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KOMATSU D51EXi-24 D51PXi-24 BULLDOZER SHOP MANUAL SEN06621-13 – PDF DOWNLOAD
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KOMATSU D51EXi-24 D51PXi-24 BULLDOZER SHOP MANUAL SEN06621-13 – PDF DOWNLOAD
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KOMATSU D51EXi-24 D51PXi-24 BULLDOZER SHOP MANUAL SEN06621-13 – PDF DOWNLOAD
Language : English
Pages : 3150
Downloadable : Yes
File Type : PDF
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TABLE OF CONTENTS:
KOMATSU D51EXi-24 D51PXi-24 BULLDOZER SHOP MANUAL SEN06621-13 – PDF DOWNLOAD
Cover.................................................................................................................................................. 1 00 Index and Foreword................................................................................................................................. 3 Index............................................................................................................................................. 4 Abbreviation List................................................................................................................................. 22 Foreword, Safety, Basic Information............................................................................................................... 28 How to Read the Shop Manual................................................................................................................... 28 Safety Notice for Operation................................................................................................................... 30 Precautions to Prevent Fire................................................................................................................... 38 Procedures If Fire Occurs..................................................................................................................... 40 Precautions When You Discard Waste Materials.................................................................................................. 41 Procedures for Exhaust Gas Regulations........................................................................................................ 42 Precautions for DEF........................................................................................................................... 43 General Character and Precautions for Handling............................................................................................ 43 Precautions When You Add.................................................................................................................. 43 Precautions for Storage................................................................................................................... 43 Precautions for Fire Hazard and Leakage................................................................................................... 43 Other Precautions......................................................................................................................... 43 Store DEF..................................................................................................................................... 44 Precautions When You Handle Hydraulic Equipment............................................................................................... 45 Precautions When You Disconnect and Connect Pipings........................................................................................... 48 Precautions When You Handle Electrical Equipment.............................................................................................. 55 Precautions When You Handle Fuel System Equipment............................................................................................. 57 Precautions When You Handle Intake System Equipment........................................................................................... 58 Practical Use of KOMTRAX...................................................................................................................... 59 Disconnect and Connect Push-Pull Type Coupler................................................................................................. 60 How to Disconnect and Connect Type 1 Push-Pull Type Coupler............................................................................... 60 How to Disconnect and Connect Type 2 Push-Pull Type Coupler............................................................................... 61 How to Disconnect and Connect Type 3 Push-Pull Type Coupler............................................................................... 62 Precautions for Disconnection and Connection of Connectors.................................................................................... 64 Disconnect and Connect Deutsch Connector...................................................................................................... 68 How to Disconnect and Connect Slide Lock Type Connector....................................................................................... 69 Disconnect and Connect Connector with Lock to Pull............................................................................................ 71 Disconnect and Connect Connector with Lock to Push............................................................................................ 72 Disconnect and Connect Connector with Housing to Rotate....................................................................................... 74 How to Read the Codes for Electric Cable...................................................................................................... 75 Explanation of Terms for Maintenance Standard................................................................................................. 79 Standard Tightening Torque Table.............................................................................................................. 82 Conversion Table.............................................................................................................................. 89 01 Specification...................................................................................................................................... 95 Table of Contents................................................................................................................................. 96 Abbreviation List................................................................................................................................. 97 Specifications.................................................................................................................................... 103 Specification Drawing......................................................................................................................... 103 Specification Drawing: D51EXI-24.......................................................................................................... 103 Specification Drawing: D51PXI-24.......................................................................................................... 105 Specifications................................................................................................................................ 107 Specifications: D51EXI-24................................................................................................................. 107 Specifications: D51PXI-24................................................................................................................. 113 Weight Table.................................................................................................................................. 118 Weight Table: D51EXI-24................................................................................................................... 118 Weight Table: D51PXI-24................................................................................................................... 120 Fuel, Coolant, Lubricants (For North America)................................................................................................. 122 How to Use Fuel, Coolant and Lubricants by Ambient Temperature............................................................................ 122 Fuel, Coolant, Lubricants (For European Union)................................................................................................ 124 How to Use Fuel, Coolant and Lubricants by Ambient Temperature............................................................................ 124 10 Structure and Function............................................................................................................................. 127 Table of Contents................................................................................................................................. 128 Abbreviation List................................................................................................................................. 132 Urea SCR System................................................................................................................................... 138 Layout Drawing of Urea SCR System............................................................................................................. 138 Urea SCR System Diagram....................................................................................................................... 140 Function of Urea SCR System................................................................................................................... 141 Function of DEF System.................................................................................................................... 141 Inducement Strategy....................................................................................................................... 144 Component Parts of Urea SCR System............................................................................................................ 158 DEF Mixing Tube........................................................................................................................... 158 SCR Assembly.............................................................................................................................. 159 DEF Tank.................................................................................................................................. 161 DEF Pump.................................................................................................................................. 163 DEF Injector.............................................................................................................................. 164 DEF Hose.................................................................................................................................. 165 DEF Tank Heating Valve.................................................................................................................... 166 Boot-up System.................................................................................................................................... 167 Layout Drawing of Boot-up System (Machine with KOMTRAX Terminal).............................................................................. 167 Layout Drawing of Boot-up System (Machine with Gateway Function Controller)................................................................... 168 System Operating Lamp System.................................................................................................................. 169 System Diagram of System Operating Lamp System (Machine with KOMTRAX Terminal)............................................................ 169 System Diagram of System Operating Lamp System (Machine with Gateway Function Controller)................................................. 169 Function of System Operating Lamp System (Machine with KOMTRAX Terminal).................................................................. 169 Function of System Operating Lamp System (Machine with Gateway Function Controller)....................................................... 170 Battery Disconnect Switch..................................................................................................................... 172 Function of Battery Disconnect Switch..................................................................................................... 172 Engine System..................................................................................................................................... 173 Layout Drawing of Engine System............................................................................................................... 173 Engine Control System......................................................................................................................... 175 Layout of Engine Control System (Machine with KOMTRAX Terminal)........................................................................... 175 Layout of Engine Control System (Machine with Gateway Function Controller)................................................................ 177 System Diagram of Engine Control System (Machine with KOMTRAX Terminal)................................................................... 179 System Diagram of Engine Control System (Machine with Gateway Function Controller)........................................................ 181 Function of Engine Control System (Machine with KOMTRAX Terminal)......................................................................... 183 Function of Engine Control System (Machine with Gateway Function Controller).............................................................. 185 Automatic Idle Stop System.................................................................................................................... 187 Automatic Idle Stop System Diagram (Machine with KOMTRAX Terminal)........................................................................ 187 System Diagram of Automatic Idle Stop System (Machine with Gateway Function Controller)................................................... 188 Function of Automatic Idle Stop System.................................................................................................... 188 Component Parts of Engine System.............................................................................................................. 191 Damper.................................................................................................................................... 191 VGT....................................................................................................................................... 192 EGR System................................................................................................................................ 195 EGR Valve................................................................................................................................. 197 EGR Cooler................................................................................................................................ 199 KCCV System............................................................................................................................... 201 KCCV Ventilator........................................................................................................................... 203 KDOC...................................................................................................................................... 205 Cooling System.................................................................................................................................... 208 Layout Drawing of Cooling System.............................................................................................................. 208 Specifications of Cooling System.......................................................................................................... 209 Cooling Fan Control System.................................................................................................................... 210 System Diagram of Cooling Fan Control System.............................................................................................. 210 Function of Cooling Fan Control System.................................................................................................... 211 Component Parts of Cooling System............................................................................................................. 213 Cooling Fan Motor......................................................................................................................... 213 Hydraulic Oil Cooler Bypass and HST Charge Safety Valve................................................................................... 218 Hydraulic Oil Cooler Bypass Valve......................................................................................................... 219 HST Charge Safety Valve................................................................................................................... 220 Control System.................................................................................................................................... 222 Layout Drawing of Control System (Machine with KOMTRAX Terminal).............................................................................. 222 Layout Drawing of Control System (Machine with Gateway Function Controller)................................................................... 223 Machine Monitor System........................................................................................................................ 224 System Diagram of Machine Monitor System (Machine with KOMTRAX Terminal).................................................................. 224 System Diagram of Machine Monitor System (Machine with Gateway Function Controller)....................................................... 225 Function of Machine Monitor System........................................................................................................ 225 KOMTRAX System................................................................................................................................ 226 KOMTRAX System Diagram (Machine with KOMTRAX Terminal).................................................................................... 226 System Diagram of KOMTRAX System (Machine with Gateway Function Controller)............................................................... 226 Function of KOMTRAX System................................................................................................................ 227 Component Parts of Control System............................................................................................................. 228 Machine Monitor........................................................................................................................... 228 KOMTRAX Terminal.......................................................................................................................... 243 Gateway Function Controller............................................................................................................... 245 Communication Terminal.................................................................................................................... 248 HST Controller............................................................................................................................ 250 Engine Controller......................................................................................................................... 254 Fuel Control Dial......................................................................................................................... 261 Decelerator and Brake Potentiometer....................................................................................................... 263 Hydraulic System.................................................................................................................................. 265 Layout Drawing of Hydraulic System............................................................................................................ 265 CLSS.......................................................................................................................................... 266 Structure of CLSS......................................................................................................................... 266 Function of CLSS.......................................................................................................................... 267 Component Parts of Hydraulic System........................................................................................................... 269 Hydraulic Tank............................................................................................................................ 269 Work Equipment and Cooling Fan Pump....................................................................................................... 271 LS Valve.................................................................................................................................. 279 PC Valve.................................................................................................................................. 280 Control Valve............................................................................................................................. 283 Power Train System................................................................................................................................ 301 Layout Drawing of HST System.................................................................................................................. 301 Operation of HST System....................................................................................................................... 302 Steering and Brake Control System............................................................................................................. 304 Layout Drawing of Steering and Brake Control System....................................................................................... 304 Function of Steering and Brake Control System............................................................................................. 304 HST Control System............................................................................................................................ 306 System Diagram of HST Control System...................................................................................................... 306 Gear Shift Control Function............................................................................................................... 307 Engine Low Speed Matching Control Function................................................................................................ 310 HST Pump and Motor Sequence Control Function.............................................................................................. 311 Deceleration and Brake Control Function................................................................................................... 312 Gear Shift Control Function by Load....................................................................................................... 314 Turn Control Function..................................................................................................................... 314 Straight Travel Correction Control Function............................................................................................... 315 Parking Brake Control System.................................................................................................................. 317 System Diagram of Parking Brake Control System............................................................................................ 317 Function of Parking Brake Control System.................................................................................................. 318 Operation of Parking Brake Control System................................................................................................. 319 Component Parts of Power Train System......................................................................................................... 320 HST Pump.................................................................................................................................. 320 HST Charge Pump........................................................................................................................... 335 HST Motor................................................................................................................................. 336 Final Drive............................................................................................................................... 349 Electric Steering Electric Lever.......................................................................................................... 353 Work Equipment System............................................................................................................................. 356 Work Equipment Control........................................................................................................................ 356 Layout Drawing of Work Equipment Control.................................................................................................. 356 Function of Work Equipment Control........................................................................................................ 357 Layout Drawing of Front Work Equipment........................................................................................................ 358 Layout Drawing of Fixed Multi-Shank Ripper.................................................................................................... 359 Component Parts of Work Equipment System...................................................................................................... 360 Ripper PPC Valve.......................................................................................................................... 360 5-Spool EPC and Solenoid Valve............................................................................................................ 364 Pilot Circuit Accumulator................................................................................................................. 370 Quick Drop Valve.......................................................................................................................... 371 Piston Valve.............................................................................................................................. 