Komatsu Crawler Dozers/Tractors D51- series Repair Service Manuals
Complete service repair manual with electrical wiring diagrams for Komatsu Crawler Dozers/Tractors D51EX, D51EXi, D51PX, D51PXi with all the shop information to maintain, diagnostic, repair, and rebuild like a professional.
Komatsu Crawler Dozers/Tractors D51EX, D51EXi, D51PX, D51PXi workshop service repair manual includes:
* Numbered table of contents easy to use so that you can find the information you need fast.
* Detailed sub-steps expand on repair procedure information
* Numbered instructions guide you through every repair procedure step by step.
* Troubleshooting and electrical service procedures are combined with detailed wiring diagrams for ease of use.
* Notes, cautions and warnings throughout each chapter pinpoint critical information.
* Bold figure number help you quickly match illustrations with instructions.
* Detailed illustrations, drawings and photos guide you through every procedure.
* Enlarged inset helps you identify and examine parts in detail.
CEAM018708 - Crawler Dozer D51EX-22, D51PX-22 Shop Manual (SN-B10001&up).pdf
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CEBM019109 - Crawler Dozer D51EX-22, D51PX-22 Shop Manual (SN-B10001&up).pdf
CEBM019110 - Crawler Dozer D51EX-22, D51PX-22 Shop Manual (SN-B10001&up)
KEBM028601 - Crawler Dozer D51EXi-22, D51PXi-22 Shop Manual (SN-B13500&up).pdf
KEBM028602 - Crawler Dozer D51EXi-22, D51PXi-22 Shop Manual (SN-B13500&up)
KEBM662102 - Crawler Dozer D51EXi-24, D51PXi-24 Shop Manual (SN-B20001 and Up, ENGINE-4D107E-3).pdf
SEN06617 - Bulldozer D51EX-24, D51PX-24 Shop Manual (SN 10001 and up).pdf
PRODUCT DETAILS:
Total Pages: 10,102 pages
File Format: PDF (Internal Links, Bookmarked, Table of Contents, Searchable, Printable, high quality)
Language: English
TABLE OF CONTENTS
00 INDEX AND FOREWORD ... 00-1
ABBREVIATION LIST ... 00-20
FOREWORD, SAFETY, BASIC INFORMATION ..... 00-26
HOW TO READ THE SHOP MANUAL.... 00-26
SAFETY NOTICE FOR OPERATION... 00-28
PRECAUTIONS TO PREVENT FIRE... 00-36
ACTIONS IF FIRE OCCURS ... 00-38
PRECAUTIONS FOR DISPOSING OF WASTE MATERIALS ..... 00-39
ACTIONS TAKEN TO MEET EXHAUST GAS REGULATIONS... 00-40
PRECAUTIONS FOR DEF.... 00-41
STORE AdBlue/DEF .... 00-42
PRECAUTIONS FOR HANDLING HYDRAULIC EQUIPMENT ... 00-43
PRECAUTIONS FOR DISCONNECTION AND CONNECTION OF PIPINGS..... 00-46
PRECAUTIONS FOR HANDLING ELECTRICAL EQUIPMENT..... 00-52
PRECAUTIONS FOR HANDLING FUEL SYSTEM EQUIPMENT ..... 00-54
PRECAUTIONS FOR HANDLING INTAKE SYSTEM EQUIPMENT .... 00-55
PRACTICAL USE OF KOMTRAX ..... 00-56
DISCONNECT AND CONNECT PUSH-PULL TYPE COUPLER ... 00-57
PRECAUTIONS FOR DISCONNECTION AND CONNECTION OF CONNECTORS ... 00-61
METHOD FOR DISCONNECTING AND CONNECTING DEUTSCH CONNECTOR ... 00-65
METHOD FOR DISCONNECTING AND CONNECTING SLIDE LOCK TYPE CONNECTOR .... 00-66
METHOD FOR DISCONNECTING AND CONNECTING CONNECTOR WITH LOCK TO PULL ... 00-68
METHOD FOR DISCONNECTING AND CONNECTING CONNECTOR WITH LOCK TO PUSH .. 00-69
METHOD FOR DISCONNECTING AND CONNECTING CONNECTOR WITH HOUSING TO ROTATE .
... 00-71
HOW TO READ ELECTRICAL WIRE CODE ... 00-72
EXPLANATION OF TERMS FOR MAINTENANCE STANDARD.... 00-76
STANDARD TIGHTENING TORQUE TABLE... 00-79
CONVERSION TABLE .... 00-86
01 SPECIFICATIONS ... 01-1
CONTENTS ..... 01-2
ABBREVIATION LIST ..... 01-3
SPECIFICATIONS .... 01-9
SPECIFICATION DRAWING... 01-9
SPECIFICATIONS .... 01-13
WEIGHT TABLE .... 01-24
FUEL, COOLANT, LUBRICANTS (FOR NORTH AMERICA) ... 01-28
FUEL, COOLANT, LUBRICANTS (FOR EUROPEAN UNION).... 01-30
10 STRUCTURE AND FUNCTION .... 10-1
CONTENTS ..... 10-2
ABBREVIATION LIST ..... 10-5
UREA SCR SYSTEM.....10-11
LAYOUT DRAWING OF UREA SCR SYSTEM ....10-11
UREA SCR SYSTEM DIAGRAM ... 10-13
FUNCTION OF UREA SCR SYSTEM..... 10-14
COMPONENT PARTS OF UREA SCR SYSTEM... 10-32
BOOT-UP SYSTEM ... 10-41
LAYOUT DRAWING OF BOOT-UP SYSTEM... 10-41
SYSTEM OPERATING LAMP SYSTEM .... 10-42
BATTERY DISCONNECT SWITCH ..... 10-44
ENGINE SYSTEM ..... 10-45
LAYOUT DRAWING OF ENGINE SYSTEM ..... 10-45
ENGINE CONTROL SYSTEM .... 10-47
AUTOMATIC IDLE STOP SYSTEM ..... 10-53
COMPONENT PARTS OF ENGINE SYSTEM .... 10-56
COOLING SYSTEM... 10-73
LAYOUT DRAWING OF COOLING SYSTEM ..... 10-73
COOLING FAN CONTROL SYSTEM... 10-75
COMPONENT PARTS OF COOLING SYSTEM..... 10-78
CONTROL SYSTEM..... 10-87
LAYOUT DRAWING OF CONTROL SYSTEM .... 10-87
MACHINE MONITOR SYSTEM ..... 10-88
KOMTRAX SYSTEM.... 10-89
COMPONENT PARTS OF CONTROL SYSTEM.... 10-90
HYDRAULIC SYSTEM....10-122
LAYOUT DRAWING OF HYDRAULIC SYSTEM ...10-122
CLSS .....10-123
COMPONENT PARTS OF HYDRAULIC SYSTEM .....10-126
POWER TRAIN SYSTEM .....10-158
LAYOUT DRAWING OF HST SYSTEM ....10-158
OPERATION OF HST SYSTEM....10-159
STEERING AND BRAKE CONTROL SYSTEM ....10-161
HST CONTROL SYSTEM....10-163
PARKING BRAKE CONTROL SYSTEM ...10-174
COMPONENT PARTS OF POWER TRAIN SYSTEM ....10-177
WORK EQUIPMENT SYSTEM ...10-213
WORK EQUIPMENT CONTROL .....10-213
LAYOUT DRAWING OF FRONT WORK EQUIPMENT.....10-215
LAYOUT OF FIXED MULTI-SHANK RIPPER.....10-216
COMPONENT PARTS OF WORK EQUIPMENT SYSTEM .....10-217
ICT SYSTEM ...10-233
LAYOUT DRAWING OF ICT SYSTEM...10-233
ICT CONTROL SYSTEM DIAGRAM...10-235
BLADE CONTROL SYSTEM .....10-237
SMOOTH START SYSTEM ....10-243
SLIP CONTROL SYSTEM ...10-245
ASSIST CONTROL SYSTEM ....10-246
HST SPEED RANGE CONTROL SYSTEM ....10-248
COMPONENT PARTS OF ICT SYSTEM .....10-250
UNDERCARRIAGE AND FRAME.....10-272
MAIN FRAME ....10-272
SUSPENSION ...10-273
TRACK FRAME AND IDLER CUSHION ...10-276
WORK EQUIPMENT....10-278
STRUCTURE OF FRONT WORK EQUIPMENT...10-278
STRUCTURE OF FIXED MULTI-SHANK RIPPER...10-279
CAB AND ITS ATTACHMENTS .....10-280
ROPS CAB .....10-280
CAB MOUNT .....10-282
20 STANDARD VALUE TABLE .... 20-1
CONTENTS ..... 20-2
