Komatsu D51EX -24 Install guide

BULLDOZER
SEN06617-02
D51EX -24
D51PX-24
SERIAL NUMBERS
D51EX-10001
D51PX-10001
and up

Find manuals at https://best-manuals.com

00 INDEX AND FOREWORD
D51EX-24, D51PX-24 00-1
Find manuals at https://best-manuals.com

INDEX
00 INDEX AND FOREWORD ........................................................................................................................ 00-1
ABBREVIATION LIST ........................................................................................................................... 00-18
FOREWORD, SAFETY, BASIC INFORMATION ................................................................................... 00-24
HOW TO READ THE SHOP MANUAL........................................................................................... 00-24
SAFETY NOTICE FOR OPERATION............................................................................................. 00-26
PRECAUTIONS TO PREVENT FIRE............................................................................................. 00-34
ACTIONS IF FIRE OCCURS ......................................................................................................... 00-36
PRECAUTIONS FOR DISPOSING OF WASTE MATERIALS ........................................................ 00-37
ACTIONS TAKEN TO MEET EXHAUST GAS REGULATIONS...................................................... 00-38
PRECAUTIONS FOR DEF............................................................................................................. 00-39
STORE AdBlue/DEF ...................................................................................................................... 00-40
PRECAUTIONS FOR HANDLING HYDRAULIC EQUIPMENT ...................................................... 00-41
PRECAUTIONS FOR DISCONNECTION AND CONNECTION OF PIPINGS................................ 00-44
PRECAUTIONS FOR HANDLING ELECTRICAL EQUIPMENT..................................................... 00-50
PRECAUTIONS FOR HANDLING FUEL SYSTEM EQUIPMENT .................................................. 00-52
PRECAUTIONS FOR HANDLING INTAKE SYSTEM EQUIPMENT .............................................. 00-53
PRACTICAL USE OF KOMTRAX .................................................................................................. 00-54
DISCONNECT AND CONNECT PUSH-PULL TYPE COUPLER ................................................... 00-55
PRECAUTIONS FOR DISCONNECTION AND CONNECTION OF CONNECTORS ..................... 00-59
METHOD FOR DISCONNECTING AND CONNECTING DEUTSCH CONNECTOR ..................... 00-63
METHOD FOR DISCONNECTING AND CONNECTING SLIDE LOCK TYPE CONNECTOR ....... 00-64
METHOD FOR DISCONNECTING AND CONNECTING CONNECTOR WITH LOCK TO PULL ... 00-66
METHOD FOR DISCONNECTING AND CONNECTING CONNECTOR WITH LOCK TO PUSH .. 00-67
METHOD FOR DISCONNECTING AND CONNECTING CONNECTOR WITH HOUSING TO ROTATE .
................................................................................................................................................... 00-69
HOW TO READ ELECTRICAL WIRE CODE ................................................................................. 00-70
EXPLANATION OF TERMS FOR MAINTENANCE STANDARD.................................................... 00-74
STANDARD TIGHTENING TORQUE TABLE................................................................................. 00-77
CONVERSION TABLE................................................................................................................... 00-84
01 SPECIFICATIONS .................................................................................................................................... 01-1
CONTENTS ............................................................................................................................................ 01-2
ABBREVIATION LIST ............................................................................................................................. 01-3
SPECIFICATIONS .................................................................................................................................. 01-9
SPECIFICATION DRAWING............................................................................................................ 01-9
SPECIFICATIONS ......................................................................................................................... 01-13
WEIGHT TABLE ............................................................................................................................ 01-23
FUEL, COOLANT, LUBRICANTS (FOR NORTH AMERICA) ......................................................... 01-27
FUEL, COOLANT, LUBRICANTS (FOR EUROPEAN UNION)....................................................... 01-29
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
INDEX 00 INDEX AND FOREWORD
00-2 D51EX-24, D51PX-24
Find manuals at https://best-manuals.com

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
UNDERCARRIAGE AND FRAME........................................................................................................10-233
MAIN FRAME ...............................................................................................................................10-233
SUSPENSION ..............................................................................................................................10-234
TRACK FRAME AND IDLER CUSHION .......................................................................................10-237
WORK EQUIPMENT............................................................................................................................10-239
STRUCTURE OF FRONT WORK EQUIPMENT...........................................................................10-239
STRUCTURE OF FIXED MULTI-SHANK RIPPER........................................................................10-240
CAB AND ITS ATTACHMENTS ...........................................................................................................10-241
ROPS CAB ...................................................................................................................................10-241
CAB MOUNT ................................................................................................................................10-243
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: D51EX-24 .................................................................... 20-9
STANDARD VALUE TABLE FOR ENGINE: D51PX-24 .................................................................. 20-13
STANDARD VALUE TABLE FOR MACHINE......................................................................................... 20-17
STANDARD VALUE TABLE FOR MACHINE: D51EX-24 ............................................................... 20-17
STANDARD VALUE TABLE FOR MACHINE: D51PX-24 ............................................................... 20-33
MACHINE POSTURE AND PROCEDURE FOR MEASURING PERFORMANCE ......................... 20-47
30 TESTING AND ADJUSTING..................................................................................................................... 30-1
CONTENTS ............................................................................................................................................ 30-2
ABBREVIATION LIST ............................................................................................................................. 30-5
RELATED INFORMATION ON TESTING AND ADJUSTING .................................................................30-11
TOOLS FOR TESTING AND ADJUSTING......................................................................................30-11
SKETCH OF TOOLS FOR TESTING AND ADJUSTING ............................................................... 30-18
ENGINE AND COOLING SYSTEM....................................................................................................... 30-19
TEST ENGINE SPEED .................................................................................................................. 30-19
TEST BOOST PRESSURE............................................................................................................ 30-21
TEST EXHAUST GAS COLOR...................................................................................................... 30-23
TEST AND ADJUST VALVE CLEARANCE .................................................................................... 30-25
TEST COMPRESSION PRESSURE.............................................................................................. 30-27
TEST BLOWBY PRESSURE ......................................................................................................... 30-32
TEST ENGINE OIL PRESSURE .................................................................................................... 30-34
00 INDEX AND FOREWORD INDEX
D51EX-24, D51PX-24 00-3
Find manuals at https://best-manuals.com

