Komatsu Bulldozer D51Exi-22 D51PXi-22 Shop Manual KEBM028604 PDF

Description

Komatsu Bulldozer D51Exi-22 D51PXi-22 Shop Manual KEBM028604 –  PDF DOWNLOAD

FILE DETAILS:

Komatsu Bulldozer D51Exi-22 D51PXi-22 Shop Manual KEBM028604 –  PDF DOWNLOAD

Language : English
Pages : 1592
Downloadable : Yes
File Type : PDF

IMAGES PREVIEW OF THE MANUAL:

TABLE OF CONTENTS:

Komatsu Bulldozer D51Exi-22 D51PXi-22 Shop Manual KEBM028604 –  PDF DOWNLOAD

• SERIAL NUMBERS B13500 and up

FOREWORD, SAFETY AND GENERAL INFORMATION . 33
IMPORTANT SAFETY NOTICE 33
HOW TO READ THE SHOP MANUAL 41
EXPLANATION OF TERMS FOR MAINTENACE STANDARD . 43
HANDLING EQUIPMENT OF FUEL SYSTEM DEVICES 45
HANDLING OF INTAKE SYSTEM PARTS 46
HANDLING OF HYDRAULIC EQUIPMENT 47
METHOD OF DISCONNECTING AND CONNECTING OF PUSH-PULL TYPE COUPLER . 49
HANDLING OF ELECTRICAL EQUIPMENT . 52
HOW TO READ ELECTRIC WIRE CODE . 60
PRECAUTIONS WHEN PERFORMING OPERATION 63
PRACTICAL USE OF KOMTRAX . 68
STANDARD TIGHTENING TORQUE TABLE . 69
LIST OF ABBREVIATION . 75
CONVERSION TABLE . 80
00 INDEX AND FOREWORD 5
01 SPECIFICATION . 87
TABLE OF CONTENTS 88
SPECIFICATION DRAWING 89
D51EXi, PXi-22 POWER ANGLE, POWER TILT DOZER WITH ROPS CAB . 89
SPECIFICATION 90
WEIGHT TABLE . 94
TABLE OF FUEL, COOLANT AND LUBRICANTS 96
RECOMMENDED PRODUCTS OTHER THAN KOMATSU GENUINE OILS . 98
10 STRUCTURE AND FUNCTION 99
TABLE OF CONTENTS 100
ENGINE AND COOLING SYSTEM 103
ENGINE RELATED PARTS . 103
COOLING SYSTEM . 105
COOLING FAN PUMP – SEE HYDRAULIC SYSTEM 2 (WORK EQUIPMENT AND FAN PUMP) 108
COOLING FAN MOTOR 109
OIL COOLER BYPASS VALVE 114
CHARGE SAFETY VALVE 117
POWER TRAIN 119
POWER TRAIN 119
HST CLOSED CIRCUIT . 121
DAMPER . 122
HST HYDRAULIC EQUIPMENT ARRANGEMENT DIAGRAM 123
STEERING AND BRAKE CONTROL . 124
HST PUMP . 126
SAFETY-SUCTION VALVE . 134
TOWING VALVE . 137
HST MOTOR 138
MOTOR CONTROL VALVE 150
SOLENOID VALVE (3-SPOOL), EPC VALVE (2-SPOOL) AND TOWING VALVE . 150
SOLENOID VALVE . 152
EPC VALVE 153
CHARGE PUMP 157
FINAL DRIVE 159
PATH OF POWER TRANSMISSION . 162
UNDER CARRIAGE AND FRAME . 163
MAIN FRAME . 163
TRACK FRAME AND RECOIL SPRING 164
IDLER 166
TRACK ROLLER . 168
CARRIER ROLLER . 172
SPROCKET . 174
SINGLE SHOE 180
SUSPENSION . 181
HYDRAULIC SYSTEM . 184
HYDRAULIC COMPONENT LAYOUT OF WORK EQUIPMENT . 184
WORK EQUIPMENT CONTROL SYSTEM 185
HYDRAULIC SYSTEM (WORK EQUIPMENT) 187
WORK EQUIPMENT AND FAN PUMP 190
SERVO VALVE 194
CONTROL VALVE 196
HYDRAULIC CIRCUIT DIAGRAM AND NAMES OF VALVES 203
UNLOAD VALVE . 205
PRESSURE COMPENSATION VALVE 208
HYDRAULIC TANK, FILTER . 218
BREATHER . 219
ACCUMULATOR 220
WORK EQUIPMENT . 221
WORK EQUIPMENT . 221
CUTTING EDGE AND END BIT . 226
RIPPER . 227
PISTON VALVE FOR ANGLE CYLINDER 228
CAB AND ITS ATTACHMENTS 229
ROPS CAB . 229
CAB DAMPER MOUNT . 230
AIR CONDITIONER 231
ELECTRICAL SYSTEM 233
MONITOR SYSTEM . 233
ENGINE CONTROL SYSTEM 235
COOLING CONTROL SYSTEM . 238
HST CONTROL SYSTEM . 240
GEAR SHIFT CONTROL SYSTEM 241
PARKING BRAKE CONTROL SYSTEM . 246
KOMTRAX SYSTEM . 248
ICT CONTROL SYSTEM . 249
ICT CONTROL FUNCTION . 250
BLADE CONTROL SYSTEM . 252
DOZING MODE 255
SMOOTH START FUNCTION 258
SLIP CONTROL . 260
BLADE ASSIST CONTROL . 262
HST SPEED RANGE CONTROL SYSTEM . 264
SYSTEM COMPONENTS 266
MONITOR PANEL 266
BUZZER CANCEL SWITCH . 267
MONITOR PANEL DISPLAY 268
HST CONTROLLER . 272
ICT CONTROLLER . 274
iB MONITOR . 277
