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KOMATSU D61EX,PX-12 SHOP MANUAL SEBM036700 – PDF DOWNLOAD
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Description
KOMATSU D61EX,PX-12 SHOP MANUAL SEBM036700 – PDF DOWNLOAD
FILE DETAILS:
KOMATSU D61EX,PX-12 SHOP MANUAL SEBM036700 – PDF DOWNLOAD
Language : English
Pages : 617
Downloadable : Yes
File Type : PDF
IMAGES PREVIEW OF THE MANUAL:
TABLE OF CONTENTS:
KOMATSU D61EX,PX-12 SHOP MANUAL SEBM036700 – PDF DOWNLOAD
COVER...................................................................................................... 1 CONTENTS................................................................................................... 2 01 GENERAL................................................................................................. 23 SPECIFICATION DRAWING.................................................................................. 24 SPECIFICATIONS......................................................................................... 26 WEIGHT TABLE........................................................................................... 31 TABLE OF FUEL,COOLANT AND LUBRICANTS................................................................... 33 10 STRUCTURE AND FUNCTION.................................................................................. 35 RADIATOR,POWER TRAIN,OIL COOLING....................................................................... 36 ENGINE CONTROL......................................................................................... 38 POWER TRAIN SYSTEM..................................................................................... 39 POWER TRAIN SKELETON................................................................................... 40 POWER TRAIN UNIT....................................................................................... 41 POWER TRAIN HYDRAULIC PIPING DIAGRAM................................................................... 42 DAMPER,UNIVERSAL JOINT................................................................................. 43 TORQUE CONVERTER AND PTO............................................................................... 44 TRANSMISSION CONTROL................................................................................... 47 TRANSMISSION........................................................................................... 48 TRANSMISSION CONTROL VALVE............................................................................. 55 MAIN RELIEF VALVE...................................................................................... 60 LUBRICATION RELIEF VALVE............................................................................... 62 STEERING AND BRAKE CONTROL............................................................................. 63 BEVEL GEAR SHAFT,HSS STEERING,STEERING BRAKE........................................................... 64 BEAKE VALVE............................................................................................ 74 SCAVENGING PUMP STRAINER............................................................................... 78 POWER TRAIN OIL STRAINER............................................................................... 79 POWER TRAIN OIL FILTER................................................................................. 80 FINAL DRIVE............................................................................................ 81 MAIN FRAME............................................................................................. 84 TRACK FRAME............................................................................................ 85 RECOIL SPRING ......................................................................................... 86 SUSPENSION ............................................................................................ 87 WORK EQUIPMENT HYDRAULIC PIPING DIAGRAM................................................................ 89 PPC CONTROL PIPING DIAGRAM............................................................................. 91 WORK EQUIPMENT CONTROL................................................................................. 92 HYDRAULIC TANK AND FILTER.............................................................................. 93 HYDRAULIC AND HSS PUMP................................................................................. 95 PPC VALVE..............................................................................................110 PPC CHARGE VALVE.......................................................................................117 MAIN CONTROL VALVE.....................................................................................119 CLSS...................................................................................................125 HSS MOTOR..............................................................................................148 SUCTION VALVE..........................................................................................153 WORK EQUIPMENT ........................................................................................155 ENGINE CONTROL.........................................................................................158 MACHINE MONITOR SYSTEM.................................................................................159 SENSORS................................................................................................163 20 TESTING AND ADJUSTING...................................................................................166 STANDARD VALUE TABLE FOR ENGINE........................................................................167 STANDARD VALUE TABLE FOR CHASSIS.......................................................................168 STANDARD VALUE TABLE FOR ELECTRICAL SYSTEM.............................................................178 TESTING AND ADJUSTING..................................................................................181 TOOLS FOR TESTING,ADJUSTING,AND TROUBLESHOOTING....................................................182 MEASURING BLOW-BY PRESSURE.........................................................................183 MEASURING EXHAUST COLOR............................................................................184 MEASURING ENGINE OIL PRESSURE......................................................................185 MEASURING