CN-S04 and

CN-S03 of monitor panel (7).
G. Insert connectors CN-P1, CN-P2 and CN-P3 and install the
monitor panel mounting bracket (5) with the mounting bolts (6)
temporarily.
D51EX/PX-22 30-127 j
TESTING AND ADJUSTING PREPARATION WORK FOR TROUBLE-
2. HST controller
A. Perform steps A – C for the "monitor panel".
B. Insert or connect the diagnostic T-adapters in connectors CN-ST1,
CN-ST2 and CN-ST3 of HST controller (1).
H If it is difficult to remove and install the connectors, remove
the controller for the ease of work.
H Since each connector is fixed with a screw, loosen the screw
before disconnecting it.
H When returning each connector, tighten its screw to the
specified torque to fix it.
Screw: 2.82 Nm {0.288 kgm}
30-128 j D51EX/PX-22
TESTING AND ADJUSTING ELECTRIC/HYDRAULIC DEVICES ARE AD-
12
ELECTRIC/HYDRAULIC DEVICES ARE ADJUSTED/REPLACED
ITEMS TO BE ADJUSTED
H If any of the following electrical/hydraulic devices are adjusted or replaced, perform the following system adjustment.
WARNING! If the system is not adjusted, the machine may not operate normally but may move
unexpectedly. Accordingly, be sure to adjust system.
System adjustment
Device
Tuning item Mode ID No. Display Reference
HST controller See page 30-130
Monitor panel See page 30-132
HST pump Forward HST pump set 3001 F-PUMP LINE page 30-103
TUNING 2
HST pump EPC Reverse HST pump set 3002 R-PUMP LINE page 30-104
HST motor HST motor set TUNING 2 3024 MOTOR LINE page 30-112
5-spool valve
HST motor EPC
Travel lever Steering lever neutral set 1012 S/T N-SET page 30-101
Steering lever left pivot turn 1010 S/T H. L-SET page 30-100
Steering lever left max. set TUNING 1 1013 S/T M.L-SET page 30-102
Steering lever right pivot turn set 1011 S/T H. R-SET page 30-101
Steering laver right max. set 1014 S/T M.R-SET page 30-102
Brake pedal Brake potentiometer neutral set 0005 BRAKE N-SET page 30-100
TUNING 1
Brake potentiometer Brake potentiometer max. set 3007 BRAKE END page 30-107
Fan Fan set ID INPUT 3033 FAN AMP SET page 30-113
Fan motor
Fan EPC
Work equipment valve
Work equipment pump
H For system adjustment, use "Tuning mode" in the service mode of monitor panel (EMMS) special function.
• For usage of monitor panel (EMMS) special function , see page 30-65.
• For usage of service mode, see page 30-79
• For usage of tuning mode, see page 30-95.
• For usage of each tuning item, see the corresponding ID number.
D51EX/PX-22 30-129 j
H For system adjustment, use "Model selection mode", "Tuning mode" or "Electrical system failure history display mode" in
the service mode of "Monitor panel (EMMS) special function".
• For usage of selection mode, see page 30-124
• For usage of electrical system failure history display mode, see page 30-81
HST CONTROLLER ADJUSTMENT AFTER REPLACEMENT

H When the machine is assembled or the HST controller is replaced,
adjust the system according to the following procedure.
WARNING! If the system is not adjusted, the machine

may not operate normally but may move
unexpectedly. Accordingly, be sure to
adjust the system.
H Precautions for replacing HST controller:

When replacing the HST controller, stop the machine on a safe place
and turn the starting switch OFF.
H For time till next maintenance, check with using "OIL/filler mainte-
nance mode" in the "Operator mode" of "Monitor panel (EMMS) spe-
cial function".
• For usage of monitor panel (EMMS) special function , see page
30-65.
• For usage of operator mode, see page 30-69
• For usage of oil/filter maintenance mode, see page 30-77.
H For telephone number, check with using "Telephone number input mode" in the "Service mode" of the monitor panel
(EMMS) special function".
• For usage of monitor panel (EMMS) special function, see page 30-65.
• For usage of service mode, see page 30-79.
• For usage of telephone number input mode, see page 30-123.
30-130 j D51EX/PX-22
12
1. Selecting machine model.
A. Turn the starting switch ON, set the monitor panel in "Machine
model selection mode" in the service mode, and select the
machine model.
B. Turn the starting switch OFF.
2. Adjusting steering lever and brake potentiometer.

A. Turn the starting switch ON again and set the monitor panel in
"Tuning mode" in the service mode.
B. Select "TUNING1" and initialize the steering lever and brake
potentiometer.
(1012, 1010, 1013, 1011, 1014, 0005, 3007)
C. Turn the starting switch OFF.
3. Adjusting HST pump and HST motor.
A. Jack up the rear part of the machine frame and brace the blade
against the ground to float all the track shoes above the ground so
that the tracks can be rotated with no load.
WARNING! Since the tracks are rotated with no load

during adjustment, check that the tracks
are floated above the ground.
B. Run the engine at high idle.

C. Set the monitor panel in "Tuning mode" in the service mode,
select "TUNING2", and initialize the HST pump and HST motor.
(3001, 3002, 3024)
D. Turn the starting switch OFF.
D51EX/PX-22 30-131 j
4. Initializing fan.
A. Adjust the HST oil temperature (hydraulic oil temperature) to 50
– 60 °C.
B. Run the engine at high idle.
C. Set the monitor panel in "Tuning mode" in the service mode,
select "ID INPUT", select fan initialization (3033), and adjust the
fan.
D. Turn the starting switch OFF.
5. Checking error code.

A. Turn the starting switch ON again and set the monitor panel in
"Electrical system failure history display mode" in the service
mode.
B. Check to see if there is any error code being indicated. If there is not any, delete all the recorded error codes.
H If there is any error code being indicated, remove the cause of the failure by troubleshooting and then perform
steps A and B.
30-132 j D51EX/PX-22
12
MONITOR PANEL ADJUSTMENT AFTER REPLACEMENT
H When the monitor panel is replaced, adjust the system according to the following procedure.
WARNING! If the system is not adjusted, the machine

may not operate normally but may move
unexpectedly. Accordingly, be sure to
adjust the system.
H Precautions before replacement of monitor panel:

If the monitor panel is replaced, the saved values of the service meter, oil and filter maintenance mode and phone No. are
reset. Accordingly, check and record the service meter reading, time before maintenance and phone No. before replacing
the monitor panel.
H For time till next maintenance, check with using "OIL/filler maintenance mode" in the "Operator mode" of "Monitor
panel (EMMS) special function".
• For usage of operator mode, see page 30-69
• For usage of oil/filter maintenance mode, see page 30-77.
H For telephone number, check with using "Telephone number input mode" in the "Service mode" of the monitor panel
(EMMS) special function".
• For usage of monitor panel (EMMS) special function, see page 30-65.
• For usage of service mode, see page 30-79.
• For usage of telephone number input mode, see page 30-123.
H Precautions for replacing monitor panel:
When replacing the monitor panel, stop the machine on a safe place and turn the starting switch OFF.
1. Selecting machine model.

A. Turn the starting switch ON, set the monitor panel in "Machine
model selection mode" in the service mode, and select the
machine model.
B. Turn the starting switch OFF.
2. Setting service meter.

Referring to "Parts and Service News", set the service meter if
required.
D51EX/PX-22 30-133 j
3. Setting phone No.
Set the monitor panel in "Telephone number input mode" in the
service mode and set the phone No.
4. Checking error code.

A. Set the monitor panel in "Electrical system failure history display
mode" in the service mode.
B. Check to see if there is any error code being indicated. If there is
not any, delete all the recorded error codes.
H If there is any error code being indicated, remove the cause of the fail-
ure by troubleshooting and then perform steps A and B.
H Precautions after replacement of monitor panel:
If the monitor panel is replaced, the service meter for the oil and filter
maintenance function restarts from 0. As a result, the replacement time shown on the monitor panel may be different from
the actual operating time. Accordingly, apply the time before the maintenance recorded before the replacement until the
first maintenance after the replacement.
30-134 j D51EX/PX-22
TESTING AND ADJUSTING PM-CLINIC
12
PM-CLINIC
PM-CLINIC SERVICE
D51EX/PX-22 30-135 j
12
Pm-clinic measuring points for D51EX/PX-22 (1/2)
Reference pages for measurement procedure designated

*1. Engine speed: Testing and adjusting, page 30-6.
*2. Blow-by pressure: Testing and adjusting, page 30-16.
*3. Engine oil pressure: Testing and adjusting, page 30-17.
*4. Boost pressure: Testing and adjusting, page 30-7.
*5. Exhaust temperature: Testing and adjusting, page 30-8.
30-136 j D51EX/PX-22
12
Pm-clinic measuring points for D51EX/PX-22 (2/2)
Reference pages for measurement procedure designated

*6. HST charge circuit pressure: Testing and adjusting HST oil pressure, page 30-33.
*7. Solenoid valve output pressure: Measuring HST solenoid valve output pressure, page 30-38.
*8. Fan speed: Measuring fan speed and fan (work equipment) pump pressure, page 30-28.
*9. Work equipment pump relief pressure: Testing and adjusting work equipment oil pressure, page 30-53
*10.Work equipment PPC valve output pressure: Measuring work equipment PPC valve output pressure, page 30-55
D51EX/PX-22 30-137 j
12
PM-CLINIC INSPECTION SHEET (1/2)
30-138 j D51EX/PX-22
12
PM-CLINIC INSPECTION SHEET (2/2)
D51EX/PX-22 30-139 j
12
PM-CLINIC UNDERCARRIAGE CHECK SHEET
30-140 j D51EX/PX-22
12
UNDERCARRIAGE TROUBLESHOOTING REPORT (NORMAL)
D51EX/PX-22 30-141 j
12
UNDERCARRIAGE TROUBLESHOOTING REPORT (IMPACT)
30-142 j D51EX/PX-22
PM-CLINIC UNDERCARRIAGE CHECK SHEET
D51EX/PX-22 30-143 j
12
UNDERCARRIAGE TROUBLESHOOTING REPORT (NORMAL)
30-144 j D51EX/PX-22
12
UNDERCARRIAGE TROUBLESHOOTING REPORT (IMPACT)
D51EX/PX-22 30-145 j
30-146 j D51EX/PX-22
40 TROUBLESHOOTING (GENERAL)
POINTS TO REMEMBER WHEN TROUBLESHOOTING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-102

SEQUENCE OF EVENTS IN TROUBLESHOOTING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-104
PRECAUTIONS WHEN CARRYING OUT MAINTENANCE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-105
PRECAUTIONS WHEN HANDLING ELECTRICAL EQUIPMENT . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-105
HANDLING ELECTRONIC CONTROL UNIT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-110
POINTS TO REMEMBER WHEN TROUBLESHOOTING ELECTRICAL
CIRCUITS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-111
ELECTRIC WIRE CODE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-112
CLASSIFICATION BY THICKNESS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-112
CLASSIFICATION BY COLOR AND CODE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-112
HOW TO READ ELECTRIC WIRE CODE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-113
POINTS TO REMEMBER WHEN HANDLING HYDRAULIC EQUIPMENT . . . . . . . . . . . . . . . . . . . . 40-115
CHECKS BEFORE TROUBLESHOOTING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-117
CATEGORIES AND METHOD OF USING TROUBLESHOOTING CHARTS . . . . . . . . . . . . . . . . . . . 40-118
TROUBLESHOOTING INDIVIDUAL ELECTRICAL CIRCUITS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-119
CONNECTION TABLE FOR CONNECTOR PIN NUMBERS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-122
T-ADAPTER TABLE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-146
MODE CHART . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-150
D51EX/PX-22 40-101
TROUBLESHOOTING POINTS TO REMEMBER WHEN TROUBLE-
POINTS TO REMEMBER WHEN TROUBLESHOOTING
WARNING! Stop the machine in a level place, and check to be sure the blocks, and parking brake are
in place.
WARNING! When carrying out operation with two or more workers, strictly agreed to a set of
signals to use, and do not allow any unauthorized person to come near during repairs.
WARNING! If the radiator cap is removed when the engine is hot, hot coolant may spurt out and
cause burns, wait for the engine to cool down before starting any troubleshooting.
WARNING! Be extremely careful not to touch any hot parts or to get caught in any rotating parts.
WARNING! When disconnecting wiring, always disconnect negative (-) terminal of the battery first.
WARNING! When removing the plug or cap from a location which is under pressure from oil, coolant,
or air, always release the internal pressure first. When installing measuring equipment,
be sure to connect it properly.
The aim of troubleshooting is to pinpoint the basic cause of the error, to carry out repairs swiftly, and to prevent reoccurrence
of the error.
When carrying out troubleshooting, an important point is to understand the structure and function of the machine. However,
a short cut to effective troubleshooting is to ask the operator various questions to form some idea of possible causes of the
error that would produce the reported symptoms.
1. When carrying out troubleshooting, do not hurry to disassemble the components. If components are disassembled
immediately after a error occurs:
• Parts that have no connection with the error or other unnecessary parts will be disassembled.
• It will become impossible to find the cause of the error.
It will also cause a waste of man hours, parts, or oil and grease. At the same time, it will also lose the confidence of
the user or operator. For this reason, when carrying out troubleshooting, it is necessary to carry out thorough prior
investigation and to carry out troubleshooting in accordance with the fixed procedure.
2. Points to ask the user or operator.
A. Have any other problems occurred apart from the problem that has been reported?
B. Was there anything strange about the machine before the error occurred?
C. Did the error occur suddenly, or were there problems with the machine condition before this?
D. Under what conditions did the error occur?
E. Had any repairs been carried out before the error? When were these repairs carried out?
F. Has the same kind of error occurred before?
40-102 D51EX/PX-22
TROUBLESHOOTING POINTS TO REMEMBER WHEN TROUBLE-
3. Check before troubleshooting.
A. Check the oil level.
B. Check for any external leakage of oil from the piping or hydraulic equipment.
C. Check the travel of the control levers.
D. Check the stroke of the control valve spool.
E. Other maintenance items can be checked externally, so check any item that is considered to be necessary.
4. Confirming the error.
A. Confirm the extent of the error yourself, and judge whether to handle it as a real error or as a problem with the
method of operation, etc.
H When operating the machine to reenact the troubleshooting symptoms, do not carry out any investigation or
measurement that may make the problem worse.
5. Troubleshooting
A. Use the results of the investigation and inspection in Steps 2 - 4 to narrow down the causes of the error, then use the
troubleshooting flowchart to locate the position of the error exactly.
B. The basic procedure for troubleshooting is as follows.
i. Start from the simple points.
ii. Start from the most likely points.
iii. Investigate other related parts or information.
6. Measures to remove root cause of error.
A. Even if the error is repaired, if the root cause of the error is not repaired, the same error will occur again.
B. To prevent this, always investigate why the problem occurred. Then, remove the root cause.
D51EX/PX-22 40-103
TROUBLESHOOTING SEQUENCE OF EVENTS IN TROUBLE-
SEQUENCE OF EVENTS IN TROUBLESHOOTING
40-104 D51EX/PX-22
TROUBLESHOOTING PRECAUTIONS WHEN CARRYING OUT
12
PRECAUTIONS WHEN CARRYING OUT MAINTENANCE
To maintain the performance of the machine over a long period, and to prevent errors or other troubles before they occur, cor-
rect operation, maintenance and inspection, troubleshooting, and repairs must be carried out. This section deals particularly
with correct repair procedures for electronics and is aimed at improving the quality of repairs. For this purpose, it gives
sections on 'Handling electric equipment' and 'Handling hydraulic equipment' (particularly hydraulic oil).
PRECAUTIONS WHEN HANDLING ELECTRICAL EQUIPMENT

1. Handling High Voltage Circuits
A. If the machine is equipped with an electronically controlled

engine, high voltage is used to control fuel injection,
(110 - 130 V) for the fuel injector drive. Never handle the
engine wiring harness while the engine is running, tamper with
or modify this circuit, sever injury may result due to the high
voltage and amps in the circuit. Always use caution when
working around this circuit.
2. Handling Wiring Harnesses And Connectors
A. Wiring harnesses consist of wiring connecting one component

to another component, connectors used for connecting and
disconnecting one wire from another wire, and protector 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.
3. Main errors Occurring In Wiring Harness
A. Faulty contact of connectors:

(faulty contact between male and female). Problems with
faulty 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 oxidation of
the contact surfaces.
D51EX/PX-22 40-105
B. Defective compression or soldering of connectors:
The pins of the male and female connectors are in contact at
the compressed terminal or soldered portion, but there is
excessive force on the wiring, and the plating peels to cause
improper connection or breakage.
C. Disconnections in wiring:
If the wiring is held and tugged and the connectors are pulled
apart, or components are lifted with a crane with the wiring
still connected, or a heavy object hits the wiring, the crimping
compression of the connectors to the wire may be loosened, or
the soldering may be damaged, or the wiring may be broken.
D. High pressure water entering a 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.
The connector is designed to prevent water from entering, but
if water does enter, it is difficult for it to be drained. Therefore,
if water should get into the connector, the pins will be
short-circuited by the water, so if any water gets in,
immediately dry the connector or take other appropriate action
before passing electricity through it.
E. Oil, grease 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, and this will cause
a defective contact.If there is oil or grease or dirt stuck to the
connector, wipe it off with a dry cloth or blow dry with air, and
spray it with a contact restorer.
H When wiping the mating portion of the connector, be
careful not to use excessive force or deform the pins.
H If there is water or oil present, it will increase the
contamination of the points, so clean with air until all
water and oil has been removed.
40-106 D51EX/PX-22
4. Removing, Installing, And Drying Connectors And Wiring
Harnesses.
A. Disconnecting connectors:
i. Hold the connectors when disconnecting.

When disconnecting the connectors, hold the connectors
and not the wires. 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.
H Never try to pull apart with one hand
ii. When removing the connectors from the clips, pull the
connector in a parallel direction to the clip.
H If the connector is twisted to the left and right or up
and down, the housing may break.
iii. When disconnecting male and female connectors, release

the lock and pull in parallel with both hands.
H Never try to pull apart with one hand.
iv. 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.
D51EX/PX-22 40-107
B. Connecting connectors:
i. Check the connector visually.

l Check that there is no oil, dirt, or water stuck to the
connector pins (mating portion).
l Check that there is no deformation, faulty contact,
corrosion, or damage to the connector pins.
l Check that there is no damage or breakage to the
outside of the connector.
H If there is any oil, water, or dirt stuck to the connector,
wipe it off with a dry cloth. If any water has gotten
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.
H If there is any damage or breakage, replace the
connector.
ii. Assemble the connector securely.

Align the position of the connector correctly, then insert it
securely.
For connectors with a lock stopper:
Push in the connector until the stopper clicks into position.
iii. Correct any protrusion of the boot and any misalignment

of the wiring harness.
For connectors fitted with boots, correct any protrusion or
the boot. In addition, if the wiring harness is misaligned,
or the clamp is out of position, adjust it to its correct
position.
H When blowing with dry air, there is danger that the oil
in the air may cause improper contact, so clean with
properly filtered air.
iv. When the wiring harness clamp of the connector has been
removed, always return it to its original condition and
check that there is no looseness of the clamp.
C. Connecting connectors (DT type connector)

Since the DT 8-pole and 12-pole DT type connectors have two
latches respectively, push them in until they click 2 times.
l Male connector (1), Female connector (2).
l Normal locking state (Horizontal): a, b, d
l Incomplete locking state (Diagonal): c
40-108 D51EX/PX-22
D. Drying wiring harness:
If there is any oil or dirt on the wiring harness, wipe it off with
a dry cloth. Avoid washing it in water or using steam. If the
connector must be washed in water, do not use high pressure
water or steam directly on the wiring harness. If water gets
directly on the connector, do as follows:
i. Disconnect the connector and wipe off the water with a

dry cloth.
H If the connector is blown dry with air, there is the risk
that oil in the air may cause a faulty contact, so avoid
blowing with air.
ii. Dry the inside of the connector with a dryer.

If water gets inside the connector, use a dryer to dry the
connector.
H Hot air from the dryer can be used, but be careful not
to make the connector or related parts too hot, as this
will cause deformation or damage to the connector.
iii. 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.
H After completely drying the connector, spray it with
contact restorer and reassemble.
D51EX/PX-22 40-109
12
HANDLING ELECTRONIC CONTROL UNIT
1. The electronic control unit contains a microcomputer and electronic
circuits.
H This controls all of the electronic circuits on the machine, so be
extremely careful when handling the control unit.
2. Do not open the cover of the control box unless necessary.
3. Do not place objects on top of the control unit.
4. Cover the control connectors with tape or a vinyl bag.
5. Do not leave the control unit in a place where it is exposed to rain.
6. Do not place the control unit on oil, water, or soil, or in any hot
place, even for a short time.
H Place it on a suitable dry stand.
7. Precautions when carrying out arc welding.

H When carrying out arc welding on the body, disconnect all
wiring harness connectors connected to the control unit. Attach
the arc welding ground close to the welding point as possible.
40-110 D51EX/PX-22
12
POINTS TO REMEMBER WHEN TROUBLESHOOTING ELECTRICAL
CIRCUITS
1. Always turn power OFF before disconnecting or connecting connectors.
2. Before carrying out troubleshooting, check that all the related connectors are properly inserted.
H Disconnect and connect the related connectors several times to check.
H Check each individual wire on the connector suspected of the problem by performing a pull test on the wire insert.
3. Always connect any disconnected connectors before going on to the next step.
H If power is turned ON with the connectors still disconnected, unnecessary abnormality displays will be generated.
4. When carrying out troubleshooting of circuits (measuring the voltage, resistance, continuity or current), move the related
wiring and connectors several times and check that there is no charge in the reading of the tester.
H If there is any charge, there is probably defective contact in that circuit.
5. When checking a single diode circuit:

H Isolate the diode from the circuit.
H Using a digital volt ohm meter, in the Ohms mode, check the
polarity of the diode as shown in the illustration. Reversing the
meter leads, you should have a reading in one direction only.
H Electrical flow should be negative (-) to positive (+) only, red
lead positive and black lead negative.
6. When checking a dual diode circuit:

H Isolate the diode from the circuit.
H Using a digital volt ohm meter, in the Ohms mode, check the
polarity of the diode as shown in the illustration. Reversing the
meter leads, you should have a reading in one direction only.
H Electrical flow should be negative (-) to positive (+) only, red
lead positive and black lead negative.
7. Always be aware of what you are measuring. Voltage, Ohms or

Amps. Always use caution when measuring a circuit.
H When measuring voltage, be sure the meter is set in the voltage
range, AC or DC and above the voltage value you are
measuring.
H When measuring ohms, be sure the circuit is dead and has (no
voltage) in it before you take any readings. Be sure the meter is
set in the proper ohms range.
H When measuring Amps, be sure your meter is rated for the
amount of amps you will be measuring. error to follow these
procedures may damage your equipment or possibly cause
injury. Always study the operators manuel for the meter you
will be using.
D51EX/PX-22 40-111
TROUBLESHOOTING ELECTRIC WIRE CODE
ELECTRIC WIRE CODE

In the wiring diagrams, various colors and symbols are employed to indicate the thickness of wires. This wire code table will
help you understand WIRING DIAGRAMS.
Example: 05WB indicates a cable having a nominal number 05 and white coating with black stripe.
CLASSIFICATION BY THICKNESS
Copper wire
Nominal Cable O.D. Current rat-
Number of Dia. Of strand Cross section Applicable circuit
number (mm) ing (A)
strands (mm) (mm)
0.85 11 0.32 0.88 2.4 12 Starting, lighting, signal etc.
2 26 0.32 2.09 3.1 20 Lighting, signal etc.
5 65 0.32 5.23 4.6 37 Charging and signal
15 84 0.45 13.36 7.0 59 Starting (Glow plug)
40 85 0.80 42.73 11.4 135 Starting
60 127 0.80 63.84 13.6 178 Starting
100 217 0.80 109.1 17.6 230 Starting
CLASSIFICATION BY COLOR AND CODE

Circuits
Priority Charging Ground Starting Lighting Instrument Signal Other
Classification
Primary
Code W B B R Y G L
1
Color White Black Black Red Yellow Green Blue
Code WR — BW RW YR GW LW
2 White & Black & Red & Yellow & Green & Blue &
Color —
Red White White Red White White
Code WB — BY RB YB GR LR
3 White & Black & Yel- Yellow & Green &
Color — Red & Black Blue & Red
Black low Black Red
Code WL — BR RY YG GY LY
Auxiliary
4 White & Red & Yel- Yellow & Green & Blue & Yel-
Color — Black & Red
Blue low Green Yellow low
Code WG — — RG YL GB LB
Color — —
Green Green Blue Black Black
Code — — — RL YW GL —
6 Yellow & Green &
Color — — — Red & Blue —
White Blue
40-112 D51EX/PX-22
12
HOW TO READ ELECTRIC WIRE CODE
H The information about the wires unique to each machine model is described in Troubleshooting section, Relational infor-
mation of troubleshooting.
In the electric circuit diagram, the material, thickness, and color of each electric wire are indicated by symbols. The electric
wire code is helpful in understanding the electric circuit diagram.
Example: AEX 0.85 L - - - Indicates blue, heat-resistant, low-voltage wire for automobile, having nominal
No. of 0.85
Indicates color of wire by color code.
Color codes are shown in Table 3.
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)
Using
Type Symbol Material temperature Example of use
range (°C)
Low-voltage Annealed copper for electric
Conductor General wiring
wire for auto- AV appliance
(Nominal No. 5 and above)
mobile Insulator Soft polyvinyl chloride
Thin-cover Annealed copper for electric –30 to +60
Conductor
low-voltage appliance General wiring
AVS
wire for auto- (Nominal No. 3 and below)
Insulator Soft polyvinyl chloride
mobile
Heat-resistant Annealed copper for electric
Conductor General wiring in extremely cold dis-
low-voltage appliance
AEX –50 to +110 trict, wiring at high-temperature
wire for auto- Heat-resistant crosslinked poly-
Insulator place
mobile ethylene
D51EX/PX-22 40-113
2. Dimensions
(Table 2)
Nominal No. 0.5f (0.5) 0.75f (0.85) 1.25f
(1.25) 2f 2 3f 3 5
Number of
strands/Diam- 20/0.18 7/0.32 30/0.18 11/0.32 50/0.18 16/0.32 37/0.26 26/0.32 58/0.26 41/0.32 65/0.32
eter of strand
Conductor Sectional area
0.51 0.56 0.76 0.88 1.27 1.29 1.96 2.09 3.08 3.30 5.23
(mm2)
d (approx.) 1.0 1.2 1.5 1.9 1.9 2.3 2.4 3.0
AVS Standard 2.0 2.2 2.5 2.9 2.9 3.5 3.6 –
Cover D
AV Standard – – – – – – – 4.6
AEX Standard 2.0 2.2 2.7 3.0 3.1 – 3.8 4.6
Nominal No. 8 15 20 30 40 50 60 85 100

Number of
strands/
50/0.45 84/0.45 41/0.80 70/0.80 85/0.80 108/0.80 127/0.80 169/0.80 217/0.80
Diameter of
Conductor strand
Sectional area
7.95 13.36 20.61 35.19 42.73 54.29 63.84 84.96 109.1
(mm2)
d (approx.) 3.7 4.8 6.0 8.0 8.6 9.8 10.4 12.0 13.6
AVS Standard – – – – – – – – –
Cover D
AV Standard 5.5 7.0 8.2 10.8 11.4 13.0 13.6 16.0 17.6
AEX Standard 5.3 7.0 8.2 10.8 11.4 13.0 13.6 16.0 17.6
“f” of nominal No. denotes flexible”.
40-114 D51EX/PX-22
12
POINTS TO REMEMBER WHEN HANDLING HYDRAULIC EQUIPMENT
With the increase in pressure and precision of hydraulic equipment, the most common cause of error is dirt (foreign material)
in the hydraulic circuit. When adding hydraulic oil, or when disassembling or assembling hydraulic equipment, it is necessary
to be particularly careful.
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 confirm 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 dust proof workshop, and the performance
should be confirmed with special test equipment.
3. Seal or cover all openings of disconnected piping.

After any piping or equipment is removed, the openings should be
sealed with caps, tape, or vinyl bags to prevent any dirt or dust from
entering. Never leave any openings opened or blocked with a rag,
this could cause particles or dirt to get into the system. Drain all oil
into a container and not unto the ground and be sure to follow the
proper environmental regulation for any disposal of oil.
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.
D51EX/PX-22 40-115
5. Change hydraulic oil when the temperature is high.
When hydraulic oil or other oil is warm, it flows easily. In addition, the sludge can also be drained out easily from the
circuit together with the oil, so it is best to change the oil when it is still warm. When changing the oil, as much as possible
of the old hydraulic oil must be drained out. (Do not drain the oil from the hydraulic tank; but drain the oil from the filter
and from the drain plug in the circuit.) If any old oil is left, the contaminants and sludge in it will mix with the new oil and
will shorten the life of the hydraulic oil.
6. Flushing operations.
After disassembling and assembling the equipment, or changing the
oil, use flushing oil to remove the contaminants, sludge, and old oil
from the hydraulic circuit.Normally, flushing is carried out twice:
primary flushing is carried out with flushing oil, and secondary
flushing is carried out with the specified hydraulic oil.
7. Cleaning operations.
After repairing the hydraulic equipment (pump, control valve, etc.)
or when running the machine, carry out oil cleaning to remove the
sludge or contaminants in the hydraulic oil circuit.The oil cleaning
equipment is used to remove the ultra fine (about 3µ) particles that
the filter built into the hydraulic equipment cannot remove, so it is
an extremely effective device.
40-116 D51EX/PX-22
TROUBLESHOOTING CHECKS BEFORE TROUBLESHOOTING
CHECKS BEFORE TROUBLESHOOTING

Item Judgement Value Action
1. Check fuel level, type of fuel  Add fuel
Lubricating oil, coolant
2. Check for impurities in fuel  Clean, drain

3. Check engine oil level, type of oil  Add oil
4. Check coolant level  Add coolant
5. Check air cleaner for clogging  Clean or replace
6. Check hydraulic oil level, type of oil  Add oil
7. Check hydraulic filter and HST charge filter  Replace
8. Check for looseness, corrosion of battery terminals, wiring  Tighten or replace
Equipment
Electrical
Before Starting Checking Item
9. Check for looseness, corrosion of alternator terminals, wiring  Tighten or replace
10. Check for looseness, corrosion of starting motor terminal, wiring  Tighten or replace
11. Check for abnormal noise or smells  Repair

Hyd. Mech.
12. Check for leaks  Repair
13. Bleed any air from circuit  Bleed air
14. Check battery voltage (with engine stopped) 20 - 30V Replace

15 Check battery electrolyte level (if available)  Add or replace
16. Check for discolored, burnt, exposed wiring  Replace
Electrical equipment
17. Check for missing wiring clamps or loose wires  Repair
18. Check for water leaking on wiring terminals or connections  Disconnect connector
and dry
19. Check for blown or corroded fuse links or fuses  Replace
20. Check alternator voltage (engine running at 1/2 throttle speed or above After running for several minutes: 27.5 - Replace
29.5V
21. Check operating sound of battery relay
 Replace
(when switch is turned ON/OFF)
D51EX/PX-22 40-117
12
CATEGORIES AND METHOD OF USING TROUBLESHOOTING CHARTS
1. Categories of troubleshooting codes
H If the machine monitor displays a error code, the name of the controller is also displayed at the same time, so the trou-
bleshooting codes are categorized according to the name of each controller. (This may also includes some error codes
for the electrical system that are not displayed)
H errors of the hydraulic and mechanical system that the machine monitor cannot display are categorized as H mode.
Troubleshooting Code Troubleshooting system
ERROR CODES Troubleshooting when error codes are displayed
E-mode Troubleshooting of electrical system
H-mode Troubleshooting of hydraulic and mechanical system
S-mode Troubleshooting of engine system
• Troubleshooting procedures
When any symptom supposed to be a error appeared on the machine, select a troubleshooting No. according to the procedures
below and proceed to the text of the relevant troubleshooting:
1. Troubleshooting procedures when any action code is displayed on the monitor panel:
When an action code is displayed on the monitor panel, display an error code in the error code display mode (electrical
system, mechanical system) on the monitor display (EMMS).
Carry out the troubleshooting of the relevant [error code] in accordance with the displayed error code.
H Since an error code flashes when a error is detected, the error has not always been corrected even if it lights when
the starting switch is set to ON. (For some codes, errors can be detected by only turning the starting switch ON.)
H When an error code has been recorded, be sure to perform the duplication operation corresponding to the error
code and confirm if the error has still remained or has been already corrected. (For the duplication method, refer
to the troubleshooting relevant to the error code.)
2. Troubleshooting procedures when an error code has been recorded:

When no action code is displayed on the monitor panel, display an error code in the error code display mode (electrical
system, mechanical system) on the monitor display (EMMS).
When an error code has been recorded, carry out the troubleshooting of the relevant [error code] in accordance with the
displayed error code.
H Since an error code flashes when a error is detected, the error has not always been corrected even if it lights when
the starting switch is set to ON. (For some codes, errors can be detected by only turning the starting switch ON.)
H When an error code has been recorded, be sure to perform the duplication operation corresponding to the error
code and confirm if the error has still remained or has been already corrected. (For the duplication method, refer
to the troubleshooting relevant to the error code.)
3. Troubleshooting procedures when no action code is displayed and an error code has not been recorded:
When an error code has not been recorded in the monitor panel (EMMS), a error that the machine cannot diagnose by
itself is supposed to have occurred in the electrical system or the hydraulic and mechanical system.
In this case, check again a symptom supposed to be a error and select the relevant symptom out of the table of “Symptom
supposed to be error and troubleshooting No.” Then, carry out the troubleshooting in the [E-Mode], [H-Mode] or [S-
Mode] related to the symptom.
40-118 D51EX/PX-22
12
TROUBLESHOOTING INDIVIDUAL ELECTRICAL CIRCUITS
This method is also displayed at the beginning of each electrical system troubleshooting mode. It is important to follow each
step in the troubleshooting chart. Do not skip steps, jump ahead or stop when a problem is found. It is important to complete all
steps due to the fact that there may be several other problems causing the error code. The chart is set-up to start with the most
likely problem first down to the least likely
Action code Error code
Display on Trouble Trouble in machine
Display on panel
panel
Contents of
• Condition at the time when the monitor panel or controller detects the trouble
trouble
Action of • The action taken by the monitor panel or controller to protect the system or devices when the monitor panel or controller
controller detects the trouble
Problem that
appears on • The problem that appears on the machine as a result of the action taken by the monitor panel or controller (shown above)
machine
Related
• Information related to the detected trouble or troubleshooting
information
Cause Standard value in normal state/Remarks on troubleshooting
<Contents of description>
1 • Standard value in normal state to judge possible causes
• Remarks on judgment
<Troubles in wiring harness>

• Disconnection
Connector is connected imperfectly or wiring harness is broken.
• Grounding fault
2 Wiring harness which is not connected to chassis ground circuit is in contact with chassis
ground circuit.
Possible causes and standard
• Short circuit with power source

value in normal state
Wiring harness which is not connected to power source (24 V) circuit is in contact with power
source (24 V) circuit.
Possible causes of trouble • Short circuit
(Given numbers are Independent wiring harnesses are in contact with each other abnormally.
3
reference numbers, which do not
indicate priority) <Precautions for troubleshooting>
1. Method of indicating connector No. and handling of T-adapter

Insert or connect T-adapter as explained below for troubleshooting, unless otherwise specified.
• If connector No. has no marks of “male” and “female”, disconnect connector and insert T-adapters
4 in both male side and female side.
• If connector No. has marks of “male” and “female”, disconnect connector and connect T-adapter to
only male side or female side.
2. Entry order of pin Nos. and handling of circuit tester leads

Connect positive (+) lead and negative (–) lead of circuit tester as explained below for troubleshoot-
ing, unless otherwise specified.
5 • Connect positive (+) lead to pin No. or harness entered on front side.
• Connect negative (–) lead to pin No. or harness entered on rear side.
D51EX/PX-22 40-119
Related circuit diagram
This is the excerpted circuit diagram related to troubleshooting.

•Connector No.: Indicates (model – number of pins) (color)
•Arrow (): Indicates the approximate mounting place on machine
40-120 D51EX/PX-22
12
Chart Use
H Repair Shop Use
• When using this chart in a repair shop environment where you have access to a copier it is advised to remove the
pages of the fault codes displayed on the machine monitor and copy these pages. After copping the needed pages,
return the original pages back to the Shop Manual for future use. On the copied pages in the right hand column of the
chart you can record your findings for final analysis. Do not write on the original chart in the Shop Manual and
complete all test procedures.
H Road Service Use
• When using this chart while on a road service call where a copier is not available it is advised to use a blank piece of
paper and number it from #1 through the last number listed in conjunction with the Shop Manual. Record your
readings by each number on the paper for final analysis. Do not write on the original chart in the Shop Manual and
complete all test procedures.
Chart Tips
• Check all fuses and fuse links first.

• If the system has a relay replace the relay with a known good relay, do not test the relay itself.
• For diode checking procedures see “POINTS TO REMEMBER WHEN TROUBLESHOOTING ELECTRICAL
CIRCUITS” page 111
• When checking Ohms in a system or component always isolate the component you are checking, this will ensure
there are no additional circuits adding continuity to the component you are testing.
• Never measure Amps unless instructed in the testing procedure. Damage to the meter or injury may result.
• Never use a welder or a battery system of a higher voltage than the machine you are troubleshooting to jump or sup-
ply electricity to. Damage to the machines electrical system may result.
D51EX/PX-22 40-121
TROUBLESHOOTING CONNECTION TABLE FOR CONNECTOR
CONNECTION TABLE FOR CONNECTOR PIN NUMBERS

H The terms male and female refer to the pins, while the terms male housing and female housing refer to the mating portion
of the housing.
H Deuscht connector has marks of pin numbers on the wiring harness side.
X Type Connector
Number
of Pins T-adapter Part
Male (Female housing) Female (Male housing) Number
1 Part number: 08055-00181 Part number: 08055-00191 799-601-7010
2 799-601-7020
Part number: 08055-00282 Part number: 08055-00292
3 799-601-7030
4 799-601-7040

Terminal part number: 79A-222-3370 Terminal part number: 79A-222-3390
• Wire size: 0.85 • Wire size: 0.85
— —
• Quantity: 20 pieces • Quantity: 20 pieces
• Grommet: black • Grommet: black
Terminal part number: 79A-222-3380 Terminal part number: 79A-222-3410
— —
• Grommet: red • Grommet: red
40-122 D51EX/PX-22
SWP Type Connector

Number of
Pins Male (Female housing) Female (Male housing) T-adapter Part
Number
6 799-601-7050
8 799-601-7060
12 799-601-7310
14 799-601-7070
D51EX/PX-22 40-123
SWP Type Connector

Number of
Number
16 799-601-7320

Terminal part number: Terminal part number:
— —
• Grommet: black • Grommet: black
Terminal part number: Terminal part number:
— —
• Grommet: red • Grommet: red
40-124 D51EX/PX-22
M Type Connector
Number of
Number
1 Part number: 08056-00171 Part number: 08056-00181 799-601-7080
2 799-601-7090
3 799-601-7110
4 799-601-7120
6 799-601-7130
D51EX/PX-22 40-125
8 799-601-7340
S Type Connector
Number of
Pins T-adapter Part
Male (Female housing) Female (Male housing)
Number
8 799-601-7140
10 (white) 799-601-7150
12 (white) 799-601-7350
40-126 D51EX/PX-22
16 (white) 799-601-7330
S Type Connector
Number of
Pins T-adapter Part
Number
10 (blue) —
— —
12 (blue) 799-601-7160
16 (blue) 799-601-7170
D51EX/PX-22 40-127
12
MIC Type Connector
Number of
Pins T-adapter Part
Number
Body part number: 79A-222-2640 Body part number: 79A-222-2630
7 (Quantity: 5 pieces) (Quantity: 5 pieces) —
11 Body part number: 79A-222-2680 Body part number: 79A-222-2670 —

(Quantity: 5 pieces) (Quantity: 5 pieces)
5 799-601-2710

9 799-601-2950

13 799-601-2720

40-128 D51EX/PX-22
MIC Type Connector

Number of
Number
17 799-601-2730

21 799-601-2740

— —
AMP040 Type Connector

Number of
Number
8 799-601-7180
Housing part number: 79A-222-3430

—
(Quantity: 5 pieces)
D51EX/PX-22 40-129
12 799-601-7190

— (Quantity: 5 pieces)
16 799-601-7210
— Housing part number: 79A-222-3450

(Quantity: 5 pieces)
20 799-601-7220

— (Quantity: 5 pieces)
H Terminal part number: 79A-222-3470 (for all numbers of pins).

AMP070 Type Connector
Number of
Pins T-adapter Part
Number
10 799-601-7510
— Part number: 08195-10210
40-130 D51EX/PX-22
12 799-601-7520
— Part number: 08195-12210
14 799-601-7530
— Part number: 08195-14210
18 799-601-7540
— Part number: 08195-18210
20 799-601-7550
— Part number: 08195-20210
L Type Connector
Number of
Pins T-adapter Part
Number
D51EX/PX-22 40-131
2 —
— —
PA Type Connector
Number of
Pins T-adapter Part
Male (Female housing) Female (Male housing) Number
9 —
— —
40-132 D51EX/PX-22
BENDIX (MS) Type Connector

Number of
Number
10 799-601-3460
— —
D51EX/PX-22 40-133
KES1 Automobile Type Connector

Number of
Number
2 —
Part number: 08027-10210 (Natural color) Part number: 08027-10260 (Natural color)
08027-10220 (Black) 08027-10270 (Black)
3 —
4 —
08027-10420 (Black) 08027-10470 (Black)
6 —
08027-10620 (Black) 08027-10670 (Black)
40-134 D51EX/PX-22
KES1 Automobile Type Connector

Number of
Number
8 —
08027-10820 (Black) 08027-10870 (Black)
D51EX/PX-22 40-135
Connector for relay (Socket)

Number of
Number
5 799-601-7360
— —
6 799-601-7370
— —
Type F Type Connector

(shell size T-adapter Part
code) Pin (Male terminal) Body (Female terminal)
Number
4 —
— —
40-136 D51EX/PX-22
H The pin No. is also marked on the connector (electric wire insertion end)
Type HD30 Series connector

code) Body (plug) Body (receptacle)
Number
Pin (male terminal) Pin (female terminal)
799-601-9210
Part number: 08191-11201, 08191-11202 Part number: 08191-14101, 08191-14102

18-8 08191-11205, 08191-11206 08191-14105, 08191-14106
(1) Pin (female terminal) Pin (male terminal)
799-601-9210

08191-11205, 08191-12206 08191-13105, 08191-13106
799-601-9220

18-14 08191-21205, 08191-12206 08191-24105, 08191-24106
799-601-9220

08191-22205, 08191-22206 08191-23105, 08191-23106
D51EX/PX-22 40-137

Number
799-601-9230
18-20 Part number: 08191-31201, 08191-31202 Part number: 08191-34101, 08191-34102

799-601-9230

799-601-9240

799-601-9240
40-138 D51EX/PX-22

Number
799-601-9250

799-601-9250

799-601-9260

24-16 08191-61205, 08191-62206 08191-64105, 08191-64106
799-601-9260

08191-62205, 08191-62206 08191-63105, 08191-63106
D51EX/PX-22 40-139

Number
799-601-9270

24-21 08191-71205, 08191-71206 08191-74105, 08191-74106
799-601-9270

08191-72205, 08191-72206 08191-73105, 08191-73106
799-601-9280
Part number: 08191-81201, 08191-81202, Part number: 08191-84101, 08191-84102,

08191-81203, 08191-81204, 08191-84103, 18191-84104,
24-22 08191-81205, 08191-80206 08191-84105, 08191-84106
799-601-9280
Part number: 08191-82201, 08191-82202, Part number: 08191-83101, 08191-83102,

08191-82203, 08191-82204, 08191-83103, 18191-83104,
08191-82205, 08191-82206 08191-83105, 08191-83106
40-140 D51EX/PX-22

Number
799-601-9290

24-31 08191-91205, 08191-91206 08191-94105, 08191-94106
799-601-9290

08191-92205, 08191-92206 08191-93105, 08191-93106
D51EX/PX-22 40-141
DT Series connector
Number
Body (plug) Body (receptacle)
Number
2 799-601-9020
Part number: 08192-12200 (normal type) Part number: 08192-12100 (normal type)
08192-22200 (fine wire type) 08192-22100 (fine wire type)
3 799-601-9030
4 799-601-9040
6 799-601-9050
40-142 D51EX/PX-22
DT Series connector
Number
Number
8GR: 799-601-9060
8B: 799-601-9070
8 8G: 799-601-9080
8BR: 799-601-9080
Part number: 08192-1820 T (normal type) Part number: 08192-1810 T (normal type)
08192-2820 T (fine wire type) 08192-2810 T (fine wire type)
12GR: 799-601-9110
12B: 799-601-9120
10 12G: 799-601-9130
12BR: 799-601-9140
Part number: 08192-1920 T (normal type) Part number: 08192-1910 T (normal type)
08192-2920 T (fine wire type) 08192-2910 T (fine wire type)
D51EX/PX-22 40-143
DTM Series connector
Number of
Pins T-adapter Part
Number
2 799-601-9010
DTHD Series connector

Number
Number
1 —
Part number: 08192-31200 (Contact size #12) Part number: 08192-31100 (Contact size #12)
08192-41200 (Contact size #8) 08192-41100 (Contact size #8)
08192-51200 (Contact size #4) 08192-51100 (Contact size #4)
40-144 D51EX/PX-22
12
DRC26 Series connector
No. of
pins T-adapter Part
Number
24 799-601-9360
 Part No. :7821-93-3110
40
799-601-9350
(A)
 Part No. :7821-93-3120
40
799-601-9350
(A)
 Part No. :7821-93-3130
50 799-601-4210
 
D51EX/PX-22 40-145
TROUBLESHOOTING T-ADAPTER TABLE
T-ADAPTER TABLE
H The part Nos. of the T-adapter boxes and T-adapters are shown in the columns and those of the wiring harness checker
assemblies are shown in the lines.
KIT No.
799-601-2500
799-601-2700
799-601-2800
799-601-2900
799-601-3000
799-601-5500
799-601-6000
799-601-6500
799-601-7000
799-601-7100
799-601-7400
799-601-7500
799-601-8000
799-601-9000
799-601-9100
799-601-9200
799-601-9300
—
Port No. Connector type Pin No.
799-601-2600 For measuring box Econo-21P O O O O O O

799-601-3100 For measuring box MS-37P O
799-601-3200 For measuring box MS-37P O
799-601-3300 For measuring box Econo-24P O
799-601-3360 Plate For MS box
799-601-3410 BENDIX(MS) 24P O O
799-601-3420 BENDIX(MS) 24P O O
799-601-3430 BENDIX(MS) 17P O O
799-601-3440 BENDIX(MS) 17P O O
799-601-3450 BENDIX(MS) 5P O O
799-601-3460 BENDIX(MS) 10P O O
799-601-3510 BENDIX(MS) 5P O O
799-601-3520 BENDIX(MS) 14P O O
799-601-3530 BENDIX(MS) 19P O O
799-601-2910 BENDIX(MS) 14P O O
799-601-3470 CASE O
799-601-2710 MIC 5P O O O O
799-601-2720 MIC 13P O O O O
799-601-2730 MIC 17P O O O O O O O
799-601-2740 MIC 21P O O O O O O O
799-601-2950 MIC 9P O O O O
799-601-2750 ECONO 2P O O
799-601-2760 ECONO 3P O O
799-601-2770 ECONO 4P O O
799-601-2780 ECONO 8P O O
799-601-2790 ECONO 12P O O
799-601-2810 DLI 8P O O
799-601-2820 DLI 12P O O
799-601-2830 DLI 16P O O
799-601-2840 Extension cable O O O
799-601-2850 CASE O
799-601-4210 DRC 50 O
799-601-7010 X 1P O O
799-601-7020 X 2P O O O O
799-601-7030 X 3P O O O O
799-601-7040 X 4P O O O O
799-601-7050 SWP 6P O O O
799-601-7060 SWP 8P O O O
40-146 D51EX/PX-22
KIT No.
799-601-2500
799-601-2700
799-601-2800
799-601-2900
799-601-3000
799-601-5500
799-601-6000
799-601-6500
799-601-7000
799-601-7100
799-601-7400
799-601-7500
799-601-8000
799-601-9000
799-601-9100
799-601-9200
799-601-9300
—
799-601-7310 SWP 12P O

799-601-7070 SWP 14P O O
799-601-7320 SWP 16P O
799-601-7080 M 1P O O
799-601-7090 M 2P O O O O
799-601-7110 M 3P O O O O
799-601-7120 M 4P O O O O
799-601-7130 M 6P O O O O
799-601-7340 M 8P O
799-601-7140 S 8P O O O O
799-601-7150 S 10P-White O O O O
799-601-7160 S 12P-Blue O O O
799-601-7170 S 16P-Blue O O O O
799-601-7330 S 16P-White O
799-601-7350 S 12P-White O
799-601-7180 AMP040 8P O
799-601-7190 AMP040 12P O O
799-601-7210 AMP040 16P O O O O
799-601-7220 AMP040 20P O O O O
799-601-7230 Short connector X-2 O O O O
799-601-7240 Case O O
799-601-7270 Case O
799-601-7510 070 10P O
799-601-7520 070 12P O
799-601-7530 070 14P O
799-601-7540 070 18P O
799-601-7550 070 20P O
799-601-7360 Relay connector 5P O
799-601-7370 Relay connector 6P O
799-601-7380 JFC connector 2P O
799-601-9010 DTM 2P O O
799-601-9020 DT 2P O O
799-601-9030 DT 3P O O
799-601-9040 DT 4P O O
799-601-9050 DT 6P O O
799-601-9060 DT 8P-Gray O O
799-601-9070 DT 8P-Black O O
799-601-9080 DT 8P-Green O O
799-601-9090 DT 8P-Blown O O
799-601-9110 DT 12P-Gray O O
799-601-9120 DT 12P-Black O O
799-601-9130 DT 12P-Green O O
799-601-9140 DT 12P-Blown O O
799-601-9210 HD30 18-8 O O
D51EX/PX-22 40-147
KIT No.
799-601-2500
799-601-2700
799-601-2800
799-601-2900
799-601-3000
799-601-5500
799-601-6000
799-601-6500
799-601-7000
799-601-7100
799-601-7400
799-601-7500
799-601-8000
799-601-9000
799-601-9100
799-601-9200
799-601-9300
—
799-601-9230 HD30 18-20 O O

799-601-9220 HD30 18-14 O O
799-601-9240 HD30 18-21 O O
799-601-9250 HD24 24-9 O O
799-601-9260 HD30 2-16 O O
799-601-9270 HD30 24-21 O O
799-601-9280 HD30 24-23 O O
799-601-9290 HD30 24-31 O O
799-601-9310 Plate For HD30 O O O
799-601-9320 For measuring box For DT, HD O O O
799-601-9330 Case O
799-601-9340 Case O
799-601-9350 DEUTSCH 40P O
799-601-9360 DEUTSCH 24P O
799-601-9410 For NE, G sensor 2P O
799-601-9420 For boost pressure, fuel 3P O
799-601-9430 PVC socket 2P O
40-148 D51EX/PX-22
KIT No.
799-601-2500
799-601-2700
799-601-2800
799-601-2900
799-601-3000
799-601-5500
799-601-6000
799-601-6500
799-601-7000
799-601-7100
799-601-7400
799-601-7500
799-601-8000
799-601-9000
799-601-9100
799-601-9200
799-601-9300
—
799-601-9230 HD30 18-20 O O

799-601-9240 HD30 18-21 O O
799-601-9250 HD24 24-9 O O
799-601-9260 HD30 2-16 O O
799-601-9270 HD30 24-21 O O
799-601-9280 HD30 24-23 O O
799-601-9290 HD30 24-31 O O
799-601-9310 Plate For HD30 O O O
799-601-9320 For measuring box For DT, HD O O O
799-601-9330 Case O
799-601-9340 Case O
799-601-9350 DEUTSCH 40P O
799-601-9360 DEUTSCH 24P O
799-601-9410 For NE, G sensor 2P O
799-601-9420 For boost pressure, fuel 3P O
799-601-9430 PVC socket 2P O
D51EX/PX-22 40-149
TROUBLESHOOTING MODE CHART
12
MODE CHART
Troubleshooting mode
No. Error or possible phenomena Code
E-mode H-mode S-mode
display
1 Action codes are displayed on machine monitor Check error code
2 If error code display function is checked, error codes are displayed l
Engine related problems
3 Engine does not start easily (Engine starting always takes time) S-1
4 Engine does not crank E-1 S-2a)
5 Engine does not start Engine cranks but no smoke comes out stack S-2b)
6 Smoke comes out stack but engine does not start S-2c)
7 Engine does not pickup smoothly (Poor follow up performance) S-3
8 Engine stops during operation S-4
9 Engine does not run smoothly (Hunts) S-5
10 Engine output is poor (lacks power) S-6
11 Exhaust smoke is black (incomplete combustion) S-7
12 Oil consumption is excessive (exhaust smoke is blue) S-8
13 Oil becomes contaminated quickly S-9
14 Fuel consumption is excessive S-10
15 Coolant contains oil (blows back or reduces) S-11
16 Oil pressure drops S-12
17 Oil level rises (Coolant or fuel in oil) S-13
18 Coolant temperature is too high (overheating) S-14
19 Abnormal noise is heard S-15
20 Vibration is excessive S-16
21 Preheat does not operate E-2
Power train related problems
Right and left travel systems do not operate in forward or reverse
22 H-1 S-6
(no travel system operates)
Right and left travel systems do not operate in forward or reverse
23 H-2
(only right or left travel system does not operate)
Right and left travel system do not operate in forward or reverse
24 H-3
(only one system does not operate)
25 Speed or power of travel is low H-4
26 Gear is not shifted H-5
27 Large shocks are felt when machine starts and stops travel H-6
28 Machine deviates greatly during travel H-7
29 Hydraulic drift of travel is great H-8
30 Engine stalls or engine speed lowers extremely during travel H-9
31 Abnormal sound comes out from around HST pump and motor H-10
32 HST oil temperature rises too high H-20
40-150 D51EX/PX-22
Troubleshooting mode
No. Error or possible phenomena Code
E-mode H-mode S-mode
display
Work equipment related problems
33 Work equipment does not operate at all E-21 H-11
34 Speed or power of all work equipment is low H-12
35 Speed or power of lifting the blade is low H-13
36 Speed or power of tilting the blade is low H-14
37 Speed or power of angling the blade is low H-15
38 Time lag in lifting the blade is great H-16
39 Hydraulic drift of lifting the blade is great H-17
40 Hydraulic drift of tilting the blade is great H-18
Abnormal sound comes out from around work equipment pump and
41 H-19
control valve
42 Hydraulic oil temperature raises too high H-20
Monitor panel related problems
43 When ignition switch is turned ON, nothing lights up E-3
44 Charge level caution lamp flashes while engine is running E-4
45 Emergency warning items flash while engine is running E-5
46 Preheat pilot lamp does not light up during preheat operation E-6
47 The coolant temperature gauge does not indicate correctly E-7
48 The HST oil temperature gauge does not indicate correctly E-8
49 Fuel level gauge does not indicate properly E-9
50 Travel lever speed shift mode indicator does not display correctly E-10
51 Multi-information unit does not display correctly E-11
52 Caution lamp does not flash or does not go off E-12
53 Caution buzzer does not sound or will not stop sounding E-13
54 Reverse travel speed setting switch does not function E-14
55 Shift mode switch does not function E-15
56 Buzzer cancel switch does not function E-16
57 Information switch does not function E-17
Other related items
58 Fan speed is abnormal (High, low or 0 rpm) H-21
59 The fan cleaning does not operate or cannot be reset E-18
60 Backup alarm does not sound E-19
61 The horn does not sound or does not stop sounding E-20
62 Head lamp or rear lamp does not light up E-22
63 Foot heater does not operate E-23
64 Air conditioner does not operate (Cab specification) E-24
65 Windshield wipers and washers do not operate (Cab specification) E-25
66 KOMTRAX system does not operate correctly E-26
D51EX/PX-22 40-151
40-152 D51EX/PX-22
40 TROUBLESHOOTING (BY ERROR CODE)
TROUBLESHOOTING BY ERROR CODE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-207

INFORMATION IN TROUBLESHOOTING TABLE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-214
ERROR CODE [6091NX] . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-216
HST CHARGE FILTER ELEMENT CLOGGING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-216
ERROR CODE [AA10NX] . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-218
AIR CLEANER CLOGGING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-218
ERROR CODE [AB00MA] . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-220
ALTERNATOR MALFUNCTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-220
ERROR CODE [B@BAZG] . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-221
ENGINE OIL LOWERING OF OIL PRESSURE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-221
ERROR CODE [B@BCNS] . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-222
COOLANT OVERHEAT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-222
ERROR CODE [B@CRNS] . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-223
HST OIL OVERHEATING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-223
ERROR CODE [B@CRZG] . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-224
HST OIL LOWERING OF OIL PRESSURE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-224
ERROR CODE [CA111] . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-225
ABNORMALITY IN ENGINE CONTROLLER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-225
ERROR CODE [CA115] . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-226
ABNORMALITY IN NE AND BKUP SPEED SENSOR SIGNAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-226
ERROR CODE [CA122] . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-228
CHARGE PRESSURE SENSOR TOO HIGH . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-228
ERROR CODE [CA123] . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-230
CHARGE PRESSURE SENSOR TOO LOW . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-230
ERROR CODE [CA131] . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-232
DECELERATOR PEDAL SENSOR TOO HIGH . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-232
ERROR CODE [CA132] . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-234
DECELERATOR PEDAL SENSOR TOO LOW . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-234
ERROR CODE [CA144] . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-236
COOLANT TEMPERATURE SENSOR TOO HIGH . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-236
ERROR CODE [CA145] . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-238
COOLANT TEMPERATURE SENSOR TOO LOW . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-238
ERROR CODE [CA153] . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-240
CHARGE TEMPERATURE SENSOR TOO HIGH . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-240
ERROR CODE [CA154] . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-242
CHARGE TEMPERATURE SENSOR TOO low . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-242
ERROR CODE [CA187] . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-244
SENSOR POWER SORCE EXCESSIVELY LOW . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-244
ERROR CODE [CA221] . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-246
ATMOSPHERIC PRESSURE SENSOR TOO HIGH . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-246
ERROR CODE [CA222] . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-248
ATMOSPHERIC PRESSURE SENSOR TOO LOW . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-248
ERROR CODE [CA227] . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-250
SENSOR POWER SORCE EXCESSIVELY HIGH . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-250
ERROR CODE [CA234] . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-252
ENGINE OVERSPEED . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-252
ERROR CODE [CA238] . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-253
D51EX/PX-22 40-201 
TROUBLESHOOTING TABLE OF CONTENTS
ABNORMAL POWER SOURCE FOR NE SPEED SENSOR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-253
ERROR CODE [CA271] . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-254
IMV/PCV1 SHORT CIRCUITED . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-254
ERROR CODE [CA272] . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-256
IMV/PCV1 OPEN . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-256
ERROR CODE [CA322] . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-258
NO.1 INJECTOR SHOWING OPEN OR SHORT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-258
ERROR CODE [CA323] . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-260
ERROR CODE [CA324] . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-262
ERROR CODE [CA325] . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-264
ERROR CODE [CA331] . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-266
ERROR CODE [CA332] . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-268
ERROR CODE [CA342] . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-270
ENGINE CONTROLLER DATA MATCHING ERROR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-270
ERROR CODE [CA352] . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-271
SENSOR POWER SOURCE TOO LOW . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-271
ERROR CODE [CA386] . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-272
SENSOR POWER SOURCE TOO HIGH . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-272
ERROR CODE [CA428] . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-274
WATER IN FUEL SENSOR VOLTAGE TOO HIGH . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-274
ERROR CODE [CA429] . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-276
WATER IN FUEL SENSOR VOLTAGE TOO LOW . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-276
ERROR CODE [CA435] . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-278
ABNORMAL ENGINE OIL PRESSURE SWITCH . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-278
ERROR CODE [CA441] . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-280
POWER SOURCE VOLTAGE IS TOO LOW . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-280
ERROR CODE [CA442] . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-282
POWER SOURCE VOLTAGE TOO HIGH . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-282
ERROR CODE [CA449] . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-284
COMMON RAIL PRESSURE TOO HIGH . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-284
ERROR CODE [CA451] . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-286
ERROR CODE [CA452] . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-288
COMMON RAIL PRESSURE TOO LOW . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-288
ERROR CODE [CA488] . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-290
CHARGE TEMPERATURE TOO HIGH AND TORQUE DERATED . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-290
ERROR CODE [CA553] . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-291
ERROR CODE [CA559] . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-292
LOSS OF PRESSURE FEED FROM SUPPLY PUMP . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-292
ERROR CODE [CA689] . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-294
ABNORMAL ENGINE NE SPEED SENSOR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-294
ERROR CODE [CA731] . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-296
ABNORMAL ENGINE BKUP SPEED SENSOR PHASE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-296
ERROR CODE [CA757] . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-298
LOSS OF ALL ENGINE CONTROLLER DATA . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-298
ERROR CODE [CA778] . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-300
ABNORMAL ENGINE BKUP SPEED SENSOR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-300
ERROR CODE [CA1633] . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-302
ABNORMAL KOMNET . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-302
ERROR CODE [CA2185] . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-304
DECELERATOR PEDAL SENSOR POWER SOURCE TOO HIGH . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-304
40-202  D51EX/PX-22
ERROR CODE [CA2186] . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-305
DECELERATOR PEDAL SENSOR POWER SOURCE TOO LOW . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-305
ERROR CODE [CA2249] . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-306
LOSS OF PRESSURE FEED FROM SUPPLY PUMP (2) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-306
ERROR CODE [CA2311] . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-308
ABNORMAL IMV SOLENOID . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-308
ERROR CODE [CA2555] . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-310
AIR INTAKE HEATER RELAY DISCONNECTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-310
ERROR CODE [CA2556] . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-312
AIR INTAKE HEATER RELAY SHORT CIRCUIT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-312
ERROR CODE [D130KA] . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-314
NEUTRAL SAFETY RELAY DISCONNECTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-314
ERROR CODE [D130KB] . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-316
NEUTRAL SAFETY RELAY SHORT CIRCUIT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-316
ERROR CODE [DAFRKR] . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-318
CAN COMMUNICATION MONITOR PANEL – HST CONTROLLER . . . . . . . . . . . . . . . . . . . . . . . . . 40-318
ERROR CODE [DAFRMC] . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-320
CAN COMMUNICATION MONITOR PANEL – ENGINE CONTROLLER . . . . . . . . . . . . . . . . . . . . . 40-320
ERROR CODE [DAJ000] . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-322
HST CONTROLLER MEMORY ERROR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-322
ERROR CODE [DAJ0KK] . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-324
HST CONTROLLER LOWERING OF SOURCE VOLTAGE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-324
ERROR CODE [DAJ0KQ] . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-326
HST CONTROLLER MACHINE CODE ERROR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-326
ERROR CODE [DAJ0KT] . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-327
HST CONTROLLER MEMORY ERROR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-327
ERROR CODE [DAJ5KK] . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-328
HST CONTROLLER POWER SUPPLY LOWING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-328
ERROR CODE [DAJ6KK] . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-330
HST POWER SUPPLY LOWING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-330
ERROR CODE [DAJRKR] . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-332
CAN COMMUNICATION HST CONTROLLER DEFECTIVE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-332
ERROR CODE [DB2RKR] . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-334
CAN COMMUNICATION HST CONTROLLER DEFECTIVE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-334
ERROR CODE [DD12KA] . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-336
SHIFT UP SWITCH DISCONNECTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-336
ERROR CODE [DD12KB] . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-338
SHIFT UP SWITCH SHORT CIRCUIT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-338
ERROR CODE [DD13KA] . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-340
SHIFT DOWN SWITCH DISCONNECTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-340
ERROR CODE [DD13KB] . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-342
SHIFT DOWN SWITCH SHORT CIRCUIT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-342
ERROR CODE [DD14KB] . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-344
TRAVEL LOCK LIMIT SWITCH 1 SHORT CIRCUIT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-344
ERROR CODE [DD1NL4] . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-346
FAN ROTATION SELECTOR SWITCH DISAGREEMENT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-346
ERROR CODE [DDDCKB] . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-348
REVERSE TRAVEL SPEED SWITCH SHORT CIRCUIT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-348
ERROR CODE [DDP6KA] . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-350
BRAKE OIL PRESSURE SENSOR DISCONNECTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-350
ERROR CODE [DDP6KB] . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-352
BRAKE OIL PRESSURE SENSOR SHORT CIRCUIT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-352
ERROR CODE [DDP6MA] . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-354
BRAKE OIL PRESSURE SENSOR MALFUNCTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-354
ERROR CODE [DDQ2KA] . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-356
TRAVEL LOCK LIMIT SWITCH 1 DISCONNECTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-356
ERROR CODE [DDT0L4] . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-358
D51EX/PX-22 40-203 
SHIFT MODE SWITCH DISAGREEMENT OF ON/ OFF SIGNALS . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-358
ERROR CODE [DDU1FS] . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-360
TRAVEL LOCK LIMIT SWITCHES 1 AND 2 FIXING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-360
ERROR CODE [DDU1KA] . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-362
TRAVEL LOCK LIMIT SWITCH 2 DISCONNECTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-362
ERROR CODE [DDU1KY] . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-364
TRAVEL LOCK LIMIT SWITCH 2 SHORT WITH POWER SUPPLY LINE . . . . . . . . . . . . . . . . . . . . . 40-364
ERROR CODE [DGS1KA] . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-366
HST OIL TEMPERATURE SENSOR DISCONNECTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-366
ERROR CODE [DGS1KX] . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-368
HST OIL TEMPERATURE SENSOR OUT OF INPUT SIGNAL RANGE . . . . . . . . . . . . . . . . . . . . . . . 40-368
ERROR CODE [DHH5KA] . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-369
LEFT HST PUMP PRESSURE SENSOR DISCONNECTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-369
ERROR CODE [DHH5KB] . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-371
LEFT HST PUMP PRESSURE SENSOR SHORT CIRCUIT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-371
ERROR CODE [DHH6KA] . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-373
RIGHT HST PUMP PRESSURE SENSOR DISCONNECTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-373
ERROR CODE [DHH6KB] . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-375
RIGHT HST PUMP PRESSURE SENSOR SHORT CIRCUIT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-375
ERROR CODE [DK10KA] . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-377
FUEL DIAL SENSOR DISCONNECTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-377
ERROR CODE [DK10KB] . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-379
FUEL DIAL SENSOR SHORT CIRCUIT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-379
ERROR CODE [DK30KA] . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-381
STEERING ANGLE SENSOR 1 DISCONNECTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-381
ERROR CODE [DK30KB] . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-383
STEERING ANGLE SENSOR 1 SHORT CIRCUIT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-383
ERROR CODE [DK30KX] . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-385
STEERING ANGLE SENSOR OUT OF INPUT SIGNAL RANGE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-385
ERROR CODE [DK30KZ] . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-386
STEERING ANGLE SENSOR DISCONNECTION OR SHORT CIRCUIT . . . . . . . . . . . . . . . . . . . . . . . 40-386
ERROR CODE [DK30L8] . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-387
STEERING ANGLE SENSOR DISAGREEMENT OF ANALOG SIGNALS . . . . . . . . . . . . . . . . . . . . . 40-387
ERROR CODE [DK31KA] . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-389
STEERING ANGLE SENSOR DISCONNECTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-389
ERROR CODE [DK31KB] . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-391
STEERING ANGLE SENSOR 2 SHORT CIRCUIT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-391
ERROR CODE [DK40KA] . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-393
BRAKE PEDAL SENSOR DISCONNECTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-393
ERROR CODE [DK40KB] . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-395
BRAKE PEDAL SENSOR SHORT CIRCUIT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-395
ERROR CODE [DK55KX] . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-397
DIRECTIONAL POTENTIOMETER OUT OF INPUT SIGNAL RANGE . . . . . . . . . . . . . . . . . . . . . . . . 40-397
ERROR CODE [DK55KZ] . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-398
DIRECTIONAL POTENTIOMETER DISCONNECTION OR SHORT CIRCUIT . . . . . . . . . . . . . . . . . 40-398
ERROR CODE [DK55L8] . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-399
DIRECTIONAL POTENTIOMETER DISAGREEMENT OF ANALOG SIGNALS . . . . . . . . . . . . . . . . 40-399
ERROR CODE [DK56KA] . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-401
DIRECTIONAL POTENTIOMETER 1 DISCONNECTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-401
ERROR CODE [DK56KB] . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-403
DIRECTIONAL POTENTIOMETER 1 SHORT CIRCUIT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-403
ERROR CODE [DK57KA] . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-405
DIRECTIONAL POTENTIOMETER 2 DISCONNECTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-405
ERROR CODE [DK57KB] . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-407
DIRECTIONAL POTENTIOMETER 2 SHORT CIRCUIT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-407
ERROR CODE [DLM0KX] . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-409
HST MOTOR SPEED SENSORS OUT OF INPUT SIGNAL RANGE . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-409
40-204  D51EX/PX-22
ERROR CODE [DLM1KA] . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-411
LEFT HST MOTOR SPEED SENSOR DISCONNECTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-411
ERROR CODE [DLM1KB] . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-413
LEFT HST MOTOR SPEED SENSOR: SHORT CIRCUIT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-413
ERROR CODE [DLM1MA] . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-415
LEFT HST MOTOR SPEED SENSOR: MALFUNCTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-415
ERROR CODE [DLM2KA] . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-417
RIGHT HST MOTOR SPEED SENSOR DISCONNECTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-417
ERROR CODE [DLM2KB] . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-419
RIGHT HST MOTOR SPEED SENSOR SHORT CIRCUIT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-419
ERROR CODE [DLM2MA] . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-421
RIGHT HST MOTOR SPEED SENSOR MALFUNCTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-421
ERROR CODE [DLM3KA] . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-423
FAN SPEED SENSOR DISCONNECTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-423
ERROR CODE [DLM3KB] . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-425
FAN SPEED SENSOR: SHORT CIRCUIT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-425
ERROR CODE [DN21FS] . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-427
BRAKE PEDAL AND PROXIMITY SWITCH FIXING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-427
ERROR CODE [DV00KB] . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-429
CAUTION BUZZER SHORT CIRCUIT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-429
ERROR CODE [DV20KB] . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-430
BACK ALARM BUZZER SHORT CIRCUIT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-430
ERROR CODE [DW4BKA] . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-431
PARKING BRAKE SOLENOID VALVE DISCONNECTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-431
ERROR CODE [DW4BKB] . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-433
PARKING BRAKE SOLENOID VALVE SHORT CIRCUIT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-433
ERROR CODE [DW4BKY] . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-435
PARKING BRAKE SOLENOID VALVE SHORTED . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-435
ERROR CODE [DW7BKA] . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-436
FAN REVERSE SOLENOID VALVE DISCONNECTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-436
ERROR CODE [DW7BKB] . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-436
FAN REVERSE SOLENOID VALVE SHORT CIRCUIT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-437
ERROR CODE [DW7BKY] . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-438
FAN REVERSE SOLENOID VALVE SHORTED . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-438
ERROR CODE [DW7EKA] . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-439
SLOW BRAKE SOLENOID VALVE DISCONNECTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-439
ERROR CODE [DW7EKB] . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-443
SLOW BRAKE SOLENOID VALVE SHORT CIRCUIT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-443
ERROR CODE [DW7EKY] . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-445
SLOW BRAKE SOLENOID VALVE SHORTED . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-445
ERROR CODE [DWN5KA] . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-447
FAN EPC SOLENOID VALVE DISCONNECTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-447
ERROR CODE [DWN5KB] . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-449
FAN EPC SOLENOID VALVE SHORT CIRCUIT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-449
ERROR CODE [DWN5KY] . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-451
FAN EPC SOLENOID VALVE SHORTED . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-451
ERROR CODE [DXA4KA] . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-453
LF HST PUMP EPC SOLENOID VALVE DISCONNECTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-453
ERROR CODE [DXA4KB] . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-455
LF HST PUMP EPC SOLENOID VALVE SHORT CIRCUIT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-455
ERROR CODE [DXA4KY] . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-456
LF HST PUMP EPC SOLENOID VALVE SHORTED . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-456
ERROR CODE [DXA5KA] . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-457
LR HST PUMP EPC SOLENOID VALVE DISCONNECTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-457
ERROR CODE [DXA5KB] . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-459
LR HST PUMP EPC SOLENOID VALVE SHORT CIRCUIT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-459
ERROR CODE [DXA5KY] . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-460
D51EX/PX-22 40-205 
LR HST PUMP EPC SOLENOID VALVE SHORTED . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-460
ERROR CODE [DXA6KA] . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-461
RF HST PUMP EPC SOLENOID VALVE DISCONNECTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-461
ERROR CODE [DXA6KB] . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-463
RF HST PUMP EPC SOLENOID VALVE SHORT CIRCUIT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-463
ERROR CODE [DXA6KY] . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-464
RF HST PUMP EPC SOLENOID VALVE SHORTED . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-464
ERROR CODE [DXA7KA] . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-465
RR HST PUMP EPC SOLENOID VALVE DISCONNECTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-465
ERROR CODE [DXA7KB] . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-466
RR HST PUMP EPC SOLENOID VALVE SHORT CIRCUIT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-466
ERROR CODE [DXA7KY] . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-467
RR HST PUMP EPC SOLENOID VALVE SHORTED . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-467
ERROR CODE [DXK1KA] . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-468
LEFT HST MOTOR EPC SOLENOID VALVE DISCONNECTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-468
ERROR CODE [DXK1KB] . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-469
LEFT HST MOTOR EPC SOLENOID VALVE SHORT CIRCUIT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-469
ERROR CODE [DXK1KY] . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-470
LEFT HST MOTOR EPC SOLENOID VALVE SHORTED . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-470
ERROR CODE [DXK2KA] . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-471
RIGHT HST MOTOR EPC SOLENOID VALVE DISCONNECTION . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-471
ERROR CODE [DXK2KB] . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-472
RIGHT HST MOTOR EPC SOLENOID VALVE SHORT CIRCUIT . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-472
ERROR CODE [DXK2KY] . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-473
RIGHT HST MOTOR EPC SOLENOID VALVE SHORTED . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-473
40-206  D51EX/PX-22
TROUBLESHOOTING TROUBLESHOOTING BY ERROR CODE
TROUBLESHOOTING BY ERROR CODE
Action Buzzer
Error codes Defective part Trouble Mode Message Lamps History
code ON
ON
6091NX HST charge filter element Clogging HST — —   Mechanical

system
Mechanical
AA10NX Air cleaner Clogging MON — — — —
system
AB00MA Alternator Malfunction MON — —  —

Mechanical
system
B@BAZG Engine oil Lowering of oil pressure ENG — —   Mechanical

system
B@BCNS Coolant Overheat ENG — —   Mechanical

system
B@CRNS HST oil Overheating HST — —   Mechanical

system
B@CRZG HST oil Lowering of oil pressure HST — —   Mechanical

system
CA111 Engine controller Abnormality in controller ENG E04

CON-
TROLLER
  Electrical
system
CA115 Abnormal engine NE, Bkup speed Abnormal speed sensor signal ENG E04
ENG
SPEED
  Electrical
system
CA122 Charge pressure sensor too high Excessively high voltage detected ENG E03 ENGINE   Electrical
system
CA123 Charge pressure sensor too low Excessively low voltage detected ENG E03 ENGINE   Electrical
system
CA131 Decelerator pedal sensor too high Excessively high voltage detected ENG E03
DECEL
PEDAL
  Electrical
system
CA132 Decelerator pedal sensor too low Excessively low voltage detected ENG E03
DECEL
PEDAL
  Electrical
system
CA144
Coolant temperature sensor too
high
Excessively high voltage detected ENG E02
WATER
TEMP
  Electrical
system
CA145
Coolant temperature sensor too
low
Excessively low voltage detected ENG E02
WATER
TEMP
  Electrical
system
Charge temperature sensor too Electrical
CA153 Excessively high voltage detected ENG E01 ENGINE — —
high system
Charge temperature sensor too Electrical
CA154 Excessively low voltage detected ENG E01 ENGINE — —
low system
CA187 Sensor power source 2 too low Excessively low voltage detected ENG E03
SENSOR
VOLTAGE
  Electrical
system
CA221
Atmospheric pressure sensor too
high
Excessively high voltage detected ENG E03 ENGINE   Electrical
system
CA222
Atmospheric pressure sensor too
low
Excessively low voltage detected ENG E03 ENGINE   Electrical
system
CA227 Sensor power source 2 too high Excessively high voltage detected ENG E03
SENSOR
VOLTAGE
  Electrical
system
CA234 Engine overspeed Excessively high speed ENG — —   Mechanical

system
CA238
Abnormal power source for Ne
speed sensor
ENG
SPEED
  Electrical
system
CA271 IMV/PCV1 short circuit Short circuit ENG E03 ENGINE   Electrical
system
CA272 IMV/PCV1 Open Open ENG E03 ENGINE   Electrical

system
CA322
Open and short circuit in injector
#1
Open or short circuit ENG E03 ENGINE   Electrical
system
D51EX/PX-22 40-207 
CA323
#5
system
CA324
#3
system
CA325
#6
system
CA331
#2
system
CA332
#4
system
CA342
Abnormal engine controller data
matching consistency
Matching inconsistency ENG E04 ENGINE   Electrical
system
CA352 Sensor power source 1 too low Excessively low voltage detected ENG E03
SENSOR
VOLTAGE
  Electrical
system
CA386 Sensor power source 1 too high Excessively high voltage detected ENG E03
SENSOR
VOLTAGE
  Electrical
system
FUEL FIL- Electrical
CA428 Water detection sensor too high Excessively high voltage detected ENG E01 — —
TER system
FUEL FIL- Electrical
CA429 Water detection sensor too low Excessively low voltage detected ENG E01 — —
TER system
CA435
Abnormal engine oil pressure
switch
Abnormal signal circuit ENG E02
ENG OIL
PRESS SW
  Electrical
system
CA441 Power supply voltage too low Excessively low voltage detected ENG E04
BATTERY
VOLTAGE
  Electrical
system
CA442 Power supply voltage too high Excessively high voltage detected ENG E04
BATTERY
VOLTAGE
  Electrical
system
CA449 Common rail pressure too high 2 Excessively high pressure detected ENG E03 ENGINE   Electrical
system
CA451
Common rail pressure sensor too
high
Excessively high voltage detected ENG E03 ENGINE   Electrical
system
CA452
Common rail pressure sensor too
low
Excessively low voltage detected ENG E03 ENGINE   Electrical
system
CAC
CA488
Charge temperature too high
torque derated
Exceeded upper control limit of
temperature
ENG E03 OVER-   Electrical
system
HEAT
CA553 Common rail pressure too high 1 Excessively high pressure detected ENG E02 ENGINE  q
Electrical
system
CA559 Supply pump no pressure 1 No pressure feeding detected ENG E02 ENGINE   Electrical
system
CA689 Abnormal engine Ne speed sensor Abnormality in signal ENG E03

ENG
SPEED
  Electrical
system
CA731
Abnormal engine Bkup speed sen-
sor phase
Abnormal phase ENG E03
ENG
SPEED
  Electrical
system
CA757
Loss of all data of engine control-
ler
Loss of all data ENG E04
CON-
TROLLER
  Electrical
system
CA778
Abnormal engine Bkup speed sen-
sor
Abnormal Bkup signal ENG E03
ENG
SPEED
  Electrical
system
Abnormal CAN communication
CA1633 (Engine controller – HST control- Abnormal communication ENG E03
DATA
LINK
  Electrical
system
ler)
CA2185
Decelerator pedal sensor power
source too high
Excessively high voltage detected ENG E03
DECEL
PEDAL
  Electrical
system
CA2186
Decelerator pedal sensor power
source too low
DECEL
PEDAL
  Electrical
system
CA2249 Supply pump no pressure 2 No pressure feeding detected ENG E03 ENGINE   Electrical
system
CA2311 Abnormal IMV solenoid Abnormal resistance ENG E03 ENGINE   Electrical
system
40-208  D51EX/PX-22
HEATER Electrical
CA2555 Open in air intake heater relay Open ENG E01 — —
RELAY system
Short circuit in air intake heater HEATER Electrical
CA2556 Short circuit ENG E01 — —
relay RELAY system
D130KA Neutral safety relay Open HST E02

N SAFETY
RELAY
  Electrical
system
D130KB Neutral safety relay Short circuit HST E02

N SAFETY
RELAY
  Electrical
system
“Defective communication
DAFRKR
CAN communication (Monitor
panel – HST controller)
(Abnormality in objective compo- MON E03
DATA
LINK
  Electrical
system
nent system)”
DAFRMC
CAN communication (Monitor
panel – Engine controller)
(Abnormality in objective compo- MON E03
DATA
LINK
  Electrical
system
nent system)”
Electrical
DAJ000 HST controller Memory error HST — — — —
system
DAJ0KK HST controller Lowing of source voltage HST E04

BATTERY
VOLTAGE
  Electrical
system
DAJ0KQ HST controller Machine code error HST E03

MACHINE
CODE
  Electrical
system
DAJ0KT HST controller Memory error HST E03

CON-
TROLLER
  Electrical
system
DAJ5KK
HST controller sensor 5V power
supply No. 1
Lowing of source voltage/Input HST E04
SENSOR
VOLTAGE
  Electrical
system
DAJ6KK
HST controller sensor 5V power
supply No. 2
Lowing of source voltage/Input HST E03
SENSOR
VOLTAGE
  Electrical
system
DAJRKR
CAN communication (HST con-
troller – Monitor panel)
(Abnormality in objective compo- HST E03
DATA
LINK
  Electrical
system
nent system)”
DB2RKR
CAN communication (HST con-
troller – Engine controller)
(Abnormality in objective compo- HST E03
DATA
LINK
  Electrical
system
nent system)”
DD12KA Shift up switch Open HST E02

SHIFT UP
SW
  Electrical
system
DD12KB Shift up switch Short circuit HST E02

SHIFT UP
SW
  Electrical
system
DD13KA Shift down switch Open HST E02

SHIFT
DOWN SW
  Electrical
system
DD13KB Shift down switch Short circuit HST E02

SHIFT
DOWN SW
  Electrical
system
DD14KB Travel lock limit switch 1 Short circuit HST E03

TRAVEL
LOCK
  Electrical
system
Electrical
DD1NL4 Fan rotation selector switch Disagreement of ON/OFF signals HST E01 FAN SW — —
system
R SPEED Electrical
DDDCKB Reverse travel speed switch Short circuit HST E01 — —
SW system
DDP6KA Brake oil pressure sensor Open HST E02

BRAKE
PRESS
  Electrical
system
DDP6KB Brake oil pressure sensor Short circuit HST E02

BRAKE
PRESS
  Electrical
system
DDP6MA Brake oil pressure sensor Malfunction HST E02

BRAKE
PRESS
  Electrical
system
DDQ2KA Travel lock limit switch 1 Open HST E03

TRAVEL
LOCK
  Electrical
system
SHIFT Electrical
DDT0L4 Shift mode switch Disagreement of ON/OFF signals HST E01 — —
MODE SW system
DDU1FS Travel lock limit switches 1 and 2 Fixing HST E03

TRAVEL
LOCK
  Electrical
system
D51EX/PX-22 40-209 
DDU1KA Travel lock limit switch 2 Open HST E03

TRAVEL
LOCK
  Electrical
system
DDU1KY Travel lock limit switch 2

Short circuit with power supply
line
HST E03
TRAVEL
LOCK
  Electrical
system
Electrical
DGS1KA HST oil temperature sensor Open HST E01 OIL TEMP — —
system
Electrical
DGS1KX HST oil temperature sensor Out of input signal range HST E01 OIL TEMP — —
system
DHH5KA Left HST pump pressure sensor Open HST E02

HST
PRESS
  Electrical
system
DHH5KB Left HST pump pressure sensor Short circuit HST E02
HST
PRESS
  Electrical
system
DHH6KA Right HST pump pressure sensor Open HST E02

HST
PRESS
  Electrical
system
DHH6KB Right HST pump pressure sensor Short circuit HST E02
HST
PRESS
  Electrical
system
DK10KA Fuel dial sensor Open HST E03

FUEL
DIAL
  Electrical
system
DK10KB Fuel dial sensor Short circuit HST E03

FUEL
DIAL
  Electrical
system
DK30KA Steering angle sensor 1 Open HST E03 ST LEVER   Electrical

system
DK30KB Steering angle sensor 1 Short circuit HST E03 ST LEVER   Electrical
system
DK30KX Steering angle sensor Out of input signal range HST E04 ST LEVER   Electrical
system
DK30KZ Steering angle sensor Open or short circuit HST E04 ST LEVER   Electrical
system
DK30L8 Steering angle sensor Disagreement of analog signals HST E03 ST LEVER   Electrical
system
DK31KA Steering angle sensor 2 Open HST E03 ST LEVER   Electrical

system
DK31KB Steering angle sensor 2 Short circuit HST E03 ST LEVER   Electrical
system
DK40KA Brake pedal sensor Open HST E03

BRAKE
PEDAL
  Electrical
system
DK40KB Brake pedal sensor Short circuit HST E03

BRAKE
PEDAL
  Electrical
system
DK55KX Directional potentiometer Out of input signal range HST E04 FR LEVER   Electrical
system
DK55KZ Directional potentiometer Open or short circuit HST E04 FR LEVER   Electrical
system
DK55L8 Directional potentiometer Disagreement of analog signals HST E03 FR LEVER   Electrical
system
DK56KA Directional potentiometer 1 Open HST E03 FR LEVER   Electrical

system
DK56KB Directional potentiometer 1 Short circuit HST E03 FR LEVER   Electrical

system
DK57KA Directional potentiometer 2 Open HST E03 FR LEVER   Electrical

system
DK57KB Directional potentiometer 2 Short circuit HST E03 FR LEVER   Electrical

system
DLM0KX HST motor speed sensor Out of input signal range HST E03
TRAVEL
SPEED
  Electrical
system
TRAVEL Electrical
DLM1KA Left HST motor speed sensor Open HST E01 — —
SPEED system
40-210  D51EX/PX-22
Electrical
DLM1KB Left HST motor speed sensor Short circuit HST — — — —
system
Electrical
DLM1MA Left HST motor speed sensor Malfunction HST — — — —
system
TRAVEL Electrical
DLM2KA Right HST motor speed sensor Open HST E01 — —
SPEED system
Electrical
DLM2KB Right HST motor speed sensor Short circuit HST — — — —
system
Electrical
DLM2MA Right HST motor speed sensor Malfunction HST — — — —
system
FAN Electrical
DLM3KA Fan speed sensor Open HST E01 — —
SPEED system
DLM3KB Fan speed sensor Short circuit HST E02

FAN
SPEED
  Electrical
system
DN21FS Brake pedal and proximity switch Fixing HST E03

BRAKE
PEDAL
  Electrical
system
Electrical
DV00KB Caution buzzer Short circuit MON E01 BUZZER — —
system
BACK Electrical
DV20KB Back alarm buzzer Short circuit HST E01 — —
ALARM system
DW4BKA Parking brake solenoid valve Open HST E04

P BRAKE
SOL
  Electrical
system
DW4BKB Parking brake solenoid valve Short circuit HST E04

P BRAKE
SOL
  Electrical
system
DW4BKY Parking brake solenoid valve

line
HST E03
P BRAKE
SOL
  Electrical
system
FAN CLN Electrical
DW7BKA Fan reverse solenoid valve Open HST E01 — —
SOL system
FAN CLN Electrical
DW7BKB Fan reverse solenoid valve Short circuit HST E01 — —
SOL system
DW7BKY Fan reverse solenoid valve

line
HST E03
FAN CLN
SOL
  Electrical
system
SLOW
DW7EKA Slow brake solenoid valve Open HST E04 BRAKE   Electrical
system
SOL
SLOW
DW7EKB Slow brake solenoid valve Short circuit HST E04 BRAKE   Electrical
system
SOL
SLOW
DW7EKY Slow brake solenoid valve
line
HST E03 BRAKE   Electrical
system
SOL
Electrical
DWN5KA Fan EPC solenoid valve Open HST E01 FAN EPC — —
system
Electrical
DWN5KB Fan EPC Solenoid valve Short circuit HST E01 FAN EPC — —
system
DWN5KY Fan EPC solenoid valve

line
HST E02 FAN EPC   Electrical
system
DXA4KA
LF HST pump EPC solenoid
valve
Open HST E03
HST PUMP
EPC
  Electrical
system
DXA4KB
valve
Short circuit HST E03
HST PUMP
EPC
  Electrical
system
DXA4KY
valve
line
HST E04
HST PUMP
EPC
  Electrical
system
DXA5KA
LR HST pump EPC solenoid
valve
Open HST E03
HST PUMP
EPC
  Electrical
system
DXA5KB
valve
HST PUMP
EPC
  Electrical
system
D51EX/PX-22 40-211 
DXA5KY
valve
line
HST E04
HST PUMP
EPC
  Electrical
system
DXA6KA
RF HST pump EPC solenoid
valve
Open HST E03
HST PUMP
EPC
  Electrical
system
DXA6KB
valve
HST PUMP
EPC
  Electrical
system
DXA6KY
valve
line
HST E04
HST PUMP
EPC
  Electrical
system
DXA7KA
RR HST pump EPC solenoid
valve
Open HST E03
HST PUMP
EPC
  Electrical
system
DXA7KB
valve
HST PUMP
EPC
  Electrical
system
DXA7KY
valve
line
HST E04
HST PUMP
EPC
  Electrical
system
HST
DXK1KA
Left HST motor EPC solenoid
valve
Open HST E02 MOTOR   Electrical
system
EPC
HST
DXK1KB
valve
Short circuit HST E02 MOTOR   Electrical
system
EPC
HST
DXK1KY
valve
line
HST E04 MOTOR   Electrical
system
EPC
HST
DXK2KA
Right HST motor EPC solenoid
valve
Open HST E02 MOTOR   Electrical
system
EPC
HST
DXK2KB
valve
Short circuit HST E02 MOTOR   Electrical
system
EPC
HST
DXK2KY
valve
line
HST E04 MOTOR   Electrical
system
EPC
H Error codes:
The error code table is written in alphabetical order and also starting from small number.
The error code in parentheses is not recorded in the failure history for both electrical system and mechanical system.
H Applicable equipment:
Applicable equipment indicates in which controller system the failure has occurred.
MON: Monitor panel system
ENG: Engine controller system
HST: HST controller system
H Error codes:
Error codes indicate what is displayed in the operator mode when a failure is detected.
H History classification:
History classification indicates in which system, either electrical system or mechanical system in the failure history
display function, a failure has been recorded.
40-212  D51EX/PX-22
12
MEMORANDUM
D51EX/PX-22 40-213 
TROUBLESHOOTING INFORMATION IN TROUBLESHOOTING TABLE
12
INFORMATION IN TROUBLESHOOTING TABLE

Display on Trouble Trouble in machine
Display on panel
panel
Contents of
• Condition at the time when the monitor panel or controller detects the trouble
trouble
Action of • The action taken by the monitor panel or controller to protect the system or devices when the monitor panel or controller
controller detects the trouble
Problem that
appears on • The problem that appears on the machine as a result of the action taken by the monitor panel or controller (shown above)
machine
Related
• Information related to the detected trouble or troubleshooting
information
<Contents of description>
1 • Standard value in normal state to judge possible causes

• Disconnection
• Grounding fault
2 Wiring harness which is not connected to chassis ground circuit is in contact with chassis
ground circuit.
Possible causes and standard

Wiring harness which is not connected to power source (24 V) circuit is in contact with power
source (24 V) circuit.
Possible causes of trouble • Short circuit
(Given numbers are Independent wiring harnesses are in contact with each other abnormally.
3
reference numbers, which do not
indicate priority) <Precautions for troubleshooting>
1. Method of indicating connector No. and handling of T-adapter

Insert or connect T-adapter as explained below for troubleshooting, unless otherwise specified.
• If connector No. has no marks of “male” and “female”, disconnect connector and insert T-adapters
4 in both male side and female side.
• If connector No. has marks of “male” and “female”, disconnect connector and connect T-adapter to
only male side or female side.
2. Entry order of pin Nos. and handling of circuit tester leads

Connect positive (+) lead and negative (–) lead of circuit tester as explained below for troubleshoot-
ing, unless otherwise specified.
5 • Connect positive (+) lead to pin No. or harness entered on front side.
40-214  D51EX/PX-22
This is the excerpted circuit diagram related to troubleshooting.

