Komatsu D61EX -24 D61EX -24E0 D61PX-24 D61PX-24E0 Bulldozer Shop Manual SEN06855-04 – PDF DOWNLOAD

Komatsu D61EX -24 D61EX -24E0 D61PX-24 D61PX-24E0 Bulldozer Shop Manual SEN06855-04 – PDF DOWNLOAD

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Komatsu D61EX -24 D61EX -24E0 D61PX-24 D61PX-24E0 Bulldozer Shop Manual SEN06855-04 – PDF DOWNLOAD

Language : English
Pages : 2810
Downloadable : Yes
File Type : PDF
Size: 64.8 MB

TABLE OF CONTENTS:

Komatsu D61EX -24 D61EX -24E0 D61PX-24 D61PX-24E0 Bulldozer Shop Manual SEN06855-04 – PDF DOWNLOAD

00 INDEX AND FOREWORD 00-1
FOREWORD, SAFETY, BASIC INFORMATION 00-19
HOW TO READ THE SHOP MANUAL 00-19
SAFETY NOTICE FOR OPERATION 00-21
PRECAUTIONS TO PREVENT FIRE 00-29
ACTIONS IF FIRE OCCURS 00-31
PRECAUTIONS FOR DISPOSING OF WASTE MATERIALS 00-32
ACTIONS TAKEN TO MEET EXHAUST GAS REGULATIONS 00-33
PRECAUTIONS FOR DEF 00-34
STORE AdBlue/DEF 00-35
PRECAUTIONS FOR HANDLING HYDRAULIC EQUIPMENT 00-36
PRECAUTIONS FOR DISCONNECTION AND CONNECTION OF PIPINGS 00-39
PRECAUTIONS FOR HANDLING ELECTRICAL EQUIPMENT 00-46
PRECAUTIONS FOR HANDLING FUEL SYSTEM EQUIPMENT 00-48
PRECAUTIONS FOR HANDLING INTAKE SYSTEM EQUIPMENT 00-49
PRACTICAL USE OF KOMTRAX 00-50
DISCONNECT AND CONNECT PUSH-PULL TYPE COUPLER 00-51
PRECAUTIONS FOR DISCONNECTION AND CONNECTION OF CONNECTORS 00-55
METHOD FOR DISCONNECTING AND CONNECTING DEUTSCH CONNECTOR 00-59
METHOD FOR DISCONNECTING AND CONNECTING SLIDE LOCK TYPE CONNECTOR 00-60
METHOD FOR DISCONNECTING AND CONNECTING CONNECTOR WITH LOCK TO PULL 00-62
METHOD FOR DISCONNECTING AND CONNECTING CONNECTOR WITH LOCK TO PUSH 00-63
METHOD FOR DISCONNECTING AND CONNECTING CONNECTOR WITH HOUSING TO ROTATE
00-65
HOW TO READ ELECTRICAL WIRE CODE 00-66
EXPLANATION OF TERMS FOR MAINTENANCE STANDARD 00-70
STANDARD TIGHTENING TORQUE TABLE 00-73
CONVERSION TABLE 00-80
ABBREVIATION LIST 00-85
01 SPECIFICATIONS 01-1
CONTENTS 01-2
SPECIFICATIONS 01-3
SPECIFICATION DRAWING 01-3
SPECIFICATIONS 01-11
WEIGHT TABLE 01-29
FUEL, COOLANT, LUBRICANTS (FOR NORTH AMERICA) 01-37
FUEL, COOLANT, LUBRICANTS (FOR EUROPEAN UNION) 01-39
10 STRUCTURE AND FUNCTION 10-1
CONTENTS 10-2
UREA SCR SYSTEM 10-5
LAYOUT DRAWING OF UREA SCR SYSTEM 10-5
UREA SCR SYSTEM DIAGRAM 10-8
FUNCTION OF UREA SCR SYSTEM 10-9
COMPONENT PARTS OF UREA SCR SYSTEM 10-25
BOOT-UP SYSTEM 10-34
LAYOUT DRAWING OF BOOT-UP SYSTEM 10-34
SYSTEM OPERATING LAMP SYSTEM 10-35
BATTERY DISCONNECT SWITCH 10-37
ENGINE SYSTEM 10-39
LAYOUT DRAWING OF ENGINE SYSTEM 10-39
ENGINE CONTROL SYSTEM 10-41
AUTOMATIC IDLE STOP SYSTEM 10-47
COMPONENT PARTS OF ENGINE SYSTEM 10-50
COOLING SYSTEM 10-69
LAYOUT DRAWING OF COOLING SYSTEM 10-69
COOLING FAN CONTROL SYSTEM 10-71
INDEX 00 INDEX AND FOREWORD
00-2 D61EX-24, D61EX-24E0, D61PX-24, D61PX-24E0
COMPONENT PARTS OF COOLING SYSTEM 10-74
CONTROL SYSTEM 10-84
LAYOUT DRAWING OF CONTROL SYSTEM 10-84
MACHINE MONITOR SYSTEM 10-85
KOMTRAX SYSTEM 10-86
COMPONENT PARTS OF CONTROL SYSTEM 10-87
HYDRAULIC SYSTEM 10-121
LAYOUT DRAWING OF HYDRAULIC SYSTEM 10-121
CLSS 10-122
COMPONENT PARTS OF HYDRAULIC SYSTEM 10-125
POWER TRAIN SYSTEM 10-160
LAYOUT DRAWING OF HST SYSTEM 10-160
OPERATION OF HST SYSTEM 10-161
STEERING AND BRAKE CONTROL SYSTEM 10-163
HST CONTROL SYSTEM 10-165
PARKING BRAKE CONTROL SYSTEM 10-176
COMPONENT PARTS OF POWER TRAIN SYSTEM 10-179
WORK EQUIPMENT SYSTEM 10-216
WORK EQUIPMENT CONTROL 10-216
LAYOUT DRAWING OF FRONT WORK EQUIPMENT 10-219
LAYOUT OF FIXED MULTI-SHANK RIPPER 10-220
COMPONENT PARTS OF WORK EQUIPMENT SYSTEM 10-221
UNDERCARRIAGE AND FRAME 10-240
MAIN FRAME 10-240
SUSPENSION 10-241
TRACK FRAME AND IDLER CUSHION 10-244
WORK EQUIPMENT 10-247
STRUCTURE OF FRONT WORK EQUIPMENT 10-247
STRUCTURE OF FIXED MULTI-SHANK RIPPER 10-248
CAB AND ITS ATTACHMENTS 10-249
ROPS CAB 10-249
CAB MOUNT 10-251
20 STANDARD VALUE TABLE 20-1
CONTENTS 20-2
STANDARD VALUE TABLE FOR ENGINE 20-3
STANDARD VALUE TABLE FOR ENGINE: D61EX-24 20-3
STANDARD VALUE TABLE FOR ENGINE: D61EX-24E0 20-7
STANDARD VALUE TABLE FOR ENGINE: D61PX-24 20-11
STANDARD VALUE TABLE FOR ENGINE: D61PX-24E0 20-15
STANDARD VALUE TABLE FOR MACHINE 20-19
STANDARD VALUE TABLE FOR MACHINE: D61EX-24 20-19
STANDARD VALUE TABLE FOR MACHINE: D61EX-24E0 20-35
STANDARD VALUE TABLE FOR MACHINE: D61PX-24 20-51
STANDARD VALUE TABLE FOR MACHINE: D61PX-24E0 20-67
MACHINE POSTURE AND PROCEDURE FOR MEASURING PERFORMANCE 20-83
30 TESTING AND ADJUSTING 30-1
CONTENTS 30-2
RELATED INFORMATION ON TESTING AND ADJUSTING 30-5
TOOLS FOR TESTING AND ADJUSTING 30-5
SKETCH OF TOOLS FOR TESTING AND ADJUSTING 30-13
ENGINE AND COOLING SYSTEM 30-16
TEST ENGINE SPEED 30-16
TEST BOOST PRESSURE 30-18
TEST EXHAUST GAS COLOR 30-20
TEST MASS AIR FLOW AND TEMPERATURE SENSOR 30-24
TEST AND ADJUST VALVE CLEARANCE 30-26
TEST COMPRESSION PRESSURE 30-28
TEST BLOWBY PRESSURE 30-33
00 INDEX AND FOREWORD INDEX
D61EX-24, D61EX-24E0, D61PX-24, D61PX-24E0 00-3
TEST ENGINE OIL PRESSURE 30-36
