Komatsu D61EX-12 D61PX-12 Wheel Loader Shop Manual SEBM018906 PDF

Description

Komatsu D61EX-12 D61PX-12 Wheel Loader Shop Manual SEBM018906 – PDF DOWNLOAD

FILE DETAILS:

Komatsu D61EX-12 D61PX-12 Wheel Loader Shop Manual SEBM018906 – PDF DOWNLOAD 

Language : English
Pages : 713
Downloadable : Yes
File Type : PDF

IMAGES PREVIEW OF THE MANUAL:

TABLE OF CONTENTS:

Komatsu D61EX-12 D61PX-12 Wheel Loader Shop Manual SEBM018906 – PDF DOWNLOAD 

MACHINE MODEL    SERIAL NUMBER
D61EX-12                     1001 and up
D61EX-12                      B1001 and up
D61PX-12                     1001 and up
D61PX-12                     B1001 and up

MAIN MENU 0
COVER 1
CONTENTS 2
SAFETY 7
FORWARD 9
01 GENERAL 27
SPECIFICATION DRAWING 28
SPECIFICATIONS 30
WEIGHT TABLE 41
TABLE OF FUEL COOLANT AND LUBRICANTS 45
10 STRUCTURE AND FUNCTION 47
RADIATOR, POWER TRAIN, OIL COOLER 48
ENGINE CONTROL 50
POWER TRAIN SYSTEM 51
POWER TRAIN SKELETON 52
POWER TRAIN UNIT 53
POWER TRAIN HYDRAULIC PIPING DIAGRAM 54
DAMPER, UNIVERSAL JOINT 55
TORQUE CONVERTER AND PTO 57
TRANSMISSION CONTROL 60
TRANSMISSION 61
TRANSMISSION CONTROL VALVE 68
MAIN RELIEF VALVE 73
LUBRICATION RELIEF VALVE 75
STEERING AND BRAKE CONTROL 76
BEVEL GEAR SHAFT, HSS STEERING, STEERING BRAKE 77
BRAKE VALVE 87
SCAVENGING PUMP STRAINER 91
POWER TRAIN OIL STRAINER 92
POWER TRAIN OIL FILTER 93
FINAL DRIVE 94
MAIN FRAME 97
TRACK FRAME 98
RECOIL SPRING 99
SUSPENSION 100
WORK EQUIPMENT HYDRAULIC PIPING DIAGRAM 102
PPC CONTROL PIPING DIAGRAM 104
WORK EQUIPMENT CONTROL 105
HYDRAULIC TANK AND FILTER 106
HYDRAULIC AND HSS PUMP SERIAL NO 1001 – 1173, SERIAL NO B1001 – B3000, MODEL HPV82 108
HYDRAULIC AND HSS PUMP SERIAL NO B3001 AND UP MODEL: HPV95 123
SERVO VALVE 129
PPC VALVE SERIAL NO 1001 – 1173, SERIAL NO B1001 – B3000 143
PPC VALVE SERIAL NO B3001 AND UP 150
PPC CHARGE VALVE 158
MAIN CONTROL VALVE SERIAL NO 1001 – 1173, SERIAL NO B1001 – B3000 160
MAIN CONTROL VALVE SERIAL NO B3001 AND UP 166
CLSS 172
HSS MOTOR SERIAL NO 1001 – 1173, SERIAL NO B1001 – B3000 196
HSS MOTOR SERIAL NO B3001 AND UP 201
SUCTION VALVE 207
WORK EQUIPMENT 209
ENGINE CONTROL 212
MACHINE MONITOR SYSTEM 213
SENSORS 217
20 TESTING AND ADJUSTING 221
STANDARD VALUE TABLE FOR ENGINE 222
STANDARD VALUE TABLE FOR CHASSIS 224