GNSS RECEIVER 279
KOMTRAX TERMINAL . 288
SENSORS 289
BRAKE OIL PRESSURE SENSOR 290
HYDRAULIC OIL TEMPERATURE SENSOR . 291
HST CIRCUIT OIL PRESSURE SENSOR 292
AIR CLEANER CLOGGING SENSOR 293
BRAKE PEDAL POTENTIOMETER 294
FUEL CONTROL DIAL 295
FUEL LEVEL SENSOR 296
CHARGE FILTER CLOGGING SENSOR 297
COOLANT TEMPERATURE SENSOR . 297
ENGINE OIL PRESSURE SWITCH . 298
ENGINE ROTATION SENSOR . 298
BOOST PRESSURE AND SENSOR 299
WIF SENSOR . 299
HST MOTOR SPEED SENSOR . 300
IMU SENSOR . 301
STROKE AND RESET SENSOR FOR LIFT CYLINDER 302
STROKE SENSOR 303
RESET SENSOR . 304
STROKE SENSOR FOR TILT CYLINDER 305
STROKE SENSOR 306
STROKE AND RESET SENSOR FOR ANGLE CYLINDER . 307
STROKE SENSOR 308
RESET SENSOR . 309
20 STANDARD VALUE TABLES . 311
TABLE OF CONTENTS 312
STANDARD VALUE TABLE FOR ENGINE 313
STANDARD VALUE TABLE FOR CHASSIS . 314
STANDARD VALUE TABLE FOR ENGINE 319
STANDARD VALUE TABLE FOR CHASSIS . 320
STANDARD VALUE TABLE FOR ICT . 325
PERFORMANCE MEASURING POSTURE AND METHOD . 327
TABLE OF CONTENTS 330
RELATED INFORMATION ON TESTING AND ADJUSTING . 332
TOOLS FOR TESTING AND ADJUSTING 332
ENGINE AND COOLING SYSTEM 335
ENGINE SPEED . 335
AIR INTAKE BOOST PRESSURE 336
EXHAUST TEMPERATURE 337
EXHAUST GAS COLOR 339
VALVE CLEARANCE 340
COMPRESSION PRESSURE . 343
BLOW-BY PRESSURE . 345
ENGINE OIL PRESSURE 346
HANDLING CONTROLLER HIGH-VOLTAGE CIRCUIT . 347
FUEL SYSTEM 348
HANDLING FUEL SYSTEM PARTS . 348
RELEASING RESIDUAL PRESSURE FROM FUEL SYSTEM . 348
BLEEDING AIR FROM FUEL CIRCUIT . 349
FUEL PRESSURE 351
FUEL RETURN RATE AND LEAKAGE . 353
FUEL CIRCUIT FOR LEAKAGE . 356
POWER TRAIN 357
HST OIL PRESSURE . 357
TRAVEL DEVIATION . 365
PARKING BRAKE LEVER 366
BRAKE PERFORMANCE 368
BRAKE PEDAL LINKAGE 369
EMERGENCY RELEASE OF PARKING BRAKE . 371
DECELERATOR PEDAL 374
UNDERCARRIAGE AND FRAME 376
IDLER CLEARANCE 376
TRACK SHOE TENSION . 378
HYDRAULIC SYSTEM . 379
FAN (WORK EQUIPMENT) PUMP PRESSURE . 379
FAN SPEED 379
FAN SPEED SENSOR . 380
WORK EQUIPMENT . 382
BLEEDING AIR . 390
WORK EQUIPMENT . 391
LOCK LEVER ADJUSTMENT 391
BLADE CENTER BALL ADJUSTMENT . 392
BLADE PITCH BALL ADJUSTMENT 392
ELECTRICAL SYSTEM 393
MONITOR PANEL (EMMS) – SPECIAL FUNCTIONS . 393
ERROR CODE TABLE . 399
PREPARATION WORK FOR TROUBLESHOOTING FOR ELECTRICAL SYSTEM . 469
SPECIAL FUNCTIONS OF iB MONITOR 470
INPUTTING WEAR AMOUNT OF BLADE EDGE AND TRACK SHOE . 496
TESTING STROKE SENSOR FOR LIFT CYLINDER 504
TESTING STROKE SENSOR FOR TILT CYLINDER 506
TESTING STROKE SENSOR FOR ANGLE CYLINDER . 507
TESTING AND ADJUSTING RESET SENSOR FOR LIFT CYLINDER . 508
TESTING AND ADJUSTING RESET SENSOR FOR ANGLE CYLINDER 509
ELECTRIC/HYDRAULIC DEVICES ARE ADJUSTED/REPLACED . 510
HST CONTROLLER ADJUSTMENT AFTER REPLACEMENT 513
MONITOR PANEL ADJUSTMENT AFTER REPLACEMENT . 515
ADJUSTMENT METHOD WHEN ICT CONTROLLER HAS BEEN REPLACED 517
HANLDING VOLTAGE CIRCUIT OF ENGINE CONTROLLER 520
HANDLING BATTERY DISCONNECT SWITCH . 521
TESTING DIODES . 522
PM-CLINIC INSPECTION SHEET (1/2) . 526
PM-CLINIC INSPECTION SHEET (2/2) . 527
PM-CLINIC UNDERCARRIAGE CHECK SHEET 528
UNDERCARRIAGE TROUBLESHOOTING REPORT (NORMAL) 529
UNDERCARRIAGE TROUBLESHOOTING REPORT (IMPACT) 530
PM-CLINIC UNDERCARRIAGE CHECK SHEET 531
UNDERCARRIAGE TROUBLESHOOTING REPORT (NORMAL) 532
UNDERCARRIAGE TROUBLESHOOTING REPORT (IMPACT) 533
30 TESTING AND ADJUSTING . 329
40 TROUBLESHOOTING . 535
