Komatsu Bulldozer D51EX-24E0 D51PX-24E0 service & repair manual

Description Komatsu Bulldozer D51EX-24E0 D51PX-24E0 service & repair manual

Komatsu Bulldozer D51EX-24E0, D51PX-24E0 pdf workshop service repair manual

Serial numbers:
20001 and up

Technical documentation, specifications, testing, troubleshooting, maintenance, electrical diagrams, hydraulic schematics, adjusting, assembly, disassembly, removal, installation instructions and other information

SERVICE MANUAL CONTENT:
INDEX AND FOREWORD
FOREWORD, SAFETY, BASIC INFORMATION
HOW TO READ THE SHOP MANUAL
SAFETY NOTICE FOR OPERATION
PRECAUTIONS TO PREVENT FIRE
ACTIONS IF FIRE OCCURS
PRECAUTIONS FOR DISPOSING OF WASTE MATERIALS
ACTIONS TAKEN TO MEET EXHAUST GAS REGULATIONS
PRECAUTIONS FOR DEF
STORE AdBlue/DEF
PRECAUTIONS FOR HANDLING HYDRAULIC EQUIPMENT
PRECAUTIONS FOR DISCONNECTION AND CONNECTION OF PIPINGS
PRECAUTIONS FOR HANDLING ELECTRICAL EQUIPMENT
PRECAUTIONS FOR HANDLING FUEL SYSTEM EQUIPMENT
PRECAUTIONS FOR HANDLING INTAKE SYSTEM EQUIPMENT
PRACTICAL USE OF KOMTRAX
DISCONNECT AND CONNECT PUSHPULL TYPE COUPLER
PRECAUTIONS FOR DISCONNECTION AND CONNECTION OF CONNECTORS
METHOD FOR DISCONNECTING AND CONNECTING DEUTSCH CONNECTOR
METHOD FOR DISCONNECTING AND CONNECTING SLIDE LOCK TYPE CONNECTOR
METHOD FOR DISCONNECTING AND CONNECTING CONNECTOR WITH LOCK TO PULL
METHOD FOR DISCONNECTING AND CONNECTING CONNECTOR WITH LOCK TO PUSH
METHOD FOR DISCONNECTING AND CONNECTING CONNECTOR WITH HOUSING TO ROTATE
HOW TO READ ELECTRICAL WIRE CODE
EXPLANATION OF TERMS FOR MAINTENANCE STANDARD
STANDARD TIGHTENING TORQUE TABLE
CONVERSION TABLE
ABBREVIATION LIST

SPECIFICATIONS
SPECIFICATION DRAWING
WEIGHT TABLE
FUEL, COOLANT, LUBRICANT

STRUCTURE AND FUNCTION
UREA SCR SYSTEM
LAYOUT DRAWING OF UREA SCR SYSTEM
UREA SCR SYSTEM DIAGRAM (DIVIDED TYPE)
FUNCTION OF UREA SCR SYSTEM
COMPONENT PARTS OF UREA SCR SYSTEM
BOOT-UP SYSTEM
LAYOUT DRAWING OF BOOTUP SYSTEM
SYSTEM OPERATING LAMP SYSTEM
BATTERY DISCONNECT SWITCH
ENGINE SYSTEM
LAYOUT DRAWING OF ENGINE SYSTEM
ENGINE CONTROL SYSTEM
AUTOMATIC IDLE STOP SYSTEM
COMPONENT PARTS OF ENGINE SYSTEM
COOLING SYSTEM
LAYOUT DRAWING OF COOLING SYSTEM
COOLING FAN CONTROL SYSTEM
COMPONENT PARTS OF COOLING SYSTEM
CONTROL SYSTEM
LAYOUT DRAWING OF CONTROL SYSTEM
MACHINE MONITOR SYSTEM
KOMTRAX SYSTEM
COMPONENT PARTS OF CONTROL SYSTEM
HYDRAULIC SYSTEM
LAYOUT DRAWING OF HYDRAULIC SYSTEM
CLSS
COMPONENT PARTS OF HYDRAULIC SYSTEM
POWER TRAIN SYSTEM
LAYOUT DRAWING OF HST SYSTEM
OPERATION OF HST SYSTEM
STEERING AND BRAKE CONTROL SYSTEM
HST CONTROL SYSTEM
PARKING BRAKE CONTROL SYSTEM
COMPONENT PARTS OF POWER TRAIN SYSTEM
WORK EQUIPMENT SYSTEM
WORK EQUIPMENT CONTROL
LAYOUT DRAWING OF FRONT WORK EQUIPMENT
LAYOUT DRAWING OF FIXED MULTI-SHANK RIPPER
COMPONENT PARTS OF WORK EQUIPMENT SYSTEM
UNDERCARRIAGE AND FRAME
MAIN FRAME
SUSPENSION
TRACK FRAME AND IDLER CUSHION
WORK EQUIPMENT
STRUCTURE OF FRONT WORK EQUIPMENT
STRUCTURE OF FIXED MULTISHANK RIPPER
CAB AND ITS ATTACHMENTS
ROPS CAB
CAB MOUNT

