D61ex PX-15

WE051Z0002
MACHINE MODEL SERIAL NUMBER
D61EX-15 B40001 and up

D61PX-15 B40001 and up
• This shop manual may contain attachments and optional equipment that are not available in your area.
Please consult your local Komatsu distributor for those items you may require.
Materials and specifications are subject to change without notice.
• D61-15 mount the SA6D114E-2 engine.

WE051Y0102
Bulldozer
D61EX-15
D61PX-15
Machine Model 1 Serial Number 1

General 1
Table of general contents.............................................................................................. 2
General
Table of general contents 1

Each shop manual is composed as shown below.
Since this table of general contents is issued each time Symbol Indication Remedy
an item is added or revised, keep the shop manual up Q Section to be newly added Add
to date accordingly to it. q Section to be replaced Replace
The brochures added or revised this time are indicated
with the symbols shown in the table at right. Add or
revise the shop manual accordingly to this table.
Form No. Section Title

WE051Z0002 The whole shop manual composition
(all the following contents are included)
WE051Y0002 General
q WE051Y0102 General Table of general contents
WE051Y0200 General Safety, foreword
WE051A0000 General
WE051A0100 General Specification dimension drawing
Specifications
Weight table
Oil and coolant table
Structure and function,
WE051B0000
Maintenance standard
WE051B0100 Engine and cooling related components
Cooling system
Power transmitting
Power train
Power train skeleton
Overall drawing of power train unit
Hydraulic piping diagram of power train
Damper and universal joint
Transmission, steering, and brake control
WE051B0200 Power transmitting system
Torque converter and PTO
Transmission
Transmission ECMV
Main relief valve
Lubrication oil relief valve
Scavenging pump
Power train and lubrication pump
HSS system
HSS pump
HSS motor
Bevel gear shaft, HSS, and brake
Brake valve
Final drive
2 WE051Y0102
General

WE051B0600 Undercarriage and frame
Frame assembly
Suspension
Track frame and recoil spring
Idler
Track roller
Carrier roller
Sprocket
Track shoe
WE051B0700 Hydraulic system
Layout of hydraulic devices for work equipment
Work equipment control
Hydraulic tank and filter
Solenoid valve
Accumulator
Hydraulic cylinder
Piston valve
Quick drop valve
Cooling fan pump
Cooling fan motor
PPC valve
Electric lever (Steering)
Control valve
CLSS
Self-pressure reducing valve
WE051B1000 Work equipment
Work equipment
Cutting edge and end bit
Ripper
Cab and its attachments
Cab mount
Cab
Air conditioner piping
WE051B1100 Electric system
Engine control system
Cooling system control system
Palm command control system
PPC lock system
Component parts of system
Monitor system
Monitor panel
Sensor
WE051C0000 Standard value table
WE051C0100 Standard value table Standard value table for engine
Standard value table for chassis
WE051Y0102 3
General

WE051D0000 Testing and adjusting
WE051D0100 Testing and adjusting Testing and adjusting (1/2)
Tools for testing, adjusting and troubleshooting
Measuring engine speed
Measuring intake air pressure (boost pressure)
Measuring exhaust color
Adjusting valve clearance
Measuring compression pressure
Measuring blow-by pressure
Testing and adjusting fuel injection timing
Measuring engine oil pressure
Testing and adjusting air conditioner compressor belt tension
Adjusting engine speed sensor
Adjusting fuel control linkage
Measuring power train oil pressure
Adjusting transmission speed sensor (replacement procedure)
Simple method of testing brake performance
Adjusting brake pedal
Adjusting parking brake lever
Emergency escape method when power train has a trouble
Adjusting idler clearance
Inspecting wear of sprocket
Testing and adjusting track shoe tension
Testing and adjusting work equipment and HSS oil pressure
Testing control circuit main pressure
Measuring PPC valve output pressure
Adjusting play of work equipment PPC valve
Measuring internal leakage of work equipment cylinder
Adjusting safety lock lever of work equipment
Releasing residual pressure in work equipment cylinder
(If PPC accumulator is not installed)
(If PPC accumulator is installed)
Bleeding air from work equipment cylinder
Measuring fan pump circuit pressure
Measuring fan motor speed
Measuring HSS motor oil leakage
Bleeding air from fan pump
Testing and adjusting operator's cab
WE051D0200 Testing and adjusting Testing and adjusting (2/2)
Special functions of monitor panel (EMMS)
Adjustment method of replaced controller
Preparatory work for troubleshooting for electric system
Pm clinic
Undercarriage troubleshooting report
4 WE051Y0102
General

WE051E0000 Troubleshooting
WE051E0100 Troubleshooting Preface
Points to remember when troubleshooting
Troubleshooting procedure
Points to remember when carrying out maintenance
Checks before troubleshooting
Classification and procedures of troubleshooting
Connector arrangement drawing and
electric circuit diagram of each system
WE051E0200 Troubleshooting Troubleshooting when error code is displayed (Error code)
Error code table
Information described in troubleshooting list
WE051E0300 Troubleshooting Troubleshooting of electrical system (E-mode)
Before troubleshooting electrical system (E-mode)
WE051E0400 Troubleshooting Troubleshooting of hydraulic and mechanical system (H-mode)
WE051E0500 Troubleshooting Troubleshooting of engine system (S-mode)
Method of using matrix troubleshooting charts
WE051F0000 Disassembly and assembly
Q WE051F0100 Disassembly and assembly Preface
How to read this manual
Standard tightening torque table
Precautions when performing operation
List of coatings
Special tool list
Sketches of special tools
Q WE051F0200 Disassembly and assembly Engine related procedures
Removal and installation of fuel injection pump assembly
Removal and installation of cylinder head assembly
Removal and installation of engine front seal
Removal and installation of engine rear seal
Removal and installation of engine assembly
Removal and installation of damper assembly
Removal and installation of radiator guard assembly
Removal and installation of radiator and
hydraulic oil cooler assembly
Removal and installation of fan drive assembly
Removal and installation of fan motor assembly
Removal and installation of engine hood assembly
Removal and installation of fuel tank assembly
Q WE051F0300 Disassembly and assembly Power train
Removal and installation of PTO, torque converter
and transmission assembly
Disconnection and connection of PTO,
torque converter and transmission assembly
Disassembly and assembly of PTO assembly
Disassembly and assembly of torque converter assembly
Disassembly and assembly of TORQFLOW transmission
assembly
Removal and installation of torque converter main relief valve
assembly
Disassembly and assembly of torque converter main relief valve
assembly
WE051Y0102 5
General
Q WE051F0400 Disassembly and assembly Power train

Removal and installation of power train and
lubricating oil pump assembly
Removal and installation of HSS and
work equipment pump assembly
Removal and installation of scavenging pump assembly
Removal and installation of HSS motor assembly
Disassembly and assembly of HSS assembly
Removal and installation of final drive assembly
Disassembly and assembly of final drive assembly
Q WE051F0500 Disassembly and assembly Undercarriage
Removal and installation of track frame assembly
Removal and installation of idler assembly
Disassembly and assembly of idler assembly
Removal and installation of recoil spring assembly
Disassembly and assembly of recoil spring assembly
Removal and installation of track roller assembly
Disassembly and assembly of track roller assembly
Removal and installation of carrier roller assembly
Disassembly and assembly of carrier roller assembly
Q WE051F0600 Disassembly and assembly Undercarriage
Check before expanding track shoe assembly
Expansion (normal), expansion (internal abnormality)
and installation of track shoe assembly
Overall disassembly and overall assembly of track shoe
assembly
Link press-fitting jig dimensions table
Field disassembly and assembly of one link
Removal and installation of pivot shaft assembly
Removal and installation of equalizer bar assembly
Removal and installation of equalizer bar side bushing
Removal and installation of segment teeth
Q WE051F0700 Disassembly and assembly Hydraulic system
Removal and installation of main control valve assembly
Assembly of main control valve assembly
Removal and installation of cooling fan pump assembly
Removal and installation of work equipment assembly
Disassembly and assembly of work equipment assembly
Disassembly and assembly of hydraulic cylinder assembly
Q WE051F0800 Disassembly and assembly Others

Removal and installation of operator's cab assembly
Removal and installation of operator's cab glass (stuck glass)
Removal and installation of ROPS canopy
Removal and installation of dashboard assembly
Removal and installation of floor frame assembly
Removal and installation of steering and transmission controller
assembly
6 WE051Y0102
General

WE051X0000 Others
WE051X0100 Others Hydraulic circuit diagram
Power train hydraulic circuit diagram
Work equipment hydraulic circuit diagram
Power angle power tilt dozer (PAT)
Power tilt dozer (PT)
Electrical circuit diagram
Electrical circuit diagram (1/6)
Cab electrical circuit diagram
WE051Y0102 7
General
D61EX-15, D61PX-15 BULLDOZER

Form No. WE051Z0002
©2004 KOMATSU
All Right Reserved
Printed in Japan 09-04 (01)
8 WE051Y0102
WE051Y0200
Bulldozer
D61EX-15
D61PX-15
Model Serial Number 1
D61EX-15 B40001-
D61PX-15 B40001-
General 1
Safety............................................................................................................................ 2
Foreword....................................................................................................................... 4
General
Safety
Safety notice
Important safety notice

Proper service and repair is extremely important for safe machine operation. The service and repair
techniques recommended by KOMATSU and described in this manual are both effective and safe.
Some of these techniques require the use of tools specially designed by KOMATSU for the specific
purpose.
To prevent injury to workers, the symbol k is used to mark safety precautions in this manual. The
cautions accompanying these symbols should always be followed carefully. If any dangerous situa-
tion arises or may possibly arise, first consider safety, and take the necessary actions to deal with
the situation.
General precautions 6. Decide a place in the repair workshop to keep

Mistakes in operation are extremely dangerous. Read tools and removed parts. Always keep the tools
the Operation and Maintenance Manual carefully and parts in their correct places. Always keep the
BEFORE operating the machine. work area clean and make sure that there is no dirt
or oil on the floor. Smoke only in the areas pro-
1. Before carrying out any greasing or repairs, read vided for smoking. Never smoke while working.
all the precautions given on the decals which are
fixed to the machine. Preparations for work
7. Before adding oil or making any repairs, park the
2. When carrying out any operation, always wear machine on hard, level ground, and block the
safety shoes and helmet. Do not wear loose work wheels or tracks to prevent the machine from mov-
clothes, or clothes with buttons missing. ing.
q Always wear safety glasses when hitting parts
with a hammer. 8. Before starting work, lower blade, ripper, bucket or
q Always wear safety glasses when grinding any other work equipment to the ground. If this is
parts with a grinder, etc. not possible, insert the safety pin or use blocks to
prevent the work equipment from falling. In addi-
3. If welding repairs are needed, always have a tion, be sure to lock all the control levers and hang
trained, experienced welder carry out the work. warning signs on them.
When carrying out welding work, always wear
welding gloves, apron, hand shield, cap and other 9. When disassembling or assembling, support the
clothes suited for welding work. machine with blocks, jacks or stands before start-
ing work.
4. When carrying out any operation with two or more
workers, always agree on the operating procedure 10. Remove all mud and oil from the steps or other
before starting. Always inform your fellow workers places used to get on and off the machine. Always
before starting any step of the operation. Before use the handrails, ladders or steps when getting
starting work, hang UNDER REPAIR signs on the on or off the machine. Never jump on or off the
controls in the operator's compartment. machine. If it is impossible to use the handrails,
ladders or steps, use a stand to provide safe foot-
5. Keep all tools in good condition and learn the cor- ing.
rect way to use them.
2 WE051Y0200
General
Precautions during work 19. Be sure to assemble all parts again in their original
11. When removing the oil filler cap, drain plug or places.
hydraulic pressure measuring plugs, loosen them Replace any damaged parts with new parts.
slowly to prevent the oil from spurting out. q When installing hoses and wires, be sure that
Before disconnecting or removing components of they will not be damaged by contact with other
the oil, water or air circuits, first remove the pres- parts when the machine is being operated.
sure completely from the circuit.
20. When installing high pressure hoses, make sure
12. The water and oil in the circuits are hot when the that they are not twisted. Damaged tubes are dan-
engine is stopped, so be careful not to get burned. gerous, so be extremely careful when installing
Wait for the oil and water to cool before carrying tubes for high pressure circuits. Also, check that
out any work on the oil or water circuits. connecting parts are correctly installed.
13. Before starting work, remove the leads from the 21. When assembling or installing parts, always use
battery. Always remove the lead from the negative the specified tightening torques. When installing
(–) terminal first. protective parts such as guards, or parts which
vibrate violently or rotate at high speed, be particu-
14. When raising heavy components, use a hoist or larly careful to check that they are installed cor-
crane. rectly.
Check that the wire rope, chains and hooks are
free from damage. 22. When aligning two holes, never insert your fingers
Always use lifting equipment which has ample or hand. Be careful not to get your fingers caught
capacity. in a hole.
Install the lifting equipment at the correct places.
Use a hoist or crane and operate slowly to prevent 23. When measuring hydraulic pressure, check that
the component from hitting any other part. Do not the measuring tool is correctly assembled before
work with any part still raised by the hoist or crane. taking any measurements.
15. When removing covers which are under internal 24. Take care when removing or installing the tracks
pressure or under pressure from a spring, always of track-type machines.
leave two bolts in position on opposite sides. When removing the track, the track separates sud-
Slowly release the pressure, then slowly loosen denly, so never let anyone stand at either end of
the bolts to remove. the track.
16. When removing components, be careful not to

break or damage the wiring. Damaged wiring may
cause electrical fires.
17. When removing piping, stop the fuel or oil from

spilling out. If any fuel or oil drips onto the floor,
wipe it up immediately. Fuel or oil on the floor can
cause you to slip, or can even start fires.
18. As a general rule, do not use gasoline to wash

parts. In particular, use only the minimum of gaso-
line when washing electrical parts.
WE051Y0200 3
General
Foreword
General
This shop manual has been prepared as an aid to improve the quality of repairs by giving the serviceman an accu-
rate 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 work-
shop. For ease of understanding, the manual is divided into the following chapters; these chapters are further
divided into the each main group of components.
Structure and function

This section explains the structure and function of each component. It serves not only to give an under-
standing of the structure, but also serves as reference material for troubleshooting.
In addition, this section may contain hydraulic circuit diagrams, electric circuit diagrams, and maintenance
standards.
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 charts correlating “Problems” with “Causes” are also included in this section.
Disassembly and assembly

This section explains the procedures for removing, installing, disassembling and assembling each compo-
nent, as well as precautions for them.
This section gives the judgment standards for inspection of disassembled parts.
The contents of this section may be described in “Structure and function”.
Others
This section mainly gives hydraulic circuit diagrams and electric circuit diagrams.
In addition, this section may give the specifications of attachments and options together.
Notice
The specifications contained in this shop manual are subject to change at any time and without any
advance notice. Use the specifications given in the book with the latest date.
4 WE051Y0200
General
How to read the shop manual

Volumes Symbols
Shop manuals are issued as a guide to carrying out So that the shop manual can be of ample practical
repairs. They are divided as follows: use, important safety and quality portions are marked
with the following symbols.
Chassis volume: Issued for every machine model
Engine volume: Issued for each engine series
Symbol Item Remarks
Each issued as one Special safety precautions
Electrical volume:
volume to cover all Safety are necessary when per-
Attachments volume: k
models forming the work.
Special technical precau-
These various volumes are designed to avoid duplicat- tions or other precautions
ing the same information. Therefore, to deal with all a Caution for preserving standards
repairs for any model, it is necessary that chassis, are necessary when per-
engine, electrical and attachment volumes be avail- forming the work.
able.
We i g h t o f pa r t s o f s y s -
tems. Caution necessary
Weight w hen selecting hoi sting
Distribution and updating 4 wire, or when working pos-
Any additions, amendments or other changes will be
ture is important, etc.
sent to KOMATSU distributors. Get the most up-to-
date information before you start any work. Places that require special
Tightening attention for the tightening
3 torque torque during assembly.
Places to be coated with
Coat adhesives and lubricants,
2
etc.
Places where oil, water or
5 Oil, water fuel must be added, and the
capacity.
Places where oil or water
Drain must be drained, and quan-
6 tity to be drained.
WE051Y0200 5
General
Hoisting instructions
Hoisting
Slinging near the edge of the hook may cause the
rope to slip off the hook during hoisting, and a seri-
k Heavy parts (25 kg or more) must be lifted
ous accident can result. Hooks have maximum
with a hoist, etc. In the Disassembly and
strength at the middle portion.
assembly section, every part weighing 25
kg or more is indicated clearly with the
symbol 4
q If a part cannot be smoothly removed from the

machine by hoisting, the following checks should
be made:
100% 88% 79% 71% 41%
1) Check for removal of all bolts fastening the SAD00479
part to the relative parts.
2) Check for existence of another part causing 3. Do not sling a heavy load with one rope alone, but
interference with the part to be removed. sling with two or more ropes symmetrically wound
onto the load.
Wire ropes a Slinging with one rope may cause turning of
1. Use adequate ropes depending on the weight of the load during hoisting, untwisting of the rope,
parts to be hoisted, referring to the table below: or slipping of the rope from its original winding
position on the load, which can result in a dan-
Wire ropes
gerous accident.
(standard “Z” or “S” twist ropes
without galvanizing)
4. Do not sling a heavy load with ropes forming a
Rope diameter Allowable load wide hanging angle from the hook.
mm kN tons When hoisting a load with two or more ropes, the
10 9.8 1.0 force subjected to each rope will increase with the
11.5 13.7 1.4 hanging angles. The table below shows the varia-
12.5 15.7 1.6 tion of allowable load kN {kg} when hoisting is
14 21.6 2.2 made with two ropes, each of which is allowed to
16 27.5 2.8 sling up to 9.8kN {1,000kg} vertically, at various
18 35.3 3.6 hanging angles.
20 43.1 4.4 When two ropes sling a load vertically, up to
22.4 54.9 5.6 19.6kN {2,000kg} of total weight can be sus-
30 98.1 10.0 pended. This weight becomes 9.8kN {1,000kg}
40 176.5 18.0 when two ropes make a 120° hanging angle. On
50 274.6 28.0 the other hand, two ropes are subjected to an
60 392.2 40.0 excessive force as large as 39.2kN {4,000kg} if
they sling a 19.6kN {2,000kg} load at a lifting angle
a The allowable load value is estimated to be one- of 150°.
sixth or one-seventh of the breaking strength of
the rope used.
2. Sling wire ropes from the middle portion of the

hook.
6 WE051Y0200
General
Method of disassembling, connecting push-pull type coupler

k Before carrying out the following work, release the Type 1
residual pressure from the hydraulic tank. For
details, see “Testing and adjusting”, Releasing
residual pressure from hydraulic tank.
k Even if the residual pressure is released from the

hydraulic tank, some hydraulic oil flows out when
the hose is disconnected. Accordingly, prepare an
oil receiving container.
Disconnection
1. Release the residual pressure from the hydraulic
tank. For details, see “Testing and adjusting”,
Releasing residual pressure from hydraulic tank.
2. Hold adapter (1) and push hose joint (2) into mat-
ing adapter (3). (see Fig. 1)
a The adapter can be pushed in about 3.5mm.
a Do not hold rubber cap portion (4).
3. After hose joint (2) is pushed into adapter (3),

press rubber cap portion (4) against (3) until it
clicks. (see Fig. 2)
4. Hold hose adapter (1) or hose (5) and pull it out.

(see Fig. 3)
a Since some hydraulic oil flows out, prepare an
oil receiving container.
Connection
1. Hold hose adapter (1) or hose (5) and insert it in
mating adapter (3), aligning them with each other.
(see Fig. 4)
a Do not hold rubber cap portion (4).
2. After inserting the hose in the mating adapter per-

fectly, pull it back to check its connecting condi-
tion. (see Fig. 5)
a When the hose is pulled back, the rubber cap
portion moves toward the hose about 3.5mm.
This does not indicate abnormality, however.
WE051Y0200 7
General
Type 2 Type 3
1. Hold the mouthpiece of the tightening portion 1. Hold the mouthpiece of the tightening portion
and push body (2) in straight until sliding pre- and push body (2) in straight until sliding pre-
vention ring (1) contacts contact surface a of vention ring (1) contacts contact surface a of
the hexagonal portion at the male end. the hexagonal portion at the male end.
2. Hold in the condition in Step 1., and turn lever 2. Hold in the condition in Step 1., and push until
(4) to the right (clockwise). cover (3) contacts contact surface a of the
hexagonal portion at the male end.
Disassembly
3. Hold in the condition in Steps 1. and 2., and 3. Hold in the condition in Steps 1. and 2., and
pull out whole body (2) to disconnect it. pull out whole body (2) to disconnect it.
q Hold the mouthpiece of the tightening portion q Hold the mouthpiece of the tightening portion
the hexagonal portion at the male end to con- the hexagonal portion at the male end to con-
nect it. nect it.
Connection
8 WE051Y0200
General
Coating materials
a The recommended coating materials such as adhesives, gasket sealants and greases used for disassembly
and assembly are listed below.
a For coating materials not listed below, use the equivalent of products shown in this list.
KOMATSU
Category Part No. Q’ty Container Main applications, features
code
q Used to prevent rubber gaskets, rubber
LT-1A 790-129-9030 150g Tube cushions, and cock plug from coming
out.
q Used in places requiring an immediately
effective, strong adhesive.
LT-1B 790-129-9050 20g Polyethylene Used for plastics (except polyethylene,
(2 pcs.) container polypropylene, tetrafluoroethlene and
vinyl chloride), rubber, metal and non-
metal.
q Features:
LT-2 09940-00030 50g Polyethylene Resistance to heat and chemicals
container q Used for anti-loosening and sealant pur-
pose for bolts and plugs.
Adhesive: q Used as adhesive or sealant for metal,
790-129-9060 1kg glass and plastic.
LT-3 (set of adhesive Hardening Can
and hardening agent:
agent) 500g
Adhesives
Polyethylene q Used as sealant for machined holes.
LT-4 790-129-9040 250g
container
Holtz q Used as heat-resisting sealant for repair-
790-126-9120 75g Tube
MH 705 ing engine.
q Quick hardening type adhesive
Three bond Polyethylene q Cure time: within 5 sec. to 3 min.
1735 790-129-9140 50g container q Used mainly for adhesion of metals, rub-
bers, plastics and woods.
q Quick hardening type adhesive
q Quick cure type
Aron-alpha Polyethylene
201 790-129-9130 2g container (max. strength after 30 minutes)
q Used mainly for adhesion of rubbers,
plastics and metals.
q Resistance to heat, chemicals
Loctite Polyethylene
79A-129-9110 50cc q Used at joint portions subject to high
648-50 container
temperatures.
q Used as adhesive or sealant for gaskets
LG-1 790-129-9010 200g Tube and packing of power train case, etc.
q Used as sealant for various threads, pipe
joints, flanges.
LG-5 790-129-9080 1kg Can q Used as sealant for tapered plugs,
elbows, nipples of hydraulic piping.
q Features: Silicon based, resistance to
heat, cold
q Used as sealant for flange surface,
LG-6 790-129-9020 200g Tube
tread.
q Used as sealant for oil pan, final drive
Gasket case, etc.
sealant q Features: Silicon based, quick hardening
type
LG-7 790-129-9070 1g Tube q Used as sealant for flywheel housing,
intake manifold, oil an, thermostat hous-
ing, etc.
Three bond q Used as heat-resisting sealant for repair-
1211 790-129-9090 100g Tube ing engine.
q Features: Silicone type, heat resistant,
Three bond vibration resistant, and impact resistant
1207B 419-15-18131 100g Tube sealing material
q Used as sealing material for transfer
case
WE051Y0200 9
General
KOMATSU
Category Part No. Q’ty Container Main applications, features
code
q Used as lubricant for sliding portion (to
LM-G 09940-00051 60g Can
prevent from squeaking).
Molybde-
q Used to prevent seizure or scuffling of
num
the thread when press-fitting or shrink fit-
disulphide LM-P 09940-00040 200g Tube ting.
lubricant q Used as lubricant for linkage, bearings,
etc.
SYG2-400LI q General purpose type
SYG2-350LI
G2-LI SYG2-400LI-A Various Various
SYG2-160LI
SYGA-160CNLI
SYG2-400CA q Used for normal temperature, light load
SYG2-350CA bearing at places in contact with water or
G2-CA SYG2-400CA-A Various Various steam.
SYG2-160CA
SYGA-160CNCA
Molybdenum q Used for heavy load portion
SYG2-400M 400g × 10 Bellows type
Grease disulphide SYG2-400M-A 400g × 20 Bellows type
grease SYGA-16CNM 16kg Can
LM-G (G2-M)
Hyper White q Seizure resistance and heat resistance
Grease G2-T SYG2-400T-A higher than molybdenum disulphide
G0-T (∗) SYG2-16CNT 400g Bellows type grease
∗:For use in cold SYG0-400T-A (∗) 16kg Can q Since this grease is white, it does not
district SYG0-16CNT (∗) stand out against machine body.
Biogrease G2B q Since this grease is decomposed by
SYG2-400B
G2-BT (∗) SYGA-16CNB 400g Bellows type bacteria in short period, it has less
∗:For high tem- SYG2-400BT (∗) 16kg Can effects on microorganisms, animals, and
perature and SYGA-16CNBT (∗) plants.
large load
SUNSTAR q Used as primer for cab side
Glass con-
PAINT PRIMER 20ml tainer (using limit: 4 months)
580 SUPER
Primer SUNSTAR q Used as primer for glass side
GLASS Glass con- (using limit: 4 months)
PRIMER 580 20ml tainer
417-926-3910
Adhesive for cab glass
SUPER
SUNSTAR q “S” is used for high-temperature
PENGUINE season (April - October) and “W” for
SEAL 580 320ml Polyethylene low-temperature season (November
SUPER “S” or container - April) as adhesive for glass.
Adhesive
“W” (using limit: 4 months)
Sika Japan, Polyethylene q Used as adhesive for glass.
20Y-54-39850 310ml
Sikaflex 256HV container (using limit: 6 months)
SUNSTAR q Used to seal joints of glass parts.
PENGUINE 417-926-3920 320ml Polyethylene (using limit: 4 months)
SEAL No. 2505 container
Caulking
material SEKISUI SILI- q Used to seal front window.
CONE SEAL- 20Y-54-55130 333ml Polyethylene (using limit: 6 months)
ANT container
10 WE051Y0200
General
Standard tightening torque

Standard tightening torque table (when using torque wrench)
a In the case of metric nuts and bolts for which there is no special instruction, tighten to the torque given in the
table below.
Tightening torque
Thread diameter Width across
of bolt flats
mm mm Nm kgm
6 10 11.8 – 14.7 1.2 – 1.5
8 13 27 – 34 2.8 – 3.5
10 17 59 – 74 6 – 7.5
12 19 98 – 123 10 – 12.5
14 22 153 – 190 15.5 – 19.5
16 24 235 – 285 23.5 – 29.5
18 27 320 – 400 33 – 41
20 30 455 – 565 46.5 – 58
22 32 610 – 765 62.5 – 78
24 36 785 – 980 80 – 100
27 41 1150 – 1440 118 – 147
30 46 1520 – 1910 155 – 195
33 50 1960 – 2450 200 – 250
36 55 2450 – 3040 250 – 310
39 60 2890 – 3630 295 – 370
Tightening torque
Thread diameter Width across
of bolt flats
mm mm Nm kgm
6 10 5.9 – 9.8 0.6 – 1.0
8 13 13.7 – 23.5 1.4 – 2.4
10 14 34.3 – 46.1 3.5 – 4.7
12 27 74.5 – 90.2 7.6 – 9.2
Sealing surface
Table of tightening torques for flared nuts
a In the case of flared nuts for which there is no spe-
cial instruction, tighten to the torque given in the
table below.
SAD00483
Thread diameter Width across flats Tightening torque

mm mm Nm kgm
14 19 24.5 ± 4.9 2.5 ± 0.5
18 24 49 ± 19.6 5±2
22 27 78.5 ± 19.6 8±2
24 32 137.3 ± 29.4 14 ± 3
30 36 176.5 ± 29.4 18 ± 3
33 41 196.1 ± 49 20 ± 5
36 46 245.2 ± 49 25 ± 5
42 55 294.2 ± 49 30 ± 5
WE051Y0200 11
General
Table of tightening torques for flared nuts

a In the case of flared nuts for which there is no special instruction, tighten to the torque given in the table below.

mm mm Nm kgm
10 14 59 – 74 6 – 7.5
12 17 98 – 123 10 – 12.5
16 22 235 – 285 23.5 – 29.5
Table of tightening torques for o-ring boss piping joints

a Unless there are special instructions, tighten the O-ring boss piping joints to the torque below.

Nominal No.
mm mm Nm kgm
02 14 35 – 63 {3.5 – 6.5} 44 {4.5}
03, 04 20 Varies depending 84 – 132 {8.5 – 13.5} 103 {10.5}
05, 06 24 on type of 128 – 186 {13.0 – 19.0} 157 {16.0}
10, 12 33 connector. 363 – 480 {37.0 – 49.0} 422 {43.0}
14 42 746 – 1010 {76.0 – 103} 883 {90.0}
Table of tightening torques for o-ring boss plugs

a Unless there are special instructions, tighten the O-ring boss plugs to the torque below.

Nominal No.
mm mm Nm kgm
08 08 14 5.88 – 8.82 {0.6 – 0.9} 7.35 {0.75}
10 10 17 9.8 – 12.74 {1.0 – 1.3} 11.27 {1.15}
12 12 19 14.7 – 19.6 {1.5 – 2.0} 17.64 {1.8}
14 14 22 19.6 – 24.5 {2.0 – 2.5} 22.54 {2.3}
16 16 24 24.5 – 34.3 {2.5 – 3.5} 29.4 {3.0}
18 18 27 34.3 – 44.1 {3.5 – 4.5} 39.2 {4.0}
20 20 30 44.1 – 53.9 {4.5 – 5.5} 49.0 {5.0}
24 24 32 58.8 – 78.4 {6.0 – 8.0} 68.6 {7.0}
30 30 32 93.1 – 122.5 {9.5 – 12.5} 107.8 {11.0}
33 33 — 107.8 – 147.0 {11.0 – 15.0} 124.4 {13.0}
36 36 36 127.4 – 176.4 {13.0 – 18.0} 151.9 {15.5}
42 42 — 181.3 – 240.1 {18.5 – 24.5} 210.7 {21.5}
52 52 — 274.4 – 367.5 {28.0 – 37.5} 323.4 {33.0}
12 WE051Y0200
General
Tightening torque for 102 engine series

1. Bolt and nuts
Use these torques for bolts and nuts (unit: mm) of Cummins Engine.
Thread diameter Tightening torque
mm Nm kgm
6 10 ± 2 1.02 ± 0.20
8 24 ± 4 2.45 ± 0.41
10 43 ± 6 4.38 ± 0.61
12 77 ± 12 7.85 ± 1.22
2. Eye joints
Use these torques for eye joints (unit: mm) of Cummins Engine.
mm Nm kgm
6 8±2 0.81 ± 0.20
8 10 ± 2 1.02 ± 0.20
10 12 ± 2 1.22 ± 0.20
12 24 ± 4 2.45 ± 0.41
14 36 ± 5 3.67 ± 0.51
3. Tapered screws
Use these torques for tapered screws (unit: inch) of Cummins Engine.
inch Nm kgm
1 / 16 3±1 0.31 ± 0.10
1/8 8±2 0.81 ± 0.20
1/4 12 ± 2 1.22 ± 0.20
3/8 15 ± 2 1.53 ± 0.41
1/2 24 ± 4 2.45 ± 0.41
3/4 36 ± 5 3.67 ± 0.51
1 60 ± 9 6.12 ± 0.92
Tightening torque table for hoses (taper seal type and face seal type)
a Tighten the hoses (taper seal type and face seal type) to the following torque, unless otherwise specified.
a Apply the following torque when the threads are coated (wet) with engine oil.
Taper seal
Tightening torque (Nm {kgm}) Face seal type
type
Nominal
Width Nominal thread
size of
across flats Thread size size – Threads Root diameter
hose Range Target
(mm) per inch, Thread (mm) (reference)
series
9
02 19 34 – 63 {3.5 – 6.5} 44 {4.5} 14 – 18UNF 14.3
16
11
22 54 – 93 {5.5 – 9.5} 74 {4.5} — – 16UN 17.5
16
03
24 59 – 98 {6.0 – 10.0} 78 {8.0} 18 — —
13
04 27 84 – 132 {8.5 – 13.5} 103 {10.5} 22 1 – 16UN 20.7
16
05 32 128 – 186 {13.0 – 19.0} 157 {16.0} 24 1 – 14UNS 25.4
3
06 36 177 – 245 {18.0 – 25.0} 216 {22.0} 30 1 – 12UNF 30.3
16
(10) 41 177 – 245 {18.0 – 25.0} 216 {22.0} 33 — —
(12) 46 197 – 294 {20.0 – 30.0} 245 {25.0} 36 — —
(14) 55 246 – 343 {25.0 – 35.0} 294 {30.0} 42 — —
WE051Y0200 13
General
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: 5WB indicates a cable having a nominal number 5 and white coating with black stripe.
Classification by thickness
Copper wire
Nominal Dia. of Cable O.D. Current rat-
Number of Cross section Applicable circuit
number strands (mm) ing (A)
strands (mm2)
(mm2)
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
Code W B B R Y G L
1 Primary
Color White Black Black Red Yellow Green Blue
Code WR — BW RW YR GW LW
2
White & White & Red & Yellow & Green & Blue &
Color —
Red Black White Red White White
Code WB — BY RB YB GR LR
3
White & Black & Red & Yellow & Green & Blue & Yel-
Color —
Black Yellow Black Black Red low
Code WL — BR RY YG GY LY
4 Auxiliary
White & Black & Red & Yel- Yellow & Green & Blue & Yel-
Color —
Blue Red low Green Yellow low
Code WG — — RG YL GB LB
5
White & Red & Yellow & Green & Blue &
Color — —
Green Green Blue Black Black
Code — — — RL YW GL —
6
Yellow & Green &
Color — — — Red & Blue —
White Blue
14 WE051Y0200
General
Conversion table
Method of using the conversion table
The Conversion Table in this section is provided to enable simple conversion of figures. For details of the
method of using the Conversion Table, see the example given below.
Example
q Method of using the Conversion Table to convert from millimeters to inches
1. Convert 55mm into inches.

1) Locate the number 50 in the vertical column at the left side, take this as (A), then draw a horizontal line
from (A).
2) Locate the number 5 in the row across the top, take this as (B), then draw a perpendicular line down from
(B).
3) Take the point where the two lines cross as (C). This point (C) gives the value when converting from milli-
meters to inches. Therefore, 55mm = 2.165inches.
2. Convert 550mm into inches.

1) The number 550 does not appear in the table, so divide by 10 (move the decimal point one place to the
left) to convert it to 55mm.
2) Carry out the same procedure as above to convert 55mm to 2.165inches.
3) The original value (550mm) was divided by 10, so multiply 2.165inches by 10 (move the decimal point one
place to the right) to return to the original value. This gives 550mm = 21.65inches.
Millimeters to inches (B)

1mm = 0.03937in
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
(C)
(A) 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
WE051Y0200 15
General
Millimeters to Inches
1mm = 0.03937in
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
1kg = 2.2046lb
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
16 WE051Y0200
General
Liter to U.S. Gallon

1l = 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

1l = 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 7.969 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
WE051Y0200 17
General
kgm to ft. lb
1kgm = 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 1352.6 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
18 WE051Y0200
General
kg/cm2 to lb/in2
1kg/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 1934 1949 1963 1977
140 1991 2005 2020 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
WE051Y0200 19
General
Temperature
Fahrenheit-Centigrade Conversion; a simple way to convert a Fahrenheit temperature reading into a Centi-
grade temperature reading or vice 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 Cen-
tigrade values, and read the corresponding Fahrenheit temperature on the right.
1°C = 33.8°F
°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 0 140.0 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
20 WE051Y0200
General
Units
In this manual, the measuring units are indicated with International System of units (SI).
As for reference, conventionally used Gravitational System of units are indicated in parentheses { }.
Example:
N {kg}
Nm {kgm}
MPa {kg/cm2}
kPa {mmH2O}
kPa {mmHg}
kW/rpm {HP/rpm}
g/kWh {g/HPh}
WE051Y0200 21
WE051A0100
Bulldozer
D61EX-15
D61PX-15
D61EX-15 B40001-
D61PX-15 B40001-
General 1
Specification dimension drawing................................................................................... 2
Specifications................................................................................................................ 3
Weight table .................................................................................................................. 8
Oil and coolant table ................................................................................................... 12
General
Specification dimension drawing 1

D61EX/PX-15 Power angle, power tilt dozer with ROPS guard, cab, and air conditioner
D61EX-15 D61PX-15
Check item Unit PAT dozer
PAT dozer PAT dozer
Long track
Machine weight kg 16,840 17,560 18,460
Engine name - KOMATSU SA6D114E-2 Diesel engine
Rated engine output kW{HP}/rpm 116{155}/1,800
A Overall length mm 5,030 5,450 5,465
Overall height
B mm 3,150 3,150 3,180
(excluding antenna)
C Overall width mm 3,275 3,275 3,860
Travel speed Forward km/h 3.3/5.8/9.4
(1st/2nd/3rd) Reverse km/h 4.3/7.3/11.2
a PAT: Abbreviation for Power Angle power Tilt
2 WE051A0100
General
Specifications 1
D61EX-15 D61PX-15
Machine name and type PAT dozer
PAT dozer PAT dozer
Long track
Serial No. B40001- B40001-
Machine weight
•Tractor unit kg 13,730 14,300 15,050
Mass
•With work equipment kg 16,130 16,850 17,750

•With work equipment and
kg 16,840 17,560 18,460
ROPS cab
Min. turning radius
m 3.6 3.7 3.7
(counter-rotation)
Gradeability deg. 30 30 30
Stability
deg. 35 35 35
(front, rear, left, right)
Performance
Overall width Overall length Ground pressure Speed
Forward (1st/2nd/3rd) km/h 3.3/5.8/9.4 3.3/5.8/9.4 3.3/5.8/9.4

Reverse (1st/2nd/3rd) km/h 4.3/7.3/11.2 4.3/7.3/11.2 4.3/7.3/11.2
kPa 43.1 37.3 26.5
Tractor unit
{kg/cm2} {0.44} {0.38} {0.27}
kPa 51.0 43.1 31.4
With work equipment
{kg/cm2} {0.52} {0.44} {0.32}
With work equipment and kPa 53.0 45.1 32.4
ROPS cab {kg/cm2} {0.54} {0.46} {0.33}
Tractor unit mm 3,920 4,160 4,210
With work equipment mm 5,030 5,450 5,465
Tractor unit mm 2,500 3,000 3,000
With work equipment mm 3,275 3,275 3,860

Dimensions
Up to exhaust pipe mm 2,945 2,945 2,970

Overall height
Up to top of operator's seat mm 2,270 2,270 2,300

When ROPS cab is installed
mm 3,150 3,150 3,180
(excluding antenna)
When ROPS canopy is
mm 3,150 3,150 3,180
installed
Track gauge mm 1,900 2,140 2,140
Length of track on ground mm 2,600 3,170 3,170
Track width
mm 600 600 860
(standard track shoe)
Minimum ground clearance mm 395 395 475
WE051A0100 3
General
D61EX-15 D61PX-15
PAT dozer PAT dozer
Long track
Serial No. B40001- B40001-
Name SA6D114E-2
4-stroke, water-cooled, in-line 6-cylinder,
Type direct injection type with turbocharger and
water-cooled aftercooler
Number of cylinders - Bore x
mm 6-114x135
Stroke
Total displacement l {cc} 8.27 {8,270}
kW/rpm
Rated output 116/1,800 {155/1,800}
{HP/rpm}
Nm/rpm
Engine
Max. torque 824/1,300 {84/1,300}

Performance
{kgm/rpm}
High idling speed under no
rpm 2,000±50
load
Low idling speed under no
rpm 900±50
load
g/kWh
Min. fuel consumption ratio 226 {168}
{g/HPh}
Starting motor 24V, 7.5kW
Alternator 24V, 60A
Battery (∗1) 12V, 140Ah•2 pieces
Type of radiator core D-6
Torque converter 3-element, 1-stage, 1-phase type
Planetary gear, multi-disc clutch, hydraulic, forced
Transmission lubrication with gear pump, 3-forward gear speed,
3-reverse gear speed, manual electronic type
Power train
Spiral bevel gear, forced lubrication

Bevel gear shaft
with gear pump type
Differential planetary gear, hydraulic motor drive,
HSS unit
HSS
manual electronic, hydraulic type
Wet multi-disc, spring pressure,
Brake
foot-drive, hydraulic type
Final drive Double reduction spur gear, splash lubrication type
Type of suspension Semi-rigid, equalizer beam type
Carrier roller 2 pieces on each side
7 pieces on
Track roller 8 pieces on each side
each side
Undercarriage
Track shoe
Width: 600mm Width: 860mm
40 pieces on 46 pieces on
•Assembly-type single grouser -
each side each side
Pitch: 190mm Pitch: 190mm
Width: 860mm
•Assembly-type special swamp 46 pieces on
- -
shoe each side
Pitch: 190mm
∗1: Battery capacity is 5-hour rate value.
4 WE051A0100
General
D61EX-15 D61PX-15
PAT dozer PAT dozer
Long track
Serial No. B40001- B40001-
HSS pump
Variable-displacement swash plate piston type,
Type
load sensing type
Theoretical capacity cm3/rev 95
Cooling fan pump
Hydraulic pump
Type Variable-displacement swash plate piston type

Theoretical capacity cm3/rev 30
Power train and lubricating oil
pump
Type Fixed-displacement external gear pump (tandem)
3
Theoretical capacity cm /rev 40.2x2
Scavenging pump
Hydraulic system
Type Fixed-displacement external gear pump

3
Theoretical capacity cm /rev 61.2
HSS motor
Hydraulic motor
Fixed-displacement swash plate piston type with

Type
brake valve
Motor capacity cm3/rev 80
Cooling fan motor
Type Fixed-displacement swash plate piston type
3
Motor capacity cm /rev 28
3+1-spool type, 1 unit
Control valve
(PAT dozer, Semi-U dozer, Semi-U dozer + Ripper, PT dozer)

Type and quantity
4+1-spool type, 1 unit
(PAT dozer + Ripper)
Control method Hydraulic assist type
Hydraulic tank Box type (external control valve type)
Hydraulic oil filter Return-to-tank side
Oil cooler Air-cooled (3A-CS)
a PT: Abbreviation for Power Tilt
WE051A0100 5
General
D61EX-15 D61PX-15
Machine name and type
Standard Long track Standard
Serial No. B40001- B40001-
Type Double acting piston
Cylinder bore mm 110
Lift cylinder
Piston rod diameter mm 55

Stroke mm 469
Max. distance between pins mm 1,322
Min. distance between pins mm 853
Tilt cylinder
PAT dozer

Stroke mm 190
Min. distance between pins mm 1,036
Angle cylinder

Work equipment hydraulic system

Stroke mm 469
Min. distance between pins mm 883
Double acting Double acting
Type -
piston piston
Lift cylinder
Cylinder bore mm 110 - 110

Piston rod diameter mm 55 - 55
Semi-U dozer, PT dozer
Stroke mm 469 - 469

Max. distance between pins mm 1,322 - 1,322
Min. distance between pins mm 853 - 853
Double acting Double acting
Type -
piston piston
Tilt cylinder
Cylinder bore mm 140 - 140

Piston rod diameter mm 70 - 70
Stroke mm 143 - 143
Max. distance between pins mm 1,027 - 1,027
Min. distance between pins mm 884 - 884
Double acting
Type - -
piston
Ripper cylinder
Cylinder bore mm 140 - -

Piston rod diameter mm 70 - -
Stroke mm 330 - -
Max. distance between pins mm 1,080 - -
Min. distance between pins mm 750 - -
6 WE051A0100
General
D61EX-15 D61PX-15
Serial No. B40001- B40001-
Type Hydraulic angle tilt dozer
Blade supporting method Right and left: Angle cylinder type
Dimensions Performance
Max. lift (above ground) mm 980 1,025 1,110

PAT dozer
Max. drop (below ground) mm 465 580 495
Max. tilting distance mm 510 510 600

Blade width mm 3,275 3,275 3,860
Blade height mm 1,200 1,200 1,160
Blade angle deg. 57 57 57
Type Hydraulic semi-U dozer
Blade supporting method Left: Brace type / Right: Tilt cylinder type
Max. lift (above ground) mm 970 - -
Work equipment
Semi-U dozer
Max. drop (below ground) mm 545 - -

Max. tilting distance mm 690 - -
Blade angle range deg. ±7 - -
Blade width mm 3,175 - -
Blade height mm 1,300 - -
Blade angle deg. 57 - -
Type Hydraulic tilt dozer
Blade supporting method Left: Brace type / Right: Tilt cylinder type
Max. lift (above ground) mm - - 1,210
Max. drop (below ground) mm - - 425

PT dozer
Max. tilting distance mm - - 600

Blade angle range deg. - - ±7
Blade width mm - - 3,600
Blade height mm - - 1,070
Blade angle deg. - - 57
Type Parallelogram - -
Beam length mm 2,170 - -
Number of shanks Piece 3 - -
Digging angle (a/b) deg. 55 / 45 - -
Ripper
Performance
Changeable to
Digging depth - -
3 levels
Max. digging depth
mm 665 - -
Max. lift mm 565 - -
Shank position (left/right) mm 950 / 950 - -
WE051A0100 7
General
Weight table 1
k This weight table is a reference table for handling and transporting of components.
Unit: kg
D61EX-15 D61PX-15
Serial No. B40001- B40001-
Engine and damper assembly
840 840 840
(excluding coolant and oil)
•Engine assembly 797 797 797
•Damper assembly 35 35 35
•Parts related to engine (wiring) 8 8 8
Universal joint 13 13 13
Cooling assembly (excluding coolant and oil) 140 140 140
•Radiator assembly (including power train oil cooler) 115 115 115
•Hydraulic oil cooler 11 11 11
Cooling fan pump 28 28 28
Cooling fan motor 13 13 13
Fuel tank (excluding fuel) 170 170 170
Power train unit assembly (excluding oil) 2,105 2,105 2,105
•Torque converter and PTO assembly 290 290 290
•Transmission assembly 340 340 340
•Transmission ECMV assembly 13 13 13
•Main relief valve assembly 6 6 6
•HSS unit assembly 1,380 1,380 1,380
•Brake valve assembly 6 6 6
HSS motor 45 45 45
HSS pump 65 65 65
Power train and lubricating oil pump 20 20 20
Scavenging pump 5 5 5
Hydraulic tank (excluding oil) 60 60 60
Control valve
•3+1-spool valve
(PAT dozer, Semi-U dozer, Semi-U dozer + Ripper, 52 52 52
PT dozer)
•4+1-spool valve
57 57 57
(PAT dozer + Ripper)
Final drive assembly (each side) 734 734 734
Sprocket (each side) 7.4x9 7.4x9 7.4x9
8 WE051A0100
General
Unit: kg
D61EX-15 D61PX-15
Serial No. B40001- B40001-
Frame assembly 1,010 1,010 1,010
Engine under guard 45 45 45
Transmission under guard 22 22 22
Track group assembly (each side) (PAT dozer) 1,378 1,470 1,470
(Semi-U dozer) 1,408 - -
(PT dozer) - - 1,520
•Track frame (PAT dozer) 467 518 518
(Semi-U dozer) 497 - -
(PT dozer) - - 568
•Idler assembly (each side) 184 184 184
•Recoil spring assembly (each side) 205 205 205
•Single flange track roller assembly (each side) 45x5 45x6 45x6
•Double flange track roller assembly (each side) 52x2 52x2 52x2
•Carrier roller assembly (each side) 25x2 25x2 25x2
Track shoe assembly (each side)
•Single grouser shoe (600mm) 1,245 1,425 -
•Swamp shoe (860mm) - - 1,570
•Single grouser shoe (860mm) - - 1,785
Pivot shaft (each side) 85 85 105
Equalizer bar 90 90 120
Floor frame assembly 300 300 300
Operator's seat 56 56 56
Cab assembly 410 410 410
ROPS guard assembly (for cab) 210 210 210
ROPS canopy assembly 390 390 390
PAT dozer assembly (standard) 2,300 2,600 2,600
(wide) 2,460 - -
(3m) - - 2,840
•Blade (including center ball) (standard) 1,130 1,130 1,290
(wide) 1,290 - -
(3m) - - 1,530
•U-frame (each side) 810 960 960
•Tilt cylinder assembly 75 75 75
•Angle cylinder assembly 58x2 58x2 58x2
WE051A0100 9
General
Unit: kg
D61EX-15 D61PX-15
Serial No. B40001- B40001-
Semi-U dozer assembly 2,040 - -
PT dozer assembly - - 1,830
•Blade 1,215 - 1,015
•Straight-frame (each side) 190 - 190
•Tilt cylinder assembly 65 - 65
Lift cylinder assembly (PAT dozer) 48x2 48x2 48x2
(Semi-U dozer, PT dozer) 50x2 - 50x2
Ripper assembly 1,530 - -
Ripper cylinder assembly 75 - -
10 WE051A0100
General
Oil and coolant table 1
∗1. ASTM D975 No.1
12 WE051A0100
General
Unit: l
Specified oil Quantity of
Fuel sulphur content
level replacement oil
Engine oil pan 23 19
Damper case 1.3 1.3
Idler (each of right and left) 0.22 0.22
Hydraulic oil system 95 55
Power train case 100 69
Final drive case
32 28.5
(each of right and left)
Fuel tank 390 -
Cooling system
44 -
(including sub-tank)
WE051A0100 13
WE051B0100
Bulldozer
D61EX-15
D61PX-15
D61EX-15 B40001-
D61PX-15 B40001-

Maintenance standard 1
Engine and cooling related components .......................................................................... 2
Cooling system ............................................................................................................. 2
Power transmitting system ............................................................................................... 4
Power train.................................................................................................................... 4
Power train skeleton ..................................................................................................... 5
Overall drawing of power train unit ............................................................................... 6
Hydraulic piping diagram of power train ....................................................................... 7
Damper and universal joint ........................................................................................... 8
Transmission, steering, and brake control .................................................................. 10
Structure and function, Maintenance standard
Engine and cooling related components 1

Cooling system 1
2 WE051B0100
A: Power train oil cooler inlet

B: Power train oil cooler outlet
C: Hydraulic oil cooler inlet
D: Hydraulic oil cooler outlet
1. Cooling fan motor

2. Radiator
3. Reservoir tank
4. Radiator inlet hose
5. Radiator outlet hose
6. Hydraulic oil cooler
7. Radiator cap
8. Cooling fan
9. Bypass valve
10. Power train oil cooler
(built in radiator lower tank)
11. Drain plug
Specifications
Power train oil

Radiator Hydraulic oil cooler
cooler
Core type D-6 PTO-OL 3A-CS
Fin pitch (mm) 4.0 - 3.5
Total heat dissipation
46.190 1.829 1.860
area (m2)
Pressure valve
88.3±14.7
cracking pressure - -
{0.9±0.15}
(kPa{kg/cm2})
Vacuum valve
0 - 4.9
cracking pressure - -
{0 - 0.05}
(kPa{kg/cm2})
WE051B0100 3
Power transmitting system 1

Power train 1
Outline
q The power generated by engine (1) has its tor- q Brake (12) built in HSS unit (10) stops the
sional vibration dampened by damper (2), and machine. Brake (12) is a wet, multiple disc clutch,
then passes through universal joint (3) and is spring boosted type.
transmitted to torque converter (7). The power sent from brake (12) is transmitted to
q The power from the engine is transmitted through final drive (13).
the oil by torque converter (7) to the transmission q Final drive (13) consists of a single-stage spur
input shaft in accordance with the change in load. gear and a single-stage planetary gear system. It
q Transmission (8) uses a combination of a plane- reduces the speed and rotates sprocket (14) to
tary gear system and hydraulic clutches to reduce drive track shoe (15) and move the machine.
the speed and shift the gears (3 forward gears and q Cooing fan pump (6) driven with PTO (5) rotates
3 reverse gears). It connects 2 sets of clutches cooling fan motor (19) with the discharged oil.
selected accordingly to the change in load and
transmits the power to bevel gear (9) from the
bevel pinion at the rear end of the transmission.
q Power transmitted to HSS unit (10) is further trans-
mitted through the bevel gear shaft to the HSS.
Pump (4) driven with PTO (5) rotates HSS motor
(11) with the discharged oil.
Turning direction is controlled by controlling the
rotations of the right and left planetary gear units
with HSS motor (11) to make a difference between
the right and left tracks in revolution speed.
The operator can revolve both tracks in the oppo-
site directions with the HSS mechanism to make
counter-rotations.
4 WE051B0100
Power train skeleton 1
1. Engine 11. HSS motor

2. Damper 12. Brake
3. Universal joint 13. Final drive
4. HSS pump 14. Sprocket
5. PTO 15. Track shoe
6. Cooling fan pump 16. Power train pump
7. Torque converter 17. Lubricating oil pump
8. Transmission 18. Scavenging pump
9. Bevel gear 19. Cooling fan motor
10. HSS unit
WE051B0100 5
Overall drawing of power train unit 1
1. HSS pump Outline

2. Cooling fan pump q The power train unit roughly consists of torque
3. HSS motor converter and PTO (6), transmission (9), and HSS
4. Lubricating oil pump unit (11). Accordingly, after the power train unit is
5. Power train pump removed, it can be divided into torque converter
6. Torque converter and PTO and PTO (6), transmission (9), and HSS unit (11).
7. Main relief valve q HSS unit (11) consists of the bevel gear unit, bevel
8. Transmission ECMV gear shaft, HSS motor (3), planetary gear mecha-
9. Transmission nism, and brake.
10. Brake valve
11. HSS unit
12. Scavenging pump
13. Power train oil strainer
6 WE051B0100
Hydraulic piping diagram of power train 1
A: Discharge oil pressure pickup port of HSS pump 1. Centralized pressure pickup ports
B: Discharge oil pressure pickup port of cooling 2. Transmission ECMV
fan pump 3. Power train oil filter
C: Main relief oil pressure pickup port 4. Oil feed pipe
D: Outlet oil pressure pickup port of torque converter 5. Brake valve
E: Inlet oil pressure pickup port of torque converter 6. Power train pump
F: Brake oil pressure pickup port 7. Lubricating oil pump
8. Main relief valve
9. Scavenging pump
10. Power train oil cooler
(built in radiator lower tank)
WE051B0100 7
Damper and universal joint 1
8 WE051B0100
Unit: mm
No. Check item Criteria Remedy
Standard size Tolerance Repair limit Plate with hard
Inside diameter of contact surfaces
1 of coupling and oil seal
0 chromium or
ø85 84.8
-0.087 replace
Facial runout: Max. 1.0 (when ø 148.38), Radial runout: Max. 1.5 [when
- Facial and radial runout of coupling
damper shaft and transmission input shaft are rotated simultaneously]
Adjusting
2. Breather Outline
3. Oil filler plug q The damper is a wet friction spring type.
4. Inspection plug Stopper angle: 4°
5. Drain plug Stopper torque: 2,670Nm {272kgm}
6. Damper case q The damper damps the torsional vibration caused
7. Coupling by fluctuation of the engine torque and the impact
8. Cross pin torque caused by sudden acceleration and heavy
9. Yoke digging work to protect the torque converter, trans-
10. Shaft mission, and other power train components.
11. Bearing
12. Cover
13. Hub
14. Friction spring
15. Friction plate
16. Stopper pin
17. Torsion spring
18. Drive plate
WE051B0100 9
Transmission, steering, and brake control 1

a PCCS: Abbreviation for Palm Command Control System
10 WE051B0100
1. Brake pedal
2. Decelerator pedal
3. Deceleration pedal potentiometer
4. Rod
5. Fuel control dial
6. Steering/directional/gearshift lever (PCCS lever)
7. Brake pedal potentiometer
8. Parking brake lever
9. Cable
10. Transmission and steering controller
11. Neutral safety limit switch
12. Brake valve
13. Transmission ECMV
14. Cable
15. Governor motor
16. Loose spring
17. Injection pump
Outline
q The transmission, steering system, and brake are
controlled with the steering/directional/gearshift
lever (PCCS lever) (6).
q Steering/directional/gear shift lever (6) sends elec-
tric signals to transmission and steering controller
(10). Upon receiving this signal, the transmission
and steering controller sends a signal to the EPC
valve of the control valve to change the flow in the
HSS pump and control the HSS motor.
q Brake pedal (1) operates brake valve (12) through
rod (4) to control the brake.
q Parking brake lever (8) operates brake valve (12),
which is also used as the parking brake valve,
through cable (9).
q The safety mechanism is employed, which works
as follows; If parking brake lever (8) is not in the
"Lock" position, neutral safety limit switch (11)
does not operate and the engine cannot start.
WE051B0100 11
WE051B0200
Bulldozer
D61EX-15
D61PX-15
D61EX-15 B40001-
D61PX-15 B40001-

Torque converter and PTO............................................................................................ 3
Transmission................................................................................................................. 8
Transmission ECMV ................................................................................................... 20
Main relief valve.......................................................................................................... 26
Lubricating oil relief valve ........................................................................................... 28

Torque converter and PTO
a PTO: Abbreviation for Power Take Off
WE051B0200 3
4 WE051B0200
A: From transmission case (to torque converter) Outline

B: To oil cooler q The torque converter is a 3-element, 1-stage, and
C: From transmission case (to scavenging pump) 1-phase type, which is combined with the trans-
D: From transmission case mission into one unit.
(to power train and lubrication pump) q Pump (15) is built up together with coupling (6),
E: To transmission case (drain) input shaft (7), PTO drive gear (8), and drive case
(12) in one unit and revolved with the power from
the engine.
1. HSS pump mounting opening q Turbine (13) is combined with transmission input
2. Power train and lubricating pump shaft (17) into one unit and rotated by the oil from
mounting opening pump (15).
3. Scavenging pump q Stator (14) is built up together with stator shaft (16)
4. PTO lubrication tube in one unit and fixed to PTO case (11).
5. Cooling fan pump mounting opening q Each pump installed to the PTO case is driven
6. Coupling with the power transmitted from PTO drive gear (8)
7. Input shaft through PTO idler gear (10) and pump drive gears
8. PTO drive gear (Number of teeth: 62) (18), (19), and (20).
9. PTO idler gear shaft
10. PTO idler gear (Number of teeth: 63)
11. PTO case
12. Drive case
13. Turbine
14. Stator
15. Pump
16. Stator shaft
17. Transmission input shaft
18. HSS and work equipment pump,
fan pump drive gear (Number of teeth: 53)
19. Power train and lubricating pump
drive gear (Number of teeth: 53)
20. Scavenging pump drive gear
(Number of teeth: 56)
21. Scavenging pump strainer
22. Power train strainer
23. Sleeve
WE051B0200 5
6 WE051B0200
Unit: mm
Standard size Tolerance Repair limit
Outside diameter of oil seal contact
1 face of input coupling 0 Plate with hard
ø110 ø109.8
-0.087 chromium or
Inside diameter of seal ring contact +0.035 replace
2 face of retainer
ø105
0
ø105.5
Backlash between PTO drive gear

3 and PTO idler gear
0.17 - 0.46
Backlash between PTO idler gear

4 and HSS pump and cooling fan 0.16 - 0.42
pump drive gear
Backlash between PTO idler gear
5 and power train and lubrication 0.16 - 0.42
pump drive gear
Backlash between PTO drive gear
6 and scavenging pump drive gear
0.17 - 0.46
Tolerance
Standard size
Shaft Hole
Fit tolerance of PTO Outside 0 -0.010
7 idler gear bearing ø110
diameter -0.015 -0.035
Inside 0 0
ø60
diameter -0.019 -0.015
Outside +0.035
diameter Replace
0
(Cover side) 0
Fit tolerance of HSS ø120
Outside -0.015
8 pump and cooling fan
diameter
+0.022
pump drive gear bearing (Case side) -0.013
Inside +0.021 0
ø55
diameter +0.002 -0.015
Outside
+0.035
diameter
0
(Cover side) 0
Fit tolerance of power ø120
Outside -0.015
9 train and lubricating oil
diameter
+0.022
pump drive gear bearing (Case side) -0.013
Inside +0.021 0
ø55
diameter +0.002 -0.015
Outside 0 +0.030
Fit tolerance of ø72
diameter -0.013 0
10 scavenging pump drive
gear bearing Inside +0.011 0
ø35
diameter -0.005 -0.010
WE051B0200 7
Transmission 1
8 WE051B0200
A: 1st clutch oil pressure pickup port

B: 3rd clutch oil pressure pickup port
C: R clutch oil pressure pickup port
D: 2nd clutch oil pressure pickup port
E: F clutch oil pressure pickup port
F: From power train pump (to brake valve)
G: To PTO case (to torque converter)
H: From oil cooler
J: To PTO case (to scavenging pump)
K: From PTO case (drain)
L: To PTO case (to power train and lubrication pump)
M: From steering case
N: From transmission ECMV (for R clutch)
P: From transmission ECMV (for 3rd clutch)
R: From transmission ECMV (for 1st clutch)
S: From transmission ECMV (for 2nd clutch)
T: From transmission ECMV (for F clutch)
WE051B0200 9
1. Main relief valve 19. Output shaft

2. Transmission ECMV cover (3rd sun gear section, Number of teeth: 17)
3. Transmission case 20. 1st carrier
4. Transmission ECMV 21. 1st clutch housing
5. Lubricating oil relief valve 22. 1st ring gear (Number of internal teeth: 75)
6. Transmission input shaft 23. 2nd clutch housing
7. R sun gear (Number of teeth: 26) 24. 2nd planetary pinion (Number teeth: 21)
8. R planetary pinion (Number of teeth: 22) 25. 2nd ring gear (Number of internal teeth: 75)
9. R ring gear (Number of teeth: 70) 26. 3rd clutch housing
10. Disc 27. 2nd and 3rd carrier
11. Plate 28. F clutch housing
12. Piston 29. F sun gear (Number of teeth: 29)
13. F planetary pinion (Number of teeth: 23) 30. F ring gear (Number of internal teeth: 75)
14. 3rd planetary pinion (Number of teeth: 30) 31. F carrier
15. 3rd ring gear (Number of internal teeth: 76) 32. F clutch housing
16. 2nd sun gear (Number of teeth: 33) 33. Return spring
17. 1st planetary pinion (Number of teeth: 18) 34. R ring gear (hub) (Number of internal teeth: 75)
18. 1st sun gear (Number of teeth: 39) 35. R carrier
10 WE051B0200
Outline
q The transmission consists of planetary gear mech-
anisms and disc clutches and has "Three forward
gear speeds and three reverse gear speeds".
q The transmission fixes two of the five sets of plan-
etary gear mechanism and disc clutch hydrauli-
cally with the ECMV to select 1 revolving direction
and revolving speed.
q The transmission changes the power of the trans-
mission input shaft to forward 1st - 3rd gear speed
or reverse 1st - 3rd gear speed by combining the F
and R clutches and three speed clutches.
Number of plates and discs

Number of Number of
Clutch No.
plates discs
R clutch 6 5
F clutch 8 7
3rd clutch 5 4
2nd clutch 5 4
1st clutch 4 3
Gear speeds and operated clutches

Reduction
Gear speed Operated clutches
ratio
Forward 1st F x 1st 1.948
Forward 2nd F x 2nd 1.096
Forward 3rd F x 3rd 0.656
Neutral ∗ -
Reverse 1st R x 1st 1.462
Reverse 2nd R x 2nd 0.823
Reverse 3rd R x 3rd 0.492
∗: The 1st, 2nd, or 3rd clutch is filled with low-pres-
sure oil.
WE051B0200 11
12 WE051B0200
Unit: mm
Standard size Repair limit
Installed
Free length Installed load Free length Installed load
1 R clutch spring (5 pieces) length
233.2 N 198 N
69.5 58.7 65.3
{23.8 kg} {20.2 kg}
95.2 N 81 N
2 F clutch spring (5 pieces) 77.0 63.6
{9.7 kg}
72.4
{8.2 kg}
146.0 N 125 N
3 3rd clutch spring (5 pieces) 59.0 44.1
{14.9 kg}
55.5
{12.7 kg}
142.1 N 121 N
4 2nd clutch spring (5 pieces) 59.0 44.5
{14.5 kg}
55.5
{12.3 kg}
144.1 N 123 N
5 1st clutch spring (5 pieces) 59.0 44.3
{14.7 kg}
55.5
{12.5 kg}
Total assembly thickness of 5 discs Standard size Tolerance Repair limit
6 and 6 plates of R clutch 36.2 ±0.33 32.2
Total assembly thickness of 7 discs
7 and 8 plates of F clutch
49.4 ±0.39 43.8

8 and 5 plates of 3rd clutch
29.6 ±0.30 26.4

9 and 5 plates of 2nd clutch
29.6 ±0.30 26.4 Replace
10 and 4 plates of 1st clutch
23.0 ±0.26 20.6
11 Thickness of clutch disc 3.4 ±0.1 2.6

12 Thickness of clutch plate 3.2 ±0.1 2.9
-0.01
Wear of seal ring of Width 3.0 2.70
13 transmission input shaft
-0.03
Thickness 2.3 ±0.10 2.15
Backlash between R, F, 2nd and
14 1st sun gears and planetary pinion
0.11 - 0.30
Backlash between 3rd sun gear and

15 planetary pinion
0.11 - 0.29
Backlash between planetary pinion

16 and internal teeth of ring gear
0.12 - 0.33
Backlash between R carrier and

17 internal teeth of ring gear
0.14 - 0.44
Backlash between F carrier and

0.14 - 0.38
Backlash between 1st carrier and

0.14 - 0.39
WE051B0200 13
Disc clutch
Structure Clutch "Disengaged" (released)

q The disc clutch consists of piston (2), plate (3), q If the oil sent from the ECMV is stopped, piston (2)
disc (4), pin (5), return spring (6), etc. to secure is returned to the right by return spring (6).
ring gear (1). q The friction force between plate (3) and disc (4) is
q The internal teeth of disc (4) are meshed with the released and ring gear (1) is released.
external teeth of ring gear (1).
q Plate (3) is secured to clutch housing (7) with pin
(5).
Operation Oil circuit in speed clutch

Clutch "Engaged" (fixed) q While the steering/directional/gearshift lever is in
q The oil sent from the ECMV is further sent through the "Neutral", the 1st, 2nd, or 3rd gear speed is
the oil path of housing (7) to the back side of pis- selected.
ton (2) to press piston (2) to the left. q The piston chamber of the clutch corresponding to
q Piston (2) presses plate (3) and disc (4) to fit them the selected gear speed is filled with oil by elec-
together, and disc (4) is stopped by the friction tronically controlling the hydraulic circuit of each
force between it and plate (3). clutch.
q Since the internal teeth of disc (4) are meshed with q If the steering/directional/gearshift lever is moved
the external teeth of ring gear (1), ring gear (1) is from the "Neutral" to "Forward" or "Reverse", the
fixed. pump must supply oil to fill the piston chamber of
the F clutch or R clutch.
q If the gear speed is changed from the "Forward
1st" to the "Forward 2nd", oil to only fit the plates
and discs of the 2nd clutch is required, since the F
clutch is filled with oil already.
q The time lag in the gear shifting operation is
reduced by controlling the oil in the clutch circuit
as explained above.
14 WE051B0200
Power train route

Forward 1st
q When the forward 1st is selected, the F clutch and q F carrier (10) and 2nd and 3rd carriers (11) are
1st clutch are engaged. The power transmitted connected by a spline, and rotate as one unit.
from the torque converter to input shaft (1) is then Accordingly, the rotation of F carrier (10) is trans-
transmitted to output shaft (21). mitted through 2nd planetary pinion (13) to 2nd
q The F clutch is operated with the oil pressure ring gear (15).
applied to the F clutch piston to fix F ring gear (4). q Since 2nd ring gear (15) and 1st carrier (16) are
The 1st clutch is actuated by the hydraulic pres- meshed with each other, the power transmitted to
sure applied to the 1st clutch piston, and holds 1st 2nd ring gear (15) is transmitted to 1st planetary
ring gear (18). pinion (17).
q The power from the torque converter is transmitted q Since 1st ring gear (18) is held by the 1st clutch,
to input shaft (1), and then transmitted through F the power transmitted to 1st planetary pinion (17)
sun gear (2) to F planetary pinion (3). is transmitted through 1st sun gear (20) to output
q Since F ring gear (4) is fixed with the F clutch, the shaft (21).
power transmitted to F planetary pinion (3) rotates
F carrier (10) in F ring gear (4).
WE051B0200 15
Forward 2nd
q When the forward 2nd is selected, the F clutch and q Since F carrier (10) and 2nd and 3rd carriers (11)
2nd clutch are engaged. The power transmitted are connected by the spline and rotated together,
from the torque converter to input shaft (1) is then the revolution of F carrier (10) is transmitted to 2nd
transmitted to output shaft (21). planetary pinion (13).
q The F clutch is operated with the oil pressure q Since 2nd ring gear (15) is held by the 2nd clutch,
applied to the F clutch piston to fix F ring gear (4). the power transmitted to 2nd planetary pinion (13)
The 2nd clutch is actuated by the hydraulic pres- is transmitted through 2nd sun gear (19) to output
sure applied to the 2nd clutch piston, and holds shaft (21).
2nd ring gear (15).
q The power from the torque converter is transmitted
to input shaft (1), and then transmitted through F
sun gear (2) to F planetary pinion (3).
q Since F ring gear (4) is fixed with the F clutch, the
16 WE051B0200
Forward 3rd
q When the forward 3rd is selected, the F clutch and q Since F carrier (10) and 2nd and 3rd carriers (11)
3rd clutch are engaged. The power transmitted are connected by the spline and rotated together,
from the torque converter to input shaft (1) is then the revolution of F carrier (10) is transmitted to 3rd
transmitted to output shaft (21). planetary pinion (12).
q The F clutch is operated with the oil pressure q Since 3rd ring gear (14) is held by the 3rd clutch,
applied to the F clutch piston to fix F ring gear (4). the power transmitted to 3rd planetary pinion (12)
The 3rd clutch is actuated by the hydraulic pres- is transmitted to output shaft (21).
sure applied to the 3rd clutch piston, and holds 3rd
ring gear (14).
q The power from the torque converter is transmitted
to input shaft (1), and then transmitted through F
sun gear (2) to F planetary pinion (3).
q Since F ring gear (4) is fixed with the F clutch, the
WE051B0200 17
Reverse 1st
q When the reverse 1st is selected, the R clutch and q F carrier (10) and 2nd and 3rd carriers (11) are
1st clutch are engaged. The power transmitted connected by a spline, and rotate as one unit.
from the torque converter to input shaft (1) is then Accordingly, the rotation of F carrier (10) is trans-
transmitted to output shaft (21). mitted through 2nd planetary pinion (13) to 2nd
q The R clutch is operated with the oil pressure ring gear (15).
applied to the R clutch piston to fix ring gear (7). q Since 2nd ring gear (15) and 1st carrier (16) are
The 1st clutch is actuated by the hydraulic pres- meshed with each other, the power transmitted to
sure applied to the 1st clutch piston, and holds 1st 2nd ring gear (15) is transmitted to 1st planetary
ring gear (18). pinion (17).
q The power from the torque converter is transmitted q Since 1st ring gear (18) is held by the 1st clutch,
to input shaft (1), and then transmitted through R the power transmitted to 1st planetary pinion (17)
sun gear (5) to R planetary pinion (6). is transmitted through 1st sun gear (20) to output
q Since ring gear (7) and carrier (8) are meshed and shaft (21).
fixed by the R clutch, the revolution of R planetary
pinion (6) rotates R ring gear (9). R ring gear (9)
rotates F carrier (10) in the opposite direction to
input shaft (1).
18 WE051B0200
Transmission ECMV 1
a ECMV: Abbreviation for Electronic Control Modulation Valve
20 WE051B0200
P: From power train pump

PF: F clutch oil pressure pickup port
PR: R clutch oil pressure pickup port
P1: 1st clutch oil pressure pickup port
P2: 2nd clutch oil pressure pickup port
P3: 3rd clutch oil pressure pickup port
CF: To F clutch
CR: To R clutch
C1: To 1st clutch
C2: To 2nd clutch
C3: To 3rd clutch
SDF: F fill switch drain
SDR: R fill switch drain
SD2: 1st fill switch drain
SD2: 2nd fill switch drain
SD3: 3rd fill switch drain
Dr: Drain
1. Fill switch (for 1st clutch)

2. Fill switch (for R clutch)
3. Fill switch (for F clutch)
4. Fill switch (for 3rd clutch)
5. Fill switch (for 2nd clutch)
6. Proportional solenoid (for 3rd clutch)
7. Proportional solenoid (for 1st clutch)
8. Proportional solenoid (for R clutch)
9. Proportional solenoid (for F clutch)
10. Proportional solenoid (for 2nd clutch)
11. Fill switch connector (for 1st clutch)
12. Fill switch connector (for R clutch)
13. Fill switch connector (for F clutch)
14. Fill switch connector (for 3rd clutch)
15. Fill switch connector (for 2nd clutch)
16. Proportional solenoid connector (for 1st clutch)
17. Proportional solenoid connector (for 3rd clutch)
18. Proportional solenoid connector (for R clutch)
19. Proportional solenoid connector (for 2nd clutch)
20. Proportional solenoid connector (for F clutch)
21. Filter
WE051B0200 21
1. Fill switch
2. Valve body (upper)
3. Pressure control valve
4. Valve body (lower)
5. Proportional solenoid
6. Oil pressure detection valve
7. Plug
22 WE051B0200
Outline of ECMV ECMV and proportional solenoid

q The ECMV consists of a pressure regulator valve q One proportional solenoid is installed for one
and a fill switch. ECMV.
q Pressure control valve After receiving the command current from the con-
Converts a current sent from the transmission controller, it produces thrust shown in the graph
troller to the proportional solenoid valve, to an oil below.
pressure. By making the proportional solenoid-produced
q Fill switch thrust act on the pressure control valve spool, it
Detects that the clutch is filled with oil. It has the produces an oil pressure shown in the graph
functions below. below. By controlling the amount of command cur-
1) When the clutch is filled with oil, a signal (the rent, the thrust is changed to operate the pressure
fill signal) is sent to the controller to notify that control valve, controlling the oil flow and oil pres-
filling is finished. sure.
2) While oil pressure is being applied to the
clutch, a signal (the fill signal) is sent to the
controller to notify that oil pressure is being Current-Thrust characteristics of proportional
applied. solenoid
A range: Before shifting gear (when drained)
B range: Filling
C range: Pressure regulation
D range: Filling (triggering)
E point: Start of filling
F point: Finish of filling
Thrust-Oil pressure characteristics of proportional

solenoid
ECMV and fill switch

q One fill switch is installed for one ECMV.
a The logic is such that the controller does not rec- If the clutch finishes filling, the fill switch is turned
ognize finish of filling even if the fill switch is turned "ON" by the pressure of the clutch. By this signal,
"ON" during the triggering operation (D range). the oil pressure starts build-up.
WE051B0200 23
ECMV operation
q The ECMV is controlled with the command current 1. Before shifting gear (when drained)
sent from the controller to the proportional sole- (A range in chart)
noid and the output signal of the fill switch. When a current is not carried to the proportional
The relationship between the proportional com- solenoid (1), the pressure control valve (2) is
mand current for the ECMV, clutch input pressure, draining the oil at the clutch port A through the
and output signal of the fill switch is shown in the drain port Dr.
graph below. Since oil pressure is not applied to oil pressure
detector valve (3) at this time, fill switch (4) is
Arange: Before shifting gear (when drained) turned "OFF".
Brange: Filling
Crange: Pressure regulation
Drange: Filling (triggering)
Epoint: Start of filling
Fpoint: Finish of filling
a The logic is such that the controller does not rec-

ognize finish of filling even if the fill switch is turned
"ON" during the triggering operation (D range).
24 WE051B0200
2. Filling (B range in chart) 3. Pressure regulation (C range in chart)

If you supply current to the proportional solenoid If you supply current to the proportional solenoid
(1) with no oil in the clutch, an oil pressure propor- (1), the solenoid produces thrust proportional to
tional to the solenoid force acts on the chamber B, the current. Pressure is regulated by balancing the
pushing the pressure control valve (2) rightward. thrust of the solenoid, the thrust of clutch port A,
As a result, pump port P and clutch port A are and reaction force of the pressure control spring
opened and oil starts filling the clutch. If the clutch (5).
is filled with oil, fill switch (4) is turned "ON".
WE051B0200 25
Main relief valve 1

Main relief and torque converter relief valve
PP: From pump 1. Body

TC: To torque converter 2. Piston
drT: Drain (torque converter relief) 3. Torque converter relief valve
dr1: Drain 4. Piston
dr2: Drain 5. Main relief valve
P1: Main relief pressure pickup port
P8: Torque converter relief pressure pickup port
Unit: mm
Standard Tolerance Standard Clearance
Clearance between main relief size Shaft Hole clearance limit
6 valve and valve body -0.035 +0.013 0.035-
ø28 0.078
-0.045 0 0.058
Clearance between torque con- -0.035 +0.013 0.035-
7 verter relief valve and valve body
ø22
-0.045 0 0.058
0.078

Installed Replace
8 Main relief valve spring (outside) length
480 N 457 N
122 78.0 118.3
{49 kg} {46.6 kg}
367.5 N 349 N
9 Main relief valve spring (inside) 108 78.0
{37.5 kg}
104.8
{35.6 kg}
182.1 N 174 N
10 Torque converter relief valve spring 50 40.5
{18.6 kg}
48.5
{17.7 kg}
26 WE051B0200
Outline Main relief valve operation

q The oil from the hydraulic pump flows through the
Torque converter relief valve filter, port A of the relief valve, and orifice a of
q The torque converter relief valve protects the spool (6) into chamber B.
torque converter from abnormally high pressure by When the oil from the pump fills the circuit, the oil
keeping the oil pressure in the torque converter pressure starts to rise.
inlet port circuit below the set pressure.
Set pressure: 1.00MPa {10.2kg/cm2}
(cracking pressure)
Main relief valve

q The main relief valve holds the oil pressure in the
transmission and brake at the set pressure.
Set pressure: 2.84MPa {29.0kg/cm2}
(at rated engine speed)
Operation
Torque converter relief valve operation

q The oil relieved from the main relief valve flows
through port C into the torque converter. It also q If the oil pressure in the circuit rises, the oil in
flows through orifice b of spool (2) into chamber D. chamber B presses piston (4), and then its reac-
When the circuit leading to the torque converter tion force compresses valve spring (7) and moves
becomes filled with oil, the oil pressure starts to spool (6) to the left to open ports A and C.
rise. Then, the oil from the pump is relieved through
port A into port C, and then it flows into the torque
q If the oil pressure applied to the torque converter converter.
rises, the oil in chamber D presses piston (9), and At this time, the oil pressure in port A is 2.84MPa
then its reaction force compresses valve spring (3) {29.0kg/cm2} (at the rated engine speed).
and moves spool (2) to the right to open ports C
and E.
Then, the oil in port C is relieved into port E and
then drained into the oil tank.
At this time, the oil pressure in port C is 1.00MPa
{10.2kg/cm2} (cracking pressure).
WE051B0200 27
Lubricating oil relief valve 1
Unit: mm
Installed
Lubricating oil relief valve Free length Installed load Free length Installed load
1 spring
length Replace
12.0 N 11.4 N
26 23.7 25.2
{1.22 kg} {1.16 kg}
2. Piston Outline
3. Spring q The oil discharged from the torque converter flows
4. Forward clutch housing through the oil cooler in the radiator lower tank and
lubricating oil relief valve to lubricate the transmis-
A: From oil cooler sion PTO.
B: Drain q The lubrication oil relief valve is installed to the
C: Drain right side face of the forward clutch housing. And
prevents any abnormal pressure in the lubrication
oil.
Specified value
Pressure under normal state
0.05-0.15 {0.5-1.5}
(MPa{kg/cm2})
Cracking pressure
0.29 {3.0}
(MPa{kg/cm2})
28 WE051B0200
WE051B0300
Bulldozer
D61EX-15
D61PX-15
D61EX-15 B40001-
D61PX-15 B40001-

Scavenging pump ......................................................................................................... 2
Power train and lubrication pump ................................................................................. 3
HSS system .................................................................................................................. 4

Scavenging pump 1
Outline
q The scavenging pump is installed to the bottom of
the PTO case and driven with the power from the
engine.
q The scavenging pump draws oil collected in the
transmission case bottom through a strainer and
returns it to the steering case.
Specifications
Type Gear pump
Theoretical capacity
61.2
(cc/rev)
Max. discharge pressure
0.29 {3.0}
(MPa{kg/cm2})
Max. revolution speed
2,500
(rpm)
2 WE051B0300
Power train and lubrication pump 1

SAL(2)40+40
1. Power train pump

2. Lubricating pump
Unit: mm
Type Standard clearance Clearance limit
3 Side clearance
SAL(2)40 0.10 - 0.15 0.19
Clearance between inside of plain
4 bearing and outside of gear shaft
SAL(2)40 0.060 - 0.125 0.20
Replace
Type Standard size Tolerance Repair limit
5 Driving depth of pin 0
SAL(2)40 12 -
-0.5
6 Rotating torque of spline 5.8 - 13.8 Nm {0.6 - 1.4 kgm}
Revolution Discharge Standard Allowable
Capacity Type speed pressure capacity capacity
-
- Oil: SAE10W (rpm) (MPa{kg/cm2}) (l/min) (l/min)
Oil temperature: 45 - 55°C 20.6
SAL(2)40 2,500 90 85
{210}
WE051B0300 3
HSS system 1
a HSS: Abbreviation for Hydrostatic Steering System
4 WE051B0300
1. Directional/steering/gearshift lever (PCCS lever) Outline

2. Transmission and steering controller q The HSS system consists of control valve (3), HSS
3. Control valve pump (5), and HSS motor (7). It can turn the
4. EPC valve machine continuously without lowering the travel
5. HSS pump speed by making a difference in speed between
6. Servo valve the right and left tracks.
7. HSS motor q Transmission and steering controller (2) controls
8. HSS circuit the revolving direction and speed of HSS motor (7)
9. Engine with EPC valve (4) of control valve (3) accordingly
10. Final drive to the operating direction and distance of direc-
11. Sprocket tional/steering/gearshift lever (1).
12. Hydraulic tank HSS motor (7) works on the planetary gear mech-
anism of the bevel gear shaft to make a difference
Input and output signals in speed between both sprockets (11) and turn the
a. Directional signals machine.
b. Steering signal q Transmission and steering controller (2) senses
c. Engine control information the engine speed and oil pressure at each part
d. Work equipment oil pressure signal and controls HSS pump (5) and control valve (3)
so that engine (9) will not stall.
WE051B0300 5
WE051B0400
Bulldozer
D61EX-15
D61PX-15
D61EX-15 B40001-
D61PX-15 B40001-

HSS pump .................................................................................................................... 2
HSS motor .................................................................................................................. 20

HSS pump 1
Model name: HPV95
Outline
q This pump consists of variable-displacement
swash-plate piston pump and servo valve.
PA: Pump discharge port Specifications

PS: Suction opening of pump Model name: HPV95 (112cm3/rev)
PD1: Pump drain plug Theoretical displacement: 112±1cm3/rev
PD2: Pump drain Rated speed: 2,280rpm
PLS1: Load pressure inlet port Max. pressure at cut-off: 41.2MPa {420kg/cm2}
PEN12: Control pressure detection plug
1. Piston pump
2. Servo valve
3. Solenoid valve
2 WE051B0400
Piston pump
PA: Pump discharge port

PS: Suction opening of pump
PA1: Pump pressure signal port
PD2: Pump drain
PNC1: Control pressure port
WE051B0400 3
1. Shaft 8. Piston
2. Case 9. Cylinder block
3. Cradle 10. Valve plate
4. Rocker cam 11. End cap
5. Shoe 12. Impeller
6. Servo piston 13. Spline
7. Rod
4 WE051B0400
Function
q The engine rotation and torque transmitted to the
pump shaft is converted to hydraulic energy and
pressurized oil is discharged accordingly to the
load.
q It is possible to change the discharge amount by
changing the swash plate angle.
Structure
q Cylinder block (9) is supported to shaft (1) by a
spline (13), and shaft (1) is supported by the front q The cylinder block (9) carries out rotation relative
and rear bearings. to valve plate (10) while sealing the pressurized
q The end of piston (8) has a concave ball shape oil, and this surface ensures that the hydraulic bal-
and shoe (5) is caulked to it to form one unit. Pis- ance is maintained correctly. The oil inside each
ton (8) and shoe (5) from a spherical bearing. cylinder chamber of cylinder block (9) is sucked in
q Rocker cam (4) holds plane A, and shoe (5) is and discharged through valve plate (10).
always pressed against this surface as it slides in q Impeller (12) is fixed to shaft (1), and rotates
a circle. together with the shaft, it makes it easier for the oil
q Rocker cam (4) forms a static being sending high sucked in from the suction port to be sucked in and
pressure oil at cylindrical surface B of cradle (3), sends it into the cylinder chamber by centrifugal
which is fixed to the case, and carries out a sliding force.
movement.
q Piston (8) carries out motion relative to the axial
direction inside each cylinder chamber of cylinder
block (9).
WE051B0400 5
Operation
1. Pump operation
q Cylinder block (9) rotates together with shaft (1), q When center line X of rocker cam (4) is the same
and shoe (5) slides on plane A. When this hap- as the axial direction of cylinder block (9) (swash
pens, rocker cam (4) moves along cylindrical sur- plate angle = 0), the difference between volumes
face α, so angle α of center line X of rocker cam E' and F' inside cylinder block (9) is 0, so pump
(4) to the axial direction of cylinder block (9) does not suction and discharge, and no pumping
changes. This angle α is called the swash plate is carried out. Actually swash plate angle does not
angle. become 0.
q The swash plate angle α is proportional to pump
discharge volume.
q With swash plate angle α formed by the angle

between center line X of rocker cam (4) to the axial
direction of cylinder block (9), plane A acts as a
cam for shoe (5).
q In this way, piston (8) slides inside cylinder block
(9), and as a result, a difference is generated
between volumes E and F inside the cylinder
block. The amount of suction and discharge is
equal to difference F - E.
q In other words, cylinder block (9) rotates, and the
volume of chamber E becomes smaller, so oil is
discharged during this process. At the same time,
the volume of chamber F becomes larger and oil is
sucked in this process.
6 WE051B0400
2. Control of discharge amount

q If swash plate angle α becomes larger, the differ-
ence between volumes E and F becomes larger,
and oil discharge Q is increased. Swash plate
angle α is changed by servo piston (6).
q Servo piston (6) carries out reciprocal movement
in a straight line accordingly to the command from
the servo valve single pressure. This straight line
movement is transmitted to rocker cam (4) through
rod (7), and rocker cam (4), which is supported on
the cylindrical surface by cradle (3) rotates on the
cylindrical surface.
q The area receiving the pressure is different at the
left and right sides of servo piston (6), and the
receiving pressure at the small diameter piston
end is always connected with main pump dis-
charge pressure (self pressure) PP.
q Output pressure PNC of the servo valve is applied
to the chamber receiving the pressure at the large
diameter piston end (which receives pressure of
the pump).
q The movement of servo piston (6) is controlled by
the relationship of the size of pump pressure PP
and the pressure at the large diameter piston end,
and the comparative size of the ratio of area
receiving the pressure at the large diameter piston
end and small diameter piston end.
WE051B0400 7
SERVO VALVE
PT: Drain port

PA1: Pump self pressure port
PLS1: Load pressure inlet port
PEN11: Control pressure port
PEN12: Control pressure detection plug
8 WE051B0400
LS valve Variable throttle valve

1. Locknut 16. Screw
2. Plug 17. Locknut
3. Spring 18. Spring
4. Spool 19. Seat
5. Sleeve 20. Spool
6. Piston 21. Block
7. Plug 22. Plug
TVC valve
8. Solenoid
9. Piston
10. Sleeve
11. Spring
12. Spring
13. Piston
14. Lever
15. Valve body
WE051B0400 9
Outline
1. LS valve
q The LS valve detects the load and controls the dis-
charge amount.
q This valve controls main pump discharge amount
Q accordingly to differential pressure ∆PLS (= PP -
PLS) (the difference between main pump pressure
PP and control valve outlet port pressure PLS)
{called the LS differential pressure}.
q Main pump pressure PP, pressure PLS {called the
LS pressure} coming from the control valve output
enter this valve.
q The relationship between discharge amount Q and
differential pressure ∆PLS, (the difference
between main pump pressure PP and LS pressure q When a large load is applied or the engine speed
PLS) (= PP - PLS) changes as shown in the graph lowers during work, a current is supplied to the
below. TVC solenoid accordingly to the command from
the controller.
q By this operation, the pump delivery (torque
absorbed by the pump) is reduced and the engine
load is reduced.
3. Variable throttle valve

q Because the main pump controls its own pressure,
there is a tendency for the response speed of the
swash plate to be quick at high pressure and slow
at low pressure.
q The variable throttle valve has been installed for
the following reasons.
1) Lower the swash plate speed between the

minimum and maximum deliveries to reduce
2. TVC Valve the impacts applied to the main pump rod, etc.
q When the pump discharge pressure PP is high, and prevent an excessive stress when high
the TVC valve controls the pump so that no more pressure is applied.
oil than the constant flow (in accordance with the 2) Prevent cavitation in the suction port caused
discharge pressure) flows even if the stroke of the by sudden increase of suction volume from the
control valve becomes larger. In this way, it carries minimum to the maximum.
out equal horsepower control so that the horse-
power absorbed by the pump does not exceed the q It has the function and property of maintaining the
engine horsepower. response during operations at low pressure by
q In other words, if the load during the operation making the area of the opening smaller at high
becomes larger and the pump discharge pressure pressure and the area of the opening larger at low
rises, it reduces the discharge amount from the pressure, and by preventing the above problems
pump; and if the pump discharge pressure drops, (1) and (2) at high pressure.
it increases the discharge amount from the pump.
q The relationship between pump discharge pres-
sure PP and pump delivery Q in this case is shown
in the above right graph, using the current as a
parameter.
10 WE051B0400
Operation
1. LS valve
1) When control valve is at "Neutral" position
q The LS valve is a three-way selector valve, with q Pump pressure PP enters the large diameter end
pressure PLS (LS pressure) from the outlet port of of the piston from port h. The same pump pressure
the control valve brought to spring chamber i, and PP also enters the small diameter end of the pis-
main pump discharge pressure PP brought to ton, so the swash plate is moved to the minimum
chamber j of plug (6). angle by the difference in area of piston (1).
q The size of the LS pressure PLS + force F of
spring (3) and the main pump pressure (self pres-
sure) PP determines the position of spool (4).
q Before the engine is started, servo piston (1) is
pushed to the right by spring (7) installed to rod (2)
(see diagram on the right).
q When the engine is started, if the control lever is in
neutral, LS pressure PLS is 0 kg/cm2 (it is inter-
connected with the drain circuit through the control
valve spool).
q At this point, spool (4) is pushed to the left, and
port d and port c are connected.
WE051B0400 11
2) Operation in maximum direction for pump discharge amount
q When the difference between main pump pressure

PP and LS pressure ∆PLS, in other words, LS dif-
ferential pressure PLS becomes smaller (for
example, when the area of opening of the control
valve becomes larger and pump pressure PP
drops), spool (4) is pushed to the right by the com-
bined force of LS pressure PLS and the force of
spring (3).
q When spool (4) moves, port b and port c are joined
and connected to the TVC valve.
q At this time, the TVC valve is connected to the
drain port and the pressure in circuit c-h is drain
pressure PT (the operation of the TVC valve will
be explained later).
q For this reason, the pressure at the large piston
diameter end of servo piston (1) becomes drain
pressure PT, and pump pressure PP enters the
small diameter end, so servo piston (1) is pushed
to the right.
q Therefore, rod (2) moves to the right and moves
the swash plate in the direction to make the dis-
charge amount larger.
12 WE051B0400
3) Operation in minimum direction for pump discharge amount
q The following explains the situation if servo piston

(1) moves to the left (the discharge amount
becomes smaller).
q When LS pressure PLS becomes larger (for exam-
ple, when the area of opening of the control valve
becomes smaller and pump pressure PP rises),
pump pressure PP pushes spool (4) to the left.
q When spool (4) moves, main pump pressure PP
flows from port d to port c, and from port h, it
enters the large piston diameter end.
q Main pump pressure PP also enters the small pis-
ton diameter end, but because of the difference in
area between the large piston diameter end of
servo piston (1) and the small piston diameter end,
servo piston (1) is pushed to the left.
q As a result, rod (2) moves in the direction to make
the swash plate angle smaller.
WE051B0400 13
4) When servo piston is balanced
q Let us take the area receiving the pressure at the

large piston diameter end as A1, the area receiv-
ing the pressure at the small diameter end as A0,
and the pressure flowing into the large piston
diameter end as PEN.
q If the main pump pressure PP of the LS valve and
the combined force of force F of spring (3) and LS
pressure PLS are balanced, and the relationship is
A0 x PP = A1 x PEN.
q The servo piston (1) will stop in that position, and
the swash plate will be kept at an intermediate
position (it will stop at a position where the open-
ing from port b to port c and from port d to port c of
spool (4) is approximately the same).
q At this point, the relationship between the area
receiving the pressure at both ends of piston (1) is
A0:A1 = 1:2, so the pressure applied to both ends
of the piston when it is balanced becomes PP:PEN
C 2:1.
q The force of spring (3) is so adjusted that this
spool (4) will be balanced and stopped at the stan-
dard center when PP - PLS = 1.96MPa {20kg/
cm2}.
14 WE051B0400
2. TVC Valve
1) When transmission and steering controller is normal

1] When the load on the actuator is small and pump pressure PP is low
a. Solenoid (1) function

q A command current from the transmission and
steering controller is flowing in solenoid (1). This
command current changes the force to press inter-
nal solenoid push pin (11).
q Piston (2) stops at a position where the force to
press solenoid push pin (11) is balanced with the
combined force of set force of springs (3) and (4)
and the force to press piston (2) with pump pres-
sure PP.
q The pressure output from the TVC valve (the pres-
sure in port c) changes accordingly to that posi-
tion.
q The level of command current X is decided by the
contents of operation (operation of the lever),
selected working mode, set engine speed, and
actual engine speed.
WE051B0400 15
b. Spring function
q The spring load of springs (3) and (4) at the TVC
valve depends on the position of the swash plate.
q When servo piston (9) moves, cam (7), which is
connected to rod (8), also moves. When this hap-
pens, lever (6) is rotated by the angle of cam (7),
and position (5) moves to the right and left.
q If piston (5) moves to the right, spring (3) is com-
pressed first. If piston (5) moves to the right fur-
ther, spring (4) touches seat (10), and then two
springs (3) and (4) work.
q In other words, the spring load is changed by pis-
ton (5) extending or contacting springs (3) and (4).
q If the command current input to solenoid (1)
changes, the force to press solenoid push pin (11)
changes. Accordingly, the spring load of springs
(3) and (4) also changes when the command cur-
rent changes.
q Port c of the TVC valve is connected to port e of
the LS valve (see "1. LS valve"). Self pressure PP
is applied to port b, small diameter side of servo
piston (9), and port a.
q When pump pressure PP is small, piston (2) is on
the right.
q At this point, port c and port d are connected, and
the pressure entering the LS valve becomes drain
pressure PT.
q At this time, if port e of the LS valve is connected
to port h (see "1. LS valve"), the pressure applied
to the large diameter side of the piston is drain
pressure PT and servo piston (9) moves to the
right.
q In this way, the pump discharge amount moves in
the direction of increase.
q As servo piston (9) moves further, piston (5) is
moved to the left by rod (8), cam (7) and lever (6).
Springs (3) and (4) expand and the spring force
becomes weaker.
q When the spring force becomes weaker, piston (2)
moves to the left, so the connection between port
c and port d is cut, and the pump discharge pres-
sure is connected to port b.
q As a result, the pressure at port c rises, and the
pressure at the large piston diameter end also
rises, so the movement of piston (9) to the right is
stopped.
q That is, the stopping position of piston (9) (= pump
delivery) depends on the position where the press-
ing force caused by pressure PP applied to piston
(2) and the pressing force of the solenoid are bal-
anced with the force of springs (3) and (4).
16 WE051B0400
2] When load on actuator is small and pump discharge pressure is high
q When the load is large and pump discharge pres- q For this reason, springs (3) and (4) are com-
sure PP is high, the force pushing piston (2) to the pressed and push back piston (2). Because of this
left becomes larger and piston (2) moves to the force, piston (2) cuts of the connection from port b
position shown in the diagram above. to port c, and port c and port d are connected.
q When this happens, as shown in the diagram q As a result, the pressure at port c (= f) drops, and
above, part of the pressurized oil from port b flows piston (9) stops moving to the left.
out to port d and the pressure oil flowing from port q The position in which piston (9) stops when this
c to the LS valve becomes approximately half of happens is further to the left than the position
main pump pressure PP. when pump pressure PP is low.
q When port h and port e of the LS valve are con-
nected (see 1. LS valve), the pressure from port f
enters the large piston diameter end of servo pis-
ton (9), and servo piston (9) stops.
q If main pump pressure PP increases further and
piston (2) moves further to the left, main pump
pressure PP flows to port c and acts to make the
discharge amount the minimum.
q When piston (9) moves to the left, piston (5) is
moved to the right by cam (7) and lever (6).
WE051B0400 17
q The relation of pump pressure PP and the position

of servo piston (9) forms a bent line because of the
double-spring effect of springs (3) and (4). The
relationship between pump pressure PP and pump
discharge amount Q is shown in the graph below.
18 WE051B0400
3. Variable throttle valve
1) Operation in maximum direction for pump q At this point, the opening area of part A
discharge amount increases and the oil flowing from the large
q Main pump pressure PP enters the variable diameter end of servo piston (1) through port c
throttle valve through port a. to port b is not limited and the moving speed of
servo piston (1) is heightened.
1] When main pump pressure PP is high
q If the pressure becomes higher than the force of 2) Operation to reduce pump discharge
spring (3) because of the difference in sectional q The hydraulic oil flows from port b through port c
area of spool (4) in chamber e, spool (4) moves to the large diameter side of servo piston (1).
to the right. q Spool (4) operates accordingly to main pump
q If spool (4) moves to the right, the opening area pressure PP as explained in the above section.
between ports c and b is reduced by the notch
at part A. Accordingly, less oil flows from the
large diameter end of servo piston (1) and the
moving speed of servo piston (1) is lowered.
2] When main pump pressure PP is low

q Even if main pump pressure PP enters chamber
e through port a, spool (4) pushes spring (3)
less strongly and moves to the right for shorter
distance.
WE051B0400 19
HSS motor 1
Model name: HM80
Outline
q Motor is composed of fixed capacity, fixed swash
plate type piston motor, flashing shuttle valve,
bypass valve and charge relief valve.
PA: From control valve 1. HSS motor assembly

PB: From control valve 2. Counterbalance valve
T2: To hydraulic tank 3. Safety valve
4. Check valve
Specifications
Model name: HMF80
Theoretical displacement: 80cc/rev
Rated pressure: 41.2MPa {420kg/cm2}
Rated speed: 2,316rpm
20 WE051B0400
1. Output shaft 10. Counterbalance valve

2. Motor case 11. Safety valve
3. Swash plate 12. Check valve
4. Piston 13. Check valve spring
5. Cylinder 14. Sub bearing
6. Valve plate 15. Spline
7. End cover 16. Shoe
8. Brake valve assembly 17. Main bearing
9. Spool return spring
Unit: mm

Free length x Installed Installed Installed
Free length
18 Spool return spring O.D. length load load Replace spring if
192 N 154 N damaged or
42.7 x 30.0 40.5 -
{19.6 kg} {15.7 kg} deformed
1.27 N 0.98 N
19 Check valve spring 43 x 13.8 32.9
{0.13 kg}
-
{0.10 kg}
WE051B0400 21
Outline
q Pressurized oil sent from pump is converted to
rotation torque and is transmitted to output shaft.
Structure
q Cylinder block (5) is supported by shaft (1) with
spline (15) and shaft (1) is supported by main and
sub bearings (17) and (14).
q The end of piston (4) has a concave ball shape
and shoe (16) is caulked to it to form one unit. Pis-
ton (4) and shoe (16) from a spherical bearing.
block (5).
q Cylinder block (5) moves relatively against valve
plate (6), while sealing the hydraulic pressure.
q This face is so designed that the hydraulic pres-
sure will be balanced well.
q The oil inside each cylinder chamber of cylinder
block (5) is sucked in and discharged through
valve plate (6).
22 WE051B0400
Operation
1. Motor operation 2. Rotation speed and torque control

q The pressurized oil sent from the pump enters cyl- q As flow Q from the HSS pump is increased, motor
inder block (5) and pushes piston (4) from the speed N is heightened.
back face. q Since the swash plate angle of the HSS motor is
q In the case of the motor, the center line of plate (3) fixed (α is constant), torque T is proportional to
is always at an angle (swash plate angle α to the pressure P.
axial direction of cylinder block (5)). q Swash plate angle α is approx. 13.4°.
q As a result, if we take the example of one of pis-
tons (4), oil pressure is applied to the back face of Q = qN
the right, and piston axial force FO is generated. (q = E - F)
q With shoe (16), which is joined to piston (4) by the
spherical surface, reaction force FR in a direction T = Pq/2x
at right angles to plane A is generated. The com-
bined force of FO and FR is FP, and this becomes Q: Total flow
the force to rotate cylinder block (5). q: Flow per 1 turn
N: Rotation speed
P: Pressure
T: Rotating torque
q Shaft (1), which is meshed to cylinder block (5) by

spline (15) transmits this rotation torque to the out-
put side.
q Cylinder block (5) rotates, and while the condition
changes from volume E to volume F, pressurized
oil from the pump flows into the cylinder chamber,
and pressure P is generated accordingly to the
load.
q On the other hand, when the condition goes
beyond volume F and changes to volume E, the oil
is pushed out and returned to the pump.
WE051B0400 23
Brake valve operation 1. Counterbalance valve, check valve

q The brake valve consists of check valve (12),
counterbalance valve (10), and safety valve and Function
(11), and forms a circuit such as that shown below. q When steering on slopes, the weight on the
q The function and operation of each component is machine produces a force in the downward direc-
as given below. tion which makes the machine try to turn faster
than the speed of the HSS motor.
q Because of this, if the engine is run at low speed
and the steering is operated, the HSS motor will
overrun, and this will create an extremely danger-
ous condition.
q To prevent this, this valve is installed to carry out
the steering in accordance with the engine speed
(pump discharge volume).
Operation when oil is supplied

q When the steering lever is operated, the pressur-
ized oil from the control valve is supplied to port
PA. It pushes open check valve (12a), and flows
from HSS motor inlet port MA to HSS motor outlet
port MB.
q However, the outlet port side of the HSS motor is
closed by check valve (12b) and spool (10), so the
pressure at the side where the oil is being supplied
rises.
24 WE051B0400
Brake action when steering downhill

q When the steering is operated on a down hill
q The pressurized oil at the side where the oil is slopes, if the machine accelerates too fast while
being supplied flows from orifice E1 of spool (10) steering downhill, the HSS motor will rotate under
into chamber S1. And when the pressure in cham- no load, and the oil pressure at the inlet port of the
ber S1 becomes greater than the spool switching HSS motor will drop. This drop in pressure will
pressure, spool (10) is pushed to the right. pass through orifice E1, so the pressure in cham-
q In this way, port MB and port PB are connected, so ber S1 will also drop.
the outlet port side of the HSS motor is opened q If the pressure in chamber S1 drops below the
and the HSS motor starts to turn. spool switching pressure, spool (10) is pushed to
the left by spring (9), and outlet port MB is throt-
tled.
q As a result, the pressure at the outlet port rises,
and this creates a resistance to the rotation of the
HSS motor which prevents the motor from over-
running.
q In other words, the spool moves to a position
where it balances the pressure at outlet port MB
with the force resulting from the weight of the
machine and the pressure at the inlet port. In this
way, it throttles the outlet port circuit and controls
the motor to a speed that matches the amount of
oil discharged from the pump.
WE051B0400 25
2. Safety valve
Function
q When the operation of the steering stops, counter-
balance valve (10) closes the circuit at the inlet
and outlet ports of the HSS motor.
q But the HSS motor continues to turn because of
inertia. As a result, the pressure at the outlet port
of the HSS motor becomes extremely high, and
this will damage the HSS motor and the piping.
q The safety valve acts to release this abnormal
pressure to the inlet port of the HSS motor to pro-
tect the equipment from damage.
Operation
q When the operation of the steering is stopped, the q If the pressure in chamber E (or chamber F) rises
check valve of the counterbalance valve closes above the set level, the force of x(D1 2 -D22)/4 x
chamber E (or chamber F) in the outlet port circuit, Pressure caused by the area difference between
but the pressure at the outlet port side continues to D1 and D2 {or the force of x(D32 -D12)/4 x Pres-
rise because of inertia. sure caused by the area difference between D3
and D1} presses the spring and moves the poppet
to the right, and then the oil flows in chamber F (or
chamber E) in the circuit on the opposite side.
26 WE051B0400
WE051B0500
Bulldozer
D61EX-15
D61PX-15
D61EX-15 B40001-
D61PX-15 B40001-

Bevel gear shaft, HSS, and brake................................................................................. 2
Brake valve ................................................................................................................. 18
Final drive ................................................................................................................... 24

Bevel gear shaft, HSS, and brake 1
a HSS: Abbreviation for Hydrostatic Steering System
2 WE051B0500
WE051B0500 3
4 WE051B0500
1. Brake valve
2. HSS motor
3. Brake spring (large)
4. Brake spring (small)
5. Hub
6. Cage
7. Piston
8. Cover
9. Plate (4 pieces on each side)
10. Disc (5 pieces on each side)
11. Brake drum
12. Brake hub
13. Gear A (Number of teeth: 37/86)
14. Cage
15. Gear B (Number of teeth: 50)
16. Bevel gear (Number of teeth: 41)
17. Bevel gear shaft
18. Shaft
19. Bearing
20. Gear C (Number of teeth: 50)
21. Planetary pinion (Number of teeth: 26)
22. Ring gear (Number of teeth: 91)
23. Pinion shaft
24. Hub
25. Carrier
26. Gear D shaft
27. Gear D (Number of teeth: 76)
28. HSS motor drive gear (Number of teeth: 39)
29. Bevel pinion (Number of teeth: 25)
30. Cage
WE051B0500 5
6 WE051B0500
Unit: mm
Replace
1 Brake plate Thickness 5.0 ±0.1 4.7
Distortion - Max. 0.15 0.3 Repair or replace
Thickness 5.2 ±0.1 4.7 Replace
2 Brake disc
Distortion - Max. 0.25 0.4 Repair or replace
Total thickness of assembled
3 4 brake plates and 5 discs
46.0 ±0.3 43.3
Backlash between gear A and Standard clearance Clearance limit

4 gear B 0.06 - 0.54 -
Replace
Backlash between gear A and
5 planetary pinion
0.14 - 0.35 -
Backlash between planetary pinion

6 and ring gear
0.15 - 0.38 -
Preload on bevel gear shaft tapered If the starting torque is less than 9.8Nm {1.0kgm}, adjust the preload.
7 roller bearing Starting torque after adjustment: 10.3 - 14.7Nm {1.05 - 1.50kgm}
Adjusting
WE051B0500 7
8 WE051B0500
Unit: mm
Backlash between gear A and Standard clearance Clearance limit
1 gear D 0.09 - 0.54 -
Backlash between gear C and
2 gear D
0.13 - 0.42 - Replace
Backlash between gear D and

3 HSS motor drive gear
0.09 - 0.35 -
Backlash between bevel pinion and

4 bevel gear
0.18 - 0.23 - Adjusting
WE051B0500 9
Outline
Bevel gear shaft Brake

q The engine power is transmitted through the q The brake is installed to stop the machine and is
torque converter to the transmission. Then, the connected to brake hub (12).
bevel gear shaft device engages bevel pinion (29) q The brake is a wet-type, multiple disc clutch-type,
with bevel gear (16) to turn the engine power at spring-boosted brake. It is driven hydraulically by
right angles into the lateral direction and reduce the brake valve operated with brake pedal.
the revolving speed. q The brake is pressure-lubricated with oil supplied
q Bevel pinion (29) and bevel gear (16) of the bevel by the lubricating oil pump and scavenging pump.
gear shaft device are spiral bevel gears, which are The lubricating oil flows through the paths in the
lubricated with oil splashed by the lubricating oil steering case, cover (8), cage (6), disc (10), and
pump and scavenging pump. plate (9).
q The bevel gear shaft device consists of bevel gear q While the engine is stopped, the back-pressure of
(16) meshed with bevel pinion (29), bevel gear the brake piston lowers and the brake is turned
shaft (17), bearing (19) to support the bevel gear "ON" even if the brake pedal is not pressed. When
shaft, and bevel gear shaft cage (14). the engine is started, however, the oil pressure in
the circuit rises and the brake is "Released". Use
HSS Therefore, the parking brake must be kept in the
q The HSS consists of the transfer section which "Lock" position.
sets the rotations of the right and left HSS motors q The brake consists of brake hub (12) coupled with
in opposite directions and transmits them to gear A carrier (25) and hub (5), disc (10) meshed with the
(13) and the planetary gear section which adjusts brake hub, plate (9), the periphery of which is cou-
the input power of ring gear (22) and gear A (13) pled with brake drum (11) by spline, piston (7) and
and outputs the adjusted power to carrier (25). springs (3) and (4) which press the discs and
The turning direction of the machine is changed by plates against each other, and cage (6) and cover
stopping and changing the revolution of HSS (8) which support these parts.
motor (2). Brake drum (11) and cover (8) are fixed to the
q The transfer section employs a helical reduction steering case.
gear unit and is lubricated by splashing the oil from
the scavenging pump and lubrication pump.
q The planetary gear unit is pressure-lubricated by
oil supplied from the scavenging and oil lubricating
pumps.
q The transfer section consists of HSS motor drive
gear (28) connected to HSS motor (2) by spline,
gear D (27) meshed with the HSS motor driven
gear, gear C (20) meshed with gear D, gear B (15)
coupled with shaft (18), gear A (13) supported on
the bearing of the bevel gear shaft, gear A (13)
meshed with gear D (27), and the case which sup-
port these parts.
q The planetary gear section consists of gear A (13),
planetary pinion (21), pinion shaft (23), hub (24)
coupled with bevel gear shaft (17) and ring gear
(22) by spline, and carrier (25) coupled with brake
hub (12).
10 WE051B0500
HSS operation
When steering system is in "Neutral" (straight travel)
q While the steering system of the PCCS lever is in