TABLE OF CONTENTS 536
RELATED INFORMATION ON TROUBLESHOOTING . 546
SEQUENCE OF EVENTS IN TROUBLESHOOTING 548
CHECKS BEFORE TROUBLESHOOTING 550
INSPECTION PROCEDURE BEFORE TROUBLESHOOTING 552
WALK-AROUND CHECK 552
PRECAUTIONS WHEN CARRYING OUT MAINTENANCE 553
PRECAUTIONS WHEN HANDLING ELECTRICAL EQUIPMENT . 553
HANDLING ELECTRONIC CONTROL UNIT . 558
POINTS TO REMEMBER WHEN TROUBLESHOOTING ELECTRICAL CIRCUITS 559
POINTS TO REMEMBER WHEN HANDLING HYDRAULIC EQUIPMENT . 560
SYMPTOM AND TROUBLESHOOTING NUMBERS 562
TROUBLESHOOTING INDIVIDUAL ELECTRICAL CIRCUITS . 566
CONNECTION TABLE FOR CONNECTOR PIN NUMBERS . 568
T-ADAPTER TABLE 591
FAILURE CODE TABLE . 595
INFORMATION IN TROUBLESHOOTING TABLE . 605
TROUBLESHOOTING BY FAILURE CODE 607
ERROR CODE [6091NX] 607
ERROR CODE [AA10NX] 609
ERROR CODE [AB00MA] 611
ERROR CODE [B@BAZG] 612
ERROR CODE [B@BCNS] 613
ERROR CODE [B@CRNS] 614
ERROR CODE [B@CRZG] 615
ERROR CODE [CA111] . 616
ERROR CODE [CA115] . 617
ERROR CODE [CA122] . 619
ERROR CODE [CA123] . 621
ERROR CODE [CA131] . 623
ERROR CODE [CA132] . 625
ERROR CODE [CA144] . 627
ERROR CODE [CA145] . 629
ERROR CODE [CA153] . 631
ERROR CODE [CA154] . 633
ERROR CODE [CA187] . 635
ERROR CODE [CA221] . 637
ERROR CODE [CA222] . 639
ERROR CODE [CA227] . 641
ERROR CODE [CA234] . 643
ERROR CODE [CA238] . 644
ERROR CODE [CA271] . 645
ERROR CODE [CA272] . 647
ERROR CODE [CA322] . 649
ERROR CODE [CA323] . 651
ERROR CODE [CA324] . 653
ERROR CODE [CA325] . 655
ERROR CODE [CA331] . 657
ERROR CODE [CA332] . 659
ERROR CODE [CA342] . 661
ERROR CODE [CA352] . 662
ERROR CODE [CA386] . 663
ERROR CODE [CA428] . 665
ERROR CODE [CA429] . 667
ERROR CODE [CA435] . 669
ERROR CODE [CA441] . 671
ERROR CODE [CA442] . 673
ERROR CODE [CA449] . 675
ERROR CODE [CA451] . 677
ERROR CODE [CA452] . 679
ERROR CODE [CA488] . 681
ERROR CODE [CA553] . 682
ERROR CODE [CA559] . 683
ERROR CODE [CA689] . 685
ERROR CODE [CA731] . 687
ERROR CODE [CA757] . 689
ERROR CODE [CA778] . 691
ERROR CODE [CA1633] 693
ERROR CODE [CA2185] 695
ERROR CODE [CA2186] 696
ERROR CODE [CA2249] 697
ERROR CODE [CA2311] 699
ERROR CODE [CA2555] 701
ERROR CODE [CA2556] 703
ERROR CODE [D130KA] 705
ERROR CODE [D130KB] 707
ERROR CODE [DAFRKR] 709
ERROR CODE [DAFRMC] 711
ERROR CODE [DAJ000] 713
ERROR CODE [DAJ0KK] 715
ERROR CODE [DAJ0KQ] 717
ERROR CODE [DAJ0KT] 718
ERROR CODE [DAJ5KK] 719
ERROR CODE [DAJ6KK] 721
ERROR CODE [DAJRKR] 723
ERROR CODE [DB2RKR] 725
ERROR CODE [DBR0KT] 727
ERROR CODE [DBR0MC] 728
ERROR CODE [DBR1KK] 729
ERROR CODE [DBR2KK] 731
ERROR CODE [DBR5KK] 733
ERROR CODE [DBR6KK] 735
ERROR CODE [DBRQKR] 737
ERROR CODE [DBTSKR] 739
ERROR CODE [DBUTKA] 741
ERROR CODE [DD12KA] 743
ERROR CODE [DD12KB] 745
ERROR CODE [DD13KA] 747
ERROR CODE [DD13KB] 749
ERROR CODE [DD14KB] 751
ERROR CODE [DD1NL4] 753
ERROR CODE [DDDCKB] 755
ERROR CODE [DDKAKA] 757
ERROR CODE [DDKAKB] 759
FAILURE CODE [DDKFL4] 761
ERROR CODE [DDKGL4] 763
ERROR CODE [DDKHKA] 765
ERROR CODE [DDKHKB] 767
ERROR CODE [DDNLKA] 769
ERROR CODE [DDNLKB] 771
ERROR CODE [DDP6KA] 773
ERROR CODE [DDP6KB] 775
ERROR CODE [DDP6MA] 777
ERROR CODE [DDQ2KA] 779
ERROR CODE [DDT0L4] 781
ERROR CODE [DDU1FS] 783
ERROR CODE [DDU1KA] 785
ERROR CODE [DDU1KY] 787
ERROR CODE [DFA4KX] 789
ERROR CODE [DFA4KZ] 790
ERROR CODE [DFA4L8] 791
ERROR CODE [DFA5KA] 792
ERROR CODE [DFA5KB] 795
ERROR CODE [DFA6KA] 797
ERROR CODE [DFA6KB] 799