ENGINE SPEED.............................................................................186 TESTING FAN BELT TENSION...........................................................................187 TESTING AND ADJUSTING BELT TENSION OF AIR CONDITIONER COMPRESSOR...................................188 MEASURING SPEED AT TORQUE CONVERTER STALL..........................................................189 MEASURING FUEL CONTROL LINKAGE.....................................................................190 ADJUSTING LINKAGES OF FORWARD-REVERSE LEVER,GEAR SHIFT LEVER,AND PARKING BRAKE LEVER...............192 ADJUSTING BRAKE PEDAL LINKAGE......................................................................194 ADJUSTING WORK EQUIPMENT LOCK LEVER................................................................195 ADJUSTING STRAIGHT TILTDOZER.......................................................................196 ADJUSTING PPC VALVE................................................................................198 MEASURING POWER TRAIN HYDRAULIC PRESSURE...........................................................199 MEASURING AND ADJUSTING WORK EQUIPMENT AND STEERING OIL PRESSURE...................................202 TESTING AND ADJUSTING CONTROL CIRCUIT PRESSURE.....................................................204 MEASURING PPC VALVE OUTPUT PRESSURE................................................................205 MEASURING OIL LEAKAGE FROM HSS MOTOR...............................................................206 MEASURING LEAKAGE INSIDE CYLINDER..................................................................206 BLEEDING AIR FROM HYDRAULIC CYLINDER...............................................................207 PROCEDURE FOR SIMPLE TEST OF STEERING BRAKE PERFORMANCE............................................208 TROUBLESHOOTING........................................................................................209 POINTS TO REMEMBER WHEN TROUBLESHOOTING............................................................210 SEQUENCE OF EVENTS IN TROUBLESHOOTING..............................................................211 POINTS TO REMEMBER WHEN CARRYING OUT MAINTENANCE...................................................212 CHECKS BEFORE TROUBLESHOOTING......................................................................220 CONNECTOR TYPES AND MOUNTING LOCATIONS.............................................................221 CONNECTOR PIN ARRANGEMENT DIAGRAM..................................................................222 CONNECTION TABLE FOR CONNECTOR PIN NUMBERS.........................................................224 HOW TO FOLLOW THE TROUBLESHOOTING FLOW DIAGRAMS....................................................246 TROUBLESHOOTING OF ELECTRICAL SYSTEM (E-MODE)......................................................248 TABLE OF FAILURE MODES AND CAUSES (ELECTRICAL SYSTEM)..........................................249 ELECTRICAL CIRCUIT DIAGRAM FOR EACH SYSTEM ....................................................250 E-1 STARTING MOTOR IS NOT CRANKED WHEN STARTING SWITCH IS TURNED TO ON.........................254 E-2 LAMPS DO NOT LIGHT UP......................................................................256 E-3 AUTOMATIC PREHEATING IS NOT CARRIED OUT WHEN GLOW SWITCH IS TURNED TO AUTO.................258 E-4 WIPER DOES NOT WORK........................................................................260 E-5 NO WASHER FLUID IS SPRAYED OUT ............................................................262 E-6 AIR CONDITIONER HAS NO EFFECT..............................................................264 TROUBLESHOOTING OF HYDRAULIC, MECHANICAL SYSTEM (H-MODE)...........................................272 TABLE OF FAILURE MODES AND CAUSES (HYDRAULIC,MECHANICAL SYSTEM)................................273 H-1 BRAKE DOES NOT WORK........................................................................275 H-2 TURNING SPEED IS SLOW (CANNOT TURN) OR LACKS POWER WHEN TURNING............................276 H-3 EXCESSIVE TIME LAG.........................................................................278 H-4 MACHINE CAN TRAVEL IN ONLY ONE DIRECTION (FORWARD OR REVERSE)..............................278 H-5 MACHINE DOES NOT MOVE (WHEN ENGINE IS STARTED AND LEVER IS SHIFTED TO 2ND OR 3RD)..........279 H-6 MACHINE DOES NOT MOVE IN ANY SPEED RANGE...................................................281 H-7 POWER TRAIN OIL TEMPERATURE RISES TOO HIGH.................................................283 H-8 DRAWBAR PULL IS WEAK,TRAVEL SPEED IS SLOW..................................................285 H-9 ABNORMAL NOISE IS GENERATED FROM AROUND HYDRAULIC,HSS PUMP.................................286 H-10 WORK EQUIPMENT SPEED IS SLOW OR LACKS POWER...............................................287 H-11 NO WORK EQUIPMENT MOVES...................................................................287 H-12 TURNING SPEED AND SPEED OF ALL WORK EQUIPMENT IS SLOW ....................................288 H-13 MACHINE CANNOT TURN ......................................................................289 H-14 TURNING LACKS POWER.......................................................................289 H-15 BLADE LIFT OR TILT CYLINDER SPEED IS SLOW OR LACKS POWER..................................290 H-16 BLADE ANGLE CYLINDER SPEED IS SLOW OR LACKS POWER.........................................291 H-17 HYDRAULIC DRIFT OF BLADE LIFT IS EXCESSIVE................................................292 H-18 HYDRAULIC DRIFT OF BLADE TILT IS EXCESSIVE................................................292 H-19 HYDRAULIC DRIFT OF BLADE ANGLE IS EXCESSIVE...............................................293 TROUBLESHOOTING OF MACHINE MONITOR SYSTEM (M-MODE).................................................294 TABLE OF FAILURE MODES AND CAUSES(MACHINE MONITOR SYSTEM)......................................295 ELECTRICAL CIRCUIT DIAGRAM FOR EACH SYSTEM.....................................................296 M-1 NO DISPLAY IS GIVEN ON MONITOR PANEL WHEN STARTING SWITCH IS TURNED TO ON..................298 M-2 WHEN STARTING SWITCH IS TURNED TO ON,ALL MONITOR PANEL LAMPS LIGHT UP AND DO NOT GO OUT....298 M-3 PREHEATING IS ABNORMAL.....................................................................299 a) PREHEATING MONITOR DOES NOT LIGHT UP....................................................299 b) PREHEATING MONITOR DOES NOT