Komatsu D51EX-24,D51PX-24 Bulldozer Shop Manual KEBM661710 PDF

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Komatsu D51EX-24,D51PX-24 Bulldozer Shop Manual KEBM661710 –  PDF DOWNLOAD

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Komatsu D51EX-24,D51PX-24 Bulldozer Shop Manual KEBM661710 –  PDF DOWNLOAD

Language : English
Pages : 2848
Downloadable : Yes
File Type : PDF

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TABLE OF CONTENTS:

Komatsu D51EX-24,D51PX-24 Bulldozer Shop Manual KEBM661710 –  PDF DOWNLOAD

SERIAL NUMBERS

• D51EX-B20001      and up
• D51PX-B20001       and up

COVER . 0
00 INDEX AND FOREWORD 3
INDEX 4
ABBREVIATION LIST 21
FOREWORD, SAFETY, BASIC INFORMATION 27
HOW TO READ THE SHOP MANUAL 27
SAFETY NOTICE FOR OPERATION 29
PRECAUTIONS TO PREVENT FIRE 37
ACTIONS IF FIRE OCCURS . 39
PRECAUTIONS FOR DISPOSING OF WASTE MATERIALS . 40
ACTIONS TAKEN TO MEET EXHAUST GAS REGULATIONS 41
PRECAUTIONS FOR DEF 42
GENERAL CHARACTER AND PRECAUTIONS FOR HANDLING . 42
PRECAUTIONS FOR ADDING . 42
PRECAUTIONS FOR STORING 42
PRECAUTIONS FOR FIRE HAZARD AND LEAKAGE 42
THE OTHER PRECAUTIONS 42
STORE AdBlue/DEF . 43
PRECAUTIONS FOR HANDLING HYDRAULIC EQUIPMENT . 44
PRECAUTIONS FOR DISCONNECTION AND CONNECTION OF PIPINGS 47
PRECAUTIONS FOR HANDLING ELECTRICAL EQUIPMENT 54
PRECAUTIONS FOR HANDLING FUEL SYSTEM EQUIPMENT . 56
PRECAUTIONS FOR HANDLING INTAKE SYSTEM EQUIPMENT . 57
PRACTICAL USE OF KOMTRAX . 58
DISCONNECT AND CONNECT PUSH-PULL TYPE COUPLER 59
METHOD FOR DISCONNECTING AND CONNECTING TYPE 1 PUSH-PULL TYPE COUPLER 59
METHOD FOR DISCONNECTING AND CONNECTING TYPE 2 PUSH-PULL TYPE COUPLER 60
METHOD FOR DISCONNECTING AND CONNECTING TYPE 3 PUSH-PULL TYPE COUPLER 61
PRECAUTIONS FOR DISCONNECTION AND CONNECTION OF CONNECTORS . 63
METHOD FOR DISCONNECTING AND CONNECTING DEUTSCH CONNECTOR 67
METHOD FOR DISCONNECTING AND CONNECTING SLIDE LOCK TYPE CONNECTOR 68
METHOD FOR DISCONNECTING AND CONNECTING CONNECTOR WITH LOCK TO PULL 70
METHOD FOR DISCONNECTING AND CONNECTING CONNECTOR WITH LOCK TO PUSH 71
METHOD FOR DISCONNECTING AND CONNECTING CONNECTOR WITH HOUSING TO ROTATE . 73
HOW TO READ ELECTRICAL WIRE CODE . 74
EXPLANATION OF TERMS FOR MAINTENANCE STANDARD 78
STANDARD TIGHTENING TORQUE TABLE . 81
CONVERSION TABLE . 88
01 SPECIFICATIONS 93
CONTENTS . 94
ABBREVIATION LIST 95
SPECIFICATIONS . 101
SPECIFICATION DRAWING 101
SPECIFICATION DRAWING: D51EX-24 101
SPECIFICATION DRAWING: D51PX-24 103
SPECIFICATIONS . 105
SPECIFICATIONS: D51EX-24 . 105
SPECIFICATIONS: D51PX-24 . 110
WEIGHT TABLE . 115
WEIGHT TABLE: D51EX-24 . 115
WEIGHT TABLE: D51PX-24 . 117
FUEL, COOLANT, LUBRICANTS (FOR NORTH AMERICA) 119
METHOD FOR USING FUEL, COOLANT AND LUBRICANTS ACCORDING TO AMBIENT TEMPERATURE . 119
FUEL, COOLANT, LUBRICANTS (FOR EUROPEAN UNION) . 121
METHOD FOR USING FUEL, COOLANT AND LUBRICANTS ACCORDING TO AMBIENT TEMPERATURE . 121
10 STRUCTURE AND FUNCTION 123
CONTENTS . 124
ABBREVIATION LIST 127
UREA SCR SYSTEM 133
LAYOUT DRAWING OF UREA SCR SYSTEM 133
UREA SCR SYSTEM DIAGRAM 135
FUNCTION OF UREA SCR SYSTEM 136
FUNCTION OF AdBlue/DEF SYSTEM 136
INDUCEMENT STRATEGY 139
COMPONENT PARTS OF UREA SCR SYSTEM . 153
AdBlue/DEF MIXING TUBE . 153
SCR ASSEMBLY . 154
AdBlue/DEF TANK 156
AdBlue/DEF PUMP 158
AdBlue/DEF INJECTOR 159
AdBlue/DEF HOSE 160
AdBlue/DEF TANK HEATING VALVE 161
BOOT-UP SYSTEM . 162
LAYOUT DRAWING OF BOOT-UP SYSTEM (MACHINE WITH KOMTRAX TERMINAL) . 162
LAYOUT DRAWING OF BOOT-UP SYSTEM (MACHINE WITH GATEWAY FUNCTION CONTROLLER) 163
SYSTEM OPERATING LAMP SYSTEM . 164
SYSTEM OPERATING LAMP SYSTEM DIAGRAM (MACHINE WITH KOMTRAX TERMINAL) . 164
SYSTEM OPERATING LAMP SYSTEM DIAGRAM (MACHINE WITH GATEWAY FUNCTION CONTROLLER) 164
FUNCTION OF SYSTEM OPERATING LAMP SYSTEM (MACHINE WITH KOMTRAX TERMINAL) . 164
FUNCTION OF SYSTEM OPERATING LAMP SYSTEM (MACHINE WITH GATEWAY FUNCTION CONTROLLER) 165
BATTERY DISCONNECT SWITCH 167
FUNCTION OF BATTERY DISCONNECT SWITCH 167
ENGINE SYSTEM 168
LAYOUT DRAWING OF ENGINE SYSTEM 168
ENGINE CONTROL SYSTEM 170
LAYOUT OF ENGINE CONTROL SYSTEM (MACHINE WITH KOMTRAX TERMINAL) 170
LAYOUT OF ENGINE CONTROL SYSTEM (MACHINE WITH GATEWAY FUNCTION CONTROLLER) . 172
ENGINE CONTROL SYSTEM DIAGRAM (MACHINE WITH KOMTRAX TERMINAL) 174
ENGINE CONTROL SYSTEM DIAGRAM (MACHINE WITH KOMTRAX TERMINAL) 176
FUNCTION OF ENGINE CONTROL SYSTEM (MACHINE WITH KOMTRAX TERMINAL) 178
FUNCTION OF ENGINE CONTROL SYSTEM (MACHINE WITH GATEWAY FUNCTION CONTROLLER) . 180
AUTOMATIC IDLE STOP SYSTEM . 182
AUTOMATIC IDLE STOP SYSTEM DIAGRAM (MACHINE WITH KOMTRAX TERMINAL) . 182
AUTOMATIC IDLE STOP SYSTEM DIAGRAM (MACHINE WITH GATEWAY FUNCTION CONTROLLER) 183
FUNCTION OF AUTOMATIC IDLE STOP SYSTEM . 183
COMPONENT PARTS OF ENGINE SYSTEM . 186
DAMPER . 186
VGT 187
EGR SYSTEM . 190
EGR VALVE 192
EGR COOLER . 194
KCCV SYSTEM 196
KCCV VENTILATOR 198
KDOC . 200
COOLING SYSTEM . 203
LAYOUT DRAWING OF COOLING SYSTEM . 203
SPECIFICATIONS OF COOLING SYSTEM . 204
COOLING FAN CONTROL SYSTEM . 205
COOLING FAN CONTROL SYSTEM DIAGRAM . 205
FUNCTION OF COOLING FAN CONTROL SYSTEM . 206
COMPONENT PARTS OF COOLING SYSTEM 208
COOLING FAN MOTOR 208
HYDRAULIC OIL COOLER BYPASS AND HST CHARGE SAFETY VALVE 213
HYDRAULIC OIL COOLER BYPASS VALVE 214
HST CHARGE SAFETY VALVE 215
CONTROL SYSTEM . 217
LAYOUT DRAWING OF CONTROL SYSTEM (MACHINE WITH KOMTRAX TERMINAL) . 217
LAYOUT DRAWING OF CONTROL SYSTEM (MACHINE WITH KOMTRAX TERMINAL) . 218
MACHINE MONITOR SYSTEM . 219
MACHINE MONITOR SYSTEM DIAGRAM (MACHINE WITH KOMTRAX TERMINAL) . 219
MACHINE MONITOR SYSTEM DIAGRAM (MACHINE WITH GATEWAY FUNCTION CONTROLLER) 220
FUNCTION OF MACHINE MONITOR SYSTEM . 220
KOMTRAX SYSTEM . 221
KOMTRAX SYSTEM DIAGRAM (MACHINE WITH KOMTRAX TERMINAL) . 221
SYSTEM DIAGRAM OF KOMTRAX SYSTEM (MACHINE WITH GATEWAY FUNCTION CONTROLLER) 221
FUNCTION OF KOMTRAX SYSTEM . 222
COMPONENT PARTS OF CONTROL SYSTEM 223
MACHINE MONITOR 223
KOMTRAX TERMINAL . 238
GATEWAY FUNCTION CONTROLLER 240
COMMUNICATION TERMINAL . 243
HST CONTROLLER . 245
ENGINE CONTROLLER 249
FUEL CONTROL DIAL 256
DECELERATOR AND BRAKE POTENTIOMETER 258
HYDRAULIC SYSTEM . 260
LAYOUT DRAWING OF HYDRAULIC SYSTEM . 260
CLSS . 261
STRUCTURE OF CLSS 261
FUNCTION OF CLSS . 262
COMPONENT PARTS OF HYDRAULIC SYSTEM 264
HYDRAULIC TANK . 264
WORK EQUIPMENT AND COOLING FAN PUMP 266
LS VALVE . 274
PC VALVE . 275
CONTROL VALVE 278
POWER TRAIN SYSTEM . 296
LAYOUT DRAWING OF HST SYSTEM . 296
OPERATION OF HST SYSTEM 297
STEERING AND BRAKE CONTROL SYSTEM 299
LAYOUT DRAWING OF STEERING AND BRAKE CONTROL SYSTEM 299
FUNCTION OF STEERING AND BRAKE CONTROL SYSTEM 299
HST CONTROL SYSTEM . 301
HST CONTROL SYSTEM DIAGRAM . 301
GEAR SHIFT CONTROL FUNCTION 302
ENGINE LOW SPEED MATCHING CONTROL FUNCTION . 305
HST PUMP AND MOTOR SEQUENCE CONTROL FUNCTION . 306
DECELERATION AND BRAKE CONTROL FUNCTION 307
GEAR SHIFT CONTROL FUNCTION BY LOAD 309