373 Electric Blade Control Lever.............................................................................................................. 374 ICT System........................................................................................................................................ 376 Layout Drawing of ICT System.................................................................................................................. 376 System Diagram of ICT Control System.......................................................................................................... 378 Blade Control System.......................................................................................................................... 380 Function of Blade Control System.......................................................................................................... 380 Leveling Mode System Diagram.............................................................................................................. 382 Function of Leveling Mode................................................................................................................. 383 Operation of Leveling Mode................................................................................................................ 383 Dozing Mode System Diagram................................................................................................................ 384 Function of Dozing Mode................................................................................................................... 384 Operation of Dozing Mode.................................................................................................................. 384 Smooth Start System........................................................................................................................... 386 Smooth Start System Diagram............................................................................................................... 386 Function of Smooth Start System........................................................................................................... 386 Operation of Smooth Start System.......................................................................................................... 386 Slip Control System........................................................................................................................... 388 Slip Control System Diagram............................................................................................................... 388 Function of Slip Control System........................................................................................................... 388 Operation of Slip Control System.......................................................................................................... 388 Assist Control System......................................................................................................................... 389 Assist Control System Diagram............................................................................................................. 389 Function of Assist Control System......................................................................................................... 389 Operation of Assist Control System........................................................................................................ 390 HST Speed Range Control System................................................................................................................ 391 HST Speed Range Control System Diagram.................................................................................................... 391 Function of HST Speed Range Control System................................................................................................ 391 Operation of HST Speed Range Control System............................................................................................... 391 Component Parts of ICT System................................................................................................................. 393 ICT Sensor Controller..................................................................................................................... 393 Control Box............................................................................................................................... 397 GNSS Receiver............................................................................................................................. 400 GNSS Antenna.............................................................................................................................. 404 IMU Sensor................................................................................................................................ 405 Stroke and Reset Sensor for Blade Lift Cylinder........................................................................................... 409 Stroke Sensor for Blade Tilt Cylinder..................................................................................................... 412 Stroke Sensor for Blade Angle Cylinder.................................................................................................... 414 Undercarriage and Frame........................................................................................................................... 416 Main Frame.................................................................................................................................... 416 Structure of Main Frame................................................................................................................... 416 Suspension.................................................................................................................................... 417 Structure of Suspension................................................................................................................... 417 Specifications of Suspension.............................................................................................................. 418 Function of Suspension.................................................................................................................... 419 Track Frame and Idler Cushion................................................................................................................. 420 Structure of Track Frame and Idler Cushion................................................................................................ 420 Function of Track Frame and Idler Cushion................................................................................................. 421 Work Equipment.................................................................................................................................... 422 Structure of Front Work Equipment............................................................................................................. 422 Structure of Fixed Multi-Shank Ripper......................................................................................................... 423 CAB Related Parts................................................................................................................................. 424 ROPS CAB...................................................................................................................................... 424 Structure of ROPS CAB (Machine with KOMTRAX Terminal)..................................................................................... 424 Structure of ROPS CAB (Machine with Gateway Function Controller).......................................................................... 425 Function of ROPS CAB...................................................................................................................... 426 CAB Mount..................................................................................................................................... 427 Structure of CAB Mount.................................................................................................................... 427 Function of CAB Mount..................................................................................................................... 427 20 Standard Value Table............................................................................................................................... 429 Table of Contents................................................................................................................................. 430 Abbreviation List................................................................................................................................. 431 Standard Value Table for Engine................................................................................................................... 437 Standard Value Table for Engine: D51EXI-24.................................................................................................... 437 Standard Value Table for Engine: D51PXI-24.................................................................................................... 441 Standard Value Table for Machine.................................................................................................................. 445 Standard Value Table for Machine: D51EXI-24................................................................................................... 445 Standard Value Table for Machine: D51PXI-24................................................................................................... 462 Machine Posture and Procedures to Measure Performance......................................................................................... 477 30 Testing and Adjusting.............................................................................................................................. 479 Table of Contents................................................................................................................................. 480 Precautions Before Work........................................................................................................................... 484 Abbreviation List................................................................................................................................. 485 Related Information on Testing and Adjusting...................................................................................................... 491 Tools for Testing and Adjusting............................................................................................................... 491 Sketch of Tools for Testing and Adjusting..................................................................................................... 499 Engine and Cooling System......................................................................................................................... 504 Examine Engine Speed.......................................................................................................................... 504 How to Examine Engine Speed............................................................................................................... 504 Examine Boost Pressure........................................................................................................................ 506 How to Examine Boost Pressure............................................................................................................. 506 Examine Exhaust Gas Color..................................................................................................................... 507 How to Examine Exhaust Gas Color with the Handy Smoke Checker............................................................................. 507 How to Examine Exhaust Gas Color with Smoke Meter......................................................................................... 508 Examine and Adjust Valve Clearance............................................................................................................ 509 Check Valve Clearance..................................................................................................................... 509 Adjust Valve Clearance.................................................................................................................... 510 Examine Compression Pressure.................................................................................................................. 511 How to Examine Compression Pressure....................................................................................................... 511 Examine Blowby Pressure....................................................................................................................... 516 How to Examine Blowby Pressure............................................................................................................ 516 Examine Engine Oil Pressure................................................................................................................... 518 How to Examine Engine Oil Pressure........................................................................................................ 518 Visual Check Inside of EGR Valve.............................................................................................................. 519 How to do the Visual Check Inside of EGR Valve............................................................................................ 519 Clean Inside of EGR Valve..................................................................................................................... 521 How to Clean Inside of EGR Valve.......................................................................................................... 521 Examine Fuel Pressure......................................................................................................................... 524 How to Examine Fuel Pressure.............................................................................................................. 525 Examine Fuel Discharge, Return and Leakage.................................................................................................... 529 How to Examine Fuel Discharge, Return, and Leakage........................................................................................ 530 Bleed Air from Fuel System.................................................................................................................... 535 How to Bleed Air from Fuel System......................................................................................................... 535 Examine Fuel Circuit for Leakage.............................................................................................................. 536 How to Examine Fuel System for Leakage.................................................................................................... 536 Handle Cylinder Cut-out Mode Operation........................................................................................................ 538 Handle No-Injection Cranking Operation........................................................................................................ 539 Examine KDOC, SCR and Muffler Stack for Looseness and Damage.................................................................................. 540 How to Examine KDOC, SCR and Muffler Stack for Looseness and Damage....................................................................... 540 Examine Installed Condition of Cylinder Heads and Manifolds................................................................................... 541 How to Examine Installed Condition of Cylinder Heads and Manifolds........................................................................ 541 Examine Engine Piping for Damage and Looseness................................................................................................ 542 How to Examine Engine Piping for Damage and Looseness..................................................................................... 542 Write Correction for Ash in Soot Accumulation to Engine Controller............................................................................ 543 How to Write Correction for Ash in Soot Accumulation to Engine Controller................................................................. 543 Examine SCR Related Functions................................................................................................................. 544 Examine DEF Pump Raised Pressure.......................................................................................................... 548 Examine Injection Volume from DEF Injector................................................................................................ 551 Examine DEF Line Heater Relay 1........................................................................................................... 555 Examine DEF Line Heater Relay 2........................................................................................................... 558 Examine DEF Pump Heater Relay............................................................................................................. 561 Examine DEF Tank Heater Valve............................................................................................................. 565 Examine SCR Denitration Efficiency........................................................................................................ 569 Clean DEF Tank................................................................................................................................ 572 How to Clean DEF Tank..................................................................................................................... 572 Clean DEF Tank Mounting Part.................................................................................................................. 576 How to Clean DEF Tank Mounting Part....................................................................................................... 576 Clean DEF Pump................................................................................................................................ 577 How to Clean DEF Pump..................................................................................................................... 577 Power Train....................................................................................................................................... 583 Examine and Adjust HST Oil Pressure........................................................................................................... 583 Examine HST Oil Pressure.................................................................................................................. 583 Adjust HST Oil Pressure................................................................................................................... 585 Bleed Air from HST Pump....................................................................................................................... 588 How to Bleed Air from HST Pump............................................................................................................ 588 Bleed Air from Servo Valve of HST Pump.................................................................................................... 588 Examine Outlet Pressure of Solenoid Valve..................................................................................................... 590 How to Examine Outlet Pressure of Solenoid Valve.......................................................................................... 590 Examine Travel Deviation...................................................................................................................... 594 How to Examine Travel Deviation........................................................................................................... 594 Examine Brake Performance Simply.............................................................................................................. 596 How to Examine Brake Performance Simply................................................................................................... 596 Examine and Adjust Deceleration/Brake Pedal................................................................................................... 597 How to Examine Deceleration/Brake Pedal................................................................................................... 597 How to Adjust Deceleration/Brake Pedal.................................................................................................... 599 Adjust Parking Brake Lever.................................................................................................................... 601 How to Adjust Parking Brake Lever......................................................................................................... 601 Move Machine When It Cannot Travel............................................................................................................ 603 Move Machine with Hydraulic Type Parking Brake Release System............................................................................. 603 Move Machine After You Remove Final Drive Shaft........................................................................................... 605 Undercarriage and Frame........................................................................................................................... 606 Examine and Adjust Idler Clearance............................................................................................................ 606 How to Adjust Idler Clearance Horizontally................................................................................................ 606 How to Adjust Idler Clearance Vertically.................................................................................................. 607 Examine Sprocket Wear......................................................................................................................... 608 How to Examine Sprocket Wear.............................................................................................................. 608 Examine and Adjust Track Tension.............................................................................................................. 609 How to Examine Track Tension.............................................................................................................. 609 How to Adjust Track Tension............................................................................................................... 609 Hydraulic System.................................................................................................................................. 611 Release Remained Pressure in Hydraulic Circuit................................................................................................ 611 How to Release Remained Pressure in Hydraulic System...................................................................................... 611 Examine and Adjust Work Equipment Circuit Oil Pressure........................................................................................ 612 How to Examine Work Equipment Circuit Oil Pressure........................................................................................ 612 Adjust Work Equipment Circuit Oil Pressure................................................................................................ 613 Examine and Adjust Oil Pressure in Control Circuit............................................................................................ 615 Examine Oil Pressure in Control Circuit................................................................................................... 615 Adjust Oil Pressure in Control Circuit.................................................................................................... 616 Examine Outlet Pressure of EPC Solenoid Valve................................................................................................. 617 How to Examine Outlet Pressure of EPC Solenoid Valve...................................................................................... 617 Bleed Air from Work Equipment and Cooling Fan Pump............................................................................................ 619 How to Bleed Air from Work Equipment and Cooling Fan Pump................................................................................. 619 Examine Cooling Fan Speed..................................................................................................................... 620 How to Examine Cooling Fan Speed.......................................................................................................... 620 Examine Cooling Fan Circuit Oil Pressure...................................................................................................... 621 How to Examine Cooling Fan Circuit Oil Pressure........................................................................................... 621 Examine Parts Which Cause Hydraulic Drift of Work Equipment................................................................................... 623 How to Examine Parts Which Cause Hydraulic Drift of Blade Lift Cylinder................................................................... 623 How to Examine the Parts Which Cause Hydraulic Drift of Blade Tilt Cylinder............................................................... 623 How to Examine the Parts Which Cause Hydraulic Drift of Ripper Lift Cylinder.............................................................. 624 Examine Oil Leakage from Work Equipment Cylinder.............................................................................................. 625 How to Examine Internal Oil Leakage of Work Equipment Cylinder............................................................................ 625 Bleed Air from Work Equipment Cylinders....................................................................................................... 628 Bleed Air from Work Equipment Cylinder.................................................................................................... 628 Work Equipment.................................................................................................................................... 629 Adjust Work Equipment Lock Lever.............................................................................................................. 629 How to Adjust Work Equipment Lock Lever................................................................................................... 629 Examine and Adjust Play of Blade Electric Lever............................................................................................... 