Komatsu Bulldozer D51ex 22 D51px 22shop Manual Shop Manual

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FOREWORD

CEBM019104

Shop
Manual

D51EX-22
D51PX-22
CRAWLER TRACTOR

D51EX-22 B10001
SERIAL NUMBERS and UP
D51PX-22 B10001

This material is proprietary to Komatsu America Corp. and is not to be reproduced, used, or disclosed except in
accordance with written authorization from Komatsu America Corp.

It is our policy to improve our products whenever it is possible and practical to do so. We reserve the right to make changes or
add improvements at any time without incurring any obligation to install such changes on products sold previously.

Due to this continuous program of research and development, periodic revisions may be made to this publication. It is
recommended that customers contact their distributor for information on the latest revision.

D51EX-22 00-1 E
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FOREWORD CONTENTS
12
CONTENTS 00

GENERAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 01-1

STRUCTURE, FUNCTION AND MAINTENANCE STANDARD . . . . . . . . . . . . . . . . . . . . 10-1

STANDARD VALUE TABLES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-1

TESTING AND ADJUSTING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-1

TROUBLESHOOTING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-1

DISASSEMBLY AND ASSEMBLY. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50-1

OTHER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 90-1

00-2 1
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The affected pages are indicated by using the following Mark Indication Action
marks. It is requested that necessary actions be taken to
these pages according to the table below. ❍ New page to be added Add
● Page to be replaced Replace

( ) Page to be deleted Discard

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● 00-1 e 00-20 10-7 10-36 d

00-2 b 00-21 10-8 10-37 d

● 00-2-1 e 00-22 10-9 10-38 d

● 00-2-2 e 00-23 10-10 10-39 d

● 00-2-3 e 00-24 10-11 10-40 d

● 00-2-4 e 00-25 10-12 10-41 d

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00-3 01-3 d 10-19 10-48 d

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00-5 01-5 10-21 10-50 d

00-6 01-6 d 10-22 10-51 d

00-7 01-7 10-23 10-52 d

00-8 01-8 10-24 10-53 d

00-9 01-9 10-25 10-54 d

00-10 01-10 10-26 10-55 d

00-11 01-11 10-27 10-56 d

00-12 01-12 10-28 d 10-57 d

00-13 10-29 d 10-58 d

00-14 10-1 d 10-30 10-59 d

00-15 10-2 d 10-31 10-60 d

00-16 10-3 10-32 10-61 d

00-17 10-4 10-33 d 10-62 d

00-18 10-5 10-34 d 10-63 d

00-19 10-6 10-35 d 10-64 d

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10-65 d 10-98 d 10-131 d 10-164

