PDF Shop Manual Komatsu D61EXi-23 D61PXi-23 Bulldozer - 5 MB
The Komatsu D61EXi-23 and D61PXi-23 are advanced bulldozers known for their intelligent machine control.
This official shop manual is your complete guide to diagnostics, repair, and overhaul procedures.
It covers everything from the engine and hydraulics to the electronics and final drive.
Professional technicians and owner-operators will find this manual indispensable for maintaining the performance and longevity of their machine.
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--- Page 1 ---
SEN06256-12
BULLDOZER D61EXi -23
D61PXi -23
D61EXi- 30324
SERIAL NUMBERS and up
D61PXi- 30324
--- Page 3 ---
00 Index and foreword
Foreword, safety and general information
ā¢ Do not use twisted or kinked wire ropes. ā¢ Do not drag a sling.
ā¢ When slinging up a load, observe the following. ā¢ When lifting up a load, stop it just after it leaves
1. Wind up the rope slowly until the wire rope the ground and check safety, and then lift it up.
tensions. When putting your hands on the ā¢ Consider the travel route in advance and lift up a
wire ropes, do not grasp them but press them load to a safe height.
down from above. If you grasp them, your ā¢ Place the control switch in a position where it will
fingers may be caught. not be an obstacle to work and passage.
2. After the wire ropes are stretched, stop the ā¢ After operating the hoist, do not swing the control
crane and check the condition of the slung switch.
load, wire ropes, and pads. ā¢ Remember the position of the main switch so that
3. If the load is unstable or the wire rope or you can turn off the power immediately in an
chains are twisted, lower the load and lift it emergency.
up again. ā¢ Shut down the main switch when the hoist stops
4. Do not lift up the load at an angle. because of a blackout. When turning on a switch
ā¢ When lowering a load, pay attention to the which is turned OFF by the ground fault circuit
following. interrupter for electric shock prevention, check
that the devices related to that switch are not in
1. When lifting down a load, stop it temporarily
operating condition.
at 30 cm above the floor, and then lower it
ā¢ If you find an obstacle around the hoist, stop the
slowly.
operation.
2. Check that the load is stable, and then
ā¢ After finishing the work, stop the hoist at the
remove the sling.
specified position and raise the hook to at least 2
3. Remove kinks and dirt from the wire ropes
meters above the floor. Do not leave the sling
and chains used for the sling work, and put
attached to the hook.
them in the specified place.
Selecting wire ropes
Precautions for using mobile crane ā¢ Select adequate ropes depending on the weight
a Read the Operation and Maintenance Manual of of the parts to be hoisted, referring to the table
the crane carefully in advance and operate the below
crane safely. Wire rope (JIS G3525, 6 x 37 - Type A)
(Standard Z twist wire ropes without galvanizing)
Precautions for using overhead traveling crane
Nominal
diameter of rope Allowable load
k The hoist or crane must be used to sling the
components weighing 25 kg or heavier. A mm kN ton
part weighing 25 kg or heavier in 10 8.8 0.9
"disassembly and assembly" section is 12 12.7 1.3
indicated with the symbol of 4 . 14 17.3 1.7
16 22.6 2.3
ā¢ Before starting work, check the wire ropes, 18 28.6 2.9
brake, clutch, controller, rails, over winding 20 35.3 3.6
prevention device, ground fault circuit 25 55.3 5.6
interrupter for electric shock prevention, crane 30 79.6 8.1
collision prevention device, and energizing
40 141.6 14.4
warning lamp, and check the following safety
items. 50 221.6 22.6
ā¢ Be sure not to touch the lifting tool and lifted 60 318.3 32.4
load directly. Use push-pull sticks or tagline
a The allowable load is calculated as one sixth of
ropes.
the breaking load of the rope to be used (safety
ā¢ Observe the signals for sling work.
coefficient: 6).
ā¢ Operate the hoist at a safe place.
ā¢ Be sure to check the directions of the direction
indication plate (north, south, east and west)
and the operating button.
ā¢ Do not sling a load at an angle. Do not move
the crane while the slung load is swinging.
