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Complete service repair manual with electrical wiring diagrams for Komatsu Crawler Dozers/Tractors D51EX, D51EXi, D51PX, D51PXi with all the shop information to maintain, diagnostic, repair, and rebuild like a professional.
Komatsu Crawler Dozers/Tractors D51EX, D51EXi, D51PX, D51PXi workshop service repair manual includes:
* Numbered table of contents easy to use so that you can find the information you need fast.
* Detailed sub-steps expand on repair procedure information
* Numbered instructions guide you through every repair procedure step by step.
* Troubleshooting and electrical service procedures are combined with detailed wiring diagrams for ease of use.
* Notes, cautions and warnings throughout each chapter pinpoint critical information.
* Bold figure number help you quickly match illustrations with instructions.
* Detailed illustrations, drawings and photos guide you through every procedure.
* Enlarged inset helps you identify and examine parts in detail.
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PRODUCT DETAILS:
Total Pages: 10,102 pages
File Format: PDF (Internal Links, Bookmarked, Table of Contents, Searchable, Printable, high quality)
Language: English
TABLE OF CONTENTS
00 INDEX AND FOREWORD … 00-1
ABBREVIATION LIST … 00-20
FOREWORD, SAFETY, BASIC INFORMATION ….. 00-26
HOW TO READ THE SHOP MANUAL…. 00-26
SAFETY NOTICE FOR OPERATION… 00-28
PRECAUTIONS TO PREVENT FIRE… 00-36
ACTIONS IF FIRE OCCURS … 00-38
PRECAUTIONS FOR DISPOSING OF WASTE MATERIALS ….. 00-39
ACTIONS TAKEN TO MEET EXHAUST GAS REGULATIONS… 00-40
PRECAUTIONS FOR DEF…. 00-41
STORE AdBlue/DEF …. 00-42
PRECAUTIONS FOR HANDLING HYDRAULIC EQUIPMENT … 00-43
PRECAUTIONS FOR DISCONNECTION AND CONNECTION OF PIPINGS….. 00-46
PRECAUTIONS FOR HANDLING ELECTRICAL EQUIPMENT….. 00-52
PRECAUTIONS FOR HANDLING FUEL SYSTEM EQUIPMENT ….. 00-54
PRECAUTIONS FOR HANDLING INTAKE SYSTEM EQUIPMENT …. 00-55
PRACTICAL USE OF KOMTRAX ….. 00-56
DISCONNECT AND CONNECT PUSH-PULL TYPE COUPLER … 00-57
PRECAUTIONS FOR DISCONNECTION AND CONNECTION OF CONNECTORS … 00-61
METHOD FOR DISCONNECTING AND CONNECTING DEUTSCH CONNECTOR … 00-65
METHOD FOR DISCONNECTING AND CONNECTING SLIDE LOCK TYPE CONNECTOR …. 00-66
METHOD FOR DISCONNECTING AND CONNECTING CONNECTOR WITH LOCK TO PULL … 00-68
METHOD FOR DISCONNECTING AND CONNECTING CONNECTOR WITH LOCK TO PUSH .. 00-69
METHOD FOR DISCONNECTING AND CONNECTING CONNECTOR WITH HOUSING TO ROTATE .
… 00-71
HOW TO READ ELECTRICAL WIRE CODE … 00-72
EXPLANATION OF TERMS FOR MAINTENANCE STANDARD…. 00-76
STANDARD TIGHTENING TORQUE TABLE… 00-79
CONVERSION TABLE …. 00-86
01 SPECIFICATIONS … 01-1
CONTENTS ….. 01-2
ABBREVIATION LIST ….. 01-3
SPECIFICATIONS …. 01-9
SPECIFICATION DRAWING… 01-9
SPECIFICATIONS …. 01-13
WEIGHT TABLE …. 01-24
FUEL, COOLANT, LUBRICANTS (FOR NORTH AMERICA) … 01-28
FUEL, COOLANT, LUBRICANTS (FOR EUROPEAN UNION)…. 01-30
10 STRUCTURE AND FUNCTION …. 10-1
CONTENTS ….. 10-2
ABBREVIATION LIST ….. 10-5
UREA SCR SYSTEM…..10-11
LAYOUT DRAWING OF UREA SCR SYSTEM ….10-11
UREA SCR SYSTEM DIAGRAM … 10-13
FUNCTION OF UREA SCR SYSTEM….. 10-14
COMPONENT PARTS OF UREA SCR SYSTEM… 10-32
BOOT-UP SYSTEM … 10-41
LAYOUT DRAWING OF BOOT-UP SYSTEM… 10-41
SYSTEM OPERATING LAMP SYSTEM …. 10-42
BATTERY DISCONNECT SWITCH ….. 10-44
ENGINE SYSTEM ….. 10-45
LAYOUT DRAWING OF ENGINE SYSTEM ….. 10-45
ENGINE CONTROL SYSTEM …. 10-47
AUTOMATIC IDLE STOP SYSTEM ….. 10-53
COMPONENT PARTS OF ENGINE SYSTEM …. 10-56
COOLING SYSTEM… 10-73
LAYOUT DRAWING OF COOLING SYSTEM ….. 10-73
COOLING FAN CONTROL SYSTEM… 10-75
COMPONENT PARTS OF COOLING SYSTEM….. 10-78
CONTROL SYSTEM….. 10-87
LAYOUT DRAWING OF CONTROL SYSTEM …. 10-87
MACHINE MONITOR SYSTEM ….. 10-88
KOMTRAX SYSTEM…. 10-89
COMPONENT PARTS OF CONTROL SYSTEM…. 10-90
HYDRAULIC SYSTEM….10-122
LAYOUT DRAWING OF HYDRAULIC SYSTEM …10-122
CLSS …..10-123
COMPONENT PARTS OF HYDRAULIC SYSTEM …..10-126
POWER TRAIN SYSTEM …..10-158
LAYOUT DRAWING OF HST SYSTEM ….10-158
OPERATION OF HST SYSTEM….10-159
STEERING AND BRAKE CONTROL SYSTEM ….10-161
HST CONTROL SYSTEM….10-163
PARKING BRAKE CONTROL SYSTEM …10-174
COMPONENT PARTS OF POWER TRAIN SYSTEM ….10-177
WORK EQUIPMENT SYSTEM …10-213
WORK EQUIPMENT CONTROL …..10-213
LAYOUT DRAWING OF FRONT WORK EQUIPMENT…..10-215
LAYOUT OF FIXED MULTI-SHANK RIPPER…..10-216
COMPONENT PARTS OF WORK EQUIPMENT SYSTEM …..10-217
ICT SYSTEM …10-233
LAYOUT DRAWING OF ICT SYSTEM…10-233
ICT CONTROL SYSTEM DIAGRAM…10-235
BLADE CONTROL SYSTEM …..10-237
SMOOTH START SYSTEM ….10-243
SLIP CONTROL SYSTEM …10-245
ASSIST CONTROL SYSTEM ….10-246
HST SPEED RANGE CONTROL SYSTEM ….10-248
COMPONENT PARTS OF ICT SYSTEM …..10-250
UNDERCARRIAGE AND FRAME…..10-272
MAIN FRAME ….10-272
SUSPENSION …10-273
TRACK FRAME AND IDLER CUSHION …10-276
WORK EQUIPMENT….10-278
STRUCTURE OF FRONT WORK EQUIPMENT…10-278
STRUCTURE OF FIXED MULTI-SHANK RIPPER…10-279
CAB AND ITS ATTACHMENTS …..10-280
ROPS CAB …..10-280
CAB MOUNT …..10-282
20 STANDARD VALUE TABLE …. 20-1
CONTENTS ….. 20-2
ABBREVIATION LIST ….. 20-3
STANDARD VALUE TABLE FOR ENGINE … 20-9
STANDARD VALUE TABLE FOR ENGINE: D51EXI-24 …. 20-9
STANDARD VALUE TABLE FOR ENGINE: D51PXI-24 ….. 20-13
STANDARD VALUE TABLE FOR MACHINE….. 20-17
STANDARD VALUE TABLE FOR MACHINE: D51EXI-24 ….. 20-17
STANDARD VALUE TABLE FOR MACHINE: D51PXI-24 ….. 20-34
MACHINE POSTURE AND PROCEDURE FOR MEASURING PERFORMANCE …. 20-49
30 TESTING AND ADJUSTING … 30-1
CONTENTS ….. 30-2
ABBREVIATION LIST ….. 30-6
RELATED INFORMATION ON TESTING AND ADJUSTING …. 30-12
TOOLS FOR TESTING AND ADJUSTING…. 30-12
SKETCH OF TOOLS FOR TESTING AND ADJUSTING … 30-19
ENGINE AND COOLING SYSTEM…. 30-23
TEST ENGINE SPEED … 30-23
TEST BOOST PRESSURE… 30-25
TEST EXHAUST GAS COLOR … 30-27
TEST AND ADJUST VALVE CLEARANCE … 30-29
TEST COMPRESSION PRESSURE…. 30-31
TEST BLOWBY PRESSURE … 30-36
TEST ENGINE OIL PRESSURE …. 30-38
TEST FUEL PRESSURE … 30-39
TEST FUEL DISCHARGE, RETURN AND LEAKAGE …. 30-44
BLEED AIR FROM FUEL SYSTEM ….. 30-50
TEST FUEL CIRCUIT FOR LEAKAGE … 30-51
HANDLE CYLINDER CUT-OUT MODE OPERATION….. 30-53
HANDLE NO-INJECTION CRANKING OPERATION … 30-54
TEST KDOC, SCR AND MUFFLER STACK FOR LOOSENESS AND DAMAGE ….. 30-55
TEST INSTALLED CONDITION OF CYLINDER HEADS AND MANIFOLDS … 30-56
TEST ENGINE PIPING FOR DAMAGE AND LOOSENESS …. 30-57
WRITE ASH IN SOOT ACCUMULATION CORRECTION TO ENGINE CONTROLLER …. 30-58
TEST SCR RELATED FUNCTIONS….. 30-59
CLEAN AdBlue/DEF TANK … 30-87
CLEAN AdBlue/DEF TANK MOUNTING PORTION ….. 30-91
POWER TRAIN…. 30-92
TEST AND ADJUST HST OIL PRESSURE ….. 30-92
BLEED AIR FROM HST PUMP ….. 30-97
TEST OUTLET PRESSURE OF SOLENOID VALVE … 30-99
TEST TRAVEL DEVIATION ….30-103
TEST BRAKE PERFORMANCE SIMPLY ….30-105
TEST AND ADJUST DECELERATION/BRAKE PEDAL….30-106
ADJUST PARKING BRAKE LEVER….30-110
MOVE MACHINE WHEN IT CANNOT TRAVEL….30-112
UNDERCARRIAGE AND FRAME…..30-115
CHECK AND ADJUST IDLER CLEARANCE …..30-115
TESTING SPROCKET WEAR …30-117
TEST AND ADJUST TRACK TENSION….30-118
HYDRAULIC SYSTEM….30-120
RELEASE REMAINING PRESSURE FROM HYDRAULIC SYSTEM…..30-120
TEST AND ADJUST WORK EQUIPMENT OIL PRESSURES …30-121
TEST AND ADJUST OIL PRESSURE OF CONTROL CIRCUIT …30-124
TEST OUTLET PRESSURE OF EPC SOLENOID VALVE …30-126
BLEED AIR FROM WORK EQUIPMENT AND COOLING FAN PUMP …..30-128
TEST COOLING FAN SPEED …30-129
TEST COOLING FAN CIRCUIT OIL PRESSURE ….30-130
TEST THE PARTS CAUSING HYDRAULIC DRIFT IN WORK EQUIPMENT…..30-132
TEST INTERNAL OIL LEAKAGE OF WORK EQUIPMENT CYLINDER …30-135
BLEED AIR FROM WORK EQUIPMENT CYLINDERS…..30-138
WORK EQUIPMENT….30-139
ADJUST WORK EQUIPMENT LOCK LEVER….30-139
ELECTRICAL SYSTEM …..30-141
SET AND OPERATE MACHINE MONITOR….30-141
METHOD FOR STARTING UP KOMTRAX TERMINAL ….30-268
ADJUSTMENT WHEN HST CONTROLLER HAS BEEN REPLACED …30-273
ADJUSTMENT WHEN ELECTRIC OR HYDRAULIC DEVICE HAS BEEN REPLACED …30-279
ADJUST REARVIEW CAMERA ANGLE …30-281
HANDLE VOLTAGE CIRCUIT OF ENGINE CONTROLLER …30-282
HANDLE BATTERY DISCONNECT SWITCH ….30-283
TEST DIODES …30-284
ICT SYSTEM …30-285
SET AND OPERATE CONTROL BOX …30-285
CALIBRATE BLADE EDGE POSITION ….30-288
CALIBRATE IMU SENSOR…..30-310
RESET CYLINDER STROKE END …..30-317
METHOD FOR INPUTTING WEAR AMOUNT OF BLADE EDGE AND TRACK SHOE ….30-320
CHECK BLADE ELEVATION, ADJUST…..30-321
TEST STROKE SENSOR FOR LIFT CYLINDER…..30-325
TEST STROKE SENSOR FOR TILT CYLINDER …..30-327
TEST STROKE SENSOR FOR ANGLE CYLINDER …30-329
TEST AND ADJUST RESET SENSOR FOR LIFT CYLINDER …..30-331
ADJUST WHEN ICT SENSOR CONTROLLER IS REPLACED ….30-333
METHOD FOR ADJUSTING WHEN ICT RELATED DEVICES ARE REPAIRED OR REPLACED30-336
Pm CLINIC….30-339
Pm CLINIC SERVICE ….30-339
40 TROUBLESHOOTING … 40-1
CONTENTS ….. 40-2
ABBREVIATION LIST … 40-13
RELATED INFORMATION ON TROUBLESHOOTING …. 40-19
GENERAL TROUBLESHOOTING POINTS ….. 40-19
TROUBLESHOOTING POINTS FOR UREA SCR SYSTEM…. 40-20
SEQUENCE OF EVENTS IN TROUBLESHOOTING… 40-32
CHECKS BEFORE TROUBLESHOOTING … 40-34
INSPECTION PROCEDURE BEFORE TROUBLESHOOTING ….. 40-36
TESTING IN ACCORDANCE WITH TESTING PROCEDURE…. 40-38
PREPARATION FOR TROUBLESHOOTING OF ELECTRICAL SYSTEM…. 40-60
PROCEDURE FOR TROUBLESHOOTING ….. 40-67
INFORMATION DESCRIBED IN TROUBLESHOOTING TABLE…. 40-70
TROUBLESHOOTING METHOD FOR OPEN CIRCUIT IN WIRING HARNESS OF PRESSURE SEN-
SOR SYSTEM…. 40-72
CONNECTORS LIST AND LAYOUT…. 40-75
CONNECTOR CONTACT IDENTIFICATION … 40-92
T-BRANCH BOX AND T-BRANCH ADAPTER TABLE …40-132
FUSE LOCATION TABLE ….40-138
PRECAUTIONS FOR REPLACING KDOC …..40-142
FAILURE CODES TABLE ….40-143
TROUBLESHOOTING BY FAILURE CODE (DISPLAY OF CODE) …..40-162
FAILURE CODE [6091NX] …40-162
FAILURE CODE [989L00] ….40-164
FAILURE CODE [989M00] …40-165
FAILURE CODE [989N00] …40-166
FAILURE CODE [A1U0N3] …..40-167
FAILURE CODE [A1U0N4] …..40-169
FAILURE CODE [A900FR]…40-171
FAILURE CODE [A900N6] …40-172
FAILURE CODE [A900NY]…40-173
FAILURE CODE [AA10NX] …..40-174
FAILURE CODE [AB00KE] …..40-176
FAILURE CODE [AQ10MB] ….40-178
FAILURE CODE [AQ10N3] …..40-180
FAILURE CODE [AS00R2]…40-182
FAILURE CODE [AS00R3]…40-183
FAILURE CODE [AS00R4]…40-184
FAILURE CODE [AS00R5]…40-185
FAILURE CODE [AS00R6]…40-186
FAILURE CODE [AS00ZK]…40-187
FAILURE CODE [AS10KM]…..40-188
FAILURE CODE [AS10NR] …..40-189
FAILURE CODE [AS10NT] …..40-190
FAILURE CODE [B@BAZG] …40-191
FAILURE CODE [B@BCNS] …40-192
FAILURE CODE [B@CRNS]…40-193
FAILURE CODE [B@CRZG]…40-194
FAILURE CODE [CA115] …..40-195
FAILURE CODE [CA122] …..40-196
FAILURE CODE [CA123] …..40-198
FAILURE CODE [CA131] …..40-200
FAILURE CODE [CA132] …..40-202
FAILURE CODE [CA144] …..40-204
FAILURE CODE [CA145] …..40-206
FAILURE CODE [CA153] …..40-208
FAILURE CODE [CA154] …..40-210
FAILURE CODE [CA187] …..40-212
FAILURE CODE [CA221] …..40-214
FAILURE CODE [CA222] …..40-216
FAILURE CODE [CA227] …..40-218
FAILURE CODE [CA234] …..40-220
FAILURE CODE [CA238] …..40-221
FAILURE CODE [CA239] …..40-222
FAILURE CODE [CA249] …..40-223
FAILURE CODE [CA256] …..40-225
FAILURE CODE [CA271] …..40-227
FAILURE CODE [CA272] …..40-229
FAILURE CODE [CA295] …..40-231
FAILURE CODE [CA322] …..40-232
FAILURE CODE [CA324] …..40-234
FAILURE CODE [CA331] …..40-236
FAILURE CODE [CA332] …..40-238
FAILURE CODE [CA343] …..40-240
FAILURE CODE [CA351] …..40-241
FAILURE CODE [CA352] …..40-243
FAILURE CODE [CA356] …..40-245
FAILURE CODE [CA357] …..40-247
FAILURE CODE [CA386] …..40-249
FAILURE CODE [CA428] …..40-250
FAILURE CODE [CA429] …..40-252
FAILURE CODE [CA435] …..40-254
FAILURE CODE [CA441] …..40-256
FAILURE CODE [CA442] …..40-258
FAILURE CODE [CA451] …..40-259
FAILURE CODE [CA452] …..40-261
FAILURE CODE [CA488] …..40-263
FAILURE CODE [CA515] …..40-264
FAILURE CODE [CA516] …..40-266
FAILURE CODE [CA553] …..40-268
FAILURE CODE [CA555] …..40-269
FAILURE CODE [CA556] …..40-270
FAILURE CODE [CA559] …..40-271
FAILURE CODE [CA595] …..40-274
FAILURE CODE [CA687] …..40-276
FAILURE CODE [CA689] …..40-278
FAILURE CODE [CA691] …..40-281
FAILURE CODE [CA692] …..40-283
FAILURE CODE [CA697] …..40-285
FAILURE CODE [CA698] …..40-286
FAILURE CODE [CA731] …..40-287
FAILURE CODE [CA778] …..40-289
FAILURE CODE [CA1117] …40-294
FAILURE CODE [CA1664] …40-296
FAILURE CODE [CA1669] …40-298
FAILURE CODE [CA1673] …40-299
FAILURE CODE [CA1677] …40-300
FAILURE CODE [CA1678] …40-301
FAILURE CODE [CA1682] …40-302
FAILURE CODE [CA1683] …40-304
FAILURE CODE [CA1684] …40-306
FAILURE CODE [CA1686] …40-308
FAILURE CODE [CA1691] …40-309
FAILURE CODE [CA1694] …40-311
FAILURE CODE [CA1695] …40-313
FAILURE CODE [CA1696] …40-314
FAILURE CODE [CA1712] …40-316
FAILURE CODE [CA1713] …40-319
FAILURE CODE [CA1714] …40-321
FAILURE CODE [CA1715] …40-322
FAILURE CODE [CA1776] …40-323
FAILURE CODE [CA1777] …40-326
FAILURE CODE [CA1843] …40-329
FAILURE CODE [CA1844] …40-331
FAILURE CODE [CA1885] …40-334
FAILURE CODE [CA1887] …40-336
FAILURE CODE [CA1896] …40-338
FAILURE CODE [CA1898] …40-339
FAILURE CODE [CA1938] …40-341
FAILURE CODE [CA1942] …40-343
FAILURE CODE [CA1961] …40-344
FAILURE CODE [CA1962] …40-345
FAILURE CODE [CA2185] …40-346
FAILURE CODE [CA2186] …40-348
FAILURE CODE [CA2198] …40-350
FAILURE CODE [CA2272] …40-352
FAILURE CODE [CA2288] …40-354
FAILURE CODE [CA2311] …40-355
FAILURE CODE [CA2349] …40-356
FAILURE CODE [CA2353] …40-358
FAILURE CODE [CA2357] …40-360
FAILURE CODE [CA2373] …40-361
FAILURE CODE [CA2374] …40-363
FAILURE CODE [CA2375] …40-365
FAILURE CODE [CA2376] …40-367
FAILURE CODE [CA2387] …40-370
FAILURE CODE [CA2554] …40-371
FAILURE CODE [CA2634] …40-372
FAILURE CODE [CA2635] …40-374
FAILURE CODE [CA2636] …40-375
FAILURE CODE [CA2637] …40-377
FAILURE CODE [CA2771] …40-379
FAILURE CODE [CA2961] …40-383
FAILURE CODE [CA2973] …40-384
FAILURE CODE [CA2976] …40-385
FAILURE CODE [CA3142] …40-387
FAILURE CODE [CA3143] …40-388
FAILURE CODE [CA3144] …40-389
FAILURE CODE [CA3146] …40-391
FAILURE CODE [CA3147] …40-392
FAILURE CODE [CA3148] …40-393
FAILURE CODE [CA3151] …40-395
FAILURE CODE [CA3165] …40-400
FAILURE CODE [CA3228] …40-402
FAILURE CODE [CA3229] …40-404
FAILURE CODE [CA3231] …40-406
FAILURE CODE [CA3232] …40-408
FAILURE CODE [CA3235] …40-412
FAILURE CODE [CA3239] …40-414
FAILURE CODE [CA3241] …40-417
FAILURE CODE [CA3242] …40-420
FAILURE CODE [CA3251] …40-423
FAILURE CODE [CA3313] …40-425
FAILURE CODE [CA3314] …40-426
FAILURE CODE [CA3315] …40-427
FAILURE CODE [CA3419] …40-429
FAILURE CODE [CA3421] …40-431
FAILURE CODE [CA3497] …40-433
FAILURE CODE [CA3498] …40-434
FAILURE CODE [CA3545] …40-435
FAILURE CODE [CA3547] …40-437
FAILURE CODE [CA3558] …40-438
FAILURE CODE [CA3559] …40-440
FAILURE CODE [CA3562] …40-442
FAILURE CODE [CA3563] …40-444
FAILURE CODE [CA3567] …40-447
FAILURE CODE [CA3568] …40-451
FAILURE CODE [CA3571] …40-455
FAILURE CODE [CA3572] …40-457
FAILURE CODE [CA3574] …40-459
FAILURE CODE [CA3575] …40-461
FAILURE CODE [CA3577] …40-463
FAILURE CODE [CA3578] …40-465
FAILURE CODE [CA3582] …40-467
FAILURE CODE [CA3583] …40-472
FAILURE CODE [CA3596] …40-474
FAILURE CODE [CA3649] …40-477
FAILURE CODE [CA3681] …40-479
FAILURE CODE [CA3682] …40-484
FAILURE CODE [CA3713] …40-489
FAILURE CODE [CA3717] …40-492
FAILURE CODE [CA3718] …40-493
FAILURE CODE [CA3724] …40-494
FAILURE CODE [CA3725] …40-495
FAILURE CODE [CA3741] …40-498
FAILURE CODE [CA3748] …40-499
FAILURE CODE [CA3755] …40-501
FAILURE CODE [CA3866] …40-503
FAILURE CODE [CA3868] …40-506
FAILURE CODE [CA4152] …40-510
FAILURE CODE [CA4155] …40-514
FAILURE CODE [CA4156] …40-517
FAILURE CODE [CA4157] …40-520
FAILURE CODE [CA4159] …40-522
FAILURE CODE [CA4164] …40-523
FAILURE CODE [CA4165] …40-525
FAILURE CODE [CA4166] …40-527
FAILURE CODE [CA4168] …40-528
FAILURE CODE [CA4169] …40-531
FAILURE CODE [CA4171] …40-533
FAILURE CODE [CA4249] …40-536
FAILURE CODE [CA4251] …40-538
FAILURE CODE [CA4261] …40-541
FAILURE CODE [CA4277] …40-544
FAILURE CODE [CA4459] …40-547
FAILURE CODE [CA4461] …40-549
FAILURE CODE [CA4533] …40-552
FAILURE CODE [CA4534] …40-553
FAILURE CODE [CA4731] …40-554
FAILURE CODE [CA4732] …40-555
FAILURE CODE [CA4739] …40-556
FAILURE CODE [CA4768] …40-557
FAILURE CODE [CA4769] …40-559
FAILURE CODE [CA4842] …40-562
FAILURE CODE [CA4952] …40-565
FAILURE CODE [CA5115] …40-567
FAILURE CODE [CA5179] …40-570
FAILURE CODE [CA5181] …40-572
FAILURE CODE [CA5387] …40-574
FAILURE CODE [CA5388] …40-576
FAILURE CODE [CA5389] …40-579
FAILURE CODE [CA5391] …40-581
FAILURE CODE [CA5392] …40-585
FAILURE CODE [CA5393] …40-587
FAILURE CODE [CA5394] …40-590
FAILURE CODE [CA5395] …40-593
FAILURE CODE [CA5396] …40-596
FAILURE CODE [CA5631] …40-597
FAILURE CODE [CA5632] …40-599
FAILURE CODE [CA5938] …40-600
FAILURE CODE [D130KA]…40-602
FAILURE CODE [D130KB]…40-605
FAILURE CODE [D130KY]…40-607
FAILURE CODE [D19JKZ] …40-609
FAILURE CODE [D811MC] …..40-612
FAILURE CODE [D862KA]…40-613
FAILURE CODE [D8ALKA] …..40-614
FAILURE CODE [D8ALKB] …..40-616
FAILURE CODE [D8AQKR] ….40-618
FAILURE CODE [DAF0MB] ….40-620
FAILURE CODE [DAF0MC] ….40-621
FAILURE CODE [DAF8KB] …..40-622
FAILURE CODE [DAF9KQ]…..40-624
FAILURE CODE [DAFGMC] …40-625
FAILURE CODE [DAFLKA] …..40-626
FAILURE CODE [DAFLKB] …..40-628
FAILURE CODE [DAFQKR] ….40-630
FAILURE CODE [DAJ000] …40-631
FAILURE CODE [DAJ0KQ] …..40-632
FAILURE CODE [DAJ0KT]…40-633
FAILURE CODE [DAJ0MC]…..40-634
FAILURE CODE [DAJ1KK] …..40-635
FAILURE CODE [DAJ2KK] …..40-637
FAILURE CODE [DAJ5KK] …..40-639
FAILURE CODE [DAJ6KK] …..40-642
FAILURE CODE [DAJLKA] …..40-644
FAILURE CODE [DAJLKB] …..40-646
FAILURE CODE [DAJPMA] ….40-648
FAILURE CODE [DAJQKR] ….40-649
FAILURE CODE [DAJRKR]…..40-650
FAILURE CODE [DB2QKR] ….40-651
FAILURE CODE [DB2RKR] ….40-656
FAILURE CODE [DBR0KT]…..40-661
FAILURE CODE [DBR0MC]….40-662
FAILURE CODE [DBR1KK]…..40-663
FAILURE CODE [DBR2KK]…..40-666
FAILURE CODE [DBR5KK]…..40-669
FAILURE CODE [DBRLKA]…..40-671
FAILURE CODE [DBRLKB]…..40-673
FAILURE CODE [DBRPMA]….40-675
FAILURE CODE [DBRQKR]….40-676
FAILURE CODE [DBRRKR]….40-678
FAILURE CODE [DBTSKR] ….40-679
FAILURE CODE [DBUTKA] ….40-682
FAILURE CODE [DD12KA] …..40-683
FAILURE CODE [DD12KB] …..40-685
FAILURE CODE [DD13KA] …..40-687
FAILURE CODE [DD13KB] …..40-689
FAILURE CODE [DD14KA] …..40-691
FAILURE CODE [DD14KB] …..40-693
FAILURE CODE [DDKAKA] ….40-695
FAILURE CODE [DDKAKB] ….40-697
FAILURE CODE [DDKFL4] …..40-699
FAILURE CODE [DDKGL4]…..40-701
FAILURE CODE [DDKHKA] ….40-703
FAILURE CODE [DDKHKB] ….40-705
FAILURE CODE [DDNLKA] ….40-707
FAILURE CODE [DDNLKB] ….40-709
FAILURE CODE [DDP6KA]…..40-711
FAILURE CODE [DDP6KB]…..40-714
FAILURE CODE [DDP6MA] ….40-716
FAILURE CODE [DDU1FS]…..40-718
FAILURE CODE [DDU1KA] ….40-720
FAILURE CODE [DDU1KY] ….40-723
FAILURE CODE [DFA4KX] …..40-725
FAILURE CODE [DFA4KZ] …..40-726
FAILURE CODE [DFA4L8] …40-727
FAILURE CODE [DFA5KA] …..40-728
FAILURE CODE [DFA5KB] …..40-731
FAILURE CODE [DFA6KA] …..40-734
FAILURE CODE [DFA6KB] …..40-737
FAILURE CODE [DFA7KX] …..40-740
FAILURE CODE [DFA7KZ] …..40-741
FAILURE CODE [DFA7L8] …40-742
FAILURE CODE [DFA8KA] …..40-743
FAILURE CODE [DFA8KB] …..40-746
FAILURE CODE [DFA9KA] …..40-749
FAILURE CODE [DFA9KB] …..40-752
FAILURE CODE [DGS1KA] ….40-755
FAILURE CODE [DGS1KX] ….40-758
FAILURE CODE [DH21KA] …..40-759
FAILURE CODE [DH21KB] …..40-761
FAILURE CODE [DHA4KA]…..40-763
FAILURE CODE [DHH7KA] ….40-765
FAILURE CODE [DHH7KB] ….40-768
FAILURE CODE [DHH8KA] ….40-770
FAILURE CODE [DHH8KB] ….40-773
FAILURE CODE [DHH9KA] ….40-775
FAILURE CODE [DHH9KB] ….40-778
FAILURE CODE [DHHAKA] ….40-780
FAILURE CODE [DHHAKB] ….40-783
FAILURE CODE [DK30KA] …..40-785
FAILURE CODE [DK30KB] …..40-788
FAILURE CODE [DK30KX] …..40-790
FAILURE CODE [DK30KZ] …..40-791
FAILURE CODE [DK30L8] …40-792
FAILURE CODE [DK31KA] …..40-793
FAILURE CODE [DK31KB] …..40-796
FAILURE CODE [DK40KA] …..40-798
FAILURE CODE [DK40KB] …..40-801
FAILURE CODE [DK55KX] …..40-803
FAILURE CODE [DK55KZ] …..40-804
FAILURE CODE [DK55L8] …40-805
FAILURE CODE [DK56KA] …..40-806
FAILURE CODE [DK56KB] …..40-809
FAILURE CODE [DK57KA] …..40-811
FAILURE CODE [DK57KB] …..40-814
FAILURE CODE [DK80KA] …..40-816
FAILURE CODE [DKS0L8]…40-818
FAILURE CODE [DKS1KA]…..40-819
FAILURE CODE [DKS1KB]…..40-821
FAILURE CODE [DKS2KA]…..40-822
FAILURE CODE [DKS2KB]…..40-824
FAILURE CODE [DKS3KA]…..40-825
FAILURE CODE [DKS3KB]…..40-827
FAILURE CODE [DKS3MB] ….40-828
FAILURE CODE [DKS4L8]…40-829
FAILURE CODE [DKS5KA]…..40-830
FAILURE CODE [DKS5KB]…..40-832
FAILURE CODE [DKS6KA]…..40-833
FAILURE CODE [DKS6KB]…..40-835
FAILURE CODE [DKS7MB] ….40-836
FAILURE CODE [DKSCL8] …..40-837
FAILURE CODE [DKSDKA] ….40-838
FAILURE CODE [DKSDKB] ….40-840
FAILURE CODE [DKSEKA] ….40-841
FAILURE CODE [DKSEKB] ….40-843
FAILURE CODE [DKSFKA]…..40-844
FAILURE CODE [DKSFKB]…..40-846
FAILURE CODE [DKSFMB] ….40-847
FAILURE CODE [DLM0KX]…..40-849
FAILURE CODE [DLM0MA] ….40-850
FAILURE CODE [DLM1KA]…..40-851
FAILURE CODE [DLM1KB]…..40-853
FAILURE CODE [DLM1MA] ….40-855
FAILURE CODE [DLM2KA]…..40-856
FAILURE CODE [DLM2KB]…..40-858
FAILURE CODE [DLM2MA] ….40-860
FAILURE CODE [DLM3KA]…..40-861
FAILURE CODE [DLM3KB]…..40-863
FAILURE CODE [DLM3MB] ….40-865
FAILURE CODE [DN21FS] …..40-866
FAILURE CODE [DR21KX] …..40-868
FAILURE CODE [DR31KX] …..40-869
FAILURE CODE [DV20KB] …..40-870
FAILURE CODE [DW4BKA]….40-872
FAILURE CODE [DW4BKB]….40-874
FAILURE CODE [DW4BKY]….40-876
FAILURE CODE [DW7BKA]….40-878
FAILURE CODE [DW7BKB]….40-880
FAILURE CODE [DW7EKA]….40-882
FAILURE CODE [DW7EKB]….40-884
FAILURE CODE [DW7EKY]….40-886
FAILURE CODE [DWN5KA]….40-888
FAILURE CODE [DWN5KB]….40-890
FAILURE CODE [DWN5KY]….40-892
FAILURE CODE [DXA4KA]…..40-894
FAILURE CODE [DXA4KB]…..40-896
FAILURE CODE [DXA4KY]…..40-898
FAILURE CODE [DXA5KA]…..40-900
FAILURE CODE [DXA5KB]…..40-902
FAILURE CODE [DXA5KY]…..40-904
FAILURE CODE [DXA6KA]…..40-906
FAILURE CODE [DXA6KB]…..40-908
FAILURE CODE [DXA6KY]…..40-910
FAILURE CODE [DXA7KA]…..40-912
FAILURE CODE [DXA7KB]…..40-914
FAILURE CODE [DXA7KY]…..40-916
FAILURE CODE [DXHRKA] ….40-918
FAILURE CODE [DXHRKB] ….40-920
FAILURE CODE [DXHRKY] ….40-922
FAILURE CODE [DXHSKA] ….40-924
FAILURE CODE [DXHSKB] ….40-926
FAILURE CODE [DXHSKY] ….40-928
FAILURE CODE [DXHTKA] ….40-930
FAILURE CODE [DXHTKB] ….40-932
FAILURE CODE [DXHTKY] ….40-934
FAILURE CODE [DXHUKA] ….40-936
FAILURE CODE [DXHUKB] ….40-938
FAILURE CODE [DXHUKY] ….40-940
FAILURE CODE [DXJ4KA] …..40-942
FAILURE CODE [DXJ4KB] …..40-944
FAILURE CODE [DXJCKA]…..40-946
FAILURE CODE [DXJCKB]…..40-948
FAILURE CODE [DXJCKY]…..40-950
FAILURE CODE [DXJDKA]…..40-952
FAILURE CODE [DXJDKB]…..40-954
FAILURE CODE [DXJDKY]…..40-956
FAILURE CODE [DXK1KA]…..40-958
FAILURE CODE [DXK1KB]…..40-960
FAILURE CODE [DXK1KY]…..40-962
FAILURE CODE [DXK2KA]…..40-964
FAILURE CODE [DXK2KB]…..40-966
FAILURE CODE [DXK2KY]…..40-968
TROUBLESHOOTING OF ELECTRICAL SYSTEM (E-MODE) …..40-970
E-1 ENGINE DOES NOT START (ENGINE DOES NOT CRANK) …40-970
E-2 MANUAL PREHEATING SYSTEM DOES NOT WORK….40-977
E-3 AUTOMATIC PREHEATING SYSTEM DOES NOT WORK ….40-980
E-4 WHILE PREHEATING IS WORKING, PREHEATING MONITOR DOES NOT LIGHT UP….40-982
E-5 WHEN STARTING SWITCH IS TURNED TO ON POSITION, MACHINE MONITOR DISPLAYS
NOTHING….40-984
E-6 WHEN STARTING SWITCH IS TURNED TO ON POSITION (WITH ENGINE STOPPED), BASIC
CHECK MONITOR LIGHTS UP …40-988
E-7 AIR CLEANER CLOGGING MONITOR LIGHTS UP IN YELLOW WHILE ENGINE IS RUNNING…..
…..40-989
E-8 CHARGE LEVEL MONITOR LIGHTS UP IN RED WHILE ENGINE IS RUNNING …..40-990
E-9 ENGINE COOLANT TEMPERATURE MONITOR LIGHTS UP IN RED WHILE ENGINE IS RUN-
NING …..40-991
E-10 ENGINE OIL PRESSURE MONITOR LIGHTS UP IN RED WHILE ENGINE IS RUNNING ..40-992
E-11 HST CHARGE PRESSURE MONITOR LIGHTS UP IN RED WHILE ENGINE IS RUNNING ….
…..40-993
E-12 HYDRAULIC OIL TEMPERATURE MONITOR LIGHTS UP IN RED WHILE ENGINE IS RUN-
NING …..40-994
E-13 HST OIL FILTER CLOGGING MONITOR LIGHTS UP IN RED WHILE ENGINE IS RUNNING ….
…..40-995
E-14 ENGINE COOLANT TEMPERATURE GAUGE DOES NOT INDICATE CORRECT TEMPERA-
TURE ….40-996
E-15 FUEL LEVEL GAUGE DOES NOT INDICATE CORRECT LEVEL …40-997
E-16 HYDRAULIC OIL TEMPERATURE GAUGE DOES NOT INDICATE CORRECT TEMPERATURE..
…40-1000
E-17 OPERATION MODE DOES NOT CHANGE…40-1001
E-18 OPERATING CUSTOMIZE SWITCH DOES NOT DISPLAY CUSTOMIZE SCREEN….40-1002
E-19 MODIFYING SETTING ON CUSTOMIZE SCREEN DOES NOT CHANGE SETTING OF MA-
CHINE ….40-1003
E-20 SERVICE METER IS NOT DISPLAYED, WHILE STARTING SWITCH IS IN OFF POSITION…
…40-1004
E-21 SERVICE MODE CANNOT BE SELECTED …..40-1005
E-22 WORK EQUIPMENT DOES NOT OPERATE …40-1006
E-23 FOOT HEATER DOES NOT OPERATE …..40-1008
E-24 HORN DOES NOT SOUND…40-1014
E-25 HORN DOES NOT STOP SOUNDING….40-1016
E-26 BACKUP ALARM DOES NOT SOUND …40-1017
E-27 BACKUP ALARM DOES NOT STOP SOUNDING…..40-1018
E-28 HEADLAMP DOES NOT LIGHT UP …..40-1019
E-29 REAR LAMP DOES NOT LIGHT UP ….40-1023
E-30 ALL WIPERS DO NOT OPERATE…..40-1026
E-31 FRONT WIPER DOES NOT OPERATE …..40-1028
E-32 REAR WIPER DOES NOT OPERATE…..40-1030
E-33 LEFT DOOR WIPER DOES NOT OPERATE …40-1032
E-34 RIGHT DOOR WIPER DOES NOT OPERATE ….40-1036
E-35 FRONT WASHER DOES NOT OPERATE…..40-1040
E-36 REAR WASHER DOES NOT OPERATE ….40-1042
E-37 LEFT DOOR WASHER DOES NOT OPERATE…40-1044
E-38 RIGHT DOOR WASHER DOES NOT OPERATE …40-1046
E-39 KOMTRAX SYSTEM DOES NOT OPERATE NORMALLY ….40-1048
E-40 CONTROL BOX SHUTS DOWN AFTER DISPLAYING THE MESSAGES [GPS receiver not con-
nected !] AND [Slope sensor not connected !] ….40-1049
E-41 CONTROL BOX DISPLAYS THE MESSAGES [GPS receiver not connected !] AND [Slope sensor
not connected !] …..40-1053
E-42 CONTROL BOX DISPLAYS THE MESSAGE [Waiting for radio link…] ….40-1058
E-43 CONTROL BOX DISPLAYS THE MESSAGE [IMU sensor not connected]….40-1059
E-44 CONTROL BOX DISPLAYS THE MESSAGE [Waiting for satellites…]…..40-1060
E-45 CONTROL BOX DISPLAYS THE MESSAGE [Komatsu controller not connected!] …40-1061
E-46 CONTROL BOX DISPLAYS THE MESSAGE [Cylinder Stroke Reading Abnormal]…40-1063
E-47 CONTROL BOX DISPLAYS THE MESSAGE [Komatsu CAN Comms Abnormal] …..40-1064
E-48 CONTROL BOX DISPLAYS THE MESSAGE [Komatsu Machine Trouble] ….40-1065
E-49 CONTROL BOX DISPLAYS THE MESSAGE [Waiting to initialize….] …40-1066
E-50 CONTROL BOX DISPLAYS THE MESSAGE [System Initializing]…..40-1067
E-51 CONTROL BOX DISPLAYS THE MESSAGE [Initializing….]…..40-1068
E-52 CONTROL BOX DISPLAYS THE MESSAGE [Configuring GPS]….40-1069
E-53 CONTROL BOX DISPLAYS THE MESSAGE [No GPS Localization…]….40-1070
E-54 CONTROL BOX DISPLAYS THE MESSAGE [Low precisions…]….40-1071
E-55 CONTROL BOX DISPLAYS THE MESSAGE [Heading Initializing] …40-1072
E-56 CONTROL BOX DISPLAYS [Out of design area…]….40-1073
E-57 CONTROL BOX CAN NOT BE TURNED ON …40-1074
E-58 CONTROL BOX DOES NOT DISPLAY INTELLIGENT MACHINE CONTROL SCREEN …40-1075
E-59 CONTROL BOX DOES NOT DISPLAY BULLDOZER IMAGE …..40-1076
E-60 CONTROL BOX DOES NOT DISPLAY DESIGN SURFACE ….40-1077
E-61 CONTROL BOX TOUCH PANEL DOES NOT RESPOND…..40-1078
E-62 CONTROL BOX TOUCH PANEL IS INACCURATE…40-1079
E-63 CYLINDER STROKE RESET INDICATION DOES NOT GO OUT…..40-1080
E-64 AUTO IS NOT DISPLAYED WHEN AUTO/MANUAL SWITCH IS PRESSED (AUTO INDICATION
GOES OUT) ….40-1081
E-65 BLADE AUTOMATIC LOWER CONTROL DOES NOT START WHILE AUTO IS DISPLAYED…..
…40-1083
E-66 BLADE AUTOMATIC RAISE CONTROL DOES NOT START WHILE AUTO IS DISPLAYED ….
…40-1084
E-67 BLADE AUTOMATIC CONTROL FUNCTION IS NOT ACTIVATED WHILE AUTO IS DISPLAYED
(BLADE AUTOMATIC CONTROL STOPS)…40-1085
E-68 WHEN CHECKING AND ADJUSTING THE BLADE ELEVATION, THE VALUE IS DIFFERENT
FROM ACTUAL MACHINE …..40-1086
E-69 FINISHED SURFACE IS INACCURATE (THE AVERAGE HEIGHT OF FINISHED SURFACE IS
LOWER THAN DESIGNED SURFACE OR BLADE DOES NOT TOUCH THE SURFACE) …..40-1087
E-70 FINISHED SURFACE IS INACCURATE (THE FINISHED SURFACE IS NOT SMOOTH) ..40-1088
E-71 FINISHED SURFACE IS INACCURATE (WHEN FINISHING SLOPE HORIZONTALLY, STEPS
ARE MADE IN EACH DIRECTION)…..40-1089
E-72 MACHINE CAN NOT ESCAPE FROM SHOES SLIP WHILE BLADE AUTOMATIC CONTROL IS
ACTIVATED (SHOES FREQUENTLY SLIPS)…..40-1091
E-73 MACHINE SPEED DOES NOT INCREASE WHILE BLADE AUTOMATIC CONTROL IS ACTI-
VATED….40-1092
E-74 BLADE TILT ANGLE DOES NOT COINCIDE WITH DESIGN SURFACE…40-1093
E-75 BLADE TILTS BACK WHILE BLADE AUTOMATIC CONTROL IS ACTIVATED…40-1095
E-76 WHEN PRESSING CUT/FILL LEVEL SWITCH (RAISE), THE DESIGN SURFACE DOES NOT
RISE….40-1097
E-77 WHEN PRESSING CUT/FILL LEVEL SWITCH (LOWER), THE DESIGN SURFACE DOES NOT
LOWER …..40-1100
E-78 WHEN STARTING SWITCH IS TURNED TO ON POSITION, REVERSE LEVELING MODE
SWITCH LED DOES NOT LIGHT UP OR DOES NOT GO OUT …40-1103
E-79 WHEN REVERSE LEVELING MODE SWITCH IS PRESSED, BUZZER DOES NOT SOUND
(DOES NOT SWITCH TO REVERSE LEVELING MODE)….40-1105
TROUBLESHOOTING FOR HYDRAULIC AND MECHANICAL SYSTEMS (H MODE) …40-1108
INFORMATION MENTIONED IN TROUBLESHOOTING TABLE (H MODE)….40-1108
FAILURE MODE AND CAUSE TABLE….40-1109
H-1 NEITHER R.H. NOR L.H. OF TRACKS CAN TRAVEL FORWARD OR REVERSE (NONE OF THE
TRAVEL SYSTEMS OPERATE) …. 40-1115
H-2 EITHER R.H. OR L.H. OF TRACK CANNOT TRAVEL BOTH FORWARD AND REVERSE (ONE
OF R.H. OR L.H. TRAVEL SYSTEMS CANNOT OPERATE) ….. 40-1117
H-3 EITHER R.H. OR L.H. OF TRACK CANNOT TRAVEL ONE OF FORWARD OR REVERSE (ONLY
ONE OF THE TRAVEL SYSTEMS CANNOT OPERATE IN ONE DIRECTION) …. 40-1119
H-4 TRAVEL SPEED OR POWER IS LOW…40-1121
H-5 SPEED RANGE DOES NOT CHANGE …..40-1123
H-6 SHOCK IS LARGE WHEN MACHINE MOVES OFF OR STOPS …..40-1124
H-7 MACHINE DEVIATES LARGELY …..40-1125
H-8 MACHINE DRIFT ON A SLOPE IS LARGE…..40-1128
H-9 ENGINE SPEED DROPS LARGELY OR ENGINE STOPS …..40-1130
H-10 UNUSUAL NOISE IS HEARD FROM AROUND HST PUMP OR MOTOR ….40-1132
H-11 HST OIL TEMPERATURE (HYDRAULIC OIL TEMPERATURE) RISES TOO HIGH ….40-1134
H-12 ALL WORK EQUIPMENT DO NOT OPERATE …40-1136
H-13 ALL WORK EQUIPMENTS SPEED OR POWER IS LOW ….40-1138
H-14 BLADE LIFT SPEED OR POWER IS LOW …40-1139
H-15 BLADE TILT SPEED OR POWER IS LOW …40-1141
H-16 BLADE ANGLE SPEED OR POWER IS LOW…..40-1142
H-17 TIME LAG OF BLADE LIFT IS LARGE …40-1143
H-18 HYDRAULIC DRIFT OF LIFTED BLADE IS LARGE ….40-1144
H-19 HYDRAULIC DRIFT OF TILTED BLADE IS LARGE…..40-1145
H-20 UNUSUAL NOISE IS HEARD FROM AROUND WORK EQUIPMENT AND COOLING FAN
PUMP OR CONTROL VALVE ….40-1146
H-21 FAN SPEED IS ABNORMAL (TOO HIGH OR LOW, OR STATIONARY) ….40-1147
H-22 UNUSUAL NOISE IS HEARD FROM AROUND FAN …40-1149
TROUBLESHOOTING OF ENGINE (S-MODE) …40-1150
INFORMATION MENTIONED IN TROUBLESHOOTING TABLE (S MODE)….40-1150
S-1 ENGINE DOES NOT CRANK WHEN STARTING SWITCH IS TURNED TO START POSITION….
…40-1151
S-2 ENGINE CRANKS BUT NO EXHAUST GAS COMES OUT ….40-1152
S-3 FUEL IS BEING INJECTED BUT ENGINE DOES NOT START (MISFIRING: ENGINE CRANKS
BUT DOES NOT START) …..40-1153
S-4 ENGINE STARTABILITY IS POOR…40-1155
S-5 ENGINE DOES NOT PICK UP SMOOTHLY …40-1157
S-6 ENGINE STOPS DURING OPERATION …40-1159
S-7 ENGINE RUNS ROUGH OR IS UNSTABLE …40-1161
S-8 ENGINE LACKS POWER…..40-1162
S-9 EXHAUST SMOKE IS BLACK….40-1164
S-10 ENGINE OIL CONSUMPTION IS EXCESSIVE …40-1166
S-11 OIL BECOMES CONTAMINATED QUICKLY ….40-1167
S-12 FUEL CONSUMPTION IS EXCESSIVE …..40-1168
S-13 OIL IS IN COOLANT (OR COOLANT SPURTS BACK OR COOLANT LEVEL GOES DOWN) ….
…40-1169
S-14 OIL PRESSURE DROPS …40-1170
S-15 FUEL MIXES INTO ENGINE OIL….40-1172
S-16 WATER MIXES INTO ENGINE OIL (MILKY) ….40-1173
S-17 COOLANT TEMPERATURE RISES TOO HIGH (OVERHEATING) …40-1174
S-18 UNUSUAL NOISE IS HEARD…40-1175
S-19 VIBRATION IS EXCESSIVE …..40-1176
S-20 AIR CANNOT BE BLED FROM FUEL CIRCUIT…..40-1177
S-21 ACTIVE REGENERATION IS EXECUTED FREQUENTLY …40-1178
S-22 ACTIVE REGENERATION TAKES TIME….40-1179
S-23 WHITE SMOKE IS EXHAUSTED DURING ACTIVE REGENERATION…40-1180
S-24 AdBlue/DEF CONSUMPTION IS EXCESSIVE ….40-1181
S-25 THERE IS UNUSUAL SMELL (IRRITATING ODOR) ….40-1183
S-26 FOREIGN MATERIALS ENTER AdBlue/DEF (AdBlue/DEF INCREASES)….40-1184
50 DISASSEMBLY AND ASSEMBLY…. 50-1
CONTENTS ….. 50-2
ABBREVIATION LIST ….. 50-7
RELATED INFORMATION ON DISASSEMBLY AND ASSEMBLY ….. 50-13
HOW TO READ THIS MANUAL….. 50-13
COATING MATERIALS LIST…. 50-15
SPECIAL TOOLS LIST … 50-20
SKETCHES OF SPECIAL TOOLS…. 50-42
ENGINE AND COOLING SYSTEM…. 50-55
REMOVE AND INSTALL SUPPLY PUMP ASSEMBLY … 50-55
REMOVE AND INSTALL INJECTOR ASSEMBLY …. 50-75
REMOVE AND INSTALL CYLINDER HEAD ASSEMBLY ….50-100
REMOVE AND INSTALL EGR VALVE ASSEMBLY…..50-143
REMOVE AND INSTALL EGR COOLER ASSEMBLY….50-150
REMOVE AND INSTALL STARTING MOTOR ASSEMBLY ….50-158
REMOVE AND INSTALL AIR CONDITIONER COMPRESSOR BELT …50-163
REMOVE AND INSTALL ALTERNATOR BELT …..50-172
REMOVE AND INSTALL AUTOMATIC TENSIONER…..50-177
REMOVE AND INSTALL RADIATOR ASSEMBLY …50-180
REMOVE AND INSTALL HYDRAULIC OIL COOLER ASSEMBLY …..50-197
REMOVE AND INSTALL AFTERCOOLER ASSEMBLY….50-208
REMOVE AND INSTALL COOLING FAN DRIVE ASSEMBLY …50-222
REMOVE AND INSTALL COOLING FAN MOTOR ASSEMBLY ….50-231
REMOVE AND INSTALL ENGINE, HST PUMP ASSEMBLY …..50-237
REMOVE AND INSTALL ENGINE FRONT OIL SEAL …50-260
REMOVE AND INSTALL ENGINE REAR OIL SEAL…50-265
REMOVE AND INSTALL ENGINE HOOD ASSEMBLY …..50-269
REMOVE AND INSTALL KDOC ASSEMBLY…..50-276
REMOVE AND INSTALL KDOC AND SCR ASSEMBLY …50-289
REMOVE AND INSTALL BELLOWS PIPE ASSEMBLY ….50-305
REMOVE AND INSTALL FUEL TANK ASSEMBLY …..50-313
REMOVE AND INSTALL AdBlue/DEF TANK ASSEMBLY …50-328
REMOVE AND INSTALL AdBlue/DEF TANK SENSOR FLANGE ASSEMBLY…50-348
REMOVE AND INSTALL AdBlue/DEF TANK SENSOR ….50-354
REMOVE AND INSTALL AdBlue/DEF TANK STRAINER ….50-358
REMOVE AND INSTALL SCR ASSEMBLY…..50-360
REMOVE AND INSTALL KCCV ASSEMBLY …..50-366
REMOVE AND INSTALL AdBlue/DEF MIXING TUBE …50-370
REMOVE AND INSTALL AdBlue/DEF INJECTOR…50-378
REMOVE AND INSTALL AdBlue/DEF PUMP ….50-388
REMOVE AND INSTALL AdBlue/DEF HOSE ….50-396
REMOVE AND INSTALL AIR CLEANER ASSEMBLY….50-438
REMOVE AND INSTALL AIR CONDITIONER COMPRESSOR ASSEMBLY …..50-443
REMOVE AND INSTALL AIR CONDITIONER CONDENSER ASSEMBLY …..50-452
POWER TRAIN…50-460
DISASSEMBLE AND ASSEMBLE FINAL DRIVE ASSEMBLY…50-460
UNDERCARRIAGE AND FRAME…..50-474
REMOVE AND INSTALL TRACK FRAME ASSEMBLY…..50-474
REMOVE AND INSTALL IDLER ASSEMBLY…..50-484
DISASSEMBLE AND ASSEMBLE IDLER ASSEMBLY …..50-489
REMOVE AND INSTALL RECOIL SPRING ASSEMBLY …..50-496
DISASSEMBLE AND ASSEMBLE RECOIL SPRING ASSEMBLY…50-497
REMOVE AND INSTALL TRACK ROLLER ASSEMBLY …50-503
DISASSEMBLE AND ASSEMBLE TRACK ROLLER ASSEMBLY …50-508
REMOVE AND INSTALL CARRIER ROLLER ASSEMBLY …..50-513
DISASSEMBLE AND ASSEMBLE CARRIER ROLLER ASSEMBLY …..50-516
REMOVE AND INSTALL PIVOT SHAFT ASSEMBLY ….50-520
SEPARATE AND CONNECT TRACK ASSEMBLY…50-523
SEPARATE AND CONNECT PLUS TYPE TRACK ASSEMBLY …50-528
DISASSEMBLE AND ASSEMBLE TRACK ASSEMBLY GENERALLY…50-529
DISASSEMBLE AND ASSEMBLE PLUS TYPE TRACK ASSEMBLY GENERALLY …50-547
DISASSEMBLE AND ASSEMBLE ONE LINK OF TRACK SHOE ASSEMBLY ON THE FIELD ….50-558
DISASSEMBLE AND ASSEMBLE ONE LINK OF PLUS TYPE TRACK SHOE ASSEMBLY ON THE
FIELD ….50-567
REMOVE AND INSTALL EQUALIZER BAR ASSEMBLY…..50-574
REMOVE AND INSTALL EQUALIZER BAR SIDE BUSHINGS …..50-579
REMOVE AND INSTALL SEGMENT TEETH…..50-581
HYDRAULIC SYSTEM….50-585
REMOVE AND INSTALL HYDRAULIC TANK ASSEMBLY…50-585
REMOVE AND INSTALL CONTROL VALVE ASSEMBLY ….50-601
WORK EQUIPMENT….50-609
REMOVE AND INSTALL BLADE ASSEMBLY …50-609
REMOVE AND INSTALL STROKE SENSING BLADE LIFT CYLINDER ASSEMBLY ….50-617
DISASSEMBLE AND ASSEMBLE STROKE SENSING BLADE LIFT CYLINDER ASSEMBLY ….50-621
REMOVE AND INSTALL STROKE SENSING BLADE TILT CYLINDER ASSEMBLY ….50-634
DISASSEMBLE AND ASSEMBLE STROKE SENSING BLADE TILT CYLINDER ASSEMBLY…..50-642
REMOVE AND INSTALL STROKE SENSING BLADE ANGLE CYLINDER ASSEMBLY …..50-651
DISASSEMBLE AND ASSEMBLE STROKE SENSING BLADE ANGLE CYLINDER ASSEMBLY50-657
REMOVE AND INSTALL U-FRAME ASSEMBLY …..50-667
CAB AND ITS ATTACHMENTS …..50-674
REMOVE AND INSTALL OPERATOR’S CAB ASSEMBLY …..50-674
REMOVE AND INSTALL OPERATOR’S CAB GLASS (ADHERED GLASS) …50-690
REMOVE AND INSTALL AIR CONDITIONER UNIT ASSEMBLY ….50-698
REMOVE AND INSTALL RECEIVER DRIER…..50-711
REMOVE AND INSTALL OPERATOR’S SEAT …..50-715
REMOVE AND INSTALL SEAT BELT ….50-717
REMOVE AND INSTALL FOOT HEATER ASSEMBLY …..50-719
DISASSEMBLE AND ASSEMBLE FOOT HEATER ASSEMBLY…50-724
ELECTRICAL SYSTEM …..50-726
REMOVE AND INSTALL ENGINE CONTROLLER ASSEMBLY …50-726
REMOVE AND INSTALL HST CONTROLLER ASSEMBLY ….50-733
REMOVE AND INSTALL MACHINE MONITOR ASSEMBLY …..50-735
REMOVE AND INSTALL MASS AIR FLOW AND TEMPERATURE SENSOR …50-738
REMOVE AND INSTALL KCCV CRANKCASE PRESSURE SENSOR…..50-742
REMOVE AND INSTALL ICT SENSOR CONTROLLER ASSEMBLY ….50-746
REMOVE AND INSTALL CONTROL BOX …50-748
REMOVE AND INSTALL GNSS RECEIVER…50-750
REMOVE AND INSTALL GNSS ANTENNA ….50-752
REMOVE AND INSTALL IMU SENSOR …50-758
60 MAINTENANCE STANDARD….. 60-1
CONTENTS ….. 60-2
ABBREVIATION LIST ….. 60-3
ENGINE AND COOLING SYSTEM… 60-9
MAINTENANCE STANDARD OF ENGINE MOUNT … 60-9
MAINTENANCE STANDARD OF DAMPER….. 60-10
MAINTENANCE STANDARD OF COOLING SYSTEM ….60-11
MAINTENANCE STANDARD OF COOLING FAN MOTOR… 60-13
MAINTENANCE STANDARD OF HYDRAULIC OIL COOLER BYPASS AND HST CHARGE SAFETY
VALVE …. 60-15
POWER TRAIN…. 60-16
MAINTENANCE STANDARD OF HST PUMP….. 60-16
MAINTENANCE STANDARD OF HST CHARGE PUMP…. 60-20
MAINTENANCE STANDARD OF HST MOTOR….. 60-22
MAINTENANCE STANDARD OF FINAL DRIVE …. 60-24
MAINTENANCE STANDARD OF SPROCKET FOR PLUS TYPE TRACK SHOE….. 60-26
MAINTENANCE STANDARD OF SPROCKET TOOTH PROFILE FULL-SCALE DRAWING FOR PLUS
TYPE TRACK SHOE… 60-27
UNDERCARRIAGE AND FRAME… 60-28
MAINTENANCE STANDARD OF SUSPENSION… 60-28
MAINTENANCE STANDARD OF TRACK FRAME AND IDLER CUSHION… 60-31
MAINTENANCE STANDARD OF IDLER … 60-34
MAINTENANCE STANDARD OF TRACK ROLLER FOR PLUS TYPE TRACK SHOES (SINGLE
FLANGE TYPE) …. 60-36
MAINTENANCE STANDARD OF TRACK ROLLER FOR PLUS TYPE TRACK SHOES (DOUBLE
FLANGE TYPE) …. 60-37
MAINTENANCE STANDARD OF CARRIER ROLLER FOR PLUS TYPE TRACK SHOE ….. 60-39
MAINTENANCE STANDARD OF PLUS TYPE TRACK SHOE…. 60-40
MAINTENANCE STANDARD OF SINGLE SHOE ….. 60-42
HYDRAULIC SYSTEM….. 60-43
MAINTENANCE STANDARD OF HYDRAULIC TANK …. 60-43
MAINTENANCE STANDARD OF WORK EQUIPMENT AND COOLING FAN PUMP ….. 60-44
MAINTENANCE STANDARD OF CONTROL VALVE… 60-47
MAINTENANCE STANDARD OF RIPPER PPC VALVE….. 60-53
MAINTENANCE STANDARD OF 5-PORT VALVE OF EPC AND SOLENOID …. 60-55
MAINTENANCE STANDARD OF QUICK DROP VALVE…. 60-57
WORK EQUIPMENT….. 60-59
MAINTENANCE STANDARD OF FRONT WORK EQUIPMENT…. 60-59
MAINTENANCE STANDARD OF CUTTING EDGE AND END BIT … 60-62
MAINTENANCE STANDARD OF STROKE SENSING BLADE LIFT CYLINDER … 60-63
MAINTENANCE STANDARD OF STROKE SENSING BLADE TILT CYLINDER … 60-64
MAINTENANCE STANDARD OF STROKE SENSING BLADE ANGLE CYLINDER …. 60-65
MAINTENANCE STANDARD OF STROKE AND RESET SENSOR FOR BLADE LIFT CYLINDER …..