10-66 d 10-99 d 10-132 d 10-165

10-67 d 10-100 d 10-133 d 10-166

10-68 d 10-101 d 10-134 d 10-167

10-69 d 10-102 d 10-135 d 10-168

10-70 d 10-103 d 10-136 d 10-169

10-71 d 10-104 d 10-137 d 10-170

10-72 d 10-105 d 10-138 d 10-171

10-73 d 10-106 d 10-139 d 10-172

10-74 d 10-107 d 10-140 d 10-173

10-75 d 10-108 d 10-141 d 10-174

10-76 d 10-109 d 10-142 10-175

10-77 d 10-110 d 10-143 10-176

10-78 d 10-111 d 10-144 10-177

10-79 d 10-112 d 10-145 10-178

10-80 d 10-113 d 10-146 10-179

10-81 d 10-114 d 10-147 10-180

10-82 d 10-115 d 10-148 10-181

10-83 d 10-116 d 10-149 10-182

10-84 d 10-117 d 10-150 10-183

10-85 d 10-118 d 10-151 10-184

10-86 d 10-119 d 10-152 10-185

10-87 d 10-120 d 10-153 10-186

10-88 d 10-121 d 10-154 10-187

10-89 d 10-122 d 10-155 10-188

10-90 d 10-123 d 10-156

10-91 d 10-124 d 10-157 20-1

10-92 d 10-125 d 10-158 ● 20-2 e

10-93 d 10-126 d 10-159 20-3

10-94 d 10-127 d 10-160 20-4

10-95 d 10-128 d 10-161 20-5

10-96 d 10-129 d 10-162 20-6

10-97 d 10-130 d 10-163 20-7

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20-8 30-30 30-63 30-96

20-9 30-31 30-64 30-97

20-10 30-32 30-65 30-98

30-33 30-66 30-99

30-1 30-34 30-67 30-100

30-2 30-35 30-68 30-101

30-3 30-36 30-69 30-102

30-4 30-37 30-70 30-103

30-5 30-38 30-71 30-104

30-6 30-39 30-72 30-105

30-7 30-40 30-73 30-106

30-8 30-41 30-74 30-107

30-9 30-42 30-75 30-108

30-10 30-43 30-76 30-109

30-11 30-44 30-77 30-110

30-12 30-45 30-78 30-111

30-13 30-46 30-79 30-112

30-14 30-47 30-80 30-113

30-15 30-48 30-81 30-114

30-16 30-49 30-82 30-115

30-17 30-50 30-83 30-116

30-18 30-51 30-84 30-117

30-19 30-52 30-85 30-118

30-20 30-53 30-86 30-119

30-21 30-54 30-87 30-120

30-22 30-55 30-88 30-121

30-23 30-56 30-89 30-122

30-24 30-57 30-90 30-123

30-25 30-58 30-91 30-124

30-26 30-59 30-92 30-125

30-27 30-60 30-93 30-126

30-28 30-61 30-94 30-127

30-29 30-62 30-95 30-128

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30-129 40-121 40-202 b 40-235 b

30-130 40-122 40-203 b 40-236 b

30-131 40-123 40-204 b 40-237 b

30-132 40-124 40-205 b 40-238 b

30-133 40-125 40-206 b 40-239 b

30-134 40-126 40-207 b 40-240 b

30-135 40-127 40-208 b 40-241 b

30-136 40-128 40-209 b 40-242 b

30-137 40-129 40-210 b 40-243 b

30-138 40-130 40-211 b 40-244 b

30-139 40-131 40-212 b 40-245 b

30-140 40-132 40-213 b 40-246 b

40-133 40-214 b 40-247 b

40-101 40-134 40-215 b 40-248 b

40-102 40-135 40-216 b 40-249 b

40-103 40-136 40-217 b 40-250 b

40-104 40-137 40-218 b 40-251 b

40-105 40-138 40-219 b 40-252 b

40-106 40-139 40-220 b 40-253 b

40-107 40-140 40-221 b 40-254 b

40-108 40-141 40-222 b 40-255 b

40-109 40-142 40-223 b 40-256 b

40-110 40-143 40-224 b 40-257 b

40-111 40-144 40-225 b 40-258 b

40-112 40-145 40-226 b 40-259 b

40-113 40-146 40-227 b 40-260 b

40-114 40-147 40-228 b 40-261 b

40-115 40-148 40-229 b 40-262 b

40-116 40-149 40-230 b 40-263 b

40-117 40-150 40-231 b 40-264 b

40-118 40-151 40-232 b 40-265 b

40-119 40-233 b 40-266 b

40-120 40-201 b 40-234 b 40-267 b

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40-268 b 40-301 b 40-334 b 40-367 b

