Komatsu D61PX-15 Dozer Bulldozer Service Repair Manual S/N B40001 and up

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This is the Highly Detailed factory service repair manual for theKOMATSU D61PX-15 DOZER BULLDOZER, this Service Manual has detailed illustrations as well as step by step instructions,It is 100 percents complete and intact. they are specifically written for the do-it-yourself-er as well as the experienced mechanic.KOMATSU D61PX-15 DOZER BULLDOZER Service Repair Workshop Manual provides step-by-step instructions based on the complete dis-assembly of the machine. It is this level of detail, along with hundreds of photos and illustrations, that guide the reader through each service and repair procedure. Complete download comes in pdf format which can work under all PC based windows operating system and Mac also, All pages are printable. Using this repair manual is an inexpensive way to keep your vehicle working properly. Service Repair Manual Covers: General Structure and Function, Maintenance Standard Testing, Adjusting and Troubleshooting Disassembly and Assembly Others File Format: PDF Compatible: All Versions of Windows & Mac Language: English Requirements: Adobe PDF Reader NO waiting, Buy from responsible seller and get INSTANT DOWNLOAD, Without wasting your hard-owned money on uncertainty or surprise! All pages are is great to haveKOMATSU D61PX-15 DOZER BULLDOZER Service Repair Workshop Manual. Looking for some other Service Repair Manual,please check: https://www.aservicemanualpdf.com/ Thanks for visiting!
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  • 1. 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
  • 2. 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
  • 3. 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
  • 4. 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
  • 5. 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
  • 6. 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
  • 7. 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
  • 8. 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
  • 9. WE051Y0200 Bulldozer D61EX-15 D61PX-15 Model Serial Number 1 D61EX-15 B40001- D61PX-15 B40001- General 1 Safety............................................................................................................................2 Foreword....................................................................................................................... 4
  • 10. General 2 WE051Y0200 Safety Safety notice General precautions Mistakes in operation are extremely dangerous. Read the Operation and Maintenance Manual carefully BEFORE operating the machine. 1. Before carrying out any greasing or repairs, read all the precautions given on the decals which are fixed to the machine. 2. When carrying out any operation, always wear safety shoes and helmet. Do not wear loose work clothes, or clothes with buttons missing. q Always wear safety glasses when hitting parts with a hammer. q Always wear safety glasses when grinding parts with a grinder, etc. 3. If welding repairs are needed, always have a trained, experienced welder carry out the work. When carrying out welding work, always wear welding gloves, apron, hand shield, cap and other clothes suited for welding work. 4. When carrying out any operation with two or more workers, always agree on the operating procedure before starting. Always inform your fellow workers before starting any step of the operation. Before starting work, hang UNDER REPAIR signs on the controls in the operator's compartment. 5. Keep all tools in good condition and learn the cor- rect way to use them. 6. Decide a place in the repair workshop to keep tools and removed parts. Always keep the tools and parts in their correct places. Always keep the work area clean and make sure that there is no dirt or oil on the floor. Smoke only in the areas pro- vided for smoking. Never smoke while working. Preparations for work 7. Before adding oil or making any repairs, park the machine on hard, level ground, and block the wheels or tracks to prevent the machine from mov- ing. 8. Before starting work, lower blade, ripper, bucket or any other work equipment to the ground. If this is not possible, insert the safety pin or use blocks to prevent the work equipment from falling. In addi- tion, be sure to lock all the control levers and hang warning signs on them. 9. When disassembling or assembling, support the machine with blocks, jacks or stands before start- ing work. 10. Remove all mud and oil from the steps or other places used to get on and off the machine. Always use the handrails, ladders or steps when getting on or off the machine. Never jump on or off the machine. If it is impossible to use the handrails, ladders or steps, use a stand to provide safe foot- ing. Important safety notice Proper service and repair is extremely important for safe machine operation. The service and repair techniques recommended by KOMATSU and described in this manual are both effective and safe. Some of these techniques require the use of tools specially designed by KOMATSU for the specific purpose. To prevent injury to workers, the symbol k is used to mark safety precautions in this manual. The cautions accompanying these symbols should always be followed carefully. If any dangerous situa- tion arises or may possibly arise, first consider safety, and take the necessary actions to deal with the situation.
  • 11. General WE051Y0200 3 Precautions during work 11. When removing the oil filler cap, drain plug or hydraulic pressure measuring plugs, loosen them slowly to prevent the oil from spurting out. Before disconnecting or removing components of the oil, water or air circuits, first remove the pres- sure completely from the circuit. 12. The water and oil in the circuits are hot when the engine is stopped, so be careful not to get burned. Wait for the oil and water to cool before carrying out any work on the oil or water circuits. 13. Before starting work, remove the leads from the battery. Always remove the lead from the negative (–) terminal first. 14. When raising heavy components, use a hoist or crane. Check that the wire rope, chains and hooks are free from damage. Always use lifting equipment which has ample capacity. Install the lifting equipment at the correct places. Use a hoist or crane and operate slowly to prevent the component from hitting any other part. Do not work with any part still raised by the hoist or crane. 15. When removing covers which are under internal pressure or under pressure from a spring, always leave two bolts in position on opposite sides. Slowly release the pressure, then slowly loosen the bolts to remove. 16. When removing components, be careful not to break or damage the wiring. Damaged wiring may cause electrical fires. 17. When removing piping, stop the fuel or oil from spilling out. If any fuel or oil drips onto the floor, wipe it up immediately. Fuel or oil on the floor can cause you to slip, or can even start fires. 18. As a general rule, do not use gasoline to wash parts. In particular, use only the minimum of gaso- line when washing electrical parts. 19. Be sure to assemble all parts again in their original places. Replace any damaged parts with new parts. q When installing hoses and wires, be sure that they will not be damaged by contact with other parts when the machine is being operated. 20. When installing high pressure hoses, make sure that they are not twisted. Damaged tubes are dan- gerous, so be extremely careful when installing tubes for high pressure circuits. Also, check that connecting parts are correctly installed. 21. When assembling or installing parts, always use the specified tightening torques. When installing protective parts such as guards, or parts which vibrate violently or rotate at high speed, be particu- larly careful to check that they are installed cor- rectly. 22. When aligning two holes, never insert your fingers or hand. Be careful not to get your fingers caught in a hole. 23. When measuring hydraulic pressure, check that the measuring tool is correctly assembled before taking any measurements. 24. Take care when removing or installing the tracks of track-type machines. When removing the track, the track separates sud- denly, so never let anyone stand at either end of the track.
  • 12. General 4 WE051Y0200 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. Notice The specifications contained in this shop manual are subject to change at any time and without any advance notice. Use the specifications given in the book with the latest date.
  • 13. Thank you very much for your reading. Please Click Here. Then Get COMPLETE MANUAL. NO WAITING NOTE: If there is no response to click on the link above, please download the PDF document first and then click on it.
  • 14. General WE051Y0200 5 How to read the shop manual Volumes Shop manuals are issued as a guide to carrying out repairs. They are divided as follows: Chassis volume: Issued for every machine model Engine volume: Issued for each engine series These various volumes are designed to avoid duplicat- ing the same information. Therefore, to deal with all repairs for any model, it is necessary that chassis, engine, electrical and attachment volumes be avail- able. Distribution and updating Any additions, amendments or other changes will be sent to KOMATSU distributors. Get the most up-to- date information before you start any work. Symbols So that the shop manual can be of ample practical use, important safety and quality portions are marked with the following symbols. Electrical volume: Attachments volume: Each issue
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