Komatsu D51EX-24 D51PX-24 CRAWLER DOZER Shop Manual KEBM661701 PDF

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Komatsu D51EX-24,D51PX-24 CRAWLER DOZER Shop Manual KEBM661701 –  PDF DOWNLOAD

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Komatsu D51EX-24 ,D51PX-24 CRAWLER DOZER Shop Manual KEBM661701 –  PDF DOWNLOAD

Language : English
Pages : 1970
Downloadable : Yes
File Type : PDF

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Komatsu D51EX-24 ,D51PX-24 CRAWLER DOZER Shop Manual KEBM661701 –  PDF DOWNLOAD

SERIAL NUMBERS

• D51EX-24 B20001 and up
  D51PX-24 B20001 and up
  ENGINE 4D107E-3

00 INDEX AND FOREWORD 3
INDEX 4
ABBREVIATION LIST 18
FOREWORD, SAFETY, BASIC INFORMATION 23
HOW TO READ THE SHOP MANUAL 23
SAFETY NOTICE FOR OPERATION 25
PRECAUTIONS TO PREVENT FIRE 33
ACTIONS IF FIRE OCCURS . 35
PRECAUTIONS FOR DISPOSING OF WASTE MATERIALS . 36
ACTIONS TAKEN TO MEET EXHAUST GAS REGULATIONS 37
PRECAUTIONS FOR DEF 38
GENERAL CHARACTER AND PRECAUTIONS FOR HANDLING . 38
PRECAUTIONS FOR ADDING . 38
PRECAUTIONS FOR STORING 38
PRECAUTIONS FOR FIRE HAZARD AND LEAKAGE 38
THE OTHER PRECAUTIONS 38
STORE AdBlue/DEF . 39
PRECAUTIONS FOR HANDLING HYDRAULIC EQUIPMENT . 40
PRECAUTIONS FOR DISCONNECTION AND CONNECTION OF PIPINGS 43
PRECAUTIONS FOR HANDLING ELECTRICAL EQUIPMENT 49
PRECAUTIONS FOR HANDLING FUEL SYSTEM EQUIPMENT . 51
PRECAUTIONS FOR HANDLING INTAKE SYSTEM EQUIPMENT . 52
PRACTICAL USE OF KOMTRAX . 53
DISCONNECT AND CONNECT PUSH-PULL TYPE COUPLER 54
METHOD FOR DISCONNECTING AND CONNECTING TYPE 1 PUSH-PULL TYPE COUPLER 54
METHOD FOR DISCONNECTING AND CONNECTING TYPE 2 PUSH-PULL TYPE COUPLER 55
METHOD FOR DISCONNECTING AND CONNECTING TYPE 3 PUSH-PULL TYPE COUPLER 56
PRECAUTIONS FOR DISCONNECTION AND CONNECTION OF CONNECTORS . 58
METHOD FOR DISCONNECTING AND CONNECTING DEUTSCH CONNECTOR 62
METHOD FOR DISCONNECTING AND CONNECTING SLIDE LOCK TYPE CONNECTOR 63
METHOD FOR DISCONNECTING AND CONNECTING CONNECTOR WITH LOCK TO PULL 65
METHOD FOR DISCONNECTING AND CONNECTING CONNECTOR WITH LOCK TO PUSH 66
METHOD FOR DISCONNECTING AND CONNECTING CONNECTOR WITH HOUSING TO ROTATE . 68
HOW TO READ ELECTRICAL WIRE CODE . 69
EXPLANATION OF TERMS FOR MAINTENANCE STANDARD 73
STANDARD TIGHTENING TORQUE TABLE . 76
CONVERSION TABLE . 83
01 SPECIFICATIONS 89
CONTENTS . 90
ABBREVIATION LIST 91
SPECIFICATIONS . 96
SPECIFICATION DRAWING 96
SPECIFICATION DRAWING: D51EX-24 96
SPECIFICATION DRAWING: D51PX-24 98
SPECIFICATIONS . 100
SPECIFICATIONS: D51EX-24 . 100
SPECIFICATIONS: D51PX-24 . 105
WEIGHT TABLE . 110
WEIGHT TABLE: D51EX-24 . 110
WEIGHT TABLE: D51PX-24 . 112
FUEL, COOLANT, LUBRICANTS (FOR NORTH AMERICA) 114
METHOD FOR USING FUEL, COOLANT AND LUBRICANTS ACCORDING TO AMBIENT TEMPERATURE . 114
FUEL, COOLANT, LUBRICANTS (FOR EUROPEAN UNION) . 116
METHOD FOR USING FUEL, COOLANT AND LUBRICANTS ACCORDING TO AMBIENT TEMPERATURE . 116
10 STRUCTURE AND FUNCTION 119
CONTENTS . 120
ABBREVIATION LIST 123
UREA SCR SYSTEM 128
LAYOUT DRAWING OF UREA SCR SYSTEM 128
UREA SCR SYSTEM DIAGRAM 130
FUNCTION OF UREA SCR SYSTEM 131
FUNCTION OF AdBlue/DEF SYSTEM 131
INDUCEMENT STRATEGY 134
COMPONENT PARTS OF UREA SCR SYSTEM . 149
AdBlue/DEF MIXING TUBE . 149
SCR ASSEMBLY . 150
AdBlue/DEF TANK 152
AdBlue/DEF PUMP 154
AdBlue/DEF INJECTOR 155
AdBlue/DEF HOSE 156
AdBlue/DEF TANK HEATING VALVE 157
BOOT-UP SYSTEM . 158
LAYOUT DRAWING OF BOOT-UP SYSTEM . 158
SYSTEM OPERATING LAMP SYSTEM . 159
SYSTEM OPERATING LAMP SYSTEM DIAGRAM . 159
FUNCTION OF SYSTEM OPERATING LAMP SYSTEM . 159
BATTERY DISCONNECT SWITCH 161
FUNCTION OF BATTERY DISCONNECT SWITCH 161
ENGINE SYSTEM 162
LAYOUT DRAWING OF ENGINE SYSTEM 162
ENGINE CONTROL SYSTEM 164
LAYOUT OF ENGINE CONTROL SYSTEM 164
ENGINE CONTROL SYSTEM DIAGRAM 166
FUNCTION OF ENGINE CONTROL SYSTEM 168
AUTOMATIC IDLE STOP SYSTEM . 170
AUTOMATIC IDLE STOP SYSTEM DIAGRAM . 170
FUNCTION OF AUTOMATIC IDLE STOP SYSTEM . 170
COMPONENT PARTS OF ENGINE SYSTEM . 173
DAMPER . 173
VGT 174
EGR SYSTEM . 177
EGR VALVE 179
EGR COOLER . 181
KCCV SYSTEM 183
KCCV VENTILATOR 185
KDOC . 187
COOLING SYSTEM . 190
LAYOUT DRAWING OF COOLING SYSTEM . 190
SPECIFICATIONS OF COOLING SYSTEM . 191
COOLING FAN CONTROL SYSTEM . 192
COOLING FAN CONTROL SYSTEM DIAGRAM . 192
FUNCTION OF COOLING FAN CONTROL SYSTEM . 193
COMPONENT PARTS OF COOLING SYSTEM 195
COOLING FAN MOTOR 195
HYDRAULIC OIL COOLER BYPASS AND HST CHARGE SAFETY VALVE 200
HYDRAULIC OIL COOLER BYPASS VALVE 201
HST CHARGE SAFETY VALVE 202
CONTROL SYSTEM . 204
LAYOUT DRAWING OF CONTROL SYSTEM . 204