•Connector No.: Indicates (model – number of pins) (color)
•Arrow (): Indicates the approximate mounting place on machine
D51EX/PX-22 40-215 
TROUBLESHOOTING ERROR CODE [6091NX]
12
ERROR CODE [6091NX]
HST CHARGE FILTER ELEMENT CLOGGING
Action code Error code HST charge filter element: Clogging

Trouble
– 6091NX (Mechanical system)
Contents of • When the HST oil temperature reached 50°C or above, the HST charge filter clogging switch was
trouble activated.
• Flashes the HST Charge Filter clogging caution lamp.
Action of
• Flashes the warning lamp and sounds the alarm buzzer.
controller
• If cause of the error disappears, the system resets itself.
Problem that
appears on • If machine is operated as it is, hydraulic components may be damaged.
machine
• Input state from the HST charge filter clogging switch (ON and OFF) can be checked with the monitoring mode.
Related
(Controller: HST, Code: 40910 D-IN [3])
information
• Method of reproducing error code: Start engine and increase the HST oil temperature to 50°C (122°F) or above.

Possibly clogging of the HST charge filter has been detected at present or in the past. It
Possible causes Clogging of HST charge filter (When
1 is, therefore, required investigate the cause and check damages and then repair or replace
and standard system is normal)
damaged parts.
value in normal
state Defective HST charge filter clogging
Carry out troubleshooting of HST charge filter clogging caution lamp system in E-mode
2 caution lamp
“Emergency warning items flash while engine is running.”
system
40-216  D51EX/PX-22
TROUBLESHOOTING ERROR CODE [6091NX]
12
MEMORANDUM
D51EX/PX-22 40-217 
TROUBLESHOOTING ERROR CODE [AA10NX]
12
ERROR CODE [AA10NX]
AIR CLEANER CLOGGING
Action code Error code Air cleaner: Clogging

Trouble
– AA10NX (Mechanical system)
Contents of
• Clogging of air cleaner was detected.
trouble
Action of
• Flashes the air cleaner clogging caution lamp.
controller
Problem that
appears on • If machine is operated as it is, the engine output may drop or the engine may be damaged.
machine
• Input state from the air cleaner clogging switch (ON and OFF) can be checked with the monitoring mode.
(Controller: MONITOR PANEL, Code: 40921 D-IN [6])
Related • If the air cleaner clogging monitor of the monitor panel lights up while engine stopped, air cleaner system may be defective.
information Carry out troubleshooting for Cause 2, 3 and 4 items.
• If the air cleaner clogging monitor of the monitor panel light up while engine running. Air cleaner may be clogging. Carry out
trouble shooting for Cause 1 item.

Clogging of the air cleaner (When
1 Check the air cleaner for clogging and then clean or replace it if clogged.
system is normal)
H Prepare with starting switch OFF, then start engine and carry out troubleshooting.
Defective air cleaner CN-116 (male) Air cleaner Resistance
2 clogging switch
(Internal disconnection) Value in normal state Max. 1 
Between (1) and (2)
Value when clogged Min. 1 M
Possible causes
and standard
Disconnection in wiring
value in normal Wiring harness between CN-S03 (female) (13) – CN-116
harness (Disconnection or Resistance Max. 1
state 3 (female) (1)
defective contact in
connector) Wiring harness between CN-116 (female) (2) and chassis
Resistance Max. 1 
ground
H Prepare with starting switch OFF, then carry out troubleshooting
without turning starting switch.
4 Defective monitor panel CN-S03 Air cleaner Voltage
Between (13) and chassis Value in normal state Max. 1 V

ground Value when clogged Min. 7 V
40-218  D51EX/PX-22
TROUBLESHOOTING ERROR CODE [AA10NX]
Circuit diagram related to clogged air cleaner
D51EX/PX-22 40-219 
TROUBLESHOOTING ERROR CODE [AB00MA]
12
ERROR CODE [AB00MA]
ALTERNATOR MALFUNCTION
Action code Error code Alternator: Malfunction

Trouble
– AB00MA (Mechanical system)
Contents of
• Battery charge caution was detected while the engine is running.
trouble
• Flashes the Battery charge caution lamp.
Action of
• Flashes the warning lamp.
controller
• If cause of error disappears, system resets itself.
Problem that
appears on • If machine is operated as it is, battery charging may be insufficient.
machine
• Power generation state of alternator (voltage) can be checked with the monitoring mode
Related
(Controller: MONITOR PANEL, Code: 04303 R SIGNAL).
information
• Method of reproducing error code: Start engine.

Possible causes Possibly insufficient battery charging has been detected at present or in
Insufficient battery charging
and standard 1 the past. It is, therefore, required to investigate the cause and check damages and then
(When system is normal)
value in normal repair or replace damaged parts.
state Defective battery charge Carry out troubleshooting for E-mode “Charge level caution flashes
2
caution lamp system while engine is running.”
40-220  D51EX/PX-22
TROUBLESHOOTING ERROR CODE [B@BAZG]
12
ERROR CODE [B@BAZG]
ENGINE OIL LOWERING OF OIL PRESSURE
Action code Error code Engine oil: Lowering of oil pressure

Trouble
– B@BAZG (Mechanical system)
Contents of
• Engine oil pressure low caution was detected while engine is running.
trouble
• Flashes the Engine oil pressure low caution lamp.
Action of
controller
• Limits output for travel (Limit injection rate and engine speed)
Problem that
• Engine output lowers.
appears on
• If machine is operated as it is, engine may be damaged.
machine
Related
information

Possible causes Possibly low engine oil pressure has been detected at present or in the past. It is,
Lowering of engine oil
and standard 1 therefore, required to investigate the cause and check
pressure
value in normal damages and then repair or replace damaged parts.
state Defective engine oil pressure If cause 1 is not detected, engine oil pressure switch system may be defective. Carry out
2
switch system troubleshooting for error code [CA435].
D51EX/PX-22 40-221 
TROUBLESHOOTING ERROR CODE [B@BAZG]
12
ERROR CODE [B@BCNS]
COOLANT OVERHEAT
Action code Error code Coolant: Overheat

Trouble
– B@BCNS (Mechanical system)
Contents of
trouble
Action of
controller
Problem that
• Engine output lowers.
appears on
• If machine is operated as it is, engine may be damaged.
machine
• Input state from the engine coolant temperature sensor (coolant temperature, sensor voltage) can be checked with the monitoring
Related
mode. (Controller: ENGINE, Code: 04107 COOLANT TEMP and code: 04105 COOLANT TEMP)
information

Possible causes
Engine coolant overheat
and standard 1 Engine coolant may be overheating. Check it and remove cause if it is overheating.
value in normal
state Defective engine coolant If cause 1 is not detected, the engine coolant sensor system may be defective. Carry out
2
temperature sensor system troubleshooting for error codes [CA144] and [CA145].
40-222  D51EX/PX-22
TROUBLESHOOTING ERROR CODE [B@CRNS]
12
ERROR CODE [B@CRNS]
HST OIL OVERHEATING
Action code Error code HST oil: Overheating

Trouble
– B@CRNS (Mechanical system)
Contents of
• The HST oil temperature caution was indicated while the engine was running.
trouble
• Flashes the HST oil temperature caution lamp.
Action of
controller
Problem that
appears on • If machine is operated as it is, HST hydraulic equipment or hydraulic equipment on the work equipment may be damaged.
machine
• Input state from the HST oil temperature sensor (oil temperature, oil temperature sensor voltage) can be checked with the moni-
Related
toring mode. (Code: 04401 HST TEMP and code: 04402 HST TEMP)
information

Possible causes Overheat of HST oil (When system Possibly overheat of HST oil has been detected at present or in the past. It is, therefore,
1
and standard is normal) required to investigate the cause and check damages and then repair or replace it.
value in normal
Defective HST oil
state Carry out troubleshooting for HST oil temperature caution lamp system in E-mode “Emer-
2 temperature caution lamp
gency warning items flash while engine is running.”
system
D51EX/PX-22 40-223 
TROUBLESHOOTING ERROR CODE [B@CRZG]
12
ERROR CODE [B@CRZG]
HST OIL LOWERING OF OIL PRESSURE
Action code Error code HST oil: Lowering of oil pressure

Trouble
– B@CRZG (Mechanical system)
Contents of trouble • When parking brake was released while the engine was running, brake pressure (charge pressure) lowered.
• Flashes the HST charge pressure caution lamp.
Action of
• Blinks the warning lamp and sounds the alarm buzzer.
controller
Problem that
appears on • If machine is operated as it is, HST hydraulic equipment or hydraulic equipment on the work equipment may be damaged.
machine
• Input state (oil pressure, voltage) from the brake pressure sensor can be checked with the
Related
monitoring mode. (Controller: HST, CODE: 91902 BRAKE PRESS, CODE: 91903 BRAKE PRESS)
information
• Method of reproducing error code: Start engine, operate parking brake lever (Free) and operate brake pedal (release)

Possibly low HST charge pressure has been detected at present or in the past. It is,
Possible causes HST charge pressure low
1 therefore, required to investigate the cause and check damages and then repair or replace
and standard (When system is normal)
it.
value in normal
state Defective HST oil
Carry out troubleshooting for HST charge pressure caution lamp system in E-mode
2 temperature caution lamp
“Emergency warning items flash while engine is running.”
system
40-224  D51EX/PX-22
TROUBLESHOOTING ERROR CODE [CA111]
12
ERROR CODE [CA111]
ABNORMALITY IN ENGINE CONTROLLER
Action code Error code Engine controller: Abnormality in controller

Trouble
CALL E04 CA111 (Engine controller system)
Failure content • An abnormality occurs in internal memory or internal power supply circuit.
Controllers action • No particular action
Symptoms that
• Engine does not start
appears on machine
General information •
Possible causes Cause Standard value in normal state/Remarks on troubleshooting

and standard
value in normal 1 Defective engine controller Internal defect of engine controller is suspected. (It cannot be diagnosed.)
state
D51EX/PX-22 40-225 
12
ERROR CODE [CA115]
ABNORMALITY IN NE AND BKUP SPEED SENSOR SIGNAL
Action code Error code Abnormal engine Ne and Bkup speed sensors: Abnormal speed
Trouble
CALL E04 CA115 sensor signal (Engine controller system)
Failure content • An abnormality occurs in both signals of engine Ne speed sensor and engine Bkup speed sensor.
Controllers action • Takes no particular action
Symptoms that • Engine stops
appears on machine • Engine will not start
General information • Duplication of failure code: Start the engine.
Possible causes Cause Standard value in normal state/Remarks on troubleshooting

and standard
value in normal Defective connection of sensor The defective (wrong) connections of engine Ne and Bkup speed
1
state connector sensor connectors are suspected. Visually check it.
40-226  D51EX/PX-22
12
MEMORANDUM
D51EX/PX-22 40-227 
12
ERROR CODE [CA122]
CHARGE PRESSURE SENSOR TOO HIGH
Action code Error code Charge pressure sensor too high: excessively high voltage detected
Trouble (Engine controller system)
CALL E03 CA122
Contents of
• Excessively high voltage is detected at pressure signal circuit of boost pressure and temperature sensor.
trouble
Action of
• Operates with a fixed charge pressure.
controller
Problem that
appears on • Engine output is reduced.
machine
• The signal voltage of boost pressure and temperature sensor on boost pressure side can be checked in monitoring function.
Related
(Code: 36501 Boost pressure sensor voltage)
information
• Duplication of failure code: turn ON the starting switch.

Defective sensor power source 2 If failure code [CA227] is displayed at the same time, carry out troubleshooting for that
1
system in advance.
H Prepare with starting switch OFF, then start troubleshooting with starting switch
ON.
Defective boost pressure and C7 Voltage
2 temperature sensor [pressure signal Between (2) - (1) Power source 4.75 - 5.25V
circuit]
Since voltage is measured with the harness connected, further diagnose the harness and
the controller if the voltage is not normal, and then make judgment after it is determined
that there is no other defective cause.
Hot short of harness (a contact with 5 ON.
3
V circuit or 24 V circuit) Between ground and wiring harness between
Possible causes and Voltage Max. 1 V
C1 (female) (44) – C7 (female) (4)
standard value in
normal state H Prepare with starting switch OFF, then start troubleshooting with starting switch
OFF.
4 Harness short (Harness internal short) Wiring harness between C1(female) (44) – C7 (female) (4)
Min.
and wiring harness among C1(female) (37) – S10 – C7 Resistance
100 k 
(female) (2)
The connections among boost pressure and temperature sensor – engine harness – engine
controller are suspected to be defective.
Visually check it.
5 Defective wiring harness connector
• Connector is loose, lock is broken, seal is broken
• Pin is corroded, bent, broken, pushed in, expanded.
• Moisture in connector, entry of dirt or sand, etc., and insufficient insulation
ON.
6 Defective engine controller
C1 Voltage
Between (37) - (47) Power source 4.75 - 5.25V
40-228  D51EX/PX-22
12
Circuit diagram related to charge pressure sensor
D51EX/PX-22 40-229 
12
ERROR CODE [CA123]
CHARGE PRESSURE SENSOR TOO LOW
Action code Error code Charge pressure sensor too low: excessively low voltage detected
CALL E03 CA123
Contents of
• Excessively low voltage is detected at pressure signal circuit of boost pressure and temperature sensor.
trouble
Action of
controller
Problem that
machine
• The signal voltage of boost pressure and temperature sensor on boost pressure side can be checked in monitoring function.
Related
(Code: 36501 Boost pressure sensor voltage)
information

1
system in advance.
ON.
Defective boost pressure and C7 Voltage
2 temperature sensor [pressure signal Between (2) - (1) Power source 4.75 - 5.25V
circuit]
Defective harness grounding OFF.
3
(Contact with ground circuit) Between ground and wiring harness between Min.
Possible causes and Resistance
C1 (female) (44) – C7 (female) (4) 100 k 
standard value in
OFF.
4 Harness short (Harness internal short) Wiring harness between C1(female) (44) – C7 (female) (4)
Min.
and wiring harness among C1(female) (47) – S11 – C7 Resistance
100 k 
(female) (1)
Visually check it.
ON.
C1 Voltage
40-230  D51EX/PX-22
12
D51EX/PX-22 40-231 
12
ERROR CODE [CA131]
DECELERATOR PEDAL SENSOR TOO HIGH
Action code Error code Decelerator pedal sensor too high: Excessively high voltage detected (Engine controller
Trouble
CALL E03 CA131 system)
Contents of
• Excessively high voltage is detected at signal circuit of decelerator pedal.
trouble
• Operates with the fixed value that is same as the value just before the abnormality is detected, if abnormality occurs with the
Action of
starting switch in the ON position.
controller
• If the starting switch is turned to the ON position in the same abnormal condition, the controller operates with 100% value.
Problem that
appears on • Engine speed cannot be controlled by decelerator pedal.
machine
Related • The signal voltage of decelerator pedal can be checked in monitoring mode. (Code: 31703 Decelerator voltage)
information • Duplication of failure code: turn ON the starting switch.

Defective throttle sensor power If failure code [CA2185] is displayed at the same time, carry out troubleshooting for that
1
supply circuit first.
ON.
DP1 Voltage
2 Defective decelerator pedal Between (B - (C) Power source 4.75 - 5.25V
3
V circuit or 24 V circuit) Between ground and wiring harness between 11S
Possible causes and Voltage Max. 1V
(female) (9) – DP1 (female) (A)
standard value in
OFF.
4 Harness short (Harness internal short) Wiring harness between 11S (female) (9) – OP1 (female)
Min.
(A) and wiring harness between 11S (female) (22) – OP1 Resistance
100 k 
(female) (B)
Visually check it.
ON.
11S Voltage
40-232  D51EX/PX-22
12
Circuit diagram related to decelerator pedal sensor
D51EX/PX-22 40-233 
12
ERROR CODE [CA132]
DECELERATOR PEDAL SENSOR TOO LOW
Action code Error code Decelerator pedal sensor too low: Excessively low voltage detected (Engine controller
Trouble
CALL E03 CA132 system)
Contents of
• Excessively low voltage is detected at signal circuit of decelerator pedal.
trouble
Action of
controller
Problem that
appears on • Engine speed cannot be controlled by decelerator pedal.
machine
Related • The signal voltage of decelerator pedal can be checked in monitoring mode. (Code: 31703 Decelerator voltage)
information • Duplication of failure code: turn ON the starting switch.

Defective throttle sensor power If failure code [CA2185] is displayed at the same time, carry out troubleshooting for that
1
supply circuit first.
ON.
DP1 Voltage
2 Defective decelerator pedal Between (B - (C) Power source 4.75 - 5.25V
3
(Contact with ground circuit) Between ground and wiring harness between 11S Min.
Resistance
Possible causes and (female) (9) – DP1 (female) (A) 100 k 
standard value in
OFF.
4 Harness short (Harness internal short) Wiring harness between 11S (female) (9) – OP1 (female)
Min.
(A) and wiring harness between 11S (female) (22) – OP1 Resistance
100 k 
(female) (B)
Visually check it.
ON.
11S Voltage
40-234  D51EX/PX-22
12
Circuit diagram related to decelerator pedal sensor
D51EX/PX-22 40-235 
12
ERROR CODE [CA144]
COOLANT TEMPERATURE SENSOR TOO HIGH
Action code Error code Coolant temperature sensor too high: Excessively high voltage detected
Trouble
Contents of
• Excessively high voltage is detected at signal circuit of engine coolant temperature sensor.
trouble
Action of
• Operates with a fixed engine coolant temperature.
controller
Problem that
• Exhaust gas color becomes white.
appears on
• Overheat prevention function does not work.
machine
• The signal voltage of engine coolant sensor can be checked in monitoring mode.
Related
(Code: 04105 Engine coolant sensor voltage)
information

Defective engine coolant temperature OFF.
1
sensor C14 Resistance
Between (1) - (2) 0.18 - 160 k
OFF.
Disconnection in wiring harness
Wiring harness between C1 (female) (15) - C14 (female)
2 (Disconnection or poor Resistance Max. 10
(2)
connector contact)
Wiring harness among C1 (female) (38) - S13 - C14
Resistance Max. 10
(female) (1)
Possible causes and OFF.
standard value in 3 Harness short (Harness internal short)
Between CE01 (female) (15) – CE01 (female) all pins
normal state Resistance Max. 100
(With all connectors in the harness disconnected)
Visually check it.
OFF.
Defect in other locations than engine
5
controller C1 (female) Resistance
Between (15) - (38) 0.18 - 160 k
Engine controller is possibly defective if no problem is found in causes 1 – 5. (Internal
failure which cannot be diagnosed)
40-236  D51EX/PX-22
12
Circuit diagram related to coolant temperature sensor
D51EX/PX-22 40-237 
12
ERROR CODE [CA145]
COOLANT TEMPERATURE SENSOR TOO LOW
Action code Error code Coolant temperature sensor too low: Excessively low voltage detected
Trouble
Contents of
• Excessively low voltage is detected at signal circuit of engine coolant temperature sensor.
trouble
Action of
• Operates with a fixed engine coolant temperature.
controller
Problem that
appears on
• Overheat prevention function does not work.
machine
• The signal voltage of engine coolant sensor can be checked in monitoring mode.
Related
(Code: 04105 Engine coolant sensor voltage)
information

Defective engine coolant temperature OFF.
1
sensor C14 Resistance
Between (1) - (2) 0.18 - 160 k
2
(Contact with ground circuit) Between ground and wiring harness between C1 (female)
(15) – C14 (female) (2)
OFF.
3 Harness short (Harness internal short)
Between CE01 (female) (15) – CE01 (female) all pins
Possible causes and Resistance Max. 100
(With all connectors in the harness disconnected)
standard value in
normal state The connections among boost pressure and temperature sensor – engine harness – engine
Visually check it.
OFF.
Defect in other locations than engine C1 (female) Resistance
5
controller
Between (15) - (38) 0.18 - 160 k
Between (15) - chassis ground Min. 100 k
40-238  D51EX/PX-22
12
Circuit diagram related to coolant temperature sensor
D51EX/PX-22 40-239 
12
ERROR CODE [CA153]
CHARGE TEMPERATURE SENSOR TOO HIGH
Action code Error code Charge temperature sensor too high: Excessively high voltage detected
CALL E01 CA153
Contents of
• Excessively high voltage is detected at temperature signal circuit of boost pressure and temperature sensor.
trouble
Action of
controller
Problem that
appears on
• Engine protection function by boost temperature does not work.
machine
• The signal voltage of boost pressure and temperature sensor on boost temperature side can be checked in monitoring function.
Related
(Code: 18501 Boost temperature sensor voltage)
information

Defective boost pressure and OFF.
1 temperature sensor [temperature
C7 (male) Resistance
signal circuit]
Between (3) - (1) 0.18 - 160 k
OFF.
Wiring harness between C1 (female) (23) – C7 (female)
2 (Disconnection or poor connector Resistance Max. 10
(3)
contact)
Wiring harness among C1 (female) (47) – S11 – C7
(female) (4)
Possible causes and OFF.
standard value in 3 Harness short (Harness internal short)
Between C1 (female) (23) – C1 (female) all pins (With all
normal state Resistance Max. 100
connectors in the harness disconnected)
Visually check it.
OFF.
5
Between (15) - (38) 0.18 - 160 k
40-240  D51EX/PX-22
12
Circuit diagram related to charge temperature sensor
D51EX/PX-22 40-241 
12
ERROR CODE [CA154]
CHARGE TEMPERATURE SENSOR TOO low
Action code Error code Charge temperature sensor too low: Excessively low voltage detected
CALL E01 CA154
Contents of
• Excessively high voltage is detected at temperature signal circuit of boost pressure and temperature sensor.
trouble
Action of
controller
Problem that
appears on
• Engine protection function by boost temperature does not work.
machine
• The signal voltage of boost pressure and temperature sensor on boost temperature side can be checked in monitoring function.
Related
(Code: 18501 Boost temperature sensor voltage)
information

OFF.
Defective boost pressure and
1 temperature sensor [temperature C7 (male) Resistance
signal circuit] Between (3) - (1) 0.18 - 160 k
2
(23) – C7 (female) (3)
OFF.
3 Harness short (Harness internal short)
Possible causes and Between C1 (female) (23) – C1 (female) all pins (With all
standard value in Resistance Max. 100
connectors in the harness disconnected)
normal state
Visually check it.
OFF.
5
controller
Between (15) - (38) 0.18 - 160 k
40-242  D51EX/PX-22
12
D51EX/PX-22 40-243 
12
ERROR CODE [CA187]
SENSOR POWER SORCE EXCESSIVELY LOW
Action code Error code Sensor power source 2 too low: Excessively low voltage detected
CALL E03 CA187
Contents of
• Excessively low voltage has been detected at sensor power source 2 circuit.
trouble
• Operates with a fixed boost pressure.
Action of
• Operates with fixed charge temperature.
controller
• Runs by limiting output.
Problem that
machine
Related
information

H Disconnect connectors with starting switch OFF, then turn it ON for troubleshooting.
Disconnect the devices on the Boost pressure and
C7
right one at a time and try to temperature sensor
1 Defective sensor or harness duplicate the problem. If the
Common rail pressure sensor C6
failure code changes from
flashing to continuously Bkup sensor C11
Possible causes and illuminating, that device or Engine harness
standard value in C1
harness is defective.
normal state
The connections among each sensor ñ engine harness - engine controller are suspected to be
defective.
2 Defective harness connector • Connector is loose, lock is broken, seal is broken
Engine controller is possibly defective if no problem is found in causes 1 - 2. (Internal

40-244  D51EX/PX-22
12
Circuit diagram related to sensor power source
D51EX/PX-22 40-245 
12
ERROR CODE [CA221]
ATMOSPHERIC PRESSURE SENSOR TOO HIGH
Action code Error code Atmospheric pressure sensor too high: Excessively high voltage detected (Engine con-
Trouble troller system)
CALL E03 CA221
Contents of
• Excessively high voltage is detected at signal circuit of atmospheric pressure sensor.
trouble
Action of
• Operates with a fixed atmospheric pressure.
controller
Problem that
• Start ability gets worse.
appears on
• Engine output is reduced.
machine
• The signal voltage of the atmospheric pressure sensor can be checked in monitoring mode. (Code: 37401 Atmospheric pressure
Related
sensor voltage)
information

1
system first.
ON.
C10 Voltage
2 Defective atmospheric pressure sensor Between (1) - (2) Power source 4.75 - 5.25 V
3
V circuit or 24 V circuit) Between ground and wiring harness between C1 (female)
Possible causes and Voltage Max. 1 V
standard value in (3) - C10 (female) (3)
OFF.
4 Harness short (Harness internal short) Wiring harness between C1 (female) (3) – C10 (female)
Min.
(3) and wiring harness between C1 (female) (33) – C10 Resistance
100 k 
(female) (1)
The connections among atmospheric pressure sensor ñ engine harness - engine controller
are suspected to be defective. Visually check it.
5 Defective wiring harness connector • Connector is loose, lock is broken, seal is broken
ON.
C1 Voltage
Between (33) - (38) Power source 4.75 - 5.25 V
40-246  D51EX/PX-22
12
Circuit diagram related to pressure sensor
D51EX/PX-22 40-247 
12
ERROR CODE [CA222]
ATMOSPHERIC PRESSURE SENSOR TOO LOW
Action code Error code Atmospheric pressure sensor too low: Excessively low voltage
Trouble
CALL E03 CA222 detected (Engine controller system)
Contents of
• Excessively low voltage is detected at signal circuit of atmospheric pressure sensor.
trouble
Action of
controller
Problem that
• Start ability gets worse.
appears on
machine
• The signal voltage of the atmospheric pressure sensor can be checked in monitoring mode. (Code: 37401 Atmospheric pressure
Related
sensor voltage)
information

1
system first.
ON.
C10 Voltage
2 Defective atmospheric pressure sensor Between (1) - (2) Power source 4.75 - 5.25V
Defective harness grounding (Contact OFF.
3
with ground circuit) Between ground and wiring harness between C1 Min.
Resistance
Possible causes and (female) (3) – C10 (female) (3) 100 k 
standard value in
OFF.
Min.
(3) and wiring harness between C1 (female) (38) – C10 Resistance
100 k 
(female) (2)
Visually check it.
ON.
C1 Voltage
40-248  D51EX/PX-22
12
Circuit diagram related to pressure sensor
D51EX/PX-22 40-249 
12
ERROR CODE [CA227]
SENSOR POWER SORCE EXCESSIVELY HIGH
Action code Error code Sensor power source too high: Excessively high voltage detected
CALL E03 CA227
Contents of
• Excessively high voltage has been detected at sensor power source 2 circuit.
trouble
• Operates with a fixed boost pressure.
Action of
• Operates with fixed charge temperature.
controller
• Runs by limiting output.
Problem that
machine
Related
information
defective.
Possible causes and
standard value in
normal state
Engine controller is possibly defective if no problem is found in causes 1. (Internal
40-250  D51EX/PX-22
12
Circuit diagram related to sensor power
D51EX/PX-22 40-251 
12
ERROR CODE [CA234]
ENGINE OVERSPEED

Trouble Engine over speed: Excessively high speed (Engine controller system)
E00 CA234
Contents of trouble • The engine speed exceeds upper control limit speed.
Action of
• Stops operation of injector until the engine speed drops to the normal speed.
controller
Problem that appears
• Engine speed fluctuates.
on machine
Related • The engine speed can be checked in monitoring function. (Code: 01000 Engine speed)
information • Duplication of failure code: Start engine and operate at high idle.
Possible causes and 1 Improper fuel has been used. The use of improper fuel is suspected. Visually check it.
standard value in 2 Improper usage The improper usage of equipped machine is suspected. Instruct the proper usage.
normal state
40-252  D51EX/PX-22
12
ERROR CODE [CA238]
ABNORMAL POWER SOURCE FOR NE SPEED SENSOR
Action code Error code Abnormal power source for Ne speed sensor: Excessively low voltage detected
Trouble
Contents of
• Excessively low voltage is detected at power source circuit of engine Ne speed sensor.
trouble
Action of
• Continues the control by engine Bakup speed sensor signal.
controller
Problem that
• Engine is hard to start.
appears on
• Engine is hunting.
machine
Related
information

H Prepare with starting switch OFF, then turn it ON for troubleshooting.
Disconnect the devices on the
right one at a time and try to Ne speed sensor C12
Possible causes and
flashing to continuously
standard value in Engine harness C1
illuminating, that device or
normal state
harness is defective.
defective.
Circuit diagram related Ne speed sensor
D51EX/PX-22 40-253 
12
ERROR CODE [CA271]
IMV/PCV1 SHORT CIRCUITED

Trouble
CALL E03 CA271 IMV/PCV1 short circuit: Short circuit (Engine controller system)
Contents of
• Short circuit has been detected at drive circuit of supply pump actuator.
trouble
Action of
• No particular action
controller
Problem that • Engine speed does not increase from low idle.
machine • Fuel pressure of common rail increases above command value.
Related
information

OFF.
1 Defective supply pump actuator
2
Resistance Min. 100 k
(2) – C9 (female) (1)
Harness short OFF.
Possible causes and 3
(Harness internal short) Between C1 (female) (2) - C1 (female) all pins (With all
standard value in Resistance Min. 100 k
normal state connectors in the harness disconnected)
The connections among inlet metering valve ñ engine harness - engine controller are
suspected to be defective. Visually check it.
Defect in other locations than engine OFF.
5
40-254  D51EX/PX-22
12
Circuit diagram related to IMV/PCV1
D51EX/PX-22 40-255 
12
ERROR CODE [CA272]
IMV/PCV1 OPEN

Trouble
CALL E03 CA272 IMV/PCV1 open: Open (Engine controller system)
Contents of
• An open has been detected at drive circuit of supply pump actuator.
trouble
Action of
controller
Problem that • Engine runs, but it does not stabilize.
appears on
• Fuel pressure of common rail increases above commanded value.
machine
Related
information

OFF.
Between (1) - (2) Max. 5
OFF.
Disconnection in wiring harness (Dis-
2 connection or poor connector Wiring harness between C1 (female) (2) – C9 (female) (1) Resistance Max 10 
contact)
Wiring harness between C1 (female) (32) – C9 (female)
Resistance Max 10 
(2)
3
V circuit) Between ground and wiring harness between C1 (female)
Voltage Max. 3 V
Possible causes and (2) – C9 (female) (1)
standard value in H Prepare with starting switch OFF, then start troubleshooting with starting switch
normal state OFF.
4 Hot short (Harness internal short)
Between CE01 (female) (2) - CE01 (female) all pins (With Resistance Min. 100 k
all connectors in the harness disconnected)
The connections among inlet metering valve - engine harness - engine controller are
suspected to be defective. Visually check it.
OFF.
6
Between (2) - (32) Min. 5 
40-256  D51EX/PX-22
12
Circuit diagram related to IMV/PCV1
D51EX/PX-22 40-257 
12
ERROR CODE [CA322]
NO.1 INJECTOR SHOWING OPEN OR SHORT

Trouble Injector No. 1 system disconnection or short circuit: disconnection, short circuit
Contents of
• A disconnection or short circuit has been detected in No. 1 injector drive circuit.
trouble
Action of
controller
Problem that
• Poor combustions or hunting occurs.
appears on
machine
Related
• Duplication of failure code: start the engine.
information

If the following failure codes are displayed at the same time, engine controller is
internally defective: ([CA322] [CA324] [CA331])
H Prepare with starting switch OFF and diagnose with starting switch still OFF.
2 Defective No. 1 injector
Between (3) - (4) Max. 2 
Between (3) - chassis ground Min 100 k
Disconnection in wiring harness Wiring harness between C1 (female) (45) - C3 (3) - No. 1
3 (Disconnection or defective contact of injector (1)
connectors)
Wiring harness between C1 (female) (53) - C3 (4) - No. 1
injector (2)
Defective harness grounding (Contact
4 Between ground and wiring harness between C1 (female)
with ground circuit) Resistance Min. 100 k
Possible causes and (45) - C3 (3) - No. 1 injector (1)
standard value in H Prepare with starting switch OFF and diagnose with starting switch still OFF.
normal state
Between C1 (female) (45) - C1 (female) all pins (All con-
5 Harness short (Harness internal short) nectors in the harness disconnected)
nectors in the harness disconnected)
Since the problem is possibly at the connections between No. 1 injector - engine harness
- engine controller, check for a defective connection.

7
controller Between (45) - (53) Max 2 
Engine controller is possibly defective if no problem is found in causes 1-7.
(Since this is an internal defect, it cannot be diagnosed.)
40-258  D51EX/PX-22
12
Circuit diagram related to injector No. 1
D51EX/PX-22 40-259 
12
ERROR CODE [CA323]

Contents of
trouble
Action of
controller
Problem that
appears on
machine
Related
information

Between (3) - (4) Max. 2 
connectors)
injector (2)
normal state
5 Harness short (Harness internal short) nectors in the harness disconnected)
nectors in the harness disconnected)

7
40-260  D51EX/PX-22
12
D51EX/PX-22 40-261 
12
ERROR CODE [CA324]

Contents of
trouble
Action of
controller
Problem that
appears on
machine
Related
information

Between (3) - (4) Max. 2 
connectors)
injector (2)
normal state
Between C1 (female) (55) - C1 (female) all pins
5 Harness short (Harness internal short) (All connectors in the harness disconnected)
(All connectors in the harness disconnected)

7
40-262  D51EX/PX-22
12
D51EX/PX-22 40-263 
12
ERROR CODE [CA325]

Contents of
trouble
Action of
controller
Problem that
appears on
machine
Related
information

Between (2) - (1) Max. 2 
Disconnection in wiring harness Wiring harness between C1 (female) (57) - C5 2) - No. 6
connectors)
injector (2)
normal state

7
40-264  D51EX/PX-22
12
D51EX/PX-22 40-265 
12
ERROR CODE [CA331]

Contents of
trouble
Action of
controller
Problem that
appears on
machine
Related
information

Between (2) - (1) Max. 2 
connectors)
injector (2)
normal state

7
40-266  D51EX/PX-22
12
D51EX/PX-22 40-267 
12
ERROR CODE [CA332]

Contents of
trouble
Action of
controller
Problem that
appears on
machine
Related
information

Between (2) - (1) Max. 2 
connectors)
injector (2)
normal state

7
40-268  D51EX/PX-22
12
D51EX/PX-22 40-269 
12
ERROR CODE [CA342]
ENGINE CONTROLLER DATA MATCHING ERROR

Trouble Engine controller data matching error: matching error (Engine controller system)
CALL E04 CA342
Contents of trouble • Data matching error has been detected in engine controller.
Action of
controller
Problem that appears • Normal operation is continued.
on machine • Engine stops or engine does not start.
Related
information

Possible causes and
Check the failure codes that are displayed at the same time. If any other codes are
standard value in 1 Defective related circuits
displayed, carry out troubleshooting for those codes.
normal state
2 Defective engine controller Internal defect of engine controller is suspected. (It cannot be diagnosed.)
40-270  D51EX/PX-22
12
ERROR CODE [CA352]
SENSOR POWER SOURCE TOO LOW
Action code Error code Sensor power source 1 too low: Excessively low voltage detected
Trouble
Contents of
• Excessively low voltage has been detected in sensor power source 1 circuit
trouble
Action of
controller
Problem that
• Start ability of engine deteriorates.
appears on
machine
Related
information

H Prepare with starting switch OFF, then turn it ON for troubleshooting.
Disconnect the devices on the
right one at a time and try to Atmospheric pressure sensor C10
flashing to continuously
Possible causes and illuminating, that device or Engine harness C1
standard value in harness is defective.
normal state
Since the connections among atmospheric pressure sensor - engine harness - engine
controller are suspected to be defective, check for a defective connection.
3 Engine controller is possibly defective if no problem is found in causes 1 – 2. (Since this is
Defective engine controller
an internal defect, it cannot be diagnosed.)
D51EX/PX-22 40-271 
12
ERROR CODE [CA386]
SENSOR POWER SOURCE TOO HIGH
Action code Error code Sensor power source 1 too high: Excessively high voltage detected
Trouble
Contents of
• Excessively high voltage has been detected in sensor power source 1 circuit
trouble
Action of
controller
Problem that
• Start ability of engine deteriorates.
appears on
machine
Related
information

Since the connections among atmospheric pressure sensor - engine harness - engine
controller are suspected to be defective, check for a defective connection.
Possible causes and
standard value in
normal state
2 Engine controller is possibly defective if no problem is found in cause 1. (Since this is an
Defective engine controller
internal defect, it cannot be diagnosed.)
40-272  D51EX/PX-22
12
MEMORANDUM
D51EX/PX-22 40-273 
12
ERROR CODE [CA428]
WATER IN FUEL SENSOR VOLTAGE TOO HIGH
Action code Error code Water detection sensor too high: Excessively high voltage detected
Trouble
E01 CA428 (Engine controller system)
Contents of
• Excessively high voltage has occurred in the fuel water detection sensor signal circuit
trouble
Action of
controller
Problem that
appears on • Water separator monitor does not display normally.
machine
• The signal status of the fuel water detection sensor can be checked with the monitoring function.
Related
(Code: 18800 Fuel filter water level signal)
information
1 Defective fuel water detection sensor 28A (female) Resistance
Between (1) - (2) Max 100 k
Wiring harness between C1 (female) (14) – 28A (male) (1) Resistance Max 10 
2 (Disconnection or defective contact of
connectors) Wiring harness between C1 (female) (47) - S11 - 28A
Resistance Max 10 
(male) (2)
Possible causes and 3 Harness short (Harness internal short) Between C1 (female) (14) - C1 (female) all pins (All con-
standard value in Resistance Min 100 k
normal state nectors in the harness disconnected)
Problem is possibly at the connections between fuel water detection sensor – engine
harness – engine controller, so inspect them directly.
5 C1 (female) Resistance
controller
Between (14) - (47) Max 100 k
Engine controller is possibly defective if no problem is found in causes 1 – 5.
40-274  D51EX/PX-22
12
Circuit diagram related to water in fuel sensor
D51EX/PX-22 40-275 
12
ERROR CODE [CA429]
WATER IN FUEL SENSOR VOLTAGE TOO LOW
Action code Error code Water detection sensor too low: Excessively low voltage detected
Trouble
E01 CA429 (Engine controller system)
Contents of
• Excessively low voltage has occurred in the fuel water detection sensor signal circuit
trouble
Action of
controller
Problem that
appears on • Water separator monitor does not display normally.
machine
• The signal status of the fuel water detection sensor can be checked with the monitoring function.
Related
(Code: 18800 Fuel filter water level signal)
information
28A (female) Resistance
1 Defective fuel water detection sensor
Between (1) - (2) Max 10 
Disconnection in wiring harness H Prepare with starting switch OFF and diagnose with starting switch still OFF.
2 (Disconnection or defective contact of Between ground and wiring harness between C1 (female)
connectors) Resistance Min 100 k
(14) – 28A (male) (1)
Possible causes and 3 Harness short (Harness internal short) Between C1 (female) (14) - C1 (female) all pins (All
Resistance Min 100 k
standard value in connectors in the harness disconnected)
normal state Problem is possibly at the connections between fuel water detection sensor – engine
harness – engine controller, so inspect them directly.

5
40-276  D51EX/PX-22
12
Circuit diagram related to water in fuel sensor
D51EX/PX-22 40-277 
12
ERROR CODE [CA435]
ABNORMAL ENGINE OIL PRESSURE SWITCH

Trouble Abnormal engine oil pressure switch: Abnormal signal circuit (Engine controller system)
E02 CA435
Contents of
• A problem has occurred in the engine oil pressure switch signal circuit
trouble
Action of
controller
Problem that
• Protection function by engine oil pressure does not operate.
appears on
• Engine oil pressure monitor does not display normally.
machine
Related
• Duplication of failure code: turn ON the starting switch or start the engine.
information

1 Defective engine oil switch C13 (male) Resistance
Between (1) - body Max 10 
Disconnection in wiring harness (Dis- H Prepare with starting switch OFF and diagnose with starting switch still OFF.
2 connection or defective contact of Wiring harness between C1 (female) (17) - C13 (female)
connectors) Resistance Max. 10 
(1)
3 Harness short (Harness internal short) Between C1 (female) (17) – C1 (female) all pins (All con-
Possible causes and Resistance Min. 100 k
standard value in nectors in the harness disconnected)
normal state Since the problem is possibly at the connections between engine oil pressure switch –
engine harness – engine controller, check for a defective connection.
5 C1 (female) Resistance
controller
Between (17) - ground Max 10 
40-278  D51EX/PX-22
12
Circuit diagram related to engine oil pressure switch
D51EX/PX-22 40-279 
12
ERROR CODE [CA441]
POWER SOURCE VOLTAGE IS TOO LOW

Trouble Power source voltage too low: Excessively low voltage detected
Contents of
• Excessively low voltage has occurred in the controller power source voltage circuit
trouble
Action of
controller
Problem that
• Engine stops.
appears on
machine
Related
information

1 Loose or corroded battery terminal Battery terminal is possibly loose or corroded, so inspect it directly.
H Prepare with starting switch OFF and diagnose with starting switch OFF and
START.
2 Defective battery voltage Battery (1 unit) Starting switch Voltage
Between (+) - (-) OFF Min. 12V

terminals START Min. 6.2V
3 Defective fuse No. 10 If fuse is blown, it is highly possible that a defective harness grounding, etc. has occurred
in the circuit (refer to cause 5).
4 (Disconnection or defective contact of Wiring harness between F01 (10) - 117 (female) (3) Resistance Max. 10 
connectors) Wiring harness between 117 (female) (3) – T20 Resistance Max. 10 
Possible causes and 5 Between ground and wiring harness between F01 (10) -
with ground circuit) Resistance Max. 100 k
standard value in 117 (female) (3)
normal state
6 Harness short (Harness internal short) Between pins 117 (female) (3) – 117 (female) (1) (Battery
terminals disconnected)
Since the problem is possibly at the connections between FS2 (9) – body harness –
engine controller, check for a defective connection.
H Prepare with starting switch OFF and diagnose with starting switch ON and
START.
Defect in other locations than engine 117 (female) Starting switch Voltage
8
controller
ON Min. 24V
Between (3) - (1)
START Min. 12V
Engine controller is possibly defective if no problem is found in causes 1 8. (Since this is

40-280  D51EX/PX-22
12
Circuit diagram related to power source
D51EX/PX-22 40-281 
12
ERROR CODE [CA442]
POWER SOURCE VOLTAGE TOO HIGH
Action code Error code Power source voltage too high: Excessively high voltage has occurred in the controller
Trouble
CALL E04 CA442 power source circuit (Engine controller system)
Contents of
• Excessively high voltage (36 V or more) has occurred in the controller power source voltage circuit
trouble
Action of
controller
Problem that
appears on • Engine may stop.
machine
Related
information

1 Defective battery voltage Battery Voltage
Between (+) - (-) terminals Max. 32V
Possible causes and H Prepare with starting switch OFF and start the engine to diagnose.
standard value in
2 Defective alternator 2 (male) Engine speed) Voltage
normal state
Between (2) - ground Medium speed or higher 27.5 - 29.5 V
H Prepare with starting switch OFF and diagnose with starting switch ON.
3 Defective engine controller 117 (female) Voltage
Between (3) - (1) Max. 32V
40-282  D51EX/PX-22
12
Circuit diagram related to power source
D51EX/PX-22 40-283 
12
ERROR CODE [CA449]
COMMON RAIL PRESSURE TOO HIGH
Action code Error code Common rail pressure too high (2): Excessively high pressure trouble occurred
CALL E03 CA449
Contents of
• Excessively high pressure trouble (2) has occurred in the common rail circuit.
trouble
Action of
• Operates with limited output.
controller
Problem that
• Engine noise becomes louder at no or light load.
appears on
machine
Related • Common rail pressure can be checked with the monitoring function. (Code: 36400 Common rail pressure)
information • Duplication of failure code: Start the engine.
1 Defective related circuits Check the failure codes that are displayed at the same time. If any other codes are
Air has possibly entered into the low pressure circuit, so inspect directly in the following
procedure:
1. Remove pressure inspection plug (on the outlet port) for the fuel main filter.
2. Operate the feed pump for the fuel pre-filter.

2 Air in the low pressure circuit
3. Inspect the fuel and air leaking from the pressure inspection plug.
• If this error occurs during the air bleeding operation after the fuel filter
replacement, air is possibly remaining in the fuel circuit, so continue to run
the engine at low idle for approximately 3 minutes. When air bleeding is
complete, engine revolutions become stable and the error display disappears.
H Refer to Testing and adjusting “Fuel Pressure Inspection” for fuel low pressure
circuit pressure inspection. Measurement on the outlet side of the fuel filter
Fuel low pressure circuit

At high idle (When engine Min. 4.9 kg/cm2
can be started) (Min. 70 psi)
Possible causes and
standard value in • Measurements on the inlet and outlet sides of the fuel filter
normal state • Fuel low pressure circuit pressure drop = fuel filter inlet pressure - fuel filter outlet
pressure
Defective fuel low pressure circuit Fuel low pressure circuit Max. 1.4 kg/cm2
3 At high idle
devices pressure drop (Max. 20 psi)
H Refer to Testing and adjusting “Fuel Pressure Inspection” for fuel suction pressure
inspection. Measurement on the gear pump fuel inlet side of the supply pump
Fuel suction circuit pressure Max. 33.9 kPa
At high idle
(Gear pump side) (Max. 5 psi)
• Measurement on the fuel connector side
Fuel suction circuit pressure Max. 27.1 kPa
At high idle
(Fuel connector side) (Max. 4 psi)
H Prepare with starting switch ON and diagnose with starting switch ON.
Monitoring code
Defective common rail pressure Monitoring information
4 (Monitor panel)
sensor
36400
When engine is stopped 0 ± 4 kg/cm2
Common rail pressure (0 ± 57 psi)
Defective O-ring for supply pump H Inspect directly if supply pump actuator O-ring is not damaged.
5
actuator
40-284  D51EX/PX-22
12
Monitoring code
Monitoring information
(Monitor panel)
36400
When engine is stopped 0 ± 4 kg/cm2
Common rail pressure (0 ± 57 psi)
6 Defective supply pump actuator H Prepare with starting switch OFF, then start the engine to diagnose. Measure after
idling for at least 1 minute.
Monitoring code
Monitoring information
(Monitor panel)
Possible causes and
standard value in 36400
At low idle 20 kg/cm2
normal state Common rail pressure (284 psi)
Problem is possibly in the common rail fuel pressure sensor connector or supply pump
actuator, so inspect them directly.
Defective engine controller ground
8 117 Resistance
harness
Be-ween (1) - ground Max 10 
9 Defective supply pump H Supply pump is possibly defective if no problem is found in causes 1 – 9.
Circuit diagram related to common rail pressure sensor
D51EX/PX-22 40-285 
12
ERROR CODE [CA451]

Trouble Common rail pressure sensor too high: Excessively high voltage detected (Engine con-
CALL E03 CA451 troller system)
Contents of
• Excessively high voltage has occurred in the common rail pressure sensor signal circuit
trouble
Action of
controller
Problem that
• Engine does not start.
appears on
• Engine speed or output is reduced.
machine
• The signal voltage of the common rail pressure sensor can be checked with the monitoring function. (Code: 36401 Common rail
Related
pressure sensor voltage)
information

Defective sensor power source 2 If failure code [CA227] is displayed at the same time, carry out troubleshooting for it
1
circuit first.
C6 Voltage
Defective common rail pressure Between (3) - (1) Power source 4.75 - 5.25V
2
sensor
Hot short of harness (a contact with 5
Possible causes and V circuit or 24 V circuit) Voltage Max. 1V
(25) - C6 (female) (2)
standard value in
normal state H Prepare with starting switch OFF and diagnose with starting switch still OFF.
(2) and wiring harness between C1 (female) (37) – S10 – Resistance Min. 100 k
C6 (female) (3)
Since the problem is possibly at the connections between common rail pressure sensor –
6 Defective engine controller C1 Voltage
40-286  D51EX/PX-22
12
D51EX/PX-22 40-287 
12
ERROR CODE [CA452]
COMMON RAIL PRESSURE TOO LOW

Trouble Common rail pressure sensor too low: Excessively low voltage detected
Contents of
• Excessively low voltage has occurred in the common rail pressure sensor signal circuit
trouble
Action of
controller
Problem that
• Engine does not start.
appears on
• Engine speed or output is reduced.
machine
• The signal voltage of the common rail pressure sensor can be checked with the monitoring function. (Code: 36401 Common rail
Related
pressure sensor voltage)
information

1
circuit first.
C6 Voltage
Defective common rail pressure Between (3) - (1) Power source 4.75 - 5.25V
2
sensor
Defective harness grounding (Contact H Prepare with starting switch OFF and diagnose with starting switch still OFF.
3 with ground circuit)
Between ground and wiring harness between C1 (female)
Possible causes and Resistance Min. 100 k
(25) – C6 (female) (2)
standard value in
normal state H Prepare with starting switch OFF and diagnose with starting switch still OFF.
(2) and wiring harness between C1 (female) (37) – S10 – Resistance Min. 100 k
C6 (female) (3)
Since the problem is possibly at the connections between common rail pressure sensor –
40-288  D51EX/PX-22
12
D51EX/PX-22 40-289 
12
ERROR CODE [CA488]
CHARGE TEMPERATURE TOO HIGH AND TORQUE DERATED
Action code Error code Charge air temperature too high and torque derated: Exceeded upper control limit of
Trouble
CALL E03 CA488 temperature (Engine controller system)
Contents of
• The temperature signal of boost pressure and temperature sensor exceeds upper control limit temperature.
trouble
Action of
controller
Problem that
appears on • Engine output decreases.
machine
Related • The boost temperature can be checked in monitoring function. (Code: 18500 Boost temperature)

The degradation of after cooler cooling performance is suspected.
Directly check the following points:
Degradation of cooling performance
1 • Fan rotation
Possible causes and of after cooler
• Insufficient cooling air amount
standard value in • Clogging of after cooler fin
normal state
Abnormal rise in turbocharger The abnormal rise in turbocharger outlet temperature is suspected. Directly check the
2
outlet temperature related parts.
Engine controller is possibly defective if no problem is found in causes 1 – 2. (Since this is
40-290  D51EX/PX-22
12
ERROR CODE [CA553]
Action code Error code Common rail pressure high trouble (1): Excessively high pressure trouble occurred (Engine
Trouble
E02 CA553 controller system)
Contents of
• Excessively high pressure trouble (1) has occurred in the common rail circuit.
trouble
Action of
controller
Problem that
• Engine noise becomes louder at no or light load.
appears on
machine

Defective related circuits Check the failure codes that are displayed at the same time. If any other codes are dis-
1
played, carry out troubleshooting for those codes.
Defective connection of the ground Defective connection of the ground terminal is suspected. Check the following terminals
Possible causes and terminal directly:
standard value in • Ground terminal of the machine body (negative terminal of the battery)
normal state 2
• Ground terminal of the engine
• Ground terminal of the engine controller
• Ground terminal of the starting motor
Damaged O-ring of supply pump
3 Since a damage of O ring of supply pump actuator is suspected, visually check the O-ring.
actuator
D51EX/PX-22 40-291 
12
ERROR CODE [CA559]
LOSS OF PRESSURE FEED FROM SUPPLY PUMP
Action code Error code Loss of pressure feed from supply pump (1): Loss of pressure feed detected (Engine
Trouble
E02 CA559 controller system)
Contents of
• Loss of pressure feed (1) occurred in the common rail circuit.
trouble
Action of
controller
Problem that • Engine does not start or engine is hard to start.
appears on • Exhaust gas color becomes black.
machine • Engine output is reduced.

Since the fuel leakage to the outside is suspected, check for a leakage. (Visually check at
1 Fuel leakage to the outside
low idle of the engine)
H Refer to Testing and adjusting “Fuel Pressure Inspection” for fuel low pressure
circuit pressure inspection.
• Measurement on the inlet side of the fuel filter
• Cranking speed: Min. 150 rpm
Fuel low pressure
When cranking Min. 1.4 kg/cm2
circuit pressure (20 psi)
• Measurement on the outlet side of the fuel filter

Fuel low pressure
At high idle Min. 4.9 kg/cm2
circuit pressure (70 psi)
• Measurements on the inlet and outlet sides of the fuel filter
• Fuel low pressure circuit pressure drop = fuel filter inlet pressure – fuel filter outlet
2 Defective low pressure circuit device pressure
Possible causes and
Fuel low pressure
At high idle Min. 1.4 kg/cm2
standard value in
circuit pressure drop (20 psi)
normal state
• Refer to Testing and adjusting “Fuel Pressure Inspection” for fuel suction pressure
inspection.
• Measurement on the gear pump fuel inlet side of the supply pump
Fuel suction circuit pressure
At high idle Max. 33.9 kPa\
(Gear pump side) (5.0 psi)
• Measurement on the fuel connector side

Fuel suction circuit pressure
At high idle Max. 27.1 kPa\
(Fuel connector side) (4.0 psi)
H As for testing return amount of injector, see testing and adjusting “Testing fuel
return and leak amount”.
Defective injector When cranking Max. 100 cc/30 sec.
3 (Including high-pressure (When engine cannot start) (Max. 3.4 oz/30 sec.)
pipes within the head) Injector return amount At low idle
Max. 300 cc/30 sec
(When engine can be
(Max. 10.1 oz/30 sec.)
started)
40-292  D51EX/PX-22
12
H As for testing return amount of supply pump, see testing and adjusting “Testing
fuel return and leak amount”.
When cranking Max. 200 cc/30 sec.
4 Defective supply pump (When engine cannot start) (Max. 8.0 oz/30 sec.)
Amount of supply pump
return At low idle
Max. 300 cc/30 sec
(When engine can be
(Max. 10.1 oz/30 sec.)
started)
H As for testing an amount of pressure limiter leak, see testing and adjusting “Test-
ing fuel return and leak amount”.
5 Defective pressure limiter
Pressure limiter
At low idle Max. 30 drops/min.
Possible causes and leak amount
standard value in 6 Defective plunger of supply pump H Remove supply pump head and visually inspect the plunger for damage.
normal state
Since a residual air in a low-pressure circuit is suspected, so inspect directly according
to the following procedure.
1. Remove pressure inspection plug (outlet side) of fuel main filter.
2. Operate feed pump of fuel pre-filter.

7 Air in low pressure circuit
3. Check the leakage of fuel and air from pressure inspection plug.
• If this error occurs during the air bleeding operation after the fuel filter
replacement, air is possibly remaining in the fuel circuit, so continue to run
the engine at low idle for approximately 3 minutes. When air bleeding is
complete, engine revolutions become stable and the error display disappears.
D51EX/PX-22 40-293 
12
ERROR CODE [CA689]
ABNORMAL ENGINE NE SPEED SENSOR
Action code Error code Abnormal engine Ne speed sensor: Abnormal signal
Trouble
Contents of
• Abnormal signal of the engine Ne speed sensor has been detected.
trouble
Action of
• Continues the control by engine Bkup speed sensor signal.
controller
Problem that • Engine is hunting.
appears on • Engine is hard to start.
machine • Engine output is reduced.
Related
information

Defective Ne speed sensor power If failure code [CA238] is displayed at the same time, carry out troubleshooting for it
1
source circuit first.
C12 Voltage
2 Defective engine Ne speed sensor Between (1) - (2) Power source 4.75 - 5.25V
Damaged engine Ne speed sensor or Since a damage or improper mounting gap of engine Ne speed sensor is suspected,
improper gap inspect it visually.
standard value in
normal state 4 Damaged speed detection wheel Since a damage of speed detection wheel is suspected, visually check it.
5 (Disconnection or defective contact of Wiring harness between C1 (female) (27) – C12 (female)
connectors) Resistance Max. 10
(3)
with ground circuit) Resistance Max. 100k 
(27) - C12 (female) (3)
Hot short in wiring harness (a contact
with 5 V or 24 V circuit) Voltage Max. 1V
(27) – C12 (female) (3)
40-294  D51EX/PX-22
12
Prepare with starting switch OFF and diagnose with starting switch still OFF.
Wiring harnesses between C1 (female) (27) – C12
(female) (3) and between C1 (female) (16) – C12 (female) Resistance Max. 100k 
8 Harness short (Harness internal short) (1)
Wiring harnesses between C1 (female) (27) - C12
(female) (3) and between C1 (female) (48) - C12 (female) Resistance Max. 100k 
(2)
Possible causes and
standard value in Since the connections among engine Ne speed sensor – engine harness – engine control-
normal state ler are suspected to be defective, check a the defective connection.
Between (16) - (48) 4.75 - 5.25V
Circuit diagram related to Ne speed sensor
D51EX/PX-22 40-295 
12
ERROR CODE [CA731]
ABNORMAL ENGINE BKUP SPEED SENSOR PHASE

Trouble Abnormal engine Bkup speed sensor phase: Abnormal phase
Contents of
• Abnormal phase is detected from the signals of engine Ne speed sensor and engine Bkup speed sensor.
trouble
Action of
• Continues the control using engine Ne speed sensor signal.
controller
Problem that • Engine can not start or engine is hard to start.
appears on • Idle speed is not stable.
machine • Exhaust gas color becomes black.
Related
information

1 Damaged engine Ne speed sensor Since a damage of engine Ne speed sensor is suspected, visually check it.
2 Damaged engine Bkup speed sensor Since a damage of engine Bkup speed sensor is suspected, visually check it.
Since a defective mounting or a damage of speed detection ring on the crankshaft side is
Defective mounting or damage of suspected, carry out the inspection according to the following procedure.
3 speed detection ring on the crankshaft • Set the No.1 cylinder to the compression top dead center (align the marks).
side • If the center of the cut-out portion on the speed detection ring is aligned with
the tip of Ne speed sensor, the mounting is normal.
Since a defective mounting or a damage of speed detection gear on the camshaft side is
suspected, carry out the inspection according to the following procedure.
Possible causes and Defective mounting or damage of
• Set the No.1 cylinder to the compression top dead center (align the marks).
standard value in 4 speed detection gear on the camshaft
normal state • Remove the Bkup speed sensor.
side
• If you can see a groove on a side face of speed detection gear through the
mounting hole of the sensor, the mounting is normal.
Defective timing adjustment of Since a defective timing adjustment of crankshaft and camshaft is suspected, inspect
5
crankshaft and camshaft directly.
Defective connection of the ground terminal is suspected. Check the following terminals
directly:
Defective connection of the ground • Ground terminal of the machine body (negative terminal of the battery)
6
terminal • Ground terminal of the engine
• Ground terminal of the engine controller
• Ground terminal of the starting motor
40-296  D51EX/PX-22
12
MEMORANDUM
D51EX/PX-22 40-297 
12
ERROR CODE [CA757]
LOSS OF ALL ENGINE CONTROLLER DATA

Trouble Loss of all engine controller data: Loss of all data (Engine controller system)
CALL E04 CA757
Contents of
• Loss of all data in engine controller has been detected.
trouble
Action of
controller
Problem that
• Engine may stop and can not restart.
appears on
• Monitoring function of monitor panel (engine controller system) may not operate normally.
machine
Related
information

Check the failure codes that are displayed at the same time. If any other codes are dis-
1 Defective related circuits
played, carry out troubleshooting for those codes.
2 Loose or corroded battery terminal Battery terminal is possibly loose or corroded, so inspect it directly.
H Prepare with starting switch OFF and diagnose with starting switch OFF and
START.
3 Defective battery voltage Battery (1 unit) Starting switch Voltage

OFF Min. 12V
Between (+) - (-) terminals
START Min. 6.2V
4 Defective fuse No. 10 If fuse is blown, it is highly possible that a defective harness grounding, etc. has occurred
in the circuit.
Possible causes and
standard value in Disconnection in wiring harness (Dis- H Prepare with starting switch OFF and diagnose with starting switch still OFF.
normal state 5 connection or defective contact of Wiring harness between F01 (10) – 117 (female) (3) Resistance Max. 10 
connectors)
Wiring harness between 117 (female) (1), (2) - T20 Resistance Max. 10 
Since the problem is possibly at the connections between F01 (10) – body harness –
engine controller, check for a defective connection.
Defective wiring harness
6 • Connector is loose, lock is broken, seal is broken
connector
H Prepare with starting switch OFF and diagnose with starting switch ON and
START.
7 Defective engine controller 117 (female) Starting switch Voltage
ON Min.24V
Between (3) - (1)
START Min. 12V
40-298  D51EX/PX-22
12
Circuit diagram related to engine controller power supply
D51EX/PX-22 40-299 
12
ERROR CODE [CA778]
ABNORMAL ENGINE BKUP SPEED SENSOR
Action code Error code Abnormal engine Bkup speed sensor: Abnormal Bkup signal
Trouble
Contents of
• Abnormal engine Bkup speed sensor signal has been detected.
trouble
Action of
• Continue the control using engine Ne speed sensor signal.
controller
Problem that
appears on
• Output decreases.
machine
Related
information

1
circuit first.
C11 Voltage
2 Defective engine Bkup speed sensor
Possible causes and Damaged engine Bkup speed sensor Since a damage of engine Bkup speed sensor or improper gap is suspected, visually
3
standard value in or improper gap check it.
normal state 4 Damaged speed detection gear Since a damage of speed detection gear is suspected, visually check it.
Disconnection in wiring harness (Dis- H Prepare with starting switch OFF and diagnose with starting switch still OFF.
5 connection or defective contact of
Wiring harness between C1 (female) (26) - C11 (female) Resistance Max. 10
connectors)
(3)
with ground circuit) Resistance Min. 100k
(26) – C11 (female) (3)
Hot short in wiring harness (a contact
with 5 V or 24 V circuit) Voltage Max. 1V
(26) – C11 (female) (3)
40-300  D51EX/PX-22
12
Wiring harnesses between C1 (female) (26) - C11
(female) (3) and among C1 (female) (37) - S10 - C11 Resistance Max. 100k 
8 Harness short (Harness internal short) (female) (1)
Wiring harnesses between C1 (female) (26) – C11
(female) (3) and among C1 (female) (47) – S11 – C11 Resistance Max. 100k 
(female) (2)
Possible causes and
standard value in Since the connections among engine Bkup speed sensor – engine harness – engine con-
normal state troller are suspected to be defective, check a the defective connection.
Between (37) - (47) 4.75 - 5.25V
Circuit diagram related to Bkup speed sensor
D51EX/PX-22 40-301 
12
ERROR CODE [CA1633]
ABNORMAL KOMNET

Trouble Abnormal KOMNET: Abnormal communication (Engine controller system)
CALL E03 CA1633
Contents of • Engine controller detected an abnormal communication in the KOMNET communication circuit between pump controller and
trouble monitor panel.
Action of • Operate in a default mode.
controller • When the cause of the failure has been eliminated, it returns to normal.
Problem that
• Machine may not operate normally because the informations which are exchanged through KOMNET communication are not
appears on
transmitted properly. (A symptom of failure depends on the location where it occurs.)
machine
Related
information

Disconnection in wiring harness (Dis- Wiring harnesses between S04 (female) (1), (6) - 115
1 connection or defective contact of (female) (46), ST2 (female) (32) and 119 (female) (A)
connectors)
Wiring harnesses between S04 (female) (3) – 115 (female)
(47), ST2 (female) (22) and 119 (female) (B)
Between ground and wiring harnesses between S04
Defective harness grounding (Contact (female) (1), (6) – 115 (female) (46), ST2 (female) 119 Resistance Min. 1 
2 (female) (A) and DT12 (male) (3)
with ground circuit)
Possible causes and (female) (3) - 115 (female) (47), ST2 (female) (22) Resistance Min. 1 
standard value in (female) (B) and DT12 (male) (10)
normal state H Prepare with starting switch OFF and diagnose with starting switch ON.
Hot short of wiring harness (a contact (female) (1), (6) – 115 (female) (46), ST2 (female) (32), Voltage Max. 5.5V
3 119 (female) (A) and DT12 (male) (3)
with 24 V circuit)
(female) (3) – 115 (female) (47), ST2 (female) (22), 119 Voltage Max. 5.5V
(female) (B) and SRV (male) (10)
Defective terminal resistance in CAN H Prepare with starting switch OFF and diagnose with starting switch still OFF.
4 (Internal short circuit and disconnec- 119 (male) Resistance
tion)
Between (A) - (B) 120 ± 12 
Engine controller is possibly defective if no problem is found in causes 1 – 4. (Since this
5 Defective pump controller
is an internal defect, it cannot be diagnosed.)
40-302  D51EX/PX-22
12
Circuit diagram related to KOMNET system
D51EX/PX-22 40-303 
12
ERROR CODE [CA2185]
DECELERATOR PEDAL SENSOR POWER SOURCE TOO HIGH
Action code Error code Trouble Decelerator pedal sensor power source too high: Excessively high voltage detected
Contents of trouble • Excessively high voltage (Min. 5.25 V) is detected in the circuit of decelerator pedal sensor power source.
Action of
controller
• Engine speed cannot be controlled by decelerator pedal.
on machine
Related
information
Between 115 (female) (22) - all pins of 115 (female) (with
Resistance Min. 100k 
1 Harness short (Harness internal short) DP1 disconnected)
Wiring harness between 115 (female) (22) – DP1 (female)
(B) and wiring harness between 115 (female) (9) – DP1 Resistance Min. 100k 
Possible causes and
(female) (A)
standard value in
normal state Since the connections among decelerator pedal - body harness - engine controller are
suspected to be defective, visually check them.
Circuit diagram related to the decelerator pedal
40-304  D51EX/PX-22
12
ERROR CODE [CA2186]
DECELERATOR PEDAL SENSOR POWER SOURCE TOO LOW
Action code Error code Trouble Decelerator pedal sensor power source too low: Excessively low voltage detected
Contents of trouble • Excessively low voltage is detected in the circuit of decelerator pedal sensor power source.
Action of
controller
• Engine speed cannot be controlled by decelerator pedal.
on machine
Related
information

1 Between ground and wiring harness between 115 (female)
with ground circuit) Resistance Min. 100k 
(9) - DP1 (female) (A)
2 Harness short (Harness internal short) Between 115 (female) (9) – all pins of 115 (female) (with
Possible causes and Resistance Min. 100k 
standard value in DCL also disconnected)
normal state Since the connections among decelerator pedal - body harness - engine controller are
suspected to be defective, visually check them.
Circuit diagram related to the decelerator pedal
D51EX/PX-22 40-305 
12
ERROR CODE [CA2249]
LOSS OF PRESSURE FEED FROM SUPPLY PUMP (2)
Action code Error code Trouble Loss of pressure feed from supply pump (2): Loss of pressure feed detected
Contents of trouble • Loss of pressure feed (2) occurred in the common rail circuit.
Action of
controller
• Exhaust gas color becomes black.
on machine
• Output decreases.
Possible causes and Cause Standard value in normal state/Remarks on troubleshooting

standard value in
1 Carry out troubleshooting of [CA559].
normal state
40-306  D51EX/PX-22
12
MEMORANDUM
D51EX/PX-22 40-307 
12
ERROR CODE [CA2311]
ABNORMAL IMV SOLENOID

Trouble
CALL E03 CA2311 Abnormal IMV solenoid: Abnormal resistance (Engine controller system)
Contents of
• Resistance value of supply pump actuator circuit is abnormally high or low.
trouble
Action of
controller
Problem that
appears on • Engine output decreases.
machine
Related
information

Check the failure codes that are displayed at the same time. If any other codes are
1 Defective related circuits
Between (1) - (2) Max. 5 
Wiring harness between C1 (female) (2) – C9 (female) (1) Resistance Min. 5 
3 (Disconnection or defective contact of
connectors) Wiring harness between C1 (female) (32) – C9 (female)
Resistance Min. 5 
(2)
Possible causes and H Prepare with starting switch OFF and diagnose with starting switch still OFF.
standard value in Defective harness grounding (Contact
normal state with ground circuit) Resistance Min. 100 k
(2) - C9 (female) (1)
Since the connections among inlet metering valve - engine harness - engine controller are
suspected to be defective, visually check for a defective connection.
6
controller Between (2) - (32) Max. 5 
40-308  D51EX/PX-22
12
Circuit diagram related to IMV solenoid system
D51EX/PX-22 40-309 
12
ERROR CODE [CA2555]
AIR INTAKE HEATER RELAY DISCONNECTION

Trouble
E01 CA2555 Air intake heater relay disconnection: Disconnection (Engine controller system)
Contents of
• Disconnection is detected in the drive circuit of air intake heater relay.
trouble
Action of
controller
Problem that
appears on • Air intake heater does not operate (Start ability deteriorates in a low temperature and white smoke is exhausted.)
machine
Related
information • Duplication of failure code: Turn the starting switch ON with coolant temperature below -4oC (25oF).
H Prepare with starting switch OFF and diagnose with starting switch still OFF
(diagnose by itself).
RHR (male) Resistance
1
Defective preheat relay (internal Between (1) - (2) 300 - 600 
disconnection)
H Prepare with starting switch OFF and diagnose with starting switch ON (diagnose
by replacing with other relay)
Replace preheat relay (RHR) with other relay and carry out the procedure to duplicate the
failure code. If failure code changes from flashing to steady ON, the relay is defective.
Disconnection in wiring harness Wiring harness between 115 (female) (40) - RHR (female)
2 (Disconnection or defective contact of (1)
connectors)
Possible causes and Wiring harness between 115 (female) (42) – RHR (female)
standard value in (2)
normal state
RHR also disconnected)
The connections among preheat relay - body harness - engine controller are suspected to
be defective. Visually check them.
5 115 (female) Resistance
controller
Between (40) - (42) 300 - 600 
40-310  D51EX/PX-22
12
Circuit diagram related to engine preheat
D51EX/PX-22 40-311 
12
ERROR CODE [CA2556]
AIR INTAKE HEATER RELAY SHORT CIRCUIT

Trouble
E01 CA2556 Air intake heater relay short circuit: Short circuit (Engine controller system)
Contents of
• Short circuit is detected in the drive circuit of air intake heater relay.
trouble
Action of
controller
Problem that
appears on • Air intake heater does not operate (Start ability deteriorates in a low temperature and white smoke is exhausted.)
machine
Related
information • Duplication of failure code: Turn the starting switch ON with coolant temperature below -4oC (25oF).
H Prepare with starting switch OFF and diagnose with starting switch still OFF
(diagnose by itself).
RHR (male) Resistance
1
Defective preheat relay (internal Between (1) - (2) 300 - 600 
disconnection)
H Prepare with starting switch OFF and diagnose with starting switch ON (diagnose
by replacing with other relay)
Replace preheat relay (RHR) with other relay and carry out the procedure to duplicate the
failure code. If failure code changes from flashing to steady ON, the relay is defective.
2 Between ground and wiring harness between 115 (female)
with ground circuit) Resistance Max. 100 k
Possible causes and (40) - RHR (female) (1)
standard value in
normal state
RHR also disconnected)
The connections among preheat relay - body harness - engine controller are suspected to
be defective. Visually check them.
5 115 (female) Resistance
controller
Between (40) - (42) 300 - 600 
40-312  D51EX/PX-22
12
Circuit diagram related to engine preheat
D51EX/PX-22 40-313 
TROUBLESHOOTING ERROR CODE [D130KA]
12
ERROR CODE [D130KA]
NEUTRAL SAFETY RELAY DISCONNECTION
Action code Error code Neutral safety relay: Disconnection

Trouble
E02 D130KA (HST controller system)
Contents of
• When the ground circuit of the neutral safety relay is disconnected, 24V is not generated
trouble
Action of • Flashes the warning lamp and sounds the alarm buzzer.
controller • Even if cause of error disappears, system does not reset itself until starting switch is turned OFF.
Problem that
• When the engine is stopped, it can not be restarted (Disconnection).
appears on
• Engine can be started regardless of the parking lever switch position (Ground fault).
machine
• Output state to the neutral safety switch (ON and OFF, voltage) can be checked with the monitoring mode.
(Controller: HST, code: 40918 D-OUT [3], code: 50901 N-SAFETY)
Related
• Method of reproducing error code: Turn the starting switch ON and operate parking brake lever (Free).
information
• This error code is generated when the primary (coil side) of neutral safety relay has failed. A failure of the secondary cannot be
detected with this code.

H Prepare with starting switch OFF and carry out troubleshooting without and with
turning starting switch.
Defective starting switch Starting switch Starting switch Resistance
1
(Internal disconnection)
Between T250 (B) and T270 OFF Min. 1 M
(ACC) ON Max. 1 
H Prepare with starting switch OFF and carry out troubleshooting without turning
starting switch.
Defective neutral safety relay (Inter-
2
nal disconnection) CN-11 (Male) Resistance
Between (1) and (2) 200 – 400
starting switch.
Disconnection of wiring
harness Wiring harness between CN-ST2 (female) (8) – CN-11
Possible causes and 3 Resistance Max. 1 
standard value in (Disconnection or defective contact of (female) (2)
normal state connector) Wiring harness between CN-11 (female) (1) – starting
switch CN-T270 (ACC)
starting switch.
Grounding fault in wiring Wiring harness between CN-ST2 (female) (8) – CN-11
Resistance Min. 1 M
4 harness (Short circuit with ground (female) (2) and chassis ground
circuit) Wiring harness between CN-11 (female) (1) – starting
switch CN-T270 (ACC), – F01 (20F) inlet and chassis Resistance Min. 1 M
ground
H Prepare with starting switch OFF, then turn starting switch ON and carry out trou-
bleshooting.
5 Defective HST controller CN-ST2 Parking brake lever Voltage
Between (8) and chassis Free 20 – 30 V

ground Lock Max. 1 V
40-314  D51EX/PX-22
TROUBLESHOOTING ERROR CODE [D130KA]
Circuit diagram related to neutral safety relay
D51EX/PX-22 40-315 
TROUBLESHOOTING ERROR CODE [D130KB]
12
ERROR CODE [D130KB]
NEUTRAL SAFETY RELAY SHORT CIRCUIT
Action code Error code Neutral safety relay: Short circuit

Trouble
E02 D130KB (HST controller system)
Contents of
• Abnormal current flowed at the GND output to the neutral safety relay.
trouble
Problem that
appears on • When the engine is stopped, it can not be restarted.
machine
• Output state to the neutral safety switch (ON, OFF, and voltage) can be checked with the monitoring mode.
(Controller: HST, code: 40918 D-OUT [3], code: 50901 N-SAFETY)
Related
• Method of reproducing error code: Turn the starting switch ON and operate parking brake lever (Lock).
information
• This error code is generated when the primary (coil side) of neutral safety relay has failed. A failure of the secondary cannot be
detected with this code.

H Prepare with starting switch OFF, then carry out troubleshooting without turning
starting switch.
Defective neutral safety relay
1
(Internal short circuit) CN-11 (Male) Resistance
Between (1) and (2) 200 – 400 
H Prepare with starting switch OFF, then turn starting switch ON and carry out
Possible causes and Short circuit with power supply line troubleshooting.
standard value in 2 circuit wiring harness
normal state (Contact with 24 V) Wiring harness between CN-ST2 (female) (8) – CN-11
Voltage Max. 1 V
(female) (2) and chassis ground
H Prepare with starting switch OFF, then turn starting switch ON and carry out trouble-
shooting.
3 Defective HST controller CN-ST2 Parking brake lever Voltage
Between (8) and chassis Free 20 – 30 V

ground Lock Max. 1 V
40-316  D51EX/PX-22
TROUBLESHOOTING ERROR CODE [D130KB]
Circuit diagram related to neutral safety relay
D51EX/PX-22 40-317 
TROUBLESHOOTING ERROR CODE [DAFRKR]
12
ERROR CODE [DAFRKR]
CAN COMMUNICATION MONITOR PANEL – HST CONTROLLER
Action code Error code CAN communication (Monitor panel – HST controller): Defective communication
Trouble (Abnormality in objective component system)
E03 DAFRKR (Monitor panel system)
Contents of trouble • The monitor panel cannot recognize the HST controller in the CAN communication circuit.
Action of
• Limits the functions partly.
controller
• The system may not work properly.
Problem that appears • Once the machine is stopped, its engine speed is limited to medium (half) speed.
on machine • Once the machine is stopped and started again, its travel speed is limited to 50%.
• The monitor panel does not display information.
• Method of reproducing error code: Turn the starting switch ON
• Indicate error code [DAFRMC], when the monitor panel cannot recognize the engine controller.
Related
• Indicate error code [DB2RKR], when HST controller cannot recognize the engine controller.
information
• Indicate error code [DAJRKR], when HST controller cannot recognize the monitor panel.
• Indicate error code [CA1633], when engine controller cannot recognize the HST controller.

Short circuit in wiring starting switch.
1
harness CN-DT12 (male) Resistance
Between (3) and (10) 50 – 70 
starting switch.
Wiring harness between CN-S04 (female) (1), (6) – CN-
115 (female) (46), – CN-ST2 (female) (32), – CN-G01 Resistance Max. 1 
harness
2 (female) (8), – CN-119 (female) (A), CN-DT12 (male) (3)
(Disconnection or defective contact in
Possible causes and connector) Wiring harness between CN-S04 (female) (3) – CN-115
standard value in (female) (47), – CN-ST2 (female) (22), – CN-G01
normal state (female) (7), – CN-119 (female) (B), CN-DT12 (male)
(10)
starting switch.
Wiring harness between CN-S04 (female)(1), (6) – CN-
Grounding fault in wiring 115 (female) (46), – CN-ST2 (female) (32), – CN-G01
harness (female) (8), – CN-119 (female) (A), CN-DT12 (male) (3)
3
(Short circuit with ground and chassis ground
circuit)
Wiring harness between CN-S04 (female) (3) – CN-115
(female) (47), – CN-ST2 (female) (22), – CN-G01
(female) (7), – CN-119 (female) (B), CN-DT12 (male)
(10) and chassis ground
40-318  D51EX/PX-22
TROUBLESHOOTING ERROR CODE [DAFRKR]

troubleshooting.
115 (female) (46), – CN-ST2 (female) (32), – CN-G01
Short circuit with power Voltage Max. 1 V
(female) (8), – CN-119 (female) (A), CN-DT12 (male) (3)
4 supply line circuit in wiring harness
and chassis ground
(Contact with 24V circuit)
Voltage Max. 1 V
Possible causes and (10) and chassis ground
standard value in
normal state
starting switch.
5 Defective CAN end point resistance
CN-119 (female) Resistance
Between (A) and (B) 100 – 140 
Defective CAN end point resistance starting switch.
6
(Internal of monitor) CN-S04 (male) Resistance
Between (3) and (6) 100 – 140 
Defective monitor panel or HST If causes 1 – 6 are not detected, monitor panel or HST controller may be defective.
7
controller (Since trouble is in system, troubleshooting cannot be carried out.)
Circuit diagram related to CAN communication
D51EX/PX-22 40-319 
TROUBLESHOOTING ERROR CODE [DAFRMC]
ERROR CODE [DAFRMC]
CAN COMMUNICATION MONITOR PANEL – ENGINE CONTROLLER
Action code Error code CAN communication (Monitor panel – ENGINE controller):
Trouble Defective communication (Abnormality in objective component system) (Monitor
E03 DAFRMC panel system)
Contents of trouble • The monitor panel cannot recognize the ENGINE controller in the CAN communication circuit.
Action of
controller
• Method of reproducing error code: Starting switch ON.
• Indicate error code [DAFRKR], when the monitor panel cannot recognize the HST controller.
Related
• Indicate error code [DB2RKR], when HST controller cannot recognize the engine controller.
information
• Indicate error code [DAJRKR], when HST controller cannot recognize the monitor panel.
• Indicate error code [CA1633], when engine controller cannot recognize the HST controller.

Short circuit in wiring starting switch.
1
Between (3) and (10) 50 – 70 
starting switch.
harness
(10)
starting switch.
Grounding fault in wiring Resistance Min. 1 M
3 harness
and chassis ground
(Short circuit with ground circuit)
40-320  D51EX/PX-22
TROUBLESHOOTING ERROR CODE [DAFRMC]

bleshooting.
and chassis ground
Voltage Max. 1 V
standard value in
normal state
starting switch.
Between (A) and (B) 100 – 140
6
Between (3) and (6) 100 – 140 
7
D51EX/PX-22 40-321 
TROUBLESHOOTING ERROR CODE [DAJ000]
ERROR CODE [DAJ000]
HST CONTROLLER MEMORY ERROR
Action code Error code HST controller: Memory error

Trouble
– DAJ000 (HST controller system)
Contents of trouble • The information in the HST controller ROM (non-volatile memory) is abnormal.
Action of
• Use normal data only in the main area and in the backup area.
controller
on machine
Related
information

Possible causes and Since trouble is in system, troubleshooting cannot be carried out. (If no visible error
1 Defective HST controller
standard value in appears on the machine, the controller can be continuously used as it is.)
normal state
Disconnection or grounding fault in The HST controller source power (VB) might have dropped when writing to memory.
2
wiring harness Carry out troubleshooting for [DAJ0KK].
40-322  D51EX/PX-22
TROUBLESHOOTING ERROR CODE [DAJ000]
12
MEMORANDUM
D51EX/PX-22 40-323 
TROUBLESHOOTING ERROR CODE [DAJ0KK]
12
ERROR CODE [DAJ0KK]
HST CONTROLLER LOWERING OF SOURCE VOLTAGE
Action code Error code HST controller: Lowering of source voltage

Trouble
E04 DAJ0KK (HST controller system)
Contents of trouble • HST controller source voltage goes to 18 V or lower.

Action of
• Limits the function partly.
controller
• If cause of the error disappears, the system resets itself.
• Once the machine is stopped, it cannot be restarted.
• Monitor panel may not display data normally.
on machine
• The relays and solenoids may become inoperable, disabling the normal operation of the system.
• Power supply state of the HST controller can be checked with the monitoring code.
Related
(Controller: HST, Code: 03207 PWR IN BATT, Code: 03202 PWR IN BRY)
information
• Method of reproducing error code: Turn the starting switch ON.

1 Battery voltage drop Battery voltage 20 – 30 V
2 Defective fuse (F01-5 or 15) If the fuse is burn, the circuit probably has a grounding fault, etc. (See cause 4.)
starting switch.
Wiring harness between CN-ST3 (female) (1), (11) – F01
(15) outlet
harness Wiring harness between CN-ST3 (female) (2), (12), (22) –
3 Resistance Max. 1
(Disconnection or defective contact in F01 (5) outlet
connector) Wiring harness between F01 (15E) – CN-T7 Resistance Max. 1
Wiring harness between F01 (5B) – CNT8 Resistance Max. 1 
Wiring harness between CN-ST3 (female) (21), (31), (32),
(33) – chassis ground
Possible causes and
standard value in H Prepare with starting switch OFF, then carry out troubleshooting without turning
normal state starting switch.
Wiring harness between CN-ST3 (female) (1), (11) – F01
Grounding fault in wiring (15) outlet and chassis ground
harness Wiring harness between CN-ST3 (female) (2), (12), (22) –
4 Resistance Min. 1 M
(Short circuit with ground F01 (5) outlet and chassis ground
circuit)
Wiring harness between F01 (15E) – CN-T7 and chassis
ground
Wiring harness between F01 (5B) – CN-T8 and chassis
ground
troubleshooting.
5 Defective HST controller ST3 Voltage
Between (1), (11), (2), (12), (22) and (21),
20 – 30 V
(31), (32), (33)
40-324  D51EX/PX-22
Circuit diagram related to HST controller power supply
D51EX/PX-22 40-325 
TROUBLESHOOTING ERROR CODE [DAJ0KQ]
12
ERROR CODE [DAJ0KQ]
HST CONTROLLER MACHINE CODE ERROR
Action code Error code HST controller: Machine code error

Trouble
E03 DAJ0KQ (HST controller system)
• There is a disagreement between the selected machine model being saved on the HST controller and that on the machine.
Contents of trouble
• Do not select machine select mode.
Action of
• Limits the function partly
controller
• Even if cause of error disappears, system does not reset itself until starting switch is turned OFF.
• Once the machine is stopped, its engine speed is limited to medium (half) speed.
on machine
• Once the machine is stopped and started again, its travel speed is limited to 50%.
• Machine model codes being recognized by the controller can be checked with the monitoring mode.
Related
(Controller: HST, Code: 00204 MACHINE CODE) and (Controller: MONITOR PANEL,
information
Code: 00205 MACHINE CODE)
Possible causes and Confirm and record the machine model that the monitor panel and the HST controller
standard value in recognize in the real monitoring mode.
normal state 1 Defective machine model selection Make appropriate setting for the machine model in the machine model selection mode.
When setting for different machine model from the one that the HST controller recog-
nizes was made, carry out all initial setting.
40-326  D51EX/PX-22
TROUBLESHOOTING ERROR CODE [DAJ0KT]
12
ERROR CODE [DAJ0KT]
HST CONTROLLER MEMORY ERROR
Action code Error code HST controller: Memory error

Trouble
E03 DAJ0KT (HST controller system)
Contents of • The information in the HST controller PROM (non-volatile memory) is abnormal.
trouble (Both the main area memory and backup area memory are abnormal)
Action of • Limits the functions partly.
controller • Clear all the memory and use default values.
Problem that
appears on
machine
• The setting of machine model is also cleared, and [DAJ0KQ] appears.
Related
information

Since trouble is in system, troubleshooting cannot be carried out.
Possible causes and
1 Defective HST controller (If no visible error appears on the machine after the machine model is reset and the
standard value in
initial adjustment is made again, the controller can be continuously used as it is.)
normal state
Disconnection or grounding fault in The HST controller source power (VB) might have dropped when writing to memory.
2
wiring harness Carry out troubleshooting for [DAJ0KK].
D51EX/PX-22 40-327 
12
ERROR CODE [DAJ5KK]
HST CONTROLLER POWER SUPPLY LOWING
Action code Error code HST controller sensor 5 V power supply No.1: Lowing of source voltage/Input
Trouble
• Voltage of 5 V power output No.1 circuit of the HST controller went to 4.5 V or lower or 5.5 V or higher.
Contents of trouble
• Abnormal current flowed in HST controller sensor 5 V power supply No. 1
Action of • Stops output of 5 V power No.1 circuit.
controller • Limits the functions partly
Problem that appears • Once the machine is stopped, it cannot be restarted.
on machine • The system may not work properly.
• If this failure occurs, individual error codes of the target components of power supply such as the pressure sensor and potentiom-
Related
eter are displayed and recorded at the same time.
information

Disconnect connector with starting switch OFF, then turn starting switch ON and carry
out troubleshooting.
Defective travel potentiometer Travel potentiometer CN-EL connector
Defective fuel dial potentiometer
Fuel dial potentiometer CN-FP connector
Defective brake potentiometer Sequentially disconnect the
Defective left HST pump devices suggested on the Brake potentiometer CN-BP1 connector
1
pressure sensor right and if error code is not Left HST pump
Defective right HST lit and displayed (reset CN-LP connector
pressure sensor
pump pressure sensor display), internal component
Defective brake pressure sensor Right HST pump pressure
may be defective. CN-RP connector
sensor
Brake pressure sensor CN-BS connector
starting switch.
Grounding fault in wiring
Possible causes and 2 harness Wiring harness between CN-ST2 (female) (22) – CN-EL
standard value in (female) (4), (5), – CN-BS (female) (3), – CN-RP (female)
(Short circuit with ground circuit) Resistance Min. 1 M
normal state (3), – CN-LP (female) (3), – CN-BP1 (female) (C), CN-
FP (female) (A) and chassis ground
troubleshooting.
Wiring harness between CN-ST2 (female) (22) – CN-EL
Short circuit with power supply line (female) (4), (5), – CN-BS (female) (3), – CN-RP (female)
Voltage Max. 1 V
3 circuit wiring harness (3), – CN-LP (female) (3), – CN-BP1 (female) (C), CN-
(Contact with 24 V) FP (female) (A) and chassis ground
If the wiring harness is short circuit with power supply line circuit in wiring harness, the
controller and each sensor may be defective, too. Check them after repairing wiring har-
ness.
bleshooting.
CN-ST1 (female) Voltage
Between (22) and (21) 4.5 – 5.5 V
40-328  D51EX/PX-22
Circuit diagram related to HST controller sensor 5 V power supply No. 1
D51EX/PX-22 40-329 
12
ERROR CODE [DAJ6KK]
HST POWER SUPPLY LOWING
Action code Error code HST controller sensor 5 V power supply No.2: Lowing of source voltage/Input
Trouble
• Voltage of 5 V power output No.2 circuit of the HST controller went to 4.5 V or lower or 5.5 V or higher.
Contents of trouble
• Abnormal current flowed in HST controller sensor 5 V power supply No. 2
• Stops output of 5 V power No.2 circuit.
Action of
• Stops use of the HST motor speed sensor.
controller
on machine
• If this error occurs, individual error codes of the target devices of power supply such as the HST motor speed sensor are dis-
Related
played and recorded at the same time.
information

troubleshooting.
Defective left HST motor speed Right HST

Sequentially disconnect the CN-RRS2 connector
sensor motor speed sensor
1 devices suggested on the
Defective right HST motor speed right and if error code is not
sensor lit and displayed (reset dis-
play), internal component
Left HST
may be defective. CN-LRS2 connector
motor speed sensor
Possible causes and Grounding fault in wiring starting switch.
standard value in 2 harness Wiring harness between CN-ST3 (female) (34) – CN-
normal state (Short circuit with ground circuit) LRS2 (female) (A), – CN-RRS2 (female) (A) and chassis Resistance Min. 1 M
ground
starting switch.
Wiring harness between CN-ST3 (female) (34) – CN-
Short circuit with power supply line
LRS2 (female) (A), – CN-RRS2 (female) (A) and chassis Voltage Max. 1 V
3 circuit wiring harness
ground
(Contact with 24 V)
If the wiring harness is short circuit with power supply line circuit wiring harness, the
controller and each HST motor revolution sensor may be defective, too. Check them
after repairing wiring harness.
troubleshooting.
HST controller Voltage
Between CN-ST3 (34) and CN-ST2 (39) 4.5 – 5.5 V
40-330  D51EX/PX-22
Circuit diagram related to HST controller sensor 5 V power supply No. 2
D51EX/PX-22 40-331 
TROUBLESHOOTING ERROR CODE [DAJRKR]
12
ERROR CODE [DAJRKR]
CAN COMMUNICATION HST CONTROLLER DEFECTIVE

Action code Error code CAN communication (HST controller – Monitor panel):
Trouble Defective communication (Abnormality in objective component system)
E03 DAJRKR (HST controller system)
Contents of trouble • The HST controller detected a communication error, but communication with the monitor panel is not available.
Action of
controller
• Though the HST controller outputs this code, the CAN communication is defective between the HST controllers and this code is
neither displayed on the monitor nor recorded.
KOMTRAX outputs it depending on the failed portion.
Related
• [DAFRKR] is output when the monitor panel cannot recognize the HST controller.
information
• [DAFRMC] is output when the monitor panel cannot recognize the engine controller.
• [DB2RKR] is output when the HST controller cannot recognize the engine controller.
• [CA1633] is output when the engine controller cannot recognize the HST controller

starting switch.
Short circuit in wiring
1
Between (3) and (10) 50 – 70 
starting switch.
harness
normal state Resistance Max. 1 
(10)
starting switch.
Resistance Min. 1 M 
3
circuit) Wiring harness between CN-S04 (female) (3) – CN-115
40-332  D51EX/PX-22
TROUBLESHOOTING ERROR CODE [DAJRKR]

bleshooting.
and chassis ground
Voltage Max. 1 V
standard value in
normal state
starting switch.
Between (A) and (B) 100 – 140 
Defective CAN end point resistance starting switch ON.
6
Between (3) and (6) 100 – 140 
7
D51EX/PX-22 40-333 
TROUBLESHOOTING ERROR CODE [DB2RKR]
ERROR CODE [DB2RKR]
CAN COMMUNICATION HST CONTROLLER DEFECTIVE

Action code Error code CAN communication (HST controller – Engine controller):
Trouble Defective communication (Abnormality in objective component system)
E03 DB2RKR (HST controller system)
Contents of trouble • Abnormality was detected in the communication between the HST controller and engine controller.
Action of
controller
Problem that
• Engine speed is limited to medium (half) speed by modulated rate.
appears on machine
• Method of reproducing error code: Turn the starting switch ON
• [DAFRKR] is output when the monitor panel cannot recognize the HST controller.
Related
• [DAFRMC] is output when the monitor panel cannot recognize the engine controller.
information
• [DAJRKR] is output when the HST controller cannot recognize the monitor panel.
• [CA1633] is output when the engine controller cannot recognize the HST controller.

starting switch.
Short circuit in wiring
1
harness CN-PT12 (male) Resistance
Between (3) and (10) 50 – 70 
H Prepare with starting switch OFF, then carry out troubleshooting without
harness
(10)
3
circuit)
40-334  D51EX/PX-22
TROUBLESHOOTING ERROR CODE [DB2RKR]

bleshooting.
and chassis ground
Voltage Max. 1 V
standard value in
normal state
starting switch.
Between (A) and (B) 100 – 140 
6
Between (3) and (6) 100 – 140 
Defective monitor panel or HST con- If causes 1 – 6 are not detected, monitor panel or HST controller may be defective.
4
troller (Since trouble is in system, troubleshooting cannot be carried out.)
D51EX/PX-22 40-335 
TROUBLESHOOTING ERROR CODE [DD12KA]
ERROR CODE [DD12KA]
SHIFT UP SWITCH DISCONNECTION
Action code Error code Shift up switch: Disconnection

Trouble
E02 DD12KA (HST controller system)
Contents of trouble • Both circuits in the shift up switch were turned off (set to OPEN) at the same time.
Action of
• Recognizes that the shift up switch is not pressed.
controller
• Resets itself 3 seconds after if the detection conditions are unmeet.
• Pressing the button does not operate the shift up.
on machine
• Both circuits of the switch are monitored, NO is used to detect the operation and NC is used to detect errors.
Related • Input state (ON/OFF) from the shift up switch can be checked with the monitoring function.
information (Controller: HST, Code: 40910 D-IN [0]: NO, [6]: NC)
• Method of reproducing error code: Turning on the starting switch and operating the shift up switch

starting switch.
Defective shift up switch (Internal Shift up switch

1 CN-38 (Male)
disconnection) OFF (Release) ON (Press)
Between (2) and (3) Max. 1  Min. 1 M 
Between (2) and (1) Min. 1 M  Max. 1 
starting switch.
Disconnection in wiring Wiring harness between CN-ST1 (female) (12) – CN-38

harness (female) (3)
2
(Disconnection or defective contact of Wiring harness between CN-ST1 (female) (23) – CN-38
connector) Resistance Max. 1 
Possible causes and (female) (1)
standard value in Wiring harness between CN-ST1 (female) (4) – CN-38
(female) (2)
troubleshooting.
Wiring harness between CN-ST1 (female) (12) – CN-38
3 circuit wiring harness Voltage Max. 1 V
(Contact with 24 V)
Voltage Max. 1 V
troubleshooting.
Shift up switch
4 Defective HST controller CN-ST1
OFF (Release) ON (Press)
Between (12) and (4) Max. 1 V 5 –11 V
Between (23) and (4) 5 – 11 V Max. 1 V
40-336  D51EX/PX-22
Circuit diagram related to the shift up switch and shift down switch
D51EX/PX-22 40-337 
TROUBLESHOOTING ERROR CODE [DD12KB]
12
ERROR CODE [DD12KB]
SHIFT UP SWITCH SHORT CIRCUIT
Action code Error code Trouble Shift up switch: Short circuit

(HST controller system)
E02 DD12KB
Contents of trouble • Both circuits in the shift up switch were turned ON (set to CLOSE) at the same time.
Action of
• Recognizes that the shift up switch is not pressed.
controller
• Pressing the button does not operate the shift up.
on machine
Related • Input state (ON/OFF) from the shift up switch can be checked with the monitoring function.
information (Controller: HST, Code: 40910 D-IN [0]: NO, [6]: NC)
• Method of reproducing error code: Turning on the starting switch and operating the shift up switch

starting switch.
Defective shift up switch (Internal Shift up switch

1 CN-38 (Male)
short) OFF (Release) ON (Press)
Between (2) and (3) Max. 1 Min. 1 M
Between (2) and (1) Min. 1 M Max. 1 
standard value in harness Wiring harness between CN-ST1 (female) (12) – CN-38
normal state 2 Resistance Min. 1 M
(Short circuit with ground (female) (3) and chassis ground
circuit)
troubleshooting.
Shift up switch
Between (12) and (4) Max. 1 V 5 –11 V
40-338  D51EX/PX-22
D51EX/PX-22 40-339 
12
ERROR CODE [DD13KA]
SHIFT DOWN SWITCH DISCONNECTION
Action code Error code Shift down switch: Disconnection

Trouble
E02 DD13KA (HST controller system)
Contents of trouble • Both circuits in the shift down switch were turned OFF (set to OPEN) at the same time.
controller • Recognizes that the shift up switch is not pressed.
• Pressing the button does not operate the shift down.
on machine
Related • Input state (ON/OFF) from the shift down switch can be checked with the monitoring function.
information (Controller: HST, code: 40910 D-IN [4]: NC, [5]: NO)
• Method of reproducing error code: Turning on the starting switch and operating the shift down switch

starting switch.
Defective shift down switch (Internal Shift down switch

1 CN-39 (female)
disconnection) OFF (Release) ON (Press)
Between (2) and (3) Max. 1 Min. 1 M
starting switch.

harness (male) (3)
2
Possible causes and (male) (1)
standard value in Wiring harness between CN-ST1 (female) (4) – CN-39
(male) (2)
troubleshooting.
(male) (3) and chassis ground
(Contact with 24 V)
Voltage Max. 1 V
bleshooting.
Shift down switch
4 Defective HST controller CN-ST1 (female)
Between (24) and (4) Max. 1 V 5 – 11 V
40-340  D51EX/PX-22
D51EX/PX-22 40-341 
12
ERROR CODE [DD13KB]
SHIFT DOWN SWITCH SHORT CIRCUIT
Action code Error code Shift down switch: Short circuit

Trouble
E02 DD13KB (HST controller system)
Contents of trouble • Both circuits in the shift down switch were turned ON (set to CLOSE) at the same time.
Action of
• Recognizes that the shift down switch is not pressed.
controller
• Pressing the button does not operate the shift down.
on machine
Related • Input state (ON/OFF) from the shift down switch can be checked with the monitoring function.
information (Controller: HST, Code: 40910 D-IN [4]: NC, [5]: NO)
• Method of reproducing error code: Turning on the starting switch and operating the shift down switch

starting switch.
Defective shift down switch (Internal Shift down switch

1 CN-39 (female)
short) OFF (Release) ON (Press)
Between (2) and (3) Max. 1  Min. 1 M
standard value in harness Wiring harness between CN-ST1 (female) (29) – CN-39
(Short circuit with ground (male) (3) and chassis ground
circuit)
troubleshooting.
Shift down switch
Between (24) and (4) Max. 1 V 5 – 11 V
40-342  D51EX/PX-22
D51EX/PX-22 40-343 
12
ERROR CODE [DD14KB]
TRAVEL LOCK LIMIT SWITCH 1 SHORT CIRCUIT
Action code Error code Travel lock limit switch 1: Short circuit
Trouble
E03 DD14KB (HST controller system)
Contents of trouble • Both circuits in the travel lock limit switch 1 Were turned ON (set to CLOSE) at the same time.
Action of • Recognizes that the travel lock lever is set to the Free position.
controller • Limits its functions partly.
Problem that
appears on machine
• The engine does not start.
Related • Input state (ON/OFF) from the travel lock limit switch 1 can be checked with the monitoring mode.
information (Controller: HST, code: 40912 D-IN [18]: NO, [19]: NC)
• Method of reproducing error code: Turn the starting switch ON and operate travel lock lever.