631 How to Examine Play of Blade Electric Lever............................................................................................... 633 Adjust Play of Blade Electric Lever....................................................................................................... 633 Replace Universal Joint................................................................................................................... 635 Electrical System................................................................................................................................. 641 Set and Operate Machine Monitor............................................................................................................... 641 Operator Mode............................................................................................................................. 645 Function to Show Technician Identification Status Screen.................................................................................. 645 Function to Show Operator Identification Input Screen..................................................................................... 645 Examine Function by LCD (Liquid Crystal Display).......................................................................................... 646 Examine Function of Service Meter......................................................................................................... 646 Usage Limitation and Change Maintenance Password.......................................................................................... 646 Service Mode.............................................................................................................................. 649 How to Operate Service Mode............................................................................................................... 649 How to See Pre-defined Monitoring Information............................................................................................. 651 How to Examine Self-Define Monitor Information............................................................................................ 657 Abnormality Record Menu................................................................................................................... 668 How to See Maintenance Record............................................................................................................. 672 Maintenance Mode Setting.................................................................................................................. 673 Set Phone Number Entry.................................................................................................................... 677 Default Menu.............................................................................................................................. 679 Diagnostic Tests Menu..................................................................................................................... 686 Adjustment Menu........................................................................................................................... 694 No-Injection Cranking Operation........................................................................................................... 762 KOMTRAX Settings Menu..................................................................................................................... 765 Show Service Message...................................................................................................................... 769 Start Up KOMTRAX Terminal (Machine with KOMTRAX Terminal)..................................................................................... 771 Stop Use of KOMTRAX Terminal (Machine with KOMTRAX Terminal).................................................................................. 776 Start Up KOMTRAX System (Machine with Gateway Function Controller)............................................................................ 778 Stop Use of KOMTRAX System (Machine with Gateway Function Controller)......................................................................... 784 Adjust After Replacement of HST Controller.................................................................................................... 786 How to Adjust After Replacement of HST Controller......................................................................................... 786 Adjust After Replacement of Electric and Hydraulic Equipment.................................................................................. 792 Adjust Rearview Camera Angle.................................................................................................................. 794 How to Adjust Rearview Camera Angle....................................................................................................... 794 Handle Voltage Circuit of Engine Controller................................................................................................... 795 Handle Battery Disconnect Switch (Machine with KOMTRAX Terminal).............................................................................. 796 Handle Battery Disconnect Switch (Machine with Gateway Function Controller)................................................................... 797 Examine Diodes................................................................................................................................ 798 Examine Diodes by Digital Tester.......................................................................................................... 798 How to Examine Diodes by Analog Tester.................................................................................................... 798 ICT System........................................................................................................................................ 799 Set and Operate Control Box................................................................................................................... 799 Examine and Adjust ICT Related Devices.................................................................................................... 800 Calibrate Blade Edge Position................................................................................................................. 803 How to Operate Blade Calibration Menu (Pitch Rod Calibration)............................................................................. 804 How to Operate Blade Calibration Menu (Machine Cal Step A)................................................................................ 806 How to Operate Blade Calibration Menu (Machine Cal Step B)................................................................................ 811 Calibrate IMU Sensor.......................................................................................................................... 825 How to Calibrate IMU Sensor............................................................................................................... 825 Reset Cylinder Stroke End..................................................................................................................... 832 Reset Lift Cylinder Stroke End............................................................................................................ 832 Reset Tilt Cylinder Stroke End............................................................................................................ 833 Reset Angle Cylinder Stroke End........................................................................................................... 833 How to Input Wear Volume of Blade Edge and Track Shoes........................................................................................ 835 Examine and Adjust Blade Elevation............................................................................................................ 836 Examine Blade Elevation (For Old Control Box)............................................................................................. 836 Examine Blade Elevation (For New Control Box)............................................................................................. 838 Adjust Blade Elevation (For Old Control Box).............................................................................................. 841 Adjust Blade Elevation (For New Control Box).............................................................................................. 842 Examine Stroke Sensor for Lift Cylinder....................................................................................................... 844 How to Examine Stroke Sensor for Lift Cylinder............................................................................................ 844 Examine Stroke Sensor for Tilt Cylinder....................................................................................................... 846 How to Examine Stroke Sensor for Tilt Cylinder............................................................................................ 846 Examine Stroke Sensor for Angle Cylinder...................................................................................................... 848 How to Examine Stroke Sensor for Angle Cylinder........................................................................................... 848 Examine and Adjust Reset Sensor for Lift Cylinder............................................................................................. 850 How to Examine Reset Sensor for Lift Cylinder............................................................................................. 850 Adjust Reset Sensor for Lift Cylinder..................................................................................................... 851 Adjust When ICT Sensor Controller is Replaced................................................................................................. 852 How to Adjust When ICT Sensor Controller is Replaced...................................................................................... 852 How to Adjust When ICT Related Devices are Repaired or Replaced............................................................................... 855 Pm Clinic......................................................................................................................................... 858 Pm Clinic Service............................................................................................................................. 858 Pm Clinic Check Sheet: D51EXI-24.......................................................................................................... 860 Pm Clinic Check Sheet: D51PXI-24.......................................................................................................... 868 Pm Clinic Check Sheet for Undercarriage: D51EXI-24........................................................................................ 875 Pm Clinic Check Sheet for Undercarriage: D51PXI-24........................................................................................ 879 40 Troubleshooting.................................................................................................................................... 883 Table of Contents................................................................................................................................. 884 Precautions Before Work........................................................................................................................... 895 Abbreviation List................................................................................................................................. 896 Related Information to Troubleshooting............................................................................................................ 902 General Troubleshooting Points................................................................................................................ 902 Troubleshooting Points for Urea SCR System.................................................................................................... 903 Sequence of Events in Troubleshooting......................................................................................................... 915 Checks Before Troubleshooting................................................................................................................. 917 Inspection Procedure Before Troubleshooting................................................................................................... 919 Walk-Around Check......................................................................................................................... 919 Test in Accordance with Testing Procedure..................................................................................................... 921 Examine Fuel Level and Type............................................................................................................... 921 Examine for Impure Ingredient in Fuel..................................................................................................... 921 Examine DEF Level and Type................................................................................................................ 922 Examine Fuel Prefilter.................................................................................................................... 922 Examine Fuel Main Filter.................................................................................................................. 924 Examine Engine Oil Level (Oil Quantity in Oil Pan) and Type............................................................................... 925 Examine Coolant Level (Reservoir Tank).................................................................................................... 927 Examine Air Cleaner Clogging.............................................................................................................. 927 Clean Outer Element....................................................................................................................... 928 Replace Element........................................................................................................................... 930 Examine Hydraulic Oil Level............................................................................................................... 931 Examine Hydraulic Oil Strainer............................................................................................................ 932 Examine Oil Level in Final Drive Case..................................................................................................... 935 Bleed Air from Fuel System................................................................................................................ 936 Bleed Air from Hydraulic System........................................................................................................... 936 How to Examine Electric Equipment......................................................................................................... 936 Preparation for Troubleshooting of Electrical System.......................................................................................... 943 Procedure for Troubleshooting................................................................................................................. 950 Symptom and Troubleshooting Numbers........................................................................................................... 953 Information Shown in Troubleshooting Table.................................................................................................... 958 Diagnose Open Circuit of Hydraulic Pressure Sensor System Wiring Harness...................................................................... 960 Connector List and Layout (Machine with KOMTRAX Terminal)..................................................................................... 963 Connector List and Layout (Machine with Gateway Function Controller).......................................................................... 980 Connector Contact Connection Table............................................................................................................ 997 T-Branch Box and T-Branch Adapter Table.......................................................................................................1037 Fuse Location Table (Machine with KOMTRAX Terminal)...........................................................................................1043 Fuse Location Table (Machine with Gateway Function Controller)................................................................................1047 Precautions When You Replace KDOC.............................................................................................................1051 Failure Code Table............................................................................................................................1052 Troubleshooting by Failure Code (Display of Code).................................................................................................1072 Failure Code [6091NX].........................................................................................................................1072 Failure Code [989L00].........................................................................................................................1074 Failure Code [989M00].........................................................................................................................1075 Failure Code [989N00].........................................................................................................................1076 Failure Code [A1U0N3].........................................................................................................................1077 Failure Code [A1U0N4].........................................................................................................................1079 Failure Code [A900FR].........................................................................................................................1081 Failure Code [A900N6].........................................................................................................................1082 Failure Code [A900NY].........................................................................................................................1083 Failure Code [AA10NX].........................................................................................................................1084 Failure Code [AB00KE].........................................................................................................................1086 Failure Code [AQ10MB].........................................................................................................................1088 Failure Code [AQ10N3].........................................................................................................................1090 Failure Code [AS00R2].........................................................................................................................1092 Failure Code [AS00R3].........................................................................................................................1093 Failure Code [AS00R4].........................................................................................................................1094 Failure Code [AS00R5].........................................................................................................................1095 Failure Code [AS00R6].........................................................................................................................1096 Failure Code [AS00ZK].........................................................................................................................1097 Failure Code [AS10KM].........................................................................................................................1098 Failure Code [AS10NR].........................................................................................................................1099 Failure Code [AS10NT].........................................................................................................................1100 Failure Code [B@BAZG].........................................................................................................................1101 Failure Code [B@BCNS].........................................................................................................................1102 Failure Code [B@CRNS].........................................................................................................................1103 Failure Code [B@CRZG].........................................................................................................................1104 Failure Code [CA115]..........................................................................................................................1105 Failure Code [CA122]..........................................................................................................................1106 Failure Code [CA123]..........................................................................................................................1108 Failure Code [CA131]..........................................................................................................................1110 Failure Code [CA132]..........................................................................................................................1112 Failure Code [CA144]..........................................................................................................................1114 Failure Code [CA145]..........................................................................................................................1116 Failure Code [CA153]..........................................................................................................................1118 Failure Code [CA154]..........................................................................................................................1120 Failure Code [CA187]..........................................................................................................................1122 Failure Code [CA221]..........................................................................................................................1124 Failure Code [CA222]..........................................................................................................................1126 Failure Code [CA227]..........................................................................................................................1128 Failure Code [CA234]..........................................................................................................................1130 Failure Code [CA238]..........................................................................................................................1131 Failure Code [CA239]..........................................................................................................................1132 Failure Code [CA249]..........................................................................................................................1133 Failure Code [CA256]..........................................................................................................................1135 Failure Code [CA271]..........................................................................................................................1137 Failure Code [CA272]..........................................................................................................................1139 Failure Code [CA295]..........................................................................................................................1141 Failure Code [CA322]..........................................................................................................................1142 Failure Code [CA324]..........................................................................................................................1144 Failure Code [CA331]..........................................................................................................................1146 Failure Code [CA332]..........................................................................................................................1148 Failure Code [CA343]..........................................................................................................................1150 Failure Code [CA351]..........................................................................................................................1151 Failure Code [CA352]..........................................................................................................................1152 Failure Code [CA356]..........................................................................................................................1154 Failure Code [CA357]..........................................................................................................................1156 Failure Code [CA386]..........................................................................................................................1158 Failure Code [CA428]..........................................................................................................................1159 Failure Code [CA429]..........................................................................................................................1161 Failure Code [CA435]..........................................................................................................................1163 Failure Code [CA441]..........................................................................................................................1165 Failure Code [CA442]..........................................................................................................................1167 Failure Code [CA451]..........................................................................................................................1168 Failure Code [CA452]..........................................................................................................................1170 Failure Code [CA488]..........................................................................................................................1172 Failure Code [CA515]..........................................................................................................................1173 Failure Code [CA516]..........................................................................................................................1175 Failure Code [CA553]..........................................................................................................................1177 