… 60-66
MAINTENANCE STANDARD OF STROKE SENSOR FOR BLADE TILT CYLINDER….. 60-67
MAINTENANCE STANDARD OF STROKE SENSOR FOR BLADE ANGLE CYLINDER… 60-68
MAINTENANCE STANDARD OF FIXED MULTI-SHANK RIPPER…. 60-69
MAINTENANCE STANDARD OF RIPPER LIFT CYLINDER…. 60-71
CAB AND ITS ATTACHMENTS … 60-72
MAINTENANCE STANDARD OF CAB MOUNT….. 60-72
ELECTRICAL SYSTEM … 60-74
MAINTENANCE STANDARD OF ELECTRIC STEERING CONTROL LEVER…. 60-74
80 APPENDIX… 80-1
CONTENTS ….. 80-2
ABBREVIATION LIST ….. 80-3
AIR CONDITIONER SYSTEM …. 80-9
PRECAUTIONS FOR REFRIGERANT ….. 80-9
AIR CONDITIONER COMPONENT ….. 80-10
SPECIFICATIONS OF AIR CONDITIONER ….. 80-13
CONFIGURATION AND FUNCTION OF REFRIGERATION CYCLE … 80-14
OUTLINE OF REFRIGERATION CYCLE … 80-15
COMPONENT PARTS OF AIR CONDITIONER SYSTEM ….. 80-17
AIR CONDITIONER UNIT….. 80-17
COMPONENT PARTS OF AIR CONDITIONER UNIT….. 80-19
COMPRESSOR ….. 80-22
CONDENSER ….. 80-23
RECEIVER DRIER…. 80-25
EXPLANATION OF PROCEDURE FOR TESTING AND TROUBLESHOOTING OF AIR CONDITIONER…
…. 80-27
CIRCUIT DIAGRAM OF AIR CONDITIONER … 80-30
AIR CONDITIONER SYSTEM DIAGRAM … 80-31
CONTROL FUNCTION OF AIR CONDITIONER….. 80-32
INSTALLATION LOCATIONS OF AIR CONDITIONER PARTS AND ARRANGEMENT OF CONNECTORS ..
…. 80-33
TEST RELAYS….. 80-37
METHOD FOR TESTING RELAYS … 80-37
AIR CONDITIONER TROUBLESHOOTING CHART 1 …. 80-39
AIR CONDITIONER TROUBLESHOOTING CHART 2 …. 80-40
INFORMATION DESCRIBED IN TROUBLESHOOTING TABLE….. 80-43
A-1 TROUBLESHOOTING FOR CONDENSER FAN…. 80-45
A-2 TROUBLESHOOTING FOR BLOWER MOTOR SYSTEM (NO AIR COMES OUT OR AIR FLOW IS
ABNORMAL) …. 80-48
A-3 TROUBLESHOOTING FOR TEMPERATURE CONTROL FUNCTION … 80-51
TROUBLESHOOTING USING GAUGE PRESSURE…. 80-55
CONNECTION OF SERVICE TOOL ….. 80-57
METHOD FOR CONNECTING SERVICE TOOL … 80-58
PRECAUTIONS FOR DISCONNECTING AND CONNECTING HOSES AND TUBES IN AIR CONDITION-
ER PIPINGS….. 80-59
HANDLE COMPRESSOR OIL ….. 80-61
90 CIRCUIT DIAGRAMS …. 90-1
CONTENTS ….. 90-2
ABBREVIATION LIST ….. 90-3
HYDRAULIC CIRCUIT DIAGRAM …. 90-9
SYMBOLS USED IN HYDRAULIC CIRCUIT DIAGRAM … 90-9
HYDRAULIC CIRCUIT DIAGRAM …. 90-13
ELECTRICAL CIRCUIT DIAGRAM …. 90-15
SYMBOLS USED IN ELECTRICAL CIRCUIT DIAGRAM… 90-15
ELECTRICAL CIRCUIT DIAGRAM (1/14)….. 90-19
ELECTRICAL CIRCUIT DIAGRAM (2/14)….. 90-21
ELECTRICAL CIRCUIT DIAGRAM (3/14)….. 90-23
ELECTRICAL CIRCUIT DIAGRAM (4/14)….. 90-25
ELECTRICAL CIRCUIT DIAGRAM (5/14)….. 90-27
ELECTRICAL CIRCUIT DIAGRAM (6/14)….. 90-29
ELECTRICAL CIRCUIT DIAGRAM (7/14)….. 90-31
ELECTRICAL CIRCUIT DIAGRAM (8/14)….. 90-33
ELECTRICAL CIRCUIT DIAGRAM (9/14)….. 90-35
ELECTRICAL CIRCUIT DIAGRAM (10/14)… 90-37
ELECTRICAL CIRCUIT DIAGRAM (11/14) … 90-39
ELECTRICAL CIRCUIT DIAGRAM (12/14)… 90-41
ELECTRICAL CIRCUIT DIAGRAM (13/14) … 90-43
ELECTRICAL CIRCUIT DIAGRAM (14/14) … 90-45
INDEX…1
CEAM018708 – Crawler Dozer D51EX-22, D51PX-22 Shop Manual (SN-B10001&up)…2
INTRODUCTION…6
FOREWORD…7
SAFETY INFORMATION…8
APPROVED AND NON-APPROVED USES…9
NON-APPROVED…9
PRODUCT IDENTIFICATION…10
PRODUCT IDENTIFICATION PLATE…10
ENGINE SERIAL NUMBER AND EMISSION LABEL…11
SERIAL NUMBERS AND DEALER INFORMATION…12
MODEL: D51EX/PX-22…12
CONTENTS…13
SAFETY…24
SAFETY AND WARNING DECALS…25
LOCATION OF THE SAFETY DECALS…26
GENERAL SAFETY RULES AND PRECAUTIONS…31
GENERAL SAFETY RULES…31
UNAUTHORIZED MODIFICATIONS…32
GENERAL SAFETY AT JOB SITE…32
WORKING ON LOOSE GROUND…32
SAFETY FEATURES…33
PERSONAL PROTECTIVE EQUIPMENT…33
FIRE AND EXPLOSION PREVENTION…34
FIRE CAUSED BY FUEL OR OIL…34
FIRE CAUSED BY ACCUMULATION OF FLAMMABLE MATERIAL…34
FIRE FROM ELECTRICAL SYSTEM…35
FIRE FROM HYDRAULIC LINE…35
WINDSHIELD WASHER FLUID…35
ACTION IF FIRE OCCURS…35
DUST HAZARDS…35
BLAST ZONE HAZARD…36
KEEP OPERATOR'S CAB CLEAN…36
UNAUTHORIZED MODIFICATIONS…36
LEAVING OPERATOR’S COMPARTMENT…37
PARKING BRAKE AND EQUIPMENT LOCKS…37
MOUNTING AND DISMOUNTING…38
CRUSH OR PINCH POINT DANGERS…38
FIRE EXTINGUISHER AND FIRST AID KIT…38
INSIDE OPERATOR’S COMPARTMENT…39
PRECAUTIONS WHEN USING ROPS…39
PRECAUTIONS BEFORE STARTING OPERATIONS…40
PRE-OPERATIONAL CHECKS…40
STARTING YOUR WORK OPERATIONS…40
WORK SITE HAZARDS…40
AVOIDING DANGEROUS SITUATIONS…41
HIGH VOLTAGE LINES…43
RULES FOR ROAD TRAVEL…44
PRECAUTIONS WHEN TRAVELING…44
USING BRAKES…44
RULES FOR TRAVELING IN REVERSE…45
TRAVELING ON ICY OR SNOW-COVERED SURFACES…45
WORKING ON LOOSE OR UNSTABLE GROUND…45
TRAVEL ON SLOPES…45
PARKING THE MACHINE…46
PRECAUTIONS DURING MAINTENANCE OPERATIONS…47
WARNING TAGS…47
EQUIPMENT STORAGE…47
WORKING UNDER THE MACHINE…48
USING DROP LAMPS…48
KEEPING THE MACHINE CLEAN…48
RUNNING THE MACHINE DURING MAINTENANCE…49
RULES FOR REFUELING THE MACHINE…49
COOLING SYSTEM PRECAUTIONS…49
WORK UNDER THE MACHINE…49
PRECAUTIONS WHEN USING HAMMER…50
REPAIR WELDING…50
ENGINE SYSTEM HIGH VOLTAGE…50
BATTERY PRECAUTIONS…51
STARTING THE MACHINE…52
HIGH PRESSURE HOSES…52
HANDLING HIGH-PRESSURE HOSES…52
PRECAUTION FOR HIGH FUEL PRESSURE…53
HIGH TEMPERATURE AREAS…53
ROTATING PARTS…53
DISPOSAL OF WASTE MATERIALS…53
USING HIGH-PRESSURE GREASE TO ADJUST TRACK TENSION…54
DO NOT DISASSEMBLE RECOIL SPRING…54
ACCUMULATOR…54
CRITICAL PARTS…55
TRANSPORTING THE MACHINE…56
LOADING AND SECURING THE MACHINE…56
TOWING THE MACHINE…57
OPERATION…60
GENERAL VIEWS…61
VIEW OF MACHINE…61
VIEW OF CONTROLS AND GAUGES…63
MACHINE MONITOR SYSTEM…65
MONITOR LAYOUT…65
BASIC OPERATION OF MONITOR PANEL…66
CHECK MONITOR SYSTEM…67
MONITOR CHECK ITEMS…68
EMERGENCY ALERTS…68
ENGINE OIL PRESSURE CAUTION LAMP…68
ENGINE COOLANT TEMPERATURE CAUTION LAMP…69
HYDRAULIC OIL TEMPERATURE CAUTION LAMP…69
HST CHARGE PRESSURE CAUTION LAMP…69
CHARGE FILTER CLOG CAUTION LAMP…69
WARNING ALERTS…70
BATTERY CHARGE CAUTION LAMP…70
AIR CLEANER CLOGGING CAUTION LAMP…71
WATER IN FUEL LAMP…71
MAINTENANCE CAUTION LAMP…71
CONSOLE CONTROL SWITCHES…72
SWITCH LAYOUT VIEW…72
LAMP SWITCH…72
BUZZER CANCEL SWITCH…73
INFORMATION SWITCH…73
HEATER SWITCH…73
IGNITION SWITCH…74
HORN SWITCH…75
WIPER SWITCH…75
CAB LAMP SWITCH…76
CIGARETTE LIGHTER…76
ACCESSORY SOCKET…76
METER DISPLAY…77
ENGINE COOLANT TEMPERATURE GAUGE…77
HYDRAULIC OIL TEMPERATURE GAUGE…78
DISPLAY PANEL (A)…78
FUEL LEVEL GAUGE…82
REVERSE TRAVEL SPEED SET SWITCH…82
SHIFT MODE SWITCH…82
ENGINE INTAKE AIR PRE-HEAT PILOT LAMP…82
DISPLAY PANEL (B)…83
FAN ROTATION SELECTOR SWITCH…84
WARNING LAMP VIEW…85
WARNING LAMP (1)…85
USING FAILURE CODE DISPLAY…86
USING MAINTENANCE MODE…87
METHOD OF SELECTING EACH MODE…88
USING OIL AND FILTER MAINTENANCE MODE…89
USING ADJUSTMENT MODE…90
CONTROL LEVERS AND PEDALS…93
LEVER LAYOUT VIEW…93
LOCK LEVERS…93
TRAVEL LEVER…94
BLADE CONTROL LEVER…95
BLADE ANGLE CONTROL…96
INTELLIGENT BLADE CONTROL…96
WORK EQUIPMENT LOCK LEVER…97
FUEL CONTROL DIAL…98
DECELERATOR PEDAL…99
BRAKE PEDAL…99
PARKING BRAKE LEVER…100
DOOR AND WINDOW SYSTEM…101
DOOR – OPEN LOCK…101
SASH GLASS INTERMEDIATE LOCK…101
SAFETY LOCKS AND SECURITY…102
DOOR LOCK…102
CAP, COVER WITH LOCK…102
METHOD OF OPENING OR CLOSING HYDRAULIC TANK CAP…103
Method of opening and closing FUEL cap with lock…104
TO LOCK THE CAP…104
LOCKABLE AREAS…105
SEAT POCKET…105
ADDITIONAL FEATURES AND ACCESSORIES…106
AIR CONDITIONER AND FEET HEATER…106
GENERAL DESCRIPTION OF CONTROL PANEL…106
MODE SELECTOR SWITCH…106
BLOWER SPEED SELECTOR SWITCH…107
TEMPERATURE CONTROL SWITCH…107
PRECAUTIONS WHEN USING AIR CONDITIONER…108
FEET HEATER…109
RADIO…110
EXPLANATION OF FEATURES…110
POWER SWITCH/VOLUME…111
AUTO-STORE/PRESET SCAN BUTTON…111
BASS CONTROL KNOB…111
TREBLE CONTROL KNOB…112
LOUDNESS BUTTON…112
TIME/RADIO DISPLAY SELECTOR BUTTON…112
TAPE EJECT BUTTON…113
CASSETTE DOOR…113
FAST FORWARD, REWIND BUTTONS…113
PRESET BUTTONS…113
METAL TAPE BUTTON…114
MANUAL TUNING BUTTONS…114
SEEK TUNING BUTTONS…114
BAND SELECTOR BUTTON…114
METHOD OF OPERATION…115
LISTENING TO RADIO…116
LISTENING TO A CASSETTE TAPE…116
REVERSING TAPE…117
PRECAUTION WHEN USING…117
ASHTRAY…118
LUNCH BOX HOLDER STRAP…118
CUP HOLDER…118
TOOL BOX…118
GREASE PUMP HOLDER…119
ELECTRICAL POWER ADAPTER…119
FUSES…120
FUSES…120
FUSE CAPACITIES AND CIRCUIT NAMES…120
PRECAUTIONS BEFORE STARTING WORK OPERATIONS…122
PRE-OPERATIONAL CHECKS…122
WALK-AROUND CHECKS…122
CHECKS BEFORE STARTING…123
ADJUSTMENTS BEFORE OPERATION…137
ADJUST ARMREST…138
FASTENING AND REMOVING SEAT BELT…138
ADJUSTING MIRROR…139
SYSTEM “ON” CHECKS…139
STARTING THE ENGINE…141
NORMAL OR COLD START PROCEDURES…141
COLD WEATHER STARTS…142
OPERATIONS AND CHECKS AFTER STARTING ENGINE…146
BREAKING IN THE MACHINE…146
WARMING UP ENGINE…146
STARTING IN COLD WEATHER…147
STOPPING THE ENGINE…149
MOVING, STEERING, STOPPING AND PARKING THE MACHINE…150
PREPARATIONS FOR MOVING THE MACHINE…150
MOVING MACHINE FORWARD OR REVERSE…151
CHANGING SPEED RANGES…153
STEERING THE MACHINE…155
NORMAL TURN…155
MAKING A LEFT OR RIGHT TURN…155
MAKING A PIVOT TURN…156
TURNING WHILE DESCENDING A SLOPE…156
COUNTER-ROTATION TURN…156
STOPPING THE MACHINE…157
PARKING MACHINE…159
CHECK AFTER FINISHING WORK…160
CHECK AFTER SHUTTING OFF ENGINE…160
STARTING YOUR WORK OPERATIONS…161
AVOIDING DANGEROUS SITUATIONS…161
HIGH VOLTAGE LINES…163
OPERATING THE MACHINE…164
PAY ATTENTION TO GAUGES…164
PERMISSIBLE WATER DEPTH…164
METHOD OF USING BRAKES…164
WHEN TRAVELING UP OR DOWN HILLS…164
PRECAUTIONS ON SLOPES…165
1. BE AWARE OF FUEL LEVEL…165
2. PRECAUTIONS WHEN ENGINE STOPS ON A SLOPES…165
ALWAYS KEEP THE DOORS CLOSED DURING OPERATIONS…165
DO NOT MODIFY THE CAB GLASS IN ANY WAY…165
PRECAUTIONS FOR BLIND SPOTS CAUSED BY CAB STAYS…165
CUTTING A GRADE…166
DOZING…166
BACK GRADING A SURFACE…166
CUTTING HARD OR FROZEN GROUND OR DITCHING…167
FELLING TREES, REMOVING STUMPS…167
SIDE-CUTTING OPERATIONS…167
UNDERCARRIAGE CARE…168
OPERATION METHOD…168
INSPECTION AND ADJUSTMENT…168
INSPECTION AND REPAIR…169
MEASURING LINK PITCH…169
MEASURING HEIGHT OF GROUSER…169
MEASURING OUTSIDE DIAMETER OF TRACK ROLLER…170
TRANSPORTING THE MACHINE…171
LOADING OR UNLOADING A TRAILER…171
PRE-TRANSPORTATION PROCEDURES…172
SECURING MACHINE…173
UNLOADING THE MACHINE…176
LIFTING THE MACHINE…177
FOR BASE MACHINE…177
FOR MACHINE EQUIPPED WITH RIPPER…178
COLD WEATHER OPERATION…179
FUEL AND LUBRICANTS…179
COOLING SYSTEM COOLANT…179
BATTERY…180
PRECAUTIONS ON PARTICULAR JOBSITES…181
DISCHARGED BATTERY…181
REMOVE AND INSTALL BATTERY…182
BATTERY CHARGES…182
STARTING ENGINE WITH BOOSTER CABLES…183
GENERAL TROUBLESHOOTING…185
AFTER RUNNING OUT OF FUEL…185
TOWING THE MACHINE…185
WHEN IT IS POSSIBLE TO START ENGINE…186
WHEN ENGINE DOES NOT START…186
RELEASING THE BRAKES…186
CONNECTING PUMP TO MACHINE…187
AFTER TOWING MACHINE…189
ELECTRICAL SYSTEM PROBLEMS…191
MONITOR PANEL…192
CHASSIS PROBLEMS…193
ENGINE PROBLEMS…194
LONG TERM STORAGE…195
BEFORE STORAGE…195
DURING STORAGE…195
AFTER STORAGE…195
MACHINES EQUIPPED WITH KOMTRAX SYSTEMS…196
BASIC PRECAUTIONS…196
MAINTENANCE…198
MAINTENANCE INFORMATION…199
SERVICE METER READING…199
KOMATSU GENUINE REPLACEMENT PARTS…199
KOMATSU GENUINE LUBRICANTS…199
WINDSHIELD WASHER FLUID…199
FRESH AND CLEAN LUBRICANTS…199
CHECK DRAINED OIL AND USED FILTER…199
FUEL STRAINER…199
WELDING INSTRUCTIONS…199
DO NOT DROP THINGS INSIDE MACHINE…200
DUSTY JOBSITE…200
AVOID MIXING LUBRICANTS…200
HYDRAULIC SYSTEM – AIR BLEEDING…200
HYDRAULIC HOSE INSTALLATION…200
CHECKS AFTER INSPECTION AND MAINTENANCE WORKS…200
LOCKING THE INSPECTION COVER…201
OPENING OR CLOSING RADIATOR GRILL…201
LUBRICANTS, COOLANT AND FILTERS…203
OUTLINE OF SERVICE…203
HANDLING OIL, FUEL, COOLANT, AND PERFORMING OIL CLINIC…203
OIL…203
FUEL…203
COOLING SYSTEM COOLANT…204
GREASE…204
CARRYING OUT KOWA (KOMATSU OIL WEAR ANALYSIS)…204
OIL AND FUEL STORAGE…205
FILTERS…205
ELECTRIC SYSTEM MAINTENANCE…206
HANDLING HYDRAULIC SYSTEM…206
WEAR PARTS LIST…207
RECOMMENDED FUEL, COOLANT, AND LUBRICANT…208
RECOMMENDED PRODUCTS OTHER THAN KOMATSU GENUINE OILS…210
LUBRICANT AND COOLANT SUPPLIER RECOMMENDATIONS…211
TIGHTENING TORQUE SPECIFICATIONS…213
PERIODIC REPLACEMENT OF SAFETY CRITICAL PARTS…214
SAFETY RELATED CRITICAL PARTS…214
MAINTENANCE SCHEDULE…215
MAINTENANCE SCHEDULE CHART…215
WHEN REQUIRED…217
CLEANING THE MACHINE…217
CLEAN TIPS…217
CLEANING THROUGH ACCESS AREAS…217
CHECK ELECTRICAL INTAKE AIR HEATER…220
CHECK, CLEAN AND REPLACE AIR CLEANER ELEMENT…220
CLEANING OR REPLACING OUTER ELEMENT…220
REPLACING INNER ELEMENT…222
CLEAN COOLING SYSTEM…224
FLUSHING THE COOLING SYSTEM…225
TRACK SYSTEM MAINTENANCE…228
CHECK AND TIGHTEN TRACK SHOE BOLTS…228
CHECKING AND ADJUSTING TRACK TENSION…228
IDLER GUIDE CLEARANCE…230
REVERSING OR REPLACING END BITS AND CUTTING EDGES…232
CHECKING IDLER OIL LEVEL…232
ADJUST PLAY IN CENTER BALL…233
MECHANICAL PITCH ROD (ADJUSTABLE)…234
ADJUSTMENT…234
SPECIFICATIONS…234
ADJUSTMENT OF PITCH ANGLE…234
DOOR HINGES…235
CHECKING WINDOW WASHER FLUID LEVEL…236
MIXTURE RATIO OF PURE WASHER FLUID AND WATER…236
CHECKING AIR CONDITIONER…237
CHECK LEVEL OF REFRIGERANT…237
OPERATING AIR CONDITIONER OFF-SEASON…237
REPLACE WIPER BLADE…238
REPLACEMENT…238
RELEASING INTERNAL PRESSURE ON HYDRAULIC SYSTEM…239
BLEEDING AIR FROM HYDRAULIC SYSTEM…240
BLEEDING AIR FROM PUMP…240
BLEEDING AIR FROM CYLINDERS…240
CLEAN, CHECK RADIATOR FINS…241
CLEANING BY ROTATING COOLING FAN IN REVERSE DIRECTION…241
CLEANING WITH COMPRESSED AIR…243
INITIAL 250 HOURS SERVICE (ONLY AFTER THE FIRST 250 HOURS)…245
REPLACE FUEL PRE-FILTER CARTRIDGE…245
INITIAL 500 HOURS SERVICE (ONLY AFTER THE FIRST 500 HOURS)…247
REPLACE MAIN FUEL FILTER CARTRIDGE…247
EVERY 50 HOURS MAINTENANCE…249
LUBRICATE…249
DRAINING SEDIMENT FROM FUEL TANK…251
EVERY 250 HOURS MAINTENANCE…252
CHECK OIL LEVEL IN FINAL DRIVE CASE…252
CHECKING FINAL DRIVE OIL LEVEL…252
LUBRICATING…252
CHECK LEVEL OF BATTERY ELECTROLYTE…254
CHECK BRAKE PERFORMANCE…255
AIR CONDITIONER AIR FILTER (FRESH/RECIRC FILTER)…257
EVERY 500 HOURS MAINTENANCE…258
REPLACE FUEL PRE-FILTER CARTRIDGE…258
CHANGE OIL IN ENGINE OIL PAN, REPLACE ENGINE OIL FILTER CARTRIDGE…261
EVERY 1000 HOURS MAINTENANCE…263
CHANGE OIL IN FINAL DRIVE CASE…263
CHECK ALTERNATOR BELT TENSION…263
CHECK ALL TIGHTENING POINTS OF ENGINE INTAKE & EXHAUST PIPE CLAMPS…263
CHECK FOR LOOSE ROPS MOUNT BOLTS…264
REPLACE PRE AND MAIN FUEL FILTER CARTRIDGES…265
EVERY 2000 HOURS MAINTENANCE…271
CHANGE OIL IN HYDRAULIC TANK, REPLACE OIL FILTER CARTRIDGE…271
CHECK ALTERNATOR, STARTING MOTOR…274
CHECK ENGINE VALVE CLEARANCE, ADJUST…274
REPLACE HYDRAULIC TANK BREATHER ELEMENT…274
CHECK CHARGE PRESSURE ACCUMULATOR (CONTROL CIRCUIT)…275
FUNCTION OF ACCUMULATOR…275
CHECKING FUNCTION OF ACCUMULATOR…275
RELEASING PRESSURE IN HYDRAULIC CIRCUIT…276
CHECKING PIVOT SHAFT OIL LEVEL…276
EVERY 4000 HOURS MAINTENANCE…277
CHECK WATER PUMP…277
CHECK VIBRATION DAMPER…277
REPLACE ACCUMULATOR (FOR CONTROL CIRCUIT)…277
CHECK FOR LOOSENESS OF HIGH-PRESSURE CLAMP, HARDENING OF RUBBER…278
CHECK FOR MISSING FUEL SPRAY CAP, HARDENING OF RUBBER…279
SPECIFICATIONS…282
SPECIFICATIONS…283
OPERATING WEIGHT…283
MACHINE DIMENSIONS AND WEIGHTS…284
MACHINE SYSTEMS SPECIFICATIONS…285
ENGINE…285
TRANSMISSION…286
STEERING SYSTEM…286
SERVICE REFILL CAPACITIES…286
UNDERCARRIAGE…286
OPTIONAL ATTACHMENTS…288
AUTHORIZED OPTIONAL EQUIPMENT…289
BASIC PRECAUTIONS…289
AIR SUSPENSION SEAT…290
FORESTRY KIT…292
CABIN POLYCARBONATE PANEL FRONT…293
EQUIPPING FIRE EXTINGUISHER AND FIRST-AID KIT…294
HANDLING HYDRAULIC RIPPER…295
GENERAL VIEW…295
EXPLANATION OF COMPONENTS…296
RIPPER CONTROL LEVER…296
MAINTENANCE…300
EVERY 250 HOURS SERVICE…300
OPERATION…297
CHECK BEFORE STARTING ENGINE, ADJUST…297
PRECAUTIONS WHEN OPERATING…297
ADJUSTING POSTURE OF WORK EQUIPMENT…297
REPLACEMENT OF POINT…298
TROUBLESHOOTING…299
OTHER TROUBLE…299
CEBM019104 – Crawler Tractor GALEO D51EX-22, D51PX-22 Shop Manual (SN-B10001&up)…302
COVER…302
00 INDEX AND FOREWORD…303
CONTENTS…303
SAFETY…314
SAFETY NOTICE…314
IMPORTANT SAFETY NOTICE…314
GENERAL PRECAUTIONS…314
PREPARATIONS FOR WORK…314
PRECAUTIONS DURING WORK…314
GENERAL…316
HOW TO READ THE SHOP MANUAL…317
VOLUMES…317
DISTRIBUTION AND UPDATING…317
FILING METHOD…317
REVISED EDITION MARK…317
REVISIONS…317
SYMBOLS…317
HOISTING INSTRUCTIONS…318
HOISTING…318
WIRE ROPES…318
PUSH PULL COUPLER…319
TYPE 1…319
DISCONNECTION…319
CONNECTION…319
TYPE 2…320
DISCONNECTION…320
CONNECTION…320
TYPE 3…321
DISCONNECTION…321
CONNECTION…321
EXPLANATION OF MAINTENANCE STANDARD TERMS…322
STANDARD TIGHTENING TORQUE…324
BOLTS AND NUTS…324
TIGHTENING TORQUE OF HOSE NUTS…325
TIGHTENING TORQUE OF SPLIT FLANGE BOLTS…325
TIGHTENING TORQUE FOR FLARED NUTS…325
TIGHTENING TORQUES FOR O-RING BOSS PIPING JOINTS…326
TABLE OF TIGHTENING TORQUES FOR O-RING BOSS PLUGS…326
TORQUE TABLE FOR HOSES (TAPER SEAL TYPE AND FACE SEAL TYPE)…326
ELECTRIC WIRE CODE…327
CLASSIFICATION BY THICKNESS…327
CLASSIFICATION BY COLOR AND CODE…327
HOW TO READ ELECTRIC WIRE CODE…328
CONVERSION TABLES…331
METHOD OF USING THE CONVERSION TABLE…331
COATING MATERIALS…337
01 GENERAL…340
SPECIFICATION DRAWING…341
D51EX, PX-22 POWER ANGLE, POWER TILT DOZER WITH ROPS CAB…341
SPECIFICATION…342
WEIGHT TABLE…346
TABLE OF FUEL, COOLANT AND LUBRICANTS…349
RECOMMENDED PRODUCTS OTHER THAN KOMATSU GENUINE OILS…351
10 STRUCTURE, FUNCTION AND MAINTENANCE STANDARD…352
ENGINE AND COOLING SYSTEM…354
ENGINE RELATED PARTS…354
COOLING SYSTEM…356
COOLING FAN PUMP – SEE HYDRAULIC SYSTEM 2 (WORK EQUIPMENT AND FAN PUMP)…359
COOLING FAN MOTOR…360
OIL COOLER BYPASS VALVE…366
CHARGE SAFETY VALVE…369
POWER TRAIN…371
POWER TRAIN…371
POWER TRAIN SYSTEM…372
DAMPER…373
FINAL DRIVE…374
PATH OF POWER TRANSMISSION…377
UNDER CARRIAGE AND FRAME…378
MAIN FRAME…378
TRACK FRAME AND RECOIL SPRING…379
SUSPENSION…381
IDLER…384
TRACK ROLLER…386
CARRIER ROLLER…390
TRACK SHOE…396
HYDRAULIC SYSTEM 1 (HST)…401
HST HYDRAULIC EQUIPMENT ARRANGEMENT DIAGRAM…401
HST PUMP…402
SAFETY-SUCTION VALVE…410
TOWING VALVE…413
HST MOTOR…414
MOTOR CONTROL VALVE…426
SOLENOID VALVE (3-SPOOL), EPC VALVE (2-SPOOL) AND TOWING VALVE…426
SOLENOID VALVE…428
EPC VALVE…429
CHARGE PUMP…433
HYDRAULIC SYSTEM 2 (WORK EQUIPMENT)…435
CLSS (CLOSED CENTER LOAD SENSING SYSTEM)…435
UNLOAD VALVE…439
PRESSURE COMPENSATION VALVE…445
LS BYPASS VALVE…446
WORK EQUIPMENT HYDRAULIC ARRANGEMENT DIAGRAM…447
WORK EQUIPMENT AND FAN PUMP…448
SERVO VALVE…453
CONTROL VALVE…455
QUICK DROP VALVE…467
BLADE PPC VALVE…469
RIPPER/WINCH PPC VALVE…475
HYDRAULIC TANK, FILTER…479
ACCUMULATOR…480
WORK EQUIPMENT…481
WORK EQUIPMENT…481
CUTTING EDGE AND END BIT…486
RIPPER…487
WORK EQUIPMENT CYLINDER…488
LIFT CYLINDER…488
TILT CYLINDER…488
ANGLE CYLINDER…489
RIPPER CYLINDER…489
PISTON VALVE FOR ANGLE CYLINDER…491
CAB AND ITS ATTACHMENTS…492
ROPS CAB…492
STEERING AND BRAKE CONTROL…493
WORK EQUIPMENT CONTROL…495
CAB DAMPER MOUNT…497
AIR CONDITIONER…498
AIR CONDITIONER AND FLOOR HEATER…498
AIR CONDITIONER PIPING…499
ELECTRICAL SYSTEM…500
MONITOR SYSTEM…500
ENGINE CONTROL…502
ENGINE CONTROL SYSTEM…503
COOLING CONTROL SYSTEM…505
HST CONTROL SYSTEM…507
GEAR SHIFT CONTROL SYSTEM…508
GEAR SHIFTING BY OPERATOR…508
SET TRAVEL SPEEDS CORRESPONDING TO GEAR SPEEDS…509
CHANGING TRAVEL SPEED ACCORDING TO CHANGE OF ENGINE SPEED…511
STRAIGHT TRAVEL CORRECTION CONTROL SYSTEM…512
PARKING BRAKE CONTROL SYSTEM…513
KOMTRAX SYSTEM…515
SYSTEM COMPONENTS…517
MONITOR PANEL…517
ENGINE CONTROLLER…521
HST CONTROLLER…523
ELECTRIC LEVER (FOR TRAVEL)…525
KOMTRAX TERMINAL…527
SENSORS…528
BRAKE OIL PRESSURE SENSOR…529
HYDRAULIC OIL TEMPERATURE SENSOR…530
HST CIRCUIT OIL PRESSURE SENSOR…531
AIR CLEANER CLOGGING SENSOR…532
DECELERATOR PEDAL POTENTIOMETER…533
BRAKE PEDAL POTENTIOMETER…533
FUEL CONTROL DIAL…534
FUEL LEVEL SENSOR…535
CHARGE FILTER CLOGGING SENSOR…536
COOLANT TEMPERATURE SENSOR…536
ENGINE OIL PRESSURE SWITCH…537
ENGINE ROTATION SENSOR…537
BOOST PRESSURE AND TEMPERATURE SENSOR…538
WIF SENSOR…538
HST MOTOR SPEED SENSOR…539
20 STANDARD VALUES TABLE…540
STANDARD VALUE TABLE FOR ENGINE…541
STANDARD VALUE TABLE FOR CHASSIS…542
PERFORMANCE MEASURING POSTURE AND METHOD…547
30 TEST AND ADJUSTING…550
LIST OF TOOLS…552
ENGINE…555
ENGINE SPEED…555
AIR INTAKE BOOST PRESSURE…556
EXHAUST TEMPERATURE…557
EXHAUST GAS COLOR…559
VALVE CLEARANCE…560
COMPRESSION PRESSURE…563
BLOW-BY PRESSURE…565
ENGINE OIL PRESSURE…566
HANDLING CONTROLLER HIGH-VOLTAGE CIRCUIT…567
FUEL SYSTEM…568
HANDLING FUEL SYSTEM PARTS…568
RELEASING RESIDUAL PRESSURE FROM FUEL SYSTEM…568
BLEEDING AIR FROM FUEL CIRCUIT…569
FUEL PRESSURE…571
FUEL RETURN RATE AND LEAKAGE…573
FUEL CIRCUIT FOR LEAKAGE…576
FAN (WORK EQUIPMENT) PUMP PRESSURE…577
FAN SPEED…577
FAN SPEED SENSOR…578
DECELERATOR PEDAL…580
HST OIL PRESSURE…582
MOTOR CONTROL VALVE OUTLET PRESSURE…587
TRAVEL DEVIATION…590
PARKING BRAKE LEVER…591
BRAKE PERFORMANCE…593
BRAKE PEDAL LINKAGE…594
EMERGENCY RELEASE OF PARKING BRAKE…596
IDLER CLEARANCE…599
TRACK SHOE TENSION…601
WORK EQUIPMENT…602
OIL PRESSURE…602
LOCK LEVER ADJUSTMENT…604
CYLINDER LEAKAGE…605
HYDRAULIC CIRCUIT…607
RELEASING RESIDUAL PRESSURE…607
BLEEDING AIR…608
BLADE CENTER BALL ADJUSTMENT…609
BLADE PITCH BALL ADJUSTMENT…609
DIODES…610
PROCEDURE FOR TESTING…610
MONITOR PANEL (EMMS) – SPECIAL FUNCTIONS…612
PREPARATION WORK FOR TROUBLESHOOTING FOR ELECTRICAL SYSTEM…673
ELECTRIC/HYDRAULIC DEVICES ARE ADJUSTED/REPLACED…675
ITEMS TO BE ADJUSTED…675
HST CONTROLLER ADJUSTMENT AFTER REPLACEMENT…676
MONITOR PANEL ADJUSTMENT AFTER REPLACEMENT…679
PM-CLINIC…681
PM-CLINIC SERVICE…681
PM-CLINIC INSPECTION SHEET (1/2)…684
PM-CLINIC INSPECTION SHEET (2/2)…685
PM-CLINIC UNDERCARRIAGE CHECK SHEET…686
UNDERCARRIAGE TROUBLESHOOTING REPORT (NORMAL)…687
UNDERCARRIAGE TROUBLESHOOTING REPORT (IMPACT)…688
40 TROUBLESHOOTING (GENERAL)…690
POINTS TO REMEMBER WHEN TROUBLESHOOTING…691
SEQUENCE OF EVENTS IN TROUBLESHOOTING…693
PRECAUTIONS WHEN CARRYING OUT MAINTENANCE…694
PRECAUTIONS WHEN HANDLING ELECTRICAL EQUIPMENT…694
HANDLING ELECTRONIC CONTROL UNIT…699
POINTS TO REMEMBER WHEN TROUBLESHOOTING ELECTRICAL CIRCUITS…700
ELECTRIC WIRE CODE…701
CLASSIFICATION BY THICKNESS…701
CLASSIFICATION BY COLOR AND CODE…701
HOW TO READ ELECTRIC WIRE CODE…702
POINTS TO REMEMBER WHEN HANDLING HYDRAULIC EQUIPMENT…704
CHECKS BEFORE TROUBLESHOOTING…706
CATEGORIES AND METHOD OF USING TROUBLESHOOTING CHARTS…707
TROUBLESHOOTING INDIVIDUAL ELECTRICAL CIRCUITS…708
CONNECTION TABLE FOR CONNECTOR PIN NUMBERS…711
T-ADAPTER TABLE…735
MODE CHART…739
TROUBLESHOOTING BY ERROR CODE…748
INFORMATION IN TROUBLESHOOTING TABLE…755
ERROR CODE [6091NX]…757
HST CHARGE FILTER ELEMENT CLOGGING…757
ERROR CODE [AA10NX]…759
AIR CLEANER CLOGGING…759
ERROR CODE [AB00MA]…761
ALTERNATOR MALFUNCTION…761
ERROR CODE [B@BAZG]…762
ENGINE OIL LOWERING OF OIL PRESSURE…762
ERROR CODE [B@BCNS]…763
COOLANT OVERHEAT…763
ERROR CODE [B@CRNS]…764
HST OIL OVERHEATING…764
ERROR CODE [B@CRZG]…765
HST OIL LOWERING OF OIL PRESSURE…765
ERROR CODE [CA111]…766
ABNORMALITY IN ENGINE CONTROLLER…766
ERROR CODE [CA115]…767
ABNORMALITY IN NE AND BKUP SPEED SENSOR SIGNAL…767
ERROR CODE [CA122]…769
CHARGE PRESSURE SENSOR TOO HIGH…769
ERROR CODE [CA123]…771
CHARGE PRESSURE SENSOR TOO LOW…771
ERROR CODE [CA131]…773
DECELERATOR PEDAL SENSOR TOO HIGH…773
ERROR CODE [CA132]…775
DECELERATOR PEDAL SENSOR TOO LOW…775
ERROR CODE [CA144]…777
COOLANT TEMPERATURE SENSOR TOO HIGH…777
ERROR CODE [CA145]…779
COOLANT TEMPERATURE SENSOR TOO LOW…779
ERROR CODE [CA153]…781
CHARGE TEMPERATURE SENSOR TOO HIGH…781
ERROR CODE [CA154]…783
CHARGE TEMPERATURE SENSOR TOO low…783
ERROR CODE [CA187]…785
SENSOR POWER SORCE EXCESSIVELY LOW…785
ERROR CODE [CA221]…787
ATMOSPHERIC PRESSURE SENSOR TOO HIGH…787
ERROR CODE [CA222]…789
ATMOSPHERIC PRESSURE SENSOR TOO LOW…789
ERROR CODE [CA227]…791
SENSOR POWER SORCE EXCESSIVELY HIGH…791
ERROR CODE [CA234]…793
ENGINE OVERSPEED…793
ERROR CODE [CA238]…794
ABNORMAL POWER SOURCE FOR NE SPEED SENSOR…794
ERROR CODE [CA271]…795
IMV/PCV1 SHORT CIRCUITED…795
ERROR CODE [CA272]…797
IMV/PCV1 OPEN…797
ERROR CODE [CA322]…799
NO.1 INJECTOR SHOWING OPEN OR SHORT…799
ERROR CODE [CA323]…801
NO.5 INJECTOR SHOWING OPEN OR SHORT…801
ERROR CODE [CA324]…803
NO.3 INJECTOR SHOWING OPEN OR SHORT…803
ERROR CODE [CA325]…805
NO.6 INJECTOR SHOWING OPEN OR SHORT…805
ERROR CODE [CA331]…807
NO.2 INJECTOR SHOWING OPEN OR SHORT…807
ERROR CODE [CA332]…809
NO.4 INJECTOR SHOWING OPEN OR SHORT…809
ERROR CODE [CA342]…811
ENGINE CONTROLLER DATA MATCHING ERROR…811
ERROR CODE [CA352]…812
SENSOR POWER SOURCE TOO LOW…812
ERROR CODE [CA386]…813
SENSOR POWER SOURCE TOO HIGH…813
ERROR CODE [CA428]…815
WATER IN FUEL SENSOR VOLTAGE TOO HIGH…815
ERROR CODE [CA429]…817
WATER IN FUEL SENSOR VOLTAGE TOO LOW…817
ERROR CODE [CA435]…819
ABNORMAL ENGINE OIL PRESSURE SWITCH…819
ERROR CODE [CA441]…821
POWER SOURCE VOLTAGE IS TOO LOW…821
ERROR CODE [CA442]…823
POWER SOURCE VOLTAGE TOO HIGH…823
ERROR CODE [CA449]…825
COMMON RAIL PRESSURE TOO HIGH…825
ERROR CODE [CA451]…827
COMMON RAIL PRESSURE TOO HIGH…827
ERROR CODE [CA452]…829
COMMON RAIL PRESSURE TOO LOW…829
ERROR CODE [CA488]…831
CHARGE TEMPERATURE TOO HIGH AND TORQUE DERATED…831
ERROR CODE [CA553]…832
COMMON RAIL PRESSURE TOO HIGH…832
ERROR CODE [CA559]…833
LOSS OF PRESSURE FEED FROM SUPPLY PUMP…833
ERROR CODE [CA689]…835
ABNORMAL ENGINE NE SPEED SENSOR…835
ERROR CODE [CA731]…837
ABNORMAL ENGINE BKUP SPEED SENSOR PHASE…837
ERROR CODE [CA757]…839
LOSS OF ALL ENGINE CONTROLLER DATA…839
ERROR CODE [CA778]…841
ABNORMAL ENGINE BKUP SPEED SENSOR…841
ERROR CODE [CA1633]…843
ABNORMAL KOMNET…843
ERROR CODE [CA2185]…845
DECELERATOR PEDAL SENSOR POWER SOURCE TOO HIGH…845
ERROR CODE [CA2186]…846
DECELERATOR PEDAL SENSOR POWER SOURCE TOO LOW…846
ERROR CODE [CA2249]…847
LOSS OF PRESSURE FEED FROM SUPPLY PUMP (2)…847
ERROR CODE [CA2311]…849
ABNORMAL IMV SOLENOID…849
ERROR CODE [CA2555]…851
AIR INTAKE HEATER RELAY DISCONNECTION…851
ERROR CODE [CA2556]…853
AIR INTAKE HEATER RELAY SHORT CIRCUIT…853
ERROR CODE [D130KA]…855
NEUTRAL SAFETY RELAY DISCONNECTION…855
ERROR CODE [D130KB]…857
NEUTRAL SAFETY RELAY SHORT CIRCUIT…857
ERROR CODE [DAFRKR]…859
CAN COMMUNICATION MONITOR PANEL – HST CONTROLLER…859
ERROR CODE [DAFRMC]…861
CAN COMMUNICATION MONITOR PANEL – ENGINE CONTROLLER…861
ERROR CODE [DAJ000]…863
HST CONTROLLER MEMORY ERROR…863
ERROR CODE [DAJ0KK]…865
HST CONTROLLER LOWERING OF SOURCE VOLTAGE…865
ERROR CODE [DAJ0KQ]…867
HST CONTROLLER MACHINE CODE ERROR…867
ERROR CODE [DAJ0KT]…868
HST CONTROLLER MEMORY ERROR…868
ERROR CODE [DAJ5KK]…869
HST CONTROLLER POWER SUPPLY LOWING…869
ERROR CODE [DAJ6KK]…871
HST POWER SUPPLY LOWING…871
ERROR CODE [DAJRKR]…873
CAN COMMUNICATION HST CONTROLLER DEFECTIVE…873
ERROR CODE [DB2RKR]…875
CAN COMMUNICATION HST CONTROLLER DEFECTIVE…875
ERROR CODE [DD12KA]…877
SHIFT UP SWITCH DISCONNECTION…877
ERROR CODE [DD12KB]…879
SHIFT UP SWITCH SHORT CIRCUIT…879
ERROR CODE [DD13KA]…881
SHIFT DOWN SWITCH DISCONNECTION…881
ERROR CODE [DD13KB]…883
SHIFT DOWN SWITCH SHORT CIRCUIT…883
ERROR CODE [DD14KB]…885
TRAVEL LOCK LIMIT SWITCH 1 SHORT CIRCUIT…885
ERROR CODE [DD1NL4]…887
FAN ROTATION SELECTOR SWITCH DISAGREEMENT…887
ERROR CODE [DDDCKB]…889
REVERSE TRAVEL SPEED SWITCH SHORT CIRCUIT…889
ERROR CODE [DDP6KA]…891
BRAKE OIL PRESSURE SENSOR DISCONNECTION…891
ERROR CODE [DDP6KB]…893
BRAKE OIL PRESSURE SENSOR SHORT CIRCUIT…893
ERROR CODE [DDP6MA]…895
BRAKE OIL PRESSURE SENSOR MALFUNCTION…895
ERROR CODE [DDQ2KA]…897
TRAVEL LOCK LIMIT SWITCH 1 DISCONNECTION…897
ERROR CODE [DDT0L4]…899
SHIFT MODE SWITCH DISAGREEMENT OF ON/ OFF SIGNALS…899
ERROR CODE [DDU1FS]…901
TRAVEL LOCK LIMIT SWITCHES 1 AND 2 FIXING…901
ERROR CODE [DDU1KA]…903
TRAVEL LOCK LIMIT SWITCH 2 DISCONNECTION…903
ERROR CODE [DDU1KY]…905
TRAVEL LOCK LIMIT SWITCH 2 SHORT WITH POWER SUPPLY LINE…905
ERROR CODE [DGS1KA]…907
HST OIL TEMPERATURE SENSOR DISCONNECTION…907
ERROR CODE [DGS1KX]…909
HST OIL TEMPERATURE SENSOR OUT OF INPUT SIGNAL RANGE…909
ERROR CODE [DHH5KA]…911
LEFT HST PUMP PRESSURE SENSOR DISCONNECTION…911
ERROR CODE [DHH5KB]…913
LEFT HST PUMP PRESSURE SENSOR SHORT CIRCUIT…913
ERROR CODE [DHH6KA]…915
RIGHT HST PUMP PRESSURE SENSOR DISCONNECTION…915
ERROR CODE [DHH6KB]…917
RIGHT HST PUMP PRESSURE SENSOR SHORT CIRCUIT…917
ERROR CODE [DK10KA]…919
FUEL DIAL SENSOR DISCONNECTION…919
ERROR CODE [DK10KB]…921
FUEL DIAL SENSOR SHORT CIRCUIT…921
ERROR CODE [DK30KA]…923
STEERING ANGLE SENSOR 1 DISCONNECTION…923
ERROR CODE [DK30KB]…925
STEERING ANGLE SENSOR 1 SHORT CIRCUIT…925
ERROR CODE [DK30KX]…927
STEERING ANGLE SENSOR OUT OF INPUT SIGNAL RANGE…927
ERROR CODE [DK30KZ]…928
STEERING ANGLE SENSOR DISCONNECTION OR SHORT CIRCUIT…928
ERROR CODE [DK30L8]…929
STEERING ANGLE SENSOR DISAGREEMENT OF ANALOG SIGNALS…929
ERROR CODE [DK31KA]…931
STEERING ANGLE SENSOR DISCONNECTION…931
ERROR CODE [DK31KB]…933
STEERING ANGLE SENSOR 2 SHORT CIRCUIT…933
ERROR CODE [DK40KA]…935
BRAKE PEDAL SENSOR DISCONNECTION…935
ERROR CODE [DK40KB]…937
BRAKE PEDAL SENSOR SHORT CIRCUIT…937
ERROR CODE [DK55KX]…939
DIRECTIONAL POTENTIOMETER OUT OF INPUT SIGNAL RANGE…939
ERROR CODE [DK55KZ]…940
DIRECTIONAL POTENTIOMETER DISCONNECTION OR SHORT CIRCUIT…940
ERROR CODE [DK55L8]…941
DIRECTIONAL POTENTIOMETER DISAGREEMENT OF ANALOG SIGNALS…941
ERROR CODE [DK56KA]…943
DIRECTIONAL POTENTIOMETER 1 DISCONNECTION…943
ERROR CODE [DK56KB]…945
DIRECTIONAL POTENTIOMETER 1 SHORT CIRCUIT…945
ERROR CODE [DK57KA]…947
DIRECTIONAL POTENTIOMETER 2 DISCONNECTION…947
ERROR CODE [DK57KB]…949
DIRECTIONAL POTENTIOMETER 2 SHORT CIRCUIT…949
ERROR CODE [DLM0KX]…951
HST MOTOR SPEED SENSORS OUT OF INPUT SIGNAL RANGE…951
ERROR CODE [DLM1KA]…953
LEFT HST MOTOR SPEED SENSOR DISCONNECTION…953
ERROR CODE [DLM1KB]…955
LEFT HST MOTOR SPEED SENSOR: SHORT CIRCUIT…955
ERROR CODE [DLM1MA]…957
LEFT HST MOTOR SPEED SENSOR: MALFUNCTION…957
ERROR CODE [DLM2KA]…959
RIGHT HST MOTOR SPEED SENSOR DISCONNECTION…959
ERROR CODE [DLM2KB]…961
RIGHT HST MOTOR SPEED SENSOR SHORT CIRCUIT…961
ERROR CODE [DLM2MA]…963
RIGHT HST MOTOR SPEED SENSOR MALFUNCTION…963
ERROR CODE [DLM3KA]…965
FAN SPEED SENSOR DISCONNECTION…965
ERROR CODE [DLM3KB]…967
FAN SPEED SENSOR: SHORT CIRCUIT…967
ERROR CODE [DN21FS]…969
BRAKE PEDAL AND PROXIMITY SWITCH FIXING…969
ERROR CODE [DV00KB]…971
CAUTION BUZZER SHORT CIRCUIT…971
ERROR CODE [DV20KB]…972
BACK ALARM BUZZER SHORT CIRCUIT…972
ERROR CODE [DW4BKA]…973
PARKING BRAKE SOLENOID VALVE DISCONNECTION…973
ERROR CODE [DW4BKB]…975
PARKING BRAKE SOLENOID VALVE SHORT CIRCUIT…975
ERROR CODE [DW4BKY]…977
PARKING BRAKE SOLENOID VALVE SHORTED…977
ERROR CODE [DW7BKA]…978
FAN REVERSE SOLENOID VALVE DISCONNECTION…978
ERROR CODE [DW7BKB]…979
FAN REVERSE SOLENOID VALVE SHORT CIRCUIT…979
ERROR CODE [DW7BKY]…980
FAN REVERSE SOLENOID VALVE SHORTED…980
ERROR CODE [DW7EKA]…981
SLOW BRAKE SOLENOID VALVE DISCONNECTION…981
ERROR CODE [DW7EKB]…985
SLOW BRAKE SOLENOID VALVE SHORT CIRCUIT…985
ERROR CODE [DW7EKY]…987
SLOW BRAKE SOLENOID VALVE SHORTED…987
ERROR CODE [DWN5KA]…989
FAN EPC SOLENOID VALVE DISCONNECTION…989
ERROR CODE [DWN5KB]…991
FAN EPC SOLENOID VALVE SHORT CIRCUIT…991
ERROR CODE [DWN5KY]…993
FAN EPC SOLENOID VALVE SHORTED…993
ERROR CODE [DXA4KA]…995
LF HST PUMP EPC SOLENOID VALVE DISCONNECTION…995
ERROR CODE [DXA4KB]…997
LF HST PUMP EPC SOLENOID VALVE SHORT CIRCUIT…997
ERROR CODE [DXA4KY]…998
LF HST PUMP EPC SOLENOID VALVE SHORTED…998
ERROR CODE [DXA5KA]…999
LR HST PUMP EPC SOLENOID VALVE DISCONNECTION…999
ERROR CODE [DXA5KB]…1001
LR HST PUMP EPC SOLENOID VALVE SHORT CIRCUIT…1001
ERROR CODE [DXA5KY]…1002
LR HST PUMP EPC SOLENOID VALVE SHORTED…1002
ERROR CODE [DXA6KA]…1003
RF HST PUMP EPC SOLENOID VALVE DISCONNECTION…1003
ERROR CODE [DXA6KB]…1005
RF HST PUMP EPC SOLENOID VALVE SHORT CIRCUIT…1005
ERROR CODE [DXA6KY]…1006
RF HST PUMP EPC SOLENOID VALVE SHORTED…1006
ERROR CODE [DXA7KA]…1007
RR HST PUMP EPC SOLENOID VALVE DISCONNECTION…1007
ERROR CODE [DXA7KB]…1009
RR HST PUMP EPC SOLENOID VALVE SHORT CIRCUIT…1009
ERROR CODE [DXA7KY]…1010
RR HST PUMP EPC SOLENOID VALVE SHORTED…1010
ERROR CODE [DXK1KA]…1011
LEFT HST MOTOR EPC SOLENOID VALVE DISCONNECTION…1011
ERROR CODE [DXK1KB]…1012
LEFT HST MOTOR EPC SOLENOID VALVE SHORT CIRCUIT…1012
ERROR CODE [DXK1KY]…1013
LEFT HST MOTOR EPC SOLENOID VALVE SHORTED…1013
ERROR CODE [DXK2KA]…1014
RIGHT HST MOTOR EPC SOLENOID VALVE DISCONNECTION…1014
ERROR CODE [DXK2KB]…1015
RIGHT HST MOTOR EPC SOLENOID VALVE SHORT CIRCUIT…1015
ERROR CODE [DXK2KY]…1016
RIGHT HST MOTOR EPC SOLENOID VALVE SHORTED…1016
BEFORE CARRYING OUT TROUBLESHOOTING (E-MODE)…1020
CONNECTION TABLE OF FUSE BOX…1020
INFORMATION IN TROUBLESHOOTING TABLE…1022
E-1…1023
STARTING MOTOR DOES NOT ROTATE…1023
E-2…1027
ENGINE IS NOT PRE-HEATED…1027
E-3…1031
WHEN STARTING SWITCH IS TURNED ON, ANY ITEM DOES NOT LIGHT…1031
E-4…1033
CHARGE LEVEL CAUTION FLASHES WHILE ENGINE IS RUNNING…1033
E-5…1035
EMERGENCY WARNING ITEMS FLASH WHILE ENGINE IS RUNNING…1035
E-6…1039
PRE-HEAT LAMP DOES NOT LIGHT DURING PRE-HEATING OPERATION…1039
E-7…1041
COOLANT TEMPERATURE GAUGE DOES NOT INDICATE CORRECTLY…1041
E-8…1042
HST OIL TEMPERATURE GAUGE DOES NOT INDICATE CORRECTLY…1042
E-9…1043
FUEL LEVEL GAUGE DOES NOT INDICATE PROPERLY…1043
E-10…1045
TRAVEL INDICATOR DOES NOT DISPLAY NORMALLY…1045
E-11…1045
MULTI-INFORMATION UNIT DOES NOT DISPLAY NORMALLY…1045
E-12…1046
CAUTION LAMP DOES NOT FLASH OR DOES NOT GO OFF…1046
E-13…1047
CAUTION BUZZER DOES NOT SOUND OR DOES NOT STOP…1047
E-14…1049
REVERSE TRAVEL SPEED SETTING SWITCH DOES NOT FUNCTION…1049
E-15…1051
SHIFT MODE SWITCH DOES NOT FUNCTION…1051
E-16…1053
BUZZER CANCEL SWITCH DOES NOT FUNCTION…1053
E-17…1055
INFORMATION SWITCH DOES NOT FUNCTION…1055
E-18…1057
THE FAN CLEANING DOES NOT OPERATE OR CANNOT BE RESET…1057
E-19…1059
BACKUP ALARM DOES NOT SOUND…1059
E-20…1060
THE HORN DOES NOT SOUND OR DOES NOT STOP…1060
E-21…1061
WORK EQUIPMENT DOES NOT MOVE…1061
E-22…1063
HEAD LAMP OR REAR LAMP DOES NOT LIGHT UP…1063
E-23…1067
FOOT HEATER DOES NOT OPERATE…1067
E-24…1071
AIR CONDITIONER DOES NOT OPERATE [CAB SPECIFICATION]…1071
E-25…1076
WIPER AND WASHER DO NOT OPERATE [CAB SPECIFICATION]…1076
E-26…1089
KOMTRAX SYSTEM DOES NOT OPERATE NORMALLY…1089
INFORMATION IN TROUBLESHOOTING TABLE…1093
H-1…1094
RIGHT AND LEFT TRAVEL SYSTEMS INOPERABLE…1094
H-2…1096
RIGHT OR LEFT TRAVEL SYSTEM DOES NOT OPERATE…1096
H-3…1097
RIGHT OR LEFT TRAVEL SYSTEM DOES NOT OPERATE…1097
H-4…1098
SPEED OR POWER OF TRAVEL IS LOW…1098
H-5…1099
GEAR IS NOT SHIFTED…1099
H-6…1100
LARGE SHOCKS ARE MADE WHEN MACHINE STARTS AND STOPS TRAVEl…1100
H-7…1101
MACHINE DEVIATES LARGELY DURING TRAVEL…1101
H-8…1102
HYDRAULIC DRIFT OF TRAVEL IS LARGE…1102
H-9…1103
ENGINE STALLS OR SPEED LOWERS EXTREMELY DURING TRAVEl…1103
H-10…1104
ABNORMAL SOUND COMES OUT FROM AROUND HST PUMP AND MOTOR…1104
H-11…1105
WORK EQUIPMENT DOSE NOT OPERATE AT ALL…1105
H-12…1106
SPEED OR POWER OF WHOLE WORK EQUIPMENT IS LOW…1106
H-13…1107
SPEED OR POWER OF LIFTING BLADE IS LOW…1107
H-14…1108
SPEED OR POWER OF TILTING BLADE IS LOW…1108
H-15…1109
SPEED OR POWER OF ANGLING BLADE IS LOW…1109
H-16…1110
TIME LAG IN LIFTING BLADE IS LARGE…1110
H-17…1111
HYDRAULIC DRIFT OF LIFTING BLADE IS LARGE…1111
H-18…1112
HYDRAULIC DRIFT OF TILTING BLADE IS LARGE…1112
H-19…1113
ABNORMAL SOUND COMES FROM WORK EQUIPMENT PUMP AND CONTROL VALVE…1113
H-20…1114
HST OIL TEMPERATURE RISES TOO HIGH…1114
H-21…1115
FAN SPEED IS ABNORMAL (HIGH, LOW, OR 0 RPM)…1115
METHOD OF USING TROUBLESHOOTING CHARTS…1117
(S-1) ENGINE STARTING PERFORMANCE IS POOR…1121
(S-2) ENGINE DOES NOT CRANK…1122
ENGINE CRANKS BUT NO EXHAUST SMOKE COMES OUT OF STACK…1123
SMOKE COMES OUT OF STACK BUT ENGINE DOES NOT START…1124
(S-3) ENGINE DOES NOT RUN SMOOTHLY…1125
(S-4) ENGINE STOPS DURING OPERATIONS…1126
(S-5) ENGINE SPEED HUNTS…1127
(S-6) ENGINE LACKS POWER…1128
(S-7) EXHAUST SMOKE IS BLACK…1130
(S-8) OIL CONSUMPTION IS EXCESSIVE OR EXHAUST SMOKE IS BLUE…1131
(S-9) OIL BECOMES CONTAMINATED QUICKLY…1132
(S-10) FUEL CONSUMPTION IS EXCESSIVE…1133
(S-11) OIL FOUND IN COOLANT, OR COOLANT SPURTS FROM RADIATOR…1134
(S-12) OIL PRESSURE CAUTION LAMP LIGHTS UP…1135
(S-13) OIL LEVEL RISES (COOLANT OR FUEL FOUND IN OIL)…1136
(S-14) COOLANT TEMPERATURE TOO HIGH (OVERHEATING)…1137
(S-15) ABNORMAL NOISE IS HEARD WHEN ENGINE IS RUNNING…1138
(S-16) EXCESSIVE VIBRATION WHEN ENGINE IS RUNNING…1139
50 DISASSEMBLY AND ASSEMBLY…1140
HOW TO USE THIS MANUAL…1143
REMOVAL AND INSTALLATION OF COMPONENTS…1143
Special Tools…1143
OVERHAUL OF COMPONENTS…1144
Special Tools…1144
Disassembly Procedures…1144
Assembly Procedures…1144
PRECAUTIONS WHEN CARRYING OUT AN OPERATION…1145
SPECIAL TOOL LIST…1147
SKETCH OF SPECIAL TOOLS…1153
CONNECTOR REPAIR PROCEDURES…1166
CONTACT TERMINAL REMOVAL (HD30 TYPE)…1166
STRIPPING INSULATION…1167
CRIMPING CONTACT TERMINAL (HD30 TYPE)…1168
INSERTION OF CONTACT TERMINAL (HD30 TYPE)…1169
CONTACT TERMINAL REMOVAL (DT TYPE)…1170
STRIPPING INSULATION…1171
CRIMPING CONTACT TERMINAL (DT TYPE)…1172
INSERTION OF CONTACT TERMINAL (DT TYPE)…1173
NOSE GUARD (HOOD)…1175
REMOVAL…1175
OPENING FRONT GRILL…1175
REMOVING SIDE PANELS…1176
DISCONNECTING HOOD-RELATED COMPONENTS…1176
REMOVAL OF HOOD…1177
INSTALLATION…1179
MUFFLER AND EXHAUST STACK…1181
REMOVAL…1181
INSTALLATION…1182
CAB…1183
REMOVAL…1183
FLOOR ACCESS PLATE…1186
LIFTING CAB OFF MACHINE…1189
INSTALLATION…1192
MONITOR PANEL AND HST CONTROLLER…1197
REMOVAL…1197
INSTALLATION…1199
KOMTRAX CONTROLLER…1200
REMOVAL…1200
INSTALLATION…1200
SEAT…1201
REMOVAL…1201
INSTALLATION…1201
AIR CONDITIONER/HEATER…1202
DISASSEMBLY OF AIR CONDITIONER…1202
REMOVING CONDENSER…1203
BLOWER MOTORS AND EVAPORATOR…1205
ASSEMBLY OF AIR CONDITIONER…1206
FOOT HEATER…1207
REMOVAL…1207
INSTALLATION…1208
FOOT HEATER OVERHAUL PROCEDURES…1209
OVERHAUL PROCEDURES…1209
ASSEMBLY PROCEDURES…1211
ENGINE AND HST PUMP…1213
REMOVAL…1213
BELLY PANS…1213
DRAINING THE COOLING SYSTEM…1213
DRAINING THE HYDRAULIC SYSTEM…1214
DISCONNECTING COMPONENTS…1215
LIFTING ENGINE AND HST PUMP ASSEMBLY…1221
INSTALLATION…1223
INSTALL ENGINE AND HST PUMP ASSEMBLY…1223
