Komatsu D51EXi-22, D51PXi-22 Crawler Dozer (B13500 and up) Service Repair Shop Manual - KEBM028601

This complete service repair workshop manual PDF download for the D51EXi-22, D51PXi-22 Komatsu Bulldozer (B13500 and up) has easy to read text sections with top quality diagrams, pictures and illustrations. The step by step instructions show you how to fault find or complete any repair or overhaul, correctly and efficiently, saving time and avoiding costly mistakes. All specifications and tolerances are listed. Functions of components and systems are also explained.


APPLICABLE MODELS :

Komatsu D51EXi-22 - S/N: B13500 and up
Komatsu D51PXi-22 - S/N: B13500 and up

ENGINE 6D107E-1


TABLE OF CONTENTS :

00 INDEX AND FOREWORD
01 SPECIFICATION
10 STRUCTURE AND FUNCTION
20 STANDARD VALUE TABLES
30 TESTING AND ADJUSTING
40 TROUBLESHOOTING
50 DISASSEMBLY AND ASSEMBLY
90 OTHERS


MANUAL SPECIFICATION :

File Format : PDF
Language : English
Printable : Yes
Searchable : Yes
Bookmarked : Yes
Product Code : KEBM028601
Total Pages : 1574


This (OEM) Komatsu Shop Manual has detailed illustrations as well as step by step instructions, It is 100 percents complete and intact. they are specifically written for the do-it-yourself-er as well as the experienced mechanic. With step by step instruction & highly detailed exploded pictures & diagrams to show you how to complete the required job correctly & efficiently Using. Provides step-by-step instructions based on the complete dis-assembly of the machine. It is this level of detail, along with hundreds of photos and illustrations, that guide the reader through each service and repair procedure. Complete download comes in pdf format which can work under all PC based windows operating system and Mac also, All pages are printable. Using this repair manual is an inexpensive way to keep your vehicle working properly.

This service repair workshop manual PDF download has been prepared as an aid to improve the quality of repairs by giving the serviceman an accurate understanding of the product and by showing him the correct way to perform repairs and make judgements. Make sure you understand the contents of this manual and use it to full effect at every opportunity. This is a must for the Do-It-Yourselfer! Saving Yourself $$$$$$ In Service Repair And Maintenance Costs !!!!

This manual PDF download contains specs, diagrams, actual real photo illustrations, and schemes. In addition to space savings, nice thing about having completly searcheble PDF files instead of a hard-printed manual is that you can use the Search feature in your PDF reader software (Adobe Acrobat) to find just what your looking for and just print out the exact pages you need or all manual easily. This is the same Repair Service manual your local dealer will use when doing a repair.

Instant Download means there is NO shipping costs or waiting for a CD or paper manual to arrive in the mail! You will receive this manual TODAY via Instant Download on completion of payment via our secure payment processor. We accept ALL major credit/debit cards/paypal.

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00 INDEX AND FOREWORD
INDEX
FOREWORD, SAFETY AND GENERAL INFORMATION
IMPORTANT SAFETY NOTICE
HOW TO READ THE SHOP MANUAL
EXPLANATION OF TERMS FOR MAINTENACE STANDARD
HANDLING EQUIPMENT OF FUEL SYSTEM DEVICES
HANDLING OF INTAKE SYSTEM PARTS
HANDLING OF HYDRAULIC EQUIPMENT
METHOD OF DISCONNECTING AND CONNECTING OF PUSH-PULL TYPE COUPLER
HANDLING OF ELECTRICAL EQUIPMENT
HOW TO READ ELECTRIC WIRE CODE
PRECAUTIONS WHEN PERFORMING OPERATION
PRACTICAL USE OF KOMTRAX
STANDARD TIGHTENING TORQUE TABLE
LIST OF ABBREVIATION
CONVERSION TABLE

01 SPECIFICATION
TABLE OF CONTENTS
SPECIFICATION DRAWING
D51EXi, PXi-22 POWER ANGLE, POWER TILT DOZER WITH ROPS CAB
SPECIFICATION
WEIGHT TABLE
TABLE OF FUEL, COOLANT AND LUBRICANTS
RECOMMENDED PRODUCTS OTHER THAN KOMATSU GENUINE OILS

