Komatsu D61EX-15E0, D61PX 15E0 Bulldozer Service Manual
1,253 pages · Publication SEN02387-05
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- Models
- D61EX-15E0, D61PX 15E0
- Serial coverage
- B45001 and up
- Manual type
- Service Manual
- Pages
- 1,253
- Publication
- SEN02387-05
- Condition
- Brand new
What's inside
From the manual's own table of contents: 203 sections, 403 entries. See sample pages (PDF, 1165 KB)
Composition of shop manual
Safety notice
How to read the shop manual
Explanation of terms for maintenance standard
Handling electric equipment and hydraulic component
How to read electric wire code
Precautions when carrying out operation
Method of disassembling and connecting push-pull type coupler
Standard tightening torque table
Conversion table
Specification dimension drawing
Specifications
Weight table
Table of fuel, coolant and lubricants
Cooling system
Cooling fan pump
Cooling fan motor
Power train
HSS system
General view of the power train unit
Power train hydraulic piping drawing
Transmission, steering, brake control
Damper and universal joint
Torque converter, PTO
Show all 203 sections
Transmission
Transmission ECMV
Main relief valve and torque converter relief valve
Lubricating oil relief valve
Bevel gear shaft, HSS and brake
Brake valve
Final drive
Main frame
Suspension
Track frame and idler cushion
Idler
Track roller
Carrier roller
Sprocket
Track shoe42 topics
- Layout of hydraulic devices for work equipment
- Work equipment control
- Hydraulic tank and filter
- Scavenging pump
- Power train and steering lubrication pump
- HSS pump
- HSS motor
- Control valve
- CLSS
- Self pressure reducing valve
- PPC valve
- Electric lever (Steering)
- Quick drop valve
- Solenoid valve
- Accumulator
- Work equipment
- Cutting edge and end bit
- Ripper
- Hydraulic cylinder
- Piston valve
- Cab mount
- Air conditioner piping diagram
- Monitor system
- Monitor panel
- Engine control
- Engine control system
- Cooling system control system
- System components
- Palm command control system
- PPC lock system
- KOMTRAX terminal system
- KOMTRAX terminal
- Sensor
- Standard value table for engine
- Standard value table for machine
- Standard value table for engine related parts
- Measuring engine speed
- Measuring intake air pressure (boost pressure)
- Measuring exhaust color
- Adjusting valve clearance
- Measuring compression pressure
- Measuring blow-by pressure
Measuring engine oil pressure
Handling fuel system equipment
Releasing residual pressure in fuel system
Measuring fuel pressure
Measuring fuel delivery amount, return rate and leakage
Bleeding air from fuel circuit
Testing leakage in fuel system
Handling of reduced cylinder mode operation
Handling of no injection cranking operation
Testing and adjusting air conditioner compressor belt tension
Replacing the fan belt
Handling controller voltage circuit
Adjusting fuel control dial and decelerator pedal
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 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 work equipment 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 motor speed
Measuring fan pump circuit pressure
Measuring HSS motor oil leakage
Bleeding air from fan pump
Testing and adjusting operator's cab
Testing and adjusting, Part 2
Handling of voltage circuit of engine controller
Adjustment method when controller has been replaced
Preparatory work for troubleshooting for electric system
Inspection procedure of diode
Pm-Clinic service
How to start operation of KOMTRAX terminal
Lamp display of KOMTRAX terminal
Failure code table
Fuse locations
Points to remember when troubleshooting
Sequence of events in troubleshooting
Checks before troubleshooting37 topics
- Classification and procedures of troubleshooting
- Contents of troubleshooting table
- Wiring table for connector pin numbers
- T-adapter box and T-adapter table
- Failure code [1500L0] Transmission clutch: Dual engagement
- Failure code [15SAL1] Forward clutch: Fill signal is ON when command current is OFF