GO OFF......................................................299 M-4 CAUTION ITEMS LIGHT UP OR FLASH............................................................301 a) (CHARGE) LIGHTS UP OR FLASHES...........................................................301 b) WHEN STARTING SWITCH IS TURNED TO ON AND ENGINE IS STARTED..............................302 c) (COOLANT TEMPERATURE) FLASHES...........................................................303 d) (POWER TRAIN OIL TEMPERATURE) FLASHES...................................................304 M-5 BUZZER IS ABNORMAL.........................................................................305 a) CAUTION ITEM FLASHES BUT BUZZER DOES NOT SOUND..........................................305 b) MONITOR DISPLAY IS NORMAL, BUT BUZZER SOUNDS............................................305 M-6 WARNING LAMP IS ABNORMAL...................................................................306 a) CAUTION ITEM IS FLASHING BUT LAMP DOES NOT FLASH........................................306 b) MONITOR DISPLAY IS NORMAL BUT LAMP FLASHES..............................................306 M-7 GAUGE IS ABNORMAL..........................................................................307 a) ABNORMALITY IN ENGINE COOLANT TEMPERATURE GAUGE.........................................307 b) ABNORMALITY IN POWER TRAIN OIL TEMPERATURE GAUGE........................................308 c) ABNORMALITY IN FUEL LEVEL GAUGE.........................................................309 M-8 SERVICE METER DOES NOT MOVE AFTER ENGINE IS STARTED........................................310 M-9 MONITOR PANEL LIGHTING DOES NOT LIGHT UP (FRONT LAMPS ARE NORMAL)..........................311 30 DISASSEMBLY AND ASSEMBLY................................................................................312 METHOD OF USING MANUAL.................................................................................314 PRECAUTIONS WHEN CARRYING OUT OPERATION................................................................316 SPECIAL TOOL LIST......................................................................................318 SKETCHES OF SPECIAL TOOLS..............................................................................324 ENGINE.................................................................................................327 REMOVAL............................................................................................327 INSTALLATION.......................................................................................328 RADIATOR AND GUARD.....................................................................................329 REMOVAL............................................................................................329 INSTALLATION.......................................................................................330 RADIATOR...............................................................................................331 REMOVAL............................................................................................331 INSTALLATION.......................................................................................333 HYDRAULIC OIL COOLER...................................................................................334 REMOVAL............................................................................................334 INSTALLATION.......................................................................................334 FUEL TANK..............................................................................................335 REMOVAL............................................................................................335 INSTALLATION.......................................................................................336 DAMPER.................................................................................................337 REMOVAL............................................................................................337 INSTALLATION.......................................................................................339 PTO, TORQUE CONVERTER AND TRANSMISSION.................................................................341 REMOVAL............................................................................................341 INSTALLATION.......................................................................................345 DISCONNECTION......................................................................................346 CONNECTION.........................................................................................347 PTO....................................................................................................348 DISASSEMBLY........................................................................................348 ASSEMBLY...........................................................................................352 TORQUE CONVERTER.......................................................................................356 DISASSEMBLY........................................................................................356 ASSEMBLY...........................................................................................358 TORQFLOW TRANSMISSION..................................................................................361 DISASSEMBLY........................................................................................361 ASSEMBLY...........................................................................................371 TORQUE CONVERTER MAIN BELIEF VALVE.....................................................................386 REMOVAL............................................................................................386 INSTALLATION.......................................................................................386 DISASSEMBLY .......................................................................................387 ASSEMBLY...........................................................................................387 TRANSMISSION CONTROL VALVE.............................................................................388 REMOVAL............................................................................................388 INSTALLATION.......................................................................................388 DISASSEMBLY .......................................................................................389 