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Komatsu D61EX-15, D61PX-15 Crawler Bulldozer Shop Manual B40001 and up – PDF DOWNLOAD
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Description
Komatsu D61EX-15, D61PX-15 Crawler Bulldozer Shop Manual B40001 and up
FILE DETAILS:
Komatsu D61EX-15, D61PX-15 Crawler Bulldozer Shop Manual B40001 and up
Brands: Komatsu
Equipment Type: Crawler Bulldozer
Manuals Type: Shop Manual
Machine Model: D61EX-15, D61PX-15
Serial Number: B40001 and up
Book Code: WE051Z0002
Language: English
Pages: 988
File Format: Portable Document Format (PDF)
DESCRIPTION:
Komatsu D61EX-15, D61PX-15 Crawler Bulldozer Shop Manual 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 accu- rate 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 work- shop. 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 under- standing 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 compo- nent, 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.
TABLE OF CONTENTS:
Komatsu D61EX-15, D61PX-15 Crawler Bulldozer Shop Manual 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
KOMATSU D61EX-15, D61PX-15 CRAWLER BULLDOZER SHOP MANUAL B40001 AND UP – PDF DOWNLOAD:
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