STANDARD VALUE TABLE FOR ELECTRICAL SYSTEM 234
TESTING AND ADJUSTING 237
TOOLS FOR TESTING, ADJUSTING, AND TROUBLESHOOTING 238
MEASURING BLOW-BY PRESSURE 239
MEASURING EXHAUST COLOR 240
MEASURING ENGINE OIL PRESSURE 241
MEASURING ENGINE SPEED 242
TESTING FAN BELT TENSION 243
TESTING AND ADJUSTING BELT TENSION OF AIR CONDITIONER COMPRESSOR 244
MEASURING SPEED AT TORQUE CONVERTER STALL 246
ADJUSTING FUEL CONTROL LINKAGE 247
ADJUSTING LINKAGES OF FORWARD-REVERSE LEVER, GEAR SHIFT LEVER, AND PARKING BRAKE LEVER 249
ADJUSTING BRAKE PEDAL LINKAGE 251
ADJUSTING WORK EQUIPMENT LOCK LEVER 252
ADJUSTING STRAIGHT TILTDOZER 253
ADJUSTING PPC VALVE 255
MEASURING POWER TRAIN HYDRAULIC PRESSURE 256
MEASURING AND ADJUSTING WORK EQUIPMENT AND STEERING OIL PRESSURE 259
TESTING AND ADJUSTING CONTROL CIRCUIT PRESSURE 261
MEASURING PPC VALVE OUTPUT PRESSURE 262
MEASURING OIL LEAKAGE FROM HSS MOTOR 263
MEASURING LINKAGE INSIDE CYLINDER 263
BLEEDING AIR FROM HYDRAULIC CYLINDER 264
PROCEDURE OF SIMPLE TEST OF STEERING BRAKE PERFORMANCE 265
TROUBLESHOOTING 267
POINTS TO REMEMBER WHEN TROUBLESHOOTING 268
SEQUENCE OF EVENTS IN TROUBLESHOOTING 269
POINTS TO REMEMBER WHEN CARRYING OUT MAINTENANCE 270
CHECKS BEFORE TROUBLESHOOTING 278
CONNECTOR TYPES AND MOUNTING LOCATIONS 279
CONNECTOR PIN ARRANGEMENT DIAGRAM 280
CONNECTION TABLE FOR CONNECTOR PIN NUMBERS 282
HOW TO FOLLOW THE TROUBLESHOOTING FLOW DIAGRAMS 305
TROUBLESHOOTING OF ELECTRICAL SYSTEM (E MODE) 307
TABLE OF FAILURE MODES AND CAUSES (ELECTRICAL SYSTEM) 308
ELECTRICAL CIRCUIT DIAGRAM FOR EACH SYSTEM 309
E-1 STARTING MOTOR IS NOT CRANKED WHEN STARTING SWITCH IS TURNED TO ON 314
E-2 LAMPS DO NOT LIGHT UP 316
E-3 AUTOMATIC PREHEATING IS NOT CARRIED OUT WHEN GLOW SWITCH IS TURNED TO AUTO 318
E-4 WIPER DOES NOT WORK 320
E-5 NO WASHER FLUID IS SPRAYED OUT 322
E-6 AIR CONDITIONER HAS NO EFFECT 324
E-7 ENGINE DOES NOT START (ENGINE STOP SOLENOID MALFUNCTIONS) 332
TROUBLESHOOTING OF HYDRAULIC, MECHANICAL SYSTEM (H MODE) 335
TABLE OF FAILURE MODES AND CAUSES (HYDRAULIC, MECHANICAL SYSTEM) 336
H-1 BRAKE DOES NOT WORK 338
H-2 TURNING SPEED IS SLOW (CANNOT TURN) OR LACKS POWER WHEN TURNING 340
H-3 EXCESSIVE TIME LAG 342
H-4 MACHINE CAN TRAVEL IN ONLY ONE DIRECTION (FORWARD OR REVERSE) 342
