Komatsu D61EX-24 D61EX-24E0 D6PX-24 D61PX-24E0 Crawler Dozer Shop Manual KEBM685502 – PDF DOWNLOAD

Komatsu D61EX-24 D61EX-24E0 D6PX-24 D61PX-24E0 Crawler Dozer Shop Manual KEBM685502 – PDF DOWNLOAD

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Komatsu D61EX-24 D61EX-24E0 D6PX-24 D61PX-24E0 Crawler Dozer Shop Manual KEBM685502 – PDF DOWNLOAD

Language : English
Pages : 2762
Downloadable : Yes
File Type : PDF
Size: 54.6 MB

TABLE OF CONTENTS:

Komatsu D61EX-24 D61EX-24E0 D6PX-24 D61PX-24E0 Crawler Dozer Shop Manual KEBM685502 – PDF DOWNLOAD

INDEX
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 30-12
ENGINE AND COOLING SYSTEM 30-13
TEST ENGINE SPEED 30-13
TEST BOOST PRESSURE 30-15
TEST EXHAUST GAS COLOR 30-17
TEST AND ADJUST VALVE CLEARANCE 30-21
TEST COMPRESSION PRESSURE 30-23
TEST BLOWBY PRESSURE 30-28
TEST ENGINE OIL PRESSURE 30-31
00 INDEX AND FOREWORD INDEX
D61EX-24, D61EX-24E0, D61PX-24, D61PX-24E0 00-3
TEST EGR VALVE AND VGT OIL PRESSURE 30-32
TEST FUEL PRESSURE 30-34
TEST FUEL DISCHARGE, RETURN AND LEAKAGE 30-40
BLEEDING AIR FROM FUEL SYSTEM 30-47
TEST FUEL CIRCUIT FOR LEAKAGE 30-48
HANDLE CYLINDER CUT-OUT MODE OPERATION 30-50
HANDLE NO-INJECTION CRANKING OPERATION 30-51
TEST KDPF, SCR AND MUFFLER STACK FOR LOOSENESS AND DAMAGE 30-52
TEST INSTALLED CONDITION OF CYLINDER HEADS AND MANIFOLDS 30-53
TEST ENGINE PIPING FOR DAMAGE AND LOOSENESS 30-54
TEST ALTERNATOR BELT 30-55
TEST AUTOMATIC TENSIONER 30-57
WRITE ASH IN SOOT ACCUMULATION CORRECTION TO ENGINE CONTROLLER 30-59
TEST SCR RELATED FUNCTIONS 30-60
CLEAN AdBlue/DEF TANK 30-89
CLEAN AdBlue/DEF TANK MOUNTING PORTION 30-93
POWER TRAIN 30-94
TEST AND ADJUST HST OIL PRESSURE 30-94
BLEED AIR FROM HST PUMP 30-99
TEST OUTLET PRESSURE OF SOLENOID VALVE 30-101
TEST TRAVEL DEVIATION 30-106
TEST BRAKE PERFORMANCE SIMPLY 30-108
TEST AND ADJUST DECELERATION/BRAKE PEDAL 30-109
ADJUST PARKING BRAKE LEVER 30-113
MOVE MACHINE WHEN IT CANNOT TRAVEL 30-115
UNDERCARRIAGE AND FRAME 30-119
CHECK AND ADJUST IDLER CLEARANCE 30-119
TESTING SPROCKET WEAR 30-120
TEST AND ADJUST TRACK TENSION 30-121
HYDRAULIC SYSTEM 30-123
RELEASE REMAINING PRESSURE FROM HYDRAULIC SYSTEM 30-123
TEST AND ADJUST WORK EQUIPMENT OIL PRESSURES 30-124
TEST AND ADJUST OIL PRESSURE OF CONTROL CIRCUIT 30-127
TEST OUTLET PRESSURE OF EPC SOLENOID VALVE 30-129
BLEED AIR FROM WORK EQUIPMENT, COOLING FAN PUMP, AND CHARGE PUMP 30-131
TEST COOLING FAN SPEED 30-132
TEST COOLING FAN CIRCUIT OIL PRESSURE 30-133
TEST THE PARTS CAUSING HYDRAULIC DRIFT IN WORK EQUIPMENT 30-135
TEST INTERNAL OIL LEAKAGE OF WORK EQUIPMENT CYLINDER 30-137
BLEED AIR FROM WORK EQUIPMENT CYLINDERS 30-140
WORK EQUIPMENT 30-141
ADJUST WORK EQUIPMENT LOCK LEVER 30-141
ELECTRICAL SYSTEM 30-143
SET AND OPERATE MACHINE MONITOR 30-143
START UP KOMTRAX SYSTEM 30-260
STOP USING OF KOMTRAX SYSTEM 30-266
ADJUSTMENT WHEN HST CONTROLLER HAS BEEN REPLACED 30-268
ADJUSTMENT WHEN ELECTRIC OR HYDRAULIC DEVICE HAS BEEN REPLACED 30-274
