Komatsu BULLDOZER D61EX-15E0 D61PX-15E0 Shop Manual SEN02387-03 PDF

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Komatsu BULLDOZER D61EX-15E0 D61PX-15E0 Shop Manual SEN02387-03  – PDF DOWNLOAD

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Komatsu BULLDOZER D61EX-15E0 D61PX-15E0 Shop Manual SEN02387-03  – PDF DOWNLOAD

Language : English
Pages : 490
Downloadable : Yes
File Type : PDF

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TABLE OF CONTENTS:

Komatsu BULLDOZER D61EX-15E0 D61PX-15E0 Shop Manual SEN02387-03  – PDF DOWNLOAD

• SERIAL NUMBERS D61EX- B45001 and up D61PX- B45001

COVER 1
00 Index and foreword 3
Index 3
Composition of shop manual 4
Table of contents 6
Foreword and general information 17
Safety notice 18
How to read the shop manual 23
Explanation of terms for maintenance standard 25
Handling electric equipment and hydraulic component 27
Connectors newly used for Tier 3 engines 36
How to read electric wire code 39
Precautions when carrying out operation 42
Method of disassembling and connecting push-pull type coupler 45
Standard tightening torque table 48
Conversion table 52
01 Specification 59
Specification and technical data 59
Specification dimension drawing 60
Specifications 61
Weight table 66
Table of fuel, coolant and lubricants 68
10 Structure, function and maintenance standard 71
Engine and cooling system 71
Cooling system 72
Cooling fan pump 74
Cooling fan motor 82
Power train, Part 1 89
Power train 90
Power train 91
HSS system 92
General view of the power train unit 94
Power train hydraulic piping drawing 95
Transmission, steering, brake control 96
Damper and universal joint 98
Torque converter, PTO 100
Transmission 106
Transmission ECMV 118
Main relief valve and torque converter relief valve 124
Lubricating oil relief valve 126
Power train, Part 2 129
Bevel gear shaft, HSS and brake 130
Brake valve 146
Final drive 152
Undercarriage and frame 159
Main frame 161
Suspension 162
Track frame and idler cushion 166
Idler 170
Track roller 172
For conventional type track shoe Single-flange type 172
For conventional type track shoe Double-flange type 173
For PLUS type track shoe Single-flange type 174
For PLUS type track shoe Double-flange type 175
Carrier roller 176
For conventional type track shoe 176
For PLUS type track shoe 177
Sprocket 178
For conventional type track shoe 178
For PLUS type track shoe 180
Track shoe 182
Conventional type track shoe 182
PLUS type track shoe 184
Single shoe 186
Swamp shoe 186
Hydraulic system, Part 1 189
Layout of hydraulic devices for work equipment 190
Work equipment control 192
Hydraulic tank and filter 194
Scavenging pump 196
Power train and steering lubrication pump 197
HSS pump 198
HSS motor 216
Hydraulic system, Part 2 225
Control valve 226
CLSS 234
Each function and each valve operation 238
Unload valve 240
Main relief valve (steering, work equipment) Centralized safety valve 243
Steering priority valve 244
Pressure reducing valve for work equipment 246
Pressure compensation valve 247
Suction valve 248
Safety-suction valve 249
LS shuttle valve (used as steering LS bypass plug, too) 251
Steering LS relief valve and main relief valve operation 252
Work equipment relief valve operation 254
Introduction of LS pressure 256
Work equipment valve (lift, tilt, angle, ripper) 257
Back pressure valve 259
Self pressure reducing valve 261
Hydraulic system, Part 3 269
PPC valve 270
Electric lever (Steering) 286
Quick drop valve 290
Solenoid valve 292
Accumulator 294
Work equipment 297
Work equipment 298
Cutting edge and end bit 304
Ripper 305
Hydraulic cylinder 306
Piston valve 309
Cab and its attachments 311
Cab mount 312
Cab 313
Air conditioner piping diagram 315
Electrical system 317
Monitor system 318
Monitor panel 320
Engine control 325
Engine control system 326
Cooling system control system 328
