KOMATSU D61EX-15, D61PX-15 BULLDOZER Service Shop Repair Manual

WE051Z0002 • This shop manual may contain attachments and optional equipment that are not available in your area. Please consult your local Komatsu distributor for those items you may require. Materials and specifications are subject to change without notice. • D61-15 mount the SA6D114E-2 engine. MACHINE MODEL SERIAL NUMBER D61EX-15 D61PX-15 B40001 and up B40001 and up

WE051Y0102 Bulldozer D61EX-15 D61PX-15 Machine Model 1 Serial Number 1 D61EX-15 B40001 and up D61PX-15 B40001 and up General 1 Table of general contents .............................................................................................. 2

General 2 WE051Y0102 Table of general contents 1 Each shop manual is composed as shown below. Since this table of general contents is issued each time an item is added or revised, keep the shop manual up to date accordingly to it. The brochures added or revised this time are indicated with the symbols shown in the table at right. Add or revise the shop manual accordingly to this table. Symbol Indication Remedy Q Section to be newly added Add q Section to be replaced Replace Form No. Section Title WE051Z0002 The whole shop manual composition (all the following contents are included) WE051Y0002 General q WE051Y0102 General Table of general contents WE051Y0200 General Safety, foreword WE051A0000 General WE051A0100 General Specification dimension drawing Specifications Weight table Oil and coolant table WE051B0000 Structure and function, Maintenance standard WE051B0100 Structure and function, Maintenance standard Engine and cooling related components Cooling system Power transmitting Power train Power train skeleton Overall drawing of power train unit Hydraulic piping diagram of power train Damper and universal joint Transmission, steering, and brake control WE051B0200 Structure and function, Maintenance standard Power transmitting system Torque converter and PTO Transmission Transmission ECMV Main relief valve Lubrication oil relief valve WE051B0300 Structure and function, Maintenance standard Power transmitting system Scavenging pump Power train and lubrication pump HSS system WE051B0400 Structure and function, Maintenance standard Power transmitting system HSS pump HSS motor WE051B0500 Structure and function, Maintenance standard Power transmitting system Bevel gear shaft, HSS, and brake Brake valve Final drive

General WE051Y0102 3 WE051B0600 Structure and function, Maintenance standard Undercarriage and frame Frame assembly Suspension Track frame and recoil spring Idler Track roller Carrier roller Sprocket Track shoe WE051B0700 Structure and function, Maintenance standard Hydraulic system Layout of hydraulic devices for work equipment Work equipment control Hydraulic tank and filter Solenoid valve Accumulator Hydraulic cylinder Piston valve Quick drop valve WE051B0800 Structure and function, Maintenance standard Hydraulic system Cooling fan pump Cooling fan motor PPC valve Electric lever (Steering) WE051B0900 Structure and function, Maintenance standard Hydraulic system Control valve CLSS Self-pressure reducing valve WE051B1000 Structure and function, Maintenance standard Work equipment Work equipment Cutting edge and end bit Ripper Cab and its attachments Cab mount Cab Air conditioner piping WE051B1100 Structure and function, Maintenance standard Electric system Engine control system Cooling system control system Palm command control system PPC lock system Component parts of system Monitor system Monitor panel Sensor WE051C0000 Standard value table WE051C0100 Standard value table Standard value table for engine Standard value table for chassis Form No. Section Title

General 4 WE051Y0102 WE051D0000 Testing and adjusting WE051D0100 Testing and adjusting Testing and adjusting (1/2) Tools for testing, adjusting and troubleshooting Measuring engine speed Measuring intake air pressure (boost pressure) Measuring exhaust color Adjusting valve clearance Measuring compression pressure Measuring blow-by pressure Testing and adjusting fuel injection timing Measuring engine oil pressure Testing and adjusting air conditioner compressor belt tension Adjusting engine speed sensor Adjusting fuel control linkage Measuring power train oil pressure Adjusting transmission speed sensor (replacement procedure) Simple method of testing brake performance Adjusting brake pedal Adjusting parking brake lever Emergency escape method when power train has a trouble Adjusting idler clearance Inspecting wear of sprocket Testing and adjusting track shoe tension Testing and adjusting work equipment and HSS oil pressure Testing control circuit main pressure Measuring PPC valve output pressure Adjusting play of work equipment PPC valve Measuring internal leakage of work equipment cylinder Adjusting safety lock lever of work equipment Releasing residual pressure in work equipment cylinder (If PPC accumulator is not installed) Releasing residual pressure in work equipment cylinder (If PPC accumulator is installed) Bleeding air from work equipment cylinder Measuring fan pump circuit pressure Measuring fan motor speed Measuring HSS motor oil leakage Bleeding air from fan pump Testing and adjusting operator's cab WE051D0200 Testing and adjusting Testing and adjusting (2/2) Special functions of monitor panel (EMMS) Adjustment method of replaced controller Preparatory work for troubleshooting for electric system Pm clinic Undercarriage troubleshooting report Form No. Section Title