ADJUST REARVIEW CAMERA ANGLE 30-276
HANDLE VOLTAGE CIRCUIT OF ENGINE CONTROLLER 30-277
BATTERY DISCONNECT SWITCH 30-278
TEST DIODES 30-279
Pm CLINIC 30-280
Pm CLINIC SERVICE 30-280
40 TROUBLESHOOTING 40-1
CONTENTS 40-2
ABBREVIATION LIST 40-12
RELATED INFORMATION ON TROUBLESHOOTING 40-18
INDEX 00 INDEX AND FOREWORD
00-4 D61EX-24, D61EX-24E0, D61PX-24, D61PX-24E0
GENERAL TROUBLESHOOTING POINTS 40-18
TROUBLESHOOTING POINTS FOR UREA SCR SYSTEM 40-19
SEQUENCE OF EVENTS IN TROUBLESHOOTING 40-31
CHECKS BEFORE TROUBLESHOOTING 40-33
INSPECTION PROCEDURE BEFORE TROUBLESHOOTING 40-35
TESTING IN ACCORDANCE WITH TESTING PROCEDURE 40-37
PREPARATION FOR TROUBLESHOOTING ELECTRICAL SYSTEM 40-59
PROCEDURE FOR TROUBLESHOOTING 40-66
INFORMATION DESCRIBED IN TROUBLESHOOTING TABLE 40-69
TROUBLESHOOTING METHOD FOR OPEN CIRCUIT IN WIRING HARNESS OF PRESSURE SENSOR
SYSTEM 40-71
CONNECTOR CONTACT IDENTIFICATION 40-74
T-BRANCH BOX AND T-BRANCH ADAPTER TABLE 40-114
FUSE LOCATION TABLE 40-120
PRECAUTIONS FOR CLEANING AND REPLACING KDPF (KCSF and KDOC) 40-124
PREPARATION OF SHORT CIRCUIT ELECTRICAL CONNECTOR (FOR FAILURE CODES [CA1883]
AND [CA3135]) 40-128
FAILURE CODES TABLE 40-130
TROUBLESHOOTING BY FAILURE CODE (DISPLAY OF CODE) 40-149
FAILURE CODE [6091NX] 40-149
FAILURE CODE [989L00] 40-151
FAILURE CODE [989M00] 40-152
FAILURE CODE [989N00] 40-153
FAILURE CODE [A1U0N3] 40-154
FAILURE CODE [A1U0N4] 40-156
FAILURE CODE [A900FR] 40-158
FAILURE CODE [A900N6] 40-159
FAILURE CODE [A900NY] 40-160
FAILURE CODE [AA10NX] 40-161
FAILURE CODE [AB00KE] 40-163
FAILURE CODE [AQ10N3] 40-165
FAILURE CODE [AS00N3] 40-167
FAILURE CODE [AS00R2] 40-169
FAILURE CODE [AS00R3] 40-170
FAILURE CODE [AS00R4] 40-171
FAILURE CODE [AS00R5] 40-172
FAILURE CODE [AS00R6] 40-173
FAILURE CODE [AS00ZK] 40-174
FAILURE CODE [AS10KM] 40-175
FAILURE CODE [AS10NR] 40-176
FAILURE CODE [AS10NT] 40-177
FAILURE CODE [B@BAZG] 40-178
FAILURE CODE [B@BCNS] 40-179
FAILURE CODE [B@BCQA] 40-180
FAILURE CODE [B@CRNS] 40-182
FAILURE CODE [B@CRZG] 40-183
FAILURE CODE [CA115] 40-184
FAILURE CODE [CA122] 40-185
FAILURE CODE [CA123] 40-187
FAILURE CODE [CA131] 40-189
FAILURE CODE [CA132] 40-191
FAILURE CODE [CA144] 40-193
FAILURE CODE [CA145] 40-195
FAILURE CODE [CA153] 40-197
FAILURE CODE [CA154] 40-200
FAILURE CODE [CA187] 40-202
FAILURE CODE [CA221] 40-204
FAILURE CODE [CA222] 40-206
00 INDEX AND FOREWORD INDEX
D61EX-24, D61EX-24E0, D61PX-24, D61PX-24E0 00-5
FAILURE CODE [CA227] 40-208
FAILURE CODE [CA234] 40-209
FAILURE CODE [CA238] 40-210
FAILURE CODE [CA239] 40-212
FAILURE CODE [CA249] 40-214
FAILURE CODE [CA256] 40-216
FAILURE CODE [CA271] 40-218
FAILURE CODE [CA272] 40-220
FAILURE CODE [CA322] 40-222
FAILURE CODE [CA323] 40-224
FAILURE CODE [CA324] 40-226
FAILURE CODE [CA325] 40-228
FAILURE CODE [CA331] 40-230
FAILURE CODE [CA332] 40-232
FAILURE CODE [CA343] 40-234
FAILURE CODE [CA351] 40-235
FAILURE CODE [CA352] 40-236