Failure Code [CA555]..........................................................................................................................1178 Failure Code [CA556]..........................................................................................................................1179 Failure Code [CA559]..........................................................................................................................1180 Failure Code [CA595]..........................................................................................................................1183 Failure Code [CA687]..........................................................................................................................1185 Failure Code [CA689]..........................................................................................................................1187 Failure Code [CA691]..........................................................................................................................1190 Failure Code [CA692]..........................................................................................................................1192 Failure Code [CA697]..........................................................................................................................1194 Failure Code [CA698]..........................................................................................................................1195 Failure Code [CA731]..........................................................................................................................1196 Failure Code [CA778]..........................................................................................................................1198 Failure Code [CA1117].........................................................................................................................1203 Failure Code [CA1664].........................................................................................................................1205 Failure Code [CA1669].........................................................................................................................1207 Failure Code [CA1673].........................................................................................................................1208 Failure Code [CA1677].........................................................................................................................1209 Failure Code [CA1678].........................................................................................................................1210 Failure Code [CA1682].........................................................................................................................1211 Failure Code [CA1683].........................................................................................................................1213 Failure Code [CA1684].........................................................................................................................1215 Failure Code [CA1686].........................................................................................................................1217 Failure Code [CA1691].........................................................................................................................1218 Failure Code [CA1694].........................................................................................................................1220 Failure Code [CA1695].........................................................................................................................1222 Failure Code [CA1696].........................................................................................................................1223 Failure Code [CA1712].........................................................................................................................1225 Failure Code [CA1713].........................................................................................................................1228 Failure Code [CA1714].........................................................................................................................1230 Failure Code [CA1715].........................................................................................................................1231 Failure Code [CA1776].........................................................................................................................1232 Failure Code [CA1777].........................................................................................................................1235 Failure Code [CA1843].........................................................................................................................1238 Failure Code [CA1844].........................................................................................................................1240 Failure Code [CA1885].........................................................................................................................1243 Failure Code [CA1887].........................................................................................................................1245 Failure Code [CA1896].........................................................................................................................1247 Failure Code [CA1898].........................................................................................................................1251 Failure Code [CA1938].........................................................................................................................1253 Failure Code [CA1942].........................................................................................................................1255 Failure Code [CA1961].........................................................................................................................1256 Failure Code [CA1962].........................................................................................................................1257 Failure Code [CA2185].........................................................................................................................1258 Failure Code [CA2186].........................................................................................................................1260 Failure Code [CA2198].........................................................................................................................1262 Failure Code [CA2272].........................................................................................................................1264 Failure Code [CA2288].........................................................................................................................1266 Failure Code [CA2311].........................................................................................................................1267 Failure Code [CA2349].........................................................................................................................1268 Failure Code [CA2353].........................................................................................................................1270 Failure Code [CA2357].........................................................................................................................1272 Failure Code [CA2373].........................................................................................................................1273 Failure Code [CA2374].........................................................................................................................1275 Failure Code [CA2375].........................................................................................................................1277 Failure Code [CA2376].........................................................................................................................1279 Failure Code [CA2387].........................................................................................................................1282 Failure Code [CA2554].........................................................................................................................1283 Failure Code [CA2555].........................................................................................................................1285 Failure Code [CA2556].........................................................................................................................1288 Failure Code [CA2634].........................................................................................................................1291 Failure Code [CA2635].........................................................................................................................1293 Failure Code [CA2636].........................................................................................................................1294 Failure Code [CA2637].........................................................................................................................1296 Failure Code [CA2771].........................................................................................................................1298 Failure Code [CA2961].........................................................................................................................1302 Failure Code [CA2973].........................................................................................................................1303 Failure Code [CA2976].........................................................................................................................1304 Failure Code [CA3142].........................................................................................................................1306 Failure Code [CA3143].........................................................................................................................1307 Failure Code [CA3144].........................................................................................................................1308 Failure Code [CA3146].........................................................................................................................1310 Failure Code [CA3147].........................................................................................................................1311 Failure Code [CA3148].........................................................................................................................1312 Failure Code [CA3151].........................................................................................................................1314 Failure Code [CA3165].........................................................................................................................1319 Failure Code [CA3228].........................................................................................................................1321 Failure Code [CA3229].........................................................................................................................1323 Failure Code [CA3231].........................................................................................................................1325 Failure Code [CA3232].........................................................................................................................1327 Failure Code [CA3235].........................................................................................................................1331 Failure Code [CA3239].........................................................................................................................1333 Failure Code [CA3241].........................................................................................................................1336 Failure Code [CA3242].........................................................................................................................1339 Failure Code [CA3251].........................................................................................................................1342 Failure Code [CA3313].........................................................................................................................1344 Failure Code [CA3314].........................................................................................................................1345 Failure Code [CA3315].........................................................................................................................1346 Failure Code [CA3419].........................................................................................................................1348 Failure Code [CA3421].........................................................................................................................1350 Failure Code [CA3497].........................................................................................................................1352 Failure Code [CA3498].........................................................................................................................1353 Failure Code [CA3545].........................................................................................................................1354 Failure Code [CA3547].........................................................................................................................1356 Failure Code [CA3558].........................................................................................................................1357 Failure Code [CA3559].........................................................................................................................1359 Failure Code [CA3562].........................................................................................................................1361 Failure Code [CA3563].........................................................................................................................1363 Failure Code [CA3567].........................................................................................................................1366 Failure Code [CA3568].........................................................................................................................1370 Failure Code [CA3571].........................................................................................................................1374 Failure Code [CA3572].........................................................................................................................1376 Failure Code [CA3574].........................................................................................................................1378 Failure Code [CA3575].........................................................................................................................1380 Failure Code [CA3577].........................................................................................................................1382 Failure Code [CA3578].........................................................................................................................1384 Failure Code [CA3582].........................................................................................................................1386 Failure Code [CA3583].........................................................................................................................1391 Failure Code [CA3596].........................................................................................................................1393 Failure Code [CA3649].........................................................................................................................1397 Failure Code [CA3681].........................................................................................................................1399 Failure Code [CA3682].........................................................................................................................1404 Failure Code [CA3713].........................................................................................................................1409 Failure Code [CA3717].........................................................................................................................1412 Failure Code [CA3718].........................................................................................................................1413 Failure Code [CA3724].........................................................................................................................1414 Failure Code [CA3725].........................................................................................................................1415 Failure Code [CA3741].........................................................................................................................1418 Failure Code [CA3748].........................................................................................................................1419 Failure Code [CA3755].........................................................................................................................1421 Failure Code [CA3866].........................................................................................................................1423 Failure Code [CA3868].........................................................................................................................1426 Failure Code [CA4152].........................................................................................................................1430 Failure Code [CA4155].........................................................................................................................1434 Failure Code [CA4156].........................................................................................................................1437 Failure Code [CA4157].........................................................................................................................1440 Failure Code [CA4159].........................................................................................................................1442 Failure Code [CA4164].........................................................................................................................1443 Failure Code [CA4165].........................................................................................................................1445 Failure Code [CA4166].........................................................................................................................1447 Failure Code [CA4168].........................................................................................................................1448 Failure Code [CA4169].........................................................................................................................1451 Failure Code [CA4171].........................................................................................................................1453 Failure Code [CA4249].........................................................................................................................1455 Failure Code [CA4251].........................................................................................................................1457 Failure Code [CA4261].........................................................................................................................1459 Failure Code [CA4277].........................................................................................................................1462 Failure Code [CA4459].........................................................................................................................1466 Failure Code [CA4461].........................................................................................................................1468 Failure Code [CA4533].........................................................................................................................1471 Failure Code [CA4534].........................................................................................................................1472 Failure Code [CA4731].........................................................................................................................1473 Failure Code [CA4732].........................................................................................................................1474 Failure Code [CA4739].........................................................................................................................1475 Failure Code [CA4768].........................................................................................................................1476 Failure Code [CA4769].........................................................................................................................1478 Failure Code [CA4842].........................................................................................................................1480 Failure Code [CA4952] (Machine with KOMTRAX Terminal).........................................................................................1483 Failure Code [CA4952] (Machine with Gateway Function Controller)..............................................................................1485 Failure Code [CA5115].........................................................................................................................1487 Failure Code [CA5179].........................................................................................................................1490 Failure Code [CA5181].........................................................................................................................1492 Failure Code [CA5387].........................................................................................................................1494 Failure Code [CA5388].........................................................................................................................1496 Failure Code [CA5389].........................................................................................................................1499 Failure Code [CA5391].........................................................................................................................1501 Failure Code [CA5392].........................................................................................................................1505 Failure Code [CA5393].........................................................................................................................1507 Failure Code [CA5394].........................................................................................................................1510 Failure Code [CA5395].........................................................................................................................1513 Failure Code [CA5396].........................................................................................................................1516 Failure Code [CA5631].........................................................................................................................1517 Failure Code [CA5632].........................................................................................................................1519 Failure Code [CA5938].........................................................................................................................1520 Failure Code [D130KA].........................................................................................................................1522 Failure Code [D130KB].........................................................................................................................1525 Failure Code [D130KY].........................................................................................................................1527 Failure Code [D19JKZ].........................................................................................................................1529 Failure Code [D811MC] (Machine with KOMTRAX Terminal).........................................................................................1532 Failure Code [D811MC] (Machine with Gateway Function Controller)..............................................................................1533 Failure Code [D862KA] (Machine with KOMTRAX Terminal).........................................................................................1534 Failure Code [D862KA] (Machine with Gateway Function Controller)..............................................................................1535 Failure Code [D8ALKA] (Machine with KOMTRAX Terminal).........................................................................................1536 Failure Code [D8ALKA] (Machine with Gateway Function Controller)..............................................................................1538 Failure Code [D8ALKB] (Machine with KOMTRAX Terminal).........................................................................................1540 Failure Code [D8ALKB] (Machine with Gateway Function Controller)..............................................................................1542 Failure Code [D8AQKR] (Machine with KOMTRAX Terminal).........................................................................................1544 Failure Code [D8AQKR] (Machine with Gateway Function Controller)..............................................................................1546 Failure Code [D8G1KT].........................................................................................................................1548 Failure Code [D8G6KT].........................................................................................................................1549 Failure Code [DAF0MB].........................................................................................................................1550 Failure Code [DAF0MC].........................................................................................................................1551 Failure Code [DAF8KB].........................................................................................................................1552 Failure Code [DAF9KQ].........................................................................................................................1554 Failure Code [DAFGMC] (Machine with KOMTRAX Terminal).........................................................................................1555 Failure Code [DAFGMC] (Machine with Gateway Function