TEST FUEL PRESSURE ............................................................................................................... 30-35
TEST FUEL DISCHARGE, RETURN AND LEAKAGE ................................................................... 30-40
BLEED AIR FROM FUEL SYSTEM ............................................................................................... 30-46
TEST FUEL CIRCUIT FOR LEAKAGE .......................................................................................... 30-47
HANDLE CYLINDER CUT-OUT MODE OPERATION.................................................................... 30-49
HANDLE NO-INJECTION CRANKING OPERATION ..................................................................... 30-50
TEST KDOC, SCR AND MUFFLER STACK FOR LOOSENESS AND DAMAGE .......................... 30-51
TEST INSTALLED CONDITION OF CYLINDER HEADS AND MANIFOLDS ................................. 30-52
TEST ENGINE PIPING FOR DAMAGE AND LOOSENESS .......................................................... 30-53
WRITE ASH IN SOOT ACCUMULATION CORRECTION TO ENGINE CONTROLLER ................ 30-54
TEST SCR RELATED FUNCTIONS............................................................................................... 30-55
CLEAN AdBlue/DEF TANK ............................................................................................................ 30-83
CLEAN AdBlue/DEF TANK MOUNTING PORTION ....................................................................... 30-87
POWER TRAIN..................................................................................................................................... 30-88
TEST AND ADJUST HST OIL PRESSURE ................................................................................... 30-88
BLEED AIR FROM HST PUMP ..................................................................................................... 30-93
TEST OUTLET PRESSURE OF SOLENOID VALVE ..................................................................... 30-95
TEST TRAVEL DEVIATION ........................................................................................................... 30-99
TEST BRAKE PERFORMANCE SIMPLY .....................................................................................30-101
TEST AND ADJUST DECELERATION/BRAKE PEDAL................................................................30-102
ADJUST PARKING BRAKE LEVER..............................................................................................30-106
MOVE MACHINE WHEN IT CANNOT TRAVEL............................................................................30-108
UNDERCARRIAGE AND FRAME........................................................................................................ 30-111
CHECK AND ADJUST IDLER CLEARANCE ................................................................................ 30-111
TESTING SPROCKET WEAR ......................................................................................................30-113
TEST AND ADJUST TRACK TENSION........................................................................................30-114
HYDRAULIC SYSTEM.........................................................................................................................30-116
RELEASE REMAINING PRESSURE FROM HYDRAULIC SYSTEM............................................30-116
TEST AND ADJUST WORK EQUIPMENT OIL PRESSURES ......................................................30-117
TEST AND ADJUST OIL PRESSURE OF CONTROL CIRCUIT...................................................30-120
TEST OUTLET PRESSURE OF EPC SOLENOID VALVE ............................................................30-122
BLEED AIR FROM WORK EQUIPMENT AND COOLING FAN PUMP .........................................30-124
TEST COOLING FAN SPEED ......................................................................................................30-125
TEST COOLING FAN CIRCUIT OIL PRESSURE .........................................................................30-126
TEST THE PARTS CAUSING HYDRAULIC DRIFT IN WORK EQUIPMENT................................30-128
TEST INTERNAL OIL LEAKAGE OF WORK EQUIPMENT CYLINDER .......................................30-130
BLEED AIR FROM WORK EQUIPMENT CYLINDERS.................................................................30-133
WORK EQUIPMENT............................................................................................................................30-134
ADJUST WORK EQUIPMENT LOCK LEVER...............................................................................30-134
ELECTRICAL SYSTEM .......................................................................................................................30-136
SET AND OPERATE MACHINE MONITOR..................................................................................30-136
METHOD FOR STARTING UP KOMTRAX TERMINAL ................................................................30-264
ADJUSTMENT WHEN HST CONTROLLER HAS BEEN REPLACED ..........................................30-269
ADJUSTMENT WHEN ELECTRIC OR HYDRAULIC DEVICE HAS BEEN REPLACED ...............30-275
ADJUST REARVIEW CAMERA ANGLE .......................................................................................30-277
HANDLE VOLTAGE CIRCUIT OF ENGINE CONTROLLER .........................................................30-278
HANDLE BATTERY DISCONNECT SWITCH ...............................................................................30-279
TEST DIODES ..............................................................................................................................30-280
Pm CLINIC...........................................................................................................................................30-281
Pm CLINIC SERVICE ...................................................................................................................30-281
40 TROUBLESHOOTING .............................................................................................................................. 40-1
CONTENTS ............................................................................................................................................ 40-2
ABBREVIATION LIST ........................................................................................................................... 40-12
RELATED INFORMATION ON TROUBLESHOOTING ......................................................................... 40-18
GENERAL TROUBLESHOOTING POINTS ................................................................................... 40-18
TROUBLESHOOTING POINTS FOR UREA SCR SYSTEM.......................................................... 40-19
SEQUENCE OF EVENTS IN TROUBLESHOOTING..................................................................... 40-31
CHECKS BEFORE TROUBLESHOOTING.................................................................................... 40-33
INDEX 00 INDEX AND FOREWORD
00-4 D51EX-24, D51PX-24
Find manuals at https://best-manuals.com

INSPECTION PROCEDURE BEFORE TROUBLESHOOTING ..................................................... 40-35
TESTING IN ACCORDANCE WITH TESTING PROCEDURE....................................................... 40-37
PREPARATION FOR TROUBLESHOOTING OF ELECTRICAL SYSTEM..................................... 40-59
PROCEDURE FOR TROUBLESHOOTING ................................................................................... 40-66
INFORMATION DESCRIBED IN TROUBLESHOOTING TABLE.................................................... 40-69
TROUBLESHOOTING METHOD FOR OPEN CIRCUIT IN WIRING HARNESS OF PRESSURE SEN-
SOR SYSTEM............................................................................................................................ 40-71
CONNECTORS LIST AND LAYOUT.............................................................................................. 40-74
CONNECTOR CONTACT IDENTIFICATION ................................................................................. 40-88
T-BRANCH BOX AND T-BRANCH ADAPTER TABLE ..................................................................40-128
FUSE LOCATION TABLE .............................................................................................................40-134
PRECAUTIONS FOR REPLACING KDOC ...................................................................................40-138
FAILURE CODES TABLE .............................................................................................................40-139
TROUBLESHOOTING BY FAILURE CODE (DISPLAY OF CODE) .....................................................40-157
FAILURE CODE [6091NX] ............................................................................................................40-157
FAILURE CODE [989L00] .............................................................................................................40-159
FAILURE CODE [989M00] ............................................................................................................40-160
FAILURE CODE [989N00] ............................................................................................................40-161
FAILURE CODE [A1U0N3] ...........................................................................................................40-162
FAILURE CODE [A1U0N4] ...........................................................................................................40-164
FAILURE CODE [A900FR]............................................................................................................40-166
FAILURE CODE [A900N6] ............................................................................................................40-167
FAILURE CODE [A900NY]............................................................................................................40-168
FAILURE CODE [AA10NX] ...........................................................................................................40-169
FAILURE CODE [AB00KE] ...........................................................................................................40-171
FAILURE CODE [AQ10MB] ..........................................................................................................40-173
FAILURE CODE [AQ10N3] ...........................................................................................................40-175
FAILURE CODE [AS00R2]............................................................................................................40-177
FAILURE CODE [AS00R3]............................................................................................................40-178
FAILURE CODE [AS00R4]............................................................................................................40-179
FAILURE CODE [AS00R5]............................................................................................................40-180
FAILURE CODE [AS00R6]............................................................................................................40-181
FAILURE CODE [AS00ZK]............................................................................................................40-182
FAILURE CODE [AS10KM]...........................................................................................................40-183
FAILURE CODE [AS10NR] ...........................................................................................................40-184
FAILURE CODE [AS10NT] ...........................................................................................................40-185
FAILURE CODE [B@BAZG] .........................................................................................................40-186
FAILURE CODE [B@BCNS] .........................................................................................................40-187
FAILURE CODE [B@CRNS].........................................................................................................40-188
FAILURE CODE [B@CRZG].........................................................................................................40-189
FAILURE CODE [CA115] ..............................................................................................................40-190
FAILURE CODE [CA122] ..............................................................................................................40-191
FAILURE CODE [CA123] ..............................................................................................................40-193
FAILURE CODE [CA131] ..............................................................................................................40-195
FAILURE CODE [CA132] ..............................................................................................................40-197
FAILURE CODE [CA144] ..............................................................................................................40-199
FAILURE CODE [CA145] ..............................................................................................................40-201
FAILURE CODE [CA153] ..............................................................................................................40-203
FAILURE CODE [CA154] ..............................................................................................................40-205
FAILURE CODE [CA187] ..............................................................................................................40-207
FAILURE CODE [CA221] ..............................................................................................................40-209
FAILURE CODE [CA222] ..............................................................................................................40-211
FAILURE CODE [CA227] ..............................................................................................................40-213
FAILURE CODE [CA234] ..............................................................................................................40-215
FAILURE CODE [CA238] ..............................................................................................................40-216
FAILURE CODE [CA239] ..............................................................................................................40-217
FAILURE CODE [CA249] ..............................................................................................................40-218
FAILURE CODE [CA256] ..............................................................................................................40-220
00 INDEX AND FOREWORD INDEX
D51EX-24, D51PX-24 00-5
Find manuals at https://best-manuals.com