H-5 MACHINE DOES NOT MOVE (WHEN ENGINE IS STARTED AND LEVER IS SHIFTED TO 2ND OR 3RD) 344
H-6 MACHINE DOES NOT MOVE IN ANY SPEED RANGE 346
H-7 POWER TRAIN OIL TEMPERATURE RISES TOO HIGH 348
H-8 DRAWBAR PULL IS WEAK, TRAVEL SPEED IS SLOW 350
H-9 ABNORMAL NOISE IS GENERATED FROM AROUND HYDRAULIC, HSS PUMP 351
H-10 WORK EQUIPMENT SPEED IS SLOW OR LACKS POWER 352
H-11 NO WORK EQUIPMENT MOVES 352
H-12 TURNING SPEED AND SPEED OF ALL WORK EQUIPMENT IS SLOW 353
H-13 MACHINE CANNOT TURN 354
H-14 TURNING LACKS POWER 354
H-15 BLADE LIFT OR TILT CYLINDER SPEED IS SLOW OR LACKS POWER 355
H-16 BLADE ANGLE CYLINDER SPEED IS SLOW OR LACKS POWER 356
H-17 HYDRAULIC DRIFT OF BLADE LIFT IS EXCESSIVE 357
H-18 HYDRAULIC DRIFT OR BLADE LIFT IS EXCESSIVE 357
H-19 HYDRAULIC DRIFT OF BLADE ANGLE IS EXCESSIVE 358
TROUBLESHOOTING OF MACHINE MONITOR SYSTEM (M MODE) 359
TABLE OF FAILURE MODES AND CAUSES (MACHINE MONITOR SYSTEM) 360
ELECTRICAL CIRCUIT DIAGRAM FOR EACH SYSTEM 362
M-1 NO DISPLAY IS GIVEN ON MONITOR PANEL WHEN STARTING SWITCH IS TURNED TO ON 366
M-2 WHEN STARTING SWITCH IS TURNED TO ON, ALL MONITOR PANEL LAMPS LIGHT UP AND DO NOT GO OUT 366
M-3 PREHEATING IS ABNORMAL 367
A) PREHEATING MONITOR DOES NOT LIGHT UP 367
B) PREHEATING MONITOR DOES NOT GO OFF 367
M-4 CAUTION ITEMS LIGHT UP OR FLASH 369
A) CHARGE LIGHTS UP OR FLASHES 369
B) WHEN STARTING SWITCH IS TURNED TO ON AND ENGINE IS STARTED, (ENGINE OIL PRESSURE) LIGHTS UP OR FLASHES 370
C) (COOLANT TEMPERATURE) FLASHES 371
D) (POWER TRAIN OIL TEMPERATURE) FLASHES 372
M-5 BUZZER IS ABNORMAL 373
A) CAUTION ITEM FLASHES BUT BUZZER DOES NOT SOUND 373
B) MONITOR DISPLAY IS NORMAL, BUT BUZZER SOUNDS 373
M-6 WARNING LAMP IS ABNORMAL 374
A) CAUTION ITEM IS FLASHING BUT LAMP DOES NOT FLASH 374
B) MONITOR DISPLAY IS NORMAL BUT LAMP FLASHES 374
M-7 GAUGE IS ABNORMAL 375
A) ABNORMALITY IN ENGINE COOLANT TEMPERATURE GAUGE 375
B) ABNORMALITY IN POWER TRAIN OIL TEMPERATURE GAUGE 376
C) ABNORMALITY IN FUEL LEVEL GAUGE 377
M-8 SERVICE MOTOR DOES NOT MOVE AFTER ENGINE IS STARTED 378
M-9 MONITOR MANEL LIGHTING DOES NOT LIGHT UP (FRONT LAMPS ARE NORMAL) 379
30 DISASSEMBLY AND ASSEMBLY 0
METHOD OF USING MANUAL 0
PRECAUTIONS WHEN CARRYING OUT OPERATION 387
SPECIAL TOOL LIST 389
SKETCHES OF SPECIAL TOOLS 395