FAILURE CODE [CA356] 40-239
FAILURE CODE [CA357] 40-241
FAILURE CODE [CA386] 40-244
FAILURE CODE [CA428] 40-245
FAILURE CODE [CA429] 40-247
FAILURE CODE [CA435] 40-249
FAILURE CODE [CA441] 40-251
FAILURE CODE [CA442] 40-253
FAILURE CODE [CA449] 40-254
FAILURE CODE [CA451] 40-255
FAILURE CODE [CA452] 40-257
FAILURE CODE [CA488] 40-259
FAILURE CODE [CA515] 40-260
FAILURE CODE [CA516] 40-262
FAILURE CODE [CA553] 40-264
FAILURE CODE [CA555] 40-265
FAILURE CODE [CA556] 40-266
FAILURE CODE [CA559] 40-267
FAILURE CODE [CA595] 40-270
FAILURE CODE [CA687] 40-271
FAILURE CODE [CA689] 40-273
FAILURE CODE [CA691] 40-276
FAILURE CODE [CA692] 40-278
FAILURE CODE [CA697] 40-280
FAILURE CODE [CA698] 40-281
FAILURE CODE [CA731] 40-282
FAILURE CODE [CA778] 40-284
FAILURE CODE [CA1117] 40-289
FAILURE CODE [CA1664] 40-290
FAILURE CODE [CA1669] 40-293
FAILURE CODE [CA1673] 40-294
FAILURE CODE [CA1677] 40-295
FAILURE CODE [CA1678] 40-296
FAILURE CODE [CA1682] 40-297
FAILURE CODE [CA1683] 40-301
FAILURE CODE [CA1684] 40-303
FAILURE CODE [CA1686] 40-305
FAILURE CODE [CA1691] 40-306
FAILURE CODE [CA1694] 40-309
FAILURE CODE [CA1695] 40-312
FAILURE CODE [CA1696] 40-313
INDEX 00 INDEX AND FOREWORD
00-6 D61EX-24, D61EX-24E0, D61PX-24, D61PX-24E0
FAILURE CODE [CA1712] 40-315
FAILURE CODE [CA1713] 40-318
FAILURE CODE [CA1714] 40-320
FAILURE CODE [CA1715] 40-321
FAILURE CODE [CA1776] 40-322
FAILURE CODE [CA1777] 40-325
FAILURE CODE [CA1843] 40-328
FAILURE CODE [CA1844] 40-330
FAILURE CODE [CA1879] 40-333
FAILURE CODE [CA1881] 40-336
FAILURE CODE [CA1883] 40-338
FAILURE CODE [CA1885] 40-342
FAILURE CODE [CA1887] 40-344
FAILURE CODE [CA1921] 40-346
FAILURE CODE [CA1922] 40-349
FAILURE CODE [CA1942] 40-354
FAILURE CODE [CA1993] 40-355
FAILURE CODE [CA2185] 40-358
FAILURE CODE [CA2186] 40-360
FAILURE CODE [CA2249] 40-362
FAILURE CODE [CA2271] 40-363
FAILURE CODE [CA2272] 40-366
FAILURE CODE [CA2288] 40-369
FAILURE CODE [CA2311] 40-370
FAILURE CODE [CA2349] 40-371
FAILURE CODE [CA2353] 40-374
FAILURE CODE [CA2357] 40-376
FAILURE CODE [CA2381] 40-377
FAILURE CODE [CA2382] 40-380
FAILURE CODE [CA2383] 40-383
FAILURE CODE [CA2386] 40-386
FAILURE CODE [CA2387] 40-388
FAILURE CODE [CA2555] 40-389
FAILURE CODE [CA2556] 40-392
FAILURE CODE [CA2637] 40-395
FAILURE CODE [CA2639] 40-397
FAILURE CODE [CA2771] 40-400
FAILURE CODE [CA2777] 40-406
FAILURE CODE [CA2976] 40-409
FAILURE CODE [CA3133] 40-411
FAILURE CODE [CA3134] 40-413
FAILURE CODE [CA3135] 40-415
FAILURE CODE [CA3142] 40-419
FAILURE CODE [CA3143] 40-420
FAILURE CODE [CA3144] 40-421
FAILURE CODE [CA3146] 40-423
FAILURE CODE [CA3147] 40-424
FAILURE CODE [CA3148] 40-425
FAILURE CODE [CA3151] 40-427
FAILURE CODE [CA3165] 40-433
FAILURE CODE [CA3229] 40-435
FAILURE CODE [CA3231] 40-437
FAILURE CODE [CA3232] 40-439
FAILURE CODE [CA3235] 40-443
FAILURE CODE [CA3239] 40-445
FAILURE CODE [CA3241] 40-448
FAILURE CODE [CA3242] 40-451
FAILURE CODE [CA3251] 40-454