10 STRUCTURE AND FUNCTION
TABLE OF CONTENTS
ENGINE AND COOLING SYSTEM
ENGINE RELATED PARTS
COOLING SYSTEM
COOLING FAN PUMP - SEE HYDRAULIC SYSTEM 2 (WORK EQUIPMENT AND FAN PUMP)
COOLING FAN MOTOR
OIL COOLER BYPASS VALVE
CHARGE SAFETY VALVE
POWER TRAIN
POWER TRAIN
HST CLOSED CIRCUIT
DAMPER
HST HYDRAULIC EQUIPMENT ARRANGEMENT DIAGRAM
STEERING AND BRAKE CONTROL
HST PUMP
SAFETY-SUCTION VALVE
TOWING VALVE
HST MOTOR
MOTOR CONTROL VALVE
SOLENOID VALVE (3-SPOOL), EPC VALVE (2-SPOOL) AND TOWING VALVE
SOLENOID VALVE
EPC VALVE
CHARGE PUMP
FINAL DRIVE
PATH OF POWER TRANSMISSION
UNDER CARRIAGE AND FRAME
MAIN FRAME
TRACK FRAME AND RECOIL SPRING
IDLER
TRACK ROLLER
CARRIER ROLLER
SPROCKET
SINGLE SHOE
SUSPENSION
HYDRAULIC SYSTEM
HYDRAULIC COMPONENT LAYOUT OF WORK EQUIPMENT
WORK EQUIPMENT CONTROL SYSTEM
HYDRAULIC SYSTEM (WORK EQUIPMENT)
WORK EQUIPMENT AND FAN PUMP
SERVO VALVE
CONTROL VALVE
HYDRAULIC CIRCUIT DIAGRAM AND NAMES OF VALVES
UNLOAD VALVE
PRESSURE COMPENSATION VALVE
HYDRAULIC TANK, FILTER
BREATHER
ACCUMULATOR
WORK EQUIPMENT
WORK EQUIPMENT
CUTTING EDGE AND END BIT
RIPPER
PISTON VALVE FOR ANGLE CYLINDER
CAB AND ITS ATTACHMENTS
ROPS CAB
CAB DAMPER MOUNT
AIR CONDITIONER
ELECTRICAL SYSTEM
MONITOR SYSTEM
ENGINE CONTROL SYSTEM
COOLING CONTROL SYSTEM
HST CONTROL SYSTEM
GEAR SHIFT CONTROL SYSTEM
PARKING BRAKE CONTROL SYSTEM
KOMTRAX SYSTEM
ICT CONTROL SYSTEM
ICT CONTROL FUNCTION
BLADE CONTROL SYSTEM
DOZING MODE
SMOOTH START FUNCTION
SLIP CONTROL
BLADE ASSIST CONTROL
HST SPEED RANGE CONTROL SYSTEM
SYSTEM COMPONENTS
MONITOR PANEL
BUZZER CANCEL SWITCH
MONITOR PANEL DISPLAY
ENGINE CONTROLLER
HST CONTROLLER
ICT CONTROLLER
iB MONITOR
GNSS RECEIVER
KOMTRAX TERMINAL
SENSORS
BRAKE OIL PRESSURE SENSOR
HYDRAULIC OIL TEMPERATURE SENSOR
HST CIRCUIT OIL PRESSURE SENSOR
AIR CLEANER CLOGGING SENSOR
BRAKE PEDAL POTENTIOMETER
FUEL CONTROL DIAL
FUEL LEVEL SENSOR
CHARGE FILTER CLOGGING SENSOR
COOLANT TEMPERATURE SENSOR
ENGINE OIL PRESSURE SWITCH
ENGINE ROTATION SENSOR
BOOST PRESSURE AND SENSOR
WIF SENSOR
HST MOTOR SPEED SENSOR
IMU SENSOR
STROKE AND RESET SENSOR FOR LIFT CYLINDER
STROKE SENSOR
RESET SENSOR
STROKE SENSOR FOR TILT CYLINDER
STROKE SENSOR
STROKE AND RESET SENSOR FOR ANGLE CYLINDER
STROKE SENSOR
RESET SENSOR