TURN CONTROL FUNCTION 309
STRAIGHT TRAVEL CORRECTION CONTROL FUNCTION 310
PARKING BRAKE CONTROL SYSTEM . 312
PARKING BRAKE CONTROL SYSTEM DIAGRAM . 312
FUNCTION OF PARKING BRAKE CONTROL SYSTEM . 313
OPERATION OF PARKING BRAKE CONTROL SYSTEM 314
COMPONENT PARTS OF POWER TRAIN SYSTEM 315
HST PUMP . 315
HST CHARGE PUMP 330
HST MOTOR 331
FINAL DRIVE 344
ELECTRIC STEERING CONTROL LEVER 348
WORK EQUIPMENT SYSTEM 351
WORK EQUIPMENT CONTROL . 351
WORK EQUIPMENT CONTROL SYSTEM DIAGRAM 351
FUNCTION OF WORK EQUIPMENT CONTROL . 352
LAYOUT DRAWING OF FRONT WORK EQUIPMENT . 353
LAYOUT OF FIXED MULTI-SHANK RIPPER . 354
COMPONENT PARTS OF WORK EQUIPMENT SYSTEM . 355
RIPPER PPC VALVE . 355
5-PORT VALVE OF EPC AND SOLENOID . 359
PILOT CIRCUIT ACCUMULATOR 365
QUICK DROP VALVE . 366
PISTON VALVE . 368
ELECTRIC BLADE CONTROL LEVER . 369
UNDERCARRIAGE AND FRAME 371
MAIN FRAME . 371
STRUCTURE OF MAIN FRAME 371
SUSPENSION . 372
STRUCTURE OF SUSPENSION 372
SPECIFICATIONS OF SUSPENSION . 373
FUNCTION OF SUSPENSION . 374
TRACK FRAME AND IDLER CUSHION 375
STRUCTURE OF TRACK FRAME AND IDLER CUSHION . 375
FUNCTION OF TRACK FRAME AND IDLER CUSHION 376
WORK EQUIPMENT . 377
STRUCTURE OF FRONT WORK EQUIPMENT 377
STRUCTURE OF FIXED MULTI-SHANK RIPPER 378
CAB AND ITS ATTACHMENTS 379
ROPS CAB . 379
STRUCTURE OF ROPS CAB (MACHINE WITH KOMTRAX TERMINAL) 379
STRUCTURE OF ROPS CAB (MACHINE WITH GATEWAY FUNCTION CONTROLLER) . 380
FUNCTION OF ROPS CAB . 381
CAB MOUNT 382
STRUCTURE OF CAB MOUNT . 382
FUNCTION OF CAB MOUNT 382
20 STANDARD VALUE TABLE 383
CONTENTS . 384
ABBREVIATION LIST 385
STANDARD VALUE TABLE FOR ENGINE 391
STANDARD VALUE TABLE FOR ENGINE: D51EX-24 391
STANDARD VALUE TABLE FOR ENGINE: D51PX-24 395
STANDARD VALUE TABLE FOR MACHINE . 399
STANDARD VALUE TABLE FOR MACHINE: D51EX-24 . 399
STANDARD VALUE TABLE FOR MACHINE: D51PX-24 . 415
MACHINE POSTURE AND PROCEDURE FOR MEASURING PERFORMANCE 429
30 TESTING AND ADJUSTING . 431
CONTENTS . 432
ABBREVIATION LIST 435
RELATED INFORMATION ON TESTING AND ADJUSTING . 441
TOOLS FOR TESTING AND ADJUSTING 441
SKETCH OF TOOLS FOR TESTING AND ADJUSTING 448
ENGINE AND COOLING SYSTEM 451
TEST ENGINE SPEED 451
METHOD FOR TESTING ENGINE SPEED 451
TEST BOOST PRESSURE 453
METHOD FOR TESTING BOOST PRESSURE 453
TEST EXHAUST GAS COLOR . 454
METHOD FOR TESTING EXHAUST GAS COLOR BY HANDY SMOKE CHECKER 454
METHOD FOR TESTING EXHAUST GAS COLOR BY SMOKE METER 455
TEST AND ADJUST VALVE CLEARANCE 456
METHOD FOR TESTING VALVE CLEARANCE . 456
METHOD FOR ADJUSTING VALVE CLEARANCE . 457
TEST COMPRESSION PRESSURE 458
METHOD FOR TESTING COMPRESSION PRESSURE 458
TEST BLOWBY PRESSURE . 463
METHOD FOR TESTING BLOWBY PRESSURE . 463
TEST ENGINE OIL PRESSURE . 465
METHOD FOR TESTING ENGINE OIL PRESSURE . 465
VISUAL CHECK INSIDE OF EGR VALVE . 466
VISUAL CHECK INSIDE OF EGR VALVE . 466
CLEAN INSIDE OF EGR VALVE 468
CLEAN INSIDE OF EGR VALVE 468
TEST FUEL PRESSURE . 471
METHOD FOR TESTING FUEL PRESSURE . 472
TEST FUEL DISCHARGE, RETURN AND LEAKAGE 476
METHOD FOR TESTING FUEL DISCHARGE, RETURN AND LEAKAGE 477
BLEED AIR FROM FUEL SYSTEM . 482
METHOD FOR BLEEDING AIR FROM FUEL SYSTEM . 482
TEST FUEL CIRCUIT FOR LEAKAGE 483
METHOD FOR TESTING FUEL CIRCUIT FOR LEAKAGE 483
HANDLE CYLINDER CUT-OUT MODE OPERATION . 485
HANDLE NO-INJECTION CRANKING OPERATION . 486
TEST KDOC, SCR AND MUFFLER STACK FOR LOOSENESS AND DAMAGE 487
METHOD FOR TESTING KDOC, SCR AND MUFFLER STACK FOR LOOSENESS AND DAMAGE 487
TEST INSTALLED CONDITION OF CYLINDER HEADS AND MANIFOLDS . 488
METHOD FOR TESTING INSTALLED CONDITION OF CYLINDER HEADS AND MANIFOLDS . 488
TEST ENGINE PIPING FOR DAMAGE AND LOOSENESS 489
METHOD FOR TESTING ENGINE PIPING FOR DAMAGE AND LOOSENESS 489
WRITE ASH IN SOOT ACCUMULATION CORRECTION TO ENGINE CONTROLLER . 490
METHOD FOR WRITING ASH IN SOOT ACCUMULATION CORRECTION TO ENGINE CONTROLLER 490
TEST SCR RELATED FUNCTIONS . 491
TEST AdBlue/DEF PUMP RAISED PRESSURE . 495
TEST INJECTION AMOUNT FROM AdBlue/DEF INJECTOR . 498
TEST AdBlue/DEF LINE HEATER RELAY 1 503
TEST AdBlue/DEF LINE HEATER RELAY 2 506
TEST AdBlue/DEF PUMP HEATER RELAY 509
TEST AdBlue/DEF TANK HEATER VALVE 513
TEST DENITRATION EFFICIENCY OF SCR . 517
CLEAN AdBlue/DEF TANK 520
METHOD FOR CLEANING AdBlue/DEF TANK 520
CLEAN AdBlue/DEF TANK MOUNTING PORTION . 524
METHOD FOR CLEANING AdBlue/DEF TANK MOUNTING PORTION . 524
CLEAN AdBlue/DEF PUMP 525
CLEAN AdBlue/DEF PUMP 525
POWER TRAIN 531
TEST AND ADJUST HST OIL PRESSURE . 531
METHOD FOR TESTING HST OIL PRESSURE 531
METHOD FOR ADJUSTING HST OIL PRESSURE 534
BLEED AIR FROM HST PUMP 536
METHOD FOR BLEEDING AIR FROM HST PUMP 536
METHOD FOR BLEEDING AIR FROM SERVO VALVE OF HST PUMP . 536
TEST OUTLET PRESSURE OF SOLENOID VALVE . 538
METHOD FOR TESTING OUTLET PRESSURE OF SOLENOID VALVE . 538
TEST TRAVEL DEVIATION 542
METHOD FOR TESTING TRAVEL DEVIATION 542
TEST BRAKE PERFORMANCE SIMPLY 544
METHOD FOR TESTING BRAKE PERFORMANCE SIMPLY 544
TEST AND ADJUST DECELERATION/BRAKE PEDAL . 545
METHOD FOR TESTING DECELERATION/BRAKE PEDAL 545
METHOD FOR ADJUSTING DECELERATION/BRAKE PEDAL 547
ADJUST PARKING BRAKE LEVER . 549
METHOD FOR ADJUSTING PARKING BRAKE LEVER . 549
MOVE MACHINE WHEN IT CANNOT TRAVEL . 551
METHOD FOR MOVING MACHINE WITH HYDRAULIC TYPE PARKING BRAKE RELEASE SYSTEM . 551
METHOD FOR MOVING DISABLED MACHINE BY REMOVING FINAL DRIVE SHAFT . 553
UNDERCARRIAGE AND FRAME 554
CHECK AND ADJUST IDLER CLEARANCE . 554
METHOD FOR ADJUSTING IDLER CLEARANCE HORIZONTALLY 554
METHOD FOR ADJUSTING IDLER CLEARANCE VERTICALLY 554
TESTING SPROCKET WEAR 556
METHOD FOR TESTING SPROCKET WEAR . 556
TEST AND ADJUST TRACK TENSION 557
METHOD FOR TESTING TRACK TENSION . 557
METHOD FOR ADJUSTING TRACK TENSION . 557
HYDRAULIC SYSTEM . 559
RELEASE REMAINING PRESSURE FROM HYDRAULIC SYSTEM . 559
METHOD FOR RELEASING REMAINING PRESSURE FROM HYDRAULIC CIRCUIT . 559
TEST AND ADJUST WORK EQUIPMENT OIL PRESSURES . 560
METHOD FOR TESTING WORK EQUIPMENT OIL PRESSURES 560
METHOD FOR ADJUSTING WORK EQUIPMENT OIL PRESSURES 561
TEST AND ADJUST OIL PRESSURE OF CONTROL CIRCUIT 563
METHOD FOR TESTING OIL PRESSURE OF CONTROL CIRCUIT . 563
METHOD FOR ADJUSTING OIL PRESSURE OF CONTROL CIRCUIT . 564
TEST OUTLET PRESSURE OF EPC SOLENOID VALVE . 565
METHOD FOR TESTING OUTLET PRESSURE OF EPC SOLENOID VALVE . 565
BLEED AIR FROM WORK EQUIPMENT AND COOLING FAN PUMP . 567
METHOD FOR BLEEDING AIR FROM WORK EQUIPMENT AND COOLING FAN PUMP . 567
TEST COOLING FAN SPEED . 568
METHOD FOR TESTING COOLING FAN SPEED . 568
TEST COOLING FAN CIRCUIT OIL PRESSURE 569
METHOD FOR TESTING COOLING FAN CIRCUIT OIL PRESSURE 569
TEST THE PARTS CAUSING HYDRAULIC DRIFT IN WORK EQUIPMENT . 571
METHOD FOR TESTING THE PARTS CAUSING HYDRAULIC DRIFT OF BLADE LIFT CYLINDER 571
METHOD FOR TESTING THE PARTS CAUSING HYDRAULIC DRIFT OF BLADE TILT CYLINDER 571
