Komatsu D51EXi-24,D51PXi-24 Bulldozer Shop Manual SEN06850-08 PDF

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Komatsu D51EXi-24,D51PXi-24 Bulldozer Shop Manual SEN06850-08 –  PDF DOWNLOAD

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Komatsu D51EXi-24,D51PXi-24 Bulldozer Shop Manual SEN06850-08 –  PDF DOWNLOAD

Language : English
Pages : 3202
Downloadable : Yes
File Type : PDF

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TABLE OF CONTENTS:

Komatsu D51EXi-24,D51PXi-24 Bulldozer Shop Manual SEN06850-08 –  PDF DOWNLOAD

• D51EXi-15001 and up
• D51PXi-15001 and up

Cover 1
00 Index and Foreword . 3
Index . 4
Foreword, Safety, Basic Information . 23
How to Read the Shop Manual . 23
Safety Notice for Operation . 25
Precautions to Prevent Fire . 33
Procedures If Fire Occurs . 35
Precautions for Disposing of Waste Materials 36
Procedures for Exhaust Gas Regulations 37
Precautions for DEF . 38
General Character and Precautions for Handling 38
Precautions for Adding 38
Precautions for Storage . 38
Precautions for Fire Hazard and Leakage . 38
Other Precautions . 38
Store DEF . 39
Precautions When You Handle Hydraulic Equipment . 40
Precautions When You Disconnect and Connect Pipings . 43
Precautions When You Handle Electrical Equipment 50
Precautions When You Handle Fuel System Equipment . 52
Precautions When You Handle Intake System Equipment . 53
Practical Use of KOMTRAX 54
Disconnect and Connect Push-Pull Type Coupler . 55
How to Disconnect and Connect Type 1 Push-Pull Type Coupler . 55
How to Disconnect and Connect Type 2 Push-Pull Type Coupler . 56
How to Disconnect and Connect Type 3 Push-Pull Type Coupler . 57
Precautions for Disconnection and Connection of Connectors 59
How to Disconnect and Connect Deutsch Connector . 63
How to Disconnect and Connect Slide Lock Type Connector . 64
How to Disconnect and Connect Connector with Lock to Pull . 66
How to Disconnect and Connect Connector with Lock to Push . 67
How to Disconnect and Connect Connector with Housing to Rotate 69
How to Read the Codes for Electric Cable 70
Explanation of Terms for Maintenance Standard . 74
Standard Tightening Torque Table 77
Conversion Table 84
Abbreviation List . 89
01 Specifications . 93
Table of Contents . 94
Specifications 95
Specification Drawing . 95
Specification Drawing: D51EXI-24 95
Specification Drawing: D51PXI-24 97
Specifications 99
Specifications: D51EXI-24 . 99
Specifications: D51PXI-24 . 105
Weight Table 110
Weight Table: D51EXI-24 . 110
Weight Table: D51PXI-24 . 112
Fuel, Coolant, Lubricant 114
How to Use Fuel, Coolant and Lubricants by Ambient Temperature 114
10 Structure and Function . 117
Table of Contents . 118
Urea SCR System . 122
Layout Drawing of Urea SCR System . 122
Urea SCR System Diagram . 124
Function of Urea SCR System . 125
Function of DEF System 125
Inducement Strategy . 128
Component Parts of Urea SCR System 142
DEF Mixing Tube . 142
SCR Assembly 143
DEF Tank 145
DEF Pump 147
DEF Injector 148
DEF Hose 149
DEF Tank Heating Valve 150
Boot-up System 151
Layout Drawing of Boot-up System 151
System Operating Lamp System 152
System Diagram of System Operating Lamp System 152
Function of Operation Lamp System . 152
Battery Disconnect Switch . 154
Function of Battery Disconnect Switch . 154
Engine System . 155
Layout Drawing of Engine System . 155
Engine Control System . 157
Layout Drawing of Engine Control System . 157
System Diagram of Engine Control 159
Function of Engine Control System . 161
Automatic Idle Stop System 163
System Diagram of Automatic Idle Stop System 163
Function of Automatic Idle Stop System 163
Component Parts of Engine System 166
Damper 166
VGT . 168
EGR System 171
EGR Valve . 173
EGR Cooler 175
KCCV System . 177
KCCV Ventilator . 179
KDOC 181
Cooling System 184
Layout Drawing of Cooling System 184
Specifications of Cooling System 185
Cooling Fan Control System 186
System Diagram of Cooling Fan Control System 186
Function of Cooling Fan Control System 187
Component Parts of Cooling System . 189
Cooling Fan Motor . 189
Hydraulic Oil Cooler Bypass and HST Charge Safety Valve . 194
Hydraulic Oil Cooler Bypass Valve . 195
HST Charge Safety Valve . 196
Control System 198
Layout Drawing of Control System 198
Machine Monitor System 199
System Diagram of Machine Monitor System 199
Function of Machine Monitor System 199
KOMTRAX System 200
System Diagram of KOMTRAX System 200
Function of KOMTRAX System 200
Component Parts of Control System . 201
Machine Monitor . 201
Gateway Function Controller . 218
Communication Terminal 221
HST Controller 223
Engine Controller . 227
Fuel Control Dial . 234
Decelerator and Brake Potentiometer . 236
Hydraulic System 238
Layout Drawing of Hydraulic System 238
CLSS 239
Structure of CLSS . 239
Function of CLSS 240
Component Parts of Hydraulic System . 242
Hydraulic Tank 242
Work Equipment and Cooling Fan Pump . 244
LS Valve 252
PC Valve 253
Control Valve . 256
Power Train System 274
Layout Drawing of HST System 274
Operation of HST System . 275
Steering and Brake Control System . 277
Layout Drawing of Steering and Brake Control System . 277
Function of Steering and Brake Control System . 277
HST Control System 279
System Diagram of HST Control System 279
Gear Shift Control Function . 280
Engine Low Speed Matching Control Function 283
HST Pump and Motor Sequence Control Function 284
Deceleration and Brake Control Function . 285
Gear Shift Control Function by Load . 287
Turn Control Function . 287
Straight Travel Correction Control Function . 288
Parking Brake Control System 290
System Diagram of Parking Brake Control System 290
Function of Parking Brake Control System 291
Operation of Parking Brake Control System . 292
Component Parts of Power Train System . 293
HST Pump 293
HST Charge Pump . 308
HST Motor . 309
Final Drive . 322
Electric Steering Electric Lever 326
Work Equipment System . 329
Work Equipment Control 329
Layout Drawing of Work Equipment Control 329
Function of Work Equipment Control 330
Layout Drawing of Front Work Equipment 331
Layout Drawing of Fixed Multi-Shank Ripper 332
Component Parts of Work Equipment System 333
Ripper PPC Valve 333
5-Spool EPC and Solenoid Valve 337
Pilot Circuit Accumulator . 343
Quick Drop Valve 344
Piston Valve 346
Electric Blade Control Lever 347
ICT System 349
Layout Drawing of ICT System 349
System Diagram of ICT Control System 351
Blade Control System 353
Function of Blade Control System 353
Simple Grading Mode System Diagram 355
Function of Simple Grading Mode . 356
Operation of Simple Grading Mode 356
Assist Control System . 358
Assist Control System Diagram . 358
Function of Assist Control System . 358
Operation of Assist Control System 359
Back Grade Mode System 360
Back Grade Mode System Diagram 360
Function of Back Grade Mode System 361
Operation of Back Grade Mode System . 361
Cut Control System 362
Cut Control System Diagram 362
Function of Cut Control System 363
Operation of Cut Control System . 363
Smooth Start System . 375
Smooth Start System Diagram . 375
Function of Smooth Start System . 376
Operation of Smooth Start System 376
Slip Control System . 377
Slip Control System Diagram . 377
Function of Slip Control System . 378
Operation of Slip Control System 378
Speed Control System 379
Speed Control System Diagram 379
Function of Speed Control System 379
Operation of Speed Control System . 379
Straight Travel Correction System . 381
Straight Travel Correction System Diagram . 381
Function of Straight Travel Correction System . 382
Operation of Straight Travel Correction System 382
Quick Surface Control System 385
Quick Surface Control System Diagram 385