Controller)..............................................................................1556 Failure Code [DAFLKA] (Machine with KOMTRAX Terminal).........................................................................................1557 Failure Code [DAFLKA] (Machine with Gateway Function Controller)..............................................................................1559 Failure Code [DAFLKB] (Machine with KOMTRAX Terminal).........................................................................................1561 Failure Code [DAFLKB] (Machine with Gateway Function Controller)..............................................................................1563 Failure Code [DAFQKR] (Machine with KOMTRAX Terminal).........................................................................................1565 Failure Code [DAFQKR] (Machine with Gateway Function Controller)..............................................................................1566 Failure Code [DAJ000].........................................................................................................................1567 Failure Code [DAJ0KQ].........................................................................................................................1568 Failure Code [DAJ0KT].........................................................................................................................1569 Failure Code [DAJ0MC].........................................................................................................................1570 Failure Code [DAJ1KK].........................................................................................................................1571 Failure Code [DAJ2KK].........................................................................................................................1573 Failure Code [DAJ5KK].........................................................................................................................1575 Failure Code [DAJ6KK].........................................................................................................................1578 Failure Code [DAJLKA] (Machine with KOMTRAX Terminal).........................................................................................1580 Failure Code [DAJLKA] (Machine with Gateway Function Controller)..............................................................................1582 Failure Code [DAJLKB] (Machine with KOMTRAX Terminal).........................................................................................1584 Failure Code [DAJLKB] (Machine with Gateway Function Controller)..............................................................................1586 Failure Code [DAJPMA].........................................................................................................................1588 Failure Code [DAJQKR] (Machine with KOMTRAX Terminal).........................................................................................1589 Failure Code [DAJQKR] (Machine with Gateway Function Controller)..............................................................................1590 Failure Code [DAJRKR].........................................................................................................................1591 Failure Code [DB2QKR] (Machine with KOMTRAX Terminal).........................................................................................1592 Failure Code [DB2QKR] (Machine with Gateway Function Controller)..............................................................................1597 Failure Code [DB2RKR].........................................................................................................................1602 Failure Code [DBR0KT].........................................................................................................................1607 Failure Code [DBR0MC].........................................................................................................................1608 Failure Code [DBR1KK].........................................................................................................................1609 Failure Code [DBR2KK].........................................................................................................................1612 Failure Code [DBR5KK].........................................................................................................................1615 Failure Code [DBRLKA].........................................................................................................................1617 Failure Code [DBRLKB].........................................................................................................................1619 Failure Code [DBRPMA].........................................................................................................................1621 Failure Code [DBRQKR].........................................................................................................................1622 Failure Code [DBRRKR].........................................................................................................................1624 Failure Code [DBTSKR].........................................................................................................................1625 Failure Code [DBUTKA].........................................................................................................................1628 Failure Code [DD12KA].........................................................................................................................1629 Failure Code [DD12KB].........................................................................................................................1631 Failure Code [DD13KA].........................................................................................................................1633 Failure Code [DD13KB].........................................................................................................................1635 Failure Code [DD14KA].........................................................................................................................1637 Failure Code [DD14KB].........................................................................................................................1639 Failure Code [DDKAKA].........................................................................................................................1641 Failure Code [DDKAKB].........................................................................................................................1643 Failure Code [DDKFL4].........................................................................................................................1645 Failure Code [DDKGL4].........................................................................................................................1647 Failure Code [DDKHKA].........................................................................................................................1649 Failure Code [DDKHKB].........................................................................................................................1651 Failure Code [DDKQKA].........................................................................................................................1653 Failure Code [DDKQKB].........................................................................................................................1655 Failure Code [DDKRKA].........................................................................................................................1657 Failure Code [DDKRKB].........................................................................................................................1659 Failure Code [DDKSKA].........................................................................................................................1661 Failure Code [DDKSKB].........................................................................................................................1663 Failure Code [DDNLKA].........................................................................................................................1665 Failure Code [DDNLKB].........................................................................................................................1667 Failure Code [DDP6KA].........................................................................................................................1669 Failure Code [DDP6KB].........................................................................................................................1672 Failure Code [DDP6MA].........................................................................................................................1674 Failure Code [DDU1FS].........................................................................................................................1676 Failure Code [DDU1KA].........................................................................................................................1678 Failure Code [DDU1KY].........................................................................................................................1681 Failure Code [DFA4KX].........................................................................................................................1683 Failure Code [DFA4KZ].........................................................................................................................1684 Failure Code [DFA4L8].........................................................................................................................1685 Failure Code [DFA5KA].........................................................................................................................1686 Failure Code [DFA5KB].........................................................................................................................1689 Failure Code [DFA6KA].........................................................................................................................1692 Failure Code [DFA6KB].........................................................................................................................1695 Failure Code [DFA7KX].........................................................................................................................1698 Failure Code [DFA7KZ].........................................................................................................................1699 Failure Code [DFA7L8].........................................................................................................................1700 Failure Code [DFA8KA].........................................................................................................................1701 Failure Code [DFA8KB].........................................................................................................................1704 Failure Code [DFA9KA].........................................................................................................................1707 Failure Code [DFA9KB].........................................................................................................................1710 Failure Code [DGS1KA].........................................................................................................................1713 Failure Code [DGS1KX].........................................................................................................................1716 Failure Code [DH21KA].........................................................................................................................1717 Failure Code [DH21KB].........................................................................................................................1719 Failure Code [DHA4KA].........................................................................................................................1721 Failure Code [DHH7KA].........................................................................................................................1723 Failure Code [DHH7KB].........................................................................................................................1726 Failure Code [DHH8KA].........................................................................................................................1728 Failure Code [DHH8KB].........................................................................................................................1731 Failure Code [DHH9KA].........................................................................................................................1733 Failure Code [DHH9KB].........................................................................................................................1736 Failure Code [DHHAKA].........................................................................................................................1738 Failure Code [DHHAKB].........................................................................................................................1741 Failure Code [DK30KA].........................................................................................................................1743 Failure Code [DK30KB].........................................................................................................................1746 Failure Code [DK30KX].........................................................................................................................1748 Failure Code [DK30KZ].........................................................................................................................1749 Failure Code [DK30L8].........................................................................................................................1750 Failure Code [DK31KA].........................................................................................................................1751 Failure Code [DK31KB].........................................................................................................................1754 Failure Code [DK40KA].........................................................................................................................1756 Failure Code [DK40KB].........................................................................................................................1759 Failure Code [DK55KX].........................................................................................................................1761 Failure Code [DK55KZ].........................................................................................................................1762 Failure Code [DK55L8].........................................................................................................................1763 Failure Code [DK56KA].........................................................................................................................1764 Failure Code [DK56KB].........................................................................................................................1767 Failure Code [DK57KA].........................................................................................................................1769 Failure Code [DK57KB].........................................................................................................................1772 Failure Code [DK80KA].........................................................................................................................1774 Failure Code [DKS0L8].........................................................................................................................1776 Failure Code [DKS1KA].........................................................................................................................1777 Failure Code [DKS1KB].........................................................................................................................1779 Failure Code [DKS2KA].........................................................................................................................1780 Failure Code [DKS2KB].........................................................................................................................1782 Failure Code [DKS3KA].........................................................................................................................1783 Failure Code [DKS3KB].........................................................................................................................1785 Failure Code [DKS3MB].........................................................................................................................1786 Failure Code [DKS4L8].........................................................................................................................1788 Failure Code [DKS5KA].........................................................................................................................1789 Failure Code [DKS5KB].........................................................................................................................1791 Failure Code [DKS6KA].........................................................................................................................1792 Failure Code [DKS6KB].........................................................................................................................1794 Failure Code [DKS7MB].........................................................................................................................1795 Failure Code [DKSCL8].........................................................................................................................1796 Failure Code [DKSDKA].........................................................................................................................1797 Failure Code [DKSDKB].........................................................................................................................1799 Failure Code [DKSEKA].........................................................................................................................1800 Failure Code [DKSEKB].........................................................................................................................1802 Failure Code [DKSFKA].........................................................................................................................1803 Failure Code [DKSFKB].........................................................................................................................1805 Failure Code [DKSFMB].........................................................................................................................1806 Failure Code [DLM0KX].........................................................................................................................1807 Failure Code [DLM0MA].........................................................................................................................1808 Failure Code [DLM1KA].........................................................................................................................1809 Failure Code [DLM1KB].........................................................................................................................1811 Failure Code [DLM1MA].........................................................................................................................1813 Failure Code [DLM2KA].........................................................................................................................1814 Failure Code [DLM2KB].........................................................................................................................1816 Failure Code [DLM2MA].........................................................................................................................1818 Failure Code [DLM3KA].........................................................................................................................1819 Failure Code [DLM3KB].........................................................................................................................1821 Failure Code [DLM3MB].........................................................................................................................1823 Failure Code [DN21FS].........................................................................................................................1824 Failure Code [DR21KX].........................................................................................................................1826 Failure Code [DR31KX].........................................................................................................................1827 Failure Code [DV20KB].........................................................................................................................1828 Failure Code [DW4BKA].........................................................................................................................1830 Failure Code [DW4BKB].........................................................................................................................1832 Failure Code [DW4BKY].........................................................................................................................1834 Failure Code [DW7BKA].........................................................................................................................1836 Failure Code [DW7BKB].........................................................................................................................1838 Failure Code [DW7EKA].........................................................................................................................1840 Failure Code [DW7EKB].........................................................................................................................1842 Failure Code [DW7EKY].........................................................................................................................1844 Failure Code [DWN5KA].........................................................................................................................1846 Failure Code [DWN5KB].........................................................................................................................1848 Failure Code [DWN5KY].........................................................................................................................1850 Failure Code [DXA4KA].........................................................................................................................1852 Failure Code [DXA4KB].........................................................................................................................1854 Failure Code [DXA4KY].........................................................................................................................1856 Failure Code [DXA5KA].........................................................................................................................1858 Failure Code [DXA5KB].........................................................................................................................1860 Failure Code [DXA5KY].........................................................................................................................1862 Failure Code [DXA6KA].........................................................................................................................1864 Failure Code [DXA6KB].........................................................................................................................1866 Failure Code [DXA6KY].........................................................................................................................1868 Failure Code [DXA7KA].........................................................................................................................1870 Failure Code [DXA7KB].........................................................................................................................1872 Failure Code [DXA7KY].........................................................................................................................1874 Failure Code [DXHRKA].........................................................................................................................1876 Failure Code [DXHRKB].........................................................................................................................1878 Failure Code [DXHRKY].........................................................................................................................1880 Failure Code [DXHSKA].........................................................................................................................1882 Failure Code [DXHSKB].........................................................................................................................1884 Failure Code [DXHSKY].........................................................................................................................1886 Failure Code [DXHTKA].........................................................................................................................1888 Failure Code [DXHTKB].........................................................................................................................1890 Failure Code [DXHTKY].........................................................................................................................1892 Failure Code [DXHUKA].........................................................................................................................1894 Failure Code [DXHUKB].........................................................................................................................1896 Failure Code [DXHUKY].........................................................................................................................1898 Failure Code [DXJ4KA].........................................................................................................................1900 Failure Code [DXJ4KB].........................................................................................................................1902 Failure Code [DXJCKA].........................................................................................................................1904 Failure Code [DXJCKB].........................................................................................................................1906 Failure Code [DXJCKY].........................................................................................................................1908 Failure Code [DXJDKA].........................................................................................................................1910 Failure Code [DXJDKB].........................................................................................................................1912 Failure Code [DXJDKY].........................................................................................................................1914 Failure Code [DXK1KA].........................................................................................................................1916 Failure Code [DXK1KB].........................................................................................................................1918 Failure Code [DXK1KY].........................................................................................................................1920 Failure Code [DXK2KA].........................................................................................................................1922 Failure Code [DXK2KB].........................................................................................................................1924 Failure Code [DXK2KY].........................................................................................................................1926 Failure Code [F313KA].........................................................................................................................1928 Failure Code [F313KB].........................................................................................................................1929 Failure Code [F318KB].........................................................................................................................1930 Failure Code [F318KY].........................................................................................................................1931 Troubleshooting of Electrical System (E-Mode).....................................................................................................1932 Engine Does Not Start (Engine Does Not Crank).................................................................................................1932 Manual Preheating System Does Not Operate.....................................................................................................1939 Automatic Preheating System Does Not Operate..................................................................................................1942 While Preheating is in Operation, Preheating Monitor Does Not Come On.........................................................................1944 When Starting Switch is Turned to ON Position, Machine Monitor Shows Nothing..................................................................1946 When Starting Switch is Turned to ON Position (with Engine Stopped), Basic Check Monitor Comes On.............................................1950 Air Cleaner Clogging Monitor Comes On in Yellow While Engine is in Operation..................................................................1951 Charge Level Monitor Comes On in Red While Engine is in Operation.............................................................................1952 Engine Coolant Temperature Monitor Comes On in Red While Engine is in Operation...............................................................1953 Engine Oil Pressure Monitor Comes On in Red While Engine is in Operation......................................................................1954 HST Charge Pressure Monitor Comes On in Red While Engine Runs.................................................................................1955 Hydraulic Oil Temperature Monitor Comes On in Red While Engine is in Operation................................................................1956 HST Oil Filter Clogging Monitor Comes On in Red While Engine Runs.............................................................................1957 Engine Coolant Temperature Gauge Does Not Show Correct Temperature............................................................................1958 DEF Level is Not Shown Correctly..............................................................................................................1959 Fuel Gauge Does Not Show Normally.............................................................................................................1962 Hydraulic Oil Temperature Gauge Does Not Show Correct Temperature.............................................................................1965 Operation Mode Does Not Change................................................................................................................1966 When You Operate Customize Switch Does Not Show Customize Screen..............................................................................1967 When You Change Setting on Customize Screen, Setting of Machine is Not Changed................................................................1968 Service Meter is Not Shown While Starting Switch is in OFF Position...........................................................................1969 Service Mode Cannot be Selected...............................................................................................................1970 Work Equipment Does Not Operate...............................................................................................................1971 Foot Heater Does Not Operate..................................................................................................................1973 Horn Does Not Sound...........................................................................................................................1979 Horn Does Not Stop............................................................................................................................1981 Backup Alarm Does Not Sound...................................................................................................................1982 Backup Alarm Does Not Stop Operation..........................................................................................................1983 Headlamp Does Not Come On.....................................................................................................................1984 Rear Lamp Does Not Come On....................................................................................................................1988 No Wiper Operates.............................................................................................................................1991 Front Wiper Does Not Operate..................................................................................................................1993 Rear Wiper Does Not Operate...................................................................................................................1995 Left Door Wiper Does Not Operate..............................................................................................................1997 Right Door Wiper Does Not Operate.............................................................................................................2001 Front Washer Does Not Operate.................................................................................................................2005 Rear Washer Does Not Operate..................................................................................................................2007 Left Door Washer Does Not Operate.............................................................................................................2009 Right Door Washer Does Not Operate............................................................................................................2011 KOMTRAX System Does Not Operate Correctly.....................................................................................................2013 Control Box Shuts Down After It Shows Messages [GPS receiver not connected!] and [Slope sensor not connected!]................................2014 Control Box Shows Messages [GPS receiver not connected !] and [Slope sensor not connected !]..................................................2018 Control Box Shows Message [Waiting for radio link...].........................................................................................2023 Control Box Shows Message [IMU sensor not connected] Show Production..........................................................................2024 Control Box Shows Message [Waiting for satellites...].........................................................................................2025 Control Box Shows Message [GPS receiver not connected!] Show Production.......................................................................2026 Control Box Shows Message [Cylinder Stroke Reading Abnormal]..................................................................................2028 Control Box Shows Message [Komatsu CAN Comms Abnormal]........................................................................................2029 Control Box Shows Message [Komatsu Machine Trouble]...........................................................................................2030 Control Box Shows Message [Waiting to initialize....].........................................................................................2031 Control Box Shows Message [System initializing]...............................................................................................2032 Control Box Shows Message [Initializing....]..................................................................................................2033 Control Box Shows Message [Configuring GPS]...................................................................................................2034 Control Box Shows Message [No GPS Localization...]............................................................................................2035 Control Box Shows Message [Low precisions...].................................................................................................2036 Control Box Shows Message [Heading Initializing]..............................................................................................2037 Control Box Displays [Out of design area...]..................................................................................................2038 Control Box Can Not be Turned on..............................................................................................................2039 Control Box Does Not Display Intelligent Machine Control Screen...............................................................................2040 Control Box Does Not Display Bulldozer Image..................................................................................................2041 Control Box Does Not Display Design Surface...................................................................................................2042 Control Box Touch Panel Does Not Respond......................................................................................................2043 Control Box Touch Panel is Inaccurate.........................................................................................................2044 Cylinder Stroke Reset Indication Does Not Go Out..............................................................................................2045 AUTO is Not Shown When AUTO/Manual Switch is Pushed (AUTO Indication Goes off)................................................................2046 Blade Automatic Lower Control Does Not Start While AUTO is Shown..............................................................................2048 Blade Automatic Raise Control Does Not Start While AUTO is Shown..............................................................................2049 Blade Automatic Control Function is Not Activated While AUTO is Shown (Blade Automatic Control Stops).........................................2050 When You Examine and Adjust the Blade Elevation, the Value is Different from Actual Machine...................................................2051 Finished Surface is Inaccurate (The Average Height of Finished Surface is Lower Than Designed Surface or Blade Does Not Touch the Surface)....2052 Finished Surface is Inaccurate (The Finished Surface is Not Smooth)...........................................................................2053 Finished Surface is Inaccurate (When You Finish Slope Horizontally, Steps are Made in Each Direction).........................................2054 Machine Cannot Escape from Shoes Slip While Blade Automatic Control is Activated (Shoes Frequently Slips).....................................2056 Machine Speed Does Not Increase While Blade Automatic Control is Activated....................................................................2057 Blade Tilt Angle Does Not Align with Design Surface...........................................................................................2058 Blade Tilts While Blade Automatic Control is Activated........................................................................................2060 When Starting Switch is Turned to ON Position, REVERSE Leveling Mode Switch LED Does Not Come On or Does Not Go Out...........................2062 Troubleshooting for Hydraulic and Mechanical Systems (H Mode).....................................................................................2064 Information Shown in Troubleshooting Table (H-Mode)...........................................................................................2064 Failure Mode and Cause Table..................................................................................................................2065 R.H. and L.H. Tracks Cannot Travel FORWARD and REVERSE (None of the Travel Systems Operate)...................................................2071 R.H. or L.H. Track Cannot Travel FORWARD and Reverse (One of R.H. or L.H. Travel Systems Cannot Operate)......................................2073 R.H. or L.H. Track Cannot Travel Forward or Reverse (Only One of the Travel Systems Cannot Operate in One Direction)..........................2075 Travel Speed or Power is Low..................................................................................................................2077 Speed Range Does Not Change...................................................................................................................2079 Shock is Large When Machine Moves Off or Stops................................................................................................2080 Travel Deviation is Large.....................................................................................................................2081 Machine Drift on a Slope is Large.............................................................................................................2084 Engine Speed Drops Largely or Engine Stops....................................................................................................2086 Unusual Noise is Heard from Around HST Pump or Motor..........................................................................................2088 HST Oil Temperature (Hydraulic Oil Temperature) Increases Too High............................................................................2090 All Work Equipment Do Not Operate.............................................................................................................2092 All Work Equipment Speed or Power is Low......................................................................................................2094 Blade Lift Speed or Power is Low..............................................................................................................2095 Blade Tilt Speed or Power is Low..............................................................................................................2097 Blade Angle Speed or Power is Low.............................................................................................................2098 Time Lag of Blade Lift is Large...............................................................................................................2099 Hydraulic Drift of Blade Lift is Large........................................................................................................2100 Hydraulic Drift of Tilted Blade is Large......................................................................................................2101 Unusual Noise is Heard from Around Work Equipment and Cooling Fan Pump or Control Valve.......................................................2102 Fan Speed is Abnormal (Too High or Low, or Does Not Rotate)...................................................................................2103 Unusual Noise is Heard from Around Fan........................................................................................................2105 Troubleshooting of Engine (S-Mode)................................................................................................................2106 Information Shown in Troubleshooting Table (S-Mode)...........................................................................................2106 Engine Does Not Crank When Starting Switch is Turned to Start Position........................................................................2107 Engine Cranks but No Exhaust Smoke Comes Out..................................................................................................2108 Fuel is Sprayed but Engine Does Not Start (Misfiring: Engine Cranks but Does Not Start).......................................................2109 Engine Startability is Unsatisfactory.........................................................................................................2111 Engine Does Not Pick Up Smoothly..............................................................................................................2113 Engine Stops During Operation.................................................................................................................2115 Engine Does Not Rotate Smoothly...............................................................................................................2117 Engine Lacks Output (or Lacks Power)..........................................................................................................2118 Exhaust Smoke is Black........................................................................................................................2120 Engine Oil Consumption is Excessive...........................................................................................................2122 Engine Oil Becomes Dirty Quickly..............................................................................................................2123 Fuel Consumption is Excessive.................................................................................................................2124 Oil is in Coolant (or Coolant Spurts Back or Coolant Level Goes Down).........................................................................2125 Engine Oil Pressure Drops.....................................................................................................................2126 Fuel Mixes Into Engine Oil....................................................................................................................2128 Water Mixes Into Engine Oil (Milky)...........................................................................................................2129 Coolant Temperature Increases Too High (Overheat).............................................................................................2130 Unusual Noise is Heard........................................................................................................................2131 Vibration is Excessive........................................................................................................................2132 Air Cannot be Bled from Fuel Circuit..........................................................................................................2133 Active Regeneration is Done Frequently........................................................................................................2134 Active Regeneration Continues Long............................................................................................................2135 White Smoke is Exhausted During Active Regeneration...........................................................................................2136 DEF Consumption is Excessive..................................................................................................................2137 There is an Unusual Smell (Irritating Odor)...................................................................................................2139 Foreign Materials Enter DEF (DEF Increases)...................................................................................................2140 50 Disassembly and Assembly...........................................................................................................................2141 Table of Contents.................................................................................................................................2142 Precautions Before Work...........................................................................................................................2147 Abbreviation List.................................................................................................................................2148 Related Information on Disassembly and Assembly...................................................................................................2154 How to Read This Manual.......................................................................................................................2154 Coating Materials List........................................................................................................................2155 Special Tool List.............................................................................................................................2160 Sketches of Special Tools.....................................................................................................................2183 Engine and Cooling System.........................................................................................................................2196 Remove and Install Supply Pump Assembly.......................................................................................................2196 Remove Supply Pump Assembly...............................................................................................................2196 Install Supply Pump Assembly..............................................................................................................2206 Remove and Install Injector Assembly..........................................................................................................2216 How to Remove Injector Assembly...........................................................................................................2216 How to Install Injector Assembly..........................................................................................................2227 Remove and Install Cylinder Head Assembly.....................................................................................................2241 How to Remove Cylinder Head Assembly......................................................................................................2241 How to Install Cylinder Head Assembly.....................................................................................................2260 Remove and Install EGR Valve Assembly.........................................................................................................2284 Remove EGR Valve Assembly.................................................................................................................2284 Install EGR Valve Assembly................................................................................................................2287 Remove and Install EGR Cooler Assembly........................................................................................................2291 How to Remove EGR Cooler Assembly.........................................................................................................2291 How to Install EGR Cooler Assembly........................................................................................................2295 Remove and Install Starter Assembly...........................................................................................................2299 Remove Starting Motor Assembly............................................................................................................2299 Install Starting Motor Assembly...........................................................................................................2301 Remove and Install Air Conditioner Compressor Belt............................................................................................2304 Remove Air Conditioner Compressor Belt....................................................................................................2304 Install Air Conditioner Compressor Belt...................................................................................................2308 Remove and Install Alternator Belt............................................................................................................2313 Remove Alternator Belt....................................................................................................................2313 Install Alternator Belt...................................................................................................................2316 Remove and Install Automatic Tensioner........................................................................................................2318 Remove Automatic Tensioner................................................................................................................2318 Install Automatic Tensioner...............................................................................................................2319 Remove and Install Radiator Assembly..........................................................................................................2321 How to Remove Radiator Assembly...........................................................................................................2322 How to Install Radiator Assembly..........................................................................................................2330 Remove and Install Hydraulic Oil Cooler Assembly..............................................................................................2338 How to Remove Hydraulic Oil Cooler Assembly...............................................................................................2339 