40-269 b 40-302 b 40-335 b 40-368 b

40-270 b 40-303 b 40-336 b 40-369 b

40-271 b 40-304 b 40-337 b 40-370 b

40-272 b 40-305 b 40-338 b 40-371 b

40-273 b 40-306 b 40-339 b 40-372 b

● 40-274 e 40-307 b 40-340 b 40-373 b

40-275 b 40-308 b 40-341 b 40-374 b

40-276 b 40-309 b 40-342 b 40-375 b

40-277 b 40-310 b 40-343 b 40-376 b

40-278 b 40-311 b 40-344 b 40-377 b

40-279 b 40-312 b 40-345 b 40-378 b

40-280 b 40-313 b 40-346 b 40-379 b

40-281 b 40-314 b 40-347 b 40-380 b

40-282 b 40-315 b 40-348 b 40-381 b

40-283 b 40-316 b 40-349 b 40-382 b

40-284 b 40-317 b 40-350 b 40-383 b

40-285 b 40-318 b 40-351 b 40-384 b

40-286 b 40-319 b 40-352 b 40-385 b

40-287 b 40-320 b 40-353 b 40-386 b

40-288 b 40-321 b 40-354 b 40-387 b

40-289 b 40-322 b 40-355 b 40-388 b

40-290 b 40-323 b 40-356 b 40-389 b

40-291 b 40-324 b 40-357 b 40-390 b

40-292 b 40-325 b 40-358 b 40-391 b

40-293 b 40-326 b 40-359 b 40-392 b

40-294 b 40-327 b 40-360 b 40-393 b

40-295 b 40-328 b 40-361 b 40-394 b

40-296 b 40-329 b 40-362 b 40-395 b

40-297 b 40-330 b 40-363 b 40-396 b

40-298 b 40-331 b 40-364 b 40-397 b

40-299 b 40-332 b 40-365 b 40-398 b

40-300 b 40-333 b 40-366 b 40-399 b

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40-400 b 40-433 b 40-466 b 40-522 b

40-401 b 40-434 b 40-467 b 40-523 b

40-402 b 40-435 b 40-468 b 40-524 b

40-403 b 40-436 b 40-469 b 40-525 b

40-404 b 40-437 b 40-470 b 40-526 b

40-405 b 40-438 b 40-471 b 40-527 b

40-406 b 40-439 b 40-472 b 40-528 b

40-407 b 40-440 b 40-473 b 40-529 b

40-408 b 40-441 b 40-474 b 40-530 b

40-409 b 40-442 b 40-475 b 40-531 b

40-410 b 40-443 b 40-476 b 40-532 b

40-411 b 40-444 b 40-533 b

40-412 b 40-445 b 40-501 b 40-534 b

40-413 b 40-446 b 40-502 b 40-535 b

40-414 b 40-447 b 40-503 b 40-536 b

40-415 b 40-448 b 40-504 b 40-537 b

40-416 b 40-449 b 40-505 b 40-538 b

40-417 b 40-450 b 40-506 b 40-539 b

40-418 b 40-451 b 40-507 b 40-540 b

40-419 b 40-452 b 40-508 b 40-541 b

40-420 b 40-453 b 40-509 b 40-542 b

40-421 b 40-454 b 40-510 b 40-543 b

40-422 b 40-455 b 40-511 b 40-544 b

40-423 b 40-456 b 40-512 b 40-545 b

40-424 b 40-457 b 40-513 b 40-546 b

40-425 b 40-458 b 40-514 b 40-547 b

40-426 b 40-459 b 40-515 b 40-548 b

40-427 b 40-460 b 40-516 b 40-549 b

40-428 b 40-461 b 40-517 b 40-550 b

40-429 b 40-462 b 40-518 b 40-551 b

40-430 b 40-463 b 40-519 b 40-552 b

40-431 b 40-464 b 40-520 b 40-553 b

40-432 b 40-465 b 40-521 b 40-554 b

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40-555 b 40-613 b 40-721 b ● 50-29 e