Function of Quick Surface Control System 385
Operation of Quick Surface Control System . 386
System of Triangulated Surface from AS-BUILT 387
System Diagram of Triangulated Surface from AS-BUILT 387
Function of System of Triangulated Surface from AS-BUILT 387
Operation of System of Triangulated Surface from AS-BUILT . 387
2 Surfaces Selection Control System . 389
2 Surfaces Selection Control System Diagram . 389
Function of 2 Surfaces Selection Control System . 390
Operation of 2 Surfaces Selection Control System 390
Lift Layer Control System . 391
Lift Layer Control System Diagram . 391
Function of Lift Layer Control System . 392
Operation of Lift Layer Control System 392
2D Laser Machine Control System . 394
System Diagram of 2D Laser Machine Control System . 394
Function of 2D Laser Machine Control System . 395
Operation of 2D Laser Machine Control System 395
Component Parts of ICT System . 396
ICT Sensor Controller . 396
Control Box . 400
GNSS Receiver . 402
GNSS Antenna 404
IMU Sensor 405
GNSS External Radio Device 408
Navigation Controller . 410
Stroke and Reset Sensor for Blade Lift Cylinder . 415
Stroke Sensor for Blade Tilt Cylinder . 418
Stroke Sensor for Blade Angle Cylinder 420
Undercarriage and Frame . 422
Main Frame 422
Structure of Main Frame . 422
Suspension 423
Structure of Suspension . 423
Specifications of Suspension 424
Function of Suspension 425
Track Frame and Idler Cushion . 426
Structure of Track Frame and Idler Cushion 426
Function of Track Frame and Idler Cushion . 427
Work Equipment 428
Structure of Front Work Equipment (Serial No.: 15001 to 15600) 428
Structure of Front Work Equipment (Serial No.: 15601 and up) 429
Structure of Fixed Multi-Shank Ripper . 430
CAB Related Parts . 431
ROPS CAB 431
Structure of ROPS CAB . 431
Function of ROPS CAB 432
CAB Mount . 433
Structure of CAB Mount 433
Function of CAB Mount . 433
20 Standard Value Table . 435
Table of Contents . 436
Standard Value Table for Engine . 437
Standard Value Table for Engine: D51EXI-24 437
Standard Value Table for Engine: D51PXI-24 441
Standard Value Table for Machine 445
Standard Value Table for Machine: D51EXI-24 . 445
Standard Value Table for Machine: D51PXI-24 . 462
Machine Posture and Procedures to Measure Performance . 477
30 Testing and Adjusting 479
Table of Contents . 480
Precautions Before Work . 484
Related Information on Testing and Adjusting 485
Differences In Machine Monitor Symbols 485
Tools for Testing and Adjusting . 486
Sketch of Tools for Testing and Adjusting . 494
Engine and Cooling System . 499
Examine Engine Speed 499
How to Examine Engine Speed . 499
Examine Boost Pressure 501
How to Examine Boost Pressure . 501
Examine Exhaust Gas Color . 502
How to Examine Exhaust Gas Color with the Handy Smoke Checker . 502
How to Examine Exhaust Gas Color with Smoke Meter . 503
Examine and Adjust Valve Clearance 504
How to Examine Valve Clearance 504
How to Adjust Valve Clearance . 505
Examine Compression Pressure 506
How to Examine Compression Pressure . 506
Examine Blowby Pressure . 511
How to Examine Blowby Pressure 511
Examine Engine Oil Pressure . 513
How to Examine Engine Oil Pressure 513
Visual Check Inside of EGR Valve 514
How to do the Visual Check Inside of EGR Valve 514
Clean Inside of EGR Valve . 516
How to Clean Inside of EGR Valve 516
Examine Fuel Pressure . 519
How to Examine Fuel Pressure 520
Examine Fuel Discharge, Return and Leakage 524
How to Examine Fuel Discharge, Return, and Leakage 525
Bleed Air from Fuel System 530
How to Bleed Air from Fuel System . 530
Examine Fuel Circuit for Leakage 531
How to Examine Fuel System for Leakage 531
Handle Cylinder Cut-out Mode Operation 533
Handle No-Injection Cranking Operation 534
Examine and Adjust Air Conditioner Compressor Belt Tension 535
Examine and Adjust Air Conditioner Compressor Belt Tension 535
How to Adjust Air Conditioner Compressor Belt Tension . 536
Examine KDOC, SCR and Muffler Stack for Looseness and Damage 537
How to Examine KDOC, SCR and Muffler Stack for Looseness and Damage . 537
Examine Installed Condition of Cylinder Heads and Manifolds . 538
How to Examine Installed Condition of Cylinder Heads and Manifolds 538
Examine Engine Piping for Damage and Looseness 539
How to Examine Engine Piping for Damage and Looseness . 539
Write Correction for Ash in Soot Accumulation to Engine Controller 540
How to Write Correction for Ash in Soot Accumulation to Engine Controller . 540
Examine SCR Related Functions . 541
Examine DEF Pump Raised Pressure 545
Examine Injection Volume from DEF Injector 548
Examine DEF Line Heater Relay 1 . 552
Examine DEF Line Heater Relay 2 . 555
Examine DEF Pump Heater Relay . 558
Examine DEF Tank Heater Valve . 562
Examine SCR Denitration Efficiency 566
Clean DEF Tank 569
How to Clean DEF Tank . 569
Clean DEF Tank Mounting Part 573
How to Clean DEF Tank Mounting Part . 573
Clean DEF Pump 574
How to Clean DEF Pump . 574
Power Train . 580
Examine and Adjust HST Oil Pressure . 580
How to Examine HST Oil Pressure . 580
How to Adjust HST Oil Pressure 582
Bleed Air from HST Pump . 585
How to Bleed Air from HST Pump 585
How to Bleed Air from Servo Valve of HST Pump . 585
Examine Outlet Pressure of Solenoid Valve . 587
How to Examine Outlet Pressure of Solenoid Valve 587
Examine Travel Deviation 591
How to Examine Travel Deviation . 591
Examine Brake Performance Simply 593
How to Examine Brake Performance Simply . 593
Examine and Adjust Deceleration/Brake Pedal . 594
How to Examine Deceleration/Brake Pedal . 594
How to Adjust Deceleration/Brake Pedal 596
Adjust Parking Brake Lever 598
How to Adjust Parking Brake Lever . 598
Move Machine When It Cannot Travel 600
How to Move Machine with Hydraulic Type Parking Brake Release System 600
How to Move Machine After You Remove Final Drive Shaft 602
Undercarriage and Frame . 603
Examine and Adjust Idler Clearance 603
How to Adjust Idler Clearance Horizontally 603
How to Adjust Idler Clearance Vertically 603
Examine Sprocket Wear . 605
How to Examine Sprocket Wear 605
Examine and Adjust Track Tension 606
How to Examine Track Tension 606
How to Adjust Track Tension . 606
Hydraulic System 608
Release Remained Pressure in Hydraulic Circuit 608
How to Release Remained Pressure in Hydraulic System 608
Examine and Adjust Work Equipment Circuit Oil Pressure 609
How to Examine Work Equipment Circuit Oil Pressure 609
How to Adjust Work Equipment Circuit Oil Pressure . 610
Examine and Adjust Oil Pressure in Control Circuit 612
How to Examine Oil Pressure in Control Circuit 612
How to Adjust Oil Pressure in Control Circuit . 613
Examine Outlet Pressure of EPC Solenoid Valve . 615
How to Examine Outlet Pressure of EPC Solenoid Valve 615
Bleed Air from Work Equipment, Cooling Fan Pump, and Charge Pump 617
How to Bleed Air from Work Equipment, Cooling Fan Pump, and Charge Pump . 617
Examine Cooling Fan Speed . 618
How to Examine Cooling Fan Speed 618
Examine Cooling Fan Circuit Oil Pressure 619
How to Examine Cooling Fan Circuit Oil Pressure . 619
Examine Parts Which Cause Hydraulic Drift of Work Equipment . 621
How to Examine Parts Which Cause Hydraulic Drift of Blade Lift Cylinder . 621
How to Examine the Parts Which Cause Hydraulic Drift of Blade Tilt Cylinder . 621
How to Examine the Parts Which Cause Hydraulic Drift of Ripper Lift Cylinder 622
Examine Oil Leakage from Work Equipment Cylinder 623
How to Examine Internal Oil Leakage of Work Equipment Cylinder 623
Bleed Air from Work Equipment Cylinders . 626
How to Bleed Air from Work Equipment Cylinder . 626
Work Equipment 627
Adjust Work Equipment Lock Lever 627
How to Adjust Work Equipment Lock Lever . 627
Examine and Adjust Play of Blade Electric Lever . 629