"Neutral", HSS motor (1) is stopped. Accordingly, Revolving direction of HSS motor
transfer section and right and left gears A (2) of the Steering opera-
planetary gear section do not revolve. Neu-
tion of PCCS Turning to right Turning to left
q Under this condition, the power from bevel gear tral
lever
shaft (3) is transmitted through hub (4) to ring gear Direction chang- ∗ ∗
(5). For- Rev For- Rev
ing operation of Any Neu- Neu-
ward erse ward erse
q The power transmitted to ring gear (5) is further PCCS lever tral tral
transmitted through planetary pinion (6) and plane- Revolving direc-
Stop
tary pinion shaft (7) to carrier (8). tion of HSS motor Righ Righ Righ
ped Left Left Left
q The power transmitted to carrier (8) is further seen from left of t t t
transmitted through brake hub (9) to hub (10). chassis
q Accordingly, the output speeds on both sides are ∗: Counter-rotation
the same and the machine travels straight.
WE051B0500 11
When machine is steered to "Right" (forward)
∗A: Transmission power q Bevel gear shaft (1) and ring gear (5) connected to
∗B: HSS motor power rotate clockwise as seen from the left side of the
∗C: Resultant power machine.
q Accordingly, because of the difference in the rotat-
∗1. Transmission output speed ing speed between both planetary gear units, the
∗2. HSS motor output speed rotating speed of left carrier (8) is higher than
∗3. Left bevel gear shaft output speed (∗1 + ∗2) when traveling straight forward by the amount of
∗4. Right bevel gear shaft output speed (∗1 - ∗2) the power of HSS motor. On the other hand, the
rotating speed of right carrier (8) is lower than
q While the machine is traveling in forward, with the when traveling straight forward. As a result, the
PCCS lever in the "Turn to the right" position while machine travels forward and turns to the right,
the machine is traveling forward, from the left side where the output speed is lower.
of the chassis you will see the HSS motor (1)
rotate to the left, left gear A (2) rotates to the right,
and right gear A (2) rotates to the left, when they
are seen from the left side of the chassis.
12 WE051B0500
When machine is steered to "Right" (reverse)
∗B: HSS motor power rotate counterclockwise as seen from the left side
∗C: Resultant power of the machine.
∗2. HSS motor output speed rotating speed of left carrier (8) is higher than
∗3. Left bevel gear shaft output speed (∗1 + ∗2) when traveling straight in reverse by the amount of
∗4. Right bevel gear shaft output speed (∗1 - ∗2) the power of HSS motor. On the other hand, the
rotating speed of right carrier (8) is lower than
q While the machine is traveling in reverse, with the when traveling straight in reverse. As a result, the
PCCS lever in the "Turn to the right" position while machine travels in reverse and turns to the right,
rotate to the right, left gear A (2) rotates to the left,
and right gear A (2) rotates to the right, when they
are seen from the left side of the chassis.
WE051B0500 13
When machine is steered to "Left" (forward)
∗B: HSS motor power rotate clockwise as seen from the left side of the
∗C: Resultant power machine.
∗2. HSS motor output speed rotating speed of right carrier (8) is higher than
∗3. Left bevel gear shaft output speed (∗1 - ∗2) when traveling straight forward by the amount of
∗4. Right bevel gear shaft output speed (∗1 + ∗2) the power of HSS motor. On the other hand, the
rotating speed of left carrier (8) is lower than when
q While the machine is traveling forward, with the traveling straight forward. As a result, the machine
PCCS lever in the "Turn to the left" position while travels forward and turns to the left, where the out-
the machine is traveling forward, from the left side put speed is lower.
rotate to the left, and right gear A (2) rotates to the
right, when they are seen from the left side of the
chassis.
14 WE051B0500
When machine is steered to "Left" (reverse)
∗B: HSS motor power rotate counterclockwise as seen from the left side
∗C: Resultant power of the machine.
∗2. HSS motor output speed rotating speed of right carrier (8) is higher than
∗3. Left bevel gear shaft output speed (∗1 - ∗2) when traveling straight in reverse by the amount of
∗4. Right bevel gear shaft output speed (∗1 + ∗2) the power of HSS motor. On the other hand, the
rotating speed of left carrier (8) is lower than when
q While the machine is traveling in reverse, with the traveling straight in reverse. As a result, the
PCCS lever in the "Turn to the left" position while machine travels in reverse and turns to the left,
rotate to the right, and right gear A (2) rotates to
the left, when they are seen from the left side of
the chassis.
WE051B0500 15
Brake operation
When brake is "Released" When brake is turned "ON"

(when brake pedal is "Pressed")
q While the brake pedal is released, the brake valve q If the brake pedal is depressed, the brake valve
is in the "Neutral" position and the back-pressure switches and the oil in the back-pressure port of
port of piston (1) is filled with oil. piston (1) is drained.
q As the oil pressure rises, piston (1) compresses q As the pressure in the back-pressure port lowers,
springs (2) and (3) to the left to release discs (4) piston (1) is moved to the right by the tension of
and plates (5). springs (2) and (3) to press discs (4) and plates (5)
q The power transmitted from the bevel gear shaft against brake drum (6). Brake drum (6) is con-
through the HSS to brake hub (7) is further trans- nected and fixed to the steering case.
mitted through hub (8) to the final drive. q The power to brake hub (7) is restricted by fitting
discs (2) and plates (3) together.
q The hydraulic force applied to piston (1), or the
braking force, can be controlled by controlling the
depressing distance of the brake pedal.
16 WE051B0500
Brake valve 1
P: From power train pump Outline

T1: To steering case q The brake valve is in the circuit between the power
T2: To steering case train pump and the brake piston in the HSS unit
Br(R): To right brake and installed to the top of the HSS unit.
Br(L): To left brake q If the brake pedal is pressed, main brake valve (3)
operates. If the parking brake lever is set in the
1. Parking brake valve "Lock" position, the parking brake valve operates.
2. Body q If each valve operates, the oil supplied to the back-
3. Main brake valve pressure port of the brake piston is stopped and
4. Piston the brake is turned "ON".
5. Shaft q If the HSS is employed, the brake is only used to
6. Guide stop the machine (it is not used for steering opera-
tion) and the right and left brakes operate simulta-
neously.
18 WE051B0500
Unit: mm
Clearance between brake valve and size Shaft Hole clearance limit
7 body -0.020 +0.013 0.020-
ø19 0.07
-0.030 0 0.043
Clearance between brake valve and -0.030 +0.015 0.030-
8 piston
ø9
-0.040 0 0.055
0.08
Clearance between parking brake -0.034 +0.013 0.034-

9 valve and body
ø19
-0.043 0 0.056
0.08
Standard size Repair limit Replace

Installed
10 Brake modulating spring length
75.3 N 71.6 N
48 36 46.6
{7.68 kg} {7.3 kg}
157.9 N 150 N
11 Brake valve return spring 52 38
{16.11 kg}
50.4
{15.3 kg}
16.7 N 15.7 N
12 Parking brake valve return spring 36.5 28.5
{1.7 kg}
35.4
{1.6 kg}
WE051B0500 19
Operation
When brake is "Released"

(brake pedal is released and parking brake lever is set in "Free" position)
q While the brake pedal is released (while it is not

pressed), parking brake valve (1) opens port P and
chamber A with the tension of return spring (2).
q Main brake valve (3) opens chamber B and port Br
with the tension of return spring (4).
q The pressure of the oil from the power train pump
is regulated by the main relief valve, and then the
oil flows through port P, chambers A and B, and
port Br to the back-pressure port of the brake pis-
ton.
q The brake piston moves to the left and com-
presses the brake spring to "Release" the brake.
q At this time, the oil pressure is settled at 2.84MPa
{29.0kg/cm2} and can be measured at oil pressure
pickup port Q.
20 WE051B0500
When brake is "Turned ON"

(brake pedal is "Pressed" and parking brake lever is set in "Free" position)
q If the brake pedal is depressed, guide (5) and q If the brake pedal is pressed further, the above
shaft (6) are pushed to the right. operation is repeated. If main brake valve (3) is
q As shaft (6) is pushed, it compresses modulating moved to the stroke end, the brake is turned on
spring (7) and its reaction force moves main brake perfectly.
valve (3) to the right. Then, ports Br and chamber q The oil pressure after port Br is decided by the ten-
B are closed and ports Br and T2 are opened. sion of return spring (6), the load on which
q The oil from the power train pump flows through changes accordingly to the stroke of the brake
port P into chamber A, and then it is stopped in pedal.
chamber B. q If the brake pedal stroke is short, the oil pressure
q A part of the oil flowing into the back-pressure port after port Br rises and the brake is applied
of the brake piston is drained through port T2 and "Partially". If the brake pedal stroke is long, the oil
the other part flows through orifice A to chamber pressure lowers and the brake is applied "Fully".
D.
q If the oil after port Br is drained through port T2
and the oil pressure lowers, the oil flows in cham-
ber D and presses piston (8). Then, the force
which has pushed main brake valve (3) to the right
is reduced and main brake valve (3) is moved to
the left by the tension of return spring (4).
q If main brake valve (3) moves to the left, ports Br
and T2 are closed, and then the oil pressure after
port Br is maintained.
WE051B0500 21
When brake is in "Parking brake" position

(brake pedal is "Released" and parking brake lever is in "Lock" position)
q If the parking brake lever is set in the "Lock" posi-

tion, parking brake valve (1) is pulled to the left.
Then, port P and chamber A are closed and cham-
bers A and C are opened.
q The oil from the power train pump is stopped in
port P.
q The oil flowing in the back-pressure port of the
brake piston is drained through port Br, chambers
B, A, and C, and port T1.
q Since parking brake valve (1) is kept pulled to the
left, the oil pressure in the back-pressure port of
the brake piston continues lowering. Then, brake
is kept "Turned ON".
q This condition is maintained even after the engine
is started again.
22 WE051B0500
Final drive 1
Outline
q The final drive is of spur gear double reduction
type.
q The lubrication is of splash type using the rotation
of the gears.
q The final drive can be removed and installed as a
single unit.
q Floating seal (1) is installed to the rotating sliding
portion of the sprocket to prevent the entry of dirt
or sand and to prevent leakage of lubricating oil.
24 WE051B0500
1. Final drive case 9. Cover

2. Bearing cage 10. Sprocket hub
3. 1st pinion (Number of teeth: 14) 11. Floating seal
4. 1st gear (Number of teeth: 64) 12. Cover
5. Bearing cage 13. Sprocket teeth
6. 2nd gear (Number of teeth: 50) 14. Cover
7. Cover 15. 2nd pinion (Number of teeth: 11)
8. Shaft
WE051B0500 25
26 WE051B0500
Unit: mm
Backlash between 1st pinion and Standard clearance Clearance limit
1 1st gear 0.24 - 0.62 1.0
Backlash between send pinion and
2 2nd gear
0.28 - 0.68 1.0
Replace
Outside diameter of oil seal contact
3 face of 1st pinion
0
ø62 ø61.9
-0.074
Standard shim thickness of
4 1st pinion bearing cage
1.52

5 2st pinion bearing cage
1.7 Adjusting

6 shaft bearing plate
1.9
Standard size Repair limit Repair by build-up

7 Wear of sprocket tooth surface
welding or replace
298 280
WE051B0500 27
Power train route
q The power from the HSS unit is transmitted to 1st

pinion (1), and then further transmitted to 1st gear
(2).
q The power transmitted to 1st gear (2) is further
transmitted to 2nd pinion (3), and then transmitted
through 2nd gear (4) and shaft (5) to sprocket hub
(6).
q The rotation force transmitted sprocket hub (6) is
transmitted to sprocket teeth (7).
28 WE051B0500
WE051B0600
Bulldozer
D61EX-15
D61PX-15
D61EX-15 B40001-
D61PX-15 B40001-

Undercarriage and frame ................................................................................................. 3
Frame assembly ........................................................................................................... 3
Suspension ................................................................................................................... 4
Track frame and recoil spring ....................................................................................... 8
Idler............................................................................................................................. 12
Track roller .................................................................................................................. 14
Carrier roller................................................................................................................ 15
Sprocket...................................................................................................................... 16
Track shoe .................................................................................................................. 18
Undercarriage and frame 1

Frame assembly 1
1. Frame assembly Outline

2. Undercover q Frame assembly (1) has hull frame structure in
3. Engine mount which the main frame and transmission under
guard are formed in one unit.
WE051B0600 3
Suspension 1
a The diagram shows D65EX-15.
4 WE051B0600
a The diagram shows D65EX-15.
1. Equalizer bar Outline

2. Center pin q The track frame moves the front part of the track
3. Side pin frame up and down around pivot shaft (4) in its
4. Pivot shaft rear.
5. Bushing q Equalizer bar (1) rocks around center pin (2) and
6. Seal is connected to both track frames by side pin (3).
7. Seal
8. Bushing
9. Bushing (large) D61EX-15 D61PX-15
10. Plug (oil filler)
Displacement at Upward 46.1 49.7
11. Bushing (small)
center of equal-
12. Cover izer bar side pin
13. Seal (mm) Downward 46.1 49.7
WE051B0600 5
Unit: mm
Clearance between pivot shaft and size Shaft Hole clearance limit
14 bushing (large) -0.145 +0.063 0.145-
ø123 1.0
-0.208 0 0.271
Clearance between pivot shaft and -0.120 +0.054 0.120-
15 bushing (small)
ø85
-0.174 0 0.228
1.0 Replace bushing
Clearance between center pin and -0.100 +0.174 0.200-

16 bushing
ø70
-0.146 +0.100 0.320
0.5
Clearance between side pin and -0.100 +0.010 0.080-

17 bushing
ø55
-0.146 -0.020 0.156
0.5
Press-fitting force of pivot shaft

18 bushing (large)
48.0kN {4.9ton}
Press-fitting force of pivot shaft -

19 bushing (small)
33.3kN {3.4ton}
- Quantity of oil in pivot shaft section 3.5l(enging oil: SAE30)
6 WE051B0600
Track frame and recoil spring 1

D61EX-15
1. Idler 11. Recoil spring

2. Carrier roller 12. Wear ring
3. Track frame 13. U-packing
4. Sprocket teeth 14. Cabin
5. Track roller end guard 15. Nut
6. Track roller center guard (if equipped) 16. Lubricator
7. Track roller 17. Cylinder
8. Yoke 18. Bushing
9. Seal 19. Holder
10. Piston
8 WE051B0600
Unit: mm
Check item Repair limit
7(in length of 3,000)
20 Deformation of track frame Repair
Bend, twist, opening of idler section 3(in length of 300)
5
Free length x Installed
Installed load Free length Installed load
21 Recoil spring O.D. length Replace
163.6kN 145.7kN
755×ø212 593 736
{16,692kg} {14,856kg}
Clearance between piston and size Shaft Hole clearance limit
22 bushing
Replace bushing
-0.030 +0.291 0.107-
ø75 1.0
-0.076 +0.077 0.367
23 Press-fitting force of idler yoke 294kN {30ton} Adjusting
- Quantity of grease 140cc(grease: G2-LI) -
Outline
q Recoil spring (11) is used to adjust the track shoe
tension by supplying grease through lubricator
(16) or discharge existing grease and moving pis-
ton (10) forward or in reverse. It also damps sud-
den shocks applied to idler (1)
Q'ty on
Flange type and arrange-
each
ment
side
D61EX-15 7 pcs. S, D, S, S, D, S, S
S: Single flange
W: Double flange
WE051B0600 9
D61PX-15
D61EX-15 (long track specification)
1. Idler 11. Recoil spring

2. Carrier roller 12. Wear ring
3. Track frame 13. U-packing
4. Sprocket teeth 14. Cabin
5. Track roller end guard 15. Nut
6. Track roller center guard 16. Lubricator
7. Track roller 17. Cylinder
8. Yoke 18. Bushing
9. Seal 19. Holder
10. Piston
10 WE051B0600
Unit: mm
Check item Repair limit
7(in length of 3,000)
20 Deformation of track frame Repair
Bend, twist, opening of idler section 3(in length of 300)
5
Free length x Installed
Installed load Free length Installed load
21 Recoil spring O.D. length Replace
163.6kN 145.7kN
755×ø212 593 736
{16,692kg} {14,856kg}
Clearance between piston and size Shaft Hole clearance limit
22 bushing
Replace bushing
-0.030 +0.291 0.107-
ø75 1.0
-0.076 +0.077 0.367
23 Press-fitting force of idler yoke 294kN {30ton} Adjusting
- Quantity of grease 140cc(grease: G2-LI) -
Outline
q Recoil spring (11) is used to adjust the track shoe
tension by supplying grease through lubricator
(16) or discharge existing grease and moving pis-
ton (10) forward or in reverse. It also damps sud-
den shocks applied to idler (1)
Q'ty on
Flange type and arrange-
each
ment
side
D61PX-15
D61EX-15 8 pcs. S, S, D, S, S, D, S, S
(long track
specification)
S: Single flange
W: Double flange
WE051B0600 11
Idler 1
12 WE051B0600
Unit: mm
1 Outside diameter of projection
ø588 -
2 Outside diameter of tread ø550 ø530
3 Depth of tread 19 29 Repair by build-up
welding or replace
4 Thickness of tread 24.4 14.4
5 Width of tread 39.5 43.5
6 Overall width 164 -
Clearance between shaft and size Shaft Hole clearance limit
7 bushing -0.215 +0.195 0.215-
ø60 -
-0.315 0 0.510
Replace
Clearance between shaft and -0.215 +0.046 0.215-
8 support
ø60
-0.315 0 0.361
-
Standard clearance Clearance limit

9 Axial play of shaft
0.26 - 0.66 -
Clearance between guide plate and Repair by build-up
10 support
2.0 -
welding or replace
Clearance between guide plate and
11 side plate
1.0 -
Adjust shim or
Standard shim thickness at side replace plate
12 plate fitting part
4.0
WE051B0600 13
Track roller 1
a The following drawing shows the double-flange type.
Unit: mm
1 Outside diameter of flange (outside)
ø233 -
2 Outside diameter of flange (inside) ø227 -
4 Thickness of tread 66.5 48.5
Repair by build-up
5 Width of flange (outside) 19.5 13.5 welding or replace
6 Width of flange (inside) 18 12
7 Width of tread (single flange type) 44.5 -
8 Width of tread (double flange type) 43.5 -
9 Overall width 212 -
10 bushing -0.244 +0.195 0.244-
ø60 -
-0.290 0 0.485
Replace
-0.250 -0.160 0.020-
11 Clearance between shaft and collar ø59.7
-0.300 -0.230 0.140
-

12 Axial play of roller
0.26 - 0.66 -
14 WE051B0600
Carrier roller 1
Unit: mm
1 Outside diameter of flange
ø190 -
Repair by build-up
3 Thickness of tread 27.5 16.5 welding or replace
4 Width of tread 45.5 51.5
5 Width of flange 17 11
6 support -0.100 +0.300 0.100-
ø61 -
-0.200 0 0.500
Standard Tolerance Standard Interference
Replace
Interference between shaft and seal size Shaft Hole interference limit
7 guard +0.150 +0.030 0.100-
ø61.5 -
+0.130 0 0.150
8 Axial play of roller
0 - 0.32 -
WE051B0600 15
Sprocket 1
Unit: mm
1 Wear of tooth root Repair by build-up
77 68
welding or replace
2 Thickness of tooth root 29.25 20
16 WE051B0600
Full-scale drawing of sprocket tooth profile

a Make a copy on an OHP sheet in the full scale.
WE051B0600 17
Track shoe 1
Standard bushing type
∗1. Single shoe

∗2. Swamp shoe
a Part P shows the link on bushing fitting side.
18 WE051B0600
Unit: mm
1 Link pitch
190.3 193.3
Turning over Turn over or
Standard size
2 Outside diameter of bushing Light load Heavy load replace
65 54.8 57.4
3 Thickness of bushing 13.2 3.0 5.6
4 Height of link Repair or replace
119 109
Thickness of link
5 (bushing fitting part)
42.5 31.5 Replace
a. Tightening torque Retightening

Regular (Nm{kgm}) (deg.)
link 539±49 {55±5} 120±10
6 Shoe bolt Tightening torque Retightening angle Lower limit of torque Retighten
b. (Nm{kgm}) (deg.) (Nm{kgm})
Master
343±39
link 180 (0/-20) 784 {80}
{35±4}
Tolerance Standard interfer-
Standard size
Interference between bushing and Shaft Hole ence
7 link +0.264 +0.074
ø59 0.160 - 0.264
+0.234 0
Interference between regular pin +0.372 +0.062
8 and link
ø37.8
+0.272 0
0.210 - 0.372 Adjust or replace
Tolerance
Standard size Standard clearance
Interference between regular pin Shaft Hole
9 and bushing +0.172 +0.902
ø38 0.230 - 0.830
+0.072 +0.402
WE051B0600 19
Single shoe
Unit: mm
1 Height of grouser Repair by build-up
57.5 25
welding or replace
2 Thickness of grouser 71 38.5
Swamp shoe
Unit: mm
1 Height of grouser Repair by build-up
91 76
welding or replace
2 Thickness of grouser 20 5
20 WE051B0600
WE051B0700
Bulldozer
D61EX-15
D61PX-15
D61EX-15 B40001-
D61PX-15 B40001-

Hydraulic system.............................................................................................................. 2
Layout of hydraulic devices for work equipment........................................................... 2
Work equipment control ................................................................................................ 4
Hydraulic tank and filter ................................................................................................ 6
Solenoid valve .............................................................................................................. 8
Accumulator................................................................................................................ 10
Hydraulic cylinder ....................................................................................................... 12
Piston valve ................................................................................................................ 16
Quick drop valve ......................................................................................................... 17
Hydraulic system 1
Layout of hydraulic devices for work equipment 1
2 WE051B0700
1. Tilt cylinder
2. Angle cylinder
3. Lift cylinder
4. HSS pump
5. Quick drop valve
6. Cooling fan pump
7. Accumulator (if equipped)
8. Hydraulic tank
9. Power train and lubricating oil pump
10. Hydraulic oil cooler
11. Radiator
12. Cooling fan motor
13. Blade PPC valve
14. Control valve
15. Power train oil filter
16. HSS motor
17. PPC lock solenoid valve
18. Transmission ECMV
20. Scavenging pump
21. Self-reducing pressure valve
WE051B0700 3
Work equipment control 1
4 WE051B0700
1. Work equipment lock lever

2. PPC lock switch
3. Blade PPC valve
4. Blade control lever
5. Ripper control lever (if equipped: D61EX-15)
6. Ripper PPC valve (if equipped: D61EX-15)
7. PPC lock solenoid valve
8. Accumulator (if equipped)
Outline
q The work equipment is controlled by the PPC
method. Each spool of the control valve is moved
by operating blade PPC valve (3) with blade con-
trol lever (4) or by operating ripper PPC valve (6)
with ripper control lever (5).
q If work equipment lock lever (1) is set in the "Lock"
position PPC lock switch (2) is turned "ON" and
PPC lock solenoid valve (7) operates. Then, blade
control lever (4) and ripper control lever (5) can be
moved but the work equipment cannot be oper-
ated.
q When blade control lever (4) is in the "Float" posi-
tion, the hydraulic detent of blade PPC valve (3)
operates and blade control lever (4) can hold itself.
If work equipment control lever (1) is set in the
"Lock" position, the hydraulic detent is reset and
blade control lever (4) returns to the "Hold" posi-
tion by itself.
q When the engine is stopped, the hydraulic detent
does not operate and blade control lever (4)
returns to the "Hold" position by itself, even if blade
control lever (4) is in the "Float" position.
WE051B0700 5
Hydraulic tank and filter 1
6 WE051B0700
1. Oil filler cap

2. Hydraulic tank
3. Strainer
4. Drain plug
5. Element
6. Bypass valve
7. Sight gauge
Specifications
Tank capacity (l) 95

Quantity of oil in tank (l) 55
Set pressure of
0.15±0.03
bypass valve
{1.5±0.3}
(MPa{kg/cm2})
Pressure valve
38±14
cracking pressure
{0.39±0.15}
(kPa{kg/cm2})
Actuating pressure of
0 - 4.5
vacuum valve
{0 - 0.046}
(kPa{kg/cm2})
WE051B0700 7
Solenoid valve 1
PPC lock solenoid valve
a PPC: Abbreviation for Proportional Pressure Control
a The diagram shows a machine equipped with the accumulator (if equipped)
8 WE051B0700
P: From cooling fan pump port P Operation

P1: To blade PPC valve port P When solenoid is "De-energized"
P2: To control valve port PEPC (when circuit is disconnected)
T: To hydraulic tank q Since the signal current does not flow in the sole-
From blade PPC valve port T noid valve, coil (1) is "De-energized".
t1: From control valve port TS q accordingly, spool (3) is pressed to the left by
ACC: To accumulator (for PPC circuit) spring (4).
q As a result, port P is closed and the hydraulic oil
from the pump does not flow from port P1 to the
1. PPC lock solenoid valve actuator.
At this time, the oil from the actuator flows from
Solenoid valve port P1 to port T, and then it is drained.
2. Nut
3. Plunger
4. Coil
5. Push pin
6. Spring
7. Spool
8. Block
Check valve
9. Plug
10. Spring (when accumulator is installed)
11. Poppet (when accumulator is installed)
Outline
q The PPC lock solenoid valve is installed between
the cooling fan and blade PPC valve. If the work When solenoid is "Energized"
equipment lever is set in the "Lock" position, the (when circuit is connected)
PPC lock switch is turned "ON" and the solenoid q If the signal current flows in the solenoid valve, coil
valve is "Energized" to stop the oil in the PPC cir- (1) is "Energized" and a rightward thrust is gener-
cuit, thus the work equipment cannot move. ated in plunger (2).
q Accordingly, spool (3) is pushed to the right by
push pin (5).
q As a result, the hydraulic oil from the pump flows
from port P through port P1 to the actuator.
At this time, port T is closed and the oil is not
drained.
WE051B0700 9
Accumulator 1
(for PPC circuit)
1. Gas plug
2. Shell
3. Poppet
4. Holder
5. Bladder
6. Oil port
Outline
q The accumulator is installed to the PPC lock sole-
noid valve. Even if the engine is stopped while the
work equipment is raised, the work equipment can
be lowered under its weight by applying the pilot
oil pressure to the control valve to operate with the
pressure of the nitrogen gas compressed in the
accumulator.
Specifications
Gas used: Nitrogen gas
Volume of gas: 300cc
Gas pressure: 1.18MPa {12kg/cm2} (at 80°C)
Max. using pressure: 6.86MPa {70kg/cm2}
10 WE051B0700
Hydraulic cylinder
For power angle power tilt dozer
Lift cylinder
Tilt cylinder
Angle cylinder
12 WE051B0700
Ripper cylinder (if equipped)

D61EX-15
Unit: mm
Cylinder Standard Tolerance Standard Clearance
name size Shaft Hole clearance limit
-0.030 +0.151 0.024-
Lift ø55 0.527
-0.076 -0.006 0.227
Clearance between -0.030 +0.259 0.093-
1 piston rod and bushing
Tilt ø70 0.635
-0.076 +0.063 0.335
-0.030 +0.250 0.085-
Angle ø65 0.626
-0.076 +0.055 0.326
-0.030 +0.259 0.093-
Ripper ø70 0.635
-0.076 +0.063 0.335
-0.025 +0.174 0.125-
Lift ø60 1.0
-0.064 +0.100 0.238
-0.025 +0.039 0.025-
Clearance between Tilt ø50 1.0 Replace bushing
-0.064 0 0.103
2 piston rod support shaft
-0.025 +0.039 0.025-
and bushing Angle ø45 1.0
-0.064 0 0.103
-0.030 +0.174 0.130-
Ripper ø75 1.0
-0.076 +0.100 0.250
-0.025 +0.174 0.125-
Lift ø60 1.0
-0.064 +0.100 0.238
-0.025 +0.039 0.025-
Clearance between Tilt ø50 1.0
-0.087 0 0.126
3 cylinder bottom support
-0.025 +0.039 0.025-
shaft and bushing Angle ø45 1.0
-0.064 0 0.103
-0.030 +0.174 0.130-
Ripper ø75 1.0
-0.076 +0.100 0.250
Lift 932±93.2Nm {95.0±9.5kgm}
Tightening torque of
Tilt 1.03±0.10kNm {105±10.5kgm}
cylinder head
4 Angle 1.23±0.12kNm {125±12.5kgm}
cylinder head mounting Ripper 162±14.7Nm {16.5±1.5kgm}
bolt Retighten
Lift 1.77±0.18kNm {180±18.0kgm} (width across flats: 60mm)

Tightening torque of Tilt 3.97±0.40kNm {405±40.5kgm} (width across flats: 80mm)
5 cylinder piston
clamping nut Angle 2.60±0.26kNm {265±26.5kgm} (width across flats: 70mm)
Ripper 3.97±0.40kNm {405±40.5kgm} (width across flats: 80mm)
WE051B0700 13
For power tilt dozer

For semi-U dozer
Lift cylinder
Tilt cylinder
Ripper cylinder (if equipped)

D61EX-15
14 WE051B0700
Unit: mm
Cylinder Standard Tolerance Standard Clearance
name size Shaft Hole clearance limit
-0.030 +0.151 0.024-
Lift ø55 0.527
Clearance between -0.076 -0.006 0.227
1 piston rod and bushing -0.030 +0.259 0.093-
Tilt ø70 0.635 Replace bushing
-0.076 +0.063 0.335
-0.030 +0.259 0.093-
Ripper ø70 0.635
-0.076 +0.063 0.335
Clearance between
-0.030 +0.174 0.130-
piston rod support shaft Lift ø60 1.0
-0.076 +0.100 0.250
and bushing
Clearance between
Sø70 (shaft) -0.1 +1.0 Adjust shim or
2 piston rod and ball of Tilt
Sø71 (hole) -0.3 0
0.2-0.5 2.0
replace
bracket
Clearance between
-0.030 +0.174 0.130-
piston rod support shaft Ripper ø75 1.0
-0.076 +0.100 0.250
and bushing
-0.025 +0.174 0.125-
Lift ø60 1.0
-0.064 +0.100 0.238 Replace bushing
Clearance between
-0.200 +0.142 0.280-
3 cylinder bottom support Tilt ø50
-0.400 +0.080 0.542
1.0
shaft and bushing
-0.030 +0.174 0.130-
Ripper ø75 1.0
-0.076 +0.100 0.250
Lift 932±93.2Nm {95.0±9.5kgm}
cylinder head
4 Tightening torque of Tilt 162±14.7Nm {16.5±1.5kgm}
cylinder head mounting
bolt Ripper 162±14.7Nm {16.5±1.5kgm} Retighten
Lift 1.42±0.14kNm {145±14.5kgm} (width across flats: 55mm)
5 cylinder piston Tilt 3.97±0.40kNm {405±40.5kgm} (width across flats: 80mm)
clamping nut
Ripper 3.97±0.40kNm {405±40.5kgm} (width across flats: 80mm)
WE051B0700 15
Piston valve 1
(lift cylinder)
For power tilt dozer
For semi-U dozer
Outline
q The piston valve is installed to the piston section of
the lift cylinder.
q 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" Piston valve is "Closed"
q The oil from the pump acts on piston (2) and piston q The end of piston valve (3) touches cylinder bot-
valve (3). tom (a) before piston rod (1) reaches the stroke
Then, piston valve (3) is pushed to the right to seal end, and then only piston (2) continues moving.
the tapered part of piston valve seat (4). At this time, the oil which has been stopped by pis-
As a result, the oil pressure in the cylinder rises to ton valve (3) is sent through piston valve seats (4)
move piston (2) to the right. and (5) to the bottom side, thus the oil pressure in
the cylinder lowers.
16 WE051B0700
Quick drop valve 1

(lift cylinder)
Unit: mm
size Shaft Hole clearance limit
1 Clearance between valve and body
-0.034 +0.025 0.034-
ø33 0.080
-0.050 0 0.075
-0.039 +0.021 0.039-
2 Clearance between piston and plug ø25
-0.054 0 0.075
0.080
Standard size Repair limit Replace

Installed
3 Valve spring length
88.2 N 79.4 N
108.3 26 97.5
{9.0 kg} {8.1 kg}
4.6 N 4.1 N
4 Piston spring 27.3 26
{0.47 kg}
24.6
{0.42 kg}
5. Plug VH: From control valve blade "Raise"

6. Piston VB: From control valve blade "Lower"
7. Valve CH1: To right lift cylinder head
8. Body CH2: To left lift cylinder head
CB1: To right lift cylinder bottom
CB2: To left lift cylinder bottom
WE051B0700 17
Outline
q The quick drop valve is installed between the con-
trol valve and lift cylinder. When the control lever is
operated to "Lower" the blade, this device pre-
vents a vacuum in the cylinder bottom and short-
ens the time lag in starting digging,
q The blade lowering speed is almost decided by the
pump discharge. It can be heightened, however,
by installing the quick drop valve.
Operation
Start of lowering blade While lowering blade
q If the blade control lever is set in the "Lower" posi- q The oil pushed out of the cylinder head side flows
tion, the oil from the control valve flows in port VB, through ports CH1 and CH2 to port VH. At this
and then flows through ports CB1 and CB2 to the time, the oil flow rate is reduced by orifice a and a
cylinder bottom side and pushes the piston to the pressure difference is made between before and
left. behind the orifice.
q The oil on the cylinder head side is pushed out by q If the oil pressure in ports CH1 and CH2 becomes
the piston, and then it enters ports CH1 and CH2 higher than the tension of springs (1) and (2),
and flows through port VH and control valve to the valve (3) and piston (4) move to the right.
hydraulic tank. q 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.
q 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.
18 WE051B0700
WE051B0800
Bulldozer
D61EX-15
D61PX-15
D61EX-15 B40001-
D61PX-15 B40001-

Cooling fan pump.......................................................................................................... 2
Cooling fan motor ....................................................................................................... 10
PPC valve ................................................................................................................... 16
Electric lever (Steering)............................................................................................... 32
Hydraulic system 1
Cooling fan pump 1
Model name: LPV30
P1: Pump discharge pressure T1: Drain plug

PS: Pump suction PEPC: EPC valve main pressure
T0: Drain PCEPC: EPC valve output pressure detection plug
2 WE051B0800
1. Shaft
2. Oil seal
3. Case
4. Rocker cam
5. Shoe
6. Piston
7. Cylinder block
8. Valve plate
9. Spring
10. Servo piston
WE051B0800 3
Function
q The engine rotation and torque transmitted to the
pump shaft is converted to hydraulic energy and
pressurized oil is discharged accordingly to the
load.
q It is possible to change the discharge amount by
changing the swash plate angle.
Structure
q Cylinder block (7) is supported on shaft (1) through
spline a. Shaft (1) is supported by the front and
rear bearings.
q The end of piston (6) has a spherical hollow which
is combined with shoe (5). Piston (6) and shoe (5)
form a spherical bearing.
q Rocker cam (4) has plane A. Shoe (5) is kept
pressed against plane A and slide circularly.
Rocker cam (4) slides around ball (11).
block (7).
q Cylinder block (7) rotates relatively against valve
plate (8), sealing the pressurized oil, and the
hydraulic balance is maintained properly.
q The oil in each cylinder of cylinder block (7) can be
sucked and discharged through valve plate (8).
4 WE051B0800
Operation
1. Pump operation
q Cylinder block (7) rotates together with shaft (1) q If center line X of rocker cam (4) is equal to the
and shoe (5) slides on plane A. At this time, rocker axial of cylinder block (7) (the swash plate angle is
cam (4) tilts around ball (11). As a result, angle α 0), there is not a difference between volumes E
between center line X of rocker cam (4) and the and F in cylinder block (7) and oil is not sucked or
axis of cylinder block (7) changes. This angle α is discharged (however, the swash plate angle is not
called the swash plate angle. actually set to 0).
q If angle α is made between center line X of rocker q The swash plate angle α is proportional to pump
cam (7) and the axis of cylinder block (7), plane A discharge volume.
works as a cam for shoe (5).
q Accordingly, piston (6) slides inside cylinder block
(7) and a difference is made between volumes E
and F in cylinder block (7). As a result, each piston
(6) sucks and discharges oil by F - E.
q That is, if cylinder block (7) rotates and the cham-
ber E volume is reduced, and the oil is discharged
through this process. On the other hand, the vol-
ume of chamber F is increased and the oil is
sucked through this process (the diagram shows
the end of suction process of chamber F and the
end of discharge process of chamber E).
WE051B0800 5
2. Control of discharge amount

q If swash plate angle α becomes larger, the differ-
ence between volumes E and F becomes larger,
and oil discharge Q is increased. Swash plate
angle α is changed by servo piston (10).
q Servo piston (10) reciprocates straight accordingly
to the signal pressure of the servo valve. This
straight motion is transmitted to rocker cam (4).
Then, rocker cam (4) supported on ball (11) slides
around ball (11).
6 WE051B0800
Servo valve
P: EPC valve main pressure

T: Drain
PE: Control piston pressure
PH: Pump discharge pressure
1. Plug
2. Lever
3. Retainer
4. Seat
5. Spool
6. Piston
7. Sleeve
WE051B0800 7
A: Drain side C: EPC output pressure received

B: Pump discharge pressure input side D: EPC output pressure
8 WE051B0800
Function Operation
q The servo valve controls the current input to the q The output pressure of the EPC valve is applied to
EPC valve and the swash plate angle of the pump the piston chamber to push the piston. Piston (6)
so that they will be related as shown in the graph pushes spool (5) until it is balanced with the
below. spring.
q Then, the land of the servo piston pressure pas-
sage is connected to the pump discharge pas-
sages by the cut of spool (5) and the discharge
pressure is led to the servo piston.
q The servo piston is raised by the rocker cam. The
position feedback is applied and the lever moves
to compress the spring.
q If spool (5) is pushed back, the pump discharge
circuit and the servo piston circuit are shut off. The
pressure in the servo piston chamber lowers and
the rocker cam returns toward the maximum
swash plate angle.
q These processes are repeated until the swash
plate is fixed to a position where the EPC output is
q The relationship between the input current to the balanced with the spring force.
EPC valve and the output pressure of the EPC q Accordingly, as the EPC output pressure is height-
valve is as shown in the graph below. ened, the swash plate angle is decreased. As the
EPC output pressure is lowered, the swash plate
angle is increased.
WE051B0800 9
Cooling fan motor 1

Model name: LMF28
P: From self pressure reducing valve

T: From oil cooler to tank
TC: To tank
Specifications
Model: LMF28
Motor capacity: 28cc/rev
Rated speed: 1,700rpm
Rated flow rate: 47.6l/min
Safety valve cracking pressure: 24.5MPa {250kg/cm2}
Check valve cracking pressure: 0.044MPa {0.45kg/cm2}
10 WE051B0800
1. Output shaft 8. Center spring

2. Case 9. Check valve spring
3. Thrust plate 10. Check valve
4. Piston assembly 11. Pilot valve
5. Cylinder block 12. Reversible valve spool
6. Valve plate 13. Reversible valve spring
7. End cover 14. Safety valve
Unit: mm

Free length x Installed Installed Installed Replace spring if
Free length
9 Check valve spring O.D. length load load damaged or
3.43 N 2.55 N deformed
13.0 x 6.5 7.0 -
{0.35 kg} {0.26 kg}
WE051B0800 11
1. Hydraulic motor unit
Function
q This hydraulic motor is called a thrust plate-type
axial piston motor. It converts the energy of the
pressurized oil sent from the hydraulic pump into
rotary motion.
Principle operation
q The oil sent from the hydraulic pump flows through
valve plate (7) into cylinder block (5). This oil can
flow on only one side of the Y - Y line connecting
the top dead center and bottom dead center of the
stroke of piston (4).
q Hydraulic oil in each side of cylinder block (5)
presses pistons (4) (two or three pieces) and gen-
erates force F1 (F1 kg = P kg/cm2 x x/4 D2 cm2).
q This force is applied to thrust plate (2). Since
thrust plate (2) is fixed to the angle of α degrees to
the output shaft (1), the force is divided into com-
ponents F2 and F3.
q The radial component F3 generates torque against
the Y - Y line connecting the top dead center and
bottom dead center (T = F3 x ri).
q The result of this torque [T = Σ (F3 x ri)] rotates the
cylinder block (5) through the piston.
q Since the cylinder block (5) is coupled with the out-
put shaft by means of spline, the output shaft
rotates to transmit the torque.
12 WE051B0800
2. Suction valve
Function 2) When pump is stopped

q If the fan pump stops, the hydraulic oil does not q If the engine is stopped and the input revolu-
flow into the motor. Since the motor continues rev- tion of the fan pump lowers to 0 rpm, the
olution because of the force of inertia, however, hydraulic oil from the pump is not supplied to
the pressure on the outlet side of the motor rises. port P any more. As the hydraulic oil is not
q When the oil stops flowing in from inlet port P, the supplied to the MA side of the motor, the
suction valve sucks in the oil on the outlet side and motor speed lowers gradually to stop.
supplies it to the port MA where there is not suffi- q If the motor shaft is revolved by the force of
cient oil to prevent cavitation. inertia while the oil flow in the port P is reduc-
ing, the oil in port T on the outlet side is sent
Operation by the suction valve (1) to the MA side to pre-
vent cavitation.
1) When pump is started
q If the hydraulic oil from the pump is supplied to
port P and the pressure on the MA side rises
and starting torque is generated in the motor,
the motor starts revolution. The oil on the out-
let MB side of the motor returns through port T
to the tank.
WE051B0800 13
3. Reversible valve operation
1) When reversible valve ON-OFF solenoid is 2) When reversible valve ON-OFF solenoid is
"De-energized" "Energized"
q If ON-OFF solenoid (1) for reversible valve is q If ON-OFF solenoid (1) for reversible valve is
"De-energized", the hydraulic oil from the "Energized", ON-OFF reversible valve (2)
pump is blocked by ON-OFF reversible valve changes to let the hydraulic oil from the pump
(2) and port C is connected to the tank circuit. flow through port C into spool chamber D.
q Accordingly, reversible valve spool (3) is q The hydraulic oil in chamber D pushes revers-
pushed by reversible valve spool spring (4) to ible valve spool (3) against reversible valve
the right to open motor port MA and then the spool spring (4). As a result, motor port MB
hydraulic oil flows in to revolve the motor for- opens and the hydraulic oil flows in to revolve
ward (clockwise). the motor in reverse (counterclockwise).
14 WE051B0800
4. Safety valve
Function
q When the engine is started, the pressure in port P
of the fan motor is heightened in some cases.
q Safety valve (1) is installed to protect the fan sys-
tem circuit.
Operation
q If the pressure in port P rises above the cracking
pressure of safety valve (1), valve (2) of safety
valve (1) opens to release the hydraulic oil into
port T.
q By this operation, generation of abnormal pressure
in port P is prevented.
WE051B0800 15
PPC valve 1
a PPC: Abbreviation for Proportional Pressure Control
For blade lift, tilt, and angle
16 WE051B0800
P: From control pump P3: To blade lift valve (raise)

T: To hydraulic tank P4: To blade lift valve (lower)
P1: To blade tilt valve (left tilt) P5: To blade angle valve (right angle)
P2: To blade tilt valve (right tilt) P6: To blade angle valve (left angle)
1. Spool 6. Cap (for connecting lever)

2. Metering spring 7. Joint
3. Centering spring 8. Plate
4. Piston 9. Retainer
5. Disc 10. Body
WE051B0800 17
Operation
1. At neutral
1) For blade lift 2) For blade tilt

q Ports P3 and P4 of the PA, PB, and PPC valves q Ports P1 and P2 of the PA, PB, and PPC valves
of the blade lift control valve are connected to of the blade tilt control valve are connected to
drain chamber D through fine control hole f of drain chamber D through fine control hole f of
spool (1). spool (1).
18 WE051B0800
3) For blade angle q By the above operation, spool (1) moves up and
q Ports P5 and P6 of the PA, PB, and PPC valves down so that the force of metering spring (2) will
of the blade angle control valve are connected to be balanced with the pressure in port P4. The rela-
drain chamber D through fine control hole f of tion between the positions of spool (1) and body
spool (1). (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).
q Accordingly, metering spring (2) is compressed in
proportion to the stroke of the control lever and the
pressure in port P4 also rises in proportion to the
stroke of the control lever.
q Then, the control valve spool moves to a position
where the pressure in the chamber PB (which is
the same as the pressure in port P4) is balanced
with the force of the control valve spool return
spring.
2. In fine control mode

(neutral o fine control)
q 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.
q At almost the same time when fine control hole f is
disconnected from drain chamber D by the above
operation, it is connected to pump pressure cham-
ber PP and the pilot pressure oil of the control
pump flows through fine control hole f and port P4
to port PB.
q If the pressure in port P4 rises, spool (1) is pushed
back. At almost the same time when fine control
hole f is disconnected to pump pressure chamber
PP, it is connected to drain chamber D and the
pressure in port P4 is released.
WE051B0800 19
3. In fine control mode 4. When lever is operated fully

(when control lever is returned)
q When disc (5) pushes down piston (4) and retainer
q If disc (5) starts being returned, spool (1) is (9) pushes down spool (1), fine control hole f is
pushed up by the force of centering spring (3) and shut off from drain chamber D and is connected to
the pressure in port P4. pump pressure chamber PP.
q By the above operation, fine control hole f is con- q Accordingly, the pilot pressure oil from the control
nected to drain chamber D and hydraulic oil in port pump flows through fine control hole f, port P4,
P4 is released. and chamber PB to push the control valve spool.
q If the pressure in port P4 lowers excessively, spool q The oil returning from chamber PA flows through
(1) is pushed down by metering spring (2). At port P3 and fine control hole f' to drain chamber D.
almost the same time when fine control hole f is
disconnected from drain chamber D, it is con-
nected to pump pressure chamber PP, and then
the pump pressure is applied until the pressure in
port P4 rises to the level equivalent to the position
of the lever.
q When the control valve spool returns, the oil in
drain chamber D flows in through fine control hole
f of the valve on the stopped side, and then it flows
through port P3 to chamber PA.
20 WE051B0800
5. When blade is operated to "Float" 6. When blade is released from "Float"
q If piston (4) on the "Lower" side of port P4 is q When disc (5) is returned from the "Float" position,
pushed down by disc (5), ball (11) touches projec- it is pushed down by a force greater than the
tion a of the piston on the stroke. (detent starts to hydraulic force in chamber E.
act.) q As a result, chamber E is shut off from passage d
q When piston (4) is pushed in further, ball (11) and is connected to the drain chamber. Therefore,
pushes up collar (12), which is being held by the oil pressure inside chamber E is lost, and the
detent spring (13). While pushing up collar (12), it "Float" position is canceled.
escapes to the outside and passes over protrusion
a of the piston.
q When this happens, piston (4') on the opposite
side is pushed up by spring (14).
q As a result, the oil inside chamber F passes
through b and c, and flows to chamber E, and pis-
ton (4') follows disc (5). Since passage d is con-
nected to port P4, the pressure in it is almost the
same as the pressure in port P4.
q Chamber E is normally connected to drain cham-
ber D, but if ball (11) passes over protrusion a of
the piston, passage d and chamber E, which were
shut off, are connected and the pressure oil flows.
q At the same time, the control valve also moves to
the "Float" position and the circuit is set to the
"Float" condition.
q Piston (4') is being pushed up by the oil pressure
inside chamber E, so even if the lever is released,
it is held at the "Float" position.
WE051B0800 21
For blade lift and tilt

T: To hydraulic tank
P1: To blade lift valve port PA3
P2: To blade lift valve port PB3
P3: To blade tilt valve port PA2
P4: To blade tilt valve port PB2
22 WE051B0800
1. Disc
2. Plate
3. Body
WE051B0800 23
Operation
1. At neutral
1) For blade lift 2) For blade tilt

q Ports PA3 and PB3 of the blade lift control valve q Ports PA2 and PB2 of the blade tilt control valve
and ports P1 and P2 of the PPC valve are con- and ports P3 and P4 of the PPC valve are con-
nected to drain chamber D through fine control nected to drain chamber D through fine control
hole f spool (1). hole f of spool (1).
24 WE051B0800

q 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.
q As a result, if fine control hole f is shut off from
drain chamber D, at almost the same time, it is
connected with pump pressure chamber PP, and
the pilot pressure oil passes through fine control
hole f and flows from port P1 to port PA3.
q When the pressure at port P1 becomes high, if
spool (1) is pushed back and fine control hole f is
shut off from pump pressure chamber PP, at
almost the same time, it is connected with drain
chamber D and released the pressure at port P1.
q As a result, spool (1) moves up and down so that
the force of metering spring (2) is balanced with
the pressure at port P1. The relation between the
positions of spool (1) and body (10) (fine control
hole f is at the midpoint between drain chamber D
and pump pressure chamber PP) does not change
until retainer (9) contacts spool (1).
q Therefore, metering spring (2) is compressed an
amount proportional to the movement of the con-
trol lever, so the pressure at port P1 also rises in
proportion to the movement of the control lever.
q The control valve spool moves to a position where
the pressure in chamber PA3 (same as pressure
at port P1) is balanced with the force of the return
spring.
WE051B0800 25
3. During fine control 4. When lever is operated fully

(when control lever is returned) q When disc (5) pushes down piston (4) and retainer
q When disc (5) starts to be returned, spool (1) is (9) pushes down spool (1), fine control hole f is
pushed up by the pressure at port P1 and the force shut off from drain chamber D and is connected to
of centering spring (3). pump pressure chamber PP.
q As a result, fine control hole f is connected to drain q Therefore, the pilot pressure oil passes through
chamber D, so the pressure oil at port P1 is fine control hole f, is taken from port P1 to cham-
relieved. ber PA3, and pushes the control valve spool.
q If the pressure at port P1 goes down too far, spool q The return oil from chamber PB3 passes from port
(1) is pushed down by metering spring (2). Fine P2 through fine control hole f', and then flows to
control hole f is shut off from drain chamber D, and drain chamber D.
at almost the same time, it is connected to pump
pressure chamber PP.
q Pump pressure is supplied until the pressure at
port P1 recovers to a pressure equivalent to the
position of the lever. When the control valve spool
returns, the oil at drain chamber D flows in from
fine control hole f' in the valve on the side that is
not moving. It passes through port P2, is taken to
chamber PB3, and the oil fills the chamber.
26 WE051B0800
5. When blade is operated to "Float" 6. When blade is released from "Float"

q When piston (4) at the port P1 "Lower" side is q When disc (5) is returned from the "Float" position,
pushed by disc (5) and moves down, ball (11) con- it is pushed down by a force greater than the
tacts protrusion a of the piston during the stroke hydraulic force in chamber E.
(detent starts to act). q As a result, chamber E is shut off from passage d
q When piston (4) is pushed in further, ball (11) and is connected to the drain chamber. Therefore,
pushes up collar (12), which is being held by the oil pressure inside chamber E is lost, and the
detent spring (13). While pushing up collar (12), it "Float" position is canceled.
escapes to the outside and passes over protrusion
a of the piston.
q When this happens, piston (4') on the opposite
side is pushed up by spring (14).
q As a result, the oil inside chamber F passes
through b and c, and flows to chamber E, and pis-
ton (4') follows disc (5). Passage d is connected to
port P1, so more or less the same pressure is
applied as is applied to port P1.
q Chamber E is normally connected to drain cham-
ber D, but if ball (11) passes over protrusion a of
the piston, passage d and chamber E, which were
shut off, are connected and the pressure oil flows.
q At the same time, the control valve also moves to
the "Float" position and the circuit is set to the
"Float" condition.
q Piston (4') is being pushed up by the oil pressure
inside chamber E, so even if the lever is released,
it is held at the "Float" position.
WE051B0800 27
For ripper
T: To tank
P1: To ripper spool (to control valve port PA4)
P2: To ripper spool (to control valve port PB4)
1. Spool 5. Lever
2. Metering spring 6. Plate
3. Centering spring 7. Retainer
4. Piston 8. Body
28 WE051B0800
Unit: mm

Free length
9 Centering spring O.D. length load load Replace spring if
33.9 x 15.3 28.4 -
{12.7 kg} {10.2 kg} deformed
16.7 N 13.3 N
10 Metering spring 22.7 x 8.10 22.0
{1.70 kg}
-
{1.36 kg}
WE051B0800 29
Operation
1. At neutral q The relation between the positions of spool (1) and

q P1 and P2 ports of the operation valves A, B and body (8) (fine control hole f is at the midpoint
PPC valve are connected to drain chamber D via between drain chamber D and pump pressure
the fine control hole f on the spool (1). chamber PP) does not change until retainer (7)
contacts spool (1).
q Therefore, metering spring (2) is compressed an
amount proportional to the movement of the con-
trol lever, so the pressure at port P1 also rises in
proportion to the movement of the control lever.
q As the result, the operation valve spool moves to
the position where the pressure of chamber A (the
same as port P1 pressure) is balanced against
force of the operation valve spool return spring.

q As the piston (4) is pushed by disk (5), the retainer
(7) is pushed too. At the same time, the spool (1)
is also pushed down via the metering spring (2).
q By this move, connection of the fine control hole f
is switched from the drain chamber D to the pump
pressure chamber PP, and pilot pressure oil is
conducted from port P1 to port A.
q When the pressure at port P1 becomes high, if
spool (1) is pushed back and fine control hole f is
shut off from pump pressure chamber PP, at
almost the same time, it is connected with drain
chamber D and released the pressure at port P1.
q As a result, spool (1) moves up and down so that
the force of metering spring (2) is balanced with
the pressure at port P1.
30 WE051B0800
3. During fine control 4. When lever is operated fully

(when control lever is returned) q When the lever (5) pushes down piston (4) and the
q As the lever (5) starts returning, the spool (1) is retainer (7) pushes down the spool (1), connection
pushed up by force of the centering spring (3) and of the fine control hole f is switched from the drain
port P1 pressure. By this move, the fine control chamber D, to the pump pressure chamber PP.
hole f is connected to the drain chamber D and q Thus, pilot pressurized oil from the control pump
relieves pressurized oil of port P1 to it. passes through fine control hole f and conducted
q If port P1 pressure goes excessively low, the spool to chamber A via port P1 to push the operation
(1) is pushed down by the metering spring (2), and valve spool.
passage between fine control hole f and drain q Return oil from chamber B is conducted from port
chamber D is shut down. And, almost at the same P2 to the drain chamber D via the fine control hole
time, the hole is connected to the pump pressure f'.
chamber PP and begins to supply pressure to a
pump. This supply continues until the port P1 pres-
sure is recovered to the level equivalent to the
lever position.
q When the operation valve spool returns, oil in the
drain chamber D flows in through the fine control
hole f' on the not moving side valve. Oil is then
conducted via port P2 to the chamber B to fill it up.
WE051B0800 31
Electric lever (Steering) 1

a Do not disassemble.
If disassembled, the output voltage characteristics and operating effort characteristics will need to be adjusted.
1. Boots 5. Screw
2. Bracket 6. Lever
3. Plate 7. Connector
4. Bolt
32 WE051B0800
Function
1. Operating effort characteristics

1) Operation for directional 2) Operation for steering
q The control lever is held at 3 positions of For- q Free return.
ward, Neutral, and Reverse.
WE051B0800 33
2. Output voltage characteristics

q The control unit is installed to the left control stand
and the control lever is installed directly onto it.
q The operating angle (stroke) of the control lever is
sensed with potentiometers and signal voltages
are output to the transmission, steering controller.
q A potentiometer is installed in each of longitudinal
direction and lateral direction. Each potentiometer
outputs 2 signal voltages which are opposite to
each other as shown in the graph at right.
34 WE051B0800
WE051B0900
Bulldozer
D61EX-15
D61PX-15
D61EX-15 B40001-
D61PX-15 B40001-

Control valve................................................................................................................. 2
CLSS .......................................................................................................................... 10
Self-pressure reducing valve ...................................................................................... 37
Hydraulic system 1
Control valve 1
Outline
The following 3 types of control valve are set.
q 4-spool valve (lift + tilt + angle + steering)
q 4-spool valve (lift + tilt + ripper + steering)
q 5-spool valve (lift + tilt + angle + ripper + steering)
The outside view and section of only the 4-spool valve are shown.
P: From pump
T: To tank
A1: To HSS motor
A2: To lift cylinder head
A3: To tilt cylinder bottom
A4: To angle cylinder bottom
B1: To HSS motor
B2: To lift cylinder bottom
B3: To tilt cylinder head
B4: To angle cylinder head
LS: To pump port LS
PI: Pump pressure pickup port
TS: To tank
CA1: Connector (from controller)
CB1: Connector (from controller)
PA2: From PPC valve
PA3: From PPC valve
PA4: From PPC valve
PB2: From PPC valve
PB3: From PPC valve
PB4: From PPC valve
PEPC: From self pressure reducing valve
2 WE051B0900
4-spool valve
(lift + tilt + angle + steering)
WE051B0900 3
Section
(1/4)
4 WE051B0900
1. Suction valve
2. Back pressure valve
3. Steering spool
4. Lift spool
5. Tilt spool
6. Angle spool
7. Cover (work equipment valve side)
8. Valve block (blade angle valve)
9. Valve block (blade tilt valve)
10. Valve block (blade lift valve)
11. Block (pump port)
12. Valve block (steering valve)
13. Cover (steering valve side)
Unit: mm

Free length
14 Suction valve spring O.D. length load load
5.1 N 4.1 N
39.2 x 4.45 33.5 -
{0.52 kg} {0.42 kg}
5.5 N 4.4 N
15 Suction valve spring 46.8 x 7.5 40.6
{0.56 kg}
-
{0.45 kg}
67.7 N 54.2 N
16 Back pressure valve spring 67.7 x 20 42.5
{6.9 kg}
-
{5.5 kg} Replace spring if
17 Spool return spring (steering) 45.7 x 28 43
{22.6 kg}
-
{18.1 kg} deformed
83.4 N 66.7 N
18 Spool return spring (lift) 41 x 18.6 39
{8.5 kg}
-
{6.8 kg}
Spool return spring (tilt), 108 N 86.3 N
19 (angle)
41.9 x 18.6 39
{11 kg}
-
{8.8 kg}
81.4 N 65.1 N
20 Spool return spring (lift) 40.5 x 24.6 37.5
{8.3 kg}
-
{6.64 kg}
51.4 N 41.1 N
21 Spool return spring (lift) 37.3 x 19.4 17
{5.24 kg}
-
{4.19 kg}
WE051B0900 5
(2/4)
6 WE051B0900
1. LS relief valve (for steering valve)

2. Pressure compensation valve R
3. Pressure compensation valve F
4. Pressure reducing valve (for work equipment valve)
5. Steering priority valve
6. Check valve (centralized safety valve)
R: Pressure reducing valve

F: Flow control valve
Unit: mm

Free length
7 Flow control valve spring O.D. length load load
9.8 N 7.85 N
36.2 x 5.30 32.0 -
{1.0 kg} {0.80 kg}
17.6 N 14.1 N
8 Pressure reducing valve spring 27.5 x 14.2 18.0
{1.8 kg}
-
{1.44 kg}
55.9 N 44.7 N
{5.7 kg}
-
{4.56 kg} Replace spring if
34.3 N 27.5 N damaged or
{3.5 kg}
-
{2.8 kg} deformed
27.6 N 22.2 N
11 Flow control valve spring 30.9 x 5.2 20
{2.82 kg}
-
{2.26 kg}
473 N 379 N
12 Steering priority valve spring 106.5 x 20 82
{48.2 kg}
-
{38.6 kg}
Work equipment valve and 126 N 100 N
13 pressure reducing valve spring
51.6 x 10.5 44.5
{12.7 kg}
-
{10.2 kg}
3.92 N 3.14 N
14 Check valve spring 27.2 x 6.9 22
{0.4 kg}
-
{0.32 kg}
WE051B0900 7
(3/4)
1. LS shuttle valve
2. Unload valve
8 WE051B0900
(4/4)
1. Centralized safety valve (for work equipment valve)

2. Pressure releasing plug
3. Main relief valve (for work equipment valve)
WE051B0900 9
CLSS 1
Outline of CLSS
Features
CLSS is an abbreviation for Closed center Load Sens-
ing System, which has the following features.
q Fine controllability which is not affected by load
q Controllability for digging in fine control mode
q Flow division performance decided by open area
of spool during compound operation
q Energy saving performance with variable pump
control
Composition
q The CLSS consists of the variable-capacity piston
pump, control valve, and actuators.
q The pump consists of the main pump, variable
throttle valve, TVC valve, and LS valve.
10 WE051B0900
Basic principle
1. Control of pump swash plate angle q If LS differential pressure ∆PLS is lower than the
q The pump swash plate angle (pump delivery) is so set pressure of the LS valve (when the actuator
controlled that LS differential pressure ∆PLS which load pressure is high), the pump swash plate
is the differential pressure between pump (dis- moves toward the maximum end.
charge) pressure PP and LS pressure PLS (actua-
tor load pressure) at the control valve outlet will be
constant (LS differential pressure ∆PLS = Pump
discharge pressure PP - LS pressure PLS).
WE051B0900 11
2. Pressure compensation control

q A valve (pressure compensation valve) is installed
to the outlet side of the control valve to balance the
load. This valves works so that pressure difference
∆P between the upstream (inlet) side of the spool
of each valve and the downstream (outlet) side will
be maintained, regardless of the load (pressure).
By this operation, the oil from the pump is distrib-
uted (compensated) in proportion to the open
areas S1 and S2 of each of the operated valves.
12 WE051B0900
Each function and each valve operation

Hydraulic circuit diagram and name of valve
14 WE051B0900
1. Unload valve
Set pressure: 3.4MPa {35kg/cm2}
3. Steering priority valve
4. Pressure reducing valve (for work equipment valve)
5. Pressure compensation valve
6. Suction valve
7. LS shuttle valve
8. LS relief valve (for steering valve)
9. Centralized safety valve (for work equipment valve)
10. Main relief valve (for work equipment valve)
11. Steering valve
12. Lift valve
13. Tilt valve
14. Angle valve
15. Back pressure valve
WE051B0900 15
Unload valve
1. When control valve is in neutral
T: Tank circuit (pressure) 1. Sleeve

PP: Pump circuit (pressure) 2. Spring
PLS: LS circuit (pressure) 3. Spool
Function
q When the control valve is in neutral, delivery Q at
the minimum pump swash plate angle is released
to the tank circuit. At this time, pump discharge
pressure PP is set to 3.4MPa {35kg/cm2} by spring
(2) in the valve (LS pressure PLS is 0MPa {0kg/
cm2}).
Operation
q Pump discharge pressure PP is applied to the right
side of spool (3) and LS pressure PLS is applied to
the left side.
q When the control valve is in neutral, LS pressure
PLS is 0. Accordingly, only pump discharge pres-
sure PP is applied and it is set with only the spring
load of spring (2).
q If pump discharge pressure PP rises to the spring
load of 3.4MPa {35kg/cm2} of spring (2), spool (3)
moves to the left and pump circuit PP is connected
to tank circuit T through hole a of sleeve (1).
q By this operation, pump discharge PP is set to
3.4MPa {35kg/cm2}.
16 WE051B0900
2. When control valve is controlled finely
T: Tank circuit (pressure) 1. Sleeve

PP: Pump circuit (pressure) 2. Spring
PLS: LS circuit (pressure) 3. Spool
Function q If, As a result, the differential pressure between

q When the control valve is controlled finely, if the pump discharge pressure PP and LS pressure
demand flow for the actuator is below the delivery (PLS) reaches the spring load of 3.4MPa {35kg/
at the minimum pump swash plate angle, pump cm2} of spring (2), spool (3) moves to the left and
discharge pressure PP is set to LS pressure PLS + pump circuit PP is connected to tank circuit T.
3.4MPa {35kg/cm2 }. If the differential pressure q That is, pump discharge pressure PP is set to
between discharge pressure PP and LS pressure spring force of 3.4MPa {35kg/cm2} + LS pressure
PLS becomes the spring load of spring (2) PLS and the flow control differential pressure
(3.4MPa {35kg/cm2}), the unload valve opens. LS below the pressure at the minimum swash plate (=
differential pressure ∆PLS is 3.4MPa {35kg/cm2}. ∆PLS) becomes 3.4MPa {35kg/cm2}.
Operation
q When the actuator is controlled with a flow rate
below the delivery at the minimum pump swash
plate angle (below Qmin. in the graph at right), if
the control valve spool is changed, LS pressure
(PLS = Load pressure) is sensed and applied to
the left end of spool (3).
q At this time, pump discharge pressure PP rises to
pass all of Qmin. As a result, the differential pres-
sure between pump discharge pressure PP and
LS pressure (PLS) is increased.
WE051B0900 17
3. When control valve is operated
Function
q When the control valve is operated, if the demand
flow for the actuator exceeds the delivery at the
minimum pump swash plate angle, the flow to tank
circuit T is stopped and all of pump delivery Q is
supplied to the actuator circuit.
Operation
q If the control valve is controlled largely, LS pres-
sure PLS is generated and applied to the left end
of spool (3). At this time, since the open area of
the control valve spool is wide, the difference
between LS differential pressure (∆PLS) and
pump discharge pressure PP is little.
q Accordingly, the differential pressure between
pump discharge pressure PP and LS pressure
PLS does not reach the spring load of 3.4MPa
{35kg/cm2} of spring (2) and spool (3) is pushed to
the right by spring (2).
q As a result, pump circuit PP is disconnected from
tank circuit T and all of pump delivery Q is supplied
to the actuator circuit.
18 WE051B0900
Main relief valve (steering, work equipment)

Centralized safety valve
Function q If pilot poppet (3) opens, the pressure in spring
q If the oil pressure rises above the set level, oil is chamber C lowers and poppet (1) moves to the
drained into the tank. As a result, the maximum right. Then, poppet (1) touches the end of pilot
pressure of the work equipment circuit is regulated poppet (3) and the oil is drained through throttle b
to protect the circuit. and the hole.
Operation
q Port A is connected to the pump circuit and port B
is connected to the drain circuit. The hydraulic oil
is supplied through diameter d1 and the hole of
poppet (1) to diameter d2 of main valve (2). Then,
main valve (2) is in contact with the sleeve
because of the difference in area (d1 < d2).
q Since the pressure in spring chamber C is lower

than the pressure in port A, main valve (2) opens
and the oil flows from port A to port B to prevent
abnormal pressure.
q If the pressure in port A reaches the set pressure

of spring (4), pilot poppet (3) opens and the oil
flows around pilot poppet (3) and through hole a
and port B, and then it is drained.
WE051B0900 19
Steering priority valve

In compound operation
20 WE051B0900
Function
q If the steering valve and the work equipment
valves on the downstream side of the steering pri-
ority valve are operated simultaneously, oil for the
steering valve is secured first, and then the rest of
the pump delivery flows to the work equipment
valve.
Operation
q If steering spool (3) is operated and some oil
flows, a difference is made between pump dis-
charge pressure PP and LS pressure PLS. This
differential pressure simultaneously controls steer-
ing priority valve (1) and pump swash plate with
∆PLS (PP - PLS) = 1.96MPa {20kg/cm2} to decide
the flow rate to the steering valve. 1. When pump swash plate does not reach maxi-
q The PP pressure is applied to right end e of priority mum angle
valve spool (1) and the PLS pressure is applied to q If the maximum pump flow is larger than the total
spring chamber d on the left side. Priority valve demand flow for the steering valve and work
spool (1) is pressed to the right by spring (2). equipment valve, oil flows in the steering valve
q Accordingly, if the differential pressure between accordingly to the open area of steering spool (3)
the PP pressure and PLS pressure is below the and in the work equipment valve decided by the
set pressure of the spring, the open area from pump pressure, load pressure, and open area of
chamber a to chamber b becomes maximum. If the spool.
the differential pressure is increased, spool (1)
moves to the left to decrease the open area for the 2. When pump swash plate is at maximum angle
steering and increase the open area for the work q When the maximum pump flow is less than the
equipment. total demand for the steering valve and work
q While steering spool (3) is operated, if work equip- equipment valve.
ment spool (4) is operated, pump pressure PP
lowers for a moment. 1) When steering valve load Z Work equipment
q accordingly, the differential pressure between PP valve load
and PLS is reduced and priority valve (1) moves to q Oil flows in the steering valve accordingly to the
the right to decrease the open area for the work open area of steering spool (3) and the rest flows
equipment with the pressure in chamber d. in the work equipment valve.
q At the same time, ∆PLS becomes smaller, so the
pump swash plate angle moves in the maximum 2) When steering valve load > Work equipment
direction to supply an oil flow to make up the valve load
amount that the pressures drops. q Pump pressure PP is decided by the steering
valve load. If the work equipment valve on the
a: Pump circuit downstream side, where the load is smaller, is
b: Steering pump circuit operated under this condition, the oil flows in the
c: Work equipment pump circuit work equipment valve because of the differential
d: Spring chamber pressure, and then the pump pressure lowers.
e: Pressure chamber q At this time, steering priority valve (1) increases
the open area for the steering and decreases the
1. Steering priority valve spool open area for the work equipment to secure the
2. Priority valve spring flow for the steering.
3. Steering spool q Under this condition, the oil flow is distributed at
4. Work equipment spool the ratio of the differential pressure between PP
and P1 to that between PP and P2. The bigger
P1 - P2 is, the smaller the flow of oil to the steer-
ing system becomes.
WE051B0900 21
Pressure reducing valve for work equipment

When work equipment valve is operated alone
a: Work equipment pump circuit (pressure) f: Orifice

b: Orifice g: Pressure chamber
c: Spring chamber h: Cut
d. Valve pressure receiving chamber i: Cut
e: Cut
1. Pressure reducing valve 6. Steering priority valve spool

2. Poppet 7. Spring
3. Spring
4. Valve PP: Pump circuit (pressure)
5. Spring T: Tank circuit
Function q If the pressure reducing valve (1) of work equip-

q The pump circuit pressure on the work equipment ment pump circuit a becomes the set pressure of
side is controlled to below 20.6MPa {210kg/cm2} 20.6MPa {210kg/cm2}, poppet (2) pushes spring
and the pump circuit pressure on the steering side (3) to the right to release the hydraulic oil in spring
is secured to 40.2MPa {410kg/cm2} during com- chamber c to tank circuit T. Accordingly, the
pound operation (work equipment + steering). hydraulic oil in pressure chamber d flows through
orifice b and spring chamber c to tank circuit T. A
Operation pressure difference is made between pressure
q If the work equipment valve (lift, tilt, angle, etc.), chamber d and spring chamber c and valve (4)
hydraulic oil PP in the pump circuit if applied to moves to the right to close cut i. Accordingly,
right-end chamber g to push spring (7) to the left pump circuit PP is disconnected from work equip-
through cut e and orifice f of spool (6). As a result, ment circuit a.
open area h of the cut becomes maximum. q Even if the steering system is operated and the
Hydraulic oil flows through cut i of valve (4) to work pump circuit pressure rises to 40.2MPa {410kg/
equipment pump circuit a. cm2}, the work equipment pump circuit pressure
does not exceed 20.6MPa {210kg/cm2}.
22 WE051B0900
Pressure compensation valve
Function
q If the load pressure is lower than the pressure in
the other actuator and the flow rate starts increas-
ing during compound operation, the pressure com-
pensation valve compensates the pressure (at this
time, the load pressure in the other actuator oper-
ated for the compound operation (on the upper
side) is higher than the load pressure on this side
(lower side)).
WE051B0900 23
Operation
q If the load pressure in the other actuator (on the
upper side) becomes high, the flow rate in actuator
circuit A on this side (lower side) starts increasing.
q In this case, LS pressure PLS in the other actuator
is applied to spring chamber PLS1 to push pres-
sure reducing valve (1) and flow control valve (2)
to the left.
q Flow control valve (2) reduces the open area
between pump circuit PP and spool upstream PPA
to make a pressure loss in the line between PP
and PPA.
q Flow control valve (2) and pressure reducing valve

(1) are stopped at a position where the pressure
difference between PA and PLS applied to both
ends of pressure reducing valve (2) is the same as
the pressure loss made in the line between PP
and PPA at the front and rear of flow control valve
(2).
q As a result, pressure difference between upstream
pressure PPA and downstream pressure PA
becomes the same at each spool operated for the
compound operation. Then, the pump flow is dis-
tributed in proportion to the open area of cut a of
each spool.
Suction valve
Function
q This valve prevents negative pressure in the cylin-
der circuit.
Operation
q Port A is connected to the cylinder circuit and port
B is connected to the drain circuit. When a load is
applied to port A, main poppet (1) opens because
of the area difference between d1 and d2. Then,
the oil flows from port B to port A to prevent nega-
tive pressure.
24 WE051B0900
Safety-suction valve
Function q Since pilot poppet (4) opens, the pressure in
q If any impact is applied to the cylinder and abnor- chamber C lowers and poppet (3) moves to the
mal pressure is generated, the abnormal pressure right. Poppet (3) is seated at the end of pilot pop-
is released through the safety valve to protect the pet (4) and the oil is drained through throttle b and
cylinder and other hydraulic parts. chamber D.
q If negative pressure is generated in the cylinder
circuit, this valve works as a suction valve.
1. Operation as safety valve

q Port A is connected to the cylinder circuit and port
B is connected to the drain circuit. The hydraulic
oil in port A is led through the hole of poppet (3) to
port C and safety valve (2) is seated to the left
since d2 < d3. The relationship between diameters
(sectional areas) is as follows d4>d1>d3>d2.
q Since the pressure in chamber C is lower than the

pressure in port A, safety valve (2) moves to the
right and the oil flows from port A to port B to pre-
vent generation of abnormal pressure.
q Even if abnormal pressure is generated, suction
valve (1) having a larger diameter does not oper-
ate since d1 < d4.
q If abnormal pressure is generated in port A and it

increases to the set pressure of spring (5), pilot
poppet (4) opens and the oil from chamber C is
drained through chamber D and periphery a of
suction valve (1).
WE051B0900 25
2. Operation as suction valve

q If negative pressure is generated in the cylinder
circuit, the pressures in port A and chamber C
becomes negative since they are connected. The
tank pressure of port B is applied to port E and the
oil pressure in suction valve (1) is increased by the
area difference between d4 and d3 because of the
tank pressure of port E. Then, the increased pres-
sure moves suction valve (1) to the right against
the tension of spring (6). Accordingly, the oil flows
from port B to port A to prevent negative pressure
in port A.
26 WE051B0900
LS shuttle valve (used as steering LS bypass plug, too)
a: Clearance filter 1. LS shuttle valve and LS bypass plug

b: LS bypass orifice (steering) 2. Ball shuttle valve
c: LS bypass orifice (work equipment side)
Function
q Used to release residual LS pressure PLS
q The rising speed of LS pressure PLS is lowered
and the discarded throttle flow is used to make
pressure loss in the throttle between P and LS of
the pressure compensation valve to lower the
effective LS differential pressure and increase the
stability.
q The higher LS pressure on the steering side or
work equipment side is selected and output.
Operation
q The PLS circuit pressure on the steering side
presses ball shuttle valve (2) to the right, and then
it is led to the upper PLS output port (when steer-
ing system is operated alone or together with
another system (when steering PLS > work equip-
ment PLS)).
q The PLS hydraulic oil flows from the clearance fil-
ter a through orifices b and c to the tank circuit.
q The pressure in the PLS circuit on the work equip-
ment side presses ball shuttle valve (2) to the left,
and then it is let to the upper PLS output port
(when steering sy stem is operated alone or
together with another system (when work equip-
ment PLS > steering PLS)).
WE051B0900 27
Steering LS relief valve and main relief valve operation
a: Pump primary circuit

b: Pump secondary circuit
c: LS circuit
1. Steering spool 4. HSS motor assembly

2. Steering LS relief valve 5. Priority valve spool
3. Main relief valve 6. Priority valve spring
28 WE051B0900
Function
q If specified the maximum pressure when the HSS
motor is operated.
q The pump LS valve senses the differential pres-
sure (PP - PLS) generated by the operation of the
LS relief valve and moves the pump swash plate
toward the minimum position. The pump delivery
is balanced at the minimum position. accordingly,
the relief oil flow is reduced.
q Main relief valve: Cuts the peak pressure caused
by a sudden external load which the LS relieve
valve cannot lower by controlling the swash plate.
Operation
q Steering spool (1) is moved and HSS motor drive
pressure (4) is increased, steering LS relief valve
(2) operates to drain the oil from pump circuit b. As
a result, the pressure difference between pump
circuit b and LS circuit c is increased.
q For the same reason, if the pressure in LS circuit c
is lowered, priority valve spool (5) moves to the left
against spring (6) to reduce the open areas of
pump primary a and secondary b. As a result, the
pressure difference between a and b is increased.
q Pump LS valve senses the LS differential pressure
(PP - PLS) generated by LS relief valve (2) and
moves the pump swash plate from the maximum
position toward the minimum position. The pump
swash plate is balanced at the minimum position
when the LS differential pressure X 2.0MPa {20kg/
cm2} (see pump swash plate control).
q When the pump swash plate is at the minimum
position (minimum flow rate), if the pump circuit
pressure (PP) - LS circuit pressure (PLS) X
3.4MPa {35kg/cm2}, the unload valve operates to
release the excessive oil and balance the swash
plate.
LS relief valve set pressure: 33.1MPa {338kg/cm2}

Main relief valve set pressure: 40.2MPa {410kg/cm2}
WE051B0900 29
Work equipment relief valve operation
1. Work equipment spool

2. Pressure reducing valve
3. Main relief valve (work equipment)
4. Main relief valve (steering)
5. Pressure reducing valve spool
30 WE051B0900
Function
q The maximum pressure is regulated when the
work equipment is operated.
q The pump LS valve senses the differential pres-
sure (PP1 - PP2 C PLS) generated by the opera-
tion of the pressure reducing valve and the relief
valve on the work equipment side and moves the
pump swash plate toward the minimum position.
The pump delivery is balanced at the minimum
position. accordingly, the relief oil flow is reduced.
Operation
q If work equipment spool (1) is moved and work
equipment operating pressure PP2 is increased,
pressure reducing valve (2) operates and pressure
reducing valve spool (5) narrows the PP1 and PP2
circuits (1.1mm2 ). Work equipment pump circuit
pressure PP2 becomes the pressure reducing
valve set pressure of 20.6MPa {210kg/cm2}.
q Since steering relief valve (4) is set high pressure,
the oil is supplied through the narrow open area of
pressure reducing valve spool (5) by the override
of the pressure reducing valve, and then the PP2
circuit pressure rises.
q Then, if the pressure reaches the work equipment
relief set pressure, the PP2 circuit pressure oil is
drained through the relief valve. Since the differen-
tial pressure between PP1 and PP2 (C PLS) is
generated by the flow from relief valve (3) and the
throttle of orifice a of the pressure reducing valve
and it minimizes the pump swash plate angle, the
pump delivery becomes minimum (same as steer-
ing LS relief function).
Reducing valve set pressure: 20.6MPa {210kg/cm2}

Relief valve set pressure: 21.6MPa {220kg/cm2}
WE051B0900 31
Introduction of LS pressure
1. Steering valve
Function q Both ends of pressure reducing valve (3) has the

q The LS pressure means the actuator load pres- same area (SA = SLS). Actuator circuit pressure
sure on the outlet side of the control valve. PA (= A) is applied to the SA side and reduced
q In the work equipment valve, pressure reducing pump discharge pressure PP is applied to the SLS
valve (3) of the pressure compensation valve side.
reduces pump discharge pressure PP to the level q Accordingly, pressure reducing valve (3) is bal-
of actuator circuit pressure A, and then introduces anced at a position where actuator circuit pressure
it to the LS circuit PLS. Orifice c is installed to pis- PA and the pressure in spring chamber PLS1 are
ton (5) on the way from pump circuit PP to pres- the same. Pump discharge pressure PP reduced
sure reducing valve (3), and it works as a damper. by cut d is introduced as actuator circuit pressure
A to LS circuit PLS.
Operation
q If spool (1) is operated, pump discharge pressure
PP flows through flow control valve (2), cut a of the
spool, and bridge circuit b to actuator circuit A.
q Since pressure reducing valve (3) also moves to
the left at this time, pump discharge pressure PP
introduced through orifice c is reduced by the pres-
sure loss in cut d and introduced to LS circuit PLS,
and then further led to spring chamber PLS1.
q At this time, LS circuit PLS is connected to tank
circuit T through LS bypass plug (4).
32 WE051B0900
Work equipment valve (lift, tilt, angle, ripper)

1. When blade is "Raised"
Operation q Accordingly, pressure reducing valve (3) is bal-

q If spool (1) is operated, pump discharge pressure anced at a position where actuator circuit pressure
PP flows through flow control valve (2), cut a of the PA and the pressure in spring chamber PLS1 are
spool, and bridge circuit b to actuator circuit A. the same. Pump discharge pressure PP reduced
q Since pressure reducing valve (3) also moves to by cut d is introduced as actuator circuit pressure
the right at this time, pump discharge pressure PP A to LS circuit PLS.
introduced through passage c is reduced by the
pressure loss in cut d and introduced to LS circuit
PLS, and then further led to spring chamber PLS1.
q At this time, LS circuit PLS is connected to tank
circuit T through LS bypass plug (4).
q Both ends of pressure reducing valve (3) has the
same area (SA = SLS). Actuator circuit pressure
PA (= A) is applied to the SA side and reduced
pump discharge pressure PP is applied to the SLS
side.
WE051B0900 33
2. When blade is "Floated"
Operation
q If the lift valve is set in the "Float" position, the cyl-
inder port is connected to drain port T and no load
is applied.
q Even if the lift valve is in the "Float" position, the
pump circuit and cylinder circuit are separated so
that the other work equipment (tilt, angle, etc.) can
be operated.
q If the work equipment control lever is set in the
"Float" position, spool (1) is set in the maximum
stroke position. Port B is connected to port A
through bridge passage b, and port A is connected
to circuit T.
q Accordingly, if the blade is loaded, it can move up
and down.
q While the lift valve is in the "Float" position, part a
of spool (1) is closed. Accordingly, if other work
equipment (tilt, angle, etc.) is operated, the pump
pressure rises and the operator can start com-
pound operation.
34 WE051B0900
Back pressure valve
Function
q When the machine is steered or stopped, the back
pressure valve increases the pressure in the steer-
ing drain circuit to prevent cavitation in the HSS
motor and increase the effect of suction valve (3).
Operation
q The drain pressure in the steering circuit is
increased by back pressure valve (1) and spring
(2).
WE051B0900 35
Self-pressure reducing valve 1
T: To tank
P1: From pump
P2: To fan motor
PR: Supplied to PPC valve, EPC valve, etc.
WE051B0900 37
1. Valve (sequence valve) 6. Spring (pressure reducing valve main)

2. Spring 7. Valve (pressure reducing valve)
3. Screw 8. Spring (safety valve)
4. Poppet 9. Ball
5. Spring (pressure reducing valve pilot) 10. Filter
38 WE051B0900
Unit: mm

Spring Free length
11 (pressure reduction valve main)
O.D. length load load
19.6 N 17.7 N
19.2 x 7.20 16.1 -
{2.0 kg} {1.80 kg} Replace spring if
Spring 31.4 N 28.4 N damaged or
12 (pressure reduction valve pilot)
17.8 x 7.20 12.1
{3.2 kg}
-
{2.9 kg} deformed
200 N 186 N
13 Spring 71.0 x 18.0 59.0
{20.4 kg}
-
{19.0 kg}
Spring 61.7 N 58.8 N
14 (safety valve)
16.1 x 7.80 13.4
{6.30 kg}
-
{6.0 kg}
Function
q The self pressure reducing valve reduces the dis-
charge pressure of the fan pump and supplies it to
the PPC valve, the EPC valve, etc. as the control
pressure.
WE051B0900 39
Operation
1. At engine stop (total low pressure)
q The spring (6) pushes the poppet (5) the seat, and
the circuit between the ports PR and T is closed.
q The spring (7) pushes the valve (8) to the left side,
and the circuit between the ports P1 and PR is
open.
q The spring (3) pushes the valve (2) to the upper
side, and the circuit between the ports P1 and P2
is closed.
40 WE051B0900
2. When the load pressure P2 is lower than the output pressure PR of the self pressure reducing valve.
q The spring (3) and the PR pressure (0MPa {0kg/

cm2} at the time of engine stop) pushes the valve
(2) in the direction to close the circuit between the
ports P1 and P2. When the hydraulic oil enters the
port P1, the expression (pressure P1 C Force of
spring (7) + (area of ød x pressure PR)) holds, and
the self pressure reducing valve will adjust the
openings of the ports P1 and P2 so that the P1
pressure can be maintained higher than the PR
pressure.
q When the PR pressure rises above the set pres-
sure, the poppet (5) will open and the hydraulic oil
flows through the route from the port PR, the hole
a in the spool (8), the poppet (5) opening to the
tank port T.
q Therefore, there will occur a differential pressure
around the hold a in the spool (8) and the spool
will move in the direction to close the port P1 and
the PR opening. Then, the P1 pressure is reduced
and adjusted to a certain pressure (set pressure)
with the opening and is supplied as the PR pres-
sure.
WE051B0900 41
3. At raise of load pressure P2
q If load pressure P2 and the pump delivery are

increased for digging operation, etc., pressure P1
is also increased (pressure P1 > force of spring (3)
+ (area of ød x pressure PR)) and valve (2) moves
to the right stroke end. As a result, the opening
between the ports P1 and P2 will increase, the
passage resistance will become smaller to reduce
engine loss horsepower.
q When the PR pressure rises above the set pres-
sure, the poppet (5) will open and the hydraulic oil
flows through the route from the port PR, the hole
a in the spool (8), the poppet (5) opening to the
tank port T.
q Therefore, there will occur a differential pressure
around the hold a in the spool (8) and the spool
will move in the direction to close the port P1 and
the PR opening. Then, the P1 pressure is reduced
and adjusted to a certain pressure (set pressure)
with the opening and is supplied as the PR pres-
sure.
42 WE051B0900
4. At occurrence of abnormal high pressure
q When the PR pressure of the self pressure reduc-

ing valve rises abnormally high, the ball (10) will
separate from the seat against the spring (9) force
to flow the hydraulic oil to the output ports PR o T
so as to reduce the PR pressure. Then, the equip-
ment (PPC valve, solenoid valve, etc.), to which
the oil pressure is supplied, is protected from the
abnormal high pressure.
WE051B0900 43
WE051B1000
Bulldozer
D61EX-15
D61PX-15
D61EX-15 B40001-
D61PX-15 B40001-

Work equipment ............................................................................................................... 2
Work equipment............................................................................................................ 2
Cutting edge and end bit............................................................................................... 8
Ripper ........................................................................................................................... 9
Cab and its attachments................................................................................................. 10
Cab mount .................................................................................................................. 10
Cab ............................................................................................................................. 11
Air conditioner piping .................................................................................................. 13
Work equipment 1
Work equipment 1
a The diagram shows D61PX-15.
1. Tilt cylinder 5. Pitching rod

2. Cutting edge 6. Angle cylinder
3. End bit 7. U-frame
4. Blade 8. Lift cylinder
2 WE051B1000
a The diagram shows D61PX-15.
WE051B1000 3
Unit: mm
Clearance between frame size Shaft Hole clearance limit
1 connecting pin and bushing +0.207 0.156-
0.5
-0.036 +0.120 0.297
ø85
Clearance between frame -0.090 +0.300 0.136-
2 connecting pin and U-frame bracket +0.100 0.390
1.0
Clearance between lift cylinder -0.030 +0.046 0.030-

3 bottom pin and frame bracket
ø60
-0.076 0 0.122
1.0

4 head pin and U-frame bracket
ø60
-0.076 +0.100 0.376
1.0
Clearance between angle cylinder -0.025 +0.300 0.125-

5 bottom pin and U-frame bracket
ø45
-0.087 +0.100 0.387
1.0
Replace
Clearance between angle cylinder -0.025 +0.300 0.125-
6 head pin and blade bracket
ø45
-0.064 +0.100 0.364
1.0
Clearance between tilt cylinder -0.025 +0.300 0.125-

7 bottom pin and blade bracket
ø50
-0.064 +0.100 0.364
1.0
Clearance between tilt cylinder -0.025 +0.300 0.125-

8 head pin and U-frame bracket
ø50
-0.064 +0.100 0.364
1.0
Clearance between pitching rod pin +0.039 0.025-

9 and bushing 0 0.103
0.5
-0.025
ø50
Clearance between pitching rod pin -0.064 +0.300 0.125-
10 and U-frame bracket +0.100 0.364
1.0
Clearance between ball of blade -0.250 +1.500 0.250-

11 and pitching rod cap
Sø90
-0.750 0 2.250
-
Clearance between ball of U-frame

12 center and blade cap
Sø177.5 - - 0.75 -
Standard thickness of shim Adjustment of shim

13 between ball of U-frame center and 8.0
blade cap
4 WE051B1000

Semi-U dozer (Semi-U)
a The diagram shows D61EX-15 semi-U dozer.
1. Tilt cylinder 6. Lift rod

2. Cutting edge 7. Blade
3. Center brace 8. Brace
4. End bit 9. Lift bracket
5. Trunnion 10. Straight frame
WE051B1000 5
a The diagram shows D61EX-15 semi-U dozer.

# $ $ % % & &

' ' ( ( ) ) * *

, , - - . . / /
0 O
] MI O_
0 0
5 '/ +7 0O ] MIO _
2 6 0O ] MIO _
,$
6 WE051B1000
Unit: mm
Spherical clearance between size Shaft Hole clearance limit Adjust shim or
1 trunnion and cap replace
-0.1 +1.5
Sø140 0.3-0.7 5.0
-0.5 0
2 bottom pin and frame bracket
ø50
-0.076 0 0.122
2.0

3 head pin and lift bracket
ø50
-0.076 +0.100 0.376
2.0
Spherical clearance between -0.1 +0.5

4 bearing and bushing
Sø90
-0.5 0
0.1-1.0 2.0 Replace
Clearance between frame mounting +0.6

5 pin and bracket +0.2
0.2-0.9 2.0
0
ø55
Clearance between frame mounting -0.3 +0.5
6 pin and bearing +0.2
0.2-0.8 2.0
Spherical clearance between -0.25 +1.5 Adjust shim or

7 pitching rod and bracket
Sø65
-0.75 0
0.3-0.7 2.0
replace
Clearance between lift bracket -0.030 +0.048 0.030-
8 mounting pin and bushing
ø60
-0.060 0 0.108
2.0
Clearance between brace +0.2

9 mounting pin and bracket 0
0.2-0.6 2.0 Replace
-0.2
ø50
Clearance between brace -0.4 +0.2
10 mounting pin and brace 0
0.2-0.6 2.0
Spherical clearance between Sø70 (shaft) -0.1 +1.0 Adjust shim or

11 bracket and brace Sø71 (hole) -0.3 0
0.3-0.7 2.0
replace
Clearance between center brace +0.2
12 mounting pin and bracket 0
0.2-0.6 2.0
-0.2
ø50 Replace
Clearance between center brace -0.4 +0.2
13 mounting pin and brace 0
0.2-0.6 2.0
Spherical clearance between Sø70 (shaft) -0.1 +1.0 Adjust shim or

14 bracket and center brace Sø71 (hole) -0.3 0
0.3-0.7 2.0
replace
WE051B1000 7
Cutting edge and end bit 1

a The diagram shows the cutting edge and end bit for the power angle power tilt dozer.
Unit: mm
PAT (EX) 204 187
Height of end bit
1 (outside) PT (PX) 204 187
SEMI-U
315 237
(EX)
PAT (EX) 325 300
PT (PX) 325 300
2 Width of end bit
SEMI-U
540 515
(EX)
PAT (EX) 204 187 Replace
Height of end bit PT (PX) 204 187
3 (inside) SEMI-U
254 237
(EX)
PAT (EX) 102 85
PT (PX) 102 85
Height of cutting edge
SEMI-U
4 (from center of bolt 102 85
hole to end face) (EX)
PAT-3m
102 85
(PX)
PAT (EX) 392-529 Nm {40-54 kgm}
PT (PX) 392-529 Nm {40-54 kgm}
Tightening torque of end SEMI-U End bit: 637-853 Nm {65-87 kgm}
5 bit and cutting edge
Retighten
(EX) Cutting edge: 392-529 Nm {40-54 kgm}
PAT-3m
392-529 Nm {40-54 kgm}
(PX)
PAT: For power angle power tilt dozer, PT: For power tilt dozer, SEMI-U: For semi-u dozer
8 WE051B1000
Ripper 1
D61EX-15
(if equipped)
Unit: mm
size Shaft Hole clearance limit
1 Clearance between pin and bushing
-0.030 +0.299 0.199-
ø56 1.0 Replace
-0.076 +0.169 0.375
2 Wear of point
222 152
3. Bracket A: Pin hole A (point digging angle: 55 deg.)

4. Upper link B: Pin hole B (point digging angle: 45 deg.)
5. Ripper cylinder
6. Beam
7. Shank
8. Point
9. Lower link
WE051B1000 9
Cab and its attachments 1

Cab mount 1
1. Support Outline
2. Damper mount (front) q Viscous damper mounts (2) and (3) are installed at
3. Damper mount (rear) two places at the front and two places at the rear
to secure the floor frame and cab.
q An oil-filled damper mount is used to absorb the
vibration.
10 WE051B1000
Cab 1
1. Front wiper
2. Front window
3. Rear wiper
4. Door
WE051B1000 11
a ROPS: Abbreviation for ROllover Protective Structure
1. ROPS guard
12 WE051B1000
Air conditioner piping 1
1. Condenser A: External air inlet

2. Valve (hot water outlet) B: Internal air circulation opening
3. Hot water pick-up piping C: Hot/Cold air outlet
4. Refrigerant piping
5. Receiver tank
6. Hot water return piping
7. Air conditioner compressor
8. Valve (hot water inlet)
9. Front window defroster
10. Air conditioner unit
11. Vent
12. Blower motor
13. Side window defroster
WE051B1000 13
WE051B1100
Bulldozer
D61EX-15
D61PX-15
D61EX-15 B40001-
D61PX-15 B40001-

Electric system ................................................................................................................. 2
Engine control system .................................................................................................. 2
Cooling system control system ..................................................................................... 4
Palm command control system..................................................................................... 6
PPC lock system........................................................................................................... 8
Component parts of system .......................................................................................... 9
Monitor system ........................................................................................................... 14
Monitor panel .............................................................................................................. 16
Sensor ........................................................................................................................ 20
Electric system 1
Engine control system 1
1. Battery 15. Brake pedal potentiometer

2. Battery relay 16. Deceleration pedal potentiometer
3. Fuse box 17. Electric lever
4. Starting switch 18. Monitor panel
5. Transmission and steering controller 19. Governor motor
6. Parking brake lever 20. Fuel injection pump
7. Neutral safety limit switch 21. Engine speed sensor
8. Fuel solenoid relay 1 22. Coolant temperature sensor (for preheating)
9. Fuel solenoid relay 2 23. Coolant temperature sensor (for monitoring)
10. Fuel solenoid 24. Engine oil pressure sensor
11. Neutral safety relay 25. Electrical intake air heater relay 1
12. Starting motor 26. Electrical intake air heater relay 2
13. Alternator 27. Electrical intake air heater
14. Fuel control dial
Function
1. The neutral safety circuit is employed to secure
safety at start of the engine.
q While the parking brake lever is not in the
"Lock" position, the engine does not start.
2 WE051B1100
Starting engine Stopping engine

q If the starting switch (4) is set in the "ON" position, q If starting switch (4) is turned "OFF", the current
transmission and steering controller (5) inputs the from the ACC terminal of starting switch (4) is cut
ACC signal and supplies the command current to out and the current does not flow in the hold coil of
the pull coil of fuel solenoid (10) for about 3 sec- fuel solenoid (10). As a result, the fuel is not sup-
onds. plied and the engine stops.
Since a current also flows in the hold coil of fuel
solenoid (10) from the ACC terminal of starting
switch (4), the solenoid is held so that fuel will still
be supplied after the pull coil is de-energized.
Accordingly, the engine stops when the electric
system has trouble, thus a fail-safe mechanism is
made up.
q Transmission and steering controller (5) receives
signals from neutral safety limit switch (7) installed
to the linkage of parking brake lever (6) and elec-
tric lever (17) and controls neutral safety relay
(11).
While parking brake lever (6) is in the "Free" posi-
tion, neutral safety relay (11) does not operate and
the starting current to starting motor (12) is cut out.
Accordingly, the engine does not start and a neu-
tral safety mechanism is made up.
Engine speed control

q The engine speed is controlled with the 1st throttle
(fuel dial signal), 2nd throttle (decelerator pedal
signal), and 3rd throttle (controller command sig-
nal).
The 3rd throttle has the following functions.
1) Automatic deceleration (F3, R3)
2) Engine speed control when trouble occurs
q Fuel control dial (14) sends the 1st throttle signal
to transmission and steering controller (5) accord-
ingly to the steering angle.
q Transmission and steering controller (5) selects
the command signal of lower engine speed from
the 1st throttle signal and the 3rd throttle calcu-
lated from the machine condition, and then con-
trols governor motor (19) so that the governor
lever of fuel injection pump (20) will be at an angle
matched to the command signal.
q The potentiometer in governor motor (19) con-
stantly monitors the governor lever to see if it is at
a proper angle.
q The decelerator pedal is connected through the
cable and linkage to fuel injection pump (20).
q The automatic deceleration is a function to lower
the engine speed temporarily when the travel
direction is changed from F3 or R3 (for protection
of transmission clutch).
WE051B1100 3
Cooling system control system 1
1. Battery Input and output signals

2. Battery relay a. Controller power supply
3. Fuse box b. Monitor panel power supply
4. Transmission and steering controller c. Fan rotation selector signal
5. Monitor panel d. Power train oil temperature signal
6. Cooling fan motor e. Hydraulic oil temperature signal
7. Cooling fan pump f. Engine speed signal
8. Fan rotation selector switch g. Coolant temperature signal
9. Power train oil temperature sensor h. CAN signal
10. Hydraulic oil temperature sensor i. Pump control signal
11. Engine j. Fan reverse signal
12. Engine speed sensor
13. Coolant temperature sensor
4 WE051B1100
Outline Selection of fan rotation mode

q The transmission and steering controller monitors q While the starting switch is in the "ON" position
the coolant, power train oil, and hydraulic oil tem- and the engine is stopped, the fan speed mode
peratures and controls the fan speed accordingly can be selected by operating the fan speed selec-
to those temperatures. tor switch.
There are the following speed modes.
1) Forward rotation mode
Function 2) Reverse rotation mode
3) Cleaning mode
Fan speed control The transmission and steering controller operates
q The transmission and steering controller controls the reverse solenoid valve of the cooling fan motor
the discharge of the cooling fan to set the fan to change the rotation direction of the fan accord-
speed properly accordingly to the information from ingly to the selected mode.
the coolant, power train oil, and hydraulic oil tem-
perature sensors. 1) Forward rotation mode
q The transmission and steering controller selects In this mode, the reverse solenoid valve does not
the maximum target fan speed obtained from the operate and the fan rotates forward. The fan
coolant, power train oil, and hydraulic oil tempera- speed varies with the temperature sensor signal.
tures and outputs it as the pump control signal to This mode is selected normally.
the cooling fan pump.
q The cooling fan pump changes its swash plate 2) Reverse rotation mode
angle to controls its oil discharge for the cooling In this mode, the reverse solenoid valve operates
fan motor. and the fan rotates in reverse. The fan can warm
the operator's cab as a substitute for a reversible
fan. Since the cooling efficiency is low in this
mode, the engine overheats easily. Accordingly,
this mode should be used only in cold weather.
3) Cleaning mode
In this mode, the fan rotates in reverse at high
speed to blow off dirt from the radiator fins, regard-
less of the temperature sensor signals. If this
mode is used periodically, the cleaning interval of
the radiator fins can be expanded.
Interlock for changing rotation mode

q 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 moni-
tor panel flashes.
WE051B1100 5
Palm command control system 1
1. Battery
2. Battery relay
3. Fuse box
4. Transmission and steering controller
5. Monitor panel
6. Automatic shift-down switch
7. Preset mode switch
8. Steering/directional/gearshift lever (PCCS lever)
9. Engine speed sensor
10. Engine
11. Torque converter
12. Transmission
13. Transmission control valve
14. Transmission output shaft speed sensor
15. HSS unit
16. Control valve
16a. Steering control valve
17. HSS motor
6 WE051B1100
Preset mode function Automatic shift-down function

q The gear speed applied for forward travel and q If the travel speed lowers because of the loading
reverse travel can be set in advance. condition, the transmission gear is shifted down
Preset mode 1: F1 - R1 automatically.
Preset mode 2: F1 - R2 1) The traction force (load on the chassis) is cal-
Preset mode 3: F2 - R2 culated from the engine speed, transmission
Preset mode 4: F2 - R3 output shaft speed, and the throttle informa-
tion sent from the transmission and steering
1. How to use controller, and then the transmission gear is
1) Set the PCCS lever in the N (neutral) position. shifted down automatically accordingly to the
2) Set preset mode switch (1) in the "ON" posi- load and travel speed.
tion. 2) Once the transmission gear is shifted auto-
3) Press the UP/DOWN switch of the PCCS lever matically, it is not shifted up again automati-
to select a mode. cally (the gear can be shifted up with the up
switch of the PCCS lever).
3) This function is applicable to both forward and
reverse travels.
1. How to use
1) Set auto shift-down switch (2) in the "ON"
position.
2. Display
q The selected mode is displayed on display
panel B of the monitor panel.
WE051B1100 7
PPC lock system 1
1. Battery Function
2. Battery relay q The PPC lock switch is connected to the work
3. Fuse box equipment lock lever. If the work equipment lock
4. Work equipment lock lever lever is set in the "Lock" position, the PPC lock
5. PPC lock switch switch is turned "OFF".
6. PPC lock solenoid valve q If the PPC lock switch is turned "OFF", the current
7. Engine to the PPC lock solenoid valve is cut out and the
8. PTO work equipment does not move even if the steer-
9. Cooling fan pump ing/directional/gearshift lever or ripper control
10. Self-reducing pressure valve lever is operated.
11. Blade PPC valve
12. Ripper PPC valve (if equipped: D61EX-15)
8 WE051B1100
Component parts of system 1

Fuel control dial
1. Knob Function
2. Dial q The fuel control dial is installed to the left side of
3. Spring the operator's seat.
4. Ball q If knob (1) is turned, the shaft of potentiometer (5)
5. Potentiometer rotates to change the resistance of the variable
6. Connector resistor and sends a throttle signal to the transmis-
sion and steering controller.
q The hatched area in the following graph is the
abnormality detection area, where the engine
speed is reduced to a half.
WE051B1100 9
Transmission and steering controller
Input and output signals
DEUTSCH-24P [CN-ST1]
Input/output Input/output
Pin No. Signal name Pin No. Signal name
signals signals
1 Decelerator pedal potentiometer Input 13 PCCS lever position FR3 Input
Coolant temperature sensor
2 PCCS lever position ST1 Input 14 Input
(for preheating)
3 Fuel control dial potentiometer Input 15 Alternator (R) Input
4 GND (signal) - 16 Sensor power supply (+24V) Output
5 N.C. - 17 N.C. -
6 Service switch Input 18 Shift-down switch (N.O.) Input
7 PCCS lever position FR4 Input 19 PCCS lever position ST2 Input
8 Pitch angle sensor Input 20 Governor potentiometer Input
9 Hydraulic oil temperature sensor Input 21 GND (analog) -
10 N.C. - 22 Sensor power supply (+5V) Output
11 N.C. - 23 N.C. -
12 Shift-up switch (N.C.) Input 24 Shift-down switch (N.C.) Input
10 WE051B1100
DEUTSCH-40P(1) [CN-ST2]
signals signals
1 N.C. - 21 N.C. -
2 N.C. - 22 CAN0 (L) Input/output
3 N.C. - 23 N.C. -
4 Flash ROM write (Rx) Input 24 Flash ROM write permission signal Input
5 Parking brake switch (N.C.) Input 25 Transmission reverse fill switch Input
6 Cursor switch 2 Input 26 Selector switch Input
7 Fan reverse switch Input 27 N.C. -
8 Neutral safety relay Output 28 N.C. -
9 Electric intake air heater relay Output 29 GND (pulse) -
10 Manual mode switch Input 30 Transmission output shaft speed sensor Input
11 N.C. - 31 N.C. -
12 CAN shield - 32 CAN0 (H) Input/output
13 Immobilize signal Input 33 N.C. -
14 Flash ROM write (Tx) Output 34 GND (flash ROM write) -
15 Parking brake switch (N.O.) Input 35 Transmission forward fill switch Input
16 Cursor switch 1 Input 36 Caution buzzer cancel switch Input
17 Fan normal speed switch Input 37 Automatic shift-down switch Input
18 Backup alarm relay Output 38 N.C. -
19 N.C. - 39 GND (pulse) -
20 Brake pedal potentiometer Input 40 Engine speed sensor Input
DEUTSCH-40P(2) [CN-ST3]
signals signals
1 Power supply (controller) Input 21 GND (power supply) -
2 Power supply (solenoid) Input 22 Power supply (solenoid) Input
3 GND (common to solenoids) - 23 GND (common to solenoids) -
4 For driving battery relay Output 24 Starting switch (ACC) Input
5 Governor motor A (+) Output 25 Governor motor B (+) Output
6 1st ECMV Output 26 3rd ECMV Output
7 TVC solenoid valve Output 27 Forward ECMV Output
8 Fuel solenoid relay Output 28 HSS EPC valve (left) Output
9 Shift-up switch (N.O.) Input 29 Transmission 2nd fill switch Input
10 N.C. - 30 Selection of HSS specification Input
11 Power supply (controller) Input 31 GND (power supply) -
12 Power supply (solenoid) Input 32 GND (power supply) -
13 GND (common to solenoids) - 33 GND (power supply) -
14 Starting switch (ACC) Input 34 N.C. -
15 Governor motor A (-) Output 35 Governor motor B (-) Output
16 2nd ECMV Output 36 Fan control solenoid valve Output
17 N.C. - 37 Reverse ECMV Output
18 Fan reverse solenoid valve Output 38 HSS EPC valve (right) Output
19 Transmission 1st fill switch Input 39 Transmission 3rd fill switch Input
20 N.C. - 40 Selection of C/B specification Input
WE051B1100 11
Governor motor
1. Potentiometer Function
2. Cover q The governor motor rotates motor (4) and controls
3. Shaft the governor lever of the fuel injection pump
4. Motor accordingly to the drive signal from the transmis-
5. Gear sion and steering controller.
6. Connector Motor (4) used as the motive power supply is a
stepping motor.
q Feedback potentiometer (1) is used to monitor the
operation of motor (4).
q Revolution of motor (4) is transmitted through gear
(5) to potentiometer (1).
Operation
While motor is stopped
q The power is supplied to both phases A and B of
the motor.
While motor is revolving
q A pulse current flows in phase A or B of the motor
to rotate the motor synchronizing with the pulse.
12 WE051B1100
Decelerator pedal potentiometer

Brake pedal potentiometer
1. Potentiometer
2. Connector
Function
q The potentiometer is connected to the decelerator
pedal and brake pedal, and its shaft rotates
accordingly to the operating angle of each pedal.
q Movement of the shaft operates the internal vari-
able resistor to change its resistance accordingly
to the change of the operating angle. Then, the
supply voltage of 5V is changed to a signal voltage
accordingly to the operating angle.
Electric lever
a See "Electric lever (Steering)".
PPC lock solenoid valve

a See "Solenoid valve".
Monitor panel
a See "Monitor system".
WE051B1100 13
Monitor system 1
a. Each sensor e. Battery

b. Sensor signal f. Power supply
c. Transmission and steering controller g. Caution buzzer
d. CAN signal h. Caution buzzer signal
q The monitor system notifies the operator of the q The monitor system consists of the monitor panel,
machine condition. It monitors the machine condi- controller, sensors, alarm buzzer, and power sup-
tion with the sensors installed to the machine and ply.
processes and displays the obtained information q The component parts are connected by wiring har-
on the monitor panel immediately. nesses and the monitor panel is powered by the
The contents displayed on the panel are roughly battery.
classified as shown bellow. q If the machine has trouble (and it is detected by a
1. Travel direction and gear speed (section a of sensor), the monitor and caution lamp flush and
display panel) the caution buzzer sounds. The alarm buzzer can
2. Engine speed, coolant temperature, hydraulic be turned "OFF" temporarily with the buzzer can-
oil temperature, Power train oil temperature, cel switch.
and fuel level (gauge section)
3. Machine trouble caution (monitor section)
4. Current and voltage of each sensor and sole-
noid, error code (section B of display panel)
14 WE051B1100
Processing by 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
q Signals (F1, R3, etc.) are sent to the monitor panel accord-
CAN signal
ingly to the information of the transmission and steering con-
troller.
2. Display of gauges of engine speed, coolant temperature,
hydraulic oil temperature, power train oil temperature, and fuel
level CAN signal
q Sensor signals are processed, replaced with the gauge No.,
and sent to the monitor panel by the controller.
Each sensor/solenoid
3. Display of troubles O
q If the machine has trouble, the signal of the corresponding
Controller
error code is sent to the monitor panel. O
q The command to sound the caution buzzer or flash the cau-
Monitor panel
tion lamp is sent accordingly to the contents of the trouble.
1) When normal
Action code is displayed CAN signal
2) In failure history display mode
Error code (6-digit code) and
q Elapsed time after first occurrence
q Elapsed time after last occurrence
q Number of occurrences
etc. are displayed.
Monitoring display
1. Display of communicating condition of each sensor, each sole-
noid, and CAN signal
CAN signal Each sensor
q Item No. and condition of each device are sent as signals to
O
the monitor panel.
Controller
2. Selection of each item with information switch, buzzer cancel O
switch, and Up/Down switch of steering/directional/gear shift Monitor panel
CAN signal
lever
(when using the mode for servicing, turn the service switch "ON")
a For details of the operation method, etc., see Testing and adjusting, Special functions of monitor panel
(EMMS).
Other items
1. Filter and oil maintenance mode
2. Pm clinic auxiliary mode
3. Error code display mode
4. Adjustment mode (user) Each sensor
5. Maintenance interval change mode O
6. Electrical system error code display mode CAN signal Controller
7. Mechanical system error code display mode O
8. Adjustment mode (service) Monitor panel
9. Load saving display mode
10.Real-time monitoring mode
11.Dual display monitoring mode
a For details of the operation method, etc., see Testing and adjusting, Special functions of monitor panel
(EMMS).
WE051B1100 15
Monitor panel 1
Outline Caution items

q The monitor panel consists of the monitor section, q The caution items are checked constantly while
which indicates an caution when the machine has the engine is running.
any trouble, and the gauge section and display Caution items and alarm lamp flash at the same
panel, which display the machine condition con- time if there is an abnormality. The alarm buzzer
stantly. may sound at this time.
The monitor panel has a microcomputer, which
processes and displays the signals from the sen- Buzzer cancel switch
sors, solenoids, and controllers. q If this switch is operated while the alarm buzzer is
The items displayed on the monitor section and sounding, the buzzer is turned OFF temporarily.
gauge section are shown in "Monitor panel dis- While the buzzer is turned OFF, if a new trouble
play". which turns on the buzzer is detected, the buzzer
sounds again.
Operation
When power is turned ON a The lamp lights up and goes off at the intervals of
(when starting switch is turned "ON") about 0.8 seconds.
q All the LC segments and lamps of the monitor a When the ambient temperature is low (about
panel light up for 2 seconds and the alarm buzzer -10°C or lower), the flashing period of the lamp
sounds for 2 seconds. changes a little. This is normal, however.
Check before starting
q 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.
16 WE051B1100
Input and output signals
AMP070-20P [CN-S03] AMP070-12P [CN-S04]

signals signals
1 Power supply (24V) Input 1 CAN0-H Input/output
2 Power supply (24V) Input 2 CAN0-H Input/output
3 GND - 3 CAN0-L Input/output
4 GND - 4 CAN0-L Input/output
5 Constant power supply (24V) Input 5 CAN shield -
6 Constant power supply (24V) Input 6 N.C. -
7 Starting switch (C) Input 7 N.C. -
8 Night lighting Input 8 N.C. -
9 Preheating Input 9 Alternator (R) Input
10 N.C. - 10 Fuel level Input
Coolant temperature sensor
11 N.C. - 11 Input
(for monitor)
12 Engine oil pressure sensor Input 12 Power train oil temperature sensor Input
13 N.C. -
14 N.C. -
15 N.C. -
16 Service switch Input
17 N.C. -
18 Alarm buzzer Output
19 N.C. -
20 N.C. -
WE051B1100 17
Monitor panel display
18 WE051B1100
Display Caution Alarm