FAILURE CODE [CA271] ..............................................................................................................40-222
FAILURE CODE [CA272] ..............................................................................................................40-224
FAILURE CODE [CA295] ..............................................................................................................40-226
FAILURE CODE [CA322] ..............................................................................................................40-227
FAILURE CODE [CA324] ..............................................................................................................40-229
FAILURE CODE [CA331] ..............................................................................................................40-231
FAILURE CODE [CA332] ..............................................................................................................40-233
FAILURE CODE [CA343] ..............................................................................................................40-235
FAILURE CODE [CA351] ..............................................................................................................40-236
FAILURE CODE [CA352] ..............................................................................................................40-238
FAILURE CODE [CA356] ..............................................................................................................40-240
FAILURE CODE [CA357] ..............................................................................................................40-242
FAILURE CODE [CA386] ..............................................................................................................40-244
FAILURE CODE [CA428] ..............................................................................................................40-245
FAILURE CODE [CA429] ..............................................................................................................40-247
FAILURE CODE [CA435] ..............................................................................................................40-249
FAILURE CODE [CA441] ..............................................................................................................40-251
FAILURE CODE [CA442] ..............................................................................................................40-253
FAILURE CODE [CA451] ..............................................................................................................40-254
FAILURE CODE [CA452] ..............................................................................................................40-256
FAILURE CODE [CA488] ..............................................................................................................40-258
FAILURE CODE [CA515] ..............................................................................................................40-259
FAILURE CODE [CA516] ..............................................................................................................40-261
FAILURE CODE [CA553] ..............................................................................................................40-263
FAILURE CODE [CA555] ..............................................................................................................40-264
FAILURE CODE [CA556] ..............................................................................................................40-265
FAILURE CODE [CA559] ..............................................................................................................40-266
FAILURE CODE [CA595] ..............................................................................................................40-269
FAILURE CODE [CA687] ..............................................................................................................40-271
FAILURE CODE [CA689] ..............................................................................................................40-273
FAILURE CODE [CA691] ..............................................................................................................40-276
FAILURE CODE [CA692] ..............................................................................................................40-278
FAILURE CODE [CA697] ..............................................................................................................40-280
FAILURE CODE [CA698] ..............................................................................................................40-281
FAILURE CODE [CA731] ..............................................................................................................40-282
FAILURE CODE [CA778] ..............................................................................................................40-284
FAILURE CODE [CA1117] ............................................................................................................40-289
FAILURE CODE [CA1664] ............................................................................................................40-291
FAILURE CODE [CA1669] ............................................................................................................40-293
FAILURE CODE [CA1673] ............................................................................................................40-294
FAILURE CODE [CA1677] ............................................................................................................40-295
FAILURE CODE [CA1678] ............................................................................................................40-296
FAILURE CODE [CA1682] ............................................................................................................40-297
FAILURE CODE [CA1683] ............................................................................................................40-299
FAILURE CODE [CA1684] ............................................................................................................40-301
FAILURE CODE [CA1686] ............................................................................................................40-303
FAILURE CODE [CA1691] ............................................................................................................40-304
FAILURE CODE [CA1694] ............................................................................................................40-306
FAILURE CODE [CA1695] ............................................................................................................40-308
FAILURE CODE [CA1696] ............................................................................................................40-309
FAILURE CODE [CA1712] ............................................................................................................40-311
FAILURE CODE [CA1713] ............................................................................................................40-314
FAILURE CODE [CA1714] ............................................................................................................40-316
FAILURE CODE [CA1715] ............................................................................................................40-317
FAILURE CODE [CA1776] ............................................................................................................40-318
FAILURE CODE [CA1777] ............................................................................................................40-321
FAILURE CODE [CA1843] ............................................................................................................40-324
FAILURE CODE [CA1844] ............................................................................................................40-326
INDEX 00 INDEX AND FOREWORD
00-6 D51EX-24, D51PX-24
Find manuals at https://best-manuals.com

FAILURE CODE [CA1885] ............................................................................................................40-329
FAILURE CODE [CA1887] ............................................................................................................40-331
FAILURE CODE [CA1896] ............................................................................................................40-333
FAILURE CODE [CA1898] ............................................................................................................40-334
FAILURE CODE [CA1938] ............................................................................................................40-336
FAILURE CODE [CA1942] ............................................................................................................40-338
FAILURE CODE [CA1961] ............................................................................................................40-339
FAILURE CODE [CA1962] ............................................................................................................40-340
FAILURE CODE [CA2185] ............................................................................................................40-341
FAILURE CODE [CA2186] ............................................................................................................40-343
FAILURE CODE [CA2198] ............................................................................................................40-345
FAILURE CODE [CA2272] ............................................................................................................40-347
FAILURE CODE [CA2288] ............................................................................................................40-349
FAILURE CODE [CA2311] ............................................................................................................40-350
FAILURE CODE [CA2349] ............................................................................................................40-351
FAILURE CODE [CA2353] ............................................................................................................40-353
FAILURE CODE [CA2357] ............................................................................................................40-355
FAILURE CODE [CA2373] ............................................................................................................40-356
FAILURE CODE [CA2374] ............................................................................................................40-358
FAILURE CODE [CA2375] ............................................................................................................40-360
FAILURE CODE [CA2376] ............................................................................................................40-362
FAILURE CODE [CA2387] ............................................................................................................40-365
FAILURE CODE [CA2554] ............................................................................................................40-366
FAILURE CODE [CA2634] ............................................................................................................40-367
FAILURE CODE [CA2635] ............................................................................................................40-369
FAILURE CODE [CA2636] ............................................................................................................40-370
FAILURE CODE [CA2637] ............................................................................................................40-372
FAILURE CODE [CA2771] ............................................................................................................40-374
FAILURE CODE [CA2961] ............................................................................................................40-378
FAILURE CODE [CA2973] ............................................................................................................40-379
FAILURE CODE [CA2976] ............................................................................................................40-380
FAILURE CODE [CA3142] ............................................................................................................40-382
FAILURE CODE [CA3143] ............................................................................................................40-383
FAILURE CODE [CA3144] ............................................................................................................40-384
FAILURE CODE [CA3146] ............................................................................................................40-386
FAILURE CODE [CA3147] ............................................................................................................40-387
FAILURE CODE [CA3148] ............................................................................................................40-388
FAILURE CODE [CA3151] ............................................................................................................40-390
FAILURE CODE [CA3165] ............................................................................................................40-395
FAILURE CODE [CA3228] ............................................................................................................40-397
FAILURE CODE [CA3229] ............................................................................................................40-399
FAILURE CODE [CA3231] ............................................................................................................40-401
FAILURE CODE [CA3232] ............................................................................................................40-403
FAILURE CODE [CA3235] ............................................................................................................40-407
FAILURE CODE [CA3239] ............................................................................................................40-409
FAILURE CODE [CA3241] ............................................................................................................40-412
FAILURE CODE [CA3242] ............................................................................................................40-415
FAILURE CODE [CA3251] ............................................................................................................40-418
FAILURE CODE [CA3313] ............................................................................................................40-420
FAILURE CODE [CA3314] ............................................................................................................40-421
FAILURE CODE [CA3315] ............................................................................................................40-422
FAILURE CODE [CA3419] ............................................................................................................40-424
FAILURE CODE [CA3421] ............................................................................................................40-426
FAILURE CODE [CA3497] ............................................................................................................40-428
FAILURE CODE [CA3498] ............................................................................................................40-429
FAILURE CODE [CA3545] ............................................................................................................40-430
FAILURE CODE [CA3547] ............................................................................................................40-432
FAILURE CODE [CA3558] ............................................................................................................40-433
00 INDEX AND FOREWORD INDEX
D51EX-24, D51PX-24 00-7
Find manuals at https://best-manuals.com