How to Examine Play of Blade Electric Lever . 631
How to Adjust Play of Blade Electric Lever 631
How to Replace Universal Joint 633
Electrical System . 639
Set and Operate Machine Monitor . 639
Operator Mode . 643
Function to Show Technician Identification Status Screen 643
Function to Show Operator Identification Input Screen . 643
Examine Function by LCD (Liquid Crystal Display) 644
Examine Function of Service Meter . 644
How to Set Usage Limitation and Change Maintenance Password . 644
Service Mode 647
How to Operate Service Mode . 647
How to See Pre-defined Monitoring Information . 648
How to Examine Self-Define Monitor Information 655
Abnormality Record Menu . 667
How to See Maintenance Record . 671
Maintenance Mode Setting 672
How to Set Phone Number Entry . 676
Default Menu 678
Diagnostic Tests Menu . 686
Adjustment Menu . 693
No-Injection Cranking Operation . 762
KOMTRAX Settings Menu . 764
How to Show Service Message . 766
How to Start Up KOMTRAX System 768
How to Stop Use of KOMTRAX System . 774
Adjust After Replacement of HST Controller 776
How to Adjust After Replacement of HST Controller . 776
Adjust After Replacement of Electric and Hydraulic Equipment 782
Adjust Rearview Camera Angle 784
How to Adjust Rearview Camera Angle . 784
Set Region of Bluetooth(R) Compatible Radio . 785
How to Set Region of Bluetooth(R) Compatible Radio 785
Handle Voltage Circuit of Engine Controller . 787
Handle Battery Disconnect Switch 788
Examine Diodes 789
How to Examine Diodes by Digital Tester . 789
How to Examine Diodes by Analog Tester 789
ICT System 790
Examine and Adjust ICT Related Devices 790
Set and Operate Control Box . 792
Machine Calibration . 793
Calibrate IMU Sensor 794
How to Operate Machine Calibration Step A . 800
How to Operate Machine Calibration Step B . 806
Calibrate GNSS Antenna (AUX) Location . 812
How to Operate Pitch Rod Calibration (Serial No.: 15001 to 15600) . 814
How to Operate Pitch Rod Calibration (Serial No.: 15601 and up) . 816
How to Input Wear Volume of Blade Edge and Track Shoes 818
Reset Cylinder Stroke End . 819
Reset Lift Cylinder Stroke End 819
Reset Tilt Cylinder Stroke End 820
Reset Angle Cylinder Stroke End . 820
How to Operate Manual Machine Calibration . 821
Examine and Adjust Blade Elevation 823
Examine Blade Elevation . 823
Adjust Blade Elevation 823
Examine Stroke Sensor for Lift Cylinder . 826
How to Examine Stroke Sensor for Lift Cylinder 826
Examine Stroke Sensor for Tilt Cylinder . 828
How to Examine Stroke Sensor for Tilt Cylinder 828
Examine Stroke Sensor for Angle Cylinder 830
How to Examine Stroke Sensor for Angle Cylinder . 830
Examine and Adjust Reset Sensor for Lift Cylinder . 832
How to Examine Reset Sensor for Lift Cylinder . 832
How to Adjust Reset Sensor for Lift Cylinder 832
Adjust When ICT Sensor Controller is Replaced . 833
How to Adjust When ICT Sensor Controller is Replaced 833
Adjust After Replacement of IMU Sensor 836
How to Adjust After Replacement of IMU Sensor . 836
How to Adjust When ICT Related Devices are Repaired or Replaced . 837
Pm Clinic . 840
Pm Clinic Service . 840
Pm Clinic Check Sheet: D51EXI-24 842
Pm Clinic Check Sheet: D51PXI-24 849
Pm Clinic Check Sheet for Undercarriage: D51EXI-24 856
Pm Clinic Check Sheet for Undercarriage: D51PXI-24 860
40 Troubleshooting 865
Table of Contents . 866
Precautions Before Work . 878
Related Information to Troubleshooting 879
General Troubleshooting Points 879
Troubleshooting Points for Urea SCR System 880
Sequence of Events in Troubleshooting . 892
Checks Before Troubleshooting . 894
Inspection Procedure Before Troubleshooting . 896
Walk-Around Check . 896
Test in Accordance with Testing Procedure . 898
Examine Fuel Level and Type . 898
Examine for Impure Ingredient in Fuel . 898
Examine DEF Level and Type 899
Examine Fuel Prefilter 899
Examine Fuel Main Filter 901
Examine Engine Oil Level (Oil Quantity in Oil Pan) and Type . 902
Examine Coolant Level (Reservoir Tank) 904
Examine Air Cleaner Clogging 904
Clean Outer Element . 905
Replace Element . 907
Examine Hydraulic Oil Level . 908
Examine Hydraulic Oil Strainer 909
Examine Oil Level in Final Drive Case . 912
Bleed Air from Fuel System 913
Bleed Air from Hydraulic System . 913
How to Examine Electric Equipment . 913
Preparation for Troubleshooting of Electrical System 920
Procedure for Troubleshooting . 927
Information Shown in Troubleshooting Table 930
How to Diagnose Open Circuit of Hydraulic Pressure Sensor System Wiring Harness . 932
Connector List and Layout . 935
Connector Contact Connection Table 953
T-Branch Box and T-Branch Adapter Table . 993
Fuse Location Table . 999
Precautions When You Replace KDOC .1003
Failure Code Table 1004
Troubleshooting by Failure Code (Display of Code) .1026
Failure Code [6091NX] .1026
Failure Code [989L00] .1028
Failure Code [989M00] .1029
Failure Code [989N00] .1030
Failure Code [A1U0N3] .1031
Failure Code [A1U0N4] .1033
Failure Code [A900FR] .1035
Failure Code [A900N6] .1036
Failure Code [A900NY] .1037
Failure Code [AA10NX] .1038
Failure Code [AB00KE] .1040
Failure Code [AQ10MB] .1042
Failure Code [AQ10N3] .1044
Failure Code [AS00R2] .1046
Failure Code [AS00R3] .1047
Failure Code [AS00R4] .1048
Failure Code [AS00R5] .1049
Failure Code [AS00R6] .1050
Failure Code [AS00ZK] .1051
Failure Code [AS10KM] .1052
Failure Code [AS10NR] .1053
Failure Code [AS10NT] .1054
Failure Code [B@BAZG] .1055
Failure Code [B@BCNS] .1056
Failure Code [B@BCQA] .1057
Failure Code [B@BCZK] .1059
Failure Code [B@CRNS] .1061
Failure Code [B@CRZG] .1062
Failure Code [CA115] 1063
Failure Code [CA122] 1064
Failure Code [CA123] 1066
Failure Code [CA131] 1068
Failure Code [CA132] 1070
Failure Code [CA144] 1072
Failure Code [CA145] 1074
Failure Code [CA153] 1076
Failure Code [CA154] 1078
Failure Code [CA187] 1080
Failure Code [CA221] 1082
Failure Code [CA222] 1084
Failure Code [CA227] 1086
Failure Code [CA234] 1088
Failure Code [CA238] 1089
Failure Code [CA239] 1090
Failure Code [CA249] 1091
Failure Code [CA256] 1093
Failure Code [CA271] 1095
Failure Code [CA272] 1097
Failure Code [CA295] 1099
Failure Code [CA322] 1100
Failure Code [CA324] 1102
Failure Code [CA331] 1104
Failure Code [CA332] 1106
Failure Code [CA343] 1108
Failure Code [CA351] 1109
Failure Code [CA352] 1110
Failure Code [CA356] 1112
Failure Code [CA357] 1114
Failure Code [CA386] 1116
Failure Code [CA428] 1117
Failure Code [CA429] 1119
Failure Code [CA435] 1121
Failure Code [CA441] 1123
Failure Code [CA442] 1125
Failure Code [CA451] 1126
Failure Code [CA452] 1128
Failure Code [CA488] 1130
Failure Code [CA515] 1131
Failure Code [CA516] 1133
Failure Code [CA553] 1135
Failure Code [CA555] 1136
Failure Code [CA556] 1137
Failure Code [CA559] 1138
Failure Code [CA595] 1141
Failure Code [CA687] 1143
Failure Code [CA689] 1145
Failure Code [CA691] 1148
Failure Code [CA692] 1150
Failure Code [CA697] 1152
Failure Code [CA698] 1153
Failure Code [CA731] 1154
Failure Code [CA778] 1156
Failure Code [CA1117] .1161
Failure Code [CA1664] .1163
Failure Code [CA1669] .1165
Failure Code [CA1673] .1166
Failure Code [CA1677] .1167
Failure Code [CA1678] .1168
Failure Code [CA1682] .1169
Failure Code [CA1683] .1171
Failure Code [CA1684] .1173
Failure Code [CA1686] .1175
Failure Code [CA1691] .1176
Failure Code [CA1694] .1178
Failure Code [CA1695] .1180
Failure Code [CA1696] .1181
Failure Code [CA1712] .1183
Failure Code [CA1713] .1186
Failure Code [CA1714] .1188
Failure Code [CA1715] .1189
Failure Code [CA1776] .1190
Failure Code [CA1777] .1193
Failure Code [CA1843] .1196
Failure Code [CA1844] .1198
Failure Code [CA1885] .1201
Failure Code [CA1887] .1203
Failure Code [CA1896] .1205