- Failure code [15SALH] Forward clutch: Fill signal is OFF when command current is ON
- Failure code [15SBL1] Reverse clutch: Fill signal is ON when command current is OFF
- Failure code [15SBLH] Reverse clutch: Fill signal is OFF when command current is ON
- Failure code [15SEL1] 1st clutch: Fill signal is ON when command current is OFF
- Failure code [15SELH] 1st clutch: Fill signal is OFF when command current is ON
- Failure code [15SFL1] 2nd clutch: Fill signal is ON when command current is OFF
- Failure code [15SFLH] 2nd clutch: Fill signal is OFF when command current is ON
- Failure code [15SGL1] 3rd clutch: Fill signal is ON when command current is OFF
- Failure code [15SGLH] 3rd clutch: Fill signal is OFF when command current is ON
- Failure code [AB00MA] Alternator: Malfunction
- Failure code [B@BAZG] Engine oil: Oil pressure too low
- Failure code [B@BCNS] Radiator coolant: Overheat
- Failure code [B@CENS] Power train oil: Overheat
- Failure code [B@HANS] Hydraulic oil: Overheat
- Failure code [CA111] Engine controller: Abnormality in controller
- Abnormal speed sensor signal
- Failure code [CA122] Charge pressure sensor too high: Excessively high voltage detected
- Failure code [CA123] Charge pressure sensor too low: Excessively low voltage detected
- Failure code [CA131] Decelerator pedal sensor too high: Excessively high voltage detected
- Failure code [CA132] Decelerator pedal sensor too low: Excessively low voltage detected
- Failure code [CA145] Coolant temperature sensor too low: Excessively low voltage detected
- Failure code [CA154] Charge temperature sensor too low: Excessively low voltage detected
- Exceeded upper control limit of temperature
- Failure code [CA187] Sensor power source 2 too low: Excessively low voltage detected
- Failure code [CA227] Sensor power source 2 too high: Excessively high voltage detected
- Failure code [CA234] Engine over speed: Excessively high speed
- Excessively low voltage detected
- Failure code [CA271] IMV/PCV1 short circuit: Short circuit
- Failure code [CA272] IMV/PCV1 disconnection: Disconnection
- disconnection, short circuit
- Failure code [CA342] Engine controller data matching error: matching error
Failure code [CA352] Sensor power source 1 too low: Excessively low voltage detected
Failure code [CA386] Sensor power source 1 too high: Excessively high voltage detected
Failure code [CA428] Water detection sensor too high: Excessively high voltage detected
Failure code [CA429] Water detection sensor too low: Excessively low voltage detected
Failure code [CA435] Abnormal engine oil pressure switch: Abnormal signal circuit
Failure code [CA441] Power source voltage too low: Excessively low voltage detected6 topics
- Excessively high voltage has occurred in the controller power source circuit
- Excessively high pressure trouble occurred
- Excessively high voltage detected
- Excessively low voltage detected
- Exceeded upper control limit of temperature
- Loss of pressure feed detected
Failure code [CA689] Abnormal engine Ne speed sensor: Abnormal signal
Failure code [CA731] Abnormal engine Bkup speed sensor phase: Abnormal phase
Failure code [CA757] Loss of all engine controller data: Loss of all data
Failure code [CA778] Abnormal engine Bkup speed sensor: Abnormal Bkup signal
Failure code [CA1633] Abnormal KOMNET: Abnormal communication
Failure code [CA2311] Abnormal IMV solenoid: Abnormal resistance
Failure code [CA2555] Air intake heater relay disconnection: Disconnection
Failure code [CA2556] Air intake heater relay short circuit: Short circuit
Failure code [D110KA] Battery relay: Short circuit
Failure code [D110KB] Battery relay: Disconnection
Failure code [D130KA] Neutral safety relay: Short circuit
Failure code [D130KB] Neutral safety relay: Disconnection
Failure code [D161KA] Back-up alarm relay: Disconnection
Failure code [D161KB] Back-up alarm relay: Short circuit
Failure code [DAFRKR] Monitor panel CAN communication: Defective communication51 topics
- Abnormality in controller
- controller: Power source voltage drop and input
