Komatsu D51EX-24,D51PX-24 Bulldozer Shop Manual KEAM683005 PDF

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Komatsu D51EX-24,D51PX-24 Bulldozer Shop Manual KEAM683005 – PDF DOWNLOAD

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Komatsu D51EX-24,D51PX-24 Bulldozer Shop Manual KEAM683005 – PDF DOWNLOAD

Language : English
Pages : 2732
Downloadable : Yes
File Type : PDF

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TABLE OF CONTENTS:

Komatsu D51EX-24,D51PX-24 Bulldozer Shop Manual KEAM683005 – PDF DOWNLOAD

SERIAL NUMBERS

• D51EX-B25001 and up
• D51PX-B25001 and up

COVER . 0
00 INDEX AND FOREWORD 3
INDEX 4
FOREWORD, SAFETY, BASIC INFORMATION 20
HOW TO READ THE SHOP MANUAL 20
SAFETY NOTICE FOR OPERATION 22
PRECAUTIONS TO PREVENT FIRE 30
ACTIONS IF FIRE OCCURS . 32
PRECAUTIONS FOR DISPOSING OF WASTE MATERIALS . 33
ACTIONS TAKEN TO MEET EXHAUST GAS REGULATIONS 34
PRECAUTIONS FOR DEF 35
GENERAL CHARACTER AND PRECAUTIONS FOR HANDLING . 35
PRECAUTIONS FOR ADDING . 35
PRECAUTIONS FOR STORING 35
PRECAUTIONS FOR FIRE HAZARD AND LEAKAGE 35
THE OTHER PRECAUTIONS 35
STORE AdBlue/DEF . 36
PRECAUTIONS FOR HANDLING HYDRAULIC EQUIPMENT . 37
PRECAUTIONS FOR DISCONNECTION AND CONNECTION OF PIPINGS 40
PRECAUTIONS FOR HANDLING ELECTRICAL EQUIPMENT 47
PRECAUTIONS FOR HANDLING FUEL SYSTEM EQUIPMENT . 49
PRECAUTIONS FOR HANDLING INTAKE SYSTEM EQUIPMENT . 50
PRACTICAL USE OF KOMTRAX . 51
DISCONNECT AND CONNECT PUSH-PULL TYPE COUPLER 52
METHOD FOR DISCONNECTING AND CONNECTING TYPE 1 PUSH-PULL TYPE COUPLER 52
METHOD FOR DISCONNECTING AND CONNECTING TYPE 2 PUSH-PULL TYPE COUPLER 53
METHOD FOR DISCONNECTING AND CONNECTING TYPE 3 PUSH-PULL TYPE COUPLER 54
PRECAUTIONS FOR DISCONNECTION AND CONNECTION OF CONNECTORS . 56
METHOD FOR DISCONNECTING AND CONNECTING DEUTSCH CONNECTOR 60
METHOD FOR DISCONNECTING AND CONNECTING SLIDE LOCK TYPE CONNECTOR 61
METHOD FOR DISCONNECTING AND CONNECTING CONNECTOR WITH LOCK TO PULL 63
METHOD FOR DISCONNECTING AND CONNECTING CONNECTOR WITH LOCK TO PUSH 64
METHOD FOR DISCONNECTING AND CONNECTING CONNECTOR WITH HOUSING TO ROTATE . 66
HOW TO READ ELECTRICAL WIRE CODE . 67
EXPLANATION OF TERMS FOR MAINTENANCE STANDARD 71
STANDARD TIGHTENING TORQUE TABLE . 74
CONVERSION TABLE . 81
ABBREVIATION LIST 86
01 SPECIFICATIONS 89
CONTENTS . 90
SPECIFICATIONS . 91
SPECIFICATION DRAWING 91
SPECIFICATION DRAWING:D51EX-24 . 91
SPECIFICATION DRAWING: D51PX-24 0
SPECIFICATIONS . 0
SPECIFICATIONS: D51EX-24 . 0
SPECIFICATIONS: D51PX-24 . 0
WEIGHT TABLE . 105
WEIGHT TABLE: D51EX-24 . 105
WEIGHT TABLE: D51PX-24 . 107
FUEL, COOLANT, LUBRICANT . 109
METHOD FOR USING FUEL, COOLANT AND LUBRICANTS ACCORDING TO AMBIENT TEMPERATURE . 109
10 STRUCTURE AND FUNCTION 111
CONTENTS . 112
UREA SCR SYSTEM 115
LAYOUT DRAWING OF UREA SCR SYSTEM 115
UREA SCR SYSTEM DIAGRAM 117
FUNCTION OF UREA SCR SYSTEM 118
FUNCTION OF AdBlue/DEF SYSTEM 118
INDUCEMENT STRATEGY 121
COMPONENT PARTS OF UREA SCR SYSTEM . 135
AdBlue/DEF MIXING TUBE . 135
SCR ASSEMBLY . 136
AdBlue/DEF TANK 138
AdBlue/DEF PUMP 140
AdBlue/DEF INJECTOR 141
AdBlue/DEF HOSE 142
AdBlue/DEF TANK HEATING VALVE 143
BOOT-UP SYSTEM . 144
LAYOUT DRAWING OF BOOT-UP SYSTEM . 144
SYSTEM OPERATING LAMP SYSTEM . 145
SYSTEM OPERATING LAMP SYSTEM DIAGRAM . 145
FUNCTION OF SYSTEM OPERATING LAMP SYSTEM . 145
BATTERY DISCONNECT SWITCH 147
FUNCTION OF BATTERY DISCONNECT SWITCH 147
ENGINE SYSTEM 148
LAYOUT DRAWING OF ENGINE SYSTEM 148
ENGINE CONTROL SYSTEM 150
LAYOUT OF ENGINE CONTROL SYSTEM 150
ENGINE CONTROL SYSTEM DIAGRAM 152
FUNCTION OF ENGINE CONTROL SYSTEM 154
AUTOMATIC IDLE STOP SYSTEM . 156
AUTOMATIC IDLE STOP SYSTEM DIAGRAM . 156
FUNCTION OF AUTOMATIC IDLE STOP SYSTEM . 156
COMPONENT PARTS OF ENGINE SYSTEM . 0
DAMPER . 0
VGT 161
EGR SYSTEM . 164
EGR VALVE 166
EGR COOLER . 168
KCCV SYSTEM 170
KCCV VENTILATOR 172
KDOC . 174
COOLING SYSTEM . 177
LAYOUT DRAWING OF COOLING SYSTEM . 177
SPECIFICATIONS OF COOLING SYSTEM . 178
COOLING FAN CONTROL SYSTEM . 179
COOLING FAN CONTROL SYSTEM DIAGRAM . 179
FUNCTION OF COOLING FAN CONTROL SYSTEM . 180
COMPONENT PARTS OF COOLING SYSTEM 182
COOLING FAN MOTOR 182
HYDRAULIC OIL COOLER BYPASS AND HST CHARGE SAFETY VALVE 187
HYDRAULIC OIL COOLER BYPASS VALVE 188
HST CHARGE SAFETY VALVE 189
CONTROL SYSTEM . 191
LAYOUT DRAWING OF CONTROL SYSTEM . 191
MACHINE MONITOR SYSTEM . 192
SYSTEM DIAGRAM OF MACHINE MONITOR 192
FUNCTION OF MACHINE MONITOR SYSTEM . 192
KOMTRAX SYSTEM . 193
KOMTRAX SYSTEM DIAGRAM . 193
FUNCTION OF KOMTRAX SYSTEM . 193
COMPONENT PARTS OF CONTROL SYSTEM 194
MACHINE MONITOR 194
GATEWAY FUNCTION CONTROLLER 209
COMMUNICATION TERMINAL . 212
HST CONTROLLER . 214
ENGINE CONTROLLER 218
FUEL CONTROL DIAL 225
DECELERATOR AND BRAKE POTENTIOMETER 227
HYDRAULIC SYSTEM . 229
LAYOUT DRAWING OF HYDRAULIC SYSTEM . 229
CLSS . 230
STRUCTURE OF CLSS 230
FUNCTION OF CLSS . 231
COMPONENT PARTS OF HYDRAULIC SYSTEM 233
HYDRAULIC TANK . 233
WORK EQUIPMENT AND COOLING FAN PUMP 235
LS VALVE . 243
PC VALVE . 244
CONTROL VALVE 247
POWER TRAIN SYSTEM . 265
LAYOUT DRAWING OF HST SYSTEM . 265
OPERATION OF HST SYSTEM 266
STEERING AND BRAKE CONTROL SYSTEM 268
LAYOUT DRAWING OF STEERING AND BRAKE CONTROL SYSTEM 268
FUNCTION OF STEERING AND BRAKE CONTROL SYSTEM 268
HST CONTROL SYSTEM . 270
HST CONTROL SYSTEM DIAGRAM . 270
GEAR SHIFT CONTROL FUNCTION 271
ENGINE LOW SPEED MATCHING CONTROL FUNCTION . 274
HST PUMP AND MOTOR SEQUENCE CONTROL FUNCTION . 275
DECELERATION AND BRAKE CONTROL FUNCTION 276
GEAR SHIFT CONTROL FUNCTION BY LOAD 278
TURN CONTROL FUNCTION 278
STRAIGHT TRAVEL CORRECTION CONTROL FUNCTION 279
PARKING BRAKE CONTROL SYSTEM . 281
PARKING BRAKE CONTROL SYSTEM DIAGRAM . 281
FUNCTION OF PARKING BRAKE CONTROL SYSTEM . 282
OPERATION OF PARKING BRAKE CONTROL SYSTEM 283
COMPONENT PARTS OF POWER TRAIN SYSTEM 284
HST PUMP . 284
HST CHARGE PUMP 299
HST MOTOR 300
FINAL DRIVE 313
ELECTRIC STEERING CONTROL LEVER 317
WORK EQUIPMENT SYSTEM 320
WORK EQUIPMENT CONTROL . 320
WORK EQUIPMENT CONTROL SYSTEM DIAGRAM 320
FUNCTION OF WORK EQUIPMENT CONTROL . 321
LAYOUT DRAWING OF FRONT WORK EQUIPMENT . 322
LAYOUT OF FIXED MULTI-SHANK RIPPER . 323
COMPONENT PARTS OF WORK EQUIPMENT SYSTEM . 324
RIPPER PPC VALVE . 324
5-PORT VALVE OF EPC AND SOLENOID . 328
PILOT CIRCUIT ACCUMULATOR 334
QUICK DROP VALVE . 335
PISTON VALVE . 337
ELECTRIC BLADE CONTROL LEVER . 338
UNDERCARRIAGE AND FRAME 340
MAIN FRAME . 340
STRUCTURE OF MAIN FRAME 340
SUSPENSION . 341
STRUCTURE OF SUSPENSION 341
SPECIFICATIONS OF SUSPENSION . 342
FUNCTION OF SUSPENSION . 343
TRACK FRAME AND IDLER CUSHION 344
STRUCTURE OF TRACK FRAME AND IDLER CUSHION . 344
FUNCTION OF TRACK FRAME AND IDLER CUSHION 345
WORK EQUIPMENT . 0