ā¢ Do not raise or lower a load while the crane is
moving longitudinally or laterally.
D61EXI-23, D61PXI-23 00-19
--- Page 4 ---
00 Index and foreword
Foreword, safety and general information
Connection Connection
1. Insert the connector securely until a click is 1. Insert the connector securely until a click is
heard. heard.
(AMP-3)
Push lock type
(BOSCH-3) Disconnection
Disconnection 1. While pressing lock (E), pull out connector (5) in
the direction of the arrow.
1. While pressing lock (C), pull out connector (3) in
the direction of the arrow.
ā¢ 114 series
Connection
1. Insert the connector securely until a click is
heard.
ā¢ 107 series (SUMITOMO-2)
Disconnection
1. While pressing lock (E), pull out connector (5) in
the direction of the arrow.
a If the lock is located on the underside, use
flat-head screwdriver [1] since you cannot
insert your fingers.
While pushing up lock (C) of the connector Connection
with flat-head screwdriver [1], pull out 1. Insert the connector securely until a click is
connector (3) in the direction of the arrow. heard.
D61EXI-23, D61PXI-23 00-39
--- Page 5 ---
00 Index and foreword
Foreword, safety and general information
Purpose of use (major
Abbrevia- Actual word spelled applicable machine (*), or Explanation
tion out equipment/device)
Komatsu Catalyzed This filter captures soot in exhaust gas.
KCSF Engine
Soot Filter It is built in to KDPF.
The catalyst used for purifying exhaust gas.
Komatsu Diesel
KDOC Engine This is built in KDPF or assembled with the
Oxidation Catalyst
muffler.
This component is used to purify the exhaust
gas. KDOC (catalyst) and KCSF (filter to
Komatsu Diesel Engine capture soot) are built-in it.
KDPF
Particulate Filter
It is installed in place of the conventional
muffler.
This function recovers the drive force of the
wheels by braking automatically with the
Komatsu Traction Travel and brake optimum force and at the same time activates
KTCS Control System the inter-axle differential lock when the wheels
(HM system)
idle while the machine travels on the soft
ground road.
Komatsu Variable
The turbocharger on which the cross-section
VGT Geometry Engine
area of the exhaust passage is made variable.
Turbocharger
Image display equipment such as a monitor
LCD Liquid Crystal Display Machine monitor which assembles in the liquid crystal element.
It refers to semiconductor element that emits
LED Light Emitting Diode Electronic parts light when the voltage is applied in forward
direction.
Local Interconnect Communication and One of communication standards that is used
LIN
Network electronic control in the network on the machine
Function that detects differential pressure of
LS Load Sensing Hydraulic system pump and controls discharge amount
corresponding to load.
Low Voltage Communication and One of communication standards that is used
LVDS Differential Signaling electronic control in the network on the machine
This indicates engine intake air flow.It is not
Engine used independently but it is used as combined
MAF Mass Air Flow
with sensor.Mass air flow sensor can be called
as MAF sensor.
Service that allows transmission and
Multimedia Messaging reception of short messages consisting of
MMS Communication characters or voice or images between cell
Service
phones.
Electric and hydraulic Device actuated to open electric or hydraulic
NC Normally Closed circuits that are normally closed if not
systems
actuated.
Electric and hydraulic Device actuated to close electric or hydraulic
NO Normally Open
systems circuits that are normally open if not actuated.
Open-center Load Hydraulic system that can operate multiple
OLSS Hydraulic system actuators at the same time, regardless of the
Sensing System
load.
Pressure
PC Hydraulic system A function used to correct oil pressure.
Compensation
System in which a controller instantly
Palm command control Steering analyses data from each lever, pedal, and
PCCS system dial, and performs optimum electronic control
(D)
of the engine and transmission.
This valve is installed at inlet port of pump and
Pre-stroke Control Engine it adjusts fuel intake amount in order to control
PCV
Valve fuel discharge amount of supply pump.
