Komatsu Bulldozer D51EXi-24 D51PXi-24 service & repair manual

Description Komatsu Bulldozer D51EXi-24 D51PXi-24 service & repair manual

Komatsu Bulldozer D51EXi-24, D51PXi-24 pdf workshop service repair manual

Serial numbers:
10001 and up
15001 and up
B20001 and up
B25001 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
Procedures If Fire Occurs
Precautions for Disposing of Waste Materials
Procedures for Exhaust Gas Regulations
Precautions for DEF
Store DEF
Precautions When You Handle Hydraulic Equipment
Precautions When You Disconnect and Connect Pipings
Precautions When You Handle Electrical Equipment
Precautions When You Handle Fuel System Equipment
Precautions When You Handle Intake System Equipment
Practical Use of KOMTRAX
Disconnect and Connect PushPull Type Coupler
Precautions for Disconnection and Connection of Connectors
How to Disconnect and Connect Deutsch Connector
How to Disconnect and Connect Slide Lock Type Connector
How to Disconnect and Connect Connector with Lock to Pull
How to Disconnect and Connect Connector with Lock to Push
How to Disconnect and Connect Connector with Housing to Rotate
How to Read the Codes for Electric Cable
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
Function of Urea SCR System
Component Parts of Urea SCR System
Boot-up System
Layout Drawing of Boot-up 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
ICT System
Layout Drawing of ICT System
System Diagram of ICT Control System
Blade Control System
Assist Control System
Back Grade Mode System
Cut Control System
Smooth Start System
Slip Control System
Speed Control System
Straight Travel Correction System
Quick Surface Control System
System of Triangulated Surface from AS-BUILT
2 Surfaces Selection Control System
Lift Layer Control System
2D Laser Machine Control System
Component Parts of ICT System
Undercarriage and Frame
Main Frame
Suspension
Track Frame and Idler Cushion
Work Equipment
Structure of Front Work Equipment
Structure of Fixed Multi-Shank Ripper
CAB Related Parts
ROPS CAB
CAB Mount

Standard Value Table
Standard Value Table for Engine
Standard Value Table for Engine: D51EXI-24
Standard Value Table for Engine: D51PXI-24
Standard Value Table for Machine
Standard Value Table for Machine: D51EXI-24
Standard Value Table for Machine: D51PXI-24
Machine Posture and Procedures to Measure Performance