20 STANDARD VALUE TABLES
TABLE OF CONTENTS
STANDARD VALUE TABLE FOR ENGINE
STANDARD VALUE TABLE FOR CHASSIS
STANDARD VALUE TABLE FOR ENGINE
STANDARD VALUE TABLE FOR CHASSIS
STANDARD VALUE TABLE FOR ICT
PERFORMANCE MEASURING POSTURE AND METHOD
TABLE OF CONTENTS
RELATED INFORMATION ON TESTING AND ADJUSTING
TOOLS FOR TESTING AND ADJUSTING
ENGINE AND COOLING SYSTEM
ENGINE SPEED
AIR INTAKE BOOST PRESSURE
EXHAUST TEMPERATURE
EXHAUST GAS COLOR
VALVE CLEARANCE
COMPRESSION PRESSURE
BLOW-BY PRESSURE
ENGINE OIL PRESSURE
HANDLING CONTROLLER HIGH-VOLTAGE CIRCUIT
FUEL SYSTEM
HANDLING FUEL SYSTEM PARTS
RELEASING RESIDUAL PRESSURE FROM FUEL SYSTEM
BLEEDING AIR FROM FUEL CIRCUIT
FUEL PRESSURE
FUEL RETURN RATE AND LEAKAGE
FUEL CIRCUIT FOR LEAKAGE
POWER TRAIN
HST OIL PRESSURE
TRAVEL DEVIATION
PARKING BRAKE LEVER
BRAKE PERFORMANCE
BRAKE PEDAL LINKAGE
EMERGENCY RELEASE OF PARKING BRAKE
DECELERATOR PEDAL
UNDERCARRIAGE AND FRAME
IDLER CLEARANCE
TRACK SHOE TENSION
HYDRAULIC SYSTEM
FAN (WORK EQUIPMENT) PUMP PRESSURE
FAN SPEED
FAN SPEED SENSOR
WORK EQUIPMENT
BLEEDING AIR
WORK EQUIPMENT
LOCK LEVER ADJUSTMENT
BLADE CENTER BALL ADJUSTMENT
BLADE PITCH BALL ADJUSTMENT
ELECTRICAL SYSTEM
MONITOR PANEL (EMMS) - SPECIAL FUNCTIONS
ERROR CODE TABLE
PREPARATION WORK FOR TROUBLESHOOTING FOR ELECTRICAL SYSTEM
SPECIAL FUNCTIONS OF iB MONITOR
INPUTTING WEAR AMOUNT OF BLADE EDGE AND TRACK SHOE
TESTING STROKE SENSOR FOR LIFT CYLINDER
TESTING STROKE SENSOR FOR TILT CYLINDER
TESTING STROKE SENSOR FOR ANGLE CYLINDER
TESTING AND ADJUSTING RESET SENSOR FOR LIFT CYLINDER
TESTING AND ADJUSTING RESET SENSOR FOR ANGLE CYLINDER
ELECTRIC/HYDRAULIC DEVICES ARE ADJUSTED/REPLACED
HST CONTROLLER ADJUSTMENT AFTER REPLACEMENT
MONITOR PANEL ADJUSTMENT AFTER REPLACEMENT
ADJUSTMENT METHOD WHEN ICT CONTROLLER HAS BEEN REPLACED
HANLDING VOLTAGE CIRCUIT OF ENGINE CONTROLLER
HANDLING BATTERY DISCONNECT SWITCH
TESTING DIODES
PM-CLINIC INSPECTION SHEET (1/2)
PM-CLINIC INSPECTION SHEET (2/2)
PM-CLINIC UNDERCARRIAGE CHECK SHEET
UNDERCARRIAGE TROUBLESHOOTING REPORT (NORMAL)
UNDERCARRIAGE TROUBLESHOOTING REPORT (IMPACT)
PM-CLINIC UNDERCARRIAGE CHECK SHEET
UNDERCARRIAGE TROUBLESHOOTING REPORT (NORMAL)
UNDERCARRIAGE TROUBLESHOOTING REPORT (IMPACT)