Parking brake lever
Defective travel lock limit switch 1 CN-26 (Male)
1
(Internal short circuit) Free (Top) Lock (Bottom)
Between (A) and (B) Max. 1  Min. 1 M
Between (A) and (C) Min. 1 M Max. 1 
H Prepare with starting switch OFF, then carry out troubleshooting without turning start-
ing switch.
Possible causes and harness Wiring harness between CN-ST2 (female) (5) – CN-26
standard value in 2 Resistance Min. 1 M
(Short circuit with ground (female) (B) and chassis ground
normal state circuit) Wiring harness between CN-ST2 (female) (15) – CN-26
(female) (C) and chassis ground
troubleshooting.
Parking brake lever
CN-ST1 and CN-ST2
Free (Top) Locked (Bottom)
Between CN-ST2 (5) and
Max. 1 V 5 – 11 V
CN-ST1 (10)
5 – 11 V Max. 1 V
CN-ST1 (10)
40-344  D51EX/PX-22
Circuit diagram related in travel lock limit switch 1
D51EX/PX-22 40-345 
TROUBLESHOOTING ERROR CODE [DD1NL4]
12
ERROR CODE [DD1NL4]
FAN ROTATION SELECTOR SWITCH DISAGREEMENT
Action code Error code Fan rotation selector switch: Disagreement of ON / OFF Signals (HST controller
Trouble
E01 DD1NL4 system)
Contents of trouble • Both circuits in fan rotation selector switch were turned ON (set to CLOSE) at the same time.
Action of • Recognizes that the fan rotation selector switch is not pressed.
• Fan rotation does not change, even if the fan rotation selector switch is pressed.
on machine
Related • Input state (ON/OFF) from the fan rotation selector switch can be checked with the monitoring mode.
information (Controller: HST, code: 40913 D-IN [26]: Reverse rotation (Right side), [27]: Normal rotation (Left side))

starting switch.
Fan rotation
CN-FAN (male) Resistance
selector switch
Center, reverse
Defective fan rotation Min. 1 M
rotation (Right)
1 selector switch Between (4) and (5)
Normal rotation
(Internal short circuit) Max. 1 
(Left)
Center, normal
Min. 1 M
rotation (Left)
Between (5) and (6)
Reverse
Max. 1 
rotation (Right)
standard value in harness Wiring harness between CN-ST2 (female) (7) – CN-FAN
(Short circuit with ground (female) (4) and chassis ground
circuit)
Wiring harness between CN-ST2 (female) (17) – CN-FAN
troubleshooting.
Fan rotation
CN-ST1 and ST2 Voltage
selector switch
Center, reverse
5 – 11 V
Between CN-ST2 (7) and rotation (Right)
CN-ST1 (10) Normal rotation
Max. 1 V
(Left)
Center, normal
5 – 11 V
Between CN-ST2 (17) and rotation (Left)
CN-ST1 (10) Reverse rotation (Right
Max. 1 V
side)
40-346  D51EX/PX-22
TROUBLESHOOTING ERROR CODE [DD1NL4]
Circuit diagram related to fan rotation selector switch
D51EX/PX-22 40-347 
TROUBLESHOOTING ERROR CODE [DDDCKB]
12
ERROR CODE [DDDCKB]
REVERSE TRAVEL SPEED SWITCH SHORT CIRCUIT
Action code Error code Reverse travel speed switch: short circuit
Trouble
E01 DDDCKB (HST controller system)
Contents of trouble • Both circuits in the reverse speed switch were turned ON (set to CLOSE) at the same time.
Action of • Recognizes that the reverse travel speed switch is not pressed.
• Setting for reverse travel speed does not change, even if the reverse travel speed switch is pressed.
on machine
• Input state (ON/OFF) from the reverse travel speed switch can be checked with the monitoring mode.
Related
(Controller: HST, code: 40912 D-IN [16]: deceleration (Left hand), [17]: acceleration (Right hand))
information
• Method of reproducing error code: Turn the starting switch ON and operate the reverse travel speed switch

starting switch.
Reverse travel
CN-REV (male) Resistance
speed switch
Defective reverse speed setup switch Center, acceleration (Right) Min. 1 M

1
(Internal short circuit) Between (4) and (5) Deceleration
Max. 1 
(Left)
Center, deceleration (Left) Min. 1 M
Between (5) and (6) Acceleration
Max. 1 
(Right)
Possible causes and starting switch.
standard value in Grounding fault in wiring harness Wiring harness between CN-ST2 (female) (35) – CN-REV
(Short circuit with ground circuit) (female) (4) and chassis ground
Wiring harness between CN-ST2 (female) (25) – CN-REV
bleshooting.
Reverse travel
CN-ST1 and ST2 Voltage
speed switch
Center, acceleration (Right) 5 – 11 V
3 Defective HST controller Between CN-ST2 (35) and
CN-ST1 (10) Deceleration
Max. 1 V
(Left)
Center, deceleration (Left) 5 – 11 V
CN-ST1 (10) Acceleration
Max. 1 V
(Right)
40-348  D51EX/PX-22
TROUBLESHOOTING ERROR CODE [DDDCKB]
Circuit diagram related to reverse travel speed switch
D51EX/PX-22 40-349 
TROUBLESHOOTING ERROR CODE [DDP6KA]
12
ERROR CODE [DDP6KA]
BRAKE OIL PRESSURE SENSOR DISCONNECTION
Action code Error code Brake oil pressure sensor: Disconnection

Trouble
E02 DDP6KA (HST controller system)
Contents of trouble • Input signal voltage from the brake oil pressure sensor dropped under 0.3 V.
Action of
controller • Recognizes the brake pressure as 2 MPa {20 kg/cm2} when the machine stopped.
Problem that
• Even when the brake oil pressure lowers, the charge pressure caution lamp does not light up.
appears on machine
• Input state from the brake oil pressure sensor (brake oil pressure and brake sensor voltage) can be checked with the monitoring
Related mode.
information (Controller: HST, code: 91902 BRAKE PRESS, Code: 91903 BRAKE PRESS)

H Prepare with starting switch OFF, then turn starting switch ON or start engine and
carry out troubleshooting.
CN-BS Voltage
Defective brake oil pressure sensor
1 Between (3) and (1) Power supply 4.5 – 5.5 V
(Internal defect)
Between (2) and (1) Signal 0.4 – 0.6 V
Voltage is measured with wiring harness connected. Accordingly, if voltage is abnormal,
check wiring harness and controller, too, for another cause of trouble, and then judge.
starting switch.
Disconnection in wiring Wiring harness between CN-ST1 (female) (22) – CN-BS

Possible causes and harness (female) (3)
2
standard value in (Disconnection or defective contact of Wiring harness between CN-ST1 (female) (21) – CN-BS
normal state connector) Resistance Max. 1 
(female) (1)
Wiring harness between CN-ST1 (female) (8) – CN-BS
(female) (2)
Grounding fault in wiring H Prepare with starting switch OFF, then carry out troubleshooting without turning
harness starting switch.
3
(Short circuit with ground Wiring harness between CN-ST1 (female) (8) – CN-BS
circuit) Resistance Min. 1 M
troubleshooting.
4 Defective HST controller CN-ST1 Voltage

Between (22) and (21) Power source 4.5 – 5.5 V
40-350  D51EX/PX-22
TROUBLESHOOTING ERROR CODE [DDP6KA]
Circuit diagram related to brake oil pressure sensor
D51EX/PX-22 40-351 
TROUBLESHOOTING ERROR CODE [DDP6KB]
12
ERROR CODE [DDP6KB]
BRAKE OIL PRESSURE SENSOR SHORT CIRCUIT
Action code Error code Brake oil pressure sensor: Short circuit
Trouble
E02 DDP6KB (HST controller system)
Contents of trouble • Input signal voltage from the brake oil pressure sensor dropped under 4.42 V.
Action of
controller • Recognizes the brake pressure as 2 MPa {20 kg/cm2} when the machine stopped.
on machine
• Input state from the brake oil pressure sensor (brake oil pressure and brake sensor voltage) can be checked with the monitoring
Related mode.
information (Controller: HST, code: 91902 BRAKE PRESS, Code: 91903 BRAKE PRESS)

bleshooting.
CN-BS Voltage
Brake oil pressure sensor (Internal
defect)
Possible causes and check wiring harness and controller, too, for another cause of trouble, and then judge.
standard value in H Prepare with starting switch OFF, then turn starting switch ON and carry out trou-
normal state Short circuit with power supply line bleshooting.
(Contact with 24 V) Wiring harness between CN-ST1 (female) (8) – CN-BS
Voltage Max. 1 V
troubleshooting.
Between (22) and (21) Power supply 4.5 – 5.5 V
40-352  D51EX/PX-22
TROUBLESHOOTING ERROR CODE [DDP6KB]
D51EX/PX-22 40-353 
TROUBLESHOOTING ERROR CODE [DDP6MA]
12
ERROR CODE [DDP6MA]
BRAKE OIL PRESSURE SENSOR MALFUNCTION
Action code Error code Brake oil pressure sensor: Malfunction

Trouble
E02 DDP6MA (HST controller system)
Contents of trouble • The Input signal voltage from the brake oil pressure sensor detected abnormal state (sensor failure).
on machine
• Input state from the brake pressure sensor (brake pressure and brake sensor voltage) can be checked with the monitoring mode.
Related
(Controller: HST, code: 91902 BRAKE PRESS, Code: 91903 BRAKE PRESS)
information

bleshooting.
CN-BP (male) Voltage
Defective brake pressure sensor
1 (Internal disconnection or short Between (3) and (1) Power supply 4.5 – 5.5 V
circuit)
Possible causes and Between (2) and (1) Signal 0.4 – 0.6 V
standard value in Voltage is measured with wiring harness connected. Accordingly, if voltage is abnormal,
normal state check wiring harness and controller, too, for another cause of trouble, and then judge.
bleshooting.

Between (22) and (21) 4.5 – 5.5 V
Between (8) and (21) 0.4 – 0.6 V
40-354  D51EX/PX-22
TROUBLESHOOTING ERROR CODE [DDP6MA]
D51EX/PX-22 40-355 
TROUBLESHOOTING ERROR CODE [DDQ2KA]
12
ERROR CODE [DDQ2KA]
TRAVEL LOCK LIMIT SWITCH 1 DISCONNECTION
Action code Error code Travel lock limit switch 1: Disconnection

Trouble
E03 DDQ2KA (HST controller system)
Contents of trouble • Both circuits in the travel lock limit switch 1 were turned OFF (set to OPEN) at the same time.
• Flashes the centralized warning lamp and sounds the alarm buzzer.
Action of • Recognizes that the travel lock lever is set to the Free position.
controller • Limits the functions partly.
• Travel speed is reduced to 50% of the value being set from the button. Likewise, the throttle opening is reduced to 50% of the set
value.
on machine
• The engine does not start.
• Input state (ON/OFF) from the travel lock limit switch 1 can be checked with the monitoring mode.
Related
(Controller: HST, code: 40912 D-IN [18]: NO, [19]: NC)
information
• Method of reproducing error code:
Turn the starting switch ON and operate travel lock lever.

starting switch.
Parking brake lever
Defective travel lock limit switch 1 CN-26 (male)
1
(Internal disconnection) Free (Top) Lock (Bottom)
Installation of travel lock limit switch Installation of travel lock limit switch 1 may be defective.
2
1 may be defective. Check them directly referencing the “Testing and adjusting”.
• Prepare with starting switch OFF, then carry out troubleshooting without

harness (female) (B)
3
Possible causes and (female) (C)
standard value in
(female) (A)
troubleshooting.
(female) (B) and chassis ground
(Contact with 24 V)
Voltage Max. 1 V
troubleshooting.
Parking brake lever
CN-ST1 and ST2
Free (Top) Lock (Bottom)
Max. 1 V 5 – 11 V
CN-ST1 (10)
5 – 11 V Max. 1 V
CN-ST1 (10)
40-356  D51EX/PX-22
TROUBLESHOOTING ERROR CODE [DDQ2KA]
Circuit diagram related in travel lock limit switch 1
D51EX/PX-22 40-357 
TROUBLESHOOTING ERROR CODE [DDT0L4]
12
ERROR CODE [DDT0L4]
SHIFT MODE SWITCH DISAGREEMENT OF ON/ OFF SIGNALS
Action code Error code Shift mode switch: Disagreement of ON/ OFF Signals
Trouble
E01 DDT0L4 (HST controller system)
Contents of trouble • Both circuits in the shift mode switch were turned ON (set to CLOSE) at the same time.
Action of • Recognizes that the shift mode switch is not pressed.
• Shift mode does not change, even if the shift mode switch is pressed.
on machine
• Input state (ON/OFF) from the shift mode switch can be checked with the monitoring mode.
Related
(Controller: HST, code: 40913 D-IN [24]: Quick shift mode (right side), [25]: Variable shift mode (Left side)
information
• Method of reproducing error code: Turn the starting switch ON and operate shift mode switch.

starting switch.
CN-MTS (male) Shift mode switch Resistance
Center and quick
Min. 1 M
shift (right side)
Defective shift mode switch Between (4) and (5)
1 Variable shift
(Internal short circuit) Max. 1
(left side)
Center and Variable shift
Min. 1 M
(left side)
Between (6) and (5)
Quick shift
Max. 1 
(right side)
standard value in harness Wiring harness between CN-ST2 (female) (27) – CN-
(Short circuit with ground MTS (female) (4) and chassis ground
circuit)
Wiring harness between ST2 (female) (37) – CN-MTS
bleshooting.
CN-ST2, ST1 Shift mode switch Voltage
Center and quick
5 – 11 V
Between CN-ST2 (27) and shift (right side)
3 Defective HST controller CN-ST1 (10) Variable shift
Max. 1 V
(left side)
Center and variable shift
5 – 11 V
Between CN-ST2 (37) and (left side)
CN-ST2 (10) Quick shift
Max. 1 V
(right side)
40-358  D51EX/PX-22
TROUBLESHOOTING ERROR CODE [DDT0L4]
Circuit diagram related to shift mode switch
D51EX/PX-22 40-359 
TROUBLESHOOTING ERROR CODE [DDU1FS]
12
ERROR CODE [DDU1FS]
TRAVEL LOCK LIMIT SWITCHES 1 AND 2 FIXING
Action code Error code Travel lock limit switches 1 and 2: Fixing
Trouble
E03 DDU1FS (HST controller system)
• Though the signal of travel lock limit switch 1 is set to LOCK, the output circuit to the brake solenoid valve is operating nor-
Contents of trouble
mally.
Action of
controller
• Input state (ON/OFF) from the travel lock limit switch can be checked with the monitoring mode.
Related
(Controller: HST, code: 40911 D-IN [12]: Switch 2 (NO), code: 40912 D-IN [18]: Switch 1 (NO), [19]: Switch 1 (NC))
information
• Method of reproducing error code: Turn the starting switch ON and operate travel lock lever.

starting switch.
Parking brake lever
Defective travel lock limit switch 1 CN-26 (male)
1
(Internal defect) Free (Top) Lock (Bottom)
Possible causes and Between (A) and (C) Min. 1 M Max. 1

Parking brake lever
Defective travel lock limit switch 2 CN-26B (male)
2
(Internal defect) Free (Top) Lock (Bottom)
Between (A) and (B) Max. 1 Min. 1 M
Defective installation of travel lock Installation of travel lock limit switches 1 and 2 may be defective. Check them directly
3
limit switches 1 and 2 referencing the “Testing and adjusting.”
40-360  D51EX/PX-22
TROUBLESHOOTING ERROR CODE [DDU1FS]
Circuit diagram related to brake system
D51EX/PX-22 40-361 
TROUBLESHOOTING ERROR CODE [DDU1KA]
12
ERROR CODE [DDU1KA]
TRAVEL LOCK LIMIT SWITCH 2 DISCONNECTION
Action code Error code Travel lock limit switch 2: Disconnection

Trouble
E03 DDU1KA (HST controller system)
• Though the signal of travel lock limit switch 1 is set to Lock position and no current flows to output circuit of the slow brake
Contents of trouble
solenoid valve, the signal of travel lock limit switch 2 (NO) was turned OFF (set to OPEN).
Action of
• Limits its function partly.
controller
Related (Controller: HST, code: 40911 D-IN [12] switch 2 (NO), code: 40912 D-IN [18] switch 1 (NO), [19] switch 1 (NC))
information • Method of reproducing error code: Turn the starting switch ON and operate travel lock lever.
• If [DW7EKA] is also output, carry out troubleshooting for it first.

starting switch.
Parking brake lever
1
(Internal failure) Free (Top) Lock (Bottom)
Between (A) and (B) Max. 1 Min. 1 M
Possible causes and Between (A) and (C) Min. 1 M Max. 1 
standard value in
normal state Defective installation of travel lock Installation of travel lock limit switches 1 and 2 may be defective. Check them directly
2
limit switches 1 and 2 referencing the “Testing and adjusting.”
starting switch.
Wiring harness between CN-ST3 (female) (9) – CN-26B
3 (Disconnection or defective contact in Resistance Max. 1 v
(female) (C)
connector)
(female) (A)
40-362  D51EX/PX-22
TROUBLESHOOTING ERROR CODE [DDU1KA]
D51EX/PX-22 40-363 
TROUBLESHOOTING ERROR CODE [DDU1KY]
12
ERROR CODE [DDU1KY]
TRAVEL LOCK LIMIT SWITCH 2 SHORT WITH POWER SUPPLY LINE
Action code Error code Travel lock limit switch 2: Short circuit with power supply line
Trouble
E03 DDU1KY (HST controller system)
• Though the signal of travel lock limit switch 1 is set to Free position and the output circuit of the slow brake solenoid valve out-
Contents of trouble
puts normally, the signal of travel lock limit switch 2 (NO) was turned ON (set to CLOSE).
Action of • When the travel lock limit switch is set to the lock position, disconnection in the slow brake solenoid may be detected.
Problem that • Once the machine is stopped, its engine speed is limited to medium (half) speed.
appears on machine • Once the machine is stopped and started again, its travel speed is limited to 50%.
Related
(Controller: HST, code: 40911 D-IN [12]: switch 2 (NO), code: 40912 D-IN [18]: switch 1 (NO), [19]: switch 1 (NC))
information
• Method of reproducing error code: Turn the starting switch ON and operate travel lock lever (FREE).

starting switch.
Parking brake lever
1
Possible causes and (Internal failure) Free (Top) Lock (Bottom)
standard value in Between (A) and (B) Max. 1  Min. 1 M
normal state
Between (A) and (C) Min. 1 M Max. 1
Short circuit with power supply line bleshooting.
(Contact with 24 V) Wiring harness between CN-ST3 (female) (9) – CN-26B
Voltage Max. 1 V
40-364  D51EX/PX-22
TROUBLESHOOTING ERROR CODE [DDU1KY]
D51EX/PX-22 40-365 
TROUBLESHOOTING ERROR CODE [DGS1KA]
12
ERROR CODE [DGS1KA]
HST OIL TEMPERATURE SENSOR DISCONNECTION
Action code Error code HST oil temperature sensor: Disconnection

Trouble
E01 DGS1KA (HST controller system)
• The signal of HST oil temperature sensor remains unchanged at low temperature even when the engine coolant temperature
Contents of trouble
rises.
Action of • Recognizes the HST oil temperature as 85°C.
Problem that appears • Monitor panel HST oil temperature is not displayed normally.
on machine • The fan speed is set to over 70%.
• Input state from the HST oil temperature sensor (HST oil temperature and HST oil temperature sensor voltage) can be checked
Related with the monitoring mode.
information (Controller: HST, code: 04401 HST TEMP, and Code: 04402 HST TEMP)
• Method of reproducing error code: Turn the starting switch ON or start the engine and wait about 10 minutes.

starting switch.
Defective HST oil temperature sensor CN-12 (male) HST oil temperature Resistance
1
(Internal disconnection) Between (1) and (2) 3.5 – 90 k
10 – 100°C
Between (1)(2) and chassis (50 - 212°F) Min. 1 M
ground
Disconnection in wiring starting switch.
harness Wiring harness between CN-ST1 (female) (9) – CN-12
2 Resistance Max. 1 
(Disconnection or defective contact of (female) (1)
Possible causes and wiring harness)
standard value in Resistance Max. 1 
normal state (female) (2)
troubleshooting.
(Contact with 24 V)
Voltage Max. 1 V
troubleshooting.
4 Defective HST controller CN-ST1 HST oil temperature Voltage
10 – 100°C
Between (9) and (21) 2.0 – 4.6 V
(50 - 212°F)
40-366  D51EX/PX-22
TROUBLESHOOTING ERROR CODE [DGS1KA]
Circuit diagram related to HST oil temperature sensor
D51EX/PX-22 40-367 
TROUBLESHOOTING ERROR CODE [DGS1KX]
12
ERROR CODE [DGS1KX]
HST OIL TEMPERATURE SENSOR OUT OF INPUT SIGNAL RANGE
Action code Error code HST oil temperature sensor: Out of input signal range
Trouble
E01 DGS1KX (HST controller system)
Contents of trouble • Input signal voltage from the HST oil temperature sensor dropped under 0.3 V.
Action of • Recognizes the HST oil temperature as 85°C (185°F).
Problem that appears • Monitor panel HST oil temperature is not displayed normally.
on machine • The fan speed is set to over 70%.
• Input state from the HST oil temperature sensor (HST oil temperature and HST oil temperature sensor voltage) can be checked
Related with the monitoring mode.
information (Controller: HST, code: 04401 HST TEMP, and Code: 04402 HST TEMP)

starting switch.
Defective HST oil CN-12 (male) HST oil temperature Resistance
1 temperature sensor (Internal short
circuit) Between (1) and (2) 3.5 – 90 k
10 – 100°C
Between (1)(2) and chassis (50 - 212°F) Min. 1 M
ground
Possible causes and
normal state Grounding fault in wiring starting switch.
2
harness (Contact with ground circuit) Wiring harness between CN-ST1 (female) (9) – CN-12
Resistance Max. 1 M
troubleshooting.
3 Defective HST controller CN-ST1 HST oil temperature Voltage
10 – 100°C
Between (9) and (21) 2.0 – 4.6 V
(50 - 212°F)
Circuit diagram related to HST oil temperature sensor
40-368  D51EX/PX-22
TROUBLESHOOTING ERROR CODE [DHH5KA]
12
ERROR CODE [DHH5KA]
LEFT HST PUMP PRESSURE SENSOR DISCONNECTION
Action code Error code Left HST pump pressure sensor: Disconnection
Trouble
E02 DHH5KA (HST controller system)
Contents of trouble • Input signal voltage from the Left HST pump pressure dropped under 0.3 V.
• Until the machine stops, the controller maintains the control using the pressure signal being received immediately prior to the
Action of failure.
controller
• Once the machine stops, the controller maintains the control assuming that the pump pressure is 100 kg/am2 (1,422 psi).
• The Left HST pump oil pressure may not be monitored in the monitoring mode.
on machine
• If 5V circuit (3) and ground circuit (1) of pressure sensor are connected inversely, pressure sensor will be broken. Accordingly,
take extreme care when checking.
Related
• Input state from the Left HST pump pressure sensor (pressure and voltage) can be checked with the monitoring mode.
information
(Controller: HST, code: 52502 HST L PRESS and code: 52503 HST L PRESS)
• Method of reproducing error code: Turn the starting switch ON or start the engine.

Defective sensor power
1 If error code [DAJ5KK] is displayed, carry out the troubleshooting first as stated.
supply system
bleshooting.
CN-LP Voltage
Defective Left HST pump pressure
2 Between (3) – (1) Power supply 4.5 – 5.5 V
sensor (Internal failure)
Between (2) – (1) Signal 0.4 – 0.6 V
Possible causes and
Wiring harness between CN-ST1 (female) (22) – CN-LP
Disconnection in wiring Resistance Max. 1
(female) (3)
3 harness (Disconnection in wiring or
defective contact in connector) Resistance Max. 1 
(female) (1)
(female) (2)
Grounding fault in wiring starting switch.
4
harness (Contact with ground circuit) Wiring harness between CN-ST1 (female) (14) – CN-LP
D51EX/PX-22 40-369 

Possible causes and troubleshooting.
standard value in
normal state
Circuit diagram related to Left HST pump pressure sensor
40-370  D51EX/PX-22
TROUBLESHOOTING ERROR CODE [DHH5KB]
12
ERROR CODE [DHH5KB]
LEFT HST PUMP PRESSURE SENSOR SHORT CIRCUIT
Action code Error code Left HST pump pressure sensor: Short circuit
Trouble
E02 DHH5KB (HST controller system)
Contents of trouble • Input signal voltage from the Left pump pressure is 4.42 V and above.
Action of failure.
controller
• Once the machine stops, the controller maintains the control assuming that the pump pressure is 100kg/cm2 (1,422 psi).
• The Left HST pump pressure may not be monitored in the monitoring mode.
on machine
Related
• Input state from the Left HST pump pressure sensor (pressure and voltage) can be checked with the monitoring mode.
information
(Controller: HST, code: 52502 HST L PRESS and code: 52503 HST L PRESS)

supply system
bleshooting.
CN-LP Voltage
Defective Left HST pump pressure
Possible causes and Voltage is measured with wiring harness connected. Accordingly, if voltage is abnormal,
standard value in check wiring harness and controller, too, for another cause of trouble, and then judge.
normal state H Prepare with starting switch OFF, then turn starting switch ON and carry out trou-
(Contact with 24 V) Wiring harness between CN-ST1 (female) (14) – CN-LP
Voltage Max. 1 V
troubleshooting.

D51EX/PX-22 40-371 
Circuit diagram related to Left HST pump pressure sensor
40-372  D51EX/PX-22
12
ERROR CODE [DHH6KA]
RIGHT HST PUMP PRESSURE SENSOR DISCONNECTION
Action code Error code Right HST pump pressure sensor: Disconnection
Trouble
E02 DHH6KA (HST controller system)
Contents of trouble • Input signal voltage from the Right HST pump pressure sensor dropped under 0.3 V.
Action of failure.
controller
• Once the machine stops, the controller maintains the control assuming that the pump pressure is 100kg/cm2 (1,422 psi).
• The Right HST pump pressure may not be monitored in the monitoring mode.
on machine
Related
• Input state from the Right HST pump pressure sensor (pressure and voltage) can be checked with the monitoring mode.
information
(Controller: HST, code: 52500 HST R PRESS and code: 52501 HST R PRESS)

supply system
bleshooting.
CN-RP Voltage
Defective Right HST pump pressure
starting switch.
Possible causes and Wiring harness between CN-ST1 (female) (22) – CN-LP
Disconnection in wiring Resistance Max. 1 
standard value in (female) (3)
normal state 3 harness (Disconnection in wiring or
(female) (1)
(female) (2)
4
harness (Contact with ground circuit) Wiring harness between CN-ST1 (female) (20) – CN-LP
troubleshooting.

D51EX/PX-22 40-373 
Circuit diagram related to Right HST pump pressure sensor
40-374  D51EX/PX-22
12
ERROR CODE [DHH6KB]
RIGHT HST PUMP PRESSURE SENSOR SHORT CIRCUIT
Action code Error code Right HST pump pressure sensor: Short circuit
Trouble
E02 DHH6KB (HST controller system)
Contents of trouble • Input signal voltage from the Right HST pump pressure sensor is above 4.42 V.
Action of failure.
controller
• Once the machine stops, the controller maintains the control assuming that the pump pressure is 100 kg/cm2 (1,422 psi).
• The Right HST pump pressure may not be monitored in the monitoring mode.
on machine
Related
• Input state from the Right HST pump pressure sensor (pressure and voltage) can be checked with the monitoring mode.
information
(Controller: HST, code: 52500 HST R PRESS and code: 52501 HST R PRESS)

supply system
bleshooting.
CN-RP Voltage
Defective Right HST pump pressure
Possible causes and Voltage is measured with wiring harness connected. Accordingly, if voltage is abnormal,
standard value in check wiring harness and controller, too, for another cause of trouble, and then judge.
normal state H Prepare with starting switch OFF, then turn starting switch ON and carry out
Short circuit with power supply line troubleshooting.
(Contact with 24 V) Wiring harness between CN-ST1 (female) (20) – CN-RP
Voltage Max. 1 V
troubleshooting.

D51EX/PX-22 40-375 
Circuit diagram related to Right HST pump pressure sensor
40-376  D51EX/PX-22
TROUBLESHOOTING ERROR CODE [DK10KA]
12
ERROR CODE [DK10KA]
FUEL DIAL SENSOR DISCONNECTION
Action code Error code Fuel dial sensor: Disconnection

Trouble
E03 DK10KA (HST controller system)
Contents of trouble • Input signal voltage from the fuel dial sensor dropped under 0.3 V.
• Until the machine stops, the controller maintains the control using the position signal being received immediately prior to the
Action of failure.
controller • Once the machine is stopped, the controller maintains the control assuming that the fuel dial is half position.
• The fuel dial operation does not work.
on machine
• Input state (voltage and command of rotation) from the fuel dial sensor can be checked with the monitoring mode.
Related
(Controller: HST, code: 03002 FUEL DIAL and code: 03003 FUEL DIAL)
information
• Method of reproducing error code: Turn the starting switch ON and operate fuel control lever.

supply system
Defective installation of fuel dial
2 Check if the fuel dial sensor (the black resin portion) is installed all the way in.
sensor
starting switch.
CN-FP (male) Resistance
Defective fuel dial
Between (A) and (C) 4.0 – 6.0 k 
3 sensor (Internal
failure) 0.5 – 4.5 k 
Between (B) and (A)
(Lo – Hi)
4.5 – 0.5 k 
Between (B) and (C)
(Lo – Hi)
Possible causes and
standard value in
starting switch.
normal state Disconnection in wiring
Wiring harness between CN-ST1 (female) (22) – CN-FP
4 harness (Disconnection in wiring or Resistance Max. 1 
(female) (A)
defective contact in connector)
(female) (B)
Grounding fault in wiring starting switch ON.
5
harness (Contact with ground circuit) Wiring harness between CN-ST1 (female) (2) – CN-FP
(female) (B) and chassis ground
troubleshooting.

D51EX/PX-22 40-377 
Circuit diagram related to fuel dial sensor
40-378  D51EX/PX-22
TROUBLESHOOTING ERROR CODE [DK10KB]
12
ERROR CODE [DK10KB]
FUEL DIAL SENSOR SHORT CIRCUIT
Action code Error code Fuel dial sensor: Short circuit

Trouble
E03 DK10KB (HST controller system)
Contents of trouble • Input signal voltage from the fuel dial sensor is above 4.5 V.
Action of failure.
controller • Once the machine is stopped, the controller maintains the control assuming that the fuel dial is half position.
• The fuel dial operation does not work.
on machine
• Input state (voltage and command of rotation) from the fuel dial sensor can be checked with the monitoring mode.
Related
(Controller: HST, code: 03002 FUEL DIAL and code: 03003 FUEL DIAL)
information
• Method of reproducing error code: Turn the starting switch ON and operate fuel control lever.

supply system
Defective installation of fuel dial
2 Check if the fuel dial sensor (the black resin portion) is installed all the way in.
sensor
starting switch.
CN-FP (male) Resistance
Defective fuel dial
Between (A) and (C) 4.0 – 6.0 k 
3 sensor (Internal
failure) 0.5 – 4.5 k 
Between (B) and (A)
(Lo – Hi)
4.5 – 0.5 k 
Possible causes and Between (B) and (C)
(Lo – Hi)
standard value in
normal state H Prepare with starting switch OFF, then carry out troubleshooting without turning
starting switch.
4 Disconnection in wiring harness
(female) (C)
• Prepare with starting switch OFF, then turn starting switch ON and carry out
(Contact with 24 V) Wiring harness between CN-ST1 (female) (2) – CN-FP
Voltage Max. 1 V
(female) (B)
troubleshooting.

D51EX/PX-22 40-379 
Circuit diagram related to fuel dial sensor
40-380  D51EX/PX-22
12
ERROR CODE [DK30KA]
STEERING ANGLE SENSOR 1 DISCONNECTION
Action code Error code Steering angle sensor 1: Disconnection

Trouble
Contents of trouble • Input voltage from the steering angle sensor 1 is above 4.5 V.
Action of
• Limits the functions partly and maintains the control using the signal from the steering angle sensor 2.
controller
• Input state (voltage) from the steering angle sensor 1 can be checked with the monitoring mode.
Related
(Controller: HST, Code: 50300 S/T LEVER 1)
information
• Method of reproducing error code: Turn the starting switch ON and operate the PCCS lever (in the steering direction)

supply system
starting switch.
Defective steering CN-EL (male) PCCS lever Resistance
2 angle sensor 1 (Internal
Between (5) and (8) 3.2 k ± 20%
failure)
Between (7) and (5) Neutral 2.4 k ± 20%
Between (7) and (8) 2.4 k ± 20%
starting switch.
Possible causes and Disconnection in wiring
standard value in 3 harness (Disconnection in wiring or Resistance Max. 1 
(female) (7)
(Contact with 24 V) Wiring harness between CN-ST1 (female) (19) – CN-EL
Voltage Max. 1 V
troubleshooting.

D51EX/PX-22 40-381 
Circuit diagram related to directional potentiometer and steering potentiometer
40-382  D51EX/PX-22
12
ERROR CODE [DK30KB]
STEERING ANGLE SENSOR 1 SHORT CIRCUIT
Action code Error code Steering angle sensor 1: Short circuit

Trouble
Contents of trouble • Input signal voltage from the steering angle sensor dropped under 0.3 V.
Action of
controller
Related
(Controller: HST, Code: 50300 S/T LEVER 1)
information

supply system
starting switch.
Between (5) and (8) 3.2 k ± 20%
failure)
Between (7) and (8) 2.4 k ± 20%
Possible causes and Disconnection in wiring starting switch.
standard value in 3 harness (Disconnection in wiring or
normal state Wiring harness between CN-ST1 (female) (22) – CN-EL
(female) (5)
4
harness (Contact with ground circuit) Wiring harness between CN-ST1 (female) (19) – CN-EL
troubleshooting.

D51EX/PX-22 40-383 
40-384  D51EX/PX-22
TROUBLESHOOTING ERROR CODE [DK30KX]
12
ERROR CODE [DK30KX]
STEERING ANGLE SENSOR OUT OF INPUT SIGNAL RANGE
Action code Error code Steering angle sensor: Out of input signal range
Trouble
E04 DK30KX (HST controller system)
• In the systems 1 and 2 of the steering angle sensor, either of the error codes [DK30KA] or [DK30KB], and [DK31KA] or
Contents of trouble
[DK31KB] occurred at the same time.
• Limits its functions partly.
Action of
controller
failure.
on machine • Once the machine is stopped, it cannot be started again.
• Input state (voltage) from the steering angle sensor 1 and 2 can be checked with the monitoring mode.
Related
(Controller: HST, code: 50300 S/T LEVER 1 and Code: 50301 S/T LEVER 2)
information

standard value in
normal state Carry out the troubleshooting for error codes [DK30KA], [DK30KB], [DK31KA] and [DK31KB].
D51EX/PX-22 40-385 
TROUBLESHOOTING ERROR CODE [DK30KZ]
12
ERROR CODE [DK30KZ]
STEERING ANGLE SENSOR DISCONNECTION OR SHORT CIRCUIT
Action code Error code Steering angle sensor: Disconnection or short circuit
Trouble
E04 DK30KZ (HST controller system)
• When the starting switch was turned ON, either of System 1 or System 2 of the steering angle sensor was defective, but, later, a
trouble occurred to the other that was normal at that time.
When the starting switch was turned ON, steering angle sensor 2 was only defective, but, later, [DK30KA] or [DK30KB]
Contents of trouble
appeared.
Or, when the starting switch was turned ON, steering angle sensor 1 was only defective, but, [DK31KA] or [DK31KB]
appeared.
• Limits its functions partly.
Action of
controller
failure.
Related
information

standard value in
normal state Carry out the troubleshooting for error codes [DK30KA], [DK30KB], [DK31KA] and [DK31KB].
40-386  D51EX/PX-22
TROUBLESHOOTING ERROR CODE [DK30L8]
12
ERROR CODE [DK30L8]
STEERING ANGLE SENSOR DISAGREEMENT OF ANALOG SIGNALS
Action code Error code Steering angle sensor: Disagreement of analog signals
Trouble
E03 DK30L8 (HST controller system)
Contents of trouble • Total voltage of the systems 1 and 2 of the steering angle sensor is below 4.41 V or above 5.59 V.
Action of • Limits the functions partly.
controller • Maintains the control using the potentiometer that outputs normal signal.
Related
information

standard value in
normal state Carry out troubleshooting for error codes [DK30KA], [DK30KB], [DK31KA] and [DK31KB].
D51EX/PX-22 40-387 
12
MEMORANDUM
40-388  D51EX/PX-22
12
ERROR CODE [DK31KA]
STEERING ANGLE SENSOR DISCONNECTION
Action code Error code Steering angle sensor 2: Disconnection

Trouble
Contents of trouble • Input signal voltage from the steering angle sensor dropped under 0.3 V.
Action of
controller
Related
(Controller: HST, code: 50301 S/T LEVER 2)
information

supply system
starting switch.
Between (5) and (8) 3.2 k ± 20%
failure)
Between (6) and (8) 2.4 k ± 20%
starting switch.
(female) (6)
4
bleshooting.

D51EX/PX-22 40-389 
40-390  D51EX/PX-22
12
ERROR CODE [DK31KB]
STEERING ANGLE SENSOR 2 SHORT CIRCUIT
Action code Error code Steering angle sensor 2: Short circuit

Trouble
Contents of trouble • Input signal voltage from the steering angle sensor 2 is above 4.5 V.
Action of
controller
Related
(Controller: HST, code: 50301 S/T LEVER 2)
information

supply system
starting switch.
Between (5) and (8) 3.2 k ± 20%
failure)
Neutral
Between (6) and (5) 2.4 k ± 20%
Between (6) and (8) 2.4 k ± 20%
Possible causes and Disconnection in wiring harness starting switch ON.
standard value in 3 (Disconnection in wiring or defective
contact in connector) Resistance Max. 1 
(female) (8)
Voltage Max. 1 V
troubleshooting.

D51EX/PX-22 40-391 
40-392  D51EX/PX-22
12
ERROR CODE [DK40KA]
BRAKE PEDAL SENSOR DISCONNECTION
Action code Error code Brake pedal sensor: Disconnection

Trouble
Contents of trouble • Input signal voltage from the brake pedal sensor dropped under 0.3 V.
Action of
failure.
controller
• Once the machine stops, the controller maintains the control assuming that the brake pedal is at stroke 0 position.
• Input state (stroke and voltage) from the brake pedal sensor can be checked with the monitoring mode.
Related
(Controller: HST, code: 50400 BRAKE PEDAL and code: 50401 BRAKE PEDAL)
information
• Method of reproducing error code: Turn the starting switch ON and operate the brake pedal

supply system
starting switch.
CN-BP1 (male) Resistance
Defective brake pedal sensor (Internal Between (B) and (C) 1.6 – 2.4 k
2
failure)
0.2 – 1.8 k
Between (A) and (B)
(Release – stroke end)
1.8 – 0.2 k
Between (A) and (C)
standard value in Disconnection in wiring
Wiring harness between CN-ST1 (female) (22) – CN-BP1
normal state 3 harness (Disconnection in wiring or Resistance Max. 1 
(female) (C)
(female) (A)
4
harness (Contact with ground circuit) Wiring harness between CN-ST1 (female) (3) – CN-BP1
(female) (A) and chassis ground
bleshooting.

D51EX/PX-22 40-393 
Circuit diagram related to brake sensor
40-394  D51EX/PX-22
12
ERROR CODE [DK40KB]
BRAKE PEDAL SENSOR SHORT CIRCUIT
Action code Error code Brake pedal sensor: Short circuit

Trouble
Contents of trouble • Input signal voltage from the brake pedal sensor is above 4.5 V.
Action of
failure.
controller
• Once the machine stops, the controller maintains the control assuming that the brake pedal is at stroke 0 position.
• Input state (stroke and voltage) from the brake pedal sensor can be checked with the monitoring mode.
Related
(Controller: HST, code: 50400 BRAKE PEDAL and code: 50401 BRAKE PEDAL)
information
• Method of reproducing error code: Turn the starting switch ON and operate the brake pedal

supply system
H Prepare by turning the starting switch off and carry out troubleshooting without
CN-BP1 (male) Resistance
Defective brake pedal sensor (Internal Between (B) and (C) 1.6 – 2.4 k
2
failure)
0.2 – 1.8 k
Between (A) and (B)
1.8 – 0.2 k
Between (A) and (C)
Possible causes and
standard value in Disconnection in wiring starting switch.
(female) (B)
(Contact with 24 V) Wiring harness between CN-ST1 (female) (3) – CN-BP1
Voltage Max. 1 V
bleshooting.
D51EX/PX-22 40-395 
Circuit diagram related to brake sensor
40-396  D51EX/PX-22
TROUBLESHOOTING ERROR CODE [DK55KX]
12
ERROR CODE [DK55KX]
DIRECTIONAL POTENTIOMETER OUT OF INPUT SIGNAL RANGE
Action code Error code Directional potentiometer: Out of input signal range
Trouble
E04 DK55KX (HST controller system)
• In the systems 1 and 2 of the directional potentiometer, either of the error codes [DK56KA] or [DK56KB], and [DK57KA] or
Contents of trouble
[DK57KB] occurred at the same.
Action of • Until the machine stops, the controller maintains the control using the position signal being received immediately prior to the
controller failure.
• Input state (voltage) from the directional potentiometers 1 and 2 can be checked with the monitoring mode.
Related
(Controller: HST, code: 50202 FR LEVER 1 and code: 50203 FR LEVER 2)
information
• Method of reproducing error code: Turn the starting switch ON and operate the PCCS lever (directional operation)

standard value in
normal state Carry out troubleshooting for the error codes [DK56KA], [DK56KB], [DK57KA], and [DK57KB].
D51EX/PX-22 40-397 
TROUBLESHOOTING ERROR CODE [DK55KZ]
12
ERROR CODE [DK55KZ]
DIRECTIONAL POTENTIOMETER DISCONNECTION OR SHORT CIRCUIT
Action code Error code Directional potentiometer: Disconnection or short circuit

Trouble
E04 DK55KZ (HST controller system)
• When the starting switch was turned ON, either of System 1 or System 2 of the directional potentiometer was defective, but,
later, a trouble occurred to the other that was normal at that time.
When the starting switch was turned ON, directional potentiometer 2 was only defective, but, later, [DK56KA] or [DK56KB]
Contents of trouble
appeared.
Or, when the starting switch was turned ON, directional potentiometer 1 was only defective, but, later, [DK57KA] or
[DK57KB] appeared.
Action of • Until the machine stops, the controller maintains the control using the position signal being received immediately prior to the
controller failure.
Problem that appears • Once the machine is stopped, Engine speed is limited to 50% of the value.
Related
information

standard value in
40-398  D51EX/PX-22
12
ERROR CODE [DK55L8]
DIRECTIONAL POTENTIOMETER DISAGREEMENT OF ANALOG SIGNALS
Action code Error code Directional potentiometer: Disagreement of analog signals

Trouble
E03 DK55L8 (HST controller system)
Contents of trouble • Total voltage of the systems 1 and 2 of the directional potentiometer is under 4.41 V or above 5.59 V.
Action of • Restricts part of the functions.
controller • Maintains the control using the potentiometer that outputs normal signal.
Related
information

standard value in
D51EX/PX-22 40-399 
12
MEMORANDUM
40-400  D51EX/PX-22
12
ERROR CODE [DK56KA]
DIRECTIONAL POTENTIOMETER 1 DISCONNECTION
Action code Error code Directional potentiometer 1: Disconnection

Trouble
Contents of trouble • Input signal voltage from directional potentiometer 1 dropped under 0.3 V.
Action of
• Restricts part of the functions and maintains the control using the signal from the directional potentiometer 2.
controller
• Input state (voltage) from the directional potentiometer 1 can be checked with the monitoring mode.
Related
(Controller: HST, code: 50202 FR LEVER 1)
information

supply system
starting switch.
CN-EL (male) PCCS lever Resistance
Defective directional
2
potentiometer 1 (Internal failure) Between (4) and (1) 3.2 k ± 20%
Between (3) and (1) 2.4 k ± 20%
starting switch.
(female) (3)
4
bleshooting.

D51EX/PX-22 40-401 
40-402  D51EX/PX-22
12
ERROR CODE [DK56KB]
DIRECTIONAL POTENTIOMETER 1 SHORT CIRCUIT
Action code Error code Directional potentiometer 1: Short circuit

Trouble
Contents of trouble • Input signal voltage from directional potentiometer sensor 1 is above 4.5 V.
Action of
• Limits the functions partly and maintains the control using the signal from the directional potentiometer 2.
controller
Related
information

supply system
starting switch.
2
Between (3) and (1) 2.4 k ± 20%
Possible causes and Disconnection in wiring harness (Dis- starting switch.
standard value in 3 connection in wiring or defective con-
tact in connector) Resistance Max. 1 
(female) (1)
Voltage Max. 1 V
bleshooting.

D51EX/PX-22 40-403 
40-404  D51EX/PX-22
12
ERROR CODE [DK57KA]
DIRECTIONAL POTENTIOMETER 2 DISCONNECTION
Action code Error code Directional potentiometer 2: Disconnection

Trouble
Contents of trouble • Input signal voltage from directional potentiometer 2 dropped under 0.3 V.
Action of
• Limits the functions partly and maintains the control using the signal from the directional potentiometer 1
controller
Related
information

supply system
starting switch.
2
Between (2) and (1) 2.4 k ± 20%
starting switch.
(female) (2)
4
bleshooting.

D51EX/PX-22 40-405 
40-406  D51EX/PX-22
12
ERROR CODE [DK57KB]
DIRECTIONAL POTENTIOMETER 2 SHORT CIRCUIT
Action code Error code Directional potentiometer 2: short circuit

Trouble
Contents of trouble • Input signal voltage from directional potentiometer 2 is above 4.5 V.
Action of
• Limits the functions partly and maintains the control using the signal from the directional potentiometer 1.
controller
Related
information

supply system
starting switch.
2
Between (2) and (1) 2.4 k ± 20%
Disconnection in wiring harness (Dis- starting switch.
Possible causes and 3 connection in wiring or defective con-
standard value in tact in connector) Resistance Max. 1 
H Prepare with starting switch OFF and then turn starting switch ON and carry out
troubleshooting.
(Contact with 24 V)
Voltage Max. 1 V
bleshooting.

D51EX/PX-22 40-407 
40-408  D51EX/PX-22
TROUBLESHOOTING ERROR CODE [DLM0KX]
12
ERROR CODE [DLM0KX]
HST MOTOR SPEED SENSORS OUT OF INPUT SIGNAL RANGE
Action code Error code HST motor speed sensors: Out of input signal range
Trouble
E03 DLM0KX (HST controller system)
• In the Left HST motor speed sensor system and Right HST motor speed sensor system, either of the error codes [DLM1KA] or
Contents of trouble
[DLM1KB], and [DLM2KA] or [DLM2KB] occurred at the same time.
Action of
controller
on machine
• Travel deviation occurs.
• Input state from the Left HST motor speed sensor and Right HST motor speed sensor (speed in frequency) can be checked with
Related the monitoring mode.
information (Controller: HST, code: 40002 R SPEED, code: 40003 L SPEED, code: 40963 R SPEED, and code: 40964 L SPEED)
• Method of reproducing error code: Turn the starting switch ON and operate the PCCS lever (forward or reverse travel)

standard value in
normal state Carry out troubleshooting for the error codes [DLM1KA], [DLM1KB], [DLM2KA], and [DLM2KB].
D51EX/PX-22 40-409 
TROUBLESHOOTING ERROR CODE [DLM0KX]
12
MEMORANDUM
40-410  D51EX/PX-22
TROUBLESHOOTING ERROR CODE [DLM1KA]
12
ERROR CODE [DLM1KA]
LEFT HST MOTOR SPEED SENSOR DISCONNECTION
Action code Error code Left HST motor speed sensor: Disconnection
Trouble
E01 DLM1KA (HST controller system)
Contents of trouble • Disconnection was detected in Left HST motor speed sensor.
Action of • Stops the straight travel correction control.
on machine
• Input state from the Left HST motor speed sensor (speed and frequency) can be checked with the monitoring mode.
Related
(Controller: HST, code: 40003 L SPEED and code: 40964 L SPEED)
information

supply system
H Prepare with starting switch OFF, then start engine, travel and carry out trouble-
shooting.
CN-LRS2 Voltage
Power supply
Between (A) and (B) 4.5 – 5.5 V
(When travel is stopped)
Defective Left HST motor
2
speed sensor (Internal failure) Signal
0 V  4.5 – 5.0 V
Between (C) and (B) (When traveling at constant
(At a constant cycle)
speed)
Left HST motor speed sensor voltage is measured with the wiring harness connected.
Accordingly, if voltage is abnormal, check the wiring harness and controller for another
cause of trouble before judgment.
starting switch.
Possible causes and
standard value in Disconnection in wiring Resistance Max. 1 
LRS2 (female) (A)
LRS2 (female) (B)
LRS2 (female) (C)
4 circuit in wiring harness (Contact
with 24V circuit) Wiring harness between CN-ST2 (female) (20) – CN-
Voltage Max. 1 V
LRS2 (female) (C) and chassis ground
H Prepare with starting switch OFF, then start engine, travel and carry out
troubleshooting.
CN-ST2 and CN-ST3 Voltage
5 Defective HST controller Between CN-ST3 (34) and Power supply

4.5 – 5.5 V
CN-ST2 (39) (When travel is stopped)
Signal
Between CN-ST2 (20) and 0 V  4.5 – 5.0 V
(When traveling at constant
CN-ST2 (39) (At a constant cycle)
speed)
D51EX/PX-22 40-411 
Circuit diagram related to HST motor speed sensor
40-412  D51EX/PX-22
TROUBLESHOOTING ERROR CODE [DLM1KB]
12
ERROR CODE [DLM1KB]
LEFT HST MOTOR SPEED SENSOR: SHORT CIRCUIT
Action code Error code Left HST motor speed sensor: Short circuit
Trouble
– DLM1KB (HST controller system)
Contents of trouble • Signal from Left HST motor speed sensor is not input despite the travel command.
on machine
• Input state from the Left HST motor speed sensor (speed in frequency) can be checked with the monitoring mode.
Related • Method of reproducing error code: Turn the starting switch ON and operate the PCCS lever (forward or reverse travel)
information • If the error code is not reproduced, improper air bleeding immediately after the assembling or modification, or false detection of
the signal being transmitted at low temperature can be suspected rather than the error of the sensor. Replacement is not
necessary.

supply system
troubleshooting.
CN-LRS2 Voltage
Voltage
Defective Left HST motor
2 Signal
speed sensor (Internal failure)
0 V  4.5 – 5.0 V
speed)
Possible causes and
standard value in Left HST motor speed sensor voltage is measured with the wiring harness connected.
normal state Accordingly, if voltage is abnormal, check the wiring harness and controller for another
3
harness (Contact with ground circuit) Wiring harness between CN-ST2 (female) (20) – CN-
troubleshooting.
Wiring harness between CN-ST3 (female) (34) – CN-LRS
(Contact with 24 V)
Voltage Max. 1 V
D51EX/PX-22 40-413 

shooting.
Possible causes and
standard value in 5 Defective HST controller Between CN-ST3 (24) and Power supply
4.5 – 5.5 V
normal state CN-ST2 (34) (When travel is stopped)
Signal
speed)
6 HST-related failure When the HST motor is not running practically, carry out troubleshooting in the H mode.
40-414  D51EX/PX-22
TROUBLESHOOTING ERROR CODE [DLM1MA]
12
ERROR CODE [DLM1MA]
LEFT HST MOTOR SPEED SENSOR: MALFUNCTION
Action code Error code Left HST motor speed sensor: Malfunction
Trouble
– DLM1MA (HST controller system)
Contents of trouble • Signal from Left HST motor speed sensor is entered but substantial portion of the pulses are lost during transmission.
on machine
• Input state from the Left HST motor speed sensor (speed and frequency) can be checked with the monitoring mode.
the signal being transmitted at low temperature can be suspected rather than the error of the sensor. Replacement is not neces-
sary.

Prepare with starting switch OFF, then start engine, travel and carry out troubleshooting.
CN-LRS2 Voltage
Possible causes and Defective Left HST motor Power supply

1 Between (A) and (B) 4.5 – 5.5 V
standard value in speed sensor (Internal failure) (When travel is stopped)
normal state Signal
0 V  4.5 – 5.0 V
speed)
Defective Left HST motor speed Left HST motor speed sensor may be defective internally (damages on the speed
2
sensor (Internal failure) detector). Check it directly.
D51EX/PX-22 40-415 
40-416  D51EX/PX-22
12
ERROR CODE [DLM2KA]
RIGHT HST MOTOR SPEED SENSOR DISCONNECTION
Action code Error code Right HST motor speed sensor: Disconnection
Trouble
Contents of trouble • Disconnection was detected in Right HST motor speed sensor.
on machine
• Input state from the Right HST motor speed sensor (speed and frequency) can be checked with the monitoring mode.
Related
(Controller: HST, code: 40002 R SPEED and code: 40963 R SPEED)
information

supply system
shooting.
CN-RRS2 Voltage
Power supply
Defective Right HST motor
2
speed sensor (Internal failure) Signal
0 V  4.5 – 5.0 V
speed)
Right HST motor speed sensor voltage is measured with the wiring harness connected.
Accordingly, if voltage is abnormal, check the wiring harness and controller for another
starting switch.
Possible causes and
standard value in Disconnection in wiring Resistance Max. 1 
RRS2 (female) (A)
RRS2 (female) (B)
RRS2 (female) (C)
with 24V circuit) Wiring harness between CN-ST2 (female) (30) – CN-
Voltage Max. 1 V
RRS2 (female) (C) and chassis ground
shooting.
5 Defective HST controller Between CN-ST3 (34) and Power supply

4.5 – 5.5 V
Signal
speed)
D51EX/PX-22 40-417 
40-418  D51EX/PX-22
12
ERROR CODE [DLM2KB]
RIGHT HST MOTOR SPEED SENSOR SHORT CIRCUIT
Action code Error code Right HST motor speed sensor: Short circuit
Trouble
– DLM2KB (HST controller system)
Contents of trouble • Signal from Right HST motor speed sensor is not input despite the travel command.
Action of • The straight travel correction control is stopped.
on machine
• Input state from the Right HST motor speed sensor (speed in frequency) is identifiable with the monitoring mode.
sary.

supply system
troubleshooting.
CN-RRS2 Voltage
Power supply
Defective Right HST motor
2 Signal
speed sensor (Internal failure)
0 V  4.5 – 5.0 V
speed)
Possible causes and
standard value in Right HST motor speed sensor voltage is measured with the wiring harness connected.
normal state Accordingly, if voltage is abnormal, check the wiring harness and controller for another
3
RRS2 (female) (C)
troubleshooting.
RRS2 (female) (A)
(Contact with 24 V)
Voltage Max. 1 V
RRS2 (female) (C)
D51EX/PX-22 40-419 

Prepare with starting switch OFF, then start engine, travel and carry out troubleshooting.
Possible causes and Between CN-ST3 (34) and Power supply
standard value in 5 Defective HST controller 4.5 – 5.5 V
normal state
Signal
speed)
6 HST-related error When the HST motor is not running practically, carry out troubleshooting in the H mode.
40-420  D51EX/PX-22
12
ERROR CODE [DLM2MA]
RIGHT HST MOTOR SPEED SENSOR MALFUNCTION
Action code Error code Right HST motor speed sensor: Malfunction
Trouble
– DLM2MA (HST controller system)
Contents of trouble • Signal from Right HST motor speed sensor is entered but substantial portion of the pulses are lost during transmission.
Action of • The straight travel correction control is stopped.
on machine
• Input state from the Right HST motor speed sensor (speed and frequency) can be checked with the monitoring mode.
sary.

starting switch ON.
CN-RRS2 Voltage
Possible causes and Defective Right HST motor Power supply
1 Between (A) and (B) 4.5 – 5.5 V
standard value in speed sensor (Internal failure) (When travel is stopped)
normal state
Signal
0 V  4.5 – 5.0 V
speed)
Defective Right HST motor sensor Right HST motor speed sensor may be defective internally (damages on the speed
2
(Internal failure) detector). Check it directly.
D51EX/PX-22 40-421 
40-422  D51EX/PX-22
12
ERROR CODE [DLM3KA]
FAN SPEED SENSOR DISCONNECTION
Action code Error code Fan speed sensor: Disconnection

Trouble
Contents of trouble • Disconnection was detected in fan speed sensor.

Action of • Stop the fan control (feedback control).
• The fan speed fails to accurately meet the specified speed.
on machine
Related • Input state from the fan speed sensor (speed and frequency) can be checked with the monitoring mode.
information (Controller: HST, code: 10007 FAN SPEED and code: 40965 FAN SPEED)

starting switch.
Defective fan speed CN-FRS (male) Resistance
1
Between (1) and (2) 400 – 1000 
Between (1) (2) and chassis ground Min. 1 M
starting switch.
Wiring harness between CN-ST2 (female) (10) – CN-FRS
standard value in Wiring harness between CN-ST2 (female) (39) – CN-FRS
(female) (2)
with 24V circuit) Wiring harness between CN-ST2 (female) (10) – CN-FRS
Voltage Max. 1 V
starting switch.
4 Defective HST controller CN-ST2 (female) Resistance

Between (10) and (39) 400 – 1000 
Between (10) and chassis ground Min. 1 M
D51EX/PX-22 40-423 
Circuit diagram related to fan speed sensor
40-424  D51EX/PX-22
12
ERROR CODE [DLM3KB]
FAN SPEED SENSOR: SHORT CIRCUIT
Action code Error code Fan speed sensor: Short circuit

Trouble
E02 DLM3KB (HST controller system)
Contents of trouble • While the engine is running, no signal is input from the fan speed sensor.
Action of
• Stop the fan control (feedback control).
controller
Problem that
• The fan speed fails to accurately meet the specified speed.
appears on machine
Related • Input state from the fan speed sensor (speed and frequency) can be checked with the monitoring mode.
information (Controller: HST, code: 10007 FAN SPEED and code: 40965 FAN SPEED)

starting switch.
Defective fan speed sensor CN-FRS (male) Resistance
1
(Internal short circuit)
Between (1) and (2) 400 – 1000 
Between (1)(2) and chassis ground Min. 1 M
Defective fan speed Adjustment of the fan speed sensor may be defective. Check it directly (see “Testing and
2
sensor adjustment adjusting”).
harness (Contact with ground circuit) Wiring harness between CN-ST2 (female) (10) – CN-FRS
standard value in Resistance Min. 1 M
normal state
(Contact with 24 V) Wiring harness between CN-ST2 (female) (10) – CN-FRS
Voltage Max. 1 V
starting switch.

Between (10) and (29) 400 – 1000 
6 Defective hydraulic system When the fan is rotating practically, carry out troubleshooting in the H mode.
D51EX/PX-22 40-425 
Circuit diagram related to fan speed sensor
40-426  D51EX/PX-22
TROUBLESHOOTING ERROR CODE [DN21FS]
12
ERROR CODE [DN21FS]
BRAKE PEDAL AND PROXIMITY SWITCH FIXING
Action code Error code Brake pedal and proximity switch: Fixing
Trouble
E03 DN21FS (HST controller system)
• The signal of travel lock limit switch 1 is set to Free position and the signal of travel lock limit switch 2 (NO) is set to OFF
Contents of trouble
(OPEN), but the output circuit to the slow brake solenoid valve is not operating.
Action of
controller
• Input state from the travel lock limit switch (ON and OFF) can be checked with the monitoring mode.
(Controller: HST, code: 40911 D-IN [12]: switch 2 (NO), code: 40912 D-IN [18]: switch 1 (NO), [19]: switch 2 (NC))
Related • Input state from the brake pedal sensor (stroke and voltage) can be checked with the monitoring mode.
information (Controller: HST, code: 50400 BRAKE PEDAL, code: 50401 BRAKE PEDAL)
• Method of reproducing error code: Start the engine, operate the parking brake lever (Free), and operate the brake pedal (press to
the full position)

starting switch.
Brake pedal
Defective center brake proximity CN-PB (male)
1 Fully-depressed
Possible causes and switch (Internal failure) Release position
position
standard value in
normal state Between (A) and (B) Max. 1 Min. 1 M
Between (A) and (C) Min. 1 M Max. 1
Defective center brake Installation of the center brake proximity switch may be defective. Check it directly (see
2
proximity switch “Testing and adjusting”).
Defective brake Installation of the brake potentiometer may be defective. Check it directly (see “Testing
3
potentiometer installation and adjusting”).
D51EX/PX-22 40-427 
TROUBLESHOOTING ERROR CODE [DN21FS]
40-428  D51EX/PX-22
TROUBLESHOOTING ERROR CODE [DV00KB]
12
ERROR CODE [DV00KB]
CAUTION BUZZER SHORT CIRCUIT
Action code Error code Caution buzzer: Short circuit

Trouble
E01 DV00KB (Monitor panel system)
Contents of trouble • Abnormal current flowed at the GND output to the caution buzzer circuit.
Action of • Stops GND output from the caution buzzer circuit.
Problem that • The caution buzzer dose not sound when the starting switch is turned ON, emergency warning items becomes abnormal, or action
appears on machine code [E02], [E03] or [E04] is displayed.
Related
information

Defective caution buzzer (Internal starting switch.
1
short circuit) CN-CB (male) Resistance
Between (1) and (2) 1.2 M
Prepare with starting switch OFF, then turn starting switch ON and carry out
Possible causes and Short circuit with power supply line troubleshooting.
standard value in 2 circuit in wiring harness
normal state (Contact with 24 V) Wiring harness between CN-S03 (female) (18) – CN-CB
Voltage Max. 1 V
troubleshooting.
3 Defective monitor panel CN-S03 Caution buzzer Voltage

Between (18) and chassis When stopped 20 – 30 V
ground When operated (sounded) Max. 1 V
Circuit diagram related to caution buzzer
D51EX/PX-22 40-429 
TROUBLESHOOTING ERROR CODE [DV20KB]
12
ERROR CODE [DV20KB]
BACK ALARM BUZZER SHORT CIRCUIT
Action code Error code Back alarm buzzer: Short circuit

Trouble
E01 DV20KB (HST controller system)
Contents of trouble • Abnormal current flowed at the output to the back alarm buzzer circuit.
Action of • Stops output to the back alarm buzzer circuit.
• Back alarm buzzer does not sound in the reverse travel.
on machine
• Output state from the back alarm buzzer (ON, OFF and voltage) can be checked with the monitoring mode.
Related
(Controller: HST, code: 40918 D-OUT [S], and code: 70401 BACK ALARM)
information
• Method of reproducing error code: Turn the starting switch ON and operate the PCCS lever (reverse travel)

1
TBA3 (female) (1) and chassis ground
Possible causes and Prepare with starting switch OFF, then turn starting switch ON and carry out trouble-
standard value in shooting.
normal state CN-ST3 PCCS lever Voltage
When neutral Max. 1 V
Between (18) and chassis
ground When operated to reverse
20 – 30 V
travel
Defective back alarm buzzer (Internal Since trouble is in system, troubleshooting cannot be carried out. (If causes 1 – 2 above
3
failure) are not detected, travel alarm may be defective.)
Circuit diagram related to back alarm buzzer
40-430  D51EX/PX-22
TROUBLESHOOTING ERROR CODE [DW4BKA]
12
ERROR CODE [DW4BKA]
PARKING BRAKE SOLENOID VALVE DISCONNECTION
Action code Error code Parking brake solenoid valve: Disconnection

Trouble
E04 DW4BKA (HST controller system)
Contents of trouble • No current flows at output to the parking brake solenoid valve circuit.
Action of • Stops output of the signal to the parking brake solenoid valve circuit.
• The machine is stopped as long as traveling is continued.
• The machine cannot be moved as long as traveling is stopped.
on machine
• Once the machine is stopped and started again, engine speed is limited to medium (half) speed.
• Output state to the parking brake solenoid valve (ON, and OFF) can be checked with the monitoring mode.
Related
(Controller: HST, code: 40914 D-OUT [14])
information

1 circuit in wiring harness If the error code [DW4BKY] is displayed, carry out troubleshooting for it first as stated.
Defective parking brake starting switch.
2 solenoid valve (Internal
CN-S4 (male) Resistance
failure)
Between (1) and (2) 40 – 60 
Possible causes and
standard value in
starting switch.
normal state
Wiring harness between CN-ST3 (female) (27) – CN-S4
(female) (1)
Wiring harness between CN-ST3 (female) (3) – CN-S4
(female) (2)
starting switch.
CN-ST3 (female) Resistance
Between (27) and (3) 40 – 60 
D51EX/PX-22 40-431 
Circuit diagram related to parking brake solenoid valve
40-432  D51EX/PX-22
TROUBLESHOOTING ERROR CODE [DW4BKB]
12
ERROR CODE [DW4BKB]
PARKING BRAKE SOLENOID VALVE SHORT CIRCUIT
Action code Error code Parking brake solenoid valve: Short circuit
Trouble
E04 DW4BKB (HST controller system)
Contents of trouble • Abnormal current flowed at output to the parking brake solenoid valve circuit.
Action of • Stops output of the signal to the parking brake solenoid valve circuit.
• The machine cannot be moved as long as traveling is stopped.
on machine
• Once the machine is stopped and started again, its engine speed is limited to medium (half) speed.
Related
information

starting switch.
Defective parking brake solenoid
1 valve CN-S4 (male) Resistance
(Internal short circuit) Between (1) and (2) 40 – 60 
Prepare with starting switch OFF, then carry out troubleshooting without turning starting
Defective assembled-type diode switch.
2
Possible causes and (Internal short circuit) CN-D4 (male) Resistance (Continuity)
standard value in Between (4) and (8) Min. 1 M (No continuity)
normal state
2
harness (Contact with ground circuit) Wiring harness between CN-ST3 (female) (27) – CN-S4
starting switch.

Between (27) and (3) 40 – 60 
D51EX/PX-22 40-433 
40-434  D51EX/PX-22
TROUBLESHOOTING ERROR CODE [DW4BKY]
12
ERROR CODE [DW4BKY]
PARKING BRAKE SOLENOID VALVE SHORTED
Action code Error code Parking brake solenoid valve: Short circuit with power supply line
Trouble
E03 DW4BKY (HST controller system)
Contents of trouble • Abnormal current constantly flows to the parking brake solenoid valve circuit.
Action of
controller
Related
information
• Method of reproducing error code: Turn the starting switch ON and operate parking brake lever (Lock).

Possible causes and Prepare with starting switch OFF, then turn starting switch ON and carry out
standard value in Short circuit with power supply line troubleshooting.
normal state 1 circuit wiring harness
(Contact with 24 V) Wiring harness between CN-ST3 (female) (27) – CN-S4
Voltage Max. 1 V
D51EX/PX-22 40-435 
12
ERROR CODE [DW7BKA]
FAN REVERSE SOLENOID VALVE DISCONNECTION
Action code Error code Fan reverse solenoid valve: Disconnection

Trouble
E01 DW7BKA (HST controller system)
Contents of trouble • No current flows at output to the fan reverse solenoid valve circuit.
Action of • Stops output of the signal to the fan reverse solenoid valve circuit.
• The fan does not rotate in reverse.
on machine
• Output state to the fan reverse solenoid valve (ON, and OFF) can be checked with the monitoring mode.
Related
information
• Method of reproducing error code: Turn the starting switch ON and operate the fan rotation selector switch (CLN).

1 circuit in wiring harness (Contact If the error code [DW7BKY] is displayed, carry out troubleshooting for it first as stated.
with 24V circuit)
Defective fan reverse starting switch.
2 solenoid valve (Internal
CN-FAR (male) Resistance
disconnection)
Possible causes and
Between (1) and (2) 40 – 60 
standard value in
starting switch.
Wiring harness between CN-ST3 (female) (7) – CN-FAR
3 harness (Disconnection in wiring or Resistance Max. 1 z
(female) (1)
Wiring harness between CN-ST3 (female) (13) – CN-FAR
Resistance Max. 1 z
(female) (2)
If causes 1 – 3 are not detected, HST controller may be defective. (Since trouble is in
system, troubleshooting cannot be carried out.)
Circuit diagram related to fan reverse solenoid valve
ERROR CODE [DW7BKB]

40-436  D51EX/PX-22
FAN REVERSE SOLENOID VALVE SHORT CIRCUIT
Action code Error code Fan reverse solenoid valve: Short circuit
Trouble
E01 DW7BKB (HST controller system)
Contents of trouble • Abnormal current flowed at output to the fan reverse solenoid valve circuit.
Action of • Stops output of the signal to the fan reverse solenoid valve circuit.
• The fan does not rotate in reverse.
on machine
Related
information
• Method of reproducing error code: Turn the starting switch ON and operate the fan rotation selector switch (CLN).

starting switch.
Defective fan reverse CN-FAR (male) Resistance
1
solenoid valve (Internal short circuit)
Between (1) and (2) 40 – 60 
Possible causes and
standard value in Between (1) and chassis ground Min. 1 M
2
harness (Contact with ground circuit) Wiring harness between CN-ST3 (female) (7) – CN-FAR
(female) (1) and chassis ground)
D51EX/PX-22 40-437 
TROUBLESHOOTING ERROR CODE [DW7BKY]
12
ERROR CODE [DW7BKY]
FAN REVERSE SOLENOID VALVE SHORTED
Action code Error code Fan reverse solenoid valve: Short circuit with power supply line
Trouble
E03 DW7BKY (HST controller system)
Contents of trouble • Abnormal current constantly flows to the fan reverse solenoid valve circuit.
Action of
controller
• The fan dose not rotate in forward.
on machine
Related (Controller: HST, code: 40914 D-OUT [8])
information • Method of reproducing error code: Turn the starting switch ON and start the cleaning operation and operate the fan rotation
selector switch (NOR)

Possible causes and H Prepare with starting switch OFF, then turn starting switch ON and carry out
(Contact with 24 V) Wiring harness between CN-ST3 (female) (7) – CN-FAR
Voltage Max. 1 V
40-438  D51EX/PX-22
TROUBLESHOOTING ERROR CODE [DW7EKA]
12
ERROR CODE [DW7EKA]
SLOW BRAKE SOLENOID VALVE DISCONNECTION
Action code Error code Slow brake solenoid valve: Disconnection

Trouble
E04 DW7EKA (HST controller system)
• Through the signal of travel lock limit switch 1 is set to Free position and the brake pedal stroke is less than 60%, no current
Contents of trouble
flows to the circuit of the slow brake solenoid valve.
Action of • Stops output of the signal to the slow brake solenoid valve circuit.
• The machine is stopped, it cannot be moved again.
on machine
• The machine is stopped, its engine speed is limited to medium (half) speed.
• Input state from the travel lock limit switch (ON, and OFF) can be checked with the monitoring mode.
(Controller: HST, code: 40911 D-IN [12]: switch 2 (NO), and code: 40912 D-IN [18]: switch 1 (NO), [19]: switch 2 (NC))
Related • Input state from the brake pedal (stroke and voltage) can be checked with the monitoring mode.
information (Controller: HST, code: 50400 BRAKE PEDAL, and code: 50401 BRAKE PEDAL)
• Method of reproducing error code: Turn on the starting switch, operate the parking brake lever (Free) and operate the brake
pedal (Release)

1 circuit in wiring harness (Contact If the error code [DW7EKY] is displayed, carry out troubleshooting for it first as stated.
with 24V circuit)
Defective slow brake starting switch.
2 solenoid valve
CN-S3 (male) Resistance
Between (1) and (2) 40 – 60 
Defective travel lock limit switch 2 starting switch.
(Internal disconnection) CN-26B (male) Travel lock lever Resistance
standard value in
normal state Between (A) and (B) Free (Top) Max. 1 
Defective installation of travel lock Installation of travel lock limit switch may be defective. Check it directly (see “Testing
4
limit switch 2 adjusting”)
bleshooting.
Brake pedal
Wiring harness between CN-26B (female) (B) – CN-S3
Defective center brake relay (Internal Release Stroke end
5 (female) (1)
disconnection) Max. 1  Min. 1 M
Resistance is measured with wiring harness connected. Accordingly, if resistance is
abnormal, check cause 6 center brake relay primary (coil side) and cause 12 wiring
harness disconnection, too, for another cause of trouble, and then judge.
D51EX/PX-22 40-439 

bleshooting.
Brake pedal
CN-11B (female)
Release Stroke end
Defective center brake relay (coil
6 Between (1) and chassis ground 20 – 30 V 20 – 30 V
side)
Between (2) and chassis ground Max. 1 V 20 – 30 V
If voltage is abnormal, check cause 7, 8, 9, 10, and 11 and then judge.
7 Defective fuse If the fuse is burn, the circuit probably has a grounding fault, etc. (See cause 11)
troubleshooting.
Brake pedal
CN-PB
Defective center brake proximity Release Stroke end
8
switch (Internal error) Between (A) and (C) 20 – 30 V 20 – 30 V
Between (B) and (C) Max. 1 V 20 – 30 V
check cause 9, 10 and 11, too, for another cause of trouble, and then judge.
Defective installation of brake poten- Installation of brake potentiometer or brake proximity switches may be defective. Check
9
tiometer or brake proximity switches them directly referencing the “Testing and adjusting”.
Possible causes and H Prepare with starting switch OFF, then carry out troubleshooting without turning
standard value in starting switch ON.
normal state Wiring harness between CN-11B (female) (1) – F01 (6)
Disconnection in wiring outlet
10 harness Wiring harness between CN-PB (female) (A) – F01 (6)
(primary side of relay) outlet
Wiring harness between CN-11B (female) (2) – CN-PB
(female) (B)
Wiring harness between CN-PB (female) (C) – CN-T36 Resistance Max. 1 
starting switch ON.
Grounding fault in wiring harness Wiring harness between CN-11B (female) (1) – CN-PB Min.
11 Resistance
(relay primary) (female) (A), – F01 (6) outlet and chassis ground 1 M
Wiring harness between CN-11B (female) (2) – CN-PB Min.
Resistance
(female) (B) and chassis ground 1M
starting switch.
Disconnection in wiring (female) (A)
12
harness Wiring harness between CN-26B (female) (B) – CN-11B
(female) (3)
Wiring harness between CN-11B (female) (5) – CN-S3
(female) (1)
40-440  D51EX/PX-22
D51EX/PX-22 40-441 
12
MEMORANDUM
40-442  D51EX/PX-22
TROUBLESHOOTING ERROR CODE [DW7EKB]
12
ERROR CODE [DW7EKB]
SLOW BRAKE SOLENOID VALVE SHORT CIRCUIT
Action code Error code Slow brake solenoid valve: Short circuit
Trouble
E04 DW7EKB (HST controller system)
Contents of trouble • Abnormal current flowed at output to the slow brake solenoid valve circuit.
Action of • Stops output of the signal to the slow brake solenoid valve circuit.
• The machine is stopped, it cannot be moved again.
on machine
• The machine is stopped, engine speed is limited to medium (half) speed.
• Input state from the travel lock limit switch (ON, and OFF) can be checked with the monitoring mode.
(Controller: HST, code: 40911 D-IN [12]: switch 2 (NO), and code: 40912 D-IN [18]: switch 1 (NO), [19]: switch 2 (NC))
Related • Input state from the brake pedal (stroke and voltage) can be checked with the monitoring mode.
information (Controller: HST, code: 50400 BRAKE PEDAL, and code: 50401 BRAKE PEDAL)
• Method of reproducing error code: Turn on the starting switch, operate the parking brake lever (Free) and operate the brake
pedal (Release)

starting switch.
Defective slow brake
1 solenoid valve CN-S3 (male) Resistance
(Internal short circuit) Between (1) and (2) 40 – 60
starting switch.
Defective assembled-type diode
2
(Internal short circuit) CN-D4 (male) Resistance (Continuity)
Between (3) and (7) Min. 1 M (No Continuity)
starting switch.
Defective travel lock limit switch 2
3
(Internal short circuit) CN-26B (male) Resistance
Possible causes and
standard value in Between (A) (B) (C) and chassis ground Min. 1 M
Defective center brake starting switch.
4 solenoid relay
CN-11B (male) Resistance
Between (3) (5) (6) and chassis ground Min. 1 M
starting switch.
Grounding fault in wiring harness (female) (A) and chassis ground
5
(Short circuit with ground circuit) Wiring harness between CN-26B (female) (B) – CN-11B
D51EX/PX-22 40-443 
TROUBLESHOOTING ERROR CODE [DW7EKB]
40-444  D51EX/PX-22
TROUBLESHOOTING ERROR CODE [DW7EKY]
12
ERROR CODE [DW7EKY]
SLOW BRAKE SOLENOID VALVE SHORTED
Action code Error code Slow brake solenoid valve: Short circuit with power supply line
Trouble
E03 DW7EKY (HST controller system)
Contents of trouble • Abnormal current constantly flows to the slow brake solenoid valve circuit.
Action of
controller
Related • Method of reproducing error code: Turn on the starting switch, operate the parking brake lever (Free) and operate the brake
information pedal (Release)

Prepare with starting switch OFF, then turn starting switch ON and carry out
troubleshooting.
Possible causes and Wiring harness between CN-ST3 (female) (37) – CN-26B
Short circuit with power supply line Voltage Max. 1 V
standard value in (female) (A) and chassis ground
(Contact with 24 V) Wiring harness between CN-26B (female) (B) – CN-11B
Voltage Max. 1 V
Voltage Max. 1 V
D51EX/PX-22 40-445 
TROUBLESHOOTING ERROR CODE [DW7EKY]
40-446  D51EX/PX-22
TROUBLESHOOTING ERROR CODE [DWN5KA]
12
ERROR CODE [DWN5KA]
FAN EPC SOLENOID VALVE DISCONNECTION
Action code Error code Fan EPC solenoid valve: Disconnection

Trouble
E01 DWN5KA (HST controller system)
Contents of trouble • No current flows at output to the fan EPC solenoid valve circuit.
Action of • Stops output of the signal to the fan EPC solenoid valve circuit.
• The fan speed is set to the maximum.
on machine
• Output state to the fan EPC solenoid valve can be checked with the monitoring mode.
Related
(Controller: HST, code: 31623 FAN EPC, and code: 31624 FAN EPC FB)
information

1 circuit in wiring harness (Contact If the error code [DWN5KY] is displayed, carry out troubleshooting for it first as stated
with 24V circuit)
starting switch.
Defective fan EPC solenoid valve
2
(Internal disconnection) CN-FAC (male) Resistance
Between (1) and (2) 5 – 15 
Possible causes and
standard value in
starting switch.
normal state
Wiring harness between CN-ST3 (female) (25) – CN-FAC
(female) (1)
(female) (2)
starting switch.
Between (25) and (23) 5 – 15 
D51EX/PX-22 40-447 
TROUBLESHOOTING ERROR CODE [DWN5KA]
Circuit diagram related to fan EPC solenoid valve
40-448  D51EX/PX-22
TROUBLESHOOTING ERROR CODE [DWN5KB]
12
ERROR CODE [DWN5KB]
FAN EPC SOLENOID VALVE SHORT CIRCUIT
Action code Error code Fan EPC solenoid valve: Short circuit
Trouble
E01 DWN5KB (HST controller system)
Contents of trouble • Abnormal current flowed at output to the fan EPC solenoid valve circuit.
Action of • Stops output of the signal to the fan EPC solenoid valve circuit.
• The fan speed is set to the maximum.
on machine
Related
information

starting switch.
Defective fan EPC solenoid valve CN-FAC (male) Resistance
1
Between (1) and (2) 5 – 15 
Possible causes and starting switch ON.
standard value in Grounding fault in wiring Wiring harness between CN-ST3 (female) (25) – CN-FAC
harness (Contact with ground circuit) (female) (1)
(female) (2)
starting switch.

Between (25) and (23) 5 – 15 
D51EX/PX-22 40-449 J
TROUBLESHOOTING ERROR CODE [DWN5KB]
40-450  D51EX/PX-22
TROUBLESHOOTING ERROR CODE [DWN5KY]
12
ERROR CODE [DWN5KY]
FAN EPC SOLENOID VALVE SHORTED
Action code Error code Fan EPC solenoid valve: Short circuit with power supply line
Trouble
E02 DWN5KY (HST controller system)
Contents of trouble • Abnormal current constantly flows to the fan EPC solenoid valve circuit.
Problem that appears • The fan speed is set to the minimum.
on machine • Tends to overheat.
Related
information

Possible causes and H Prepare with starting switch OFF, then turn starting switch ON and carry out trou-
standard value in Short circuit with power supply line bleshooting.
(Contact with 24 V) Wiring harness between CN-ST3 (female) (25) – CN-FAC
Voltage Max. 1 V
D51EX/PX-22 40-451 
TROUBLESHOOTING ERROR CODE [DWN5KY]
12
MEMORANDUM
40-452  D51EX/PX-22
TROUBLESHOOTING ERROR CODE [DXA4KA]
12
ERROR CODE [DXA4KA]
LF HST PUMP EPC SOLENOID VALVE DISCONNECTION
Action code Error code LF HST pump EPC solenoid valve: Disconnection
Trouble
E03 DXA4KA (HST controller system)
Contents of trouble • When the signal is output to the LF HST pump EPC solenoid valve, no current flows.
• Flashes the warning lamp and sounds the warning buzzer.
• Stops outputting the signal to the LF HST pump EPC solenoid valve circuit.
Action of
• Stops outputting the signal to the RF HST pump EPC solenoid valve circuit, too.
controller
• Even if the cause of the error disappears, the system does not reset itself until the starting switch is turned OFF.
• If the machine has been traveling forward, it stops.
Problem that appears • If the machine has been stopped, it cannot start forward.
on machine • Once the machine is stopped, its engine speed is limited to medium (half) speed.
• Once the machine is stopped, its travel speed is limited to 50%
• The output state (command current, sensed current) to the LF HST pump EPC solenoid valve can be checked in the monitoring
Related mode.
information (Controller: HST, Code: 52401 – LF PUMP, Code: 52409 – LF PUMP FB)
• Method of reproducing error code: Start engine and operate the PCCS lever (in the forward direction).

1 in wiring harness If error code [DXA4KY] is displayed, carry out troubleshooting for it first.
Defective LF HST pump EPC starting switch.
2 solenoid valve
CN-LF (male) Resistance
Between (1) and (2) 5 – 15
Possible causes and
standard value in
starting switch.
harness (Disconnection in wiring Wiring harness between CN-ST3 (female) (5) and CN-LF
harness or defective contact in (female) (1)
connector)
Wiring harness between CN-ST3 (female) (13) and CN-
LF (female) (2)
starting switch.
Between (5) and (13) 5 – 15 
D51EX/PX-22 40-453 
Circuit diagram related to LF HST pump EPC solenoid valve
40-454  D51EX/PX-22
TROUBLESHOOTING ERROR CODE [DXA4KB]
12
ERROR CODE [DXA4KB]
LF HST PUMP EPC SOLENOID VALVE SHORT CIRCUIT
Action code Error code LF HST pump EPC solenoid valve: Short circuit
Trouble
E03 DXA4KB (HST controller system)
Contents of trouble • When the signal is output to the LF HST pump EPC solenoid valve, an abnormal current flows.
• Stops outputting the signal to the LF HST pump EPC solenoid valve circuit.
Action of
• Stops outputting the signal to the RF HST pump EPC solenoid valve circuit, too.
controller
• Once the machine is stopped, its travel speed is limited to 50%.
Related mode.

starting switch.
Defective LF HST pump EPC
1 solenoid valve CN-LF (male) Resistance
standard value in Short circuit with chassis ground in starting switch.
normal state 2 wiring harness (Contact with ground
circuit) Between CN-ST3 (female) (5) – CN-LF (female) (1) wir-
ing harness and chassis ground
starting switch.

Between (5) and (13) 5 – 15 
D51EX/PX-22 40-455 
TROUBLESHOOTING ERROR CODE [DXA4KY]
ERROR CODE [DXA4KY]
LF HST PUMP EPC SOLENOID VALVE SHORTED
Action code Error code LF HST pump EPC solenoid valve: Short circuit with power supply line
Trouble
E04 DXA4KY (HST controller system)
Contents of trouble • A current is constantly flowing to the LF HST pump EPC solenoid valve circuit.
Action of
controller
• The left-hand track keeps rotating forward.
on machine
• Once the machine is stopped, it cannot start again.
Related mode.

normal state 1 in wiring harness
(Contact with 24V circuit) Between CN-ST3 (female) (5) – CN-LF (female) (1) wir-
Voltage Max. 1 V
ing harness and chassis ground.
40-456  D51EX/PX-22
12
ERROR CODE [DXA5KA]
LR HST PUMP EPC SOLENOID VALVE DISCONNECTION
Action code Error code LR HST pump EPC solenoid valve: Disconnection
Trouble
Contents of trouble • When the signal is output to the LR HST pump EPC solenoid valve, no current flows.
• Stops outputting the signal to the LR HST pump EPC solenoid valve circuit.
Action of
• Stops outputting the signal to the RR HST pump EPC solenoid valve circuit, too.
controller
• If the machine has been traveling in reverse, it stops.
Problem that appears • If the machine has been stopped, it cannot start in reverse.
• The output state (command current, sensed current) to the LR HST pump EPC solenoid valve can be checked in the monitoring
Related mode.
information (Controller: HST, Code: 52403 – LR PUMP, Code: 52411 – LR PUMP FB)
• Method of reproducing error code: Start engine and operate the PCCS lever (in the reverse direction).

Defective LR HST pump EPC sole- starting switch.
2 noid valve
CN-LR (male) Resistance
Between (1) and (2) 5 – 15 
Possible causes and
standard value in
starting switch.
harness (Disconnection in wiring Wiring harness between CN-ST3 (female) (6) and CN-LR
harness or defective contact in con- (female) (1)
nector)
LR (female) (2)
starting switch.
Between (6) and (13) 5 – 15 
D51EX/PX-22 40-457 
Circuit diagram related to LR HST pump EPC solenoid valve
40-458  D51EX/PX-22
12
ERROR CODE [DXA5KB]
LR HST PUMP EPC SOLENOID VALVE SHORT CIRCUIT
Action code Error code LR HST pump EPC solenoid valve: Short circuit
Trouble
Contents of trouble • When the signal is output to the LR HST pump EPC solenoid valve, an abnormal current flows.
• Stops outputting the signal to the LR HST pump EPC solenoid valve circuit.
Action of
• Stops outputting the signal to the RR HST pump EPC solenoid valve circuit, too.
controller
• If the machine has been traveling in the reverse, it stops.
Problem that appears • If the machine has been stopped, it cannot start in the reverse.
Related mode.

starting switch.
Defective LR HST pump EPC sole- CN-LR (male) Resistance
1
noid valve (Internal short circuit)
Between (1) and (2) 5 – 15 
Between (1) and chassis ground Min. 1
normal state 2
wiring (Contact with ground circuit) Between CN-ST3 (female) (6) – CN-LR (female) (1) wir-
ing harness and chassis ground
starting switch.