System components 330
Palm command control system 338
PPC lock system 340
KOMTRAX terminal system 341
KOMTRAX terminal 342
Sensor 343
20 Standard value table 347
Standard service value table 347
Standard value table for engine 348
Standard value table for machine 349
30 Testing and adjusting 359
Testing and adjusting, Part 1 359
Standard value table for engine related parts 361
Measuring engine speed 364
Measuring intake air pressure (boost pressure) 366
Measuring exhaust color 368
Adjusting valve clearance 369
Measuring compression pressure 371
Measuring blow-by pressure 374
Measuring engine oil pressure 375
Handling fuel system equipment 376
Releasing residual pressure in fuel system 376
Measuring fuel pressure 377
Measuring fuel delivery amount, return rate and leakage 379
Bleeding air from fuel circuit 383
Testing leakage in fuel system 385
Handling of reduced cylinder mode operation 386
Handling of no injection cranking operation 386
Testing and adjusting air conditioner compressor belt tension 387
Replacing the fan belt 387
Handling controller voltage circuit 388
Adjusting fuel control dial and decelerator pedal 389
Testing and adjusting, Part 2 393
Measuring power train oil pressure 395
Adjusting transmission speed sensor (replacement procedure) 399
Simple method of testing brake performance 401
Adjusting brake pedal 402
Adjusting parking brake lever 404
Emergency escape method when power train has trouble 405
Adjusting idler clearance 408
Inspecting wear of sprocket 408
Testing and adjusting track shoe tension 409
Testing and adjusting work equipment and HSS oil pressure 410
Testing control circuit main pressure 414
Measuring PPC valve output pressure 415
Adjusting play of work equipment PPC valve 418
Measuring internal leakage of work equipment cylinder 419
Adjusting work equipment lock lever of work equipment 420
Releasing residual pressure in work equipment cylinder (If PPC accumulator is not installed) 421
Releasing residual pressure in work equipment cylinder (If PPC accumulator is installed) 421
Bleeding air from work equipment cylinder 422
Measuring fan motor speed 423
Measuring fan pump circuit pressure 424
Measuring HSS motor oil leakage 425
Bleeding air from fan pump 425
Testing and adjusting operator’s cab 426
Testing and adjusting, Part 3 433
Special functions of monitor panel (EMMS) 434
Testing and adjusting, Part 4 473
Handling of voltage circuit of engine controller 474
Adjustment method when controller has been replaced 474
Preparatory work for troubleshooting for electric system 476
Inspection procedure of diode 481
Pm-Clinic service 482
How to start operation of KOMTRAX terminal 494
Lamp display of KOMTRAX terminal 498
40 Troubleshooting 503
Failure code table and fuse locations 503
Failure code table 504
Fuse locations 511
General information on troubleshooting 515
Points to remember when troubleshooting 516
Sequence of events in troubleshooting 517
Checks before troubleshooting 518
Classification and procedures of troubleshooting 519
Contents of troubleshooting table 520
Wiring table for connector pin numbers 524
T-adapter box and T-adapter table 557
Troubleshooting by failure code (Display of code), Part 1 561
Failure code [1500L0] Transmission clutch: Dual engagement 563
Failure code [15SAL1] Forward clutch: Fill signal is ON when command current is OFF 564
Failure code [15SALH] Forward clutch: Fill signal is OFF when command current is ON 566
Failure code [15SBL1] Reverse clutch: Fill signal is ON when command current is OFF 568
Failure code [15SBLH] Reverse clutch: Fill signal is OFF when command current is ON 570
Failure code [15SEL1] 1st clutch: Fill signal is ON when command current is OFF 572
Failure code [15SELH] 1st clutch: Fill signal is OFF when command current is ON 574
Failure code [15SFL1] 2nd clutch: Fill signal is ON when command current is OFF 576
