Komatsu BULLDOZER D51EXi -24 D51PXi-24 Shop Manual SEN06621-06 PDF

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Komatsu BULLDOZER D51EXi -24 D51PXi-24 Shop Manual SEN06621-06 PDF- PDF DOWNLOAD

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Komatsu BULLDOZER D51EXi -24 D51PXi-24 Shop Manual SEN06621-06 PDF- PDF DOWNLOAD

Language : English
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Komatsu BULLDOZER D51EXi -24 D51PXi-24 Shop Manual SEN06621-06 PDF- PDF DOWNLOAD

SERIAL NUMBERS D51EXi-10001
D51PXi-10001 and up

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Komatsu BULLDOZER D51EXi -24 D51PXi-24 Shop Manual SEN06621-06 PDF- PDF DOWNLOAD

SERIAL NUMBERS D51EXi-10001
D51PXi-10001 and up

COVER 1
00 INDEX AND FOREWORD 3
INDEX 4
ABBREVIATION LIST 22
FOREWORD, SAFETY, BASIC INFORMATION 28
HOW TO READ THE SHOP MANUAL 28
SAFETY NOTICE FOR OPERATION 30
PRECAUTIONS TO PREVENT FIRE 38
ACTIONS IF FIRE OCCURS 40
PRECAUTIONS FOR DISPOSING OF WASTE MATERIALS 41
ACTIONS TAKEN TO MEET EXHAUST GAS REGULATIONS 42
PRECAUTIONS FOR DEF 43
GENERAL CHARACTER AND PRECAUTIONS FOR HANDLING 43
PRECAUTIONS FOR ADDING 43
PRECAUTIONS FOR STORING 43
PRECAUTIONS FOR FIRE HAZARD AND LEAKAGE 43
THE OTHER PRECAUTIONS 43
STORE AdBlue/DEF 44
PRECAUTIONS FOR HANDLING HYDRAULIC EQUIPMENT 45
PRECAUTIONS FOR DISCONNECTION AND CONNECTION OF PIPINGS 48
PRECAUTIONS FOR HANDLING ELECTRICAL EQUIPMENT 55
PRECAUTIONS FOR HANDLING FUEL SYSTEM EQUIPMENT 57
PRECAUTIONS FOR HANDLING INTAKE SYSTEM EQUIPMENT 58
PRACTICAL USE OF KOMTRAX 59
DISCONNECT AND CONNECT PUSH-PULL TYPE COUPLER 60
METHOD FOR DISCONNECTING AND CONNECTING TYPE 1 PUSH-PULL TYPE COUPLER 60
METHOD FOR DISCONNECTING AND CONNECTING TYPE 2 PUSH-PULL TYPE COUPLER 61
METHOD FOR DISCONNECTING AND CONNECTING TYPE 3 PUSH-PULL TYPE COUPLER 62
PRECAUTIONS FOR DISCONNECTION AND CONNECTION OF CONNECTORS 64
METHOD FOR DISCONNECTING AND CONNECTING DEUTSCH CONNECTOR 68
METHOD FOR DISCONNECTING AND CONNECTING SLIDE LOCK TYPE CONNECTOR 69
METHOD FOR DISCONNECTING AND CONNECTING CONNECTOR WITH LOCK TO PULL 71
METHOD FOR DISCONNECTING AND CONNECTING CONNECTOR WITH LOCK TO PUSH 72
METHOD FOR DISCONNECTING AND CONNECTING CONNECTOR WITH HOUSING TO ROTATE 74
HOW TO READ ELECTRICAL WIRE CODE 75
EXPLANATION OF TERMS FOR MAINTENANCE STANDARD 79
STANDARD TIGHTENING TORQUE TABLE 82
CONVERSION TABLE 89
01 SPECIFICATIONS 95
CONTENTS 96
ABBREVIATION LIST 97
SPECIFICATIONS 103
SPECIFICATION DRAWING 103
SPECIFICATION DRAWING: D51EXI-24 103
SPECIFICATION DRAWING: D51PXI-24 105
SPECIFICATIONS 107
SPECIFICATIONS: D51EXI-24 107
SPECIFICATIONS: D51PXI-24 113
WEIGHT TABLE 118
WEIGHT TABLE: D51EXI-24 118
WEIGHT TABLE: D51PXI-24 120
FUEL, COOLANT, LUBRICANTS (FOR NORTH AMERICA) 122
METHOD FOR USING FUEL, COOLANT AND LUBRICANTS ACCORDING TO AMBIENT TEMPERATURE 122
FUEL, COOLANT, LUBRICANTS (FOR EUROPEAN UNION) 124
METHOD FOR USING FUEL, COOLANT AND LUBRICANTS ACCORDING TO AMBIENT TEMPERATURE 124
10 STRUCTURE AND FUNCTION 127
CONTENTS 128
ABBREVIATION LIST 131
UREA SCR SYSTEM 137
LAYOUT DRAWING OF UREA SCR SYSTEM 137
UREA SCR SYSTEM DIAGRAM 139
FUNCTION OF UREA SCR SYSTEM 140
FUNCTION OF AdBlue/DEF SYSTEM 140
INDUCEMENT STRATEGY 143
COMPONENT PARTS OF UREA SCR SYSTEM 157
AdBlue/DEF MIXING TUBE 157
SCR ASSEMBLY 158
AdBlue/DEF TANK 160
AdBlue/DEF PUMP 162
AdBlue/DEF INJECTOR 163
AdBlue/DEF HOSE 164
AdBlue/DEF TANK HEATING VALVE 165
BOOT-UP SYSTEM 166
LAYOUT DRAWING OF BOOT-UP SYSTEM 166
SYSTEM OPERATING LAMP SYSTEM 167
SYSTEM OPERATING LAMP SYSTEM DIAGRAM 167
FUNCTION OF SYSTEM OPERATING LAMP SYSTEM 167
BATTERY DISCONNECT SWITCH 169
FUNCTION OF BATTERY DISCONNECT SWITCH 169
ENGINE SYSTEM 170
LAYOUT DRAWING OF ENGINE SYSTEM 170
ENGINE CONTROL SYSTEM 172
LAYOUT OF ENGINE CONTROL SYSTEM 172
ENGINE CONTROL SYSTEM DIAGRAM 174
FUNCTION OF ENGINE CONTROL SYSTEM 176
AUTOMATIC IDLE STOP SYSTEM 178
AUTOMATIC IDLE STOP SYSTEM DIAGRAM 178
FUNCTION OF AUTOMATIC IDLE STOP SYSTEM 178
COMPONENT PARTS OF ENGINE SYSTEM 181
DAMPER 181
VGT 182
EGR SYSTEM 185
EGR VALVE 187
EGR COOLER 189
KCCV SYSTEM 191
KCCV VENTILATOR 193
KDOC 195
COOLING SYSTEM 198
LAYOUT DRAWING OF COOLING SYSTEM 198
SPECIFICATIONS OF COOLING SYSTEM 199
COOLING FAN CONTROL SYSTEM 200
COOLING FAN CONTROL SYSTEM DIAGRAM 200
FUNCTION OF COOLING FAN CONTROL SYSTEM 201
COMPONENT PARTS OF COOLING SYSTEM 203
COOLING FAN MOTOR 203
HYDRAULIC OIL COOLER BYPASS AND HST CHARGE SAFETY VALVE 208
HYDRAULIC OIL COOLER BYPASS VALVE 209
HST CHARGE SAFETY VALVE 210
CONTROL SYSTEM 212
LAYOUT DRAWING OF CONTROL SYSTEM 212
MACHINE MONITOR SYSTEM 213
MACHINE MONITOR SYSTEM DIAGRAM 213
FUNCTION OF MACHINE MONITOR SYSTEM 213
KOMTRAX SYSTEM 214
KOMTRAX SYSTEM DIAGRAM 214
FUNCTION OF KOMTRAX SYSTEM 214
COMPONENT PARTS OF CONTROL SYSTEM 215
MACHINE MONITOR 215
KOMTRAX TERMINAL 230
HST CONTROLLER 232
ENGINE CONTROLLER 236
FUEL CONTROL DIAL 243
DECELERATOR AND BRAKE POTENTIOMETER 245
HYDRAULIC SYSTEM 247
LAYOUT DRAWING OF HYDRAULIC SYSTEM 247
CLSS 248
STRUCTURE OF CLSS 248
FUNCTION OF CLSS 249
COMPONENT PARTS OF HYDRAULIC SYSTEM 251
HYDRAULIC TANK 251
WORK EQUIPMENT AND COOLING FAN PUMP 253
LS VALVE 261
PC VALVE 262
CONTROL VALVE 265
POWER TRAIN SYSTEM 283
LAYOUT DRAWING OF HST SYSTEM 283
OPERATION OF HST SYSTEM 284
STEERING AND BRAKE CONTROL SYSTEM 286
LAYOUT DRAWING OF STEERING AND BRAKE CONTROL SYSTEM 286
FUNCTION OF STEERING AND BRAKE CONTROL SYSTEM 286
HST CONTROL SYSTEM 288
HST CONTROL SYSTEM DIAGRAM 288
GEAR SHIFT CONTROL FUNCTION 289
ENGINE LOW SPEED MATCHING CONTROL FUNCTION 292
HST PUMP AND MOTOR SEQUENCE CONTROL FUNCTION 293
DECELERATION AND BRAKE CONTROL FUNCTION 294
GEAR SHIFT CONTROL FUNCTION BY LOAD 296
TURN CONTROL FUNCTION 296
STRAIGHT TRAVEL CORRECTION CONTROL FUNCTION 297
PARKING BRAKE CONTROL SYSTEM 299
PARKING BRAKE CONTROL SYSTEM DIAGRAM 299
FUNCTION OF PARKING BRAKE CONTROL SYSTEM 300
OPERATION OF PARKING BRAKE CONTROL SYSTEM 301
COMPONENT PARTS OF POWER TRAIN SYSTEM 302
HST PUMP 302
HST CHARGE PUMP 317
HST MOTOR 318
FINAL DRIVE 331
ELECTRIC STEERING CONTROL LEVER 335
WORK EQUIPMENT SYSTEM 338
WORK EQUIPMENT CONTROL 338
WORK EQUIPMENT CONTROL SYSTEM DIAGRAM 338
FUNCTION OF WORK EQUIPMENT CONTROL 339
LAYOUT DRAWING OF FRONT WORK EQUIPMENT 340
LAYOUT OF FIXED MULTI-SHANK RIPPER 341
COMPONENT PARTS OF WORK EQUIPMENT SYSTEM 342
RIPPER PPC VALVE 342
5-PORT VALVE OF EPC AND SOLENOID 346
PILOT CIRCUIT ACCUMULATOR 352
QUICK DROP VALVE 353
PISTON VALVE 354
ELECTRIC BLADE CONTROL LEVER 356
ICT SYSTEM 358
LAYOUT DRAWING OF ICT SYSTEM 358
ICT CONTROL SYSTEM DIAGRAM 360
BLADE CONTROL SYSTEM 362
FUNCTION OF BLADE CONTROL SYSTEM 362
LEVELING MODE SYSTEM DIAGRAM 364
FUNCTION OF LEVELING MODE 365
OPERATION OF LEVELING MODE 365
DOZING MODE SYSTEM DIAGRAM 366
FUNCTION OF DOZING MODE 366
OPERATION OF DOZING MODE 366
SMOOTH START SYSTEM 368
SMOOTH START SYSTEM DIAGRAM 368
FUNCTION OF SMOOTH START SYSTEM 368
OPERATION OF SMOOTH START SYSTEM 368
SLIP CONTROL SYSTEM 370
SLIP CONTROL SYSTEM DIAGRAM 370
FUNCTION OF SLIP CONTROL SYSTEM 370