ABBREVIATION LIST ..... 20-3
STANDARD VALUE TABLE FOR ENGINE ... 20-9
STANDARD VALUE TABLE FOR ENGINE: D51EXI-24 .... 20-9
STANDARD VALUE TABLE FOR ENGINE: D51PXI-24 ..... 20-13
STANDARD VALUE TABLE FOR MACHINE..... 20-17
STANDARD VALUE TABLE FOR MACHINE: D51EXI-24 ..... 20-17
STANDARD VALUE TABLE FOR MACHINE: D51PXI-24 ..... 20-34
MACHINE POSTURE AND PROCEDURE FOR MEASURING PERFORMANCE .... 20-49
30 TESTING AND ADJUSTING ... 30-1
CONTENTS ..... 30-2
ABBREVIATION LIST ..... 30-6
RELATED INFORMATION ON TESTING AND ADJUSTING .... 30-12
TOOLS FOR TESTING AND ADJUSTING.... 30-12
SKETCH OF TOOLS FOR TESTING AND ADJUSTING ... 30-19
ENGINE AND COOLING SYSTEM.... 30-23
TEST ENGINE SPEED ... 30-23
TEST BOOST PRESSURE... 30-25
TEST EXHAUST GAS COLOR ... 30-27
TEST AND ADJUST VALVE CLEARANCE ... 30-29
TEST COMPRESSION PRESSURE.... 30-31
TEST BLOWBY PRESSURE ... 30-36
TEST ENGINE OIL PRESSURE .... 30-38
TEST FUEL PRESSURE ... 30-39
TEST FUEL DISCHARGE, RETURN AND LEAKAGE .... 30-44
BLEED AIR FROM FUEL SYSTEM ..... 30-50
TEST FUEL CIRCUIT FOR LEAKAGE ... 30-51
HANDLE CYLINDER CUT-OUT MODE OPERATION..... 30-53
HANDLE NO-INJECTION CRANKING OPERATION ... 30-54
TEST KDOC, SCR AND MUFFLER STACK FOR LOOSENESS AND DAMAGE ..... 30-55
TEST INSTALLED CONDITION OF CYLINDER HEADS AND MANIFOLDS ... 30-56
TEST ENGINE PIPING FOR DAMAGE AND LOOSENESS .... 30-57
WRITE ASH IN SOOT ACCUMULATION CORRECTION TO ENGINE CONTROLLER .... 30-58
TEST SCR RELATED FUNCTIONS..... 30-59
CLEAN AdBlue/DEF TANK ... 30-87
CLEAN AdBlue/DEF TANK MOUNTING PORTION ..... 30-91
POWER TRAIN.... 30-92
TEST AND ADJUST HST OIL PRESSURE ..... 30-92
BLEED AIR FROM HST PUMP ..... 30-97
TEST OUTLET PRESSURE OF SOLENOID VALVE ... 30-99
TEST TRAVEL DEVIATION ....30-103
TEST BRAKE PERFORMANCE SIMPLY ....30-105
TEST AND ADJUST DECELERATION/BRAKE PEDAL....30-106
ADJUST PARKING BRAKE LEVER....30-110
MOVE MACHINE WHEN IT CANNOT TRAVEL....30-112
UNDERCARRIAGE AND FRAME.....30-115
CHECK AND ADJUST IDLER CLEARANCE .....30-115
TESTING SPROCKET WEAR ...30-117
TEST AND ADJUST TRACK TENSION....30-118
HYDRAULIC SYSTEM....30-120
RELEASE REMAINING PRESSURE FROM HYDRAULIC SYSTEM.....30-120
TEST AND ADJUST WORK EQUIPMENT OIL PRESSURES ...30-121
TEST AND ADJUST OIL PRESSURE OF CONTROL CIRCUIT ...30-124
TEST OUTLET PRESSURE OF EPC SOLENOID VALVE ...30-126
BLEED AIR FROM WORK EQUIPMENT AND COOLING FAN PUMP .....30-128
TEST COOLING FAN SPEED ...30-129
TEST COOLING FAN CIRCUIT OIL PRESSURE ....30-130
TEST THE PARTS CAUSING HYDRAULIC DRIFT IN WORK EQUIPMENT.....30-132
TEST INTERNAL OIL LEAKAGE OF WORK EQUIPMENT CYLINDER ...30-135
BLEED AIR FROM WORK EQUIPMENT CYLINDERS.....30-138
WORK EQUIPMENT....30-139
ADJUST WORK EQUIPMENT LOCK LEVER....30-139
ELECTRICAL SYSTEM .....30-141
SET AND OPERATE MACHINE MONITOR....30-141
METHOD FOR STARTING UP KOMTRAX TERMINAL ....30-268
ADJUSTMENT WHEN HST CONTROLLER HAS BEEN REPLACED ...30-273
ADJUSTMENT WHEN ELECTRIC OR HYDRAULIC DEVICE HAS BEEN REPLACED ...30-279
ADJUST REARVIEW CAMERA ANGLE ...30-281
HANDLE VOLTAGE CIRCUIT OF ENGINE CONTROLLER ...30-282
HANDLE BATTERY DISCONNECT SWITCH ....30-283
TEST DIODES ...30-284
ICT SYSTEM ...30-285
SET AND OPERATE CONTROL BOX ...30-285
CALIBRATE BLADE EDGE POSITION ....30-288
CALIBRATE IMU SENSOR.....30-310
RESET CYLINDER STROKE END .....30-317
METHOD FOR INPUTTING WEAR AMOUNT OF BLADE EDGE AND TRACK SHOE ....30-320
CHECK BLADE ELEVATION, ADJUST.....30-321
TEST STROKE SENSOR FOR LIFT CYLINDER.....30-325
TEST STROKE SENSOR FOR TILT CYLINDER .....30-327
TEST STROKE SENSOR FOR ANGLE CYLINDER ...30-329
TEST AND ADJUST RESET SENSOR FOR LIFT CYLINDER .....30-331
ADJUST WHEN ICT SENSOR CONTROLLER IS REPLACED ....30-333
METHOD FOR ADJUSTING WHEN ICT RELATED DEVICES ARE REPAIRED OR REPLACED30-336
Pm CLINIC....30-339
Pm CLINIC SERVICE ....30-339
40 TROUBLESHOOTING ... 40-1
CONTENTS ..... 40-2
ABBREVIATION LIST ... 40-13
RELATED INFORMATION ON TROUBLESHOOTING .... 40-19
GENERAL TROUBLESHOOTING POINTS ..... 40-19
TROUBLESHOOTING POINTS FOR UREA SCR SYSTEM.... 40-20
SEQUENCE OF EVENTS IN TROUBLESHOOTING... 40-32
CHECKS BEFORE TROUBLESHOOTING ... 40-34
INSPECTION PROCEDURE BEFORE TROUBLESHOOTING ..... 40-36
TESTING IN ACCORDANCE WITH TESTING PROCEDURE.... 40-38
PREPARATION FOR TROUBLESHOOTING OF ELECTRICAL SYSTEM.... 40-60
PROCEDURE FOR TROUBLESHOOTING ..... 40-67
INFORMATION DESCRIBED IN TROUBLESHOOTING TABLE.... 40-70
TROUBLESHOOTING METHOD FOR OPEN CIRCUIT IN WIRING HARNESS OF PRESSURE SEN-
SOR SYSTEM.... 40-72
CONNECTORS LIST AND LAYOUT.... 40-75
CONNECTOR CONTACT IDENTIFICATION ... 40-92
T-BRANCH BOX AND T-BRANCH ADAPTER TABLE ...40-132
FUSE LOCATION TABLE ....40-138
PRECAUTIONS FOR REPLACING KDOC .....40-142
FAILURE CODES TABLE ....40-143
TROUBLESHOOTING BY FAILURE CODE (DISPLAY OF CODE) .....40-162
FAILURE CODE [6091NX] ...40-162
FAILURE CODE [989L00] ....40-164
FAILURE CODE [989M00] ...40-165
FAILURE CODE [989N00] ...40-166
FAILURE CODE [A1U0N3] .....40-167
FAILURE CODE [A1U0N4] .....40-169
FAILURE CODE [A900FR]...40-171
FAILURE CODE [A900N6] ...40-172
FAILURE CODE [A900NY]...40-173
FAILURE CODE [AA10NX] .....40-174
FAILURE CODE [AB00KE] .....40-176
FAILURE CODE [AQ10MB] ....40-178
FAILURE CODE [AQ10N3] .....40-180
FAILURE CODE [AS00R2]...40-182
FAILURE CODE [AS00R3]...40-183
FAILURE CODE [AS00R4]...40-184
FAILURE CODE [AS00R5]...40-185
FAILURE CODE [AS00R6]...40-186
FAILURE CODE [AS00ZK]...40-187
FAILURE CODE [AS10KM].....40-188
FAILURE CODE [AS10NR] .....40-189
FAILURE CODE [AS10NT] .....40-190
FAILURE CODE [B@BAZG] ...40-191
FAILURE CODE [B@BCNS] ...40-192
FAILURE CODE [B@CRNS]...40-193
FAILURE CODE [B@CRZG]...40-194
FAILURE CODE [CA115] .....40-195
FAILURE CODE [CA122] .....40-196
FAILURE CODE [CA123] .....40-198
FAILURE CODE [CA131] .....40-200
FAILURE CODE [CA132] .....40-202