Between (6) and (13) 5 – 15 
D51EX/PX-22 40-459 
ERROR CODE [DXA5KY]
LR HST PUMP EPC SOLENOID VALVE SHORTED
Action code Error code LR HST pump EPC solenoid valve: Short circuit with power supply line
Trouble
Contents of trouble A current is constantly flowing to the LR HST pump EPC solenoid valve circuit.
Action of
controller
• The left-hand track keeps rotating in the reverse.
on machine
• Once the machine is stopped, it cannot start again.
Related mode.

(Contact with 24V circuit) Between CN-ST3 (female) (6) – CN-LR (female) (1)
Voltage Max. 1 V
wiring harness and chassis ground.
40-460  D51EX/PX-22
12
ERROR CODE [DXA6KA]
RF HST PUMP EPC SOLENOID VALVE DISCONNECTION
Action code Error code RF HST pump EPC solenoid valve: Disconnection
Trouble
Contents of trouble • When the signal is output to the RF HST pump EPC solenoid valve, no current flows.
• Stops outputting the signal to the RF HST pump EPC solenoid valve circuit.
Action of
• Stops outputting the signal to the LF HST pump EPC solenoid valve circuit, too.
controller
• The output state (command current, sensed current) to the RF HST pump EPC solenoid valve can be checked in the monitoring
Related mode.
information (Controller: HST, Code: 52400 – RF PUMP, Code: 52408 – RF PUMP FB)

Defective RF HST pump EPC sole- starting switch.
2 noid valve
CN-RF (male) Resistance
Between (1) and (2) 5 – 15 
Possible causes and
standard value in
starting switch.
harness (Disconnection in wiring har- Wiring harness between CN-ST3 (female) (15) and CN-
ness or defective contact in connec- RF (female) (1)
tor)
RF (female) (2)
starting switch.
Between (15) and (23) 5 – 15 
D51EX/PX-22 40-461 
Circuit diagram related to RF HST pump EPC solenoid valve
40-462  D51EX/PX-22
12
ERROR CODE [DXA6KB]
RF HST PUMP EPC SOLENOID VALVE SHORT CIRCUIT
Action code Error code RF HST pump EPC solenoid valve: Short circuit
Trouble
Contents of trouble • When the signal is output to the RF HST pump EPC solenoid valve, an abnormal current flows.
• Stops outputting the signal to the RF HST pump EPC solenoid valve circuit.
Action of
• Stops outputting the signal to the LF HST pump EPC solenoid valve circuit, too.
controller
Related mode.

starting switch.
Defective RF HST pump EPC
1 solenoid valve CN-RF (male) Resistance
(Internal short circuit) Between (1) and (2) 5 – 15
circuit) Between CN-ST3 (female) (15) – CN-RF (female) (1)
wiring harness and chassis ground
starting switch.

Between (15) and (23) 5 – 15 
D51EX/PX-22 40-463 
ERROR CODE [DXA6KY]
RF HST PUMP EPC SOLENOID VALVE SHORTED
Action code Error code RF HST pump EPC solenoid valve: Short circuit with power supply line
Trouble
Contents of trouble • A current is constantly flowing to the RF HST pump EPC solenoid valve circuit.
Action of
controller
• The right-hand track keeps rotating forward.
on machine
• Once the machine is stopped, it cannot moved again.
Related mode.

(Contact with 24V circuit) Between CN-ST3 (female) (15) – CN-RF (female) (1)
Voltage Max. 1 V
40-464  D51EX/PX-22
12
ERROR CODE [DXA7KA]
RR HST PUMP EPC SOLENOID VALVE DISCONNECTION
Action code Error code RR HST pump EPC solenoid valve: Disconnection
Trouble
Contents of trouble • When the signal is output to the RR HST pump EPC solenoid valve, no current flows.
• Stops outputting the signal to the RR HST pump EPC solenoid valve circuit.
Action of
• Stops outputting the signal to the LR HST pump EPC solenoid valve circuit, too.
controller
• If the machine has been traveling in reverse, it stops.
Problem that appears • If the machine has been stopped, it cannot start in reverse.
• The output state (command current, sensed current) to the RR HST pump EPC solenoid valve can be checked in the monitoring
Related
mode. (Controller: HST, Code: 52402 – RR PUMP, Code: 52410 – RR PUMP FB)
information

Defective RR HST pump EPC starting switch.
2 solenoid valve
CN-RR (male) Resistance
Between (1) and (2) 5 – 15 
Possible causes and
standard value in
normal state
harness (Disconnection in wiring Wiring harness between CN-ST3 (female) (16) and CN-
harness or defective contact in RR (female) (1)
connector)
RR (female) (2)
starting switch.
Between (16) and (23) 5 – 15 
Circuit diagram related to RR HST pump EPC solenoid valve
D51EX/PX-22 40-465 
12
ERROR CODE [DXA7KB]
RR HST PUMP EPC SOLENOID VALVE SHORT CIRCUIT
Action code Error code RR HST pump EPC solenoid valve: Short circuit
Trouble
Contents of trouble • When the signal is output to the RR HST pump EPC solenoid valve, an abnormal current flows.
• Stops outputting the signal to the RR HST pump EPC solenoid valve circuit.
Action of
• Stops outputting the signal to the LR HST pump EPC solenoid valve circuit, too.
controller
• If the machine has been traveling in the reverse, it stops.
Problem that appears • If the machine has been stopped, it cannot start in the reverse.
Related mode.
information (Controller: HST, Code: 52402 – RR PUMP, Code: 52410 – RR PUMP FB)

starting switch.
Defective RR HST pump EPC
1 solenoid valve CN-RR (male) Resistance
circuit) Between CN-ST3 (female) (16) – CN-RR (female) (1)
starting switch.
Between (16) and (23) 5 – 15 
40-466  D51EX/PX-22
ERROR CODE [DXA7KY]
RR HST PUMP EPC SOLENOID VALVE SHORTED
Action code Error code RR HST pump EPC solenoid valve: Short circuit with power supply line
Trouble
Contents of trouble • A current is constantly flowing to the RR HST pump EPC solenoid valve circuit.
Action of
controller
• The right-hand track keeps rotating in the reverse.
on machine
• Once the machine is stopped, it cannot move again.
Related mode.
information (Controller: HST, Code: 52402 – RR PUMP, Code: 52410 – RR PUMP FB)

(Contact with 24V circuit) Between CN-ST3 (female) (16) – CN-RR (female) (1)
Voltage Max. 1 V
D51EX/PX-22 40-467 
TROUBLESHOOTING ERROR CODE [DXK1KA]
12
ERROR CODE [DXK1KA]
LEFT HST MOTOR EPC SOLENOID VALVE DISCONNECTION
Action code Error code Left HST motor EPC solenoid valve: Disconnection
Trouble
E02 DXK1KA (HST controller system)
Contents of trouble • When the signal is output to the Left HST motor EPC solenoid valve, no current flows.
Action of • Stops outputting to the Left HST motor EPC solenoid valve circuit.
controller • Stops outputting to the Right HST motor EPC solenoid valve circuit, too.
Problem that appears • If the machine has been traveling at high-speed, it decelerates.
on machine • The machine cannot travel at high-speed.
• The output state (command current, sensed current) to the Left HST motor EPC solenoid valve can be checked in the monitoring
Related mode.
information (Controller: HST, Code: 52302 – L MOTOR, Code: 52304 – L PUMP FB)
• Method of reproducing error code: Start engine and travel the machine at high-speed.

1 in wiring harness If error code [DXK1KY] is displayed, carry out troubleshooting for it first.
Defective Left HST motor EPC starting switch.
2 solenoid valve
CN-LME (male) Resistance
Between (1) and (2) 5 – 15 
Possible causes and
standard value in
starting switch.
3 harness (Disconnection or defective Resistance Max. 1 
LME (female) (1)
contact in connector)
LME (female) (2)
starting switch.
Between (26) and (3) 5 – 15 
Circuit diagram related to Left HST motor EPC solenoid valve
40-468  D51EX/PX-22
TROUBLESHOOTING ERROR CODE [DXK1KB]
ERROR CODE [DXK1KB]
LEFT HST MOTOR EPC SOLENOID VALVE SHORT CIRCUIT
Action code Error code Left HST motor EPC solenoid valve: Short circuit
Trouble
E02 DXK1KB (HST controller system)
Contents of trouble • When the signal is output to the Left HST motor EPC solenoid valve, an abnormal current flows.
Action of • Stops outputting the signal to the Left HST motor EPC solenoid valve circuit.
controller • Stops outputting the signal to the Right HST motor EPC solenoid valve circuit, too.
• The output state (command current, sensed current) to the Left HST motor EPC solenoid valve can be checked in the monitoring
Related mode.

starting switch.
Defective Left HST motor EPC sole- CN-LME (male) Resistance
1
noid valve (Internal short circuit)
Between (1) and (2) 5 – 15 
circuit) Between CN-ST3 (female) (26) – CN-LME (female) (1)
starting switch.

Between (26) and (3) 5 – 15 
D51EX/PX-22 40-469 
TROUBLESHOOTING ERROR CODE [DXK1KY]
12
ERROR CODE [DXK1KY]
LEFT HST MOTOR EPC SOLENOID VALVE SHORTED
Action code Error code Left HST motor EPC solenoid valve: Short circuit with power supply line
Trouble
E04 DXK1KY (HST controller system)
Contents of trouble A current is constantly flowing to the Left HST motor EPC solenoid valve circuit.
Flashes the warning lamp and sounds the warning buzzer.
Action of
Limits the functions partly.
controller
Even if the cause of the error disappears, the system does not reset itself until the starting switch is turned OFF.
The speed of the Left-hand track becomes fast.
Once the machine is stopped, its engine speed is limited to medium (half) speed.
on machine
Once the machine is stopped, it cannot move again.
The output state (command current, sensed current) to the Left HST motor EPC solenoid valve can be checked in the monitoring
Related mode.
Method of reproducing error code: Turn the starting switch ON.

Possible causes and H Prepare with starting switch OFF, then turn starting switch ON and carry out
(Contact with 24V circuit) Between CN-ST3 (female) (26) – CN-LME (female) (1)
Voltage Max. 1 V
40-470  D51EX/PX-22
TROUBLESHOOTING ERROR CODE [DXK2KA]
12
ERROR CODE [DXK2KA]
RIGHT HST MOTOR EPC SOLENOID VALVE DISCONNECTION
Action code Error code Right HST motor EPC solenoid valve: Disconnection
Trouble
E02 DXK2KA (HST controller system)
Contents of trouble • When the signal is output to the Right HST motor EPC solenoid valve, no current flows.
Action of • Stops outputting to the Right HST motor EPC solenoid valve circuit.
controller • Stops outputting to the Left HST motor EPC solenoid valve circuit, too.
• The output state (command current, sensed current) to the Right HST motor EPC solenoid valve can be checked in the monitor-
Related
ing mode. (Controller: HST, Code: 52301 – R MOTOR, Code: 52303 – R PUMP FB)
information

1 in wiring harness If error code [DXK2KY] is displayed, carry out troubleshooting for it first.
Defective Right HST motor EPC starting switch.
5 solenoid valve
CN-RME (male) Resistance
Between (1) and (2) 5 – 15 
Possible causes and
standard value in
starting switch.
normal state
3 harness (Disconnection or defective Resistance Max. 1 z
RME (female) (1)
contact in connector)
Resistance Max. 1 z
RME (female) (2)
starting switch.
Between (36) and (3) 5 – 15 
Circuit diagram related to Right HST motor EPC solenoid valve
D51EX/PX-22 40-471 
TROUBLESHOOTING ERROR CODE [DXK2KB]
ERROR CODE [DXK2KB]
RIGHT HST MOTOR EPC SOLENOID VALVE SHORT CIRCUIT
Action code Error code Right HST motor EPC solenoid valve: Short circuit
Trouble
E02 DXK2KB (HST controller system)
Contents of trouble • When the signal is output to the Right HST motor EPC solenoid valve, an abnormal current flows.
Action of • Stops outputting the signal to the Right HST motor EPC solenoid valve circuit.
controller • Stops outputting the signal to the Left HST motor EPC solenoid valve circuit, too.
Related
ing mode. (Controller: HST, Code: 52301 – R MOTOR, Code: 52303 – R PUMP FB)
information

starting switch.
Defective Right HST motor EPC
1 solenoid valve CN-RME (male) Resistance
circuit) Between CN-ST3 (female) (36) – CN-RME (female) (1)
starting switch.

Between (36) and (3) 5 – 15 
40-472  D51EX/PX-22
12
ERROR CODE [DXK2KY]
RIGHT HST MOTOR EPC SOLENOID VALVE SHORTED
Action code Error code Right HST motor EPC solenoid valve: Short circuit with power supply line
Trouble
E04 DXK2KY (HST controller system)
Contents of trouble • A current is constantly flowing to the Right HST motor EPC solenoid valve circuit.
Action of
controller
• The speed of the Right-hand track becomes fast.
on machine
• Once the machine is stopped, it cannot move again.
Related ing mode.
information (Controller: HST, Code: 52301 – R MOTOR, Code: 52303 – R PUMP FB)

(Contact with 24V circuit) Between CN-ST3 (female) (36) – CN-RME (female) (1)
Voltage Max. 1 V
D51EX/PX-22 40-473 
40-474  D51EX/PX-22
D51EX/PX-22 40-475 
40-476  D51EX/PX-22
40 TROUBLESHOOTING (E-MODE)
12
BEFORE CARRYING OUT TROUBLESHOOTING (E-MODE) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-503
CONNECTION TABLE OF FUSE BOX . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-503
E-1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-506
STARTING MOTOR DOES NOT ROTATE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-506
E-2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-510
ENGINE IS NOT PRE-HEATED . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-510
E-3 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-514
WHEN STARTING SWITCH IS TURNED ON, ANY ITEM DOES NOT LIGHT . . . . . . . . . . . . . . . . . 40-514
E-4 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-516
CHARGE LEVEL CAUTION FLASHES WHILE ENGINE IS RUNNING . . . . . . . . . . . . . . . . . . . . . . . 40-516
E-5 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-518
EMERGENCY WARNING ITEMS FLASH WHILE ENGINE IS RUNNING . . . . . . . . . . . . . . . . . . . . . 40-518
E-6 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-522
PRE-HEAT LAMP DOES NOT LIGHT DURING PRE-HEATING OPERATION . . . . . . . . . . . . . . . . . 40-522
E-7 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-524
COOLANT TEMPERATURE GAUGE DOES NOT INDICATE CORRECTLY . . . . . . . . . . . . . . . . . . . 40-524
E-8 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-525
HST OIL TEMPERATURE GAUGE DOES NOT INDICATE CORRECTLY . . . . . . . . . . . . . . . . . . . . . 40-525
E-9 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-526
FUEL LEVEL GAUGE DOES NOT INDICATE PROPERLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-526
E-10 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-528
TRAVEL INDICATOR DOES NOT DISPLAY NORMALLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-528
E-11 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-528
MULTI-INFORMATION UNIT DOES NOT DISPLAY NORMALLY . . . . . . . . . . . . . . . . . . . . . . . . . . 40-528
E-12 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-529
CAUTION LAMP DOES NOT FLASH OR DOES NOT GO OFF . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-529
E-13 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-530
CAUTION BUZZER DOES NOT SOUND OR DOES NOT STOP . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-530
E-14 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-532
REVERSE TRAVEL SPEED SETTING SWITCH DOES NOT FUNCTION . . . . . . . . . . . . . . . . . . . . . . 40-532
E-15 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-534
SHIFT MODE SWITCH DOES NOT FUNCTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-534
E-16 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-536
BUZZER CANCEL SWITCH DOES NOT FUNCTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-536
E-17 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-538
INFORMATION SWITCH DOES NOT FUNCTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-538
E-18 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-540
THE FAN CLEANING DOES NOT OPERATE OR CANNOT BE RESET . . . . . . . . . . . . . . . . . . . . . . . 40-540
E-19 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-542
BACKUP ALARM DOES NOT SOUND . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-542
E-20 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-543
THE HORN DOES NOT SOUND OR DOES NOT STOP . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-543
E-21 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-544
WORK EQUIPMENT DOES NOT MOVE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-544
E-22 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-546
HEAD LAMP OR REAR LAMP DOES NOT LIGHT UP . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-546
D51EX/PX-22 40-501 
TROUBLESHOOTING
E-23 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-550
FOOT HEATER DOES NOT OPERATE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-550
E-24 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-554
AIR CONDITIONER DOES NOT OPERATE [CAB SPECIFICATION] . . . . . . . . . . . . . . . . . . . . . . . . . 40-554
E-25 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-559
WIPER AND WASHER DO NOT OPERATE [CAB SPECIFICATION] . . . . . . . . . . . . . . . . . . . . . . . . . 40-559
E-26 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-572
KOMTRAX SYSTEM DOES NOT OPERATE NORMALLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-572
40-502  D51EX/PX-22
TROUBLESHOOTING BEFORE CARRYING OUT TROUBLESHOOTING (E-MODE)
12
BEFORE CARRYING OUT TROUBLESHOOTING (E-MODE)
CONNECTION TABLE OF FUSE BOX

• This connection table shows the devices to which each power supply of the fuse box supplies power (A switch power
supply is a device which supplies power while the starting switch is at the ON position and a constant power supply is a
device which supplies power while the starting switch is at position (ON/OFF)).
• When carrying out troubleshooting related to the electrical system, you should check the fuse box to see if the power is
supplied normally.
Fuse box A (CN-F01)
Capacity of
Type of power supply Fuse No. Destination of power
fuse
1
20 A Head lamp and rear lamp
(Between terminals 1 and 1A)
2
10 A Horn
3
10 A PPC lock
4
30 A Air conditioner (Cab specification)
Switch power supply (Between terminals 4 and 4A)
(Battery relay terminal M) 5
10 A HST controller (Solenoid power supply)
(Between terminals 5 and 5B)
6
10 A Center brake
(Between terminals 6 and 6B)
7 Switch power supply of fuse box B
30 A
(Between terminals 7 and 7B) (Cab specification)
8 Switch power supply of fuse box B
30 A
(Between terminals 8 and 8B) (Cab specification)
9
15 A Starting switch (terminal B)
Constant power supply (Between terminals 9 and 9C)
(Battery relay terminal B) 10
30 A Engine controller (Main power supply)
(Between terminals 10 and 10C)
11
20 A Spare power supply (No destination)
(Between terminals 11 and 11D)
12
15 A pre-heat
Switch power supply (Between terminals 12 and 12D)
(Battery relay terminal M) 13
10 A Foot heater (If equipped)
14
15 A Air suspension seat
15
10 A HST controller (Main power supply)
(Between terminals 15 and 15E)
16
10 A Monitor panel
Constant power supply 17
10 A KOMTRAX controller
(Battery relay terminal B) (Between terminals 17 and 17E)
18
10 A Service connector (CN-DT12 connector)
19
10 A Constant power supply of fuse box B
Switch power supply 20
5A Engine controller (ACC signal)
(Starting switch terminal ACC) (Between terminals 20 and 20F)
D51EX/PX-22 40-503 
TROUBLESHOOTING BEFORE CARRYING OUT TROUBLESHOOTING (E-MODE)
Fuse box B (FUSE) [Cab specification]
Fuse
Type of power supply Fuse No. Destination of power
capacity
Constant power supply (Fuse 1
10A Radio (Constant power supply)
box CN-F01 (19)) (Between terminals 1 and F)
2
20A Additional working lamp
(Between terminals 2 and B)
3
20A Lighter, 12 V socket
Switch power supply (Fuse 4
10A Room lamp, radio
box F01- (7) (8)) (Between terminals 4 and B)
5
10A Front wiper and washer, rear wiper and washer
6
10A Left and right door wiper and washer
Locations and Numbers of fuses
40-504  D51EX/PX-22
12
• The following information is summarized in the troubleshooting table and the related electrical circuit diagram. Before
carrying out troubleshooting, understand that information fully.
Trouble Trouble which occurred in the machine

Related
Information related to the detected trouble or troubleshooting
information

<Contents of description)
• Standard value in normal state to judge possible causes
1 • Remarks on judgment
• Disconnection
• Grounding fault
Wiring harness which is not connected to chassis ground circuit is in contact
2 with chassis ground circuit.
Wiring harness which is not connected to power source (24 V) circuit is in
Possible causes contact with power source (24 V) circuit.
and Possible causes of trouble • Short circuit
standard value in (Given numbers are reference Independent wiring harnesses are in contact with each other abnormally.
normal state 3 numbers, which do not indicate
priority) <Precautions for troubleshooting>
1) Method of indicating connector No. and handling of T-adapter
Insert or connect T-adapter as explained below for troubleshooting, unless
otherwise specified.
• If connector No. has no marks of “male” and “female”, disconnect connector
and insert T-adapters in both male side and female side.
• If connector No. has marks of “male” and “female”, disconnect connector
4 and connect T-adapter to only male side or female side.
1) Entry order of pin Nos. and handling of circuit tester leads
Connect positive (+) lead and negative (–) lead of circuit tester as explained
below for troubleshooting, unless otherwise specified.
• Connect positive (+) lead to pin No. or harness entered on front side.
This is a circuit diagram of the part related to troubleshooting.

• Connector No.: Shows the “Type-Number of pin” 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 har-
ness.
• Arrow ( ): Roughly shows the location on the machine.
D51EX/PX-22 40-505 
TROUBLESHOOTING E-1
E-1
STARTING MOTOR DOES NOT ROTATE
Trouble • When starting switch is turned to START position, starting motor does not rotate.
• Since the engine starting circuit has the neutral safety function, the engine does not start unless the parking brake lever is in the
LOCK position and the travel lever is in the neutral position. (When the engine can start, [P] is lighted up on the monitor panel.)
• KOMTRAX has start lock function. If start lock is not reset, engine cannot start.
Related • If “monitor panel does not light” or “battery relay operation sound is not heard” when starting switch is turned ON, main power
information supply system may be defective. Check main power supply system.
• Since the HST controller controls the neutral safety relay with the travel lock switch signal, check that a related error code is not
displayed before carrying out troubleshooting. (If error code [D130KA], [D130KB], [DD14KB], or [DDQ2KA] is displayed, carry
out troubleshooting for it first.)

Battery voltage Electrolyte specific gravity
1 Low charge level of battery
Min. 24 V Min. 1.26
H Prepare with starting switch OFF (Disconnect CN-T250), then carry out
troubleshooting with starting switch in OFF and START positions.
Defective starting switch (Internal
2 Starting switch Switch position Resistance
disconnection)
Between CN-T250 and CN- OFF Min. 1 M
T280 START Max. 1 
H Prepare with starting switch ON, then carry out troubleshooting in real-time
monitoring mode.
Controller: HST
3 Defective adjustment of steering lever Monitoring code: 50303 S/T LEVER
PCCS lever Stroke
Neutral –10 – +10%
Possible causes and If there is any abnormality, initialize steering lever.
standard value in
normal state
Defective neutral safety relay troubleshooting.
4
(Internal disconnection) Operate the travel lock switch between FREE and LOCK positions. If the neutral safety
relay makes an operating sound, it is normal.
H Prepare with starting switch OFF (keeping wiring harness connected), then carry
out troubleshooting with starting switch in START position.
Safety relay Voltage
Between CN-T3 and chassis
Power supply input 20 – 30 V
ground
Defective starting motor safety relay Between CN-4 (1) and

Starting input 20 – 30 V
5 chassis ground
Between CN-4 (2) and
Charging input Max. 1 V
chassis ground
Starting output 20 – 30 V
ground
If the power supply input, starting input, and charging input are normal and the starting
output is not normal, the starting motor safety relay is defective.
40-506  D51EX/PX-22
TROUBLESHOOTING E-1

a Prepare with starting switch OFF (keeping wiring harness connected), then carry out
troubleshooting with starting switch in START position.
Starting motor Voltage
Defective starting motor (Internal Power supply input 20 – 30 V
6 ground
defect)
Starting input 20 – 30 V
ground
If the power supply input and starting input are normal and the starting motor does not
rotate, the starting motor is defective.
Defective alternator out troubleshooting with starting switch ON.
7
(Internal short circuit) Alternator Voltage
Between CN-T16 and chassis ground Max. 1 V
Defective diode troubleshooting.
8
Between (1) and (2) Min. 1 M (Broken)
starting switch.
Wiring harness between CN-T280 and CN-11 (female) (3) Resistance Max. 1 
Possible causes and Disconnection in wiring harness
Wiring harness between CN-11 (female) (5) and CN-4
standard value in 9 (Disconnection in wiring harness or Resistance Max. 1 
(female) (1)
normal state defective contact in connector)
Wiring harness between CN-T4 and CN-T2 Resistance Max. 1 
starting switch.
Between CN-T280 – CN-11 (female) (3) or CN-ST3
(female) (10), or CN-G01 (female) (27) wiring harness Resistance Min. 1 M
and chassis ground
Between CN-11 (female) (5) – CN-4 (female) (1) or CN-
Short circuit with chassis ground in S03 (female) (7) wiring harness and chassis ground
10 wiring harness (Contact with ground Between CN-T4 – CN-T2 wiring harness and chassis
circuit) ground
Between CN-T8 – CN-T1 wiring harness and chassis
ground
ground
Between CN-ST2 (female) (13) – CN-G01 (female) (20)
Short circuit with power source in troubleshooting.
11 wiring harness (Contact with 24 V Between CN-4 (female) (2) – CN-T16 or CN-S04
circuit) (female) (9) or CN-ST1 (female) (15) or CN-G01 (female) Voltage Max. 1 V
(28) wiring harness and chassis ground
D51EX/PX-22 40-507 
TROUBLESHOOTING E-1
Circuit diagram related to engine pre-heating, starting, charging, and stopping functions
40-508  D51EX/PX-22
TROUBLESHOOTING E-1
MEMORANDUM
D51EX/PX-22 40-509 
TROUBLESHOOTING E-2
12
E-2
ENGINE IS NOT PRE-HEATED

Trouble • Engine is not pre-heated
• This troubleshooting is for the case when the intake air heater is not heated during the pre-heating operation. (When only the pre-
heater lamp does not light up, carry out troubleshooting for “Pre-heater lamp does not light up”.)
• Pre-heating system has “automatic pre-heating function” and “manual pre-heating function”.
Related When either of those functions operates, pre-heater lamp lights.
information • If “monitor panel does not light” or “battery relay operation sound is not heard” when starting switch is turned ON, main power
supply system may be defective. Check main power supply system.
• Before carrying out troubleshooting, check that no related error code is displayed.
(If error code [CA153], [CA154], [CA2555] or [CA2556] is displayed, carry out troubleshooting for it first.)

H Prepare with starting switch OFF (Disconnect CN-T250), then carry out trouble-
shooting with starting switch in OFF and HEAT positions.
Defective starting switch (Internal
disconnection)
Between CN-T250 and OFF Min. 1 M
CN-T255 HEAT Max. 1 
Disconnection of fuse
2 If fuse is broken, circuit probably has ground fault etc.
(CN-F01 (12), CN-106 (1) and (3))
Defective pre-heater relay bleshooting.
3
(Internal disconnection) Replace pre-heater relay RHR with another relay when intake air temperature is –5°C
or lower. If pre-heating starts, pre-heater relay RHR is defective.
out troubleshooting with starting switch in HEAT position.
Possible causes and Heater relay Voltage
standard value in Between CN-T12 and
normal state Power supply input 20 – 30 V
chassis ground
Defective heater relay (Internal
4 Between CN-T5 and
defect) Pre-heating input 20 – 30 V
chassis ground
Between CN-T6 and
Pre-heating output 20 – 30 V
chassis ground
If the power supply input and pre-heating input are normal and the pre-heating output
is not normal, the heater relay is defective.
Defective diode starting switch.
5
Defective intake air heater starting switch.
6
(Internal disconnection) Intake air heater Continuity
Between terminals There is continuity
40-510  D51EX/PX-22
TROUBLESHOOTING E-2

starting switch.
Wiring harness between CN-T255 – CN-RHR (female)
Disconnection in wiring harness Resistance Max. 1 
(3) – CN-T5
7 (Disconnection in wiring harness or
Wiring harness between CN-F01 (12) outlet – CN-RHR
(female) (5)
Possible causes and Wiring harness between CN-T6 and CN-RH Resistance Max. 1 
standard value in
normal state
starting switch.
Between CN-T255 – CN-RHR (female) (3) – CN-T5
Short circuit with chassis ground in
Between CN-F01 (12) outlet – CN-RHR (female) (5)
8 wiring harness (Contact with ground Resistance Min. 1 M
circuit) wiring harness and chassis ground
ground
Between CN-T6 – CN-RH wiring harness and chassis
ground
D51EX/PX-22 40-511 
TROUBLESHOOTING E-2
40-512  D51EX/PX-22
TROUBLESHOOTING E-2
12
MEMORANDUM
D51EX/PX-22 40-513 
TROUBLESHOOTING E-3
12
E-3
WHEN STARTING SWITCH IS TURNED ON, ANY ITEM DOES NOT LIGHT
Trouble • When starting switch is turned ON, any item does not light up.
Related • When the starting switch is turned ON, the gear speed/Set travel speed/Shift mode indicator section, multi-information section,
information gauge section, and lamp section light up for approx 2 seconds.

starting switch.
1 Low charge level of battery
Battery voltage (2pieces) Electrolyte specific gravity
Min. 24 V Min. 1.26
2 If the fuse is broken, the circuit probably has a grounding fault, etc. (See Cause 5.)
(CN-F01 (9C), (16E))
H Prepare with starting switch OFF (Disconnect CN-T250), then carry out trouble-
shooting with starting switch in OFF and ON positions.
Defective starting switch Starting switch Switch position Resistance
3
Between CN-T250 and OFF Min.1 M
CN-T270 ON Max.1 
a Prepare with starting switch OFF, then carry out troubleshooting without turning
starting switch.
Wiring harness between battery (–) terminal and chassis
ground
Wiring harness between battery (+) terminal – CN-T7, –
Disconnection in wiring harness CN-F01 (9C) (16E)
Possible causes and Wiring harness between CN-F01 (16) and CN-S03 (5)
standard value in (6)
normal state
Wiring harness between CN-S03 (3) (4) and chassis
ground (CN-T36)
Wiring harness between CN-F01 (9) and CN-T250 Resistance Max. 1 
Wiring harness between CN-T270 and CN-S03 (1) (2) Resistance Max. 1 
starting switch.
Between battery (+) terminal – CN-T7 – CN-F01 (9C)
(16E) wiring harness and chassis ground
5 wiring harness (Contact with ground Between CN-F01 (16) – CN-S03 (5) or (6) or another
related circuit wiring harness and chassis ground
circuit)
Between CN-F01 (9) – CN-T250 or another related circuit
Between CN-T270 – CN-S03 (1) or (2) or another related
circuit wiring harness and chassis ground
H Prepare with starting switch OFF, then turn starting switch OFF and ON and
Starting
6 Defective monitor panel CN-S03 Voltage
switch
Between (5), (6) and (3), (4) OFF 20 – 30 V
Between (1), (2) and (3), (4) ON 20 – 30 V
40-514  D51EX/PX-22
TROUBLESHOOTING E-3
Circuit diagram related to monitor panel power supply
D51EX/PX-22 40-515 
TROUBLESHOOTING E-4
12
E-4
CHARGE LEVEL CAUTION FLASHES WHILE ENGINE IS RUNNING

Trouble • Charge level caution flashes while engine is running.
Related
• The charge caution lamp flashes when abnormality is detected while the engine is running.
information

Defective alternator Alternator Engine speed Voltage
1
(Defective generation)
Between CN-T16 and Above medium (half)
20 – 30 V
chassis ground speed
harness
Wiring harness between CN-S04 (female) (9) and CN-
2 (Disconnection in wiring Resistance Max. 1 
T16
Possible causes and harness or defective contact in con-
nector) Between CN-T17 and CN-T20A wiring harness and
normal state chassis ground
starting switch.
3 wiring harness (Contact with ground Between CN-S04 (female) (9) – CN-T16 or CN-4
circuit) (female) (2) or CN-ST1 (female) (15) or CN-G01
(female) (28) or CN-ST3 (female) (4) or CN-T260 or
CN-T13 wiring harness and chassis ground
CN-S04 Engine speed Voltage
4 Defective monitor panel
Between (9) and chassis Above medium (half)
20 – 30 V
ground speed
40-516  D51EX/PX-22
TROUBLESHOOTING E-4
D51EX/PX-22 40-517 
TROUBLESHOOTING E-5
12
E-5
EMERGENCY WARNING ITEMS FLASH WHILE ENGINE IS RUNNING

Trouble (1) Engine oil pressure caution lamp flashes.
Related • When any abnormality is detected during engine running, the engine oil pressure caution lamp flashes and the alarm buzzer sounds.
information • The engine oil pressure switch signal is used to communicate with the engine controller.
Cause Standard value in normal state / Remarks on troubleshooting

Reduction of engine oil pressure Check the engine oil pressure as the drop of engine oil pressure is detected.
1
Possible (When system is normal) • Carry out the troubleshooting of “S-12 The oil pressure drops.”
causes and standard When the possible cause 1 is not the real cause, the engine oil pressure switch circuit is
value in normal state 2 Defective engine oil pressure system assumed to be defective. So, carry out the troubleshooting of “Error code [CA435]
Abnormal engine oil pressure switch.”
3 Defective monitor panel Since this is an internal defect, it cannot be diagnosed.
Trouble (2) Engine coolant temperature caution lamp flashes.

• When any abnormality is detected while engine is running, the coolant temperature caution lamp flashes and the alarm buzzer
sounds.
Related • The coolant temperature caution lamp flashes or goes out in accordance with an indication on the engine coolant temperature
information gauge.
• The input state (temperature) from the coolant temperature sensor can be checked in the monitoring mode.
(Controller: ENGINE, Code: 04107 COOLANT TEMP)

Since the coolant overheat is detected, check the coolant temperature. (At the coolant
Coolant overheats
1 temperature over 105°C, the lamp flashes and the buzzer sounds. Over 102°C, just the
Possible (When system is normal)
lamp flashes.)
causes and standard
value in normal state Defective coolant temperature When the cause 1 is not the real cause, the coolant temperature sensor circuit is assumed
2 sensor system to be defective. So, carry out the troubleshooting of “E-7 The coolant temperature gauge
(Engine controller circuit) does not indicate correctly.”
40-518  D51EX/PX-22
TROUBLESHOOTING E-5
Trouble (3) HST oil temperature caution lamp flashes.

• When any abnormality is detected while engine is running, the HST oil temperature caution lamp flashes and the alarm buzzer
sounds.
• The HST oil temperature caution lamp flashes or goes out in accordance with indication on the HST oil temperature gauge.
Related
• The input state (temperature) from the HST oil temperature sensor can be checked at monitoring mode.
information
(Controller: HST, Code: 04401 HST TEMP)
• Before starting the troubleshooting, validate that the related error code is not displayed.
(If the error code [DGS1KA] or [DGS1KX] is displayed, firstly diagnose the displayed code.)

Since the HST oil overheat is detected, check the HST oil temperature. (At the HST oil
HST oil overheats
1 temperature over 110°C, the lamp flashes and the buzzer sounds. Over 100°C, just the
Possible (When system is normal)
lamp flashes.)
causes and standard
value in normal state Defective HST oil temperature sensor When the cause 1 is not the real cause, the HST oil temperature sensor circuit is
2 circuit assumed to be defective. So, carry out the troubleshooting of “E-8 The HST oil temper-
(Monitor panel circuit) ature gauge does not indicate correctly”
Trouble (4) The caution lamp of water level in the fuel filter lights up.
Related • The caution lamp of water level in the fuel filter lights up when the water level in the water separator located under the fuel
information pre-heater rises, and goes out by draining the water.

The water level in the water separator
Since the water in the water separator is detected, check the water separator and drain
1 rises.
Possible the water.
(When the system is normal.)
causes and standard
value in normal state When the possible cause 1 is not the real cause, the fuel filter circuit is assumed to be
Defective fuel filter sensor circuit
2 defective. So, carry out the troubleshooting of “Error codes [CA428] [CA429] Abnor-
(Engine controller circuit)
mal water detection sensor”
D51EX/PX-22 40-519 
TROUBLESHOOTING E-5
Trouble (5) HST charge filter clogging caution lamp flashes.

• If abnormality is detected while the engine is running, the HST charge filter clogging caution lamp flashes and the caution buzzer
sounds.
Related
• The signals from the HST charge filter clogging switch are received from the HST controller through the communication system.
information
• The input state (ON/OFF) from the HST charge filter clogging switch can be checked in the monitoring mode. (Controller: HST,
Code: 40910 D-IN [3])

Clogging of HST charge filter
1 Since clogging of the HST charge filter is detected, check it.
H Prepare with starting switch OFF, then hold starting switch OFF and start engine
and carry out troubleshooting.
Difference between inlet
Defective HST charge filter clogging CN-CFS (male) and outlet pressures of HST Resistance
2 switch filter
(Internal short circuit) Max. 0.2 MPa
Min. 1 M
{Max. 2 kg/cm2}
Between (1) and (2)
Min. 0.2 MPa
Max. 1 
{Min. 2 kg/cm2}
Possible causes and
standard value in
Short circuit with chassis ground in starting switch.
circuit) Between CN-ST1 (female) (5) – CN-CFS (female) (1)
H Prepare with starting switch OFF, then hold starting switch ON and start engine
Difference between inlet
CN-ST1 and outlet pressures of HST Voltage
4 Defective HST controller filter
Max. 0.2 MPa
5 – 11 V
Between (5) and chassis {Max. 2 kg/cm2}
ground Min. 0.2 MPa
Max. 1 V
{Min. 2 kg/cm2}
If none of causes 1 – 4 is the cause of the trouble, the monitor panel may be defective
(Troubleshooting cannot be carried out since the defect is in the monitor panel).
Circuit diagram related to HST charge filter clogging switch
40-520  D51EX/PX-22
TROUBLESHOOTING E-5
Trouble (6) HST charge pressure caution lamp flashes.

• If abnormality is detected while the engine is running, the HST charge pressure caution lamp flashes and the caution buzzer sounds.
Related
• Input state (pressure) from HST charge pressure sensor (brake oil pressure sensor) can be checked in monitoring mode.
information
(Controller: HST, Code: 91902 BRAKE PRESS)

Low HST charge
Possible causes and 1 pressure Since low HST charge pressure is detected, check it.
standard value in (When system is normal)
normal state Defective brake oil If cause 1 is not detected, brake oil pressure sensor system may be defective. Carry out
2
pressure sensor system troubleshooting for [DDP6KA], [DDP6KB] and [DDP6MA].
3 Defective monitor panel Troubleshooting cannot be carried out since the defect is in the monitor panel.
D51EX/PX-22 40-521 
TROUBLESHOOTING E-6
12
E-6
PRE-HEAT LAMP DOES NOT LIGHT DURING PRE-HEATING OPERATION
Trouble • Pre-heating pilot lamp does not light up during pre-heating operation.
• This troubleshooting is for the case when the pre-heating pilot lamp does not light up during the pre-heating operation. (When the
intake air heater is not heated, carry out troubleshooting for “Engine is not pre-heated”.)
Related • pre-heating system has “automatic pre-heating function” and “manual pre-heating function”. When either of those functions oper-
information ates, pre-heater lamp lights.
• The input state (ON/OFF) from the heater relay can be checked in the monitoring mode. (Controller: MONITOR PANEL, Code:
40921 D-IN [2])

Disconnection in wiring H Prepare with starting switch OFF, then carry out troubleshooting without turning
harness starting switch.
1 (Disconnection in wiring
harness or defective contact in connec- Wiring harness between CN-S03 (female) (9) and CN-T5 Resistance Max. 1 
tor)
Possible causes and Short circuit with chassis ground in
starting switch.
standard value in 2 wiring harness (Contact with ground
normal state circuit) Between CN-S03 (female) (9) – CN-T5 wiring harness
and chassis ground
H Prepare with starting switch OFF, then hold starting switch in OFF and HEAT
position and carry out troubleshooting.
3 Defective monitor panel CN-S03 Starting switch Voltage
Between (9) and chassis OFF Max. 1 V

ground HEAT 20 – 30 V
40-522  D51EX/PX-22
TROUBLESHOOTING E-6
Circuit diagram related to engine pre-heating, starting, charging, and stopping function
D51EX/PX-22 40-523 
TROUBLESHOOTING E-7
12
E-7
COOLANT TEMPERATURE GAUGE DOES NOT INDICATE CORRECTLY
(1)Although the coolant temperature is rising normally, the indication of the coolant temperature stays in white range (a).
Trouble
(2)Although the coolant temperature is stabilized normally, the indication of the coolant temperature rises to red range (c).
• Signals of the coolant temperature sensor are input into the engine controller and that information is transmitted to the monitor
Related panel through communication system.
information • The input state (temperature) from the coolant temperature sensor can be checked in the monitoring mode.
(Controller: ENGINE, Code: 04107 COOLANT TEMP)

Possible Defective coolant temperature Since the coolant temperature sensor circuit is assumed to be defective, carry out the
1
causes and standard sensor circuit troubleshooting of error codes [CA144] and [CA145].
value in normal state When the possible cause 1 is not the real cause, the monitor panel is assumed to be
defective. (As it is an internal defect, it cannot be diagnosed.)
(3)The coolant temperature does not match to the indication of coolant temperature gauge.
Trouble
(4)The coolant temperature gauge does not match with the indication of coolant temperature monitor.
• Signals of the coolant temperature sensor are input into the engine controller and that information is transmitted to the monitor
Related panel through communication system.
information • The input state (temperature) from the coolant temperature sensor can be checked in the monitoring mode. (Controller: ENGINE,
Code: 04107 COOLANT TEMP)

a Diagnose with starting switch ON or with engine started.
Possible
Caution lamp (d)
causes and standard
value in normal state 1 Defective monitor panel OFF Flashing
White range (a)
Red range (c)
Green range (b)
Coolant temperature gauge and caution lamp
40-524  D51EX/PX-22
TROUBLESHOOTING E-8
12
E-8
HST OIL TEMPERATURE GAUGE DOES NOT INDICATE CORRECTLY
(1)Although the HST oil temperature is rising normally, the indication of the HST oil temperature stays in white range (a).
Trouble
(2)Although the HST oil temperature is stabilized normally, the indication of the HST oil temperature rises to red range (c).
• Signals of the HST oil temperature sensor are input into the HST controller and that information is transmitted to the monitor panel
Related through communication system.
information • The input state (temperature) from the HST oil temperature sensor can be checked in the monitoring mode.
(Controller: HST, Code: 04401 HST TEMP)

Possible Defective HST oil temperature Since the HST oil temperature sensor circuit is assumed to be defective, carry out the
1
causes and standard sensor circuit troubleshooting of error codes [DGS1KA] and [DGS1KX].
value in normal state When the possible cause 1 is not the real cause, the monitor panel is assumed to be
defective. (As it is an internal defect, it cannot be diagnosed.)
(3)The HST oil temperature does not match to the indication of HST oil temperature gauge.
Trouble
(4)The HST oil temperature gauge does not match with the indication of HST oil temperature monitor.
• Signals of the HST oil temperature sensor are input into the HST controller and that information is transmitted to the monitor panel
Related through communication system.
information • The input state (temperature) from the HST oil temperature sensor can be checked in the monitoring mode. (Controller: HST, Code:
04001 HST TEMP)

a Diagnose with starting switch ON or with engine started.
Possible
Caution lamp (d)
causes and standard
value in normal state 1 Defective monitor panel OFF Flashing
White range (a)
Red range (c)
Green range (b)
HST oil temperature gauge and caution lamp
D51EX/PX-22 40-525 
TROUBLESHOOTING E-9
12
E-9
FUEL LEVEL GAUGE DOES NOT INDICATE PROPERLY
Trouble • Fuel level gauge does not indicate properly

Related The Input state (voltage signal) from the fuel level sensor can be checked in monitoring mode.
information (Controller: MONITOR PANEL, Code: 04200 FUEL SENSOR)

starting switch.
Defective fuel level sensor
1 (Internal disconnection or short CN-13 (male) Fuel tank Resistance
circuit) Full Max. 10 
Between (1) and (2)
Empty Min. 73 
harness
2 (Disconnection in wiring Wiring harness between CN-S04 (female) (10) and CN-
13 (female) (1)
harness or defective contact in con-
nector) Wiring harness between CN-13 (female) (2) and CN-S03
normal state Short circuit with chassis ground in
starting switch.
3 wiring harness (Contact with ground
circuit) Between CN-S04 (female) (10) – CN-13 (female) (1)
Short circuit with power source in bleshooting.
4 wiring harness (Contact with 24 V cir-
cuit) Between CN-S04 (female) (10) – CN-13 (female) (1)
Voltage Max. 1 V
starting switch.
CN-S03 (female)
5 Defective monitor panel Fuel tank Resistance
CN-S04 (female)
Between CN-S04 (10) and Full Max. 10 

CN-S03 (3) Empty Min. 73 
40-526  D51EX/PX-22
TROUBLESHOOTING E-9
Circuit diagram related to fuel level sensor
D51EX/PX-22 40-527 
TROUBLESHOOTING E-10
12
E-10
TRAVEL INDICATOR DOES NOT DISPLAY NORMALLY
Trouble • Gear speed, set travel speed, and shift mode indicator does not display normally.
Related • Display information of the gear speed, set travel speed, and shift mode indicator is received from the HST controller through the
information communication system.

standard value in
normal state 1 Defective monitor panel Troubleshooting cannot be carried out since the defect is in the monitor panel.
E-11
MULTI-INFORMATION UNIT DOES NOT DISPLAY NORMALLY
Trouble (1) Service meter does not move forward while engine is running.
Related • Service meter starts counting when monitor panel receives engine start signal (alternator R signal).
information • While the service meter is moving forward, the hourglass mark is displayed.

Possible causes and
Defective alternator speed signal If the charge caution lamp blinks while engine is running, carry out the troubleshooting
standard value in 1
sensor for “E-4 Charge level caution flashes while engine is running” first.
normal state
2 Defective monitor panel Troubleshooting cannot be carried out since the defect is in the monitor panel.
Trouble (2) Multi-information section does not display any item.

Related
information

standard value in
40-528  D51EX/PX-22
12
E-12
CAUTION LAMP DOES NOT FLASH OR DOES NOT GO OFF
Trouble • Caution lamp does not flash or does not go off.

Related
information

standard value in
D51EX/PX-22 40-529 
E-13
CAUTION BUZZER DOES NOT SOUND OR DOES NOT STOP
Trouble • Caution buzzer does not sound or does not stop.

Related • If there is a short circuit in the caution buzzer system, an error code is [DV00KB] displayed. No error codes are displayed when
information other troubles occur, however.

H Prepare with starting switch OFF (Disconnect CN-T250), then carry out
troubleshooting with starting switch in OFF and ON position.
Defective starting switch
Between CN-T250 and CN- OFF Min. 1 M
T270 ON Max. 1 
starting switch.
Defective caution buzzer (Internal CN-CB (male) Resistance
2
disconnection or short circuit) Between (2) and (1) Min. 1 k
Between (1), (2) and
Min. 1 M
chassis ground
Possible causes and

starting switch.
standard value in
normal state Wiring harness between CN-T270 and CN-CB (female)
3 (Disconnection in wiring harness or Resistance Max. 1 
(1)
Wiring harness between CN-CB (female) (2) and CN-S03
(female) (18)
starting switch.
Between CN-T270 – CN-CB (female) (1) or CN-S03
circuit) (female) (1) or (2) wiring harness and chassis ground
Between CN-CB (female) (2) – CN-S03 (female) (18)
troubleshooting.
5 Defective monitor panel CN-S03 Caution buzzer Voltage
Between (18) and chassis Stopped 20 – 30 V

ground Operated (Sounded) Max. 3 V
40-530  D51EX/PX-22
Circuit diagram related to caution buzzer
D51EX/PX-22 40-531 
12
E-14
REVERSE TRAVEL SPEED SETTING SWITCH DOES NOT FUNCTION
Trouble • Reverse travel speed setting switch does not function.

Related • If there is a short circuit in the reverse travel speed setting system, an error code [DDDCKB] is displayed. No error codes are dis-
information played when other troubles occur, however.

starting switch.
Reverse travel speed setting
CN-REV (male) Resistance
switch
Defective reverse travel speed setting
1 switch Neutral, Higher speed
Min. 1 M
(Internal disconnection or short circuit) Between (4) and (5) (Right)
Lower speed (Left) Max. 1 
Neutral, Lower speed (Left) Min. 1 M
Between (5) and (6)
Higher speed (Right) Max. 1 
starting switch.
Disconnection in wiring harness Resistance Max. 1
REV (female) (4)
defective contact in connector) Wiring harness between CN-ST2 (female) (25) and CN-
Possible causes and REV (female) (6)
standard value in Wiring harness between CN-ST1 (female) (10) and CN-
REV (female) (5)
starting switch.
Between CN-ST2 (female) (35) – CN-REV (female) (4)
circuit)
Between CN-ST2 (female) (25) – CN-REV (female) (6)
bleshooting.
Reverse travel speed setting
CN-ST1, CN-ST2 Voltage
switch
4 Defective HST controller Neutral, Higher speed
Between CN-ST2 (35) and 5 – 11 V
(Right)
CN-ST1 (10)
Lower speed (Left) Max. 1 V
Between CN-ST2 (25) and Neutral, Lower speed (Left) 5 – 11 V

CN-ST1 (10) Higher speed (Right) Max. 1 V
40-532  D51EX/PX-22
Circuit diagram related to reverse travel speed setting switch
D51EX/PX-22 40-533 
12
E-15
SHIFT MODE SWITCH DOES NOT FUNCTION
Trouble • Shift mode switch does not function.

Related • If there is a short circuit in the shift mode switch system, an error code [DDT0L4] in displayed. No error codes are displayed when

starting switch.
CN-MTS (male) Shift mode switch Resistance
Center and quick shift
Defective shift mode switch Min. 1 M
1 Between (4) and (5) (Right)
(Internal disconnection or short circuit)
Variable shift (Left) Max. 1 
Min. 1 M
Between (6) and (5) (Left)
Quick shift (Right) Max. 1 
starting switch.
Disconnection in wiring harness Resistance Max. 1
MTS (female) (4)
Possible causes and MTS (female) (6)
standard value in Wiring harness between CN-ST1 (female) (10) and CN-
MTS (female) (5)
starting switch.
Between CN-ST2 (female) (27) – CN-MTS (female) (4)
circuit)
Between CN-ST2 (female) (37) – CN-MTS (female) (6)
troubleshooting.
CN-ST1, CN-ST2 Shift mode switch Voltage
Center and quick shift
4 Defective HST controller (Right)
CN-ST1 (10)
Variable shift (Left) Max. 1 V
(Left)
CN-ST2 (10)
Quick shift (Right) Max. 1 V
40-534  D51EX/PX-22
Circuit diagram related to shift mode switch
D51EX/PX-22 40-535 
12
E-16
BUZZER CANCEL SWITCH DOES NOT FUNCTION
Trouble • Buzzer cancel switch does not function.

Related
information

starting switch.
CN-BUZ (male) Buzzer cancel switch Resistance
1
Defective buzzer cancel switch Neutral,  (Left) Min. 1 M
(Internal disconnection or short circuit) Between (5) and (6)
t (Right) Max. 1 
Neutral, t (Right) Min. 1 M
Between (5) and (4)
 (Left) Max. 1 
starting switch.
BUZ (female) (6)
defective contact in connector) Wiring harness between CN-S03 (female) (16) and CN-
BUZ (female) (4)
Wiring harness between CN-S03 (female) (5) (6)and CN-
BUZ (female) (5)
Possible causes and
standard value in
starting switch.
normal state Short circuit with chassis ground in
Between CN-S03 (female) (17) – CN-BUZ (female) (6)
circuit)
troubleshooting.
Short circuit with power source in
4 wiring harness (Contact with 24V Between CN-S03 (female) (17) – CN-BUZ (female) (6)
Voltage Max. 1 V
circuit)
Voltage Max. 1 V
troubleshooting.
CN-S03/CN-BUZ Buzzer cancel switch Voltage
5 Defective monitor panel Between CN-503 (17) and Neutral,  (Left) Max. 1 V
chassis ground t (Right) 20 – 30 V
Between CN-503 (16) and Neutral, t (Right) Max. 1 V

chassis ground  (Left) 20 – 30 V
40-536  D51EX/PX-22
Circuit diagram related to buzzer cancel switch
D51EX/PX-22 40-537 
12
E-17
INFORMATION SWITCH DOES NOT FUNCTION
Trouble • Information switch does not function.

Related
information

starting switch.
CN-CUR (male) Information switch Resistance
Defective information switch
1 Neutral, < (Left) Min. 1 M
> (Right) Max. 1 
Neutral, > (Right) Min. 1 M
Between (5) and (4)
< (Left) Max. 1 
starting switch.
CUR (female) (6)
defective contact in connector) Wiring harness between CN-S03 (female) (14) and CN-
Possible causes and CUR (female) (4)
standard value in Wiring harness between CN-S03 (female) (3) (4) and CN-
CUR (female) (5)
starting switch.
Between CN-S03 (female) (15) – CN-CUR (female) (6)
circuit) wiring harness and chassis ground
Between CN-S03 (female) (14) – CN-CUR (female) (4)
troubleshooting.
CN-S03/CN-CUR Information switch Voltage
4 Defective monitor panel Between CN-503 (15) and Neutral, < (Left) 5 – 11 V
(3) (4) > (Right) Max. 1 V
Between CN-503 (14) and Neutral, > (Right) 5 – 11 V

(3) (4) < (Left) Max. 1 V
40-538  D51EX/PX-22
Circuit diagram related to information switch
D51EX/PX-22 40-539 
12
E-18
THE FAN CLEANING DOES NOT OPERATE OR CANNOT BE RESET
Trouble The fan cleaning does not operate or cannot be reset.

a This troubleshooting describes the procedures to be followed when the fan rotation selector switch is abnormal.
• In case fan operation confirmation lamp correctly lights up and goes off by switch operation, but fan does not reverse or reverses,
carry out troubleshooting for error codes [DW7BKA], [DW7BKB], [DW7EKY].
Related
• If there is a short circuit in the fan rotation selector switch, an error code [DD1NL4] is displayed. No error codes are displayed
information
when other troubles occur, however.
• The input state (ON/OFF) from the rotation selector switch can be checked in the monitoring mode.
(Controller: HST, Code: 40913 D-IN, [26]: Reverse (Right), [27]: Forward (Left))
Cause Standard value when normal and remarks for troubleshooting

starting switch.
Fan rotation selector
CN-FAN (male) Resistance
Defective fan rotation selector switch switch
1 (Internal disconnection or short cir-
Neutral, reverse (Right) Min. 1 M
cuit) Between (4) and (5)
Forward (Left) Max. 1 
Neutral, forward (Left) Min. 1 M
Between (6) and (5)
Reverse (Right) Max. 1 
starting switch.
Wiring harness between CN-ST2 (female) (7) – CN-FAN
(female) (4)
Possible FAN (female) (6)
causes and standard Wiring harness between CS-ST1 (female) (10) and CN-
value in normal state Resistance Max. 1 
FAN (female) (5)
starting switch.
Between CN-ST2 (female) (7) – CN-FAN (female) (4)
3 wiring harness Resistance Min. 1 M
(Contact with ground circuit)
Between CN-ST2 (female) (17) – CN-FAN (female) (6)
troubleshooting.
Fan rotation selector
CN-ST1, CN-ST2 Voltage
switch
Between CN-ST2 (7) and Neutral, reverse (Right) 5 – 11 V
CN-ST1 (10) Forward (Left) Max. 1 V
Between CN-ST2 (17) and Neutral, forward (Left) 5 – 11 V

CN-ST1 (10) Reverse (Right) Max. 1 V
40-540  D51EX/PX-22
Circuit diagram related to fan rotation selector switch
D51EX/PX-22 40-541 
12
E-19
BACKUP ALARM DOES NOT SOUND
Trouble • Backup alarm does not sound.

Related • If there is a short circuit in the backup alarm system, an error code [DV20KB] is displayed. No error codes are displayed when

H Prepare with starting switch OFF, then carry out troubleshooting
without turning starting switch.
defective contact in connector) TBA (female) (1)
Wiring harness between CN-TBA (female) (2) and chassis
Possible causes and Resistance Max. 1 
ground (CN-TG1)
standard value in
normal state H Prepare with starting switch OFF, then turn starting switch ON
2 Defective HST controller CN-ST3 PCCS lever Voltage
Between (18) and chassis Neutral Max. 1 V

ground Reverse travel position 20 – 30 V
3 Defective backup alarm If neither of causes 1 and 2 is the cause of the trouble, judge the backup alarm defective.
Circuit diagram related to backup alarm
40-542  D51EX/PX-22
12
E-20
THE HORN DOES NOT SOUND OR DOES NOT STOP

Trouble • The horn does not sound or does not stop.
Related
information

1 If the fuse is broken, the circuit probably has a grounding fault, etc. (See cause 4)
CN-F01 (2A)
starting switch.
Defective horn switch
2 Terminal (switch) Horn switch Resistance
OFF Min. 1 M
CN-T37 and CN-T38
ON Max. 1 
Disconnection in wiring harness starting switch.
Wiring harness between CN-F01 (2) and CN-T37 Resistance Max. 1 
Possible defective contact in connector)
causes and standard Wiring harness between CN-T38 and CN-21 Resistance Max. 1 
starting switch.
Between CN-F01 (2) – CN-T37 wiring harness and
chassis ground
Between CN-T38 – CN21 wiring harness and chassis
ground
Short circuit with power source in wir- troubleshooting.
5 ing harness
(Contact with 24 V circuit) Between CN-T38 – CN21 wiring harness and chassis
Voltage Max. 1 V
ground
Defective horn
6 If neither of causes 1 – 5 is the cause of the trouble, the horn may be defective.
(Internal defect)
Circuit diagram related to horn
D51EX/PX-22 40-543 
E-21
WORK EQUIPMENT DOES NOT MOVE
Trouble • Work equipment does not move

• This troubleshooting procedure is for case where work equipment lock solenoid valve is not excited when work equipment lock lever
Related
is set in FREE position. (If work equipment does not move while work equipment lock solenoid valve is excited, carry out
information
troubleshooting “H-11. No work equipment moves”.

1
(CN-F01 (3A))
H If the fuse is broken, the circuit probably has a grounding fault, etc. (See cause 7.)
starting switch.
Defective work equipment lock sole-
2 noid valve CN-PSL (male) Resistance
(Internal defect) Between (1) and (2) 40 – 60
Between (1), (2) and chassis ground Min. 1 M
starting switch.
Work equipment lock lever
Defective work equipment lock switch CN-PSW (male) FREE LOCK
3
(Internal defect) (Upper position) (Lower position)
Between (A) and (C) Max. 1  Min. 1 M
Between (A), (C) and
Min. 1 M Min. 1 M
chassis ground
Possible causes and Defective installation of work Work equipment lock switch may be installed defectively. Check it directly (See Testing
4
equipment lock switch and adjusting).
standard value in
Defective diode starting switch.
5
starting switch.
Wiring harness between CN-F01 (3) and CN-PSW
(female) (A)
defective contact in connector) Wiring harness between CN-PSW (female) (C) and CN-
PSL (female) (1)
Wiring harness between CN-PSL (female) (2) and chassis
ground (CN-T35)
starting switch.
Between CN-F01 (3) – CN-PSW (female) (A) wiring har-
7 wiring harness Resistance Min. 1M 
ness and chassis ground
Between CN-PSW (female) (C) – CN-PSL (female) (1)
40-544  D51EX/PX-22
Electric circuit diagram related to “work equipment does not move”
D51EX/PX-22 40-545 
12
E-22
HEAD LAMP OR REAR LAMP DOES NOT LIGHT UP
Trouble • Head lamp or rear lamp does not light up.

Related
information

Defective left head lamp If only the left head lamp does not light up, it may have a bad contact or a broken bulb.
1
(Bad contact or breakage of bulb) Check it directly.
Defective center head lamp If only the right head lamp does not light up, it may have a bad contact or a broken bulb.
2
Defective right head lamp If only the right head lamp does not light up, it may have a bad contact or a broken bulb.
3
Defective left rear lamp (Defective If only left rear lamp does not light up, cause may be defective contact or broken bulb.
4
contact or broken bulb) Check them directly.
Defective right rear lamp (Defective If only right rear lamp does not light up, cause may be defective contact or broken bulb.
5
contact or broken bulb) Check them directly.
(CN-F01 (1))
starting switch.
CN-FWL (male) Working lamp switch Resistance
Defective working lamp switch (Inter-
7 Between (5) and (6) F/R Max. 1 
nal disconnection)
Between (5) and (6)
Neutral Min. 1 M
Between (5) and (4)
Between (5) and (4) F Max. 1 
H Prepare with starting switch OFF, then turn starting switch ON and working lamp
Possible causes and
Defective head lamp relay (Internal switch F and carry out troubleshooting.
standard value in 8
defect) H Replace head lamp relay (No. at right) with rear lamp relay. If head
normal state CN-54
lamp becomes normal, relay is defective.
H Prepare with starting switch OFF, then turn starting switch ON and working lamp
Defective rear lamp relay (Internal switch F/R and carry out troubleshooting.
9
defect) Replace rear lamp relay (No. at right) with head lamp relay. If rear lamp
CN-54B
becomes normal, relay is defective.
• Prepare with starting switch OFF, then carry out troubleshooting without
Defective diode turning starting switch.
10
(Internal disconnection) CN-WLD (male) Continuity
Between (2) and (1) Broken
starting switch ON.
Wiring harness between CN-F01 (1) and CN-54 (female)
(1)
Disconnection in wiring Wiring harness between CN-F01 (1) and CN-54B
harness (female) (1)
11
(Disconnection in wiring harness or Wiring harness between CN-F01 (1) and CN-FWL
(female) (5)
Wiring harness between CN-FWL (female) (4) and CN-54
(female) (5)
Wiring harness between CN-FWL (female) (6) and CN-
54B (female) (5)
40-546  D51EX/PX-22

WLD (female) (1)
WLD (female) (2)
Wiring harness between CN-54 (female) (6) and CN-FG
(female)
Wiring harness between CN-54B (female) (6) and CN-FG
(female)
Wiring harness between CN-54 (female) (2) and CN-
LMP1 (female) (2)
LMP2 (female) (2)
LMP5 (female) (2)
Wiring harness between CN-FG (female) and CN-LMP1
standard value in Wiring harness between CN-FG (female) and CN-LMP2
(female) (1)
(female) (1)
Wiring harness between CN-54B (female) (2) and CN-
LMP3 (female) (2)
Wiring harness between CN-54B (female) (2) and CN-
LMP4 (female) (2)
(female) (1)
(female) (1)
Between CN-F01 (1) – CN-54 (female) (1) wiring harness
and chassis ground
Between CN-F01 (1) – CN-54B (female) (1) wiring har-
Between CN-F01 (1) – CN-FWL (female) (5) wiring har-
D51EX/PX-22 40-547 
Circuit diagram related to lamp and panel night lighting system
40-548  D51EX/PX-22
12
MEMORANDUM
D51EX/PX-22 40-549 
12
E-23
FOOT HEATER DOES NOT OPERATE
Trouble • Foot heater does not operate.

Related • This troubleshooting is for the case when the blower motor does not rotate. (When the blower motor rotates but air is not heated,
information hot water may not flow in from the engine. In this case, check the hot water system.)

(CN-F01 (13))
starting switch.
CN-HET (male) Heater switch Resistance
OFF Min. 1 M
Defective heater switch Between (5) and (6) I Max. 1 
2
II Min. 1 M
OFF Min. 1 M
Between (5) and (4) I Min. 1 M
II Max. 1 
H Prepare with starting switch OFF, then turn starting switch ON and set heater
Defective heater HI relay (Internal switch in HI position and carry out troubleshooting.
3
defect) Replace heater HI relay (No. at right) with heater LO relay. If heater HI
CN-HRH
H Prepare with starting switch OFF, then turn starting switch ON and set heater
Defective heater LO relay (Internal switch in LO position and carry out troubleshooting.
4
defect) Replace heater LO relay (No. at right) with heater HI relay. If heater LO
Possible causes and CN-HRL
standard value in
starting switch.
CN-HET (male) Foot heater switch Resistance
Defective foot heater switch (Internal
5
disconnection) Between (5) and (6) HI Max. 1 
Between (5) and (6)
Neutral Min. 1 M
Between (5) and (4)
Between (5) and (4) LO Max. 1 
starting switch.
Wiring harness between CN-F01 (13) and CN-HET
(female) (5)
Wiring harness between CN-F01 (13) and CN-HEAT1
(female) (C)
Wiring harness between CN-HET (female) (4) and CN-
AC8 (female) (2)
Wiring harness between CN-HET (female) (6) and CN-
AC7 (female) (2)
Wiring harness between CN-HRL (female) (1) and CN-
AC8 (female) (2)
Wiring harness between CN-HRH (female) (1) and CN-
AC7 (female) (2)
40-550  D51EX/PX-22

Wiring harness between CN-T36 and CN-HET (female)
(2)
Wiring harness between CN-T36 and CN-HRH (female)
(2)
Wiring harness between CN-T36 and CN-HRL (female)
(2)
HEAT1 (female) (A)
Wiring harness between CN-HRL (female) (3) and CN-
HEAT1 (female) (B)
Possible causes and FG (female)
standard value in Wiring harness between CN-HRL (female) (5) and CN-
normal state FG (female)
starting switch.
Between CN-F01 (13) – CN-HET (female) (5) wiring har-
Between CN-F01 (13) – CN-HEAT1 (female) (C) wiring
(Contact with ground circuit) harness and chassis ground
Between CN-HRH (female) (3) – CN-HEAT1 (female)
(A) wiring harness and chassis ground
Between CN-HRL (female) (3) – CN-HEAT1 (female) (B)
Defective heater unit
8 If none of causes 1 – 7 is the cause of the trouble, the heater unit may be defective.
(Internal defect)
D51EX/PX-22 40-551 
Circuit diagram related to foot heater
40-552  D51EX/PX-22
12
MEMORANDUM
D51EX/PX-22 40-553 
12
E-24
AIR CONDITIONER DOES NOT OPERATE [CAB SPECIFICATION]
Trouble (1) Air does not come out.

Related
information

1 If the fuse is broken, the circuit probably has a grounding fault, etc.
((CN-F01 (4))
starting switch.
CN-AC4 (male) Blower selector switch Resistance
OFF Min. 1 M
Between (2) and (4)
HI Max. 1 
Defective blower selector switch
2 OFF Min. 1 M
MID2 Max. 1 
OFF Min. 1 M
Between (6) and (4)
MID1 Max. 1 
OFF Min. 1 M
Between (3) and (4)
LO Max. 1 
CN-ACR (male) Resistance
Between (1) and (2) 1.5 
3 Defective resistor
Possible causes and
standard value in H Prepare with starting switch OFF, then turn starting switch ON and carry out
normal state troubleshooting.
4 Defective blower motor
When the air flow selector switch is set in the “Lo” position, if the blower motor rotates,
the blower motor is normal.
starting switch.
Wiring harness between CN-F01 (4) and CN-AC4
(female) (4)
Wiring harness between CN-F01 (4) and CN-AC4
(female) (7)
Wiring harness between CN-AC4 (female) (2) and CN-
AC6 (female) (6)
defective contact in connector) Wiring harness between CN-AC4 (female) (1) and CN-
AC6 (female) (5)
AC6 (female) (3)
AC6 (female) (2)
Wiring harness between CN-FG (female) and CN-AC6
(female) (1)
If the cause is not found out, a mistake may be made in check the trouble. In this case,
6 Mistake in checking trouble
carry out troubleshooting for “Air is not cooled”.
40-554  D51EX/PX-22
Trouble (2) Air is not cooled.

Related
information

1 If the fuse is broken, the circuit probably has a grounding fault, etc.
(CN-F01 (4))
starting switch.
Defective blower selector switch
2 CN-AC4 (male) Blower selector switch Resistance
OFF Min. 1 M
Between (5) and (4)
Other than OFF Max. 1 
starting switch.
Defective mode selector switch
3 CN-AC5 (male) Mode selector switch Resistance
(Internal disconnection or short circuit
COOL Min. 1 M
Between (1) and (3)
A/C Max. 1 
H Prepare with starting switch OFF, then turn starting switch and blower switch ON
Defective heater mode relay (Contact
4 CN-ACR1 (male) Mode selector switch Voltage
side)
Between (87A) and chassis
Other than HEAT 20 – 30 V
ground
Defective compressor clutch relay starting switch.
standard value in (Coil side) CN-ACR2 (male) Resistance
normal state
Between (86) and (85) 305 ± 15 
Defective compressor clutch relay starting switch.
6
(Contact side) CN-ACR2 (male) Resistance
Between (30) and (87A) Max. 1 
Defective condenser fan relay (Coil starting switch.
7
side) CN-ACR3 (male) Resistance
Between (86) and (85) 305 ± 15 
Defective condenser fan relay (Contact
side)
Other than HEAT 20 – 30 V
ground
9 Defective condenser motor
Turn blower switch ON and set mode selector switch in position other than HEAT. If
condenser motor rotates at this time, condenser motor is normal.
10 Defective compressor magnetic clutch The compressor magnetic clutch may be defective. Check it directly
11 Defective compressor The compressor may be defective. Check it directly.
D51EX/PX-22 40-555 

starting switch.
Possible causes and AC5 (female) (1)
standard value in Disconnection in wiring harness
normal state 12 (Disconnection in wiring harness or Resistance Max. 1 
defective contact in connector) AC6 (female) (4)
Wiring harness between CN-AC6 (female) (7) and CN-23
(female) (1)
Wiring harness between CN-AC6 (female) (8) and CN-FG
(female)
Trouble (3) Air is not heated

Related
information

starting switch.
Defective blower selector switch CN-AC4 (male) Blower selector switch Resistance
1
OFF Min. 1 M
Between (5) and (4)
Other than OFF Max. 1 
starting switch.
Defective mode selector switch
2 CN-AC5 (male) Mode selector switch Resistance
COOL Min. 1 M
Between (1) and (4)
HEAT Max. 1 
starting switch.
Defective speed regulator switch
Possible causes and 3 Temperature regulator
(Internal disconnection or short circuit) CN-AC3 (male) Resistance
standard value in switch
normal state Between (A) and (C) Any position Max. 1 
starting switch.
4 Defective heater mode relay (Coil side)
CN-ACR1 (male) Resistance
Between (86) and (85) 305 ± 15 
Defective heater mode relay (Contact
side)
HEAT 20 – 30 V
ground
Defective A/C mode diode (Internal starting switch.
6
disconnection) CN-AC9 (male) Continuity
Between (2) and (1) Secured
40-556  D51EX/PX-22

Defective foot heater LO diode starting switch.
7
(Internal disconnection) CN-AC8 (male) Continuity
Defective foot heater HI diode (Inter- starting switch.
8
nal disconnection) CN-AC7 (male) Continuity
starting switch.
FG (female)
AC5 (female) (4)
AC9 (female) (2)
Possible causes and
normal state AC5 (female) (3)
Wiring harness between CN-AC1 (male) (5) and CN-AC7
(female) (2)
Wiring harness between CN-AC1 (male) (6) and CN-AC8
(female) (2)
defective contact in connector) Wiring harness between CN-AC7 (female) (1) and CN-
AC3 (female) (C)
AC3 (female) (C)
AC3 (female) (C)
AC3 (female) (B)
F01 (4)
FG (female)
Wiring harness between CN-AC3 (female) (A) and CN-
FG (female)
D51EX/PX-22 40-557 
Circuit diagram related to air conditioner
40-558  D51EX/PX-22
12
E-25
WIPER AND WASHER DO NOT OPERATE [CAB SPECIFICATION]
Trouble (1) No windshield wipers and window washers do not operate.

Related
information

1 If the fuse is broken, the circuit probably has a grounding fault, etc. (See cause 3).
(CN-F01 (7), (8))
Disconnection in wiring harness starting switch.
Possible causes and defective contact in connector) Wiring harness between CN-F01 (7) and Fuse (B) Resistance Max. 1 
standard value in Wiring harness between CN-F01 (8) and Fuse (B) Resistance Max. 1 
normal state
starting switch.
3 wiring harness Between CN-F01 (7) – Fuse (B) wiring harness and chas-
sis ground
Between CN-F01 (8) – Fuse (B) wiring harness and chas-
sis ground
D51EX/PX-22 40-559 
Trouble (2) Front windshield wiper does not operate.

Related • If fuse (FUSE (5)) is broken, operations of both front windshield wiper and rear windshield wiper become defective.
information • Carry out troubleshooting with front wiper switch ON.

1 Disconnection of fuse (FUSE (5)) If fuse is broken, circuit probably has ground fault (See cause 6).
troubleshooting.
Defective front wiper motor (Internal
2 CN-A23 Front wiper switch Voltage
defect)
Between (3) and (1) ON 20 – 30 V
If voltage is normal but wiper does not operate, motor is defective.
starting switch.
Defective front wiper switch (Internal CN-A14 (male) Front wiper switch Resistance
3
disconnection)
OFF Min. 1 M
Between (2) and (3)
ON Max. 1 
Defective front wiper selector relay bleshooting.
4
(Internal defect) Replace front wiper selector relay (Right No.) with another relay. If front
CN-A28
Possible causes and wiper becomes normal at this time, front wiper selector relay is defective.
standard value in
normal state
starting switch.
Wiring harness between FUSE (5) and CN-A14 (female)
(3)
Wiring harness between CN-A28 (female) (1) and CN-
A14 (female) (2)
Disconnection in wiring harness Wiring harness between CN-A28 (female) (2) and GND3 Resistance Max. 1 
defective contact in connector) Wiring harness between CN-A28 (female) (3) and CN-
A23 (female) (3)
A23 (female) (2)
(4)
Wiring harness between CN-A23 (female) (1) and GND1 Resistance Max. 1 
Between FUSE (5) – CN-A14 (female) (3) wiring harness
Short circuit with chassis ground in Resistance Min. 1 M
and chassis ground
6 wiring harness
(Contact with ground circuit) Between FUSE (5) – CN-A23 (female) (4) wiring harness
and chassis ground
40-560  D51EX/PX-22
Trouble (3) Rear windshield wiper does not operate (Continuous operation is defective).
Related • If fuse (FUSE (5)) is broken, operations of both front windshield wiper and rear windshield wiper become defective.
information • Carry out troubleshooting with rear wiper switch ON.

1 Disconnection of fuse (FUSE (5)) If the fuse is broken, the circuit probably has a grounding fault, etc. (See cause 6).
troubleshooting.
Defective rear wiper motor (Internal
2 CN-A37 Rear wiper switch Voltage
defect)
starting switch.
Defective rear wiper switch (Internal CN-A12 (male) Rear wiper switch Resistance
3
disconnection)
OFF Min. 1 M
Between (2) and (3)
ON Max. 1 
troubleshooting.
Defective rear wiper selector relay
4 Replace rear wiper selector relay (Right No.) with another relay. If rear
(Internal defect)
wiper becomes normal at this time, rear wiper selector relay is CN-A32
Possible causes and
defective.
standard value in
starting switch.
(3)
A12 (female) (2)
A37 (female) (3)
A37 (female) (2)
(4)
and chassis ground
6 wiring harness
and chassis ground
D51EX/PX-22 40-561 
Trouble (4) Right door wiper does not operate (Continuous operation is defective).
Related • If fuse (FUSE (6)) is broken, operations of both right door wiper and left door wiper become defective.
information • Carry out troubleshooting with right door wiper switch ON and intermittent switch OFF.

troubleshooting.
Defective right door wiper motor
2 CN-A17 Right door wiper switch Voltage
(Internal defect)
starting switch.
Defective right door wiper switch CN-A13 (male) Right door wiper switch Resistance
3
OFF Min. 1 M
Between (2) and (3)
ON Max. 1 
troubleshooting.
Defective right door wiper intermittent
4 Replace right door wiper intermittent selector relay (Right No.) with
selector relay (Internal defect)
another relay. If right door wiper becomes normal at this time, intermit- CN-A31
tent selector relay is defective.
Defective right door wiper intermittent troubleshooting.
Possible causes and 5 relay Replace right door wiper intermittent relay (Right No.) with another
standard value in (Internal defect) relay. If right door wiper becomes normal at this time, intermittent relay CN-A30
normal state is defective.
starting switch.
(3)
A13 (female) (2)
A30 (female) (4)
A17 (female) (3)
A17 (female) (2)
(4)
and chassis ground
7 wiring harness
and chassis ground
40-562  D51EX/PX-22
12
Trouble (5) Right door wiper does not operate intermittently.
• Before carrying out troubleshooting, check that continuous operation is normal.
Related
• Carry out troubleshooting with right door wiper switch and intermittent switch ON.
information
• During intermittent operation, wiper stops for 5 seconds after each cycle of operation.

starting switch ON.
Defective intermittent switch (Internal
1 CN-A11 (male) Intermittent switch Resistance
disconnection)
OFF Min. 1 M
Between (5) and (6)
ON Max. 1 
bleshooting.
Defective right door wiper intermittent
2 Replace right door wiper intermittent selector relay (Right No.) with
selector relay (Internal defect)
another relay. If right door wiper becomes normal at this time, intermit- CN-A31
tent selector relay is defective.
Possible causes and Defective right door wiper intermittent troubleshooting.
standard value in 3 relay Replace right door wiper intermittent relay (Right No.) with another
normal state (Internal defect) relay. If right door wiper becomes normal at this time, intermittent relay CN-A30
is defective.
starting switch.
Disconnection in wiring harness (5)
4 (Disconnection in wiring harness or Wiring harness between CN-A31 (female) (1) and CN-
defective contact in connector) A11 (female) (6)
A30 (female) (2)
and chassis ground
D51EX/PX-22 40-563 
Trouble (6) Left door wiper does not operate (Continuous operation is defective).
Related • If fuse (FUSE (6)) is broken, operations of both right door wiper and left door wiper become defective.
information • Carry out troubleshooting with left door wiper switch ON and intermittent switch OFF.

troubleshooting.
Defective left door wiper motor
2 CN-A24 Left door wiper switch Voltage
(Internal defect)
starting switch.
Defective left door wiper switch CN-A15 (male) Left door wiper switch Resistance
3
OFF Min. 1 M
Between (2) and (3)
ON Max. 1 
Defective left door wiper troubleshooting.
4 intermittent selector relay (Internal Replace left door wiper intermittent selector relay (Right No.) with
defect) another relay. If left door wiper becomes normal at this time, intermittent CN-A27
selector relay is defective.
Possible causes and 5 intermittent relay Replace left door wiper intermittent relay (Right No.) with another relay.
standard value in (Internal defect) If left door wiper becomes normal at this time, intermittent relay is defec- CN-A26
normal state tive.
starting switch.
(3)
A15 (female) (2)
harness A26 (female) (4)
6
(Disconnection in wiring harness or Wiring harness between CN-A26 (female) (6) and GND3 Resistance Max. 1 
A24 (female) (3)
A24 (female) (2)
(4)
and chassis ground
7 wiring harness
and chassis ground
40-564  D51EX/PX-22
Trouble (7) Left door wiper does not operate intermittently.

• Before carrying out troubleshooting, check that continuous operation is normal.
Related
• Carry out troubleshooting with left door wiper switch and intermittent switch ON.
information
• During intermittent operation, wiper stops for 5 seconds after each cycle of operation.

starting switch.
Defective intermittent switch (Internal CN-A11 (male) Intermittent switch Resistance
1
disconnection)
OFF Min. 1 M
Between (5) and (6)
ON Max. 1 
2 intermittent selector relay (Internal Replace left door wiper intermittent selector relay (Right No.) with
defect) another relay. If left door wiper becomes normal at this time, intermittent CN-A27
selector relay is defective.
Defective left door wiper
standard value in 3 Replace left door wiper intermittent relay (Right No.) with another relay.
intermittent relay (Internal defect)
normal state If left door wiper becomes normal at this time, intermittent relay is defec- CN-A26
tive.
starting switch.
(5)
harness
4 Wiring harness between CN-A27 (female) (1) and CN-
(Disconnection in wiring harness or Resistance Max. 1 
defective contact in connector) A11 (female) (6)
A26 (female) (2)
and chassis ground
D51EX/PX-22 40-565 
Trouble (8) Water does not come out from front window washer.
Related • Before carrying out troubleshooting, check that windshield wiper operates normally.
information • If fuse (FUSE (5)) is broken, operations of both front window washer and rear window washer become defective.

bleshooting.
Defective front window washer motor
2 CN-362 Front wiper switch Voltage
(Internal defect)
Between (1) and (2) ON (Wash position) 20 – 30 V
If voltage is normal but washer does not operate, motor is defective.
starting switch.
Defective front wiper switch (Internal CN-A14 (male) Front wiper switch Resistance
disconnection)
standard value in OFF Min. 1 M
normal state Between (5) and (6)
ON (Wash position) Max. 1 
starting switch.
harness Resistance Max. 1 
4 (5)
(Disconnection in wiring harness or
362 (female) (1)
Wiring harness between CN-362 (female) (2) and GND8 Resistance Max. 1 
and chassis ground
40-566  D51EX/PX-22
Trouble (9) Water does not come out from rear window washer.
information • If fuse (FUSE (5)) is broken, operations of both front window washer and rear window washer become defective.

troubleshooting.
Defective rear window washer motor
2 CN-364 Rear wiper switch Voltage
(Internal defect)
starting switch.
Defective rear wiper switch (Internal CN-A12 (male) Rear wiper switch Resistance
disconnection)
starting switch.
harness Resistance Max. 1 
4 (5)
(Disconnection in wiring harness or
364 (female) (1)
and chassis ground
D51EX/PX-22 40-567 
Trouble (10) Water does not come out from right door washer.
information • If fuse (FUSE (6)) is broken, operations of both right door washer and left door washer become defective.

bleshooting
Defective right door washer motor
2 CN-363 Right door wiper switch Voltage
(Internal defect)
starting switch.
Defective right door wiper switch CN-A13 (male) Right door wiper switch Resistance
ON (Wash position) Max. 1
starting switch.
Disconnection in wiring harness Wiring harness between FUSE (6) and CN-A13 (female)
4 (Disconnection in wiring harness or (5)
363 (female) (1)
and chassis ground
40-568  D51EX/PX-22
Trouble (11) Water does not come out from left door washer.
information • If fuse (FUSE (6)) is broken, operations of both right door washer and left door washer become defective.

bleshooting.
Defective left door washer motor
2 CN-361 Left door wiper switch Voltage
(Internal defect)
starting switch.
Defective left door wiper switch CN-A15 (male) Left door wiper switch Resistance
starting switch.
Disconnection in wiring harness Wiring harness between FUSE (6) and CN-A15 (female)
4 (Disconnection in wiring harness or (5)
361 (female) (1)
and chassis ground
D51EX/PX-22 40-569 
Circuit diagram related to windshield wiper and window washer
40-570  D51EX/PX-22
12
MEMORANDUM
D51EX/PX-22 40-571 
12
E-26
KOMTRAX SYSTEM DOES NOT OPERATE NORMALLY
Trouble KOMTRAX system does not operate normally.

• If KOMTRAX system administrator makes request for checking system on machine side for trouble, carry out following trouble-
Related
shooting.
information
• Even if KOMTRAX system has trouble, it does not particularly appear on machine.

starting switch.
1 Defective power supply CN-G01 Signal Voltage
Between (39), (40) and Constant power
20 – 30 V
(37), (38) supply
H Start engine and carry out troubleshooting.
LED (1) Normal state
LED-C1 ON
Defective starting switch ACC signal H Prepare with starting switch OFF, then start engine and carry out troubleshooting.
2
and alternator R signal CN-G01 Signal Voltage
Between (36) and Starting switch
20 – 30 V
(37), (38) ACC supply
Between (28) and
Alternator R 20 – 30 V
(37), (38)
standard value in 3 Defective starting switch C signal CN-G01 Signal Voltage
normal state
Between (27) and
Starting switch C 20 – 30 V
(37), (38)
H Turn starting switch ON and carry out troubleshooting.
LED-C4 ON
4 State of CAN connection
H Prepare with starting switch OFF and carry out troubleshooting.
CN-G01 (female) Signal Resistance
Between (7) and (8) CAN 40 – 80 
H Turn starting switch ON and carry out troubleshooting.
Number of mails not
5 LED (7) Normal state
transmitted yet
7-segment 0–9
H Turn starting switch ON and carry out troubleshooting
6 State of positioning with GPS Dot ON
In an outdoor location within radio waves' penetration range, it sometimes takes more
than a minute from turning on of the starting switch to completion of the positioning.
40-572  D51EX/PX-22
12
LED display unit
CK01 connector
D51EX/PX-22 40-573 
40-574  D51EX/PX-22
40 TROUBLESHOOTING (H-MODE)
12
H-1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-603
RIGHT AND LEFT TRAVEL SYSTEMS INOPERABLE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-603
H-2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-605
RIGHT OR LEFT TRAVEL SYSTEM DOES NOT OPERATE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-605
H-3 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-606
RIGHT OR LEFT TRAVEL SYSTEM DOES NOT OPERATE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-606
H-4 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-607
SPEED OR POWER OF TRAVEL IS LOW . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-607
H-5 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-608
GEAR IS NOT SHIFTED . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-608
H-6 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-609
LARGE SHOCKS ARE MADE WHEN MACHINE STARTS AND STOPS TRAVEl . . . . . . . . . . . . . . 40-609
H-7 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-610
MACHINE DEVIATES LARGELY DURING TRAVEL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-610
H-8 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-611
HYDRAULIC DRIFT OF TRAVEL IS LARGE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-611
H-9 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-612
ENGINE STALLS OR SPEED LOWERS EXTREMELY DURING TRAVEl . . . . . . . . . . . . . . . . . . . . . 40-612
H-10 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-613
ABNORMAL SOUND COMES OUT FROM AROUND HST PUMP AND MOTOR . . . . . . . . . . . . . . . 40-613
H-11 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-614
WORK EQUIPMENT DOSE NOT OPERATE AT ALL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-614
H-12 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-615
SPEED OR POWER OF WHOLE WORK EQUIPMENT IS LOW . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-615
H-13 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-616
SPEED OR POWER OF LIFTING BLADE IS LOW . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-616
H-14 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-617
SPEED OR POWER OF TILTING BLADE IS LOW . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-617
H-15 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-618
SPEED OR POWER OF ANGLING BLADE IS LOW . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-618
H-16 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-619
TIME LAG IN LIFTING BLADE IS LARGE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-619
H-17 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-620
HYDRAULIC DRIFT OF LIFTING BLADE IS LARGE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-620
H-18 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-621
HYDRAULIC DRIFT OF TILTING BLADE IS LARGE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-621
H-19 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-622
ABNORMAL SOUND COMES FROM WORK EQUIPMENT PUMP AND
CONTROL VALVE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-622
H-20 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-623
HST OIL TEMPERATURE RISES TOO HIGH . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-623
H-21 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-624
FAN SPEED IS ABNORMAL (HIGH, LOW, OR 0 RPM) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-624
D51EX/PX-22 40-601 B
TROUBLESHOOTING INFORMATION IN TROUBLESHOOTING TA-
12
H The following information is summarized in the troubleshooting table. Before carrying out troubleshooting, understand
that information fully.
Contents of trouble Trouble which occurred in the machine

Related
Information related to the detected trouble or troubleshooting
information
Possible causes and 2 Possible causes of trouble (Given

standard value in <Contents of description>
numbers are
normal state • Standard value in normal state to judge possible causes
reference numbers, which do not indi-
3 cate priority)
40-602 b D51EX/PX-22
TROUBLESHOOTING H-1
12
H-1
RIGHT AND LEFT TRAVEL SYSTEMS INOPERABLE

Contents of trouble • Right and left travel systems do not operate forward and in reverse (No travel systems operate).
• Check that the oil level in the hydraulic tank is normal before carrying out troubleshooting.
How to check
1) If work equipment does not move and fan is stopped, HST pump may be stopped. Check for cause 1.
2) When parking brake lever is set in FREE position, if charge pressure low caution is turned ON and work equipment does not
Related
move and fan continues running at high speed, charge pressure may be low. Check for causes 2, 3, 4 and 5.
information
3) When travel operation is performed, if relief sound is heard from HST pump and engine speed lowers, parking brake in HST
motor may not be released. Check for causes 6 and 7.
4) When travel operation is performed and machine is steered, if either track moves, HST pump EPC connector may be connected
wrongly. Check for cause 9.

1 Defect in rear damper The rear damper may have a defect in it. Check it directly.
2 Defect in charge pump The charge pump and engine front PTO may have a defect in it. Check it directly.
The charge filter may be clogged. Check it directly. Clogging of the charge filter can be
3 Clogging of charge filter checked in the monitoring mode
(Controller: HST 40910-S/T SW1, 4th from left).
H Prepare with engine stopped, then run engine at high idle, set parking brake lever
in FREE position, and carry out troubleshooting.
Monitor panel
(Real-time PCCS lever HST charge circuit pressure
Defective adjustment or monitoring mode)
4 malfunction of oil cooler bypass valve
Possible causes and (charge safety valve) Controller: HST
Neutral 33 ± 3 kg/cm2
91902-BRAKE PRESS (469 ± 43 psi)
standard value in
normal state If the oil pressure does not become normal after the adjustment, the charge safety valve
of the oil cooler bypass valve may have malfunction or defect in it. Check the charge
safety valve directly.
H Prepare with engine stopped, then run engine at high idle, perform travel operation,
Monitor panel
5 malfunction of HST motor
(charge relief valve) Controller: HST
Forward or reverse 31 ± 5 kg/cm2
If the oil pressure does not become normal after the adjustment, the charge relief valve
of the HST motor may have malfunction or defect in it. Check the charge relief valve
directly.
D51EX/PX-22 40-603 b
TROUBLESHOOTING H-1

H Prepare with engine stopped, then run engine at high idle and carry out trouble-
shooting.
Parking brake
Parking brake lever and Slow brake solenoid valve
Malfunction of parking brake sole- solenoid valve output
brake pedal output pressure
6 noid valve or slow brake solenoid pressure
valve Lever: Free position 33 ± 5 kg/cm2 33 ± 5 kg/cm2
Possible causes and Pedal: Released (469 ± 71 psi) (469 ± 71 psi)
standard value in
Lever: Lock position 0 kg/cm2 0 kg/cm2
normal state
Pedal: Pressed fully (0 psi) (0 psi)
Wrong operation of towed valve of 5- The towed valve of 5-spool valve may be operated (changed over) wrongly. Check it
7
spool valve directly.
Defect in HST pump
8 The pump unit of the HST pump may have a defect in it. Check it directly.
(pump unit)
Pair of RF and LR or LF and RR may be connected in reverse. Check that color bands of
Wrong connection of HST pump EPC
9 connectors are correct.
connector
• Color bands LF: Yellow, RF: Green, LR: Red, RR: Blue
40-604 b D51EX/PX-22
TROUBLESHOOTING H-2
12
H-2
RIGHT OR LEFT TRAVEL SYSTEM DOES NOT OPERATE

• Right or left travel system does not operate forward and in reverse
Contents of trouble
(Only right or left travel system does not operate).
Related
information

Malfunction of HST pump (servo
1 The servo valve of the HST pump (on 1 side) may be malfunctioning. Check it directly.
valve)
Wrong operation of HST pump The towed valve of the HST pump (on 1 side) may be operated (opened) wrongly. Check
2
(towed valve) it directly.
Possible causes and
Defect in HST pump The pump unit of the HST pump (on 1 side) may have a defect in it.
standard value in 3
(pump unit) Check it directly.
normal state
Defect in HST pump The parking brake of the HST motor (on 1 side) may have a defect in it. Check it
4
(parking brake) directly.
Defect in HST motor The motor unit of the HST motor (on 1 side) may have a defect in it.
5
(motor unit) Check it directly.
6 Defect in final drive The final drive (on 1 side) may have a defect in it. Check it directly.
D51EX/PX-22 40-605 b
TROUBLESHOOTING H-3
12
H-3
RIGHT OR LEFT TRAVEL SYSTEM DOES NOT OPERATE
Contents of trouble • Right or left travel system does not operate forward or in reverse (Only 1 system does not operate).
• If this trouble occurs just after the initial adjustment of the pump, the pump may be adjusted wrongly. In this case, perform the ini-
tial adjustment of the pump again.
(During idle travel: 3001-F-PUMP LINE, 3002-R-PUMP LINE)
(During actual travel: 3003-F-PUMP RUN1, 3004-R-PUMP RUN1, 3005-F-PUMP RUN2, 3006-R-PUMP RUN2)
• HST pump capacity command value and HST pump EPC current command value can be checked in the real-time monitoring
mode.
Controller: HST
Related Capacity command Current command
information
value value
Right front 52404 52400 RF PUMP
Left front 52405 52401 LF PUMP
Right rear 52406 52402 RR PUMP
Left rear 52407 52403 LR PUMP
a If each command value is 0, cause of failure is not in hydraulic system but in electrical system (on controller side).