STRUCTURE OF FRONT WORK EQUIPMENT (Serial No.: 15001 to 15600) . 0
STRUCTURE OF FRONT WORK EQUIPMENT (Serial No.: 15601 and up) . 0
STRUCTURE OF FIXED MULTI-SHANK RIPPER 348
CAB AND ITS ATTACHMENTS 349
ROPS CAB . 349
STRUCTURE OF ROPS CAB 349
FUNCTION OF ROPS CAB . 350
CAB MOUNT 351
STRUCTURE OF CAB MOUNT . 351
FUNCTION OF CAB MOUNT 351
20 STANDARD VALUE TABLE 353
CONTENTS . 354
STANDARD VALUE TABLE FOR ENGINE 355
STANDARD VALUE TABLE FOR ENGINE: D51EX-24 355
STANDARD VALUE TABLE FOR ENGINE: D51PX-24 359
STANDARD VALUE TABLE FOR MACHINE . 363
STANDARD VALUE TABLE FOR MACHINE: D51EX-24 . 363
STANDARD VALUE TABLE FOR MACHINE: D51PX-24 . 379
MACHINE POSTURE AND PROCEDURE FOR MEASURING PERFORMANCE 393
30 TESTING AND ADJUSTING . 395
CONTENTS . 396
RELATED INFORMATION ON TESTING AND ADJUSTING . 399
TOOLS FOR TESTING AND ADJUSTING 399
SKETCH OF TOOLS FOR TESTING AND ADJUSTING 406
ENGINE AND COOLING SYSTEM 409
TEST ENGINE SPEED 409
METHOD FOR TESTING ENGINE SPEED 409
TEST BOOST PRESSURE 411
METHOD FOR TESTING BOOST PRESSURE 411
TEST EXHAUST GAS COLOR . 412
METHOD FOR TESTING EXHAUST GAS COLOR BY HANDY SMOKE CHECKER 412
METHOD FOR TESTING EXHAUST GAS COLOR BY SMOKE METER 413
TEST AND ADJUST VALVE CLEARANCE 414
METHOD FOR TESTING VALVE CLEARANCE . 414
METHOD FOR ADJUSTING VALVE CLEARANCE . 415
TEST COMPRESSION PRESSURE 416
METHOD FOR TESTING COMPRESSION PRESSURE 416
TEST BLOWBY PRESSURE . 421
METHOD FOR TESTING BLOWBY PRESSURE . 421
TEST ENGINE OIL PRESSURE . 423
METHOD FOR TESTING ENGINE OIL PRESSURE . 423
VISUAL CHECK INSIDE OF EGR VALVE . 424
VISUAL CHECK INSIDE OF EGR VALVE . 424
CLEAN INSIDE OF EGR VALVE 426
CLEAN INSIDE OF EGR VALVE 426
TEST FUEL PRESSURE . 429
METHOD FOR TESTING FUEL PRESSURE . 430
TEST FUEL DISCHARGE, RETURN AND LEAKAGE 434
METHOD FOR TESTING FUEL DISCHARGE, RETURN AND LEAKAGE 435
BLEED AIR FROM FUEL SYSTEM . 440
METHOD FOR BLEEDING AIR FROM FUEL SYSTEM . 440
TEST FUEL CIRCUIT FOR LEAKAGE 441
METHOD FOR TESTING FUEL CIRCUIT FOR LEAKAGE 441
HANDLE CYLINDER CUT-OUT MODE OPERATION . 443
HANDLE NO-INJECTION CRANKING OPERATION . 444
TEST KDOC, SCR AND MUFFLER STACK FOR LOOSENESS AND DAMAGE 445
METHOD FOR TESTING KDOC, SCR AND MUFFLER STACK FOR LOOSENESS AND DAMAGE 445
TEST INSTALLED CONDITION OF CYLINDER HEADS AND MANIFOLDS . 446
METHOD FOR TESTING INSTALLED CONDITION OF CYLINDER HEADS AND MANIFOLDS . 446
TEST ENGINE PIPING FOR DAMAGE AND LOOSENESS 447
METHOD FOR TESTING ENGINE PIPING FOR DAMAGE AND LOOSENESS 447
WRITE ASH IN SOOT ACCUMULATION CORRECTION TO ENGINE CONTROLLER . 448
METHOD FOR WRITING ASH IN SOOT ACCUMULATION CORRECTION TO ENGINE CONTROLLER 449
TEST SCR RELATED FUNCTIONS . 450
TEST AdBlue/DEF PUMP RAISED PRESSURE . 454
TEST INJECTION AMOUNT FROM AdBlue/DEF INJECTOR . 457
TEST AdBlue/DEF LINE HEATER RELAY 1 462
TEST AdBlue/DEF LINE HEATER RELAY 2 465
TEST AdBlue/DEF PUMP HEATER RELAY 468
TEST AdBlue/DEF TANK HEATER VALVE 472
TEST DENITRATION EFFICIENCY OF SCR . 476
CLEAN AdBlue/DEF TANK 479
METHOD FOR CLEANING AdBlue/DEF TANK 479
CLEAN AdBlue/DEF PUMP 483
CLEAN AdBlue/DEF PUMP 483
CLEAN AdBlue/DEF TANK MOUNTING PORTION . 489
METHOD FOR CLEANING AdBlue/DEF TANK MOUNTING PORTION . 489
POWER TRAIN 490
TEST AND ADJUST HST OIL PRESSURE . 490
METHOD FOR TESTING HST OIL PRESSURE 490
METHOD FOR ADJUSTING HST OIL PRESSURE 493
BLEED AIR FROM HST PUMP 495
METHOD FOR BLEEDING AIR FROM HST PUMP 495
METHOD FOR BLEEDING AIR FROM SERVO VALVE OF HST PUMP . 495
TEST OUTLET PRESSURE OF SOLENOID VALVE . 497
METHOD FOR TESTING OUTLET PRESSURE OF SOLENOID VALVE . 497
TEST TRAVEL DEVIATION 501
METHOD FOR TESTING TRAVEL DEVIATION 501
TEST BRAKE PERFORMANCE SIMPLY 503
METHOD FOR TESTING BRAKE PERFORMANCE SIMPLY 503
TEST AND ADJUST DECELERATION/BRAKE PEDAL . 504
METHOD FOR TESTING DECELERATION/BRAKE PEDAL 504
METHOD FOR ADJUSTING DECELERATION/BRAKE PEDAL 506
ADJUST PARKING BRAKE LEVER . 508
METHOD FOR ADJUSTING PARKING BRAKE LEVER . 508
MOVE MACHINE WHEN IT CANNOT TRAVEL . 510
METHOD FOR MOVING MACHINE WITH HYDRAULIC TYPE PARKING BRAKE RELEASE SYSTEM . 510
METHOD FOR MOVING DISABLED MACHINE BY REMOVING FINAL DRIVE SHAFT . 512
UNDERCARRIAGE AND FRAME 513
CHECK AND ADJUST IDLER CLEARANCE . 513
METHOD FOR ADJUSTING IDLER CLEARANCE HORIZONTALLY 513
METHOD FOR ADJUSTING IDLER CLEARANCE VERTICALLY 513
TESTING SPROCKET WEAR 515
METHOD FOR TESTING SPROCKET WEAR . 515
TEST AND ADJUST TRACK TENSION 516
METHOD FOR TESTING TRACK TENSION . 516
METHOD FOR ADJUSTING TRACK TENSION . 516
HYDRAULIC SYSTEM . 518
RELEASE REMAINING PRESSURE FROM HYDRAULIC SYSTEM . 518
METHOD FOR RELEASING REMAINING PRESSURE FROM HYDRAULIC CIRCUIT . 518
TEST AND ADJUST WORK EQUIPMENT OIL PRESSURES . 519
METHOD FOR TESTING WORK EQUIPMENT OIL PRESSURES 519
METHOD FOR ADJUSTING WORK EQUIPMENT OIL PRESSURES 520
TEST AND ADJUST OIL PRESSURE OF CONTROL CIRCUIT 522
METHOD FOR TESTING OIL PRESSURE OF CONTROL CIRCUIT . 522
METHOD FOR ADJUSTING OIL PRESSURE OF CONTROL CIRCUIT . 523
TEST OUTLET PRESSURE OF EPC SOLENOID VALVE . 524
METHOD FOR TESTING OUTLET PRESSURE OF EPC SOLENOID VALVE . 524
BLEED AIR FROM WORK EQUIPMENT, COOLING FAN PUMP, AND CHARGE PUMP . 526
BLEED AIR FROM WORK EQUIPMENT, COOLING FAN PUMP, AND CHARGE PUMP . 526
TEST COOLING FAN SPEED . 527
METHOD FOR TESTING COOLING FAN SPEED . 527
TEST COOLING FAN CIRCUIT OIL PRESSURE 528
METHOD FOR TESTING COOLING FAN CIRCUIT OIL PRESSURE 528
TEST THE PARTS CAUSING HYDRAULIC DRIFT IN WORK EQUIPMENT . 530
METHOD FOR TESTING THE PARTS CAUSING HYDRAULIC DRIFT OF BLADE LIFT CYLINDER 530
METHOD FOR TESTING THE PARTS CAUSING HYDRAULIC DRIFT OF BLADE TILT CYLINDER 530
METHOD FOR TESTING THE PARTS CAUSING HYDRAULIC DRIFT OF RIPPER LIFT CYLINDER . 531
TEST INTERNAL OIL LEAKAGE OF WORK EQUIPMENT CYLINDER . 532
METHOD FOR TESTING INTERNAL OIL LEAKAGE OF WORK EQUIPMENT CYLINDER . 532
BLEED AIR FROM WORK EQUIPMENT CYLINDERS 535
METHOD FOR BLEEDING AIR FROM WORK EQUIPMENT CYLINDERS 535
WORK EQUIPMENT . 536
ADJUST WORK EQUIPMENT LOCK LEVER . 536
METHOD FOR ADJUSTING WORK EQUIPMENT LOCK LEVER . 536
TEST AND ADJUST PLAY OF BLADE ELECTRIC LEVER . 538
TEST PLAY OF BLADE ELECTRIC LEVER 540
ADJUST PLAY OF BLADE ELECTRIC LEVER 540
REPLACE UNIVERSAL JOINT 542
ELECTRICAL SYSTEM 548
SET AND OPERATE MACHINE MONITOR 548
OPERATOR MODE 552
DISPLAY FUNCTION OF TECHNICIAN IDENTIFICATION STATUS SCREEN 552
DISPLAY FUNCTION OF OPERATOR IDENTIFICATION INPUT SCREEN . 552
CHECK FUNCTION BY LCD (LIQUID CRYSTAL DISPLAY) . 553
CHECK FUNCTION OF SERVICE METER 553
USAGE LIMITATION AND CHANGING MAINTENANCE PASSWORD . 553
SERVICE MODE . 556
OPERATE SERVICE MODE . 556
METHOD FOR CHECKING PRE-DEFINED MONITORING INFORMATION . 557