TEST EGR VALVE AND VGT OIL PRESSURE 30-37
TEST FUEL PRESSURE 30-39
TEST FUEL DISCHARGE, RETURN AND LEAKAGE 30-45
BLEEDING AIR FROM FUEL SYSTEM 30-52
TEST FUEL CIRCUIT FOR LEAKAGE 30-53
HANDLE CYLINDER CUT-OUT MODE OPERATION 30-55
HANDLE NO-INJECTION CRANKING OPERATION 30-56
TEST KDPF, SCR AND MUFFLER STACK FOR LOOSENESS AND DAMAGE 30-57
TEST INSTALLED CONDITION OF CYLINDER HEADS AND MANIFOLDS 30-58
TEST ENGINE PIPING FOR DAMAGE AND LOOSENESS 30-59
TEST ALTERNATOR BELT 30-60
TEST AUTOMATIC TENSIONER 30-62
WRITE ASH IN SOOT ACCUMULATION CORRECTION TO ENGINE CONTROLLER 30-64
TEST SCR RELATED FUNCTIONS 30-65
CLEAN AdBlue/DEF TANK 30-94
CLEAN AdBlue/DEF TANK MOUNTING PORTION 30-98
CLEAN AdBlue/DEF PUMP 30-99
POWER TRAIN 30-105
TEST AND ADJUST HST OIL PRESSURE 30-105
BLEED AIR FROM HST PUMP 30-110
TEST OUTLET PRESSURE OF SOLENOID VALVE 30-112
TEST TRAVEL DEVIATION 30-117
TEST BRAKE PERFORMANCE SIMPLY 30-119
TEST AND ADJUST DECELERATION/BRAKE PEDAL 30-120
ADJUST PARKING BRAKE LEVER 30-124
MOVE MACHINE WHEN IT CANNOT TRAVEL 30-126
UNDERCARRIAGE AND FRAME 30-130
CHECK AND ADJUST IDLER CLEARANCE 30-130
TESTING SPROCKET WEAR 30-131
TEST AND ADJUST TRACK TENSION 30-132
HYDRAULIC SYSTEM 30-134
RELEASE REMAINING PRESSURE FROM HYDRAULIC SYSTEM 30-134
TEST AND ADJUST WORK EQUIPMENT OIL PRESSURES 30-135
TEST AND ADJUST OIL PRESSURE OF CONTROL CIRCUIT 30-138
TEST OUTLET PRESSURE OF EPC SOLENOID VALVE 30-140
BLEED AIR FROM WORK EQUIPMENT, COOLING FAN PUMP, AND CHARGE PUMP 30-142
TEST COOLING FAN SPEED 30-143
TEST COOLING FAN CIRCUIT OIL PRESSURE 30-144
TEST THE PARTS CAUSING HYDRAULIC DRIFT IN WORK EQUIPMENT 30-146
TEST INTERNAL OIL LEAKAGE OF WORK EQUIPMENT CYLINDER 30-148
BLEED AIR FROM WORK EQUIPMENT CYLINDERS 30-151
WORK EQUIPMENT 30-152
ADJUST WORK EQUIPMENT LOCK LEVER 30-152
TEST AND ADJUST PLAY OF BLADE ELECTRIC LEVER 30-154
ELECTRICAL SYSTEM 30-164
SET AND OPERATE MACHINE MONITOR 30-164
START UP KOMTRAX SYSTEM 30-281
STOP USING OF KOMTRAX SYSTEM 30-287
ADJUSTMENT WHEN HST CONTROLLER HAS BEEN REPLACED 30-289
ADJUSTMENT WHEN ELECTRIC OR HYDRAULIC DEVICE HAS BEEN REPLACED 30-295
ADJUST REARVIEW CAMERA ANGLE 30-297
HANDLE VOLTAGE CIRCUIT OF ENGINE CONTROLLER 30-298
BATTERY DISCONNECT SWITCH 30-299
TEST DIODES 30-300
Pm CLINIC 30-301
Pm CLINIC SERVICE 30-301
40 TROUBLESHOOTING 40-1
INDEX 00 INDEX AND FOREWORD
00-4 D61EX-24, D61EX-24E0, D61PX-24, D61PX-24E0
CONTENTS 40-2
ABBREVIATION LIST 40-12
RELATED INFORMATION ON TROUBLESHOOTING 40-18
GENERAL TROUBLESHOOTING POINTS 40-18
TROUBLESHOOTING POINTS FOR UREA SCR SYSTEM 40-19
SEQUENCE OF EVENTS IN TROUBLESHOOTING 40-34
CHECKS BEFORE TROUBLESHOOTING 40-36
INSPECTION PROCEDURE BEFORE TROUBLESHOOTING 40-38
TESTING IN ACCORDANCE WITH TESTING PROCEDURE 40-40
PREPARATION FOR TROUBLESHOOTING ELECTRICAL SYSTEM 40-62
PROCEDURE FOR TROUBLESHOOTING 40-69
INFORMATION DESCRIBED IN TROUBLESHOOTING TABLE 40-72
TROUBLESHOOTING METHOD FOR OPEN CIRCUIT IN WIRING HARNESS OF PRESSURE SENSOR
SYSTEM 40-74
CONNECTORS LIST AND LAYOUT 40-77
CONNECTOR CONTACT IDENTIFICATION 40-94
T-BRANCH BOX AND T-BRANCH ADAPTER TABLE 40-134
FUSE LOCATION TABLE 40-140
PRECAUTIONS FOR CLEANING AND REPLACING KDPF (KCSF and KDOC) 40-144
PREPARATION OF SHORT CIRCUIT ELECTRICAL CONNECTOR (FOR FAILURE CODES [CA1883]
AND [CA3135]) 40-148
FAILURE CODES TABLE 40-150
TROUBLESHOOTING BY FAILURE CODE (DISPLAY OF CODE) 40-169
FAILURE CODE [6091NX] 40-169
FAILURE CODE [989L00] 40-171
FAILURE CODE [989M00] 40-172
FAILURE CODE [989N00] 40-173
FAILURE CODE [A1U0N3] 40-174
FAILURE CODE [A1U0N4] 40-176
FAILURE CODE [A900FR] 40-178
FAILURE CODE [A900N6] 40-179
FAILURE CODE [A900NY] 40-180
FAILURE CODE [AA10NX] 40-181
FAILURE CODE [AB00KE] 40-183
FAILURE CODE [AQ10N3] 40-185
FAILURE CODE [AS00N3] 40-187
FAILURE CODE [AS00R2] 40-189
FAILURE CODE [AS00R3] 40-190
FAILURE CODE [AS00R4] 40-191
FAILURE CODE [AS00R5] 40-192
FAILURE CODE [AS00R6] 40-193
FAILURE CODE [AS00ZK] 40-194
FAILURE CODE [AS10KM] 40-195
FAILURE CODE [AS10NR] 40-196
FAILURE CODE [AS10NT] 40-197
FAILURE CODE [B@BAZG] 40-198
FAILURE CODE [B@BCNS] 40-199
FAILURE CODE [B@BCQA] 40-200
FAILURE CODE [B@CRNS] 40-202
FAILURE CODE [B@CRZG] 40-203
FAILURE CODE [CA115] 40-204
FAILURE CODE [CA122] 40-205
FAILURE CODE [CA123] 40-207
FAILURE CODE [CA131] 40-209
FAILURE CODE [CA132] 40-211
FAILURE CODE [CA144] 40-213
FAILURE CODE [CA145] 40-215
FAILURE CODE [CA153] 40-217
00 INDEX AND FOREWORD INDEX
D61EX-24, D61EX-24E0, D61PX-24, D61PX-24E0 00-5
FAILURE CODE [CA154] 40-220
FAILURE CODE [CA187] 40-222
FAILURE CODE [CA221] 40-224
FAILURE CODE [CA222] 40-226
FAILURE CODE [CA227] 40-228
FAILURE CODE [CA234] 40-229
FAILURE CODE [CA238] 40-230
FAILURE CODE [CA239] 40-232
FAILURE CODE [CA249] 40-234
FAILURE CODE [CA256] 40-236
FAILURE CODE [CA271] 40-238
FAILURE CODE [CA272] 40-240
FAILURE CODE [CA322] 40-242
FAILURE CODE [CA323] 40-244
FAILURE CODE [CA324] 40-246
FAILURE CODE [CA325] 40-248
FAILURE CODE [CA331] 40-250
FAILURE CODE [CA332] 40-252