00 INDEX AND FOREWORD INDEX
D61EX-24, D61EX-24E0, D61PX-24, D61PX-24E0 00-7
FAILURE CODE [CA3253] 40-456
FAILURE CODE [CA3254] 40-459
FAILURE CODE [CA3255] 40-462
FAILURE CODE [CA3256] 40-465
FAILURE CODE [CA3311] 40-467
FAILURE CODE [CA3312] 40-469
FAILURE CODE [CA3313] 40-472
FAILURE CODE [CA3314] 40-473
FAILURE CODE [CA3315] 40-474
FAILURE CODE [CA3316] 40-477
FAILURE CODE [CA3317] 40-478
FAILURE CODE [CA3318] 40-479
FAILURE CODE [CA3319] 40-482
FAILURE CODE [CA3321] 40-483
FAILURE CODE [CA3322] 40-485
FAILURE CODE [CA3419] 40-488
FAILURE CODE [CA3421] 40-490
FAILURE CODE [CA3497] 40-492
FAILURE CODE [CA3498] 40-493
FAILURE CODE [CA3543] 40-494
FAILURE CODE [CA3545] 40-501
FAILURE CODE [CA3547] 40-503
FAILURE CODE [CA3558] 40-504
FAILURE CODE [CA3559] 40-506
FAILURE CODE [CA3562] 40-508
FAILURE CODE [CA3563] 40-510
FAILURE CODE [CA3567] 40-513
FAILURE CODE [CA3568] 40-516
FAILURE CODE [CA3571] 40-522
FAILURE CODE [CA3572] 40-524
FAILURE CODE [CA3574] 40-526
FAILURE CODE [CA3575] 40-528
FAILURE CODE [CA3577] 40-530
FAILURE CODE [CA3578] 40-532
FAILURE CODE [CA3582] 40-534
FAILURE CODE [CA3583] 40-542
FAILURE CODE [CA3596] 40-544
FAILURE CODE [CA3649] 40-547
FAILURE CODE [CA3681] 40-549
FAILURE CODE [CA3682] 40-554
FAILURE CODE [CA3713] 40-560
FAILURE CODE [CA3717] 40-563
FAILURE CODE [CA3718] 40-564
FAILURE CODE [CA3725] 40-565
FAILURE CODE [CA3741] 40-568
FAILURE CODE [CA3748] 40-569
FAILURE CODE [CA3751] 40-571
FAILURE CODE [CA3755] 40-573
FAILURE CODE [CA3866] 40-575
FAILURE CODE [CA3867] 40-579
FAILURE CODE [CA3868] 40-582
FAILURE CODE [CA3899] 40-586
FAILURE CODE [CA3911] 40-588
FAILURE CODE [CA3912] 40-592
FAILURE CODE [CA3932] 40-594
FAILURE CODE [CA3933] 40-596
FAILURE CODE [CA3934] 40-598
FAILURE CODE [CA3935] 40-601
INDEX 00 INDEX AND FOREWORD
00-8 D61EX-24, D61EX-24E0, D61PX-24, D61PX-24E0
FAILURE CODE [CA3936] 40-603
FAILURE CODE [CA4151] 40-605
FAILURE CODE [CA4152] 40-609
FAILURE CODE [CA4155] 40-613
FAILURE CODE [CA4156] 40-615
FAILURE CODE [CA4157] 40-618
FAILURE CODE [CA4158] 40-620
FAILURE CODE [CA4159] 40-621
FAILURE CODE [CA4161] 40-622
FAILURE CODE [CA4162] 40-625
FAILURE CODE [CA4163] 40-628
FAILURE CODE [CA4164] 40-630
FAILURE CODE [CA4165] 40-632
FAILURE CODE [CA4166] 40-634
FAILURE CODE [CA4168] 40-636
FAILURE CODE [CA4169] 40-639
FAILURE CODE [CA4171] 40-641
FAILURE CODE [CA4249] 40-644
FAILURE CODE [CA4251] 40-646
FAILURE CODE [CA4259] 40-648
FAILURE CODE [CA4261] 40-651
FAILURE CODE [CA4277] 40-654
FAILURE CODE [CA4281] 40-658
FAILURE CODE [CA4459] 40-661
FAILURE CODE [CA4461] 40-664
FAILURE CODE [CA4658] 40-667
FAILURE CODE [CA4731] 40-671
FAILURE CODE [CA4732] 40-672
FAILURE CODE [CA4739] 40-673
FAILURE CODE [CA4768] 40-674
FAILURE CODE [CA4769] 40-676
FAILURE CODE [CA4842] 40-679
FAILURE CODE [CA4952] 40-683
FAILURE CODE [CA5115] 40-685
FAILURE CODE [CA5383] 40-688
FAILURE CODE [D130KA] 40-690
FAILURE CODE [D130KB] 40-693