30 TESTING AND ADJUSTING

40 TROUBLESHOOTING
TABLE OF CONTENTS
RELATED INFORMATION ON TROUBLESHOOTING
SEQUENCE OF EVENTS IN TROUBLESHOOTING
CHECKS BEFORE TROUBLESHOOTING
INSPECTION PROCEDURE BEFORE TROUBLESHOOTING
WALK-AROUND CHECK
PRECAUTIONS WHEN CARRYING OUT MAINTENANCE
PRECAUTIONS WHEN HANDLING ELECTRICAL EQUIPMENT
HANDLING ELECTRONIC CONTROL UNIT
POINTS TO REMEMBER WHEN TROUBLESHOOTING ELECTRICAL CIRCUITS
POINTS TO REMEMBER WHEN HANDLING HYDRAULIC EQUIPMENT
SYMPTOM AND TROUBLESHOOTING NUMBERS
TROUBLESHOOTING INDIVIDUAL ELECTRICAL CIRCUITS
CONNECTION TABLE FOR CONNECTOR PIN NUMBERS
T-ADAPTER TABLE
FAILURE CODE TABLE
INFORMATION IN TROUBLESHOOTING TABLE
TROUBLESHOOTING BY FAILURE CODE
ERROR CODE [6091NX]
ERROR CODE [AA10NX]
ERROR CODE [AB00MA]
ERROR CODE [B@BAZG]
ERROR CODE [B@BCNS]
ERROR CODE [B@CRNS]
ERROR CODE [B@CRZG]
ERROR CODE [CA111]
ERROR CODE [CA115]
ERROR CODE [CA122]
ERROR CODE [CA123]
ERROR CODE [CA131]
ERROR CODE [CA132]
ERROR CODE [CA144]
ERROR CODE [CA145]
ERROR CODE [CA153]
ERROR CODE [CA154]
ERROR CODE [CA187]
ERROR CODE [CA221]
ERROR CODE [CA222]
ERROR CODE [CA227]
ERROR CODE [CA234]
ERROR CODE [CA238]
ERROR CODE [CA271]
ERROR CODE [CA272]
ERROR CODE [CA322]
ERROR CODE [CA323]
ERROR CODE [CA324]
ERROR CODE [CA325]
ERROR CODE [CA331]
ERROR CODE [CA332]
ERROR CODE [CA342]
ERROR CODE [CA352]
ERROR CODE [CA386]
ERROR CODE [CA428]
ERROR CODE [CA429]
ERROR CODE [CA435]
ERROR CODE [CA441]
ERROR CODE [CA442]
ERROR CODE [CA449]
ERROR CODE [CA451]
ERROR CODE [CA452]
ERROR CODE [CA488]
ERROR CODE [CA553]
ERROR CODE [CA559]
ERROR CODE [CA689]
ERROR CODE [CA731]
ERROR CODE [CA757]
ERROR CODE [CA778]
ERROR CODE [CA1633]
ERROR CODE [CA2185]
ERROR CODE [CA2186]
ERROR CODE [CA2249]
ERROR CODE [CA2311]
ERROR CODE [CA2555]
ERROR CODE [CA2556]
ERROR CODE [D130KA]
ERROR CODE [D130KB]
ERROR CODE [DAFRKR]
ERROR CODE [DAFRMC]
ERROR CODE [DAJ000]
ERROR CODE [DAJ0KK]
ERROR CODE [DAJ0KQ]
ERROR CODE [DAJ0KT]
ERROR CODE [DAJ5KK]
ERROR CODE [DAJ6KK]
ERROR CODE [DAJRKR]
ERROR CODE [DB2RKR]
ERROR CODE [DBR0KT]
ERROR CODE [DBR0MC]
ERROR CODE [DBR1KK]
ERROR CODE [DBR2KK]
ERROR CODE [DBR5KK]
ERROR CODE [DBR6KK]
ERROR CODE [DBRQKR]
ERROR CODE [DBTSKR]
ERROR CODE [DBUTKA]
ERROR CODE [DD12KA]
ERROR CODE [DD12KB]
ERROR CODE [DD13KA]
ERROR CODE [DD13KB]
ERROR CODE [DD14KB]
ERROR CODE [DD1NL4]
ERROR CODE [DDDCKB]
ERROR CODE [DDKAKA]
ERROR CODE [DDKAKB]
FAILURE CODE [DDKFL4]
ERROR CODE [DDKGL4]
ERROR CODE [DDKHKA]
ERROR CODE [DDKHKB]
ERROR CODE [DDNLKA]
ERROR CODE [DDNLKB]
ERROR CODE [DDP6KA]
ERROR CODE [DDP6KB]
ERROR CODE [DDP6MA]
ERROR CODE [DDQ2KA]
ERROR CODE [DDT0L4]
ERROR CODE [DDU1FS]
ERROR CODE [DDU1KA]
ERROR CODE [DDU1KY]
ERROR CODE [DFA4KX]
ERROR CODE [DFA4KZ]
ERROR CODE [DFA4L8]
ERROR CODE [DFA5KA]
ERROR CODE [DFA5KB]