Failure Code [CA1898] .1209
Failure Code [CA1938] .1211
Failure Code [CA1942] .1213
Failure Code [CA1961] .1214
Failure Code [CA1962] .1215
Failure Code [CA2185] .1216
Failure Code [CA2186] .1218
Failure Code [CA2198] .1220
Failure Code [CA2272] .1222
Failure Code [CA2288] .1224
Failure Code [CA2311] .1225
Failure Code [CA2349] .1226
Failure Code [CA2353] .1228
Failure Code [CA2357] .1230
Failure Code [CA2373] .1231
Failure Code [CA2374] .1233
Failure Code [CA2375] .1235
Failure Code [CA2376] .1237
Failure Code [CA2387] .1240
Failure Code [CA2554] .1241
Failure Code [CA2555] .1243
Failure Code [CA2556] .1246
Failure Code [CA2634] .1249
Failure Code [CA2635] .1251
Failure Code [CA2636] .1252
Failure Code [CA2637] .1254
Failure Code [CA2771] .1256
Failure Code [CA2961] .1260
Failure Code [CA2973] .1261
Failure Code [CA2976] .1262
Failure Code [CA3142] .1264
Failure Code [CA3143] .1265
Failure Code [CA3144] .1266
Failure Code [CA3146] .1268
Failure Code [CA3147] .1269
Failure Code [CA3148] .1270
Failure Code [CA3151] .1272
Failure Code [CA3165] .1277
Failure Code [CA3228] .1279
Failure Code [CA3229] .1281
Failure Code [CA3231] .1283
Failure Code [CA3232] .1285
Failure Code [CA3235] .1289
Failure Code [CA3239] .1291
Failure Code [CA3241] .1294
Failure Code [CA3242] .1297
Failure Code [CA3251] .1300
Failure Code [CA3313] .1302
Failure Code [CA3314] .1303
Failure Code [CA3315] .1304
Failure Code [CA3419] .1306
Failure Code [CA3421] .1308
Failure Code [CA3497] .1310
Failure Code [CA3498] .1311
Failure Code [CA3545] .1312
Failure Code [CA3547] .1314
Failure Code [CA3558] .1315
Failure Code [CA3559] .1317
Failure Code [CA3562] .1319
Failure Code [CA3563] .1321
Failure Code [CA3567] .1324
Failure Code [CA3568] .1328
Failure Code [CA3571] .1332
Failure Code [CA3572] .1334
Failure Code [CA3574] .1336
Failure Code [CA3575] .1338
Failure Code [CA3577] .1340
Failure Code [CA3578] .1342
Failure Code [CA3582] .1344
Failure Code [CA3583] .1349
Failure Code [CA3596] .1351
Failure Code [CA3649] .1354
Failure Code [CA3681] .1356
Failure Code [CA3682] .1361
Failure Code [CA3713] .1366
Failure Code [CA3717] .1369
Failure Code [CA3718] .1370
Failure Code [CA3724] .1371
Failure Code [CA3725] .1372
Failure Code [CA3741] .1375
Failure Code [CA3748] .1376
Failure Code [CA3755] .1378
Failure Code [CA3866] .1380
Failure Code [CA3868] .1383
Failure Code [CA4152] .1387
Failure Code [CA4155] .1391
Failure Code [CA4156] .1394
Failure Code [CA4157] .1397
Failure Code [CA4159] .1399
Failure Code [CA4164] .1400
Failure Code [CA4165] .1402
Failure Code [CA4166] .1404
Failure Code [CA4168] .1405
Failure Code [CA4169] .1408
Failure Code [CA4171] .1410
Failure Code [CA4249] .1412
Failure Code [CA4251] .1414
Failure Code [CA4261] .1416
Failure Code [CA4277] .1419
Failure Code [CA4459] .1423
Failure Code [CA4461] .1425
Failure Code [CA4533] .1428
Failure Code [CA4534] .1429
Failure Code [CA4731] .1430
Failure Code [CA4732] .1431
Failure Code [CA4739] .1432
Failure Code [CA4768] .1433
Failure Code [CA4769] .1435
Failure Code [CA4842] .1437
Failure Code [CA4952] .1440
Failure Code [CA5115] .1442
Failure Code [CA5179] .1445
Failure Code [CA5181] .1447
Failure Code [CA5387] .1449
Failure Code [CA5388] .1451
Failure Code [CA5389] .1454
Failure Code [CA5391] .1456
Failure Code [CA5392] .1460
Failure Code [CA5393] .1462
Failure Code [CA5394] .1465
Failure Code [CA5395] .1468
Failure Code [CA5396] .1471
Failure Code [CA5631] .1472
Failure Code [CA5632] .1474
Failure Code [CA5938] .1475
Failure Code [D130KA] .1477
Failure Code [D130KB] .1480
Failure Code [D130KY] .1482
Failure Code [D19DKA] .1484
Failure Code [D19DKB] .1486
Failure Code [D19DKY] .1488
Failure Code [D19JKZ] .1491
Failure Code [D811MC] .1494
Failure Code [D862KA] .1495
Failure Code [D8ALKA] .1496
Failure Code [D8ALKB] .1500
Failure Code [D8AQKR] .1503
Failure Code [D8G1KT] .1505
Failure Code [D8G6KT] .1506
Failure Code [DAF0MB] .1507
Failure Code [DAF0MC] .1508
Failure Code [DAF8KB] .1509
Failure Code [DAF9KQ] .1511
Failure Code [DAFGMC] .1512
Failure Code [DAFLKA] .1513
Failure Code [DAFLKB] .1515
Failure Code [DAFQKR] .1517
Failure Code [DAJ000] .1518
Failure Code [DAJ0KQ] .1519
Failure Code [DAJ0KT] .1520
Failure Code [DAJ0MC] .1521
Failure Code [DAJ1KK] .1522
Failure Code [DAJ2KK] .1524
Failure Code [DAJ5KK] .1526
Failure Code [DAJ6KK] .1529
Failure Code [DAJLKA] .1531
Failure Code [DAJLKB] .1533
Failure Code [DAJPMA] .1535
Failure Code [DAJQKR] .1536
Failure Code [DAJRKR] .1537
Failure Code [DB2QKR] .1538
Failure Code [DB2RKR] .1545
Failure Code [DBR0KT] .1550
Failure Code [DBR0MC] .1551
Failure Code [DBR1KK] .1552
Failure Code [DBR2KK] .1555
Failure Code [DBR5KK] .1558
Failure Code [DBRLKA] .1560
Failure Code [DBRLKB] .1562
Failure Code [DBRPMA] .1564
Failure Code [DBRQKR] .1565
Failure Code [DBRRKR] .1567
Failure Code [DBU0KR] .1568
Failure Code [DBUSKR] .1569
Failure Code [DBUTKA] .1574
Failure Code [DBUTKN] .1576
Failure Code [DBUTMA] .1578
Failure Code [DBUUKA] .1579
Failure Code [DBUUKN] .1581
Failure Code [DD12KA] .1583
Failure Code [DD12KB] .1585
Failure Code [DD13KA] .1587
Failure Code [DD13KB] .1589
Failure Code [DD14KA] .1591
Failure Code [DD14KB] .1593
Failure Code [DDKAKA] .1595
Failure Code [DDKAKB] .1597
Failure Code [DDKFL4] .1599
Failure Code [DDKGL4] .1601
Failure Code [DDKHKA] .1603
Failure Code [DDKHKB] .1605
Failure Code [DDKQKA] .1607
Failure Code [DDKQKB] .1609
Failure Code [DDKRKA] .1611
Failure Code [DDKRKB] .1613
Failure Code [DDKSKA] .1615
Failure Code [DDKSKB] .1617
Failure Code [DDNLKA] .1619
Failure Code [DDNLKB] .1621
Failure Code [DDP6KA] .1623
Failure Code [DDP6KB] .1626
Failure Code [DDP6MA] .1628
Failure Code [DDU1FS] .1630
Failure Code [DDU1KA] .1632
Failure Code [DDU1KY] .1635
Failure Code [DFA4KX] .1637
Failure Code [DFA4KZ] .1638
Failure Code [DFA4L8] .1639
Failure Code [DFA5KA] .1640
Failure Code [DFA5KB] .1643
Failure Code [DFA6KA] .1646
Failure Code [DFA6KB] .1649
Failure Code [DFA7KX] .1652
Failure Code [DFA7KZ] .1653
Failure Code [DFA7L8] .1654
Failure Code [DFA8KA] .1655
Failure Code [DFA8KB] .1658
Failure Code [DFA9KA] .1661
Failure Code [DFA9KB] .1664
Failure Code [DGS1KA] .1667
Failure Code [DGS1KX] .1670
Failure Code [DH21KA] .1671
Failure Code [DH21KB] .1673
Failure Code [DHA4KA] .1675
Failure Code [DHH7KA] .1677
Failure Code [DHH7KB] .1680
Failure Code [DHH8KA] .1682
Failure Code [DHH8KB] .1685
Failure Code [DHH9KA] .1687
Failure Code [DHH9KB] .1690
Failure Code [DHHAKA] .1692
Failure Code [DHHAKB] .1695
Failure Code [DHRUKA] .1697
Failure Code [DHRUKB] .1699
Failure Code [DHRVKA] .1701
Failure Code [DHRVKB] .1703
Failure Code [DK30KA] .1705
Failure Code [DK30KB] .1708
Failure Code [DK30KX] .1710
Failure Code [DK30KZ] .1711
Failure Code [DK30L8] .1712
Failure Code [DK31KA] .1713
Failure Code [DK31KB] .1716
Failure Code [DK40KA] .1718
Failure Code [DK40KB] .1721
Failure Code [DK55KX] .1723
Failure Code [DK55KZ] .1724
Failure Code [DK55L8] .1725
Failure Code [DK56KA] .1726
Failure Code [DK56KB] .1729
Failure Code [DK57KA] .1731
Failure Code [DK57KB] .1734
Failure Code [DK80KA] .1736
Failure Code [DK80KR] .1739
Failure Code [DK80KT] .1744
Failure Code [DKS0L8] .1747
Failure Code [DKS1KA] .1748
Failure Code [DKS1KB] .1750
Failure Code [DKS2KA] .1752
Failure Code [DKS2KB] .1754
Failure Code [DKS3KA] .1756
Failure Code [DKS3KB] .1758
Failure Code [DKS3MB] .1760
Failure Code [DKS4L8] .1762
Failure Code [DKS5KA] .1763
Failure Code [DKS5KB] .1765
Failure Code [DKS6KA] .1767
Failure Code [DKS6KB] .1769
Failure Code [DKS7MB] .1771
Failure Code [DKSCL8] .1772
Failure Code [DKSDKA] .1773
Failure Code [DKSDKB] .1775
Failure Code [DKSEKA] .1777