FAILURE CODE [D130KY] 40-695
FAILURE CODE [D19JKZ] 40-697
FAILURE CODE [D811MC] 40-700
FAILURE CODE [D862KA] 40-701
FAILURE CODE [D8ALKA] 40-702
FAILURE CODE [D8ALKB] 40-704
FAILURE CODE [D8AQKR] 40-706
FAILURE CODE [D8G1KT] 40-708
FAILURE CODE [D8G6KT] 40-709
FAILURE CODE [DAF0MB] 40-710
FAILURE CODE [DAF0MC] 40-711
FAILURE CODE [DAF8KB] 40-712
FAILURE CODE [DAF9KQ] 40-714
FAILURE CODE [DAFGMC] 40-715
FAILURE CODE [DAFLKA] 40-716
FAILURE CODE [DAFLKB] 40-718
FAILURE CODE [DAFQKR] 40-720
FAILURE CODE [DAJ000] 40-721
FAILURE CODE [DAJ0KQ] 40-722
FAILURE CODE [DAJ0KT] 40-723
FAILURE CODE [DAJ0MC] 40-724
00 INDEX AND FOREWORD INDEX
D61EX-24, D61EX-24E0, D61PX-24, D61PX-24E0 00-9
FAILURE CODE [DAJ1KK] 40-725
FAILURE CODE [DAJ2KK] 40-727
FAILURE CODE [DAJ5KK] 40-729
FAILURE CODE [DAJ6KK] 40-732
FAILURE CODE [DAJLKA] 40-734
FAILURE CODE [DAJLKB] 40-736
FAILURE CODE [DAJPMA] 40-738
FAILURE CODE [DAJQKR] 40-739
FAILURE CODE [DAJRKR] 40-740
FAILURE CODE [DB2QKR] 40-741
FAILURE CODE [DB2RKR] 40-746
FAILURE CODE [DD12KA] 40-751
FAILURE CODE [DD12KB] 40-753
FAILURE CODE [DD13KA] 40-755
FAILURE CODE [DD13KB] 40-757
FAILURE CODE [DD14KA] 40-759
FAILURE CODE [DD14KB] 40-761
FAILURE CODE [DDKAKA] 40-763
FAILURE CODE [DDKAKB] 40-765
FAILURE CODE [DDKFL4] 40-767
FAILURE CODE [DDKGL4] 40-769
FAILURE CODE [DDKHKA] 40-771
FAILURE CODE [DDKHKB] 40-773
FAILURE CODE [DDNLKA] 40-775
FAILURE CODE [DDNLKB] 40-777
FAILURE CODE [DDP6KA] 40-779
FAILURE CODE [DDP6KB] 40-782
FAILURE CODE [DDP6MA] 40-784
FAILURE CODE [DDU1FS] 40-786
FAILURE CODE [DDU1KA] 40-788
FAILURE CODE [DDU1KY] 40-791
FAILURE CODE [DFA4KX] 40-793
FAILURE CODE [DFA4KZ] 40-794
FAILURE CODE [DFA4L8] 40-795
FAILURE CODE [DFA5KA] 40-796
FAILURE CODE [DFA5KB] 40-799
FAILURE CODE [DFA6KA] 40-802
FAILURE CODE [DFA6KB] 40-805
FAILURE CODE [DFA7KX] 40-808
FAILURE CODE [DFA7KZ] 40-809
FAILURE CODE [DFA7L8] 40-810
FAILURE CODE [DFA8KA] 40-811
FAILURE CODE [DFA8KB] 40-814
FAILURE CODE [DFA9KA] 40-817
FAILURE CODE [DFA9KB] 40-820
FAILURE CODE [DGS1KA] 40-823
FAILURE CODE [DGS1KX] 40-826
FAILURE CODE [DH21KA] 40-827
FAILURE CODE [DH21KB] 40-829
FAILURE CODE [DHA4KA] 40-831
FAILURE CODE [DHAAMA] 40-833
FAILURE CODE [DHACMA] 40-835
FAILURE CODE [DHH7KA] 40-837
FAILURE CODE [DHH7KB] 40-840
FAILURE CODE [DHH8KA] 40-842
FAILURE CODE [DHH8KB] 40-845
FAILURE CODE [DHH9KA] 40-847
FAILURE CODE [DHH9KB] 40-850
INDEX 00 INDEX AND FOREWORD
00-10 D61EX-24, D61EX-24E0, D61PX-24, D61PX-24E0
FAILURE CODE [DHHAKA] 40-852
FAILURE CODE [DHHAKB] 40-855
FAILURE CODE [DHRUKA] 40-857
FAILURE CODE [DHRUKB] 40-859
FAILURE CODE [DHRVKA] 40-861
FAILURE CODE [DHRVKB] 40-863
FAILURE CODE [DK30KA] 40-865
FAILURE CODE [DK30KB] 40-868
FAILURE CODE [DK30KX] 40-870
FAILURE CODE [DK30KZ] 40-871
FAILURE CODE [DK30L8] 40-872
FAILURE CODE [DK31KA] 40-873
FAILURE CODE [DK31KB] 40-876
FAILURE CODE [DK40KA] 40-878
FAILURE CODE [DK40KB] 40-881
FAILURE CODE [DK55KX] 40-883