FAILURE CODE [CA3559] ............................................................................................................40-435
FAILURE CODE [CA3562] ............................................................................................................40-437
FAILURE CODE [CA3563] ............................................................................................................40-439
FAILURE CODE [CA3567] ............................................................................................................40-442
FAILURE CODE [CA3568] ............................................................................................................40-446
FAILURE CODE [CA3571] ............................................................................................................40-450
FAILURE CODE [CA3572] ............................................................................................................40-452
FAILURE CODE [CA3574] ............................................................................................................40-454
FAILURE CODE [CA3575] ............................................................................................................40-456
FAILURE CODE [CA3577] ............................................................................................................40-458
FAILURE CODE [CA3578] ............................................................................................................40-460
FAILURE CODE [CA3582] ............................................................................................................40-462
FAILURE CODE [CA3583] ............................................................................................................40-467
FAILURE CODE [CA3596] ............................................................................................................40-469
FAILURE CODE [CA3649] ............................................................................................................40-472
FAILURE CODE [CA3681] ............................................................................................................40-474
FAILURE CODE [CA3682] ............................................................................................................40-479
FAILURE CODE [CA3713] ............................................................................................................40-484
FAILURE CODE [CA3717] ............................................................................................................40-487
FAILURE CODE [CA3718] ............................................................................................................40-488
FAILURE CODE [CA3724] ............................................................................................................40-489
FAILURE CODE [CA3725] ............................................................................................................40-490
FAILURE CODE [CA3741] ............................................................................................................40-493
FAILURE CODE [CA3748] ............................................................................................................40-494
FAILURE CODE [CA3755] ............................................................................................................40-496
FAILURE CODE [CA3866] ............................................................................................................40-498
FAILURE CODE [CA3868] ............................................................................................................40-501
FAILURE CODE [CA4152] ............................................................................................................40-505
FAILURE CODE [CA4155] ............................................................................................................40-509
FAILURE CODE [CA4156] ............................................................................................................40-512
FAILURE CODE [CA4157] ............................................................................................................40-515
FAILURE CODE [CA4159] ............................................................................................................40-517
FAILURE CODE [CA4164] ............................................................................................................40-518
FAILURE CODE [CA4165] ............................................................................................................40-520
FAILURE CODE [CA4166] ............................................................................................................40-522
FAILURE CODE [CA4168] ............................................................................................................40-523
FAILURE CODE [CA4169] ............................................................................................................40-526
FAILURE CODE [CA4171] ............................................................................................................40-528
FAILURE CODE [CA4249] ............................................................................................................40-531
FAILURE CODE [CA4251] ............................................................................................................40-533
FAILURE CODE [CA4261] ............................................................................................................40-536
FAILURE CODE [CA4277] ............................................................................................................40-539
FAILURE CODE [CA4459] ............................................................................................................40-542
FAILURE CODE [CA4461] ............................................................................................................40-544
FAILURE CODE [CA4533] ............................................................................................................40-547
FAILURE CODE [CA4534] ............................................................................................................40-548
FAILURE CODE [CA4731] ............................................................................................................40-549
FAILURE CODE [CA4732] ............................................................................................................40-550
FAILURE CODE [CA4739] ............................................................................................................40-551
FAILURE CODE [CA4768] ............................................................................................................40-552
FAILURE CODE [CA4769] ............................................................................................................40-554
FAILURE CODE [CA4842] ............................................................................................................40-557
FAILURE CODE [CA4952] ............................................................................................................40-560
FAILURE CODE [CA5115] ............................................................................................................40-562
FAILURE CODE [CA5179] ............................................................................................................40-565
FAILURE CODE [CA5181] ............................................................................................................40-567
FAILURE CODE [CA5387] ............................................................................................................40-569
FAILURE CODE [CA5388] ............................................................................................................40-571
INDEX 00 INDEX AND FOREWORD
00-8 D51EX-24, D51PX-24
Find manuals at https://best-manuals.com

FAILURE CODE [CA5389] ............................................................................................................40-574
FAILURE CODE [CA5391] ............................................................................................................40-576
FAILURE CODE [CA5392] ............................................................................................................40-580
FAILURE CODE [CA5393] ............................................................................................................40-582
FAILURE CODE [CA5394] ............................................................................................................40-585
FAILURE CODE [CA5395] ............................................................................................................40-588
FAILURE CODE [CA5396] ............................................................................................................40-591
FAILURE CODE [CA5631] ............................................................................................................40-592
FAILURE CODE [CA5632] ............................................................................................................40-594
FAILURE CODE [CA5938] ............................................................................................................40-595
FAILURE CODE [D130KA]............................................................................................................40-597
FAILURE CODE [D130KB]............................................................................................................40-600
FAILURE CODE [D130KY]............................................................................................................40-602
FAILURE CODE [D19JKZ] ............................................................................................................40-604
FAILURE CODE [D811MC] ...........................................................................................................40-607
FAILURE CODE [D862KA]............................................................................................................40-608
FAILURE CODE [D8ALKA] ...........................................................................................................40-609
FAILURE CODE [D8ALKB] ...........................................................................................................40-611
FAILURE CODE [D8AQKR] ..........................................................................................................40-613
FAILURE CODE [DAF0MB] ..........................................................................................................40-615
FAILURE CODE [DAF0MC] ..........................................................................................................40-616
FAILURE CODE [DAF8KB] ...........................................................................................................40-617
FAILURE CODE [DAF9KQ]...........................................................................................................40-619
FAILURE CODE [DAFGMC] .........................................................................................................40-620
FAILURE CODE [DAFLKA] ...........................................................................................................40-621
FAILURE CODE [DAFLKB] ...........................................................................................................40-623
FAILURE CODE [DAFQKR] ..........................................................................................................40-625
FAILURE CODE [DAJ000] ............................................................................................................40-626
FAILURE CODE [DAJ0KQ] ...........................................................................................................40-627
FAILURE CODE [DAJ0KT]............................................................................................................40-628
FAILURE CODE [DAJ0MC]...........................................................................................................40-629
FAILURE CODE [DAJ1KK] ...........................................................................................................40-630
FAILURE CODE [DAJ2KK] ...........................................................................................................40-632
FAILURE CODE [DAJ5KK] ...........................................................................................................40-634
FAILURE CODE [DAJ6KK] ...........................................................................................................40-637
FAILURE CODE [DAJLKA] ...........................................................................................................40-639
FAILURE CODE [DAJLKB] ...........................................................................................................40-641
FAILURE CODE [DAJPMA] ..........................................................................................................40-643
FAILURE CODE [DAJQKR] ..........................................................................................................40-644
FAILURE CODE [DAJRKR]...........................................................................................................40-645
FAILURE CODE [DB2QKR] ..........................................................................................................40-646
FAILURE CODE [DB2RKR] ..........................................................................................................40-651
FAILURE CODE [DD12KA] ...........................................................................................................40-656
FAILURE CODE [DD12KB] ...........................................................................................................40-658
FAILURE CODE [DD13KA] ...........................................................................................................40-660
FAILURE CODE [DD13KB] ...........................................................................................................40-662
FAILURE CODE [DD14KA] ...........................................................................................................40-664
FAILURE CODE [DD14KB] ...........................................................................................................40-666
FAILURE CODE [DDKAKA] ..........................................................................................................40-668
FAILURE CODE [DDKAKB] ..........................................................................................................40-670
FAILURE CODE [DDKFL4] ...........................................................................................................40-672
FAILURE CODE [DDKGL4]...........................................................................................................40-674
FAILURE CODE [DDKHKA] ..........................................................................................................40-676
FAILURE CODE [DDKHKB] ..........................................................................................................40-678
FAILURE CODE [DDNLKA] ..........................................................................................................40-680
FAILURE CODE [DDNLKB] ..........................................................................................................40-682
FAILURE CODE [DDP6KA]...........................................................................................................40-684
FAILURE CODE [DDP6KB]...........................................................................................................40-687
00 INDEX AND FOREWORD INDEX
D51EX-24, D51PX-24 00-9