MACHINE MONITOR SYSTEM . 205
MACHINE MONITOR SYSTEM DIAGRAM . 205
FUNCTION OF MACHINE MONITOR SYSTEM . 205
KOMTRAX SYSTEM . 206
KOMTRAX SYSTEM DIAGRAM . 206
FUNCTION OF KOMTRAX SYSTEM . 206
COMPONENT PARTS OF CONTROL SYSTEM 207
MACHINE MONITOR 207
KOMTRAX TERMINAL . 222
HST CONTROLLER . 224
ENGINE CONTROLLER 228
FUEL CONTROL DIAL 235
DECELERATOR AND BRAKE POTENTIOMETER 237
HYDRAULIC SYSTEM . 239
LAYOUT DRAWING OF HYDRAULIC SYSTEM . 239
CLSS . 240
STRUCTURE OF CLSS 240
FUNCTION OF CLSS . 241
COMPONENT PARTS OF HYDRAULIC SYSTEM 243
HYDRAULIC TANK . 243
WORK EQUIPMENT AND COOLING FAN PUMP 245
LS VALVE . 253
PC VALVE . 254
CONTROL VALVE 257
POWER TRAIN SYSTEM . 275
LAYOUT DRAWING OF HST SYSTEM . 275
OPERATION OF HST SYSTEM 276
STEERING AND BRAKE CONTROL SYSTEM 278
LAYOUT DRAWING OF STEERING AND BRAKE CONTROL SYSTEM 278
FUNCTION OF STEERING AND BRAKE CONTROL SYSTEM 278
HST CONTROL SYSTEM . 280
HST CONTROL SYSTEM DIAGRAM . 280
GEAR SHIFT CONTROL FUNCTION 281
ENGINE LOW SPEED MATCHING CONTROL FUNCTION . 284
HST PUMP AND MOTOR SEQUENCE CONTROL FUNCTION . 285
DECELERATION AND BRAKE CONTROL FUNCTION 286
GEAR SHIFT CONTROL FUNCTION BY LOAD 288
TURN CONTROL FUNCTION 288
STRAIGHT TRAVEL CORRECTION CONTROL FUNCTION 289
PARKING BRAKE CONTROL SYSTEM . 291
PARKING BRAKE CONTROL SYSTEM DIAGRAM . 291
FUNCTION OF PARKING BRAKE CONTROL SYSTEM . 292
OPERATION OF PARKING BRAKE CONTROL SYSTEM 293
COMPONENT PARTS OF POWER TRAIN SYSTEM 294
HST PUMP . 294
HST CHARGE PUMP 309
HST MOTOR 310
FINAL DRIVE 323
ELECTRIC STEERING CONTROL LEVER 327
WORK EQUIPMENT SYSTEM 330
WORK EQUIPMENT CONTROL . 330
WORK EQUIPMENT CONTROL SYSTEM DIAGRAM 330
FUNCTION OF WORK EQUIPMENT CONTROL . 331
LAYOUT DRAWING OF FRONT WORK EQUIPMENT . 332
LAYOUT OF FIXED MULTI-SHANK RIPPER . 333
COMPONENT PARTS OF WORK EQUIPMENT SYSTEM . 334
RIPPER PPC VALVE . 334
5-PORT VALVE OF EPC AND SOLENOID . 338
PILOT CIRCUIT ACCUMULATOR 344
QUICK DROP VALVE . 345
PISTON VALVE . 347
ELECTRIC BLADE CONTROL LEVER . 348
UNDERCARRIAGE AND FRAME 350
MAIN FRAME . 350
STRUCTURE OF MAIN FRAME 350
SUSPENSION . 351
STRUCTURE OF SUSPENSION 351
SPECIFICATIONS OF SUSPENSION . 352
FUNCTION OF SUSPENSION . 353
TRACK FRAME AND IDLER CUSHION 354
STRUCTURE OF TRACK FRAME AND IDLER CUSHION . 354
FUNCTION OF TRACK FRAME AND IDLER CUSHION 355
WORK EQUIPMENT . 356
STRUCTURE OF FRONT WORK EQUIPMENT 356
STRUCTURE OF FIXED MULTI-SHANK RIPPER 357
CAB AND ITS ATTACHMENTS 358
ROPS CAB . 358
STRUCTURE OF ROPS CAB 358
FUNCTION OF ROPS CAB . 359
CAB MOUNT 360
STRUCTURE OF CAB MOUNT . 360
FUNCTION OF CAB MOUNT 360
20 STANDARD VALUE TABLE 361
CONTENTS . 362
ABBREVIATION LIST 363
STANDARD VALUE TABLE FOR ENGINE 368
STANDARD VALUE TABLE FOR ENGINE: D51EX-24 368
STANDARD VALUE TABLE FOR ENGINE: D51PX-24 372
STANDARD VALUE TABLE FOR MACHINE . 376
STANDARD VALUE TABLE FOR MACHINE: D51EX-24 . 376
STANDARD VALUE TABLE FOR MACHINE: D51PX-24 . 392
MACHINE POSTURE AND PROCEDURE FOR MEASURING PERFORMANCE 406
30 TESTING AND ADJUSTING . 409
CONTENTS . 410
ABBREVIATION LIST 413
RELATED INFORMATION ON TESTING AND ADJUSTING . 418
TOOLS FOR TESTING AND ADJUSTING 418
SKETCH OF TOOLS FOR TESTING AND ADJUSTING 425
ENGINE AND COOLING SYSTEM 426
TEST ENGINE SPEED 426
METHOD FOR TESTING ENGINE SPEED 426
TEST BOOST PRESSURE 428
METHOD FOR TESTING BOOST PRESSURE 428
TEST EXHAUST GAS COLOR . 430
METHOD FOR TESTING EXHAUST GAS COLOR BY HANDY SMOKE CHECKER 430
METHOD FOR TESTING EXHAUST GAS COLOR BY SMOKE METER 431
TEST AND ADJUST VALVE CLEARANCE 432
METHOD FOR TESTING VALVE CLEARANCE . 432
METHOD FOR ADJUSTING VALVE CLEARANCE . 433
TEST COMPRESSION PRESSURE 434
METHOD FOR TESTING COMPRESSION PRESSURE 434
TEST BLOWBY PRESSURE . 439
METHOD FOR TESTING BLOWBY PRESSURE . 439
TEST ENGINE OIL PRESSURE . 441
METHOD FOR TESTING ENGINE OIL PRESSURE . 441
TEST FUEL PRESSURE . 442
METHOD FOR TESTING FUEL PRESSURE . 443
TEST FUEL DISCHARGE, RETURN AND LEAKAGE 447
METHOD FOR TESTING FUEL DISCHARGE, RETURN AND LEAKAGE 448
BLEED AIR FROM FUEL SYSTEM . 453
METHOD FOR BLEEDING AIR FROM FUEL SYSTEM . 453
TEST FUEL CIRCUIT FOR LEAKAGE 454
METHOD FOR TESTING FUEL CIRCUIT FOR LEAKAGE 454
HANDLE CYLINDER CUT-OUT MODE OPERATION . 456
HANDLE NO-INJECTION CRANKING OPERATION . 457
TEST KDOC, SCR AND MUFFLER STACK FOR LOOSENESS AND DAMAGE 458
METHOD FOR TESTING KDOC, SCR AND MUFFLER STACK FOR LOOSENESS AND DAMAGE 458
TEST INSTALLED CONDITION OF CYLINDER HEADS AND MANIFOLDS . 459
METHOD FOR TESTING INSTALLED CONDITION OF CYLINDER HEADS AND MANIFOLDS . 459
TEST ENGINE PIPING FOR DAMAGE AND LOOSENESS 460