Failure Code [DKSEKB] .1779
Failure Code [DKSFKA] .1781
Failure Code [DKSFKB] .1783
Failure Code [DKSFMB] .1784
Failure Code [DLM0KX] .1785
Failure Code [DLM0MA] .1786
Failure Code [DLM1KA] .1787
Failure Code [DLM1KB] .1789
Failure Code [DLM1MA] .1791
Failure Code [DLM2KA] .1792
Failure Code [DLM2KB] .1794
Failure Code [DLM2MA] .1796
Failure Code [DLM3KA] .1797
Failure Code [DLM3KB] .1799
Failure Code [DLM3MB] .1801
Failure Code [DN21FS] .1802
Failure Code [DR21KX] .1804
Failure Code [DR31KX] .1805
Failure Code [DV20KB] .1806
Failure Code [DW4BKA] .1808
Failure Code [DW4BKB] .1810
Failure Code [DW4BKY] .1812
Failure Code [DW7BKA] .1814
Failure Code [DW7BKB] .1816
Failure Code [DW7EKA] .1818
Failure Code [DW7EKB] .1820
Failure Code [DW7EKY] .1822
Failure Code [DWN5KA] .1824
Failure Code [DWN5KB] .1826
Failure Code [DWN5KY] .1828
Failure code [DXA4KA] .1830
Failure code [DXA4KB] .1832
Failure code [DXA4KY] .1834
Failure code [DXA5KA] .1836
Failure code [DXA5KB] .1838
Failure code [DXA5KY] .1840
Failure code [DXA6KA] .1842
Failure code [DXA6KB] .1844
Failure code [DXA6KY] .1846
Failure code [DXA7KA] .1848
Failure code [DXA7KB] .1850
Failure code [DXA7KY] .1852
Failure Code [DXHRKA] .1854
Failure Code [DXHRKB] .1856
Failure Code [DXHRKY] .1858
Failure Code [DXHSKA] .1860
Failure Code [DXHSKB] .1862
Failure Code [DXHSKY] .1864
Failure Code [DXHTKA] .1866
Failure Code [DXHTKB] .1868
Failure Code [DXHTKY] .1870
Failure Code [DXHUKA] .1872
Failure Code [DXHUKB] .1874
Failure Code [DXHUKY] .1876
Failure Code [DXJ4KA] .1878
Failure Code [DXJ4KB] .1880
Failure Code [DXJCKA] .1882
Failure Code [DXJCKB] .1884
Failure Code [DXJCKY] .1886
Failure Code [DXJDKA] .1888
Failure Code [DXJDKB] .1890
Failure Code [DXJDKY] .1892
Failure Code [DXK1KA] .1894
Failure Code [DXK1KB] .1896
Failure Code [DXK1KY] .1898
Failure Code [DXK2KA] .1900
Failure Code [DXK2KB] .1902
Failure Code [DXK2KY] .1904
Failure Code [F311KA] .1906
Failure Code [F311KB] .1908
Failure Code [F312KA] .1910
Failure Code [F312KB] .1912
Failure Code [F313KA] .1914
Failure Code [F313KB] .1916
Failure Code [F314KA] .1919
Failure Code [F314KB] .1921
Failure Code [F315KB] .1923
Failure Code [F315KY] .1925
Failure Code [F316KB] .1927
Failure Code [F316KY] .1929
Failure Code [F318KB] .1931
Failure Code [F318KY] .1934
Failure Code [F31AKB] .1936
Failure Code [F31AKY] .1938
Failure Code [F31BKB] .1940
Failure Code [F31BKY] .1942
Failure Code [F31CKB] .1944
Failure Code [F31CKY] .1946
Failure Code [F31DKB] .1948
Failure Code [F31DKY] .1950
Failure Code [F31EKB] .1952
Failure Code [F31EKY] .1954
Failure Code [F7A0KQ] .1956
Failure Code [F7A0KT] .1957
Failure Code [F7A1KK] .1958
Failure Code [F7ALKB] .1961
Failure Code [F7AQKR] .1963
Failure Code [F7ASKA] .1964
Failure Code [FE0AKA] .1966
Failure Code [FS10ZE] .1968
Troubleshooting of Electrical System (E-Mode) .1969
Engine Does Not Start (Engine Does Not Crank) .1969
Manual Preheating System Does Not Operate .1976
Automatic Preheating System Does Not Operate 1979
While Preheating is in Operation, Preheating Monitor Does Not Come On .1981
When Starting Switch is Turned to ON Position, Machine Monitor Shows Nothing 1983
When Starting Switch is Turned to ON Position (with Engine Stopped), Basic Check Monitor Comes On .1987
Air Cleaner Clogging Monitor Comes On in Yellow While Engine is in Operation 1988
Charge Level Monitor Comes On in Red While Engine is in Operation .1989
Engine Coolant Temperature Monitor Comes On in Red While Engine is in Operation .1990
Engine Oil Pressure Monitor Comes On in Red While Engine is in Operation 1991
HST Charge Pressure Monitor Comes On in Red While Engine Runs .1992
Hydraulic Oil Temperature Monitor Comes On in Red While Engine is in Operation 1993
HST Oil Filter Clogging Monitor Comes On in Red While Engine Runs .1994
Engine Coolant Temperature Gauge Does Not Show Correct Temperature 1995
DEF Level is Not Shown Correctly 1996
Fuel Gauge Does Not Show Normally .1999
Hydraulic Oil Temperature Gauge Does Not Show Correct Temperature .2002
Operation Mode Does Not Change 2003
When You Operate Customize Switch Does Not Show Customize Screen 2004
When You Change Setting on Customize Screen, Setting of Machine is Not Changed 2005
Service Meter is Not Shown While Starting Switch is in OFF Position .2006
Service Mode Cannot be Selected .2007
Work Equipment Does Not Operate .2008
Foot Heater Does Not Operate 2010
Horn Does Not Sound .2016
Horn Does Not Stop 2018
Backup Alarm Does Not Sound .2019
Backup Alarm Does Not Stop Operation 2020
Headlamp Does Not Come On .2021
Rear Lamp Does Not Come On 2025
No Wiper Operates .2028
Front Wiper Does Not Operate 2030
Rear Wiper Does Not Operate .2032
Left Door Wiper Does Not Operate 2034
Right Door Wiper Does Not Operate .2038
Front Washer Does Not Operate .2042
Rear Washer Does Not Operate 2044
Left Door Washer Does Not Operate .2046
Right Door Washer Does Not Operate 2048
KOMTRAX System Does Not Operate Correctly .2050
Control Box Shows Message [Waiting for radio link .] .2051
Control Box Shows Message [Waiting for satellites .] .2053
Control Box Shows Message [GPS receiver not connected !] and [Komatsu Machine Trouble] 2054
Control Box Shows Message [Komatsu Machine Trouble] .2055
Control Box Shows Message [Waiting to initialize .] 2056
Control Box Shows Message [System initializing] .2057
Control Box Shows Message [Initializing .] .2058
Control Box Shows Message [Connecting to GPS .] 2059
Elevation Control Key on Control Box Shows Message [Low precisions .] 2060
Control Box Shows Message [Heading Initializing] 2061
Control Box Shows Message [Out of design area .] .2062
Control Box Shows Message [No GPS localization .] 2063
Control Box Shows Message [Loading Design Surface data .] 2064
Control Box Shows Message [Design Surface data invalid] .2065
Control Box Shows Message [Starting switch is OFF] 2066
Control Box Shows Message [Waiting for satellites .] and [Komatsu Machine Trouble] .2068
Control Box Can Not be Turned on 2069
Control Box Does Not Display Intelligent Machine Control Screen .2071
Control Box Does Not Display Bulldozer Image 2072
Control Box Does Not Display Design Surface .2073
Control Box Touch Panel Does Not Respond 2074
Control Box Touch Panel is Inaccurate .2075
Cylinder Stroke Reset Indication Does Not Go Out 2076
AUTO or Strikethrough is Not Shown When AUTO/Manual Switch is Pushed (AUTO or Strikethrough Goes Out) .2077
When You Examine and Adjust the Blade Elevation, the Value is Different from Actual Machine .2079
Blade Automatic Lower Control Does Not Start While AUTO is Shown 2080
Blade Automatic Raise Control Does Not Start While AUTO is Shown 2081
Blade Automatic Control Function is Not Activated While AUTO is Shown (Blade Automatic Control Stops) .2082
Finished Surface is Inaccurate (The Average Height of Finished Surface is Lower Than Designed Surface or Blade Does Not Touch the Surface) 2083
Finished Surface is Inaccurate (The Finished Surface is Not Smooth) .2084
Finished Surface is Inaccurate (When You Finish Slope Horizontally, Steps are Made in Each Direction) .2085
Machine Cannot Escape from Shoes Slip While Blade Automatic Control is Activated (Shoes Frequently Slips) .2087
Machine Speed Does Not Increase While Blade Automatic Control is Activated 2088
Blade Tilt Angle Does Not Respond with Design Surface While Blade Automatic Control is Activated 2089
Blade Tilts While Blade Automatic Control is Activated 2091
Even After Lift Layer Control is Activated, Measured Lift Layer Terrain Shape Does Not Agree with Actual Terrain 2093
The Surface Made with Quick Surface Creation Function is Different from the One in Machine Front Direction, Blade Edge Position .2095