ERROR CODE [DFA7KX] 801
ERROR CODE [DFA7KZ] 802
ERROR CODE [DFA7L8] 803
ERROR CODE [DFA8KA] 804
ERROR CODE [DFA8KB] 807
ERROR CODE [DFA9KA] 809
ERROR CODE [DFA9KB] 811
ERROR CODE [DGS1KA] 813
ERROR CODE [DGS1KX] 815
ERROR CODE [DH21KA] 816
ERROR CODE [DH21KB] 819
ERROR CODE [DHH5KA] 821
ERROR CODE [DHH5KB] 823
ERROR CODE [DHH6KA] 825
ERROR CODE [DHH6KB] 827
ERROR CODE [DK10KA] 829
ERROR CODE [DK10KB] 831
ERROR CODE [DK30KA] 833
ERROR CODE [DK30KB] 835
ERROR CODE [DK30KX] 837
ERROR CODE [DK30KZ] 838
ERROR CODE [DK30L8] 839
ERROR CODE [DK31KA] 841
ERROR CODE [DK31KB] 843
ERROR CODE [DK40KA] 845
ERROR CODE [DK40KB] 847
ERROR CODE [DK55KX] 849
ERROR CODE [DK55KZ] 850
ERROR CODE [DK55L8] 851
ERROR CODE [DK56KA] 853
ERROR CODE [DK56KB] 855
ERROR CODE [DK57KA] 857
ERROR CODE [DK57KB] 859
ERROR CODE [DK80KA] 861
ERROR CODE [DKS0L8] 863
ERROR CODE [DKS1KA] 865
ERROR CODE [DKS1KB] 867
ERROR CODE [DKS2KA] 869
ERROR CODE [DKS2KB] 871
ERROR CODE [DKS3KA] 873
ERROR CODE [DKS3KB] 875
ERROR CODE [DKS3MB] 877
ERROR CODE [DKS4L8] 878
ERROR CODE [DKS5KA] 879
ERROR CODE [DKS5KB] 881
ERROR CODE [DKS6KA] 883
ERROR CODE [DKS6KB] 885
ERROR CODE [DKS7MB] 887
ERROR CODE [DKSCL8] 888
ERROR CODE [DKSDKA] 889
ERROR CODE [DKSDKB] 891
ERROR CODE [DKSEKA] 893
ERROR CODE [DKSEKB] 895
ERROR CODE [DKSFKA] 897
ERROR CODE [DKSFKB] 899
ERROR CODE [DKSFMB] 901
ERROR CODE [DLM0KX] 902
ERROR CODE [DLM1KA] 903
ERROR CODE [DLM1KB] 905
ERROR CODE [DLM1MA] 907
ERROR CODE [DLM2KA] 909
ERROR CODE [DLM2KB] 911
ERROR CODE [DLM2MA] 913
ERROR CODE [DLM3KA] 915
ERROR CODE [DLM3KB] 917
ERROR CODE [DN21FS] 919
ERROR CODE [DV00KB] 921
ERROR CODE [DV20KB] 922
ERROR CODE [DW4BKA] 923
ERROR CODE [DW4BKB] 925
ERROR CODE [DW4BKY] 927
ERROR CODE [DW7BKA] 928
ERROR CODE [DW7BKB] 929
ERROR CODE [DW7BKY] 930
ERROR CODE [DW7EKA] 931
ERROR CODE [DW7EKB] 935
ERROR CODE [DW7EKY] 937
ERROR CODE [DWN5KA] 939
ERROR CODE [DWN5KB] 941
ERROR CODE [DWN5KY] 943
ERROR CODE [DXA4KA] 945
ERROR CODE [DXA4KB] 947
ERROR CODE [DXA4KY] 948
ERROR CODE [DXA5KA] 949
ERROR CODE [DXA5KB] 950
ERROR CODE [DXA5KY] 951
ERROR CODE [DXA6KA] 952
ERROR CODE [DXA6KB] 953
ERROR CODE [DXA6KY] 954
ERROR CODE [DXA7KA] 955
ERROR CODE [DXA7KB] 956
ERROR CODE [DXA7KY] 957
ERROR CODE [DXHRKA] 959
ERROR CODE [DXHRKB] 961
ERROR CODE [DXHRKY] 963
ERROR CODE [DXHSKA] 965
ERROR CODE [DXHSKB] 967
ERROR CODE [DXHSKY] 969
ERROR CODE [DXHTKA] 971
ERROR CODE [DXHTKB] 973
ERROR CODE [DXHTKY] 975
ERROR CODE [DXHUKA] 977
ERROR CODE [DXHUKB] 979
ERROR CODE [DXHUKY] 981
ERROR CODE [DXJ4KA] 983
ERROR CODE [DXJ4KB] 985
ERROR CODE [DXJCKA] 987
ERROR CODE [DXJCKB] 988
ERROR CODE [DXJCKY] 989
ERROR CODE [DXJDKA] 991
ERROR CODE [DXJDKB] 992
ERROR CODE [DXJDKY] 993
ERROR CODE [DXK1KA] 995
ERROR CODE [DXK1KB] 996
ERROR CODE [DXK1KY] 997
ERROR CODE [DXK2KA] 998
ERROR CODE [DXK2KB] 999
ERROR CODE [DXK2KY] 1000
TROUBLESHOOTING OF ELECTRICAL SYSTEM (E-MODE) 1001
BEFORE CARRYING OUT TROUBLESHOOTING (E-MODE) .1001
INFORMATION IN TROUBLESHOOTING TABLE .1003
E-1 STARTING MOTOR DOES NOT ROTATE .1004
E-2 ENGINE IS NOT PRE-HEATED .1007
E-3 WHEN STARTING SWITCH IS TURNED ON, ANY ITEM DOES NOT LIGHT .1010
E-4 CHARGE LEVEL CAUTION FLASHES WHILE ENGINE IS RUNNING .1012
E-5 EMERGENCY WARNING ITEMS FLASH WHILE ENGINE IS RUNNING 1014
E-6 PRE-HEAT LAMP DOES NOT LIGHT DURING PRE-HEATING OPERATION 1018
E-7 COOLANT TEMPERATURE GAUGE DOES NOT INDICATE CORRECTLY 1020