ERROR CODE [DFA6KA]
ERROR CODE [DFA6KB]
ERROR CODE [DFA7KX]
ERROR CODE [DFA7KZ]
ERROR CODE [DFA7L8]
ERROR CODE [DFA8KA]
ERROR CODE [DFA8KB]
ERROR CODE [DFA9KA]
ERROR CODE [DFA9KB]
ERROR CODE [DGS1KA]
ERROR CODE [DGS1KX]
ERROR CODE [DH21KA]
ERROR CODE [DH21KB]
ERROR CODE [DHH5KA]
ERROR CODE [DHH5KB]
ERROR CODE [DHH6KA]
ERROR CODE [DHH6KB]
ERROR CODE [DK10KA]
ERROR CODE [DK10KB]
ERROR CODE [DK30KA]
ERROR CODE [DK30KB]
ERROR CODE [DK30KX]
ERROR CODE [DK30KZ]
ERROR CODE [DK30L8]
ERROR CODE [DK31KA]
ERROR CODE [DK31KB]
ERROR CODE [DK40KA]
ERROR CODE [DK40KB]
ERROR CODE [DK55KX]
ERROR CODE [DK55KZ]
ERROR CODE [DK55L8]
ERROR CODE [DK56KA]
ERROR CODE [DK56KB]
ERROR CODE [DK57KA]
ERROR CODE [DK57KB]
ERROR CODE [DK80KA]
ERROR CODE [DKS0L8]
ERROR CODE [DKS1KA]
ERROR CODE [DKS1KB]
ERROR CODE [DKS2KA]
ERROR CODE [DKS2KB]
ERROR CODE [DKS3KA]
ERROR CODE [DKS3KB]
ERROR CODE [DKS3MB]
ERROR CODE [DKS4L8]
ERROR CODE [DKS5KA]
ERROR CODE [DKS5KB]
ERROR CODE [DKS6KA]
ERROR CODE [DKS6KB]
ERROR CODE [DKS7MB]
ERROR CODE [DKSCL8]
ERROR CODE [DKSDKA]
ERROR CODE [DKSDKB]
ERROR CODE [DKSEKA]
ERROR CODE [DKSEKB]
ERROR CODE [DKSFKA]
ERROR CODE [DKSFKB]
ERROR CODE [DKSFMB]
ERROR CODE [DLM0KX]
ERROR CODE [DLM1KA]
ERROR CODE [DLM1KB]
ERROR CODE [DLM1MA]
ERROR CODE [DLM2KA]
ERROR CODE [DLM2KB]
ERROR CODE [DLM2MA]
ERROR CODE [DLM3KA]
ERROR CODE [DLM3KB]
ERROR CODE [DN21FS]
ERROR CODE [DV00KB]
ERROR CODE [DV20KB]
ERROR CODE [DW4BKA]
ERROR CODE [DW4BKB]
ERROR CODE [DW4BKY]
ERROR CODE [DW7BKA]
ERROR CODE [DW7BKB]
ERROR CODE [DW7BKY]
ERROR CODE [DW7EKA]
ERROR CODE [DW7EKB]
ERROR CODE [DW7EKY]
ERROR CODE [DWN5KA]
ERROR CODE [DWN5KB]
ERROR CODE [DWN5KY]
ERROR CODE [DXA4KA]
ERROR CODE [DXA4KB]
ERROR CODE [DXA4KY]
ERROR CODE [DXA5KA]
ERROR CODE [DXA5KB]
ERROR CODE [DXA5KY]
ERROR CODE [DXA6KA]
ERROR CODE [DXA6KB]
ERROR CODE [DXA6KY]
ERROR CODE [DXA7KA]
ERROR CODE [DXA7KB]
ERROR CODE [DXA7KY]
ERROR CODE [DXHRKA]
ERROR CODE [DXHRKB]
ERROR CODE [DXHRKY]
ERROR CODE [DXHSKA]
ERROR CODE [DXHSKB]
ERROR CODE [DXHSKY]
ERROR CODE [DXHTKA]
ERROR CODE [DXHTKB]
ERROR CODE [DXHTKY]
ERROR CODE [DXHUKA]
ERROR CODE [DXHUKB]
ERROR CODE [DXHUKY]
ERROR CODE [DXJ4KA]
ERROR CODE [DXJ4KB]
ERROR CODE [DXJCKA]
ERROR CODE [DXJCKB]
ERROR CODE [DXJCKY]
ERROR CODE [DXJDKA]
ERROR CODE [DXJDKB]
ERROR CODE [DXJDKY]
ERROR CODE [DXK1KA]
ERROR CODE [DXK1KB]
ERROR CODE [DXK1KY]
ERROR CODE [DXK2KA]
ERROR CODE [DXK2KB]
ERROR CODE [DXK2KY]
TROUBLESHOOTING OF ELECTRICAL SYSTEM (E-MODE)
BEFORE CARRYING OUT TROUBLESHOOTING (E-MODE)
INFORMATION IN TROUBLESHOOTING TABLE
E-1 STARTING MOTOR DOES NOT ROTATE
E-2 ENGINE IS NOT PRE-HEATED
E-3 WHEN STARTING SWITCH IS TURNED ON, ANY ITEM DOES NOT LIGHT
E-4 CHARGE LEVEL CAUTION FLASHES WHILE ENGINE IS RUNNING
E-5 EMERGENCY WARNING ITEMS FLASH WHILE ENGINE IS RUNNING
