Komatsu D61EX-15,D61PX-15 Bulldozer Shop Manual WE051Z0002 – PDF DOWNLOAD

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Komatsu D61EX-15,D61PX-15 Bulldozer Shop Manual WE051Z0002 – PDF DOWNLOAD

FILE DETAILS:

Komatsu D61EX-15,D61PX-15 Bulldozer Shop Manual WE051Z0002 – PDF DOWNLOAD

Language : English
Pages : 988
Downloadable : Yes
File Type : PDF

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TABLE OF CONTENTS:

Komatsu D61EX-15,D61PX-15 Bulldozer Shop Manual WE051Z0002 – PDF DOWNLOAD

MACHINE MODEL SERIAL NUMBER

• D61EX-15                B40001 and up
• D61PX-15                B40001 and up

MAIN MENU . 0
COVER . 1
TABLE OF GENERAL CONTENTS . 4
GENERAL – FOREWARD 11
SAFETY 12
FOREWARD 14
01 GENERAL 33
Specification dimension drawing . 34
Specifications 35
Weight table 40
Oil and coolant table . 44
10 GENERAL – STRUCTURE AND FUNCTION, MAINTENANCE STANDARD . 47
Engine and cooling related components . 48
Cooling system 48
Power transmitting system . 50
Power train . 50
Power train skeleton 51
Overall drawing of power train unit . 52
Hydraulic piping diagram of power train . 53
Damper and universal joint 54
Transmission, steering, and brake control . 56
Power transmitting system . 61
Torque converter and PTO 61
Transmission 66
Transmission ECMV . 78
Main relief valve . 84
Lubricating oil relief valve 86
Power transmitting system . 88
Scavenging pump . 88
Power train and lubrication pump 89
HSS system 90
Power transmitting system . 94
HSS pump 94
HSS motor .112
Power transmitting system .120
Bevel gear shaft, HSS, and brake 120
Brake valve .136
Final drive .142
Undercarriage and frame .149
Frame assembly 149
Suspension 150
Track frame and recoil spring .154
Idler .158
Track roller 160
Carrier roller 161
Sprocket 162
Track shoe 164
Hydraulic system 168
Layout of hydraulic devices for work equipment 168
Work equipment control 170
Hydraulic tank and filter .172
Solenoid valve 174
Accumulator .176
Hydraulic cylinder 178
Piston valve 182
Quick drop valve 183
Hydraulic system 186
Cooling fan pump 186
Cooling fan motor .194
PPC valve .200
Electric lever (Steering) .216
Hydraulic system 220
Control valve .220
CLSS 228
Self-pressure reducing valve 255
Work equipment 264
Work equipment 264
Cutting edge and end bit 270
Ripper 271
Cab and its attachments .272
Cab mount .272
Cab .273
Air conditioner piping 275
Electric system .278
Engine control system .278
Cooling system control system .280
Palm command control system .282
PPC lock system .284
Component parts of system .285
Monitor system 290
Monitor panel .292
Sensor 296
20 TESTING, ADJUSTING & TROUBLESHOOTING .301
Standard value table 301
Standard value table for engine .302
Standard value table for chassis 303
Testing and adjusting .315
Testing and adjusting (1/2) .317
Tools for testing, adjusting and troubleshooting 317
Measuring engine speed 319
Measuring intake air pressure (boost pressure) 321
Measuring exhaust color .322
Adjusting valve clearance .323
Measuring compression pressure 326
Measuring blow-by pressure 328
Testing and adjusting fuel injection timing .329
Measuring engine oil pressure .332
Testing and adjusting air conditioner compressor belt tension .333
Adjusting engine speed sensor .333
Adjusting fuel control linkage 334
Measuring power train oil pressure 338
Adjusting transmission speed sensor (replacement procedure) .342
Simple method of testing brake performance 343
Adjusting brake pedal .344
Adjusting parking brake lever .346
Emergency escape method when power train has a trouble 347
Adjusting idler clearance .351
Inspecting wear of sprocket .351
Testing and adjusting track shoe tension 352
Testing and adjusting work equipment and HSS oil pressure .353
Testing control circuit main pres sure 357
Measuring PPC valve output pres sure 358
Adjusting play of work equipment PPC valve 361
Measuring internal leakage of work equipment cylinder .362
Adjusting safety lock lever of work equipment .363
Releasing residual pressure in work equipment cylinder (If PPC accumulator is not installed) 364
Releasing residual pressure in work equipment cylinder (If PPC accumulator is installed) 364
Bleeding air from work equipment cylinder .365
Measuring fan pump circuit pres sure 366
Measuring fan motor speed .367
Measuring HSS motor oil leakage .368
Bleeding air from fan pump 368
Testing and adjusting operator’s cab 369
Testing and adjusting (2/2) .374
Special functions of monitor panel (EMMS) .374