Failure code [15SFLH] 2nd clutch: Fill signal is OFF when command current is ON 578
Failure code [15SGL1] 3rd clutch: Fill signal is ON when command current is OFF 580
Failure code [15SGLH] 3rd clutch: Fill signal is OFF when command current is ON 582
Failure code [AB00MA] Alternator: Malfunction 584
Failure code [B@BAZG] Engine oil: Oil pressure too low 584
Failure code [B@BCNS] Radiator coolant: Overheat 585
Failure code [B@CENS] Power train oil: Overheat 585
Failure code [B@HANS] Hydraulic oil: Overheat 586
Failure code [CA111] Engine controller: Abnormality in controller 587
Failure code [CA115] Abnormal engine Ne and Bkup speed sensors: Abnormal speed sensor signal 587
Failure code [CA122] Charge pressure sensor too high: Excessively high voltage detected 588
Failure code [CA123] Charge pressure sensor too low: Excessively low voltage detected 590
Failure code [CA131] Decelerator pedal sensor too high: Excessively high voltage detected 592
Failure code [CA132] Decelerator pedal sensor too low: Excessively low voltage detected 594
Failure code [CA144] Coolant temperature sensor too high: Excessively high voltage detected 596
Failure code [CA145] Coolant temperature sensor too low: Excessively low voltage detected 598
Failure code [CA153] Charge temperature sensor too high: Excessively high voltage detected 600
Failure code [CA154] Charge temperature sensor too low: Excessively low voltage detected 602
Failure code [CA155] Charge temperature too high and engine speed derated: Exceeded upper control limit of temperature 604
Failure code [CA187] Sensor power source 2 too low: Excessively low voltage detected 606
Failure code [CA221] Atmospheric pressure sensor too high: Excessively high voltage detected 608
Failure code [CA222] Atmospheric pressure sensor too low: Excessively low voltage detected 610
Failure code [CA227] Sensor power source 2 too high: Excessively high voltage detected 612
Failure code [CA234] Engine over speed: Excessively high speed 614
Failure code [CA238] Abnormal power source for Ne speed sensor: Excessively low voltage detected 615
Failure code [CA271] IMV/PCV1 short circuit: Short circuit 616
Failure code [CA272] IMV/PCV1 disconnection: Disconnection 618
Troubleshooting by failure code (Display of code), Part 2 621
Failure code [CA322] Injector No 1 system disconnection or short circuit: disconnection, short circuit 624
Failure code [CA323] Injector No 5 system disconnection or short circuit: disconnection, short circuit 626
Failure code [CA324] Injector No 3 system disconnection or short circuit: disconnection, short circuit 628
Failure code [CA325] Injector No 6 system disconnection or short circuit: disconnection, short circuit 630
Failure code [CA331] Injector No 2 system disconnection or short circuit: disconnection, short circuit 632
Failure code [CA332] Injector No 4 system disconnection or short circuit: disconnection, short circuit 634
Failure code [CA342] Engine controller data matching error: matching error 636
Failure code [CA352] Sensor power source 1 too low: Excessively low voltage detected 638
Failure code [CA386] Sensor power source 1 too high: Excessively high voltage detected 640
Failure code [CA428] Water detection sensor too high: Excessively high voltage detected 642
Failure code [CA429] Water detection sensor too low: Excessively low voltage detected 644
Failure code [CA435] Abnormal engine oil pressure switch: Abnormal signal circuit 646
Failure code [CA441] Power source voltage too low: Excessively low voltage detected 648
Failure code [CA442] Power source voltage too high: Excessively high voltage has occurred in the controller power source circuit 650
Failure code [CA449] Common rail pressure too high (2): Excessively high pressure trouble occurred 652
Failure code [CA451] Common rail pressure sensor too high: Excessively high voltage detected 654