METHOD FOR CHECKING SELF-DEFINE MONITORING INFORMATION . 564
ABNORMALITY RECORD MENU 574
METHOD FOR CONFIRMING MAINTENANCE RECORD . 578
METHOD FOR OPERATING MAINTENANCE MODE SETTING 579
METHOD FOR OPERATING PHONE NUMBER ENTRY SETTING 583
DEFAULT MENU . 585
DIAGNOSTIC TESTS MENU 593
ADJUSTMENT MENU 600
METHOD FOR PERFORMING NO-INJECTION CRANKING 657
KOMTRAX SETTINGS MENU 659
METHOD FOR DISPLAYING SERVICE MESSAGE 661
START UP KOMTRAX SYSTEM 663
STOP USING OF KOMTRAX SYSTEM . 669
ADJUSTMENT WHEN HST CONTROLLER HAS BEEN REPLACED . 671
ADJUSTMENT METHOD WHEN HST CONTROLLER HAS BEEN REPLACED 671
ADJUSTMENT WHEN ELECTRIC OR HYDRAULIC DEVICE HAS BEEN REPLACED . 677
ADJUST REARVIEW CAMERA ANGLE . 679
METHOD FOR ADJUSTING REARVIEW CAMERA ANGLE . 679
SET REGION OF Bluetooth(R) COMPATIBLE RADIO 680
SET REGION OF Bluetooth(R) COMPATIBLE RADIO 680
HANDLE VOLTAGE CIRCUIT OF ENGINE CONTROLLER 682
BATTERY DISCONNECT SWITCH 683
TEST DIODES 684
METHOD FOR TESTING DIODE USING DIGITAL TESTER 684
METHOD FOR TESTING DIODE USING ANALOG TESTER . 684
Pm CLINIC 685
Pm CLINIC SERVICE 685
Pm CLINIC CHECK SHEET: D51EX-24 687
Pm CLINIC CHECK SHEET: D51PX-24 695
Pm CLINIC CHECK SHEET FOR UNDERCARRIAGE: D51EX-24 703
Pm CLINIC CHECK SHEET FOR UNDERCARRIAGE: D51PX-24 707
40 TROUBLESHOOTING . 711
CONTENTS . 712
RELATED INFORMATION ON TROUBLESHOOTING . 722
GENERAL TROUBLESHOOTING POINTS . 722
TROUBLESHOOTING POINTS FOR UREA SCR SYSTEM . 723
SEQUENCE OF EVENTS IN TROUBLESHOOTING 735
CHECKS BEFORE TROUBLESHOOTING 737
INSPECTION PROCEDURE BEFORE TROUBLESHOOTING 739
WALK-AROUND CHECK 739
TESTING IN ACCORDANCE WITH TESTING PROCEDURE . 741
CHECK FUEL LEVEL AND TYPE 741
CHECK IMPURE INGREDIENT IN FUEL 741
CHECK AdBule/DEF LEVEL AND TYPE 742
CHECK FUEL PREFILTER . 742
CHECK MAIN FILTER 744
CHECK ENGINE OIL LEVEL (OIL AMOUNT IN OIL PAN) AND TYPE 745
CHECK COOLANT LEVEL (RESERVOIR TANK) . 747
CHECK CLOGGING OF AIR CLEANER 747
CLEAN OUTER ELEMENT 748
REPLACE ELEMENT 750
CHECK HYDRAULIC OIL LEVEL 751
CHECK HYDRAULIC OIL STRAINER . 752
CHECK OIL LEVEL IN FINAL DRIVE CASE 755
BLEED AIR FROM FUEL SYSTEM . 756
BLEED AIR FROM HYDRAULIC SYSTEM 756
METHOD FOR CHECKING ELECTRIC EQUIPMENT . 756
PREPARATION FOR TROUBLESHOOTING ELECTRICAL SYSTEM 763
PROCEDURE FOR TROUBLESHOOTING 770
SYMPTOM AND TROUBLESHOOTING NUMBERS 773
INFORMATION DESCRIBED IN TROUBLESHOOTING TABLE . 776
TROUBLESHOOTING METHOD FOR OPEN CIRCUIT IN WIRING HARNESS OF PRESSURE SENSOR SYSTEM 778
CONNECTORS LIST AND LAYOUT . 781
CONNECTOR CONTACT IDENTIFICATION . 799
T-BRANCH BOX AND T-BRANCH ADAPTER TABLE 839
FUSE LOCATION TABLE 845
PRECAUTIONS FOR REPLACING KDOC . 849
FAILURE CODES TABLE 850
TROUBLESHOOTING BY FAILURE CODE (DISPLAY OF CODE) 868
FAILURE CODE [6091NX] 868
FAILURE CODE [989L00] 870
FAILURE CODE [989M00] 871
FAILURE CODE [989N00] 872
FAILURE CODE [A1U0N3] 873
FAILURE CODE [A1U0N4] 875
FAILURE CODE [A900FR] 877
FAILURE CODE [A900N6] 878
FAILURE CODE [A900NY] 879
FAILURE CODE [AA10NX] 880
FAILURE CODE [AB00KE] 882
FAILURE CODE [AQ10MB] 884
FAILURE CODE [AQ10N3] 886
FAILURE CODE [AS00R2] 888
FAILURE CODE [AS00R3] 889
FAILURE CODE [AS00R4] 890
FAILURE CODE [AS00R5] 891
FAILURE CODE [AS00R6] 892
FAILURE CODE [AS00ZK] 893
FAILURE CODE [AS10KM] 894
FAILURE CODE [AS10NR] 895
FAILURE CODE [AS10NT] 896
FAILURE CODE [B@BAZG] 897
FAILURE CODE [B@BCNS] 898
FAILURE CODE [B@BCQA] 899
FAILURE CODE [B@BCZK] 901
FAILURE CODE [B@CRNS] 903
FAILURE CODE [B@CRZG] 904
FAILURE CODE [CA115] . 905
FAILURE CODE [CA122] . 906
FAILURE CODE [CA123] . 908
FAILURE CODE [CA131] . 910
FAILURE CODE [CA132] . 912
FAILURE CODE [CA144] . 914
FAILURE CODE [CA145] . 916
FAILURE CODE [CA153] . 918
FAILURE CODE [CA154] . 920
FAILURE CODE [CA187] . 922
FAILURE CODE [CA221] . 924
FAILURE CODE [CA222] . 926
FAILURE CODE [CA227] . 928
FAILURE CODE [CA234] . 930
FAILURE CODE [CA238] . 931
FAILURE CODE [CA239] . 932
FAILURE CODE [CA249] . 933
FAILURE CODE [CA256] . 935
FAILURE CODE [CA271] . 937
FAILURE CODE [CA272] . 939
FAILURE CODE [CA295] . 941
FAILURE CODE [CA322] . 942
FAILURE CODE [CA324] . 944
FAILURE CODE [CA331] . 946
FAILURE CODE [CA332] . 948
FAILURE CODE [CA343] . 950
FAILURE CODE [CA351] . 951
FAILURE CODE [CA352] . 952
FAILURE CODE [CA356] . 954
FAILURE CODE [CA357] . 956
FAILURE CODE [CA386] . 958
FAILURE CODE [CA428] . 959
FAILURE CODE [CA429] . 961
FAILURE CODE [CA435] . 963
FAILURE CODE [CA441] . 965
FAILURE CODE [CA442] . 967
FAILURE CODE [CA451] . 968
FAILURE CODE [CA452] . 970
FAILURE CODE [CA488] . 972
FAILURE CODE [CA515] . 973
FAILURE CODE [CA516] . 975
FAILURE CODE [CA553] . 977
FAILURE CODE [CA555] . 978
FAILURE CODE [CA556] . 979
FAILURE CODE [CA559] . 980
FAILURE CODE [CA595] . 983
FAILURE CODE [CA687] . 985
FAILURE CODE [CA689] . 987
FAILURE CODE [CA691] . 990
FAILURE CODE [CA692] . 992
FAILURE CODE [CA697] . 994
FAILURE CODE [CA698] . 995
FAILURE CODE [CA731] . 996
FAILURE CODE [CA778] . 998
FAILURE CODE [CA1117] 1003
FAILURE CODE [CA1664] 1005
FAILURE CODE [CA1669] 1007
FAILURE CODE [CA1673] 1008
FAILURE CODE [CA1677] 1009
FAILURE CODE [CA1678] 1010
FAILURE CODE [CA1682] 1011
FAILURE CODE [CA1683] 1014
FAILURE CODE [CA1684] 1016
FAILURE CODE [CA1686] 1018
FAILURE CODE [CA1691] 1019
FAILURE CODE [CA1695] 1021
FAILURE CODE [CA1696] 1022
FAILURE CODE [CA1712] 1024
FAILURE CODE [CA1713] 1027
FAILURE CODE [CA1714] 1030
FAILURE CODE [CA1715] 1031
FAILURE CODE [CA1776] 1032
FAILURE CODE [CA1777] 1035
FAILURE CODE [CA1843] 1038
FAILURE CODE [CA1844] 1040
FAILURE CODE [CA1885] 1043
FAILURE CODE [CA1887] 1045
FAILURE CODE [CA1896] 1047
FAILURE CODE [CA1898] 1051
FAILURE CODE [CA1938] 1053
FAILURE CODE [CA1942] 1055
FAILURE CODE [CA1961] 1056
FAILURE CODE [CA1962] 1057
FAILURE CODE [CA2185] 1058
FAILURE CODE [CA2186] 1060
FAILURE CODE [CA2198] 1062
FAILURE CODE [CA2272] 1064
FAILURE CODE [CA2288] 1066
FAILURE CODE [CA2311] 1067
FAILURE CODE [CA2349] 1068
FAILURE CODE [CA2353] 1070
FAILURE CODE [CA2357] 1072
FAILURE CODE [CA2373] 1073
FAILURE CODE [CA2374] 1075
FAILURE CODE [CA2375] 1077
FAILURE CODE [CA2376] 1079
FAILURE CODE [CA2387] 1082
FAILURE CODE [CA2554] 1083
FAILURE CODE [CA2555] 1085
FAILURE CODE [CA2556] 1088
FAILURE CODE [CA2634] 1091
FAILURE CODE [CA2635] 1093
FAILURE CODE [CA2636] 1094
FAILURE CODE [CA2637] 1096
FAILURE CODE [CA2771] 1098
FAILURE CODE [CA2961] 1102
FAILURE CODE [CA2973] 1103
FAILURE CODE [CA2976] 1104
FAILURE CODE [CA3142] 1106
FAILURE CODE [CA3143] 1107
FAILURE CODE [CA3144] 1108
FAILURE CODE [CA3146] 1110
FAILURE CODE [CA3147] 1111
FAILURE CODE [CA3148] 1112
FAILURE CODE [CA3151] 1114
FAILURE CODE [CA3165] 1119
FAILURE CODE [CA3228] 1121
FAILURE CODE [CA3229] 1123
FAILURE CODE [CA3231] 1125