D61EXI-23, D61PXI-23 00-59
--- Page 6 ---
01 Specification
Specifications
D61PXI-23
Machine model 860 mm
Unit single grouser shoe
Serial No. 30324 and up
Work equipment hydraulic system
Work equipment and cooling fan pump
Variable displacement swash plate piston
Type x quantity ā
type x 1
Discharge cm3/rev 90
MPa {kg/
Max. discharge pressure 27.4 {280}
cm2}
Cooling fan motor
Fixed displacement swash plate type
Type ā
piston motor
Motor capacity cm3/rev 28
Control valve
Type x quantity ā 4-spool valve x 1
Operating method ā Hydraulic pilot type
Lift cylinder
Type ā Double-acting piston type
Cylinder bore mm 100
Piston rod outside diameter mm 55
Piston stroke mm 461
Max. distance between pins mm 1,317
Min. distance between pins mm 856
Lift cylinder with stroke and reset sensor
Type ā Double-acting piston type
Cylinder bore mm 100
Piston rod outside diameter mm 55
Piston stroke mm 461
Max. distance between pins mm 1,317
Min. distance between pins mm 856
Tilt cylinder with stroke sensor
Type ā Double-acting piston type
Cylinder bore mm 120
Piston rod outside diameter mm 70
Piston stroke mm 164
Max. distance between pins mm 919
Min. distance between pins mm 755
Angle cylinder
Type ā Double-acting piston type
Cylinder bore mm 110
Piston rod outside diameter mm 65
452/448(*4)
Piston stroke (max.)/(effective) mm
467/463(*5)
1,345/1,343(*4)
Max. distance between pins (max.)/(effective) mm
1,366/1,364(*5)
893/895(*4)
Min. distance between pins (min.)/(effective) mm
899/901(*5)
D61EXI-23, D61PXI-23 01-13
--- Page 7 ---
10 Structure and function
EGR system piping drawing
EGR system piping drawing (WA380-A9J0-04D-K-00-A)
a EGR: Abbreviation for Exhaust Gas Recirculation
a The shape is subject to machine models.
1. KVGT
2. EGR valve
3. Air intake pipe
4. Air intake connector
5. Exhaust manifold
6. EGR cooler
D61EXI-23, D61PXI-23 10-13
--- Page 8 ---
10 Structure and function
Cooling fan motor
Cooling fan motor (D61-B5L0-041-K-00-A)
P: From cooling fan pump
T: To oil cooler
TC: To hydraulic tank
D61EXI-23, D61PXI-23 10-33
--- Page 9 ---
10 Structure and function
HST pump
HST pump (D61-C172-041-K-00-A)
a HST: Abbreviation for Hydrostatic Transmission
D61EXI-23, D61PXI-23 10-53
--- Page 10 ---
10 Structure and function
HST motor
Change of steplessly-variable type motor capacity (D61-C400-042-K-01-A)
ā¢ The servo mechanism portion has chambers (A), (B), and (C).
ā¢ The self pressures in chambers (A) and (C) act on their respective pressure receiving areas , and servo
piston (1) operates according to the balance of the forces acting on the chambers.
ā¢ When the output pressure from EPC valve (2) is 0 MPa {0 kg/cm 2}, servo piston (1) is at the lowest
position. (Max. side)
ā¢ The capacity control pressure is supplied from EPC valve (2) to chamber (B) according to the command
current to EPC valve (2).
ā¢ Servo spool (3) leads the self pressure into chamber (C) up to the set motor capacity, according to the
balance of the force generated by the capacity control pressure in chamber (B) and the force of servo
spring (4).
When motor capacity is maximum
D61EXI-23, D61PXI-23 10-73
--- Page 11 ---
10 Structure and function
Final drive
a Figure shows D61EX-23, D61EXI-23 equipped with PLUS type track shoes.