Adjustment method of replaced controller 406
Preparatory work for troubleshooting for electric system 408
Pm clinic .409
Undercarriage troubleshooting report 416
Troubleshooting .421
Preface .422
Points to remember when troubleshooting .422
Troubleshooting procedure .423
Points to remember when carrying out maintenance 424
Checks before troubleshooting .431
Classification and procedures of troubleshooting 432
Connector arrangement drawing and electric circuit diagram of each system .435
Troubleshooting when error code is displayed (Error code) – CONTENTS 479
Troubleshooting when error code is displayed (Error code) .483
Error code table 483
Information described in troubleshooting list .486
Error code [1500L0] (Transmission clutch: Double engaging) 488
Error code [15SAL1] (Forward clutch: Fill signal is ON when command current is OFF.) 489
Error code [15SALH] (Forward clutch: Fill signal is OFF when command current is ON.) 490
Error code [15SBL1] (Reverse clutch: Fill signal is ON when command current is OFF.) 491
Error code [15SBLH] (Reverse clutch: Fill signal is OFF when command current is ON.) 492
Error code [15SEL1] (1st clutch: Fill signal is ON when command current is OFF.) 493
Error code [15SELH] (1st clutch: Fill signal is OFF when command current is ON.) 494
Error code [15SFL1] (2nd clutch: Fill signal is ON when command current is OFF.) 495
Error code [15SFLH] (2nd clutch: Fill signal is OFF when command current is ON.) 496
Error code [15SGL1] (3rd clutch: Fill signal is ON when command current is OFF.) 497
Error code [15SGLH] (3rd clutch: Fill signal is OFF when command current is ON.) 498
Error code [A000N1] (Engine: Overrun) .499
Error code [AB00MA] (Alternator: Malfunction) .500
Error code [B@BAZG] (Engine oil: Oil pressure reduction) 501
Error code [B@BCNS] (Coolant: Overheating) 502
Error code [B@CENS] (Power train oil: Overheating) 503
Error code [B@HANS] (Hydraulic oil: Overheating) 504
Error code [D110KA] (Battery relay: Short circuit) 505
Error code [D110KB] (Battery relay: Disconnection) 506
Error code [D130KA] (Safety relay: Short circuit) .508
Error code [D130KB] (Safety relay: Disconnection) .510
Error code [D161KA] (Back-up alarm relay: Short circuit) 512
Error code [D161KB] (Back-up alarm relay: Disconnection) 514
Error code [D182KZ] (Preheater relay coil: Disconnection or short circuit) 516
Error code [DAFRKR] (Monitor controller CAN communication: Defective communication (Abnormality in objective component system)) .518
Error code [DAQ0KK] [DB30KK] (Steering and transmission controller: Source voltage reduction/input) .520
Error code [DAQ0KT] (Steering and transmission controller: Abnormality in controller) .522
Error code [DAQ5KK] or [DB35KK] (Steering and transmission controller sensor 5 V power supply: Source voltage reduction) 523
Error code [DAQ6KK] [DB36KK] (Steering and transmission controller sensor 24 V power supply: Source voltage reduction/input) 525
Error code [DAQ9KQ] [DB39KQ] (Steering and transmission controller model collation: Model selection signal inconsistency) .526
Error code [DB3RKR] (Steering and transmission controller CAN communication: Defective communication) .527
Error code [DB30KK] [DAQ0KK] (Steering and transmission controller: Source voltage reduction/input) .529
Error code [DB35KK] [DAQ5KK] (Steering and transmission controller sensor 5 V power supply: Source voltage reduction/input) .529
Error code [DB36KK] [DAQ6KK] (Steering and transmission controller sensor 24 V power supply: Source voltage reduction/input) 529
Error code [DB39KQ] [DAQ9KQ] (Steering and transmission controller model collation: Model selection signal inconsistency) .529
Error code [DD12KA] (Shift up switch: Disconnection) 530
Error code [DD12KB] (Shift up switch: Short circuit) 532
Error code [DD13KA] (Shift down switch: Disconnection) 534
Error code [DD13KB] (Shift down switch: Short circuit) 536
Error code [DD14KA] [DDQ2KA] (Travel lock switch: Disconnection) 538
Error code [DD14KB] [DDQ2KB] (Travel lock switch: Short circuit) 540
Error code [DDE2L6] (Engine oil pressure switch: Signals of engine oil pressure switch are inconsistent with operation state or stop state.) 542
Error code [DDN7KA] (Pitch control switch: Disconnection) .544
Error code [DDN7KB] (Pitch control switch: Short circuit) .545
Error code [DDQ2KA] [DD14KA] (Travel lock switch: Disconnection) 546
Error code [DDQ2KB] [DD14KB] (Travel lock switch: Short circuit) 546