STANDARD VALUE TABLE
STANDARD VALUE TABLE FOR ENGINE
STANDARD VALUE TABLE FOR ENGINE: D51EX-24E0
STANDARD VALUE TABLE FOR ENGINE: D51PX-24E0
STANDARD VALUE TABLE FOR MACHINE
STANDARD VALUE TABLE FOR MACHINE: D51EX-24E0
STANDARD VALUE TABLE FOR MACHINE: D51PX-24E0
MACHINE POSTURE AND PROCEDURE FOR MEASURING PERFORMANCE

TESTING AND ADJUSTING
RELATED INFORMATION ON TESTING AND ADJUSTING
TOOLS FOR TESTING AND ADJUSTING
SKETCH OF TOOLS FOR TESTING AND ADJUSTING
ENGINE AND COOLING SYSTEM
TEST ENGINE SPEED
TEST BOOST PRESSURE
TEST EXHAUST GAS COLOR
TEST AND ADJUST VALVE CLEARANCE
TEST COMPRESSION PRESSURE
TEST BLOWBY PRESSURE
TEST ENGINE OIL PRESSURE
TEST FUEL PRESSURE
TEST FUEL DISCHARGE, RETURN AND LEAKAGE
BLEED AIR FROM FUEL SYSTEM
TEST FUEL CIRCUIT FOR LEAKAGE
HANDLE CYLINDER CUTOUT MODE OPERATION
HANDLE NOINJECTION CRANKING OPERATION
TEST KDPF, SCR AND MUFFLER STACK FOR LOOSENESS AND DAMAGE
TEST INSTALLED CONDITION OF CYLINDER HEADS AND MANIFOLDS
TEST ENGINE PIPING FOR DAMAGE AND LOOSENESS
WRITE ASH IN SOOT ACCUMULATION CORRECTION TO ENGINE CONTROLLER
TEST SCR RELATED FUNCTIONS
CLEAN AdBlue/DEF TANK
CLEAN AdBlue/DEF TANK MOUNTING PORTION
CLEAN AdBlue/DEF PUMP
POWER TRAIN
TEST AND ADJUST HST OIL PRESSURE
BLEED AIR FROM HST PUMP
TEST OUTLET PRESSURE OF SOLENOID VALVE
TEST TRAVEL DEVIATION
TEST BRAKE PERFORMANCE SIMPLY
TEST AND ADJUST DECELERATION/BRAKE PEDAL
ADJUST PARKING BRAKE LEVER
MOVE MACHINE WHEN IT CANNOT TRAVEL
UNDERCARRIAGE AND FRAME
CHECK AND ADJUST IDLER CLEARANCE
TESTING SPROCKET WEAR
TEST AND ADJUST TRACK TENSION
HYDRAULIC SYSTEM
RELEASE REMAINING PRESSURE FROM HYDRAULIC SYSTEM
TEST AND ADJUST WORK EQUIPMENT OIL PRESSURES
TEST AND ADJUST OIL PRESSURE OF CONTROL CIRCUIT
TEST OUTLET PRESSURE OF EPC SOLENOID VALVE
BLEED AIR FROM WORK EQUIPMENT, COOLING FAN PUMP, AND CHARGE PUMP
TEST COOLING FAN SPEED
TEST COOLING FAN CIRCUIT OIL PRESSURE
TEST THE PARTS CAUSING HYDRAULIC DRIFT IN WORK EQUIPMENT
TEST INTERNAL OIL LEAKAGE OF WORK EQUIPMENT CYLINDER
BLEED AIR FROM WORK EQUIPMENT CYLINDERS
WORK EQUIPMENT
ADJUST WORK EQUIPMENT LOCK LEVER
TEST AND ADJUST PLAY OF BLADE ELECTRIC LEVER
ELECTRICAL SYSTEM
SET AND OPERATE MACHINE MONITOR
START UP KOMTRAX SYSTEM
STOP USING OF KOMTRAX SYSTEM
ADJUSTMENT WHEN HST CONTROLLER HAS BEEN REPLACED
ADJUSTMENT WHEN ELECTRIC OR HYDRAULIC DEVICE HAS BEEN REPLACED
ADJUST REARVIEW CAMERA ANGLE
SET REGION OF Bluetooth® COMPATIBLE RADIO
HANDLE VOLTAGE CIRCUIT OF ENGINE CONTROLLER
BATTERY DISCONNECT SWITCH
TEST DIODES
Pm CLINIC
Pm CLINIC SERVICE