General WE051Y0102 5 WE051E0000 Troubleshooting WE051E0100 Troubleshooting Preface Points to remember when troubleshooting Troubleshooting procedure Points to remember when carrying out maintenance Checks before troubleshooting Classification and procedures of troubleshooting Connector arrangement drawing and electric circuit diagram of each system WE051E0200 Troubleshooting Troubleshooting when error code is displayed (Error code) Error code table Information described in troubleshooting list WE051E0300 Troubleshooting Troubleshooting of electrical system (E-mode) Before troubleshooting electrical system (E-mode) Information described in troubleshooting list WE051E0400 Troubleshooting Troubleshooting of hydraulic and mechanical system (H-mode) Information described in troubleshooting list WE051E0500 Troubleshooting Troubleshooting of engine system (S-mode) Method of using matrix troubleshooting charts WE051F0000 Disassembly and assembly Q WE051F0100 Disassembly and assembly Preface How to read this manual Standard tightening torque table Precautions when performing operation List of coatings Special tool list Sketches of special tools Q WE051F0200 Disassembly and assembly Engine related procedures Removal and installation of fuel injection pump assembly Removal and installation of cylinder head assembly Removal and installation of engine front seal Removal and installation of engine rear seal Removal and installation of engine assembly Removal and installation of damper assembly Removal and installation of radiator guard assembly Removal and installation of radiator and hydraulic oil cooler assembly Removal and installation of fan drive assembly Removal and installation of fan motor assembly Removal and installation of engine hood assembly Removal and installation of fuel tank assembly Q WE051F0300 Disassembly and assembly Power train Removal and installation of PTO, torque converter and transmission assembly Disconnection and connection of PTO, torque converter and transmission assembly Disassembly and assembly of PTO assembly Disassembly and assembly of torque converter assembly Disassembly and assembly of TORQFLOW transmission assembly Removal and installation of torque converter main relief valve assembly Disassembly and assembly of torque converter main relief valve assembly Form No. Section Title

General 6 WE051Y0102 Q WE051F0400 Disassembly and assembly Power train Removal and installation of power train and lubricating oil pump assembly Removal and installation of HSS and work equipment pump assembly Removal and installation of scavenging pump assembly Removal and installation of HSS motor assembly Disassembly and assembly of HSS assembly Removal and installation of final drive assembly Disassembly and assembly of final drive assembly Q WE051F0500 Disassembly and assembly Undercarriage Removal and installation of track frame assembly Removal and installation of idler assembly Disassembly and assembly of idler assembly Removal and installation of recoil spring assembly Disassembly and assembly of recoil spring assembly Removal and installation of track roller assembly Disassembly and assembly of track roller assembly Removal and installation of carrier roller assembly Disassembly and assembly of carrier roller assembly Q WE051F0600 Disassembly and assembly Undercarriage Check before expanding track shoe assembly Expansion (normal), expansion (internal abnormality) and installation of track shoe assembly Overall disassembly and overall assembly of track shoe assembly Link press-fitting jig dimensions table Field disassembly and assembly of one link Removal and installation of pivot shaft assembly Removal and installation of equalizer bar assembly Removal and installation of equalizer bar side bushing Removal and installation of segment teeth Q WE051F0700 Disassembly and assembly Hydraulic system Removal and installation of main control valve assembly Assembly of main control valve assembly Removal and installation of cooling fan pump assembly Removal and installation of work equipment assembly Disassembly and assembly of work equipment assembly Disassembly and assembly of hydraulic cylinder assembly Q WE051F0800 Disassembly and assembly Others Removal and installation of operator's cab assembly Removal and installation of operator's cab glass (stuck glass) Removal and installation of ROPS canopy Removal and installation of dashboard assembly Removal and installation of floor frame assembly Removal and installation of steering and transmission controller assembly Form No. Section Title

General WE051Y0102 7 WE051X0000 Others WE051X0100 Others Hydraulic circuit diagram Power train hydraulic circuit diagram Work equipment hydraulic circuit diagram Power angle power tilt dozer (PAT) Work equipment hydraulic circuit diagram Power tilt dozer (PT) Electrical circuit diagram Electrical circuit diagram (1/6) Electrical circuit diagram (2/6) Electrical circuit diagram (3/6) Electrical circuit diagram (4/6) Electrical circuit diagram (5/6) Electrical circuit diagram (6/6) Cab electrical circuit diagram Form No. Section Title

KOMATSU D61EX-15, D61PX-15 BULLDOZER Service Shop Repair Manual

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