How to Install Hydraulic Oil Cooler Assembly..............................................................................................2344 Remove and Install Aftercooler Assembly.......................................................................................................2349 Remove Aftercooler Assembly...............................................................................................................2350 Install Aftercooler Assembly..............................................................................................................2356 Remove and Install Cooling Fan Drive Assembly.................................................................................................2363 Remove Cooling Fan Drive Assembly.........................................................................................................2363 Install Cooling Fan Drive Assembly........................................................................................................2368 Remove and Install Cooling Fan Motor Assembly.................................................................................................2372 Remove Cooling Fan Motor Assembly.........................................................................................................2372 Install Cooling Fan Motor Assembly........................................................................................................2375 Remove and Install Engine and HST Pump Assembly...............................................................................................2378 Remove Engine and HST Pump Assembly.......................................................................................................2378 Install Engine and HST Pump Assembly......................................................................................................2389 Remove and Install Engine Front Oil Seal......................................................................................................2401 How to Remove Engine Front Oil Seal.......................................................................................................2401 How to Install Engine Front Oil Seal......................................................................................................2403 Remove and Install Engine Rear Oil Seal.......................................................................................................2405 How to Remove Engine Rear Oil Seal........................................................................................................2405 How to Install Engine Rear Oil Seal.......................................................................................................2406 Remove and Install Engine Hood Assembly.......................................................................................................2409 How to Remove Engine Hood Assembly........................................................................................................2409 How to Install Engine Hood Assembly.......................................................................................................2413 Remove and Install KDOC Assembly..............................................................................................................2417 How to Remove KDOC Assembly...............................................................................................................2417 How to Install KDOC Assembly..............................................................................................................2423 Remove and Install KDOC and SCR Assembly......................................................................................................2430 Remove KDOC and SCR Assembly..............................................................................................................2431 Install KDOC and SCR Assembly.............................................................................................................2437 Remove and Install Bellows Pipe Assembly......................................................................................................2445 Remove Bellows Pipe Assembly..............................................................................................................2445 Install Bellows Pipe Assembly.............................................................................................................2448 Remove and Install Fuel Tank Assembly.........................................................................................................2452 Remove Fuel Tank Assembly.................................................................................................................2453 Install Fuel Tank Assembly................................................................................................................2460 Remove and Install DEF Tank Assembly..........................................................................................................2467 How to Remove DEF Tank Assembly...........................................................................................................2468 How to Install DEF Tank Assembly..........................................................................................................2478 Remove and Install DEF Tank Sensor Flange Assembly............................................................................................2487 How to Remove DEF Tank Sensor Flange Assembly.............................................................................................2487 How to Install DEF Tank Sensor Flange Assembly............................................................................................2489 Remove and Install DEF Tank Sensor............................................................................................................2493 Remove DEF Tank Sensor....................................................................................................................2493 Install DEF Tank Sensor...................................................................................................................2494 Remove and Install DEF Tank Strainer..........................................................................................................2501 Remove DEF Tank Strainer..................................................................................................................2501 Install DEF Tank Strainer.................................................................................................................2502 Remove and Install SCR Assembly...............................................................................................................2503 How to Remove SCR Assembly................................................................................................................2503 How to Install SCR Assembly...............................................................................................................2506 Remove and Install KCCV Assembly..............................................................................................................2509 Remove KCCV Assembly......................................................................................................................2509 Install KCCV Assembly.....................................................................................................................2510 Remove and Install DEF Mixing Tube............................................................................................................2513 Remove DEF Mixing Tube....................................................................................................................2513 Install DEF Mixing Tube...................................................................................................................2517 Remove and Install DEF Injector...............................................................................................................2522 Remove DEF Injector.......................................................................................................................2522 Install DEF Injector......................................................................................................................2527 Remove and Install DEF Pump...................................................................................................................2532 Remove DEF Pump...........................................................................................................................2532 Install DEF Pump..........................................................................................................................2536 Remove and Install DEF Hose...................................................................................................................2540 Remove DEF Hose...........................................................................................................................2542 Install DEF Hose..........................................................................................................................2561 Remove and Install Air Cleaner Assembly.......................................................................................................2582 Remove Air Cleaner Assembly...............................................................................................................2582 Install Air Cleaner Assembly..............................................................................................................2584 Remove and Install Air Conditioner Compressor Assembly........................................................................................2587 Remove Air Conditioner Compressor Assembly................................................................................................2587 How to Install Air Conditioner Compressor Assembly........................................................................................2591 Remove and Install Air Conditioner Condenser Assembly.........................................................................................2596 How to Remove Air Conditioner Condenser Assembly..........................................................................................2596 How to Install Air Conditioner Condenser Assembly.........................................................................................2600 Power Train.......................................................................................................................................2604 Disassemble and Assemble Final Drive Assembly.................................................................................................2604 Disassemble Final Drive Assembly..........................................................................................................2605 Assemble Final Drive Assembly.............................................................................................................2609 Undercarriage and Frame...........................................................................................................................2618 Remove and Install Track Frame Assembly.......................................................................................................2618 Remove Track Frame Assembly...............................................................................................................2618 Install Track Frame Assembly..............................................................................................................2623 Remove and Install Idler Assembly.............................................................................................................2628 Remove Idler Assembly.....................................................................................................................2628 Install Idler Assembly....................................................................................................................2630 Disassemble and Assemble Idler Assembly.......................................................................................................2633 Disassemble Idler Assembly................................................................................................................2633 Assemble Idler Assembly...................................................................................................................2635 Remove and Install Recoil Spring Assembly.....................................................................................................2640 Remove Recoil Spring Assembly.............................................................................................................2640 Install Recoil Spring Assembly............................................................................................................2640 Disassemble and Assemble Recoil Spring Assembly...............................................................................................2641 Disassemble Recoil Spring Assembly........................................................................................................2641 Assemble Recoil Spring Assembly...........................................................................................................2644 Remove and Install Track Roller Assembly......................................................................................................2647 Remove Track Roller Assembly..............................................................................................................2647 Install Track Roller Assembly.............................................................................................................2649 Disassemble and Assemble Track Roller Assembly................................................................................................2653 Disassemble Track Roller Assembly.........................................................................................................2653 Assemble Track Roller Assembly............................................................................................................2654 Remove and Install Carrier Roller Assembly....................................................................................................2658 Remove Carrier Roller Assembly............................................................................................................2658 Install Carrier Roller Assembly...........................................................................................................2659 Disassemble and Assemble Carrier Roller Assembly..............................................................................................2661 Disassemble Carrier Roller Assembly.......................................................................................................2661 Assemble Carrier Roller Assembly..........................................................................................................2662 Remove and Install Pivot Shaft Assembly.......................................................................................................2665 Remove Pivot Shaft Assembly...............................................................................................................2665 Install Pivot Shaft Assembly..............................................................................................................2666 Separate and Connect Track Assembly...........................................................................................................2668 Examine Before Separation of Track Assembly...............................................................................................2668 Separate Track Assembly (Standard)........................................................................................................2669 How to Separate Track Assembly (When Track Frame Has Internal Defect).....................................................................2670 Install Track Assembly....................................................................................................................2671 Separate and Connect PLUS Type Track Assembly.................................................................................................2673 Separate PLUS Type Track Assembly Generally...............................................................................................2673 Install PLUS Type Track Assembly..........................................................................................................2673 Disassemble and Assemble Track Assembly Generally.............................................................................................2675 How to Disassemble Full Track Shoes Assembly..............................................................................................2675 How to Assemble Full Track Shoes Assembly.................................................................................................2680 Disassemble and Assemble PLUS Type Track Assembly Generally...................................................................................2693 Disassemble PLUS Type Track Assembly Generally............................................................................................2694 How to Assemble PLUS Type Track Shoes Assembly Generally..................................................................................2695 Disassemble and Assemble One Track Link Assembly in Field (Track Assembly)....................................................................2704 Disassemble One Track Link Assembly in Field (Track Assembly).............................................................................2705 Assemble One Track Link Assembly in Field (Track Assembly)................................................................................2706 Disassemble and Assemble One Track Link Assembly in Field (PLUS Type Track Assembly)..........................................................2713 Disassemble One Track Link Assembly in Field (PLUS Type Track Assembly)...................................................................2714 Assemble One Track Link Assembly in Field (PLUS Type Track Assembly)......................................................................2716 Remove and Install Equalizer Bar Assembly.....................................................................................................2720 Remove Equalizer Bar Assembly.............................................................................................................2720 Install Equalizer Bar Assembly............................................................................................................2722 Remove and Install Equalizer Bar Side Bushing.................................................................................................2725 How to Remove Equalizer Bar Side Bushings.................................................................................................2725 How to Install Equalizer Bar Side Bushings................................................................................................2726 Remove and Install Segment Teeth..............................................................................................................2727 Remove Segment Teeth......................................................................................................................2727 Install Segment Teeth.....................................................................................................................2729 Hydraulic System..................................................................................................................................2731 Remove and Install Hydraulic Tank Assembly....................................................................................................2731 Remove Hydraulic Tank Assembly............................................................................................................2732 How to Install Hydraulic Tank Assembly....................................................................................................2738 Remove and Install Control Valve Assembly.....................................................................................................2747 How to Remove Control Valve Assembly......................................................................................................2747 How to Install Control Valve Assembly.....................................................................................................2751 Work Equipment....................................................................................................................................2755 Remove and Install Blade Assembly.............................................................................................................2755 Remove Blade Assembly.....................................................................................................................2755 Install Blade Assembly....................................................................................................................2758 Remove and Install Stroke and Reset Sensing Blade Lift Cylinder Assembly......................................................................2763 Remove Stroke and Reset Sensing Blade Lift Cylinder Assembly..............................................................................2763 Install Stroke and Reset Sensing Blade Lift Cylinder Assembly.............................................................................2765 Disassemble and Assemble Stroke and Reset Sensing Blade Lift Cylinder Assembly................................................................2768 Disassemble Stroke and Reset Sensing Blade Lift Cylinder Assembly.........................................................................2769 Assemble Stroke and Reset Sensing Blade Lift Cylinder Assembly............................................................................2773 Remove and Install Stroke Sensing Blade Tilt Cylinder Assembly................................................................................2781 Remove Stroke Sensing Blade Tilt Cylinder Assembly........................................................................................2781 Install Stroke Sensing Blade Tilt Cylinder Assembly.......................................................................................2784 Disassemble and Assemble Stroke Sensing Blade Tilt Cylinder Assembly..........................................................................2787 Disassemble Stroke Sensing Blade Tilt Cylinder Assembly...................................................................................2787 Assemble Stroke Sensing Blade Tilt Cylinder Assembly......................................................................................2791 Remove and Install Stroke Sensing Blade Angle Cylinder Assembly...............................................................................2796 Remove Stroke Sensing Blade Angle Cylinder Assembly.......................................................................................2796 Install Stroke Sensing Blade Angle Cylinder Assembly......................................................................................2799 Disassemble and Assemble Stroke Sensing Blade Angle Cylinder Assembly.........................................................................2802 Disassemble Stroke Sensing Blade Angle Cylinder Assembly..................................................................................2803 Assemble Stroke Sensing Blade Angle Cylinder Assembly.....................................................................................2806 Remove and Install U-Frame Assembly...........................................................................................................2811 Remove U-Frame Assembly...................................................................................................................2811 Install U-Frame Assembly..................................................................................................................2815 CAB Related Parts.................................................................................................................................2818 Remove and Install Operator Cab Assembly......................................................................................................2818 How to Remove Operator Cab Assembly.......................................................................................................2819 Install Operator CAB Assembly.............................................................................................................2827 Remove and Install Operator Cab Glass (Adhered Glass).........................................................................................2835 Remove Operator CAB Glass (Adhered Glass).................................................................................................2837 Install Operator CAB Glass (Adhered Glass)................................................................................................2837 Remove and Install Air Conditioner Unit Assembly..............................................................................................2843 Remove Air Conditioner Unit Assembly......................................................................................................2843 Install Air Conditioner Unit Assembly.....................................................................................................2849 Remove and Install Receiver Drier.............................................................................................................2856 Remove Receiver Drier.....................................................................................................................2856 Install Receiver Drier....................................................................................................................2857 Remove and Install Operator Seat..............................................................................................................2860 Remove Operator's Seat....................................................................................................................2860 Install Operator's Seat...................................................................................................................2861 How to Remove and Install Seat Belt...........................................................................................................2862 How to Remove Seat Belt...................................................................................................................2862 How to Install Seatbelt...................................................................................................................2862 