FAILURE CODE [CA343] 40-254
FAILURE CODE [CA351] 40-255
FAILURE CODE [CA352] 40-256
FAILURE CODE [CA356] 40-259
FAILURE CODE [CA357] 40-261
FAILURE CODE [CA386] 40-264
FAILURE CODE [CA428] 40-265
FAILURE CODE [CA429] 40-267
FAILURE CODE [CA435] 40-269
FAILURE CODE [CA441] 40-271
FAILURE CODE [CA442] 40-273
FAILURE CODE [CA449] 40-274
FAILURE CODE [CA451] 40-275
FAILURE CODE [CA452] 40-277
FAILURE CODE [CA488] 40-279
FAILURE CODE [CA515] 40-280
FAILURE CODE [CA516] 40-282
FAILURE CODE [CA553] 40-284
FAILURE CODE [CA555] 40-285
FAILURE CODE [CA556] 40-286
FAILURE CODE [CA559] 40-287
FAILURE CODE [CA595] 40-290
FAILURE CODE [CA687] 40-291
FAILURE CODE [CA689] 40-293
FAILURE CODE [CA691] 40-296
FAILURE CODE [CA692] 40-298
FAILURE CODE [CA697] 40-300
FAILURE CODE [CA698] 40-301
FAILURE CODE [CA731] 40-302
FAILURE CODE [CA778] 40-304
FAILURE CODE [CA1117] 40-309
FAILURE CODE [CA1664] 40-310
FAILURE CODE [CA1669] 40-313
FAILURE CODE [CA1673] 40-314
FAILURE CODE [CA1677] 40-315
FAILURE CODE [CA1678] 40-316
FAILURE CODE [CA1682] 40-317
FAILURE CODE [CA1683] 40-321
FAILURE CODE [CA1684] 40-323
FAILURE CODE [CA1686] 40-325
INDEX 00 INDEX AND FOREWORD
00-6 D61EX-24, D61EX-24E0, D61PX-24, D61PX-24E0
FAILURE CODE [CA1691] 40-326
FAILURE CODE [CA1694] 40-329
FAILURE CODE [CA1695] 40-332
FAILURE CODE [CA1696] 40-333
FAILURE CODE [CA1712] 40-335
FAILURE CODE [CA1713] 40-338
FAILURE CODE [CA1714] 40-340
FAILURE CODE [CA1715] 40-341
FAILURE CODE [CA1776] 40-342
FAILURE CODE [CA1777] 40-345
FAILURE CODE [CA1843] 40-348
FAILURE CODE [CA1844] 40-350
FAILURE CODE [CA1879] 40-353
FAILURE CODE [CA1881] 40-356
FAILURE CODE [CA1883] 40-358
FAILURE CODE [CA1885] 40-362
FAILURE CODE [CA1887] 40-364
FAILURE CODE [CA1921] 40-366
FAILURE CODE [CA1922] 40-369
FAILURE CODE [CA1942] 40-374
FAILURE CODE [CA1993] 40-375
FAILURE CODE [CA2185] 40-378
FAILURE CODE [CA2186] 40-380
FAILURE CODE [CA2249] 40-382
FAILURE CODE [CA2271] 40-383
FAILURE CODE [CA2272] 40-386
FAILURE CODE [CA2288] 40-389
FAILURE CODE [CA2311] 40-390
FAILURE CODE [CA2349] 40-391
FAILURE CODE [CA2353] 40-394
FAILURE CODE [CA2357] 40-396
FAILURE CODE [CA2381] 40-397
FAILURE CODE [CA2382] 40-400
FAILURE CODE [CA2383] 40-403
FAILURE CODE [CA2386] 40-406
FAILURE CODE [CA2387] 40-408
FAILURE CODE [CA2555] 40-413
FAILURE CODE [CA2556] 40-416
FAILURE CODE [CA2637] 40-419
FAILURE CODE [CA2639] 40-421
FAILURE CODE [CA2771] 40-424
FAILURE CODE [CA2777] 40-430
FAILURE CODE [CA2976] 40-433
FAILURE CODE [CA3133] 40-435
FAILURE CODE [CA3134] 40-437
FAILURE CODE [CA3135] 40-439
FAILURE CODE [CA3142] 40-443
FAILURE CODE [CA3143] 40-444
FAILURE CODE [CA3144] 40-445
FAILURE CODE [CA3146] 40-447
FAILURE CODE [CA3147] 40-448
FAILURE CODE [CA3148] 40-449
FAILURE CODE [CA3151] 40-451
FAILURE CODE [CA3165] 40-457
FAILURE CODE [CA3229] 40-460
FAILURE CODE [CA3231] 40-462
FAILURE CODE [CA3232] 40-464
FAILURE CODE [CA3235] 40-468
00 INDEX AND FOREWORD INDEX
D61EX-24, D61EX-24E0, D61PX-24, D61PX-24E0 00-7
FAILURE CODE [CA3239] 40-470
FAILURE CODE [CA3241] 40-473
FAILURE CODE [CA3242] 40-476
FAILURE CODE [CA3251] 40-479
FAILURE CODE [CA3253] 40-481
FAILURE CODE [CA3254] 40-484
FAILURE CODE [CA3255] 40-487
FAILURE CODE [CA3256] 40-490
FAILURE CODE [CA3311] 40-492
FAILURE CODE [CA3312] 40-494
FAILURE CODE [CA3313] 40-497
FAILURE CODE [CA3314] 40-498
FAILURE CODE [CA3315] 40-499
FAILURE CODE [CA3316] 40-502
FAILURE CODE [CA3317] 40-503
FAILURE CODE [CA3318] 40-504
FAILURE CODE [CA3319] 40-507
FAILURE CODE [CA3321] 40-508
FAILURE CODE [CA3322] 40-510
FAILURE CODE [CA3419] 40-513
FAILURE CODE [CA3421] 40-515
FAILURE CODE [CA3497] 40-517
FAILURE CODE [CA3498] 40-518
FAILURE CODE [CA3543] 40-519
FAILURE CODE [CA3545] 40-526
FAILURE CODE [CA3547] 40-528
FAILURE CODE [CA3558] 40-529
FAILURE CODE [CA3559] 40-531
FAILURE CODE [CA3562] 40-533
FAILURE CODE [CA3563] 40-535
FAILURE CODE [CA3567] 40-538
FAILURE CODE [CA3568] 40-542
FAILURE CODE [CA3571] 40-548
FAILURE CODE [CA3572] 40-550
FAILURE CODE [CA3574] 40-552
FAILURE CODE [CA3575] 40-555
FAILURE CODE [CA3577] 40-557
FAILURE CODE [CA3578] 40-559
FAILURE CODE [CA3582] 40-561
FAILURE CODE [CA3583] 40-569
FAILURE CODE [CA3596] 40-571
FAILURE CODE [CA3649] 40-574
FAILURE CODE [CA3681] 40-576
FAILURE CODE [CA3682] 40-581
FAILURE CODE [CA3713] 40-587
FAILURE CODE [CA3717] 40-590
FAILURE CODE [CA3718] 40-591
FAILURE CODE [CA3725] 40-592
FAILURE CODE [CA3741] 40-595
FAILURE CODE [CA3748] 40-596
FAILURE CODE [CA3751] 40-598
FAILURE CODE [CA3755] 40-600
FAILURE CODE [CA3866] 40-602
FAILURE CODE [CA3867] 40-606
FAILURE CODE [CA3868] 40-609
FAILURE CODE [CA3899] 40-613
FAILURE CODE [CA3911] 40-615
FAILURE CODE [CA3912] 40-619
INDEX 00 INDEX AND FOREWORD
00-8 D61EX-24, D61EX-24E0, D61PX-24, D61PX-24E0
FAILURE CODE [CA3932] 40-621
FAILURE CODE [CA3933] 40-623
FAILURE CODE [CA3934] 40-625
FAILURE CODE [CA3935] 40-628
FAILURE CODE [CA3936] 40-630
FAILURE CODE [CA4151] 40-632