E-8 HST OIL TEMPERATURE GAUGE DOES NOT INDICATE CORRECTLY 1021
E-9 FUEL LEVEL GAUGE DOES NOT INDICATE PROPERLY 1022
E-10 TRAVEL INDICATOR DOES NOT DISPLAY NORMALLY 1023
E-11 MULTI-INFORMATION UNIT DOES NOT DISPLAY NORMALLY 1023
E-12 CAUTION LAMP DOES NOT FLASH OR DOES NOT GO OFF 1024
E-13 CAUTION BUZZER DOES NOT SOUND OR DOES NOT STOP 1026
E-14 REVERSE TRAVEL SPEED SETTING SWITCH DOES NOT FUNCTION .1028
E-15 SHIFT MODE SWITCH DOES NOT FUNCTION .1030
E-16 BUZZER CANCEL SWITCH DOES NOT FUNCTION 1032
E-17 INFORMATION SWITCH DOES NOT FUNCTION 1034
E-18 THE FAN CLEANING DOES NOT OPERATE OR CANNOT BE RESET 1036
E-19 BACKUP ALARM DOES NOT SOUND .1038
E-20 THE HORN DOES NOT SOUND OR DOES NOT STOP 1039
E-21 WORK EQUIPMENT DOES NOT OPERATE .1041
E-22 HEAD LAMP OR REAR LAMP DOES NOT LIGHT UP 1043
E-23 FOOT HEATER DOES NOT OPERATE 1047
E-24 AIR CONDITIONER DOES NOT OPERATE [CAB SPECIFICATION] 1049
E-25 WIPER AND WASHER DO NOT OPERATE [CAB SPECIFICATION] .1054
E-26 KOMTRAX SYSTEM DOES NOT OPERATE NORMALLY 1066
E-27 iB MONITOR SHUTS DOWN AFTER DISPLAYING THE MESSAGES [GPS RECEIVER NOT CONNECTED!] AND [SLOPE SENSOR NOT CONNECTED!] .1068
E-28 iB MONITOR DISPLAYS THE MESSAGES[GPS RECEIVER NOT CONECTED!] AND [SLOPE SENSOR NOT CONNECTED!] 1071
E-29 iB MONITOR DISPLAYS THE MESSAGE [WAITING FOR RADIO LINK .] .1074
E-30 iB MONITOR DISPLAYS THE MESSAGE [IMU SENSOR NOT CONNECTED] 1075
E-31 iB MONITOR DISPLAYS THE MESSAGE [WAITING FOR SATELLITES .] .1076
E-32 iB MONITOR DISPLAYS THE MESSAGE [KOMATSU CONTROLLER NOT CONNECTED] 1077
E-33 iB MONITOR DISPLAYS THE MESSAGE [CYLINDER STROKE READING ABNORMAL] 1079
E-34 iB MONITOR DISPLAYS THE MESSAGE [KOMATSU CAN COMMS ABNORMAL] 1080
E-35 iB MONITOR DISPLAYS THE MESSAGE [KOMATSU MACHINE TROUBLE] .1081
E-36 iB MONITOR DISPLAYS THE MESSAGE [WAITING TO INITIALIZE .] 1082
E-37 iB MONITOR DISPLAYS THE MESSAGE [SYSTEM INITIALIZING .] 1083
E-38 iB MONITOR DISPLAYS THE MESSAGE [INITIALIZING .] .1084
E-39 iB MONITOR DISPLAYS THE MESSAGE [CONFIGURING GPS] .1085
E-40 iB MONITOR DISPLAYS THE MESSAGE [NO GPS LOCALIZATION . ] .1086
E-41 iB MONITOR DISPLAYS THE MESSAGE [LOW PRECISIONS .] .1087
E-42 iB MONITOR DISPLAYS THE MESSAGE [HEADING INITIALIZING] 1088
E-43 iB MONITOR DISPLAYS [OUT OF DESIGN AREA .] .1089
E-44 iB MONITOR CAN NOT BE TURNED ON .1090
E-45 iB MONITOR DOES NOT DISPLAY INTELLIGENT MACHINE CONTROL SCREN .1091
E-46 iB MONITOR DOES NOT DISPLAY BULLDOZER IMAGE .1092
E-47 iB MONITOR DOES NOT DISPLAY DESIGN SURFACE 1093
E-48 iB MONITOR TOUCH PANEL DOES NOT RESPOND .1094
E-49 iB MONITOR TOUCH PANEL IS INACCURATE 1095
E-50 CYLINDER STROKE RESET INDICATION DOES NOT GO OUT 1096
E-51 AUTO IS NOT DISPLAYED WHEN AUTO/MANUAL SWITCH IS PRESSED (AUTO INDICATION GOES OUT) .1097
E-52 BLADE AUTOMATIC RAISE CONTROL DOES NOT START WHILE AUTO IS DISPLAYED 1098
E-53 BLADE AUTOMATIC LOWER CONTROL DOES NOT START WHILE AUTO IS DISPLAYED 1099
E-54 BLADE AUTOMATIC CONTROL FUNCTION IS NOT ACTIVATED WHILE AUTO IS DISPLAYED (BLADE AUTOMATIC CONTROL STOPS) .1100
E-55 WHEN CHECKING AND ADJUSTING THE BLADE ELEVATION, THE VALUE IS DIFFERENT FROM ACTUAL MACHINE .1101
E-56 FINISHED SURFACE IS INACCURATE (THE AVERAGE HEIGHT OF FINISHED SURFACE IS LOWER THAN DESIGNED SURFACE OR BLADE DOES NOT TOUCH THE SURFACE) 1102
E-57 FINISHED SURFACE IS INACCURATE (THE FINISHED IS NOT SMOOTH) .1103