Failure code [CA452] Common rail pressure sensor too low: Excessively low voltage detected 656
Failure code [CA488] Charge temperature too high and torque derated: Exceeded upper control limit of temperature 658
Failure code [CA553] Common rail pressure too high (1): Excessively high pressure detected 659
Failure code [CA559] Loss of pressure feed from supply pump (1): Loss of pressure feed detected 660
Failure code [CA689] Abnormal engine Ne speed sensor: Abnormal signal 662
Failure code [CA731] Abnormal engine Bkup speed sensor phase: Abnormal phase 664
Failure code [CA757] Loss of all engine controller data: Loss of all data 666
Failure code [CA778] Abnormal engine Bkup speed sensor: Abnormal Bkup signal 668
Failure code [CA1633] Abnormal KOMNET: Abnormal communication 670
Failure code [CA2185] Decelerator pedal sensor power source too high: Excessively high voltage detected 672
Failure code [CA2186] Decelerator pedal sensor power source too low: Excessively low voltage detected 674
Failure code [CA2249] Loss of pressure feed from supply pump (2): Loss of pressure feed detected 676
Failure code [CA2311] Abnormal IMV solenoid: Abnormal resistance 678
Failure code [CA2555] Air intake heater relay disconnection: Disconnection 680
Failure code [CA2556] Air intake heater relay short circuit: Short circuit 682
Troubleshooting by failure code (Display of code), Part 3 685
Failure code [D110KA] Battery relay: Short circuit 688
Failure code [D110KB] Battery relay: Disconnection 690
Failure code [D130KA] Neutral safety relay: Short circuit 692
Failure code [D130KB] Neutral safety relay: Disconnection 694
Failure code [D161KA] Back-up alarm relay: Disconnection 696
Failure code [D161KB] Back-up alarm relay: Short circuit 698
Failure code [DAFRKR] Monitor panel CAN communication: Defective communication 700
Failure code [DAQ0KT] [DB30KT] Steering and transmission controller: Abnormality in controller 702
Failure code [DAQ1KK] [DB31KK] Main power source of steering and transmission controller: Power source voltage drop and input 704
Failure code [DAQ2KK] [DB32KK] Load power source of steering and transmission controller: Power source voltage drop and input 706
Failure code [DAQ5KK] [DB35KK] Steering and transmission controller sensor 5 V power source: Power source voltage drop and input 708
Failure code [DAQ6KK] [DB36KK] Steering and transmission controller sensor 24 V power source: Power source voltage drop and input 710
Failure code [DAQ9KQ] [DB39KQ] Steering and transmission controller model selection: Inconsistency in model select signal 712
Failure code [DB2RKR] Steering and transmission controller CAN communication: Defective communication 714
Failure code [DB30KT] [DAQ0KT] Steering and transmission controller: Abnormality in controller 716
Failure code [DB31KK] [DAQ1KK] Main power source of steering and transmission controller: Power source voltage drop and input 716
Failure code [DAB32KK] [DAQ2KK] Load power source of steering and transmission controller: Power source voltage drop and input 716
Failure code [DB35KK] [DAQ5KK] Steering and transmission controller sensor 5 V power source: Power source voltage drop and input 716
Failure code [DB36KK] [DAQ6KK] Steering and transmission controller sensor 24 V power source: Power source voltage drop and input 716
Failure code [DB39KQ] [DAQ9KQ] Steering and transmission controller model selection: Inconsistency in model select signal 716
Failure code [DD12KA] Shift up switch: Disconnection 718
Failure code [DD12KB] Shift up switch: Short circuit 720
Failure code [DD13KA] Shift down switch: Disconnection 722
Failure code [DD13KB] Shift down switch: Short circuit 724
Failure code [DD14KA] [DDQ2KA] Parking brake lever switch: Disconnection 726
Failure code [DD14KB] [DDQ2KB] Parking brake lever switch: Short circuit 728