E-6 PRE-HEAT LAMP DOES NOT LIGHT DURING PRE-HEATING OPERATION
E-7 COOLANT TEMPERATURE GAUGE DOES NOT INDICATE CORRECTLY
E-8 HST OIL TEMPERATURE GAUGE DOES NOT INDICATE CORRECTLY
E-9 FUEL LEVEL GAUGE DOES NOT INDICATE PROPERLY
E-10 TRAVEL INDICATOR DOES NOT DISPLAY NORMALLY
E-11 MULTI-INFORMATION UNIT DOES NOT DISPLAY NORMALLY
E-12 CAUTION LAMP DOES NOT FLASH OR DOES NOT GO OFF
E-13 CAUTION BUZZER DOES NOT SOUND OR DOES NOT STOP
E-14 REVERSE TRAVEL SPEED SETTING SWITCH DOES NOT FUNCTION
E-15 SHIFT MODE SWITCH DOES NOT FUNCTION
E-16 BUZZER CANCEL SWITCH DOES NOT FUNCTION
E-17 INFORMATION SWITCH DOES NOT FUNCTION
E-18 THE FAN CLEANING DOES NOT OPERATE OR CANNOT BE RESET
E-19 BACKUP ALARM DOES NOT SOUND
E-20 THE HORN DOES NOT SOUND OR DOES NOT STOP
E-21 WORK EQUIPMENT DOES NOT OPERATE
E-22 HEAD LAMP OR REAR LAMP DOES NOT LIGHT UP
E-23 FOOT HEATER DOES NOT OPERATE
E-24 AIR CONDITIONER DOES NOT OPERATE [CAB SPECIFICATION]
E-25 WIPER AND WASHER DO NOT OPERATE [CAB SPECIFICATION]
E-26 KOMTRAX SYSTEM DOES NOT OPERATE NORMALLY
E-27 iB MONITOR SHUTS DOWN AFTER DISPLAYING THE MESSAGES [GPS RECEIVER NOT CONNECTED!] AND [SLOPE SENSOR NOT CONNECTED!]
E-28 iB MONITOR DISPLAYS THE MESSAGES[GPS RECEIVER NOT CONECTED!] AND [SLOPE SENSOR NOT CONNECTED!]
E-29 iB MONITOR DISPLAYS THE MESSAGE [WAITING FOR RADIO LINK...]
E-30 iB MONITOR DISPLAYS THE MESSAGE [IMU SENSOR NOT CONNECTED]
E-31 iB MONITOR DISPLAYS THE MESSAGE [WAITING FOR SATELLITES...]
E-32 iB MONITOR DISPLAYS THE MESSAGE [KOMATSU CONTROLLER NOT CONNECTED]
E-33 iB MONITOR DISPLAYS THE MESSAGE [CYLINDER STROKE READING ABNORMAL]
E-34 iB MONITOR DISPLAYS THE MESSAGE [KOMATSU CAN COMMS ABNORMAL]
E-35 iB MONITOR DISPLAYS THE MESSAGE [KOMATSU MACHINE TROUBLE]
E-36 iB MONITOR DISPLAYS THE MESSAGE [WAITING TO INITIALIZE...]
E-37 iB MONITOR DISPLAYS THE MESSAGE [SYSTEM INITIALIZING...]
E-38 iB MONITOR DISPLAYS THE MESSAGE [INITIALIZING...]
E-39 iB MONITOR DISPLAYS THE MESSAGE [CONFIGURING GPS]
E-40 iB MONITOR DISPLAYS THE MESSAGE [NO GPS LOCALIZATION... ]
E-41 iB MONITOR DISPLAYS THE MESSAGE [LOW PRECISIONS...]
E-42 iB MONITOR DISPLAYS THE MESSAGE [HEADING INITIALIZING]
E-43 iB MONITOR DISPLAYS [OUT OF DESIGN AREA...]
E-44 iB MONITOR CAN NOT BE TURNED ON
E-45 iB MONITOR DOES NOT DISPLAY INTELLIGENT MACHINE CONTROL SCREN
E-46 iB MONITOR DOES NOT DISPLAY BULLDOZER IMAGE
E-47 iB MONITOR DOES NOT DISPLAY DESIGN SURFACE
E-48 iB MONITOR TOUCH PANEL DOES NOT RESPOND
E-49 iB MONITOR TOUCH PANEL IS INACCURATE
E-50 CYLINDER STROKE RESET INDICATION DOES NOT GO OUT.
E-51 AUTO IS NOT DISPLAYED WHEN AUTO/MANUAL SWITCH IS PRESSED (AUTO INDICATION GOES OUT)
E-52 BLADE AUTOMATIC RAISE CONTROL DOES NOT START WHILE AUTO IS DISPLAYED
E-53 BLADE AUTOMATIC LOWER CONTROL DOES NOT START WHILE AUTO IS DISPLAYED