1. Oil level plug
2. Drain plug
3. No. 1 sun gear (number of teeth: 15)
4. No. 2 sun gear (number of teeth: 21)
5. No. 1 planetary carrier
6. Cover
7. Sprocket
8. No. 2 planetary carrier
9. Floating seal
10. HST motor
11. Hub
12. No. 2 planetary pinion (number of teeth: 43)
13. Ring gear (number of teeth: 108)
14. No. 1 planetary pinion (number of teeth: 46)
D61EXI-23, D61PXI-23 10-93
--- Page 12 ---
10 Structure and function
Work equipment and cooling fan pump
1. Bearing
2. Ball retainer
3. Shaft
4. Oil seal
5. Spring
6. Sleeve
7. Servo piston
8. Shoe retainer
9. End cap
10. Valve plate
11. Cylinder block
12. Piston
13. Shoe
14. Rocker cam
15. Case
16. Shuttle valve
17. Filter
D61EXI-23, D61PXI-23 10-113
--- Page 13 ---
10 Structure and function
Control valve
1. Unload valve
Set pressure: 3.4 MPa {34.5 kg/cm2}
2. Main relief valve
Set pressure: 27.4 MPa {280 kg/cm2}
3. Pressure compensation valve
4. Suction valve
5. Fan port relief valve
6. Centralized safety valve (for work equipment valve)
Set pressure: 31.4 MPa {320 kg/cm2}
7. Cooling fan valve
8. Lift valve
9. Tilt valve
10.Angle valve
11.Ripper valve
12.Back pressure valve
13.LS bypass valve
D61EXI-23, D61PXI-23 10-133
--- Page 14 ---
10 Structure and function
Angle control EPC valve
Angle control EPC valve (D65-LSLH-041-K-00-A)
P: From pump
C: To control valve (angle port)
T: To hydraulic tank
1. Body
2. Plug
3. Spool
4. Push pin
5. Coil
6. Plunger
7. Connector
D61EXI-23, D61PXI-23 10-153
--- Page 15 ---
10 Structure and function
Electrical control system
ā¢ When the joystick (steering, directional and gear shift lever) is in "NEUTRAL", the set travel speed is 0 km/
h.
ā¢ The 1st, 2nd, and 3rd travel speed settings can be changed with "1st Travel Speed Setting", "2nd Travel
Speed Setting", and "3rd Travel Speed Setting" of the quick shift mode in the customize menu (5 levels
each in the 1st and 2nd, and 3 levels in the 3rd).
a The following figure shows the setting of reverse travel speed (C) in the 1st gear speed (default).
D61EXI-23, D61PXI-23 10-173
--- Page 16 ---
10 Structure and function
Electrical control system
Blade height adjustment
ā¢ In the leveling mode as shown in the following figure, blade height is adjusted by operating the lift cylinder
and the blade is controlled so that its tip center position (A) follows the earthmoving operation design
surface (T).
A: The center position of blade tip
S: Current surface
T: Earthmoving operation design surface
Blade angle adjustment
ā¢ In the leveling mode as shown in the following figure, blade angle is adjusted by operating the tilt cylinder
and the blade is controlled so that blade angle (B) follows the earthmoving operation design surface (T).
B: Blade angle
S: Current surface
T: Earthmoving operation design surface
D61EXI-23, D61PXI-23 10-193
--- Page 17 ---
10 Structure and function
Machine monitor system
Display (D61-Q1LA-042-K-00-A)
a All caution monitor symbols are not shown in this figure.
D61EXI-23, D61PXI-23 10-213
--- Page 18 ---
10 Structure and function
KOMTRAX system
Input and output signals of KOMTRAX terminal (D61-Q220-03C-K-00-A)
070-18P [CN-CK01]
Input/Output
Pin No. Signal name
Signal
1 (*1) ā
2 (*1) ā
3 (*1) ā
4 (*1) ā
5 (*1) ā
6 (*1) ā
7 (*1) ā
8 (*1) ā
9 (*1) ā
10 CAN_H (KOMNET/c) Input/Output
11 CAN_L (KOMNET/c) Input/Output
12 (*1) ā
13 (*1) ā
14 External starting signal Input/Output
15 System operation lamp Output
16 (*1) ā
17 (*1) ā
18 (*1) ā
*1: Never connect these pins. Malfunctions or failures may occur.