Failure code [DDQ2KA] [DD14KA] Parking brake lever switch: Disconnection 730
Failure code [DDQ2KB] [DD14KB] Parking brake lever switch: Short circuit 730
Failure code [DGS1KX] Hydraulic oil temperature sensor: Input signal is out of normal range 732
Failure code [DGT1KA] Power train oil temperature sensor: Disconnection 734
Failure code [DGT1KX] Power train oil temperature sensor: Input signal is out of normal range 735
Failure code [DK10KA] Fuel dial: Disconnection 736
Failure code [DK10KB] Fuel dial: Short circuit 738
Failure code [DK30KA] Steering potentiometer (1): Disconnection 740
Failure code [DK30KB] Steering potentiometer (1): Short circuit 742
Failure code [DK30KX] Steering potentiometer: Input signal is out of normal range 744
Failure code [DK30KZ] Steering potentiometer: Disconnection or short circuit (Double failure) 745
Failure code [DK30L8] Steering potentiometer: Inconsistent analog signal 745
Failure code [DK31KA] Steering potentiometer (2): Disconnection 746
Failure code [DK31KB] Steering potentiometer (2): Short circuit 748
Failure code [DK40KA] Brake potentiometer: Disconnection 750
Failure code [DK40KB] Brake potentiometer: Short circuit 751
Troubleshooting by failure code (Display of code), Part 4 753
Failure code [DK55KX] Forward-reverse potentiometer: Input signal is out of normal range 755
Failure code [DK55KZ] Forward-reverse potentiometer: Disconnection or short circuit (Double failure) 756
Failure code [DK55L8] Forward-reverse potentiometer: Inconsistent analog signal 757
Failure code [DK56KA] Forward-reverse potentiometer (1): Short circuit 758
Failure code [DK56KB] Forward-reverse potentiometer (1): Disconnection 760
Failure code [DK57KA] Forward-reverse potentiometer (2): Disconnection 762
Failure code [DK57KB] Forward-reverse potentiometer (2): Short circuit 764
Failure code [DKH1KA] [DKH1KX] Pitch angle sensor: Short circuit 766
Failure code [DKH1KB] [DKH1KX] Pitch angle sensor: Disconnection 768
Failure code [DKH1KX], [DKH1KA] or [DKH1KB] Pitch angle sensor: Input signal out of range 769
Failure code [DLT3KA] Transmission output speed sensor: Disconnection 770
Failure code [DLT3KB] Transmission output speed sensor: Short circuit 771
Failure code [DV00KB] Alarm buzzer: Short circuit 772
Failure code [DW7BKA] Fan reverse solenoid: Disconnection 773
Failure code [DW7BKB] Fan reverse solenoid: Short circuit 774
Failure code [DWN1KA] HSS EPC solenoid right: Disconnection 775
Failure code [DWN1KB] HSS EPC solenoid right: Short circuit 776
Failure code [DWN1KY] HSS EPC solenoid right: Short circuit to power source line 777
Failure code [DWN2KA] HSS EPC solenoid left: Disconnection 778
Failure code [DWN2KB] HSS EPC solenoid left: Short circuit 779
Failure code [DWN2KY] HSS EPC solenoid left: Short circuit to power source line 780
Failure code [DWN5KA] Fan pump TVC solenoid: Disconnection 781
Failure code [DWN5KB] Fan pump TVC solenoid: Short circuit 782
Failure code [DWN5KY] Fan pump TVC solenoid: Short circuit in power source line 783
Failure code [DXA0KA] HSS pump TVC solenoid: Disconnection 784
Failure code [DXA0KB] HSS pump TVC solenoid: Short circuit 785
Failure code [DXA0KY] HSS pump TVC solenoid: Short circuit to power source line 786
Failure code [DXH4KA] 1st clutch ECMV: Disconnection 787
Failure code [DXH4KB] 1st clutch ECMV: Short circuit 788
Failure code [DXH4KY] 1st clutch ECMV: Short circuit to power source line 790
Failure code [DXH5KA] 2nd clutch ECMV: Disconnection 791
Failure code [DXH5KB] 2nd clutch ECMV: Short circuit 792
Failure code [DXH5KY] 2nd clutch ECMV: Short circuit to power source line 794
Failure code [DXH6KA] 3rd clutch ECMV: Disconnection 795
Failure code [DXH6KB] 3rd clutch ECMV: Short circuit 796
Failure code [DXH6KY] 3rd clutch ECMV: Short circuit to power source line 798