40-556 b 40-614 b 40-722 b ● 50-30 e

40-557 b 40-615 b 40-723 b ● 50-31 e

40-558 b 40-616 b 40-724 b ● 50-32 e

40-559 b 40-617 b ● 50-33 e

40-560 b 40-618 b ● 50-1 e ● 50-34 e

40-561 b 40-619 b ● 50-2 e ● 50-35 e

40-562 b 40-620 b ● 50-3 e ● 50-36 e

40-563 b 40-621 b 50-4 b ● 50-37 e

40-564 b 40-622 b 50-5 b ● 50-38 e

40-565 b 40-623 b 50-6 b ● 50-39 e

40-566 b 40-624 b 50-7 b ● 50-40 e

40-567 b ● 50-8 e ● 50-41 e

40-568 b 40-701 b 50-9 b ● 50-42 e

40-569 b 40-702 b ● 50-10 e ● 50-43 e

40-570 b 40-703 b ● 50-11 e ● 50-44 e

40-571 b 40-704 b ● 50-12 e ● 50-45 e

40-572 b 40-705 b ● 50-13 e ● 50-46 e

40-573 b 40-706 b ● 50-14 e ● 50-47 e

40-574 b 40-707 b ● 50-15 e ● 50-48 e

40-708 b ● 50-16 e ● 50-49 e

40-601 b 40-709 b ● 50-17 e ● 50-50 e

40-602 b 40-710 b ● 50-18 e ● 50-51 e

40-603 b 40-711 b ● 50-19 e ● 50-52 e

40-604 b 40-712 b ● 50-20 e ● 50-53 e

40-605 b 40-713 b ● 50-21 e ● 50-54 e

40-606 b 40-714 b ● 50-22 e ● 50-55 e

40-607 b 40-715 b ● 50-23 e ● 50-56 e

40-608 b 40-716 b ● 50-24 e ● 50-57 e

40-609 b 40-717 b ● 50-25 e ● 50-58 e

40-610 b 40-718 b ● 50-26 e ● 50-59 e

40-611 b 40-719 b ● 50-27 e ● 50-60 e

40-612 b 40-720 b ● 50-28 e ● 50-61 e

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● 50-62 e ● 50-95 e ● 50-128 e ● 50-161 e

● 50-63 e ● 50-96 e ● 50-129 e ● 50-162 e

● 50-64 e ● 50-97 e ● 50-130 e ● 50-163 e

● 50-65 e ● 50-98 e ● 50-131 e ● 50-164 e

● 50-66 e ● 50-99 e ● 50-132 e ● 50-165 e

● 50-67 e ● 50-100 e ● 50-133 e ● 50-166 e

● 50-68 e ● 50-101 e ● 50-134 e ● 50-167 e

● 50-69 e ● 50-102 e ● 50-135 e ● 50-168 e

● 50-70 e ● 50-103 e ● 50-136 e ● 50-169 e

● 50-71 e ● 50-104 e ● 50-137 e ● 50-170 e

● 50-72 e ● 50-105 e ● 50-138 e ● 50-171 e

● 50-73 e ● 50-106 e ● 50-139 e ● 50-172 e

● 50-74 e ● 50-107 e ● 50-140 e ● 50-173 e

● 50-75 e ● 50-108 e ● 50-141 e ● 50-174 e

● 50-76 e ● 50-109 e ● 50-142 e ● 50-175 e

● 50-77 e ● 50-110 e ● 50-143 e ● 50-176 e

● 50-78 e ● 50-111 e ● 50-144 e ● 50-177 e

● 50-79 e ● 50-112 e ● 50-145 e ● 50-178 e

● 50-80 e ● 50-113 e ● 50-146 e ● 50-179 e

● 50-81 e ● 50-114 e ● 50-147 e ● 50-180 e

● 50-82 e ● 50-115 e ● 50-148 e ● 50-181 e

● 50-83 e ● 50-116 e ● 50-149 e ● 50-182 e

● 50-84 e ● 50-117 e ● 50-150 e ● 50-183 e

● 50-85 e ● 50-118 e ● 50-151 e ● 50-184 e

● 50-86 e ● 50-119 e ● 50-152 e ● 50-185 e

● 50-87 e ● 50-120 e ● 50-153 e ● 50-186 e

● 50-88 e ● 50-121 e ● 50-154 e ● 50-187 e

● 50-89 e ● 50-122 e ● 50-155 e ● 50-188 e

● 50-90 e ● 50-123 e ● 50-156 e ● 50-189 e

● 50-91 e ● 50-124 e ● 50-157 e ● 50-190 e

● 50-92 e ● 50-125 e ● 50-158 e ● 50-191 e

● 50-93 e ● 50-126 e ● 50-159 e ● 50-192 e

● 50-94 e ● 50-127 e ● 50-160 e ● 50-193 e

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● 50-194 e ● 50-227 e ● 50-260 e ● 50-293 e