FAILURE CODE [CA144] .....40-204
FAILURE CODE [CA145] .....40-206
FAILURE CODE [CA153] .....40-208
FAILURE CODE [CA154] .....40-210
FAILURE CODE [CA187] .....40-212
FAILURE CODE [CA221] .....40-214
FAILURE CODE [CA222] .....40-216
FAILURE CODE [CA227] .....40-218
FAILURE CODE [CA234] .....40-220
FAILURE CODE [CA238] .....40-221
FAILURE CODE [CA239] .....40-222
FAILURE CODE [CA249] .....40-223
FAILURE CODE [CA256] .....40-225
FAILURE CODE [CA271] .....40-227
FAILURE CODE [CA272] .....40-229
FAILURE CODE [CA295] .....40-231
FAILURE CODE [CA322] .....40-232
FAILURE CODE [CA324] .....40-234
FAILURE CODE [CA331] .....40-236
FAILURE CODE [CA332] .....40-238
FAILURE CODE [CA343] .....40-240
FAILURE CODE [CA351] .....40-241
FAILURE CODE [CA352] .....40-243
FAILURE CODE [CA356] .....40-245
FAILURE CODE [CA357] .....40-247
FAILURE CODE [CA386] .....40-249
FAILURE CODE [CA428] .....40-250
FAILURE CODE [CA429] .....40-252
FAILURE CODE [CA435] .....40-254
FAILURE CODE [CA441] .....40-256
FAILURE CODE [CA442] .....40-258
FAILURE CODE [CA451] .....40-259
FAILURE CODE [CA452] .....40-261
FAILURE CODE [CA488] .....40-263
FAILURE CODE [CA515] .....40-264
FAILURE CODE [CA516] .....40-266
FAILURE CODE [CA553] .....40-268
FAILURE CODE [CA555] .....40-269
FAILURE CODE [CA556] .....40-270
FAILURE CODE [CA559] .....40-271
FAILURE CODE [CA595] .....40-274
FAILURE CODE [CA687] .....40-276
FAILURE CODE [CA689] .....40-278
FAILURE CODE [CA691] .....40-281
FAILURE CODE [CA692] .....40-283
FAILURE CODE [CA697] .....40-285
FAILURE CODE [CA698] .....40-286
FAILURE CODE [CA731] .....40-287
FAILURE CODE [CA778] .....40-289
FAILURE CODE [CA1117] ...40-294
FAILURE CODE [CA1664] ...40-296
FAILURE CODE [CA1669] ...40-298
FAILURE CODE [CA1673] ...40-299
FAILURE CODE [CA1677] ...40-300
FAILURE CODE [CA1678] ...40-301
FAILURE CODE [CA1682] ...40-302
FAILURE CODE [CA1683] ...40-304
FAILURE CODE [CA1684] ...40-306
FAILURE CODE [CA1686] ...40-308
FAILURE CODE [CA1691] ...40-309
FAILURE CODE [CA1694] ...40-311
FAILURE CODE [CA1695] ...40-313
FAILURE CODE [CA1696] ...40-314
FAILURE CODE [CA1712] ...40-316
FAILURE CODE [CA1713] ...40-319
FAILURE CODE [CA1714] ...40-321
FAILURE CODE [CA1715] ...40-322
FAILURE CODE [CA1776] ...40-323
FAILURE CODE [CA1777] ...40-326
FAILURE CODE [CA1843] ...40-329
FAILURE CODE [CA1844] ...40-331
FAILURE CODE [CA1885] ...40-334
FAILURE CODE [CA1887] ...40-336
FAILURE CODE [CA1896] ...40-338
FAILURE CODE [CA1898] ...40-339
FAILURE CODE [CA1938] ...40-341
FAILURE CODE [CA1942] ...40-343
FAILURE CODE [CA1961] ...40-344
FAILURE CODE [CA1962] ...40-345
FAILURE CODE [CA2185] ...40-346
FAILURE CODE [CA2186] ...40-348
FAILURE CODE [CA2198] ...40-350
FAILURE CODE [CA2272] ...40-352
FAILURE CODE [CA2288] ...40-354
FAILURE CODE [CA2311] ...40-355
FAILURE CODE [CA2349] ...40-356
FAILURE CODE [CA2353] ...40-358
FAILURE CODE [CA2357] ...40-360
FAILURE CODE [CA2373] ...40-361
FAILURE CODE [CA2374] ...40-363
FAILURE CODE [CA2375] ...40-365
FAILURE CODE [CA2376] ...40-367
FAILURE CODE [CA2387] ...40-370
FAILURE CODE [CA2554] ...40-371
FAILURE CODE [CA2634] ...40-372
FAILURE CODE [CA2635] ...40-374
FAILURE CODE [CA2636] ...40-375
FAILURE CODE [CA2637] ...40-377
FAILURE CODE [CA2771] ...40-379
FAILURE CODE [CA2961] ...40-383
FAILURE CODE [CA2973] ...40-384
FAILURE CODE [CA2976] ...40-385
FAILURE CODE [CA3142] ...40-387
FAILURE CODE [CA3143] ...40-388
FAILURE CODE [CA3144] ...40-389
FAILURE CODE [CA3146] ...40-391
FAILURE CODE [CA3147] ...40-392
FAILURE CODE [CA3148] ...40-393
FAILURE CODE [CA3151] ...40-395
FAILURE CODE [CA3165] ...40-400
FAILURE CODE [CA3228] ...40-402
FAILURE CODE [CA3229] ...40-404
FAILURE CODE [CA3231] ...40-406
FAILURE CODE [CA3232] ...40-408
FAILURE CODE [CA3235] ...40-412
FAILURE CODE [CA3239] ...40-414
FAILURE CODE [CA3241] ...40-417
FAILURE CODE [CA3242] ...40-420
FAILURE CODE [CA3251] ...40-423
FAILURE CODE [CA3313] ...40-425
FAILURE CODE [CA3314] ...40-426
FAILURE CODE [CA3315] ...40-427
FAILURE CODE [CA3419] ...40-429
FAILURE CODE [CA3421] ...40-431
FAILURE CODE [CA3497] ...40-433
FAILURE CODE [CA3498] ...40-434
FAILURE CODE [CA3545] ...40-435
FAILURE CODE [CA3547] ...40-437
FAILURE CODE [CA3558] ...40-438
FAILURE CODE [CA3559] ...40-440
FAILURE CODE [CA3562] ...40-442
FAILURE CODE [CA3563] ...40-444
FAILURE CODE [CA3567] ...40-447
FAILURE CODE [CA3568] ...40-451
FAILURE CODE [CA3571] ...40-455
FAILURE CODE [CA3572] ...40-457
FAILURE CODE [CA3574] ...40-459
FAILURE CODE [CA3575] ...40-461
FAILURE CODE [CA3577] ...40-463
FAILURE CODE [CA3578] ...40-465
FAILURE CODE [CA3582] ...40-467
FAILURE CODE [CA3583] ...40-472
FAILURE CODE [CA3596] ...40-474
FAILURE CODE [CA3649] ...40-477
FAILURE CODE [CA3681] ...40-479
FAILURE CODE [CA3682] ...40-484
FAILURE CODE [CA3713] ...40-489
FAILURE CODE [CA3717] ...40-492
FAILURE CODE [CA3718] ...40-493
FAILURE CODE [CA3724] ...40-494
FAILURE CODE [CA3725] ...40-495
FAILURE CODE [CA3741] ...40-498
FAILURE CODE [CA3748] ...40-499
FAILURE CODE [CA3755] ...40-501
FAILURE CODE [CA3866] ...40-503
FAILURE CODE [CA3868] ...40-506
FAILURE CODE [CA4152] ...40-510
FAILURE CODE [CA4155] ...40-514
FAILURE CODE [CA4156] ...40-517
FAILURE CODE [CA4157] ...40-520
FAILURE CODE [CA4159] ...40-522
FAILURE CODE [CA4164] ...40-523
FAILURE CODE [CA4165] ...40-525
FAILURE CODE [CA4166] ...40-527
FAILURE CODE [CA4168] ...40-528
FAILURE CODE [CA4169] ...40-531
FAILURE CODE [CA4171] ...40-533
FAILURE CODE [CA4249] ...40-536
FAILURE CODE [CA4251] ...40-538
FAILURE CODE [CA4261] ...40-541
FAILURE CODE [CA4277] ...40-544
FAILURE CODE [CA4459] ...40-547
FAILURE CODE [CA4461] ...40-549
FAILURE CODE [CA4533] ...40-552
FAILURE CODE [CA4534] ...40-553
FAILURE CODE [CA4731] ...40-554
FAILURE CODE [CA4732] ...40-555
FAILURE CODE [CA4739] ...40-556
FAILURE CODE [CA4768] ...40-557