TROUBLESHOOTING
RELATED INFORMATION ON TROUBLESHOOTING
GENERAL TROUBLESHOOTING POINTS
TROUBLESHOOTING POINTS FOR UREA SCR SYSTEM
SEQUENCE OF EVENTS IN TROUBLESHOOTING
CHECKS BEFORE TROUBLESHOOTING
INSPECTION PROCEDURE BEFORE TROUBLESHOOTING
TESTING IN ACCORDANCE WITH TESTING PROCEDURE
PREPARATION FOR TROUBLESHOOTING ELECTRICAL SYSTEM
PROCEDURE FOR TROUBLESHOOTING
SYMPTOM AND TROUBLESHOOTING NUMBERS
INFORMATION DESCRIBED IN TROUBLESHOOTING TABLE
TROUBLESHOOTING METHOD FOR OPEN CIRCUIT IN WIRING HARNESS OF PRESSURE SENSOR SYSTEM
CONNECTORS LIST
CONNECTOR LAYOUT
CONNECTOR CONTACT IDENTIFICATION
TBRANCH BOX AND TBRANCH ADAPTER TABLE
FUSE LOCATION TABLE
PRECAUTIONS FOR CLEANING AND REPLACING KDPF (KCSF and KDOC)
PREPARATION OF SHORT CIRCUIT ELECTRICAL CONNECTOR (FOR FAILURE CODES [CA1883] AND [CA3135])
FAILURE CODES TABLE
TROUBLESHOOTING BY FAILURE CODE (DISPLAY OF CODE)
TROUBLESHOOTING OF ELECTRICAL SYSTEM (E-MODE)
TROUBLESHOOTING FOR HYDRAULIC AND MECHANICAL SYSTEMS (H MODE)
TROUBLESHOOTING OF ENGINE (S-MODE)