Error code [DGE2KX] (Engine coolant temperature sensor (for high temperature): Input signal is out of normal range) .547
Error code [DGE3L6] (Engine coolant temperature sensor: Signals of engine coolant temperature sensor are inconsistent with operation state or stop state.) 549
Error code [DGS1KX] (Hydraulic oil temperature sensor: Input signal is out of normal range) .551
Error code [DK10KX] (Fuel control dial: Input signal is out of normal range) 552
Error code [DK12KX] (Deceleration pedal potentiometer: Input signal is out of normal range) .554
Error code [DK30KA] (Steering potentiometer 1: Disconnection) .556
Error code [DK30KB] (Steering potentiometer 1: Short circuit) .558
Error code [DK30KX] (Steering potentiometer 1: Input signal is out of normal range) .560
Error code [DK30KZ] (Steering potentiometer 1: Disconnection or short circuit) 561
Error code [DK30L8] (Steering potentiometer 1: Disagreement of analog signals) 562
Error code [DK31KA] (Steering potentiometer 2: Short circuit) .563
Error code [DK31KB] (Steering potentiometer 2: Disconnection) .565
Error code [DK40KA] (Brake potentiometer: Short circuit) 567
Error code [DK40KB] (Brake potentiometer: Disconnection) 569
Error code [DK54KZ] (Governor motor potentiometer: Disconnection or short circuit) 571
Error code [DK55KX] (Forward-reverse potentiometer: Input signal is out of normal range) 573
Error code [DK55KZ] (Forward-reverse potentiometer 1: Disconnection or short circuit) .574
Error code [DK55L8] (Forward-reverse potentiometer: Disagreement of analog signals) .575
Error code [DK56KA] (Forward-reverse potentiometer 1: Short circuit) 576
Error code [DK56KB] (Forward-reverse potentiometer 1: Disconnection) 578
Error code [DK57KA] (Forward-reverse potentiometer 2: Short circuit) 580
Error code [DK57KB] (Forward-reverse potentiometer 2: Disconnection) 582
Error code [DKH1KA] (Pitch angle sensor: Short circuit) .584
Error code [DKH1KB] (Pitch angle sensor: Disconnection) .585
Error code [DLE2MA] (Engine speed sensor: Malfunction) 587
Error code [DLF1KA] (Transmission output speed sensor: Disconnection) .588
Error code [DV00KB] (Buzzer: Short circuit) .589
Error code [DW5AKA] (Pitch control solenoid: Disconnection) .590
Error code [DW5AKB] (Pitch control solenoid: Short circuit) .591
Error code [DW7BKA] (Fan reverse solenoid: Disconnection) .592
Error code [DW7BKB] (Fan reverse solenoid: Short circuit) .593
Error code [DWN1KA] (HSS EPC solenoid right: Disconnection) .594
Error code [DWN1KB] (HSS EPC solenoid right: Short circuit) .595
Error code [DWN2KA] (HSS EPC solenoid left: Disconnection) 596
Error code [DWN2KB] (HSS EPC solenoid left: Short circuit) 597
Error code [DWN5KA] (Fan pump TVC solenoid: Disconnection) 598
Error code [DWN5KB] (Fan pump TVC solenoid: Short circuit) 599
Error code [DXA0KA] (HSS pump TVC solenoid: Disconnection) 600
Error code [DXA0KB] (HSS pump TVC solenoid: Short circuit) 601
Error code [DXH4KA] (1st clutch ECMV: Disconnection) 602
Error code [DXH4KB] (1st clutch ECMV: Short circuit) 603
Error code [DXH5KA] (2nd clutch ECMV: Disconnection) 604
Error code [DXH5KB] (2nd clutch ECMV: Short circuit) 605
Error code [DXH6KA] (3rd clutch ECMV: Disconnection) 606
Error code [DXH6KB] (3rd clutch ECMV: Short circuit) 607
Error code [DXH7KA] (Reverse clutch ECMV: Disconnection) 608
Error code [DXH7KB] (Reverse clutch ECMV: Short circuit) 609
Error code [DXH8KA] (Forward clutch ECMV: Disconnection) 610
Error code [DXH8KB] (Forward clutch ECMV: Short circuit) 611
Error code [DY10K4] (Governor motor: Loss of synchronism) .612
Error code [DY10KA] (Governor motor: Disconnection) .613
Error code [DY10KB] (Governor motor: Short circuit) .614
Error code [DY45KA] (Engine stop solenoid relay: Disconnection) .616
Error code [DY45KB] (Engine stop solenoid relay: Short circuit) .618
Troubleshooting of electrical system (E-mode) – CONTENTS 621
Troubleshooting of electrical system (E-mode) .623
Before troubleshooting electrical system (E-mode) .623
Information described in troubleshooting list .625
E-1 Engine does not start .626
E-2 Preheater does not operate 631
E-3 No monitor panel lamps light at all when starting switch is turned ON .634
E-4 All lamps continue to light on monitor panel when starting switch is turned ON 635
E-5 While engine is running, battery charge level warning lamp flashes 636
E-6 While engine is operating, an emergency warning item flashes 638