● 50-195 e ● 50-228 e ● 50-261 e ● 50-294 e

● 50-196 e ● 50-229 e ● 50-262 e ● 50-295 e

● 50-197 e ● 50-230 e ● 50-263 e ● 50-296 e

● 50-198 e ● 50-231 e ● 50-264 e ● 50-297 e

● 50-199 e ● 50-232 e ● 50-265 e ● 50-298 e

● 50-200 e ● 50-233 e ● 50-266 e ❍ 50-299 e

● 50-201 e ● 50-234 e ● 50-267 e ❍ 50-300 e

● 50-202 e ● 50-235 e ● 50-268 e ❍ 50-301 e

● 50-203 e ● 50-236 e ● 50-269 e ❍ 50-302 e

● 50-204 e ● 50-237 e ● 50-270 e ❍ 50-303 e

● 50-205 e ● 50-238 e ● 50-271 e ❍ 50-304 e

● 50-206 e ● 50-239 e ● 50-272 e ❍ 50-305 e

● 50-207 e ● 50-240 e ● 50-273 e ❍ 50-306 e

● 50-208 e ● 50-241 e ● 50-274 e ❍ 50-307 e

● 50-209 e ● 50-242 e ● 50-275 e ❍ 50-308 e

● 50-210 e ● 50-243 e ● 50-276 e ❍ 50-309 e

● 50-211 e ● 50-244 e ● 50-277 e ❍ 50-310 e

● 50-212 e ● 50-245 e ● 50-278 e ❍ 50-311 e

● 50-213 e ● 50-246 e ● 50-279 e ❍ 50-312 e

● 50-214 e ● 50-247 e ● 50-280 e ❍ 50-313 e

● 50-215 e ● 50-248 e ● 50-281 e ❍ 50-314 e

● 50-216 e ● 50-249 e ● 50-282 e ❍ 50-315 e

● 50-217 e ● 50-250 e ● 50-283 e ❍ 50-316 e

● 50-218 e ● 50-251 e ● 50-284 e ❍ 50-317 e

● 50-219 e ● 50-252 e ● 50-285 e ❍ 50-318 e

● 50-220 e ● 50-253 e ● 50-286 e ❍ 50-319 e

● 50-221 e ● 50-254 e ● 50-287 e ❍ 50-320 e

● 50-222 e ● 50-255 e ● 50-288 e ❍ 50-321 e

● 50-223 e ● 50-256 e ● 50-289 e ❍ 50-322 e

● 50-224 e ● 50-257 e ● 50-290 e ❍ 50-323 e

● 50-225 e ● 50-258 e ● 50-291 e ❍ 50-324 e

● 50-226 e ● 50-259 e ● 50-292 e ❍ 50-325 e

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❍ 50-326 e 90-7
❍ 50-327 e 90-9