Display
No. Display item Display range Display method lamp buzzer Remarks
section color
Output Output
Corresponding segment
1a Gauge See diagram at left - - Black LCD
(1 place) All light up
Coolant temperature 104°C or lower OFF OFF OFF
1b Caution 104°C - 110°C Flashing FLASHING OFF Red LED
110°C or higher Flashing FLASHING ON
Power train oil 120°C or lower OFF OFF OFF
level
2b Caution 120°C - 130°C Flashing Flashing OFF Red LED
130°C or higher Flashing Flashing ON
Hydraulic oil
100°C or lower OFF OFF OFF
temperature
3b Caution 100°C - 110°C Flashing Flashing OFF Red LED
110°C or higher Flashing Flashing ON
At corresponding segment
4 Gauge Fuel level See diagram at left - -
or lower all light up
P: Parking brake lever in
"Lock" and PCCS lever in
Travel direction neutral
(P,N,F,R) N: PCCS lever in "Neutral"
F: PCCS lever in "Forward"
[∗1] R: PCCS lever in "Reverse"
Display panel A
Indicator 1: PCCS lever gear speed OFF OFF
(travel direction,
5 switch in "1st"
gear speed, Black LCD
Gear speed 2: PCCS lever gear speed
engine tachome-
(1,2,3) switch in "2nd"
ter)
3: PCCS lever gear speed
switch in "3rd"
At corresponding segment
Gauge See diagram at left - -
or lower all light up
[∗1] Time is counted while
Character
6 display
Display panel B 0 - 99999.9h engine is running - -
(service meter) (alternator is generating)
Lamp is OFF
OFF OFF
When charge is abnormal (while engine is stopped)
7 Charge level
(12V or lower) Lamp is flashing
Flashing OFF
(while engine is running)
Caution Red
Lamp is OFF
OFF OFF
Engine oil pressure Specified value or lower (while engine is stopped)
8
(H) (49kPa {0.5kg/cm2}) Lamp is flashing
Flashing ON
(while engine is running)
9 Pilot Preheating In preheating mode Lamp is ON OFF OFF Green
Before 30h or more OFF
After starting switch is
10 Maintenance turned "ON" OFF OFF Orange
Before 30h - Replacement time
Lamp lights up for
30 seconds
LED
11 Warning lamp See the "Caution lamp output" column of this table - - Red
Before 30h or more OFF
Replacement time Before 30h - Replacement time After starting switch Lamp
12 is ON OFF OFF Yellow
of filter and oil is turned "ON"
Flash-
Caution After replacement time for 30 seconds ing
• From when the starting switch is
turned "ON" in the fan reverse and
Lamp is ON
cleaning mode when the engine is
stopped
Check of opera-
13 • Fan and selector switch are operated OFF OFF Orange
tion of fan
while the engine is running
• Time to keep the power ON after the Flashing
starting switch is turned "OFF" in the
fan reverse and cleaning mode
∗1: For details of the operation in the service mode, see Testing and adjusting, Special functions of monitor panel (EMMS).
WE051B1100 19
Sensor 1
q Signals from the sensor are input to the monitor panel or controller.
q The sensors are classified into 4 types of contact, resistance, electromagnetic, and capacitor.
q Either side of a sensor of contact type is always connected to the chassis ground.
Name of sensor Type of sensor When normal When abnormal

Engine oil pressure Contact OFF ON
Coolant temperature Resistance - -
Power train oil temperature Resistance - -
Hydraulic oil temperature Resistance - -
Fuel level Resistance - -
Engine speed Electromagnetic - -
Transmission output shaft speed Electromagnetic - -
Pitch angle Capacitor - -
Engine oil pressure sensor
1. Plug 4. Diaphragm
2. Contact ring 5. Spring
3. Contact 6. Terminal
Function
q The engine oil pressure sensor is installed to the engine cylinder block. The diaphragm senses the oil pres-
sure. If the oil pressure lowers below the specified level, the switch is turned "ON".
20 WE051B1100
Coolant temperature sensor (for monitor)

Power train oil temperature sensor
Hydraulic oil temperature sensor
1. Connector 3. Thermistor
2. Plug
Function
q The coolant temperature sensor (for monitor) is installed to the engine cylinder block, the power train oil tem-
perature sensor to the power train outlet piping, and the hydraulic oil temperature sensor to the hydraulic pip-
ing. They sense the change of temperature as the change of resistance, and then generate signals.
The temperature signals are sent through the network to the monitor panel or transmission and steering con-
troller and used to control the cooling fan.
Coolant temperature sensor (for preheating)
1. Connector 3. Thermistor
2. Plug
Function
q The coolant temperature sensor (for preheating) is installed to the engine cylinder block. It senses the change
of temperature as the change of resistance of thermistor, and then generates A signal.
WE051B1100 21
Fuel level sensor
1. Connector 5. Spring
2. Float 6. Contact
3. Arm 7. Spacer
4. Body
Function
q The fuel level sensor is installed to the side of the fuel tank. Its float moves up and down accordingly 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.
22 WE051B1100
Engine speed sensor
1. Connector 3. Sensor
2. O-ring
Function
q The engine speed sensor is installed to the ring gear of the flywheel housing. It generates pulse voltages as
the gear rotates.
Transmission output shaft speed sensor
1. Magnet 4. Terminal
2. Wire 5. Boots
3. Housing 6. Connector
Function
q The transmission output shaft speed sensor is installed to the bevel gear of steering case. It generates pulse
voltages as the gear rotates.
WE051B1100 23
Machine pitch angle sensor
1. Body 3. Wire
2. Tube 4. Connector
Function
q The machine pitch angle sensor is installed to the ROPS board in the filter cover on the right side of the chas-
sis.
q There are multiple electrodes and oil in this sensor. The changes of the oil level made by inclination of the
machine are sensed by the differences in electrostatic capacity between the electrodes, and then those differ-
ences are converted into voltage signals.
24 WE051B1100
WE051C0100
Bulldozer
1Shop Manual
D61EX-15
D61PX-15

Standard value table 1

Standard value table for engine........................................................................................ 2
Standard value table for chassis ...................................................................................... 3
Standard value table Shop Manual
Standard value table for engine 1
D61EX-15
Machine model
D61PX-15
Engine SA6D114E-2
Standard value for
Item Measurement conditions Unit Service limit value
new machine
High idling 2,000±50 2,000±50
Engine speed Low idling rpm 900±50 900±50
Rated speed 1,800 -
Air supply kPa Min. 79.8 63.8
At rated output
(Boost pressure) {mmHg} {Min. 600} {480}
At sharp acceleration Bosch Max. 5.5 6.5
Exhaust gas color
At high idling index Max. 1.0 2.0
Valve clearance Intake valve 0.33 -
mm
(Normal temperature) Exhaust valve 0.71 -
Oil temperature: 40 - 60°C MPa Min. 3.1
Compression pressure
{kg/cm2} {Min. 32} -
(SAE30)
(Engine speed) rpm (200 - 250)
Blow-by pressure (Water temperature: Operating range) kPa Max. 0.49 0.98
(SAE30 or SAE15W-40) At rated output {mmH2O} {Max. 50} {100}
(Water temperature: Operating range)
294 - 490 206
At high idling {3.0 - 5.0} {2.1}
(SAE30 or SAE15W-40)
At high idling kPa 245 - 441 176
Oil pressure (SAE10W) {kg/cm2} {2.5 - 4.5} {1.8}
At low idling Min. 147 69
(SAE30 or SAE15W-40) {Min. 1.5} {0.7}
At low idling Min. 98 69
(SAE10W) {Min. 1.0} {0.7}
Oil temperature Whole speed range (Inside oil pan) °C 90 - 110 Min. 120
Deflection when pressed Air conditioner
Belt tension with finger force of compressor - mm 15 - 18 -
approx. 98 N {10 kg} crankshaft pulley
2 WE051C0100
Shop Manual Standard value table
Standard value table for chassis 1

D61EX-15
Machine model D61EX-15
Cate- Standard value Service

Item Measurement conditions Unit
gory for new machine limit value
• Engine coolant temperature:
Decelerator pedal Within operating range +50 +50
Engine speed
speed • Power train oil temperature: 1,150 +0 1,150 +0

Within operating range
rpm
• Hydraulic oil temperature:
Torque converter Within operating range
1,620±100 1,500
stall speed • Decelerator pedal speed: Press pedal.
• Torque converter stall speed: F3
Neutral to
30±10 30±10
Forward Forward
and reverse Neutral to
30±10 30±10
PCCS • Engine stopped Reverse
lever • Center of lever knob Neutral to 40±15 40±15
Left (Play: Max. 3) (Play: Max. 3)
Steering
Neutral to 40±15 40±15
Right (Play: Max. 3) (Play: Max. 3)
• Engine stopped
Decelerator pedal 52±9 52±9
• Center of pedal
• Engine low idling
Control lever/ Pedal stroke
Brake pedal All stroke 79±12 79±12

• Center of pedal
mm
Neutral to
72±11 72±11
Raise/Float
Straight Neutral to
52±9 52±9
tiltdozer Lower
Neutral to
54±8 54±8
• Engine low idling Left/Right tilt
Blade • Hydraulic oil Neutral to
47±9 47±9
lever temperature: 45 - 55°C Raise/Float
Power • Center of lever knob Neutral to
71±11 71±11
angle and Lower
power Neutral to
52±8 52±8
tiltdozer Left/Right tilt
Neutral to
° (deg) 15±3 15±3
Left/Right angle
Ripper lever • Hydraulic oil Neutral to
mm 54±8 54±8
(If equipped) temperature: 45-55°C Raise/Lower
• Center of lever knob
WE051C0100 3

Neutral to
56.9±19.6 56.9±19.6
Forward/
{5.8±2.0} {5.8±2.0}
Forward Reverse
and reverse Forward/
51±19.6 51±19.6
Reverse to
{5.2±2.0} {5.2±2.0}
PCCS • Engine stopped Neutral
lever • Center of lever knob
Neutral to 24.5±9.8 24.5±9.8
Left {2.5±1.0} {2.5±1.0}
Steering
Neutral to 27.4±9.8 27.4±9.8
Right {2.8±1.0} {2.8±1.0}
• Engine low idling 73.5±24.5 73.5±24.5

Decelerator pedal
• Center of pedal {7.5±2.5} {7.5±2.5}
Control lever/ pedal
• Engine low idling 510±88 666

Brake pedal
operating effort
• Center of pedal {52±9.0} {68}

Neutral to N 29.4±9.8 29.4±9.8
Raise/Lower {kg} {3.0±1.0} {3.0±1.0}
Straight Neutral to 74.5±19.6 74.5±19.6
tiltdozer Float {7.6±2.0} {7.6±2.0}
Neutral to 25.5±9.8 25.5±9.8
• Engine low idling Left/Right tilt {2.6±1.0} {2.6±1.0}
Blade • Hydraulic oil Neutral to 25.5±9.8 25.5±9.8
lever temperature: 45-55°C Raise/Lower {2.6±1.0} {2.6±1.0}
Power • Center of lever knob Neutral to 69.6±19.6 69.6±19.6
angle and Float {7.1±2.0} {7.1±2.0}
power Neutral to 25.5±9.8 25.5±9.8
tiltdozer Left/Right tilt {2.6±1.0} {2.6±1.0}
Neutral to 4.4±1.0 4.4±1.0
Left/Right angle {0.45±0.1} {0.45±0.1}
• Engine low idling Neutral to 25.5±9.8 25.5±9.8
Ripper lever • Hydraulic oil Raise {2.6±1.0} {2.6±1.0}
(If equipped) temperature: 45-55°C Neutral to 25.5±9.8 25.5±9.8
• Center of lever knob Lower {2.6±1.0} {2.6±1.0}
Engine low 0.1 - 0.5 0.1 - 0.5
Torque converter idling {1 - 5} {1 - 5}
inlet pressure Engine high Max. 0.88 Max. 0.88
Power train oil pressure
idling {Max. 9} {Max. 9}

Engine low 0.09 - 0.29 0.09 - 0.29
Torque converter idling {0.9 - 3} {0.9 - 3}
outlet pressure • Power train oil Engine high MPa 0.44 - 0.69 0.44 - 0.69
temperature: 70 - 80°C idling {kg/cm2} {4.5 - 7} {4.5 - 7}
Engine low 2.65±0.1 Min. 2.35

idling {27±1.0} {Min. 24}
Transmission main
relief pressure +0.24
Engine high 2.84 +0 Min. 2.65
idling +3 {Min. 27}
{29 +0 }
4 WE051C0100

idling {27±1.0} {Min. 24}
Transmission
+0.24
F clutch pressure Engine high 2.84 +0 Min. 2.65
idling +3 {Min. 27}
{29 +0 }
idling {27±1.0} {Min. 24}
Transmission
+0.24
R clutch pressure Engine high 2.84 +0 Min. 2.65
idling +3 {Min. 27}
{29 +0 }
idling {27±1.0} {Min. 24}
Transmission
+0.24
1st clutch pressure Engine high 2.84 +0 Min. 2.65

idling +3 {Min. 27}
{29 +0 }
• Power train oil
idling {27±1.0} {Min. 24}
Transmission temperature: 70 - 80°C
+0.24
2nd clutch pressure Engine high 2.84 +0 Min. 2.65
idling MPa +3 {Min. 27}
{29 +0 }
{kg/cm2}
idling {27±1.0} {Min. 24}
Transmissiom
+0.24
3rd clutch pressure Engine high 2.84 +0 Min. 2.65
idling +3 {Min. 27}
{29 +0 }
Transmission
lubricating oil Engine high 0.09 - 0.29 0.09 - 0.29
pressure idling {0.9 - 3.0} {0.9 - 3.0}
(For reference)
Engine low 2.75 - 2.94 2.55
idling {28 - 30} {26}
Brake pressure
Engine high 2.75 - 2.94 2.55
idling {28 - 30} {26}
+2.0
Steering relief 35.1 -3.0 Min. 29.9
oil pressure
pressure +20 {Min. 305}

• Hydraulic oil temperature: 45-55°C {358 -30 }
HSS
LS pressure • Engine high idling

33.1±2.0 Min. 28.9
(Load sensing
{338±20} {Min. 295}
pressure)
• Flat road F1 3.3±0.2 3.3±0.2
Performance of
F2 5.6±0.3 5.6±0.3
power train

• Power train oil temperature: F3 8.9±0.5 8.9±0.5
Travel speed km/h
70 - 80°C R1 4.3±0.3 4.3±0.3
• Engine high idling
R2 7.4±0.4 7.4±0.4
• Run up distance: 10 - 30 m
• Measuring distance: 20 m R3 11.4±0.6 11.4±0.6
WE051C0100 5

+1.37 +1.37
Engine high 3.43 +0 3.43 +0
Unload pressure
idling +14 +14
{35 +0 } {35 +0 }
Engine low Min. 19.1 Min. 19.1
Blade lift relief idling {Min. 195} {Min. 195}
pressure • Hydraulic oil tempera- Engine high 20.6±0.98 17.6
Work equipment oil pressure
ture: 45 - 55°C idling {210±10} {180}

• Unload pressure: Set all
equipment in neutral.
Blade tilt relief idling {Min. 195} {Min. 195}
• Relief pressure: Set cyl-
pressure inder to stroke end Engine high MPa 20.6±0.98 17.6
idling {kg/cm2} {210±10} {180}
Ripper lift relief idling {Min. 195} {Min. 195}
pressure Engine high 20.6±0.98 17.6
idling {210±10} {180}
Control circuit main
3.72±0.49 3.72±0.49
pressurer
• Hydraulic oil temperature: 45 - 55°C {38±5} {38±5}
(HSS, PPC, fan)
PPC valve output 3.72±0.49 3.72±0.49
pressure {38±5} {38±5}
aSee figure A
• Hydraulic oil Raise 2.5±0.2 3.0
temperature: 45 - 55°C
Blade lift • Apply no load to blade.
• Between ground level
and rising end of blade Lower 1.8±0.2 2.1
Power angle
aSee figure B and 2.5±0.2 3.0
Left tilt
• Hydraulic oil Power tiltdozer

temperature: Straight tiltdozer
45 - 55°C and 2.5±0.2 3.0
• Apply no load to semi-U dozer
Blade tilt
blade. Power angle
• Between left tilt and 2.5±0.2 3.0
Work equipment speed
Right tilt
end and right tilt Power tiltdozer

Work equipment
end Straight tiltdozer

• Engine high idling and 2.5±0.2 3.0
semi-U dozer sec
aSee figure C Low idling 2.4±0.2 2.9
Raise
• Hydraulic oil tem-

perature: 45 - 55°C High idling 1.4±0.2 1.9
Ripper lift • Apply no load to
(If equipped) ripper. Low idling 1.9±0.2 2.4
Lower
• Between ground
level and rising end
High idling 1.1±0.2 1.6
of blade
aSee figure D
• Hydraulic oil Angle
temperature: 45 - 55°C 3.5±0.3 4.4
(L.H.)
• Blade edge 300 mm
above the ground
Blade angle
• Body level on the flat
ground
Angle
• Left angle end - Right 3.5±0.3 4.4
(R.H.)
angle end
6 WE051C0100

• Hydraulic oil temperature: 45 - 55°C
• Set lever to full storoke
Time lag
• Lower blade from max. rising position and

Blade sec Max. 1.0 Max. 1.5
measure time after blade comes in
contact with ground until idler is lifted.
• High idling
aSee figure E
Hydraulic drift
• Engine stopped Max. 100 Max. 100
of lifted blade
• Height of the lower edge of blade h
hydraulic drift
Work equipment
Left tilt
Hydraulic drift
aSee figure F Max. 200 Max. 200

Hydraulic drift • Hydraulic oil temperature: 45 - 55°C mm/
of tilted blade • Engine stopped 15 min
Right tilt
• Reduction of blade tip height Max. 200 Max. 200
aSee figure G
Hydraulic drift • Hydraulic oil temperature: 45 - 55°C
of lifted ripper • Engine stopped Max. 50 Max. 50
(If equipped) • Height of the lower edge of shank h
hydraulic drift (15 min)
Blade tilt
from cylinder
• Engine high idling 4 16

Leakage
cylinder • Hydraulic oil temperature: 45 - 55°C

cc/min
Blade lift • Relieve cylinder and measure leakage for
1 minute. 4 16
cylinder
HSS Motor
• Steering lever: Full

Leakage • Transmission lever: Neutral l/min Max. 15 30
• Brake pedal: Pressed
• Engine low
idling
• Coolant
Min. speed
temperature,
800±50 700
Power train
oil tempera-
• Hydraulic oil ture 80°C or
temperature: below
Fan speed rpm
45 - 55°C
Cooling fan
• Fan forward
Max. speed
• Engine high
idling +100
1,700 +0 1,600
• Fan 100%
speed mode

• Fan forward MPa 16.7 - 19.6 14.7
Fan pump pressure
• Fan 100% speed mode {kg/cm2} {170 - 200} {150}
WE051C0100 7
D61PX-15
Machine model D61PX-15

Decelerator pedal Within operating range +25 +25
Engine speed
speed • Power train oil temperature: 1,150 +0 1,150 +0

rpm
• Hydraulic oil temperature:
Torque converter Within operating range
1,620±100 1,500
stall speed • Decelerator pedal speed: Press pedal.
• Torque converter stall speed: F3
Neutral to
30±10 30±10
Forward Forward
and reverse Neutral to
30±10 30±10
PCCS • Engine stopped Reverse
lever • Center of lever knob Neutral to 40±15 40±15
Left (Play: Max. 3) (Play: Max. 3)
Steering
Neutral to 40±15 40±15
Right (Play: Max. 3) (Play: Max. 3)
• Engine stopped
Decelerator pedal 52±9 52±9
Control lever/pedal stroke
• Center of pedal
Brake pedal All stroke 79±12 79±12
• Center of pedal
mm
Neutral to
72±11 72±11
Raise/Float
Straight Neutral to
52±9 52±9
tiltdozer Lower
Neutral to
54±8 54±8
• Engine low idling Left/Right tilt
Blade • Hydraulic oil Neutral to
47±9 47±9
lever temperature: 45 - 55°C Raise/Float
Power • Center of lever knob Neutral to
71±11 71±11
angle and Lower
power Neutral to
52±8 52±8
tiltdozer Left/Right tilt
Neutral to
° (deg) 15±3 15±3
Left/Right angle
Neutral to 56.9±19.6 56.9±19.6
Forward Forward/Reverse {5.8±2.0} {5.8±2.0}
Control lever/pedal
and reverse Forward/Reverse 51±19.6 51±19.6

operating effort
PCCS • Engine stopped to Neutral {5.2±2.0} {5.2±2.0}

lever • Center of lever knob Neutral to N 24.5±9.8 24.5±9.8
Left {kg} {2.5±1.0} {2.5±1.0}
Steering
Neutral to 27.4±9.8 27.4±9.8
Right {2.8±1.0} {2.8±1.0}
• Engine low idling 73.5±24.5 73.5±24.5
Decelerator pedal
• Center of pedal {7.5±2.5} {7.5±2.5}
8 WE051C0100

• Engine low idling 510±88 666
Brake pedal
• Center of pedal {52±9.0} {68}
Neutral to 29.4±9.8 29.4±9.8
Raise/Lower {3.0±1.0} {3.0±1.0}
Straight Neutral to 74.5±19.6 74.5±19.6
Control lever/ pedal
tiltdozer Float {7.6±2.0} {7.6±2.0}

operating effort
Neutral to 25.5±9.8 25.5±9.8

• Engine low idling Left/Right tilt N {2.6±1.0} {2.6±1.0}
Blade • Hydraulic oil Neutral to {kg} 25.5±9.8 25.5±9.8
lever temperature: 45 - 55°C Raise/Lower {2.6±1.0} {2.6±1.0}
Power • Center of lever knob Neutral to 69.6±19.6 69.6±19.6
angle and Float {7.1±2.0} {7.1±2.0}
power tilt- Neutral to 25.5±9.8 25.5±9.8
dozer Left/Right tilt {2.6±1.0} {2.6±1.0}
Neutral to 4.4±1.0 4.4±1.0
Left/Right angle {0.45±0.1} {0.45±0.1}
Engine low 0.1 - 0.5 0.1 - 0.5
Torque converter idling {1 - 5} {1 - 5}
inlet pressure Engine high Max. 0.88 Max. 0.88
idling {Max. 9} {Max. 9}
Engine low 0.09 - 0.29 0.09 - 0.29
Torque converter idling {0.9 - 3} {0.9 - 3}
outlet pressure Engine high 0.44 - 0.69 0.44 - 0.69
idling {4.5 - 7} {4.5 - 7}

idling {27±1.0} {Min. 24}
Transmission main
relief pressure +0.24
idling +3
{29 +0 } {Min. 27}

• Power train oil MPa
idling {27±1.0} {Min. 24}
Transmission temperature: 70 - 80°C {kg/cm2}
F clutch pressure +0.24
idling +3
{29 +0 } {Min. 27}

idling {27±1.0} {Min. 24}
Transmission
R clutch pressure +0.24
idling +3
{29 +0 } {Min. 27}

idling {27±1.0} {Min. 24}
Transmission
1st clutch pressure +0.24
idling +3
{29 +0 } {Min. 27}
WE051C0100 9


idling {27±1.0} {Min. 24}
Transmission
2nd clutch pressure +0.24
idling +3
{29 +0 } {Min. 27}

idling {27±1.0} {Min. 24}
Transmission
3rd clutch pressure • Power train oil +0.24
idling +3
{29 +0 } {Min. 27}
Transmission MPa
lubricating oil Engine high {kg/cm2} 0.09 - 0.29 0.09 - 0.29
pressure idling {0.9 - 3.0} {0.9 - 3.0}
(For reference)
Engine low 2.75 - 2.94 Min. 2.55
idling {28 - 30} {Min. 26}
Brake pressure
Engine high 2.75 - 2.94 Min. 2.55
idling {28 - 30} {Min. 26}
+2.0
Steering relief 35.1 -3.0 Min. 29.9
oil pressure
pressure +20
{358 -30 } {Min. 305}
HSS
LS pressure • Engine high idling

33.1±2.0 Min. 28.9
(Load sensing
{338±20} {Min. 295}
pressure)
• Flat road F1 3.3±0.2 3.3±0.2
Performance of
F2 5.6±0.3 5.6±0.3
power train
• Power train oil temperature: F3 8.9±0.5 8.9±0.5

Travel speed km/h
70 - 80°C R1 4.3±0.3 4.3±0.3
R2 7.4±0.4 7.4±0.4
• Run up distance: 10 - 30 m
• Measuring distance: 20 m R3 11.4±0.6 11.4±0.6
+1.37 +1.37
• Hydraulic oil Engine high 3.43 +0 3.43 +0
Unload pressure
temperature: 45 - 55°C idling +14
{35 +0 }
+14
{35 +0 }
• Unload pressure: Set all MPa
equipment in neutral. {kg/cm2}
Blade lift relief idling {Min. 195} {Min. 195}
Work equipment oil pressure

pressure inder to stroke end Engine high 20.6±0.98 17.6
idling {210±10} {180}
• Hydraulic oil tempera- Engine low Min. 19.1 Min. 19.1
ture: 45 - 55°C idling {Min. 195} {Min. 195}
Blade tilt relief • Unload pressure: Set all
pressure equipment in neutral.
Engine high 20.6±0.98 17.6
inder to stroke end idling MPa {210±10} {180}
{kg/cm2}
Control circuit main
3.72±0.49 3.72±0.49
pressure
• Hydraulic oil temperature: 45 - 55°C {38±5} {38±5}
(HSS, PPC, fan)
PPC valve output 3.72±0.49 3.72±0.49
pressure {38±5} {38±5}
10 WE051C0100

aSee figure A
• Hydraulic oil Raise 2.5±0.2 3.0
Blade lift • Apply no load to blade.
• Between ground level
and rising end of blade Lower 1.8±0.2 2.1
aSee figure B
• Hydraulic oil Power angle
Left tilt
temperature: and 2.5±0.2 3.0
Work equipment speed
45 - 55°C Power tiltdozer

Blade tilt • Apply no load to
blade. Straight tiltdozer
Right tilt
• Between left tilt end
Work equipment
and 2.5±0.2 3.0

and right tilt end semi-U dozer
sec
aSee figure D
• Hydraulic oil Angle
temperature: 45 - 55°C 3.5±0.3 4.4
(L.H.)
• Blade edge 300mm
above the ground
Blade angle
• Body level on the flat
ground
Angle
• Left angle end -Right 3.5±0.3 4.4
(R.H.)
angle end
• Set lever to full stroke
Time lag
• Lower blade from max. rising position and

Blade Max. 1.0 Max. 1.5
measure time after blade comes in contact
with ground until idler is lifted.
• High idling
aSee figure E
Hydraulic drift
• Engine stopped Max. 100 Max. 100
of lifted blade
• Height of the lower edge of blade h
Hydraulic drift
hydraulic drift
mm/
Right tilt Left tilt
Work equipment
15 min Max. 200 Max. 200

aSee figure F
Hydraulic drift • Hydraulic oil temperature: 45 - 55°C
of tilted blade • Engine stopped
• Reduction of blade tip height Max. 200 Max. 200
Blade tilt
Leakage from
• Engine high idling 4 16

cylinder
cylinder

cc/min
• Relieve cylinder and measure leakage for
Blade lift
1 minute. 4 16
cylinder
• Steering lever: Full
motor
HSS
Leakage • Transmission lever: Neutral l/min Max. 15 30

• Brake pedal: Pressed
WE051C0100 11

• Engine low
idling
• Coolant
Min. speed
temperature,
800±50 700
Power train
• Hydraulic oil
oil tempera-
temperature:
Fan speed ture 80°C or rpm
45 - 55°C
Cooling fan
below
• Fan forward
Max. speed
• Engine high
idling +100
1,700 +0 1,600
• Fan 100%
speed mode
• Fan forward MPa 16.7 - 19.6 14.7
Fan pump pressure
• Fan 100% speed mode {kg/cm2} {170 - 200} {150}
Illustration related to standard value table
Fig. A Fig. C
Fig. D
Fig. B
12 WE051C0100
Fig. E
Fig. F
Fig. G
WE051C0100 13
14 WE051C0100
WE051D0100
Bulldozer
1Shop Manual
D61EX-15
D61PX-15

Testing and adjusting 1

Testing and adjusting (1/2) ............................................................................................... 3
Tools for testing, adjusting and troubleshooting............................................................ 3
Measuring engine speed .............................................................................................. 5
Measuring intake air pressure (boost pressure) ........................................................... 7
Measuring exhaust color............................................................................................... 8
Adjusting valve clearance ............................................................................................. 9
Measuring compression pressure............................................................................... 12
Measuring blow-by pressure....................................................................................... 14
Testing and adjusting fuel injection timing .................................................................. 15
Measuring engine oil pressure.................................................................................... 18
Testing and adjusting air conditioner compressor belt tension ................................... 19
Adjusting engine speed sensor................................................................................... 19
Adjusting fuel control linkage ...................................................................................... 20
Measuring power train oil pressure............................................................................. 24
Adjusting transmission speed sensor (replacement procedure) ................................. 28
Testing and adjusting Shop Manual
Simple method of testing brake performance .............................................................29

Adjusting brake pedal .................................................................................................30
Adjusting parking brake lever......................................................................................32
Emergency escape method when power train has a trouble ......................................33
Adjusting idler clearance .............................................................................................37
Inspecting wear of sprocket ........................................................................................37
Testing and adjusting track shoe tension ....................................................................38
Testing and adjusting work equipment and HSS oil pressure .....................................39
Testing control circuit main pressure...........................................................................43
Measuring PPC valve output pressure .......................................................................44
Adjusting play of work equipment PPC valve .............................................................47
Measuring internal leakage of work equipment cylinder .............................................48
Adjusting safety lock lever of work equipment ............................................................49
(If PPC accumulator is not installed)........................................................................50
(If PPC accumulator is installed)..............................................................................50
Bleeding air from work equipment cylinder .................................................................51
Measuring fan pump circuit pressure..........................................................................52
Measuring fan motor speed ........................................................................................53
Measuring HSS motor oil leakage ..............................................................................54
Bleeding air from fan pump.........................................................................................54
Testing and adjusting operator's cab...........................................................................55
2 WE051D0100
Shop Manual Testing and adjusting
Testing and adjusting (1/2)

Tools for testing, adjusting and troubleshooting 1
Symbol
Testing and
Q'ty
Part No. Name Remarks
adjusting item
1 799-101-5002 Hydraulic tester 1

Intake air pressure
A -101 to 200 kPa
(Boost pressure) 2 799-201-2202 Boost gauge kit 1
{-760 to -1,500 mmHg}
Water temperature
B 799-101-1502 Digital temperature gauge 1 -99.9 to 1,299°C
and oil temperature
1 799-201-9000 Handy smoke checker 1 Discoloration: 0 - 70% (with stan-
dard color)
Exhaust color C Commercially
2 Smoke meter 1 (Discoloration x 1/10 C Bosch
available
index)
1 795-799-1131 Gear 1
Valve clearance D 2 Purchased Feeler gauge 1
3 795-799-1900 Pin assembly 1
1 795-790-3610 Compression gauge 1 For 114 Series engine
Compression
E 2 795-790-3710 Tester 1 For 114 Series engine
pressure
3 795-799-1171 Puller 1
Blow-by pressure F 799-201-1504 Blow-by kit 1
1 795-799-1131 Gear 1 For 102 and 114 Series engines
Fuel injection timing G 2 795-799-1900 Pin assembly 1 For 102 and 114 Series engines
3 795-799-1950 Lock pin 1 For 102 and 114 Series engines
Pressure gauge:
799-101-5002 Hydraulic tester 1 2.5, 5.9, 39.2, 58.8 MPa
1 {25, 60, 400, 600 kg/cm2}
Engine oil pressure H Pressure gauge:
790-261-1203 Digital hydraulic tester 1
58.8 MPa {600 kg/cm2}
Pressure gauge:
2 799-401-2320 Hydraulic tester 1
1.0 MPa {10 kg/cm2}
799-101-5002 Hydraulic tester 1 *Common to H1
1
Power train Pressure gauge:
J 2 799-401-2320 Hydraulic tester 1
pressure 1.0 MPa {10 kg/cm2}
799-101-5220 Nipple (10 x 1.25 mm) 1
3
07002-11023 O-ring 1
19M-06-32820 Switch assembly 1
1
134-06-72810 Wiring harness 1
Emergency escape 7824-66-6430 Redundant resistance 1
when power train K 2
7827-10-1520 Redundant resistance 1
has trouble
3 790-190-1600 Pump assembly 1
4 144-865-6260 Elbow (R 3/8 x M18) 1
1
Testing and 790-261-1203 Digital hydraulic tester 1
adjusting work 799-101-5220 Nipple (10 x 1.25 mm) 2
L 2
equipment and HSS 07002-11023 O-ring 2
oil pressure 790-261-1321 Elbow 1
3
07002-11023 O-ring 1
WE051D0100 3
Symbol
Testing and
Q'ty
Part No. Name Remarks
adjusting item

Testing control 1
circuit main M
799-101-5220 Nipple (10 x 1.25 mm) 1
pressure 2
07002-11023 O-ring 1
1
Measuring PPC 790-261-1203 Digital hydraulic tester 1
valve output N Oil pressure pickup
pressure 799-401-3100 1
2 adapter (Size 02)
02896-11008 O-ring 1
Measuring internal
Commercially
leakage of work O Measuring cylinder 1
available
equipment cylinder
Measuring fan 1
pump circuit P
799-101-5220 Nipple (10 x 1.25 mm) 1
pressure 2
07002-11023 O-ring 1
Measuring fan
Q 799-205-1100 Tachometer kit 1
motor speed
79A-264-0021 0 - 294 N {0 - 30 kg} 1
Operating effort R
79A-264-0091 0 - 490 N {0 - 50 kg} 1
Stroke and Commercially
S Scale 1
hydraulic drift available
Work equipment Commercially
T Stopwatch 1
speed available
Voltage or Commercially
U Tester 1
resistance available
4 WE051D0100
Measuring engine speed 1 2. Measuring low idling speed

1) Start the engine and set the fuel control lever
a Measure the engine speed under the following in the low idling position.
condition. 2) Set the PCCS lever and work equipment con-
q Engine coolant temperature: trol lever in neutral and measure the engine
Within operating range speed.
q Hydraulic oil temperature:
Within operating range 3. Measuring high idling speed
q Power train oil temperature: 1) Start the engine and set the fuel control dial in
Within operating range the high idling position.
2) Set the PCCS lever and work equipment con-
1. Preparation work trol lever in neutral and measure the engine
Turn the starting switch ON and set the monitor speed.
panel in the "Monitoring mode" to prepare for mea-
suring the engine speed. 4. Measuring decelerator pedal engine speed
a For the operating method, see "Special func- 1) Start the engine and set the fuel control dial in
tions of monitor panel (EMMS)". the high idling position.
q Monitoring code: 01000 (Engine speed) 2) Set the PCCS lever and work equipment con-
trol lever in neutral, press the decelerator
pedal, and measure the engine speed.
5. Measuring torque converter stall speed

1) Start the engine and set the fuel control dial in
the low idling position.
2) Press the brake pedal securely and set the
parking brake lever in the Free position and
set the PCCS lever in the Forward and the 3rd
gear speed position.
a Check that the upper display unit of the
monitor panel is set in the normal display
state showing [F3], then go to the next
step.
a Keep the steering unit in neutral.
3) Press the decelerator pedal and set the fuel
control dial in the high idling position.
4) Return the decelerator pedal slowly until the
torque converter is stalled with the engine in
high idling.
k Keep the brake pedal pressing securely
and keep your right foot on the decelerator
pedal for safety until the work is finished.
5) Just after the power train oil temperature
gauge reads the top line of the green range,
return the PCCS lever to neutral.
WE051D0100 5
6) Repeat above steps 2) - 5) 3 times.

7) Perform steps 2) - 4) again, and measure the
engine speed about 5 seconds after the power
train oil temperature gauge reads the top line
of the green range.
a After finishing measurement, return the
PCCS lever to neutral and lower the
power train oil temperature with the
engine in high idling.
a The engine speed can be measured also
by the following operation.
q "Pm clinic auxiliary mode" on the mon-
itor panel
q When the monitor panel is in the nor-
mal display state, the display in the
multi-information section changes
between service meter and engine
speed every time the information
switch is turned to the right or left.
6 WE051D0100
Measuring intake air pressure 3. Install nipple (R 1/4) of hydraulic tester A1, and
(boost pressure) 1 connect gauge [2] of boost gauge kit A2 to the
tester.
a Measuring instruments for intake air pressure
(boost pressure) 4. Run the engine at a medium or higher speed and
drain the oil from the hose.
a Insert the joint of the gauge and hose half way
Symbol Part No. Part Name
and open the self-seal on the hose side
1 799-101-5002 Hydraulic tester repeatedly, and the oil will be drained.
A
2 799-201-2202 Boost gauge kit a If Pm kit (A) is available, the air-bleeding cou-
pling (790-261-1130) in the kit may be used.
a If any oil is left in the hose, the gauge does not
k When installing or removing the measuring work. Accordingly, be sure to drain the oil.
instrument, take care not to touch a hot part of
the engine. 5. Measure the intake air pressure (boost pressure)
a Measure the intake air pressure (boost pressure) when the torque converter is stalled with the
under the following conditions. engine in high idling.
q Engine coolant temperature: a For the procedure for stalling the torque con-
Within operating range verter, see "Measuring engine speed".
q Power train oil temperature: a Normally, the intake air pressure (boost pres-
Within operating range sure) should be measured while the engine is
q Hydraulic oil temperature: operated at the rated output. In the field, how-
Within operating range ever, an approximate value can be obtained
by stalling the torque converter.
1. Open the left side cover of the engine.
2. Remove air intake connector boost pressure pick-

up plug (PT 1/4) (1).
6. After finishing measurement, remove the measur-

ing instruments and return the removed parts.
WE051D0100 7
Measuring exhaust color 1

a Measuring instrument for exhaust gas color
Symbol Part No. Name

1 799-201-9000 Handy smoke checker
C Commercially
2 Smoke meter
available
k When installing or removing the measuring instru-

ments, take care not to touch a hot part.
a 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. 2) Connect the probe hose, receptacle of the
a Measure the exhaust gas color under the following accelerator switch, and air hose to smoke
conditions. meter C2.
q Engine coolant temperature: a Limit the supplied air pressure to 1.5 MPa
Within operating range {15 kg/cm2}.
3) Connect the power cable to a receptacle of AC
1. Measuring with handy smoke checker C1 100 V.
1) Attach a filter paper sheet to smoke checker a Before connecting the cable, check that
C1. the power switch of the smoke meter is
2) Insert the exhaust gas intake pipe into exhaust turned off.
pipe (1). 4) Loosen the cap nut of the suction pump and fit
3) Start the engine. the filter paper.
4) Accelerate the engine sharply or run it at high a Fit the filter paper securely so that the
idling, and operate the handle of smoke exhaust gas will not leak.
checker C1 to make the filter paper absorb the 5) Turn on the power switch of smoke meter C2.
exhaust gas.
6) Start the engine.

7) Accelerate the engine sharply or run it at high
5) Remove the filter paper and compare it with
idling, press the accelerator pedal of smoke
the attached scale to make decision.
meter C2, and collect the exhaust gas into the
6) After finishing measurement, remove the mea-
filter paper.
suring instruments and return the removed
8) Place the contaminated filter paper on the
parts.
clean filter paper (at least 10 sheets) in the fil-
ter paper holder and read the indicated value.
2. Measuring with smoke meter C2
1) Insert probe [1] of smoke meter C2 into the
outlet of exhaust pipe (1), and fix it to the
parts.
exhaust pipe with a clip.
8 WE051D0100
Adjusting valve clearance 1 5. Remove plate (4) from the flywheel housing.
a Just loosening two plate-mounting bolts (11)
a Adjusting instrument for valve clearance gets plate (4) removed.

1 795-799-1131 Gear
Commercially
D 2 Feeler gauge
available
3 795-799-1900 Pin assembly
1. Remove the inspection cover from the left side of

radiator guard.
2. Remove cylinder head cover (1). For details, see

DISASSEMBLY AND ASSEMBLY, Disassembly
and Assembly of Cylinder Head Assembly.
6. Remove cap (5).
3. Remove the left side cover of the engine.
4. Remove the mounting bolts of washer tank ass'y 7. Install gear D1.
(2) and air conditioning receiver (3), and fix them
with a rope, etc.
WE051D0100 9
8. Turn the crankshaft to the forward direction with 9. When cylinder No.1 is at the compression top
gear D1 until the yellow paint (a) on the crank pul- dead center, adjust the valve clearance at the
ley reaches the uppermost point, and set cylinder point marked with q in the figure below according
No. 1 to the compression top dead center with tim- to the following procedures:
ing pin (6).
a At the top dead center, the rocker arm of cylin-
der No. 1 can be moved the distance of the
valve clearance with a hand. If the rocker arm
cannot be moved, the cylinder is not at the
compression top dead center. Turn the crank-
shaft one more time.
a Push-in depth of timing pin: 8 mm
a If it is difficult to check with the timing pin
installed in the engine, you may use another
metallic pin assembly D3.
a After setting cylinder No. 1 to the compression
top dead center, paint match-marks on the
crank pulley and front cover.
1) Insert feeler gauge D2 in the clearance (b)

between rocker arm (7) and valve stem (8),
and adjust the clearance with adjustment
screw (9).
a While the filler gauge is inserted, turn and
adjust the adjustment screw so that the
filler gauge can be moved with a little
force.
2) Fix adjustment screw (9) and tighten locknut
(10).
3 Locknut: 24±4 Nm {2.45±0.41 kgm}
a After tightening the locknut, check the
valve clearance again.
a After completing adjustment of all the
valves marked with q, return timing pin (6)
and go to the next step.
10 WE051D0100
10. Turn the crankshaft to the forward direction with

gear D1 until the match marks on the crank pulley
and front cover match, setting cylinder No. 6 at the
compression top dead center.
11. While cylinder No.6 is at the compression top dead

center, adjust the valve clearance marked with Q.
a Its procedure is the same as step 9.
12. After finishing adjustment, return the removed

parts.
3 Cylinder head cover mounting bolt:
24±4 Nm {2.45±0.41 kgcm}
WE051D0100 11
Measuring compression pressure 1 5. Remove the mounting bolts and nozzle holder (3)
of the cylinder to be measured.
a Measuring instruments for compression pressure a Take care that dirt or foreign matters will not
enter the mounting part of the nozzle holder.
Symbol Part No. Name a If the nozzle holder is difficult to remove, use
tool E3.
1 795-790-3610 Compression gauge
E 2 795-790-3710 Tester
3 795-799-1171 Puller
k When measuring the compression pressure, take

care not to burn yourself on the exhaust manifold,
muffler, etc. or get caught in a rotating part.
1. Warm up the engine until oil temperature reaches

40 - 60°C.
2. Adjust the valve clearance.

a See "Adjusting Valve Clearance".
3. Prepare for measuring engine speed.

a See "Testing and Adjusting Engine Speed". 6. Attach tester E2 and compression gauge E1 to the
nozzle holder mounting section.
4. Disconnect spill tube (1) and fuel injection tube (2).
12 WE051D0100
7. Disconnect E31 connector (4) from the engine

stop solenoid.
8. Crank the engine with the starting motor and mea-

sure the compression pressure.
a Read the pressure when the pointer of the
compression gauge is stabilized.
a While measuring the compression pressure,
measure the engine speed, too, and check
that it is within the range of measurement con-
dition.

WE051D0100 13
Measuring blow-by pressure 1 3. Measure the blow-by pressure when the torque
converter is stalled with the engine in high idling.
a Measuring instrument for blow-by pressure a For the procedure for stalling the torque con-
verter, see "Measuring engine speed". (Nor-
Symbol Part No. Name m a l l y, t h e b l o w - b y p r e s s u r e s h o u l d b e
measured when the engine is run with the
F 799-201-1504 Blow-by kit
rated output.)
In the field, stalling the torque converter gives
an approximate value.
a Measure the blow-by pressure under the following
a If it is impossible to run the engine at the rated
conditions.
output or stall the torque converter, measure
q Engine coolant temperature:
while the engine is running at high idling. The
value obtained in this case is about 80% of the
q Power train oil temperature:
blow-by pressure at the rated output.
a The blow-by pressure may vary largely
q Hydraulic oil temperature:
depending on the engine condition. If the mea-
sured value is judged abnormal, check for
increase of oil consumption, bad exhaust gas
1. Open the left side cover of the engine.
color, deterioration of oil, high deterioration
rate of oil, etc., which are related to the abnor-
2. Install nozzle [1] of blow-by checker F to blow-by
mal blow-by pressure.
hose (1) and connect them to gauge [2].

14 WE051D0100
Testing and adjusting fuel injection 5. Remove plate (4) from the flywheel housing.
timing 1 a Just loosening two plate-mounting bolts (11)
gets the plate (4) removed.
a Instruments for testing and adjusting fuel injection
timing

1 795-799-1131 Gear
G 2 795-799-1900 Pin ass'y
3 795-799-1950 Lock pin
Testing
1. Remove the inspection cover from the left side of
radiator guard.
2. Remove cylinder head cover (1). For details, see

DISASSEMBLY AND ASSEMBLY, Disassembly
and Assembly of Cylinder Head Assembly. 6. Remove cap (5).
3. Remove the left side cover of the engine. 7. Install gear G1.
4. Remove the mounting bolts of washer tank ass'y

(2) and air conditioning receiver (3), and fix them
with a rope, etc.
WE051D0100 15
8. Turn the crankshaft to the forward direction with 9. Remove plug (7) of the fuel injection pump.
gear G1 until the yellow paint (a) on the crank pul-
ley reaches the uppermost point, and set cylinder 10. Turn over and insert timing pin (8) of the fuel injec-
No. 1 to the compression top dead center with tim- tion pump, and check that its cut fits to projection
ing pin (6). (b) in the pump.
a Check that the rocker arm of cylinder No. 1 at a If the timing pin can be inserted smoothly, the
the top dead center can be moved the dis- injection timing is correct.
tance of the valve clearance with a hand. If the a If the timing pin cannot be inserted, the injec-
rocker arm cannot be moved, the cylinder is tion timing is not correct. In this case, adjust
not at the compression top dead center. Turn the injection timing.
the crankshaft one more time a If it is difficult to check with the timing pin
a Push-in depth of timing pin: 8 mm installed in the fuel injection pump, use another
a If the pin cannot be pushed in, move crank- metallic pin G3.
shaft slightly with gear G1.
a If it is difficult to check with the timing pin
installed in the engine, use another metallic
pin assembly G2.
11. After finishing testing, remove the measuring

instruments and return the removed parts.
3 Cylinder head cover mounting bolt:
24±4 Nm {2.45±0.41 kgcm}
k Be sure to return timing pin (6) of the drive
gear and timing pin (8) of the fuel injection
pump.
a If adjustment is made, leave gear G1 and tim-
ing pin (6) as they are.
16 WE051D0100
Adjusting
a If the fuel injection timing is not correct, adjust it
according to the following procedure.
1. Check that the fuel injection timing of the drive
gear is fixed with timing pin (6).
a If the timing pin is returned after testing, insert
it again according to the testing procedure.
2. Remove the fuel injection pump.

a See DISASSEMBLY AND ASSEMBLY, Removal
and installation of fuel injection pump assembly.
3. Turn over and insert timing pin (8) of the fuel injec-
tion pump, and turn the shaft until the cut of the pin
fits to a projection (b) in the pump.
a After adjusting the timing pin of the fuel injec-
tion pump, tighten and fix plug (7).
4. Install the fuel injection pump.

a See DISASSEMBLY AND ASSEMBLY, Removal
and installation of fuel injection pump assembly.
5. After finishing adjustment, remove the adjusting

instruments and return the removed parts.
k Return timing pin (6) of the drive gear and
timing pin (8) of the fuel injection pump
without fail.
WE051D0100 17
Measuring engine oil pressure 1 3. Start the engine and measure the oil pressure at
low and high idling.
a Measuring instruments for engine oil pressure

799-101-5002 Hydraulic tester
1
790-261-1203 Digital hydraulic tester
H
Hydraulic tester
2 799-401-2320
(1.0 MPa {10 kg/cm2})
a Measure the engine oil pressure under the follow-

ing conditions.
q Engine coolant temperature: Within operating
range
1. Open the left side cover of the engine and remove

plug (1) (R 1/8) for measuring oil pressure. 4. After finishing measurement, remove the measur-
2. Install nipple [1] of hydraulic tester H1 and connect

them to hydraulic tester H2.
18 WE051D0100
Testing and adjusting air conditioner Adjusting engine speed sensor

compressor belt tension 1 1
Testing a Before starting adjustment, remove engine speed
q Press the middle point between air conditioner sensor (1). Check that the sensor's tip has no iron
compressor pulley and drive pulley with a finger powder stuck or damage, and attach it.
and measure deflection a of the belt.
a Pressing force: Approx. 98 N {Approx. 10 kg}
1. Screw in sensor (1) until its tip touches the tooth

tip of flywheel ring gear (2).
2 Threads: Gasket sealant (LG-6)
Adjusting
a If the deflection is abnormal, adjust it according to
the following procedure.
2. Return sensor (1) by the specified angle.
a Returning angle of sensor: 3/6-4/6 turn
1. Loosen 4 compressor bracket mounting bolts (1).
a Adjust gap (a) between the sensor tip and
gear tooth tip to 0.75 - 1.0 mm.
2. Loosen locknut (2) and adjust the belt tension by
turning adjustment bolt (3).
3. Fasten sensor (1) with nut (3).
2 Nut: 49.0 - 68.6 Nm {5 - 7 kgm}
3. After the tension is adjusted to the reference
value, tighten locknut (2) and 4 compressor
bracket mounting bolts (1).
4. After finishing adjustment, check that the engine

speed is displayed normally on the monitor panel
by its monitoring function.
a For the monitoring function, see "Special func-
tions of monitor panel".
WE051D0100 19
Adjusting fuel control linkage 1
1. Turn the starting switch ON, and set the fuel dial to 3. Install deceleration cable (6).
high-idling position.
4. Adjust installed dimension (b) of deceleration
2. Adjust installed dimension a of loose spring (3) so cable (6) so that decelerator pedal (7) touches
that governor lever (1) touches stopper (2) on the stopper (2) on the full side of the pedal assembly.
full-rotation side of the injection pump. q Standard installed dimension of deceleration
q Standard installed dimension (a) of loose cable (6) : 267mm
spring (3) : 375mm a Use turnbackle (10) for adjustment. (Don't
a Make the adjustment with rod end (4) or (5). adjust stopper (8) on the full side of the pedal
During the adjustment, take care so that loose assembly.))
spring (3) may not be extended.
20 WE051D0100
5. Start the engine and set the monitor panel in the

"Dual display monitoring mode" to prepare for
measurement of the engine speed and the voltage
on deceleration potentiometer.
a For the operating method, see "Special func-
tions of monitor panel (EMMS)".
q Monitoring code: 50001 (voltage value of the
decelerator pedal)
(The voltage is displayed in mV.)
q Monitoring code: 01000 (engine speed)
(The engine speed is displayed in rpm.)
WE051D0100 21
6. High idling speed 2) If deceleration cable (6) is short and pulled too
Set the fuel control dial to the high idling position, much, extend it by loosening turnbackle (10).
and check that the high idling speed is normal. In this case, take care so that decelerator
q High idling speed: 1,950 - 2,050 rpm pedal (7) may not lose contact with stopper (8)
q Potentiometer output: 2.5 V±0.05 V on the full side.
q Standard installed dimension (c) of stopper a If the potentiometer output is abnormal, do the
bolt (8) : 26.5mm following procedures.
a If the engine speed is abnormal, do the follow- q If the potentiometer output is 2.45 V or lower:
ing procedures. Loosen turnbackle (10) to decline decelerator
q If engine speed is 1,950 rpm or less: pedal (7).
1) If loose spring (3) is too long to be pulled fully, q If the potentiometer output is 2.55 V or higher:
shorten it by driving rod end (4) or (5). In this Tighten turnbackle (10) to raise the decelera-
case, take care so that loose spring (3) may tor pedal.
not be extended.
22 WE051D0100
7. Adjusting decelerator pedal speed

Set the fuel control dial to the high idling position,
press decelerator pedal (7) until it touches stopper
bolt (9). Check that the decelerator pedal speed is
normal in this state.
q Decelerator pedal engine speed:
1,150 - 1,200 rpm
q Potentiometer output: 3.1±0.2 V
a If the decelerator pedal speed is abnormal,
adjust installed dimension (d) of stopper bolt
(9).
q Standard installed dimension of stopper bolt
(d) : 15.5mm
8. Adjusting governor motor

After adjusting the high idling speed and the decel-
eration pedal speed, adjust the governor motor
(adjustment mode: 0801).
WE051D0100 23
Measuring power train oil pressure1

a Measuring instruments for power train oil pressure

1
Hydraulic tester
J 2 799-401-2320
(1.0 MPa {10 kg/cm2})
799-101-5220 Nipple (10 x 1.25 mm)
3
07002-11023 O-ring
k Stop the machine on a level place, lower the

work equipment to the ground, and set the
1. Measuring brake pressure
parking brake lever and safety lock lever in the
1) Remove the plug on oil pressure measuring
LOCK position.
section (2) and connect nipple J3 and oil pres-
a Measure the power train oil pressure under the fol-
sure gauge [1] of hydraulic tester J1 to the
lowing conditions.
plug hole.
q Power train oil temperature: 70 - 80°C
a Use an oil pressure gauge of 5.9 MPa {60 kg/
a The power train oil pressure measuring section
cm2}.
(centralized pressure detection port) is installed
inside inspection cover (1) on the right outside of
the operator's cab.
2) Start the engine and set the parking brake

lever in the Free position.
3) Measure the oil pressure when the engine is
a List of pressure measuring point and gauges to
running at low idling and high idling.
use
a Check that the oil pressure is 0 when the
brake pedal is pressed or the parking brake
Gauge lever is set in the Lock position.
No. Measuring point
(MPa {kg/cm2})
1 Brake pressure 5.9 {60}
2 Torque converter inlet oil pressure 2.5 {25}
3 Torque converter outlet oil pressure 0.98 {10}
4 Transmission main relief pressure 5.9 {60}
24 WE051D0100
4) After finishing measurement, remove the mea- 3. Measuring torque converter outlet pressure
suring instruments and return the removed 1) Remove the plug on oil pressure measuring
parts. section (4) and connect nipple J3 and hydrau-
lic tester J2 to the plug hole.
2. Measuring torque converter inlet pressure a Use an oil pressure gauge of 0.98 MPa {10 kg/
1) Remove the plug on oil pressure measuring cm2}.
section (3) and connect nipple J3 and oil pres-
sure gauge [1] of hydraulic tester J1 to the
plug hole.
a Use an oil pressure gauge of 2.5 MPa {25 kg/
cm2}.
2) Start the engine and set the PCCS lever in the

full neutral position.

parts.

parts.
WE051D0100 25
4. Measuring transmission main relief oil pressure 5. Measuring clutch pressure

1) Remove the plug on oil pressure measuring q Remove the operator's seat assembly and
section (5) and connect nipple J3 and oil pres- measure the clutch oil pressure from the top of
sure gauge [1] of hydraulic tester J1 to the the floor frame.
plug hole. a Table of locations of centralized pressure
a Use an oil pressure gauge of 5.9 MPa {60 pickup points for measuring oil pressure and
kg/cm2}. gauges to use
Gauge
No. Measuring point
(MPa {kg/cm2})
Transmission forward clutch oil
5 5.9 {60}
pressure
Transmission reverse clutch oil
6 5.9 {60}
pressure
Transmission 1st clutch oil
7 5.9 {60}
pressure
Transmission 2nd clutch oil
8 5.9 {60}
pressure
Transmission 3rd clutch oil
9 5.9 {60}
pressure

parts.
26 WE051D0100
1) Measuring transmission forward clutch pres- 5] After finishing measurement, remove the
sure measuring instruments and return the
1] Remove oil pressure pickup plug (6) and removed parts.
connect oil pressure gauge [1] of hydraulic
tester J1 to the plug hole. 4) Measuring transmission 2nd clutch pressure
a Use an oil pressure gauge of 5.9 MPa 1] Remove oil pressure pickup plug (9) and
{60 kg/cm2}. connect oil pressure gauge [1] of hydraulic
2] Start the engine and set the parking brake tester J1 to the plug hole.
lever in the FREE position. a Use an oil pressure gauge of 5.9 MPa
3] While pressing the brake pedal, set the {60 kg/cm2}.
PCCS lever in the Forward and the 3rd 2] Start the engine and set the parking brake
gear position. lever in the Free position.
4] Measure the oil pressure when the engine 3] While pressing the brake pedal, set the
is running at high idling. PCCS lever in the Reverse and the 2nd
k To stall the torque converter, hold gear position.
the brake pedal pressed securely. 4] Measure the oil pressure when the engine
5] After finishing measurement, remove the is running at low idling.
measuring instruments and return the k To stall the torque converter, hold
removed parts. the brake pedal pressed securely.
k Do not raise the engine speed to
2) Measuring transmission reverse clutch pres- high idling during the measurement.
sure 5] After finishing measurement, remove the
1] Remove oil pressure pickup plug (7) and measuring instruments and return the
connect oil pressure gauge [1] of hydraulic removed parts.
tester J1 to the plug hole.
a Use an oil pressure gauge of 5.9 MPa 5) Measuring transmission 3rd clutch oil pressure
{60 kg/cm2}. 1] Remove oil pressure pickup plug (10) and
2] Start the engine and set the parking brake connect oil pressure gauge [1] of hydraulic
lever in the Free position. tester J1 to the plug hole.
3] While pressing the brake pedal, set the a Use an oil pressure gauge of 5.9 MPa
PCCS lever in the Reverse and the 3rd {60 kg/cm2}.
gear position. 2] Start the engine and set the parking brake
4] Measure the oil pressure when the engine lever in the Free position.
is running at high idling. 3] While pressing the brake pedal, set the
k To stall the torque converter, hold PCCS lever in the Forward and the 3rd
the brake pedal pressed securely. gear position.
5] After finishing measurement, remove the 4] Measure the oil pressure when the engine
measuring instruments and return the is running at low idling.
removed parts. k To stall the torque converter, hold
the brake pedal pressed securely.
3) Measuring transmission 1st clutch pressure k Do not raise the engine speed to
1] Remove oil pressure pickup plug (8) and high idling during the measurement.
connect oil pressure gauge [1] of hydraulic 5] After finishing measurement, remove the
tester J1 to the plug hole. measuring instruments and return the
a Use an oil pressure gauge of 5.9 MPa removed parts.
{60 kg/cm2}.
2] Start the engine and set the parking brake
lever in the Free position.
3] While pressing the brake pedal, set the
PCCS lever in the Forward and the 1st
gear position.
4] Measure the oil pressure while the engine
is running at low idling.
k To stall the torque converter, hold
the brake pedal pressed securely.
k Do not raise the engine speed to
high idling during the measurement.
WE051D0100 27
Adjusting transmission speed sensor 2) Pull the connector of sensor (3) from the
(replacement procedure) 1 flange hole of tube (6), and insert it into con-
nector assembly (7). (Insert it securely until a
1. Remove the undercover of the fuel tank. Then click sounds.)
remove transmission speed sensor assembly (1)
from steering case (2).
3) Install connector assembly (7) on tube (6).

3 Mounting bolt:
4.9 - 6.9 Nm {0.5 - 0.7 kgm}
2. Measure installed dimension L of removed sensor 4) Insert sensor (3) in the boss of tube (6) and
(3). secure it with nuts (4) and (5).
a When replacing the sensor, be sure to mea- a Installed dimension of sensor: Dimension
sure dimension L. measured when removed L ± 0.2 mm
3 Locknut: 49 - 68.7 Nm {5 - 7 kgm}
2 Threads of sensor:
Liquid adhesive (LT-2)
4. Install sensor assembly (1) in steering case (2).

q Standard clearance between the bevel gear
and the sensor tip: 0.65 - 1.65 mm
5. After finishing adjustment, set the monitor panel in

the "Real-time monitoring mode" and check that it
displays the transmission speed normally.
a Monitoring code:
31400 (Transmission speed)
3. Procedure to assemble the sensor assembly
1) Remove only nut (4) from sensor (3), and
insert the connector side of sensor (3) into the
opening at the end of tube (6).
28 WE051D0100
Simple method of testing brake

performance 1
a Carry out the simple test of the brake performance
under the following conditions.
q Power train oil temperature:
1. Set the blade and ripper (if equipped) in the travel-

ing position on a level place.
2. Start the engine and set the parking lever in the

Free position.
3. While running the engine at low idling and press-

ing the brake pedal, set the PCCS lever in the For-
ward and the 2nd gear position.
k If this test is carried out in the 1st gear
position, the brake will be overloaded.
Accordingly, be sure to carry it out in the
2nd gear position.
a Hold the steering unit in neutral.
4. Press the decelerator pedal and set the fuel con-

trol dial to the high idling position.
5. Return the decelerator pedal slowly. Check that

the machine does not start when the engine speed
reaches the high idling speed.
k To stall the torque converter, hold the
brake pedal pressed securely. Keep your
right foot on the decelerator pedal for
safety until the work is finished.
WE051D0100 29
Adjusting brake pedal 1
k Tighten the locknuts of the rods and cables 3. Adjust installed dimension (d) of rod (6) on the
securely, and bend the cotter pins securely. pedal side, then connect the rod to brake pedal
(1).
1. Adjust stroke (a) of brake pedal (1) to installed q Installed dimension (d) of rod: 171 mm
dimension (b) of damper (2).
q Pedal stroke (a): 77.5 mm 4. While pushing lightly rod (3) on the valve side
q Installed dimension (b) of damper: 25 mm toward the rear of the machine, connect rods (3)
and (6) by turning only joint (7).
a Push rod (3) with force of about 9.8 - 19.6 N {1
- 2 kg}.
3 Joint: 34.3 - 58.8 Nm {3.5 - 6.0 kgm}
2. Adjust installed dimension (c) of rod (3) on the

valve side, then connect the rod to brake valve
lever (4).
q Installed dimension (c) of rod: 700 mm
a Screw fully joint (5) into the valve side.
30 WE051D0100
5. While keeping brake pedal (1) released, adjust its

play to dimension (e) between the pins of rod
assembly (8).
q Play of pedal: 3 - 8 mm (at the center of pedal)
q Dimension (e) between pins of rod assembly:
898 mm
a Adjust the play by turning joints (5) and (7) in
the same direction.
6. With brake pedal (1) released, check that brake

pedal (1) touches damper (2).
7. Check the brake oil pressure by referring to "Mea-

suring power train oil pressure".
Oil pressure:
Remarks
MPa {kg/cm2}
Brake OFF Min. 2.4 {Min. 24} Engine at full throttle
Brake ON 0
8. After adjusting the pedal, adjust the zero point of

the brake potentiometer (Adjustment mode: 0005).
WE051D0100 31
Adjusting parking brake lever 1
1. Assembling and installing lever assembly 3. Checking brake oil pressure

1) Assemble lever assembly (1) and adjust the Check that the brake oil pressure is as follows
operation of limit switch (2). when the parking brake lever is at the Free and
a When assembling the lever assembly, dis- Lock positions.
connect the parking brake cable from the a For the method of measuring the brake oil
lever. pressure, see "Measuring power train oil pres-
q Lever up position: OFF, sure".
lever down position: ON q Lock position: 0,
q Operation stroke of limit switch: 3 mm Free position: Specified pressure
2) Install lever assembly (1).
4. Checking limit switch
2. Adjusting installed length of parking cable Change the monitor panel to the monitoring dis-
1) Connect parking brake cable (3) to the lever play mode and set the parking brake lever in the
and valve and adjust dimensions (a) and (b). Free and Lock positions. Then check that the limit
q Installed dimension (a) of cable: 148.5 mm switch signal is normal.
q Installed dimension (b) of cable: 166 mm a For the method of operating the monitoring
2) Operate parking brake lever (4) at the Free display mode, see "Special functions of moni-
and Lock positions, and adjust the position of tor panel (EMMS)".
rod end (6) so that spool stroke (h) of brake q Monitoring code: 40910 (Steering related con-
valve (5) becomes normal. troller input signal 1)
q Spool stroke (h): 13.3 mm
32 WE051D0100
Emergency escape method when 2) Remove the cover on the left at the toe board,
power train has a trouble 1 and connect wiring harness [2] to PL1 connec-
tor (1) and PL2 connector (2).
a Devices used for emergency escape q PL1 connector (1):
Connect to the male and female sides.
q PL2 connector (2):
Connect to the female side.
19M-06-32820 Switch assembly a Since the male side of the PL2 connector
1
134-06-72810 Wiring harness is left disconnected, mask it with a vinyl
7824-66-6430 Redundant resistance sheet, etc.
K 2
7827-10-1520 Redundant resistance
3 790-190-1600 Pump assembly
4 144-865-6260 Elbow (R3/8 x M18)
1. Emergency escape with switch box (Use K1)

a If the machine stopped running because of a
trouble in the electric system of the power train
control unit (travel direction, gear, steering),
escape emergently according to the following
procedure.
a This procedure requires that the engine can
start. If engine cannot start, see "Emergency
escape with brake releasing device".
1) Connect switch assembly [1] and redundant
resistance K2 to wiring harness [2] of emer- 3) Remove the left side cover of the engine, then
gency escape device K1. air conditioner receiver (3).
k Set all the gear switches in switch
assembly [1] to OFF and the traveling
direction switch to P so as to prevent
sudden unexpected operation of the
machine.
WE051D0100 33
4) Disconnect governor motor connectors E61

(4) and E62 (5).
k Be sure to disconnect these connec-
tors; or, the governor motor might
operate unexpectedly when the engine
is running, suffering mechanical dam-
ages.
7) Disconnect the back alarm relay (BKA) and

connect pins [2] and [5] on the wiring harness
side.
5) Open the battery cover on the left side of the

cab and remove the cover of relay box (6).
8) With the starting switch turned ON, open the

left engine hood and draw the rod of engine
stop solenoid (7) up to the position where it is
attracted by an electro-magnet.
6) Disconnect the neutral safety relay (NSF) and

connect pins [3] and [5] of the connector on
the wiring harness side.
a Disconnecting a connector (PL2) causes
the model selection error, leading to
undriven neutral safety relay. The above
step is intended to avoid such results.
k Starting the engine in this way makes
the neutral safety function unoperat-
able. Accordingly, before starting the
engine, set the parking lever in the
Lock position and the PCCS lever in
the full neutral position.
k Use this way to start the engine only for
emergency escape. In other cases the
engine does not start, be sure to trou-
bleshoot and repair the cause of the
trouble found.
34 WE051D0100
9) Start the engine and set the parking lever in 2) Install volume pump [1] of pump assembly K3
the Free position. on the outside of the operator's cab.
10) Operate switch assembly [1] to move the
machine to a safe place.
a The gear switch has an electric circuit
which gives priority to the switch operation
on the lower gear side.
k Note that rightward or leftward steering
is reversed when traveling backward.
3) Remove the fuel tank undercover, then plug

(9) (R3/8) of the brake release pressure oil
supply port of brake valve (8).
2. Emergency escape with brake releasing device

(Use K2)
a If the engine cannot be started nor can the
parking brake be released, escape emergently
1) Assemble pump assembly K2.
4) Install elbow K3 to the plug hole, and connect

end hose [2] of pump assembly K2 to the
elbow.
WE051D0100 35
a Alternatively, remove brake oil pressure mea-

suring plug (10) on the right centralized pres-
sure detection port, and connect end hose [2]
of pump assembly K2.
5) Turn the starting switch ON and set the park-

ing brake lever in the FREE position.
6) Operate the vacuum pump to raise the brake
releasing oil pressure up to the initial pressure.
q Initial pressure:
Approx. 2.74 MPa {28 kg/cm2}
a Since an accumulator is installed in the
circuit 30 - 50 times of handle operation
may be needed before the oil pressure
rises.
a If the oil pressure does not rise above a
certain level, the relief valve may have
been set to a lower pressure. In this case,
adjust the pressure set for the valve.
7) Tow the machine to a safe place.
a The brake releasing oil pressure lowers
gradually because of internal leakage and
the brake begins to work again about 1
minute after. Accordingly, work quickly.
a If the brake releasing oil pressure lowers
to about 1.57MPa {16 kg/cm2}, the brake
will operate. In such a case, operate the
side volume pump to raise the brake
releasing pressure up to its initial pres-
sure.
8) After finishing the work, loosen the screw
slowly to disconnect the hose. Don't stand in
the direction oil spouts.
36 WE051D0100
Adjusting idler clearance 1 Inspecting wear of sprocket 1

a If the lateral guide plates of the idler are so worn a Use "Full-scale drawing of sprocket teeth profile"
that the idler runs out or slants, adjust the idler as the gauge to measure the worn sprocket. See
clearance according to the following procedure. "Sprocket" in Structure and function, Maintenance
Standard Section.
Adjustment procedure a Make a copy of the "Full-scale drawing of sprocket
1) Drive the machine 1 - 2 m on the flat ground, teeth profile" on a transparent paper or other sheet
then measure clearance (a) between the track and apply it directly to the sprocket to see if the
frame and guide plate (at 4 places on both sprocket is appropriate for use.
sides, inside, and outside).
2) If clearance (a) is larger than 4 mm, adjust the
clearance by loosening bolt (1) and reducing
shim (2).
q Standard clearance (a) on each side:
0.5 - 1.0 mm
q Shim thickness: 1.0 mm
WE051D0100 37
Testing and adjusting track shoe Adjusting

tension 1 a If the track shoe tension is abnormal, adjust it
Testing
1. Drive the machine slowly on a level place, then 1. Remove cover (1).
stop it.
a Do not apply the brake when stopping. 2. When tension is too high:
Loosen plug (2) to discharge the grease.
k Since the valve may jump out because of the
2. Place a straight steel bar between the idler and
front carrier roller, and measure the maximum high-pressure grease, do not loosen it more
than 1 turn.
3
clearance (a) between the bottom of the steel bar
and the shoe grouser. Plug: 59 - 88 Nm {6 - 9 kgm}
q Standard maximum clearance (a): 20 - 30 mm
3. When tension is low:
Add grease through grease fitting (3).
a If the track shoe is not tensed well, drive the
machine forward and backward slowly.
38 WE051D0100
Testing and adjusting work 1. Measuring unload pressure

equipment and HSS oil pressure 1 1) Remove the plug on oil pressure measuring
section (2), and connect nipple L2 and oil
a Instruments for testing and adjusting work equip- pressure gauge [1] of hydraulic tester L1 to
ment and HSS oil pressure the plug hole.
a Use an oil pressure gauge of 39.2 MPa {400
kg/cm2}.
1
799-101-5220 Nipple (10 x 1.25 mm)
L 2
07002-11023 O-ring
790-261-1231 Elbow
3
07002-11023 O-ring

LOCK position.
a Measure the work equipment and HSS oil pres-
sure under the following conditions.
q Hydraulic oil temperature: Within operating
range
a The work equipment oil pressure measuring sec-
tion (centralized pressure detection port) is
installed inside inspection cover (1) on the right
outside of the operator's cab.
2) Start the engine and keep it at high idling, set

the work equipment lever and the PCCS lever
in neutral, then measure the oil pressure.

parts.
WE051D0100 39
2. Measuring work equipment and HSS oil pres- 2) Remove load sensing pressure measuring plug
sure (steering oil pressure) (3) from the main control valve assembly.
1) Remove the plug on oil pressure measuring (Applies only to measuring HSS oil pressure.)
section (2), and connect nipple L2 and oil 3) Connect elbow L3, nipple [2] of hydraulic
pressure gauge [1] of hydraulic tester L1 to tester L1 and oil pressure gauge [1] to the plug
the plug hole. hole.
a Use an oil pressure gauge of 58.8 MPa
{600 kg/cm2}.
40 WE051D0100
Work equipment oil pressure HSS oil pressure (steering oil pressure)
1) Start the engine and set the work equipment 1) Start the engine, set the parking lever in the
lock lever in the Free position. Free position, and press the brake pedal.
2) Run the engine at high idling, operate the k Because steering circuit is relieved, hold
blade lever and ripper lever to relieve each the brake pedal pressed securely and
cylinder at the stroke end, then measure the keep your right foot on the deceleration
oil pressure. pedal for safety until the work is finished.
a Block the return hose of the blade lift cylinder. 2) Run the engine at high idling, set PCCS lever
in N (neutral), steer to the right or left to relieve
steering, then measure the oil pressure.

parts.
parts.
WE051D0100 41
3. Adjusting 2) Work equipment oil pressure

1) LS pressure (Load Sensing pressure) of HSS a Don't adjust the work equipment oil pres-
Loosen locknut (5) of HSS LS relief valve (4) sure.
and turn adjustment screw (6) to adjust the LS
pressure.
a Turning the adjustment screw
q clockwise raises the oil pressure;
q turning it counterclockwise lowers the
oil pressure.
a Value adjusted by 1 turn of the adjustment
screw: 15.1 MPa {154 kg/cm2}.
3 Locknut: 68.6 - 78.5 Nm {7- 8 kgm}
q After adjusting, check again the relief
pressure and LS pressure of the work
equipment.
42 WE051D0100
Testing control circuit main pres- 1. Remove the plug on oil pressure measuring sec-
sure 1 tion (2) and connect nipple M2 and oil pressure
gauge [1] of hydraulic tester M1 to the plug hole.
a Instruments for testing and adjusting control circuit a Use an oil pressure gauge of 5.9 MPa {60 kg/
main pressure cm2}.

1
M
799-101-5220 Nipple (10 x 1.25 mm)
2
07002-11023 O-ring
a The control circuit main pressure is the pressure

lowered by the self-pressure reducing valve. It is
shared by blade PPC, fan pump control, steering
EPC and ripper PPC (if equipped).
Measuring
LOCK position.
a Measure the reduced control circuit pressure
under the following conditions.
range
a The reduced control circuit pressure measuring
section (centralized pressure detection port) is
installed inside inspection cover (1) on the right
outside of the operator's cab.
2. Start and keep the engine at high idling, set the

blade lever and ripper lever in neutral, then mea-
sure the oil pressure.

Adjusting
a The self-pressure reducing valve is not adjust-
able.
WE051D0100 43
Measuring PPC valve output pres- 3. Install oil pressure pickup adapter N2 to the valve,
sure 1 and connect the disconnected hose again.
a Measuring instruments for PPC valve output pres- 4. Install nipple [1] of hydraulic tester N1 and connect
sure oil pressure gauge [2].

1
N Oil pressure pickup adapter
799-401-3100
2 (Size 02)
02896-11008 O-ring
k Stop the machine on a level place, place the

work equipment on the ground, and set the
parking lever and safety lock lever in the Lock
position.
a Before measuring the PPC valve output pressure,
check that the control circuit main pressure is nor-
5. Start the engine and set the safety lock lever in the
mal.
Free position.
a Measure the PPC valve output pressure under the
following conditions.
6. Run the engine at high idling, operate the control
lever of the circuit to be measured, and measure
range
the oil pressure.
a Measure the oil pressure with the lever at a
1. Open the side cover of main control valve on the
stroke end.
right side of the operator's cab.
a When the blade is lowering, operate the lever
up to the Float position.
2. Disconnect PPC valve output pressure hose (1).
a To select the circuit to be measured, see the
drawing on the next page.

44 WE051D0100
a Straight-tiltdozer
1. Main valve A. Blade LOWER

2. Self-pressure reducing valve B. Blade RIGHT TILT
3. PPC lock solenoid valve C. Ripper RAISE
4. Accumulator (if equipped) D. Ripper LOWER
5. Blade PPC valve E. Blade LEFT TILT
6. Ripper PPC valve (if equipped) F. Blade RAISE
WE051D0100 45
a Power angle-tiltdozer and power tiltdozer
1. Main valve A. Blade LOWER

2. Self-pressure reducing valve B. Blade LEFT TILT
3. PPC lock solenoid valve C. Left ANGLE
4. Accumulator (if equipped) D. Ripper RAISE
5. Blade PPC valve E. Ripper LOWER
6. Ripper PPC valve (if equipped) F. Right ANGLE
G. Blade RIGHT TILT
H. Blade RAISE
46 WE051D0100
Adjusting play of work equipment

PPC valve 1
a The ripper valve is not adjustable.
a If the play of the blade lever end is excessive,
adjust it on the PPC valve side according to the
following procedure.
q Standard play (a):

0.5 - 3.0 mm at 200 mm from revolution center of
lever (in both longitudinal and lateral directions)
1. Remove boots (1).
2. Loosen locknut (2), and turn disc (3) to adjust the

play.
a Do not move the piston at this time.
3. Fix the position of disc (3) and tighten locknut (2).

3 Locknut: 98 - 127 Nm {10 - 13 kgm}
4. Install boots (1).
For straight-tiltdozer For power angle-tiltdozer and power tiltdozer
WE051D0100 47
Measuring internal leakage of work 3. With the engine run at high idling, apply the relief
equipment cylinder 1 pressure to the cylinder bottom side.
q Blade lift cylinder: Lower operation
a Measuring instruments for internal leakage of work q Blade tilt cylinder: Left tilt operation
equipment cylinder q Blade angle cylinder: Right or left angle opera-
tion
(Apply the relief pressure to the bottom side of
the cylinder from which the hose has been dis-
O Purchased Measuring cylinder connected.)
q Ripper lift cylinder: Lower operation
a Measure the internal leakage in work equipment 4. Measure leakage in one minute after 30 seconds
cylinder under the following conditions. elapsed.
q Hydraulic oil temperature: 45 - 55°C
a Since the blade lift cylinder is equipped with a pis-
5. After finishing measurement, return the removed
ton valve, its internal leakage cannot be mea- parts.
sured.
1. Extend the cylinder to be measured to the stroke

end and set the machine in the measuring posi-
tion.
1) Blade lift cylinder
Put the front part of the track shoe on a block,
and extend the cylinder rod fully.
2) Blade tilt cylinder
Lower the blade tip to the ground.
3) Blade angle cylinder
Extend the angle cylinder rod fully and lower
the blade to the ground.
4) Ripper lift cylinder (if equipped)
Pull out the shank pin and lower the ripper to
the end.
2. Disconnect hose on the cylinder head side and

block the hose side with a plug.
a Remove the hose cover of the blade tilt cylin-
der.
k Take care not to disconnect the hose on
the bottom side.
48 WE051D0100
Adjusting safety lock lever of work

equipment 1
1. With lock lever (1) of the work equipment set in 2. With lock lever (1) of the work equipment set in
Lock position, make the following adjustment: Free position, make the following adjustment:
1) Adjust length (a) of limit switch (2). 1) Adjust length (d) of the limit switch so that its
q Dimension (a) : 29.1 mm stroke becomes (c).
2) Adjust height (b) of stopper (3). q Dimension (c) : 5 mm
q Dimension (b) : 27.5 mm q Dimension (d) : 24.1 mm
2) Check that the distance from the floor surface
to the tip of lever (1) is (e).
q Dimension (e) : 427.6 mm
WE051D0100 49
Releasing residual pressure in work Releasing residual pressure in work

equipment cylinder equipment cylinder
(If PPC accumulator is not (If PPC accumulator is installed) 1
installed) 1
a When disconnecting the piping between the con-
a When disconnecting the piping between the control valve and work equipment cylinder, release
trol valve and work equipment cylinder, release first the residual pressure in the circuit according
first the residual pressure in the circuit according to the following procedure.
to the following procedure.
1. Loosen the hydraulic tank cap gradually to release
1. Run the engine at low idling and lower the blade the residual pressure in the tank.
and ripper to the ground without relieving any
hydraulic cylinder. 2. Turn the starting switch ON, set the safety lock
a Lower the blade slowly to the ground. Just lever in the Free position, and operate the blade
after the blade reaches the ground, set the lever and ripper lever both in the longitudinal and
blade lever in the Float position. lateral directions.
a Lower the ripper slowly to the ground. a Two or three times of operation will release the
residual pressure in the accumulator.
2. Leave the machine as it is for five or ten minutes
after the engine stopped. 3. Start the engine, and run it at low idling for about 5
seconds, then stop it.
3. Loosen the hydraulic tank cap gradually to release
the residual pressure in the tank. 4. Repeat steps 2 - 3 mentioned above two or three
times.
4. Apply cloths to the joint of the cylinder piping, and
loosen the sleeve nut gradually to release the
residual pressure while shaking the hose slowly.
a Check that the residual pressure has been
released and oil does not spout out any more,
then disconnect the piping completely.
50 WE051D0100
Bleeding air from work equipment

cylinder 1
a If the work equipment cylinder is removed and
installed or its piping is disconnected and con-
nected, bleed air from its circuit according to the
1. Start the engine, and run it at low idling for about 5

minutes.
2. With the engine run at low idling, extend and

retract the cylinder to be bled four or five times.
a Move the piston rod within a range of about
100 mm before the stroke end, and take care
never to cause relief.
3. Do the operation in step 2 with the engine run at

high idling.
4. With the engine run at low idling, move the cylin-

der to the stroke end to cause relief.
WE051D0100 51
Measuring fan pump circuit pres- 4. Install nipple P2 to oil pressure gauge [1] of
sure 1 hydraulic tester P1, connect it to the plug hole.
a Use an oil pressure gauge of 39.2 MPa {400
a Measuring instruments for fun pump circuit pres- kg/cm2}.
sure
5. Close radiator mask (1).
k To avoid possible hazard caused by turn-
ing fan, be sure to close the radiator mask.
1
790-261-1203 Digital hydraulic tester 6. Start the engine and set the monitor panel in the
P
799-101-5220 Nipple (10 x 1.25 mm) adjustment mode.
2
07002-11023 O-ring a For the method of operating the adjustment
mode, see "Special functions of monitor panel
(EMMS)".
1. Open radiator mask (1). a Adjustment code:
1005 (100% fan speed mode)
2. Remove fan guard (greater one) (2).
7. Measure the fan circuit oil pressure with the
engine running at high idling.
3. Remove plug (3).

52 WE051D0100
Measuring fan motor speed 1 5. Close radiator mask (1).

k To avoid possible hazard caused by turn-
a Measuring instruments for fan motor speed ing fan, be sure to close the radiator mask.
Symbol Part No. Name 6. Start the engine and set the monitor panel in the
adjustment mode.
Q 799-205-1100 Tachometer kit
a For the method of operating the adjustment
mode, see "Special functions of monitor panel
(EMMS)".
1. Open radiator mask (1).
a Adjustment code:
1005 (100% fan speed mode)
2. Remove fan guard (greater one) (2).
7. With the engine run at high idling and low idling,
measure the fan motor speed.
k Be sure to close the radiator mask before
starting the engine. Never start the engine
with radiator mask open.
3. Stick one strip of reflecting tape [1] to fan (2).
4. Set probe [2] of tachometer kit Q on stand [3],

matching it to reflecting tape [1], then connect it to
tachometer [4].
k Take care that the probe will not interfere
with the fan. 8. After finishing measurement, remove the measur-
WE051D0100 53
Measuring HSS motor oil leakage 1 Bleeding air from fan pump 1
a Hydraulic oil temperature: 45 - 55°C a If the fan pump was removed and installed or its
a Lower the work equipment up to the ground and piping was disconnected and connected, bleed air
stop the engine. from the pump case according to the following pro-
k Loosen the hydraulic tank cap gradually to cedure.
release the pressure in the tank. a Before performing the following procedure, check
that the hydraulic oil is at the specified level.
1. Disconnect drain hose (1) and install a blind plug a Remove the operator's seat.
to the tank side.
1. Remove the inspection cover on the right of the
2. Set the gear shift lever in neutral, and press the floor.
brake pedal.
2. Loosen air bleeder (1) and leave it for 15 minutes.
3. With the steering and forward-reverse levers set to
the left or right end, cause the HSS motor relieve
for one minute, and measure leakage with a mea-
suring cylinder, etc.
a Repeat measurement several times for each
case the levers are set to the right or left.
3. After 15 minutes elapsed, start the engine, and

keep it at low idling.
4. If oil flows out of air bleeder (1), tighten the air

bleeder.
54 WE051D0100
Testing and adjusting operator's

cab 1
Check after installing cab assembly
1. Measure the internal pressure of the cab.
q Criterion:
Measured value X 58.9 Pa {6 mmH2O}.
q Engine speed: High idling
q Fan motor speed: 100% fan speed mode
q Blower operation: High (Hi)
q EXTERNAL/INTERNAL air changeover switch:
Fresh air position
a If the measured value is lower than the stan-
dard value, check the seals of the holes for
wiring harnesses and optional parts in the cab.
1) A simple way for measuring the internal pres- 2. Check of sealing performance
sure is as follows. 1) Close the all openings of the cab.
1] Prepare a transparent vinyl hose. 2) Splash water around the hatched part of the
q Outside diameter: 6 mm, cab for 10 minutes at a rate of 19 l/min.
Length: 3,000 mm q At this time, it is not necessary to splash
2] Fix the inside end of the hose to the top of pressurized water.
the back seat with a tape. 3) Splash water horizontally with a hose on
3] Remove bolt (1) under the left console sealed surfaces (4).
box, and insert the other end of the hose 4) Check around the dashboard carefully.
into the bolt hole, taking it out of inspection a If leakage is found, caulk the leaking part
cover (2) on the left side of the cab. and check again.
4] Seal the hole of bolt (1) with tape (3).

5] Inject water into the hose up to about half
level.
6] Mark the same water level in the vinyl
hose outside and inside the cab.
7] With the engine run at high idling and the
fan at 100% speed, read difference (c) of
water levels. [(c) value: Pa {mmH2O}]
a Side (a): Inside the cab (Pressurized)
Side (b): Outside the cab
(Atmospheric pressure)
WE051D0100 55
3. Testing door lock

Close the door and check the relationship between
the operator's cab and door. If there is any fault,
repair it.
1) Check of condition
1] Check the installed height of damper rub-
ber (1).
(Check 2 points on each side.)
q Stick sealing tape [1] etc. to the con-
tact surface of damper rubber (1), and
open and close the door a few times.
After that, check the section where
sealing tape [1] contacts operator's
cab.
Normal: When the door is closed,
the sealing tape comes in
contact lightly with the
operator's cab.
Abnormal: When the door is closed,
the sealing tape does not
come in contact with the
operator's cab, or hits the
cab so strongly that the
sealing tape comes off.
2) Adjusting
1] Adjusting height of damper rubber
q Increase or decrease shims (5)
inserted beneath damper rubber (1) to
adjust the height of the damper rubber
normal.
2] Check the relation between the door notch

and striker (on both sides).
q Move door (2) to the closing direction,
and check the engagement of latch (3)
and striker (4).
q Normal: Difference at (a) is 0.5 mm or
less.
a Check difference (a) between latch
center (y) and striker center (x) from
direction A.
56 WE051D0100
2] Adjusting height of latch and striker a Move the door in the opening direction
a. After tightening temporarily the mount- to check the engagement of the latch
ing bolt of striker (4), open and close and striker.
the door a few times, and align the 2] Check the installed height of stopper rub-
centers of latch (3) and striker (4). ber.
b. Check the engagement of latch (3) (Check 2 points on each side.)
and striker (4). a. Shake the door in open lock to and
c. Tighten securely the mounting bolt of fro, and check if any play is found.
striker (4). b. Check if the operation of the unlock
d. Open and close the door, and check lever requires greater force.
that the door lock can be released c. Check if striker (4) slants against cen-
smoothly. If the door lock cannot be ter (d) of the latch.
released smoothly (e.g. knob requires d. Check if the center (e) of latch and
greater force to turn), repeat adjust- striker is unaligned.
ment from the beginning. q Normal: Difference at (e) is 0.5 mm
a Force to turn knob: or less.
49±19.6 N {5±2 kg}
3] Apply grease (G2-LI) to latch (3).
a If the grease in latch (3) is depleted,
the knob requires greater force.
Accordingly, apply the grease suffi-
ciently.
4. Testing open lock

Lock the door open and check the relationship
between the operator's cab and door. If there is
any fault, repair it.
1) Check of condition
1] Check the relation between open lock
latch (3) and striker (4) from direction B.
2) Adjusting
1] Adjusting latch and striker
q Loosen mounting bolt (7) of striker (4),
adjust striker (4) upright, and tighten
the bolt.
WE051D0100 57
2] Adjusting installed height of stopper rub-

ber
a. Loosen locknuts (10) and (11) of stop-
per rubbers (8) and (9) (upper and
lower ones, respectively).
b. If any play is found, project (heighten)

the stopper rubber until the play disap-
pears.
a If the door is not locked easily or the
unlock lever requires greater force to
operate, return (lower) the stopper
rubber to the extent that the door has
no play.
c. Tighten the locknut.
58 WE051D0100
WE051D0200
Bulldozer
1Shop Manual
D61EX-15
D61PX-15

Testing and adjusting 1

Testing and adjusting (2/2) ............................................................................................... 2
Special functions of monitor panel (EMMS) .................................................................. 2
Adjustment method of replaced controller .................................................................. 34
Preparatory work for troubleshooting for electric system............................................ 36
Pm clinic ..................................................................................................................... 37
Undercarriage troubleshooting report ......................................................................... 44
Testing and adjusting (2/2) 1

Special functions of monitor panel (EMMS) 1
Display section of special functions Operation section 2 of special functions

1. Upper display section (Gear speed display section) (Selecting operation)
2. Lower display section (Multi-information section) 4. Buzzer cancel switch
5. Information switch
Operation section 1 of special functions 6. Shift-up switch
(Basic operation) 7. Shift-down switch
3. Service switch
a EMMS: Equipment Management Monitoring System
2 WE051D0200
Normal function and special functions of monitor panel (EMMS)
The monitor panel (EMMS) has the normal function and special functions and displays information of various types
at the gear speed display section at its center and the multi-information section.
Some items are displayed automatically according to the internal setting of the monitor panel and the others are
displayed according to the operation of the switches.
1) Normal function: Operator mode
With this function, the operator can display and change the items displayed ordinarily.
2) Special function: Service mode
With this function, a serviceman can display and change the displayed items with special switches for testing,
adjusting, and troubleshooting.
Flow of modes and functions
Operator mode
Normal display (Default) 1 Oil, filter maintenance mode Maintenance item: 12 items
[>] [<]
2 Pm clinic auxiliary mode Auxiliary menu: 2 items
Travel direction/Gear speed [>] [<]
[U ]
+
( ) 3 Error code display mode
Shift mode/Service meter
[>] [<]
[T] 4 Adjustment mode Adjustment menu: 3 items
[>] [<]
(Automatic) 1 Oil, filter maintenance mode
Action code display function
[ON] & [U ] ( ) [T]
Service mode
Maintenance interval change

5 Maintenance item: 12 items
mode
[>] [<]
Electric system error code
6
display mode
[>] [<]
Mechanical system error code
7
display mode
[>] [<]
8 Adjustment mode Adjustment menu: 16 items
[>] [<]
9 Load memory display mode Display menu: 3 items
[>] [<]
10 Real-time monitoring mode
[>] [<]
11 Dual display monitoring mode [ON] : Service switch
[>] [<] [U ] : Buzzer cancel switch (Left)
[ T ]: Buzzer cancel switch (Right)
Maintenance interval change [ > ]: Information switch (Right)
5
mode [ < ]: Information switch (Left)
( ): Min. 2.5 sec
WE051D0200 3
Operation and display in operator mode 1. Maintenance mode

(Outline) (1-OIL, FILTER MAINTENANCE MODE)
In this mode, the time up to the next replacement
a In this section, only the outline of the operator of oils and filters is displayed on multi-information
mode is described. For details of the contents and section (2) and reset after the replacement.
operation method of each function and mode, see a Gear speed display section (1) keeps display-
Operation and Maintenance Manual. ing normally.
Normal display mode (Default)

The monitor panel displays the following information
normally.
Gear speed display section (1):

q Front side: Travel direction (P/N/F/R)
q Rear side: Gear speed (1/2/3)
q Graphics: Engine speed
Multi-information section (2):

q Information is displayed in 2 lines of 16 characters
each.
q Front side: Gear shift mode (F1-R1, F1-R2, F2-
R2, F2-R3) (To be displayed when the
preset mode is set.)
q Rear side: Service meter (Unit: 0.1h)
q Each time the information switch is set to the right
or left, the service meter and engine speed are dis-
played alternately.
No. Maintenance item

01 Engine oil
02 Engine oil filter
03 Fuel filter
04 Hydraulic oil filter
05 Corrosion resistor
06 Bypass filter (*)
07 Damper oil
08 Final drive oil
09 Hydraulic oil
10 Power train oil
11 Power train oil filter
12 HSS charge filter (*)
a The items marked with (*) are displayed but

not used for this machine.
4 WE051D0200
2. Pm clinic auxiliary mode 3. Error code display mode

(2-PM CLINIC MODE) (3-ERROR CODE DISPLAY MODE)
In this mode, the condition of the machine is dis- In this mode, the contents of each fault in the
played on multi-information section (2) as an auxil- machine are displayed by a 6-character error code
iary function of the periodic diagnoses such as the on multi-information section (2).
Pm clinic, even if any measuring instrument is not When the user or the operator needs to be notified
connected. of the error code of each fault, this mode is
a Gear speed display section (1) keeps display- applied.
ing normally. a Gear speed display section (1) keeps display-
ing normally.
No. Pm clinic auxiliary item a When a serviceman needs to check the error
1 Engine speed codes for troubleshooting, the "Electric system
error code display mode" and the "Mechanical
2 Battery voltage
system error code display mode" should be
used for more detailed information.
a Method of checking error code:
Set buzzer cancel switch (4) in the [U] posi-
tion on the screen shown above, and all the
error codes detected currently are displayed at
the interval of about 2 seconds. (To finish dis-
playing, turn the buzzer cancel switch to the
[T] position.)
a For details of the displayed error codes, see
"Error codes list" in "Troubleshooting when
error code is displayed (Error code)".
WE051D0200 5
4. Adjustment mode Action code display function

(4-USER ADJUST MODE) If a fault to be notified to the operator occurs during
In this mode, the display condition of the monitor work, an action code and a phone No. are displayed
panel can be adjusted on multi-information section on multi-information section (2).
(2). a Gear speed display section (1) keeps displaying
a Gear speed display section (1) keeps display- normally.
ing normally. a The phone No. is displayed for only important
action codes. The display shown below is an
example. (The form of the displayed phone No.
depends on the form of the input No.)
a If an important action code is displayed, the warn-
ing lamp flashes and the caution buzzer sounds.
No. Adjustment item

01 Brightness of LCD
02 Brightness of display
03 Contrast of display
6 WE051D0200
<Reference>
An action code is displayed only when a serious fault
occurs.
Even if an action code is not displayed, a fault may
have occurred. If you feel any abnormality, be sure to
check for an error code in the "Electric system error
code display mode" and "Mechanical system error
code display mode" of the service mode.
Action codes table
Action Indication method of

Contents of fault Remedy
code fault
• Automatic function stops or normal
• Only action code is dis- • Backup alarm does not sound. function stops partially but machine
E01
played. • Fan speed is kept at maximum. can work.
• Call your Komatsu distributor for repair.
• Stop the engine and start it again,
• Action code is displayed. and you can operate the machine
• Gear is not shifted up or down.
E02 • Warning lamp flashes. without limiting function. But you
• The engine rotates irregularly.
• Caution buzzer sounds. must take care.
• Usable gear speeds are limited.
• Action code is displayed. • Engine speed does not rise fully.
• Move the machine to a safe place.
CALL E03 • Warning lamp flashes. • Gear shifting shocks become
• Caution buzzer sounds. large.
• Steering performance lowers.
• Action code is displayed. • Engine cannot be controlled.
• Stop the machine immediately.
CALL E04 • Warning lamp flashes. • Machine cannot travel.
• Caution buzzer sounds. • Machine stops.
WE051D0200 7
Operation and display in service mode
Gear speed
Sequence
section
display
Method of changing to service mode
a When using the service mode, change the screen Service mode items
by the following special operation.
1) Special operation of switches 5 1C Maintenance interval change mode

Set the monitor panel in the service mode by oper- 6 EE Electric system error code display mode
ating service switch (3) and buzzer cancel switch Mechanical system error code display
(4). 7 bE
mode
a Keeping the service switch in the ON position, 8 Cb Adjustment mode
hold the buzzer cancel switch in the [U] posi-
9 Ld Load memory display mode
tion for 2.5 seconds.
a If the monitor panel is set in the service mode, 10 5R Real-time monitoring mode
[1C] is displayed on the gear speed display 11 dR Dual display monitoring mode
section (1).
a When the service mode is selected, "Mainte-
nance interval change mode" is displayed first. 2) Selecting and executing mode to be used
Select the mode to be used with information switch
(5) and execute it with buzzer cancel switch (4).
q [>] : Next mode No.
q [<] : Previous mode No.
q [U] : Execute mode.
a For details of operation in each mode, see the
following pages.
3) Finishing mode and function

The current mode and function can be finished by
either of the following method, regardless of the
current mode and hierarchy.
1] When continuing the operation in another
mode, function or in the operator mode:
Return to the mode screen or function screen
to be used next by operating buzzer cancel
switch (4).
q [T] : Screen returns.
2] When finishing the all operation:
Turn off the starting switch.
8 WE051D0200
5. Maintenance interval change mode 2) Selecting and displaying maintenance item

(5-EXCHG. INTVAL. SET MODE) 1] Operate information switch (5) on the
In this mode, you can check and set the mainte- maintenance item selection screen to
nance interval times of various filters and oils select a maintenance item.
which are the bases of the maintenance display q [>] : Next code
function in the operator mode. q [<] : Previous code
2] Display the maintenance item selection
screen by operating buzzer cancel switch
(4).
q [U] : Execute item.
3) Contents of information screen

The following items are displayed on the infor-
mation screen.
(a) : Code
(b) : Maintenance item
(c) : Replacement interval time (Set time)
a The items shown below are examples.
a If the replacement interval does not need
to be changed, finish the operation on this
screen.
a If the replacement interval needs to be
changed, go to step 4).
1) Selecting and executing mode
1] Select "Maintenance interval change
mode" on the mode selection screen.
a If the mode is selected, code [1C] is
displayed on gear speed section (1)
and the title is displayed on multi-infor-
mation section (2).
2] Display the maintenance item selection
screen by operating buzzer cancel switch
(4).
WE051D0200 9
4) Changing replacement interval time 2] If the input time is correct, enter the
1] Change the set time by operating informa- change of setting by operating buzzer
tion switch (5), shift-up switch (6), and cancel switch (4).
shift-down switch (7). q [U] : Enter change.
q [>]: Move cursor to right. a If the change is finished normally, the
q [<]: Move cursor to left. information display screen appears
q [UP]: Increase number. after the screen shown below is dis-
q [DOWN]: Decrease number. played.
a If you do not use the maintenance a If the change is not finished normally,
function, set the all times to 0. the information display screen before
the change appears after the screen
shown below. In this case, execute the
above operation again.
10 WE051D0200
Maintenance items table
Replacement interval time

Code Maintenance item 1st time 2nd time
(Cannot be changed) (Can be changed)
01 ENG OIL Engine oil 0500 h 0500 h
02 ENG FILT Engine oil filter 0500 h 0500 h
03 FUEL FILT Fuel filter 0500 h 0500 h
04 HYD FILT Hydraulic oil filter 2000 h 2000 h
05 CORR RES Corrosion resistor 0500 h 0500 h
06 BYPS FILT Bypass filter - -
07 DAMP OIL Damper oil 2000 h 2000 h
08 FNL OIL Final drive oil 1000 h 1000 h
09 HYD OIL Hydraulic oil 2000 h 2000 h
10 POWL OIL Power train oil 1000 h 1000 h
11 POWL FILT Power train oil filter 0500 h 0500 h
12 12:HST FILT HSS charge filter (HSS specification) - -
a The first replacement interval is the same as the second and after replacement intervals, and the former can-
not be changed.
WE051D0200 11
6. Electric system error code display mode 2) Display in the case where no codes are
(6-ELEC. ERROR CODE MODE) recorded
In this mode, you can check the past electric sys- If no error codes have been output up to now,
tem error codes. the information section displays as shown
below.
3) Display in the case where 1 or more codes are

recorded
If any error code has been output up to now,
the information section displays as shown
below.
(a) : Record No. (Up to 20)
(b) : Error code (Code being output currently
is flashing)
(c) : Number of past occurrences
(d) : Time measured by service meter after
first occurrence
(e) : Time measured by service meter after
last occurrence
a For details of the displayed error codes,
1) Selecting and executing mode see "Error codes list" in "Troubleshooting
1] Select "Electric system error code display when error code is displayed (Error
mode" on the mode selection screen. code)".
a If the mode is selected, code [EE] is
mation section (2).
2] Display the error code display screen by
operating buzzer cancel switch (4).
a Flashing and lighting of error code

Flashing: Code is being output currently.
Lighting: Code is not being output currently.
12 WE051D0200
a Condition for detecting and keeping error 7. Mechanical system error code display mode
code (7-MACHINE ERROR CODE MODE)
If a error code other than communication In this mode, you can check the mechanical sys-
is output, it keeps flashing until the starting tem error codes among the codes of the faults
switch is turned off. After the starting which occurred in the past or which are occurring
switch is turned on or the engine is started currently in the machine.
again, the error code keeps lighting until
the same fault is detected.
A error code of communication starts light-
ing when the fault is solved, even if the
starting switch is turned off.
4) Operation to take when multiple codes are

recorded.
When multiple codes are recorded, they can
be displayed one by one by operating informa-
tion switch (5).
q [>]: Next code
q [<]: Previous code
a The error codes are displayed from the
oldest one in order of length of time after
they were output.
5) Method of deleting error code

While a error code to be deleted is displayed,
operate shift-up switch (6) or shift-down switch
(7).
q [UP] or [DOWN]: Delete error code.
a A error code which is being output cur-
rently (which is flashing) cannot be
deleted.

1] Select "Mechanical system error code dis-
play mode" on the mode selection screen.
a If the mode is selected, code [bE] is
displayed on gear speed display sec-
tion (1) and the title is displayed on
multi-information section (2).
2] Display the error code display screen by
operating buzzer cancel switch (4).
WE051D0200 13
2) Display in the case where no codes are a Condition for detecting and keeping error
recorded code
If no error codes have been output up to now, If a error code other than communication
the information section displays as shown below. is output, it keeps flashing until the starting
switch is turned off. After the starting
switch is turned on or the engine is started
again, the error code keeps lighting until
the same fault is detected.
A error code of communication starts light-
ing when the fault is solved, even if the
starting switch is turned off.
4) Operation to take when multiple codes are

recorded.
When multiple codes are recorded, they can
be displayed one by one by operating informa-
tion switch (5).
q [>]: Next code
q [<]: Previous code
3) Display in the case where 1 or more codes are a All the error codes, including the error
recorded codes which are not output, are displayed
If any error code has been output up to now, in the order set internally.
the information section displays as shown
below. 5) Method of deleting error code
(a) : No. The mechanical system error codes cannot be
(b) : Error code (Code being output currently deleted.
is flashing)
(c) : Number of past occurrences
(d) : Time measured by service meter after
first occurrence
(e) : Time measured by service meter after
last occurrence
a For details of the displayed error codes,
see the "Error codes list" in "Troubleshoot-
ing when error code is displayed (Error
code)".
a Flashing and lighting of error code

Flashing: Code is being output currently.
Lighting: Code is not being output currently.
14 WE051D0200
8. Adjustment mode 2) Selecting adjustment items

(8-SERVICE ADJUST MODE) 1] On the adjustment code input screen,
In this mode, you can adjust the control system input the 4-digit code of the item to be
and various devices of the machine. adjusted by operating information switch
(5), shift-up switch (6), and shift-down
switch (7).
q [>]: Move cursor to right.
q [<]: Move cursor to left.
q [UP]: Increase number.
q [DOWN]: Decrease number.
2] After inputting the codes, display the mon-
itoring screen by operating buzzer cancel
switch (4).
q [U] : Enter input codes.
a If an incorrect code is input, the

adjustment code input screen appears
again after the screen shown below is
displayed. In this case, execute the
above operation again.
1] Select the "Adjustment mode" on the
mode selection screen.
a If the mode is selected, code [Cb] is
mation section (2).
2] Display the adjustment code input screen
by operating buzzer cancel switch (4).
WE051D0200 15
3) Contents of display on adjustment screen 5) Changing adjustment item (Limited function)

(a) : Code Once the items are selected, they can be
(b) : Adjustment item selected with the information switch without
(c) : Related information inputting the codes again.
a For the detailed information and adjust- q [>] : Next code
ment procedure, see "Adjustment mode q [<] : Previous code
table and adjustment procedure". a This function is limited to the numbers
marked with a in the "Adjustment mode
table".
a This operation is not accepted while the
parking brake lever is in the Free position.
Take care.
a An adjustment item can be selected by
returning to the input screen and inputting
the code for that item.
4) When operating machine in adjustment mode

If the parking brake lever is set in the Free
position, gear speed display section (1) dis-
plays normally and the machine can be oper-
ated normally.
a At this time, even if shift-up switch (6) or
shift-down switch (7) is pressed with the
PCCS lever in the neutral position, the
shift cannot be changed.
To change the shift, set the PCCS lever in
the Forward or Reverse position and
press shift-up switch (6) or shift-down
switch (7) while the machine is traveling.
a When selecting another screen, return the
parking brake lever to the Lock position,
and then perform the necessary operation.
16 WE051D0200
Adjustment mode table and adjustment procedure
Related Disassembly/
No. Code Display Item
information Assembly
1 0001 INP TEL NO. Phone No. input mode Figure/Symbol
Steering and transmission controller
a 2 0002 S/T S. CODE Code q
specification set
a 3 0004 BODY TYPE Machine specification set Code q
a 4 0005 BRAKE BASE Brake potentiometer zero point adjustment Voltage q
a 5 0007 ENG. FULL CH Engine decelerator cut mode Speed
a 6 0009 PITCH SENS. Pitch angle sensor initial set Voltage q
a 7 0010 FAN 70%MODE Fan 70% speed mode Adjustment data
8 0801 GOV MTR ADJ Governor motor adjustment Speed q
a 9 1005 FAN100%MODE Fan 100% speed mode Adjustment data
10 1012 S/T N-SET Steering lever neutral set Voltage
11 1013 S/T M. L-SET Steering lever left max. set Voltage
12 1014 S/T M. R-SET Steering lever right max. set Voltage
13 2222 HSS ADJUST HSS lever initial current set Current
14 9997 HI IDLE SET High idling limit mode Speed
15 9998 SFT INHIBIT Gear speed limit mode Symbol
q Items marked with q in the Disassembly/Assembly column of the above table must be adjusted after the
machine is assembled or any controller is replaced. (For the adjustment procedure, see "Adjustment after
replacement of controller".)
The numbers marked with a can be displayed in order by adjusting the information switch to ">" or to "<."
WE051D0200 17
[0001]: Phone No. input mode

q This code is used to input and change the phone
No. displayed together with the action code.
q The phone No. and symbols are displayed on the
lower line.
q Adjustment method:
1) Set buzzer cancel switch (4) in the [U] posi-
tion and check that the caution buzzer sounds.
2) Check that the displayed specification code
has changed from [4*4] to [444].
q Usable characters: 0 1 2 3 4 5 6 7 8 9 : ; < > ? a If specification code [444] is not displayed, the
q How to use: controller wiring harness or the controller unit
1) Input the phone No. and symbols by operating may be defective.
information switch (5), shift-up switch (6), and a Even if this code is turned off, the setting is
shift-down switch (7). effective.
q [>]: Move cursor to right.
q [<]: Move cursor to left. [0004]: Machine specification set
q [UP]: Increase number or select next char- q This code is used to have the machine specifica-
acter (in the order of usable characters). tion recognized by the controllers which compose
q [DOWN]: Decrease number or select pre- the system.
vious character (in the order of usable q The machine specification code is displayed on
characters). the lower line.
a Sixteen digits of numeric characters are pro-
vided. To avoid confusion, input symbols other
than numeric characters at digits you will not
use.
a 0 (zero) is input at all places of the low part
before shipment from our factory. (No phone
number is displayed under this condition.)
a Even if this code is turned off, the setting is
effective.
[0002]: Steering and transmission controller specifica-

tion set
q This code is used to initialize the specification
codes recognized by the steering controller and No. Specifications
the set values of the memory in the controller. 000 Standard
q The specification code is displayed on the lower
080 For cold districts
line.
008 Not used for this machine.
18 WE051D0200
q Adjustment method: [0009]: Pitch angle sensor initial set

a Since this code is reset when "Steering and q This code is used to adjust the zero point and
transmission controller specification set" is installation error of the pitch angle sensor.
executed, adjust it after that. q The deviation from the neutral position to the
1) Select the machine specification code by standard is displayed by voltage on the lower line
operating shift-up switch (6). (Display range: -2500 - 2500).
k If the machine specification is different from
the setting in the controller, the machine may
move abnormally or an error may occur.
Accordingly, be sure to match the setting to
the machine specification.
effective.
[0005]: Brake potentiometer zero point adjustment

q This code is used to adjust the zero point of the
potentiometer of the brake pedal.
q The deviation from the standard is displayed by
voltage on the lower line (Display range: -2500 -
2500). q Adjustment method:
Stop the machine on level ground, then set buzzer
cancel switch (4) in the [U] position and check
that the caution buzzer sounds.
a The display of the lower line does not change
after adjustment.
effective.
[0010]: Fan 70% speed mode

q This code forcedly sets the rpm of cooling fan at
approximately 70% of the maximum speed.
q The lower part displays data for adjustment.
With the brake pedal released, set buzzer cancel
switch (4) in the [U] position and check that the
caution buzzer sounds.
after adjustment.
effective.
a This code is not for adjustment of the braking
performance.
[0007]: Engine decelerator cut mode

a Since the auto-deceleration function is not avail- q How to use:
able on this machine, the high idling speed does The function is enabled with this code displayed to
not change before and after this code is displayed. control the rpm of cooling fan to approximately
70% of the maximum speed.
a Ending this code disables the function.
WE051D0200 19
[0801]: Governor motor adjustment [1005]: Fan 100% speed mode

q This code is used to compensate the relations q This code forcedly sets the rpm of cooling fan at
between governor motor position and engine approximately 100% of the maximum speed.
speed and to correct difference between the target q The lower part displays data for adjustment.
speed and actual speed of the engine with the fuel
control dial.
a Use this code after adjusting the fuel control link-
age.
k Since engine speed changes automatically
when this code is used, use it very carefully so
that the machine does not move unexpectedly.
q The engine speed is displayed on the lower line
(Display range: 0 - 3000).
1) Change the engine speed to the high idling
speed by operating shift-up switch (6) and
shift-down switch (7).
a The fuel control dial does not function.
q [UP]: Increase engine speed. q How to use:
q [Down]: Decrease engine speed. The function is enabled with this code displayed to
2) Set buzzer cancel switch (4) in the [U] posi- control the rpm of cooling fan to approximately
tion and check that the caution buzzer sounds. 100% of the maximum speed.
Engine speed is automatically corrected while a Ending this code disables the function.
being changed.
3) When engine speed changed to low idling, [1012]: Steering lever neutral set
make it sure again that the caution buzzer q This code is used to adjust the neutral position of
sounds. the steering potentiometer of the PCCS lever.
a Even if this code is turned off, the setting is q The signal output of the steering potentiometer is
effective. displayed by voltage on the lower line.
(Display range: 0 - 5000)
1) Set the PCCS lever in the steering neutral
position.
after adjustment.
effective.
a This code is not used to adjust the steering
performance, etc.
20 WE051D0200
[1013]: Steering lever left max. set q Adjustment method:

q This code is used to adjust the left maximum posi- 1) Set the PCCS lever to the right steering stroke
tion of the steering potentiometer of the PCCS end.
lever. 2) Set buzzer cancel switch (4) in the [U] posi-
q The signal output of the steering potentiometer is tion and check that the caution buzzer sounds.
displayed by voltage on the lower line. a The display of the lower line does not change
(Display range: 0 - 5000) after adjustment.
effective.
performance, etc.
[2222]: HSS lever initial current set

q When the steering start feeling is different by the
steering direction, this code is used to adjust the
turning radius at the start of steering.
q The current to drive the HSS EPC solenoid is dis-
played on the lower line [Display range: -350 (Left
end) - 0 - 350 (Right end)].
1) Set the PCCS lever to the left steering stroke
end.
after adjustment.
effective.
performance, etc.
[1014]: Steering lever right max. set q Adjustment method:

q This code is used to adjust the right maximum 1) Gradually turning the PPC lever to the left or
position of the steering potentiometer of the PCCS right, display and keep the current to be set.
lever. q If the lever is turned to the left, the current
q The signal output of the steering potentiometer is becomes negative.
displayed by voltage on the lower line. q If the lever is turned to the right, the cur-
(Display range: 0 - 5000) rent becomes positive.
a As the set current is increased in the positive
or negative direction, the turning radius at the
start of steering is decreased (the machine
turns more quickly).
a The figure shows an example that the set cur-
rent for steering to the left is reduced to
increase the turning radius.
effective.
WE051D0200 21
[9998]: Gear speed limit mode

q This code is used to prevent shifting the gear to
the 3rd gear speeds.
q The usable gear speeds are displayed by bits on
the lower line (in the order of the 3rd, 2nd, and 1st
from the left).
[9997]: High idling limit mode

q This code is used to limit the high idling speed.
q The limited speed (0 - 400) is displayed on the
lower line.
q Limit range: High idling speed to -400 rpm
q How to use:
Limit or allow the use of the maximum gear speed
by operating information switch (5) and buzzer
cancel switch (4).
q [>]: Do not prohibit shifting to 3rd gear speed.
q [<]: Limit shifting to 3rd gear speed.
q [U]: Enter the selection.
q Display on lower line [o]: Gear speed is effec-
tive.
q Display on lower line [ _ ]: Gear speed is inef-
fective.
a If the use of a gear speed is limited, the trans-
mission is not shifted to that gear speed even
if the gear shift-up switch is operated.
q How to use: a Even if this code is turned off, the setting is
1) Select a limit speed by setting information effective.
switch (5) in the [>] position or [<] position.
a If the high idling speed is limited, the engine
speed is not raised to the normal high idling
level even if the fuel control dial is controlled
so.
effective.
22 WE051D0200
9. Load memory display mode 3) Display information of 1,000 rpm service meter
(9-LOAD MEMORY DISPLAY MODE) (01)
In this mode, you can check the load on the This code is used to display the service meter
machine, odometer, and reverse odometer. which integrates the operation hours only
while the engine speed is higher than 1,000
rpm.
a The data cannot be reset.
4) Display information of forward odometer (02)

On this screen, the integrated forward travel
distance of the machine is displayed.