DISASSEMBLY AND ASSEMBLY
RELATED INFORMATION ON DISASSEMBLY AND ASSEMBLY
HOW TO READ THIS MANUAL
COATING MATERIALS LIST
SPECIAL TOOLS LIST
SKETCHES OF SPECIAL TOOLS
PREPARATION
DRAIN AND ADD COOLANT
DRAIN AND ADD HYDRAULIC OIL
DRAIN AND ADD FUEL
COLLECT AND REFILL REFRIGERANT
ENGINE AND COOLING SYSTEM
REMOVE AND INSTALL SUPPLY PUMP ASSEMBLY
REMOVE AND INSTALL INJECTOR ASSEMBLY
REMOVE AND INSTALL CYLINDER HEAD ASSEMBLY
REMOVE AND INSTALL STARTING MOTOR ASSEMBLY
REMOVE AND INSTALL AIR CONDITIONER COMPRESSOR BELT
REMOVE AND INSTALL ALTERNATOR BELT
REMOVE AND INSTALL AUTOTENSIONER
REMOVE AND INSTALL RADIATOR ASSEMBLY
REMOVE AND INSTALL HYDRAULIC OIL COOLER ASSEMBLY
REMOVE AND INSTALL AFTERCOOLER ASSEMBLY
REMOVE AND INSTALL COOLING FAN DRIVE ASSEMBLY
REMOVE AND INSTALL COOLING FAN MOTOR ASSEMBLY
REMOVE AND INSTALL ENGINE AND HST PUMP ASSEMBLY
REMOVE AND INSTALL ENGINE FRONT OIL SEAL
REMOVE AND INSTALL ENGINE REAR OIL SEAL
REMOVE AND INSTALL ENGINE HOOD ASSEMBLY
REMOVE AND INSTALL KDPF ASSEMBLY
DISASSEMBLE AND ASSEMBLE KDPF ASSEMBLY
REMOVE AND INSTALL KDPF AND SCR ASSEMBLY
REMOVE AND INSTALL BELLOWS PIPE ASSEMBLY
REMOVE AND INSTALL FUEL TANK ASSEMBLY
REMOVE AND INSTALL AdBlue/DEF TANK ASSEMBLY
REMOVE AND INSTALL AdBlue/DEF TANK SENSOR FLANGE ASSEMBLY
REMOVE AND INSTALL AdBlue/DEF TANK SENSOR
REMOVE AND INSTALL AdBlue/DEF TANK STRAINER
REMOVE AND INSTALL SCR ASSEMBLY
REMOVE AND INSTALL AdBlue/DEF INJECTOR
REMOVE AND INSTALL AdBlue/DEF PUMP
REMOVE AND INSTALL AdBlue/DEF HOSE
REMOVE AND INSTALL AIR CLEANER ASSEMBLY
REMOVE AND INSTALL AIR CONDITIONER COMPRESSOR ASSEMBLY
REMOVE AND INSTALL AIR CONDITIONER CONDENSER ASSEMBLY
POWER TRAIN
DISASSEMBLE AND ASSEMBLE FINAL DRIVE ASSEMBLY
UNDERCARRIAGE AND FRAME
REMOVE AND INSTALL TRACK FRAME ASSEMBLY
REMOVE AND INSTALL IDLER ASSEMBLY
DISASSEMBLE AND ASSEMBLE IDLER ASSEMBLY
REMOVE AND INSTALL RECOIL SPRING ASSEMBLY
DISASSEMBLE AND ASSEMBLE RECOIL SPRING ASSEMBLY
REMOVE AND INSTALL TRACK ROLLER ASSEMBLY
DISASSEMBLE AND ASSEMBLE TRACK ROLLER ASSEMBLY
REMOVE AND INSTALL CARRIER ROLLER ASSEMBLY
DISASSEMBLE AND ASSEMBLE CARRIER ROLLER ASSEMBLY
REMOVE AND INSTALL PIVOT SHAFT ASSEMBLY
SEPARATE AND INSTALL TRACK ASSEMBLY
SEPARATE AND CONNECT PLUS TYPE TRACK ASSEMBLY
DISASSEMBLE AND ASSEMBLE TRACK ASSEMBLY GENERALLY
DISASSEMBLE AND ASSEMBLE PLUS TYPE TRACK ASSEMBLY GENERALLY
DISASSEMBLE AND ASSEMBLE ONE TRACK LINK ASSEMBLY IN FIELD
REMOVE AND INSTALL EQUALIZER BAR ASSEMBLY
REMOVE AND INSTALL EQUALIZER BAR SIDE BUSHING
REMOVE AND INSTALL SEGMENT TEETH
HYDRAULIC SYSTEM
REMOVE AND INSTALL HYDRAULIC TANK ASSEMBLY
REMOVE AND INSTALL CONTROL VALVE ASSEMBLY
WORK EQUIPMENT
REMOVE AND INSTALL BLADE ASSEMBLY
REMOVE AND INSTALL BLADE LIFT CYLINDER ASSEMBLY
REMOVE AND INSTALL BLADE TILT CYLINDER ASSEMBLY
REMOVE AND INSTALL BLADE ANGLE CYLINDER ASSEMBLY
REMOVE AND INSTALL UFRAME ASSEMBLY
CAB AND ITS ATTACHMENTS
REMOVE AND INSTALL OPERATOR CAB ASSEMBLY
REMOVE AND INSTALL OPERATOR CAB GLASS (ADHERED GLASS)
REMOVE AND INSTALL AIR CONDITIONER UNIT ASSEMBLY
REMOVE AND INSTALL RECEIVER DRIER
REMOVE AND INSTALL OPERATOR'S SEAT
REMOVE AND INSTALL SEATBELT
REMOVE AND INSTALL FOOT HEATER ASSEMBLY
DISASSEMBLE AND ASSEMBLE FOOT HEATER ASSEMBLY
ELECTRICAL SYSTEM
REMOVE AND INSTALL ENGINE CONTROLLER ASSEMBLY
REMOVE AND INSTALL HST CONTROLLER ASSEMBLY
REMOVE AND INSTALL MACHINE MONITOR ASSEMBLY
REMOVE AND INSTALL INTAKE MANIFOLD PRESSURE AND TEMPERATURE SENSOR
REMOVE AND INSTALL KDPF TEMPERATURE SENSOR
REMOVE AND INSTALL KDPF DIFFERENTIAL PRESSURE SENSOR
REMOVE AND INSTALL SCR TEMPERATURE SENSOR
REMOVE AND INSTALL SCR OUTLET NOx SENSOR
REMOVE AND INSTALL GATEWAY FUNCTION CONTROLLER
REMOVE AND INSTALL COMMUNICATION TERMINAL