ASSEMBLY...........................................................................................389 STEERING BRAKE.........................................................................................391 REMOVAL............................................................................................391 INSTALLATION.......................................................................................391 DISASSEMBLY........................................................................................392 ASSEMBLY...........................................................................................395 HSS....................................................................................................398 REMOVAL............................................................................................398 INSTALLATION.......................................................................................405 BRAKE VALVE............................................................................................413 REMOVAL............................................................................................413 INSTALLATION.......................................................................................413 DISASSEMBLY........................................................................................414 ASSEMBLY...........................................................................................415 HSS MOTOR..............................................................................................416 REMOVAL............................................................................................416 INSTALLATION.......................................................................................416 DISASSEMBLY........................................................................................417 ASSEMBLY...........................................................................................421 SCAVENGING PUMP........................................................................................428 REMOVAL............................................................................................428 INSTALLATION.......................................................................................428 POWER TRAIN AND LUBRICATING OIL PUMP...................................................................429 REMOVAL............................................................................................429 INSTALLATION.......................................................................................429 FINAL DRIVE............................................................................................430 REMOVAL............................................................................................430 INSTALLATION.......................................................................................430 DISASSEMBLY........................................................................................431 ASSEMBLY...........................................................................................437 TRACK FRAME............................................................................................446 REMOVAL............................................................................................446 INSTALLATION.......................................................................................447 RECOIL SPRING..........................................................................................448 REMOVAL............................................................................................448 INSTALLATION.......................................................................................448 DISASSEMBLY........................................................................................449 ASSEMBLY...........................................................................................451 IDLER..................................................................................................453 REMOVAL............................................................................................453 INSTALLATION ......................................................................................453 DISASSEMBLY........................................................................................454 ASSEMBLY ..........................................................................................455 TRACK ROLLER...........................................................................................459 REMOVAL............................................................................................459 INSTALLATION.......................................................................................459 DISASSEMBLY........................................................................................460 ASSEMBLY...........................................................................................462 CARRIER ROLLER.........................................................................................464 REMOVAL............................................................................................464 INSTALLATION.......................................................................................464 DISASSEMBLY........................................................................................465 ASSEMBLY...........................................................................................466 TRACK SHOE.............................................................................................467 CHECKING BEFORE REMOVAL............................................................................467 REMOVAL (NORMAL)...................................................................................467 REMOVAL (WHEN THERE IS ABNORMALITY INSIDE TRACK FRAME).............................................468 INSTALLATION.......................................................................................469 OVERALL DISASSEMBLY................................................................................470 OVERALL ASSEMBLY...................................................................................475 PRESS-FITTING JIG DIMENSION TABLE FOR LINK PRESS.......................................................489 ONE LINK...............................................................................................490 