OPERATION OF SLIP CONTROL SYSTEM 370
ASSIST CONTROL SYSTEM 371
ASSIST CONTROL SYSTEM DIAGRAM 371
FUNCTION OF ASSIST CONTROL SYSTEM 371
OPERATION OF ASSIST CONTROL SYSTEM 372
HST SPEED RANGE CONTROL SYSTEM 373
HST SPEED RANGE CONTROL SYSTEM DIAGRAM 373
FUNCTION OF HST SPEED RANGE CONTROL SYSTEM 373
OPERATION OF HST SPEED RANGE CONTROL SYSTEM 373
COMPONENT PARTS OF ICT SYSTEM 375
ICT SENSOR CONTROLLER 375
CONTROL BOX 379
GNSS RECEIVER 382
GNSS ANTENNA 386
IMU SENSOR 387
STROKE AND RESET SENSOR FOR BLADE LIFT CYLINDER 391
STROKE SENSOR FOR BLADE TILT CYLINDER 394
STROKE SENSOR FOR BLADE ANGLE CYLINDER 396
UNDERCARRIAGE AND FRAME 398
MAIN FRAME 398
STRUCTURE OF MAIN FRAME 398
SUSPENSION 399
STRUCTURE OF SUSPENSION 399
SPECIFICATIONS OF SUSPENSION 400
FUNCTION OF SUSPENSION 401
TRACK FRAME AND IDLER CUSHION 402
STRUCTURE OF TRACK FRAME AND IDLER CUSHION 402
FUNCTION OF TRACK FRAME AND IDLER CUSHION 403
WORK EQUIPMENT 404
STRUCTURE OF FRONT WORK EQUIPMENT 404
STRUCTURE OF FIXED MULTI-SHANK RIPPER 405
CAB AND ITS ATTACHMENTS 406
ROPS CAB 406
STRUCTURE OF ROPS CAB 406
FUNCTION OF ROPS CAB 407
CAB MOUNT 408
STRUCTURE OF CAB MOUNT 408
FUNCTION OF CAB MOUNT 408
20 STANDARD VALUE TABLE 409
CONTENTS 410
ABBREVIATION LIST 411
STANDARD VALUE TABLE FOR ENGINE 417
STANDARD VALUE TABLE FOR ENGINE: D51EXI-24 417
STANDARD VALUE TABLE FOR ENGINE: D51PXI-24 421
STANDARD VALUE TABLE FOR MACHINE 425
STANDARD VALUE TABLE FOR MACHINE: D51EXI-24 425
STANDARD VALUE TABLE FOR MACHINE: D51PXI-24 442
MACHINE POSTURE AND PROCEDURE FOR MEASURING PERFORMANCE 457
30 TESTING AND ADJUSTING 459
CONTENTS 460
ABBREVIATION LIST 464
RELATED INFORMATION ON TESTING AND ADJUSTING 470
TOOLS FOR TESTING AND ADJUSTING 470
SKETCH OF TOOLS FOR TESTING AND ADJUSTING 477
ENGINE AND COOLING SYSTEM 481
TEST ENGINE SPEED 481
METHOD FOR TESTING ENGINE SPEED 481
TEST BOOST PRESSURE 483
METHOD FOR TESTING BOOST PRESSURE 483
TEST EXHAUST GAS COLOR 484
METHOD FOR TESTING EXHAUST GAS COLOR BY HANDY SMOKE CHECKER 484
METHOD FOR TESTING EXHAUST GAS COLOR BY SMOKE METER 485
TEST AND ADJUST VALVE CLEARANCE 486
METHOD FOR TESTING VALVE CLEARANCE 486
METHOD FOR ADJUSTING VALVE CLEARANCE 487
TEST COMPRESSION PRESSURE 488
METHOD FOR TESTING COMPRESSION PRESSURE 488
TEST BLOWBY PRESSURE 493
METHOD FOR TESTING BLOWBY PRESSURE 493
TEST ENGINE OIL PRESSURE 495
METHOD FOR TESTING ENGINE OIL PRESSURE 495
TEST FUEL PRESSURE 496
METHOD FOR TESTING FUEL PRESSURE 497
TEST FUEL DISCHARGE, RETURN AND LEAKAGE 501
METHOD FOR TESTING FUEL DISCHARGE, RETURN AND LEAKAGE 502
BLEED AIR FROM FUEL SYSTEM 507
METHOD FOR BLEEDING AIR FROM FUEL SYSTEM 507
TEST FUEL CIRCUIT FOR LEAKAGE 508
METHOD FOR TESTING FUEL CIRCUIT FOR LEAKAGE 508
HANDLE CYLINDER CUT-OUT MODE OPERATION 510
HANDLE NO-INJECTION CRANKING OPERATION 511
TEST KDOC, SCR AND MUFFLER STACK FOR LOOSENESS AND DAMAGE 512
METHOD FOR TESTING KDOC, SCR AND MUFFLER STACK FOR LOOSENESS AND DAMAGE 512
TEST INSTALLED CONDITION OF CYLINDER HEADS AND MANIFOLDS 513
METHOD FOR TESTING INSTALLED CONDITION OF CYLINDER HEADS AND MANIFOLDS 513
TEST ENGINE PIPING FOR DAMAGE AND LOOSENESS 514
METHOD FOR TESTING ENGINE PIPING FOR DAMAGE AND LOOSENESS 514
WRITE ASH IN SOOT ACCUMULATION CORRECTION TO ENGINE CONTROLLER 515
METHOD FOR WRITING ASH IN SOOT ACCUMULATION CORRECTION TO ENGINE CONTROLLER 515
TEST SCR RELATED FUNCTIONS 516
TEST AdBlue/DEF PUMP RAISED PRESSURE 520
TEST INJECTION AMOUNT FROM AdBlue/DEF INJECTOR 523
TEST AdBlue/DEF LINE HEATER RELAY 1 528
TEST AdBlue/DEF LINE HEATER RELAY 2 531
TEST AdBlue/DEF PUMP HEATER RELAY 534
TEST AdBlue/DEF TANK HEATER VALVE 538
TEST DENITRATION EFFICIENCY OF SCR 542
CLEAN AdBlue/DEF TANK 545
METHOD FOR CLEANING AdBlue/DEF TANK 545
CLEAN AdBlue/DEF TANK MOUNTING PORTION 549
METHOD FOR CLEANING AdBlue/DEF TANK MOUNTING PORTION 549
POWER TRAIN 550
TEST AND ADJUST HST OIL PRESSURE 550
METHOD FOR TESTING HST OIL PRESSURE 550
METHOD FOR ADJUSTING HST OIL PRESSURE 553
BLEED AIR FROM HST PUMP 555
METHOD FOR BLEEDING AIR FROM HST PUMP 555
METHOD FOR BLEEDING AIR FROM SERVO VALVE OF HST PUMP 555
TEST OUTLET PRESSURE OF SOLENOID VALVE 557
METHOD FOR TESTING OUTLET PRESSURE OF SOLENOID VALVE 557
TEST TRAVEL DEVIATION 561
METHOD FOR TESTING TRAVEL DEVIATION 561
TEST BRAKE PERFORMANCE SIMPLY 563
METHOD FOR TESTING BRAKE PERFORMANCE SIMPLY 563
TEST AND ADJUST DECELERATION/BRAKE PEDAL 564
METHOD FOR TESTING DECELERATION/BRAKE PEDAL 564
METHOD FOR ADJUSTING DECELERATION/BRAKE PEDAL 566
ADJUST PARKING BRAKE LEVER 568
METHOD FOR ADJUSTING PARKING BRAKE LEVER 568
MOVE MACHINE WHEN IT CANNOT TRAVEL 570
METHOD FOR MOVING MACHINE WITH HYDRAULIC TYPE PARKING BRAKE RELEASE SYSTEM 570
METHOD FOR MOVING DISABLED MACHINE BY REMOVING FINAL DRIVE SHAFT 572
UNDERCARRIAGE AND FRAME 573
CHECK AND ADJUST IDLER CLEARANCE 573
METHOD FOR ADJUSTING IDLER CLEARANCE HORIZONTALLY 573
METHOD FOR ADJUSTING IDLER CLEARANCE VERTICALLY 573
TESTING SPROCKET WEAR 575
METHOD FOR TESTING SPROCKET WEAR 575
TEST AND ADJUST TRACK TENSION 576
METHOD FOR TESTING TRACK TENSION 576
METHOD FOR ADJUSTING TRACK TENSION 576
HYDRAULIC SYSTEM 578
RELEASE REMAINING PRESSURE FROM HYDRAULIC SYSTEM 578
METHOD FOR RELEASING REMAINING PRESSURE FROM HYDRAULIC CIRCUIT 578
TEST AND ADJUST WORK EQUIPMENT OIL PRESSURES 579
METHOD FOR TESTING WORK EQUIPMENT OIL PRESSURES 579
METHOD FOR ADJUSTING WORK EQUIPMENT OIL PRESSURES 580
TEST AND ADJUST OIL PRESSURE OF CONTROL CIRCUIT 582
METHOD FOR TESTING OIL PRESSURE OF CONTROL CIRCUIT 582
METHOD FOR ADJUSTING OIL PRESSURE OF CONTROL CIRCUIT 583
TEST OUTLET PRESSURE OF EPC SOLENOID VALVE 584
METHOD FOR TESTING OUTLET PRESSURE OF EPC SOLENOID VALVE 584
BLEED AIR FROM WORK EQUIPMENT AND COOLING FAN PUMP 586
METHOD FOR BLEEDING AIR FROM WORK EQUIPMENT AND COOLING FAN PUMP 586
TEST COOLING FAN SPEED 587
METHOD FOR TESTING COOLING FAN SPEED 587
TEST COOLING FAN CIRCUIT OIL PRESSURE 588
METHOD FOR TESTING COOLING FAN CIRCUIT OIL PRESSURE 588
TEST THE PARTS CAUSING HYDRAULIC DRIFT IN WORK EQUIPMENT 590
METHOD FOR TESTING THE PARTS CAUSING HYDRAULIC DRIFT OF BLADE LIFT CYLINDER 590
METHOD FOR TESTING THE PARTS CAUSING HYDRAULIC DRIFT OF BLADE TILT CYLINDER 591
METHOD FOR TESTING THE PARTS CAUSING HYDRAULIC DRIFT OF RIPPER LIFT CYLINDER 592
TEST INTERNAL OIL LEAKAGE OF WORK EQUIPMENT CYLINDER 593
METHOD FOR TESTING INTERNAL OIL LEAKAGE OF WORK EQUIPMENT CYLINDER 593
BLEED AIR FROM WORK EQUIPMENT CYLINDERS 596
METHOD FOR BLEEDING AIR FROM WORK EQUIPMENT CYLINDERS 596
WORK EQUIPMENT 597
ADJUST WORK EQUIPMENT LOCK LEVER 597
METHOD FOR ADJUSTING WORK EQUIPMENT LOCK LEVER 597
ELECTRICAL SYSTEM 599
SET AND OPERATE MACHINE MONITOR 599
OPERATOR MODE 603
DISPLAY FUNCTION OF TECHNICIAN IDENTIFICATION STATUS SCREEN 603
DISPLAY FUNCTION OF OPERATOR IDENTIFICATION INPUT SCREEN 603
CHECKING FUNCTION BY LCD (LIQUID CRYSTAL DISPLAY) 604
CHECKING FUNCTION OF SERVICE METER 604
METHOD FOR SETTING USAGE LIMITATION AND CHANGING MAINTENANCE PASSWORD 604
SERVICE MODE 607
METHOD FOR OPERATING SERVICE MODE 607