- power source: Power source voltage drop and input
- Inconsistency in model select signal
- Defective communication
- controller: Power source voltage drop and input
- power source: Power source voltage drop and input
- selection: Inconsistency in model select signal
- Failure code [DD12KA] Shift up switch: Disconnection
- Failure code [DD12KB] Shift up switch: Short circuit
- Failure code [DD13KA] Shift down switch: Disconnection
- Failure code [DD13KB] Shift down switch: Short circuit
- Failure code [DD14KA] [DDQ2KA] Parking brake lever switch: Disconnection
- Failure code [DD14KB] [DDQ2KB] Parking brake lever switch: Short circuit
- Failure code [DDQ2KA] [DD14KA] Parking brake lever switch: Disconnection
- Failure code [DDQ2KB] [DD14KB] Parking brake lever switch: Short circuit
- Failure code [DGS1KX] Hydraulic oil temperature sensor: Input signal is out of normal range
- Failure code [DGT1KA] Power train oil temperature sensor: Disconnection
- Failure code [DK10KA] Fuel dial: Disconnection
- Failure code [DK10KB] Fuel dial: Short circuit
- Failure code [DK30KA] Steering potentiometer (1): Disconnection
- Failure code [DK30KB] Steering potentiometer (1): Short circuit
- Failure code [DK30KX] Steering potentiometer: Input signal is out of normal range
- Failure code [DK30L8] Steering potentiometer: Inconsistent analog signal
- Failure code [DK31KA] Steering potentiometer (2): Disconnection
- Failure code [DK31KB] Steering potentiometer (2): Short circuit
- Failure code [DK40KA] Brake potentiometer: Disconnection
- Failure code [DK40KB] Brake potentiometer: Short circuit
- Failure code [DK55KX] Forward-reverse potentiometer: Input signal is out of normal range
- Disconnection or short circuit (Double failure)
- Failure code [DK55L8] Forward-reverse potentiometer: Inconsistent analog signal
- Failure code [DK56KA] Forward-reverse potentiometer (1): Short circuit
- Failure code [DK56KB] Forward-reverse potentiometer (1): Disconnection
- Failure code [DK57KA] Forward-reverse potentiometer (2): Disconnection
- Failure code [DK57KB] Forward-reverse potentiometer (2): Short circuit
- Failure code [DKH1KA] [DKH1KX] Pitch angle sensor: Short circuit
- Failure code [DKH1KB] [DKH1KX] Pitch angle sensor: Disconnection
- Failure code [DLT3KA] Transmission output speed sensor: Disconnection
- Failure code [DLT3KB] Transmission output speed sensor: Short circuit
- Failure code [DV00KB] Alarm buzzer: Short circuit
- Failure code [DW7BKA] Fan reverse solenoid: Disconnection
- Failure code [DW7BKB] Fan reverse solenoid: Short circuit
- Failure code [DWN1KA] HSS EPC solenoid right: Disconnection
- Failure code [DWN1KB] HSS EPC solenoid right: Short circuit
- Failure code [DWN1KY] HSS EPC solenoid right: Short circuit to power source line
- Failure code [DWN2KA] HSS EPC solenoid left: Disconnection
- Failure code [DWN2KB] HSS EPC solenoid left: Short circuit
- Failure code [DWN2KY] HSS EPC solenoid left: Short circuit to power source line
- Failure code [DWN5KA] Fan pump TVC solenoid: Disconnection
- Failure code [DWN5KB] Fan pump TVC solenoid: Short circuit
- Failure code [DWN5KY] Fan pump TVC solenoid: Short circuit in power source line
Failure code [DXA0KA] HSS pump TVC solenoid: Disconnection
Failure code [DXA0KB] HSS pump TVC solenoid: Short circuit
Failure code [DXA0KY] HSS pump TVC solenoid: Short circuit to power source line
Failure code [DXH4KA] 1st clutch ECMV: Disconnection
Failure code [DXH4KB] 1st clutch ECMV: Short circuit
Failure code [DXH4KY] 1st clutch ECMV: Short circuit to power source line
Failure code [DXH5KA] 2nd clutch ECMV: Disconnection
Failure code [DXH5KB] 2nd clutch ECMV: Short circuit
Failure code [DXH5KY] 2nd clutch ECMV: Short circuit to power source line
Failure code [DXH6KA] 3rd clutch ECMV: Disconnection
Failure code [DXH6KB] 3rd clutch ECMV: Short circuit
Failure code [DXH6KY] 3rd clutch ECMV: Short circuit to power source line
Failure code [DXH7KA] Reverse clutch ECMV: Disconnection
Failure code [DXH7KB] Reverse clutch ECMV: Short circuit