E-58 FINISHED SURFACE IS INACCURATE (WHEN FINISHING SLOPE HORIZONTALLY, STEPS ARE MADE IN EACH DIRECTION) 1104
E-59 MACHINE CAN NOT ESCAPE FROM SHOES SLIP WHILE BLADE AUTOMATIC CONTROL IS ACTIVATED (SHOES FREQUENTLY SLIPS) 1106
E-60 MACHINE SPEED DOES NOT INCREASE WHILE BLADE AUTOMATIC CONTROL IS ACTIVATED 1107
E-61 BLADE TILT ANGLE DOES NOT COINCIDE WITH DESIGN SURFACE 1108
E-62 BLADE TILTS BACK WHILE BLADE AUTOMATIC CONTROL IS ACTIVATED .1110
TROUBLESHOOTING OF HYDRAULIC AND MECHANICAL SYSTEM (H- MODE) .1113
INFORMATION IN TROUBLESHOOTING TABLE .1113
H-1 RIGHT AND LEFT TRAVEL SYSTEMS INOPERABLE .1114
H-2 RIGHT OR LEFT TRAVEL SYSTEM DOES NOT OPERATE .1116
H-3 RIGHT OR LEFT TRAVEL SYSTEM DOES NOT OPERATE .1117
H-4 SPEED OR POWER OF TRAVEL IS LOW 1118
H-5 GEAR IS NOT SHIFTED 1119
H-6 LARGE SHOCKS ARE MADE WHEN MACHINE STARTS AND STOPS TRAVEL .1120
H-7 MACHINE DEVIATES LARGELY DURING TRAVEL .1121
H-8 HYDRAULIC DRIFT OF TRAVEL IS LARGE .1122
H-9 ENGINE STALLS OR SPEED LOWERS EXTREMELY DURING TRAVEL 1123
H-10 ABNORMAL SOUND COMES OUT FROM AROUND HST PUMP AND MOTOR .1124
H-11 WORK EQUIPMENT DOSE NOT OPERATE AT ALL 1125
H-12 SPEED OR POWER OF WHOLE WORK EQUIPMENT IS LOW .1126
H-13 BLADE LIFT SPEED OR POWER IS LOW 1127
H-14 BLADE TILT SPEED OR POWER IS LOW 1128
H-15 BLADE ANGLE SPEED OR POWER IS LOW .1129
H-16 TIME LAG OF BLADE LIFT IS LARGE .1130
H-17 HYDRAULIC DRIFT OF LIFTED BLADE IS LARGE 1131
H-18 HYDRAULIC DRIFT OF TILTING BLADE IS LARGE .1132
H-19 UNUSUAL NOISE IS HEARD FROM WORK EQUIPMENT PUMP OR CONTROL VALVE 1133
H-20 HST OIL TEMPERATURE RISES TOO HIGH 1134
H-21 FAN SPEED IS ABNORMAL (HIGH, LOW, OR 0 RPM) .1135
TROUBLESHOOTING OF ENGINE (S-MODE) .1137
METHOD OF USING TROUBLESHOOTING CHARTS .1137
(S-1) ENGINE STARTING PERFORMANCE IS POOR 1141
(S-2) ENGINE DOES NOT CRANK 1142
ENGINE CRANKS BUT NO EXHAUST SMOKE COMES OUT OF STACK 1143
SMOKE COMES OUT OF STACK BUT ENGINE DOES NOT START .1144
(S-3) ENGINE DOES NOT RUN SMOOTHLY .1145
(S-4) ENGINE STOPS DURING OPERATIONS .1146
(S-5) ENGINE SPEED HUNTS .1147
(S-6) ENGINE LACKS POWER .1148
(S-7) EXHAUST SMOKE IS BLACK .1150
(S-8) OIL CONSUMPTION IS EXCESSIVE OR EXHAUST SMOKE IS BLUE 1151
(S-9) OIL BECOMES CONTAMINATED QUICKLY .1152
(S-10) FUEL CONSUMPTION IS EXCESSIVE .1153
(S-11) OIL FOUND IN COOLANT, OR COOLANT SPURTS FROM RADIATOR .1154
(S-12) OIL PRESSURE CAUTION LAMP LIGHTS UP .1155
(S-13) OIL LEVEL RISES (COOLANT OR FUEL FOUND IN OIL) 1156
(S-14) COOLANT TEMPERATURE TOO HIGH (OVERHEATING) 1157
(S-15) ABNORMAL NOISE IS HEARD WHEN ENGINE IS RUNNING 1158
(S-16) EXCESSIVE VIBRATION WHEN ENGINE IS RUNNING 1159
50 DISASSEMBLY AND ASSEMBLY 1161
TABLE OF CONTENTS 1162
RELATED INFORMATION ON DISASSEMBLY AND ASSEMBLY 1165
HOW TO READ THIS MANUAL 1165
SPECIAL TOOL LIST 1173
SKETCH OF SPECIAL TOOLS 1180
CONNECTOR REPAIR PROCEDURES 1195
CONTACT TERMINAL REMOVAL (HD30 TYPE) .1195
STRIPPING INSULATION .1196
CRIMPING CONTACT TERMINAL (HD30 TYPE) 1197
INSERTION OF CONTACT TERMINAL (HD30 TYPE) 1198
CONTACT TERMINAL REMOVAL (DT TYPE) .1199
STRIPPING INSULATION .1200
CRIMPING CONTACT TERMINAL (DT TYPE) 1201
INSERTION OF CONTACT TERMINAL (DT TYPE) 1202
NOSE GUARD (HOOD) 1204
REMOVAL 1204
INSTALLATION .1208
MUFFLER AND EXHAUST STACK 1210
REMOVAL 1210
INSTALLATION .1211
CAB AND ITS ATTACHMENTS 1212
CAB 1212
MONITOR PANEL AND HST CONTROLLER .1227
KOMTRAX CONTROLLER .1230