METHOD FOR TESTING THE PARTS CAUSING HYDRAULIC DRIFT OF RIPPER LIFT CYLINDER . 572
TEST INTERNAL OIL LEAKAGE OF WORK EQUIPMENT CYLINDER . 573
METHOD FOR TESTING INTERNAL OIL LEAKAGE OF WORK EQUIPMENT CYLINDER . 573
BLEED AIR FROM WORK EQUIPMENT CYLINDERS 576
METHOD FOR BLEEDING AIR FROM WORK EQUIPMENT CYLINDERS 576
WORK EQUIPMENT . 577
ADJUST WORK EQUIPMENT LOCK LEVER . 577
METHOD FOR ADJUSTING WORK EQUIPMENT LOCK LEVER . 577
TEST AND ADJUST PLAY OF BLADE ELECTRIC LEVER . 579
TEST PLAY OF BLADE ELECTRIC LEVER 581
ADJUST PLAY OF BLADE ELECTRIC LEVER 581
REPLACE UNIVERSAL JOINT 583
ELECTRICAL SYSTEM 589
SET AND OPERATE MACHINE MONITOR 589
OPERATOR MODE 593
DISPLAY FUNCTION OF TECHNICIAN IDENTIFICATION STATUS SCREEN 593
DISPLAY FUNCTION OF OPERATOR IDENTIFICATION INPUT SCREEN . 593
CHECKING FUNCTION BY LCD (LIQUID CRYSTAL DISPLAY) 594
CHECKING FUNCTION OF SERVICE METER . 594
METHOD FOR SETTING USAGE LIMITATION AND CHANGING MAINTENANCE PASSWORD 594
SERVICE MODE . 597
METHOD FOR OPERATING SERVICE MODE 597
METHOD FOR CHECKING PRE-DEFINED MONITORING INFORMATION . 599
METHOD FOR CHECKING SELF-DEFINE MONITORING INFORMATION . 605
ABNORMALITY RECORD MENU 615
METHOD FOR CONFIRMING MAINTENANCE RECORD . 619
METHOD FOR OPERATING MAINTENANCE MODE SETTING 620
METHOD FOR OPERATING PHONE NUMBER ENTRY SETTING 624
DEFAULT MENU . 626
DIAGNOSTIC TESTS MENU 633
ADJUSTMENT MENU 641
METHOD FOR PERFORMING NO-INJECTION CRANKING 698
KOMTRAX SETTINGS MENU 700
METHOD FOR DISPLAYING SERVICE MESSAGE 704
START UP KOMTRAX TERMINAL (MACHINE WITH KOMTRAX TERMINAL) 706
STOP USING OF KOMTRAX TERMINAL (MACHINE WITH KOMTRAX TERMINAL) . 711
START UP KOMTRAX SYSTEM (MACHINE WITH GATEWAY FUNCTION CONTROLLER) . 713
STOP USING OF KOMTRAX SYSTEM (MACHINE WITH GATEWAY FUNCTION CONTROLLER) 719
ADJUSTMENT WHEN HST CONTROLLER HAS BEEN REPLACED . 721
ADJUSTMENT METHOD WHEN HST CONTROLLER HAS BEEN REPLACED 721
ADJUSTMENT WHEN ELECTRIC OR HYDRAULIC DEVICE HAS BEEN REPLACED . 727
ADJUST REARVIEW CAMERA ANGLE . 729
METHOD FOR ADJUSTING REARVIEW CAMERA ANGLE . 729
HANDLE VOLTAGE CIRCUIT OF ENGINE CONTROLLER 730
HANDLE BATTERY DISCONNECT SWITCH (MACHINE WITH KOMTRAX TERMINAL) . 731
HANDLE BATTERY DISCONNECT SWITCH (MACHINE WITH GATEWAY FUNCTION CONTROLLER) 732
TEST DIODES 733
METHOD FOR TESTING DIODE USING DIGITAL TESTER 733
METHOD FOR TESTING DIODE USING ANALOG TESTER . 733
Pm CLINIC 734
Pm CLINIC SERVICE 734
Pm CLINIC CHECK SHEET: D51EX-24 736
Pm CLINIC CHECK SHEET: D51PX-24 744
Pm CLINIC CHECK SHEET FOR UNDERCARRIAGE: D51EX-24 752
Pm CLINIC CHECK SHEET FOR UNDERCARRIAGE: D51PX-24 756
40 TROUBLESHOOTING . 761
CONTENTS . 762
ABBREVIATION LIST 772
RELATED INFORMATION ON TROUBLESHOOTING . 778
GENERAL TROUBLESHOOTING POINTS . 778
TROUBLESHOOTING POINTS FOR UREA SCR SYSTEM . 779
SEQUENCE OF EVENTS IN TROUBLESHOOTING 791
CHECKS BEFORE TROUBLESHOOTING 793
INSPECTION PROCEDURE BEFORE TROUBLESHOOTING 795
WALK-AROUND CHECK 795
TESTING IN ACCORDANCE WITH TESTING PROCEDURE . 797
CHECK FUEL LEVEL AND TYPE 797
CHECK IMPURE INGREDIENT IN FUEL 797
CHECK AdBule/DEF LEVEL AND TYPE 798
CHECK FUEL PREFILTER . 798
CHECK MAIN FILTER 800
CHECK ENGINE OIL LEVEL (OIL AMOUNT IN OIL PAN) AND TYPE 801
CHECK COOLANT LEVEL (RESERVOIR TANK) . 803
CHECK CLOGGING OF AIR CLEANER 803
CLEAN OUTER ELEMENT 804
REPLACE ELEMENT 806
CHECK HYDRAULIC OIL LEVEL 807
CHECK HYDRAULIC OIL STRAINER . 808
CHECK OIL LEVEL IN FINAL DRIVE CASE 811
BLEED AIR FROM FUEL SYSTEM . 812
BLEED AIR FROM HYDRAULIC SYSTEM 812
METHOD FOR CHECKING ELECTRIC EQUIPMENT . 812
PREPARATION FOR TROUBLESHOOTING ELECTRICAL SYSTEM 819
PROCEDURE FOR TROUBLESHOOTING 826
SYMPTOM AND TROUBLESHOOTING NUMBERS 829
INFORMATION DESCRIBED IN TROUBLESHOOTING TABLE . 832
TROUBLESHOOTING METHOD FOR OPEN CIRCUIT IN WIRING HARNESS OF PRESSURE SENSOR SYSTEM 834
CONNECTORS LIST AND LAYOUT (MACHINE WITH KOMTRAX TERMINAL) . 837
CONNECTORS LIST AND LAYOUT (MACHINE WITH GATEWAY FUNCTION CONTROLLER) 851
CONNECTOR CONTACT IDENTIFICATION . 865
T-BRANCH BOX AND T-BRANCH ADAPTER TABLE 905
FUSE LOCATION TABLE (MACHINE WITH KOMTRAX TERMINAL) 911
FUSE LOCATION TABLE (MACHINE WITH GATEWAY FUNCTION CONTROLLER) . 915
PRECAUTIONS FOR REPLACING KDOC . 919
FAILURE CODES TABLE 920
TROUBLESHOOTING BY FAILURE CODE (DISPLAY OF CODE) 938
FAILURE CODE [6091NX] 938
FAILURE CODE [989L00] 940
FAILURE CODE [989M00] 941
FAILURE CODE [989N00] 942
FAILURE CODE [A1U0N3] 943
FAILURE CODE [A1U0N4] 945
FAILURE CODE [A900FR] 947
FAILURE CODE [A900N6] 948
FAILURE CODE [A900NY] 949
FAILURE CODE [AA10NX] 950
FAILURE CODE [AB00KE] 952
FAILURE CODE [AQ10MB] 954
FAILURE CODE [AQ10N3] 956
FAILURE CODE [AS00R2] 958
FAILURE CODE [AS00R3] 959
FAILURE CODE [AS00R4] 960
FAILURE CODE [AS00R5] 961
FAILURE CODE [AS00R6] 962
FAILURE CODE [AS00ZK] 963
FAILURE CODE [AS10KM] 964
FAILURE CODE [AS10NR] 965
FAILURE CODE [AS10NT] 966
FAILURE CODE [B@BAZG] 967
FAILURE CODE [B@BCNS] 968
FAILURE CODE [B@CRNS] 969
FAILURE CODE [B@CRZG] 970
FAILURE CODE [CA115] . 971
FAILURE CODE [CA122] . 972
FAILURE CODE [CA123] . 974
FAILURE CODE [CA131] . 976
FAILURE CODE [CA132] . 978
FAILURE CODE [CA144] . 980
FAILURE CODE [CA145] . 982
FAILURE CODE [CA153] . 984
FAILURE CODE [CA154] . 986
FAILURE CODE [CA187] . 988
FAILURE CODE [CA221] . 990
FAILURE CODE [CA222] . 992
FAILURE CODE [CA227] . 994
FAILURE CODE [CA234] . 996
FAILURE CODE [CA238] . 997
FAILURE CODE [CA239] . 998
FAILURE CODE [CA249] . 999
FAILURE CODE [CA256] .1001
FAILURE CODE [CA271] .1003
FAILURE CODE [CA272] .1005
FAILURE CODE [CA295] .1007
FAILURE CODE [CA322] .1008
FAILURE CODE [CA324] .1010
FAILURE CODE [CA331] .1012
FAILURE CODE [CA332] .1014
FAILURE CODE [CA343] .1016
FAILURE CODE [CA351] .1017
FAILURE CODE [CA352] .1018
FAILURE CODE [CA356] .1020
FAILURE CODE [CA357] .1022
FAILURE CODE [CA386] .1024
FAILURE CODE [CA428] .1025
FAILURE CODE [CA429] .1027
FAILURE CODE [CA435] .1029
FAILURE CODE [CA441] .1031
FAILURE CODE [CA442] .1033
FAILURE CODE [CA451] .1034
FAILURE CODE [CA452] .1036
FAILURE CODE [CA488] .1038
FAILURE CODE [CA515] .1039
FAILURE CODE [CA516] .1041
FAILURE CODE [CA553] .1043
FAILURE CODE [CA555] .1044
FAILURE CODE [CA556] .1045
FAILURE CODE [CA559] .1046
FAILURE CODE [CA595] .1049
FAILURE CODE [CA687] .1051
FAILURE CODE [CA689] .1053
FAILURE CODE [CA691] .1056
FAILURE CODE [CA692] .1058
FAILURE CODE [CA697] .1060
FAILURE CODE [CA698] .1061
FAILURE CODE [CA731] .1062
FAILURE CODE [CA778] .1064
FAILURE CODE [CA1117] 1069
FAILURE CODE [CA1664] 1071
FAILURE CODE [CA1669] 1073
FAILURE CODE [CA1673] 1074
FAILURE CODE [CA1677] 1075
FAILURE CODE [CA1678] 1076
FAILURE CODE [CA1682] 1077
FAILURE CODE [CA1683] 1080
FAILURE CODE [CA1684] 1082
FAILURE CODE [CA1686] 1084
FAILURE CODE [CA1691] 1085
FAILURE CODE [CA1694] 1087
FAILURE CODE [CA1695] 1089
FAILURE CODE [CA1696] 1090
FAILURE CODE [CA1712] 1092
FAILURE CODE [CA1713] 1095
FAILURE CODE [CA1714] 1098
FAILURE CODE [CA1715] 1099