REMOVAL FROM ENGINE…1225
INSTALLATION TO ENGINE…1228
DRIVE DAMPENER…1229
REMOVAL…1229
INSTALLATION…1230
HST PUMP OVERHAUL PROCEDURES…1231
DISASSEMBLY PROCEDURES…1231
REMOVAL OF ACCESSORIES…1231
REMOVAL OF REAR PUMP…1232
REMOVAL OF END CAP…1232
DISASSEMBLY OF CYLINDER BLOCK AND PISTONS…1233
DISASSEMBLY OF ROCKER CAM…1234
REMOVAL OF FRONT SHAFT…1235
DISASSEMBLY OF SHAFT…1236
DISASSEMBLY OF FRONT COVER…1237
DISASSEMBLY FRONT SERVO PISTON…1238
DISASSEMBLY OF END CAP…1239
DISASSEMBLY OF REAR PUMP…1239
DISASSEMBLY OF REAR SHAFT…1239
ASSEMBLY PROCEDURES…1240
INSTALLATION OF REAR SERVO PISTON…1241
INSTALLATION OF REAR COVER…1243
INSTALLATION OF REAR SHAFT…1244
ASSEMBLY OF REAR ROCKER CAM…1245
INSTALLATION OF REAR CYLINDER BLOCK AND PISTON…1246
ASSEMBLY OF END CAP…1246
ASSEMBLY OF FRONT COVER…1247
INSTALLATION OF FRONT OIL SEAL…1247
INSTALLATION OF END CAP…1248
INSTALLATION OF REAR PUMP…1248
INSTALLATION OF ACCESSORIES…1249
WORK EQUIPMENT PUMP OVERHAUL PROCEDURES…1250
DISASSEMBLY PROCEDURES…1250
PUMP…1250
(PC VALVE)…1251
(LS VALVE)…1251
REMOVAL OF END CAP…1252
DISASSEMBLY OF CYLINDER BLOCK AND PISTON…1252
DISASSEMBLY OF SHAFT ASSEMBLY…1253
DISASSEMBLY OF ROCKER CAM…1254
REMOVAL OF BALLS AND PISTON…1255
ASSEMBLY PROCEDURES…1256
INSTALLATION OF PUMP CASE…1256
INSTALLATION OF ROCKER CAM…1256
ASSEMBLY AND INSTALLATION OF SHAFT…1257
INSTALLATION OF OIL SEAL…1258
INSTALLATION OF CYLINDER BLOCK AND PISTON…1259
INSTALLATION OF END CAP…1260
ASSEMBLY OF SERVO VALVE…1260
INSTALLATION OF SERVO VALVE ASSEMBLY…1262
DIESEL ENGINE OVERHAUL PROCEDURES…1263
DISASSEMBLY OF EXTERNAL COMPONENTS…1263
PREPARATION WORK…1263
STARTING MOTOR…1264
ENGINE SLING BRACKET ON REAR SIDE…1264
FAN PULLEY…1264
VIBRATION DAMPER AND CRANKSHAFT PULLEY…1264
BELT TENSIONER…1265
FAN HUB…1265
ALTERNATOR…1265
THERMOSTAT…1266
WATER PUMP…1266
TURBOCHARGER AND EXHAUST MANIFOLD…1266
FUEL FILTER ASSEMBLY…1267
WIRING HARNESS ASSEMBLY…1267
FUEL PIPING AND COMMON RAIL…1268
DISASSEMBLY OF ENGINE TOP END…1269
INTAKE MANIFOLD…1269
VALVE COVER HOUSING…1269
ROCKER ARM ASSEMBLY AND CROSSHEAD…1270
PUSH RODS…1270
FUEL INJECTORS…1270
CYLINDER HEAD…1271
REMOVAL OF OIL COOLER, ENGINE CONTROLLER AND FUEL PUMP…1273
OIL COOLER…1273
ENGINE CONTROLLER…1273
FUEL SUPPLY PUMP…1274
DISASSEMBLY OF ENGINE LOWER END…1275
FLYWHEEL…1275
REAR OIL SEAL…1275
FLYWHEEL HOUSING…1276
OIL PAN…1276
FRONT COVER…1276
OIL PUMP…1277
CAMSHAFT…1277
GEAR HOUSING…1278
PISTONS AND CONNECTING RODS…1278
CRANKSHAFT…1279
PISTON COOLING NOZZLES…1281
TAPPETS…1281
CYLINDER BLOCK…1281
ASSEMBLY OF ENGINE LOWER END…1282
PREPARATION WORK…1282
TAPPETS…1282
PISTON COOLING NOZZLE…1282
CRANKSHAFT…1283
MAIN CAP MOUNTING BOLTS…1284
PISTON AND CONNECTING ROD ASSEMBLY…1285
GEAR HOUSING…1289
CAMSHAFT…1290
FLYWHEEL HOUSING…1291
REAR OIL SEAL…1292
FLYWHEEL…1293
OIL PUMP…1294
FRONT COVER…1295
OIL PAN…1296
VIBRATION DAMPER…1297
INSTALLATION OF OIL COOLER, ENGINE CONTROLLER AND FUEL PUMP…1298
FUEL SUPPLY PUMP…1298
ENGINE CONTROLLER…1298
OIL COOLER…1298
CYLINDER HEAD…1300
FUEL INJECTORS…1302
PUSH RODS…1303
ROCKER ARM ASSEMBLY…1303
ADJUSTING VALVE CLEARANCE…1303
VALVE COVER HOUSING…1304
AIR INTAKE MANIFOLD COVER…1305
ASSEMBLY OF EXTERNAL COMPONENTS…1307
PREPARATION WORK…1307
HARNESS ASSEMBLY…1307
FUEL FILTER ASSEMBLY…1307
EXHAUST MANIFOLD AND TURBOCHARGER…1307
WATER PUMP…1308
THERMOSTAT…1308
ALTERNATOR…1309
FAN HUB…1309
BELT TENSIONER…1310
FAN PULLEY…1310
ENGINE SLING BRACKET ON REAR SIDE…1310
STARTER MOTOR…1310
REFILLING WITH OIL…1311
TRACK SYSTEM…1313
SPREADING THE TRACK (CONVENTIONAL TYPE TRACK SHOE)…1313
Whole disassembly…1337
Whole assembly…1340
1. When recycling for lubricated track…1340
FIELD DISASSEMBLY AND ASSEMBLY OF ONE LINK (CONVENTIONAL TYPE TRACK SHOE)…1350
Special tools…1350
Disassembly…1351
Assembly…1352
FIELD DISASSEMBLY AND ASSEMBLY OF ONE LINK (PLUS TYPE TRACK SHOE)…1358
Special tools…1358
Disassembly…1359
Assembly…1363
TRACK FRAME…1366
REMOVAL OF TRACK FRAME…1366
REMOVING TRACKS…1366
TRACK FRAME REMOVAL PREPARATIONS…1369
LIFTING TRACK FRAME FROM MACHINE…1371
INSTALLATION OF TRACK FRAME…1373
FRONT TRACK IDLER…1375
REMOVING FRONT IDLER…1375
PULLING IDLER FROM TRACK FRAME…1376
INSTALLING FRONT IDLER…1378
TRACK ROLLER…1379
REMOVAL…1379
INSTALLATION…1379
TRACK ROLLER OVERHAUL PROCEDURES…1380
DISASSEMBLY…1380
ASSEMBLY…1381
CARRIER ROLLER OVERHAUL PROCEDURES…1385
DISASSEMBLY…1385
ASSEMBLY…1386
FINAL DRIVE…1387
FINAL DRIVE REMOVAL…1387
INSTALLING THE FINAL DRIVE…1391
FINAL DRIVE OVERHAUL PROCEDURES…1393
DISASSEMBLY PROCEDURES…1393
DRAINING OIL…1393
COVER…1394
RING GEAR…1394
NO. 1 PLANETARY CARRIER ASSEMBLY…1395
NO. 1 SUN GEAR…1395
NO. 2 SUN GEAR…1395
NO. 2 PLANETARY CARRIER ASSEMBLY…1396
HUB ASSEMBLY…1397
NO.2 PLANETARY CARRIER (HST MOTOR ASSEMBLY)…1398
ASSEMBLY OF FINAL DRIVE…1399
NO.2 PLANETARY CARRIER (HST MOTOR ASSEMBLY)…1399
ASSEMBLY OF HUB…1399
NO. 2 PLANETARY CARRIER ASSEMBLY…1402
NO. 2 SUN GEAR…1403
NO. 1 SUN GEAR…1403
NO. 1 PLANETARY CARRIER ASSEMBLY…1403
RING GEAR…1404
COVER…1405
REFILLING WITH OIL…1405
TRAVEL MOTOR OVERHAUL PROCEDURES…1407
DISASSEMBLY PROCEDURES…1407
TRAVEL MOTOR…1407
REMOVAL OF END COVER…1407
DISASSEMBLY OF END COVER…1408
REMOVAL OF RELIEF VALVE…1408
DISASSEMBLY OF SHUTTLE VALVE…1409
REMOVAL OF CYLINDER BLOCK…1409
REMOVAL OF PISTONS…1409
DISASSEMBLY OF BRAKE AND PISTON…1410
REMOVAL AND DISASSEMBLY OF DRIVE SHAFT…1410
REMOVAL OF OIL SEAL…1411
ASSEMBLY PROCEDURES…1412
INSTALLATION OF MOTOR CASE…1412
ASSEMBLY OF DRIVE SHAFT…1412
ASSEMBLY OF PISTONS…1413
INSTALLATION OF DRIVE SHAFT ASSEMBLY…1414
INSTALLATION OF DISCS AND PLATES…1415
INSTALLATION OF BRAKE PISTON…1415
ASSEMBLY OF END COVER…1415
ASSEMBLY OF SHUTTLE VALVE…1415
ASSEMBLY OF MAIN PISTON…1416
INSTALLATION OF MAIN VALVE…1416
INSTALLATION OF VALVE PLATE…1417
NSTALLATION OF END COVER…1418
CHECK OF SHAFT ROTATION TORQUE…1418
FAN MOTOR…1419
REMOVAL PROCEDURES…1419
DISCONNECTING THE GRILL FROM THE FAN…1419
DISCONNECTING HYDRAULIC FAN MOTOR…1420
REMOVING THE FAN GUARD…1421
REMOVING THE FAN MOTOR…1422
INSTALLATION PROCEDURES…1423
FAN MOTOR OVERHAUL PROCEDURES…1425
DISASSEMBLY PROCEDURES…1425
REMOVAL OF END COVER…1425
DISASSEMBLY OF END COVER…1425
DISASSEMBLY OF PILOT VALVE…1426
CYLINDER BLOCK, SHAFT AND PISTON…1427
DISASSEMBLY OF CYLINDER BLOCK AND PISTON…1427
DISASSEMBLY OF SHAFT…1428
DISASSEMBLY OF MOTOR CASE…1428
ASSEMBLY PROCEDURES…1429
INSTALLATION OF MOTOR CASE…1429
ASSEMBLY AND INSTALLATION OF SHAFT…1429
ASSEMBLY OF CYLINDER BLOCK AND PISTON…1430
INSTALLATION OF CYLINDER BLOCK AND PISTON…1431
INSTALLATION OF OIL SEAL…1432
ASSEMBLY OF END COVER…1432
INSTALLATION OF END COVER…1434
CHECK OF SHAFT ROTATION TORQUE…1435
DB 12 VALVE…1437
REMOVAL…1437
INSTALLATION…1440
COOLING PACKAGE…1441
REMOVING THE GRILL AND COOLING FAN ASSEMBLY…1441
REMOVING THE GRILL FRAME…1441
REMOVING THE COOLING FAN ASSEMBLY…1448
REMOVING THE COOLING PACKAGE…1452
REMOVING THE FAN SHROUD…1452
REMOVING THE RADIATOR…1455
REMOVING THE OIL COOLER…1457
REMOVING THE AIR CHARGE COOLER…1458
INSTALLING THE COOLING PACKAGE…1460
INSTALLING THE GRILL AND COOLING FAN ASSEMBLY…1461
FUEL TANK…1465
REMOVING THE FUEL TANK…1465
PREPARATIONS FOR REMOVAL…1465
LIFTING THE FUEL TANK OFF THE MACHINE…1468
INSTALLING THE FUEL TANK…1469
HYDRAULIC TANK…1470
REMOVING THE HYDRAULIC TANK…1470
PREPARATIONS FOR REMOVAL…1470
LIFTING THE HYDRAULIC TANK OFF THE MACHINE…1474
INSTALLING THE HYDRAULIC TANK…1476
WORK EQUIPMENT…1477
REMOVING OR INSTALLING PINS…1477
FRONT BLADE, TILT AND ANGLE CYLINDERS…1478
REMOVAL…1478
ADJUSTING BLADE CENTER BALL AND PITCH ROD PLAY…1483
PITCH ROD…1483
CENTER BALL…1484
INSTALLATION…1484
“C” FRAME…1485
REMOVAL…1485
INSTALLATION…1487
LIFT CYLINDERS…1488
REMOVAL…1488
INSTALLATION…1489
CYLINDER OVERHAUL PROCEDURES…1490
DISASSEMBLY PROCEDURES…1490
PISTON AND ROD…1490
PISTON AND HEAD ASSEMBLY…1491
DISASSEMBLY OF GLAND NUT…1491
ASSEMBLY PROCEDURES…1491
GLAND NUT ASSEMBLY AND PISTON ASSEMBLY…1491
DISASSEMBLY OF PISTON…1492
PISTON ROD ASSEMBLY…1493
EXPANSION AND INSTALLATION OF TRACK SHOE ASSEMBLY (PLUS TYPE TRACK SHOE)…1315
Expansion normal…1315
Installation…1315
WHOLE DISASSEMBLY AND ASSEMBLY OF TRACK SHOE ASSEMBLY (CONVENTIONAL TYPE TRACK SHOE)…1316
Special tools…1316
Whole disassembly…1316
Whole assembly…1321
WHOLE DISASSEMBLY AND ASSEMBLY OF TRACK SHOE (PLUS TYPE TRACK SHOE)…1336
Special tools…1336
90 OTHERS…1494
CONNECTOR ARRANGEMENT DRAWING AND ELECTRICAL CIRCUIT DIAGRAM…1496
CONNECTOR LIST…1496
CONNECTOR LOCATION VIEW…1500
CAB ELECTRICAL ACCESSORIES…1514
AIR CONDITIONER AND HEATER UNIT…1516
HYDRAULIC SYSTEM (VIEW 1 OF 2)…1518
VIEW (2 OF 2)…1520
IN CAB SWITCHES, RELAYS AND CONNECTORS (VIEW 1 OF 5)…1522
CAB HARNESS AND CONTROLLER CONNECTIONS (VIEW 2 OF 5 )…1524
ENGINE HARNESS AND CONTROLLER (VIEW 3 OF 5)…1526
MONITOR PANEL AND SWITCHES (VIEW 4 OF 5)…1528
KOMTRAX AND CONNECTORS (VIEW 5 OF 5)…1530
CEBM019109 – Crawler Dozer D51EX-22, D51PX-22 Shop Manual (SN-B10001&up)…1532
FOREWORD…0
CONTENTS…1533
SAFETY…1544
SAFETY NOTICE…1544
IMPORTANT SAFETY NOTICE…1544
GENERAL PRECAUTIONS…1544
PREPARATIONS FOR WORK…1544
PRECAUTIONS DURING WORK…1544
GENERAL…1546
HOW TO READ THE SHOP MANUAL…1547
VOLUMES…1547
DISTRIBUTION AND UPDATING…1547
FILING METHOD…1547
REVISED EDITION MARK…1547
REVISIONS…1547
SYMBOLS…1547
HOISTING INSTRUCTIONS…1548
HOISTING…1548
WIRE ROPES…1548
PUSH PULL COUPLER…1549
TYPE 1…1549
DISCONNECTION…1549
CONNECTION…1549
TYPE 2…1550
DISCONNECTION…1550
CONNECTION…1550
TYPE 3…1551
DISCONNECTION…1551
CONNECTION…1551
EXPLANATION OF MAINTENANCE STANDARD TERMS…1552
STANDARD TIGHTENING TORQUE…1554
BOLTS AND NUTS…1554
TIGHTENING TORQUE OF HOSE NUTS…1555
TIGHTENING TORQUE OF SPLIT FLANGE BOLTS…1555
TIGHTENING TORQUE FOR FLARED NUTS…1555
TIGHTENING TORQUES FOR O-RING BOSS PIPING JOINTS…1556
TABLE OF TIGHTENING TORQUES FOR O-RING BOSS PLUGS…1556
TORQUE TABLE FOR HOSES (TAPER SEAL TYPE AND FACE SEAL TYPE)…1556
ELECTRIC WIRE CODE…1557
CLASSIFICATION BY THICKNESS…1557
CLASSIFICATION BY COLOR AND CODE…1557
HOW TO READ ELECTRIC WIRE CODE…1558
CONVERSION TABLES…1561
METHOD OF USING THE CONVERSION TABLE…1561
COATING MATERIALS…1567
01 …1570
SPECIFICATION DRAWING…1571
D51EX, PX-22 POWER ANGLE, POWER TILT DOZER WITH ROPS CAB…1571
SPECIFICATION…1572
WEIGHT TABLE…1576
TABLE OF FUEL, COOLANT AND LUBRICANTS…1579
RECOMMENDED PRODUCTS OTHER THAN KOMATSU GENUINE OILS…1581
10 STRUCTURE, FUNCTION AND MAINTENANCE STANDARD…1582
ENGINE AND COOLING SYSTEM…1584
ENGINE RELATED PARTS…1584
COOLING SYSTEM…1586
COOLING FAN PUMP – SEE HYDRAULIC SYSTEM 2 (WORK EQUIPMENT AND FAN PUMP)…1589
COOLING FAN MOTOR…1590
OIL COOLER BYPASS VALVE…1596
CHARGE SAFETY VALVE…1599
POWER TRAIN…1601
POWER TRAIN…1601
POWER TRAIN SYSTEM…1602
DAMPER…1603
FINAL DRIVE…1604
PATH OF POWER TRANSMISSION…1607
UNDER CARRIAGE AND FRAME…1608
MAIN FRAME…1608
TRACK FRAME AND RECOIL SPRING…1609
SUSPENSION…1611
IDLER…1614
TRACK ROLLER…1616
CARRIER ROLLER…1620
TRACK SHOE…1626
HYDRAULIC SYSTEM 1 (HST)…1631
HST HYDRAULIC EQUIPMENT ARRANGEMENT DIAGRAM…1631
HST PUMP…1632
SAFETY-SUCTION VALVE…1640
TOWING VALVE…1643
HST MOTOR…1644
MOTOR CONTROL VALVE…1656
SOLENOID VALVE (3-SPOOL), EPC VALVE (2-SPOOL) AND TOWING VALVE…1656
SOLENOID VALVE…1658
EPC VALVE…1659
CHARGE PUMP…1663
HYDRAULIC SYSTEM 2 (WORK EQUIPMENT)…1665
CLSS (CLOSED CENTER LOAD SENSING SYSTEM)…1665
UNLOAD VALVE…1669
PRESSURE COMPENSATION VALVE…1675
LS BYPASS VALVE…1676
WORK EQUIPMENT HYDRAULIC ARRANGEMENT DIAGRAM…1677
WORK EQUIPMENT AND FAN PUMP…1678
SERVO VALVE…1683
CONTROL VALVE…1685
QUICK DROP VALVE…1697
BLADE PPC VALVE…1699
RIPPER/WINCH PPC VALVE…1705
HYDRAULIC TANK, FILTER…1709
ACCUMULATOR…1710
WORK EQUIPMENT…1711
WORK EQUIPMENT…1711
CUTTING EDGE AND END BIT…1716
RIPPER…1717
WORK EQUIPMENT CYLINDER…1718
LIFT CYLINDER…1718
TILT CYLINDER…1718
ANGLE CYLINDER…1719
RIPPER CYLINDER…1719
PISTON VALVE FOR ANGLE CYLINDER…1721
CAB AND ITS ATTACHMENTS…1722
ROPS CAB…1722
STEERING AND BRAKE CONTROL…1723
WORK EQUIPMENT CONTROL…1725
CAB DAMPER MOUNT…1727
AIR CONDITIONER…1728
AIR CONDITIONER AND FLOOR HEATER…1728
AIR CONDITIONER PIPING…1729
ELECTRICAL SYSTEM…1730
MONITOR SYSTEM…1730
ENGINE CONTROL…1732
ENGINE CONTROL SYSTEM…1733
COOLING CONTROL SYSTEM…1735
HST CONTROL SYSTEM…1737
GEAR SHIFT CONTROL SYSTEM…1738
GEAR SHIFTING BY OPERATOR…1738
SET TRAVEL SPEEDS CORRESPONDING TO GEAR SPEEDS…1739
CHANGING TRAVEL SPEED ACCORDING TO CHANGE OF ENGINE SPEED…1741
STRAIGHT TRAVEL CORRECTION CONTROL SYSTEM…1742
PARKING BRAKE CONTROL SYSTEM…1743
KOMTRAX SYSTEM…1745
SYSTEM COMPONENTS…1747
MONITOR PANEL…1747
ENGINE CONTROLLER…1751
HST CONTROLLER…1753
ELECTRIC LEVER (FOR TRAVEL)…1755
KOMTRAX TERMINAL…1757
SENSORS…1758
BRAKE OIL PRESSURE SENSOR…1759
HYDRAULIC OIL TEMPERATURE SENSOR…1760
HST CIRCUIT OIL PRESSURE SENSOR…1761
AIR CLEANER CLOGGING SENSOR…1762
DECELERATOR PEDAL POTENTIOMETER…1763
BRAKE PEDAL POTENTIOMETER…1763
FUEL CONTROL DIAL…1764
FUEL LEVEL SENSOR…1765
CHARGE FILTER CLOGGING SENSOR…1766
COOLANT TEMPERATURE SENSOR…1766
ENGINE OIL PRESSURE SWITCH…1767
ENGINE ROTATION SENSOR…1767
BOOST PRESSURE AND TEMPERATURE SENSOR…1768
WIF SENSOR…1768
HST MOTOR SPEED SENSOR…1769
20 STANDARD VALUE TABLES…1770
STANDARD VALUE TABLE FOR ENGINE…1771
STANDARD VALUE TABLE FOR CHASSIS…1772
PERFORMANCE MEASURING POSTURE AND METHOD…1777
30 TESTING AND ADJUSTING…1780
LIST OF TOOLS…1782
ENGINE…1785
ENGINE SPEED…1785
AIR INTAKE BOOST PRESSURE…1786
EXHAUST TEMPERATURE…1787
EXHAUST GAS COLOR…1789
VALVE CLEARANCE…1790
COMPRESSION PRESSURE…1793
BLOW-BY PRESSURE…1795
ENGINE OIL PRESSURE…1796
HANDLING CONTROLLER HIGH-VOLTAGE CIRCUIT…1797
FUEL SYSTEM…1798
HANDLING FUEL SYSTEM PARTS…1798
RELEASING RESIDUAL PRESSURE FROM FUEL SYSTEM…1798
BLEEDING AIR FROM FUEL CIRCUIT…1799
FUEL PRESSURE…1801
FUEL RETURN RATE AND LEAKAGE…1803
FUEL CIRCUIT FOR LEAKAGE…1806
FAN (WORK EQUIPMENT) PUMP PRESSURE…1807
FAN SPEED…1807
FAN SPEED SENSOR…1808
DECELERATOR PEDAL…1810
HST OIL PRESSURE…1812
MOTOR CONTROL VALVE OUTLET PRESSURE…1817
TRAVEL DEVIATION…1820
PARKING BRAKE LEVER…1821
BRAKE PERFORMANCE…1823
BRAKE PEDAL LINKAGE…1824
EMERGENCY RELEASE OF PARKING BRAKE…1826
IDLER CLEARANCE…1829
TRACK SHOE TENSION…1831
WORK EQUIPMENT…1832
OIL PRESSURE…1832
WORK EQUIPMENT PPC VALVE…1834
OIL PRESSURE…1834
PPC circuit connection diagram…1835
ADJUSTING PLAY OF WORK EQUIPMENT PPC VALVE 1…1836
LOCK LEVER ADJUSTMENT…1837
CYLINDER LEAKAGE…1838
HYDRAULIC CIRCUIT…1840
RELEASING RESIDUAL PRESSURE…1840
BLEEDING AIR…1841
BLADE CENTER BALL ADJUSTMENT…1842
BLADE PITCH BALL ADJUSTMENT…1842
DIODES…1843
PROCEDURE FOR TESTING…1843
MONITOR PANEL (EMMS) – SPECIAL FUNCTIONS…1845
PREPARATION WORK FOR TROUBLESHOOTING FOR ELECTRICAL SYSTEM…1906
ELECTRIC/HYDRAULIC DEVICES ARE ADJUSTED/REPLACED…1908
ITEMS TO BE ADJUSTED…1908
HST CONTROLLER ADJUSTMENT AFTER REPLACEMENT…1909
MONITOR PANEL ADJUSTMENT AFTER REPLACEMENT…1912
PM-CLINIC…1914
PM-CLINIC SERVICE…1914
PM-CLINIC INSPECTION SHEET (1/2)…1917
PM-CLINIC INSPECTION SHEET (2/2)…1918
PM-CLINIC UNDERCARRIAGE CHECK SHEET…1919
UNDERCARRIAGE TROUBLESHOOTING REPORT (NORMAL)…1920
UNDERCARRIAGE TROUBLESHOOTING REPORT (IMPACT)…1921
PM-CLINIC UNDERCARRIAGE CHECK SHEET…1922
UNDERCARRIAGE TROUBLESHOOTING REPORT (NORMAL)…1923
UNDERCARRIAGE TROUBLESHOOTING REPORT (IMPACT)…1924
40 TROBULESHOOTING …1926
POINTS TO REMEMBER WHEN TROUBLESHOOTING…1927
SEQUENCE OF EVENTS IN TROUBLESHOOTING…1929
PRECAUTIONS WHEN CARRYING OUT MAINTENANCE…1930
PRECAUTIONS WHEN HANDLING ELECTRICAL EQUIPMENT…1930
HANDLING ELECTRONIC CONTROL UNIT…1935
POINTS TO REMEMBER WHEN TROUBLESHOOTING ELECTRICAL CIRCUITS…1936
ELECTRIC WIRE CODE…1937
CLASSIFICATION BY THICKNESS…1937
CLASSIFICATION BY COLOR AND CODE…1937
HOW TO READ ELECTRIC WIRE CODE…1938
POINTS TO REMEMBER WHEN HANDLING HYDRAULIC EQUIPMENT…1940
CHECKS BEFORE TROUBLESHOOTING…1942
CATEGORIES AND METHOD OF USING TROUBLESHOOTING CHARTS…1943
TROUBLESHOOTING INDIVIDUAL ELECTRICAL CIRCUITS…1944
CONNECTION TABLE FOR CONNECTOR PIN NUMBERS…1947
T-ADAPTER TABLE…1971
MODE CHART…1975
40 …1978
TROUBLESHOOTING BY ERROR CODE…1984
INFORMATION IN TROUBLESHOOTING TABLE…1991
ERROR CODE [6091NX]…1993
HST CHARGE FILTER ELEMENT CLOGGING…1993
ERROR CODE [AA10NX]…1995
AIR CLEANER CLOGGING…1995
ERROR CODE [AB00MA]…1997
ALTERNATOR MALFUNCTION…1997
ERROR CODE [B@BAZG]…1998
ENGINE OIL LOWERING OF OIL PRESSURE…1998
ERROR CODE [B@BCNS]…1999
COOLANT OVERHEAT…1999
ERROR CODE [B@CRNS]…2000
HST OIL OVERHEATING…2000
ERROR CODE [B@CRZG]…2001
HST OIL LOWERING OF OIL PRESSURE…2001
ERROR CODE [CA111]…2002
ABNORMALITY IN ENGINE CONTROLLER…2002
ERROR CODE [CA115]…2003
ABNORMALITY IN NE AND BKUP SPEED SENSOR SIGNAL…2003
ERROR CODE [CA122]…2005
CHARGE PRESSURE SENSOR TOO HIGH…2005
ERROR CODE [CA123]…2007
CHARGE PRESSURE SENSOR TOO LOW…2007
ERROR CODE [CA131]…2009
DECELERATOR PEDAL SENSOR TOO HIGH…2009
ERROR CODE [CA132]…2011
DECELERATOR PEDAL SENSOR TOO LOW…2011
ERROR CODE [CA144]…2013
COOLANT TEMPERATURE SENSOR TOO HIGH…2013
ERROR CODE [CA145]…2015
COOLANT TEMPERATURE SENSOR TOO LOW…2015
ERROR CODE [CA153]…2017
CHARGE TEMPERATURE SENSOR TOO HIGH…2017
ERROR CODE [CA154]…2019
CHARGE TEMPERATURE SENSOR TOO low…2019
ERROR CODE [CA187]…2021
SENSOR POWER SORCE EXCESSIVELY LOW…2021
ERROR CODE [CA221]…2023
ATMOSPHERIC PRESSURE SENSOR TOO HIGH…2023
ERROR CODE [CA222]…2025
ATMOSPHERIC PRESSURE SENSOR TOO LOW…2025
ERROR CODE [CA227]…2027
SENSOR POWER SORCE EXCESSIVELY HIGH…2027
ERROR CODE [CA234]…2029
ENGINE OVERSPEED…2029
ERROR CODE [CA238]…2030
ABNORMAL POWER SOURCE FOR NE SPEED SENSOR…2030
ERROR CODE [CA271]…2031
IMV/PCV1 SHORT CIRCUITED…2031
ERROR CODE [CA272]…2033
IMV/PCV1 OPEN…2033
ERROR CODE [CA322]…2035
NO.1 INJECTOR SHOWING OPEN OR SHORT…2035
ERROR CODE [CA323]…2037
NO.5 INJECTOR SHOWING OPEN OR SHORT…2037
ERROR CODE [CA324]…2039
NO.3 INJECTOR SHOWING OPEN OR SHORT…2039
ERROR CODE [CA325]…2041
NO.6 INJECTOR SHOWING OPEN OR SHORT…2041
ERROR CODE [CA331]…2043
NO.2 INJECTOR SHOWING OPEN OR SHORT…2043
ERROR CODE [CA332]…2045
NO.4 INJECTOR SHOWING OPEN OR SHORT…2045
ERROR CODE [CA342]…2047
ENGINE CONTROLLER DATA MATCHING ERROR…2047
ERROR CODE [CA352]…2048
SENSOR POWER SOURCE TOO LOW…2048
ERROR CODE [CA386]…2049
SENSOR POWER SOURCE TOO HIGH…2049
ERROR CODE [CA428]…2051
WATER IN FUEL SENSOR VOLTAGE TOO HIGH…2051
ERROR CODE [CA429]…2053
WATER IN FUEL SENSOR VOLTAGE TOO LOW…2053
ERROR CODE [CA435]…2055
ABNORMAL ENGINE OIL PRESSURE SWITCH…2055
ERROR CODE [CA441]…2057
POWER SOURCE VOLTAGE IS TOO LOW…2057
ERROR CODE [CA442]…2059
POWER SOURCE VOLTAGE TOO HIGH…2059
ERROR CODE [CA449]…2061
COMMON RAIL PRESSURE TOO HIGH…2061
ERROR CODE [CA451]…2063
COMMON RAIL PRESSURE TOO HIGH…2063
ERROR CODE [CA452]…2065
COMMON RAIL PRESSURE TOO LOW…2065
ERROR CODE [CA488]…2067
CHARGE TEMPERATURE TOO HIGH AND TORQUE DERATED…2067
ERROR CODE [CA553]…2068
COMMON RAIL PRESSURE TOO HIGH…2068
ERROR CODE [CA559]…2069
LOSS OF PRESSURE FEED FROM SUPPLY PUMP…2069
ERROR CODE [CA689]…2071
ABNORMAL ENGINE NE SPEED SENSOR…2071
ERROR CODE [CA731]…2073
ABNORMAL ENGINE BKUP SPEED SENSOR PHASE…2073
ERROR CODE [CA757]…2075
LOSS OF ALL ENGINE CONTROLLER DATA…2075
ERROR CODE [CA778]…2077
ABNORMAL ENGINE BKUP SPEED SENSOR…2077
ERROR CODE [CA1633]…2079
ABNORMAL KOMNET…2079
ERROR CODE [CA2185]…2081
DECELERATOR PEDAL SENSOR POWER SOURCE TOO HIGH…2081
ERROR CODE [CA2186]…2082
DECELERATOR PEDAL SENSOR POWER SOURCE TOO LOW…2082
ERROR CODE [CA2249]…2083
LOSS OF PRESSURE FEED FROM SUPPLY PUMP (2)…2083
ERROR CODE [CA2311]…2085
ABNORMAL IMV SOLENOID…2085
ERROR CODE [CA2555]…2087
AIR INTAKE HEATER RELAY DISCONNECTION…2087
ERROR CODE [CA2556]…2089
AIR INTAKE HEATER RELAY SHORT CIRCUIT…2089
ERROR CODE [D130KA]…2091
NEUTRAL SAFETY RELAY DISCONNECTION…2091
ERROR CODE [D130KB]…2093
NEUTRAL SAFETY RELAY SHORT CIRCUIT…2093
ERROR CODE [DAFRKR]…2095
CAN COMMUNICATION MONITOR PANEL – HST CONTROLLER…2095
ERROR CODE [DAFRMC]…2097
CAN COMMUNICATION MONITOR PANEL – ENGINE CONTROLLER…2097
ERROR CODE [DAJ000]…2099
HST CONTROLLER MEMORY ERROR…2099
ERROR CODE [DAJ0KK]…2101
HST CONTROLLER LOWERING OF SOURCE VOLTAGE…2101
ERROR CODE [DAJ0KQ]…2103
HST CONTROLLER MACHINE CODE ERROR…2103
ERROR CODE [DAJ0KT]…2104
HST CONTROLLER MEMORY ERROR…2104
ERROR CODE [DAJ5KK]…2105
HST CONTROLLER POWER SUPPLY LOWING…2105
ERROR CODE [DAJ6KK]…2107
HST POWER SUPPLY LOWING…2107
ERROR CODE [DAJRKR]…2109
CAN COMMUNICATION HST CONTROLLER DEFECTIVE…2109
ERROR CODE [DB2RKR]…2111
CAN COMMUNICATION HST CONTROLLER DEFECTIVE…2111
ERROR CODE [DD12KA]…2113
SHIFT UP SWITCH DISCONNECTION…2113
ERROR CODE [DD12KB]…2115
SHIFT UP SWITCH SHORT CIRCUIT…2115
ERROR CODE [DD13KA]…2117
SHIFT DOWN SWITCH DISCONNECTION…2117
ERROR CODE [DD13KB]…2119
SHIFT DOWN SWITCH SHORT CIRCUIT…2119
ERROR CODE [DD14KB]…2121
TRAVEL LOCK LIMIT SWITCH 1 SHORT CIRCUIT…2121
ERROR CODE [DD1NL4]…2123
FAN ROTATION SELECTOR SWITCH DISAGREEMENT…2123
ERROR CODE [DDDCKB]…2125
REVERSE TRAVEL SPEED SWITCH SHORT CIRCUIT…2125
ERROR CODE [DDP6KA]…2127
BRAKE OIL PRESSURE SENSOR DISCONNECTION…2127
ERROR CODE [DDP6KB]…2129
BRAKE OIL PRESSURE SENSOR SHORT CIRCUIT…2129
ERROR CODE [DDP6MA]…2131
BRAKE OIL PRESSURE SENSOR MALFUNCTION…2131
ERROR CODE [DDQ2KA]…2133
TRAVEL LOCK LIMIT SWITCH 1 DISCONNECTION…2133
ERROR CODE [DDT0L4]…2135
SHIFT MODE SWITCH DISAGREEMENT OF ON/ OFF SIGNALS…2135
ERROR CODE [DDU1FS]…2137
TRAVEL LOCK LIMIT SWITCHES 1 AND 2 FIXING…2137
ERROR CODE [DDU1KA]…2139
TRAVEL LOCK LIMIT SWITCH 2 DISCONNECTION…2139
ERROR CODE [DDU1KY]…2141
TRAVEL LOCK LIMIT SWITCH 2 SHORT WITH POWER SUPPLY LINE…2141
ERROR CODE [DGS1KA]…2143
HST OIL TEMPERATURE SENSOR DISCONNECTION…2143
ERROR CODE [DGS1KX]…2145
HST OIL TEMPERATURE SENSOR OUT OF INPUT SIGNAL RANGE…2145
ERROR CODE [DHH5KA]…2146
LEFT HST PUMP PRESSURE SENSOR DISCONNECTION…2146
ERROR CODE [DHH5KB]…2148
LEFT HST PUMP PRESSURE SENSOR SHORT CIRCUIT…2148
ERROR CODE [DHH6KA]…2150
RIGHT HST PUMP PRESSURE SENSOR DISCONNECTION…2150
ERROR CODE [DHH6KB]…2152
RIGHT HST PUMP PRESSURE SENSOR SHORT CIRCUIT…2152
ERROR CODE [DK10KA]…2154
FUEL DIAL SENSOR DISCONNECTION…2154
ERROR CODE [DK10KB]…2156
FUEL DIAL SENSOR SHORT CIRCUIT…2156
ERROR CODE [DK30KA]…2158
STEERING ANGLE SENSOR 1 DISCONNECTION…2158
ERROR CODE [DK30KB]…2160
STEERING ANGLE SENSOR 1 SHORT CIRCUIT…2160
ERROR CODE [DK30KX]…2162
STEERING ANGLE SENSOR OUT OF INPUT SIGNAL RANGE…2162
ERROR CODE [DK30KZ]…2163
STEERING ANGLE SENSOR DISCONNECTION OR SHORT CIRCUIT…2163
ERROR CODE [DK30L8]…2164
STEERING ANGLE SENSOR DISAGREEMENT OF ANALOG SIGNALS…2164
ERROR CODE [DK31KA]…2166
STEERING ANGLE SENSOR DISCONNECTION…2166
ERROR CODE [DK31KB]…2168
STEERING ANGLE SENSOR 2 SHORT CIRCUIT…2168
ERROR CODE [DK40KA]…2170
BRAKE PEDAL SENSOR DISCONNECTION…2170
ERROR CODE [DK40KB]…2172
BRAKE PEDAL SENSOR SHORT CIRCUIT…2172
ERROR CODE [DK55KX]…2174
DIRECTIONAL POTENTIOMETER OUT OF INPUT SIGNAL RANGE…2174
ERROR CODE [DK55KZ]…2175
DIRECTIONAL POTENTIOMETER DISCONNECTION OR SHORT CIRCUIT…2175
ERROR CODE [DK55L8]…2176
DIRECTIONAL POTENTIOMETER DISAGREEMENT OF ANALOG SIGNALS…2176
ERROR CODE [DK56KA]…2178
DIRECTIONAL POTENTIOMETER 1 DISCONNECTION…2178
ERROR CODE [DK56KB]…2180
DIRECTIONAL POTENTIOMETER 1 SHORT CIRCUIT…2180
ERROR CODE [DK57KA]…2182
DIRECTIONAL POTENTIOMETER 2 DISCONNECTION…2182
ERROR CODE [DK57KB]…2184
DIRECTIONAL POTENTIOMETER 2 SHORT CIRCUIT…2184
ERROR CODE [DLM0KX]…2186
HST MOTOR SPEED SENSORS OUT OF INPUT SIGNAL RANGE…2186
ERROR CODE [DLM1KA]…2188
LEFT HST MOTOR SPEED SENSOR DISCONNECTION…2188
ERROR CODE [DLM1KB]…2190
LEFT HST MOTOR SPEED SENSOR: SHORT CIRCUIT…2190
ERROR CODE [DLM1MA]…2192
LEFT HST MOTOR SPEED SENSOR: MALFUNCTION…2192
ERROR CODE [DLM2KA]…2194
RIGHT HST MOTOR SPEED SENSOR DISCONNECTION…2194
ERROR CODE [DLM2KB]…2196
RIGHT HST MOTOR SPEED SENSOR SHORT CIRCUIT…2196
ERROR CODE [DLM2MA]…2198
RIGHT HST MOTOR SPEED SENSOR MALFUNCTION…2198
ERROR CODE [DLM3KA]…2200
FAN SPEED SENSOR DISCONNECTION…2200
ERROR CODE [DLM3KB]…2202
FAN SPEED SENSOR: SHORT CIRCUIT…2202
ERROR CODE [DN21FS]…2204
BRAKE PEDAL AND PROXIMITY SWITCH FIXING…2204
ERROR CODE [DV00KB]…2206
CAUTION BUZZER SHORT CIRCUIT…2206
ERROR CODE [DV20KB]…2207
BACK ALARM BUZZER SHORT CIRCUIT…2207
ERROR CODE [DW4BKA]…2208
PARKING BRAKE SOLENOID VALVE DISCONNECTION…2208
ERROR CODE [DW4BKB]…2210
PARKING BRAKE SOLENOID VALVE SHORT CIRCUIT…2210
ERROR CODE [DW4BKY]…2212
PARKING BRAKE SOLENOID VALVE SHORTED…2212
ERROR CODE [DW7BKA]…2213
FAN REVERSE SOLENOID VALVE DISCONNECTION…2213
ERROR CODE [DW7BKB]…2213
FAN REVERSE SOLENOID VALVE SHORT CIRCUIT…2214
ERROR CODE [DW7BKY]…2215
FAN REVERSE SOLENOID VALVE SHORTED…2215
ERROR CODE [DW7EKA]…2216
SLOW BRAKE SOLENOID VALVE DISCONNECTION…2216
ERROR CODE [DW7EKB]…2220
SLOW BRAKE SOLENOID VALVE SHORT CIRCUIT…2220
ERROR CODE [DW7EKY]…2222
SLOW BRAKE SOLENOID VALVE SHORTED…2222
ERROR CODE [DWN5KA]…2224
FAN EPC SOLENOID VALVE DISCONNECTION…2224
ERROR CODE [DWN5KB]…2226
FAN EPC SOLENOID VALVE SHORT CIRCUIT…2226
ERROR CODE [DWN5KY]…2228
FAN EPC SOLENOID VALVE SHORTED…2228
ERROR CODE [DXA4KA]…2230
LF HST PUMP EPC SOLENOID VALVE DISCONNECTION…2230
ERROR CODE [DXA4KB]…2232
LF HST PUMP EPC SOLENOID VALVE SHORT CIRCUIT…2232
ERROR CODE [DXA4KY]…2233
LF HST PUMP EPC SOLENOID VALVE SHORTED…2233
ERROR CODE [DXA5KA]…2234
LR HST PUMP EPC SOLENOID VALVE DISCONNECTION…2234
ERROR CODE [DXA5KB]…2236
LR HST PUMP EPC SOLENOID VALVE SHORT CIRCUIT…2236
ERROR CODE [DXA5KY]…2237
LR HST PUMP EPC SOLENOID VALVE SHORTED…2237
ERROR CODE [DXA6KA]…2238
RF HST PUMP EPC SOLENOID VALVE DISCONNECTION…2238
ERROR CODE [DXA6KB]…2240
RF HST PUMP EPC SOLENOID VALVE SHORT CIRCUIT…2240
ERROR CODE [DXA6KY]…2241
RF HST PUMP EPC SOLENOID VALVE SHORTED…2241
ERROR CODE [DXA7KA]…2242
RR HST PUMP EPC SOLENOID VALVE DISCONNECTION…2242
ERROR CODE [DXA7KB]…2243
RR HST PUMP EPC SOLENOID VALVE SHORT CIRCUIT…2243
ERROR CODE [DXA7KY]…2244
RR HST PUMP EPC SOLENOID VALVE SHORTED…2244
ERROR CODE [DXK1KA]…2245
LEFT HST MOTOR EPC SOLENOID VALVE DISCONNECTION…2245
ERROR CODE [DXK1KB]…2246
LEFT HST MOTOR EPC SOLENOID VALVE SHORT CIRCUIT…2246
ERROR CODE [DXK1KY]…2247
LEFT HST MOTOR EPC SOLENOID VALVE SHORTED…2247
ERROR CODE [DXK2KA]…2248
RIGHT HST MOTOR EPC SOLENOID VALVE DISCONNECTION…2248
ERROR CODE [DXK2KB]…2249
RIGHT HST MOTOR EPC SOLENOID VALVE SHORT CIRCUIT…2249
ERROR CODE [DXK2KY]…2250
RIGHT HST MOTOR EPC SOLENOID VALVE SHORTED…2250
40 TROUBLESHOOTING (E-MODE)…2254
BEFORE CARRYING OUT TROUBLESHOOTING (E-MODE)…2256
CONNECTION TABLE OF FUSE BOX…2256
INFORMATION IN TROUBLESHOOTING TABLE…2258
E-1…2259
STARTING MOTOR DOES NOT ROTATE…2259
E-2…2263
ENGINE IS NOT PRE-HEATED…2263
E-3…2267
WHEN STARTING SWITCH IS TURNED ON, ANY ITEM DOES NOT LIGHT…2267
E-4…2269
CHARGE LEVEL CAUTION FLASHES WHILE ENGINE IS RUNNING…2269
E-5…2271
EMERGENCY WARNING ITEMS FLASH WHILE ENGINE IS RUNNING…2271
E-6…2275
PRE-HEAT LAMP DOES NOT LIGHT DURING PRE-HEATING OPERATION…2275
E-7…2277
COOLANT TEMPERATURE GAUGE DOES NOT INDICATE CORRECTLY…2277
E-8…2278
HST OIL TEMPERATURE GAUGE DOES NOT INDICATE CORRECTLY…2278
E-9…2279
FUEL LEVEL GAUGE DOES NOT INDICATE PROPERLY…2279
E-10…2281
TRAVEL INDICATOR DOES NOT DISPLAY NORMALLY…2281
E-11…2281
MULTI-INFORMATION UNIT DOES NOT DISPLAY NORMALLY…2281
E-12…2282
CAUTION LAMP DOES NOT FLASH OR DOES NOT GO OFF…2282
E-13…2283
CAUTION BUZZER DOES NOT SOUND OR DOES NOT STOP…2283
E-14…2285
REVERSE TRAVEL SPEED SETTING SWITCH DOES NOT FUNCTION…2285
E-15…2287
SHIFT MODE SWITCH DOES NOT FUNCTION…2287
E-16…2289
BUZZER CANCEL SWITCH DOES NOT FUNCTION…2289
E-17…2291
INFORMATION SWITCH DOES NOT FUNCTION…2291
E-18…2293
THE FAN CLEANING DOES NOT OPERATE OR CANNOT BE RESET…2293
E-19…2295
BACKUP ALARM DOES NOT SOUND…2295
E-20…2296
THE HORN DOES NOT SOUND OR DOES NOT STOP…2296
E-21…2297
WORK EQUIPMENT DOES NOT MOVE…2297
E-22…2299
HEAD LAMP OR REAR LAMP DOES NOT LIGHT UP…2299
E-23…2303
FOOT HEATER DOES NOT OPERATE…2303
E-24…2307
AIR CONDITIONER DOES NOT OPERATE [CAB SPECIFICATION]…2307
E-25…2312
WIPER AND WASHER DO NOT OPERATE [CAB SPECIFICATION]…2312
E-26…2325
KOMTRAX SYSTEM DOES NOT OPERATE NORMALLY…2325
40 TROUBLESHOOTING (H-MODE)…2328
INFORMATION IN TROUBLESHOOTING TABLE…2329
H-1…2330
RIGHT AND LEFT TRAVEL SYSTEMS INOPERABLE…2330
H-2…2332
RIGHT OR LEFT TRAVEL SYSTEM DOES NOT OPERATE…2332
H-3…2333
RIGHT OR LEFT TRAVEL SYSTEM DOES NOT OPERATE…2333
H-4…2334
SPEED OR POWER OF TRAVEL IS LOW…2334
H-5…2335
GEAR IS NOT SHIFTED…2335
H-6…2336
LARGE SHOCKS ARE MADE WHEN MACHINE STARTS AND STOPS TRAVEl…2336
H-7…2337
MACHINE DEVIATES LARGELY DURING TRAVEL…2337
H-8…2338
HYDRAULIC DRIFT OF TRAVEL IS LARGE…2338
H-9…2339
ENGINE STALLS OR SPEED LOWERS EXTREMELY DURING TRAVEl…2339
H-10…2340
ABNORMAL SOUND COMES OUT FROM AROUND HST PUMP AND MOTOR…2340
H-11…2341
WORK EQUIPMENT DOSE NOT OPERATE AT ALL…2341
H-12…2342
SPEED OR POWER OF WHOLE WORK EQUIPMENT IS LOW…2342
H-13…2343
SPEED OR POWER OF LIFTING BLADE IS LOW…2343
H-14…2344
SPEED OR POWER OF TILTING BLADE IS LOW…2344
H-15…2345
SPEED OR POWER OF ANGLING BLADE IS LOW…2345
H-16…2346
TIME LAG IN LIFTING BLADE IS LARGE…2346
H-17…2347
HYDRAULIC DRIFT OF LIFTING BLADE IS LARGE…2347
H-18…2348
HYDRAULIC DRIFT OF TILTING BLADE IS LARGE…2348
H-19…2349
ABNORMAL SOUND COMES FROM WORK EQUIPMENT PUMP AND CONTROL VALVE…2349
H-20…2350
HST OIL TEMPERATURE RISES TOO HIGH…2350
H-21…2351
FAN SPEED IS ABNORMAL (HIGH, LOW, OR 0 RPM)…2351
40 TROUBLESHOOTING (S-MODE)…2352
METHOD OF USING TROUBLESHOOTING CHARTS…2353
(S-1) ENGINE STARTING PERFORMANCE IS POOR…2357
(S-2) ENGINE DOES NOT CRANK…2358
ENGINE CRANKS BUT NO EXHAUST SMOKE COMES OUT OF STACK…2359
SMOKE COMES OUT OF STACK BUT ENGINE DOES NOT START…2360
(S-3) ENGINE DOES NOT RUN SMOOTHLY…2361
(S-4) ENGINE STOPS DURING OPERATIONS…2362
(S-5) ENGINE SPEED HUNTS…2363
(S-6) ENGINE LACKS POWER…2364
(S-7) EXHAUST SMOKE IS BLACK…2366
(S-8) OIL CONSUMPTION IS EXCESSIVE OR EXHAUST SMOKE IS BLUE…2367
(S-9) OIL BECOMES CONTAMINATED QUICKLY…2368
(S-10) FUEL CONSUMPTION IS EXCESSIVE…2369
(S-11) OIL FOUND IN COOLANT, OR COOLANT SPURTS FROM RADIATOR…2370
(S-12) OIL PRESSURE CAUTION LAMP LIGHTS UP…2371
(S-13) OIL LEVEL RISES (COOLANT OR FUEL FOUND IN OIL)…2372
(S-14) COOLANT TEMPERATURE TOO HIGH (OVERHEATING)…2373
(S-15) ABNORMAL NOISE IS HEARD WHEN ENGINE IS RUNNING…2374
(S-16) EXCESSIVE VIBRATION WHEN ENGINE IS RUNNING…2375
50 DISASSEMBLY AND ASSEMBLY…2376
HOW TO USE THIS MANUAL…2379
REMOVAL AND INSTALLATION OF COMPONENTS…2379
Special Tools…2379
OVERHAUL OF COMPONENTS…2380
Special Tools…2380
Disassembly Procedures…2380
Assembly Procedures…2380
PRECAUTIONS WHEN CARRYING OUT AN OPERATION…2381
SPECIAL TOOL LIST…2383
SKETCH OF SPECIAL TOOLS…2390
CONNECTOR REPAIR PROCEDURES…2405
CONTACT TERMINAL REMOVAL (HD30 TYPE)…2405
STRIPPING INSULATION…2406
CRIMPING CONTACT TERMINAL (HD30 TYPE)…2407
INSERTION OF CONTACT TERMINAL (HD30 TYPE)…2408
CONTACT TERMINAL REMOVAL (DT TYPE)…2409
STRIPPING INSULATION…2410
CRIMPING CONTACT TERMINAL (DT TYPE)…2411
INSERTION OF CONTACT TERMINAL (DT TYPE)…2412
NOSE GUARD (HOOD)…2414
REMOVAL…2414
OPENING FRONT GRILL…2414
REMOVING SIDE PANELS…2415
DISCONNECTING HOOD-RELATED COMPONENTS…2415
REMOVAL OF HOOD…2416
INSTALLATION…2418
MUFFLER AND EXHAUST STACK…2420
REMOVAL…2420
INSTALLATION…2421
CAB…2422
REMOVAL…2422
FLOOR ACCESS PLATE…2425
LIFTING CAB OFF MACHINE…2428
INSTALLATION…2431
MONITOR PANEL AND HST CONTROLLER…2436
REMOVAL…2436
INSTALLATION…2438
KOMTRAX CONTROLLER…2439
REMOVAL…2439
INSTALLATION…2439
SEAT…2440
REMOVAL…2440
INSTALLATION…2440
AIR CONDITIONER/HEATER…2441
DISASSEMBLY OF AIR CONDITIONER…2441
REMOVING CONDENSER…2442
BLOWER MOTORS AND EVAPORATOR…2444
ASSEMBLY OF AIR CONDITIONER…2445
FOOT HEATER…2446
REMOVAL…2446
INSTALLATION…2447
FOOT HEATER OVERHAUL PROCEDURES…2448
OVERHAUL PROCEDURES…2448
ASSEMBLY PROCEDURES…2450
ENGINE AND HST PUMP…2452
REMOVAL…2452
BELLY PANS…2452
DRAINING THE COOLING SYSTEM…2452
DRAINING THE HYDRAULIC SYSTEM…2453
DISCONNECTING COMPONENTS…2454
LIFTING ENGINE AND HST PUMP ASSEMBLY…2460
INSTALLATION…2462
INSTALL ENGINE AND HST PUMP ASSEMBLY…2462
REMOVAL FROM ENGINE…2464
INSTALLATION TO ENGINE…2467
DRIVE DAMPENER…2468
REMOVAL…2468
INSTALLATION…2469
HST PUMP OVERHAUL PROCEDURES…2470
DISASSEMBLY PROCEDURES…2470
REMOVAL OF ACCESSORIES…2470
REMOVAL OF REAR PUMP…2471
REMOVAL OF END CAP…2471
DISASSEMBLY OF CYLINDER BLOCK AND PISTONS…2472
DISASSEMBLY OF ROCKER CAM…2473
REMOVAL OF FRONT SHAFT…2474
DISASSEMBLY OF SHAFT…2475
DISASSEMBLY OF FRONT COVER…2476
DISASSEMBLY FRONT SERVO PISTON…2477
DISASSEMBLY OF END CAP…2478
DISASSEMBLY OF REAR PUMP…2478
DISASSEMBLY OF REAR SHAFT…2478
ASSEMBLY PROCEDURES…2479
INSTALLATION OF REAR SERVO PISTON…2480
INSTALLATION OF REAR COVER…2482
INSTALLATION OF REAR SHAFT…2483
ASSEMBLY OF REAR ROCKER CAM…2484
INSTALLATION OF REAR CYLINDER BLOCK AND PISTON…2485
ASSEMBLY OF END CAP…2486
ASSEMBLY OF FRONT COVER…2488
INSTALLATION OF FRONT OIL SEAL…2488
INSTALLATION OF END CAP…2488
INSTALLATION OF REAR PUMP…2489
INSTALLATION OF ACCESSORIES…2490
WORK EQUIPMENT PUMP OVERHAUL PROCEDURES…2491
DISASSEMBLY PROCEDURES…2491
PUMP…2491
(PC VALVE)…2492
(LS VALVE)…2492
REMOVAL OF END CAP…2493
DISASSEMBLY OF CYLINDER BLOCK AND PISTON…2493
DISASSEMBLY OF SHAFT ASSEMBLY…2494
DISASSEMBLY OF ROCKER CAM…2496
REMOVAL OF BALLS AND PISTON…2496
ASSEMBLY PROCEDURES…2498
INSTALLATION OF PUMP CASE…2498
INSTALLATION OF ROCKER CAM…2498
ASSEMBLY AND INSTALLATION OF SHAFT…2499
INSTALLATION OF OIL SEAL…2500
INSTALLATION OF CYLINDER BLOCK AND PISTON…2501
INSTALLATION OF END CAP…2502
ASSEMBLY OF SERVO VALVE…2502
INSTALLATION OF SERVO VALVE ASSEMBLY…2504
REMOVAL…2505
INSTALL…2506
CHARGE PUMP OVERHAUL PROCEDURES…2507
TOOLS REQUIRED…2507
DISASSEMBLY PROCEDURES…2507
INSPECT PARTS FOR WEAR…2511
ASSEMBLY PROCEDURES…2513
GENERAL NOTES…2513
PLACING PUMP BACK INTO SERVICE…2518
DIESEL ENGINE OVERHAUL PROCEDURES…2519
DISASSEMBLY OF EXTERNAL COMPONENTS…2519
PREPARATION WORK…2519
STARTING MOTOR…2520
ENGINE SLING BRACKET ON REAR SIDE…2520
FAN PULLEY…2520
VIBRATION DAMPER AND CRANKSHAFT PULLEY…2520
BELT TENSIONER…2521
FAN HUB…2521
ALTERNATOR…2521
THERMOSTAT…2522
WATER PUMP…2522
TURBOCHARGER AND EXHAUST MANIFOLD…2522
FUEL FILTER ASSEMBLY…2523
WIRING HARNESS ASSEMBLY…2523
FUEL PIPING AND COMMON RAIL…2524
DISASSEMBLY OF ENGINE TOP END…2525
INTAKE MANIFOLD…2525
VALVE COVER HOUSING…2525
ROCKER ARM ASSEMBLY AND CROSSHEAD…2526
PUSH RODS…2526
FUEL INJECTORS…2526
CYLINDER HEAD…2527
REMOVAL OF OIL COOLER, ENGINE CONTROLLER AND FUEL PUMP…2529
OIL COOLER…2529
ENGINE CONTROLLER…2529
FUEL SUPPLY PUMP…2530
DISASSEMBLY OF ENGINE LOWER END…2531
FLYWHEEL…2531
REAR OIL SEAL…2531
FLYWHEEL HOUSING…2532
OIL PAN…2532
FRONT COVER…2532
OIL PUMP…2533
CAMSHAFT…2533
GEAR HOUSING…2534
PISTONS AND CONNECTING RODS…2534
CRANKSHAFT…2535
PISTON COOLING NOZZLES…2537
TAPPETS…2537
CYLINDER BLOCK…2537
ASSEMBLY OF ENGINE LOWER END…2538
PREPARATION WORK…2538
TAPPETS…2538
PISTON COOLING NOZZLE…2538
CRANKSHAFT…2539
MAIN CAP MOUNTING BOLTS…2540
PISTON AND CONNECTING ROD ASSEMBLY…2541
GEAR HOUSING…2545
CAMSHAFT…2546
FLYWHEEL HOUSING…2547
REAR OIL SEAL…2548
FLYWHEEL…2549
OIL PUMP…2550
FRONT COVER…2551
OIL PAN…2552
VIBRATION DAMPER…2553
INSTALLATION OF OIL COOLER, ENGINE CONTROLLER AND FUEL PUMP…2554
FUEL SUPPLY PUMP…2554
ENGINE CONTROLLER…2554
OIL COOLER…2554
CYLINDER HEAD…2556
FUEL INJECTORS…2558
PUSH RODS…2559
ROCKER ARM ASSEMBLY…2559
ADJUSTING VALVE CLEARANCE…2559
VALVE COVER HOUSING…2560
AIR INTAKE MANIFOLD COVER…2561
ASSEMBLY OF EXTERNAL COMPONENTS…2563
PREPARATION WORK…2563
HARNESS ASSEMBLY…2563
FUEL FILTER ASSEMBLY…2563
EXHAUST MANIFOLD AND TURBOCHARGER…2563
WATER PUMP…2564
THERMOSTAT…2564
ALTERNATOR…2565
FAN HUB…2565
BELT TENSIONER…2566
FAN PULLEY…2566
ENGINE SLING BRACKET ON REAR SIDE…2566
STARTER MOTOR…2566
REFILLING WITH OIL…2567
TRACK SYSTEM…2569
SPREADING THE TRACK…2569
(CONVENTIONAL TYPE TRACK SHOE)…2569
Whole disassembly…2593
Whole assembly…2596
1. When recycling for lubricated track…2596
FIELD DISASSEMBLY AND ASSEMBLY OF ONE LINK (CONVENTIONAL TYPE TRACK SHOE)…2606
Special tools…2606
Disassembly…2606
Assembly…2608
FIELD DISASSEMBLY AND ASSEMBLY OF ONE LINK (PLUS TYPE TRACK SHOE)…2614
Special tools…2614
Disassembly…2615
Assembly…2619
TRACK FRAME…2622
REMOVAL OF TRACK FRAME…2622
REMOVING TRACKS…2622
TRACK FRAME REMOVAL PREPARATIONS…2625
LIFTING TRACK FRAME FROM MACHINE…2627
FRONT TRACK IDLER…2631
REMOVING FRONT IDLER…2631
PULLING IDLER FROM TRACK FRAME…2632
INSTALLING FRONT IDLER…2634
TRACK ROLLER…2635
REMOVAL…2635
INSTALLATION…2635
TRACK ROLLER OVERHAUL PROCEDURES…2636
DISASSEMBLY…2636
ASSEMBLY…2637
CARRIER ROLLER OVERHAUL PROCEDURES…2641
DISASSEMBLY…2641
ASSEMBLY…2642
FINAL DRIVE…2643
FINAL DRIVE REMOVAL…2643
INSTALLING THE FINAL DRIVE…2647
FINAL DRIVE OVERHAUL PROCEDURES…2649
DISASSEMBLY PROCEDURES…2649
DRAINING OIL…2649
COVER…2650
RING GEAR…2650
NO. 1 PLANETARY CARRIER ASSEMBLY…2651
NO. 1 SUN GEAR…2651
NO. 2 SUN GEAR…2651
NO. 2 PLANETARY CARRIER ASSEMBLY…2652
HUB ASSEMBLY…2653
NO.2 PLANETARY CARRIER (HST MOTOR ASSEMBLY)…2654
ASSEMBLY OF FINAL DRIVE…2655
NO.2 PLANETARY CARRIER (HST MOTOR ASSEMBLY)…2655
ASSEMBLY OF HUB…2655
NO. 2 PLANETARY CARRIER ASSEMBLY…2658
NO. 2 SUN GEAR…2659
NO. 1 SUN GEAR…2659
NO. 1 PLANETARY CARRIER ASSEMBLY…2659
RING GEAR…2660
COVER…2661
REFILLING WITH OIL…2661
TRAVEL MOTOR OVERHAUL PROCEDURES…2663
DISASSEMBLY PROCEDURES…2663
TRAVEL MOTOR…2663
REMOVAL OF END COVER…2663
DISASSEMBLY OF END COVER…2664
REMOVAL OF RELIEF VALVE…2664
DISASSEMBLY OF SHUTTLE VALVE…2665
REMOVAL OF CYLINDER BLOCK…2665
REMOVAL OF PISTONS…2665
DISASSEMBLY OF BRAKE AND PISTON…2666
REMOVAL AND DISASSEMBLY OF DRIVE SHAFT…2666
REMOVAL OF OIL SEAL…2667
ASSEMBLY PROCEDURES…2668
INSTALLATION OF MOTOR CASE…2668
Install of oil seal…2668
ASSEMBLY OF DRIVE SHAFT…2674
ASSEMBLY OF PISTONS…2675
INSTALLATION OF DRIVE SHAFT ASSEMBLY…2675
INSTALLATION OF DISCS AND PLATES…2676
INSTALLATION OF BRAKE PISTON…2676
ASSEMBLY OF END COVER…2676