FAILURE CODE [CA4152] 40-636
FAILURE CODE [CA4155] 40-640
FAILURE CODE [CA4156] 40-643
FAILURE CODE [CA4157] 40-646
FAILURE CODE [CA4158] 40-648
FAILURE CODE [CA4159] 40-649
FAILURE CODE [CA4161] 40-650
FAILURE CODE [CA4162] 40-653
FAILURE CODE [CA4163] 40-656
FAILURE CODE [CA4164] 40-658
FAILURE CODE [CA4165] 40-660
FAILURE CODE [CA4166] 40-662
FAILURE CODE [CA4168] 40-664
FAILURE CODE [CA4169] 40-667
FAILURE CODE [CA4171] 40-669
FAILURE CODE [CA4249] 40-672
FAILURE CODE [CA4251] 40-674
FAILURE CODE [CA4259] 40-676
FAILURE CODE [CA4261] 40-679
FAILURE CODE [CA4277] 40-682
FAILURE CODE [CA4281] 40-686
FAILURE CODE [CA4459] 40-689
FAILURE CODE [CA4461] 40-692
FAILURE CODE [CA4658] 40-695
FAILURE CODE [CA4731] 40-699
FAILURE CODE [CA4732] 40-700
FAILURE CODE [CA4739] 40-701
FAILURE CODE [CA4768] 40-702
FAILURE CODE [CA4769] 40-704
FAILURE CODE [CA4842] 40-707
FAILURE CODE [CA4952] 40-711
FAILURE CODE [CA5115] 40-713
FAILURE CODE [CA5383] 40-716
FAILURE CODE [D130KA] 40-718
FAILURE CODE [D130KB] 40-721
FAILURE CODE [D130KY] 40-723
FAILURE CODE [D19JKZ] 40-725
FAILURE CODE [D811MC] 40-728
FAILURE CODE [D862KA] 40-729
FAILURE CODE [D8ALKA] 40-730
FAILURE CODE [D8ALKB] 40-732
FAILURE CODE [D8AQKR] 40-734
FAILURE CODE [D8G1KT] 40-736
FAILURE CODE [D8G6KT] 40-737
FAILURE CODE [DAF0MB] 40-738
FAILURE CODE [DAF0MC] 40-739
FAILURE CODE [DAF8KB] 40-740
FAILURE CODE [DAF9KQ] 40-742
FAILURE CODE [DAFGMC] 40-743
FAILURE CODE [DAFLKA] 40-744
FAILURE CODE [DAFLKB] 40-746
FAILURE CODE [DAFQKR] 40-748
00 INDEX AND FOREWORD INDEX
D61EX-24, D61EX-24E0, D61PX-24, D61PX-24E0 00-9
FAILURE CODE [DAJ000] 40-749
FAILURE CODE [DAJ0KQ] 40-750
FAILURE CODE [DAJ0KT] 40-751
FAILURE CODE [DAJ0MC] 40-752
FAILURE CODE [DAJ1KK] 40-753
FAILURE CODE [DAJ2KK] 40-755
FAILURE CODE [DAJ5KK] 40-757
FAILURE CODE [DAJ6KK] 40-760
FAILURE CODE [DAJLKA] 40-762
FAILURE CODE [DAJLKB] 40-764
FAILURE CODE [DAJPMA] 40-766
FAILURE CODE [DAJQKR] 40-767
FAILURE CODE [DAJRKR] 40-768
FAILURE CODE [DB2QKR] 40-769
FAILURE CODE [DB2RKR] 40-774
FAILURE CODE [DD12KA] 40-779
FAILURE CODE [DD12KB] 40-781
FAILURE CODE [DD13KA] 40-783
FAILURE CODE [DD13KB] 40-785
FAILURE CODE [DD14KA] 40-787
FAILURE CODE [DD14KB] 40-789
FAILURE CODE [DDKAKA] 40-791
FAILURE CODE [DDKAKB] 40-793
FAILURE CODE [DDKFL4] 40-795
FAILURE CODE [DDKGL4] 40-797
FAILURE CODE [DDKHKA] 40-799
FAILURE CODE [DDKHKB] 40-801
FAILURE CODE [DDNLKA] 40-803
FAILURE CODE [DDNLKB] 40-805
FAILURE CODE [DDP6KA] 40-807
FAILURE CODE [DDP6KB] 40-810
FAILURE CODE [DDP6MA] 40-812
FAILURE CODE [DDU1FS] 40-814
FAILURE CODE [DDU1KA] 40-816
FAILURE CODE [DDU1KY] 40-819
FAILURE CODE [DFA4KX] 40-821
FAILURE CODE [DFA4KZ] 40-822
FAILURE CODE [DFA4L8] 40-823
FAILURE CODE [DFA5KA] 40-824
FAILURE CODE [DFA5KB] 40-827
FAILURE CODE [DFA6KA] 40-830
FAILURE CODE [DFA6KB] 40-833
FAILURE CODE [DFA7KX] 40-836
FAILURE CODE [DFA7KZ] 40-837
FAILURE CODE [DFA7L8] 40-838
FAILURE CODE [DFA8KA] 40-839
FAILURE CODE [DFA8KB] 40-842
FAILURE CODE [DFA9KA] 40-845
FAILURE CODE [DFA9KB] 40-848
FAILURE CODE [DGS1KA] 40-851
FAILURE CODE [DGS1KX] 40-854
FAILURE CODE [DH21KA] 40-855
FAILURE CODE [DH21KB] 40-857
FAILURE CODE [DHA4KA] 40-859
FAILURE CODE [DHAAMA] 40-861
FAILURE CODE [DHACMA] 40-863
FAILURE CODE [DHH7KA] 40-865
FAILURE CODE [DHH7KB] 40-868
INDEX 00 INDEX AND FOREWORD
00-10 D61EX-24, D61EX-24E0, D61PX-24, D61PX-24E0
FAILURE CODE [DHH8KA] 40-870
FAILURE CODE [DHH8KB] 40-873
FAILURE CODE [DHH9KA] 40-875
FAILURE CODE [DHH9KB] 40-878
FAILURE CODE [DHHAKA] 40-880
FAILURE CODE [DHHAKB] 40-883
FAILURE CODE [DHRUKA] 40-885
FAILURE CODE [DHRUKB] 40-887
FAILURE CODE [DHRVKA] 40-889
FAILURE CODE [DHRVKB] 40-891
FAILURE CODE [DK30KA] 40-893
FAILURE CODE [DK30KB] 40-896
FAILURE CODE [DK30KX] 40-898
FAILURE CODE [DK30KZ] 40-899
FAILURE CODE [DK30L8] 40-900
FAILURE CODE [DK31KA] 40-901
FAILURE CODE [DK31KB] 40-904
FAILURE CODE [DK40KA] 40-906
FAILURE CODE [DK40KB] 40-909
FAILURE CODE [DK55KX] 40-911
FAILURE CODE [DK55KZ] 40-912
FAILURE CODE [DK55L8] 40-913
FAILURE CODE [DK56KA] 40-914
FAILURE CODE [DK56KB] 40-917
FAILURE CODE [DK57KA] 40-919
FAILURE CODE [DK57KB] 40-922
FAILURE CODE [DLM0KX] 40-924
FAILURE CODE [DLM1KA] 40-925
FAILURE CODE [DLM1KB] 40-927
FAILURE CODE [DLM1MA] 40-929
FAILURE CODE [DLM2KA] 40-930
FAILURE CODE [DLM2KB] 40-932
FAILURE CODE [DLM2MA] 40-934
FAILURE CODE [DLM3KA] 40-935
FAILURE CODE [DLM3KB] 40-937
FAILURE CODE [DLM3MB] 40-939
FAILURE CODE [DN21FS] 40-940
FAILURE CODE [DR21KX] 40-942
FAILURE CODE [DR31KX] 40-943
FAILURE CODE [DV20KB] 40-944
FAILURE CODE [DW4BKA] 40-946
FAILURE CODE [DW4BKB] 40-948
FAILURE CODE [DW4BKY] 40-950
FAILURE CODE [DW7BKA] 40-952
FAILURE CODE [DW7BKB] 40-954
FAILURE CODE [DW7EKA] 40-956
FAILURE CODE [DW7EKB] 40-958
FAILURE CODE [DW7EKY] 40-960
FAILURE CODE [DWN5KA] 40-962
FAILURE CODE [DWN5KB] 40-964
FAILURE CODE [DWN5KY] 40-966
FAILURE CODE [DXA4KA] 40-968
FAILURE CODE [DXA4KB] 40-970
FAILURE CODE [DXA4KY] 40-972
FAILURE CODE [DXA5KA] 40-974