E-54 BLADE AUTOMATIC CONTROL FUNCTION IS NOT ACTIVATED WHILE AUTO IS DISPLAYED (BLADE AUTOMATIC CONTROL STOPS)
E-55 WHEN CHECKING AND ADJUSTING THE BLADE ELEVATION, THE VALUE IS DIFFERENT FROM ACTUAL MACHINE
E-56 FINISHED SURFACE IS INACCURATE (THE AVERAGE HEIGHT OF FINISHED SURFACE IS LOWER THAN DESIGNED SURFACE OR BLADE DOES NOT TOUCH THE SURFACE)
E-57 FINISHED SURFACE IS INACCURATE (THE FINISHED IS NOT SMOOTH)
E-58 FINISHED SURFACE IS INACCURATE (WHEN FINISHING SLOPE HORIZONTALLY, STEPS ARE MADE IN EACH DIRECTION)
E-59 MACHINE CAN NOT ESCAPE FROM SHOES SLIP WHILE BLADE AUTOMATIC CONTROL IS ACTIVATED (SHOES FREQUENTLY SLIPS)
E-60 MACHINE SPEED DOES NOT INCREASE WHILE BLADE AUTOMATIC CONTROL IS ACTIVATED
E-61 BLADE TILT ANGLE DOES NOT COINCIDE WITH DESIGN SURFACE
E-62 BLADE TILTS BACK WHILE BLADE AUTOMATIC CONTROL IS ACTIVATED
TROUBLESHOOTING OF HYDRAULIC AND MECHANICAL SYSTEM (H- MODE)
INFORMATION IN TROUBLESHOOTING TABLE
H-1 RIGHT AND LEFT TRAVEL SYSTEMS INOPERABLE
H-2 RIGHT OR LEFT TRAVEL SYSTEM DOES NOT OPERATE
H-3 RIGHT OR LEFT TRAVEL SYSTEM DOES NOT OPERATE
H-4 SPEED OR POWER OF TRAVEL IS LOW
H-5 GEAR IS NOT SHIFTED
H-6 LARGE SHOCKS ARE MADE WHEN MACHINE STARTS AND STOPS TRAVEL
H-7 MACHINE DEVIATES LARGELY DURING TRAVEL
H-8 HYDRAULIC DRIFT OF TRAVEL IS LARGE
H-9 ENGINE STALLS OR SPEED LOWERS EXTREMELY DURING TRAVEL
H-10 ABNORMAL SOUND COMES OUT FROM AROUND HST PUMP AND MOTOR
H-11 WORK EQUIPMENT DOSE NOT OPERATE AT ALL
H-12 SPEED OR POWER OF WHOLE WORK EQUIPMENT IS LOW
H-13 BLADE LIFT SPEED OR POWER IS LOW
H-14 BLADE TILT SPEED OR POWER IS LOW
H-15 BLADE ANGLE SPEED OR POWER IS LOW
H-16 TIME LAG OF BLADE LIFT IS LARGE
H-17 HYDRAULIC DRIFT OF LIFTED BLADE IS LARGE
H-18 HYDRAULIC DRIFT OF TILTING BLADE IS LARGE
H-19 UNUSUAL NOISE IS HEARD FROM WORK EQUIPMENT PUMP OR CONTROL VALVE
H-20 HST OIL TEMPERATURE RISES TOO HIGH
H-21 FAN SPEED IS ABNORMAL (HIGH, LOW, OR 0 RPM)
TROUBLESHOOTING OF ENGINE (S-MODE)
METHOD OF USING TROUBLESHOOTING CHARTS
(S-1) ENGINE STARTING PERFORMANCE IS POOR
(S-2) ENGINE DOES NOT CRANK
ENGINE CRANKS BUT NO EXHAUST SMOKE COMES OUT OF STACK
SMOKE COMES OUT OF STACK BUT ENGINE DOES NOT START
(S-3) ENGINE DOES NOT RUN SMOOTHLY
(S-4) ENGINE STOPS DURING OPERATIONS
(S-5) ENGINE SPEED HUNTS
(S-6) ENGINE LACKS POWER
(S-7) EXHAUST SMOKE IS BLACK
(S-8) OIL CONSUMPTION IS EXCESSIVE OR EXHAUST SMOKE IS BLUE
(S-9) OIL BECOMES CONTAMINATED QUICKLY
(S-10) FUEL CONSUMPTION IS EXCESSIVE
(S-11) OIL FOUND IN COOLANT, OR COOLANT SPURTS FROM RADIATOR
(S-12) OIL PRESSURE CAUTION LAMP LIGHTS UP
(S-13) OIL LEVEL RISES (COOLANT OR FUEL FOUND IN OIL)
(S-14) COOLANT TEMPERATURE TOO HIGH (OVERHEATING)
(S-15) ABNORMAL NOISE IS HEARD WHEN ENGINE IS RUNNING
(S-16) EXCESSIVE VIBRATION WHEN ENGINE IS RUNNING