Machine Does Not Travel Straight While Tilt Steering Control is Activated .2096
Control Box Continues to Show Progress Bar in Machine Manual Cal Screen .2097
Engine Hunting Occurs When You Lower the Blade While Ground Line Assist is Activated 2098
[Laser Receiver Error (Red)] Icon is Shown on Control Box (2D Laser Machine Control) 2099
[System Error (Red)] Icon is Shown on Control Box (2D Laser Machine Control) 2103
[AUTO (Green)] is Not Shown on Control Box (2D Laser Machine Control) .2104
Finished Surface is Inaccurate (2D Laser Machine Control) .2105
Ground Surface Becomes Rough in Leveling Work (2D Laser Machine Control) 2106
Current Slope Value on Control Box is Different from Actual Value (2D Laser Machine Control) 2107
Automatic Control Cannot be Done If You Change Application (2D Laser Machine Control) .2108
Troubleshooting for Hydraulic and Mechanical Systems (H Mode) .2109
Information Shown in Troubleshooting Table (H-Mode) .2109
Failure Mode and Cause Table 2110
R.H. and L.H. Tracks Cannot Travel FORWARD and REVERSE (None of the Travel Systems Operate) .2116
R.H. or L.H. Track Cannot Travel FORWARD and REVERSE (One of R.H. or L.H. Travel Systems Cannot Operate) 2118
R.H. or L.H. Track Cannot Travel FORWARD or REVERSE (Only One of the Travel Systems Cannot Operate in One Direction) 2120
Travel Speed or Power is Low 2122
Speed Range Does Not Change .2124
Shock is Large When Machine Moves Off or Stops 2125
Travel Deviation is Large .2126
Machine Drift on a Slope is Large .2129
Engine Speed Drops Largely or Engine Stops 2131
Unusual Noise is Heard from Around HST Pump or Motor 2133
HST Oil Temperature (Hydraulic Oil Temperature) Increases Too High 2135
All Work Equipment Do Not Operate .2137
All Work Equipment Speed or Power is Low 2139
Blade Lift Speed or Power is Low 2140
Blade Tilt Speed or Power is Low 2142
Blade Angle Speed or Power is Low .2143
Time Lag of Blade Lift is Large .2144
Hydraulic Drift of Blade Lift is Large 2145
Hydraulic Drift of Tilted Blade is Large 2146
Unusual Noise is Heard from Around Work Equipment and Cooling Fan Pump or Control Valve .2147
Fan Speed is Abnormal (Too High or Low, or Does Not Rotate) .2148
Unusual Noise is Heard from Around Fan 2150
Troubleshooting of Engine (S-Mode) 2151
Information Shown in Troubleshooting Table (S-Mode) .2151
Engine Does Not Crank When Starting Switch is Turned to Start Position 2152
Engine Cranks but No Exhaust Smoke Comes Out 2153
Fuel is Sprayed but Engine Does Not Start (Misfiring: Engine Cranks but Does Not Start) .2154
Engine Startability is Unsatisfactory .2156
Engine Does Not Pick Up Smoothly 2158
Engine Stops During Operation .2160
Engine Does Not Rotate Smoothly .2162
Engine Lacks Output (or Lacks Power) 2163
Exhaust Smoke is Black 2165
Engine Oil Consumption is Excessive .2167
Engine Oil Becomes Dirty Quickly 2168
Fuel Consumption is Excessive .2169
Oil is in Coolant (or Coolant Spurts Back or Coolant Level Goes Down) .2170
Engine Oil Pressure Drops .2171
Fuel Mixes Into Engine Oil 2173
Water Mixes Into Engine Oil (Milky) .2174
Coolant Temperature Increases Too High (Overheat) .2175
Unusual Noise is Heard 2176
Vibration is Excessive 2177
Air Cannot be Bled from Fuel Circuit 2178
Active Regeneration is Done Frequently 2179
Active Regeneration Continues Long 2180
White Smoke is Exhausted During Active Regeneration .2181
DEF Consumption is Excessive 2182
There is an Unusual Smell (Irritating Odor) .2184
Foreign Materials Enter DEF (DEF Increases) .2185
50 Disassembly and Assembly .2187
Table of Contents .2188
Precautions Before Work .2193
Related Information on Disassembly and Assembly .2194
How to Read This Manual .2194
Coating Materials List 2195
Special Tool List .2200
Sketches of Special Tools .2223
Engine and Cooling System .2236
Remove and Install Supply Pump Assembly .2236
How to Remove Supply Pump Assembly 2236
How to Install Supply Pump Assembly .2246
Remove and Install Injector Assembly 2256
How to Remove Injector Assembly .2256
How to Install Injector Assembly 2267
Remove and Install Cylinder Head Assembly .2281
How to Remove Cylinder Head Assembly 2281
How to Install Cylinder Head Assembly .2300
Remove and Install EGR Valve Assembly .2324
How to Remove EGR Valve Assembly 2324
How to Install EGR Valve Assembly .2327
Remove and Install EGR Cooler Assembly 2331
How to Remove EGR Cooler Assembly .2331
How to Install EGR Cooler Assembly 2335
Remove and Install Starter Assembly .2339
How to Remove Starting Motor Assembly .2339
How to Install Starting Motor Assembly 2341
Remove and Install Air Conditioner Compressor Belt 2344
How to Remove Air Conditioner Compressor Belt .2344
How to Install Air Conditioner Compressor Belt 2348
Remove and Install Alternator Belt 2353
How to Remove Alternator Belt .2353
How to Install Alternator Belt 2356
Remove and Install Automatic Tensioner 2358
How to Remove Automatic Tensioner .2358
How to Install Automatic Tensioner 2359
Remove and Install Radiator Assembly 2361
How to Remove Radiator Assembly .2362
How to Install Radiator Assembly 2370
Remove and Install Hydraulic Oil Cooler Assembly 2378
How to Remove Hydraulic Oil Cooler Assembly .2379
How to Install Hydraulic Oil Cooler Assembly 2384
Remove and Install Aftercooler Assembly .2389
How to Remove Aftercooler Assembly 2390
How to Install Aftercooler Assembly .2396
Remove and Install Cooling Fan Drive Assembly .2403
How to Remove Cooling Fan Drive Assembly 2403
How to Install Cooling Fan Drive Assembly .2408
Remove and Install Cooling Fan Motor Assembly .2412
How to Remove Cooling Fan Motor Assembly 2412
How to Install Cooling Fan Motor Assembly .2415
Remove and Install Engine and HST Pump Assembly .2418
How to Remove Engine and HST Pump Assembly 2418
Install Engine and HST Pump Assembly 2429
Remove and Install Engine Front Oil Seal 2441
How to Remove Engine Front Oil Seal .2441
How to Install Engine Front Oil Seal 2443
Remove and Install Engine Rear Oil Seal .2445
How to Remove Engine Rear Oil Seal 2445
How to Install Engine Rear Oil Seal .2446
Remove and Install Engine Hood Assembly .2449
How to Remove Engine Hood Assembly 2449
How to Install Engine Hood Assembly .2453
Remove and Install KDOC Assembly 2457
How to Remove KDOC Assembly .2457
How to Install KDOC Assembly 2463
Remove and Install KDOC and SCR Assembly 2470
How to Remove KDOC and SCR Assembly .2471
How to Install KDOC and SCR Assembly 2477
Remove and Install Bellows Pipe Assembly 2485
How to Remove Bellows Pipe Assembly .2485
How to Install Bellows Pipe Assembly 2488
Remove and Install Fuel Tank Assembly .2492
How to Remove Fuel Tank Assembly 2493
Install Fuel Tank Assembly 2500
Remove and Install DEF Tank Assembly 2507
How to Remove DEF Tank Assembly .2508
How to Install DEF Tank Assembly 2518
Remove and Install DEF Tank Sensor Flange Assembly 2527
How to Remove DEF Tank Sensor Flange Assembly .2527
How to Install DEF Tank Sensor Flange Assembly 2529
Remove and Install DEF Tank Sensor 2533
How to Remove DEF Tank Sensor .2533
How to Install DEF Tank Sensor 2534
Remove and Install DEF Tank Strainer 2541
How to Remove DEF Tank Strainer .2541
How to Install DEF Tank Strainer 2542
Remove and Install SCR Assembly .2543
How to Remove SCR Assembly 2543
How to Install SCR Assembly .2546
Remove and Install KCCV Assembly 2549
How to Remove KCCV Assembly .2549
How to Install KCCV Assembly 2550
Remove and Install DEF Mixing Tube 2553
How to Remove DEF Mixing Tube .2553
How to Install DEF Mixing Tube 2557
Remove and Install DEF Injector .2562
How to Remove DEF Injector 2562
How to Install DEF Injector .2567
Remove and Install DEF Pump .2572
