Komatsu Crawler Dozer D51EX-22 D51PX-22 service & repair manual

Description Komatsu Crawler Dozer D51EX-22 D51PX-22 service & repair manual

Komatsu Crawler Dozer D51EX-22, D51PX-22 pdf workshop service repair manual + operation & maintenance manual

Serial number B10001 and up

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

SERVICE MANUAL CONTENT:
GENERAL
SPECIFICATION DRAWING
POWER ANGLE, POWER TILT DOZER WITH ROPS CAB
SPECIFICATION
WEIGHT TABLE
TABLE OF FUEL, COOLANT AND LUBRICANTS
RECOMMENDED PRODUCTS OTHER THAN KOMATSU GENUINE OILS

STRUCTURE, FUNCTION AND MAINTENANCE STANDARD
ENGINE RELATED PARTS
COOLING SYSTEM
COOLING FAN PUMP
COOLING FAN MOTOR
OIL COOLER BYPASS VALVE
CHARGE SAFETY VALVE
POWER TRAIN
POWER TRAIN SYSTEM
DAMPER
FINAL DRIVE
PATH OF POWER TRANSMISSION
UNDER CARRIAGE AND FRAME
MAIN FRAME
TRACK FRAME AND RECOIL SPRING
SUSPENSION
IDLER
TRACK ROLLER
CARRIER ROLLER
TRACK SHOE
HYDRAULIC SYSTEM (HST)
HST HYDRAULIC EQUIPMENT ARRANGEMENT DIAGRAM
HST PUMP
SAFETY-SUCTION VALVE
TOWING VALVE
HST MOTOR
MOTOR CONTROL VALVE
SOLENOID VALVE (3-SPOOL), EPC VALVE (2-SPOOL) AND TOWING VALVE
SOLENOID VALVE
EPC VALVE
CHARGE PUMP
HYDRAULIC SYSTEM (WORK EQUIPMENT)
CLSS (CLOSED CENTER LOAD SENSING SYSTEM)
UNLOAD VALVE
PRESSURE COMPENSATION VALVE
LS BYPASS VALVE
WORK EQUIPMENT HYDRAULIC ARRANGEMENT DIAGRAM
WORK EQUIPMENT AND FAN PUMP
SERVO VALVE
CONTROL VALVE
QUICK DROP VALVE
BLADE PPC VALVE
RIPPER/WINCH PPC VALVE
HYDRAULIC TANK, FILTER
ACCUMULATOR
WORK EQUIPMENT
CUTTING EDGE AND END BIT
RIPPER
WORK EQUIPMENT CYLINDER
LIFT CYLINDER
TILT CYLINDER
ANGLE CYLINDER
RIPPER CYLINDER
PISTON VALVE FOR ANGLE CYLINDER
CAB AND ITS ATTACHMENTS
ROPS CAB
STEERING AND BRAKE CONTROL
WORK EQUIPMENT CONTROL
CAB DAMPER MOUNT
AIR CONDITIONER
AIR CONDITIONER AND FLOOR HEATER
AIR CONDITIONER PIPING
ELECTRICAL SYSTEM
MONITOR SYSTEM
ENGINE CONTROL
ENGINE CONTROL SYSTEM
COOLING CONTROL SYSTEM
HST CONTROL SYSTEM
GEAR SHIFT CONTROL SYSTEM
GEAR SHIFTING BY OPERATOR
SET TRAVEL SPEEDS CORRESPONDING TO GEAR SPEEDS
CHANGING TRAVEL SPEED ACCORDING TO CHANGE OF ENGINE SPEED
STRAIGHT TRAVEL CORRECTION CONTROL SYSTEM
PARKING BRAKE CONTROL SYSTEM
KOMTRAX SYSTEM
SYSTEM COMPONENTS
MONITOR PANEL
ENGINE CONTROLLER
HST CONTROLLER
ELECTRIC LEVER (FOR TRAVEL)
KOMTRAX TERMINAL
SENSORS
BRAKE OIL PRESSURE SENSOR
HYDRAULIC OIL TEMPERATURE SENSOR
HST CIRCUIT OIL PRESSURE SENSOR
AIR CLEANER CLOGGING SENSOR
DECELERATOR PEDAL POTENTIOMETER
BRAKE PEDAL POTENTIOMETER
FUEL CONTROL DIAL
FUEL LEVEL SENSOR
CHARGE FILTER CLOGGING SENSOR
COOLANT TEMPERATURE SENSOR
ENGINE OIL PRESSURE SWITCH
ENGINE ROTATION SENSOR
BOOST PRESSURE AND TEMPERATURE SENSOR
WIF SENSOR
HST MOTOR SPEED SENSOR

STANDARD VALUE TABLES
STANDARD VALUE TABLE FOR ENGINE
STANDARD VALUE TABLE FOR CHASSIS
PERFORMANCE MEASURING POSTURE AND METHOD