ENGINE 398
REMOVAL 398
INSTALLATION 399
RADIATOR AND GAURD 400
REMOVAL 400
INSTALLATION 401
RADIATOR 402
REMOVAL 402
INSTALLATION 404
HYDRAULIC OIL COOLER 405
REMOVAL 405
INSTALLATION 405
FUEL TANK 406
REMOVAL 406
INSTALLATION 407
DAMPER 409
REMOVAL 409
INSTALLATION 411
PTO, TORQUE CONVERTER AND TRANSMISSION 413
REMOVAL 413
INSTALLATION 417
DISCONNECTION 418
CONNECTION 419
PTO 420
DISASSEMBLY 420
ASSEMBLY 424
TORQUE CONVERTER 428
DISASSEMBLY 428
ASSEMBLY 430
TORQFLOW TRANSMISSION 433
DISASSEMBLY 433
ASSEMBLY 443
TORQUE CONVERTER MAIN RELIEF VALVE 458
REMOVAL 458
INSTALLATION 458
DISASSEMBLY 459
ASSEMBLY 459
TRANSMISSION CONTROL VALVE 460
REMOVAL 460
INSTALLATION 460
DISASSEMBLY 462
ASSEMBLY 462
STEERING BRAKE 464
REMOVAL 464
INSTALLATION 464
DISASSEMBLY 465
ASSEMBLY 468
HSS 471
REMOVAL 471
INSTALLATION 478
BRAKE VALVE 486
REMOVAL 486
INSTALLATION 486
DISASSEMBLY 487
ASSEMBLY 488
HSS MOTOR 489
REMOVAL 489
INSTALLATION 489
DISASSEMBLY 490
ASSEMBLY 494
SCAVENGING PUMP 0
REMOVAL 0
INSTALLATION 0
POWER TRAIN AND LUBRICATING OIL PUMP 0
REMOVAL 0
INSTALLATION 0
FINAL DRIVE 0
REMOVAL 0
INSTALLATION 0
DISASSEMBLY 0
ASSEMBLY 0
TRACK FRAME 0
REMOVAL 0
INSTALLATION 0
RECOIL SPRING 0
REMOVAL 0
INSTALLATION 0
DISASSEMBLY 0
ASSEMBLY 0
IDLER 0
REMOVAL 0
INSTALLATION 0
DISASSEMBLY 0
ASSEMBLY 0
TRACK ROLLER 0
REMOVAL 0
INSTALLATION 0
DISASSEMBLY 0
ASSEMBLY 0
CARRIER ROLLER 0
REMOVAL 0
INSTALLATION 0
DISASSEMBLY 0
ASSEMBLY 0
TRACK SHOE 0
CHECKING BEFORE REMOVAL 0
REMOVAL (NORMAL) 0
REMOVAL (WHEN THERE IS ABNORMALITY INSIDE TRACK FRAME) 0
INSTALLATION 0
OVERALL DISASSEMBLY 548
OVERALL ASSEMBLY 553
PRESS-FITTING JIG DIMENTION TABLE FOR LINK PRESS 567
ONE LINK 568
FIELD DISASSEMBLY 568
FIELD ASSEMBLY 569
PIVOT SHAFT 575
REMOVAL 575
INSTALLATION 575
EQUALIZER BAR 576
REMOVAL 576
INSTALLATION 577
EQUALIZER BAR SIDE BUSHING 578
REMOVAL 578
INSTALLATION 578
SEGMENT TEETH 579
REMOVAL 579
INSTALLATION 579
HSS AND HYDRAULIC PUMP 580
REMOVAL 580
INSTALLATION 580
DISASSEMBLY 581
ASSEMBLY 586
PPC PUMP AND PPC CHARGE RELIEF VALVE 595
REMOVAL 595
INSTALLATION 595
DISASSEMBLY 596
ASSEMBLY 596
MAIN CONTROL VALVE 597
REMOVAL 597
INSTALLATION 598
DISASSEMBLY 599
ASSEMBLY 605
STEERING PPC VALVE 612
REMOVAL 612
INSTALLATION 613
DISASSEMBLY 614
ASSEMBLY 615