FAILURE CODE [DXA5KB] 40-976
FAILURE CODE [DXA5KY] 40-978
FAILURE CODE [DXA6KA] 40-980
00 INDEX AND FOREWORD INDEX
D61EX-24, D61EX-24E0, D61PX-24, D61PX-24E0 00-11
FAILURE CODE [DXA6KB] 40-982
FAILURE CODE [DXA6KY] 40-984
FAILURE CODE [DXA7KA] 40-986
FAILURE CODE [DXA7KB] 40-988
FAILURE CODE [DXA7KY] 40-990
FAILURE CODE [DXHRKA] 40-992
FAILURE CODE [DXHRKB] 40-994
FAILURE CODE [DXHRKY] 40-996
FAILURE CODE [DXHSKA] 40-998
FAILURE CODE [DXHSKB] 40-1000
FAILURE CODE [DXHSKY] 40-1002
FAILURE CODE [DXHTKA] 40-1004
FAILURE CODE [DXHTKB] 40-1006
FAILURE CODE [DXHTKY] 40-1008
FAILURE CODE [DXHUKA] 40-1010
FAILURE CODE [DXHUKB] 40-1012
FAILURE CODE [DXHUKY] 40-1014
FAILURE CODE [DXJ4KA] 40-1016
FAILURE CODE [DXJ4KB] 40-1018
FAILURE CODE [DXJCKA] 40-1020
FAILURE CODE [DXJCKB] 40-1022
FAILURE CODE [DXJCKY] 40-1024
FAILURE CODE [DXJDKA] 40-1026
FAILURE CODE [DXJDKB] 40-1028
FAILURE CODE [DXJDKY] 40-1030
FAILURE CODE [DXK1KA] 40-1032
FAILURE CODE [DXK1KB] 40-1034
FAILURE CODE [DXK1KY] 40-1036
FAILURE CODE [DXK2KA] 40-1038
FAILURE CODE [DXK2KB] 40-1040
FAILURE CODE [DXK2KY] 40-1042
FAILURE CODE [F313KA] 40-1044
FAILURE CODE [F313KB] 40-1045
FAILURE CODE [F318KB] 40-1046
FAILURE CODE [F318KY] 40-1047
TROUBLESHOOTING OF ELECTRICAL SYSTEM (E-MODE) 40-1048
E-1 ENGINE DOES NOT START (ENGINE DOES NOT CRANK) 40-1048
E-2 MANUAL PREHEATING SYSTEM DOES NOT WORK 40-1055
E-3 AUTOMATIC PREHEATING SYSTEM DOES NOT WORK 40-1058
E-4 WHILE PREHEATING IS WORKING, PREHEATING MONITOR DOES NOT LIGHT UP 40-1060
E-5 WHEN STARTING SWITCH IS TURNED TO ON POSITION, MACHINE MONITOR DISPLAYS
NOTHING 40-1062
E-6 WHEN STARTING SWITCH IS TURNED TO ON POSITION (WITH ENGINE STOPPED), BASIC
CHECK MONITOR LIGHTS UP 40-1066
E-7 AIR CLEANER CLOGGING MONITOR LIGHTS UP IN YELLOW WHILE ENGINE IS RUNNING
40-1067
E-8 CHARGE LEVEL MONITOR LIGHTS UP IN RED WHILE ENGINE IS RUNNING 40-1068
E-9 ENGINE COOLANT TEMPERATURE MONITOR LIGHTS UP IN RED WHILE ENGINE IS RUNNING
40-1069
E-10 ENGINE OIL PRESSURE MONITOR LIGHTS UP IN RED WHILE ENGINE IS RUNNING 40-1070
E-11 HST CHARGE PRESSURE MONITOR LIGHTS UP IN RED WHILE ENGINE IS RUNNING
40-1071
E-12 HYDRAULIC OIL TEMPERATURE MONITOR LIGHTS UP IN RED WHILE ENGINE IS RUNNING
40-1072
E-13 HST OIL FILTER CLOGGING MONITOR LIGHTS UP IN RED WHILE ENGINE IS RUNNING
40-1073
E-14 ENGINE COOLANT TEMPERATURE GAUGE DOES NOT INDICATE CORRECT TEMPERATURE
40-1074
INDEX 00 INDEX AND FOREWORD
00-12 D61EX-24, D61EX-24E0, D61PX-24, D61PX-24E0
E-15 FUEL LEVEL GAUGE DOES NOT INDICATE CORRECT LEVEL 40-1075
E-16 HYDRAULIC OIL TEMPERATURE GAUGE DOES NOT INDICATE CORRECT TEMPERATURE
40-1078
E-17 OPERATION MODE DOES NOT CHANGE 40-1079
E-18 OPERATING CUSTOMIZE SWITCH DOES NOT DISPLAY CUSTOMIZE SCREEN 40-1080
E-19 MODIFYING SETTING ON CUSTOMIZE SCREEN DOES NOT CHANGE SETTING OF MACHINE
40-1081
E-20 SERVICE METER IS NOT DISPLAYED, WHILE STARTING SWITCH IS IN OFF POSITION
40-1082
E-21 SERVICE MODE CANNOT BE SELECTED 40-1083
E-22 WORK EQUIPMENT DOES NOT OPERATE 40-1084
E-23 FOOT HEATER DOES NOT OPERATE 40-1086
E-24 HORN DOES NOT SOUND 40-1092
E-25 HORN DOES NOT STOP SOUNDING 40-1094
E-26 BACKUP ALARM DOES NOT SOUND 40-1095
E-27 BACKUP ALARM DOES NOT STOP SOUNDING 40-1096
E-28 HEADLAMP DOES NOT LIGHT UP 40-1097
E-29 REAR LAMP DOES NOT LIGHT UP 40-1101
E-30 ALL WIPERS DO NOT OPERATE 40-1104
E-31 FRONT WIPER DOES NOT OPERATE 40-1106
E-32 REAR WIPER DOES NOT OPERATE 40-1108
E-33 LEFT DOOR WIPER DOES NOT OPERATE 40-1110
E-34 RIGHT DOOR WIPER DOES NOT OPERATE 40-1114
E-35 FRONT WASHER DOES NOT OPERATE 40-1118
E-36 REAR WASHER DOES NOT OPERATE 40-1120
E-37 LEFT DOOR WASHER DOES NOT OPERATE 40-1122
E-38 RIGHT DOOR WASHER DOES NOT OPERATE 40-1124
E-39 KOMTRAX SYSTEM DOES NOT OPERATE NORMALLY 40-1126
TROUBLESHOOTING FOR HYDRAULIC AND MECHANICAL SYSTEMS (H MODE) 40-1127
INFORMATION MENTIONED IN TROUBLESHOOTING TABLE (H MODE) 40-1127
FAILURE MODE AND CAUSE TABLE 40-1128
H-1 NEITHER R H NOR L H OF TRACKS CAN TRAVEL FORWARD OR REVERSE (NONE OF THE
TRAVEL SYSTEMS OPERATE) 40-1134
H-2 EITHER R H OR L H OF TRACK CANNOT TRAVEL BOTH FORWARD AND REVERSE (ONE
OF R H OR L H TRAVEL SYSTEMS CANNOT OPERATE) 40-1136
H-3 EITHER R H OR L H OF TRACK CANNOT TRAVEL ONE OF FORWARD OR REVERSE (ONLY
ONE OF THE TRAVEL SYSTEMS CANNOT OPERATE IN ONE DIRECTION) 40-1138
H-4 TRAVEL SPEED OR POWER IS LOW 40-1140
H-5 SPEED RANGE DOES NOT CHANGE 40-1142
H-6 SHOCK IS LARGE WHEN MACHINE MOVES OFF OR STOPS 40-1143
H-7 MACHINE DEVIATES LARGELY 40-1144
H-8 MACHINE DRIFT ON A SLOPE IS LARGE 40-1147
H-9 ENGINE SPEED DROPS LARGELY OR ENGINE STOPS 40-1149
H-10 UNUSUAL NOISE IS HEARD FROM AROUND HST PUMP OR MOTOR 40-1151
H-11 HST OIL TEMPERATURE (HYDRAULIC OIL TEMPERATURE) RISES TOO HIGH 40-1153
H-12 ALL WORK EQUIPMENT DO NOT OPERATE 40-1155
H-13 ALL WORK EQUIPMENTS SPEED OR POWER IS LOW 40-1157
H-14 BLADE LIFT SPEED OR POWER IS LOW 40-1158
H-15 BLADE TILT SPEED OR POWER IS LOW 40-1160
H-16 BLADE ANGLE SPEED OR POWER IS LOW 40-1161