1] Select "Load memory display mode" on
the mode selection screen.
a If the mode is selected, code [Ld] is
displayed on gear speed display sec-
tion (1) and the title is displayed on
multi-information section (2).
5) Display information of reverse odometer (03)
2] Display the information screen of Mainte-
On this screen, the integrated reverse travel
nance Item by operating buzzer cancel
distance of the machine is displayed.
switch (4).
2) Changing information screen

Change the information screen by operating
information switch (5).
q [>] : Next screen
q [<] : Previous screen
No. Display information

01 1,000 rpm service meter
02 Forward odometer
03 Reverse odometer
WE051D0200 23
6) When operating machine in load memory dis- 10. Real-time monitoring mode
play mode (10-REAL TIME MONITORING MODE)
If the parking brake lever is set in the Free In this mode, the speeds, oil pressures, oil temper-
position, gear speed display section (1) dis- atures, currents, voltages, etc. can be monitored
plays normally and the machine can be oper- by using the signals from sensors, switches, and
ated normally. solenoids installed various parts of the machine.
a At this time, even if shift-up switch (6) or shift- a This mode is used to monitor only 1 item.
down switch (7) is pressed with the PCCS When monitoring 2 items simultaneously, use
lever in the neutral position, the shift cannot be the "Dual display monitoring mode".
changed.
To change the shift, set the PCCS lever in the
Forward or Reverse position and press shift-
up switch (6) or shift-down switch (7) while the
machine is traveling.
a When selecting another screen, set the park-
ing brake lever in the Lock position tempo-
rarily, and then perform the necessary
operation.

1] Select "Real-time monitoring mode" on the
mode selection screen.
a If the mode is selected, code [5R] is
mation section (2).
2] Display the monitoring code input screen
24 WE051D0200
2) Selecting and executing monitored items a If the input codes are abnormal, the code input
1] On the code input screen, input the 5-digit screen appears again after the screen shown
codes of the items to be monitored to the below.
upper and lower lines by operating infor-
mation switch (5), shift-up switch (6), and
q [>]: Move cursor to left.
q [<]: Move cursor to right.
3) Contents of display on monitoring screen (Fig-

ure below shows examples)
(a) : Code
(b) : Monitoring item
(c) : Information
(d) : Unit (Not displayed for some items)
a For details, see the "Monitoring mode
2] After inputting the codes, display the mon- table".
switch (4).
a If the input codes are normal, the
monitoring screen shown below
appears.
WE051D0200 25
4) Function of holding monitoring information 6) Changing monitored items (Limited function)

If an information item such as the engine Once the monitoring screen is selected in step
speed is not stabilized and cannot be read 2), the monitored item can be changed by
easily in the monitoring mode, it can be held operating only information switch (5) without
and released by operating buzzer cancel inputting the code again.
switch (4).
q [U] : Hold and release.
a While the monitored item is held, the letter
"H" is displayed at the left end of the lower
line.
q [>] : Next code

q [<] : Previous code
a This function is applicable to only the num-
bers marked with a.
a This operation is not accepted while the
5) When operating machine in monitoring mode parking lever is in the Free position. Take
If the parking brake lever is set in the Free care.
ated normally.
a When selecting another screen, set the
parking brake lever in the Lock position
temporarily, and then perform the neces-
sary operation.
26 WE051D0200
Monitoring mode table
Display
No. Code Item Unit
range
a1 01000 ENG. SPEED Engine speed rpm 0-3000
2 01300 TVC SOL F/B Output FB current of TVC solenoid mA 0-1000
3 01301 TVC SOL OUT Output command current of TVC solenoid mA 0-1000
4 03000 FUEL DIAL Voltage of fuel control dial mV 0-5000
5 03100 GOV M F/B Governor motor FB potentiometer voltage value mV 0-5000
a6 03200 BATTERY Battery voltage mV 0-30000
7 03300 MOTOR PH. A Governor motor phase A current mA -1000-1000
8 03400 MOTOR PH. B Governor motor phase B current mA -1000-1000
a9 04102 WATER HIGH Engine coolant temperature (High temperature side) °C 0 - 150
a10 04104 WATER LOW Engine coolant temperature (Low temperature side) °C -30 - 100
a11 04200 FUEL SENS Fuel level sensor voltage mV 0 - 5000
12 04401 HYD. TEMP. Hydraulic oil temperature °C 0-150
13 04402 HYD. TEMP. Hydraulic oil temperature sensor voltage mV 0 - 5000
14 10000 FAN REVO. Command speed of cooling fan rpm 0 - 2000
15 20200 MON. PROGRM Monitor panel (Tachometer module) program No. Character
16 20202 S/T. PROGRM Steering controller program No. Character
17 20300 KOMTRAX KOMTRAX LED display (For Japan only) -
a18 30100 T/C TEMP. Torque converter oil temperature °C 0 - 150
a19 31400 T/M OUT Transmission speed rpm 0 - 5000
(See detailed
20 31520 T/M-FILL Input state of transmission-related fill switch Bit
information.)
21 31602 1st CLUTCH Output command current of 1st clutch ECMV mA 0 - 1000
22 31603 2nd CLUTCH Output command current of 2nd clutch ECMV mA 0 - 1000
23 31604 3rd CLUTCH Output command current of 3rd clutch ECMV mA 0 - 1000
24 31606 Rev CLUTCH Output command current of reverse clutch ECMV mA 0 - 1000
25 31608 Frd CLUTCH Output command current of forward clutch ECMV mA 0 - 1000
a26 31612 1 CLUTCH F Output FB current of 1st clutch ECMV mA 0 - 1000
a27 31613 2 CLUTCH F Output FB current of 2nd clutch ECMV mA 0 - 1000
a28 31614 3 CLUTCH F Output FB current of 3rd clutch ECMV mA 0 - 1000
a29 31616 R CLUTCH F Output FB current of reverse clutch ECMV mA 0 - 1000
a30 31622 F CLUTCH F Output FB current of forward clutch ECMV mA 0 - 1000
31 31623 FAN PUMP. O Output command current of cooling fan pump solenoid mA 0 - 1000
32 31624 FAN PUMP. F Output FB current of cooling fan pump solenoid mA 0 - 1000
a33 32900 BODY ANGLE Machine pitch angle ° -30 - 30
a34 40001 VEHICLE SP Travel speed (Theoretical value) km/h 0 - 100
(See detailed
35 40900 ENG-SW 1 Engine-related controller input signal 1 Bit
information.)
(See detailed
36 40905 T/M-SW1 Transmission-related controller input signal 1 Bit
information.)
(See detailed
37 40906 T/M-SW2 Transmission-related controller input signal 2 Bit
information.)
(See detailed
38 40909 TM SOL. 2 Transmission-related controller output signal Bit
information.)
(See detailed
39 40910 S/T SW1 Steering-related controller input signal 1 Bit
information.)
(See detailed
40 40911 S/T SW2 Steering-related controller input signal 2 Bit
information.)
WE051D0200 27
Display
No. Code Item Unit
range
(See detailed
41 40913 S/T-SW5 Steering-related controller input signal 5 Bit
information.)
(See detailed
42 40914 S/T SOL.1 Output signal of steering controller Bit
information.)
43 50001 DECEL PEDL Decelerator pedal voltage mV 0 - 5000
44 50002 DECEL PEDL Deceleration command speed rpm 0 - 2500
a45 50200 T/M LEVER 1 Voltage of forward-reverse potentiometer 1 mV 0 - 5000
a46 50201 T/M LEVER 2 Voltage of forward-reverse potentiometer 2 mV 0 - 5000
a47 50300 S/T LEVER 1 Voltage of steering potentiometer 1 mV 0 - 5000
a48 50301 S/T LEVER 2 Voltage of steering potentiometer 2 mV 0 - 5000
a49 50400 BRAKE PEDL Voltage of brake potentiometer mV 0 - 5000
a50 50600 HSS L.H.F Output FB current of left HSS solenoid mA 0 - 1000
a51 50601 HSS R.H.F Output FB current of right HSS solenoid mA 0 - 1000
52 50602 HSS L.H.O Output command current of left HSS solenoid mA 0 - 1000
53 50603 HSS R.H.O Output command current of right HSS solenoid mA 0 - 1000
a54 50900 N-SAFETY Drive current of neutral safety relay mV 0 - 30000
55 51000 SSC ORDER 3rd throttle command speed rpm 0 - 3000
56 51100 FUEL DIAL Acceleration command speed rpm 0 - 2500
a57 60000 TRACTION Drawbar pull (Theoretical value) W 0-0
58 60100 BODY ANGLE Machine pitch angle sensor voltage mV 0 - 5000
59 60600 BR HOLD Drive voltage of battery relay mV 0 - 30000
60 60700 S/T MODE Steering state code Character
61 60800 FILL MODE Variable for setting fill condition Character
62 60909 MOD. MODE Variable for setting of modulation condition Character
63 70000 CHG. P. MODE Variable for setting condition of gear shift point Character
64 70400 BACK ALARM Drive voltage of back-up alarm relay mV 0 - 30000
The numbers marked with a can be displayed in order by operating the information switch to ">" or to "<".
28 WE051D0200
Examples of display of bit information [40900]: Engine-related controller input signal 1

a The display position of the bit information in the (a) : Starting switch signal C : Input
"Real-time monitoring mode (Display of only 1 (b) : (Unused)
item)" is different from that in the "Dual display (c) : (Unused)
monitoring mode (Simultaneous display of 2 (d) : Engine oil pressure switch : ON
items)". (e) : (Unused)
a The bit information is displayed by [ _ ] for OFF (f) : (Unused)
and [o] for ON in the places (a) - (h). (g) : (Unused)
a The state of each item shown below is the condi- (h) : (Unused)
tion for turning on the bit.
[40905]: Transmission-related controller input signal 1

[31520]: Transmission-related fill switch input state (a) : Shift-up switch : OFF
(a) : Forward clutch fill switch :ON, (b) : Shift-up switch : ON
(b) : Reverse clutch fill switch : ON, (c) : Shift-down switch : OFF
(c) : 1st clutch fill switch : ON, (d) : Shift-down switch : ON
(d) : 2nd clutch fill switch : ON, (e) : (Unused)
(e) : 3rd clutch fill switch : ON, (f) : (Unused)
(f) : (Unused) (g) : (Unused)
(g) : (Unused) (h) : (Unused)
(h) : (Unused)
WE051D0200 29
[40906]:Transmission-related controller input signal 2 [40910]: Steering-related controller input signal 1

(a) : Auto shift-down switch : ON (a) : (Unused)
(b) : Fan reverse rotation mode : ON (b) : (Unused)
(c) : Fan reverse rotation 100% mode : ON (c) : (Unused)
(d) : (Unused) (d) : (Unused)
(e) : (Unused) (e) : Parking lever switch : FREE
(f) : (Unused) (f) : Parking lever switch : LOCK
(g) : (Unused) (g) : (Unused)
(h) : (Unused) (h) : (Unused)
[40909]: Transmission-related controller output signal [40911] : Steering-related controller input signal 2
(a) : Transmission N-signal: ON (a) : Buzzer cancel switch : U position
(b) : (Unused) (b) : Buzzer cancel switch : T position
(c) : (Unused) (c) : Information switch : > position
(d) : Backup alarm relay : ON (d) : Information switch : < position
(e) : Neutral safety relay: ON (e) : Service switch: ON
(f) : (Unused) (f) : (Unused)
(g) : (Unused) (g) : (Unused)
(h) : (Unused) (h) : (Unused)
30 WE051D0200
[40913]: Steering-related controller output signal 5 11. Dual display monitoring mode
(a) : ACC signal : ON (11-DUAL DISPLAY MONITORING MODE)
(b) : (Unused) In this mode, 2 monitored items can be displayed
(c) : (Unused) simultaneously.
(d) : Motoring signal : ON a Note that only codes and monitoring informa-
(e) : (Unused) tion are displayed in this mode since the
(f) : (Unused) usable display columns are limited. (Item
(g) : (Unused) names and units cannot be displayed.)
(h) : (Unused)
[40914]: Steering-related controller output signal

(a) : (Unused)
(b) : Engine stop solenoid : ON
(c) : Fan reverse rotation solenoid : ON
(d) : (Unused)
(e) : Battery relay drive : ON
(f) : (Unused)
(g) : (Unused)
(h) : (Unused)

1] Select "Dual display monitoring mode" on
the mode selection screen.
a If the mode is selected, code [dR] is
mation section (2).
2] Display the monitoring code input screen
WE051D0200 31
2) Selecting and executing monitored items a If the input codes are abnormal, the
1] On the code input screen, input the 5-digit code input screen appears again after
codes of the items to be monitored to the the screen shown below.
upper and lower lines by operating infor-
mation switch (5), shift-up switch (6), and
q [>]: Move cursor to left.
q [<]: Move cursor to right.
3) Contents of display on monitoring screen (Fig-

ure below shows examples)
(a) : Code 1
(b) : Information 1
(c) : Code 2
(d) : Information 2
a For details, see the "Monitoring mode
2] After inputting the codes, display the mon- table".
switch (4).
a If the input codes are normal, the
m o n i t o r in g s c r e e n s h o w n b e l o w
appears.
32 WE051D0200
4) When operating machine in monitoring mode

If the parking brake lever is set in the Free
ated normally.
a When selecting another screen, set the
parking lever in the Free position tempo-
rarily, and then perform the necessary
operation.
WE051D0200 33
Adjustment method of replaced 4. Adjusting machine specification

controller 1 Select Machine specification set (0004) and adjust
the machine specification.
a After the machine is assembled or steering and
transmission controller is replaced, adjust the sys-
tem according to the following procedure.
k If the system is not adjusted, the machine may
not operate normally and may move suddenly.
Accordingly, be sure to adjust it.
a Precautions for replacing a controller: If a control-
ler is replaced, the memory of the oil and filter
maintenance mode is reset. Accordingly, take a
record of the next replacement periods of the oils
and filters.
a Precautions for replacing a controller: When
replacing a controller, stop the machine in a safe
place and turn the starting switch off.
1. Changing to service mode 5. Adjusting brake potentiometer

Turn the starting switch on and set the monitor Select Brake potentiometer initial set (0005) and
panel in the "Adjustment mode" of the service adjust the brake potentiometer.
mode.
2. Adjusting steering and transmission controller

Select steering and transmission controller specifi-
cation set (0002) and adjust the steering and
transmission controller.
6. Adjusting pitch angle sensor

Select and adjust the initial setting (0009) of the
pitch angle sensor.
3. Turning power on again

Turn the starting switch off and on, then set the
monitor panel in the "Adjustment mode" of the ser-
vice mode again.
34 WE051D0200
7. Adjusting governor motor

Select Adjusting governor motor (0801) and adjust
the governor motor.
8. Turning power on again

Turn the starting switch off at first and turn it on
again.
9. Adjusting error code:

1) Set the monitor panel in the "Electric system
error code display mode" of the service mode.
2) See if any error code is being output currently.
If any error code is not being output, delete the
all recorded error codes.
a If any error code is being output, remove
its cause by troubleshooting and execute
steps 6 and 7 again.
a Precautions after replacing controller:
If any controller is replaced, the service
meter in the oil and filter maintenance
mode is reset to 0.
As a result, the replacement period dis-
played on the monitor panel may be differ-
ent from the actual operating hours. The
remaining time recorded before the
replacement is used for management until
the first maintenance after the replace-
ment.
WE051D0200 35
Preparatory work for troubleshooting 2. Steering transmission controller

for electric system 1 1) Remove left console box inspection cover (3).
a When carrying out troubleshooting for an electric

circuit related to the monitor panel, engine control-
ler or steering and transmission controller, expose
the related connectors according to the following
procedure.
1. Monitor panel
1) Remove cover (1) above the dashboard.
2) Insert or connect the T-adapters for trouble-

shooting in or to connectors ST1, ST2, and
ST3 of steering and transmission controller
(5).
a If the connectors cannot be disconnected
and connected easily, remove the control-
ler from the floor frame in advance.
a Since the connectors are secured with
screws, loosen those screws before dis-
2) Insert or connect the branch adapters for trou- connecting.
bleshooting in or to connectors S03 and S04 a When connecting the connectors again,
on the back side of monitor panel (2). tighten their screws to the specified
torque.
3 Screw: 2.82 Nm {0.288 kgm}
36 WE051D0200
Pm clinic 1
Pm CLINIC SERVICE
Model Serial No. Service meter
D61EX, PX-15 h
User name Date of clinic Serviceman
Specifications
Blade Attachment Shoe width
Power angle, power tilt blade Multi-shank ripper 600 mm
Semi-U blade Towing winch 860 mm
Straight tilt blade CAB
ROPS
Operating conditions
Quarry, mine Construction Type of soil (specific gravity ) Type of work
Coal Construction, civil engineering Rock Dozing, digging %
Gold Roads, residential development Gravel Side cutting %
Limestone Tunnels Sand Grading %
Clay Travel %
Existence of abnormalities
Oil, coolant level check
Engine coolant level When necessary
Engine oil level Power train Damper case
Hydraulic oil level Final drive ( )
Engine coolant temperature Max. range Power train oil temperature Max. range Ambient temperature
Max.
Min.
Height above sea level
m
Operator's opinion
Visual check results
Service code history
E h E h
Content: Content:
E h E h
Content: Content:
WE051D0200 37
Pm-clinic measuring points (1/2)
Reference page for measurement procedure

*1. Engine speed : Pages D0100-5 to -6
*2. Blow-by pressure : Page D0100-14
*3. Engine oil pressure : Page D0100-18
*4. Boost pressure : Page D0100-7
38 WE051D0200
Pm-clinic measuring points (2/2)
Reference page for measurement procedure

*6. Items related to torque converter : Pages D0100-25
*7. Items related to transmission : Pages D0100-26
*8. Items related to steering brake : Pages D0100-24
*9. Items related work equipment and HSS : Pages D0100-39
WE051D0200 39
Machine serial T D61EX-15 #

Pm clinic check sheet number T D61PX-15 #
Work order No. Date Service meter Serviceman

h
Standard value Service limit Measurement

Item Measurement conditions Unit Pass Fail
for new machine value result
Low idling 850 - 950 850 - 950
Full Deceleration pedal depressed 1,150 - 1,200 1,150 - 1,200
Engine speed rpm
Full 1,950 - 2,050 1,950 - 2,050
Torque converter stool 1,520 - 1,720 1,500
Blow-by kPa Max. 0.49 Max. 0.98
Torque converter stool
pressure {mmAq} {Max. 50} {Max. 100}
Engine at low Min. 0.10 0.07
Engine
idling {Min. 1.0} {0.7}

SAE10W
Engine at full 0.25 - 0.44 0.18
Engine oil throttle MPa {2.5 - 4.5} {1.8}
pressure Engine at low {kg/cm2} Min. 0.15 0.07
idling {Min. 1.5} {0.7}
SAE15W-40, SAE30
Engine at full 0.29 - 0.49 0.21
throttle {3.0 - 5.0} {2.1}
Boost kPa Min. 79.8 63.8
Torque converter stool
pressure {mmHg} {Min. 600} {480}

Inlet oil 0.1 - 0.5 0.1 - 0.5
pressure {1 - 5} {1 - 5}
Torque converter
Engine at low idling

Outlet oil Transmission : 0.09 - 0.29 0.09 - 0.29
pressure Neutral MPa {0.9 - 3} {0.9 - 3}
Inlet oil Oil temperature: {kg/cm2} Max. 0.88 Max. 0.88
pressure 70 - 90°C {Max. 9} {Max. 9}
Engine at full throttle
Outlet oil 0.44 - 0.69 0.44 - 0.69
pressure {4.5 - 7} {4.5 - 7}

2.55 - 2.74 Min. 2.35
Transmission

Main relief Transmission : MPa {26 - 28} {Min. 24}
pressure Neutral Engine at full {kg/cm2} 2.84 - 3.14 Min. 2.65
throttle {29 - 32} {Min. 27}
• Fan 100% speed mode Min.
800±50 700
• Engine at low idling speed
Cooling fan
Fan speed rpm

• Fan 100% speed mode Max. -100
1,700 -0 1,600
• Engine at high idling speed
Fan pump • Fan 100% speed mode MPa 16.7 - 19.6 14.7
oil pressure • Engine high idling {kg/cm2} {170 - 200} {150}
40 WE051D0200
Machine serial T D61EX-15 #

Pm clinic inspection sheet number T D61PX-15 #

h
Measurement Standard value Service limit Measurement

Item Unit Pass Fail
conditions for new machine value result
31.1 - 35.1 Min. 28.9
Steering load sending pressure
Steering
Engine at full {318 - 358} {Min. 295}

throttle MPa 32.1 - 37.0 Min. 29.9
Steering relief pressure
{kg/cm2} {328 - 378} {Min. 305}
Engine at full 2.75 - 2.94 Min. 2.55
Brake actuating pressure
throttle {28 - 30} {Min. 26.0}
Brake
Apply the brakes and bring the engine to full

Brake performance Machine must not move
throttle with the transmission at F2.

Min. 19.1 Min. 19.1
Ripper lift relief
{Min. 195} {Min. 195}
Min. 19.1 Min. 19.1
Blade tilt relief
HSS and work {Min. 195} {Min. 195}
components
Hydraulic
equipment pump MPa 19.6 - 21.6 Min. 17.6

Ripper lift relief
{kg/cm2} {200 - 220} {Min. 180}
Engine at full 19.6 - 21.6 Min. 17.6
Blade tilt relief
throttle {200 - 220} {Min. 180}
PPC valve output 3.82 - 4.12 3.82 - 4.12
Blade tilt relief
pressure {39 - 42} {39 - 42}

Item Unit Pass Fail
Engine at full
Work equipment
Blade lift 2.3 - 2.7 Min. 3.0

throttle
Engine at full
speed
Single tile (Left o Right) sec 2.3 - 2.7 Min. 3.0

throttle
Engine at full
Ripper RAISE (D61EX-15 (OP)) 1.2 - 1.6 Min. 1.9
throttle

Item Unit Pass Fail
Hydraulic oil temperature °C 44 - 55 -
Hydraulic
drift
Blade lift cylinder Engine stopped mm/ Max. 100 Max. 100
Blade tilt cylinder 15 min. Max. 200 Max. 200

Item Unit Pass Fail
There must be no excessive
Visual inspection of final drive drain plug Engine stopped -
metal particles
Always fill in the record when repairing, adjusting, or replacing main parts.
Date Service meter Repair record Date Service meter Repair record
WE051D0200 41
Pm clinic
Machine
undercarriage check sheet serial number
T D61EX-15 #

h
q Measure the bushing temperature immediately after operations

Left side of machine
Measurement Pas
results
Fail
s
Right side of machine
Measurement Pas
results
Fail
s
q Opening of track link

Left track A: Clearance between links
Pin No. 1.2
Right track A: Clearance between links

Pin No. 1.2
42 WE051D0200
Pm clinic
Machine
undercarriage check sheet serial number
T D61PX-15 #

h
q Measure the bushing temperature immediately after operations

Left side of machine
Measurement Pas
results
Fail
s
Right side of machine
Measurement Pas
results
Fail
s
q Opening of track link

Left track A: Clearance between links
Pin No. 1.2
Right track A: Clearance between links

Pin No. 1.2
WE051D0200 43
Undercarriage troubleshooting report 1

D61EX-15 (Normal) (Program form No. : SELA195001)
44 WE051D0200
D61EX-15 (Impact) (Program form No. : SELA195001)
WE051D0200 45
D61PX-15 (Normal) (Program form No. : SELA195001)
46 WE051D0200
D61PX-15 (Impact) (Program form No. : SELA195001)
WE051D0200 47
48 WE051D0200
WE051E0100
Bulldozer
1Shop Manual
D61EX-15
D61PX-15

Troubleshooting 1
Preface............................................................................................................................. 2
Points to remember when troubleshooting ................................................................... 2
Troubleshooting procedure ........................................................................................... 3
Points to remember when carrying out maintenance.................................................... 4
Checks before troubleshooting ................................................................................... 11
Classification and procedures of troubleshooting ....................................................... 12
Connector arrangement drawing and electric circuit diagram of each system ........... 15
Troubleshooting Shop Manual
Preface 1
Points to remember when troubleshooting 1
k Park the machine in a level place, and check that the safety pin and chocks are securely fitted and
parking brake is applied.
k When carrying out the operation with two or more workers, keep strictly to the agreed signals, and do
not allow any unauthorized person to come near.
k If the radiator cap is removed when the engine is hot, hot water may spurt out and cause burns, so
wait for the engine to cool down before starting troubleshooting.
k Be extremely careful not to touch any hot parts or to get caught in any rotating parts.
k When disconnecting wiring, always disconnect the negative (-) terminal of the battery first.
k When removing the plug or cap from a location which is under pressure from oil, water, or air, always
release the internal pressure first. When installing measuring equipment, be sure to connect it prop-
erly.
The aim of troubleshooting is to pinpoint the basic cause of the failure, to carry out repairs swiftly, and to prevent
reoccurrence of the failure. When carrying out troubleshooting, and important point is of course to understand the
structure and function of the machine. However, a short cut to effective troubleshooting is to ask the operator vari-
ous questions to form some idea of possible causes of the failure that would produce the reported symptoms.
1. When carrying out troubleshooting, do not hurry to disassemble the components.

If components are disassembled immediately any failure occurs:
q Parts that have no connection with the failure or other unnecessary parts will be disassembled.
q It will become impossible to find the cause of the failure.
It will also cause a waste of manhours, parts, or oil or grease, and at the same time, will also lose the reliability
of the user or operator.
For this reason, when carrying out troubleshooting, it is necessary to carry out thorough prior investigation and
to carry out troubleshooting in accordance with the fixed procedure.
2. Points to ask user or operator
1) Have any other problems occurred apart from the problem that has been reported?
2) Was there anything strange about the machine before the failure occurred?
3) Did the failure occur suddenly, or were there problems with the machine condition before this?
4) Under what conditions did the failure occur?
5) Had any repairs been carried out before the failure? When were these repairs carried out?
6) Has the same kind of failure occurred before?
3. Checks before troubleshooting
1) Check the machine for a sign of abnormality.
2) Check items to be checked for work.
3) Check other items to be checked.
4) Check other related maintenance items that can be visually checked.
4. Confirming failure
Confirm the extent of the failure, and make a judgment whether it is a real failure or machine was operated
correctly.
a When operating the machine to reenact the troubleshooting symptoms, do not carry out any investigation
or measurement that may make the problem worse.
5. Troubleshooting
Use the results of the investigation and inspection in Items 2 - 4 to narrow down the causes of failure, then use
the troubleshooting flowchart to locate the position of the failure exactly.
a The basic procedure for troubleshooting is as follows.
1] Start from the simple points.
2] Start from the most likely points.
3] Investigate other related parts or information.
6. Measures to remove root cause of failure
Even if the failure is repaired, if the root cause of the failure is not repaired, the same failure will occur again.
To prevent this, always investigate why the problem occurred. Then, remove the root cause.
2 WE051E0100
Shop Manual Troubleshooting
Troubleshooting procedure 1
WE051E0100 3
Points to remember when carrying

out maintenance 1
To maintain the performance of the machine over a
long period, and to prevent failures or other troubles
before they occur, correct operation, maintenance and
inspection, troubleshooting, and repairs must be car-
ried out. This section deals particularly with correct
repair procedures for mechatronics and is aimed at
improving the quality of repairs. For this purpose, it
gives sections on "Handling electric equipment" and
"Handling hydraulic equipment" (particularly gear oil
and hydraulic oil).
1. Points to remember when handling electric equip- 2] Defective crimping or soldering of connectors
ment The pins of the male and female connectors
1) Handling wiring harnesses and connectors are in contact at the crimped terminal or sol-
Wiring harnesses consist of wiring connecting dered portion, but if an excessive force is
one component to another component, con- exerted on the wiring, the plating at the joint
nectors used for connecting and disconnecting will peel and cause improper connection or
one wire from another wire, and protectors or breakage.
tubes used for protecting the wiring.
Compared with other electrical components fit-
ted 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 dam-
age. For this reason, it is necessary to be
extremely careful when handling wiring har-
nesses.
3] Disconnections in wiring
If the connectors are pulled apart by holding
the wire, or components are lifted with a crane
with the wiring still connected, or a heavy
object hits the wiring, the crimping of the con-
nector may separate, or the soldering may be
damaged, or the wiring may be broken.
Main failures occurring in wiring harness

1] Defective contact of connectors (defective
contact between male and female)
Problems with defective contact are likely to
occur because the male connector is not prop-
erly inserted into the female connector, or
because one or both of the connectors are
deformed or the position is not correctly
aligned, or because there is corrosion or oxi-
dization of the contact surfaces.
4 WE051E0100
4] High-pressure water entering connector 2) Removing, installing, and drying connectors

The connector is designed to make it difficult and wiring harnesses
for water to enter (drip-proof structure), but if 1] Disconnecting connectors
high-pressure water is sprayed directly on the q Hold the connectors when disconnect-
connector, water may enter the connecter, ing.
depending on the direction of the water jet. When disconnecting the connectors,
As already said, the connector is designed to hold the connectors but not the wires.
prevent water from entering, but at the same For connectors held by a screw,
time, if water does enter, it is difficult for it to be loosen the screw fully, then hold the
drained. Therefore, if water should get into male and female connectors in each
the connector, the pins will be short-circuited hand and pull apart parallel. For con-
by the water, so if any water gets in, immedi- nectors which have a lock stopper,
ately dry the connector or take other appropri- press down the stopper with your
ate action before passing electricity through it. thumb and pull the connectors apart.
a Never pull them with one hand.
5] Oil or dirt stuck to connector

If oil or grease are stuck to the connector and
q When removing from clips
an oil film is formed on the mating surface
When removing a connector from a
between the male and female pins, the oil will
clip, pull the connector in a parallel
not let the electricity pass, so there will be
direction to the clip.
defective contact.
a If the connector is twisted up or down
If there is oil or grease stuck to the connector,
or to the left or right, the housing may
wipe it off with a dry cloth or blow it dry with
break.
compressed air and spray it with a contact
restorer.
a When wiping the mating portion of the
connector, be careful not to use excessive
force or deform the pins.
a If there is oil or water in the compressed
air, the contacts will become even dirtier,
so remove the oil and water from the com-
pressed air completely before cleaning
with compressed air.
WE051E0100 5
q Action to take after removing connec-

q Fix the connector securely.
tors
Align the position of the connector cor-
After removing any connector, cover it
rectly, then insert it securely. For con-
with a vinyle bag to prevent any dust,
nectors with a lock stopper, push in
dirt, oil, or water from getting in the
the connector until the stopper clicks
connector portion.
into position.
a If the machine is left disassembled for
a long time, it is particularly easy for
improper contact to occur, so always
cover the connector.
q Correct any protrusion of the boot and

any misalignment of the wiring har-
ness
2] Connecting connectors For connectors fitted with boots, cor-
q Check the connector visually. rect any protrusion of the boot. In
Check that there is no oil, dirt, or water addition, if the wiring harness is mis-
stuck to the connector pins (mating aligned, or the clamp is out of position,
portion). adjust it to its correct position.
Check that there is no deformation, a If the connector cannot be corrected
defective contact, corrosion, or dam- easily, remove the clamp and adjust
age to the connector pins. the position.
Check that there is no damage or
breakage to the outside of the connec- q If the connector clamp has been
tor. removed, be sure to return it to its
a If there is any oil, water, or dirt stuck to original position. Check also that
the connector, wipe it off with a dry clamps are not loosened.
cloth. If any water has entered the
connector, warm the inside of the wir-
ing with a dryer, but be careful not to
make it too hot as this will cause short
circuits.
a If there is any damage or breakage,
replace the connector.
6 WE051E0100
3] Connecting connectors (DT type connec-

tor) q Dry the inside of the connector with a
Since the DT 8-pole and DT 12-pole type dryer.
connectors have 2 latches respectively, If water gets inside the connector, use
press them in until they click 2 times. a dryer to dry the connector.
1. Male connector, 2. Female connector a Hot air from the dryer can be used, but
q Normal locking state (Horizontal): regulate the time that the hot air is
a, b, d used in order not to make the connec-
q Incomplete locking state (Diagonal): c tor or related parts too hot, as this will
cause deformation or damage to the
connector.
4] Drying wiring harness

If there is any oil or dirt on the wiring har- q Carry out a continuity test on the con-
ness, wipe it off with a dry cloth. Avoid nector.
washing it in water or using steam. If the After drying, leave the wiring harness
connector must be washed in water, do disconnected and carry out a continu-
not use high-pressure water or steam ity test to check for any short circuits
directly on the wiring harness. between pins caused by water.
If water gets directly on the connector, do a After completely drying the connector,
as follows. blow a contact restorer and reassemble.
q Disconnect the connector and wipe off
the water with a dry cloth.
a If the connector is blown dry with com-
pressed air, there is the risk that oil in
the air may cause defective contact,
so remove all oil and water from the
compressed air before blowing with
air.
WE051E0100 7
3) Handling control box

1] The control box contains a microcomputer
and electronic control circuits. These con-
trol all of the electronic circuits on the
machine, so be extremely careful when
handling the control box.
2] Do not open the cover of the control box
unless necessary.
2. Points to remember when troubleshooting electric

circuits
1) Always turn the power OFF before disconnect-
ing or connecting connectors.
2) Before carrying out troubleshooting, check
that all the related connectors are properly
inserted.
3] Do not place objects on top of the control
a Disconnect and connect the related con-
box.
nectors several times to check.
4] Cover the control connectors with tape or
3) Always connect any disconnected connectors
a vinyl bag.
before going on the next step.
Never touch the connector contacts with
a If the power is turned ON with the connec-
your hand.
tors 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 con-
nectors several times and check that there is
no change in the reading of the tester.
a If there is any change, there is probably
defective contact in that circuit.
3. Points to remember when handling hydraulic

equipment
With the increase in pressure and precision of
hydraulic equipment, the most common cause of
failure is dirt (foreign material) in the hydraulic cir-
cuit. When adding hydraulic oil, or when disas-
5] During rainy weather, do not leave the sembling or assembling hydraulic equipment, it is
control box in a place exposed to rain. necessary to be particularly careful.
6] Do not place the control box on oil, water,
or soil, or in any hot place, even for a short 1) Be careful of the operating environment.
time. (Place it on a suitable dry stand). Avoid adding hydraulic oil, replacing filters, or
7] Precautions when carrying out arc welding repairing the machine in rain or high winds, or
When carrying out arc welding on the extremely dusty places.
body, disconnect all wiring harness con-
nectors connected to the control box. Fit
an arc welding ground close to the welding
point.
8 WE051E0100
2) Disassembly and maintenance work in the 4) Do not let any dirt or dust enter during refilling
field operations.
If disassembly or maintenance work is carried Be careful not to let any dirt or dust enter when
out on hydraulic equipment in the field, there is refilling with hydraulic oil. Always keep the oil
danger of dust entering the equipment. It is filler and the area around it clean, and also
also difficult to confirm the performance after use clean pumps and oil containers. If an oil
repairs, so it is desirable to use unit exchange. cleaning device is used, it is possible to filter
Disassembly and maintenance of hydraulic out the dirt that has collected during storage,
equipment should be carried out in a specially so this is an even more effective method.
prepared dustproof workshop, and the perfor-
mance should be confirmed with special test
equipment.
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
3) Sealing openings
drained out easily from the circuit together with
After any piping or equipment is removed, the
the oil, so it is best to change the oil when it is
openings should be sealed with caps, tapes,
still warm. When changing the oil, as much as
or vinyl bags to prevent any dirt or dust from
possible of the old hydraulic oil must be
entering. If the opening is left open or is
drained out. (Drain the oil from the hydraulic
blocked with a rag, there is danger of dirt
tank; also drain the oil from the filter and from
entering or of the surrounding area being
the drain plug in the circuit.) If any old oil is left,
made dirty by leaking oil so never do this.
the contaminants and sludge in it will mix with
Do not simply drain oil out onto the ground.
the new oil and will shorten the life of the
Collect it and ask the customer to dispose of it,
hydraulic oil.
or take it back with you for disposal.
WE051E0100 9
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 sec-
ondary flushing is carried out with the speci-
fied 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 from the hydraulic oil
circuit.
The oil cleaning equipment is used to remove
the ultrafine (about 3µ) particles that the filter
built into the hydraulic equipment cannot
remove, so it is an extremely effective device
10 WE051E0100
Checks before troubleshooting 1
Item Judgment value Action

1. Check fuel level, type of fuel - Add oil
2. Check for impurities in fuel - Clean, drain
3. Check engine oil pan level, type of oil - Add oil
Lubricating
oil, coolant
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 damper case oil level. - Add oil
8. Check hydraulic oil filter for clogging - Replace
1. Check for looseness, corrosion of battery terminal, wiring - Tighten or replace
equipment
Hydraulic, mechanical Electrical
2. Check for looseness, corrosion of alternator terminal, wiring - Tighten or replace

3. Check for looseness, corrosion of starting motor terminal, wiring - Tighten or replace
1. Check for abnormal noise, smell - Repair

equipment
2. Check for oil leakage - Repair
3. Carry out air bleeding - Bleeding air
4. Check travel of brake pedal - Adjusting
1. Check battery voltage (engine stopped) 20 - 30 V Add or replace

2. Check battery electrolyte level - Add or replace
3. Check for discolored, burnt, exposed wiring - Replace
Electrics, electrical
4. Check for missing wiring clamps, hanging wiring - Repair

5. Check for water leaking on wiring (Pay particularly careful Disconnect connector
equipment
-
attention to water leaking on connectors or terminals) and dry it.
6. Check for disconnection, corrosion of fusible links and fuses - Replace
After running for
7. Check alternator voltage
several minutes: Replace
(engine running at 1/2 throttle or above)
27.5 - 29.5 V
8. Check operating sound of battery relay
- Replace
(when switch is turned ON/OFF)
WE051E0100 11
Classification and procedures of troubleshooting 1

Classification of troubleshooting
Mode Contents
Error code Troubleshooting when error code is displayed
E-mode Troubleshooting for electric system
H-mode Troubleshooting for hydraulic and mechanical system
S-mode Troubleshooting for engine unit
Procedure for troubleshooting

If a phenomenon supposed to be a failure appeared on machine, select a proper troubleshooting No. according to
the following procedure, and then go to the corresponding troubleshooting section.
1. Procedure for troubleshooting procedure to be taken when action code is displayed on monitor panel:
If an action code is displayed on the monitor panel, display the error code in the error code display mode (for
the electrical system and the mechanical system) of the monitor panel (EMMS).
Carry out troubleshooting under the displayed error code.
a Each error code "flashes" when the relevant trouble is detected. Even if an error code "lights up" when the
starting switch is turned ON, the relevant trouble has not been necessarily repaired (some troubles can be
detected by simply turning the starting switch ON).
a If an error code is recorded, be sure to perform the operation for reproducing it to see if the relevant trou-
ble has been repaired (For the method of reproducing the error code, see the troubleshooting under the
error code).
2. Procedure for troubleshooting to be taken when error code is recorded:

If an action code is not displayed on the monitor panel, check for an error code in the error code display mode
(for the electrical system and the mechanical system) of the monitor panel (EMMS).
If an error code is recorded, carry out troubleshooting under it.
a Each error code "flashes" when the relevant trouble is detected. Even if an error code "lights up" when the
starting switch is turned ON, the relevant trouble has not have been necessarily repaired (some troubles
can be detected by simply turning the starting switch ON).
a If an error code is recorded, be sure to perform the operation for reproducing it to see if the relevant trou-
ble has been repaired (For the method of reproducing the error code, see the troubleshooting under the
error code).
3. Procedure for troubleshooting to be taken when action code is not displayed and error code is not
recorded:
If an error code is not recorded in the monitor panel (EMMS), a trouble that the machine cannot find out by
itself may have occurred in the electrical system or hydraulic and mechanical system.
In this case, check the phenomenon supposed to be a failure again and select the relevant phenomenon from
the table of "Phenomena supposed to be Failure and Troubleshooting No.", and then carry out troubleshooting
related to that phenomenon in the "E mode", "H mode", or "S mode".
12 WE051E0100
Phenomena supposed to be failure and troubleshooting
Troubleshooting
No. Phenomena supposed to be failure Error
E-mode H-mode S-mode
code
Phenomena related to action code or error code
1 Action codes are displayed on monitor panel. Check error codes.
2 Error codes are displayed in error code display mode. q
Phenomena related to engine
3 Engine does not start easily (It always takes time to start) S-1
4 Engine does not crank E-1 (1) S-2 a)
Engine cranks but exhaust smoke does not
5 Engine does not E-1 (2) S-2 b)
come out.
start
Exhaust smoke comes out but engine does not
6 S-2 c)
start
7 Engine speed does not rise sharply (Follow-up performance is low) S-3
8 Engine stops during operation S-4
9 Engine rotation is abnormal (Hunting) S-5
10 Output is insufficient (Power is low) S-6
11 Exhaust gas color is bad (Incomplete combustion) S-7
12 Oil is consumed much (or exhaust gas color is bad). S-8
13 Oil becomes dirty quickly. S-9
14 Fuel is consumed much S-10
15 Coolant contains oil (or it blows back or reduces) S-11
16 Engine oil pressure warning lamp lights up (Oil pressure lowers). S-12
17 Oil level rises (Water or fuel is mixed in oil). S-13
18 Water temperature rises too high (Overheat). S-14
19 Abnormal sound comes out. S-15
20 Vibration is excessive. S-16
21 Engine is not preheated normally (Manual preheating mechanism). E-2
Phenomena related to power train
22 There is no travel power (No drawbar pull). H-1
23 Machine does not move (At 2nd or 3rd speed). H-2
24 Machine does not move at all gear speeds. H-3
25 Machine travels only in one direction forward or in reverse. H-4
26 Time lag is excessive when shifting gear or changing direction. H-5
Machine does not turn.
27 H-6
(The machine does not turn leftward or rightward.)
28 Steering speed or power is insufficient. H-7
29 Brake does not work. H-8
30 The oil temperature of the power train overheats. H-9
Abnormal sound comes out from around HSS and work equip-
31 H-10
ment pump or HSS motor.
32 All work equipment speeds are slow. H-11
33 Work equipment does not move. H-12
34 Speed or power of blade lift is low H-13
35 Speed or power of blade tilt is low. H-14
WE051E0100 13
Troubleshooting
No. Phenomena supposed to be failure Error
E-mode H-mode S-mode
code
Phenomena related to work equipment
36 Speed or power of blade angle is low. H-15
37 Speed or power of ripper lift is low. H-16
38 Hydraulic drift of blade lift is large. H-17
39 Hydraulic drift of blade tilt is large. H-18
40 Hydraulic drift of blade angle is large. H-19
41 Hydraulic drift of ripper lift is large. H-20
Phenomena related to monitor panel (Operator mode: Ordinary screen)
42 When starting switch is turned ON, any item does not light up E-3
When starting switch is turned ON, all items light up and none of
43 E-4
them goes off.
44 Charge level warning lamp flashes while engine is running E-5
45 Emergency warning items flash while engine is running. E-6
46 Preheating pilot lamp does not light up during preheating operation. E-7
47 Indication of engine coolant temperature gauge. E-8
48 Indication of power train temperature gauge is abnormal. E-9
49 Indication of hydraulic oil temperature gauge is abnormal. E-10
50 Indication of fuel level gauge is abnormal. E-11
51 Indication of gear speed is abnormal. E-12
52 Indication of preset mode service meter is abnormal. E-13
53 Warning lamp does not flash or does not go off. E-14
54 Indication of engine speed is abnormal. E-15
55 Indication of transmission rpm and traveling speed is abnormal. E-16
56 Alarm buzzer does not sound or does not stop E-17
57 Auto shift-down does not work or is not released. E-18
58 Buzzer cancel switch does not work. E-19
59 Information switch does not work. E-20
60 Reverse rotation and cleaning of fan are not work or cancelled. E-21
61 The preset mode does not be operated or cancelled. E-22
Phenomena related to monitor panel (Service mode: Special function screen)
60 System is not set in service mode or is not set out of service mode. E-23
Other phenomena
61 Backup alarm does not sound. E-24
62 Headlamp or rear lamp does not light up. E-25
63 Horn does not sound or does not stop. E-26
64 Work equipment lock lever does not function or is not released. E-27
65 Wiper malfunctions E-28
66 Washing water does not come out. E-29
67 The air conditioner does not operate. E-30
14 WE051E0100
Connector arrangement drawing and electric circuit diagram of each system1

Connectors list
a The addresses roughly show the places of the connectors in the 3-dimensional connectors arrangement draw-
ing and the electric circuit diagram of each system.
Address
Electric circuit diagram
No. of pins
Connector
of each system
No.
Type Name of device Stereo-

ST MON
gram
system system
diagram diagram
1 DT 4 Intermediate connector [Cab specification] I-9
2 KES1 2 Rear speaker (Left) [Cab specification] I-8
4 KES1 2 Rear speaker (Right) [Cab specification] H-9
6 Plug 1 Heater wire glass [Cab specification] H-9
7 PA 9 Radio [Cab specification] B-9
8 DT 2 Accessory (12 V) [Cab specification] B-9
9 YAZAKI 3 Heater wire glass switch [Cab specification] B-8
9 KES1 2 Washer motor (Left) E-1
10 M 2 Additional light switch [Cab specification] B-8
10 KES1 2 Washer motor (Right) E-1
11 M 2 Wiper intermittent switch [Cab specification] B-9
11 KES1 2 Washer motor (Front) E-1
12 KES1 6 Rear wiper switch [Cab specification] A-9
12 KES1 2 Washer motor (Rear) F-1
13 KES1 6 Right door wiper switch [Cab specification] A-9
13 SWP 6 Intermediate connector (Washer motor) F-1
14 KES1 6 Front wiper switch [Cab specification] A-9
15 KES1 6 Left door wiper switch [Cab specification] A-9
16 KES1 2 Room lamp [Cab specification] B-7
17 DT 4 Right door wiper [Cab specification] B-7
Intermediate connector (Additional light)
18 DT 4 F-8
[Cab specification]
Intermediate connector (Washer motor)
19 DT 4 C-5, W-3
[Cab specification]
20 DTHD#8 1 Cab power supply [Cab specification] C-5, W-2
21 DTHD#12 1 Cab power supply (Battery direct) [Cab specification] C-6, W-3
23 DT 6 Front wiper [Cab specification] E-8
24 DT 4 Left door wiper [Cab specification] C-5
Relay
25 4 For light [Cab specification] B-8
(YAZAKI)
Relay
26 6 Left wiper intermittent relay [Cab specification] C-8
(YAZAKI)
27 Relay 5 Left wiper intermittent selector relay [Cab specification] C-7
Relay
28 6 Front wiper intermittent relay [Cab specification] C-8
(YAZAKI)
29 Relay 5 Front wiper intermittent selector relay [Cab specification] C-7
Relay
30 6 Right wiper intermittent relay [Cab specification] C-8
(YAZAKI)
31 Relay 5 Right wiper intermittent selector relay [Cab specification] C-7
Relay
32 6 Rear wiper intermittent relay [Cab specification] C-8
(YAZAKI)
WE051E0100 15
Address
No. of pins
Connector
of each system
No.

ST MON
gram
system system
diagram diagram
33 Relay 5 Rear wiper intermittent selector relay [Cab specification] D-8
Relay
34 4 Heater wire glass relay [Cab specification] C-8
(YAZAKI)
35 M 4 Converter [Cab specification] C-8
36 Plug 1 Heater wire glass [Cab specification] J-8
37 KES1 4 Rear wiper [Cab specification] I-9
101 DT 8 Intermediate connector D-5 J-8 H-5
203 DT 2 Right head lamp B-4 K-5
204 DT 2 Left head lamp B-4 K-5
205 090II 2 Horn B-3
214 DT (B) 12 Intermediate connector [Dashboard] P-1 C-7 A-6
215 DT (G) 12 Intermediate connector [Dashboard] Q-1 D-7 E-6
217 DT 2 Caution buzzer 0-3 C-8
218 DT (Br) 12 Intermediate connector [Air conditioner] Q-1
224 DT 2 Rear lamp (LH) J-8 K-6
228 DT 2 Rear lamp (If equipped) K-7 K-6
244 DT 2 Backup alarm K-7 K-8
247 DT 2 Intermediate connector [Rear lamp] J-8 J-6
250 Terminal 1 Starting switch (Terminal B) N-5 C-9 D-9
255 Terminal 1 Starting switch (Terminal R1) N-4 C-9 D-9
260 Terminal 1 Starting switch (Terminal BR) N-4 C-9 D-9
262 DT 2 Horn switch S-9
270 Terminal 1 Starting switch (Terminal ACC) N-5 D-9 D-9
280 Terminal 1 Starting switch (Terminal C) N-5 C-9 D-9
423 DT 2 Fuel level sensor J-8 K-6
453 DT 2 Torque converter oil temperature sensor AI-3 H-8
800 DTHD#12 1 Service power supply W-3 I-8
1SOL DT 2 1st clutch ECMV solenoid AE-2 W-8
1SW DT 2 1st clutch ECMV fill switch AF-3 W-8
1SOL DT 2 2nd clutch ECMV solenoid AG-3 W-8
2SW DT 2 2nd clutch ECMV fill switch AF-3 W-7
3SOL DT 2 3rd clutch ECMV solenoid AE-3 W-7
3SW DT 2 3rd clutch ECMV fill switch AE-2 W-7
AC1 MIC 17 Air conditioner unit O-7
AC2 AMP 16 Auto air conditioner controller P-7
AC3 AMP 12 Auto air conditioner controller P-7
ACC YAZAKI 2 Accessory socket [Cab specification] D-6
Intermediate connector [Air suspension seat]
ASA DT 2 S-9
(If equipped)
ASD KES1 4 Auto shift down switch N-7 E-9
BKA Relay 5 Backup alarm relay U-1 G-9
BRK DT 3 Brake pedal potentiometer R-1 I-8
BUZ KES1 3 Buzzer cancel switch P-8 F-9
C Terminal 1 Battery relay power supply outlet W-5 K-7 D-1
CA1 DT 3 CAN terminal resistance (Controller side) W-1 B-8 A-2
16 WE051E0100
Address
No. of pins
Connector
of each system
No.

ST MON
gram
system system
diagram diagram
CA2 DT 3 CAN terminal resistance (Monitor side) P-7 B-8 C-9
CAN DT (Gr) 12 Intermediate connector [KOMTRAX] (For Japan only) W-3
CB1 Plug 2 Circuit breaker (20 A) (Starting switch) M-7 C-9 D-8
CB2: Plug 2 Circuit breaker (20 A) (Air conditioner) M-7
D1 SWP 2 Diode M-7
Additional head lamp (LH) [ROPS canopy specification]
CFL DT 2 - J-8
(If equipped)
Additional head lamp (RH) [ROPS canopy specification]
CFR DT 2 - J-9
(If equipped)
CIG YAZAKI 2 Cigarette lighter D-6
CN-9 KES1 2 Washer motor [ROPS canopy specification] -
CN-13 X 6 Intermediate connector (Washer motor) -
CNL DT 3 Additional lamp - J-8
CNR Relay 6 Light relay - I-8
Additional rear lamp (LH) [ROPS canopy specification]
CRL DT 2 - K-8
(If equipped)
Additional rear lamp (RH) [ROPS canopy specification]
CRR DT 2 - K-9
(If equipped)
CUR KES1 3 Information switch O-7 E-9
DCL DT 3 Decelerator pedal potentiometer O-5 I-8
DIAL DT 3 Fuel control dial potentiometer V-8 P-9
E21 DT (B) 12 Intermediate connector (Engine) E-6, AA-8 T-3 H-5
E22 DT (Gr) 12 Intermediate connector (Engine) E-6, AA-8 T-2 H-4
E31 DT 3 Engine stop solenoid AD-5 X-2 L-2
E32 SWP 2 Diode Z-8 X-3 L-3
E33 SWP 2 Diode AB-8 X-2 L-2
E34 Terminal 1 Ground [Engine] AD-7 W-1 K-1
E41 DT 2 Stop solenoid relay (Coil) AD-5 V-2 J-2
E42 Terminal 1 Stop solenoid relay (Output) AD-4 W-2 K-2
E43 Terminal 1 Stop solenoid relay (Input) AD-5 W-2 K-2
E44 SWP 2 Diode AD-5 X-1 L-2
E51 DT 2 Engine speed sensor AD-7 W-6
E61 DT 4 Governor motor AD-3 W-6
E62 DT 3 Governor motor AD-4 W-5
E71 Terminal 1 Alternator Y-5 X-4 G-3
E73 L 2 Fusible link (Alternator) AC-3 W-4 H-3
E81 Terminal 1 Electrical intake air heater relay (Terminal A) AB-8 V-4 H-1
E82 Terminal 1 Electrical intake air heater relay (Terminal B) AC-7 V-4 H-1
E83 Terminal 1 Electrical intake air heater relay (Coil terminal) AC-7 U-4 H-1
E85 SWP 2 Diode AC-7 X-1 L-1
E91 DT 2 Air conditioner compressor AB-2
E101 DT 2 Safety relay AC-2 W-3 H-2
WE051E0100 17
Address
No. of pins
Connector
of each system
No.

ST MON
gram
system system
diagram diagram
E102 Terminal 1 Starting motor Z-8 W-3 H-2
E111 DT 2 Engine coolant temperature sensor (High temperature) AD-6 K-4
E120 Terminal 1 Ground [Engine] Y-4 W-4 H-3
E121 Terminal 1 Engine oil pressure switch AC-3 K-4
E131 DT 3 Engine coolant temperature sensor (Low temperature) AD-6 W-6
ESS Relay 5 Stop solenoid relay (Signal) U-1 H-9 F-8
FAC DT 2 Fan pump TVC solenoid AF-8 Q-7
FAM KES1 4 Fan reverse mode switch O-7 D-9
FAR DT 2 Fan reverse solenoid B-3 J-9
Intermediate connector [ROPS canopy specification]
FCF DT 6 - K-8
(If equipped)
Intermediate connector [ROPS canopy specification]
FCM DT 6 - I-8
(If equipped)
H-6, I-8,
FFC DT 6 Intermediate connector J-2 K-7
L-8
FL DT 2 Front additional light G-9
FL1 L 2 Fusible link [Cab specification] W-3
FR DT 2 Front additional light F-8
FS1 - - Fuse box W-4 L-9 A-1
FS2 - - Fuse box W-4 L-8 A-1
FSOL DT 2 Forward clutch ECMV solenoid AG-2 W-9
FSW DT 2 Forward clutch ECMV (Fill switch) AG-2 W-9
FWL KES1 4 Head lamp switch O-7 D-8
GND01 Terminal 1 Ground [Floor] W-4 G-1 F-1
GND03 Terminal 1 Ground [Fender] J-2 K-8 J-5
GND04 Terminal 1 Ground [Frame] D-5 G-1 E-1
GND1 Terminal 1 Ground (In cab) D-8
GND4 Terminal 1 Chassis ground H-9
H Terminal 1 Battery relay power supply inlet W-4 K-7 D-1
HSA DT 2 HSS-EPC (Left swing) AG-9 Q-7
HSB DT 2 HSS-EPC (Right swing) AG-8 Q-7
HSP DT 2 HSS and work equipment pump TVC solenoid AE-7 Q-6
Intermediate connector (Starting switch)
KEY DT 6 O-9
[ROPS canopy specification]
M26 M 6 Air conditioner unit O-6
MAM KES1 4 Manual mode switch O-7 D-9
NSF Relay 5 Neutral safety relay T-1 G-9 F-8
NSW DT 3 Safety lock switch W-8 I-8
PL1 HD-24 23 Intermediate connector [Power train] S-1, AH-3 T-9
PL2 HD-24 31 Intermediate connector [Power train] S-1, AH-3 O-7 G-6
PSL DT 2 PPC lock solenoid valve Q-9
PSW DT 2 PPC lock switch Q-9
PT1 DT 3 Pitch angle sensor Q-8 J-9
18 WE051E0100
Address
No. of pins
Connector
of each system
No.

ST MON
gram
system system
diagram diagram
RHR Relay 5 Preheater relay U-1 H-9 E-8
RL DT 2 Rear additional light (Left) [Cab specification] I-8
RR DT 2 Rear additional light (Right) [Cab specification] G-9
RSOL DT 2 Reverse clutch ECMV solenoid AF-3 W-9
RSW DT 2 Reverse clutch ECMV fill switch AF-3 W-8
RWL KES1 4 Rear lamp switch O-7 E-8
S03 AMP070 20 Monitor panel N-9 A-9 A-8
S04 AMP070 12 Monitor panel N-9 A-9 B-8
S13 DT-T (Gr) 12 Intermediate connector P-1 C-7 C-6
S24 Terminal 4 Service switch M-7 C-9 C-9
SDS DT 2 Hydraulic oil temperature sensor AE-4 Q-5
SFTD C 3 Shift-down switch U-9 Q-8
SFTU C 3 Shift-up switch U-9 Q-8
ST1 DRC26 24 Steering and transmission controller V-2 A-7 A-4
ST2 DRC26 40 Steering and transmission controller V-2 A-6 A-4
ST3 DRC26 40 Steering and transmission controller W-2 A-3 A-3
Software writing connector
STF X 4 V-1 B-7
(Steering and transmission controller)
SW Terminal 1 Battery relay terminal BR W-8 L-7 D-1
SWG Terminal 1 Battery relay ground W-8 L-7 D-1
TL1 DT (Gr) 12 Intermediate connector [Shift switch] W-8 O-9
TL2 DT (B) 8 Travel lever V-8 P-9
TL3 DT 6 Intermediate connector [Shift switch] V-9 P-8
TL4 DT 6 Intermediate connector [Shift switch] W-8 O-8
TM1 DT 2 Transmission bevel speed sensor AI-8 Q-6
TMV HD-24 23 Intermediate connector [Transmission ECMV] AE-3 V-9
a The color symbols of the bodies of the heavy duty wire connectors (DT-8 poles) and (DT-12 poles) are as fol-
lows.
(Gr) = Gray, (B) = Black, (G) = Green, (Br) = Brown
WE051E0100 19
Connector type Details

AMP Connector manufactured by NIPPON AMP
AMP070 Connector of type 070 manufactured by NIPPON AMP
BNC Connector of type BNC for coaxial cable
C Connector of type C manufactured by CALSONIC KANSEI
DRC-26 DRC type connector
DT DT type connector (08192-XXXXX)
DTHD DTHD type connector (08192-XXXXX)
GT5 Connector of type GT5 for coaxial cable of GPS antenna
HD30 HD30 type connector (08191-XXXXX)
KES1 Connector of KES1 type (08027-1XXXX)
L Connector of type L manufactured by YAZAKI (08056-2XXXX)
M Connector of type M manufactured by YAZAKI (08056-0XXXX)
MIC Connector of MIC type manufactured by NIPPON AMP
ML L-connector of M type for coaxial cable
PA Connector of PA type manufactured by YAZAKI
SUMITOMO Connector manufactured by SUMITOMO DENSO
SWP Connector of SWP type manufactured by YAZAKI (08055-1XXXX)
X Connector of X type manufactured by YAZAKI (08055-0XXXX)
YAZAKI YAZAKI type connector
Plug 1-pole connector of pin type
Terminal Round terminal or ordinary terminal
Relay Connector of PH166-05020 type manufactured by SHINAGAWA JIDOSHA DENSEN
Relay (YAZAKI) Connector manufactured by YAZAKI (For relay)
090II Connector of type 090II manufactured by YAZAKI (08160-70001)
20 WE051E0100
Connector arrangement drawing
22 WE051E0100
WE051E0100 23
24 WE051E0100
WE051E0100 25
26 WE051E0100
WE051E0100 27
Monitor panel system circuit diagram (M circuit)
28 WE051E0100
a This circuit diagram was drawn by extracting the monitor panel system, engine preheating/starting/charging/
stopping system, light system, and communication network system from the general electric circuit diagram.
("Connector No. and pin No." from each branching/merging point indicate the ends of branch or source of
merging within the parts of the same wiring harness.)
WE051E0100 29
Steering and transmission controller circuit diagram (ST, TM circuit)
30 WE051E0100
a This circuit diagram was drawn by extracting the steering and transmission controller system from the general
electric circuit diagram. ("Connector No. and pin No." from each branching/merging point indicate the ends of
branch or source of merging within the parts of the same wiring harness.)
WE051E0100 31
32 WE051E0100
a This circuit diagram was drawn by extracting the steering and transmission controller system from the general
electric circuit diagram. ("Connector No. and pin No." from each branching/merging point indicate the ends of
branch or source of merging within the parts of the same wiring harness.)
WE051E0100 33
Connection table for connector pin numbers

a 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.
X type connector
No.of
pins T-adapter
Male (female housing) Female (male housing)
Part No.
1 Part No.: 08055-00181 Part No.: 08055-00191 799-601-7010
2 799-601-7020
Part No.: 08055-00282 Part No.: 08055-00292
3 799-601-7030
Part No.: 08055-00381 Part No.: 08055-00391
4 799-601-7040
Part No.: 08055-00481 Part No.: 08055-00491

Terminal part No.: 79A-222-3370 Terminal part No.: 79A-222-3390
• Electric wire size: 0.85 • Electric wire size: 0.85
— —
• Grommet: Black • Grommet: Black
• Q’ty: 20 • Q’ty: 20
Terminal part No.: 79A-222-3380 Terminal part No.: 79A-222-3410
— —
• Grommet: Red • Grommet: Red
• Q’ty: 20 • Q’ty: 20
34 WE051E0100
SWP type connector

No.of
pins T-adapter
Part No.
6 799-601-7050
Part No.: 08055-10681 Part No.: 08055-10691
8 799-601-7060
Part No.: 08055-10881 Part No.: 08055-10891
12 799-601-7310
Part No.: 08055-11281 Part No.: 08055-11291
14 799-601-7070
Part No.: 08055-11481 Part No.: 08055-11491
WE051E0100 35
SWP type connector

No. of
pins T-adapter
Part No.
16 799-601-7320
Part No.: 08055-11681 Part No.: 08055-11691

Terminal part No.: Terminal part No.:
— —
• Grommet: Black • Grommet: Black
• Q’ty: 20 • Q’ty: 20
Terminal part No.: Terminal part No.:
— —
• Grommet: Red • Grommet: Red
• Q’ty: 20 • Q’ty: 20
36 WE051E0100
M type connector
No.of
pins T-adapter
Part No.
1 Part No.: 08056-00171 Part No.: 08056-00181 799-601-7080
2 799-601-7090
Part No.: 08056-00271 Part No.: 08056-00281
3 799-601-7110
Part No.: 08056-00371 Part No.: 08056-00381
4 799-601-7120
Part No.: 08056-00471 Part No.: 08056-00481
6 799-601-7130
Part No.: 08056-00671 Part No.: 08056-00681
8 799-601-7340
Part No.: 08056-00871 Part No.: 08056-00881
WE051E0100 37
S type connector
No.of
pins T-adapter
Part No.
8 799-601-7140
Part No.: 08056-10871 Part No.: 08056-10881
10
799-601-7150
(White)
Part No.: 08056-11071 Part No.: 08056-11081
12
799-601-7350
(White)
Part No.: 08056-11271 Part No.: 08056-11281
16
799-601-7330
(White)
Part No.: 08056-11671 Part No.: 08056-11681
38 WE051E0100
S type connector
No.of
pins T-adapter
Part No.
10
—
(Blue)
— —
12
799-601-7160
(Blue)
Part No.: 08056-11272 Part No.: 08056-11282
16
799-601-7170
(Blue)
Part No.: 08056-11672 Part No.: 08056-11682
WE051E0100 39
MIC type connector

No.of
pins T-adapter
Part No.
7 Body part No.: 79A-222-2640 (Q’ty: 5) Body part No.: 79A-222-2630 (Q’ty: 5) —
11 Body part No.: 79A-222-2680 (Q’ty: 5) Body part No.: 79A-222-2670 (Q’ty: 5) —
5 799-601-2710
Body part No.: 79A-222-2620 (Q’ty: 5) Body part No.: 79A-222-2610 (Q’ty: 5)
9 799-601-2950
13 799-601-2720
40 WE051E0100
MIC type connector

No.of
pins T-adapter
Part No.
17 799-601-2730
21 799-601-2740
Terminal part No.:79A-222-2770 Terminal part No.:79A-222-2760
—
(Q’ty: 50) (Q’ty: 50)
WE051E0100 41
AMP040 type connector

No.of
pins T-adapter
Part No.
8 799-601-7180
— Housing part No.: 79A-222-3430 (Q’ty: 5)
12 799-601-7190
16 799-601-7210
20 799-601-7220
a Terminal part No.: 79A-222-3470 (No relation with number of pins)
42 WE051E0100
AMP070 type connector

No.of
pins T-adapter
Part No.
10 799-601-7510
— Part No.: 08195-10210
12 799-601-7520
— Part No.: 08195-12210
14 799-601-7530
— Part No.: 08195-14210
18 799-601-7540
— Part No.: 08195-18210
20 799-601-7550
— Part No.: 08195-20210
WE051E0100 43
L type connector
No.of
pins T-adapter
Part No.
2 —
— —
Connector for PA
No.of
pins T-adapter
Part No.
9 —
— —
Bendix MS connector
No.of
pins T-adapter
Part No.
10 799-601-3460
— —
44 WE051E0100
KES 1 (Automobile) connector

No.of
pins T-adapter
Part No.
2 —
Part No.:08027-10210 (Natural color) Part No.:08027-10260 (Natural color)

08027-10220 (Black) 08027-10270 (Black)
3 —
Part No.: 08027-10310 Part No.: 08027-10360
4 —

08027-10420 (Black) 08027-10470 (Black)
6 —

08027-10620 (Black) 08027-10670 (Black)
WE051E0100 45
KES 1 (Automobile) connector

No.of
pins T-adapter
Part No.
8 —

08027-10820 (Black) 08027-10870 (Black)
Connector for relay (Socket type)

No.of
pins T-adapter
Part No.
5 799-601-7360
— —
6 799-601-7370
— —
46 WE051E0100
F type connector
No.of
pins T-adapter
Part No.
4 —
— —
WE051E0100 47
[The pin No. is also marked on the connector (electric wire insertion end)]
HD30 Series connector

No.of
pins T-adapter
Body (plug) Body (receptacle)
Part No.
Pin (male terminal) Pin (female termial)
799-601-9210
Part No.:08191-11201, 08191-11202, Part No.:08191-14101, 08191-14102,

18-8 08191-11205, 08191-11206 08191-14105, 08191-14106
(1) Pin (female terminal) Pin (male termial)
799-601-9210
Part No.:08191-12201, 08191-12202, Part No.:08191-13101, 08191-13102,

08191-12205, 08191-12206 08191-13105, 08191-13106
799-601-9220
Part No.:08191-21201, 08191-12202, Part No.:08191-24101, 08191-24102,

18-14 08191-21205, 08191-12206 08191-24105, 08191-24106
799-601-9220
Part No.:08191-22201, 08191-22202, Part No.:08191-23101, 08191-23102,

08191-22205, 08191-22206 08191-23105, 08191-23106
48 WE051E0100
Type HD30 Series connector

(shell size T-adapter
code) Body (plug) Body (receptacle)
Part No.
799-601-9230
18-20 Part No.: 08191-31201, 08191-31202 Part No.: 08191-34101, 08191-34102

799-601-9230
Part No.: 08191-32201, 08191-32202 Part No.: 08191-33101, 08191-33102

799-601-9240
18-21 Part No.: 08191-41201, 08191-42202 Part No.: 08191-44101, 08191-44102

799-601-9240
Part No.: 08191-42201, 08191-42202 Part No.: 08191-43101, 08191-43102
WE051E0100 49

Part No.
799-601-9250
24-9 Part No.: 08191-51201, 08191-51202 Part No.: 08191-54101, 08191-54102

799-601-9250
Part No.: 08191-52201, 08191-52202 Part No.: 08191-53101, 08191-53102

799-601-9260
Part No.:08191-61201, 08191-62202, Part No.:08191-64101, 08191-64102,

24-16 08191-61205, 08191-62206 08191-64105, 08191-64106
799-601-9260
Part No.:08191-62201, 08191-62202, Part No.:08191-63101, 08191-63102,

08191-62205, 08191-62206 08191-63105, 08191-63106
50 WE051E0100

Part No.
799-601-9270
Part No.:08191-71201, 08191-71202, Part No.:08191-74101, 08191-74102,

24-21 08191-71205, 08191-71206 08191-74105, 08191-74106
799-601-9270
Part No.:08191-72201, 08191-72202, Part No.:08191-73101, 08191-73102,

08191-72205, 08191-72206 08191-73105, 08191-73106
799-601-9280
Part No.:08191-81201, 08191-81202, Part No.:08191-84101, 08191-84102,

08191-81203, 08191-81204, 08191-84103, 08191-84104,
24-23 08191-81205, 08191-80206 08191-84105, 08191-84106
799-601-9280
Part No.:08191-82201, 08191-82202, Part No.:08191-83101, 08191-83102,

08191-82203, 08191-82204, 08191-83103, 08191-83104,
08191-82205, 08191-82206 08191-83105, 08191-83106
WE051E0100 51

Part No.
Pin (male termial) Pin (female terminal)
799-601-9290
Part No.:08191-91203, 08191-91204, Part No.:08191-94103, 08191-94104,

24-31 08191-91205, 08191-91206 08191-94105, 08191-94106
799-601-9290
Part No.:08191-92203, 08191-92204, Part No.:08191-93103, 08191-93104,

08191-92205, 08191-92206 08191-93105, 08191-93106
52 WE051E0100
DT Series connector
No.of
pins T-adapter
Part No.
2 799-601-9020
Part No.:08192-12200 (normal type) Part No.: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

WE051E0100 53
DT Series connector
No.of
pins T-adapter
Part No.
8GR: 799-601-9060
8B: 799-601-9070
8 8G: 799-601-9080
8BR: 799-601-9090
Part No.:08192-1820 T (normal type) Part No.: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
12
12G: 799-601-9130
12BR:799-601-9140
Part No.:08192-1920 T (normal type) Part No.:08192-1910 T (normal type)

08192-2920 T (fine wire type) 08192-2910 T (fine wire type)
54 WE051E0100
[The p in No. is also marked on the connector (electric wire insertion end)]
DTM Series connector

No.of
pins T-adapter
Part No.
2 799-601-9010
Part No.: 08192-02200 Part No.: 08192-02100
DTHD Series connector

No.of
pins T-adapter
Part No.
1 —
Part No.: 08192-31200 (Contact size#12) Part No.: 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)
WE051E0100 55
DRC26 Series connector

No.of
pins T-adapter
Part No.
24 799-601-9250
— Part No.:7821-93-3110
40
799-601-9250
(A)
— Part No.:7821-93-3120
40
799-601-9260
(B)
— Part No.:7821-93-3130
56 WE051E0100
T-branch box and T-branch table

a The vertical column shows part number of T-Branch Box or T-Branch, and horizontal column shows part num-
ber of Harness Checker Ass'y.
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
Connector type
Part No. No. of pins
-
or type
799-601-2600 Measurement box Econo-21P Q Q Q Q Q Q

799-601-3100 Measurement box MS-37P Q
799-601-3200 Measurement box MS-37P Q
799-601-3300 Measurement box Econo-24P Q
799-601-3360 Plate For MS box
799-601-3410 BENDIX (MS) 24P Q Q
799-601-3420 BENDIX (MS) 24P Q Q
799-601-3430 BENDIX (MS) 17P Q Q
799-601-3440 BENDIX (MS) 17P Q Q
799-601-3450 BENDIX (MS) 5P Q Q
799-601-3460 BENDIX (MS) 10P Q Q
799-601-3510 BENDIX (MS) 5P Q Q
799-601-3520 BENDIX (MS) 14P Q Q
799-601-3530 BENDIX (MS) 19P Q Q
799-601-2910 BENDIX (MS) 14P Q Q
799-601-3470 Case Q
799-601-2710 MIC 5P Q Q Q Q
799-601-2720 MIC 13P Q Q Q Q
799-601-2730 MIC 17P Q Q Q Q Q Q Q
799-601-2740 MIC 21P Q Q Q Q Q Q Q
799-601-2950 MIC 9P Q Q Q Q
799-601-2750 ECONO 2P Q Q
799-601-2760 ECONO 3P Q Q
799-601-2770 ECONO 4P Q Q
799-601-2780 ECONO 8P Q Q
799-601-2790 ECONO 12P Q Q
799-601-2810 DLI 8P Q Q
799-601-2820 DLI 12P Q Q
799-601-2830 DLI 16P Q Q
799-601-2840 Extension cable Q Q Q
799-601-2850 Case Q
799-601-7010 X 1P Q Q
799-601-7020 X 2P Q Q Q Q
799-601-7030 X 3P Q Q Q Q
799-601-7040 X 4P Q Q Q Q
799-601-7050 SWP 6P Q Q Q
799-601-7060 SWP 8P Q Q Q
799-601-7310 SWP 12P Q
799-601-7070 SWP 14P Q Q
799-601-7320 SWP 16P Q
799-601-7080 M 1P Q Q
799-601-7090 M 2P Q Q Q Q
799-601-7110 M 3P Q Q Q Q
799-601-7120 M 4P Q Q Q Q
799-601-7130 M 6P Q Q Q Q
799-601-7340 M 8P Q
WE051E0100 57
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
Connector type
Part No. No. of pins
-
or type
799-601-7140 S 8P Q Q Q Q
799-601-7150 S 10P - White Q Q Q Q
799-601-7160 S 12P - Blue Q Q Q
799-601-7170 S 16P - Blue Q Q Q Q
799-601-7330 S 16P - White Q
799-601-7350 S 12P - White Q
799-601-7180 AMP040 8P Q
799-601-7190 AMP040 12P Q Q
799-601-7210 AMP040 16P Q Q Q Q
799-601-7220 AMP040 20P Q Q Q Q
799-601-7230 Short connector X-2 Q Q Q Q
799-601-7240 Case Q Q
799-601-7270 Case Q
799-601-7510 070 10P Q
799-601-7520 070 12P Q
799-601-7530 070 14P Q
799-601-7540 070 18P Q
799-601-7550 070 20P Q
799-601-7360 Relay connector 5P Q
799-601-7370 Relay connector 6P Q
799-601-7380 JFC connector 2P Q
799-601-9010 DTM 2P Q Q
799-601-9020 DT 2P Q Q
799-601-9030 DT 3P Q Q
799-601-9040 DT 4P Q Q
799-601-9050 DT 6P Q Q
799-601-9060 DT 8P - Gray Q Q
799-601-9070 DT 8P - Black Q Q
799-601-9080 DT 8P - Green Q Q
799-601-9090 DT 8P - Brown Q Q
799-601-9110 DT 12P - Gray Q Q
799-601-9120 DT 12P - Black Q Q
799-601-9130 DT 12P - Green Q Q
799-601-9140 DT 12P - Brown Q Q
799-601-9210 HD30 18-8 Q Q
799-601-9220 HD30 18-14 Q Q
799-601-9230 HD30 18-20 Q Q
799-601-9240 HD30 18-21 Q Q
799-601-9250 HD24 24-9 Q Q
799-601-9260 HD30 24-16 Q Q
799-601-9270 HD30 24-21 Q Q
799-601-9280 HD30 24-23 Q Q
799-601-9290 HD30 24-31 Q Q
799-601-9310 Plate For HD30 Q Q Q
799-601-9320 Measurement box For DT, HD Q Q Q
799-601-9330 Case Q
799-601-9340 Case Q
799-601-9350 DRC 40P Q
799-601-9360 DRC 24P Q
799-601-9410 For NE, G sensor 2P Q
799-601-9420 For fuel, boost press. 3P Q
799-601-9430 PVC socket 2P Q
58 WE051E0100
WE051E0200
Bulldozer
1Shop Manual
D61EX-15
D61PX-15

Troubleshooting 1
Troubleshooting when error code is displayed (Error code)............................................. 5
Error code table ............................................................................................................ 5
Information described in troubleshooting list ................................................................ 8
Error code [1500L0] (Transmission clutch: Double engaging).................................... 10
Error code [15SAL1]
(Forward clutch: Fill signal is ON when command current is OFF.)......................... 11
Error code [15SALH]
(Forward clutch: Fill signal is OFF when command current is ON.) ........................ 12
Error code [15SBL1]
(Reverse clutch: Fill signal is ON when command current is OFF.) ........................ 13
Error code [15SBLH]
(Reverse clutch: Fill signal is OFF when command current is ON.) ........................ 14
Error code [15SEL1] (1st clutch: Fill signal is ON when command current is OFF.)... 15
Error code [15SELH] (1st clutch: Fill signal is OFF when command current is ON.).. 16
Error code [15SFL1] (2nd clutch: Fill signal is ON when command current is OFF.).. 17
Error code [15SFLH] (2nd clutch: Fill signal is OFF when command current is ON.) .18
Error code [15SGL1] (3rd clutch: Fill signal is ON when command current is OFF.) ..19
Error code [15SGLH] (3rd clutch: Fill signal is OFF when command current is ON.) .20
Error code [A000N1] (Engine: Overrun)......................................................................21
Error code [AB00MA] (Alternator: Malfunction)...........................................................22
Error code [B@BAZG] (Engine oil: Oil pressure reduction) ........................................23
Error code [B@BCNS] (Coolant: Overheating)...........................................................24
Error code [B@CENS] (Power train oil: Overheating) ................................................25
Error code [B@HANS] (Hydraulic oil: Overheating)....................................................26
Error code [D110KA] (Battery relay: Short circuit).......................................................27
Error code [D110KB] (Battery relay: Disconnection) ...................................................28
Error code [D130KA] (Safety relay: Short circuit) .......................................................30
Error code [D130KB] (Safety relay: Disconnection) ....................................................32
Error code [D161KA] (Back-up alarm relay: Short circuit) ..........................................34
Error code [D161KB] (Back-up alarm relay: Disconnection) .......................................36
Error code [D182KZ] (Preheater relay coil: Disconnection or short circuit).................38
Error code [DAFRKR] (Monitor controller CAN communication:
Defective communication (Abnormality in objective component system))...............40
Error code [DAQ0KK] [DB30KK]
(Steering and transmission controller: Source voltage reduction/input)...................42
Error code [DAQ0KT]
(Steering and transmission controller: Abnormality in controller) ............................44
Error code [DAQ5KK] or [DB35KK] (Steering and transmission controller sensor
5 V power supply: Source voltage reduction) ..........................................................45
Error code [DAQ6KK] [DB36KK] (Steering and transmission controller sensor
24 V power supply: Source voltage reduction/input) ...............................................47
Error code [DAQ9KQ] [DB39KQ] (Steering and transmission controller
model collation: Model selection signal inconsistency) ...........................................48
Error code [DB3RKR] (Steering and transmission controller CAN communication:
Defective communication) .......................................................................................49
Error code [DB30KK] [DAQ0KK] (Steering and transmission controller:
Source voltage reduction/input) ...............................................................................51
Error code [DB35KK] [DAQ5KK] (Steering and transmission controller sensor
5 V power supply: Source voltage reduction/input) .................................................51
Error code [DB36KK] [DAQ6KK] (Steering and transmission controller sensor
24 V power supply: Source voltage reduction/input) ...............................................51
Error code [DB39KQ] [DAQ9KQ] (Steering and transmission controller
model collation: Model selection signal inconsistency) ...........................................51
Error code [DD12KA] (Shift up switch: Disconnection) ...............................................52
Error code [DD12KB] (Shift up switch: Short circuit)...................................................54
Error code [DD13KA] (Shift down switch: Disconnection)...........................................56
Error code [DD13KB] (Shift down switch: Short circuit) ..............................................58
Error code [DD14KA] [DDQ2KA] (Travel lock switch: Disconnection) ........................60
Error code [DD14KB] [DDQ2KB] (Travel lock switch: Short circuit)............................62
Error code [DDE2L6] (Engine oil pressure switch: Signals of engine oil pressure
switch are inconsistent with operation state or stop state.) .....................................64
Error code [DDN7KA] (Pitch control switch: Disconnection) .......................................66
Error code [DDN7KB] (Pitch control switch: Short circuit) ..........................................67
Error code [DDQ2KA] [DD14KA] (Travel lock switch: Disconnection) ........................68
Error code [DDQ2KB] [DD14KB] (Travel lock switch: Short circuit)............................68
2 WE051E0200
Error code [DGE2KX] (Engine coolant temperature sensor (for high temperature):
Input signal is out of normal range) .........................................................................69
Error code [DGE3L6] (Engine coolant temperature sensor:
Signals of engine coolant temperature sensor are inconsistent
with operation state or stop state.)...........................................................................71
Error code [DGS1KX]
(Hydraulic oil temperature sensor: Input signal is out of normal range) ..................73
Error code [DK10KX] (Fuel control dial: Input signal is out of normal range)..............74
Error code [DK12KX]
(Deceleration pedal potentiometer: Input signal is out of normal range) .................76
Error code [DK30KA] (Steering potentiometer 1: Disconnection) ...............................78
Error code [DK30KB] (Steering potentiometer 1: Short circuit) ...................................80
Error code [DK30KX]
(Steering potentiometer 1: Input signal is out of normal range) ...............................82
Error code [DK30KZ] (Steering potentiometer 1: Disconnection or short circuit) ........83
Error code [DK30L8] (Steering potentiometer 1: Disagreement of analog signals) ....84
Error code [DK31KA] (Steering potentiometer 2: Short circuit) ...................................85
Error code [DK31KB] (Steering potentiometer 2: Disconnection) ...............................87
Error code [DK40KA] (Brake potentiometer: Short circuit)..........................................89
Error code [DK40KB] (Brake potentiometer: Disconnection) ......................................91
Error code [DK54KZ]
(Governor motor potentiometer: Disconnection or short circuit) ..............................93
Error code [DK55KX]
(Forward-reverse potentiometer: Input signal is out of normal range).....................95
Error code [DK55KZ]
(Forward-reverse potentiometer 1: Disconnection or short circuit)..........................96
Error code [DK55L8]
(Forward-reverse potentiometer: Disagreement of analog signals).........................97
Error code [DK56KA] (Forward-reverse potentiometer 1: Short circuit)......................98
Error code [DK56KB] (Forward-reverse potentiometer 1: Disconnection) ................100
Error code [DK57KA] (Forward-reverse potentiometer 2: Short circuit)....................102
Error code [DK57KB] (Forward-reverse potentiometer 2: Disconnection) ................104
Error code [DKH1KA] (Pitch angle sensor: Short circuit) ..........................................106
Error code [DKH1KB] (Pitch angle sensor: Disconnection) ......................................107
Error code [DLE2MA] (Engine speed sensor: Malfunction) ......................................109
Error code [DLF1KA] (Transmission output speed sensor: Disconnection) .............. 110
Error code [DV00KB] (Buzzer: Short circuit) ............................................................. 111
Error code [DW5AKA] (Pitch control solenoid: Disconnection) ................................. 112
Error code [DW5AKB] (Pitch control solenoid: Short circuit)..................................... 113
Error code [DW7BKA] (Fan reverse solenoid: Disconnection).................................. 114
Error code [DW7BKB] (Fan reverse solenoid: Short circuit) ..................................... 115
Error code [DWN1KA] (HSS EPC solenoid right: Disconnection)............................. 116
Error code [DWN1KB] (HSS EPC solenoid right: Short circuit) ................................ 117
Error code [DWN2KA] (HSS EPC solenoid left: Disconnection) ............................... 118
Error code [DWN2KB] (HSS EPC solenoid left: Short circuit)................................... 119
Error code [DWN5KA] (Fan pump TVC solenoid: Disconnection) ............................120
Error code [DWN5KB] (Fan pump TVC solenoid: Short circuit)................................121
Error code [DXA0KA] (HSS pump TVC solenoid: Disconnection) ............................122
Error code [DXA0KB] (HSS pump TVC solenoid: Short circuit)................................123
Error code [DXH4KA] (1st clutch ECMV: Disconnection) .........................................124
Error code [DXH4KB] (1st clutch ECMV: Short circuit) .............................................125
WE051E0200 3
Error code [DXH5KA] (2nd clutch ECMV: Disconnection) ........................................126

Error code [DXH5KB] (2nd clutch ECMV: Short circuit)............................................127
Error code [DXH6KA] (3rd clutch ECMV: Disconnection) .........................................128
Error code [DXH6KB] (3rd clutch ECMV: Short circuit).............................................129
Error code [DXH7KA] (Reverse clutch ECMV: Disconnection).................................130
Error code [DXH7KB] (Reverse clutch ECMV: Short circuit) ....................................131
Error code [DXH8KA] (Forward clutch ECMV: Disconnection) .................................132
Error code [DXH8KB] (Forward clutch ECMV: Short circuit).....................................133
Error code [DY10K4] (Governor motor: Loss of synchronism) .................................134
Error code [DY10KA] (Governor motor: Disconnection) ...........................................135
Error code [DY10KB] (Governor motor: Short circuit) ...............................................136
Error code [DY45KA] (Engine stop solenoid relay: Disconnection) ..........................138
Error code [DY45KB] (Engine stop solenoid relay: Short circuit) ..............................140
4 WE051E0200
Troubleshooting when error code is displayed (Error code) 1

Error code table 1
Action
Error code Defective part Trouble
code
1500L0 Transmission clutch Double engaging CALL E03
15SAL1 Forward clutch Fill signal is ON when command current is OFF CALL E03
15SALH Forward clutch Fill signal is OFF when command current is ON CALL E03
15SBL1 Reverse clutch Fill signal is ON when command current is OFF CALL E03
15SBLH Reverse clutch Fill signal is OFF when command current is ON CALL E03
15SEL1 1st clutch Fill signal is ON when command current is OFF CALL E03
15SELH 1st clutch Fill signal is OFF when command current is ON CALL E03
15SFL1 2nd clutch Fill signal is ON when command current is OFF CALL E03
15SFLH 2nd clutch Fill signal is OFF when command current is ON CALL E03
15SGL1 3rd clutch Fill signal is ON when command current is OFF CALL E03
15SGLH 3rd clutch Fill signal is OFF when command current is ON CALL E03
A000N1 Engine Overrun -
AB00MA Alternator Malfunction -
B@BAZG Engine oil Lowering of oil pressure -
B@BCNS Coolant Overheating -
B@CENS Power train oil Overheating -
B@HANS Hydraulic oil Overheating -
D110KA (*1) Battery relay Short circuit -
D110KB (*2) Battery relay Disconnection -
D130KA (*1) Neutral safety relay Short circuit E02
D130KB (*2) Neutral safety relay Disconnection E02
D161KA (*1) Backup alarm relay Short circuit E01
D161KB (*2) Backup alarm relay Disconnection E01
D182KZ Preheater relay coil Disconnection or short circuit E01
Defective communication
DAFRKR Monitor controller CAN signal CALL E03
(Abnormality in objective component)
DAQ0KK
Steering and transmission controller Source voltage reduction/input CALL E04
[DB30KK]
DAQ0KT Steering and transmission controller Internal defect of controller E02
DAQ5KK Steering and transmission controller sensor
Source voltage reduction/input CALL E03
[DB35KK] 5 V power supply
DAQ6KK Steering and transmission controller sensor
[DB36KK] 24 V power supply
DAQ9KQ Steering and transmission controller model
Type selection signal inconsistency CALL E04
[DB39KQ] collation
Steering and transmission controller CAN
DB3RKR Defective communication CALL E03
communication
DB30KK
Steering and transmission controller Source voltage reduction/input CALL E04
[DAQ0KK]
DB35KK Steering and transmission controller sensor
[DAQ5KK] 5 V power supply
DB36KK Steering and transmission controller sensor
[DAQ36KK] 24 V power supply
DB39KQ Steering and transmission controller model
Type select signal inconsistency CALL E04
[DAQ9KQ] collation
DD12KA Shift up switch Disconnection E02
DD12KB Shift up switch Short circuit E02
DD13KA Shift down switch Disconnection E02
DD13KB Shift down switch Short circuit E02
WE051E0200 5
Action
code
DD14KA
Travel lock switch Disconnection CALL E03
[DDQ2KA]
DD14KB
Travel lock switch Short circuit CALL E03
[DDQ2KB]
Engine operation and stop states are inconsistent
DDE2L6 Engine oil pressure switch E01
with signals.
DDN7KA (a) Pitch control switch Disconnection E02
DDN7KB (a) Pitch control switch Short circuit E02
DDQ2KA
Travel lock switch Disconnection CALL E03
[DD14KA]
DDQ2KB
Travel lock switch Short circuit CALL E03
[DD14KB]
Engine coolant temperature sensor
DGE2KX Out of input signal range E01
(for high temperature)
Engine coolant temperature sensor Engine operation and stop states are inconsistent
DGE3L6 E01
(for low temperature) with signals.
DGS1KX Hydraulic oil temperature sensor Out of input signal range -
DK10KX Fuel control dial Out of input signal range CALL E03
DK12KX Decelerator pedal potentiometer Out of input signal range E01
DK30KA Steering potentiometer 1 Disconnection CALL E03
DK30KB Steering potentiometer 1 Short circuit CALL E03
DK30KX Steering potentiometer 1 Out of input signal range CALL E04
DK30KZ Steering potentiometer 1 Disconnection or short circuit CALL E04
DK30L8 Steering potentiometer 1 Disagreement of analog signals CALL E03
DK31KA (*1) Steering potentiometer 2 Short circuit CALL E03
DK31KB (*2) Steering potentiometer 2 Disconnection CALL E03
DK40KA (*1) Brake potentiometer Short circuit E01
DK40KB (*2) Brake potentiometer Disconnection E01
DK54KZ Governor motor potentiometer Disconnection or short circuit E02
DK55KX Forward-reverse potentiometer Out of input signal range CALL E04
DK55KZ Forward-reverse potentiometer Disconnection or short circuit CALL E04
DK55L8 Forward-reverse potentiometer Disagreement of analog signals CALL E03
DK56KA (*1) Forward-reverse potentiometer 1 Short circuit CALL E03
DK56KB (*2) Forward-reverse potentiometer 1 Disconnection CALL E03
DK57KA (*1) Forward-reverse potentiometer 2 Short circuit CALL E03
DK57KB (*2) Forward-reverse potentiometer 2 Disconnection CALL E03
DKH1KA (*1) Pitch angle sensor Short circuit CALL E03
DKH1KB (*2) Pitch angle sensor Disconnection CALL E03
DLE2MA Engine speed sensor Malfunction E01
DLF1KA Transmission output speed sensor Disconnection E01
DV00KB Buzzer Short circuit -
DW5AKA (a) Pitch control solenoid Disconnection E02
DW5AKB (a) Pitch control solenoid Short circuit E02
DW7BKA Fan reverse solenoid Disconnection E01
DW7BKB Fan reverse solenoid Short circuit E01
DWN1KA HSS EPC solenoid right Disconnection CALL E03
DWN1KB HSS EPC solenoid right Short circuit CALL E03
DWN2KA HSS EPC solenoid left Disconnection CALL E03
DWN2KB HSS EPC solenoid left Short circuit CALL E03
DWN5KA Fan pump TVC solenoid Disconnection E01
DWN5KB Fan pump TVC solenoid Short circuit E01
DXA0KA HSS and work equipment pump TVC solenoid Disconnection E01
DXA0KB HSS and work equipment pump TVC solenoid Short circuit E01
DXH4KA 1st clutch ECMV Disconnection CALL E03
6 WE051E0200
Action
code
DXH4KB 1st clutch ECMV Short circuit CALL E03
DXH5KA 2nd clutch ECMV Disconnection CALL E03
DXH5KB 2nd clutch ECMV Short circuit CALL E03
DXH6KA 3rd clutch ECMV Disconnection CALL E03
DXH6KB 3rd clutch ECMV Short circuit CALL E03
DXH7KA Reverse clutch ECMV Disconnection CALL E03
DXH7KB Reverse clutch ECMV Short circuit CALL E03
DXH8KA Forward clutch ECMV Disconnection CALL E03
DXH8KB Forward clutch ECMV Short circuit CALL E03
DY10K4 Governor motor Loss of synchronism E02
DY10KA Governor motor Disconnection CALL E03
DY10KB Governor motor Short circuit CALL E03
DY45KB Engine stop solenoid relay Short circuit E02
DY45KA Engine stop solenoid relay Disconnection E02
DK54KZ Governor motor potentiometer Disconnection or short circuit E02
a: This item displays error occurrence only but not used for this machine.
*1: Normally, a trouble code (KA) indicates disconnection, but a trouble code (KA) is displayed when short circuit
occurs on this machine.
*2: Normaly, a trouble code (KB) indicates short circuit, but a trouble code (KB) is displayed when disconnection
occurs on this machine.
WE051E0200 7
Information described in troubleshooting list 1

Action code Error code
Trouble Trouble in machine
Panel display Panel display
Contents of
Condition at the time when monitor panel or controller detects trouble
trouble
Action of The action taken by monitor panel or controller to protect system or devices when monitor panel or
controller controller detects trouble
Problem that
The problem that appears on machine as a result of the action taken by monitor panel or controller
appears
(shown above)
on machine
Related
Information related to detected trouble or troubleshooting
information
Cause Standard value in normal state/Remarks on troubleshooting

<Contents>
• Standard value in normal state to judge possible causes
• Remarks on judgment
1 <Troubles in wiring harness>
• Disconnection in wiring
Connector connection is defective or wiring harness is
disconnected.
• Grounding fault
Wiring harness which is not connected to chassis ground circuit
is in contact with chassis ground circuit.
• Defective hot circuit
Wiring harness which is not connected to power supply (24 V)
2
circuit is in contact with power supply (24 V) circuit.
• Defective short
Possible causes Cause supposed to have
A harness of an independent circuit abnormally comes into
and standard caused failure
contact with one of another circuit.
value in normal (The sequence shows
state <Precautions for troubleshooting>
reference numbers and
does not mean priority.) (1) Method of indicating connector numbers and handling T-junction
For troubleshooting, insert or connect T-junction adapter as
3 shown below unless especially 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 and connect T-adapter to only male side or female
side.
(2) Connect plus (+) lead and minus (-) lead of circuit tester as
explained below for troubleshooting, unless otherwise specified.
4
• Connect plus (+) lead to pin No. or harness entered on front
side.
• Connect minus (-) lead to pin No. or harness entered on rear
side.
8 WE051E0200
Related circuit diagram
Circuit diagram of the part related to troubleshooting

• Connector No.: Indicates (Type - No. of pins) (Color).
• Arrow ( ): Indicates approximate mounting place on machine.
WE051E0200 9
Error code [1500L0] (Transmission clutch: Double engaging) 1

Action code Error code Transmission clutch: See the list.
Trouble
CALL E03 1500L0 (Steering and transmission controller system)
• Of error codes related to transmission clutch, following codes were displayed at the same time.
(Gear speed limit)
(1) Either [DXHKA] or [DXH4KB] and either [DXH5KA] or [DXH5KB]
• Of error codes related to transmission clutch, following codes were displayed at the same time
(defective travel).
(2) Either [DXH8KA] or [DXH8KB] and either [DXH7KA] or [DXH7KB]
Contents of
(3) Either of [DXH6KA] or [DXH6KB] and (1) above
trouble
(4) [15SFL1] and [15SGL1]
(5) [15SFLH] and [15SGLH]
(6) [15SAL1], [15SBL1], and [15SEL1]
(7) [15SALH] and [15SBLH]
(8) [15SALH] and [15SELH]
(9) [15SBLH] and [15SELH]
Action of • Flashes warning lamp and turns on caution buzzer.
controller • Limits operation of engine and transmission.
• Auto shift down function does not work.
Problem that
• Once machine is stopped, engine speed is limited to medium (half).
appears
• Once machine is stopped, running is limited to specific gear speeds.
on machine
• Machine cannot travel.
Related
• Method of reproducing error code: Start engine and travel.
information

Possible causes
and standard Confirm error codes displayed at the same time, then carry out troubleshooting for the codes.
[15SAL1], [15SALH], [15SBL1], [15SBLH], [15SEL1], [15SELH], [15SFL1], [15SFLH], [15SGL1], [15SGLH]
value in normal
[DXH4KA], [DXH4KB], [DXH5KA], [DXH5KB], [DXH6KA], [DXH6KB], [DXH7KA], [DXH7KB], [DXH8KA],
state
[DXH8KB]
10 WE051E0200
Error code [15SAL1] (Forward clutch: Fill signal is ON when command

current is OFF.) 1
Action code Error code Forward clutch: Fill signal is ON when command current is OFF.
Trouble
CALL E03 15SAL1 (Steering and transmission controller system)
Contents of
• Fill switch signal is not set off at output stop of transmission forward clutch solenoid circuit.
trouble
• Flashes warning lamp and turns on caution buzzer.
Action of
• Decides that engine speed is neutral (N) at reverse operation.
controller
• Limits operation of engine and transmission.
Problem that
appears
• Once machine is stopped, travel is limited to F1.
on machine
• Input state (ON/OFF) from forward clutch fill switch can be checked in monitoring mode.
Related (Code 31520: Transmission fill switch input state)
information • Method of reproducing error code: Start engine and drive machine forward, and then travel lever to
neutral

a Prepare with starting switch OFF, then start engine and carry out trou-
Defective forward clutch bleshooting.
1 fill switch FSW (male) PCCS lever Resistance
(Internal short circuit) Between (1) and N Min. 1 Mz
chassis ground F (Forward) Max. 1 z
Defective harness a Prepare with starting switch OFF and carry out troubleshooting with
Possible causes switch OFF.
grounding
and standard 2
(Contact with ground Between ST2 (female) (35) - FSW (female) (1)
value in normal Resistance Min. 1 Mz
circuit) wiring harness and chassis ground
state
bleshooting.
Defective steering and
3 ST2 PCCS lever Voltage
transmission controller
Between (35) and N 5 - 11 V
chassis ground F (Forward) Max. 1 V
Defective hydraulic When no fault is detected in electric system, hydraulic pressure system is
4
pressure system assumed to be abnormal. Carry out related troubleshooting (H mode).
Circuit diagram related to transmission forward clutch ECMV
WE051E0200 11
Error code [15SALH] (Forward clutch: Fill signal is OFF when command
current is ON.) 1
Action code Error code Forward clutch: Fill signal is OFF when command current is ON.
Trouble
CALL E03 15SALH (Steering and transmission controller system)
Contents of
• Fill switch signal is not set off at output to transmission forward clutch solenoid circuit.
trouble
Action of
controller
Problem that
appears
• Once machine is stopped, travel is limited to R1.
on machine
• Input state (ON/OFF) from forward clutch fill switch can be checked in monitoring mode.
Related
(Code 31520: Input state of transmission fill switch)
information
• Method of reproducing error code: Start engine and drive machine forward.

1 fill switch FSW (male) PCCS lever Resistance
(Internal disconnection) Between (1) - N Min. 1 Mz
chassis ground F (Forward) Max. 1 z
Disconnection in wiring a Prepare with starting switch OFF and carry out troubleshooting with
Possible causes harness switch OFF.
and standard 2 (Disconnection in wiring
value in normal harness or defective Wiring harness between ST2 (female) (35) -
Resistance Max. 1 z
state contact in connector) FSW (female) (1)
bleshooting.
Between (35) - N 5 - 11 V
chassis ground F (Forward) Max. 1 V
4
12 WE051E0200
Error code [15SBL1] (Reverse clutch: Fill signal is ON when command

current is OFF.) 1
Action code Error code Reverse clutch: Fill signal is ON when command current is OFF.
Trouble
CALL E03 15SBLH (Steering and transmission controller system)
Contents of
• Fill switch signal is not set off at output stop of transmission reverse clutch solenoid circuit.
trouble
Action of
controller
Problem that
appears
on machine
• Input state (ON/OFF) from reverse clutch fill switch can be checked in monitoring mode.
Related (Code 31520: Input state of transmission fill switch)
information • Method of reproducing error code: Start engine and drive machine reverse, and then travel lever to
neutral

1 fill switch RSW (male) PCCS lever Resistance
(Internal short circuit) Between (1) - N Min. 1 Mz
chassis ground R (Reverse) Max. 1 z
Possible causes switch OFF.
grounding
and standard 2
(Contact with ground Between ST2 (female) (25) - RSW (female) (1)
state
bleshooting.
Between (25) - N 5 - 11 V
chassis ground R (Reverse) Max. 1 V
4
Circuit diagram related to transmission reverse clutch ECMV
WE051E0200 13
Error code [15SBLH] (Reverse clutch: Fill signal is OFF when command
current is ON.) 1
Action code Error code Reverse clutch: Fill signal is OFF when command current is ON.
Trouble
CALL E03 15SBLH (Steering and transmission controller system)
Contents of
• Fill switch signal is not set on at output to transmission reverse clutch solenoid circuit.
trouble
Action of
controller
Problem that
appears
on machine
• Input state (ON/OFF) from reverse clutch fill switch can be checked in monitoring mode.
Related
information
• Method of reproducing error code: Start engine and drive machine in reverse.

Defective reverse clutch fill bleshooting.
1 switch RSW (male) PCCS lever Resistance
(Internal disconnection) Between (1) - N Min. 1 Mz
chassis ground R (Reverse) Max. 1 z
Resistance Max. 1 z
state contact in connector) RSW (female) (1)
bleshooting.
Between (25) - N 5 - 11 V
chassis ground R (Reverse) Max. 1 V
4
14 WE051E0200
Error code [15SEL1] (1st clutch: Fill signal is ON when command current is
OFF.) 1
Action code Error code 1st clutch: Fill signal is ON when command current is OFF.
Trouble
CALL E03 15SEL1 (Steering and transmission controller system)
Contents of
• Fill switch signal is not set off at stop of output of transmission 1st clutch solenoid circuit.
trouble
Problem that
appears
• Once machine is stopped, travel is limited to F1 and R1.
on machine
• Input state (ON/OFF) from 1st clutch fill switch can be checked in monitoring mode.
information • Method of reproducing error code: Start engine and drive machine in F1 or R1 mode, and then travel
lever to neutral

Defective 1st clutch fill bleshooting.
1 switch 1SW (male) PCCS lever Resistance
(Internal short circuit) Between (1) - Other than F1/R1 Min. 1 Mz
chassis ground F1 . R1 Max. 1 z
Possible causes
grounding switch OFF.
and standard 2
(Contact with ground Between ST3 (female) (19) - 1SW (female) (1)
state
bleshooting.
Between (19) - Other than F1/R1 5 - 11 V
chassis ground F1 . R1 Max. 1 V
4
Circuit diagram related to transmission 1st clutch ECMV
WE051E0200 15
Error code [15SELH] (1st clutch: Fill signal is OFF when command current
is ON.) 1
Action code Error code 1st clutch: Fill signal is OFF when command current is ON.
Trouble
CALL E03 15SELH (Steering and transmission controller system)
Contents of
• Fill switch signal is not set on at output to transmission 1st clutch solenoid circuit.
trouble
Problem that • Automatic shift down function does not work.
appears • Once machine is stopped, engine speed is limited to medium (half).
on machine • Once machine is stopped, travel is limited to F2 and R2.
• Input state (ON/OFF) from 1st clutch fill switch can be checked in monitoring mode.
Related
information
• Method of reproducing error code: Start engine and drive machine in F1 or R1 mode.

Defective 1st clutch fill bleshooting.
(Internal disconnection) Between (1) - Other than F1/R1 Min. 1 Mz
Wiring harness between ST3 (female) (19) -
value in normal harness or defective Resistance Max. 1 z
1SW (female) (1)
state contact in connector)
bleshooting.
Between (19) - N other than F1/R1 5 - 11 V
4
16 WE051E0200
Error code [15SFL1] (2nd clutch: Fill signal is ON when command current is
OFF.) 1
Action code Error code 2nd clutch: Fill signal is ON when command current is OFF.
Trouble
CALL E03 15SFL1 (Steering and transmission controller system)
Contents of
• Fill switch signal is not set off at stop of output of transmission 2nd clutch solenoid circuit.
trouble
• Input state (ON/OFF) from 2nd clutch fill switch can be checked in monitoring mode.
information • Method of reproducing error code: Start engine and drive machine in F2 or R2 mode, and then travel
lever to neutral

Defective 2nd clutch bleshooting.
1 fill switch 2SW (male) PCCS lever Resistance
Possible causes
and standard 2
state
bleshooting.
4
Circuit diagram related to transmission 2nd clutch ECMV
WE051E0200 17
Error code [15SFLH] (2nd clutch: Fill signal is OFF when command current
is ON.) 1
Action code Error code 2nd clutch: Fill signal is OFF when command current is ON.
Trouble
CALL E03 15SFLH (Steering and transmission controller system)
Contents of
• Fill switch signal is not set on at output to transmission 2nd clutch solenoid circuit.
trouble
Problem that
appears
on machine
• Input state (ON/OFF) from 2nd clutch fill switch can be checked in monitoring mode.
Related
information
• Method of reproducing error code: Engine start and drive machine in F2 or R2 mode.