FAILURE CODE [CA3232] 1127
FAILURE CODE [CA3235] 1131
FAILURE CODE [CA3239] 1133
FAILURE CODE [CA3241] 1136
FAILURE CODE [CA3242] 1139
FAILURE CODE [CA3251] 1142
FAILURE CODE [CA3313] 1144
FAILURE CODE [CA3314] 1145
FAILURE CODE [CA3315] 1146
FAILURE CODE [CA3419] 1148
FAILURE CODE [CA3421] 1150
FAILURE CODE [CA3497] 1152
FAILURE CODE [CA3498] 1153
FAILURE CODE [CA3545] 1154
FAILURE CODE [CA3547] 1156
FAILURE CODE [CA3558] 1157
FAILURE CODE [CA3559] 1159
FAILURE CODE [CA3562] 1161
FAILURE CODE [CA3563] 1163
FAILURE CODE [CA3567] 1166
FAILURE CODE [CA3568] 1170
FAILURE CODE [CA3571] 1174
FAILURE CODE [CA3572] 1176
FAILURE CODE [CA3574] 1178
FAILURE CODE [CA3575] 1180
FAILURE CODE [CA3577] 1182
FAILURE CODE [CA3578] 1184
FAILURE CODE [CA3582] 1186
FAILURE CODE [CA3583] 1191
FAILURE CODE [CA3596] 1193
FAILURE CODE [CA3649] 1197
FAILURE CODE [CA3681] 1199
FAILURE CODE [CA3682] 1204
FAILURE CODE [CA3713] 1209
FAILURE CODE [CA3717] 1212
FAILURE CODE [CA3718] 1213
FAILURE CODE [CA3724] 1214
FAILURE CODE [CA3725] 1215
FAILURE CODE [CA3741] 1218
FAILURE CODE [CA3748] 1219
FAILURE CODE [CA3755] 1221
FAILURE CODE [CA3866] 1223
FAILURE CODE [CA3868] 1226
FAILURE CODE [CA4152] 1230
FAILURE CODE [CA4155] 1234
FAILURE CODE [CA4156] 1237
FAILURE CODE [CA4157] 1240
FAILURE CODE [CA4159] 1242
FAILURE CODE [CA4164] 1243
FAILURE CODE [CA4165] 1245
FAILURE CODE [CA4166] 1247
FAILURE CODE [CA4168] 1248
FAILURE CODE [CA4169] 1251
FAILURE CODE [CA4171] 1253
FAILURE CODE [CA4249] 1255
FAILURE CODE [CA4251] 1257
FAILURE CODE [CA4261] 1259
FAILURE CODE [CA4277] 1262
FAILURE CODE [CA4459] 1266
FAILURE CODE [CA4461] 1268
FAILURE CODE [CA4533] 1271
FAILURE CODE [CA4534] 1272
FAILURE CODE [CA4731] 1273
FAILURE CODE [CA4732] 1274
FAILURE CODE [CA4739] 1275
FAILURE CODE [CA4768] 1276
FAILURE CODE [CA4769] 1278
FAILURE CODE [CA4842] 1281
FAILURE CODE [CA4952] 1284
FAILURE CODE [CA5115] 1286
FAILURE CODE [CA5179] 1289
FAILURE CODE [CA5181] 1291
FAILURE CODE [CA5387] 1293
FAILURE CODE [CA5388] 1295
FAILURE CODE [CA5389] 1298
FAILURE CODE [CA5391] 1300
FAILURE CODE [CA5392] 1304
FAILURE CODE [CA5393] 1306
FAILURE CODE [CA5394] 1309
FAILURE CODE [CA5395] 1312
FAILURE CODE [CA5396] 1315
FAILURE CODE [CA5631] 1316
FAILURE CODE [CA5632] 1318
FAILURE CODE [CA5938] 1319
FAILURE CODE [D130KA] 1321
FAILURE CODE [D130KB] 1324
FAILURE CODE [D130KY] 1326
FAILURE CODE [D19JKZ] 1328
FAILURE CODE [D811MC] 1331
FAILURE CODE [D862KA] 1332
FAILURE CODE [D8ALKA] 1333
FAILURE CODE [D8ALKB] 1335
FAILURE CODE [D8AQKR] 1337
FAILURE CODE [D8G1KT] 1339
FAILURE CODE [D8G6KT] 1340
FAILURE CODE [DAF0MB] 1341
FAILURE CODE [DAF0MC] 1342
FAILURE CODE [DAF8KB] 1343
FAILURE CODE [DAF9KQ] 1345
FAILURE CODE [DAFGMC] 1346
FAILURE CODE [DAFLKA] 1347
FAILURE CODE [DAFLKB] 1349
FAILURE CODE [DAFQKR] 1351
FAILURE CODE [DAJ000] 1352
FAILURE CODE [DAJ0KQ] 1353
FAILURE CODE [DAJ0KT] 1354
FAILURE CODE [DAJ0MC] 1355
FAILURE CODE [DAJ1KK] 1356
FAILURE CODE [DAJ2KK] 1358
FAILURE CODE [DAJ5KK] 1360
FAILURE CODE [DAJ6KK] 1363
FAILURE CODE [DAJLKA] 1365
FAILURE CODE [DAJLKB] 1367
FAILURE CODE [DAJPMA] 1369
FAILURE CODE [DAJQKR] 1370
FAILURE CODE [DAJRKR] 1371
FAILURE CODE [DB2QKR] 1372
FAILURE CODE [DB2RKR] 1377
FAILURE CODE [DD12KA] 1382
FAILURE CODE [DD12KB] 1384
FAILURE CODE [DD13KA] 1386
FAILURE CODE [DD13KB] 1388
FAILURE CODE [DD14KA] 1390
FAILURE CODE [DD14KB] 1392
FAILURE CODE [DDKAKA] 1394
FAILURE CODE [DDKAKB] 1396
FAILURE CODE [DDKFL4] 1398
FAILURE CODE [DDKGL4] 1400
FAILURE CODE [DDKHKA] 1402
FAILURE CODE [DDKHKB] 1404
FAILURE CODE [DDNLKA] 1406
FAILURE CODE [DDNLKB] 1408
FAILURE CODE [DDP6KA] 1410
FAILURE CODE [DDP6KB] 1413
FAILURE CODE [DDP6MA] 1415
FAILURE CODE [DDU1FS] 1417
FAILURE CODE [DDU1KA] 1419
FAILURE CODE [DDU1KY] 1422
FAILURE CODE [DFA4KX] 1424
FAILURE CODE [DFA4KZ] 1425
FAILURE CODE [DFA4L8] 1426
FAILURE CODE [DFA5KA] 1427
FAILURE CODE [DFA5KB] 1430
FAILURE CODE [DFA6KA] 1433
FAILURE CODE [DFA6KB] 1436
FAILURE CODE [DFA7KX] 1439
FAILURE CODE [DFA7KZ] 1440
FAILURE CODE [DFA7L8] 1441
FAILURE CODE [DFA8KA] 1442
FAILURE CODE [DFA8KB] 1445
FAILURE CODE [DFA9KA] 1448
FAILURE CODE [DFA9KB] 1451
FAILURE CODE [DGS1KA] 1454
FAILURE CODE [DGS1KX] 1457
FAILURE CODE [DH21KA] 1458
FAILURE CODE [DH21KB] 1460
FAILURE CODE [DHA4KA] 1462
FAILURE CODE [DHH7KA] 1464
FAILURE CODE [DHH7KB] 1467
FAILURE CODE [DHH8KA] 1469
FAILURE CODE [DHH8KB] 1472
FAILURE CODE [DHH9KA] 1474
FAILURE CODE [DHH9KB] 1477
FAILURE CODE [DHHAKA] 1479
FAILURE CODE [DHHAKB] 1482
FAILURE CODE [DHRUKA] 1484
FAILURE CODE [DHRUKB] 1486
FAILURE CODE [DHRVKA] 1488
FAILURE CODE [DHRVKB] 1490
FAILURE CODE [DK30KA] 1492
FAILURE CODE [DK30KB] 1495
FAILURE CODE [DK30KX] 1497
FAILURE CODE [DK30KZ] 1498
FAILURE CODE [DK30L8] 1499
FAILURE CODE [DK31KA] 1500
FAILURE CODE [DK31KB] 1503
FAILURE CODE [DK40KA] 1505
FAILURE CODE [DK40KB] 1508
FAILURE CODE [DK55KX] 1510
FAILURE CODE [DK55KZ] 1511
FAILURE CODE [DK55L8] 1512
FAILURE CODE [DK56KA] 1513
FAILURE CODE [DK56KB] 1516
FAILURE CODE [DK57KA] 1518
FAILURE CODE [DK57KB] 1521
FAILURE CODE [DLM0KX] 1523
FAILURE CODE [DLM1KA] 1524
FAILURE CODE [DLM1KB] 1526
FAILURE CODE [DLM1MA] 1528
FAILURE CODE [DLM2KA] 1529
FAILURE CODE [DLM2KB] 1531
FAILURE CODE [DLM2MA] 1533
FAILURE CODE [DLM3KA] 1534
FAILURE CODE [DLM3KB] 1536
FAILURE CODE [DLM3MB] 1538
FAILURE CODE [DN21FS] 1539
FAILURE CODE [DR21KX] 1541
FAILURE CODE [DR31KX] 1542
FAILURE CODE [DV20KB] 1543
FAILURE CODE [DW4BKA] 1545
FAILURE CODE [DW4BKB] 1547
FAILURE CODE [DW4BKY] 1549
FAILURE CODE [DW7BKA] 1551
FAILURE CODE [DW7BKB] 1553
FAILURE CODE [DW7EKA] 1555
FAILURE CODE [DW7EKB] 1557
FAILURE CODE [DW7EKY] 1559
FAILURE CODE [DWN5KA] 1561
FAILURE CODE [DWN5KB] 1563
FAILURE CODE [DWN5KY] 1565
FAILURE CODE [DXA4KA] 1567
FAILURE CODE [DXA4KB] 1569
FAILURE CODE [DXA4KY] 1571
FAILURE CODE [DXA5KA] 1573
FAILURE CODE [DXA5KB] 1575
FAILURE CODE [DXA5KY] 1577
FAILURE CODE [DXA6KA] 1579
FAILURE CODE [DXA6KB] 1581
FAILURE CODE [DXA6KY] 1583
FAILURE CODE [DXA7KA] 1585
FAILURE CODE [DXA7KB] 1587
FAILURE CODE [DXA7KY] 1589
FAILURE CODE [DXHRKA] 1591
FAILURE CODE [DXHRKB] 1593
FAILURE CODE [DXHRKY] 1595
FAILURE CODE [DXHSKA] 1597
FAILURE CODE [DXHSKB] 1599
FAILURE CODE [DXHSKY] 1601
FAILURE CODE [DXHTKA] 1603
FAILURE CODE [DXHTKB] 1605
FAILURE CODE [DXHTKY] 1607
FAILURE CODE [DXHUKA] 1609
FAILURE CODE [DXHUKB] 1611
FAILURE CODE [DXHUKY] 1613
FAILURE CODE [DXJ4KA] 1615
FAILURE CODE [DXJ4KB] 1617
FAILURE CODE [DXJCKA] 1619
FAILURE CODE [DXJCKB] 1621
FAILURE CODE [DXJCKY] 1623
FAILURE CODE [DXJDKA] 1625
FAILURE CODE [DXJDKB] 1627
FAILURE CODE [DXJDKY] 1629
FAILURE CODE [DXK1KA] 1631
FAILURE CODE [DXK1KB] 1633
FAILURE CODE [DXK1KY] 1635