FAILURE CODE [CA4769] ...40-559
FAILURE CODE [CA4842] ...40-562
FAILURE CODE [CA4952] ...40-565
FAILURE CODE [CA5115] ...40-567
FAILURE CODE [CA5179] ...40-570
FAILURE CODE [CA5181] ...40-572
FAILURE CODE [CA5387] ...40-574
FAILURE CODE [CA5388] ...40-576
FAILURE CODE [CA5389] ...40-579
FAILURE CODE [CA5391] ...40-581
FAILURE CODE [CA5392] ...40-585
FAILURE CODE [CA5393] ...40-587
FAILURE CODE [CA5394] ...40-590
FAILURE CODE [CA5395] ...40-593
FAILURE CODE [CA5396] ...40-596
FAILURE CODE [CA5631] ...40-597
FAILURE CODE [CA5632] ...40-599
FAILURE CODE [CA5938] ...40-600
FAILURE CODE [D130KA]...40-602
FAILURE CODE [D130KB]...40-605
FAILURE CODE [D130KY]...40-607
FAILURE CODE [D19JKZ] ...40-609
FAILURE CODE [D811MC] .....40-612
FAILURE CODE [D862KA]...40-613
FAILURE CODE [D8ALKA] .....40-614
FAILURE CODE [D8ALKB] .....40-616
FAILURE CODE [D8AQKR] ....40-618
FAILURE CODE [DAF0MB] ....40-620
FAILURE CODE [DAF0MC] ....40-621
FAILURE CODE [DAF8KB] .....40-622
FAILURE CODE [DAF9KQ].....40-624
FAILURE CODE [DAFGMC] ...40-625
FAILURE CODE [DAFLKA] .....40-626
FAILURE CODE [DAFLKB] .....40-628
FAILURE CODE [DAFQKR] ....40-630
FAILURE CODE [DAJ000] ...40-631
FAILURE CODE [DAJ0KQ] .....40-632
FAILURE CODE [DAJ0KT]...40-633
FAILURE CODE [DAJ0MC].....40-634
FAILURE CODE [DAJ1KK] .....40-635
FAILURE CODE [DAJ2KK] .....40-637
FAILURE CODE [DAJ5KK] .....40-639
FAILURE CODE [DAJ6KK] .....40-642
FAILURE CODE [DAJLKA] .....40-644
FAILURE CODE [DAJLKB] .....40-646
FAILURE CODE [DAJPMA] ....40-648
FAILURE CODE [DAJQKR] ....40-649
FAILURE CODE [DAJRKR].....40-650
FAILURE CODE [DB2QKR] ....40-651
FAILURE CODE [DB2RKR] ....40-656
FAILURE CODE [DBR0KT].....40-661
FAILURE CODE [DBR0MC]....40-662
FAILURE CODE [DBR1KK].....40-663
FAILURE CODE [DBR2KK].....40-666
FAILURE CODE [DBR5KK].....40-669
FAILURE CODE [DBRLKA].....40-671
FAILURE CODE [DBRLKB].....40-673
FAILURE CODE [DBRPMA]....40-675
FAILURE CODE [DBRQKR]....40-676
FAILURE CODE [DBRRKR]....40-678
FAILURE CODE [DBTSKR] ....40-679
FAILURE CODE [DBUTKA] ....40-682
FAILURE CODE [DD12KA] .....40-683
FAILURE CODE [DD12KB] .....40-685
FAILURE CODE [DD13KA] .....40-687
FAILURE CODE [DD13KB] .....40-689
FAILURE CODE [DD14KA] .....40-691
FAILURE CODE [DD14KB] .....40-693
FAILURE CODE [DDKAKA] ....40-695
FAILURE CODE [DDKAKB] ....40-697
FAILURE CODE [DDKFL4] .....40-699
FAILURE CODE [DDKGL4].....40-701
FAILURE CODE [DDKHKA] ....40-703
FAILURE CODE [DDKHKB] ....40-705
FAILURE CODE [DDNLKA] ....40-707
FAILURE CODE [DDNLKB] ....40-709
FAILURE CODE [DDP6KA].....40-711
FAILURE CODE [DDP6KB].....40-714
FAILURE CODE [DDP6MA] ....40-716
FAILURE CODE [DDU1FS].....40-718
FAILURE CODE [DDU1KA] ....40-720
FAILURE CODE [DDU1KY] ....40-723
FAILURE CODE [DFA4KX] .....40-725
FAILURE CODE [DFA4KZ] .....40-726
FAILURE CODE [DFA4L8] ...40-727
FAILURE CODE [DFA5KA] .....40-728
FAILURE CODE [DFA5KB] .....40-731
FAILURE CODE [DFA6KA] .....40-734
FAILURE CODE [DFA6KB] .....40-737
FAILURE CODE [DFA7KX] .....40-740
FAILURE CODE [DFA7KZ] .....40-741
FAILURE CODE [DFA7L8] ...40-742
FAILURE CODE [DFA8KA] .....40-743
FAILURE CODE [DFA8KB] .....40-746
FAILURE CODE [DFA9KA] .....40-749
FAILURE CODE [DFA9KB] .....40-752
FAILURE CODE [DGS1KA] ....40-755
FAILURE CODE [DGS1KX] ....40-758
FAILURE CODE [DH21KA] .....40-759
FAILURE CODE [DH21KB] .....40-761
FAILURE CODE [DHA4KA].....40-763
FAILURE CODE [DHH7KA] ....40-765
FAILURE CODE [DHH7KB] ....40-768
FAILURE CODE [DHH8KA] ....40-770
FAILURE CODE [DHH8KB] ....40-773
FAILURE CODE [DHH9KA] ....40-775
FAILURE CODE [DHH9KB] ....40-778
FAILURE CODE [DHHAKA] ....40-780
FAILURE CODE [DHHAKB] ....40-783
FAILURE CODE [DK30KA] .....40-785
FAILURE CODE [DK30KB] .....40-788
FAILURE CODE [DK30KX] .....40-790
FAILURE CODE [DK30KZ] .....40-791
FAILURE CODE [DK30L8] ...40-792
FAILURE CODE [DK31KA] .....40-793
FAILURE CODE [DK31KB] .....40-796
FAILURE CODE [DK40KA] .....40-798
FAILURE CODE [DK40KB] .....40-801
FAILURE CODE [DK55KX] .....40-803
FAILURE CODE [DK55KZ] .....40-804
FAILURE CODE [DK55L8] ...40-805
FAILURE CODE [DK56KA] .....40-806
FAILURE CODE [DK56KB] .....40-809
FAILURE CODE [DK57KA] .....40-811
FAILURE CODE [DK57KB] .....40-814
FAILURE CODE [DK80KA] .....40-816
FAILURE CODE [DKS0L8]...40-818
FAILURE CODE [DKS1KA].....40-819
FAILURE CODE [DKS1KB].....40-821
FAILURE CODE [DKS2KA].....40-822
FAILURE CODE [DKS2KB].....40-824
FAILURE CODE [DKS3KA].....40-825
FAILURE CODE [DKS3KB].....40-827
FAILURE CODE [DKS3MB] ....40-828
FAILURE CODE [DKS4L8]...40-829
FAILURE CODE [DKS5KA].....40-830
FAILURE CODE [DKS5KB].....40-832
FAILURE CODE [DKS6KA].....40-833
FAILURE CODE [DKS6KB].....40-835
FAILURE CODE [DKS7MB] ....40-836
FAILURE CODE [DKSCL8] .....40-837
FAILURE CODE [DKSDKA] ....40-838
FAILURE CODE [DKSDKB] ....40-840
FAILURE CODE [DKSEKA] ....40-841
FAILURE CODE [DKSEKB] ....40-843
FAILURE CODE [DKSFKA].....40-844
FAILURE CODE [DKSFKB].....40-846
FAILURE CODE [DKSFMB] ....40-847
FAILURE CODE [DLM0KX].....40-849
FAILURE CODE [DLM0MA] ....40-850
FAILURE CODE [DLM1KA].....40-851
FAILURE CODE [DLM1KB].....40-853
FAILURE CODE [DLM1MA] ....40-855
FAILURE CODE [DLM2KA].....40-856
FAILURE CODE [DLM2KB].....40-858
FAILURE CODE [DLM2MA] ....40-860
FAILURE CODE [DLM3KA].....40-861
FAILURE CODE [DLM3KB].....40-863
FAILURE CODE [DLM3MB] ....40-865
FAILURE CODE [DN21FS] .....40-866
FAILURE CODE [DR21KX] .....40-868
FAILURE CODE [DR31KX] .....40-869
FAILURE CODE [DV20KB] .....40-870
FAILURE CODE [DW4BKA]....40-872
FAILURE CODE [DW4BKB]....40-874
FAILURE CODE [DW4BKY]....40-876
FAILURE CODE [DW7BKA]....40-878
FAILURE CODE [DW7BKB]....40-880
FAILURE CODE [DW7EKA]....40-882
FAILURE CODE [DW7EKB]....40-884
FAILURE CODE [DW7EKY]....40-886
FAILURE CODE [DWN5KA]....40-888
FAILURE CODE [DWN5KB]....40-890
FAILURE CODE [DWN5KY]....40-892
FAILURE CODE [DXA4KA].....40-894