FIELD DISASSEMBLY..................................................................................490 FIELD ASSEMBLY.....................................................................................491 PIVOT SHAFT............................................................................................497 REMOVAL............................................................................................497 INSTALLATION.......................................................................................497 EQUALIZER BAR..........................................................................................498 REMOVAL............................................................................................498 INSTALLATION.......................................................................................499 EQUALIZER BAR SIDE BUSHING.............................................................................500 REMOVAL............................................................................................500 INSTALLATION.......................................................................................500 SEGMENT TEETH..........................................................................................501 REMOVAL............................................................................................501 INSTALLATION.......................................................................................501 HSS AND HYDRAULIC PUMP.................................................................................502 REMOVAL............................................................................................502 INSTALLATION.......................................................................................502 DISASSEMBLY........................................................................................503 ASSEMBLY...........................................................................................508 PPC PUMP AND PPC CHARGE RELIEF VALVE...................................................................517 REMOVAL............................................................................................517 INSTALLATION.......................................................................................517 DISASSEMBLY........................................................................................518 ASSEMBLY...........................................................................................518 MAIN CONTROL VALVE.....................................................................................519 REMOVAL............................................................................................519 INSTALLATION.......................................................................................520 DISASSEMBLY........................................................................................521 ASSEMBLY...........................................................................................527 STEERING PPC VALVE.....................................................................................534 REMOVAL............................................................................................534 INSTALLATION.......................................................................................535 DISASSEMBLY........................................................................................536 ASSEMBLY...........................................................................................537 SUCTION VALVE..........................................................................................538 REMOVAL............................................................................................538 INSTALLATION.......................................................................................538 BLADE ANGLE CYLINDER...................................................................................539 REMOVAL............................................................................................539 INSTALLATION.......................................................................................539 BLADE TILT CYLINDER....................................................................................540 REMOVAL............................................................................................540 INSTALLATION.......................................................................................540 BLADE LIFT CYLINDER....................................................................................541 REMOVAL............................................................................................541 INSTALLATION.......................................................................................541 HYDRAULIC CYLINDER.....................................................................................542 DISASSEMBLY........................................................................................542 ASSEMBLY...........................................................................................544 WORK EQUIPMENT.........................................................................................547 REMOVAL............................................................................................547 INSTALLATION.......................................................................................548 DISASSEMBLY........................................................................................549 ASSEMBLY...........................................................................................551 ROPS GUARD(ROPS CANOPY)................................................................................553 REMOVAL............................................................................................553 INSTALLATION.......................................................................................553 CANOPY.................................................................................................553 REMOVAL............................................................................................553 INSTALLATION.......................................................................................553 DASHBOARD..............................................................................................554 REMOVAL............................................................................................554 