Defective 2nd clutch fill bleshooting.
(Internal disconnection) Between (1) - Other than F2/R2 Min. 1 Mz
Resistance Max. 1 z
state contact in connector) 2SW (female) (1)
bleshooting.
4
18 WE051E0200
Error code [15SGL1] (3rd clutch: Fill signal is ON when command current is
OFF.) 1
Action code Error code 3rd clutch: Fill signal is ON when command current is OFF.
Trouble
CALL E03 15SGL1 (Steering and transmission controller system)
Contents of
• Fill switch signal is not set off at stop of output of transmission 3rd clutch solenoid circuit.
trouble
• Input state (ON/OFF) from 3rd clutch fill switch can be checked in monitoring mode.
information • Method of reproducing error code: Start engine and drive in F3 or R3 mode, and then travel lever to
neutral

Defective 3rd clutch fill bleshooting.
Possible causes
and standard 2
state
bleshooting.
4
Circuit diagram related to transmission 3rd clutch ECMV
WE051E0200 19
Error code [15SGLH] (3rd clutch: Fill signal is OFF when command current
is ON.) 1
Action code Error code 3rd clutch: Fill signal is OFF when command current is ON.
Trouble
CALL E03 15SGLH (Steering and transmission controller system)
Contents of
• Fill switch signal is not set off at stop of output of transmission 3rd clutch solenoid circuit.
trouble
Problem that
appears
on machine
• Input state (ON/OFF) from 3rd clutch fill switch can be checked in monitoring mode.
Related
information

Defective 3rd clutch fill bleshooting.
Resistance Max. 1 z
state contact in connector) 3SW (female) (1)
bleshooting.
4
20 WE051E0200
Error code [A000N1] (Engine: Overrun) 1

Action code Error code Engine overrun
Trouble
- A000N1 (Mechanical system)
Contents of • All segments of engine speed bar graph of monitor panel lighted up to red range and engine speed
trouble exceeded the specified speed (2,750 rpm).
Action of
• Saves trouble but does not make any alarm.
controller
Problem that
• None in particular.
appears
• Stops fuel injection until engine speed lowers below the specified speed.
on machine
Related • Engine speed (rpm) can be checked in monitoring mode. (Code 01000: Engine speed)
information • Method of reproducing error code: Start engine

Possible causes If any other error code is displayed and recorded at the same time, carry out troubleshooting for that
1
and standard error code first.
value in normal 2 Improper use Instruct using procedure again.
state Defective steering and
3 Check that engine speed is displayed normally.
WE051E0200 21
Error code [AB00MA] (Alternator: Malfunction) 1

Action code Error code Alternator: Malfunction
Trouble
- AB00MA (Mechanical system)
Contents of
• During rotation of engine, charge level warning lamp flashes.
trouble
Action of
• Flashes warning lamp.
controller
Problem that
appears • If machine is operated as it is, battery may be discharged.
on machine
Related
• Method of reproducing error code: Start engine
information

Possible causes It is suspected that problem causing defective battery charge is occurring
Defective battery charge
and standard 1 at present or occurred in past. Investigate cause and damage condition,
(When system is in normal)
value in normal and correct it.
state Defective charge level Carry out troubleshooting in accordance with "During running of engine,
2
warning lamp system battery charge warning item flashes" in E mode.
22 WE051E0200
Error code [B@BAZG] (Engine oil: Oil pressure reduction) 1

Action code Error code Engine oil: Oil pressure reduction
Trouble
- B@BAZG (Mechanical system)
Contents of
• During rotation of engine, engine oil pressure warning lamp flashes.
trouble
Action of
• Flashes warning lamp and sounds caution buzzer (Function of monitor panel).
controller
Problem that
appears • If machine is operated as it is, engine may be damaged.
on machine
Related
information

Engine oil pressure It is suspected that problem causing defective battery charge is occurring
Possible causes
1 reduction at present or occurred in past. Investigate cause and damage condition,
and standard
(When system is in normal) and correct it.
value in normal
state Defective engine oil Carry out troubleshooting of engine oil pressure warning lamp system in
2 pressure warning lamp accordance with "During running of engine, emergency warning item
system flashes" in E mode.
WE051E0200 23
Error code [B@BCNS] (Coolant: Overheating) 1

Action code Error code Coolant: Overheating
Trouble
- B@BCNS (Mechanical system)
Contents of
• During rotation of engine, engine oil pressure warning lamp flashes.
trouble
• Flashes engine coolant temperature warning lamp.
Action of
• Flashes warning lamp and sounds caution buzzer (Function of warning lamp).
monitor panel
• Even if cause of the failure disappears, system does not reset itself until starting switch is turned OFF.
Problem that
appears • If machine is operated as it is, engine may be damaged.
on machine
• Input state (coolant temperature, voltage) from engine coolant temperature sensor can be checked in
Related monitoring mode.
information (Code: 04102-WATER HIGH, Code: 04104-WATER LOW)

It is suspected that problem causing defective battery charge is occurring
Possible causes Overheated engine coolant
1 at present or occurred in past. Investigate cause and damage condition,
and standard (When system is normal)
and correct it.
value in normal
state Defective engine coolant Carry out troubleshooting of engine coolant temperature lamp system in
2 temperature warning lamp accordance with "During running of engine, emergency warning item
system flashes" in E mode.
24 WE051E0200
Error code [B@CENS] (Power train oil: Overheating) 1

Action code Error code Power train oil: Overheating
Trouble
- B@CENS (Mechanical system)
Contents of
• During rotation of engine, power train oil temperature warning lamp flashes.
trouble
Action of
controller
Problem that
appears • If machine is operated as it is, power train may be damaged.
on machine
Related
information

Power train oil temperature It is suspected that problem causing power train oil temperature overheat
Possible causes
1 overheating is occurring at present or occurred in past. Investigate cause and damage
and standard
(When system is in normal) condition, and correct it.
value in normal
state Defective power train oil Carry out troubleshooting of power train oil temperature warning lamp
2 temperature overheat system in accordance with "During running of engine, emergency warning
warning lamp system item flashes" in E mode.
WE051E0200 25
Error code [B@HANS] (Hydraulic oil: Overheating) 1

Action code Error code Hydraulic oil: Overheating
Trouble
- B@HANS (Mechanical system)
Contents of
• During rotation of engine, hydraulic oil temperature warning lamp flashes.
trouble
Action of
controller
Problem that
appears • If machine is operated as it is, work equipment circuit units may be damaged.
on machine
Related
information

Hydraulic oil temperature: It is suspected that problem causing hydraulic oil temperature overheat is
Possible causes
1 overheat occurring at present or occurred in past. Investigate cause and damage
and standard
(When system is normal) condition, and correct it.
value in normal
state Defective hydraulic oil Carry out troubleshooting of hydraulic oil temperature warning lamp sys-
2 temperature warning lamp tem in accordance with "During running of engine, emergency warning
system item flashes" in E mode.
26 WE051E0200
Error code [D110KA] (Battery relay: Short circuit) 1

Action code Error code Battery relay: Short circuit
Trouble
- D110KA (Steering and transmission controller system)
Contents of
• Abnormal current flowed to battery relay circuit when outputting it.
trouble
Action of
• Stops output to battery relay circuit.
controller
Problem that
appears • Problem may occur in data writing to ROM (non-volatile memory) of each controller.
on machine
• Output state (voltage) to battery relay can be checked in monitoring mode.
(Code: 60600: Battery relay drive voltage)
Related
• Method of reproducing error code: Switch starting switch from ON to OFF
information
• Usually, a trouble code (KB) is displayed when short circuit occurs, but a trouble code (KA) is displayed
when it occurs in this circuit.

a Prepare with starting switch OFF and carry out troubleshooting with
switch OFF.
Defective battery relay Battery relay Continuity
1
(Internal short circuit) Between terminals SW - SWG There is continuity
Between terminal SW -
40 - 60 z
chassis ground
Possible causes
and standard Short circuit with chassis switch OFF.
value in normal ground in wiring harness
state 2 Wiring harness between ST3 (female) (4) - bat-
(Contact with ground
tery relay SW terminal - starting switch BR (260) Resistance Min. 1 Mz
circuit)
with chassis ground
a Prepare with starting switch OFF, then turn it ON and carry out trouble-
shooting.
3 ST3 Starting switch Voltage
Between (4) -
ON 20 - 30 V
chassis ground
Circuit diagram related to battery relay
WE051E0200 27
Error code [D110KB] (Battery relay: Disconnection) 1

Action code Error code Battery relay: Disconnection
Trouble
- D110KB (Steering and transmission controller system)
Contents of
• Current does not flow when outputting it to battery relay circuit.
trouble
Action of
• Stops output to battery relay circuit.
controller
Problem that
appears • Problem may occur in data writing to ROM (nonvolatile memory) of each controller.
on machine
• Output state (voltage) to battery relay can be checked in monitoring mode.
(Code 60600: Battery relay drive voltage)
Related
• Method of reproducing error code: Switch starting switch from ON to OFF
information
• Usually, a trouble code (KA) is displayed when disconnection occurs, but a trouble code (KB) is displayed
when it occurs in this circuit.

Defective battery relay switch OFF.
1
(Internal disconnection) Battery relay Continuity
Between terminals SW - SWG 40 - 60 z
harness switch OFF.
2 (Disconnection in wiring Wiring harness between ST3 (female) (4) - bat-
Possible causes Resistance Max. 1 z
harness or defective tery relay SW terminal
and standard
contact in connector) Wiring harness between SWG terminal - GND03 Resistance Max. 1 z
value in normal
state a Prepare with starting switch OFF, then turn it ON and carry out trouble-
Hot short circuit in wiring shooting.
3 harness Wiring harness between ST3 (female) (4) - bat-
(Contact with 24 V circuit) tery relay SW terminal - starting switch BR (260) Voltage Max. 1 V
with chassis ground
Defective steering and switch OFF.
4
transmission controller ST3 Voltage
Between (4) - chassis ground Max. 1 V
28 WE051E0200
Circuit diagram related to battery relay
WE051E0200 29
Error code [D130KA] (Safety relay: Short circuit) 1

Action code Error code Neutral safety relay: Short circuit
Trouble
E02 D130KA (Steering and transmission controller system)
Contents of
• Abnormal current flowed in neutral safety relay circuit at the time of ground output.
trouble
controller • Stops ground output to neutral safety relay circuit.
Problem that
appears • Engine cannot be started.
on machine
• Output state (voltage) to neutral safety relay can be checked in monitoring mode.
(Code: 50900: Neutral safety relay drive voltage)
• Method of reproducing error code: Turn starting switch ON and set parking brake lever in Lock position.
Related
a This error code detects abnormality on the primary side (coil side) of neutral safety relay but does not
information
detect abnormality on the secondary side (contact side).
• Usually, a trouble code (KB) is displayed when short-circuiting occurs, but a trouble code (KA) is
displayed when it occurs in this circuit.

Defective neutral safety switch OFF.
1
relay (Internal short circuit) NSF (male) Resistance
Between (1) - (2) 200 - 400 z
Possible causes a Prepare with starting switch OFF, then turn it ON and carry out trouble-
Hot short circuit in wiring
and standard shooting.
2 harness
value in normal
(Contact with 24 V circuit) Wiring harness between ST2 (female) (8) - NSW Voltage Max. 1 V
state (female) (2) with chassis ground
shooting.
3 ST2 Parking brake lever Voltage
Between (8) - FREE 20 - 30 V
chassis ground LOCK Max. 1 V
30 WE051E0200
Circuit diagram related to neutral safety relay
WE051E0200 31
Error code [D130KB] (Safety relay: Disconnection) 1

Action code Error code Neutral safety relay: Disconnection
Trouble
E02 D130KB (Steering and transmission controller system)
Contents of
• When ground circuit of neutral safety relay is interrupted, 24 V is not generated.
trouble
controller • Stops ground output to neutral safety relay circuit.
Problem that
• Engine cannot be started. (Disconnection)
appears
• Engine can be started, regardless of the position of parking brake lever (Short circuit with chassis ground).
on machine
• Output state (voltage) to neutral safety relay can be checked in monitoring mode.
(Code: 50900: Neutral safety relay drive voltage)
• Method of reproducing error code: Turn starting switch ON and operate parking brake lever in Free
Related position.
information a This error code detects abnormality on the primary side (coil side) of neutral safety relay but does not
• Usually, a trouble code (KA) is displayed when disconnection occurs, but a trouble code (KB) is

Defective neutral safety switch OFF.
1 relay
NSF (male) Resistance
(Internal disconnection)
Between (1) - (2) 200 - 400 z
Disconnection in wiring switch OFF.
harness
Wiring harness between ST2 (female) (8) - NSF
2 (Disconnection in wiring Resistance Max. 1 z
(female) (2)
harness or defective
Possible causes contact in connector) Wiring harness between NSF (female) (1) - start-
Resistance Max. 1 z
and standard ing switch ACC (270)
value in normal a Prepare with starting switch OFF and carry out troubleshooting with
state Short circuit with chassis switch OFF.
ground in wiring harness Wiring harness between ST2 (female) (8) - NST
3 Resistance Min. 1 Mz
(Contact with ground (female) (2) with chassis ground
circuit) Wiring harness between NSF (female) (1) - start-
Resistance Min. 1 Mz
ing switch ACC (270) with chassis ground
shooting.
4 ST2 Parking brake lever Voltage
Between (8) - FREE 20 - 30 V
chassis ground LOCK Max. 1 V
32 WE051E0200
Circuit diagram related to neutral safety relay
WE051E0200 33
Error code [D161KA] (Back-up alarm relay: Short circuit) 1

Action code Error code Backup alarm relay: Short circuit
Trouble
E01 D161KA (Steering and transmission controller system)
Contents of
• Abnormal current flowed in back-up alarm relay circuit at the time of ground output.
trouble
Action of
• Stops output to back-up alarm relay circuit.
controller
Problem that
appears • Backup alarm does not sound.
on machine
• Output state (voltage) to back-up alarm relay can be checked in monitoring mode.
(Code 70400: Back-up alarm relay drive voltage)
• Method of reproducing error code: Turn starting switch ON and operate steering and drive machine
Related forward and reverse, Set gear shift lever in Reverse position).
information a This error code detects abnormality on the primary side (coil side) of back-up alarm relay but does not

Defective back-up alarm switch OFF.
1 relay
BKA (male) Resistance
(Internal short circuit)
Between (1) - (2) 200 - 400 z
and standard
2 harness
value in normal Wiring harness between ST2 (female) (18) -
(Contact with 24 V circuit) Voltage Max. 1 V
state BKA (female) (2) with chassis ground
shooting.
Between (18) - Neutral 20 - 30 V
chassis ground Reverse Max. 1 V
34 WE051E0200
Circuit diagram related to back-up alarm relay
WE051E0200 35
Error code [D161KB] (Back-up alarm relay: Disconnection) 1

Action code Error code Backup alarm relay: Disconnection
Trouble
E01 D161KB (Steering and transmission controller system)
Contents of
• When ground circuit of neutral safety relay is interrupted, 24 V is not generated.
trouble
Action of
• Stops output to back-up alarm relay circuit.
controller
Problem that • Backup alarm does not sound (disconnection).
appears • Back-up alarm is turned on, regardless of positions of steering and forward-reverse lever and gearshift
on machine lever. (Short circuit with chassis ground)
• Output state (voltage) to back-up alarm relay can be checked in monitoring mode.
(Code 70400: Back-up alarm relay drive voltage)
• Method of reproducing error code: Turn starting switch ON and operate steering and drive machine
Related forward and reverse, Set shift lever in Neutral position
information a This error code detects abnormality on the primary side (coil side) of back-up alarm relay but does not

If fuse is burn out, circuit probably has short circuit with chassis ground,
1 Defective fuse FS2-9
etc.
Defective back-up alarm switch OFF.
2 relay
BKA (male) Resistance
Between (1) - (2) 200 - 400 z
harness
Possible causes Wiring harness between ST2 (female) (18) -
and standard BKA (female) (2)
value in normal contact in connector) Wiring harness between BKA (female) (1) - FS2-
Resistance Max. 1 z
state 9 outlet port
Short circuit with chassis a Prepare with starting switch OFF and carry out troubleshooting with
ground in wiring harness switch OFF.
4
(Contact with ground Wiring harness between ST2 (female) (18) -
circuit) BKA (female) (2) with chassis ground
shooting.
Between (18) - Neutral 20 - 30 V
chassis ground Reverse Max. 1 V
36 WE051E0200
Circuit diagram related to back-up alarm relay
WE051E0200 37
Error code [D182KZ] (Preheater relay coil: Disconnection or short circuit) 1

Action code Error code Preheater relay coil: Disconnection or short circuit
Trouble
E01 D182KZ (Steering and transmission controller system)
Contents of
• Drive circuit of preheater relay has a trouble.
trouble
Action of
• Stops ground output to preheater relay.
controller
Problem that • Preheater relay cannot be driven. (Disconnection, hot short circuit)
appears • Preheater relay is driven, regardless of atmospheric temperature. (Short circuit with chassis ground in
on machine wiring harness)
Related a This error code detects abnormality on the primary side (coil side) of preheater relay but does not detect
information abnormality on the secondary side (contact side).

Defective preheater relay a Prepare with starting switch OFF and carry out troubleshooting with
(RHR) switch OFF.
1
(Internal disconnection or 200 -
Between RHR (female) (1) - (2) Resistance
short circuit) 400 z
harness Wiring harness between RHR (female) (2) - ST2
Resistance Max. 1 z
2 (Disconnection in wiring (female) (9)
harness or defective Wiring harness between RHR (female) (1) - 270 Resistance Max. 1 z
contact in connector) Wiring harness between RHR (female) (1) - ST3
Resistance Max. 1 z
(female) (14), (24)
Possible causes a Prepare with starting switch OFF and carry out troubleshooting with
and standard Short circuit with chassis switch OFF.
value in normal ground in wiring harness Wiring harness between RHR (female) (2) - ST2
state (Contact with ground (female) (9) with chassis ground
circuit) Wiring harness between RHR (female) (1) - ST3
(female) (14), (24) with chassis ground
4 harness
Wiring harness between RHR (female) (2) - ST2
(female) (9) with chassis ground
shooting.
Defective steering and Voltage
5
transmission controller Between ST2 (female) When relay is driven Max. 1 V
(9) - chassis ground When relay is
20 - 30 V
not driven
38 WE051E0200
Circuit diagram related to preheater relay coil
WE051E0200 39
Error code [DAFRKR] (Monitor controller CAN communication: Defective

communication (Abnormality in objective component system)) 1
Action code Error code Monitor controller CAN communication: Defective communication
Trouble
CALL E03 DAFRKR (Monitor panel system)
Contents of
• Monitor panel cannot recognize steering and transmission controller with CAN communication circuit.
trouble
Action of
controller
• When cause of the failure disappears, system recovers to normal.
Problem that • Monitor panel cannot display information.
Related
• Method of reproducing error code: Turn starting switch ON.
information

switch OFF.
Disconnection in wiring
Wiring harness between S04 (female) (1), (2) -
harness
ST2 (female) (32), -CA1 (female) (A), -CA2 Resistance Max. 1 z
1 (Disconnection in wiring
(female) (A), -CAN (male) (3)
contact in connector) Wiring harness between S04 (female) (3), (4) -
ST2 (female) (22), -CA1 (female) (B), -CA2 Resistance Max. 1 z
(female) (B), -CAN (male) (10)
switch OFF.
Short circuit with chassis ST2 (female) (32), -CA1 (female) (A), - CA2
ground in wiring harness (female) (A), -CAN (male) (3) with chassis
2
(Contact with ground ground
circuit) Wiring harness between S04 (female) (3), (4) -
Possible causes ST2 (female) (22), -CA1 (female) (B), -CA2
and standard (female) (B), -CAN (male) (10) with chassis
value in normal ground
shooting.
ST2 (female) (32), -CA1 (female) (A), -CA2
Hot short circuit in wiring Voltage Max. 1 V
(female) (A), -CAN (male) (3) with chassis
3 harness
ground
(Contact with 24 V circuit)
ST2 (female) (22), -CA1 (female) (B), - CA2
Voltage Max. 1 V
(female) (B), -CAN (male) (10) with chassis
ground
Defective CAN terminal switch OFF.
4
resistance CA1 (male), CA2 (male) Resistance
Between (A) - (B) 100 z - 140 z
Defective monitor panel or If no problem is found in causes 1 to 4, it is suspected that monitor panel
5 defective steering and or steering and transmission controller is defective. (Troubleshooting can-
transmission controller not be carried out since it is internal defect.)
40 WE051E0200
Circuit diagram related to CAN communication
WE051E0200 41
Error code [DAQ0KK] [DB30KK] (Steering and transmission controller:

Source voltage reduction/input) 1
Steering and transmission controller: Source voltage reduction/input
DAQ0KK Trouble
CALL E04 (Steering and transmission controller system)
DB30KK
Contents of
• Source voltage of steering and transmission controller is below 17 V.
trouble
Action of
controller
• Monitor panel may not display normally.
Problem that
• Relays and solenoids cannot operate, not allowing system operate normally.
appears
on machine
• Once machine is stopped, it cannot travel any more.
• Both of DAQ0KK and DB30KK are displayed.
Related • Charge level (voltage) of battery can be checked in monitoring mode.
information (Code 03200: Battery voltage)

If any of fuses FS1-9 is broken, circuit probably has short circuit with chas-
1 Defective fuse FS1-9
sis ground.
switch OFF.
Disconnection in wiring Wiring harness between ST3 (female) (1), (2),
harness Resistance Max. 1 z
(11), (12), (22) - SF1-9
harness or defective Wiring harness between FS1-9 - battery relay
Resistance Max. 1 z
contact in connector) terminal C
Possible causes Wiring harness between ST-3 (female) (21),
Resistance Max. 1 z
and standard (31), (32), (33) with chassis ground
state Short circuit with chassis switch OFF.
ground in wiring harness Wiring harness between ST3 (female) (1), (2),
(Contact with ground (11), (12), (22) - SF1-9 with chassis ground
circuit) Wiring harness between inlet FS1-9 - battery
relay terminal C with chassis ground
shooting.
4 ST3 Voltage
(1), (2), (11), (12), (22) -
20 - 30 V
(21), (31), (32), (33)
42 WE051E0200
Circuit diagram related to steering and transmission controller power supply
WE051E0200 43
Error code [DAQ0KT] (Steering and transmission controller: Abnormality in

controller) 1
Action code Error code Steering and transmission controller: Abnormality in controller
Trouble
E02 DAQ0KT (Steering and transmission controller system)
Contents of
• Information of ROM (nonvolatile memory) of steering and transmission controller is not normal.
trouble
controller • Sets default internal adjustment value.
Problem that
appears • Gear shift feeling of transmission may become worse.
on machine
Related
information

Troubleshooting cannot be carried out since it is internal defect.
Defective steering and • Adjust once in adjustment mode (Code: 0002)
Possible causes 1
transmission controller (It is no problem even if you use controller unless no visible problem
and standard
appears on machine.)
value in normal
state If error code [D110KA] or [D110KB] is displayed or if monitor is turned
Defective holding of battery OFF just after starting switch is turned OFF, battery relay may not be held
2
relay normally. In this case, carry out troubleshooting for error code [D110KA]
or [D110KB], too.
44 WE051E0200
Error code [DAQ5KK] or [DB35KK] (Steering and transmission controller

sensor 5 V power supply: Source voltage reduction) 1
Action code Error code Steering and transmission controller sensor 5 V power supply:
DAQ5KK Trouble Source voltage reduction/input
CALL E03
DB35KK (Steering and transmission controller system)
• Voltage of 5 V power supply circuit of steering and transmission controller sensor is below 4.5 V or
Contents of
above 5.5 V.
trouble
• Abnormal current flowed in 5 V power supply circuit of steering and transmission controller sensor.
Action of
• Stops output to 5 V power supply circuit if abnormal voltage flows
controller
Problem that • System may not operate normally.
• If this trouble occurs, respective error codes of the brake, forward and reverse travel unit, steering, fuel
dial, decelerator pedal, governor motor feedback potentiometer powered by 5 V power supply are also
Related
displayed and recorded.
information
• Both of DAQ5KK and DB35KK are displayed.

It is internal defect if error code lights on (reset display) when
Defective brake
disconnecting right connector. BRK
1 potentiometer
a Disconnect connector with starting switch OFF, then turn Connector
starting switch ON and carry out troubleshooting.
switch OFF.
Defective forward-reverse
TL2 (male) Resistance
2 potentiometer
(Internal short circuit) Between (4) - (1) 3.2 kz±20%
Sensor Between (4) -
Min. 1 Mz
chassis ground
switch OFF.
Defective steering
TL2 (male) Resistance
3 potentiometer
(Internal short circuit) Between (5) - (8) 3.2 kz±20%
Possible causes Sensor Between (5) -
Min. 1 Mz
and standard chassis ground
value in normal It is internal defect if service code lights on (reset display)
state Defective fuel control dial when disconnecting right connector. DIAL
4
potentiometer a Disconnect connector with starting switch OFF, then turn Connector
It is internal defect if service code lights on (reset display)
Defective deceleration
when disconnecting right connector. DCL
5 pedal potentiometer
Governor motor feedback when disconnecting right connector. E62
6
potentiometer a Disconnect connector with starting switch OFF, then turn Connector
Short circuit with chassis switch OFF.
ground in wiring harness Wiring harness between ST1 (female) (22) - TL2
7
(Contact with ground (female) (5), - TL2 (female) (4), - BRK (female)
circuit) (A), - DIAL (A), -DCL (C), - E62 (A) with chassis
ground
WE051E0200 45

shooting.
8 harness Wiring harness between ST1 (female) (22) - TL2
Possible causes (female) (5), - TL2 (female) (4), - BRK (female)
and standard (Contact with 24 V circuit) Voltage Max. 1 V
(A), - DIAL (A), -DCL (C), - E62 (A) with chassis
state
Defective steering and shooting.
9
Between (22) - (21) 4.5 - 5.5 V
Circuit diagram related to steering and transmission controller 5 V power supply
46 WE051E0200
Error code [DAQ6KK] [DB36KK] (Steering and transmission controller

sensor 24 V power supply: Source voltage reduction/input) 1
Action code Error code Steering and transmission controller sensor 24 V power supply:
DAQ6KK Trouble Source voltage reduction/input (KK)
CALL E03
DB36KK (Steering and transmission controller system)
• Voltage of 24 V power supply circuit of steering and transmission controller sensor is below 17 V or
Contents of
above 30 V.
trouble
• Abnormal current flowed in 24 V power supply circuit of steering and transmission controller sensor.
Action of
controller
• Stops output to 24 V power supply circuit if abnormal voltage flows
• If this trouble occurs, respective error codes of the pitch angle sensor powered by 5 V power supply are
Related also displayed and recorded.
information • Both of DAQ6KK and DB36KK are displayed.

Defective pitch angle
when disconnecting right connector. PT1
1 sensor
Possible causes a Prepare with starting switch OFF and carry out troubleshooting with
Short circuit with chassis
and standard switch OFF.
ground in wiring harness
value in normal 2
(Contact with ground Wiring harness between CN1 (female) (16) - PT1
state circuit) Resistance Min. 1 Mz
(female) (C) with chassis ground
3
Between (16) - (21) 20 - 30 V
Circuit diagram related to steering and transmission controller 24 V power supply
WE051E0200 47
Error code [DAQ9KQ] [DB39KQ] (Steering and transmission controller

model collation: Model selection signal inconsistency) 1
Action code Error code Steering and transmission controller model collation:
DAQ9KQ Trouble Model selection signal inconsistency
CALL E04
DB39KQ (Steering and transmission controller system)
Contents of • Internal spec. setting of steering and transmission controller is inconsistent with spec. set signal.
trouble (Steering and transmission controller cannot be recognized normally.)
Action of
• Stops all outputs to steering and transmission controller.
controller
Problem that • Machine does not operate at all.
on machine • Once machine is stopped, it cannot travel any more.
Related • Both of DAQ9KQ and DB39KQ are displayed.
information • Method of reproducing error code: Turn starting switch ON.

Defective adjustment of If error code lights up (to indicated restoration), system is normal.
1 steering and transmission • Adjustment code: 0002:
controller Steering and transmission controller specification set
harness switch OFF.
Wiring harness between ST3 (female) (30) with
Possible causes harness or defective Resistance Max. 1 z
GND01
and standard contact in connector)
value in normal Short circuit with chassis a Prepare with starting switch OFF and carry out troubleshooting with
state ground in wiring harness switch OFF.
3
(Contact with ground Wiring harness between ST3 (female) (40) - PL2
circuit) (18) with chassis ground
shooting.
4 ST3 Voltage
Between (30) - chassis ground Max. 1 V
Between (40) - chassis ground 5 - 11 V
Circuit diagram related to steering and transmission controller type select
48 WE051E0200
Error code [DB3RKR] (Steering and transmission controller CAN

communication: Defective communication) 1
Action code Error code Steering and transmission controller CAN communication:
Trouble Defective communication
CALL E03 DB3RKR (Steering and transmission controller system)
Contents of
• Steering and transmission controller cannot recognize monitor panel with CAN communication circuit.
trouble
Action of
controller
Related
information

switch OFF.
harness
ST2 (female) (32), -CA1 (female) (A), -CA2 Resistance Max. 1 z
(female) (A), -CAN (male) (3)
contact in connector) Wiring harness between S04 (female) (3), (4) -
ST2 (female) (22), -CA1 (female) (B), -CA2 Resistance Max. 1 z
(female) (B), -CAN (male) (10)
switch OFF.
Short circuit with chassis ST2 (female) (32), -CA1 (female) (A), -CA2
ground in wiring harness (female) (A), -CAN (male) (3) with chassis
2
(Contact with ground ground
circuit) Wiring harness between S04 (female) (3), (4) -
Possible causes ST2 (female) (22), -CA1 (female) (B), -CA2
and standard (female) (B), -CAN (male) (10) with chassis
shooting.
ST2 (female) (32), -CA1 (female) (A), -CA2
Hot short circuit in wiring Voltage Max. 1 V
(female) (A), -CAN (male) (3) with chassis
3 harness
ground
ST2 (female) (22), -CA1 (female) (B), -CA2
Voltage Max. 1 V
(female) (B), -CAN (male) (10) with chassis
ground
Defective CAN terminal switch OFF.
4
resistance CA1 (male), CA2 (male) Resistance
Between (A) - (B) 100 - 140 z
Defective monitor panel or If no problem is found in causes 1 to 4, it is suspected that monitor panel
5 defective steering and or steering and transmission controller is defective. (Troubleshooting can-
transmission controller not be carried out since it is internal defect.)
WE051E0200 49
Circuit diagram related to CAN communication
50 WE051E0200
Error code [DB30KK] [DAQ0KK] (Steering and transmission controller:

Source voltage reduction/input) 1
a See DAQ0KK.
Error code [DB35KK] [DAQ5KK] (Steering and transmission controller

a See DAQ5KK.
Error code [DB36KK] [DAQ6KK] (Steering and transmission controller

a See DAQ6KK.
Error code [DB39KQ] [DAQ9KQ] (Steering and transmission controller

model collation: Model selection signal inconsistency) 1
a See DAQ9KQ.
WE051E0200 51
Error code [DD12KA] (Shift up switch: Disconnection) 1

Action code Error code Shift up switch: Disconnection
Trouble
E02 DD12KA (Steering and transmission controller system)
Contents of
• Signals of two systems of shift up switch were turned OFF (opened) simultaneously.
trouble
Action of • Flashes warning lamp and sounds caution buzzer.
controller • Recognizes switch is not pushed.
Problem that
• Shift up is not possible.
appears
on machine
• NO signal of two systems of the switch is for sensing operations and NC signal is for sensing errors.
Related • Input state (ON/OFF) from shift down switch can be checked in monitoring mode.
information (Code: 40905 Transmission controller input signal 1)
• Method of reproducing error code: Turn starting switch ON and shift up the gear.

switch OFF.
Shift up switch
SFTU (male)
Defective shift up switch OFF (Released) ON (Pressed)
1
(Internal disconnection) Resistance between
Max. 1 z Min. 1 Mz
(2) - (3)
Resistance between
Min. 1 Mz Max. 1 z
(2) - (1)
switch OFF.
Disconnection in wiring Wiring harness between ST1 (female) (12) -
SFTU (female) (3)
harness or defective Wiring harness between ST3 (female) (9) -
contact in connector) SFTU (female) (1)
and standard
Resistance Max. 1 z
state SFTU (female) (2)
shooting.
3 harness Voltage Max. 1 V
SFTU (female) (3) with chassis ground
Voltage Max. 1 V
shooting.
Shift up switch
ST1, ST3
Defective steering and OFF (Released) ON (Pressed)
4
transmission controller Between ST1 (12) -
Max. 1 V 5 - 11 V
ST1 (4) Voltage
Between ST1 (9) -
5 - 11 V Max. 1 V
ST1 (4) Voltage
52 WE051E0200
Circuit diagram related to shift up switch and shift down switch
WE051E0200 53
Error code [DD12KB] (Shift up switch: Short circuit) 1

Action code Error code Shift up switch: Short circuit
Trouble
E02 DD12KB (Steering and transmission controller system)
Contents of
• Signals of two systems of shift up switch are turned ON (closed) simultaneously.
trouble
Problem that
• Shift up is not possible.
appears
on machine
Related • Input state (ON/OFF) from shift up switch can be checked in monitoring mode.
• Method of reproducing error code: Turn starting switch ON and shift up the gear.

switch OFF.
Shift up switch
SFTU (male)
Defective shift up switch OFF (Released) ON (Pressed)
1
(Internal short circuit) Resistance between
Max. 1 z Min. 1 Mz
(2) - (3)
Resistance between
Min. 1 Mz Max. 1 z
(2) - (1)
Possible causes
and standard
value in normal ground in wiring harness Wiring harness between ST1 (female) (12) -
(Contact with ground SFTU (female) (3) with chassis ground
state
circuit) Wiring harness between ST3 (female) (9) -
shooting.
Shift up switch
ST1, ST3
3
Max. 1 V 5 - 11 V
ST1 (4) Voltage
Between ST3 (9) -
5 - 11 V Max. 1 V
ST1 (4) Voltage
54 WE051E0200
WE051E0200 55
Error code [DD13KA] (Shift down switch: Disconnection) 1

Action code Error code Shift down switch: Disconnection
Trouble
E02 DD13KA (Steering and transmission controller system)
Contents of
• Signals of two systems of shift down switch were turned OFF (opened) simultaneously.
trouble
Problem that
• Shift down is not possible.
appears
on machine
• Method of reproducing error code: Turn starting switch ON and shift down the gear.

switch OFF.
Shift down switch
SFTD (female)
Defective shift down switch OFF (Released) ON (Pressed)
1
(Internal disconnection) Resistance between
Max. 1 z Min. 1 Mz
(2) - (3)
Resistance between
Min. 1 Mz Max. 1 z
(2) - (1)
switch OFF.
SFTD (male) (3)
harness or defective Wiring harness between ST1 (female) (18) -
contact in connector) SFTD (female) (1)
and standard
Resistance Max. 1 z
state SFTD (female) (2)
shooting.
SFTD (male) (3) with chassis ground
Voltage Max. 1 V
shooting.
Shift down switch
ST1
4
Max. 1 V 5 - 11 V
ST1 (4) Voltage
Between ST1 (18) -
5 - 11 V Max. 1 V
ST1 (4) Voltage
56 WE051E0200
WE051E0200 57
Error code [DD13KB] (Shift down switch: Short circuit) 1

Action code Error code Shift down switch: Short circuit
Trouble
E02 DD13KB (Steering and transmission controller system)
Contents of
• Signals of two systems of shift down switch are turned ON (closed) simultaneously.
trouble
Problem that
• Shift down is not possible.
appears
on machine
• Method of reproducing error code: Turn starting switch ON and shift down the gear.

switch OFF.
Shift down switch
SFTD (female)
Defective shift down switch OFF (Released) ON (Pressed)
1
(Internal short circuit) Resistance between
Max. 1 z Min. 1 Mz
(2) - (3)
Resistance between
Min. 1 Mz Max. 1 z
(2) - (1)
Possible causes
and standard
value in normal ground in wiring harness Wiring harness between ST1 (female) (24) -
(Contact with ground SFTD (male) (3) with chassis ground
state
circuit) Wiring harness between ST1 (female) (18) -
shooting.
Shift down switch
ST1
3
Max. 1 V 5 - 11 V
ST1 (4) Voltage
Between ST1 (18) -
5 - 11 V Max. 1 V
ST1 (4) Voltage
58 WE051E0200
WE051E0200 59
Error code [DD14KA] [DDQ2KA] (Travel lock switch: Disconnection) 1

Travel lock switch: Disconnection
DD14KA Trouble
DDQ2KA
Contents of • Signals of two systems of travel lock switch (parking brake lever switch) are turned OFF (opened)
trouble simultaneously.
• Flashes warning lamp and sounds caution buzzer.
Action of
• Recognizes parking brake lever is in Free position.
controller
Problem that • Once machine is stopped, engine speed is limited to medium (half).
appears • Once machine is stopped, travel is limited to F1 and R1.
on machine • Engine cannot be started.
• Both of DD14AK and DDQ2KA are displayed.
Related
• Input state (ON/OFF) from travel lock switch can be checked in monitoring mode.
information
(Code: 40910 Steering controller input signal 1)
• Method of reproducing error code: Turn starting switch ON and operate parking brake lever.

switch OFF.
Travel lock switch Parking brake lever
NSW (male)
(Parking brake lever Free position Lock position
1
switch) Between (A) - (B) with
(Internal disconnection) Max. 1 z Min. 1 Mz
chassis ground
Between (A) - (C) with
Min. 1 Mz Max. 1 z
chassis ground
switch OFF.
NSW (female) (C)
harness or defective Wiring harness between ST2 (female) (5) - NSW
contact in connector) (female) (B)
and standard
value in normal Wiring harness between ST1 (female) (4) - NSW
Resistance Max. 1 z
state (female) (A)
shooting.
NSW (female) (C) with chassis ground
Wiring harness between ST2 (female) (5) - NSW
Voltage Max. 1 V
(female) (B) with chassis ground
shooting.
Parking brake lever
ST2
Defective steering and Free position Lock position
4
transmission controller Between (15) -
Max. 1 V 5 - 11 V
chassis ground
Between (5) -
5 - 11 V Max. 1 V
chassis ground
60 WE051E0200
Circuit diagram related to travel lock switch (Parking brake lever switch)
WE051E0200 61
Error code [DD14KB] [DDQ2KB] (Travel lock switch: Short circuit) 1

Travel lock switch: Short circuit
DD14KB Trouble
DDQ2KB
Contents of • Signals of two systems of travel lock switch (parking brake lever switch) are turned ON (closed)
trouble simultaneously.
Action of
• Recognizes parking brake lever is in Free position.
controller
Problem that • Once machine is stopped, engine speed is limited to medium (half).
appears • Once machine is stopped, travel is limited to F1 and R1.
on machine • Engine cannot be started.
• Both of DD14KB and DDQ2KB are displayed.
Related
• Input state (ON/OFF) from parking brake switch can be checked in monitoring mode.
information
(Code: 40910 Steering controller input signal 1)
• Method of reproducing error code: Turn starting switch ON and operate parking brake lever.

Travel lock switch switch OFF.
(Parking brake lever Parking brake lever
1 NSW (male)
switch) Free position Lock position
(Internal short circuit) Between (A) - (B) Max. 1 z Min. 1 Mz
Between (A) - (C) Min. 1 Mz Max. 1 z
Possible causes
ground in wiring harness Wiring harness between NSW (female) (B) -
and standard 2 Resistance Min. 1 Mz
(Contact with ground STS (female) (5) with chassis ground
value in normal
circuit) Wiring harness between NSW (female) (C) - ST2
state Resistance Min. 1 Mz
shooting.
Parking brake lever
ST2
Defective steering and Free position Lock position
3
transmission controller Between (15) -
Max. 1 V 5 - 11 V
chassis ground
Between (5) -
5 - 11 V Max. 1 V
chassis ground
62 WE051E0200
Circuit diagram related to travel lock switch (Parking brake lever switch)
WE051E0200 63
Error code [DDE2L6] (Engine oil pressure switch: Signals of engine oil
pressure switch are inconsistent with operation state or stop state.) 1
Action code Error code Engine oil pressure switch: Signals of engine oil pressure switch are
Trouble inconsistent with operation state or stop state.
E01 DDE2L6 (Steering and transmission controller system)
Contents of
• Signals of engine oil pressure switch are inconsistent with engine state.
trouble
Action of
controller
Problem that
appears • When engine oil pressure lowers, warning signal is not output.
on machine
• Input state (ON/OFF) from engine oil pressure switch can be checked in monitoring mode.
Related
(Code: 40900 Engine input signal 1)
information
• Method of reproducing error code: Turn starting switch ON or Start engine.

a Prepare with starting switch OFF, then carry out troubleshooting with-
Defective engine oil out turning switch ON or after starting engine.
1 pressure switch E121 Engine Resistance
(Internal disconnection) Between terminal - Stop Max. 1 z
chassis ground Min. 600 rpm Min. 1 Mz
harness switch OFF.
harness or defective Wiring harness between S03 (female) (12) -
Resistance Min. 1 z
Possible causes E121
contact in connector)
and standard
value in normal Hot short circuit in wiring shooting.
state 2 harness
Wiring harness between S03 (female) (12) -
E121 with chassis ground
If engine speed is not indicated during running of engine, carry out trou-
Defective engine speed
4 bleshooting in accordance with "Engine speed is indicated incorrectly" in
sensor system
E mode.
a Prepare with starting switch OFF, then carry out troubleshooting by
holding starting switch OFF or after starting engine.
5 Defective monitor panel S03 Engine Voltage
Stop Max. 1 V
Between (12) - ground
Min. 600 rpm 5 - 11 V
64 WE051E0200
Circuit diagram related to engine oil pressure switch
WE051E0200 65
Error code [DDN7KA] (Pitch control switch: Disconnection) 1

Action code Error code Pitch control switch: Disconnection
Trouble
E02 DDN7KA (Steering and transmission controller system)
Contents of
• Signals of two systems of pitch control switch were turned OFF (opened) simultaneously.
trouble
Action of
controller
Problem that
appears • None in particular.
on machine
• This error code is not used since pitch-function-equipped work equipment is not installed on this
Related
machine.
information

Defective adjustment of
Possible causes If error code lights up (to indicated restoration), system is normal.
1 steering and transmission
and standard • Adjustment code: 0004: Machine specification set
controller
value in normal
state If no problem is found in above cause 1, it is suspected that steering and
2 transmission controller is defective.
(Troubleshooting cannot be carried out since it is internal defect.)
66 WE051E0200
Error code [DDN7KB] (Pitch control switch: Short circuit) 1

Action code Error code Pitch control switch: Short circuit
Trouble
E02 DDN7KB (Steering and transmission controller system)
Contents of
• Signals of two systems of pitch control switch were turned ON (closed) simultaneously.
trouble
Action of
controller
Problem that
on machine
Related
machine.
information

controller
value in normal
WE051E0200 67
Error code [DDQ2KA] [DD14KA] (Travel lock switch: Disconnection) 1

a See DD14KA.
Error code [DDQ2KB] [DD14KB] (Travel lock switch: Short circuit) 1

a See DD14KB.
68 WE051E0200
Error code [DGE2KX] (Engine coolant temperature sensor (for high

temperature): Input signal is out of normal range) 1
Action code Error code Engine coolant temperature sensor (for high temperature):
Trouble Input signal is out of normal range
E01 DGE2KX (Monitor panel system)
Contents of
• High engine coolant temperature sensor signal is out of normal range.
trouble
Action of • Fixes coolant temperature signal output for monitor panel at 90°C.
controller • When cause of the failure disappears, system recovers to normal.
Problem that • Monitor panel does not display engine coolant temperature normally.
appears • When engine coolant overheats, caution signal is not output.
on machine • Fan speed is limited to half.
• Engine coolant temperature state (temperature) can be checked in monitoring mode.
Related
(Code 04102: Engine coolant temperature (high temperature side)
information
• Method of reproducing error code: Turn starting switch ON or Run engine at least 30 min.

Defective high engine a Prepare with starting switch OFF and carry out troubleshooting with
coolant temperature switch OFF.
1 sensor E111(male) Resistance
(Internal disconnection or Between (A) - (B) 3.5 k - 90 kz (30 - 100°C)
short circuit) Between (A), (B) - chassis ground Min. 1 Mz
harness
E111 (female) (A)
contact in connector) Wiring harness between S03 (female) (3) (4) -
E111 (female) (B)
and standard
3
(Contact with ground Wiring harness between S04 (female) (11) -
circuit) E111 (female) (A) with chassis ground
4 harness
(Contact with 24 V circuit) Wiring harness between S04 (female) (11) -
Voltage Max. 1 V
E111 (female) (A) with chassis ground
switch OFF.
5 Defective monitor panel S03, S04 Voltage
Between S03 (female) (3) (4) -
2.0 - 4.8 V (30 - 100°C)
S04 (female) (11)
WE051E0200 69
Circuit diagram related to engine coolant temperature sensor (for high temperature)
70 WE051E0200
Error code [DGE3L6] (Engine coolant temperature sensor: Signals of engine

coolant temperature sensor are inconsistent with operation state or stop
state.) 1
Action code Error code Engine coolant temperature sensor (for low temperature): See table.
Trouble
E01 DGE3L6 (Monitor panel system)
Contents of
• Signals of low engine coolant temperature sensor are inconsistent with engine state.
trouble
Action of
controller
Problem that
appears • Preheater relay is driven, regardless of atmospheric temperature.
on machine
• Engine coolant temperature state (temperature) can be checked in monitoring mode.
Related
(Code 04104: Engine coolant temperature (low temperature side)
information
• Method of reproducing error code: Run engine at least 30 min.

Defective low engine a Prepare with starting switch OFF and carry out troubleshooting with
coolant temperature switch OFF.
1 sensor E131 (male) Resistance
(Internal disconnection or Between (A) - (B) 3.5 k - 9 kz (10 - 100°C)
short circuit) Between (A), (B) - chassis ground Min. 1 Mz
harness
Possible causes Wiring harness between ST1 (female) (14) -
and standard E131 (female) (A)
contact in connector) Resistance Max. 1 z
state E131 (female) (B)
shooting.
3 harness
E131 (female) (A) with chassis ground
4
Between (14) - (21) 0.3 - 3.3 V (10 - 100°C)
WE051E0200 71
Circuit diagram related to engine coolant temperature sensor (for low temperature)
72 WE051E0200
Error code [DGS1KX] (Hydraulic oil temperature sensor: Input signal is out
of normal range) 1
Action code Error code Hydraulic oil temperature sensor: Input signal is out of normal range
Trouble
- DGS1KX (Steering and transmission controller system)
Contents of
• Hydraulic oil temperature sensor signal is out of normal range.
trouble
Action of
• Saves trouble but does not make any alarm.
controller
Problem that
• Hydraulic oil temperature of monitor panel is not displayed normally.
appears
• Fan speed is limited to half.
on machine
• When this failure occurs, hydraulic oil overheating [B@HANS] is also displayed and recorded
simultaneously.
Related
• Hydraulic oil temperature state (temperature) can be checked in monitoring mode
information
(Code 04401: Hydraulic oil temperature)
• Method of reproducing error code: Turn starting switch ON or Start engine.

Defective hydraulic oil switch OFF.
temperature sensor
1 SDS (male) Resistance
(Internal disconnection or
short circuit) Between (1) - (2) 3.5 k - 90 kz (10 - 100°C)
Between (1), (2) - chassis ground Min. 1 Mz
harness
SDS (female) (1)
Possible causes contact in connector) Wiring harness between ST1 (female) (21) -
Resistance Max. 1 z
and standard SDS (female) (2)
3
(Contact with ground Wiring harness between ST1 (female) (9) - SDS
circuit) (female) (1) with chassis ground
4 harness
Wiring harness between ST1 (female) (9) - SDS
5
Between (9) - (21) 2.0 - 4.8 V (10 - 100°C)
Circuit diagram related to hydraulic oil temperature sensor
WE051E0200 73
Error code [DK10KX] (Fuel control dial: Input signal is out of normal range)1
Action code Error code Fuel control dial: Input is out of normal range
Trouble
CALL E03 DK10KX (Steering and transmission controller system)
Contents of
• Signal voltage of fuel control dial circuit is below 0.5 V or above 4.5 V.
trouble
Action of • Limits operation of engine and transmission.
controller • Controls machine with the position signal received just before the trouble occurs until machine is
stopped.
Problem that
appears
on machine
• Inputting from fuel control dial (Voltage) can be checked in monitoring mode.
Related
(Code 03000: Voltage of fuel control dial)
information
• Method of reproducing error code: Turn starting switch ON and operate fuel control dial.

Defective 5 V sensor See if error code [DAQ5KK] or [DB35KK] is displayed. If it is displayed,
1
power source system carry out troubleshooting for it first.
switch OFF.
Defective fuel control dial DIAL (male) Resistance
2 (Internal disconnection or
Between (A) - (C) 4.0 - 6.0 kz
short circuit)
Between (A) - (B) 0.5 - 4.5 kz
Between (B) - (C) 0.5 - 4.5 kz
switch OFF.
Disconnection in wiring Wiring harness between ST1 (female) (22) and
DIAL (female) (A)
harness or defective Wiring harness between ST1 (female) (3) and
Resistance Max. 1 z
DIAL (female) (B)
Possible causes contact in connector)
and standard Wiring harness between ST1 (female) (21) and
Resistance Max. 1 z
value in normal DIAL (female) (C)
state a Prepare with starting switch OFF and carry out troubleshooting with
ground in wiring harness Wiring harness between ST1 (female) (22) -
(Contact with ground DIAL (female) (A) with chassis ground
circuit) Wiring harness between ST1 (female) (3) - DIAL
shooting.
DIAL (female) (A) with chassis ground
Wiring harness between ST1 (female) (3) - DIAL
Voltage Max. 1 V
6
Between (3) - (21) 0.5-4.5 kz
74 WE051E0200
Circuit diagram related to fuel control dial
WE051E0200 75
Error code [DK12KX] (Deceleration pedal potentiometer: Input signal is out

of normal range) 1
Action code Error code Deceleration pedal potentiometer: Input is out of normal range
Trouble
E01 DK12KX (Steering and transmission controller system)
Contents of
• Signal voltage of deceleration pedal potentiometer circuit is below 0.5 V or above 4.5 V.
trouble
Action of
• Recognizes deceleration pedal is not pressed.
controller
Problem that
appears • Auto shift down function does not work.
on machine
• Inputting from deceleration pedal potentiometer (Voltage) can be checked in monitoring mode.
Related
(Code 50001: Voltage of deceleration pedal potentiometer)
information
• Method of reproducing error code: Turn starting switch ON and press deceleration pedal.

1
• Defective deceleration a Prepare with starting switch OFF and carry out troubleshooting with
pedal potentiometer switch OFF.
(Internal disconnection DCL (male) Resistance
2
or short circuit) Between (A) - (C) 4.0 - 6.0 kz
• Defective installation of Between (A) - (B) 2.0 - 4.2 kz (Free - Full stroke)
potentiometer Between (B) - (C) 3.0 - 1.2 kz (Free - Full stroke)
switch OFF.
DCL (female) (A)
Wiring harness between ST1 (female) (1) - DCL
harness or defective Resistance Max. 1 z
(female) (B)
and standard Resistance Max. 1 z
DCL (female) (C)
value in normal
ground in wiring harness Wiring harness between ST1 (female) (22) -
(Contact with ground DCL (female) (C) with chassis ground
circuit) Wiring harness between ST1 (female) (1) - DCL
shooting.
DCL (female) (C) with chassis ground
Wiring harness between ST1 (female) (1) - DCL
Voltage Max. 1 V
6
Between (1) - (21) 2.4 - 3.5 V (Free - Full stroke)
76 WE051E0200
Circuit diagram related to deceleration pedal potentiometer
WE051E0200 77
Error code [DK30KA] (Steering potentiometer 1: Disconnection) 1

Action code Error code Steering potentiometer 1: Disconnection
Trouble
CALL E03 DK30KA (Steering and transmission controller system)
Contents of
• Signal voltage of steering potentiometer 1 system is above 4.5 V.
trouble
Action of
• Continues controlling with signal of steering potentiometer 2 system.
controller
Problem that
appears
on machine
• Inputting from steering potentiometer 1 (Voltage) can be checked in monitoring mode.
Related
(Code 50300: Voltage of steering potentiometer 1)
information
• Method of reproducing error code: Turn starting switch ON and (operate PCCS lever (steering)).

1
Defective steering switch OFF.
potentiometer 1 TL2 (male) Resistance
2
(Internal disconnection or Between (5) - (8) 3.2 kz±20%
short circuit) Between (7) - (5) 1 - 6 kz (Right - Left steering)
Between (7) - (8) 6 - 1 kz (Right - Left steering)
Possible causes Disconnection in wiring switch OFF.
and standard harness
value in normal Wiring harness between ST1 (female) (21) - TL2
state (female) (8)
contact in connector) Wiring harness between ST1 (female) (2) - TL2
Resistance Max. 1 z
(female) (7)
4 harness
Wiring harness between ST1 (female) (2) - TL2
5
Between (2) - (21) 0.5 - 4.5 V
78 WE051E0200
Circuit diagram related to steering potentiometer
WE051E0200 79
Error code [DK30KB] (Steering potentiometer 1: Short circuit) 1

Action code Error code Steering potentiometer 1: Short circuit
Trouble
CALL E03 DK30KB (Steering and transmission controller system)
Contents of
• Signal voltage of steering potentiometer 1 system is below 0.5 V.
trouble
Action of
controller
Problem that
appears
on machine
Related
information

Defective 5 V sensor See if error code [DAQ5KK] [DB35KK] is displayed. If it is displayed,
1
2
Possible causes Short circuit with chassis a Prepare with starting switch OFF and carry out troubleshooting with
and standard ground in wiring harness switch OFF.
value in normal 3
(Contact with ground Wiring harness between ST1 (female) (2) - TL2
harness switch OFF.
(female) (5)
5
Between (2) - (21) 0.5 - 4.5 V
80 WE051E0200
WE051E0200 81
Error code [DK30KX] (Steering potentiometer 1: Input signal is out of

normal range) 1
Action code Error code Steering potentiometer 1: Input signal is out of normal range.
Trouble
Contents of • In steering potentiometer systems 1 and 2, either of error codes [DK30KA] and [DK30KB] and either of
trouble error codes [DK31KA] and [DK31KB] are turned ON simultaneously.
controller • Controls machine with the position signal received just before the trouble occurs until PCCS lever is set
in NEUTRAL position.
Problem that
appears
on machine
• Inputting from steering potentiometer (Voltage) can be checked in monitoring mode.
Related (Code 50300: Voltage of steering potentiometer 1)
information (Code 50301: Voltage of steering potentiometer 2)
Possible causes Cause Standard value in normal state/Remarks on troubleshooting

and standard
value in normal Carry out troubleshooting for error codes [DK30KA], [DK30KB], [DK31KA], and [DK31KB].
state
82 WE051E0200
Error code [DK30KZ] (Steering potentiometer 1: Disconnection or short circuit)1

Action code Error code Steering potentiometer 1: Disconnection or short circuit
Trouble
CALL E04 DK30KZ (Steering and transmission controller system)
• Either of steering potentiometer systems 1 and 2 is abnormal when starting switch is turned ON, and
Contents of
then either of error codes [DK30KA] and [DK30KB], and either of error codes [DK31KA] and [DK31KB]
trouble
are turned ON simultaneously in those systems.
controller • Controls machine with the position signal received just before the trouble occurs until PCCS lever is set
in NEUTRAL position.
Problem that
appears
on machine
Related (Code 50300: Voltage of steering potentiometer 1)
information (Code 50301: Voltage of steering potentiometer 2)

and standard
state
WE051E0200 83
Error code [DK30L8] (Steering potentiometer 1: Disagreement of analog

signals) 1
Action code Error code Steering potentiometer 1: Disagreement of analog signals
Trouble
CALL E03 DK30L8 (Steering and transmission controller system)
Contents of • Total signal voltage of each of steering potentiometer 1 system and 2 system is below 4.41 V or above
trouble 5.59 V.
Action of • Continues controlling with signal of normal one of steering potentiometer 1 system and 2 system when
controller starting switch is turned ON.
Problem that
appears
on machine
Related
information
• Method of reproducing error code: Turn starting switch ON and (operate PCCS lever (forward and
reverse)).

and standard
state
84 WE051E0200
Error code [DK31KA] (Steering potentiometer 2: Short circuit) 1

Action code Error code Steering potentiometer 2: Short circuit
Trouble
Contents of
• Signal voltage of steering potentiometer 2 system is above 4.5 V.
trouble
Action of
controller
Problem that
appears
on machine
Related
information

1
2
and standard Hot short circuit in wiring
shooting.
value in normal 3 harness
state (Contact with 24 V circuit) Voltage Max. 1 V
harness switch OFF.
harness or defective Wiring harness between ST1 (female) (21) - TL2
Resistance Max. 1 z
contact in connector) (female) (8)
5
Between (19) - (21) 0.5 - 4.5 V
WE051E0200 85
86 WE051E0200
Error code [DK31KB] (Steering potentiometer 2: Disconnection) 1

Action code Error code Steering potentiometer 2: Disconnection
Trouble
Contents of
• Signal voltage of steering potentiometer 2 system is below 0.5 V.
trouble
Action of
controller
Problem that
appears
on machine
Related
information

1
2
state (female) (5)
Resistance Max. 1 z
(female) (6)
4
5
Between (19) - (21) 0.5 - 4.5 V
WE051E0200 87
88 WE051E0200
Error code [DK40KA] (Brake potentiometer: Short circuit) 1

Action code Error code Brake potentiometer: Short circuit
Trouble
E01 DK40KA (Steering and transmission controller system)
Contents of
• Signal voltage of brake potentiometer circuit is below 1.5 V.
trouble
Action of
• Recognizes brake is half-applied.
controller
Problem that
appears • Auto shift down function does not work normally.
on machine
• Inputting from brake potentiometer (Voltage) can be checked in monitoring mode.
(Code 50400: Voltage of brake potentiometer)
Related
• Method of reproducing error code: Turn starting switch ON and (press brake pedal)
information

1
• Defective brake a Prepare with starting switch OFF and carry out troubleshooting with
potentiometer switch OFF.
(Internal disconnection BRK (male) Resistance
2
value in normal 3 (Disconnection in wiring Resistance Max. 1 z
BRK (female) (A)
state harness or defective
contact in connector) Wiring harness between ST2 (female) (20) -
Resistance Max. 1 z
BRK (female) (B)
4
circuit) BRK (female) (B) with chassis ground
shooting.
5 ST1, ST2 Voltage
Between ST2 (female) (20) -
2.7 - 1.5 V (Free - Full stroke)
ST1 (female) (21)
WE051E0200 89
Circuit diagram related to brake pedal potentiometer
90 WE051E0200
Error code [DK40KB] (Brake potentiometer: Disconnection) 1

Action code Error code Brake potentiometer: Disconnection
Trouble
E01 DK40KB (Steering and transmission controller system)
Contents of
• Signal voltage of brake potentiometer circuit is above 3.0 V.
trouble
Action of
• Recognizes brake is half-applied.
controller
Problem that
appears • Auto shift down function does not work normally.
on machine
• Inputting from brake potentiometer (Voltage) can be checked in monitoring mode.
(Code 50400: Voltage of brake potentiometer)
Related
• Method of reproducing error code: Turn starting switch ON and (press brake pedal)
information

1
• Defective brake pedal a Prepare with starting switch OFF and carry out troubleshooting with
potentiometer switch OFF.
(Internal disconnection BRK (male) Resistance
2
Possible causes shooting.
and standard 3 harness
value in normal BRK (female) (B) with chassis ground
harness
BRK (female) (C)
harness or defective con-
tact in connector) Wiring harness between ST2 (female) (20) -
Resistance Max. 1 z
BRK (female) (B)
shooting.
5 ST1, ST2 Voltage
Between ST2 (female) (20) -
2.7 - 1.5 V (Free - Full stroke)
ST1 (female) (21)
WE051E0200 91
Circuit diagram related to brake potentiometer
92 WE051E0200
Error code [DK54KZ] (Governor motor potentiometer: Disconnection or

short circuit) 1
Action code Error code Governor motor potentiometer: Disconnection or short circuit
Trouble
E02 DK54KZ (Steering and transmission controller system)
Contents of
• Signal voltage of governor motor feedback potentiometer circuit is below 0.4 V or above 4.7 V.
trouble
controller • Controls engine rotation without signals from governor motor feedback potentiometer.
Problem that
appears • Precision of engine rotation control becomes lower.
on machine
• Inputting from governor motor feedback potentiometer (Voltage) can be checked in monitoring mode.
Related
(Code 03100: Voltage of governor motor feedback potentiometer)
information

1
Defective governor motor switch OFF.
feedback potentiometer E62 (male) Resistance
2
(Internal disconnection or Between (A) - (C) 4.0 - 6.0 kz
short circuit) Between (A) - (B) 5.2 - 1.9 kz (High - Low idling
Between (B) - (C) 0.5 - 3.2 kz (High - Low idling
switch OFF.
Disconnection in wiring Wiring harness between ST1 (female) (22) - E62
(female) (A)
Wiring harness between ST1 (female) (20) - E62
(female) (B)
(female) (C)
value in normal
ground in wiring harness Wiring harness between ST1 (female) (22) - E62
(Contact with ground (female) (A) with chassis ground
circuit) Wiring harness between ST1 (female) (20) - E62
shooting.
Voltage Max. 1 V
(female) (C) with chassis ground
6
Between (20) - (21) 0.6 - 2.7 V (High - Low idling)
WE051E0200 93
Circuit diagram related to governor motor potentiometer
94 WE051E0200
Error code [DK55KX] (Forward-reverse potentiometer: Input signal is out of

normal range) 1
Action code Error code Forward-reverse potentiometer: Input signal is out of normal range
Trouble
Contents of • In forward-reverse potentiometer systems 1 and 2, either of error codes [DK56KA] and [DK56KB] and
trouble either of error codes [DK57KA] and [DK57KB] are turned ON simultaneously.
Action of • Limits operation of engine, transmission, and brake.
stopped.
Problem that
appears
on machine
• Inputting from forward-reverse potentiometer (Voltage) can be checked in monitoring mode.
(Code 50200: Voltage of forward-reverse potentiometer 1)
Related
information
reverse)).

and standard
value in normal Carry out troubleshooting for error codes [DK56KA],[DK56KB],[DK57KA], and [DK57KB].
state
WE051E0200 95
Error code [DK55KZ] (Forward-reverse potentiometer 1: Disconnection or

short circuit) 1
Action code Error code Forward-reverse potentiometer: Disconnection or short circuit
Trouble
CALL E04 DK55KZ (Steering and transmission controller system)
• Either of forward-reverse potentiometer systems 1 and 2 is abnormal when starting switch is turned ON,
Contents of
and either of error codes [DK56KA] and [DK56KB] and either of error codes [DK57KA] and [DK57KB]
trouble
are turned ON simultaneously.
Action of • Limits operation of engine, transmission, and brake.
stopped.
Problem that
appears
on machine
Related
information
reverse)).

and standard
state
96 WE051E0200
Error code [DK55L8] (Forward-reverse potentiometer: Disagreement of

analog signals) 1
Action code Error code Forward-reverse potentiometer: Disagreement of analog signals
Trouble
CALL E03 DK55L8 (Steering and transmission controller system)
Contents of • Total signal voltage of each of forward-reverse potentiometer 1 system and 2 system is below 4.41 V or
trouble above 5.59 V.
Action of • Continues controlling with signal of normal one of forward-reverse potentiometer 1 system and 2 system
controller when starting switch is turned ON.
Problem that
appears
on machine
Related
information
reverse)).

and standard
state
WE051E0200 97
Error code [DK56KA] (Forward-reverse potentiometer 1: Short circuit) 1

Action code Error code Forward-reverse potentiometer 1: Short circuit
Trouble
Contents of
• Signal voltage of forward-reverse potentiometer 1 system is above 4.5 V.
trouble
Action of
• Continues controlling with signal of forward-reverse potentiometer 2 system.
controller
Problem that
appears
on machine
• Inputting from forward-reverse potentiometer 1 (Voltage) can be checked in monitoring mode.
Related • Method of reproducing error code: Turn starting switch ON and (operate PCCS lever (forward and
information reverse)).

1
Defective forward-reverse switch OFF.
2
short circuit) Between (3) - (4) 5.5 - 1.5 kz (Forward - Reverse)
Between (3) - (1) 1.5 - 5.5 kz (Forward - Reverse)
and standard Hot short circuit in wiring shooting.
value in normal 3 harness
state (Contact with 24 V circuit) Voltage Max. 1 V
harness switch OFF.
(female) (1)
5
Between (13) - (21) 0.5 - 4.5 V
98 WE051E0200
Circuit diagram related to forward-reverse potentiometer
WE051E0200 99
Error code [DK56KB] (Forward-reverse potentiometer 1: Disconnection) 1

Action code Error code Forward-reverse potentiometer 1: Disconnection
Trouble
Contents of
• Signal voltage of forward-reverse potentiometer 1 system is below 0.5 V.
trouble
Action of
controller
Problem that
appears
on machine

1
2
state (female) (4)
Resistance Max. 1 z
(female) (3)
Hot short circuit in wiring switch OFF.
4 harness
(Contact with 24 V circuit) Resistance Min. 1 Mz
5
Between (13) - (21) 0.5 - 4.5 V
100 WE051E0200
WE051E0200 101
Error code [DK57KA] (Forward-reverse potentiometer 2: Short circuit) 1

Action code Error code Forward-reverse potentiometer 2: Short circuit
Trouble
Contents of
• Signal voltage of forward-reverse potentiometer 2 system is above 4.5 V.
trouble
Action of
controller
Problem that
appears
on machine

harness
See if error code [DAQ5KK] [DB35KK] is displayed. If it is displayed,
carry out troubleshooting for it first.
2
Possible causes
and standard
value in normal a Prepare with starting switch OFF, then turn it ON and carry out trouble-
state 3 harness
harness switch OFF.
harness or defective Wiring harness between ST1 (female) (21) - TL2
Resistance Max. 1 z
contact in connector) (female) (1)
5
Between (7) - (21) 0.5 - 4.5 V
102 WE051E0200
WE051E0200 103
Error code [DK57KB] (Forward-reverse potentiometer 2: Disconnection) 1

Action code Error code Forward-reverse potentiometer 2: Disconnection
Trouble
Contents of
• Signal voltage of forward-reverse potentiometer 2 system is below 0.5 V.
trouble
Action of
controller
Problem that
appears
on machine

1
2
state (female) (4)
Resistance Max. 1 z
(female) (2)
4
5
Between (7) - (21) 0.5 - 4.5 V
104 WE051E0200
WE051E0200 105
Error code [DKH1KA] (Pitch angle sensor: Short circuit) 1

Action code Error code Pitch angle sensor: Short circuit
Trouble
CALL E03 DKH1KA (Steering and transmission controller system)
Contents of
• Signal voltage of pitch angle sensor is above 4.85 V.
trouble
Action of
• Cannot recognize pitch angle.
controller
Problem that • Shocks are made when gear is shifted on slope.
• Inputting from pitch angle sensor (Voltage) can be checked in monitoring mode.
(Code 60100: Voltage of pitch angle sensor)
Related
information

1
Defective pitch angle shooting.
2 sensor
PT1 Max. 1 V
Possible causes (Internal defect)
Between (A) - (B) 0.15 - 4.85 V
and standard
value in normal Hot short circuit in wiring shooting.
state 3 harness
Between ST1 (female) (8) - PT1 (female) (B) wir-
ing harness and chassis ground
4
Between (8) - (21) 0.15 - 4.85 V
Circuit diagram related to pitch angle sensor
106 WE051E0200
Error code [DKH1KB] (Pitch angle sensor: Disconnection) 1

Action code Error code Pitch angle sensor: Disconnection
Trouble
CALL E03 DKH1KB (Steering and transmission controller system)
Contents of
• Signal voltage of pitch angle sensor is below 0.15 V.
trouble
Action of
• Cannot recognize pitch angle.
controller
Problem that • Shocks are made when gear is shifted on slope.
• Inputting from pitch angle sensor (Voltage) can be checked in monitoring mode.
(Code 60100: Voltage of pitch angle sensor)
Related
information

1
Defective pitch angle switch OFF.
2
sensor (Internal defect) PT1 Voltage
Between (B) - (A) 0.15 - 4.85 V
Possible causes harness
Wiring harness between ST1 (female) (16) - PT1
and standard 3 (Disconnection in wiring Resistance Max. 1 z
(female) (C)
value in normal harness or defective
state contact in connector) Wiring harness between ST1 (female) (8) - PT1
Resistance Max. 1 z
(female) (B)
4
(Contact with ground Wiring harness between ST1 (female) (8) - PT1
circuit) (female) (B) with chassis ground
5
Between (8) - (21) 0.15 - 4.85 V
WE051E0200 107
Circuit diagram related to pitch angle sensor
108 WE051E0200
Error code [DLE2MA] (Engine speed sensor: Malfunction) 1

Action code Error code Defective engine speed sensor: Malfunction
Trouble
E01 DLE2MA (Steering and transmission controller system)
Contents of
• No signals are input from engine speed sensor.
trouble
Action of
• Recognizes engine speed is 0 rpm.
controller
Problem that • Engine speed cannot be monitored.
appears • Gear shift shock is made.
on machine • Fan speed is limited to half.
• Engine speed can be checked in monitoring mode.
Related
(Code 01000: Engine speed)
information

Defective engine speed switch OFF.
sensor
1 E51 (male) Resistance
short circuit) Between (1) - (2) 400 - 1000 z
Between (1) - chassis ground Min. 1 Mz
harness
Possible causes 2 (Disconnection in wiring Resistance Max. 1 z
(female) (1)
and standard harness or defective
contact in connector) Wiring harness between ST2 (female) (39) - E51
value in normal Resistance Max. 1 z
(female) (2)
state
3
(Contact with ground Wiring harness between ST2 (female) (40) - E51
switch OFF.
4 ST2 (female) Resistance
Between (40) - (39) 400 - 1000 z
Circuit diagram related to engine speed sensor
WE051E0200 109
Error code [DLF1KA] (Transmission output speed sensor: Disconnection) 1

Action code Error code Transmission output speed sensor: Disconnection
Trouble
E01 DLFKA (Steering and transmission controller system)
Contents of
• Signal is not input from transmission output speed sensor.
trouble
Action of
• Recognizes transmission output speed is 0 rpm.
controller
• Transmission speed cannot be monitored.
Problem that
• Traction force cannot be calculated.
appears
• Gear shift shock is made.
on machine
• Auto shift down function does not work normally.
a Transmission output speed can be checked in monitoring mode.
Related
(Code 31400: Transmission speed)
information
• Method of reproducing error code: Start engine and travel machine actually.

Defective transmission switch OFF.
output speed sensor
1 TM1 (male) Resistance
short circuit) Between (1) - (2) 400 - 1000 z
harness
TM1 (female) (1)
contact in connector) Wiring harness between ST2 (female) (29) -
TM1 (female) (2)
state
3
circuit) TM1 (female) (1) with chassis ground
switch OFF.
Between (30) - (29) 400 - 1000 z
Circuit diagram related to transmission output speed sensor
110 WE051E0200
Error code [DV00KB] (Buzzer: Short circuit) 1

Action code Error code Buzzer: Short circuit
Trouble
- DV00KB (Monitor panel system)
Contents of
• When caution buzzer circuit is output to the ground, an abnormal current flows.
trouble
Action of
• Stops outputting to ground circuit of caution buzzer circuit.
controller
Problem that
appears • Caution buzzer does not sound.
on machine
Related • Method of reproducing error code: Turn starting switch ON (When it is turned ON, buzzer sounds for 1
information second).

Defective caution buzzer switch OFF.
1
(Internal short circuit) 217 (male) Resistance
Between (1) - (2) 200 z
and standard shooting.
2 harness
value in normal Wiring harness between 217 (female) (1) - S03
state (female) (18) with chassis ground
shooting.
3 Defective monitor panel S03 Caution buzzer Voltage
Between (18) - Stopped 20 - 30 V
chassis ground Operated (Sounded) Max. 3 V
Circuit diagram related to buzzer
WE051E0200 111
Error code [DW5AKA] (Pitch control solenoid: Disconnection) 1

Action code Error code Pitch control solenoid: Disconnection
Trouble
E02 DW5AKA (Steering and transmission controller system)
Contents of
• Any current does not flow when power is output to pitch control solenoid circuit.
trouble
Action of
controller
Problem that
on machine
Related
machine.
information

controller
value in normal
112 WE051E0200
Error code [DW5AKB] (Pitch control solenoid: Short circuit) 1

Action code Error code Pitch control solenoid: Short circuit
Trouble
E02 DW5AKB (Steering and transmission controller system)
Contents of
• Abnormal current flowed when power is output to pitch control solenoid circuit.
trouble
Action of
controller
Problem that
on machine
Related
machine.
information

controller
value in normal
(Troubleshooting cannot be carried out since it is internal defect..)
WE051E0200 113
Error code [DW7BKA] (Fan reverse solenoid: Disconnection) 1

Action code Error code Fan reverse solenoid: Disconnection
Trouble
E01 DW7BKA (Steering and transmission controller system)
Contents of
• When signal is output to fan reverse solenoid circuit, any current does not flow.
trouble
Action of
• Stops outputting to fan reverse solenoid circuit.
controller
Problem that
appears • Fan reversing function cannot be used.
on machine
• Output (ON/OFF) to fan reverse solenoid can be checked in monitoring mode.
Related (Code: 40914 Steering controller output signal)
information • Method of reproducing service code: Turn starting switch ON and operate fan in reverse/cleaning
position.

Defective fan reverse switch OFF.
1 solenoid
FAR (male) Resistance
Between (1) - (2) 34 - 44 z
harness
Wiring harness between ST3 (female) (18) - FAR
(female) (1)
value in normal contact in connector) Wiring harness between ST3 (female) (13) - FAR
Resistance Max. 1 z
state (female) (2)
shooting.
3 harness
Wiring harness between ST3 (female) (18) - FAR
4
transmission controller ST3 Resistance
Between (18) - (13) 34 - 44 z
Circuit diagram related to fan reverse solenoid
114 WE051E0200
Error code [DW7BKB] (Fan reverse solenoid: Short circuit) 1

Action code Error code Fan reverse solenoid: Short circuit
Trouble
E01 DW7BKB (Steering and transmission controller system)
Contents of
• When signal was output to fan reverse solenoid circuit, an abnormal current flows.
trouble
Action of
• Stops outputting to fan reverse solenoid circuit.
controller
Problem that
appears • Fan reversing function cannot be used.
on machine
• Output (ON/OFF) to fan reverse solenoid can be checked in monitoring mode.
Related (Code: 40914 Steering controller output signal)
information • Method of reproducing service code: Turn starting switch ON and operate fan in reverse/cleaning
position.

Defective fan reverse switch OFF.
1 solenoid FAR (male) Resistance
(Internal short circuit) Between (1) - (2) 34 - 44 z
2
Possible causes (Contact with ground Wiring harness between ST3 (female) (18) - FAR
and standard circuit) (female) (1) with chassis ground
state Defective short circuit in switch OFF.
wiring harness
3 Wiring harness between ST3 (female) (18) - FAR
(Short circuit in wiring
(female) (1) and ST3 (female) (13) - FAR Resistance Min. 1 Mz
harness)
(female) (2)
switch OFF.
Between (18) - (13) 34 - 44 z
Circuit diagram related to fan reverse solenoid
WE051E0200 115
Error code [DWN1KA] (HSS EPC solenoid right: Disconnection) 1

Action code Error code HSS EPC solenoid right: Disconnection
Trouble
CALL E03 DWN1KA (Steering and transmission controller system)
Contents of
• When signal is output to HSS EPC solenoid right circuit, any current does not flow.
trouble
Action of
• Stops outputting to HSS EPC solenoid right circuit.
controller
Problem that
appears
on machine
• Output (Current) to HSS EPC solenoid right can be checked in monitoring mode.
Related (Code 50601:Output feedback current of right HSS solenoid, Code 50603: Output current of right HSS
information solenoid)
• Method of reproducing error code: Turn starting switch ON and operate PCCS lever (right steering).

Defective HSS EPC switch OFF.
1 solenoid right
HSB (male) Resistance
Between (1) - (2) 5 - 15 z
harness
Possible causes 2 (Disconnection in wiring Resistance Min. 1 z
HSB (female) (1)
contact in connector) Wiring harness between ST3 (female) (3) - HSB
value in normal Resistance Min. 1 z
(female) (2)
state
3 harness
HSB (female) (1) with chassis ground
4
transmission controller ST3 (female) Resistance
Between (38) - (3) 5 - 15 z
Circuit diagram related to HSS EPC solenoid right
116 WE051E0200
Error code [DWN1KB] (HSS EPC solenoid right: Short circuit) 1

Action code Error code HSS EPC solenoid right: Short circuit
Trouble
CALL E03 DWN1KB (Steering and transmission controller system)
Contents of
• When signal is output to HSS EPC solenoid right circuit, current flowed.
trouble
Action of
• Stops outputting to HSS EPC solenoid right circuit.
controller
Problem that
appears
on machine
• Output (Current) to HSS EPC solenoid right can be checked in monitoring mode.
Related (Code 50601:Output feedback current of right HSS solenoid, Code 50603: Output current of right HSS
• Method of reproducing error code: Turn starting switch ON and operate PCCS lever (right steering).

1 solenoid right HSB (male) Resistance
2
Possible causes (Contact with ground Wiring harness between ST3 (female) (38) -
and standard circuit) HSB (female) (1) with chassis ground
state Defective short circuit in
switch OFF.
wiring harness
3 Wiring harness between ST3 (female) (38) -
harness) HSB (female) (1) and ST3 (female) (3) - HSB Resistance Min. 1 Mz
(female) (2)
switch OFF.
Between (38) - (3) 5 - 15 z
Circuit diagram related to HSS EPC solenoid right
WE051E0200 117
Error code [DWN2KA] (HSS EPC solenoid left: Disconnection) 1

Action code Error code HSS EPC solenoid left: Disconnection
Trouble
CALL E03 DWN2KA (Steering and transmission controller system)
Contents of
• When signal is output to HSS EPC solenoid left circuit, any current does not flow.
trouble
Action of
• Stops outputting to HSS EPC solenoid left circuit.
controller
Problem that
appears
on machine
• Output (Current) to HSS EPC solenoid left can be checked in monitoring mode.
Related (Code 50600: Output feedback current of left HSS solenoid, Code 50602: Output current of left HSS
• Method of reproducing error code: Turn starting switch ON and operate PCCS lever (left steering).

1 solenoid left
HSA (male) Resistance
Between (1) - (2) 5 - 15 z
harness
HSA (female) (1)
contact in connector) Wiring harness between ST3 (female) (3) - HSA
(female) (2)
state
3 harness
HSA (female) (1) with chassis ground
4
Between (28) - (3) 5 - 15 z
Circuit diagram related to HSS EPC solenoid left
118 WE051E0200
Error code [DWN2KB] (HSS EPC solenoid left: Short circuit) 1

Action code Error code HSS EPC solenoid left: Short circuit
Trouble
CALL E03 DWN2KB (Steering and transmission controller system)
Contents of
• When signal was output to HSS EPC solenoid left circuit, an abnormal current flows.
trouble
Action of
• Stops outputting to HSS EPC solenoid left circuit.
controller
Problem that
appears
on machine
• Output (Current) to HSS EPC solenoid left can be checked in monitoring mode.
Related (Code 50600: Output feedback current of left HSS solenoid, Code 50602: Output current of left HSS
• Method of reproducing error code: Turn starting switch ON and operate PCCS lever (left steering).

1 solenoid left HSA (male) Resistance
2
and standard circuit) HSA (female) (1) with chassis ground
state Defective short circuit in
switch OFF.
wiring harness
harness) HSA (female) (1) and ST3 (female) (3) - HSA Resistance Min. 1 Mz
(female) (2)
switch OFF.
Between (28) - (3) 5 - 15 z
Circuit diagram related to HSS EPC solenoid left
WE051E0200 119
Error code [DWN5KA] (Fan pump TVC solenoid: Disconnection) 1

Action code Error code Fan pump TVC solenoid: Disconnection
Trouble
E01 DWN5KA (Steering and transmission controller system)
Contents of
• When signal is output to fan pump TVC solenoid circuit, any current does not flow.
trouble
Action of
• Stops outputting to fan pump TVC solenoid circuit.
controller
Problem that
appears • Fan speed is kept at maximum.
on machine
• Output (Current) to fan pump TVC solenoid can be checked in monitoring mode.
Related
(Code 31623, 31624: Cooling fan solenoid output current)
information

Defective fan pump switch OFF.
1 solenoid
FAC (male) Resistance
Between (1) - (2) 5 - 15 z
harness
Wiring harness between ST3 (female) (36) - FAC
(female) (1)
contact in connector) Wiring harness between ST3 (female) (23) - FAC
(female) (2)
state
3 harness
Wiring harness between ST3 (female) (36) - FAC
4
Between (36) - (23) 5 - 15 z
Circuit diagram related to fan pump TVC solenoid
120 WE051E0200
Error code [DWN5KB] (Fan pump TVC solenoid: Short circuit) 1

Action code Error code Fan pump TVC solenoid: Short circuit
Trouble
E01 DWN5KB (Steering and transmission controller system)
Contents of
• When signal was output to fan pump TVC solenoid circuit, an abnormal current flows.
trouble
Action of
• Stops outputting to fan pump TVC solenoid circuit.
controller
Problem that
appears • Fan speed is kept at maximum.
on machine
• Output (Current) to fan pump TVC solenoid can be checked in monitoring mode.
Related
(Code 31623, 31624: Cooling fan solenoid output current)
information

Defective fan pump switch OFF.
1 solenoid FAC (male) Resistance
2
Possible causes (Contact with ground Wiring harness between ST3 (female) (36) - FAC
wiring harness
3 Wiring harness between ST3 (female) (36) - FAC
(female) (1) and ST3 (female) (23) - FAC Resistance Min. 1 Mz
harness)
(female) (2)
switch OFF.
Between (36) - (23) 5 - 15 z
Circuit diagram related to fan pump TVC solenoid
WE051E0200 121
Error code [DXA0KA] (HSS pump TVC solenoid: Disconnection) 1

Action code Error code HSS pump TVC solenoid: Disconnection
Trouble
E01 DXA0KA (Steering and transmission controller system)
Contents of
• When signal is output to HSS and hydraulic pump TVC solenoid circuit, any current does not flow.
trouble
Action of
• Stops outputting to HSS and hydraulic pump TVC solenoid circuit.
controller
Problem that
appears • Engine stalls when a load is applied under low engine speed.
on machine
• Output (Current) to HSS and hydraulic pump TVC solenoid can be checked in monitoring mode.
Related
(Code 01300, 01301: TVC solenoid output current)
information

Defective HSS and a Prepare with starting switch OFF and carry out troubleshooting with
hydraulic pump TVC switch OFF.
1
solenoid HSP (male) Resistance
(Internal disconnection) Between (1) - (2) 9 - 19 z
harness
Wiring harness between ST3 (female) (7) - HSP
(female) (1)
contact in connector) Wiring harness between ST3 (female) (3) - HSP
(female) (2)
state
3 harness
Wiring harness between ST3 (female) (7) - HSP
4
Between (7) - (3) 9 - 19 z
Circuit diagram related to HSS pump TVC solenoid
122 WE051E0200
Error code [DXA0KB] (HSS pump TVC solenoid: Short circuit) 1

Action code Error code HSS pump TVC solenoid: Short circuit
Trouble
E01 DXA0KB (Steering and transmission controller system)
Contents of
• When signal is output to HSS and hydraulic pump TVC solenoid circuit, an abnormal current flows.
trouble
Action of
• Stops outputting to HSS and hydraulic pump TVC solenoid.
controller
Problem that
appears • Engine stalls when a load is applied under low engine speed.
on machine
• Output (Current) to HSS and hydraulic pump TVC solenoid can be checked in monitoring mode.
Related
(Code 01300, 01301: TVC solenoid output current)
information

Defective HSS and switch OFF.
hydraulic pump TVC
1 HSP (male) Resistance
solenoid
2
Possible causes (Contact with ground Wiring harness between ST3 (female) (7) - HSP
wiring harness
3 Wiring harness between ST3 (female) (7) - HSP
(female) (1) and ST3 (female) (3) - HSP (female) Resistance Min. 1 Mz
harness)
(2)
switch OFF.
Between (7) - (3) 9 - 19 z
Circuit diagram related to HSS pump TVC solenoid
WE051E0200 123
Error code [DXH4KA] (1st clutch ECMV: Disconnection) 1

Action code Error code 1st clutch ECMV: Disconnection
Trouble
CALL E03 DXH4KA (Steering and transmission controller system)
Contents of
• When signal is output to transmission 1st clutch ECMV circuit, any current does not flow.
trouble
Action of
• Stops outputting to transmission 1st clutch ECMV circuit.
controller
Problem that • Auto shift down function does not work.
• Output (Current) to 1st clutch ECMV can be checked in monitoring mode.
Related
(Code 31602, 31612: Output current of 1st clutch ECMV)
information

Defective 1st clutch ECMV switch OFF.
1
(Internal disconnection) 1SOL (male) Resistance
Between (1) - (2) 5 - 25 z
harness
1SOL (female) (1)
value in normal contact in connector) Wiring harness between ST3 (female) (23) -
Resistance Max. 1 z
state 1SOL (female) (2)
shooting.
3 harness
1SOL (female) (1) with chassis ground
4
Between (6) - (23) 5 - 25 z
124 WE051E0200
Error code [DXH4KB] (1st clutch ECMV: Short circuit) 1

Action code Error code 1st clutch ECMV: Short circuit
Trouble
CALL E03 DXH4KB (Steering and transmission controller system)
Contents of
• When signal is output to transmission 1st clutch ECMV circuit, an abnormal current flows.
trouble
Action of
• Stops outputting to transmission 1st clutch ECMV circuit.
controller
• Output (Current) to 1st clutch ECMV can be checked in monitoring mode.
Related
(Code 31602, 31612: Output current of 1st clutch ECMV)
information

switch OFF.
Defective 1st clutch ECMV
1 1SOL (male) Resistance
Between (1) - (2) 5 - 25 z
2
and standard circuit) 1SOL (female) (1) with chassis ground
wiring harness
1SOL (female) (1) and ST3 (female) (23) - 1SOL Resistance Min. 1 Mz
harness)
(female) (2)
switch OFF.
Between (6) - (23) 5 - 25 z
WE051E0200 125
Error code [DXH5KA] (2nd clutch ECMV: Disconnection) 1

Action code Error code 2nd clutch ECMV: Disconnection
Trouble
Contents of
• When signal is output to transmission 2nd clutch ECMV circuit, any current does not flow.
trouble
Action of
• Stops outputting to transmission 2nd clutch ECMV circuit.
controller
• Output (Current) to 2nd clutch ECMV can be checked in monitoring mode.
Related
(Code 31603, 31613: Output current of 2nd clutch ECMV)
information

Defective 2nd clutch switch OFF.
1 ECMV
2SOL (male) Resistance
Between (1) - (2) 5 - 25 z
harness
2SOL (female) (1)
Resistance Max. 1 z
shooting.
3 harness
4
Between (16) - (23) 5 - 25 z
126 WE051E0200
Error code [DXH5KB] (2nd clutch ECMV: Short circuit) 1

Action code Error code 2nd clutch ECMV: Short circuit
Trouble
Contents of
• When signal is output to transmission 2nd clutch ECMV circuit, an abnormal current flows.
trouble
Action of
• Stops outputting to transmission 2nd clutch ECMV circuit.
controller
Problem that
appears
on machine
• Output (Current) to 2nd clutch ECMV can be checked in monitoring mode.
Related
(Code 31603, 31613: Output current of 2nd clutch ECMV)
information

Defective 2nd clutch switch OFF.
1 ECMV 2SOL (male) Resistance
2
wiring harness
harness)
(female) (2)
switch OFF.
Between (16) - (23) 5 - 25 z
WE051E0200 127
Error code [DXH6KA] (3rd clutch ECMV: Disconnection) 1

Action code Error code 3rd clutch ECMV: Disconnection
Trouble
Contents of
• When signal is output to transmission 3rd clutch ECMV circuit, any current does not flow.
trouble
Action of
• Stops outputting to transmission 3rd clutch ECMV circuit.
controller
• Output (Current) to 3rd clutch ECMV can be checked in monitoring mode.
Related
(Code 31604, 31614: Output current of 3rd clutch ECMV)
information

Defective 3rd clutch ECMV switch OFF.
1
(Internal disconnection) 3SOL (male) Resistance
Between (1) - (2) 5 - 25 z
harness
3SOL (female) (1)
and standard harness or defective c
value in normal ontact in connector) Wiring harness between ST3 (female) (23) -
Resistance Max. 1 z
shooting.
3 harness
4
Between (26) - (23) 5 - 25 z
128 WE051E0200
Error code [DXH6KB] (3rd clutch ECMV: Short circuit) 1

Action code Error code 3rd clutch ECMV: Short circuit
Trouble
Contents of
• When signal is output to transmission 3rd clutch ECMV circuit, an abnormal current flows.
trouble
Action of
• Stops outputting to transmission 3rd clutch ECMV circuit.
controller
Problem that
appears
on machine
• Output (Current) to 3rd clutch ECMV can be checked in monitoring mode.
Related
(Code 31604, 31614: Output current of 3rd clutch ECMV)
information

switch OFF.
Defective 3rd clutch ECMV
1 3SOL (male) Resistance
Between (1) - (2) 5 - 25 z
2
wiring harness
harness)
(female) (2)
switch OFF.
4 ST3 Resistance
Between (26) - (23) 5 - 25 z
WE051E0200 129
Error code [DXH7KA] (Reverse clutch ECMV: Disconnection) 1

Action code Error code Reverse clutch ECMV: Disconnection
Trouble
Contents of
• When signal is output to transmission reverse clutch ECMV circuit, any current does not flow.
trouble
Action of
• Stops outputting to transmission reverse clutch ECMV circuit.
controller
Problem that
appears
on machine
• Output (Current) to reverse clutch ECMV can be checked in monitoring mode.
Related
(Code 31606, 31616: Output current of reverse clutch ECMV)
information
• Method of reproducing error code: Start engine and drive machine reverse

Defective reverse clutch switch OFF.
1 ECMV
RSOL (male) Resistance
Between (1) - (2) 5 - 25 z
harness
RSOL (female) (1)
Resistance Max. 1 z
state RSOL (female) (2)
shooting.
3 harness
RSOL (female) (1) with chassis ground
4
Between (37) - (13) 5 - 25 z
130 WE051E0200
Error code [DXH7KB] (Reverse clutch ECMV: Short circuit) 1

Action code Error code Reverse clutch ECMV: Short circuit
Trouble
Contents of
• When signal is output to transmission reverse clutch ECMV circuit, an abnormal current flows.
trouble
Action of
• Stops outputting to transmission reverse clutch ECMV circuit.
controller
Problem that
appears
on machine
• Output (Current) to reverse clutch ECMV can be checked in monitoring mode.
Related
(Code 31606, 31616: Output current of reverse clutch ECMV)
information
• Method of reproducing error code: Start engine and drive machine reverse

Defective reverse clutch switch OFF.
1 solenoid RSOL (male) Resistance
2
and standard circuit) RSOL (female) (1) with chassis ground
wiring harness
RSOL (female) (1) and ST3 (female) (13) - Resistance Min. 1 Mz
harness)
RSOL (female) (2)
switch OFF.
Between (37) - (13) 5 - 25 z
WE051E0200 131
Error code [DXH8KA] (Forward clutch ECMV: Disconnection) 1

Action code Error code Forward clutch ECMV: Disconnection
Trouble
Contents of
• When signal is output to transmission forward clutch ECMV circuit, any current does not flow.
trouble
Action of
• Stops outputting to transmission forward clutch ECMV circuit.
controller
Problem that
appears
on machine
• Output (Current) to forward clutch ECMV can be checked in monitoring mode.
Related
(Code 31608, 31622: Output current of forward clutch ECMV)
information

Defective forward clutch switch OFF.
1 ECMV
FSOL (male) Resistance
Between (1) - (2) 5 - 25 z
harness
FSOL (female) (1)
Resistance Max. 1 z
state FSOL (female) (2)
shooting.
3 harness
FSOL (female) (1) with chassis ground
4
Between (27) - (13) 5 - 25 z
132 WE051E0200
Error code [DXH8KB] (Forward clutch ECMV: Short circuit) 1

Action code Error code Forward clutch ECMV: Short circuit
Trouble
Contents of
• When signal is output to transmission forward clutch ECMV circuit, an abnormal current flows.
trouble
Action of
• Stops outputting to transmission forward clutch ECMV circuit.
controller
Problem that
appears
on machine
• Output (Current) to forward clutch ECMV can be checked in monitoring mode.
Related
(Code 31608, 31622: Output current of forward clutch ECMV)
information

Defective forward clutch switch OFF.
1 ECMV FSOL (male) Resistance
2
and standard circuit) FSOL (female) (1) with chassis ground
wiring harness
FSOL (female) (1) and ST3 (female) (13) - FSOL Resistance Min. 1 Mz
harness)
(female) (2)
switch OFF.
Between (27) - (13) 5 - 25 z
WE051E0200 133
Error code [DY10K4] (Governor motor: Loss of synchronism) 1

Action code Error code Governor motor: Loss of synchronism
Trouble
E02 DY10K4 (Steering and transmission controller system)
Contents of
• Difference between input signal from governor potentiometer and set value in controller is large.
trouble
Action of • Repeats control operation (Loses synchronization).
controller • Flashes warning lamp and turns on caution buzzer.
Problem that
• Engine speed cannot be controlled.
appears
• There is hunting in engine rotation.
on machine
Related
information

Defective fuel control dial
1 If error code [DK10KX] is displayed, carry out troubleshooting for it first.
system
Defective governor
2 If error code [DK54KZ] is displayed, carry out troubleshooting for it first.
potentiometer system
Defective governor motor
3 If error code [DY10KA] is displayed, carry out troubleshooting for it first.
Possible causes system (Disconnection)
and standard Defective governor motor
4 If error code [DY10KB] is displayed, carry out troubleshooting for it first.
value in normal system (Short circuit)
state Defective adjustment of
5 See TESTING AND ADJUSTING, Adjusting fuel control linkage.
governor lever
Defective engine fuel
6 See Engine Shop Manual for "114 Series".
control system
Troubleshooting cannot be carried out since it is internal defect.
7 (If none of causes 1 - 6 is cause of trouble, it is suspected controller defec-
tive.)
134 WE051E0200
Error code [DY10KA] (Governor motor: Disconnection) 1

Action code Error code Governor motor: Disconnection
Trouble
CALL E03 DY10KA (Steering and transmission controller system)
Contents of
• When signal is output to governor motor, any current does not flow.
trouble
Problem that
• Engine speed is limited to that immediately before error occurrence.
appears
on machine
• Operation condition (current) of governor motor can be checked in monitoring mode.
Related
(Code: 03300 Governor motor phase A current, code: 03400 Governor motor phase B current)
information

switch OFF.
Defective governor motor
Between (1) - (2) 2.5 - 7.5 z
Between (3) - (4) 2.5 - 7.5 z
switch OFF.
Possible causes Disconnection in wiring Resistance Max. 1 z
(female) (1)
value in normal 2 (Disconnection in wiring Resistance Max. 1 z
(female) (2)
state harness or defective
contact in connector) Wiring harness between ST3 (female) (25) - E61
Resistance Max. 1 z
(female) (3)
Resistance Max. 1 z
(female) (4)
switch OFF.
Between (5) - (15) 2.5 - 7.5 z
Between (25) - (35) 2.5 - 7.5 z
WE051E0200 135
Error code [DY10KB] (Governor motor: Short circuit) 1

Action code Error code Governor motor: Short circuit
Trouble
CALL E03 DY10KB (Steering and transmission controller system)
Contents of
• When signal is output to governor motor, an abnormal current flows.
trouble
Problem that
• Engine speed is limited to that immediately before error occurrence.
appears
on machine
• Operation condition (current) of governor motor can be checked in monitoring mode.
Related
(Code: 03300 Governor motor phase A current, code: 03400 Governor motor phase B current)
information

switch OFF.
Defective governor motor E61 (male) Resistance
1 (Internal short circuit or Between (1) - (2) 2.5 - 7.5 z
ground fault) Between (3) - (4) 2.5 - 7.5 z
switch OFF.
Short circuit with chassis (female) (1) with chassis ground
Possible causes ground in wiring harness Wiring harness between ST3 (female) (15) - E61
and standard 2 Resistance Min. 1 Mz
(Contact with ground (female) (2) with chassis ground
value in normal circuit) Wiring harness between ST3 (female) (25) - E61
switch OFF.
ST3 (female) Resistance
Between (5) - (15) 2.5 - 7.5 z
4 Between (25) - (35) 2.5 - 7.5 z
136 WE051E0200
WE051E0200 137
Error code [DY45KA] (Engine stop solenoid relay: Disconnection) 1

Action code Error code Engine stop solenoid relay: Disconnection
Trouble
E02 DY45KA (Steering and transmission controller system)
Contents of
• When signal is output to engine stop solenoid relay circuit, any current does not flow.
trouble
controller • Stops outputting power to engine stop solenoid relay circuit.
Problem that
on machine
a This error code detects failure only on the primary side (coil side) of engine stop solenoid relay.
If defective engine stop solenoid operation is suspected, check power supply and wiring harness sole-
Related noid on the secondary side (contact side) of the relay.
information • Operation state (ON/OFF) of engine stop solenoid relay can be checked in monitoring mode.
(Code: 40914 Steering controller output signal)

Defective engine stop switch OFF.
1 solenoid
ESS (male) Resistance
Between (1) - (2) 200 - 400 z
harness switch OFF.
Possible causes 2 (Disconnection in wiring Wiring harness between ST3 (female) (8) - ESS
Resistance Max. 1 z
and standard harness or defective (female) (1)
value in normal contact in connector) Wiring harness between ESS (female) - GND03 Resistance Max. 1 z
3 harness
Wiring harness between ST3 (female) (8) - ESS
4
Between (8) - chassis ground 200 - 400 z
138 WE051E0200
Circuit diagram related to engine stop solenoid
WE051E0200 139
Error code [DY45KB] (Engine stop solenoid relay: Short circuit) 1

Action code Error code Engine stop solenoid relay: Short circuit
Trouble
E02 DY45KB (Steering and transmission controller system)
Contents of
• When signal is output to engine stop solenoid relay circuit, an abnormal current flows.
trouble
controller • Stops outputting power to engine stop solenoid relay circuit.
Problem that
on machine
• This error code detects failure only on the primary side (coil side) of engine stop solenoid relay.
If defective engine stop solenoid operation is suspected, check power supply and wiring harness
Related solenoid on the secondary side (contact side) of the relay.
information • Operation state (ON/OFF) of engine stop solenoid relay can be checked in monitoring mode.
(Code: 40914 Steering controller output signal)

Defective engine stop switch OFF.
1 solenoid relay
ESS (male) Resistance
Between (1) - (2) 200 - 400 z
Possible causes
and standard Short circuit with chassis a Prepare with starting switch OFF and carry out troubleshooting with
value in normal ground in wiring harness switch OFF.
2
state Between ST3 (female) (8) - ESS (female) (1) Resistance Min. 1 Mz
circuit)
3
Between (8) - chassis ground 200 - 400 z
140 WE051E0200
Circuit diagram related to engine stop solenoid
WE051E0200 141
142 WE051E0200
WE051E0300
Bulldozer
1Shop Manual
D61EX-15
D61PX-15

Troubleshooting 1
Troubleshooting of electrical system (E-mode) ................................................................ 3
Before troubleshooting electrical system (E-mode) ...................................................... 3
E-1 Engine does not start........................................................................................... 6
E-2 Preheater does not operate............................................................................... 11
E-3 No monitor panel lamps light at all when starting switch is turned ON .............. 14
E-4 All lamps continue to light on monitor panel
when starting switch is turned ON ..................................................................... 15
E-5 While engine is running, battery charge level warning lamp flashes ................. 16
E-6 While engine is operating, an emergency warning item flashes........................ 18
E-7 Preheating pilot lamp does not light during preheating ..................................... 22
E-8 Engine coolant temperature gauge does not indicate normally......................... 24
E-9 Power train oil temperature gauge does not indicate normally.......................... 25
E-10 Hydraulic oil temperature gauge does not indicate normally............................. 26
E-11 Fuel gauge does not indicate normally.............................................................. 27
E-12 Gear speed is indicated incorrectly....................................................................28

E-13 Indication of preset mode service meter is abnormal ........................................28
E-14 Warning lamp does not flash or does not go out ...............................................28
E-15 Engine speed is indicated incorrectly ................................................................29
E-16 Transmission speed or travel speed is indicated incorrectly .............................30
E-17 Caution buzzer does not sound or does not stop ..............................................31
E-18 Auto shift down does not function or it is not released ......................................32
E-19 Buzzer cancel switch does not function.............................................................33
E-20 Information switch does not function .................................................................35
E-21 Reverse fan rotation and cleaning functions do not operate,
or they are not released....................................................................................37
E-22 Preset mode cannot be selected or released ....................................................39
E-23 Service mode cannot be selected or it is selected errorneously........................40
E-24 Backup alarm does not sound ...........................................................................42
E-25 Headlamp and rear lamp do not light.................................................................44
E-26 Horn does not sound or does not stop...............................................................46
E-27 Work equipment lock lever does not function or it cannot be released .............47
E-28 Wiper malfunction ..............................................................................................49
E-29 Washing water does not come out ....................................................................61
E-30 Air conditioner does not operate........................................................................66
2 WE051E0300
Troubleshooting of electrical system (E-mode) 1

Before troubleshooting electrical system (E-mode) 1
Connection table of fuse box
a 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 OFF position).
a 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 1 (FS1)

Fuse
Type of power supply Fuse No. Destination of power
capacity
1
20 A Spare power supply (Connector 800)
(Between terminals 1 and 6)
Preheater relay coil
2
15 A Horn switch
Switch power supply (Between terminals 2 and 7)
Air suspension seat (if equipped)
(Battery relay CN-C)
3
20 A Head lamp and rear lamp
4
20 A Steering and transmission controller
Fuses in cab
Constant power supply 5
10 A Service switch
(Battery relay CN-H) (Between terminals 5 and 10)
Monitor panel (Constant power supply)
Fuse box 2 (FS2)

Fuse
capacity
1 Monitor panel
15 A
(Between terminals 1 and 6) Caution buzzer
2
10 A PPC lock switch
Switch power supply (Between terminals 2 and 7)
(Battery relay CN-C) 3
30 A Circuit breaker for air conditioner
4
10 A Backup alarm relay
Constant power supply 5
30 A Circuit breaker for starting switch
(Battery relay CN-H) (Between terminals 5 and 10)
WE051E0300 3
Fuse box 3 (FS3)

Fuse
capacity
1
10 A Converter
(Between terminals 1 and B3)
Radio (Switch power supply)
2
20 A Cigarette lighter, light relay, and additional lamp switch
Room lamp
3 Heat absorbing glass switch
20 A
(Between terminals 3 and B3) Heat absorbing glass relay
Switch power supply
4 Rear wiper switch
(Battery relay CN-C) 30 A
(Between terminals 4 and B2) Rear wiper motor, and rear wiper intermittent relay
Intermittent wiper switch
5
10 A Windshield wiper switch, windshield wiper motor, and inter-
mittent relay for windshield wiper
10 A RH wiper switch, LH wiper switch, and RH door wiper motor
6
LH door wiper motor, and intermittent relay for LH wind-
(Between terminals 6 and B2) 10 A
shield wiper
Locations and Nos. of fuses
4 WE051E0300

a Troubleshooting lists and related circuit diagrams contain the following information all together. Understand
the contents carefully and troubleshoot the machine.
Trouble Problem that appears on the machine.
Related
Information related to detected trouble or troubleshooting
information

<Discribed contents>
• Standard value in normal state required to judge the assumed
cause (good or not)
• Remarks required to judge whether the cause is good
1
<Phenomenon of defective harness>
• Disconnection in wiring
The connector connection is defective or the wiring harness is
disconnected.
• Grounding fault
A harness not connected to the ground (earth) circuit comes into
contact with the ground (earth) circuit.
• Defective hot short
2 A harness not connected to the power (24 V) circuit comes into
contact with the power (24 V) circuit.
• Defective short
Possible causes Cause by which a trouble
A harness of an independent circuit abnormally comes into
and standard is assumed to be detected
contact with one of another circuit.
value in normal (The order number
state indicates a serial number, <Notes on troubleshooting>
(1) Method of indicating connector numbers and handling T-junction
not a priority sequence.)
For troubleshooting, insert or connect the T-junction adapter as
shown below unless especially specified.
3
• When "male" or "female" is not indicated for a connector
number, disconnect the connector, and insert the T-junction
adapter in both the male and female.
• When "male" or "female" is indicated for a connector number,
disconnect the connector, and insert the T-junction adapter in
only either the male or female.
(2) Pin number description sequence and tester lead handling
For troubleshooting, connect the plus (+) and minus (-) leads as
4 shown below unless especially specified.
• Connect the plus (+) lead to a pin or harness indicated in the
front.
• Connect the minus (-) lead to a pin or harness indicated in the
rear.
Related circuit diagram
This is the excerpted circuit diagram related to trouble

• Connector No.: Indicates (Model-No. of pins) (Color).
• "Connector No. and Pin No." from the junction/connection:
Indicates destination or junction within the part of the same wiring harness.
• Arrow ( ): Roughly indicates mounting place on machine.
WE051E0300 5
E-1 Engine does not start

Trouble (1) Engine does not start (or rotate).
• Engine start circuit has neutral safety function, and engine does not start unless parking brake lever is
set to lock position and travel lever is in neutral position.
• If "the monitor panel does not come on" or "the battery relay does not cause operating sound" when
Related
starting switch is turned ON, main electric power supply may have failed. Inspect main electric power
information
supply system.
• Make sure that no error code is displayed before starting troubleshooting.
(If error code [D130KA], [D130KB], [DD14KB], or [DDQ2KA] is displayed, troubleshoot it first.)
Cause Standard value in normal state or remarks on troubleshooting

Battery voltage Battery specific gravity
1 Insufficient battery capacity
Min. 24 V Min. 1.26
holding starting switch OFF.
Defective starting switch
2 Starting switch Switch position Resistance
Between 250 (B) OFF Min. 1 Mz
- 280 (C) START Max. 1 z
a Prepare with starting switch OFF, then turn starting switch ON and
Defective parking brake carry out troubleshooting.
lever switch Parking brake lever
3
(Internal failure or poor Free position Lock position
Monitor panel
adjustment) Other than "P"
"P" is displayed.
is displayed.
a Prepare with starting switch OFF, and carry out troubleshooting after
Defective neutral safety starting engine.
4 relay (NSF) Turn starting switch OFF and replace neutral safety relay (NSF) with
(Internal disconnection) another one. If engine starts in accordance with engine starting arrange-
ment, the relay is defective.
Defective alternator carry out troubleshooting.
Possible causes 5
and standard (Internal short circuit) Alternator Voltage
value in normal Between terminal R - ground Max. 12 V
state a Prepare with starting switch OFF, and carry out troubleshooting after
starting engine.
Starting motor Voltage
Power supply:
20 - 30 V
Between terminal B - ground
Defective starting motor
6 Charge: Between terminal
(Internal defect) Max. 12 V
E101 (2) - ground
Charge: Between terminal
20 - 30 V
E101 (1) - ground
If voltage is normal for power supply, recharging and startup and if starting
motor does not rotate, the starting motor is defective.
Disconnection in wiring holding starting switch OFF.
harness
Wiring harness between 280 (C) - NSF (female)
7 (Disconnection in wiring or Resistance Max. 1 z
(3)
defective contact in
connector) Wiring harness between NSF (female) (5) - E101
Resistance Max. 1 z
(female) (1)
Hot short circuit of wiring carry out troubleshooting.
8 harness Wiring harness between E71 - E101 (female)
(Contact with 24 V circuit) (2), E71 - ST1 (female) (15), E71 - S04 (female) Voltage Max. 1 V
(9) or E71 - CAN (female) (8) with the ground
6 WE051E0300

Possible causes
Short circuit with chassis Wiring harness between 280 (C) - NSF (female)
and standard Resistance Min. 1 Mz
ground in wiring harness (3) and the ground
value in normal 9
(Contact with ground Wiring harness between NSF (female) (5) - E101
circuit) (female) (1) and the ground
CAN (female) (5) and ground
WE051E0300 7
Circuit diagram related to engine preheating, starting, charging, and stopping functions
8 WE051E0300
Trouble (2) Engine does not start (but it can rotate).

Related • Make sure that no error code is displayed before starting troubleshooting.
information (If error code [DY54KA] or [DY54KB] is displayed, carry out its troubleshooting first.)

Between 250 (B) OFF Min. 1 Mz
- 270 (ACC) START Max. 1 z
Defective engine stop holding starting switch OFF.
solenoid terminal
(internal disconnection or
short circuit) Between (A) - (C) 0.6 - 1.0 z
Between (B) - (C) 37 - 46 z
Defective engine stop starting engine.
3 solenoid relay (ESS) Turn starting switch OFF and replace relay with another one. If engine
(Internal disconnection) starts in accordance with engine starting arrangement, engine stop sole-
noid relay (ESS) is defective.
carry out troubleshooting.
Engine stop solenoid Turn starting 3 seconds after starting
Defective engine stop
Possible causes (suction) relay switch OFF. switch has turned ON
and standard 4 solenoid (suction) relay
(Internal defect) Voltage between termi-
value in normal Max. 1 V 20 - 30 V
nals E41 (1) - (2)
state Between terminals
Min. 1 Mz Max. 1 z
E42 - E43
Wiring harness between 270 (ACC) - ESS
Disconnection in wiring Resistance Max. 1 z
(female) (5)
harness Wiring harness between E31 (female) (B) - E43 Resistance Max. 1 z
5 (Disconnection in wiring or
defective contact in Wiring harness between ESS (female) (3) - E41
Resistance Max. 1 z
(female) (1)
connector)
Wiring harness between E31 (female) (A) - E42 Resistance Max. 1 z
Between E31 (female) (C) - E41 (female) (2) wir-
Resistance Max. 1 z
ing harness and ground
Short circuit with chassis Wiring harness between 270 (ACC) - ESS
ground in wiring harness (female) (5), E31 (female) (B) or E43 and ground
6
(Contact with ground Wiring harness between ESS (female) (3) - E41
circuit) (female) (1) and ground
Wiring harness between E31 (female) (A) - E42
and ground
WE051E0300 9
Circuit diagram related to engine startup (engine stop solenoids and relays)
10 WE051E0300
E-2 Preheater does not operate

Trouble • Preheater does not operate.
a This troubleshooting covers procedure to be followed if electrical intake air heater mounting section is
not preheated by automatic or manual preheating function.
(If only preheating lamp does not light, carry out troubleshooting of "Preheating lamp does not come
on".)
Related
• Both "Automatic Preheating Function" and "Manual Preheating Function" are provided for preheating.
information
Preheating lamp comes on even if either of functions is operating.
• If "the monitor panel does not come on" or "the battery relay does not cause operating sound" when
starting switch is turned ON, main electric power supply may have failed. Inspect main electric power
supply system.

Between 250 (B) - OFF Min. 1 Mz
255 (R1) terminals HEAT Max. 1 z
Defective fuse
2 If fuse has blown, a grounding error of the circuit may have occurred.
(Fuse, FS1 or FS2)
Defective preheating relay
3 Turn starting switch OFF, disconnect coolant sensor E131, and replace it
with another relay. If preheating starts when starting switch is turned ON,
preheater relay RHR is defective.
a Prepare with starting switch OFF, then set the starting switch to HEAT
and carry out troubleshooting.
Heater relay Voltage
Possible causes Power supply: Between terminal
Defective heater relay 20 - 30 V
and standard 4 E82 (B) - chassis ground
(Internal defect)
value in normal Signal: Between terminal E83 (C)
state 20 - 30 V
- chassis ground
If both power supply and signal voltages are normal and if no operating
sound is heard, heater relay is defective.
Defective electrical intake holding starting switch OFF.
5 air heater
Electrical intake air heater Continuity
(Internal defect)
Between terminals Conductive
Wiring harness between starting switch 255 (R1)
- RHR (female) (3) and E83 (C)
harness
Wiring harness between RHR (female) (5) - FS1
(7)
connector) Wiring harness between battery relay C - E102
Resistance Max. 1 z
and E82 terminal
Wiring harness between heater relay E81 (A)
Resistance Max. 1 z
terminal - electrical intake air heater
WE051E0300 11

Wiring harness starting switch 255 (R1) -
Possible causes Resistance Min. 1 Mz
Short circuit with chassis between RHR (3), E83 (C) terminals and ground
and standard
ground in wiring harness Wiring harness between RHR (female) (5) - FS1
value in normal 7 Resistance Min. 1 Mz
(Contact with ground (7) and ground
state
circuit) Wiring harness between battery relay C - E102
terminal, E82 and chassis ground
Wiring harness between heater relay E81 - ter-
minal of electrical intake air heater and ground
12 WE051E0300
WE051E0300 13
E-3 No monitor panel lamps light at all when starting switch is turned ON
• If "the operation sound of the battery is not heard" when starting switch is turned ON, main power supply
Trouble may have failed. Check main power supply.
• No monitor panel lamps light when starting switch is turned ON.
Related • When starting switch is turned ON, all lamps must light on gear speed indicator, multi-information
information section, gauge section and lamp section. They must go out after approximately 2 seconds.