How to Remove DEF Pump 2572
How to Install DEF Pump .2576
Remove and Install DEF Hose .2580
How to Remove DEF Hose 2582
How to Install DEF Hose .2601
Remove and Install Air Cleaner Assembly .2622
How to Remove Air Cleaner Assembly 2622
How to Install Air Cleaner Assembly .2624
Remove and Install Air Conditioner Compressor Assembly 2627
How to Remove Air Conditioner Compressor Assembly .2627
How to Install Air Conditioner Compressor Assembly 2631
Remove and Install Air Conditioner Condenser Assembly .2636
How to Remove Air Conditioner Condenser Assembly 2636
How to Install Air Conditioner Condenser Assembly .2640
Power Train .2644
Disassemble and Assemble Final Drive Assembly .2644
How to Disassemble Final Drive Assembly .2645
How to Assemble Final Drive Assembly 2649
Undercarriage and Frame .2658
Remove and Install Track Frame Assembly .2658
How to Remove Track Frame Assembly 2658
How to Install Track Frame Assembly .2663
Remove and Install Idler Assembly .2668
How to Remove Idler Assembly 2668
How to Install Idler Assembly .2670
Disassemble and Assemble Idler Assembly .2673
How to Disassemble Idler Assembly .2673
How to Assemble Idler Assembly 2675
Remove and Install Recoil Spring Assembly .2680
How to Remove Recoil Spring Assembly 2680
How to Install Recoil Spring Assembly .2680
Disassemble and Assemble Recoil Spring Assembly .2681
How to Disassemble Recoil Spring Assembly .2681
How to Assemble Recoil Spring Assembly 2684
Remove and Install Track Roller Assembly 2687
How to Remove Track Roller Assembly .2687
How to Install Track Roller Assembly 2689
Disassemble and Assemble Track Roller Assembly 2693
How to Disassemble Track Roller Assembly 2693
How to Assemble Track Roller Assembly .2694
Remove and Install Carrier Roller Assembly 2698
How to Remove Carrier Roller Assembly .2698
How to Install Carrier Roller Assembly 2699
Disassemble and Assemble Carrier Roller Assembly 2701
How to Disassemble Carrier Roller Assembly 2701
How to Assemble Carrier Roller Assembly .2702
Remove and Install Pivot Shaft Assembly .2705
How to Remove Pivot Shaft Assembly 2705
How to Install Pivot Shaft Assembly .2706
Separate and Connect Track Assembly .2708
How to Examine Before Separation of Track Assembly 2708
How to Separate Track Assembly (Standard) .2709
How to Separate Track Assembly (When Track Frame Has Internal Defect) .2710
How to Install Track Assembly .2711
Separate and Connect PLUS Type Track Assembly .2713
Separate PLUS Type Track Assembly Generally .2713
Install PLUS Type Track Assembly 2713
Disassemble and Assemble Track Assembly Generally .2715
How to Disassemble Full Track Shoes Assembly 2715
How to Assemble Full Track Shoes Assembly .2720
Disassemble and Assemble PLUS Type Track Assembly Generally .2733
Disassemble PLUS Type Track Assembly Generally 2734
How to Assemble PLUS Type Track Shoes Assembly Generally 2735
Disassemble and Assemble One Track Link Assembly in Field (Track Assembly) 2744
How to Disassemble One Track Link Assembly in Field (Track Assembly) 2745
How to Assemble One Track Link Assembly in Field (Track Assembly) .2746
Disassemble and Assemble One Track Link Assembly in Field (PLUS Type Track Assembly) 2753
Disassemble One Track Link Assembly in Field (PLUS Type Track Assembly) .2754
Assemble One Track Link Assembly in Field (PLUS Type Track Assembly) 2756
Remove and Install Equalizer Bar Assembly .2760
How to Remove Equalizer Bar Assembly 2760
How to Install Equalizer Bar Assembly .2762
Remove and Install Equalizer Bar Side Bushing .2765
How to Remove Equalizer Bar Side Bushings .2765
How to Install Equalizer Bar Side Bushings 2766
Remove and Install Segment Teeth 2767
How to Remove Segment Teeth .2767
How to Install Segment Teeth 2769
Hydraulic System 2771
Remove and Install Hydraulic Tank Assembly 2771
How to Remove Hydraulic Tank Assembly .2772
How to Install Hydraulic Tank Assembly 2778
Remove and Install Control Valve Assembly .2787
How to Remove Control Valve Assembly 2787
How to Install Control Valve Assembly .2791
Work Equipment 2795
Remove and Install Blade Assembly (Serial No.: 15001 to 15600) 2795
How to Remove Blade Assembly (Serial No.: 15001 to 15600) .2795
How to Install Blade Assembly (Serial No.: 15001 to 15600) 2798
Remove and Install Blade Assembly (Serial No.: 15601 and up) 2803
How to Remove Blade Assembly (Serial No.: 15601 and up) .2804
How to Install Blade Assembly (Serial No.: 15601 and up) 2807
Remove and Install Stroke and Reset Sensing Blade Lift Cylinder Assembly 2812
How to Remove Stroke and Reset Sensing Blade Lift Cylinder Assembly .2812
How to Install Stroke and Reset Sensing Blade Lift Cylinder Assembly 2814
Disassemble and Assemble Stroke and Reset Sensing Blade Lift Cylinder Assembly 2818
How to Disassemble Stroke and Reset Sensing Blade Lift Cylinder Assembly 2819
How to Assemble Stroke and Reset Sensing Blade Lift Cylinder Assembly .2823
Remove and Install Stroke Sensing Blade Tilt Cylinder Assembly (Serial No.: 15001 to 15600) .2832
How to Remove Stroke Sensing Blade Tilt Cylinder Assembly (Serial No.: 15001 to 15600) 2832
How to Install Stroke Sensing Blade Tilt Cylinder Assembly (Serial No.: 15001 to 15600) .2835
Remove and Install Stroke Sensing Blade Tilt Cylinder Assembly (Serial No.: 15601 and up) .2838
How to Remove Stroke Sensing Blade Tilt Cylinder Assembly (Serial No.: 15601 and up) 2838
How to Install Stroke Sensing Blade Tilt Cylinder Assembly (Serial No.: 15601 and up) .2843
Disassemble and Assemble Stroke Sensing Blade Tilt Cylinder Assembly 2848
How to Disassemble Stroke Sensing Blade Tilt Cylinder Assembly 2848
How to Assemble Stroke Sensing Blade Tilt Cylinder Assembly .2852
Remove and Install Stroke Sensing Blade Angle Cylinder Assembly .2857
How to Remove Stroke Sensing Blade Angle Cylinder Assembly 2857
How to Install Stroke Sensing Blade Angle Cylinder Assembly .2860
Disassemble and Assemble Stroke Sensing Blade Angle Cylinder Assembly .2863
How to Disassemble Stroke Sensing Blade Angle Cylinder Assembly .2864
How to Assemble Stroke Sensing Blade Angle Cylinder Assembly 2867
Remove and Install U-Frame Assembly (Serial No.: 15001 to 15600) 2872
How to Remove U-frame Assembly (serial No.: 15001 to 15600) .2872
How to Install U-frame Assembly (serial No.: 15001 to 15600) 2876
Remove and Install U-Frame Assembly (Serial No.: 15601 and up) 2879
How to Remove U-Frame Assembly (Serial No.: 15601 and up) .2879
How to Install U-Frame Assembly (Serial No.: 15601 and up) 2882
CAB Related Parts .2885
Remove and Install Operator Cab Assembly 2885
How to Remove Operator Cab Assembly .2886
How to Install Operator Cab Assembly 2895
Remove and Install Operator Cab Glass (Adhered Glass) .2904
How to Remove Operator Cab Glass (Adhered Glass) 2906
How to Install Operator Cab Glass (Adhered Glass) .2906
Remove and Install Air Conditioner Unit Assembly 2912
How to Remove Air Conditioner Unit Assembly .2912
How to Install Air Conditioner Unit Assembly 2918
Remove and Install Receiver Drier .2925
How to Remove Receiver Drier 2925
How to Install Receiver Drier .2926
Remove and Install Operator Seat 2929
How to Remove Operator Seat .2929
How to Install Operator Seat 2930
How to Remove and Install Seat Belt .2931
How to Remove Seat Belt .2931
How to Install Seatbelt .2931
Remove and Install Foot Heater Assembly .2933
How to Remove Foot Heater Assembly 2933
How to Install Foot Heater Assembly .2935
Disassemble and Assemble Foot Heater Assembly .2938
How to Disassemble Foot Heater Assembly .2938
How to Assemble Foot Heater Assembly 2939
Electrical System .2940
Remove and Install Engine Controller Assembly .2940
How to Remove Engine Controller Assembly 2940