FAILURE CODE [DK55KZ] 40-884
FAILURE CODE [DK55L8] 40-885
FAILURE CODE [DK56KA] 40-886
FAILURE CODE [DK56KB] 40-889
FAILURE CODE [DK57KA] 40-891
FAILURE CODE [DK57KB] 40-894
FAILURE CODE [DLM0KX] 40-896
FAILURE CODE [DLM1KA] 40-897
FAILURE CODE [DLM1KB] 40-899
FAILURE CODE [DLM1MA] 40-901
FAILURE CODE [DLM2KA] 40-902
FAILURE CODE [DLM2KB] 40-904
FAILURE CODE [DLM2MA] 40-906
FAILURE CODE [DLM3KA] 40-907
FAILURE CODE [DLM3KB] 40-909
FAILURE CODE [DLM3MB] 40-911
FAILURE CODE [DN21FS] 40-912
FAILURE CODE [DR21KX] 40-914
FAILURE CODE [DR31KX] 40-915
FAILURE CODE [DV20KB] 40-916
FAILURE CODE [DW4BKA] 40-918
FAILURE CODE [DW4BKB] 40-920
FAILURE CODE [DW4BKY] 40-922
FAILURE CODE [DW7BKA] 40-924
FAILURE CODE [DW7BKB] 40-926
FAILURE CODE [DW7EKA] 40-928
FAILURE CODE [DW7EKB] 40-930
FAILURE CODE [DW7EKY] 40-932
FAILURE CODE [DWN5KA] 40-934
FAILURE CODE [DWN5KB] 40-936
FAILURE CODE [DWN5KY] 40-938
FAILURE CODE [DXA4KA] 40-940
FAILURE CODE [DXA4KB] 40-942
FAILURE CODE [DXA4KY] 40-944
FAILURE CODE [DXA5KA] 40-946
FAILURE CODE [DXA5KB] 40-948
FAILURE CODE [DXA5KY] 40-950
FAILURE CODE [DXA6KA] 40-952
FAILURE CODE [DXA6KB] 40-954
FAILURE CODE [DXA6KY] 40-956
FAILURE CODE [DXA7KA] 40-958
FAILURE CODE [DXA7KB] 40-960
00 INDEX AND FOREWORD INDEX
D61EX-24, D61EX-24E0, D61PX-24, D61PX-24E0 00-11
FAILURE CODE [DXA7KY] 40-962
FAILURE CODE [DXHRKA] 40-964
FAILURE CODE [DXHRKB] 40-966
FAILURE CODE [DXHRKY] 40-968
FAILURE CODE [DXHSKA] 40-970
FAILURE CODE [DXHSKB] 40-972
FAILURE CODE [DXHSKY] 40-974
FAILURE CODE [DXHTKA] 40-976
FAILURE CODE [DXHTKB] 40-978
FAILURE CODE [DXHTKY] 40-980
FAILURE CODE [DXHUKA] 40-982
FAILURE CODE [DXHUKB] 40-984
FAILURE CODE [DXHUKY] 40-986
FAILURE CODE [DXJ4KA] 40-988
FAILURE CODE [DXJ4KB] 40-990
FAILURE CODE [DXJCKA] 40-992
FAILURE CODE [DXJCKB] 40-994
FAILURE CODE [DXJCKY] 40-996
FAILURE CODE [DXJDKA] 40-998
FAILURE CODE [DXJDKB] 40-1000
FAILURE CODE [DXJDKY] 40-1002
FAILURE CODE [DXK1KA] 40-1004
FAILURE CODE [DXK1KB] 40-1006
FAILURE CODE [DXK1KY] 40-1008
FAILURE CODE [DXK2KA] 40-1010
FAILURE CODE [DXK2KB] 40-1012
FAILURE CODE [DXK2KY] 40-1014
FAILURE CODE [F313KA] 40-1016
FAILURE CODE [F313KB] 40-1017
FAILURE CODE [F318KB] 40-1018
FAILURE CODE [F318KY] 40-1019
TROUBLESHOOTING OF ELECTRICAL SYSTEM (E-MODE) 40-1020
E-1 ENGINE DOES NOT START (ENGINE DOES NOT CRANK) 40-1020
E-2 MANUAL PREHEATING SYSTEM DOES NOT WORK 40-1027
E-3 AUTOMATIC PREHEATING SYSTEM DOES NOT WORK 40-1030
E-4 WHILE PREHEATING IS WORKING, PREHEATING MONITOR DOES NOT LIGHT UP 40-1032
E-5 WHEN STARTING SWITCH IS TURNED TO ON POSITION, MACHINE MONITOR DISPLAYS
NOTHING 40-1034
E-6 WHEN STARTING SWITCH IS TURNED TO ON POSITION (WITH ENGINE STOPPED), BASIC
CHECK MONITOR LIGHTS UP 40-1038
E-7 AIR CLEANER CLOGGING MONITOR LIGHTS UP IN YELLOW WHILE ENGINE IS RUNNING
40-1039
E-8 CHARGE LEVEL MONITOR LIGHTS UP IN RED WHILE ENGINE IS RUNNING 40-1040
E-9 ENGINE COOLANT TEMPERATURE MONITOR LIGHTS UP IN RED WHILE ENGINE IS RUNNING
