Komatsu D51EX-22 D51PX-22 Crawler Tractor Shop Manual 2007 PDF – Repair & Troubleshooting

Description

Komatsu D51EX-22 & D51PX-22 Crawler Tractor Shop Manual – CEBM019100

This Komatsu D51EX-22 and D51PX-22 crawler tractor shop manual is the comprehensive technical publication for professional service, repair, and maintenance of these machines. Covering serial numbers B10001 and up, this April 2007 edition (document CEBM019100) gives technicians the structure, function, testing, adjusting, troubleshooting, and maintenance standard information needed to keep these Komatsu dozers working reliably.

Whether you are diagnosing an HST fault, setting valve clearance, checking track shoe tension, or rebuilding a final drive, this D51EX-22 D51PX-22 shop manual provides the procedures, values, diagrams, and judgement criteria required. It covers the Komatsu SAA6D107E-1 diesel engine, the hydrostatic transmission system, undercarriage components, work equipment hydraulics, the electrical monitoring and control systems, and more.

File Details

• Manual Type: Shop Manual
• Brand: Komatsu
• Models Covered: D51EX-22, D51PX-22
• Serial Numbers: D51EX-22 B10001 and up; D51PX-22 B10001 and up
• Document Number: CEBM019100
• Publication Date: April 2007
• Language: English
• Page Count: Approximately 764 pages
• File Format: PDF

Chapters Covered

• 01 General
• 10 Structure, Function and Maintenance Standard
• 20 Standard Value Tables
• 30 Testing and Adjusting
• 40 Troubleshooting
• 50 Disassembly and Assembly (Issued later — not included in this publication)
• 90 Other

01 General

This opening chapter provides the specification drawing for the D51EX-22 and D51PX-22 power angle, power tilt dozer with ROPS cab, along with complete machine specifications and a weight table. You get the machine dimensions, engine rated horsepower, travel speeds, ground pressure data, track gauge, track shoe widths, and component weights needed for reference during service and transport planning. The chapter also includes the table of fuel, coolant, and lubricants with ambient temperature ranges and recommended Komatsu fluids, plus recommended products other than Komatsu genuine oils.

10 Structure, Function and Maintenance Standard

This is the largest technical reference chapter in the D51EX-22 D51PX-22 manual. It explains the structure and function of every major component and gives the maintenance standard values needed when inspecting disassembled parts. Coverage includes the engine and cooling system — radiator, oil cooler, aftercooler, cooling fan pump and motor, thermostat operation, and water pump. The power train section covers the damper, HST pump, HST motor, final drive, and the path of power transmission through the planetary gear sets. Undercarriage coverage includes the main frame, idler, track roller, carrier roller, recoil spring, track shoe, sprocket, and the equalizer bar and pivot shaft assembly with clearances and adjustment values. The hydraulic system chapters cover the HST pump and motor controls, charge pump, servo valve, safety-suction valve, shuttle valve, charge relief valve, parking brake, speed sensor, and the work equipment closed center load sensing system (CLSS) with the main pump, PC valve, LS valve, control valve, pressure compensation valve, PPC valves, quick drop valve, hydraulic tank, and accumulator. Electrical system coverage includes the monitor system, engine controller, HST controller, electric lever, KOMTRAX terminal, and all sensors. The work equipment chapter covers the blade, tilt cylinder, angle cylinder, lift cylinder, ripper cylinder, and cutting edge adjustments.

20 Standard Value Tables

This chapter provides the standard value tables for engine and chassis. The engine table gives you high and low idling speeds, intake air boost pressure, exhaust temperature, valve clearance, compression pressure, blow-by pressure, engine oil pressure, oil temperature, and oil consumption ratio. The chassis table gives PCCS lever stroke and operating effort, brake pedal stroke and effort, decelerator pedal stroke and effort, work equipment control lever strokes and operating efforts, HST oil pressure (main circuit and charge circuit), travel speed in quick shift and variable shift modes, travel deviation, hydraulic drift of travel, work equipment relief pressure, PPC valve output pressure, blade lifting, tilting and angling speeds, time lag, hydraulic drift of work equipment, cylinder leakage limits, and fan speed with work equipment pump pressure. Performance measuring posture and method illustrations are included.