FAILURE CODE [CA1776] 1100
FAILURE CODE [CA1777] 1103
FAILURE CODE [CA1843] 1106
FAILURE CODE [CA1844] 1108
FAILURE CODE [CA1885] 1111
FAILURE CODE [CA1887] 1113
FAILURE CODE [CA1896] 1115
FAILURE CODE [CA1898] 1117
FAILURE CODE [CA1938] 1119
FAILURE CODE [CA1942] 1121
FAILURE CODE [CA1961] 1122
FAILURE CODE [CA1962] 1123
FAILURE CODE [CA2185] 1124
FAILURE CODE [CA2186] 1126
FAILURE CODE [CA2198] 1128
FAILURE CODE [CA2272] 1130
FAILURE CODE [CA2288] 1132
FAILURE CODE [CA2311] 1133
FAILURE CODE [CA2349] 1134
FAILURE CODE [CA2353] 1136
FAILURE CODE [CA2357] 1138
FAILURE CODE [CA2373] 1139
FAILURE CODE [CA2374] 1141
FAILURE CODE [CA2375] 1143
FAILURE CODE [CA2376] 1145
FAILURE CODE [CA2387] 1148
FAILURE CODE [CA2554] 1149
FAILURE CODE [CA2555] 1151
FAILURE CODE [CA2556] 1154
FAILURE CODE [CA2634] 1157
FAILURE CODE [CA2635] 1159
FAILURE CODE [CA2636] 1160
FAILURE CODE [CA2637] 1162
FAILURE CODE [CA2771] 1164
FAILURE CODE [CA2961] 1168
FAILURE CODE [CA2973] 1169
FAILURE CODE [CA2976] 1170
FAILURE CODE [CA3142] 1172
FAILURE CODE [CA3143] 1173
FAILURE CODE [CA3144] 1174
FAILURE CODE [CA3146] 1176
FAILURE CODE [CA3147] 1177
FAILURE CODE [CA3148] 1178
FAILURE CODE [CA3151] 1180
FAILURE CODE [CA3165] 1185
FAILURE CODE [CA3228] 1187
FAILURE CODE [CA3229] 1189
FAILURE CODE [CA3231] 1191
FAILURE CODE [CA3232] 1193
FAILURE CODE [CA3235] 1197
FAILURE CODE [CA3239] 1199
FAILURE CODE [CA3241] 1202
FAILURE CODE [CA3242] 1205
FAILURE CODE [CA3251] 1208
FAILURE CODE [CA3313] 1210
FAILURE CODE [CA3314] 1211
FAILURE CODE [CA3315] 1212
FAILURE CODE [CA3419] 1214
FAILURE CODE [CA3421] 1216
FAILURE CODE [CA3497] 1218
FAILURE CODE [CA3498] 1219
FAILURE CODE [CA3545] 1220
FAILURE CODE [CA3547] 1222
FAILURE CODE [CA3558] 1223
FAILURE CODE [CA3559] 1225
FAILURE CODE [CA3562] 1227
FAILURE CODE [CA3563] 1229
FAILURE CODE [CA3567] 1232
FAILURE CODE [CA3568] 1236
FAILURE CODE [CA3571] 1240
FAILURE CODE [CA3572] 1242
FAILURE CODE [CA3574] 1244
FAILURE CODE [CA3575] 1246
FAILURE CODE [CA3577] 1248
FAILURE CODE [CA3578] 1250
FAILURE CODE [CA3582] 1252
FAILURE CODE [CA3583] 1257
FAILURE CODE [CA3596] 1259
FAILURE CODE [CA3649] 1263
FAILURE CODE [CA3681] 1265
FAILURE CODE [CA3682] 1270
FAILURE CODE [CA3713] 1275
FAILURE CODE [CA3717] 1278
FAILURE CODE [CA3718] 1279
FAILURE CODE [CA3724] 1280
FAILURE CODE [CA3725] 1281
FAILURE CODE [CA3741] 1284
FAILURE CODE [CA3748] 1285
FAILURE CODE [CA3755] 1287
FAILURE CODE [CA3866] 1289
FAILURE CODE [CA3868] 1292
FAILURE CODE [CA4152] 1296
FAILURE CODE [CA4155] 1300
FAILURE CODE [CA4156] 1303
FAILURE CODE [CA4157] 1306
FAILURE CODE [CA4159] 1308
FAILURE CODE [CA4164] 1309
FAILURE CODE [CA4165] 1311
FAILURE CODE [CA4166] 1313
FAILURE CODE [CA4168] 1314
FAILURE CODE [CA4169] 1317
FAILURE CODE [CA4171] 1319
FAILURE CODE [CA4249] 1321
FAILURE CODE [CA4251] 1323
FAILURE CODE [CA4261] 1325
FAILURE CODE [CA4277] 1328
FAILURE CODE [CA4459] 1332
FAILURE CODE [CA4461] 1334
FAILURE CODE [CA4533] 1337
FAILURE CODE [CA4534] 1338
FAILURE CODE [CA4731] 1339
FAILURE CODE [CA4732] 1340
FAILURE CODE [CA4739] 1341
FAILURE CODE [CA4768] 1342
FAILURE CODE [CA4769] 1344
FAILURE CODE [CA4842] 1347
FAILURE CODE [CA4952] (MACHINE WITH KOMTRAX TERMINAL) 1350
FAILURE CODE [CA4952] (MACHINE WITH GATEWAY FUNCTION CONTROLLER) .1352
FAILURE CODE [CA5115] 1354
FAILURE CODE [CA5179] 1357
FAILURE CODE [CA5181] 1359
FAILURE CODE [CA5387] 1361
FAILURE CODE [CA5388] 1363
FAILURE CODE [CA5389] 1366
FAILURE CODE [CA5391] 1368
FAILURE CODE [CA5392] 1372
FAILURE CODE [CA5393] 1374
FAILURE CODE [CA5394] 1377
FAILURE CODE [CA5395] 1380
FAILURE CODE [CA5396] 1383
FAILURE CODE [CA5631] 1384
FAILURE CODE [CA5632] 1386
FAILURE CODE [CA5938] 1387
FAILURE CODE [D130KA] 1389
FAILURE CODE [D130KB] 1392
FAILURE CODE [D130KY] 1394
FAILURE CODE [D19JKZ] 1396
FAILURE CODE [D811MC] (MACHINE WITH KOMTRAX TERMINAL) 1399
FAILURE CODE [D811MC] (MACHINE WITH GATEWAY FUNCTION CONTROLLER) .1400
FAILURE CODE [D862KA] (MACHINE WITH KOMTRAX TERMINAL) 1401
FAILURE CODE [D862KA] (MACHINE WITH GATEWAY FUNCTION CONTROLLER) .1402
FAILURE CODE [D8ALKA] (MACHINE WITH KOMTRAX TERMINAL) 1403
FAILURE CODE [D8ALKA] (MACHINE WITH GATEWAY FUNCTION CONTROLLER) .1405
FAILURE CODE [D8ALKB] (MACHINE WITH KOMTRAX TERMINAL) 1407
FAILURE CODE [D8ALKB] (MACHINE WITH GATEWAY FUNCTION CONTROLLER) .1409
FAILURE CODE [D8AQKR] (MACHINE WITH KOMTRAX TERMINAL) 1411
FAILURE CODE [D8AQKR] (MACHINE WITH GATEWAY FUNCTION CONTROLLER) .1413
FAILURE CODE [D8G1KT] 1415
FAILURE CODE [D8G6KT] 1416
FAILURE CODE [DAF0MB] 1417
FAILURE CODE [DAF0MC] 1418
FAILURE CODE [DAF8KB] 1419
FAILURE CODE [DAF9KQ] 1421
FAILURE CODE [DAFGMC] (MACHINE WITH KOMTRAX TERMINAL) 1422
FAILURE CODE [DAFGMC] (MACHINE WITH GATEWAY FUNCTION CONTROLLER) .1423
FAILURE CODE [DAFLKA] (MACHINE WITH KOMTRAX TERMINAL) 1424
FAILURE CODE [DAFLKA] (MACHINE WITH GATEWAY FUNCTION CONTROLLER) .1426
FAILURE CODE [DAFLKB] (MACHINE WITH KOMTRAX TERMINAL) 1428
FAILURE CODE [DAFLKB] (MACHINE WITH GATEWAY FUNCTION CONTROLLER) .1430
FAILURE CODE [DAFQKR] (MACHINE WITH KOMTRAX TERMINAL) 1432
FAILURE CODE [DAFQKR] (MACHINE WITH GATEWAY FUNCTION CONTROLLER) .1433
FAILURE CODE [DAJ000] 1434
FAILURE CODE [DAJ0KQ] 1435
FAILURE CODE [DAJ0KT] 1436
FAILURE CODE [DAJ0MC] 1437
FAILURE CODE [DAJ1KK] 1438
FAILURE CODE [DAJ2KK] 1440
FAILURE CODE [DAJ5KK] 1442
FAILURE CODE [DAJ6KK] 1445
FAILURE CODE [DAJLKA] (MACHINE WITH KOMTRAX TERMINAL) 1447
FAILURE CODE [DAJLKA] (MACHINE WITH GATEWAY FUNCTION CONTROLLER) .1449
FAILURE CODE [DAJLKB] (MACHINE WITH KOMTRAX TERMINAL) 1451
FAILURE CODE [DAJLKB] (MACHINE WITH GATEWAY FUNCTION CONTROLLER) .1453
FAILURE CODE [DAJPMA] 1455
FAILURE CODE [DAJQKR] (MACHINE WITH KOMTRAX TERMINAL) 1456
FAILURE CODE [DAJQKR] (MACHINE WITH GATEWAY FUNCTION CONTROLLER) .1457
FAILURE CODE [DAJRKR] 1458
FAILURE CODE [DB2QKR] (MACHINE WITH KOMTRAX TERMINAL) 1459
FAILURE CODE [DB2QKR] (MACHINE WITH GATEWAY FUNCTION CONTROLLER) .1464
FAILURE CODE [DB2RKR] 1469
FAILURE CODE [DD12KA] 1474
FAILURE CODE [DD12KB] 1476
FAILURE CODE [DD13KA] 1478
FAILURE CODE [DD13KB] 1480
FAILURE CODE [DD14KA] 1482
FAILURE CODE [DD14KB] 1484
FAILURE CODE [DDKAKA] 1486
FAILURE CODE [DDKAKB] 1488
FAILURE CODE [DDKFL4] 1490
FAILURE CODE [DDKGL4] 1492
FAILURE CODE [DDKHKA] 1494
FAILURE CODE [DDKHKB] 1496
FAILURE CODE [DDNLKA] 1498
FAILURE CODE [DDNLKB] 1500
FAILURE CODE [DDP6KA] 1502
FAILURE CODE [DDP6KB] 1505
FAILURE CODE [DDP6MA] 1507
FAILURE CODE [DDU1FS] 1509
FAILURE CODE [DDU1KA] 1511
FAILURE CODE [DDU1KY] 1514
FAILURE CODE [DFA4KX] 1516
FAILURE CODE [DFA4KZ] 1517
FAILURE CODE [DFA4L8] 1518
FAILURE CODE [DFA5KA] 1519
FAILURE CODE [DFA5KB] 1522
FAILURE CODE [DFA6KA] 1525
FAILURE CODE [DFA6KB] 1528
FAILURE CODE [DFA7KX] 1531
FAILURE CODE [DFA7KZ] 1532
FAILURE CODE [DFA7L8] 1533
FAILURE CODE [DFA8KA] 1534
FAILURE CODE [DFA8KB] 1537
FAILURE CODE [DFA9KA] 1540