SUCTION VALVE 616
REMOVAL 616
INSTALLATION 616
BLADE ANGLE CYLINDER 617
REMOVAL 617
INSTALLATION 617
BLADE TILT CYLINDER 618
REMOVAL 618
INSTALLATION 618
BLADE LIFT CYLINDER 619
REMOVAL 619
INSTALLATION 619
HYDRAULIC CYLINDER 620
DISASSEMBLY 620
ASSEMBLY 622
WORK EQUIPMENT 625
REMOVAL 625
INSTALLATION 626
DISASSEMBLY 627
ASSEMBLY 629
ROPS GUARD (ROPS CANOPY) 631
REMOVAL 631
INSTALLATION 631
DASHBOARD 632
REMOVAL 632
INSTALLATION 632
MONITOR PANEL 633
REMOVAL 633
INSTALLATION 633
FLOOR FRAME 634
REMOVAL 634
INSTALLATION 0
40 MAINTENANCE STANDARD 649
DAMPER, UNIVERSAL JOINT 650
TORQUE CONVERTER, PTO 652
TRANSMISSION 654
TRANSMISSION CONTROL VALVE 656
MAIN RELIEF VALVE 657
BEVEL GEAR SHAFT, HSS STEERING, BRAKE 658
BRAKE VALVE 664
WORK EQUIPMENT, HSS PUMP 665
HSS MOTOR 668
POWER TRAIN LUBRICATION PUMP 671
PCC CONTROL PUMP 672
PPC VALVE 673
PPC CHARGE VALVE 674
FINAL DRIVE 675
TRACK FRAME, RECOIL SPRING 676
IDLER 677
TRACK ROLLER 678
CARRIER ROLLER 679
TRACK SHOE 680
DIMENSIONS OF SHAPE OF SPROCKET TOOTH (ACTUAL SIZE) 682
SUSPENSION 684
MAIN CONTROL VALVE 686
WORK EQUIPMENT CYLINDER 694
WORK EQUIPMENT 698
CUTTING EDGE AND BIT 704
RIPPER 706
90 OTHERS 707
ELECTRIC CIRCUIT DIAGRAM FOR CAB 708
POWER TRAIN HYDRAULIC CIRCUIT DIAGRAM 709
STEERING- WORK EQUIPMENT HYDRAULIC CIRCUIT DIAGRAM SERIAL NO 1001 – 1173, SERIAL NO B1001 – B3000 710
STEERING- WORK EQUIPMENT HYDRAULIC CIRCUIT DIAGRAM SERIAL NO B3001 AND UP 711
ELECTRIC CIRCUIT DIAGRAM SERIAL NO 1001 – 1173, SERIAL NO B1001 – B3000 CAB SPECIFICATION 712
ELECTRIC CIRCUIT DIAGRAM SERIAL NO B3001 AND UP CAB SPECIFICATION 713
ELECTRIC CIRCUIT DIAGRAM SERIAL NO 1001 – 1173, SERIAL NO B1001 – B3000 CANOPY SPECIFICATION 714
ELECTRIC CIRCUIT DIAGRAM SERIAL NO B3001 CANOPY SPECIFICATION 715

DESCRIPTION:

Komatsu D61EX-12 D61PX-12 Wheel Loader Shop Manual SEBM018906 – PDF DOWNLOAD 

MACHINE MODEL    SERIAL NUMBER
D61EX-12                     1001 and up
D61EX-12                      B1001 and up
D61PX-12                     1001 and up
D61PX-12                     B1001 and up

GENERAL PRECAUTIONS :

Mistakes in operation are extremely dangerous. Read the OPERATION & MAINTENANCE MANUAL carefully BEFORE operating the machine.

PREPARATIONS FOR WORK:

PRECAUTIONS DURING WORK :

S.V 29/12/24