Failure code [DXH7KA] Reverse clutch ECMV: Disconnection 799
Failure code [DXH7KB] Reverse clutch ECMV: Short circuit 800
Failure code [DXH7KY] Reverse clutch ECMV: Short circuit to power source line 801
Failure code [DXH8KA] Forward clutch ECMV: Disconnection 802
Failure code [DXH8KB] Forward clutch ECMV: Short circuit 804
Failure code [DXH8KY] Forward clutch ECMV: Short circuit to power source line 806
Troubleshooting of electrical system (E-mode) 809
Before troubleshooting of electrical system 811
Contents of troubleshooting table 813
E-1 The engine does not start (the starting motor does not turn) 815
E-2 The preheater does not operate 819
E-3 The monitor panel does not light up at all when the starting switch is turned ON 822
E-4 When the starting switch is turned on, the monitor panel completely remains lighted and does not go out 823
E-5 While the engine is running, the battery charge level caution lamp flashes 824
E-6 While the engine is running, the emergency warning item flashes 826
E-7 While the preheater is operating, the preheating pilot lamp does not light up 830
E-8 The coolant temperature gauge does not indicate correctly 832
E-9 The power train oil temperature gauge does not indicate correctly 834
E-10 Hydraulic oil temperature gauge does not indicate properly 836
E-11 Fuel gauge does not indicate properly 838
E-12 Gear speed and engine speed are not indicated properly 839
E-13 The preset mode service meter does not indicate normally 839
E-14 The warning lamp does not flash or does not go out 839
E-15 The alarm buzzer does not sound or does not stop 840
E-16 Auto shift down is not possible or is not released 842
E-17 The buzzer cancel switch does not work 844
E-18 The information switch does not work 846
E-19 The fan cleaning does not operate or cannot be reset 848
E-20 The preset mode does not operate or cannot be reset 850
E-21 The monitor panel cannot be set in the service mode or cannot be set out of the service mode 852
E-22 The back-up alarm does not sound 854
E-23 The head lamp and rear lamp do not light up 857
E-24 The horn does not sound or does not stop 860
E-25 Malfunction of wipers 862
E-26 Washer does not spray water 878
E-27 The air conditioner does not operate 884
E-28 KOMTRAX system does not operate normally 888
Troubleshooting of hydraulic and mechanical system (H-mode) 891
Contents of troubleshooting table 893
H-1 There is no travel power (no drawbar pull) 894
H-2 Machine does not move (at 2nd or 3rd speed) 895
H-3 Machine does not move at any gear speed 896
H-4 Machine travels only in one direction, forward or in reverse 897
H-5 When gear is shifted or travel direction is changed, large time lag is made 898
H-6 Machine cannot be steered (Machine does not turn leftward or rightward) 899
H-7 Steering speed or power is low 899
H-8 Brake does not work 900
H-9 Overheat of power train oil 901
H-10 Abnormal sound comes out from around HSS and work equipment pump or HSS motor 902
H-11 All work equipment speeds are slow 902
H-12 Work equipment does not move 903
H-13 Blade lift speed is slow or lacks power 903
H-14 Blade tilt speed is slow or lacks power 904
H-15 Angling blade speed is slow or lacks power 904
H-16 Ripper lift speed is slow or lacks power 905
H-17 Excessive hydraulic drift of blade lift 905
H-18 Excessive hydraulic drift of blade tilt 906
H-19 Excessive hydraulic drift of blade angle 906
H-20 Excessive hydraulic drift of ripper lift 907
Troubleshooting of engine (S-mode) 909
Method of using troubleshooting charts 911
S-1 Starting performance is poor 914
S-2 Engine does not start 915
S-3 Engine does not pick up smoothly 918
S-4 Engine stops during operations 919
S-5 Engine does not rotate smoothly 920
S-6 Engine lacks output (or lacks power) 921
S-7 Exhaust smoke is black (incomplete combustion) 922
S-8 Oil consumption is excessive (or exhaust smoke is blue) 923