FAILURE CODE [DFA9KB] 1543
FAILURE CODE [DGS1KA] 1546
FAILURE CODE [DGS1KX] 1549
FAILURE CODE [DH21KA] 1550
FAILURE CODE [DH21KB] 1552
FAILURE CODE [DHA4KA] 1554
FAILURE CODE [DHH7KA] 1556
FAILURE CODE [DHH7KB] 1559
FAILURE CODE [DHH8KA] 1561
FAILURE CODE [DHH8KB] 1564
FAILURE CODE [DHH9KA] 1566
FAILURE CODE [DHH9KB] 1569
FAILURE CODE [DHHAKA] 1571
FAILURE CODE [DHHAKB] 1574
FAILURE CODE [DK30KA] 1576
FAILURE CODE [DK30KB] 1579
FAILURE CODE [DK30KX] 1581
FAILURE CODE [DK30KZ] 1582
FAILURE CODE [DK30L8] 1583
FAILURE CODE [DK31KA] 1584
FAILURE CODE [DK31KB] 1587
FAILURE CODE [DK40KA] 1589
FAILURE CODE [DK40KB] 1592
FAILURE CODE [DK55KX] 1594
FAILURE CODE [DK55KZ] 1595
FAILURE CODE [DK55L8] 1596
FAILURE CODE [DK56KA] 1597
FAILURE CODE [DK56KB] 1600
FAILURE CODE [DK57KA] 1602
FAILURE CODE [DK57KB] 1605
FAILURE CODE [DLM0KX] 1607
FAILURE CODE [DLM1KA] 1608
FAILURE CODE [DLM1KB] 1610
FAILURE CODE [DLM1MA] 1612
FAILURE CODE [DLM2KA] 1613
FAILURE CODE [DLM2KB] 1615
FAILURE CODE [DLM2MA] 1617
FAILURE CODE [DLM3KA] 1618
FAILURE CODE [DLM3KB] 1620
FAILURE CODE [DLM3MB] 1622
FAILURE CODE [DN21FS] 1623
FAILURE CODE [DR21KX] 1625
FAILURE CODE [DR31KX] 1626
FAILURE CODE [DV20KB] 1627
FAILURE CODE [DW4BKA] 1629
FAILURE CODE [DW4BKB] 1631
FAILURE CODE [DW4BKY] 1633
FAILURE CODE [DW7BKA] 1635
FAILURE CODE [DW7BKB] 1637
FAILURE CODE [DW7EKA] 1639
FAILURE CODE [DW7EKB] 1641
FAILURE CODE [DW7EKY] 1643
FAILURE CODE [DWN5KA] 1645
FAILURE CODE [DWN5KB] 1647
FAILURE CODE [DWN5KY] 1649
FAILURE CODE [DXA4KA] 1651
FAILURE CODE [DXA4KB] 1653
FAILURE CODE [DXA4KY] 1655
FAILURE CODE [DXA5KA] 1657
FAILURE CODE [DXA5KB] 1659
FAILURE CODE [DXA5KY] 1661
FAILURE CODE [DXA6KA] 1663
FAILURE CODE [DXA6KB] 1665
FAILURE CODE [DXA6KY] 1667
FAILURE CODE [DXA7KA] 1669
FAILURE CODE [DXA7KB] 1671
FAILURE CODE [DXA7KY] 1673
FAILURE CODE [DXHRKA] 1675
FAILURE CODE [DXHRKB] 1677
FAILURE CODE [DXHRKY] 1679
FAILURE CODE [DXHSKA] 1681
FAILURE CODE [DXHSKB] 1683
FAILURE CODE [DXHSKY] 1685
FAILURE CODE [DXHTKA] 1687
FAILURE CODE [DXHTKB] 1689
FAILURE CODE [DXHTKY] 1691
FAILURE CODE [DXHUKA] 1693
FAILURE CODE [DXHUKB] 1695
FAILURE CODE [DXHUKY] 1697
FAILURE CODE [DXJ4KA] 1699
FAILURE CODE [DXJ4KB] 1701
FAILURE CODE [DXJCKA] 1703
FAILURE CODE [DXJCKB] 1705
FAILURE CODE [DXJCKY] 1707
FAILURE CODE [DXJDKA] 1709
FAILURE CODE [DXJDKB] 1711
FAILURE CODE [DXJDKY] 1713
FAILURE CODE [DXK1KA] 1715
FAILURE CODE [DXK1KB] 1717
FAILURE CODE [DXK1KY] 1719
FAILURE CODE [DXK2KA] 1721
FAILURE CODE [DXK2KB] 1723
FAILURE CODE [DXK2KY] 1725
FAILURE CODE [F313KA] 1727
FAILURE CODE [F313KB] 1728
FAILURE CODE [F318KB] 1729
FAILURE CODE [F318KY] 1730
TROUBLESHOOTING OF ELECTRICAL SYSTEM (E-MODE) 1731
ENGINE DOES NOT START (ENGINE DOES NOT CRANK) 1731
MANUAL PREHEATING SYSTEM DOES NOT WORK .1738
AUTOMATIC PREHEATING SYSTEM DOES NOT WORK 1741
WHILE PREHEATING IS WORKING, PREHEATING MONITOR DOES NOT LIGHT UP 1743
WHEN STARTING SWITCH IS TURNED TO ON POSITION, MACHINE MONITOR DISPLAYS NOTHING 1745
WHEN STARTING SWITCH IS TURNED TO ON POSITION (WITH ENGINE STOPPED), BASIC CHECK MONITOR LIGHTS UP .1749
AIR CLEANER CLOGGING MONITOR LIGHTS UP IN YELLOW WHILE ENGINE IS RUNNING .1750
CHARGE LEVEL MONITOR LIGHTS UP IN RED WHILE ENGINE IS RUNNING 1751
ENGINE COOLANT TEMPERATURE MONITOR LIGHTS UP IN RED WHILE ENGINE IS RUNNING 1752
ENGINE OIL PRESSURE MONITOR LIGHTS UP IN RED WHILE ENGINE IS RUNNING .1753
HST CHARGE PRESSURE MONITOR LIGHTS UP IN RED WHILE ENGINE IS RUNNING .1754
HYDRAULIC OIL TEMPERATURE MONITOR LIGHTS UP IN RED WHILE ENGINE IS RUNNING .1755
HST OIL FILTER CLOGGING MONITOR LIGHTS UP IN RED WHILE ENGINE IS RUNNING .1756
ENGINE COOLANT TEMPERATURE GAUGE DOES NOT INDICATE CORRECT TEMPERATURE .1757
AdBlue/DEF LEVEL IS NOT DISPLAYED PROPERLY .1758
FUEL LEVEL GAUGE DOES NOT INDICATE CORRECT LEVEL .1761
HYDRAULIC OIL TEMPERATURE GAUGE DOES NOT INDICATE CORRECT TEMPERATURE 1764
OPERATION MODE DOES NOT CHANGE .1765
OPERATING CUSTOMIZE SWITCH DOES NOT DISPLAY CUSTOMIZE SCREEN .1766
MODIFYING SETTING ON CUSTOMIZE SCREEN DOES NOT CHANGE SETTING OF MACHINE .1767
SERVICE METER IS NOT DISPLAYED, WHILE STARTING SWITCH IS IN OFF POSITION .1768
SERVICE MODE CANNOT BE SELECTED 1769
WORK EQUIPMENT DOES NOT OPERATE 1770
FOOT HEATER DOES NOT OPERATE .1772
HORN DOES NOT SOUND 1778
HORN DOES NOT STOP SOUNDING 1780
BACKUP ALARM DOES NOT SOUND 1781
BACKUP ALARM DOES NOT STOP SOUNDING 1782
HEADLAMP DOES NOT LIGHT UP .1783
REAR LAMP DOES NOT LIGHT UP 1787
ALL WIPERS DO NOT OPERATE 1790
FRONT WIPER DOES NOT OPERATE .1792
REAR WIPER DOES NOT OPERATE 1794
LEFT DOOR WIPER DOES NOT OPERATE .1796
RIGHT DOOR WIPER DOES NOT OPERATE 1800
FRONT WASHER DOES NOT OPERATE 1804
REAR WASHER DOES NOT OPERATE .1806
LEFT DOOR WASHER DOES NOT OPERATE 1808
RIGHT DOOR WASHER DOES NOT OPERATE .1810
KOMTRAX SYSTEM DOES NOT OPERATE NORMALLY .1812
TROUBLESHOOTING FOR HYDRAULIC AND MECHANICAL SYSTEMS (H MODE) 1813
INFORMATION MENTIONED IN TROUBLESHOOTING TABLE (H MODE) 1813
FAILURE MODE AND CAUSE TABLE .1814
NEITHER R.H. NOR L.H. OF TRACKS CAN TRAVEL FORWARD OR REVERSE (NONE OF THE TRAVEL SYSTEMS OPERATE) .1820
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) 1822
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) 1824
TRAVEL SPEED OR POWER IS LOW .1826
SPEED RANGE DOES NOT CHANGE 1828
SHOCK IS LARGE WHEN MACHINE MOVES OFF OR STOPS .1829
MACHINE DEVIATES LARGELY .1830
MACHINE DRIFT ON A SLOPE IS LARGE 1833
ENGINE SPEED DROPS LARGELY OR ENGINE STOPS .1835
UNUSUAL NOISE IS HEARD FROM AROUND HST PUMP OR MOTOR .1837
HST OIL TEMPERATURE (HYDRAULIC OIL TEMPERATURE) RISES TOO HIGH .1839
ALL WORK EQUIPMENT DO NOT OPERATE 1841
ALL WORK EQUIPMENTS SPEED OR POWER IS LOW 1843
BLADE LIFT SPEED OR POWER IS LOW .1844
BLADE TILT SPEED OR POWER IS LOW .1846
BLADE ANGLE SPEED OR POWER IS LOW 1847
TIME LAG OF BLADE LIFT IS LARGE 1848
HYDRAULIC DRIFT OF LIFTED BLADE IS LARGE .1849
HYDRAULIC DRIFT OF TILTED BLADE IS LARGE .1850
UNUSUAL NOISE IS HEARD FROM AROUND WORK EQUIPMENT AND COOLING FAN PUMP OR CONTROL VALVE 1851
FAN SPEED IS ABNORMAL (TOO HIGH OR LOW, OR STATIONARY) .1852
UNUSUAL NOISE IS HEARD FROM AROUND FAN .1854
TROUBLESHOOTING OF ENGINE (S-MODE) .1855
INFORMATION MENTIONED IN TROUBLESHOOTING TABLE (S MODE) 1855
ENGINE DOES NOT CRANK WHEN STARTING SWITCH IS TURNED TO START POSITION .1856
ENGINE CRANKS BUT NO EXHAUST GAS COMES OUT .1857
FUEL IS BEING INJECTED BUT ENGINE DOES NOT START (MISFIRING: ENGINE CRANKS BUT DOES NOT START) .1858
ENGINE STARTABILITY IS POOR 1860
ENGINE DOES NOT PICK UP SMOOTHLY .1862
ENGINE STOPS DURING OPERATION 1864
ENGINE RUNS ROUGH OR IS UNSTABLE .1866
ENGINE LACKS POWER .1867
EXHAUST SMOKE IS BLACK .1869
ENGINE OIL CONSUMPTION IS EXCESSIVE 1871
OIL BECOMES CONTAMINATED QUICKLY .1872
FUEL CONSUMPTION IS EXCESSIVE 1873
OIL IS IN COOLANT (OR COOLANT SPURTS BACK OR COOLANT LEVEL GOES DOWN) 1874