ASSEMBLY OF SHUTTLE VALVE…2677
ASSEMBLY OF MAIN PISTON…2677
INSTALLATION OF MAIN VALVE…2678
INSTALLATION OF VALVE PLATE…2678
NSTALLATION OF END COVER…2679
CHECK OF SHAFT ROTATION TORQUE…2680
FAN MOTOR…2681
REMOVAL PROCEDURES…2681
DISCONNECTING THE GRILL FROM THE FAN…2681
DISCONNECTING HYDRAULIC FAN MOTOR…2682
REMOVING THE FAN GUARD…2683
REMOVING THE FAN MOTOR…2684
INSTALLATION PROCEDURES…2685
FAN MOTOR OVERHAUL PROCEDURES…2687
DISASSEMBLY PROCEDURES…2687
REMOVAL OF END COVER…2687
DISASSEMBLY OF END COVER…2687
DISASSEMBLY OF PILOT VALVE…2688
CYLINDER BLOCK, SHAFT AND PISTON…2689
DISASSEMBLY OF CYLINDER BLOCK AND PISTON…2689
DISASSEMBLY OF SHAFT…2690
DISASSEMBLY OF MOTOR CASE…2690
ASSEMBLY PROCEDURES…2691
INSTALLATION OF MOTOR CASE…2691
ASSEMBLY AND INSTALLATION OF SHAFT…2691
ASSEMBLY OF CYLINDER BLOCK AND PISTON…2692
INSTALLATION OF CYLINDER BLOCK AND PISTON…2693
INSTALLATION OF OIL SEAL…2694
ASSEMBLY OF END COVER…2694
INSTALLATION OF END COVER…2696
CHECK OF SHAFT ROTATION TORQUE…2697
DB 12 VALVE…2699
REMOVAL…2699
INSTALLATION…2702
COOLING PACKAGE…2703
REMOVING THE GRILL AND COOLING FAN ASSEMBLY…2703
REMOVING THE GRILL FRAME…2703
REMOVING THE COOLING FAN ASSEMBLY…2710
REMOVING THE COOLING PACKAGE…2714
REMOVING THE FAN SHROUD…2714
REMOVING THE RADIATOR…2717
REMOVING THE OIL COOLER…2719
REMOVING THE AIR CHARGE COOLER…2720
INSTALLING THE COOLING PACKAGE…2722
INSTALLING THE GRILL AND COOLING FAN ASSEMBLY…2723
FUEL TANK…2727
REMOVING THE FUEL TANK…2727
PREPARATIONS FOR REMOVAL…2727
LIFTING THE FUEL TANK OFF THE MACHINE…2730
INSTALLING THE FUEL TANK…2731
HYDRAULIC TANK…2732
REMOVING THE HYDRAULIC TANK…2732
PREPARATIONS FOR REMOVAL…2732
LIFTING THE HYDRAULIC TANK OFF THE MACHINE…2736
INSTALLING THE HYDRAULIC TANK…2738
WORK EQUIPMENT…2739
REMOVING OR INSTALLING PINS…2739
FRONT BLADE, TILT AND ANGLE CYLINDERS…2740
REMOVAL…2740
ADJUSTING BLADE CENTER BALL AND PITCH ROD PLAY…2745
PITCH ROD…2745
CENTER BALL…2746
INSTALLATION…2746
“C” FRAME…2747
REMOVAL…2747
INSTALLATION…2749
LIFT CYLINDERS…2750
REMOVAL…2750
INSTALLATION…2751
CYLINDER OVERHAUL PROCEDURES…2752
DISASSEMBLY PROCEDURES…2752
PISTON AND ROD…2752
PISTON AND HEAD ASSEMBLY…2753
DISASSEMBLY OF GLAND NUT…2753
ASSEMBLY PROCEDURES…2753
GLAND NUT ASSEMBLY AND PISTON ASSEMBLY…2753
DISASSEMBLY OF PISTON…2754
PISTON ROD ASSEMBLY…2755
EXPANSION AND INSTALLATION OF TRACK SHOE ASSEMBLY…2571
(PLUS TYPE TRACK SHOE)…2571
Expansion normal…2571
Installation…2571
WHOLE DISASSEMBLY AND ASSEMBLY OF TRACK SHOE ASSEMBLY (CONVENTIONAL TYPE TRACK SHOE)…2572
Special tools…2572
Whole disassembly…2572
Whole assembly…2577
WHOLE DISASSEMBLY AND ASSEMBLY OF TRACK SHOE (PLUS TYPE TRACK SHOE)…2592
Special tools…2592
90 OTHERS…2756
CONNECTOR ARRANGEMENT DRAWING AND ELECTRICAL CIRCUIT DIAGRAM…2758
CONNECTOR LIST…2758
CONNECTOR LOCATION VIEW…2762
CAB ELECTRICAL ACCESSORIES…2776
AIR CONDITIONER AND HEATER UNIT…2778
HYDRAULIC SYSTEM (VIEW 1 OF 2)…2780
VIEW (2 OF 2)…2782
IN CAB SWITCHES, RELAYS AND CONNECTORS (VIEW 1 OF 5)…2784
CAB HARNESS AND CONTROLLER CONNECTIONS (VIEW 2 OF 5 )…2786
ENGINE HARNESS AND CONTROLLER (VIEW 3 OF 5)…2788
MONITOR PANEL AND SWITCHES (VIEW 4 OF 5)…2790
KOMTRAX AND CONNECTORS (VIEW 5 OF 5)…2792
CEBM019110 – Crawler Dozer D51EX-22, D51PX-22 Shop Manual (SN-B10001&up)…2794
00 …2796
CONTENTS…2797
SAFETY…2808
SAFETY NOTICE…2808
IMPORTANT SAFETY NOTICE…2808
GENERAL PRECAUTIONS…2808
PREPARATIONS FOR WORK…2808
PRECAUTIONS DURING WORK…2808
GENERAL…2810
HOW TO READ THE SHOP MANUAL…2811
VOLUMES…2811
DISTRIBUTION AND UPDATING…2811
FILING METHOD…2811
REVISED EDITION MARK…2811
REVISIONS…2811
SYMBOLS…2811
HOISTING INSTRUCTIONS…2812
HOISTING…2812
WIRE ROPES…2812
PUSH PULL COUPLER…2813
TYPE 1…2813
DISCONNECTION…2813
CONNECTION…2813
TYPE 2…2814
DISCONNECTION…2814
CONNECTION…2814
TYPE 3…2815
DISCONNECTION…2815
CONNECTION…2815
EXPLANATION OF MAINTENANCE STANDARD TERMS…2816
STANDARD TIGHTENING TORQUE…2818
BOLTS AND NUTS…2818
TIGHTENING TORQUE OF HOSE NUTS…2819
TIGHTENING TORQUE OF SPLIT FLANGE BOLTS…2819
TIGHTENING TORQUE FOR FLARED NUTS…2819
TIGHTENING TORQUES FOR O-RING BOSS PIPING JOINTS…2820
TABLE OF TIGHTENING TORQUES FOR O-RING BOSS PLUGS…2820
TORQUE TABLE FOR HOSES (TAPER SEAL TYPE AND FACE SEAL TYPE)…2820
ELECTRIC WIRE CODE…2821
CLASSIFICATION BY THICKNESS…2821
CLASSIFICATION BY COLOR AND CODE…2821
HOW TO READ ELECTRIC WIRE CODE…2822
CONVERSION TABLES…2825
METHOD OF USING THE CONVERSION TABLE…2825
COATING MATERIALS…2831
01 GENERAL…2834
SPECIFICATION DRAWING…2835
D51EX, PX-22 POWER ANGLE, POWER TILT DOZER WITH ROPS CAB…2835
SPECIFICATION…2836
WEIGHT TABLE…2840
TABLE OF FUEL, COOLANT AND LUBRICANTS…2843
RECOMMENDED PRODUCTS OTHER THAN KOMATSU GENUINE OILS…2845
10 STRUCTURE, FUNCTION ANDMAINTENANCE STANDARD…2846
ENGINE AND COOLING SYSTEM…2848
ENGINE RELATED PARTS…2848
COOLING SYSTEM…2850
COOLING FAN PUMP – SEE HYDRAULIC SYSTEM 2 (WORK EQUIPMENT AND FAN PUMP)…2853
COOLING FAN MOTOR…2854
OIL COOLER BYPASS VALVE…2860
CHARGE SAFETY VALVE…2863
POWER TRAIN…2865
POWER TRAIN…2865
POWER TRAIN SYSTEM…2866
DAMPER…2867
FINAL DRIVE…2868
PATH OF POWER TRANSMISSION…2871
UNDER CARRIAGE AND FRAME…2872
MAIN FRAME…2872
TRACK FRAME AND RECOIL SPRING…2873
SUSPENSION…2875
IDLER…2878
TRACK ROLLER…2880
CARRIER ROLLER…2884
TRACK SHOE…2890
HYDRAULIC SYSTEM 1 (HST)…2895
HST HYDRAULIC EQUIPMENT ARRANGEMENT DIAGRAM…2895
HST PUMP…2896
SAFETY-SUCTION VALVE…2904
TOWING VALVE…2907
HST MOTOR…2908
MOTOR CONTROL VALVE…2920
SOLENOID VALVE (3-SPOOL), EPC VALVE (2-SPOOL) AND TOWING VALVE…2920
SOLENOID VALVE…2922
EPC VALVE…2923
CHARGE PUMP…2927
HYDRAULIC SYSTEM 2 (WORK EQUIPMENT)…2929
CLSS (CLOSED CENTER LOAD SENSING SYSTEM)…2929
UNLOAD VALVE…2933
PRESSURE COMPENSATION VALVE…2939
LS BYPASS VALVE…2940
WORK EQUIPMENT HYDRAULIC ARRANGEMENT DIAGRAM…2941
WORK EQUIPMENT AND FAN PUMP…2942
SERVO VALVE…2947
CONTROL VALVE…2949
QUICK DROP VALVE…2961
BLADE PPC VALVE…2963
RIPPER/WINCH PPC VALVE…2969
HYDRAULIC TANK, FILTER…2973
ACCUMULATOR…2974
WORK EQUIPMENT…2975
WORK EQUIPMENT…2975
CUTTING EDGE AND END BIT…2980
RIPPER…2981
WORK EQUIPMENT CYLINDER…2982
LIFT CYLINDER…2982
TILT CYLINDER…2982
ANGLE CYLINDER…2983
RIPPER CYLINDER…2983
PISTON VALVE FOR ANGLE CYLINDER…2985
CAB AND ITS ATTACHMENTS…2986
ROPS CAB…2986
STEERING AND BRAKE CONTROL…2987
WORK EQUIPMENT CONTROL…2989
CAB DAMPER MOUNT…2991
AIR CONDITIONER…2992
AIR CONDITIONER AND FLOOR HEATER…2992
AIR CONDITIONER PIPING…2993
ELECTRICAL SYSTEM…2994
MONITOR SYSTEM…2994
ENGINE CONTROL…2996
ENGINE CONTROL SYSTEM…2997
COOLING CONTROL SYSTEM…2999
HST CONTROL SYSTEM…3001
GEAR SHIFT CONTROL SYSTEM…3002
GEAR SHIFTING BY OPERATOR…3002
SET TRAVEL SPEEDS CORRESPONDING TO GEAR SPEEDS…3003
CHANGING TRAVEL SPEED ACCORDING TO CHANGE OF ENGINE SPEED…3005
STRAIGHT TRAVEL CORRECTION CONTROL SYSTEM…3006
PARKING BRAKE CONTROL SYSTEM…3007
KOMTRAX SYSTEM…3009
SYSTEM COMPONENTS…3011
MONITOR PANEL…3011
ENGINE CONTROLLER…3015
HST CONTROLLER…3017
ELECTRIC LEVER (FOR TRAVEL)…3019
KOMTRAX TERMINAL…3021
SENSORS…3022
BRAKE OIL PRESSURE SENSOR…3023
HYDRAULIC OIL TEMPERATURE SENSOR…3024
HST CIRCUIT OIL PRESSURE SENSOR…3025
AIR CLEANER CLOGGING SENSOR…3026
DECELERATOR PEDAL POTENTIOMETER…3027
BRAKE PEDAL POTENTIOMETER…3027
FUEL CONTROL DIAL…3028
FUEL LEVEL SENSOR…3029
CHARGE FILTER CLOGGING SENSOR…3030
COOLANT TEMPERATURE SENSOR…3030
ENGINE OIL PRESSURE SWITCH…3031
ENGINE ROTATION SENSOR…3031
BOOST PRESSURE AND TEMPERATURE SENSOR…3032
WIF SENSOR…3032
HST MOTOR SPEED SENSOR…3033
20 STANDARD VALUE TABLES…3034
STANDARD VALUE TABLE FOR ENGINE…3035
STANDARD VALUE TABLE FOR CHASSIS…3036
PERFORMANCE MEASURING POSTURE AND METHOD…3041
30 TESTING AND ADJUSTING…3044
LIST OF TOOLS…3046
ENGINE…3049
ENGINE SPEED…3049
AIR INTAKE BOOST PRESSURE…3050
EXHAUST TEMPERATURE…3051
EXHAUST GAS COLOR…3053
VALVE CLEARANCE…3054
COMPRESSION PRESSURE…3057
BLOW-BY PRESSURE…3059
ENGINE OIL PRESSURE…3060
HANDLING CONTROLLER HIGH-VOLTAGE CIRCUIT…3061
FUEL SYSTEM…3062
HANDLING FUEL SYSTEM PARTS…3062
RELEASING RESIDUAL PRESSURE FROM FUEL SYSTEM…3062
BLEEDING AIR FROM FUEL CIRCUIT…3063
FUEL PRESSURE…3065
FUEL RETURN RATE AND LEAKAGE…3067
FUEL CIRCUIT FOR LEAKAGE…3070
FAN (WORK EQUIPMENT) PUMP PRESSURE…3071
FAN SPEED…3071
FAN SPEED SENSOR…3072
DECELERATOR PEDAL…3074
HST OIL PRESSURE…3076
MOTOR CONTROL VALVE OUTLET PRESSURE…3081
TRAVEL DEVIATION…3084
PARKING BRAKE LEVER…3085
BRAKE PERFORMANCE…3087
BRAKE PEDAL LINKAGE…3088
EMERGENCY RELEASE OF PARKING BRAKE…3090
IDLER CLEARANCE…3093
TRACK SHOE TENSION…3095
WORK EQUIPMENT…3096
OIL PRESSURE…3096
WORK EQUIPMENT PPC VALVE…3098
OIL PRESSURE…3098
PPC circuit connection diagram…3099
ADJUSTING PLAY OF WORK EQUIPMENT PPC VALVE 1…3100
LOCK LEVER ADJUSTMENT…3101
CYLINDER LEAKAGE…3102
HYDRAULIC CIRCUIT…3104
RELEASING RESIDUAL PRESSURE…3104
BLEEDING AIR…3105
BLADE CENTER BALL ADJUSTMENT…3106
BLADE PITCH BALL ADJUSTMENT…3106
DIODES…3107
PROCEDURE FOR TESTING…3107
MONITOR PANEL (EMMS) – SPECIAL FUNCTIONS…3109
PREPARATION WORK FOR TROUBLESHOOTING FOR ELECTRICAL SYSTEM…3170
ELECTRIC/HYDRAULIC DEVICES ARE ADJUSTED/REPLACED…3172
ITEMS TO BE ADJUSTED…3172
HST CONTROLLER ADJUSTMENT AFTER REPLACEMENT…3173
MONITOR PANEL ADJUSTMENT AFTER REPLACEMENT…3176
PM-CLINIC…3178
PM-CLINIC SERVICE…3178
PM-CLINIC INSPECTION SHEET (1/2)…3181
PM-CLINIC INSPECTION SHEET (2/2)…3182
PM-CLINIC UNDERCARRIAGE CHECK SHEET…3183
UNDERCARRIAGE TROUBLESHOOTING REPORT (NORMAL)…3184
UNDERCARRIAGE TROUBLESHOOTING REPORT (IMPACT)…3185
PM-CLINIC UNDERCARRIAGE CHECK SHEET…3186
UNDERCARRIAGE TROUBLESHOOTING REPORT (NORMAL)…3187
UNDERCARRIAGE TROUBLESHOOTING REPORT (IMPACT)…3188
40 TROUBLESHOOTING…3190
…3190
POINTS TO REMEMBER WHEN TROUBLESHOOTING…3191
SEQUENCE OF EVENTS IN TROUBLESHOOTING…3193
PRECAUTIONS WHEN CARRYING OUT MAINTENANCE…3194
PRECAUTIONS WHEN HANDLING ELECTRICAL EQUIPMENT…3194
HANDLING ELECTRONIC CONTROL UNIT…3199
POINTS TO REMEMBER WHEN TROUBLESHOOTING ELECTRICAL CIRCUITS…3200
ELECTRIC WIRE CODE…3201
CLASSIFICATION BY THICKNESS…3201
CLASSIFICATION BY COLOR AND CODE…3201
HOW TO READ ELECTRIC WIRE CODE…3202
POINTS TO REMEMBER WHEN HANDLING HYDRAULIC EQUIPMENT…3204
CHECKS BEFORE TROUBLESHOOTING…3206
CATEGORIES AND METHOD OF USING TROUBLESHOOTING CHARTS…3207
TROUBLESHOOTING INDIVIDUAL ELECTRICAL CIRCUITS…3208
CONNECTION TABLE FOR CONNECTOR PIN NUMBERS…3211
T-ADAPTER TABLE…3235
MODE CHART…3239
TROUBLESHOOTING (BY ERROR CODE)…3242
TROUBLESHOOTING BY ERROR CODE…3248
INFORMATION IN TROUBLESHOOTING TABLE…3255
ERROR CODE [6091NX]…3257
HST CHARGE FILTER ELEMENT CLOGGING…3257
ERROR CODE [AA10NX]…3259
AIR CLEANER CLOGGING…3259
ERROR CODE [AB00MA]…3261
ALTERNATOR MALFUNCTION…3261
ERROR CODE [B@BAZG]…3262
ENGINE OIL LOWERING OF OIL PRESSURE…3262
ERROR CODE [B@BCNS]…3263
COOLANT OVERHEAT…3263
ERROR CODE [B@CRNS]…3264
HST OIL OVERHEATING…3264
ERROR CODE [B@CRZG]…3265
HST OIL LOWERING OF OIL PRESSURE…3265
ERROR CODE [CA111]…3266
ABNORMALITY IN ENGINE CONTROLLER…3266
ERROR CODE [CA115]…3267
ABNORMALITY IN NE AND BKUP SPEED SENSOR SIGNAL…3267
ERROR CODE [CA122]…3269
CHARGE PRESSURE SENSOR TOO HIGH…3269
ERROR CODE [CA123]…3271
CHARGE PRESSURE SENSOR TOO LOW…3271
ERROR CODE [CA131]…3273
DECELERATOR PEDAL SENSOR TOO HIGH…3273
ERROR CODE [CA132]…3275
DECELERATOR PEDAL SENSOR TOO LOW…3275
ERROR CODE [CA144]…3277
COOLANT TEMPERATURE SENSOR TOO HIGH…3277
ERROR CODE [CA145]…3279
COOLANT TEMPERATURE SENSOR TOO LOW…3279
ERROR CODE [CA153]…3281
CHARGE TEMPERATURE SENSOR TOO HIGH…3281
ERROR CODE [CA154]…3283
CHARGE TEMPERATURE SENSOR TOO low…3283
ERROR CODE [CA187]…3285
SENSOR POWER SORCE EXCESSIVELY LOW…3285
ERROR CODE [CA221]…3287
ATMOSPHERIC PRESSURE SENSOR TOO HIGH…3287
ERROR CODE [CA222]…3289
ATMOSPHERIC PRESSURE SENSOR TOO LOW…3289
ERROR CODE [CA227]…3291
SENSOR POWER SORCE EXCESSIVELY HIGH…3291
ERROR CODE [CA234]…3293
ENGINE OVERSPEED…3293
ERROR CODE [CA238]…3294
ABNORMAL POWER SOURCE FOR NE SPEED SENSOR…3294
ERROR CODE [CA271]…3295
IMV/PCV1 SHORT CIRCUITED…3295
ERROR CODE [CA272]…3297
IMV/PCV1 OPEN…3297
ERROR CODE [CA322]…3299
NO.1 INJECTOR SHOWING OPEN OR SHORT…3299
ERROR CODE [CA323]…3301
NO.5 INJECTOR SHOWING OPEN OR SHORT…3301
ERROR CODE [CA324]…3303
NO.3 INJECTOR SHOWING OPEN OR SHORT…3303
ERROR CODE [CA325]…3305
NO.6 INJECTOR SHOWING OPEN OR SHORT…3305
ERROR CODE [CA331]…3307
NO.2 INJECTOR SHOWING OPEN OR SHORT…3307
ERROR CODE [CA332]…3309
NO.4 INJECTOR SHOWING OPEN OR SHORT…3309
ERROR CODE [CA342]…3311
ENGINE CONTROLLER DATA MATCHING ERROR…3311
ERROR CODE [CA352]…3312
SENSOR POWER SOURCE TOO LOW…3312
ERROR CODE [CA386]…3313
SENSOR POWER SOURCE TOO HIGH…3313
ERROR CODE [CA428]…3315
WATER IN FUEL SENSOR VOLTAGE TOO HIGH…3315
ERROR CODE [CA429]…3317
WATER IN FUEL SENSOR VOLTAGE TOO LOW…3317
ERROR CODE [CA435]…3319
ABNORMAL ENGINE OIL PRESSURE SWITCH…3319
ERROR CODE [CA441]…3321
POWER SOURCE VOLTAGE IS TOO LOW…3321
ERROR CODE [CA442]…3323
POWER SOURCE VOLTAGE TOO HIGH…3323
ERROR CODE [CA449]…3325
COMMON RAIL PRESSURE TOO HIGH…3325
ERROR CODE [CA451]…3327
COMMON RAIL PRESSURE TOO HIGH…3327
ERROR CODE [CA452]…3329
COMMON RAIL PRESSURE TOO LOW…3329
ERROR CODE [CA488]…3331
CHARGE TEMPERATURE TOO HIGH AND TORQUE DERATED…3331
ERROR CODE [CA553]…3332
COMMON RAIL PRESSURE TOO HIGH…3332
ERROR CODE [CA559]…3333
LOSS OF PRESSURE FEED FROM SUPPLY PUMP…3333
ERROR CODE [CA689]…3335
ABNORMAL ENGINE NE SPEED SENSOR…3335
ERROR CODE [CA731]…3337
ABNORMAL ENGINE BKUP SPEED SENSOR PHASE…3337
ERROR CODE [CA757]…3339
LOSS OF ALL ENGINE CONTROLLER DATA…3339
ERROR CODE [CA778]…3341
ABNORMAL ENGINE BKUP SPEED SENSOR…3341
ERROR CODE [CA1633]…3343
ABNORMAL KOMNET…3343
ERROR CODE [CA2185]…3345
DECELERATOR PEDAL SENSOR POWER SOURCE TOO HIGH…3345
ERROR CODE [CA2186]…3346
DECELERATOR PEDAL SENSOR POWER SOURCE TOO LOW…3346
ERROR CODE [CA2249]…3347
LOSS OF PRESSURE FEED FROM SUPPLY PUMP (2)…3347
ERROR CODE [CA2311]…3349
ABNORMAL IMV SOLENOID…3349
ERROR CODE [CA2555]…3351
AIR INTAKE HEATER RELAY DISCONNECTION…3351
ERROR CODE [CA2556]…3353
AIR INTAKE HEATER RELAY SHORT CIRCUIT…3353
ERROR CODE [D130KA]…3355
NEUTRAL SAFETY RELAY DISCONNECTION…3355
ERROR CODE [D130KB]…3357
NEUTRAL SAFETY RELAY SHORT CIRCUIT…3357
ERROR CODE [DAFRKR]…3359
CAN COMMUNICATION MONITOR PANEL – HST CONTROLLER…3359
ERROR CODE [DAFRMC]…3361
CAN COMMUNICATION MONITOR PANEL – ENGINE CONTROLLER…3361
ERROR CODE [DAJ000]…3363
HST CONTROLLER MEMORY ERROR…3363
ERROR CODE [DAJ0KK]…3365
HST CONTROLLER LOWERING OF SOURCE VOLTAGE…3365
ERROR CODE [DAJ0KQ]…3367
HST CONTROLLER MACHINE CODE ERROR…3367
ERROR CODE [DAJ0KT]…3368
HST CONTROLLER MEMORY ERROR…3368
ERROR CODE [DAJ5KK]…3369
HST CONTROLLER POWER SUPPLY LOWING…3369
ERROR CODE [DAJ6KK]…3371
HST POWER SUPPLY LOWING…3371
ERROR CODE [DAJRKR]…3373
CAN COMMUNICATION HST CONTROLLER DEFECTIVE…3373
ERROR CODE [DB2RKR]…3375
CAN COMMUNICATION HST CONTROLLER DEFECTIVE…3375
ERROR CODE [DD12KA]…3377
SHIFT UP SWITCH DISCONNECTION…3377
ERROR CODE [DD12KB]…3379
SHIFT UP SWITCH SHORT CIRCUIT…3379
ERROR CODE [DD13KA]…3381
SHIFT DOWN SWITCH DISCONNECTION…3381
ERROR CODE [DD13KB]…3383
SHIFT DOWN SWITCH SHORT CIRCUIT…3383
ERROR CODE [DD14KB]…3385
TRAVEL LOCK LIMIT SWITCH 1 SHORT CIRCUIT…3385
ERROR CODE [DD1NL4]…3387
FAN ROTATION SELECTOR SWITCH DISAGREEMENT…3387
ERROR CODE [DDDCKB]…3389
REVERSE TRAVEL SPEED SWITCH SHORT CIRCUIT…3389
ERROR CODE [DDP6KA]…3391
BRAKE OIL PRESSURE SENSOR DISCONNECTION…3391
ERROR CODE [DDP6KB]…3393
BRAKE OIL PRESSURE SENSOR SHORT CIRCUIT…3393
ERROR CODE [DDP6MA]…3395
BRAKE OIL PRESSURE SENSOR MALFUNCTION…3395
ERROR CODE [DDQ2KA]…3397
TRAVEL LOCK LIMIT SWITCH 1 DISCONNECTION…3397
ERROR CODE [DDT0L4]…3399
SHIFT MODE SWITCH DISAGREEMENT OF ON/ OFF SIGNALS…3399
ERROR CODE [DDU1FS]…3401
TRAVEL LOCK LIMIT SWITCHES 1 AND 2 FIXING…3401
ERROR CODE [DDU1KA]…3403
TRAVEL LOCK LIMIT SWITCH 2 DISCONNECTION…3403
ERROR CODE [DDU1KY]…3405
TRAVEL LOCK LIMIT SWITCH 2 SHORT WITH POWER SUPPLY LINE…3405
ERROR CODE [DGS1KA]…3407
HST OIL TEMPERATURE SENSOR DISCONNECTION…3407
ERROR CODE [DGS1KX]…3409
HST OIL TEMPERATURE SENSOR OUT OF INPUT SIGNAL RANGE…3409
ERROR CODE [DHH5KA]…3410
LEFT HST PUMP PRESSURE SENSOR DISCONNECTION…3410
ERROR CODE [DHH5KB]…3412
LEFT HST PUMP PRESSURE SENSOR SHORT CIRCUIT…3412
ERROR CODE [DHH6KA]…3414
RIGHT HST PUMP PRESSURE SENSOR DISCONNECTION…3414
ERROR CODE [DHH6KB]…3416
RIGHT HST PUMP PRESSURE SENSOR SHORT CIRCUIT…3416
ERROR CODE [DK10KA]…3418
FUEL DIAL SENSOR DISCONNECTION…3418
ERROR CODE [DK10KB]…3420
FUEL DIAL SENSOR SHORT CIRCUIT…3420
ERROR CODE [DK30KA]…3422
STEERING ANGLE SENSOR 1 DISCONNECTION…3422
ERROR CODE [DK30KB]…3424
STEERING ANGLE SENSOR 1 SHORT CIRCUIT…3424
ERROR CODE [DK30KX]…3426
STEERING ANGLE SENSOR OUT OF INPUT SIGNAL RANGE…3426
ERROR CODE [DK30KZ]…3427
STEERING ANGLE SENSOR DISCONNECTION OR SHORT CIRCUIT…3427
ERROR CODE [DK30L8]…3428
STEERING ANGLE SENSOR DISAGREEMENT OF ANALOG SIGNALS…3428
ERROR CODE [DK31KA]…3430
STEERING ANGLE SENSOR DISCONNECTION…3430
ERROR CODE [DK31KB]…3432
STEERING ANGLE SENSOR 2 SHORT CIRCUIT…3432
ERROR CODE [DK40KA]…3434
BRAKE PEDAL SENSOR DISCONNECTION…3434
ERROR CODE [DK40KB]…3436
BRAKE PEDAL SENSOR SHORT CIRCUIT…3436
ERROR CODE [DK55KX]…3438
DIRECTIONAL POTENTIOMETER OUT OF INPUT SIGNAL RANGE…3438
ERROR CODE [DK55KZ]…3439
DIRECTIONAL POTENTIOMETER DISCONNECTION OR SHORT CIRCUIT…3439
ERROR CODE [DK55L8]…3440
DIRECTIONAL POTENTIOMETER DISAGREEMENT OF ANALOG SIGNALS…3440
ERROR CODE [DK56KA]…3442
DIRECTIONAL POTENTIOMETER 1 DISCONNECTION…3442
ERROR CODE [DK56KB]…3444
DIRECTIONAL POTENTIOMETER 1 SHORT CIRCUIT…3444
ERROR CODE [DK57KA]…3446
DIRECTIONAL POTENTIOMETER 2 DISCONNECTION…3446
ERROR CODE [DK57KB]…3448
DIRECTIONAL POTENTIOMETER 2 SHORT CIRCUIT…3448
ERROR CODE [DLM0KX]…3450
HST MOTOR SPEED SENSORS OUT OF INPUT SIGNAL RANGE…3450
ERROR CODE [DLM1KA]…3452
LEFT HST MOTOR SPEED SENSOR DISCONNECTION…3452
ERROR CODE [DLM1KB]…3454
LEFT HST MOTOR SPEED SENSOR: SHORT CIRCUIT…3454
ERROR CODE [DLM1MA]…3456
LEFT HST MOTOR SPEED SENSOR: MALFUNCTION…3456
ERROR CODE [DLM2KA]…3458
RIGHT HST MOTOR SPEED SENSOR DISCONNECTION…3458
ERROR CODE [DLM2KB]…3460
RIGHT HST MOTOR SPEED SENSOR SHORT CIRCUIT…3460
ERROR CODE [DLM2MA]…3462
RIGHT HST MOTOR SPEED SENSOR MALFUNCTION…3462
ERROR CODE [DLM3KA]…3464
FAN SPEED SENSOR DISCONNECTION…3464
ERROR CODE [DLM3KB]…3466
FAN SPEED SENSOR: SHORT CIRCUIT…3466
ERROR CODE [DN21FS]…3468
BRAKE PEDAL AND PROXIMITY SWITCH FIXING…3468
ERROR CODE [DV00KB]…3470
CAUTION BUZZER SHORT CIRCUIT…3470
ERROR CODE [DV20KB]…3471
BACK ALARM BUZZER SHORT CIRCUIT…3471
ERROR CODE [DW4BKA]…3472
PARKING BRAKE SOLENOID VALVE DISCONNECTION…3472
ERROR CODE [DW4BKB]…3474
PARKING BRAKE SOLENOID VALVE SHORT CIRCUIT…3474
ERROR CODE [DW4BKY]…3476
PARKING BRAKE SOLENOID VALVE SHORTED…3476
ERROR CODE [DW7BKA]…3477
FAN REVERSE SOLENOID VALVE DISCONNECTION…3477
ERROR CODE [DW7BKB]…3477
FAN REVERSE SOLENOID VALVE SHORT CIRCUIT…3478
ERROR CODE [DW7BKY]…3479
FAN REVERSE SOLENOID VALVE SHORTED…3479
ERROR CODE [DW7EKA]…3480
SLOW BRAKE SOLENOID VALVE DISCONNECTION…3480
ERROR CODE [DW7EKB]…3484
SLOW BRAKE SOLENOID VALVE SHORT CIRCUIT…3484
ERROR CODE [DW7EKY]…3486
SLOW BRAKE SOLENOID VALVE SHORTED…3486
ERROR CODE [DWN5KA]…3488
FAN EPC SOLENOID VALVE DISCONNECTION…3488
ERROR CODE [DWN5KB]…3490
FAN EPC SOLENOID VALVE SHORT CIRCUIT…3490
ERROR CODE [DWN5KY]…3492
FAN EPC SOLENOID VALVE SHORTED…3492
ERROR CODE [DXA4KA]…3494
LF HST PUMP EPC SOLENOID VALVE DISCONNECTION…3494
ERROR CODE [DXA4KB]…3496
LF HST PUMP EPC SOLENOID VALVE SHORT CIRCUIT…3496
ERROR CODE [DXA4KY]…3497
LF HST PUMP EPC SOLENOID VALVE SHORTED…3497
ERROR CODE [DXA5KA]…3498
LR HST PUMP EPC SOLENOID VALVE DISCONNECTION…3498
ERROR CODE [DXA5KB]…3500
LR HST PUMP EPC SOLENOID VALVE SHORT CIRCUIT…3500
ERROR CODE [DXA5KY]…3501
LR HST PUMP EPC SOLENOID VALVE SHORTED…3501
ERROR CODE [DXA6KA]…3502
RF HST PUMP EPC SOLENOID VALVE DISCONNECTION…3502
ERROR CODE [DXA6KB]…3504
RF HST PUMP EPC SOLENOID VALVE SHORT CIRCUIT…3504
ERROR CODE [DXA6KY]…3505
RF HST PUMP EPC SOLENOID VALVE SHORTED…3505
ERROR CODE [DXA7KA]…3506
RR HST PUMP EPC SOLENOID VALVE DISCONNECTION…3506
ERROR CODE [DXA7KB]…3507
RR HST PUMP EPC SOLENOID VALVE SHORT CIRCUIT…3507
ERROR CODE [DXA7KY]…3508
RR HST PUMP EPC SOLENOID VALVE SHORTED…3508
ERROR CODE [DXK1KA]…3509
LEFT HST MOTOR EPC SOLENOID VALVE DISCONNECTION…3509
ERROR CODE [DXK1KB]…3510
LEFT HST MOTOR EPC SOLENOID VALVE SHORT CIRCUIT…3510
ERROR CODE [DXK1KY]…3511
LEFT HST MOTOR EPC SOLENOID VALVE SHORTED…3511
ERROR CODE [DXK2KA]…3512
RIGHT HST MOTOR EPC SOLENOID VALVE DISCONNECTION…3512
ERROR CODE [DXK2KB]…3513
RIGHT HST MOTOR EPC SOLENOID VALVE SHORT CIRCUIT…3513
ERROR CODE [DXK2KY]…3514
RIGHT HST MOTOR EPC SOLENOID VALVE SHORTED…3514
TROUBLESHOOTING (E-MODE)…3518
BEFORE CARRYING OUT TROUBLESHOOTING (E-MODE)…3520
CONNECTION TABLE OF FUSE BOX…3520
INFORMATION IN TROUBLESHOOTING TABLE…3522
E-1…3523
STARTING MOTOR DOES NOT ROTATE…3523
E-2…3527
ENGINE IS NOT PRE-HEATED…3527
E-3…3531
WHEN STARTING SWITCH IS TURNED ON, ANY ITEM DOES NOT LIGHT…3531
E-4…3533
CHARGE LEVEL CAUTION FLASHES WHILE ENGINE IS RUNNING…3533
E-5…3535
EMERGENCY WARNING ITEMS FLASH WHILE ENGINE IS RUNNING…3535
E-6…3539
PRE-HEAT LAMP DOES NOT LIGHT DURING PRE-HEATING OPERATION…3539
E-7…3541
COOLANT TEMPERATURE GAUGE DOES NOT INDICATE CORRECTLY…3541
E-8…3542
HST OIL TEMPERATURE GAUGE DOES NOT INDICATE CORRECTLY…3542
E-9…3543
FUEL LEVEL GAUGE DOES NOT INDICATE PROPERLY…3543
E-10…3545
TRAVEL INDICATOR DOES NOT DISPLAY NORMALLY…3545
E-11…3545
MULTI-INFORMATION UNIT DOES NOT DISPLAY NORMALLY…3545
E-12…3546
CAUTION LAMP DOES NOT FLASH OR DOES NOT GO OFF…3546
E-13…3547
CAUTION BUZZER DOES NOT SOUND OR DOES NOT STOP…3547
E-14…3549
REVERSE TRAVEL SPEED SETTING SWITCH DOES NOT FUNCTION…3549
E-15…3551
SHIFT MODE SWITCH DOES NOT FUNCTION…3551
E-16…3553
BUZZER CANCEL SWITCH DOES NOT FUNCTION…3553
E-17…3555
INFORMATION SWITCH DOES NOT FUNCTION…3555
E-18…3557
THE FAN CLEANING DOES NOT OPERATE OR CANNOT BE RESET…3557
E-19…3559
BACKUP ALARM DOES NOT SOUND…3559
E-20…3560
THE HORN DOES NOT SOUND OR DOES NOT STOP…3560
E-21…3561
WORK EQUIPMENT DOES NOT MOVE…3561
E-22…3563
HEAD LAMP OR REAR LAMP DOES NOT LIGHT UP…3563
E-23…3567
FOOT HEATER DOES NOT OPERATE…3567
E-24…3571
AIR CONDITIONER DOES NOT OPERATE [CAB SPECIFICATION]…3571
E-25…3576
WIPER AND WASHER DO NOT OPERATE [CAB SPECIFICATION]…3576
E-26…3589
KOMTRAX SYSTEM DOES NOT OPERATE NORMALLY…3589
TROUBLESHOOTING (H-MODE)…3592
INFORMATION IN TROUBLESHOOTING TABLE…3593
H-1…3594
RIGHT AND LEFT TRAVEL SYSTEMS INOPERABLE…3594
H-2…3596
RIGHT OR LEFT TRAVEL SYSTEM DOES NOT OPERATE…3596
H-3…3597
RIGHT OR LEFT TRAVEL SYSTEM DOES NOT OPERATE…3597
H-4…3598
SPEED OR POWER OF TRAVEL IS LOW…3598
H-5…3599
GEAR IS NOT SHIFTED…3599
H-6…3600
LARGE SHOCKS ARE MADE WHEN MACHINE STARTS AND STOPS TRAVEl…3600
H-7…3601
MACHINE DEVIATES LARGELY DURING TRAVEL…3601
H-8…3602
HYDRAULIC DRIFT OF TRAVEL IS LARGE…3602
H-9…3603
ENGINE STALLS OR SPEED LOWERS EXTREMELY DURING TRAVEl…3603
H-10…3604
ABNORMAL SOUND COMES OUT FROM AROUND HST PUMP AND MOTOR…3604
H-11…3605
WORK EQUIPMENT DOSE NOT OPERATE AT ALL…3605
H-12…3606
SPEED OR POWER OF WHOLE WORK EQUIPMENT IS LOW…3606
H-13…3607
SPEED OR POWER OF LIFTING BLADE IS LOW…3607
H-14…3608
SPEED OR POWER OF TILTING BLADE IS LOW…3608
H-15…3609
SPEED OR POWER OF ANGLING BLADE IS LOW…3609
H-16…3610
TIME LAG IN LIFTING BLADE IS LARGE…3610
H-17…3611
HYDRAULIC DRIFT OF LIFTING BLADE IS LARGE…3611
H-18…3612
HYDRAULIC DRIFT OF TILTING BLADE IS LARGE…3612
H-19…3613
ABNORMAL SOUND COMES FROM WORK EQUIPMENT PUMP AND CONTROL VALVE…3613
H-20…3614
HST OIL TEMPERATURE RISES TOO HIGH…3614
H-21…3615
FAN SPEED IS ABNORMAL (HIGH, LOW, OR 0 RPM)…3615
TROUBLESHOOTING (S-MODE)…3616
METHOD OF USING TROUBLESHOOTING CHARTS…3617
(S-1) ENGINE STARTING PERFORMANCE IS POOR…3621
(S-2) ENGINE DOES NOT CRANK…3622
ENGINE CRANKS BUT NO EXHAUST SMOKE COMES OUT OF STACK…3623
SMOKE COMES OUT OF STACK BUT ENGINE DOES NOT START…3624
(S-3) ENGINE DOES NOT RUN SMOOTHLY…3625
(S-4) ENGINE STOPS DURING OPERATIONS…3626
(S-5) ENGINE SPEED HUNTS…3627
(S-6) ENGINE LACKS POWER…3628
(S-7) EXHAUST SMOKE IS BLACK…3630
(S-8) OIL CONSUMPTION IS EXCESSIVE OR EXHAUST SMOKE IS BLUE…3631
(S-9) OIL BECOMES CONTAMINATED QUICKLY…3632
(S-10) FUEL CONSUMPTION IS EXCESSIVE…3633
(S-11) OIL FOUND IN COOLANT, OR COOLANT SPURTS FROM RADIATOR…3634
(S-12) OIL PRESSURE CAUTION LAMP LIGHTS UP…3635
(S-13) OIL LEVEL RISES (COOLANT OR FUEL FOUND IN OIL)…3636
(S-14) COOLANT TEMPERATURE TOO HIGH (OVERHEATING)…3637
(S-15) ABNORMAL NOISE IS HEARD WHEN ENGINE IS RUNNING…3638
(S-16) EXCESSIVE VIBRATION WHEN ENGINE IS RUNNING…3639
50 DISASSEMBLY AND ASSEMBLY…3640
HOW TO USE THIS MANUAL…3643
REMOVAL AND INSTALLATION OF COMPONENTS…3643
Special Tools…3643
OVERHAUL OF COMPONENTS…3644
Special Tools…3644
Disassembly Procedures…3644
Assembly Procedures…3644
PRECAUTIONS WHEN CARRYING OUT AN OPERATION…3645
SPECIAL TOOL LIST…3647
SKETCH OF SPECIAL TOOLS…3654
CONNECTOR REPAIR PROCEDURES…3669
CONTACT TERMINAL REMOVAL (HD30 TYPE)…3669
STRIPPING INSULATION…3670
CRIMPING CONTACT TERMINAL (HD30 TYPE)…3671
INSERTION OF CONTACT TERMINAL (HD30 TYPE)…3672
CONTACT TERMINAL REMOVAL (DT TYPE)…3673
STRIPPING INSULATION…3674
CRIMPING CONTACT TERMINAL (DT TYPE)…3675
INSERTION OF CONTACT TERMINAL (DT TYPE)…3676
NOSE GUARD (HOOD)…3678
REMOVAL…3678
OPENING FRONT GRILL…3678
REMOVING SIDE PANELS…3679
DISCONNECTING HOOD-RELATED COMPONENTS…3679
REMOVAL OF HOOD…3680
INSTALLATION…3682
MUFFLER AND EXHAUST STACK…3684
REMOVAL…3684
INSTALLATION…3685
CAB…3686
REMOVAL…3686
FLOOR ACCESS PLATE…3689
LIFTING CAB OFF MACHINE…3692
INSTALLATION…3695
MONITOR PANEL AND HST CONTROLLER…3700
REMOVAL…3700
INSTALLATION…3702
KOMTRAX CONTROLLER…3703
REMOVAL…3703
INSTALLATION…3703
SEAT…3704
REMOVAL…3704
INSTALLATION…3704
AIR CONDITIONER/HEATER…3705
DISASSEMBLY OF AIR CONDITIONER…3705
REMOVING CONDENSER…3706
BLOWER MOTORS AND EVAPORATOR…3708
ASSEMBLY OF AIR CONDITIONER…3709
FOOT HEATER…3710
REMOVAL…3710
INSTALLATION…3711
FOOT HEATER OVERHAUL PROCEDURES…3712
OVERHAUL PROCEDURES…3712
ASSEMBLY PROCEDURES…3714
ENGINE AND HST PUMP…3716
REMOVAL…3716
BELLY PANS…3716
DRAINING THE COOLING SYSTEM…3716
DRAINING THE HYDRAULIC SYSTEM…3717
DISCONNECTING COMPONENTS…3718
LIFTING ENGINE AND HST PUMP ASSEMBLY…3724
INSTALLATION…3726
INSTALL ENGINE AND HST PUMP ASSEMBLY…3726
REMOVAL FROM ENGINE…3728
INSTALLATION TO ENGINE…3731
DRIVE DAMPENER…3732
REMOVAL…3732
INSTALLATION…3733
HST PUMP OVERHAUL PROCEDURES…3734
DISASSEMBLY PROCEDURES…3734
REMOVAL OF ACCESSORIES…3734
REMOVAL OF REAR PUMP…3735
REMOVAL OF END CAP…3735
DISASSEMBLY OF CYLINDER BLOCK AND PISTONS…3736
DISASSEMBLY OF ROCKER CAM…3737
REMOVAL OF FRONT SHAFT…3738
DISASSEMBLY OF SHAFT…3739
DISASSEMBLY OF FRONT COVER…3740
DISASSEMBLY FRONT SERVO PISTON…3741
DISASSEMBLY OF END CAP…3742
DISASSEMBLY OF REAR PUMP…3742
DISASSEMBLY OF REAR SHAFT…3742
ASSEMBLY PROCEDURES…3743
INSTALLATION OF REAR SERVO PISTON…3744
INSTALLATION OF REAR COVER…3746
INSTALLATION OF REAR SHAFT…3747
ASSEMBLY OF REAR ROCKER CAM…3748
INSTALLATION OF REAR CYLINDER BLOCK AND PISTON…3749
ASSEMBLY OF END CAP…3750
ASSEMBLY OF FRONT COVER…3752
INSTALLATION OF FRONT OIL SEAL…3752
INSTALLATION OF END CAP…3752
INSTALLATION OF REAR PUMP…3753
INSTALLATION OF ACCESSORIES…3754
WORK EQUIPMENT PUMP OVERHAUL PROCEDURES…3755
DISASSEMBLY PROCEDURES…3755
PUMP…3755
(PC VALVE)…3756
(LS VALVE)…3756
REMOVAL OF END CAP…3757
DISASSEMBLY OF CYLINDER BLOCK AND PISTON…3757
DISASSEMBLY OF SHAFT ASSEMBLY…3758
DISASSEMBLY OF ROCKER CAM…3760
REMOVAL OF BALLS AND PISTON…3760
ASSEMBLY PROCEDURES…3762
INSTALLATION OF PUMP CASE…3762
INSTALLATION OF ROCKER CAM…3762
ASSEMBLY AND INSTALLATION OF SHAFT…3763
INSTALLATION OF OIL SEAL…3764
INSTALLATION OF CYLINDER BLOCK AND PISTON…3765
INSTALLATION OF END CAP…3766
ASSEMBLY OF SERVO VALVE…3766
INSTALLATION OF SERVO VALVE ASSEMBLY…3768
REMOVAL…3769
INSTALL…3770
CHARGE PUMP OVERHAUL PROCEDURES…3771
TOOLS REQUIRED…3771
DISASSEMBLY PROCEDURES…3771
INSPECT PARTS FOR WEAR…3775
ASSEMBLY PROCEDURES…3777
GENERAL NOTES…3777
PLACING PUMP BACK INTO SERVICE…3782
DIESEL ENGINE OVERHAUL PROCEDURES…3783
DISASSEMBLY OF EXTERNAL COMPONENTS…3783
PREPARATION WORK…3783
STARTING MOTOR…3784
ENGINE SLING BRACKET ON REAR SIDE…3784
FAN PULLEY…3784
VIBRATION DAMPER AND CRANKSHAFT PULLEY…3784
BELT TENSIONER…3785
FAN HUB…3785
ALTERNATOR…3785
THERMOSTAT…3786
WATER PUMP…3786
TURBOCHARGER AND EXHAUST MANIFOLD…3786
FUEL FILTER ASSEMBLY…3787
WIRING HARNESS ASSEMBLY…3787
FUEL PIPING AND COMMON RAIL…3788
DISASSEMBLY OF ENGINE TOP END…3789
INTAKE MANIFOLD…3789
VALVE COVER HOUSING…3789
ROCKER ARM ASSEMBLY AND CROSSHEAD…3790
PUSH RODS…3790
FUEL INJECTORS…3790
CYLINDER HEAD…3791
REMOVAL OF OIL COOLER, ENGINE CONTROLLER AND FUEL PUMP…3793
OIL COOLER…3793
ENGINE CONTROLLER…3793
FUEL SUPPLY PUMP…3794
DISASSEMBLY OF ENGINE LOWER END…3795
FLYWHEEL…3795
REAR OIL SEAL…3795
FLYWHEEL HOUSING…3796
OIL PAN…3796
FRONT COVER…3796
OIL PUMP…3797
CAMSHAFT…3797
GEAR HOUSING…3798
PISTONS AND CONNECTING RODS…3798
CRANKSHAFT…3799
PISTON COOLING NOZZLES…3801
TAPPETS…3801
CYLINDER BLOCK…3801
ASSEMBLY OF ENGINE LOWER END…3802
PREPARATION WORK…3802
TAPPETS…3802
PISTON COOLING NOZZLE…3802
CRANKSHAFT…3803
MAIN CAP MOUNTING BOLTS…3804
PISTON AND CONNECTING ROD ASSEMBLY…3805
GEAR HOUSING…3809
CAMSHAFT…3810
FLYWHEEL HOUSING…3811
REAR OIL SEAL…3812
FLYWHEEL…3813
OIL PUMP…3814
FRONT COVER…3815
OIL PAN…3816
VIBRATION DAMPER…3817
INSTALLATION OF OIL COOLER, ENGINE CONTROLLER AND FUEL PUMP…3818
FUEL SUPPLY PUMP…3818
ENGINE CONTROLLER…3818
OIL COOLER…3818
CYLINDER HEAD…3820
FUEL INJECTORS…3822
PUSH RODS…3823
ROCKER ARM ASSEMBLY…3823
ADJUSTING VALVE CLEARANCE…3823
VALVE COVER HOUSING…3824
AIR INTAKE MANIFOLD COVER…3825
ASSEMBLY OF EXTERNAL COMPONENTS…3827
PREPARATION WORK…3827
HARNESS ASSEMBLY…3827
FUEL FILTER ASSEMBLY…3827
EXHAUST MANIFOLD AND TURBOCHARGER…3827
WATER PUMP…3828
THERMOSTAT…3828
ALTERNATOR…3829
FAN HUB…3829
BELT TENSIONER…3830
FAN PULLEY…3830
ENGINE SLING BRACKET ON REAR SIDE…3830
STARTER MOTOR…3830
REFILLING WITH OIL…3831
TRACK SYSTEM…3833
SPREADING THE TRACK…3833
(CONVENTIONAL TYPE TRACK SHOE)…3833
Whole disassembly…3857
Whole assembly…3860
1. When recycling for lubricated track…3860
WHOLE DISASSEMBLY AND ASSEMBLY OF TRACK SHOE (PLUS TYPE TRACK SHOE)…3856
Special tools…3856
FIELD DISASSEMBLY AND ASSEMBLY OF ONE LINK (CONVENTIONAL TYPE TRACK SHOE)…3870
Special tools…3870
Disassembly…3870
Assembly…3872
FIELD DISASSEMBLY AND ASSEMBLY OF ONE LINK (PLUS TYPE TRACK SHOE)…3878
Special tools…3878
Disassembly…3879
Assembly…3883
TRACK FRAME…3886
REMOVAL OF TRACK FRAME…3886
REMOVING TRACKS…3886
TRACK FRAME REMOVAL PREPARATIONS…3889
LIFTING TRACK FRAME FROM MACHINE…3891
FRONT TRACK IDLER…3895
REMOVING FRONT IDLER…3895
PULLING IDLER FROM TRACK FRAME…3896
INSTALLING FRONT IDLER…3898
TRACK ROLLER…3899
REMOVAL…3899
INSTALLATION…3899
TRACK ROLLER OVERHAUL PROCEDURES…3900
DISASSEMBLY…3900
ASSEMBLY…3901
CARRIER ROLLER OVERHAUL PROCEDURES…3905
DISASSEMBLY…3905
ASSEMBLY…3906
FINAL DRIVE…3907
FINAL DRIVE REMOVAL…3907
INSTALLING THE FINAL DRIVE…3911
FINAL DRIVE OVERHAUL PROCEDURES…3913
DISASSEMBLY PROCEDURES…3913
DRAINING OIL…3913
COVER…3914
RING GEAR…3914
NO. 1 PLANETARY CARRIER ASSEMBLY…3915
NO. 1 SUN GEAR…3915
NO. 2 SUN GEAR…3915
NO. 2 PLANETARY CARRIER ASSEMBLY…3916
HUB ASSEMBLY…3917
NO.2 PLANETARY CARRIER (HST MOTOR ASSEMBLY)…3918
ASSEMBLY OF FINAL DRIVE…3919
NO.2 PLANETARY CARRIER (HST MOTOR ASSEMBLY)…3919
ASSEMBLY OF HUB…3919
NO. 2 PLANETARY CARRIER ASSEMBLY…3922
NO. 2 SUN GEAR…3923
NO. 1 SUN GEAR…3923
NO. 1 PLANETARY CARRIER ASSEMBLY…3923
RING GEAR…3924
COVER…3925
REFILLING WITH OIL…3925
TRAVEL MOTOR OVERHAUL PROCEDURES…3927
DISASSEMBLY PROCEDURES…3927
TRAVEL MOTOR…3927
REMOVAL OF END COVER…3927
DISASSEMBLY OF END COVER…3928
REMOVAL OF RELIEF VALVE…3928
DISASSEMBLY OF SHUTTLE VALVE…3929
REMOVAL OF CYLINDER BLOCK…3929
REMOVAL OF PISTONS…3929
DISASSEMBLY OF BRAKE AND PISTON…3930
REMOVAL AND DISASSEMBLY OF DRIVE SHAFT…3930
REMOVAL OF OIL SEAL…3931
ASSEMBLY PROCEDURES…3932
INSTALLATION OF MOTOR CASE…3932
Install of oil seal…3932
ASSEMBLY OF DRIVE SHAFT…3938
ASSEMBLY OF PISTONS…3939
INSTALLATION OF DRIVE SHAFT ASSEMBLY…3939
INSTALLATION OF DISCS AND PLATES…3940
INSTALLATION OF BRAKE PISTON…3940
ASSEMBLY OF END COVER…3940
ASSEMBLY OF SHUTTLE VALVE…3941
ASSEMBLY OF MAIN PISTON…3941
INSTALLATION OF MAIN VALVE…3942
INSTALLATION OF VALVE PLATE…3942
NSTALLATION OF END COVER…3943
CHECK OF SHAFT ROTATION TORQUE…3944
FAN MOTOR…3945
REMOVAL PROCEDURES…3945
DISCONNECTING THE GRILL FROM THE FAN…3945
DISCONNECTING HYDRAULIC FAN MOTOR…3946
REMOVING THE FAN GUARD…3947
REMOVING THE FAN MOTOR…3948
INSTALLATION PROCEDURES…3949
FAN MOTOR OVERHAUL PROCEDURES…3951
DISASSEMBLY PROCEDURES…3951
REMOVAL OF END COVER…3951
DISASSEMBLY OF END COVER…3951
DISASSEMBLY OF PILOT VALVE…3952
CYLINDER BLOCK, SHAFT AND PISTON…3953
DISASSEMBLY OF CYLINDER BLOCK AND PISTON…3953
DISASSEMBLY OF SHAFT…3954
DISASSEMBLY OF MOTOR CASE…3954
ASSEMBLY PROCEDURES…3955
INSTALLATION OF MOTOR CASE…3955
ASSEMBLY AND INSTALLATION OF SHAFT…3955
ASSEMBLY OF CYLINDER BLOCK AND PISTON…3956
INSTALLATION OF CYLINDER BLOCK AND PISTON…3957
INSTALLATION OF OIL SEAL…3958
ASSEMBLY OF END COVER…3958
INSTALLATION OF END COVER…3960
CHECK OF SHAFT ROTATION TORQUE…3961
DB 12 VALVE…3963
REMOVAL…3963
INSTALLATION…3966
COOLING PACKAGE…3967
REMOVING THE GRILL AND COOLING FAN ASSEMBLY…3967
REMOVING THE GRILL FRAME…3967
REMOVING THE COOLING FAN ASSEMBLY…3974
REMOVING THE COOLING PACKAGE…3978
REMOVING THE FAN SHROUD…3978
REMOVING THE RADIATOR…3981
REMOVING THE OIL COOLER…3983
REMOVING THE AIR CHARGE COOLER…3984
INSTALLING THE COOLING PACKAGE…3986
INSTALLING THE GRILL AND COOLING FAN ASSEMBLY…3987
FUEL TANK…3991
REMOVING THE FUEL TANK…3991
PREPARATIONS FOR REMOVAL…3991
LIFTING THE FUEL TANK OFF THE MACHINE…3994
INSTALLING THE FUEL TANK…3995
HYDRAULIC TANK…3996
REMOVING THE HYDRAULIC TANK…3996
PREPARATIONS FOR REMOVAL…3996
LIFTING THE HYDRAULIC TANK OFF THE MACHINE…4000
INSTALLING THE HYDRAULIC TANK…4002
WORK EQUIPMENT…4003
REMOVING OR INSTALLING PINS…4003
FRONT BLADE, TILT AND ANGLE CYLINDERS…4004
REMOVAL…4004
ADJUSTING BLADE CENTER BALL AND PITCH ROD PLAY…4009
PITCH ROD…4009
CENTER BALL…4010
INSTALLATION…4010
“C” FRAME…4011
REMOVAL…4011
INSTALLATION…4013
LIFT CYLINDERS…4014
REMOVAL…4014
INSTALLATION…4015
CYLINDER OVERHAUL PROCEDURES…4016
DISASSEMBLY PROCEDURES…4016
PISTON AND ROD…4016
PISTON AND HEAD ASSEMBLY…4017
DISASSEMBLY OF GLAND NUT…4017
ASSEMBLY PROCEDURES…4017
GLAND NUT ASSEMBLY AND PISTON ASSEMBLY…4017
DISASSEMBLY OF PISTON…4018
PISTON ROD ASSEMBLY…4019
EXPANSION AND INSTALLATION OF TRACK SHOE ASSEMBLY…3835
(PLUS TYPE TRACK SHOE)…3835
Expansion normal…3835
Installation…3835
WHOLE DISASSEMBLY AND ASSEMBLY OF TRACK SHOE ASSEMBLY (CONVENTIONAL TYPE TRACK SHOE)…3836
Special tools…3836
Whole disassembly…3836
Whole assembly…3841
90 OTHERS…4020
CONNECTOR ARRANGEMENT DRAWING AND ELECTRICAL CIRCUIT DIAGRAM…4022
CONNECTOR LIST…4022
CONNECTOR LOCATION VIEW…4026
CAB ELECTRICAL ACCESSORIES…4040
AIR CONDITIONER AND HEATER UNIT…4042
HYDRAULIC SYSTEM…4044
VIEW (1 OF 2)…4044
VIEW (2 OF 2)…4046
ELECTRICAL DIAGRAMS…0
IN CAB SWITCHES, RELAYS AND CONNECTORS (VIEW 1 OF 5)…4048
CAB HARNESS AND CONTROLLER CONNECTIONS (VIEW 2 OF 5 )…4050
ENGINE HARNESS AND CONTROLLER (VIEW 3 OF 5)…4052
MONITOR PANEL AND SWITCHES (VIEW 4 OF 5)…4054
KOMTRAX AND CONNECTORS (VIEW 5 OF 5)…4056
CONVENTIONAL iB WIRING DIAGRAM (1 OF 2)…4058
CONVENTIONAL iB WIRING DIAGRAM (2 OF 2)…4060
Blank Page…2795
KEBM028601 – Crawler Dozer D51EXi-22, D51PXi-22 Shop Manual (SN-B13500&up)…4062
COVER…4062
00 INDEX AND FOREWORD…4064
INDEX…4065
FOREWORD, SAFETY AND GENERAL INFORMATION…4078
IMPORTANT SAFETY NOTICE…4078
HOW TO READ THE SHOP MANUAL…4085
EXPLANATION OF TERMS FOR MAINTENACE STANDARD…4087
HANDLING EQUIPMENT OF FUEL SYSTEM DEVICES…4089
HANDLING OF INTAKE SYSTEM PARTS…4090
HANDLING OF HYDRAULIC EQUIPMENT…4091
METHOD OF DISCONNECTING AND CONNECTING OF PUSH-PULL TYPE COUPLER…4093
HANDLING OF ELECTRICAL EQUIPMENT…4096
HOW TO READ ELECTRIC WIRE CODE…4104
PRECAUTIONS WHEN PERFORMING OPERATION…4107
PRACTICAL USE OF KOMTRAX…4112
STANDARD TIGHTENING TORQUE TABLE…4113
LIST OF ABBREVIATION…4119
CONVERSION TABLE…4124
01 SPECIFICATION…4130
TABLE OF CONTENTS…4131
SPECIFICATION DRAWING…4132
D51EXi, PXi-22 POWER ANGLE, POWER TILT DOZER WITH ROPS CAB…4132
SPECIFICATION…4133
WEIGHT TABLE…4137
TABLE OF FUEL, COOLANT AND LUBRICANTS…4139
RECOMMENDED PRODUCTS OTHER THAN KOMATSU GENUINE OILS…4141
10 STRUCTURE AND FUNCTION…4142
TABLE OF CONTENTS…4143
ENGINE AND COOLING SYSTEM…4146
ENGINE RELATED PARTS…4146
COOLING SYSTEM…4148
COOLING FAN PUMP – SEE HYDRAULIC SYSTEM 2 (WORK EQUIPMENT AND FAN PUMP)…4151
COOLING FAN MOTOR…4152
OIL COOLER BYPASS VALVE…4157
CHARGE SAFETY VALVE…4160
POWER TRAIN…4162
POWER TRAIN…4162
HST CLOSED CIRCUIT…4164
DAMPER…4165
HST HYDRAULIC EQUIPMENT ARRANGEMENT DIAGRAM…4166
STEERING AND BRAKE CONTROL…4167
HST PUMP…4169
SAFETY-SUCTION VALVE…4177
TOWING VALVE…4180
HST MOTOR…4181
MOTOR CONTROL VALVE…4193
SOLENOID VALVE (3-SPOOL), EPC VALVE (2-SPOOL) AND TOWING VALVE…4193
SOLENOID VALVE…4195
EPC VALVE…4196
CHARGE PUMP…4200
FINAL DRIVE…4202
PATH OF POWER TRANSMISSION…4205
UNDER CARRIAGE AND FRAME…4206
MAIN FRAME…4206
TRACK FRAME AND RECOIL SPRING…4207
IDLER…4209
TRACK ROLLER…4211
CARRIER ROLLER…4215
SPROCKET…4217
SINGLE SHOE…4223
SUSPENSION…4224
HYDRAULIC SYSTEM…4227
HYDRAULIC COMPONENT LAYOUT OF WORK EQUIPMENT…4227
WORK EQUIPMENT CONTROL SYSTEM…4228
HYDRAULIC SYSTEM (WORK EQUIPMENT)…4230
WORK EQUIPMENT AND FAN PUMP…4233
SERVO VALVE…4237
CONTROL VALVE…4239
HYDRAULIC CIRCUIT DIAGRAM AND NAMES OF VALVES…4246
UNLOAD VALVE…4248
PRESSURE COMPENSATION VALVE…4251
HYDRAULIC TANK, FILTER…4261
BREATHER…4262
ACCUMULATOR…4263
WORK EQUIPMENT…4264