H-17 TIME LAG OF BLADE LIFT IS LARGE 40-1162
H-18 HYDRAULIC DRIFT OF LIFTED BLADE IS LARGE 40-1163
H-19 HYDRAULIC DRIFT OF TILTED BLADE IS LARGE 40-1164
H-20 UNUSUAL NOISE IS HEARD FROM AROUND WORK EQUIPMENT AND COOLING FAN
PUMP OR CONTROL VALVE 40-1165
H-21 FAN SPEED IS ABNORMAL (TOO HIGH OR LOW, OR STATIONARY) 40-1166
H-22 UNUSUAL NOISE IS HEARD FROM AROUND FAN 40-1168
TROUBLESHOOTING OF ENGINE (S-MODE) 40-1169
00 INDEX AND FOREWORD INDEX
D61EX-24, D61EX-24E0, D61PX-24, D61PX-24E0 00-13
INFORMATION MENTIONED IN TROUBLESHOOTING TABLE (S MODE) 40-1169
S-1 ENGINE DOES NOT CRANK WHEN STARTING SWITCH IS TURNED TO START POSITION
40-1170
S-2 ENGINE CRANKS BUT NO EXHAUST GAS COMES OUT 40-1171
S-3 FUEL IS BEING INJECTED BUT ENGINE DOES NOT START (MISFIRING: ENGINE CRANKS
BUT DOES NOT START) 40-1172
S-4 ENGINE STARTABILITY IS POOR 40-1174
S-5 ENGINE DOES NOT PICK UP SMOOTHLY 40-1176
S-6 ENGINE STOPS DURING OPERATION 40-1178
S-7 ENGINE RUNS ROUGH OR IS UNSTABLE 40-1180
S-8 ENGINE LACKS POWER 40-1181
S-9 KDPF GETS CLOGGED IN A SHORT TIME 40-1183
S-10 ENGINE OIL CONSUMPTION IS EXCESSIVE 40-1185
S-11 OIL BECOMES CONTAMINATED QUICKLY 40-1186
S-12 FUEL CONSUMPTION IS EXCESSIVE 40-1187
S-13 OIL IS IN COOLANT (OR COOLANT SPURTS BACK OR COOLANT LEVEL GOES DOWN)
40-1188
S-14 OIL PRESSURE DROPS 40-1189
S-15 FUEL MIXES INTO ENGINE OIL 40-1191
S-16 WATER MIXES INTO ENGINE OIL (MILKY) 40-1192
S-17 COOLANT TEMPERATURE RISES TOO HIGH (OVERHEATING) 40-1193
S-18 UNUSUAL NOISE IS HEARD 40-1194
S-19 VIBRATION IS EXCESSIVE 40-1195
S-20 AIR CANNOT BE BLED FROM FUEL CIRCUIT 40-1196
S-21 ACTIVE REGENERATION IS EXECUTED FREQUENTLY 40-1197
S-22 ACTIVE REGENERATION TAKES TIME 40-1199
S-23 WHITE SMOKE IS EXHAUSTED DURING ACTIVE REGENERATION 40-1200
S-24 AdBlue/DEF CONSUMPTION IS EXCESSIVE 40-1201
S-25 THERE IS UNUSUAL SMELL (IRRITATING ODOR) 40-1203
S-26 FOREIGN MATERIALS ENTER AdBlue/DEF (AdBlue/DEF INCREASES) 40-1204
50 DISASSEMBLY AND ASSEMBLY 50-1
CONTENTS 50-2
ABBREVIATION LIST 50-7
RELATED INFORMATION ON DISASSEMBLY AND ASSEMBLY 50-13
HOW TO READ THIS MANUAL 50-13
COATING MATERIALS LIST 50-15
SPECIAL TOOLS LIST 50-19
SKETCHES OF SPECIAL TOOLS 50-38
ENGINE AND COOLING SYSTEM 50-51
REMOVE AND INSTALL SUPPLY PUMP ASSEMBLY 50-51
REMOVE AND INSTALL INJECTOR ASSEMBLY 50-64
REMOVE AND INSTALL CYLINDER HEAD ASSEMBLY 50-81
REMOVE AND INSTALL EGR VALVE ASSEMBLY 50-111
REMOVE AND INSTALL EGR COOLER ASSEMBLY 50-114
REMOVE AND INSTALL STARTING MOTOR ASSEMBLY 50-119
REMOVE AND INSTALL ALTERNATOR BELT 50-123
REMOVE AND INSTALL AUTOMATIC TENSIONER 50-126
REMOVE AND INSTALL RADIATOR ASSEMBLY 50-127
REMOVE AND INSTALL HYDRAULIC OIL COOLER ASSEMBLY 50-134
REMOVE AND INSTALL AFTERCOOLER ASSEMBLY 50-140
REMOVE AND INSTALL COOLING FAN DRIVE ASSEMBLY 50-147
REMOVE AND INSTALL COOLING FAN MOTOR ASSEMBLY 50-154
REMOVE AND INSTALL ENGINE, HST PUMP ASSEMBLY 50-161
REMOVE AND INSTALL ENGINE FRONT OIL SEAL 50-181
REMOVE AND INSTALL ENGINE REAR OIL SEAL 50-184
REMOVE AND INSTALL ENGINE HOOD ASSEMBLY 50-189
REMOVE AND INSTALL FUEL TANK ASSEMBLY 50-196
REMOVE AND INSTALL AdBlue/DEF TANK ASSEMBLY 50-209
INDEX 00 INDEX AND FOREWORD
00-14 D61EX-24, D61EX-24E0, D61PX-24, D61PX-24E0
REMOVE AND INSTALL AdBlue/DEF TANK SENSOR FLANGE ASSEMBLY 50-221
REMOVE AND INSTALL AdBlue/DEF TANK SENSOR 50-225
REMOVE AND INSTALL AdBlue/DEF TANK STRAINER 50-233
REMOVE AND INSTALL AdBlue/DEF TANK FILLER PORT FILTER 50-235
REMOVE AND INSTALL KDPF ASSEMBLY 50-239
DISASSEMBLE AND ASSEMBLE OF KDPF ASSEMBLY 50-246
REMOVE AND INSTALL SCR ASSEMBLY 50-256
REMOVE AND INSTALL KDPF, SCR ASSEMBLY 50-262
REMOVE AND INSTALL KCCV ASSEMBLY 50-276
REMOVE AND INSTALL VGT ASSEMBLY 50-280
REMOVE AND INSTALL AdBlue/DEF MIXING TUBE 50-285
REMOVE AND INSTALL AdBlue/DEF INJECTOR 50-292
REMOVE AND INSTALL AdBlue/DEF PUMP 50-299
REMOVE AND INSTALL AdBlue/DEF HOSE 50-305
REMOVE AND INSTALL AIR CLEANER ASSEMBLY 50-315
REMOVE AND INSTALL AIR CONDITIONER COMPRESSOR ASSEMBLY 50-320
REMOVE AND INSTALL AIR CONDITIONER CONDENSER ASSEMBLY 50-323
POWER TRAIN 50-331
REMOVE AND INSTALL DAMPER ASSEMBLY 50-331
REMOVE AND INSTALL HST PUMP ASSEMBLY 50-334
REMOVE AND INSTALL HST MOTOR AND FINAL DRIVE ASSEMBLY 50-338
DISASSEMBLE AND ASSEMBLE FINAL DRIVE ASSEMBLY 50-344
UNDERCARRIAGE AND FRAME 50-359
REMOVE AND INSTALL TRACK FRAME ASSEMBLY 50-359
REMOVE AND INSTALL IDLER ASSEMBLY 50-369
DISASSEMBLE AND ASSEMBLE IDLER ASSEMBLY 50-373
REMOVE AND INSTALL RECOIL SPRING ASSEMBLY 50-380
DISASSEMBLE AND ASSEMBLE RECOIL SPRING ASSEMBLY 50-382
REMOVE AND INSTALL TRACK ROLLER ASSEMBLY 50-388
DISASSEMBLE AND ASSEMBLE TRACK ROLLER ASSEMBLY 50-392
REMOVE AND INSTALL CARRIER ROLLER ASSEMBLY 50-398
DISASSEMBLE AND ASSEMBLE CARRIER ROLLER ASSEMBLY 50-401
REMOVE AND INSTALL PIVOT SHAFT ASSEMBLY 50-405
SEPARATE AND CONNECT TRACK ASSEMBLY 50-408
SEPARATE AND CONNECT PLUS TYPE TRACK ASSEMBLY 50-413
DISASSEMBLE AND ASSEMBLE TRACK ASSEMBLY GENERALLY 50-415