E-7 Preheating pilot lamp does not light during preheating 642
E-8 Engine coolant temperature gauge does not indicate normally .644
E-9 Power train oil temperature gauge does not indicate normally 645
E-10 Hydraulic oil temperature gauge does not indicate normally .646
E-11 Fuel gauge does not indicate normally 647
E-12 Gear speed is indicated incorrectly 648
E-13 Indication of preset mode service meter is abnormal 648
E-14 Warning lamp does not flash or does not go out .648
E-15 Engine speed is indicated incorrectly 649
E-16 Transmission speed or travel speed is indicated incorrectly 650
E-17 Caution buzzer does not sound or does not stop .651
E-18 Auto shift down does not function or it is not released 652
E-19 Buzzer cancel switch does not function .653
E-20 Information switch does not function .655
E-21 Reverse fan rotation and cleaning functions do not operate, or they are not released .657
E-22 Preset mode cannot be selected or released .659
E-23 Service mode cannot be selected or it is selected errorneously .660
E-24 Backup alarm does not sound 662
E-25 Headlamp and rear lamp do not light 664
E-26 Horn does not sound or does not stop .666
E-27 Work equipment lock lever does not function or it cannot be released .667
E-28 Wiper malfunction 669
E-29 Washing water does not come out 681
E-30 Air conditioner does not operate .686
Troubleshooting of hydraulic and mechanical system (H-mode) – CONTENTS 691
Troubleshooting of hydraulic and mechanical system (H-mode) .693
Information described in troubleshooting list .693
H-1 No travel power (No drawbar pull) .694
H-2 Machine does not move (At 2nd or 3rd speed) .695
H-3 Machine does not move in any speed range 696
H-4 Machine travels only in one direction forward or in reverse .697
H-5 When gear is shifted or travel direction is changed, large time lag is made .698
H-6 Machine does not turn (Not turned rightward or leftward) 699
H-7 Steering speed or power is low 700
H-8 Brake does not work .701
H-9 Overheat of power train oil temperature .702
H-10 Abnormal sound comes out from around HSS and work equipment pump or HSS motor 703
H-11 All work equipment speeds are slow .704
H-12 Work equipment does not move .705
H-13 Blade lift speed is slow or lacks power 706
H-14 Blade tilt speed is slow or lacks power 707
H-15 Angling blade speed is slow or lacks power .708
H-16 Ripper lift speed is slow or lacks power .709
H-17 Excessive hydraulic drift of blade lift 710
H-18 Excessive hydraulic drift of blade tilt 711
H-19 Excessive hydraulic drift of blade angle .712
H-20 Excessive hydraulic drift of ripper lift .713
Troubleshooting of engine system (S-mode) – CONTENTS 715
Troubleshooting of engine system (S-mode) .718
Method of using matrix troubleshooting charts .718
S-1 Starting performance is poor (starting always takes time) .722
S-2 Engine does not start .723
S-3 Engine does not pick up smoothly (follow-up is poor) 726
S-4 Engine stopped during operation .727
S-5 Engine does not rotate smoothly (hunting) .728
S-6 Engine lacks output (or lacks power) 729
S-7 Exhaust gas color is black (incomplete combustion) 730
S-8 Oil consumption is excessive (or exhaust gas color is blue) .731
S-9 Oil becomes contaminated quickly 732
S-10 Fuel consumption is excessive 733
S-11 Oil is in coolant, coolant spurts back, or coolant level goes down .734
S-12 Oil pressure monitor is turned on (drop in oil pressure) .735
S-13 Oil level rises (water or fuel in oil) .736
S-14 Water temperature becomes too high (overheating) .737
S-15 Abnormal noise is made .738
S-16 Vibration is excessive .739
30 DISASSEMBLY AND ASSEMBLY .741
Preface .742
How to read this manual .742
Standard tightening torque table 744
Precautions when performing operation .747
List of coatings 752
Special tool list .754
Sketches of special tools .758
Engine related procedures .762
Removal and installation of fuel injection pump assembly 762
Removal and installation of cylinder head assembly 767
Removal and installation of engine front seal .774
Removal and installation of engine rear seal 775
Removal and installation of engine assembly .779
Removal and installation of damper assembly .782
Removal and installation of radiator guard assembly .786
Removal and installation of radiator and hydraulic oil cooler assembly 790
Removal and installation of fan drive assembly 793
Removal and installation of fan motor assembly 794
Removal and installation of engine hood assembly 795
Removal and installation of fuel tank assembly 796