MAINTENANCE STANDARD
ENGINE AND COOLING SYSTEM
MAINTENANCE STANDARD OF ENGINE MOUNT
MAINTENANCE STANDARD OF DAMPER
MAINTENANCE STANDARD OF COOLING SYSTEM
MAINTENANCE STANDARD OF COOLING FAN MOTOR
MAINTENANCE STANDARD OF HYDRAULIC OIL COOLER BYPASS AND HST CHARGE SAFETY VALVE
POWER TRAIN
MAINTENANCE STANDARD OF HST PUMP
MAINTENANCE STANDARD OF HST CHARGE PUMP
MAINTENANCE STANDARD OF HST MOTOR
MAINTENANCE STANDARD OF FINAL DRIVE
MAINTENANCE STANDARD OF SPROCKET FOR PLUS TYPE TRACK SHOE
MAINTENANCE STANDARD OF SPROCKET TOOTH PROFILE FULL-SCALE DRAWING FOR PLUS TYPE TRACK SHOE
UNDERCARRIAGE AND FRAME
MAINTENANCE STANDARD OF SUSPENSION
MAINTENANCE STANDARD OF TRACK FRAME AND IDLER CUSHION
MAINTENANCE STANDARD OF IDLER
MAINTENANCE STANDARD OF TRACK ROLLER FOR PLUS TYPE TRACK SHOES
MAINTENANCE STANDARD OF CARRIER ROLLER FOR PLUS TYPE TRACK SHOE
MAINTENANCE STANDARD OF PLUS TYPE TRACK SHOE
MAINTENANCE STANDARD OF SINGLE SHOE
HYDRAULIC SYSTEM
MAINTENANCE STANDARD OF HYDRAULIC TANK
MAINTENANCE STANDARD OF WORK EQUIPMENT AND COOLING FAN PUMP
MAINTENANCE STANDARD OF CONTROL VALVE
MAINTENANCE STANDARD OF RIPPER PPC VALVE
MAINTENANCE STANDARD OF PORT VALVE OF EPC AND SOLENOID
MAINTENANCE STANDARD OF QUICK DROP VALVE
WORK EQUIPMENT
MAINTENANCE STANDARD OF FRONT WORK EQUIPMENT
MAINTENANCE STANDARD OF CUTTING EDGE AND END BIT
MAINTENANCE STANDARD OF BLADE LIFT CYLINDER
MAINTENANCE STANDARD OF BLADE TILT CYLINDER
MAINTENANCE STANDARD OF BLADE ANGLE CYLINDER
MAINTENANCE STANDARD OF FIXED MULTISHANK RIPPER
MAINTENANCE STANDARD OF RIPPER LIFT CYLINDER
CAB AND ITS ATTACHMENTS
MAINTENANCE STANDARD OF CAB MOUNT
ELECTRICAL SYSTEM
MAINTENANCE STANDARD OF ELECTRIC STEERING CONTROL LEVER