METHOD FOR CHECKING PRE-DEFINED MONITORING INFORMATION 609
METHOD FOR CHECKING SELF-DEFINE MONITORING INFORMATION 615
ABNORMALITY RECORD MENU 626
METHOD FOR CONFIRMING MAINTENANCE RECORD 630
METHOD FOR OPERATING MAINTENANCE MODE SETTING 631
METHOD FOR OPERATING PHONE NUMBER ENTRY SETTING 635
DEFAULT MENU 636
DIAGNOSTIC TESTS MENU 643
ADJUSTMENT MENU 651
METHOD FOR PERFORMING NO-INJECTION CRANKING 719
KOMTRAX SETTINGS MENU 722
METHOD FOR DISPLAYING SERVICE MESSAGE 724
METHOD FOR STARTING UP KOMTRAX TERMINAL 726
ADJUSTMENT WHEN HST CONTROLLER HAS BEEN REPLACED 731
ADJUSTMENT METHOD WHEN HST CONTROLLER HAS BEEN REPLACED 731
ADJUSTMENT WHEN ELECTRIC OR HYDRAULIC DEVICE HAS BEEN REPLACED 737
ADJUST REARVIEW CAMERA ANGLE 739
METHOD FOR ADJUSTING REARVIEW CAMERA ANGLE 739
HANDLE VOLTAGE CIRCUIT OF ENGINE CONTROLLER 740
HANDLE BATTERY DISCONNECT SWITCH 741
TEST DIODES 742
METHOD FOR TESTING DIODE USING DIGITAL TESTER 742
METHOD FOR TESTING DIODE USING ANALOG TESTER 742
ICT SYSTEM 743
SET AND OPERATE CONTROL BOX 743
TEST AND ADJUST ICT RELATED DEVICES 744
CALIBRATE BLADE EDGE POSITION 747
METHOD FOR OPERATING BLADE CALIBRATION MENU (PITCH ROD CALIBRATION) 748
METHOD FOR OPERATING BLADE CALIBRATION MENU (MACHINE CAL STEP A) 750
METHOD FOR OPERATING BLADE CALIBRATION MENU (MACHINE CAL STEP B) 755
CALIBRATE IMU SENSOR 769
METHOD FOR CALIBRATING IMU SENSOR 769
RESET CYLINDER STROKE END 776
RESET LIFT CYLINDER STROKE END 776
RESET TILT CYLINDER STROKE END 777
RESET ANGLE CYLINDER STROKE END 777
METHOD FOR INPUTTING WEAR AMOUNT OF BLADE EDGE AND TRACK SHOE 779
CHECK BLADE ELEVATION, ADJUST 780
CHECK BLADE ELEVATION (FOR OLD CONTROL BOX) 780
CHECK BLADE ELEVATION (FOR NEW CONTROL BOX) 782
ADJUST BLADE ELEVATION (FOR OLD CONTROL BOX) 785
ADJUST BLADE ELEVATION (FOR NEW CONTROL BOX) 786
TEST STROKE SENSOR FOR LIFT CYLINDER 788
METHOD FOR TESTING STROKE SENSOR FOR LIFT CYLINDER 788
TEST STROKE SENSOR FOR TILT CYLINDER 790
METHOD FOR TESTING STROKE SENSOR FOR TILT CYLINDER 790
TEST STROKE SENSOR FOR ANGLE CYLINDER 792
METHOD FOR TESTING STROKE SENSOR FOR ANGLE CYLINDER 792
TEST AND ADJUST RESET SENSOR FOR LIFT CYLINDER 794
METHOD FOR TESTING RESET SENSOR FOR LIFT CYLINDER 794
METHOD FOR ADJUSTING RESET SENSOR FOR LIFT CYLINDER 795
ADJUST WHEN ICT SENSOR CONTROLLER IS REPLACED 796
METHOD FOR ADJUSTING WHEN ICT SENSOR CONTROLLER IS REPLACED 796
METHOD FOR ADJUSTING WHEN ICT RELATED DEVICES ARE REPAIRED OR REPLACED 799
Pm CLINIC 802
Pm CLINIC SERVICE 802
Pm CLINIC CHECK SHEET: D51EXI-24 804
Pm CLINIC CHECK SHEET: D51PXI-24 812
Pm CLINIC CHECK SHEET FOR UNDERCARRIAGE: D51EXI-24 820
Pm CLINIC CHECK SHEET FOR UNDERCARRIAGE: D51PXI-24 824
40 TROUBLESHOOTING 829
CONTENTS 830
ABBREVIATION LIST 841
RELATED INFORMATION ON TROUBLESHOOTING 847
GENERAL TROUBLESHOOTING POINTS 847
TROUBLESHOOTING POINTS FOR UREA SCR SYSTEM 848
SEQUENCE OF EVENTS IN TROUBLESHOOTING 860
CHECKS BEFORE TROUBLESHOOTING 862
INSPECTION PROCEDURE BEFORE TROUBLESHOOTING 864
WALK-AROUND CHECK 864
TESTING IN ACCORDANCE WITH TESTING PROCEDURE 866
CHECK FUEL LEVEL AND TYPE 866
CHECK IMPURE INGREDIENT IN FUEL 866
CHECK AdBule/DEF LEVEL AND TYPE 867
CHECK FUEL PREFILTER 867
CHECK MAIN FILTER 869
CHECK ENGINE OIL LEVEL (OIL AMOUNT IN OIL PAN) AND TYPE 870
CHECK COOLANT LEVEL (RESERVOIR TANK) 872
CHECK CLOGGING OF AIR CLEANER 872
CLEAN OUTER ELEMENT 873
REPLACE ELEMENT 875
CHECK HYDRAULIC OIL LEVEL 876
CHECK HYDRAULIC OIL STRAINER 877
CHECK OIL LEVEL IN FINAL DRIVE CASE 880
BLEED AIR FROM FUEL SYSTEM 881
BLEED AIR FROM HYDRAULIC SYSTEM 881
METHOD FOR CHECKING ELECTRIC EQUIPMENT 881
PREPARATION FOR TROUBLESHOOTING OF ELECTRICAL SYSTEM 888
PROCEDURE FOR TROUBLESHOOTING 895
SYMPTOM AND TROUBLESHOOTING NUMBERS 898
INFORMATION DESCRIBED IN TROUBLESHOOTING TABLE 903
TROUBLESHOOTING METHOD FOR OPEN CIRCUIT IN WIRING HARNESS OF PRESSURE SENSOR SYSTEM 905
CONNECTORS LIST AND LAYOUT 908
CONNECTOR CONTACT IDENTIFICATION 925
T-BRANCH BOX AND T-BRANCH ADAPTER TABLE 965
FUSE LOCATION TABLE 971
PRECAUTIONS FOR REPLACING KDOC 975
FAILURE CODES TABLE 976
TROUBLESHOOTING BY FAILURE CODE (DISPLAY OF CODE) 996
FAILURE CODE [6091NX] 996
FAILURE CODE [989L00] 998
FAILURE CODE [989M00] 999
FAILURE CODE [989N00]1000
FAILURE CODE [A1U0N3]1001
FAILURE CODE [A1U0N4]1003
FAILURE CODE [A900FR]1005
FAILURE CODE [A900N6]1006
FAILURE CODE [A900NY]1007
FAILURE CODE [AA10NX]1008
FAILURE CODE [AB00KE]1010
FAILURE CODE [AQ10MB]1012
FAILURE CODE [AQ10N3]1014
FAILURE CODE [AS00R2]1016
FAILURE CODE [AS00R3]1017
FAILURE CODE [AS00R4]1018
FAILURE CODE [AS00R5]1019
FAILURE CODE [AS00R6]1020
FAILURE CODE [AS00ZK]1021
FAILURE CODE [AS10KM]1022
FAILURE CODE [AS10NR]1023
FAILURE CODE [AS10NT]1024
FAILURE CODE [B@BAZG]1025
FAILURE CODE [B@BCNS]1026
FAILURE CODE [B@CRNS]1027
FAILURE CODE [B@CRZG]1028
FAILURE CODE [CA115]1029
FAILURE CODE [CA122]1030
FAILURE CODE [CA123]1032
FAILURE CODE [CA131]1034
FAILURE CODE [CA132]1036
FAILURE CODE [CA144]1038
FAILURE CODE [CA145]1040
FAILURE CODE [CA153]1042
FAILURE CODE [CA154]1044
FAILURE CODE [CA187]1046
FAILURE CODE [CA221]1048
FAILURE CODE [CA222]1050
FAILURE CODE [CA227]1052
FAILURE CODE [CA234]1054
FAILURE CODE [CA238]1055
FAILURE CODE [CA239]1056
FAILURE CODE [CA249]1057
FAILURE CODE [CA256]1059
FAILURE CODE [CA271]1061
FAILURE CODE [CA272]1063
FAILURE CODE [CA295]1065
FAILURE CODE [CA322]1066
FAILURE CODE [CA324]1068
FAILURE CODE [CA331]1070
FAILURE CODE [CA332]1072
FAILURE CODE [CA343]1074
FAILURE CODE [CA351]1075
FAILURE CODE [CA352]1076
FAILURE CODE [CA356]1078
FAILURE CODE [CA357]1080
FAILURE CODE [CA386]1082
FAILURE CODE [CA428]1083
FAILURE CODE [CA429]1085
FAILURE CODE [CA435]1087
FAILURE CODE [CA441]1089
FAILURE CODE [CA442]1091
FAILURE CODE [CA451]1092
FAILURE CODE [CA452]1094
FAILURE CODE [CA488]1096
FAILURE CODE [CA515]1097
FAILURE CODE [CA516]1099
FAILURE CODE [CA553]1101
FAILURE CODE [CA555]1102
FAILURE CODE [CA556]1103
FAILURE CODE [CA559]1104
FAILURE CODE [CA595]1107
FAILURE CODE [CA687]1109
FAILURE CODE [CA689]1111
FAILURE CODE [CA691]1114
FAILURE CODE [CA692]1116
FAILURE CODE [CA697]1118
FAILURE CODE [CA698]1119
FAILURE CODE [CA731]1120
FAILURE CODE [CA778]1122
FAILURE CODE [CA1117]1127
FAILURE CODE [CA1664]1129
FAILURE CODE [CA1669]1131
FAILURE CODE [CA1673]1132
FAILURE CODE [CA1677]1133
FAILURE CODE [CA1678]1134
FAILURE CODE [CA1682]1135
FAILURE CODE [CA1683]1137
FAILURE CODE [CA1684]1139
FAILURE CODE [CA1686]1141
FAILURE CODE [CA1691]1142
FAILURE CODE [CA1694]1144
FAILURE CODE [CA1695]1146
FAILURE CODE [CA1696]1147
FAILURE CODE [CA1712]1149
FAILURE CODE [CA1713]1152
FAILURE CODE [CA1714]1154
FAILURE CODE [CA1715]1155
FAILURE CODE [CA1776]1156
FAILURE CODE [CA1777]1159
FAILURE CODE [CA1843]1162
FAILURE CODE [CA1844]1164
FAILURE CODE [CA1885]1167
FAILURE CODE [CA1887]1169
FAILURE CODE [CA1896]1171
FAILURE CODE [CA1898]1172
FAILURE CODE [CA1938]1174
FAILURE CODE [CA1942]1176
FAILURE CODE [CA1961]1177
FAILURE CODE [CA1962]1178
FAILURE CODE [CA2185]1179
FAILURE CODE [CA2186]1181
FAILURE CODE [CA2198]1183
FAILURE CODE [CA2272]1185
FAILURE CODE [CA2288]1187
FAILURE CODE [CA2311]1188
FAILURE CODE [CA2349]1189
FAILURE CODE [CA2353]1191
FAILURE CODE [CA2357]1193
FAILURE CODE [CA2373]1194
FAILURE CODE [CA2374]1196
FAILURE CODE [CA2375]1198
FAILURE CODE [CA2376]1200
FAILURE CODE [CA2387]1203
FAILURE CODE [CA2554]1204
FAILURE CODE [CA2555]1205
FAILURE CODE [CA2556]1208
FAILURE CODE [CA2634]1211
FAILURE CODE [CA2635]1213
FAILURE CODE [CA2636]1214
FAILURE CODE [CA2637]1216
FAILURE CODE [CA2771]1218
FAILURE CODE [CA2961]1222
FAILURE CODE [CA2973]1223
FAILURE CODE [CA2976]1224
FAILURE CODE [CA3142]1226
FAILURE CODE [CA3143]1227
FAILURE CODE [CA3144]1228
FAILURE CODE [CA3146]1230
FAILURE CODE [CA3147]1231
FAILURE CODE [CA3148]1232
FAILURE CODE [CA3151]1234
FAILURE CODE [CA3165]1239
FAILURE CODE [CA3228]1241
FAILURE CODE [CA3229]1243
FAILURE CODE [CA3231]1245
FAILURE CODE [CA3232]1247
FAILURE CODE [CA3235]1251
FAILURE CODE [CA3239]1253
FAILURE CODE [CA3241]1256
FAILURE CODE [CA3242]1259
FAILURE CODE [CA3251]1262
FAILURE CODE [CA3313]1264
FAILURE CODE [CA3314]1265
FAILURE CODE [CA3315]1266
FAILURE CODE [CA3419]1268
FAILURE CODE [CA3421]1270
FAILURE CODE [CA3497]1272
FAILURE CODE [CA3498]1273
FAILURE CODE [CA3545]1274
FAILURE CODE [CA3547]1276
FAILURE CODE [CA3558]1277
FAILURE CODE [CA3559]1279
FAILURE CODE [CA3562]1281
FAILURE CODE [CA3563]1283
FAILURE CODE [CA3567]1286
FAILURE CODE [CA3568]1290
FAILURE CODE [CA3571]1294
FAILURE CODE [CA3572]1296
FAILURE CODE [CA3574]1298
FAILURE CODE [CA3575]1300
FAILURE CODE [CA3577]1302
FAILURE CODE [CA3578]1304
FAILURE CODE [CA3582]1306
FAILURE CODE [CA3583]1311
FAILURE CODE [CA3596]1313
FAILURE CODE [CA3649]1316
FAILURE CODE [CA3681]1318
FAILURE CODE [CA3682]1323
FAILURE CODE [CA3713]1328
FAILURE CODE [CA3717]1331
FAILURE CODE [CA3718]1332
FAILURE CODE [CA3724]1333
FAILURE CODE [CA3725]1334
FAILURE CODE [CA3741]1337
FAILURE CODE [CA3748]1338
FAILURE CODE [CA3755]1340
FAILURE CODE [CA3866]1342
FAILURE CODE [CA3868]1345
FAILURE CODE [CA4152]1349
FAILURE CODE [CA4155]1353
FAILURE CODE [CA4156]1356
FAILURE CODE [CA4157]1359
FAILURE CODE [CA4159]1361
FAILURE CODE [CA4164]1362
FAILURE CODE [CA4165]1364
FAILURE CODE [CA4166]1366
FAILURE CODE [CA4168]1367
FAILURE CODE [CA4169]1370
FAILURE CODE [CA4171]1372
FAILURE CODE [CA4249]1374
FAILURE CODE [CA4251]1376
FAILURE CODE [CA4261]1378
FAILURE CODE [CA4277]1381
FAILURE CODE [CA4459]1385
FAILURE CODE [CA4461]1387
FAILURE CODE [CA4533]1390
FAILURE CODE [CA4534]1391
FAILURE CODE [CA4731]1392
FAILURE CODE [CA4732]1393
FAILURE CODE [CA4739]1394
FAILURE CODE [CA4768]1395
FAILURE CODE [CA4769]1397
FAILURE CODE [CA4842]1400
FAILURE CODE [CA4952]1403
FAILURE CODE [CA5115]1405
FAILURE CODE [CA5179]1408
FAILURE CODE [CA5181]1410
FAILURE CODE [CA5387]1412
FAILURE CODE [CA5388]1414
FAILURE CODE [CA5389]1417
FAILURE CODE [CA5391]1419
FAILURE CODE [CA5392]1423
FAILURE CODE [CA5393]1425
FAILURE CODE [CA5394]1428
FAILURE CODE [CA5395]1431
FAILURE CODE [CA5396]1434
FAILURE CODE [CA5631]1435
FAILURE CODE [CA5632]1437
FAILURE CODE [CA5938]1438
FAILURE CODE [D130KA]1440
FAILURE CODE [D130KB]1443
FAILURE CODE [D130KY]1445
FAILURE CODE [D19JKZ]1447
FAILURE CODE [D811MC]1450
FAILURE CODE [D862KA]1451
FAILURE CODE [D8ALKA]1452
FAILURE CODE [D8ALKB]1454
FAILURE CODE [D8AQKR]1456
FAILURE CODE [DAF0MB]1458
FAILURE CODE [DAF0MC]1459
FAILURE CODE [DAF8KB]1460
FAILURE CODE [DAF9KQ]1462
FAILURE CODE [DAFGMC]1463
FAILURE CODE [DAFLKA]1464
FAILURE CODE [DAFLKB]1466
FAILURE CODE [DAFQKR]1468
FAILURE CODE [DAJ000]1469
FAILURE CODE [DAJ0KQ]1470
FAILURE CODE [DAJ0KT]1471
FAILURE CODE [DAJ0MC]1472
FAILURE CODE [DAJ1KK]1473
FAILURE CODE [DAJ2KK]1475
FAILURE CODE [DAJ5KK]1477
FAILURE CODE [DAJ6KK]1480
FAILURE CODE [DAJLKA]1482
FAILURE CODE [DAJLKB]1484
FAILURE CODE [DAJPMA]1486
FAILURE CODE [DAJQKR]1487
FAILURE CODE [DAJRKR]1488
FAILURE CODE [DB2QKR]1489
FAILURE CODE [DB2RKR]1494
FAILURE CODE [DBR0KT]1499
FAILURE CODE [DBR0MC]1500
FAILURE CODE [DBR1KK]1501
FAILURE CODE [DBR2KK]1504
FAILURE CODE [DBR5KK]1507
FAILURE CODE [DBRLKA]1509
FAILURE CODE [DBRLKB]1511
FAILURE CODE [DBRPMA]1513
FAILURE CODE [DBRQKR]1514
FAILURE CODE [DBRRKR]1516
FAILURE CODE [DBTSKR]1517
FAILURE CODE [DBUTKA]1520
FAILURE CODE [DD12KA]1521
FAILURE CODE [DD12KB]1523
FAILURE CODE [DD13KA]1525
FAILURE CODE [DD13KB]1527
FAILURE CODE [DD14KA]1529
FAILURE CODE [DD14KB]1531
FAILURE CODE [DDKAKA]1533
FAILURE CODE [DDKAKB]1535
FAILURE CODE [DDKFL4]1537
FAILURE CODE [DDKGL4]1539
FAILURE CODE [DDKHKA]1541
FAILURE CODE [DDKHKB]1543
FAILURE CODE [DDKQKA]1545
FAILURE CODE [DDKQKB]1547
FAILURE CODE [DDKRKA]1549
FAILURE CODE [DDKRKB]1551
FAILURE CODE [DDKSKA]1553
FAILURE CODE [DDKSKB]1555
FAILURE CODE [DDNLKA]1557
FAILURE CODE [DDNLKB]1559
FAILURE CODE [DDP6KA]1561
FAILURE CODE [DDP6KB]1564
FAILURE CODE [DDP6MA]1566
FAILURE CODE [DDU1FS]1568
FAILURE CODE [DDU1KA]1570
FAILURE CODE [DDU1KY]1573
FAILURE CODE [DFA4KX]1575
FAILURE CODE [DFA4KZ]1576
FAILURE CODE [DFA4L8]1577
FAILURE CODE [DFA5KA]1578
FAILURE CODE [DFA5KB]1581
FAILURE CODE [DFA6KA]1584
FAILURE CODE [DFA6KB]1587
FAILURE CODE [DFA7KX]1590
FAILURE CODE [DFA7KZ]1591
FAILURE CODE [DFA7L8]1592
FAILURE CODE [DFA8KA]1593
FAILURE CODE [DFA8KB]1596
FAILURE CODE [DFA9KA]1599
FAILURE CODE [DFA9KB]1602
FAILURE CODE [DGS1KA]1605
FAILURE CODE [DGS1KX]1608
FAILURE CODE [DH21KA]1609
FAILURE CODE [DH21KB]1611
FAILURE CODE [DHA4KA]1613
FAILURE CODE [DHH7KA]1615
FAILURE CODE [DHH7KB]1618
FAILURE CODE [DHH8KA]1620
FAILURE CODE [DHH8KB]1623
FAILURE CODE [DHH9KA]1625
FAILURE CODE [DHH9KB]1628
FAILURE CODE [DHHAKA]1630
FAILURE CODE [DHHAKB]1633
FAILURE CODE [DK30KA]1635
FAILURE CODE [DK30KB]1638
FAILURE CODE [DK30KX]1640
FAILURE CODE [DK30KZ]1641
FAILURE CODE [DK30L8]1642
FAILURE CODE [DK31KA]1643
FAILURE CODE [DK31KB]1646
FAILURE CODE [DK40KA]1648
FAILURE CODE [DK40KB]1651
FAILURE CODE [DK55KX]1653
FAILURE CODE [DK55KZ]1654
FAILURE CODE [DK55L8]1655
FAILURE CODE [DK56KA]1656
FAILURE CODE [DK56KB]1659
FAILURE CODE [DK57KA]1661
FAILURE CODE [DK57KB]1664
FAILURE CODE [DK80KA]1666
FAILURE CODE [DKS0L8]1668
FAILURE CODE [DKS1KA]1669
FAILURE CODE [DKS1KB]1671
FAILURE CODE [DKS2KA]1672
FAILURE CODE [DKS2KB]1674
FAILURE CODE [DKS3KA]1675
FAILURE CODE [DKS3KB]1677
FAILURE CODE [DKS3MB]1678
FAILURE CODE [DKS4L8]1680
FAILURE CODE [DKS5KA]1681
FAILURE CODE [DKS5KB]1683
FAILURE CODE [DKS6KA]1684
FAILURE CODE [DKS6KB]1686
FAILURE CODE [DKS7MB]1687
FAILURE CODE [DKSCL8]1688
FAILURE CODE [DKSDKA]1689
FAILURE CODE [DKSDKB]1691
FAILURE CODE [DKSEKA]1692
FAILURE CODE [DKSEKB]1694
FAILURE CODE [DKSFKA]1695
FAILURE CODE [DKSFKB]1697
FAILURE CODE [DKSFMB]1698
FAILURE CODE [DLM0KX]1699
FAILURE CODE [DLM0MA]1700
FAILURE CODE [DLM1KA]1701
FAILURE CODE [DLM1KB]1703
FAILURE CODE [DLM1MA]1705
FAILURE CODE [DLM2KA]1706
FAILURE CODE [DLM2KB]1708
FAILURE CODE [DLM2MA]1710
FAILURE CODE [DLM3KA]1711
FAILURE CODE [DLM3KB]1713
FAILURE CODE [DLM3MB]1715
FAILURE CODE [DN21FS]1716
FAILURE CODE [DR21KX]1718
FAILURE CODE [DR31KX]1719
FAILURE CODE [DV20KB]1720
FAILURE CODE [DW4BKA]1722
FAILURE CODE [DW4BKB]1724
FAILURE CODE [DW4BKY]1726
FAILURE CODE [DW7BKA]1728
FAILURE CODE [DW7BKB]1730
FAILURE CODE [DW7EKA]1732
FAILURE CODE [DW7EKB]1734
FAILURE CODE [DW7EKY]1736
FAILURE CODE [DWN5KA]1738
FAILURE CODE [DWN5KB]1740
FAILURE CODE [DWN5KY]1742
FAILURE CODE [DXA4KA]1744
FAILURE CODE [DXA4KB]1746
FAILURE CODE [DXA4KY]1748
FAILURE CODE [DXA5KA]1750
FAILURE CODE [DXA5KB]1752
FAILURE CODE [DXA5KY]1754
FAILURE CODE [DXA6KA]1756
FAILURE CODE [DXA6KB]1758
FAILURE CODE [DXA6KY]1760
FAILURE CODE [DXA7KA]1762
FAILURE CODE [DXA7KB]1764
FAILURE CODE [DXA7KY]1766
FAILURE CODE [DXHRKA]1768
FAILURE CODE [DXHRKB]1770
FAILURE CODE [DXHRKY]1772
FAILURE CODE [DXHSKA]1774
FAILURE CODE [DXHSKB]1776
FAILURE CODE [DXHSKY]1778
FAILURE CODE [DXHTKA]1780
FAILURE CODE [DXHTKB]1782
FAILURE CODE [DXHTKY]1784
FAILURE CODE [DXHUKA]1786
FAILURE CODE [DXHUKB]1788
FAILURE CODE [DXHUKY]1790
FAILURE CODE [DXJ4KA]1792
FAILURE CODE [DXJ4KB]1794
FAILURE CODE [DXJCKA]1796
FAILURE CODE [DXJCKB]1798
FAILURE CODE [DXJCKY]1800
FAILURE CODE [DXJDKA]1802
FAILURE CODE [DXJDKB]1804
FAILURE CODE [DXJDKY]1806
FAILURE CODE [DXK1KA]1808
FAILURE CODE [DXK1KB]1810
FAILURE CODE [DXK1KY]1812
FAILURE CODE [DXK2KA]1814
FAILURE CODE [DXK2KB]1816
FAILURE CODE [DXK2KY]1818
TROUBLESHOOTING OF ELECTRICAL SYSTEM (E-MODE)1820
E-1 ENGINE DOES NOT START (ENGINE DOES NOT CRANK)1820
E-2 MANUAL PREHEATING SYSTEM DOES NOT WORK1827
E-3 AUTOMATIC PREHEATING SYSTEM DOES NOT WORK1830
E-4 WHILE PREHEATING IS WORKING, PREHEATING MONITOR DOES NOT LIGHT UP1832
E-5 WHEN STARTING SWITCH IS TURNED TO ON POSITION, MACHINE MONITOR DISPLAYS NOTHING1834
E-6 WHEN STARTING SWITCH IS TURNED TO ON POSITION (WITH ENGINE STOPPED), BASIC CHECK MONITOR LIGHTS UP1838
E-7 AIR CLEANER CLOGGING MONITOR LIGHTS UP IN YELLOW WHILE ENGINE IS RUNNING1839
E-8 CHARGE LEVEL MONITOR LIGHTS UP IN RED WHILE ENGINE IS RUNNING1840
E-9 ENGINE COOLANT TEMPERATURE MONITOR LIGHTS UP IN RED WHILE ENGINE IS RUNNING1841
E-10 ENGINE OIL PRESSURE MONITOR LIGHTS UP IN RED WHILE ENGINE IS RUNNING1842
E-11 HST CHARGE PRESSURE MONITOR LIGHTS UP IN RED WHILE ENGINE IS RUNNING1843
E-12 HYDRAULIC OIL TEMPERATURE MONITOR LIGHTS UP IN RED WHILE ENGINE IS RUNNING1844
E-13 HST OIL FILTER CLOGGING MONITOR LIGHTS UP IN RED WHILE ENGINE IS RUNNING1845
E-14 ENGINE COOLANT TEMPERATURE GAUGE DOES NOT INDICATE CORRECT TEMPERATURE1846
E-15 AdBlue/DEF LEVEL IS NOT DISPLAYED PROPERLY1847
E-16 FUEL LEVEL GAUGE DOES NOT INDICATE CORRECT LEVEL1850
E-17 HYDRAULIC OIL TEMPERATURE GAUGE DOES NOT INDICATE CORRECT TEMPERATURE1853
E-18 OPERATION MODE DOES NOT CHANGE1854
E-19 OPERATING CUSTOMIZE SWITCH DOES NOT DISPLAY CUSTOMIZE SCREEN1855
E-20 MODIFYING SETTING ON CUSTOMIZE SCREEN DOES NOT CHANGE SETTING OF MACHINE1856
E-21 SERVICE METER IS NOT DISPLAYED, WHILE STARTING SWITCH IS IN OFF POSITION1857
E-22 SERVICE MODE CANNOT BE SELECTED1858
E-23 WORK EQUIPMENT DOES NOT OPERATE1859
E-24 FOOT HEATER DOES NOT OPERATE1861
E-25 HORN DOES NOT SOUND1867
E-26 HORN DOES NOT STOP SOUNDING1869
E-27 BACKUP ALARM DOES NOT SOUND1870
E-28 BACKUP ALARM DOES NOT STOP SOUNDING1871
E-29 HEADLAMP DOES NOT LIGHT UP1872
E-30 REAR LAMP DOES NOT LIGHT UP1876
E-31 ALL WIPERS DO NOT OPERATE1879
E-32 FRONT WIPER DOES NOT OPERATE1881
E-33 REAR WIPER DOES NOT OPERATE1883
E-34 LEFT DOOR WIPER DOES NOT OPERATE1885
E-35 RIGHT DOOR WIPER DOES NOT OPERATE1889
E-36 FRONT WASHER DOES NOT OPERATE1893
E-37 REAR WASHER DOES NOT OPERATE1895
E-38 LEFT DOOR WASHER DOES NOT OPERATE1897
E-39 RIGHT DOOR WASHER DOES NOT OPERATE1899
E-40 KOMTRAX SYSTEM DOES NOT OPERATE NORMALLY1901
E-41 CONTROL BOX SHUTS DOWN AFTER DISPLAYING THE MESSAGES [GPS receiver not connected !] AND [Slope sensor not connected !]1902
E-42 CONTROL BOX DISPLAYS THE MESSAGES [GPS receiver not connected !] AND [Slope sensor not connected !]1906
E-43 CONTROL BOX DISPLAYS THE MESSAGE [Waiting for radio link]1911
E-44 CONTROL BOX DISPLAYS THE MESSAGE [IMU sensor not connected]1912
E-45 CONTROL BOX DISPLAYS THE MESSAGE [Waiting for satellites]1913
E-46 CONTROL BOX DISPLAYS THE MESSAGE [Komatsu controller not connected!]1914
E-47 CONTROL BOX DISPLAYS THE MESSAGE [Cylinder Stroke Reading Abnormal]1916
E-48 CONTROL BOX DISPLAYS THE MESSAGE [Komatsu CAN Comms Abnormal]1917
E-49 CONTROL BOX DISPLAYS THE MESSAGE [Komatsu Machine Trouble]1918
E-50 CONTROL BOX DISPLAYS THE MESSAGE [Waiting to initialize]1919
E-51 CONTROL BOX DISPLAYS THE MESSAGE [System Initializing]1920
E-52 CONTROL BOX DISPLAYS THE MESSAGE [Initializing]1921
E-53 CONTROL BOX DISPLAYS THE MESSAGE [Configuring GPS]1922
E-54 CONTROL BOX DISPLAYS THE MESSAGE [No GPS Localization]1923
E-55 CONTROL BOX DISPLAYS THE MESSAGE [Low precisions]1924
E-56 CONTROL BOX DISPLAYS THE MESSAGE [Heading Initializing]1925
E-57 CONTROL BOX DISPLAYS [Out of design area]1926
E-58 CONTROL BOX CAN NOT BE TURNED ON1927
E-59 CONTROL BOX DOES NOT DISPLAY INTELLIGENT MACHINE CONTROL SCREEN1928
E-60 CONTROL BOX DOES NOT DISPLAY BULLDOZER IMAGE1929
E-61 CONTROL BOX DOES NOT DISPLAY DESIGN SURFACE1930
E-62 CONTROL BOX TOUCH PANEL DOES NOT RESPOND1931
E-63 CONTROL BOX TOUCH PANEL IS INACCURATE1932
E-64 CYLINDER STROKE RESET INDICATION DOES NOT GO OUT1933
E-65 AUTO IS NOT DISPLAYED WHEN AUTO/MANUAL SWITCH IS PRESSED (AUTO INDICATION GOES OUT)1934
E-66 BLADE AUTOMATIC LOWER CONTROL DOES NOT START WHILE AUTO IS DISPLAYED1936
E-67 BLADE AUTOMATIC RAISE CONTROL DOES NOT START WHILE AUTO IS DISPLAYED1937
E-68 BLADE AUTOMATIC CONTROL FUNCTION IS NOT ACTIVATED WHILE AUTO IS DISPLAYED (BLADE AUTOMATIC CONTROL STOPS)1938
E-69 WHEN CHECKING AND ADJUSTING THE BLADE ELEVATION, THE VALUE IS DIFFERENT FROM ACTUAL MACHINE1939
E-70 FINISHED SURFACE IS INACCURATE (THE AVERAGE HEIGHT OF FINISHED SURFACE IS LOWER THAN DESIGNED SURFACE OR BLADE DOES NOT TOUCH THE SURFACE)1940
E-71 FINISHED SURFACE IS INACCURATE (THE FINISHED SURFACE IS NOT SMOOTH)1941
E-72 FINISHED SURFACE IS INACCURATE (WHEN FINISHING SLOPE HORIZONTALLY, STEPS ARE MADE IN EACH DIRECTION)1942
E-73 MACHINE CAN NOT ESCAPE FROM SHOES SLIP WHILE BLADE AUTOMATIC CONTROL IS ACTIVATED (SHOES FREQUENTLY SLIPS)1944
E-74 MACHINE SPEED DOES NOT INCREASE WHILE BLADE AUTOMATIC CONTROL IS ACTIVATED1945
E-75 BLADE TILT ANGLE DOES NOT COINCIDE WITH DESIGN SURFACE1946
E-76 BLADE TILTS BACK WHILE BLADE AUTOMATIC CONTROL IS ACTIVATED1948
E-77 WHEN STARTING SWITCH IS TURNED TO ON POSITION, REVERSE LEVELING MODE SWITCH LED DOES NOT LIGHT UP OR DOES NOT GO OUT1950
TROUBLESHOOTING FOR HYDRAULIC AND MECHANICAL SYSTEMS (H MODE)1952
INFORMATION MENTIONED IN TROUBLESHOOTING TABLE (H MODE)1952
FAILURE MODE AND CAUSE TABLE1953
H-1 NEITHER RH NOR LH OF TRACKS CAN TRAVEL FORWARD OR REVERSE (NONE OF THE TRAVEL SYSTEMS OPERATE)1959
H-2 EITHER RH OR LH OF TRACK CANNOT TRAVEL BOTH FORWARD AND REVERSE (ONE OF RH OR LH TRAVEL SYSTEMS CANNOT OPERATE)1961
H-3 EITHER RH OR LH OF TRACK CANNOT TRAVEL ONE OF FORWARD OR REVERSE (ONLY ONE OF THE TRAVEL SYSTEMS CANNOT OPERATE IN ONE DIRECTION)1963
H-4 TRAVEL SPEED OR POWER IS LOW1965
H-5 SPEED RANGE DOES NOT CHANGE1967
H-6 SHOCK IS LARGE WHEN MACHINE MOVES OFF OR STOPS1968
H-7 MACHINE DEVIATES LARGELY1969
H-8 MACHINE DRIFT ON A SLOPE IS LARGE1972
H-9 ENGINE SPEED DROPS LARGELY OR ENGINE STOPS1974
H-10 UNUSUAL NOISE IS HEARD FROM AROUND HST PUMP OR MOTOR1976
H-11 HST OIL TEMPERATURE (HYDRAULIC OIL TEMPERATURE) RISES TOO HIGH1978
H-12 ALL WORK EQUIPMENT DO NOT OPERATE1980
H-13 ALL WORK EQUIPMENTS SPEED OR POWER IS LOW1982
H-14 BLADE LIFT SPEED OR POWER IS LOW1983
H-15 BLADE TILT SPEED OR POWER IS LOW1985
H-16 BLADE ANGLE SPEED OR POWER IS LOW1986
H-17 TIME LAG OF BLADE LIFT IS LARGE1987
H-18 HYDRAULIC DRIFT OF LIFTED BLADE IS LARGE1988
H-19 HYDRAULIC DRIFT OF TILTED BLADE IS LARGE1989
H-20 UNUSUAL NOISE IS HEARD FROM AROUND WORK EQUIPMENT AND COOLING FAN PUMP OR CONTROL VALVE1990
H-21 FAN SPEED IS ABNORMAL (TOO HIGH OR LOW, OR STATIONARY)1991
H-22 UNUSUAL NOISE IS HEARD FROM AROUND FAN1993
TROUBLESHOOTING OF ENGINE (S-MODE)1994
INFORMATION MENTIONED IN TROUBLESHOOTING TABLE (S MODE)1994
S-1 ENGINE DOES NOT CRANK WHEN STARTING SWITCH IS TURNED TO START POSITION1995
S-2 ENGINE CRANKS BUT NO EXHAUST GAS COMES OUT1996
S-3 FUEL IS BEING INJECTED BUT ENGINE DOES NOT START (MISFIRING: ENGINE CRANKS BUT DOES NOT START)1997
S-4 ENGINE STARTABILITY IS POOR1999
S-5 ENGINE DOES NOT PICK UP SMOOTHLY2001
S-6 ENGINE STOPS DURING OPERATION2003
S-7 ENGINE RUNS ROUGH OR IS UNSTABLE2005
S-8 ENGINE LACKS POWER2006
S-9 EXHAUST SMOKE IS BLACK2008
S-10 ENGINE OIL CONSUMPTION IS EXCESSIVE2010
S-11 OIL BECOMES CONTAMINATED QUICKLY2011
S-12 FUEL CONSUMPTION IS EXCESSIVE2012
S-13 OIL IS IN COOLANT (OR COOLANT SPURTS BACK OR COOLANT LEVEL GOES DOWN)2013
S-14 OIL PRESSURE DROPS2014
S-15 FUEL MIXES INTO ENGINE OIL2016
S-16 WATER MIXES INTO ENGINE OIL (MILKY)2017
S-17 COOLANT TEMPERATURE RISES TOO HIGH (OVERHEATING)2018
S-18 UNUSUAL NOISE IS HEARD2019
S-19 VIBRATION IS EXCESSIVE2020
S-20 AIR CANNOT BE BLED FROM FUEL CIRCUIT2021
S-21 ACTIVE REGENERATION IS EXECUTED FREQUENTLY2022
S-22 ACTIVE REGENERATION TAKES TIME2023
S-23 WHITE SMOKE IS EXHAUSTED DURING ACTIVE REGENERATION2024
S-24 AdBlue/DEF CONSUMPTION IS EXCESSIVE2025
S-25 THERE IS UNUSUAL SMELL (IRRITATING ODOR)2027
S-26 FOREIGN MATERIALS ENTER AdBlue/DEF (AdBlue/DEF INCREASES)2028
50 DISASSEMBLY AND ASSEMBLY2029
CONTENTS2030
ABBREVIATION LIST2035
RELATED INFORMATION ON DISASSEMBLY AND ASSEMBLY2041
HOW TO READ THIS MANUAL2041
COATING MATERIALS LIST2043
SPECIAL TOOLS LIST2047
SKETCHES OF SPECIAL TOOLS2070
ENGINE AND COOLING SYSTEM2083
REMOVE AND INSTALL SUPPLY PUMP ASSEMBLY2083
METHOD FOR REMOVING SUPPLY PUMP ASSEMBLY2083
METHOD FOR INSTALLING SUPPLY PUMP ASSEMBLY2093
REMOVE AND INSTALL INJECTOR ASSEMBLY2103
METHOD FOR REMOVING INJECTOR ASSEMBLY2103
METHOD FOR INSTALLING INJECTOR ASSEMBLY2114
REMOVE AND INSTALL CYLINDER HEAD ASSEMBLY2128
METHOD FOR REMOVING CYLINDER HEAD ASSEMBLY2128
METHOD FOR INSTALLING CYLINDER HEAD ASSEMBLY2147
REMOVE AND INSTALL EGR VALVE ASSEMBLY2171
METHOD FOR REMOVING EGR VALVE ASSEMBLY2171
METHOD FOR INSTALLING EGR VALVE ASSEMBLY2174
REMOVE AND INSTALL EGR COOLER ASSEMBLY2178
METHOD FOR REMOVING EGR COOLER ASSEMBLY2178
METHOD FOR INSTALLING EGR COOLER ASSEMBLY2182
REMOVE AND INSTALL STARTING MOTOR ASSEMBLY2186
METHOD FOR REMOVING STARTING MOTOR ASSEMBLY2186
METHOD FOR INSTALLING STARTING MOTOR ASSEMBLY2188
REMOVE AND INSTALL AIR CONDITIONER COMPRESSOR BELT2191
METHOD FOR REMOVING AIR CONDITIONER COMPRESSOR BELT2191
METHOD FOR INSTALLING AIR CONDITIONER COMPRESSOR BELT2195
REMOVE AND INSTALL ALTERNATOR BELT2200
METHOD FOR REMOVING ALTERNATOR BELT2200
METHOD FOR INSTALLING ALTERNATOR BELT2202
REMOVE AND INSTALL AUTOMATIC TENSIONER2205
METHOD FOR REMOVING AUTOMATIC TENSIONER2205
METHOD FOR INSTALLING AUTOMATIC TENSIONER2206
REMOVE AND INSTALL RADIATOR ASSEMBLY2208
METHOD FOR REMOVING RADIATOR ASSEMBLY2209
METHOD FOR INSTALLING RADIATOR ASSEMBLY2217
REMOVE AND INSTALL HYDRAULIC OIL COOLER ASSEMBLY2225
METHOD FOR REMOVING HYDRAULIC OIL COOLER ASSEMBLY2226
METHOD FOR INSTALLING HYDRAULIC OIL COOLER ASSEMBLY2231
REMOVE AND INSTALL AFTERCOOLER ASSEMBLY2236
METHOD FOR REMOVING AFTERCOOLER ASSEMBLY2237
METHOD FOR INSTALLING AFTERCOOLER ASSEMBLY2243
REMOVE AND INSTALL COOLING FAN DRIVE ASSEMBLY2250
METHOD FOR REMOVING COOLING FAN DRIVE ASSEMBLY2250
METHOD FOR INSTALLING COOLING FAN DRIVE ASSEMBLY2254
REMOVE AND INSTALL COOLING FAN MOTOR ASSEMBLY2259
METHOD FOR REMOVING COOLING FAN MOTOR ASSEMBLY2259
METHOD FOR INSTALLING COOLING FAN MOTOR ASSEMBLY2262
REMOVE AND INSTALL ENGINE, HST PUMP ASSEMBLY2265
METHOD FOR REMOVING ENGINE, HST PUMP ASSEMBLY2265
METHOD FOR INSTALLING ENGINE, HST PUMP ASSEMBLY2276
REMOVE AND INSTALL ENGINE FRONT OIL SEAL2288
METHOD FOR REMOVING ENGINE FRONT OIL SEAL2288
METHOD FOR INSTALLING ENGINE FRONT OIL SEAL2290
REMOVE AND INSTALL ENGINE REAR OIL SEAL2293
METHOD FOR REMOVING ENGINE REAR OIL SEAL2293
METHOD FOR INSTALLING ENGINE REAR OIL SEAL2294
REMOVE AND INSTALL ENGINE HOOD ASSEMBLY2297
METHOD FOR REMOVING ENGINE HOOD ASSEMBLY2297
METHOD FOR INSTALLING ENGINE HOOD ASSEMBLY2300
REMOVE AND INSTALL KDOC ASSEMBLY2304
METHOD FOR REMOVING KDOC ASSEMBLY2304
METHOD FOR INSTALLING KDOC ASSEMBLY2309
REMOVE AND INSTALL KDOC AND SCR ASSEMBLY2317
METHOD FOR REMOVING KDOC AND SCR ASSEMBLY2318
METHOD FOR INSTALLING KDOC AND SCR ASSEMBLY2324
REMOVE AND INSTALL BELLOWS PIPE ASSEMBLY2332
METHOD FOR REMOVING BELLOWS PIPE ASSEMBLY2332
METHOD FOR INSTALLING BELLOWS PIPE ASSEMBLY2335
REMOVE AND INSTALL FUEL TANK ASSEMBLY2339
METHOD FOR REMOVING FUEL TANK ASSEMBLY2340
METHOD FOR INSTALLING FUEL TANK ASSEMBLY2347
REMOVE AND INSTALL AdBlue/DEF TANK ASSEMBLY2354
METHOD FOR REMOVING AdBlue/DEF TANK ASSEMBLY2355
METHOD FOR INSTALLING AdBlue/DEF TANK ASSEMBLY2365
REMOVE AND INSTALL AdBlue/DEF TANK SENSOR FLANGE ASSEMBLY2374
METHOD FOR REMOVING AdBlue/DEF TANK SENSOR FLANGE ASSEMBLY2374
METHOD FOR INSTALLING AdBlue/DEF TANK SENSOR FLANGE ASSEMBLY2376
REMOVE AND INSTALL AdBlue/DEF TANK SENSOR2380
METHOD FOR REMOVING AdBlue/DEF TANK SENSOR2380
METHOD FOR INSTALLING AdBlue/DEF TANK SENSOR2381
REMOVE AND INSTALL AdBlue/DEF TANK STRAINER2388
METHOD FOR REMOVING AdBlue/DEF TANK STRAINER2388
METHOD FOR INSTALLING AdBlue/DEF TANK STRAINER2389
REMOVE AND INSTALL AdBlue/DEF TANK FILLER PORT FILTER2390
METHOD FOR REMOVING AdBlue/DEF TANK FILLER PORT FILTER2390
METHOD FOR INSTALLING AdBlue/DEF TANK FILLER PORT FILTER2391
REMOVE AND INSTALL SCR ASSEMBLY2394
METHOD FOR REMOVING SCR ASSEMBLY2394
METHOD FOR INSTALLING SCR ASSEMBLY2397
REMOVE AND INSTALL KCCV ASSEMBLY2400
METHOD FOR REMOVING KCCV ASSEMBLY2400
METHOD FOR INSTALLING KCCV ASSEMBLY2401
REMOVE AND INSTALL AdBlue/DEF MIXING TUBE2404
METHOD FOR REMOVING AdBlue/DEF MIXING TUBE2404
METHOD FOR INSTALLING AdBlue/DEF MIXING TUBE2408
REMOVE AND INSTALL AdBlue/DEF INJECTOR2412
METHOD FOR REMOVING AdBlue/DEF INJECTOR2412
METHOD FOR INSTALLING AdBlue/DEF INJECTOR2417
REMOVE AND INSTALL AdBlue/DEF PUMP2422
METHOD FOR REMOVING AdBlue/DEF PUMP2422
METHOD FOR INSTALLING AdBlue/DEF PUMP2426
REMOVE AND INSTALL AdBlue/DEF HOSE2430
METHOD FOR REMOVING AdBlue/DEF HOSE2432
METHOD FOR INSTALLING AdBlue/DEF HOSE2451
REMOVE AND INSTALL AIR CLEANER ASSEMBLY2472
METHOD FOR REMOVING AIR CLEANER ASSEMBLY2472
METHOD FOR INSTALLING AIR CLEANER ASSEMBLY2474
REMOVE AND INSTALL AIR CONDITIONER COMPRESSOR ASSEMBLY2477
METHOD FOR REMOVING AIR CONDITIONER COMPRESSOR ASSEMBLY2477
METHOD FOR INSTALLING AIR CONDITIONER COMPRESSOR ASSEMBLY2481
REMOVE AND INSTALL AIR CONDITIONER CONDENSER ASSEMBLY2486
METHOD FOR REMOVING AIR CONDITIONER CONDENSER ASSEMBLY2486
METHOD FOR INSTALLING AIR CONDITIONER CONDENSER ASSEMBLY2490
POWER TRAIN2494
DISASSEMBLE AND ASSEMBLE FINAL DRIVE ASSEMBLY2494
METHOD FOR DISASSEMBLING FINAL DRIVE ASSEMBLY2495
METHOD FOR ASSEMBLING FINAL DRIVE ASSEMBLY2499
UNDERCARRIAGE AND FRAME2508
REMOVE AND INSTALL TRACK FRAME ASSEMBLY2508
METHOD FOR REMOVING TRACK FRAME ASSEMBLY2508
METHOD FOR INSTALLING TRACK FRAME ASSEMBLY2513
REMOVE AND INSTALL IDLER ASSEMBLY2518
METHOD FOR REMOVING IDLER ASSEMBLY2518
METHOD FOR INSTALLING IDLER ASSEMBLY2520
DISASSEMBLE AND ASSEMBLE IDLER ASSEMBLY2523
METHOD FOR DISASSEMBLING IDLER ASSEMBLY2523
METHOD FOR ASSEMBLING IDLER ASSEMBLY2525
REMOVE AND INSTALL RECOIL SPRING ASSEMBLY2530
METHOD FOR REMOVING RECOIL SPRING ASSEMBLY2530
METHOD FOR INSTALLING RECOIL SPRING ASSEMBLY2530
DISASSEMBLE AND ASSEMBLE RECOIL SPRING ASSEMBLY2531
METHOD FOR DISASSEMBLING AND ASSEMBLING RECOIL SPRING ASSEMBLY2531
METHOD FOR ASSEMBLING RECOIL SPRING ASSEMBLY2534
REMOVE AND INSTALL TRACK ROLLER ASSEMBLY2537
METHOD FOR REMOVING TRACK ROLLER ASSEMBLY2537
METHOD FOR INSTALLING TRACK ROLLER ASSEMBLY2539
DISASSEMBLE AND ASSEMBLE TRACK ROLLER ASSEMBLY2542
METHOD FOR DISASSEMBLING TRACK ROLLER ASSEMBLY2542
METHOD FOR ASSEMBLING TRACK ROLLER ASSEMBLY2543
REMOVE AND INSTALL CARRIER ROLLER ASSEMBLY2547
METHOD FOR REMOVING CARRIER ROLLER ASSEMBLY2547
METHOD FOR INSTALLING CARRIER ROLLER ASSEMBLY2548
DISASSEMBLE AND ASSEMBLE CARRIER ROLLER ASSEMBLY2550
METHOD FOR DISASSEMBLING CARRIER ROLLER ASSEMBLY2550
METHOD FOR ASSEMBLING CARRIER ROLLER ASSEMBLY2551
REMOVE AND INSTALL PIVOT SHAFT ASSEMBLY2554
METHOD FOR REMOVING PIVOT SHAFT ASSEMBLY2554
METHOD FOR INSTALLING PIVOT SHAFT ASSEMBLY2555
SEPARATE AND CONNECT TRACK ASSEMBLY2557
METHOD FOR CHECKING BEFORE SEPARATING TRACK ASSEMBLY2557
METHOD FOR SEPARATING TRACK ASSEMBLY (NORMAL)2558
METHOD FOR SEPARATING TRACK ASSEMBLY (WHEN TRACK FRAME HAS INTERNAL DEFECT)2559
METHOD FOR CONNECTING TRACK ASSEMBLY2560
SEPARATE AND CONNECT PLUS TYPE TRACK ASSEMBLY2562
METHOD FOR SEPARATING PLUS TYPE TRACK ASSEMBLY2562
METHOD FOR CONNECTING PLUS TYPE TRACK ASSEMBLY2562
DISASSEMBLE AND ASSEMBLE TRACK ASSEMBLY GENERALLY2563
METHOD FOR DISASSEMBLING TRACK ASSEMBLY GENERALLY2563
METHOD FOR ASSEMBLING TRACK ASSEMBLY GENERALLY2568
DISASSEMBLE AND ASSEMBLE PLUS TYPE TRACK ASSEMBLY GENERALLY2581
METHOD FOR DISASSEMBLING PLUS TYPE TRACK ASSEMBLY GENERALLY2582
METHOD FOR ASSEMBLING PLUS TYPE TRACK ASSEMBLY GENERALLY2583
DISASSEMBLE AND ASSEMBLE ONE LINK OF TRACK SHOE ASSEMBLY ON THE FIELD2592
METHOD FOR DISASSEMBLING ONE LINK OF TRACK SHOE ASSEMBLY ON THE FIELD2593
METHOD FOR ASSEMBLING ONE LINK OF TRACK SHOE ASSEMBLY ON THE FIELD2594
DISASSEMBLE AND ASSEMBLE ONE LINK OF PLUS TYPE TRACK SHOE ASSEMBLY ON THE FIELD2601
METHOD FOR DISASSEMBLING ONE LINK OF PLUS TYPE TRACK SHOE ASSEMBLY ON THE FIELD2602
METHOD FOR ASSEMBLING ONE LINK OF PLUS TYPE TRACK SHOE ASSEMBLY ON THE FIELD2604
REMOVE AND INSTALL EQUALIZER BAR ASSEMBLY2608
METHOD FOR REMOVING EQUALIZER BAR ASSEMBLY2608
METHOD FOR INSTALLING EQUALIZER BAR ASSEMBLY2610
REMOVE AND INSTALL EQUALIZER BAR SIDE BUSHINGS2613
METHOD FOR REMOVING EQUALIZER BAR SIDE BUSHINGS2613
METHOD FOR INSTALLING EQUALIZER BAR SIDE BUSHINGS2614
REMOVE AND INSTALL SEGMENT TEETH2615
METHOD FOR REMOVING SEGMENT TEETH2615
METHOD FOR INSTALLING SEGMENT TEETH2617
HYDRAULIC SYSTEM2619
REMOVE AND INSTALL HYDRAULIC TANK ASSEMBLY2619
METHOD FOR REMOVING HYDRAULIC TANK ASSEMBLY2620
METHOD FOR INSTALLING HYDRAULIC TANK ASSEMBLY2626
REMOVE AND INSTALL CONTROL VALVE ASSEMBLY2635
METHOD FOR REMOVING CONTROL VALVE ASSEMBLY2635
METHOD FOR INSTALLING CONTROL VALVE ASSEMBLY2639
WORK EQUIPMENT2643
REMOVE AND INSTALL BLADE ASSEMBLY2643
METHOD FOR REMOVING BLADE ASSEMBLY2643
METHOD FOR INSTALLING BLADE ASSEMBLY2646
REMOVE AND INSTALL STROKE SENSING BLADE LIFT CYLINDER ASSEMBLY2651
METHOD FOR REMOVING STROKE SENSING BLADE LIFT CYLINDER ASSEMBLY2651
METHOD FOR INSTALLING STROKE SENSING BLADE LIFT CYLINDER ASSEMBLY2653
DISASSEMBLE AND ASSEMBLE STROKE SENSING BLADE LIFT CYLINDER ASSEMBLY2656
METHOD FOR DISASSEMBLING STROKE SENSING BLADE LIFT CYLINDER ASSEMBLY2657
METHOD FOR ASSEMBLING STROKE SENSING BLADE LIFT CYLINDER ASSEMBLY2661
REMOVE AND INSTALL STROKE SENSING BLADE TILT CYLINDER ASSEMBLY2669
METHOD FOR REMOVING STROKE SENSING BLADE TILT CYLINDER ASSEMBLY2669
METHOD FOR INSTALLING STROKE SENSING BLADE TILT CYLINDER ASSEMBLY2672
DISASSEMBLE AND ASSEMBLE STROKE SENSING BLADE TILT CYLINDER ASSEMBLY2675
METHOD FOR DISASSEMBLING STROKE SENSING BLADE TILT CYLINDER ASSEMBLY2675
METHOD FOR ASSEMBLING STROKE SENSING BLADE TILT CYLINDER ASSEMBLY2679
REMOVE AND INSTALL STROKE SENSING BLADE ANGLE CYLINDER ASSEMBLY2684
METHOD FOR REMOVING STROKE SENSING BLADE ANGLE CYLINDER ASSEMBLY2684
METHOD FOR INSTALLING STROKE SENSING BLADE ANGLE CYLINDER ASSEMBLY2687
DISASSEMBLE AND ASSEMBLE STROKE SENSING BLADE ANGLE CYLINDER ASSEMBLY2690
METHOD FOR DISASSEMBLING STROKE SENSING BLADE ANGLE CYLINDER ASSEMBLY2691
METHOD FOR ASSEMBLING STROKE SENSING BLADE ANGLE CYLINDER ASSEMBLY2694
REMOVE AND INSTALL U-FRAME ASSEMBLY2699
METHOD FOR REMOVING U-FRAME ASSEMBLY2699
METHOD FOR INSTALLING U-FRAME ASSEMBLY2703
CAB AND ITS ATTACHMENTS2706
REMOVE AND INSTALL OPERATOR’S CAB ASSEMBLY2706
METHOD FOR REMOVING OPERATOR’S CAB ASSEMBLY2707
METHOD FOR INSTALLING OPERATOR’S CAB ASSEMBLY2715
REMOVE AND INSTALL OPERATOR’S CAB GLASS (ADHERED GLASS)2723
METHOD FOR REMOVING OPERATOR’S CAB GLASS (ADHERED GLASS)2725
METHOD FOR INSTALLING OPERATOR’S CAB GLASS (ADHERED GLASS)2725
REMOVE AND INSTALL AIR CONDITIONER UNIT ASSEMBLY2731
METHOD FOR REMOVING AIR CONDITIONER UNIT ASSEMBLY2731
METHOD FOR INSTALLING AIR CONDITIONER UNIT ASSEMBLY2737
REMOVE AND INSTALL RECEIVER DRIER2744
METHOD FOR REMOVING RECEIVER DRIER2744
METHOD FOR INSTALLING RECEIVER DRIER2745
REMOVE AND INSTALL OPERATOR’S SEAT2748
METHOD FOR REMOVING OPERATOR’S SEAT2748
METHOD FOR INSTALLING OPERATOR’S SEAT2749
REMOVE AND INSTALL SEAT BELT2750
METHOD FOR REMOVING SEAT BELT2750
METHOD FOR INSTALLING SEAT BELT2750
REMOVE AND INSTALL FOOT HEATER ASSEMBLY2752
METHOD FOR REMOVING FOOT HEATER ASSEMBLY2752
METHOD FOR INSTALLING FOOT HEATER ASSEMBLY2754
DISASSEMBLE AND ASSEMBLE FOOT HEATER ASSEMBLY2757
METHOD FOR DISASSEMBLING FOOT HEATER ASSEMBLY2757
METHOD FOR ASSEMBLING FOOT HEATER ASSEMBLY2758
ELECTRICAL SYSTEM2759
REMOVE AND INSTALL ENGINE CONTROLLER ASSEMBLY2759
METHOD FOR REMOVING ENGINE CONTROLLER ASSEMBLY2759
METHOD FOR INSTALLING ENGINE CONTROLLER ASSEMBLY2762
REMOVE AND INSTALL HST CONTROLLER ASSEMBLY2766
METHOD FOR REMOVING HST CONTROLLER ASSEMBLY2766
METHOD FOR INSTALLING HST CONTROLLER ASSEMBLY2767
REMOVE AND INSTALL MACHINE MONITOR ASSEMBLY2768
METHOD FOR REMOVING MACHINE MONITOR ASSEMBLY2768
METHOD FOR INSTALLING MACHINE MONITOR ASSEMBLY2769
REMOVE AND INSTALL MASS AIR FLOW AND TEMPERATURE SENSOR2771
METHOD FOR REMOVING MASS AIR FLOW AND TEMPERATURE SENSOR2771
METHOD FOR INSTALLING MASS AIR FLOW AND TEMPERATURE SENSOR2773
REMOVE AND INSTALL KCCV CRANKCASE PRESSURE SENSOR2775
METHOD FOR REMOVING KCCV CRANKCASE PRESSURE SENSOR2775
METHOD FOR INSTALLING KCCV CRANKCASE PRESSURE SENSOR2777
REMOVE AND INSTALL ICT SENSOR CONTROLLER ASSEMBLY2779
METHOD FOR REMOVING ICT SENSOR CONTROLLER ASSEMBLY2779
METHOD FOR INSTALLING ICT SENSOR CONTROLLER ASSEMBLY2779
REMOVE AND INSTALL CONTROL BOX2781
METHOD FOR REMOVING CONTROL BOX (FOR OLD CONTROL BOX)2781
METHOD FOR REMOVING CONTROL BOX (FOR NEW CONTROL BOX)2782
METHOD FOR INSTALLING CONTROL BOX (FOR OLD CONTROL BOX)2782
METHOD FOR INSTALLING CONTROL BOX (FOR NEW CONTROL BOX)2783
REMOVE AND INSTALL GNSS RECEIVER2785
METHOD FOR REMOVING GNSS RECEIVER2785
METHOD FOR INSTALLING GNSS RECEIVER2785
REMOVE AND INSTALL GNSS ANTENNA2787
METHOD FOR REMOVING GNSS ANTENNA2787
METHOD FOR INSTALLING GNSS ANTENNA2788
REMOVE AND INSTALL IMU SENSOR2793
METHOD FOR REMOVING IMU SENSOR2793
METHOD FOR INSTALLING IMU SENSOR2795
60 MAINTENANCE STANDARD2799
CONTENTS2800
ABBREVIATION LIST2801
ENGINE AND COOLING SYSTEM2807
MAINTENANCE STANDARD OF ENGINE MOUNT2807
MAINTENANCE STANDARD OF DAMPER2808
MAINTENANCE STANDARD OF COOLING SYSTEM2809
MAINTENANCE STANDARD OF COOLING FAN MOTOR2811
MAINTENANCE STANDARD OF HYDRAULIC OIL COOLER BYPASS AND HST CHARGE SAFETY VALVE2813
POWER TRAIN2814
MAINTENANCE STANDARD OF HST PUMP2814
MAINTENANCE STANDARD OF EPC VALVE OF HST PUMP2816
MAINTENANCE STANDARD OF TOW RECEIVING VALVE OF HST PUMP2817
MAINTENANCE STANDARD OF HST CHARGE PUMP2818
MAINTENANCE STANDARD OF HST MOTOR2820
MAINTENANCE STANDARD OF FINAL DRIVE2822
MAINTENANCE STANDARD OF SPROCKET FOR PLUS TYPE TRACK SHOE2824
MAINTENANCE STANDARD OF SPROCKET TOOTH PROFILE FULL-SCALE DRAWING FOR PLUS TYPE TRACK SHOE2825
UNDERCARRIAGE AND FRAME2826
MAINTENANCE STANDARD OF SUSPENSION2826
MAINTENANCE STANDARD OF TRACK FRAME AND IDLER CUSHION2829
MAINTENANCE STANDARD OF IDLER2832
MAINTENANCE STANDARD OF TRACK ROLLER FOR PLUS TYPE TRACK SHOES (SINGLE FLANGE TYPE)2834
MAINTENANCE STANDARD OF TRACK ROLLER FOR PLUS TYPE TRACK SHOES (DOUBLE FLANGE TYPE)2835
MAINTENANCE STANDARD OF CARRIER ROLLER FOR PLUS TYPE TRACK SHOE2837
MAINTENANCE STANDARD OF PLUS TYPE TRACK SHOE2838
MAINTENANCE STANDARD OF SINGLE SHOE2840
HYDRAULIC SYSTEM2841
MAINTENANCE STANDARD OF HYDRAULIC TANK2841
MAINTENANCE STANDARD OF WORK EQUIPMENT AND COOLING FAN PUMP2842
MAINTENANCE STANDARD OF SERVO VALVE OF WORK EQUIPMENT AND COOLING FAN PUMP2843
MAINTENANCE STANDARD OF CONTROL VALVE2845
MAINTENANCE STANDARD OF RIPPER PPC VALVE2851
MAINTENANCE STANDARD OF 5-PORT VALVE OF EPC AND SOLENOID2853
MAINTENANCE STANDARD OF EPC VALVE2854
MAINTENANCE STANDARD OF QUICK DROP VALVE2855
WORK EQUIPMENT2857
MAINTENANCE STANDARD OF FRONT WORK EQUIPMENT2857
MAINTENANCE STANDARD OF CUTTING EDGE AND END BIT2860
MAINTENANCE STANDARD OF STROKE SENSING BLADE LIFT CYLINDER2861
MAINTENANCE STANDARD OF STROKE SENSING BLADE TILT CYLINDER2862
MAINTENANCE STANDARD OF STROKE SENSING BLADE ANGLE CYLINDER2863
MAINTENANCE STANDARD OF STROKE AND RESET SENSOR FOR BLADE LIFT CYLINDER2864
MAINTENANCE STANDARD OF STROKE SENSOR FOR BLADE TILT CYLINDER2865
MAINTENANCE STANDARD OF STROKE SENSOR FOR BLADE ANGLE CYLINDER2866
MAINTENANCE STANDARD OF FIXED MULTI-SHANK RIPPER2867
MAINTENANCE STANDARD OF RIPPER LIFT CYLINDER2869
CAB AND ITS ATTACHMENTS2870
MAINTENANCE STANDARD OF CAB MOUNT2870
ELECTRICAL SYSTEM2872
MAINTENANCE STANDARD OF ELECTRIC STEERING CONTROL LEVER2872
80 APPENDIX2873
CONTENTS2874
ABBREVIATION LIST2875
AIR CONDITIONER SYSTEM2881
PRECAUTIONS FOR REFRIGERANT2881
AIR CONDITIONER COMPONENT2882
SPECIFICATIONS OF AIR CONDITIONER2885
CONFIGURATION AND FUNCTION OF REFRIGERATION CYCLE2886
OUTLINE OF REFRIGERATION CYCLE2887
COMPONENT PARTS OF AIR CONDITIONER SYSTEM2889
AIR CONDITIONER UNIT2889
CONFIGURATION DIAGRAM OF AIR CONDITIONER UNIT2889
FUNCTION OF AIR CONDITIONER UNIT2890
COMPONENT PARTS OF AIR CONDITIONER UNIT2891
FUNCTION OF EVAPORATOR AS AIR CONDITIONER UNIT COMPONENT2891
FUNCTION OF HEATER CORE AS AIR CONDITIONER UNIT COMPONENT2891
FUNCTION OF THERMISTOR AS AIR CONDITIONER UNIT COMPONENT2891
STRUCTURE OF EXPANSION VALVE AS AIR CONDITIONER UNIT COMPONENT2891
FUNCTION OF EXPANSION VALVE AS AIR CONDITIONER UNIT COMPONENT2892
OPERATE EXPANSION VALVE AS AIR CONDITIONER UNIT COMPONENT2892
FUNCTION OF DUAL PRESSURE SWITCH2893
FUNCTION OF PRESSURE SWITCH2893
COMPRESSOR2894
STRUCTURE OF COMPRESSOR2894
SPECIFICATIONS OF COMPRESSOR2894
FUNCTION OF COMPRESSOR2894
CONDENSER2895
STRUCTURE OF CONDENSER2895
SPECIFICATIONS OF CONDENSER2895
FUNCTION OF CONDENSER2896
RECEIVER DRIER2897
STRUCTURE OF RECEIVER DRIER2897
SPECIFICATIONS OF RECEIVER DRIER2897
FUNCTION OF RECEIVER DRIER2897
EXPLANATION OF PROCEDURE FOR TESTING AND TROUBLESHOOTING OF AIR CONDITIONER2899
CIRCUIT DIAGRAM OF AIR CONDITIONER2902
AIR CONDITIONER SYSTEM DIAGRAM2903
CONTROL FUNCTION OF AIR CONDITIONER2904
INSTALLATION LOCATIONS OF AIR CONDITIONER PARTS AND ARRANGEMENT OF CONNECTORS2905
TEST RELAYS2909
METHOD FOR TESTING RELAYS2909
AIR CONDITIONER TROUBLESHOOTING CHART 12911
AIR CONDITIONER TROUBLESHOOTING CHART 22912
INFORMATION DESCRIBED IN TROUBLESHOOTING TABLE2915
A-1 TROUBLESHOOTING FOR CONDENSER FAN2917
A-2 TROUBLESHOOTING FOR COMPRESSOR AND REFRIGERANT SYSTEM (AIR IS NOT COOLED)2920
A-3 TROUBLESHOOTING FOR BLOWER MOTOR SYSTEM (NO AIR COMES OUT OR AIR FLOW IS ABNORMAL)2924
A-4 TROUBLESHOOTING FOR TEMPERATURE CONTROL FUNCTION2927
TROUBLESHOOTING USING GAUGE PRESSURE2931
CONNECTION OF SERVICE TOOL2933
METHOD FOR CONNECTING SERVICE TOOL2934
PRECAUTIONS FOR DISCONNECTING AND CONNECTING HOSES AND TUBES IN AIR CONDITIONER PIPINGS2935
HANDLE COMPRESSOR OIL2937
90 CIRCUIT DIAGRAMS2939
CONTENTS2940
ABBREVIATION LIST2941
HYDRAULIC CIRCUIT DIAGRAM2947
SYMBOLS USED IN HYDRAULIC CIRCUIT DIAGRAM2947
HYDRAULIC CIRCUIT DIAGRAM2951
ELECTRICAL CIRCUIT DIAGRAM2953
SYMBOLS USED IN ELECTRICAL CIRCUIT DIAGRAM2953
ELECTRICAL CIRCUIT DIAGRAM (1/14)2957
ELECTRICAL CIRCUIT DIAGRAM (2/14)2959
ELECTRICAL CIRCUIT DIAGRAM (3/14)2961
ELECTRICAL CIRCUIT DIAGRAM (4/14)2963
ELECTRICAL CIRCUIT DIAGRAM (5/14)2965
ELECTRICAL CIRCUIT DIAGRAM (6/14)2967
ELECTRICAL CIRCUIT DIAGRAM (7/14)2969
ELECTRICAL CIRCUIT DIAGRAM (8/14)2971
ELECTRICAL CIRCUIT DIAGRAM (9/14)2973
ELECTRICAL CIRCUIT DIAGRAM (10/14)2975
ELECTRICAL CIRCUIT DIAGRAM (11/14)2977
ELECTRICAL CIRCUIT DIAGRAM (12/14)2979
ELECTRICAL CIRCUIT DIAGRAM (13/14)2981
ELECTRICAL CIRCUIT DIAGRAM (14/14)2983
INDEX2985

S.M 28/12/24