METHOD FOR TESTING ENGINE PIPING FOR DAMAGE AND LOOSENESS 460
WRITE ASH IN SOOT ACCUMULATION CORRECTION TO ENGINE CONTROLLER . 461
METHOD FOR WRITING ASH IN SOOT ACCUMULATION CORRECTION TO ENGINE CONTROLLER 461
TEST SCR RELATED FUNCTIONS . 462
TEST AdBlue/DEF PUMP RAISED PRESSURE . 466
TEST INJECTION AMOUNT FROM AdBlue/DEF INJECTOR . 469
TEST AdBlue/DEF LINE HEATER RELAY 1 473
TEST AdBlue/DEF LINE HEATER RELAY 2 476
TEST AdBlue/DEF PUMP HEATER RELAY 479
TEST AdBlue/DEF TANK HEATER VALVE 483
TEST DENITRATION EFFICIENCY OF SCR . 487
CLEAN AdBlue/DEF TANK 490
METHOD FOR CLEANING AdBlue/DEF TANK 490
CLEAN AdBlue/DEF TANK MOUNTING PORTION . 494
METHOD FOR CLEANING AdBlue/DEF TANK MOUNTING PORTION . 494
POWER TRAIN 495
TEST AND ADJUST HST OIL PRESSURE . 495
METHOD FOR TESTING HST OIL PRESSURE 495
METHOD FOR ADJUSTING HST OIL PRESSURE 498
BLEED AIR FROM HST PUMP 500
METHOD FOR BLEEDING AIR FROM HST PUMP 500
METHOD FOR BLEEDING AIR FROM SERVO VALVE OF HST PUMP . 500
TEST OUTLET PRESSURE OF SOLENOID VALVE . 502
METHOD FOR TESTING OUTLET PRESSURE OF SOLENOID VALVE . 502
TEST TRAVEL DEVIATION 506
METHOD FOR TESTING TRAVEL DEVIATION 506
TEST BRAKE PERFORMANCE SIMPLY 508
METHOD FOR TESTING BRAKE PERFORMANCE SIMPLY 508
TEST AND ADJUST DECELERATION/BRAKE PEDAL . 509
METHOD FOR TESTING DECELERATION/BRAKE PEDAL 509
METHOD FOR ADJUSTING DECELERATION/BRAKE PEDAL 511
ADJUST PARKING BRAKE LEVER . 513
METHOD FOR ADJUSTING PARKING BRAKE LEVER . 513
MOVE MACHINE WHEN IT CANNOT TRAVEL . 515
METHOD FOR MOVING MACHINE WITH HYDRAULIC TYPE PARKING BRAKE RELEASE SYSTEM . 515
METHOD FOR MOVING DISABLED MACHINE BY REMOVING FINAL DRIVE SHAFT . 517
UNDERCARRIAGE AND FRAME 518
CHECK AND ADJUST IDLER CLEARANCE . 518
METHOD FOR ADJUSTING IDLER CLEARANCE HORIZONTALLY 518
METHOD FOR ADJUSTING IDLER CLEARANCE VERTICALLY 518
TESTING SPROCKET WEAR 520
METHOD FOR TESTING SPROCKET WEAR . 520
TEST AND ADJUST TRACK TENSION 521
METHOD FOR TESTING TRACK TENSION . 521
METHOD FOR ADJUSTING TRACK TENSION . 521
HYDRAULIC SYSTEM . 523
RELEASE REMAINING PRESSURE FROM HYDRAULIC SYSTEM . 523
METHOD FOR RELEASING REMAINING PRESSURE FROM HYDRAULIC CIRCUIT . 523
TEST AND ADJUST WORK EQUIPMENT OIL PRESSURES . 524
METHOD FOR TESTING WORK EQUIPMENT OIL PRESSURES 524
METHOD FOR ADJUSTING WORK EQUIPMENT OIL PRESSURES 525
TEST AND ADJUST OIL PRESSURE OF CONTROL CIRCUIT 527
METHOD FOR TESTING OIL PRESSURE OF CONTROL CIRCUIT . 527
METHOD FOR ADJUSTING OIL PRESSURE OF CONTROL CIRCUIT . 528
TEST OUTLET PRESSURE OF EPC SOLENOID VALVE . 529
METHOD FOR TESTING OUTLET PRESSURE OF EPC SOLENOID VALVE . 529
BLEED AIR FROM WORK EQUIPMENT AND COOLING FAN PUMP . 531
METHOD FOR BLEEDING AIR FROM WORK EQUIPMENT AND COOLING FAN PUMP . 531
TEST COOLING FAN SPEED . 532
METHOD FOR TESTING COOLING FAN SPEED . 532
TEST COOLING FAN CIRCUIT OIL PRESSURE 533
METHOD FOR TESTING COOLING FAN CIRCUIT OIL PRESSURE 533
TEST THE PARTS CAUSING HYDRAULIC DRIFT IN WORK EQUIPMENT . 535
METHOD FOR TESTING THE PARTS CAUSING HYDRAULIC DRIFT OF BLADE LIFT CYLINDER 535
METHOD FOR TESTING THE PARTS CAUSING HYDRAULIC DRIFT OF BLADE TILT CYLINDER 535
METHOD FOR TESTING THE PARTS CAUSING HYDRAULIC DRIFT OF RIPPER LIFT CYLINDER . 536
TEST INTERNAL OIL LEAKAGE OF WORK EQUIPMENT CYLINDER . 537
METHOD FOR TESTING INTERNAL OIL LEAKAGE OF WORK EQUIPMENT CYLINDER . 537
BLEED AIR FROM WORK EQUIPMENT CYLINDERS 540
METHOD FOR BLEEDING AIR FROM WORK EQUIPMENT CYLINDERS 540
WORK EQUIPMENT . 541
ADJUST WORK EQUIPMENT LOCK LEVER . 541
METHOD FOR ADJUSTING WORK EQUIPMENT LOCK LEVER . 541
ELECTRICAL SYSTEM 543
SET AND OPERATE MACHINE MONITOR 543
OPERATOR MODE 547
DISPLAY FUNCTION OF TECHNICIAN IDENTIFICATION STATUS SCREEN 547
DISPLAY FUNCTION OF OPERATOR IDENTIFICATION INPUT SCREEN . 547
CHECKING FUNCTION BY LCD (LIQUID CRYSTAL DISPLAY) 548
CHECKING FUNCTION OF SERVICE METER . 548
METHOD FOR SETTING USAGE LIMITATION AND CHANGING MAINTENANCE PASSWORD 548
SERVICE MODE . 551
METHOD FOR OPERATING SERVICE MODE 551
METHOD FOR CHECKING PRE-DEFINED MONITORING INFORMATION . 553
METHOD FOR CHECKING SELF-DEFINE MONITORING INFORMATION . 565
ABNORMALITY RECORD MENU 583
METHOD FOR CONFIRMING MAINTENANCE RECORD . 587
METHOD FOR OPERATING MAINTENANCE MODE SETTING 588
METHOD FOR OPERATING PHONE NUMBER ENTRY SETTING 592
DEFAULT MENU . 593
DIAGNOSTIC TESTS MENU 600
ADJUSTMENT MENU 608
METHOD FOR PERFORMING NO-INJECTION CRANKING 665
KOMTRAX SETTINGS MENU 667
METHOD FOR DISPLAYING SERVICE MESSAGE 669
METHOD FOR STARTING UP KOMTRAX TERMINAL 671