WORK EQUIPMENT…4264
CUTTING EDGE AND END BIT…4269
RIPPER…4270
PISTON VALVE FOR ANGLE CYLINDER…4271
CAB AND ITS ATTACHMENTS…4272
ROPS CAB…4272
CAB DAMPER MOUNT…4273
AIR CONDITIONER…4274
ELECTRICAL SYSTEM…4276
MONITOR SYSTEM…4276
ENGINE CONTROL SYSTEM…4278
COOLING CONTROL SYSTEM…4281
HST CONTROL SYSTEM…4283
GEAR SHIFT CONTROL SYSTEM…4284
PARKING BRAKE CONTROL SYSTEM…4289
KOMTRAX SYSTEM…4291
ICT CONTROL SYSTEM…4292
ICT CONTROL FUNCTION…4293
BLADE CONTROL SYSTEM…4295
DOZING MODE…4298
SMOOTH START FUNCTION…4301
SLIP CONTROL…4303
BLADE ASSIST CONTROL…4305
HST SPEED RANGE CONTROL SYSTEM…4307
SYSTEM COMPONENTS…4309
MONITOR PANEL…4309
BUZZER CANCEL SWITCH…4310
MONITOR PANEL DISPLAY…4311
ENGINE CONTROLLER…4313
HST CONTROLLER…4315
ICT CONTROLLER…4317
iB MONITOR…4320
GNSS RECEIVER…4322
KOMTRAX TERMINAL…4331
SENSORS…4332
BRAKE OIL PRESSURE SENSOR…4333
HYDRAULIC OIL TEMPERATURE SENSOR…4334
HST CIRCUIT OIL PRESSURE SENSOR…4335
AIR CLEANER CLOGGING SENSOR…4336
BRAKE PEDAL POTENTIOMETER…4337
FUEL CONTROL DIAL…4338
FUEL LEVEL SENSOR…4339
CHARGE FILTER CLOGGING SENSOR…4340
COOLANT TEMPERATURE SENSOR…4340
ENGINE OIL PRESSURE SWITCH…4341
ENGINE ROTATION SENSOR…4341
BOOST PRESSURE AND SENSOR…4342
WIF SENSOR…4342
HST MOTOR SPEED SENSOR…4343
IMU SENSOR…4344
STROKE AND RESET SENSOR FOR LIFT CYLINDER…4345
STROKE SENSOR…4346
RESET SENSOR…4347
STROKE SENSOR FOR TILT CYLINDER…4348
STROKE SENSOR…4349
STROKE AND RESET SENSOR FOR ANGLE CYLINDER…4350
STROKE SENSOR…4351
RESET SENSOR…4352
20 STANDARD VALUE TABLES…4354
TABLE OF CONTENTS…4355
STANDARD VALUE TABLE FOR ENGINE…4356
STANDARD VALUE TABLE FOR CHASSIS…4357
STANDARD VALUE TABLE FOR ENGINE…4362
STANDARD VALUE TABLE FOR CHASSIS…4363
STANDARD VALUE TABLE FOR ICT…4368
PERFORMANCE MEASURING POSTURE AND METHOD…4370
TABLE OF CONTENTS…4373
RELATED INFORMATION ON TESTING AND ADJUSTING…4375
TOOLS FOR TESTING AND ADJUSTING…4375
ENGINE AND COOLING SYSTEM…4378
ENGINE SPEED…4378
AIR INTAKE BOOST PRESSURE…4379
EXHAUST TEMPERATURE…4380
EXHAUST GAS COLOR…4382
VALVE CLEARANCE…4383
COMPRESSION PRESSURE…4386
BLOW-BY PRESSURE…4388
ENGINE OIL PRESSURE…4389
HANDLING CONTROLLER HIGH-VOLTAGE CIRCUIT…4390
FUEL SYSTEM…4391
HANDLING FUEL SYSTEM PARTS…4391
RELEASING RESIDUAL PRESSURE FROM FUEL SYSTEM…4391
BLEEDING AIR FROM FUEL CIRCUIT…4392
FUEL PRESSURE…4394
FUEL RETURN RATE AND LEAKAGE…4396
FUEL CIRCUIT FOR LEAKAGE…4399
POWER TRAIN…4400
HST OIL PRESSURE…4400
TRAVEL DEVIATION…4408
PARKING BRAKE LEVER…4409
BRAKE PERFORMANCE…4411
BRAKE PEDAL LINKAGE…4412
EMERGENCY RELEASE OF PARKING BRAKE…4414
DECELERATOR PEDAL…4417
UNDERCARRIAGE AND FRAME…4419
IDLER CLEARANCE…4419
TRACK SHOE TENSION…4421
HYDRAULIC SYSTEM…4422
FAN (WORK EQUIPMENT) PUMP PRESSURE…4422
FAN SPEED…4422
FAN SPEED SENSOR…4423
WORK EQUIPMENT…4425
BLEEDING AIR…4433
WORK EQUIPMENT…4434
LOCK LEVER ADJUSTMENT…4434
BLADE CENTER BALL ADJUSTMENT…4435
BLADE PITCH BALL ADJUSTMENT…4435
ELECTRICAL SYSTEM…4436
MONITOR PANEL (EMMS) – SPECIAL FUNCTIONS…4436
ERROR CODE TABLE…4442
PREPARATION WORK FOR TROUBLESHOOTING FOR ELECTRICAL SYSTEM…4512
SPECIAL FUNCTIONS OF iB MONITOR…4513
INPUTTING WEAR AMOUNT OF BLADE EDGE AND TRACK SHOE…4539
TESTING STROKE SENSOR FOR LIFT CYLINDER…4547
TESTING STROKE SENSOR FOR TILT CYLINDER…4549
TESTING STROKE SENSOR FOR ANGLE CYLINDER…4550
TESTING AND ADJUSTING RESET SENSOR FOR LIFT CYLINDER…4551
TESTING AND ADJUSTING RESET SENSOR FOR ANGLE CYLINDER…4552
ELECTRIC/HYDRAULIC DEVICES ARE ADJUSTED/REPLACED…4553
HST CONTROLLER ADJUSTMENT AFTER REPLACEMENT…4556
MONITOR PANEL ADJUSTMENT AFTER REPLACEMENT…4558
ADJUSTMENT METHOD WHEN ICT CONTROLLER HAS BEEN REPLACED…4560
HANLDING VOLTAGE CIRCUIT OF ENGINE CONTROLLER…4563
HANDLING BATTERY DISCONNECT SWITCH…4564
TESTING DIODES…4565
PM-CLINIC INSPECTION SHEET (1/2)…4569
PM-CLINIC INSPECTION SHEET (2/2)…4570
PM-CLINIC UNDERCARRIAGE CHECK SHEET…4571
UNDERCARRIAGE TROUBLESHOOTING REPORT (NORMAL)…4572
UNDERCARRIAGE TROUBLESHOOTING REPORT (IMPACT)…4573
PM-CLINIC UNDERCARRIAGE CHECK SHEET…4574
UNDERCARRIAGE TROUBLESHOOTING REPORT (NORMAL)…4575
UNDERCARRIAGE TROUBLESHOOTING REPORT (IMPACT)…4576
30 TESTING AND ADJUSTING…4372
40 TROUBLESHOOTING…4578
TABLE OF CONTENTS…4579
RELATED INFORMATION ON TROUBLESHOOTING…4589
SEQUENCE OF EVENTS IN TROUBLESHOOTING…4591
CHECKS BEFORE TROUBLESHOOTING…4593
INSPECTION PROCEDURE BEFORE TROUBLESHOOTING…4595
WALK-AROUND CHECK…4595
PRECAUTIONS WHEN CARRYING OUT MAINTENANCE…4596
PRECAUTIONS WHEN HANDLING ELECTRICAL EQUIPMENT…4596
HANDLING ELECTRONIC CONTROL UNIT…4601
POINTS TO REMEMBER WHEN TROUBLESHOOTING ELECTRICAL CIRCUITS…4602
POINTS TO REMEMBER WHEN HANDLING HYDRAULIC EQUIPMENT…4603
SYMPTOM AND TROUBLESHOOTING NUMBERS…4605
TROUBLESHOOTING INDIVIDUAL ELECTRICAL CIRCUITS…4609
CONNECTION TABLE FOR CONNECTOR PIN NUMBERS…4611
T-ADAPTER TABLE…4634
FAILURE CODE TABLE…4638
INFORMATION IN TROUBLESHOOTING TABLE…4648
TROUBLESHOOTING BY FAILURE CODE…4650
ERROR CODE [6091NX]…4650
ERROR CODE [AA10NX]…4652
ERROR CODE [AB00MA]…4654
ERROR CODE [B@BAZG]…4655
ERROR CODE [B@BCNS]…4656
ERROR CODE [B@CRNS]…4657
ERROR CODE [B@CRZG]…4658
ERROR CODE [CA111]…4659
ERROR CODE [CA115]…4660
ERROR CODE [CA122]…4662
ERROR CODE [CA123]…4664
ERROR CODE [CA131]…4666
ERROR CODE [CA132]…4668
ERROR CODE [CA144]…4670
ERROR CODE [CA145]…4672
ERROR CODE [CA153]…4674
ERROR CODE [CA154]…4676
ERROR CODE [CA187]…4678
ERROR CODE [CA221]…4680
ERROR CODE [CA222]…4682
ERROR CODE [CA227]…4684
ERROR CODE [CA234]…4686
ERROR CODE [CA238]…4687
ERROR CODE [CA271]…4688
ERROR CODE [CA272]…4690
ERROR CODE [CA322]…4692
ERROR CODE [CA323]…4694
ERROR CODE [CA324]…4696
ERROR CODE [CA325]…4698
ERROR CODE [CA331]…4700
ERROR CODE [CA332]…4702
ERROR CODE [CA342]…4704
ERROR CODE [CA352]…4705
ERROR CODE [CA386]…4706
ERROR CODE [CA428]…4708
ERROR CODE [CA429]…4710
ERROR CODE [CA435]…4712
ERROR CODE [CA441]…4714
ERROR CODE [CA442]…4716
ERROR CODE [CA449]…4718
ERROR CODE [CA451]…4720
ERROR CODE [CA452]…4722
ERROR CODE [CA488]…4724
ERROR CODE [CA553]…4725
ERROR CODE [CA559]…4726
ERROR CODE [CA689]…4728
ERROR CODE [CA731]…4730
ERROR CODE [CA757]…4732
ERROR CODE [CA778]…4734
ERROR CODE [CA1633]…4736
ERROR CODE [CA2185]…4738
ERROR CODE [CA2186]…4739
ERROR CODE [CA2249]…4740
ERROR CODE [CA2311]…4742
ERROR CODE [CA2555]…4744
ERROR CODE [CA2556]…4746
ERROR CODE [D130KA]…4748
ERROR CODE [D130KB]…4750
ERROR CODE [DAFRKR]…4752
ERROR CODE [DAFRMC]…4754
ERROR CODE [DAJ000]…4756
ERROR CODE [DAJ0KK]…4758
ERROR CODE [DAJ0KQ]…4760
ERROR CODE [DAJ0KT]…4761
ERROR CODE [DAJ5KK]…4762
ERROR CODE [DAJ6KK]…4764
ERROR CODE [DAJRKR]…4766
ERROR CODE [DB2RKR]…4768
ERROR CODE [DBR0KT]…4770
ERROR CODE [DBR0MC]…4771
ERROR CODE [DBR1KK]…4772
ERROR CODE [DBR2KK]…4774
ERROR CODE [DBR5KK]…4776
ERROR CODE [DBR6KK]…4778
ERROR CODE [DBRQKR]…4780
ERROR CODE [DBTSKR]…4782
ERROR CODE [DBUTKA]…4784
ERROR CODE [DD12KA]…4786
ERROR CODE [DD12KB]…4788
ERROR CODE [DD13KA]…4790
ERROR CODE [DD13KB]…4792
ERROR CODE [DD14KB]…4794
ERROR CODE [DD1NL4]…4796
ERROR CODE [DDDCKB]…4798
ERROR CODE [DDKAKA]…4800
ERROR CODE [DDKAKB]…4802
FAILURE CODE [DDKFL4]…4804
ERROR CODE [DDKGL4]…4806
ERROR CODE [DDKHKA]…4808
ERROR CODE [DDKHKB]…4810
ERROR CODE [DDNLKA]…4812
ERROR CODE [DDNLKB]…4814
ERROR CODE [DDP6KA]…4816
ERROR CODE [DDP6KB]…4818
ERROR CODE [DDP6MA]…4820
ERROR CODE [DDQ2KA]…4822
ERROR CODE [DDT0L4]…4824
ERROR CODE [DDU1FS]…4826
ERROR CODE [DDU1KA]…4828
ERROR CODE [DDU1KY]…4830
ERROR CODE [DFA4KX]…4832
ERROR CODE [DFA4KZ]…4833
ERROR CODE [DFA4L8]…4834
ERROR CODE [DFA5KA]…4835
ERROR CODE [DFA5KB]…4838
ERROR CODE [DFA6KA]…4840
ERROR CODE [DFA6KB]…4842
ERROR CODE [DFA7KX]…4844
ERROR CODE [DFA7KZ]…4845
ERROR CODE [DFA7L8]…4846
ERROR CODE [DFA8KA]…4847
ERROR CODE [DFA8KB]…4850
ERROR CODE [DFA9KA]…4852
ERROR CODE [DFA9KB]…4854
ERROR CODE [DGS1KA]…4856
ERROR CODE [DGS1KX]…4858
ERROR CODE [DH21KA]…4859
ERROR CODE [DH21KB]…4862
ERROR CODE [DHH5KA]…4864
ERROR CODE [DHH5KB]…4866
ERROR CODE [DHH6KA]…4868
ERROR CODE [DHH6KB]…4870
ERROR CODE [DK10KA]…4872
ERROR CODE [DK10KB]…4874
ERROR CODE [DK30KA]…4876
ERROR CODE [DK30KB]…4878
ERROR CODE [DK30KX]…4880
ERROR CODE [DK30KZ]…4881
ERROR CODE [DK30L8]…4882
ERROR CODE [DK31KA]…4884
ERROR CODE [DK31KB]…4886
ERROR CODE [DK40KA]…4888
ERROR CODE [DK40KB]…4890
ERROR CODE [DK55KX]…4892
ERROR CODE [DK55KZ]…4893
ERROR CODE [DK55L8]…4894
ERROR CODE [DK56KA]…4896
ERROR CODE [DK56KB]…4898
ERROR CODE [DK57KA]…4900
ERROR CODE [DK57KB]…4902
ERROR CODE [DK80KA]…4904
ERROR CODE [DKS0L8]…4906
ERROR CODE [DKS1KA]…4908
ERROR CODE [DKS1KB]…4910
ERROR CODE [DKS2KA]…4912
ERROR CODE [DKS2KB]…4914
ERROR CODE [DKS3KA]…4916
ERROR CODE [DKS3KB]…4918
ERROR CODE [DKS3MB]…4920
ERROR CODE [DKS4L8]…4921
ERROR CODE [DKS5KA]…4922
ERROR CODE [DKS5KB]…4924
ERROR CODE [DKS6KA]…4926
ERROR CODE [DKS6KB]…4928
ERROR CODE [DKS7MB]…4930
ERROR CODE [DKSCL8]…4931
ERROR CODE [DKSDKA]…4932
ERROR CODE [DKSDKB]…4934
ERROR CODE [DKSEKA]…4936
ERROR CODE [DKSEKB]…4938
ERROR CODE [DKSFKA]…4940
ERROR CODE [DKSFKB]…4942
ERROR CODE [DKSFMB]…4944
ERROR CODE [DLM0KX]…4945
ERROR CODE [DLM1KA]…4946
ERROR CODE [DLM1KB]…4948
ERROR CODE [DLM1MA]…4950
ERROR CODE [DLM2KA]…4952
ERROR CODE [DLM2KB]…4954
ERROR CODE [DLM2MA]…4956
ERROR CODE [DLM3KA]…4958
ERROR CODE [DLM3KB]…4960
ERROR CODE [DN21FS]…4962
ERROR CODE [DV00KB]…4964
ERROR CODE [DV20KB]…4965
ERROR CODE [DW4BKA]…4966
ERROR CODE [DW4BKB]…4968
ERROR CODE [DW4BKY]…4970
ERROR CODE [DW7BKA]…4971
ERROR CODE [DW7BKB]…4972
ERROR CODE [DW7BKY]…4973
ERROR CODE [DW7EKA]…4974
ERROR CODE [DW7EKB]…4978
ERROR CODE [DW7EKY]…4980
ERROR CODE [DWN5KA]…4982
ERROR CODE [DWN5KB]…4984
ERROR CODE [DWN5KY]…4986
ERROR CODE [DXA4KA]…4988
ERROR CODE [DXA4KB]…4990
ERROR CODE [DXA4KY]…4991
ERROR CODE [DXA5KA]…4992
ERROR CODE [DXA5KB]…4993
ERROR CODE [DXA5KY]…4994
ERROR CODE [DXA6KA]…4995
ERROR CODE [DXA6KB]…4996
ERROR CODE [DXA6KY]…4997
ERROR CODE [DXA7KA]…4998
ERROR CODE [DXA7KB]…4999
ERROR CODE [DXA7KY]…5000
ERROR CODE [DXHRKA]…5002
ERROR CODE [DXHRKB]…5004
ERROR CODE [DXHRKY]…5006
ERROR CODE [DXHSKA]…5008
ERROR CODE [DXHSKB]…5010
ERROR CODE [DXHSKY]…5012
ERROR CODE [DXHTKA]…5014
ERROR CODE [DXHTKB]…5016
ERROR CODE [DXHTKY]…5018
ERROR CODE [DXHUKA]…5020
ERROR CODE [DXHUKB]…5022
ERROR CODE [DXHUKY]…5024
ERROR CODE [DXJ4KA]…5026
ERROR CODE [DXJ4KB]…5028
ERROR CODE [DXJCKA]…5030
ERROR CODE [DXJCKB]…5031
ERROR CODE [DXJCKY]…5032
ERROR CODE [DXJDKA]…5034
ERROR CODE [DXJDKB]…5035
ERROR CODE [DXJDKY]…5036
ERROR CODE [DXK1KA]…5038
ERROR CODE [DXK1KB]…5039
ERROR CODE [DXK1KY]…5040
ERROR CODE [DXK2KA]…5041
ERROR CODE [DXK2KB]…5042
ERROR CODE [DXK2KY]…5043
TROUBLESHOOTING OF ELECTRICAL SYSTEM (E-MODE)…5044
BEFORE CARRYING OUT TROUBLESHOOTING (E-MODE)…5044
INFORMATION IN TROUBLESHOOTING TABLE…5046
E-1 STARTING MOTOR DOES NOT ROTATE…5047
E-2 ENGINE IS NOT PRE-HEATED…5050
E-3 WHEN STARTING SWITCH IS TURNED ON, ANY ITEM DOES NOT LIGHT…5053
E-4 CHARGE LEVEL CAUTION FLASHES WHILE ENGINE IS RUNNING…5055
E-5 EMERGENCY WARNING ITEMS FLASH WHILE ENGINE IS RUNNING…5057
E-6 PRE-HEAT LAMP DOES NOT LIGHT DURING PRE-HEATING OPERATION…5061
E-7 COOLANT TEMPERATURE GAUGE DOES NOT INDICATE CORRECTLY…5063
E-8 HST OIL TEMPERATURE GAUGE DOES NOT INDICATE CORRECTLY…5064
E-9 FUEL LEVEL GAUGE DOES NOT INDICATE PROPERLY…5065
E-10 TRAVEL INDICATOR DOES NOT DISPLAY NORMALLY…5066
E-11 MULTI-INFORMATION UNIT DOES NOT DISPLAY NORMALLY…5066
E-12 CAUTION LAMP DOES NOT FLASH OR DOES NOT GO OFF…5067
E-13 CAUTION BUZZER DOES NOT SOUND OR DOES NOT STOP…5069
E-14 REVERSE TRAVEL SPEED SETTING SWITCH DOES NOT FUNCTION…5071
E-15 SHIFT MODE SWITCH DOES NOT FUNCTION…5073
E-16 BUZZER CANCEL SWITCH DOES NOT FUNCTION…5075
E-17 INFORMATION SWITCH DOES NOT FUNCTION…5077
E-18 THE FAN CLEANING DOES NOT OPERATE OR CANNOT BE RESET…5079
E-19 BACKUP ALARM DOES NOT SOUND…5081
E-20 THE HORN DOES NOT SOUND OR DOES NOT STOP…5082
E-21 WORK EQUIPMENT DOES NOT OPERATE…5084
E-22 HEAD LAMP OR REAR LAMP DOES NOT LIGHT UP…5086
E-23 FOOT HEATER DOES NOT OPERATE…5090
E-24 AIR CONDITIONER DOES NOT OPERATE [CAB SPECIFICATION]…5092
E-25 WIPER AND WASHER DO NOT OPERATE [CAB SPECIFICATION]…5097
E-26 KOMTRAX SYSTEM DOES NOT OPERATE NORMALLY…5109
E-27 iB MONITOR SHUTS DOWN AFTER DISPLAYING THE MESSAGES [GPS RECEIVER NOT CONNECTED!] AND [SLOPE SENSOR NOT CONNECTED!]…5111
E-28 iB MONITOR DISPLAYS THE MESSAGES[GPS RECEIVER NOT CONECTED!] AND [SLOPE SENSOR NOT CONNECTED!]…5114
E-29 iB MONITOR DISPLAYS THE MESSAGE [WAITING FOR RADIO LINK…]…5117
E-30 iB MONITOR DISPLAYS THE MESSAGE [IMU SENSOR NOT CONNECTED]…5118
E-31 iB MONITOR DISPLAYS THE MESSAGE [WAITING FOR SATELLITES…]…5119
E-32 iB MONITOR DISPLAYS THE MESSAGE [KOMATSU CONTROLLER NOT CONNECTED]…5120
E-33 iB MONITOR DISPLAYS THE MESSAGE [CYLINDER STROKE READING ABNORMAL]…5122
E-34 iB MONITOR DISPLAYS THE MESSAGE [KOMATSU CAN COMMS ABNORMAL]…5123
E-35 iB MONITOR DISPLAYS THE MESSAGE [KOMATSU MACHINE TROUBLE]…5124
E-36 iB MONITOR DISPLAYS THE MESSAGE [WAITING TO INITIALIZE…]…5125
E-37 iB MONITOR DISPLAYS THE MESSAGE [SYSTEM INITIALIZING…]…5126
E-38 iB MONITOR DISPLAYS THE MESSAGE [INITIALIZING…]…5127
E-39 iB MONITOR DISPLAYS THE MESSAGE [CONFIGURING GPS]…5128
E-40 iB MONITOR DISPLAYS THE MESSAGE [NO GPS LOCALIZATION… ]…5129
E-41 iB MONITOR DISPLAYS THE MESSAGE [LOW PRECISIONS…]…5130
E-42 iB MONITOR DISPLAYS THE MESSAGE [HEADING INITIALIZING]…5131
E-43 iB MONITOR DISPLAYS [OUT OF DESIGN AREA…]…5132
E-44 iB MONITOR CAN NOT BE TURNED ON…5133
E-45 iB MONITOR DOES NOT DISPLAY INTELLIGENT MACHINE CONTROL SCREN…5134
E-46 iB MONITOR DOES NOT DISPLAY BULLDOZER IMAGE…5135
E-47 iB MONITOR DOES NOT DISPLAY DESIGN SURFACE…5136
E-48 iB MONITOR TOUCH PANEL DOES NOT RESPOND…5137
E-49 iB MONITOR TOUCH PANEL IS INACCURATE…5138
E-50 CYLINDER STROKE RESET INDICATION DOES NOT GO OUT…5139
E-51 AUTO IS NOT DISPLAYED WHEN AUTO/MANUAL SWITCH IS PRESSED (AUTO INDICATION GOES OUT)…5140
E-52 BLADE AUTOMATIC RAISE CONTROL DOES NOT START WHILE AUTO IS DISPLAYED…5141
E-53 BLADE AUTOMATIC LOWER CONTROL DOES NOT START WHILE AUTO IS DISPLAYED…5142
E-54 BLADE AUTOMATIC CONTROL FUNCTION IS NOT ACTIVATED WHILE AUTO IS DISPLAYED (BLADE AUTOMATIC CONTROL STOPS)…5143
E-55 WHEN CHECKING AND ADJUSTING THE BLADE ELEVATION, THE VALUE IS DIFFERENT FROM ACTUAL MACHINE…5144
E-56 FINISHED SURFACE IS INACCURATE (THE AVERAGE HEIGHT OF FINISHED SURFACE IS LOWER THAN DESIGNED SURFACE OR BLADE DOES NOT TOUCH THE SURFACE)…5145
E-57 FINISHED SURFACE IS INACCURATE (THE FINISHED IS NOT SMOOTH)…5146
E-58 FINISHED SURFACE IS INACCURATE (WHEN FINISHING SLOPE HORIZONTALLY, STEPS ARE MADE IN EACH DIRECTION)…5147
E-59 MACHINE CAN NOT ESCAPE FROM SHOES SLIP WHILE BLADE AUTOMATIC CONTROL IS ACTIVATED (SHOES FREQUENTLY SLIPS)…5149
E-60 MACHINE SPEED DOES NOT INCREASE WHILE BLADE AUTOMATIC CONTROL IS ACTIVATED…5150
E-61 BLADE TILT ANGLE DOES NOT COINCIDE WITH DESIGN SURFACE…5151
E-62 BLADE TILTS BACK WHILE BLADE AUTOMATIC CONTROL IS ACTIVATED…5153
TROUBLESHOOTING OF HYDRAULIC AND MECHANICAL SYSTEM (H- MODE)…5156
INFORMATION IN TROUBLESHOOTING TABLE…5156
H-1 RIGHT AND LEFT TRAVEL SYSTEMS INOPERABLE…5157
H-2 RIGHT OR LEFT TRAVEL SYSTEM DOES NOT OPERATE…5159
H-3 RIGHT OR LEFT TRAVEL SYSTEM DOES NOT OPERATE…5160
H-4 SPEED OR POWER OF TRAVEL IS LOW…5161
H-5 GEAR IS NOT SHIFTED…5162
H-6 LARGE SHOCKS ARE MADE WHEN MACHINE STARTS AND STOPS TRAVEL…5163
H-7 MACHINE DEVIATES LARGELY DURING TRAVEL…5164
H-8 HYDRAULIC DRIFT OF TRAVEL IS LARGE…5165
H-9 ENGINE STALLS OR SPEED LOWERS EXTREMELY DURING TRAVEL…5166
H-10 ABNORMAL SOUND COMES OUT FROM AROUND HST PUMP AND MOTOR…5167
H-11 WORK EQUIPMENT DOSE NOT OPERATE AT ALL…5168
H-12 SPEED OR POWER OF WHOLE WORK EQUIPMENT IS LOW…5169
H-13 BLADE LIFT SPEED OR POWER IS LOW…5170
H-14 BLADE TILT SPEED OR POWER IS LOW…5171
H-15 BLADE ANGLE SPEED OR POWER IS LOW…5172
H-16 TIME LAG OF BLADE LIFT IS LARGE…5173
H-17 HYDRAULIC DRIFT OF LIFTED BLADE IS LARGE…5174
H-18 HYDRAULIC DRIFT OF TILTING BLADE IS LARGE…5175
H-19 UNUSUAL NOISE IS HEARD FROM WORK EQUIPMENT PUMP OR CONTROL VALVE…5176
H-20 HST OIL TEMPERATURE RISES TOO HIGH…5177
H-21 FAN SPEED IS ABNORMAL (HIGH, LOW, OR 0 RPM)…5178
TROUBLESHOOTING OF ENGINE (S-MODE)…5180
METHOD OF USING TROUBLESHOOTING CHARTS…5180
(S-1) ENGINE STARTING PERFORMANCE IS POOR…5184
(S-2) ENGINE DOES NOT CRANK…5185
ENGINE CRANKS BUT NO EXHAUST SMOKE COMES OUT OF STACK…5186
SMOKE COMES OUT OF STACK BUT ENGINE DOES NOT START…5187
(S-3) ENGINE DOES NOT RUN SMOOTHLY…5188
(S-4) ENGINE STOPS DURING OPERATIONS…5189
(S-5) ENGINE SPEED HUNTS…5190
(S-6) ENGINE LACKS POWER…5191
(S-7) EXHAUST SMOKE IS BLACK…5193
(S-8) OIL CONSUMPTION IS EXCESSIVE OR EXHAUST SMOKE IS BLUE…5194
(S-9) OIL BECOMES CONTAMINATED QUICKLY…5195
(S-10) FUEL CONSUMPTION IS EXCESSIVE…5196
(S-11) OIL FOUND IN COOLANT, OR COOLANT SPURTS FROM RADIATOR…5197
(S-12) OIL PRESSURE CAUTION LAMP LIGHTS UP…5198
(S-13) OIL LEVEL RISES (COOLANT OR FUEL FOUND IN OIL)…5199
(S-14) COOLANT TEMPERATURE TOO HIGH (OVERHEATING)…5200
(S-15) ABNORMAL NOISE IS HEARD WHEN ENGINE IS RUNNING…5201
(S-16) EXCESSIVE VIBRATION WHEN ENGINE IS RUNNING…5202
50 DISASSEMBLY AND ASSEMBLY…5204
TABLE OF CONTENTS…5205
RELATED INFORMATION ON DISASSEMBLY AND ASSEMBLY…5208
HOW TO READ THIS MANUAL…5208
SPECIAL TOOL LIST…5216
SKETCH OF SPECIAL TOOLS…5223
CONNECTOR REPAIR PROCEDURES…5238
CONTACT TERMINAL REMOVAL (HD30 TYPE)…5238
STRIPPING INSULATION…5239
CRIMPING CONTACT TERMINAL (HD30 TYPE)…5240
INSERTION OF CONTACT TERMINAL (HD30 TYPE)…5241
CONTACT TERMINAL REMOVAL (DT TYPE)…5242
STRIPPING INSULATION…5243
CRIMPING CONTACT TERMINAL (DT TYPE)…5244
INSERTION OF CONTACT TERMINAL (DT TYPE)…5245
NOSE GUARD (HOOD)…5247
REMOVAL…5247
INSTALLATION…5251
MUFFLER AND EXHAUST STACK…5253
REMOVAL…5253
INSTALLATION…5254
CAB AND ITS ATTACHMENTS…5255
CAB…5255
MONITOR PANEL AND HST CONTROLLER…5270
KOMTRAX CONTROLLER…5273
REMOVAL AND INSTALLATION OF ICT SENSOR CONTROLLER ASSEMBLY…5274
REMOVAL AND INSTALLATION OF iB MONITOR…5275
REMOVAL AND INSTALLATION OF GNSS RECEIVER…5277
REMOVAL AND INSTALLATION OF iB GNSS ANTENNA…5279
REMOVAL AND INSTALLATION OF IMU SENSOR…5284
SEAT…5288
AIR CONDITIONER/HEATER…5289
DISASSEMBLY OF AIR CONDITIONER…5289
ASSEMBLY OF AIR CONDITIONER…5293
FOOT HEATER…5294
REMOVAL…5294
INSTALLATION…5296
FOOT HEATER OVERHAUL PROCEDURES…5296
ASSEMBLY PROCEDURES…5298
ENGINE AND COOLING SYSTEM…5300
REMOVAL…5300
ENGINE AND HST PUMP…5307
INSTALLATION…5309
REMOVAL FROM ENGINE…5311
INSTALLATION TO ENGINE…5314
DRIVE DAMPENER…5315
REMOVAL…5315
INSTALLATION…5316
HST PUMP OVERHAUL PROCEDURES…5317
DISASSEMBLY PROCEDURES…5317
ASSEMBLY PROCEDURES…5326
WORK EQUIPMENT PUMP OVERHAUL PROCEDURES…5338
DISASSEMBLY PROCEDURES…5338
ASSEMBLY PROCEDURES…5344
REMOVAL…5351
INSTALL…5352
CHARGE PUMP OVERHAUL PROCEDURES…5353
DISASSEMBLY PROCEDURES…5353
ASSEMBLY PROCEDURES…5359
DIESEL ENGINE OVERHAUL PROCEDURES…5365
DISASSEMBLY OF EXTERNAL COMPONENTS…5365
DISASSEMBLY OF ENGINE TOP END…5371
REMOVAL OF OIL COOLER, ENGINE CONTROLLER AND FUEL PUMP…5375
DISASSEMBLY OF ENGINE LOWER END…5377
ASSEMBLY OF ENGINE LOWER END…5384
INSTALLATION OF OIL COOLER, ENGINE CONTROLLER AND FUEL PUMP…5400
ASSEMBLY OF EXTERNAL COMPONENTS…5409
TRACK SYSTEM…5436
SPREADING THE TRACK…5436
(CONVENTIONAL TYPE TRACK SHOE)…5436
EXPANSION AND INSTALLATION OF TRACK SHOE ASSEMBLY (PLUS TYPE TRACK SHOE)…5438
FIELD DISASSEMBLY AND ASSEMBLY OF ONE LINK (CONVENTIONAL TYPE TRACK SHOE)…5452
FIELD DISASSEMBLY AND ASSEMBLY OF ONE LINK (PLUS TYPE TRACK SHOE)…5460
TRACK FRAME…5467
REMOVAL OF TRACK FRAME…5467
FRONT TRACK IDLER…5476
REMOVING FRONT IDLER…5476
INSTALLING FRONT IDLER…5478
TRACK ROLLER…5479
REMOVAL…5479
INSTALLATION…5479
TRACK ROLLER OVERHAUL PROCEDURES…5480
CARRIER ROLLER OVERHAUL PROCEDURES…5485
FINAL DRIVE…5487
FINAL DRIVE REMOVAL…5487
INSTALLING THE FINAL DRIVE…5491
FINAL DRIVE OVERHAUL PROCEDURES…5493
DISASSEMBLY PROCEDURES…5493
ASSEMBLY OF FINAL DRIVE…5499
TRAVEL MOTOR OVERHAUL PROCEDURES…5507
DISASSEMBLY PROCEDURES…5507
ASSEMBLY PROCEDURES…5512
FAN MOTOR…5525
REMOVAL PROCEDURES…5525
INSTALLATION PROCEDURES…5529
FAN MOTOR OVERHAUL PROCEDURES…5531
DISASSEMBLY PROCEDURES…5531
ASSEMBLY PROCEDURES…5535
DB 12 VALVE…5542
REMOVAL…5542
INSTALLATION…5544
COOLING PACKAGE…5545
REMOVING THE GRILL AND COOLING FAN ASSEMBLY…5545
REMOVING THE COOLING PACKAGE…5556
INSTALLING THE COOLING PACKAGE…5564
INSTALLING THE GRILL AND COOLING FAN ASSEMBLY…5565
FUEL TANK…5569
REMOVING THE FUEL TANK…5569
INSTALLING THE FUEL TANK…5574
HYDRAULIC TANK…5575
REMOVING THE HYDRAULIC TANK…5575
INSTALLING THE HYDRAULIC TANK…5581
WORK EQUIPMENT…5582
REMOVING OR INSTALLING PINS…5582
FRONT BLADE, TILT AND ANGLE CYLINDERS…5583
ADJUSTING BLADE CENTER BALL AND PITCH ROD PLAY…5588
“C” FRAME…5590
LIFT CYLINDERS…5593
CYLINDER OVERHAUL PROCEDURES…5595
DISASSEMBLY PROCEDURES…5595
ASSEMBLY PROCEDURES…5596
WHOLE DISASSEMBLY AND ASSEMBLY OF TRACK SHOE (PLUS TYPE TRACK SHOE)…5435
WHOLE DISASSEMBLY AND ASSEMBLY OF TRACK SHOE ASSEMBLY (CONVENTIONAL TYPE TRACK SHOE)…5415
90 OTHERS…5600
TABLE OF CONTENTS…5601
CONNECTOR ARRANGEMENT DRAWING AND ELECTRICAL CIRCUITDIAGRAM…5602
CONNECTOR LIST…5602
CONNECTOR LOCATION VIEW…5606
HYDRAULIC SYSTEM…5623
SYMBOLS IN HYDRAULIC CIRCUIT DIAGRAMS…5623
HYDRAULIC SYSTEM…5624
ELECTRICAL SYSTEM…5625
SYMBOLS IN ELECTRICAL CIRCUIT DIAGRAMS …5625
CAB ELECTRICAL ACCESSORIES…5626
AIR CONDITIONER CIRCUIT DIAGRAM…5627
Electrical Circuit Diagram (1/8)…5628
Electrical Circuit Diagram (2/8)…5629
Electrical Circuit Diagram (3/8)…5630
Electrical Circuit Diagram (4/8)…5631
Electrical Circuit Diagram (5/8)…5632
Electrical Circuit Diagram (6/8)…5633
Electrical Circuit Diagram (7/8)…5634
Electrical Circuit Diagram (8/8)…5635
KEBM028602 – Crawler Dozer D51EXi-22, D51PXi-22 Shop Manual (SN-B13500&up)…5636
COVER…5636
INNER COVER…5638
00 INDEX AND FOREWORD…5652
INDEX…5653
FOREWORD, SAFETY AND GENERAL INFORMATION…5666
IMPORTANT SAFETY NOTICE…5666
HOW TO READ THE SHOP MANUAL…5673
EXPLANATION OF TERMS FOR MAINTENACE STANDARD…5675
HANDLING EQUIPMENT OF FUEL SYSTEM DEVICES…5677
HANDLING OF INTAKE SYSTEM PARTS…5678
HANDLING OF HYDRAULIC EQUIPMENT…5679
METHOD OF DISCONNECTING AND CONNECTING OF PUSH-PULL TYPE COUPLER…5681
HANDLING OF ELECTRICAL EQUIPMENT…5684
HOW TO READ ELECTRIC WIRE CODE…5692
PRECAUTIONS WHEN PERFORMING OPERATION…5695
PRACTICAL USE OF KOMTRAX…5700
STANDARD TIGHTENING TORQUE TABLE…5701
LIST OF ABBREVIATION…5707
CONVERSION TABLE…5712
01 SPECIFICATION…5718
TABLE OF CONTENTS…5719
SPECIFICATION DRAWING…5720
D51EXi, PXi-22 POWER ANGLE, POWER TILT DOZER WITH ROPS CAB…5720
SPECIFICATION…5721
WEIGHT TABLE…5725
TABLE OF FUEL, COOLANT AND LUBRICANTS…5727
RECOMMENDED PRODUCTS OTHER THAN KOMATSU GENUINE OILS…5729
10 STRUCTURE AND FUNCTION…5730
TABLE OF CONTENTS…5731
ENGINE AND COOLING SYSTEM…5734
ENGINE RELATED PARTS…5734
COOLING SYSTEM…5736
COOLING FAN PUMP – SEE HYDRAULIC SYSTEM 2 (WORK EQUIPMENT AND FAN PUMP)…5739
COOLING FAN MOTOR…5740
OIL COOLER BYPASS VALVE…5745
CHARGE SAFETY VALVE…5748
POWER TRAIN…5750
POWER TRAIN…5750
HST CLOSED CIRCUIT…5752
DAMPER…5753
HST HYDRAULIC EQUIPMENT ARRANGEMENT DIAGRAM…5754
STEERING AND BRAKE CONTROL…5755
HST PUMP…5757
SAFETY-SUCTION VALVE…5765
TOWING VALVE…5768
HST MOTOR…5769
MOTOR CONTROL VALVE…5781
SOLENOID VALVE (3-SPOOL), EPC VALVE (2-SPOOL) AND TOWING VALVE…5781
SOLENOID VALVE…5783
EPC VALVE…5784
CHARGE PUMP…5788
FINAL DRIVE…5790
PATH OF POWER TRANSMISSION…5793
UNDER CARRIAGE AND FRAME…5794
MAIN FRAME…5794
TRACK FRAME AND RECOIL SPRING…5795
IDLER…5797
TRACK ROLLER…5799
CARRIER ROLLER…5803
SPROCKET…5805
SINGLE SHOE…5811
SUSPENSION…5812
HYDRAULIC SYSTEM…5815
HYDRAULIC COMPONENT LAYOUT OF WORK EQUIPMENT…5815
WORK EQUIPMENT CONTROL SYSTEM…5816
HYDRAULIC SYSTEM (WORK EQUIPMENT)…5818
WORK EQUIPMENT AND FAN PUMP…5821
SERVO VALVE…5825
CONTROL VALVE…5827
HYDRAULIC CIRCUIT DIAGRAM AND NAMES OF VALVES…5834
UNLOAD VALVE…5836
PRESSURE COMPENSATION VALVE…5839
HYDRAULIC TANK, FILTER…5849
BREATHER…5850
ACCUMULATOR…5851
WORK EQUIPMENT…5852
WORK EQUIPMENT…5852
CUTTING EDGE AND END BIT…5857
RIPPER…5858
PISTON VALVE FOR ANGLE CYLINDER…5859
CAB AND ITS ATTACHMENTS…5860
ROPS CAB…5860
CAB DAMPER MOUNT…5861
AIR CONDITIONER…5862
ELECTRICAL SYSTEM…5864
MONITOR SYSTEM…5864
ENGINE CONTROL SYSTEM…5866
COOLING CONTROL SYSTEM…5869
HST CONTROL SYSTEM…5871
GEAR SHIFT CONTROL SYSTEM…5872
PARKING BRAKE CONTROL SYSTEM…5877
KOMTRAX SYSTEM…5879
ICT CONTROL SYSTEM…5880
ICT CONTROL FUNCTION…5881
BLADE CONTROL SYSTEM…5883
DOZING MODE…5886
SMOOTH START FUNCTION…5889
SLIP CONTROL…5891
BLADE ASSIST CONTROL…5893
HST SPEED RANGE CONTROL SYSTEM…5895
SYSTEM COMPONENTS…5897
MONITOR PANEL…5897
BUZZER CANCEL SWITCH…5898
MONITOR PANEL DISPLAY…5899
ENGINE CONTROLLER…5901
HST CONTROLLER…5903
ICT CONTROLLER…5905
iB MONITOR…5908
GNSS RECEIVER…5910
KOMTRAX TERMINAL…5919
SENSORS…5920
BRAKE OIL PRESSURE SENSOR…5921
HYDRAULIC OIL TEMPERATURE SENSOR…5922
HST CIRCUIT OIL PRESSURE SENSOR…5923
AIR CLEANER CLOGGING SENSOR…5924
BRAKE PEDAL POTENTIOMETER…5925
FUEL CONTROL DIAL…5926
FUEL LEVEL SENSOR…5927
CHARGE FILTER CLOGGING SENSOR…5928
COOLANT TEMPERATURE SENSOR…5928
ENGINE OIL PRESSURE SWITCH…5929
ENGINE ROTATION SENSOR…5929
BOOST PRESSURE AND SENSOR…5930
WIF SENSOR…5930
HST MOTOR SPEED SENSOR…5931
IMU SENSOR…5932
STROKE AND RESET SENSOR FOR LIFT CYLINDER…5933
STROKE SENSOR…5934
RESET SENSOR…5935
STROKE SENSOR FOR TILT CYLINDER…5936
STROKE SENSOR…5937
STROKE AND RESET SENSOR FOR ANGLE CYLINDER…5938
STROKE SENSOR…5939
RESET SENSOR…5940
20 STANDARD VALUE TABLES…5942
TABLE OF CONTENTS…5943
STANDARD VALUE TABLE FOR ENGINE…5944
STANDARD VALUE TABLE FOR CHASSIS…5945
STANDARD VALUE TABLE FOR ENGINE…5950
STANDARD VALUE TABLE FOR CHASSIS…5951
STANDARD VALUE TABLE FOR ICT…5956
PERFORMANCE MEASURING POSTURE AND METHOD…5958
30 TESTING AND ADJUSTING…5960
TABLE OF CONTENTS…5961
RELATED INFORMATION ON TESTING AND ADJUSTING…5963
TOOLS FOR TESTING AND ADJUSTING…5963
ENGINE AND COOLING SYSTEM…5966
ENGINE SPEED…5966
AIR INTAKE BOOST PRESSURE…5967
EXHAUST TEMPERATURE…5968
EXHAUST GAS COLOR…5970
VALVE CLEARANCE…5971
COMPRESSION PRESSURE…5974
BLOW-BY PRESSURE…5976
ENGINE OIL PRESSURE…5977
HANDLING CONTROLLER HIGH-VOLTAGE CIRCUIT…5978
FUEL SYSTEM…5979
HANDLING FUEL SYSTEM PARTS…5979
RELEASING RESIDUAL PRESSURE FROM FUEL SYSTEM…5979
BLEEDING AIR FROM FUEL CIRCUIT…5980
FUEL PRESSURE…5982
FUEL RETURN RATE AND LEAKAGE…5984
FUEL CIRCUIT FOR LEAKAGE…5987
POWER TRAIN…5988
HST OIL PRESSURE…5988
TRAVEL DEVIATION…5996
PARKING BRAKE LEVER…5997
BRAKE PERFORMANCE…5999
BRAKE PEDAL LINKAGE…6000
EMERGENCY RELEASE OF PARKING BRAKE…6002
DECELERATOR PEDAL…6005
UNDERCARRIAGE AND FRAME…6007
IDLER CLEARANCE…6007
TRACK SHOE TENSION…6009
HYDRAULIC SYSTEM…6010
FAN (WORK EQUIPMENT) PUMP PRESSURE…6010
FAN SPEED…6010
FAN SPEED SENSOR…6011
WORK EQUIPMENT…6013
BLEEDING AIR…6021
WORK EQUIPMENT…6022
LOCK LEVER ADJUSTMENT…6022
BLADE CENTER BALL ADJUSTMENT…6023
BLADE PITCH BALL ADJUSTMENT…6023
ELECTRICAL SYSTEM…6024
MONITOR PANEL (EMMS) – SPECIAL FUNCTIONS…6024
ERROR CODE TABLE…6030
PREPARATION WORK FOR TROUBLESHOOTING FOR ELECTRICAL SYSTEM…6100
SPECIAL FUNCTIONS OF iB MONITOR…6101
INPUTTING WEAR AMOUNT OF BLADE EDGE AND TRACK SHOE…6127
TESTING STROKE SENSOR FOR LIFT CYLINDER…6135
TESTING STROKE SENSOR FOR TILT CYLINDER…6137
TESTING STROKE SENSOR FOR ANGLE CYLINDER…6138
TESTING AND ADJUSTING RESET SENSOR FOR LIFT CYLINDER…6139
TESTING AND ADJUSTING RESET SENSOR FOR ANGLE CYLINDER…6140
ELECTRIC/HYDRAULIC DEVICES ARE ADJUSTED/REPLACED…6141
HST CONTROLLER ADJUSTMENT AFTER REPLACEMENT…6144
MONITOR PANEL ADJUSTMENT AFTER REPLACEMENT…6146
ADJUSTMENT METHOD WHEN ICT CONTROLLER HAS BEEN REPLACED…6148
HANLDING VOLTAGE CIRCUIT OF ENGINE CONTROLLER…6151
HANDLING BATTERY DISCONNECT SWITCH…6152
TESTING DIODES…6153
PM-CLINIC INSPECTION SHEET (1/2)…6157
PM-CLINIC INSPECTION SHEET (2/2)…6158
PM-CLINIC UNDERCARRIAGE CHECK SHEET…6159
UNDERCARRIAGE TROUBLESHOOTING REPORT (NORMAL)…6160
UNDERCARRIAGE TROUBLESHOOTING REPORT (IMPACT)…6161
PM-CLINIC UNDERCARRIAGE CHECK SHEET…6162
UNDERCARRIAGE TROUBLESHOOTING REPORT (NORMAL)…6163
UNDERCARRIAGE TROUBLESHOOTING REPORT (IMPACT)…6164
40 TROUBLESHOOTING…6166
TABLE OF CONTENTS…6167
RELATED INFORMATION ON TROUBLESHOOTING…6177
SEQUENCE OF EVENTS IN TROUBLESHOOTING…6179
CHECKS BEFORE TROUBLESHOOTING…6181
INSPECTION PROCEDURE BEFORE TROUBLESHOOTING…6183
WALK-AROUND CHECK…6183
PRECAUTIONS WHEN CARRYING OUT MAINTENANCE…6184
PRECAUTIONS WHEN HANDLING ELECTRICAL EQUIPMENT…6184
HANDLING ELECTRONIC CONTROL UNIT…6189
POINTS TO REMEMBER WHEN TROUBLESHOOTING ELECTRICAL CIRCUITS…6190
POINTS TO REMEMBER WHEN HANDLING HYDRAULIC EQUIPMENT…6191
SYMPTOM AND TROUBLESHOOTING NUMBERS…6193
TROUBLESHOOTING INDIVIDUAL ELECTRICAL CIRCUITS…6197
CONNECTION TABLE FOR CONNECTOR PIN NUMBERS…6199
T-ADAPTER TABLE…6222
FAILURE CODE TABLE…6226
INFORMATION IN TROUBLESHOOTING TABLE…6236
TROUBLESHOOTING BY FAILURE CODE…6238
ERROR CODE [6091NX]…6238
ERROR CODE [AA10NX]…6240
ERROR CODE [AB00MA]…6242
ERROR CODE [B@BAZG]…6243
ERROR CODE [B@BCNS]…6244
ERROR CODE [B@CRNS]…6245
ERROR CODE [B@CRZG]…6246
ERROR CODE [CA111]…6247
ERROR CODE [CA115]…6248
ERROR CODE [CA122]…6250
ERROR CODE [CA123]…6252
ERROR CODE [CA131]…6254
ERROR CODE [CA132]…6256
ERROR CODE [CA144]…6258
ERROR CODE [CA145]…6260
ERROR CODE [CA153]…6262
ERROR CODE [CA154]…6264
ERROR CODE [CA187]…6266
ERROR CODE [CA221]…6268
ERROR CODE [CA222]…6270
ERROR CODE [CA227]…6272
ERROR CODE [CA234]…6274
ERROR CODE [CA238]…6275
ERROR CODE [CA271]…6276
ERROR CODE [CA272]…6278
ERROR CODE [CA322]…6280
ERROR CODE [CA323]…6282
ERROR CODE [CA324]…6284
ERROR CODE [CA325]…6286
ERROR CODE [CA331]…6288
ERROR CODE [CA332]…6290
ERROR CODE [CA342]…6292
ERROR CODE [CA352]…6293
ERROR CODE [CA386]…6294
ERROR CODE [CA428]…6296
ERROR CODE [CA429]…6298
ERROR CODE [CA435]…6300
ERROR CODE [CA441]…6302
ERROR CODE [CA442]…6304
ERROR CODE [CA449]…6306
ERROR CODE [CA451]…6308
ERROR CODE [CA452]…6310
ERROR CODE [CA488]…6312
ERROR CODE [CA553]…6313
ERROR CODE [CA559]…6314
ERROR CODE [CA689]…6316
ERROR CODE [CA731]…6318
ERROR CODE [CA757]…6320
ERROR CODE [CA778]…6322
ERROR CODE [CA1633]…6324
ERROR CODE [CA2185]…6326
ERROR CODE [CA2186]…6327
ERROR CODE [CA2249]…6328
ERROR CODE [CA2311]…6330
ERROR CODE [CA2555]…6332
ERROR CODE [CA2556]…6334
ERROR CODE [D130KA]…6336
ERROR CODE [D130KB]…6338
ERROR CODE [DAFRKR]…6340
ERROR CODE [DAFRMC]…6342
ERROR CODE [DAJ000]…6344
ERROR CODE [DAJ0KK]…6346
ERROR CODE [DAJ0KQ]…6348
ERROR CODE [DAJ0KT]…6349
ERROR CODE [DAJ5KK]…6350
ERROR CODE [DAJ6KK]…6352
ERROR CODE [DAJRKR]…6354
ERROR CODE [DB2RKR]…6356
ERROR CODE [DBR0KT]…6358
ERROR CODE [DBR0MC]…6359
ERROR CODE [DBR1KK]…6360
ERROR CODE [DBR2KK]…6362
ERROR CODE [DBR5KK]…6364
ERROR CODE [DBR6KK]…6366
ERROR CODE [DBRQKR]…6368
ERROR CODE [DBTSKR]…6370
ERROR CODE [DBUTKA]…6372
ERROR CODE [DD12KA]…6374
ERROR CODE [DD12KB]…6376
ERROR CODE [DD13KA]…6378
ERROR CODE [DD13KB]…6380
ERROR CODE [DD14KB]…6382
ERROR CODE [DD1NL4]…6384
ERROR CODE [DDDCKB]…6386
ERROR CODE [DDKAKA]…6388
ERROR CODE [DDKAKB]…6390
FAILURE CODE [DDKFL4]…6392
ERROR CODE [DDKGL4]…6394
ERROR CODE [DDKHKA]…6396
ERROR CODE [DDKHKB]…6398
ERROR CODE [DDNLKA]…6400
ERROR CODE [DDNLKB]…6402
ERROR CODE [DDP6KA]…6404
ERROR CODE [DDP6KB]…6406
ERROR CODE [DDP6MA]…6408
ERROR CODE [DDQ2KA]…6410
ERROR CODE [DDT0L4]…6412
ERROR CODE [DDU1FS]…6414
ERROR CODE [DDU1KA]…6416
ERROR CODE [DDU1KY]…6418
ERROR CODE [DFA4KX]…6420
ERROR CODE [DFA4KZ]…6421
ERROR CODE [DFA4L8]…6422
ERROR CODE [DFA5KA]…6423
ERROR CODE [DFA5KB]…6426
ERROR CODE [DFA6KA]…6428
ERROR CODE [DFA6KB]…6430
ERROR CODE [DFA7KX]…6432
ERROR CODE [DFA7KZ]…6433
ERROR CODE [DFA7L8]…6434
ERROR CODE [DFA8KA]…6435
ERROR CODE [DFA8KB]…6438
ERROR CODE [DFA9KA]…6440
ERROR CODE [DFA9KB]…6442
ERROR CODE [DGS1KA]…6444
ERROR CODE [DGS1KX]…6446
ERROR CODE [DH21KA]…6447
ERROR CODE [DH21KB]…6450
ERROR CODE [DHH5KA]…6452
ERROR CODE [DHH5KB]…6454
ERROR CODE [DHH6KA]…6456
ERROR CODE [DHH6KB]…6458
ERROR CODE [DK10KA]…6460
ERROR CODE [DK10KB]…6462
ERROR CODE [DK30KA]…6464
ERROR CODE [DK30KB]…6466
ERROR CODE [DK30KX]…6468
ERROR CODE [DK30KZ]…6469
ERROR CODE [DK30L8]…6470
ERROR CODE [DK31KA]…6472
ERROR CODE [DK31KB]…6474
ERROR CODE [DK40KA]…6476
ERROR CODE [DK40KB]…6478
ERROR CODE [DK55KX]…6480
ERROR CODE [DK55KZ]…6481
ERROR CODE [DK55L8]…6482
ERROR CODE [DK56KA]…6484
ERROR CODE [DK56KB]…6486
ERROR CODE [DK57KA]…6488
ERROR CODE [DK57KB]…6490
ERROR CODE [DK80KA]…6492
ERROR CODE [DKS0L8]…6494
ERROR CODE [DKS1KA]…6496
ERROR CODE [DKS1KB]…6498
ERROR CODE [DKS2KA]…6500
ERROR CODE [DKS2KB]…6502
ERROR CODE [DKS3KA]…6504
ERROR CODE [DKS3KB]…6506
ERROR CODE [DKS3MB]…6508
ERROR CODE [DKS4L8]…6509
ERROR CODE [DKS5KA]…6510
ERROR CODE [DKS5KB]…6512
ERROR CODE [DKS6KA]…6514
ERROR CODE [DKS6KB]…6516
ERROR CODE [DKS7MB]…6518
ERROR CODE [DKSCL8]…6519
ERROR CODE [DKSDKA]…6520
ERROR CODE [DKSDKB]…6522
ERROR CODE [DKSEKA]…6524
ERROR CODE [DKSEKB]…6526
ERROR CODE [DKSFKA]…6528
ERROR CODE [DKSFKB]…6530
ERROR CODE [DKSFMB]…6532
ERROR CODE [DLM0KX]…6533
ERROR CODE [DLM1KA]…6534
ERROR CODE [DLM1KB]…6536
ERROR CODE [DLM1MA]…6538
ERROR CODE [DLM2KA]…6540
ERROR CODE [DLM2KB]…6542
ERROR CODE [DLM2MA]…6544
ERROR CODE [DLM3KA]…6546
ERROR CODE [DLM3KB]…6548
ERROR CODE [DN21FS]…6550
ERROR CODE [DV00KB]…6552
ERROR CODE [DV20KB]…6553
ERROR CODE [DW4BKA]…6554
ERROR CODE [DW4BKB]…6556
ERROR CODE [DW4BKY]…6558
ERROR CODE [DW7BKA]…6559
ERROR CODE [DW7BKB]…6560
ERROR CODE [DW7BKY]…6561
ERROR CODE [DW7EKA]…6562
ERROR CODE [DW7EKB]…6566
ERROR CODE [DW7EKY]…6568
ERROR CODE [DWN5KA]…6570
ERROR CODE [DWN5KB]…6572
ERROR CODE [DWN5KY]…6574
ERROR CODE [DXA4KA]…6576
ERROR CODE [DXA4KB]…6578
ERROR CODE [DXA4KY]…6579
ERROR CODE [DXA5KA]…6580
ERROR CODE [DXA5KB]…6581
ERROR CODE [DXA5KY]…6582
ERROR CODE [DXA6KA]…6583
ERROR CODE [DXA6KB]…6584
ERROR CODE [DXA6KY]…6585
ERROR CODE [DXA7KA]…6586
ERROR CODE [DXA7KB]…6587
ERROR CODE [DXA7KY]…6588
ERROR CODE [DXHRKA]…6590
ERROR CODE [DXHRKB]…6592
ERROR CODE [DXHRKY]…6594
ERROR CODE [DXHSKA]…6596
ERROR CODE [DXHSKB]…6598
ERROR CODE [DXHSKY]…6600
ERROR CODE [DXHTKA]…6602
ERROR CODE [DXHTKB]…6604
ERROR CODE [DXHTKY]…6606
ERROR CODE [DXHUKA]…6608
ERROR CODE [DXHUKB]…6610
ERROR CODE [DXHUKY]…6612
ERROR CODE [DXJ4KA]…6614
ERROR CODE [DXJ4KB]…6616
ERROR CODE [DXJCKA]…6618
ERROR CODE [DXJCKB]…6619
ERROR CODE [DXJCKY]…6620
ERROR CODE [DXJDKA]…6622
ERROR CODE [DXJDKB]…6623
ERROR CODE [DXJDKY]…6624
ERROR CODE [DXK1KA]…6626
ERROR CODE [DXK1KB]…6627
ERROR CODE [DXK1KY]…6628
ERROR CODE [DXK2KA]…6629
ERROR CODE [DXK2KB]…6630
ERROR CODE [DXK2KY]…6631
TROUBLESHOOTING OF ELECTRICAL SYSTEM (E-MODE)…6632
BEFORE CARRYING OUT TROUBLESHOOTING (E-MODE)…6632
INFORMATION IN TROUBLESHOOTING TABLE…6634
E-1 STARTING MOTOR DOES NOT ROTATE…6635
E-2 ENGINE IS NOT PRE-HEATED…6638
E-3 WHEN STARTING SWITCH IS TURNED ON, ANY ITEM DOES NOT LIGHT…6641
E-4 CHARGE LEVEL CAUTION FLASHES WHILE ENGINE IS RUNNING…6643
E-5 EMERGENCY WARNING ITEMS FLASH WHILE ENGINE IS RUNNING…6645
E-6 PRE-HEAT LAMP DOES NOT LIGHT DURING PRE-HEATING OPERATION…6649
E-7 COOLANT TEMPERATURE GAUGE DOES NOT INDICATE CORRECTLY…6651
E-8 HST OIL TEMPERATURE GAUGE DOES NOT INDICATE CORRECTLY…6652
E-9 FUEL LEVEL GAUGE DOES NOT INDICATE PROPERLY…6653
E-10 TRAVEL INDICATOR DOES NOT DISPLAY NORMALLY…6654
E-11 MULTI-INFORMATION UNIT DOES NOT DISPLAY NORMALLY…6654
E-12 CAUTION LAMP DOES NOT FLASH OR DOES NOT GO OFF…6655
E-13 CAUTION BUZZER DOES NOT SOUND OR DOES NOT STOP…6657
E-14 REVERSE TRAVEL SPEED SETTING SWITCH DOES NOT FUNCTION…6659
E-15 SHIFT MODE SWITCH DOES NOT FUNCTION…6661
E-16 BUZZER CANCEL SWITCH DOES NOT FUNCTION…6663
E-17 INFORMATION SWITCH DOES NOT FUNCTION…6665
E-18 THE FAN CLEANING DOES NOT OPERATE OR CANNOT BE RESET…6667
E-19 BACKUP ALARM DOES NOT SOUND…6669
E-20 THE HORN DOES NOT SOUND OR DOES NOT STOP…6670
E-21 WORK EQUIPMENT DOES NOT OPERATE…6672
E-22 HEAD LAMP OR REAR LAMP DOES NOT LIGHT UP…6674
E-23 FOOT HEATER DOES NOT OPERATE…6678
E-24 AIR CONDITIONER DOES NOT OPERATE [CAB SPECIFICATION]…6680
E-25 WIPER AND WASHER DO NOT OPERATE [CAB SPECIFICATION]…6685
E-26 KOMTRAX SYSTEM DOES NOT OPERATE NORMALLY…6697
E-27 iB MONITOR SHUTS DOWN AFTER DISPLAYING THE MESSAGES [GPS RECEIVER NOT CONNECTED!] AND [SLOPE SENSOR NOT CONNECTED!]…6699
E-28 iB MONITOR DISPLAYS THE MESSAGES[GPS RECEIVER NOT CONECTED!] AND [SLOPE SENSOR NOT CONNECTED!]…6702
E-29 iB MONITOR DISPLAYS THE MESSAGE [WAITING FOR RADIO LINK…]…6705
E-30 iB MONITOR DISPLAYS THE MESSAGE [IMU SENSOR NOT CONNECTED]…6706
E-31 iB MONITOR DISPLAYS THE MESSAGE [WAITING FOR SATELLITES…]…6707
E-32 iB MONITOR DISPLAYS THE MESSAGE [KOMATSU CONTROLLER NOT CONNECTED]…6708
E-33 iB MONITOR DISPLAYS THE MESSAGE [CYLINDER STROKE READING ABNORMAL]…6710
E-34 iB MONITOR DISPLAYS THE MESSAGE [KOMATSU CAN COMMS ABNORMAL]…6711
E-35 iB MONITOR DISPLAYS THE MESSAGE [KOMATSU MACHINE TROUBLE]…6712
E-36 iB MONITOR DISPLAYS THE MESSAGE [WAITING TO INITIALIZE…]…6713
E-37 iB MONITOR DISPLAYS THE MESSAGE [SYSTEM INITIALIZING…]…6714
E-38 iB MONITOR DISPLAYS THE MESSAGE [INITIALIZING…]…6715
E-39 iB MONITOR DISPLAYS THE MESSAGE [CONFIGURING GPS]…6716
E-40 iB MONITOR DISPLAYS THE MESSAGE [NO GPS LOCALIZATION… ]…6717
E-41 iB MONITOR DISPLAYS THE MESSAGE [LOW PRECISIONS…]…6718
E-42 iB MONITOR DISPLAYS THE MESSAGE [HEADING INITIALIZING]…6719
E-43 iB MONITOR DISPLAYS [OUT OF DESIGN AREA…]…6720
E-44 iB MONITOR CAN NOT BE TURNED ON…6721
E-45 iB MONITOR DOES NOT DISPLAY INTELLIGENT MACHINE CONTROL SCREN…6722
E-46 iB MONITOR DOES NOT DISPLAY BULLDOZER IMAGE…6723
E-47 iB MONITOR DOES NOT DISPLAY DESIGN SURFACE…6724
E-48 iB MONITOR TOUCH PANEL DOES NOT RESPOND…6725
E-49 iB MONITOR TOUCH PANEL IS INACCURATE…6726
E-50 CYLINDER STROKE RESET INDICATION DOES NOT GO OUT…6727
E-51 AUTO IS NOT DISPLAYED WHEN AUTO/MANUAL SWITCH IS PRESSED (AUTO INDICATION GOES OUT)…6728
E-52 BLADE AUTOMATIC RAISE CONTROL DOES NOT START WHILE AUTO IS DISPLAYED…6729