❍ 50-328 e 90-11

❍ 50-329 e 90-13
❍ 50-330 e 90-15

❍ 50-331 e ● 90-17 e

❍ 50-332 e 90-19
❍ 50-333 e 90-21

❍ 50-334 e 90-23

❍ 50-335 e 90-25 d

❍ 50-336 e 90-27 d
❍ 50-337 e 90-29

❍ 50-338 e 90-31

❍ 50-339 e 90-33

❍ 50-340 e 90-35

❍ 50-341 e 90-37 d

❍ 50-342 e

❍ 50-343 e

❍ 50-344 e

❍ 50-345 e

❍ 50-346 e

❍ 50-347 e

❍ 50-348 e
❍ 50-349 e

❍ 50-350 e

❍ 50-351 e
❍ 50-352 e

❍ 50-353 e

❍ 50-354 e
90-1

90-3

90-4
90-5

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12
SAFETY
SAFETY NOTICE 00
IMPORTANT SAFETY NOTICE
Proper service and repair is extremely important for the safe operation of your machine. The service and repair techniques
recommended and described in this manual are both effective and safe methods of operation. Some of these operations
require the use of tools specially designed for the purpose.
To prevent injury to workers, the symbols and are used to mark safety precautions in this manual. The cautions
accompanying these symbols should always be followed carefully. If any dangerous situation arises or may possibly arise,
first consider safety, and take the necessary actions to deal with the situation.
GENERAL PRECAUTIONS 00
Mistakes in operation are extremely dangerous. Read the
OPERATION & MAINTENANCE MANUAL carefully
BEFORE operating the machine.
1. Before carrying out any greasing or repairs, read all the
precautions given on the decals which are fixed to the
machine.
2. When carrying out any operation, always wear safety
shoes and helmet. Do not wear loose work clothes, or
clothes with buttons missing.
• Always wear safety glasses when hitting parts with
a hammer.
• Always wear safety glasses when grinding parts
with a grinder, etc.
3. If welding repairs are needed, always have a trained,
experienced welder carry out the work. When carrying
out welding work, always wear welding gloves, apron,
glasses, cap and other clothes suited for welding work.
4. When carrying out any operation with two or more
workers, always agree on the operating procedure
before starting. Always inform your fellow workers
before starting any step of the operation. Before starting
work, hang UNDER REPAIR signs on the controls in
the operator's compartment.
5. Keep all tools in good condition and learn the correct
way to use them.
6. Decide a place in the repair workshop to keep tools and
removed parts. Always keep the tools and parts in their
correct places. Always keep the work area clean and
make sure that there is no dirt or oil on the floor. Smoke
only in the areas provided for smoking. Never smoke
while working.
SAFETY
00
00
PREPARATIONS FOR WORK 00
1. Before adding oil or making repairs, park the machine
on hard, level ground, and block the wheels or tracks to
prevent the machine from moving.
2. Before starting work, lower blade, ripper, bucket or any
other work equipment to the ground. If this is not
possible, insert the safety pin or use blocks to prevent
the work equipment from falling. In addition, be sure to
lock all the control levers and hang warning signs on
them.
3. When disassembling or assembling, support the
machine with blocks, jacks or stands before starting
work.
4. Remove all mud and oil from the steps or other places
used to get on and off the machine. Always use the
handrails, ladders or steps when getting on or off the
machine. Never jump on or off the machine. If it is
impossible to use the handrails, ladders or steps, use a
stand to provide safe footing.
PRECAUTIONS DURING WORK 00
1. When removing the oil filler cap, drain plug or
hydraulic pressure measuring plugs, loosen them slowly
to prevent the oil from spurting out. Before
disconnecting or removing components of the oil, water
or air circuits, first remove the pressure completely from
the circuit.
2. The water and oil in the circuits are hot when the engine
is stopped, so be careful not to get burned. Wait for the
oil and water to cool before carrying out any work on
the oil or water circuits.
3. Before starting work, remove the leads from the battery.
ALWAYS remove the lead from the negative (-)
terminal first.
00-3
FOREWORD SAFETY
12
4. When raising heavy components, use a hoist or crane. Check that the wire rope, chains and hooks are free from damage.
Always use lifting equipment which has ample capacity. Install the lifting equipment at the correct places. Use a hoist or
crane and operate slowly to prevent the component from hitting any other part. Do not work with any part still raised by
the hoist or crane.

5. When removing covers which are under internal pressure or under pressure from a spring, always leave two bolts in
position on opposite sides. Slowly release the pressure, then slowly loosen the bolts to remove.

6. When removing components, be careful not to break or damage the wiring. Damaged wiring may cause electrical fires.

7. When removing piping, stop the fuel or oil from spilling out. If any fuel or oil drips on to the floor, wipe it up immediately.
Fuel or oil on the floor can cause you to slip, or can even start fires.

8. Never use flammable liquids to clean parts, use only non-flammable approved cleaning solutions to clean parts.

9. Be sure to assemble all parts again in their original places. Replace any damaged part with new parts.
• When installing hoses and wires, be sure that they will not be damaged by contact with other parts when the machine
is being operated.

10. When installing high pressure hoses, make sure that they are not twisted. Damaged tubes are dangerous, so be extremely
careful when installing tubes for high pressure circuits. Also check that connecting parts are correctly installed.

11. When assembling or installing parts, always use the specified tightening torques. When installing protective parts such as
guards, or parts which vibrate violently or rotate at high speed, be particularly careful to check that they are installed
correctly.

12. When aligning two holes, never insert your fingers or hand. Be careful not to get your fingers caught in a hole.

13. When measuring hydraulic pressure, check that the measuring tool is correctly assembled before taking any
measurements.

14. Take care when removing or installing the tracks of track-type machines. When removing the track, the track separates
suddenly, so never let anyone stand at either end of the track.

00-4
FOREWORD GENERAL
12
GENERAL 00

This shop manual has been prepared as an aid to improve the quality of repairs by giving the serviceman an accurate
understanding of the product and by showing him the correct way to perform repairs and make judgements. Make sure you
understand the contents of this manual and use it to full effect at every opportunity.