40-1041
E-10 ENGINE OIL PRESSURE MONITOR LIGHTS UP IN RED WHILE ENGINE IS RUNNING 40-1042
E-11 HST CHARGE PRESSURE MONITOR LIGHTS UP IN RED WHILE ENGINE IS RUNNING
40-1043
E-12 HYDRAULIC OIL TEMPERATURE MONITOR LIGHTS UP IN RED WHILE ENGINE IS RUNNING
40-1044
E-13 HST OIL FILTER CLOGGING MONITOR LIGHTS UP IN RED WHILE ENGINE IS RUNNING
40-1045
E-14 ENGINE COOLANT TEMPERATURE GAUGE DOES NOT INDICATE CORRECT TEMPERATURE
40-1046
E-15 FUEL LEVEL GAUGE DOES NOT INDICATE CORRECT LEVEL 40-1047
E-16 HYDRAULIC OIL TEMPERATURE GAUGE DOES NOT INDICATE CORRECT TEMPERATURE
40-1050
E-17 OPERATION MODE DOES NOT CHANGE 40-1051
INDEX 00 INDEX AND FOREWORD
00-12 D61EX-24, D61EX-24E0, D61PX-24, D61PX-24E0
E-18 OPERATING CUSTOMIZE SWITCH DOES NOT DISPLAY CUSTOMIZE SCREEN 40-1052
E-19 MODIFYING SETTING ON CUSTOMIZE SCREEN DOES NOT CHANGE SETTING OF MACHINE
40-1053
E-20 SERVICE METER IS NOT DISPLAYED, WHILE STARTING SWITCH IS IN OFF POSITION
40-1054
E-21 SERVICE MODE CANNOT BE SELECTED 40-1055
E-22 WORK EQUIPMENT DOES NOT OPERATE 40-1056
E-23 FOOT HEATER DOES NOT OPERATE 40-1058
E-24 HORN DOES NOT SOUND 40-1064
E-25 HORN DOES NOT STOP SOUNDING 40-1066
E-26 BACKUP ALARM DOES NOT SOUND 40-1067
E-27 BACKUP ALARM DOES NOT STOP SOUNDING 40-1068
E-28 HEADLAMP DOES NOT LIGHT UP 40-1069
E-29 REAR LAMP DOES NOT LIGHT UP 40-1073
E-30 ALL WIPERS DO NOT OPERATE 40-1076
E-31 FRONT WIPER DOES NOT OPERATE 40-1078
E-32 REAR WIPER DOES NOT OPERATE 40-1080
E-33 LEFT DOOR WIPER DOES NOT OPERATE 40-1082
E-34 RIGHT DOOR WIPER DOES NOT OPERATE 40-1086
E-35 FRONT WASHER DOES NOT OPERATE 40-1090
E-36 REAR WASHER DOES NOT OPERATE 40-1092
E-37 LEFT DOOR WASHER DOES NOT OPERATE 40-1094
E-38 RIGHT DOOR WASHER DOES NOT OPERATE 40-1096
E-39 KOMTRAX SYSTEM DOES NOT OPERATE NORMALLY 40-1098
TROUBLESHOOTING FOR HYDRAULIC AND MECHANICAL SYSTEMS (H MODE) 40-1099
INFORMATION MENTIONED IN TROUBLESHOOTING TABLE (H MODE) 40-1099
FAILURE MODE AND CAUSE TABLE 40-1100
H-1 NEITHER R H NOR L H OF TRACKS CAN TRAVEL FORWARD OR REVERSE (NONE OF THE
TRAVEL SYSTEMS OPERATE) 40-1106
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) 40-1108
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) 40-1110
H-4 TRAVEL SPEED OR POWER IS LOW 40-1112
H-5 SPEED RANGE DOES NOT CHANGE 40-1114
H-6 SHOCK IS LARGE WHEN MACHINE MOVES OFF OR STOPS 40-1115
H-7 MACHINE DEVIATES LARGELY 40-1116
H-8 MACHINE DRIFT ON A SLOPE IS LARGE 40-1119
H-9 ENGINE SPEED DROPS LARGELY OR ENGINE STOPS 40-1121
H-10 UNUSUAL NOISE IS HEARD FROM AROUND HST PUMP OR MOTOR 40-1123
H-11 HST OIL TEMPERATURE (HYDRAULIC OIL TEMPERATURE) RISES TOO HIGH 40-1125
H-12 ALL WORK EQUIPMENT DO NOT OPERATE 40-1127
H-13 ALL WORK EQUIPMENTS SPEED OR POWER IS LOW 40-1129
H-14 BLADE LIFT SPEED OR POWER IS LOW 40-1130
H-15 BLADE TILT SPEED OR POWER IS LOW 40-1132
H-16 BLADE ANGLE SPEED OR POWER IS LOW 40-1133
H-17 TIME LAG OF BLADE LIFT IS LARGE 40-1134
H-18 HYDRAULIC DRIFT OF LIFTED BLADE IS LARGE 40-1135