ADJUSTMENT WHEN HST CONTROLLER HAS BEEN REPLACED . 676
ADJUSTMENT METHOD WHEN HST CONTROLLER HAS BEEN REPLACED 676
ADJUSTMENT WHEN ELECTRIC OR HYDRAULIC DEVICE HAS BEEN REPLACED . 682
ADJUST REARVIEW CAMERA ANGLE . 684
METHOD FOR ADJUSTING REARVIEW CAMERA ANGLE . 684
HANDLE VOLTAGE CIRCUIT OF ENGINE CONTROLLER 685
HANDLE BATTERY DISCONNECT SWITCH . 686
TEST DIODES 687
METHOD FOR TESTING DIODE USING DIGITAL TESTER 687
METHOD FOR TESTING DIODE USING ANALOG TESTER . 687
Pm CLINIC 688
Pm CLINIC SERVICE 688
Pm CLINIC CHECK SHEET: D51EX-24 690
Pm CLINIC CHECK SHEET: D51PX-24 698
Pm CLINIC CHECK SHEET FOR UNDERCARRIAGE: D51EX-24 706
Pm CLINIC CHECK SHEET FOR UNDERCARRIAGE: D51PX-24 710
40 TROUBLESHOOTING . 715
CONTENTS . 716
ABBREVIATION LIST 726
RELATED INFORMATION ON TROUBLESHOOTING . 731
GENERAL TROUBLESHOOTING POINTS . 731
TROUBLESHOOTING POINTS FOR UREA SCR SYSTEM . 732
SEQUENCE OF EVENTS IN TROUBLESHOOTING 744
CHECKS BEFORE TROUBLESHOOTING 746
INSPECTION PROCEDURE BEFORE TROUBLESHOOTING 748
WALK-AROUND CHECK 748
TESTING IN ACCORDANCE WITH TESTING PROCEDURE . 750
CHECK FUEL LEVEL AND TYPE 750
CHECK IMPURE INGREDIENT IN FUEL 750
CHECK AdBule/DEF LEVEL AND TYPE 751
CHECK FUEL PREFILTER . 751
CHECK MAIN FILTER 753
CHECK ENGINE OIL LEVEL (OIL AMOUNT IN OIL PAN) AND TYPE 754
CHECK COOLANT LEVEL (RESERVOIR TANK) . 756
CHECK CLOGGING OF AIR CLEANER 756
CLEAN OUTER ELEMENT 757
REPLACE ELEMENT 759
CHECK HYDRAULIC OIL LEVEL 760
CHECK HYDRAULIC OIL STRAINER . 761
CHECK OIL LEVEL IN FINAL DRIVE CASE 764
BLEED AIR FROM FUEL SYSTEM . 765
BLEED AIR FROM HYDRAULIC SYSTEM 765
METHOD FOR CHECKING ELECTRIC EQUIPMENT . 765
PREPARATION FOR TROUBLESHOOTING OF ELECTRICAL SYSTEM . 772
PROCEDURE FOR TROUBLESHOOTING 779
INFORMATION DESCRIBED IN TROUBLESHOOTING TABLE . 782
TROUBLESHOOTING METHOD FOR OPEN CIRCUIT IN WIRING HARNESS OF PRESSURE SENSOR SYSTEM 784
CONNECTORS LIST AND LAYOUT . 787
CONNECTOR CONTACT IDENTIFICATION . 801
T-BRANCH BOX AND T-BRANCH ADAPTER TABLE 841
FUSE LOCATION TABLE 847
PRECAUTIONS FOR REPLACING KDOC . 851
FAILURE CODES TABLE 852
TROUBLESHOOTING BY FAILURE CODE (DISPLAY OF CODE) 870
FAILURE CODE [6091NX] 870
FAILURE CODE [989L00] 872
FAILURE CODE [989M00] 873
FAILURE CODE [989N00] 874
FAILURE CODE [A1U0N3] 875
FAILURE CODE [A1U0N4] 877
FAILURE CODE [A900FR] 879
FAILURE CODE [A900N6] 880
FAILURE CODE [A900NY] 881
FAILURE CODE [AA10NX] 882
FAILURE CODE [AB00KE] 884
FAILURE CODE [AQ10MB] 886
FAILURE CODE [AQ10N3] 888
FAILURE CODE [AS00R2] 890
FAILURE CODE [AS00R3] 891
FAILURE CODE [AS00R4] 892
FAILURE CODE [AS00R5] 893
FAILURE CODE [AS00R6] 894
FAILURE CODE [AS00ZK] 895
FAILURE CODE [AS10KM] 896
FAILURE CODE [AS10NR] 897
FAILURE CODE [AS10NT] 898
FAILURE CODE [B@BAZG] 899
FAILURE CODE [B@BCNS] 900
FAILURE CODE [B@CRNS] 901
FAILURE CODE [B@CRZG] 902
FAILURE CODE [CA115] . 903
FAILURE CODE [CA122] . 904
FAILURE CODE [CA123] . 906
FAILURE CODE [CA131] . 908
FAILURE CODE [CA132] . 910
FAILURE CODE [CA144] . 912
FAILURE CODE [CA145] . 914
FAILURE CODE [CA153] . 916
FAILURE CODE [CA154] . 918
FAILURE CODE [CA187] . 920
FAILURE CODE [CA221] . 922
FAILURE CODE [CA222] . 924
FAILURE CODE [CA227] . 926
FAILURE CODE [CA234] . 928
FAILURE CODE [CA238] . 929
FAILURE CODE [CA239] . 930
FAILURE CODE [CA249] . 931
FAILURE CODE [CA256] . 933
FAILURE CODE [CA271] . 935
FAILURE CODE [CA272] . 937
FAILURE CODE [CA295] . 939
FAILURE CODE [CA322] . 940
FAILURE CODE [CA324] . 942
FAILURE CODE [CA331] . 944
FAILURE CODE [CA332] . 946
FAILURE CODE [CA343] . 948
FAILURE CODE [CA351] . 949
FAILURE CODE [CA352] . 951
FAILURE CODE [CA356] . 953
FAILURE CODE [CA357] . 955
FAILURE CODE [CA386] . 957
FAILURE CODE [CA428] . 958
FAILURE CODE [CA429] . 960
FAILURE CODE [CA435] . 962
FAILURE CODE [CA441] . 964
FAILURE CODE [CA442] . 966
FAILURE CODE [CA451] . 967
FAILURE CODE [CA452] . 969
FAILURE CODE [CA488] . 971
FAILURE CODE [CA515] . 972
FAILURE CODE [CA516] . 974
FAILURE CODE [CA553] . 976
FAILURE CODE [CA555] . 977
FAILURE CODE [CA556] . 978
FAILURE CODE [CA559] . 979
FAILURE CODE [CA595] . 982
FAILURE CODE [CA687] . 984
FAILURE CODE [CA689] . 986
FAILURE CODE [CA691] . 989
FAILURE CODE [CA692] . 991
FAILURE CODE [CA697] . 993
FAILURE CODE [CA698] . 994
FAILURE CODE [CA731] . 995
FAILURE CODE [CA778] . 997
FAILURE CODE [CA1117] 1002
FAILURE CODE [CA1664] 1004
FAILURE CODE [CA1669] 1006
FAILURE CODE [CA1673] 1007
FAILURE CODE [CA1677] 1008
FAILURE CODE [CA1678] 1009
FAILURE CODE [CA1682] 1010
FAILURE CODE [CA1683] 1012
FAILURE CODE [CA1684] 1014
FAILURE CODE [CA1686] 1016