H Prepare with starting switch ON, then run engine at high idle and carry out
troubleshooting.
Monitor panel
PCCS lever HST main circuit pressure
Malfunction of HST pump (Tuning mode)
1
(safety-suction valve) 20 – 50 kg/cm2
Neutral
3016-STALL CHECK (284 - 711 psi)
(Stall pressure test mode)
Forward or Reverse 400 – 460 kg/cm2
(5,689 - 6,543 psi)
Possible causes and
standard value in H Prepare with engine stopped, then run engine at high idle and carry out
normal state troubleshooting.
PCCS lever EPC valve output pressure
Malfunction of HST pump (EPC
2
valve) F1 (Travel) Min. 10 kg/cm2 (142 psi)
N (Neutral) 0 kg/cm2 (0 psi)
R1 (Travel) Min. 10 kg/cm2 (142 psi)
Malfunction of HST pump (servo The servo valve of the HST pump (on 1 side) may be malfunctioning.
3
valve) Check it directly.
Defect in HST pump The pump unit of the HST pump (on 1 side) may have a defect in it.
4
(pump unit) Check it directly.
40-606 b D51EX/PX-22
TROUBLESHOOTING H-4
12
H-4
SPEED OR POWER OF TRAVEL IS LOW

Contents of trouble • Speed or power of travel is low.
• If this trouble occurs just after the initial adjustment of the pump or motor, the pump may be adjusted wrongly. In this case, perform
the initial adjustment of the pump or motor again.
(During idle travel: TUNING 1 3001-F-PUMP LINE, 3002-R-PUMP LINE, 3024-MOTOR LINE)
• HST motor capacity command value and HST motor EPC current command value can be checked in the real-time monitoring
Related mode.
information Controller: HST
Motor capacity command value: 52300 MOTOR
Right motor EPC current command value: 52301 R MOTOR
Left motor EPC current command value: 52302 L MOTOR
a If each command value is 0, cause of failure is not in hydraulic system but in electrical system (on controller side).

Monitor panel
(charge safety valve) Controller: HST
Possible causes and 91902-BRAKE PRESS (469 ± 43 psi)
standard value in If the oil pressure does not become normal after the adjustment, the charge safety valve
normal state
H Prepare with engine stopped, then run engine at high idle, perform travel operation,
Monitor panel
directly.
H Prepare with starting switch ON, then run engine at high idle and carry out
troubleshooting.
Monitor panel
Possible causes and PCCS lever HST main circuit pressure
Malfunction of HST pump (Tuning mode)
standard value in 5
(safety-suction valve) 20 – 50 kg/cm2
normal state Neutral
3016-STALL CHECK (284 - 711 psi)
(Stall pressure test mode)
Forward or Reverse 400 – 460 kg/cm2
(5,689 - 6,543 psi)
6 Loosened CAC piping Clamp of CAC piping may be loosened and air may be leaking. Check piping directly.
D51EX/PX-22 40-607 b
TROUBLESHOOTING H-5
12
H-5
GEAR IS NOT SHIFTED

Contents of trouble • When gear speed is set to 2nd or higher, travel speed is not increased.
• If gear stopped shifting just after initial adjustment of HST motor, perform initial adjustment again since it may have been per-
formed wrongly.
(TUNING 1: 3024-MOTOR LINE)
• HST motor capacity command value and HST motor EPC current command value can be checked in the real-time monitoring
Related mode.
information Controller: HST
Motor capacity command value: 52300 MOTOR
Right motor EPC current command value: 52301 R MOTOR
Left motor EPC current command value: 52302 L MOTOR
H If each command value is 0, cause of failure is not in hydraulic system but in electrical system (on controller side).

H Prepare with engine stopped, then carry out troubleshooting.
Travel speed and travel con- Output pressure of right and
Travel mode
dition left HST motor EPC valves
Possible causes and
Malfunction of 5-spool valve (HST Stop and travel in 1st 0 kg/cm2 (0 psi)
standard value in 1
motor EPC valve)
normal state
Travel in 2nd 15 ± 5 kg/cm2
Quick shift mode (213 ± 71 psi)
Travel in 3rd 22 ± 5 kg/cm2

(313 ± 71 psi)
2 Malfunction of HST motor HST motor may be malfunctioning. Check it directly.
40-608 b D51EX/PX-22
TROUBLESHOOTING H-6
12
H-6
LARGE SHOCKS ARE MADE WHEN MACHINE STARTS AND STOPS TRAVEl
Contents of trouble • Large shocks are made when machine starts and stops travel.
Related
information

Defective air bleeding from HST
1 Air may be left in the servo valve of the HST pump. Bleed air again.
pump
Warm up the engine (to the green range of the HST oil
2 Low HST oil temperature thermometer).
Possible causes and
standard value in HST oil thermometer Green range
normal state The initial adjustment of the pump may be defective. Adjust the pump again.
H If failure is still not corrected, adjust in fine Tuning mode.
3 Defective initial adjustment of pump Change of forward pump start adjustment value (Change right and left sides simul-
taneously) 3037-F-PUMP MAP2
Change of reverse pump start adjustment value (Change right and left sides simul-
taneously) 3038-R-PUMP MAP2
D51EX/PX-22 40-609 b
TROUBLESHOOTING H-7
12
H-7
MACHINE DEVIATES LARGELY DURING TRAVEL

Contents of trouble • Machine deviates largely during travel.
Related
information

valve)
Wrong operation of HST pump The towed valve of the HST pump (on 1 side) may be operated (opened) wrongly. Check
2
(towed valve) it directly.
Defect in HST pump
3 The pump unit of the HST pump (on 1 side) may have a defect in it. Check it directly.
(pump unit)
H Prepare with engine stopped, then carry out troubleshooting.
Travel mode
4 motor EPC valve)

Possible causes and (313 ± 71 psi)
standard value in Defect in HST pump The parking brake of the HST motor (on 1 side) may have a defect in it. Check it
5
normal state (parking brake) directly.
Malfunction of HST motor The charge relief valve of the HST motor (on 1 side) may be malfunctioning. Check it
6
(charge relief valve) directly.
Defect in HST motor
7 The motor unit of the HST motor (on 1 side) may have a defect in it. Check it directly.
(motor unit)
Defective HST motor If error code [DLM1KB], [DLM1MA], [DLM2KB], or [DLM2MA] is displayed,
8
(speed sensor) carry out troubleshooting for it.
pump
Initial adjustment of HST pump may have been performed wrongly. Perform it again. If
there is still travel deviation at low travel speed, adjust in fine tuning mode.
Defective initial adjustment of HST Change of forward pump start adjustment value (Change right and left sides separately)
10
pump 3035-F-PUMP MAP1
Change of reverse pump start adjustment value (Change right and left sides simultane-
ously) 3036-R-PUMP MAP1
Defective initial adjustment of HST
11 Initial adjustment of HST motor may have been performed wrongly. Perform it again.
motor
40-610 b D51EX/PX-22
TROUBLESHOOTING H-8
12
H-8
HYDRAULIC DRIFT OF TRAVEL IS LARGE

Contents of trouble • Hydraulic drift of travel is large.
Related
information

a Prepare with starting switch ON, then run engine at high idle and carry out trouble-
shooting.
Monitor panel PCCS lever HST relief pressure
Malfunction of HST pump
1
(safety-suction valve) Forward 400 – 460 kg/cm2
Stall pressure test mode (5,689 - 6,543 psi)
[3016]
Possible causes and Reverse 400 – 460 kg/cm2
standard value in (5,689 - 6,543 psi)
normal state Wrong operation of HST pump The towed valves of the HST pumps (on both sides) may be operated (opened) wrongly.
2
(towed valve) Check it directly.
Defect in HST pump Oil may be leaking in the pump unit of the HST pump (on both sides). Check the pump
3
(pump unit) unit directly.
Malfunction of HST pump (servo The neutral positions of the servo valves of the HST motors (on both sides) may be
4
valve) adjusted wrongly. Check them directly.
Oil may be leaking in the motor units of the HST motors (on both sides). Check the
5 Leakage in HST motor (motor unit)
motor units directly.
D51EX/PX-22 40-611 b
TROUBLESHOOTING H-9
12
H-9
ENGINE STALLS OR SPEED LOWERS EXTREMELY DURING TRAVEl

Contents of trouble • Engine stalls or engine speed lowers extremely during travel.
Related
information

H Prepare with engine stopped, then run engine at high idle and carry out
troubleshooting.
PCCS lever EPC valve output pressure
Malfunction of HST pump (EPC
1
valve) F1 (Travel) Min. 10 kg/cm2 (142 psi)
N (Neutral) 0 kg/cm2 (0 psi)
R1 (Travel) Min. 10 kg/cm2 (142 psi)
valve)
Possible causes and
standard value in 3 Defect in HST pump (pump unit) The pump unit of the HST pump (on 1 side) may have a defect in it. Check it directly.
normal state H Prepare with engine stopped, then carry out troubleshooting.
Travel mode
4
motor EPC valve)

(313 ± 71 psi)
Internal defect of HST motor (motor The motor unit of the HST motor (on 1 side) may have a defect in it.
5
unit) Check it directly.
40-612 b D51EX/PX-22
TROUBLESHOOTING H-10
12
H-10
ABNORMAL SOUND COMES OUT FROM AROUND HST PUMP AND MOTOR
Contents of trouble • Abnormal sound comes out from around HST pump and motor.
Related
information

Low oil level in hydraulic tank or use The oil level in the hydraulic tank may be low or improper oil may be used. Check the
1
of improper oil oil directly.
Clogging of charge pump suction
2 The charge pump suction strainer may be clogged. Check it directly.
strainer
Loosening of charge pump suction
3 The charge pump suction piping may be loosened. Check it directly.
piping
4 Defect in charge pump The charge pump may have a defect in it. Check it directly.
5 Clogging of charge filter The charge filter may be clogged. Check it directly.
Monitor panel
If the oil pressure does not become normal after the adjustment, the charge safety valve
Possible causes and
standard value in
normal state H Prepare with engine stopped, then run engine at high idle, perform travel operation,
Monitor panel
directly.
Defect in HST pump
(pump unit)
Loosening of piping between HST
9 The piping between the HST pump and HST motor may be loosened. Check it directly.
pump and HST motor
Defect in HST motor The motor unit of the HST motor may have a defect in it. Check it directly.
10
(motor unit) Troubleshooting cannot be carried out since the defect is in the motor unit.
pump
12 Loosened CAC piping Clamp of CAC piping may be loosened and air may be leaking. Check piping directly.
D51EX/PX-22 40-613 b
12
H-11
WORK EQUIPMENT DOSE NOT OPERATE AT ALL

Contents of trouble • Work equipment dose not operate at all.
How to guess
1) When the engine is started and the work equipment lock lever is set in the FREE position, if the work equipment PPC
Related
lever does not hold itself in the FLOAT position, the PPC basic pressure may be low.If the fan is rotating at high speed at
information
this time, the charge pressure may be low. Check for 2, 3 and 4.If the fan is rotating at the normal speed, check for 5.
2) If the machine cannot travel and the fan is stopped, the HST pump may be stopped. Check for 1.
3) If the machine can travel but the fan is stopped, check for 6, 7 and 8.

1 Defect in rear damper The rear damper may have a defect in it. Check it directly.
The charge pump and engine front PTO may have a defect in it.
2 Defect in charge pump
Check it directly.
The charge filter may be clogged. Check it directly. Clogging of the charge filter can
3 Clogging of charge filter be checked in the monitoring mode.
(Controller: HST 40910-S/T SW1, 4th from left)
H Prepare with engine stopped, then run engine at high idle, set parking brake
lever in FREE position, and carry out troubleshooting.
Monitor panel
HST charge circuit
Defective adjustment or (Real-time monitoring PCCS lever
pressure
malfunction of oil cooler bypass mode)
4
valve Controller: HST 91902-
(charge safety valve) BRAKE PRESS (469 ± 71 psi)
If the oil pressure does not become normal after adjustment, the charge safety valve
Possible causes and H Prepare with engine stopped, then run engine at high idle and carry out
standard value in troubleshooting.
normal state
Work equipment lock solenoid valve
Work equipment lock lever
|output pressure
Malfunction of 5-spool valve (Work
5 equipment lock LOCK 0 kg/cm2 (0 psi)
solenoid valve)
FREE 35 ± 5 kg/cm2 (498 ± 71 psi)
When the work equipment lock lever is set in the FREE position, if the work
equipment lock solenoid valve is not energized, carry out troubleshooting for “Work
equipment does not move” in the E-mode.
6 Defect in work equipment pump The work equipment pump may have a defect in it. Check it directly.
Malfunction of control valve
7 The unload valve of the control valve may be malfunctioning. Check it directly.
(unload valve)
troubleshooting.
Defective adjustment or malfunc- Blade control lever Work equipment pump relief pressure
8 tion of control valve (main relief Relieve blade circuit
valve) (by lifting or tilting). 280 ± 10 kg/cm2 (3,983 ± 142 psi)
If the oil pressure does not become normal after adjustment, the main relief valve
may have a malfunction or a defect in it. Check the main relief valve directly.
40-614 b D51EX/PX-22
12
H-12
SPEED OR POWER OF WHOLE WORK EQUIPMENT IS LOW

Contents of trouble • Speed or power of whole work equipment is low.
Related
information

Monitor panel
Possible causes and
standard value in If the oil pressure does not become normal after the adjustment, the charge safety valve
normal state of the oil cooler bypass valve may have malfunction or defect in it. Check the charge
4 Defect in work equipment pump The work equipment pump may have a defect in it. Check it directly.
Malfunction of control valve (unload
5 The unload valve of the control valve may be malfunctioning. Check it directly.
valve)
H Prepare with engine stopped, then run engine at high idle and
Defective adjustment or Blade control lever Work equipment pump relief pressure
6 malfunction of control valve (main
Relief of blade circuit 280 ± 10 kg/cm2
relief valve)
(by lifting or tilting) (3,983 ± 142 psi)
If the oil pressure does not become normal after adjustment, the main relief valve may
have a malfunction or a defect in it. Check the main relief valve directly.
D51EX/PX-22 40-615 b
12
H-13
SPEED OR POWER OF LIFTING BLADE IS LOW

Contents of trouble • Speed or power of lifting blade is low.
Related
• Check that the blade has not been modified before carrying out troubleshooting.
information

shooting.
Blade control lever PPC valve output pressure
1 Malfunction of boom PPC valve (lift) Raising stroke end Min. 16.8 kg/cm2 (239 psi)
Lowering position Min. 14.0 kg/cm2 (199 psi)
Floating stroke end Min. 21.0 kg/cm2 (299 psi)
Possible causes and Malfunction of blade lift
2 The spool of the blade lift control valve may be malfunctioning. Check it directly.
standard value in control valve (spool)
normal state Malfunction of blade lift
The pressure compensation valve of the blade lift control valve may be malfunctioning.
3 control valve
Check it directly.
(pressure compensation valve)
Malfunction of blade lift The suction valve of the blade lift control valve may be malfunctioning. Check it
4
control valve (suction valve) directly.
5 Defect in blade lift cylinder
Blade lift cylinder Leakage from cylinder
Relief by raising 6.5 cc/min (0.22 oz/min)
40-616 b D51EX/PX-22
12
H-14
SPEED OR POWER OF TILTING BLADE IS LOW

Contents of trouble • Speed or power of tilting blade is low.
Related
information

1 Malfunction of boom PPC valve (tilt) Blade control lever PPC valve output pressure
Left tilting stroke end Min. 17.5 kg/cm2 (249 psi)
Right tilting stroke end Min. 17.5 kg/cm2 (249 psi)
Possible causes and
Malfunction of blade lift control valve
standard value in 2 The spool of the blade lift control valve may be malfunctioning. Check it directly.
(spool)
normal state
Malfunction of blade tilt
The pressure compensation valve of the blade tilt control valve may be malfunctioning.
3 control valve
Check it directly.
carry out troubleshooting
4 Defect in blade tilt cylinder
Blade tilt cylinder Leakage from cylinder
Relief by tilting left 6.5 cc/min (0.22 oz/min.)
D51EX/PX-22 40-617 b
12
H-15
SPEED OR POWER OF ANGLING BLADE IS LOW

Contents of trouble • Speed or power of angling blade is low.
Related
information

shooting.
Malfunction of boom PPC valve Blade control lever PPC valve output pressure
1
(angle)
Left angling stroke end Min. 20.0 kg/cm2 (284 psi)
Right angling stroke end Min. 20.0 kg/cm2 (284 psi)
Malfunction of blade angle control
Possible causes and 2 The spool of the blade angle control valve may be malfunctioning. Check it directly.
valve (spool)
standard value in
normal state Malfunction of blade angle control
The pressure compensation valve of the blade angle control valve may be
3 valve
malfunctioning. Check it directly.
Malfunction of blade angle control The safety valve of the blade angle control valve may be malfunctioning. Check it
4
valve (safety valve) directly.
Malfunction of blade angle control The suction valve of the blade angle control valve may be malfunctioning. Check it
5
valve (suction valve) directly.
Defect in blade angle The blade angle cylinder may have a malfunction or a defect in it. Check the blade angle
6
cylinder cylinder directly.
40-618 b D51EX/PX-22
12
H-16
TIME LAG IN LIFTING BLADE IS LARGE

Contents of trouble • Time lag in lifting blade is large.
Related
information

standard value in Malfunction of blade lift control valve The suction valve of the blade lift control valve may be malfunctioning. Check it
normal state 1
(suction valve) directly.
D51EX/PX-22 40-619 b
12
H-17
HYDRAULIC DRIFT OF LIFTING BLADE IS LARGE

Contents of trouble • Hydraulic drift of lifting blade is large.
Related
information

Defective seal of blade lift control
1 The seal of the blade lift control valve may be defective. Check it directly.
valve (spool)
Possible causes and
standard value in H Prepare with engine stopped, then run engine at high idle and carry out trouble-
normal state shooting.
2 Defective seal of blade lift cylinder
Blade lift cylinder Leakage from cylinder
Relief by raising 6.5 cc/min (0.22 oz/min)
40-620 b D51EX/PX-22
12
H-18
HYDRAULIC DRIFT OF TILTING BLADE IS LARGE

Contents of trouble • Hydraulic drift of tilting blade is large.
Related
information

Defective seal of blade tilt control
1 The seal of the blade tilt control valve may be defective. Check it directly.
valve (spool)
Possible causes and
standard value in H Prepare with engine stopped, then run engine at high idle and carry out trouble-
normal state shooting.
2 Defective seal of blade tilt cylinder
Blade tilt cylinder Leakage from cylinder
Relief by tilting left 6.5 cc/min (0.22 oz/min)
D51EX/PX-22 40-621 b
12
H-19
ABNORMAL SOUND COMES FROM WORK EQUIPMENT PUMP AND

CONTROL VALVE
Contents of trouble • Abnormal sound comes out from around work equipment pump and control valve.
Related
information

1
Clogging of work equipment pump
2 The work equipment pump suction strainer may be clogged. Check it directly.
suction strainer
Looseness of work
3 The work equipment suction piping may be loosened. Check it directly.
equipment suction piping
Possible causes and
shooting.
standard value in
normal state Defective adjustment or Blade control lever Work equipment pump relief pressure
4 malfunction of control valve (main Relief of blade circuit
relief valve) (by lifting or tilting) 280 ± 10 kg/cm2 (3,983 ± 142 psi)
Defect in work equipment pump
5 The pump unit of the work equipment pump may have a defect in it. Check it directly.
(pump unit)
Loosening of piping between HST
6 The piping between the HST pump and HST motor may be loosened. Check it directly.
pump and HST motor
40-622 b D51EX/PX-22
12
H-20
HST OIL TEMPERATURE RISES TOO HIGH

Contents of trouble • HST oil temperature (Hydraulic oil temperature) rises too high.
Related
information

1
2 Clogging of hydraulic oil cooler The fins and cores of the hydraulic oil cooler may be clogged. Check them directly.
Malfunction of HST motor (charge
3 The charge relief valve of the HST motor may be malfunctioning. Check it directly.
relief valve)
H Prepare with starting switch ON, then run engine at high idle and carry out trouble-
shooting
Monitor panel PCCS lever HST relief pressure
Malfunction of HST pump (safety-
4 400 – 460 kg/cm2
suction valve) Forward
Stall pressure test mode (5,689 - 5,643 psi)
Possible causes and [3016]
Reverse 400 – 460 kg/cm2
standard value in (5,689 - 5,643 psi)
normal state
Defect in HST pump
(pump unit)
troubleshooting.
Defective adjustment or Blade control lever Work equipment pump relief pressure
6 malfunction of control valve (main Relief of blade circuit
relief valve) (by lifting or tilting) 280 ± 10 kg/cm2 (3,983 ± 142 psi)
Defect in work equipment pump
7 The pump unit of the work equipment pump may have a defect in it. Check it directly.
(pump unit)
8 Wrong installed direction of fan See fan from rear of machine and check that its vanes are concave.
If coolant temperature is too high, fan speed may be low.
Increase oil temperature to above 50°C and check fan
1500 rpm
speed at high idle in fan 100% mode.
H If the HST oil temperature is below 45°C and the engine coolant temperature is
below 60°C, the fan EPC command current is set to 1,000 mA and the fan speed
lowers below 200 rpm even in the fan 100% mode. In this case, increase the oil
temperature to above 55°C and the coolant temperature to above 65°C and then
check again.
Possible causes and Tuning code:

Fan 100% mode
3032 – FAN MODE
standard value in 9 Low fan speed
normal state Controller: HST
Fan speed Real-time monitoring code: 10007 (rpm) –
FAN SPEED
If fan speed does not reach standard value in 1 minute, initialize fan.
Tuning code:
Initialization of fan
3030 – FAN AMP SET
Engine: High idle Oil temperature: 50 – 60°C (122 - 140°F)
H If the fan speed cannot be set to the standard range by repeating initialization,
perform the troubleshooting for H-21.
10 Oil cooler bypass valve Oil cooler bypass valve may be malfunctioning. Check it directly.
D51EX/PX-22 40-623 b
12
H-21
FAN SPEED IS ABNORMAL (HIGH, LOW, OR 0 RPM)

• Fan speed is abnormally high.
• Fan speed is not set to standard value in 1 minute after set in fan 100% mode.
Standard value: 1,500 rpm (Oil temperature: Min. 50°C, Engine: High idle)
• If the HST oil temperature is below 45°C and the engine coolant temperature is below 60°C, the fan EPC command current is set to
Contents of trouble 1,000 mA and the fan speed lowers below 200 rpm even in the fan 100% mode. In this case, increase the oil temperature to above
55°C and the coolant temperature to above 65°C and then check again.
• HST oil temperature: Controller: HST, Real-time monitoring code: 04401 (°C) – HST TEMP.
• Engine coolant temperature: Controller: ENG, Real-time monitoring code: 04107 (°C) – COOLANT TEMP.
• While engine is running, fan is stopped (Error code DLM3KB is indicated).
• If travel or work equipment is also abnormal, carry out troubleshooting for it first.
• When engine is started for first time after hydraulic oil is replaced, fan speed may become high momentarily. This phenomenon is
Related
not abnormal.
information
• Fan 100% mode Tuning code: 3032 – FAN MODE
• Fan speed Controller: HST, Real-time monitoring mode: 10007 (rpm) – FAN SPEED

Since fan may be initialized defectively, initialize it again.
1 Defective initialization of fan Tuning code 3030 – FAN AMP SET
Oil temperature 50 – 60°C (122 - 140°F), Engine: High idle
Malfunction of fan control valve (Fan
2 Fan control valve (Fan EPC valve) may be malfunctioning. Check it directly.
EPC valve)
Malfunction of fan control valve
3 Fan control valve (Spool) may be malfunctioning. Check it directly.
Possible causes and (Spool)
standard value in
Malfunction of fan control valve Fan control valve (Pressure compensation valve) may be malfunctioning. Check it
normal state 4
(Pressure compensation valve) directly.
Malfunction of fan control valve
5 Fan control valve (Safety valve) may be malfunctioning. Check it directly.
(Safety valve)
Malfunction of fan motor (Directional
6 Fan motor (Directional spool) may be malfunctioning. Check it directly.
spool)
Malfunction of fan motor (Suction
7 Fan motor (Suction valve) may be malfunctioning. Check it directly.
valve)
8 Defect in fan motor Fan motor may have trouble in it. Check it directly.
40-624 b D51EX/PX-22
40 TROUBLESHOOTING (S-MODE)
12
METHOD OF USING TROUBLESHOOTING CHARTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-702
(S-1) ENGINE STARTING PERFORMANCE IS POOR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-706
(S-2) ENGINE DOES NOT CRANK . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-707
ENGINE CRANKS BUT NO EXHAUST SMOKE COMES OUT OF STACK . . . . . . . . . . . . . . . . . . . . 40-708
SMOKE COMES OUT OF STACK BUT ENGINE DOES NOT START . . . . . . . . . . . . . . . . . . . . . . . . . 40-709
(S-3) ENGINE DOES NOT RUN SMOOTHLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-710
(S-4) ENGINE STOPS DURING OPERATIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-711
(S-5) ENGINE SPEED HUNTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-712
(S-6) ENGINE LACKS POWER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-713
(S-7) EXHAUST SMOKE IS BLACK . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-715
(S-8) OIL CONSUMPTION IS EXCESSIVE OR EXHAUST SMOKE IS BLUE . . . . . . . . . . . . . . . . . . . . . . 40-716
(S-9) OIL BECOMES CONTAMINATED QUICKLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-717
(S-10) FUEL CONSUMPTION IS EXCESSIVE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-718
(S-11) OIL FOUND IN COOLANT, OR COOLANT SPURTS FROM RADIATOR . . . . . . . . . . . . . . . . . . . 40-719
(S-12) OIL PRESSURE CAUTION LAMP LIGHTS UP . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-720
(S-13) OIL LEVEL RISES (COOLANT OR FUEL FOUND IN OIL) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-721
(S-14) COOLANT TEMPERATURE TOO HIGH (OVERHEATING) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-722
(S-15) ABNORMAL NOISE IS HEARD WHEN ENGINE IS RUNNING . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-723
(S-16) EXCESSIVE VIBRATION WHEN ENGINE IS RUNNING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-724
D51EX/PX-22 40-701 b
TROUBLESHOOTING METHOD OF USING TROUBLESHOOTING CHARTS
METHOD OF USING TROUBLESHOOTING CHARTS

This troubleshooting chart is divided into three sections: Questions, Check Items, and Troubleshooting. The questions and
check items are used to pinpoint high probability causes that can be located from the failure symptoms or simple inspection
without using troubleshooting tools. Next, troubleshooting tools or direct inspection are used to check the high probability
causes to make final confirmation.
[Questions]
Sections (A) + (B) in the chart on the right corresponds to the items where answers can be obtained from the user. The items in
B are items that can be obtained from the user, depending on the user’s level.
[Check Items]
The serviceman carries out simple inspection to narrow down the causes. The items under (C) in the chart on the right
correspond to this. The serviceman narrows down the causes from information (A) that he has obtained from the user and the
results of (C) that he has obtained from his own inspection.
[Troubleshooting]
Troubleshooting is carried out in the order of probability, starting with the causes that have been marked as having the highest
probability from information gained from [Questions] and [Check items].
Causes
(b) (2) (3)
(a) j
Questions
(A) (b) j
(c) j
(d) m
(e) m
(B)
Check items
(C)
i l
Trouble-
shooting
ii l
iii l
40-702 b D51EX/PX-22
12
The basic method of using the troubleshooting chart is as follows.

Items listed for [Questions] and [Check items] that have a relationship with the
Cause items are marked with , and these, causes that have a high probability are
marked with j. Causes
Check each of [Questions] and [Check items] in turn, and marked the  or j in
the chart for items where the problem appeared. The vertical column (Causes)
)
ction
that has the highest number of points is the most probable cause, so start
troubleshooting for that item to make final confirmation of the causes.
inje
*1. For [Confirm recent repair history] in the [Questions] Section, ask the
ssive
ce
user, and mark the Cause column with # to use as reference for locating
ozzle
feren
(exce
the cause of the failure. However, do not use this when making calcula-
g, cy ment
tion n
tions to narrow down the causes.
air cle ger, inter
der
tion p g
ump
in
ele
*2. Use the # in the Cause column as reference for [Degree of use (Operated
ion tim
injec
li
aner
for long period)] in the [Questions] section as reference. As a rule, do
har
eized
not use it when calculating the points for locating the causes, but it can
n rin
t
injec
injec
be included if necessary to determine the order for troubleshooting. rboc
pisto
s
e d tu
ctive
ged,
oper
ged
Worn
Defe
Clog
Clog
I mp r
Seiz
*1 Confirm recent repair history

*2 Degree of use of machine Operated for long period   
j
D51EX/PX-22 40-703 b
12
• Example of troubleshooting when exhaust gas is black
Let us assume that [Clogged air cleaner] is taken to be the cause of black exhaust gas. Three symptoms have causal
relationship with this problem: [Exhaust gas slowly became black], [Power slowly became weaker], and [Dust indicator is
red].
If we look from these three symptoms to find the causes, we find that there is a relationship with five causes. Let us
explain here the method of using this causal relationship to pinpoint the most probable cause.
S-7 Exhaust gas is black (incomplete combustion)

General causes why exhaust gas is black
• Insufficient intake of air Causes
• Improper condition of fuel injection
ead
tion)
• Excessive injection fuel
)
nd h
eized
injec
pray
, plun seat
ger a
ger s
tive s
valve
sive
char
ce
s
tion ti le, defec
Legend
feren
e xce
and
turbo
ent
(rack
m: Possible causes (judging from Questions and
air cle er, inter
mp (
valve
der
n ce
uffler
elem
ming
n
check items)
ump
zz
n
e
cleara
n pu
li
e
n no
ed m
j: Most probable causes (judging from Questions g , cy
ct of
betw
aner
tion p
harg
Impro e injectio
jectio
onta
and Check items)
clogg
n rin
alve
of air
injec
rboc
injec
n: Possible causes due to length of use (used for a
c
in
per v
pisto
ed tu
ctive
hed,
oper
ctive
age
ged
ged
ctiv
long period)
W o rn
Leak
Crus
Defe
Defe
Clog
Clog
Impr
Defe
Seiz
l: Items to confirm the causes.

Confirm recent repair history
Degree of use Operated for long period    
Suddenly became black j m m
Questions
Color of exhaust gas Gradually became black j m m

Black under light load j
Engine oil must be added more frequently j
Power was lost Suddenly j m m m
Gradually mm mm
Non-specified fuel is being used m m
Noise of interference is heard from around tur- j
Dust indicator lamp is red j
Blow-by gas excessive j
Engine pickup is poor and combustion is irregu- m j mmm m
Check items
When exhaust manifold is touched immediately j m

Match marks on fuel injection pump are out of j
Seal on injection pump has come off j
Clanging sound is heard from around cylinder j
Exhaust noise is abnormal m m j
Muffler is crushed j
Leakage of air between turbocharger and head, j
When turbocharger is rotated by hand, it is l
When air cleaner element is inspected directly, it is l
When compression pressure is measured, it is l l
Speed does not change when operation of l
Troubleshooting
certain cylinders is stopped

When check is made using delivery method, l
injection timing is found to be incorrect
Injection pump test shows that injection amount l
When valve clearance is checked directly, it is l
found to be outside standard value
When muffler is removed, exhaust color returns l
When control rack is pushed, it is found to be l
heavy, or does not return
Replace
Replace
Replace
Replace
Replace
Replace
Correct
Adjust
Adjust
Adjust
Rem-
Clean
edy
40-704 b D51EX/PX-22
Five causes
Step 1
Clarify the relationship between the three
symptoms in the [Questions] and [Check items]
section and the five Causes items in the vertical
column.
Three symptoms
Step 2
Add up the total of m and j marks where the
horizontal lines for the three symptoms and the
vertical columns for the causes intersect:
(1) Clogged air cleaner element: jmj
(2) Air leakage between turbocharger
and head mm
(3) Clogged, seized injection nozzle: m
(4) Defective contact of valve, valve seat: m
(5) Worn position ring, cylinder: m
Step 3
The calculation in Step 2 show that the closest
relationship is with [Clogged air cleaner
element]. Follow this column down to the
troubleshooting area and carry out the
troubleshooting item marked l. The Remedy is
given as [Clean], so carry out cleaning, and the
exhaust gas color should return to normal.
D51EX/PX-22 40-705 b
TROUBLESHOOTING (S-1) ENGINE STARTING PERFORMANCE IS POOR
12
(S-1) ENGINE STARTING PERFORMANCE IS POOR
Causes
Defective contact of valves or valve seats

General causes why engine takes time to start
Leaking or clogged fuel piping (fuel inlet)
Defective alternator (regulator section)

• Defective electrical system
• Insufficient supply of fuel
Defective intake air heating system

Worn piston rings or cylinder bore
Stuck, sized supply pump plunger

• Insufficient intake of air supply
Clogged fuel tank vent system

• Improper selection of fuel
(At ambient temperature of -10°C or below, ASTM D975 No. 2 diesel fuel is used)
Clogged fuel filter element

• The common rail fuel injection system (CRI) recognizes the fuel injection timing
Defective fuel injector

electrically. Accordingly, even if the starting operation is carried out, the engine
Defective alternator
Clogged air clearer
may not start until the crankshaft revolves 2 turns at maximum.
Defective battery
This phenomenon does not indicate a trouble, however

Degree of use of machine Operated for long period   
Ease of starting Gradually became worse mjj m
Questions
Starts when warm j j

Non-specified fuel has being used mmm
Replacement of filters has not been carried out according to operation Manual j jmm
Engine oil replacement times are longer j
Preheat monitor does not indicate normal operation during a preheat at low temperatures j
Charge level monitor indicates abnormal charging during operation jj
Air cleaner clogging monitor indicates j
Air vent in fuel tank cap is clogged j
Fuel leaking from fuel piping j m
When priming pump is operated, it makes no reaction or is too heavy jm
Starter motor cranks slowly
When Engine is cranked with starting motor, j
Check items
1) Little or no fuel comes out even when the plug is removed from the fuel filter j
2) If fuel return line to fuel tank is removed little or no fuel comes out j
Exhaust manifold has cold areas after start up when touched j
Engine pick up is poor or irregular mm j
There is hunting from engine (rotation is irregular) mjm
Excessive blow-by gasses j
When air cleaner element is inspected directly, it is found to be clogged l
When compression pressure is measured, it is found to be low l l
l
Troubleshooting
When air is bled from fuel system, air comes out

Inspect fuel filter, strainer directly l
Carry out troubleshooting in “No-pressure feed by supply pump (1)* in code display l
During cylinder cut-out mode engine speed does not change l
Intake air heater mount does not warm up during preheat operations l
Is voltage 26 to 30V between alternator “B” and “E” terminal during Yes l
low engine idle No l
What is the condition of the battery l
Remedy
Replace
Replace
Replace
Replace
Replace
Replace
Replace
Replace
Repair
Clean
Clean
Clean
(1)*See Failure Code [CA559] and [CA2249]
40-706 b D51EX/PX-22
TROUBLESHOOTING (S-2) ENGINE DOES NOT CRANK
(S-2) ENGINE DOES NOT CRANK

General causes why engine does not turn Cause
• Internal parts of engine are seized
H If internal parts of the engine are seized, carry out troubleshooting for
“Engine stops during operations”. (See S-4)
• Defective electrical system
Poor battery connections and grounds

• Problem in drive devices on applicable machine side
Defective or deteriorated battery
Defective steering circuit wiring

Broken flywheel ring gear
Defective ignition switch
Defective starter motor

Defective battery relay
Confirm recent repair history Defective safety relay

Questions
Degree of use of machine Operated for long period  

Condition of horn when ignition switch Horn sounds m m j
is turned ON Horn volume is low j
Speed of rotation is low j
When ignition switch is turned to Makes grating noise j j
START, pinion moves out, but Soon disengages pinion again j
Makes rattling noise and does not turn m mm
Check items
When ignition switch is turned to START, pinion does not move out m m j
When ignition switch is turned to ON, there is no clicking sound m j
Battery terminal is loose j
For following conditions 1) - 5), turn the ignition switch OFF, connect remote switch, and carry out
troubleshooting
1) When terminal B and terminal C of ignition switch are connected, engine cranks l
2) When terminal at safety switch and terminal B of starter motor are connected,
Applicable machine
l
engine cranks
Troubleshooting
3) When terminal B and terminal C of starting safety relay are connected, engine l
cranks
4) Even if terminal B and C at safety relay are connected engine does not crank. l
5) There is no 20 to 30V between battery relay terminal B and terminal E l
When ring gear is inspected directly, tooth surface is found to be chipped l
Replace
Replace
Replace
Replace
Replace
Replace
Replace
Replace
Remedy
D51EX/PX-22 40-707 b
12
ENGINE CRANKS BUT NO EXHAUST SMOKE COMES OUT OF STACK
General causes why engine turns but no exhaust smoke comes out Causes
Defective operation of overflow valve (not closing)

• Supply of fuel depleted
• Supply of fuel is extremely low
Leaking or clogged fuel piping (entry of air)

• Improper selection of fuel (particularly in winter)
H Standards for use of fuel
Defective common rail pressure limiter

Stuck or seized supply pump plunger
Seized, abnormally worn feed pump
AMBIENT TEMPERATURE
TYPES
Clogged air vent hole in fuel cap

-4 14 32 50 68°C
Defective supply pump MPROP

OF FLUID
-20 -10 0 10 20°F
Insufficient fuel in the tank
Clogged fuel filter element
Broken supply pump shaft

ASTM D975 No. 2
Defective fuel injector

Diesel fuel
ASTM D975 No. 1
Use of improper fuel

Questions

Exhaust smoke suddenly stops coming out (when starting again) jmjj 
Replacement of filters has not been carried out according to Operation Manual j  m
Fuel tank is found to be empty j
Air vent holes in fuel tank cap are clogged mj
Rust and water are found when fuel is drained m  
There is leakage from fuel piping j
Fuel leaking from fuel piping j
When removed no fuel was found in fuel filter j j
When priming pump is operated, it makes no reaction or it is heavy jm
Check items
When engine is cranked with starting motor,

m m jm
1) No fuel comes out even when fuel filter air bleed plug is loosened
2) No fuel flows from fuel return line m jjj m
When air is bled from fuel system, air comes out l

Inspect fuel filter directly l
Inspect feed pump directly l
Troubleshooting
Carry out troubleshooting according to the displayed code “No pressure feed by l l
supply pump (1)*
Carry out troubleshooting according to the displayed code. “Abnormality in supply l
pump IMV/PCV (2)*
Inspect overflow valve directly l
Engine can be started in reduced cylinder mode l
Fuel flows out when pressure limiter return piping is disconnected l
Replace
Replace
Replace
Replace
Replace
Replace
Replace
Replace
Replace
Repair
Repair
(1)*See Failure Code [CA559] and [CA2249] Remedy

Add
40-708 b D51EX/PX-22
12
SMOKE COMES OUT OF STACK BUT ENGINE DOES NOT START
General causes why exhaust smoke comes out of stack but engine does not Causes
start
Defective coolant temperature sensor and harness

Worn dynamic valve system (Valve, rocker lever)
• Lack of cranking force due to defective electrical system
Leaking or clogged fuel system, entry of air

• Insufficient intake air
Clogged injector, defective spray pattern

• Improper selection of fuel and oil
Worn piston rings and cylinder bore
Stick, seized supply pump plunger
Defective intake air heater system

Defective or deteriorated battery
Clogged air cleaner element
Clogged fuel tank vent

Use of improper fuel
Clogged fuel filter

Suddenly failed to start j j m
mm
Questions
Non-specified fuel is being used

Replacement of filters has not been carried out according to OMM j j
Engine oil usage has increased j
Preheat monitor does not indicate normal operation during cold temperatures j
Air cleaner clogging monitor indicates j
Mud is stuck to fuel tank cap m
Rust and water are found when fuel tank is drained
When fuel filter is drained, no fuel comes out j
When priming pump is operated, it has no reaction or it is heavy jm
Check items
Starter motor cranks engine slowly j

When engine is cranked abnormal sounds are heard around the cylinder head area j
When engine is cranked with starting motor,
m j
1) Little fuel comes out even when fuel filter air bleed plug is loosened
2) No fuel comes out when return line is removed j
When exhaust manifold is touched immediately after starting engine,
temperature of some cylinders is low j
Remove air cleaner and check directly l

Inspect valve system and rocker arms l
When compression pressure is measured, it is found to be low l
Troubleshooting

Inspect fuel filter directly l
Carry out troubleshooting according to the displayed code. No-pressure feed by l
supply pump (1)*
Engine can be started in reduced cylinder mode l
Coolant temperature gauge does not indicate normally l
Intake air heater mounting area does not warm during preheat l
Replace
Replace
Replace
Replace
Replace
Replace
Replace
Replace
Repair
Clean
Clean
Clean
D51EX/PX-22 40-709 b
TROUBLESHOOTING (S-3) ENGINE DOES NOT RUN SMOOTHLY
(S-3) ENGINE DOES NOT RUN SMOOTHLY

General causes why engine does not run smoothly Causes
Leaking or clogged fuel piping, entry of air

Seizure or interference of the turbocharger
Defective contact of valve and valve seat
Stuck or seized supply pump plunger

Worn piston rings or cylinder liner
• Improper fuel used
• Controller in derated control mode
Clogged or defective injector

(limiting injection rate (output) because of an error in electrical system)
Improper valve clearance
Clogging of fuel filter

Clogged air cleaner

Degree of use of machine Operated for long period    
Replacement of filters has not been carried out according to Operation Manual j mm m
Questions
Engine pick-up suddenly became poor jjj

Non-specified fuel is being used j j
Replacement of filters has not been carried out according to OMM j
Air cleaner clogging monitor indicates
Mud is stuck to fuel tank cap j
Rust and water are found when oil is drained j
When priming pump is operated, it has no reaction or it is heavy jm
When exhaust manifold is touched immediately after starting engine, mj
temperature of some cylinders is low
Check items
Noise of interference is heard from around turbocharger

Color of exhaust gas Blue under light load jm j j
Black j
When engine is cranked abnormal sounds are heard around the cylinder head area j
When engine is cranked abnormal sounds are heard around the turbocharger j
High idling speed under no load is normal, but speed suddenly drops when load m j
is applied
There is hunting from engine (rotation is irregular) m m m
When air cleaner element is inspected directly, it is found to be clogged l

Troubleshooting
Check valve clearance l

When turbocharger is rotated by hand, it is found to be heavy l
Inspect fuel filter, strainer directly l
Carry out troubleshooting according to the displayed code. No-pressure feed by supply l
pump (1)*
When a cylinder cut-out operation is made engine speed does not change l
Replace
Replace
Replace
Replace
Replace
Repair
Adjust
Adjust
Clean
Clean
40-710 b D51EX/PX-22
TROUBLESHOOTING (S-4) ENGINE STOPS DURING OPERATIONS
12
(S-4) ENGINE STOPS DURING OPERATIONS
General causes why engine stops during operations Causes
• Seized parts inside engine
Broken auxiliary equipment (pump, components)

Breakage of valve system (valves, rocker arm)

• Overheating
H If there is overheating and the engine stops, carry out
troubleshooting for overheating.
Broken, seized piston, connecting rod
Stuck, seized supply pump plunger

• Failure in power train
Broken, sized crankshaft bearing

H If the engine stops because of a failure in the power
Leaking or clogged fuel piping

train, carry out troubleshooting for the chassis.
Broken or seized gear train
Broken supply pump shaft

Broken, seized feed pump
Insufficient fuel in tank
Failure of power train

Degree of use of machine Operated for long period 
Abnormal noise was heard and engine j j j j mjmjj
stopped suddenly
jm m
Questions
Condition when engine stopped Engine overheated and stopped

Engine stopped slowly j m
There was hunting and engine stopped jm mm
Non-specified fuel is being used mm m
Replacement of filters has not been carried out according to Operation
Manual j
Fuel level monitor indicates low fuel level (with monitor installed) j
Fuel is leaking from fuel piping j
When feed pump is operated, operation is too light or too heavy jm
Check items
Rust and water are found when fuel tank is drained j

Metal particles are found when oil pan is drained jjj
Does not turn at all jj
When it is attempted to turn by Turns in opposite direction j
hand using barring tool Moves amount of backlash j j
Shaft does not turn j
Engine turns, but stops when load is applied to machine j
Remove head cover and inspect directly l
Remove oil pan and inspect directly l
Inspect pistons and connecting rods directly l
Troubleshooting
See (H-mode)
Inspect crankshaft bearings directly l

Inspect gear train directly l
Inspect fuel filter and fuel strainer l
Inspect feed pump directly l
Carry out troubleshooting according to the displayed code. No-pressure feed l
by supply pump (1)*
Engine rotates when pump or auxiliary equipment is removed l
Replace
Replace
Replace
Replace
Replace
Replace
Replace
Replace
Replace
Correct
Clean
Clean

Add
D51EX/PX-22 40-711 b
TROUBLESHOOTING (S-5) ENGINE SPEED HUNTS
12
(S-5) ENGINE SPEED HUNTS
General causes why engine does not idle smoothly Causes
• Air in fuel system
• Defective speed sensor (Error at degree that it is not indicating)
Leaking or clogged fuel piping, entry of air
Clogged injector, defective spray pattern
Defective Bkup speed sensor system

Clogged air vent system in fuel tank
Defective Ne speed sensor system

Insufficient fuel in tank

Questions
Occurs at a certain speed range mm

Condition of hunting Occurs at low idling mmmmm
Occurs even when speed is raised m mm
Occurs on slopes j
Replacement of filters has not been carried out according to Operation Manual j
Check items

Rust and water are found when tank is drained m
Fuel is leakage from fuel piping j
When feed pump is operated, operation is too light or too heavy jm

Troubleshooting
Inspect fuel filter and strainer directly l

When a cylinder cut-out operation is made engine speed does not change l
Carry out troubleshooting according to the displayed code. Abnormality in Ne speed l
sensor (1)*
Carry out troubleshooting according to the displayed code. Abnormality in Bkup speed l
sensor (2)*
Replace
Replace
Replace
Replace
Replace
(1)*See Failure Code [CA689]

Clean
Remedy
Add
(1)*See Failure Code [CA778]
40-712 b D51EX/PX-22
TROUBLESHOOTING (S-6) ENGINE LACKS POWER
12
(S-6) ENGINE LACKS POWER
General causes why engine lacks power Causes
Defective boost pressure sensor installation

Defective boost pressure sensor system

• Improper fuel used
Seizure or interference in turbocharger
Worn piston rings and cylinder liners

(if non-specified fuel is used, output drops)
Defective fuel injector drive system

Air leakage from air intake piping
Clogged or defective fuel injector

• Lack of output due to overheating
Leaking or clogged fuel piping

H If there is overheating and lack of output, carry out
Clogged fuel return piping

troubleshooting for overheating. See S14 Coolant temperature
Incorrect valve clearance

rises too high (overheating) for the troubleshooting.
• Controller in derate control mode (limiting injection rate (output)
Clogged air cleaner
Clogged fuel filter

because of an error in electrical system)

Suddenly mj mmmm
Questions
Power was lost

Gradually m m m m m m
Non-specified fuel is being used mmm
Replacement of filters has not been carried out according to j j
Operation Manual
Engine oil must be added more frequently m m
Air cleaner clogging monitor indicates jj
Mud is stuck to fuel tank cap j j
Leakage from fuel piping j
Output becomes insufficient after short stop of operation j
Color of exhaust gas Black j j
Check items
When exhaust manifold is touched immediately after starting engine, jj

When engine is cranked abnormal noise is heard around turbocharger j
When engine is cranked abnormal noise is heard around cylinder head j
High idle speed is too high m
High idle speed under no load is normal, but speed drops when load is m jmm
applied
Engine does not pickup smoothly and combustion is irregular jj mm j
There is hunting from engine (rotation is irregular) mmm mm
Blow-by gasses are excessive j j
D51EX/PX-22 40-713 b
TROUBLESHOOTING (S-6) ENGINE LACKS POWER
Inspect air cleaner directly l

Inspect air intake piping l
When boost pressure is measured pressure is low l l l
When compression is measured pressure is low l l
Inspect valve clearance l
Troubleshooting
Inspect fuel piping l

Inspect fuel filter and strainer l
Inspect spill port check valve l
Carry out troubleshooting according to the displayed code. No pressure feed l
from supply pump (1)*
When a cylinder cut-out operation is made engine speed does not change l l
Inspect boost pressure sensor installation l
Carry out troubleshooting according to the displayed code. According to boost l
pressure sensor (2)*
Replace
Replace
Replace
Replace
Replace
Replace
Replace
Replace
Replace
Adjust
Repair
Repair
Repair
Clean
Remedy Clean
40-714 b D51EX/PX-22
TROUBLESHOOTING (S-7) EXHAUST SMOKE IS BLACK
12
(S-7) EXHAUST SMOKE IS BLACK
General causes why exhaust smoke is black Causes
Leakage of air between turbocharger and intake

Defective coolant temperature sensor system

• Improper selection of fuel

• Overheating
Seizure or interference of turbocharger

H If there is overheating and lack of output, carry out

troubleshooting for overheating. See S14 Coolant temperature rises
Improper fuel injection pressure

Improper fuel injection timing
Worn piston rings or cylinders
too high (overheating) for the troubleshooting.
Clogged air cleaner element
Crushed or clogged muffler
Abnormal wear of injectors

Clogged or seized injector
• Controller in derate control mode (limiting injection rate (output) because

of an error in electrical system)

Suddenly became black j j mmm
Color of exhaust gas Gradually became black j m
Questions

Non-specified fuel is being used mm
Power was lost Suddenly j m mm
Gradually m m m m
Air cleaner clogging monitor indicates- j
Leakage of air between turbocharger cooling core and head, loose clamp j
Engine is operated in low-temperature mode at normal temperatures mmm
When exhaust manifold is touched immediately after starting engine, mj
Check items
Noise of interference is heard from around turbocharger j

Clanging sound is heard from around cylinder head j
Pump relief speed is high (Fuel is injected excessively) m
Exhaust noise is abnormal m j m
Engine pickup is poor and combustion is irregular m mmm mj
Fuel return line has an excessive amount of fuel returned j
Inspect air cleaner directly l

When turbocharger is rotated by hand it is found to be tight l
Troubleshooting

When muffler is removed, engine runs normal l
Carry out troubleshooting according to the displayed code. No pressure feed from l l
supply pump (1)*
When cylinder cut out is performed, engine speed does not change l
Carry out troubleshooting according to the displayed code. Abnormality in coolant l
temperature sensor (2)*
Check using the monitor functions l l
Replace
Replace
Replace
Replace
Replace
Replace
Replace
Replace
Replace
Repair
Adjust
Adjust

Clean
D51EX/PX-22 40-715 b
TROUBLESHOOTING (S-8) OIL CONSUMPTION IS EXCESSIVE OR EXHAUST SMOKE IS
(S-8) OIL CONSUMPTION IS EXCESSIVE OR EXHAUST SMOKE IS

BLUE
Causes
Oil leaking from oil pan or cylinder head

H Do not run the engine at idling for more than 20 minutes
Worn or damaged valve stems or seals
Worn piston rings or cylinder liners

continuously. (Both low and high idling)
General causes why oil consumption is excessive Dust sucked in from intake system
Worn or damaged rear oil seal

Worn seal at turbocharger end
• Abnormal combustion of oil
Oil leaking from drain plug

Oil leaking from oil piping
Oil leaking from oil cooler
Oil leaking from oil filter
• External leakage of oil Worn seal at blower end
• Wear of lubrication system
• Low compression Broken piston ring
Broken oil cooler

Questions
Oil consumption suddenly increased j m

Engine oil must be added more frequently j m
Engine oil becomes contaminated quickly mmj
Area around engine is dirty with oil jjjjj
Clamps for intake system are loose j
When turbocharger air supply pipe is removed, inside is found to be dirty mj
Check items
with oil
When exhaust pipe is removed, inside is found to be dirty with oil j
There is oil in engine coolant j
Exhaust smoke is blue under light load jj
Amount of blow-by gas Excessive m m jj
None j
When intake manifold is removed, dust is found inside l

l
Troubleshooting
When intake manifold is removed, inside is found to be excessively dirty

Excessive play of turbocharger shaft l l
Check breather and breather hose directly l
When compression is measures it is excessively low l l
Inspect rear seal directly l
Pressure test of oil cooler indicates there is leakage l l
There is external leakage of oil from engine l l l l
Replace
Replace
Replace
Replace
Replace
Replace
Repair
Repair
Repair
Repair
Repair
Repair
Repair
Clean
Remedy
40-716 b D51EX/PX-22
TROUBLESHOOTING (S-9) OIL BECOMES CONTAMINATED QUICKLY
12
(S-9) OIL BECOMES CONTAMINATED QUICKLY
General causes why oil becomes contaminated quickly Causes
• Entry of exhaust gas due to internal wear
• Clogging of lubrication passage
• Improper fuel
Defective seal at turbocharger turbine end

• Improper oil used
Worn valves and valve guides or seals

Worn piston rings and cylinder liners
• Operation under excessive load
Defective oil filter bypass valve

Clogged turbocharger drain line
Clogged breather, breather hose
Exhaust smoke is excessive

Clogged oil cooler
Confirm recent repair history Clogged oil filter
Questions
Non-specified fuel is being used m m

Metal particles are found when oil is drained mm j
Inside of exhaust pipe is contaminated with excessive oil j
Engine oil temperature rises quickly
Check items
Color of exhaust gas Black under light load j

Black j j
Amount of blow-by gas Excessive mmj m
None j
Excessive play of turbocharger shaft l
Troubleshooting
When compression pressure is measured, pressure is low l l

Check breather and breather hose directly l
Inspect oil cooler directly l
See S-7
Inspect oil filter directly l

Oil filter bypass valve is broken l
Inspect turbocharger drain line directly l
Replace
Replace
Replace
Replace
Replace
Clean
Clean
Clean
Remedy
D51EX/PX-22 40-717 b
TROUBLESHOOTING (S-10) FUEL CONSUMPTION IS EXCESSIVE
12
(S-10) FUEL CONSUMPTION IS EXCESSIVE
General causes why fuel consumption is excessive Causes
• Leakage fuel
Defective coolant temperature sensor system

• Excessive injection of fuel
Fuel leakage from fuel filter piping
Defective common rail pressure

Defective supply pump plunger
Defective injector spray pattern

Fuel leakage inside valve cover
Defective operation of injector

Defective feed pump oil seal

Questions
More than for other machines of same model m mmm

Condition of fuel
consumption Gradually increased m m
Suddenly increased mm
Fuel leakage around outside of system j
There is irregular combustion j
Engine oil level rises and smells of diesel fuel j j
When exhaust manifold is touched immediately after starting engine, temperature of j
Check items
some cylinders is low

Engine low idling and high idling speeds are high m
Pump relief speed is high m
Color of exhaust smoke
Black mm mm
Blue m
Remove valve cover and check directly l

l
Troubleshooting
Inspect feed pump oil seal directly

Carry out troubleshooting for code. No pressure feed by supply pump (1)* l
When a cylinder cut out is performed engine speed does not change l
Remove fuel return line and inspect directly l
Carry out troubleshooting for code. Abnormality in coolant temperature sensor (2)* l
Check the system using the monitor l l
Replace
Replace
Replace
Replace
Replace
Replace
Repair
Repair
Repair

40-718 b D51EX/PX-22
TROUBLESHOOTING(S-11) OIL FOUND IN COOLANT, OR COOLANT SPURTS FROM RA-
(S-11) OIL FOUND IN COOLANT, OR COOLANT SPURTS FROM

RADIATOR
General causes why oil is in coolant Causes
• Internal leakage in lubrication system
• Internal leakage in cooling system
Leaking hydraulic or power train oil cooler

Cracked cylinder head or leaking gasket
Crack in cylinder block
Cylinder liners pitted
Leaking oil cooler
Questions

Oil level Suddenly increased m m
Gradually increased mm
Hard water is being used as cooling system mm
Engine oil level has risen, oil is cloudy white mmj
Check items
Excessive air bubbles inside radiator spurts back j

Hydraulic oil, transmission oil is cloudy white j
When hydraulic oil transmission oil is drained, water is found j
Pressure-tightness test of oil cooler shows there is leakage l

Trouble-
shooting
See H
mode
Remove oil pan and inspect directly l l

Pressure-tightness test of cylinder head shows there is leakage l
Replace
Replace
Replace
Replace
Replace
Remedy
D51EX/PX-22 40-719 b
TROUBLESHOOTING (S-12) OIL PRESSURE CAUTION LAMP LIGHTS UP
12
(S-12) OIL PRESSURE CAUTION LAMP LIGHTS UP
General causes why oil pressure lamp lights up Causes
• Leakage, clogging, wear of lubricating system
• Defective oil pressure control
• Improper oil used (improper viscosity)
• Deterioration of oil due to overheating
Leaking crushed or clogged oil piping

Clogged or broken oil pickup pipe
Defective oil level sensor system

Defective oil pressure regulator
Worn bearings and journals
Clogged oil pickup strainer

Coolant or fuel in the oil
Lack of oil in oil pan
Defective oil pump
Clogged oil filter

Questions
Oil pressure monitor indicates low oil pressure mj

Non-specified fuel is being used m
Replacement of filters has not been carried out according to
Operation Manual j
Lights up at low idling j
Condition when oil pressure Lights up at low, high idling m jjjm
lamp lights up Lights up on slopes j
Sometimes lights up j m
Check items
Oil pressure monitor indicates low pressure level j j

Oil level in oil pan is low j
External oil piping is leaking or crushed
Oil is cloudy white or smells of diesel oil j
Metal particles are found when oil is drained j
Metal particles are stuck to oil filter element j m
When oil filter is inspected, it is found to be clogged l

Troubleshooting
Remove oil pan and inspect directly l l

See S-13
Oil pump rotation is heavy, there is play l

There is catching of relief valve or regulator valve, spring or valve guide l
is broken
Inspect oil filter directly l
When oil pressure sensor is replace oil pressure is normal l
Replace
Replace
Repair
Adjust
Clean
Clean
Clean
Clean
Remedy

Add
40-720 b D51EX/PX-22
TROUBLESHOOTING (S-13) OIL LEVEL RISES (COOLANT OR FUEL FOUND IN OIL)
(S-13) OIL LEVEL RISES (COOLANT OR FUEL FOUND IN OIL)

Causes
Cracked cylinder head or leaking head gasket
Defective seal of auxiliary equipment

H If there is oil in the cooling water, carry out
troubleshooting for “Oil is in cooling water”.
General causes why oil level rises
Cracks inside cylinder block
Worn, damaged rear oil seal

• Coolant in oil (milky white)
Defects in supply pump

Leaking injector O-ring
Holes in cylinder liners

• Fuel in oil (diluted, and smells of diesel fuel)
• Entry of oil from other component (See S-11)
Leaking oil cooler

Questions

Fuel must be added more frequently j j
Coolant must be added more frequently m m
There is oil in radiator coolant mmmm j
Engine oil smells of diesel fuel j j
Engine oil is milky m m
Check items
When engine is first started, drops of water come from muffler m

Leave radiator cap open. When engine is run at idling, an abnormal number of j m
bubbles appear, or water spurts back
Exhaust smoke is white m
Oil level goes down in hydraulic tank j
Pressure-tightness test of oil cooler shows there is leakage l

Pressure-tightness test of cylinder head shows there is leakage l
Troubleshooting

Inspect rear seal directly l
When pump auxiliary equipment is removed, seal is found to be damaged l
Remove head cover and inspect directly l
Remove injection pump and inspect directly l
Defective contact with thermostat seal valve l
Remove oil pan and check directly
Replace
Replace
Replace
Replace
Replace
Repair
Repair
Repair
Remedy
D51EX/PX-22 40-721 b
TROUBLESHOOTING (S-14) COOLANT TEMPERATURE TOO HIGH (OVERHEATING)
(S-14) COOLANT TEMPERATURE TOO HIGH (OVERHEATING)

General causes why coolant temperature becomes too high Causes
• Lack of cooling air (deformation, damage of fan)
• Drop in heat dissipation efficiency
• Defective cooling circulation system
• Rise in oil temperature in power train
Cracked cylinder head or head gasket
Defective coolant temperature gauge

H Carry out troubleshooting for H-mode
Clogged or leaking oil cooler
Damaged or blocked radiator
Defective fan operation

Holes in cylinder liners
Defective radiator cap

Plugged radiator core
Defective thermostat
Bad water pump
Lack of coolant
Confirm recent repair history Slow fan speed

Suddenly overheated mj m
Questions
Condition of overheating
Always tends to overheat mjj m
Water temperature gauge Rise quickly m j
Does not go down from red range j
Radiator coolant level drops under low level j
Engine oil level has risen, oil is milky jm
Fan speed is slow j
Fan does not rotate j
Check items
Milky oil is floating on coolant j

Excessive air bubbles in radiator (coolant spurts out of radiator) j
When light bulb is held behind radiator, no light passes through j
Radiator shroud, inside of undergird are clogged with dirt or mud j
Coolant is leaking because of cracks in hose or loose clamps j
Coolant flows from radiator overflow hose j
Inspect cylinder liner directly l
Troubleshooting
Inspect oil cooler directly l

See H-mode
Temperature difference between upper and lower tank is great l

Thermostat does not open at cracking temperature l
Temperature difference between upper and lower tank is slight l
Inspect radiator core l
When radiator cap is checked, cracking pressure is low l
Inspect fan speed directly l
When coolant temperatures measured it is found to be normal l
Replace
Replace
Replace
Replace
Replace
Replace
Replace
Repair
Repair
Repair
Remedy -
Add
40-722 b D51EX/PX-22
TROUBLESHOOTING (S-15) ABNORMAL NOISE IS HEARD WHEN ENGINE IS RUNNING
(S-15) ABNORMAL NOISE IS HEARD WHEN ENGINE IS RUNNING

Causes
Leakage of air between turbocharger and cylinder head

Interference of turbocharger, seized turbocharger
Excessive wear of piston rings or cylinder liners

Broken dynamic valve system (valves, rockers)
H Judging if the noise is an internal noise or an external
noise.
General causes why abnormal noise is made

• Abnormality due to defective parts
Improper gear train backlash
Clogged or seized injector

• Abnormal combustion
Removed seized bushing

• Air leakage from charge air line
Dirt caught in injector

Defective muffler

Gradually occurred m
Questions
Condition of abnormal noise

Suddenly occurred mm m
Non-specified fuel is being used
Engine oil must be added more frequently m
Metal particles found in oil filter j
Air leaks between turbocharger, cooling core and cylinder head j j j
Noise of interference is heard from around turbocharger j
When engine is cranked, abnormal noise is generated around cylinder head j j
Abnormal noise is heard around muffler j
Check items
If exhaust manifold is touched after start up there are cold spots on manifold jm
Color of exhaust smoke
Blue under light load j
Black mj m
Engine does not pick up smoothly and combustion is irregular j
Abnormal noise is heard when engine is accelerated m m m
Blow-by gasses are excessive j
When turbocharger is rotated by hand it is found to be heavy l

Inspect valve system directly l
When muffler is removed abnormal noise disappears l
Troubleshooting

When compression pressure is measured it is found to be low l
Inspect gear train l l
Inspect charge air clamp tightening torque l
When cylinder is cut out for reduced cylinder mode engine speed does not l l
change
Abnormal noise is heard only when engine is started l
Confirm with INSITE or monitoring function on machine side l
Replace
Replace
Replace
Replace
Replace
Replace
Replace
Replace
Repair
Repair
Repair
Remedy
D51EX/PX-22 40-723 b
TROUBLESHOOTING (S-16) EXCESSIVE VIBRATION WHEN ENGINE IS RUNNING
12
(S-16) EXCESSIVE VIBRATION WHEN ENGINE IS RUNNING
Causes
Stuck dynamic valve system (valves, rocker)

H If there are abnormal noise together with the vibration,
carry out troubleshooting also for “Abnormal noise is
Worn or damaged connecting rod

made”. (See S-15)
Damage in power train system

Improper gear train backlash
General causes why vibration is excessive
• Defective parts (abnormal wear, breakage)
Loose engine mountings

Worn camshaft bushing
• Improper combustion
• Abnormal combustion

Questions
Condition of vibration Suddenly increased m m

Gradually increased m m m
Non-specified oil is being used m m
Metal particles are found in oil filter j j
Metal particles are found when oil is drained j j
Check items
Oil pressure is low at low idling m m

Vibration occurs at mid-range speed mm
Vibration follows engine speed m mm
Exhaust smoke is black j m
Inspect valve system directly l

Troubleshooting
Inspect main bearings and connecting rods l

Inspect gear train directly l
Inspect cam shaft bushings directly l
Check the monitoring functions l
Check all engine mounting points l
Injection power train l
Replace
Replace
Replace
Replace
Replace
Replace
Replace
Remedy
40-724 b D51EX/PX-22
50 DISASSEMBLY AND ASSEMBLY
12install
HOW TO USE THIS MANUAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50-4
REMOVAL AND INSTALLATION OF COMPONENTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50-4
OVERHAUL OF COMPONENTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50-5
PRECAUTIONS WHEN CARRYING OUT AN OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50-6
SPECIAL TOOL LIST . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50-8
SKETCH OF SPECIAL TOOLS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50-15
CONNECTOR REPAIR PROCEDURES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50-30
CONTACT TERMINAL REMOVAL (HD30 TYPE) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50-30
STRIPPING INSULATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50-31
CRIMPING CONTACT TERMINAL (HD30 TYPE) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50-32
INSERTION OF CONTACT TERMINAL (HD30 TYPE) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50-33
CONTACT TERMINAL REMOVAL (DT TYPE) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50-34
STRIPPING INSULATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50-35
CRIMPING CONTACT TERMINAL (DT TYPE) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50-36
INSERTION OF CONTACT TERMINAL (DT TYPE) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50-37
NOSE GUARD (HOOD) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50-39
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50-39
INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50-43
MUFFLER AND EXHAUST STACK . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50-45
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50-45
INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50-46
CAB . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50-47
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50-47
INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50-56
MONITOR PANEL AND HST CONTROLLER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50-61
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50-61
INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50-63
KOMTRAX CONTROLLER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50-64
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50-64
INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50-64
SEAT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50-65
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50-65
INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50-65
AIR CONDITIONER/HEATER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50-66
DISASSEMBLY OF AIR CONDITIONER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50-66
ASSEMBLY OF AIR CONDITIONER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50-70
FOOT HEATER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50-71
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50-71
INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50-72
FOOT HEATER OVERHAUL PROCEDURES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50-73
OVERHAUL PROCEDURES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50-73
ASSEMBLY PROCEDURES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50-75
ENGINE AND HST PUMP . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50-77
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50-77
INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50-87
REMOVAL FROM ENGINE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50-89
INSTALLATION TO ENGINE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50-92
50-1 H
DRIVE DAMPENER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50-93
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50-93
INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50-94
HST PUMP OVERHAUL PROCEDURES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50-95
DISASSEMBLY PROCEDURES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50-95
ASSEMBLY PROCEDURES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50-104
WORK EQUIPMENT PUMP OVERHAUL PROCEDURES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50-116
DISASSEMBLY PROCEDURES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50-116
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50-130
INSTALL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50-131
CHARGE PUMP OVERHAUL PROCEDURES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50-132
DIESEL ENGINE OVERHAUL PROCEDURES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50-144
DISASSEMBLY OF EXTERNAL COMPONENTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50-144
DISASSEMBLY OF ENGINE TOP END . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50-150
REMOVAL OF OIL COOLER, ENGINE CONTROLLER AND FUEL PUMP . . . . . . . . . . . . . . . . . . . . 50-154
DISASSEMBLY OF ENGINE LOWER END . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50-156
ASSEMBLY OF ENGINE LOWER END . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50-163
INSTALLATION OF OIL COOLER, ENGINE CONTROLLER AND FUEL PUMP . . . . . . . . . . . . . . . 50-179
ASSEMBLY OF EXTERNAL COMPONENTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50-188
TRACK SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50-194
SPREADING THE TRACK . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50-194
(CONVENTIONAL TYPE TRACK SHOE) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50-194
EXPANSION AND INSTALLATION OF TRACK SHOE ASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . 50-196
(PLUS TYPE TRACK SHOE) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50-196
WHOLE DISASSEMBLY AND ASSEMBLY OF TRACK SHOE ASSEMBLY
(CONVENTIONAL TYPE TRACK SHOE) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50-197
WHOLE DISASSEMBLY AND ASSEMBLY OF TRACK SHOE (PLUS TYPE TRACK SHOE) . . . . . . . . 50-217
FIELD DISASSEMBLY AND ASSEMBLY OF ONE LINK (CONVENTIONAL TYPE TRACK SHOE) . . 50-231
FIELD DISASSEMBLY AND ASSEMBLY OF ONE LINK (PLUS TYPE TRACK SHOE) . . . . . . . . . . . . . 50-239
TRACK FRAME . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50-247
REMOVAL OF TRACK FRAME . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50-247
FRONT TRACK IDLER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50-256
REMOVING FRONT IDLER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50-256
INSTALLING FRONT IDLER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50-259
TRACK ROLLER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50-260
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50-260
INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50-260
TRACK ROLLER OVERHAUL PROCEDURES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50-261
CARRIER ROLLER OVERHAUL PROCEDURES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50-266
FINAL DRIVE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50-268
FINAL DRIVE REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50-268
INSTALLING THE FINAL DRIVE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50-272
FINAL DRIVE OVERHAUL PROCEDURES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50-274
ASSEMBLY OF FINAL DRIVE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50-280
TRAVEL MOTOR OVERHAUL PROCEDURES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50-288
FAN MOTOR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50-306
REMOVAL PROCEDURES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50-306
INSTALLATION PROCEDURES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50-310
FAN MOTOR OVERHAUL PROCEDURES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50-312
50-2 I
DB 12 VALVE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50-324
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50-324
INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50-327
COOLING PACKAGE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50-328
REMOVING THE GRILL AND COOLING FAN ASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50-328
REMOVING THE COOLING PACKAGE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50-339
INSTALLING THE COOLING PACKAGE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50-347
INSTALLING THE GRILL AND COOLING FAN ASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50-348
FUEL TANK . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50-352
REMOVING THE FUEL TANK . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50-352
INSTALLING THE FUEL TANK . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50-356
HYDRAULIC TANK . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50-357
REMOVING THE HYDRAULIC TANK . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50-357
INSTALLING THE HYDRAULIC TANK . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50-363
WORK EQUIPMENT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50-364
REMOVING OR INSTALLING PINS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50-364
FRONT BLADE, TILT AND ANGLE CYLINDERS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50-365
ADJUSTING BLADE CENTER BALL AND PITCH ROD PLAY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50-370
“C” FRAME . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50-372
LIFT CYLINDERS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50-375
CYLINDER OVERHAUL PROCEDURES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50-377
50-3 I
DISASSEMBLY AND ASSEMBLY HOW TO USE THIS MANUAL
HOW TO USE THIS MANUAL
REMOVAL AND INSTALLATION OF COMPONENTS

Special Tools
• Special tools that are deemed necessary for removal or installation of parts are listed.
• List of the special tools contains the following kind of information.
1) Necessity
n Special tools which cannot be substituted, should always be used.
l Special tools which are very useful if available, can be substituted with commercially available tools.
2) Distinction of new and existing special tools
N: Tools with new part numbers, newly developed for this model.
R: Tools with upgraded part numbers, remodeled from already available tools for other models.
Blanks: Tools already available for other models, used without any modification.
Circle mark m in sketch column:
A circle mark means that a sketch of the special tool is presented in the section of Sketches for Special Tools.
H Part No. of special tools starting with 79*T means that they are locally made parts and as such not interchangeable with
those made by Komatsu in Japan e.g. 79*T---xxx---xxxx.
Removal
• The REMOVAL section contains procedures, precautions and the amount of oil or water to be drained.
• Various symbols used in the REMOVAL section are explained and listed below.
This indicates safety-related precautions which must be followed when doing the
WARNING!
work.
Remark This mark gives guidance or precautions when doing the procedure.
This mark shows oil or water to be drained and quantity.
Mass of a part or component.
Installation
• Except where otherwise instructed, install parts in the reverse order of removal.
• Marks shown in the INSTALLATION section stand for the following.
WARNING! This mark indicates safety-related precautions which must be followed when doing the work.
This mark gives guidance or precautions when doing the procedure.
This mark stands for a specific coating agent to be used.
This mark indicates the specified torque.
This mark indicates an amount of oil, coolant or fuel to be added.
50-4 B
DISASSEMBLY AND ASSEMBLY HOW TO USE THIS MANUAL
12
OVERHAUL OF COMPONENTS
Special Tools
• Special tools which are deemed necessary for disassembly and assembly are listed in this section.
• List of the special tools contains the following kind of information.
1) Necessity
n Special tools which cannot be substituted, should always be used.
l Special tools which are very useful if available, can be substituted with commercially available tools.
2) Distinction of new and existing special tools
N: Tools with new part numbers, newly developed for this model.
R: Tools with upgraded part numbers, remodeled from already available tools for other models.
Blanks: Tools already available for other models, used without any modification.
3) Circle mark m in sketch column:
A circle mark means that a sketch of the special tool is presented in the section of Sketches for Special Tools.
H Part No. of special tools starting with 79*T means that they are locally made parts and as such not interchangeable with
those made by Komatsu in Japan e.g. 79*T---xxx---xxxx.
Disassembly Procedures
• The DISASSEMBLY section contains procedures, precautions and the amount of oil or water to be drained.
• Various symbols used in the DISASSEMBLY section are explained and listed below.
WARNING! This mark indicates safety-related precautions which must be followed when doing
the work.
Remark This mark gives guidance or precautions when doing the procedure.
This mark shows amount of oil or coolant to be drained.
Assembly Procedures
• Section titled ASSEMBLY contain procedures, precautions and the know-how for the work, as well as the amount of oil
or water to be added.
• Various symbols used in the ASSEMBLY section are explained and listed below.
WARNING! This mark indicates safety-related precautions which must be followed when doing
the work.
This mark gives guidance or precautions when doing the procedure.
This mark stands for a specific coating agent to be used.
This mark indicates the specified torque.
This mark indicates an amount of oil, coolant or fuel to be added.
Sketches Of Special Tools
• Various special tools are illustrated for the convenience of local manufacture.
50-5 B
DISASSEMBLY AND ASSEMBLYPRECAUTIONS WHEN CARRYING OUT AN OPERATION
12
PRECAUTIONS WHEN CARRYING OUT AN OPERATION
When carrying out removal or installation (disassembly or assembly) of units, be sure to follow the general precautions given
below when carrying out the operation.
1. Precautions when carrying out removal work

• If draining a system always dispose of the fluids correctly.
• After disconnecting hoses or tubes, cover them or fit blind plugs to prevent dirt or dust from entering.
• 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.
• Install wires and hoses with tags to show their installation position to prevent any mistake when installing.
• Check the number of thickness of the shims, and keep in a safe place.
• When raising components, be sure to use lifting equipment of ample strength and always stand clear of what you are
lifting.
• When using forcing screws to remove any components, tighten the forcing screws uniformly in turn.
• Before removing any unit, clean the surrounding area and install a cover to prevent any dust or dirt from entering
after removal.
2. Precautions When Handling Piping During Disassembly install the following blind plugs into the piping after
disconnecting it during disassembly operations.
A. Face seal type hoses and tubes

Nominal Plug (nut end) Nut (elbow end)
number
02 07376-70210 02789-00210
03 07376-70315 02789-00315
04 07376-70422 02789-00422
05 07376-70522 02789-00522
06 07376-70628 02789-00628
B. Split flange type hoses and tubes

Nominal Flange (hose end) Sleeve head (tube end) Split flange
number
04 07379-00400 07378-10400 07371-30400
05 07379-00500 07378-10500 07371-30500
C. If the part is not under hydraulic pressure, the following plugs can be used.
Nominal Dimensions (mm)

Part Number
number D d L
06 07049-00608 6 5 8
08 07049-00811 8 6.5 11
10 07049-01012 10 8.5 12
12 07049-01215 12 10 15
14 07049-01418 14 11.5 18
16 07049-01620 16 13.5 20
18 07049-01822 18 15 22
20 07049-02025 20 17 25
22 07049-02228 22 18.5 28
50-6 B
DISASSEMBLY AND ASSEMBLYPRECAUTIONS WHEN CARRYING OUT AN OPERATION
Nominal Dimensions (mm)

Part Number
number D d L
24 07049-02430 24 20 30
27 07049-02734 27 22.5 34
3.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.
• 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 to be sure 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 to be sure 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 eye-bolts, check to be sure 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.
H 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:
A. Start the engine and run at low idling.
B. Operate the work equipment control lever to operate the hydraulic cylinder 4 – 5 times, stopping the cylinder 100 mm
(4.0in) from the end of its stroke.
C. Next, operate the hydraulic cylinder 3 – 4 times to the end of its stroke.
H When using the machine for the first time after repair or long storage, follow the same procedure.
50-7 B
DISASSEMBLY AND ASSEMBLY SPECIAL TOOL LIST
SPECIAL TOOL LIST

H Tools with part number 79mT-mmm-mmmm cannot be supplied (they are items to be locally manufactured).
Necessity:
(n) Cannot be substituted, should always be installed (used).
(l) Extremely useful if available, can be substituted with commercially available part.
H New/remodel: (N) Tools with new part numbers, newly developed for this model.
(R) Tools with upgraded part numbers, remodeled from items already available for other models.
(Blank) Tools already available for other models, used without any modification.
H Tools marked m in the Sketch column are tools introduced in special sketches (See SKETCHES OF SPECIAL TOOLS).
New/remodel
Necessity
Symbol
Sketch
Q’ty
Component Part No. Part Name Nature Of Work, Remarks
HST pump, travel 1 790-501-5200 Repair stand n 1

motor, work equip- Disassembly and assembly
ment and fan pump 2 790-901-2110 Bracket n 1
of pump and motor assembly
3 791T-B67-1210 Plate n 1 N m
1 790-201-3610 Bolt n 1
2 792-422-1120 Washer n 1
4 3 01643-32460 Washer l 1 Installation of spring
4 01643-32060 Washer l 1
5 01582-02016 Nut l 1
5 790-201-2180 Plate n 1 Removal of bearing
A 6 790-201-2710 Spacer n 1 Remove & install snap ring
HST pump 7 797T-622-1170 Push tool n 1 m Remove & install shaft assy.
8 796-760-9110 Push tool n 1 Installation of bearing (shaft)
9 79G-05V-0301L Push tool n 1 Installation of bearing (case)
1 790-101-5001 Push tool kit n 1
2 790-101-5151 • Plate 1 Installation of oil seal to
10
3 790-101-5021 • Grip 1 holder
4 01010-50816 • Bolt 1
11 796-751-1510 Spline socket n 1
12 791T-B1L-1110 Box wrench n 1 N m Torquing pump bolts
1 791T-B65-1210 Plate n 1 N m Diss. &assy. of motor
2 791T-527-1210 Driver n 1 N m Install oil seal
3 793T-659-1110 Push tool n 1 m Install main bearing
4 790-445-3810 Push tool n 1 Install sub bearing
Travel motor B 5 791T-B65-1220 Push tool n 1 m Install shaft assembly
6 791T-465-1120 Push tool n 1 m Install dowel pin
7 791T-B65-1120 Push tool n 1 m Attach valve plate
8 791T-465-1230 Plate n 1 N m Attach cylinder block
9 791-B65-1160 Spline wrench n 1 N Check shaft rotation
50-8 h
New/remodel
Necessity
Symbol
Sketch
Q’ty
10 791T-527-1310 Plate n 1 N m
11 791T-527-1320 Bolt n 2 N m
Installation of oil seal to
Travel motor B 12 791T-527-1330 Bolt n 1 N m
holder
13 791T-527-1340 Block n 1 N m
14 791T-527-1350 Driver n 1 N m
1 796T-267-1130 Plate n 1 N m Dissemble & assemble pump
1 01017-61400 Bolt l 1
2 796T-266-1120 Washer n 1 m
2 3 01643-32060 Washer l 1 Installation of spring
4 01643-31445 Washer l 1
5 01580-01411 Nut l 1
3 796T-267-1180 Push tool n 1 m Install bearing
Work equipment and
C 4 791-615-2130 Sleeve n 1 Install shaft
fan pump
1 790-101-5001 Push tool kit n 1 Assemble oil seal
2 790-101-5081 • Plate n 1
5
3 790-101-5021 • Grip n 1
4 01010-50816 • Bolt l 1
6 791-B67-1410 Guide n 1 N Protecting oil seal
1 790-445-2620 Wrench n 1 N
7 Checking shaft rotation
2 01306-10616 Screw l 1 N
1 791T-B7R-1110 Plate n 1 m Diss. & assy. of motor
1 01010-81260 Bolt l 1
2 796T-126-1160 Washer n 1 m
2 Installation of spring
3 01643-31445 Washer l 1
Fan motor D
4 01582-01210 Nut l 1
3 796T-267-1140 Push tool n 1 m Install main bearing
4 791T-B7R-1130 Push tool n 1 m Install sub bearing
5 791T-B7R-1120 Push tool n 1 m Install oil seal
50-9 h
New/remodel
Necessity
Symbol
Sketch
Q’ty
790-501-2001 n 1
1 Repair stand
Disassembly and 795-799-1150 n 1
assembly of engine 2  l 1
Adapter For Cummins or Komatsu
3 795-799-7210 n 1
Remove or install 795-102-2103 n 1
intake or exhaust 4 Spring pusher
valves 795-799-8800 n 1
5 795-100-2800 Ring tool l 1 75 - 175 mm

Pistons
6 795-921-110 Holder l 1
Injectors 7 795-799-6700 Puller l 1
Rear seal 8 795-799-6500 Driver l 1
Front seal E 9 795-799-6400 Driver l 1
790-331-1120 Wrench (angle) l 1
Tightening bolts 10
795-799-2240 Angle gauge l 1
Adjusting valves 13  Clearance gauge l 1
Backlash and play 14  Gauge and stand l 1
Fuel inlet 15 795-799-8150 Remover l 1 N
Injector assembly 795-799-6700 Puller n 1 Removal and installation
Main bearings 16 795-799-2270 Rem. and inst. l 1
Crankshaft 17 795-799-1131 Bearing tool l 1
Harness nut 18 795-799-7110 Torque wrench l 1 N
Bolt length 19 795-790-4510 Gauge l 1 N
20 791-630-3200 Remover n 1
Track system F 21 790-101-1300 Jack (100 tons) n 1 Removal of tracks
22 790-101-1102 Pump n 1
1 791T-430-3220 Push tool n 1 m
2 790-201-1841 Push tool n 1
3 791-601-1000 Oil pump n 1 Overhaul of track rollers
Track roller
G 4 791-651-1510 Installer n 1
5 790-601-1000 Oil pump n 1
6 791-430-3230 Installer n 1
Carrier roller 7 791T-B30-1110 Sleeve n 1 N m Press in carrier roller
50-10 h
New/remodel
Necessity
Symbol
Sketch
Q’ty
1 791-830-1320 Rod n 1
2 01580-01613 Nut n 1
3 01643-31645 Washer n 1
4 790-101-2540 Washer n 1 Extraction of planet pinion
1
5 790-101-2102 Puller assembly n 1 shaft
6 790-201-2830 Spacer n 1
7 791-850-1410 Adapter n 1
Final drive J
8 790-101-1102 Hydraulic pump n 1
Removal and installation of
2 791-427-1410 Wrench n 1
round nut
3 791-580-1510 Installer n 1 Installation of floating seal
4 791T-B27-1130 Push tool n 1 N Press fitting of outer bearing
5 791T-B27-1120 Push tool n 1 N Press fitting of inner bearing
6 79A-264-0091 Scale n 1 Preload of adjusting bearing
8 791T-430-3210 Push tool n 1
Idler assembly Removal and installation
9 796-670-1020 Installer n 1
10 791-685-8006 Compressor (B) n 1
11 790-201-2860 Spacer n 1
I 12 791-635-3160 Extension n 1
Recoil spring 13 790-101-1600 Cylinder (70 ton) n 1 Removal and installation
14 790-201-1610 Plate n 1
15 790-201-1702 Push tool kit n 1
16 790-201-1791 Push tool kit n 1
50-11 h
1 791-646-7351 Push tool n 1 Removal of small plug

2 791-660-7460 Pin brush n 1 Cleaning of pin hole
791-432-1110 Push tool n 1
Installation pin plug of track
3 791-646-7550 Bar n 1
link (for large plug)
791-646-7560 Guide n 1
791-701-3000 Seal
4 or n 2 Supply oil
791-601-1000 Oil pump
791-932-1110 Push tool n 1
Installation pin plug of track
5 791-646-7523 Bar n 1
link (for small plug)
791-646-7590 Guide n 1
6 791T-B32-1020 Installer n 1 Installation of seal assembly
1 790-101-1102 Pump assembly n 1
2 790-101-1300 Cylinder (980 kN {100 t}) n 1
3 790-105-2300 Puller (294 kN {30 t}) n 1
4 790-532-2210 Plate n 1
5 791-532-2220 Plate n 1
6 791-532-2230 Block n 1
7 791-532-2240 Stud bolt n 2
8 791-532-2390 Rod n 2
Track shoe Disassembly, assembly of
R 9 791-532-2260 Plate n 1
assembly link
7
10 791-532-2270 Boss n 2
11 791-532-2280 Boss n 2
12 791-532-2320 Plate n 1
13 01582-12722 Nut n 4
14 791-532-2380 Washer n 2
15 01252-61645 Bolt n 2
16 02205-12437 Nut n 4
17 791-532-2370 Plate n 1
18 791-532-2360 Push tool n 2 Press fitting of wedge ring
793T-B32-1100 Push tool assembly n 1 m
793T-B32-1110 • Adapter n 1 m Installation and press fitting
8 793T-B32-1010 • Holder n 1 m of wedge ring (For small
793T-B32-1030 • Bar n 1 m plug side)
01580-11210 • Nut n 1
793T-B32-1000 Push tool assembly n 1 m
793T-B32-1020 • Adapter n 1 m Installation and press fitting
9 793T-B32-1010 • Holder n 1 m of wedge ring (For large
793T-B32-1030 • Bar n 1 m plug side)
01580-11210 • Nut n 1
50-12 h
790-101-1102 Pump n 1
10 Cylinder
790-101-1300 n 1
(980 kN {100 ton}
790-101-1102 Pump n 1
11 Jack
790-105-2300 n 1
(294 kN {30 tons})
791-635-3110 Frame n 1
791-635-3160 Extension n 1
791-635-3170 Nut n 4
12 791-635-3180 Screw n 2
791-635-3190 Screw n 1
791-645-3510 Adapter n 1
791-646-3260 Pusher n 1
13 791T-B32-1210 Pusher n 1
14 791-432-1110 Push tool n 1
15 791T-B32-1220 Guide n 1
791-635-3110 Frame n 1
791-635-3160 Extension n 1
791-635-3170 Nut n 4
791-635-3180 Screw n 2
Field disassem- 16
bly and assembly R 791-635-3190 Screw n 1
of one link 791-645-3510 Adapter n 1
791-645-3520 Adapter n 1
791-645-3530 Pusher n 1
791-635-3110 Frame n 1
791-635-3160 Extension n 1
791-635-3170 Nut n 4
791-635-3180 Screw n 2
17
791-635-3190 Screw n 1
791-645-3520 Adapter n 1
791T-630-3570 Guide n 1
791-630-3560 Pusher n 1
790-101-1102 Pump n 1
18
790-105-2300 Jack n 1
19 791T-B32-1230 Guide n 1
791-635-3110 Frame n 1
791-635-3160 Extension n 1
791-635-3170 Nut n 4
20
791-635-3180 Screw n 2
791-635-3190 Screw n 1
791-645-3510 Adapter n 1
50-13 h
Field disassem- 21 791-646-8002 Lubricator n 1

bly and assembly R
of one link 22 791-932-1110 Plug push tool n 1
1 790-502-1003 Repair stand n 1

14
2 790-101-1102 Pump n 1
15 790-330-1100 Wrench n 1
16 790-302-1270 Socket n 1
17 790-302-1280 Socket n 1
18 790-102-1320 Socket n 1
19 790-720-1000 Expander n 1
1 796-720-1650 Rubber band l 1
20 2 796-720-1660 Rubber band n 1
3 07281-01029 Clamp l 1
21 07281-01159 Clamp n 1
22 790-201-1702 Push tool kit n 1
Cylinder assem- 23 790-201-1761 • Push tool kit n 1
U
blies 24 790-201-1771 • Push tool kit n 1
25 790-201-1781 • Push tool kit n 1
1 790-201-1720 Push tool kit n 1
2 790-201-1751 • Push tool n 1
26
3 790-101-5021 • Grip n 1
4 01010-50816 • Bolt n 1
1 790-201-1500 Push tool kit n 1
2 790-201-1570 • Plate n 1
3 790-201-1580 • Plate n 1
27 4 790-201-1590 • Plate n 1
5 790-201-1560 • Push tool n 1
6 790-101-5021 • Grip n 1
7 01010-50816 • Bolt n 1
50-14 h
12
SKETCH OF SPECIAL TOOLS
Komatsu cannot accept any responsibility for special tools manufactured according to these sketches.
A3 Plate
A7 Push tool
50-15 h
A12 Wrench
B1 Plate
50-16 h
B2 Push tool
B3 Push tool
50-17 h
12
B5 Push tool
B6 Push too
50-18 h
B7 Push tool
B8 Plate
50-19 h
B10 Plate
B11 Bolt
50-20 h
B12 Bolt
B13 Block
50-21 h
B14 Driver
C1 Plate
50-22 h
C2-2 Washer
C3 Push tool
50-23 h
D1 Plate
D2-2 Washer
50-24 h
D3 Push tool
D4 Push tool
50-25 h
D5 Push tool
R6 Push tool
R0
.5
R0
.5 .5
R0
.5
R0
59.5 ± 0.1
58.0 ± 0.1
42. 0
71. 0
4.85 ± 0.1
CJZ1304
1.10 ± 0.1
18. 0 791T-B32-1030
50-26 h
R8 Push tool assembly
6Ō $

6Ō $

CJ Z1 3 0 5
6Ō $

PUSH TOOL ASSEMBLY
793T–B32 –1100
R8 Holder
FRAME HARDENING ANDTEMPER
MATERIAL HARDNESS H RC 36 ~ 42
FREE FROM BURRS AT CORNERS

CJ Z 1 3 0 6
SCM435 H
HOLDER
793T–B32 –1010
50-27 h
R8 Bar
CJ Z 1 3 0 7
SS400B
BAR
793T–B32 –1030
R8 Guide
CJ Z 1 3 0 8
SCM43 5H
GUI DE
793T–B32 –1110
50-28 h
R9 Push tool assembly
6Ō $

6Ō $

CJ Z 1 3 0 9
6Ō $

PUSH TOOL ASSEMBLY
793T–B32 –1000
R9 Guide
CJ Z 1 3 1 0
SCM43 5H
GUI DE
793T–B32 –1020
50-29 h
DISASSEMBLY AND ASSEMBLY CONNECTOR REPAIR PROCEDURES
CONNECTOR REPAIR PROCEDURES

These steps outline the proper repair procedures for the HD30 and DT type wire connectors. Failure to follow these procedures
may result in a failed contact situation in the electrical circuit or damage to the connector or wiring harness.
CONTACT TERMINAL REMOVAL (HD30 TYPE)
1. Obtain the correct removal tool according to the wire size used in
the connector.
2. With the rear insert part of the connector facing you, snap the
removal tool over the wire of the contact terminal you will be
removing.
Remark
Using a removal tool that is too large or too small will hinder wire
removal and may damage the connector or removal tool. Always
use the correct removal tool size for the wire gauge you are
servicing.
3. In a straight line, carefully slid the removal tool along the wire and
into the grommet until a contact resistance is felt.
Remark
Do not pull on the wire or twist the tool when inserting removal tool
into the grommet. Damage to the tool or connector may result.
4. Once tool is fully inserted into the connector, carefully pull the
removal tool and contact terminal-wire out of the connector.
5. If contact terminal-wire will not come out, remove tool and reinsert
removal tool again.
50-30 h
12
STRIPPING INSULATION
After obtaining the proper terminal size for the wire gauge you will be using in the connector repair, remove all damaged or
corroded sections of the wire being repaired referring to the Deutsch Table below.
Deutsch Table
Deutsch Terminal Part Number Wire Gauge Range Strip Length: mm (in)
0460 - 202 - 20141 20 AWG 3.96 - 5.53 (.156 - .218)

0462 - 201 - 20141 20 AWG 3.96 - 5.53 (.156 - .218)
0460 - 202 - 16141 16, 18 and 20 AWG 6.35 - 7.92 (.250 - .312)
0462 - 201 - 16141 16, 18 and 20 AWG 6.35 - 7.92 (.250 - .312)
0460 - 215 - 16141 14 AWG 6.35 - 7.92 (.250 - .312)

0462 - 209 - 16141 14 AWG 6.35 - 7.92 (.250 - .312)
0460 - 204 - 12141 12 and 14 AWG 5.64 - 7.21 (.222 - .284)

0462 - 203 - 12141 12 and 14 AWG 5.64 - 7.21 (.222 - .284)
0460 - 204 - 08141 8 and 10 AWG 10.92 - 12.47 (.430 - .492)

0462 - 203 - 08141 8 and 10 AWG 10.92 - 12.47 (.430 - .492)
0460 - 204 - 0490 6 AWG 10.92 - 12.47 (.430 - .492)

0462 - 203 - 04141 6 AWG 10.92 - 12.47 (.430 - .492)
Using wire insulation stripers, remove only the measured amount of

insulation from the wire according to the size contact terminal listed in
the “Strip Length” above.
Wire Inspection
After stripping insulation from wire, inspect wire strands for:

• Corrosion, straightness and uniformity
• Broken or nicked wire strands are unexcitable and may cause
high resistance in the circuit.
• Do not twist or wrap the wire strands as this may cause wire
strand breakage during the crimping process.
50-31 h
12
CRIMPING CONTACT TERMINAL (HD30 TYPE)
1. After insulation has been stripped from the wire and contact
terminal is ready for crimping, raise selector knob on
Crimp Tool #HDT48-00 and rotate until arrow is aligned with
wire size to be crimped.
2. Loosen locknut, turn adjusting screw in until it stops.
3. Insert contact terminal with barrel up. Turn adjusting screw

counterclockwise until contact terminal surface is flush with
indenter cover. Tighten locknut.
4. Insert wire into contact terminal. Be sure contact terminal is

centered between indicators.
5. Close crimp tool handle until crimp cycle is completed.
6. Release the tool handle and remove the crimped contact terminal.
7. Using the inspection hole in the contact terminal inspect the

crimped contact terminal to ensure that all strands are in the
crimped barrel.
Remark
The tool must be readjusted for each type/size of contact. Use
Crimp tool HDT04-08 for size 8 and 4 contacts.
50-32 h
12
INSERTION OF CONTACT TERMINAL (HD30 TYPE)
1. Grasp contact terminal approximately 25.2mm (1in) behind the
crimped barrel.
2. Holding connector with rear grommet facing you.
3. Insert completed contact terminal straight into connector grommet

until a positive stop is felt.
4. Once contact terminal is in connector, a slight tug will confirm that

the contact terminal is properly locked in place.
5. For unused wire cavities, insert sealing plugs for full environmental
sealing.
50-33 h
12
CONTACT TERMINAL REMOVAL (DT TYPE)
1. Remove the wedge lock using needle nose pliers or a hooked
shaped wire.
2. Pull the wedge lock straight out and save for reinstallation.
3. To remove the contact terminal gently pull the wire backwards

while at the same time releasing the locking finger by pushing it
away from the terminal with a small screwdriver.
4. Hold the rear seal grommet in place and pull the contact terminal
out of the connector.
50-34 h
12
STRIPPING INSULATION
After obtaining the proper terminal size for the wire gauge you will be using in the connector repair, remove all damaged or
corroded sections of the wire being repaired referring to the Deutsch Table below.
Deutsch Table
Deutsch Terminal Part Number Wire Gauge Range Strip Length: mm (in)
0460 - 202 - 20141 20 AWG 3.96 - 5.53 (.156 - .218)

0462 - 201 - 20141 20 AWG 3.96 - 5.53 (.156 - .218)
0460 - 202 - 16141 16, 18 and 20 AWG 6.35 - 7.92 (.250 - .312)
0462 - 201 - 16141 16, 18 and 20 AWG 6.35 - 7.92 (.250 - .312)
0460 - 215 - 16141 14 AWG 6.35 - 7.92 (.250 - .312)

0462 - 209 - 16141 14 AWG 6.35 - 7.92 (.250 - .312)
0460 - 204 - 12141 12 and 14 AWG 5.64 - 7.21 (.222 - .284)

0462 - 203 - 12141 12 and 14 AWG 5.64 - 7.21 (.222 - .284)
0460 - 204 - 08141 8 and 10 AWG 10.92 - 12.47 (.430 - .492)

0462 - 203 - 08141 8 and 10 AWG 10.92 - 12.47 (.430 - .492)
0460 - 204 - 0490 6 AWG 10.92 - 12.47 (.430 - .492)

0462 - 203 - 04141 6 AWG 10.92 - 12.47 (.430 - .492)
Using wire insulation stripers, remove only the measured amount of

insulation from the wire according to the size contact terminal listed in
the “Strip Length” above.
Wire Inspection
After stripping insulation from wire, inspect wire strands for:

• Corrosion, straightness and uniformity
• Broken or nicked wire strands are unexcitable and may cause
high resistance in the circuit.
• Do not twist or wrap the wire strands as this may cause wire
strand breakage during the crimping process.
50-35 h
12
CRIMPING CONTACT TERMINAL (DT TYPE)
1. After insulation has been stripped from the wire and contact
terminal is ready for crimping, raise selector knob on
Crimp Tool #HDT48-00 and rotate until arrow is aligned with
wire size to be crimped.
2. Loosen locknut, turn adjusting screw in until it stops.
3. Insert contact terminal with barrel up. Turn adjusting screw

counterclockwise until contact terminal surface is flush with
indenter cover. Tighten locknut.
4. Insert wire into contact terminal. Be sure contact terminal is

centered between indicators.
5. Close crimp tool handle until crimp cycle is completed.
6. Release the tool handle and remove the crimped contact terminal.
7. Using the inspection hole in the contact terminal inspect the

crimped contact terminal to ensure that all strands are in the
crimped barrel.
Remark
The tool must be readjusted for each type/size of contact. Use
Crimp tool HDT04-08 for size 8 and 4 contacts.
50-36 h
12
INSERTION OF CONTACT TERMINAL (DT TYPE)
1. Grasp the crimped contact terminal approximately 25.2mm (1in)
behind the crimped barrel.
2. Hold the connector with the rear grommet facing you and insert the
completed wire into the connector.
3. Push the contact terminal straight into the connector until a “click”
is felt. A slight tug will confirm that the contact terminal is properly
locked in place.
4. Once all contact terminals are in place, insert the wedge lock with
the arrow pointing toward exterior locking mechanism. The
wedge lock will snap into place. Rectangular wedges are not
oriented and may fit either way.
Remark
As the connector receptacle is shown - use the same procedures for
a plug.
50-37 h
12
MEMORANDUM
50-38 h
DISASSEMBLY AND ASSEMBLY NOSE GUARD (HOOD)
12
NOSE GUARD (HOOD)
REMOVAL
OPENING FRONT GRILL
1. Remove four bolts (1) and open the grill using a 24mm wrench.
H Read warning decal (2) first before proceeding with any further
disassembly procedures.
WARNING! BEFORE REMOVING ENGINE HOOD

• Relocate water separator to hang on engine
belt guard. Keep hoses attached.
• Remove horn and bracket.
• Detach harness ground terminal from main
frame.
2. Unplug connector (3) from water separator sensor.
3. Dismount fuel filter assembly, pull drain hose through hose clamp.
Then remove “P” clips for supply and return lines using a 14 mm
wrench.
4. Hang fuel filter assembly on front engine bracket.
Remark
This procedure is to allow the technician the option of
running the engine for testing and adjusting with the
hood removed. It is not recommended to operate the
machine with the hood removed.
50-39 h
5. Unplug connector (4) and remove “P” clip (5) then remove ground
cable (6).
6. Unplug horn connector (7).
REMOVING SIDE PANELS
1. Remove the right side hood panels (8) using a 19 mm wrench, and
open the left side panel.
DISCONNECTING HOOD-RELATED
COMPONENTS
1. Remove air cleaner intake hose on compressor hose clamp (9)

using a 10 mm socket.
50-40 h
2. Remove exhaust outlet pipe on clamp (10) from turbocharger using
an 11 mm socket.
H Cap turbocharger openings to prevent dirt and debris from

entering.
REMOVAL OF HOOD
1. Remove one bolt at the top of the hood in front of the windshield
using a 24 mm socket and replace it with a 16 mm lifting eye (11).
50-41 h
2. Sling the hood assembly, as shown in the illustration, to prepare for
the lifting procedure.
Remark
Use a three point hitch set up [a], [b], [c] to lift the hood
straight up and evenly.
3. Remove the four bolts that mount the hood to the front of the frame,
two bolts on the right side (12) and two bolts on the left side (13)
using a 24 mm wrench.
4. Remove the two right and two left side lower bolts (14) (four bolts
total) using a 24 mm wrench.
50-42 h
5. Lift hood about 76 to 10 mm (3 to 4 inches) to be sure all electrical
wires and hoses are disconnected or out of the way.
6. Pull the hood forward about 76 to 100 mm (3 to 4 inches) being

extremely careful not to damage the cab and air conditioning lines.
7. Slowly lift the hood straight up and off the machine.
Hood with Air Cleaner and Exhaust Stack:

259 kg (570 lbs)
INSTALLATION
WARNING! When installing hood assembly, be careful not to damage the air conditioning
lines.
1. Installation is carried out in the reverse order of removal.

