Komatsu Crawler Dozer D51EXi-22 D51PXi-22 service & repair manual

Description Komatsu Crawler Dozer D51EXi-22 D51PXi-22 service & repair manual

Komatsu Crawler Dozer D51EXi-22, D51PXi-22 pdf workshop service repair manual + operation & maintenance manual

Serial number B13500 and up

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

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

STRUCTURE AND FUNCTION
ENGINE AND COOLING SYSTEM
ENGINE RELATED PARTS
COOLING SYSTEM
COOLING FAN PUMP (WORK EQUIPMENT AND FAN PUMP)
COOLING FAN MOTOR
OIL COOLER BYPASS VALVE
CHARGE SAFETY VALVE
POWER TRAIN
HST CLOSED CIRCUIT
DAMPER
HST HYDRAULIC EQUIPMENT ARRANGEMENT DIAGRAM
STEERING AND BRAKE CONTROL
HST PUMP
SAFETY-SUCTION VALVE
TOWING VALVE
HST MOTOR
MOTOR CONTROL VALVE
SOLENOID VALVE (3-SPOOL), EPC VALVE (2-SPOOL) AND TOWING VALVE
SOLENOID VALVE
EPC VALVE
CHARGE PUMP
FINAL DRIVE
PATH OF POWER TRANSMISSION
UNDER CARRIAGE AND FRAME
MAIN FRAME
TRACK FRAME AND RECOIL SPRING
IDLER
TRACK ROLLER
CARRIER ROLLER
SPROCKET
SINGLE SHOE
SUSPENSION
HYDRAULIC SYSTEM
HYDRAULIC COMPONENT LAYOUT OF WORK EQUIPMENT
WORK EQUIPMENT CONTROL SYSTEM
HYDRAULIC SYSTEM (WORK EQUIPMENT)
CLSS (CLOSED CENTER LOAD SENSING SYSTEM)
WORK EQUIPMENT AND FAN PUMP
SERVO VALVE
CONTROL VALVE
HYDRAULIC CIRCUIT DIAGRAM AND NAMES OF VALVES
UNLOAD VALVE
WHEN CONTROL VALVE IS IN NEUTRAL POSITION
WHEN CONTROL VALVE IS IN THE CONTROL RANGE
PRESSURE COMPENSATION VALVE
WORK EQUIPAMENT VALVE (LIFT, TILT, ANGLE, RIPPER)
LS BYPASS VALVE
QUICK DROP VALVE
RIPPER/WINCH PPC VALVE
HYDRAULIC TANK, FILTER
BREATHER
ACCUMULATOR
WORK EQUIPMENT
CUTTING EDGE AND END BIT
RIPPER
PISTON VALVE FOR ANGLE CYLINDER
CAB AND ITS ATTACHMENTS
ROPS CAB
CAB DAMPER MOUNT
CAB MOUNT AND ROPS STOPPER
AIR CONDITIONER
AIR CONDITIONER AND FLOOR HEATER
AIR CONDITIONER PIPING
ELECTRICAL SYSTEM
MONITOR SYSTEM
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
KOMTRAX TERMINAL SYSTEM
ICT CONTROL SYSTEM
ICT CONTROL FUNCTION
BLADE CONTROL SYSTEM
LEVELING MODEL
INPUT / OUPUT SIGNAL
BLADE HEIGHT ADJUSTMENT
BLADE ANGLE ADJUSTMENT
DOZING MODE
SETTING OF DOZING CONTROL
SMOOTH START FUNCTION
SLIP CONTROL
BLADE ASSIST CONTROL
HST SPEED RANGE CONTROL SYSTEM
SYSTEM COMPONENTS
MONITOR PANEL
BUZZER CANCEL SWITCH
INPUT AND OUTPUT SIGNALS
MONITOR PANEL DISPLAY
ENGINE CONTROLLER
HST CONTROLLER
INPUT AND OUPUT SIGNALS
ICT CONTROLLER
INPUT AND OUTPUT SIGNALS OF ICT SENSOR CONTROLLER
iB MONITOR
INPUT AND OUTPUT SIGNALS OF iB MONITOR
GNSS RECEIVER
INPUT AND OUTPUT SIGNALS OF GNSS RECEIVER
iB GNSS ANTENNA
ELECTRIC BLADE CONTROL LEVER
ELECTRIC STEERING LEVER
OPERATION FOR RIGHT LEFT STEERING
KOMTRAX TERMINAL
INPUT AND OUTPUT SIGNAL
SENSORS
BRAKE OIL PRESSURE SENSOR (HST CHARGE OIL PRESSURE SENSOR)
HYDRAULIC OIL TEMPERATURE SENSOR
HST CIRCUIT OIL PRESSURE SENSOR
AIR CLEANER CLOGGING SENSOR
BRAKE PEDAL POTENTIOMETER
FUEL CONTROL DIAL
FUEL LEVEL SENSOR
CHARGE FILTER CLOGGING SENSOR
COOLANT TEMPERATURE SENSOR
ENGINE OIL PRESSURE SWITCH
ENGINE ROTATION SENSOR
BOOST PRESSURE AND SENSOR
WIF SENSOR (WATER-IN-FUEL)
HST MOTOR SPEED SENSOR
IMU SENSOR
STROKE AND RESET SENSOR FOR LIFT CYLINDER
STROKE SENSOR
RESET SENSOR
STROKE SENSOR FOR TILT CYLINDER
STROKE AND RESET SENSOR FOR ANGLE CYLINDER