APPENDIX
AIR CONDITIONER SYSTEM
PRECAUTIONS FOR REFRIGERANT
AIR CONDITIONER COMPONENT
SPECIFICATIONS OF AIR CONDITIONER
CONFIGURATION AND FUNCTION OF REFRIGERATION CYCLE
OUTLINE OF REFRIGERATION CYCLE
COMPONENT PARTS OF AIR CONDITIONER SYSTEM
AIR CONDITIONER UNIT
COMPONENT PARTS OF AIR CONDITIONER UNIT
COMPRESSOR
CONDENSER
RECEIVER DRIER
EXPLANATION OF PROCEDURE FOR TESTING AND TROUBLESHOOTING OF AIR CONDITIONER
CIRCUIT DIAGRAM OF AIR CONDITIONER
AIR CONDITIONER SYSTEM DIAGRAM
CONTROL FUNCTION OF AIR CONDITIONER
INSTALLATION LOCATIONS OF AIR CONDITIONER PARTS AND ARRANGEMENT OF CONNECTORS
TEST RELAYS
METHOD FOR TESTING RELAYS
AIR CONDITIONER TROUBLESHOOTING CHART
INFORMATION DESCRIBED IN TROUBLESHOOTING TABLE
A-1 TROUBLESHOOTING FOR CONDENSER FAN
A-2 TROUBLESHOOTING FOR COMPRESSOR AND REFRIGERANT SYSTEM (AIR IS NOT COOLED)
A-3 TROUBLESHOOTING FOR BLOWER MOTOR SYSTEM (NO AIR COMES OUT OR AIR FLOW IS ABNORMAL)
A-4 TROUBLESHOOTING FOR TEMPERATURE CONTROL FUNCTION
TROUBLESHOOTING USING GAUGE PRESSURE
CONNECTION OF SERVICE TOOL
METHOD FOR CONNECTING SERVICE TOOL
PRECAUTIONS FOR DISCONNECTING AND CONNECTING HOSES AND TUBES IN AIR CONDITIONER PIPINGS
HANDLE COMPRESSOR OIL

CIRCUIT DIAGRAMS
HYDRAULIC CIRCUIT DIAGRAM
SYMBOLS USED IN HYDRAULIC CIRCUIT DIAGRAM
ELECTRICAL CIRCUIT DIAGRAM
SYMBOLS USED IN ELECTRICAL CIRCUIT DIAGRAM

Engine SAA4D107E-5 workshop service manual