How to Install Engine Controller Assembly .2943
Remove and Install HST Controller Assembly 2947
How to Remove HST Controller Assembly .2947
How to Install HST Controller Assembly 2948
Remove and Install Machine Monitor Assembly .2949
How to Remove Machine Monitor Assembly 2949
How to Install Machine Monitor Assembly .2950
Remove and Install Mass Air Flow and Temperature Sensor .2952
How to Remove Mass Air Flow and Temperature Sensor 2952
How to Install Mass Air Flow and Temperature Sensor .2954
Remove and Install KCCV Crankcase Pressure Sensor .2956
How to Remove KCCV Crankcase Pressure Sensor 2956
How to Install KCCV Crankcase Pressure Sensor .2958
Remove and Install Gateway Function Controller Assembly .2960
How to Remove Gateway Function Controller Assembly 2960
How to Install Gateway Function Controller Assembly .2961
Remove and Install Navigation Controller 2962
How to Remove Navigation Controller .2963
How to Install Navigation Controller 2967
Remove and Install ICT Sensor Controller Assembly .2972
How to Remove ICT Sensor Controller Assembly 2972
How to Install ICT Sensor Controller Assembly .2972
Remove and Install Control Box 2974
How to Remove Control Box .2974
How to Install Control Box 2975
Remove and Install GNSS Receiver 2976
How to Remove GNSS Receiver .2977
How to Install GNSS Receiver 2977
Remove and Install GNSS Antenna .2979
How to Remove GNSS Antenna 2980
How to Install GNSS Antenna .2984
Remove and Install IMU Sensor .2989
How to Remove IMU Sensor 2989
How to Install IMU Sensor .2991
Remove and Install Communication Terminal .2993
How to Remove Communication Terminal 2993
How to Install Communication Terminal .2996
Remove and Install Communication Antenna 2999
How to Remove Communication Antenna .3000
How to Install Communication Antenna 3002
60 Maintenance Standard .3005
Table of Contents .3006
Engine and Cooling System .3007
Maintenance Standard for Engine Mount .3007
Maintenance Standard for Damper (Serial No.: 15001 to 15600) 3008
Maintenance Standard for Damper (Serial No.: 15601 and up) 3009
Maintenance Standard for Cooling System .3010
Maintenance Standard for Cooling Fan Motor 3012
Maintenance Standard for Hydraulic Oil Cooler Bypass and HST Charge Safety Valve 3014
Power Train .3015
Maintenance Standard for HST Pump .3015
Maintenance Standard for EPC Valve of HST Pump 3017
Maintenance Standard for Tow Receiving Valve of HST Pump 3018
Maintenance Standard for HST Charge Pump 3019
Maintenance Standard for HST Motor 3021
Maintenance Standard for Final Drive 3023
Maintenance Standard for Sprocket for PLUS Type Track Shoes .3025
Maintenance Standard for Sprocket Tooth Profile Full-Scale Drawing for PLUS Type Track Shoes 3026
Undercarriage and Frame .3027
Maintenance Standard for Suspension .3027
Maintenance Standard for Track Frame and Idler Cushion 3030
Maintenance Standard for Idler 3033
Maintenance Standard for Track Roller for PLUS Type Track Shoes (Single Flange Type) 3035
Maintenance Standard for Track Roller for PLUS Type Track Shoes (Double Flange Type) 3036
Maintenance Standard for Carrier Roller for PLUS Type Track Shoes .3038
Maintenance Standard for PLUS Type Track Shoes 3039
Maintenance Standard for Single Shoes .3041
Hydraulic System 3042
Maintenance Standard for Hydraulic Tank .3042
Maintenance Standard for Work Equipment and Cooling Fan Pump 3043
Maintenance Standard for Servo Valve of Work Equipment and Cooling Fan Pump .3044
Maintenance Standard for Control Valve 3046
Maintenance Standard for Ripper PPC Valve .3052
Maintenance Standard for 5-Spool EPC and Solenoid Valve .3054
Maintenance Standard for EPC Valve 3055
Maintenance Standard for Quick Drop Valve .3056
Work Equipment 3058
Maintenance Standard for Front Work Equipment (Serial No.: 15001 to 15600) 3058
Maintenance Standard for Front Work Equipment (Serial No.: 15601 and up) 3061
Maintenance Standard for Cutting Edge and End Bit .3064
Maintenance Standard for Blade Lift Cylinder 3065
Maintenance Standard for Blade Tilt Cylinder 3066
Maintenance Standard for Blade Angle Cylinder .3067
Maintenance Standard for Fixed Multi-Shank Ripper .3068
Maintenance Standard for Ripper Lift Cylinder .3070
CAB Related Parts .3071
Maintenance Standard for CAB Mount 3071
Electrical System .3073
Maintenance Standard for Steering Electric Lever 3073
80 Appendix .3075
Table of Contents .3076
Precautions Before Work .3077
Air Conditioner System 3078
Precautions for Refrigerant .3078
Air Conditioner Component .3079
Specifications of Air Conditioner .3082
Structure and Function of Refrigeration Cycle .3083
Outline of Refrigeration Cycle 3084
Component Parts of Air Conditioner System .3086
Air Conditioner Unit 3086
Configuration Diagram of Air Conditioner Unit .3086
Function of Air Conditioner Unit 3087
Component Parts of Air Conditioner Unit .3088
Function of Evaporator as Air Conditioner Unit Component 3088
Function of Heater Core as Air Conditioner Unit Component .3088
Function of Thermistor as Air Conditioner Unit Component 3088
Structure of Expansion Valve as Air Conditioner Unit Component 3089
Function of Expansion Valve as Air Conditioner Unit Component .3089
Operate Expansion Valve as Air Conditioner Unit Component .3089
Function of Dual Pressure Switch 3090
Function of Pressure Switch .3090
Compressor 3091
Structure of Compressor .3091
Specifications of Compressor 3091
Function of Compressor 3091
Condenser .3092
Structure of Condenser 3092
Specifications of Condenser .3092
Function of Condenser .3093
Receiver Drier 3094
Structure of Receiver Dryer .3094
Specifications of Receiver Dryer 3094
Function of Receiver Dryer 3094
Explanation of Procedure for Test of and Troubleshooting of Air Conditioner .3096
Circuit Diagram of Air Conditioner 3099
System Diagram of Air Conditioner .3100
Control Function of Air Conditioner .3101
Locations of Air Conditioner Parts and Layout of Connectors .3102
Examine Relay .3106
How to Examine Relay 3106
Air Conditioner Troubleshooting Chart 1 .3108
Air Conditioner Troubleshooting Chart 2 .3109
Information Shown in Troubleshooting Table 3112
Troubleshooting for Condenser Fan .3113
Troubleshooting for Compressor and Refrigerant System (Air is Not Cooled) .3116
Troubleshooting for Blower Motor System (No Air Comes Out or Air Flow is Abnormal) 3120
Troubleshooting for Temperature Control Function 3123
Troubleshooting by Gauge Pressure .3127
Connect Service Tool 3129
How to Connect Service Tool .3130
Precautions for Disconnection and Connection of Air Conditioner Piping 3131
Handle Compressor Oil .3133
90 Circuit Diagrams .3135
Table of Contents .3136
Hydraulic Circuit Diagram .3137
Symbols Used in Hydraulic Circuit Diagram .3137
Hydraulic Circuit Diagram .3141
Electrical Circuit Diagram 3143
Symbols Used in Electric Circuit Diagram 3143
Electrical Circuit Diagram (1/16) .3147
Electrical Circuit Diagram (2/16) .3149
Electrical Circuit Diagram (3/16) .3151
Electrical Circuit Diagram (4/16) .3153
Electrical Circuit Diagram (5/16) .3155
Electrical Circuit Diagram (6/16) .3157
Electrical Circuit Diagram (7/16) .3159
Electrical Circuit Diagram (8/16) .3161
Electrical Circuit Diagram (9/16) .3163
Electrical Circuit Diagram (10/16) 3165
Electrical Circuit Diagram (11/16) 3167
Electrical Circuit Diagram (12/16) 3169
Electrical Circuit Diagram (13/16) 3171
Electrical Circuit Diagram (14/16) 3173
Electrical Circuit Diagram (15/16) 3175
Electrical Circuit Diagram (16/16) 3177
Electrical Circuit Diagram (2D Laser Machine Control) .3179
Index 3181

DESCRIPTION:

Komatsu D51EXi-24,D51PXi-24 Bulldozer Shop Manual SEN06850-08 –  PDF DOWNLOAD

• D51EXi-15001 and up
• D51PXi-15001 and up

G.B 28/12/24