FAILURE CODE [DXK2KA] 1637
FAILURE CODE [DXK2KB] 1639
FAILURE CODE [DXK2KY] 1641
FAILURE CODE [F313KA] 1643
FAILURE CODE [F313KB] 1644
FAILURE CODE [F318KB] 1645
FAILURE CODE [F318KY] 1646
TROUBLESHOOTING OF ELECTRICAL SYSTEM (E-MODE) 1647
ENGINE DOES NOT START (ENGINE DOES NOT CRANK) 1647
MANUAL PREHEATING SYSTEM DOES NOT WORK .1654
AUTOMATIC PREHEATING SYSTEM DOES NOT WORK 1657
WHILE PREHEATING IS WORKING, PREHEATING MONITOR DOES NOT LIGHT UP 1659
WHEN STARTING SWITCH IS TURNED TO ON POSITION, MACHINE MONITOR DISPLAYS NOTHING 1661
WHEN STARTING SWITCH IS TURNED TO ON POSITION (WITH ENGINE STOPPED), BASIC CHECK MONITOR LIGHTS UP .1665
AIR CLEANER CLOGGING MONITOR LIGHTS UP IN YELLOW WHILE ENGINE IS RUNNING .1666
CHARGE LEVEL MONITOR LIGHTS UP IN RED WHILE ENGINE IS RUNNING 1667
ENGINE COOLANT TEMPERATURE MONITOR LIGHTS UP IN RED WHILE ENGINE IS RUNNING 1668
ENGINE OIL PRESSURE MONITOR LIGHTS UP IN RED WHILE ENGINE IS RUNNING .1669
HST CHARGE PRESSURE MONITOR LIGHTS UP IN RED WHILE ENGINE IS RUNNING .1670
HYDRAULIC OIL TEMPERATURE MONITOR LIGHTS UP IN RED WHILE ENGINE IS RUNNING .1671
HST OIL FILTER CLOGGING MONITOR LIGHTS UP IN RED WHILE ENGINE IS RUNNING .1672
ENGINE COOLANT TEMPERATURE GAUGE DOES NOT INDICATE CORRECT TEMPERATURE .1673
AdBlue/DEF LEVEL IS NOT DISPLAYED PROPERLY .1674
FUEL LEVEL GAUGE DOES NOT INDICATE CORRECT LEVEL .1677
HYDRAULIC OIL TEMPERATURE GAUGE DOES NOT INDICATE CORRECT TEMPERATURE 1680
OPERATION MODE DOES NOT CHANGE .1681
OPERATING CUSTOMIZE SWITCH DOES NOT DISPLAY CUSTOMIZE SCREEN .1682
MODIFYING SETTING ON CUSTOMIZE SCREEN DOES NOT CHANGE SETTING OF MACHINE .1683
SERVICE METER IS NOT DISPLAYED, WHILE STARTING SWITCH IS IN OFF POSITION .1684
SERVICE MODE CANNOT BE SELECTED 1685
WORK EQUIPMENT DOES NOT OPERATE 1686
FOOT HEATER DOES NOT OPERATE .1688
HORN DOES NOT SOUND 1694
HORN DOES NOT STOP SOUNDING 1696
BACKUP ALARM DOES NOT SOUND 1697
BACKUP ALARM DOES NOT STOP SOUNDING 1698
HEADLAMP DOES NOT LIGHT UP .1699
REAR LAMP DOES NOT LIGHT UP 1703
ALL WIPERS DO NOT OPERATE 1706
FRONT WIPER DOES NOT OPERATE .1708
REAR WIPER DOES NOT OPERATE 1710
LEFT DOOR WIPER DOES NOT OPERATE .1712
RIGHT DOOR WIPER DOES NOT OPERATE 1716
FRONT WASHER DOES NOT OPERATE 1720
REAR WASHER DOES NOT OPERATE .1722
LEFT DOOR WASHER DOES NOT OPERATE 1724
RIGHT DOOR WASHER DOES NOT OPERATE .1726
KOMTRAX SYSTEM DOES NOT OPERATE NORMALLY .1728
TROUBLESHOOTING FOR HYDRAULIC AND MECHANICAL SYSTEMS (H MODE) 1729
INFORMATION MENTIONED IN TROUBLESHOOTING TABLE (H MODE) 1729
FAILURE MODE AND CAUSE TABLE .1730
NEITHER R.H. NOR L.H. OF TRACKS CAN TRAVEL FORWARD OR REVERSE (NONE OF THE TRAVEL SYSTEMS OPERATE) .1736
EITHER R.H. OR L.H. OF TRACK CANNOT TRAVEL BOTH FORWARD AND REVERSE (ONE OF R.H. OR L.H. TRAVEL SYSTEMS CANNOT OPERATE) 1738
EITHER R.H. OR L.H. OF TRACK CANNOT TRAVEL ONE OF FORWARD OR REVERSE (ONLY ONE OF THE TRAVEL SYSTEMS CANNOT OPERATE IN ONE DIRECTION) 1740
TRAVEL SPEED OR POWER IS LOW .1742
SPEED RANGE DOES NOT CHANGE 1744
SHOCK IS LARGE WHEN MACHINE MOVES OFF OR STOPS .1745
MACHINE DEVIATES LARGELY .1746
MACHINE DRIFT ON A SLOPE IS LARGE 1749
ENGINE SPEED DROPS LARGELY OR ENGINE STOPS .1751
UNUSUAL NOISE IS HEARD FROM AROUND HST PUMP OR MOTOR .1753
HST OIL TEMPERATURE (HYDRAULIC OIL TEMPERATURE) RISES TOO HIGH .1755
ALL WORK EQUIPMENT DO NOT OPERATE 1757
ALL WORK EQUIPMENTS SPEED OR POWER IS LOW 1759
BLADE LIFT SPEED OR POWER IS LOW .1760
BLADE TILT SPEED OR POWER IS LOW .1762
BLADE ANGLE SPEED OR POWER IS LOW 1763
TIME LAG OF BLADE LIFT IS LARGE 1764
HYDRAULIC DRIFT OF LIFTED BLADE IS LARGE .1765
HYDRAULIC DRIFT OF TILTED BLADE IS LARGE .1766
UNUSUAL NOISE IS HEARD FROM AROUND WORK EQUIPMENT AND COOLING FAN PUMP OR CONTROL VALVE 1767
FAN SPEED IS ABNORMAL (TOO HIGH OR LOW, OR STATIONARY) .1768
UNUSUAL NOISE IS HEARD FROM AROUND FAN .1770
TROUBLESHOOTING OF ENGINE (S-MODE) .1771
INFORMATION MENTIONED IN TROUBLESHOOTING TABLE (S MODE) 1771
ENGINE DOES NOT CRANK WHEN STARTING SWITCH IS TURNED TO START POSITION .1772
ENGINE CRANKS BUT NO EXHAUST GAS COMES OUT .1773
FUEL IS BEING INJECTED BUT ENGINE DOES NOT START (MISFIRING: ENGINE CRANKS BUT DOES NOT START) .1774
ENGINE STARTABILITY IS POOR 1776
ENGINE DOES NOT PICK UP SMOOTHLY .1778
ENGINE STOPS DURING OPERATION 1780
ENGINE RUNS ROUGH OR IS UNSTABLE .1782
ENGINE LACKS POWER .1783
EXHAUST SMOKE IS BLACK .1785
ENGINE OIL CONSUMPTION IS EXCESSIVE 1787
OIL BECOMES CONTAMINATED QUICKLY .1788
FUEL CONSUMPTION IS EXCESSIVE 1789
OIL IS IN COOLANT (OR COOLANT SPURTS BACK OR COOLANT LEVEL GOES DOWN) 1790
OIL PRESSURE DROPS .1791
FUEL MIXES INTO ENGINE OIL .1793
WATER MIXES INTO ENGINE OIL (MILKY) 1794
COOLANT TEMPERATURE RISES TOO HIGH (OVERHEATING) .1795
UNUSUAL NOISE IS HEARD .1796
VIBRATION IS EXCESSIVE .1797
AIR CANNOT BE BLED FROM FUEL CIRCUIT .1798
ACTIVE REGENERATION IS EXECUTED FREQUENTLY .1799
ACTIVE REGENERATION TAKES TIME .1800
WHITE SMOKE IS EXHAUSTED DURING ACTIVE REGENERATION 1801
AdBlue/DEF CONSUMPTION IS EXCESSIVE 1802
THERE IS UNUSUAL SMELL (IRRITATING ODOR) .1804
FOREIGN MATERIALS ENTER AdBlue/DEF (AdBlue/DEF INCREASES) 1805
50 DISASSEMBLY AND ASSEMBLY 1807
CONTENTS .1808
RELATED INFORMATION ON DISASSEMBLY AND ASSEMBLY 1813
HOW TO READ THIS MANUAL 1813
COATING MATERIALS LIST .1815
SPECIAL TOOLS LIST .1819
SKETCHES OF SPECIAL TOOLS 1839
ENGINE AND COOLING SYSTEM 1852
REMOVE AND INSTALL SUPPLY PUMP ASSEMBLY 1852
METHOD FOR REMOVING SUPPLY PUMP ASSEMBLY .1852
METHOD FOR INSTALLING SUPPLY PUMP ASSEMBLY .1862
REMOVE AND INSTALL INJECTOR ASSEMBLY .1872
METHOD FOR REMOVING INJECTOR ASSEMBLY 1872
METHOD FOR INSTALLING INJECTOR ASSEMBLY 1883
REMOVE AND INSTALL CYLINDER HEAD ASSEMBLY 1897
METHOD FOR REMOVING CYLINDER HEAD ASSEMBLY .1897
METHOD FOR INSTALLING CYLINDER HEAD ASSEMBLY .1916
REMOVE AND INSTALL EGR VALVE ASSEMBLY 1940
METHOD FOR REMOVING EGR VALVE ASSEMBLY .1940
METHOD FOR INSTALLING EGR VALVE ASSEMBLY .1943
REMOVE AND INSTALL EGR COOLER ASSEMBLY .1947
METHOD FOR REMOVING EGR COOLER ASSEMBLY 1947
METHOD FOR INSTALLING EGR COOLER ASSEMBLY 1951
REMOVE AND INSTALL STARTING MOTOR ASSEMBLY .1955
METHOD FOR REMOVING STARTING MOTOR ASSEMBLY 1955
METHOD FOR INSTALLING STARTING MOTOR ASSEMBLY 1957
REMOVE AND INSTALL AIR CONDITIONER COMPRESSOR BELT .1960
METHOD FOR REMOVING AIR CONDITIONER COMPRESSOR BELT 1960
METHOD FOR INSTALLING AIR CONDITIONER COMPRESSOR BELT 1964
REMOVE AND INSTALL ALTERNATOR BELT .1969
METHOD FOR REMOVING ALTERNATOR BELT 1969
METHOD FOR INSTALLING ALTERNATOR BELT 1972
REMOVE AND INSTALL AUTOMATIC TENSIONER .1974
METHOD FOR REMOVING AUTOMATIC TENSIONER 1974
METHOD FOR INSTALLING AUTOMATIC TENSIONER 1975
REMOVE AND INSTALL RADIATOR ASSEMBLY .1977