If fuse FS2-(6) has blown, a grounding error of the circuit may have
1 Defective fuse FS2-(6)
occurred.
harness
Wiring harness between S03 (female) (1) (2) -
fuse FS2-(6)
Possible causes defective contact in
connector) Wiring harness between S03 (female) (3) (4) -
GND 01 and chassis ground
value in normal
Short circuit with chassis a Prepare with starting switch OFF, then carry out troubleshooting by
state
ground in wiring harness holding starting switch OFF.
3
(Contact with ground Wiring harness between S03 (female) (1) (2) -
circuit) fuse FS2-(6) and ground
4 Defective monitor panel
S03 Voltage
Between terminals (1), (2) - (3), (4) 20 - 30 V
Circuit diagram related to monitor panel power supply
14 WE051E0300
E-4 All lamps continue to light on monitor panel when starting switch is
turned ON
Trouble • When starting switch is turned ON, all lamps light but they do not go out.
Related • When starting switch is turned ON, all lamps must light on gear speed indicator, multi-information
information section, gauge section and lamp section. They must go out after approximately 2 seconds.
Possible causes Cause Standard value in normal state or remarks on troubleshooting

and standard
value in normal 1 Defective monitor panel You cannot troubleshoot monitor panel as its internal system has failed.
state
WE051E0300 15
E-5 While engine is running, battery charge level warning lamp flashes
Trouble • Battery charge level warning lamp flashes.
Related
• If an error is detected when engine is running, battery charge level warning lamp will flash.
information

Defective alternator starting engine.
1 (Insufficient generation Alternator Engine speed Voltage
power) Between E71 (R) Above medium (half)
20 - 30 V
- chassis ground speed
harness
Wiring harness between S04 (female) (9) - E71
Possible causes (R)
and standard connector) Wiring harness between E118 (E) - E120 (GND)
Resistance Max. 1 z
value in normal and ground
state a Prepare with starting switch OFF, then carry out troubleshooting by
3 Wiring harness between S04 (female) (9) - E71
(R), ST1 (female) (15) and CAN (female) (5) and Resistance Min. 1 Mz
circuit)
ground
4 Defective monitor panel S04 Engine speed Voltage
Between (9) - Above medium (half)
20 - 30 V
chassis ground speed
16 WE051E0300
WE051E0300 17
E-6 While engine is operating, an emergency warning item flashes

Trouble (1) Engine oil pressure warning lamp flashes.
• If an error is detected when engine is running, engine oil pressure warning lamp flashes and caution
buzzer sounds.
Related
• Engine oil pressure switch signals are sent to or received from engine controller through communication.
information
• You can check signal input status (ON or OFF) from engine oil pressure switch in Monitoring mode.
(Code 40900: Engine controller input signal 1)

Dropped engine oil
1 pressure Check engine oil pressure as dropped pressure has been detected.
(when system is normal)
a Prepare with starting switch OFF, and carry out troubleshooting by
Defective engine oil holding switch OFF or by starting up engine.
2 pressure switch E121 terminal Engine Resistance
Possible causes (Internal short circuit) Between terminal - Stop Max. 1 z
and standard chassis ground Min. 600 rpm Min. 1 Mz
value in normal Short circuit with chassis a Prepare with starting switch OFF, then carry out troubleshooting by
state ground in wiring harness holding starting switch OFF.
3
(Contact with ground Wiring harness between S03 (female) (12) -
circuit) E121 and ground
a Prepare with starting switch OFF, and carry out troubleshooting by
holding switch OFF or after starting the engine.
4 Defective monitor panel S03 Engine Voltage
Between (12) - Stop Max. 1V
chassis ground Min. 600 rpm 5 - 11 V
Circuit diagram related to engine oil pressure switch
18 WE051E0300
Trouble (2) Engine coolant temperature warning lamp flashes.

• If an error is detected when engine is running, engine coolant temperature warning lamp flashes and
• Engine coolant temperature warning lamp flashes or goes off according to indication of engine coolant
Related
thermometer.
information
• Input status (temperature) from engine coolant temperature (high-temperature side) sensor can be
checked in monitoring mode.
(Code 04102: Engine coolant temperature (high-temperature side))

Overheated engine coolant Check engine coolant temperature as its overheating has been detected.
1 temperature (Warning lamp flashes and buzzer sounds if temperature exceeds 110°C,
(when system is normal) but only warning lamp flashes if temperature reaches 104°C.)
Check indication on the engine coolant temperature gauge. If indication is
Possible causes abnormal, carry out troubleshooting of "Engine coolant temperature
and standard gauge does not indicate normally".
Defective engine coolant
value in normal Coolant temperature a Coolant temperatures are guides for selecting
2 temperature sensor system
state gauge indications.
(Monitor panel)
White range or
Coolant temperature Red range
green range
lamp
Off Flashing
If trouble is NOT by Cause 1 or Cause 2, monitor panel may be defective.
(You cannot troubleshoot monitor panel as its internal system has failed.)
Indication of engine coolant temperature gauge

(a Engine coolant temperatures are guides for select-
ing indications.)
WE051E0300 19
Trouble (3) Power train oil temperature warning lamp flashes.

• If an error is detected when engine is running, power train oil temperature warning lamp flashes and
Related • Power train oil temperature warning lamp flashes or goes out as it links with indication on power train oil
information temperature gauge.
• Input status (temperature) from power train oil temperature sensor can be checked in monitoring mode.
(Code 30100: Torque converter oil temperature)

As an overheated power train oil temperature has been detected, check
Overheated power train oil
power train oil temperature.
1 temperature
(Warning lamp flashes and buzzer sounds if oil temperature exceeds
130°C, but only warning lamp flashes if oil temperature reaches 120°C.)
Check indication on power train oil temperature gauge. If indication is
Possible causes abnormal, carry out troubleshooting of "Power train oil temperature gauge
and standard does not indicate normally".
value in normal Defective power train oil
a Oil temperatures are guides for selecting indi-
state 2 temperature sensor system Oil temperature gauge
cations.
(Monitor panel)
White range or
Red range
Oil temperature lamp green range
Off Flashing
Indication of power train oil temperature gauge

(a Power train oil temperatures are guides for select-
ing indications.)
20 WE051E0300
Trouble (4) Hydraulic oil temperature warning lamp flashes.

• If an error is detected when engine is running, hydraulic oil temperature warning lamp flashes and
Related • Hydraulic oil temperature warning lamp flashes or goes out as it links with indication on hydraulic oil
information temperature gauge.
• Input status (temperature) from hydraulic oil temperature sensor can be checked in monitoring mode.
(Code 04401: Hydraulic oil temperature)

Check hydraulic oil temperature as its overheating has been detected.
Overheated hydraulic oil
(Warning lamp flashes and buzzer sounds if hydraulic oil temperature
1 temperature
exceeds 110°C, but only warning lamp flashes if temperature reaches
100°C.)
Check indication on hydraulic oil temperature gauge. If indication is abnor-
Possible causes mal, carry out troubleshooting of "Hydraulic oil temperature gauge does
and standard not indicate normally".
Defective hydraulic oil
value in normal
temperature sensor system Oil temperature gauge a Oil temperatures are guides for selecting indi-
state 2
(Steering and transmission cations.
controller) White range or
Red range
Oil temperature lamp green range
Off Flashing
Indication of hydraulic oil temperature gauge

(a Hydraulic oil temperatures are guides for selecting
indications.)
WE051E0300 21
E-7 Preheating pilot lamp does not light during preheating

Trouble • Preheating pilot lamp does not light during preheating.
a This troubleshooting describes procedures to be followed when preheating lamp does not come on.
(When electrical intake air heater mounting section is not heated, carry out troubleshooting of "Preheater
Related
does not operate".)
information
• Both "Automatic Preheating Function" and "Manual Preheating Function" are provided for preheating.
Preheating lamp comes on even if either of functions is operating.

Disconnection in wiring a Prepare with starting switch OFF, then carry out troubleshooting by
harness holding starting switch OFF.
defective contact in Resistance Max. 1 z
heater relay E81 (A)
connector)
Possible causes a Prepare with starting switch OFF, then carry out troubleshooting by
and standard holding starting switch OFF.
value in normal 2 Wiring harness between S03 (female) (9) -
state heater relay E81 (A) terminal and chassis Resistance Min. 1 Mz
circuit)
ground
3 Defective monitor panel S03 Starting switch Voltage
Between (9) - ON Max. 1 V
chassis ground HEAT Min. 7 V
22 WE051E0300
WE051E0300 23
E-8 Engine coolant temperature gauge does not indicate normally

Trouble • Engine coolant temperature gauge does not indicate normally.
• If an error has occurred in engine coolant high temperature sensor system, error code [DGE2KX] may
Related be displayed.
information • Signals of engine coolant high temperature sensor are sent to or received from monitor panel through
communication.

Defective engine coolant holding starting switch OFF.
high temperature sensor
short circuit) Between (1) - (2) 3.5 k - 90 kz (30 - 100°C)
Between (1) (2) - chassis ground Min. 1 Mz
harness
E111 (A)
Possible causes connector) Wiring harness between S03 (female) (3) (4) -
Resistance Max. 1 z
and standard E111 (female) (B)
3
(Contact with ground Wiring harness between S04 (female) (11) and
circuit) E111 (female) (A) and chassis ground
Hot short circuit of wiring carry out troubleshooting.
4 harness
(Contact with 24 V circuit) Wiring harness between S04 (female) (11) - Voltage Max. 1 V
E111 (female) (A) and chassis ground
Terminals S03 and S04 Voltage
Between S04 (11) - S03 (3) (4) 2.0 - 4.8 V (30 - 100°C)
Circuit diagram related to engine coolant temperature sensor
24 WE051E0300
E-9 Power train oil temperature gauge does not indicate normally
Trouble • Power train oil temperature gauge does not indicate normally.
Related • Signals of power train oil temperature sensor are sent to or received from monitor panel through
information communication.

Defective power train oil
Torque converter oil
temperature sensor 453 (male) Resistance
1 temperature
short circuit) Between (1) - (2) 3.5 k - 90 kz
Between (1) - 10 - 100°C
Min. 1 Mz
chassis ground
harness
Wiring harness between S04 (female) (12) - 453
(female) (1)
connector) Wiring harness between 453 (female) (2) - S03
Resistance Max. 1 z
Possible causes (female) (3)
and standard Short circuit with chassis a Prepare with starting switch OFF, then carry out troubleshooting by
value in normal ground in wiring harness holding starting switch OFF.
state 3
(Contact with ground Between wiring harness S04 (female) (12) - 453
Hot short circuit of wiring
(female) (1) and ground
Wiring harness between 453 (female) (2) - S03
Voltage Max. 1 V
Torque converter
5 Defective monitor panel S04 Voltage
oil temperature
Between (12) -
10 - 100°C 2.0 - 4.8 V
chassis ground
Circuit diagram related to power train oil temperature sensor
WE051E0300 25
E-10 Hydraulic oil temperature gauge does not indicate normally

Trouble • Hydraulic oil temperature gauge does not indicate normally.
• Signals of hydraulic oil temperature sensor are sent to or received from steering and transmission
Related controller through communication.
information • If an error has occurred in hydraulic oil temperature sensor system, error code [DGS1KX] may be
displayed.

Defective hydraulic oil holding starting switch OFF.
temperature sensor
1 SDS (male) Resistance
Between (1) - (2) 3.5 k - 90 kz
short circuit)
harness
(female) (1)
connector) Wiring harness between ST1 (female) (21) -
Resistance Max. 1 z
SDS (female) (2)
Possible causes Short circuit with chassis a Prepare with starting switch OFF, then carry out troubleshooting by
and standard ground in wiring harness holding starting switch OFF.
3
value in normal (Contact with ground Wiring harness between ST1 (female) (9) - SDS
circuit) (female) (1) and chassis ground
(female) (1) and chassis ground
Voltage Max. 1 V
SDS (female) (2) and chassis ground
5 Hydraulic oil
temperature
Between (9) - (21) 10 - 100°C 2.0 - 4.8 V
6 Defective monitor panel Troubleshooting cannot be carried out since it is internal defect.
Circuit diagram related to hydraulic oil temperature sensor
26 WE051E0300
E-11 Fuel gauge does not indicate normally

Trouble • Fuel level gauge does not indicate normally.
Related
• Signals of fuel level sensor are sent or received through communication by monitor panel.
information

Defective fuel level sensor. holding starting switch OFF.
1 (Internal disconnection or 423 (male) terminal Remained fuel level Resistance
short circuit) Between (1), (2) and Full Approx. 4 z
chassis ground Empty Approx. 85 z
harness
(female) (1)
connector) Wiring harness between 423 (female) (2) - S03
Resistance Max. 1 z
(female) (3) (4) and ground
Possible causes
and standard
value in normal 3
state (Contact with ground Wiring harness between S04 (female) (10) - 423
Wiring harness between 423 (female) (2) - S03
Voltage Max. 1 V
(female) (3) (4) and ground
5 Defective monitor panel S04 Remained fuel level Voltage
Between (10) -
Full - Empty 0.1 - 2 V
chassis ground
Circuit diagram related to fuel level sensor
WE051E0300 27
E-12 Gear speed is indicated incorrectly

Trouble • Gear speed is indicated incorrectly.
Related • Gear speed signals are sent to or received from steering and transmission controller through
information communication.

and standard
value in normal 1 Defective monitor panel Troubleshooting cannot be carried out since it is internal defect.
state
E-13 Indication of preset mode service meter is abnormal

Trouble (1) Service meter value is not incremented when engine is running.
• Service meter measures time when monitor panel is receiving engine drive signals (alternator signals).
Related
• Preset mode service meter signals are sent to or received from steering and transmission controller
information
through communication.

Possible causes If battery charge level warning lamp flashes when engine is running,
Defective alternator signals
and standard 1 carry out troubleshooting of "While engine is operating, caution items
system
value in normal flash."
state Defective monitor panel
2 Troubleshooting cannot be carried out since it is internal defect.
(Gauge or lamp module)
Trouble (2) Shift mode service meter are not displayed at all.
Related
• Display data is sent and received through communication by steering and transmission controller.
information

and standard
state
E-14 Warning lamp does not flash or does not go out

Trouble • Warning lamp does not flash or does not go off.
Related
-
information

and standard
state
28 WE051E0300
E-15 Engine speed is indicated incorrectly

Trouble • Engine speed is indicated incorrectly.
• Engine speed signals are sent or received through communication by steering and transmission
Related
controller.
information
• If an error has occurred in engine speed sensor system, error code [DLE2MA] may be displayed.

A mounting error of engine
1 See Testing and adjusting, "Adjusting engine speed sensor."
speed sensor
Defective engine speed holding starting switch OFF.
sensor E51 (male) terminal Resistance
2
(Internal disconnection or Between (1) - (2) 400 - 1,000 z
short circuit) Between terminal (1) -
Min. 1 Mz
chassis ground
harness
(female) (1)
connector) Wiring harness between ST2 (female) (39) - E51
(female) (2)
and standard
value in normal
state 4
(Contact with ground Wiring harness between ST2 (female) (40) - E51
circuit) (female) (1) and chassis ground
Voltage Max. 1 V
Between (40) - (39) 400 - 1,000 z
Circuit diagram related to engine speed sensor
WE051E0300 29
E-16 Transmission speed or travel speed is indicated incorrectly

Trouble • Transmission speed or travel speed is indicated incorrectly.
• Transmission speed signals are sent or received through communication by steering and transmission
Related
controller.
information
• If an error has occurred in transmission speed sensor system, error code [DLF1KA] may be displayed.

A mounting error of
1 transmission output speed See Testing and adjusting, "Adjusting transmission speed sensor."
sensor
Defective transmission holding starting switch OFF.
output speed sensor TM1 (male) terminal Resistance
2
(Internal disconnection or Between terminals (1) - (2) 400 - 1,000 z
short circuit) Between terminal (1)
Min. 1 Mz
- chassis ground
harness
TM1 (female) (1) terminals
connector) Wiring harness between ST2 (female) (29) -
Resistance Max. 1 z
TM1 (female) (2) terminals
value in normal 4 Between wiring harness connecting ST2
state (female) (30) - TM1 (female) (1) terminals and Resistance Min. 1 Mz
circuit)
ground
Between wiring harness connecting ST2
(female) (30) - TM1 (female) (1) terminals and Voltage Max. 1 V
5 harness
ground
Between wiring harness connecting ST2
(female) (29) - TM1 (female) (2) terminals and Voltage Max. 1 V
ground
Defective steering and ST2 (female) terminal Resistance
6
transmission controller Between terminals (30) - (29) 400 - 1,000 z
Between terminal (30)
Min. 1 Mz
- chassis ground
Circuit diagram related to transmission output speed sensor
30 WE051E0300
E-17 Caution buzzer does not sound or does not stop

Trouble • Caution buzzer does not sound or does not stop.
Related • If a short-circuit has occurred in caution buzzer system, error code [DV00KB] is displayed. However, no
information error codes are displayed if another error has occurred.

If fuse (6) of FS2 has blown, a grounding error of the circuit may have
1 Defective fuse FS2-(6)
occurred.
Defective caution buzzer
217 (male) terminal Resistance
2 (Internal disconnection or
short circuit) Between terminals (2) - (1) Min. 1 kz
Between terminals (1) (2)
Min. 1 Mz
- chassis ground
harness
Possible causes Wiring harness between S03 (female) (18) - 217
and standard (female) (1)
value in normal connector) Wiring harness between 217 (female) (2) - FS2
Resistance Max. 1 z
state (6)
Short circuit with chassis holding starting switch OFF.
ground in wiring harness Between SF2 (6) - 217 (female) (2) wiring har-
(Contact with ground ness and ground
circuit) Between 217 (female) (1) - S03 (female) (18)
wiring harness and ground
Defective monitor panel
5 S03 terminal Caution buzzer Voltage
(Gauge lamp module)
Between terminal (18) Stopped 20 - 30 V
- chassis ground Operated (Sounding) Max. 3 V
Circuit diagram related to caution buzzer
WE051E0300 31
E-18 Auto shift down does not function or it is not released

Trouble • Auto shift down does not function or it is not released.
Related
-
information

Defective auto shift down holding starting switch OFF.
switch
1 ASD (male) terminal Auto shift down switch Resistance
short circuit) Between terminals OFF (0) Min. 1 Mz
(2) - (3) ON (1) Min. 1 z
harness
ASD (female) (2)
connector) Wiring harness between ASD (female) (3) -
Resistance Max. 1 z
chassis ground
Possible causes Short circuit with chassis a Prepare with starting switch OFF, then turn starting switch ON and
and standard ground in wiring harness carry out troubleshooting.
3
value in normal (Contact with ground Between ST2 (female) (37) - ASD (female) (2)
Voltage Max. 1 V
state circuit) wiring harness and chassis ground
Defective steering and Between terminal (37) Auto shift down switch Voltage
4
transmission controller of ST2 - terminals (21),
OFF (0) 5 - 11 V
(31), (32) and (33) of
ST3 ON (1) Max. 1 V
If trouble is not by Causes 1 to 4, the functions may have been limited by
steering and transmission controller due to some other causes.
• Check the log of error codes if any.
Limitation of function by
5 • Make sure that both engine speed and transmission speed are
controller
indicated correctly.
• Make sure that all of brake pedal, fuel control dial, and deceleration
pedal have been adjusted correctly.
Circuit diagram related to auto shift down switch
32 WE051E0300
E-19 Buzzer cancel switch does not function

Trouble • Buzzer cancel switch does not function.
Related
-
information

Defective buzzer cancel BUZ (male) terminal Buzzer cancel switch Resistance
switch
1 Between terminals OFF (0) Min. 1 Mz
(1) - (2) t Max. 1 z
short circuit)
Between terminals OFF (0) Min. 1 Mz
(1) - (3) U Max. 1 z
Disconnection in wiring Wiring harness between ST2 (36) - BUZ
(female) (2)
Wiring harness between ST2 (26) - BUZ
connector) (female) (3)
Wiring harness between BUZ (female) (1) - GND
04
and standard
value in normal
state
ground in wiring harness Between ST2 (36) - BUZ (female) (2) wiring har-
circuit) Between ST2 (female) (26) - BUZ (female) (3)
Steering & transmission
Buzzer cancel switch Voltage
controller
OFF (0) 5 - 11 V
Defective steering and of ST2 (female) - termi-
4
transmission controller nals (21), (31), (32) and
t Max. 1 V
(33) of ST3 (female)
OFF (0) 5 - 11 V
of ST2 (female) - termi-
nals (21), (31), (32) and
U Max. 1 V
(33) of ST3 (female)
WE051E0300 33
Circuit diagram related to buzzer cancel switch
34 WE051E0300
E-20 Information switch does not function

Trouble • Information switch does not function.
Related
-
information

Defective Information CUR (male) terminal Information switch Resistance
switch
1 Between terminals OFF (0) Min. 1 Mz
(1) - (2) > Max. 1 z
short circuit)
Between terminals OFF (0) Min. 1 Mz
(1) - (3) < Max. 1 z
Disconnection in wiring Wiring harness between ST2 (16) - CUR
(female) (2)
Wiring harness between ST2 (6) - CUR (female)
connector) (3)
Wiring harness between CUR (female) (1) -
GND 04
and standard
value in normal
state
ground in wiring harness Between wiring harness connecting ST2 (16) -
(Contact with ground CUR (female) (2) terminals and ground
circuit) Between ST2 (6) - CUR (female) (3) wiring har-
ness and ground
Steering & transmission
Information switch Voltage
controller
OFF (0) 5 - 11 V
Defective steering and of ST2 - terminals (21),
4
transmission controller (31), (32) and (33) of
> Max. 1 V
ST3
Between terminal (6) of
OFF (0) 5 - 11 V
ST2 - terminals (21),
(31), (32) and (33) of
< Max. 1 V
ST3
WE051E0300 35
Circuit diagram related to Information switch
36 WE051E0300
E-21 Reverse fan rotation and cleaning functions do not operate, or they
are not released
Trouble • Reverse fan rotation and cleaning functions do not operate, or they are not released.
Related
-
information

Defective fan rotation Fan rotation
FAM (male) terminal Resistance
selector switch selector switch
1
(Internal short circuit or Between terminals OFF (0) Min. 1 Mz
disconnection) (3) - (4) REV, CLN Max. 1 z
Between terminals OFF (0), REV Min. 1 Mz
(3) - (2) CLN Max. 1 z
FAM (female) (4)
defective contact in Wiring harness between ST2 (female) (7) - FAM
Resistance Max. 1 z
connector) (female) (2)
Wiring harness between FAM (female) (3) - GND
Resistance Max. 1 z
04
value in normal
ground in wiring harness Between ST2 (17) - FAM (female) (4) wiring har-
state 3 Resistance Min. 1 Mz
circuit) Between ST2 (female) (7) - FAM (female) (2) wir-
ing harness and ground
Steering & transmission Fan rotation
Voltage
controller selector switch
OFF (0) 5 - 11 V
Defective steering and of ST2 - terminals (21),
4
transmission controller (31), (32) and (33) of
REV, CLN Max. 1 V
ST3
Between terminal (7) of
OFF (0), REV 5 - 11 V
ST2 - terminals (21),
(31), (32) and (33) of
CLN Max. 1 V
ST3
If trouble is not by Causes 1 to 4, the functions may have been limited by
5 steering and transmission controller due to some other causes. Check the
controller
log of error codes if any.
WE051E0300 37
Circuit diagram related to fan rotation selector switch
38 WE051E0300
E-22 Preset mode cannot be selected or released

Trouble • Preset mode cannot be selected or released.
Related
-
information

Defective preset mode holding starting switch OFF.
1 switch MAM (male) terminal Preset mode switch Resistance
(Internal disconnection) Between terminals OFF (0) Min. 1 Mz
(2) - (3) ON (1) Min. 1 z
2 (Disconnected harness Resistance Max. 1 z
MAM (female) (2)
leads or poor connector
Possible causes contact) Wring harness between MAM (female) (3) -
Resistance Max. 1 z
and standard chassis ground
3
(Contact with ground Between ST2 (female) (10) - MAM (female) (2)
Resistance Max. 1 Mz
circuit) wiring harness and ground
4 ST2 terminal Preset mode switch Voltage
Between terminal (10) OFF (0) 5 - 11 V
- chassis ground ON (1) Max. 1 V
If trouble is not by Causes 1 to 4, the functions may have been restricted
5 by steering and transmission controller due to some other causes.
controller
Check the log of error codes if any.
Circuit diagram related to preset mode switch
WE051E0300 39
E-23 Service mode cannot be selected or it is selected errorneously

Trouble • Service mode cannot be selected or it is selected errorneously.
Related
-
information

Defective buzzer cancel Buzzer cancel switch system may have failed. Carry out troubleshooting
1
switch system of "Buzzer cancel switch does not work".
Defective information Information switch system may have failed. Carry out troubleshooting of
2
switch system "Information switch does not work".
If fuse (10) of FS1 has blown, a grounding error of the circuit may have
3 Defective fuse FS1 (10)
occurred.
S24 (switch) Service switch Resistance
Defective service switch
4 Between terminals
(Internal disconnection) OFF Min. 1 Mz
(1) - (2)
Between terminals
ON Max. 1 z
(5) - (4)
Wiring harness between SF1 (10) outlet - S24
(1) terminals
harness
Wiring harness between S24 (4) - chassis
ground
connector) Wiring harness between S03 (female) (16) - S24
Resistance Max. 1 z
(2)
Wiring harness between ST1 (female) (6) - S24
Resistance Max. 1 z
Possible causes (5)
and standard a Prepare with starting switch OFF, then carry out troubleshooting by
value in normal holding starting switch OFF.
state Between FS1 (10), S24 (1), - S03 (female) (5)
Short circuit with chassis Resistance Min. 1 Mz
ground in wiring harness (6) wiring harness and ground
6
(Contact with ground Between S24 (5) - ST1 (female) (6) wiring har-
circuit) ness and ground
Between S24 (2) - S03 (female) (16) wiring har-
ness and ground
Hot short circuit of wiring Between S24 (2) - S03 (female) (16) wiring har-
Voltage Max. 1 V
7 harness ness and ground
(Contact with 24 V circuit) Between S24 (5) - ST1 (female) (6) wiring har-
Voltage Max. 1 V
ness and ground
Between S24 (4) terminal - chassis ground Voltage Max. 1 V
8 Defective monitor panel S03 terminal Service switch Voltage
Between terminal (16) OFF Max. 1 V
- chassis ground ON 20 - 30 V
9 ST1 Service switch Voltage
Between terminal (6) OFF 5 - 11 V
- chassis ground ON Max. 1 V
40 WE051E0300
Circuit diagram related to service switch
WE051E0300 41
E-24 Backup alarm does not sound

Trouble • Backup alarm does not sound.
Related • If a failure has occurred on primary circuit (coil side) of Backup alarm relay, its error code is displayed.
information However, if a failure has occurred on secondary circuit (contact side), no error code is displayed.

1 Defective fuse (FS2-(9)) If fuse has blown, a grounding error of the circuit may have occurred.
Defective backup alarm carry out troubleshooting.
2 relay Turn starting switch OFF and replace problem relay with another one.
(Internal disconnection) Turn starting switch ON and shift lever to backward position. When alarm
sounds, backup alarm relay (BKA) is defective.
Wiring harness between FS2 (9) - BKA (female)
(1) and (3)
harness
Possible causes Wiring harness between BKA (female) (2) - ST2
and standard (female) (18)
value in normal Wiring harness between BKA (female) (5) - posi-
connector) Resistance Max. 1 z
state tive backup alarm terminals
Wiring harness between negative backup alarm
Resistance Max. 1 z
terminal - GND 03 terminal
Between (1) and (3) of FS2-9 BKA (female) wir-
ground in wiring harness Resistance Min. 1 Mz
4 ing harness and chassis ground
circuit) Between wiring harness connecting BKA
(female) (5) - positive backup alarm terminals Resistance Min. 1 Mz
and ground
Defective backup alarm
5 If problem is not by Causes 1 to 4, backup alarm may have failed.
(Internal defect)
42 WE051E0300
Circuit diagram related to backup alarm
WE051E0300 43
E-25 Headlamp and rear lamp do not light

Trouble (1) Headlamp does not light.
Related
-
information

Defective headlamp
1 Check headlamp bulb as head lamp may be defective.
(Broken bulb)
2 Defective fuse FS1 (8) If fuse has brown, a grounding error of the circuit may have occurred.
Defective headlamp switch
3 FWL (male) terminal switch Resistance
Between terminals OFF Min. 1 Mz
(2) - (3) ON Max. 1 z
Possible causes
and standard Disconnection in wiring
value in normal Wiring harness between FWL (female) (2) - FS1
state (8)
Wiring harness between FWL (female) (3) - 203
(female) (2) and 204 (female) (2)
connector)
Wiring harness between 203 (female) (1) - 204
Resistance Max. 1 z
(female) (1) and GND 04
ground in wiring harness Between FWL (female) (2) - FS1 (8) wiring har-
circuit) Between FWL (female) (3) - 203 (female) (2) and
204 (female) (2) wiring harness and ground
Trouble (2) Rear lamp does not light.

Related
-
information

Defective rear lamp
1 Check bulb of rear lamp as rear lamp may be defective.
(Broken bulb)
2 Defective fuse FS1 (8) If fuse has blown, a grounding error of the circuit may have occurred.
Defective rear lamp switch
3 RWL (male) terminal switch Resistance
Between terminals OFF Min. 1 Mz
(2) - (3) ON Max. 1 z
Possible causes
and standard Disconnection in wiring
value in normal Wiring harness between RWL (female) (2) - FS1
state (8)
defective contact in Wiring harness between RWL (female) (3) - 224
Resistance Max. 1 z
connector) (female) (2) and 228 (female) (1)
Wiring harness between 224 (female) (1) - 228
Resistance Max. 1 z
(female) (2) and GND 03
ground in wiring harness Between RWL (female) (2) - FS1 (8) wiring har-
circuit) Between RWL (female) (3) - 224 (female) (2)
and 228 (female) (1) wiring harness and ground
44 WE051E0300
Circuit diagram related to panel lamp, headlamp, rear lamp and ripper point lamp
WE051E0300 45
E-26 Horn does not sound or does not stop

Trouble • Horn does not sound or does not stop.
Related
-
information

1 Defective fuse (FS1 (7)) If fuse has blown, a grounding error of the circuit may have occurred.
Defective horn switch holding starting switch OFF.
2 (Internal short circuit or Terminal (switch) Horn switch Resistance
disconnection) OFF Min. 1 Mz
265-266
ON Max. 1 z
harness Wiring harness between FS1 (7) - 266 Resistance Max. 1 z
Wiring harness between 265 - 205 (female) (2) Resistance Max. 1 z
defective contact in con-
Possible causes nector) Wiring harness between 205 (female) (1) - GND
Resistance Max. 1 z
and standard 04
value in normal a Prepare with starting switch OFF, then carry out troubleshooting by
state Short circuit with chassis holding starting switch OFF.
ground in wiring harness Between FS1 (7) - 266 wiring harness and chas-
(Contact with ground sis ground
circuit) Between 265 - 205 (female) (2) wiring harness
and chassis ground
Between 265 - 205 (female) (2) wiring harness
and chassis ground
Between 205 (female) (1) - GND 04 wiring har-
Voltage Max. 1 V
ness and chassis ground
Defective horn
6 If problem is not by Causes 1 to 5, horn may have failed.
(Internal defect)
Circuit diagram related to horn
46 WE051E0300
E-27 Work equipment lock lever does not function or it cannot be released
Trouble • Work equipment lock lever does not function or it cannot be released.
Related
-
information

1 Defective fuse (FS2 (7)) If fuse has brown, a grounding error of the circuit may have occurred.
Defective PPC lock switch
Work equipment lock
2 (Internal failure or PSW (male) terminal Resistance
lever
adjustment error)
Free position Max. 1 z
(1)-(2)
Lock position Min. 1 Mz
Disconnection in wiring Wiring harness between FS2 (7) - PSW (female)
(1)
Wiring harness between PSW (female) (2) - PSL
defective contact in con- Resistance Max. 1 z
nector) (female) (1)
Possible causes
and standard Wiring harness between PSL (female) (2) - GND
Resistance Max. 1 z
value in normal 03
ground in wiring harness Between FS2 (7) - PSW (female) (1) wiring har-
circuit) Between PSW (female) (2) - PSL (female) (1)
Between PSW (female) (2) - PSL (female) (1)
Between PSL (female) (2) - GND 03 wiring har-
Voltage Max. 1 V
Defective PPC lock
If problem is not by Causes 1 to 5, PPC lock solenoid switch may have
6 Solenoid switch
failed.
(Internal defect)
WE051E0300 47
Circuit diagram related to work equipment lock lever
48 WE051E0300
E-28 Wiper malfunction

Trouble (1) Front wiper does not operate (or does not operate continuously).
• If only front wipers malfunction
Related • If fuse (5) in cab is blown, intermittent operation of all wipers may fail.
information • If all wipers do not function, check fusible link (FL1).
• When starting troubleshooting, turn intermittent switch OFF but turn wiper switch ON.

If fusible link is broken, the circuit may have been grounded or any other
1 Defective fusible link (FL1)
problem may have occurred.
Fuse (5) in cab is used for front wiper system and intermittent switch sys-
2 Defective fuse (5) in cab
tem. Any of these two systems may have been grounded.
Between CN23 (6) - chassis ground Voltage 20 - 30 V
3 Defective front wiper motor a Prepare with starting switch OFF, then carry out troubleshooting by
Wiring harness between CN23 (female) (1) -
Resistance Max. 1 z
chassis ground
Defective front wiper
4 CN14 (male) terminal Switch position Resistance
switch
Between terminals ON Max. 1 z
(3) - (4) OFF Min. 1 Mz
• Replace problem relay with any of relays CN27, CN31 and CN33. If
problem is solved, the relay is defective.
Defective front wiper carry out troubleshooting.
5
intermittent selector relay
Between CN29 (3) and chassis ground Voltage 20 - 30 V
Possible causes
and standard Between CN29 (6) and chassis ground Voltage 20 - 30 V
value in normal Between CN29 (1) and chassis ground Voltage Max. 1 V
state • Replace problem relay with any of relays CN26, CN30 and CN32. If
Defective front wiper carry out troubleshooting.
6
intermittent relay
Resistance Max. 1 z
CN29 (female) (3)
Disconnection or incorrect Between CN14 (female) (4) - CN29 (female) (3) Resistance Min. 1 Mz
grounding of wiring wiring harness and ground
harness Between CN29 (female) (6) - CN28 (female) (4)
Resistance Max. 1 z
(Disconnected harness wiring harness and ground
7
leads, poor connector Between CN29 (female) (6) - CN28 (female) (4)
contact, or incorrect Resistance Min. 1 Mz
contact to grounding Between wiring harness fuse (5) - CN14 (female)
circuit) (2), (3), or fuse (5) - CN23 (female) (3) - CN28 Resistance Max. 1 z
(female) (3)
Wiring harness between fuse (5) - CN14
(female) (2), (3), or fuse (5) - CN23 (female) (3) - Resistance Min. 1 Mz
CN28 (female) (3)- with chassis ground
WE051E0300 49

Disconnection or incorrect Wiring harness between CN28 (female) (5) -
Resistance Max. 1 z
grounding of wiring CN23 (female) (6)
Possible causes
harness Between CN28 (female) (5) - CN23 (female) (6)
and standard Resistance Min. 1 Mz
(Disconnected harness wiring harness and ground
value in normal 7
leads, poor connector Wiring harness between CN28 (female) (6) -
state Resistance Max. 1 z
contact, or incorrect chassis ground
contact to grounding Wiring harness between CN23 (female) (1) -
circuit) Resistance Max. 1 z
chassis ground
Trouble (2) Front wiper does not operate intermittently.

• If ordinary wiper operations are normal:
Related
• Turn both wiper switch and intermittent wiper switch ON, and carry out troubleshooting.
information
• If wipers stop approximately 5 seconds after a single stroke of wiper movement:

• If ordinary wiper operations are normal but if wipers do not operate
intermittently, intermittent wiper switch may have failed.
Defective intermittent wiper holding starting switch OFF.
1
switch
CN11 (male) terminal Switch position Resistance
(1) - (2) OFF Min. 1 Mz
• Replace problem relay with any of relays CN27, CN31 and CN33. If
Defective front wiper a Prepare with starting switch OFF, then turn starting switch ON and
2 carry out troubleshooting.
Possible causes
and standard • Replace problem relay with any of relays CN26, CN30 and CN32. If
value in normal problem is solved, the relay is defective.
state 3 a Prepare with starting switch OFF, then turn starting switch ON and
intermittent relay
Disconnection or incorrect CN29 (female) (1) Resistance Max. 1 z
grounding of wiring
Between CN11 (female) (2) - CN29 (female) (1)
harness Resistance Min. 1 Mz
4 (Line disconnection,
poor connector contact, Resistance Max. 1 z
or incorrect contact to GND CN28 (female) (2)
circuit) Between CN29 (female) (5) - CN28 (female) (2)
Wring harness between CN29 (female) (2) -
Resistance Max. 1 z
chassis ground
50 WE051E0300
Circuit diagram related to wiper system
WE051E0300 51
Trouble (3) Rear wiper does not operate (or does not operate continuously).
• If only rear wiper does not function:
Related
• If all wipers do not function, check fusible link (FL1).
information
• When starting troubleshooting, turn Intermittent switch OFF but turn Wiper switch ON.

Fuse (4) in cab is used only for rear wiper system. Rear wiper system may
2 Defective fuse (4) in cab
have been grounded or any other problem may have occurred.
3 Defective rear wiper motor a Prepare with starting switch OFF, then carry out troubleshooting by
Resistance Max. 1 z
chassis ground
4 Defective rear wiper switch CN12 (male) terminal Switch position Resistance
(3) - (4) OFF Min. 1 Mz
• Replace the relay with any of relays CN27, CN29 and CN31. If problem
is solved, the relay is defective.
Defective rear wiper carry out troubleshooting.
5
Possible causes
and standard
value in normal Between CN33 (1) - chassis ground Voltage Max. 1 V
state • Replace the relay with any of relays CN26, CN28 and CN30. If problem
Defective rear wiper carry out troubleshooting.
6
intermittent relay
Resistance Max. 1 z
CN33 (female) (3)
Disconnection or incorrect Resistance Min. 1 Mz
grounding of wiring
CN32 (female) (4)
poor connector contact, Resistance Min. 1 Mz
or incorrect contact to GND wiring harness and ground
circuit) Wiring harness between fuse (4) - CN12
Resistance Max. 1 z
(female) (2), (3)
Between fuse (4) - CN12 (female) (2), (3) wiring
harness and ground
Resistance Max. 1 z
(female) (3) - CN37 (female) (3)
52 WE051E0300

Between fuse (4) - CN32 (female) (3) - CN37
Resistance Max. 1 z
(female) (3) wiring harness and ground
Disconnection or incorrect Wiring harness between CN32 (female) (5) -
Possible causes grounding of wiring Resistance Max. 1 z
CN37 (female) (1)
value in normal 7 (Line disconnection, Resistance Min. 1 Mz
state poor connector contact,
or incorrect contact to GND Wiring harness between CN32 (female) (6) - Resistance Max. 1 z
circuit) chassis ground
Resistance Max. 1 z
chassis ground
Trouble (4) Rear wiper does not operate intermittently.

Related
information

1
switch
(1) - (2) OFF Min. 1 Mz
Defective rear wiper a Prepare with starting switch OFF, then turn starting switch ON and
Possible causes
and standard • Replace the relay with any of relays CN26, CN28 and CN30. If problem
value in normal is solved, the relay is defective.
Defective rear wiper
intermittent relay
grounding of wiring
circuit) Between CN33 (female) (5) and CN32 (female)
(2) wiring harness and ground
Resistance Max. 1 z
chassis ground
WE051E0300 53
54 WE051E0300
Trouble (5) Right door wiper does not operate (or does not operate continuously).
• If only right door wiper does not function (if fuse (6) in cab is blown, both right and left door wipers do not
Related operate):

Fuse (6) in cab is used for both right and left door wiper systems. One of
2 Defective fuse (6) in cab above wiper systems may have been grounded or any other problem may
have occurred.
Between connector (3) just before motor - chas-
Voltage 20 - 30 V
Defective right door wiper sis ground
3
motor a Prepare with starting switch OFF, then carry out troubleshooting by
Wiring harness between connector (1) just
Resistance Max. 1 z
before motor - chassis ground
Defective right door wiper
switch
(3) - (4) OFF Min. 1 Mz
Defective right door wiper carry out troubleshooting.
5
Possible causes
and standard
value in normal Between CN31 (1) - chassis ground Voltage Max. 1 V
state • Replace the relay with any of relays CN26, CN28 and CN32. If problem
6
intermittent relay
Resistance Max. 1 z
CN31 (female) (3)
Disconnection or incorrect
grounding of wiring Resistance Max. 1 z
CN30 (female) (4)
harness
7 (Line disconnection, Between CN31 (female) (6) - CN30 (female) (4)
poor connector contact, wiring harness and ground
or incorrect contact to GND Wiring harness between fuse (6) - CN13
circuit) (female) (2) (3), CN17 (4) - connector (female)
Resistance Max. 1 z
(4) just before motor - CN13 (female) (2), (3) ter-
minals
(female) (2), (3), CN17 (4) - connector (female)
just before motor - CN13 (female) (2), (3) termi-
nals and chassis ground
WE051E0300 55

Resistance Max. 1 z
(female) (3)
Between fuse (6) - CN30 (female) (3) wiring har-
ness and ground
Disconnection or incorrect Wiring harness between connector (female) (3)
Possible causes grounding of wiring terminal just before motor - CN17 (3) - CN30 Resistance Max. 1 z
(female) (5) terminal
value in normal 7 (Line disconnection,
state Wiring harness between connector (female) (3)
poor connector contact,
or incorrect contact to GND terminal just before motor - CN17 (3) - CN30 Resistance Min. 1 Mz
circuit) (female) (5) terminal and chassis ground
Resistance Max. 1 z
chassis ground
Wiring harness between connector (female) (1)
Resistance Max. 1 z
just before motor - CN17 (1) - chassis ground
Trouble (6) Right door wiper does not operate intermittently.

Related
information

1
switch
(1) - (2) OFF Min. 1 Mz
Defective right door wiper a Prepare with starting switch OFF, then turn starting switch ON and
Possible causes
Defective right door wiper
intermittent relay
grounding of wiring Between CN11 (female) (2) - CN31 (female) (1)
Resistance Max. 1 z
chassis ground
56 WE051E0300
WE051E0300 57
Trouble (7) Left door wiper does not operate (or does not operate continuously).
• If only left door wiper does not function (if fuse (6) in cab is blown, both right and left door wipers do not
Related operate):

Fuse (6) in cab is used for both right and left door wiper systems. One of
2 Defective fuse (6) in cab above wiper systems may have been grounded or any other problem may
have occurred.
Between connector (3) just before motor - chas-
Voltage 20 - 30 V
Defective left door wiper sis ground
3
motor a Prepare with starting switch OFF, then carry out troubleshooting by
Wiring harness between connector (1) just
Resistance Max. 1 z
before motor - chassis ground
Defective left door wiper
switch
(3) - (4) OFF Min. 1 Mz
Defective left door wiper carry out troubleshooting.
5
Possible causes intermittent selector relay
and standard
value in normal
state Between CN27 (1) - chassis ground Voltage Max. 1 V
6
intermittent relay
Resistance Max. 1 z
CN27 (female) (3)
Disconnection or incorrect wiring harness and ground Resistance Min. 1 Mz
grounding of wiring
CN26 (female) (4)
poor connector contact, Between CN27 (female) (6) - CN26 (female) (4)
or incorrect contact to GND wiring harness and ground
circuit) Wiring harness between terminal of fuse (6) -
CN26 (female) (3) - CN24 (4) connector (female) Resistance Max. 1 z
just before motor
Between wiring harness connecting terminal of
fuse (6) - CN26 (female) (3) - CN24 (4) connec- Resistance Min. 1 Mz
tor (female) just before motor and ground
58 WE051E0300

(female) (2), (3)
Between fuse (6) - CN15 (female) (2), (3) wiring
Resistance Max. 1 z
harness and ground
Disconnection or incorrect Wiring harness between CN24 (3) connector
Possible causes grounding of wiring (female) (3) - terminal just before motor - CN26 Resistance Max. 1 z
(female) (5) terminal
value in normal 7 (Line disconnection,
state Wiring harness between connector - (female) (3)
poor connector contact,
Resistance Max. 1 z
or incorrect contact to GND terminal just before motor - CN24 (3) - CN26
circuit) (female) (5) terminal and ground
Resistance Max. 1 z
chassis ground
Wiring harness between connector (female) (1)
Resistance Max. 1 z
just before motor - CN24 (1) - chassis ground
Trouble (8) Left door wiper does not operate intermittently.

Related
information

1
switch
(1) - (2) OFF Min. 1 Mz
Defective left door wiper a Prepare with starting switch OFF, then turn starting switch ON and
2
intermittent selector relay carry out troubleshooting.
Possible causes
intermittent relay
grounding of wiring
Resistance Max. 1 z
chassis ground
WE051E0300 59
60 WE051E0300
E-29 Washing water does not come out

Trouble (1) Washing water of front washer does not come out.
Related • If front wipers operate normally:
information (If wiper does not operate either, carry out troubleshooting in E-28 Wiper malfunction first.)

Wiring harness between 11 (female) (1) - chassis
Defective front washer Resistance Max. 1 z
1 ground
motor
a Prepare with starting switch OFF, then turn starting switch ON (at W/I
switch position) and carry out troubleshooting.
Between 11 (2) - chassis ground Voltage 20 - 30 V
2 CN14 (female) terminal Switch position Resistance
Possible causes switch
Between terminals W/I or W/II Max. 1 z
and standard
(2) - (1) OFF Min. 1 Mz
value in normal
Disconnection or incorrect (female) (2) Resistance Max. 1 z
grounding of wiring
Wiring harness between CN14 (female) (1) - 19
(3) - 13 (3) - 11 (female) (2)
or incorrect contact to GND
circuit) Between CN14 (female) (1) - 19 (3) - 13 (3) - 11
(female) (2) wiring harness and chassis ground
Resistance Max. 1 z
ground
WE051E0300 61
Circuit diagram related to washers
62 WE051E0300
Trouble (2) Washing water of rear washer does not come out.
Related • If rear wiper operates normally:
information (If wiper does not operate either, carry out troubleshooting in E-28 Wiper malfunction first.)

Wiring harness between 12 (female) (1) - chas-
Defective rear washer Resistance Max. 1 z
1 sis ground
motor
2 Defective rear wiper switch CN12 (female) terminal Switch position Resistance
Possible causes
and standard
(2) - (1) OFF Min. 1 Mz
value in normal
grounding of wiring Between fuse (4) - CN12 (female) (2) wiring har-
(4) - 13 (4) - 12 (female) (2)
Resistance Max. 1 z
sis ground
*For the electric circuit diagram of each system, see Trouble (1).
WE051E0300 63
Trouble (3) Washing water of left door washer does not come out.
• If left door wiper operates normally:
Related (If wiper does not operate either, carry out troubleshooting in E-28 Wiper malfunction first.)
information • Fuse (6) is used for both right and left door wiper switches. If this fuse blows, both wiper switches do not
operate.

Defective left door washer Resistance Max. 1 z
1 ground
motor
2 CN15 (female) terminal Switch position Resistance
Possible causes switch
and standard
(2) - (1) OFF Min. 1 Mz
value in normal
grounding of wiring
ness and ground
or incorrect contact to GND (1) - 13 (1) - 9 (female) (2)
Resistance Max. 1 z
ground
64 WE051E0300
Trouble (4) Washing water of right door washer does not come out.
• If right door wiper operates normally:
Related (If wiper does not operate either, carry out troubleshooting in E-28 Wiper malfunction first.)
information • Fuse (6) is used for both right and left door wiper switches. If this fuse blows, both wiper switches do not
operate.

Defective right door Resistance Max. 1 z
1 sis ground
washer motor
Defective right door wiper CN13 (female)
2 Switch position Resistance
Possible causes switch terminal
and standard Between terminals W/I or W/II Max. 1 z
value in normal (2) - (1) OFF Min. 1 Mz
grounding of wiring Between fuse (6) - CN13 (female) (2) wiring har-
ness and ground
(2) - 13 (2) - 10 (female) (2)
Resistance Max. 1 z
sis ground
WE051E0300 65
E-30 Air conditioner does not operate

Trouble (1) Air does not come out.
Related
-
information

Defective circuit breaker If circuit breaker has been cut off, a grounding error or a similar error may
1
(CB2) have occurred in the circuit.
Defective blower main holding starting switch OFF.
2 relay
CN-R1 (male) terminal Resistance
(windings side)
Between terminals (1) - (2) 240±40 z
Defective blower main carry out troubleshooting.
3
relay (contact side) CN-R1 (male) terminal Voltage
Between (8C) - chassis ground 20 - 30 V
Defective "Blower Hi" relay holding starting switch OFF.
4
(windings side) CN-R2 (male) terminal Resistance
Defective "Blower Hi" relay carry out troubleshooting.
5
(contact side) Turn ON both starting switch and blower Hi switch. The relay is normal if
motor rotates.
Defective "Blower Mi1" holding starting switch OFF.
6
relay (windings side) CN-R3 (male) terminal Resistance
Possible causes Defective "Blower Mi1" carry out troubleshooting.
and standard 7
relay (contact side) Turn ON both starting switch and blower Mi switch. The relay is normal if
value in normal
motor rotates.
state
Defective "Blower Mi2" holding starting switch OFF.
8
relay (windings side) CN-R4 (male) terminal Resistance
Defective "Blower Mi2" carry out troubleshooting.
9
relay (contact side) Turn ON both starting switch and blower Lo switch. The motor is normal if
it rotates.
10 Defective blower motor
Turn ON both starting switch and blower Lo switch. The motor is normal if
it rotates.
Wiring harness between CN-R4 (female) (14C),
AC1 (female) (14A), CN-R (female) (S141), CN-
Resistance Max. 1 z
Disconnection in wiring R2 (female) (14E) - CN-R3 (female) (14N) and
harness ground
11 (Disconnection in wiring or Wiring harness between CN-B (female) (11B) -
Resistance Max. 1 z
defective contact in CN-R1 (female) (11A)
connector) Wiring harness between CN-B (female) (12A) -
Resistance Max. 1 z
CN-R2 (female) (12B) - CN-R (female) (11C)
Wiring harness between CB outlet - AC1
(female) (1A), CN-R1 (female) (1D) - CN-R2 Resistance Max. 1 z
(female) (1E) - CN-R4 (female) (11)
66 WE051E0300

Wiring harness between CN-R1 (female) (2B) -
Resistance Max. 1 z
AC1 (female) (2A)
Disconnection wiring Wiring harness between CN-R3 (female) (3B) -
Possible causes AC1 (female) (3B)
and standard Wiring harness between CN-R2 (female) (5B) -
value in normal AC1 (female) (5A)
connector)
state Wiring harness between CN-R4 (female) (4B) -
Resistance Max. 1 z
AC1 (female) (4A)
12 Defective control panel If problem is NOT by Causes 1 to 11, control panel may have failed.
Mistake in checking If problem cause cannot be isolated, a mistake may be made in checking
13
trouble the problem. Carry out troubleshooting for "Air is not cooled."
WE051E0300 67
Trouble (2) Air is not cooled.

Related
-
information

1 Defective pressure switch CN-P Blower switch Voltage
Between terminal (6B)
ON 20 - 30 V
- chassis ground
Defective compressor holding starting switch OFF.
2 clutch relay
CN-5 (male) terminal Resistance
(windings side)
Defective compressor carry out troubleshooting.
3 clutch relay CN-R5 (male) terminal Voltage
(contact side) Between terminal (18A)
20 - 30 V
- chassis ground
Defective capacitor relay
4 CN-R6 terminal Voltage
(contact side)
Between terminal (23A)
20 - 30 V
- chassis ground
5 Defective thermistor
AC1 (male) terminal Resistance
Possible causes Between (9A) - (13A) terminals Max. 3,500 z
and standard a Prepare with starting switch OFF, then carry out troubleshooting by
value in normal Defective capacitor blower holding starting switch OFF.
state 6
resistor Capacitor blower resistor Resistance
Between terminals 2.8 z±5%
a Turn starting switch ON and carry out troubleshooting.
7 Defective capacitor motor
The motor is normal if it rotates when air conditioner is turned ON.
Defective compressor a Start engine and carry out troubleshooting.
8
magnetic clutch Inspect compressor directly as it is supposed to be out of order.
a Start engine and carry out troubleshooting.
9 Defective compressor
Inspect compressor directly as it is supposed to be out of order.
Wiring harness between CB2 outlet - CN-R6
(female) (8B) - CN-R5 (female) (8D) - CN-R1 Resistance Max. 1 z
(female) (8C)
Disconnection in wiring Wiring harness between CN-R5 (female) (18A) -
Resistance Max. 1 z
harness A/C (female) (1)
10 (Disconnection in wiring or Wiring harness between CB2 outlet - CN-R5
Resistance Max. 1 z
defective contact in (female) (1K)
connector) Wiring harness between CN-T (female) (9B) -
Resistance Max. 1 z
AC1 (female) (9A)
Wiring harness between CN-P (female) (7B) -
Resistance Max. 1 z
CN-R5 (female) (7A)
Wiring harness between CN-P (female) (6B) -
Resistance Max. 1 z
AC1 (female) (6A)
11 Defective control panel If problem is not by causes 1 - 10, control panel may have failed.
68 WE051E0300
Circuit diagram related to air conditioner
WE051E0300 69
70 WE051E0300
WE051E0400
Bulldozer
1Shop Manual
D61EX-15
D61PX-15

Troubleshooting 1
Troubleshooting of hydraulic and mechanical system (H-mode) ..................................... 3
H-1 No travel power (No drawbar pull)....................................................................... 4
H-2 Machine does not move (At 2nd or 3rd speed) ................................................... 5
H-3 Machine does not move in any speed range....................................................... 6
H-4 Machine travels only in one direction forward or in reverse ................................ 7
H-5 When gear is shifted or travel direction is changed, large time lag is made........ 8
H-6 Machine does not turn (Not turned rightward or leftward) ................................... 9
H-7 Steering speed or power is low ......................................................................... 10
H-8 Brake does not work.......................................................................................... 11
H-9 Overheat of power train oil temperature ............................................................ 12
H-10 Abnormal sound comes out from around HSS
and work equipment pump or HSS motor ......................................................... 13
H-11 All work equipment speeds are slow ................................................................. 14
H-12 Work equipment does not move........................................................................ 15
H-13 Blade lift speed is slow or lacks power ..............................................................16

H-14 Blade tilt speed is slow or lacks power ..............................................................17
H-15 Angling blade speed is slow or lacks power ......................................................18
H-16 Ripper lift speed is slow or lacks power.............................................................19
H-17 Excessive hydraulic drift of blade lift..................................................................20
H-18 Excessive hydraulic drift of blade tilt..................................................................21
H-19 Excessive hydraulic drift of blade angle.............................................................22
H-20 Excessive hydraulic drift of ripper lift .................................................................23
2 WE051E0400
Troubleshooting of hydraulic and mechanical system (H-mode) 1

a Troubleshooting lists contain the following information all together. Understand the contents carefully and trou-
bleshoot the machine.
Trouble Trouble that appears on the machine

Related
Information related problems occurred or troubleshooting
information
Possible causes Cause supposed to have

and standard 2 caused failure <Contents>
value in normal (The sequence shows • Standard value in normal state to judge possible causes
state 3 reference numbers and • Remarks for marking judgment
does not mean priority.)
WE051E0400 3
H-1 No travel power (No drawbar pull)

Trouble • There is no travel power. (No drawbar pull)
Related
• Confirm that oil quantity on power train is normal before troubleshooting.
information

a Prepare with starting switch OFF, then drive engine in high idling mode
for troubleshooting.
1 Defective engine
Measurement conditions Engine speed
F3 stall Min. 1,500 rpm
Defective power train
2 Power train pump is assumed to be defective; directly check it.
pump
Internally defective torque Original pressure of Torque converter
3 PCCS lever
converter torque converter delivery pressure
Max. 0.88 MPa 0.44 - 0.69 MPa
Full neutral
{Max. 9 kg/cm2} {4.5 - 7 kg/cm2}
PCCS lever Transmission main relief pressure
Full neutral Min. 2.65 MPa {Min. 24 kg/cm2}
Defective set pressure of a Prepare with starting switch OFF, then carry out troubleshooting with-
4 transmission main relief out turning starting switch ON.
Possible causes valve or internal defect Directly check that spring length and number of shims are normal and
and standard
also that spool rotates smoothly.
value in normal
• Free length of large spring: 122 mm
state
• Free length of small spring: 108 mm
• Number of shims: 6
a Prepare with starting switch OFF, then drive engine in low idling mode
Transmission clutch Clutch pressure
Defective transmission FWD Min. 2.65 MPa {Min. 27 kg/cm2}
5
valve (ECMV) function REV Min. 2.65 MPa {Min. 27 kg/cm2}
1ST Min. 2.65 MPa {Min. 27 kg/cm2}
2ND Min. 2.65 MPa {Min. 27 kg/cm2}
3RD Min. 2.65 MPa {Min. 27 kg/cm2}
6 Defective brake valve
Parking brake lever Brake pressure
FREE Min. 2.55 MPa {Min. 26 kg/cm2}
Defective parking brake If result of the troubleshooting in cause 6 is abnormal, parking brake lever
7 lever or brake pedal or brake pedal linkage is not assumed to be adjusted normally. Directly
linkage check it.
Internally defective
8 Transmission is assumed to be defective internally; directly check it.
transmission
4 WE051E0400
H-2 Machine does not move (At 2nd or 3rd speed)

Trouble • Machine does not move (At 2nd or 3rd speed)
Related • Confirm that oil quantity on power train is normal before troubleshooting.
information • Confirm that transmission main relief pressure is normal before troubleshooting. (See H-1)

1 PCCS lever
Max. 0.88 MPa 0.44 - 0.69 MPa
Full neutral
{Max. 9 kg/cm2} {4.5 - 7 kg/cm2}
Possible causes Defective transmission Transmission clutch Clutch pressure
2
and standard valve (ECMV) function
value in normal
state 3RD Min. 2.65 MPa {Min. 27 kg/cm2}
Internally defective Transmission clutch (2nd or 3rd speed) is assumed to be defective inter-
3
transmission clutch nally; directly check it.
Defective parking brake Parking brake function is assumed to be defective (dragged); check link-
4
function (Drag) age valves.
a Move to a flat place (a hard road), then start engine for troubleshooting.
Defective brake function
5 When the machine does not run by low idling and F2 operation, brake
(Drag)
drag occurs. (Carry out troubleshooting "Brake does not work".)
Internally defective
6 Transmission is assumed to be defective internally; directly check it.
transmission
WE051E0400 5
H-3 Machine does not move in any speed range

Trouble • Machine does not move in any speed range.
Related
information

pump
valve or internal defect Directly check that spring length and number of shims are normal and
Possible causes for troubleshooting. (Before this, confirm that transmission main relief
and standard pressure is normal.)
value in normal Transmission clutch Clutch pressure
state Defective transmission FWD Min. 2.65 MPa {Min. 27 kg/cm2}
3
valve (ECMV) function
REV Min. 2.65 MPa {Min. 27 kg/cm2}
Internally defective Transmission clutch is assumed to be defective internally; directly check
4
transmission cluch it.
a Move to a flat place, and drive engine in high idling mode for trouble-
shooting. (Before this, confirm that transmission main relief pressure is
normal.)
Brake pedal Brake hydraulic pressure (left/right)
5 Defective brake function
Release Min. 2.55 MPa {Min. 26 kg/cm2}
Depress 0 MPa {0 kg/cm2}
When hydraulic pressure is abnormal, carry out troubleshooting "Brake
does not work".
6 WE051E0400
H-4 Machine travels only in one direction forward or in reverse

Trouble • Machine travels only in one direction Forward or in reverse.
Related
information

pump
Possible causes also that spool rotates smoothly.
and standard • Free length of large spring: 122 mm
value in normal • Free length of small spring: 108 mm
state • Number of shims: 6
for troubleshooting. (Before this, confirm that transmission main relief
Defective transmission pressure is normal.)
3 Transmission clutch Clutch pressure
FWD Min. 2.65 MPa {Min. 27 kg/cm2}
Defective transmission When troubleshooting in cause 3 is abnormal, clutch seal is assume to be
4
clutch seal defective; directly check it.
Internally defective Transmission clutch (forward or backward) is assumed to be defective
5
transmission clutch internally; directly check it.
WE051E0400 7
H-5 When gear is shifted or travel direction is changed, large time lag is made
Trouble • Time lag is excessive when shifting gear or changing direction.
Related
information

pump
a Prepare with starting switch OFF, then drive the engine in high idling
mode for troubleshooting.
Possible causes
and standard a Prepare with starting switch OFF, then drive engine in low idling mode
value in normal for troubleshooting. (Before this, confirm that transmission main relief
state pressure is normal.)
Transmission clutch Clutch pressure
Defective transmission FWD Min. 2.65 MPa {Min. 27 kg/cm2}
3
Defective transmission When troubleshooting in cause 3 is abnormal, clutch seal is assume to be
4
clutch seal defective; directly check it.
Internally defective Transmission clutch is assumed to be defective internally; directly check
5
transmission clutch it.
a Move to a flat place (a hard road), then start engine for troubleshooting.
6 When machine does not run in low idling mode and F2 operation, brake is
(Drag)
dragging. (Carry out troubleshooting "Brake does not work".)
8 WE051E0400
H-6 Machine does not turn (Not turned rightward or leftward)

Trouble • Machine does not turn. (Machine does not turn leftward or rightward.)
Related
• Confirm that oil quantity of hydraulic oil tank is normal before troubleshooting.
information

Defective set pressure or a Prepare with starting engine, then drive the engine in high idling mode
defective function of for troubleshooting.
Possible causes
1 self-pressure reducing PCCS lever Original pressure of control circuit
and standard
valve
value in normal Neutral 3.72±0.49 MPa {38±5 kg/cm2}
(PPC source pressure)
state
If an abnormal sound occurs in HSS peripheral equipment, carry out trou-
Abnormal sound from HSS
2 bleshooting "Abnormal Sound around HSS and Work Equipment Pump or
peripheral equipment
HSS Motor".
WE051E0400 9
H-7 Steering speed or power is low

Trouble • Steering speed or power is insufficient.
Related
information

a Prepare with starting engine, then drive the engine in high idling mode
Defective set pressure or for troubleshooting.
1 defective function of HSS
PCCS lever HSS relief pressure
main relief valve
Left or right stroke end Min. 28.9 MPa {Min. 295 kg/cm2}
Possible causes
and standard Defective set pressure or a Prepare with starting engine, then drive the engine in high idling mode
value in normal defective function of for troubleshooting.
state 2 self-pressure reducing PCCS lever Original pressure of control circuit
valve
(PPC source pressure) Neutral 3.72±0.49 MPa {38±5 kg/cm2}
If an abnormal sound occurs in HSS peripheral equipment, carry out trou-
Abnormal sound from HSS
3 bleshooting "Abnormal Sound around HSS and Work Equipment Pump or
peripheral equipment
HSS Motor".
10 WE051E0400
H-8 Brake does not work

Trouble • Brake does not work.
Related • Confirm that oil quantity on power train is normal before troubleshooting.
information • Confirm that transmission main relief pressure is normal before troubleshooting. (See H-1)

Defective brake valve Brake pedal Brake hydraulic pressure
1
function
Possible causes Released Min. 2.55 MPa {Min. 26 kg/cm2}
and standard At pedaling 0 MPa {0 kg/cm2}
value in normal Defective adjustment of If troubleshooting in cause 1 is abnormal, the adjustment of brake pedal
state 2
brake pedal linkage linkage is assumed to be abnormal; directly check it.
If troubleshooting in cause 1 is abnormal, rake seal is assumed to be
3 Defective brake seal
defective; directly check it.
Slipped or abrasive brake
4 Brake disc plate is assumed to be slipped or abrasive; directly check it.
disc plate
WE051E0400 11
H-9 Overheat of power train oil temperature

Trouble • Oil temperature of power train overheats.
• Confirm that the value of oil temperature of power train matches actual oil temperature before
Related
troubleshooting. (If they do not match, carry out troubleshooting "Abnormal Power Train Oil
information
temperature".)
• Confirm that transmission main relief pressure is normal before troubleshooting. (See H-1)

Engine cooling system is assumed to be defective or engine output is
1 Defective engine system
assumed to be increased; see Shop Manual: Engine.
Power train pump is assumed to be defective or aired from suction circuit;
2 pump or air from suction
directly check it.
circuit
Possible causes
and standard 3 PCCS lever
value in normal
state Max. 0.88 MPa 0.44 - 0.69 MPa
Full neutral
{Max. 9 kg/cm2} {4.5 - 7 kg/cm2}
Defective transmission Transmission clutch is assumed to be defective internally (slipped);
4
clutch function (Slip) directly check it.
a Prepare with starting engine for troubleshooting.
1. Run engine at low idling on a flat place (a hard road).
5 2. Set gearshift lever in F2.
(Drag)
3. See if machine moves (travels). If it does not move, brake drag occurs.
(Carry out troubleshooting "Brake does not work".)
12 WE051E0400
H-10 Abnormal sound comes out from around HSS and work equipment
pump or HSS motor
Trouble • Abnormal noise from around HSS and work equipment pump.
Related
information

1 Inappropriate oil Oil used is assumed to be inappropriate; directly check it.
Clogged hydraulic oil tank
2 Strainer of hydraulic oil tank is assumed to be clogged; directly check it.
Possible causes strainer
and standard Air is assumed to be inhaled in suction circuit of HSS and work equipment
3 Air inhaled in suction circuit
value in normal pump; directly check the pipes.
state Internally defective HSS HSS and work equipment pump is assumed to be defective internally;
4
pump directly check it.
Internally defective HSS
5 HSS motor is assumed to be defective internally; directly check it.
motor
WE051E0400 13
H-11 All work equipment speeds are slow

Trouble • All work equipment speeds are slow.
Related
information

Defective PTO
PTO pump drive unit of HSS and work equipment is assumed to be defec-
1 (Pump drive unit of HSS
tive; directly check it.
and work equipment)
Defective HSS and work HSS and work equipment pump is assumed to be defective; directly check
2
equipment pump it.
Defective unload valve
3 Work equipment control lever Unload pressure
function
+1.37 +14
Full neutral 3.43 +0 MPa {35 +0 kg/cm2}
Possible causes Defective set pressure or for troubleshooting.
and standard 4 defective function of main
Work equipment control lever Main relief pressure
value in normal relief valve
Stroke end Min. 19.1 MPa {Min. 195 kg/cm2}
state
Defective function of a Prepare with starting switch OFF, then drive engine in high idling mode
self-pressure reducing for troubleshooting.
5
valve Work equipment control lever Original pressure of control circuit
(PPC original pressure) Full neutral 3.72±0.49 MPa {38±5 kg/cm2}
Internally defective PPC When troubleshooting in cause 5 is abnormal, PPC valve is assumed to
6
valve be defective internally; directly check it.
Defective function of PPC PPC lock solenoid may be malfunctioning. (get caught foreign materials)
7
lock solenoid function Check it directly.
1) Last chance filter (coin type) is assumed to be clogged, so check it
Clogging of last chance directly. (Loading on PPC block inlet)
6
filter 2) PPC valve input filter (plug-loading type) is assumed to be clogged.
Check it directly.
14 WE051E0400
H-12 Work equipment does not move

Trouble • Work equipment dose not operate at all.
Related
information

Defective PTO
PTO pump drive unit of HSS and work equipment is assumed to be defec-
1 (Pump drive unit of HSS
tive; directly check it.
and work equipment)
Defective HSS and work HSS and work equipment pump is assumed to be defective; directly check
2
equipment pump it.
Possible causes Defective unload valve
3 Work equipment control lever Unload pressure
and standard function
+1.37 +14
value in normal Full neutral 3.43 +0 MPa {35 +0 kg/cm2}
state a Prepare with starting switch OFF, then drive engine in high idling mode
Defective set pressure or for troubleshooting.
4 defective function of main
Work equipment control lever Main relief pressure
relief valve
Stroke end Min. 19.1 MPa {Min. 195 kg/cm2}
Defective function of a Prepare with starting switch OFF, then drive engine in high idling mode
self-pressure reducing for troubleshooting.
5
valve Work equipment control lever Original pressure of control circuit
(PPC original pressure) Full neutral 3.72±0.49 MPa {38±5 kg/cm2}
WE051E0400 15
H-13 Blade lift speed is slow or lacks power

Trouble • Speed or power of lifting blade is low.
Related • Confirm whether the blade is remodeled.
information • When hydraulic drift rate of blade lift is also high, carry out troubleshooting "Excessive hydraulic drift of
blade lift".

Defective PPC valve for troubleshooting.
Possible causes 1
function Blade lever PPC valve output pressure
and standard
value in normal Lift stroke end 3.72±0.49 MPa {38±5 kg/cm2}
state Defective function of blade
2 Spool of blade lift control valve may be malfunctioning. Check it directly.
lift control valve (spool)
Blade lift cylinder is assumed to be aired; carry out air bleed and observe
3 Aired blade lift cylinder
how the phenomenon changes.
16 WE051E0400
H-14 Blade tilt speed is slow or lacks power

Trouble • Speed or power of tilting blade is low.
information • When hydraulic drift rate of blade tilt is also high, carry out troubleshooting "Excessive hydraulic drift of
blade tilt".

Possible causes 1
and standard
value in normal Tilt stroke end 3.72±0.49 MPa {38±5 kg/cm2}
state Defective function of blade
2 Spool of blade tilt control valve may be malfunctioning. Check it directly.
tilt control valve (spool)
Blade tilt cylinder is assumed to be aired; carry out air bleed and observe
3 Aired blade tilt cylinder
WE051E0400 17
H-15 Angling blade speed is slow or lacks power

Trouble • Speed or power of angling blade is low.
information • When hydraulic drift rate of angling blade is also high, carry out troubleshooting "Excessive hydraulic
drift of blade angle".

Possible causes 1
and standard
value in normal Angle stroke end 3.72±0.49 MPa {38±5 kg/cm2}
state Defective function of blade Spool of blade angle control valve may be malfunctioning. Check it
2
angle control valve (spool) directly.
Blade angle cylinder is assumed to be aired; carry out air bleed and
3 Aired blade angle cylinder
observe how the phenomenon changes.
18 WE051E0400
H-16 Ripper lift speed is slow or lacks power

Trouble • Speed or power of ripper (if equipped) lift is low.
Related • Confirm whether the ripper is remodeled.
information • When hydraulic drift rate of ripper lift is also high, carry out troubleshooting "Excessive hydraulic drift of
ripper lift".

1
function Ripper control lever PPC valve output pressure
Lift stroke end 3.72±0.49 MPa {38±5 kg/cm2}
Possible causes Defective function of
and standard Spool function of ripper lift control valve is assumed to be defective;
2 ripper lift control valve
value in normal directly check it.
(spool)
state Suction valve of ripper lift control valve is assumed to be defective;
Defective function of
directly check it.
3 ripper lift control valve
a Replace suction valve in the head with one at the bottom, and observe
(suction valve)
Ripper lift cylinder is assumed to be aired; carry out air bleed and observe
4 Aired ripper lift cylinder
WE051E0400 19
H-17 Excessive hydraulic drift of blade lift

Trouble • Hydraulic drift of lifting blade is large
information • Confirm that no oil leaks circuits in work equipment before troubleshooting.

a Prepare with starting engine, then stop the engine for troubleshooting.
1. Raise the blade (about 800 mm).
Possible causes
Defective seal of blade lift 2. Disconnect hose on cylinder head side and block it.
and standard 1 3. Measure hydraulic drift of blade tip.
control valve (spool)
value in normal
Blade lift Hydraulic drift
state
Block blade lift circuit 100 mm/15 min
Defective seal of blade lift
2 Seal of blade lift cylinder is assumed to be defective; directly check it.
cylinder
20 WE051E0400
H-18 Excessive hydraulic drift of blade tilt

Trouble • Hydraulic drift of tilting blade is large

a Prepare with starting engine, then carry out troubleshooting when
engine stops.
Possible causes 1. Fully extend blade tilt cylinder.
Defective seal of blade tilt
and standard 1 2. Disconnect hose on cylinder head side and block it.
control valve (spool) 3. Measure hydraulic drift of blade tip.
value in normal
state Blade tilt Hydraulic drift
Block blade tilt circuit 200 mm/15 min
Defective seal of blade tilt
2 Seal of blade tilt cylinder is assumed to be defective; directly check it.
cylinder
WE051E0400 21
H-19 Excessive hydraulic drift of blade angle

Trouble • Hydraulic drift of angling blade is large.

1. Fully extend blade angle cylinder.
2. Lower the blade to the ground.
Possible causes
Defective seal of blade 3. Disconnect hose on cylinder head side and block it.
and standard 1 4. Operate right or left angle cylinder and apply relief pressure to the bot-
angle cylinder
value in normal tom side of the disconnected cylinder.
state 5. Cylinder internal leakage
Blade angle Cylinder internal leakage
Block blade angle circuit Max. 8 cc/min
Defective seal of blade Blade angle control valve seal and centralized safety valve are assumed
2
angle control valve (spool) to be defective. Check them directly.
22 WE051E0400
H-20 Excessive hydraulic drift of ripper lift

Trouble • Hydraulic drift of lifting ripper is large
Related • Confirm whether the ripper is remodeled.

a Prepare with starting engine, then stop the engine for troubleshooting.
Defective seal of ripper lift
Possible causes 1. Pull out shank pin and raise the ripper to the maximum.
control valve (spool) or 2. Disconnect hose on cylinder head side and block it.
and standard 1
defective suction safety
value in normal Ripper lift Hydraulic drift
valve
state Block ripper lift circuit 50 mm/15 min
Defective seal of ripper lift
2 Seal of ripper lift cylinder is assumed to be defective; directly check it.
cylinder
WE051E0400 23
24 WE051E0400
WE051E0500
Bulldozer
1Shop Manual
D61EX-15
D61PX-15

Troubleshooting 2
Troubleshooting of engine system (S-mode) ................................................................... 4
Method of using matrix troubleshooting charts ............................................................. 4
S-1 Starting performance is poor (starting always takes time)l .................................. 8
S-2 Engine does not start........................................................................................... 9
S-3 Engine does not pick up smoothly (follow-up is poor) ....................................... 12
S-4 Engine stopped during operation....................................................................... 13
S-5 Engine does not rotate smoothly (hunting)........................................................ 14
S-6 Engine lacks output (or lacks power)................................................................. 15
S-7 Exhaust gas color is black (incomplete combustion)......................................... 16
S-8 Oil consumption is excessive (or exhaust gas color is blue) ............................. 17
S-9 Oil becomes contaminated quickly .................................................................... 18
S-10 Fuel consumption is excessive.......................................................................... 19
S-11 Oil is in coolant, coolant spurts back, or coolant level goes down..................... 20
S-12 Oil pressure monitor is turned on (drop in oil pressure) .................................... 21
S-13 Oil level rises (water or fuel in oil)...................................................................... 22
S-14 Water temperature becomes too high (overheating) .........................................23

S-15 Abnormal noise is made ....................................................................................24
S-16 Vibration is excessive ........................................................................................25
2 WE051E0500
2
Troubleshooting of engine system (S-mode) 2

Method of using matrix troubleshooting charts 1
This troubleshooting chart is divided into three sec-
tions: [Questions], [Check items], and [Troubleshoot-
ing]. 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
inspections to narrow down causes.
C in the chart on the right corre-
sponds to it.
The serviceman narrows down causes
from A obtained from users and C
inspected by himself.
[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].
4 WE051E0500
The basic method of using the troubleshooting chart is as follows. Items listed for [Questions] and [Check items]
that have a relationship with the Cause items are marked with Q, and of these, causes that have a high probability
are marked with w.
Check each of the [Questions] and [Check items] in turn, taking note of the Q and w marks in the chart for the hor-
izontal lines of symptoms applicable to the machine. The vertical column (Causes) that has the highest number of
applicable Q and w marks is the most probable cause, so start troubleshooting for that item to make final confir-
mation of the cause.
*1. For (Confirm recent repair history) in the [Questions] Section, ask the user, and mark the Cause column with
E to use as reference for locating the cause of the fairure. However, do not use this when marking calucula-
tions to narrow down causes.
*2. Use the E in the Cause column as reference for [Degree of use (Operated for long period)] in the [Questions]
section as reference. As a rule, do not use it when calculating the points for locating the cause, but it can be
included if necessary to determine the order for troubleshooting.
Cause
Defective fuel injection pump (fuel injection is excessive)

Clogged, seized fuel injection nozzle
Seized turbocharger, interference
Worn piston ring, cylinder liner
Defective fuel injection timing

Clogged air cleaner element
*1 Confirm recent repair history

*2 Degree of use of machine Operated for long period E E E
WE051E0500 5
q Example of troubleshooting when exhaust gas is black

Let us assume that [Clogged air cleaner] is taken to be the cause of black exhaust gas. Three symptoms have
a causal relationship with this problem: [Exhaust gas gradually became black], [Power gradually became
weaker], and [Dust indicator lamp is red].
6 WE051E0500
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.
WE051E0500 7
S-1 Starting performance is poor (starting always takes time)

a Battery charge level
Cause
Battery charge level Temperature 100% 90% 80% 75% 70%
20°C 1.28 1.26 1.24 1.23 1.22
0°C 1.29 1.27 1.25 1.24 1.23
Defective fuel injection pump (stuck rack, plunger)

-10°C 1.30 1.28 1.26 1.25 1.24
Defective boost compensator cancellation

q When the battery charge level in the above chart is
more than 70% in the specific gravity, the startability is
Defective contact of valve, valve seat
Clogged air breather hole in fuel tank

Leakage, clogging, air in fuel system
satisfactory.
Defective intake air heater system
Defective or deteriorated battery

q In the cold season, the battery charge level is required
Clogged feed pump gauze filter

Defective fuel injection nozzle

to be more than 75% in specific gravity.

Clogged fuel filter, strainer
General cause why exhaust smoke comes out but the
engine takes time to start
Defective feed pump

Defective alternator
Defective regulator
q Defective electric system
q Insufficient supply of fuel
q Insufficient air intake
q Improper selection of fuel
(When the temperature is 10°C or below, use
ASTM D975 No. 1 or No. 2.)
Confirm recent repair history
Degree of use of machine Operated for long period E E E E
Gradually became worse w w Q Q Q
Questions
Ease of starting
Starts when warm w w w
Preheating indicator lamp does not light up w
Engine oil must be added more frequently w
Replacement of filters has not been carried out according to Operation Manual w w w Q Q
Non-specified fuel is being used Q Q Q Q
Air cleaner clogging monitor lights up w
Charging warning lamp lights up w w
Starting motor cranks engine slowly w
When exhaust manifold is touched immediately after starting engine, tem-
w
perature of some cylinders is low
Engine does not pick up smoothly and combustion is irregular Q Q w
Blow-by gas is excessive w
Check items
Timing lock of fuel injection pump can not be adjust w

Fuel tank cap is stained with mud Q
When engine is cranked with starting motor
1) Spill flow is small when sleeve nut of fuel injection pipe is loosened. w
2) Spill flow is small when air bleeding plug of fuel filter is loosened. w w w w
Leakage of fuel from fuel piping Q w
There is hunting from engine (rotation is irregular) Q Q w Q
When compression pressure is measured, it is found to be low q q

When air cleaner is inspected directly, it is found to be clogged q
When fuel filter or strainer is inspected directly, it is found to be clogged q q
When fuel feed pump strainer is inspected directly, it is found to be clogged q
Intake air heater mount does not become warm q
Troubleshooting
Is voltage 20 - 26 V between alternator terminal B and termi- Yes q

nal E with engine at low idling? No q
When specific gravity of electrolyte or voltage of battery is measured, it is
q
found to be low
Engine speed does not change when operation of certain cylinders is
q
stopped in reduced cylinder mode
Control rack, when depressed, is felt heavy and does not return.
q
(Inspection after fuel injection pump is removed)
When fuel tank cap is checked directly, it is found to be clogged q
Replace
Replace
Replace
Replace
Replace
Replace
Replace
Replace
Replace
Correct
Correct
*Adjust
Clean
Clean
Clean
Clean
a Adjust on test stand. Remedy
8 WE051E0500
S-2 Engine does not start

(1) Engine does not crank
General causes why engine does not turn Cause

q Seizure inside the engine
Defective battery terminal connection

a Seizure inside the engine is checked in
Improper wiring of starting circuit

the paragraph [Engine stopped during
operation.]
Defective fuel cut solenoid

q Failure of hydraulic pump system

Defective starting motor
q Defective electric system
Defective battery relay

Defective safety relay
Defective ring gear
Questions
Degree of use of machine Operated for long period E E

Condition of horn when Horn does not sound w Q Q
starting switch is turned ON Horn volume is low w
Speed of rotation is low w
When starting switch is Makes grating noise w w
turned to START, Soon disengages again w
pinion moves out, but Makes rattling noise and does not
Q Q Q
turn
When starting switch is turned to START, pinion does not move
w Q Q
out
Check items
When starting switch is turned to ON, there is no actuation sound Q w

Battery terminal is loose w
Carry out troubleshooting "defective starting circuit"
When starting switch is turned to ON, linkage does not work w

When battery is checked, battery electrolyte is found to be low w
When specific gravity of electrolyte or voltage of battery is mea-

q
sured, it is found to be low
Turn the starting switch OFF, connect the cord, and carry out trou-
bleshooting at ON
1) When terminal B and terminal C of starting switch are con-
q
nected, engine starts
Troubleshooting
2) When terminal B and terminal C of starting motor are con-

q
3) When terminal B and terminal C of safety relay are con-
q
4) There is no voltage 24V between battery relay terminal B
q
and terminal E
When flywheel ring gear is inspected directly, tooth face is found
q
to be chipped
Even if fuel cut solenoid linkage is disconnected, the engine does
q q
not move
Replace
Replace
Replace
Replace
Replace
Replace
Replace
Replace
Remedy -
WE051E0500 9
(2) The engine rotates but exhaust smoke does not come out. (Fuel is not injected.)
General causes why engine turns but no Cause

exhaust smoke comes out
Broken fuel injection pump drive shaft, key

q Fuel cannot be supplied.
Fuel is supplied but a very few.

q
q Improper selection of fuel (especially in win-
Seized, broken feed pump piston
Clogged fuel feed pump strainer
Leakage, clogging of fuel piping

ter)
Defective fuel injection pump
Defective fuel cut solenoid

Insufficient fuel in tank

(stuck rack, plunger)
Improper fuel used

Questions
Degree of use of machine Operated for long period E E E

Exhaust smoke suddenly stops coming out (when starting again) w w w
Replacement of filters has not been carried out according to
w w
Operation Manual
Fuel tank is found to be empty w
There is leakage from fuel piping w
Fuel tank cap is stained with mud w
When starting switch is turned to ON, linkage does not work w
When fuel filter is removed, there is no fuel in filter w
1) No fuel comes out even when fuel filter air bleed plug is
Check items
w Q Q Q
loosened
2) Spill flow is small when sleeve nut of fuel injection pipe is
w w w
loosened
Rust and water are found when fuel tank is drained Q Q Q
Check fuel filter directly q

Control rack, when depressed, is felt heavy and does not return. q
Check feed pump directly q
Troubleshooting
When fuel filter or strainer is inspected directly, it is found to be

q q
clogged
When fuel feed pump strainer is inspected directly, it is found to
q
be clogged
When fuel tank cap is inspected directly, it is found to be clogged q
Even if fuel cut solenoid linkage is disconnected, the engine does
q
not move
Replace
Replace
Replace
Replace
Replace
Correct
Correct
Clean
Clean
Add
Remedy
a Applicable fuel standard

Selection of fuel according to
a When No. 3 diesel fuel is not available in winter,
ambient temperature No. 2 diesel fuel and kerosene may be mixed
Type of fuel
–22 –4 –14 32 50 68 86 104°F equally for use.
–30 –20 –10 0 10 20 30 140°C
ASTM D975 No.2

Diesel fuel
ASTM D975A
No.1
10 WE051E0500
(3) Exhaust smoke comes out but the engine does not start (Fuel is being injected)
General causes why exhaust smoke comes out Cause

but the engine does not start
Clogged fuel injection nozzle, defective spray

q Insufficient rotating force due to defective
Defective, broken dynamic valve system

electric system

Leakage, clogging, air in fuel system
Defective intake air heater system

Insufficient air intake

q

Improper selection of fuel

q

Worn piston ring, cylinder
(valve, rocker lever, etc.)
Improper fuel used

Suddenly failed to start w w
Questions
When engine is cranked, abnormal noise is heard from around cylinder

w
head
Non-specified fuel is being used Q Q
Replacement of filters has not been carried out according to Operation
w w w
Manual
Rust and water are found when fuel tank is drained w w
Dust indicator lamp is red w
Preheating indicator lamp does not light up w
Starting motor cranks engine slowly w
Fuel tank cap is stained with mud Q
Bring fuel dial to Full position, but it does not come to stopper. Q
Check items
1) Loosen sleeve nut of fuel injection pipe, but only a little fuel comes
w
out.
2) No fuel comes out even when fuel filter air bleed plug is loosened w w Q
w
No fuel comes out when fuel is drained w
Remove head cover and check directly q

When compression pressure is measured, it is found to be low q
When fuel filter or strainer is inspected directly, it is found to be clogged q q
When fuel feed pump strainer is inspected directly, it is found to be
q
Troubleshooting
clogged
When air cleaner element is inspected directly, it is found to be clogged q
Intake air heater mount does not become warm q
When specific gravity of electrolyte or voltage of battery is measured it is
q
found to be low
When fuel priming pump is operated, there is no response, or operation is
q
too heavy
q
Replace
Replace
Replace
Replace
Replace
Correct
Correct
Clean
Clean
Clean
Clean
Clean
Remedy
WE051E0500 11
S-3 Engine does not pick up smoothly (follow-up is poor)
General causes why engine does not pick up Cause

smoothly
Defective contact of valve and valve seat


Leakage, clogging, air in fuel piping

Stuck fuel injection pump plunger
q Improper fuel injecting state

q Improper selection of fuel
Clogged fuel injection nozzle,

Worn piston ring, cylinder
Improper valve clearance

defective spray
Degree of use of machine Operated for long period E E E E E
Questions

w w w
Operation Manual
Non-specified fuel is being used w w w w
Engine has suddenly come to pick up poorly. Q w Q Q
Noise of interference is heard from around turbocharger w
Blue under light load Q w
Color of exhaust gas
Black w w w Q
Abnormal noise is heard from around cylinder head w
Check items
High idling speed is normal, but speed suddenly drops when load
w w Q
is applied
There is hunting from engine (rotation is irregular) Q w Q Q
When exhaust manifold is touched immediately after starting
w Q
engine, temperature of some cylinders is low
When air cleaner is inspected directly, it is found to be clogged q

q
clogged
When fuel feed pump strainer is inspected directly, it is found to
q
be clogged
Troubleshooting
Engine speed does not change when operation of certain cylin-

q
ders is stopped in reduced cylinder mode
When turbocharger is rotated by hand, it is found to be heavy q
When valve clearance is inspected, it is found to be upset q
When fuel priming pump is operated, there is no response, or
q
operation is too heavy
Replace
Replace
Replace
Replace
Correct
Correct
Adjust
Clean
Clean
Clean
Clean
Remedy
12 WE051E0500
S-4 Engine stopped during operation
General causes why the engine stops during Cause

operation
Failure in power train mounted on machine

Broken fuel injection pump drive shaft, key
q Seizure inside the engine
Insufficient supply of fuel
Broken, seized piston, connecting rod

q
Broken, seized fuel feed pump piston

Overheat
Broken, seized crankshaft bearing

q
a When the engine stopped due to over-
Broken dynamic valve system

heat, check the engine in the paragraph
Clogged feed pump strainer
Clogged, leaking fuel piping

Broken auxiliary equipment

Broken, seized gear train
(pump, compressor, etc.)

"Overheat".

q Failure of power train

a Check the power train on the machine
side.

Abnormal noise was heard and
w w w w w w Q Q w
engine stopped suddenly
Questions
Condition when engine Engine overheated and stopped w Q Q

stopped Engine stopped slowly w Q Q
There was hunting and engine
w Q Q Q
stopped
Replacement of filters has not been carried out according to Opera-
w w
tion Manual
Non-specified fuel is being used Q Q Q Q
Fuel level warning lamp lights up w
When feed pump is operated, there is no response, or operation is
Q Q w
too heavy
Engine rotates, but stops when travel lever and work equipment con-
w
trol lever is operated
Does not turn at all w w
Check items
Turns in opposite direction w w

When it is attempted to turn
engine by hand Moves amount of backlash w w
Fuel injection pump drive shaft does
not turn
w
Troubleshooting of machine

Metal particles are found when oil is drained w w Q Q
Remove oil pan and check directly q q

When gear train is inspected, engine does not turn q
Troubleshooting
When auxiliary equipment (pump, etc.) is removed, engine turns q

q
clogged
q
clogged
Check the feed pump directly. q
Replace
Replace
Replace
Replace
Replace
Replace
Replace
Replace
Correct
Clean
Clean
Clean
Add
Remedy -
WE051E0500 13
S-5 Engine does not rotate smoothly (hunting)
General causes of irregular rotation Cause

q Airing into fuel system
Clogging, air in between feed pump and fuel injection nozzle

q Defective governor mechanism
q Defective governor motor mechanism
a Disconnect the governor spring, and the
engine does not hunt.
Clogging, air in between fuel tank and feed pump

In that case, check it in the E mode.

Defective control rack operation
Defective governor operation
Clogged feed pump strainer

Low idling speed is too low

Governor out of adjust

Occurs at a certain speed range w w w Q
Questions
Occurs at low idling Q w Q Q Q Q

Condition of hunting
Occurs even when speed is raised Q Q Q Q
Occurs on slopes w
w w
Operation Manual
Rust and water are found when fuel tank is drained Q Q
There is leakage from fuel piping w w
When fuel priming pump is operated w
1) There is no response, light, return is quick
Check items
2) There is no response, light, return is normal

Engine speed sometimes rises too far w w
Engine is sometimes difficult to stop w w
Seal on injection pump has come off w w
When governor lever is moved it is found to be stiff q q

When injection pump is tested, governor is found to be improperly
q
adjusted
Troubleshooting
When control rack is pushed, it is found to be heavy, or does not

q
return
When fuel tank cap is checked directly, it is found to be clogged q q
When fuel filter or strainer is checked directly, it is found to be
q
clogged
When fuel feed pump strainer is checked directly, it is found to be
q
clogged
Correct
Correct
Adjust
Adjust
Adjust
Adjust
Clean
Clean
Clean
Add
Remedy
14 WE051E0500
S-6 Engine lacks output (or lacks power)
General causes of insufficient output Cause

Straightness of governor spring, out of adjust

Defective boost compensator diaphragm


q Improper fuel
Seized fuel injection pump plunger

(when an unspecified fuel is used, the out-

Clogged fuel injection nozzle,

put decreases.)
Clogged, leaking fuel piping

Insufficient output due to overheat

q
a When the output decreases due to over-
heat, check the engine in the paragraph
"Overheat".
defective spray
Degree of use of machine Operated for long period E E E E E
Suddenly w w
Questions
Power was lost

Gradually Q Q Q Q Q Q
Replacement of filters has not been carried out according to Operation
Manual
w w w
Non-specified fuel is being used w w w w
Black w w
Blue under light load w
Noise of interference is heard from around turbocharger when engine is
run
w
Blow-by gas is excessive w Q
Engine pickup is poor and combustion is irregular w Q Q Q
High idling speed is normal, but speed suddenly drops when load is
applied
w w Q
Check items

w Q
There is hunting from engine (rotation is irregular) Q Q Q Q
Abnormal noise is heard from around cylinder head when engine is run w
High idling speed of engine is low Q w
When air cleaner element is inspected directly, it is found to be clogged q

When fuel filter or strainer is inspected directly, it is found to be clogged q
Troubleshooting
q
clogged
q
Bring fuel dial to Full position, but lever does not come to stopper. q
When fuel priming pump is operated, there is no response, or operation is
q
too heavy
Replace
Replace
Replace
Replace
Replace
Correct
Correct
Adjust
Adjust
Clean
Clean
Clean
Clean
Remedy
WE051E0500 15
S-7 Exhaust gas color is black (incomplete combustion)
General causes why exhaust gas color becomes Cause

black

Leakage of air between turbocharger


q Excessive injection of fuel


Crush or clogging of muffler

(fuel injection is excessive)

and intake manifold
became black suddenly. w Q w Q
w
Questions
Color of exhaust gas became black gradually. Q Q

Suddenly w Q Q Q
Power was lost
Gradually Q Q Q Q
Noise of interference is heard from around turbocharger when
w
engine is run
Engine pickup is poor and combustion is irregular Q w Q Q Q Q
w Q
Timing lock of fuel injection pump can not be adjusted w
Check items
Seal of fuel injection pump is removed. w

Abnormal noise is heard from around cylinder head when engine
w
is run
Exhaust sound is abnormal. Q Q w
Muffler is crushed. w
Leakage of air between turbocharger and cylinder head w

When air cleaner element is inspected directly, it is found to be
q
clogged
Troubleshooting

q
Use delivery method for inspection, and fuel injection timing is not
q
correct.
Test fuel injection pump, and fuel injection amount is not correct. q
Remove the muffler, and exhaust gas color becomes better. q
Replace
Replace
Replace
Replace
Replace
Replace
Correct
Adjust
Adjust
Adjust
Clean
Remedy
16 WE051E0500
S-8 Oil consumption is excessive (or exhaust gas color is blue)
a Do not keep idling the engine for more than Cause

20 minutes.
Turbocharger
(for both low idling and high idling)
Leakage from oil pan or cylinder head

General causes why oil consumption increases
Clogged breather or breather hose
Dust sucked in from intake system

Worn, broken valve (stem, guide)
Abnormal combustion of oil
Leakage from oil filter, oil cooler

q

q Oil leak to outside
Leakage from oil drain plug

q Wear of lubrication system
Worn seal at turbine end

Worn seal at blower end
Leakage from oil piping
Worn, broken rear seal

Broken piston ring
Broken oil cooler

E E E E
Questions
Degree of use of machine Operated for long period

Oil consumption suddenly increased w Q
Engine oil must be added more frequently w Q
Engine oil becomes contaminated quickly Q w Q
Exhaust smoke is blue under light load w w
Excessive w w Q Q
Amount of blow-by gas
None w
Outside of engine is dirty with oil w w w w
There is oil in engine cooling water w
Check items
When exhaust pipe is removed, inside is found to be dirty with oil w Q

Inside of turbocharger air supply pipe is dirty with oil w
Oil level in damper chamber rises w
Loose piping clamp in air intake system w

When breather element is inspected directly, it is found to be
q
clogged with oil stain
Troubleshooting
There is external leakage of oil from engine q q q q

Pressure-tightness test of oil cooler shows there is leakage q
Excessive play of turbocharger shaft q q
Check rear oil seal directly q
When intake manifold is removed, dust is found inside q
When intake manifold is removed, inside is found to be extremely
q
dirty with oil
Replace
Replace
Replace
Replace
Replace
Correct
Correct
Correct
Correct
Correct
Correct
Correct
Clean
Remedy
WE051E0500 17
S-9 Oil becomes contaminated quickly
General causes why oil becomes contaminated Cause

quickly
Defective seal at turbocharger turbine end

q Entry of exhaust gas due to internal wear
q Clogging of lubrication passage
Clogged turbocharger oil drain tube

q Improper fuel
Clogged breather, breather tube

q Improper oil
Exhaust smoke color is poor

q Operation under excessive load
Worn valve, valve guide

Clogged oil cooler
Clogged oil filter
Questions

Non-specified oil is being used Q
Black w
Excessive w Q Q Q
Amount of blow-by gas
None w
Check items
When oil filter is inspected, metal particles are found Q w Q

Check also in the paragraph of
[Exhaust gas color is black].
When exhaust pipe is removed, inside is found to be dirty with oil w
Engine oil temperature rises quickly w

When breather element is inspected, hose is kinking or clogged
q
Troubleshooting
with oil stain

When oil filter is inspected directly, it is found to be clogged q
When oil cooler is inspected directly, it is found to be clogged q
Turbocharger drain tube is clogged q
Excessive play of turbocharger shaft q
When oil filter safety valve is inspected directly, spring catching
and broken
Replace
Replace
Replace
Replace
Clean
Clean
Clean
Remedy -
18 WE051E0500
S-10 Fuel consumption is excessive
General causes why fuel consumption increases Cause

q Fuel leak

q Excessive injection of fuel
Defective oil seal inside feed pump (piston)

External leakage from fuel piping, fuel filter
Defective fuel injection nozzle spray
Leakage of fuel inside head cover

Defective fuel injection plunger
Fuel lever linkage out of adjust

Questions
More than for other machines of

w Q
Condition of fuel same model
consumption Gradually increased Q Q
Suddenly increased Q Q
Black w Q Q Q
Exhaust gas color
White Q
There is irregular combustion w
w Q
Check items
Match marks of fuel injection pump are not aligned. w

There is external leakage of fuel from engine w
Engine oil level rises and smells of diesel fuel Q w w
Low idling and high idling speed are high Q w
When flow of oil from fuel injection pump is measured, it is found

q
to be excessive
q
Troubleshooting

Use delivery method for inspection, and fuel injection timing is not
q
correct.
Remove feed pump and check directly q
Measure rotating speed, low idling and high idling speeds are
q
fast.
Replace
Replace
Correct
Correct
Correct
Adjust
Adjust
Adjust
Remedy
WE051E0500 19
S-11 Oil is in coolant, coolant spurts back, or coolant level goes down
General causes why oil enters in cooling water Cause

q Internal leak in lubrication system
Broken hydraulic cooler or power train oil cooler

q Internal leak in cooling system
Broken cylinder head, head gasket
Internal cracks in cylinder block

Broken oil cooler core, O-ring
Holes caused by pitting

Questions

Suddenly increased Q Q Q
Oil level
Gradually increased Q Q
Hard water is being used as cooling water Q Q
Engine oil level has risen, oil is cloudy white w Q Q
Excessive air bubbles inside radiator, spurts back w
Check
items
Hydraulic oil is cloudy white w

When hydraulic oil is drained, water is found w
Pressure-tightness test of oil cooler shows there is leakage q q

shooting
Trouble-
Pressure-tightness test of cylinder head shows there is leakage q

Replace
Replace
Replace
Replace
Replace
Remedy
20 WE051E0500
S-12 Oil pressure monitor is turned on (drop in oil pressure)
General causes why the oil pressure monitor is Cause

turned on
Clogged, broken oil pipe inside oil pan

q Leak from, clogging or wear of lubrication
Leaking, clogged hydraulic piping

system
Broken suction pipe brazing part

Clogged strainer inside oil pan
q Improper oil pressure control
Defective oil pressure sensor

q Improper oil (improper viscosity)
Defective oil level sensor

Defective regulator valve
q Oil deterioration due to overheat
Worn bearing, journal
Defective relief valve

Lack of oil in oil pan
Defective oil pump
Clogged oil filter
Water, fuel in oil

Questions

Replacement of filters has not been carried out according to Oper-
w
ation Manual
Non-specified oil is being used Q Q
Oil pressure warning lamp lights up w Q
Lights up at low idling w Q
Condition when oil pressure Lights up at low idling and high idling w w w w Q Q Q
lamp light up Lights up on slopes w
Sometimes lights up w w Q Q
There is crushing, external leakage from hydraulic piping w
Oil level warning lamp lights up w w
Check items
Oil level in oil pan is low w

Metal particles are found when oil is drained w
Metal particles are found inside oil filter element w Q
Oil is cloudy white or smells of diesel fuel w
When oil filter is inspected, it is found to be clogged q q

paragraph of [Oil level rises].
Troubleshooting in the
Remove oil pan and check directly q q q
Troubleshooting
Oil pump rotation is heavy, there is play q

Deterioration, damage of valve, spring in oil pump relief valve q q
When oil level sensor is replaced, oil pressure warning lamp goes
q
out
When oil pressure is measured, it is within the standard value q
Replace
Replace
Replace
Correct
Correct
Adjust
Adjust
Clean
Clean
Clean
Clean
Add
Remedy -
a Criteria for use of engine oil

Selection of oil according to
Type of
ambient temperature
oil
–30 –20 –10 0 10 20 30 140°C
SAE30CD
Engine SAE10WCD
oil SAE10W-30CD
SAE15W-40CD
WE051E0500 21
S-13 Oil level rises (water or fuel in oil)
a When oil is mixed in coolant, check in the Cause

paragraph "Oil enters in cooling water." as
Defective auxiliary equipment seal (pump)

well.
Defective part inside fuel injection pump

General causes why oil increases

Entry of water (clouded)
Leakage of fuel inside head cover

q
Entry of fuel (diluted, smell of diesel fuel)
Defective nozzle holder sleeve

q
Broken oil cooler core, O-ring
Worn, damaged rear oil seal

Entry from other equipment
Cracks inside cylinder block

q
Defective thermostat
Hole made by pitting
Questions

There is oil in engine cooling water w Q Q Q Q
Fuel must be added more frequently w w
Exhaust smoke is white w Q
When engine is started, drops of water come from muffler w
When radiator cap is left open and engine is run at idling, an
w Q
abnormal number of bubbles appear, or water spurts back
Check items
Oil level goes down in damper chamber w

Oil level goes down in hydraulic tank w
Oil smells of diesel fuel w w
Water temperature is low w
Pressure-tightness test of oil cooler shows there is leakage q

Pressure-tightness test of cylinder head shows there is leakage q
Troubleshooting

Check rear oil seal directly q
When auxiliary equipment (pump) is removed, seal is broken q
Remove fuel injection pump and check directly q
Improper contact is detected in thermostat seal valve. q
Replace
Replace
Replace
Replace
Replace
Replace
Replace
Correct
Correct
Correct
Remedy
22 WE051E0500
S-14 Water temperature becomes too high (overheating)
General causes why water temperature rises Cause

too high
Raise in torque converter oil temperature

q Lack of cooling air (deformation, damage of
fan)
Defective water temperature gauge

Defective actuation of thermostat
Fan belt slipping, worn fan pulley

q Drop in heat dissipation efficiency
Clogged, crushed radiator core
Defective coolant temperature

q Defective cooling circulation system
q Rise of oil temperature in hydraulic pump
Clogged, broken oil cooler

Defective pressure valve
system
Clogged radiator core

a Check on the machine side.
Hole made by pitting

Broken water pump
Questions
Suddenly overheated w Q Q
Condition of overheating
Always tends to overheat w w Q Q
Rises quickly w Q
Water temperature gauge
Does not go down from red range w
Radiator water level warning lamp lights up w
Fan belt whines under sudden acceleration w
Cloudy white oil is floating on cooling water w
Cooling water flows out from radiator overflow hose w
Excessive air bubbles inside radiator, water spurts back w
Engine oil level has risen, oil is cloudy white Q w
There is play when fan pulley is rotated w
Radiator shroud, inside of under guard are clogged with dirt or
w w
mud
Check items
When light bulb is held behind radiator, no light passes through w

Water is leaking because of cracks in hose or loose clamps w
When belt tension is inspected, it is found to be loose w
Power train oil temperature enters red range faster than engine
w
water temperature
Temperature difference between top and bottom radiator tanks is

q
excessive
Temperature difference between top and bottom radiator tanks is
Troubleshooting of machine
q
small
Troubleshooting
When radiator is inspected, radiator core is clogged q

When function test is carried out on thermostat, it does not open
q
even at cracking temperature
When water temperature is measured, it is found to be normal q
When oil cooler is inspected directly, it is found to be clogged q
When function test is carried out on radiator cap, cracking pres-
q
sure is found to be low
Remove oil pan and check directly q
Replace
Replace
Replace
Replace
Replace
Replace
Replace
Correct
Correct
Correct
Add
Remedy -
WE051E0500 23
S-15 Abnormal noise is made
a Judge if the noise is an external or internal Cause

one.
Defective fuel injection pump (stuck rack, plunger)

Defective fuel injection pump (excessive injection)
General causes why abnormal noise is made
q Abnormal noise caused by defective parts
Excessive wear of piston ring, cylinder liner

q Abnormal combustion
q Air suction from air intake system
Leakage of air between turbocharger

Deformed fan, fan belt interference

(dividing board out of position)

Broken dynamic valve system
Improper gear train backlash


Missing, seized bushing
Defective inside muffler

and intake manifold
Degree of use of machine Operated for long period E
Questions
Condition of abnormal Gradually occurred Q Q

noise Suddenly occurred Q Q Q
Black w Q Q
Metal particles are found in oil drained from oil filter w w
Noise of interference is heard from around turbocharger when
w
engine is run
Engine pickup is poor and combustion is abnormal w
w Q
Check items

Abnormal noise is loud when accelerating Q Q Q Q Q Q
Abnormal noise is heard from around cylinder head when engine
w w
is run
Leakage of air between turbocharger and cylinder head w
Vibrating noise is heard from around muffler when engine is run w

Remove timing gear cover and check directly. q
Troubleshooting

q
Fuel injection pump test shows fuel injection amount is not correct q
Fan is deformed and belt tension is loose q
Remove cylinder head cover and check directly q
When muffler is removed, abnormal noise disappears q
Replace
Replace
Replace
Replace
Replace
Replace
Replace
Replace
Replace
Correct
Correct
Correct
Remedy
24 WE051E0500
S-16 Vibration is excessive
a If there is abnormal noise together with the Cause

vibration, carry out troubleshooting also for
Defective dynamic valve system (valve, rocker lever, etc.)