Testing and Adjusting
Precautions Before Work
Related Information on Testing and Adjusting
Differences In Machine Monitor Symbols
Tools for Testing and Adjusting
Sketch of Tools for Testing and Adjusting
Engine and Cooling System
Examine Engine Speed
Examine Boost Pressure
Examine Exhaust Gas Color
Examine and Adjust Valve Clearance
Examine Compression Pressure
Examine Blowby Pressure
Examine Engine Oil Pressure
Visual Check Inside of EGR Valve
Clean Inside of EGR Valve
Examine Fuel Pressure
Examine Fuel Discharge, Return and Leakage
Bleed Air from Fuel System
Examine Fuel Circuit for Leakage
Handle Cylinder Cutout Mode Operation
Handle NoInjection Cranking Operation
Examine and Adjust Air Conditioner Compressor Belt Tension
Examine KDOC, SCR and Muffler Stack for Looseness and Damage
Examine Installed Condition of Cylinder Heads and Manifolds
Examine Engine Piping for Damage and Looseness
Write Correction for Ash in Soot Accumulation to Engine Controller
Examine SCR Related Functions
Clean DEF Tank
Clean DEF Tank Mounting Part
Clean DEF Pump
Power Train
Examine and Adjust HST Oil Pressure
Bleed Air from HST Pump
Examine Outlet Pressure of Solenoid Valve
Examine Travel Deviation
Examine Brake Performance Simply
Examine and Adjust Deceleration/Brake Pedal
Adjust Parking Brake Lever
Move Machine When It Cannot Travel
Undercarriage and Frame
Examine and Adjust Idler Clearance
Examine Sprocket Wear
Examine and Adjust Track Tension
Hydraulic System
Release Remained Pressure in Hydraulic Circuit
Examine and Adjust Work Equipment Circuit Oil Pressure
Examine and Adjust Oil Pressure in Control Circuit
Examine Outlet Pressure of EPC Solenoid Valve
Bleed Air from Work Equipment, Cooling Fan Pump, and Charge Pump
Examine Cooling Fan Speed
Examine Cooling Fan Circuit Oil Pressure
Examine Parts Which Cause Hydraulic Drift of Work Equipment
Examine Oil Leakage from Work Equipment Cylinder
Bleed Air from Work Equipment Cylinders
Work Equipment
Adjust Work Equipment Lock Lever
Examine and Adjust Play of Blade Electric Lever
Electrical System
Set and Operate Machine Monitor
How to Start Up KOMTRAX System
How to Stop Use of KOMTRAX System
Adjust After Replacement of HST Controller
Adjust After Replacement of Electric and Hydraulic Equipment
Adjust Rearview Camera Angle
Set Region of Bluetooth® Compatible Radio
Handle Voltage Circuit of Engine Controller
Handle Battery Disconnect Switch
Examine Diodes
ICT System
Examine and Adjust ICT Related Devices
Set and Operate Control Box
Machine Calibration
How to Operate Pitch Rod Calibration
How to Input Wear Volume of Blade Edge and Track Shoes
Reset Cylinder Stroke End
How to Operate Manual Machine Calibration
Examine and Adjust Blade Elevation
Examine Stroke Sensor for Lift Cylinder
Examine Stroke Sensor for Tilt Cylinder
Examine Stroke Sensor for Angle Cylinder
Examine and Adjust Reset Sensor for Lift Cylinder
Adjust When ICT Sensor Controller is Replaced
Adjust After Replacement of IMU Sensor
How to Adjust When ICT Related Devices are Repaired or Replaced
Pm Clinic
Pm Clinic Service

Troubleshooting
Precautions Before Work
Related Information to Troubleshooting
General Troubleshooting Points
Troubleshooting Points for Urea SCR System
Sequence of Events in Troubleshooting
Checks Before Troubleshooting
Inspection Procedure Before Troubleshooting
Test in Accordance with Testing Procedure
Preparation for Troubleshooting of Electrical System
Procedure for Troubleshooting
Information Shown in Troubleshooting Table
How to Diagnose Open Circuit of Hydraulic Pressure Sensor System Wiring Harness
Connector List and Layout
Connector Contact Connection Table
T-Branch Box and T-Branch Adapter Table
Fuse Location Table
Precautions When You Replace KDOC
Failure Code 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
Precautions Before Work
Related Information on Disassembly and Assembly
How to Read This Manual
Coating Materials List
Special Tool List
Sketches of Special Tools
Engine and Cooling System
Remove and Install Supply Pump Assembly
Remove and Install Injector Assembly
Remove and Install Cylinder Head Assembly
Remove and Install EGR Valve Assembly
Remove and Install EGR Cooler Assembly
Remove and Install Starter Assembly
Remove and Install Air Conditioner Compressor Belt
Remove and Install Alternator Belt
Remove and Install Automatic Tensioner
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 KDOC Assembly
Remove and Install KDOC and SCR Assembly
Remove and Install Bellows Pipe Assembly
Remove and Install Fuel Tank Assembly
Remove and Install DEF Tank Assembly
Remove and Install DEF Tank Sensor Flange Assembly
Remove and Install DEF Tank Sensor
Remove and Install DEF Tank Strainer
Remove and Install SCR Assembly
Remove and Install KCCV Assembly
Remove and Install DEF Mixing Tube
Remove and Install DEF Injector
Remove and Install DEF Pump
Remove and Install 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 Connect 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 Stroke and Reset Sensing Blade Lift Cylinder Assembly
Disassemble and Assemble Stroke and Reset Sensing Blade Lift Cylinder Assembly
Remove and Install Stroke Sensing Blade Tilt Cylinder Assembly
Disassemble and Assemble Stroke Sensing Blade Tilt Cylinder Assembly
Remove and Install Stroke Sensing Blade Angle Cylinder Assembly
Disassemble and Assemble Stroke Sensing Blade Angle Cylinder Assembly
Remove and Install U-Frame Assembly
CAB Related Parts
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 Seat
How to Remove and Install Seat Belt
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 Mass Air Flow and Temperature Sensor
Remove and Install KCCV Crankcase Pressure Sensor
Remove and Install Gateway Function Controller Assembly
Remove and Install Navigation Controller
Remove and Install ICT Sensor Controller Assembly
Remove and Install Control Box
Remove and Install GNSS Receiver
Remove and Install GNSS Antenna
Remove and Install IMU Sensor
Remove and Install Communication Terminal
Remove and Install Communication Antenna