REMOVAL AND INSTALLATION OF ICT SENSOR CONTROLLER ASSEMBLY .1231
REMOVAL AND INSTALLATION OF iB MONITOR .1232
REMOVAL AND INSTALLATION OF GNSS RECEIVER 1234
REMOVAL AND INSTALLATION OF iB GNSS ANTENNA 1236
REMOVAL AND INSTALLATION OF IMU SENSOR .1241
SEAT .1245
AIR CONDITIONER/HEATER .1246
DISASSEMBLY OF AIR CONDITIONER .1246
ASSEMBLY OF AIR CONDITIONER 1250
FOOT HEATER 1251
REMOVAL 1251
INSTALLATION .1253
FOOT HEATER OVERHAUL PROCEDURES 1253
ASSEMBLY PROCEDURES 1255
ENGINE AND COOLING SYSTEM 1257
REMOVAL 1257
ENGINE AND HST PUMP 1264
INSTALLATION .1266
REMOVAL FROM ENGINE 1268
INSTALLATION TO ENGINE .1271
DRIVE DAMPENER .1272
REMOVAL 1272
INSTALLATION .1273
HST PUMP OVERHAUL PROCEDURES .1274
DISASSEMBLY PROCEDURES .1274
ASSEMBLY PROCEDURES 1283
WORK EQUIPMENT PUMP OVERHAUL PROCEDURES 1295
DISASSEMBLY PROCEDURES .1295
ASSEMBLY PROCEDURES 1301
REMOVAL 1308
INSTALL 1309
CHARGE PUMP OVERHAUL PROCEDURES 1310
DISASSEMBLY PROCEDURES .1310
ASSEMBLY PROCEDURES 1316
DIESEL ENGINE OVERHAUL PROCEDURES 1322
DISASSEMBLY OF EXTERNAL COMPONENTS .1322
DISASSEMBLY OF ENGINE TOP END 1328
REMOVAL OF OIL COOLER, ENGINE CONTROLLER AND FUEL PUMP .1332
DISASSEMBLY OF ENGINE LOWER END 1334
ASSEMBLY OF ENGINE LOWER END .1341
INSTALLATION OF OIL COOLER, ENGINE CONTROLLER AND FUEL PUMP 1357
ASSEMBLY OF EXTERNAL COMPONENTS 1366
TRACK SYSTEM .1393
SPREADING THE TRACK 1393
(CONVENTIONAL TYPE TRACK SHOE) .1393
EXPANSION AND INSTALLATION OF TRACK SHOE ASSEMBLY (PLUS TYPE TRACK SHOE) .1395
FIELD DISASSEMBLY AND ASSEMBLY OF ONE LINK (CONVENTIONAL TYPE TRACK SHOE) 1409
FIELD DISASSEMBLY AND ASSEMBLY OF ONE LINK (PLUS TYPE TRACK SHOE) 1417
TRACK FRAME 1424
REMOVAL OF TRACK FRAME .1424
FRONT TRACK IDLER 1433
REMOVING FRONT IDLER .1433
INSTALLING FRONT IDLER .1435
TRACK ROLLER .1436
REMOVAL 1436
INSTALLATION .1436
TRACK ROLLER OVERHAUL PROCEDURES .1437
CARRIER ROLLER OVERHAUL PROCEDURES .1442
FINAL DRIVE 1444
FINAL DRIVE REMOVAL 1444
INSTALLING THE FINAL DRIVE .1448
FINAL DRIVE OVERHAUL PROCEDURES 1450
DISASSEMBLY PROCEDURES .1450
ASSEMBLY OF FINAL DRIVE 1456
TRAVEL MOTOR OVERHAUL PROCEDURES .1464
DISASSEMBLY PROCEDURES .1464
ASSEMBLY PROCEDURES 1469
FAN MOTOR 1482
REMOVAL PROCEDURES .1482
INSTALLATION PROCEDURES 1486
FAN MOTOR OVERHAUL PROCEDURES 1488
DISASSEMBLY PROCEDURES .1488
ASSEMBLY PROCEDURES 1492
DB 12 VALVE 1499
REMOVAL 1499
INSTALLATION .1501
COOLING PACKAGE 1502
REMOVING THE GRILL AND COOLING FAN ASSEMBLY 1502
REMOVING THE COOLING PACKAGE .1513
INSTALLING THE COOLING PACKAGE .1521
INSTALLING THE GRILL AND COOLING FAN ASSEMBLY 1522
FUEL TANK 1526
REMOVING THE FUEL TANK .1526
INSTALLING THE FUEL TANK .1531
HYDRAULIC TANK .1532
REMOVING THE HYDRAULIC TANK 1532
INSTALLING THE HYDRAULIC TANK 1538
WORK EQUIPMENT .1539
REMOVING OR INSTALLING PINS 1539
FRONT BLADE, TILT AND ANGLE CYLINDERS 1540
ADJUSTING BLADE CENTER BALL AND PITCH ROD PLAY .1545
“C” FRAME 1547
LIFT CYLINDERS .1550
CYLINDER OVERHAUL PROCEDURES .1552
DISASSEMBLY PROCEDURES .1552
ASSEMBLY PROCEDURES 1553
WHOLE DISASSEMBLY AND ASSEMBLY OF TRACK SHOE (PLUS TYPE TRACK SHOE) 1392
WHOLE DISASSEMBLY AND ASSEMBLY OF TRACK SHOE ASSEMBLY (CONVENTIONAL TYPE TRACK SHOE) .1372
90 OTHERS 1557
HYDRAULIC SYSTEM 1580
TABLE OF CONTENTS .1558
CONNECTOR ARRANGEMENT DRAWING AND ELECTRICAL CIRCUIT DIAGRAM .1559
CONNECTOR LIST 1559
CONNECTOR LOCATION VIEW 1563
ELECTRICAL SYSTEM .1582