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

TESTING AND ADJUSTING
RELATED INFORMATION ON TESTING AND ADJUSTING
TOOLS FOR TESTING AND ADJUSTING
ENGINE AND COOLING SYSTEM
ENGINE SPEED
AIR INTAKE BOOST PRESSURE
EXHAUST TEMPERATURE
EXHAUST GAS COLOR
VALVE CLEARANCE
COMPRESSION PRESSURE
BLOW-BY PRESSURE
ENGINE OIL PRESSURE
HANDLING CONTROLLER HIGH-VOLTAGE CIRCUIT
FUEL SYSTEM
HANDLING FUEL SYSTEM PARTS
RELEASING RESIDUAL PRESSURE FROM FUEL SYSTEM
BLEEDING AIR FROM FUEL CIRCUIT
FUEL PRESSURE
FUEL RETURN RATE AND LEAKAGE
FUEL CIRCUIT FOR LEAKAGE
POWER TRAIN
HST OIL PRESSURE
PARKING BRAKE LEVER
BRAKE PERFORMANCE
BRAKE PEDAL LINKAGE
EMERGENCY RELEASE OF PARKING BRAKE
DECELERATOR PEDAL
UNDERCARRIAGE AND FRAME
IDLER CLEARANCE
TRACK SHOE TENSION
HYDRAULIC SYSTEM
FAN (WORK EQUIPMENT) PUMP PRESSURE
FAN SPEED
FAN SPEED SENSOR
WORK EQUIPMENT
BLEEDING AIR
LOCK LEVER ADJUSTMENT
BLADE CENTER BALL ADJUSTMENT
BLADE PITCH BALL ADJUSTMENT
ELECTRICAL SYSTEM
MONITOR PANEL (EMMS) - SPECIAL FUNCTIONS
ERROR CODE TABLE
PREPARATION WORK FOR TROUBLESHOOTING FOR ELECTRICAL SYSTEM
SPECIAL FUNCTIONS OF iB MONITOR
INPUTTING WEAR AMOUNT OF BLADE EDGE AND TRACK SHOE
TESTING STROKE SENSOR FOR LIFT CYLINDER
TESTING STROKE SENSOR FOR TILT CYLINDER
TESTING STROKE SENSOR FOR ANGLE CYLINDER
TESTING AND ADJUSTING RESET SENSOR FOR LIFT CYLINDER
TESTING AND ADJUSTING RESET SENSOR FOR ANGLE CYLINDER
ELECTRIC/HYDRAULIC DEVICES ARE ADJUSTED/REPLACED
HST CONTROLLER ADJUSTMENT AFTER REPLACEMENT
MONITOR PANEL ADJUSTMENT AFTER REPLACEMENT
ADJUSTMENT METHOD WHEN ICT CONTROLLER HAS BEEN REPLACED
HANLDING VOLTAGE CIRCUIT OF ENGINE CONTROLLER
HANDLING BATTERY DISCONNECT SWITCH
TESTING DIODES
PM-CLINIC INSPECTION SHEET
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
RELATED INFORMATION ON TROUBLESHOOTING
TROUBLESHOOTING POINTS
SEQUENCE OF EVENTS IN TROUBLESHOOTING
CHECKS BEFORE TROUBLESHOOTING
INSPECTION PROCEDURE BEFORE TROUBLESHOOTING
WALK-AROUND CHECK
PRECAUTIONS WHEN CARRYING OUT MAINTENANCE
PRECAUTIONS WHEN HANDLING ELECTRICAL EQUIPMENT
HANDLING ELECTRONIC CONTROL UNIT
POINTS TO REMEMBER WHEN TROUBLESHOOTING ELECTRICAL CIRCUITS
POINTS TO REMEMBER WHEN HANDLING HYDRAULIC EQUIPMENT
SYMPTOM AND TROUBLESHOOTING NUMBERS
TROUBLESHOOTING INDIVIDUAL ELECTRICAL CIRCUITS
CONNECTION TABLE FOR CONNECTOR PIN NUMBERS
T-ADAPTER TABLE
FAILURE CODE TABLE
INFORMATION IN TROUBLESHOOTING TABLE
TROUBLESHOOTING BY FAILURE CODE

DISASSEMBLY AND ASSEMBLY
RELATED INFORMATION ON DISASSEMBLY AND ASSEMBLY
SPECIAL TOOL LIST
SKETCH OF SPECIAL TOOLS
CONNECTOR REPAIR PROCEDURES