30 Testing and Adjusting

This chapter walks you through the testing and adjusting procedures for the Komatsu D51EX-22 D51PX-22. Engine procedures include measuring engine speed, air intake boost pressure, exhaust temperature, exhaust gas color, valve clearance, compression pressure, blow-by pressure, and engine oil pressure. Fuel system coverage includes handling precautions, releasing residual pressure, bleeding air, fuel pressure, fuel return rate and leakage, and fuel circuit leak testing. Fan and work equipment pump pressure, fan speed and fan speed sensor adjustment, decelerator pedal adjustment, HST oil pressure measurement and adjustment, 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, PPC valve output pressure, PPC valve adjusting, lock lever adjustment, cylinder leakage, hydraulic circuit residual pressure release, bleeding air, blade center ball adjustment, blade pitch ball adjustment, and diode testing are all covered. The monitor panel (EMMS) special functions chapter explains the service mode, tuning mode, real-time monitoring, error code display, and the preparation work for electrical troubleshooting. The chapter closes with electric/hydraulic device adjustment and replacement procedures, including HST controller and monitor panel replacement adjustment, plus PM Clinic inspection sheets and undercarriage troubleshooting reports.

40 Troubleshooting

The troubleshooting chapter is extensive and covers general troubleshooting points, sequence of events, precautions for maintenance, handling electrical equipment, electronic control unit handling, electrical circuit troubleshooting, electric wire code, handling hydraulic equipment, checks before troubleshooting, categories and method of using troubleshooting charts, and individual electrical circuit troubleshooting with connector pin numbers, T-adapter tables, and mode charts. Troubleshooting is further divided into troubleshooting by error code (covering all error codes with causes, standard values, and remedies), E-mode troubleshooting (starting motor, pre-heating, monitor panel, charge level, emergency warning items, coolant temperature gauge, HST oil temperature gauge, fuel level gauge, travel indicator, caution lamps, caution buzzer, reverse travel speed switch, shift mode switch, buzzer cancel switch, information switch, fan cleaning, backup alarm, horn, work equipment movement, headlamp and rear lamp, foot heater, air conditioner, wiper and washer, KOMTRAX system), H-mode troubleshooting (travel systems, speed and power, gear shifting, shocks, deviation, hydraulic drift, engine stall, abnormal sound, work equipment, HST oil temperature, fan speed), and S-mode troubleshooting (engine starting, cranking, smooth running, engine stops, hunting, lack of power, exhaust smoke, oil consumption, oil contamination, fuel consumption, oil in coolant, oil pressure caution lamp, oil level rise, overheating, abnormal noise, vibration).

50 Disassembly and Assembly

This section is noted in the manual’s table of contents as “Issued later” and is not included in this publication. The rest of the manual — General, Structure/Function/Maintenance Standard, Standard Value Tables, Testing and Adjusting, Troubleshooting, and Other — is complete.

90 Other

The Other chapter contains the connector arrangement drawing and electrical circuit diagram, connector list, connector location views, cab electrical accessories, air conditioning and heater unit diagrams, hydraulic system views, and electrical system views including in-cab switches, relays and connectors, cab harness and controller connections, engine harness and controller, monitor panel and switches, and KOMTRAX and connectors.

What This Komatsu Shop Manual Enables You to Do

With this D51EX-22 D51PX-22 crawler tractor shop manual on hand, you can perform a full range of professional service tasks: diagnose and repair the Komatsu SAA6D107E-1 engine; test and adjust the HST pump, HST motor, charge pump, and all related valves; service the final drive, idler, track roller, carrier roller, recoil spring, and track assembly; troubleshoot the closed center load sensing hydraulic system, PPC valves, control valve, and work equipment cylinders; interpret electrical error codes, test sensors, solenoids, and controllers, and repair wiring faults; and carry out PM Clinic inspections and undercarriage checks. Every procedure is supported by the structure/function explanations, maintenance standards, standard values, and troubleshooting charts needed to make correct judgements.

Why Correct Procedures and Specifications Matter

Heavy equipment repair is not a place for guesswork. Incorrect valve clearance, wrong hydraulic pressures, misadjusted HST controls, or improper track tension can lead to poor performance, accelerated wear, component failure, or unsafe operation. This manual gives you the exact testing and adjusting values, clearances, torque values, and judgement criteria that Komatsu specifies for these machines. The troubleshooting charts correlate problems to causes and guide you through systematic diagnosis, so you can pinpoint faults efficiently and repair them correctly the first time. The structure and function chapter helps you understand how each system works, which makes diagnosis faster and more accurate.

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This Komatsu D51EX-22 D51PX-22 shop manual is delivered as an instant PDF download after payment. There is no shipping, no waiting, and no physical media to lose. You can access it on any device — laptop, desktop, tablet, or smartphone — and print the pages you need for the workshop. Whether you are a professional technician, a fleet maintenance manager, or an owner-operator, this manual gives you the technical depth and procedural detail required to service and repair these Komatsu crawler tractors correctly. Add it to your library today and have the information you need at your fingertips.