"Abnormal noise is made."
General causes why vibrations occur
q Defective parts (abnormal wear, breakage,
etc.)
Misalignment between engine and power train

Loose engine mounting bolts, broken cushion
q Improper alignment
q Abnormal combustion
Worn main bearing, connecting rod
Improper gear train backlash

Broken part inside damper
Worn cam bushing
Questions

Suddenly increased Q Q
Condition of vibration
Gradually increased Q Q Q
Metal particles are found in oil drained from oil filter w w
Metal particles are found when oil pan is drained w w
Oil pressure is low at low idling Q Q
Vibration occurs at mid-range speed Q Q
Check items
Vibration follows engine speed Q Q Q Q

Exhaust smoke is black w Q
Remove oil pan and check directly q

Remove side cover and check directly q
Check loose engine mounting bolts or broken cushion directly q
Troubleshooting
Check inside damper directly q

When face runout and radial runout are inspected, they are found
q
to be incorrect
Remove front cover and check directly q
Remove fuel head cover and check directly q
Fuel injection pump test shows fuel injection amount is not cor-
q
rect.
Replace
Replace
Replace
Replace
Replace
Correct
Correct
Adjust
Remedy
WE051E0500 25
26 WE051E0500
WE051F0100
Bulldozer
1Shop Manual
D61EX-15
D61PX-15

Disassembly and assembly1

Preface............................................................................................................................. 2
How to read this manual ............................................................................................... 2
Standard tightening torque table ................................................................................... 4
Precautions when performing operation ....................................................................... 7
List of coatings............................................................................................................ 12
Special tool list ............................................................................................................ 14
Sketches of special tools ............................................................................................ 18
Disassembly and assembly Shop Manual
Preface 1 Installation
q Except where otherwise instructed, install parts is
How to read this manual 1 the reverse order to removal.
q Instructions and precautions for installing parts are
1. Removal and Installation of assemblies shown with [*1] mark in the Installation Section,
Special tools identifying which step the instructions are intended
q Special tools that are deemed necessary for for.
removal or installation of parts are listed. q Marks shown in the Installation Section stand for
List of the special tools contains the following the following.
k
q
kind of information. : This mark indicates safety-related precautions
1) Necessity which must be followed when doing the work.
t: Special tools which cannot be substi- a : This mark gives guidance or precautions when
tuted, should always be used. doing the procedure.
q: Special tools which are very useful if 2 : This mark stands for a specific coating agent
available, can be substituted with com- to be used.
mercially available tools. 3 : This mark indicates the specified torque.
2) New/Remodel 5 : This mark indicates an amount of oil or water
N: Tools with new part numbers, newly to be added.
developed for this model.
R: Tools with upgraded part numbers, Sketches of special tools
remodeled from already available tools q Various special tools are illustrated for the conve-
for other models. nience of local manufacture.
Blank: Tools already available for other mod-
els, used without any modification.
3) Circle mark Q in sketch column:
A circle mark means that a sketch of the spe-
c i al t oo l is p r e s en t ed i n t he s ec t i on o f
Sketches for Special Tools.
a 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. 79xT--- xxx --- xxxx.
Removal
q The Removal Section contains procedures, pre-
cautions and the amount of oil or water to be
drained.
q Various symbols used in the Removal Section are
explained and listed below.
k : This mark indicates safety-related precautions
which must be followed when doing the work.
a : This mark gives guidance or precautions when
doing the procedure.
[*1] : This mark shows that there are instructions or
precautions for installing parts.
6 : This mark shows oil or water to be drained
4 : This mark shows the weight of a part or a
device.
2 WE051F0100
Shop Manual Disassembly and assembly
2. Disassembly and assembly of assemblies Assembly

Special tools q Section titled Assembly contain procedures, pre-
q Special tools which are deemed necessary for cautions and the know-how for the work, as well
disassembly and assembly of parts are listed. as the amount of oil or water to be added.
q List of the special tools contains the following q Various symbols used in Assembly Section are
kind of information. explained and listed below.
1) Necessity k : This mark indicates safety-related precautions
t: Special tools which cannot be substi- which must be followed when doing the work.
tuted, should always be used. a : This mark gives guidance or precautions when
q: Special tools which are very useful if doing the procedure.
available, can be substituted with com- 2 : This mark stands for a specific coating agent
mercially available tools. to be used.
2) New/Remodel 3 : This mark indicates the specified torque.
N: Tools with new part numbers, newly 5 : This mark indicates an amount of oil or water
developed for this model. to be added.
R: Tools with upgraded part numbers,
remodeled from already available tools Sketches of special tools
for other models. q Various special tools are illustrated for the conve-
Blank: Tools already available for other mod- nience of local manufacture.
els, used without any modification.
3) Circle mark Q in sketch column:
A circle mark means that a sketch of the spe-
c i a l t o ol i s pr e s e nt e d i n t h e s e c ti o n o f
Sketches for Special Tools.
a 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. 79xT--- xxx --- xxxx.
Disassembly
q The Disassembly Section contains procedures,
precautions and the amount of oil or water to be
drained.
q Various symbols used in the Disassembly Section
are explained and listed below.
k : This mark indicates safety-related precautions
which must be followed when doing the work.
a : This mark gives guidance or precautions when
doing the procedure.
6 : This mark shows oil or water to be drained
WE051F0100 3
Standard tightening torque table 1

1. General tightening torque table
a In the case of metric nuts and bolts for which there is no special instruction, tighten to the torque given in the
table below. (when using torque wrench)
a The following table applies to the bolts shown at
the right.
Width
Thread
across Tightening torque
diameter
flats
mm mm Nm kgm
6 10 11.8-14.7 1.2-1.5
8 13 27-34 2.8-3.5
10 17 59-74 6-7.5
12 19 98-123 10-12.5
14 22 153-190 15.5-19.5
16 24 235-285 23.5-29.5
18 27 320-400 33-41
20 30 455-565 46.5-58
22 32 610-765 62.5-78
24 36 785-980 80-100
27 41 1,150-1,440 118-147
30 46 1,520-1,910 155-195
33 50 1,960-2,450 200-250
36 55 2,450-3,040 250-310
39 60 2,890-3,630 295-370
a The following table applies to the bolts shown at

the right.
Width
Thread
diameter
flats
mm mm Nm kgm
6 10 5.9-9.8 0.6-1.0
8 13 13.7-23.5 1.4-2.4
10 14 34.3-46.1 3.5-4.7
12 27 74.5-90.2 7.6-9.2
2. Table of tightening torque for split flange bolts

a In the case of split flange bolts for which there
is no special instruction, tighten to the torque
given in the table below.
Width
Thread
diameter
flats
mm mm Nm kgm
10 14 59-74 6-7.5
12 17 98-123 10-12.5
16 22 235-285 23.5-29.5
4 WE051F0100
3. Table of tightening torque for pipe joints for O-ring bosses

a In the case of O-ring boss pipe joints for which there is no special instruction, tighten to the torque given in the
table below.
Thread diameter Width across flats Tightening torque Nm{kgm}

Nominal number
mm mm Range Target
02 14 35-63{3.5-6.5} 44{4.5}
03, 04 20 Varies depending 84-132{8.5-13.5} 103{10.5}
05, 06 24 upon the type of 128-186{13.0-19.0} 157{16.0}
10, 12 33 pipe joint used. 363-480{37.0-49.0} 422{43.0}
14 42 746-1,010{76.0-103} 883{90.0}
4. Table of tightening torque for O-ring boss plugs

a In the case of O-ring boss plugs for which there in no special instruction, tighten to the torque given in the table
below.
Thread diameter Width across flats Tightening torque Nm{kgm}

Nominal number
mm mm Range Target
08 8 14 5.88-8.82{0.6-0.9} 7.35{0.75}
10 10 17 9.8-12.74{1.0-1.3} 11.27{1.15}
12 12 19 14.7-19.6{1.5-2.0} 17.64{1.8}
14 14 22 19.6-24.5{2.0-2.5} 22.54{2.3}
16 16 24 24.5-34.3{2.5-3.5} 29.4{3.0}
18 18 27 34.3-44.1{3.5-4.5} 39.2{4.0}
20 20 30 44.1-53.9{4.5-5.5} 49.0{5.0}
24 24 32 58.8-78.4{6.0-8.0} 68.6{7.0}
30 30 32 93.1-122.5{9.5-12.5} 107.8{11.0}
33 33 - 107.8-147.0{11.0-15.0} 127.4{13.0}
36 36 36 127.4-176.4{13.0-18.0} 151.9{15.5}
42 42 - 181.3-240.1{18.5-24.5} 210.7{21.5}
52 52 - 274.4-367.5{28.0-37.5} 323.4{33.0}
5. Table of tightening torque for 102- and 114-Series engines (bolts and nuts)
a In the case of metric nuts and bolts, in the 102- and 114-Series engines, for which there is no special instruc-
tion, tighten to the torque given in the table below.

mm Nm kgm
6 10±2 1.02±0.20
8 24±4 2.45±0.41
10 43±6 4.38±0.61
12 77±12 7.85±1.22
6. Table of tightening torque for 102- and 114-Series engines (eye joints)
a In the case of metric threaded eye joints, in the 102- and 114-Series engines, for which there is no special
instruction, tighten to the torque given in the table below.

mm Nm kgm
6 8±2 0.81±0.20
8 10±2 1.02±0.20
10 12±2 1.22±0.20
12 24±4 2.45±0.41
14 36±5 3.67±0.51
WE051F0100 5
7. Table of tightening torque for 102- and 114-Series engines (tapered screws)
a In the case of inch threaded tapered screws, in the 102- and 114-Series engines, for which there is no special
instruction, tighten to the torque given in the table below.

inch Nm kgm
1/16 3±1 0.31±0.10
1/8 8±2 0.81±0.20
1/4 12±2 1.22±0.20
3/8 15±2 1.53±0.20
1/2 24±4 2.45±0.41
3/4 36±5 3.67±0.51
1 60±9 6.12±0.92
8. Table of tightening torque for hoses (taper seals and face seals)
a In the case of hoses (taper seals and face seals) for which there is no special instruction, tighten to the torque
given in the table below.
a Apply torque to them with threads wetted with engine oil.
Taper seal
Tightening torque (Nm {kgm}) Face seal type
type
Nominal size Width across
Thread size Nominal
of hose flats thread size Root diameter
Range Target - Threads per inch, (mm)
(mm) (Reference)
Thread series
9
02 19 34 - 63 {3.5 - 6.5} 44 {4.5} 14 — - 18UNF 14.3
16
11
22 54 - 93 {5.5 - 9.5} 74 {4.5} – — - 16UN 17.5
03 16
24 59 - 98 {6.0 - 10.0} 78 {8.0} 18 – –
13
04 27 84 - 132 {8.5 - 13.5} 103 {10.5} 22 — - 16UN 20.7
16
05 32 128 - 186 {13.0 - 19.0} 157 {16.0} 24 1 - 14UNS 25.4
3
06 36 177 - 245 {18.0 - 25.0} 216 {22.0} 30 1 — - 12UNF 30.3
16
(10) 41 177 - 245 {18.0 - 25.0} 216 {22.0} 33 – –
(12) 46 197 - 294 {20.0 - 30.0} 245 {25.0} 36 – –
(14) 55 246 - 343 {25.0 - 35.0} 294 {30.0} 42 – –
6 WE051F0100
Precautions when performing operation 1

Be sure to follow the general precautions given below when performing removal or installation (disassembly or
assembly) of units.
1. Precautions when performing removal work
q If the engine coolant water contains antifreeze, dispose of it properly.
q After disconnecting hoses or tubes, cover them or install blind plugs to prevent dirt or dust from entering.
q When draining oil, prepare a container of adequate size to catch the oil.
q Confirm the match marks showing the installation position, and make match marks in the necessary places
before removal to prevent any mistake during assembly.
q To avoid loosening any wire contacts, do not pull on the wires. In order to prevent excessive force to the wir-
ing, hold onto the connectors when disconnecting them.
q Fasten tags to wires and hoses to identify them and show their installation position. This helps prevent any
mistakes when re-installing.
q Check the quantity and thickness of the shims and keep in a safe place.
q When raising or lifting components, be sure to use proper lifting equipment of ample strength and safety.
q When using forcing screws to remove any components, tighten the forcing screws uniformly in turn.
q Before removing any unit, clean the surrounding area and install a cover to prevent any dust or dirt from enter-
ing after removal.
a Precautions when handling piping during disassembly
Install the following blind plugs into the piping after disconnecting it during disassembly operations.
1) Face seal type hoses and tubes
Nominal number Plug (nut end) Nut (elbow end)

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
2) Split flange type hoses and tubes
Nominal number Flange (hose end) Sleeve head (tube end) Split flange
04 07379 - 00400 07378 - 10400 07371 - 30400
05 07379 - 00500 07378 - 10500 07371 - 30500
3) If the part is not under hydraulic pressure, the following corks can be used:
Dimensions (mm)
Nominal number Part No.
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
24 07049-02430 24 20 30
27 07049-02734 22.5 22.5 34
WE051F0100 7
2. Precautions when carrying out installation work

q Tighten all bolts and nuts (sleeve nuts) to the specified (KES) torque.
q Install the hoses without twisting or interference.
q Replace all gaskets, O-rings, cotter pins, and lock plates with new parts.
q Bend the cotter pin or lock plate securely.
q When coating with adhesive, clean the part and remove all oil and grease, then coat the threaded portion with
two or three drops of adhesive.
q When coating with gasket sealant, clean the surface and remove all oil and grease, check that there is no dirt
or damage, then coat uniformly with gasket sealant.
q Clean all parts, and correct any damage, dents, burrs, or rust.
q Coat rotating parts and sliding parts with engine oil.
q When press-fitting parts, coat the surface with anti-friction compound (LM-P).
q After installing snap rings, check that the snap ring is installed securely in the ring groove.
q When connecting wiring connectors, clean the connector to remove all oil dirt, or water, then connect it
securely.
q When using eyebolts, check that there is no deformation or deterioration. Screw them in fully, and align the
direction of the hook.
q When tightening split flanges, tighten uniformly in turn to prevent excessive tightening on one side.
a When operating the hydraulic cylinders for the first time after reassembling the cylinders, pumps and other
hydraulic equipment removed for repair, bleed the air as follows:
1) Start the engine and run it at low idle.
2) Operate the work equipment control lever to operate the hydraulic cylinders, 4 - 5 times, stopping the cyl-
inders 100 mm from the end of their stroke.
3) Next, operate the hydraulic cylinder 3 - 4 times to the end of its stroke.
a When using the machine for the first time after repair or long storage, follow the same procedure.
8 WE051F0100
3. Disconnecting and connecting push-pull coupler

k Before doing the following procedures, release the
residual pressure from the fuel system, referring to
"Releasing residual pressure from hydraulic tank"
in Testing and adjusting.
k When the residual pressure is relieved from the
hydraulic tank, some amount of hydraulic oil drips
when disconnecting the hose, so put an oil pan to
catch it.
Type 1
1) Disconnecting coupler
1] Release the residual pressure from the
hydraulic tank. For details, see Testing
and adjusting, Releasing residual pres-
sure from hydraulic tank.
2] Holding pipe sleeve (1), push hose joint
(2) onto adapter (3). (See Fig. 1.)
a The hose joint can be inserted as far
as approximately 3.5 mm.
a Take care not to hold rubber cap (4).
3] Further push rubber cap (4) onto adapter
(3) until you hear a click. (See Fig. 2.)
4] Holding hose sleeve (1) or hose body (5),
disconnect the joint from the adapter.
(See Fig. 3.)
a Use an oil pan to catch a small
amount of oil that drips out when dis-
connecting the hose.
2) Connecting coupler
1] Holding hose sleeve (1) or hose body (5),
push the hose onto adapter (3). (See Fig.
4.)
a Take care not to hold rubber cap (4).
2] Pull the hose to check that it is tightly con-
nected. (See Fig. 5.)
a When the hose is pulled, the rubber
cap is moved approximately 3.5 mm
towards the hose.
WE051F0100 9
Type 2 Type 3
1) Hold the mouthpiece of the tightening portion 1) Hold the mouthpiece of the tightening portion
the hexagonal portion at the male end. the hexagonal portion at the male end.
2) Hold in the condition in Step 1), and turn 2) Hold in the condition in Step 1), and push
lever (4) to the right (clockwise). until cover (3) contacts contact surface a of
the hexagonal portion at the male end.
Disassembly
3) Hold in the condition in Steps 1) and 2), and 3) Hold in the condition in Steps 1) and 2), and
pull out whole body (2) to disconnect it. pull out whole body (2) to disconnect it.
• Hold the mouthpiece of the tightening portion • Hold the mouthpiece of the tightening portion
the hexagonal portion at the male end to con- the hexagonal portion at the male end to con-
nect it. nect it.
Connection
10 WE051F0100
4. Precautions when completing the operations

q If the engine coolant water has been drained, tighten the drain valve, and add coolant water to the specified
level. Run the engine to circulate the coolant water through the system. Then check the coolant water level
again.
q If the hydraulic equipment has been removed and installed again, add engine oil to the specified level. Run
the engine to circulate the oil through the system. Then check the oil level again.
q If the hydraulic equipment was removed, bleed air from each part referring to the relevant section in Testing
and adjusting.
q Add the specified amount of grease (molybdenum disulphide grease) to the work equipment related parts.
WE051F0100 11
List of coatings 1
a The coating, such as adhesives, gasket sealants, and greases, that is used during disassembly and assembly
is listed below.
a For any coating agent that is not included on the list, use an equivalent to the one described in the manual.
Classification
Komatsu Code Part No. Capacity Container Main Features and Intended Use
• Used to prevent rubber gaskets, rubber cushion

LT-1A 790-129-9030 150 g Tube
and cork stoppers from loosening.
• Used to provide instant, strong bonds to resins
20 g Plastic (excluding polyethylene, polypropylene, PTFE,
LT-1B 790-129-9050
(two pack) container and vinyl chloride), rubbers, metals and non-
metals.
• Heat and chemical resistant
Plastic
LT-2 09940-00030 50 g • Used to prevent bolts, plugs, and the like from
container
loosening or to seal joints.
Adhesive:
790-129-9060
1 kg • Used to bond metals, glasses, plastics, etc. or
LT-3 Adhesive & Tin
Hardener: to seal joints.
Liquid adhesive
hardener
500 g
Plastic
LT-4 790-129-9040 250 g • Used to seal plugs for drilled holes, etc.
container
Holts MH705 790-129-9120 75 g Tube • Heat resistant sealant for repairing engines
• Instant adhesive
Plastic • Set up time is 5 seconds to 3 minutes.
ThreeBond 1735 790-129-9140 50 g
container • Used primarily for bonding metals, rubbers,
plastics, and woods.
• Instant adhesive
• Fast curing type (reaching full strength in 30
Plastic
Aron Alpha201 790-129-9130 2g minutes)
container
• Used primarily for bonding metals, rubbers, and
plastics.
• Heat and chemical resistant
Plastic
Loc-Tite 648-50 79A-129-9110 50 cc • Used to bond fittings performed at high temper-
container
ature.
• Used to bond gaskets and packings in power
LT-1 790-129-9010 200 g Tube
train cases, etc. or to seal joints.
• Used to bond bolts, screws and other fasteners,
Plastic pipe joints, and flanges.
LG-5 790-129-9080 1 kg
container • Used to seal tapered plugs, elbows, nipples,
etc. for hydraulic pipes.
Gasket sealant
• Heat and cold resistant silicon adhesive

• Used to seal flanged surfaces and bolted and
LT-6 790-129-9020 200 g Tube
screwed connections.
• Used to seal oil pans, final drive cases, etc.
• Fast curing silicon adhesive
LT-7 790-129-9070 1 kg Tube • Used to seal flywheel housings, intake mani-
folds, oil pans, thermostat housings, etc.
ThreeBond 1211 790-129-9090 100 g Tube • Gasket sealant for repairing engines
• Heat, vibration, and impact resistant silicon
ThreeBond 1207B 419-15-18131 100 g Tube adhesive
• Used to seal transfer cases.
12 WE051F0100
Classification
Komatsu Code Part No. Capacity Container Main Features and Intended Use
molybdenum disulfide
Lubricant containing
• Lubricant for sliding surfaces to prevent creak-

LM-G 09940-00051 60 g Tin
ing.
• Used to prevent seizing or galling of press- or

LM-P 09940-00040 200 g Tube shrink-fit joints or screws.
• Lubricant for linkages, bearings, etc.
SYG2-400LI
Available in Available in
SYG2-350LI
various various
G2-LI SYG2-400LI-A • Multi-purpose type grease
types of types of
SYG2-160LI
containers containers
SYGA-160CNLI
SYG2-400CA
Available in Available in
SYG2-350CA
various various • Used for normal temperature, low-load bear-
G2-CA SYG2-400CA-A
types of types of ings that are subjected to water and heat.
SYG2-160CA
containers containers
SYGA-160CNCA
Grease containing SYG2-400M 400 g x 10 Bellows-style
Grease
molybdenum disul- SYG2-400M-A 400 g x 20 grease • Used where increased loads are encountered.
fide LM-G (G2-M) SYGA-16CNM 16 kg cartridge
Hyper White
SYG2-400T-A • More resistant to seizure and heat than grease
Grease Bellows-style
SYG2-16CNT 400 g containing molybdenum disulfide
G2-T G0-T(*) grease
SYG0-400T-A (*) 16 kg • White grease makes dirt and stains on vehicle
*: For cold weather cartridge
SYG0-16CNT (*) bodies less noticeable.
regions
Bio Grease G2-B,
SYG2-400B
G2-BT (*) Bellows-style • Degraded by natural bacteria within a short
SYGA-16CNB 400 g
*: Heat resistant grease period time, minimizing effects on microorgan-
SYG2-400BT (*) 16 kg
grease for high cartridge isms, animals and plants.
SYGA-16CNBT (*)
load applications
Sunstar Primer 580
Glass • Used as primer on cabs.
Super for Coated 20 ml
Primer
container (shelf life: 4 months)

Surfaces
Sunstar Primer 580 Glass • Used as primer on glasses.
20 ml
For bonding cab glasses
Super for Glass container (shelf life: 4 months)

417-926-3910
• "S" is used to bond glasses at high ambi-
Sunstar Penguin ent temperatures (e.g., April-October);
Plastic
Sealant 580 Super 320 ml "W" is used to bond glasses at low ambi-
Adhesive
container
S or W ent temperatures (e.g., October-April).
(shelf life: 4 months)
Sikaflex 256HV Plastic • Used to bond glasses.
20Y-54-39850 310 ml
(Sika Ltd. Japan) container (shelf life: 6 months)
Sunstar Penguin Plastic • Used to seal joints between glasses.
417-926-3920 320 ml
Caulking
Sealant 2505 container (shelf life: 4 months)

Silicon Sealant Plastic • Used to seal windshields.
20Y-54-55130 333 ml
(Sekisui Chemical) container (shelf life: 6 months)
WE051F0100 13
Special tool list 1

a Tools with part number 79QT-QQQ-QQQQ cannot be supplied (they are items to be locally manufactured).
a Necessity : t ............Cannot be substituted, should always be installed (used).
: q ............Extremely useful if available, can be substituted with commercially available part.
a New/Remodel : N ............Tools with new part numbers, newly developed for this model.
: R ............Tools with upgraded part numbers, remodeled from items already available for other
models.
: Blank......Tools already available for other models, used without any modification.
a Tools marked Q in the Sketch column are tools introduced in the sketches of the special tools (See Sketches
of special tools).
New/Remodel
Necessity
Sketch
Q'ty
Component Symbol Part No. Part name Nature of work, remarks
Removal and Installation of 1 795-799-1131 Gear t 1 Removal of fuel injection

fuel injection pump assembly 2 795-799-1390 Remover t 1 pump
3 795-799-1170 Puller q 1 Removal of nozzle holder
Removal and installation of A
cylinder head assembly Tightening of cylinder head
4 790-331-1110 Wrench t 1
bolt
Removal of engine seal 5 795-931-1100 Seal puller q 1 Removal of engine seal
Operation check of clutch
of TORQFLOW transmis- D 1 799-301-1600 Oil leak tester t 1
piston
sion assembly
Removal and installation of
1 709-302-1500 Wrench kit q 1
bevel pinion nut
2 796-730-2140 Wrench q 1
E Commercially Adjustment of preload on
of HSS assembly
available bevel gear shaft and bevel
3 Torque wrench q 1 gear assembly
products or
795-630-1810
796-730-2300 Wrench t 1 Measurement of rotation
1
795-630-1803 Torque wrench t 1 torque of No. 1 pinion
Disassembly and assembly 2 791T-427-1330 Guide t 1 Q Positioning of No. 1 gear
J
of final drive assembly 3 791-545-1510 Installer t 1 Installation of floating seal
Press fitting of bearing into
4 791T-427-1280 Push tool t 1 Q
output shaft
Disassembly and assembly 1 791-515-1520 Installer t 1 Press fitting of floating seal
of idler assembly 2 791-601-1000 Oil pump q 1 Oil charging
L 3 791-515-1520 Installer t 1
of track roller assembly
Press fitting of floating seal
4 796-230-1110 Installer t 1
of carrier roller assembly
791-685-8006 Compressor (B) t 1
791-635-3160 Extension t 1
Disassembly and assembly 790-201-2770 Spacer t 1 Disassembly and assembly
M
of recoil spring assembly 791-101-1102 Pump t 1 of recoil spring
Cylinder
790-101-1600 t 1
(686kN{70ton})
791-450-1100 Remover t 1
Removal and installation of Puller Removal of equalizer center
N 790-101-2102 t 1
equalizer bar assembly (294kN{30 tons}) pin
790-101-1102 Pump t 1
14 WE051F0100
New/Remodel
Necessity
Sketch
Q'ty
791T-450-1130 Push tool t 1 Q

791T-450-1140 Plate t 1 Q
791-181-1010 Adapter t 1
791-520-4140 Screw t 1
Removal and installation of 791-201-2750 Spacer t 1 Press fitting of pivot shaft
P
pivot shaft assembly 790-101-2540 Washer t 1 ring
791-112-1180 Nut t 1
790-101-2102 Puller t 1
Pump
790-101-1102 t 1
(294kN{30 tons})
1 791-646-7531 Remover t 1 Removal of pin plug
Cleaning of lubricated track
2 791-660-7460 Pin brush t 1
Whole disassembly and pin
whole assembly of track 3 791-432-1110 Push tool for plug t 1 Driving of pin plug (large)
shoe assembly 4 791-932-1110 Push tool for plug t 1 Driving of pin plug (small)
Check of track link for air-
5 790-701-3000 Seal checker t 1
tightness and oil filling
790-101-1102 Pump t 1
6 Cylinder Removal of pin
790-101-1300 t 1
(980kN{100ton})
790-101-1102 Pump t 1
7 Disconnection of links
790-105-2300 Jack (294kN{30ton}) t 1
791-635-3110 Frame t 1
791-635-3160 Extension t 1
791-635-3170 Nut t 4
8 791-635-3180 Screw t 2 Removal of pin
791-635-3190 Screw t 1
791-645-3510 Adapter t 1
791-646-3260 Pusher t 1
R 9 791-630-3560 Pusher t 1 Installation of bushing
10 791-432-1110 Push tool t 1 Driving of pin plug (large)
11 791T-630-3570 Guide t 1 Q Installation of link
Field disassembly and 791-635-3110 Frame t 1
assembly of one link
791-635-3160 Extension t 1
791-635-3170 Nut t 4
791-635-3180 Screw t 2
12 Installation of pin
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
13 Installation of bushing
791-635-3190 Screw t 1
791-645-3520 Adapter t 1
791T-630-3570 Guide t 1 Q
791-630-3560 Pusher t 1
WE051F0100 15
New/Remodel
Necessity
Sketch
Q'ty
790-101-1102 Pump t 1
14 Installation of link
790-105-2300 Jack t 1
15 791-646-3270 Guide t 1 Installation of pin
791-635-3110 Frame t 1
791-635-3160 Extension t 1
Field disassembly and
R 791-635-3170 Nut t 4
assembly of one link 16 Installation of pin
791-635-3180 Screw t 2
791-635-3190 Screw t 1
791-645-3510 Adapter t 1
17 791-646-8002 Lubricator t 1 Lubrication
18 791-932-1110 Push tool for plug t 1 Driving of pin plug (small)
790-502-1003 Repair stand t 1 Disassembly, assembly of
1
790-101-1102 Hydraulic pump t 1 hydraulic cylinder
Wrench assembly Removal
Lift cylinder
790-330-1100 • Angle and lift 1 and
Angle cylinder
2 (ST, PAT) t installation
of round
790-102-3802 • Tilt (PAT) 1 Tilt cylinder head
Socket
790-302-1280 • Width across flats 1
(55 mm)
• Width across flats
790-302-1290 1 Removal and installation of
3 (60 mm) t
piston nut
790-302-1340 1
(80 mm)
790-302-1320 1
(70 mm)
1 790-720-1000 Expander q 1 Expansion of piston ring
796-720-1660 Ring q 1 Lift (ST, PAT)
Disassembly and assembly 07281-01159 Clamp q 1 and angle
of hydraulic cylinder assem- U Installation
4 769-720-1670 Ring q 1
bly 2 Tilt (PAT) of piston
07281-01279 Clamp q 1 ring
796-720-1680 Ring q 1 Tilt (ST) and
07281-01589 Clamp q 1 ripper
790-201-1702 Push tool kit t 1 Common to
790-101-5021 • Grip 1 the following
01010-50816 • Bolt 1 cylinders.
Press fitting
5 790-201-1771 • Push tool 1 Lift (ST, PAT) of roll bush
Tilt (ST, PAT)
790-201-1811 • Push tool 1
and ripper
790-201-1791 • Push tool 1 Angle
790-201-1500 Push tool kit t 1 Common to
790-101-5021 • Grip 1 the following
01010-50816 • Bolt 1 cylinders
Press fitting
6 790-201-1580 • Plate 1 Lift (ST, PAT) of dust seal
Tilt (ST, PAT)
790-201-1620 • Plate 1
and ripper
790-201-1610 • Plate 1 Angle
16 WE051F0100
New/Remodel
Necessity
Sketch
Q'ty

Installation of windshield
operator's cab glass X1 793-498-1210 Lifter (Suction cup) t 2
glass
(Stuck glass)
fuel injection pump assembly 799-703-1200 Service tool kit t 1
cylinder head assembly
Removal and installation of 799-703-1100 Vacuum pump (100 V) t 1
radiator guard assembly
Charging air conditioner
radiator and hydraulic oil X2 799-703-1110 Vacuum pump (220 V) t 1
with refrigerant
cooler assembly
engine assembly 799-703-1120 Vacuum pump (240 V) t 1
floor frame assembly
Removal and installation of 799-703-1400 Gas leak tester t 1
dashboard assembly
WE051F0100 17
Sketches of special tools 1

Note: Komatsu cannot accept any responsibility for special tools manufactured according to these sketches.
J2 Guide
J4 Push tool
18 WE051F0100
P Push tool
P Plate
WE051F0100 19
R11 and 13 Guides
20 WE051F0100
WE051F0200
Bulldozer
1Shop Manual
D61EX-15
D61PX-15


Engine related procedures ............................................................................................... 2
Removal and installation of fuel injection pump assembly............................................ 2
Removal and installation of cylinder head assembly .................................................... 7
Removal and installation of engine front seal ............................................................. 14
Removal and installation of engine rear seal .............................................................. 15
Removal and installation of engine assembly............................................................. 19
Removal and installation of damper assembly ........................................................... 22
Removal and installation of radiator guard assembly ................................................. 26
Removal and installation of radiator and hydraulic oil cooler assembly...................... 30
Removal and installation of fan drive assembly.......................................................... 33
Removal and installation of fan motor assembly ........................................................ 34
Removal and installation of engine hood assembly.................................................... 35
Removal and installation of fuel tank assembly .......................................................... 36
Engine related procedures 1 4. Disconnect air cleaner hose (1). [*1]
Removal and installation of fuel 5. Remove air cleaner band (2). [*2]
injection pump assembly 1
6. Remove air cleaner (3).
Special tools
7. Remove muffler cover (4).
New/Remodel
Necessity
Symbol
Sketch
Q'ty
Part No. Part name
1 795-799-1131 Gear t 1
A
2 795-799-1390 Remover t 1
799-703-1200 Service tool kit t 1
799-703-1100 Vacuum pump (100 V) t 1
X2 799-703-1110 Vacuum pump (220 V) t 1
799-703-1120 Vacuum pump (240 V) t 1
799-703-1400 Gas leak tester t 1
Removal
8. Disconnect muffler drain tube (5).
k Collect the air conditioner refrigerant (R134a).
9. Remove muffler (6).
1. Close the fuel stop valve.
10. Remove tube (7).
2. Remove engine hood assembly. For details, see
Removal of engine hood assembly. 11. Remove bracket (8).
3. Remove left-side engine cover (70). 12. Disconnect two air conditioner hoses (9). [*3]
13. Disconnect heater hose (10).
2 WE051F0200
14. Remove fuel tube (11) and fuel filter (12). [*4]
15. Disconnect two clips (13).
16. Remove cover and disconnect heater relay (14).

a Remove bracket without removing terminal.
17. Lift off bracket (15).

a Disconnect four hoses from A.
4 Bracket (15): 35 kg
21. Disconnect fuel control linkage (19). [*7]
22. Remove boost compensator tube (20). [*8]
23. Disconnect fuel supply hose (21) and fuel return

hose (22). [*9]
24. Remove pin (24) from the back of fuel injection

pump (23) and disconnect engine stop solenoid B.
[*10]
18. Remove air tube and air hose (16). [*5]
19. Disconnect spill hose (17).
20. Remove six fuel injection tubes (18). [*6]
WE051F0200 3
25. Remove lubrication tube (24). [*11] 29. Remove cover (30).
26. Disconnect lubrication hose (25). 30. Remove cap (31).

a Use a filter wrench, etc. to remove the cap.
27. Remove bracket (26).
28. Using tool A1, gear, rotate the crankshaft clock-

wise to No.1 TOP.
1) Turn crank until mark (29) in damper (28) is at
the top.
2) If timing pin (27) goes in deeply, cylinder No. 1
comes to TOP, otherwise cylinder No. 6 is
TOP, so cranking again.
a For details, see Testing and adjusting,
Testing and adjusting fuel injection timing.
31. Remove nut (32) and washer (33) from fuel pump.
a Take care not to drop the nut and washer into
the case.
32. Using tool A2, disconnect the fuel injection pump

shaft and drive gear.
33. Remove four fuel injection pump mounting nuts

(34) and fuel injection pump assembly (23).
4 WE051F0200
Installation 4. Attach washer (33) and nut (32) to the fuel injec-
tion pump and temporarily tighten them.
1. Preparatory work for installing fuel injection pump a Take care not to drop the nut into the case.
1) Check that timing pin (27) is at No. 1 TOP. 3 Nut: 95±10 Nm {9.7±1.01 kgm}
a See step 28 of the removal procedure. a When tightening the nut, take care not to
2) Remove plug (35) and remove timing pin (36) exceed the above tightening torque to prevent
from the fuel injection pump, and then turn it the locating pin at the cylinder No. 1 compres-
over to reinstall it. sion top dead center from being damaged.
3) Align slot (a) in timing pin (36) with pointer (37)
in the fuel injection pump, install the timing pin
to the fuel injection pump again, and tempo-
rarily tighten plug (35).
a If the slot is not aligned with pointer (37) in
the fuel injection pump, turn the pump
shaft until it is aligned.
5. Disengage timing pin (27) at the cylinder No.1

compression top dead center to return it to its orig-
inal position. (unlatch the meshing position.)
6. Remove plug (35) and remove timing pin (36) from

the fuel injection pump, and then turn it over to
reinstall it. (unlatch the mesh (a) position.)
a Install the fuel injection pump assembly 3 Plug: 14.7 Nm {1.5 kgm}
2. Install fuel injection pump assembly (23) and

tighten four nuts (34).
3 Fuel injection pump mounting nut:
30±5 Nm {3.06±0.51 kgm}
3. Install fuel injection pump bracket (26).

3 Fuel injection pump bracket mounting bolt:
43±6 Nm {4.38±0.61 kgm}
7. Tighten nut (32) on the injection pump.

3 Nut: 95±10 Nm {9.7±1.02 kgm}
q Carry out the reinstallation procedures that fol-

low by reversing the order to removal.
WE051F0200 5
[*1] [*8]
3 Air cleaner hose clamp: 3 Boost compensator tube nut:
1.07±0.5 Nm {1.07±0.05 kgm} 8±2 Nm {0.81±0.20 kgm}
[*2] [*9]
3 Air cleaner band: 9.8±1 Nm {1±0.1 kgm} 3 Fuel hose joint bolt:
29.5±4.5 Nm {3.01±0.41 kgm}
[*3]
a Install each hose so that it will not be twisted. [*10]
a When installing the air conditioner hoses, take 3 Engine stop solenoid locknut:
care that dirt, dust, water, etc. will not enter 8±2 Nm {0.81±0.20 kgm}
them. a Adjust the engine stop solenoid. For details,
a When tightening each joint of the air condi- see Testing and adjusting, Adjusting engine
tioner hose, check that O-ring (46) is fitted to stop solenoid linkage.
it.
a Apply an appropriate amount of compressor [*11]
oil (Showa-Shell Suniso 4G, 5G or equivalent) 3 Lubrication tube joint bolt:
to each O-ring. 11.5±1.5 Nm {1.17±0.15 kgm}
q Charging air conditioner with refrigerant
Using tool X2, charge the air conditioner circuit with

air conditioner refrigerant (R134a). (1000±50 g)
3 Tightening torque of air conditioner refrig-

erant piping
Thread size Tightening torque

16 x 1.5 11.8-14.7 Nm {1.2-1.5 kgm}
22 x 1.5 19.6-24.5 Nm {2.0-2.5 kgm}
24 x 1.5 29.4-34.3 Nm {3.0-3.5 kgm}
[*4]
3 Fuel tube joint (bolt on fuel filter side, nut
on hose connection side):
24±4 Nm {2.45±0.41 kgm}
[*5]
3 Air hose clamp: 10±2 Nm {0.98±0.19 kgm}
[*6]
3 Fuel injection tube nut:
24±4 Nm {2.45±0.41 kgm}
[*7]
a Adjust the fuel control linkage. For details, see
Testing and adjusting, Adjusting fuel control
linkage.
6 WE051F0200
Removal and installation of 5. Disconnect air cleaner hose (1). [*1]

cylinder head assembly 1
6. Remove air cleaner band (2). [*2]
Special tools
7. Remove air cleaner (3).
New/Remodel
8. Disconnect reservoir tank hose (4) and remove
Necessity
Symbol
Sketch
reservoir tank (5) together with the bracket.
Q'ty
Part No. Part name
9. Remove muffler cover (6).

3 795-799-1170 Puller t 1
A
4 790-331-1110 Wrench q 1
799-703-1100 Vacuum pump (100 V) t 1
X2 799-703-1110 Vacuum pump (220 V) t 1
799-703-1120 Vacuum pump (240 V) t 1
Removal
k Disconnect the cable from the negative (-) ter-

minal of the battery.
k Allow the radiator to cool down before draining
the coolant to avoid being scalded.
k Collect the air conditioner refrigerant (R134a). 10. Disconnect muffler drain tube (7).
1. Close the fuel stop valve. 11. Remove muffler (8).
2. Loosen the radiator cap to drain the coolant. 12. Remove tube (9).
6 Total amount of coolant:
Approximately 44 l
14. Disconnect two air conditioner hoses (11). [*3]
3. Remove engine hood assembly. For details, see
Removal of engine hood assembly.
15. Disconnect two heater hoses (12).
4. Remove left-side engine cover (70).
WE051F0200 7
16. Remove fuel tube (13) and fuel filter (14). [*4] 20. Disconnect heater hose clip (18).
17. Disconnect two clips (15). 21. Remove cover (19).
18. Remove cover and disconnect heater relay (16). 22. Disconnect turbocharger lubrication inlet hose
a Remove bracket without removing terminal. (20). [*5]
19. Lift off bracket (17). 23. Remove turbocharger lubrication return tube (21).
a Disconnect four hoses from A. [*5]
4 Bracket (17): 35 kg
24. Disconnect two air conditioner hoses (22).
25. Disconnect wiring connector E91 (23) from the

compressor.
26. Remove compressor belt (24). [*6]
27. Remove compressor (25). [*7]
8 WE051F0200
29. Remove air tube (27).
30. Disconnect washer hose (28).
31. Disconnect connector CN21 (29).
32. Remove washer tank (30) together with bracket.
40. Remove air tube and air hose (40). [*9]
41. Remove the mounting bolt from connector bracket

(41).
42. Remove blow-by tube (42).
33. Disconnect brackets (31) and (32). [*8] 43. Disconnect spill hose (43).
34. Disconnect clip (33). 44. Remove six fuel injection tubes (44). [*10]
35. Disconnect spill hose (34). 45. Remove boost compensator tube (45). [*11]
36. Disconnect heater terminal from wiring harness

(35).
38. Disconnect two hoses (38) from intake core (37).
39. Remove two bracket mounting bolts (39) from the

back of the cylinder head.
WE051F0200 9
47. Remove intake core (47). [*12]
48. Remove cylinder head cover (48). [*13]
49. Disconnect connector E111 (49) from the engine

coolant temperature sensor.
50. Remove engine coolant temperature sensor (50).
55. Lift off cylinder head/exhaust manifold/turbo-

charger assembly (58) to remove it.
4 Cylinder head/exhaust manifold/turbocharger
assembly: 120 kg
56. Remove cylinder head gasket (59).
51. Remove mounting bolt (51) to remove six nozzle

holder assemblies (52).
a If the nozzle holder is difficult to remove, use
tool A3.
a Take care that dirt and foreign matter will not
enter the mounting part of the nozzle holder
assembly.
52. Loosen locknut (53), and then loosen adjustment

screw (54) by 2 - 3 turns. (Repeat the same for the
remaining eleven places.)
53. Remove two mounting bolts (55) to remove rocker

arm shaft assembly (56).
54. Remove push rods (57).
10 WE051F0200
Installation 3 2nd time: Further tighten the bolts

with a torque of 145±10 Nm
q Install the rocker arm assembly and cylinder head {14.8±1.0 kgm} in the fol-
assembly according to the following procedure. lowing sequence: [1], [2],
[7], [8], [9], [10], [15], [16],
a Check that there is not dirt or foreign matter on the [18], [23], [24], [25], and
mounting face of the cylinder head or in the cylin- [26].
der. a Check that these bolts have been tightened
1) Set cylinder head gasket (59) to the cylinder with a torque of 145±10 Nm {14.8±1.0 kgm}
block. in the same sequence as above.
a Check that the gasket is aligned with the 3 3rd time: Retighten all bolts with a
hole in the block. t orque of 90±5° in num-
2) Lift off cylinder head/exhaust manifold/turbo- bered sequence [1] - [26].
charger assembly (58) to set it to the cylinder 1] When using tool A4:
block.
2] When not using tool A4:

3) Tighten the mounting bolts for the cylinder q Using a felt pen or the like, mark each
heads using the sequence shown in the figure. bolt and head with aligning marks
a Do not reuse any bolt whose head has five before retighten them with a torque of
punch marks that identify the number of 90±5°.
times it was used.
2 Apply engine oil (SAE15W-40) to the
threads and seats of the mounting
bolts.
3 Cylinder head mounting bolt:
1st time: Tighten the bolts with a
torque of 70±5 Nm
{7.1±0.51 kgm} in numbered
sequence [1] - [26].
a Check that all bolts have been tightened
with a torque of 70±5 Nm {7.1±0.51 kgm}
in the same sequence.
WE051F0200 11
a After tightening, make a punch mark on all bolt 6) Secure rocker arm assembly (56).
heads. 3 Rocker arm mounting bolt (55):
65±5 Nm {6.6±0.5 kgm}
a Adjust the valve clearance. For details,
see Testing and adjustment, Adjusting
valve clearance.
3 Locknut (53):
24±4 Nm {2.45±0.41 kgm}
7) Install nozzle holder (52).
3 Nozzle holder mounting bolt (51):
24±4 Nm {2.45±0.41 kgm}
4) Install push rods (57).

a Apply engine oil to the push rod.
q Carry out the reinstallation procedures that fol-

low by reversing the order to removal.
[*1]
3 Air cleaner hose clamp:
1.07±0.5 Nm {1.07±0.05 kgm}
[*2]
5) Install rocker arm assembly (56) and tighten 3 Air cleaner band: 9.8±1 Nm {1±0.1 kgm}
mounting bolts (55) with the fingers.
a Check that the ball of the adjustment [*3]
screw is fitted to the socket of push rod. a Install each hose so that it will not be twisted.
a Apply engine oil to the threads and seats a When installing the air conditioner hoses, take
of the mounting bolts. care that dirt, dust, water, etc. will not enter them.
a When tightening each joint of the air conditioner
hose, check that O-ring (46) is fitted to it.
a Apply an appropriate amount of compressor oil
(Showa-Shell Suniso 4G, 5G or equivalent) to
each O-ring.
12 WE051F0200
3 Tightening torque of air conditioner refrigerant Reference

piping Installation of exhaust manifold
Thread size Tightening torque a Tighten the mounting bolts for the exhaust mani-
16 x 1.5 11.8-14.7 Nm {1.2-1.5 kgm} fold using the sequence shown in the figure.
22 x 1.5 19.6-24.5 Nm {2.0-2.5 kgm} 3 Exhaust manifold mounting bolt:
24 x 1.5 29.4-34.3 Nm {3.0-3.5 kgm}
1st time: Tighten the bolts with a torque of
23.5±4 Nm {2.4±0.41 kgm}
[*4] in numbered sequence [1] - [12].
3 Fuel tube joint (bolt on fuel filter side, nut on
hose connection side): 2nd time: Tighten the bolts numbered [1] - [4]
24±4 Nm {2.45±0.41 kgm} with a torque of
23.5±4 Nm {2.4±0.41 kgm}
[*5] in that order.
3 Turbocharger lubrication hose (20)
Mounting nut: 19.6-28.4 Nm {2.0-2.9 kgm} 3rd time: Tighten the bolts numbered [1] - [12]
Turbocharger lubrication tube (21) with a torque of
Mounting bolt: 24±4 Nm {2.45±0.41 kgm} 43.1±6 Nm {4.4±0.61 kgm}
in that order.
[*6]
a Adjust the tension of the air conditioner compres- 4th time: Tighten the bolts numbered [1]-[4]
sor belt. For details, see Testing and adjusting, with a torque of
Testing and adjusting air conditioner compressor 43.1±6 Nm {4.4±0.61 kgm}
belt tension. in that order.
a Bend the washer over the head of the bolt.
[*7]
3 Air compressor mounting bolt:
98-122.5 Nm {10.0-12.5 kgm}
[*8]
3 Intake core mounting bolt:
24±4 Nm {2.45±0.41 kgm}
[*9]
3 Air hose clamp: 10±2 Nm {0.98±0.19 kgm}
[*10]
3 Fuel injection tube nut:
24±4 Nm {2.45±0.41 kgm}
[*11]
3 Boost compensator tube nut:
8±2 Nm {0.81±0.20 kgm} q Refilling with water
a Add water through the water filler to the speci-
[*12] fied level. Run the engine to circulate the
3 Intake core mounting bolt: water. Then, check the water level again.
24±4 Nm {2.45±0.41 kgm} 5 Total amount of coolant: Approximately 44 l
[*13]
3 Cylinder head cover mounting bolt: q Charging air conditioner with refrigerant
24±4 Nm {2.45±0.41 kgm} Using tool X2, charge the air conditioner circuit with
WE051F0200 13
Removal and installation of engine Installation

front seal 1
a The plastic part (P) in the engine front seal is pro-
Removal vided as a pilot (guide) that is used in installing the
crankshaft. So, do not remove it.
1. Remove the radiator guard assembly. For details, 1. Apply some amount of neutral detergent to the
see Removal and installation of radiator guard outer periphery of engine front seal.
assembly.
2. Using the lever, remove fan belt (1) from A.

k Use care not to allow your fingers to be
caught between the tensioner and the fan
pulley.
3. Remove four mounting bolts (3) and remove

crankshaft pulley/damper (2). [*1]
a Since the 1.6 TOP pointer is on the crankshaft
pulley, scribe an alignment mark on the crank-
shaft pulley and front cover.
2. Using a clean cloth, remove adherents from the

crankshaft flange.
4. Remove five mounting bolts from seal carrier (4) to

remove it.
5. Remove front seal (5) from seal carrier (4). [*3]

3. Apply the following to the mounting hole for the
seal carrier.
2 Inside of seal carrier mounting hole:
Apply a 1-2 mm diameter ThreeBond
1207D or its equivalent.
14 WE051F0200
4. Install engine front seal (5) to seal carrier (4). Removal and installation of engine
a Mounting dimension: 0.5-1mm rear seal 1
Special tools
New/Remodel
Necessity
Symbol
Sketch
Q'ty
Part No. Part name
A5 795-931-1100 Seal puller q 1
Removal

5. Push pilot P against the crankshaft and push it
together with seal carrier (4) into the crankshaft. 1. Remove the floor frame assembly. For details, see
Removal and installation of floor frame assembly.
6. Remove pilot P.
2. Remove the damper assembly. For details, see
7. Tighten five seal carrier (4) mounting bolts using Removal and installation of damper assembly.
the sequence shown in the figure below.
3 Seal carrier mounting bolt: 3. Disconnect engine speed sensor connector (1)
9.8±2 Nm {1±0.2 kgm} and loosen locknut (2) to disconnect engine speed
a Check that the engine front seal has been sensor (3) from flywheel housing (5). [*1]
mounted to the seal carrier to 0.5-1 mm.
q Carry out installation in the reverse order to

removal.
[*1]
a Temporarily install the crankshaft pulley and
damper, apply the fan belt and then tighten
them to the specified torque.
3 Crankshaft pulley/damper mounting bolt:
200±10 Nm {20.4±1 kgm}
WE051F0200 15
4. Remove the mounting bolt, set the guide bolt, and Installation
then lift off flywheel (4) to remove it. [*2]
4 Flywheel assembly: 45 kg 1. Clean and degrease the surface of gasket
between the rear cover and the cylinder block and
5. Temporarily lift off flywheel housing (5), remove let dry.
the mounting bolt, set the guide bolt, and then lift
off the flywheel housing to remove it. [*3] 2. Clean and degrease the surface of seal lip (on the
4 Flywheel housing (5): 70 kg crankshaft periphery) and let dry.
6. Remove rear cover (6).
7. Remove rear seal (7) from rear cover (6).

a Take care not to damage the seal attached to
the flywheel housing and the surface of the
seal in contact with the crankshaft.
3. Apply some amount of neutral detergent to the

outer periphery of engine rear seal.
a The plastic part (P) in the engine rear seal is
provided as a pilot (guide) that is used in
installing the crankshaft. So, do not remove it.
a If you cannot easily remove engine rear seal

(7) from the crankshaft, drill a hole in the right
and left sides of engine rear seal, approxi-
mately 3 mm in diameter. Using seal puller
A5, remove the seal through the pulling impact
created by slide hammer (SH).
4. Install engine rear seal (7) to rear cover (6).
16 WE051F0200
5. Using alignment tool A provided with the engine 9. Reinstall alignment tool A to check that rear seal
rear seal, push rear seal (7) into rear cover (6) until (7) is fitted up to the desired depth.
the desired depth is reached. a The difference between the cylinder block bot-
tom and rear cover (6) bottom must be within
6. Remove alignment tool A. 0.00±0.10 mm.
7. Push pilot P against the crankshaft and push it a Do the above procedure without removing
together with rear cover (6) into the crankshaft. alignment tool A.
a Remember to put gasket G between the cylin-
der block and the rear cover. 10. Remove guide pin [2] and tighten eight rear cover
a Use guide pin [2]. mounting bolts using the sequence shown in the
figure below.
8. Remove pilot P. 3 Rear cover mounting bolt:
10±2 Nm {1.02±0.2 kgm}
a The projection of rear cover gasket G above
the cylinder block bottom must be within 0.25
mm.
11. Remove alignment tool A.

removal.
WE051F0200 17
[*1] [*3]
2 Thread of engine speed sensor: LG-6 2 Apply a 1-3 mm diameter gasket sealant to the
periphery of mounting bolt hole at the cylinder
a Installing the engine speed sensor: block: Gasket sealant (LG-6)
1. Screw the sensor until it comes into contact
with the gear. a Tighten the mounting bolts using the sequence
2. Back off it 1±1/6 turns and tighten the locknut. shown in the figure.
a Clearance between engine speed sensor and fly- 3 Flywheel housing mounting bolt:
wheel: 0.75-1mm 77±12 Nm {7.85±1.22 kgm}
3 Engine speed sensor locknut:

69-74 Nm {7-7.5 kgm}
[*2]
a Tighten the mounting bolts using the sequence
shown in the figure.
3 Flywheel mounting bolt:
137±7 Nm {13.97±0.71 kgm}
a There should be no more than 0.2 mm variation of

flywheel to flywheel housing.
18 WE051F0200
Removal and installation of engine 6. Remove receiver dryer (3).

assembly 1
7. Disconnect spill hose (4).
Special tools a Prepare a plug to stop the fuel from flowing
out.
New/Remodel
8. Disconnect the spill hose clip. (Remember that
Necessity
Symbol
Sketch
spacer (5) comes off.)
Q'ty
Part No. Part name

799-703-1100 Vacuum pump (100 V) t 1
X2 799-703-1110 Vacuum pump (220 V) t 1
799-703-1120 Vacuum pump (240 V) t 1
Removal

k Collect the air conditioner refrigerant (R134a). 9. Remove pin (6) and loosen locknut (7) to discon-
nect deceleration cable (8). [*2]
1. Loosen the radiator cap to drain the coolant.
6 Total amount of coolant: 10. Disconnect ground (9). [*3]
Approximately 44 l
11. Disconnect fuel supply hose (10). [*4]
2. Close the fuel stop valve.
12. Disconnect clips (11) and fuel return hose (12).
3. Remove radiator guard assembly. For details, see
Removal of radiator guard assembly.
4. Disconnect two air conditioner hoses (1). [*1]
5. Disconnect two heater hoses (2).
WE051F0200 19
13. Disconnect clips (13) and starting motor terminal 18. Remove cover (21) to remove engine mounts (22).
(14) on the right hand side of the engine. [*5]
14. Disconnect connectors, E22 (15) and E21 (16).
15. Disconnect starting motor connector E101 (17).
16. Disconnect ground (18) from the frame.

a Letter "A" indicates the starting motor. Con-
nector B has been disconnected when the
radiator guard assembly was removed.
19. Remove right and left transmission covers (indi-

cated by C in the photo) and remove the rear
engine mount using a pipe [1].
20. Lift off engine assembly (20).

4 Engine assembly: 1,000 kg
17. Disconnect universal joint (19) from engine

assembly (20). [*6]
a Bottom View
20 WE051F0200
Installation [*6]
2 Universal joint mounting bolt: LT-2
q Carry out installation in the reverse order to 3 Universal joint mounting bolt:
removal. 98-123 Nm {10-12.5 kgm}
[*1]
a Install each hose so that it will not be twisted. q Refilling with water
a When installing the air conditioner hoses, take a Add water through the water filler to the specified
care that dirt, dust, water, etc. will not enter level. Run the engine to circulate the water. Then,
them. check the water level again.
a When tightening each joint of the air condi- 5 Total amount of coolant: Approximately 44 l
tioner hose, check that O-ring (46) is fitted to
it.
a Apply an appropriate amount of compressor q Refilling with oil (hydraulic tank)
oil (Showa-Shell Suniso 4G, 5G or equivalent) a Add oil through the oil filler to the specified level.
to each O-ring. Run the engine to circulate the oil through the sys-
tem. Then, check the oil level again.
5 Hydraulic tank: 55 l(EO10-CD)
q Bleeding air from fan pump and work equip-

ment cylinder
a Bleed air from the fan pump circuit, referring to the
section of "Bleeding air from fan pump" in Testing
and adjusting.
a Bleed air from the work equipment cylinder circuit,
referring to the section of "Bleeding air from work
equipment cylinder circuit" in Testing and adjust-
ing.
Charging air conditioner with refrigerant

3
q
Tightening torque of air conditioner refrig- Using tool X2, charge the air conditioner circuit with
erant piping air conditioner refrigerant (R134a). (1000±50g)

16 x 1.5 11.8-14.7 Nm {1.2-1.5 kgm}
22 x 1.5 19.6-24.5 Nm {2.0-2.5 kgm}
24 x 1.5 29.4-34.3 Nm {3.0-3.5 kgm}
[*2]
linkage.
[*3]
3 Engine ground terminal:
98-123 Nm {10-12.5 kgm}
[*4]
3 Fuel hose joint bolt:
29.5±4.5 Nm {3.01±0.46 kgm}
[*5]
3 Starting motor + terminal:
19.6-25.5 Nm {2.0-2.6 kgm}
WE051F0200 21
Removal and installation of damper 6. Remove damper cover assembly by following the
assembly 1 steps below.
1) Sling damper cover assembly (5) temporarily,
Removal attach two guide bolts [2], and remove the
assembly using forcing screws [3].
1. Remove the power train and lubricating oil pump a Remove damper cover assembly (5)
assembly. For details, see Removal of power train approximately 90 mm until its pilot portion
and lubricating oil pump assembly. comes out of the flywheel housing.
2) Remove forcing screws [3], lift off damper
2. Remove suction pipe (1) from the power train and cover assembly (5) using eyebolt [1] and
lubricating oil pump assembly. remove it from the bottom of chassis.
3. Remove universal joint (2).
7. Remove damper (7).
4. Remove coupling (3). 8. Remove bearing (8) from the flywheel.
5. Remove drain plug (4) and drain the oil from the
damper case.
6 Damper case: 1.3 l
22 WE051F0200
9. Disassemble the damper cover by following the Installation

steps below.
1) Remove snap ring (10) from damper cover (9). 1. Reassemble the damper cover by following the
2) Turn over the damper cover to set it to the steps below.
block and knock shaft assembly (11) out using 1) Install snap ring (15) to shaft (13).
an appropriate tool such as plastic hammer 2) Using push tool [4], press fit bearing (16).
[3].
3) Install snap ring (14) to shaft (13).

3) Remove oil seal (12) from the damper cover. a Check that the snap ring is fitted securely
4) Remove snap rings, (14) and (15), from shaft in the groove in the shaft.
(13). 4) Set damper cover (9) to the block and drive
shaft assembly (11) into the block using an
appropriate tool such as plastic hammer [3].
5) Using push tool [4], remove bearing (16) from

shaft (13) with press.
WE051F0200 23
5) Install snap ring (10) to damper cover (9). 3. Install damper (7).
a Check that the snap ring is fitted securely 3 Mounting bolt: 57-73.5 Nm {6-7.5 kgm}
in the groove.
6) Turn over the damper cover and install oil seal
(12).
2 Surface that is press-fit in the oil seal:
Gasket sealant (LG-5)
a Apply a small amount of gasket sealant to
the inner surface of the cover hole before
press fitting the oil seal.
a Take care not to allow the sealant to
adhere to the oil seal lip.
2 Oil seal lip: Grease (G2-LI)
4. Install damper cover assembly by following the

steps below.
1) Lift off damper cover assembly (5) and install it
to the flywheel housing.
a Using guide bolts [2], align the damper
cover assembly with the flywheel housing
to push the damper cover into the hous-
ing.
2 Contacting surface:
2 Threads of mounting bolt at :
2. Install bearing (8) to the flywheel. Gasket sealant (LG-6)
2 Apply grease (G2-LI) to the inside and out-
side diameters of the bearing and the
inside of bearing, taking care not to apply
it to an area around holes drilled into the
shaft.
24 WE051F0200
2) Install coupling (3).

3) Tighten drain plug (4), install oil filler plug (17)
and level plug (18) to add oil to the damper
case.
5 Damper case:
Approximately 1.3 l(EO30-CD)
3 Plugs, (4), (17) and (18):
58.8-78.5 Nm {6-8 kgm}
5. Install universal joint (2).

2 Universal joint mounting bolt:
6. Install suction pipe (1) to the power train and lubri-

cating oil pump assembly.
7. Carry out the reinstallation procedures that follow

in the reverse order to removal.
WE051F0200 25
Removal and installation of radiator 5. Remove the bottom cover of the radiator.
guard assembly 1
Special tools 6 Total amount of coolant:
Approximately 44 l
New/Remodel
Necessity
Symbol
Sketch
reservoir tank (3) together with the bracket.
Q'ty
Part No. Part name
8. Disconnect bracket (4).

799-703-1100 Vacuum pump (100 V) t 1 9. Disconnect radiator inlet hose (5) and (6). [*1]
X2 799-703-1110 Vacuum pump (220 V) t 1
10. Disconnect harness (7) as shown below.
799-703-1120 Vacuum pump (240 V) t 1
Removal

k Lower the work equipment to the ground and
stop the engine. Gradually open the oil filler
cap of the hydraulic tank to release the internal
pressure of the hydraulic tank.
k Operate the work equipment control lever sev-
eral times to release any remaining pressure.
k Collect the air conditioner refrigerant (R134a). 11. Disconnect clips (8) and connector CN101 (9) and
move harness (7) towards the radiator guard.
1. Drain the hydraulic oil. a Letter "A" indicates the starting motor.
6 Hydraulic tank: Approximately 55 l

Approximately 44 l
3. Remove the engine hood. For details, see Removal

and installation of engine hood.
4. Remove right and left engine covers (1).
26 WE051F0200
17. Remove the mounting bolts and open radiator

mask (15).
18. Lift off radiator mask (15) to remove it.

4 Radiator mask assembly: 50 kg
19. Remove lock bar (16).
20. Remove upper right cover (17) to remove fan

guard (18).
12. Disconnect washer hoses (10).
15. Disconnect receiver dryer hose (13).

a Be sure to disconnect the clips, too.
22. Remove plates (20) and (21).
16. Disconnect air compressor hose (14).

WE051F0200 27
23. Disconnect hose TC (22), discharge port (23) and 27. Sling radiator guard assembly (31) temporarily,
drain port (24). remove four mounting bolts (30) at the front and
four at the rear (indicated by "C" in the above
photo). [*2]
24. Disconnect radiator outlet hose (25). [*1]
28. Lift off radiator guard assembly (31) to remove it.

4 Radiator guard assembly: 420 kg
a Pull the assembly forward to lift it up.
25. Disconnect radiator hoses (26) and (27).
26. Disconnect oil cooler hoses (28) and (29).

a Prepare a plug before disconnecting these
hoses.
a Letter "B" indicates the air compressor hose.

Take care not to allow any part of assembly to
catch on the hose.
a Letter "C" indicates the mounting bolt holes at
the rear.
28 WE051F0200
Installation

removal.
[*1]
2 Radiator hose connection:
Gasket sealant (LG-6 or LG-7)
3 Radiator hose clamp:
8.8±0.5 Nm {0.9±0.05 kgm}
[*2]
a Check that the coolant drain hose is not caught
when reinstalling the radiator guard assembly.
3 Mounting bolt: 455-565 Nm {46.5-58 kgm}
q Refilling with water

a Add water through the water filler to the specified
level. Run the engine to circulate the water. Then,
check the water level again.
5 Total amount of coolant: Approximately 44 l
q Refilling with oil (hydraulic tank)

a Add oil through the oil filler to the specified level.
Run the engine to circulate the oil through the sys-
5 Hydraulic tank: 55 l (EO10-CD)

ment cylinder
and adjusting.
ing.

Using tool X2, charge the air conditioner circuit with
WE051F0200 29
Removal and installation of radiator 5. Remove the bottom cover of the radiator.
and hydraulic oil cooler assembly 1
Special tools reservoir tank (3) together with the bracket.
7. Disconnect bracket (4).
New/Remodel
Necessity
Symbol
Sketch
8. Disconnect radiator inlet hose (5) and (6). [*1]
Q'ty
Part No. Part name
9. Disconnect clips (7) and get harness (8) out of the

way.
799-703-1100 Vacuum pump (100 V) t 1
X2 799-703-1110 Vacuum pump (220 V) t 1
799-703-1120 Vacuum pump (240 V) t 1 11. Loosen bolt (10) to remove bracket (11). [*2]
Removal
k Lower the work equipment to the ground and

stop the engine. Gradually open the oil filler
cap of the hydraulic tank to release the internal
k Collect the air conditioner refrigerant (R134a).
1. Drain the hydraulic oil.

2. Loosen the radiator cap to drain the coolant. 12. Disconnect washer hoses (12).
Approximately 44 l
3. Remove the engine hood. For details, see
Removal and installation of engine hood.
15. Disconnect receiver dryer hose (15).
4. Remove right and left engine covers (1).
30 WE051F0200
16. Disconnect air compressor hose (16).

21. Remove mount (22) for the radiator and hydraulic

oil cooler assembly.
17. Disconnect radiator outlet hose (17). [*1]
22. Lift off radiator and hydraulic oil cooler assembly
(23) to remove it.
a Take care not to allow any part of assembly to

catch on air compressor hoses (15) and (16)
when lifting the assembly up.
4 Radiator and hydraulic oil cooler assem-
bly: 150 kg
a B: Hydraulic oil cooler, C: Air conditioner con-

denser
18. Disconnect radiator hoses (18).
19. Disconnect oil cooler hoses (19).

hoses.
20. Disconnect oil cooler hose (20) and remove elbow

(21) to prevent it from interferring with the move-
ment during the lifting up.
WE051F0200 31
Installation

removal.
[*1]
2 Radiator hose connection:
Gasket sealant (LG-6 or LG-7)
3 Radiator hose clamp:
8.8±0.5 Nm {0.9±0.05 kgm}
[*2]
3 Bolt (10): 59-74 Nm {6.0-7.5 kgm}
q Refilling with water

a Add water through the water filler to the speci-
fied level. Run the engine to circulate the
water. Then, check the water level again.
5 Total amount of coolant: Approximately 44 l

a 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.
q Bleeding air from fan pump and work

equipment cylinder
a Bleed air from the fan pump circuit, referring to
the section of "Bleeding air from fan pump" in
Testing and adjusting.
a Bleed air from the work equipment cylinder cir-
cuit, referring to the section of "Bleeding air
from work equipment cylinder circuit" in Test-
ing and adjusting.

Using tool X2, charge the air conditioner circuit
with air conditioner refrigerant (R134a). (1000±50
g)
32 WE051F0200
Removal and installation of fan 8. Disconnect wiring connector FAR (8).

drive assembly 1
Removal


2. Remove the mounting bolts and open radiator

mask (1).
3. Lift off radiator mask (1) to remove it.

4 Radiator mask assembly: 50 kg
9. Disconnect hose TC (9), discharge port (10) and
4. Remove lock bar (2). drain port (11).
5. Remove upper right cover (3) to remove fan guard hoses.
(4).
10. Remove piping TC (12), discharge port (13) and
drain port (14).
11. Lift off fan drive assembly (15) to remove it.

4 Fan drive assembly: 60 kg
7. Remove plates (6) and (7).
Installation

removal.

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.
WE051F0200 33
Removal and installation of fan 4. Using puller [1], disconnect fan (4) from the fan
motor assembly 1 motor shaft.
Removal 5. Remove the nut to remove fan (4).
1. Remove the fan drive assembly. For details, see

Removal and installation of fan drive assembly.
2. Remove mounting bolt (1) to remove lockplate (2).

[*1]
6. Remove four mounting bolts from fan motor

assembly (5) to remove it. [*3]
3. Loosen nut (3). [*2]

a Leave the nut engaging the 2nd or 3rd thread.
Installation

removal.
[*1][*2]
3 Nut(3): 132-157 Nm {13.5-16 kgm}
1. Align the mounting bolt hole in the both sides of
lockplate (2) and further tighten nut (2) on the side
that requires a smaller amount of adjustment.
2. Tighten mounting bolt (1).

2 Mounting bolt: Liquid adhesive (LT-2)
[*3]
q Wipe off and degrease the engagement
between the fan motor and fan boss.
34 WE051F0200
Removal and installation of engine

hood assembly 1
Removal

1. Open the right and left engine hood covers.
2. Loosen clamp (1) to disconnect air hose (2).
3. Disconnect dust indicator bracket (3).
4. Disconnect reservoir tank hose (4).
5. Remove mounting bolt and lift off engine hood (5)

to remove it.
4 Engine hood: 200 kg
Installation

removal.
WE051F0200 35
Removal and installation of fuel tank 6. Open the battery cover and disconnect connector
assembly 1 FCC (7), ground GND03 (8) and clips (9).
Removal 7. Push harness (10) as far as it goes.

1. Drain the fuel.

6 Fuel tank capacity: Approximately 391 l
2. Remove caps and mounting bolts to remove cover

(1) under the fuel tank.
3. Remove caps (2) for purposes of the rear mount-

ing bolts.
8. Remove cover (11) from the back of operator's

seat.
4. Disconnect hose (3), clip (4) and water separator

(5).
9. Disconnect spill hoses (12) and clip (13).
10. Disconnect clip (14) from hydraulic tank A.
36 WE051F0200
11. Remove mounting bolt front cover (15) and

remove mounting bolt (16). [*1]
12. Temporarily lift off fuel tank (18) and remove

mounting bolt (17). [*1]
13. Lift off fuel tank (18) and move backward to

remove it.
4 Fuel tank assembly: 190 kg (with no fuel)
Installation
removal.
[*1]
3 Fuel tank mounting bolt:
455-565 Nm {46.5±58 kgm}
WE051F0200 37
38 WE051F0200
WE051F0300
Bulldozer
1Shop Manual
D61EX-15
D61PX-15


Power train ....................................................................................................................... 2
Removal and installation of PTO, torque converter and transmission assembly.......... 2
Disconnection and connection of PTO, torque converter and transmission assembly . 6
Disassembly and assembly of PTO assembly.............................................................. 8
Disassembly and assembly of torque converter assembly ......................................... 13
Disassembly and assembly of TORQFLOW transmission assembly ......................... 17
Removal and installation of torque converter main relief valve assembly .................. 34
Disassembly and assembly of torque converter main relief valve assembly .............. 35
Power train 1 a View Showing Hose Connections
Removal and installation of PTO,

torque converter and transmission
assembly 1
Removal

2. Drain oil from the HSS.

6 HSS case: 69 l (excluding oil contained in
the transmission case)
3. Remove the floor frame assembly. For details,

see Removal and installation of floor frame assem- 10. Remove the right transmission cover.
bly.
11. Remove the undercover of the universal joint.
4. Remove the control valve assembly. For details,
see Removal and installation of control valve 12. HSS and hydraulic pump assembly (17)
assembly. 1) Disconnect connector HSP (9) and two clips
(10).
5. Disconnect clip (1). 2) Disconnect the following pipes.
a Discharge hose A (connected to the con-
6. Loosen locknut (2) to remove pins (3) and (4). trol valve) has already been disconnected
a Before disconnecting this cable, measure its when the control valve assembly was
installed length. removed.
a Prepare a plug before disconnecting the
7. Remove parking brake wire (5). hose.
a Identify all hoses using labels or any other
8. Remove pin (6) and nut (7). appropriate means.
q (11): Drain hose (connected to drain
9. Remove brake rod (8). block)
q (12): LS press fit hose (connected from
control valve)
q (13): Oil pressure pickup hose that mea-
sures pump discharge pressure
(connected to the right fender pres-
sure detection port)
q (14): Block
2 WE051F0300
q (15): Suction pipe 13. Power train and lubricating oil pump assembly (22)
(connected from hydraulic tank) 1) Disconnect the following pipes.
q (16): Block q (19): Pump discharge hose
(connected to HSS lubrication)
q (20): Pump discharge pressure hose
(connected to power train filter)
q (21): Suction pipe
(connected from pipe)
2) Remove power train and lubricating oil pump
assembly (22). [*2]
3) Lift off HSS and hydraulic pump assembly (17)

to remove it. [*1]
4HSS and hydraulic pump assembly (17):
70 kg
14. Disconnect clips (23), (24), (25) and (26) on the

left hand side.
15. Disconnect connector (18).
16. Disconnect power train oil cooler hoses (27) and

(28) and disconnect oil pressure pickup hose (29).
a Connector C: PL1 and PL2 have been discon-

nected when the floor frame assembly was
removed.
WE051F0300 3
17. Disconnect clip (30).
18. Disconnect drain hoses (31) and (32).
19. Disconnect brake hose (33).
20. Disconnect HSS lubrication hose (34) from the

scavenging pump and disconnect hose (35) from
the power train and lubrication pump.
21. Disconnect two clips (36) and (37).
22. Remove hose and tube (38).
23. Remove hose (39).
24. Disconnect oil pressure pickup hose (40). 32. Remove fuel tank undercover (51).
25. Disconnect PPC basic pressure hoses (41) and 33. Remove cover (52).
(42) from fan pump assembly B.
34. Disconnect connector TM1 (53) and clip (54).
26. Disconnect oil pressure pickup hose (43).
27. Disconnect blowoff hose (44) from the pump.
28. Disconnect two clips (45) and (46).
29. Disconnect drain hoses (47) and (48) from the fan
pump assembly side.
30. Remove drain block (49).
31. Disconnect transmission lubrication hose (50)

from the power train filter.
4 WE051F0300
35. Disconnect universal joint assembly (55). [*3] Installation

removal.
[*1][*2]
a Check that there are no missing O-rings and/or no
O-rings get caught on components before install-
ing the pump.
[*3]
2 Universal joint mounting bolt:
[*4]
3 Mounting bolt: 235-285Nm{23.5-29.5 kgm}
36. Lift off PTO, torque converter and transmission
assembly (56) to remove it.[*4]
4 PTO, torque converter and transmission q Refilling with oil (hydraulic tank)
assembly (56): 850 kg Add oil through the oil filler to the specified level. Run
a Move the assembly towards the front of the the engine to circulate the oil through the system.
machine body until the bevel shaft comes off Then, check the oil level again.
the bevel pinion.
a Take care not to damage the pipes and har-
nesses. q Refilling with oil (transmission and HSS)
5 HSS case: 69 l (excluding oil contained in the
transmission case) (EO30-CD)

ment cylinder
and adjusting.
ing.
WE051F0300 5
Disconnection and connection of 7. Remove scavenging pump (7).

PTO, torque converter and
8. Remove power train and lubrication pump suction
transmission assembly 1 pipe (8).
Disconnection
9. Remove bolt (9) and holder (10) to remove cou-
pling (11). [*1]
1. Drain oil from the transmission case.
6 Transmission case
2. Remove tubes (1) and (2).
10. Lift off the PTO, torque converter, and transmis-

sion assembly and re-set it on the block with the
PTO pointing upward.
3. Remove suction pipe and hose (3). 11. Remove sleeves (12) and (13).
4. Remove suction hose (4).
5. Remove harness (5).
6. Remove fan drive assembly (6).

4 Fan drive assembly (6): 25 kg
6 WE051F0300
12. Sling PTO assembly (14) temporarily, remove 13 Connection

mounting bolts and disconnect it from transmission
assembly (15). [*2] q Connect the assemblies in the reverse order of
4 PTO and torque converter (case) assem- disconnection.
blies:
320 kg (including torque converter) [*1]
a The torque converter assembly is left on the 2 Coupling mounting bolt:
transmission side. Liquid adhesive (LT-2)
3 Coupling mounting bolt:
245.1-309.0Nm{25.0-31.5 kgm}
[*2]
3 Mounting bolt between torque converter case
and transmission case:
98-123Nm{10-12.5 kgm}
[*3]
3 Mounting bolt between torque converter
assembly and transmission:
58.8-73.5Nm{6.0-7.5 kgm}
13. Remove eight mounting bolts. Using eyebolt [3],

remove torque converter assembly (19).[*3]
4 Torque converter assembly: 150 kg
WE051F0300 7
Disassembly and assembly of PTO 4. Cover assembly (left)

assembly 1 1) Remove mounting bolts, then using forcing
screw [2] remove cover assembly (8).
Disassembly
1. Remove lubrication tubes (1) and (2).
2. Remove cover (20).
2) Knock out gear assembly (9) from cover (10)

and remove.
3. Cover assembly (right)

1) Remove mounting bolts, then using forcing
screw [1] remove cover assembly (3).
3) Remove bearings (11) from gear (12).
2) Knock out gear assembly (4) from cover (5)

and remove.
3) Remove bearings (6) from gear (7).
8 WE051F0300
5. Idler gear 6. Scavenging pump drive gear

1) Remove mounting bolt to remove plate (13). 1) Remove snap ring (21).
2) Knock out gear (22) from snap ring side.
2) Remove mounting bolts, then using forcing

screw [3] remove shaft (14). 3) Remove snap ring (24).
4) Remove bearing (23).
3) Remove bearing (16) and spacer (17) from

gear (15).
a If these parts are to be used again, do not
change the sets. Put them in sets with the
outer race and keep them in a safe place.
4) Remove outer race (18) from gear (15).
WE051F0300 9
7. Input shaft Assembly

1) Remove retainer (25).
2) Remove oil seal (26) from retainer (25). a Clean the all parts and check them for dirt or dam-
3) Remove snap ring (27) and input shaft bearing age before assembling them.
(28). a Apply 6 cc of engine oil to the rotating portion of
the bearing and then rotate it ten turns.
a Check that the snap ring is fitted securely in the
groove.
1. Input shaft
1) Using push tool [1], install oil seal (26) to
retainer (25).
2) Press fit bearing (28), and install snap ring

(27).
a See the figure to the left.
3) Install retainer (25).
a See the figure to the left.
2. Scavenging pump drive gear

1) Install bearing (23) and snap ring (24).
10 WE051F0300
2) Holding the inner race of bearing (23), install 3) Install spacer (17).
gear (22) to the bearing. 4) Install outer race (18) to gear (15).
3) Install snap ring (21). 5) Install gear (15).

6) Install bearing (16).
a Press fit inner race side.
3. Idler gear
1) Press the O-ring onto the idle gear and install
shaft (14). 7) Fit plate (13) and tighten bolts.
2) Install bearing (16). 2 Mounting bolt: Liquid adhesive (LT-2)
3 Mounting bolt:
156.9-196.1Nm{16.0-20.0 kgm}
WE051F0300 11
4. Cover assembly (left) 5. Cover assembly (right)

1) Install bearings (11) to gear (12). 1) Install bearings (6) to gear (7).
2) Install gear assembly (4) to cover (5).
2) Install gear assembly (9) to cover (10).

3) Push the O-ring onto cover assembly (3) and
install it so that it engages the idler gear.
3) Push the O-ring onto cover assembly (8) and

install it so that it engages the idler gear.
6. Install cover (20).
7. Install lubrication tubes (2) and (1).

3 Eye joint: 19.6-29.4{2.0-3.0 kgm}
12 WE051F0300
Disassembly and assembly of 3) Using puller [2], disconnect case assembly

torque converter assembly 1 (10) from turbine (11).
Disassembly
1. Remove 24 bolts from the bottom of the assembly.

Lift off case, turbine assembly (1) using eyebolts
[1] to remove it.
4. Remove snap ring (14) to remove stator (15).
2. Remove bolts (2) to remove gear (3) and input

shaft (4).
5. Pump assembly
1) Using forcing screws [3] on the stator shaft
end, remove pump assembly (16) from stator
shaft (17).
3. Case
1) Remove snap ring (8).
2) Remove spacer (9).
WE051F0300 13
2) Pull cage (18) out of pump (19). Assembly
a Clean the all parts and check them for dirt or

damage before assembling them.
a Apply 6 cc of engine oil to the rotating portion
of the bearing and then rotate it ten turns.
a Check that the snap ring is fitted securely in
the groove.
a Apply a thin coat of grease (G2-LI) to the seal
ring.
1. Pump assembly
1) Press fit bearing (21) to cage (18), and install
snap ring (22).
3) Remove snap ring (22) and bearing (21) from

cage (18).
2) Install cage (18) to pump (19).
14 WE051F0300
3) Install pump assembly (16) to stator shaft (17). 2) Push inner race end of bearing and install
a Push the inner race of the bearing to press case assembly (10) to boss portion of turbine
fit. (11).
a Apply 6 cc of engine oil to the rotating por-
tion of the bearing and then rotate pump
assembly (16) more than ten turns.
3) Install spacer (9).

4) Install snap ring (8).
2. Stator
1) Install stator (15).
4. Gear and input shaft

1) Press fit inner race (7) to collar (6).
2) Install collar (6) to input shaft (5).
3. Case
1) Install bearing (13) to case (12).
a Apply 6 cc of engine oil to the bearing and
then rotate the bearing more than ten
turns.
WE051F0300 15
3) Install input shaft (4) and gear (3).

4) Install bolts (2).
3 Mounting bolt:
58.9-73.6Nm{6-7.5 kgm}
5. Case, turbine assembly

1) Using eyebolt [1], install case and turbine
assembly (1) so that the drain plug is fully
seated in the groove of the case.

3 Mounting bolt:
49.0-58.8Nm{5.0-6.0 kgm}
2) Install drain plug.
3 Drain plug: 5.9-8.8Nm{0.6-0.9 kgm}
16 WE051F0300
Disassembly and assembly of 4) Disconnect ten connectors (6) of the ECMV.

TORQFLOW transmission 5) Remove cover (7) and wiring harness (8) as a
single unit.
assembly 1
Special tools
New/Remodel
Necessity
Symbol
Sketch
Q'ty
Part No. Part name
D 1 799-301-1600 Oil leak tester q 1
Disassembly
a Keep the removed discs and plates on a flat place

so that they will not be warped.
6) Remove control valve assembly (9).
1. Remove relief valve assembly (1).
2. Remove sleeve (2).
3. Control valve assembly

1) Remove cover (3).
4. Transmission case
1) Set the transmission assembly on the block
securely with the torque converter side up.
2) Remove eleven tie bolts (10) (used to secure
the transmission case).
2) Remove flange (4).

3) Using eyebolt [1], remove sleeve (5).
WE051F0300 17
3) Using eyebolt [2], remove transmission case 4) Remove snap ring (21).
(11). 5) Drive out the input shaft (22) from the torque
a Hang the transmission case vertically by converter side and remove front plate assem-
using a lever block. bly (23).
6) Remove snap ring (24), then remove input

5. Input shaft/Front plate/No. 1 carrier assembly
shaft (22) by driving it out to the torque con-
1) Remove remaining three tie bolts (12).
verter side.
2) Using eyebolts [3], remove input shaft/front
plate/No. 1 carrier assembly (13).
7) Remove snap ring (25) to remove No. 1 ring

gear (26).
6. Disassemble the Input shaft/Front plate/No. 1 8) Pull out shaft (27) and remove thrust washer
carrier assembly as follows. (28), gear (29), bearing (30), and ball (31).
1) Remove snap ring (14) to remove No. 2 sun a Take care not to lose the ball (31).
gear (15) and snap ring (16).
2) Remove snap ring (17) to remove No. 1 sun
gear (18).
3) Remove snap rings (19) and (20).
18 WE051F0300
7. No. 1 discs, plates, and springs

1) Remove five springs (32).
2) Remove six plate (33) and five discs (34).
12. No. 2 housing and No. 2 carrier assembly

1) Push up the output shaft lightly from under-
side.
8. No. 1 housing assembly 2) Remove snap ring (42).
1) Using eyebolts [4], remove No. 1 housing 3) Using eyebolts [5], remove No. 2 housing and
assembly (35). No. 2 carrier assembly (43).
2) Remove No. 1 piston (36) from the housing.
13. Disassemble No. 2 housing and No. 2 carrier

9. Remove No. 2 piston (37). assembly as follows.
1) Remove snap ring (44) and pull No. 2 carrier
10. Remove five guide pins (38). assembly (45) out of No. 2 housing (46).

1) Remove five No. 2 clutch springs (39).
2) Remove seven discs (40) and eight plates
(41).
WE051F0300 19
2) Remove spacer (47) from No. 2 carrier assem- 14. No. 3 discs, plates, and springs
bly (45). 1) Remove five No. 3 springs (57).
3) Remove No. 2 ring gear (48). 2) Remove four No. 5 discs (58) and five plates
4) Pull out shaft (49) and remove thrust washer (59).
(50), gear (51), bearing (52), and ball (53).
a Take care not to lose ball (53).
15. Remove No.3 ring gear (60).

16. Using eyebolt [7], remove No. 3 and No. 4 carriers
6) Remove snap ring (55) to remove ring gear
and output shaft assembly (61).
(56).
a Contract snap ring (55) by inserting round
rods [6] with a diameter of less than 3 mm
in 2 diagonal holes of 4 on the ring gear
and pull out ring gear (56).
17. Disassemble No. 3 and No. 4 carriers and out-

put shaft assembly as follows.
1) Remove snap ring (62), then remove output
shaft assembly (63) from No. 3 and No. 4 car-
riers (64) with push tool [8].
20 WE051F0300
2) Remove seal ring (65). 18. No. 3 housing

3) Drive pin (66) into shaft (67). 1) Using eyebolts [9], remove No. 3 housing (83).
4) Drive out shaft (67) from No. 3 carrier side. 2) Remove No. 3 piston (84).
5) Remove thrust washer (68), No. 4 planetary
gear (69), and bearing (70).
a Pull the pin (66) out of shaft (67).

1) Remove five springs (85).
2) Remove four discs (86) and five plates (87).
6) Drive out shaft (71) and remove thrust washer
(72), No. 3 planetary gear (73), bearing (74),
and ball (75).
20. No. 5 carrier and No. 4 ring gear assembly

1) Remove four mounting bolts (88).
2) Remove No. 5 carrier and No. 4 ring gear
7) Remove snap ring (76), then remove No. 4 assembly (89).
sun gear (77) from output shaft (78).
8) Remove snap rings (79) and (80), then
remove No. 5 sun gear (81) from output shaft
(78).
9) Remove inner race (82) from the bearing.
WE051F0300 21
21. Disassemble No. 5 carrier and No. 4 ring gear 23. Remove five guide pins (100) and No. 5 piston
assembly as follows. (101).
1) Drive out shaft (90) and remove thrust washer
(91), gear (92), bearing (93), and ball (94).
24. Remove five springs (102), three discs (103), and

four plates (104).
2) Remove snap ring (95), then remove No. 4
ring gear (96) from carrier (97).
25. Remove No. 5 ring gear (105).
22. No. 4 housing assembly

1) Remove No. 4 housing assembly (98).
2) Remove No. 4 piston (99).
22 WE051F0300
26. Cage (for fixing No. 5 carrier) 27. Output shaft bearing
1) Remove snap ring (106). 1] Remove snap ring (110).
2] Remove bearing (111) from housing (112).
2) Using forcing screws [10], remove cage (107)

and bearing (108) as a single unit.
Assembly
q Precautions for assembly

a Clean the all parts and check them for dirt or dam-
age before assembling them.
a Coat the sliding surfaces of each part with engine
oil before assembling.
a Install seal ring (a) for the piston and piston hous-
ing with power receiving side (b) facing to housing
(c) as shown in the figure.
a Apply grease (G2-LI) to the seal ring and install it
evenly.
a Before cooling the bearing in dry ice, etc. for
3) Remove seal ring (109) and bearing (108) expansion fit, apply approximately 6 cc of engine
from cage (107). oil (EO10-CD or EO30-CD) to the bearing and
rotate it ten turns.
WE051F0300 23
1. Output shaft bearing 3. Install No. 5 ring gear (105).

1) Using push tool [11], install bearing (111) to
housing (112).
4. Install five guide pins (100).

2. Cage (for fixing No. 5 carrier) 1) Install plates (104) and discs (103) alternately
1) Install bearing (108) to cage (107) with the from the bottom.
push tool. a Three discs and four plates
2) Install seal ring (109) to cage (107). 2) Install five springs (102).
a Free length of spring: 59mm
3) Install cage (107) to housing (112) with push

tool [12].
a Press fit the inner race side of bearing
(108).
24 WE051F0300
6. No. 5 piston 3) Install No. 4 piston (99) to No. 4 housing (98).

1) Install seal ring (113) to No. 5 piston (101). 4) Install No. 4 housing (98), matching it to No. 5
a When installing the seal ring, check the piston.
direction of the pressure receiving side.
2) Install No. 5 piston (101), matching it to
springs (102).
a Check that the springs are fitted securely
in the grooves of the piston.
8. Assemble No. 5 carrier and No. 4 ring gear

assembly as follows.
1) Set No. 4 ring gear (96) to carrier (97) and
install snap ring (95).
7. No. 4 housing
1) Install seal ring (114) to No. 4 housing (98).
a When installing the seal ring, check the
2) Install seal ring (115) to No. 4 piston (99).
2) Install bearing (93) into gear (92) and fit thrust

washers (91) to both sides, then set them to
the carrier.
3) Install ball (94) and shaft (90).
WE051F0300 25
9. Using a guide bolt, install No. 5 carrier and No. 4

ring gear assembly (89) and tighten bolts (88).
3 Mounting bolt: 27-34Nm{2.8-3.5 kgm}
4) Using two forcing screws [13], tighten No. 3

housing (83) and insert dowel pin into the
housing securely.
a Keep two forcing screws [13] installed until
10. No. 4 discs, plates, and springs step 13.
1) Install plates (87) and discs (86) alternately
from the bottom.
a Four discs and five plates
2) Install five springs (85).
a Free length of spring: 59mm
12. Assemble No. 3 and No. 4 carrier and output

shaft assembly as follows.
1) Install inner race (82) to output shaft (78).
2) Install No. 5 sun gear (81) and snap rings (80)
and (79).
11. No. 3 housing 3) Install No. 4 sun gear (77) and snap ring (76).
1) Install the seal ring to No. 3 housing (83) and
No. 3 piston (84).
2) Install the No. 3 piston into the No. 3 housing.
3) Using eyebolts [9], install No. 3 housing (83).
a Check that the springs are fitted securely
into the grooves.
26 WE051F0300
4) Press fit bearing (116) to No. 3 carrier and

11) Set No. 3 and No. 4 carrier assemblies (64) to

output shaft (78).
5) Install bearing (74) into No. 3 planetary gear 12) Set jig [14] on the inner race side of bearing
(73) and fit thrust washers (72) to both sides, (116) and tighten bolt [15] to press fit bearing
then set them to the carrier. (116) to output shaft (78).
6) Install ball (75) and shaft (71). a Dimensions of tap hole:M10 x 1.5,
32mm deep
7) Install bearing (70) into No. 4 planetary gear

(69) and fit thrust washers (68) to both sides, 13) Install snap ring (62).
then set them to the carrier.
8) Align the pin hole in the shaft with the one in 13. No. 3 and No. 4 carrier assemblies and output
the carrier and install shaft (67). shaft assembly
9) Check that the pin holes are aligned before 1) Using eyebolt [7], install No. 3 and No. 4 carri-
driving pin (66). ers and output shaft assembly (61).
a Check the pin hole in carrier (64) for burrs 2) Remove two forcing screws [13].
before driving pin (66). If found, deburr the
hole using a sand paper before driving pin
(66).
10) Install seal ring (65).
WE051F0300 27
14. Install No. 3 ring gear (60). 2) Set ring gear (56) to No. 2 carrier (45) and
a Direct the notched side of the outside teeth install snap ring (55).
down.

15. Install guide pin (38). washers (50) to both sides, then set them to
the carrier.
16. Install plates (59) and discs (58) alternately from 4) Install ball (53) and shaft (49).
the bottom. a After assembling two gear sets, install
a Four discs and five plates snap ring (42).
17. Assemble No. 2 housing and No. 2 carrier 5) Install the seal ring to No. 2 housing.
assembly as follows. 6) Install No. 2 ring gear (48).
1) Press fit bearing (118) to No. 2 housing (46) 7) Install spacer (47).
and install snap ring (44). a Install the spacer with the cut inside end
directed to the carrier.
28 WE051F0300
8) Install No. 2 housing (46) to carrier assembly 4) Install sleeve (119).

(45). a If the sleeve has been removed, install it
a Press fit the inner race side of the housing to the bolt hole marked in the figure
bearing. with the slit side (d) facing down.
18. No. 2 housing and No. 2 carrier assembly

1) Using eyebolts [16], install No. 2 housing and
No. 2 carrier assembly (43).
5) Install spring (120) and valve (121).
2) Clamp No. 2 housing with tie bolt (10) and

pipe [17] and push the dowel pin into the hous-
ing securely.
3) Push up output shaft (42) lightly from under-
side and install snap ring (63).
WE051F0300 29
19. Install plates (41) and discs (40) alternately from

the bottom.
a Seven discs and eight plates
23. Assemble input shaft and No. 1 carrier assem-

bly as follows.
20. Install five springs (39).
washers (28) to both sides, then set them to
a Free length of spring: 77.0mm
the carrier.
2) Install ball (31) and shaft (27).
21. No. 2 piston
1) Install the seal ring to the No. 2 piston.
2) Install No. 2 piston (37).
a Align spring (39) with the spring groove in
the piston.
3) Set No. 1 ring gear (26) to No. 1 carrier and

4) Press fit bearing (122) to input shaft (22).
5) Install snap rings (20) and (19) to the input
shaft.
22. No. 1 housing assembly

1) Install the seal ring to the No. 1 housing and
No. 1 piston.
2) Install No. 1 piston (36) to housing.
3) Using eyebolts [4], install No. 1 housing
assembly (35) so that it is aligned with No. 2
piston.
a Press the housing and hit the dowel pin.
30 WE051F0300
6) Install input shaft (22) to No. 1 carrier assem- 24. Using eyebolt [3], lift off input shaft and No. 1 car-
bly (123), and then install snap ring (24). rier assembly (124) and install it so that No. 2 sun
gear engages with No. 2 planetary gear.
7) Install No. 1 sun gear (18).

1) Install plates (33) and discs (34) alternately
from the bottom.
a Five discs and six plates
a Free length of spring: 69.5mm
2) Install five springs (32).
8) Install snap rings (17) and (16).

9) Install No. 2 sun gear (15) and snap ring (14).
26. Front plate assembly

1) Press fit bearing (126) to front plate (125).
2) Install seal ring (127).
WE051F0300 31
3) Install collar (128) to No. 1 carrier (129). Using tool D1, check operation and stroke of each
piston.
Piston Standard stroke (mm)

No. 1 5
No. 2 7
No. 3 4
No. 4 4
No. 5 3
4) Using eyebolts [18], install front plate assem-

bly (23) so that it is aligned with the guide pin
and spring.
5) Press fit the inner race side of bearing (126) to
input shaft (22) and install snap ring (21).
a Check that the spring is fitted to the cover
securely.
29. Transmission case

1) Fit the O-ring and install transmission case
(11) using eyebolts [2].
27. Install three tie bolts (12).

3 Tie bolts: 156.9-176.5Nm{16.0-18.0 kgm}
28. Checking operation of piston
32 WE051F0300
2) Tighten eleven tie bolts (10) (to secure the 5) Fit the O-ring and install sleeve (5) using eye-
transmission case). bolt [1].
3 Tie bolts 6) Install flange (4).
156.9-176.5Nm{16.0-18.0 kgm}
7) Install cover (3).

3
30. Control valve
Cover: Gasket sealant (LG-6)
1) Set the transmission assembly on its side.
2) Fit the O-ring and install control valve assem-
31. Install sleeve (2).
bly (9).
3 Mounting bolt:
32. Install relief valve assembly (1).
3
44.1-53.9Nm{4.5-5.5 kgm}
Mounting bolt: 44.1-53.9Nm{4.5-5.5 kgm}
3) Install cover (7) and wiring harness (8) as a

single unit.
2 Cover: Gasket sealant (LG-6)
2 One bolt marked with an asterisk ( ):
4) Connect ten ECMV connectors (6).
WE051F0300 33
Removal and installation of torque

converter main relief valve assembly1
Removal
1. Remove the left side transmission cover.
2. Remove oil pressure pickup hoses (1) and (2).
3. Remove torque converter relief valve assembly

(3).[*1]
Installation

removal.
[*1]
3 Mounting bolt for torque converter main
relief valve: 44.1-53.9Nm{4.5-5.5 kgm}
34 WE051F0300
Disassembly and assembly of Assembly

torque converter main relief valve
a Clean all parts and check them for dirt or damage.
assembly 1 Coat the sliding surfaces of each part with engine
oil before assembling.
Disassembly
1. Assemble spring (15) and guide (14) onto spool
1. Remove plug (1) and remove valve (2), spring (3),
(16).
valve (4), valve (5), two shims (6), and springs (7)
and (8) from valve body (9).
2. Assemble valve (19), spring (18), and valve (17)
onto spool (16), assemble them onto valve body
a Check the quantity and thickness of the shims
(9), and install plugs (20) and (13).
and keep in a safe place.
3. Assemble springs (8) and (7) onto plug (10) and
2. Remove plug (10).
install them to valve body (9).
3. Remove plug (13) and remove guide (14), spring
4. Assemble valve (2), spring (3), and valve (4),
(15), spool (16), valve (17), spring (18), and valve
assemble them onto valve (5), and install shims
(19).
(6) on opposite side.
4. Remove plug (20).
a Check the thickness and quantity of shims
when assembling.
Standard shim thickness: 0.5mm
5. Assemble valve (5) onto valve body (9), and install

plug (1).
6. Tighten plugs (10) and (1).
WE051F0300 35
36 WE051F0300
WE051F0400
Bulldozer
1Shop Manual
D61EX-15
D61PX-15


Power train ....................................................................................................................... 2
Removal and installation of power train and lubricating oil pump assembly................. 2
Removal and installation of HSS and work equipment pump assembly....................... 4
Removal and installation of scavenging pump assembly ............................................. 5
Removal and installation of HSS motor assembly ........................................................ 5
Disassembly and assembly of HSS assembly.............................................................. 6
Removal and installation of final drive assembly ........................................................ 24
Disassembly and assembly of final drive assembly.................................................... 25
Power train 1
Removal and installation of power
train and lubricating oil pump
assembly 1
k Lower the work equipment to the ground fully
and stop the engine. Then, loosen the hydrau-
lic oil filler cap slowly to release the internal
1. Remove the operator's cab assembly. For details,

see Removal of operator's cab assembly. (Only
when the operator's cab is installed.)

3. Remove cover (1) and disconnect cover (2)

mounting bolt.
7. Remove the bottom cover of the universal joint.
8. Disconnect pump discharge hoses (9) and (10).

a Prepare plugs before disconnecting these
hoses
4. Raise cover (2) with block [1]. a Have tags or the like handy to match the areas
to which hoses are connected.
5. Remove deceleration pedal (3) as below:
1) Disconnect bracket (4) and fuel control cable 9. Disconnect pump suction hose (11).
(5).[*1]
2) Disconnect connector DCL (6). 10. Remove power train and lubricating oil pump
assembly (12).[*3]
6. Remove cover (2) as below:
1) Disconnect brake cable (7).[*2]
a Before disconnecting this cable, measure
its installed dimensions length.
2) Disconnect connector BRK (8).
2 WE051F0400
Installation

removal.
[*1]
a Adjust the deceleration cable. For details, see
linkage.
[*2]
a Adjust the deceleration cable. For details, see
Testing and adjusting, Adjusting brake pedal
linkage.
[*3]
a When installing, check that the O-ring is not
dropped off or caught in the assembly.
q Refilling with oil (Hydraulic tank)

Add oil through the oil filler to the specified level.
Run the engine to circulate the oil through the sys-
5 Hydraulic tank:55 l(EO10-CD)
WE051F0400 3
Removal and installation of HSS and q (8): Suction pipe

work equipment pump assembly 1 Hydraulic tank
q (9): Block
Removal
k Lower the work equipment to the ground fully

and stop the engine. Then, loosen the hydrau-
k Operate the work equipment control levers a
couple of times and release the residual pres-
sure from the work equipment circuit.


see Removal and installation of floor frame assem-
bly. 6. Lift off HSS and work equipment pump assembly
(10).[*1]
3. Remove the transmission right side cover. 4 HSS and work equipment pump assem-
bly: 70 kg
4. Disconnect connector HSP (1) and clip (2).
5. Disconnect the following pipes and blocks.

pipes and blocks.
a Have tags or the like handy to match the areas
to which hoses are connected.
q (3): Discharge hose
(Connected to control valve)
q (4): Pump discharge pressure detection hose
(Connected to the right fender pressure
detection port)
q (5): Block
q (6): Drain hose (Connected to drain block)
q (7): LS pressure input hose
(Connected from control valve)
a A is a pump servo valve.
Installation

removal.
[*1]
a Be careful not to damage the hose nipple when
removing.
a When installing, check that the O-ring is not
dropped off or caught in the assembly.
q Refilling with oil (Hydraulic tank)

4 WE051F0400
Removal and installation of Removal and installation of HSS

scavenging pump assembly 1 motor assembly 1
Removal Removal
1. Drain oil from the transmission case. 1. Remove the fuel tank assembly. For details, see
6 Transmission case: Removal and Installation of Fuel Tank Assembly.
69l (including oil in the HSS case)
2. Disconnect hoses (1) and (2) (between the main
2. Remove the undercover of the universal joint. control valve and HSS motor).
3. Remove hose (1). hoses.
a Have tags or the like handy to match the areas
4. Remove scavenging pump assembly (2) from the to which hoses are connected.
bottom of the machine.
3. Disconnect hydraulic tank return hose (3).
5. Lift off HSS motor assembly (5).

4 HSS motor assembly: 50 kg
Installation

removal.
q Refilling with oil (Transmission case)

Add oil through the oil filler to the specified Installation
level. Run the engine to circulate the oil
through the system. Then, check the oil level q Carry out installation in the reverse order to
again. removal.
5 Transmission case: 69l (including oil in the
HSS case)(EO30-CD) q Refilling with oil (Hydraulic tank)
WE051F0400 5
Disassembly and assembly of HSS Disassembly

assembly 1
1. Removal of upper cover assembly
Special tool 1) Disconnect clip (1).
2) Loosen locknut (2) and remove pins (3) and
(4).
New/Remodel
a Before disconnecting them, measure their
Necessity
Symbol
Sketch
installed dimensions lengths.
Q'ty
Part No. Part name
3) Disconnect parking brake cable (5).[*1]
4) Remove pin (6) and nut (7).
5) Remove brake rod (8).[*2]
1 709-302-1500 Wrench kit q 1
2 796-730-2140 Wrench q 1
E Commercially
3 available or Torque wrench q 1
795-630-1810
q Setup
1. To disassemble the upper cover assembly only:
1) Remove the floor frame assembly. For details,
see Removal and installation of floor frame
assembly.
2) Remove the fuel tank assembly. For details,
see Removal and installation of fuel tank
assembly.
3) Remove the HSS motor assembly. For
details, see Removal and installation of HSS 6) Disconnect HSS lubrication hoses (9) (con-
motor assembly. nected from scavenging pump) and (10) (con-
nected from power train and lubric ating
2. To disassemble the brake and carrier assembly pump).
only: a Prepare plugs before disconnecting these
a Carry out disassembly of one side or both hoses.
sides as necessary. a Have tags or the like handy to match the
1) Remove the track shoe assembly. For details, areas to which hoses are connected.
see Removal of track shoe assembly. 7) Disconnect brake hose (11).
2) Remove the final drive assembly. For details, 8) Disconnect drain hoses (12) and (13).
see Removal and installation of final drive 9) Remove hose and tube (14).
assembly. 10) Remove hose (15).
a Perform the steps after 3. Removal of the 11) Disconnect pressure detection hose (16).
brake assembly. 12) Disconnect clip (17).
3. To disassemble the bevel pinion and bevel gear

shaft assembly (all):
1) Perform the steps 2. 1) and 2) (both sides) and
then 1. 1) - 3) above.
2) Remove the PTO and torque converter trans-
mission assembly. For details, see Removal
and installation of PTO, toque converter and
transmission assembly.
a Perform the steps after 1.13) on the fol-
lowing page.
6 WE051F0400
13) Disconnect clip (18). 19) Remove five sleeves (24) and two sleeves
14) Remove cover (19) and disconnect connector (25) from the HSS case.
(20). 20) Remove four dowel pins (90) from the HSS
15) Remove bracket (21). case (as they may be left in the cover).
k Be sure to remove four dowel pins (90).
Failure to do so could damage sleeves
(24) and (25) and cut the O-ring when
assembling.
16) Remove brake valve assembly (22).

17) Remove cover assembly (23) mounting bolt.
18) Using forcing screw [1], remove the pilot por-
tion and lift off upper cover assembly (23).
a Slowly raise horizontally as there are 2. Disassembly of upper cover assembly
sleeves, tubes, etc. 1) Remove oil temperature sensor (26), tubes
4Upper cover assembly (23): 140 kg (27) and (28).
2) Input gear assembly

1] Remove snap ring (29).
WE051F0400 7
2] Pull out gear assembly (30) and cage (31) 5] Remove bearing (42) and spacer (42a)
together with puller [2], and then remove from gear assembly (39).
gear assembly (30) from cage (31).
3] Remove bearing (33) from gear assembly
(30).
6] Using gear puller [3], push out shaft (43).
3) Intermediate gear
1] Take off bolt (35) and remove holder (36).
a Remove them from both sides.
2] Remove gear (37).
3] Take off the bolt and remove holder (38).
7] Remove snap ring (44) and bearing (45)

from cover A.
8] Remove outer race (46) from cover B.
4] Tap out shaft (40) from the bolt side and

remove gear (39).
8 WE051F0400
9] Remove bearing (47) from shaft (43). 4. Disassembly of brake assembly

1) Remove flange (49).
2) Detach snap ring (50) and remove spacer
(51).
3. Removal of brake assembly

1) Sling the brake assembly temporarily with pipe
[4] (with a bar inside), take off the mounting
k
bolt, and disconnect brake carrier assembly
Set tool [8] so that the cover won't fly off by
(48), using forcing screw [5] and guide bolt [6].
the spring force.
(with the assembly put on guide bolt [6])
3) Set puller [7] and tool [8] and tighten bolt C
a Do not remove four hexagon socket head
while loosening four hexagon socket head
bolts.
bolts and tool [8].
4) Even after the four hexagon socket head bolts
have been removed, continue to tighten bolt C
while slowly loosening tool [8] evenly.
a The inner race side of the bearing comes
out.
5) Temporarily fix the piston (at the rear) with bolt
D and lift off cover assembly (52).
a Since the piston (at the rear) is attached to
the c over wit h a spri ng, r emov e t he
assembly altogether after temporarily fix-
ing the piston.
2) Bring down the assembly to the ground by bal-

ancing with brake carrier assembly (48) weigh-
ing 150 kg.
k Be careful not to drop brake assembly
(48) from pipe [4] (with a bar inside). (A
load of 150 kg will be imposed suddenly.)
WE051F0400 9
6) Remove bearing (53) from cover (52). 12) Remove drum (62).
13) Detach snap ring (63), then remove bearing
(64).
a Pry up the bearing from the notch of the
hub.
14) Take off 18 mounting bolts, then remove hub
(65) from hub (66).
7) Turn over cover assembly (52) and remove

bolt D.
8) Remove cage (54) and piston (55).
9) Remove seal rings (56) and (57) from cage
(54).
10) Remove double springs (58).
15) Remove bushing (67) from hub (65).
11) Remove spring (59), disc (60), and plate (61)

in this order from drum (62).
5. Disassembly of carrier assembly
q Spring (59) and disc (60): 5 pieces
q Plate (61): 4 pieces
1) Reverse hub (66), detach bolt (68) and
remove carrier assembly (69).
10 WE051F0400
2) Extract cage assembly (70) from hub (66). 2) Using gear puller [9], remove sun gear (81)
3) Reverse cage assembly (70), take off snap and bearing (82).
ring (71) and remove ring gear (72).
3) Using the bearing race puller, remove bearing

4) Drive in roll pin (73) into shaft (74). (83).
5) Pull out shaft (74) and remove gear (75), 4) Remove collar (84).
thrust washer (76), and bearing (77). 5) Remove snap ring (85).
a Pull roll pin (73) out of the shaft. a Only the right side of the machine.
6) Remove bushing (78).
7. Bevel pinion assembly

1) Remove mounting bolt (94).
6. Sun gear
2) Using the guide bolt and forcing screw,
1) Take off snap ring (79) and remove collar (80).
remove bevel pinion assembly (95) .
a Check the quantity and thickness of the
shims and store them.
WE051F0400 11
3) Disassembly of bevel pinion assembly 6] Remove bearing (106) and spacer (108)
1] Take off bolt (97) and remove plate (99) from bevel pinion (102).
and pin (100).
8. Bevel gear shaft and bevel gear assembly

2] Secure the pinion with a press and 1) Sling bevel gear and shaft assembly (110)
remove nut (101) with tool E1. temporarily.
3] Using push tool [11], remove bevel pinion 2) Remove cage assemblies (111) and (112).
(102) from cage (103) . a Check the thickness, quantity, and posi-
tions of shims (113).
a Since both cages are different from each
other, mark them.
4] Remove bearing (104).

5] Remove outer races (105) and (107) from
cage (103).
3) Move bevel gear and shaft assembly (110) to
the left end fully and remove bearing (114)
with puller [12].
a Remove only the bearing on the left side
of the machine.
12 WE051F0400
4) Lift bevel gear (115), take off mounting nut Assembly

(116), and remove bevel gear (115) from bevel
gear shaft assembly (117). q Precautions for assembly
5) Extract bevel gear shaft assembly (117) to the a Clean all parts and check them for dirt or damage
left of the machine and remove it. before installing.
a Drop engine oil onto the rotating parts of each
bearing and rotate it several turns.
a Coat the sliding parts with engine oil before install-
ing.
2 Rotary seal ring: Fix each seal ring with
grease (G2-LI) and install it very carefully not
to get caught in the parts.
a Check that the snap rings are fitted in the grooves.
1. Bevel gear shaft and bevel gear assembly

1) Install seal ring (121) to bevel gear shaft (117).
6) Remove bearing (118).

7) Remove bolts (119).
8) Remove outer races (120) from cages (111)
and (112).
2) Install bolt (119) to bevel gear shaft (117).

3) Heat bearing (118) with a bearing heater, etc.
and install it to the left side of the bevel gear
shaft by shrink fit.
a If the bearing is heated too much, its heat
treatment hardness is lowered. Accord-
ingly, do not raise the bearing temperature
more than 120°C.
9) Remove seal ring (121) from bevel gear shaft a After installing the bearing, drop engine oil
(117). onto its rotating parts and rotate it several
turns.
a Check that the clearance at the bearing
end is 0.03 mm or less.
4) Install outer race (120) to cages (111) and
(112).
WE051F0400 13
5) Insert bevel gear shaft (117) in bevel gear 7) Install cages (111) and (112) to bevel gear and
(115) slung at the center of the case from the shaft assembly (110).
right side of the machine. a Since both cages are different from each
a Temporarily tighten mounting nut (116) in other, take care not to mistake them.
advance. a Install shims (113) of the thickness and
quantity recorded when removed.
q Standard shim thickness:1.5mm
q Type of shim thickness:
0.2mm, 0.3mm, and 0.5mm
3 Mounting bolt:
98.1-122.6Nm {10-12.5 kgm}
8) Place a plastic hammer or the like between
the bevel gear and the case to stop rotation.
3 Mounting nut:
245-309Nm {25-31.5kgm}
6) Heat bearing (114) with a bearing heater, etc.

and install it to the left side of the bevel gear
shaft by shrink fit.
more than 120°C.
a After installing the bearing, drop engine oil
onto its rotating parts and rotate it several
turns.
a Check that the clearance at the bearing 9) Adjusting pre-load
end is 0.03 mm or less. a Adjust the pre-load with the bevel pinion
assembly removed.
1] Rotate the bevel gear and shaft assembly
several turns to fit the bearing.
2] Install tool E2 to the end of bevel gear
shaft (110) and measure the rotation
torque with a torque wrench E3.
q Standard rotation torque:
10.3-14.7Nm {1.05-1.5kgm}
a If the rotation torque is lower than the
standard value, reduce the quantity of
shims (113) in step 7. If the former is
higher, increase the latter.
14 WE051F0400
2. Bevel pinion assembly

1) Assembly of bevel pinion
1] Using push tool, press fit bearing (106) to
bevel pinion (102) and install spacer (108).
7] Install pin (100) then tighten plate (99)

mounting bolt (97).
3 Bolt: 11.8-14.7Nm {1.2-1.5kgm}
2] Using the push tool, press fit outer races

(105) and (107) to cage (103).
3] Place bevel pinion (102) on the press
stand and set cage (103).
2) Install shims and bevel pinion assembly (95)

with a guide bolt.
a Install shims of the thickness and quantity
recorded when removed.
q Standard shim thickness:2mm
4] Press fit bearing (104) into cage (103) with q Type of shim thickness:
the press. 0.2, 0.3, and 1.0 mm
5] Secure the pinion with the press and
tighten locknut (101) with tool E1.
2 Locknut: Liquid adhesive (LT-2)
3 Locknut: 392-441Nm {40-45kgm}
6] After tightening the nut, return it until one
of its pin holes (8 places) aligns with one
of the pin holes of the pinion shaft (5
places).
a Return the nut by 0 - 9°C.
a Tighten the nut while turning the cage.
a After tightening the nut, check that the
bevel pinion rotates smoothly.
WE051F0400 15
3. Adjusting backlash and tooth contact 2) Adjusting tooth contact

1) Adjusting backlash Inspection
Apply the probe of dial gauge [13] to the tooth 1] Apply red lead thinly to the tooth surfaces
tip at the end of the bevel gear at right angles. of the bevel gear and turn the bevel gear
Fix the bevel pinion and move the bevel gear in the forward and reverse directions, then
forward and backward, and read the value at check the tooth contact pattern on the
this time. bevel gear.
a Backlash standard value: 0.18 - 0.23 mm
a Measure the backlash diagonally at three
or more places.
q If the measured backlash is out of the
standard range, adjust it using he follow-
ing procedure.
2] The tooth contact must be as follows:

(The standard distance is measured from
the tooth tip of the bevel pinion.)
a) Center of tooth contact: 20 - 40% of
face width (from the small end)
b) Width of tooth contact: 30 - 50% of the
a Increase or decrease the number of right face width
and left shims to adjust backlash. Do not c) Center of tooth contact: 35 - 65% of
change the total thickness of both shims tooth depth
so that the pre-load will not change. (If the d) Width of tooth contact: 60 - 80% of
thickness of the shim on one side is tooth depth
increased, equally decrease the thickness Check that tooth tip A, bottom B, small
of the other side, and vice versa.) end C, and large end D of the teeth
q When backlash is insufficient are not subject to any strong tooth
Decrease the thickness of the shim on the contact.
right side of the machine body and equally a If the bevel gear and bevel pinion are
increase the thickness on the left side. adjusted in this way, their teeth come
(Move the bevel gear in the direction A.) in contact with each other correctly
q When backlash is too large when they are loaded.
Decrease the thickness of the shim on the
left side of the machine body and equally
increase the thickness on the right side.
(Move the bevel gear in the direction B.))
16 WE051F0400
Adjusting
If the tooth contact pattern is not proper, adjust the
tooth contact using the following procedure.
1] If the bevel pinion is too far from the center line of
the bevel gear, the contact is at the small end of
the bevel gear tooth faces curved outward and at
the large end of the bevel gear tooth faces curved
inward.
q In this case, adjust the tooth contact using the fol-
lowing procedure.
Adjust the thickness of the shims on the bevel pin-
ion side to move the bevel pinion in the direction A.
Move the bevel gear in the direction B, then check
the tooth contact pattern and backlash again.
4. Sun gear
1) Install snap ring (85) to the shaft.
a Perform this work only for the right side of
the machine.
2) Install collar (84).
3) Install bearing (83) with a push tool.
2] If the bevel pinion is too close to the center line of

the bevel gear, contact is at the large end of the
bevel gear tooth faces curved outward and the
small end of the bevel gear tooth faces curved
inward.
q In this case, adjust the tooth contact using the fol-
lowing procedure.
Adjust the thickness of the shims on the bevel pin- 4) Install sun gear (81).
ion side to move the bevel pinion in the direction A. 5) Install bearing (82) with the push tool.
Move the bevel gear in the direction B, then check a Press fit the inner race and outer race
the tooth contact pattern and backlash again. simultaneously.
a Do not change the total thickness of the shims on
both sides. 6) Install collar (80) and snap ring (79).
3] When adjustment is finished, tighten the mounting
bolts of the cage and bevel pinion assembly to the
specified torque.
3 Mounting bolts of cage and bevel pinion
assembly: 98 - 123 Nm {10 - 12.5 kgm)
WE051F0400 17
5. Assembly of carrier assembly 7) Install carrier assembly (69) in hub (66) and
a Check roll pin (73) hole for sharp fin. Remove install bolts (68).
the sharp fin with a paper if any. 3 Mounting bolt: 59-74Nm {6.0-7.5kgm}
1) Install bushing (78) to carrier assembly (69).
2) Install bearing (77) to gear (75). Fit thrust
washers (76) to the top and bottom of the
bearing, then set them to the carrier.
3) Install shaft (74), aligning the inside of the
thrust washers and bearing with the shaft hole
of the carrier.
a Align the roll pin hole accurately.
4) Install roll pin (73).
After installation, caulk three spots around the
roll pin hole.
6. Assembly of brake assembly

1) Fit bushing (67) in hub (65).
5) Set cage (70) in ring gear (72) and install snap

ring (71).
6) Reverse cage assembly (70) to install it to hub
(66).
2) Reverse hub (66).