FAILURE CODE [DDP6MA] ..........................................................................................................40-689
FAILURE CODE [DDU1FS]...........................................................................................................40-691
FAILURE CODE [DDU1KA] ..........................................................................................................40-693
FAILURE CODE [DDU1KY] ..........................................................................................................40-696
FAILURE CODE [DFA4KX] ...........................................................................................................40-698
FAILURE CODE [DFA4KZ] ...........................................................................................................40-699
FAILURE CODE [DFA4L8] ............................................................................................................40-700
FAILURE CODE [DFA5KA] ...........................................................................................................40-701
FAILURE CODE [DFA5KB] ...........................................................................................................40-704
FAILURE CODE [DFA6KA] ...........................................................................................................40-707
FAILURE CODE [DFA6KB] ...........................................................................................................40-710
FAILURE CODE [DFA7KX] ...........................................................................................................40-713
FAILURE CODE [DFA7KZ] ...........................................................................................................40-714
FAILURE CODE [DFA7L8] ............................................................................................................40-715
FAILURE CODE [DFA8KA] ...........................................................................................................40-716
FAILURE CODE [DFA8KB] ...........................................................................................................40-719
FAILURE CODE [DFA9KA] ...........................................................................................................40-722
FAILURE CODE [DFA9KB] ...........................................................................................................40-725
FAILURE CODE [DGS1KA] ..........................................................................................................40-728
FAILURE CODE [DGS1KX] ..........................................................................................................40-731
FAILURE CODE [DH21KA] ...........................................................................................................40-732
FAILURE CODE [DH21KB] ...........................................................................................................40-734
FAILURE CODE [DHA4KA]...........................................................................................................40-736
FAILURE CODE [DHH7KA] ..........................................................................................................40-738
FAILURE CODE [DHH7KB] ..........................................................................................................40-741
FAILURE CODE [DHH8KA] ..........................................................................................................40-743
FAILURE CODE [DHH8KB] ..........................................................................................................40-746
FAILURE CODE [DHH9KA] ..........................................................................................................40-748
FAILURE CODE [DHH9KB] ..........................................................................................................40-751
FAILURE CODE [DHHAKA] ..........................................................................................................40-753
FAILURE CODE [DHHAKB] ..........................................................................................................40-756
FAILURE CODE [DK30KA] ...........................................................................................................40-758
FAILURE CODE [DK30KB] ...........................................................................................................40-761
FAILURE CODE [DK30KX] ...........................................................................................................40-763
FAILURE CODE [DK30KZ] ...........................................................................................................40-764
FAILURE CODE [DK30L8] ............................................................................................................40-765
FAILURE CODE [DK31KA] ...........................................................................................................40-766
FAILURE CODE [DK31KB] ...........................................................................................................40-769
FAILURE CODE [DK40KA] ...........................................................................................................40-771
FAILURE CODE [DK40KB] ...........................................................................................................40-774
FAILURE CODE [DK55KX] ...........................................................................................................40-776
FAILURE CODE [DK55KZ] ...........................................................................................................40-777
FAILURE CODE [DK55L8] ............................................................................................................40-778
FAILURE CODE [DK56KA] ...........................................................................................................40-779
FAILURE CODE [DK56KB] ...........................................................................................................40-782
FAILURE CODE [DK57KA] ...........................................................................................................40-784
FAILURE CODE [DK57KB] ...........................................................................................................40-787
FAILURE CODE [DLM0KX]...........................................................................................................40-789
FAILURE CODE [DLM1KA]...........................................................................................................40-790
FAILURE CODE [DLM1KB]...........................................................................................................40-792
FAILURE CODE [DLM1MA] ..........................................................................................................40-794
FAILURE CODE [DLM2KA]...........................................................................................................40-795
FAILURE CODE [DLM2KB]...........................................................................................................40-797
FAILURE CODE [DLM2MA] ..........................................................................................................40-799
FAILURE CODE [DLM3KA]...........................................................................................................40-800
FAILURE CODE [DLM3KB]...........................................................................................................40-802
FAILURE CODE [DLM3MB] ..........................................................................................................40-804
FAILURE CODE [DN21FS] ...........................................................................................................40-805
INDEX 00 INDEX AND FOREWORD
00-10 D51EX-24, D51PX-24

FAILURE CODE [DR21KX] ...........................................................................................................40-807
FAILURE CODE [DR31KX] ...........................................................................................................40-808
FAILURE CODE [DV20KB] ...........................................................................................................40-809
FAILURE CODE [DW4BKA]..........................................................................................................40-811
FAILURE CODE [DW4BKB]..........................................................................................................40-813
FAILURE CODE [DW4BKY]..........................................................................................................40-815
FAILURE CODE [DW7BKA]..........................................................................................................40-817
FAILURE CODE [DW7BKB]..........................................................................................................40-819
FAILURE CODE [DW7EKA]..........................................................................................................40-821
FAILURE CODE [DW7EKB]..........................................................................................................40-823
FAILURE CODE [DW7EKY]..........................................................................................................40-825
FAILURE CODE [DWN5KA]..........................................................................................................40-827
FAILURE CODE [DWN5KB]..........................................................................................................40-829
FAILURE CODE [DWN5KY]..........................................................................................................40-831
FAILURE CODE [DXA4KA]...........................................................................................................40-833
FAILURE CODE [DXA4KB]...........................................................................................................40-835
FAILURE CODE [DXA4KY]...........................................................................................................40-837
FAILURE CODE [DXA5KA]...........................................................................................................40-839
FAILURE CODE [DXA5KB]...........................................................................................................40-841
FAILURE CODE [DXA5KY]...........................................................................................................40-843
FAILURE CODE [DXA6KA]...........................................................................................................40-845
FAILURE CODE [DXA6KB]...........................................................................................................40-847
FAILURE CODE [DXA6KY]...........................................................................................................40-849
FAILURE CODE [DXA7KA]...........................................................................................................40-851
FAILURE CODE [DXA7KB]...........................................................................................................40-853
FAILURE CODE [DXA7KY]...........................................................................................................40-855
FAILURE CODE [DXHRKA] ..........................................................................................................40-857
FAILURE CODE [DXHRKB] ..........................................................................................................40-859
FAILURE CODE [DXHRKY] ..........................................................................................................40-861
FAILURE CODE [DXHSKA] ..........................................................................................................40-863
FAILURE CODE [DXHSKB] ..........................................................................................................40-865
FAILURE CODE [DXHSKY] ..........................................................................................................40-867
FAILURE CODE [DXHTKA] ..........................................................................................................40-869
FAILURE CODE [DXHTKB] ..........................................................................................................40-871
FAILURE CODE [DXHTKY] ..........................................................................................................40-873
FAILURE CODE [DXHUKA] ..........................................................................................................40-875
FAILURE CODE [DXHUKB] ..........................................................................................................40-877
FAILURE CODE [DXHUKY] ..........................................................................................................40-879
FAILURE CODE [DXJ4KA] ...........................................................................................................40-881
FAILURE CODE [DXJ4KB] ...........................................................................................................40-883
FAILURE CODE [DXJCKA]...........................................................................................................40-885
FAILURE CODE [DXJCKB]...........................................................................................................40-887
FAILURE CODE [DXJCKY]...........................................................................................................40-889
FAILURE CODE [DXJDKA]...........................................................................................................40-891
FAILURE CODE [DXJDKB]...........................................................................................................40-893
FAILURE CODE [DXJDKY]...........................................................................................................40-895
FAILURE CODE [DXK1KA]...........................................................................................................40-897
FAILURE CODE [DXK1KB]...........................................................................................................40-899
FAILURE CODE [DXK1KY]...........................................................................................................40-901
FAILURE CODE [DXK2KA]...........................................................................................................40-903
FAILURE CODE [DXK2KB]...........................................................................................................40-905
FAILURE CODE [DXK2KY]...........................................................................................................40-907
TROUBLESHOOTING OF ELECTRICAL SYSTEM (E-MODE) ...........................................................40-909
E-1 ENGINE DOES NOT START (ENGINE DOES NOT CRANK) ................................................40-909
E-2 MANUAL PREHEATING SYSTEM DOES NOT WORK..........................................................40-916
E-3 AUTOMATIC PREHEATING SYSTEM DOES NOT WORK ....................................................40-919
E-4 WHILE PREHEATING IS WORKING, PREHEATING MONITOR DOES NOT LIGHT UP.......40-921
00 INDEX AND FOREWORD INDEX
D51EX-24, D51PX-24 00-11