METHOD FOR REMOVING RADIATOR ASSEMBLY 1978
METHOD FOR INSTALLING RADIATOR ASSEMBLY 1986
REMOVE AND INSTALL HYDRAULIC OIL COOLER ASSEMBLY .1994
METHOD FOR REMOVING HYDRAULIC OIL COOLER ASSEMBLY 1995
METHOD FOR INSTALLING HYDRAULIC OIL COOLER ASSEMBLY 2000
REMOVE AND INSTALL AFTERCOOLER ASSEMBLY 2005
METHOD FOR REMOVING AFTERCOOLER ASSEMBLY .2006
METHOD FOR INSTALLING AFTERCOOLER ASSEMBLY .2012
REMOVE AND INSTALL COOLING FAN DRIVE ASSEMBLY 2019
METHOD FOR REMOVING COOLING FAN DRIVE ASSEMBLY .2019
METHOD FOR INSTALLING COOLING FAN DRIVE ASSEMBLY .2024
REMOVE AND INSTALL COOLING FAN MOTOR ASSEMBLY 2028
METHOD FOR REMOVING COOLING FAN MOTOR ASSEMBLY .2028
METHOD FOR INSTALLING COOLING FAN MOTOR ASSEMBLY .2031
REMOVE AND INSTALL ENGINE, HST PUMP ASSEMBLY .2034
METHOD FOR REMOVING ENGINE, HST PUMP ASSEMBLY 2034
METHOD FOR INSTALLING ENGINE, HST PUMP ASSEMBLY 2045
REMOVE AND INSTALL ENGINE FRONT OIL SEAL .2057
METHOD FOR REMOVING ENGINE FRONT OIL SEAL 2057
METHOD FOR INSTALLING ENGINE FRONT OIL SEAL 2059
REMOVE AND INSTALL ENGINE REAR OIL SEAL 2062
METHOD FOR REMOVING ENGINE REAR OIL SEAL .2062
METHOD FOR INSTALLING ENGINE REAR OIL SEAL .2063
REMOVE AND INSTALL ENGINE HOOD ASSEMBLY 2066
METHOD FOR REMOVING ENGINE HOOD ASSEMBLY .2066
METHOD FOR INSTALLING ENGINE HOOD ASSEMBLY .2070
REMOVE AND INSTALL KDOC ASSEMBLY .2074
METHOD FOR REMOVING KDOC ASSEMBLY 2074
METHOD FOR INSTALLING KDOC ASSEMBLY 2080
REMOVE AND INSTALL KDOC AND SCR ASSEMBLY .2087
METHOD FOR REMOVING KDOC AND SCR ASSEMBLY 2088
METHOD FOR INSTALLING KDOC AND SCR ASSEMBLY 2094
REMOVE AND INSTALL BELLOWS PIPE ASSEMBLY .2102
METHOD FOR REMOVING BELLOWS PIPE ASSEMBLY 2102
METHOD FOR INSTALLING BELLOWS PIPE ASSEMBLY 2105
REMOVE AND INSTALL FUEL TANK ASSEMBLY 2109
METHOD FOR REMOVING FUEL TANK ASSEMBLY .2110
METHOD FOR INSTALLING FUEL TANK ASSEMBLY .2117
REMOVE AND INSTALL AdBlue/DEF TANK ASSEMBLY 2124
METHOD FOR REMOVING AdBlue/DEF TANK ASSEMBLY .2125
METHOD FOR INSTALLING AdBlue/DEF TANK ASSEMBLY .2135
REMOVE AND INSTALL AdBlue/DEF TANK SENSOR FLANGE ASSEMBLY 2144
METHOD FOR REMOVING AdBlue/DEF TANK SENSOR FLANGE ASSEMBLY .2144
METHOD FOR INSTALLING AdBlue/DEF TANK SENSOR FLANGE ASSEMBLY .2146
REMOVE AND INSTALL AdBlue/DEF TANK SENSOR 2150
METHOD FOR REMOVING AdBlue/DEF TANK SENSOR .2150
METHOD FOR INSTALLING AdBlue/DEF TANK SENSOR .2151
REMOVE AND INSTALL AdBlue/DEF TANK STRAINER 2158
METHOD FOR REMOVING AdBlue/DEF TANK STRAINER .2158
METHOD FOR INSTALLING AdBlue/DEF TANK STRAINER .2159
REMOVE AND INSTALL AdBlue/DEF TANK FILLER PORT FILTER 2160
METHOD FOR REMOVING AdBlue/DEF TANK FILLER PORT FILTER .2160
METHOD FOR INSTALLING AdBlue/DEF TANK FILLER PORT FILTER .2161
REMOVE AND INSTALL SCR ASSEMBLY 2164
METHOD FOR REMOVING SCR ASSEMBLY .2164
METHOD FOR INSTALLING SCR ASSEMBLY .2167
REMOVE AND INSTALL KCCV ASSEMBLY .2170
METHOD FOR REMOVING KCCV ASSEMBLY 2170
METHOD FOR INSTALLING KCCV ASSEMBLY 2171
REMOVE AND INSTALL AdBlue/DEF MIXING TUBE 2174
METHOD FOR REMOVING AdBlue/DEF MIXING TUBE .2174
METHOD FOR INSTALLING AdBlue/DEF MIXING TUBE .2178
REMOVE AND INSTALL AdBlue/DEF INJECTOR .2183
METHOD FOR REMOVING AdBlue/DEF INJECTOR 2183
METHOD FOR INSTALLING AdBlue/DEF INJECTOR 2188
REMOVE AND INSTALL AdBlue/DEF PUMP .2193
METHOD FOR REMOVING AdBlue/DEF PUMP 2193
METHOD FOR INSTALLING AdBlue/DEF PUMP 2197
REMOVE AND INSTALL AdBlue/DEF HOSE .2201
METHOD FOR REMOVING AdBlue/DEF HOSE 2203
METHOD FOR INSTALLING AdBlue/DEF HOSE 2222
REMOVE AND INSTALL AIR CLEANER ASSEMBLY 2243
METHOD FOR REMOVING AIR CLEANER ASSEMBLY .2243
METHOD FOR INSTALLING AIR CLEANER ASSEMBLY .2245
REMOVE AND INSTALL AIR CONDITIONER COMPRESSOR ASSEMBLY .2248
METHOD FOR REMOVING AIR CONDITIONER COMPRESSOR ASSEMBLY 2248
METHOD FOR INSTALLING AIR CONDITIONER COMPRESSOR ASSEMBLY 2252
REMOVE AND INSTALL AIR CONDITIONER CONDENSER ASSEMBLY 2257
METHOD FOR REMOVING AIR CONDITIONER CONDENSER ASSEMBLY .2257
METHOD FOR INSTALLING AIR CONDITIONER CONDENSER ASSEMBLY .2261
POWER TRAIN 2265
DISASSEMBLE AND ASSEMBLE FINAL DRIVE ASSEMBLY 2265
METHOD FOR DISASSEMBLING FINAL DRIVE ASSEMBLY 2266
METHOD FOR ASSEMBLING FINAL DRIVE ASSEMBLY .2270
UNDERCARRIAGE AND FRAME 2279
REMOVE AND INSTALL TRACK FRAME ASSEMBLY 2279
REMOVE TRACK FRAME ASSEMBLY 2279
INSTALL TRACK FRAME ASSEMBLY .2284
REMOVE AND INSTALL IDLER ASSEMBLY 2289
METHOD FOR REMOVING IDLER ASSEMBLY .2289
METHOD FOR INSTALLING IDLER ASSEMBLY .2291
DISASSEMBLE AND ASSEMBLE IDLER ASSEMBLY 2294
METHOD FOR DISASSEMBLING IDLER ASSEMBLY 2294
METHOD FOR ASSEMBLING IDLER ASSEMBLY .2296
REMOVE AND INSTALL RECOIL SPRING ASSEMBLY 2301
METHOD FOR REMOVING RECOIL SPRING ASSEMBLY .2301
METHOD FOR INSTALLING RECOIL SPRING ASSEMBLY .2301
DISASSEMBLE AND ASSEMBLE RECOIL SPRING ASSEMBLY 2302
METHOD FOR DISASSEMBLING AND ASSEMBLING RECOIL SPRING ASSEMBLY .2302
METHOD FOR ASSEMBLING RECOIL SPRING ASSEMBLY .2305
REMOVE AND INSTALL TRACK ROLLER ASSEMBLY .2308
METHOD FOR REMOVING TRACK ROLLER ASSEMBLY 2308
METHOD FOR INSTALLING TRACK ROLLER ASSEMBLY 2310
DISASSEMBLE AND ASSEMBLE TRACK ROLLER ASSEMBLY .2313
METHOD FOR DISASSEMBLING TRACK ROLLER ASSEMBLY .2313
METHOD FOR ASSEMBLING TRACK ROLLER ASSEMBLY 2314
REMOVE AND INSTALL CARRIER ROLLER ASSEMBLY .2318
METHOD FOR REMOVING CARRIER ROLLER ASSEMBLY 2318
METHOD FOR INSTALLING CARRIER ROLLER ASSEMBLY 2319
DISASSEMBLE AND ASSEMBLE CARRIER ROLLER ASSEMBLY .2321
METHOD FOR DISASSEMBLING CARRIER ROLLER ASSEMBLY .2321
METHOD FOR ASSEMBLING CARRIER ROLLER ASSEMBLY 2322
REMOVE AND INSTALL PIVOT SHAFT ASSEMBLY 2325
METHOD FOR REMOVING PIVOT SHAFT ASSEMBLY .2325
METHOD FOR INSTALLING PIVOT SHAFT ASSEMBLY .2326
SEPARATE AND CONNECT TRACK ASSEMBLY 2328
METHOD FOR CHECKING BEFORE SEPARATING TRACK ASSEMBLY .2328
METHOD FOR SEPARATING TRACK ASSEMBLY (NORMAL) 2329
METHOD FOR SEPARATING TRACK ASSEMBLY (WHEN TRACK FRAME HAS INTERNAL DEFECT) 2330
METHOD FOR CONNECTING TRACK ASSEMBLY .2331
SEPARATE AND CONNECT PLUS TYPE TRACK ASSEMBLY 2334
METHOD FOR SEPARATING PLUS TYPE TRACK ASSEMBLY .2334
METHOD FOR CONNECTING PLUS TYPE TRACK ASSEMBLY .2334
DISASSEMBLE AND ASSEMBLE TRACK ASSEMBLY GENERALLY 2336
METHOD FOR DISASSEMBLING TRACK ASSEMBLY GENERALLY 2336
METHOD FOR ASSEMBLING TRACK ASSEMBLY GENERALLY .2341
DISASSEMBLE AND ASSEMBLE PLUS TYPE TRACK ASSEMBLY GENERALLY 2354
METHOD FOR DISASSEMBLING PLUS TYPE TRACK ASSEMBLY GENERALLY 2355
METHOD FOR ASSEMBLING PLUS TYPE TRACK ASSEMBLY GENERALLY .2356
DISASSEMBLE AND ASSEMBLE ONE LINK OF TRACK SHOE ASSEMBLY ON THE FIELD 2365
METHOD FOR DISASSEMBLING ONE LINK OF TRACK SHOE ASSEMBLY ON THE FIELD 2366
METHOD FOR ASSEMBLING ONE LINK OF TRACK SHOE ASSEMBLY ON THE FIELD .2367
