Komatsu Bulldozer D61EX-23M0 service & repair manual

Description Komatsu Bulldozer D61EX-23M0 service & repair manual

Komatsu Bulldozer D61EX-23M0 pdf workshop service repair manual

Serial number B50001 and up

Technical documentation, specifications, troubleshooting, maintenance, electrical diagrams, hydraulic schematics, adjusting, assembly, disassembly, removal, installation instructions and other information

MANUAL CONTENT:
Index and foreword
Foreword, safety and general information
Important safety notice
How to read the shop manual
Explanation of terms for maintenance standard
Handling equipment of fuel system devices
Handling of intake system parts
Handling of hydraulic equipment
Method of disconnecting and connecting of push-pull type coupler
Handling of electrical equipment
How to read electric wire code
Precautions when performing operation
Practical use of KOMTRAX
Standard tightening torque table
List of abbreviation
Conversion table

Specification
Specification drawing
Weight table
Table of fuel, coolant, and lubricants

Structure and function
Engine and cooling system
Engine related parts
Cooling system
Cooling fan motor
Oil cooler bypass and HST charge safety valve
Power train
Power train system
Damper
Hydraulic component layout of HST
Steering and brake control
HST pump
HST motor
Charge pump
Solenoid valve
Final drive
Undercarriage and frame
Main frame
Suspension
Track frame and idler cushion
Hydraulic system
Hydraulic component layout of work equipment
Work equipment control system
Hydraulic tank
CLSS
Work equipment and cooling fan pump
Control valve
Ripper PPC valve
Quick drop valve
Angle control EPC valve
Accumulator
Work equipment
Blade
Ripper
Piston valve
Cab and its attachments
ROPS cab
Cab mount
Electrical system
Engine control system
Cooling system control system
HSTcontrol system
Parking brake control system
System operating lamp function
Battery disconnect switch function
Machine monitor system
KOMTRAX system
System component parts
Sensor

Standard value tables
Standard service value table
Standard value table for engine
Standard value table for machine
Standard value table for electrical system

Testing and adjusting
Related information on testing and adjusting
Tools for testing and adjusting
Sketch of tools for testing and adjusting
Engine and cooling system
Testing engine speed
Testing boost pressure
Measuring exhaust color
Testing and adjusting valve clearance
Measuring compression pressure
Testing blowby pressure
Testing engine oil pressure
Testing fuel pressure
Testing fuel discharge, return and leakage
Bleeding air from fuel system
Testing fuel circuit for leakage
Handling cylinder cutout mode operation
Handling noinjection cranking operation
Testing of installed condition of cylinder heads and manifolds
Testing engine piping for damage and looseness
Replacing alternator belt
Power train
Testing and adjusting HSToil pressure
Testing output pressure of solenoid valve
Testing if machine travels straight
Simple test procedure for brake performance
Adjusting deceleration/brake pedal
Adjusting parking brake lever
Move disabled machine urgently
Undercarriage and frame
Adjusting idler clearance
Checking sprocket wear
Testing and adjusting track tension
Hydraulic system
Releasing remaining pressure in work equipment cylinder
Testing and adjusting work equipment oil pressure
Testing source pressure of control circuit
Testing outlet pressure of work equipment EPC valve and fan EPC valve
Isolating the parts causing hydraulic drift in blade and ripper
Testing internal oil leakage of work equipment cylinder
Testing fan speed
Testing fan circuit oil pressure
Bleeding air from hydraulic circuit
Work equipment
Adjusting work equipment lock lever
Adjusting play of blade center ball
Electrical system
Special functions of machine monitor
Adjustment method when HST controller has been replaced
Adjustment method when electric or hydraulic device has been replaced
Adjusting rear view camera angle
Handling voltage circuit of engine controller
Handling battery disconnect switch
Testing diodes
Pm clinic
Pm Clinic service
Pm Clinic check sheet

Troubleshooting
Related information on troubleshooting
Troubleshooting points
Sequence of events in troubleshooting
Checks before troubleshooting
Inspection procedure before troubleshooting
Preparation for troubleshooting of electrical system
Classification and procedures for troubleshooting
Symptom and troubleshooting numbers
Information in troubleshooting table
Procedure for troubleshooting wiring harness of pressure sensor system for open circuit
Connector list and layout
Connector contact identification
T-branch box and T-branch adapter table
Fuse location table
Failure codes table
Troubleshooting by failure code (Display of code)
Troubleshooting of electrical system (E-mode)
Troubleshooting of hydraulic and mechanical system (H-mode)
Troubleshooting of engine (S-mode)