FAILURE CODE [DXA4KB].....40-896
FAILURE CODE [DXA4KY].....40-898
FAILURE CODE [DXA5KA].....40-900
FAILURE CODE [DXA5KB].....40-902
FAILURE CODE [DXA5KY].....40-904
FAILURE CODE [DXA6KA].....40-906
FAILURE CODE [DXA6KB].....40-908
FAILURE CODE [DXA6KY].....40-910
FAILURE CODE [DXA7KA].....40-912
FAILURE CODE [DXA7KB].....40-914
FAILURE CODE [DXA7KY].....40-916
FAILURE CODE [DXHRKA] ....40-918
FAILURE CODE [DXHRKB] ....40-920
FAILURE CODE [DXHRKY] ....40-922
FAILURE CODE [DXHSKA] ....40-924
FAILURE CODE [DXHSKB] ....40-926
FAILURE CODE [DXHSKY] ....40-928
FAILURE CODE [DXHTKA] ....40-930
FAILURE CODE [DXHTKB] ....40-932
FAILURE CODE [DXHTKY] ....40-934
FAILURE CODE [DXHUKA] ....40-936
FAILURE CODE [DXHUKB] ....40-938
FAILURE CODE [DXHUKY] ....40-940
FAILURE CODE [DXJ4KA] .....40-942
FAILURE CODE [DXJ4KB] .....40-944
FAILURE CODE [DXJCKA].....40-946
FAILURE CODE [DXJCKB].....40-948
FAILURE CODE [DXJCKY].....40-950
FAILURE CODE [DXJDKA].....40-952
FAILURE CODE [DXJDKB].....40-954
FAILURE CODE [DXJDKY].....40-956
FAILURE CODE [DXK1KA].....40-958
FAILURE CODE [DXK1KB].....40-960
FAILURE CODE [DXK1KY].....40-962
FAILURE CODE [DXK2KA].....40-964
FAILURE CODE [DXK2KB].....40-966
FAILURE CODE [DXK2KY].....40-968
TROUBLESHOOTING OF ELECTRICAL SYSTEM (E-MODE) .....40-970
E-1 ENGINE DOES NOT START (ENGINE DOES NOT CRANK) ...40-970
E-2 MANUAL PREHEATING SYSTEM DOES NOT WORK....40-977
E-3 AUTOMATIC PREHEATING SYSTEM DOES NOT WORK ....40-980
E-4 WHILE PREHEATING IS WORKING, PREHEATING MONITOR DOES NOT LIGHT UP....40-982
E-5 WHEN STARTING SWITCH IS TURNED TO ON POSITION, MACHINE MONITOR DISPLAYS
NOTHING....40-984
E-6 WHEN STARTING SWITCH IS TURNED TO ON POSITION (WITH ENGINE STOPPED), BASIC
CHECK MONITOR LIGHTS UP ...40-988
E-7 AIR CLEANER CLOGGING MONITOR LIGHTS UP IN YELLOW WHILE ENGINE IS RUNNING.....
.....40-989
E-8 CHARGE LEVEL MONITOR LIGHTS UP IN RED WHILE ENGINE IS RUNNING .....40-990
E-9 ENGINE COOLANT TEMPERATURE MONITOR LIGHTS UP IN RED WHILE ENGINE IS RUN-
NING .....40-991
E-10 ENGINE OIL PRESSURE MONITOR LIGHTS UP IN RED WHILE ENGINE IS RUNNING ..40-992
E-11 HST CHARGE PRESSURE MONITOR LIGHTS UP IN RED WHILE ENGINE IS RUNNING ....
.....40-993
E-12 HYDRAULIC OIL TEMPERATURE MONITOR LIGHTS UP IN RED WHILE ENGINE IS RUN-
NING .....40-994
E-13 HST OIL FILTER CLOGGING MONITOR LIGHTS UP IN RED WHILE ENGINE IS RUNNING ....
.....40-995
E-14 ENGINE COOLANT TEMPERATURE GAUGE DOES NOT INDICATE CORRECT TEMPERA-
TURE ....40-996
E-15 FUEL LEVEL GAUGE DOES NOT INDICATE CORRECT LEVEL ...40-997
E-16 HYDRAULIC OIL TEMPERATURE GAUGE DOES NOT INDICATE CORRECT TEMPERATURE..
...40-1000
E-17 OPERATION MODE DOES NOT CHANGE...40-1001
E-18 OPERATING CUSTOMIZE SWITCH DOES NOT DISPLAY CUSTOMIZE SCREEN....40-1002
E-19 MODIFYING SETTING ON CUSTOMIZE SCREEN DOES NOT CHANGE SETTING OF MA-
CHINE ....40-1003
E-20 SERVICE METER IS NOT DISPLAYED, WHILE STARTING SWITCH IS IN OFF POSITION...
...40-1004
E-21 SERVICE MODE CANNOT BE SELECTED .....40-1005
E-22 WORK EQUIPMENT DOES NOT OPERATE ...40-1006
E-23 FOOT HEATER DOES NOT OPERATE .....40-1008
E-24 HORN DOES NOT SOUND...40-1014
E-25 HORN DOES NOT STOP SOUNDING....40-1016
E-26 BACKUP ALARM DOES NOT SOUND ...40-1017
E-27 BACKUP ALARM DOES NOT STOP SOUNDING.....40-1018
E-28 HEADLAMP DOES NOT LIGHT UP .....40-1019
E-29 REAR LAMP DOES NOT LIGHT UP ....40-1023
E-30 ALL WIPERS DO NOT OPERATE.....40-1026
E-31 FRONT WIPER DOES NOT OPERATE .....40-1028
E-32 REAR WIPER DOES NOT OPERATE.....40-1030
E-33 LEFT DOOR WIPER DOES NOT OPERATE ...40-1032
E-34 RIGHT DOOR WIPER DOES NOT OPERATE ....40-1036
E-35 FRONT WASHER DOES NOT OPERATE.....40-1040
E-36 REAR WASHER DOES NOT OPERATE ....40-1042
E-37 LEFT DOOR WASHER DOES NOT OPERATE...40-1044
E-38 RIGHT DOOR WASHER DOES NOT OPERATE ...40-1046
E-39 KOMTRAX SYSTEM DOES NOT OPERATE NORMALLY ....40-1048
E-40 CONTROL BOX SHUTS DOWN AFTER DISPLAYING THE MESSAGES [GPS receiver not con-
nected !] AND [Slope sensor not connected !] ....40-1049
E-41 CONTROL BOX DISPLAYS THE MESSAGES [GPS receiver not connected !] AND [Slope sensor
not connected !] .....40-1053
E-42 CONTROL BOX DISPLAYS THE MESSAGE [Waiting for radio link...] ....40-1058
E-43 CONTROL BOX DISPLAYS THE MESSAGE [IMU sensor not connected]....40-1059
E-44 CONTROL BOX DISPLAYS THE MESSAGE [Waiting for satellites...].....40-1060
E-45 CONTROL BOX DISPLAYS THE MESSAGE [Komatsu controller not connected!] ...40-1061
E-46 CONTROL BOX DISPLAYS THE MESSAGE [Cylinder Stroke Reading Abnormal]...40-1063
E-47 CONTROL BOX DISPLAYS THE MESSAGE [Komatsu CAN Comms Abnormal] .....40-1064
E-48 CONTROL BOX DISPLAYS THE MESSAGE [Komatsu Machine Trouble] ....40-1065
E-49 CONTROL BOX DISPLAYS THE MESSAGE [Waiting to initialize....] ...40-1066
E-50 CONTROL BOX DISPLAYS THE MESSAGE [System Initializing].....40-1067
E-51 CONTROL BOX DISPLAYS THE MESSAGE [Initializing....].....40-1068
E-52 CONTROL BOX DISPLAYS THE MESSAGE [Configuring GPS]....40-1069
E-53 CONTROL BOX DISPLAYS THE MESSAGE [No GPS Localization...]....40-1070
E-54 CONTROL BOX DISPLAYS THE MESSAGE [Low precisions...]....40-1071
E-55 CONTROL BOX DISPLAYS THE MESSAGE [Heading Initializing] ...40-1072
E-56 CONTROL BOX DISPLAYS [Out of design area...]....40-1073
E-57 CONTROL BOX CAN NOT BE TURNED ON ...40-1074
E-58 CONTROL BOX DOES NOT DISPLAY INTELLIGENT MACHINE CONTROL SCREEN ...40-1075
E-59 CONTROL BOX DOES NOT DISPLAY BULLDOZER IMAGE .....40-1076
E-60 CONTROL BOX DOES NOT DISPLAY DESIGN SURFACE ....40-1077
E-61 CONTROL BOX TOUCH PANEL DOES NOT RESPOND.....40-1078
E-62 CONTROL BOX TOUCH PANEL IS INACCURATE...40-1079
E-63 CYLINDER STROKE RESET INDICATION DOES NOT GO OUT.....40-1080
E-64 AUTO IS NOT DISPLAYED WHEN AUTO/MANUAL SWITCH IS PRESSED (AUTO INDICATION
GOES OUT) ....40-1081
E-65 BLADE AUTOMATIC LOWER CONTROL DOES NOT START WHILE AUTO IS DISPLAYED.....