Maintenance Standard
Engine and Cooling System
Maintenance Standard for Engine Mount
Maintenance Standard for Damper
Maintenance Standard for Cooling System
Maintenance Standard for Cooling Fan Motor
Maintenance Standard for Hydraulic Oil Cooler Bypass and HST Charge Safety Valve
Power Train
Maintenance Standard for HST Pump
Maintenance Standard for HST Charge Pump
Maintenance Standard for HST Motor
Maintenance Standard for Final Drive
Maintenance Standard for Sprocket for PLUS Type Track Shoes
Maintenance Standard for Sprocket Tooth Profile Full-Scale Drawing for PLUS Type Track Shoes
Undercarriage and Frame
Maintenance Standard for Suspension
Maintenance Standard for Track Frame and Idler Cushion
Maintenance Standard for Idler
Maintenance Standard for Track Roller for PLUS Type Track Shoes
Maintenance Standard for Carrier Roller for PLUS Type Track Shoes
Maintenance Standard for PLUS Type Track Shoes
Maintenance Standard for Single Shoes
Hydraulic System
Maintenance Standard for Hydraulic Tank
Maintenance Standard for Work Equipment and Cooling Fan Pump
Maintenance Standard for Control Valve
Maintenance Standard for Ripper PPC Valve
Maintenance Standard for Spool EPC and Solenoid Valve
Maintenance Standard for Quick Drop Valve
Work Equipment
Maintenance Standard for Front Work Equipment
Maintenance Standard for Cutting Edge and End Bit
Maintenance Standard for Blade Lift Cylinder
Maintenance Standard for Blade Tilt Cylinder
Maintenance Standard for Blade Angle Cylinder
Maintenance Standard for Fixed MultiShank Ripper
Maintenance Standard for Ripper Lift Cylinder
CAB Related Parts
Maintenance Standard for CAB Mount
Electrical System
Maintenance Standard for Steering Electric Lever

Appendix
Precautions Before Work
Air Conditioner System
Precautions for Refrigerant
Air Conditioner Component
Specifications of Air Conditioner
Structure 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 Test of and Troubleshooting of Air Conditioner
Circuit Diagram of Air Conditioner
System Diagram of Air Conditioner
Control Function of Air Conditioner
Locations of Air Conditioner Parts and Layout of Connectors
Examine Relay
How to Examine Relay
Air Conditioner Troubleshooting Chart
Information Shown 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 by Gauge Pressure
Connect Service Tool
How to Connect Service Tool
Precautions for Disconnection and Connection of Air Conditioner Piping
Handle Compressor Oil

Circuit Diagrams
Hydraulic Circuit Diagram
Symbols Used in Hydraulic Circuit Diagram
Electrical Circuit Diagram
Symbols Used in Electric Circuit Diagram

Engine SAA4D107E-3 workshop service manual