Disassembly and assembly
Related information on disassembly and assembly
How to read this manual
Coating materials list
Special tools list
Sketches of special tools
Engine and cooling system
Removal and installation of supply pump assembly
Removal and installation of fuel injector assembly
Removal and installation of cylinder head assembly
Removal and installation of radiator assembly
Removal and installation of aftercooler assembly
Removal and installation of hydraulic oil cooler assembly
Removal and installation of cooling fan drive assembly
Removal and installation of cooling fan motor assembly
Removal and installation of engine assembly
Disassembly and assembly of damper assembly
Removal and installation of engine front oil seal
Removal and installation of engine rear oil seal
Removal and installation of engine hood assembly
Removal and installation of fuel tank assembly
Removal and installation of muffler
Removal and installation of belt for alternator and air conditioner compressor
Removal and installation of air cleaner assembly
Power train
Removal and installation of HST pump assembly
Removal and installation of HST motor and final drive assembly
Disassembly and assembly of final drive
Undercarriage and frame
Removal and installation of track frame assembly
Removal and installation of idler assembly
Disassembly and assembly of idler
Removal and installation of recoil spring assembly
Disassembly and assembly of recoil spring
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
Removal and installation of segment teeth
Separation and connection of track shoe assembly (Standard type track shoe)
Overall disassembly and assembly of track shoe assembly (Standard type track shoe)
Disassembly and assembly of one track link assembly in field (Standard type track shoe)
Removal and installation of pivot shaft assembly
Removal and installation of equalizer bar assembly
Removal and installation of equalizer bar side bushing
Hydraulic system
Removal and installation of hydraulic tank assembly
Removal and installation of control valve assembly
Disassembly and assembly of hydraulic cylinder assembly
Work equipment
Removal and installation of work equipment assembly
Removal and installation of blade assembly
Removal and installation of Uframe assembly
Cab and its attachments
Removal and installation of ROPS cab assembly
Removal and installation of operator's cab glass (adhesion glass)
Removal and installation of operator's seat
Removal and installation of seat belt
Removal and installation of foot heater assembly
Disassembly and assembly of foot heater assembly
Removal and installation of air conditioner unit assembly
Removal and installation of air conditioner compressor assembly
Electrical system
Removal and installation of machine monitor assembly
Removal and installation of engine controller assembly
Removal and installation of HSTcontroller assembly
Removal and installation of KOMTRAX terminal

Maintenance standard
Engine and cooling system
Engine mount
Cooling fan motor
Oil cooler bypass and HSTcharge safety valve
Power train
Damper
HST pump
HST motor
Charge pump
Solenoid valve
Final drive
Sprocket
Full-scale drawing of sprocket tooth profile
Undercarriage and frame
Suspension
Track frame and idler cushion
Idler
Track roller
Carrier roller
Hydraulic system
Hydraulic tank
Work equipment and cooling fan pump
Control valve
Ripper PPC valve
Quick drop valve
Angle control EPC valve
Work equipment
Blade
Cutting edge and end bit
Ripper
Lift cylinder
Tilt cylinder
Angle cylinder
Ripper cylinder
Cab and its attachments
Cab mount
Electrical system
Electric steering lever

Appendix
Air conditioner components
Precautions for refrigerant
Air conditioner component
Configuration and function of refrigeration cycle
Outline of refrigeration cycle
Air conditioner unit
Dual pressure switch
Pressure switch
Compressor
Condenser
Receiver drier
Procedure for testing and troubleshooting
Electrical circuit diagram
System diagram
Parts and connectors layout
Testing relays
Troubleshooting chart
Information described in troubleshooting table
A-1 Troubleshooting for condenser fan
A-2 Troubleshooting for compressor and refrigerant system (Air is not cooled)
A-3 Troubleshooting for blower motor system (No air comes out or air flow is abnormal)
A-4 Troubleshooting for temperature control
Troubleshooting with gauge pressure
Connection of service tool
Precautions for disconnecting and connecting hoses and tubes in air conditioner circuit
Handling of compressor oil

Diagrams and drawings
Hydraulic circuit diagram
Symbols in hydraulic circuit diagram
Electric circuit diagram
Symbols in electric circuit diagram

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