...40-1083
E-66 BLADE AUTOMATIC RAISE CONTROL DOES NOT START WHILE AUTO IS DISPLAYED ....
...40-1084
E-67 BLADE AUTOMATIC CONTROL FUNCTION IS NOT ACTIVATED WHILE AUTO IS DISPLAYED
(BLADE AUTOMATIC CONTROL STOPS)...40-1085
E-68 WHEN CHECKING AND ADJUSTING THE BLADE ELEVATION, THE VALUE IS DIFFERENT
FROM ACTUAL MACHINE .....40-1086
E-69 FINISHED SURFACE IS INACCURATE (THE AVERAGE HEIGHT OF FINISHED SURFACE IS
LOWER THAN DESIGNED SURFACE OR BLADE DOES NOT TOUCH THE SURFACE) .....40-1087
E-70 FINISHED SURFACE IS INACCURATE (THE FINISHED SURFACE IS NOT SMOOTH) ..40-1088
E-71 FINISHED SURFACE IS INACCURATE (WHEN FINISHING SLOPE HORIZONTALLY, STEPS
ARE MADE IN EACH DIRECTION).....40-1089
E-72 MACHINE CAN NOT ESCAPE FROM SHOES SLIP WHILE BLADE AUTOMATIC CONTROL IS
ACTIVATED (SHOES FREQUENTLY SLIPS).....40-1091
E-73 MACHINE SPEED DOES NOT INCREASE WHILE BLADE AUTOMATIC CONTROL IS ACTI-
VATED....40-1092
E-74 BLADE TILT ANGLE DOES NOT COINCIDE WITH DESIGN SURFACE...40-1093
E-75 BLADE TILTS BACK WHILE BLADE AUTOMATIC CONTROL IS ACTIVATED...40-1095
E-76 WHEN PRESSING CUT/FILL LEVEL SWITCH (RAISE), THE DESIGN SURFACE DOES NOT
RISE....40-1097
E-77 WHEN PRESSING CUT/FILL LEVEL SWITCH (LOWER), THE DESIGN SURFACE DOES NOT
LOWER .....40-1100
E-78 WHEN STARTING SWITCH IS TURNED TO ON POSITION, REVERSE LEVELING MODE
SWITCH LED DOES NOT LIGHT UP OR DOES NOT GO OUT ...40-1103
E-79 WHEN REVERSE LEVELING MODE SWITCH IS PRESSED, BUZZER DOES NOT SOUND
(DOES NOT SWITCH TO REVERSE LEVELING MODE)....40-1105
TROUBLESHOOTING FOR HYDRAULIC AND MECHANICAL SYSTEMS (H MODE) ...40-1108
INFORMATION MENTIONED IN TROUBLESHOOTING TABLE (H MODE)....40-1108
FAILURE MODE AND CAUSE TABLE....40-1109
H-1 NEITHER R.H. NOR L.H. OF TRACKS CAN TRAVEL FORWARD OR REVERSE (NONE OF THE
TRAVEL SYSTEMS OPERATE) .... 40-1115
H-2 EITHER R.H. OR L.H. OF TRACK CANNOT TRAVEL BOTH FORWARD AND REVERSE (ONE
OF R.H. OR L.H. TRAVEL SYSTEMS CANNOT OPERATE) ..... 40-1117
H-3 EITHER R.H. OR L.H. OF TRACK CANNOT TRAVEL ONE OF FORWARD OR REVERSE (ONLY
ONE OF THE TRAVEL SYSTEMS CANNOT OPERATE IN ONE DIRECTION) .... 40-1119
H-4 TRAVEL SPEED OR POWER IS LOW...40-1121
H-5 SPEED RANGE DOES NOT CHANGE .....40-1123
H-6 SHOCK IS LARGE WHEN MACHINE MOVES OFF OR STOPS .....40-1124
H-7 MACHINE DEVIATES LARGELY .....40-1125
H-8 MACHINE DRIFT ON A SLOPE IS LARGE.....40-1128
H-9 ENGINE SPEED DROPS LARGELY OR ENGINE STOPS .....40-1130
H-10 UNUSUAL NOISE IS HEARD FROM AROUND HST PUMP OR MOTOR ....40-1132
H-11 HST OIL TEMPERATURE (HYDRAULIC OIL TEMPERATURE) RISES TOO HIGH ....40-1134
H-12 ALL WORK EQUIPMENT DO NOT OPERATE ...40-1136
H-13 ALL WORK EQUIPMENTS SPEED OR POWER IS LOW ....40-1138
H-14 BLADE LIFT SPEED OR POWER IS LOW ...40-1139
H-15 BLADE TILT SPEED OR POWER IS LOW ...40-1141
H-16 BLADE ANGLE SPEED OR POWER IS LOW.....40-1142
H-17 TIME LAG OF BLADE LIFT IS LARGE ...40-1143
H-18 HYDRAULIC DRIFT OF LIFTED BLADE IS LARGE ....40-1144
H-19 HYDRAULIC DRIFT OF TILTED BLADE IS LARGE.....40-1145
H-20 UNUSUAL NOISE IS HEARD FROM AROUND WORK EQUIPMENT AND COOLING FAN
PUMP OR CONTROL VALVE ....40-1146
H-21 FAN SPEED IS ABNORMAL (TOO HIGH OR LOW, OR STATIONARY) ....40-1147
H-22 UNUSUAL NOISE IS HEARD FROM AROUND FAN ...40-1149
TROUBLESHOOTING OF ENGINE (S-MODE) ...40-1150
INFORMATION MENTIONED IN TROUBLESHOOTING TABLE (S MODE)....40-1150
S-1 ENGINE DOES NOT CRANK WHEN STARTING SWITCH IS TURNED TO START POSITION....
...40-1151
S-2 ENGINE CRANKS BUT NO EXHAUST GAS COMES OUT ....40-1152
S-3 FUEL IS BEING INJECTED BUT ENGINE DOES NOT START (MISFIRING: ENGINE CRANKS
BUT DOES NOT START) .....40-1153
S-4 ENGINE STARTABILITY IS POOR...40-1155
S-5 ENGINE DOES NOT PICK UP SMOOTHLY ...40-1157
S-6 ENGINE STOPS DURING OPERATION ...40-1159
S-7 ENGINE RUNS ROUGH OR IS UNSTABLE ...40-1161
S-8 ENGINE LACKS POWER.....40-1162
S-9 EXHAUST SMOKE IS BLACK....40-1164
S-10 ENGINE OIL CONSUMPTION IS EXCESSIVE ...40-1166
S-11 OIL BECOMES CONTAMINATED QUICKLY ....40-1167
S-12 FUEL CONSUMPTION IS EXCESSIVE .....40-1168
S-13 OIL IS IN COOLANT (OR COOLANT SPURTS BACK OR COOLANT LEVEL GOES DOWN) ....