E-5 WHEN STARTING SWITCH IS TURNED TO ON POSITION, MACHINE MONITOR DISPLAYS
NOTHING..................................................................................................................................40-923
E-6 WHEN STARTING SWITCH IS TURNED TO ON POSITION (WITH ENGINE STOPPED), BASIC
CHECK MONITOR LIGHTS UP ................................................................................................40-927
E-7 AIR CLEANER CLOGGING MONITOR LIGHTS UP IN YELLOW WHILE ENGINE IS RUNNING.....
..................................................................................................................................................40-928
E-8 CHARGE LEVEL MONITOR LIGHTS UP IN RED WHILE ENGINE IS RUNNING .................40-929
E-9 ENGINE COOLANT TEMPERATURE MONITOR LIGHTS UP IN RED WHILE ENGINE IS RUN-
NING .........................................................................................................................................40-930
E-10 ENGINE OIL PRESSURE MONITOR LIGHTS UP IN RED WHILE ENGINE IS RUNNING..40-931
E-11 HST CHARGE PRESSURE MONITOR LIGHTS UP IN RED WHILE ENGINE IS RUNNING ..........
..................................................................................................................................................40-932
E-12 HYDRAULIC OIL TEMPERATURE MONITOR LIGHTS UP IN RED WHILE ENGINE IS RUN-
NING .........................................................................................................................................40-933
E-13 HST OIL FILTER CLOGGING MONITOR LIGHTS UP IN RED WHILE ENGINE IS RUNNING.......
..................................................................................................................................................40-934
E-14 ENGINE COOLANT TEMPERATURE GAUGE DOES NOT INDICATE CORRECT TEMPERA-
TURE ........................................................................................................................................40-935
E-15 FUEL LEVEL GAUGE DOES NOT INDICATE CORRECT LEVEL .......................................40-936
E-16 HYDRAULIC OIL TEMPERATURE GAUGE DOES NOT INDICATE CORRECT TEMPERATURE..
..................................................................................................................................................40-939
E-17 OPERATION MODE DOES NOT CHANGE..........................................................................40-940
E-18 OPERATING CUSTOMIZE SWITCH DOES NOT DISPLAY CUSTOMIZE SCREEN............40-941
E-19 MODIFYING SETTING ON CUSTOMIZE SCREEN DOES NOT CHANGE SETTING OF MA-
CHINE .......................................................................................................................................40-942
E-20 SERVICE METER IS NOT DISPLAYED, WHILE STARTING SWITCH IS IN OFF POSITION.........
..................................................................................................................................................40-943
E-21 SERVICE MODE CANNOT BE SELECTED.........................................................................40-944
E-22 WORK EQUIPMENT DOES NOT OPERATE .......................................................................40-945
E-23 FOOT HEATER DOES NOT OPERATE ...............................................................................40-947
E-24 HORN DOES NOT SOUND..................................................................................................40-953
E-25 HORN DOES NOT STOP SOUNDING.................................................................................40-955
E-26 BACKUP ALARM DOES NOT SOUND ................................................................................40-956
E-27 BACKUP ALARM DOES NOT STOP SOUNDING................................................................40-957
E-28 HEADLAMP DOES NOT LIGHT UP .....................................................................................40-958
E-29 REAR LAMP DOES NOT LIGHT UP ....................................................................................40-962
E-30 ALL WIPERS DO NOT OPERATE........................................................................................40-965
E-31 FRONT WIPER DOES NOT OPERATE ...............................................................................40-967
E-32 REAR WIPER DOES NOT OPERATE..................................................................................40-969
E-33 LEFT DOOR WIPER DOES NOT OPERATE .......................................................................40-971
E-34 RIGHT DOOR WIPER DOES NOT OPERATE .....................................................................40-975
E-35 FRONT WASHER DOES NOT OPERATE............................................................................40-979
E-36 REAR WASHER DOES NOT OPERATE ..............................................................................40-981
E-37 LEFT DOOR WASHER DOES NOT OPERATE....................................................................40-983
E-38 RIGHT DOOR WASHER DOES NOT OPERATE .................................................................40-985
E-39 KOMTRAX SYSTEM DOES NOT OPERATE NORMALLY ...................................................40-987
TROUBLESHOOTING FOR HYDRAULIC AND MECHANICAL SYSTEMS (H MODE) .......................40-988
INFORMATION MENTIONED IN TROUBLESHOOTING TABLE (H MODE).................................40-988
FAILURE MODE AND CAUSE TABLE..........................................................................................40-989
H-1 NEITHER R.H. NOR L.H. OF TRACKS CAN TRAVEL FORWARD OR REVERSE (NONE OF THE
TRAVEL SYSTEMS OPERATE)................................................................................................40-995
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) ....................................................40-997
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) ........................40-999
H-4 TRAVEL SPEED OR POWER IS LOW.................................................................................40-1001
H-5 SPEED RANGE DOES NOT CHANGE................................................................................40-1003
H-6 SHOCK IS LARGE WHEN MACHINE MOVES OFF OR STOPS .........................................40-1004
INDEX 00 INDEX AND FOREWORD
00-12 D51EX-24, D51PX-24