Failure code [DXH7KY] Reverse clutch ECMV: Short circuit to power source line
Failure code [DXH8KA] Forward clutch ECMV: Disconnection
Failure code [DXH8KB] Forward clutch ECMV: Short circuit
Failure code [DXH8KY] Forward clutch ECMV: Short circuit to power source line
Before troubleshooting of electrical system
Contents of troubleshooting table
The engine does not start (the starting motor does not turn)
The preheater does not operate
The monitor panel does not light up at all when the starting switch is turned ON1 topic
- and does not go out
While the engine is running, the battery charge level caution lamp flashes
While the engine is running, the emergency warning item flashes
While the preheater is operating, the preheating pilot lamp does not light up
The coolant temperature gauge does not indicate correctly
The power train oil temperature gauge does not indicate correctly
Hydraulic oil temperature gauge does not indicate properly
Fuel gauge does not indicate properly
Gear speed and engine speed are not indicated properly
The preset mode service meter does not indicate normally
The warning lamp does not flash or does not go out
The alarm buzzer does not sound or does not stop
Auto shift down is not possible or is not released
The buzzer cancel switch does not work
The information switch does not work
The fan cleaning does not operate or cannot be reset
The preset mode does not operate or cannot be reset1 topic
- service mode
The back-up alarm does not sound
The head lamp and rear lamp do not light up
The horn does not sound or does not stop
Malfunction of wipers
Washer does not spray water
The air conditioner does not operate
KOMTRAX system does not operate normally
There is no travel power (no drawbar pull)
Machine does not move (at 2nd or 3rd speed)
Machine does not move at any gear speed
Machine travels only in one direction, forward or in reverse47 topics
- When gear is shifted or travel direction is changed, large time lag is made
- Machine cannot be steered (Machine does not turn leftward or rightward)
- Steering speed or power is low
- Brake does not work
- Overheat of power train oil
- All work equipment speeds are slow
- Work equipment does not move
- Blade lift speed is slow or lacks power
- Blade tilt speed is slow or lacks power
- Angling blade speed is slow or lacks power
- Ripper lift speed is slow or lacks power
- Excessive hydraulic drift of blade lift
- Excessive hydraulic drift of blade tilt
- Excessive hydraulic drift of blade angle
- Excessive hydraulic drift of ripper lift
- Method of using troubleshooting charts
- Starting performance is poor
- Engine does not start
- Engine does not pick up smoothly
- Engine stops during operations
- Engine does not rotate smoothly
- Engine lacks output (or lacks power)
- Exhaust smoke is black (incomplete combustion)
- Oil consumption is excessive (or exhaust smoke is blue)
- Oil becomes contaminated quickly
- Fuel consumption is excessive
- Oil is in coolant (or coolant spurts back or coolant level goes down)
- Oil pressure drops
- Oil level rises (Entry of coolant or fuel)
- Coolant temperature becomes too high (overheating)
- Abnormal noise is made
- Vibration is excessive
- How to read this manual
- Coating materials list
- Special tool list
- Sketches of special tools
- Removal and installation of radiator guard assembly
- Removal and installation of engine assembly
- Removal and installation of radiator assembly
- Removal and installation of aftercooler assembly
- Removal and installation of power train oil cooler assembly
- Removal and installation of hydraulic cooler assembly
- Removal and installation of cooling fan drive assembly
- Removal and installation of cooling fan motor assembly
- Removal and installation of damper assembly
- Removal and installation of fuel tank assembly
- Removal and installation of engine hood assembly
Removal and installation of fuel supply pump assembly
Removal and installation of fuel injector 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 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