CONTACT TERMINAL REMOVAL (HD30 TYPE)
STRIPPING INSULATION
CRIMPING CONTACT TERMINAL (HD30 TYPE)
INSERTION OF CONTACT TERMINAL (HD30 TYPE)
CONTACT TERMINAL REMOVAL (DT TYPE)
STRIPPING INSULATION
CRIMPING CONTACT TERMINAL (DT TYPE)
INSERTION OF CONTACT TERMINAL (DT TYPE)
NOSE GUARD (HOOD)
MUFFLER AND EXHAUST STACK
CAB AND ITS ATTACHMENTS
CAB
AIR CONDITIONER/HEATER
DISASSEMBLY OF AIR CONDITIONER
ASSEMBLY OF AIR CONDITIONER
FOOT HEATER
FOOT HEATER OVERHAUL PROCEDURES
ASSEMBLY PROCEDURES
ENGINE AND COOLING SYSTEM
ENGINE AND HST PUMP
REMOVAL FROM ENGINE
INSTALLATION TO ENGINE
DRIVE DAMPENER
HST PUMP OVERHAUL PROCEDURES
DISASSEMBLY PROCEDURES
ASSEMBLY PROCEDURES
WORK EQUIPMENT PUMP OVERHAUL PROCEDURES
DISASSEMBLY PROCEDURES
ASSEMBLY PROCEDURES
CHARGE PUMP OVERHAUL PROCEDURES
DISASSEMBLY PROCEDURES
ASSEMBLY PROCEDURES
DIESEL ENGINE OVERHAUL PROCEDURES
DISASSEMBLY OF EXTERNAL COMPONENTS
DISASSEMBLY OF ENGINE TOP END
REMOVAL OF OIL COOLER, ENGINE CONTROLLER AND FUEL PUMP
DISASSEMBLY OF ENGINE LOWER END
ASSEMBLY OF ENGINE LOWER END
INSTALLATION OF OIL COOLER, ENGINE CONTROLLER AND FUEL PUMP
ASSEMBLY OF EXTERNAL COMPONENTS
WHOLE DISASSEMBLY AND ASSEMBLY OF TRACK SHOE ASSEMBLY (CONVENTIONAL TYPE TRACK SHOE)
WHOLE DISASSEMBLY AND ASSEMBLY OF TRACK SHOE (PLUS TYPE TRACK SHOE)
TRACK SYSTEM
SPREADING THE TRACK (CONVENTIONAL TYPE TRACK SHOE)
EXPANSION AND INSTALLATION OF TRACK SHOE ASSEMBLY (PLUS TYPE TRACK SHOE)
FIELD DISASSEMBLY AND ASSEMBLY OF ONE LINK (CONVENTIONAL TYPE TRACK SHOE)
FIELD DISASSEMBLY AND ASSEMBLY OF ONE LINK (PLUS TYPE TRACK SHOE)
TRACK FRAME
REMOVAL OF TRACK FRAME
FRONT TRACK IDLER
REMOVING FRONT IDLER
INSTALLING FRONT IDLER
TRACK ROLLER
TRACK ROLLER OVERHAUL PROCEDURES
CARRIER ROLLER OVERHAUL PROCEDURES
FINAL DRIVE
FINAL DRIVE REMOVAL
INSTALLING THE FINAL DRIVE
FINAL DRIVE OVERHAUL PROCEDURES
DISASSEMBLY PROCEDURES
ASSEMBLY OF FINAL DRIVE
TRAVEL MOTOR OVERHAUL PROCEDURES
DISASSEMBLY PROCEDURES
ASSEMBLY PROCEDURES
FAN MOTOR
REMOVAL PROCEDURES
INSTALLATION PROCEDURES
FAN MOTOR OVERHAUL PROCEDURES
DISASSEMBLY PROCEDURES
ASSEMBLY PROCEDURES
DB 12 VALVE
COOLING PACKAGE
REMOVING THE GRILL AND COOLING FAN ASSEMBLY
REMOVING THE COOLING PACKAGE
INSTALLING THE COOLING PACKAGE
INSTALLING THE GRILL AND COOLING FAN ASSEMBLY
FUEL TANK
REMOVING THE FUEL TANK
INSTALLING THE FUEL TANK
HYDRAULIC TANK
REMOVING THE HYDRAULIC TANK
INSTALLING THE HYDRAULIC TANK
WORK EQUIPMENT
REMOVING OR INSTALLING PINS
FRONT BLADE, TILT AND ANGLE CYLINDERS
ADJUSTING BLADE CENTER BALL AND PITCH ROD PLAY
“C” FRAME
LIFT CYLINDERS
CYLINDER OVERHAUL PROCEDURES
DISASSEMBLY PROCEDURES
ASSEMBLY PROCEDURES

OTHERS
HYDRAULIC SYSTEM
ELECTRICAL SYSTEM

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