3) Install hub (65) to hub (66) and tighten 18
mounting bolts.
3 Mounting bolt: 59-74Nm {6.0-7.5kgm}
4) Install bearing (64).
6) Set brake drum (62) in hub (66).
18 WE051F0400
7) Install disc (60), spring (59), and plate (61) in 10) Fit O-ring (130) in cage (54).
this order to drum (62). 11) Install piston (55).
q Spring (59) and disc (60): 5 pieces a Check that the spring is fitted in both pis-
q Plate (61): 4 pieces ton and case.
12) Align O-ring (130) with oil hole E and install
cage (54).
13) Temporarily fix cage (54) with the bolt from
underneath.
8) Install spring (58) to cover (52).
14) Lift and install cover assembly (52).

a Align the cover with the four oil holes F on
the drum. FF is an oil path.
15) Set tool [8], tighten cover (52), and install four
hexagon socket head bolts (131).
9) Install piston seal rings (56) and (57) to cage

(54).
a Install the seal rings evenly, being careful
to the pressure receiving side.
2 Seal ring: G2-LI grease
WE051F0400 19
16) Install bearing (53). 8. Assembly of cover assembly

17) Install spacer (51) and attach snap ring (50).
18) Install flange (49). 1) Left carrier drive gear
1] Press fit bearing (47) to shaft (43).
7. Installation of brake and carrier assembly

2] Press fit bearing (45) to cover A, then
1) Install brake carrier assembly (48) weighing
150 kg to the guide bolt by balancing, using
3] Press fit outer race (46) to cover B.
pipe [4] (with a bar inside) and guide bolt [6].
a Align the assembly with four oil holes FF.
k Check that the bar is deep inside and
take care not to drop brake assembly
(48) weighing 150 kg.
2) Using block [15] and jack [16], install brake
carrier assembly (48).
4] Using puller [18], press fit shaft (43) to the

inner race side of bearing (45).
a Replace the bolt with one having dif-
ferent length.
20 WE051F0400
2) Intermediate gear assembly

1] Install bearings (42) and spacer (42a) to
gear (39).
4) Input gear assembly

1] Install bearings (33) to gear (30).
2] Install gear assembly (30).
2] Align ball (41) and press fit shaft (40) to
3] Install cage (31) and ball (32), aligning
the bearing inner race side of gear (39).
them with ball (32) hole.
3] Install ball (41) during the press fitting of
4] Install snap ring (29).
the shaft and install shaft (40) and gear
(39).
5) Install tubes (27) and (28) and oil temperature

sensor (26).
4] Install gear (37).
5] Install holder (36) and tighten bolt (35).
3 Mounting bolt:
98-123Nm {10-12.5kgm}
6] Install holder (38).
3 Mounting bolt:
98-123Nm {10-12.5kgm}
3) Install the valve and spring in the cover, then
install plug (34).
WE051F0400 21
9. Installation of cover assembly 3) Install cover assembly (23) horizontally, being

1) Install two sleeves (25) and five sleeves (24) careful with the tube, sleeves, etc.a
on the HSS case. k Check that sleeves (24) and (25) are
2) Be sure to remove the dowel pin (marked properly engaged with the mating
with an asterisk( )) from the cover (23) parts. (They should not be raised when
and case. cover assembly (23) is placed. If the
k Be sure to check that no dowel pin is sleeves are raised, swing cover assem-
i n stal l ed , be cau se i t c an da ma ge bly (23) back and forth and around.)
sleeves (24) and (25) and cut O-ring. Damaged sleeves (24) and (25) and O-
ri ng could cause seri ous damage
i ncl uding defecti ve l ubricati on of
power line.
q Apply gasket sealant to the cover mounting face

using the following procedure.
a The mating faces of the case and cover must be
free of dent, rust, oil and grease, and water. 4) Install dowel pins (see an asterisk in 2)) in
a Seamlessly apply gasket sealant to both sides of four places.
the mating faces of the case and cover in the fol- 5) Install cover assembly (23).
lowing manner. 3 Mounting bolt:
2 The cover mating face on the HSS: 245-309Nm {25.0-31.5kgm}
Gasket sealant (LG-6) a Since there are five different lengths of a
mounting bold, check positions by referring to
the figure.
Bolt A: 70 mm (1)
Bolt B: 55mm (14)
Bolt C: 75mm (3)
Bolt D: 85mm (2)
Bolt E: 140mm (1)
a Secure the bracket (21) (see the diagram
below).
22 WE051F0400
6) Install brake valve assembly (22).

3 Mounting bolt: 44.1-53.9Nm {4.5-5.5kgm}
7) Install connector (20) and cover (19).
8) Install clip (18).
q To install from then on, reverse the removal proce-

dure.
[*1]
a Adjust the parking brake lever. For details, see
Testing and adjusting, Adjusting parking brake
lever.
[*2]
a Adjust the brake pedal. For details, see Testing
and adjusting, Adjusting brake pedal.
WE051F0400 23
Removal and installation of final 8. Remove final drive assembly (3) slowly by pulling
drive assembly 1 it outward. [*2]
4 Final drive assembly: 800 kg (one side)
Removal
1. Remove the track shoe assembly. For details, see

Removal and installation of track shoe assembly.
2. Using jacks, lift up machine body and support front

frame and HSS case on stands or blocks [1] and
[2], then lower equipment to ground..
k Set the stands securely.
Installation

removal.
[*1]
2 Guard mounting bolt: Liquid adhesive (LT-2)
3. Drain oil from final drive case. 3 Guard mounting bolt:
4 Final drive: 28.5 l (one side) 235-285Nm {23.5-29.5kgm}
4. Remove guards (1) and (2). [*1] [*2]

Since connection is made with a spline, align engage-
ment using transmission jack [1], plate [3], lever block
[4], bar [5], etc.
3 Final drive mounting bolt:
490-608Nm {50-62kgm}
5. Remove all mounting bolts of final drive assembly,

except 2 - 3 on top.
6. Sling final drive assembly (3) temporarily and sup-

port the lower side on transmission jack [1].
k Do not sling the final drive assembly by its q Refilling with oil (final drive case)
sprocket. If it is slung so, it will rotate. Add oil through the oil filler to the specified level. Run
7. Remove remaining mounting bolts, then discon- Then, check the oil level again.
nect final drive assembly from HSS case, using 5 Final drive case: approximately 32 l(EO30-CD)
forcing screws [2].
24 WE051F0400
Disassembly and assembly of final 2) Remove output shaft cover (3).

drive assembly 1
Special tool
New/Remodel
Necessity
Symbol
Sketch
Q'ty
Part No. Part name
796-730-2300 Wrench t 1
1
795-630-1803 Torque wrench t 1
J 2 791T-427-1330 Guide t 1 Q
3 791-545-1510 Installer t 1
4 791T-427-1280 Push tool t 1 Q
3) Remove three bolts to remove plate (4).

Disassembly a Check the thickness and quantity of shim
(5).
1. Sprocket assembly
1) Place final drive assembly (1) on block [1] with
the sprocket side up.
2) Remove mounting bolts and lift off sprocket
assembly (2).
4) Using plates [3] and [4], puller [5] and bolt [6],
push out output shaft assembly (6).
a The bearing is removed together with the
output shaft.
2. Output shaft
1) Sling final drive assembly (1) and turn it over,
then support it on jacks or blocks [2] securely.
a Distance (a) between the output shaft and
ground must be at least 50 mm.
WE051F0400 25
5) Using eyebolt [7], remove case assembly (7) 3. No.2 gear

from output shaft assembly (6). 1) Support case assembly (7) on a blocks or
jacks [8] securely.
2) Remove floating seal (40).
a Store the floating seal so that its metallic
contact surfaces will not be damaged.
3) Remove cover (12).
6) Disassemble output shaft assembly according

1] Remove floating seal (8) from output shaft
(9).
a Store the floating seal so that its
metallic contact surfaces will not be 4) Remove spacer (13).
damaged.
2] Remove spacer (10).
3] Remove bearing (11).
5) Pull No.2 gear (14) out of case, then lift it off.
26 WE051F0400
4. No.2 pinion 4) Using plates [10] and [11], puller [12] and three
1) Remove No.2 pinion cover (15). bolts [13], push out and remove No.2 pinion
and bearing assembly (20).
a The No. 2 pinion and bearing assembly is
removed together with the bearing (on the
HSS side) and outer race (on the sprocket
side).
2) Remove No.2 pinion cage and outer race

assembly (16) and shim (17).
a Use forcing screw [9] to remove these
assembly and shim.
a Check the thickness, quantity, and loca-
tion of the shim. 5) Remove gear cover (21).
6) Remove No.1 gear (22).
3) Remove outer race (18) from No.2 pinion cage

(19). 7) Disassemble No.2 pinion and bearing assem-
bly.
1] Remove bearing (23) from No.2 pinion
(24).
WE051F0400 27
5. No.1 pinion cage 2) Remove bearings (31) and (32) from No.1 pin-
1) Remove No.1 pinion cage assembly (25) and ion (33).
shims (26).
a Remove the assembly using forcing screw
[14].
a Check the thickness, quantity, and posi-
tions of shims.
7. Outer race
1) Remove outer races (34) and (35) from output
shaft of case (36).
2) Remove outer races (37) from No.1 pinion of
case (36).
2) Remove oil seal (27) from No.1 pinion cage
(28).
3) Remove outer race (29).
8. Cover
1) Turn over case assembly and place it on
blocks [15].
6. No.1 pinion 2) Remove cover (38) from case (39).
1) Remove No.1 pinion and bearing assembly
(30).
28 WE051F0400
Assembly 3. No.1 pinion

1) Using push tool [15] and press, press fit bear-
a Clean and dry all parts thoroughly, and check them ing (31) to No.1 pinion (33).
for dirt, dent. etc. Coat the sliding surfaces of all a Press fit bearing (32) with the same way.
parts with engine oil before reinstalling them. a Press fit bearing (32) following bearing
(31). If the bearings are press fitted in
1. Cover reverse order, it may damage ball-cage
1) Place case (39) on blocks [15]. (K) of bearing (32).
2) Fit the O-ring, then install cover (38) to output a To temporarily place the bearings with
shaft portion of case. bearing (32) side down, have table (P)
2 Mounting bolt: Liquid adhesive (LT-2) handy.
3 Mounting bolt:
98-123Nm {10-12.5kgm}
a After press fitting, check that there is no

clearance between the bearing and No.1
pin using a 0.03 mm-clearance gauge.
2. Outer race
1) Press fit outer race (37) until it touches case
(36).
a Install it on No.1 pinion shaft.
clearance between the outer race and the
case using a 0.03 mm-clearance gauge.
a Apply engine oil to the rolling surfaces of
the bearing.
2) Press fit outer races (34) and (35) until they
touch case (36).
a Install them on the output shaft.
case using a 0.03 mm-clearance gauge.
the bearing.
WE051F0400 29
2) Install the No.1 pinion and bearing assembly 2) Using push tool [16], press fit oil seal (27).
(30) in the case. 2 Oil seal press fitting surface:
a Replace the oil seal with new one.
a Apply gasket sealant thinly to the No. 1
pinion cage side, and wipe off projected
sealant.
2 Oil seal lip: Grease (G2-LI)
4. No.1 pinion cage

1) Press fit outer race (29) until it touches No.1
pinion cage (28).
cage using a 0.03 mm-clearance gauge.
3) Insert shims (26) between No.1 pinion cage
assembly (25) and case (36), then tighten 8
the bearing.
mounting bolts evenly.
a Set the thickness of shim (26) to 2.5mm.
a When installing the No. 1 pinion cage
assembly, take care not to damage the oil
seal lip with the No. 1 pinion spline.
3 Mounting bolt:
98-123Nm {10-12.5kgm}
30 WE051F0400
5. No.2 pinion
1) Using push tool [17] and press, press fit bear-
ing (on the sprocket side) (23) to No.2 pinion
(24).
clearance between the bearing and No.2
pinion using a 0.03 mm-clearance gauge.
7) Using push tool [19], press fit outer race (41)

into case (36).
a Do not press fit outer race (41) completely, but
press fit only about 19 mm from end of case.
(Leave about 5 mm.)
2) Install No.1 gear positioning tool J2 to case

(36).
3) Reverse the case to set tool J2 side down.
4) Set No.1 gear (22) to tool J2.
5) Install gear cover (21).
3 Mounting bolt:
98-123Nm {10-12.5kgm}
8) Fit the O-ring, then install No.2 pinion cover

(15).
3 Mounting bolt:
98-123Nm {10-12.5kgm}
a Press fit outer race (41) completely by
installing No. 2 pinion cover. (to eliminate
the clearance between the outer race and
No.2 pinion cover).
6) Using eyebolt [18], sling and install No.2 pin-

ion and bearing assembly (20) in No.1 gear.
WE051F0400 31
9) Turn over case assembly to set No.1 pinion 13) Insert shims (17) between No.2 pinion cage
spline side up. and outer race assembly (16) and the case,
10) Remove tool J2. then tighten ten mounting bolts evenly.
11) Heat bearing (42) with a bearing heater or the a Install shims (17) as thick as 3.0mm.
like and install it to No.2 pinion (24) by shrink 3 Mounting bolt:
fit. 98-123Nm {10-12.5kgm}
more than 120°C.
6. Floating seal
1) Turn over case assembly to set No..1 pinion
spline down.
2) Using tool J3, press fit floating seal (40) into
12) Press fit outer race (18) until it touches No.1 case (36).
pinion cage (19). a Remove all oil and grease from the O-ring
a After press fitting, check that there is no and O-ring contact surface, and dry before
clearance between the outer race and the installing.
cage using a 0.03 mm-clearance gauge. a After installing the floating seal, check that
a Apply engine oil to the rolling surfaces of its inclination is 1 mm or less.
the bearing. a Check that the metallic contact surfaces of
the floating seal are free from dirt.
32 WE051F0400
3) Using tool J3, press fit floating seal (8) to out- 8. Output shaft
put shaft (9). 1) Using tool J4, press fit bearing (11) onto out-
a For precautions when fitting the floating put shaft (9).
seal, see 2) above. a After press fitting, check that there is no
clearance between the bearing and the
output shaft using a 0.03 mm-clearance
gauge.
2) Install spacer (10) to output shaft.
7. No.2 gear
1) Turn over case assembly to set No.1 pinion
spline side up.
2) Sling No.2 gear (14) and install it to inside of case.
3) Using eyebolt [7], sling and insert case assem-
bly (7) in output shaft assembly (6).
a Take care not to damage the outer race of
the bearing with the output shaft.
a Check that the metallic contact surfaces of
the floating seal are free from damage,
dirt, oil, and grease.
a Float case assembly (7) about 10 mm so
that the metallic contact surfaces of the
floating seal will not be damaged.
3) Install cover (12) to case assembly (7).

2 Mating face of the cover:
3 Mounting bolt:
455-565Nm {46.5-58kgm}
WE051F0400 33
1] Heat bearing (43) with bearing heater, etc. 2] Using tool J1, measure the rotation torque
and fit it to output shaft assembly (6) by of No.1 pinion (30).
shrink fit. q Standard rotation torque:
a If the bearing is heated too much, its 4-5Nm {0.4-0.5kgm}
heat treatment hardness is lowered. a At this time, rotate the output shaft at
Accordingly, do not raise the bearing least one full turn.
temperature more than 120°C. a When the rotation torque is outside
a Insert the bearing while slowly lower- the standard value, further tighten the
ing the case assembly. At this time, bolts 1/6 turn according to 1] above
take care not to damage the metallic again.
contact surfaces of the floating seal or
not to cause an inclination in the float-
ing seal.
3] Remove plate (4) and measure the step

height (d) between the top face of output
shaft assembly (6) and that of bearing
4) Select shim (5) for plate (4) according to the (43).
following procedure. a Under this condition, check that the
a Perform the following procedure while vertical play of the output shaft on
bearing is lubricated with a little amount of case assembly (7) is 0.1 mm maxi-
oil and it is at the normal temperature mum
1] Clamp shim (5) between plate (4) and out-
put shaft assembly (6) with three mounting
bolts evenly.
a Install shims (5) as thick as 3.3mm.
a Tighten three mounting bolts evenly
by 1/6 turn
3 Mounting bolt:
588-1,030Nm {60-105kgm}
34 WE051F0400
4] Select and insert shim (5) so that its thick- 5) Fit the O-ring, then install output shaft cover
ness will be level difference (d) measured (3).
above + 0 to 0.1 mm. 3 Mounting bolt:
q Standard shim thickness:1.9mm 98-123Nm {10-12.5kgm}
q Type of shim thickness:
0.2, 0.3, and 1.0 mm
5] Install plate (4).
3 Mounting bolt:
824-1,030Nm {84-105kgm}
9. Adjusting shims of No.2 pinion cage assembly

1) Select shim (17) for No.2 pinion (19) according
a Perform the following procedure while
bearing is lubricated with a little amount of
(Reference): Clearance between cover (38) and oil and it is at the normal temperature
out put sh aft assem bly (6) aft er 1] Clamp No. 2 pinion cage and outer race
adjustment of shim (5). assembly (16) with four mounting bolts
Clearance (e) standard value: 1.8 - 3.3 mm evenly.
a Do not insert any shim.
a Rotating the No. 1 gear (22) 1 turn or
more, tighten the mounting bolts.
3 Mounting bolt: 15 Nm {1.5 kgm}
2] Measure the clearance (c) between No.2
pinion cage, outer race assembly (16) and
case (36).
a Measure the clearance at two to four
places and calculate the average.
WE051F0400 35
3] Select and insert shims (17) so that their 10. Adjusting shim of No.1 pinion cage assembly
thickness will be average clearance calcu- 1) Select shim (26) for No. 1 pinion cage assem-
lated in the above step + 0.1 mm. bly (25) according to the following procedure.
q Standard shim thickness:1.7mm a Perform the following procedure while
q Type of shim thickness: bearing is lubricated with a little amount of
0.2, 0.3, and 1.0 mm oil and it is at the normal temperature
4] Fit the O-ring, then tighten 10 mounting 1] Clamp No. 1 pinion cage assembly (25)
bolts of No.2 pinion cage and outer race with four mounting bolts evenly.
assembly (16) evenly. a Do not insert any shim.
3 Mounting bolt: a Rotate No.1 pinion 1 full turn or more
98-123Nm {10-12.5kgm} and tighten the mounting bolts.
3 Mounting bolt: 15 Nm {1.5 kgm}
2] Measure the clearance (b) between No.1
pinion cage assembly (25) and case (36).
a Measure the clearance at two to four
places and calculate the average.
2) Using tool J1, measure the rotation torque of

No.1 pinion (30).
q Standard rotation torque: Rotation torque
measured in 8-4) + 0 to 3 Nm {+ 0 to 0.3
kgm}
3] Select and insert shims (26) so that their
a If the rotation torque is out of the standard
thickness will be average clearance calcu-
range, select shim according to step 1)
lated in the above step + 0.1 mm.
again.
q Standard shim thickness:1.52mm
q Type of shim thickness: 0.2, 0.3, and
1.0 mm
4] Fit the O-ring, then tighten eight mounting
bolts of No.1 pinion cage assembly (25)
evenly.
3 Mounting bolt:
98-123Nm {10-12.5kgm}
36 WE051F0400
2) Using tool J1, measure the rotation torque of

No.1 pinion (30).
q Standard rotation torque: Rotation torque
measured in 9-2) + 0 to 5 Nm {+ 0 to 0.5
kgm}
a If the rotation torque is outside the stan-
dard value, select shims again as in step
1) above.
11. Sprocket assembly

1) Turn over case assembly to set No.1 pinion
spline down.
2) Sling and install sprocket assembly (2).
3 Mounting bolt:
1,010-1,157Nm {103-118kgm}
WE051F0400 37
38 WE051F0400
WE051F0500
Bulldozer
1Shop Manual
D61EX-15
D61PX-15


Undercarriage .................................................................................................................. 2
Removal and installation of track frame assembly........................................................ 2
Removal and installation of idler assembly................................................................... 4
Disassembly and assembly of idler assembly .............................................................. 5
Removal and installation of recoil spring assembly ...................................................... 9
Disassembly and assembly of recoil spring assembly................................................ 10
Removal and installation of track roller assembly....................................................... 13
Disassembly and assembly of track roller assembly .................................................. 14
Removal and installation of carrier roller assembly .................................................... 17
Disassembly and assembly of carrier roller assembly ................................................ 18
Undercarriage 1 7. Remove pivot shaft cover (4).

[*2]
Removal and installation of track
frame assembly 1
Removal
1. Expand the track shoe assembly. For details, see

Expansion and installation of track shoe assembly.
2. Using jacks, lift up machine body and support front

frame and HSS case on stands or blocks [1] and
[2], then lower equipment to ground.
k Set the stands securely.
8. Remove plate (5). [*3]
3. Support track shoe on opposite side of track frame

to be removed on blocks, etc.
k If the equalizer bar side pin is removed, the
track frame on the opposite side falls.
Accordingly, support the track shoe on the
opposite side securely. 9. Sling track frame assembly (6), pull it out to the
outside of the machine until it comes off the pivot
4. Remove cover (1) from equalizer bar A. shaft and remove it. [*4]
a Since oil flows out of the pivot chamber, place
5. Remove grease tube (2). an oil receiver under the pivot shaft.
a Remove elbow, also. 4 Track frame assembly: 1,350kg(D61EX)
1,500kg(D61PX)
6. Sling track frame assembly with two carrier rollers 6 Pivot chamber: 3.5 l
temporarily, then remove lock plate and side pin
(3). [*1]
2 WE051F0500
Installation

removal.
[*1]
2 Between seal and bushing:
Charge with grease (G2-LI)
[*2][*3]
3 Pivot shaft cover and plate mounting bolt:
245 - 309 Nm (25 - 31.5 kgm)
[*4]
a Apply oil (EO30-CD) to face (a) of the track frame
which will be in contact with the pivot shaft oil seal.
a Remove oil filler plug (7) and supply oil to the pivot
chamber until distance (b) between the oil filler
plug hole becomes 120 mm, then tighten the oil
filler plug.
5 Pivot: 3.5 l(EO30-CD)
WE051F0500 3
Removal and installation of idler Installation

assembly 1
Removal removal.
[*1]
3
1. Expand the track shoe assembly. For details, see
Expansion and installation of track shoe assembly. Lubricator: 58.8 - 88.2 Nm {6 - 9 kgm}
[*2]
2
2. Detach lock plate (1), then remove lubricator (2).
[*1} Support mounting bolt:
k Negative pressure is applied inside the 3 Support mounting bolt:
recoil spring. Accordingly, if the lubricator 235-285Nm {23.5-29.5kgm}
is not removed, the yoke is pulled back
toward the cylinder when the idler mount-
ing bolts are removed.
k Never stand in front of the idler yoke to
avoid danger.
3. Raise the idler assembly and pull it out, then

remove mounting bolts (5) of support (3) and yoke
(4). [*2]
4. Lift off idler assembly (6).

4 Idler assembly: 190kg (one side)
4 WE051F0500
Disassembly and assembly of idler 2) Sling idler (5) and pull it out of shaft and sup-
assembly 1 port assembly (8).
a Prevent the sling wires [2] from opening
Special tool with wires or ropes. (Part A)
3) Remove floating seals (9) and (10) from idler
(5).
New/Remodel
Necessity
Symbol
Sketch
Q'ty
Part No. Part name
1 791-515-1520 Installer t 1
L
2 791-601-1000 Oil pump q 1
Disassembly
1. Support
1) Remove guide (1) and shims (2).
a Check the thickness and quantity of
shims.
2) Remove nut (3) and drive out bolt (4) from the
nut side.
4) Remove floating seal (11) from the shaft and

support assembly.
3) Using push puller [1], pull support (6) out of
idler (5). 3. Shaft
1) Remove nut (12) and drive out bolt (13) from
2. Floating seal the nut side.
1) Remove floating seal (7) from support (6). 2) Similarly to step 1-3), using the push puller,
pull shaft (15) out of support (14)
WE051F0500 5
4. Remove two bushings (16) from idler (5). 3) Using tool L1, install floating seal (11) to shaft
and support assembly (8), then assemble O-
ring to shaft.
a When assembling the floating seal, clean
the thick line portion (O-ring and O-ring
c ontact surf ac e), r em ov e al l oi l and
grease, and dry it.
a After fitting the floating seal, check that its
inclination is 1 mm maximum.
projection (a) is 7 - 11 mm.
Assembly
1. Using push tool [2], press fit piston (16) to idler (5).
2. Idler
1) Fit the O-ring to shaft (15) and install them to
support (14).
a When installing the shaft, match it to the
groove of the support.
2) Drive in bolt (13) and tighten nut (12).
3 Nut:
230.4 - 308.9 Nm {23.5 - 31.5 kgm}
6 WE051F0500
4) Using tool L1, install floating seals (10) into 6) Using tool L1, install floating seals (9) into idler
idler (5). (5).
a When assembling the floating seal, clean a When assembling the floating seal, clean
the thick line portion (O-ring and O-ring the thick line portion (O-ring and O-ring
contact surface), remove all oil and contact surface), remove all oil and
grease, and dry it. grease, and dry it. See the figure below.
a After installing the floating seals, check a After installing the floating seals, check
that their slant is less than 1 mm and their that their slant is less than 1 mm and their
projection (a) is 7 - 11 mm. See 3) in the projection (a) is 7 - 11 mm. See the figure
above section. below.
5) Sling and install idler (3) to shaft and support 3. Refilling with oil
assembly (6). Fill the idler with oil.
a Prevent sling wires [2] from opening with 5 Idler: 220 cc {EO-30CD}
wires or ropes. (Part A)
4. Support
1) Using tool L1, install floating seals (7) to sup-
port (6).
contact surface), remove all oil and
grease, and dry it.
inclination is 1 mm maximum.
projection (a) is 7 - 11 mm.
WE051F0500 7
2) Install support (6) to idler (5) with bolt (4) and

2) For the method of evacuating the system
nut (3).
3
before feeding oil:
Nut:
1] Remove plug (17) from the shaft.
230.4 - 308.9 Nm {23.5 - 31.5 kgm}
2] Using tool L2, tighten plug (17) after filling
3) Install guide (1) with shims (2) inserted.
the idler assembly with oil.
5 Idler: 220 cc {EO-30CD}
q Standard shim thickness: 4mm
q Per sheet thickness of shim: 1 mm
5. Charge the idler assembly with oil.

1) For the standard method of oil feeding:
1] Remove plug (17) from the shaft and fill
the assembly with the specified level of
engine oil through oil filler port.
5 Idler: 220 cc {EO30-CD}
2] After oil feeding, install plug (17) onto the
shaft.
8 WE051F0500
Removal and installation of recoil Installation

spring assembly 1
Removal removal.
1. Remove the idler assembly. For details, see [*1]

Removal of idler assembly. a After inserting recoil spring assembly (1), slightly
raise it on the lubricator side and push in the idler
2. Lift off recoil spring assembly (1). [*1] until the recoil spring is housed fully.
a Take care not to damage the grease fitting.
4 Recoil spring assembly: 350 kg (one side)
WE051F0500 9
Disassembly and assembly of recoil 3) Using push tool [1], remove piston (10) from
spring assembly 1 yoke (9) with press.
Special tool
New/Remodel
Necessity
Symbol
Sketch
Q'ty
Part No. Part name
791-685-8006 Compressor (B) t 1

790-201-2770 Spacer t 1
791-635-3160 Extension t 1
M
Cylinder
790-101-1600 t 1
(686 kN {70 tons})
790-101-1102 Pump t 1
3. Seal
Disassembly
2) Remove spacer (12) and seal (13).
1. Yoke and piston assembly
Remove yoke and piston assembly (2) from recoil
spring assembly (1).
4. Cylinder
1) Set recoil spring assembly (1) to tool M.
k The spring is under a high installed
load, so be careful to set it correctly.
2. Disassembly of yoke and piston assembly a Installed load of spring:
1) Remove snap ring (3), then remove packing 163.6 kN {16,692 km}
(4) and ring (5).
2) Remove bolt (6), then remove lockplate (7)
and washer (8).
10 WE051F0500
2) Apply hydraulic pressure slowly to compress Assembly

the spring and tighten nut (14) until spacer 1. Cylinder
(15) comes out. 1) Press fit bushing (19) into cylinder (17).
3) Then remove spacer (15), nut (14), and pilot 2 Bushing: Grease (G2-LI)
(16). 2) Temporarily assemble spring (18) and cylinder
(17), then set to tool M.
k The spring is under a high installed
load, so be careful to set it correctly.
3) Apply hydraulic pressure slowly to compress
the spring and set it so that the installed length
of the spring is the standard value.
a When compressing the spring, be careful
not to damage the thread. Use lever block
[2] and carry out centering while com-
pressing the spring.
a Installed length of spring: 593 mm
a Installed load of spring:
163.6 kN {16,692 km}
4) Gradually release hydraulic pressure to

remove tension of spring.
5) Remove spring (18) from cylinder (17).
6) Remove bushing (19) from cylinder (17).
WE051F0500 11
4) Install pilot (16), then install nut (14) and 2) Assemble washer (8) and plate (7), and
spacer (15). tighten bolt (6).
5) Gradually release hydraulic pressure to com- a Bend the plate securely.
pletely loosen spring tension, then remove 3) Fit ring (5) and packing (4) and then install
recoil spring assembly (1) from tool M. snap ring (3).
2. Seal 4. Assemble yoke and piston assembly (2) to recoil

1) Install seal (13). spring assembly (1).
2 Seal lip: Grease (G2-LI)
2) Install spacer (12) and snap ring (11).
2 Spacer: Grease (G2-LI)
3. Assembly of yoke and piston assembly

1) Using push tool [1], press fit piston (10) to
yoke (9).
12 WE051F0500
Removal and installation of track 5. Remove track roller assembly (5). [*3]
roller assembly 1 4 Track roller assembly:
45 kg (1 piece of single type)
Removal 52 kg (1 piece of double type)
1. Remove top cover of track frame, and loosen lubri-

cator (1), then loosen track shoe tension. [*1]
k Do not loosen lubricator (1) more than 1
turn.
a If the track shoe assembly is not loosened
after the lubricator is loosened, move the
machine forward and in reverse.
Installation

removal.
[*1]
a Referring to the operation manual, adjust the track
shoe tension.
2. Remove mounting bolts from guard (2) and track
roller guard (3). [*2] [*2]
2 Guard (2) and (3) mounting bolt:
3. Remove track roller mounting bolts (4). Liquid adhesive (LT-2)
3 Guard (2) and (3) mounting bolt:
235-285Nm {23.5-29.5kgm}
[*3]
2 Track roller mounting bolt:
3 Track roller mounting bolt:
235-285Nm {23.5-29.5kgm}
a Install so that the oil plug is on the outside of the
chassis.
4. Start the engine and operate the blade and the rip-
per or hydraulic jack to jack up the machine.
k After jacking up the machine, set blocks on
top of the track shoe and lock the work
equipment control levers and brake lock
lever.
WE051F0500 13
Disassembly and assembly of track 6. Sling roller (7) and pull it out of shaft assembly (8).
roller assembly 1
7. Remove floating seal (9) from rollar (7).
Special tool
New/Remodel
Necessity
Symbol
Sketch
Q'ty
Part No. Part name
L 3 791-651-1520 Installer t 1
Disassembly
1. Remove plug (2) from roller assembly (1) and

drain oil.
6 Track roller: 250 cc (GO140)
8. Remove floating seal (10) from shaft assembly (8).
2. Set track roller assembly (1) on block [1].
9. Remove lock pin (11), then remove collar (13) from
shaft (12).
3. Using push puller [2], push in collar (3) , and then
remove lock (4) and collar (3).
10. Remove floating seal (14) from collar (13).

4. Remove floating seal (5) from collar (3).
11. Remove bushing (15) from roller (7), then turn it
over, and remove bushing (16).
5. Remove floating seal (6) from track roller assem-
bly (1).
14 WE051F0500
Assembly 3. Fit the O-ring to shaft (12), then install collar (13)
and lock pin (11).
1. Using push tool [3], press fit bushings (16) and
(15) into roller (7). 4. Using tool L3, install floating seal (10) to shaft
assembly (8).
a When assembling the floating seal, clean the
thick line portion (O-ring and O-ring contact
surface), remove all oil and grease, and dry it.
See 2. in the above section.
a After installing the floating seals, check that
their slant is less than 1 mm and their projec-
tion (a) is 7 to 11 mm. See 2. in the above
section.
2. Using tool L3, install floating seal (14) to collar

(13).
a Check that its inclination is 1 mm maximum.
a After fitting the floating seal, check that its pro-
jection (a) is 7 to 11 mm.
5. Using tool L3, install floating seal (9) to collar (7).

section.
WE051F0500 15
6. Sling roller (7) and install shaft assembly (8).
9. Fill the roller with oil.

7. Using tool L3, install floating seal (6). 5 Track roller: 250 cc (GO140)
thick line portion (O-ring and O-ring contact 10. Fit the O-ring to the shaft and install collar (3).
See 2. in the above section. 11. Using push puller [2], push in collar (3) and install
a After installing the floating seals, check that lock (4).
section.
12. Check the oil level and tighten plug (2) to roller
assembly (1).
3 Plug: 98 to 137.2 Nm {10 to14 kgm}
8. Using tool L3, install floating seal (5) to collar (3).
section.
16 WE051F0500
Removal and installation of carrier 3. Remove mounting bolt (2).

roller assembly 1
4. Sling carrier roller assembly (3) and pull and
Removal remove it out of support (4). [*2]
4 Carrier roller assembly: 25 kg (1 piece)
1. Remove top cover of track frame, and loosen lubri-
cator (1), then loosen track shoe tension. [*1]
k Do not loosen lubricator (1) more than 1
turn.
a If the track shoe assembly is not loosened
after the lubricator is loosened, move the
Installation

removal.
[*1]
a Referring to the operation manual, adjust the
2. Using hydraulic jack [1], raise the track shoe. track shoe tension.
[*2]
a Set 3 mm for the clearance (a) between the
carrier roller and the support when installing.
WE051F0500 17
Disassembly and assembly of 7. Disassemble the shaft assembly according to the

carrier roller assembly 1 following procedure.
1) Remove collar (8) from shaft assembly (6).
Special tool 2) Remove floating seal (9).
3) Remove floating seal (10) from collar (8).
New/Remodel
Necessity
Symbol
Sketch
Q'ty
Part No. Part name
L 4 796-230-1110 Installer t 1
Disassembly
1. Remove plug (1) and drain oil

6 Carrier roller: 215 cc (GO140)
2. Remove snap ring (2) and cover (3).

4) Remove bearing (12) from shaft (11).
3. Remove bolt (4) and spacer (5).
8. Remove outer race (14) from roller (13), then turn
it over and remove outer race (15).
4. Set the carrier roller on block [1].
5. Using push tool [2] and a press, pull out shaft

assembly (6).
6. Remove bearing (7).
18 WE051F0500
Assembly
1. Press fit outer races (15) and (14) to roller (13).
2. Disassemble the shaft assembly according to the

1) Using push tool [3], press fit collar (8) to shaft
(11).
3. Set shaft assembly (6) to block [5] and install roller

(13).
4. Using push tool [6], install bearing (7) and press fit
it .
a Rotate the roller when press fitting the bear-
ing, and press fit until the rotation of the roller
starts to become heavy.
2) Using tool L4, install floating seal (10).
grease, and dry it.
3) Install floating seal (9) and using push tool [4],
press fit bearing (12).
grease, and dry it.
a Check that its inclination is 1 mm maxi-
mum.
projection (a) is 7 to 11 mm.
WE051F0500 19
5. Install spacer (5) with bolts (4).

3 Bolt: 245 - 309 Nm {25 - 31.5 kgm}
6. Supply oil to the carrier roller.

5 Carrier roller: 215 cc (GO140)
7. Fit the O-ring to cover (3) and install them to the

roller, and then install snap ring (2).
8. Check the oil level and tighten plug (1).
20 WE051F0500
WE051F0600
Bulldozer
1Shop Manual
D61EX-15
D61PX-15


Undercarriage .................................................................................................................. 2
Check before expanding track shoe assembly ............................................................. 2
Expansion (normal), expansion (internal abnormality) and
installation of track shoe assembly............................................................................ 2
Overall disassembly and overall assembly of track shoe assembly ............................. 4
Link press-fitting jig dimensions table ......................................................................... 20
Field disassembly and assembly of one link............................................................... 21
Removal and installation of pivot shaft assembly ....................................................... 28
Removal and installation of equalizer bar assembly................................................... 30
Removal and installation of equalizer bar side bushing.............................................. 31
Removal and installation of segment teeth ................................................................. 32
Undercarriage 1 Expansion (normal), expansion

(internal abnormality) and
Check before expanding track shoe installation of track shoe assembly1
assembly 1
Expansion (normal)
k Since it may be very dangerous to expand the
track shoe assembly, check the following a If any abnormality is not detected by Check before
items in advance. expanding track shoe assembly, perform the fol-
lowing procedure.
q Check before starting
1. Loosen lubricator (1) at the adjustment cylinder, 1. Set the master link position.
remove the grease, move the machine backwards a Set the block (300 mm high) or hydraulic jack
and forwards a short distance, and check that the [1] so as to position the master link at about
track tension is relieved. If the track tension is not 500 mm from the ground on the front side.
relieved and the track shoe assembly remains
tense, there may be an abnormality inside the 2. Loosen the track shoe.[*1]
track frame (recoil spring cylinder (2) is broken, or k Do not loosen lubricator (1) more than one
nut (3) at the end of shaft has fallen off). turn.
k Do not loosen the lubricator more than one a If the track shoe assembly is not loosened
turn. after the lubricator is loosened, move the
3. Remove mounting bolts of track shoe (4) and mas-

ter link (5).[*2]
4. Raise the tip of the master link, move the machine

slowly forwards, and lay out track shoe assembly
(4).
2 WE051F0600
Expand (When track frame has internal trouble)
a If any abnormality is detected by Check before

expanding track shoe assembly, perform the fol-
lowing procedure.
k If there is any abnormality inside the track

frame, there is danger that the track shoe
assembly may spring back when it is removed
or that the idler may spring out when the track
shoe assembly is removed. This may lead to
serious injury, so remove the track shoe
assembly as follows.
k If there is any interference or abnormal catch-
ing around the idler assembly, examine care-
fully and remove the problem before starting.
Installation
1. Loosen lubricator (1) of the adjustment cylinder,
then move machine backwards and forwards to q Carry out installation in the reverse order to
release grease[*1] removal.
k Do not loosen the lubricator more than one
turn. [*1]
a Check that the all grease has been removed. a Referring to the operation manual, adjust the tack
shoe tension.
[*2]
a Tighten the shoe bolts in the order shown in the
diagram.
2 Shoe bolt: Lubricant containing molybde-
num disulfide (LM-P)
3 Shoe bolt: (Master link)
Initial torque: 343±39 Nm(35±4 kgm}
Tightening angle:180 +0°
-20
2. Move the machine slowly forward against large

block [1] or a wall (or the blade of another machine
of the similar size of the machine to be repaired, if
available) to press the track shoe on the idler side.
When the recoil spring and track shoe slacken,
stop and apply the brake. When doing this, set so
that master link is between idler and front carrier
roller. For safety reason, fit a lever block between
carrier roller support and link to prevent the shoe
from springing.
q Remove track shoe (4) and disconnect master
link (5).[*2]
k Be extremely careful to ensure safety when
disconnecting the track shoe.
q Move the machine slowly in reverse, and lay
out track shoe assembly.
WE051F0600 3
Overall disassembly and overall 3. Sling the shoe assembly and set it with the shoe
assembly of track shoe assembly 1 up on the floor and remove the shoe of regular link
by using an impact wrench.
Special tools a When moving the shoe assembly, take care
not to damage the master link.
a If it is obliged to cut a shoe nut with gas cutter,
New/Remodel
keep the seal temperature below 80°C to pre-
Necessity
Symbol
Sketch
vent thermal deterioration of the seal and take
Q'ty
Part No. Part name
measures to prevent the spatters from enter-
ing through the clearances among the links.
1 791-646-7531 Remover t 1
2 791-660-7460 Pin brush t 1
R 3 791-432-1110 Plug push tool t 1
4 791-932-1110 Plug push tool t 1
5 790-701-3000 Seal checker t 1
Overall disassembly
a This section describes only the procedure for

the lubricated track.
1. Set the shoe assembly on a flat floor with the shoe

facing up and remove the shoe bolt at the master
link and remove the shoe. 4. Oil drain
a Do not use an impact wrench when loosening Before disassembling the link assembly, drain the
the master link bolt. oil from inside the pin and take precautions so that
the link press does not become dirty with oil.
a Before disassembling, if it is judged that it is
necessary to rebuild the tack as a dry type
track, the following work need not be carried
out.
1) 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.
a If the shoe is disassembled with burrs still
at the end face of the pin, the pin press-fit-
ting hole of the link will be scratched, and
this will cause leakage from the pin press-
fitting portion after rebuilding.
2. Because of the weight of the track assembly, if the

1/2 assembly is too large and there are problems
with disassembly and assembly work, divide into
1/4 assemblies.
4 WE051F0600
2) Using a drill (ø10 mm), make a hole in the

large plug, then remove the large plug.
a 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.
5. Disassembly of link
1) Set the link assembly on a link press and hit it
with a hammer so that the bushing will be fit-
ted to jaw [1].
a If the link tread, outside diameter of the
bushing, etc. are worn, adjust the height of
3) After removing the large plug, use a baby jaw [1] or guide plate and align the left and
grinder (angle of grinder tip: 45° - 60°), and right disassembly jig [2], [3] with the pin
chamfer the pin hole so that the plug is not and bushing center so that the link hole
damaged when the plug is knocked in. will not be damaged during disassembly
work.
a If the pin and bushing are not aligned well,
the link hole may be damaged and the pin
and bushing may be broken during disas-
sembly work.
4) 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.
a If the small plug hole is blocked with burrs,
grind with a grinder until the hole can be
seen completely.
5) Using a drill (ø10 mm), chamfer the small plug
hole.
6) 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.
WE051F0600 5
2) Operate the left cylinder to pull out the pin and 4) Return the right cylinder and take out the links,
bushing press-fitting portion from the left link pins, bushings, and spacers on both sides and
simultaneously. feed the next 1 set of the link assembly to the
a Check the pulling out force of the pin and jaw.
bushing to see if the necessary press fit- a To decide if the seal can be used again,
ting force for the pin and bushing can be carry out inspection with the seal installed
obtained when reversed and assembled to the link. So do not remove the seal
again. from the link.
a Do not push the disassembly jig inside a If oil is remaining, this can be used as a
more than necessary as the spacer may guideline for reuse of the seal, so mark
break. such links or seals.
a If the bushing ends and sealing surfaces
are damaged, oil will leak. Accordingly,
handle them carefully.
3) Return the left cylinder and operate the right

cylinder to pull out the pin and bushing press-
fitting portion from the right link simulta-
neously. 6. Inspection
Check the parts for the following items to see if
they can be used for a lubricated track or a
grease-filled track, then examine them generally
and determine to use them for a lubricated track or
grease-filled track.
a For judgment of reuse of the parts, see "Guid-
ance for Reusable Parts, Undercarriage,
Lubricated Track".
1) Visually check damaged state of pin, bushing,
link and spacer. Check questionable parts
with color check or magnetic flaw detector.
Cracked parts are not reusable. Scrap them.
2) Visually check the external appearance of the
seal and the end face of the bushing to deter-
mine if they can be used again.
a 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.
6 WE051F0600
3) Using calipers, measure spacer thickness (a) 5) Using a micrometer and cylinder gauge, mea-
and overall length (b) of the sliding portion of sure the outside diameter of the pin and bush-
the bushing and spacer. Check if it is possible ing press-fit ting portion, and the insi de
to obtain the specified seal mounting dimen- diameter of the pin and bushing press-fitting
sion when reassembling. portion of the link to determine if the allowable
a If the amount of wear of the spacer and interference can be obtained. However, when
bushing is greater than the specified rebuilding as a lubricated track, check that the
amount, the assembly precision of the standard interference for the pin and the link
seal portion cannot be guaranteed, so can be obtained.
replace with new parts or rebuild as a a If the allowable fitting interference is not
grease-filled track. obtained, replace the parts with new ones
or over size parts.
a For details of the dimensions when mak-
ing judgment, see Maintenance standard.
4) 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.
a 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.
a For details of the dimensions when mak-
ing judgment, see Maintenance standard.
WE051F0600 7
a Precautions for storage (3) Mark on the end face at the small plug end to
show the direction of the side hole (hole in the
1) Store the seal without removing it from the link so radial direction) in the pin when assem-
that the counterbore portion will not be rusted and bling.( Mark)
take care not to damage the seal lip. a When reusing the pin, assemble in the
2) Apply rust-preventive oil to the pin and bushing fit- same direction as when the part is new
ting parts, shoe mating surface, and master link (side hole on the link tread side).
mating surface of the link.
3) When storing, apply rust-preventive oil to the all
surfaces of the pin, bushing, and spacer. Take
care not to damage the ends of the bushing in par-
ticular.
Overall assembly
1. When reusing for lubricated track

1) Preparation work
(1) Cleaning seal assembly
a W7 type seal
F or seal s t o b e reused, l eave t hem
installed to the link, and do not wash them. (4) If any link, pin, bushing and spacer are dirty,
(2) When reusing the pin, chamfer the corner of wash them. Use a grinder to remove any pro-
the end face smooth with a grinder. Use a truding parts stuck to the ring and bushing.
grinder to remove any protruding parts stuck a Since these parts rust easily, clean them
to the press fitting portion. just before assembling them.
a If the ends are worn and sharpened, they a Use tool R2 to wash the pin hole.
may scuff the press fitting parts and cause a Do not polish the bushing ends. If they are
oil leakage. polished, oil may leak.
8 WE051F0600
(5) Using tools R3, drive in large plugs (3). (7) Adjust the dimensions of the press fitting jig of
a Coat the outside circumference of large the link press to keep the projection of the pin
plug (3) with GO90 and knock in the and bushing constant and keep the installed
smaller diameter part first. dimensions of the seal within the standard
i) Insert large plug (3) into the guide hole range.
through the plug insertion window. a For details of the standard dimensions,
ii) Push the bar of tool R3 with the hand until see PRESS-FITTING JIG DIMENSION
the large plug stops. TABLE FOR LINK PRESS.
iii) Push large plug (3) with the bar of R3 and a To leave a small space for the pin when
push the pin to the guide itself. assembling, ensure that the dimension
iv) Drive in the bar with a hammer. (dimension (a')) is greater than dimension
a Driving distance (a) from pin end: 6±2 (a) at the pin pushing portion of the left
mm press-fitting jig.
a If the chamfered part of the pin hole When assembling in order of [1] press fit-
has been worn, chamfer it with a ting left link and [2] press fitting right link,
small-sized grinder (grindstone tip provide the extra space for the pin on the
angle: 45° - 60°) so that the plug will right press-fitting jig.
not be damaged. a 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.
(6) Installation of seal assembly

q F5 type seal
When reusing the link and replacing the
seal with a new part, clean the link coun-
terbore (section A) then push the seal in
fully to the bottom.
a If oil or grease is sticking to the counter-
bore portion of the link and seal assembly,
the seal will turn and its sealing perfor-
mance will lower. Accordingly, do not apply
any oil or grease to that portion. In addition,
be careful not to let oil get into the counter-
bore portion of the seal when pushing in.
WE051F0600 9
(8) Adjust the relief pressure of the link press so (2) Press fit the master links on both bushing
that the pressing force of the press will not sides to the bushing with the shoe fitting sur-
exceed the standard value. face facing up.
a If the pressing force is too strong, the a At this time, use the master links on the
spacer will be pressed forcibly against the pin side as supports.
bushing. As a result, the spacer may be a Press fitting force for bushing:
broken and it and bushing may be worn 49 - 196 Nm {5 - 20 tons}
abnormally.
)
(3) Using the shoe bolt hole pitch gauge, press fit
a If the interference at the press-fitting por- the master links until the distance between the
tion is different from when the part is new, shoe bolt holes of both links is the standard
as when reusing a pin or bushing, mea- value.
sure several of the press-fitting portions, a Remove the all steel chips caused by
and determine the set pressing force press fitting of the bushing with com-
according to the average interference. pressed air.
a Pushing force for pin and bushing:
588 kN {60 ton}
Pushing force C 1.8 x average press-fitting
force (Adjust the relief pressure of the link
press and set the pushing force).
2) Assembly of link
(1) Apply oil (GO90) to the mating surfaces of the
pin and bus hing with a clean brush and
assemble them, then set them before the jaw
of the link press.
a When reusing (reversing) the bushing, set
the worn outside surface of the bushing on
the shoe fitting side of the link (facing
upward on the link press).
10 WE051F0600
(4) Turn over the master links and check that they (7) To prevent oil from leaking out from scuff
are press fitted in parallel. marks on the pin press-fitting portion, coat the
(5) Measure the projections of the bushing on pin press-fitting hole in the link and the outside
both sides with a depth gauge. diameter of the pin press-fitting portion with
a Adjust the press fitting jig of the link press gasket sealant (198-32-19890).
so that the projections on both sides will
be even.
(8) Set the right link and install the spacer to the
pin.
(6) Feed the master links and set the next pin and a Check that there is no dirt or dust stuck to
bushing. the surface of the seal or the end face on
a When reusing a pin, install it so that the the bushing, then coat with oil (GO90)
side hole will be on the link tread side sim- using a clean cloth or small brush.
ilarly to a new one. If it is not installed as a When installing the spacer, wipe it with a
specified, its strength may be lowered. clean cloth.
Accordingly, indicate the direction of the
side hole(i) on the end face to prevent a
mistake.
a Align the large plugs so that they are on
the left side facing the link press when
assembling.
WE051F0600 11
(9) Set the right jig on the receiving side and the (11) Set the right link and install the spacer to the
left one on the pushing side and press fit the pin.
pin and bushing simultaneously. a Apply oil similarly to the right link.
a If the pin and bushing have play when
they are press fitted, the seal may come
off the link. To prevent this, press fit
smoothly.
If the seal comes off the link, stop press fit-
ting and set the seal to the link correctly,
then start press fitting again.
a Press-fitting force for pin and bushing:
196-392 kN {20-40 tons}
(12)Set the left jig on the receiving side and the

right one on the pushing side and press fit the
left link.
a When press fitting, take care that both
seals and spacers will not come off.
a Provide enough play on the left jig so that
the end face of the pin does not contact
with the bottom of the jig.
a Press-fitting force for link: 196-392 kN {20-
(10)Using spacer [6] for fine adjustment, press fit 40 tons}
the pin and bushing until the pin end is fitted to
the bottom of the receiving jig.
a Adjust the depth of the receiving jig hole
so that the projections of the pin on both
sides will be even.
12 WE051F0600
(13)Press fit until the link, spacer, and bushing are (15)Using a shoe bolt hole pitch gauge, measure
fitted together. the distance between the shoe bolt holes and
a Actually, you cannot see from outside if check that the result is within the standard
the above parts are fitted. Accordingly, range.
control the hydraulic pressure of the link a If the distance between the shoe bolt
press. Set the relief pressure to a proper holes is longer than the standard range,
level and heighten the hydraulic pressure disassemble and check for abnormality,
to that level. then press fit again.
a For setting of the relief pressure, see a If the distance between the shoe bolt
Preparation work. holes is shorter than the standard range
a Check that adjacent links swivel freely in and the shoe cannot be installed, the
relation to each other. spacer or bushing end may be worn more
than the allowable limit. In this case, dis-
assemble and replace the parts.
a If the end play is too large, the sealing per-
formance will drop, so set the end play to
a small value.
(14)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 assem-
bled within the specified value.
a If the end play does not come within 0 to
0.13 mm even when applying the pushing (16)After each link is assembled, bleed air from
force until the relief valve is actuated, raise the pin by using tool R5 and check the sealing
the relief pressure setting gradually to performance.
adjust. a Hold the space inside the pin at a vacuum
a Adjust the relief pressure setting carefully of 92.7±2.0 kPa {695±15 mmHg} for 5
and be sure not to raise the pushing force seconds and check t hat t here is no
of the link press higher than necessary. change in pressure.
If the pressure changes, disassemble and
check the seal for any abnormality, then
assemble again.
WE051F0600 13
(17)Assemble the master link on the pin side at (2) After supplying oil, drive in the small plug to
last. the following specified position, using tool R4.
a Check that the master links on both sides are a Apply oil (GO90) around the small plug.
press fitted in parallel. a The depth to knock in the plug is as fol-
lows.
3) Charging with oil Driving depth from end: 2.5±1 mm
After completion of assembly of the link assembly,
add oil through the pin hole.
(1) Using tool R5, remove the air inside the pin
from the small plug hole. Set to a vacuum of
92.7±2.0 kPa {69±15 mmHg}, then fill with oil
(GO90) until the pressure is 0.2 to 0.3 MPa {2
to 3 kg/cm2}.
a In cold or very cold areas, instead of
GO90, fill with Komatsu genuine oil (150-
09-19270) which has excellent low-tem-
perature qualities.
a If the oil pressure is heightened too much,
it has bad effects on the seal. Take care.
4) 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: 539±49 Nm {55±5 kgm}
Tightening angle: 120°±10°
a To determine the oil amount, set the large

plug end (B) facing downward (stand the
link assembly 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
14 WE051F0600
5) Connecting to make 1/2 assembly

Set two completely assembled portions of shoe on
a flat surface in a straight line with the shoes fac-
ing 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 con-
nect the two parts with the master bolt.
2 Shoe bolt: Lubricant containing molyb-
denum disulfide (LM-P)
Initial torque: 343±39Nm {35±4 kgm}
+0°
Tightening angle:180 -20
a Tighten the bolts in the order of 1 - 4.
2. When reusing for grease-filled track

1) Preparation work
(1) Cleaning seal assembly
a F5 type seal
For seal s t o b e reused , l eave t hem
installed to the link, and do not wash them.
(2) When reusing the pin, chamfer its end corners

carefully with a grinder so that it will be press
fitted smoothly.
a Do not use an impact wrench for the master

link.
WE051F0600 15
(3) Mark on the end face at the small plug end to (7) Installation of seal assembly
show the direction of the side hole (hole in the F5 type seal
radial direction) in the pin when assem- When reusing the link and replacing the seal
bling.(*Mark) with a new part, clean the link counterbore
a When reusing the pin, assemble in the (section A) then push the seal in fully to the
same direction as when the part is new bottom.
(side hole on the link tread side). a If oil or grease is sticking to the counter-
bore portion of the link and seal assembly
(section A), the seal will turn and its seal-
ing performance will lower. Accordingly,
do not apply any oil or grease to that por-
tion.
(4) Using tools R3 and R4, drive in the large and

small plugs.
q Tool R3 (large plug)
q Tool R4 (small plug)
i) Insert plug (3) into the guide hole through
the plug insertion window. (Coat plug (3) (8) Adjust the dimensions of the press fitting jig of
with oil.) the link press to keep the projection of the pin
ii) Push the bar of tool R3, R4 with the hand and bushing constant and keep the installed
until plug (3) stops. dimensions of the seal within the standard
iii) Push plug (3) with the bar of R3, R4 and range.
push pin (4) to the guide itself. a For details of the standard dimensions,
iv) Drive in the bar of tools R3, R4 with a see Press-fitting jig dimension table for
hammer. link press.
a Driving distance (a) from pin end: a If the pin end (part P) or link sides (parts Q
Small plug: 2.5±1 mm and R) are worn, add the dimensions of
Large plug: 6±2 mm the worn parts to the standard dimension
a If the plugs were not pulled out when when adjusting the dimension of the
the shoe was disassembled, reuse press-fitting jig so that the projections of
them as they are. the left and right pins and bushings on
(5) If the outside of the pin, surfaces of the spacer, both sides will be even.
and ends and inside of the bushing are dirty,
clean them.
(6) Apply grease to the outside of the pin and sur-
faces of the spacer.
16 WE051F0600
2) Assembly of link (3) Using the shoe bolt hole pitch gauge, press fit
(1) Apply lithium grease (G2-LI) to the mating sur- the master links until the distance between the
faces of the pin and bushing and assemble shoe bolt holes of both links is the standard
them, then set them before the jaw of the link value.
press. a Remove the all steel chips caused by
a When reusing (reversing) the bushing, set press fitting of the bushing with com-
the worn outside surface of the bushing on pressed air.
the shoe fitting side of the link (facing
upward on the link press).
(4) Turn over the master links and check that they
are press fitted in parallel.
(2) Press fit the master links on both bushing (5) Measure the projections of the bushing on
sides to the bushing with the shoe fitting sur- both sides with a depth gauge.
face facing up. a Adjust the press fitting jig of the link press
a At this time, use the master links on the so that the projections on both sides will
pin side as supports. be even.
a Press fitting force for bushing: 49 - 196
Nm {5 - 20 tons}
WE051F0600 17
(6) Feed the master links and set the next pin and (8) Using a shoe bolt hole pitch gauge, measure
bushing. the distance between the shoe bolt holes.
a When reusing a pin, install it so that its When the distance is in the standard range,
side hole will be on the link tread side sim- stop press fitting.
ilarly to a new one. If it is not installed as (9) Assemble the master link on the pin side at
specified, its strength may be lowered. last.
Accordingly, indicate the direction of the a Check that the master links on both sides
side hole on the end face to prevent a mis- are press fitted in parallel.
take.
a If the outside of the pin is worn, install it so
that the un-worn surface will be on the
traction side. In this case, install the pin
so that its side hole will face the link tread
side, too.
3) Shoe bolt (regular link)

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)
(7) Set both links and operate both pushing jigs to Tightening angle: 120°±10°
press fit the pin and bushing simultaneously.
a If the pin and bushing have play when
they are press fitted, the seal may come
off the link. To prevent this, press fit
smoothly.
If the seal comes off the link, stop press fit-
ting and set the seal to the link correctly,
then start press fitting again.
588 kN {60 tons}
Pushing force C 1.8 x average press-fitting
force (Adjust the relief pressure of the link
press and set the pushing force.)
18 WE051F0600
4) Connecting to make 1/2 assembly a Do not use an impact wrench for the master
Set two completely assembled portions of shoe on link.
a flat surface in a straight line with the shoes fac-
ing 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 con-
nect the two parts with the master bolt.
2 Shoe bolt: Lubricant containing molyb-
+0
Tightening angle: 180 -20°
a Tighten the bolts in the order of 1 - 4.
WE051F0600 19
Link press-fitting jig dimensions

table 1
Unit: mm
Jig dimensions
a b c
4.0±2 3.05±0.13 45.8
20 WE051F0600
Field disassembly and assembly of Disassembly

one link 1
1. Positioning track shoe assembly
Special tools Set track shoe assembly on block [1] (approx. 300
mm high).
New/Remodel
Necessity
Symbol
Sketch
Q'ty
Part No. Part name
790-101-1102 Pump t 1
6 Cylinder
790-101-1300 t 1
(980kN{100ton})
790-101-1102 Pump t 1
7 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
2. Pin
8 791-635-3180 Screw t 2 Using tool R8 (frame, extension, nut, screw,
791-635-3190 Screw t 1 adapter, pusher), and tool R6 (pump, cylinder),
791-645-3510 Adapter t 1 remove pins (1) and (2).
791-646-3260 Pusher t 1 a If the tip of the pin or the side of the link are
9 791-630-3560 Pusher t 1 unevenly worn, correct with a hand grinder to
10 791-432-1110 Push tool t 1 ensure that the part is at a right angle to tool
11 791T-630-3570 Guide t 1 R8.
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
12
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
13
791-635-3190 Screw t 1
791-645-3520 Adapter t 1
791T-630-3570 Guide t 1 Q
791-630-3560 Pusher t 1
790-101-1102 Pump t 1
14
790-105-2300 Jack t 1
15 791-646-3270 Guide t 1
791-635-3110 Frame t 1
16 791-635-3160 Extension t 1
791-635-3170 Nut t 4
R 791-635-3180 Screw t 2
16 791-635-3190 Screw t 1
791-645-3510 Adapter t 1
17 791-646-8002 Lubricator t 1
18 791-932-1110 Plug push tool t 1
WE051F0600 21
3. Link Assembly
1) Put tool R7 and spacer [2] of the dimensions
given below in contact with the tread of links 1. Bushing
(3) and (4). Applying tool R9 to the end of link (4) and using a
a Set tool R7 as close to the tip of the link as press or a remover, press fit bushing (7).
possible. a Press fitting force for bushing:
49 - 147 kN {5 - 15 tons}
a Always use a new bushing.
2) Apply hydraulic pressure slowly to the puller

until the tip of the link opens 6 - 8 mm, then
disconnect the link. 2. Pin
a There is danger that the bushing will come 1) Using tool R10, knock a large plug into the oil
out, so do not apply more hydraulic pres- hole of pin (1).
sure than necessary. a Always use a new pin.
a If an electric pump is used, there is danger
that more hydraulic pressure will be
applied than necessary, so always use a
hand pump.
3) Disconnect links (5) and (6) in the same way.
Spacer [2] dimensions:
outside diameter 55 mm x thickness 47 mm
2) To determine the pushing pressure when car-

rying out the final assembly, measure the out-
side diameter of the pin with a micrometer.
22 WE051F0600
3) Coat the press-fitting hole for the pin in link (4) 3. Seal
with gasket sealant (198-32-19890). Install seal (8).
a If the link is used again, finish the press fit- a Check that there is no oil on the contact sur-
ting hole for the pin smoothly with sandpa- face of the link and seal.
per. a Carry out steps 1 - 3 in advance.
4) Applying tool R9 to the end of link (4) and 4. Link sub-assembly

using a press or a remover, press fit pin (1). 1) Install link sub-assembly (10).
a Press fit so that the side hole (a) in the pin a Check that there is no dirt or dust stuck to
is on the same side as the link tread. the surface of the seal or the end face on
a Press-fitting force for pin: the bushing, then coat with oil (GO90)
147-245 kN {15-25 tons} using a clean cloth or small brush.
a Always use a new pin.
2) Install tool R11 (guide used when press fitting

link) to bushing (7).
WE051F0600 23
5. Link
1) To determine the pushing pressure when car-
rying out the final assembly, measure the
press-fitting hole dimensions of link (3) with a
cylinder gauge.
4) Using tool R12, press fit pin portion of link (3)

to link sub-assembly (10).
a Press-fitting force for pin:
294-490 kN {30-50 tons}
a G: Guide
2) Coat the press-fitting hole for the pin in link (3)
with gasket sealant (198-32-19890).
a If the link is used again, finish the press fit-
ting hole for the pin smoothly with sandpa-
per.
5) Using tool R13, press fit bushing portion of link

(3) to link sub-assembly (10).
a To prevent the use of any excessive force,
press fit the pin portion and bushing por-
tion gradually in turn.
3) Install seal (8). a Press-fitting force for pin and bushing:
a Check that there is no oil on the contact 196-392 kN {20-40 tons}
surface of the link and seal.
a Check that there is no dirt or dust stuck to
the surface of the seal or the end face on
the bushing, then coat with oil (GO90)
using a clean cloth or small brush.
24 WE051F0600
6. Connecting link 4) Install seals (13) and (14) to links (5) and (6).
1) Finish the inside surface of the press-fitting a Always use new seals.
hole for the pin in link (5) and (6) smoothly with a Check that there is no oil on the contact
sandpaper. surface of the link and seal.
a Check that there is no dirt or dust stuck to
the surface of the seal or the end face on
bushing (7), then coat with oil (GO90)
using a clean cloth or small brush.
2) Remove block [1], and lower the track shoe

assembly to the ground.
3) Set lever block [3] to the left and right link
assemblies as shown in the figure below. Put
tool R14 and spacer [2] in contact with the 5) Apply hydraulic pressure slowly to the puller
tread of links (5) and (6). until the tips of links (5) and (6) open 6 - 8 mm.
a Set tool R14 as close to the tip of the link a There is danger that the bushing will come
as possible. out, so do not apply more hydraulic pres-
sure than necessary.
a If an electric pump is used, there is danger
that more hydraulic pressure will be
applied than necessary, so always use a
hand pump.
6) Operate lever block [3], align the centers of
the link hole and bushing hole, and connect
the links with tool R15 (guide pin).
a Operate lever block [3] slowly and be
careful not to damage the seal or get sand
stuck to the seal surface.
WE051F0600 25
7. Pin
1) Using tool R10, knock a large plug into the oil
hole of pin (2).
a Always use a new pin.
8) Using tool R12, apply the specified pressure to

links (3) and (4) and links (5) and (6).
588 kN {60 tons}
2) To determine the pushing pressure, measure Pushing force C 1.8 x average press-fitting
the outside diameter of pin (2) with a microme- force (Adjust the relief pressure of the link
ter. press and set the pushing force.)
3) Set the track shoe assembly on block [1]
again.
4) Using tool R16, press fit pin (2) to links (5) and
(6).
a Press fit so that the side hole in the pin is
on the same side as the link tread.
a Press fitting force for bushing:
49 - 147 kN {5 - 15 tons}
5) Temporarily stop press fitting when there is 15
- 20 mm left for press fitting pin (2).
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 sealing performance.
a Check that the airtightness is maintained for 5
seconds at a negative pressure of 92.7±2.0
kPa {695±15 mmHg}.
6) Coat the remaining press-fitting portion of pin

(2) with gasket sealant (198-32-19890).
7) Coat the press-fitting hole for the pin in link (6)
with gasket sealant (198-32-19890), then con-
tinue to press fit pin (2).
26 WE051F0600
9. Charging with oil

1) Using tool R17, charge with oil (GO90)
through the small plug hole in the pin.
a Be careful not to raise the pressure too
high when charging with oil. This will have
an adverse effect on the seal.
a Take into consideration the expansion of
the oil under heat, and be careful not to
charge with too much oil.
2) Using tool R18, drive in the small plug quickly.

a Apply oil (GO90) around the small plug.
a The depth to drive in the plug is as follows.
Driving depth from end: 2.5±1 mm
WE051F0600 27
Removal and installation of pivot 4. Remove seal (2).[*2]

shaft assembly 1
5. Remove ring (3).[*3]
Special tools
New/Remodel
Necessity
Symbol
Sketch
Q'ty
Part No. Part name
791T-450-1130 Push tool t 1 Q

791T-450-1140 Plate t 1 Q
791-181-1010 Adapter t 1
791-520-4140 Screw t 1
791-201-2750 Spacer t 1
P
790-101-2540 Washer t 1
791-112-1180 Nut t 1
790-101-2102 Puller t 1
Pump
790-101-1102 t 1
(294 kN {30 tons})
Removal
1. Remove track frame assembly. For details, see

Removal of track frame assembly.
2. Sling pivot shaft assembly (1) temporarily.
3. Remove mounting bolts, then using forcing screws

[1], raise pivot shaft assembly and pull out.[*1]
4 Pivot shaft assembly: 85 kg (D61EX)
105kg(D61PX)
28 WE051F0600
Installation

removal.
[*1]
3 Pivot shaft mounting bolt:
455-565Nm{46.5-58kgm}
[*2]
a Assemble the seal as follows. (See diagram
below.)
1) Turn over the seal so that the embossed let-
ters on the seal are on the inside. (Turn Over)
2) With the seal turned over, insert seal (2) on the
shaft.
a Insert seal (2) to ring (3).
a When inserting the seal, be careful not to
damage the surface.
[*3]
a Press fit ring (3) using tool P.
a Press fitting force: 18.6 kN {1.9 tons}
WE051F0600 29
Removal and installation of 6. Remove seal (4) from the side pin fitting por-
equalizer bar assembly 1 tion.[*1]
Special tools
New/Remodel
Necessity
Symbol
Sketch
Q'ty
Part No. Part name
791-450-1100 Remover t 1
Puller
N 790-101-2102 t 1
(294 kN {30 tons})
790-101-1102 Pump t 1
Removal
7. Remove grease hose (5) from center pin (7).
1. Remove track frame assembly. For details, see a Remove the elbow too.
Removal of track frame assembly.
8. Remove lock plate (6) from center pin (7).
2. Remove the bottom cover of the universal joint.
9. Using tool N, pull out center pin (7).[*2]
3. Remove cover (1) from equalizer bar (A) on the
opposite side of removed track frame
4. Remove grease tube (2).

a Remove the elbow too.
5. Remove the lock plate and then side pin (3). [*1]
k Before removing the side pin, support the
track shoe on blocks, etc. securely.
30 WE051F0600
10. Pull equalizer bar (8) out of the frame with forklift, Removal and installation of
etc. equalizer bar side bushing 1
11. Lift off equalizer bar. Removal
4 Equalizer bar assembly: 180 kg (D61EX) 1. Remove equalizer bar assembly. For details, see
: 200 kg (D61PX) Removal of equalizer bar assembly.
2. Remove two seals (1).
3. Remove two snap rings (2).
4. Remove spherical bushing (3).
Installation

removal.
[*1]
2 Between seal and bushing:
Fill with grease (G2-LI) Installation
1. Install ring (2) to one side.
[*2]
2 Joint of pin and bushing: Grease (G2-LI) 2. Using push tool [1] and a press, press fit spherical
2 Between bushings: Fill with grease (G2-LI) bushing (3).
2 Boss of frame: Lubricant containing molyb- a Press fitting force: 15.68 kN {1.6 tons}
3. Install ring (2) to opposite side.
4. Install seal (1).

2 Between bushing and seal:
Fill grease (G2-LI)
5. Install equalizer bar assembly. For details, see

Removal and installation of equalizer bar assem-
bly.
WE051F0600 31

segment teeth 1
Removal
1. Stop machine at place where teeth can be

removed easily (between shoe and track frame).
2. Remove mounting bolts (1) to remove teeth (2).[*1]
Installation

removal.
[*1]
2 Threads of teeth mounting bolt:
3 Teeth mounting nut:
461-559 Nm {47-57 kgm}
a Assemble the teeth so that clearance (a) in
them will be even all round.
q Clearance (a): 0 - 2 mm
q Level difference (b): max. 0.5 mm
32 WE051F0600
WE051F0700
Bulldozer
1Shop Manual
D61EX-15
D61PX-15


Hydraulic system .............................................................................................................. 2
Removal and installation of main control valve assembly............................................. 2
Assembly of main control valve assembly .................................................................... 4
Removal and installation of cooling fan pump assembly .............................................. 7
Removal and installation of work equipment assembly ................................................ 8
Disassembly and assembly of work equipment assembly.......................................... 10
Disassembly and assembly of hydraulic cylinder assembly ....................................... 13
Hydraulic system 1 8. Disconnect the following hoses.

q (11), (12): HSS motor
Removal and installation of main q (13): HSS/work equipment pump
control valve assembly 1 q (14): HSS/work equipment pump
q (15) two hoses: lift cylinder
Removal q (16) two hoses: tilt cylinder
q (17) two hoses: angle cylinder
k Lower the work equipment fully to the ground
and stop the engine. Then loosen the hydrau-
k Operate the work equipment control lever 2 - 3
times to release the residual pressure from the
work equipment circuit.

6 Hydraulic tank: approx. 55 l

bly.
3. Disconnect hose (2) from ripper operation control 9. Disconnect connectors HAS (18) and HSB (19).
lever assembly (1). (If equipped)
a Prepare a plug before disconnecting the hose. 10. Disconnect TS port hose (20) and EPC pressure
a Arrange for the tags to indicate the corre- hose (21).
sponding hose to joint to.
4. Disconnect clips (3) and (4). (If equipped)
5. Disconnect drain hose (5).
6. Disconnect PPC hose. From inside

q (6): Red
q (7): Brown
q (8): Green
q (9): White (Ripper operation control lever
assembly (1) - : If equipped)

a (A) is the blade operation PPC valve.
11. Remove inside mounting bolts (22).
2 WE051F0700
12. Remove outside mounting bolts (section B) and lift

main control valve assembly (27).
4 Main control valve assembly
(Ripper + lift + tilt angle + steering): 80 kg
13. Disconnect the lower PPC hose (multi-coupler).

From outside
q (23): none Wound with a spiral tube.
(If equipped)
q (24): blue
q (25): white
q (26): Brown
14. Lift off main control valve assembly (27).
Installation
removal.
q Refilling oil (hydraulic oil tank)

Run the engine to circulate the oil through the pip-
ing system. Then, check the oil level again.
5 Hydraulic oil tank: 55 l (EO10-CD)
WE051F0700 3
Assembly of main control valve

assembly 1
a This section describes only cautions in assembling the main control valve assembly.
a 4-spool control valve

(Lift + tilt + angle + steering)
4 WE051F0700
a Be careful for the tightening torque as follows. (For

others, see Main control valve of structure and
function.)
1. T (mounting of upper cover):
q Tighten the nuts in 3 times in the order of 1 - 4.
3 1st time: 19.6 - 29.4 Nm {2 - 3 kgm}
3 2nd time: 39.2 - 49.0 Nm {4 - 5 kgm}
3 3rd time: 58.8 - 49.0 Nm {6 - 5 kgm}
2. TT (mounting of lower cover):

qTighten the nuts in 3 times in the order of 1 - 4.
3 1st time: 58.8 - 68.6 Nm {6 - 7 kgm}
3 2nd time: 78.5 - 88.3 Nm {8 - 9 kgm}
3 3rd time: 98.1 - 113 Nm {10 - 11.5 kgm}
3. Plug T1-5L:
2 Plug T1-5L: Apply a drop of Loctite
No.638 (see the diagram below)
3 Plug T1-5L: 14.7-19.6 Nm {1.5-2 kgm}
a Degrease and clean plug T1-5L and the
female thread portion with drysol, etc. and dry.
Do not apply pressure two hours after tighten-
ing.
WE051F0700 5
a Be careful for the following during assembly.

1. Assemble steering spool (STSPL) in direction by
which the groove will be on the side of A1 port.
2. Assemble washer (W) of section G-G so that slit

face will be on the side of spool (SPL).
6 WE051F0700
Removal and installation of cooling 13. Remove cooling fan pump assembly (10).
fan pump assembly 1 4 Cooling fan pump assembly: 25 kg
Removal


6 Hydraulic tank: approx. 55 l

bly.
3. Remove both mounting bolts (20) of control valve

assembly (A) and retain the assembly (A) in
floated condition using blocks, etc.
a (10) is the cooling fan pump assembly.
a (B): Ripper control lever assembly
(If equipped)
Installation

removal.
[*1]
3 Hose clamp: 8.8±0.5 Nm {90±5 kgcm}

Run the engine to circulate the oil through the pip-
ing system. Then, check the oil level again.
q Air bleeding
4. Disconnect clip (1). a Bleed air from the circuit by referring to the
section of "Bleeding air from fan pump" in
5. Disconnect PPC basic pressure hoses (2) and (3) Testing and adjusting.
from fan pump assembly (10).
6. Disconnect pressure pick-up hose (4).
7. Disconnect pump discharge hose (5).
8. Disconnect connector FAC (6).
9. Remove bracket (7) of main control valve assem-

bly.
10. Disconnect drain hose (8).
11. Remove the right fender lower cover (upper side).
12. Remove the suction tube under the fan pump and
suction hose (9).
WE051F0700 7
Removal and installation of work 4. Remove right hose cover (4) and left hose cover
equipment assembly 1 (5).
Removal
k Move the machine to a flat surface.

and stop the engine. Then loosen the hydrau-
k Operate the work equipment control lever 2 - 3
times to release the residual pressure from the
work equipment circuit.
1. Set block [1] to under the work equipment frame.
5. Disconnect four cylinder hoses (6) from the right

side of the machine and two cylinder hoses (7)
from the left side.
2. Remove lockplate (1).

3. Sling lift cylinder assembly (2) temporarily and
remove head pin (3).[*1]
a Using removed head pin hole, fasten lift cylin-
der assembly (2) to handrail (A) with rope, etc.
a Both lift cylinders
6. Sling work equipment assembly (8) temporarily.
a Sling by 4 points; left and right sides of the
blade for the front side and the work equip-
ment frame (lift cylinder head pin mounting
portions) for the rear side. In addition, use a
chain block.
8 WE051F0700
7. Remove two work equipment frame pins (9) on the Installation

left and right. Gradually move work equipment
assembly (8) in front of the machine to remove. q Carry out installation in the reverse order to
[*2] removal.
[*1] [*2]
2 Pin: Grease (G2-LI) or Hyper White Grease
(G2-T)

the engine to circulate the oil through the piping sys-
q Air bleeding
Bleed air from the cylinder by referring to the section of
"Bleeding air from hydraulic cylinder" in Testing and
adjusting.
4 Work equipment assembly:
2,100 kg (D61EX)
1,900 kg (D61PX)
WE051F0700 9
Disassembly and assembly of work 2. Blade

equipment assembly 1 1) Sling blade (6) temporarily, then remove two
head pins (8) from both blade angle cylinder
Disassembly assemblies (7).
a Before removing the head pins, support
k Set three blocks [1] under the work equipment the cylinders on blocks, etc.
frame, then secure the work equipment assem- 2) Remove cap (9) of blade connecting portion
bly. and the mounting bolts (eight to ten bolts) of
trunnion (10) on U frame side (10a) or on the
blade side.
a Trunnion (10) blade side: Check the thick-
ness, quantity and location of the shim
installed to cap (10b).
3) Lift off blade (6).
4Blade : 1,250 kg (D61EX)
: 1,050 kg (D61PX)
1. Blade tilt cylinder

1) Disconnect head hose (1) and bottom hose
(2).
k Plug the pipes to prevent dirt from
entering them.
2) Sling cylinder temporarily, then remove head
pin (3).
3) Remove bottom pin (4), then lift off blade tilt
cylinder assembly (5).
4Blade tilt cylinder assembly: 80 kg
10 WE051F0700
3. Blade angle cylinder 3) Remove cover (20) from work equipment

1) Remove cover (11). frame (19), then remove six hoses (21).
2) Disconnect grease hose (12). 4Work equipment frame: 900 kg
a Disconnect the hose clamps, too.
3) Disconnect hoses (13) and (14).
4) Remove bottom pin (15), then lift off blade
angle cylinder assemblies (16) on both sides.
4Blade angle cylinder assembly:
55 kg (one side)
Assembly
k Set three blocks [1] under the work equipment

frame and secure the work equipment assem-
bly.
4. Work equipment frame 1. Work equipment frame

1) Remove pin (17). 1) Install six hoses (21) to work equipment frame
2) Remove lever (18). (19), then install covers (20).
2) Install lever (18).

3) Install pin (17).
WE051F0700 11
2. Blade angle cylinder 4) Install head pins (8) to both blade angle cylin-
1) Sling and install blade angle cylinder assembly der assemblies (7).
(16), then install bottom pin (15).
4Blade angle cylinder assembly:
55 kg (one side)
2 Pin: Grease (G2-LI) or Hyper White
Grease (G2-T)
2) Connect hoses (13) and (14).
3) Connect grease hose (12).
a Connect the hose clamp, too.
4) Install cover (11).
4. Blade tilt cylinder

1) Sling and install blade tilt cylinder assembly
(5), then install bottom pin (4).
4Blade tilt cylinder assembly: 80 kg
Grease (G2-T)
2) Install head pin (3).
Grease (G2-T)
3. Blade 3) Connect head hose (1) and bottom hose (2).
1) Install trunnion (10) to blade (6) with cap (10b).
a Adjust clearance between cap (10b) and
the ball to 0.5 mm with the shim.
q Standard shim thickness: 3.0 mm
q Thickness of shim unit: 0.5 mm, 1.0 mm
3 Mounting bolt of cap (10b):
785-980 Nm {80-100 kgm}
2) Sling blade (6) and set it to the connecting

position of work equipment frame.
4Blade : 1,250 kg (D61EX)
: 1,050 kg (D61PX)
3) Install blade connecting position cap (9) and
trunnion (10).
4Mounting bolt (10a) of trunnion (10):
455-565 Nm {46.5-58 kgm}
12 WE051F0700
Disassembly and assembly of

hydraulic cylinder assembly 1
Special tools
New/Remodel
New/Remodel
Necessity
Necessity
Symbol
Symbol
Sketch
Sketch
Q'ty
Q'ty
Part No. Part name Part No. Part name
790-502-1003 Repair stand t 1 790-201-1500 Push tool kit t 1

1
790-101-1102 Hydraulic pump t 1 790-101-5021 • Grip 1
Wrench assembly 01010-50816 Bolt 1
790-330-1100 1
2 • Angle, lift (ST, PAT) t • Plate
790-201-1580 1
790-102-3802 • Tilt (PAT) 1 Lift (ST, PAT)
U 6
Socket • Plate
790-302-1280 • Width across flats 1 790-201-1620 Tilt (ST, PAT) 1
(55 mm) Ripper
• Width across flats • Plate
790-302-1290 1 790-201-1610 1
3 (60 mm) t Angle
790-302-1340 1
(80 mm)
• Width across flats Disassembly
790-302-1320 1
(70 mm) 1. Piston rod assembly
4 1) Set cylinder assembly (1) to tool U1.
790-720-1000 Expander q 1
-1 2) Using hydraulic pump or power wrench, dis-
Ring connect cylinder head assembly (2) with tool
796-720-1660 q 1
• Angle, lift (ST, PAT) U2.
Clamp a Angle cylinder, tilt cylinder (inside pat
07281-01159 q 1
• Angle, lift (ST, PAT) specifications), lift cylinder
U
Ring
796-720-1670 q 1
• Tilt (PAT)
4 Clamp
07281-01279 q 1
-2 • Tilt (PAT)
Ring
796-720-1680 • Tilt (ST) q 1
• Ripper
Clamp
07281-01589 • Tilt (ST) q 1
• Ripper
790-201-1702 Push tool kit t 1
790-101-5021 • Grip 1
01010-50816 • Bolt 1
• Push tool
790-201-1771 1
5 Lift (ST, PAT)
• Push tool
790-201-1811 Tilt (ST, PAT) 1
Ripper
• Push tool
790-201-1791 1
Angle
WE051F0700 13
3) Remove mounting bolts and disconnect cylin- 3) Remove piston assembly (6) and head
der head assembly (2). assembly (2).
a Ripper cylinder, tilt cylinder (straight tilt,
semi-U dozer specifications)
a Portion A is not installed to the ripper cyl-
inder.
3. Disassembly of piston assembly

1) Remove wear ring (7).
2) Remove piston ring (8).
a Ripper cylinder, tilt cylinder, angle cylinder,
4) Pull out piston rod assembly (3) from cylinder lift cylinder (inside PAT specifications)
(4).
a Set a container under the cylinder to catch the
oil.
a Lift cylinder (straight tilt, semi-U dozer

specifications)
2. Piston assembly, head assembly

1) Set piston rod assembly (3) to tool U1.
2) Using tool U3, loosen nylon nut (5) and
remove.
Width across
Name of cylinder
flats of nut
Blade lift
60 mm
(inside PAT specification)
Blade lift
55 mm
(straight tilt, semi-U dozer specifications)
Blade angle 70 mm
Blade tilt 80 mm
Ripper 80 mm
14 WE051F0700
a Perform 3) and 4) for only the lift cylinder Assembly

of straight tilt and semi-U dozer specifica- a Coat the sliding surfaces of all parts with engine oil
tions. before installing. Take care not to damage the rod,
3) Remove two covers (9) and two pins (10). packing, dust seal and O-rings when assembling.
4) Remove four shafts (11) and eight seats (12). a Do not try to force the backup ring into position.
Warm it in warm water of approx. 50 - 60°C before
installation.
1. Assembly of head assembly

1) Using tool U5, press fit bushing (20).
2) Install buffer ring (19).
3) Install rod packing (18).
4) Using tool U6, install dust seal (17), and install
snap ring (16) to fix.
5) Install backup ring and O-ring (15).
a Lift, angle and tilt (inside PAT) cylinders
only
6) Install O-ring (21).
4. Disassembly of head assembly

1) Remove O-ring and backup ring (15).
2) Remove snap ring (16), then remove dust seal
(17).
3) Remove rod packing (18).
4) Remove buffer ring (19).
5) Remove bushing (20).
6) Remove O-ring (21).
a Lift, angle and tilt (inside PAT) cylinders
only
WE051F0700 15
2. Assembly of piston assembly a Perform 5) and 6) for only the lift cylinder
of straight tilt specification.
1) Set piston ring (8) on tool U4-1 and turn the 5) Install eight seats (12) and four shafts (11).
handle 8 - 10 times to expand the ring. 6) Install two pins (10), then install two covers
2) Remove piston ring (8) from tool U4-1, and (9).
install to piston (6).
3) Using tool U4-2, compress piston ring (8).
3. Piston rod assembly
4) Install wear ring (7). 1) Set piston rod to tool U1, and assemble head
assembly (2) and piston assembly (6), then
using tool U3, tighten nut (5).
a Lift cylinder (for straight tilt and semi-U

dozer) has two wear rings (7).
Width across
Tightening
Name of cylinder flats of nuts
torque
(mm)
Blade lift (inside PAT dozer 1.77±0.18 kNm
60
specification) {180±18.0 kgm}
Blade lift (straight tilt, semi- 1.42±0.14 kNm
55
U dozer specifications) {145±14.5 kgm}
2.60±0.26 kNm
Blade angle 70
{265±26.5 kgm}
3.97±0.4 kNm
Blade tilt 80
{405±40.5 kgm}
3.97±0.4 kNm
Ripper 80
{405±40.5 kgm}
16 WE051F0700
a Thoroughly clean the thread of the piston rod 4) Tighten mounting bolt of cylinder head (2).
and remove all oil and grease before assem- a Ripper cylinder, tilt cylinder (straight tilt,
bling the nut. semi-U dozer specifications)
2 Rod thread: Liquid adhesive 3 Mounting bolt:
(Loctite No. 262 or equivalent) 162±14.7 Nm {16.5±1.5 kgm}
2) Set cylinder (1) to tool U1, and assemble pis- a Portion A is not installed to the ripper cyl-
ton rod assembly (3) in cylinder (4). inder.
3) Using hydraulic pump or power wrench,

tighten cylinder head assembly (2) with tool
U2.
a Perform 4) for ripper cylinder and tilt cylinder
(straight tilt, semi-U dozer specifications).
Name of
Cylinder head tightening torque
cylinder
Blade lift 932±93.2 Nm {95±95 kgcm}
1st time: Tighten with torque of 1,225
Nm {125 kgm}.
Blade angle 2nd time: Loosen to 0 Nm {0 kgm}.
3rd time: Tighten with torque of 1,225
Nm {125 kgm}.
Blade tilt
1.03±0.10 kNm {105±10.5 kgm}
(inside PAT)
WE051F0700 17
18 WE051F0700
WE051F0800
Bulldozer
1Shop Manual
D61EX-15
D61PX-15


Others .............................................................................................................................. 2
Removal and installation of operator's cab assembly................................................... 2
Removal and installation of operator's cab glass (stuck glass) .................................... 7
Removal and installation of ROPS canopy ................................................................. 16
Removal and installation of dashboard assembly....................................................... 17
Removal and installation of floor frame assembly ...................................................... 18
Removal and installation of steering and transmission controller assembly............... 23
Others 1
operator's cab assembly 1
Removal
a Arrange for the following sealants when removing

operator's cab from the floor frame. See [*3] sec-
tion in Assembly.
17A-Z11-3552...1 unit (Seal B)

17A-Z11-3541...5 units (Seal (D) - (G))
17A-Z11-2320...2 units (C)
198-Z11-3960 Three Bond(1207B)
...1 unit (Liquid sealant (A)) 5. Open cover (13).
1. Sling ROPS guard (1) temporarily.
2. Remove eight mounting bolts (2). [*1]
3. Lift off ROPS guard (1).

4 ROPS guard (Operator's cab specifica-
tion): 260 kg
6. Disconnect connectors CN19 (14), CN21 (15) and

CN20 (16). [*2]
7. Disconnect washer hose (17).
4. Remove covers (3), (4) and (5).

a Remove cover (5) after disconnecting connec-
tors SIG (6) and ACC (7) on the back.
2 WE051F0800
8. Pull out grommet (18) in the operator's cab. [*2] 12. Lift off operator's cab assembly (22). [*3]
9. Remove covers (19) on both sides. 4 Operator's cab assembly: 410 kg
a Check if removal of any harness, clip or hose

is overlooked.
10. Remove covers (20) on both sides, and remove

mounting bolts (21).
11. Remove mounting bolt of q mark.
WE051F0800 3
Installation 1. Installation of seal to air conditioner box

1) Remove dirt, oil and grease from the position
q Carry out installation in the reverse order to on the top surface of floor frame for coating liq-
removal. uefied sealants. Implement the cleaning on
both sides.
[*1] 2) Coat section A on the top surface of floor
3 Mounting bolt of ROPS guard: frame (31) with liquefied sealant, Three Bond
785-980 Nm {80-100 kgm} 1207B. (See the diagram to the left)
3) Install air conditioner box (32).
[*2] 4) Coat the section on both sides of air condi-
a Do not mistake connector No. when connecting tioner box (32) in contact with U-shaped frame
connectors. (the range on the floor frame shown in the dia-
a Install the grommet securely after connecting the gram) for 8 mm with liquid gasket Three Bond
window washer hose and the connector. 1207B.
[*3]
q When assembling a cab in the field, follow the
present procedure.
a When the cab is removed from the floor frame,
arrange for the following sealants to retain pres-
surization and watertightness when the cab is
assembled again.
17A-Z11-3552...1 unit (Seal B)
17A-Z11-3541...5 units (Seal (D) - (G))
17A-Z11-2320...2 units (C)
198-Z11-3960 Three Bond (1207B)
...1 unit (Liquid sealant (A))
5) Coat adhesive (LT-1A) on the inner surface

around seal B (sealing surface with the air
conditioner box).
4 WE051F0800
6) Set seal B inside guide plate (33) of air condi-

tioner box.
a Pull seal B downward and install by press-
ing hard on liquid sealant coated in 2).
a Fix with adhesive (LT-1A) so that clear-
ance (a) between seal B and the floor
frame will be zero.
q Details
1) Make the end face of seal C with the wall without

any gap. (See the diagram above for A portion.)
2) Before cutting the end of C, adhere seal D to the
groove, then adhere seal E.
a Check that the ends of D and E have no gap
7) Coat the outer surface around seal B (sealing between C.
surface with the cab) with grease (G2-LI). 3) Cut seal C at a position where it is flush with seal
a This is for improving sliding after installing the E.
cab to prevent dislocation and/or deformation a Use remaining portion of seal E as seal F.
of the seal.
2. Installing seal to the cab mating surfaces

1) Sling cab assembly.
2) Remove dirt, oil and grease from the seal
pasting surfaces.
a Take care not to allow the seal to enter
under the cab.
q General
Seeing the diagram, install seals C, D, E, F and G
in this order.
a Install seal without gap at the seal joint positions.
WE051F0800 5
3. Be careful for the following points when installing 5) Check that the gap (e) between air conditioner
operator's cab. duct (26) and monitor (27) on the cab side is
1) Lower the operator's cab assembly gently on equal on both sides. At the same time, check
the floor frame. that air conditioner duct seal (f) on the cab
a Lower carefully as the seal sponge has a side is in contact with surface (C) on both
large reaction force. sides of air conditioner duct (28) on the dash-
a Check that the seal of the air conditioner board side without lateral dislocation.
duct on the cab side is closely in contact a If gap (e) between the air conditioner duct
with the air conditioner duct on the dash- and monitor on the cab side is not equal
board side. on both sides, loosen screws for mounting
a Lower the cab carefully as the gap is nar- air conditioner duct on the cab side, and
row between the air conditioner duct on shift the position so that the gap will be
the cab side and the monitor. equal.
2) Tighten mounting bolts temporarily. Similarly, if dislocation is present in the lat-
3) Check that seal is securely in contact between eral direction on the side of cab and air
air conditioner bracket (23) and cab (22). conditioner, carry out the same corrective
4) Check that no gap is present at the mating measures.
portion (a) between the seal and floor frame. 6) Tighten the mounting bolts of the dashboard
bracket.
6 WE051F0800

operator's cab glass (stuck glass) 1
*Among the operator's cab window glasses, adhesive (1) : Front window glass
type glass is 3 consisting of (1) and (2) for the left and (2) : Left door window glass
right as shown in the diagram. This section describes : Right door window glass
replacement procedure for adhesive type glass. (3) : Dam rubber
(4) : Trim seal
(5) : Door handle
WE051F0800 7
Special tools
New/Remodel
Necessity
Symbol
Sketch
Q'ty
Part No. Part name
X1 793-498-1210 Lifter (Suction cup) t 2
Removal
*Remove the window glass for replacement according

to the following instructions.
1. Using seal cutter [1], cut through adhesive

a When removing window glass broken in
between broken window glass (6) and operator's
pieces, cutter knife [4] and a driver may be
cab (sheet metal) (7).
used.
a Expand a section with a standard-tipped
driver, and cut the dam rubber and adhesive
with a cutter knife [4].
(The diagram below shows an operator's cab
on a wheel loader.)
a If seal cutter is unavailable, use a reamer to

drill a hole to the adhesive and dam rubber,
then put a fine wire (piano wire, etc.) [2]
through the hole. Hold both ends of the fine
wire put through the hole with pliers [3] (or
winding each end on a piece of wood, etc. to
2. Remove the window glass.
fix), and cut the adhesive and dam rubber by
moving the wire left and right.
The wire may be sheared by friction heat.
Apply lubricant to the wire and carry on work.
(The diagram shows an operator's cab on a
wheel loader.)
8 WE051F0800
Installation 3. Install dam rubber (double adhesive tape) (3)

along the inner edges of the front window glass,
1. Using the cutter knife and scraper [5], remove left and right window glasses mounting section.
residual adhesive and dam rubber on the sheet a Do not remove the tape from the glass adhe-
metal side (adhesion face) of operator's cab. sion side of dam rubber before installing glass.
a Residual adhesive and dam rubber on the a When installing dam rubber, avoid touching
sheet metal surface may be removed to a the cleaned surfaces as much as possible.
state that does not give adverse effect on a Regarding adhesion of dam rubber to the cor-
newly applied adhesive. Take care not to ners, special care should be taken not to allow
damage coated surface by excessive scrap- dam rubber to float.
ing. a Install dam rubber (3) so that it will not overlap
(Damaged coated surface causes deteriora- each other at the joint portion where the start-
tion of adhesive force.) ing and ending dam rubbers meet.
(The diagram below shows an operator's cab Or provide the mating portion (a) with a clear-
on a wheel loader.) ance of approx. 5 mm.
2. Remove oil, grease, dust, contamination, etc. on

the adhesion surfaces on cab (7) and window
glass (8) with white gasoline.
a Clean thoroughly as incomplete cleaning
causes defective adhesion.
a Wholly clean the rear black portion of the win-
dow glasses.
a After cleaning, let glasses dry spontaneously
for over 5 minutes.
WE051F0800 9
4. Install trim seal (4) to the left and right door win- a Start positioning front window glass (1)
dow glasses (2). from inside operator's cab (7). Adjust the
f r on t w i n do w g l a ss s o t h a t t he ga p
between the black coated portion (black
ceramic) and operator's cab (7) sheet
metal will be equal to the left, right and up
and down.
a For positioning the left and right door win-
dow glasses (2), align the center of handle
holes (d) of door (9) (glass side, and door
sheet metal side). Then adjust the door
window glass so that the relation of glass
and door sheet metal position will be equal
all round.
2) After positioning, paste tape [6] at 3 positions,
left, right and bottom, across front window
glass (1) and operator's cab (7), and at 3 posi-
tions, left, right and bottom, across door win-
a Install trim seal (4) so that it will be jointed at dow glass (2) and door (9) on both sides.
position (c) where dimension (b) from the cor- Draw line (e) on each tape for positioning pur-
ner reads 90 mm. pose.
3) Cut the tape with a cutter knife, etc. between
window glasses (1), (2) and operator's cab (7),
and then remove respective window glasses.
a Do not remove tapes left on the window
glasses and operator's cab until installing
window glass.
5. Position window glass to be replaced.

1) Using tool X1, set the window glass to the
installation position. Check the left/right and
up and down clearance with operator's cab
and adjust the window glass so that the clear-
ance will be equal.
10 WE051F0800
6. Coat with adhesive. 3) Set adhesive cartridge (10) to calking gun [7].
2 Adhesive: Sika Ltd. Japan Sikaflex 256HV a Electric calking gun has better workability.
a Do not use primer.
a Since the effective limit of adhesive agents is 6
months after the date of manufacture, do not
use adhesives beyond the effective service
limit.
a Store adhesives in a cold, dark place at under
25°C.
a Never heat adhesives to higher than 30°C.
a When reusing adhesive, completely remove
hardened adhesive at the nozzle tip before
using.
1) Break aluminum moistureproof film (11) cover-
ing the outlet end of adhesive cartridge (10),
and install the nozzle.
4) Peel tape (3a) covering the glass adhesion

side of dam rubber off.
2) Cut the tip of adhesive nozzle (12) to the

dimensions of (f) and (g) as shown in the dia-
gram.
q (f) dimension: 10 mm
q (g) dimension: 15 mm 5) Apply adhesive (13) to the outside of dam rub-
ber (3) for the operator's cab.
WE051F0800 11
7. Install front window glass.

1) Aligning with line (e) on position-matching tape
[6] in preceding 5, install operator's cab (7)
and front window glass (1) using tool X1.
a As it is not possible to correct the pasting
of window glass once installed, paste with
utmost care.
a Paste window glass within 5 minutes after
applying adhesive.
2) After pasting window glass, press window
glass all around until it is closely adhered to
dam rubber.
a Press corners of window glass firmly.
a To dam rubber (3) of operator's cab (7),

apply adhesive (13) to the dimensions of
(h) and (j) in the diagram.
q (h) dimension: 10 mm
q (j) dimension: 15 mm
a Apply adhesive (13) higher than dam rub-
ber (3).
a Apply adhesive uniformly without irregu-
larity in height.
3) Apply masking tape [8] to front window glass

(1) and operator's cab (7).
4) Apply calking agent (14) to the gap between
front window glass (1) and operator's cab (7)
all around.
2 Calking agent:
Sekisui Silicone Sealant
a Since the effective limit of adhesive agents
is 6 months after the date of manufacture,
do not use adhesives beyond the effective
service limit.
12 WE051F0800
5) After applying calking agent (14) to front win- 8. Install the left and right window glasses.
dow glass (1), adjust the contour of calking 1) Aligning with line (e) on position-matching tape
agent as follows: [6] in preceding 5, install doors (9) and left and
a Use rubber spatula [9] to around the hand- right door window glasses (2) using tool X1.
rail, etc. where it is difficult to finish the a As it is not possible to correct the pasting
contour with a finger of window glass once installed, paste with
utmost care.
a Paste window glass within 5 minutes after
applying adhesive.
2) After pasting window glass, press window
glass all around until it is closely adhered to
dam rubber.
a Press corners of window glass firmly.
WE051F0800 13
a If excessive adhesive agent (13) protrudes

from trim seal (4) of the pasted left and right
door window glasses, remove it with rubber
spatula [9].
9. Fix window glass (9).

1) To completely fix the front window glass in
close contact with the cab, use Styrofoam [10]
and rubber band [11] to fix it securely for cur-
ing.
3) Calk between the left and right door window
a Or use adhesive tape for fixing.
glasses and trim seal within the range of
(The diagram shows an operator's cab on a
dimension (k).
hydraulic excavator.)
1] Mask the left and right door window
glasses within the range of dimension (k).
2] Apply calking agent to the clearance (m)
between the left and right door window
glasses (2) and trim seal (4).
a Since the effective limit of calking
agents is 6 months after the date of
manufacture, do not use calking agent
beyond the effective service limit.
a Apply calking agent to trim seal joint
position (c) too.
2 Calking agent:
Sekisui Silicone Sealant
14 WE051F0800
2) Install and fix door handle (5) to the door win-

dow glass on both sides immediately after
pasting.
10. After completing the pasting of window glasses,

remove excessive primer and adhesive attached
to window glasses and operator's cab.
a Using white gasoline, wipe adhesive off before
drying.
a During cleaning, take care not to give impact
to the window glasses.
11. Cure the pasted window glasses.

1) Leave them fixed for 10 hours without remov-
ing stopper rubber, Styrofoam and rubber
bands,
(Temperature 20°C/ humidity 65%)
2) Cure adhesive for 24 hours before actually
operating the machine.
WE051F0800 15
Removal and installation of ROPS

canopy 1
Removal
1. Sling ROPS canopy (1) temporarily.
2. Remove 8 mounting bolts (2). [*1]
3. Lift off ROPS canopy (1).

4 ROPS canopy: 370 kg
Installation

removal.
[*1]
3 Mounting bolt of ROPS canopy:
785-980 Nm {80-100 kgm}
16 WE051F0800

dashboard assembly 1
Special tools
New/Remodel
Necessity
Symbol
Sketch
Q'ty
Part No. Part name

799-703-1100 Vacuum pump (100 V) t 1
X2 799-703-1110 Vacuum pump (220 V) t 1
799-703-1120 Vacuum pump (240 V) t 1
Installation
Removal q Carry out installation in the reverse order to

removal.
k Recover the air conditioner gas (R143a).
[*1]
1. Remove the operator's cab assembly. For details, a Install each hose so that it will not be twisted.
see Removal and installation of operator's cab a When installing the air conditioner hose circuit,
assembly. (Only for operator's cab specifications) take care that dirt, dust, water, etc. will not
enter the hose.
2. Disconnect air compressor hose (1). [*1] a Before tightening, check that the joints of the
air conditioner hose piping are provided with
3. Disconnect heater hose (2). O-ring (46).
a Apply sufficient compressor oil (Showa-Shell
4. Disconnect connector (3). Suniso 4G, 5G or equivalent) to each O-ring.
q S13 : Gray
q S214: Black
q S215: Green
q S218: Brown (for cab specifications only)
3 Tightening torque of air conditioner refrig-

erant piping:

16 x 1.5 11.8-14.7 Nm {1.2-1.5 kgm}
22 x 1.5 19.6-24.5 Nm {2.0-2.5 kgm}
5. Lift off dashboard assembly (4).
4
24 x 1.5 29.4-34.3 Nm {3.0-3.5 kgm}
Dashboard assembly: 30 kg

q Filling of air conditioner refrigerant
is overlooked.
Using tool X2, fill the air conditioner circuit with
refrigerant gas (R134a). (1000±50 g)
WE051F0800 17
Removal and installation of floor

frame assembly 1
Special tools
New/Remodel
Necessity
Symbol
Sketch
Q'ty
Part No. Part name

799-703-1100 Vacuum pump (100 V) t 1
X2 799-703-1110 Vacuum pump (220 V) t 1
799-703-1120 Vacuum pump (240 V) t 1
Removal 8. Disconnect horn connector (8), then remove cover

(7).
k Recover the air conditioner refrigerant gas
(R143a). 9. Disconnect connectors CN262 (9) and PSW (10).
and release the residual pressure inside the
piping. For details, see Release of residual
pressure from work equipment cylinder in
inspection and adjustment.
q Sling the controller and harness together with the
floor assembly.
1. Remove the engine hood assembly. For details, see

Removal and installation of engine hood assembly.
2. Remove the operator's cab assembly. For details,

see Removal and installation of operator's cab
assembly.
3. Open cover (1).
4. Disconnect clips (2) and (3) (If equipped).
5. Disconnect connectors PSL and PT1.
18 WE051F0800
10. Disconnect ripper control lever (12). (If equipped) 16. Disconnect grounding (21) and (22).
11. Remove mounting bolts (13) and remove blade 17. Disconnect parking brake cable (23).[*1]
control lever (14).
18. Disconnect connector CAN (24).
12. Remove cover assembly (15).

4 Cover assembly (15): 55 kg 19. Disconnect washer hose (27).

a Disconnect the clips, too.
13. Disconnect clip (16) and connector FFC (17).
14. Disconnect the cable from the battery relay termi-

nal (18). 21. Disconnect air compressor hose (29). [*2]
15. Disconnect plate assembly (19) and bracket 22. Disconnect heater hose (30).
assembly (20).
WE051F0800 19
23. Remove cover (32), and remove cover (33)

mounting bolt.
28. Disconnect clip (42) from the right side of the

engine.
24. Retain cover (33) in floating state with block [1]. a (A) is starting motor.
25. Remove decelerator pedal (34) as follows. 29. Disconnect the following terminals and connec-
1) Disconnect bracket (35) and fuel control cable tors:
(36). [*3] q (43): Starting motor +terminal [*5]
2) Disconnect connector DCL (37). q (44): E22
q (45): E21
26. Remove cover (33) as follows. q (46): Starting motor connector E101
1) Disconnect parking brake cable (38). [*4] q (60): CN101 (Connected to radiator guard)
2) Disconnect connector BRK (39).
30. Disconnect grounding terminal (61) from the
27. Disconnect connectors PL1 (40) and PL2 (41). frame.
a Remember the clip.
20 WE051F0800
31. Remove floor frame front mounting bolt (46). [*6] 34. Lift off floor frame (52).
4 Floor frame: 380 kg

is overlooked.
32. Remove cooler box (47), and then remove floor

frame front mounting bolt (48). (Only for operator's
cab specifications)
Installation
q Before installing floor frame (52), remove the oper-

ator's seat assembly in advance.
a Remember connectors.
q Carry out the following installation in the reverse

order to removal.
[*1]
a Adjust the parking brake lever. For details, see
Adjustment of parking brake lever.
[*2]
33. Remove brackets (49) and (50), and then remove
a Install each hose so that it will not be twisted.
floor frame rear mounting bolts (51) four each on
a When installing the air conditioner hose circuit,
the left and right sides. [*7]
take care that dirt, dust, water, etc. will not enter
the hose.
a Before tightening, check that the joints of the air
conditioner hose piping are provided with O-ring
(46).
a Apply sufficient compressor oil (Showa-Shell
Suniso 4G, 5G or equivalent) to each O-ring.
WE051F0800 21
3 Tightening torque of air conditioner refrigerant

piping:

16 x 1.5 11.8-14.7 Nm {1.2-1.5 kgm}
22 x 1.5 19.6-24.5 Nm {2.0-2.5 kgm}
24 x 1.5 29.4-34.3 Nm {3.0-3.5 kgm}
[*3]
Adjustment of fuel control linkage in Testing and
adjusting.
[*4]
a Adjust the brake pedal. For details, see Adjust-
ment of brake pedaL in Testing and adjusting.
[*5]
3 Starting motor + terminal:
19.6-25.5 Nm {2.0-2.6 kgm}
[*6]
3 Floor frame front mounting bolt (46):
:642±29 Nm {65.5±3 kgm}
[*7]
3 Floor frame rear mounting bolt (51):
235-285 Nm {23.5-29.0 kgm}
q Filling of air conditioner refrigerant

Using tool X2, fill the air conditioner circuit with refrig-
erant gas (R134a). (1000±50 g)
22 WE051F0800
Removal and installation of steering 4. Disconnect wiring connectors ST1 (4), ST2 (5) and
and transmission controller assembly1 ST3 (6) and remove steering and transmission
controller assembly (3).
Removal a To disconnect each connector, loosen mount-
ing screws (hexagon socket) A at the center of
k Disconnect the cable from the negative (-) ter- each harness.
1. Lift off operator's seat assembly (1).

4 Operator's seat assembly: 60 kg
2. Remove side cover (2) to the lower left side of

operator's seat.
Installation
a Since wiring weighs heavy, install the controller

first.
1. Install steering and transmission controller assem-
bly (3) with four mounting bolts.
2. Connect wiring connectors ST1 (4), ST2 (5) and

3. Remove four mounting bolts and slowly pull out
ST3 (6) to steering and transmission controller
steering and transmission controller assembly (3)
assembly (3).
to the floor.
3 Mounting screw: 2.82 Nm {0.286 kgm}
q Carry out the following installation in the

reverse order to removal.
WE051F0800 23
24 WE051F0800
WE051X0100
Bulldozer
D61EX-15
D61PX-15
D61EX-15 B40001-
D61PX-15 B40001-
Others 1
Hydraulic circuit diagram.................................................................................................. 3
Power train hydraulic circuit diagram............................................................................ 3
Power angle power tilt dozer (PAT)............................................................................... 5
Power tilt dozer (PT) ..................................................................................................... 7
Electrical circuit diagram .................................................................................................. 9
Electrical circuit diagram (1/6) ...................................................................................... 9
Electrical circuit diagram (2/6) .................................................................................... 11
Cab electrical circuit diagram...................................................................................... 21
Hydraulic circuit diagram
Power train hydraulic circuit diagram
WE051X0100 3
WE051X0100 5
WE051X0100 7
Electrical circuit diagram
WE051X0100 9
WE051X0100 11
WE051X0100 13
WE051X0100 15
WE051X0100 17
WE051X0100 19
Cab electrical circuit diagram
WE051X0100 21

D61ex PX-15

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WE051Z0002

MACHINE MODEL SERIAL NUMBER

D61EX-15 B40001 and up

• D61-15 mount the SA6D114E-2 engine.

Machine Model 1 Serial Number 1

D61EX-15 B40001 and up

Table of general contents 1

Form No. Section Title

Form No. Section Title

Form No. Section Title

Form No. Section Title

Q WE051F0400 Disassembly and assembly Power train

Q WE051F0800 Disassembly and assembly Others

Form No. Section Title

D61EX-15, D61PX-15 BULLDOZER

Model Serial Number 1

Important safety notice

General precautions 6. Decide a place in the repair workshop to keep

16. When removing components, be careful not to

17. When removing piping, stop the fuel or oil from

18. As a general rule, do not use gasoline to wash

Structure and function

Testing and adjusting

Disassembly and assembly

How to read the shop manual

q If a part cannot be smoothly removed from the

2. Sling wire ropes from the middle portion of the

Method of disassembling, connecting push-pull type coupler

k Even if the residual pressure is released from the

3. After hose joint (2) is pushed into adapter (3),

4. Hold hose adapter (1) or hose (5) and pull it out.

2. After inserting the hose in the mating adapter per-

Standard tightening torque

Thread diameter Width across flats Tightening torque

Table of tightening torques for flared nuts

Thread diameter Width across flats Tightening torque

Table of tightening torques for o-ring boss piping joints

Thread diameter Width across flats Tightening torque

Table of tightening torques for o-ring boss plugs

Thread diameter Width across flats Tightening torque

Tightening torque for 102 engine series

(12) 46 197 – 294 {20.0 – 30.0} 245 {25.0} 36 — —

(14) 55 246 – 343 {25.0 – 35.0} 294 {30.0} 42 — —

Electric wire code

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

1. Convert 55mm into inches.

2. Convert 550mm into inches.

Millimeters to inches (B)

Liter to U.S. Gallon

Liter to U.K. Gallon

–28.3 –19 –2.2 –8.9 16 60.8 10.6 51 123.8 30.0 86 186.8

–25.6 –14 6.8 –6.1 21 69.8 13.3 56 132.8 32.8 91 195.8