H When installing hood, be careful not to damage fuel, air conditioning lines and wiring.
Grill mounting bolts: 245 - 309 N•m (181 - 228 lbf/ft)
H After hood is installed:
A. Align and install hood mounting bolts (11), (12), (13), (14).
Hood bolts: 245 - 309 N•m (181 - 228 lbf/ft)
B. Attach exhaust pipe (10) to turbocharger.
Exhaust clamp: 8 N•m (6 lbf/ft)
C. Attach air intake elbow (9) to turbocharger compressor.
Intake clamp: 10.5 ± 0.5 N•m (7.7 ± 0.4 lbf/ft)
D. Reattach fuel filter assembly to hood.
E. Reattach all wiring.
50-43 h
12
MEMORANDUM
50-44 h
DISASSEMBLY AND ASSEMBLY MUFFLER AND EXHAUST STACK
12
MUFFLER AND EXHAUST STACK
H Removal of the muffler must be done with the hood off the machine. See“NOSE GUARD (HOOD)” on page 50-39.
H Before removing the muffler be sure the exhaust system has cooled down thoroughly.
REMOVAL
1. At the back of the hood, remove cover (2) by removing four
mounting bolts (1) using a 13 mm wrench to access muffler.
2. Remove the four mounting bolts (3) using a 19 mm wrench and

remove exhaust stack as one unit.
3. Loosen clamp (4) using an 11 mm wrench and remove exhaust flex

pipe (5) from hood.
50-45 h
DISASSEMBLY AND ASSEMBLY MUFFLER AND EXHAUST STACK
4. After removing flex pipe (5), remove the four muffler mounting
bolts (6) using a 19 mm wrench.
5. Remove bolts (7) and pull out muffler drain line.
6. Remove muffler (8) from the mounting plate.
INSTALLATION
H Installation of the muffler (8) and exhaust stack is done in the reverse order.
H Check the condition of the hood insulation after removing the muffler, if the insulation is deteriorated, worn or
damaged, replace the insulation.
50-46 h
DISASSEMBLY AND ASSEMBLY CAB
CAB
REMOVAL
H Removal and installation of the cab assembly is a two-person
operation. Due to the size and complexity of the D51 cab, Komatsu
recommends two people remove or install the cab assembly.
H Remove engine hood, see “NOSE GUARD (HOOD)” on page 50-
39.
H Before preceding with any dissemble or removal procedures, open
the left rear access battery compartment door of the machine and
disconnect the negative [-] battery terminals (1).
H While in the battery compartment:
A. Remove the battery cable lower “P” clip (2) from bracket to
allow the battery cable to remain with the cab assembly using a
17 mm wrench.
B. Unplug the window washer hoses (3) and pull them through
the “P” clip mounting.
Remark
When removing the hoses be sure to match mark each
hose for the proper reassembly process.
C. Remove “P” clip (5) and unplug the washer motor electrical
connector (4).
50-47 h
1. On the right rear side of the engine, disconnect the main cable (6)
from battery to starter at the starter motor using a 17 mm socket.
2. Using a 4 mm allen wrench, remove the three allen head screws (7)
that mount the threshold plates to the floor mat
H Both sides.
3. Remove the right and left footrests (8) (two mounting bolts each)
using a 17mm wrench.
4. Remove the floor mat (9) and set aside.
50-48 h
5. Remove twelve bolts and remove the floor access plate (10) from
the machine using a 19 mm wrench.
Remark
An impact wrench should be used to remove fasteners
only, never use an impact wrench to start or tighten bolts.
All bolts should be torqued.
6. At this time, remove the bolts that mount the front belly pan using a
19 mm wrench and remove the front belly pan (11) from under
machine.
7. Open the drain valve (12) and drain the engine coolant at the front
of the engine.
WARNING! Slowly loosen the radiator cap to

release the pressure inside the
cooling system.
A. Set a suitable size container under the engine coolant drain to

catch the coolant that is drained from the cooling system.
B. Place the drain hose into the container and open the drain valve
two to three turns to drain the engine coolant.
C. Open the vent valve (a) on top of the engine outlet coolant
piping.
Remark
It is a violation of EPA laws to drain coolant on the ground,
in rivers or lakes or in a city sewer system.
Coolant must be captured and recycled according to EPA
laws. Failure to do so may result in fines or
punishment.
Engine coolant: Approximately 37 liters (10 US gal.)
50-49 h
12
FLOOR ACCESS PLATE
H With the floor access plate removed, the listed components can now
be disconnected from the underside of the cab floor so that the cab
can be safely separated from the machine.
Remark
The Right and Left side of the under cab floor access is
indicated as shown in the illustration.
A. Disconnect the two heater hoses from the heater core under the
center of the floor. Outlet (13) and inlet (14).
B. Recover air conditioning refrigerant from system, then

disconnect HI (15) and LO (16) pressure air conditioning lines
under cab floor on the left side.
H Cap and seal all open refrigerant lines to prevent moisture
damage to the air conditioning system.
C. Remove the two P-clips (17) using a 14mm socket from the
bracket that supports the EPC wiring harness on right side of
the floor frame.
50-50 h
D. Unplug three connectors (18) that supply electric to the cab and
remove one “P” clip (19) using a 14mm socket that
supports the wiring harness on the left side of the floor frame.
E. Remove the electrical connector support (20) - under cab floor.
F. Unplug the MC (21) and FG (22) cab wiring harness from

under cab floor.
G. Remove the cab-to-frame ground wire (23) also on the left side
of the floor frame, (one bolt) using a 17mm wrench.
50-51 h
1. Open the right rear access door on the machine and remove the “P”
clip (25) holding the wiring harness in place. Disconnect
both black and gray connectors (24).
2. Disconnect the orange coded hose (26) on the right side of the floor
opening to the EPC solenoid valve block using a 22 mm wrench.
H Cap all hose and fitting to prevent dirt and debris from entering
the system.
3. Remove the DB12 valve assembly. See “DB 12 VALVE” on page

50-324.
50-52 h
12
LIFTING CAB OFF MACHINE
H Using a 24 mm socket wrench, replace the two front bolts with two
16 mm lifting eyes on the roof of the cab. Then attach hoisting
chains to the two lifting eyes in front and two lifting brackets at the
rear of the cab as shown in the illustration.
1. Sling the cab as shown in the illustration to prepare to lift the cab
completely off the machine.
Cab Assembly: 949 kg (2,092 lbs)
A. At the front left and right side of the cab below the step,
remove the lower trim panels (28) on both sides of the cab
B. Remove six bolts (29) outside at each step (three bolts

per step) using a 24 mm wrench.
C. Remove two front bolts (30) under floor panel using a 24 mm

wrench.
50-53 h
D. Remove two rear bolts (31) under floor panel using a 36 mm
wrench.
E. In the cab, remove the right side rear cover plate (lunch box or
document holder) using a 4 mm allen head screw.
F. In the cab, remove the left side rear cover plate (lunch box or
document holder) using a 4 mm allen head screw.
Remark
By removing these plates, you will expose the rear cab
mounting bolts.
G. With the cover plates removed, remove two large bolts (33) -
back corners of cab (1 each side). using a 36 mm wrench.
H. Leave two bolts [a] at back corners of cab (one each side).
These bolts are for the mounting plate that the cab rides on and
keeps the plate stationary. Do not remove two bolts [a].
I. Remove eight mounting bolts (32) using a 24 mm wrench

(both left and right side, four bolts per side).
50-54 h
2. Using two people, carefully lift the cab off the machine completely.
Slowly lift the cab about 100 - 152 mm (4 - 6 inches), making sure
all hoses and electrical wires are disconnected.
3. After the cab is completely off the machine, rest it on two heavy
duty stands [1] at the rear, and two 4 x 4 wooden blocks [2] under
the steps in front to protect the AC lines, hydraulic hoses, and elec-
trical wiring from damage.
50-55 h
INSTALLATION
1. Attach hoisting chains to the two lifting eyes in front and two lifting brackets at the rear of the cab and prepare the cab for
reinstallation on the machine.
Cab Assembly: 949 kg (2,092 lbs)
A. Swing the cab mount brackets into place as shown in the

illustration.
B. Hang the cab over the machine in the mounting position about
100 - 152 mm (4 - 6 inches) above the cab mounts.
C. Position the two front ROPS mounting lugs with the tabs
facing toward the rear of the machine so when the cab is
lowered the tabs will fit between the cab lugs on the bottom of
the cab as shown in the illustration.
D. Use a 19 mm wrench to remove the right side cab work light

(34) and let it hang.
E. Unbolt the right side cab pillar trim (35) using a 13 mm

wrench.
50-56 h
F. Remove the hand rail bracket (36) from the fuel tank to allow
removal of the right side and bottom trim cover.
G. Remove the bottom trim cover (37) using a 13 mm wrench to

allow access to the rear ROPS mounting brackets.
Remark
It is important these trim pieces be removed to allow
access to the rear ROPS mountings (38) for proper
installation of the cab.
H. Once the trim pieces are removed place a 4 x 4 safety block [1]
under the rear outer rail of the cab as shown in the illustration
to allow access to the rear ROPS mounting pins.
WARNING! Do not place your hands or arms under

the cab unless a safety block [1] is in
place before preceding to the next
step. Failure to do so may lead to seri-
ous injury.
50-57 h
I. While one person is lifting up on the rear ROPS mountings
(38) holding it in place between the cab lock lugs, the person in
the cab installs the mounting bolt.
Remark
Be sure the bolt is installed completely pulling the
mounting bracket (38) into the locked position under the
cab between the cab lock lugs.
2. Once the rear ROPS mountings are in place, remove the 4 x 4 wood
block to allow the installation of the cab.
3. Reinstall the trim pieces, work light and hand rail.
4. To install the front ROPS mounting tabs (a), lift them up using a pry
bar (c) to hold between the lock lugs.
5. Install the bolts completely. Be sure the ROPS mounting is pulled

up into the lock lugs (b) under the cab before lowering the cab.
WARNING! Do not place your hands under the cab

when installing the front ROPS tab
mountings. Doing so may lead to
serious injury.
6. Once all four of the ROPS mounting tabs are in place, carefully
lower the cab completely until it fully rests on the machine chassis.
7. Install the front (29), (30), (31) and rear (32), (33) mounting bolts.
8. Install two lunch box trays using a 4mm allen head screw.
9. On the right side of the machine in the hydraulic tank compartment, install the DB12 valve assembly (12).
H See “DB 12 VALVE” on page 50-324.
10. Connect hose with orange band (26) to EPC Solenoid Valve Block.
11. Connect the main starter cable (6) with two P-clamps.
12. Attach and clamp heater hoses (13) and (14).
13. Connect the HI (15) and LO (16) air conditioning lines.
14. Under the floor on the right side of the cab, attach the bracket using a 17mm wrench for the right heater line.
Plug electrical connector (21) and (22) to bracket for the right heater line (20).
15. Attach P-clips for electrical, plug connectors (17), and attach.
16. Attach ground cable (23) to ground cab to main frame.
Ground strap: 11.8 - 19.6 N•m (9 - 15 lbf/ft)
17. In the battery box, connect washer lines (3) to the window washer tanks, and connect the electrical connectors (4) to the
window washer pumps.
H Connect one “P” clip (5) for the electrical washer pump wires.
50-58 h
18. Connect the battery cables.
A. Attach one “P” clip to back of battery tray for the positive (+) cable (2).
B. Do not connect the negative (-) cable (1) until after hood installation.
19. Check and be sure all hydraulic lines and electrical connections are connected.
20. Install the floor access plate (10) with twelve mounting bolts using a 19 mm wrench.
21. Install the floor mat (9), install two footrests with two mounting bolts each using a 17 mm wrench.
22. Install the left threshold plate (7) with four allen head screws using a 4 mm wrench, then install the left side cover under
the cab step with two mounting bolts using a 19 mm wrench.
23. Install the right threshold plate (7) with four allen head screws using a 4 mm wrench, then install the right side cover
under the cab step with two mounting bolts using a 19mm wrench.
24. Install the hood, see “INSTALLATION” on page 50-43. Then connect the negative (-) battery cable.
50-59 h
12
MEMORANDUM
50-60 h
DISASSEMBLY AND ASSEMBLY MONITOR PANEL AND HST CONTROLLER
12
MONITOR PANEL AND HST CONTROLLER
H Before removing the monitor panel or HST controller be sure to disconnect the battery.
REMOVAL
H Before removing the monitor panel, take note of the switch
locations before removing the bezel cover.
Left side of dash Right side of dash

1. Lamp switch 5. Reverse travel set switch
2. Fan rotation switch 6. Shift mode switch
3. Buzzer cancel switch 7. Heater switch (foot heater)
4. Information switch 8. Ignition switch
1. To remove the monitor panel or to access the HST controller,

remove the four bezel cover mounting screws (1) using a 5 mm
allen wrench.
H Two allen screws on each side.
2. Carefully remove the bezel cover so the switches can be removed.
50-61 h
3. Remove and unplug each switch taking note of it’s proper location
in the bezel cover.
H Tag each connector using the chart listed above after removing
the rocker switch.
H To remove switch from bezel cover, push tab on side of switch.
Remark
Be careful not to damage plastic tabs when removing
switches.
4. Once switches are removed, stack them in order of reinstallation on

top of dash as shown in the illustration.
5. Remove the two top mounting bolts (2) using a 13 mm wrench.
6. Remove the four bottom mounting bolts (3) using a 13 mm wrench.

H Two bolts per side.
50-62 h
7. Once bolts (2) and (3) are removed, roll the monitor assembly back
and unplug black and grey connectors (4).
8. To remove HST controller, remove the four mounting bolts (5) and
disconnect HST controller.
H To disconnect HST controller remove the 4 mm allen head
screw in the connector, doing so will unplug the connector
from the HST controller
Remark
Do not pry the connector from the controller, doing so will
damage the connector or controller.
INSTALLATION
H Installation of the monitor and HST controller are done in the reverse order.
Remark
Be careful not to damage plastic tabs when installing switches.
50-63 h
DISASSEMBLY AND ASSEMBLY KOMTRAX CONTROLLER
12
KOMTRAX CONTROLLER
H Before removing the KOMTRAX controller be sure to disconnect the battery.
H Before removing the controller, the seat must be removed. See “SEAT” on page 50-65.
REMOVAL
1. After removing the seat, remove the right side access panel by
removing the four allen head bolts (1) using a 5 mm allen head
wrench.
2. Once the panel is removed, you can access the KOMTRAX

controller.
H To remove controller remove the four mounting bolts (2) using
a 13 mm wrench.
INSTALLATION
H Installation of the KOMTRAX controller is done in the reverse order.
H Reinstall the seat.
50-64 h
DISASSEMBLY AND ASSEMBLY SEAT
12
SEAT
H This job requires two people to perform this operation.
REMOVAL
1. To remove the seat, push the seat to the rearward position and
remove the two front mounting bolts (1) using a 16 mm wrench.
2. Push the seat to the forward position and fold the seat back forward
and remove the two rear mounting bolts (2) using a 16 mm wrench.
3. Remove the seat belt straps, two bolts (3) using a 19 mm wrench
and remove the seat belts.
4. Using two people, lift up on the seat bottom and pull it out of the
cab, backrest first, as shown in the illustration.
H Be careful not to damage any interior components when lifting
the seat out of the cab.
Seat: 44 kg (96 lbs)
INSTALLATION
H Installation of the seat is done in the reverse order.
H Reinstall the seat using two people. Roll the seat back into the cab, seat bottom first.
H Be careful not to damage any interior components when lifting the seat back in place.
50-65 h
DISASSEMBLY AND ASSEMBLY AIR CONDITIONER/HEATER
12
AIR CONDITIONER/HEATER
DISASSEMBLY OF AIR CONDITIONER

H Before removing any air conditioner components that are directly
related to the refrigerant system, it is advised to recover all the
refrigerant first using refrigerant line ports (1) on the left front side
of the machine.
WARNING! When working with refrigerants, be

sure to keep open flames away from
refrigerants. Deadly gas is produced
when an open flame comes in contact
with a refrigerant.
1. To access the air conditioning system, remove the top cover (2)
2. Carefully slip the grommet for the KOMTRAX antenna off the
cover.
3. Remove the rear cover (2) using a 13 mm wrench while leaving

cover (3) in place on both sides.
4. If the evaporator is to be removed disconnect lines (4) using a 19

and 22 mm wrench.
H Cap all hose and fittings to prevent dirt and debris from
entering the system.
50-66 h
5. Disconnect the fan wiring harness connector plug (5)
REMOVING CONDENSER
1. To remove the condenser, remove top frame (7) and prepare to

remove the right side support bracket (8).
H If the condenser fan is to be replaced, remove the four bolts (a)

and unplug fan connector (b).
2. Remove the left side mounting bolts (9) using a 13 mm wrench.

H Both sides
H Do not remove the left side support bracket.
50-67 h
3. Remove the three bottom bolts using a 13 mm wrench.
4. Remove the five top and side support bracket mounting bolts (11)
5. Remove the two retainer bolts (6) and remove the retainer.
6. Remove the bottom bracket support bolts (13) using a 17 mm

wrench.
H Right side support bracket only
50-68 h
7. Once free, lift bracket (8) out of the support frame.
8. Carefully lift out condenser and fan assembly.
BLOWER MOTORS AND EVAPORATOR

H After condenser and cooling fans are removed, the evaporator can
now be accessed.
1. To access blower motors, remove cover (12).
2. To remove evaporator or heater core, remove blower motors (b).
50-69 h
3. On the left side of the evaporator/heater core is the receiver dryer
(a).
4. To remove the heater core or evaporator, the evaporator lines (1)

and (2) must be removed. Lines (3) and (4) are the heater core
supply, and line (5) (both sides) is the run off line for condensation
from the evaporator.
ASSEMBLY OF AIR CONDITIONER

H Assembly of the air conditioning unit is done in the reverse order.
H When reinstalling the cover for the evaporator and heater core, it is
advised to use a sealant around the enclosure.
Apply LG-6 liquid gasket to mating surface.
50-70 h
DISASSEMBLY AND ASSEMBLY FOOT HEATER
12
FOOT HEATER
H The foot heater is located under the operator’s seat. Before removal of the foot heater, the seat must be removed and the
cooling system must be drained. See “SEAT” on page 50-65 and “DRAINING THE COOLING SYSTEM” on page 50-
77.
REMOVAL
1. After the seat is removed, remove heater housing cover (1) using a
19 mm wrench.
Heater cover: 14.5 kg (32 lbs)
2. Remove the floor mat and remove cover (2) to access the heater
connections under the cab floor.
Remark
3. Remove “P” clip (3) and disconnect connectors (5) and (6).
4. Drain the cooling system. See “DRAINING THE COOLING SYS-

TEM” on page 50-77 and disconnect the two heater supply hoses
(4).
50-71 h
DISASSEMBLY AND ASSEMBLY FOOT HEATER
5. Once the heater is disconnected, remove the four mounting bolts (7)
6. Lift the heater up to be sure nothing is attached to the underside of

the housing.
7. Carefully remove the heater assembly out of the cab.
Heater assembly: 21.7 kg (48 lbs)
INSTALLATION
H Installation of the foot heater is done in the reverse order.
H Be careful not to damage any interior components when installing the foot heater back in place.
50-72 h
DISASSEMBLY AND ASSEMBLY FOOT HEATER OVERHAUL PROCEDURES
12
FOOT HEATER OVERHAUL PROCEDURES
H The blower motor and heater core is one assembly and cannot be separated.
OVERHAUL PROCEDURES
1. With heater assembly on a work bench, disconnect hose (1) from
heater mounting pad and disconnect “P” clip (3) as well as
electrical connector (2).
2. Remove hose (4) from bottom of heater floor housing.
3. Unbolt and lift heater (5) out of floor frame housing (6).
50-73 h
4. Remove the two heater mounting bolts (7) from heater mounting
pad.
5. Disconnect hose (8) from heater mounting pad.
6. Lift heater motor and core assembly (5) off of heater mounting pad.
50-74 h
12
ASSEMBLY PROCEDURES
1. Remount new heater (5) to heater mounting pad.
2. Install bolts (7).
3. Reconnect “P” clip (3).
4. Reconnect heater hoses (1) and (8).
5. Reinstall heater assembly (5) into the floor frame housing (6).
6. Reinstall heater into the floor of the machine.

H Be sure heater outlet is facing the front of the cab.
H Reconnect electrical lines and hoses.
H Install floor plate and floor mat.
H Install heater housing cover (1).

H Install the seat. See “SEAT” on page 50-65.
50-75 h
12
MEMORANDUM
50-76 h
DISASSEMBLY AND ASSEMBLY ENGINE AND HST PUMP
ENGINE AND HST PUMP
REMOVAL
WARNING! Always plug and cap all disconnected hydraulic, coolant, and fuel lines to prevent
leakage and/or dirt and debris from entering the system.
H Before preceding with removal or installation of the engine or HST pump, the hood and cab must be removed from the
machine. See “NOSE GUARD (HOOD)” on page 50-39 and “CAB” on page 50-47 for removal procedures.
BELLY PANS
1. Remove six bolts that mount the rear belly pan (1) using a 24 mm
wrench.
2. Remove four bolts that mount the middle belly pan (2) using a 24
mm wrench.
3. Remove four bolts that mount the front belly pan (3) with a 19 mm
wrench.
DRAINING THE COOLING SYSTEM

WARNING! It is in violation of EPA laws to drain engine coolant on the ground, in rivers or
lakes or in a city or sewer systems. All coolant must be captured and recycled
according to EPA laws. Failure to do so may result in fines or punishment.
A. Push down on radiator cap (a) and turn counter-clockwise

until it contacts the stopper, then remove it.
B. Remove the right side engine covers and open front grill to
access cooling system components.
Engine Coolant: 35 liters (9.25 gal)
50-77 h
C. Locate all drain points within the cooling system. Open drain valves (b) and (c). Open vent plug (d) and precede to
recover all coolant in appropriate containers
DRAINING THE HYDRAULIC SYSTEM

WARNING! Slowly loosen the hydraulic tank oil cap to release the pressure inside the
hydraulic tank. It is in violation of EPA laws to drain hydraulic oil on the ground, in
rivers or lakes or in a city or sewer systems. All oils must be captured and
recycled according to EPA laws. Failure to do so may result in fines or
punishment.
1. Set a container under the hydraulic oil drain port to catch the oil
that is drained from the hydraulic tank.
2. Remove grommet (5) from bottom of hydraulic tank.
3. Attach a hose (4) to the tank drain valve outlet that is long enough
to reach container for collecting the hydraulic oil.
Hydraulic Oil: 63 liters (17 gal)
50-78 h
4. Loosen drain valve (6) at the bottom of the hydraulic tank, drain the
oil, then tighten drain valve again.
H When loosening drain valve, be careful not to get oil on
yourself.
DISCONNECTING COMPONENTS
H When disconnecting any components always cover all openings,
cap hydraulic or fuel lines and protect wiring connectors from
damage.
1. Using a 17 mm socket and 6 inch extension, disconnect the four

hydraulic drive lines at the HST pump.
A. Remove the split flanges on the two lines for each pump on the
left side (7).
B. Remove the split flanges on the two lines for each pump on the
right side (8).
H These lines are disconnected at the split flange because it
is easier to reassemble than trying to maneuver the stiff
hoses in tight quarters.
2. Disconnect clamp (9) for the rubber hose on the supply line to
charge pump.
50-79 h
3. Disconnect the HST supply pump main supply line clamp (10) and
remove charge pump “P” clip (11).
A. Using an appropriate container, catch the remainder of the

hydraulic oil that spills from HST pump supply lines.
Remark
Draining the HST pump, lower supply line and drive lines
will take time. It is advised to leave the container under
these components until you are ready to reinstall the
engine and HST pump.
4. Swing both front cab mounting brackets (12) parallel with the
machine frame and remove the top air charge line clamp (13) using
a 13 mm wrench.
5. Remove upper air charge line clamp (14) using a 13 mm wrench

and the two U-bolts (15) using a 19 mm wrench.
H Remove the complete air charge line for clearance to lift
engine and HST pumps out of the machine.
6. Remove lower air charge line clamp (16) using a 13 mm wrench.
50-80 h
7. Disconnect upper coolant line hose clamps (17) and slide hose back
on to the solid coolant pipe using a 8mm wrench.
8. Disconnect lower coolant line hose clamps (18) and pull it off the
lower inlet pipe using a 8 mm wrench to engine block.
9. Remove three mounting bolts (19) using a 17 mm wrench to EPC

mounting bracket. One “P” clamp (20) using a 19 mm wrench.
A. One EPC ground bolt (21) using a 17 mm wrench.
50-81 h
B. Disconnect hose (22) at the accumulator.
H Cap and seal all open lines to prevent damage to the
hydraulic system.
C. Then set EPC valve block aside out of the way for engine and
HST pump removal.
10. Disconnect charge pump supply (23) and return line (24).
hydraulic system.
11. Disconnect DB12 valve lines (25) (two), filter base line (26) from
work pump using a 36 mm wrench.
hydraulic system.
50-82 h
12. Disconnect cooler line (27) using a 36 mm wrench.
hydraulic system.
13. On top of HST pump disconnect DB12 line (29) and pump supply
and return lines (28).
hydraulic system.
14. Disconnect fuel supply line at rear part of the cylinder head (31)
with a 17 mm wrench for banjo bolt and remove “P” clip (30).
15. Disconnect the fuel line from the pre-filter to fuel pump (33) (Banjo
bolt - 17mm wrench), two “P” clips (32) (17mm wrench).
H Plug banjo bolt hole with a standard bolt to prevent fuel
leakage and/or dirt from entering the system.
50-83 h
16. Disconnect the engine ground cable (34) to the frame using a 19mm
wrench.
The Engine And HST Pump Are Ready To Remove
H These components must be disconnected or removed in order to allow clear removal of the engine or HST pump
assembly.
1. Air charge piping 4. EPC valve block 7. HST pump supply lines
2. HST pump supply hose 5. Upper coolant line 8. Lower pump cooler line
3. Charge pump supply hose 6. DB12 and filter lines 9. Fuel return line
50-84 h
12
LIFTING ENGINE AND HST PUMP ASSEMBLY
H Once all lines and components have been removed or disconnected
from the engine and HST pump, sling the engine as shown in the
illustration. (use the lifting brackets equipped with the engine).
1. Once the engine is slung, remove the two front motor mounts (35)
(one on each side).
2. Remove the two rear motor mounts (36) (one on each side).
50-85 h
3. After the front and rear motor mounts are removed, carefully lift the
engine out of the chassis. Be sure all lines, components, or wiring
are removed during the lifting procedure.
50-86 h
INSTALLATION
INSTALL ENGINE AND HST PUMP ASSEMBLY
1. Hook engine and HST pump assembly to hoist, lift and move into place. While lowering the engine into position, feed the
lower suction line for the charge pump onto the hard line.
Engine and HST Pump Assembly: 866 kg (1,910 lbs)
• Feeding the lower suction line onto the hard line is done for ease of assembly, it is much more difficult to do this step
after the engine is set into place.
2. Set lower cushions (1) in place on the frame for the front engine
mounts (left and right side). Then set lower cushions (5) in place on
the frame for the rear engine mounts (left and right side).
3. Lower the engine and set into place on the engine mounts and
install the engine mount bolts (4 and 8) with upper cushions (2 and
6) and washers (3 and 7). Then tighten and torque the bolts (4 and
8).
Front Engine Mounts: 245 - 308 N•m (181 - 227 lbf/ft)

Rear Engine Mounts: 490 - 607 N•m (361 - 448 lbf/ft)
4. Attach fuel, coolant, hydraulic lines and electrical lines.
A. Tighten the hose clamp for the lower suction line (9) for the charge pump that was attached to the hard line.
B. On the left side of the engine attach the fuel lines to the fuel supply pump.
H Banjo bolt for fuel (32) (17 mm wrench).
H Two “P” clamps (33) (17 mm wrench).
C. On the right side of the engine, attach and tighten the hose clamp for the lower coolant hose (18) using an 8 mm
wrench.
D. Attach the engine ground cable (34) using a 19 mm wrench.
E. Attach the fuel return hose (30) at the head in the back of the engine. Also attach P-clamp to bottom of L-bracket on
the frame (31).
H Do Not twist the hose. Use a 22 mm open end wrench and 19 mm open end wrench to prevent twisting the hose.
H Add one “P” clamp using a 17 mm wrench.
F. Attach the upper coolant hose (17) with two hose clamps using an 8 mm wrench.
5. Attaching the HST drive lines (from underneath).
A. Attach the two left (7) travel motor lines to the bottom front ports of the HST pump with four split flanges and eight
bolts and washers.
B. Attach the two right (8) travel motor lines to the bottom front ports of the HST pump with four split flanges and eight
bolts and washers.
50-87 h
C. Torque the sixteen split flange bolts.
Split Flange Bolts: 98. 0 123 N•m (72 - 91 lbf/ft)
6. Attaching charge pump line (10) (from underneath).
A. Tighten the charge pump hose using a 36 mm and 30 mm wrench to prevent the hose from twisting.
7. Attaching HST pump to oil cooler line (from underneath).
A. Attach the hose from the oil cooler (27) to the HST pump.
8. On the right side of the HST pump assembly, mount the solenoid valve block into place using a 17mm wrench.
9. Attach hose (22) to accumulator using a 22mm wrench.
10. Attach the P-clip (20) using a 17mm wrench and hose at front of block to tee for drive motors located on bracket on bot-
tom of frame using 22 mm and 19 mm wrenches.
11. Attach P-clamps (11) using a 17mm wrench for two lines from side of solenoid block to each drive motor. Attach to upper
part of L-bracket (fuel return line is attached to this L-bracket).
12. Attach line from hydraulic tank (29) to top rear of HST pump (w/tee attached).
13. Attach lower line (25) from back of solenoid block to tee at top rear of HST pump.
14. Attach hose from filter (28) to top middle of HST pump. Use a 30 mm and 36 mm wrench to prevent twisting.
15. Attach lower air charge line and tighten hose clamps with a 13mm wrench.
16. Attach upper air charge line (15) and tighten hose clamps (13mm wrench) and U-bolts (19mm wrench).
17. Double check and be sure hydraulic lines to the HST pump, work equipment pump, charge pump are connected. Be sure
all P-clamps and solenoid valve block are installed correctly.
18. Install the cab assembly, see “INSTALLATION” on page 50-56.
50-88 h
12
SEPARATING PUMPS FROM ENGINE
Special Tools
Distinction
Necessary
Sketch
Qty.
Symbol Part number Part name
A 12 791T-B1L-110 Box wrench n 1 m
REMOVAL FROM ENGINE
WARNING! When separating the pumps from the engine, be sure to properly support the
engine to avoid any unstable conditions. Failure to do so may result in damage to
the components or injury to personnel.
H Place the engine in the proper support position as shown in the

illustration. Be sure the engine and pump assembly are stable
and ready for separation.
1. Disconnect the electrical harness (2) and (3) on the right side of
the pump and remove the “P” clips (1).
50-89 h
2. Disconnect the electrical harness (5) and (6) on the left side of the
pump and remove the “P” clips (4).
3. Remove the three “P” clips (7) and remove the work equipment
harness from the pump housing.
4. Sling the pumps as shown in the illustration.

H Be sure to use a choke type loop to avoid any slippage when
separating the pump from the engine.
Pump assembly: 199.6 kg (440 lbs)
5. Using tool A12 remove the six mounting bolts (8) (3 per side) that
hold the pump assembly to the bell housing.
50-90 h
H To separate the pumps from the bell housing, use a bolt and nut
combination as shown in the illustration. Once the nut and bolt are
between the housings, back off (unscrew) the nut and bolt to push
the pump housing away from the bell housing using two wrenches.
6. After the seal between the pump and bell housing is broken,
carefully pull the pump assembly away from the engine bell
housing
7. Place the pump assembly on a stable support for further servicing.

H Clean the pump mounting flange and bell housing surface.
50-91 h
12
INSTALLATION TO ENGINE
Apply LG-6 liquid gasket to mating surface of HST

pump.
2. Line pump assembly up with the dampener, so male teeth on pump gear mate with the female teeth on the dampener. Push
the pump assembly forward until teeth are fully engaged and the mating surfaces meet.
3. Attach six mounting bolts (30mm wrench) and tighten. Then using special tool torque the bolts.
HST Pump Mounting Bolts: 490 - 607 N•m (361 - 448 lbf/ft)
• Use tool A12 for torquing

• On left side bolts use short extension on middle bolt.
• On left side bolts use 10" extension on bottom bolt.
2. Set torque wrench and tool A12 at a 90o angle to achieve the correct
torque when torquing the pump mounting bolts.
Remark
It is important to maintain a 90o angle when torquing the
mounting bolts. Failure to do so may change the torque
value resulting in over-torquing or under-torquing the
bolts.
50-92 h
DISASSEMBLY AND ASSEMBLY DRIVE DAMPENER
DRIVE DAMPENER
REMOVAL
1. Remove engine and HST pump from machine, see “ENGINE AND
HST PUMP” on page 50-77.
2. Separate HST and Work Equipment pump assembly from the

engine, see “REMOVAL FROM ENGINE” on page 50-89.
3. Remove two mounting bolts using a 14mm wrench for the wiring
harness bracket (1), then remove the bracket.
4. Remove 12 dampener housing cover mounting bolts (2) using a

17mm wrench.
H Place two mounting bolts (3) in the two threaded holes for
breaking the cover away from the housing.
5. Remove the cover.
Dampener Cover: 19 kg (42 lbs)
6. Make note of how the dampener is removed for reassembly. After

removing the mounting bolts, remove the dampener.
50-93 h
DISASSEMBLY AND ASSEMBLY DRIVE DAMPENER
7. To remove the inner drive plate (4) remove the eight mounting bolts
(5) and lift the drive plate off the flywheel.
8. To remove the pump drive gear (7), remove the allen bolt (6) and
pull the gear off of the pump shaft splines.
INSTALLATION
1. Completely clean all mating surfaces, bolt and bolt hole threads.
2. Install pump drive gear.
Pump drive gear: 98 - 123 N•m (72 - 91 lbf/ft)
3. Install the drive dampener, being careful not to install incorrectly. Then fasten with mounting bolts.
Drive Dampener: 44.1 - 53.9 N•m (33 - 40 lbf/ft)
4. Apply a small amount of liquid gasket to the mating surface of the housing cover, mount and fasten with 12 mounting
bolts.
Housing Cover Mounting Bolts: 58.8 - 75.5 N•m (43 - 54 lbf/ft)
Apply LG-6 liquid gasket to mating surface of the Housing Cover.
5. Attach the wiring harness brackets with two mounting bolts.
50-94 h
DISASSEMBLY AND ASSEMBLY HST PUMP OVERHAUL PROCEDURES
12
HST PUMP OVERHAUL PROCEDURES
Special Tools
Distinction
Necessary
Sketch
Qty.
1 790-501-5200 Repair stand n 1

2 790-901-2110 Bracket n 1
3 791T-B67-1210 Plate n 1 N m
1 790-201-3610 Bolt n 1
2 792-422-1120 Washer n 1
4 3 01643-32460 Washer l 1
4 01643-32060 Washer l 1
5 01582-02016 Nut l 1
5 790-201-2180 Plate n 1
A
6 790-201-2710 Spacer n 1
7 797T-622-1170 Push tool n 1 m
8 796-760-9110 Push tool n 1
9 79G-05V-0301L Push tool n 1
1 790-101-5001 Push tool kit n 1
2 790-101-5151 . Plate 1
10
3 790-101-5021 . Grip 1
4 01010-50816 . Bolt 1
11 796-751-1510 Spline socket n 1
DISASSEMBLY PROCEDURES
REMOVAL OF ACCESSORIES
1. Install tool A3 to tool A2, then install tool A2 to tool A1.
2. Install hydraulic pump assembly (1) to tool A3.
3. Remove condenser and bracket assembly (2) (two pieces on the

right and left side).
4. Remove EPC valve assembly (3) (4).
5. Remove housing (5).
50-95 h
6. Remove lower covers (6) and (7) from front pump assembly and
rear pump assembly.
Remark
Do not remove the plugs which are blocking the machined
holes of the front pump case, end cap case and rear
pump case.
• Front pump case: 13 places
• End cap case: 13 places
• Rear pump case: 14 places
• Servo piston: 10 places
REMOVAL OF REAR PUMP
1. Remove two lower mounting bolts (8).
2. Sling rear pump assembly (9) and remove two upper mounting
bolts (11).
3. Lift off the rear pump assembly (9).

H Since valve plate may come off end cap assembly (10) and
may fall, pull out the rear pump assembly toward this side with
care.
REMOVAL OF END CAP
1. Remove valve plate (12) on the rear side.
50-96 h
2. Remove two upper mounting bolts (13).
3. Sling end cap assembly (10) and remove two lower mounting bolts
(14).
4. Lift off end cap assembly (10).
DISASSEMBLY OF CYLINDER BLOCK AND PISTONS
1. Remove valve plate.
2. Take out cylinder block and piston assembly (15).
Remark
Slant the case a little so that the cylinder block and piston
assembly will come out together.
3. Disassemble piston assembly according to the following procedure.
A. Pull piston assembly (16) out of cylinder block (17).
B. Remove nine pistons (18) from shoe retainer (19).
50-97 h
C. Remove retainer guide (19a) from cylinder block
assembly (17).
D. Remove three pins (21).
E. Set tool A4 to cylinder block assembly (17) and compress the

spring (22).
F. Remove snap ring (23) from the cylinder block, and remove
tool A4.
G. Remove seat (24), spring (22) and seat (25).
DISASSEMBLY OF ROCKER CAM
1. Remove rocker cam (26) and slider (27) together.
2. Remove slider (27) from rocker cam (26).
50-98 h
3. Remove right and left cradle bearings (30) and bearing seats (31).
H The right, left, front and rear cradle bearings and bearing seats
are the same.
4. Pull out pin (32) and remove pin (33) and plate (34).
H Pull out from the right and left sides.
REMOVAL OF FRONT SHAFT
1. Removal of oil seal
A. Remove snap ring (35).
B. Remove oil seal holder (36).
C. Apply flat-head screwdriver [1] to the snap ring groove, set a

block of about 5 mm between the screwdriver tip and front
case, and push the screwdriver grip to pull out oil seal cover
assembly.
50-99 h
D. Set oil seal holder (38), and remove oil seal (37) from oil seal
holder (38).
H Set oil seal holder (38) to vise [2], apply a flat-head screw-
driver as shown in the photo, and tap the screwdriver grip
with a hammer to remove the oil seal.
DISASSEMBLY OF SHAFT
1. Using tool, tap the outer race of bearing (39) from inside of the case
to remove shaft assembly (40).
2. Tap the periphery of the outer race evenly to remove.
3. Remove snap ring (41) and washer (42).

H Since washer (42) is an elective part, record its thickness.
4. Using tool A5 and the press, remove bearing (39) from shaft (43).
50-100 h
DISASSEMBLY OF FRONT COVER
1. Remove maximum delivery adjustment screw locknut (44) of left

cover assembly.
2. After removing cover (46), remove adjustment screw (45).
3. Remove neutral position adjustment rod locknut (47) of left cover

assembly (46).
4. Before loosening the locknut, measure dimension (g) of

adjustment rod (48).
5. Adjustment rod (48) cannot be removed at this time.
6. Remove four cover mounting bolts (49).
7. Rotate the neutral position adjustment rod clockwise with a hexag-

onal wrench (width across flats: 5 mm) to disconnect it from cover
(46) and remove cover (46).
8. Remove the maximum delivery adjustment screw (45) from the

cover assembly (46).
A. Remove right cover assembly (52) similarly.

H After removing right cover assembly (52), remove maximum delivery adjustment screw (51) and neutral position
adjustment screw (54) from cover assembly (52).
50-101 h
12
DISASSEMBLY FRONT SERVO PISTON
1. Pull servo piston assembly (55) out of case (56).
2. Using tool A6 and the press, push retainer (59) to remove snap ring
(58).
3. Pull out retainer (59), adjustment rod (60), spring (61) and retainer
(62) together.
4. Remove plug (63).
5. Remove retainer (64).
6. Retainer (64) is split into two pieces.
7. Remove spool (65) and sleeve (66) assembly.
8. Disassemble the spool assembly according to the following

procedure.
A. Loosen plug (67) and remove it from sleeve (66).
B. Remove plug (68) and adjustment screw (69) from sleeve (66).
C. Remove bolt (70) with hexagonal wrench (width across flats: 5 mm).
D. Remove retainer (71), spring (72) and retainer (73) from spool (65).
50-102 h
12
DISASSEMBLY OF END CAP
1. Remove four safety suction valve assemblies (74) (two places at

upper section and two places on right and left sides).
2. Remove towed plugs (75) (two places).
3. Before removing the following plugs, measure their respective

installed heights.
4. Remove plugs (76) (two places).
5. Remove plugs (77) and (78).
7. Pull out bearing (80) (front side and rear side).

H Do not reuse the bearings, but replace them with new ones.
8. Pull out coupling (81).
DISASSEMBLY OF REAR PUMP

Set rear pump assembly (9) to tool A3.
1. Removal and disassembly of rear cylinder block and piston

assembly
For removal and disassembly procedure, see “REMOVAL AND
DISASSEMBLY OF FRONT CYLINDER BLOCK AND PISTON
ASSEMBLY.”
2. Removal and disassembly of rear rocker cam assembly

DISASSEMBLY OF FRONT ROCKER CAM ASSEMBLY.”
DISASSEMBLY OF REAR SHAFT
1. Using tool, tap the outer race of bearing (82) from inside of the case
to remove shaft assembly (83).
H Tap the periphery of the outer race evenly to remove.
50-103 h
2. Remove snap ring (84) and washer (85) from shaft (86).
H Since washer (85) is an elective part, record its thickness.
3. Using tool A5 and the press, remove bearing (82) from shaft (86).
H For the following removal and disassembly procedure, see
“REMOVAL AND DISASSEMBLY OF FRONT SHAFT.”
4. Removal and disassembly of rear cover

DISASSEMBLY OF FRONT COVER.”
H Measure the installed dimensions (n) of the neutral
position adjustment rod (88) on left side.
ASSEMBLY PROCEDURES
H Clean each part carefully and remove burrs, etc. In particular, clean
the drilled oil passages thoroughly.
H Coat the rotating/sliding parts with engine oil (EO10) before
installing.
H Before installing the following parts, be sure to check their contact,
referring to “Contact check of each part”.
• Pump case and rocker cam
• Cylinder block and valve plate
• Valve plate and end cap
50-104 h
12
INSTALLATION OF REAR SERVO PISTON
1. Set rear pump case to repair stand.
2. Assembly and installation of rear servo piston assembly as listed:
A. Install retainer (93), spring (94) and retainer (95) together to spool (92).
B. Put washer (97) to screw (96), and tighten the screw (96) (width across flats of hexagonal wrench: 5 mm).
Screw: 11.8 - 14.7 N•m (9.0 - 11.0 lbf/ft)
C. Assemble spool (92) sub assembly to sleeve (98).
D. Assemble adjustment screw (90) to plug (99).
E. Assemble plug (100) to plug (99) with “O” ring.
F. Assemble plug (99) sub assembly to sleeve (98) with O-ring.
G. Tighten plug (99) temporarily at this moment.
H. Put O-ring to sleeve and assemble it to servo piston (101).
I. Set servo piston (101) assembly to vice.

H Tighten the plug (99) at specified torque.
Plug: 78.4 - 102.9 N•m (58.0 - 76.0 lbf/ft)
J. Install retainer (102) and tighten with plug (103).

H Refer to procedure I) for tightening method of plug (103).
Plug: 58.8 - 78.4 N•m (43.3 - 58.0 lbf/ft)
K. Assemble retainer (104), spring (105) and retainer (106) to

adjustment rod (88).
L. Assemble adjustment rod (88) to servo piston (101) with O-

ring.
50-105 h
M. Using tool A6 and the press, push in retainer (106) and install
snap ring (107).
N. Install rear servo piston assembly (101) to rear case (91).
50-106 h
12
INSTALLATION OF REAR COVER
(LEFT COVER)
1. Install maximum delivery adjustment screw (87) to cover (108) and install it with the locknut (109).
H Install the adjustment screw so that dimension (m) between the adjustment screw left end face and cover mounting
face will be as follows:
H Dimension (m) = 6.2 ± 0.1 mm (0.24 ± 0.004 inches)
Locknut: 49 - 58.8 N•m (36.1 - 44.0 lbf/ft)
2. Set the cover (108) to rear case (91) and pull out neutral position adjustment rod (88) about 10 mm with a hexagonal
wrench.
3. Tighten the cover (108) with 4 cover mounting bolts.
Cover mounting bolt: 59 - 74 N•m (44 - 55 lbf/ft)
4. Set the dimension between left end face of adjustment rod and
surface of cover to dimension (n) which measured at disassembly
procedure, then install the adjustment rod with locknut (110).
Locknut: 49 - 58.8 N•m (36.1 - 44.0 lbf/ft)
(RIGHT COVER)
5. Install maximum delivery adjustment screw (89) to the cover (150)

and install it with the locknut (111).
H Install the adjustment screw so that dimension (p) between the
adjustment screw right end face and cover mounting face will
be as follows:
H Dimension (p) = 6.2 ± 0.1 mm (0.24 ± 0.004 inches)
Locknut: 49 - 58.8 N•m (36.1 - 44.0 lbf/ft)
6. Set the cover (150) to rear case (91) and pull out neutral position adjustment screw (90) about 10 mm with a hexagonal
wrench.
7. Tighten the cover (150) with four cover mounting bolts.
Cover mounting bolt: 59 - 74 N•m (44 - 55 lbf/ft)
8. Set the adjustment screw (90) so that dimension (q) between the
adjustment screw right end face and cover mounting face will be as
follows, then install the adjustment screw (90) with locknut (112).
H Dimension (q) = 13.5 ± 0.1 mm
Locknut: 49 - 58.8 N•m (36.1 - 44.0 lbf/ft)
50-107 h
12
INSTALLATION OF REAR SHAFT
1. Using tool A8 and the press, install bearing (113) to shaft (114).
H Apply grease sufficiently to the press fitting surfaces (inside of
the inner race and outside of the shaft).
2. Install washer (115) and install it with snap ring (116).

H Use removed washer (115).
H If either or both of the shaft and bearing were replaced with
new ones, select washer (115) according to the
A. Measure dimension (s) between the bearing inner race end face
and snap ring groove corner (r).
B. Select an installed washer so that installed washer thickness (t)

= (s) - (v).
H Thickness (v) = 1.45 - 1.60 mm
H Washer thickness (t): 2.8 mm, 2.9 mm, 3.0 mm, 3.1 mm
3. Using tool A7, install shaft assembly (114) to rear case (91).
H Apply grease sufficiently to the press fitting surfaces
(outside of the outer race and inside of the case).
H While tapping the bearing lightly, insert the bearing
evenly.
4. Install washer (117) and install it with snap ring (118).
50-108 h
ASSEMBLY OF REAR ROCKER CAM
1. Install pin (121) and plate (120) to rear case, then install them with
pin (119).
2. Install right and left bearing seats (122) and cradle bearing (123).
3. Install slider (124) to rocker cam (125).
4. Install slider (124) and rocker cam (125) together.

H When sticking the slider, set it to the groove of the rear servo
piston assembly.
H Check to be sure sliding part of the rocker cam is fitted to the
cradle bearing.
50-109 h
12
INSTALLATION OF REAR CYLINDER BLOCK AND PISTON
H Assemble the rear cylinder block and piston assembly
1. Install seat (126), spring (127) and seat (128) to cylinder block
(129).
2. Set tool A4 to cylinder block assembly (129) and compress spring

(127).
3. Install snap ring (130) and remove tool A4.
4. Install three pins (131) to cylinder block assembly (129).
5. Install retainer guide (132) to cylinder block assembly (129).
6. Install nine pistons (133) to shoe retainer (134).
7. Install piston assembly (135) to cylinder block assembly (129).
8. Install rear cylinder block and piston assembly (129) to the case.
H Check to be sure shaft is meshed with the cylinder block spline
and the rocker cam is fitted to the sliding surface of the piston
shoe.
50-110 h
ASSEMBLY OF END CAP
1. Using tool A9, press fit bearing (136).
2. Install snap ring (138) to coupling (137) and install them to the
case.
3. Reverse the case. Using tool A9, press fit bearing (139) similarly to
the procedure 1).
50-111 h
4. Install four relief valves (140).
Plug: 147 - 186 N•m (108 - 137 lbf/ft)
5. Install two towed plugs (141).
Screw: 24.5 - 34.3 N•m (18 - 25 lbf/ft)

Plug: 24.5 - 34.3 N•m (18 - 25 lbf/ft)
6. Install two shuttle valves (142).
Plug: 34.3 - 44.1 N•m (25 - 32 lbf/ft)
7. Install plug (143).
50-112 h
12
ASSEMBLY OF FRONT COVER
1. For assembly and installation of front case and front shaft, see “ASSEMBLY AND INSTALLATION OF REAR COVER
ASSEMBLY.”
INSTALLATION OF FRONT OIL SEAL
1. Using tool A10, assemble oil seal (145) to oil seal holder (146).
2. Using tool A7, install oil seal assembly (146) to front pump case.
3. Install snap ring (35).
A. Assembly and installation of front rocker cam assembly

For assembly and installation of procedure, see “ASSEMBLY
AND INSTALLATION OF REAR SERVO PISTON.”
INSTALLATION OF END CAP
1. Install the valve plate (147).
50-113 h
2. Sling and install end cap assembly (10).
H Take care that the valve plate will not fall.
3. Tighten four mounting bolts (14).
Three mounting bolts: 59 - 74 N•m (44 - 55 lbf/ft)
INSTALLATION OF REAR PUMP
1. Install the valve plate (12).
2. Sling and install rear pump assembly (9) to end cap assembly (10).
H Take care that the valve plate does not fall.
3. Tighten four mounting bolts (11).
Mounting bolts: 59 - 74 N•m (44 - 55 lbf/ft)
H Check of shaft rotation torque

After finishing assembly, check the shaft rotation torque with tool
A11 according to the following procedure.
A. Rotate the shaft at a constant speed of 3 - 5 sec/turn and

measure its rotation torque.
B. The rotation torque must be even and in the following range.

• Unevenness: Max. 2.94 N•m (2.2 lbf/ft)
• Rotation torque: 6.86 - 20.6 N•m (5.1 - 15.2 lbf/ft)
50-114 h
INSTALLATION OF ACCESSORIES
1. Install lower covers (6) and (7).
2. Install housing (5).
Mounting bolt: 98 - 123 N•m (72 - 91 lbf/ft)
3. Install EPC valve assemblies (3) and (4).
4. Install condenser bracket assemblies (2) (two pieces on the right

and left sides).
5. Remove HST pump assembly (1) from tool A3.
50-115 h
DISASSEMBLY AND ASSEMBLY WORK EQUIPMENT PUMP OVERHAUL PROCEDURES
12
WORK EQUIPMENT PUMP OVERHAUL PROCEDURES
Special Tools
Distinction
Necessary
Sketch
Qty.
1 790-501-5200 Repair stand n 1

A
2 790-901-2110 Bracket n 1
1 796T-267-1130 Plate n 1 N m
1 01017-61400 Bolt l 1
2 796T-266-1120 Washer n 1 m
2 3 01643-32060 Washer l 1
4 01643-31445 Washer l 1
5 01580-01411 Nut l 1
3 796T-267-1180 Push tool n 1 m
C 4 791-615-2130 Sleeve n 1
1 790-101-5001 Push tool kit n 1
2 790-101-5081 . Plate n 1
5
3 790-101-5021 . Grip n 1
4 01010-50816 . Bolt l 1
6 791-B67-1410 Guide n 1 N
1 790-445-2620 Wrench n 1 N
7
2 01306-10616 Screw l 1 N
PUMP
1. Install tool C1 to tool A2, then install tool A2 to tool A1.
2. Install hydraulic pump assembly (1) to tool C1.
50-116 h
3. Removal of servo valve assembly
Remove four servo valve assembly mounting bolts (2) and servo
valve assembly (3).
4. Disassembly of servo valve assembly
(PC VALVE)
A. Loosen sleeve (4) and remove it and spool (11) together from
servo valve assembly (3).
B. Remove plug (5).
C. Loosen locknut (6) and remove plug (7).
D. Before removing the locknut, measure respective installed

height (L1) of plug (7).
E. Remove lever (8) and spacer (51).
F. Pull out piston (12), spring (13), retainer (14) and spool (15).
(LS VALVE)
A. Loosen locknut (9) and remove plug (16).

H Before removing the locknut, measure respective installed
height (L2) of plug (16).
50-117 h
B. Remove spring (17) and retainer (18).
C. Remove plug (10).
D. Remove spool assembly (19).
REMOVAL OF END CAP
1. Remove four mounting bolts (20) and end cap (21).

H When the end cap is removed, the valve plate may come off
and fall.
2. Remove valve plate (22).
DISASSEMBLY OF CYLINDER BLOCK AND PISTON
A. Pull out cylinder block and piston assembly (23) from case
(24).
H Slant the case a little so that the cylinder block and piston
50-118 h
B. Disassemble the piston assembly according to the following
procedure.
i. Pull out piston (25) and shoe retainer (26) together from
cylinder block (27).
ii. Remove 10 pistons (25) from shoe retainer (26).
C. Disassemble the cylinder block assembly according to the

i. Remove retainer guide (28) from cylinder block (27).
ii. Remove 3 pins (29).
iii. Set tool C2 to cylinder block (27) and compress spring

(30).
iv. Remove snap ring (31) from the cylinder block and
remove C2.
v. Remove seat (32) and spring (30).
DISASSEMBLY OF SHAFT ASSEMBLY

Removal of oil seal
50-119 h
B. Remove oil seal holder assembly (35).
H Set two flat-head screwdrivers [1] to groove of oil seal
holder like picture, then pull out the oil seal holder assem-
bly.
C. Set oil seal holder (35) to vice [2], and remove oil seal (36)
from the oil seal holder (35).
D. Removal and disassembly of shaft assembly
i. Using tool, remove shaft assembly (37).
ii. Remove snap ring (38).
iii. Using bearing puller, remove bearing (39).
50-120 h
DISASSEMBLY OF ROCKER CAM
1. Loosen locknut (40) and remove maximum swash plate angle

adjustment plug (41).
2. Loosen locknut (42) and remove minimum swash plate angle

adjustment plug (43).
H Make a mark on the minimum swash plate angle adjustment
plug so that you will not mistake it for the maximum swash
plate angle adjustment plug.
3. Remove rocker cam (44).
4. Remove bolt (45), spacer (46) and ball (47) from rocker cam (44).
REMOVAL OF BALLS AND PISTON
1. Remove two balls (48).
50-121 h
2. Remove piston assembly (50) and spring (49).
50-122 h
12
ASSEMBLY PROCEDURES
H Clean each part carefully and remove burrs, etc. In particular, clean the drilled oil passages thoroughly.
H Coat the rotating/sliding parts with engine oil (EO10) before installing.
H Before installing the following parts, be sure to check their contact, referring to “Contact check of each part”.
A. Pump case, ball and rocker cam
B. Cylinder block and valve plate
C. Valve plate and end cap
INSTALLATION OF PUMP CASE
1. Install pump case to repair stand.
2. Installation of balls and piston assembly
3. Install spring (49) to piston assembly (50) and install them to the
case.
4. Install two balls (48).
INSTALLATION OF ROCKER CAM
1. Install ball (47) and spacer (46) to rocker cam (44) and install them
with bolt (45).
Bolt: 11.8 - 14.7 N•m (9 - 11 lbf/ft)
50-123 h
2. Install the rocker cam assembly to the case.
H If case (24), ball (48) or rocker cam (44) was replaced with
new one, check the contact of the following parts.
H The rocker cam and case must be in contact all round the ball
without breakage at height of at least 2/3 from their spherical
bottoms [a] [b].
H The contact surface must be an unbroken ring and must be free
from local strong contact.
A. Install maximum swash plate angle adjustment plug (41) and

install it with locknut (40).
H Install the plug so that the standard dimension (L3) = 1.7
mm.
Bolt: 68.6 - 83.4 N•m (51 - 62 lbf/ft)
B. Install minimum swash plate angle adjustment plug (43) and

install it with locknut (42).
H Install the plug so that the standard dimension (L4) = 3.3
mm (0.13 inches).
Bolt: 68.6 - 83.4 N•m (51 - 62 lbf/ft)
ASSEMBLY AND INSTALLATION OF SHAFT
1. Using tool C3 and the press, install bearing (39) to shaft (37).
H Apply grease sufficiently to the press fitting surfaces (inside of
the inner race and outside of the shaft).
2. Install with snap ring (38).
50-124 h
3. Using tool C4, install shaft assembly to case (24).
H Apply grease sufficiently to the press fitting surfaces
(outside of the outer race and inside of the case).
INSTALLATION OF OIL SEAL
1. Using tool C5, install oil seal (36) to oil seal holder (35).
2. Using tool C6, install the oil seal holder assembly (35) to the shaft.
H Never use a paper tape instead of the tool C6 since it can be
broken off and left inside.
3. Install with snap ring (34).
50-125 h
12
INSTALLATION OF CYLINDER BLOCK AND PISTON
H Assemble the cylinder block assembly according to the
A. Install seat (33), spring (30) and seat (32).
B. Set tool C2 to cylinder block (27) and compress spring (30).
C. Install snap ring (31) and remove tool C2.
D. Install three pins (29) to cylinder block (27).
E. Install retainer guide (28).
F. Install ten pistons (25) to shoe retainer (26).
G. Install piston (25) and shoe retainer (26) together to cylinder

block (27).
H. Install cylinder block and piston assembly (23) to case (24).

H Slant the case a little when installing it.
50-126 h
INSTALLATION OF END CAP
1. Install valve plate (22) to end cap (21).

H Set the pin [a] on the end cap side to the pin groove [b] of the
valve plate and check to be sure valve plate is fitted to the end
cap.
2. Install end cap (21) with four mounting bolts (20).
ASSEMBLY OF SERVO VALVE
(LS valve)
A. Install spool assembly (19).
B. Install O-ring to plug (10) and tighten the plug (10).
Plug: 27.4 - 34.3 N•m (20 - 25 lbf/ft)
C. Install spring (17) and retainer (18).
D. Install O-ring to plug (16) and install the plug (16).
E. Adjust depth (L2) which was measured at disassembling

procedure (LS valve) Step 1.
H LS set change 13.2 kg/cm2 (1,914 psi) by one turn of plug (16).
50-127 h
F. Install the plug (16) with the locknut (9).
Locknut: 27.4 - 34.3 N•m (20 - 25 lbf/ft)
H (PC valve)
G. Install spool (15), retainer (14), spring (13) and piston (12).
H. Install and adjust plug (7) according to the following

procedure.
i. Install spacer (51) and lever (8).
ii. Tighten plug (7) with O-ring until it reaches spacer (51).
H Put mark (S) on the top of plug (7) for confirming rotation degree of the plug (16).
iii. After plug (7) reaches spacer (51), loosen it to direction (R) at least 180o and tighten locknut (6) when mark (S)
is in position 0o.
Locknut (6): 27.4 - 34.3 N•m (20 - 25 lbf/ft)
H When plug (7) reaches spacer (51), if mark (S) is at where 180 -
360o, loosen the plug at least one turn to the temporary assembly to
position (0o).
Plug: 27.4 - 34.3 N•m (20 - 25 lbf/ft)
H (Temporary assembly position)

H When play (X) is 1.5 mm (0.06 inches) and up after assembling
lever (8), adjust depth (L1).
I. Install plug (5) to servo valve assembly (3) with O-ring.
Plug: 27.4 - 34.3 N•m (20 - 25 lbf/ft)
J. Install spool (11) and install it with sleeve (4).
K. Install sleeve (4) to servo valve assembly (3) with O-ring.
Sleeve: 27.4 - 34.3 N•m (20 - 25 lbf/ft)
50-128 h
12
INSTALLATION OF SERVO VALVE ASSEMBLY
Install servo valve assembly (3) with four servo valve assembly
mounting bolts (2).
H Check that O-ring is installed.
Bolt: 11.8 - 14.7 N•m (9 - 11 lbf/ft)
H Check shaft rotation torque

After finishing assembly, check the shaft rotation torque with tool
C7 according to the following procedure.
A. Rotate the shaft at a constant speed of 3 - 5 sec/turn and

B. The rotation torque must be even and in the following range.

50-129 h
DISASSEMBLY OF CHARGE PUMP ASSEMBLY

REMOVAL
WARNING! Always plug and cap all disconnected hydraulic, coolant, and fuel lines to prevent
leakage and/or dirt and debris from entering the system.
1. Loosen one mounting bolt (1), two locknuts (2) and disconnect the
two hoses (3) from fuel line on engine.
H These lines (3) have Quick Coupling Connectors.
2. Remove four mounting bolts (4) from suction line tube.
3. Disconnect tube (5).
4. Remove two mounting bolts (7) and then remove the charge pump
(6) from engine.
Charge pump 15 kg (33 lbs)
5. Remove the locknut and washer (8) to remove the rear gear acces-
sory drive (9) and remove and discard the gasket (10) and then dis-
assemble the charge pump assembly.
50-130 I
INSTALL
1. Before starting the installation procedure make sure to align the
gear teeth to the boss at rear gear housing to fit the teeth gear of
charge pump in it.
3. Fit the new gasket (10) on charge pump.
4. Reinstall gear (9) and tighten locknut and washer (8).
Locknut: 98 - 124 N•m (72 - 92 lbf/ft)
5. Reinstall the charge pump (6) with two mounting bolts (7).
Flange mounting bolt: 98 - 123 N•m (72 - 91 lbf/ft)
6. Replace o-ring and tighten fitting tube (5).
Tube sleeve nut: 177 - 230 N•m (131 - 170 lbf/ft)
7. Replace o-ring and plug and tighten tube with four bolts (4).
8. Tighten one mounting bolt (1), two locknuts (2) and reconnect the two hoses (1) on engine.
Locknut: 11 - 27 N•m (8 - 20 lbf/ft)
50-131 I
CHARGE PUMP OVERHAUL PROCEDURES

Remark
The photo images of the shaft end of the input gear is a generic shape, and does not represent the shape of
the Komatsu part. The Komatsu part is a tapered shaft with a threaded end.
TOOLS REQUIRED
• Socket Set (1/2" Drive, 7/8" & 11/16")
• Internal Snap Ring Pliers
• Shaft Seal Sleeve or clear tape
• Torque Wrench (28 kg-m capacity)
• Plastic Mallet
• Torque wrench box end adapters (7/8" & 11/16")
• Structural illustration
1. Plug ports and wash exterior of the pump with a proper cleaning solvent before continuing.
2. Remove port plugs and drain oil from pump.
Remark
It is not necessary to mark the outside of pump before disassembly as the front cover, center section and
rear cover all have notches cast into the edges of these parts. By lining up the notches of these three parts
the pump will be properly assembled and proper rotation of the pump will be assured.
50-132 I
3. Loosen and remove the eight nuts (1) and lockwashers (2) from the
stud bolts (7).
4. Remove pump from vise and place on clean work bench. Use a
plastic mallet to separate the front cover (3) from the rest of the
pump. The two dowel pins which align the front cover (3), center
section and rear cover are a tight fit and will require the use of the
plastic mallet to separate these parts. (Do not use a screwdriver or
other pry tool to separate these parts as damage will result).
5. After removed front cover (3), identify intersecting teeth of drive

gear (4) and driven gear (5) with a paint pen before removing from
pump. Carefully remove drive gear (4) from pump and place on
work bench.
6. Remove driven gear (5) from pump and place on clean work bench.
7. Remove center section (6) from pump.
50-133 I
8. Remove the eight studs (7) from rear cover (12).
9. Remove wear plate (8) from rear cover (12).
10. Remove seal retainer (9) from rear cover (12) and discard as it will
be replaced as a new part.
11. Remove seal gland (10) from rear cover (12) and discard as it will
50-134 I
12. Remove square cross section o-ring (11) from rear cover (12) and
discard as it will be replaced as a new part.
13. Remove wear plate (13) from front cover (3). Remove rubber plug
(14) from seal weep hole.
14. Remove seal retainer (15) from front cover (3) and discard as it will
15. Remove seal gland (16) from front cover (3) and discard as it will
50-135 I
16. Remove square cross section o-ring from (17) front cover (3) and
discard as it will be replaced as a new part.
17. Remove seal retainer (18) if applicable from front cover (3) and use
a screwdriver or seal removal tool to remove the shaft seal (19) and
(20) from front cover (3). Note whether seal has spring side facing
in or out. The spring loaded member of shaft seal faces the outside
of the pump in the D51-22 application.
INSPECT PARTS FOR WEAR
1. Clean and dry all parts thoroughly prior to inspection. It is not

necessary to inspect the seals as they will be replaced as new items.
2. Check the drive gear (4) splines for twisted or broken teeth, nicks
or excessive wear. Inspect gear journals for scratches and discolor-
ation. Any discoloration of shaft requires replacement of drive gear.
Inspect gear teeth for spalding, scratches or excessive wear.
Replace if necessary. Light stoning of teeth to remove sharp edges
is permissable.
3. Inspect gear face of both the drive gear (4) and driven gear (5) for
scoring or excessive wear. If the face edge of gear teeth are sharp,
they will mill into the wear plates. If wear on the face of the gears
has occurred, the gears must be replaced.
50-136 I
4. Inspect bearings in front cover (3) for excessive wear, scoring,
flaking or movement of bearings.
5. Inspect bearings in rear cover (12) for excessive wear, scoring,

flaking or movement of bearings.
6. Inspect the gear pockets inside the center section (6). It is normal
for the surface inside the gear housing to show a clean “wipe” on
the inside gear pocket wall on the intake side. There should not be
excessive wear or deep scratches and gauges.
7. Inspect bronze side of both wear plates (8) and (13) for erosion, pit-
ting, scratches or scoring, replace if damaged.
50-137 I
ASSEMBLY PROCEDURES
GENERAL NOTES
• It is important that the relationship of the front cover, center section and rear cover is correct. Notches cast into the
outside surface of these three parts must be aligned for proper reassembly of this pump. Failure to properly assemble
this pump will result in low flow, low pressure and possible damage to the pump.
• Upon reassembly of pump, all parts should be lightly oiled with clean hydraulic fluid or approved assembly fluid. Use
small amounts of graphite grease to hold seal retainer and seal in place during assembly.
• Shaft Rotation of Pump (Note: This pump is not bi-rotational and the shaft rotation cannot be reversed).
• New seal glands, seal retainers, square cross section o-rings, shaft seals should be installed upon reassembly of pump
and are included in the seal kits available for these pumps.
H Typical contents of seal repair kit.
50-138 I
1. Install new shaft seal (20) in front cover (3), make sure the spring
loaded member of shaft seal faces the inside of the pump (reference
the following illustration for seal installation). Press the seal into
the seal bore until the seal reaches the bottom of the bore.
Retain with snap ring (18).
Next install a new outer shaft seal (19) which has a larger O.D. in
seal cavity. Make sure the spring loaded member of shaft seal faces
the same as noted during disassembly.
H Uniform pressure [F] must be used to prevent misalignment or

damage to the seal (19) and (20). Press until seal is seated
properly.
<Double Shaft Seal Arrangement>
2. Place rear cover (12) on clean work bench with seal cavity area
facing up. Coat seal cavity with graphite grease to hold seals in
place.
50-139 I
3. Coat both the seal gland (10) and plastic seal retainer (9) with
graphite grease. Carefully install the seal gland (10) in the groove
in the seal retainer (9), make sure the seal gland (10) is seated com-
pletely in the seal retainer (9).
4. Install the assembled seal gland (10) and seal retainer (9) in the
cavity in the rear cover (12). Very carefully press this assembly in
place until it is firmly seated in the machined recess. This is impor-
tant for proper installation of the bronze wear plate.
5. Lubricate the bronze face of the wear plate (8) and install over the
seal retainer. When properly placed the bronze face will be next to
the gears and flush with the surface of the rear cover.
6. Apply a light coating of graphite grease to the square cross section

o-ring (11) and carefully install in groove in rear cover (12). Be
very careful that the o-ring does not twist in the groove, it must be
flat in the groove or the pump will leak at this seam.
50-140 I
7. Install the eight studs (7) in the rear cover. The course thread end of
the studs thread into the rear cover. Torque studs to 33.3 - 47.1 N.m
(3.4 to 4.8 kgm) by using two nuts tightened against each other.
8. Install center section (6) over studs, make very sure the notches are
in alignment with the notch in the rear cover. It may be necessary to
use a plastic mallet to seat the center section due to the tight fit of
the dowel pins. Hold the wearplate in position while tapping center
section.
9. Lubricate the drive gear (4) and driven gear (5) and install the gears
in the proper bearings in the rear cover (12). Align marked gear
teeth [G] at this time.
10. Place front cover (3) on clean work bench with seal cavity area
facing up. Coat seal cavity with graphite grease to hold seals in
place.
50-141 I
11. Coat both the seal gland (16) and plastic seal retainer (15) with
graphite grease. Carefully install the seal gland (16) in the groove
in the seal retainer (15), make sure the seal gland (16) is seated
completely in the seal retainer (15).
12. Install the assembled seal gland (16) and seal retainer (15) in the
cavity in the front cover (3). Very carefully press this assembly in
place until it is firmly seated in the machined recess. This is impor-
tant for proper installation of the bronze wear plate.
13. Apply a light coating of graphite grease to the square cross section
o-ring (17) and carefully install in groove in front cover (3). Be
very carefull that the o-ring does not twist in the groove, it must be
flat in the groove or the pump will leak at this seam.
14. Lubricate the steel side of the bronze wear plate (13) with graphite
grease and install over the seal retainer. When properly positioned,
the bronze face will be next to the gears and flush with the surface
of the front cover (3).
50-142 I
15. Very carefully slide front cover (3) over drive shaft (4) and studs
(7). Engage front cover (3) over dowel pins. Press firmly until front
cover (3) is fully seated against center section (6). Make sure all
notches are in alignment, if not pump is incorrectly assembled.
Make sure all seals and wear plate have stayed in their proper posi-
tion.
H Install lock washers and nuts on studs.

Torque nuts to 88 - 101 N.m (9 - 10.3 kgm).
16. Place a small amount of clean oil in the inlet of the pump and rotate the drive shaft away from the inlet one revolution. No
binding should be evident during this operation. The breakaway torque to turn the drive shaft must not exceed 47.5 Nm
(35 lb/ft) after assembly.
17. The Charge Pump is assembled to the engine using the mounting hardware and installation instructions shown in the
figure above.
PLACING PUMP BACK INTO SERVICE
A. Mount pump on equipment as shown in step 17, run engine at mid throttle for three minutes.
B. Increase engine speed to full throttle and run for three minutes.
C. Stop the engine and check pump for external leaks.
50-143 I
DISASSEMBLY AND ASSEMBLY DIESEL ENGINE OVERHAUL PROCEDURES
12
DIESEL ENGINE OVERHAUL PROCEDURES
DISASSEMBLY OF EXTERNAL COMPONENTS

H This document describes the general disassembly procedure of SAA6D107E-1. The shapes, quantity, locations, etc. of the
parts depend on each applicable machine. Take care.
PREPARATION WORK
Before disassembling the top end, check its parts. Clean and
carefully inspect all parts and assemblies for wear or damage.
H Before cleaning the engine, carefully seal or remove the
openings, electric parts, and wiring connectors so that water
will not enter them.
H Prepare a stable engine stand (Blocks [1]) on both sides and
place the engine assembly on the stands so that it will not tip
over.
1. Remove oil gauge assembly (2).
2. Lift engine assembly (1) and then install it on repair stand A.
Engine assembly: Approximately 520 kg (551 lbs)
H (The weight depends on the applicable machines.)
3. Install tool B.
H Engine side mounting bolt: M12 x 1.75
Mounting bolt: 77 ± 12 N•m (57 ± 9 lbf/ft)
4. Drain the engine coolant and engine oil.
Engine oil: Approximately 23 liters (6.1 gal.)
50-144 I
STARTING MOTOR
1. Remove mounting bolt (1) and then remove starting motor assem-
bly (2).
ENGINE SLING BRACKET ON REAR SIDE
1. Remove rear engine sling bracket (1) from the cylinder head.
FAN PULLEY
1. Remove fan belt (1).

H Turn tensioner (2) in the opposite direction to the winding
direction to reduce the belt tension.
2. Remove bolt (3) and then remove fan pulley (4).
VIBRATION DAMPER AND CRANKSHAFT PULLEY
1. Remove bolt (1) and then remove vibration damper (2).
50-145 I
BELT TENSIONER
1. Remove bolt (1) and then remove tensioner (2).
FAN HUB
1. Remove four bolts (1) and then remove fan hub (2).
ALTERNATOR
1. Remove plate (1).
2. Remove bolt (2) and then remove alternator (3).
3. Remove alternator bracket (4) and front side sling bracket (5).
50-146 I
THERMOSTAT
1. Remove coolant outlet connector (1).
2. Remove thermostat (2).
WATER PUMP
1. Remove coolant inlet connector (1).
2. Remove water pump (2).
TURBOCHARGER AND EXHAUST MANIFOLD
1. Remove turbocharger lubrication inlet tube (1) and drain tube (2).
50-147 I
2. Remove turbocharger assembly (3) and exhaust manifold (4).
FUEL FILTER ASSEMBLY
1. Disconnect hoses (1) and (2) from the filter.
2. Disconnect drain hose (3) from filter bracket (4).
3. Remove fuel filter assembly (5).

• Removal of hose
A. Remove the hose by prying the hose end face with screwdriver
while pushing the tabs in the openings on both sides of the
hose.
WIRING HARNESS ASSEMBLY
1. Disconnect the harness from the sensor and controller, and then
remove the clamp to remove harness assembly (1).
50-148 I
FUEL PIPING AND COMMON RAIL
1. Remove boots (9) of high-pressure pipings (1) to (7) and then

remove the high pressure pipings.
2. Remove fuel drain hose (8).
3. Remove common rail (10).
A. Removal of hose
i. Remove the hose by prying the hose end face with screw-
driver while pushing the tabs at the openings on both sides
of the hose.
50-149 I
12
DISASSEMBLY OF ENGINE TOP END
H Before disassembling the top end, check its parts. Clean and carefully inspect all parts and assemblies for wear or damage.
INTAKE MANIFOLD
1. Remove tube (1) and electrical intake air heater (2).
2. Remove manifold covers (3) and (4).
VALVE COVER HOUSING
1. Remove duct (1).
2. Remove nut (2) and then remove head cover (3).
3. Remove nuts (4) of the harness from injector

H Harness installation position.
Cable color Cylinder number
White 1, 3, 5
Black 2, 4, 6
4. Remove seven bolts (5) and then remove rocker housing assembly
(6).
50-150 I
12
ROCKER ARM ASSEMBLY AND CROSSHEAD
1. Remove 12 bolts (1) and then remove rocker arm assembly (2).
H Loosen locknut to loosen adjustment screw by 2 - 3 turns so
that excessive force may not be applied to push rod when the
rocker arm is installed.
2. Remove cross head (3).

H Record the installation position and shape of holes in parts (a)
and (b). (So that it may be installed in the same direction in
reassembly.)
PUSH RODS
1. Remove 12 push rods (1).
FUEL INJECTORS
1. Remove retainer (5) and then remove six inlet connectors (1).
H Use tool M when removing the inlet connector.
2. Remove mounting bolts (3) of injector (2) and then remove holder
(4).
3. Remove injector (2).
50-151 I
4. Lift and remove the injector using tool F. (Don't try to pry the top of
the injector.)
CYLINDER HEAD
1. Remove 26 bolts (1) and cylinder head assembly (2).
Cylinder head assembly: 70 kg (154 lbs)
2. Disassemble the cylinder head assembly according to the following

procedure.
H Using tool C, compress valve spring (3) to remove valve cotter
(4).
3. Remove upper seat (5) and valve spring (3).
50-152 I
12
4. Raise the cylinder head assembly, pull and remove valve (6) and
then remove valve seal (7).
H Apply a marking to valve (6) to make it identifiable to which
cylinder head it should be combined.
50-153 I
12
REMOVAL OF OIL COOLER, ENGINE CONTROLLER AND FUEL PUMP
H Before disassembling the top end, check its parts. Clean and carefully inspect all parts and assemblies for wear or damage.
OIL COOLER
1. Remove oil filter (1).
2. Remove cover (2) and cover gasket (3).
3. Remove oil cooler (4) and cooler gasket (5).
ENGINE CONTROLLER
1. Remove engine controller (1).
2. Disconnect ground cable (2).
3. Remove cooling plate (3).
50-154 I
FUEL SUPPLY PUMP
1. Remove hose (1).
2. Remove three nuts (2) and then remove supply pump (3).
50-155 I
12
DISASSEMBLY OF ENGINE LOWER END
H Before disassembling the lower end, check its parts. Clean and carefully inspect all parts and assemblies for wear or
damage.
FLYWHEEL
1. Install guide bolt [1] and then remove flywheel (1).
Flywheel: 35 kg (77 lbs)
WARNING! Be careful when performing this

operation so your fingers may not get
injured by the flywheel which can fall
off from the crank shaft boss.
REAR OIL SEAL
1. Install tool G to the crankshaft.
2. Screw in tapping screw [1] of tool G to the seal carrier section of

rear oil seal (1).
3. Turn the handle counterclockwise to remove rear oil seal (1).
50-156 I
FLYWHEEL HOUSING
1. Remove 20 bolts (1) and then remove flywheel housing (2).
OIL PAN
1. Remove 32 bolts (1) and then remove oil pan (2).
2. Remove pick-up tube (3).
3. Remove plate (4) and three plates (5).
FRONT COVER
1. Remove 13 bolts (1) and then remove front cover (2).
2. Remove front seal (3).
50-157 I
OIL PUMP
1. Remove four bolts (1) and then remove oil pump assembly (2).
CAMSHAFT
H Rotate the crankshaft to align punch mark A on camshaft gear (1) to
the chamfered tooth of crankshaft gear (4) (to prevent interference
with the connecting rod when removing the camshaft).
1. Remove gear (1).
2. Remove thrust plate (2).
50-158 I
3. Rotate camshaft (3) when removing the plate.
GEAR HOUSING
1. Remove 10 bolts (1) and then remove gear housing (2).
PISTONS AND CONNECTING RODS
1. Rotate the crankshaft and bring the piston to be removed to the bot-
tom dead center.
2. Clean the carbon off the top wall of the cylinder liner with fine
sandpaper.
3. Mark each of the connecting rod caps’ (1) assembly position on

respective cylinders.
H Before removing the piston and connecting rod assembly,
measure the side clearance between the connecting rod
and crankshaft using tool K.
4. Remove bolt (2).
5. Tap connecting rod cap (1) with a plastic hammer lightly, and
remove connecting rod cap (1) and connecting rod bearing as a unit.
50-159 I
6. Push in and remove the piston and connecting rod assembly with a
wood bar from the oil pan side, while supporting piston (6) on the
cylinder head side.
H Take care in the removal so that inner surface of the cylinder
liner may not be damaged by corners of the connecting rod.
H Mark each piston and there direction as they are removed.
7. Remove the other piston and connecting rod assemblies according

to the above procedure.
H Take care not to damage the sliding portions of the pistons and
bearings.
H Disassemble the piston and connecting rod assembly according to

the following procedure.
B. Separate piston (6) from connecting rod by pulling out piston

wrist pin (5) while supporting connecting rod (4) with hand.
C. Remove the snap ring on the opposite side.
D. Using tool D, remove piston ring (7).
E. Keep the piston, connecting rod, connecting rod bearing, pis-

ton rings, and piston pin by cylinder.
CRANKSHAFT
H Before removing the crankshaft, measure its end play X with dial
gauge.
50-160 I
1. Remove mounting bolts (2) of main cap (1).
2. Insert the bolts in the bolt holes of main cap (1) and remove the cap,
while shaking it.
H Installation position numbers are marked on the main cap. No.
1 starts from the front side of the cylinder block.
H Make sure that markings (numbers are marked in section A) on

the main cap are faced to the oil cooler.
3. Remove bottom lower bearing (3) from main cap (1).

H Mark the installation position number on claw (A) of the
removed bearing. (Don't apply the number on the sliding
surface of the bearing.)
4. Lift off crankshaft (4) using the nylon sling.

H When lifting and removing the crankshaft, take care not to
damage it by bumping against the cylinder block.
H Keep the crankshaft in a safe place so that its sliding portions
will not be damaged.
Crankshaft: 60 kg (133 lbs)
50-161 I
5. Remove upper thrust bearing (5) and six upper bearings (6).
H Mark the assembly position on the main cap, upper bearing and
upper thrust bearing (in the claw of the bearing). It is advised
to maintain the bearings of a main cap separately from that for
another main cap. And take care not to damage these parts.
PISTON COOLING NOZZLES
1. Remove bolt (1) and then remove six piston cooling nozzles (2).
TAPPETS
1. Remove 12 tappets (1) and then mark the installation position on

them.
H When reusing the camshafts and tappets, be sure to install them
in the original position.
CYLINDER BLOCK
1. Remove cylinder block (1) from repair stand A.
Cylinder block: 140 kg (229 lbs)
50-162 I
12
ASSEMBLY OF ENGINE LOWER END
H This document describes the general assembly procedure of SAA6D107E-1. The shapes, quantity, locations, etc. of the
parts depend on each applicable machine.
H When reusing a part, be sure to install it to its original position.
PREPARATION WORK
1. Install tool B.
2. Install cylinder block (1) to repair stand A.
Cylinder block: 140 kg (229 lbs)
TAPPETS
1. Apply engine oil (EO15W-40) to tappets (1).
2. Install 12 tappets (1).

H When reusing the camshafts and tappets, be sure to install them
in the original position.
H Don't invert the cylinder block by 90o or more. Otherwise, the
tappet may fall off from the mounting hole during assembly.
PISTON COOLING NOZZLE

Set six piston cooling nozzles (2) and then tighten them using mounting
bolt (1).
Mounting bolt: 15 ± 2 N•m (11 ± 1.4 lbf/ft)
50-163 I
CRANKSHAFT
1. Install six upper bearings (6) and an upper thrust bearing (5).
H Set the projection of each bearing to the notch of the cylinder
block.
H When installing the bearings, check to be sure its back sides
are free from foreign matter.
H Apply engine oil (EO15W-40) to inner surface of metal. Don't
apply the oil to the backside.
H When reusing the bearings, check the marks made on them
when removed and install them to their original positions.
2. Using a nylon sling, lift up and install crankshaft (4).

H When installing, take care so that the upper thrust bearing may
not be damaged.
Crankshaft: 60 kg (133 lbs)
3. Fit lower bearing (3) to the main cap, matching the projection of the
former to the notch of the latter.
H Make sure ring dowel (7) is installed on the main cap.
4. Apply engine oil (EO15W-40) to the journal surfaces of the

crankshaft.
5. Before installation, check the number stamped on main cap (1).