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
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
Check before expanding track shoe assembly1 topic
- ventional type track shoe)
Expansion and installation of track shoe assembly (Plus type track shoe)
Link press-fitting jig dimensions table
Overall disassembly and overall assembly of track shoe assembly (PLUS type track shoe)
Field disassembly and assembly of one link (Conventional type track shoe)
Field disassembly and assembly of one link (PLUS 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
Removal and installation of segment teeth
Removal and installation of main control valve assembly
Assembly of main control valve assembly
Removal and installation of cooling fan pump assembly
Disassembly and assembly of hydraulic cylinder assembly
Removal and installation of work equipment assembly
Disassembly and assembly of work equipment assembly14 topics
- Removal and installation of ROPS guard
- Removal and installation of operator's cab assembly
- Removal and installation of operator's cab glass (stuck glass)
- Removal and installation of monitor panel assembly
- Removal and installation of dashboard assembly
- Removal and installation of floor frame assembly
- Removal and installation of engine controller assembly
- Removal and installation of steering and transmission controller assembly
- Removal and installation of KOMTRAX terminal assembly
- Removal and installation of air conditioner unit assembly
- Power train hydraulic circuit diagram
- Work equipment hydraulic circuit diagram
- Electrical circuit diagram
- Connector arrangement diagram
Inside this manual
Real pages from this service manual (1,253 pages). Open the sample pages (PDF, 1164 KB)
- Specifications, page 433: 30 Testing and adjusting
- Diagram, page 680: Circuit diagram related to engine Bkup speed sensor
- Troubleshooting, page 756: Failure code [DK30KZ] Steering potentiometer: Disconnection or short
- Foldout diagram: Connector arrangement diagram
Other manuals for this machine
Save 10% on 2 manuals, 15% on 3 or more. Other manuals for the D61EX-15E0, D61PX 15E0 are listed below. Editions cover different serial number ranges: check the serial coverage and tick only the ones that match your machine.
This manual: Service Manual SEN02387-05$129.95
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This is a service manual
Here's how it compares to the other manual types.
This manual
Service manual
Factory repair procedures and technical information such as specifications, troubleshooting, and wiring and hydraulic diagrams, for the models and systems the manual covers. See What's inside for its topics.
Operator's manual
Safe operation, controls, maintenance schedules, lubrication points, inspections, and basic checks. Repair procedures are in the service manual.
Parts manual
Illustrated diagrams with factory part numbers for identifying components and ordering parts. Repair procedures are in the service manual.
Engine service manuals are sometimes sold separately, since certain machine models were offered with more than one engine option.
What it's used for
Factory manual for in-house farm and construction shop use. Straightforward, complete, and easy to follow. It contains the OEM information dealership service departments and parts counters use to diagnose problems, identify components, and perform maintenance or repairs correctly.
Service shops and owner/operators who repair their own equipment
Identifying correct parts and seeing how assemblies come apart and go back together
Keeping equipment running with less downtime
Factory manual, 1,253 pages
Quantity one is the manual described above.
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Manuals over about 300 pages may need a standard 3-ring binder, which you can buy locally to keep the pages organized for shop use.
Other editions and similar models
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