OIL PRESSURE DROPS .1875
FUEL MIXES INTO ENGINE OIL .1877
WATER MIXES INTO ENGINE OIL (MILKY) 1878
COOLANT TEMPERATURE RISES TOO HIGH (OVERHEATING) .1879
UNUSUAL NOISE IS HEARD .1880
VIBRATION IS EXCESSIVE .1881
AIR CANNOT BE BLED FROM FUEL CIRCUIT .1882
ACTIVE REGENERATION IS EXECUTED FREQUENTLY .1883
ACTIVE REGENERATION TAKES TIME .1884
WHITE SMOKE IS EXHAUSTED DURING ACTIVE REGENERATION 1885
AdBlue/DEF CONSUMPTION IS EXCESSIVE 1886
THERE IS UNUSUAL SMELL (IRRITATING ODOR) .1888
FOREIGN MATERIALS ENTER AdBlue/DEF (AdBlue/DEF INCREASES) 1889
50 DISASSEMBLY AND ASSEMBLY 1891
CONTENTS .1892
ABBREVIATION LIST 1897
RELATED INFORMATION ON DISASSEMBLY AND ASSEMBLY 1903
HOW TO READ THIS MANUAL 1903
COATING MATERIALS LIST .1905
SPECIAL TOOLS LIST .1909
SKETCHES OF SPECIAL TOOLS 1929
ENGINE AND COOLING SYSTEM 1942
REMOVE AND INSTALL SUPPLY PUMP ASSEMBLY 1942
METHOD FOR REMOVING SUPPLY PUMP ASSEMBLY .1942
METHOD FOR INSTALLING SUPPLY PUMP ASSEMBLY .1952
REMOVE AND INSTALL INJECTOR ASSEMBLY .1962
METHOD FOR REMOVING INJECTOR ASSEMBLY 1962
METHOD FOR INSTALLING INJECTOR ASSEMBLY 1973
REMOVE AND INSTALL CYLINDER HEAD ASSEMBLY 1987
METHOD FOR REMOVING CYLINDER HEAD ASSEMBLY .1987
METHOD FOR INSTALLING CYLINDER HEAD ASSEMBLY .2006
REMOVE AND INSTALL EGR VALVE ASSEMBLY 2030
METHOD FOR REMOVING EGR VALVE ASSEMBLY .2030
METHOD FOR INSTALLING EGR VALVE ASSEMBLY .2033
REMOVE AND INSTALL EGR COOLER ASSEMBLY .2037
METHOD FOR REMOVING EGR COOLER ASSEMBLY 2037
METHOD FOR INSTALLING EGR COOLER ASSEMBLY 2041
REMOVE AND INSTALL STARTING MOTOR ASSEMBLY .2045
METHOD FOR REMOVING STARTING MOTOR ASSEMBLY 2045
METHOD FOR INSTALLING STARTING MOTOR ASSEMBLY 2047
REMOVE AND INSTALL AIR CONDITIONER COMPRESSOR BELT .2050
METHOD FOR REMOVING AIR CONDITIONER COMPRESSOR BELT 2050
METHOD FOR INSTALLING AIR CONDITIONER COMPRESSOR BELT 2054
REMOVE AND INSTALL ALTERNATOR BELT .2059
METHOD FOR REMOVING ALTERNATOR BELT 2059
METHOD FOR INSTALLING ALTERNATOR BELT 2062
REMOVE AND INSTALL AUTOMATIC TENSIONER .2064
METHOD FOR REMOVING AUTOMATIC TENSIONER 2064
METHOD FOR INSTALLING AUTOMATIC TENSIONER 2065
REMOVE AND INSTALL RADIATOR ASSEMBLY .2067
METHOD FOR REMOVING RADIATOR ASSEMBLY 2068
METHOD FOR INSTALLING RADIATOR ASSEMBLY 2076
REMOVE AND INSTALL HYDRAULIC OIL COOLER ASSEMBLY .2084
METHOD FOR REMOVING HYDRAULIC OIL COOLER ASSEMBLY 2085
METHOD FOR INSTALLING HYDRAULIC OIL COOLER ASSEMBLY 2090
REMOVE AND INSTALL AFTERCOOLER ASSEMBLY 2095
METHOD FOR REMOVING AFTERCOOLER ASSEMBLY .2096
METHOD FOR INSTALLING AFTERCOOLER ASSEMBLY .2102
REMOVE AND INSTALL COOLING FAN DRIVE ASSEMBLY 2109
METHOD FOR REMOVING COOLING FAN DRIVE ASSEMBLY .2109
METHOD FOR INSTALLING COOLING FAN DRIVE ASSEMBLY .2114
REMOVE AND INSTALL COOLING FAN MOTOR ASSEMBLY 2118
METHOD FOR REMOVING COOLING FAN MOTOR ASSEMBLY .2118
METHOD FOR INSTALLING COOLING FAN MOTOR ASSEMBLY .2121
REMOVE AND INSTALL ENGINE, HST PUMP ASSEMBLY .2124
METHOD FOR REMOVING ENGINE, HST PUMP ASSEMBLY 2124
METHOD FOR INSTALLING ENGINE, HST PUMP ASSEMBLY 2135
REMOVE AND INSTALL ENGINE FRONT OIL SEAL .2147
METHOD FOR REMOVING ENGINE FRONT OIL SEAL 2147
METHOD FOR INSTALLING ENGINE FRONT OIL SEAL 2149
REMOVE AND INSTALL ENGINE REAR OIL SEAL 2152
METHOD FOR REMOVING ENGINE REAR OIL SEAL .2152
METHOD FOR INSTALLING ENGINE REAR OIL SEAL .2153
REMOVE AND INSTALL ENGINE HOOD ASSEMBLY 2156
METHOD FOR REMOVING ENGINE HOOD ASSEMBLY .2156
METHOD FOR INSTALLING ENGINE HOOD ASSEMBLY .2160
REMOVE AND INSTALL KDOC ASSEMBLY .2164
METHOD FOR REMOVING KDOC ASSEMBLY 2164
METHOD FOR INSTALLING KDOC ASSEMBLY 2170
REMOVE AND INSTALL KDOC AND SCR ASSEMBLY .2177
METHOD FOR REMOVING KDOC AND SCR ASSEMBLY 2178
METHOD FOR INSTALLING KDOC AND SCR ASSEMBLY 2184
REMOVE AND INSTALL BELLOWS PIPE ASSEMBLY .2192
METHOD FOR REMOVING BELLOWS PIPE ASSEMBLY 2192
METHOD FOR INSTALLING BELLOWS PIPE ASSEMBLY 2195
REMOVE AND INSTALL FUEL TANK ASSEMBLY 2199
METHOD FOR REMOVING FUEL TANK ASSEMBLY .2200
METHOD FOR INSTALLING FUEL TANK ASSEMBLY .2207
REMOVE AND INSTALL AdBlue/DEF TANK ASSEMBLY 2214
METHOD FOR REMOVING AdBlue/DEF TANK ASSEMBLY .2215
METHOD FOR INSTALLING AdBlue/DEF TANK ASSEMBLY .2225
REMOVE AND INSTALL AdBlue/DEF TANK SENSOR FLANGE ASSEMBLY 2234
METHOD FOR REMOVING AdBlue/DEF TANK SENSOR FLANGE ASSEMBLY .2234
METHOD FOR INSTALLING AdBlue/DEF TANK SENSOR FLANGE ASSEMBLY .2236
REMOVE AND INSTALL AdBlue/DEF TANK SENSOR 2240
METHOD FOR REMOVING AdBlue/DEF TANK SENSOR .2240
METHOD FOR INSTALLING AdBlue/DEF TANK SENSOR .2241
REMOVE AND INSTALL AdBlue/DEF TANK STRAINER 2248
METHOD FOR REMOVING AdBlue/DEF TANK STRAINER .2248
METHOD FOR INSTALLING AdBlue/DEF TANK STRAINER .2249
REMOVE AND INSTALL AdBlue/DEF TANK FILLER PORT FILTER 2250
METHOD FOR REMOVING AdBlue/DEF TANK FILLER PORT FILTER .2250
METHOD FOR INSTALLING AdBlue/DEF TANK FILLER PORT FILTER .2251
REMOVE AND INSTALL SCR ASSEMBLY 2254
METHOD FOR REMOVING SCR ASSEMBLY .2254
METHOD FOR INSTALLING SCR ASSEMBLY .2257
REMOVE AND INSTALL KCCV ASSEMBLY .2260
METHOD FOR REMOVING KCCV ASSEMBLY 2260
METHOD FOR INSTALLING KCCV ASSEMBLY 2261
REMOVE AND INSTALL AdBlue/DEF MIXING TUBE 2264
METHOD FOR REMOVING AdBlue/DEF MIXING TUBE .2264
METHOD FOR INSTALLING AdBlue/DEF MIXING TUBE .2268
REMOVE AND INSTALL AdBlue/DEF INJECTOR .2273
METHOD FOR REMOVING AdBlue/DEF INJECTOR 2273
METHOD FOR INSTALLING AdBlue/DEF INJECTOR 2278
REMOVE AND INSTALL AdBlue/DEF PUMP .2283
METHOD FOR REMOVING AdBlue/DEF PUMP 2283
METHOD FOR INSTALLING AdBlue/DEF PUMP 2287
REMOVE AND INSTALL AdBlue/DEF HOSE .2291
METHOD FOR REMOVING AdBlue/DEF HOSE 2293
METHOD FOR INSTALLING AdBlue/DEF HOSE 2312
REMOVE AND INSTALL AIR CLEANER ASSEMBLY 2333
METHOD FOR REMOVING AIR CLEANER ASSEMBLY .2333
METHOD FOR INSTALLING AIR CLEANER ASSEMBLY .2335
REMOVE AND INSTALL AIR CONDITIONER COMPRESSOR ASSEMBLY .2338
METHOD FOR REMOVING AIR CONDITIONER COMPRESSOR ASSEMBLY 2338
METHOD FOR INSTALLING AIR CONDITIONER COMPRESSOR ASSEMBLY 2342
REMOVE AND INSTALL AIR CONDITIONER CONDENSER ASSEMBLY 2347
METHOD FOR REMOVING AIR CONDITIONER CONDENSER ASSEMBLY .2347
METHOD FOR INSTALLING AIR CONDITIONER CONDENSER ASSEMBLY .2351
POWER TRAIN 0
DISASSEMBLE AND ASSEMBLE FINAL DRIVE ASSEMBLY 0
METHOD FOR DISASSEMBLING FINAL DRIVE ASSEMBLY 2356
METHOD FOR ASSEMBLING FINAL DRIVE ASSEMBLY .2360
UNDERCARRIAGE AND FRAME 2369
REMOVE AND INSTALL TRACK FRAME ASSEMBLY 2369
METHOD FOR REMOVING TRACK FRAME ASSEMBLY .2369
METHOD FOR INSTALLING TRACK FRAME ASSEMBLY .2374
REMOVE AND INSTALL IDLER ASSEMBLY 2379
METHOD FOR REMOVING IDLER ASSEMBLY .2379
METHOD FOR INSTALLING IDLER ASSEMBLY .2381
DISASSEMBLE AND ASSEMBLE IDLER ASSEMBLY 2384
METHOD FOR DISASSEMBLING IDLER ASSEMBLY 2384
METHOD FOR ASSEMBLING IDLER ASSEMBLY .2386
REMOVE AND INSTALL RECOIL SPRING ASSEMBLY 2391
METHOD FOR REMOVING RECOIL SPRING ASSEMBLY .2391
METHOD FOR INSTALLING RECOIL SPRING ASSEMBLY .2391