H Installation shall start from the front side of the cylinder block
in a numerical order.
H In the installation, make sure the stamped number (section A)
is faced to the oil cooler.
H Push in each main cap by tapping it lightly with a plastic
hammer or rubber hammer.
6. Before tightening the main cap mounting bolt (2), check the
following.
A. Measure stem length (a) of every bolt to make sure that they
are within the using limit.
H Using limit length of bolt stem: Less than 120 mm (5.0 inches)
H If a bolt is longer than the using limit, do not reuse it but replace it.
50-164 I
12
7. Tightening procedure of main cap mounting bolts (2).
H Apply engine oil (EO15W-40) to the bolts.
H Tightening shall be done according to the sequence [1] o [14]

shown in the figure.
MAIN CAP MOUNTING BOLTS

H When current bolts are used again:
A. 60 ± 5 N•m (44 ± 4 lbf/ft)
B. 80 ± 5 N•m (59 ± 4 lbf/ft)
C. 90o ± 5o (when angle tightening tool J is used)
H When new bolts are used:
A. 120 ± 5 N•m (89 ± 4 lbf/ft)
B. Loosen by 360o
C. 60 ± 5 N•m (44 ± 4 lbf/ft)
D. 85 ± 5 N•m (63 ± 4 lbf/ft)
E. 120o ± 5o (when angle tightening tool J is used)
50-165 I
H When tool J is not used:
H After applying a paint marking to the main cap and bolt,
tighten the bolt by 90o ± 5o or 120o ± 5o.
1. After tightening the bolts, make sure that the crankshaft turns
smoothly.
2. Measure the end play of the crankshaft with a dial gauge.

H End play X: 0.24 ± 0.175 mm (0.01 ± 0.006 inches)
PISTON AND CONNECTING ROD ASSEMBLY

H Using tool D, fit piston rings (7) to the piston.
H Install rings
1. Set the oil ring so that its abutment joint comes in a position at 180o
to the end of expander (8).
50-166 I
2. Fit second ring (10) with the stamp of “TOP” near the abutment
joint up.
3. Fit top ring (11) with the “dot” mark near the abutment joint up.
4. When fitting each ring, set the abutment joint off the thrust,
anti-thrust, and piston axis directions.
5. Apply engine oil (EO15W-40) to piston ring and piston skirt.
6. Set the piston and connecting rod.

H When “FRONT” mark of piston (6) head is set at the top, con-
necting rod (4) must be facing to the direction shown in the fig-
ure.
7. Apply engine oil (EO15W-40) to the piston pin hole and piston pin.
8. Insert piston pin (5) and then assemble piston (6) to connecting rod
(4).
9. Install snap ring (3) to both sides.
50-167 I
10. Install the bearing to the connecting rod and connecting rod cap.
H Check to be sure back side of the bearing is free from foreign
matter.
H Fit the bearing to the connecting rod and cap, matching the
projection of the former to the notch of the connecting rod and
cap.
11. Set the crankshaft to the bottom dead center of the cylinder to
install the piston and apply engine oil (EO15W-40) to the inside of
the cylinder.
12. Insert the piston and connecting rod assembly setting “FRONT”
mark of piston to the front side of the cylinder.
H Check the directions of the abutment joints of the piston rings
again.
H When inserting the connecting rod, take care not to damage the
wall of the cylinder.
H When installing the assembly, take care so that it may tap the
cooling nozzle.
H Using tool E, reduce the piston rings and push in the piston
head with a wood bar, etc.
13. Install connecting rod cap (2) by tightening bolt (1) in the following
procedure.
H Apply engine oil (EO15W-40) to the threaded portions of the
bolts and inside of the connecting rod bearings.
50-168 I
H Mounting bolts (tighten both bolts alternately):
A. 30 ± 3 N•m (22 ± 2 lbf/ft)
B. 60 ± 5 N•m (44 ± 4 lbf/ft)
C. 60o ± 5o (when angle tightening tool J is used)
H When not using tool J:

Mark on the main cap and bolt with paint and then tighten the bolt
by 60° ± 5°.
14. After installing the piston and connecting rod assembly, rotate the
crankshaft to make sure that it turns smoothly without getting hung
up.
15. Measure the side clearance between the connecting rod and crank-
shaft with tool K.
H Side clearance: 0.10 - 0.33 mm (0.004 - 0.013 inches)
50-169 I
GEAR HOUSING
1. Apply gasket sealant to installation surface (A) of housing (2).
Housing: Gasket sealant (LG-7)
H Diameter of gasket sealant line shall be 1 - 2 mm (0.04 - 0.1

inches).
H Excessive gasket sealant can fill up blow-by oil groove (B).
Use care to avoid excessive use of the sealant.
2. Make sure that each dowel ring of the gear housing is correctly
inserted to the dowel hole at both the top and bottom (indicated
with. mark).
H Otherwise, they can be damaged when bolt-tightened.
3. Press the gear housing against the cylinder block so that its entire
mating surface with the cylinder block is closely contacted.
H Don't apply torque to the mounting bolts until the entire mating
surface is closely contacted.
4. Tighten the mounting bolts.
A. Bolts tightening procedure:
i. Tighten the bolts according to the numbers [1] › [10]

shown in the figure.
ii.
Four types of bolts are used. Make sure when tightening
that specified torque is applied.
H Mounting bolt:
• M12: 77 ± 7 N•m (57 ± 5 lbf/ft)
[No marking]
• M10: 43 ± 5 N•m (32 ± 4 lbf/ft)
[ mark = 30, q mark = 50]
• M8: 24 ± 4 N•m (18 ± 3 lbf/ft)
[E mark]
50-170 I
CAMSHAFT
H Rotate the crankshaft to set the No. 1 cylinder to the top dead cen-
ter.
1. Apply engine oil (EO15W-40) to the camshaft bore, camshaft

journal and lobed surface. Then lightly push in and rotate camshaft
(3) to install.
2. Install thrust plate (2).
3. When installing, fit in the thrust plate to timing mark A on camshaft

gear (1) as well as to the chamfered tooth (a single location) of
crankshaft gear (4).
4. Measure the end play and backlash of the camshaft with a dial
gauge.
H End play: 0.10 - 0.36 mm (0.004 - 0.014 inches)
H The end play is determined by thickness of the thrust plate and
groove of the camshaft.
H Backlash: 0.076 - 0.280 mm (0.003 - 0.011 inches)
50-171 I
FLYWHEEL HOUSING
1. Install flywheel housing (2) using bolt (1).

H Apply gasket sealant (LG-7) to the flanged housing installation
surface as well as circumference of the mounting bolt hole.
inches).
Bolts Tightening Procedure
H Tighten the bolts according to the numbers [1] › [20] shown

in the figure.
H Two types of bolts are used.
H Make sure when tightening that the specified torque is used.
• M12: 85 ± 10 N•m (63 ± 7 lbf/ft) [E mark]
• M10: 49 ± 5 N•m (36 ± 4 lbf/ft) [T mark]
1. After installing the flywheel housing, measure the radial run out
and facial run out with tool L.
H Radial run out: Max. 0.20 mm (0.007 inches)
H Facial run out: Max. 0.20 mm (0.007 inches)
Measurement Of Radial Run Out
A. Install tool L to the crankshaft end face.
B. Contact the probe of the dial gauge at right angle against part
of the flange joint of the flywheel housing.
C. Set graduations of the dial gauge to “0” and then rotate the
crankshaft by a turn to measure differences in the maximum
deflections of the gauge pointer.
D. Make sure after rotating the crankshaft by a turn that the gauge pointer is returned to the position where it had situated
when the crankshaft started to turn.
Measurement Of Facial Run Out
A. As in measuring the radial run out, contact the probe of the dial
gauge at right angle against the end face of the flywheel hous-
ing.
H Before conducting the measurement, move the crankshaft
either in the front or rear side in order to prevent errors due
to the end play.
B. Set graduations of the dial gauge to “0” and then rotate the
crankshaft by a turn to measure the difference in the maximum
deflections of the gauge pointer.
50-172 I
12
REAR OIL SEAL
1. Insert pilot [2] to rear oil seal (4).

H Before inserting the pilot, clean, de-grease and dry the oil
seal lip surface.
2. Insert oil seal (4), together with pilot [2], to the crankshaft and then
push in the seal carrier of oil seal (4) to the flywheel housing (1).
H Before inserting the oil seal, clean, de-grease and dry the sur-
face where the seal is contacted against the crankshaft.
3. Pull out pilot [2] and then further push in oil seal (4).
4. Using tool G, insert the oil seal to an appropriate depth.
H When pushing in the oil seal, make sure that the seal carrier is
free from bending.
H Installed dimension X = Max. 0.38 mm (0.015 inches)
50-173 I
FLYWHEEL
1. Install guide bolt [1] and flywheel (1).

H Apply gasket sealant to the circumference of the bolt hole
(eight locations) on the mounting surface of the crankshaft.
inches).
Flywheel mounting surface: Gasket sealant (LG-7)
Flywheel assembly: 35 kg (77 lbs)
2. Tighten the mounting bolts in the order indicated in the figure.
3. After installing the flywheel, measure the radial run out and facial
run out with tool L.
H Radial run out: Max. 0.13 mm (0.005 inches)
H Facial run out: Max. 0.20 mm (0.01 inches)
Measurement Of Radial Run Out
1. Install tool L to the flywheel housing.
2. Contact the probe of the dial gauge at right angle against section (a)
of the flange or periphery of the flywheel housing.
3. Rotate the flywheel by a turn to measure the differences in the max-

imum deflections of the dial gauge pointer.
4. Make sure after rotating the flywheel by a turn that the dial gauge pointer is returned to the position where it had situated
when the flywheel was started to turn.
Measurement Of Facial Run Out
1. As in measuring the radial run out, contact the probe of the dial gauge at right angle against end face situated near the
periphery of the flywheel housing.
H Before conducting the measurement, move the crankshaft either in the front or rear side in order to prevent errors due
to the end play.
2. Rotate the flywheel by a turn to measure the differences in the maximum deflections of the dial gauge pointer.
50-174 I
OIL PUMP
1. Fill up the oil pump rotor space and the idler shaft bore with engine
oil (EO15W- 40) and then rotate the rotor by two turns.
2. Install oil pump assembly (2) with bolts (1).
3. Tighten the mounting bolts in the order indicated in the figure.

H Mounting Bolt
1st time: 8 ± 1 N•m (6 ± 1 lbf/ft) (Fig.a)

2nd time: 24 ± 4 N•m (18 ± 3 lbf/ft) (Fig.b)
Measurement Of Backlash
1. Move gear on each side and then measure backlash (C) of the pump
and idler gear.
H Magnitude of backlash (C): 0.2 ± 0.05 mm (0.01 ± 0.002
inches)
50-175 I
FRONT COVER
1. Apply gasket sealant to installation surface (A) of cover (2).
Front cover: Gasket sealant (LG-7)

inches).

in the figure.
1. Using tool H, install front seal (3).

H Before installing the seal, check to be sure end corners and lip
sliding surfaces of the crankshaft are free from flaw, burr, and
rust of the housing.
H When installing the seal, do not apply oil or grease to the shaft
and seal lip.
H Wipe off the oil from the shaft.
50-176 I
H When measured from cover (2) of seal (3):
H Extrusion (x): Max. 0.38 mm (0.015 inches)
H Facial run out (TIR) (y): Max. 0.25 mm (0.01 inches)
OIL PAN
1. Install plate (4) and 3 plates (5).
2. Install suction tube (3).
Flange mounting bolt: 24 ± 4 N•m (18 ± 3 lbf/ft)
3. Apply gasket sealant to installation surface (A).
Oil pan: Gasket sealant (LG-7)
H Diameter of gasket sealant line: Straight line: 3 mm (0.12

inches), curved line: 1 mm (0.04 inches)
4. Install oil pan (2) with bolts (1).
50-177 I

in the figure.
VIBRATION DAMPER
1. Install damper (2) by fitting in its knock hole to dowel pin (a) of the
crankshaft.
Bolt (1) Tightening Procedure
H Tighten the bolt's opposing corner sequentially with 55 ± 5

N•m (41 ± 4 lbf/ft).
H Loosen the bolt by 180o.
H Tighten the bolt's opposing corner sequentially with 55 ± 5
N•m (41 ± 4 lbf/ft).
H 90o ± 5o (When angle tightening tool J is used)
1. When the angle tightening tool is not used:

H After applying a paint marking to the vibration damper and
bolt, tighten the bolt by 90o ± 5o.
50-178 I
12
INSTALLATION OF OIL COOLER, ENGINE CONTROLLER AND FUEL PUMP
FUEL SUPPLY PUMP
1. Install supply pump (3) with three nuts (2).
Mounting nut: 24 ± 4 N•m (18 ± 3 lbf/ft)
2. Install hose (1).
ENGINE CONTROLLER
1. Install cooling plate assembly (2) with three bolts (4).
2. Install engine controller (1) with five bolts (5).
3. Connect ground cable (3).
OIL COOLER
1. Using bolts (6), install gaskets (5) and (3), oil cooler (4) and cover
(2).
50-179 I
H Tighten the bolts according to the numbers shown in the figure.
2. Install oil filter (1).

H Apply engine oil (EO15W-40) on the sealed portion.
Filter: 13 ± 2 N•m (10 ± 1.5 lbf/ft)
3. Or tighten the bolt by a 3/4 turn after contact is made.
50-180 I
12
ASSEMBLY OF ENGINE TOP END
parts depend on each applicable machine. Take care.
H When reusing a part, be sure to install it to its original position.
CYLINDER HEAD
1. Assemble the cylinder head assembly according to the following

procedure.
A. Install valve seal (7).
B. Apply engine oil (EO15W-40) to the valve stem and inside of

valve guide and install valve (6).
C. Raise the cylinder head and install valve spring (3) and upper
seat (5).
D. Using tool C, compress valve spring (3) to install valve cotter

(4).
H Tap the valve stem lightly with a plastic hammer to make
sure that the valve collet is positively fitted to the groove
of the valve stem.
50-181 I
2. Before tightening the cylinder head mounting bolt, check the
following.
H Measure stem length (a) of every bolt to make sure that they
are within the using limit.
H Using limit length of bolt stem (a): Max. 132.1 mm (5.20
inches)
H If a bolt is longer than the using limit, do not reuse it but
replace it.
3. Check to be sure cylinder head mounting face and inside of the

cylinder are free from foreign matter and then set cylinder head
gasket (8).
H Make sure that the gasket is fitted in the hole on the cylinder
head.
4. Set cylinder head assembly (2) on the cylinder block and then
tighten it using mounting bolts (1).
5. First, tighten the mounting bolts by 2 - 3 turns or more by hand, and

then tighten them according to the following procedure. Apply
engine oil (EO15W-40) to the threaded portion and head seat of
each bolt.
6. Tighten the bolts in the order shown below.

H 90 ± 3 N•m (66 ± 2 lbf/ft)
H 90 ± 3 N•m (66 ± 2 lbf/ft)
H 90o ± 5o (When tightened with angle tightening tool)
50-182 I
H When the angle tightening tool is not used:
7. After applying a paint marking to the cylinder head and bolt,

tighten the bolt by 90o ± 5o.
FUEL INJECTORS
H Make sure that the injector sleeve is free from damages or dirt.
1. Attach the gasket and O-ring to injector (2).
2. Apply engine oil (EO15W-40) to the O-ring of injector (2) as well

as the head side.
3. Insert injector (2) to the cylinder head while directing its fuel inlet
hole to the manifold.
4. Install holder (4) and then tighten bolt (3) three to four threads.
5. Apply engine oil (EO15W-40) to the O-ring of inlet connector (1) as well as the head side.
6. Install inlet connector (1) temporarily (push it into the injector hole).
7. Tighten bolts (3) alternately.
Bolt: 8 ± 0.8 N•m (6 ± 0.6 lbf/ft)
8. Tighten retainer (5).
Retainer: 50 ± 5 N•m (37 ± 4 lbf/ft)
50-183 I
12
PUSH RODS
1. Install push rod (1).

H Check to be sure push rod is fitted in the tappet.
H Refill the push rod socket with engine oil (EO15W-40).
ROCKER ARM ASSEMBLY
1. Install cross head (3).
2. Install rocker arm assembly (2) and tighten bolts (1).

H Before tightening the mounting bolts, check to be sure ball of
the adjustment screw is fitted to the socket of the push rod.
Bolt: 36 ± 5 N•m (27 ± 4 lbf/ft)
H Shape of the holes (a) and (b) on the cross head is not identical.
Thus when using this part again, the same air intake and
exhaust valves must be assembled in the same direction.
ADJUSTING VALVE CLEARANCE
1. Adjust the valve clearance according to the following procedure.
A. As the valve clearance, adjust the clearance between the

cross head and rocker arm to the following value.
2. Valve clearance (when cold)
Unit: mm
Intake valve Exhaust valve
0.25 ± 0.05 0.51 ± 0.05
3. While watching move of the rocker arm, rotate the crankshaft for-
ward to set No. 1 cylinder to compression top dead center (T.D.C).
Above operation shifts the stamped (T.D.C) of the vibration damper
to the directly above position.
H When the No. 1 cylinder is at the compression top dead center,
the rocker arm of the No. 1 cylinder can be moved by the valve
clearance with the hand. If the rocker arm cannot be moved,
rotate the crankshaft one more turn.
50-184 I
12
4. While the No. 1 cylinder is at the compression top dead center,
adjust the valve clearances marked with l in the valve arrangement
drawing.
5. Insert clearance gauge K between rocker arm (3) and cross head (4)
and tighten adjustment screw (5) to the degree that the clearance
gauge can be moved lightly.
6. Tighten locknut (5) under this condition.
Locknut: 24 ± 4 N•m (18 ± 3 lbf/ft)
H After tightening the locknut, check the valve clearance again.

H After adjusting every l marked valve, rotate the crankshaft
forward one turn to set No. 6 cylinder to the compression top
dead center with the stamped (T.D.C) of the vibration damper
being located at the directly above position.
7. While the No. 6 cylinder is at the compression top dead center, adjust the valve clearances marked with m in the valve
arrangement drawing.
H Adjust the valve clearance according to steps 3 and 4 above.
VALVE COVER HOUSING
1. Install cover assembly (6) with bolt (5).
2. Install nuts (4) of the harness.

H Harness installation position
Color of cable Cylinder No.

White 1,3,5
Black 2,4,6
Mounting nut: 1.5 ± 0.25 N•m (1.1 ± 0.2 lbf/ft)
50-185 I
3. Fit the gasket and then install head cover (3) using nut (2).
4. Install duct (1).
AIR INTAKE MANIFOLD COVER
1. Fit the gasket and then install manifold covers (3) and (4).
2. Fit the gasket and then install tube (1) and electrical intake air
heater (2).
Tube mounting bolt: 24 ± 4 N•m (18 ± 3 lbf/ft)
Fuel Piping And Common Rail
WARNING!
• It is prohibited to bend high-pressure pipings
used.
• The clamps used for attach high-pressure
pipings must be the genuine part.
• And the specified tightening torque must be
strictly observed.
• A clearance of 10 mm (0.5 inches) minimum
must be provided between the installed high
pressure piping and harness.
H Fuel leakage can occur on a high-pressure piping that has visible lengthwise slits (b) or dents such as patchy damages (c)
on its taper seal of the piping connection (part (a): 2 mm (0.1 inches) space from the tip). The same holds true for a high-
pressure piping that catches claw because of fatigued steps in part (d) (end of the taper seal: a 2 mm (0.1 inches) space
from the tip). Such high-pressure piping must be replaced.
1. Temporarily install common rail (10) and high-pressure pipings (1) to (7).
Mounting nut and bolt: 0.2 - 0.8 N•m (2.0 - 7.0 in/lbs)
50-186 I
2. Tighten high-pressure pipings (1) to (7) according to the following
procedure.
Mounting nut: 35 ± 3.5 N•m (26 ± 3 lbf/ft)
A. Head side of high-pressure pipings (6) and (1)
B. Rail side of high-pressure pipings (6) and (1)
C. Head side of high-pressure pipings (2) › (3) › (4) › (5)
D. Rail side of high-pressure pipings (2) › (3) › (4) › (5)
E. Pump side of high-pressure piping (7) and then its rail side
3. Tighten the clamp of high-pressure piping (7).
4. Tighten common rail (10) with four bolts.

H Apply sealant (LG-7) to the threaded part of two bolts inside the engine.
5. Install boots (9) (14 pieces).

H Set the slits of each boots out and down.
H The boots are installed so that fuel will not spout over the hot parts of the engine and catch fire when it leaks for some
reason.
6. Install fuel drain hose (8).
Joint bolt: 24 ± 4 N•m (18 ± 3 lbf/ft)
50-187 I
12
ASSEMBLY OF EXTERNAL COMPONENTS
parts depend on each applicable machine.
PREPARATION WORK
H Before assembling the final parts. Clean and carefully inspect all parts and assemblies for wear or damage.
HARNESS ASSEMBLY
1. Connect harness assembly (1) to the controller and sensor and then
install it to the engine.
WARNING! Before connecting the harness

connector, clean sands, dusts or water
in the controller side connector.
FUEL FILTER ASSEMBLY
1. Install filter bracket assembly (4).
2. Install drain hose (3) to the filter bracket.
3. Install filter inlet hose (1) and outlet hose (2).
4. Install fuel filter (5).

H As the gasket touched the filter head, tighten the bolt 1/2 turn
to install it.
EXHAUST MANIFOLD AND TURBOCHARGER
50-188 I
1. Fit the gasket and then install exhaust manifold (4) to the cylinder
head. Tighten the mounting bolts according to the numbers shown
in the figure.
Mounting Bolts Tightening Procedure:
H Tighten every bolt with 24 ± 4 N•m (18 ± 3 lbf/ft).

H Tighten every bolt with 53 ± 6 N•m (39 ± 4 lbf/ft).
H Tighten [1] to [4] bolts alone in the figure in this order with 53
± 6 N•m (39 ± 4 lbf/ft).
1. Fit the gasket and install turbocharger assembly (3).
H Tighten the mounting nut in the diagonal position alternately.
2. Install turbocharger lubrication inlet tube (1).
3. Fit the gasket to the turbocharger side and then install drain tube
(2).
WATER PUMP
1. Attach the seal ring and then install water pump (2).
2. Attach the seal ring and then install coolant inlet connector (1).
THERMOSTAT
1. Install thermostat (2).
50-189 I
2. Install coolant outlet connector (1).
ALTERNATOR
1. Install front side sling bracket (5) and alternator bracket (4).
2. Install alternator (3) temporarily using mounting bolt (2).
3. Install plate (1).
4. Tightening alternator mounting bolt (2).
FAN HUB
1. Install fan hub (2) with mounting bolt (1).
50-190 I
12
BELT TENSIONER
1. Install tensioner (2) with mounting bolt (1).
2. Check visually or using a ruler, that the belt mounts of the tensioner
pulley and alternator pulley are parallel.
FAN PULLEY
1. Install fan pulley (4) with mounting bolt (3).
2. Install fan belt (1).
3. Install tensioner (2) rotating it in the direction opposite to the hoist-

ing direction.
ENGINE SLING BRACKET ON REAR SIDE
1. Install engine sling bracket (1) to the cylinder bracket.
STARTER MOTOR
1. Fit the gasket and then install starting motor assembly (2) with bolt
(1).
2. Apply 1 mm (0.1 inch) wide gasket sealant (LG- 7) to the entire cir-
cumference of the front and back sides of the gasket.
50-191 I
Removal From Engine Repair Stand
1. Lift engine assembly (1) temporarily and then separate it from

repair stand A.
Engine assembly: Approximately 520 kg (1,146 lbs)
H (The weight depends on the applicable machines.)
2. Remove tool B.
3. Set engine assembly (1) on stable engine stand [1] provided on both
sides.
4. Install oil gauge assembly (2).
REFILLING WITH OIL
1. Check to be sure engine oil drain plug is tightened.
2. Add oil through the oil filler to the specified level.
Engine oil pan: Approximately 23 liters (6.1 gal.)
50-192 I
12
MEMORANDUM
50-193 I
DISASSEMBLY AND ASSEMBLY TRACK SYSTEM
12
TRACK SYSTEM
WARNING! Be extremely careful when removing machine tracks, be sure you have the proper
equipment and a flat hard level surface before preceding with any removal
procedures. Failure to do so may result in damage to the machine or personal
injury.
SPECIAL TOOLS
Distinction
Necessary
Sketch
Qty.
20 791-630-3200 Remover n 1
F 21 790-101-1300 Jack (100 tons) n 1
22 790-101-1102 Pump n 1
SPREADING THE TRACK

(CONVENTIONAL TYPE TRACK SHOE)
1. Position the master link properly.
H Start the engine and position each master link in front of the
idler.
H Set a block, jack, etc. under the track shoe in front of each idler.
2. Remove mounting bolts and cover (1).
3. Loosen lubricator (2) to lower the tension of the track shoe.
WARNING! Since the pressure in the recoil spring

cylinder is very high, do not loosen the
lubricator more than one turn. If the
track tension is not lowered, move the
machine forward and in reverse.
50-194 I
4. Remove the track shoe of master link (3).
H Pull both sides of the master link with wires and chain blocks
and remove the master link bolts to disconnect the master link.
5. Guiding the track link end with a crane, move the machine slowly
in reverse to spread the track shoe assembly (4).
50-195 I
12
EXPANSION AND INSTALLATION OF TRACK SHOE ASSEMBLY
(PLUS TYPE TRACK SHOE)
H In this section, the points different from the conventional type track shoe are described.
EXPANSION NORMAL
H For details of expansion and installation of the track shoe assembly, see "Expansion and installation of track shoe assem-
bly (conventional type track shoe)" which is also applicable to the track shoe assembly of the PLUS type track shoe.
INSTALLATION
H Install the master link shoe according to the following procedure.
Set and install the shoe so that master link (1) and shoe grouser (2)
will be positioned as shown on the right.
%&#
H Tighten the master link shoe bolts according to the following proce-
dure.
• Tighten all 4 shoe bolts (3) with the fingers until master link
mating faces (a) are fitted.
• If shoe bolts (3) are tightened forcibly before master link mat-
ing faces (a) are fitted, their threads and master link threads
may be damaged.
• Tighten 4 shoe bolts (3) in the following order.

Shoe bolt:
Molybdenum disulfide lubricant (LM-P)
Shoe bolt (Master link)
Initial torque: 294 ± 29 Nm {30 ± 3 kgm}
Retightening angle: 180 (+0/-20)o
50-196 I
WHOLE DISASSEMBLY AND ASSEMBLY OF TRACK SHOE ASSEMBLY

SPECIAL TOOLS
New/remodel
Necessity
Symbol Part No. Part name

Sketch
Q’ty
1 791-646-7351 Remover n 1
2 791-660-7460 Pin brush n 1
791-432-1110 Plug push tool n 1
3 791-646-7550 Bar n 1
791-646-7560 Guide n 1
R 790-701-3000 Seal checker
4 or n 2
791-601-1000 Oil pump
791-932-1110 Push tool n 1
5 791-646-7523 Bar n 1
791-646-7590 Guide n 1
WHOLE DISASSEMBLY
H This section describes only the procedure for the lubricated track.
1. Sling the shoe assembly and set it with the shoe up on the floor
and remove the shoe of regular link by using an impact wrench.
H When moving the shoe assembly, take care not to damage
the master link.
H If it is obliged to cut a shoe nut with gas cutter, keep the
seal temperature below 80°C to prevent thermal deteriora-
tion of the seal and take measures to prevent the spatters
from entering through the clearances among the links.
50-197 I
2. Oil drain
Before disassembling the link assembly, drain the oil from
inside the pin and take precautions so that the link press does
not become dirty with oil.
H Before disassembling, if it is judged that it is necessary to
rebuild the track as a dry type track, the following work
need not be carried out.
A. Set the link assembly on a flat floor with the large plug
side facing up, then chamfer the burrs on the end face of
the pin with a grinder.
H If the shoe is disassembled with burrs still at the end
face of the pin, the pin press-fitting hole of the link
will be scratched, and this will cause leakage from the
pin press-fitting portion after rebuilding.
B. Using a drill (ø10 mm), make a hole in the large plug, then
remove the large plug.
H If any dirt or deteriorated oil is stuck to the pin hole,
drill through with a longer drill to remove it. When
doing this, be careful not to damage the oil hole of the
pin.
C. After removing the large plug, use a baby grinder (angle of

grinder tip: 45 – 60°), and chamfer the pin hole so that the
plug is not damaged when the plug is knocked in.
50-198 I
D. Turn over the link assembly so that the small plug side is
facing up, remove the burrs at the end face of the pin with
a grinder, then use tool R1 to knock the small plug to the
inside.
H If the small plug hole is blocked with burrs, grind with
a grinder until the hole can be seen completely.
E. Using a drill (ø10 mm), chamfer the small plug hole.
F. Blow with compressed air to remove the oil inside the pin
and the metal particles produced when removing the burrs,
then wash the link assembly with high-pressure water or
steam.
3. Disassembly of link
A. Set the link assembly on a link press and hit it with a ham-
mer so that the bushing will be fitted to jaw [1].
H If the link tread, outside diameter of the bushing, etc.
are worn, adjust the height of jaw [1] or guide plate
and align the left and right disassembly jig [2], [3]
with the pin and bushing center so that the link hole
will not be damaged during disassembly work.
H If the pin and bushing are not aligned well, the link
hole may be damaged and the pin and bushing may be
broken during disassembly work.
B. Operate the left cylinder to pull out the pin and bushing
press-fitting portion from the left link simultaneously.
H Check the pulling out force of the pin and bushing to
see if the necessary press fitting force for the pin and
bushing can be obtained when reversed and assembled
again.
H Do not push the disassembly jig inside more than nec-
essary as the spacer may break.
C. Return the left cylinder and operate the right cylinder to

pull out the pin and bushing press-fitting portion from the
right link simultaneously.
50-199 I
D. Return the right cylinder and take out the links, pins, bush-
ings, and spacers on both sides and feed the next 1 set of
the link assembly to the jaw.
H To decide if the seal can be used again, carry out
inspection with the seal installed to the link. So do not
remove the seal from the link.
H If oil is remaining, this can be used as a guideline for
reuse of the seal, so mark such links or seals.
H If the bushing ends and sealing surfaces are damaged,
oil will leak. Accordingly, handle them carefully.
4. Inspection
Check the parts for the following items to see if they can
be used for a lubricated track or a grease-filled track, then
examine them generally and determine to use them for a
lubricated track or grease-filled track.
H For judgment of reuse of the parts, see Guidance for
Reusable Parts, "Undercarriage, Lubricated Track".
A. Visually check damaged state of pin, bushing, link and

spacer. Check questionable parts with color check or
magnetic flaw detector. Cracked parts are not reus-
able. Scrap them.
B. Visually check the external appearance of the seal and

the end face of the bushing to determine if they can be
used again.
H If only the bushing is replaced with a new part, the worn or damaged part of the seal lip will contact the end face
of the bushing directly, so it may not be able to carry out its sealing function. For this reason, always replace the
seal together with the bushing, or rebuild as a grease-filled track.
C. Using calipers, measure spacer thickness (a) and overall length (b) of the sliding portion of the bushing and spacer.
Check if it is possible to obtain the specified seal mounting dimension when reassembling.
H If the amount of wear of the spacer and bushing is greater than the specified amount, the assembly precision of
the seal portion cannot be guaranteed, so replace with new parts or rebuild as a grease-filled track.
D. Using calipers, micrometer and cylinder gauge, measure

the outside diameter of the pin and the inside diameter of
the bushing at the worn portion, and judge if the parts can
be used again.
H If the amount of wear is greater than the specified
amount, there will be play during travel, and it will
cause oil leakage, so replace with new parts or rebuild
as a grease-filled track.
H For details of the dimensions when making judgment,
see "Structure, function and maintenance standard".
50-200 I
E. Using a micrometer and cylinder gauge, measure the out-
side diameter of the pin and bushing press-fitting portion,
and the inside diameter of the pin and bushing press-fitting
portion of the link to determine if the allowable interfer-
ence can be obtained. However, when rebuilding as a
lubricated track, check that the standard interference for
the pin and the link can be obtained.
H If the allowable fitting interference is not obtained,
replace the parts with new ones or over size parts.
H For details of the dimensions when making judgment,
see "Structure, function and maintenance standard".
H Precautions for storage
i. Store the seal without removing it from the link so that the counterbore portion will not be rusted and take care
not to damage the seal lip.
ii. Apply rust-preventive oil to the pin and bushing fitting parts, shoe mating surface, and master link mating sur-
face of the link.
iii. When storing, apply rust-preventive oil to the all surfaces of the pin, bushing, and spacer. Take care not to dam-
age the ends of the bushing in particular.
50-201 I
WHOLE ASSEMBLY
1. When reusing for lubricated track
A. (Preparation work)
i. Cleaning seal assembly
ii. When reusing the pin, chamfer the corner of the end
face smooth with a grinder. Use a grinder to remove
any protruding parts stuck to the press fitting portion.
H If the ends are worn and sharpened, they may
scuff the press fitting parts and cause oil leakage.
iii. Mark ※ on the end face at the small plug end to show
the direction of the side hole (hole in the radial direc-
tion) in the pin when assembling.
H When reusing the pin, assemble in the same
direction as when the part is new (side hole on the
link tread side).
iv. If any link, pin, bushing and spacer are dirty, wash
them. Use a grinder to remove any protruding parts
stuck to the ring and bushing.
H Since these parts rust easily, clean them just
before assembling them.
H Use tool R2 to wash the pin hole.
H Do not polish the bushing ends. If they are pol-
ished, oil may leak.
50-202 I
v. Using tools R3, drive in large plugs (3).
H Coat the outside circumference of large plug (3)
with oil (GO90) and knock in the smaller diame-
ter part first.
1> Insert large plug (3) into the guide hole through the
plug insertion window.
2> Push the bar of tool R3 with the hand until the
large plug stops.
3> Push large plug (3) with the bar of R3 and push the
pin to the guide itself.
4> Drive in the bar with a hammer.
H Driving distance (a) from pin end:
6 ± 2 mm
H If the chamfered part of the pin hole has been worn, chamfer it with a small-sized grinder (grindstone tip
angle: 45 – 60°) so that the plug will not be damaged.
vi. Installation of seal assembly

• When reusing the link and replacing the seal with
a new part, clean the link counterbore (section
(A)) then push the seal in fully to the bottom.
H If oil or grease is sticking to the counterbore por-
tion of the link and seal assembly, the seal will
turn and its sealing performance will lower.
Accordingly, do not apply any oil or grease to that
portion. In addition, be careful not to let oil get
into the counterbore portion of the seal when
pushing in.
vii. Adjust the dimensions of the press fitting jig of the

link press to keep the projection of the pin and bush-
ing constant and keep the installed dimensions of the
seal within the standard range.
H For details of the standard dimensions, see "Link
press-fitting jig dimensions table".
H To leave a small space for the pin when assem-
bling, ensure that the dimension (dimension (a'))
is greater than dimension (a) at the pin pushing
portion of the left press-fitting jig.
H When assembling in order of [1] press fitting left
link and [2] press fitting right link, provide the
extra space for the pin on the right press-fitting
jig.
50-203 I
H If the pin end (part (P)) or link sides (parts (Q)
and (R)) are worn, add the dimensions of the
worn parts to the standard dimension when
adjusting the dimension of the press-fitting jig so
that the projections of the left and right pins and
bushings on both sides will be even.
viii. Adjust the relief pressure of the link press so that the
pressing force of the press will not exceed the stan-
dard value.
H If the pressing force is too strong, the spacer will
be pressed forcibly against the bushing. As a
result, the spacer may be broken and it and bush-
ing may be worn abnormally.
H If the interference at the press-fitting portion is different from when the part is new, as when reusing a pin or
bushing, measure several of the press-fitting portions, and determine the set pressing force according to the
average interference.
H Pushing force for pin and bushing: 392 kN {40 tons}
Pushing force C 1.8 x average press-fitting force (Adjust the relief pressure of the link press and set the push-
ing force).
B. Assembly of link
i. Apply oil (GO90) to the mating surfaces of the pin

and bushing with a clean brush and assemble them,
then set them before the jaw of the link press.
H When reusing (reversing) the bushing, set the
worn outside surface of the bushing on the shoe
fitting side of the link (facing upward on the link
press).
50-204 I
ii. Press fit the master links on both bushing sides to the
bushing with the shoe fitting surface facing up.
H At this time, use the master links on the pin side
as supports.
H Press fitting force for bushing:
49 – 147 Nm {5 – 15 tons}
iii. Using the shoe bolt hole pitch gauge, press fit the mas-
ter links until the distance between the shoe bolt holes
of both links is the standard value.
H Remove the all steel chips caused by press fitting
of the bushing with compressed air.
iv. Turn over the master links and check that they are
press fitted in parallel.
v. Measure the projections of the bushing on both sides

with a depth gauge.
H Adjust the press fitting jig of the link press so that
the projections on both sides will be even.
vi. Feed the master links and set the next pin and bushing.
H When reusing a pin, install it so that the side hole
will be on the link tread side similarly to a new
one. If it is not installed as specified, its strength
may be lowered. Accordingly, indicate the direc-
tion of the side hole (i) on the end face to prevent
a mistake.
H Align the large plugs so that they are on the left
side facing the link press when assembling.
Di r ec t i o n o f
si de hol e
50-205 I
vii. To prevent oil from leaking out from scuff marks on
the pin press-fitting portion, coat the pin press-fitting
hole in the link and the outside diameter of the pin
press-fitting portion with gasket sealant (198-32-
19890).
viii. Set the right link and install the spacer to the pin.
H Check that there is no dirt or dust stuck to the sur-
face of the seal or the end face on the bushing,
then coat with oil (GO90) using a clean cloth or
small brush.
H When installing the spacer, wipe it with a clean
cloth.
ix. Set the right jig on the receiving side and the left one
on the pushing side and press fit the pin and bushing
simultaneously.
H If the pin and bushing have play when they are
press fitted, the seal may come off the link. To
prevent this, press fit smoothly.
If the seal comes off the link, stop press fitting
and set the seal to the link correctly, then start
press fitting again.
H Press-fitting force for pin and bushing:
147 – 294 kN {15 – 30 tons}
x. Using spacer [6] for fine adjustment, press fit the pin
and bushing until the pin end is fitted to the bottom of
the receiving jig.
H Adjust the depth of the receiving jig hole so that
the projections of the pin on both sides will be
even.
50-206 I
xi. Set the right link and install the spacer to the pin.
H Apply oil similarly to the right link.
xii. Set the left jig on the receiving side and the right one
on the pushing side and press fit the left link.
H When press fitting, take care that both seals and
spacers will not come off.
H Provide enough play on the left jig so that the end
face of the pin does not contact with the bottom of
the jig.
H Press-fitting force for link:
147 – 294 kN {15 – 30 tons}
xiii. Press fit until the link, spacer, and bushing are fitted
together.
H Actually, you cannot see from outside if the above
parts are fitted. Accordingly, control the hydraulic
pressure of the link press. Set the relief pressure
to a proper level and heighten the hydraulic pres-
sure to that level.
H For setting of the relief pressure, see "1) Prepara-
tion work."
H Check that adjacent links swivel freely in relation
to each other.
xiv. After assembling each link, use a dial gauge and pinch
bar to measure the end play with a preceding link to
check that the link is assembled within the specified
value.
H If the end play does not come within 0 to 0.13
mm even when applying the pushing force until
the relief valve is actuated, raise the relief pres-
sure setting gradually to adjust.
H Adjust the relief pressure setting carefully and be
sure not to raise the pushing force of the link
press higher than necessary.
50-207 I
xv. Using a shoe bolt hole pitch gauge, measure the dis-
tance between the shoe bolt holes and check that the
result is within the standard range.
H If the distance between the shoe bolt holes is lon-
ger than the standard range, disassemble and
check for abnormality, then press fit again.
H If the distance between the shoe bolt holes is
shorter than the standard range and the shoe can-
not be installed, the spacer or bushing end may be
worn more than the allowable limit. In this case,
disassemble and replace the parts.
H If the end play is too large, the sealing perfor-
mance will drop, so set the end play to a small
value.
xvi. After each link is assembled, bleed air from the pin by
using tool R4 and check the sealing performance.
H Hold the space inside the pin at a vacuum of 92.7
± 2.0 kPa {695 ± 15 mmHg} for 5 seconds and
check that there is no change in pressure.
If the pressure changes, disassemble and check
the seal for any abnormality, then assemble again. R4
xvii.Assemble the master link on the pin side at last.

H Check that the master links on both sides are press fitted in parallel.
C. Charging with oil

After completion of assembly of the link assembly, add oil
through the pin hole.
i. Using tool R4, remove the air inside the pin from the
small plug hole. Set to a vacuum of 92.7 ± 2.0 kPa
{695 ± 15 mmHg}, then fill with oil (GO90) until the
pressure is 0.2 to 0.3 MPa {2 to 3 kg/cm2}.
H In cold or very cold areas, instead of GO90, fill
with Komatsu genuine oil (150-09-19270) which
has excellent low-temperature qualities.
H If the oil pressure is heightened too much, it has 4 A
bad effects on the seal. Take care.
50-208 I
H To determine the oil amount, set the large plug
end (B) facing downward (stand the link assem-
bly on its side), leave for 30 minutes, then fill
with oil so that depth (J) of the space at the pin
hole is within the specified value below:
Dimension (J): 30 – 50 mm
ii. After supplying oil, drive in the small plug to the fol-
lowing specified position, using tool R5.
H Apply oil (GO90) around the small plug.
H The depth to knock in the plug is as follows.
Driving depth from end:
2.5 ± 1 mm
D. Installation of shoe
i. Set the link assembly on the bed and install the shoe
with a shoe bolt impact wrench and a torque wrench.
3Shoe bolt (regular link):
Initial torque:
196 ± 20 Nm {20 ± 2 kgm}
Tightening angle: 120 ± 10°
50-209 I
ii. Set 2 completely assembled portions of shoe on a flat
surface in a straight line with the shoes facing up. Pull
master link (5) at the pin end to master link (6) at the
bushing end, and set them at the mating surfaces.
Then put shoe (7) on top, check that shoe bolt (8) goes
in easily by hand, and connect the 2 parts with the
master bolt.
2 Shoe bolt: Lubricant containing
molybdenum disulfide (LM-P)
3 Shoe bolt (Master link):
Initial torque:
196 ± 20 Nm {20 ± 2 kgm}
Tightening angle:180 ± 10°
H Tighten the shoe bolts in the order of [1] – [4].
H Do not use an impact wrench for the master link.
2. When reusing for grease-filled track
A. Preparation work
i. Cleaning seal assembly

For seals to be reused, leave them installed to the
link, and do not wash them.
50-210 I
ii. When reusing the pin, chamfer its end corners care-
fully with a grinder so that it will be press fitted
smoothly.
iii. Mark ※on the end face at the small plug end to show
the direction of the side hole (hole in the radial direc-
tion) in the pin when assembling.
H When reusing the pin, assemble in the same
direction as when the part is new (side hole on the
link tread side).
iv. Using tools R3 and R5, drive in the large and small
plugs.
• Tool R3 (large plug) 5
• Tool R5 (small plug)
1> Insert plug (3) into the guide hole through the
plug insertion window. (Coat plug (3) with oil.)
2> Push the bar of tool R3, R5 with the hand until
plug (3) stops.
3> Push plug (3) with the bar of R3, R5 and push pin
(4) to the guide itself.
4> Drive in the bar of tools R3, R5 with a hammer.
H Driving distance (a) from pin end: A
Small plug: 2.5 ± 1 mm
Large plug: 6 ± 2 mm
H If the plugs were not pulled out when the shoe was disassembled, reuse them as they are.
v. If the outside of the pin, surfaces of the spacer, and ends and inside of the bushing are dirty, clean them.
vi. Apply grease to the outside of the pin and surfaces of the spacer.
50-211 I
vii. Installation of seal assembly
When reusing the link and replacing the seal with a
new part, clean the link counterbore (section A) then
push the seal in fully to the bottom.
H If oil or grease is sticking to the counterbore por-
tion of the link and seal assembly (section A), the
seal will turn and its sealing performance will
lower. Accordingly, do not apply any oil or grease
to that portion.
viii. Adjust the dimensions of the press fitting jig of the

link press to keep the projection of the pin and bush-
ing constant and keep the installed dimensions of the
seal within the standard range.
H For details of the standard dimensions, see "Link
press-fitting jig dimensions table".
H If the pin end (part (P)) or link sides (parts (Q)
and (R)) are worn, add the dimensions of the
worn parts to the standard dimension when
adjusting the dimension of the press-fitting jig so
that the projections of the left and right pins and
bushings on both sides will be even.
B. Assembly of link
i. Apply lithium grease (G2-LI) to the mating surfaces

of the pin and bushing and assemble them, then set
them before the jaw of the link press.
H When reusing (reversing) the bushing, set the
worn outside surface of the bushing on the shoe
fitting side of the link (facing upward on the link
press).
ii. Press fit the master links on both bushing sides to the
bushing with the shoe fitting surface facing up.
H At this time, use the master links on the pin side
as supports.
49 – 147 Nm {5 – 15 tons}
50-212 I
iii. Using the shoe bolt hole pitch gauge, press fit the mas-
ter links until the distance between the shoe bolt holes
of both links is the standard value.
H Remove the all steel chips caused by press fitting
of the bushing with compressed air.
iv. Turn over the master links and check that they are
v. Measure the projections of the bushing on both sides

with a depth gauge.
H Adjust the press fitting jig of the link press so that
the projections on both sides will be even.
vi. Feed the master links and set the next pin and bushing.
H When reusing a pin, install it so that its side hole
will be on the link tread side similarly to a new
one. If it is not installed as specified, its strength
may be lowered. Accordingly, indicate the direc-
tion of the side hole on the end face to prevent a
mistake.
H If the outside of the pin is worn, install it so that
the un-worn surface will be on the traction side.
In this case, install the pin so that its side hole will
face the link tread side, too.
vii. Set both links and operate both pushing jigs to press
fit the pin and bushing simultaneously.
H If the pin and bushing have play when they are
press fitted, the seal may come off the link. To
prevent this, press fit smoothly.
If the seal comes off the link, stop press fitting
and set the seal to the link correctly, then start
press fitting again.
H Pushing force for pin and bushing: 392 kN {40
tons}
Pushing force C 1.8 × average press-fitting force
(Adjust the relief pressure of the link press and set
the pushing force.)
50-213 I
viii. Using a shoe bolt hole pitch gauge, measure the dis-
tance between the shoe bolt holes. When the distance
is in the standard range, stop press fitting.
ix. Assemble the master link on the pin side at last.

H Check that the master links on both sides are
C. Installation of shoe
i. Set the link assembly on the bed and install the shoe
with a shoe bolt impact wrench and a torque wrench.
3 Shoe bolt (regular link):
Initial torque:
196 ± 20 Nm {20 ± 2 kgm}
ii. Set 2 completely assembled portions of shoe on a flat

surface in a straight line with the shoes facing up. Pull
master link (5) at the pin end to master link (6) at the
bushing end, and set them at the mating surfaces.
Then put shoe (7) on top, check that shoe bolt (8) goes
in easily by hand, and connect the 2 parts with the
master bolt.
2Shoe bolt: Lubricant containing
molybdenum disulfide (LM-P)

3Shoe bolt (Master link):
Initial torque:
196 ± 20 Nm {20 ± 2 kgm}
H Tighten the bolts in the order of [1] – [4].
50-214 I
H Do not use an impact wrench for the master link.
50-215 I
LINK PRESS-FITTING JIG DIMENSIONS TABLE 1
Jig dimensions (mm)

a 3.0 ± 2
b 2 ± 0.3
c 43.8
50-216 I
DISASSEMBLY AND ASSEMBLY WHOLE DISASSEMBLY AND ASSEMBLY OF TRACK
WHOLE DISASSEMBLY AND ASSEMBLY OF TRACK SHOE (PLUS

TYPE TRACK SHOE)
SPECIAL TOOLS
New/remodel
Necessity
Symbol Part No. Part name Sketch

Q’ty
1 791-646-7351 Push tool n 1

2 791-660-7460 Pin brush n 1
791-432-1110 Push tool n 1
3 791-646-7550 Bar n 1
791-646-7560 Guide n 1
790-701-3000 Seal checker
4 or n 2
791-601-1000 Oil pump
791-932-1110 Push tool n 1
5 791-646-7523 Bar n 1
791-646-7590 Guide n 1
R 6 791T-B32-1020 Installer n 1
793T-B32-1100 Push tool assembly n 1
793T-B32-1110 • Adapter n 1
8 793T-B32-1010 • Holder n 1
793T-B32-1010 • Bar n 1
01580-11210 • Nut n 1
793T-B32-1000 Push tool assembly n 1
793T-B32-1020 • Adapter n 1
9 793T-B32-1010 • Holder n 1
793T-B32-1030 • Bar n 1
01580-11210 • Nut n 1
50-217 I
WHOLE DISASSEMBLY
H When disassembling the track shoe, see "Parts judgement guide, Undercarriage, Lubricated track" and "Parts judgement
guide, Undercarriage, Reversing procedure for pin bushing".
1. Removal of shoe
Sling the shoe assembly and set it with the shoe up on the floor and
remove the shoe by using a shoe bolt impact wrench.
H If a shoe bolt is not loosened after it is unscrewed by 1 turn (If
its torque is not reduced to 0), loosen the other bolts first, and it
will be removed smoothly.
H If a shoe bolt is turned forcibly while its torque is not 0, it and
link will adhere to each other and they will need to be repaired.
H When moving the shoe assembly, take care not to damage the
master link.
H If it is obliged to cut a shoe nut with gas, keep the seal temper-
ature below 80°C to prevent thermal deterioration of the seal
and take measures to prevent the spatters from entering
through the clearances among the links.
2. Disassembly of link
H Use a track press having protective cover [1].
50-218 I
H When removing the pin, totally cover pin end push tool [2] and
wedge ring (1) with thick cloth [3] so that the broken pieces of
wedge ring (1) will not be scattered.
H Ensure that thick cloth [3] and protective cover [1] are
installed, and then start the work.
H The track press operator and other workers must put on
helmets, safety glasses and earplugs.
H When the wedge ring is cut, it makes a cracking sound.
This phenomenon is normal, however.
H Since the cut wedge ring has sharp edges, which are dan-
gerous, be sure to put on leather gloves when working.
A. Set the link assembly on a link press and hit it with a hammer
so that the bushing will be fitted to the jaw.
H If the link tread, outside of the bushing, etc. are worn,
adjust the height of the jaw or guide plate and align the pin
and bushing with the disassembly jig so that the link hole
will not be damaged during disassembly work.
H If the pin and bushing are not aligned well, the link hole
may be damaged and the pin and bushing may be broken
during disassembly work.
Left di sassembl y j i g Ri ght di sassembl y j i g

Jaw
CPD17246
50-219 I
H Using tool R1, drive the small plug of the pin inward after
the disassembly work so that the workplace will not
become dirty.
B. Operate the left cylinder to pull out the pins from the left link
simultaneously.
H Check the pulling out force of the pins which will be
reversed and assembled again, then pull out them simulta-
neously.
H The wedge link is broken with a bang. This sound does not
indicate abnormality.
CPD17247
C. Return the left cylinder and operate the right cylinder to pull
out the pins from the right link simultaneously.
CPD17248
D. Return the right cylinder and take out the links, pins, bushings,
and spacers on both sides and feed the next 1 set of the link
assembly to the jaw.
H If the bushing ends and sealing surfaces are damaged, oil
will leak. Accordingly, handle them carefully.
H Since the broken wedge link has sharp edges, take care not
to cut your hands with them.
CPD17249
50-220 I
3. Inspection
Check the parts for the following items to see if they can be used for a lubricated track or a grease-filled track, then exam-
ine them generally and determine to use them for a lubricated track or grease-filled track.
H For judgement of reuse of the parts, see "Parts judgement guide, Undercarriage, Lubricated track".
A. Check the parts visually for damage. If a part seems to be damaged, check it by dye penetrant test or mangnaflux
inspection. If it has any crack, it cannot be used again. Discard it.
B. Measure the outside diameter of the press fitting parts of the

pin and bushing and the inside diameter of the pin and bushing
fitting parts of the link with a micrometer and a cylinder gauge
to see if the allowable fitting allowance is obtained. When
using the pin, bushing, and link for a lubricated track, however,
secure the standard fitting allowance between the pin and link.
H If the allowable fitting allowance is not obtained, replace
the parts with new one.
H For the dimensional criteria, see Maintenance standard.
DLD00295A
H Precautions for storage

i. Store the seal without removing it from the link so that the
counterbore portion will not bre rusted and take care not to
damage the seal slip.
ii. Apply rust-preventive oil to the pin and bushing fitting
parts, shoe mating surface, and master link mating surface
of the link.
iii. When storing, apply rust-preventive oil to the all surfaces
of the pin, bushing, and spacer. Take care not to damage
the ends of the bushing in particular.
WHOLE ASSEMBLY
H For the whole assembly of the track shoe, see "Parts judgement guide, Undercarriage, Reversing procedure for pin bush-
ing".
1. When recycling for lubricated track
1. Preparation work
Load ri ng
A. Cleaning seal assembly
Remove the seal assembly from the link and divide it into the Seal ri ng
seal ling and load ring, then clean them.
H Since the seal ring and load ring are deteriorated easily by
the cleaning liquid (trichloroethylene etc.), clean them
quicly. After cleaning them, wipe off the cleaning agent
from them.
DJD03452
50-221 I
B. When reusing the pin, chamfer its end corners smoothly with a
grinder. Remove the nodules sticking to the press fitting parts
with the grinder, too.
H If the ends are worn and sharpened, they may scuff the
press fitting parts and cause oil leakage.
C.If the link, pin, bushing and spacer are dirty, clean them.
Remove the nodules sticking to the link and bushing with the
grinder, too.
H Since these parts rust easily, clean them just before assem-
bling them.
H Do not polish the bushing ends. If they are polished, oil
may leak.
D. If the large plug was pulled out, drive it in by using tool R3.
In this case, clean the pin hole in advance by using tool R2.
i. Insert the plug through the plug insertion window into the
guide hole.
ii. Push the bar with the hand until the plug stops.
iii. Push the plug with the bar to press the guide against the
pin.
iv. Drive in the bar with a hammer.
H Driving distance (a) from pin end:
6 ± 2 mm
H If the chamfered part of the pin hole has been worn,
chamfer it with a small-sized grinder (grindstone tip
angle: 45°– 60°) so that the plug will not be damaged.
H Coat the plug with GO90 and drive it with the small
diameter end ahead
E. Installation of seal assembly.

Clean the counterbore portion of the link carefully and push in Remove al l oi l and
the seal to the bottom by using tool R6. grease from port i ons
marked by bol d l i ne
Q5
H If oil is sticking to the counterbore portion of the link or
seal assembly, the seal will turn and its sealing perfor-
mance will lower. Accordingly, do not apply any oil. Di recti on of
When inserting the seal in the counterbore portion, take i nsert i on
care that oil not stick to the seal and counterbore portion.
50-222 I
F. Adjust the dimensions of the press fitting jig of the link press.
H Adjust the dimensionsto keep the projection dimensions of
the pin and bushing constant and keep the installed dimen-
sion of the seal within the specified range.
H Press fitting jigs and their installed dimensions.
Dimension (b): 4.7 mm
Dimension (c): 83 mm
Dimension (d): 83 mm
H Set the link receiving face of jaw [4] vertically.

H Wear plate [5] should be a replaceable one, if possible.
G. Adjust the relief pressure of the link press so that the pressing force of the press will not exceed the following speci-
fied value.
Specified pressing force: 265 kN {27 ton}
H Too strong pressing force can cause the following troubles.
• The spacer will be pressed forcibly against the bushing to breakage.
• The spacer and bushing end face will be worn abnormally.
50-223 I
2. Assembly of link (When even number of link assemblies are set)
A. Assemble pin (1), bushing (2) and 2 spacers (3) temporarily

and prepare 2 pin sub-assemblies (4).
B. Set pin sub-assemblies (4a) and (4b) to the jaw.
C. Install inner links (5), to which the seals have been installed, to
the right and left of pin sub-assemblies (4a) and (4b) with the
shoe mounting faces (e) up.
H Adjust the positions of the inner links so that the spacers
and seals will not be caught.
D. Set spacers (7) to the right and left of pin sub-assembly (4a) at
the front.
E. Set roller tread-side master links (13), to which the seals have
been installed, to the positions shown below with master link
engaging faces (m) up.
F. Press fit roller tread-side master links (13) to pin sub-assembly

(4a) at the front.
H Before press fitting, align the pin hole of the link with the
pin.
50-224 I
H When reusing a pin, install it so that its side hole will be
the link tread side similarly to a new one. If it is not
installed so, its strenght may be lowered. Accordingly,
indicate the direction of the side hole on the end face to
prevent a mistake.
H When installing, take care that the right and left seals will
not come off and the seal and spacer (7) will not be caught.
H Press fit the right and left sides of pin sub-assembly (4a)
simultaneously.
H Ensure that the right and left master links are press fitted Di r ec t i o n o f
in parallel. si de hol e
H The press fitting force of the pin sub-assembly must not

exceed the following force.
Press fitting force: 265 kN {27 ton}.
H Using depth gauge [6], measure projection dimension (g)
and adjust it to the following dimension while press fitting
the pin.
Projection dimension (g):
4.7 ± 0.2 mm
G. Using shoe bolt hole pitch gauge [7], check that the shoe bolt
pitch is in the specified range.
If longer than specified range:
Disassemble and check for abnormality and then reassemble.
If shorter than specified range:
The wear of the spacer or bushing end face may have exceeded
the allowable limit. Disassemble and replace the worn parts.
50-225 I
H. Set wedge ring (10) to tool R8.
I. Align tool R8 (small plug side) with the pin and push in until
wedge ring (10) is fitted to the pin groove.
H Install wedge ring (10) with opening (j) toward the shoe
mounting face of the ring.
H When wedge ring (10) is fitted to the pin groove, it clicks.
J. Using tool R9 (large plug side), similarly install the wedge

ring on the opposite side. (See the tool list).
K. Using too R8 and R9, press fit the right and left wedge rings
simultaneously.
H The wedge ring press fitting force must not exceed the
following force.
Press fitting force:
98 – 192 kN {10 – 20 ton}
50-226 I
L. Each time 1 link is assembled, bleed air from the pin with tool
R4 and check the sealing performance.
H Keep the space in the pin at a vacuum degree of 91 – 95
kPa {680 – 710 mmHg} for 5 seconds and ensure that the
pressure does not change.
If the pressure changes, disassemble and check the seal. If
no abnormality is detected, reassemble.
R4
M. Using too R4, charge oil (GO90) until the charge pressure
becomes 196 – 294 kPa {2 – 3 kg/cm2}.
H Increasing the oil pressure too high has bad effects on the
seal.
R4
H Set the link assembly with the small plug side up and leave
it as it is for 30 minutes and then check the oil level.
H Charge oil (GO90) so that space depth (L) of the pin hole
will be in the following specified range.
Space depth (L): 30 – 50 mm
N. After charging the oil, drive the small plug into the specified
position with tool R5.
H Before driving the small plug, apply oil (GO90) to its out-
side.
H Driving depth of small plug from pin end face: 1 ± 1 mm
R5
50-227 I
O. Assemble pin (1), bushing (2) and 2 spacers (3) temprarily and
prepare 3 pin subassemblies (4).
P. Move assembled link assembly (11) toward the front of the

ring press bed.
Q. Set pin sub-assembly (4d) to the center of the jaw and set (4e)
on this side of the jaw.
R. Install inner links (5), to which the seals have been installed, to
the right and left of pin sub-assemblies (4d) and (4e) with the
shoe mounting faces (e) up.
H Adjust the positions of the inner links so that the spacers
and seals will not be caught.
50-228 I
S. Set spacers (7) to the right and left of pin sub-assembly (4c) at
the front and pin sub-assembly (4d) at the center.
T. Set outer links (12), to which the seals have been installed, to
the positions shown below with shoe mounting faces (k) up.
U. Press fit outer links (12) to pin sub-assembly (4c) at the front
and pin sub-assembly (4d) at the center.
H Before press fitting, align the pin hole of the link with the
pin.
H When installing, take care that the right and left seals will
not come off and the seal and spacer (7) will not be caught.
H Press fit the right and left sides of pin sub-assemblies (4c)
and (4d) simultaneously.
H The press fitting force of the pin sub-assembly must not
exceed the following force.
Press fitting force: 265 kN {27 ton}
H Using depth gauge [6], measure projection dimension (g)
and adjust it to the following dimension while press fitting
the pin.
Projection dimension (g):
4.7 ± 0.2 mm
V. Perform steps 7) – 14) above.
W. Perform steps 15) – 19) above.
X. Assemble the master link on the roller tread side finally.

H Ensure that the right and left master links are press fitted in parallel.
50-229 I
3. Installation of shoe
H Set and install the shoe so that master link (1) and shoe grouser
(2) on the shoe side will be positioned as shown below.
%&#
H Set the link assembly on the link press bed and install the shoe
with the shoe bolt impact wrench and torque wrench.
H Tighten the shoe bolts in the following order.
Shoe bolt:
Molybdenum disulfide lubricant (LM-P)
Shoe bolt (Regular link)
Initial torque: 245 ± 29 Nm {25 ± 3 kgm}
Retightening angle: 120 ± 10o
50-230 I
DISASSEMBLY AND ASSEMBLY FIELD DISASSEMBLY AND ASSEMBLY OF ONE LINK
FIELD DISASSEMBLY AND ASSEMBLY OF ONE LINK

SPECIAL TOOLS
New/Remodel
Necessity
Symbol
Sketch
Q'ty
Part No. Part name
790-101-1102 Pump t 1
10 Cylinder
790-101-1300 t 1
(980 kN {100 ton})
790-101-1102 Pump t 1
11 Jack
790-105-2300 t 1
(294 kN {30 tons})
791-635-3110 Frame t 1
791-635-3160 Extension t 1
791-635-3170 Nut t 4
12 791-635-3180 Screw t 2
791-635-3190 Screw t 1
791-645-3510 Adapter t 1
791-646-3260 Pusher t 1
13 791T-B32-1210 Pusher t 1
14 791-432-1110 Push tool t 1
15 791T-B32-1220 Guide t 1
791-635-3110 Frame t 1
R 791-635-3160 Extension t 1
791-635-3170 Nut t 4
791-635-3180 Screw t 2
16
791-635-3190 Screw t 1
791-645-3510 Adapter t 1
791-645-3520 Adapter t 1
791-645-3530 Pusher t 1
791-635-3110 Frame t 1
791-635-3160 Extension t 1
791-635-3170 Nut t 4
791-635-3180 Screw t 2
17
791-635-3190 Screw t 1
791-645-3520 Adapter t 1
791T-630-3570 Guide t 1
791-630-3560 Pusher t 1
790-101-1102 Pump t 1
18
790-105-2300 Jack t 1
19 791T-B32-1230 Guide t 1
791-635-3110 Frame t 1
791-635-3160 Extension t 1
20 791-635-3170 Nut t 4
R 791-635-3180 Screw t 2
791-635-3190 Screw t 1
791-645-3510 Adapter t 1
21 791-646-8002 Lubricator t 1
22 791-932-1110 Plug push tool t 1
DISASSEMBLY
50-231 I
1. Positioning track shoe assembly
Set track shoe assembly on block [1] (approx. 300 mm high).
2. Pin
Using tool R12 (frame, extension, nut, screw, adapter, pusher),
and tool R10 (pump, cylinder), remove pins (1) and (2).
H If the tip of the pin or the side of the link are unevenly
worn, correct with a hand grinder to ensure that the part is
at a right angle to tool R12.
10
12
3. Link
A. Put tool R11 and spacer [2] of the dimensions given below 11
in contact with the tread of links (3) and (4).
H Set tool R11 as close to the tip of the link as possible.
B. Apply hydraulic pressure slowly to the puller until the tip

of the link opens 6 – 8 mm, then disconnect the link.
H There is danger that the bushing will come out, so do
not apply more hydraulic pressure than necessary.
H If an electric pump is used, there is danger that more
hydraulic pressure will be applied than necessary, so
always use a hand pump.
C. Disconnect links (5) and (6) in the same way.

11
50-232 I
ASSEMBLY
1. Bushing
Applying tool R13 to the end of link (4) and using a press or a
remover, press fit bushing (7).
49 – 147 kN {5 – 15 tons}
H Always use a new bushing.
13
2. Pin
A. Using tool R14, knock a large plug into the oil hole of pin
(1).
H Always use a new pin.
14
B. To determine the pushing pressure when carrying out the

final assembly, measure the outside diameter of the pin
with a micrometer.
C. Coat the press-fitting hole for the pin in link (4) with gas-
ket sealant (198-32-19890).
H If the link is used again, finish the press fitting hole for
the pin smoothly with sandpaper.
50-233 I
D. Applying tool R13 to the end of link (4) and using a press
or a remover, press fit pin (1).
H Press fit so that the side hole (a) in the pin is on the
same side as the link tread.
H Press-fitting force for pin:
98 – 147 kN {10 – 15 tons}
13
3. Seal
Install seal (8).
H Check that there is no oil on the contact surface of the link
and seal.
H Carry out steps 1 – 3 in advance.
4. Link sub-assembly
A. Install link sub-assembly (10).

H Check that there is no dirt or dust stuck to the surface
of the seal or the end face on the bushing, then coat
with oil (GO90) using a clean cloth or small brush.
B. Install tool R15 (guide used when press fitting link) to

bushing (7).
15
50-234 I
5. Link
A. To determine the pushing pressure when carrying out the

final assembly, measure the press-fitting hole dimensions
of link (3) with a cylinder gauge.
B. Coat the press-fitting hole for the pin in link (3) with gas-
ket sealant (198-32-19890).
H If the link is used again, finish the press fitting hole for
the pin smoothly with sandpaper.
C. Install seal (8).

H Check that there is no oil on the contact surface of the
link and seal.
of the seal or the end face on the bushing, then coat
D. Using tool R16, press fit pin portion of link (3) to link sub-
assembly (10). 16
H Press-fitting force for pin:
196 – 294 kN {20 – 30 tons}
H (G): Guide
50-235 I
E. Using tool R17, press fit bushing portion of link (3) to link
sub-assembly (10).
H To prevent the use of any excessive force, press fit the 17
pin portion and bushing portion gradually in turn.
H Press-fitting force for pin and bushing: 147 – 294 kN
{15 – 30 tons}
6. Connecting link
A. Finish the inside surface of the press-fitting hole for the pin
in links (5) and (6) smoothly with sandpaper.
B. Remove block [1], and lower the track shoe assembly to

the ground.
18
C. Set lever block [3] to the left and right link assemblies as
shown in the figure below. Put tool R18 and spacer [2] in
contact with the tread of links (5) and (6).
H Set tool R18 as close to the tip of the link as possible.
D. Install seals (13) and (14) to links (5) and (6).

H Always use new seals.
H Check that there is no oil on the contact surface of the
link and seal.
of the seal or the end face on bushing (7), then coat
50-236 I
E. Apply hydraulic pressure slowly to the puller until the tips
of links (5) and (6) open 6 – 8 mm.
H There is danger that the bushing will come out, so do
not apply more hydraulic pressure than necessary.
H If an electric pump is used, there is danger that more
hydraulic pressure will be applied than necessary, so
always use a hand pump.
F. Operate lever block [3], align the centers of the link hole
and bushing hole, and connect the links with tool R19
(guide pin).
19
H Operate lever block [3] slowly and be careful not to
damage the seal or get sand stuck to the seal surface.
7. Pin
A. Using tool R14, knock a large plug into the oil hole of pin
(2).
14
B. To determine the pushing pressure, measure the outside

diameter of pin (2) with a micrometer. 20
C. Set the track shoe assembly on block [1] again.
D. Using tool R20, press fit pin (2) to links (5) and (6).
H Press fit so that the side hole in the pin is on the same
side as the link tread.
49 – 147 kN {5 – 15 tons}
E. Temporarily stop press fitting when there is 15 – 20 mm

left for press fitting pin (2).
F. Coat the remaining press-fitting portion of pin (2) with

gasket sealant (198-32-19890).
G. Coat the press-fitting hole for the pin in link (6) with gas-
ket sealant (198-32-19890), then continue to press fit pin
(2).
50-237 I
H. Using tool R16, apply the specified pressure to links (3)
and (4) and links (5) and (6). 16
H Pushing force for pin and bushing:
392 kN {40 tons
Pushing force C 1.8 × average press-fitting force
(Adjust the relief pressure of the link press and set the
pushing force.)
8. Vacuum test
Using hand vacuum pump [4], remove the air from the small
plug hole at the end face of pins (1) and (2) and check the seal-
ing performance.
H Check that the airtightness is maintained for 5 seconds at a
negative pressure of 92.7 ± 2.0 kPa {695 ± 15 mmHg}.
9. Charging with oil
A. Using tool R21, charge with oil (GO90) through the small
plug hole in the pin.
H Be careful not to raise the pressure too high when
charging with oil. This will have an adverse effect on
the seal.
H Take into consideration the expansion of the oil under
heat, and be careful not to charge with too much oil.
21
B. Using tool R22, drive in the small plug quickly.

H Apply oil (GO90) around the small plug.
H The depth to drive in the plug is as follows.
Driving depth from end: 2.5 ± 1 mm
22
50-238 I
FIELD DISASSEMBLY AND ASSEMBLY OF ONE LINK (PLUS TYPE

TRACK SHOE)
H In this section, how to use the special tools is described.
H For details of disassembly and assembly, see "Whole disassembly and whole assembly of track shoe assembly (PLUS
type track shoe)".
SPECIAL TOOLS
New/remodel
Necessity
Symbol Part No. Part name
Sketch
Q’ty
1 791-101-1102 Pump assembly n 1

2 790-101-1300 Cylinder (980 kN {100t} n 1
3 790-105-2300 Puller (294 kN {30 t} n 1
4 790-532-2210 Plate n 1
5 791-532-2220 Plate n 1
6 791-532-2230 Block n 1
7 791-532-2240 Stud bolt n 2
8 791-532-2390 Rod n 2
9 791-532-2260 Plate n 1
R 7
10 791-532-2270 Boss n 2
11 791-532-2280 Boss n 2
12 791-532-2320 Plate n 1
13 01582-12722 Nut n 4
14 791-532-2380 Washer n 2
15 01252-61645 Bolt n 2
16 02205-12437 Nut n 4
17 791-532-2370 Plate n 1
18 791-532-2360 Push tool n 2
50-239 I
DISASSEMBLY
1. Shoe
A. Set the track so that the link to be disconnected will be on the

upper side.
B. Referring to "Whole disassembly and whole assembly of track

shoe assembly (PLUS type track shoe)", remove 4 shoe mount-
ing bolts (1) and shoe (2).
H Remove shoes (2a) and (2b) similarly so that the pins can
be removed easily.
2. Wedge ring
• If the wedge ring is stuck, release it according to the following
procedure.
A. Sling tool R7 and set it to the link assembly.
• Sketch of tool (See the tool list)
50-240 I
B. While slinging tool R7, align it with the pin.
C. Apply tool R7-12 to outer link (3) of the wedge ring to be

removed.
D. Operate tool R7-1 (See the tool list) to press tool R7-12 in the
direction of the arrow and make a clearance between wedge
ring (4) and outer link (3).
H The pressing force of tool R7-12 must not exceed 265 kN
{27 ton}.
E. Remove tool R7.
F. Using snap ring pliers [1] and a flat-head screwdriver, remove

wedge ring (4).
H When removing the wedge ring, do not damage the wedge
ring contact surfaces of the outer link and pin.
H Do not reuse the removed wedge ring.
3. Master link
A. Remove the shoe of the master link. For details, see "Expan-
sion and installation of track shoe assembly".
B. Disconnect 2 master links (5) and expand the link assembly.
50-241 I
4. Regualr link
A. Set the link assembly on a flat place.
B. Sling tool R17 and set it to the link assembly.
C. While lifting tool R7, holder outer link (3) between tool R7-12
and R7-9 and align the tools with the pin.
H Hold and fix outer link (3) securely. If it is not fixed
securely, the right and left pin may not come out simulta-
neously.
H Tool R7-9 is set diagonally since it is applied to the rusted
surface of outer link (3). Using shims, adjust tool R7-9 in
parallel with tool R7-12.
D. Operate tool R7-1 (See the tool list) to press tool R7-9 in the direction of the arrow and remove outer link (3).
E. Remove tool R7.

• Condition when disassembled (See the tool list)
a. Thickness of tool R7-4: 36 mm
b. Thickness of tool R7-13: 22 mm
c. Thickness of tool R7-12: 32 mm
d. Thickness of tool R7-9: 32 + 6 mm
e. Thickness of tool R7-13: 22 mm
f. Dimension: 74.5 mm
g. Dimension: 35 mm
h. Pulling distance: 25 mm
Arrow: Moving direction of tool R7-2 cylinder
(3) Outer link
(6) Outer link
5. Pins and bushing
A. Remove outer link (6) and 2 pins (7).
50-242 I
B. Using tool R7-3, increase dimension (j) of inner link (8) a lit-
tle.
H Increase dimension (j) of inner link (8) to a degree that
bushing (9) can be pulled out lightly. If dimension (j) is
increased too much, the oil seal on the opposite site to the
disassembled side may be broken.
C. Remove bushing (9).
6. Oil seal and ring

Remove the oil seal and spacer from the removed link and clean
them thoroughly.
50-243 I
ASSEMBLY
• Carry out assembly in the reverse order to disassembly.
1. Install the oil seal and spacer to the link
2. Bushing
A. Using tool R7-3, increase dimension (j) of inner link (8) a lit-
tle.
H Increase dimension (j) of inner link (8) to a degree that
bushing (9) can be pulled out lightly. If dimension (j) is
increased too much, the oil seal on the opposite side to the
disassembled side may broken.
B. Install bushing (9) to inner link (8).
3. Pins and outer link
A. Install outer link (6) and 2 pins (7).Sling
B. Sling tool R7 and set it to the link.
C. While lifting tool R7, align it with the pin.

H Hold and fix outer link (3) securely. If it is not fixed
securely, the right and left pin may not be inserted simulta-
neously.
H Tool R7-9 is set diagonally since it is applied to the rusted
surface of outer link (3). Using shims, adjust tool R7-9 in
parallel with tool R7-12.
D. Operate tool R7-1 (See the tool list) to press tool R7-12 in the
direction of the arrow and press fit outer links (3) and (6).
E. Remove tool R7.
50-244 I
• Condition when assembled (See the tool list)
a. Thickness of tool R17-4: 36 mm
b. Thickness of tool R17-13: 22 mm
c. Thickness of tool R17-12: 32 mm
d. Thickness of tool R17-9: 32 + 6 mm
e. Thickness of tool R17-13: 22 mm
f. Dimension: 74.5 mm
g. Dimension: 35 mm
h. Pressing distance: 25 mm
arrow: Moving direction of tool R17-2 cylinder
(3) Outer link
(6) Outer link
F. Using depth gauge [2], measure projection dimension (k) of

the pin (7) end from outer link (3).
Standard projection dimension (k):
4.7 ± 0.2 mm
G. Using snap ring pliers [1], install wedge ring (4).

H Install wedge ring (4) with its opening toward the shoe
mounting face of the link.
H Install the wedge ring so that its height above the side of
the link will be even.
50-245 I
H. Sling tool R7 and set it to the link.
I. While lifting tool R7, align it with the pin.
J. Operate tool R7-1 (See the tool list) to press tool R7-18 in the
direction of the arrow with the following specified force and fit
the pin to the wedge ring.
Specified force:
98 – 192 kN {10 – 20 ton}
K. Remove tool R7.
• Carry out the following assembly in the reverse order to

disassembly.
4. Charging with oil

Charge the track with oil similarly to the ordinary oil lubricated track. For details, see "Whole disassembly and whole
assembly of track shoe assembly (PLUS type track shoe)".
50-246 I
DISASSEMBLY AND ASSEMBLY TRACK FRAME
TRACK FRAME
WARNING! Be extremely careful when removing machine tracks and track frame, be sure you
have the proper equipment and a flat hard level surface before preceding with any
removal procedures. Failure to do so may result in damage to the machine or
personal injury.
REMOVAL OF TRACK FRAME

REMOVING TRACKS
H This manner is used when machine is set in a stationary position
and elevated on jack stands. When removing or repairing the tracks
with the machine on the ground, see “SPREADING THE TRACK”
on page 50-194.
1. Remove mounting bolts and cover (1).
2. Remove retaining bolts (a) and retainer (b) then loosen lubricator
(2) to lower the tension of the track shoe.
WARNING! Since the pressure in the recoil spring

cylinder is very high, do not loosen the
lubricator more than one turn. If the
track tension is not lowered, move the
machine forward or in reverse.
3. Position the master link (3) properly.

H Start the engine and position the master link in the center rear
section of the drive gears leaving an equal amount of gear teeth
between the top and bottom portion of the master link.
WARNING! It is important the master link sit firmly

in the gear teeth before separating the
links.
50-247 I
4. Raise machine and support front blade as shown in the illustration
using blocks (A) positioned under each side of the blade.
5. Raise the machine and support it under the frame using jacks (B) in
front and (C) in the rear.
H Be sure to leave enough clearance between the jack supports
and machine tracks.
6. With the machine raised 153.4 - 203.2 mm (6 - 8 inches) off the

ground and level, be sure all areas are clear around and behind the
machine.
7. To separate the track, support the lower track section in a stable

manner to prepare for opening the master link coupling.
50-248 I
8. Remove the master link bolts as shown in the illustration pattern.
H Be sure there is no tension on the tracks at this point.
9. Once the master link is free and off the drive gear, lay the bottom
portion of the track (7) on the floor and prepare to pull the tracks off
of the machine from under the track frame.
H If necessary, release the machines brakes to allow the travel
motor to move slightly. See "RELEASING BRAKE" in the
Operator’s Manual.
10. Carefully and slowly pull track (7) on the floor under the track
frame and away from the rear of the machine in a straight line.
H Use a pry bar and block to lift track off sprocket while pulling.
WARNING! Do not use your hands to guide the

track when removing it from the track
frame. Always use a pry bar or other
device to maneuver the tracks.
Failure to do so may result in serious
injury.
11. With the tracks clear of the machines track frame prepare to remove
the track frame (17).
50-249 I
12
TRACK FRAME REMOVAL PREPARATIONS
1. Remove outer rock guard (1) using a 24 mm wrench.
2. Remove inner top rock guard cover (2) using a 24 mm wrench.
3. Remove top (3) and bottom (4) inner covers using a 24 mm wrench
to access hydraulic lines.
4. Remove two outer hydraulic lines (5) and speed sensor (6) as well
as the two “P” clips (7) holding the hydraulic lines in place.
H Cap all hydraulic lines to prevent any dirt or debris from
entering them.
50-250 I
5. Remove the inner travel hydraulic top line (8) and bottom line (9).
entering them.
6. Remove hydraulic case drain line (10) and cap opening.
7. After lines are disconnected, remove inner mud guard (11).
H Bundle all lines and be sure to protect speed sensor (6) from
any damage.
50-251 I
8. Remove the pivot shaft cover (12) to expose the retaining cap.
LIFTING TRACK FRAME FROM MACHINE
1. At this point sling the track frame (17) in the manner shown in the
illustration.
H Support the front area of the frame to allow easy removal of

front track frame pin.
2. Remove grease line (13) from rear of pin.
50-252 I
3. Remove lock tab (14) and push out pin (15).
4. Remove pivot shaft retainer cap (16) and prepare to remove track
frame assembly.
5. Carefully remove track frame (17) from the machine keeping it as

level as possible.
H Prepare a container under pivot shaft when removing track
frame to catch any residual oil that will spill out from the frame
housing.
Track frame: 1,792.1 kg (3,950 lbs)
Pivot shaft oil: Approximately 3.7 liters (1 gal.)
H It is not necessary to remove the pivot shaft when removing the

track frame. However, if the pivot shaft must be removed, sling the
pivot shaft as shown in the illustration after removing top and
bottom hose guard and securing hydraulic hoses. Remove the 15
mounting bolts (a) using a 30 mm wrench.
H When reinstalling pivot shaft be sure to align the bolt
pattern with the widely spaced bolts on top.
Pivot shaft: 80.1 kg (178 lbs)
50-253 I
12
INSTALLATION OF TRACK FRAME
H Carry out installation of track frame in reverse order.
H Before installing track frame, replace inner seal (18) on pivot shaft.
H If pivot shaft was removed, the proper torque for the 15
mounting bolts (a):
Pivot shaft bolts (a): 490 - 607 N•m (361 - 448 lbf/ft)
H Install seal (18) according to the following procedure.

A. Reverse seal (18) so that the molded letter (c) face will be on
the inside.
B. With the seal reversed. Insert seal (18) in pivot shaft (a).
C. Apply engine oil (For details, see "Table of fuel, coolant and
lubricants") to face (d) of track frame assembly (17).
D. Install track frame assembly (17) to the pivot shaft (a).
H Replace cover shaft seal (19).
1. Using a hoist and floor jack raise the track frame (17) into position
and push in place carefully onto tapers pivot shaft.
2. Once on pivot shaft, reinstall pin (15) and lock (14).
Lock (14): 23.5 - 31.5 N•m (173 - 227 lbf/ft)
3. Reinstall retainer cap (16) and cover (12).

H Retainer cap (16).
Retainer cap (16): 245 - 308 N•m (181 - 228 lbf/ft)
H Cover (12).
Cover (12): 245 - 308 N•m (181 - 228 lbf/ft)
4. Refill pivot shaft chamber with oil through fill port (20)
Pivot shaft oil: Approximately 3.7 liters (1 gal.)
5. Attach hoses (5), (8), (9) and (10).
6. Reinstall speed sensor (6) and “P” clips (7).
7. Attach grease line (13) and grease pin.
Lock nuts: 14.7 - 21.3 N•m (11 - 16 lbf/ft)
8. Reinstall rock guard covers (11), (1), (2), (3) and (4).
9. Reinstall tracks in reverse order.
50-254 I
12
MEMORANDUM
50-255 I
DISASSEMBLY AND ASSEMBLY FRONT TRACK IDLER
12
FRONT TRACK IDLER
H Before proceeding with the removal and installation of the front idler, See “REMOVING TRACKS” on page 50-247 or
“SPREADING THE TRACK” on page 50-194.
REMOVING FRONT IDLER
WARNING! If the track frame has been removed

from the machine, it is important to
support the track frame in a secure
manner as shown in illustration.
H Using wood block (a), support track frame (17) and prepare to
remove idler assembly (1).
1. Remove top support mounting bolts (4) and remove the top support
covers (5).
2. Remove side support mounting bolts (2) and remove the side
support brackets (3).
H Keep track of the shim packs (c) for each side when removing
top cover (4). Do not mix up shims. Doing so will change
initial idler adjustment with track frame.
50-256 I
H Keep track of the shim packs for each side when removing side
covers (3). Do not mix up shims (a) and (b). Doing so will
change initial idler adjustment with track frame.
Shim Placement Is As Shown In The Illustration
a. Front side shims changes side to side movement.
b. Rear side shims changes side to side movement.
c. Top shims changes spring tension (two sets)
d. Top bottom shims changes up and down movement (two sets)
H Always be aware of these shims and their locations when

preparing idler for removal. Failure to do so may change the track
frame adjustment when idler is assembled.
PULLING IDLER FROM TRACK FRAME
1. After removing support covers (3) and (5), install eye bolts in the
locations shown in the illustration and sling the idler assembly.
2. Prepare to pull the idler assembly (1) out of the frame (17).
50-257 I
3. Carefully and slowly pull idler assembly out of the track frame.
4. As the idler is being pulled from the track frame, prepare to receive
the slider plate (7) and springs (6) as well as the bolt plates (not
shown), as these will fall out.
Idler assembly: 170 kg (375 lbs)
50-258 I
12
INSTALLING FRONT IDLER
H Carry out installation of front idler in reverse order.
1. Slide idler assembly (1) into track frame (17)

H When sliding idler recoil spring assembly into track frame, use a bottle jack to support the back of the recoil spring
nut and grease fitting as the idler assembly is installed into the track frame.
2. Once fully into frame, install bolt plate, slider plate (7) and springs
(6).
H The illustration shows the order in which the spring assemblies are
installed into the idler boss above.
a. Bolt plates (on top)
b. Springs (in middle)
c. Slider (on bottom)
3. Install shims and covers (3) and (5).

H Side support mounting bolts (2).
Bolts (2): 245 - 309 N•m (181 - 228 lbf/ft)
H Top support mounting bolts (4).
Bolts (2): 230.4 - 308.9 N•m (170 - 228 lbf/ft)
H Track tensioner large nut (2) “REMOVAL OF TRACK FRAME” on page 50-247.
Main nut (2): 147 N•m (108 lbf/ft)
H Small lock nut (2).
Main nut (2): 58.8 - 88.2 N•m (43 - 65 lbf/ft)
50-259 I
DISASSEMBLY AND ASSEMBLY TRACK ROLLER
12
TRACK ROLLER
H Before removing the top or bottom track rollers see “TRACK SYSTEM” on page 50-194.
REMOVAL
1. To remove the bottom track rollers, remove rock guard (1) and
unbolt the track roller assembly by removing bolts (2) on the
outside and on the inside of the track frame.
2. To remove the top carrier rollers, remove the mounting bolts (3)
and pull track roller assembly out of the frame boss.
INSTALLATION
H Carry out installation in the reverse order of removal.
H Adjust the tension of the track shoe.
H For details, see "UNDERCARRIAGE CARE" in the Operator’s Manual.
H Tension of track shoe: 20 - 30 mm (1.0 - 1.2 inches)
1. When winding the track shoe, use a bar, etc. to prevent the link from parting from the sprocket.
2. Take proper measures so that the mating faces and threads of the master link will not be rusted, bruised, or deformed. In
addition, check to be sure mating faces and threads are free from dirt.
3. Tighten track roller mounting bolts (2) and (3).
Mounting bolts (2) and (3): 235 - 285 N•m (173 - 210 lbf/ft)
50-260 I
12
TRACK ROLLER OVERHAUL PROCEDURES
SPECIAL TOOLS
Distinction
Necessary
Sketch
Qty.
1 791T-430-3220 Push tool n 1 m

G 2 791-651-1510 Installer n 1
3 790-601-1000 Oil pump n 1
DISASSEMBLY
1. Remove plug (1) and drain oil.
Track roller: Approximately 150 ml (5.3 oz)
2. Set roller assembly (2) to block [1].
3. Push collar (3) and pull out ring (4), then remove collar (3).
4. Remove floating seal (5) from collar (3).
5. Pull out roller (6) from shaft.
50-261 I
6. Remove floating seals (7) and (8) from roller (6).
7. Remove bushing (9) and (10) from roller (6).
8. Remove ring (11), then remove collar (12) from shaft (13).
9. Remove floating seal (14) from collar (12).
10. Remove O-rings (15) from shaft (13).
ASSEMBLY
1. Install O-rings (15) to shaft (13) and assemble collar (12), then
install ring (11).
H After assembling, tighten plug (1) temporarily.
50-262 I
2. Using tool L4, install floating seal (14) to collar (12).
H Precautions when assembling floating seal.
A. When assembling the floating seal, degrease and dry the parts
indicated with thick line A (O-ring and mating face of the O-
ring).
B. After assembling the floating seal, check that the angle of the
seal is less than 1 mm (0.04 inches).
C. After assembling, check that protrusion [a] of the floating seal

is within a range of 7 - 11 mm (0.3 - 0.4 inches).
3. Using push tool [1], press fit bushings (9) and (10) to roller (6).
H Bushing press-fitting portion: Engine oil (EO30-CD)
H Bushing press-fitting force: 29.4 ± 3.92 kN (3.0 ± 0.4 ton)
4. Install floating seal (8) to roller (6).

H For details of the precautions when installing the floating seals,
see Step 2.
50-263 I
Precautions When Assembling Floating Seal.
A. Set shaft (13) and collar (12) assembly on block [2], then
assemble roller (6).
B. Coat the sliding surface of the floating seal with engine oil, and
make sure that no dirt or dust sticks to the surface.
C. When assembling the roller, coat the shaft or bushing with

engine oil.
Refilling With Oil
1. Pour oil through clearance between shaft (13) and roller (6).
Roller: Approximately 150 ml (5.3 oz) [EO30-CD]
H When using tool B to add the oil, add the oil after completing the
total assembly.
2. Install floating seal (8).

H For details of the precautions when installing the floating seals,
see Step 2.
Precautions When Assembling Floating Seal.
1. Install floating seal (5) to collar (3).
2. For details of the precautions when installing the floating seals, see
Step 2.
50-264 I
Precaution When Assembling Floating Seal.
1. Coat the sliding surface of the floating seal with engine oil, and
make sure that no dirt or dust sticks to the surface.
2. Install roller (2) to collar (3), then install ring (4).
3. Using tool L5, apply basic pressure to roller oil filler port, and
check for leakage of air from seal.
H Basic pressure: 1 kg/cm2 (14.2 psi)
Method Of Checking
H The basic pressure shall be maintained for 10 seconds and the

indicator of the gauge shall not go down.
1. If oil was not added in Step 6, use tool L5, to fill track roller
assembly with oil.
Roller: Approximately 150 ml (5.3 oz) [EO30-CD]
2. Stand the track roller as shown in the diagram below and leave it
for a short time, then insert a wire from the oil filler port and check
height L to the oil surface.
3. Distance L from end face of shaft to oil surface: 106 mm (4.2

inches).
4. Tighten plug (1).
Plug: 117.7 ± 19.6 N•m (87 ± 14.5 lbf/ft)
50-265 I
12
CARRIER ROLLER OVERHAUL PROCEDURES
SPECIAL TOOLS
Distinction
Necessary
Sketch
Qty.
G 4 791-430-3230 Installer n 1
DISASSEMBLY
1. Remove cap (1) from carrier roller assembly.
2. Remove bolt (2), then remove plate (3).
3. Remove roller assembly (4).
Disassembly Of Roller Assembly
1. Remove floating seal (5) from roller assembly (4).
2. Set roller assembly on block [1], and using push tool [2], remove
bushing (6).
Disassembly Of Shaft, Support Assembly
1. Remove floating seal (8) from shaft and support assembly (7).
2. Set shaft and support assembly (7) on block [3], and using push tool
[4], remove shaft (10) from support (9) with press.
50-266 I
12
ASSEMBLY
1. Assembly of shaft, support assembly.
A. Set support (9) on block [5], and using push tool [6], press fit
shaft (10).
B. Press-fitting force: 19.6 - 106.8 kN (2 - 10.9 ton)
Shaft: Anti-friction compound (LM-P)
2. Install floating seals (8) and (5).

H When installing the floating seal, de-grease and dry the parts
indicated with thick line A (O-ring and mating face of the
O-ring).
H After installing the floating seal, check that its slant is within 1
mm and its projection [a] is 4 - 8 mm (0.2 - 0.3 inches).
Assembly Of Roller Assembly.
1. Using push tool [7], press fit bushing (6).
2. Set shaft and support assembly (7) in position, and assemble roller
assembly (4).
3. Assemble plate (3), and tighten with bolt (2).
Mounting bolt: 176.5 ± 19.6 N•m (130 ± 14 lbf/ft)
4. Fill roller with oil.