TESTING AND ADJUSTING
LIST OF TOOLS
ENGINE
ENGINE SPEED
AIR INTAKE BOOST PRESSURE
EXHAUST TEMPERATURE
EXHAUST GAS COLOR
VALVE CLEARANCE
COMPRESSION PRESSURE
BLOW-BY PRESSURE
ENGINE OIL PRESSURE
HANDLING CONTROLLER HIGH-VOLTAGE CIRCUIT
FUEL SYSTEM
HANDLING FUEL SYSTEM PARTS
RELEASING RESIDUAL PRESSURE FROM FUEL SYSTEM
BLEEDING AIR FROM FUEL CIRCUIT
FUEL PRESSURE
FUEL RETURN RATE AND LEAKAGE
FUEL CIRCUIT FOR LEAKAGE
FAN (WORK EQUIPMENT) PUMP PRESSURE
FAN SPEED
FAN SPEED SENSOR
DECELERATOR PEDAL
HST OIL PRESSURE
MOTOR CONTROL VALVE OUTLET PRESSURE
TRAVEL DEVIATION
PARKING BRAKE LEVER
BRAKE PERFORMANCE
BRAKE PEDAL LINKAGE
EMERGENCY RELEASE OF PARKING BRAKE
IDLER CLEARANCE
TRACK SHOE TENSION
WORK EQUIPMENT
OIL PRESSURE
WORK EQUIPMENT PPC VALVE
OIL PRESSURE
ADJUSTING PLAY OF WORK EQUIPMENT PPC VALVE
LOCK LEVER ADJUSTMENT
CYLINDER LEAKAGE
HYDRAULIC CIRCUIT
RELEASING RESIDUAL PRESSURE
BLEEDING AIR
BLADE CENTER BALL ADJUSTMENT
BLADE PITCH BALL ADJUSTMENT
DIODES
PROCEDURE FOR TESTING
MONITOR PANEL (EMMS) - SPECIAL FUNCTIONS
PREPARATION WORK FOR TROUBLESHOOTING FOR ELECTRICAL SYSTEM
ELECTRIC/HYDRAULIC DEVICES ARE ADJUSTED/REPLACED
ITEMS TO BE ADJUSTED
HST CONTROLLER ADJUSTMENT AFTER REPLACEMENT
MONITOR PANEL ADJUSTMENT AFTER REPLACEMENT
PM-CLINIC SERVICE
PM-CLINIC INSPECTION SHEET
PM-CLINIC UNDERCARRIAGE CHECK SHEET
UNDERCARRIAGE TROUBLESHOOTING REPORT (NORMAL)
UNDERCARRIAGE TROUBLESHOOTING REPORT (IMPACT)
PM-CLINIC UNDERCARRIAGE CHECK SHEET
UNDERCARRIAGE TROUBLESHOOTING REPORT (NORMAL)
UNDERCARRIAGE TROUBLESHOOTING REPORT (IMPACT)

TROUBLESHOOTING (GENERAL)
POINTS TO REMEMBER WHEN TROUBLESHOOTING
SEQUENCE OF EVENTS IN TROUBLESHOOTING
PRECAUTIONS WHEN CARRYING OUT MAINTENANCE
PRECAUTIONS WHEN HANDLING ELECTRICAL EQUIPMENT
HANDLING ELECTRONIC CONTROL UNIT
POINTS TO REMEMBER WHEN TROUBLESHOOTING ELECTRICAL CIRCUITS
ELECTRIC WIRE CODE
CLASSIFICATION BY THICKNESS
CLASSIFICATION BY COLOR AND CODE
HOW TO READ ELECTRIC WIRE CODE
POINTS TO REMEMBER WHEN HANDLING HYDRAULIC EQUIPMENT
CHECKS BEFORE TROUBLESHOOTING
CATEGORIES AND METHOD OF USING TROUBLESHOOTING CHARTS
TROUBLESHOOTING INDIVIDUAL ELECTRICAL CIRCUITS
CONNECTION TABLE FOR CONNECTOR PIN NUMBERS
T-ADAPTER TABLE
MODE CHART

TROUBLESHOOTING (BY ERROR CODE)
TROUBLESHOOTING (E-MODE)
TROUBLESHOOTING (H-MODE)
TROUBLESHOOTING (S-MODE)

DISASSEMBLY AND ASSEMBLY
REMOVAL AND INSTALLATION OF COMPONENTS
OVERHAUL OF COMPONENTS
PRECAUTIONS WHEN CARRYING OUT AN OPERATION
SPECIAL TOOL LIST
SKETCH OF SPECIAL TOOLS
CONNECTOR REPAIR PROCEDURES
CONTACT TERMINAL REMOVAL (HD30 TYPE)
STRIPPING INSULATION
CRIMPING CONTACT TERMINAL (HD30 TYPE)
INSERTION OF CONTACT TERMINAL (HD30 TYPE)
CONTACT TERMINAL REMOVAL (DT TYPE)
STRIPPING INSULATION
CRIMPING CONTACT TERMINAL (DT TYPE)
INSERTION OF CONTACT TERMINAL (DT TYPE)

OTHERS
CONNECTOR ARRANGEMENT DRAWING
ELECTRICAL CIRCUIT DIAGRAM
CONNECTOR LIST
CONNECTOR LOCATION VIEW
CAB ELECTRICAL ACCESSORIES
AIR CONDITIONER AND HEATER UNIT
ELECTRICAL SYSTEM
IN CAB SWITCHES, RELAYS AND CONNECTORS
CAB HARNESS AND CONTROLLER CONNECTIONS
ENGINE HARNESS AND CONTROLLER
MONITOR PANEL AND SWITCHES
KOMTRAX AND CONNECTORS

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