070-12P [CN-CK02]
Input/Output
Pin No. Signal name
Signal
1 GND ā
2 GND ā
3 Starting switch ACC signal Input
4 Alternator R signal Input
5 (*1) ā
6 Power supply Input
7 Power supply Input
8 (*1) ā
9 (*1) ā
10 (*1) ā
11 Starting switch C signal Input
12 (*1) ā
*1: Never connect these pins. Malfunctions or failures may occur.
D61EXI-23, D61PXI-23 10-233
--- Page 19 ---
10 Structure and function
System component parts
Function (D61-PK80-042-K-00-A)
Operating effort characteristics
ā¢ The characteristics in all of the forward, reverse, rightward, and leftward directions are as follows.
ā¢ Free return (operating effort characteristic curve)
Output voltage characteristics
ā¢ This lever is installed to the right control stand and the control lever is fixed directly onto it.
ā¢ The operating angle (stroke) of the control lever is detected with the potentiometer and signal voltages are
output to the controller.
ā¢ A potentiometer is installed to detect each of longitudinal displacement and lateral displacement. Each
potentiometer outputs two signal voltages which are opposite in phase as shown in the figure on the right.
D61EXI-23, D61PXI-23 10-253
--- Page 20 ---
10 Structure and function
Sensor
Hydraulic oil temperature sensor (D65-PMT1-041-K-00-A)
1. Connector
2. Plug
3. Thermistor
Function (D65-PMT1-042-K-00-A)
ā¢ This sensor is installed to the hydraulic tank.
ā¢ This sensor detects the oil temperature and converts it into corresponding electric signals, and outputs the
signals.
D61EXI-23, D61PXI-23 10-273
--- Page 21 ---
20 Standard value tables
Standard value table for engine
Standard service value table (ALL-A000-001-K-00-A)
Standard value table for engine (D61_23-A000-033-K-01-A)
Machine model D61EXI-23, D61PXI-23
Engine SAA6D107Eā2
Classifi-
Standard value
cation
Item Measurement condition Unit for new Repair limit
machine
ā¢ Coolant High P mode 1,995 Ā± 50 1,995 Ā± 50
rpm
temperature: 60 to idle E mode 1,670 Ā± 50 1,670 Ā± 50
100 ā Low idle rpm 975 Ā± 25 975 Ā±50
speed ā¢ HST oil
temperature
(hydraulic oil Rated speed rpm 2,200 2,200
temperature): 40 to
60 Ā°C
ā¢ Aftercooler inlet
ā¢ Coolant temperature: 60 to 100 ā
kPa
Boost pressure ā¢ HST oil temperature (hydraulic oil Min. 113 {850} Min. 87 {650}
temperature): 40 to 60 Ā°C {mmHg}
ā¢ HST stall (*1) and work equipment
relief
ā¢ Coolant temperature: 60 Engine outlet
to 100ā (between
ā¢ HST oil temperature turbocharger Bosch ā Max. 2.7
(hydraulic oil and KDPF index
Exhaust gas temperature): 40 to 60 Ā° inlet)
color C
ā¢ HST stall (*1) and work KDPF outlet
equipment relief (exhaust Bosch ā Max. 0.5
ā¢ After kept for 5 seconds pipe outlet) index
at normal condition
Engine
Intake valve mm 0.25 0.152 to 0.381
Valve ā¢ Coolant temperature:
clearance Normal temperature Exhaust mm 0.51 0.381 to 0.762
valve
Compression ā¢ Engine oil temperature: 40 to 60 Ā°C MPa
Min. 2.41 {24.6} Min. 1.69 {17.2}
pressure ā¢ Engine speed: 250 to 280 rpm {kg/cm2}
ā¢ Coolant temperature: 60 to 100ā
ā¢ HST oil temperature (hydraulic oil
Blowby temperature): 40 to 60 Ā°C kPa
Max. 0.98 {100} Max. 1.96 {200}
pressure ā¢ HST stall (*1) and work equipment {mmH2O}
relief
ā¢ KCCV circuit disconnected
MPa
Engine oil ā¢ Coolant temperature: 60 to High idle {kg/cm2} Min. 0.29 {3.0} Min. 0.25 {2.5}
pressure 100 ā
ā¢ EO15W40-LA MPa