H Carrier roller: Approximately 200 - 220 ml (Engine oil
EO30-CD)
5. Fit O-ring to cap (1) and install to carrier roller assembly.
50-267 I
DISASSEMBLY AND ASSEMBLY FINAL DRIVE
12
FINAL DRIVE
H Before removing the travel motor see “SPREADING THE TRACK” on page 50-194 or “TRACK FRAME REMOVAL
PREPARATIONS” on page 50-250.
FINAL DRIVE REMOVAL

1. Prepare machine for removal of the final drive assembly (12).
2. Remove outer rock guard (1) using a 24 mm wrench.
3. Remove inner top rock guard cover (2) using a 24 mm wrench.
50-268 I
4. Remove top (3) and bottom (4) inner covers using a 24 mm wrench
to access hydraulic lines.
5. Remove two outer hydraulic lines (5) and speed sensor (6) as well
as the two “P” clips (7) holding the hydraulic lines in place.
entering them.
6. Remove the inner travel hydraulic top line (8) and bottom line (9).
entering them.
7. Remove hydraulic case drain line (10) and cap opening.
50-269 I
8. After lines are disconnected, remove inner mud guard (11).
H Bundle all lines and be sure to protect speed sensor (6) from
any damage.
9. Remove one gear segment at the top of the drive gear to prepare for
lifting the final drive.
50-270 I
10. Sling the final drive as shown in the illustration.
Final drive assembly: 423.6 kg (934 lbs)
11. Remove all mounting bolts (13) from final drive (12).
12. Pull the final drive (12) out and away from the machines track
frame and mount it in the proper tool for dissemble.
50-271 I
12
INSTALLING THE FINAL DRIVE
H Carry out installation of travel motor in reverse order.
H Place an eye hook in the same location the final drive was removed to realign the position of the travel motor hoses.
1. Reinstall the final drive assembly (12) back into the track frame
(17) in its same position.
2. Once in position, reinstall all 24 mm bolts and torque bolts to the

proper specification.
H Use a Locktite 262 on each bolt before installing them.
Final drive bolts: 490 - 608 N•m (361 - 448 lbf/ft)
3. Attach hoses (8), (9) and (10) then install speed sensor (6) and
hoses (5).
H Inner travel hydraulic top line (8)
Final drive bolts: 98 - 123 N•m (72 - 91 lbf/ft)
4. Reinstall “P” clips (7).
5. Install covers (1), (2), (3), (4) and (11).
6. Reinstall gear segment and tracks.
50-272 I
12
MEMORANDUM
50-273 I
DISASSEMBLY AND ASSEMBLY FINAL DRIVE OVERHAUL PROCEDURES
12
FINAL DRIVE OVERHAUL PROCEDURES
Special Tools
Distinction
Necessary
Sketch
Qty.
1 791-830-1320 Rod n 1
2 01580-01613 Nut n 1
3 01643-31645 Washer n 1
4 790-101-2540 Washer n 1
1
5 790-101-2102 Puller assembly n 1
6 790-201-2830 Spacer n 1
J 7 791-850-1410 Adapter n 1
8 790-101-1102 Hydraulic pump n 1
2 791-427-1410 Wrench n 1
3 791-580-1510 Installer n 1
4 791T-B27-1130 Push tool n 1 N m
5 791T-B27-1120 Push tool n 1 N m
6 79A-264-0091 Scale n 1
DRAINING OIL
1. Remove the drain plug to drain the oil from the final drive case.
Final drive case: 6.0 liter (6.3 qts.)
50-274 I
COVER
1. Remove 16 mounting bolts (1).
H Using two forcing screws M12 [1], remove cover (2).
RING GEAR
1. Remove 28 mounting bolts (3).
H Using two forcing screws M12 [2], remove ring gear (4).
50-275 I
12
NO. 1 PLANETARY CARRIER ASSEMBLY
1. Remove thrust washer (5).
2. Remove No. 1 planetary carrier assembly (6).
3. Disassemble No. 1 planetary carrier assembly according to the

A. Drive pin (7) into shaft (8) (three sets).
B. Remove shaft (8) from No. 1 planetary carrier assembly.
C. After removing the shaft, remove pin (7) from shaft (8) (three
sets).
D. Remove two thrust washers (9), gear (10), and bearing (11)
(three sets).
NO. 1 SUN GEAR
1. Remove No. 1 sun gear (12) first.
NO. 2 SUN GEAR
2. Remove No. 2 sun gear (14).
50-276 I
1. Remove mounting bolts (15) (three sets).
H Using tools J1, pull shaft (16) out of No. 2 planetary carrier
assembly (three sets).
2. Remove ball (17) (three sets).
3. Remove gear (18) from No. 2 planetary carrier assembly (three

sets).
4. Remove two inner race bearings (19) from gear (18) (three sets).
5. Remove two outer race bearings (20) from the gear (three sets).
50-277 I
HUB ASSEMBLY
1. Remove lock plate (22).
A. Using tool J2, remove nut (23).
B. Using two eye-bolts [3], remove hub assembly (24) from No. 2
planetary carrier (HST motor assembly).
50-278 I
2. Disassemble the hub assembly according to the following proce-
dure.
A. Remove floating seal (25).
B. Remove two monobloc bearings (26).
NO.2 PLANETARY CARRIER (HST MOTOR

ASSEMBLY)
1. Remove floating seal (28) from No.2 planetary carrier (29).
50-279 I
12
ASSEMBLY OF FINAL DRIVE
H Clean the all parts and check them for dirt or damage. Coat their sliding surfaces with engine oil before installing.
H Adjust the preload at the normal temperature while the temperature difference between the No.2 planetary carrier
(HST motor assembly), bearing, hub, and nut is 3o or less.
NO.2 PLANETARY CARRIER (HST MOTOR

ASSEMBLY)
1. Using tool J3, install floating seal (28).
A. Remove all oil and grease from the O-ring and O-ring contact
surface, and dry them before installing the floating seal.
B. Insert the tool by pushing the O-ring.

H After installing the floating seal, check that its slant is
within 1 mm (0.4 inches).
H After installing the floating seal, thinly apply engine oil
(TO30) to the sliding parts.
ASSEMBLY OF HUB
1. Using the push tool, press fit two monobloc bearings (26).
H Press fit each bearing until its outer race end comes in full
contact with the hub.
H After press fitting each bearing, check that a thickness
gauge of 0.03 mm cannot go through the clearance
between the outer race end and hub.
2. Using tool J3, install floating seal (25) to the hub assembly.
H For the installation procedure, see step 1 above.
50-280 I
3. Using eye-bolts [3], set hub assembly (24) to No. 2 planetary car-
rier assembly (HST motor assembly).
4. Using push tool [4], press the inner race on the bearing on the nut
side with a press.
H Pressing force on inner race: 10.1 - 14.7 kN (2,270 - 3,304 lbf)
H After installing hub assembly (24), revolve the hub by 2 - 3
turns against the No.2 planetary carrier to fit the rollers bearing
properly.
5. Using tool J2 the nut (23):
A. Tighten the nut to 588 N.m (434 lbf/ft)
B. Revolve the hub by 3 turns to right and 3 turns to left, against

the No.2 planetary carrier.
C. Again, tighten the nut to 588 N.m (434 lbf/ft).
D. Loose the nut to less than 245 N.m (181 lbf/ft).
Remark
Nevertheless, the torque can reach to 0 N.m.
In case of occur 0 N.m torque, then repeat the
operation from step B.> on.
E. Tighten the nut to 314 N.m (232 lbf/ft).
F. Revolve the hub by 3 turns to right and 3 turns to left, against the No.2 planetary carrier.
G. Again, tighten the nut to 314 N.m (232 lbf/ft).
H Nut: Anti-Friction compound (LM-P).

(Apply on contact surface of bearing)
50-281 I
6. Make match marks on nut (23) and No.2 planetary carrier.
7. Using push-pull scale [5], tighten the nut so that the rotating force
of the hub will be as follows:
Nut: 314 - 588 N•m (232 - 434 lbf/ft)
H Rotating force on hole used to assembly tooth (external circumfer-

ence of hub: 142 - 255 N (32 - 57 lbf)
H When tightening the nut to the above torque, check by the

match marks that the nut rotates by 0 - 1 notch.
8. Install lock plate (22).
50-282 I
9. If the lock plate is turned over, it deviates by 1/2 notch.
Accordingly, install it so that its claw will be fitted to a notch of the
nut.
H Threads of mounting bolt: Adhesive (LT-2)
Mounting bolt: 58.8 - 73.5 N•m (43 - 54 lbf/ft)
If the claw of lock plate does not match to a notch of the nut, tighten
the nut in the spec of step 7.
1. Install thrust washer (21).
2. Install two outer race bearings (20) to the gear (three sets).
3. Install two inner race bearings (19) to gear (18) (three sets).
4. Install gear (18) to No. 2 planetary carrier (three sets).
5. Install shaft (16) and ball (17) to No. 2 planetary carrier.

(Recommend apply grease to assemble).
H When installing, take care so that the ball may not be loosened
and/or displaced.
6. Install the shaft by expansion fit.

H Match the hole of the shaft to that of the carrier and install the
shaft by tapping it lightly with a plastic hammer, etc. (three
sets).
50-283 I
7. Tighten mounting bolt (15).
Mounting bolt: 245 - 308.7 N•m (181 - 228 lbf/ft)
H After assembling No. 2 planetary carrier assembly, check that

gear (18) rotates smoothly (three sets).
NO. 2 SUN GEAR
1. Install sun gear (14) and thrust washer (13) to No. 2 planetary
carrier assembly.
NO. 1 SUN GEAR
1. Install No. 1 sun gear (12).
1. Assemble No. 1 planetary carrier assembly according to the

A. Replace the thrust washers and pin with new ones.
B. Install bearing (11) to gear (10) and fit upper and lower thrust
washers (9), then set gear (10) to No. 1 planetary carrier
assembly.
50-284 I
C. Match the pin hole of shaft (8) to that of the carrier and install
shaft (8) by tapping it lightly with a plastic hammer, etc.
D. Take care not to damage the thrust washers.
E. Insert pin (7).

H After inserting the pin, bend pin “a” of the carrier.
H After assembling No. 1 planetary carrier assembly, check
that gear (10) rotates smoothly.
2. Install No. 1 planetary carrier assembly (6).
3. Install thrust washer (5).
RING GEAR
1. Fit the O-ring to the hub side. Using eye-bolts [2] and matching the
bolt holes of ring gear (4) to those of the hub, install ring gear (4).
H Degrease the mating faces of the ring gear and hub.
2. Tighten ring gear (4) with 28 mounting bolts (3).
50-285 I
COVER
1. Using two bolts [1], install cover (2).
2. Install cover (2) to the ring gear with 16 mounting bolts (1).
Cover mating face: Gasket sealant (1207B)
REFILLING WITH OIL
1. Tighten the plug and add engine oil through the oil filler.
Plug: 58.8 - 78.4 N•m (43 - 58 lbf/ft)
Final drive case: Approximately 6.0 liters (6.3 qts.)

(SAE30-CD)
2. Check the oil level after installing the travel motor and final drive assembly to the machine body.
50-286 I
12
MEMORANDUM
50-287 I
DISASSEMBLY AND ASSEMBLY TRAVEL MOTOR OVERHAUL PROCEDURES
12
TRAVEL MOTOR OVERHAUL PROCEDURES
SPECIAL TOOLS
Distinction
Necessary
Sketch
Qty.
1 790-501-5200 Repair stand n 1

A
2 790-901-2110 Bracket n 1
1 791T-B65-1210 Plate n 1  m
2 791T-B65-1140 Push tool n 1  m
3 793T-659-1110 Push tool n 1 m
4 790-445-3810 Push tool n 1
5 791T-B65-1220 Push tool n 1 m
6 791T-465-1120 Push tool n 1 m
7 791T-B65-1120 Push tool n 1 m
B
8 791T-465-1230 Plate n 1  m
9 791-B65-1160 Spline wrench n 1  m
10 791T-527-1310 Plate n 1  m
11 791T-527-1320 Plate n 2  m
12 791T-527-1330 Bolt n 1  m
13 791T-527-1340 Block n 1  m
14 791T-527-1350 Driver n 1  m
TRAVEL MOTOR
1. Install tool B1 to tool A2, then install tool A2 to tool A1.
2. Install travel motor assembly (1) to tool B1.
REMOVAL OF END COVER
1. Remove hose (2).
2. Removal of end cover assembly
A. Remove six mounting bolts (3) and lift off end cover assembly (4).
H When removing the end cover, the valve plate may come off and fall.
End cover assembly: 45 kg (99 lbs)
50-288 I
DISASSEMBLY OF END COVER
1. Disassembly of main valve assembly
A. Remove four bolts and cover sub assembly (5).
B. Remove spring (6) and seat (7).
C. Remove locknut (8).

H Before loosening locknut (8), measure installed dimension
(L1) of adjustment screw (9).
D. Remove locknut (10).

H Before loosening locknut (10), measure installed dimension
(L2) of sleeve (11).
E. Remove adjustment screw (9) and sleeve (11) from cover (5).
2. Disassembly of main piston
A. Remove cover (12).
B. Loosen plug (13).
C. Remove screw (14).
D. Remove pin (15).

H Since pin (15) must be installed in the correct direction,
record its installed direction when removing it.
E. Remove piston (16) to direction (P).
F. Remove plug (13) and sleeve (17) from piston (16).
REMOVAL OF RELIEF VALVE
1. Loosen the screw of relief valve (19) and remove relief valve
assembly (18) from end cover (4).
2. Replace the relief valve with an assembly, when it is abnormal.
50-289 I
DISASSEMBLY OF SHUTTLE VALVE
1. Remove plugs (30) from left side and right side.
2. Remove spring (31), seat (34), and spool (33).
3. Remove two plugs (35).
REMOVAL OF CYLINDER BLOCK
2. Remove bushing (37) from valve plate (36).
3. Pull out six springs (38).
4. Pull out cylinder block (39).
REMOVAL OF PISTONS
1. Remove retainer mounting screws (40).
2. Remove center shaft assembly (41), piston sub-assembly (42) and

retainer (43) as a set.
3. Remove spring (44), center ring (45) and center shaft (41) from
retainer (43).
4. Remove seven piston sub-assemblies (42).
50-290 I
DISASSEMBLY OF BRAKE AND PISTON
1. Sling brake piston assembly (46).
2. Apply air pressure through the oil hole to float brake piston
assembly (46).
3. Lift off brake piston assembly (46).
4. Remove four plates (47) and three discs (48) in order.
5. Remove plate (58).
REMOVAL AND DISASSEMBLY OF DRIVE SHAFT
1. Lift off drive shaft assembly (49).
50-291 I
2. Remove snap ring (50) and spacer (51).
3. Using bearing puller, remove sub bearing (52), retainer (53) and
main bearing (54) as a set.
H Record the installed direction of retainer (53).
4. Remove sub bearing (52) and main bearing (54) from shaft.
REMOVAL OF OIL SEAL
1. Remove oil seal (57) from motor case (56).
50-292 I
12
ASSEMBLY PROCEDURES
H Clean each part carefully and remove burrs etc. In particular, clean the drilled oil passages thoroughly.
H Coat the rotating/sliding parts with engine oil (EO10 or equivalent) before installing.
INSTALLATION OF MOTOR CASE
1. Set motor case (56) to tool B1.
Install of oil seal.

H A new retainer and spacer to prevent slope of the oil seal (57),
and clearance (a) of between motor case (56) and oil seal (57)
is adjusted less than 0.3 mm using the spacer (61).
50-293 I
Parts and serial number introduction

Current type Improved type
No. Parts Parts Serial Parts Serial
number number number number
EEY50001
Motor EEY52650
706-8H-01110 to 706-8H-01111
L.H. and up
EEY52649
1
EEZ50002
Motor EEZ52631
706-8H-01120 to 706-8H-01121
R.H. and up
EEZ52630
New parts number

Parts number Spacer
No. Parts
Current type Improved type thickness
Motor
56 706-8H-41310 706-8H-41311
Case
57 Oil Seal 708-27-22811 706-8H-41880
60 Retainer 706-7H-41870
706-8H-41820 0.5 mm
706-8H-41830 0.6 mm
61 Spacer 706-8H-41840 0.7 mm
706-8H-41850 0.8 mm
706-8H-41860 0.9 mm
1. Decide to insert the spacer thickness.

A. Measure of case’s height (H2) and the oil seal’s width (H1).
i. Measure height of the oil seal insertion portion on the case
(56) by the depth gauge [1]. Height of the oil seal insertion
portion: H2 = b - c
50-294 J
B. Measure width of the oil seal (57): H1. Measure the oil seal
(57) by depth gauge [2].
H Oil seal’s width: H1 = 12 ± 0.4
2. Selection of spacer thickness.

H Selection thickness = H2 - H1. (Height of the oil seal insertion portion Oil seal’s width). Select the applicable spacer
(61) from the following list (table 1).
Table 1: Selection table of spacer for oil seal
The use spacer is assumed to

Necessary thickness
be Q sings of the table below

of spacer [total
of two spacer]
Thickness of spacer
No. H1-H2
0.5 0.6 0.7 0.8 0.9
1 1.45 -1.600 1.3 Q Q

2 1.35 - 1.449 1.2 QQ
3 1.25 - 1.369 1.1 Q Q
4 1.05 - 1.249 1.0 QQ
5 1.05 - 1.149 0.9 Q
6 0.95 - 1.049 0.8 Q
7 0.85 - 0.949 0.7 Q
8 0.75 - 0.849 0.6 Q
9 0.6 - 0.749 0.5 Q
706-8H- 706-8H- 706-8H- 706-8H- 706-8H-
Part No. of spacer
41820 41830 41840 41850 41860
50-295 I
3. Press the oil seal (57) to motor case (56) with tool B2 by hammer
[3].
H Check pressed condition.
H Check whether there is damage or dent. (d, e portion)
4. Insert tool B3 into the oil seal (57).

H Check whether there is damage or dent. (f portion)
5. Insert the spacer (61) selected from table - 1.

H Set in the spacer (61) slowly.
50-296 I
6. Insert the retainer (60) into motor case (56).
H Both grooves of the motor case (56) and the retainer (60) are
put together at this time. This time, portion the motor case (56)
groove (g) and the retainer (60) groove (h).
7. Using tool list of the retainer (60) insertion.

H Using tool B10 to B14.
A. Mount tool B14.

H Mount tool B14 slowly.
B. Set tool B10 to B12.

i. Tool B10 is assembled with tool B11 on the motor case (56).
ii. Set tool B12 on the tool B10.
iii. Tightening tool B12 by the set wrench.
H Tightening torque: Tighten tool B12 with 50 Nm to 60
Nm.
50-297 I
C. Remove tool B10 and B12 from the motor case (56).
D. Check of the pressed retainer (60) condition.
H Check whether retainer (60) is pressed horizontally or not.
H Check whether there is damage or dent.
8. Remove tool B13.

H Remove tool B13 slowly.
50-298 I
ASSEMBLY OF DRIVE SHAFT
1. Assemble the drive shaft assembly according to the following

procedure.
H Using tool B3 and the press, install main bearing (54) to drive
shaft (49).
2. Apply oil to the press fitting surface of the main bearing in advance.
Press fitting surface: Engine oil (EO10) or equivalent
3. Press fit the main bearing until its inner race end face (d) is fitted to
the drive shaft.
H Press fitting load: 17.7 - 44.1 kN (3,979 - 9,914 lbf)
4. Install retainer (53) and the outer race of sub bearing (52).
H Take care not to mistake the installed direction of the retainer.
H Using tool B4 and the press, press fit sub bearing (52).
5. Apply oil to the press fitting surface of the sub bearing in advance.
H Press fitting surface: Engine oil (EO10) or equivalent
6. Press fit the sub bearing until its outer race end face is fitted to the
drive shaft.
H Press fitting load: 9.82 - 24.5 kN (2,208 - 5,508 lbf)
7. Install spacer (51) and install it temporarily with snap ring (50).
H Check to be sure snap ring is fitted to the snap ring groove.
8. Select spacer (51) so that clearance (L4) between snap ring (50) and
inner race of sub bearing (52) will be 0.02 - 0.10 mm (0.001 - 0.004
inches).
Dimension [L4] Spacer thickness

Part number
mm (in) mm (in)
2.14 - 2.149
1.9 (0.1) 706-7H-41220
(0.1 - 0.1)
2.15 - 2.349
2.1 (0.1) 706-7H-41230
(0.1 - 0.1)
2.35 - 2.549
2.3 (0.1) 706-7H-41240
(0.1 - 0.10)
2.55 - 2.749
2.5 (0.1) 706-7H-41250
(0.10 - 0.11)
2.75 - 2.86
2.7 (0.11) 706-7H-41260
(0.11 - 0.11)
9. Install selected spacer (51) and install it with snap ring (50).
50-299 I
10. Push out drive shaft (49) until the end surface of inner race of sub bearing (52), spacer (51) and snap ring (50) are brought
into full contact.
H Push out load [P]: 1.53 - 4.63 kN (344 - 1,041 lbf)
ASSEMBLY OF PISTONS
1. Assemble center shaft (41) and piston sub assembly (42) to retainer
(43).
2. Install center shaft and piston sub assembly and retainer to drive
shaft assembly as a set.
3. Install retainer (43) with screw (40).

H Do not reuse screw (40) but replace it with new one.
H Degrease the threaded parts (male and female) thoroughly and
dry them, and then apply two drops (about 0.04 g) of adhesive
to each of them.
Threaded part: Adhesive (LOCTITE No. 262)
4. Be sure to install screws (40) in the order of [1], [4], [7], [3], [6], [2]
and [5] as shown in the figure.
H Tighten screws (40) according to the following procedure.
• 1st time: Temporarily tightening [Max. 0.98 N•m (1.0 lbf/
ft)]
• 2nd time: 7.8 - 9.8 N•m (6 - 7 lbf/ft)
• 3rd time: 22.6 - 26.5 N•m (17 - 20 lbf/ft)
H After tightening screws (40), check that adhesive is not
projected.
H After tightening screws (40), do not apply pressure for 30
minutes.
H After tightening screws (40), check to be sure large spherical
part of piston assembly (42) and drive shaft (49) move
smoothly.
H After tightening screws (40) and the adhesive is hardened perfectly, the return torque must be 26.5 N•m (20 lbf/ft) or
larger.
H After tightening screws (40), check to be sure play of the piston assembly and center shaft in the axial direction is 0.5
mm (0.2 inches) or less.
INSTALLATION OF DRIVE SHAFT ASSEMBLY
1. Sling and install drive shaft assembly (49).
2. Install center ring (45) and spring (44) to center shaft (41).
3. Install cylinder block (39).
50-300 I
H Using tool B5, press fit drive shaft assembly (49) to motor case
(56).
H Press fit until the outer race end face of main bearing (55) is
fitted to the case.
INSTALLATION OF DISCS AND PLATES
1. Install plate (58).
2. Install plates (47) and discs (48) alternately.

H Before installing the discs, apply lubricating oil to them. (Do
not clean the discs with trichloroethylene, denatured alcohol,
etc. or blow air strongly against them.)
H Plates (47) and discs (48) may be installed to any positions in
the arc phase.
INSTALLATION OF BRAKE PISTON
1. Sling and install brake piston (46).
2. Install spring (38).
ASSEMBLY OF END COVER

H Installation of dowel pin
H If dowel pin (59) was removed, install it to end cover accord-
ing to the following procedure (in figure).
• Br: Brake piston side
• Ec: End cover piston side
1. Using tool B6, install the dowel pin with the grooved side (G) on
the brake piston side (Br).
2. Install the dowel pin so that installed dimension (L5) will be in the
following range.
H L5: 16.5 - 17.9 mm (1.0 - 1.0 inches)
50-301 I
ASSEMBLY OF SHUTTLE VALVE
1. Install spring (31), spool (33), and seat (34).
Plug: 63 - 83 N•m (46 - 61 lbf/ft)
3. Install the spring and plug on the opposite side.
H Installation of relief valve assembly
4. Install relief valve assembly (18) to end cover (4).
Sleeve: 49 - 59 N•m (36 - 44 lbf/ft)
ASSEMBLY OF MAIN PISTON
1. Install spool (17) to piston (16).
2. Put O-ring to plug (13) and install plug (13) to piston (16).
Plug: 63 - 83 N•m (46 - 61 lbf/ft)
3. Put O-ring to piston assembly (16) and install piston assembly (16)
to end cover.
4. Install pin (15) and install it with screw (14).

H Check the installed direction of pin (15).
H Check dimension (L6) to confirm that screw (14) is installed in the hole of pin (15).
5. Degrease the threaded parts of the screw and piston thoroughly with trichloroethylene and dry them, and then apply two
drops (about 0.04 g) of adhesive to each of them.
H After tightening the screw, do not apply oil for at least one hour until the LOCTITE is hardened.
H After tightening the screw, do not apply pressure for at least six hours.
Threaded part: Adhesive (LOCTITE No. 262)
Screw: 5.9 - 7.8 N•m (4.4 - 6 lbf/ft)

(width across flats of screw: 3 mm)
6. Put O-ring to cover (12), and install cover (12) to end case.
50-302 I
INSTALLATION OF MAIN VALVE
1. Install adjustment screw (9), spring (6) and seat (7) to sleeve (11).
H Put O-ring to adjustment screw (9) before installing it.
2. Install sleeve assembly to cover (5).

H Put two O-rings to sleeve before installing them.
3. Set installing height to dimension (L2) which was measured at dis-

assembling procedure.
4. Install locknut (10).
Locknut: 78.5 - 103 N•m (58 - 76 lbf/ft)
5. Set installing height of adjustment screw (9) to dimension (L1) which was measured at disassembling procedure.
6. Install locknut (8).
Locknut: 98 - 123 N•m (72 - 91 lbf/ft)
INSTALLATION OF VALVE PLATE
1. Set valve plate assembly (36) and a spherical portion of pin to be

the same axis, and put the valve plate assembly on the circular
cylinder surface of end cover (4).
2. Install the portion [S] of valve plate (36) by pushing the hollow on
the side of it by tool B7.
50-303 I
H This procedure prevents the valve plate (36) from falling down
when turning over end cover (4).
NSTALLATION OF END COVER
1. Install tool B8 to guide bars (F) installed to the two bolt holes of
motor case (56).
2. Set the bolt holes of the end cover (4) to guide bars (F) installed to
the motor case (56). Lower the end cover along the guide bars while
setting the center shaft to the valve plate bushing, brake piston and
dowel pin.
H Finger tighten the bolts lightly into the four bolt holes other
than the ones to which guide bars (F) are installed.
3. Pull out guide bars (F) and remove tool B8.

H Install the bolts to the bolt holes from which guide bars (F)
were pulled out.
4. Tighten the six mounting bolts to the specified torque.
5. Remove sling and eye-bolts [1], and install two plugs.
Plugs: 34.3 - 44.1 N•m (25 - 33 lbf/ft)
6. Remove tool B7 and install the plug.
Plug: 19.6 - 27.5 N•m (14 - 20 lbf/ft)
50-304 I
CHECK OF SHAFT ROTATION TORQUE

H Using tool B9, rotate the shaft at a constant speed of about five
sec/turn and measure its rotation torque.
H The rotation torque must be even and in the following range.
H When measuring the rotation torque, apply the following pressure
to port (B) to release the brake.
H (B) port pressure: 2.45 ± 0.49 MPa (355 ± 71 psi)
Unevenness: Max 1.47 N•m (1.1 lbf/ft)

Rotation torque: 7.8 - 19.6 N•m (6 - 14 lbf/ft)
50-305 I
DISASSEMBLY AND ASSEMBLY FAN MOTOR
12
FAN MOTOR
WARNING! When opening the rear grill be sure rear grill is secured in place before proceeding
under this grill. Failure to do so may result in serious injury.
Do not start the engine when fan guard is removed. If engine is started without fan
guard in place, serious injury may result.
REMOVAL PROCEDURES
H Position the machine on a flat level work surface.
H Be sure the area around the rear of the machine is clear so the grill can be opened and closed to its full position.
DISCONNECTING THE GRILL FROM THE FAN
1. To prepare the grill (1) for opening, remove the two middle
mounting bolts (a) first, using a 24 mm wrench.
WARNING! Do not remove mounting bolts (c).

Leave these mounting bolts in place
until you are ready to open the grill in
Step 3.
2. On the top of grill (1), remove the two top mounting bolts (b) using
a 24 mm wrench.
3. Once the middle bolts (a) are removed and the top bolts (b) are
removed, remove the last two bottom mounting bolts (c) using a 24
mm wrench.
WARNING! When removing bottom bolts (c), hold

on to the grill assembly as shown in
the illustration to prevent the grill from
springing open suddenly. Failure to do
so may result in personal injury.
50-306 I
12
4. Once both bolts (c) are removed, grasp the grill firmly with both
hands and carefully lift the grill (1) to a completely open position so
pump (2) can be accessed.
WARNING! Always be aware that the grill is

spring-loaded and will open quickly.
Keep your upper body out of the way
and both hands on the grill when open-
ing the grill.
DISCONNECTING HYDRAULIC FAN MOTOR
1. Remove fan speed sensor cover (3) using a 14 mm wrench to access

the wiring harness for the reverse solenoid.
2. Disconnect connector (4) and remove the three “P” clips (5).
3. Disconnect the three hydraulic hoses (6) from motor.

hydraulic system.
50-307 I
4. Once hoses and wiring harness are disconnected, lower grill (1)
back down to the closed position and reinstall middle bolts (a) to
secure grill to fan blade guard (7).

and both hands on the grill when clos-
ing the grill.
H Tighten middle bolts (a) to a temporary torque to secure grill

and shroud.
Middle grill bolts: 33.8 N•m (25 lbf/ft)
REMOVING THE FAN GUARD
1. Raise the grill (1) back up to the open position and remove fan
blade guard (7). To access fan motor remove four bolts using a 14
mm wrench.
Fan guard: 10.1 kg (23 lbs)
2. Fan blades (8) must be removed in order to remove fan motor (2).
A. Remove bolt and lock (9) first using a 17 mm wrench.
B. Once lock (9) is removed, loosen shaft nut (10) four to five
turns only.
C. Using a two-jaw puller, pull the fan hub off the tapered shaft of
the motor using the pre-taped bolt holes in the fan hub as
shown in the illustration.
Remark
Do not remove shaft nut (10) until the fan hub is loose on
the taper shaft.
Fan assembly: 9.1 kg (20 lbs)
50-308 I
REMOVING THE FAN MOTOR
1. Remove the four fan motor mounting bolts (11) being careful not to
damage the fan speed sensor (12).
2. Once the fan motor bolts (11) are removed, lower the grill assembly
(1) back down and remove bolts (a).

and both hands on the grill when clos-
ing or opening the grill.
3. Open grill (1) to the full position.
4. Lift out the fan motor assembly (2) from its mounting.
50-309 I
12
INSTALLATION PROCEDURES
1. Set fan motor (2) securely in place and carefully lower grill (1).

and both hands on the grill when
closing or opening the grill.
2. Reinstall middle bolts (a) and torque to temporary specifications.
Middle grill bolts: 33.8 N•m (25 lbf/ft)
3. Raise grill (1) and install the fan mounting bolts (11) while rotating
fan motor (2) back and forth to align the proper bolt holes.
Motor bolts: 59 - 74 N•m (44 - 55 lbf/ft)
Remark
Be careful not to damage the fan speed sensor when
installing the fan motor.
4. Reinstall fan (8) and torque the shaft nut (10) to proper
specifications.
Fan shaft nut (10): 98 - 127.5 N•m (72 - 94 lbf/ft)
5. Install lock and bolt (9) then torque to proper specifications.
Lock bolt (9): 59 - 74 N•m (44 - 55 lbf/ft)
6. Reinstall fan guard (7) on to grill (1) and torque the four mounting
bolts to the proper specifications.
Fan guard (7):59 - 74 N•m (44 - 55 lbf/ft)
50-310 I
7. Close grill assembly (1) and remove middle bolts (a).
WARNING! When removing middle bolts (a), hold

on to the grill assembly to prevent the
grill from springing open suddenly.
Failure to do so may result in personal
injury.
8. Grasp the grill firmly with both hands and carefully lift the grill (1)
to a completely open position so pump (2) can be accessed.
9. Reinstall the hoses (6), connect wiring harness (4) and install “P”
clips (5).
10. Reinstall fan speed sensor cover (3).
11. Once all hoses, “P” clips and wiring harness is connected, close
grill (1) and install bottom bolts (c) first then middle bolts (a) and
top bolts (b).
Grill bolts: 245 - 309 N•m (181 - 228 lbf/ft)
12. Start the engine and check the operation of the fan.
H Check for any leaks or abnormalities when fan is operating.
50-311 I
DISASSEMBLY AND ASSEMBLY FAN MOTOR OVERHAUL PROCEDURES
12
FAN MOTOR OVERHAUL PROCEDURES
SPECIAL TOOLS
Distinction
Necessary
Sketch
Qty.
1 790-501-5200 Repair stand n 1

A
2 790-901-2110 Bracket n 1
1 791T-B7R-1110 Plate n 1  m
1 01010-81260 Bolt l 1
2 796T-126-1160 Washer n 1 m
2
3 01643-31445 Washer l 1
D
4 01582-01210 Nut l 1
3 796T-267-1140 Push tool n 1 m
4 791T-B7R-1130 Push tool n 1  m
5 791T-B7R-1120 Push tool n 1  m
FAN MOTOR
1. Install tool D1 to tool A2, then install tool A2 to tool A1.
2. Install fan motor assembly (1) to tool D1.
REMOVAL OF END COVER
1. Remove four mounting bolts (2) and end cover assembly (3).
H When removing the end cover, the valve plate may come off
and fall.
DISASSEMBLY OF END COVER
1. Remove outer race (4) of the sub bearing.
2. Remove spacer (5).
50-312 I
3. Remove four mounting bolts (6) and pilot valve assembly (7).
4. Remove four mounting bolts (8) and cover (9).
5. Remove spring (10), spacer (11) and spool (12).
6. Remove spool (13).
7. Remove two plugs (14).
9. Remove plug (16) and spring (16a).
10. Remove suction valve (17)
DISASSEMBLY OF PILOT VALVE
1. Remove two mounting bolts (18) and remove solenoid valve

assembly (19) from pilot valve assembly (7).
2. Remove spool (20) and spring (21).
3. Remove plugs (22), (23), (24).
4. Remove plug (25) and filter (26).
50-313 I
CYLINDER BLOCK, SHAFT AND PISTON
2. Pull out cylinder block and piston assembly (28) from motor case
(29).
H Direct the case aside so that the cylinder block and piston
DISASSEMBLY OF CYLINDER BLOCK AND

PISTON
1. Remove bearing (30) from shaft (31) by using bearing puller.
2. Remove cylinder block and piston assembly (28) from shaft (31).
3. Remove thrust plate (34a).
4. Pull out piston assembly (32) from cylinder block assembly (33).
5. Remove seven pistons (32) from shoe retainer (34).
50-314 I
6. Remove retainer guide (35).
7. Remove three pins (36).
H Set tool D2 to cylinder block assembly (33) and compress

spring (37).
8. Remove snap ring (38) from cylinder block (33) and remove tool
D2.
9. Remove seat (39), spring (37) and seat (39).
DISASSEMBLY OF SHAFT
1. Using bearing puller, remove bearing from shaft.
DISASSEMBLY OF MOTOR CASE

H Removal of oil seal
B. Using tool, remove oil seal (42) from inside of the motor case.
50-315 I
12
ASSEMBLY PROCEDURES
H Clean each part carefully and remove burrs etc. In particular, clean the drilled oil passages thoroughly.
H Coat the rotating/sliding parts with engine oil (EO10) before installing.
INSTALLATION OF MOTOR CASE
1. Set tool D1 to tool A2 and install motor case (29) to tool D1.
2. Install bearing outer race (43) to motor case (29).
ASSEMBLY AND INSTALLATION OF SHAFT
1. Using tool D3 and the press, press fit bearing (40) to shaft (31).
2. Apply grease sufficiently to the press fitting surfaces (inside of the

inner race and outside of the shaft).
3. Press fit the bearing until the end surface (a) of it is fitted to the
shaft flange.
4. Press fitting load: 1670 - 7000 N (375 - 1,574 lbf)
5. Install shaft assembly (28) to motor case (29).
50-316 I
ASSEMBLY OF CYLINDER BLOCK AND PISTON
1. Install seat (39), spring (37) and seat (39) to cylinder block (33).
H Set tool D2 to cylinder block (33) and compress spring (37).
2. Install snap ring (38) and remove tool D2.
3. Install three pins (36) to cylinder block.
4. Install retainer guide (35).
5. Install seven pistons (32) to shoe retainer (34).
H The dispersion of flange thickness (Ts) of the seven pistons

must be the following thickness (Ts).
H Ts: Max ± 0.005
6. Install piston (32) and shoe retainer (34) together to cylinder block
(33).
7. Install thrust plate (34a).
50-317 I
INSTALLATION OF CYLINDER BLOCK AND

PISTON
1. Install cylinder block and piston assembly (28) to motor case (29).
H Direct the case aside so that the cylinder block and piston
assembly will not come off.
H Using tool D4 and the press, press fit sub bearing (30) to shaft
(31).
2. Press fit the outer race of main bearing to the motor case in
advance.
3. Press fit the sub bearing until the end surface (a) of inner race is
fitted to the shaft end face.
H Press fitting load: 1300 - 2750 N (292 - 618 lbf)
4. Select spacer which is installed with sub bearing outer race at

procedure.
5. Put outer race of sub bearing after press fitting inner race of sub
bearing (30) to shaft (31).
6. Measure the height (X1) between upper surface of motor case and
end surface of outer race, and depth (X2) of end cover.
7. Select spacer to conform to following table.

H (X) = (X2) - (X1)
X is mm (in) Part number

1.29 - 1.38 (0.050 - 0.054) 708-7S-12260
1.19 - 1.28 (0.05 - 0.05) 708-7S-12320
1.09 - 1.18 (0.043 - 0.046) 708-7S-12250
0.99 - 1.08 (0.04 - 0.04) 708-7S-12310
0.89 - 0.98 (0.04 - 0.04) 708-7S-12240
0.79 - 0.88 (0.031 - 0.035) 708-7S-12290
50-318 I
INSTALLATION OF OIL SEAL
1. Using tool D5, press fit oil seal (42).
2. Press fit surface (a) of tool D5 until surface (b) of motor case (29).
3. Clean oil seal and apply lubricant top of lip (c), before install the oil
seal.
Lip (c): Lithium grease (G2-LI-S)
ASSEMBLY OF END COVER

H Assembly of pilot valve assembly
1. Install filter (26), and tighten plug (25).
Plug: 19.6 - 24.5 N•m (14.4 - 18 lbf/ft)
50-319 I
2. Install plugs (22), (23), (24).
3. Replace these plugs with new ones.
Plug (22): 9.8 - 12.74 N•m (7.2 - 9.4 lbf/ft)

Plug (23), (24): 7.8 - 13.7 N•m (6 - 10 lbf/ft)
4. Install shaft (21) and piston (20).
5. Install solenoid valve assembly (19) to pilot valve assembly (7),

then tighten with 2 bolts (18).
Bolts: 11.8 - 14.7 N•m (8.7 - 11 lbf/ft)
6. Install suction valve (17).
7. Install spring (16a) and plug (16).
Plug: 147 - 186 N•m (108 - 137 lbf/ft)
Plug: 19.6 - 24.5 N•m (14.4 - 18 lbf/ft)
9. Install two plugs (14).
Plugs: 24.5 - 34.5 N•m (18 - 25 lbf/ft)
10. Install spool (13).
11. Install spring (10), spacer (11) and spool (12).
12. Install cover assembly (9), and tighten with four bolts (8).
Bolts: 27 - 34 N•m (20 - 25 lbf/ft)
13. Install pilot valve assembly (7), and tighten with four bolts (6).
Bolts: 27 - 34 N•m (20 - 25 lbf/ft)
50-320 I
INSTALLATION OF END COVER
1. Install spacer (5).
2. Install outer race of sub bearing (4).
3. Install valve plate (27).

H Make sure that valve plate does not interfere with sub bearing
and dowel pin (44).
H No impact such as tapping on valve plate permissible in
assembling.
H Mating face between valve plate (27) and end cover (3) must
be completely fitted, contacting surface not less than 80%.
4. Install end cover (3) to motor case (1), and tighten with four bolts
(2).
H Make sure that end cover does not interfere with dowel pin in
mounting on case.
H Take care not to bite O-ring.
H Apply gasket sealant on mating surface between end cover and
motor case.
H Mating surface between end cover and motor case: Gasket
sealant (LG-5/LG-7)
5. After finishing assembly, measure the end play of the shaft (31).
H If the end play is 0, replace sub bearing (31) with new one.
Bolt: 59 - 74 N•m (44 - 55 lbf/ft)
50-321 I
CHECK OF SHAFT ROTATION TORQUE

H Set the torque wrench with bolt (M = 8, P = 1.25) to the shaft
(31).
H Rotate the shaft at a constant speed of 3 - 5 sec/turn and
H The rotation torque must be even and in the following range.
50-322 I
12
MEMORANDUM
50-323 I
DISASSEMBLY AND ASSEMBLY DB 12 VALVE
12
DB 12 VALVE
H Park the machine on a level and stable surface before preceding with removal and installation procedures.
H Be sure all pressure is relieved in the hydraulic system.
REMOVAL
1. Disconnect hose bank (1).
H Be sure to color-tag all hoses for correct installation.
H Cap all hoses and fittings to prevent dirt and debris from
H To access the inner side of the DB12 valve you can remove the
operator’s seat and right lower access panel. see “SEAT” on
page 50-65.
H To remove panel, remove the six bolts using a 5 mm allen
wrench.
2. Disconnect hydraulic lines on DB12 (PPC) valve.

H Cap all hoses and fittings to prevent dirt and debris from
A. Three Front lines (2), (3), (4)

Three Rear lines (Blue - Top; White - Middle; Red - bottom)
One top line
B. Disconnect the three front lines. Tag lines (2, 3, 4 and 5) for
reassembly.
50-324 I
C. Remove the top line (6) and lay to the side for access to the rear
lines.
D. Remove the three rear lines (7), (8) and (9).

H These lines have Quick Coupling Connectors
H View is shown with cab removed from machine.
50-325 I
INSTRUCTIONS
i. Locate the lines with rubber selves.
ii. Peel rubber sleeve on hose fitting back to expose the

plastic lock on the coupler.
iii. With one hand push hose inward and at the same time with
a small flat head screw driver push down on the
plastic lock (you will hear a click sound).
iv. In one motion pull up and remove the hose and plastic
lock from the valve fitting.
1. Disconnect electrical connector (10) and remove mounting bolts

(11), then lift DB12 valve off the frame.
50-326 I
INSTALLATION
1. Install valve body to frame using set up in illustration.

H Bolt (a), large washers (b), rubber cushions (c), spacer (d) and
O-ring (e).
H Torque bolts (a).
Mounting bolts (a): 98 - 122.5 N•m (72 - 90 lbf/ft)
2. Install all hydraulic lines in order, then torque couplings.
Hydraulic lines: 29.4 - 39.2 N•m (22 - 29 lbf/ft)
3. Add hydraulic oil if necessary.
4. Start engine and operate work equipment while checking for leaks.
50-327 I
DISASSEMBLY AND ASSEMBLY COOLING PACKAGE
12
COOLING PACKAGE
Always pay attention to the spring tension on the grill when removing or installing
any of the grill components. Keep all upper body parts away from the grill when
opening or closing it.
REMOVING THE GRILL AND COOLING FAN ASSEMBLY

H Although this procedure is shown with the operator cab removed, it is not necessary to remove the cab in order to remove
the grill or any related parts of the cooling package.
REMOVING THE GRILL FRAME

H In order to remove any parts of the cooling package, it is necessary
to remove the grill and cooling fan assembly first.
1. To prepare grill frame (10) for removal, remove the two middle
bolts (1) completely using a 24 mm wrench.
2. Remove one bottom bolt (2) completely and loosen bolt (3) using a
24 mm wrench.
Remark
Do not remove bolt (3) at this time.
3. Remove the two top grill frame bolts (4) completely using a 24 mm
wrench.
H It is not necessary to remove top cover at this time.
4. Grasp the grill frame with one hand and remove the final bottom
bolt (3) using a 24 mm wrench.
WARNING! When removing bottom bolt (3), hold

on to the grill assembly as shown in
the illustration to prevent the grill from
springing open suddenly. Failure to do
so may result in personal injury.
50-328 I
5. With both hands on the grill frame (10), open the grill frame
completely.
WARNING! Grill frame is spring-loaded. Keep your

upper body out of the way and both
hands on the grill frame when opening
the grill.
6. Once the grill frame is open, sling the grill frame (10) as shown in
the illustration to prepare for removing the gas-filled struts and
latching mechanisms.
7. Using a flat blade screw driver, pry down on strut cylinder (6) and
remove pin (7) on each side of grill frame (10).
50-329 I
8. Once the struts (6) are released from grill frame (10) remove struts
(6) completely from both sides of the grill and set them aside.
9. Remove the pins (8) that link the latching linkage (9) together on
each side of the grill frame.
H Wire each upper latch arm (9) to the grill frame (10) as shown
in the illustration. This will prevent the latch from getting
caught when the grill is lowered.
50-330 I
H Lift grill frame (10) up as high as possible to access the top
cooling fan hardware.
Remark
If the cab is on the machine when lifting the grill frame
(10), be careful not to lift it too high as you may cause
damage to the rear window.
10. At this time, it is best to remove the baffles on each side of the
cooling fan shroud.
H Removing the baffles will allow access to the top pins that
support the grill frame and cooling fan assembly.
A. The left side baffle (12) cannot be removed completely.

However, it is important to remove the two mounting bolts (11)
using a 13 mm wrench so the left side baffle can be pulled for-
ward.
H To access pivot pin (15), the left side baffle (12) must be
pulled forward.
50-331 I
B. Remove bolts (13) using a 13 mm wrench and remove right
side baffle (14).
H Baffle (14) can be lifted off the fan shroud completely.
11. Remove the cotter pins and washers from the pivot pins (15) on
each side of the grill frame and cooling fan.
Remark
Do not remove the pivot pins at this point, just remove the
cotter pins and washers.
H Once the pivot pins (15) are prepared for removal and the right
baffle (14) is removed as well as the left baffle (12) is loosened,
lower the grill frame (10) back down to the closed position.
50-332 I
12. Unhook the sling at this point to reposition it above the grill frame
for lifting the grill frame (10) off the machine.
13. If the top cover (5) has not been removed, remove the top cover (5)
using a 17 mm wrench to access the pivot pins (15) under the cover.
50-333 I
14. Using the taped bolt holes in the top part of the grill frame (10),
install two 17 mm eye-bolts and sling the frame as shown in the
illustration to prepare for removing the grill frame (10).
H When the operator’s cab is in place you can sling the grill
frame as well as the cooling fan assembly using this method
shown in the illustration.
H Avoid using any chains or cables to lift these components as
the chains or cables may damage the cab. Always use a soft
nylon strap that will not damage cab components.
H Be aware of the air conditioning unit and rear glass when
lifting the grill frame or cooling fan assembly.
H With slight upward tension on the grill frame (10), pull the
pivot pins (15) out far enough to release the grill frame from
the cooling fan frame as shown in the illustration.
WARNING! Do not remove the pivot pins (15)

completely. Doing so will cause the
cooling fan assembly to fall down into
the machine frame.
50-334 I
15. Once the grill frame is free from both sides, lift it up from the
machine to expose the cooling fan assembly.
Grill frame: 96 kg (154 lbs)
REMOVING THE COOLING FAN ASSEMBLY
1. Remove speed sensor cover (1) using a 14 mm wrench.
2. Remove the two left side hydraulic hoses (2) and the one right side
hose (3) from the fan motor (hoses 22 mm and 27 mm wrench).
hydraulic system.
3. On the left side of the cooling fan assembly, remove the two “P”
clamps (4) that support the two left side hydraulic hoses (2)
50-335 I
4. On the right side of the cooling fan assembly, remove the two “P”
clips (5) that support the one right side hydraulic hose (3) using a
19 mm wrench.
5. Disconnect the one gray wiring harness connector (6) from the
main harness.
6. Lay both sets of hoses (2) and hose (3) over the hydraulic and fuel
tank to keep them away from the cooling fan assembly.
H At this point, install two 10 mm eye-bolts into the top of the

cooling fan assembly frame and sling the assembly as shown in
the illustration.
50-336 I
7. Lift up on the cooling fan assembly slightly and remove both pivot
pins (15) completely.
H At this time the cooling fan assembly should be free and ready
to come off the machine.
8. Move the cooling fan assembly away from the machine in a rear-
ward direction first and then lift it out of the machine frame.
Cooling fan assembly: 49.9 kg (110 lbs)
50-337 I
H The cooling package is now ready to be removed from the machine.
50-338 I
12
REMOVING THE COOLING PACKAGE
H The cooling package consists of three cooling components:
A. Radiator.
B. Hydraulic cooler.
C. Charge air cooler.
REMOVING THE FAN SHROUD

H The fan shroud is joined in two sections (1) and (2) and must come
out one section at a time.
1. To remove the right fan shroud (1), first remove the top junction
bracket (3) using a 17 mm wrench.
2. Remove the bottom junction bracket (4) using a 17 mm wrench.
3. Remove the right side mounting bolts (5) on outside of fan shroud
(1) using a 17 mm wrench.
50-339 I
4. Pull the rubber gasket (6) off of the fan shroud (1) to remove right
side fan shroud (1).
Remark
It is not necessary to remove the rubber gasket (6) from
the left side fan shroud (2), this can be left in place.
5. Carefully lift out fan shroud (1) being careful not to make any
contact with the radiator core of the cooling package.
6. Lift out baffle (12) so removal of the left side fan shroud (2) can be
accomplished.
H Remember to reinstall this baffle before installing the cooling
fan assembly and grill, this cannot be installed after the cooling
fan or grill are in place.
50-340 I
7. Remove two top bolts (8) from fan shroud (2) using a 17 mm
wrench.
8. Remove bracket (7) before removing fan shroud (2).
9. Carefully lift out fan shroud (2) being careful not to make any
contact with the air charge core of the cooling package.
H The cooling package may now be removed.
50-341 I
12
REMOVING THE RADIATOR
H Drain the cooling system first, see “DRAINING THE COOLING SYSTEM” on page 50-77.
1. After the cooling system is empty, remove the top aeration hose (1)
and top inlet hose (2).
H The front upper hose connections for the cooling package can
be accessed without removing the cab. However, the operator’s
seat must be removed in order to access the rear panel mount-
ing bolts (3) using a 5 mm allen wrench to remove the access
panel. see “SEAT” on page 50-65.
2. Remove the lower outlet hose (4).

H The lower cooling package hoses can be accessed by removing
the rear belly pan access plate.
3. Remove the overflow hose (5) and remove the two retaining bolts
(6) using a 19 mm wrench. Lift the bracket (7) off the rubber retain-
ing cushion.
50-342 I
H Pull the radiator (A) forward enough to clear all the upper
hardware.
H Be careful when pulling radiator forward not to damage the oil
cooler.
4. Sling the radiator (A) and remove it from the machine frame
opening.
Radiator: 38.1 kg (84 lbs)
50-343 I
12
REMOVING THE OIL COOLER
H Drain the hydraulic system first,
see “DRAINING THE HYDRAULIC SYSTEM” on page 50-78.
1. Remove the four mounting bolts and remove the cooler distribution
block (8) using a 17 mm wrench.
H Prepare a container to catch any residual oil that may be
remaining in the cooler and hydraulic system.
2. Remove the two retaining bolts (6) using a 19 mm wrench. Lift the
bracket (7) off the rubber retaining cushion.
3. Sling the oil cooler (B), pull it forward and remove it from the
machine frame opening.
Oil cooler: 27.2 kg (60 lbs)
H Be careful when pulling the oil cooler forward not to damage

the radiator or air charge cooler.
50-344 I
12
REMOVING THE AIR CHARGE COOLER
1. Remove upper air charge hose (9) using a 13 mm wrench.

H When disconnecting air charge lines, always cover their
openings to prevent debris from entering the engine intake
system.
2. Remove lower air charge hose (10) using a 13 mm wrench.

H When disconnecting air charge lines, always cover their
openings to prevent debris from entering the engine intake
system.
3. Remove the two retaining bolts (6) using a 19 mm wrench. Lift the
bracket (7) off the rubber retaining cushion.
50-345 I
4. Sling the air charge cooler (C), pull it forward and remove it from
the machine frame opening.
Air charge cooler: 24.5 kg (54 lbs)
H Be careful when pulling the air charge cooler forward not to

damage the oil cooler.
50-346 I
12
INSTALLING THE COOLING PACKAGE
H Reinstallation of the cooling package is done in the reverse order.
H Order of installation of each cooler unit does not matter. However,
it is important to be sure the cooler frame’s rubber retaining
cushions sit squarely in their mounting saddles, both on top and
especially on the bottom.
1. Once the cooler is installed, reinstall top brackets (7) and tighten
bolts (6) to the proper specifications.
Top bracket bolts (6): 98 - 122.5 N•m (72 - 90 lbf/ft)
2. Reconnect required hoses and torque the clamps.

H Air charge hose clamps (9) and (10).
H Check inlet and outlet for any foreign objects before installing
them.
Clamps: 8.8 ± .5 N•m (87 ± 4 lbf/ft)
H Radiator hose clamps (2) and (4).
Clamps: 8.8 ± .5 N•m (87 ± 4 lbf/ft)
H Oil cooler distribution block (8) four bolts

H Replace the “O” ring on the distribution block, do not reuse the
old “O” ring.
Bolts: 59 - 74 N•m (44 - 55 lbf/ft)
H Fill the cooling system or hydraulic system as required.

H Cooling system.
Engine Coolant: 35 liters (9.25 gal)
H Hydraulic system.
3. Install the fan shrouds (1) and (2) as well as left bracket (7).
H When installing the fan shrouds, be sure they fit into the bot-
tom grove of the cooling package.
4. Install junction brackets (3) to top and (4) to bottom.
5. Install rubber gasket (6).

H Bond gasket in place using.
Bonding: LT-1A glue
6. Place left side baffle (12) on top of left fan shroud (2).
50-347 I
12
INSTALLING THE GRILL AND COOLING FAN ASSEMBLY
Always pay attention to the spring tension on the grill when removing or installing
any of the grill components. Keep all upper body parts away from the grill when
opening or closing it.
1. Reinstall the cooling fan assembly.

H When reinstalling the cooling fan assembly, carefully move it
into the fan shroud so not to damage the fan shroud. Once in
place, install pivot pins (15).
2. Slide the pivot pins (15) in just 63.5 mm (1.5 inches) only.
50-348 I
3. Install the grill frame (10).
4. Push the pivot pins (15) all the way in.
5. Sling the bottom of the grill frame (10) as shown in illustration.
50-349 I
6. Open the grill frame (10) completely to reinstall washers and
cotter pins.
7. Reinstall washers and cotter pins to the pivot pins (15) in place.
8. Reattach the cooling fan motor hoses (2) and (3) and reinstall the
speed sensor cover (1).
9. Install both side hose “P” clips (4) and (5) and reconnect grey
electrical connector (6).
10. Reattach baffle cover (12) using the mounting bolts (11).
H (This cover should have been installed earlier.)
11. Reinstall baffle cover (14) and install mounting bolts (13).
12. Reattach grill frame (10) linkages (9) using the pins (8).
50-350 I
13. Install gas strut cylinders (6) using a flat blade screw driver to
position the strut (6) into its mounting (10) while inserting pin (7)
in place.
14. Once all components are installed, close grill (10) back down.
WARNING! Keep your upper body out of the way

and both hands on the grill frame
when closing the grill.
15. Install bolts (1), (2), (3) completely and torque to proper
specification.
Grill bolts: 245 - 309 N•m (181 - 228 lbf/ft)
16. Install top cover (5) and bolts (4).
17. Start the machine and check the operation of the components as
well as checking for any leaks.
50-351 I
DISASSEMBLY AND ASSEMBLY FUEL TANK
12
FUEL TANK
WARNING! Do not attempt to remove or install the fuel tank with fuel in it. Before servicing this
tank, be sure it is completely empty.
H To remove the fuel tank, the cab assembly, grill frame and cooling fan assembly must be removed from the machine. See
“CAB” on page 50-47, “REMOVING THE GRILL FRAME” on page 50-328, “REMOVING THE COOLING FAN
ASSEMBLY” on page 50-335.
REMOVING THE FUEL TANK
WARNING! It is in violation of EPA laws to drain any fluids on to the ground, in rivers, lakes,
storm drains or in a city sewer system. All fluids must be captured and recycled
according to EPA laws. Failure to do so may result in fines or punishment.
H Park the machine on a level stable surface.

H Be sure all the fuel is drained from the fuel tank before proceeding
with any removal procedures.
H To drain fuel from the fuel tank, place a container of a suitable size
under the fuel tank drain and open valve (A) to drain the fuel tank.
Fuel tank capacity: 270 liter (71.3 U.S. gal)
PREPARATIONS FOR REMOVAL
1. After draining the fuel tank, close valve (1) at the rear of the fuel
tank and disconnect fuel supply hose (2).
H Cap and seal all open lines to prevent damage to the fuel
system.
H Valve (1) is shown in a closed position.
2. At the front part of the fuel tank below the hydraulic filter, close
valve (3) and disconnect fuel line (4).
system.
H Valve (3) is shown in a closed position.
50-352 I
3. At the front part of the fuel tank above the hydraulic filter,
disconnect the top fuel return line (5).
system.
4. Remove “P” clip (6) using a 19 mm wrench and unplug both grey
and black electrical connectors (7).
5. Disconnect hydraulic hose (8) from filter mounting.

H Cap and seal all open lines to prevent damage to the hydraulic
system.
6. Remove “P” clip (9) using a 17 mm wrench and remove the bolts
(10) that support the DB12 valve. See “DB 12 VALVE” on page 50-
324.
50-353 I
7. Disconnect hydraulic hoses (11) and (12) and remove lower “P”
clip (13) using a 19 mm wrench.
system.
8. Remove upper fuel return hose “P” clips (14) using a 17 mm

wrench.
9. Remove lower fuel return hose “P” clip (14) using a 17 mm

wrench.
10. Unplug speed sensor connector (16) and remove “P” clip (15) using
a 17 mm wrench.
H With all the components disconnected or removed, check the area

around the fuel tank to be sure there is nothing attached to the tank
before proceeding with any removal procedures.
50-354 I
LIFTING THE FUEL TANK OFF THE MACHINE
1. Sling the tank as shown in the illustration.
2. Use a 12 mm eye-bolt for the front part of the tank and a strap for
the hand hold on the rear part of the tank.
3. With the tank properly slung, apply a slight amount of tension on

the straps lifting the tank and remove the front three bottom bolts
(17) using a 30 mm wrench.
50-355 I
4. Remove the rear four bottom bolts (18) using a 30 mm wrench.
5. Remove the top three bolts (19) using a 24 mm wrench.
6. Carefully lift the tank off as shown in the illustration. Lift up (a)
then move the tank away from the machine.
Fuel tank (empty): 203.2 kg (448 lbs)
INSTALLING THE FUEL TANK

H Installation of the fuel tank is done in the reverse order.
H When installing the fuel tank, tighten the lower mounting bolts (17) and (18) before tightening the top mounting bolts
(19).
H When installing the DB12 valve see “DB 12 VALVE” on page 50-324.
H Lower tank mounting bolts to the frame.
Bolts (17) and (18): 490 - 608 N•m (361 - 448 lbf/ft)
H Top mounting bolts to frame.
Bolts (19): 309 - 373 N•m (228 - 275 lbf/ft)
50-356 I
DISASSEMBLY AND ASSEMBLY HYDRAULIC TANK
12
HYDRAULIC TANK
WARNING! Do not attempt to remove or install the hydraulic tank with hydraulic oil in it. Before
servicing this tank, be sure it is completely empty.
H To remove the hydraulic tank the cab assembly, grill frame and cooling fan assembly must be removed from the machine.
See “CAB” on page 50-47, “REMOVING THE GRILL FRAME” on page 50-328, “REMOVING THE COOLING FAN
ASSEMBLY” on page 50-335.
REMOVING THE HYDRAULIC TANK
WARNING! Slowly loosen the hydraulic tank oil cap to release the pressure inside the
hydraulic tank. It is in violation of EPA laws to drain hydraulic oil on the ground, in
rivers or lakes or in a city or sewer system. All oils must be captured and
recycled according to EPA laws. Failure to do so may result in fines or
punishment.
1. Set a container under the hydraulic oil drain port to catch the oil
that is drained from the hydraulic tank.
2. Remove grommet (5) from bottom of hydraulic tank.
3. Attach a hose (4) to the tank drain valve outlet that is long enough
to reach container for collecting the hydraulic oil.
PREPARATIONS FOR REMOVAL
1. After hydraulic tank is drained, remove the five mounting bolts (1)
using a 19 mm wrench and remove tool box/grease gun support
bracket (2).
50-357 I
H When removing the five mounting bolts (1), always support
the tool box/grease gun assembly (2) to keep it from falling on
the batteries.
2. Remove the “P” clip (6) and disconnect coolant recovery hose (7)
from recovery tank.
3. To remove the batteries (9), remove the front hold down studs (8)
H It is not necessary to remove the rear battery hold down
brackets.
WARNING!
Be careful when working around batteries:
• Keep metal tools away from battery if possible.
• Do not set tools or parts on battery tops.
• The battery generates flammable gas and there
is danger of explosion. Do not bring fire or
sparks near the battery.
• Battery electrolyte is dangerous. If it gets in
your eyes or on your skin, wash it off with large
amounts of water and consult a doctor.
4. Disconnect all battery terminals (10) using a 17 mm wrench to pre-

pare for battery removal.
50-358 I
12
5. Carefully slide each battery (9) out of the battery tray and set each
battery aside.
Battery: 46.3 kg (102 lbs)
H Keep track of the separator pad (11) that sits between the
batteries. This must be reinstalled between the batteries when
installing the batteries, do not discard this item. If damaged or
deteriorated replace separator pad.
6. Remove battery tray to access the hydraulic lines by removing the

four bolts (12) using a 19 mm wrench.
Battery tray: 19.1 kg (42 lbs)
7. Disconnect the main charge supply line (14) and auxiliary line (13).
H Prepare a container to catch any hydraulic oil that may spill
from these lines.
50-359 I
8. Remove top clamp (15) on suction line.
H Be sure to mark the location of the clamp for reinstalling.

H Once clamp is removed, pull clamp (a) and rubber grommet (b)
upward to protect them when reinstalling the hydraulic tank.
9. Remove “P” clip (16) and disconnect hoses (17) from DB12 valve,
(18) to HST pump and (19) to filter.
system.
H Hose (17) feeds the DB12 valve.
50-360 I
12
LIFTING THE HYDRAULIC TANK OFF THE MACHINE
1. Sling the hydraulic tank as shown in the illustrations.

H Install a 10 mm eye-bolt in the front part of the hydraulic tank
frame.
H Strap the rear hand hold on the hydraulic tank.
2. Lift up slightly on the sling and prepare to remove the bottom and
top mounting bolts.
50-361 I
12
3. Remove the three bottom front bolts (20) using a 30 mm wrench.
4. Remove the four rear bottom bolts (21) using a 30 mm wrench.
5. Remove the three top rear mounting bolts (22) using a 24 mm

wrench.
6. Carefully lift tank up and out the machine frame being careful not
to damage the hydraulic piping.
Hydraulic tank: 213.2 kg (470 lbs)
50-362 I
12
INSTALLING THE HYDRAULIC TANK
H Installation of the hydraulic tank is done in the reverse order.
H When installing the hydraulic tank, carefully set the tank in
place, lining up the hydraulic connections first then install one
bolt (22) to hold tank in place.
H Once the hydraulic lines are in place, install and tighten the
lower bolts (20) and (21) before tightening the top bolts (22).
H Install the batteries and fill the hydraulic tank.
H Battery terminals torque.
Battery terminals: 5.9 - 9.8 N•m (52 - 87 lbf/ft)
H Lower tank mounting bolts to the frame.
Bolts (20) and (21): 490 - 608 N•m (361 - 448 lbf/ft)
H Top mounting bolts to frame.
Bolts (22): 309 - 373 N•m (228 - 275 lbf/ft)
H Tool box/grease gun (2) mounting bolts (1).
Bolts (1): 98 - 122.5 N•m (72 - 90 lbf/ft)
H Battery tray bolts (12).
Bolts (12): 98 - 122.5 N•m (72 - 90 lbf/ft)
H Battery hold down studs (8).
Studs (8): 1.5 - 2.0 N•m (13 - 18 lbf/ft)
50-363 I
DISASSEMBLY AND ASSEMBLY WORK EQUIPMENT
12
WORK EQUIPMENT
H Removal and installation of the work equipment consists of the following:
• Blade • Angle cylinders • Pitch rod and center ball • Lift cylinders • “C” frame
H Park the machine on a level and stable surface before proceeding with removal and installation procedures.
REMOVING OR INSTALLING PINS

H When removing the pins it is important to be careful not to damage
the end faces of the pins when installing or removing them.
H To remove a pin with a lock grove in the pin body, always drive
the pin in the direction shown in the illustration (away from the
lock grove). Failure to do so may damage the bushing surface.
H If the pin cannot be driven out using a hammer and brass drift,
use the grove in the pin as a point to pry the pin out.
H Always use a brass drift to install pins. A steel drift or hammer

face will damage or distort the end face of the pin.
WARNING! When aligning the pin holes, use a

bar. Never insert your fingers in the
pin holes.
50-364 I
12
FRONT BLADE, TILT AND ANGLE CYLINDERS
REMOVAL
H Chock the tracks, both front and rear.
H To remove the front blade, you must be able to access the front pins
of the lift cylinders. Therefore, the hood assembly must be removed
from the machine. See “NOSE GUARD (HOOD)” on page 50-39.
H Before removing any of the pins the lock tabs (5) must be removed
first using a 19 mm wrench.
H To remove the pins See “REMOVING OR INSTALLING PINS”
on page 50-364.
1. Remove the front blade tilt cylinder by removing the cover (1) then
remove cylinder (2).
H This tilt cylinder must be removed in order to be able to
remove the right angle cylinder.
Angle cylinder: 36.3 kg (80 lbs)
2. Disconnect the right and left angle cylinders (3) from the blade.
50-365 I
3. To remove the angle cylinder (3), first remove cover (a) using a 17
mm wrench.
4. Remove the grease fitting lines (b) using a 19 mm wrench and dis-
connect hydraulic line (c) using a 17 mm wrench.
system.
5. Remove “P” clip (d) and disconnect hydraulic hose (e).

system.
6. Remove pin lock and partially remove pin (f) and remove the angle
cylinder.
50-366 I
7. Sling the cylinder as shown in the illustration and remove the rear
pin (f) completely.
H Once the right and left cylinders are off the machine set it aside
for reinstallation later.
Angle cylinders: 44.6 kg (98 lbs)
8. Sling the blade as shown in the illustration.
50-367 I
9. Remove the front pins for the raise and lower cylinders (4).
10. Secure both raise and lower cylinders (4) up and out of the way to
prepare for removing the front blade.
11. Using a crane, lift the blade up to a full workable height so it will
pivot freely on the ball.
Front blade: 968.1 kg (2,134 lbs)
12. Block it securely under the “C” frame as shown in the illustration.
50-368 I
13. Lower the crane down so the “C” frame is resting on the blocks and
remove the five center ball bolts (6) on each side using a 30 mm
wrench.
14. Once the center ball mounting is loose, remove the pin (7) on the
pitch rod.
Remark
15. After removing the center pin, carefully move the blade away from
the machine as shown in the illustration.
16. Lay the blade down on a flat surface so the center ball or pitch rod
can be removed or serviced.
50-369 I
12
ADJUSTING BLADE CENTER BALL AND PITCH ROD PLAY
H Although the center ball and pitch rod free play can be adjusted while the blade is attached to the machine, it is much
easier to adjust the free play in the center ball and pitch rod while the blade is off the machine.
PITCH ROD
1. To adjust the pitch rod play, remove the four retaining bolts (1) to
add or remove shims.
Remark
2. Lift the pitch rod out of the socket.
pitch rod: 26.3 kg (58 lbs)
3. Add or remove shims (a) to remove any loose movement in the

pitch rod socket seat.
H Reinstall the four bolts hand tight only.
4. Torque the four bolts (1) to the proper specifications.
Pitch rod bolts: 823 - 1,029 N•m (607 - 759 lbf/ft)
5. Recheck the movement of the pitch rod and add or subtract shims
as needed.
50-370 I
12
CENTER BALL
1. Remove the 12 bolts that attach the center ball (2) to the blade and
lift out the center ball.
Remark
2. Add or remove shims (b) to remove any loose movement in the

center ball socket seat.
H Reinstall the 12 bolts hand tight only.
3. Torque the four bolts to the proper specifications.
Center ball bolts: 608 - 726 N•m (448 - 536 lbf/ft)
Recheck the movement of the pitch rod and add or subtract shims as
needed.
INSTALLATION
1. Center ball to “C” frame mounting bolt torque.
WARNING! When aligning the pin holes, use a bar.

Never insert your fingers in the pin holes.
Mounting bolts: 455 - 565 N•m (336 - 417 lbf/ft)
2. Refilling with oil (Hydraulic tank)

H Add oil through the oil filler to the specified level. Run the engine to circulate the oil through the system. Then, check
the oil level again.
3. Greasing
H After assembling the blade assembly, apply grease to the removed pins securely.
50-371 I
12
“C” FRAME
REMOVAL
H Before removing the “C” frame the front blade must be removed.
See “FRONT BLADE, TILT AND ANGLE CYLINDERS” on
page 50-365.
1. Remove angle cylinder supply line cover (1) off of the “C” frame
2. Disconnect angle cylinder supply lines (2).

system.
3. Remove frame clamp from “C” frame and lay hoses (3) on the left
track.
4. Remove hose bundle (3) from “C” frame and lay it on to the
right track.
50-372 I
5. Sling “C” frame as shown in the illustration.
6. Remove lock plate (4) and pull out frame fitting pin (5).
H Both sides
7. With frame pin (5) partly out, prepare to remove the “C” frame
from the machine chassis.
H Keep track of the shims (a) on the inside of the frame boss, be
sure the shims go back on the inside of the frame.
50-373 I
8. Once the pins are clear of the “C” frame bushing, move the “C”
frame in a forward direction away from the machine.
INSTALLATION
H Be sure to install the shims in their proper location.
WARNING! When aligning the pin holes, use a

bar. Never insert your fingers in the
pin holes.
H When pins (5) are installed, install lock (4) and torque bolts.
Lock (4): 23.5 - 31.5 N•m (173 - 227 lbf/ft)
50-374 I
12
LIFT CYLINDERS
H Park the machine on a level and stable surface before proceeding with removal and installation procedures.
H To remove the lift cylinders the hood assembly must be removed. See “NOSE GUARD (HOOD)” on page 50-39.
REMOVAL
1. Remove lower hose cover (1) using a 17 mm wrench and set cover
aside.
2. Remove hose (2), “P” clip (3) and hose (4).

system.
3. Sling lift cylinder as shown in the illustration.
50-375 I
4. Remove rear pin lock (5).
H See “REMOVING OR INSTALLING PINS” on page 50-364.
5. Remove front pin lock (5).

H See “REMOVING OR INSTALLING PINS” on page 50-364.
6. Carefully lift the cylinder assembly off the machine as shown in the
illustration.
Lift cylinder: 41.7 kg (92 lbs)
INSTALLATION
H Carry out installation in the reverse order to removal.
WARNING! When aligning the pin holes, use a bar.

Never insert your fingers in the pin holes.
1. Refilling with oil (Hydraulic tank)

H Add oil through the oil filler to the specified level. Run the engine to circulate the oil through the system. Then, check
the oil level again.
2. Greasing
H After assembling the blade assembly, apply grease to the removed pins securely.
50-376 I
DISASSEMBLY AND ASSEMBLY CYLINDER OVERHAUL PROCEDURES
12
CYLINDER OVERHAUL PROCEDURES
SPECIAL TOOLS
Distinction
Necessary
Sketch
Qty.
1 790-502-1003 Repair stand n 1

1
2 790-101-1102 Pump n 1
2 790-330-1100 Wrench n 1
3 790-302-1270 Socket n 1
4 790-720-1000 Expander n 1
1 796-720-1650 Rubber band l 1
5
2 07281-01029 Clamp l 1
U 1 790-201-1720 Push tool kit
2 790-201-1751 . Push tool n 1
6
3 790-101-5021 . Grip n 1
4 01010-50816 . Bolt n 1
1 790-201-1500 Push tool kit
2 790-201-1560 . Push tool n 1
7
3 790-101-5021 . Grip n 1
4 01010-50816 . Bolt n 1
PISTON AND ROD
1. Set cylinder assembly (1) to tool U1.
2. Using a hydraulic pump or a power wrench and tool U2, disconnect

the gland nut assembly (2).
3. Pull out piston rod assembly (3).

H Place an oil receiving pan, etc. under the cylinder bottom to
receive the oil.
50-377 I
PISTON AND HEAD ASSEMBLY
1. Set piston rod assembly (3) to tool U1.
2. Using tool U3, remove nut (4).
3. Remove piston assembly (5) and head assembly (6).
4. Disassembly of piston assembly

H Remove wear ring (7).
H Remove piston ring (8).
DISASSEMBLY OF GLAND NUT
1. Remove backup ring (9) and O-ring.
2. Remove packing (10).
3. Remove snap ring (11) and dust seal (12).
4. Remove bushing (13).
ASSEMBLY PROCEDURES
H (Blade lift, angle, and tilt cylinders)
H Apply engine oil to the sliding surfaces of each part and take care
not to damage the rod, packing, dust seal, and O-ring.
GLAND NUT ASSEMBLY AND PISTON ASSEMBLY

H Assembly of the gland nut
1. Press fit bushing (13) with tool U6.
50-378 I
2. Using tool U7, install dust seal (12).
4. Install packing (10).
5. Install backup ring (9) and O-ring.

H Warm the backup ring in water at 50 - 60oC (122 - 140 oF)
before installing it.
DISASSEMBLY OF PISTON
1. Set piston ring (8) to tool U4.
2. Rotate the handle by 8 - 10 turns to expand the piston ring.
3. Remove piston ring (8) from tool U4.
4. Install piston ring (8) to piston assembly (5).
5. Using tool U5, reduce piston ring (8).
6. Install wear ring (7).
50-379 I
12
PISTON ROD ASSEMBLY
1. Set the piston rod to tool
2. Install head assembly (6) and piston assembly (5).
3. Using tool U3, tighten nut (4).
Cylinder Width
Tightening torque Remarks
name across flats
1420 ± 140 N•m
Blade lift 55 mm
(1047 ± 105 lbf/ft)
1390 ± 140 N•m
50 mm
(1025 ± 103 lbf/ft)
Blade angle
1950 ± 200 N•m Improvement
55 mm
(1438 ± 144 lbf/ft) in strength
1670 ± 170 N•m
Blade tilt 55 mm
(1231 ± 123 lbf/ft)
H Before installing the nut, degrease the threads of the piston rod
thoroughly.
Threads of rod: Adhesive (LOCTITE N262)
4. Set cylinder (1) to tool U1.
5. Install piston rod assembly (3) to the cylinder.
6. Using a hydraulic pump or a power wrench and tool U2, tighten

head assembly (2).
Tightening torque of gland

Cylinder name
nut
677 ± 68 N•m
Blade lift
(500 ± 50 lbf/ft)
677 ± 68 N•m
Blade angle
(500 ± 50 lbf/ft)
785 ± 78.5 N•m
Blade tilt
(580 ± 58 lbf/ft)
50-380 I
90 OTHERS
CONNECTOR ARRANGEMENT DRAWING AND

ELECTRICAL CIRCUIT DIAGRAM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 90-3
CONNECTOR LIST. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 90-3
CONNECTOR LOCATION VIEW . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 90-7
CAB ELECTRICAL ACCESSORIES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 90-21
AIR CONDITIONER AND HEATER UNIT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 90-23
VIEW (2 OF 2) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 90-27
ELECTRICAL SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 90-29
IN CAB SWITCHES, RELAYS AND CONNECTORS (VIEW 1 OF 5) . . . . . . . . . . . . 90-29
CAB HARNESS AND CONTROLLER CONNECTIONS (VIEW 2 OF 5 ) . . . . . . . . . 90-31
ENGINE HARNESS AND CONTROLLER (VIEW 3 OF 5) . . . . . . . . . . . . . . . . . . . . . 90-33
MONITOR PANEL AND SWITCHES (VIEW 4 OF 5) . . . . . . . . . . . . . . . . . . . . . . . . . 90-35
KOMTRAX AND CONNECTORS (VIEW 5 OF 5). . . . . . . . . . . . . . . . . . . . . . . . . . . . 90-37
D51EX/PX-22 90-1
OTHERS
12
90-2 D51EX/PX-22
OTHERS CONNECTOR ARRANGEMENT DRAWING AND ELECTRICAL CIRCUIT DIAGRAM
12
CONNECTOR ARRANGEMENT DRAWING AND ELECTRICAL CIRCUIT DIAGRAM
CONNECTOR LIST
H The address roughly shows the places of the connectors in the 3-dimensional connector arrangement drawing and circuit diagrams
Connector No. of Connector No. of

Type Name of device Stereogram Type Name of device Stereogram
No. pins No. pins
CN-T250 Terminal - B 1 Ignition switch (Terminal B) 9-FC CN-364 M 2 Rear windshield washer motor (Cab specification) 4-HJ
CN-T255 Terminal - R1 1 Ignition switch (Terminal R1) 8-FD CN-362 M 2 Front windshield washer motor (Cab specifications) 5-HK
CN-T260 Terminal - BR 1 Ignition switch (Terminal BR) 7-FC CN-A12 SWP 6 Rear wiper switch (Cab specifications) 7-ED
CN-T270 Terminal - ACC 1 Ignition switch (Terminal ACC) 7-FB CN-A14 SWP 6 Front wiper switch (Cab specifications) 7-ED
CN-T280 Terminal - C 1 Ignition switch (Terminal C) 8-FB     
CN-A1 DT 2 Intermediate connector 7EF CN-A23 DT-T 4 Front wiper (Cab specifications) 7-EB
CN-2 DT 8 Intermediate connector 2-GK/8-BG CN-A37 DT-T 4 Rear wiper motor (Cab specification) 3-EG
CN-3 DT 12 Intermediate connector 1-GI/8-BG CN-A2 M 2 Rear speaker (Left, cab specifications) 6-EE
CN-4 DT 2 Starter motor safety relay (Terminal S and R) 2-BJ CN-A4 M 2 Rear speaker (Right, cab specification) 6-EE
CN-NM1 DT-T 6 Intermediate connector 4-CM CN-A16 KES1 2 Room lamp (Cab specification) 7-EB
CN-FM1 DT-T 12 Intermediate connector 3-CH CN-LMP3 DT 2 Rear lamp (Cab specification, left) 9-EL
CN-A8 DT 4 intermediate connector 3-HD/7-ED CN-LMP1 DT 2 Head lamp (Left cab specification) 8-EH
CN-11 SHINAGAWA 6 Neutral and park relay 8-GK CN-LMP2 DT 2 Head lamp (Right cab specification) 7-EH
CN-12 DT 2 HST oil temperature sensor 3-BF CN-AC5 DT 4 Air conditioner panel (Cab specification) 6-MF
CN-13 DT 2 Fuel lever sensor 2-CH CN-AC4 DT 6 Air conditioner control panel (Cab specification) 4-HG
CN-104 DT 12 Intermediate connector 2-GL CN-CIG M 2 Cigarette lighter (Cab specifications) 4-FC
CN-CLG DT 8 Intermediate connector 6-CH CN-AC6 DT 12 Air conditioner unit (Cab specification) 7-HH
CN-102 DT-T 12 intermediate connector 9-CE CN-AC2 DT 4 Water valve 2-HD
CN-17 DTHD 1 Spare power supply connector 6-GF CN-AC3 DT 3 Heater potentiometer 4-HF
CN-20 DT 3 Intermediate connector 6-GK CN-92 DT 4 Intermediate connector 3-GJ
CN-21 Terminal 1 Horn 6-CK CN-BP1 DT 3 Brake pedal potentiometer 8-GC
CN-RS DT-T 88 Intermediate connector 6-GK/8-CE CN-BS  3 Brake oil and HST charge oil pressure switch 8-DK
CN-23 DT 2 Air conditioner compressor [Cab specifications] 8-BA CN-BUZ KES1 6 Buzzer cancel switch 8-FI
CN-26 DT 3 Neutral and parking limit switch 1 4-GI CN-119 DT-T 3 CAN terminal resistance 2-BB
CN-26B DT 3 Neutral and parking limit switch 2 4-GI CN-T20A Terminal 1 Engine ground (Right side) 1-BK
CN-27 DT 6 Intermediate connector 5-GI CN-CB M 2 Caution buzzer 3-FC
CN-MC DT-T 12 Intermediate connector 4-DB/3-GK CN-CUR KES1 6 Information switch 7-FI
CN-LMP DT 4 Intermediate connector 3-EE/6-GJ CN-D20 DT 2 Diode 3-BC
CN-38 KANSEI 3 Shift up switch 2-GC CN-D4 SWP 8 Assembled diode 8-DK
CN-39 KANSEI 3 Shift down switch 2-GC CN-DP1 DT 3 Decelerator pedal potentiometer 7-GB
CN-45 DT 12 Intermediate connector 5-GJ CN-EL DT 8 PCCS lever (steering lever) 4-GI
CN-A7 SHINAGAWA 6 Lighting relay (Front) 3-HE/7-EE CN-106-1 Terminal 1 Fusible link 4-BM
90-3

No. pins No. pins
CN-FG DT-HD 1 Intermediate connector 3-GK/4-DB CN-ST3 DRC26 40 HST controller 8-GI
CN-FP DT 3 Fuel control potentiometer 3-GF CN-T1 Terminal 1 Starter motor (Terminal B) 6-BL
CN-DT12 DT 12 Personal computer connecting terminal 7-GB CN-T2 Terminal 1 Starter motor (Terminal C) 6-BL
CN-FWL KES1 6 Work lamp switch 8-FI CN-T3 Terminal 1 Starter motor safety relay (Terminal B) 3-BL
CN-PSW DT-T 3 PPC lock switch 4-GK CN-T4 Terminal 1 Starter motor safety relay (Terminal C) 3-BL
CN-28A DT-T 2 Water in fuel sensor 6-CK CN-T5 Terminal 1 Heater relay (Terminal S) 3-BC
CN-116 DT 2 Dust indicator 3-DF CN-T6 Terminal 1 Heater relay (Terminal L) 3-BC
CN-HET SWP 6 Heater switch (Cab specification) 7-FK CN-T7 Terminal 1 Battery relay (Terminal B) 8-GL
CN-C8 DT-T 2 Intermediate connector 5-BC CN-T8 Terminal 1 Battery relay (Terminal M) 8-GL
CN-LF DT 2 HST pump left forward EPC valve 5-BG CN-T9 Terminal 1 Battery relay (Negative terminal) 8-GL
CN-LP  3 HST pump left circuit pressure sensor 6-BE CN-TG1 Terminal 1 Fender ground 8-CL
CN-LR DT 2 HST pump left reserve EPC valve 4-BG/6-BE CN-T12 Terminal 1 Heater relay (Terminal B) 3-BC
CN-LRS2 DT 3 Left HST motor speed sensor 3-D1 CN-T13 Terminal 1 Battery relay (Position (+) terminal) 8-GL
CN-MTS KES1 6 Shift mode switch 7-FL CN-T15 Terminal 1 Alternator (Terminal B) 8-BK
CN-P1 DT 12 Intermediate connector 8-GH/2-FD CN-T16 Terminal 1 Alternator (Terminal R) 8-BK
CN-P2 DT 8 intermediate connector 8-GH/2-FD CN-T17 Terminal 1 Alternator (Terminal E) 8-BK
CN-P3 DT 12 Intermediate connector 8-GH/2-FD CN-FAN SWP 6 Fan reverse switch 7-FI
CN-AC DT 6 Intermediate connector 4-HD CN-WLD SWP 2 Diode for work lamp 4-FC
CN-PB DT 3 Backup alarm switch 7-GB CN-T20 Terminal 1 Engine ground 2-BC
CN-106-3 Terminal 1 Fusible link 5-BL CN-CFS 0T 2 HST charge filter clogging switch 8-CI
CN-106-4 Terminal 1 Fusible link 5-BM CN-T35 Terminal 1 Main frame ground 6-DK
CN-REV KES1 6 Reverse travel speed switch 8-FK CN-T36 Terminal 1 Floor ground 7-GB
CN-RF DT 2 HST pump right forward EPC valve 5-BG CN-T37 Terminal 1 Horn switch 6-GK
CN-RH Terminal 1 Electrical intake air heater 4-BD CN-T38 terminal 1 Horn switch 6-GK
CN-RP  3 HST pump right circuit pressure sensor 4-BG CN-TBA DT 2 Back-up alarm 6-CG
CN-RR DT 2 HST pump right reverse EPC valve 6-BE F01   Fuse box (1)
CN-RRS2 DT 3 Right HST motor speed sensor 7-CJ GND1 Terminal 1 Ground 7-ED
CN-S03 070 20 Monitor panel 4-FD GND2 Terminal 1 Ground 7-ED
CN-S04 070 12 Monitor panel 4-FD GND4 Terminal 1 Ground 3-EG
CN-D1 DT-T 2 Diode 7-GD GND5 Terminal 1 Ground 3-EC
CN-D2 DT-T 2 Diode 7-GD GND6 Terminal 1 Ground 2-ED
CN-S3 DT 2 Slow brake solenoid valve 8-DK GND7 Terminal 1 Ground 3-EE
CN-S4 DT 2 Parking brake solenoid valve 8-DK GND8 Terminal 1 Ground 2-EB
CN-126 Terminal 1 Gust indicator ground 2-DF A17 DT-T 4 Intermittent connector 4-ED
CN-ST1 DRC26 24 HST controller 8-GI LMP4 DT 2 Right rear head lamp (Cab specifications) 6-EL
CN-ST2 DRC26 40 HST controller 8-GI LMP5 DT 2 Head lamp (center) (Cab specifications) 8-EH
90-4

No. pins No. pins
CN-A DT-T 4 Right wiper motor (Cab specification 8-HK CN-A15 SWP 6 Left hand wiper switch (Cab specification) 7-ED
CN-11B SHINAGANA 6 Center brake relay (Cab specification) 9-GL CN-A13 SWP 6 Right wiper switch (Cab specification) 7-ED
CN-RNR SHINAGANA 6 Pre heater relay (Cab specification) 9-GK CN-FAR DT-T 2 Fan reverse solenoid 4-DK
CN-54B SHINAGANA 6 Rear lamp relay (Cab specification) 8-GK CN-ASA DT-T 2 Intermediate connector 4-GJ
CN-R23 SHINAGANA 6 Engine controller relay (Cab specification) 8-GK CN-19 DT 6 Intermediate connector 3-EC
CN-R24 SHINAGANA 6 Engine controller 2 relay (Cab specification) 8-GK CN-KOM4  1 Intermediate connector 6-EH
CN-D10 DT-T 2 Diode 7-GE CN-A18 DT 2 Intermediate connector 6-EA
CN-D11 DT-T 2 Diode 6-GD CN-G01  40 KOMTRAX controller 2-EI
CN-FAC DT-T 2 Fan EPC valve 8-CE CN-ACF DT-T 3 Intermediate connector 2-EK
CN-A25  5 Additional lamp relay (Cab specification) 6-EB CN-T1F DT-T 2 Intermediate connector 3-EK
CN-A28  5 Front wiper OFF relay (Cab specification) 6-EC
CN-CV1 DT 6 DC-DC cooler (Cab specifications) 3-EC
CN-A26  6 Left hand wiper intermittent relay (Cab specification) 6-EC
CN-361 M 2 Left windshield washer motor (Cab specification) 2-NJ
CN-HRH DT 5 Heater high relay 4-FE
CN-HRL DT 5 Heater low relay 4-FD
CN-117 DTP 4 Cummins J3 connector 2-BB
CN-115 DRC 50 Cummins J2 connector 2-BB
CN-363 M 2 Right windshield washer motor (Cab specification) 2-HJ
CN-KOM3  1 Orbitcom antenna (KOMTRAX) 3-EJ
CN-A24 DT-T 4 Intermittent connector 3-EC
CN-LME DT-T 2 Left motor EPC 7-DK
CN-RME DT-T 2 Right motor EPC 7-DK
CN-KOM2  1 GPS antenna (KOMTRAX) 3-E1
CN-A31  5 Right intermittent ON/OFF relay (Cab specification) 6-EC
CN-PSL DT-T 2 PPC lick solenoid valve 7-DJ
CN-A32  5 Rear wiper ON/OFF relay (Cab specification) 6-EC
CN-ACC Terminal 2 Accessory socket (Cab specification) 3-EC
CN-A27  5 Left intermittent ON/OFF relay (Cab specification) 6-EC
CN-A30  6 Right wiper intermittent relay (Cab specification) 6-EC
CN-FRS DT-T 2 Fan motor speed sensor 4-DK
CN-A11 SWP 6 Wiper ON/OFF switch (Cab specification) 7-ED
CN-A10 SWP 6 Additional lamp switch (Cab specification) 7-ED
90-5
OTHERS
12
90-6
OTHERS CONNECTOR LOCATION VIEW
CONNECTOR LOCATION VIEW
90-7
12
90-8
12
90-9
12
90-10
12
90-11
12
90-12
12
90-13
90-14
12
90-15
90-16
12
90-17 e
90-18
12
90-19
12
90-20
OTHERS CAB ELECTRICAL ACCESSORIES
12
CAB ELECTRICAL ACCESSORIES
90-21
OTHERS CAB ELECTRICAL ACCESSORIES
12
90-22
OTHERS AIR CONDITIONER AND HEATER UNIT
12
AIR CONDITIONER AND HEATER UNIT
90-23
OTHERS AIR CONDITIONER AND HEATER UNIT
12
90-24
OTHERS HYDRAULIC SYSTEM (VIEW 1 OF 2)
12
HYDRAULIC SYSTEM (VIEW 1 OF 2)
90-25 d
12
90-26
12
VIEW (2 OF 2)
90-27 d
12
90-28
OTHERS ELECTRICAL SYSTEM
IN CAB SWITCHES, RELAYS AND CONNECTORS (VIEW 1 OF 5)
D51EX/PX-22 90-29
D51EX/PX-22
12
90-30 D51EX/PX-22
CAB HARNESS AND CONTROLLER CONNECTIONS (VIEW 2 OF 5 )
D51EX/PX-22 90-31
12
90-32 D51EX/PX-22
12
ENGINE HARNESS AND CONTROLLER (VIEW 3 OF 5)
D51EX/PX-22 90-33
12
90-34 D51EX/PX-22
12
MONITOR PANEL AND SWITCHES (VIEW 4 OF 5)
D51EX/PX-22 90-35
12
90-36 D51EX/PX-22
12
KOMTRAX AND CONNECTORS (VIEW 5 OF 5)
D51EX/PX-22 90-37 d
90-38 D51EX/PX-22

D51 Manual de Serviço PDF

Uploaded by

Copyright:

Available Formats

D51 Manual de Serviço PDF

Uploaded by

Document Information

Original Title

Copyright

Available Formats

Share this document

Share or Embed Document

Sharing Options

Did you find this document useful?

Is this content inappropriate?

Copyright:

Available Formats

D51 Manual de Serviço PDF

Uploaded by

Copyright:

Available Formats

CEBM019109

Copyright 2013 Komatsu

STRUCTURE, FUNCTION AND MAINTENANCE STANDARD . . . . . . . . . . . . . . . . . . . . 10-1

STANDARD VALUE TABLES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-1

TESTING AND ADJUSTING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-1

DISASSEMBLY AND ASSEMBLY. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50-1

l Page to be replaced Replace

( ) Page to be deleted Discard

l 00-1 J 00-20 10-7 10-36 d

00-2 b 00-21 10-8 10-37 d

l 00-2-1 J 00-22 10-9 10-38 d

l 00-2-2 J 00-23 10-10 10-39 d

l 00-2-3 J 00-24 10-11 10-40 d

l 00-2-4 J 00-25 10-12 10-41 d

l 00-2-5 J 00-26 10-13 10-42 d

l 00-2-6 J 00-27 10-14 10-43 d

l 00-2-7 J 00-28 10-15 10-44 d

l 00-2-8 J 10-16 10-45 d

l 00-2-9 J 01-1 10-17 10-46 d

l 00-2-10 J 01-2 d 10-18 10-47 d

00-3 01-3 d 10-19 10-48 d

00-4 01-4 10-20 10-49 d

00-5 01-5 10-21 10-50 d

00-6 01-6 d 10-22 10-51 d

00-7 01-7 10-23 10-52 d

00-8 01-8 10-24 10-53 d

00-9 01-9 10-25 10-54 d

00-10 01-10 10-26 10-55 d

00-11 01-11 10-27 10-56 d

00-12 01-12 10-28 d 10-57 d

00-13 10-29 d 10-58 d

00-14 10-1 d 10-30 10-59 d

00-15 10-2 d 10-31 10-60 d

00-16 10-3 10-32 10-61 d

00-17 10-4 10-33 d 10-62 d

00-18 10-5 10-34 d 10-63 d

00-19 10-6 10-35 d 10-64 d

D51EX/PX-22 D51EX/PX-22 00-2-1 J

10-65 d 10-98 d 10-131 d 10-164

10-66 d 10-99 d 10-132 d 10-165

10-67 d 10-100 d 10-133 d 10-166

10-68 d 10-101 d 10-134 d 10-167

10-69 d 10-102 d 10-135 d 10-168

10-70 d 10-103 d 10-136 d 10-169

10-71 d 10-104 d 10-137 d 10-170

10-72 d l 10-105 J 10-138 d 10-171

10-73 d 10-106 d 10-139 d 10-172

10-74 d 10-107 d 10-140 d 10-173

10-75 d 10-108 d 10-141 d 10-174

10-76 d 10-109 d 10-142 10-175

10-77 d 10-110 d 10-143 10-176

10-78 d 10-111 d 10-144 10-177

10-79 d 10-112 d 10-145 10-178

10-80 d 10-113 d 10-146 10-179

10-81 d 10-114 d 10-147 10-180

10-82 I 10-115 d 10-148 10-181

10-83 d 10-116 d 10-149 10-182

10-84 d 10-117 d 10-150 10-183

10-85 d l 10-118 J 10-151 10-184