FAILURE CODE [CA1691] 1017
FAILURE CODE [CA1694] 1019
FAILURE CODE [CA1695] 1021
FAILURE CODE [CA1696] 1022
FAILURE CODE [CA1712] 1024
FAILURE CODE [CA1713] 1027
FAILURE CODE [CA1714] 1029
FAILURE CODE [CA1715] 1030
FAILURE CODE [CA1776] 1031
FAILURE CODE [CA1777] 1034
FAILURE CODE [CA1843] 1037
FAILURE CODE [CA1844] 1039
FAILURE CODE [CA1885] 1042
FAILURE CODE [CA1887] 1044
FAILURE CODE [CA1896] 1046
FAILURE CODE [CA1898] 1047
FAILURE CODE [CA1938] 1049
FAILURE CODE [CA1942] 1051
FAILURE CODE [CA1961] 1052
FAILURE CODE [CA1962] 1053
FAILURE CODE [CA2185] 1054
FAILURE CODE [CA2186] 1056
FAILURE CODE [CA2198] 1058
FAILURE CODE [CA2272] 1060
FAILURE CODE [CA2288] 1062
FAILURE CODE [CA2311] 1063
FAILURE CODE [CA2349] 1064
FAILURE CODE [CA2353] 1066
FAILURE CODE [CA2357] 1068
FAILURE CODE [CA2373] 1069
FAILURE CODE [CA2374] 1071
FAILURE CODE [CA2375] 1073
FAILURE CODE [CA2376] 1075
FAILURE CODE [CA2387] 1078
FAILURE CODE [CA2554] 1079
FAILURE CODE [CA2634] 1080
FAILURE CODE [CA2635] 1082
FAILURE CODE [CA2636] 1083
FAILURE CODE [CA2637] 1085
FAILURE CODE [CA2771] 1087
FAILURE CODE [CA2961] 1091
FAILURE CODE [CA2973] 1092
FAILURE CODE [CA2976] 1093
FAILURE CODE [CA3142] 1095
FAILURE CODE [CA3143] 1096
FAILURE CODE [CA3144] 1097
FAILURE CODE [CA3146] 1099
FAILURE CODE [CA3147] 1100
FAILURE CODE [CA3148] 1101
FAILURE CODE [CA3151] 1103
FAILURE CODE [CA3165] 1108
FAILURE CODE [CA3228] 1110
FAILURE CODE [CA3229] 1112
FAILURE CODE [CA3231] 1114
FAILURE CODE [CA3232] 1116
FAILURE CODE [CA3235] 1120
FAILURE CODE [CA3239] 1122
FAILURE CODE [CA3241] 1125
FAILURE CODE [CA3242] 1128
FAILURE CODE [CA3251] 1131
FAILURE CODE [CA3313] 1133
FAILURE CODE [CA3314] 1134
FAILURE CODE [CA3315] 1135
FAILURE CODE [CA3419] 1137
FAILURE CODE [CA3421] 1139
FAILURE CODE [CA3497] 1141
FAILURE CODE [CA3498] 1142
FAILURE CODE [CA3545] 1143
FAILURE CODE [CA3547] 1145
FAILURE CODE [CA3558] 1146
FAILURE CODE [CA3559] 1148
FAILURE CODE [CA3562] 1150
FAILURE CODE [CA3563] 1152
FAILURE CODE [CA3567] 1155
FAILURE CODE [CA3568] 1159
FAILURE CODE [CA3571] 1163
FAILURE CODE [CA3572] 1165
FAILURE CODE [CA3574] 1167
FAILURE CODE [CA3575] 1169
FAILURE CODE [CA3577] 1171
FAILURE CODE [CA3578] 1173
FAILURE CODE [CA3582] 1175
FAILURE CODE [CA3583] 1180
FAILURE CODE [CA3596] 1182
FAILURE CODE [CA3649] 1185
FAILURE CODE [CA3681] 1187
FAILURE CODE [CA3682] 1192
FAILURE CODE [CA3713] 1197
FAILURE CODE [CA3717] 1200
FAILURE CODE [CA3718] 1201
FAILURE CODE [CA3724] 1202
FAILURE CODE [CA3725] 1203
FAILURE CODE [CA3741] 1206
FAILURE CODE [CA3748] 1207
FAILURE CODE [CA3755] 1209
FAILURE CODE [CA3866] 1211
FAILURE CODE [CA3868] 1214
FAILURE CODE [CA4152] 1218
FAILURE CODE [CA4155] 1222
FAILURE CODE [CA4156] 1225
FAILURE CODE [CA4157] 1228
FAILURE CODE [CA4159] 1230
FAILURE CODE [CA4164] 1231
FAILURE CODE [CA4165] 1233
FAILURE CODE [CA4166] 1235
FAILURE CODE [CA4168] 1236
FAILURE CODE [CA4169] 1239
FAILURE CODE [CA4171] 1241
FAILURE CODE [CA4249] 1244
FAILURE CODE [CA4251] 1246
FAILURE CODE [CA4261] 1249
FAILURE CODE [CA4277] 1252
FAILURE CODE [CA4459] 1255
FAILURE CODE [CA4461] 1257
FAILURE CODE [CA4533] 1260
FAILURE CODE [CA4534] 1261
FAILURE CODE [CA4731] 1262
FAILURE CODE [CA4732] 1263
FAILURE CODE [CA4739] 1264
FAILURE CODE [CA4768] 1265
FAILURE CODE [CA4769] 1267
FAILURE CODE [CA4842] 1270
FAILURE CODE [CA4952] 1273
FAILURE CODE [CA5115] 1275
FAILURE CODE [CA5179] 1278
FAILURE CODE [CA5181] 1280
FAILURE CODE [CA5387] 1282
FAILURE CODE [CA5388] 1284
FAILURE CODE [CA5389] 1287
FAILURE CODE [CA5391] 1289
FAILURE CODE [CA5392] 1293
FAILURE CODE [CA5393] 1295
FAILURE CODE [CA5394] 1298
FAILURE CODE [CA5395] 1301
FAILURE CODE [CA5396] 1304
FAILURE CODE [CA5631] 1305
FAILURE CODE [CA5632] 1307
FAILURE CODE [CA5938] 1308
FAILURE CODE [D130KA] 1310
FAILURE CODE [D130KB] 1313
FAILURE CODE [D130KY] 1315
FAILURE CODE [D19JKZ] 1317
FAILURE CODE [D811MC] 1320
FAILURE CODE [D862KA] 1321
FAILURE CODE [D8ALKA] 1322
FAILURE CODE [D8ALKB] 1324
FAILURE CODE [D8AQKR] 1326
FAILURE CODE [DAF0MB] 1328
FAILURE CODE [DAF0MC] 1329
FAILURE CODE [DAF8KB] 1330
FAILURE CODE [DAF9KQ] 1332
FAILURE CODE [DAFGMC] 1333
FAILURE CODE [DAFLKA] 1334
FAILURE CODE [DAFLKB] 1336
FAILURE CODE [DAFQKR] 1338
FAILURE CODE [DAJ000] 1339
FAILURE CODE [DAJ0KQ] 1340
FAILURE CODE [DAJ0KT] 1341
FAILURE CODE [DAJ0MC] 1342
FAILURE CODE [DAJ1KK] 1343
FAILURE CODE [DAJ2KK] 1345
FAILURE CODE [DAJ5KK] 1347
FAILURE CODE [DAJ6KK] 1350
FAILURE CODE [DAJLKA] 1352
FAILURE CODE [DAJLKB] 1354
FAILURE CODE [DAJPMA] 1356
FAILURE CODE [DAJQKR] 1357
FAILURE CODE [DAJRKR] 1358