This shop manual mainly contains the necessary technical information for operations performed in a service workshop. For
ease of understanding, the manual is divided into the following sections. These sections are further divided into each main
group of components.

GENERAL

This section lists the general machine dimensions, performance specifications, component weights, and fuel, coolant and
lubricant specification charts.

STRUCTURE, FUNCTION AND MAINTENANCE STANDARD

This section explains the structure and function of each component. It serves not only to give an understanding of the
structure, but also serves as reference material for troubleshooting. In addition, this section gives the judgement standards
when inspecting disassembled parts.

TESTING AND ADJUSTING

This section explains checks to be made before and after performing repairs, as well as adjustments to be made at
completion of the checks and repairs.

TROUBLESHOOTING

Troubleshooting charts correlating “Problems” to “Causes” are also included in this section.

DISASSEMBLY AND ASSEMBLY

This section explains the order to be followed when removing, installing, disassembling or assembling each component,
as well as precautions to be taken for these operations.

OTHER

This section has the foldout drawings for the machine.

NOTICE

The specifications contained in this shop manual are subject to change at any time and without any advance notice. Contact
your distributor for the latest information.

00-5
FOREWORD HOW TO READ THE SHOP MANUAL
12
HOW TO READ THE SHOP MANUAL 00

VOLUMES 00

REVISIONS 00

Shop manuals are issued as a guide to carrying out repairs.

Revised pages are shown at the LIST OF REVISED PAGES
They are divided as follows:
between the title page and SAFETY page.
Chassis volume: Issued for every machine model
Engine volume: Issued for each engine series SYMBOLS 00

Electrical volume: Each issued as one to cover all models So that the shop manual can be of ample practical use,
Attachment volume: Each issued as one to cover all models important places for safety and quality are marked with the
following symbols.
These various volumes are designed to avoid duplication of
information. Therefore to deal with all repairs for any model, Symbol Item Remarks
it is necessary that chassis, engine, electrical and attachment
be available. Special safety precautions are
Safety necessary when performing the
work.
DISTRIBUTION AND UPDATING 00

Special technical precautions or

Any additions, amendments or other changes will be sent to other precautions for preserving
★ Caution
your distributors. Get the most up-to-date information before standards are necessary when
you start any work. performing the work.
Weight of parts or systems.
FILING METHOD 00
Caution necessary when
Weight selecting hoisting wire or when
1. See the page number on the bottom of the page. File the working posture is important,
pages in correct order. etc.
2. Following examples show how to read the page number:
Example: Places that require special
Tightening
attention for tightening torque
torque
10 - 3 during assembly.
Places to be coated with
Item number (10. Structure and Function) Coat
adhesives and lubricants etc.
Consecutive page number for each item Places where oil, water or fuel
Fill
must be added, and the capacity.
3. Additional pages: Additional pages are indicated by a
hyphen (-) and numbered after the page number. File as Places where oil or water must
in the example. Drain be drained, and quantity to be
Example: drained.
10-4
10-4-1
Added pages
10-4-2

10-5

REVISED EDITION MARK 00

When a manual is revised, an edition mark (123…) is

recorded on the bottom outside corner of the pages.

00-6
FOREWORD HOISTING INSTRUCTIONS
12
HOISTING INSTRUCTIONS 00

HOISTING 00
can result. Hooks have maximum strength at the middle
portion.
WARNING! Heavy parts (25 kg or more)
must be lifted with a hoist etc.
In the DISASSEMBLY AND
ASSEMBLY section, every
part weighing 25 kg or more is
indicated clearly with the
symbol.