DISASSEMBLE AND ASSEMBLE PLUS TYPE TRACK ASSEMBLY GENERALLY 50-433
DISASSEMBLE AND ASSEMBLE ONE LINK OF TRACK SHOE ASSEMBLY ON THE FIELD 50-450
DISASSEMBLE AND ASSEMBLE ONE LINK OF PLUS TYPE TRACK SHOE ASSEMBLY ON THE
FIELD 50-459
REMOVE AND INSTALL EQUALIZER BAR ASSEMBLY 50-466
REMOVE AND INSTALL EQUALIZER BAR SIDE BUSHINGS 50-471
REMOVE AND INSTALL SEGMENT TEETH 50-473
HYDRAULIC SYSTEM 50-475
REMOVE AND INSTALL HYDRAULIC TANK ASSEMBLY 50-475
REMOVE AND INSTALL CONTROL VALVE ASSEMBLY 50-485
WORK EQUIPMENT 50-495
REMOVE AND INSTALL BLADE ASSEMBLY 50-495
REMOVE AND INSTALL WORK EQUIPMENT ASSEMBLY 50-500
METHOD FOR DISASSEMBLING AND ASSEMBLING WORK EQUIPMENT CYLINDER ASSEMBLY
50-504
REMOVE AND INSTALL U-FRAME ASSEMBLY 50-510
CAB AND ITS ATTACHMENTS 50-514
REMOVE AND INSTALL OPERATOR’S CAB ASSEMBLY 50-514
REMOVE AND INSTALL OPERATOR’S CAB GLASS (ADHERED GLASS) 50-529
REMOVE AND INSTALL AIR CONDITIONER UNIT ASSEMBLY 50-537
REMOVE AND INSTALL RECEIVER DRIER 50-550
REMOVE AND INSTALL OPERATOR’S SEAT 50-554
00 INDEX AND FOREWORD INDEX
D61EX-24, D61EX-24E0, D61PX-24, D61PX-24E0 00-15
REMOVE AND INSTALL SEAT BELT 50-556
REMOVE AND INSTALL FOOT HEATER ASSEMBLY 50-558
DISASSEMBLE AND ASSEMBLE FOOT HEATER ASSEMBLY 50-563
ELECTRICAL SYSTEM 50-565
REMOVE AND INSTALL ENGINE CONTROLLER ASSEMBLY 50-565
REMOVE AND INSTALL HST CONTROLLER ASSEMBLY 50-570
REMOVE AND INSTALL MACHINE MONITOR ASSEMBLY 50-572
REMOVE AND INSTALL MASS AIR FLOW AND TEMPERATURE SENSOR 50-575
REMOVE AND INSTALL KCCV CRANKCASE PRESSURE SENSOR 50-578
REMOVE AND INSTALL SCR TEMPERATURE SENSOR 50-582
REMOVE AND INSTALL GATEWAY FUNCTION CONTROLLER ASSEMBLY 50-585
REMOVE AND INSTALL COMMUNICATION TERMINAL 50-587
60 MAINTENANCE STANDARD 60-1
CONTENTS 60-2
ABBREVIATION LIST 60-4
ENGINE AND COOLING SYSTEM 60-10
MAINTENANCE STANDARD OF ENGINE MOUNT 60-10
MAINTENANCE STANDARD OF DAMPER 60-11
MAINTENANCE STANDARD OF COOLING SYSTEM 60-12
MAINTENANCE STANDARD OF COOLING FAN MOTOR 60-14
MAINTENANCE STANDARD OF WORK EQUIPMENT AND COOLING FAN PUMP 60-16
POWER TRAIN 60-17
MAINTENANCE STANDARD OF HST PUMP 60-17
MAINTENANCE STANDARD OF HST CHARGE PUMP 60-20
MAINTENANCE STANDARD OF HST MOTOR 60-22
MAINTENANCE STANDARD OF FINAL DRIVE 60-23
MAINTENANCE STANDARD OF SPROCKET FOR CONVENTIONAL TYPE TRACK SHOE 60-25
MAINTENANCE STANDARD OF SPROCKET TOOTH PROFILE FULL-SCALE DRAWING FOR CONVENTIONAL
TYPE TRACK SHOE 60-26
MAINTENANCE STANDARD OF SPROCKET FOR PLUS TYPE TRACK SHOE 60-28
MAINTENANCE STANDARD OF SPROCKET TOOTH PROFILE FULL-SCALE DRAWING FOR PLUS
TYPE TRACK SHOE 60-29
UNDERCARRIAGE AND FRAME 60-31
MAINTENANCE STANDARD OF SUSPENSION 60-31
MAINTENANCE STANDARD OF TRACK FRAME AND IDLER CUSHION 60-33
MAINTENANCE STANDARD OF IDLER 60-35
MAINTENANCE STANDARD OF TRACK ROLLER FOR CONVENTIONAL TYPE TRACK SHOES
(SINGLE FLANGE TYPE) 60-37
MAINTENANCE STANDARD OF TRACK ROLLER FOR CONVENTIONAL TYPE TRACK SHOES
(DOUBLE FLANGE TYPE) 60-38
MAINTENANCE STANDARD OF TRACK ROLLER FOR PLUS TYPE TRACK SHOES (SINGLE
FLANGE TYPE) 60-39
MAINTENANCE STANDARD OF TRACK ROLLER FOR PLUS TYPE TRACK SHOES (DOUBLE
FLANGE TYPE) 60-40
MAINTENANCE STANDARD OF CARRIER ROLLER FOR CONVENTIONAL TYPE TRACK SHOE
60-41
MAINTENANCE STANDARD OF CARRIER ROLLER FOR PLUS TYPE TRACK SHOE 60-42
MAINTENANCE STANDARD OF CONVENTIONAL TYPE TRACK SHOE 60-43
MAINTENANCE STANDARD OF PLUS TYPE TRACK SHOE 60-45
MAINTENANCE STANDARD OF SINGLE SHOE 60-47
MAINTENANCE STANDARD OF SWAMP SHOE 60-48
HYDRAULIC SYSTEM 60-49
MAINTENANCE STANDARD OF HYDRAULIC TANK 60-49
MAINTENANCE STANDARD OF WORK EQUIPMENT AND COOLING FAN PUMP 60-50
MAINTENANCE STANDARD OF CONTROL VALVE 60-53
MAINTENANCE STANDARD OF RIPPER PPC VALVE 60-60
MAINTENANCE STANDARD OF 5-PORT VALVE OF EPC AND SOLENOID 60-62
MAINTENANCE STANDARD OF ANGLE OPERATION EPC VALVE 60-64
INDEX 00 INDEX AND FOREWORD
00-16 D61EX-24, D61EX-24E0, D61PX-24, D61PX-24E0
MAINTENANCE STANDARD OF QUICK DROP VALVE 60-65
WORK EQUIPMENT 60-67
MAINTENANCE STANDARD OF FRONT WORK EQUIPMENT 60-67
MAINTENANCE STANDARD OF CUTTING EDGE AND END BIT 60-70
MAINTENANCE STANDARD OF BLADE LIFT CYLINDER 60-71
MAINTENANCE STANDARD OF BLADE TILT CYLINDER 60-72
MAINTENANCE STANDARD OF BLADE ANGLE CYLINDER 60-73
MAINTENANCE STANDARD OF FIXED MULTI-SHANK RIPPER 60-74
MAINTENANCE STANDARD OF RIPPER LIFT CYLINDER 60-76
CAB AND ITS ATTACHMENTS 60-77
MAINTENANCE STANDARD OF CAB MOUNT 60-77
ELECTRICAL SYSTEM 60-78
MAINTENANCE STANDARD OF ELECTRIC STEERING CONTROL LEVER 60-78
80 APPENDIX 80-1
CONTENTS 80-2
ABBREVIATION LIST 80-3
AIR CONDITIONER SYSTEM 80-9
PRECAUTIONS FOR REFRIGERANT 80-9
AIR CONDITIONER COMPONENT 80-10
SPECIFICATIONS OF AIR CONDITIONER 80-13
CONFIGURATION AND FUNCTION OF REFRIGERATION CYCLE 80-14
OUTLINE OF REFRIGERATION CYCLE 80-15
COMPONENT PARTS OF AIR CONDITIONER SYSTEM 80-17
AIR CONDITIONER UNIT 80-17
COMPONENT PARTS OF AIR CONDITIONER UNIT 80-19
COMPRESSOR 80-22
CONDENSER 80-23
RECEIVER DRIER 80-25