E-53 BLADE AUTOMATIC LOWER CONTROL DOES NOT START WHILE AUTO IS DISPLAYED…6730
E-54 BLADE AUTOMATIC CONTROL FUNCTION IS NOT ACTIVATED WHILE AUTO IS DISPLAYED (BLADE AUTOMATIC CONTROL STOPS)…6731
E-55 WHEN CHECKING AND ADJUSTING THE BLADE ELEVATION, THE VALUE IS DIFFERENT FROM ACTUAL MACHINE…6732
E-56 FINISHED SURFACE IS INACCURATE (THE AVERAGE HEIGHT OF FINISHED SURFACE IS LOWER THAN DESIGNED SURFACE OR BLADE DOES NOT TOUCH THE SURFACE)…6733
E-57 FINISHED SURFACE IS INACCURATE (THE FINISHED IS NOT SMOOTH)…6734
E-58 FINISHED SURFACE IS INACCURATE (WHEN FINISHING SLOPE HORIZONTALLY, STEPS ARE MADE IN EACH DIRECTION)…6735
E-59 MACHINE CAN NOT ESCAPE FROM SHOES SLIP WHILE BLADE AUTOMATIC CONTROL IS ACTIVATED (SHOES FREQUENTLY SLIPS)…6737
E-60 MACHINE SPEED DOES NOT INCREASE WHILE BLADE AUTOMATIC CONTROL IS ACTIVATED…6738
E-61 BLADE TILT ANGLE DOES NOT COINCIDE WITH DESIGN SURFACE…6739
E-62 BLADE TILTS BACK WHILE BLADE AUTOMATIC CONTROL IS ACTIVATED…6741
TROUBLESHOOTING OF HYDRAULIC AND MECHANICAL SYSTEM (H- MODE)…6744
INFORMATION IN TROUBLESHOOTING TABLE…6744
H-1 RIGHT AND LEFT TRAVEL SYSTEMS INOPERABLE…6745
H-2 RIGHT OR LEFT TRAVEL SYSTEM DOES NOT OPERATE…6747
H-3 RIGHT OR LEFT TRAVEL SYSTEM DOES NOT OPERATE…6748
H-4 SPEED OR POWER OF TRAVEL IS LOW…6749
H-5 GEAR IS NOT SHIFTED…6750
H-6 LARGE SHOCKS ARE MADE WHEN MACHINE STARTS AND STOPS TRAVEL…6751
H-7 MACHINE DEVIATES LARGELY DURING TRAVEL…6752
H-8 HYDRAULIC DRIFT OF TRAVEL IS LARGE…6753
H-9 ENGINE STALLS OR SPEED LOWERS EXTREMELY DURING TRAVEL…6754
H-10 ABNORMAL SOUND COMES OUT FROM AROUND HST PUMP AND MOTOR…6755
H-11 WORK EQUIPMENT DOSE NOT OPERATE AT ALL…6756
H-12 SPEED OR POWER OF WHOLE WORK EQUIPMENT IS LOW…6757
H-13 BLADE LIFT SPEED OR POWER IS LOW…6758
H-14 BLADE TILT SPEED OR POWER IS LOW…6759
H-15 BLADE ANGLE SPEED OR POWER IS LOW…6760
H-16 TIME LAG OF BLADE LIFT IS LARGE…6761
H-17 HYDRAULIC DRIFT OF LIFTED BLADE IS LARGE…6762
H-18 HYDRAULIC DRIFT OF TILTING BLADE IS LARGE…6763
H-19 UNUSUAL NOISE IS HEARD FROM WORK EQUIPMENT PUMP OR CONTROL VALVE…6764
H-20 HST OIL TEMPERATURE RISES TOO HIGH…6765
H-21 FAN SPEED IS ABNORMAL (HIGH, LOW, OR 0 RPM)…6766
TROUBLESHOOTING OF ENGINE (S-MODE)…6768
METHOD OF USING TROUBLESHOOTING CHARTS…6768
(S-1) ENGINE STARTING PERFORMANCE IS POOR…6772
(S-2) ENGINE DOES NOT CRANK…6773
ENGINE CRANKS BUT NO EXHAUST SMOKE COMES OUT OF STACK…6774
SMOKE COMES OUT OF STACK BUT ENGINE DOES NOT START…6775
(S-3) ENGINE DOES NOT RUN SMOOTHLY…6776
(S-4) ENGINE STOPS DURING OPERATIONS…6777
(S-5) ENGINE SPEED HUNTS…6778
(S-6) ENGINE LACKS POWER…6779
(S-7) EXHAUST SMOKE IS BLACK…6781
(S-8) OIL CONSUMPTION IS EXCESSIVE OR EXHAUST SMOKE IS BLUE…6782
(S-9) OIL BECOMES CONTAMINATED QUICKLY…6783
(S-10) FUEL CONSUMPTION IS EXCESSIVE…6784
(S-11) OIL FOUND IN COOLANT, OR COOLANT SPURTS FROM RADIATOR…6785
(S-12) OIL PRESSURE CAUTION LAMP LIGHTS UP…6786
(S-13) OIL LEVEL RISES (COOLANT OR FUEL FOUND IN OIL)…6787
(S-14) COOLANT TEMPERATURE TOO HIGH (OVERHEATING)…6788
(S-15) ABNORMAL NOISE IS HEARD WHEN ENGINE IS RUNNING…6789
(S-16) EXCESSIVE VIBRATION WHEN ENGINE IS RUNNING…6790
50 DISASSEMBLY AND ASSEMBLY…6792
TABLE OF CONTENTS…6793
RELATED INFORMATION ON DISASSEMBLY AND ASSEMBLY…6796
HOW TO READ THIS MANUAL…6796
SPECIAL TOOL LIST…6804
SKETCH OF SPECIAL TOOLS…6811
CONNECTOR REPAIR PROCEDURES…6826
CONTACT TERMINAL REMOVAL (HD30 TYPE)…6826
STRIPPING INSULATION…6827
CRIMPING CONTACT TERMINAL (HD30 TYPE)…6828
INSERTION OF CONTACT TERMINAL (HD30 TYPE)…6829
CONTACT TERMINAL REMOVAL (DT TYPE)…6830
STRIPPING INSULATION…6831
CRIMPING CONTACT TERMINAL (DT TYPE)…6832
INSERTION OF CONTACT TERMINAL (DT TYPE)…6833
NOSE GUARD (HOOD)…6835
REMOVAL…6835
INSTALLATION…6839
MUFFLER AND EXHAUST STACK…6841
REMOVAL…6841
INSTALLATION…6842
CAB AND ITS ATTACHMENTS…6843
CAB…6843
MONITOR PANEL AND HST CONTROLLER…6858
KOMTRAX CONTROLLER…6861
REMOVAL AND INSTALLATION OF ICT SENSOR CONTROLLER ASSEMBLY…6862
REMOVAL AND INSTALLATION OF iB MONITOR…6863
REMOVAL AND INSTALLATION OF GNSS RECEIVER…6865
REMOVAL AND INSTALLATION OF iB GNSS ANTENNA…6867
REMOVAL AND INSTALLATION OF IMU SENSOR…6872
SEAT…6876
AIR CONDITIONER/HEATER…6877
DISASSEMBLY OF AIR CONDITIONER…6877
ASSEMBLY OF AIR CONDITIONER…6881
FOOT HEATER…6882
REMOVAL…6882
INSTALLATION…6884
FOOT HEATER OVERHAUL PROCEDURES…6884
ASSEMBLY PROCEDURES…6886
ENGINE AND COOLING SYSTEM…6888
REMOVAL…6888
ENGINE AND HST PUMP…6895
INSTALLATION…6897
REMOVAL FROM ENGINE…6899
INSTALLATION TO ENGINE…6902
DRIVE DAMPENER…6903
REMOVAL…6903
INSTALLATION…6904
HST PUMP OVERHAUL PROCEDURES…6905
DISASSEMBLY PROCEDURES…6905
ASSEMBLY PROCEDURES…6914
WORK EQUIPMENT PUMP OVERHAUL PROCEDURES…6926
DISASSEMBLY PROCEDURES…6926
ASSEMBLY PROCEDURES…6932
REMOVAL…6939
INSTALL…6940
CHARGE PUMP OVERHAUL PROCEDURES…6941
DISASSEMBLY PROCEDURES…6941
ASSEMBLY PROCEDURES…6947
DIESEL ENGINE OVERHAUL PROCEDURES…6953
DISASSEMBLY OF EXTERNAL COMPONENTS…6953
DISASSEMBLY OF ENGINE TOP END…6959
REMOVAL OF OIL COOLER, ENGINE CONTROLLER AND FUEL PUMP…6963
DISASSEMBLY OF ENGINE LOWER END…6965
ASSEMBLY OF ENGINE LOWER END…6972
INSTALLATION OF OIL COOLER, ENGINE CONTROLLER AND FUEL PUMP…6988
ASSEMBLY OF EXTERNAL COMPONENTS…6997
TRACK SYSTEM…7024
SPREADING THE TRACK…7024
(CONVENTIONAL TYPE TRACK SHOE)…7024
EXPANSION AND INSTALLATION OF TRACK SHOE ASSEMBLY (PLUS TYPE TRACK SHOE)…7026
FIELD DISASSEMBLY AND ASSEMBLY OF ONE LINK (CONVENTIONAL TYPE TRACK SHOE)…7040
FIELD DISASSEMBLY AND ASSEMBLY OF ONE LINK (PLUS TYPE TRACK SHOE)…7048
TRACK FRAME…7055
REMOVAL OF TRACK FRAME…7055
FRONT TRACK IDLER…7064
REMOVING FRONT IDLER…7064
INSTALLING FRONT IDLER…7066
TRACK ROLLER…7067
REMOVAL…7067
INSTALLATION…7067
TRACK ROLLER OVERHAUL PROCEDURES…7068
CARRIER ROLLER OVERHAUL PROCEDURES…7073
FINAL DRIVE…7075
FINAL DRIVE REMOVAL…7075
INSTALLING THE FINAL DRIVE…7079
FINAL DRIVE OVERHAUL PROCEDURES…7081
DISASSEMBLY PROCEDURES…7081
ASSEMBLY OF FINAL DRIVE…7087
TRAVEL MOTOR OVERHAUL PROCEDURES…7095
DISASSEMBLY PROCEDURES…7095
ASSEMBLY PROCEDURES…7100
FAN MOTOR…7113
REMOVAL PROCEDURES…7113
INSTALLATION PROCEDURES…7117
FAN MOTOR OVERHAUL PROCEDURES…7119
DISASSEMBLY PROCEDURES…7119
ASSEMBLY PROCEDURES…7123
DB 12 VALVE…7130
REMOVAL…7130
INSTALLATION…7132
COOLING PACKAGE…7133
REMOVING THE GRILL AND COOLING FAN ASSEMBLY…7133
REMOVING THE COOLING PACKAGE…7144
INSTALLING THE COOLING PACKAGE…7152
INSTALLING THE GRILL AND COOLING FAN ASSEMBLY…7153
FUEL TANK…7157
REMOVING THE FUEL TANK…7157
INSTALLING THE FUEL TANK…7162
HYDRAULIC TANK…7163
REMOVING THE HYDRAULIC TANK…7163
INSTALLING THE HYDRAULIC TANK…7169
WORK EQUIPMENT…7170
REMOVING OR INSTALLING PINS…7170
FRONT BLADE, TILT AND ANGLE CYLINDERS…7171
ADJUSTING BLADE CENTER BALL AND PITCH ROD PLAY…7176
“C” FRAME…7178
LIFT CYLINDERS…7181
CYLINDER OVERHAUL PROCEDURES…7183
DISASSEMBLY PROCEDURES…7183
ASSEMBLY PROCEDURES…7184
WHOLE DISASSEMBLY AND ASSEMBLY OF TRACK SHOE (PLUS TYPE TRACK SHOE)…7023
WHOLE DISASSEMBLY AND ASSEMBLY OF TRACK SHOE ASSEMBLY (CONVENTIONAL TYPE TRACK SHOE)…7003
90 OTHERS…7188
TABLE OF CONTENTS…7189
CONNECTOR ARRANGEMENT DRAWING AND ELECTRICAL CIRCUIT DIAGRAM…7190
CONNECTOR LIST…7190
CONNECTOR LOCATION VIEW…7194
HYDRAULIC SYSTEM…7211
SYMBOLS UN HYDRAULIC CIRCUIT DIAGRAMS…7211
ELECTRICAL SYSTEM…7213
SYMBOLS IN ELECTRICAL CIRCUIT DIAGRAMS…7213
CAB ELECTRICAL ACCESSORIES…7214
AIR CONDITIONER CIRCUIT DIAGRAM…7215
Electrical Circuit Diagram (1/8)…7216
Electrical Circuit Diagram (2/8)…7217
Electrical Circuit Diagram (3/8)…7218
Electrical Circuit Diagram (4/8)…7219
Electrical Circuit Diagram (5/8)…7220
Electrical Circuit Diagram (6/8)…7221
Electrical Circuit Diagram (7/8)…7222
Electrical Circuit Diagram (8/8)…7223
KEBM662102 – Crawler Dozer D51EXi-24, D51PXi-24 Shop Manual (SN-B20001 and Up, ENGINE-4D107E-3)…7224
00 INDEX AND FOREWORD…7225
INDEX…7226
ABBREVIATION LIST…7244
FOREWORD, SAFETY, BASIC INFORMATION…7250
HOW TO READ THE SHOP MANUAL…7250
SAFETY NOTICE FOR OPERATION…7252
PRECAUTIONS TO PREVENT FIRE…7260
ACTIONS IF FIRE OCCURS…7262
PRECAUTIONS FOR DISPOSING OF WASTE MATERIALS…7263
ACTIONS TAKEN TO MEET EXHAUST GAS REGULATIONS…7264
PRECAUTIONS FOR DEF…7265
GENERAL CHARACTER AND PRECAUTIONS FOR HANDLING…7265
PRECAUTIONS FOR ADDING…7265
PRECAUTIONS FOR STORING…7265
PRECAUTIONS FOR FIRE HAZARD AND LEAKAGE…7265
THE OTHER PRECAUTIONS…7265
STORE AdBlue/DEF…7266
PRECAUTIONS FOR HANDLING HYDRAULIC EQUIPMENT…7267
PRECAUTIONS FOR DISCONNECTION AND CONNECTION OF PIPINGS…7270
PRECAUTIONS FOR HANDLING ELECTRICAL EQUIPMENT…7276
PRECAUTIONS FOR HANDLING FUEL SYSTEM EQUIPMENT…7278
PRECAUTIONS FOR HANDLING INTAKE SYSTEM EQUIPMENT…7279
PRACTICAL USE OF KOMTRAX…7280
DISCONNECT AND CONNECT PUSH-PULL TYPE COUPLER…7281
METHOD FOR DISCONNECTING AND CONNECTING TYPE 1 PUSH-PULL TYPE COUPLER…7281
METHOD FOR DISCONNECTING AND CONNECTING TYPE 2 PUSH-PULL TYPE COUPLER…7282
METHOD FOR DISCONNECTING AND CONNECTING TYPE 3 PUSH-PULL TYPE COUPLER…7283
PRECAUTIONS FOR DISCONNECTION AND CONNECTION OF CONNECTORS…7285
METHOD FOR DISCONNECTING AND CONNECTING DEUTSCH CONNECTOR…7289
METHOD FOR DISCONNECTING AND CONNECTING SLIDE LOCK TYPE CONNECTOR…7290
METHOD FOR DISCONNECTING AND CONNECTING CONNECTOR WITH LOCK TO PULL…7292
METHOD FOR DISCONNECTING AND CONNECTING CONNECTOR WITH LOCK TO PUSH…7293
METHOD FOR DISCONNECTING AND CONNECTING CONNECTOR WITH HOUSING TO ROTATE…7295
HOW TO READ ELECTRICAL WIRE CODE…7296
EXPLANATION OF TERMS FOR MAINTENANCE STANDARD…7300
STANDARD TIGHTENING TORQUE TABLE…7303
CONVERSION TABLE…7310
01 SPECIFICATIONS…7315
CONTENTS…7316
ABBREVIATION LIST…7317
SPECIFICATIONS…7323
SPECIFICATION DRAWING…7323
SPECIFICATION DRAWING: D51EXI-24…7323
SPECIFICATION DRAWING: D51PXI-24…7325
SPECIFICATIONS…7327
SPECIFICATIONS: D51EXI-24…7327
SPECIFICATIONS: D51PXI-24…7333
WEIGHT TABLE…7338
WEIGHT TABLE: D51EXI-24…7338
WEIGHT TABLE: D51PXI-24…7340
FUEL, COOLANT, LUBRICANTS (FOR NORTH AMERICA)…7342
METHOD FOR USING FUEL, COOLANT AND LUBRICANTS ACCORDING TO AMBIENT TEMPERATURE…7342
FUEL, COOLANT, LUBRICANTS (FOR EUROPEAN UNION)…7344
METHOD FOR USING FUEL, COOLANT AND LUBRICANTS ACCORDING TO AMBIENT TEMPERATURE…7344
10 STRUCTURE AND FUNCTION…7347
CONTENTS…7348
ABBREVIATION LIST…7351
UREA SCR SYSTEM…7357
LAYOUT DRAWING OF UREA SCR SYSTEM…7357
UREA SCR SYSTEM DIAGRAM…7359
FUNCTION OF UREA SCR SYSTEM…7360
FUNCTION OF AdBlue/DEF SYSTEM…7360
INDUCEMENT STRATEGY…7363
COMPONENT PARTS OF UREA SCR SYSTEM…7378
AdBlue/DEF MIXING TUBE…7378
SCR ASSEMBLY…7379
AdBlue/DEF TANK…7381
AdBlue/DEF PUMP…7383
AdBlue/DEF INJECTOR…7384
AdBlue/DEF HOSE…7385
AdBlue/DEF TANK HEATING VALVE…7386
BOOT-UP SYSTEM…7387
LAYOUT DRAWING OF BOOT-UP SYSTEM…7387
SYSTEM OPERATING LAMP SYSTEM…7388
SYSTEM OPERATING LAMP SYSTEM DIAGRAM…7388
FUNCTION OF SYSTEM OPERATING LAMP SYSTEM…7388
BATTERY DISCONNECT SWITCH…7390
FUNCTION OF BATTERY DISCONNECT SWITCH…7390
ENGINE SYSTEM…7391
LAYOUT DRAWING OF ENGINE SYSTEM…7391
ENGINE CONTROL SYSTEM…7393
LAYOUT OF ENGINE CONTROL SYSTEM…7393
ENGINE CONTROL SYSTEM DIAGRAM…7395
FUNCTION OF ENGINE CONTROL SYSTEM…7397
AUTOMATIC IDLE STOP SYSTEM…7399
AUTOMATIC IDLE STOP SYSTEM DIAGRAM…7399
FUNCTION OF AUTOMATIC IDLE STOP SYSTEM…7399
COMPONENT PARTS OF ENGINE SYSTEM…7402
DAMPER…7402
VGT…7403
EGR SYSTEM…7406
EGR VALVE…7408
EGR COOLER…7410
KCCV SYSTEM…7412
KCCV VENTILATOR…7414
KDOC…7416
COOLING SYSTEM…7419
LAYOUT DRAWING OF COOLING SYSTEM…7419
SPECIFICATIONS OF COOLING SYSTEM…7420
COOLING FAN CONTROL SYSTEM…7421
COOLING FAN CONTROL SYSTEM DIAGRAM…7421
FUNCTION OF COOLING FAN CONTROL SYSTEM…7422
COMPONENT PARTS OF COOLING SYSTEM…7424
COOLING FAN MOTOR…7424
HYDRAULIC OIL COOLER BYPASS AND HST CHARGE SAFETY VALVE…7429
HYDRAULIC OIL COOLER BYPASS VALVE…7430
HST CHARGE SAFETY VALVE…7431
CONTROL SYSTEM…7433
LAYOUT DRAWING OF CONTROL SYSTEM…7433
MACHINE MONITOR SYSTEM…7434
MACHINE MONITOR SYSTEM DIAGRAM…7434
FUNCTION OF MACHINE MONITOR SYSTEM…7434
KOMTRAX SYSTEM…7435
KOMTRAX SYSTEM DIAGRAM…7435
FUNCTION OF KOMTRAX SYSTEM…7435
COMPONENT PARTS OF CONTROL SYSTEM…7436
MACHINE MONITOR…7436
KOMTRAX TERMINAL…7451
HST CONTROLLER…7453
ENGINE CONTROLLER…7457
FUEL CONTROL DIAL…7464
DECELERATOR AND BRAKE POTENTIOMETER…7466
HYDRAULIC SYSTEM…7468
LAYOUT DRAWING OF HYDRAULIC SYSTEM…7468
CLSS…7469
STRUCTURE OF CLSS…7469
FUNCTION OF CLSS…7470
COMPONENT PARTS OF HYDRAULIC SYSTEM…7472
HYDRAULIC TANK…7472
WORK EQUIPMENT AND COOLING FAN PUMP…7474
LS VALVE…7482
PC VALVE…7483
CONTROL VALVE…7486
POWER TRAIN SYSTEM…7504
LAYOUT DRAWING OF HST SYSTEM…7504
OPERATION OF HST SYSTEM…7505
STEERING AND BRAKE CONTROL SYSTEM…7507
LAYOUT DRAWING OF STEERING AND BRAKE CONTROL SYSTEM…7507
FUNCTION OF STEERING AND BRAKE CONTROL SYSTEM…7507
HST CONTROL SYSTEM…7509
HST CONTROL SYSTEM DIAGRAM…7509
GEAR SHIFT CONTROL FUNCTION…7510
ENGINE LOW SPEED MATCHING CONTROL FUNCTION…7513
HST PUMP AND MOTOR SEQUENCE CONTROL FUNCTION…7514
DECELERATION AND BRAKE CONTROL FUNCTION…7515
GEAR SHIFT CONTROL FUNCTION BY LOAD…7517
TURN CONTROL FUNCTION…7517
STRAIGHT TRAVEL CORRECTION CONTROL FUNCTION…7518
PARKING BRAKE CONTROL SYSTEM…7520
PARKING BRAKE CONTROL SYSTEM DIAGRAM…7520
FUNCTION OF PARKING BRAKE CONTROL SYSTEM…7521
OPERATION OF PARKING BRAKE CONTROL SYSTEM…7522
COMPONENT PARTS OF POWER TRAIN SYSTEM…7523
HST PUMP…7523
HST CHARGE PUMP…7538
HST MOTOR…7539
FINAL DRIVE…7552
ELECTRIC STEERING CONTROL LEVER…7556
WORK EQUIPMENT SYSTEM…7559
WORK EQUIPMENT CONTROL…7559
WORK EQUIPMENT CONTROL SYSTEM DIAGRAM…7559
FUNCTION OF WORK EQUIPMENT CONTROL…7560
LAYOUT DRAWING OF FRONT WORK EQUIPMENT…7561
LAYOUT OF FIXED MULTI-SHANK RIPPER…7562
COMPONENT PARTS OF WORK EQUIPMENT SYSTEM…7563
RIPPER PPC VALVE…7563
5-PORT VALVE OF EPC AND SOLENOID…7567
PILOT CIRCUIT ACCUMULATOR…7573
QUICK DROP VALVE…7574
PISTON VALVE…7575
ELECTRIC BLADE CONTROL LEVER…7577
ICT SYSTEM…7579
LAYOUT DRAWING OF ICT SYSTEM…7579
ICT CONTROL SYSTEM DIAGRAM…7581
BLADE CONTROL SYSTEM…7583
FUNCTION OF BLADE CONTROL SYSTEM…7583
LEVELING MODE SYSTEM DIAGRAM…7585
FUNCTION OF LEVELING MODE…7586
OPERATION OF LEVELING MODE…7586
DOZING MODE SYSTEM DIAGRAM…7587
FUNCTION OF DOZING MODE…7587
OPERATION OF DOZING MODE…7587
SMOOTH START SYSTEM…7589
SMOOTH START SYSTEM DIAGRAM…7589
FUNCTION OF SMOOTH START SYSTEM…7589
OPERATION OF SMOOTH START SYSTEM…7589
SLIP CONTROL SYSTEM…7591
SLIP CONTROL SYSTEM DIAGRAM…7591
FUNCTION OF SLIP CONTROL SYSTEM…7591
OPERATION OF SLIP CONTROL SYSTEM…7591
ASSIST CONTROL SYSTEM…7592
ASSIST CONTROL SYSTEM DIAGRAM…7592
FUNCTION OF ASSIST CONTROL SYSTEM…7592
OPERATION OF ASSIST CONTROL SYSTEM…7593
HST SPEED RANGE CONTROL SYSTEM…7594
HST SPEED RANGE CONTROL SYSTEM DIAGRAM…7594
FUNCTION OF HST SPEED RANGE CONTROL SYSTEM…7594
OPERATION OF HST SPEED RANGE CONTROL SYSTEM…7594
COMPONENT PARTS OF ICT SYSTEM…7596
ICT SENSOR CONTROLLER…7596
CONTROL BOX…7600
GNSS RECEIVER…7602
GNSS ANTENNA…7606
IMU SENSOR…7607
STROKE AND RESET SENSOR FOR BLADE LIFT CYLINDER…7611
STROKE SENSOR FOR BLADE TILT CYLINDER…7614
STROKE SENSOR FOR BLADE ANGLE CYLINDER…7616
UNDERCARRIAGE AND FRAME…7618
MAIN FRAME…7618
STRUCTURE OF MAIN FRAME…7618
SUSPENSION…7619
STRUCTURE OF SUSPENSION…7619
SPECIFICATIONS OF SUSPENSION…7620
FUNCTION OF SUSPENSION…7621
TRACK FRAME AND IDLER CUSHION…7622
STRUCTURE OF TRACK FRAME AND IDLER CUSHION…7622
FUNCTION OF TRACK FRAME AND IDLER CUSHION…7623
WORK EQUIPMENT…7624
STRUCTURE OF FRONT WORK EQUIPMENT…7624
STRUCTURE OF FIXED MULTI-SHANK RIPPER…7625
CAB AND ITS ATTACHMENTS…7626
ROPS CAB…7626
STRUCTURE OF ROPS CAB…7626
FUNCTION OF ROPS CAB…7627
CAB MOUNT…7628
STRUCTURE OF CAB MOUNT…7628
FUNCTION OF CAB MOUNT…7628
20 STANDARD VALUE TABLE…7629
CONTENTS…7630
ABBREVIATION LIST…7631
STANDARD VALUE TABLE FOR ENGINE…7637
STANDARD VALUE TABLE FOR ENGINE: D51EXI-24…7637
STANDARD VALUE TABLE FOR ENGINE: D51PXI-24…7641
STANDARD VALUE TABLE FOR MACHINE…7645
STANDARD VALUE TABLE FOR MACHINE: D51EXI-24…7645
STANDARD VALUE TABLE FOR MACHINE: D51PXI-24…7662
MACHINE POSTURE AND PROCEDURE FOR MEASURING PERFORMANCE…7677
30 TESTING AND ADJUSTING…7679
CONTENTS…7680
ABBREVIATION LIST…7684
RELATED INFORMATION ON TESTING AND ADJUSTING…7690
TOOLS FOR TESTING AND ADJUSTING…7690
SKETCH OF TOOLS FOR TESTING AND ADJUSTING…7697
ENGINE AND COOLING SYSTEM…7701
TEST ENGINE SPEED…7701
METHOD FOR TESTING ENGINE SPEED…7701
TEST BOOST PRESSURE…7703
METHOD FOR TESTING BOOST PRESSURE…7703
TEST EXHAUST GAS COLOR…7705
METHOD FOR TESTING EXHAUST GAS COLOR BY HANDY SMOKE CHECKER…7705
METHOD FOR TESTING EXHAUST GAS COLOR BY SMOKE METER…7706
TEST AND ADJUST VALVE CLEARANCE…7707
METHOD FOR TESTING VALVE CLEARANCE…7707
METHOD FOR ADJUSTING VALVE CLEARANCE…7708
TEST COMPRESSION PRESSURE…7709
METHOD FOR TESTING COMPRESSION PRESSURE…7709
TEST BLOWBY PRESSURE…7714
METHOD FOR TESTING BLOWBY PRESSURE…7714
TEST ENGINE OIL PRESSURE…7716
METHOD FOR TESTING ENGINE OIL PRESSURE…7716
TEST FUEL PRESSURE…7717
METHOD FOR TESTING FUEL PRESSURE…7718
TEST FUEL DISCHARGE, RETURN AND LEAKAGE…7722
METHOD FOR TESTING FUEL DISCHARGE, RETURN AND LEAKAGE…7723
BLEED AIR FROM FUEL SYSTEM…7728
METHOD FOR BLEEDING AIR FROM FUEL SYSTEM…7728
TEST FUEL CIRCUIT FOR LEAKAGE…7729
METHOD FOR TESTING FUEL CIRCUIT FOR LEAKAGE…7729
HANDLE CYLINDER CUT-OUT MODE OPERATION…7731
HANDLE NO-INJECTION CRANKING OPERATION…7732
TEST KDOC, SCR AND MUFFLER STACK FOR LOOSENESS AND DAMAGE…7733
METHOD FOR TESTING KDOC, SCR AND MUFFLER STACK FOR LOOSENESS AND DAMAGE…7733
TEST INSTALLED CONDITION OF CYLINDER HEADS AND MANIFOLDS…7734
METHOD FOR TESTING INSTALLED CONDITION OF CYLINDER HEADS AND MANIFOLDS…7734
TEST ENGINE PIPING FOR DAMAGE AND LOOSENESS…7735
METHOD FOR TESTING ENGINE PIPING FOR DAMAGE AND LOOSENESS…7735
WRITE ASH IN SOOT ACCUMULATION CORRECTION TO ENGINE CONTROLLER…7736
METHOD FOR WRITING ASH IN SOOT ACCUMULATION CORRECTION TO ENGINE CONTROLLER…7736
TEST SCR RELATED FUNCTIONS…7737
TEST AdBlue/DEF PUMP RAISED PRESSURE…7741
TEST INJECTION AMOUNT FROM AdBlue/DEF INJECTOR…7744
TEST AdBlue/DEF LINE HEATER RELAY 1…7748
TEST AdBlue/DEF LINE HEATER RELAY 2…7751
TEST AdBlue/DEF PUMP HEATER RELAY…7754
TEST AdBlue/DEF TANK HEATER VALVE…7758
TEST DENITRATION EFFICIENCY OF SCR…7762
CLEAN AdBlue/DEF TANK…7765
METHOD FOR CLEANING AdBlue/DEF TANK…7765
CLEAN AdBlue/DEF TANK MOUNTING PORTION…7769
METHOD FOR CLEANING AdBlue/DEF TANK MOUNTING PORTION…7769
POWER TRAIN…7770
TEST AND ADJUST HST OIL PRESSURE…7770
METHOD FOR TESTING HST OIL PRESSURE…7770
METHOD FOR ADJUSTING HST OIL PRESSURE…7773
BLEED AIR FROM HST PUMP…7775
METHOD FOR BLEEDING AIR FROM HST PUMP…7775
METHOD FOR BLEEDING AIR FROM SERVO VALVE OF HST PUMP…7775
TEST OUTLET PRESSURE OF SOLENOID VALVE…7777
METHOD FOR TESTING OUTLET PRESSURE OF SOLENOID VALVE…7777
TEST TRAVEL DEVIATION…7781
METHOD FOR TESTING TRAVEL DEVIATION…7781
TEST BRAKE PERFORMANCE SIMPLY…7783
METHOD FOR TESTING BRAKE PERFORMANCE SIMPLY…7783
TEST AND ADJUST DECELERATION/BRAKE PEDAL…7784
METHOD FOR TESTING DECELERATION/BRAKE PEDAL…7784
METHOD FOR ADJUSTING DECELERATION/BRAKE PEDAL…7786
ADJUST PARKING BRAKE LEVER…7788
METHOD FOR ADJUSTING PARKING BRAKE LEVER…7788
MOVE MACHINE WHEN IT CANNOT TRAVEL…7790
METHOD FOR MOVING MACHINE WITH HYDRAULIC TYPE PARKING BRAKE RELEASE SYSTEM…7790
METHOD FOR MOVING DISABLED MACHINE BY REMOVING FINAL DRIVE SHAFT…7792
UNDERCARRIAGE AND FRAME…7793
CHECK AND ADJUST IDLER CLEARANCE…7793
METHOD FOR ADJUSTING IDLER CLEARANCE HORIZONTALLY…7793
METHOD FOR ADJUSTING IDLER CLEARANCE VERTICALLY…7793
TESTING SPROCKET WEAR…7795
METHOD FOR TESTING SPROCKET WEAR…7795
TEST AND ADJUST TRACK TENSION…7796
METHOD FOR TESTING TRACK TENSION…7796
METHOD FOR ADJUSTING TRACK TENSION…7796
HYDRAULIC SYSTEM…7798
RELEASE REMAINING PRESSURE FROM HYDRAULIC SYSTEM…7798
METHOD FOR RELEASING REMAINING PRESSURE FROM HYDRAULIC CIRCUIT…7798
TEST AND ADJUST WORK EQUIPMENT OIL PRESSURES…7799
METHOD FOR TESTING WORK EQUIPMENT OIL PRESSURES…7799
METHOD FOR ADJUSTING WORK EQUIPMENT OIL PRESSURES…7800
TEST AND ADJUST OIL PRESSURE OF CONTROL CIRCUIT…7802
METHOD FOR TESTING OIL PRESSURE OF CONTROL CIRCUIT…7802
METHOD FOR ADJUSTING OIL PRESSURE OF CONTROL CIRCUIT…7803
TEST OUTLET PRESSURE OF EPC SOLENOID VALVE…7804
METHOD FOR TESTING OUTLET PRESSURE OF EPC SOLENOID VALVE…7804
BLEED AIR FROM WORK EQUIPMENT AND COOLING FAN PUMP…7806
METHOD FOR BLEEDING AIR FROM WORK EQUIPMENT AND COOLING FAN PUMP…7806
TEST COOLING FAN SPEED…7807
METHOD FOR TESTING COOLING FAN SPEED…7807
TEST COOLING FAN CIRCUIT OIL PRESSURE…7808
METHOD FOR TESTING COOLING FAN CIRCUIT OIL PRESSURE…7808
TEST THE PARTS CAUSING HYDRAULIC DRIFT IN WORK EQUIPMENT…7810
METHOD FOR TESTING THE PARTS CAUSING HYDRAULIC DRIFT OF BLADE LIFT CYLINDER…7810
METHOD FOR TESTING THE PARTS CAUSING HYDRAULIC DRIFT OF BLADE TILT CYLINDER…7811
METHOD FOR TESTING THE PARTS CAUSING HYDRAULIC DRIFT OF RIPPER LIFT CYLINDER…7812
TEST INTERNAL OIL LEAKAGE OF WORK EQUIPMENT CYLINDER…7813
METHOD FOR TESTING INTERNAL OIL LEAKAGE OF WORK EQUIPMENT CYLINDER…7813
BLEED AIR FROM WORK EQUIPMENT CYLINDERS…7816
METHOD FOR BLEEDING AIR FROM WORK EQUIPMENT CYLINDERS…7816
WORK EQUIPMENT…7817
ADJUST WORK EQUIPMENT LOCK LEVER…7817
METHOD FOR ADJUSTING WORK EQUIPMENT LOCK LEVER…7817
ELECTRICAL SYSTEM…7819
SET AND OPERATE MACHINE MONITOR…7819
OPERATOR MODE…7823
DISPLAY FUNCTION OF TECHNICIAN IDENTIFICATION STATUS SCREEN…7823
DISPLAY FUNCTION OF OPERATOR IDENTIFICATION INPUT SCREEN…7823
CHECKING FUNCTION BY LCD (LIQUID CRYSTAL DISPLAY)…7824
CHECKING FUNCTION OF SERVICE METER…7824
METHOD FOR SETTING USAGE LIMITATION AND CHANGING MAINTENANCE PASSWORD…7824
SERVICE MODE…7827
METHOD FOR OPERATING SERVICE MODE…7827
METHOD FOR CHECKING PRE-DEFINED MONITORING INFORMATION…7829
METHOD FOR CHECKING SELF-DEFINE MONITORING INFORMATION…7835
ABNORMALITY RECORD MENU…7846
METHOD FOR CONFIRMING MAINTENANCE RECORD…7850
METHOD FOR OPERATING MAINTENANCE MODE SETTING…7851
METHOD FOR OPERATING PHONE NUMBER ENTRY SETTING…7855
DEFAULT MENU…7856
DIAGNOSTIC TESTS MENU…7863
ADJUSTMENT MENU…7871
METHOD FOR PERFORMING NO-INJECTION CRANKING…7939
KOMTRAX SETTINGS MENU…7942
METHOD FOR DISPLAYING SERVICE MESSAGE…7944
METHOD FOR STARTING UP KOMTRAX TERMINAL…7946
ADJUSTMENT WHEN HST CONTROLLER HAS BEEN REPLACED…7951
ADJUSTMENT METHOD WHEN HST CONTROLLER HAS BEEN REPLACED…7951
ADJUSTMENT WHEN ELECTRIC OR HYDRAULIC DEVICE HAS BEEN REPLACED…7957
ADJUST REARVIEW CAMERA ANGLE…7959
METHOD FOR ADJUSTING REARVIEW CAMERA ANGLE…7959
HANDLE VOLTAGE CIRCUIT OF ENGINE CONTROLLER…7960
HANDLE BATTERY DISCONNECT SWITCH…7961
TEST DIODES…7962
METHOD FOR TESTING DIODE USING DIGITAL TESTER…7962
METHOD FOR TESTING DIODE USING ANALOG TESTER…7962
ICT SYSTEM…7963
SET AND OPERATE CONTROL BOX…7963
TEST AND ADJUST ICT RELATED DEVICES…7963
CALIBRATE BLADE EDGE POSITION…7966
METHOD FOR OPERATING BLADE CALIBRATION MENU (PITCH ROD CALIBRATION)…7967
METHOD FOR OPERATING BLADE CALIBRATION MENU (MACHINE CAL STEP A)…7969
METHOD FOR OPERATING BLADE CALIBRATION MENU (MACHINE CAL STEP B)…7974
CALIBRATE IMU SENSOR…7988
METHOD FOR CALIBRATING IMU SENSOR…7988
RESET CYLINDER STROKE END…7995
RESET LIFT CYLINDER STROKE END…7995
RESET TILT CYLINDER STROKE END…7996
RESET ANGLE CYLINDER STROKE END…7996
METHOD FOR INPUTTING WEAR AMOUNT OF BLADE EDGE AND TRACK SHOE…7998
CHECK BLADE ELEVATION, ADJUST…7999
CHECK BLADE ELEVATION…7999
ADJUST BLADE ELEVATION…8001
TEST STROKE SENSOR FOR LIFT CYLINDER…8003
METHOD FOR TESTING STROKE SENSOR FOR LIFT CYLINDER…8003
TEST STROKE SENSOR FOR TILT CYLINDER…8005
METHOD FOR TESTING STROKE SENSOR FOR TILT CYLINDER…8005
TEST STROKE SENSOR FOR ANGLE CYLINDER…8007
METHOD FOR TESTING STROKE SENSOR FOR ANGLE CYLINDER…8007
TEST AND ADJUST RESET SENSOR FOR LIFT CYLINDER…8009
METHOD FOR TESTING RESET SENSOR FOR LIFT CYLINDER…8009
METHOD FOR ADJUSTING RESET SENSOR FOR LIFT CYLINDER…8010
ADJUST WHEN ICT SENSOR CONTROLLER IS REPLACED…8011
METHOD FOR ADJUSTING WHEN ICT SENSOR CONTROLLER IS REPLACED…8011
METHOD FOR ADJUSTING WHEN ICT RELATED DEVICES ARE REPAIRED OR REPLACED…8014
Pm CLINIC…8017
Pm CLINIC SERVICE…8017
Pm CLINIC CHECK SHEET: D51EXI-24…8019
Pm CLINIC CHECK SHEET: D51PXI-24…8027
Pm CLINIC CHECK SHEET FOR UNDERCARRIAGE: D51EXI-24…8035
Pm CLINIC CHECK SHEET FOR UNDERCARRIAGE: D51PXI-24…8039
40 TROUBLESHOOTING…8043
CONTENTS…8044
ABBREVIATION LIST…8055
RELATED INFORMATION ON TROUBLESHOOTING…8061
GENERAL TROUBLESHOOTING POINTS…8061
TROUBLESHOOTING POINTS FOR UREA SCR SYSTEM…8062
SEQUENCE OF EVENTS IN TROUBLESHOOTING…8074
CHECKS BEFORE TROUBLESHOOTING…8076
INSPECTION PROCEDURE BEFORE TROUBLESHOOTING…8078
WALK-AROUND CHECK…8078
TESTING IN ACCORDANCE WITH TESTING PROCEDURE…8080
CHECK FUEL LEVEL AND TYPE…8080
CHECK IMPURE INGREDIENT IN FUEL…8080
CHECK AdBule/DEF LEVEL AND TYPE…8081
CHECK FUEL PREFILTER…8081
CHECK MAIN FILTER…8083
CHECK ENGINE OIL LEVEL (OIL AMOUNT IN OIL PAN) AND TYPE…8084
CHECK COOLANT LEVEL (RESERVOIR TANK)…8086
CHECK CLOGGING OF AIR CLEANER…8086
CLEAN OUTER ELEMENT…8087
REPLACE ELEMENT…8089
CHECK HYDRAULIC OIL LEVEL…8090
CHECK HYDRAULIC OIL STRAINER…8091
CHECK OIL LEVEL IN FINAL DRIVE CASE…8094
BLEED AIR FROM FUEL SYSTEM…8095
BLEED AIR FROM HYDRAULIC SYSTEM…8095
METHOD FOR CHECKING ELECTRIC EQUIPMENT…8095
PREPARATION FOR TROUBLESHOOTING OF ELECTRICAL SYSTEM…8102
PROCEDURE FOR TROUBLESHOOTING…8109
INFORMATION DESCRIBED IN TROUBLESHOOTING TABLE…8112
TROUBLESHOOTING METHOD FOR OPEN CIRCUIT IN WIRING HARNESS OF PRESSURE SENSOR SYSTEM…8114
CONNECTORS LIST AND LAYOUT…8117
CONNECTOR CONTACT IDENTIFICATION…8134
T-BRANCH BOX AND T-BRANCH ADAPTER TABLE…8174
FUSE LOCATION TABLE…8180
PRECAUTIONS FOR REPLACING KDOC…8184
FAILURE CODES TABLE…8185
TROUBLESHOOTING BY FAILURE CODE (DISPLAY OF CODE)…8204
FAILURE CODE [6091NX]…8204
FAILURE CODE [989L00]…8206
FAILURE CODE [989M00]…8207
FAILURE CODE [989N00]…8208
FAILURE CODE [A1U0N3]…8209
FAILURE CODE [A1U0N4]…8211
FAILURE CODE [A900FR]…8213
FAILURE CODE [A900N6]…8214
FAILURE CODE [A900NY]…8215
FAILURE CODE [AA10NX]…8216
FAILURE CODE [AB00KE]…8218
FAILURE CODE [AQ10MB]…8220
FAILURE CODE [AQ10N3]…8222
FAILURE CODE [AS00R2]…8224
FAILURE CODE [AS00R3]…8225
FAILURE CODE [AS00R4]…8226
FAILURE CODE [AS00R5]…8227
FAILURE CODE [AS00R6]…8228
FAILURE CODE [AS00ZK]…8229
FAILURE CODE [AS10KM]…8230
FAILURE CODE [AS10NR]…8231
FAILURE CODE [AS10NT]…8232
FAILURE CODE [B@BAZG]…8233
FAILURE CODE [B@BCNS]…8234
FAILURE CODE [B@CRNS]…8235
FAILURE CODE [B@CRZG]…8236
FAILURE CODE [CA115]…8237
FAILURE CODE [CA122]…8238
FAILURE CODE [CA123]…8240
FAILURE CODE [CA131]…8242
FAILURE CODE [CA132]…8244
FAILURE CODE [CA144]…8246
FAILURE CODE [CA145]…8248
FAILURE CODE [CA153]…8250
FAILURE CODE [CA154]…8252
FAILURE CODE [CA187]…8254
FAILURE CODE [CA221]…8256
FAILURE CODE [CA222]…8258
FAILURE CODE [CA227]…8260
FAILURE CODE [CA234]…8262
FAILURE CODE [CA238]…8263
FAILURE CODE [CA239]…8264
FAILURE CODE [CA249]…8265
FAILURE CODE [CA256]…8267
FAILURE CODE [CA271]…8269
FAILURE CODE [CA272]…8271
FAILURE CODE [CA295]…8273
FAILURE CODE [CA322]…8274
FAILURE CODE [CA324]…8276
FAILURE CODE [CA331]…8278
FAILURE CODE [CA332]…8280
FAILURE CODE [CA343]…8282
FAILURE CODE [CA351]…8283
FAILURE CODE [CA352]…8285
FAILURE CODE [CA356]…8287
FAILURE CODE [CA357]…8289
FAILURE CODE [CA386]…8291
FAILURE CODE [CA428]…8292
FAILURE CODE [CA429]…8294
FAILURE CODE [CA435]…8296
FAILURE CODE [CA441]…8298
FAILURE CODE [CA442]…8300
FAILURE CODE [CA451]…8301
FAILURE CODE [CA452]…8303
FAILURE CODE [CA488]…8305
FAILURE CODE [CA515]…8306
FAILURE CODE [CA516]…8308
FAILURE CODE [CA553]…8310
FAILURE CODE [CA555]…8311
FAILURE CODE [CA556]…8312
FAILURE CODE [CA559]…8313
FAILURE CODE [CA595]…8316
FAILURE CODE [CA687]…8318
FAILURE CODE [CA689]…8320
FAILURE CODE [CA691]…8323
FAILURE CODE [CA692]…8325
FAILURE CODE [CA697]…8327
FAILURE CODE [CA698]…8328
FAILURE CODE [CA731]…8329
FAILURE CODE [CA778]…8331
FAILURE CODE [CA1117]…8336
FAILURE CODE [CA1664]…8338
FAILURE CODE [CA1669]…8340
FAILURE CODE [CA1673]…8341
FAILURE CODE [CA1677]…8342
FAILURE CODE [CA1678]…8343
FAILURE CODE [CA1682]…8344
FAILURE CODE [CA1683]…8346
FAILURE CODE [CA1684]…8348
FAILURE CODE [CA1686]…8350
FAILURE CODE [CA1691]…8351
FAILURE CODE [CA1694]…8353
FAILURE CODE [CA1695]…8355
FAILURE CODE [CA1696]…8356
FAILURE CODE [CA1712]…8358
FAILURE CODE [CA1713]…8361
FAILURE CODE [CA1714]…8363
FAILURE CODE [CA1715]…8364
FAILURE CODE [CA1776]…8365
FAILURE CODE [CA1777]…8368
FAILURE CODE [CA1843]…8371
FAILURE CODE [CA1844]…8373
FAILURE CODE [CA1885]…8376
FAILURE CODE [CA1887]…8378
FAILURE CODE [CA1896]…8380
FAILURE CODE [CA1898]…8381
FAILURE CODE [CA1938]…8383
FAILURE CODE [CA1942]…8385
FAILURE CODE [CA1961]…8386
FAILURE CODE [CA1962]…8387
FAILURE CODE [CA2185]…8388
FAILURE CODE [CA2186]…8390
FAILURE CODE [CA2198]…8392
FAILURE CODE [CA2272]…8394
FAILURE CODE [CA2288]…8396
FAILURE CODE [CA2311]…8397
FAILURE CODE [CA2349]…8398
FAILURE CODE [CA2353]…8400
FAILURE CODE [CA2357]…8402
FAILURE CODE [CA2373]…8403
FAILURE CODE [CA2374]…8405
FAILURE CODE [CA2375]…8407
FAILURE CODE [CA2376]…8409
FAILURE CODE [CA2387]…8412
FAILURE CODE [CA2554]…8413
FAILURE CODE [CA2634]…8414
FAILURE CODE [CA2635]…8416
FAILURE CODE [CA2636]…8417
FAILURE CODE [CA2637]…8419
FAILURE CODE [CA2771]…8421
FAILURE CODE [CA2961]…8425
FAILURE CODE [CA2973]…8426
FAILURE CODE [CA2976]…8427
FAILURE CODE [CA3142]…8429
FAILURE CODE [CA3143]…8430
FAILURE CODE [CA3144]…8431
FAILURE CODE [CA3146]…8433
FAILURE CODE [CA3147]…8434
FAILURE CODE [CA3148]…8435
FAILURE CODE [CA3151]…8437
FAILURE CODE [CA3165]…8442
FAILURE CODE [CA3228]…8444
FAILURE CODE [CA3229]…8446
FAILURE CODE [CA3231]…8448
FAILURE CODE [CA3232]…8450
FAILURE CODE [CA3235]…8454
FAILURE CODE [CA3239]…8456
FAILURE CODE [CA3241]…8459
FAILURE CODE [CA3242]…8462
FAILURE CODE [CA3251]…8465
FAILURE CODE [CA3313]…8467
FAILURE CODE [CA3314]…8468
FAILURE CODE [CA3315]…8469
FAILURE CODE [CA3419]…8471
FAILURE CODE [CA3421]…8473
FAILURE CODE [CA3497]…8475
FAILURE CODE [CA3498]…8476
FAILURE CODE [CA3545]…8477
FAILURE CODE [CA3547]…8479
FAILURE CODE [CA3558]…8480
FAILURE CODE [CA3559]…8482
FAILURE CODE [CA3562]…8484
FAILURE CODE [CA3563]…8486
FAILURE CODE [CA3567]…8489
FAILURE CODE [CA3568]…8493
FAILURE CODE [CA3571]…8497
FAILURE CODE [CA3572]…8499
FAILURE CODE [CA3574]…8501
FAILURE CODE [CA3575]…8503
FAILURE CODE [CA3577]…8505
FAILURE CODE [CA3578]…8507
FAILURE CODE [CA3582]…8509
FAILURE CODE [CA3583]…8514
FAILURE CODE [CA3596]…8516
FAILURE CODE [CA3649]…8519
FAILURE CODE [CA3681]…8521
FAILURE CODE [CA3682]…8526
FAILURE CODE [CA3713]…8531
FAILURE CODE [CA3717]…8534
FAILURE CODE [CA3718]…8535
FAILURE CODE [CA3724]…8536
FAILURE CODE [CA3725]…8537
FAILURE CODE [CA3741]…8540
FAILURE CODE [CA3748]…8541
FAILURE CODE [CA3755]…8543
FAILURE CODE [CA3866]…8545
FAILURE CODE [CA3868]…8548
FAILURE CODE [CA4152]…8552
FAILURE CODE [CA4155]…8556
FAILURE CODE [CA4156]…8559
FAILURE CODE [CA4157]…8562
FAILURE CODE [CA4159]…8564
FAILURE CODE [CA4164]…8565
FAILURE CODE [CA4165]…8567
FAILURE CODE [CA4166]…8569
FAILURE CODE [CA4168]…8570
FAILURE CODE [CA4169]…8573
FAILURE CODE [CA4171]…8575
FAILURE CODE [CA4249]…8578
FAILURE CODE [CA4251]…8580
FAILURE CODE [CA4261]…8583
FAILURE CODE [CA4277]…8586
FAILURE CODE [CA4459]…8589
FAILURE CODE [CA4461]…8591
FAILURE CODE [CA4533]…8594
FAILURE CODE [CA4534]…8595
FAILURE CODE [CA4731]…8596
FAILURE CODE [CA4732]…8597
FAILURE CODE [CA4739]…8598
FAILURE CODE [CA4768]…8599
FAILURE CODE [CA4769]…8601
FAILURE CODE [CA4842]…8604
FAILURE CODE [CA4952]…8607
FAILURE CODE [CA5115]…8609
FAILURE CODE [CA5179]…8612
FAILURE CODE [CA5181]…8614
FAILURE CODE [CA5387]…8616
FAILURE CODE [CA5388]…8618
FAILURE CODE [CA5389]…8621
FAILURE CODE [CA5391]…8623
FAILURE CODE [CA5392]…8627
FAILURE CODE [CA5393]…8629
FAILURE CODE [CA5394]…8632
FAILURE CODE [CA5395]…8635
FAILURE CODE [CA5396]…8638
FAILURE CODE [CA5631]…8639
FAILURE CODE [CA5632]…8641
FAILURE CODE [CA5938]…8642
FAILURE CODE [D130KA]…8644
FAILURE CODE [D130KB]…8647
FAILURE CODE [D130KY]…8649
FAILURE CODE [D19JKZ]…8651
FAILURE CODE [D811MC]…8654
FAILURE CODE [D862KA]…8655
FAILURE CODE [D8ALKA]…8656
FAILURE CODE [D8ALKB]…8658
FAILURE CODE [D8AQKR]…8660
FAILURE CODE [DAF0MB]…8662
FAILURE CODE [DAF0MC]…8663
FAILURE CODE [DAF8KB]…8664
FAILURE CODE [DAF9KQ]…8666
FAILURE CODE [DAFGMC]…8667
FAILURE CODE [DAFLKA]…8668
FAILURE CODE [DAFLKB]…8670
FAILURE CODE [DAFQKR]…8672
FAILURE CODE [DAJ000]…8673
FAILURE CODE [DAJ0KQ]…8674
FAILURE CODE [DAJ0KT]…8675
FAILURE CODE [DAJ0MC]…8676
FAILURE CODE [DAJ1KK]…8677
FAILURE CODE [DAJ2KK]…8679
FAILURE CODE [DAJ5KK]…8681
FAILURE CODE [DAJ6KK]…8684
FAILURE CODE [DAJLKA]…8686
FAILURE CODE [DAJLKB]…8688
FAILURE CODE [DAJPMA]…8690
FAILURE CODE [DAJQKR]…8691
FAILURE CODE [DAJRKR]…8692
FAILURE CODE [DB2QKR]…8693
FAILURE CODE [DB2RKR]…8698
FAILURE CODE [DBR0KT]…8703
FAILURE CODE [DBR0MC]…8704
FAILURE CODE [DBR1KK]…8705
FAILURE CODE [DBR2KK]…8708
FAILURE CODE [DBR5KK]…8711
FAILURE CODE [DBRLKA]…8713
FAILURE CODE [DBRLKB]…8715
FAILURE CODE [DBRPMA]…8717
FAILURE CODE [DBRQKR]…8718
FAILURE CODE [DBRRKR]…8720
FAILURE CODE [DBTSKR]…8721
FAILURE CODE [DBUTKA]…8724
FAILURE CODE [DD12KA]…8725
FAILURE CODE [DD12KB]…8727
FAILURE CODE [DD13KA]…8729
FAILURE CODE [DD13KB]…8731
FAILURE CODE [DD14KA]…8733
FAILURE CODE [DD14KB]…8735
FAILURE CODE [DDKAKA]…8737
FAILURE CODE [DDKAKB]…8739
FAILURE CODE [DDKFL4]…8741
FAILURE CODE [DDKGL4]…8743
FAILURE CODE [DDKHKA]…8745
FAILURE CODE [DDKHKB]…8747
FAILURE CODE [DDNLKA]…8749
FAILURE CODE [DDNLKB]…8751
FAILURE CODE [DDP6KA]…8753
FAILURE CODE [DDP6KB]…8756
FAILURE CODE [DDP6MA]…8758
FAILURE CODE [DDU1FS]…8760
FAILURE CODE [DDU1KA]…8762
FAILURE CODE [DDU1KY]…8765
FAILURE CODE [DFA4KX]…8767
FAILURE CODE [DFA4KZ]…8768
FAILURE CODE [DFA4L8]…8769
FAILURE CODE [DFA5KA]…8770
FAILURE CODE [DFA5KB]…8773
FAILURE CODE [DFA6KA]…8776
FAILURE CODE [DFA6KB]…8779
FAILURE CODE [DFA7KX]…8782
FAILURE CODE [DFA7KZ]…8783
FAILURE CODE [DFA7L8]…8784
FAILURE CODE [DFA8KA]…8785
FAILURE CODE [DFA8KB]…8788
FAILURE CODE [DFA9KA]…8791
FAILURE CODE [DFA9KB]…8794
FAILURE CODE [DGS1KA]…8797
FAILURE CODE [DGS1KX]…8800
FAILURE CODE [DH21KA]…8801
FAILURE CODE [DH21KB]…8803
FAILURE CODE [DHA4KA]…8805
FAILURE CODE [DHH7KA]…8807
FAILURE CODE [DHH7KB]…8810
FAILURE CODE [DHH8KA]…8812
FAILURE CODE [DHH8KB]…8815
FAILURE CODE [DHH9KA]…8817
FAILURE CODE [DHH9KB]…8820
FAILURE CODE [DHHAKA]…8822
FAILURE CODE [DHHAKB]…8825
FAILURE CODE [DK30KA]…8827
FAILURE CODE [DK30KB]…8830
FAILURE CODE [DK30KX]…8832
FAILURE CODE [DK30KZ]…8833
FAILURE CODE [DK30L8]…8834
FAILURE CODE [DK31KA]…8835
FAILURE CODE [DK31KB]…8838
FAILURE CODE [DK40KA]…8840
FAILURE CODE [DK40KB]…8843
FAILURE CODE [DK55KX]…8845
FAILURE CODE [DK55KZ]…8846
FAILURE CODE [DK55L8]…8847
FAILURE CODE [DK56KA]…8848
FAILURE CODE [DK56KB]…8851
FAILURE CODE [DK57KA]…8853
FAILURE CODE [DK57KB]…8856
FAILURE CODE [DK80KA]…8858
FAILURE CODE [DKS0L8]…8860
FAILURE CODE [DKS1KA]…8861
FAILURE CODE [DKS1KB]…8863
FAILURE CODE [DKS2KA]…8864
FAILURE CODE [DKS2KB]…8866
FAILURE CODE [DKS3KA]…8867
FAILURE CODE [DKS3KB]…8869
FAILURE CODE [DKS3MB]…8870
FAILURE CODE [DKS4L8]…8871
FAILURE CODE [DKS5KA]…8872
FAILURE CODE [DKS5KB]…8874
FAILURE CODE [DKS6KA]…8875
FAILURE CODE [DKS6KB]…8877
FAILURE CODE [DKS7MB]…8878
FAILURE CODE [DKSCL8]…8879
FAILURE CODE [DKSDKA]…8880
FAILURE CODE [DKSDKB]…8882
FAILURE CODE [DKSEKA]…8883
FAILURE CODE [DKSEKB]…8885
FAILURE CODE [DKSFKA]…8886
FAILURE CODE [DKSFKB]…8888
FAILURE CODE [DKSFMB]…8889
FAILURE CODE [DLM0KX]…8891
FAILURE CODE [DLM0MA]…8892
FAILURE CODE [DLM1KA]…8893
FAILURE CODE [DLM1KB]…8895
FAILURE CODE [DLM1MA]…8897
FAILURE CODE [DLM2KA]…8898
FAILURE CODE [DLM2KB]…8900
FAILURE CODE [DLM2MA]…8902
FAILURE CODE [DLM3KA]…8903
FAILURE CODE [DLM3KB]…8905
FAILURE CODE [DLM3MB]…8907
FAILURE CODE [DN21FS]…8908
FAILURE CODE [DR21KX]…8910
FAILURE CODE [DR31KX]…8911
FAILURE CODE [DV20KB]…8912
FAILURE CODE [DW4BKA]…8914
FAILURE CODE [DW4BKB]…8916
FAILURE CODE [DW4BKY]…8918
FAILURE CODE [DW7BKA]…8920
FAILURE CODE [DW7BKB]…8922
FAILURE CODE [DW7EKA]…8924
FAILURE CODE [DW7EKB]…8926
FAILURE CODE [DW7EKY]…8928
FAILURE CODE [DWN5KA]…8930
FAILURE CODE [DWN5KB]…8932
FAILURE CODE [DWN5KY]…8934
FAILURE CODE [DXA4KA]…8936
FAILURE CODE [DXA4KB]…8938
FAILURE CODE [DXA4KY]…8940
FAILURE CODE [DXA5KA]…8942
FAILURE CODE [DXA5KB]…8944
FAILURE CODE [DXA5KY]…8946
FAILURE CODE [DXA6KA]…8948
FAILURE CODE [DXA6KB]…8950
FAILURE CODE [DXA6KY]…8952
FAILURE CODE [DXA7KA]…8954
FAILURE CODE [DXA7KB]…8956
FAILURE CODE [DXA7KY]…8958
FAILURE CODE [DXHRKA]…8960
FAILURE CODE [DXHRKB]…8962
FAILURE CODE [DXHRKY]…8964
FAILURE CODE [DXHSKA]…8966
FAILURE CODE [DXHSKB]…8968
FAILURE CODE [DXHSKY]…8970
FAILURE CODE [DXHTKA]…8972
FAILURE CODE [DXHTKB]…8974
FAILURE CODE [DXHTKY]…8976
FAILURE CODE [DXHUKA]…8978
FAILURE CODE [DXHUKB]…8980
FAILURE CODE [DXHUKY]…8982
FAILURE CODE [DXJ4KA]…8984
FAILURE CODE [DXJ4KB]…8986
FAILURE CODE [DXJCKA]…8988
FAILURE CODE [DXJCKB]…8990
FAILURE CODE [DXJCKY]…8992
FAILURE CODE [DXJDKA]…8994
FAILURE CODE [DXJDKB]…8996
FAILURE CODE [DXJDKY]…8998
FAILURE CODE [DXK1KA]…9000
FAILURE CODE [DXK1KB]…9002
FAILURE CODE [DXK1KY]…9004
FAILURE CODE [DXK2KA]…9006
FAILURE CODE [DXK2KB]…9008
FAILURE CODE [DXK2KY]…9010
TROUBLESHOOTING OF ELECTRICAL SYSTEM (E-MODE)…9012
E-1 ENGINE DOES NOT START (ENGINE DOES NOT CRANK)…9012
E-2 MANUAL PREHEATING SYSTEM DOES NOT WORK…9019
E-3 AUTOMATIC PREHEATING SYSTEM DOES NOT WORK…9022
E-4 WHILE PREHEATING IS WORKING, PREHEATING MONITOR DOES NOT LIGHT UP…9024
E-5 WHEN STARTING SWITCH IS TURNED TO ON POSITION, MACHINE MONITOR DISPLAYS NOTHING…9026
E-6 WHEN STARTING SWITCH IS TURNED TO ON POSITION (WITH ENGINE STOPPED), BASIC CHECK MONITOR LIGHTS UP…9030
E-7 AIR CLEANER CLOGGING MONITOR LIGHTS UP IN YELLOW WHILE ENGINE IS RUNNING…9031
E-8 CHARGE LEVEL MONITOR LIGHTS UP IN RED WHILE ENGINE IS RUNNING…9032
E-9 ENGINE COOLANT TEMPERATURE MONITOR LIGHTS UP IN RED WHILE ENGINE IS RUNNING…9033