Power train .800
Removal and installation of PTO, torque converter and transmission assembly .800
Disconnection and connection of PTO, torque converter and transmission assembly .804
Disassembly and assembly of PTO assembly 806
Disassembly and assembly of torque converter assembly .811
Disassembly and assembly of TORQFLOW transmission assembly 815
Removal and installation of torque converter main relief valve assembly .832
Disassembly and assembly of torque converter main relief valve assembly .833
Power train .836
Removal and installation of power train and lubricating oil pump assembly .836
Removal and installation of HSS and work equipment pump assembly 838
Removal and installation of scavenging pump assembly 839
Removal and installation of HSS motor assembly 839
Disassembly and assembly of HSS assembly 840
Removal and installation of final drive assembly 858
Disassembly and assembly of final drive assembly 859
Undercarriage .874
Removal and installation of track frame assembly 874
Removal and installation of idler assembly 876
Disassembly and assembly of idler assembly 877
Removal and installation of recoil spring assembly 881
Disassembly and assembly of recoil spring assembly 882
Removal and installation of track roller assembly .885
Disassembly and assembly of track roller assembly .886
Removal and installation of carrier roller assembly .889
Disassembly and assembly of carrier roller assembly .890
Undercarriage .894
Check before expanding track shoe assembly 894
Expansion (normal), expansion (internal abnormality) and installation of track shoe assembly 894
Overall disassembly and overall assembly of track shoe assembly .896
Link press-fitting jig dimensions table .912
Field disassembly and assembly of one link 913
Removal and installation of pivot shaft assembly 920
Removal and installation of equalizer bar assembly 922
Removal and installation of equalizer bar side bushing 923
Removal and installation of segment teeth .924
Hydraulic system 926
Removal and installation of main control valve assembly .926
Assembly of main control valve assembly .928
Removal and installation of cooling fan pump assembly .931
Removal and installation of work equipment assembly .932
Disassembly and assembly of work equipment assembly .934
Disassembly and assembly of hydraulic cylinder assembly .937
Others 944
Removal and installation of operator’s cab assembly .944
Removal and installation of operator’s cab glass (stuck glass) 949
Removal and installation of ROPS canopy .958
Removal and installation of dashboard assembly 959
Removal and installation of floor frame assembly 960
Removal and installation of steering and transmission controller assembly .965
90 OTHERS .967
Hydraulic circuit diagram .968
Power train hydraulic circuit diagram .968
Work equipment hydraulic circuit diagram Power angle power tilt dozer (PAT) .970
Work equipment hydraulic circuit diagram Power tilt dozer (PT) 972
Electrical circuit diagram 974
Electrical circuit diagram (1/6) 974
Electrical circuit diagram (2/6) 976
Electrical circuit diagram (3/6) 978
Electrical circuit diagram (4/6) 980
Electrical circuit diagram (5/6) 982
Electrical circuit diagram (6/6) 984
Cab electrical circuit diagram 986

DESCRIPTION:

Komatsu D61EX-15,D61PX-15 Bulldozer Shop Manual WE051Z0002 – PDF DOWNLOAD

MACHINE MODEL SERIAL NUMBER

• D61EX-15                B40001 and up
• D61PX-15                B40001 and up

Foreword
General
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 chapters; these chapters are further
divided into the each main group of components.
Structure and function
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 may contain hydraulic circuit diagrams, electric circuit diagrams, and maintenance
standards.
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 charts correlating “Problems” with “Causes” are also included in this section.
Disassembly and assembly
This section explains the procedures for removing, installing, disassembling and assembling each component,
as well as precautions for them.
Maintenance standard
This section gives the judgment standards for inspection of disassembled parts.
The contents of this section may be described in “Structure and function”.
Others
This section mainly gives hydraulic circuit diagrams and electric circuit diagrams.
In addition, this section may give the specifications of attachments and options together.
Notice

G.B 30/12/24