DESCRIPTION:

Komatsu Bulldozer D51Exi-22 D51PXi-22 Shop Manual KEBM028604 –  PDF DOWNLOAD

• SERIAL NUMBERS B13500 and up

HOW TO READ THE SHOP MANUAL :
• Some attachments and optional parts described in this shop manual may not be arranged for certain
areas. Contact your Komatsu distributor if one or some of them are required.
• Materials and specifications are subject to change without notice.
• The shop manuals are available for “Machine part” and “Engine part”. For the engine, see the shop
manual for the same model of the engine as the one which is mounted on the machine.
Composition of shop manual
• This shop manual describes the technical information required for the services performed in a workshop.
The shop manual is divided into the following chapters for the convenience of use.
00. Index and foreword
• This section includes the index, foreword, safety and basic information.
01. Specification
• This section explains the specifications of the machine.
10. Structure and function
• This section explains the structure and function of the machine. The section of “Structure and function”
serves not only to give an understanding for the structure of each component, but also serves as
reference material for troubleshooting.
20. Standard value table
• The standard values for a new machine and trouble shooting are indicated. This standard value table is
used for testing and adjusting, and determining a failure at troubleshooting.
30. Testing and adjusting
• This section describes the measuring tools and how to measure, and how to adjust various parts. As for
the standard value and failure criterion, see the standard value table.
40. Troubleshooting
• This section describes the troubleshooting in a suspected area when a failure occurs and the remedy for
the failure. Troubleshooting is described by each failure mode.
50. Disassembly and assembly
• This section explains the procedures for removing, installing, disassembling, and assembling each part or
component and the special tools for the works as well as precautions for doing them safely. In addition,
tightening torque, and quantity and weight of coating material, oil, grease, and coolant required for the
works are also explained.
60. Maintenance standard
• This section describes the maintenance standard values for each component. This section gives the
criterion values for each component and required remedy at disassembly or maintenance.
80. Appendix
• The structure and function, testing and adjusting, and troubleshooting for all of the other components or
equipment which can not be separately classified are explained together in the appendix.
90. Diagrams and drawings
• This section gives hydraulic circuit diagrams and electrical circuit diagrams.

G.B 22/ 12/24