FAILURE CODE [DB2QKR] 1359
FAILURE CODE [DB2RKR] 1364
FAILURE CODE [DD12KA] 1369
FAILURE CODE [DD12KB] 1371
FAILURE CODE [DD13KA] 1373
FAILURE CODE [DD13KB] 1375
FAILURE CODE [DD14KA] 1377
FAILURE CODE [DD14KB] 1379
FAILURE CODE [DDKAKA] 1381
FAILURE CODE [DDKAKB] 1383
FAILURE CODE [DDKFL4] 1385
FAILURE CODE [DDKGL4] 1387
FAILURE CODE [DDKHKA] 1389
FAILURE CODE [DDKHKB] 1391
FAILURE CODE [DDNLKA] 1393
FAILURE CODE [DDNLKB] 1395
FAILURE CODE [DDP6KA] 1397
FAILURE CODE [DDP6KB] 1400
FAILURE CODE [DDP6MA] 1402
FAILURE CODE [DDU1FS] 1404
FAILURE CODE [DDU1KA] 1406
FAILURE CODE [DDU1KY] 1409
FAILURE CODE [DFA4KX] 1411
FAILURE CODE [DFA4KZ] 1412
FAILURE CODE [DFA4L8] 1413
FAILURE CODE [DFA5KA] 1414
FAILURE CODE [DFA5KB] 1417
FAILURE CODE [DFA6KA] 1420
FAILURE CODE [DFA6KB] 1423
FAILURE CODE [DFA7KX] 1426
FAILURE CODE [DFA7KZ] 1427
FAILURE CODE [DFA7L8] 1428
FAILURE CODE [DFA8KA] 1429
FAILURE CODE [DFA8KB] 1432
FAILURE CODE [DFA9KA] 1435
FAILURE CODE [DFA9KB] 1438
FAILURE CODE [DGS1KA] 1441
FAILURE CODE [DGS1KX] 1444
FAILURE CODE [DH21KA] 1445
FAILURE CODE [DH21KB] 1447
FAILURE CODE [DHA4KA] 1449
FAILURE CODE [DHH7KA] 1451
FAILURE CODE [DHH7KB] 1454
FAILURE CODE [DHH8KA] 1456
FAILURE CODE [DHH8KB] 1459
FAILURE CODE [DHH9KA] 1461
FAILURE CODE [DHH9KB] 1464
FAILURE CODE [DHHAKA] 1466
FAILURE CODE [DHHAKB] 1469
FAILURE CODE [DK30KA] 1471
FAILURE CODE [DK30KB] 1474
FAILURE CODE [DK30KX] 1476
FAILURE CODE [DK30KZ] 1477
FAILURE CODE [DK30L8] 1478
FAILURE CODE [DK31KA] 1479
FAILURE CODE [DK31KB] 1482
FAILURE CODE [DK40KA] 1484
FAILURE CODE [DK40KB] 1487
FAILURE CODE [DK55KX] 1489
FAILURE CODE [DK55KZ] 1490
FAILURE CODE [DK55L8] 1491
FAILURE CODE [DK56KA] 1492
FAILURE CODE [DK56KB] 1495
FAILURE CODE [DK57KA] 1497
FAILURE CODE [DK57KB] 1500
FAILURE CODE [DLM0KX] 1502
FAILURE CODE [DLM1KA] 1503
FAILURE CODE [DLM1KB] 1505
FAILURE CODE [DLM1MA] 1507
FAILURE CODE [DLM2KA] 1508
FAILURE CODE [DLM2KB] 1510
FAILURE CODE [DLM2MA] 1512
FAILURE CODE [DLM3KA] 1513
FAILURE CODE [DLM3KB] 1515
FAILURE CODE [DLM3MB] 1517
FAILURE CODE [DN21FS] 1518
FAILURE CODE [DR21KX] 1520
FAILURE CODE [DR31KX] 1521
FAILURE CODE [DV20KB] 1522
FAILURE CODE [DW4BKA] 1524
FAILURE CODE [DW4BKB] 1526
FAILURE CODE [DW4BKY] 1528
FAILURE CODE [DW7BKA] 1530
FAILURE CODE [DW7BKB] 1532
FAILURE CODE [DW7EKA] 1534
FAILURE CODE [DW7EKB] 1536
FAILURE CODE [DW7EKY] 1538
FAILURE CODE [DWN5KA] 1540
FAILURE CODE [DWN5KB] 1542
FAILURE CODE [DWN5KY] 1544
FAILURE CODE [DXA4KA] 1546
FAILURE CODE [DXA4KB] 1548
FAILURE CODE [DXA4KY] 1550
FAILURE CODE [DXA5KA] 1552
FAILURE CODE [DXA5KB] 1554
FAILURE CODE [DXA5KY] 1556
FAILURE CODE [DXA6KA] 1558
FAILURE CODE [DXA6KB] 1560
FAILURE CODE [DXA6KY] 1562
FAILURE CODE [DXA7KA] 1564
FAILURE CODE [DXA7KB] 1566
FAILURE CODE [DXA7KY] 1568
FAILURE CODE [DXHRKA] 1570
FAILURE CODE [DXHRKB] 1572
FAILURE CODE [DXHRKY] 1574
FAILURE CODE [DXHSKA] 1576
FAILURE CODE [DXHSKB] 1578
FAILURE CODE [DXHSKY] 1580
FAILURE CODE [DXHTKA] 1582
FAILURE CODE [DXHTKB] 1584
FAILURE CODE [DXHTKY] 1586
FAILURE CODE [DXHUKA] 1588
FAILURE CODE [DXHUKB] 1590
FAILURE CODE [DXHUKY] 1592
FAILURE CODE [DXJ4KA] 1594
FAILURE CODE [DXJ4KB] 1596
FAILURE CODE [DXJCKA] 1598
FAILURE CODE [DXJCKB] 1600
FAILURE CODE [DXJCKY] 1602
FAILURE CODE [DXJDKA] 1604
FAILURE CODE [DXJDKB] 1606
FAILURE CODE [DXJDKY] 1608
FAILURE CODE [DXK1KA] 1610
FAILURE CODE [DXK1KB] 1612
FAILURE CODE [DXK1KY] 1614
FAILURE CODE [DXK2KA] 1616
FAILURE CODE [DXK2KB] 1618
FAILURE CODE [DXK2KY] 1620
TROUBLESHOOTING OF ELECTRICAL SYSTEM (E-MODE) 1622
E-1 ENGINE DOES NOT START (ENGINE DOES NOT CRANK) 1622
E-2 MANUAL PREHEATING SYSTEM DOES NOT WORK .1629
E-3 AUTOMATIC PREHEATING SYSTEM DOES NOT WORK 1632
E-4 WHILE PREHEATING IS WORKING, PREHEATING MONITOR DOES NOT LIGHT UP 1634
E-5 WHEN STARTING SWITCH IS TURNED TO ON POSITION, MACHINE MONITOR DISPLAYS NOTHING 1636
E-6 WHEN STARTING SWITCH IS TURNED TO ON POSITION (WITH ENGINE STOPPED), BASIC CHECK MONITOR LIGHTS UP .1640
E-7 AIR CLEANER CLOGGING MONITOR LIGHTS UP IN YELLOW WHILE ENGINE IS RUNNING .1641
E-8 CHARGE LEVEL MONITOR LIGHTS UP IN RED WHILE ENGINE IS RUNNING 1642
E-9 ENGINE COOLANT TEMPERATURE MONITOR LIGHTS UP IN RED WHILE ENGINE IS RUNNING 1643
E-10 ENGINE OIL PRESSURE MONITOR LIGHTS UP IN RED WHILE ENGINE IS RUNNING 1644
E-11 HST CHARGE PRESSURE MONITOR LIGHTS UP IN RED WHILE ENGINE IS RUNNING 1645
E-12 HYDRAULIC OIL TEMPERATURE MONITOR LIGHTS UP IN RED WHILE ENGINE IS RUNNING 1646
E-13 HST OIL FILTER CLOGGING MONITOR LIGHTS UP IN RED WHILE ENGINE IS RUNNING 1647