INSTALLATION.......................................................................................554 MONITOR PANEL..........................................................................................555 REMOVAL............................................................................................555 INSTALLATION.......................................................................................555 FLOOR FRAME............................................................................................556 REMOVAL............................................................................................556 INSTALLATION.......................................................................................560 40 MAINTENANCE STANDARD....................................................................................561 DAMPER,UNIVERSAL JOINT.................................................................................562 TORQUE CONVERTER,PTO...................................................................................563 TRANSMISSION...........................................................................................565 TRANSMISSION CONTROL VALVE.............................................................................567 MAIN RELIEF VALVE......................................................................................568 BEVEL GEAR SHAFT,HSS STEERING,BRAKE(1/2)...............................................................569 BEVEL GEAR SHAFT,HSS STEERING,BRAKE(2/2)...............................................................572 BRAKE VALVE............................................................................................574 WORK EQUIPMENT,HSS PUMP................................................................................575 HSS MOTOR..............................................................................................576 POWER TRAIN LUBRICATION PUMP...........................................................................577 PPC CONTROL PUMP.......................................................................................578 PPC VALVE..............................................................................................579 PPC CHARGE VALVE.......................................................................................580 FINAL DRIVE............................................................................................581 TRACK FRAME,RECOIL SPRING..............................................................................582 IDLER..................................................................................................583 TRACK ROLLER...........................................................................................584 CARRIER ROLLER.........................................................................................585 TRACK SHOP.............................................................................................586 DIMENSIONS OF SHAPE OF SPROCKET TOOTH(ACTUAL SIZE).....................................................588 SUSPENSION.............................................................................................589 MAIN CONTROL VALVE.....................................................................................591 WORK EQUIPMENT CYLINDER................................................................................598 WORK EQUIPMENT.........................................................................................601 CUTTING EDGE,END BIT...................................................................................607 RIPPER.................................................................................................609 90 OTHER...................................................................................................610 ELECTRIC CIRCUIT DIAGRAM FOR CAB.......................................................................611 POWER TRAIN HYDRAULIC CIRCUIT DIAGRAM..................................................................612 STEERING・WORK EQUIPMENT HYDRAULIC CIRCUIT DIAGRAM......................................................613 ELECTRIC CIRCUIT DIAGRAM...............................................................................614 CAB SPECIFICATION..................................................................................614 CANOPY SPECIFICATION...............................................................................615 ELECTRIC CIRCUIT DIAGRAM(FOR IRAQU SPEC.) CANOPY SPECIFICATION (1/2)...................................616 ELECTRIC CIRCUIT DIAGRAM(FOR IRAQU SPEC.) CANOPY SPECIFICATION (2/2)...................................617
DESCRIPTION:
KOMATSU D61EX,PX-12 SHOP MANUAL SEBM036700 – PDF DOWNLOAD
FOREWORD
GENERAL
This shop manual has been prepared as an aid to improve the quality of repairs by giving the serviceman an accurate understanding of the product and by showing him the correct way to perform repairs and make judgements. Make sure you understand the contents of this manual and use it to full effect at every opportunity.
This shop manual mainly contains the necessary technical information for operations performed in a service workshop. For ease of understanding, the manual is divided into the following chapters; these chapters are further divided into the each main group of components.
STRUCTURE AND FUNCTION
This section explains the structure and function of each component. It serves not only to give an understanding of the structure, but also serves as reference material for troubleshooting. In addition, this section may contain hydraulic circuit diagrams, electric circuit diagrams, and maintenance standards.
TESTING AND ADJUSTING
This section explains checks to be made before and after performing repairs, as well as adjustments to be made at completion of the checks and repairs. Troubleshooting charts correlating “Problems” with “Causes” are also included in this section.
DISASSEMBLY AND ASSEMBLY
This section explains the procedures for removing, installing, disassembling and assembling each component, as well as precautions for them.
MAINTENANCE STANDARD
This section gives the judgment standards for inspection of disassembled parts. The contents of this section may be described in STRUCTURE AND FUNCTION.
OTHERS
This section mainly gives hydraulic circuit diagrams and electric circuit diagrams. In addition, this section may give the specifications of attachments and options together.
S.S 26/12/24