H-19 HYDRAULIC DRIFT OF TILTED BLADE IS LARGE 40-1136
H-20 UNUSUAL NOISE IS HEARD FROM AROUND WORK EQUIPMENT AND COOLING FAN
PUMP OR CONTROL VALVE 40-1137
H-21 FAN SPEED IS ABNORMAL (TOO HIGH OR LOW, OR STATIONARY) 40-1138
H-22 UNUSUAL NOISE IS HEARD FROM AROUND FAN 40-1140
TROUBLESHOOTING OF ENGINE (S-MODE) 40-1141
INFORMATION MENTIONED IN TROUBLESHOOTING TABLE (S MODE) 40-1141
S-1 ENGINE DOES NOT CRANK WHEN STARTING SWITCH IS TURNED TO START POSITION
40-1142
S-2 ENGINE CRANKS BUT NO EXHAUST GAS COMES OUT 40-1143
00 INDEX AND FOREWORD INDEX
D61EX-24, D61EX-24E0, D61PX-24, D61PX-24E0 00-13
S-3 FUEL IS BEING INJECTED BUT ENGINE DOES NOT START (MISFIRING: ENGINE CRANKS
BUT DOES NOT START) 40-1144
S-4 ENGINE STARTABILITY IS POOR 40-1146
S-5 ENGINE DOES NOT PICK UP SMOOTHLY 40-1148
S-6 ENGINE STOPS DURING OPERATION 40-1150
S-7 ENGINE RUNS ROUGH OR IS UNSTABLE 40-1152
S-8 ENGINE LACKS POWER 40-1153
S-9 KDPF GETS CLOGGED IN A SHORT TIME 40-1155
S-10 ENGINE OIL CONSUMPTION IS EXCESSIVE 40-1157
S-11 OIL BECOMES CONTAMINATED QUICKLY 40-1158
S-12 FUEL CONSUMPTION IS EXCESSIVE 40-1159
S-13 OIL IS IN COOLANT (OR COOLANT SPURTS BACK OR COOLANT LEVEL GOES DOWN)
40-1160
S-14 OIL PRESSURE DROPS 40-1161
S-15 FUEL MIXES INTO ENGINE OIL 40-1163
S-16 WATER MIXES INTO ENGINE OIL (MILKY) 40-1164
S-17 COOLANT TEMPERATURE RISES TOO HIGH (OVERHEATING) 40-1165
S-18 UNUSUAL NOISE IS HEARD 40-1166
S-19 VIBRATION IS EXCESSIVE 40-1167
S-20 AIR CANNOT BE BLED FROM FUEL CIRCUIT 40-1168
S-21 ACTIVE REGENERATION IS EXECUTED FREQUENTLY 40-1169
S-22 ACTIVE REGENERATION TAKES TIME 40-1171
S-23 WHITE SMOKE IS EXHAUSTED DURING ACTIVE REGENERATION 40-1172
S-24 AdBlue/DEF CONSUMPTION IS EXCESSIVE 40-1173
S-25 THERE IS UNUSUAL SMELL (IRRITATING ODOR) 40-1175
S-26 FOREIGN MATERIALS ENTER AdBlue/DEF (AdBlue/DEF INCREASES) 40-1176
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
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
INDEX 00 INDEX AND FOREWORD
00-14 D61EX-24, D61EX-24E0, D61PX-24, D61PX-24E0
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
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
00 INDEX AND FOREWORD INDEX
D61EX-24, D61EX-24E0, D61PX-24, D61PX-24E0 00-15
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
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
INDEX 00 INDEX AND FOREWORD
00-16 D61EX-24, D61EX-24E0, D61PX-24, D61PX-24E0
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
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
00 INDEX AND FOREWORD INDEX
D61EX-24, D61EX-24E0, D61PX-24, D61PX-24E0 00-17
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 D6PX-24 D61PX-24E0 Crawler Dozer Shop Manual KEBM685502 – PDF DOWNLOAD

SERIAL NUMBERS

D61EX-24 B65001 and up
D61EX-24E0 B65001 and up
D61PX-24 B65001 and up
D61PX-24E0 B65001 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.

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