DISASSEMBLE AND ASSEMBLE ONE LINK OF PLUS TYPE TRACK SHOE ASSEMBLY ON THE FIELD 2374
METHOD FOR DISASSEMBLING ONE LINK OF PLUS TYPE TRACK SHOE ASSEMBLY ON THE FIELD 2375
METHOD FOR ASSEMBLING ONE LINK OF PLUS TYPE TRACK SHOE ASSEMBLY ON THE FIELD .2377
REMOVE AND INSTALL EQUALIZER BAR ASSEMBLY 2381
METHOD FOR REMOVING EQUALIZER BAR ASSEMBLY .2381
METHOD FOR INSTALLING EQUALIZER BAR ASSEMBLY .2383
REMOVE AND INSTALL EQUALIZER BAR SIDE BUSHINGS .2386
METHOD FOR REMOVING EQUALIZER BAR SIDE BUSHINGS 2386
METHOD FOR INSTALLING EQUALIZER BAR SIDE BUSHINGS 2387
REMOVE AND INSTALL SEGMENT TEETH .2388
METHOD FOR REMOVING SEGMENT TEETH 2388
METHOD FOR INSTALLING SEGMENT TEETH 2390
HYDRAULIC SYSTEM .2392
REMOVE AND INSTALL HYDRAULIC TANK ASSEMBLY .2392
METHOD FOR REMOVING HYDRAULIC TANK ASSEMBLY 2393
METHOD FOR INSTALLING HYDRAULIC TANK ASSEMBLY 2399
REMOVE AND INSTALL CONTROL VALVE ASSEMBLY 2408
METHOD FOR REMOVING CONTROL VALVE ASSEMBLY .2408
METHOD FOR INSTALLING CONTROL VALVE ASSEMBLY .2412
WORK EQUIPMENT . 0
REMOVE AND INSTALL BLADE ASSEMBLY (Serial No.: 15001 to 15600) . 0
METHOD FOR REMOVING BLADE ASSEMBLY (Serial No.: 15001 to 15600) 0
METHOD FOR INSTALLING BLADE ASSEMBLY (Serial No.: 15001 to 15600) 0
REMOVE AND INSTALL BLADE ASSEMBLY (Serial No.: 15601 and up) . 0
REMOVE BLADE ASSEMBLY (Serial No.: 15601 and up) . 0
INSTALL BLADE ASSEMBLY (Serial No.: 15601 and up) 0
REMOVE AND INSTALL BLADE LIFT CYLINDER ASSEMBLY 2433
REMOVE BLADE LIFT CYLINDER ASSEMBLY 2433
INSTALL BLADE LIFT CYLINDER ASSEMBLY .2435
REMOVE AND INSTALL BLADE TILT CYLINDER ASSEMBLY (Serial No.: 15001 to 15600) . 0
METHOD FOR REMOVING BLADE TILT CYLINDER ASSEMBLY (Serial No.: 15001 to 15600) 0
METHOD FOR INSTALLING BLADE TILT CYLINDER ASSEMBLY (Serial No.: 15001 to 15600) 0
REMOVE AND INSTALL BLADE TILT CYLINDER ASSEMBLY (Serial No.: 15601 and up) . 0
REMOVE BLADE TILT CYLINDER ASSEMBLY (Serial No.: 15601 and up) . 0
INSTALL BLADE TILT CYLINDER ASSEMBLY (Serial No.: 15601 and up) 0
REMOVE AND INSTALL BLADE ANGLE CYLINDER ASSEMBLY .2443
REMOVE BLADE ANGLE CYLINDER ASSEMBLY .2443
INSTALL BLADE ANGLE CYLINDER ASSEMBLY 2445
REMOVE AND INSTALL U-FRAME ASSEMBLY (Serial No.: 15001 to 15600) . 0
METHOD FOR REMOVING U-FRAME ASSEMBLY (Serial No.: 15001 to 15600) 0
METHOD FOR INSTALLING U-FRAME ASSEMBLY (Serial No.: 15001 to 15600) 0
REMOVE AND INSTALL U-FRAME ASSEMBLY (Serial No.: 15601 and up) . 0
REMOVE U-FRAME ASSEMBLY (Serial No.: 15601 and up) . 0
INSTALL U-FRAME ASSEMBLY (Serial No.: 15601 and up) 0
CAB AND ITS ATTACHMENTS 2460
REMOVE AND INSTALL OPERATOR’S CAB ASSEMBLY .2460
REMOVE OPERATOR CAB ASSEMBLY .2461
INSTALL OPERATOR CAB ASSEMBLY 2468
REMOVE AND INSTALL OPERATOR’S CAB GLASS (ADHERED GLASS) 2476
METHOD FOR REMOVING OPERATOR’S CAB GLASS (ADHERED GLASS) .2478
METHOD FOR INSTALLING OPERATOR’S CAB GLASS (ADHERED GLASS) .2478
REMOVE AND INSTALL AIR CONDITIONER UNIT ASSEMBLY .2484
METHOD FOR REMOVING AIR CONDITIONER UNIT ASSEMBLY 2484
METHOD FOR INSTALLING AIR CONDITIONER UNIT ASSEMBLY 2490
REMOVE AND INSTALL RECEIVER DRIER 2497
METHOD FOR REMOVING RECEIVER DRIER .2497
METHOD FOR INSTALLING RECEIVER DRIER .2498
REMOVE AND INSTALL OPERATOR’S SEAT .2501
METHOD FOR REMOVING OPERATOR’S SEAT 2501
METHOD FOR INSTALLING OPERATOR’S SEAT 2502
REMOVE AND INSTALL SEAT BELT .2503
METHOD FOR REMOVING SEAT BELT 2503
METHOD FOR INSTALLING SEAT BELT 2503
REMOVE AND INSTALL FOOT HEATER ASSEMBLY 2505
METHOD FOR REMOVING FOOT HEATER ASSEMBLY .2505
METHOD FOR INSTALLING FOOT HEATER ASSEMBLY .2507
DISASSEMBLE AND ASSEMBLE FOOT HEATER ASSEMBLY 2510
METHOD FOR DISASSEMBLING FOOT HEATER ASSEMBLY 2510
METHOD FOR ASSEMBLING FOOT HEATER ASSEMBLY .2511
ELECTRICAL SYSTEM 2512
REMOVE AND INSTALL ENGINE CONTROLLER ASSEMBLY 2512
METHOD FOR REMOVING ENGINE CONTROLLER ASSEMBLY .2512
METHOD FOR INSTALLING ENGINE CONTROLLER ASSEMBLY .2515
REMOVE AND INSTALL HST CONTROLLER ASSEMBLY .2519
METHOD FOR REMOVING HST CONTROLLER ASSEMBLY 2519
METHOD FOR INSTALLING HST CONTROLLER ASSEMBLY 2520
REMOVE AND INSTALL MACHINE MONITOR ASSEMBLY 2521
REMOVE MACHINE MONITOR ASSEMBLY 2521
INSTALL MACHINE MONITOR ASSEMBLY .2522
REMOVE AND INSTALL MASS AIR FLOW AND TEMPERATURE SENSOR 2524
METHOD FOR REMOVING MASS AIR FLOW AND TEMPERATURE SENSOR .2524
METHOD FOR INSTALLING MASS AIR FLOW AND TEMPERATURE SENSOR .2526
REMOVE AND INSTALL KCCV CRANKCASE PRESSURE SENSOR 2528
METHOD FOR REMOVING KCCV CRANKCASE PRESSURE SENSOR .2528
METHOD FOR INSTALLING KCCV CRANKCASE PRESSURE SENSOR .2530
REMOVE AND INSTALL GATEWAY FUNCTION CONTROLLER ASSEMBLY 2532
REMOVE GATEWAY FUNCTION CONTROLLER ASSEMBLY 2532
INSTALL GATEWAY FUNCTION CONTROLLER ASSEMBLY .2533
REMOVE AND INSTALL COMMUNICATION TERMINAL 2534
REMOVE COMMUNICATION TERMINAL 2534
INSTALL COMMUNICATION TERMINAL .2537
60 MAINTENANCE STANDARD 2541
CONTENTS . 0
ENGINE AND COOLING SYSTEM 2543
MAINTENANCE STANDARD OF ENGINE MOUNT .2543
MAINTENANCE STANDARD OF DAMPER (Serial No.: 15001 to 15600) 0
MAINTENANCE STANDARD OF DAMPER (Serial No.: 15601 and up) 0
MAINTENANCE STANDARD OF COOLING SYSTEM .2546
MAINTENANCE STANDARD OF COOLING FAN MOTOR 2548
MAINTENANCE STANDARD OF HYDRAULIC OIL COOLER BYPASS AND HST CHARGE SAFETY VALVE 2550
POWER TRAIN 2551
MAINTENANCE STANDARD OF HST PUMP .2551
MAINTENANCE STANDARD OF EPC VALVE OF HST PUMP 2553
MAINTENANCE STANDARD OF TOW RECEIVING VALVE OF HST PUMP 2554
MAINTENANCE STANDARD OF HST CHARGE PUMP 2555
MAINTENANCE STANDARD OF HST MOTOR 2557
MAINTENANCE STANDARD OF FINAL DRIVE 2559
MAINTENANCE STANDARD OF SPROCKET FOR PLUS TYPE TRACK SHOE 2561
MAINTENANCE STANDARD OF SPROCKET TOOTH PROFILE FULL-SCALE DRAWING FOR PLUS TYPE TRACK SHOE .2562
UNDERCARRIAGE AND FRAME 2563
MAINTENANCE STANDARD OF SUSPENSION .2563
MAINTENANCE STANDARD OF TRACK FRAME AND IDLER CUSHION 2566
MAINTENANCE STANDARD OF IDLER 2569
MAINTENANCE STANDARD OF TRACK ROLLER FOR PLUS TYPE TRACK SHOES (SINGLE FLANGE TYPE) 2571
MAINTENANCE STANDARD OF TRACK ROLLER FOR PLUS TYPE TRACK SHOES (DOUBLE FLANGE TYPE) 2572
MAINTENANCE STANDARD OF CARRIER ROLLER FOR PLUS TYPE TRACK SHOE 2574
MAINTENANCE STANDARD OF PLUS TYPE TRACK SHOE .2575
MAINTENANCE STANDARD OF SINGLE SHOE 2577
HYDRAULIC SYSTEM .2578
MAINTENANCE STANDARD OF HYDRAULIC TANK .2578
MAINTENANCE STANDARD OF WORK EQUIPMENT AND COOLING FAN PUMP 2579
MAINTENANCE STANDARD OF SERVO VALVE OF WORK EQUIPMENT AND COOLING FAN PUMP .2580
MAINTENANCE STANDARD OF CONTROL VALVE 2582
MAINTENANCE STANDARD OF RIPPER PPC VALVE .2588
MAINTENANCE STANDARD OF 5-PORT VALVE OF EPC AND SOLENOID .2590
MAINTENANCE STANDARD OF EPC VALVE 2591
MAINTENANCE STANDARD OF QUICK DROP VALVE .2592
WORK EQUIPMENT . 0
MAINTENANCE STANDARD OF FRONT WORK EQUIPMENT(Serial No.: 15001 to 15600) . 0