E-14 ENGINE COOLANT TEMPERATURE GAUGE DOES NOT INDICATE CORRECT TEMPERATURE 1648
E-15 FUEL LEVEL GAUGE DOES NOT INDICATE CORRECT LEVEL 1649
E-16 HYDRAULIC OIL TEMPERATURE GAUGE DOES NOT INDICATE CORRECT TEMPERATURE .1652
E-17 OPERATION MODE DOES NOT CHANGE 1653
E-18 OPERATING CUSTOMIZE SWITCH DOES NOT DISPLAY CUSTOMIZE SCREEN 1654
E-19 MODIFYING SETTING ON CUSTOMIZE SCREEN DOES NOT CHANGE SETTING OF MACHINE 1655
E-20 SERVICE METER IS NOT DISPLAYED, WHILE STARTING SWITCH IS IN OFF POSITION 1656
E-21 SERVICE MODE CANNOT BE SELECTED .1657
E-22 WORK EQUIPMENT DOES NOT OPERATE .1658
E-23 FOOT HEATER DOES NOT OPERATE 1660
E-24 HORN DOES NOT SOUND .1666
E-25 HORN DOES NOT STOP SOUNDING .1668
E-26 BACKUP ALARM DOES NOT SOUND .1669
E-27 BACKUP ALARM DOES NOT STOP SOUNDING .1670
E-28 HEADLAMP DOES NOT LIGHT UP 1671
E-29 REAR LAMP DOES NOT LIGHT UP .1675
E-30 ALL WIPERS DO NOT OPERATE .1678
E-31 FRONT WIPER DOES NOT OPERATE 1680
E-32 REAR WIPER DOES NOT OPERATE .1682
E-33 LEFT DOOR WIPER DOES NOT OPERATE 1684
E-34 RIGHT DOOR WIPER DOES NOT OPERATE .1688
E-35 FRONT WASHER DOES NOT OPERATE .1692
E-36 REAR WASHER DOES NOT OPERATE 1694
E-37 LEFT DOOR WASHER DOES NOT OPERATE .1696
E-38 RIGHT DOOR WASHER DOES NOT OPERATE 1698
E-39 KOMTRAX SYSTEM DOES NOT OPERATE NORMALLY 1700
TROUBLESHOOTING FOR HYDRAULIC AND MECHANICAL SYSTEMS (H MODE) 1701
INFORMATION MENTIONED IN TROUBLESHOOTING TABLE (H MODE) 1701
FAILURE MODE AND CAUSE TABLE .1702
H-1 NEITHER R.H. NOR L.H. OF TRACKS CAN TRAVEL FORWARD OR REVERSE (NONE OF THE TRAVEL SYSTEMS OPERATE) .1708
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) 1710
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) 1712
H-4 TRAVEL SPEED OR POWER IS LOW .1714
H-5 SPEED RANGE DOES NOT CHANGE 1716
H-6 SHOCK IS LARGE WHEN MACHINE MOVES OFF OR STOPS .1717
H-7 MACHINE DEVIATES LARGELY .1718
H-8 MACHINE DRIFT ON A SLOPE IS LARGE 1721
H-9 ENGINE SPEED DROPS LARGELY OR ENGINE STOPS .1723
H-10 UNUSUAL NOISE IS HEARD FROM AROUND HST PUMP OR MOTOR 1725
H-11 HST OIL TEMPERATURE (HYDRAULIC OIL TEMPERATURE) RISES TOO HIGH 1727
H-12 ALL WORK EQUIPMENT DO NOT OPERATE .1729
H-13 ALL WORK EQUIPMENTS SPEED OR POWER IS LOW .1731
H-14 BLADE LIFT SPEED OR POWER IS LOW 1732
H-15 BLADE TILT SPEED OR POWER IS LOW 1734
H-16 BLADE ANGLE SPEED OR POWER IS LOW .1735
H-17 TIME LAG OF BLADE LIFT IS LARGE .1736
H-18 HYDRAULIC DRIFT OF LIFTED BLADE IS LARGE 1737
H-19 HYDRAULIC DRIFT OF TILTED BLADE IS LARGE 1738
H-20 UNUSUAL NOISE IS HEARD FROM AROUND WORK EQUIPMENT AND COOLING FAN PUMP OR CONTROL VALVE .1739
H-21 FAN SPEED IS ABNORMAL (TOO HIGH OR LOW, OR STATIONARY) 1740
H-22 UNUSUAL NOISE IS HEARD FROM AROUND FAN 1742
TROUBLESHOOTING OF ENGINE (S-MODE) .1743
INFORMATION MENTIONED IN TROUBLESHOOTING TABLE (S MODE) 1743
S-1 ENGINE DOES NOT CRANK WHEN STARTING SWITCH IS TURNED TO START POSITION .1744
S-2 ENGINE CRANKS BUT NO EXHAUST GAS COMES OUT .1745
S-3 FUEL IS BEING INJECTED BUT ENGINE DOES NOT START (MISFIRING: ENGINE CRANKS BUT DOES NOT START) .1746
S-4 ENGINE STARTABILITY IS POOR 1748
S-5 ENGINE DOES NOT PICK UP SMOOTHLY .1750
S-6 ENGINE STOPS DURING OPERATION 1752
S-7 ENGINE RUNS ROUGH OR IS UNSTABLE .1754
S-8 ENGINE LACKS POWER .1755
S-9 EXHAUST SMOKE IS BLACK .1757
S-10 ENGINE OIL CONSUMPTION IS EXCESSIVE .1759
S-11 OIL BECOMES CONTAMINATED QUICKLY 1760
S-12 FUEL CONSUMPTION IS EXCESSIVE .1761
S-13 OIL IS IN COOLANT (OR COOLANT SPURTS BACK OR COOLANT LEVEL GOES DOWN) .1762
S-14 OIL PRESSURE DROPS 1763
S-15 FUEL MIXES INTO ENGINE OIL 1765
S-16 WATER MIXES INTO ENGINE OIL (MILKY) .1766
S-17 COOLANT TEMPERATURE RISES TOO HIGH (OVERHEATING) 1767
S-18 UNUSUAL NOISE IS HEARD 1768
S-19 VIBRATION IS EXCESSIVE 1769
S-20 AIR CANNOT BE BLED FROM FUEL CIRCUIT 1770
S-21 ACTIVE REGENERATION IS EXECUTED FREQUENTLY 1771
S-22 ACTIVE REGENERATION TAKES TIME 1772
S-23 WHITE SMOKE IS EXHAUSTED DURING ACTIVE REGENERATION .1773
S-24 AdBlue/DEF CONSUMPTION IS EXCESSIVE .1774
S-25 THERE IS UNUSUAL SMELL (IRRITATING ODOR) 1776
S-26 FOREIGN MATERIALS ENTER AdBlue/DEF (AdBlue/DEF INCREASES) .1777
60 MAINTENANCE STANDARD 1779
CONTENTS .1780
ABBREVIATION LIST 1781
ENGINE AND COOLING SYSTEM 1786
MAINTENANCE STANDARD OF ENGINE MOUNT .1786
MAINTENANCE STANDARD OF DAMPER .1787
MAINTENANCE STANDARD OF COOLING SYSTEM .1788
MAINTENANCE STANDARD OF COOLING FAN MOTOR 1790
MAINTENANCE STANDARD OF HYDRAULIC OIL COOLER BYPASS AND HST CHARGE SAFETY VALVE 1792
POWER TRAIN 1793
MAINTENANCE STANDARD OF HST PUMP .1793
MAINTENANCE STANDARD OF EPC VALVE OF HST PUMP 1795