...40-1169
S-14 OIL PRESSURE DROPS ...40-1170
S-15 FUEL MIXES INTO ENGINE OIL....40-1172
S-16 WATER MIXES INTO ENGINE OIL (MILKY) ....40-1173
S-17 COOLANT TEMPERATURE RISES TOO HIGH (OVERHEATING) ...40-1174
S-18 UNUSUAL NOISE IS HEARD...40-1175
S-19 VIBRATION IS EXCESSIVE .....40-1176
S-20 AIR CANNOT BE BLED FROM FUEL CIRCUIT.....40-1177
S-21 ACTIVE REGENERATION IS EXECUTED FREQUENTLY ...40-1178
S-22 ACTIVE REGENERATION TAKES TIME....40-1179
S-23 WHITE SMOKE IS EXHAUSTED DURING ACTIVE REGENERATION...40-1180
S-24 AdBlue/DEF CONSUMPTION IS EXCESSIVE ....40-1181
S-25 THERE IS UNUSUAL SMELL (IRRITATING ODOR) ....40-1183
S-26 FOREIGN MATERIALS ENTER AdBlue/DEF (AdBlue/DEF INCREASES)....40-1184
50 DISASSEMBLY AND ASSEMBLY.... 50-1
CONTENTS ..... 50-2
ABBREVIATION LIST ..... 50-7
RELATED INFORMATION ON DISASSEMBLY AND ASSEMBLY ..... 50-13
HOW TO READ THIS MANUAL..... 50-13
COATING MATERIALS LIST.... 50-15
SPECIAL TOOLS LIST ... 50-20
SKETCHES OF SPECIAL TOOLS.... 50-42
ENGINE AND COOLING SYSTEM.... 50-55
REMOVE AND INSTALL SUPPLY PUMP ASSEMBLY ... 50-55
REMOVE AND INSTALL INJECTOR ASSEMBLY .... 50-75
REMOVE AND INSTALL CYLINDER HEAD ASSEMBLY ....50-100
REMOVE AND INSTALL EGR VALVE ASSEMBLY.....50-143
REMOVE AND INSTALL EGR COOLER ASSEMBLY....50-150
REMOVE AND INSTALL STARTING MOTOR ASSEMBLY ....50-158
REMOVE AND INSTALL AIR CONDITIONER COMPRESSOR BELT ...50-163
REMOVE AND INSTALL ALTERNATOR BELT .....50-172
REMOVE AND INSTALL AUTOMATIC TENSIONER.....50-177
REMOVE AND INSTALL RADIATOR ASSEMBLY ...50-180
REMOVE AND INSTALL HYDRAULIC OIL COOLER ASSEMBLY .....50-197
REMOVE AND INSTALL AFTERCOOLER ASSEMBLY....50-208
REMOVE AND INSTALL COOLING FAN DRIVE ASSEMBLY ...50-222
REMOVE AND INSTALL COOLING FAN MOTOR ASSEMBLY ....50-231
REMOVE AND INSTALL ENGINE, HST PUMP ASSEMBLY .....50-237
REMOVE AND INSTALL ENGINE FRONT OIL SEAL ...50-260
REMOVE AND INSTALL ENGINE REAR OIL SEAL...50-265
REMOVE AND INSTALL ENGINE HOOD ASSEMBLY .....50-269
REMOVE AND INSTALL KDOC ASSEMBLY.....50-276
REMOVE AND INSTALL KDOC AND SCR ASSEMBLY ...50-289
REMOVE AND INSTALL BELLOWS PIPE ASSEMBLY ....50-305
REMOVE AND INSTALL FUEL TANK ASSEMBLY .....50-313
REMOVE AND INSTALL AdBlue/DEF TANK ASSEMBLY ...50-328
REMOVE AND INSTALL AdBlue/DEF TANK SENSOR FLANGE ASSEMBLY...50-348
REMOVE AND INSTALL AdBlue/DEF TANK SENSOR ....50-354
REMOVE AND INSTALL AdBlue/DEF TANK STRAINER ....50-358
REMOVE AND INSTALL SCR ASSEMBLY.....50-360
REMOVE AND INSTALL KCCV ASSEMBLY .....50-366
REMOVE AND INSTALL AdBlue/DEF MIXING TUBE ...50-370
REMOVE AND INSTALL AdBlue/DEF INJECTOR...50-378
REMOVE AND INSTALL AdBlue/DEF PUMP ....50-388
REMOVE AND INSTALL AdBlue/DEF HOSE ....50-396
REMOVE AND INSTALL AIR CLEANER ASSEMBLY....50-438
REMOVE AND INSTALL AIR CONDITIONER COMPRESSOR ASSEMBLY .....50-443
REMOVE AND INSTALL AIR CONDITIONER CONDENSER ASSEMBLY .....50-452
POWER TRAIN...50-460
DISASSEMBLE AND ASSEMBLE FINAL DRIVE ASSEMBLY...50-460
UNDERCARRIAGE AND FRAME.....50-474
REMOVE AND INSTALL TRACK FRAME ASSEMBLY.....50-474
REMOVE AND INSTALL IDLER ASSEMBLY.....50-484
DISASSEMBLE AND ASSEMBLE IDLER ASSEMBLY .....50-489
REMOVE AND INSTALL RECOIL SPRING ASSEMBLY .....50-496
DISASSEMBLE AND ASSEMBLE RECOIL SPRING ASSEMBLY...50-497
REMOVE AND INSTALL TRACK ROLLER ASSEMBLY ...50-503
DISASSEMBLE AND ASSEMBLE TRACK ROLLER ASSEMBLY ...50-508
REMOVE AND INSTALL CARRIER ROLLER ASSEMBLY .....50-513
DISASSEMBLE AND ASSEMBLE CARRIER ROLLER ASSEMBLY .....50-516
REMOVE AND INSTALL PIVOT SHAFT ASSEMBLY ....50-520
SEPARATE AND CONNECT TRACK ASSEMBLY...50-523
SEPARATE AND CONNECT PLUS TYPE TRACK ASSEMBLY ...50-528
DISASSEMBLE AND ASSEMBLE TRACK ASSEMBLY GENERALLY...50-529
DISASSEMBLE AND ASSEMBLE PLUS TYPE TRACK ASSEMBLY GENERALLY ...50-547
DISASSEMBLE AND ASSEMBLE ONE LINK OF TRACK SHOE ASSEMBLY ON THE FIELD ....50-558
DISASSEMBLE AND ASSEMBLE ONE LINK OF PLUS TYPE TRACK SHOE ASSEMBLY ON THE
FIELD ....50-567
REMOVE AND INSTALL EQUALIZER BAR ASSEMBLY.....50-574
REMOVE AND INSTALL EQUALIZER BAR SIDE BUSHINGS .....50-579
REMOVE AND INSTALL SEGMENT TEETH.....50-581
HYDRAULIC SYSTEM....50-585
REMOVE AND INSTALL HYDRAULIC TANK ASSEMBLY...50-585
REMOVE AND INSTALL CONTROL VALVE ASSEMBLY ....50-601
WORK EQUIPMENT....50-609
REMOVE AND INSTALL BLADE ASSEMBLY ...50-609
REMOVE AND INSTALL STROKE SENSING BLADE LIFT CYLINDER ASSEMBLY ....50-617
DISASSEMBLE AND ASSEMBLE STROKE SENSING BLADE LIFT CYLINDER ASSEMBLY ....50-621
REMOVE AND INSTALL STROKE SENSING BLADE TILT CYLINDER ASSEMBLY ....50-634
DISASSEMBLE AND ASSEMBLE STROKE SENSING BLADE TILT CYLINDER ASSEMBLY.....50-642
REMOVE AND INSTALL STROKE SENSING BLADE ANGLE CYLINDER ASSEMBLY .....50-651
DISASSEMBLE AND ASSEMBLE STROKE SENSING BLADE ANGLE CYLINDER ASSEMBLY50-657
REMOVE AND INSTALL U-FRAME ASSEMBLY .....50-667
CAB AND ITS ATTACHMENTS .....50-674
REMOVE AND INSTALL OPERATOR'S CAB ASSEMBLY .....50-674
REMOVE AND INSTALL OPERATOR'S CAB GLASS (ADHERED GLASS) ...50-690
REMOVE AND INSTALL AIR CONDITIONER UNIT ASSEMBLY ....50-698
REMOVE AND INSTALL RECEIVER DRIER.....50-711
REMOVE AND INSTALL OPERATOR'S SEAT .....50-715
REMOVE AND INSTALL SEAT BELT ....50-717
REMOVE AND INSTALL FOOT HEATER ASSEMBLY .....50-719
DISASSEMBLE AND ASSEMBLE FOOT HEATER ASSEMBLY...50-724
ELECTRICAL SYSTEM .....50-726
REMOVE AND INSTALL ENGINE CONTROLLER ASSEMBLY ...50-726
REMOVE AND INSTALL HST CONTROLLER ASSEMBLY ....50-733
REMOVE AND INSTALL MACHINE MONITOR ASSEMBLY .....50-735