H-7 MACHINE DEVIATES LARGELY .........................................................................................40-1005
H-8 MACHINE DRIFT ON A SLOPE IS LARGE..........................................................................40-1008
H-9 ENGINE SPEED DROPS LARGELY OR ENGINE STOPS ..................................................40-1010
H-10 UNUSUAL NOISE IS HEARD FROM AROUND HST PUMP OR MOTOR .........................40-1012
H-11 HST OIL TEMPERATURE (HYDRAULIC OIL TEMPERATURE) RISES TOO HIGH ..........40-1014
H-12 ALL WORK EQUIPMENT DO NOT OPERATE ..................................................................40-1016
H-13 ALL WORK EQUIPMENTS SPEED OR POWER IS LOW .................................................40-1018
H-14 BLADE LIFT SPEED OR POWER IS LOW ........................................................................40-1019
H-15 BLADE TILT SPEED OR POWER IS LOW ........................................................................40-1021
H-16 BLADE ANGLE SPEED OR POWER IS LOW....................................................................40-1022
H-17 TIME LAG OF BLADE LIFT IS LARGE ..............................................................................40-1023
H-18 HYDRAULIC DRIFT OF LIFTED BLADE IS LARGE ..........................................................40-1024
H-19 HYDRAULIC DRIFT OF TILTED BLADE IS LARGE...........................................................40-1025
H-20 UNUSUAL NOISE IS HEARD FROM AROUND WORK EQUIPMENT AND COOLING FAN
PUMP OR CONTROL VALVE .................................................................................................40-1026
H-21 FAN SPEED IS ABNORMAL (TOO HIGH OR LOW, OR STATIONARY) ............................40-1027
H-22 UNUSUAL NOISE IS HEARD FROM AROUND FAN .........................................................40-1029
TROUBLESHOOTING OF ENGINE (S-MODE) .................................................................................40-1030
INFORMATION MENTIONED IN TROUBLESHOOTING TABLE (S MODE)...............................40-1030
S-1 ENGINE DOES NOT CRANK WHEN STARTING SWITCH IS TURNED TO START POSITION.......
................................................................................................................................................40-1031
S-2 ENGINE CRANKS BUT NO EXHAUST GAS COMES OUT .................................................40-1032
S-3 FUEL IS BEING INJECTED BUT ENGINE DOES NOT START (MISFIRING: ENGINE CRANKS
BUT DOES NOT START) ........................................................................................................40-1033
S-4 ENGINE STARTABILITY IS POOR.......................................................................................40-1035
S-5 ENGINE DOES NOT PICK UP SMOOTHLY ........................................................................40-1037
S-6 ENGINE STOPS DURING OPERATION ..............................................................................40-1039
S-7 ENGINE RUNS ROUGH OR IS UNSTABLE ........................................................................40-1041
S-8 ENGINE LACKS POWER.....................................................................................................40-1042
S-9 EXHAUST SMOKE IS BLACK..............................................................................................40-1044
S-10 ENGINE OIL CONSUMPTION IS EXCESSIVE ..................................................................40-1046
S-11 OIL BECOMES CONTAMINATED QUICKLY ......................................................................40-1047
S-12 FUEL CONSUMPTION IS EXCESSIVE .............................................................................40-1048
S-13 OIL IS IN COOLANT (OR COOLANT SPURTS BACK OR COOLANT LEVEL GOES DOWN) .......
................................................................................................................................................40-1049
S-14 OIL PRESSURE DROPS ...................................................................................................40-1050
S-15 FUEL MIXES INTO ENGINE OIL........................................................................................40-1052
S-16 WATER MIXES INTO ENGINE OIL (MILKY) ......................................................................40-1053
S-17 COOLANT TEMPERATURE RISES TOO HIGH (OVERHEATING)....................................40-1054
S-18 UNUSUAL NOISE IS HEARD.............................................................................................40-1055
S-19 VIBRATION IS EXCESSIVE ...............................................................................................40-1056
S-20 AIR CANNOT BE BLED FROM FUEL CIRCUIT.................................................................40-1057
S-21 ACTIVE REGENERATION IS EXECUTED FREQUENTLY ................................................40-1058
S-22 ACTIVE REGENERATION TAKES TIME............................................................................40-1059
S-23 WHITE SMOKE IS EXHAUSTED DURING ACTIVE REGENERATION..............................40-1060
S-24 AdBlue/DEF CONSUMPTION IS EXCESSIVE ...................................................................40-1061
S-25 THERE IS UNUSUAL SMELL (IRRITATING ODOR) ..........................................................40-1063
S-26 FOREIGN MATERIALS ENTER AdBlue/DEF (AdBlue/DEF INCREASES).........................40-1064
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................................................................................................. 50-40
ENGINE AND COOLING SYSTEM....................................................................................................... 50-53
REMOVE AND INSTALL SUPPLY PUMP ASSEMBLY .................................................................. 50-53
00 INDEX AND FOREWORD INDEX
D51EX-24, D51PX-24 00-13

REMOVE AND INSTALL INJECTOR ASSEMBLY ......................................................................... 50-73
REMOVE AND INSTALL CYLINDER HEAD ASSEMBLY .............................................................. 50-98
REMOVE AND INSTALL EGR VALVE ASSEMBLY.......................................................................50-141
REMOVE AND INSTALL EGR COOLER ASSEMBLY...................................................................50-148
REMOVE AND INSTALL STARTING MOTOR ASSEMBLY ..........................................................50-156
REMOVE AND INSTALL AIR CONDITIONER COMPRESSOR BELT ..........................................50-161
REMOVE AND INSTALL ALTERNATOR BELT .............................................................................50-170
REMOVE AND INSTALL AUTOMATIC TENSIONER....................................................................50-175
REMOVE AND INSTALL RADIATOR ASSEMBLY ........................................................................50-178
REMOVE AND INSTALL HYDRAULIC OIL COOLER ASSEMBLY ...............................................50-195
REMOVE AND INSTALL AFTERCOOLER ASSEMBLY................................................................50-206
REMOVE AND INSTALL COOLING FAN DRIVE ASSEMBLY ......................................................50-220
REMOVE AND INSTALL COOLING FAN MOTOR ASSEMBLY ....................................................50-229
REMOVE AND INSTALL ENGINE, HST PUMP ASSEMBLY ........................................................50-235
REMOVE AND INSTALL ENGINE FRONT OIL SEAL ..................................................................50-258
REMOVE AND INSTALL ENGINE REAR OIL SEAL.....................................................................50-263
REMOVE AND INSTALL ENGINE HOOD ASSEMBLY .................................................................50-267
REMOVE AND INSTALL KDOC ASSEMBLY ................................................................................50-274
REMOVE AND INSTALL KDOC AND SCR ASSEMBLY ...............................................................50-287
REMOVE AND INSTALL BELLOWS PIPE ASSEMBLY ................................................................50-303
REMOVE AND INSTALL FUEL TANK ASSEMBLY .......................................................................50-311
REMOVE AND INSTALL AdBlue/DEF TANK ASSEMBLY ............................................................50-326
REMOVE AND INSTALL AdBlue/DEF TANK SENSOR FLANGE ASSEMBLY..............................50-346
REMOVE AND INSTALL AdBlue/DEF TANK SENSOR ................................................................50-352
REMOVE AND INSTALL AdBlue/DEF TANK STRAINER .............................................................50-356
REMOVE AND INSTALL SCR ASSEMBLY...................................................................................50-358
REMOVE AND INSTALL KCCV ASSEMBLY ................................................................................50-364
REMOVE AND INSTALL AdBlue/DEF MIXING TUBE ..................................................................50-368
REMOVE AND INSTALL AdBlue/DEF INJECTOR........................................................................50-376
REMOVE AND INSTALL AdBlue/DEF PUMP ...............................................................................50-386
REMOVE AND INSTALL AdBlue/DEF HOSE ...............................................................................50-394
REMOVE AND INSTALL AIR CLEANER ASSEMBLY...................................................................50-436
REMOVE AND INSTALL AIR CONDITIONER COMPRESSOR ASSEMBLY ................................50-441
REMOVE AND INSTALL AIR CONDITIONER CONDENSER ASSEMBLY ...................................50-450
POWER TRAIN....................................................................................................................................50-458
DISASSEMBLE AND ASSEMBLE FINAL DRIVE ASSEMBLY......................................................50-458
UNDERCARRIAGE AND FRAME........................................................................................................50-472
REMOVE AND INSTALL TRACK FRAME ASSEMBLY.................................................................50-472
REMOVE AND INSTALL IDLER ASSEMBLY................................................................................50-482
DISASSEMBLE AND ASSEMBLE IDLER ASSEMBLY .................................................................50-487
REMOVE AND INSTALL RECOIL SPRING ASSEMBLY ..............................................................50-494
DISASSEMBLE AND ASSEMBLE RECOIL SPRING ASSEMBLY................................................50-495
REMOVE AND INSTALL TRACK ROLLER ASSEMBLY ...............................................................50-501
DISASSEMBLE AND ASSEMBLE TRACK ROLLER ASSEMBLY ................................................50-506
REMOVE AND INSTALL CARRIER ROLLER ASSEMBLY ...........................................................50-511
DISASSEMBLE AND ASSEMBLE CARRIER ROLLER ASSEMBLY ............................................50-514
REMOVE AND INSTALL PIVOT SHAFT ASSEMBLY ...................................................................50-518
SEPARATE AND CONNECT TRACK ASSEMBLY........................................................................50-521
SEPARATE AND CONNECT PLUS TYPE TRACK ASSEMBLY ...................................................50-526
DISASSEMBLE AND ASSEMBLE TRACK ASSEMBLY GENERALLY..........................................50-527
DISASSEMBLE AND ASSEMBLE PLUS TYPE TRACK ASSEMBLY GENERALLY .....................50-545
DISASSEMBLE AND ASSEMBLE ONE LINK OF TRACK SHOE ASSEMBLY ON THE FIELD ....50-556
DISASSEMBLE AND ASSEMBLE ONE LINK OF PLUS TYPE TRACK SHOE ASSEMBLY ON THE
FIELD ........................................................................................................................................50-565
REMOVE AND INSTALL EQUALIZER BAR ASSEMBLY..............................................................50-572
REMOVE AND INSTALL EQUALIZER BAR SIDE BUSHINGS .....................................................50-577
REMOVE AND INSTALL SEGMENT TEETH................................................................................50-579
HYDRAULIC SYSTEM.........................................................................................................................50-583
INDEX 00 INDEX AND FOREWORD
00-14 D51EX-24, D51PX-24