DISASSEMBLE AND ASSEMBLE RECOIL SPRING ASSEMBLY 2392
METHOD FOR DISASSEMBLING AND ASSEMBLING RECOIL SPRING ASSEMBLY .2392
METHOD FOR ASSEMBLING RECOIL SPRING ASSEMBLY .2395
REMOVE AND INSTALL TRACK ROLLER ASSEMBLY .2398
METHOD FOR REMOVING TRACK ROLLER ASSEMBLY 2398
METHOD FOR INSTALLING TRACK ROLLER ASSEMBLY 2400
DISASSEMBLE AND ASSEMBLE TRACK ROLLER ASSEMBLY .2403
METHOD FOR DISASSEMBLING TRACK ROLLER ASSEMBLY .2403
METHOD FOR ASSEMBLING TRACK ROLLER ASSEMBLY 2404
REMOVE AND INSTALL CARRIER ROLLER ASSEMBLY .2408
METHOD FOR REMOVING CARRIER ROLLER ASSEMBLY 2408
METHOD FOR INSTALLING CARRIER ROLLER ASSEMBLY 2409
DISASSEMBLE AND ASSEMBLE CARRIER ROLLER ASSEMBLY .2411
METHOD FOR DISASSEMBLING CARRIER ROLLER ASSEMBLY .2411
METHOD FOR ASSEMBLING CARRIER ROLLER ASSEMBLY 2412
REMOVE AND INSTALL PIVOT SHAFT ASSEMBLY 2415
METHOD FOR REMOVING PIVOT SHAFT ASSEMBLY .2415
METHOD FOR INSTALLING PIVOT SHAFT ASSEMBLY .2416
SEPARATE AND CONNECT TRACK ASSEMBLY 2418
METHOD FOR CHECKING BEFORE SEPARATING TRACK ASSEMBLY .2418
METHOD FOR SEPARATING TRACK ASSEMBLY (NORMAL) 2419
METHOD FOR SEPARATING TRACK ASSEMBLY (WHEN TRACK FRAME HAS INTERNAL DEFECT) 2420
METHOD FOR CONNECTING TRACK ASSEMBLY .2421
SEPARATE AND CONNECT PLUS TYPE TRACK ASSEMBLY 2424
METHOD FOR SEPARATING PLUS TYPE TRACK ASSEMBLY .2424
METHOD FOR CONNECTING PLUS TYPE TRACK ASSEMBLY .2424
DISASSEMBLE AND ASSEMBLE TRACK ASSEMBLY GENERALLY 2426
METHOD FOR DISASSEMBLING TRACK ASSEMBLY GENERALLY 2426
METHOD FOR ASSEMBLING TRACK ASSEMBLY GENERALLY .2431
DISASSEMBLE AND ASSEMBLE PLUS TYPE TRACK ASSEMBLY GENERALLY 2444
METHOD FOR DISASSEMBLING PLUS TYPE TRACK ASSEMBLY GENERALLY 2445
METHOD FOR ASSEMBLING PLUS TYPE TRACK ASSEMBLY GENERALLY .2446
DISASSEMBLE AND ASSEMBLE ONE LINK OF TRACK SHOE ASSEMBLY ON THE FIELD 2455
METHOD FOR DISASSEMBLING ONE LINK OF TRACK SHOE ASSEMBLY ON THE FIELD 2456
METHOD FOR ASSEMBLING ONE LINK OF TRACK SHOE ASSEMBLY ON THE FIELD .2457
DISASSEMBLE AND ASSEMBLE ONE LINK OF PLUS TYPE TRACK SHOE ASSEMBLY ON THE FIELD 2464
METHOD FOR DISASSEMBLING ONE LINK OF PLUS TYPE TRACK SHOE ASSEMBLY ON THE FIELD 2465
METHOD FOR ASSEMBLING ONE LINK OF PLUS TYPE TRACK SHOE ASSEMBLY ON THE FIELD .2467
REMOVE AND INSTALL EQUALIZER BAR ASSEMBLY 2471
METHOD FOR REMOVING EQUALIZER BAR ASSEMBLY .2471
METHOD FOR INSTALLING EQUALIZER BAR ASSEMBLY .2473
REMOVE AND INSTALL EQUALIZER BAR SIDE BUSHINGS .2476
METHOD FOR REMOVING EQUALIZER BAR SIDE BUSHINGS 2476
METHOD FOR INSTALLING EQUALIZER BAR SIDE BUSHINGS 2477
REMOVE AND INSTALL SEGMENT TEETH .2478
METHOD FOR REMOVING SEGMENT TEETH 2478
METHOD FOR INSTALLING SEGMENT TEETH 2480
HYDRAULIC SYSTEM .2482
REMOVE AND INSTALL HYDRAULIC TANK ASSEMBLY .2482
METHOD FOR REMOVING HYDRAULIC TANK ASSEMBLY 2483
METHOD FOR INSTALLING HYDRAULIC TANK ASSEMBLY 2489
REMOVE AND INSTALL CONTROL VALVE ASSEMBLY 2498
METHOD FOR REMOVING CONTROL VALVE ASSEMBLY .2498
METHOD FOR INSTALLING CONTROL VALVE ASSEMBLY .2502
WORK EQUIPMENT .2506
REMOVE AND INSTALL BLADE ASSEMBLY 2506
METHOD FOR REMOVING BLADE ASSEMBLY .2506
METHOD FOR INSTALLING BLADE ASSEMBLY .2509
REMOVE AND INSTALL BLADE LIFT CYLINDER ASSEMBLY 2514
METHOD FOR REMOVING BLADE LIFT CYLINDER ASSEMBLY .2514
METHOD FOR INSTALLING BLADE LIFT CYLINDER ASSEMBLY .2516
REMOVE AND INSTALL BLADE TILT CYLINDER ASSEMBLY 2518
METHOD FOR REMOVING BLADE TILT CYLINDER ASSEMBLY .2518
METHOD FOR INSTALLING BLADE TILT CYLINDER ASSEMBLY .2519
REMOVE AND INSTALL BLADE ANGLE CYLINDER ASSEMBLY .2521
METHOD FOR REMOVING BLADE ANGLE CYLINDER ASSEMBLY 2521
METHOD FOR INSTALLING BLADE ANGLE CYLINDER ASSEMBLY 2523
REMOVE AND INSTALL U-FRAME ASSEMBLY 2525
METHOD FOR REMOVING U-FRAME ASSEMBLY .2525
METHOD FOR INSTALLING U-FRAME ASSEMBLY .2529
CAB AND ITS ATTACHMENTS 2532
REMOVE AND INSTALL OPERATOR’S CAB ASSEMBLY .2532
METHOD FOR REMOVING OPERATOR’S CAB ASSEMBLY 2533
METHOD FOR INSTALLING OPERATOR’S CAB ASSEMBLY 2540
REMOVE AND INSTALL OPERATOR’S CAB GLASS (ADHERED GLASS) 2548
METHOD FOR REMOVING OPERATOR’S CAB GLASS (ADHERED GLASS) .2550
METHOD FOR INSTALLING OPERATOR’S CAB GLASS (ADHERED GLASS) .2550
REMOVE AND INSTALL AIR CONDITIONER UNIT ASSEMBLY .2556
METHOD FOR REMOVING AIR CONDITIONER UNIT ASSEMBLY 2556
METHOD FOR INSTALLING AIR CONDITIONER UNIT ASSEMBLY 2562
REMOVE AND INSTALL RECEIVER DRIER 2569
METHOD FOR REMOVING RECEIVER DRIER .2569
METHOD FOR INSTALLING RECEIVER DRIER .2570
REMOVE AND INSTALL OPERATOR’S SEAT .2573
METHOD FOR REMOVING OPERATOR’S SEAT 2573
METHOD FOR INSTALLING OPERATOR’S SEAT 2574
REMOVE AND INSTALL SEAT BELT .2575
METHOD FOR REMOVING SEAT BELT 2575
METHOD FOR INSTALLING SEAT BELT 2575
REMOVE AND INSTALL FOOT HEATER ASSEMBLY 2577
METHOD FOR REMOVING FOOT HEATER ASSEMBLY .2577
METHOD FOR INSTALLING FOOT HEATER ASSEMBLY .2579
DISASSEMBLE AND ASSEMBLE FOOT HEATER ASSEMBLY 2582
METHOD FOR DISASSEMBLING FOOT HEATER ASSEMBLY 2582
METHOD FOR ASSEMBLING FOOT HEATER ASSEMBLY .2583
ELECTRICAL SYSTEM 2584
REMOVE AND INSTALL ENGINE CONTROLLER ASSEMBLY 2584
METHOD FOR REMOVING ENGINE CONTROLLER ASSEMBLY .2584
METHOD FOR INSTALLING ENGINE CONTROLLER ASSEMBLY .2587
REMOVE AND INSTALL HST CONTROLLER ASSEMBLY .2591
METHOD FOR REMOVING HST CONTROLLER ASSEMBLY 2591
METHOD FOR INSTALLING HST CONTROLLER ASSEMBLY 2592
REMOVE AND INSTALL MACHINE MONITOR ASSEMBLY 2593
METHOD FOR REMOVING MACHINE MONITOR ASSEMBLY .2593
METHOD FOR INSTALLING MACHINE MONITOR ASSEMBLY .2594
REMOVE AND INSTALL MASS AIR FLOW AND TEMPERATURE SENSOR 2596
METHOD FOR REMOVING MASS AIR FLOW AND TEMPERATURE SENSOR .2596
METHOD FOR INSTALLING MASS AIR FLOW AND TEMPERATURE SENSOR .2598
REMOVE AND INSTALL KCCV CRANKCASE PRESSURE SENSOR 2600
METHOD FOR REMOVING KCCV CRANKCASE PRESSURE SENSOR .2600
METHOD FOR INSTALLING KCCV CRANKCASE PRESSURE SENSOR .2602
REMOVE AND INSTALL KOMTRAX TERMINAL ASSEMBLY .2604
METHOD FOR REMOVING KOMTRAX TERMINAL ASSEMBLY 2604
METHOD FOR INSTALLING KOMTRAX TERMINAL ASSEMBLY 2605
REMOVE AND INSTALL GATEWAY FUNCTION CONTROLLER ASSEMBLY 2606
REMOVE GATEWAY FUNCTION CONTROLLER ASSEMBLY 2606
INSTALL GATEWAY FUNCTION CONTROLLER ASSEMBLY .2607
REMOVE AND INSTALL COMMUNICATION TERMINAL 2608
REMOVE COMMUNICATION TERMINAL 2608
INSTALL COMMUNICATION TERMINAL .2611
60 MAINTENANCE STANDARD 2615
CONTENTS .2616
ABBREVIATION LIST 2617
ENGINE AND COOLING SYSTEM 2623
MAINTENANCE STANDARD OF ENGINE MOUNT .2623
MAINTENANCE STANDARD OF DAMPER .2624
MAINTENANCE STANDARD OF COOLING SYSTEM .2625
MAINTENANCE STANDARD OF COOLING FAN MOTOR 2627
MAINTENANCE STANDARD OF HYDRAULIC OIL COOLER BYPASS AND HST CHARGE SAFETY VALVE 2629
POWER TRAIN 2630
MAINTENANCE STANDARD OF HST PUMP .2630
MAINTENANCE STANDARD OF EPC VALVE OF HST PUMP 2632
MAINTENANCE STANDARD OF TOW RECEIVING VALVE OF HST PUMP 2633
MAINTENANCE STANDARD OF HST CHARGE PUMP 2634
MAINTENANCE STANDARD OF HST MOTOR 2636
MAINTENANCE STANDARD OF FINAL DRIVE 2638