● If a part cannot be smoothly removed from the machine

by hoisting, the following checks should be made: 3. Do not sling a heavy load with one rope alone, but sling
1. Check for removal of all bolts fastening the part to the with two or more ropes symmetrically wound on to the
relative parts. load.
2. Check for existence of another part causing interface
with the part to be removed. WARNING! Slinging with one rope may
cause turning of the load
WIRE ROPES 00

during hoisting, untwisting of

the rope, or slipping of the
1. Use adequate ropes depending on the weight of parts to rope from its original winding
be hoisted, referring to the table below: position on the load, which
Wire ropes can result in a dangerous
(Standard “Z” or “S” twist ropes without galvanizing) accident

Rope diameter Allowable load 4. Do not sling a heavy load with ropes forming a wide
hanging angle from the hook. When hoisting a load with
mm kN tons
two or more ropes, the force subjected to each rope will
10 9.8 1.0 increase with the hanging angles. The table below
shows the variation of allowable load (kg) when
11.2 13.7 1.4
hoisting is made with two ropes, each of which is
12.5 15.7 1.6 allowed to sling up to 1000 kg vertically, at various
hanging angles. When two ropes sling a load vertically,
14 21.6 2.2
up to 2000 kg of total weight can be suspended. This
16 27.5 2.8 weight becomes 1000 kg when two ropes make a 120°
hanging angle. On the other hand, two ropes are subject
18 35.3 3.6
to an excessive force as large as 4000 kg if they sling a
20 43.1 4.4 2000 kg load at a lifting angle of 150°.
22.4 54.9 5.6
30 98.1 10.0
40 176.5 18.0
50 274.6 28.0
60 392.2 40.0

★ The allowable load value is estimated to be 1/6 or 1/7 of

the breaking strength of the rope used.Sling wire ropes
from the middle portion of the hook.
2. Slinging near the edge of the hook may cause the rope to
slip off the hook during hoisting, and a serious accident

00-7
FOREWORD PUSH PULL COUPLER
12
PUSH PULL COUPLER 00

WARNING! Before carrying out the following work,

release the residual pressure from the
hydraulic tank. For details, see TESTING
AND ADJUSTING, Releasing residual
pressure from hydraulic tank.

WARNING! Even if the residual pressure is released from

the hydraulic tank, some hydraulic oil flows
out when the hose is disconnected.
Accordingly, prepare an oil receiving
container.

TYPE 1 00

DISCONNECTION 00

1. Release the residual pressure from the hydraulic tank. For details,
see TESTING AND ADJUSTING, Releasing residual pressure
from hydraulic tank.
2. Hold the adapter (1) and push the hose joint (2) into the mating
adapter (3). The adapter can be pushed in about 3.5 mm. Do not
hold the rubber cap portion (4).
3. After the hose joint (2) is pushed into the adapter (3), press the
rubber cap portion (4) against the adapter until it clicks.

4. Hold the hose adapter (1) or hose (5) and pull it out. Since some
hydraulic oil flows out, prepare an oil receiving container.

CONNECTION 00

1. Hold the hose adapter (1) or hose (5) and insert it in the mating
adapter (3), aligning them with each other. Do not hold the rubber
cap portion (4).
2. After inserting the hose in the mating adapter, pull it back to check
its connecting condition. When the hose is pulled back, the rubber
cap portion moves toward the hose about 3.5 mm. This does not
indicate an abnormality.

00-8
FOREWORD PUSH PULL COUPLER

TYPE 2 00

DISCONNECTION 00

1. Hold the mouthpiece of the tightening portion and push body (2) in
straight until sliding prevention ring (1) contacts contact surface a
of the hexagonal portion at the male end.

2. Hold in the condition in Step 1, and turn the lever (4) to the
right - clockwise.

3. Hold in the condition in Steps 1 and 2, and pull out the whole body
(2) to disconnect it.

CONNECTION 00

1. Hold the connector of the tightening portion and push body (2) in
straight until sliding prevention ring (1) contacts surface a of the
hexagonal portion at the male end to connect it.

00-9
Komatsu Bulldozer D51ex 22 D51px 22shop Manual Shop Manual
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FOREWORD PUSH PULL COUPLER
12
TYPE 3 00

DISCONNECTION 00

1. Hold the connector of the tightening portion and push the body (2)
in straight until sliding prevention ring (1) contacts surface a of the
hexagonal portion at the male end.

2. Hold in the condition in Step 1, and push until the cover (3)
contacts surface a of the hexagonal portion at the male end.

3. Hold in the condition in Steps 1 and 2, and pull out the whole body
(2) to disconnect it.

CONNECTION 00

1. Hold the connector of the tightening portion and push the body (2)
in straight until the slide prevention ring (1) contacts surface a of
the hexagonal portion at the male end to connect it.

00-10
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