MAINTENANCE STANDARD OF FRONT WORK EQUIPMENT (Serial No.: 15601 and up) 0
MAINTENANCE STANDARD OF CUTTING EDGE AND END BIT .2600
MAINTENANCE STANDARD OF BLADE LIFT CYLINDER 2601
MAINTENANCE STANDARD OF BLADE TILT CYLINDER 2602
MAINTENANCE STANDARD OF BLADE ANGLE CYLINDER .2603
MAINTENANCE STANDARD OF FIXED MULTI-SHANK RIPPER .2604
MAINTENANCE STANDARD OF RIPPER LIFT CYLINDER .2606
CAB AND ITS ATTACHMENTS 2607
MAINTENANCE STANDARD OF CAB MOUNT 2607
ELECTRICAL SYSTEM 2609
MAINTENANCE STANDARD OF ELECTRIC STEERING CONTROL LEVER 2609
80 APPENDIX 2611
CONTENTS .2612
AIR CONDITIONER SYSTEM .2613
PRECAUTIONS FOR REFRIGERANT 2613
AIR CONDITIONER COMPONENT 2614
SPECIFICATIONS OF AIR CONDITIONER 2617
CONFIGURATION AND FUNCTION OF REFRIGERATION CYCLE 2618
OUTLINE OF REFRIGERATION CYCLE .2619
COMPONENT PARTS OF AIR CONDITIONER SYSTEM 2621
AIR CONDITIONER UNIT .2621
CONFIGURATION DIAGRAM OF AIR CONDITIONER UNIT 2621
FUNCTION OF AIR CONDITIONER UNIT .2622
COMPONENT PARTS OF AIR CONDITIONER UNIT 2623
FUNCTION OF EVAPORATOR AS AIR CONDITIONER UNIT COMPONENT .2623
FUNCTION OF HEATER CORE AS AIR CONDITIONER UNIT COMPONENT 2623
FUNCTION OF THERMISTOR AS AIR CONDITIONER UNIT COMPONENT .2623
STRUCTURE OF EXPANSION VALVE AS AIR CONDITIONER UNIT COMPONENT .2624
FUNCTION OF EXPANSION VALVE AS AIR CONDITIONER UNIT COMPONENT 2624
OPERATE EXPANSION VALVE AS AIR CONDITIONER UNIT COMPONENT 2624
FUNCTION OF DUAL PRESSURE SWITCH .2625
FUNCTION OF PRESSURE SWITCH 2625
COMPRESSOR .2626
STRUCTURE OF COMPRESSOR 2626
SPECIFICATIONS OF COMPRESSOR .2626
FUNCTION OF COMPRESSOR .2626
CONDENSER 2627
STRUCTURE OF CONDENSER .2627
SPECIFICATIONS OF CONDENSER 2627
FUNCTION OF CONDENSER 2628
RECEIVER DRIER .2629
STRUCTURE OF RECEIVER DRIER 2629
SPECIFICATIONS OF RECEIVER DRIER .2629
FUNCTION OF RECEIVER DRIER .2629
EXPLANATION OF PROCEDURE FOR TESTING AND TROUBLESHOOTING OF AIR CONDITIONER 2631
CIRCUIT DIAGRAM OF AIR CONDITIONER .2634
AIR CONDITIONER SYSTEM DIAGRAM .2635
CONTROL FUNCTION OF AIR CONDITIONER 2636
INSTALLATION LOCATIONS OF AIR CONDITIONER PARTS AND ARRANGEMENT OF CONNECTORS 2637
TEST RELAYS 2641
METHOD FOR TESTING RELAYS 2641
AIR CONDITIONER TROUBLESHOOTING CHART 1 2643
AIR CONDITIONER TROUBLESHOOTING CHART 2 2644
INFORMATION DESCRIBED IN TROUBLESHOOTING TABLE .2647
TROUBLESHOOTING FOR CONDENSER FAN 2649
TROUBLESHOOTING FOR COMPRESSOR AND REFRIGERANT SYSTEM (AIR IS NOT COOLED) 2652
TROUBLESHOOTING FOR BLOWER MOTOR SYSTEM (NO AIR COMES OUT OR AIR FLOW IS ABNORMAL) .2656
TROUBLESHOOTING FOR TEMPERATURE CONTROL FUNCTION .2659
TROUBLESHOOTING USING GAUGE PRESSURE .2663
CONNECTION OF SERVICE TOOL .2665
METHOD FOR CONNECTING SERVICE TOOL .2666
PRECAUTIONS FOR DISCONNECTING AND CONNECTING HOSES AND TUBES IN AIR CONDITIONER PIPINGS 2667
HANDLE COMPRESSOR OIL 2669
90 CIRCUIT DIAGRAMS 2671
CONTENTS .2672
HYDRAULIC CIRCUIT DIAGRAM 2673
SYMBOLS USED IN HYDRAULIC CIRCUIT DIAGRAM 2673
HYDRAULIC CIRCUIT DIAGRAM 2677
ELECTRICAL CIRCUIT DIAGRAM .2679
SYMBOLS USED IN ELECTRICAL CIRCUIT DIAGRAM .2679
ELECTRICAL CIRCUIT DIAGRAM (1/16) 2683
ELECTRICAL CIRCUIT DIAGRAM (2/16) 2685
ELECTRICAL CIRCUIT DIAGRAM (3/16) 2687
ELECTRICAL CIRCUIT DIAGRAM (4/16) 2689
ELECTRICAL CIRCUIT DIAGRAM (5/16) 2691
ELECTRICAL CIRCUIT DIAGRAM (6/16) 2693
ELECTRICAL CIRCUIT DIAGRAM (7/16) 2695
ELECTRICAL CIRCUIT DIAGRAM (8/16) 2697
ELECTRICAL CIRCUIT DIAGRAM (9/16) 2699
ELECTRICAL CIRCUIT DIAGRAM (10/16) .2701
ELECTRICAL CIRCUIT DIAGRAM (11/16) .2703
ELECTRICAL CIRCUIT DIAGRAM (12/16) .2705
ELECTRICAL CIRCUIT DIAGRAM (13/16) .2707
ELECTRICAL CIRCUIT DIAGRAM (14/16) .2709
ELECTRICAL CIRCUIT DIAGRAM (15/16) .2711
ELECTRICAL CIRCUIT DIAGRAM (16/16) .2713
INDEX .2715

DESCRIPTION:

Komatsu D51EX-24,D51PX-24 Bulldozer Shop Manual KEAM683005 – PDF DOWNLOAD

SERIAL NUMBERS

• D51EX-B25001 and up
• D51PX-B25001 and up

FOREWORD, SAFETY, BASIC INFORMATION
HOW TO READ THE SHOP MANUAL
• Some of the attachments and options described in this shop manual may not be available in some areas. If
they are required, consult your Komatsu distributor.
• The materials and specifications are subject to change without notice.
• Shop Manuals are available for “machine part” and “engine part”. For the engine unit, see the shop manual
for the machine which has the same engine model.
• Actual machine may differ from the images which are contained in this manual. A typical model is shown in
the illustrations of this shop manual.
Composition of the shop manual
This shop manual contains technical information necessary to perform services in workshops. It is divided into
the following chapters for the ease of use.
00 INDEX AND FOREWORD
This section describes the index, foreword, safety, and basic information.
01 SPECIFICATIONS
This section describes the specifications of the machine.
10 STRUCTURE AND FUNCTION
This section describes the structure and operation of each component with respect to each system. “STRUCTURE
AND FUNCTION” is helpful in not only understanding the structure of each component but performing
troubleshooting.
20 STANDARD VALUE TABLE
This section describes the standard values for new machine and failure criteria for testing and adjusting, and
troubleshooting. Use the standard values table to check the standard values for testing and adjusting, and judge
troubles in troubleshooting.
30 TESTING AND ADJUSTING
This section describes the measuring tools and measuring methods for testing and adjusting as well as the adjusting
method of each part. The standard values and repair limit for TESTING AND ADJUSTING are described
in “STANDARD VALUE TABLE”.
40 TROUBLESHOOTING
This section describes troubleshooting of failure part and its remedy method on the occurrence of the failure.
Descriptions of troubleshooting are sorted by failure mode.
50 DISASSEMBLY AND ASSEMBLY
This section describes the special tools, work procedures, and safety precautions necessary for removal, installation,
disassembly, and assembly of the components and parts. In addition, tightening torques, quantity, and
weight of the coating materials, lubricants, and coolant necessary to these works are shown.
60 MAINTENANCE STANDARD
This section describes the maintenance standard value of each component. The maintenance standard shows
the criteria and remedies for disassembly and assembly.
80 THE OTHER INFORMATION
This section describes the structure and function, testing and adjusting, and troubleshooting for all of the other
components or equipment which cannot be separately classified in the appendix.
90 Circuit diagrams
This section describes hydraulic circuit diagrams and electrical circuit diagrams.

G.B 30/12/24