E-10 ENGINE OIL PRESSURE MONITOR LIGHTS UP IN RED WHILE ENGINE IS RUNNING…9034
E-11 HST CHARGE PRESSURE MONITOR LIGHTS UP IN RED WHILE ENGINE IS RUNNING…9035
E-12 HYDRAULIC OIL TEMPERATURE MONITOR LIGHTS UP IN RED WHILE ENGINE IS RUNNING…9036
E-13 HST OIL FILTER CLOGGING MONITOR LIGHTS UP IN RED WHILE ENGINE IS RUNNING…9037
E-14 ENGINE COOLANT TEMPERATURE GAUGE DOES NOT INDICATE CORRECT TEMPERATURE…9038
E-15 FUEL LEVEL GAUGE DOES NOT INDICATE CORRECT LEVEL…9039
E-16 HYDRAULIC OIL TEMPERATURE GAUGE DOES NOT INDICATE CORRECT TEMPERATURE…9042
E-17 OPERATION MODE DOES NOT CHANGE…9043
E-18 OPERATING CUSTOMIZE SWITCH DOES NOT DISPLAY CUSTOMIZE SCREEN…9044
E-19 MODIFYING SETTING ON CUSTOMIZE SCREEN DOES NOT CHANGE SETTING OF MACHINE…9045
E-20 SERVICE METER IS NOT DISPLAYED, WHILE STARTING SWITCH IS IN OFF POSITION…9046
E-21 SERVICE MODE CANNOT BE SELECTED…9047
E-22 WORK EQUIPMENT DOES NOT OPERATE…9048
E-23 FOOT HEATER DOES NOT OPERATE…9050
E-24 HORN DOES NOT SOUND…9056
E-25 HORN DOES NOT STOP SOUNDING…9058
E-26 BACKUP ALARM DOES NOT SOUND…9059
E-27 BACKUP ALARM DOES NOT STOP SOUNDING…9060
E-28 HEADLAMP DOES NOT LIGHT UP…9061
E-29 REAR LAMP DOES NOT LIGHT UP…9065
E-30 ALL WIPERS DO NOT OPERATE…9068
E-31 FRONT WIPER DOES NOT OPERATE…9070
E-32 REAR WIPER DOES NOT OPERATE…9072
E-33 LEFT DOOR WIPER DOES NOT OPERATE…9074
E-34 RIGHT DOOR WIPER DOES NOT OPERATE…9078
E-35 FRONT WASHER DOES NOT OPERATE…9082
E-36 REAR WASHER DOES NOT OPERATE…9084
E-37 LEFT DOOR WASHER DOES NOT OPERATE…9086
E-38 RIGHT DOOR WASHER DOES NOT OPERATE…9088
E-39 KOMTRAX SYSTEM DOES NOT OPERATE NORMALLY…9090
E-40 CONTROL BOX SHUTS DOWN AFTER DISPLAYING THE MESSAGES [GPS receiver not connected !] AND [Slope sensor not connected !]…9091
E-41 CONTROL BOX DISPLAYS THE MESSAGES [GPS receiver not connected !] AND [Slope sensor not connected !]…9095
E-42 CONTROL BOX DISPLAYS THE MESSAGE [Waiting for radio link…]…9100
E-43 CONTROL BOX DISPLAYS THE MESSAGE [IMU sensor not connected]…9101
E-44 CONTROL BOX DISPLAYS THE MESSAGE [Waiting for satellites…]…9102
E-45 CONTROL BOX DISPLAYS THE MESSAGE [Komatsu controller not connected!]…9103
E-46 CONTROL BOX DISPLAYS THE MESSAGE [Cylinder Stroke Reading Abnormal]…9105
E-47 CONTROL BOX DISPLAYS THE MESSAGE [Komatsu CAN Comms Abnormal]…9106
E-48 CONTROL BOX DISPLAYS THE MESSAGE [Komatsu Machine Trouble]…9107
E-49 CONTROL BOX DISPLAYS THE MESSAGE [Waiting to initialize…]…9108
E-50 CONTROL BOX DISPLAYS THE MESSAGE [System Initializing]…9109
E-51 CONTROL BOX DISPLAYS THE MESSAGE [Initializing…]…9110
E-52 CONTROL BOX DISPLAYS THE MESSAGE [Configuring GPS]…9111
E-53 CONTROL BOX DISPLAYS THE MESSAGE [No GPS Localization…]…9112
E-54 CONTROL BOX DISPLAYS THE MESSAGE [Low precisions…]…9113
E-55 CONTROL BOX DISPLAYS THE MESSAGE [Heading Initializing]…9114
E-56 CONTROL BOX DISPLAYS [Out of design area…]…9115
E-57 CONTROL BOX CAN NOT BE TURNED ON…9116
E-58 CONTROL BOX DOES NOT DISPLAY INTELLIGENT MACHINE CONTROL SCREEN…9117
E-59 CONTROL BOX DOES NOT DISPLAY BULLDOZER IMAGE…9118
E-60 CONTROL BOX DOES NOT DISPLAY DESIGN SURFACE…9119
E-61 CONTROL BOX TOUCH PANEL DOES NOT RESPOND…9120
E-62 CONTROL BOX TOUCH PANEL IS INACCURATE…9121
E-63 CYLINDER STROKE RESET INDICATION DOES NOT GO OUT…9122
E-64 AUTO IS NOT DISPLAYED WHEN AUTO/MANUAL SWITCH IS PRESSED (AUTO INDICATION GOES OUT)…9123
E-65 BLADE AUTOMATIC LOWER CONTROL DOES NOT START WHILE AUTO IS DISPLAYED…9125
E-66 BLADE AUTOMATIC RAISE CONTROL DOES NOT START WHILE AUTO IS DISPLAYED…9126
E-67 BLADE AUTOMATIC CONTROL FUNCTION IS NOT ACTIVATED WHILE AUTO IS DISPLAYED (BLADE AUTOMATIC CONTROL STOPS)…9127
E-68 WHEN CHECKING AND ADJUSTING THE BLADE ELEVATION, THE VALUE IS DIFFERENT FROM ACTUAL MACHINE…9128
E-69 FINISHED SURFACE IS INACCURATE (THE AVERAGE HEIGHT OF FINISHED SURFACE IS LOWER THAN DESIGNED SURFACE OR BLADE DOES NOT TOUCH THE SURFACE)…9129
E-70 FINISHED SURFACE IS INACCURATE (THE FINISHED SURFACE IS NOT SMOOTH)…9130
E-71 FINISHED SURFACE IS INACCURATE (WHEN FINISHING SLOPE HORIZONTALLY, STEPS ARE MADE IN EACH DIRECTION)…9131
E-72 MACHINE CAN NOT ESCAPE FROM SHOES SLIP WHILE BLADE AUTOMATIC CONTROL IS ACTIVATED (SHOES FREQUENTLY SLIPS)…9133
E-73 MACHINE SPEED DOES NOT INCREASE WHILE BLADE AUTOMATIC CONTROL IS ACTIVATED…9134
E-74 BLADE TILT ANGLE DOES NOT COINCIDE WITH DESIGN SURFACE…9135
E-75 BLADE TILTS BACK WHILE BLADE AUTOMATIC CONTROL IS ACTIVATED…9137
E-76 WHEN PRESSING CUT/FILL LEVEL SWITCH (RAISE), THE DESIGN SURFACE DOES NOT RISE…9139
E-77 WHEN PRESSING CUT/FILL LEVEL SWITCH (LOWER), THE DESIGN SURFACE DOES NOT LOWER…9142
E-78 WHEN STARTING SWITCH IS TURNED TO ON POSITION, REVERSE LEVELING MODE SWITCH LED DOES NOT LIGHT UP OR DOES NOT GO OUT…9145
E-79 WHEN REVERSE LEVELING MODE SWITCH IS PRESSED, BUZZER DOES NOT SOUND (DOES NOT SWITCH TO REVERSE LEVELING MODE)…9147
TROUBLESHOOTING FOR HYDRAULIC AND MECHANICAL SYSTEMS (H MODE)…9150
INFORMATION MENTIONED IN TROUBLESHOOTING TABLE (H MODE)…9150
FAILURE MODE AND CAUSE TABLE…9151
H-1 NEITHER R.H. NOR L.H. OF TRACKS CAN TRAVEL FORWARD OR REVERSE (NONE OF THE TRAVEL SYSTEMS OPERATE)…9157
H-2 EITHER R.H. OR L.H. OF TRACK CANNOT TRAVEL BOTH FORWARD AND REVERSE (ONE OF R.H. OR L.H. TRAVEL SYSTEMS CANNOT OPERATE)…9159
H-3 EITHER R.H. OR L.H. OF TRACK CANNOT TRAVEL ONE OF FORWARD OR REVERSE (ONLY ONE OF THE TRAVEL SYSTEMS CANNOT OPERATE IN ONE DIRECTION)…9161
H-4 TRAVEL SPEED OR POWER IS LOW…9163
H-5 SPEED RANGE DOES NOT CHANGE…9165
H-6 SHOCK IS LARGE WHEN MACHINE MOVES OFF OR STOPS…9166
H-7 MACHINE DEVIATES LARGELY…9167
H-8 MACHINE DRIFT ON A SLOPE IS LARGE…9170
H-9 ENGINE SPEED DROPS LARGELY OR ENGINE STOPS…9172
H-10 UNUSUAL NOISE IS HEARD FROM AROUND HST PUMP OR MOTOR…9174
H-11 HST OIL TEMPERATURE (HYDRAULIC OIL TEMPERATURE) RISES TOO HIGH…9176
H-12 ALL WORK EQUIPMENT DO NOT OPERATE…9178
H-13 ALL WORK EQUIPMENTS SPEED OR POWER IS LOW…9180
H-14 BLADE LIFT SPEED OR POWER IS LOW…9181
H-15 BLADE TILT SPEED OR POWER IS LOW…9183
H-16 BLADE ANGLE SPEED OR POWER IS LOW…9184
H-17 TIME LAG OF BLADE LIFT IS LARGE…9185
H-18 HYDRAULIC DRIFT OF LIFTED BLADE IS LARGE…9186
H-19 HYDRAULIC DRIFT OF TILTED BLADE IS LARGE…9187
H-20 UNUSUAL NOISE IS HEARD FROM AROUND WORK EQUIPMENT AND COOLING FAN PUMP OR CONTROL VALVE…9188
H-21 FAN SPEED IS ABNORMAL (TOO HIGH OR LOW, OR STATIONARY)…9189
H-22 UNUSUAL NOISE IS HEARD FROM AROUND FAN…9191
TROUBLESHOOTING OF ENGINE (S-MODE)…9192
INFORMATION MENTIONED IN TROUBLESHOOTING TABLE (S MODE)…9192
S-1 ENGINE DOES NOT CRANK WHEN STARTING SWITCH IS TURNED TO START POSITION…9193
S-2 ENGINE CRANKS BUT NO EXHAUST GAS COMES OUT…9194
S-3 FUEL IS BEING INJECTED BUT ENGINE DOES NOT START (MISFIRING: ENGINE CRANKS BUT DOES NOT START)…9195
S-4 ENGINE STARTABILITY IS POOR…9197
S-5 ENGINE DOES NOT PICK UP SMOOTHLY…9199
S-6 ENGINE STOPS DURING OPERATION…9201
S-7 ENGINE RUNS ROUGH OR IS UNSTABLE…9203
S-8 ENGINE LACKS POWER…9204
S-9 EXHAUST SMOKE IS BLACK…9206
S-10 ENGINE OIL CONSUMPTION IS EXCESSIVE…9208
S-11 OIL BECOMES CONTAMINATED QUICKLY…9209
S-12 FUEL CONSUMPTION IS EXCESSIVE…9210
S-13 OIL IS IN COOLANT (OR COOLANT SPURTS BACK OR COOLANT LEVEL GOES DOWN)…9211
S-14 OIL PRESSURE DROPS…9212
S-15 FUEL MIXES INTO ENGINE OIL…9214
S-16 WATER MIXES INTO ENGINE OIL (MILKY)…9215
S-17 COOLANT TEMPERATURE RISES TOO HIGH (OVERHEATING)…9216
S-18 UNUSUAL NOISE IS HEARD…9217
S-19 VIBRATION IS EXCESSIVE…9218
S-20 AIR CANNOT BE BLED FROM FUEL CIRCUIT…9219
S-21 ACTIVE REGENERATION IS EXECUTED FREQUENTLY…9220
S-22 ACTIVE REGENERATION TAKES TIME…9221
S-23 WHITE SMOKE IS EXHAUSTED DURING ACTIVE REGENERATION…9222
S-24 AdBlue/DEF CONSUMPTION IS EXCESSIVE…9223
S-25 THERE IS UNUSUAL SMELL (IRRITATING ODOR)…9225
S-26 FOREIGN MATERIALS ENTER AdBlue/DEF (AdBlue/DEF INCREASES)…9226
50 DISASSEMBLY AND ASSEMBLY…9227
CONTENTS…9228
ABBREVIATION LIST…9233
RELATED INFORMATION ON DISASSEMBLY AND ASSEMBLY…9239
HOW TO READ THIS MANUAL…9239
COATING MATERIALS LIST…9241
SPECIAL TOOLS LIST…9246
SKETCHES OF SPECIAL TOOLS…9268
ENGINE AND COOLING SYSTEM…9281
REMOVE AND INSTALL SUPPLY PUMP ASSEMBLY…9281
METHOD FOR REMOVING SUPPLY PUMP ASSEMBLY…9281
METHOD FOR INSTALLING SUPPLY PUMP ASSEMBLY…9291
REMOVE AND INSTALL INJECTOR ASSEMBLY…9301
METHOD FOR REMOVING INJECTOR ASSEMBLY…9301
METHOD FOR INSTALLING INJECTOR ASSEMBLY…9312
REMOVE AND INSTALL CYLINDER HEAD ASSEMBLY…9326
METHOD FOR REMOVING CYLINDER HEAD ASSEMBLY…9326
METHOD FOR INSTALLING CYLINDER HEAD ASSEMBLY…9345
REMOVE AND INSTALL EGR VALVE ASSEMBLY…9369
METHOD FOR REMOVING EGR VALVE ASSEMBLY…9369
METHOD FOR INSTALLING EGR VALVE ASSEMBLY…9372
REMOVE AND INSTALL EGR COOLER ASSEMBLY…9376
METHOD FOR REMOVING EGR COOLER ASSEMBLY…9376
METHOD FOR INSTALLING EGR COOLER ASSEMBLY…9380
REMOVE AND INSTALL STARTING MOTOR ASSEMBLY…9384
METHOD FOR REMOVING STARTING MOTOR ASSEMBLY…9384
METHOD FOR INSTALLING STARTING MOTOR ASSEMBLY…9386
REMOVE AND INSTALL AIR CONDITIONER COMPRESSOR BELT…9389
METHOD FOR REMOVING AIR CONDITIONER COMPRESSOR BELT…9389
METHOD FOR INSTALLING AIR CONDITIONER COMPRESSOR BELT…9393
REMOVE AND INSTALL ALTERNATOR BELT…9398
METHOD FOR REMOVING ALTERNATOR BELT…9398
METHOD FOR INSTALLING ALTERNATOR BELT…9400
REMOVE AND INSTALL AUTOMATIC TENSIONER…9403
METHOD FOR REMOVING AUTOMATIC TENSIONER…9403
METHOD FOR INSTALLING AUTOMATIC TENSIONER…9404
REMOVE AND INSTALL RADIATOR ASSEMBLY…9406
METHOD FOR REMOVING RADIATOR ASSEMBLY…9407
METHOD FOR INSTALLING RADIATOR ASSEMBLY…9415
REMOVE AND INSTALL HYDRAULIC OIL COOLER ASSEMBLY…9423
METHOD FOR REMOVING HYDRAULIC OIL COOLER ASSEMBLY…9424
METHOD FOR INSTALLING HYDRAULIC OIL COOLER ASSEMBLY…9429
REMOVE AND INSTALL AFTERCOOLER ASSEMBLY…9434
METHOD FOR REMOVING AFTERCOOLER ASSEMBLY…9435
METHOD FOR INSTALLING AFTERCOOLER ASSEMBLY…9441
REMOVE AND INSTALL COOLING FAN DRIVE ASSEMBLY…9448
METHOD FOR REMOVING COOLING FAN DRIVE ASSEMBLY…9448
METHOD FOR INSTALLING COOLING FAN DRIVE ASSEMBLY…9452
REMOVE AND INSTALL COOLING FAN MOTOR ASSEMBLY…9457
METHOD FOR REMOVING COOLING FAN MOTOR ASSEMBLY…9457
METHOD FOR INSTALLING COOLING FAN MOTOR ASSEMBLY…9460
REMOVE AND INSTALL ENGINE, HST PUMP ASSEMBLY…9463
METHOD FOR REMOVING ENGINE, HST PUMP ASSEMBLY…9463
METHOD FOR INSTALLING ENGINE, HST PUMP ASSEMBLY…9474
REMOVE AND INSTALL ENGINE FRONT OIL SEAL…9486
METHOD FOR REMOVING ENGINE FRONT OIL SEAL…9486
METHOD FOR INSTALLING ENGINE FRONT OIL SEAL…9488
REMOVE AND INSTALL ENGINE REAR OIL SEAL…9491
METHOD FOR REMOVING ENGINE REAR OIL SEAL…9491
METHOD FOR INSTALLING ENGINE REAR OIL SEAL…9492
REMOVE AND INSTALL ENGINE HOOD ASSEMBLY…9495
METHOD FOR REMOVING ENGINE HOOD ASSEMBLY…9495
METHOD FOR INSTALLING ENGINE HOOD ASSEMBLY…9498
REMOVE AND INSTALL KDOC ASSEMBLY…9502
METHOD FOR REMOVING KDOC ASSEMBLY…9502
METHOD FOR INSTALLING KDOC ASSEMBLY…9507
REMOVE AND INSTALL KDOC AND SCR ASSEMBLY…9515
METHOD FOR REMOVING KDOC AND SCR ASSEMBLY…9516
METHOD FOR INSTALLING KDOC AND SCR ASSEMBLY…9522
REMOVE AND INSTALL BELLOWS PIPE ASSEMBLY…9531
METHOD FOR REMOVING BELLOWS PIPE ASSEMBLY…9531
METHOD FOR INSTALLING BELLOWS PIPE ASSEMBLY…9534
REMOVE AND INSTALL FUEL TANK ASSEMBLY…9539
METHOD FOR REMOVING FUEL TANK ASSEMBLY…9540
METHOD FOR INSTALLING FUEL TANK ASSEMBLY…9547
REMOVE AND INSTALL AdBlue/DEF TANK ASSEMBLY…9554
METHOD FOR REMOVING AdBlue/DEF TANK ASSEMBLY…9555
METHOD FOR INSTALLING AdBlue/DEF TANK ASSEMBLY…9565
REMOVE AND INSTALL AdBlue/DEF TANK SENSOR FLANGE ASSEMBLY…9574
METHOD FOR REMOVING AdBlue/DEF TANK SENSOR FLANGE ASSEMBLY…9574
METHOD FOR INSTALLING AdBlue/DEF TANK SENSOR FLANGE ASSEMBLY…9576
REMOVE AND INSTALL AdBlue/DEF TANK SENSOR…9580
METHOD FOR REMOVING AdBlue/DEF TANK SENSOR…9580
METHOD FOR INSTALLING AdBlue/DEF TANK SENSOR…9581
REMOVE AND INSTALL AdBlue/DEF TANK STRAINER…9584
METHOD FOR REMOVING AdBlue/DEF TANK STRAINER…9584
METHOD FOR INSTALLING AdBlue/DEF TANK STRAINER…9585
REMOVE AND INSTALL SCR ASSEMBLY…9586
METHOD FOR REMOVING SCR ASSEMBLY…9586
METHOD FOR INSTALLING SCR ASSEMBLY…9589
REMOVE AND INSTALL KCCV ASSEMBLY…9592
METHOD FOR REMOVING KCCV ASSEMBLY…9592
METHOD FOR INSTALLING KCCV ASSEMBLY…9593
REMOVE AND INSTALL AdBlue/DEF MIXING TUBE…9596
METHOD FOR REMOVING AdBlue/DEF MIXING TUBE…9596
METHOD FOR INSTALLING AdBlue/DEF MIXING TUBE…9600
REMOVE AND INSTALL AdBlue/DEF INJECTOR…9604
METHOD FOR REMOVING AdBlue/DEF INJECTOR…9604
METHOD FOR INSTALLING AdBlue/DEF INJECTOR…9609
REMOVE AND INSTALL AdBlue/DEF PUMP…9614
METHOD FOR REMOVING AdBlue/DEF PUMP…9614
METHOD FOR INSTALLING AdBlue/DEF PUMP…9618
REMOVE AND INSTALL AdBlue/DEF HOSE…9622
METHOD FOR REMOVING AdBlue/DEF HOSE…9624
METHOD FOR INSTALLING AdBlue/DEF HOSE…9643
REMOVE AND INSTALL AIR CLEANER ASSEMBLY…9664
METHOD FOR REMOVING AIR CLEANER ASSEMBLY…9664
METHOD FOR INSTALLING AIR CLEANER ASSEMBLY…9666
REMOVE AND INSTALL AIR CONDITIONER COMPRESSOR ASSEMBLY…9669
METHOD FOR REMOVING AIR CONDITIONER COMPRESSOR ASSEMBLY…9669
METHOD FOR INSTALLING AIR CONDITIONER COMPRESSOR ASSEMBLY…9673
REMOVE AND INSTALL AIR CONDITIONER CONDENSER ASSEMBLY…9678
METHOD FOR REMOVING AIR CONDITIONER CONDENSER ASSEMBLY…9678
METHOD FOR INSTALLING AIR CONDITIONER CONDENSER ASSEMBLY…9682
POWER TRAIN…9686
DISASSEMBLE AND ASSEMBLE FINAL DRIVE ASSEMBLY…9686
METHOD FOR DISASSEMBLING FINAL DRIVE ASSEMBLY…9687
METHOD FOR ASSEMBLING FINAL DRIVE ASSEMBLY…9691
UNDERCARRIAGE AND FRAME…9700
REMOVE AND INSTALL TRACK FRAME ASSEMBLY…9700
METHOD FOR REMOVING TRACK FRAME ASSEMBLY…9700
METHOD FOR INSTALLING TRACK FRAME ASSEMBLY…9705
REMOVE AND INSTALL IDLER ASSEMBLY…9710
METHOD FOR REMOVING IDLER ASSEMBLY…9710
METHOD FOR INSTALLING IDLER ASSEMBLY…9712
DISASSEMBLE AND ASSEMBLE IDLER ASSEMBLY…9715
METHOD FOR DISASSEMBLING IDLER ASSEMBLY…9715
METHOD FOR ASSEMBLING IDLER ASSEMBLY…9717
REMOVE AND INSTALL RECOIL SPRING ASSEMBLY…9722
METHOD FOR REMOVING RECOIL SPRING ASSEMBLY…9722
METHOD FOR INSTALLING RECOIL SPRING ASSEMBLY…9722
DISASSEMBLE AND ASSEMBLE RECOIL SPRING ASSEMBLY…9723
METHOD FOR DISASSEMBLING AND ASSEMBLING RECOIL SPRING ASSEMBLY…9723
METHOD FOR ASSEMBLING RECOIL SPRING ASSEMBLY…9726
REMOVE AND INSTALL TRACK ROLLER ASSEMBLY…9729
METHOD FOR REMOVING TRACK ROLLER ASSEMBLY…9729
METHOD FOR INSTALLING TRACK ROLLER ASSEMBLY…9731
DISASSEMBLE AND ASSEMBLE TRACK ROLLER ASSEMBLY…9734
METHOD FOR DISASSEMBLING TRACK ROLLER ASSEMBLY…9734
METHOD FOR ASSEMBLING TRACK ROLLER ASSEMBLY…9735
REMOVE AND INSTALL CARRIER ROLLER ASSEMBLY…9739
METHOD FOR REMOVING CARRIER ROLLER ASSEMBLY…9739
METHOD FOR INSTALLING CARRIER ROLLER ASSEMBLY…9740
DISASSEMBLE AND ASSEMBLE CARRIER ROLLER ASSEMBLY…9742
METHOD FOR DISASSEMBLING CARRIER ROLLER ASSEMBLY…9742
METHOD FOR ASSEMBLING CARRIER ROLLER ASSEMBLY…9743
REMOVE AND INSTALL PIVOT SHAFT ASSEMBLY…9746
METHOD FOR REMOVING PIVOT SHAFT ASSEMBLY…9746
METHOD FOR INSTALLING PIVOT SHAFT ASSEMBLY…9747
SEPARATE AND CONNECT TRACK ASSEMBLY…9749
METHOD FOR CHECKING BEFORE SEPARATING TRACK ASSEMBLY…9749
METHOD FOR SEPARATING TRACK ASSEMBLY (NORMAL)…9750
METHOD FOR SEPARATING TRACK ASSEMBLY (WHEN TRACK FRAME HAS INTERNAL DEFECT)…9751
METHOD FOR CONNECTING TRACK ASSEMBLY…9752
SEPARATE AND CONNECT PLUS TYPE TRACK ASSEMBLY…9754
METHOD FOR SEPARATING PLUS TYPE TRACK ASSEMBLY…9754
METHOD FOR CONNECTING PLUS TYPE TRACK ASSEMBLY…9754
DISASSEMBLE AND ASSEMBLE TRACK ASSEMBLY GENERALLY…9755
METHOD FOR DISASSEMBLING TRACK ASSEMBLY GENERALLY…9755
METHOD FOR ASSEMBLING TRACK ASSEMBLY GENERALLY…9760
DISASSEMBLE AND ASSEMBLE PLUS TYPE TRACK ASSEMBLY GENERALLY…9773
METHOD FOR DISASSEMBLING PLUS TYPE TRACK ASSEMBLY GENERALLY…9774
METHOD FOR ASSEMBLING PLUS TYPE TRACK ASSEMBLY GENERALLY…9775
DISASSEMBLE AND ASSEMBLE ONE LINK OF TRACK SHOE ASSEMBLY ON THE FIELD…9784
METHOD FOR DISASSEMBLING ONE LINK OF TRACK SHOE ASSEMBLY ON THE FIELD…9785
METHOD FOR ASSEMBLING ONE LINK OF TRACK SHOE ASSEMBLY ON THE FIELD…9786
DISASSEMBLE AND ASSEMBLE ONE LINK OF PLUS TYPE TRACK SHOE ASSEMBLY ON THE FIELD…9793
METHOD FOR DISASSEMBLING ONE LINK OF PLUS TYPE TRACK SHOE ASSEMBLY ON THE FIELD…9794
METHOD FOR ASSEMBLING ONE LINK OF PLUS TYPE TRACK SHOE ASSEMBLY ON THE FIELD…9796
REMOVE AND INSTALL EQUALIZER BAR ASSEMBLY…9800
METHOD FOR REMOVING EQUALIZER BAR ASSEMBLY…9800
METHOD FOR INSTALLING EQUALIZER BAR ASSEMBLY…9802
REMOVE AND INSTALL EQUALIZER BAR SIDE BUSHINGS…9805
METHOD FOR REMOVING EQUALIZER BAR SIDE BUSHINGS…9805
METHOD FOR INSTALLING EQUALIZER BAR SIDE BUSHINGS…9806
REMOVE AND INSTALL SEGMENT TEETH…9807
METHOD FOR REMOVING SEGMENT TEETH…9807
METHOD FOR INSTALLING SEGMENT TEETH…9809
HYDRAULIC SYSTEM…9811
REMOVE AND INSTALL HYDRAULIC TANK ASSEMBLY…9811
METHOD FOR REMOVING HYDRAULIC TANK ASSEMBLY…9812
METHOD FOR INSTALLING HYDRAULIC TANK ASSEMBLY…9818
REMOVE AND INSTALL CONTROL VALVE ASSEMBLY…9827
METHOD FOR REMOVING CONTROL VALVE ASSEMBLY…9827
METHOD FOR INSTALLING CONTROL VALVE ASSEMBLY…9831
WORK EQUIPMENT…9835
REMOVE AND INSTALL BLADE ASSEMBLY…9835
METHOD FOR REMOVING BLADE ASSEMBLY…9835
METHOD FOR INSTALLING BLADE ASSEMBLY…9838
REMOVE AND INSTALL STROKE SENSING BLADE LIFT CYLINDER ASSEMBLY…9843
METHOD FOR REMOVING STROKE SENSING BLADE LIFT CYLINDER ASSEMBLY…9843
METHOD FOR INSTALLING STROKE SENSING BLADE LIFT CYLINDER ASSEMBLY…9845
DISASSEMBLE AND ASSEMBLE STROKE SENSING BLADE LIFT CYLINDER ASSEMBLY…9847
METHOD FOR DISASSEMBLING STROKE SENSING BLADE LIFT CYLINDER ASSEMBLY…9848
METHOD FOR ASSEMBLING STROKE SENSING BLADE LIFT CYLINDER ASSEMBLY…9852
REMOVE AND INSTALL STROKE SENSING BLADE TILT CYLINDER ASSEMBLY…9860
METHOD FOR REMOVING STROKE SENSING BLADE TILT CYLINDER ASSEMBLY…9860
METHOD FOR INSTALLING STROKE SENSING BLADE TILT CYLINDER ASSEMBLY…9863
DISASSEMBLE AND ASSEMBLE STROKE SENSING BLADE TILT CYLINDER ASSEMBLY…9868
METHOD FOR DISASSEMBLING STROKE SENSING BLADE TILT CYLINDER ASSEMBLY…9868
METHOD FOR ASSEMBLING STROKE SENSING BLADE TILT CYLINDER ASSEMBLY…9872
REMOVE AND INSTALL STROKE SENSING BLADE ANGLE CYLINDER ASSEMBLY…9877
METHOD FOR REMOVING STROKE SENSING BLADE ANGLE CYLINDER ASSEMBLY…9877
METHOD FOR INSTALLING STROKE SENSING BLADE ANGLE CYLINDER ASSEMBLY…9880
DISASSEMBLE AND ASSEMBLE STROKE SENSING BLADE ANGLE CYLINDER ASSEMBLY…9883
METHOD FOR DISASSEMBLING STROKE SENSING BLADE ANGLE CYLINDER ASSEMBLY…9884
METHOD FOR ASSEMBLING STROKE SENSING BLADE ANGLE CYLINDER ASSEMBLY…9887
REMOVE AND INSTALL U-FRAME ASSEMBLY…9893
METHOD FOR REMOVING U-FRAME ASSEMBLY…9893
METHOD FOR INSTALLING U-FRAME ASSEMBLY…9897
CAB AND ITS ATTACHMENTS…9900
REMOVE AND INSTALL OPERATOR'S CAB ASSEMBLY…9900
METHOD FOR REMOVING OPERATOR'S CAB ASSEMBLY…9900
METHOD FOR INSTALLING OPERATOR'S CAB ASSEMBLY…9907
REMOVE AND INSTALL OPERATOR'S CAB GLASS (ADHERED GLASS)…9916
METHOD FOR REMOVING OPERATOR'S CAB GLASS (ADHERED GLASS)…9918
METHOD FOR INSTALLING OPERATOR'S CAB GLASS (ADHERED GLASS)…9918
REMOVE AND INSTALL AIR CONDITIONER UNIT ASSEMBLY…9924
METHOD FOR REMOVING AIR CONDITIONER UNIT ASSEMBLY…9924
METHOD FOR INSTALLING AIR CONDITIONER UNIT ASSEMBLY…9930
REMOVE AND INSTALL RECEIVER DRIER…9937
METHOD FOR REMOVING RECEIVER DRIER…9937
METHOD FOR INSTALLING RECEIVER DRIER…9938
REMOVE AND INSTALL OPERATOR'S SEAT…9941
METHOD FOR REMOVING OPERATOR'S SEAT…9941
METHOD FOR INSTALLING OPERATOR'S SEAT…9942
REMOVE AND INSTALL SEAT BELT…9943
METHOD FOR REMOVING SEAT BELT…9943
METHOD FOR INSTALLING SEAT BELT…9943
REMOVE AND INSTALL FOOT HEATER ASSEMBLY…9945
METHOD FOR REMOVING FOOT HEATER ASSEMBLY…9945
METHOD FOR INSTALLING FOOT HEATER ASSEMBLY…9947
DISASSEMBLE AND ASSEMBLE FOOT HEATER ASSEMBLY…9950
METHOD FOR DISASSEMBLING FOOT HEATER ASSEMBLY…9950
METHOD FOR ASSEMBLING FOOT HEATER ASSEMBLY…9951
ELECTRICAL SYSTEM…9952
REMOVE AND INSTALL ENGINE CONTROLLER ASSEMBLY…9952
METHOD FOR REMOVING ENGINE CONTROLLER ASSEMBLY…9952
METHOD FOR INSTALLING ENGINE CONTROLLER ASSEMBLY…9955
REMOVE AND INSTALL HST CONTROLLER ASSEMBLY…9959
METHOD FOR REMOVING HST CONTROLLER ASSEMBLY…9959
METHOD FOR INSTALLING HST CONTROLLER ASSEMBLY…9960
REMOVE AND INSTALL MACHINE MONITOR ASSEMBLY…9961
METHOD FOR REMOVING MACHINE MONITOR ASSEMBLY…9961
METHOD FOR INSTALLING MACHINE MONITOR ASSEMBLY…9962
REMOVE AND INSTALL MASS AIR FLOW AND TEMPERATURE SENSOR…9964
METHOD FOR REMOVING MASS AIR FLOW AND TEMPERATURE SENSOR…9964
METHOD FOR INSTALLING MASS AIR FLOW AND TEMPERATURE SENSOR…9966
REMOVE AND INSTALL KCCV CRANKCASE PRESSURE SENSOR…9968
METHOD FOR REMOVING KCCV CRANKCASE PRESSURE SENSOR…9968
METHOD FOR INSTALLING KCCV CRANKCASE PRESSURE SENSOR…9970
REMOVE AND INSTALL ICT SENSOR CONTROLLER ASSEMBLY…9972
METHOD FOR REMOVING ICT SENSOR CONTROLLER ASSEMBLY…9972
METHOD FOR INSTALLING ICT SENSOR CONTROLLER ASSEMBLY…9972
REMOVE AND INSTALL CONTROL BOX…9974
METHOD FOR REMOVING CONTROL BOX…9974
METHOD FOR INSTALLING CONTROL BOX…9975
REMOVE AND INSTALL GNSS RECEIVER…9976
METHOD FOR REMOVING GNSS RECEIVER…9976
METHOD FOR INSTALLING GNSS RECEIVER…9976
REMOVE AND INSTALL GNSS ANTENNA…9978
METHOD FOR REMOVING GNSS ANTENNA…9978
METHOD FOR INSTALLING GNSS ANTENNA…9979
REMOVE AND INSTALL IMU SENSOR…9984
METHOD FOR REMOVING IMU SENSOR…9984
METHOD FOR INSTALLING IMU SENSOR…9986
60 MAINTENANCE STANDARD…9989
CONTENTS…9990
ABBREVIATION LIST…9991
ENGINE AND COOLING SYSTEM…9997
MAINTENANCE STANDARD OF ENGINE MOUNT…9997
MAINTENANCE STANDARD OF DAMPER…9998
MAINTENANCE STANDARD OF COOLING SYSTEM…9999
MAINTENANCE STANDARD OF COOLING FAN MOTOR…10001
MAINTENANCE STANDARD OF HYDRAULIC OIL COOLER BYPASS AND HST CHARGE SAFETY VALVE…10003
POWER TRAIN…10004
MAINTENANCE STANDARD OF HST PUMP…10004
MAINTENANCE STANDARD OF EPC VALVE OF HST PUMP…10006
MAINTENANCE STANDARD OF TOW RECEIVING VALVE OF HST PUMP…10007
MAINTENANCE STANDARD OF HST CHARGE PUMP…10008
MAINTENANCE STANDARD OF HST MOTOR…10010
MAINTENANCE STANDARD OF FINAL DRIVE…10012
MAINTENANCE STANDARD OF SPROCKET FOR PLUS TYPE TRACK SHOE…10014
MAINTENANCE STANDARD OF SPROCKET TOOTH PROFILE FULL-SCALE DRAWING FOR PLUS TYPE TRACK SHOE…10015
UNDERCARRIAGE AND FRAME…10016
MAINTENANCE STANDARD OF SUSPENSION…10016
MAINTENANCE STANDARD OF TRACK FRAME AND IDLER CUSHION…10019
MAINTENANCE STANDARD OF IDLER…10022
MAINTENANCE STANDARD OF TRACK ROLLER FOR PLUS TYPE TRACK SHOES (SINGLE FLANGE TYPE)…10024
MAINTENANCE STANDARD OF TRACK ROLLER FOR PLUS TYPE TRACK SHOES (DOUBLE FLANGE TYPE)…10025
MAINTENANCE STANDARD OF CARRIER ROLLER FOR PLUS TYPE TRACK SHOE…10027
MAINTENANCE STANDARD OF PLUS TYPE TRACK SHOE…10028
MAINTENANCE STANDARD OF SINGLE SHOE…10030
HYDRAULIC SYSTEM…10031
MAINTENANCE STANDARD OF HYDRAULIC TANK…10031
MAINTENANCE STANDARD OF WORK EQUIPMENT AND COOLING FAN PUMP…10032
MAINTENANCE STANDARD OF SERVO VALVE OF WORK EQUIPMENT AND COOLING FAN PUMP…10033
MAINTENANCE STANDARD OF CONTROL VALVE…10035
MAINTENANCE STANDARD OF RIPPER PPC VALVE…10041
MAINTENANCE STANDARD OF 5-PORT VALVE OF EPC AND SOLENOID…10043
MAINTENANCE STANDARD OF EPC VALVE…10044
MAINTENANCE STANDARD OF QUICK DROP VALVE…10045
WORK EQUIPMENT…10047
MAINTENANCE STANDARD OF FRONT WORK EQUIPMENT…10047
MAINTENANCE STANDARD OF CUTTING EDGE AND END BIT…10050
MAINTENANCE STANDARD OF STROKE SENSING BLADE LIFT CYLINDER…10051
MAINTENANCE STANDARD OF STROKE SENSING BLADE TILT CYLINDER…10052
MAINTENANCE STANDARD OF STROKE SENSING BLADE ANGLE CYLINDER…10053
MAINTENANCE STANDARD OF STROKE AND RESET SENSOR FOR BLADE LIFT CYLINDER…10054
MAINTENANCE STANDARD OF STROKE SENSOR FOR BLADE TILT CYLINDER…10055
MAINTENANCE STANDARD OF STROKE SENSOR FOR BLADE ANGLE CYLINDER…10056
MAINTENANCE STANDARD OF FIXED MULTI-SHANK RIPPER…10057
MAINTENANCE STANDARD OF RIPPER LIFT CYLINDER…10059
CAB AND ITS ATTACHMENTS…10060
MAINTENANCE STANDARD OF CAB MOUNT…10060
ELECTRICAL SYSTEM…10062
MAINTENANCE STANDARD OF ELECTRIC STEERING CONTROL LEVER…10062
80 APPENDIX…10063
CONTENTS…10064
ABBREVIATION LIST…10065
AIR CONDITIONER SYSTEM…10071
PRECAUTIONS FOR REFRIGERANT…10071
AIR CONDITIONER COMPONENT…10072
SPECIFICATIONS OF AIR CONDITIONER…10075
CONFIGURATION AND FUNCTION OF REFRIGERATION CYCLE…10076
OUTLINE OF REFRIGERATION CYCLE…10077
COMPONENT PARTS OF AIR CONDITIONER SYSTEM…10079
AIR CONDITIONER UNIT…10079
CONFIGURATION DIAGRAM OF AIR CONDITIONER UNIT…10079
FUNCTION OF AIR CONDITIONER UNIT…10080
COMPONENT PARTS OF AIR CONDITIONER UNIT…10081
FUNCTION OF EVAPORATOR AS AIR CONDITIONER UNIT COMPONENT…10081
FUNCTION OF HEATER CORE AS AIR CONDITIONER UNIT COMPONENT…10081
FUNCTION OF THERMISTOR AS AIR CONDITIONER UNIT COMPONENT…10081
STRUCTURE OF EXPANSION VALVE AS AIR CONDITIONER UNIT COMPONENT…10081
FUNCTION OF EXPANSION VALVE AS AIR CONDITIONER UNIT COMPONENT…10082
OPERATE EXPANSION VALVE AS AIR CONDITIONER UNIT COMPONENT…10082
FUNCTION OF DUAL PRESSURE SWITCH…10083
FUNCTION OF PRESSURE SWITCH…10083
COMPRESSOR…10084
STRUCTURE OF COMPRESSOR…10084
SPECIFICATIONS OF COMPRESSOR…10084
FUNCTION OF COMPRESSOR…10084
CONDENSER…10085
STRUCTURE OF CONDENSER…10085
SPECIFICATIONS OF CONDENSER…10085
FUNCTION OF CONDENSER…10086
RECEIVER DRIER…10087
STRUCTURE OF RECEIVER DRIER…10087
SPECIFICATIONS OF RECEIVER DRIER…10087
FUNCTION OF RECEIVER DRIER…10087
EXPLANATION OF PROCEDURE FOR TESTING AND TROUBLESHOOTING OF AIR CONDITIONER…10089
CIRCUIT DIAGRAM OF AIR CONDITIONER…10092
AIR CONDITIONER SYSTEM DIAGRAM…10093
CONTROL FUNCTION OF AIR CONDITIONER…10094
INSTALLATION LOCATIONS OF AIR CONDITIONER PARTS AND ARRANGEMENT OF CONNECTORS…10095
TEST RELAYS…10099
METHOD FOR TESTING RELAYS…10099
AIR CONDITIONER TROUBLESHOOTING CHART 1…10101
AIR CONDITIONER TROUBLESHOOTING CHART 2…10102
INFORMATION DESCRIBED IN TROUBLESHOOTING TABLE…10105
A-1 TROUBLESHOOTING FOR CONDENSER FAN…10107
A-2 TROUBLESHOOTING FOR BLOWER MOTOR SYSTEM (NO AIR COMES OUT OR AIR FLOW IS ABNORMAL)…10110
A-3 TROUBLESHOOTING FOR TEMPERATURE CONTROL FUNCTION…10113
TROUBLESHOOTING USING GAUGE PRESSURE…10117
CONNECTION OF SERVICE TOOL…10119
METHOD FOR CONNECTING SERVICE TOOL…10120
PRECAUTIONS FOR DISCONNECTING AND CONNECTING HOSES AND TUBES IN AIR CONDITIONER PIPINGS…10121
HANDLE COMPRESSOR OIL…10123
90 CIRCUIT DIAGRAMS…10125
CONTENTS…10126
ABBREVIATION LIST…10127
HYDRAULIC CIRCUIT DIAGRAM…10133
SYMBOLS USED IN HYDRAULIC CIRCUIT DIAGRAM…10133
ELECTRICAL CIRCUIT DIAGRAM…10139
SYMBOLS USED IN ELECTRICAL CIRCUIT DIAGRAM…10139
INDEX…10171
SEN06617 – Bulldozer D51EX-24, D51PX-24 Shop Manual (SN 10001 and up)…10191
COVER…10191
00 INDEX AND FOREWORD…10193
INDEX…10194
ABBREVIATION LIST…10210
FOREWORD, SAFETY, BASIC INFORMATION…10216
HOW TO READ THE SHOP MANUAL…10216
SAFETY NOTICE FOR OPERATION…10218
PRECAUTIONS TO PREVENT FIRE…10226
ACTIONS IF FIRE OCCURS…10228
PRECAUTIONS FOR DISPOSING OF WASTE MATERIALS…10229
ACTIONS TAKEN TO MEET EXHAUST GAS REGULATIONS…10230
PRECAUTIONS FOR DEF…10231
GENERAL CHARACTER AND PRECAUTIONS FOR HANDLING…10231
PRECAUTIONS FOR ADDING…10231
PRECAUTIONS FOR STORING…10231
PRECAUTIONS FOR FIRE HAZARD AND LEAKAGE…10231
THE OTHER PRECAUTIONS…10231
STORE AdBlue/DEF…10232
PRECAUTIONS FOR HANDLING HYDRAULIC EQUIPMENT…10233
PRECAUTIONS FOR DISCONNECTION AND CONNECTION OF PIPINGS…10236
PRECAUTIONS FOR HANDLING ELECTRICAL EQUIPMENT…10242
PRECAUTIONS FOR HANDLING FUEL SYSTEM EQUIPMENT…10244
PRECAUTIONS FOR HANDLING INTAKE SYSTEM EQUIPMENT…10245
PRACTICAL USE OF KOMTRAX…10246
DISCONNECT AND CONNECT PUSH-PULL TYPE COUPLER…10247
METHOD FOR DISCONNECTING AND CONNECTING TYPE 1 PUSH-PULL TYPE COUPLER…10247
METHOD FOR DISCONNECTING AND CONNECTING TYPE 2 PUSH-PULL TYPE COUPLER…10248
METHOD FOR DISCONNECTING AND CONNECTING TYPE 3 PUSH-PULL TYPE COUPLER…10249
PRECAUTIONS FOR DISCONNECTION AND CONNECTION OF CONNECTORS…10251
METHOD FOR DISCONNECTING AND CONNECTING DEUTSCH CONNECTOR…10255
METHOD FOR DISCONNECTING AND CONNECTING SLIDE LOCK TYPE CONNECTOR…10256
METHOD FOR DISCONNECTING AND CONNECTING CONNECTOR WITH LOCK TO PULL…10258
METHOD FOR DISCONNECTING AND CONNECTING CONNECTOR WITH LOCK TO PUSH…10259
METHOD FOR DISCONNECTING AND CONNECTING CONNECTOR WITH HOUSING TO ROTATE…10261
HOW TO READ ELECTRICAL WIRE CODE…10262
EXPLANATION OF TERMS FOR MAINTENANCE STANDARD…10266
STANDARD TIGHTENING TORQUE TABLE…10269
CONVERSION TABLE…10276
01 SPECIFICATIONS…10281
CONTENTS…10282
ABBREVIATION LIST…10283
SPECIFICATIONS…10289
SPECIFICATION DRAWING…10289
SPECIFICATION DRAWING: D51EX-24…10289
SPECIFICATION DRAWING: D51PX-24…10291
SPECIFICATIONS…10293
SPECIFICATIONS: D51EX-24…10293
SPECIFICATIONS: D51PX-24…10298
WEIGHT TABLE…10303
WEIGHT TABLE: D51EX-24…10303
WEIGHT TABLE: D51PX-24…10305
FUEL, COOLANT, LUBRICANTS (FOR NORTH AMERICA)…10307
METHOD FOR USING FUEL, COOLANT AND LUBRICANTS ACCORDING TO AMBIENT TEMPERATURE…10307
FUEL, COOLANT, LUBRICANTS (FOR EUROPEAN UNION)…10309
METHOD FOR USING FUEL, COOLANT AND LUBRICANTS ACCORDING TO AMBIENT TEMPERATURE…10309
10 STRUCTURE AND FUNCTION…10311
CONTENTS…10312
ABBREVIATION LIST…10315
UREA SCR SYSTEM…10321
LAYOUT DRAWING OF UREA SCR SYSTEM…10321
UREA SCR SYSTEM DIAGRAM…10323
FUNCTION OF UREA SCR SYSTEM…10324
FUNCTION OF AdBlue/DEF SYSTEM…10324
INDUCEMENT STRATEGY…10327
COMPONENT PARTS OF UREA SCR SYSTEM…10342
AdBlue/DEF MIXING TUBE…10342
SCR ASSEMBLY…10343
AdBlue/DEF TANK…10345
AdBlue/DEF PUMP…10347
AdBlue/DEF INJECTOR…10348
AdBlue/DEF HOSE…10349
AdBlue/DEF TANK HEATING VALVE…10350
BOOT-UP SYSTEM…10351
LAYOUT DRAWING OF BOOT-UP SYSTEM…10351
SYSTEM OPERATING LAMP SYSTEM…10352
SYSTEM OPERATING LAMP SYSTEM DIAGRAM…10352
FUNCTION OF SYSTEM OPERATING LAMP SYSTEM…10352
BATTERY DISCONNECT SWITCH…10354
FUNCTION OF BATTERY DISCONNECT SWITCH…10354
ENGINE SYSTEM…10355
LAYOUT DRAWING OF ENGINE SYSTEM…10355
ENGINE CONTROL SYSTEM…10357
LAYOUT OF ENGINE CONTROL SYSTEM…10357
ENGINE CONTROL SYSTEM DIAGRAM…10359
FUNCTION OF ENGINE CONTROL SYSTEM…10361
AUTOMATIC IDLE STOP SYSTEM…10363
AUTOMATIC IDLE STOP SYSTEM DIAGRAM…10363
FUNCTION OF AUTOMATIC IDLE STOP SYSTEM…10363
COMPONENT PARTS OF ENGINE SYSTEM…10366
DAMPER…10366
VGT…10367
EGR SYSTEM…10370
EGR VALVE…10372
EGR COOLER…10374
KCCV SYSTEM…10376
KCCV VENTILATOR…10378
KDOC…10380
COOLING SYSTEM…10383
LAYOUT DRAWING OF COOLING SYSTEM…10383
SPECIFICATIONS OF COOLING SYSTEM…10384
COOLING FAN CONTROL SYSTEM…10385
COOLING FAN CONTROL SYSTEM DIAGRAM…10385
FUNCTION OF COOLING FAN CONTROL SYSTEM…10386
COMPONENT PARTS OF COOLING SYSTEM…10388
COOLING FAN MOTOR…10388
HYDRAULIC OIL COOLER BYPASS AND HST CHARGE SAFETY VALVE…10393
HYDRAULIC OIL COOLER BYPASS VALVE…10394
HST CHARGE SAFETY VALVE…10395
CONTROL SYSTEM…10397
LAYOUT DRAWING OF CONTROL SYSTEM…10397
MACHINE MONITOR SYSTEM…10398
MACHINE MONITOR SYSTEM DIAGRAM…10398
FUNCTION OF MACHINE MONITOR SYSTEM…10398
KOMTRAX SYSTEM…10399
KOMTRAX SYSTEM DIAGRAM…10399
FUNCTION OF KOMTRAX SYSTEM…10399
COMPONENT PARTS OF CONTROL SYSTEM…10400
MACHINE MONITOR…10400
KOMTRAX TERMINAL…10415
HST CONTROLLER…10417
ENGINE CONTROLLER…10421
FUEL CONTROL DIAL…10428
DECELERATOR AND BRAKE POTENTIOMETER…10430
HYDRAULIC SYSTEM…10432
LAYOUT DRAWING OF HYDRAULIC SYSTEM…10432
CLSS…10433
STRUCTURE OF CLSS…10433
FUNCTION OF CLSS…10434
COMPONENT PARTS OF HYDRAULIC SYSTEM…10436
HYDRAULIC TANK…10436
WORK EQUIPMENT AND COOLING FAN PUMP…10438
LS VALVE…10446
PC VALVE…10447
CONTROL VALVE…10450
POWER TRAIN SYSTEM…10468
LAYOUT DRAWING OF HST SYSTEM…10468
OPERATION OF HST SYSTEM…10469
STEERING AND BRAKE CONTROL SYSTEM…10471
LAYOUT DRAWING OF STEERING AND BRAKE CONTROL SYSTEM…10471
FUNCTION OF STEERING AND BRAKE CONTROL SYSTEM…10471
HST CONTROL SYSTEM…10473
HST CONTROL SYSTEM DIAGRAM…10473
GEAR SHIFT CONTROL FUNCTION…10474
ENGINE LOW SPEED MATCHING CONTROL FUNCTION…10477
HST PUMP AND MOTOR SEQUENCE CONTROL FUNCTION…10478
DECELERATION AND BRAKE CONTROL FUNCTION…10479
GEAR SHIFT CONTROL FUNCTION BY LOAD…10481
TURN CONTROL FUNCTION…10481
STRAIGHT TRAVEL CORRECTION CONTROL FUNCTION…10482
PARKING BRAKE CONTROL SYSTEM…10484
PARKING BRAKE CONTROL SYSTEM DIAGRAM…10484
FUNCTION OF PARKING BRAKE CONTROL SYSTEM…10485
OPERATION OF PARKING BRAKE CONTROL SYSTEM…10486
COMPONENT PARTS OF POWER TRAIN SYSTEM…10487
HST PUMP…10487
HST CHARGE PUMP…10502
HST MOTOR…10503
FINAL DRIVE…10516
ELECTRIC STEERING CONTROL LEVER…10520
WORK EQUIPMENT SYSTEM…10523
WORK EQUIPMENT CONTROL…10523
WORK EQUIPMENT CONTROL SYSTEM DIAGRAM…10523
FUNCTION OF WORK EQUIPMENT CONTROL…10524
LAYOUT DRAWING OF FRONT WORK EQUIPMENT…10525
LAYOUT OF FIXED MULTI-SHANK RIPPER…10526
COMPONENT PARTS OF WORK EQUIPMENT SYSTEM…10527
RIPPER PPC VALVE…10527
5-PORT VALVE OF EPC AND SOLENOID…10531
PILOT CIRCUIT ACCUMULATOR…10537
QUICK DROP VALVE…10538
PISTON VALVE…10540
ELECTRIC BLADE CONTROL LEVER…10541
UNDERCARRIAGE AND FRAME…10543
MAIN FRAME…10543
STRUCTURE OF MAIN FRAME…10543
SUSPENSION…10544
STRUCTURE OF SUSPENSION…10544
SPECIFICATIONS OF SUSPENSION…10545
FUNCTION OF SUSPENSION…10546
TRACK FRAME AND IDLER CUSHION…10547
STRUCTURE OF TRACK FRAME AND IDLER CUSHION…10547
FUNCTION OF TRACK FRAME AND IDLER CUSHION…10548
WORK EQUIPMENT…10549
STRUCTURE OF FRONT WORK EQUIPMENT…10549
STRUCTURE OF FIXED MULTI-SHANK RIPPER…10550
CAB AND ITS ATTACHMENTS…10551
ROPS CAB…10551
STRUCTURE OF ROPS CAB…10551
FUNCTION OF ROPS CAB…10552
CAB MOUNT…10553
STRUCTURE OF CAB MOUNT…10553
FUNCTION OF CAB MOUNT…10553
20 STANDARD VALUE TABLE…10555
CONTENTS…10556
ABBREVIATION LIST…10557
STANDARD VALUE TABLE FOR ENGINE…10563
STANDARD VALUE TABLE FOR ENGINE: D51EX-24…10563
STANDARD VALUE TABLE FOR ENGINE: D51PX-24…10567
STANDARD VALUE TABLE FOR MACHINE…10571
STANDARD VALUE TABLE FOR MACHINE: D51EX-24…10571
STANDARD VALUE TABLE FOR MACHINE: D51PX-24…10587
MACHINE POSTURE AND PROCEDURE FOR MEASURING PERFORMANCE…10601
30 TESTING AND ADJUSTING…10603
CONTENTS…10604
ABBREVIATION LIST…10607
RELATED INFORMATION ON TESTING AND ADJUSTING…10613
TOOLS FOR TESTING AND ADJUSTING…10613
SKETCH OF TOOLS FOR TESTING AND ADJUSTING…10620
ENGINE AND COOLING SYSTEM…10621
TEST ENGINE SPEED…10621
METHOD FOR TESTING ENGINE SPEED…10621
TEST BOOST PRESSURE…10623
METHOD FOR TESTING BOOST PRESSURE…10623
TEST EXHAUST GAS COLOR…10625
METHOD FOR TESTING EXHAUST GAS COLOR BY HANDY SMOKE CHECKER…10625
METHOD FOR TESTING EXHAUST GAS COLOR BY SMOKE METER…10626
TEST AND ADJUST VALVE CLEARANCE…10627
METHOD FOR TESTING VALVE CLEARANCE…10627
METHOD FOR ADJUSTING VALVE CLEARANCE…10628
TEST COMPRESSION PRESSURE…10629
METHOD FOR TESTING COMPRESSION PRESSURE…10629
TEST BLOWBY PRESSURE…10634
METHOD FOR TESTING BLOWBY PRESSURE…10634
TEST ENGINE OIL PRESSURE…10636
METHOD FOR TESTING ENGINE OIL PRESSURE…10636
TEST FUEL PRESSURE…10637
METHOD FOR TESTING FUEL PRESSURE…10638
TEST FUEL DISCHARGE, RETURN AND LEAKAGE…10642
METHOD FOR TESTING FUEL DISCHARGE, RETURN AND LEAKAGE…10643
BLEED AIR FROM FUEL SYSTEM…10648
METHOD FOR BLEEDING AIR FROM FUEL SYSTEM…10648
TEST FUEL CIRCUIT FOR LEAKAGE…10649
METHOD FOR TESTING FUEL CIRCUIT FOR LEAKAGE…10649
HANDLE CYLINDER CUT-OUT MODE OPERATION…10651
HANDLE NO-INJECTION CRANKING OPERATION…10652
TEST KDOC, SCR AND MUFFLER STACK FOR LOOSENESS AND DAMAGE…10653
METHOD FOR TESTING KDOC, SCR AND MUFFLER STACK FOR LOOSENESS AND DAMAGE…10653
TEST INSTALLED CONDITION OF CYLINDER HEADS AND MANIFOLDS…10654
METHOD FOR TESTING INSTALLED CONDITION OF CYLINDER HEADS AND MANIFOLDS…10654
TEST ENGINE PIPING FOR DAMAGE AND LOOSENESS…10655
METHOD FOR TESTING ENGINE PIPING FOR DAMAGE AND LOOSENESS…10655
WRITE ASH IN SOOT ACCUMULATION CORRECTION TO ENGINE CONTROLLER…10656
METHOD FOR WRITING ASH IN SOOT ACCUMULATION CORRECTION TO ENGINE CONTROLLER…10656
TEST SCR RELATED FUNCTIONS…10657
TEST AdBlue/DEF PUMP RAISED PRESSURE…10661
TEST INJECTION AMOUNT FROM AdBlue/DEF INJECTOR…10664
TEST AdBlue/DEF LINE HEATER RELAY 1…10668
TEST AdBlue/DEF LINE HEATER RELAY 2…10671
TEST AdBlue/DEF PUMP HEATER RELAY…10674
TEST AdBlue/DEF TANK HEATER VALVE…10678
TEST DENITRATION EFFICIENCY OF SCR…10682
CLEAN AdBlue/DEF TANK…10685
METHOD FOR CLEANING AdBlue/DEF TANK…10685
CLEAN AdBlue/DEF TANK MOUNTING PORTION…10689
METHOD FOR CLEANING AdBlue/DEF TANK MOUNTING PORTION…10689
POWER TRAIN…10690
TEST AND ADJUST HST OIL PRESSURE…10690
METHOD FOR TESTING HST OIL PRESSURE…10690
METHOD FOR ADJUSTING HST OIL PRESSURE…10693
BLEED AIR FROM HST PUMP…10695
METHOD FOR BLEEDING AIR FROM HST PUMP…10695
METHOD FOR BLEEDING AIR FROM SERVO VALVE OF HST PUMP…10695
TEST OUTLET PRESSURE OF SOLENOID VALVE…10697
METHOD FOR TESTING OUTLET PRESSURE OF SOLENOID VALVE…10697
TEST TRAVEL DEVIATION…10701
METHOD FOR TESTING TRAVEL DEVIATION…10701
TEST BRAKE PERFORMANCE SIMPLY…10703
METHOD FOR TESTING BRAKE PERFORMANCE SIMPLY…10703
TEST AND ADJUST DECELERATION/BRAKE PEDAL…10704
METHOD FOR TESTING DECELERATION/BRAKE PEDAL…10704
METHOD FOR ADJUSTING DECELERATION/BRAKE PEDAL…10706
ADJUST PARKING BRAKE LEVER…10708
METHOD FOR ADJUSTING PARKING BRAKE LEVER…10708
MOVE MACHINE WHEN IT CANNOT TRAVEL…10710
METHOD FOR MOVING MACHINE WITH HYDRAULIC TYPE PARKING BRAKE RELEASE SYSTEM…10710
METHOD FOR MOVING DISABLED MACHINE BY REMOVING FINAL DRIVE SHAFT…10712
UNDERCARRIAGE AND FRAME…10713
CHECK AND ADJUST IDLER CLEARANCE…10713
METHOD FOR ADJUSTING IDLER CLEARANCE HORIZONTALLY…10713
METHOD FOR ADJUSTING IDLER CLEARANCE VERTICALLY…10713
TESTING SPROCKET WEAR…10715
METHOD FOR TESTING SPROCKET WEAR…10715
TEST AND ADJUST TRACK TENSION…10716
METHOD FOR TESTING TRACK TENSION…10716
METHOD FOR ADJUSTING TRACK TENSION…10716
HYDRAULIC SYSTEM…10718
RELEASE REMAINING PRESSURE FROM HYDRAULIC SYSTEM…10718
METHOD FOR RELEASING REMAINING PRESSURE FROM HYDRAULIC CIRCUIT…10718
TEST AND ADJUST WORK EQUIPMENT OIL PRESSURES…10719
METHOD FOR TESTING WORK EQUIPMENT OIL PRESSURES…10719
METHOD FOR ADJUSTING WORK EQUIPMENT OIL PRESSURES…10720
TEST AND ADJUST OIL PRESSURE OF CONTROL CIRCUIT…10722
METHOD FOR TESTING OIL PRESSURE OF CONTROL CIRCUIT…10722
METHOD FOR ADJUSTING OIL PRESSURE OF CONTROL CIRCUIT…10723
TEST OUTLET PRESSURE OF EPC SOLENOID VALVE…10724
METHOD FOR TESTING OUTLET PRESSURE OF EPC SOLENOID VALVE…10724
BLEED AIR FROM WORK EQUIPMENT AND COOLING FAN PUMP…10726
METHOD FOR BLEEDING AIR FROM WORK EQUIPMENT AND COOLING FAN PUMP…10726
TEST COOLING FAN SPEED…10727
METHOD FOR TESTING COOLING FAN SPEED…10727