Remove and Install Foot Heater Assembly.......................................................................................................2864 Remove Foot Heater Assembly...............................................................................................................2864 Install Foot Heater Assembly..............................................................................................................2866 Disassemble and Assemble Foot Heater Assembly.................................................................................................2869 Disassemble Foot Heater Assembly..........................................................................................................2869 Assemble Foot Heater Assembly.............................................................................................................2870 Electrical System.................................................................................................................................2871 Remove and Install Engine Controller Assembly.................................................................................................2871 Remove Engine Controller Assembly.........................................................................................................2871 Install Engine Controller Assembly........................................................................................................2874 Remove and Install HST Controller Assembly....................................................................................................2878 Remove HST Controller Assembly............................................................................................................2878 How to Install HST Controller Assembly....................................................................................................2879 Remove and Install Machine Monitor Assembly...................................................................................................2880 Remove Machine Monitor Assembly...........................................................................................................2880 Install Machine Monitor Assembly..........................................................................................................2881 Remove and Install Mass Air Flow and Temperature Sensor.......................................................................................2883 How to Remove Mass Air Flow and Temperature Sensor........................................................................................2883 How to Install Mass Air Flow and Temperature Sensor.......................................................................................2885 Remove and Install KCCV Crankcase Pressure Sensor.............................................................................................2887 How to Remove KCCV Crankcase Pressure Sensor..............................................................................................2887 How to Install KCCV Crankcase Pressure Sensor.............................................................................................2889 Remove and Install ICT Sensor Controller Assembly.............................................................................................2891 Remove ICT Sensor Controller Assembly.....................................................................................................2891 Install ICT Sensor Controller Assembly....................................................................................................2891 Remove and Install Control Box................................................................................................................2893 How to Remove Control Box (For Old Control Box)...........................................................................................2893 How to Remove Control Box (For New Control Box)...........................................................................................2894 How to Install Control Box (For Old Control Box)..........................................................................................2894 How to Install Control Box (For New Control Box)..........................................................................................2895 Remove and Install GNSS Receiver..............................................................................................................2897 Remove GNSS Receiver......................................................................................................................2897 Install GNSS Receiver.....................................................................................................................2897 Remove and Install GNSS Antenna...............................................................................................................2899 Remove GNSS Antenna.......................................................................................................................2899 Install GNSS Antenna......................................................................................................................2900 Remove and Install IMU Sensor.................................................................................................................2905 Remove IMU Sensor.........................................................................................................................2905 Install IMU Sensor........................................................................................................................2907 60 Maintenance Standard...............................................................................................................................2911 Table of Contents.................................................................................................................................2912 Abbreviation List.................................................................................................................................2913 Engine and Cooling System.........................................................................................................................2919 Maintenance Standard for Engine Mount.........................................................................................................2919 Maintenance Standard for Damper...............................................................................................................2920 Maintenance Standard for Cooling System.......................................................................................................2921 Maintenance Standard for Cooling Fan Motor....................................................................................................2923 Maintenance Standard for Hydraulic Oil Cooler Bypass and HST Charge Safety Valve..............................................................2925 Power Train.......................................................................................................................................2926 Maintenance Standard for HST Pump.............................................................................................................2926 Maintenance Standard for EPC Valve of HST Pump............................................................................................2928 Maintenance Standard for Tow Receiving Valve of HST Pump..................................................................................2929 Maintenance Standard for HST Charge Pump......................................................................................................2930 Maintenance Standard for HST Motor............................................................................................................2932 Maintenance Standard for Final Drive..........................................................................................................2934 Maintenance Standard for Sprocket for PLUS Type Track Shoes...................................................................................2936 Maintenance Standard for Sprocket Tooth Profile Full-Scale Drawing for PLUS Type Track Shoes..................................................2937 Undercarriage and Frame...........................................................................................................................2938 Maintenance Standard for Suspension...........................................................................................................2938 Maintenance Standard for Track Frame and Idler Cushion........................................................................................2941 Maintenance Standard for Idler................................................................................................................2944 Maintenance Standard for Track Roller for PLUS Type Track Shoes (Single Flange Type)..........................................................2946 Maintenance Standard for Track Roller for PLUS Type Track Shoes (Double Flange Type)..........................................................2947 Maintenance Standard for Carrier Roller for PLUS Type Track Shoes.............................................................................2949 Maintenance Standard for PLUS Type Track Shoes................................................................................................2950 Maintenance Standard for Single Shoes.........................................................................................................2952 Hydraulic System..................................................................................................................................2953 Maintenance Standard for Hydraulic Tank.......................................................................................................2953 Maintenance Standard for Work Equipment and Cooling Fan Pump..................................................................................2954 Maintenance Standard for Servo Valve of Work Equipment and Cooling Fan Pump...............................................................2955 Maintenance Standard for Control Valve........................................................................................................2957 Maintenance Standard for Ripper PPC Valve.....................................................................................................2963 Maintenance Standard for 5-Spool EPC and Solenoid Valve.......................................................................................2965 Maintenance Standard for EPC Valve........................................................................................................2966 Maintenance Standard for Quick Drop Valve.....................................................................................................2967 Work Equipment....................................................................................................................................2969 Maintenance Standard for Front Work Equipment.................................................................................................2969 Maintenance Standard for Cutting Edge and End Bit.............................................................................................2972 Maintenance Standard for Stroke and Reset Sensing Blade Lift Cylinder.........................................................................2973 Maintenance Standard for Stroke Sensing Blade Tilt Cylinder...................................................................................2974 Maintenance Standard for Stroke Sensing Blade Angle Cylinder..................................................................................2975 Maintenance Standard for Stroke and Reset Sensor for Blade Lift Cylinder......................................................................2976 Maintenance Standard for Stroke Sensor for Blade Tilt Cylinder................................................................................2977 Maintenance Standard for Stroke Sensor for Blade Angle Cylinder...............................................................................2978 Maintenance Standard for Fixed Multi-Shank Ripper.............................................................................................2979 Maintenance Standard for Ripper Lift Cylinder.................................................................................................2981 CAB Related Parts.................................................................................................................................2982 Maintenance Standard for CAB Mount............................................................................................................2982 Electrical System.................................................................................................................................2984 Maintenance Standard for Steering Electric Lever..............................................................................................2984 80 Appendix...........................................................................................................................................2985 Table of Contents.................................................................................................................................2986 Precautions Before Work...........................................................................................................................2987 Abbreviation List.................................................................................................................................2988 Air Conditioner System............................................................................................................................2994 Precautions for Refrigerant...................................................................................................................2994 Air Conditioner Component.....................................................................................................................2995 Specifications of Air Conditioner.............................................................................................................2998 Structure and Function of Refrigeration Cycle.................................................................................................2999 Outline of Refrigeration Cycle................................................................................................................3000 Component Parts of Air Conditioner System.........................................................................................................3002 Air Conditioner Unit..........................................................................................................................3002 Configuration Diagram of Air Conditioner Unit.............................................................................................3002 Function of Air Conditioner Unit..........................................................................................................3003 Component Parts of Air Conditioner Unit.......................................................................................................3004 Function of Evaporator as Air Conditioner Unit Component..................................................................................3004 Function of Heater Core as Air Conditioner Unit Component.................................................................................3004 Function of Thermistor as Air Conditioner Unit Component..................................................................................3004 Structure of Expansion Valve as Air Conditioner Unit Component............................................................................3005 Function of Expansion Valve as Air Conditioner Unit Component.............................................................................3005 Operate Expansion Valve as Air Conditioner Unit Component.................................................................................3005 Function of Dual Pressure Switch..........................................................................................................3006 Function of Pressure Switch...............................................................................................................3006 Compressor....................................................................................................................................3007 Structure of Compressor...................................................................................................................3007 Specifications of Compressor..............................................................................................................3007 Function of Compressor....................................................................................................................3007 Condenser.....................................................................................................................................3008 Structure of Condenser....................................................................................................................3008 Specifications of Condenser...............................................................................................................3008 Function of Condenser.....................................................................................................................3009 Receiver Drier................................................................................................................................3010 Structure of Receiver Dryer...............................................................................................................3010 Specifications of Receiver Dryer..........................................................................................................3010 Function of Receiver Dryer................................................................................................................3010 Explanation of Procedure for Test of and Troubleshooting of Air Conditioner.......................................................................3012 Circuit Diagram of Air Conditioner................................................................................................................3015 System Diagram of Air Conditioner.................................................................................................................3016 Control Function of Air Conditioner...............................................................................................................3017 Locations of Air Conditioner Parts and Layout of Connectors.......................................................................................3018 Examine Relay.....................................................................................................................................3022 How to Examine Relay..........................................................................................................................3022 Air Conditioner Troubleshooting Chart 1...........................................................................................................3024 Air Conditioner Troubleshooting Chart 2...........................................................................................................3025 Information Shown in Troubleshooting Table........................................................................................................3028 Troubleshooting for Condenser Fan.................................................................................................................3029 Troubleshooting for Compressor and Refrigerant System (Air is Not Cooled).........................................................................3032 Troubleshooting for Blower Motor System (No Air Comes Out or Air Flow is Abnormal)................................................................3036 Troubleshooting for Temperature Control Function..................................................................................................3039 Troubleshooting by Gauge Pressure.................................................................................................................3043 Connect Service Tool..............................................................................................................................3045 How to Connect Service Tool...................................................................................................................3046 Precautions for Disconnection and Connection of Air Conditioner Piping............................................................................3047 Handle Compressor Oil.............................................................................................................................3049 90 Circuit Diagrams...................................................................................................................................3051 Table of Contents.................................................................................................................................3052 Abbreviation List.................................................................................................................................3053 Hydraulic Circuit Diagram.........................................................................................................................3059 Symbols Used in Hydraulic Circuit Diagram.....................................................................................................3059 Hydraulic Circuit Diagram.....................................................................................................................3063 Electrical Circuit Diagram........................................................................................................................3065 Symbols Used in Electric Circuit Diagram......................................................................................................3065 Electrical Circuit Diagram (Machine with KOMTRAX Terminal) (1/14).............................................................................3069 Electrical Circuit Diagram (Machine with KOMTRAX Terminal) (2/14).............................................................................3071 Electrical Circuit Diagram (Machine with KOMTRAX Terminal) (3/14).............................................................................3073 Electrical Circuit Diagram (Machine with KOMTRAX Terminal) (4/14).............................................................................3075 Electrical Circuit Diagram (Machine with KOMTRAX Terminal) (5/14).............................................................................3077 Electrical Circuit Diagram (Machine with KOMTRAX Terminal) (6/14).............................................................................3079 Electrical Circuit Diagram (Machine with KOMTRAX Terminal) (7/14).............................................................................3081 Electrical Circuit Diagram (Machine with KOMTRAX Terminal) (8/14).............................................................................3083 Electrical Circuit Diagram (Machine with KOMTRAX Terminal) (9/14).............................................................................3085 Electrical Circuit Diagram (Machine with KOMTRAX Terminal) (10/14)............................................................................3087 Electrical Circuit Diagram (Machine with KOMTRAX Terminal) (11/14)............................................................................3089 Electrical Circuit Diagram (Machine with KOMTRAX Terminal) (12/14)............................................................................3091 Electrical Circuit Diagram (Machine with KOMTRAX Terminal) (13/14)............................................................................3093 Electrical Circuit Diagram (Machine with KOMTRAX Terminal) (14/14)............................................................................3095 Electrical Circuit Diagram (Machine with Gateway Function Controller) (1/16)..................................................................3097 Electrical Circuit Diagram (Machine with Gateway Function Controller) (2/16)..................................................................3099 Electrical Circuit Diagram (Machine with Gateway Function Controller) (3/16)..................................................................3101 Electrical Circuit Diagram (Machine with Gateway Function Controller) (4/16)..................................................................3103 Electrical Circuit Diagram (Machine with Gateway Function Controller) (5/16)..................................................................3105 Electrical Circuit Diagram (Machine with Gateway Function Controller) (6/16)..................................................................3107 Electrical Circuit Diagram (Machine with Gateway Function Controller) (7/16)..................................................................3109 Electrical Circuit Diagram (Machine with Gateway Function Controller) (8/16)..................................................................3111 Electrical Circuit Diagram (Machine with Gateway Function Controller) (9/16)..................................................................3113 Electrical Circuit Diagram (Machine with Gateway Function Controller) (10/16).................................................................3115 Electrical Circuit Diagram (Machine with Gateway Function Controller) (11/16).................................................................3117 Electrical Circuit Diagram (Machine with Gateway Function Controller) (12/16).................................................................3119 Electrical Circuit Diagram (Machine with Gateway Function Controller) (13/16).................................................................3121 Electrical Circuit Diagram (Machine with Gateway Function Controller) (14/16).................................................................3123 Electrical Circuit Diagram (Machine with Gateway Function Controller) (15/16).................................................................3125 Electrical Circuit Diagram (Machine with Gateway Function Controller) (16/16).................................................................3127 INDEX..................................................................................................................................................3129
DESCRIPTION:
KOMATSU D51EXi-24 D51PXi-24 BULLDOZER SHOP MANUAL SEN06621-13 – PDF DOWNLOAD
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 Specification
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 Others
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.
S.S 29/12/24