MAINTENANCE STANDARD OF TOW RECEIVING VALVE OF HST PUMP 1796
MAINTENANCE STANDARD OF HST CHARGE PUMP 1797
MAINTENANCE STANDARD OF HST MOTOR 1799
MAINTENANCE STANDARD OF FINAL DRIVE 1801
MAINTENANCE STANDARD OF SPROCKET FOR PLUS TYPE TRACK SHOE 1803
MAINTENANCE STANDARD OF SPROCKET TOOTH PROFILE FULL-SCALE DRAWING FOR PLUS TYPE TRACK SHOE .1804
UNDERCARRIAGE AND FRAME 1805
MAINTENANCE STANDARD OF SUSPENSION .1805
MAINTENANCE STANDARD OF TRACK FRAME AND IDLER CUSHION 1808
MAINTENANCE STANDARD OF IDLER 1811
MAINTENANCE STANDARD OF TRACK ROLLER FOR PLUS TYPE TRACK SHOES (SINGLE FLANGE TYPE) 1813
MAINTENANCE STANDARD OF TRACK ROLLER FOR PLUS TYPE TRACK SHOES (DOUBLE FLANGE TYPE) 1814
MAINTENANCE STANDARD OF CARRIER ROLLER FOR PLUS TYPE TRACK SHOE 1816
MAINTENANCE STANDARD OF PLUS TYPE TRACK SHOE .1817
MAINTENANCE STANDARD OF SINGLE SHOE 1819
HYDRAULIC SYSTEM .1820
MAINTENANCE STANDARD OF HYDRAULIC TANK .1820
MAINTENANCE STANDARD OF WORK EQUIPMENT AND COOLING FAN PUMP 1821
MAINTENANCE STANDARD OF SERVO VALVE OF WORK EQUIPMENT AND COOLING FAN PUMP .1822
MAINTENANCE STANDARD OF CONTROL VALVE 1824
MAINTENANCE STANDARD OF RIPPER PPC VALVE .1830
MAINTENANCE STANDARD OF 5-PORT VALVE OF EPC AND SOLENOID .1832
MAINTENANCE STANDARD OF EPC VALVE 1833
MAINTENANCE STANDARD OF QUICK DROP VALVE .1834
WORK EQUIPMENT .1836
MAINTENANCE STANDARD OF FRONT WORK EQUIPMENT .1836
MAINTENANCE STANDARD OF CUTTING EDGE AND END BIT .1839
MAINTENANCE STANDARD OF BLADE LIFT CYLINDER 1840
MAINTENANCE STANDARD OF BLADE TILT CYLINDER 1841
MAINTENANCE STANDARD OF BLADE ANGLE CYLINDER .1842
MAINTENANCE STANDARD OF FIXED MULTI-SHANK RIPPER .1843
MAINTENANCE STANDARD OF RIPPER LIFT CYLINDER .1845
CAB AND ITS ATTACHMENTS 1846
MAINTENANCE STANDARD OF CAB MOUNT 1846
ELECTRICAL SYSTEM 1848
MAINTENANCE STANDARD OF ELECTRIC STEERING CONTROL LEVER 1848
80 APPENDIX 1849
CONTENTS .1850
ABBREVIATION LIST 1851
AIR CONDITIONER SYSTEM .1856
PRECAUTIONS FOR REFRIGERANT 1856
AIR CONDITIONER COMPONENT 1857
SPECIFICATIONS OF AIR CONDITIONER 1860
CONFIGURATION AND FUNCTION OF REFRIGERATION CYCLE 1861
OUTLINE OF REFRIGERATION CYCLE .1862
COMPONENT PARTS OF AIR CONDITIONER SYSTEM 1864
AIR CONDITIONER UNIT .1864
CONFIGURATION DIAGRAM OF AIR CONDITIONER UNIT 1864
FUNCTION OF AIR CONDITIONER UNIT .1865
COMPONENT PARTS OF AIR CONDITIONER UNIT 1866
FUNCTION OF EVAPORATOR AS AIR CONDITIONER UNIT COMPONENT .1866
FUNCTION OF HEATER CORE AS AIR CONDITIONER UNIT COMPONENT 1866
FUNCTION OF THERMISTOR AS AIR CONDITIONER UNIT COMPONENT .1866
STRUCTURE OF EXPANSION VALVE AS AIR CONDITIONER UNIT COMPONENT .1866
FUNCTION OF EXPANSION VALVE AS AIR CONDITIONER UNIT COMPONENT 1867
OPERATE EXPANSION VALVE AS AIR CONDITIONER UNIT COMPONENT 1867
FUNCTION OF DUAL PRESSURE SWITCH .1868
FUNCTION OF PRESSURE SWITCH 1868
COMPRESSOR .1869
STRUCTURE OF COMPRESSOR 1869
SPECIFICATIONS OF COMPRESSOR .1869
FUNCTION OF COMPRESSOR .1869
CONDENSER 1870
STRUCTURE OF CONDENSER .1870
SPECIFICATIONS OF CONDENSER 1870
FUNCTION OF CONDENSER 1871
RECEIVER DRIER .1872
STRUCTURE OF RECEIVER DRIER 1872
SPECIFICATIONS OF RECEIVER DRIER .1872
FUNCTION OF RECEIVER DRIER .1872
EXPLANATION OF PROCEDURE FOR TESTING AND TROUBLESHOOTING OF AIR CONDITIONER 1874
CIRCUIT DIAGRAM OF AIR CONDITIONER .1877
AIR CONDITIONER SYSTEM DIAGRAM .1878
CONTROL FUNCTION OF AIR CONDITIONER 1879
INSTALLATION LOCATIONS OF AIR CONDITIONER PARTS AND ARRANGEMENT OF CONNECTORS 1880
TEST RELAYS 1884
METHOD FOR TESTING RELAYS 1884
AIR CONDITIONER TROUBLESHOOTING CHART 1 1886
AIR CONDITIONER TROUBLESHOOTING CHART 2 1887
INFORMATION DESCRIBED IN TROUBLESHOOTING TABLE .1890
A-1 TROUBLESHOOTING FOR CONDENSER FAN 1892
A-2 TROUBLESHOOTING FOR BLOWER MOTOR SYSTEM (NO AIR COMES OUT OR AIR FLOW IS ABNORMAL) .1895
A-3 TROUBLESHOOTING FOR TEMPERATURE CONTROL FUNCTION .1898
TROUBLESHOOTING USING GAUGE PRESSURE .1902
CONNECTION OF SERVICE TOOL .1904
METHOD FOR CONNECTING SERVICE TOOL .1905
PRECAUTIONS FOR DISCONNECTING AND CONNECTING HOSES AND TUBES IN AIR CONDITIONER PIPINGS 1906
HANDLE COMPRESSOR OIL 1908
90 CIRCUIT DIAGRAMS 1911
CONTENTS .1912
ABBREVIATION LIST 1913
HYDRAULIC CIRCUIT DIAGRAM 1918
SYMBOLS USED IN HYDRAULIC CIRCUIT DIAGRAM 1918
ELECTRICAL CIRCUIT DIAGRAM .1925
SYMBOLS USED IN ELECTRICAL CIRCUIT DIAGRAM .1925
INDEX 1957
Blank Page . 2

DESCRIPTION:

Komatsu D51EX-24 ,D51PX-24 CRAWLER DOZER Shop Manual KEBM661701 –  PDF DOWNLOAD

SERIAL NUMBERS

• D51EX-24 B20001 and up
  D51PX-24 B20001 and up
  ENGINE 4D107E-3

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

G.B 22/ 12/24