50 DISASSEMBLY AND ASSEMBLY
TABLE OF CONTENTS
RELATED INFORMATION ON DISASSEMBLY AND ASSEMBLY
HOW TO READ THIS MANUAL
SPECIAL TOOL LIST
SKETCH OF SPECIAL TOOLS
CONNECTOR REPAIR PROCEDURES
CONTACT TERMINAL REMOVAL (HD30 TYPE)
STRIPPING INSULATION
CRIMPING CONTACT TERMINAL (HD30 TYPE)
INSERTION OF CONTACT TERMINAL (HD30 TYPE)
CONTACT TERMINAL REMOVAL (DT TYPE)
STRIPPING INSULATION
CRIMPING CONTACT TERMINAL (DT TYPE)
INSERTION OF CONTACT TERMINAL (DT TYPE)
NOSE GUARD (HOOD)
REMOVAL
INSTALLATION
MUFFLER AND EXHAUST STACK
REMOVAL
INSTALLATION
CAB AND ITS ATTACHMENTS
CAB
MONITOR PANEL AND HST CONTROLLER
KOMTRAX CONTROLLER
REMOVAL AND INSTALLATION OF ICT SENSOR CONTROLLER ASSEMBLY
REMOVAL AND INSTALLATION OF iB MONITOR
REMOVAL AND INSTALLATION OF GNSS RECEIVER
REMOVAL AND INSTALLATION OF iB GNSS ANTENNA
REMOVAL AND INSTALLATION OF IMU SENSOR
SEAT
AIR CONDITIONER/HEATER
DISASSEMBLY OF AIR CONDITIONER
ASSEMBLY OF AIR CONDITIONER
FOOT HEATER
REMOVAL
INSTALLATION
FOOT HEATER OVERHAUL PROCEDURES
ASSEMBLY PROCEDURES
ENGINE AND COOLING SYSTEM
REMOVAL
ENGINE AND HST PUMP
INSTALLATION
REMOVAL FROM ENGINE
INSTALLATION TO ENGINE
DRIVE DAMPENER
REMOVAL
INSTALLATION
HST PUMP OVERHAUL PROCEDURES
DISASSEMBLY PROCEDURES
ASSEMBLY PROCEDURES
WORK EQUIPMENT PUMP OVERHAUL PROCEDURES
DISASSEMBLY PROCEDURES
ASSEMBLY PROCEDURES
REMOVAL
INSTALL
CHARGE PUMP OVERHAUL PROCEDURES
DISASSEMBLY PROCEDURES
ASSEMBLY PROCEDURES
DIESEL ENGINE OVERHAUL PROCEDURES
DISASSEMBLY OF EXTERNAL COMPONENTS
DISASSEMBLY OF ENGINE TOP END
REMOVAL OF OIL COOLER, ENGINE CONTROLLER AND FUEL PUMP
DISASSEMBLY OF ENGINE LOWER END
ASSEMBLY OF ENGINE LOWER END
INSTALLATION OF OIL COOLER, ENGINE CONTROLLER AND FUEL PUMP
ASSEMBLY OF EXTERNAL COMPONENTS
TRACK SYSTEM
SPREADING THE TRACK
(CONVENTIONAL TYPE TRACK SHOE)
EXPANSION AND INSTALLATION OF TRACK SHOE ASSEMBLY (PLUS TYPE TRACK SHOE)
FIELD DISASSEMBLY AND ASSEMBLY OF ONE LINK (CONVENTIONAL TYPE TRACK SHOE)
FIELD DISASSEMBLY AND ASSEMBLY OF ONE LINK (PLUS TYPE TRACK SHOE)
TRACK FRAME
REMOVAL OF TRACK FRAME
FRONT TRACK IDLER
REMOVING FRONT IDLER
INSTALLING FRONT IDLER
TRACK ROLLER
REMOVAL
INSTALLATION
TRACK ROLLER OVERHAUL PROCEDURES
CARRIER ROLLER OVERHAUL PROCEDURES
FINAL DRIVE
FINAL DRIVE REMOVAL
INSTALLING THE FINAL DRIVE
FINAL DRIVE OVERHAUL PROCEDURES
DISASSEMBLY PROCEDURES
ASSEMBLY OF FINAL DRIVE
TRAVEL MOTOR OVERHAUL PROCEDURES
DISASSEMBLY PROCEDURES
ASSEMBLY PROCEDURES
FAN MOTOR
REMOVAL PROCEDURES
INSTALLATION PROCEDURES
FAN MOTOR OVERHAUL PROCEDURES
DISASSEMBLY PROCEDURES
ASSEMBLY PROCEDURES
DB 12 VALVE
REMOVAL
INSTALLATION
COOLING PACKAGE
REMOVING THE GRILL AND COOLING FAN ASSEMBLY
REMOVING THE COOLING PACKAGE
INSTALLING THE COOLING PACKAGE
INSTALLING THE GRILL AND COOLING FAN ASSEMBLY
FUEL TANK
REMOVING THE FUEL TANK
INSTALLING THE FUEL TANK
HYDRAULIC TANK
REMOVING THE HYDRAULIC TANK
INSTALLING THE HYDRAULIC TANK
WORK EQUIPMENT
REMOVING OR INSTALLING PINS
FRONT BLADE, TILT AND ANGLE CYLINDERS
ADJUSTING BLADE CENTER BALL AND PITCH ROD PLAY
“C” FRAME
LIFT CYLINDERS
CYLINDER OVERHAUL PROCEDURES
DISASSEMBLY PROCEDURES
ASSEMBLY PROCEDURES
WHOLE DISASSEMBLY AND ASSEMBLY OF TRACK SHOE (PLUS TYPE TRACK SHOE)
WHOLE DISASSEMBLY AND ASSEMBLY OF TRACK SHOE ASSEMBLY (CONVENTIONAL TYPE TRACK SHOE)

90 OTHERS

TABLE OF CONTENTS
CONNECTOR ARRANGEMENT DRAWING AND ELECTRICAL CIRCUITDIAGRAM
CONNECTOR LIST

CONNECTOR LOCATION VIEW

HYDRAULIC SYSTEM

SYMBOLS IN HYDRAULIC CIRCUIT DIAGRAMS

HYDRAULIC SYSTEM
ELECTRICAL SYSTEM

SYMBOLS IN ELECTRICAL CIRCUIT DIAGRAMS
CAB ELECTRICAL ACCESSORIES
AIR CONDITIONER CIRCUIT DIAGRAM

Electrical Circuit Diagram (1/8)
Electrical Circuit Diagram (2/8)
Electrical Circuit Diagram (3/8)
Electrical Circuit Diagram (4/8)
Electrical Circuit Diagram (5/8)
Electrical Circuit Diagram (6/8)
Electrical Circuit Diagram (7/8)
Electrical Circuit Diagram (8/8)

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