TEST COOLING FAN CIRCUIT OIL PRESSURE…10728
METHOD FOR TESTING COOLING FAN CIRCUIT OIL PRESSURE…10728
TEST THE PARTS CAUSING HYDRAULIC DRIFT IN WORK EQUIPMENT…10730
METHOD FOR TESTING THE PARTS CAUSING HYDRAULIC DRIFT OF BLADE LIFT CYLINDER…10730
METHOD FOR TESTING THE PARTS CAUSING HYDRAULIC DRIFT OF BLADE TILT CYLINDER…10730
METHOD FOR TESTING THE PARTS CAUSING HYDRAULIC DRIFT OF RIPPER LIFT CYLINDER…10731
TEST INTERNAL OIL LEAKAGE OF WORK EQUIPMENT CYLINDER…10732
METHOD FOR TESTING INTERNAL OIL LEAKAGE OF WORK EQUIPMENT CYLINDER…10732
BLEED AIR FROM WORK EQUIPMENT CYLINDERS…10735
METHOD FOR BLEEDING AIR FROM WORK EQUIPMENT CYLINDERS…10735
WORK EQUIPMENT…10736
ADJUST WORK EQUIPMENT LOCK LEVER…10736
METHOD FOR ADJUSTING WORK EQUIPMENT LOCK LEVER…10736
ELECTRICAL SYSTEM…10738
SET AND OPERATE MACHINE MONITOR…10738
OPERATOR MODE…10742
DISPLAY FUNCTION OF TECHNICIAN IDENTIFICATION STATUS SCREEN…10742
DISPLAY FUNCTION OF OPERATOR IDENTIFICATION INPUT SCREEN…10742
CHECKING FUNCTION BY LCD (LIQUID CRYSTAL DISPLAY)…10743
CHECKING FUNCTION OF SERVICE METER…10743
METHOD FOR SETTING USAGE LIMITATION AND CHANGING MAINTENANCE PASSWORD…10743
SERVICE MODE…10746
METHOD FOR OPERATING SERVICE MODE…10746
METHOD FOR CHECKING PRE-DEFINED MONITORING INFORMATION…10748
METHOD FOR CHECKING SELF-DEFINE MONITORING INFORMATION…10760
ABNORMALITY RECORD MENU…10778
METHOD FOR CONFIRMING MAINTENANCE RECORD…10782
METHOD FOR OPERATING MAINTENANCE MODE SETTING…10783
METHOD FOR OPERATING PHONE NUMBER ENTRY SETTING…10787
DEFAULT MENU…10788
DIAGNOSTIC TESTS MENU…10795
ADJUSTMENT MENU…10803
METHOD FOR PERFORMING NO-INJECTION CRANKING…10860
KOMTRAX SETTINGS MENU…10862
METHOD FOR DISPLAYING SERVICE MESSAGE…10864
METHOD FOR STARTING UP KOMTRAX TERMINAL…10866
ADJUSTMENT WHEN HST CONTROLLER HAS BEEN REPLACED…10871
ADJUSTMENT METHOD WHEN HST CONTROLLER HAS BEEN REPLACED…10871
ADJUSTMENT WHEN ELECTRIC OR HYDRAULIC DEVICE HAS BEEN REPLACED…10877
ADJUST REARVIEW CAMERA ANGLE…10879
METHOD FOR ADJUSTING REARVIEW CAMERA ANGLE…10879
HANDLE VOLTAGE CIRCUIT OF ENGINE CONTROLLER…10880
HANDLE BATTERY DISCONNECT SWITCH…10881
TEST DIODES…10882
METHOD FOR TESTING DIODE USING DIGITAL TESTER…10882
METHOD FOR TESTING DIODE USING ANALOG TESTER…10882
Pm CLINIC…10883
Pm CLINIC SERVICE…10883
Pm CLINIC CHECK SHEET: D51EX-24…10885
Pm CLINIC CHECK SHEET: D51PX-24…10893
Pm CLINIC CHECK SHEET FOR UNDERCARRIAGE: D51EX-24…10901
Pm CLINIC CHECK SHEET FOR UNDERCARRIAGE: D51PX-24…10905
40 TROUBLESHOOTING…10909
CONTENTS…10910
ABBREVIATION LIST…10920
RELATED INFORMATION ON TROUBLESHOOTING…10926
GENERAL TROUBLESHOOTING POINTS…10926
TROUBLESHOOTING POINTS FOR UREA SCR SYSTEM…10927
SEQUENCE OF EVENTS IN TROUBLESHOOTING…10939
CHECKS BEFORE TROUBLESHOOTING…10941
INSPECTION PROCEDURE BEFORE TROUBLESHOOTING…10943
WALK-AROUND CHECK…10943
TESTING IN ACCORDANCE WITH TESTING PROCEDURE…10945
CHECK FUEL LEVEL AND TYPE…10945
CHECK IMPURE INGREDIENT IN FUEL…10945
CHECK AdBule/DEF LEVEL AND TYPE…10946
CHECK FUEL PREFILTER…10946
CHECK MAIN FILTER…10948
CHECK ENGINE OIL LEVEL (OIL AMOUNT IN OIL PAN) AND TYPE…10949
CHECK COOLANT LEVEL (RESERVOIR TANK)…10951
CHECK CLOGGING OF AIR CLEANER…10951
CLEAN OUTER ELEMENT…10952
REPLACE ELEMENT…10954
CHECK HYDRAULIC OIL LEVEL…10955
CHECK HYDRAULIC OIL STRAINER…10956
CHECK OIL LEVEL IN FINAL DRIVE CASE…10959
BLEED AIR FROM FUEL SYSTEM…10960
BLEED AIR FROM HYDRAULIC SYSTEM…10960
METHOD FOR CHECKING ELECTRIC EQUIPMENT…10960
PREPARATION FOR TROUBLESHOOTING OF ELECTRICAL SYSTEM…10967
PROCEDURE FOR TROUBLESHOOTING…10974
INFORMATION DESCRIBED IN TROUBLESHOOTING TABLE…10977
TROUBLESHOOTING METHOD FOR OPEN CIRCUIT IN WIRING HARNESS OF PRESSURE SENSOR SYSTEM…10979
CONNECTORS LIST AND LAYOUT…10982
CONNECTOR CONTACT IDENTIFICATION…10996
T-BRANCH BOX AND T-BRANCH ADAPTER TABLE…11036
FUSE LOCATION TABLE…11042
PRECAUTIONS FOR REPLACING KDOC…11046
FAILURE CODES TABLE…11047
TROUBLESHOOTING BY FAILURE CODE (DISPLAY OF CODE)…11065
FAILURE CODE [6091NX]…11065
FAILURE CODE [989L00]…11067
FAILURE CODE [989M00]…11068
FAILURE CODE [989N00]…11069
FAILURE CODE [A1U0N3]…11070
FAILURE CODE [A1U0N4]…11072
FAILURE CODE [A900FR]…11074
FAILURE CODE [A900N6]…11075
FAILURE CODE [A900NY]…11076
FAILURE CODE [AA10NX]…11077
FAILURE CODE [AB00KE]…11079
FAILURE CODE [AQ10MB]…11081
FAILURE CODE [AQ10N3]…11083
FAILURE CODE [AS00R2]…11085
FAILURE CODE [AS00R3]…11086
FAILURE CODE [AS00R4]…11087
FAILURE CODE [AS00R5]…11088
FAILURE CODE [AS00R6]…11089
FAILURE CODE [AS00ZK]…11090
FAILURE CODE [AS10KM]…11091
FAILURE CODE [AS10NR]…11092
FAILURE CODE [AS10NT]…11093
FAILURE CODE [B@BAZG]…11094
FAILURE CODE [B@BCNS]…11095
FAILURE CODE [B@CRNS]…11096
FAILURE CODE [B@CRZG]…11097
FAILURE CODE [CA115]…11098
FAILURE CODE [CA122]…11099
FAILURE CODE [CA123]…11101
FAILURE CODE [CA131]…11103
FAILURE CODE [CA132]…11105
FAILURE CODE [CA144]…11107
FAILURE CODE [CA145]…11109
FAILURE CODE [CA153]…11111
FAILURE CODE [CA154]…11113
FAILURE CODE [CA187]…11115
FAILURE CODE [CA221]…11117
FAILURE CODE [CA222]…11119
FAILURE CODE [CA227]…11121
FAILURE CODE [CA234]…11123
FAILURE CODE [CA238]…11124
FAILURE CODE [CA239]…11125
FAILURE CODE [CA249]…11126
FAILURE CODE [CA256]…11128
FAILURE CODE [CA271]…11130
FAILURE CODE [CA272]…11132
FAILURE CODE [CA295]…11134
FAILURE CODE [CA322]…11135
FAILURE CODE [CA324]…11137
FAILURE CODE [CA331]…11139
FAILURE CODE [CA332]…11141
FAILURE CODE [CA343]…11143
FAILURE CODE [CA351]…11144
FAILURE CODE [CA352]…11146
FAILURE CODE [CA356]…11148
FAILURE CODE [CA357]…11150
FAILURE CODE [CA386]…11152
FAILURE CODE [CA428]…11153
FAILURE CODE [CA429]…11155
FAILURE CODE [CA435]…11157
FAILURE CODE [CA441]…11159
FAILURE CODE [CA442]…11161
FAILURE CODE [CA451]…11162
FAILURE CODE [CA452]…11164
FAILURE CODE [CA488]…11166
FAILURE CODE [CA515]…11167
FAILURE CODE [CA516]…11169
FAILURE CODE [CA553]…11171
FAILURE CODE [CA555]…11172
FAILURE CODE [CA556]…11173
FAILURE CODE [CA559]…11174
FAILURE CODE [CA595]…11177
FAILURE CODE [CA687]…11179
FAILURE CODE [CA689]…11181
FAILURE CODE [CA691]…11184
FAILURE CODE [CA692]…11186
FAILURE CODE [CA697]…11188
FAILURE CODE [CA698]…11189
FAILURE CODE [CA731]…11190
FAILURE CODE [CA778]…11192
FAILURE CODE [CA1117]…11197
FAILURE CODE [CA1664]…11199
FAILURE CODE [CA1669]…11201
FAILURE CODE [CA1673]…11202
FAILURE CODE [CA1677]…11203
FAILURE CODE [CA1678]…11204
FAILURE CODE [CA1682]…11205
FAILURE CODE [CA1683]…11207
FAILURE CODE [CA1684]…11209
FAILURE CODE [CA1686]…11211
FAILURE CODE [CA1691]…11212
FAILURE CODE [CA1694]…11214
FAILURE CODE [CA1695]…11216
FAILURE CODE [CA1696]…11217
FAILURE CODE [CA1712]…11219
FAILURE CODE [CA1713]…11222
FAILURE CODE [CA1714]…11224
FAILURE CODE [CA1715]…11225
FAILURE CODE [CA1776]…11226
FAILURE CODE [CA1777]…11229
FAILURE CODE [CA1843]…11232
FAILURE CODE [CA1844]…11234
FAILURE CODE [CA1885]…11237
FAILURE CODE [CA1887]…11239
FAILURE CODE [CA1896]…11241
FAILURE CODE [CA1898]…11242
FAILURE CODE [CA1938]…11244
FAILURE CODE [CA1942]…11246
FAILURE CODE [CA1961]…11247
FAILURE CODE [CA1962]…11248
FAILURE CODE [CA2185]…11249
FAILURE CODE [CA2186]…11251
FAILURE CODE [CA2198]…11253
FAILURE CODE [CA2272]…11255
FAILURE CODE [CA2288]…11257
FAILURE CODE [CA2311]…11258
FAILURE CODE [CA2349]…11259
FAILURE CODE [CA2353]…11261
FAILURE CODE [CA2357]…11263
FAILURE CODE [CA2373]…11264
FAILURE CODE [CA2374]…11266
FAILURE CODE [CA2375]…11268
FAILURE CODE [CA2376]…11270
FAILURE CODE [CA2387]…11273
FAILURE CODE [CA2554]…11274
FAILURE CODE [CA2634]…11275
FAILURE CODE [CA2635]…11277
FAILURE CODE [CA2636]…11278
FAILURE CODE [CA2637]…11280
FAILURE CODE [CA2771]…11282
FAILURE CODE [CA2961]…11286
FAILURE CODE [CA2973]…11287
FAILURE CODE [CA2976]…11288
FAILURE CODE [CA3142]…11290
FAILURE CODE [CA3143]…11291
FAILURE CODE [CA3144]…11292
FAILURE CODE [CA3146]…11294
FAILURE CODE [CA3147]…11295
FAILURE CODE [CA3148]…11296
FAILURE CODE [CA3151]…11298
FAILURE CODE [CA3165]…11303
FAILURE CODE [CA3228]…11305
FAILURE CODE [CA3229]…11307
FAILURE CODE [CA3231]…11309
FAILURE CODE [CA3232]…11311
FAILURE CODE [CA3235]…11315
FAILURE CODE [CA3239]…11317
FAILURE CODE [CA3241]…11320
FAILURE CODE [CA3242]…11323
FAILURE CODE [CA3251]…11326
FAILURE CODE [CA3313]…11328
FAILURE CODE [CA3314]…11329
FAILURE CODE [CA3315]…11330
FAILURE CODE [CA3419]…11332
FAILURE CODE [CA3421]…11334
FAILURE CODE [CA3497]…11336
FAILURE CODE [CA3498]…11337
FAILURE CODE [CA3545]…11338
FAILURE CODE [CA3547]…11340
FAILURE CODE [CA3558]…11341
FAILURE CODE [CA3559]…11343
FAILURE CODE [CA3562]…11345
FAILURE CODE [CA3563]…11347
FAILURE CODE [CA3567]…11350
FAILURE CODE [CA3568]…11354
FAILURE CODE [CA3571]…11358
FAILURE CODE [CA3572]…11360
FAILURE CODE [CA3574]…11362
FAILURE CODE [CA3575]…11364
FAILURE CODE [CA3577]…11366
FAILURE CODE [CA3578]…11368
FAILURE CODE [CA3582]…11370
FAILURE CODE [CA3583]…11375
FAILURE CODE [CA3596]…11377
FAILURE CODE [CA3649]…11380
FAILURE CODE [CA3681]…11382
FAILURE CODE [CA3682]…11387
FAILURE CODE [CA3713]…11392
FAILURE CODE [CA3717]…11395
FAILURE CODE [CA3718]…11396
FAILURE CODE [CA3724]…11397
FAILURE CODE [CA3725]…11398
FAILURE CODE [CA3741]…11401
FAILURE CODE [CA3748]…11402
FAILURE CODE [CA3755]…11404
FAILURE CODE [CA3866]…11406
FAILURE CODE [CA3868]…11409
FAILURE CODE [CA4152]…11413
FAILURE CODE [CA4155]…11417
FAILURE CODE [CA4156]…11420
FAILURE CODE [CA4157]…11423
FAILURE CODE [CA4159]…11425
FAILURE CODE [CA4164]…11426
FAILURE CODE [CA4165]…11428
FAILURE CODE [CA4166]…11430
FAILURE CODE [CA4168]…11431
FAILURE CODE [CA4169]…11434
FAILURE CODE [CA4171]…11436
FAILURE CODE [CA4249]…11439
FAILURE CODE [CA4251]…11441
FAILURE CODE [CA4261]…11444
FAILURE CODE [CA4277]…11447
FAILURE CODE [CA4459]…11450
FAILURE CODE [CA4461]…11452
FAILURE CODE [CA4533]…11455
FAILURE CODE [CA4534]…11456
FAILURE CODE [CA4731]…11457
FAILURE CODE [CA4732]…11458
FAILURE CODE [CA4739]…11459
FAILURE CODE [CA4768]…11460
FAILURE CODE [CA4769]…11462
FAILURE CODE [CA4842]…11465
FAILURE CODE [CA4952]…11468
FAILURE CODE [CA5115]…11470
FAILURE CODE [CA5179]…11473
FAILURE CODE [CA5181]…11475
FAILURE CODE [CA5387]…11477
FAILURE CODE [CA5388]…11479
FAILURE CODE [CA5389]…11482
FAILURE CODE [CA5391]…11484
FAILURE CODE [CA5392]…11488
FAILURE CODE [CA5393]…11490
FAILURE CODE [CA5394]…11493
FAILURE CODE [CA5395]…11496
FAILURE CODE [CA5396]…11499
FAILURE CODE [CA5631]…11500
FAILURE CODE [CA5632]…11502
FAILURE CODE [CA5938]…11503
FAILURE CODE [D130KA]…11505
FAILURE CODE [D130KB]…11508
FAILURE CODE [D130KY]…11510
FAILURE CODE [D19JKZ]…11512
FAILURE CODE [D811MC]…11515
FAILURE CODE [D862KA]…11516
FAILURE CODE [D8ALKA]…11517
FAILURE CODE [D8ALKB]…11519
FAILURE CODE [D8AQKR]…11521
FAILURE CODE [DAF0MB]…11523
FAILURE CODE [DAF0MC]…11524
FAILURE CODE [DAF8KB]…11525
FAILURE CODE [DAF9KQ]…11527
FAILURE CODE [DAFGMC]…11528
FAILURE CODE [DAFLKA]…11529
FAILURE CODE [DAFLKB]…11531
FAILURE CODE [DAFQKR]…11533
FAILURE CODE [DAJ000]…11534
FAILURE CODE [DAJ0KQ]…11535
FAILURE CODE [DAJ0KT]…11536
FAILURE CODE [DAJ0MC]…11537
FAILURE CODE [DAJ1KK]…11538
FAILURE CODE [DAJ2KK]…11540
FAILURE CODE [DAJ5KK]…11542
FAILURE CODE [DAJ6KK]…11545
FAILURE CODE [DAJLKA]…11547
FAILURE CODE [DAJLKB]…11549
FAILURE CODE [DAJPMA]…11551
FAILURE CODE [DAJQKR]…11552
FAILURE CODE [DAJRKR]…11553
FAILURE CODE [DB2QKR]…11554
FAILURE CODE [DB2RKR]…11559
FAILURE CODE [DD12KA]…11564
FAILURE CODE [DD12KB]…11566
FAILURE CODE [DD13KA]…11568
FAILURE CODE [DD13KB]…11570
FAILURE CODE [DD14KA]…11572
FAILURE CODE [DD14KB]…11574
FAILURE CODE [DDKAKA]…11576
FAILURE CODE [DDKAKB]…11578
FAILURE CODE [DDKFL4]…11580
FAILURE CODE [DDKGL4]…11582
FAILURE CODE [DDKHKA]…11584
FAILURE CODE [DDKHKB]…11586
FAILURE CODE [DDNLKA]…11588
FAILURE CODE [DDNLKB]…11590
FAILURE CODE [DDP6KA]…11592
FAILURE CODE [DDP6KB]…11595
FAILURE CODE [DDP6MA]…11597
FAILURE CODE [DDU1FS]…11599
FAILURE CODE [DDU1KA]…11601
FAILURE CODE [DDU1KY]…11604
FAILURE CODE [DFA4KX]…11606
FAILURE CODE [DFA4KZ]…11607
FAILURE CODE [DFA4L8]…11608
FAILURE CODE [DFA5KA]…11609
FAILURE CODE [DFA5KB]…11612
FAILURE CODE [DFA6KA]…11615
FAILURE CODE [DFA6KB]…11618
FAILURE CODE [DFA7KX]…11621
FAILURE CODE [DFA7KZ]…11622
FAILURE CODE [DFA7L8]…11623
FAILURE CODE [DFA8KA]…11624
FAILURE CODE [DFA8KB]…11627
FAILURE CODE [DFA9KA]…11630
FAILURE CODE [DFA9KB]…11633
FAILURE CODE [DGS1KA]…11636
FAILURE CODE [DGS1KX]…11639
FAILURE CODE [DH21KA]…11640
FAILURE CODE [DH21KB]…11642
FAILURE CODE [DHA4KA]…11644
FAILURE CODE [DHH7KA]…11646
FAILURE CODE [DHH7KB]…11649
FAILURE CODE [DHH8KA]…11651
FAILURE CODE [DHH8KB]…11654
FAILURE CODE [DHH9KA]…11656
FAILURE CODE [DHH9KB]…11659
FAILURE CODE [DHHAKA]…11661
FAILURE CODE [DHHAKB]…11664
FAILURE CODE [DK30KA]…11666
FAILURE CODE [DK30KB]…11669
FAILURE CODE [DK30KX]…11671
FAILURE CODE [DK30KZ]…11672
FAILURE CODE [DK30L8]…11673
FAILURE CODE [DK31KA]…11674
FAILURE CODE [DK31KB]…11677
FAILURE CODE [DK40KA]…11679
FAILURE CODE [DK40KB]…11682
FAILURE CODE [DK55KX]…11684
FAILURE CODE [DK55KZ]…11685
FAILURE CODE [DK55L8]…11686
FAILURE CODE [DK56KA]…11687
FAILURE CODE [DK56KB]…11690
FAILURE CODE [DK57KA]…11692
FAILURE CODE [DK57KB]…11695
FAILURE CODE [DLM0KX]…11697
FAILURE CODE [DLM1KA]…11698
FAILURE CODE [DLM1KB]…11700
FAILURE CODE [DLM1MA]…11702
FAILURE CODE [DLM2KA]…11703
FAILURE CODE [DLM2KB]…11705
FAILURE CODE [DLM2MA]…11707
FAILURE CODE [DLM3KA]…11708
FAILURE CODE [DLM3KB]…11710
FAILURE CODE [DLM3MB]…11712
FAILURE CODE [DN21FS]…11713
FAILURE CODE [DR21KX]…11715
FAILURE CODE [DR31KX]…11716
FAILURE CODE [DV20KB]…11717
FAILURE CODE [DW4BKA]…11719
FAILURE CODE [DW4BKB]…11721
FAILURE CODE [DW4BKY]…11723
FAILURE CODE [DW7BKA]…11725
FAILURE CODE [DW7BKB]…11727
FAILURE CODE [DW7EKA]…11729
FAILURE CODE [DW7EKB]…11731
FAILURE CODE [DW7EKY]…11733
FAILURE CODE [DWN5KA]…11735
FAILURE CODE [DWN5KB]…11737
FAILURE CODE [DWN5KY]…11739
FAILURE CODE [DXA4KA]…11741
FAILURE CODE [DXA4KB]…11743
FAILURE CODE [DXA4KY]…11745
FAILURE CODE [DXA5KA]…11747
FAILURE CODE [DXA5KB]…11749
FAILURE CODE [DXA5KY]…11751
FAILURE CODE [DXA6KA]…11753
FAILURE CODE [DXA6KB]…11755
FAILURE CODE [DXA6KY]…11757
FAILURE CODE [DXA7KA]…11759
FAILURE CODE [DXA7KB]…11761
FAILURE CODE [DXA7KY]…11763
FAILURE CODE [DXHRKA]…11765
FAILURE CODE [DXHRKB]…11767
FAILURE CODE [DXHRKY]…11769
FAILURE CODE [DXHSKA]…11771
FAILURE CODE [DXHSKB]…11773
FAILURE CODE [DXHSKY]…11775
FAILURE CODE [DXHTKA]…11777
FAILURE CODE [DXHTKB]…11779
FAILURE CODE [DXHTKY]…11781
FAILURE CODE [DXHUKA]…11783
FAILURE CODE [DXHUKB]…11785
FAILURE CODE [DXHUKY]…11787
FAILURE CODE [DXJ4KA]…11789
FAILURE CODE [DXJ4KB]…11791
FAILURE CODE [DXJCKA]…11793
FAILURE CODE [DXJCKB]…11795
FAILURE CODE [DXJCKY]…11797
FAILURE CODE [DXJDKA]…11799
FAILURE CODE [DXJDKB]…11801
FAILURE CODE [DXJDKY]…11803
FAILURE CODE [DXK1KA]…11805
FAILURE CODE [DXK1KB]…11807
FAILURE CODE [DXK1KY]…11809
FAILURE CODE [DXK2KA]…11811
FAILURE CODE [DXK2KB]…11813
FAILURE CODE [DXK2KY]…11815
TROUBLESHOOTING OF ELECTRICAL SYSTEM (E-MODE)…11817
E-1 ENGINE DOES NOT START (ENGINE DOES NOT CRANK)…11817
E-2 MANUAL PREHEATING SYSTEM DOES NOT WORK…11824
E-3 AUTOMATIC PREHEATING SYSTEM DOES NOT WORK…11827
E-4 WHILE PREHEATING IS WORKING, PREHEATING MONITOR DOES NOT LIGHT UP…11829
E-5 WHEN STARTING SWITCH IS TURNED TO ON POSITION, MACHINE MONITOR DISPLAYS NOTHING…11831
E-6 WHEN STARTING SWITCH IS TURNED TO ON POSITION (WITH ENGINE STOPPED), BASIC CHECK MONITOR LIGHTS UP…11835
E-7 AIR CLEANER CLOGGING MONITOR LIGHTS UP IN YELLOW WHILE ENGINE IS RUNNING…11836
E-8 CHARGE LEVEL MONITOR LIGHTS UP IN RED WHILE ENGINE IS RUNNING…11837
E-9 ENGINE COOLANT TEMPERATURE MONITOR LIGHTS UP IN RED WHILE ENGINE IS RUNNING…11838
E-10 ENGINE OIL PRESSURE MONITOR LIGHTS UP IN RED WHILE ENGINE IS RUNNING…11839
E-11 HST CHARGE PRESSURE MONITOR LIGHTS UP IN RED WHILE ENGINE IS RUNNING…11840
E-12 HYDRAULIC OIL TEMPERATURE MONITOR LIGHTS UP IN RED WHILE ENGINE IS RUNNING…11841
E-13 HST OIL FILTER CLOGGING MONITOR LIGHTS UP IN RED WHILE ENGINE IS RUNNING…11842
E-14 ENGINE COOLANT TEMPERATURE GAUGE DOES NOT INDICATE CORRECT TEMPERATURE…11843
E-15 FUEL LEVEL GAUGE DOES NOT INDICATE CORRECT LEVEL…11844
E-16 HYDRAULIC OIL TEMPERATURE GAUGE DOES NOT INDICATE CORRECT TEMPERATURE…11847
E-17 OPERATION MODE DOES NOT CHANGE…11848
E-18 OPERATING CUSTOMIZE SWITCH DOES NOT DISPLAY CUSTOMIZE SCREEN…11849
E-19 MODIFYING SETTING ON CUSTOMIZE SCREEN DOES NOT CHANGE SETTING OF MACHINE…11850
E-20 SERVICE METER IS NOT DISPLAYED, WHILE STARTING SWITCH IS IN OFF POSITION…11851
E-21 SERVICE MODE CANNOT BE SELECTED…11852
E-22 WORK EQUIPMENT DOES NOT OPERATE…11853
E-23 FOOT HEATER DOES NOT OPERATE…11855
E-24 HORN DOES NOT SOUND…11861
E-25 HORN DOES NOT STOP SOUNDING…11863
E-26 BACKUP ALARM DOES NOT SOUND…11864
E-27 BACKUP ALARM DOES NOT STOP SOUNDING…11865
E-28 HEADLAMP DOES NOT LIGHT UP…11866
E-29 REAR LAMP DOES NOT LIGHT UP…11870
E-30 ALL WIPERS DO NOT OPERATE…11873
E-31 FRONT WIPER DOES NOT OPERATE…11875
E-32 REAR WIPER DOES NOT OPERATE…11877
E-33 LEFT DOOR WIPER DOES NOT OPERATE…11879
E-34 RIGHT DOOR WIPER DOES NOT OPERATE…11883
E-35 FRONT WASHER DOES NOT OPERATE…11887
E-36 REAR WASHER DOES NOT OPERATE…11889
E-37 LEFT DOOR WASHER DOES NOT OPERATE…11891
E-38 RIGHT DOOR WASHER DOES NOT OPERATE…11893
E-39 KOMTRAX SYSTEM DOES NOT OPERATE NORMALLY…11895
TROUBLESHOOTING FOR HYDRAULIC AND MECHANICAL SYSTEMS (H MODE)…11896
INFORMATION MENTIONED IN TROUBLESHOOTING TABLE (H MODE)…11896
FAILURE MODE AND CAUSE TABLE…11897
H-1 NEITHER R.H. NOR L.H. OF TRACKS CAN TRAVEL FORWARD OR REVERSE (NONE OF THE TRAVEL SYSTEMS OPERATE)…11903
H-2 EITHER R.H. OR L.H. OF TRACK CANNOT TRAVEL BOTH FORWARD AND REVERSE (ONE OF R.H. OR L.H. TRAVEL SYSTEMS CANNOT OPERATE)…11905
H-3 EITHER R.H. OR L.H. OF TRACK CANNOT TRAVEL ONE OF FORWARD OR REVERSE (ONLY ONE OF THE TRAVEL SYSTEMS CANNOT OPERATE IN ONE DIRECTION)…11907
H-4 TRAVEL SPEED OR POWER IS LOW…11909
H-5 SPEED RANGE DOES NOT CHANGE…11911
H-6 SHOCK IS LARGE WHEN MACHINE MOVES OFF OR STOPS…11912
H-7 MACHINE DEVIATES LARGELY…11913
H-8 MACHINE DRIFT ON A SLOPE IS LARGE…11916
H-9 ENGINE SPEED DROPS LARGELY OR ENGINE STOPS…11918
H-10 UNUSUAL NOISE IS HEARD FROM AROUND HST PUMP OR MOTOR…11920
H-11 HST OIL TEMPERATURE (HYDRAULIC OIL TEMPERATURE) RISES TOO HIGH…11922
H-12 ALL WORK EQUIPMENT DO NOT OPERATE…11924
H-13 ALL WORK EQUIPMENTS SPEED OR POWER IS LOW…11926
H-14 BLADE LIFT SPEED OR POWER IS LOW…11927
H-15 BLADE TILT SPEED OR POWER IS LOW…11929
H-16 BLADE ANGLE SPEED OR POWER IS LOW…11930
H-17 TIME LAG OF BLADE LIFT IS LARGE…11931
H-18 HYDRAULIC DRIFT OF LIFTED BLADE IS LARGE…11932
H-19 HYDRAULIC DRIFT OF TILTED BLADE IS LARGE…11933
H-20 UNUSUAL NOISE IS HEARD FROM AROUND WORK EQUIPMENT AND COOLING FAN PUMP OR CONTROL VALVE…11934
H-21 FAN SPEED IS ABNORMAL (TOO HIGH OR LOW, OR STATIONARY)…11935
H-22 UNUSUAL NOISE IS HEARD FROM AROUND FAN…11937
TROUBLESHOOTING OF ENGINE (S-MODE)…11938
INFORMATION MENTIONED IN TROUBLESHOOTING TABLE (S MODE)…11938
S-1 ENGINE DOES NOT CRANK WHEN STARTING SWITCH IS TURNED TO START POSITION…11939
S-2 ENGINE CRANKS BUT NO EXHAUST GAS COMES OUT…11940
S-3 FUEL IS BEING INJECTED BUT ENGINE DOES NOT START (MISFIRING: ENGINE CRANKS BUT DOES NOT START)…11941
S-4 ENGINE STARTABILITY IS POOR…11943
S-5 ENGINE DOES NOT PICK UP SMOOTHLY…11945
S-6 ENGINE STOPS DURING OPERATION…11947
S-7 ENGINE RUNS ROUGH OR IS UNSTABLE…11949
S-8 ENGINE LACKS POWER…11950
S-9 EXHAUST SMOKE IS BLACK…11952
S-10 ENGINE OIL CONSUMPTION IS EXCESSIVE…11954
S-11 OIL BECOMES CONTAMINATED QUICKLY…11955
S-12 FUEL CONSUMPTION IS EXCESSIVE…11956
S-13 OIL IS IN COOLANT (OR COOLANT SPURTS BACK OR COOLANT LEVEL GOES DOWN)…11957
S-14 OIL PRESSURE DROPS…11958
S-15 FUEL MIXES INTO ENGINE OIL…11960
S-16 WATER MIXES INTO ENGINE OIL (MILKY)…11961
S-17 COOLANT TEMPERATURE RISES TOO HIGH (OVERHEATING)…11962
S-18 UNUSUAL NOISE IS HEARD…11963
S-19 VIBRATION IS EXCESSIVE…11964
S-20 AIR CANNOT BE BLED FROM FUEL CIRCUIT…11965
S-21 ACTIVE REGENERATION IS EXECUTED FREQUENTLY…11966
S-22 ACTIVE REGENERATION TAKES TIME…11967
S-23 WHITE SMOKE IS EXHAUSTED DURING ACTIVE REGENERATION…11968
S-24 AdBlue/DEF CONSUMPTION IS EXCESSIVE…11969
S-25 THERE IS UNUSUAL SMELL (IRRITATING ODOR)…11971
S-26 FOREIGN MATERIALS ENTER AdBlue/DEF (AdBlue/DEF INCREASES)…11972
50 DISASSEMBLY AND ASSEMBLY…11973
CONTENTS…11974
ABBREVIATION LIST…11979
RELATED INFORMATION ON DISASSEMBLY AND ASSEMBLY…11985
HOW TO READ THIS MANUAL…11985
COATING MATERIALS LIST…11987
SPECIAL TOOLS LIST…11992
SKETCHES OF SPECIAL TOOLS…12012
ENGINE AND COOLING SYSTEM…12025
REMOVE AND INSTALL SUPPLY PUMP ASSEMBLY…12025
METHOD FOR REMOVING SUPPLY PUMP ASSEMBLY…12025
METHOD FOR INSTALLING SUPPLY PUMP ASSEMBLY…12035
REMOVE AND INSTALL INJECTOR ASSEMBLY…12045
METHOD FOR REMOVING INJECTOR ASSEMBLY…12045
METHOD FOR INSTALLING INJECTOR ASSEMBLY…12056
REMOVE AND INSTALL CYLINDER HEAD ASSEMBLY…12070
METHOD FOR REMOVING CYLINDER HEAD ASSEMBLY…12070
METHOD FOR INSTALLING CYLINDER HEAD ASSEMBLY…12089
REMOVE AND INSTALL EGR VALVE ASSEMBLY…12113
METHOD FOR REMOVING EGR VALVE ASSEMBLY…12113
METHOD FOR INSTALLING EGR VALVE ASSEMBLY…12116
REMOVE AND INSTALL EGR COOLER ASSEMBLY…12120
METHOD FOR REMOVING EGR COOLER ASSEMBLY…12120
METHOD FOR INSTALLING EGR COOLER ASSEMBLY…12124
REMOVE AND INSTALL STARTING MOTOR ASSEMBLY…12128
METHOD FOR REMOVING STARTING MOTOR ASSEMBLY…12128
METHOD FOR INSTALLING STARTING MOTOR ASSEMBLY…12130
REMOVE AND INSTALL AIR CONDITIONER COMPRESSOR BELT…12133
METHOD FOR REMOVING AIR CONDITIONER COMPRESSOR BELT…12133
METHOD FOR INSTALLING AIR CONDITIONER COMPRESSOR BELT…12137
REMOVE AND INSTALL ALTERNATOR BELT…12142
METHOD FOR REMOVING ALTERNATOR BELT…12142
METHOD FOR INSTALLING ALTERNATOR BELT…12144
REMOVE AND INSTALL AUTOMATIC TENSIONER…12147
METHOD FOR REMOVING AUTOMATIC TENSIONER…12147
METHOD FOR INSTALLING AUTOMATIC TENSIONER…12148
REMOVE AND INSTALL RADIATOR ASSEMBLY…12150
METHOD FOR REMOVING RADIATOR ASSEMBLY…12151
METHOD FOR INSTALLING RADIATOR ASSEMBLY…12159
REMOVE AND INSTALL HYDRAULIC OIL COOLER ASSEMBLY…12167
METHOD FOR REMOVING HYDRAULIC OIL COOLER ASSEMBLY…12168
METHOD FOR INSTALLING HYDRAULIC OIL COOLER ASSEMBLY…12173
REMOVE AND INSTALL AFTERCOOLER ASSEMBLY…12178
METHOD FOR REMOVING AFTERCOOLER ASSEMBLY…12179
METHOD FOR INSTALLING AFTERCOOLER ASSEMBLY…12185
REMOVE AND INSTALL COOLING FAN DRIVE ASSEMBLY…12192
METHOD FOR REMOVING COOLING FAN DRIVE ASSEMBLY…12192
METHOD FOR INSTALLING COOLING FAN DRIVE ASSEMBLY…12196
REMOVE AND INSTALL COOLING FAN MOTOR ASSEMBLY…12201
METHOD FOR REMOVING COOLING FAN MOTOR ASSEMBLY…12201
METHOD FOR INSTALLING COOLING FAN MOTOR ASSEMBLY…12204
REMOVE AND INSTALL ENGINE, HST PUMP ASSEMBLY…12207
METHOD FOR REMOVING ENGINE, HST PUMP ASSEMBLY…12207
METHOD FOR INSTALLING ENGINE, HST PUMP ASSEMBLY…12218
REMOVE AND INSTALL ENGINE FRONT OIL SEAL…12230
METHOD FOR REMOVING ENGINE FRONT OIL SEAL…12230
METHOD FOR INSTALLING ENGINE FRONT OIL SEAL…12232
REMOVE AND INSTALL ENGINE REAR OIL SEAL…12235
METHOD FOR REMOVING ENGINE REAR OIL SEAL…12235
METHOD FOR INSTALLING ENGINE REAR OIL SEAL…12236
REMOVE AND INSTALL ENGINE HOOD ASSEMBLY…12239
METHOD FOR REMOVING ENGINE HOOD ASSEMBLY…12239
METHOD FOR INSTALLING ENGINE HOOD ASSEMBLY…12242
REMOVE AND INSTALL KDOC ASSEMBLY…12246
METHOD FOR REMOVING KDOC ASSEMBLY…12246
METHOD FOR INSTALLING KDOC ASSEMBLY…12251
REMOVE AND INSTALL KDOC AND SCR ASSEMBLY…12259
METHOD FOR REMOVING KDOC AND SCR ASSEMBLY…12260
METHOD FOR INSTALLING KDOC AND SCR ASSEMBLY…12266
REMOVE AND INSTALL BELLOWS PIPE ASSEMBLY…12275
METHOD FOR REMOVING BELLOWS PIPE ASSEMBLY…12275
METHOD FOR INSTALLING BELLOWS PIPE ASSEMBLY…12278
REMOVE AND INSTALL FUEL TANK ASSEMBLY…12283
METHOD FOR REMOVING FUEL TANK ASSEMBLY…12284
METHOD FOR INSTALLING FUEL TANK ASSEMBLY…12291
REMOVE AND INSTALL AdBlue/DEF TANK ASSEMBLY…12298
METHOD FOR REMOVING AdBlue/DEF TANK ASSEMBLY…12299
METHOD FOR INSTALLING AdBlue/DEF TANK ASSEMBLY…12309
REMOVE AND INSTALL AdBlue/DEF TANK SENSOR FLANGE ASSEMBLY…12318
METHOD FOR REMOVING AdBlue/DEF TANK SENSOR FLANGE ASSEMBLY…12318
METHOD FOR INSTALLING AdBlue/DEF TANK SENSOR FLANGE ASSEMBLY…12320
REMOVE AND INSTALL AdBlue/DEF TANK SENSOR…12324
METHOD FOR REMOVING AdBlue/DEF TANK SENSOR…12324
METHOD FOR INSTALLING AdBlue/DEF TANK SENSOR…12325
REMOVE AND INSTALL AdBlue/DEF TANK STRAINER…12328
METHOD FOR REMOVING AdBlue/DEF TANK STRAINER…12328
METHOD FOR INSTALLING AdBlue/DEF TANK STRAINER…12329
REMOVE AND INSTALL SCR ASSEMBLY…12330
METHOD FOR REMOVING SCR ASSEMBLY…12330
METHOD FOR INSTALLING SCR ASSEMBLY…12333
REMOVE AND INSTALL KCCV ASSEMBLY…12336
METHOD FOR REMOVING KCCV ASSEMBLY…12336
METHOD FOR INSTALLING KCCV ASSEMBLY…12337
REMOVE AND INSTALL AdBlue/DEF MIXING TUBE…12340
METHOD FOR REMOVING AdBlue/DEF MIXING TUBE…12340
METHOD FOR INSTALLING AdBlue/DEF MIXING TUBE…12344
REMOVE AND INSTALL AdBlue/DEF INJECTOR…12348
METHOD FOR REMOVING AdBlue/DEF INJECTOR…12348
METHOD FOR INSTALLING AdBlue/DEF INJECTOR…12353
REMOVE AND INSTALL AdBlue/DEF PUMP…12358
METHOD FOR REMOVING AdBlue/DEF PUMP…12358
METHOD FOR INSTALLING AdBlue/DEF PUMP…12362
REMOVE AND INSTALL AdBlue/DEF HOSE…12366
METHOD FOR REMOVING AdBlue/DEF HOSE…12368
METHOD FOR INSTALLING AdBlue/DEF HOSE…12387
REMOVE AND INSTALL AIR CLEANER ASSEMBLY…12408
METHOD FOR REMOVING AIR CLEANER ASSEMBLY…12408
METHOD FOR INSTALLING AIR CLEANER ASSEMBLY…12410
REMOVE AND INSTALL AIR CONDITIONER COMPRESSOR ASSEMBLY…12413
METHOD FOR REMOVING AIR CONDITIONER COMPRESSOR ASSEMBLY…12413
METHOD FOR INSTALLING AIR CONDITIONER COMPRESSOR ASSEMBLY…12417
REMOVE AND INSTALL AIR CONDITIONER CONDENSER ASSEMBLY…12422
METHOD FOR REMOVING AIR CONDITIONER CONDENSER ASSEMBLY…12422
METHOD FOR INSTALLING AIR CONDITIONER CONDENSER ASSEMBLY…12426
POWER TRAIN…12430
DISASSEMBLE AND ASSEMBLE FINAL DRIVE ASSEMBLY…12430
METHOD FOR DISASSEMBLING FINAL DRIVE ASSEMBLY…12431
METHOD FOR ASSEMBLING FINAL DRIVE ASSEMBLY…12435
UNDERCARRIAGE AND FRAME…12444
REMOVE AND INSTALL TRACK FRAME ASSEMBLY…12444
METHOD FOR REMOVING TRACK FRAME ASSEMBLY…12444
METHOD FOR INSTALLING TRACK FRAME ASSEMBLY…12449
REMOVE AND INSTALL IDLER ASSEMBLY…12454
METHOD FOR REMOVING IDLER ASSEMBLY…12454
METHOD FOR INSTALLING IDLER ASSEMBLY…12456
DISASSEMBLE AND ASSEMBLE IDLER ASSEMBLY…12459
METHOD FOR DISASSEMBLING IDLER ASSEMBLY…12459
METHOD FOR ASSEMBLING IDLER ASSEMBLY…12461
REMOVE AND INSTALL RECOIL SPRING ASSEMBLY…12466
METHOD FOR REMOVING RECOIL SPRING ASSEMBLY…12466
METHOD FOR INSTALLING RECOIL SPRING ASSEMBLY…12466
DISASSEMBLE AND ASSEMBLE RECOIL SPRING ASSEMBLY…12467
METHOD FOR DISASSEMBLING AND ASSEMBLING RECOIL SPRING ASSEMBLY…12467
METHOD FOR ASSEMBLING RECOIL SPRING ASSEMBLY…12470
REMOVE AND INSTALL TRACK ROLLER ASSEMBLY…12473
METHOD FOR REMOVING TRACK ROLLER ASSEMBLY…12473
METHOD FOR INSTALLING TRACK ROLLER ASSEMBLY…12475
DISASSEMBLE AND ASSEMBLE TRACK ROLLER ASSEMBLY…12478
METHOD FOR DISASSEMBLING TRACK ROLLER ASSEMBLY…12478
METHOD FOR ASSEMBLING TRACK ROLLER ASSEMBLY…12479
REMOVE AND INSTALL CARRIER ROLLER ASSEMBLY…12483
METHOD FOR REMOVING CARRIER ROLLER ASSEMBLY…12483
METHOD FOR INSTALLING CARRIER ROLLER ASSEMBLY…12484
DISASSEMBLE AND ASSEMBLE CARRIER ROLLER ASSEMBLY…12486
METHOD FOR DISASSEMBLING CARRIER ROLLER ASSEMBLY…12486
METHOD FOR ASSEMBLING CARRIER ROLLER ASSEMBLY…12487
REMOVE AND INSTALL PIVOT SHAFT ASSEMBLY…12490
METHOD FOR REMOVING PIVOT SHAFT ASSEMBLY…12490
METHOD FOR INSTALLING PIVOT SHAFT ASSEMBLY…12491
SEPARATE AND CONNECT TRACK ASSEMBLY…12493
METHOD FOR CHECKING BEFORE SEPARATING TRACK ASSEMBLY…12493
METHOD FOR SEPARATING TRACK ASSEMBLY (NORMAL)…12494
METHOD FOR SEPARATING TRACK ASSEMBLY (WHEN TRACK FRAME HAS INTERNAL DEFECT)…12495
METHOD FOR CONNECTING TRACK ASSEMBLY…12496
SEPARATE AND CONNECT PLUS TYPE TRACK ASSEMBLY…12498
METHOD FOR SEPARATING PLUS TYPE TRACK ASSEMBLY…12498
METHOD FOR CONNECTING PLUS TYPE TRACK ASSEMBLY…12498
DISASSEMBLE AND ASSEMBLE TRACK ASSEMBLY GENERALLY…12499
METHOD FOR DISASSEMBLING TRACK ASSEMBLY GENERALLY…12499
METHOD FOR ASSEMBLING TRACK ASSEMBLY GENERALLY…12504
DISASSEMBLE AND ASSEMBLE PLUS TYPE TRACK ASSEMBLY GENERALLY…12517
METHOD FOR DISASSEMBLING PLUS TYPE TRACK ASSEMBLY GENERALLY…12518
METHOD FOR ASSEMBLING PLUS TYPE TRACK ASSEMBLY GENERALLY…12519
DISASSEMBLE AND ASSEMBLE ONE LINK OF TRACK SHOE ASSEMBLY ON THE FIELD…12528
METHOD FOR DISASSEMBLING ONE LINK OF TRACK SHOE ASSEMBLY ON THE FIELD…12529
METHOD FOR ASSEMBLING ONE LINK OF TRACK SHOE ASSEMBLY ON THE FIELD…12530
DISASSEMBLE AND ASSEMBLE ONE LINK OF PLUS TYPE TRACK SHOE ASSEMBLY ON THE FIELD…12537
METHOD FOR DISASSEMBLING ONE LINK OF PLUS TYPE TRACK SHOE ASSEMBLY ON THE FIELD…12538
METHOD FOR ASSEMBLING ONE LINK OF PLUS TYPE TRACK SHOE ASSEMBLY ON THE FIELD…12540
REMOVE AND INSTALL EQUALIZER BAR ASSEMBLY…12544
METHOD FOR REMOVING EQUALIZER BAR ASSEMBLY…12544
METHOD FOR INSTALLING EQUALIZER BAR ASSEMBLY…12546
REMOVE AND INSTALL EQUALIZER BAR SIDE BUSHINGS…12549
METHOD FOR REMOVING EQUALIZER BAR SIDE BUSHINGS…12549
METHOD FOR INSTALLING EQUALIZER BAR SIDE BUSHINGS…12550
REMOVE AND INSTALL SEGMENT TEETH…12551
METHOD FOR REMOVING SEGMENT TEETH…12551
METHOD FOR INSTALLING SEGMENT TEETH…12553
HYDRAULIC SYSTEM…12555
REMOVE AND INSTALL HYDRAULIC TANK ASSEMBLY…12555
METHOD FOR REMOVING HYDRAULIC TANK ASSEMBLY…12556
METHOD FOR INSTALLING HYDRAULIC TANK ASSEMBLY…12562
REMOVE AND INSTALL CONTROL VALVE ASSEMBLY…12571
METHOD FOR REMOVING CONTROL VALVE ASSEMBLY…12571
METHOD FOR INSTALLING CONTROL VALVE ASSEMBLY…12575
WORK EQUIPMENT…12579
REMOVE AND INSTALL BLADE ASSEMBLY…12579
METHOD FOR REMOVING BLADE ASSEMBLY…12579
METHOD FOR INSTALLING BLADE ASSEMBLY…12582
REMOVE AND INSTALL BLADE LIFT CYLINDER ASSEMBLY…12587
METHOD FOR REMOVING BLADE LIFT CYLINDER ASSEMBLY…12587
METHOD FOR INSTALLING BLADE LIFT CYLINDER ASSEMBLY…12589
REMOVE AND INSTALL BLADE TILT CYLINDER ASSEMBLY…12591
METHOD FOR REMOVING BLADE TILT CYLINDER ASSEMBLY…12591
METHOD FOR INSTALLING BLADE TILT CYLINDER ASSEMBLY…12592
REMOVE AND INSTALL BLADE ANGLE CYLINDER ASSEMBLY…12594
METHOD FOR REMOVING BLADE ANGLE CYLINDER ASSEMBLY…12594
METHOD FOR INSTALLING BLADE ANGLE CYLINDER ASSEMBLY…12596
REMOVE AND INSTALL U-FRAME ASSEMBLY…12598
METHOD FOR REMOVING U-FRAME ASSEMBLY…12598
METHOD FOR INSTALLING U-FRAME ASSEMBLY…12602
CAB AND ITS ATTACHMENTS…12605
REMOVE AND INSTALL OPERATOR'S CAB ASSEMBLY…12605
METHOD FOR REMOVING OPERATOR'S CAB ASSEMBLY…12606
METHOD FOR INSTALLING OPERATOR'S CAB ASSEMBLY…12613
REMOVE AND INSTALL OPERATOR'S CAB GLASS (ADHERED GLASS)…12621
METHOD FOR REMOVING OPERATOR'S CAB GLASS (ADHERED GLASS)…12623
METHOD FOR INSTALLING OPERATOR'S CAB GLASS (ADHERED GLASS)…12623
REMOVE AND INSTALL AIR CONDITIONER UNIT ASSEMBLY…12629
METHOD FOR REMOVING AIR CONDITIONER UNIT ASSEMBLY…12629
METHOD FOR INSTALLING AIR CONDITIONER UNIT ASSEMBLY…12635
REMOVE AND INSTALL RECEIVER DRIER…12642
METHOD FOR REMOVING RECEIVER DRIER…12642
METHOD FOR INSTALLING RECEIVER DRIER…12643
REMOVE AND INSTALL OPERATOR'S SEAT…12646
METHOD FOR REMOVING OPERATOR'S SEAT…12646
METHOD FOR INSTALLING OPERATOR'S SEAT…12647
REMOVE AND INSTALL SEAT BELT…12648
METHOD FOR REMOVING SEAT BELT…12648
METHOD FOR INSTALLING SEAT BELT…12648
REMOVE AND INSTALL FOOT HEATER ASSEMBLY…12650
METHOD FOR REMOVING FOOT HEATER ASSEMBLY…12650
METHOD FOR INSTALLING FOOT HEATER ASSEMBLY…12652
DISASSEMBLE AND ASSEMBLE FOOT HEATER ASSEMBLY…12655
METHOD FOR DISASSEMBLING FOOT HEATER ASSEMBLY…12655
METHOD FOR ASSEMBLING FOOT HEATER ASSEMBLY…12656
ELECTRICAL SYSTEM…12657
REMOVE AND INSTALL ENGINE CONTROLLER ASSEMBLY…12657
METHOD FOR REMOVING ENGINE CONTROLLER ASSEMBLY…12657
METHOD FOR INSTALLING ENGINE CONTROLLER ASSEMBLY…12660
REMOVE AND INSTALL HST CONTROLLER ASSEMBLY…12664
METHOD FOR REMOVING HST CONTROLLER ASSEMBLY…12664
METHOD FOR INSTALLING HST CONTROLLER ASSEMBLY…12665
REMOVE AND INSTALL MACHINE MONITOR ASSEMBLY…12666
METHOD FOR REMOVING MACHINE MONITOR ASSEMBLY…12666
METHOD FOR INSTALLING MACHINE MONITOR ASSEMBLY…12667
REMOVE AND INSTALL MASS AIR FLOW AND TEMPERATURE SENSOR…12669
METHOD FOR REMOVING MASS AIR FLOW AND TEMPERATURE SENSOR…12669
METHOD FOR INSTALLING MASS AIR FLOW AND TEMPERATURE SENSOR…12671
REMOVE AND INSTALL KCCV CRANKCASE PRESSURE SENSOR…12673
METHOD FOR REMOVING KCCV CRANKCASE PRESSURE SENSOR…12673
METHOD FOR INSTALLING KCCV CRANKCASE PRESSURE SENSOR…12675
60 MAINTENANCE STANDARD…12677
CONTENTS…12678
ABBREVIATION LIST…12679
ENGINE AND COOLING SYSTEM…12685
MAINTENANCE STANDARD OF ENGINE MOUNT…12685
MAINTENANCE STANDARD OF DAMPER…12686
MAINTENANCE STANDARD OF COOLING SYSTEM…12687
MAINTENANCE STANDARD OF COOLING FAN MOTOR…12689
MAINTENANCE STANDARD OF HYDRAULIC OIL COOLER BYPASS AND HST CHARGE SAFETY VALVE…12691
POWER TRAIN…12692
MAINTENANCE STANDARD OF HST PUMP…12692
MAINTENANCE STANDARD OF EPC VALVE OF HST PUMP…12694
MAINTENANCE STANDARD OF TOW RECEIVING VALVE OF HST PUMP…12695
MAINTENANCE STANDARD OF HST CHARGE PUMP…12696
MAINTENANCE STANDARD OF HST MOTOR…12698
MAINTENANCE STANDARD OF FINAL DRIVE…12700
MAINTENANCE STANDARD OF SPROCKET FOR PLUS TYPE TRACK SHOE…12702
MAINTENANCE STANDARD OF SPROCKET TOOTH PROFILE FULL-SCALE DRAWING FOR PLUS TYPE TRACK SHOE…12703
UNDERCARRIAGE AND FRAME…12704
MAINTENANCE STANDARD OF SUSPENSION…12704
MAINTENANCE STANDARD OF TRACK FRAME AND IDLER CUSHION…12707
MAINTENANCE STANDARD OF IDLER…12710
MAINTENANCE STANDARD OF TRACK ROLLER FOR PLUS TYPE TRACK SHOES (SINGLE FLANGE TYPE)…12712
MAINTENANCE STANDARD OF TRACK ROLLER FOR PLUS TYPE TRACK SHOES (DOUBLE FLANGE TYPE)…12713
MAINTENANCE STANDARD OF CARRIER ROLLER FOR PLUS TYPE TRACK SHOE…12715
MAINTENANCE STANDARD OF PLUS TYPE TRACK SHOE…12716
MAINTENANCE STANDARD OF SINGLE SHOE…12718
HYDRAULIC SYSTEM…12719
MAINTENANCE STANDARD OF HYDRAULIC TANK…12719
MAINTENANCE STANDARD OF WORK EQUIPMENT AND COOLING FAN PUMP…12720
MAINTENANCE STANDARD OF SERVO VALVE OF WORK EQUIPMENT AND COOLING FAN PUMP…12721
MAINTENANCE STANDARD OF CONTROL VALVE…12723
MAINTENANCE STANDARD OF RIPPER PPC VALVE…12729
MAINTENANCE STANDARD OF 5-PORT VALVE OF EPC AND SOLENOID…12731
MAINTENANCE STANDARD OF EPC VALVE…12732
MAINTENANCE STANDARD OF QUICK DROP VALVE…12733
WORK EQUIPMENT…12735
MAINTENANCE STANDARD OF FRONT WORK EQUIPMENT…12735
MAINTENANCE STANDARD OF CUTTING EDGE AND END BIT…12738
MAINTENANCE STANDARD OF BLADE LIFT CYLINDER…12739
MAINTENANCE STANDARD OF BLADE TILT CYLINDER…12740
MAINTENANCE STANDARD OF BLADE ANGLE CYLINDER…12741
MAINTENANCE STANDARD OF FIXED MULTI-SHANK RIPPER…12742
MAINTENANCE STANDARD OF RIPPER LIFT CYLINDER…12744
CAB AND ITS ATTACHMENTS…12745
MAINTENANCE STANDARD OF CAB MOUNT…12745
ELECTRICAL SYSTEM…12747
MAINTENANCE STANDARD OF ELECTRIC STEERING CONTROL LEVER…12747
80 APPENDIX…12749
CONTENTS…12750
ABBREVIATION LIST…12751
AIR CONDITIONER SYSTEM…12757
PRECAUTIONS FOR REFRIGERANT…12757
AIR CONDITIONER COMPONENT…12758
SPECIFICATIONS OF AIR CONDITIONER…12761
CONFIGURATION AND FUNCTION OF REFRIGERATION CYCLE…12762
OUTLINE OF REFRIGERATION CYCLE…12763
COMPONENT PARTS OF AIR CONDITIONER SYSTEM…12765
AIR CONDITIONER UNIT…12765
CONFIGURATION DIAGRAM OF AIR CONDITIONER UNIT…12765
FUNCTION OF AIR CONDITIONER UNIT…12766
COMPONENT PARTS OF AIR CONDITIONER UNIT…12767
FUNCTION OF EVAPORATOR AS AIR CONDITIONER UNIT COMPONENT…12767
FUNCTION OF HEATER CORE AS AIR CONDITIONER UNIT COMPONENT…12767
FUNCTION OF THERMISTOR AS AIR CONDITIONER UNIT COMPONENT…12767
STRUCTURE OF EXPANSION VALVE AS AIR CONDITIONER UNIT COMPONENT…12767
FUNCTION OF EXPANSION VALVE AS AIR CONDITIONER UNIT COMPONENT…12768
OPERATE EXPANSION VALVE AS AIR CONDITIONER UNIT COMPONENT…12768
FUNCTION OF DUAL PRESSURE SWITCH…12769
FUNCTION OF PRESSURE SWITCH…12769
COMPRESSOR…12770
STRUCTURE OF COMPRESSOR…12770
SPECIFICATIONS OF COMPRESSOR…12770
FUNCTION OF COMPRESSOR…12770
CONDENSER…12771
STRUCTURE OF CONDENSER…12771
SPECIFICATIONS OF CONDENSER…12771
FUNCTION OF CONDENSER…12772
RECEIVER DRIER…12773
STRUCTURE OF RECEIVER DRIER…12773
SPECIFICATIONS OF RECEIVER DRIER…12773
FUNCTION OF RECEIVER DRIER…12773
EXPLANATION OF PROCEDURE FOR TESTING AND TROUBLESHOOTING OF AIR CONDITIONER…12775
CIRCUIT DIAGRAM OF AIR CONDITIONER…12778
AIR CONDITIONER SYSTEM DIAGRAM…12779
CONTROL FUNCTION OF AIR CONDITIONER…12780
INSTALLATION LOCATIONS OF AIR CONDITIONER PARTS AND ARRANGEMENT OF CONNECTORS…12781
TEST RELAYS…12785
METHOD FOR TESTING RELAYS…12785
AIR CONDITIONER TROUBLESHOOTING CHART 1…12787
AIR CONDITIONER TROUBLESHOOTING CHART 2…12788
INFORMATION DESCRIBED IN TROUBLESHOOTING TABLE…12791
A-1 TROUBLESHOOTING FOR CONDENSER FAN…12793
A-2 TROUBLESHOOTING FOR BLOWER MOTOR SYSTEM (NO AIR COMES OUT OR AIR FLOW IS ABNORMAL)…12796
A-3 TROUBLESHOOTING FOR TEMPERATURE CONTROL FUNCTION…12799
TROUBLESHOOTING USING GAUGE PRESSURE…12803
CONNECTION OF SERVICE TOOL…12805
METHOD FOR CONNECTING SERVICE TOOL…12806
PRECAUTIONS FOR DISCONNECTING AND CONNECTING HOSES AND TUBES IN AIR CONDITIONER PIPINGS…12807
HANDLE COMPRESSOR OIL…12809
90 CIRCUIT DIAGRAMS…12811
CONTENTS…12812
ABBREVIATION LIST…12813
HYDRAULIC CIRCUIT DIAGRAM…12819
SYMBOLS USED IN HYDRAULIC CIRCUIT DIAGRAM…12819
HYDRAULIC CIRCUIT DIAGRAM…12823
ELECTRICAL CIRCUIT DIAGRAM…12824
SYMBOLS USED IN ELECTRICAL CIRCUIT DIAGRAM…12824
ELECTRICAL CIRCUIT DIAGRAM (1/14)…12828
ELECTRICAL CIRCUIT DIAGRAM (2/14)…12829
ELECTRICAL CIRCUIT DIAGRAM (3/14)…12830
ELECTRICAL CIRCUIT DIAGRAM (4/14)…12831
ELECTRICAL CIRCUIT DIAGRAM (5/14)…12832
ELECTRICAL CIRCUIT DIAGRAM (6/14)…12833
ELECTRICAL CIRCUIT DIAGRAM (7/14)…12834
ELECTRICAL CIRCUIT DIAGRAM (8/14)…12835
ELECTRICAL CIRCUIT DIAGRAM (9/14)…12836
ELECTRICAL CIRCUIT DIAGRAM (10/14)…12837
ELECTRICAL CIRCUIT DIAGRAM (11/14)…12838
ELECTRICAL CIRCUIT DIAGRAM (12/14)…12839
ELECTRICAL CIRCUIT DIAGRAM (13/14)…12840
ELECTRICAL CIRCUIT DIAGRAM (14/14)…12841
INDEX…12842
Komatsu Crawler Dozers/Tractors D51- series Repair Service Manuals
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