EXPLANATION OF PROCEDURE FOR TESTING AND TROUBLESHOOTING OF AIR CONDITIONER
80-27
CIRCUIT DIAGRAM OF AIR CONDITIONER 80-30
AIR CONDITIONER SYSTEM DIAGRAM 80-31
CONTROL FUNCTION OF AIR CONDITIONER 80-32
INSTALLATION LOCATIONS OF AIR CONDITIONER PARTS AND ARRANGEMENT OF CONNECTORS
80-33
TEST RELAYS 80-37
METHOD FOR TESTING RELAYS 80-37
AIR CONDITIONER TROUBLESHOOTING CHART 1 80-39
AIR CONDITIONER TROUBLESHOOTING CHART 2 80-40
INFORMATION DESCRIBED IN TROUBLESHOOTING TABLE 80-43
A-1 TROUBLESHOOTING FOR CONDENSER FAN 80-45
A-2 TROUBLESHOOTING FOR COMPRESSOR AND REFRIGERANT SYSTEM (AIR IS NOT COOLED)
80-48
A-3 TROUBLESHOOTING FOR BLOWER MOTOR SYSTEM (NO AIR COMES OUT OR AIR FLOW IS
ABNORMAL) 80-52
A-4 TROUBLESHOOTING FOR TEMPERATURE CONTROL FUNCTION 80-55
TROUBLESHOOTING USING GAUGE PRESSURE 80-59
CONNECTION OF SERVICE TOOL 80-61
METHOD FOR CONNECTING SERVICE TOOL 80-61
PRECAUTIONS FOR DISCONNECTING AND CONNECTING HOSES AND TUBES IN AIR CONDITIONER
PIPINGS 80-62
HANDLE COMPRESSOR OIL 80-64
90 CIRCUIT DIAGRAMS 90-1
CONTENTS 90-2
HYDRAULIC CIRCUIT DIAGRAM 90-3
SYMBOLS USED IN HYDRAULIC CIRCUIT DIAGRAM 90-3
HYDRAULIC CIRCUIT DIAGRAM 90-7
ELECTRICAL CIRCUIT DIAGRAM 90-9
00 INDEX AND FOREWORD INDEX
D61EX-24, D61EX-24E0, D61PX-24, D61PX-24E0 00-17
SYMBOLS USED IN ELECTRICAL CIRCUIT DIAGRAM 90-9
ELECTRICAL CIRCUIT DIAGRAM (1/16) 90-13
ELECTRICAL CIRCUIT DIAGRAM (2/16) 90-15
ELECTRICAL CIRCUIT DIAGRAM (3/16) 90-17
ELECTRICAL CIRCUIT DIAGRAM (4/16) 90-19
ELECTRICAL CIRCUIT DIAGRAM (5/16) 90-21
ELECTRICAL CIRCUIT DIAGRAM (6/16) 90-23
ELECTRICAL CIRCUIT DIAGRAM (7/16) 90-25
ELECTRICAL CIRCUIT DIAGRAM (8/16) 90-27
ELECTRICAL CIRCUIT DIAGRAM (9/16) 90-29
ELECTRICAL CIRCUIT DIAGRAM (10/16) 90-31
ELECTRICAL CIRCUIT DIAGRAM (11/16) 90-33
ELECTRICAL CIRCUIT DIAGRAM (12/16) 90-35
ELECTRICAL CIRCUIT DIAGRAM (13/16) 90-37
ELECTRICAL CIRCUIT DIAGRAM (14/16) 90-39
ELECTRICAL CIRCUIT DIAGRAM (15/16) 90-41
ELECTRICAL CIRCUIT DIAGRAM (16/16) 90-43
INDEX 1

DESCRIPTION:

Komatsu D61EX -24 D61EX -24E0 D61PX-24 D61PX-24E0 Bulldozer Shop Manual SEN06855-04 – PDF DOWNLOAD

SERIAL NUMBERS

D61EX-45001 and up
D61PX-45001 and up

FOREWORD, SAFETY, BASIC INFORMATION
HOW TO READ THE SHOP MANUAL
• Some of the attachments and options described in this shop manual may not be available in some areas. If
they are required, consult your Komatsu distributor.
• The materials and specifications are subject to change without notice.
• Shop Manuals are available for “machine part” and “engine part”. For the engine unit, see the shop manual
for the machine which has the same engine model.
• Actual machine may differ from the images which are contained in this manual. A typical model is shown in
the illustrations of this shop manual.
Composition of the shop manual
This shop manual contains technical information necessary to perform services in workshops. It is divided into
the following chapters for the ease of use.
00 INDEX AND FOREWORD
This section describes the index, foreword, safety, and basic information.
01 SPECIFICATIONS
This section describes the specifications of the machine.
10 STRUCTURE AND FUNCTION
This section describes the structure and operation of each component with respect to each system. “STRUCTURE
AND FUNCTION” is helpful in not only understanding the structure of each component but performing
troubleshooting.
20 STANDARD VALUE TABLE
This section describes the standard values for new machine and failure criteria for testing and adjusting, and
troubleshooting. Use the standard values table to check the standard values for testing and adjusting, and judge
troubles in troubleshooting.
30 TESTING AND ADJUSTING
This section describes the measuring tools and measuring methods for testing and adjusting as well as the adjusting
method of each part. The standard values and repair limit for TESTING AND ADJUSTING are described
in “STANDARD VALUE TABLE”.
40 TROUBLESHOOTING
This section describes troubleshooting of failure part and its remedy method on the occurrence of the failure.
Descriptions of troubleshooting are sorted by failure mode.
50 DISASSEMBLY AND ASSEMBLY
This section describes the special tools, work procedures, and safety precautions necessary for removal, installation,
disassembly, and assembly of the components and parts. In addition, tightening torques, quantity, and
weight of the coating materials, lubricants, and coolant necessary to these works are shown.
60 MAINTENANCE STANDARD
This section describes the maintenance standard value of each component. The maintenance standard shows
the criteria and remedies for disassembly and assembly.
80 THE OTHER INFORMATION
This section describes the structure and function, testing and adjusting, and troubleshooting for all of the other
components or equipment which cannot be separately classified in the appendix.
90 Circuit diagrams
This section describes hydraulic circuit diagrams and electrical circuit diagrams.

IMAGES PREVIEW OF THE MANUAL: