Komatsu D51EX D51EXi D51PX D51PXi D51-22 D51-24 Crawler Dozer Tractor Workshop Repair Service Manual PDF - MKMTSD51OPEK.zip
Full shop service manual featuring complete electrical wiring schematics for the Komatsu Crawler Dozers/Tractors D51EX, D51EXi, D51PX and D51PXi, containing everything a professional needs to service, troubleshoot, fix and rebuild these machines.
The Komatsu D51EX, D51EXi, D51PX and D51PXi crawler dozer/tractor workshop manual provides:
* Numbered table of contents easy to use so that you can find the information you need fast.
* Detailed sub-steps expand on repair procedure information
* Numbered instructions guide you through every repair procedure step by step.
* Troubleshooting and electrical service procedures are combined with detailed wiring diagrams for ease of use.
* Notes, cautions and warnings throughout each chapter pinpoint critical information.
* Bold figure number help you quickly match illustrations with instructions.
* Detailed illustrations, drawings and photos guide you through every procedure.
* Enlarged inset helps you identify and examine parts in detail.
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PRODUCT DETAILS:
Total Pages: 10,102 pages
File Format: PDF (Internal Links, Bookmarked, Table of Contents, Searchable, Printable, high quality)
Language: English
TABLE OF CONTENTS
00 INDEX AND FOREWORD ... 00-1
ABBREVIATION LIST ... 00-20
FOREWORD, SAFETY, BASIC INFORMATION ..... 00-26
HOW TO READ THE SHOP MANUAL.... 00-26
SAFETY NOTICE FOR OPERATION... 00-28
PRECAUTIONS TO PREVENT FIRE... 00-36
ACTIONS IF FIRE OCCURS ... 00-38
PRECAUTIONS FOR DISPOSING OF WASTE MATERIALS ..... 00-39
ACTIONS TAKEN TO MEET EXHAUST GAS REGULATIONS... 00-40
PRECAUTIONS FOR DEF.... 00-41
STORE AdBlue/DEF .... 00-42
PRECAUTIONS FOR HANDLING HYDRAULIC EQUIPMENT ... 00-43
PRECAUTIONS FOR DISCONNECTION AND CONNECTION OF PIPINGS..... 00-46
PRECAUTIONS FOR HANDLING ELECTRICAL EQUIPMENT..... 00-52
PRECAUTIONS FOR HANDLING FUEL SYSTEM EQUIPMENT ..... 00-54
PRECAUTIONS FOR HANDLING INTAKE SYSTEM EQUIPMENT .... 00-55
PRACTICAL USE OF KOMTRAX ..... 00-56
DISCONNECT AND CONNECT PUSH-PULL TYPE COUPLER ... 00-57
PRECAUTIONS FOR DISCONNECTION AND CONNECTION OF CONNECTORS ... 00-61
METHOD FOR DISCONNECTING AND CONNECTING DEUTSCH CONNECTOR ... 00-65
METHOD FOR DISCONNECTING AND CONNECTING SLIDE LOCK TYPE CONNECTOR .... 00-66
METHOD FOR DISCONNECTING AND CONNECTING CONNECTOR WITH LOCK TO PULL ... 00-68
METHOD FOR DISCONNECTING AND CONNECTING CONNECTOR WITH LOCK TO PUSH .. 00-69
METHOD FOR DISCONNECTING AND CONNECTING CONNECTOR WITH HOUSING TO ROTATE .
... 00-71
HOW TO READ ELECTRICAL WIRE CODE ... 00-72
EXPLANATION OF TERMS FOR MAINTENANCE STANDARD.... 00-76
STANDARD TIGHTENING TORQUE TABLE... 00-79
CONVERSION TABLE .... 00-86
01 SPECIFICATIONS ... 01-1
CONTENTS ..... 01-2
ABBREVIATION LIST ..... 01-3
SPECIFICATIONS .... 01-9
SPECIFICATION DRAWING... 01-9
SPECIFICATIONS .... 01-13
WEIGHT TABLE .... 01-24
FUEL, COOLANT, LUBRICANTS (FOR NORTH AMERICA) ... 01-28
FUEL, COOLANT, LUBRICANTS (FOR EUROPEAN UNION).... 01-30
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
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
ICT SYSTEM ...10-233
LAYOUT DRAWING OF ICT SYSTEM...10-233
ICT CONTROL SYSTEM DIAGRAM...10-235
BLADE CONTROL SYSTEM .....10-237
SMOOTH START SYSTEM ....10-243
SLIP CONTROL SYSTEM ...10-245
ASSIST CONTROL SYSTEM ....10-246
HST SPEED RANGE CONTROL SYSTEM ....10-248
COMPONENT PARTS OF ICT SYSTEM .....10-250
UNDERCARRIAGE AND FRAME.....10-272
MAIN FRAME ....10-272
SUSPENSION ...10-273
TRACK FRAME AND IDLER CUSHION ...10-276
WORK EQUIPMENT....10-278
STRUCTURE OF FRONT WORK EQUIPMENT...10-278
STRUCTURE OF FIXED MULTI-SHANK RIPPER...10-279
CAB AND ITS ATTACHMENTS .....10-280
ROPS CAB .....10-280
CAB MOUNT .....10-282
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: D51EXI-24 .... 20-9
STANDARD VALUE TABLE FOR ENGINE: D51PXI-24 ..... 20-13
STANDARD VALUE TABLE FOR MACHINE..... 20-17
STANDARD VALUE TABLE FOR MACHINE: D51EXI-24 ..... 20-17
STANDARD VALUE TABLE FOR MACHINE: D51PXI-24 ..... 20-34
MACHINE POSTURE AND PROCEDURE FOR MEASURING PERFORMANCE .... 20-49
30 TESTING AND ADJUSTING ... 30-1
CONTENTS ..... 30-2
ABBREVIATION LIST ..... 30-6
RELATED INFORMATION ON TESTING AND ADJUSTING .... 30-12
TOOLS FOR TESTING AND ADJUSTING.... 30-12
SKETCH OF TOOLS FOR TESTING AND ADJUSTING ... 30-19
ENGINE AND COOLING SYSTEM.... 30-23
TEST ENGINE SPEED ... 30-23
TEST BOOST PRESSURE... 30-25
TEST EXHAUST GAS COLOR ... 30-27
TEST AND ADJUST VALVE CLEARANCE ... 30-29
TEST COMPRESSION PRESSURE.... 30-31
TEST BLOWBY PRESSURE ... 30-36
TEST ENGINE OIL PRESSURE .... 30-38
TEST FUEL PRESSURE ... 30-39
TEST FUEL DISCHARGE, RETURN AND LEAKAGE .... 30-44
BLEED AIR FROM FUEL SYSTEM ..... 30-50
TEST FUEL CIRCUIT FOR LEAKAGE ... 30-51
HANDLE CYLINDER CUT-OUT MODE OPERATION..... 30-53
HANDLE NO-INJECTION CRANKING OPERATION ... 30-54
TEST KDOC, SCR AND MUFFLER STACK FOR LOOSENESS AND DAMAGE ..... 30-55
TEST INSTALLED CONDITION OF CYLINDER HEADS AND MANIFOLDS ... 30-56
TEST ENGINE PIPING FOR DAMAGE AND LOOSENESS .... 30-57
WRITE ASH IN SOOT ACCUMULATION CORRECTION TO ENGINE CONTROLLER .... 30-58
TEST SCR RELATED FUNCTIONS..... 30-59
CLEAN AdBlue/DEF TANK ... 30-87
CLEAN AdBlue/DEF TANK MOUNTING PORTION ..... 30-91
POWER TRAIN.... 30-92
TEST AND ADJUST HST OIL PRESSURE ..... 30-92
BLEED AIR FROM HST PUMP ..... 30-97
TEST OUTLET PRESSURE OF SOLENOID VALVE ... 30-99
TEST TRAVEL DEVIATION ....30-103
TEST BRAKE PERFORMANCE SIMPLY ....30-105
TEST AND ADJUST DECELERATION/BRAKE PEDAL....30-106
ADJUST PARKING BRAKE LEVER....30-110
MOVE MACHINE WHEN IT CANNOT TRAVEL....30-112
UNDERCARRIAGE AND FRAME.....30-115
CHECK AND ADJUST IDLER CLEARANCE .....30-115
TESTING SPROCKET WEAR ...30-117
TEST AND ADJUST TRACK TENSION....30-118
HYDRAULIC SYSTEM....30-120
RELEASE REMAINING PRESSURE FROM HYDRAULIC SYSTEM.....30-120
TEST AND ADJUST WORK EQUIPMENT OIL PRESSURES ...30-121
TEST AND ADJUST OIL PRESSURE OF CONTROL CIRCUIT ...30-124
TEST OUTLET PRESSURE OF EPC SOLENOID VALVE ...30-126
BLEED AIR FROM WORK EQUIPMENT AND COOLING FAN PUMP .....30-128
TEST COOLING FAN SPEED ...30-129
TEST COOLING FAN CIRCUIT OIL PRESSURE ....30-130
TEST THE PARTS CAUSING HYDRAULIC DRIFT IN WORK EQUIPMENT.....30-132
TEST INTERNAL OIL LEAKAGE OF WORK EQUIPMENT CYLINDER ...30-135
BLEED AIR FROM WORK EQUIPMENT CYLINDERS.....30-138
WORK EQUIPMENT....30-139
ADJUST WORK EQUIPMENT LOCK LEVER....30-139
ELECTRICAL SYSTEM .....30-141
SET AND OPERATE MACHINE MONITOR....30-141
METHOD FOR STARTING UP KOMTRAX TERMINAL ....30-268
ADJUSTMENT WHEN HST CONTROLLER HAS BEEN REPLACED ...30-273
ADJUSTMENT WHEN ELECTRIC OR HYDRAULIC DEVICE HAS BEEN REPLACED ...30-279
ADJUST REARVIEW CAMERA ANGLE ...30-281
HANDLE VOLTAGE CIRCUIT OF ENGINE CONTROLLER ...30-282
HANDLE BATTERY DISCONNECT SWITCH ....30-283
TEST DIODES ...30-284
ICT SYSTEM ...30-285
SET AND OPERATE CONTROL BOX ...30-285
CALIBRATE BLADE EDGE POSITION ....30-288
CALIBRATE IMU SENSOR.....30-310
RESET CYLINDER STROKE END .....30-317
METHOD FOR INPUTTING WEAR AMOUNT OF BLADE EDGE AND TRACK SHOE ....30-320
CHECK BLADE ELEVATION, ADJUST.....30-321
TEST STROKE SENSOR FOR LIFT CYLINDER.....30-325
TEST STROKE SENSOR FOR TILT CYLINDER .....30-327
TEST STROKE SENSOR FOR ANGLE CYLINDER ...30-329
TEST AND ADJUST RESET SENSOR FOR LIFT CYLINDER .....30-331
ADJUST WHEN ICT SENSOR CONTROLLER IS REPLACED ....30-333
METHOD FOR ADJUSTING WHEN ICT RELATED DEVICES ARE REPAIRED OR REPLACED30-336
Pm CLINIC....30-339
Pm CLINIC SERVICE ....30-339
40 TROUBLESHOOTING ... 40-1
CONTENTS ..... 40-2
ABBREVIATION LIST ... 40-13
RELATED INFORMATION ON TROUBLESHOOTING .... 40-19
GENERAL TROUBLESHOOTING POINTS ..... 40-19
TROUBLESHOOTING POINTS FOR UREA SCR SYSTEM.... 40-20
SEQUENCE OF EVENTS IN TROUBLESHOOTING... 40-32
CHECKS BEFORE TROUBLESHOOTING ... 40-34
INSPECTION PROCEDURE BEFORE TROUBLESHOOTING ..... 40-36
TESTING IN ACCORDANCE WITH TESTING PROCEDURE.... 40-38
PREPARATION FOR TROUBLESHOOTING OF ELECTRICAL SYSTEM.... 40-60
PROCEDURE FOR TROUBLESHOOTING ..... 40-67
INFORMATION DESCRIBED IN TROUBLESHOOTING TABLE.... 40-70
TROUBLESHOOTING METHOD FOR OPEN CIRCUIT IN WIRING HARNESS OF PRESSURE SEN-
SOR SYSTEM.... 40-72
CONNECTORS LIST AND LAYOUT.... 40-75
CONNECTOR CONTACT IDENTIFICATION ... 40-92
T-BRANCH BOX AND T-BRANCH ADAPTER TABLE ...40-132
FUSE LOCATION TABLE ....40-138
PRECAUTIONS FOR REPLACING KDOC .....40-142
FAILURE CODES TABLE ....40-143
TROUBLESHOOTING BY FAILURE CODE (DISPLAY OF CODE) .....40-162
FAILURE CODE [6091NX] ...40-162
FAILURE CODE [989L00] ....40-164
FAILURE CODE [989M00] ...40-165
FAILURE CODE [989N00] ...40-166
FAILURE CODE [A1U0N3] .....40-167
FAILURE CODE [A1U0N4] .....40-169
FAILURE CODE [A900FR]...40-171
FAILURE CODE [A900N6] ...40-172
FAILURE CODE [A900NY]...40-173
FAILURE CODE [AA10NX] .....40-174
FAILURE CODE [AB00KE] .....40-176
FAILURE CODE [AQ10MB] ....40-178
FAILURE CODE [AQ10N3] .....40-180
FAILURE CODE [AS00R2]...40-182
FAILURE CODE [AS00R3]...40-183
FAILURE CODE [AS00R4]...40-184
FAILURE CODE [AS00R5]...40-185
FAILURE CODE [AS00R6]...40-186
FAILURE CODE [AS00ZK]...40-187
FAILURE CODE [AS10KM].....40-188
FAILURE CODE [AS10NR] .....40-189
FAILURE CODE [AS10NT] .....40-190
FAILURE CODE [B@BAZG] ...40-191
FAILURE CODE [B@BCNS] ...40-192
FAILURE CODE [B@CRNS]...40-193
FAILURE CODE [B@CRZG]...40-194
FAILURE CODE [CA115] .....40-195
FAILURE CODE [CA122] .....40-196
FAILURE CODE [CA123] .....40-198
FAILURE CODE [CA131] .....40-200
FAILURE CODE [CA132] .....40-202
FAILURE CODE [CA144] .....40-204
FAILURE CODE [CA145] .....40-206
FAILURE CODE [CA153] .....40-208
FAILURE CODE [CA154] .....40-210
FAILURE CODE [CA187] .....40-212
FAILURE CODE [CA221] .....40-214
FAILURE CODE [CA222] .....40-216
FAILURE CODE [CA227] .....40-218
FAILURE CODE [CA234] .....40-220
FAILURE CODE [CA238] .....40-221
FAILURE CODE [CA239] .....40-222
FAILURE CODE [CA249] .....40-223
FAILURE CODE [CA256] .....40-225
FAILURE CODE [CA271] .....40-227
FAILURE CODE [CA272] .....40-229
FAILURE CODE [CA295] .....40-231
FAILURE CODE [CA322] .....40-232
FAILURE CODE [CA324] .....40-234
FAILURE CODE [CA331] .....40-236
FAILURE CODE [CA332] .....40-238
FAILURE CODE [CA343] .....40-240
FAILURE CODE [CA351] .....40-241
FAILURE CODE [CA352] .....40-243
FAILURE CODE [CA356] .....40-245
FAILURE CODE [CA357] .....40-247
FAILURE CODE [CA386] .....40-249
FAILURE CODE [CA428] .....40-250
FAILURE CODE [CA429] .....40-252
FAILURE CODE [CA435] .....40-254
FAILURE CODE [CA441] .....40-256
FAILURE CODE [CA442] .....40-258
FAILURE CODE [CA451] .....40-259
FAILURE CODE [CA452] .....40-261
FAILURE CODE [CA488] .....40-263
FAILURE CODE [CA515] .....40-264
FAILURE CODE [CA516] .....40-266
FAILURE CODE [CA553] .....40-268
FAILURE CODE [CA555] .....40-269