REMOVE AND INSTALL HYDRAULIC TANK ASSEMBLY............................................................50-583
REMOVE AND INSTALL CONTROL VALVE ASSEMBLY .............................................................50-599
WORK EQUIPMENT............................................................................................................................50-607
REMOVE AND INSTALL BLADE ASSEMBLY ..............................................................................50-607
REMOVE AND INSTALL BLADE LIFT CYLINDER ASSEMBLY ...................................................50-615
REMOVE AND INSTALL BLADE TILT CYLINDER ASSEMBLY....................................................50-619
REMOVE AND INSTALL BLADE ANGLE CYLINDER ASSEMBLY...............................................50-622
REMOVE AND INSTALL U-FRAME ASSEMBLY ..........................................................................50-626
CAB AND ITS ATTACHMENTS ...........................................................................................................50-633
REMOVE AND INSTALL OPERATOR'S CAB ASSEMBLY ...........................................................50-633
REMOVE AND INSTALL OPERATOR'S CAB GLASS (ADHERED GLASS) .................................50-649
REMOVE AND INSTALL AIR CONDITIONER UNIT ASSEMBLY .................................................50-657
REMOVE AND INSTALL RECEIVER DRIER................................................................................50-670
REMOVE AND INSTALL OPERATOR'S SEAT .............................................................................50-674
REMOVE AND INSTALL SEAT BELT ...........................................................................................50-676
REMOVE AND INSTALL FOOT HEATER ASSEMBLY .................................................................50-678
DISASSEMBLE AND ASSEMBLE FOOT HEATER ASSEMBLY...................................................50-683
ELECTRICAL SYSTEM .......................................................................................................................50-685
REMOVE AND INSTALL ENGINE CONTROLLER ASSEMBLY ...................................................50-685
REMOVE AND INSTALL HST CONTROLLER ASSEMBLY ..........................................................50-692
REMOVE AND INSTALL MACHINE MONITOR ASSEMBLY ........................................................50-694
REMOVE AND INSTALL MASS AIR FLOW AND TEMPERATURE SENSOR ..............................50-697
REMOVE AND INSTALL KCCV CRANKCASE PRESSURE SENSOR.........................................50-701
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
00 INDEX AND FOREWORD INDEX
D51EX-24, D51PX-24 00-15

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 BLADE LIFT CYLINDER ........................................................... 60-63
MAINTENANCE STANDARD OF BLADE TILT CYLINDER ........................................................... 60-64
MAINTENANCE STANDARD OF BLADE ANGLE CYLINDER....................................................... 60-65
MAINTENANCE STANDARD OF FIXED MULTI-SHANK RIPPER................................................. 60-66
MAINTENANCE STANDARD OF RIPPER LIFT CYLINDER.......................................................... 60-68
CAB AND ITS ATTACHMENTS ............................................................................................................ 60-69
MAINTENANCE STANDARD OF CAB MOUNT............................................................................. 60-69
ELECTRICAL SYSTEM ........................................................................................................................ 60-71
MAINTENANCE STANDARD OF ELECTRIC STEERING CONTROL LEVER............................... 60-71
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
INDEX 00 INDEX AND FOREWORD
00-16 D51EX-24, D51PX-24

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
00 INDEX AND FOREWORD INDEX
D51EX-24, D51PX-24 00-17

ABBREVIATION LIST
• This list of abbreviations includes the abbreviations used in the text of the shop manual for parts, compo-
nents, and functions whose meaning is not immediately clear. The spelling is given in full with an outline of
the meaning.
• Abbreviations that are used in general society may not be included.
• Special abbreviations which appear infrequently are noted in the text.
• This list of abbreviations consists of two parts. The first part is a list of the abbreviations used in the text of
the manual, and the second part is a list of the abbreviations used in the circuit diagrams.
List of abbreviations used in the text
Abbrevia-
tion Actual word spelled out
Purpose of use (major ap-
plicable machine (*1), or
component/system)
Explanation
ABS Anti-skid Brake System
Travel and brake When the tires skid (wheels stop rotating), the
brakes are released, and when the wheels start
to rotate, the brakes are applied again.
(HD, HM)
AISS Automatic Idling Setting
System Engine This function automatically sets the idle speed.
AJSS Advanced Joystick
Steering System
Steering A lever is used to perform the steering operations
instead of a steering wheel. Moreover, it shifts
gear and changes direction (FORWARD or RE-
VERSE).
(WA)
ARAC Automatic Retarder Ac-
celerator Control
Travel and brake When the accelerator pedal is released while the
machine is traveling downhill, this function auto-
matically applies the retarder with a constant
braking force.
(HD, HM)
ARSC Automatic Retarder
Speed Control
Travel and brake When the accelerator pedal is released while the
machine is traveling downhill, this function auto-
matically applies the retarder to ensure that the
machine speed does not accelerate above the
speed set by the operator.
(HD, HM)
ASR Automatic Spin Regula-
tor
Travel and brake When the tires spin on soft ground surfaces, this
function automatically uses the optimum braking
force to drive both wheels.
(HD, HM)
ATT Attachment Work equipment A device that can be fixed onto the standard ma-
chine in order to enable it to do different jobs.
BCV Brake cooling oil control
valve
Brake When the retarder is not being used, this valve
bypasses part of the brake cooling oil to reduce
the load on the hydraulic pump.
(HD)
CAN Controller Area Network Communication and elec-
tronic control
One of communication standards that is used in
the network on the machine.
CDR Crankcase Depression
Regulator Engine
A regulator valve which is installed to KCCV ven-
tilator. It is written as CDR valve and it is not
used independently.
CLSS Closed-center Load
Sensing System Hydraulic system
This system can simultaneously actuate multiple
actuators regardless of the load (provides better
combined operation than OLSS).
CRI Common Rail Injection Engine
Engine controller electronically controls supply
pump, common rail, and injector. This function
maintains optimum fuel injection amount and fuel
injection timing.
ABBREVIATION LIST 00 INDEX AND FOREWORD
00-18 D51EX-24, D51PX-24