S-9 Oil becomes contaminated quickly 924
S-10 Fuel consumption is excessive 925
S-11 Oil is in coolant (or coolant spurts back or coolant level goes down) 926
S-12 Oil pressure drops 927
S-13 Oil level rises (Entry of coolant or fuel) 928
S-14 Coolant temperature becomes too high (overheating) 929
S-15 Abnormal noise is made 930
S-16 Vibration is excessive 931
50 Disassembly and assembly 933
General information on disassembly and assembly 933
How to read this manual 934
Coating materials list 936
Special tool list 939
Sketches of special tools 946
Engine and cooling system (SAA6D107E-1) 957
Removal and installation of radiator guard assembly 958
Removal 958
Installation 961
Removal and installation of engine assembly 962
Removal 962
Installation 966
Removal and installation of radiator assembly 967
Removal 967
Installation 969
Removal and installation of aftercooler assembly 970
Removal 970
Installation 972
Removal and installation of power train oil cooler assembly 973
Removal 973
Installation 973
Removal and installation of hydraulic cooler assembly 974
Removal 974
Installation 976
Removal and installation of cooling fan drive assembly 977
Removal 977
Installation 978
Removal and installation of cooling fan motor assembly 979
Removal 979
Installation 979
Removal and installation of damper assembly 980
Special tools 980
Removal 980
Installation 982
Removal and installation of fuel tank assembly 985
Removal 985
Installation 986
Removal and installation of engine hood assembly 987
Removal 987
Installation 987
Engine (SAA6D170E-1) 989
Removal and installation of fuel supply pump assembly 990
Removal 990
Installation 991
Removal and installation of fuel injector assembly 992
Special tools 992
Removal 992
Installation 998
Removal and installation of cylinder head assembly 1001
Special tools 1001
Removal 1001
Installation 1008
Removal and installation of engine front seal 1014
Special tools 1014
Removal 1014
Installation 1015
Removal and installation of engine rear seal 1017
Special tools 1017
Removal 1017
Installation 1018
Power train, Part 1 1021
Removal and installation of PTO, torque converter and transmission assembly 1022
Removal 1022
Installation 1025
Disconnection and connection of PTO, torque converter and transmission assembly 1026
Disconnection 1026
Connection 1027
Disassembly and assembly of PTO assembly 1028
Disassembly 1028
Assembly 1030
Disassembly and assembly of torque converter assembly 1033
Disassembly 1033
Assembly 1034
Disassembly and assembly of TORQFLOW transmission assembly 1037
Special tools 1037
Disassembly 1037
Assembly 1043
Removal and installation of torque converter main relief valve assembly 1054
Removal 1054
Installation 1054
Disassembly and assembly of torque converter main relief valve assembly 1055
Disassembly 1055
Assembly 1055
Power train, Part 2 1057
Removal and installation of power train and lubricating oil pump assembly 1058
Removal 1058
Installation 1059
Removal and installation of HSS and work equipment pump assembly 1060
Removal 1060
Installation 1060
Removal and installation of scavenging pump assembly 1061
Removal 1061
Installation 1061
Removal and installation of HSS motor assembly 1061
Removal 1061
Installation 1061
Disassembly and assembly of HSS assembly 1062
Special tool 1062
Disassembly 1062
Assembly 1069
Adjusting 1073
Removal and installation of final drive assembly 1080
Removal 1080
Installation 1080
Disassembly and assembly of final drive assembly 1081
Special tool 1081
Disassembly 1081
Assembly 1085
Undercarriage and frame, Part 1 1095
Removal and installation of track frame assembly 1096
Removal 1096
Installation 1097
Removal and installation of idler assembly 1098
Removal 1098
Installation 1098
Disassembly and assembly of idler assembly 1099
Special tool 1099
Disassembly 1099
Assembly 1100
Removal and installation of recoil spring assembly 1103