MAINTENANCE STANDARD OF SPROCKET FOR PLUS TYPE TRACK SHOE 2640
MAINTENANCE STANDARD OF SPROCKET TOOTH PROFILE FULL-SCALE DRAWING FOR PLUS TYPE TRACK SHOE .2641
UNDERCARRIAGE AND FRAME 2642
MAINTENANCE STANDARD OF SUSPENSION .2642
MAINTENANCE STANDARD OF TRACK FRAME AND IDLER CUSHION 2645
MAINTENANCE STANDARD OF IDLER 2648
MAINTENANCE STANDARD OF TRACK ROLLER FOR PLUS TYPE TRACK SHOES (SINGLE FLANGE TYPE) 2650
MAINTENANCE STANDARD OF TRACK ROLLER FOR PLUS TYPE TRACK SHOES (DOUBLE FLANGE TYPE) 2651
MAINTENANCE STANDARD OF CARRIER ROLLER FOR PLUS TYPE TRACK SHOE 2653
MAINTENANCE STANDARD OF PLUS TYPE TRACK SHOE .2654
MAINTENANCE STANDARD OF SINGLE SHOE 2656
HYDRAULIC SYSTEM .2657
MAINTENANCE STANDARD OF HYDRAULIC TANK .2657
MAINTENANCE STANDARD OF WORK EQUIPMENT AND COOLING FAN PUMP 2658
MAINTENANCE STANDARD OF SERVO VALVE OF WORK EQUIPMENT AND COOLING FAN PUMP .2659
MAINTENANCE STANDARD OF CONTROL VALVE 2661
MAINTENANCE STANDARD OF RIPPER PPC VALVE .2667
MAINTENANCE STANDARD OF 5-PORT VALVE OF EPC AND SOLENOID .2669
MAINTENANCE STANDARD OF EPC VALVE 2670
MAINTENANCE STANDARD OF QUICK DROP VALVE .2671
WORK EQUIPMENT .2673
MAINTENANCE STANDARD OF FRONT WORK EQUIPMENT .2673
MAINTENANCE STANDARD OF CUTTING EDGE AND END BIT .2676
MAINTENANCE STANDARD OF BLADE LIFT CYLINDER 2677
MAINTENANCE STANDARD OF BLADE TILT CYLINDER 2678
MAINTENANCE STANDARD OF BLADE ANGLE CYLINDER .2679
MAINTENANCE STANDARD OF FIXED MULTI-SHANK RIPPER .2680
MAINTENANCE STANDARD OF RIPPER LIFT CYLINDER .2682
CAB AND ITS ATTACHMENTS 2683
MAINTENANCE STANDARD OF CAB MOUNT 2683
ELECTRICAL SYSTEM 2685
MAINTENANCE STANDARD OF ELECTRIC STEERING CONTROL LEVER 2685
80 APPENDIX 2687
CONTENTS .2688
ABBREVIATION LIST 2689
AIR CONDITIONER SYSTEM .2695
PRECAUTIONS FOR REFRIGERANT 2695
AIR CONDITIONER COMPONENT 2696
SPECIFICATIONS OF AIR CONDITIONER 2699
CONFIGURATION AND FUNCTION OF REFRIGERATION CYCLE 2700
OUTLINE OF REFRIGERATION CYCLE .2701
COMPONENT PARTS OF AIR CONDITIONER SYSTEM 2703
AIR CONDITIONER UNIT .2703
CONFIGURATION DIAGRAM OF AIR CONDITIONER UNIT 2703
FUNCTION OF AIR CONDITIONER UNIT .2704
COMPONENT PARTS OF AIR CONDITIONER UNIT 2705
FUNCTION OF EVAPORATOR AS AIR CONDITIONER UNIT COMPONENT .2705
FUNCTION OF HEATER CORE AS AIR CONDITIONER UNIT COMPONENT 2705
FUNCTION OF THERMISTOR AS AIR CONDITIONER UNIT COMPONENT .2705
STRUCTURE OF EXPANSION VALVE AS AIR CONDITIONER UNIT COMPONENT .2706
FUNCTION OF EXPANSION VALVE AS AIR CONDITIONER UNIT COMPONENT 2706
OPERATE EXPANSION VALVE AS AIR CONDITIONER UNIT COMPONENT 2706
FUNCTION OF DUAL PRESSURE SWITCH .2707
FUNCTION OF PRESSURE SWITCH 2707
COMPRESSOR .2708
STRUCTURE OF COMPRESSOR 2708
SPECIFICATIONS OF COMPRESSOR .2708
FUNCTION OF COMPRESSOR .2708
CONDENSER 2709
STRUCTURE OF CONDENSER .2709
SPECIFICATIONS OF CONDENSER 2709
FUNCTION OF CONDENSER 2710
RECEIVER DRIER .2711
STRUCTURE OF RECEIVER DRIER 2711
SPECIFICATIONS OF RECEIVER DRIER .2711
FUNCTION OF RECEIVER DRIER .2711
EXPLANATION OF PROCEDURE FOR TESTING AND TROUBLESHOOTING OF AIR CONDITIONER 2713
CIRCUIT DIAGRAM OF AIR CONDITIONER .2716
AIR CONDITIONER SYSTEM DIAGRAM .2717
CONTROL FUNCTION OF AIR CONDITIONER 2718
INSTALLATION LOCATIONS OF AIR CONDITIONER PARTS AND ARRANGEMENT OF CONNECTORS 2719
TEST RELAYS 2723
METHOD FOR TESTING RELAYS 2723
AIR CONDITIONER TROUBLESHOOTING CHART 1 2725
AIR CONDITIONER TROUBLESHOOTING CHART 2 2726
INFORMATION DESCRIBED IN TROUBLESHOOTING TABLE .2729
TROUBLESHOOTING FOR CONDENSER FAN 2731
TROUBLESHOOTING FOR COMPRESSOR AND REFRIGERANT SYSTEM (AIR IS NOT COOLED) 2734
TROUBLESHOOTING FOR BLOWER MOTOR SYSTEM (NO AIR COMES OUT OR AIR FLOW IS ABNORMAL) .2738
TROUBLESHOOTING FOR TEMPERATURE CONTROL FUNCTION .2741
TROUBLESHOOTING USING GAUGE PRESSURE .2745
CONNECTION OF SERVICE TOOL .2747
METHOD FOR CONNECTING SERVICE TOOL .2748
PRECAUTIONS FOR DISCONNECTING AND CONNECTING HOSES AND TUBES IN AIR CONDITIONER PIPINGS 2749
HANDLE COMPRESSOR OIL 2751
90 CIRCUIT DIAGRAMS 2753
CONTENTS .2754
ABBREVIATION LIST 2755
HYDRAULIC CIRCUIT DIAGRAM 2761
SYMBOLS USED IN HYDRAULIC CIRCUIT DIAGRAM 2761
HYDRAULIC CIRCUIT DIAGRAM 2765
ELECTRICAL CIRCUIT DIAGRAM .2767
SYMBOLS USED IN ELECTRICAL CIRCUIT DIAGRAM .2767
ELECTRICAL CIRCUIT DIAGRAM (MACHINE WITH KOMTRAX TERMINAL) (1/14) 2771
ELECTRICAL CIRCUIT DIAGRAM (MACHINE WITH KOMTRAX TERMINAL) (2/14) 2773
ELECTRICAL CIRCUIT DIAGRAM (MACHINE WITH KOMTRAX TERMINAL) (3/14) 2775
ELECTRICAL CIRCUIT DIAGRAM (MACHINE WITH KOMTRAX TERMINAL) (4/14) 2777
ELECTRICAL CIRCUIT DIAGRAM (MACHINE WITH KOMTRAX TERMINAL) (5/14) 2779
ELECTRICAL CIRCUIT DIAGRAM (MACHINE WITH KOMTRAX TERMINAL) (6/14) 2781
ELECTRICAL CIRCUIT DIAGRAM (MACHINE WITH KOMTRAX TERMINAL) (7/14) 2783
ELECTRICAL CIRCUIT DIAGRAM (MACHINE WITH KOMTRAX TERMINAL) (8/14) 2785
ELECTRICAL CIRCUIT DIAGRAM (MACHINE WITH KOMTRAX TERMINAL) (9/14) 2787
ELECTRICAL CIRCUIT DIAGRAM (MACHINE WITH KOMTRAX TERMINAL) (10/14) .2789
ELECTRICAL CIRCUIT DIAGRAM (MACHINE WITH KOMTRAX TERMINAL) (11/14) .2791
ELECTRICAL CIRCUIT DIAGRAM (MACHINE WITH KOMTRAX TERMINAL) (12/14) .2793
ELECTRICAL CIRCUIT DIAGRAM (MACHINE WITH KOMTRAX TERMINAL) (13/14) .2795
ELECTRICAL CIRCUIT DIAGRAM (MACHINE WITH KOMTRAX TERMINAL) (14/14) .2797
ELECTRICAL CIRCUIT DIAGRAM (MACHINE WITH GATEWAY FUNCTION CONTROLLER) (1/16) .2799
ELECTRICAL CIRCUIT DIAGRAM (MACHINE WITH GATEWAY FUNCTION CONTROLLER) (2/16) .2801
ELECTRICAL CIRCUIT DIAGRAM (MACHINE WITH GATEWAY FUNCTION CONTROLLER) (3/16) .2803
ELECTRICAL CIRCUIT DIAGRAM (MACHINE WITH GATEWAY FUNCTION CONTROLLER) (4/16) .2805
ELECTRICAL CIRCUIT DIAGRAM (MACHINE WITH GATEWAY FUNCTION CONTROLLER) (5/16) .2807
ELECTRICAL CIRCUIT DIAGRAM (MACHINE WITH GATEWAY FUNCTION CONTROLLER) (6/16) .2809
ELECTRICAL CIRCUIT DIAGRAM (MACHINE WITH GATEWAY FUNCTION CONTROLLER) (7/16) .2811
ELECTRICAL CIRCUIT DIAGRAM (MACHINE WITH GATEWAY FUNCTION CONTROLLER) (8/16) .2813
ELECTRICAL CIRCUIT DIAGRAM (MACHINE WITH GATEWAY FUNCTION CONTROLLER) (9/16) .2815
ELECTRICAL CIRCUIT DIAGRAM (MACHINE WITH GATEWAY FUNCTION CONTROLLER) (10/16) 2817
ELECTRICAL CIRCUIT DIAGRAM (MACHINE WITH GATEWAY FUNCTION CONTROLLER) (11/16) 2819
ELECTRICAL CIRCUIT DIAGRAM (MACHINE WITH GATEWAY FUNCTION CONTROLLER) (12/16) 2821
ELECTRICAL CIRCUIT DIAGRAM (MACHINE WITH GATEWAY FUNCTION CONTROLLER) (13/16) 2823
ELECTRICAL CIRCUIT DIAGRAM (MACHINE WITH GATEWAY FUNCTION CONTROLLER) (14/16) 2825
ELECTRICAL CIRCUIT DIAGRAM (MACHINE WITH GATEWAY FUNCTION CONTROLLER) (15/16) 2827
ELECTRICAL CIRCUIT DIAGRAM (MACHINE WITH GATEWAY FUNCTION CONTROLLER) (16/16) 2829
INDEX .2831

DESCRIPTION:

Komatsu D51EX-24,D51PX-24 Bulldozer Shop Manual KEBM661710 –  PDF DOWNLOAD

SERIAL NUMBERS

• D51EX-B20001      and up
• D51PX-B20001       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. “STRUC- TURE 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 ad- justing 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