REMOVE AND INSTALL MASS AIR FLOW AND TEMPERATURE SENSOR ...50-738
REMOVE AND INSTALL KCCV CRANKCASE PRESSURE SENSOR.....50-742
REMOVE AND INSTALL ICT SENSOR CONTROLLER ASSEMBLY ....50-746
REMOVE AND INSTALL CONTROL BOX ...50-748
REMOVE AND INSTALL GNSS RECEIVER...50-750
REMOVE AND INSTALL GNSS ANTENNA ....50-752
REMOVE AND INSTALL IMU SENSOR ...50-758
60 MAINTENANCE STANDARD..... 60-1
CONTENTS ..... 60-2
ABBREVIATION LIST ..... 60-3
ENGINE AND COOLING SYSTEM... 60-9
MAINTENANCE STANDARD OF ENGINE MOUNT ... 60-9
MAINTENANCE STANDARD OF DAMPER..... 60-10
MAINTENANCE STANDARD OF COOLING SYSTEM ....60-11
MAINTENANCE STANDARD OF COOLING FAN MOTOR... 60-13
MAINTENANCE STANDARD OF HYDRAULIC OIL COOLER BYPASS AND HST CHARGE SAFETY
VALVE .... 60-15
POWER TRAIN.... 60-16
MAINTENANCE STANDARD OF HST PUMP..... 60-16
MAINTENANCE STANDARD OF HST CHARGE PUMP.... 60-20
MAINTENANCE STANDARD OF HST MOTOR..... 60-22
MAINTENANCE STANDARD OF FINAL DRIVE .... 60-24
MAINTENANCE STANDARD OF SPROCKET FOR PLUS TYPE TRACK SHOE..... 60-26
MAINTENANCE STANDARD OF SPROCKET TOOTH PROFILE FULL-SCALE DRAWING FOR PLUS
TYPE TRACK SHOE... 60-27
UNDERCARRIAGE AND FRAME... 60-28
MAINTENANCE STANDARD OF SUSPENSION... 60-28
MAINTENANCE STANDARD OF TRACK FRAME AND IDLER CUSHION... 60-31
MAINTENANCE STANDARD OF IDLER ... 60-34
MAINTENANCE STANDARD OF TRACK ROLLER FOR PLUS TYPE TRACK SHOES (SINGLE
FLANGE TYPE) .... 60-36
MAINTENANCE STANDARD OF TRACK ROLLER FOR PLUS TYPE TRACK SHOES (DOUBLE
FLANGE TYPE) .... 60-37
MAINTENANCE STANDARD OF CARRIER ROLLER FOR PLUS TYPE TRACK SHOE ..... 60-39
MAINTENANCE STANDARD OF PLUS TYPE TRACK SHOE.... 60-40
MAINTENANCE STANDARD OF SINGLE SHOE ..... 60-42
HYDRAULIC SYSTEM..... 60-43
MAINTENANCE STANDARD OF HYDRAULIC TANK .... 60-43
MAINTENANCE STANDARD OF WORK EQUIPMENT AND COOLING FAN PUMP ..... 60-44
MAINTENANCE STANDARD OF CONTROL VALVE... 60-47
MAINTENANCE STANDARD OF RIPPER PPC VALVE..... 60-53
MAINTENANCE STANDARD OF 5-PORT VALVE OF EPC AND SOLENOID .... 60-55
MAINTENANCE STANDARD OF QUICK DROP VALVE.... 60-57
WORK EQUIPMENT..... 60-59
MAINTENANCE STANDARD OF FRONT WORK EQUIPMENT.... 60-59
MAINTENANCE STANDARD OF CUTTING EDGE AND END BIT ... 60-62
MAINTENANCE STANDARD OF STROKE SENSING BLADE LIFT CYLINDER ... 60-63
MAINTENANCE STANDARD OF STROKE SENSING BLADE TILT CYLINDER ... 60-64
MAINTENANCE STANDARD OF STROKE SENSING BLADE ANGLE CYLINDER .... 60-65
MAINTENANCE STANDARD OF STROKE AND RESET SENSOR FOR BLADE LIFT CYLINDER .....
... 60-66
MAINTENANCE STANDARD OF STROKE SENSOR FOR BLADE TILT CYLINDER..... 60-67
MAINTENANCE STANDARD OF STROKE SENSOR FOR BLADE ANGLE CYLINDER... 60-68
MAINTENANCE STANDARD OF FIXED MULTI-SHANK RIPPER.... 60-69
MAINTENANCE STANDARD OF RIPPER LIFT CYLINDER.... 60-71
CAB AND ITS ATTACHMENTS ... 60-72
MAINTENANCE STANDARD OF CAB MOUNT..... 60-72
ELECTRICAL SYSTEM ... 60-74
MAINTENANCE STANDARD OF ELECTRIC STEERING CONTROL LEVER.... 60-74
80 APPENDIX... 80-1
CONTENTS ..... 80-2
ABBREVIATION LIST ..... 80-3
AIR CONDITIONER SYSTEM .... 80-9
PRECAUTIONS FOR REFRIGERANT ..... 80-9
AIR CONDITIONER COMPONENT ..... 80-10
SPECIFICATIONS OF AIR CONDITIONER ..... 80-13
CONFIGURATION AND FUNCTION OF REFRIGERATION CYCLE ... 80-14
OUTLINE OF REFRIGERATION CYCLE ... 80-15
COMPONENT PARTS OF AIR CONDITIONER SYSTEM ..... 80-17
AIR CONDITIONER UNIT..... 80-17
COMPONENT PARTS OF AIR CONDITIONER UNIT..... 80-19
COMPRESSOR ..... 80-22
CONDENSER ..... 80-23
RECEIVER DRIER.... 80-25
EXPLANATION OF PROCEDURE FOR TESTING AND TROUBLESHOOTING OF AIR CONDITIONER...
.... 80-27
CIRCUIT DIAGRAM OF AIR CONDITIONER ... 80-30
AIR CONDITIONER SYSTEM DIAGRAM ... 80-31
CONTROL FUNCTION OF AIR CONDITIONER..... 80-32
INSTALLATION LOCATIONS OF AIR CONDITIONER PARTS AND ARRANGEMENT OF CONNECTORS ..
.... 80-33
TEST RELAYS..... 80-37
METHOD FOR TESTING RELAYS ... 80-37
AIR CONDITIONER TROUBLESHOOTING CHART 1 .... 80-39
AIR CONDITIONER TROUBLESHOOTING CHART 2 .... 80-40
INFORMATION DESCRIBED IN TROUBLESHOOTING TABLE..... 80-43
A-1 TROUBLESHOOTING FOR CONDENSER FAN.... 80-45
A-2 TROUBLESHOOTING FOR BLOWER MOTOR SYSTEM (NO AIR COMES OUT OR AIR FLOW IS
ABNORMAL) .... 80-48
A-3 TROUBLESHOOTING FOR TEMPERATURE CONTROL FUNCTION ... 80-51
TROUBLESHOOTING USING GAUGE PRESSURE.... 80-55
CONNECTION OF SERVICE TOOL ..... 80-57
METHOD FOR CONNECTING SERVICE TOOL ... 80-58
PRECAUTIONS FOR DISCONNECTING AND CONNECTING HOSES AND TUBES IN AIR CONDITION-
ER PIPINGS..... 80-59
HANDLE COMPRESSOR OIL ..... 80-61
90 CIRCUIT DIAGRAMS .... 90-1
CONTENTS ..... 90-2
ABBREVIATION LIST ..... 90-3
HYDRAULIC CIRCUIT DIAGRAM .... 90-9
SYMBOLS USED IN HYDRAULIC CIRCUIT DIAGRAM ... 90-9
HYDRAULIC CIRCUIT DIAGRAM .... 90-13
ELECTRICAL CIRCUIT DIAGRAM .... 90-15
SYMBOLS USED IN ELECTRICAL CIRCUIT DIAGRAM... 90-15
ELECTRICAL CIRCUIT DIAGRAM (1/14)..... 90-19
ELECTRICAL CIRCUIT DIAGRAM (2/14)..... 90-21
ELECTRICAL CIRCUIT DIAGRAM (3/14)..... 90-23
ELECTRICAL CIRCUIT DIAGRAM (4/14)..... 90-25
ELECTRICAL CIRCUIT DIAGRAM (5/14)..... 90-27
ELECTRICAL CIRCUIT DIAGRAM (6/14)..... 90-29
ELECTRICAL CIRCUIT DIAGRAM (7/14)..... 90-31
ELECTRICAL CIRCUIT DIAGRAM (8/14)..... 90-33
ELECTRICAL CIRCUIT DIAGRAM (9/14)..... 90-35
ELECTRICAL CIRCUIT DIAGRAM (10/14)... 90-37
ELECTRICAL CIRCUIT DIAGRAM (11/14) ... 90-39
ELECTRICAL CIRCUIT DIAGRAM (12/14)... 90-41
ELECTRICAL CIRCUIT DIAGRAM (13/14) ... 90-43
ELECTRICAL CIRCUIT DIAGRAM (14/14) ... 90-45
INDEX...1
Komatsu Crawler Dozers/Tractors D51- series Repair Service Manuals