Removal 1103
Installation 1103
Disassembly and assembly of recoil spring assembly 1104
Special tool 1104
Disassembly 1104
Assembly 1105
Removal and installation of track roller assembly 1107
Removal 1107
Installation 1107
Disassembly and assembly of track roller assembly 1108
Special tool 1108
Disassembly 1108
Assembly 1109
Removal and installation of carrier roller assembly 1111
Removal 1111
Installation 1111
Disassembly and assembly of carrier roller assembly 1112
Special tool 1112
Disassembly 1112
Assembly 1113
Expansion and installation of track shoe assembly (Plus type track shoe) 1120
Expansion (normal) 1120
Installation 1120
Undercarriage and frame, Part 2 1117
Check before expanding track shoe assembly 1118
Expansion (normal), expansion (internal abnormality) and installation of track shoe assembly (Conventional type track shoe) 1118
Expansion (normal) 1118
Expand (When track frame has internal trouble) 1119
Installation 1119
Overall disassembly and overall assembly of track shoe assembly (Conventional type track shoe) 1121
Special tools 1121
Overall disassembly 1121
Overall assembly 1125
Link press-fitting jig dimensions table 1137
Field disassembly and assembly of one link (Conventional type track shoe) 1145
Special tools 1145
Disassembly 1145
Assembly 1146
Field disassembly and assembly of one link (PLUS type track shoe) 1152
Special tools 1152
Disassembly 1152
Assembly 1155
Removal and installation of pivot shaft assembly 1157
Special tools 1157
Removal 1157
Installation 1158
Removal and installation of equalizer bar assembly 1159
Special tools 1159
Installation 1160
Removal and installation of equalizer bar side bushing 1160
Removal 1160
Installation 1160
Removal and installation of segment teeth 1161
Removal 1161
Installation 1161
Overall disassembly and overall assembly of track shoe assembly (PLUS type track shoe) 1138
Hydraulic system 1163
Removal and installation of main control valve assembly 1164
Removal 1164
Installation 1165
Assembly of main control valve assembly 1166
Removal and installation of cooling fan pump assembly 1169
Removal 1169
Installation 1169
Disassembly and assembly of hydraulic cylinder assembly 1170
Special tools 1170
Disassembly 1170
Assembly 1172
Work equipment 1177
Removal and installation of work equipment assembly 1178
Removal 1178
Installation 1179
Disassembly and assembly of work equipment assembly 1180
Disassembly 1180
Assembly 1181
Cab and its attachments 1185
Removal and installation of ROPS guard 1186
Removal 1186
Installation 1186
Removal and installation of operator’s cab assembly 1187
Removal 1187
Installation 1189
Removal and installation of operator’s cab glass (stuck glass) 1193
Special tools 1194
Removal 1194
Installation 1195
Removal and installation of monitor panel assembly 1202
Removal 1202
Installation 1202
Removal and installation of dashboard assembly 1203
Special tools 1203
Removal 1203
Installation 1205
Removal and installation of floor frame assembly 1206
Special tools 1206
Removal 1206
Installation 1210
Electrical system 1213
Removal and installation of engine controller assembly 1214
Removal 1214
Installation 1214
Removal and installation of steering and transmission controller assembly 1215
Removal 1215
Installation 1215
Removal and installation of KOMTRAX terminal assembly 1216
Removal 1216
Installation 1216
Removal and installation of air conditioner unit assembly 1217
Special tools 1217
Removal 1217
Installation 1220
90 Diagrams and drawings 1223
Hydraulic diagrams and drawings 1223
Power train hydraulic circuit diagram 1225
Work equipment hydraulic circuit diagram 1227
Power angle, power tilt dozer (PAT) 1227
Power tilt dozer (PT) 1229
Electrical circuit diagram 1235
Connector arrangement diagram 1237

DESCRIPTION:

• SERIAL NUMBERS D61EX- B45001 and up D61PX- B45001

G.B 22/ 12/24