Komatsu Bulldozer D61EX-23M0 Shop Manual KEBM601001 PDF

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Komatsu Bulldozer D61EX-23M0 Shop Manual KEBM601001  – PDF  DOWNLOAD

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Komatsu Bulldozer D61EX-23M0 Shop Manual KEBM601001  – PDF  DOWNLOAD

Language : English
Pages : 1424
Downloadable : Yes
File Type : PDF

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TABLE OF CONTENTS:

Komatsu Bulldozer D61EX-23M0 Shop Manual KEBM601001  – PDF  DOWNLOAD

• Serial Numbers B50001 and up

00 Index and foreword 3
Index 4
Foreword, safety and general information . 15
Important safety notice 15
How to read the shop manual 22
Explanation of terms for maintenance standard 24
Handling equipment of fuel system devices 26
Handling of intake system parts 27
Handling of hydraulic equipment 28
Method of disconnecting and connecting of push-pull type coupler . 30
Handling of electrical equipment . 33
How to read electric wire code . 41
Precautions when performing operation 44
Practical use of KOMTRAX . 49
Standard tightening torque table . 50
List of abbreviation . 56
Conversion table . 61
01 Specification . 67
Table of contents 68
Specifications . 69
Specification drawing 69
Specifications . 70
Weight table . 76
Table of fuel, coolant, and lubricants . 78
10 Structure and function 79
Table of contents 80
Engine and cooling system 81
Engine related parts . 81
Cooling system . 83
Cooling fan motor 85
Oil cooler bypass and HST charge safety valve 91
Power train 96
Power train system . 96
Damper . 99
Hydraulic component layout of HST 100
Steering and brake control . 101
HST pump . 103
HST motor 116
Charge pump 130
Solenoid valve . 131
Final drive 140
Undercarriage and frame 144
Main frame . 144
Suspension . 145
Track frame and idler cushion 147
Hydraulic system . 149
Hydraulic component layout of work equipment . 149
Work equipment control system 151
Hydraulic tank . 153
CLSS . 155
Work equipment and cooling fan pump 158
Control valve 169
Ripper PPC valve . 189
Quick drop valve . 194
Angle control EPC valve 197
Accumulator 202
Work equipment . 204
Blade 204
Ripper . 205
Piston valve . 206
Cab and its attachments 207
ROPS cab . 207
Cab mount 209
Electrical system 210
Engine control system 210
Cooling system control system 213
HST control system . 215
Parking brake control system . 227
System operating lamp function . 229
Battery disconnect switch function . 230
Machine monitor system . 232
KOMTRAX system . 254
System component parts . 257
Sensor . 271
20 Standard value tables . 281
Table of contents 282
Standard service value table . 283
Standard value table for engine 283
Standard value table for machine . 284
Standard value table for electrical system . 291
30 Testing and adjusting . 301
Table of contents 302
Related information on testing and adjusting . 303
Tools for testing and adjusting 303
Sketch of tools for testing and adjusting 306
Engine and cooling system 308
Testing engine speed . 308
Testing boost pressure . 310
Measuring exhaust color 312
Testing and adjusting valve clearance 313
Measuring compression pressure . 316
Testing blowby pressure 319
Testing engine oil pressure 320
Testing fuel pressure 321
Testing fuel discharge, return and leakage . 326
Bleeding air from fuel system 332
Testing fuel circuit for leakage . 334
Handling cylinder cutout mode operation 335
Handling no-injection cranking operation . 336
Testing of installed condition of cylinder heads and manifolds . 337
Testing engine piping for damage and looseness . 338
Replacing alternator belt 339
Power train 340
Testing and adjusting HST oil pressure . 340
Testing output pressure of solenoid valve 345
Testing if machine travels straight 349
Simple test procedure for brake performance 350
Adjusting deceleration/brake pedal . 351
Adjusting parking brake lever 354
Move disabled machine urgently . 356
Undercarriage and frame 359
Adjusting idler clearance 359
Checking sprocket wear . 360
Testing and adjusting track tension 361
Hydraulic system . 362
Releasing remaining pressure in work equipment cylinder 362
Testing and adjusting work equipment oil pressure 363
Testing source pressure of control circuit . 365
Testing outlet pressure of work equipment EPC valve and fan EPC valve 366
Isolating the parts causing hydraulic drift in blade and ripper 368
Testing internal oil leakage of work equipment cylinder 369
Testing fan speed 371
Testing fan circuit oil pressure . 372
Bleeding air from hydraulic circuit 373
Work equipment . 374
Adjusting work equipment lock lever 374
Adjusting play of blade center ball 376
Electrical system 377
Special functions of machine monitor . 377
Adjustment method when HST controller has been replaced 451
Adjustment method when electric or hydraulic device has been replaced 454
Adjusting rearview camera angle 455
Handling voltage circuit of engine controller 456
Handling battery disconnect switch . 457
Testing diodes . 458
Pm clinic 459
Pm Clinic service 459
Pm Clinic check sheet 461
40 Troubleshooting . 467
Table of contents 468
Related information on troubleshooting . 474
Troubleshooting points . 474
Sequence of events in troubleshooting 476
Checks before troubleshooting 478
Inspection procedure before troubleshooting 480
Preparation for troubleshooting of electrical system . 497
Classification and procedures for troubleshooting 501
Symptom and troubleshooting numbers 503
Information in troubleshooting table . 505
Procedure for troubleshooting wiring harness of pressure sensor system for open circuit 507
Connector list and layout 510
Connector contact identification . 522
T-branch box and T-branch adapter table 560
Fuse location table 565
Failure codes table 570
Troubleshooting by failure code (Display of code) 578
Failure code [6091NX] HST Oil Filter Clogging 578
Failure code [989L00] Engine Controller Lock Caution 1 . 580
Failure code [989M00] Engine Controller Lock Caution 2 . 581
Failure code [989N00] Engine Controller Lock Caution 3 . 582
Failure code [AA10NX] Air Cleaner Clogging . 583
Failure code [AB00KE] Charge Voltage Low . 585
Failure code [B@BAZG] Eng Oil Press Low 587
Failure code [B@BCNS] Eng Water Overheat . 588
Failure code [B@CRNS] HST Oil Overheat . 589
Failure code [B@CRZG] HST Charge Press Low . 590
Failure code [CA111] ECM Critical Internal Failure . 591
Failure code [CA115] Eng Ne and Bkup Speed Sens Error 592
Failure code [CA122] Chg Air Press Sensor High Error . 593
Failure code [CA123] Chg Air Press Sensor Low Error 595
Failure code [CA131] Throttle Sensor High Error 597
Failure code [CA132] Throttle Sensor Low Error . 599
Failure code [CA144] Coolant Temp Sens High Error 601
Failure code [CA145] Coolant Temp Sens Low Error . 603
Failure code [CA153] Chg Air Temp Sensor High Error 605
Failure code [CA154] Chg Air Temp Sensor Low Error . 607
Failure code [CA187] Sensor 2 Supply Volt Low Error 609
Failure code [CA221] Ambient Press Sensor High Error . 611
Failure code [CA222] Ambient Press Sensor Low Error 613
Failure code [CA227] Sensor 2 Supply Volt High Error . 615
Failure code [CA234] Eng Overspeed . 616
Failure code [CA238] Ne Speed Sensor Supply Volt Error . 617
Failure code [CA271] IMV/PCV1 Short Error 618
Failure code [CA272] IMV/PCV1 Open Error . 619
Failure code [CA322] Inj #1(L#1) Open/Short Error 621
Failure code [CA323] Inj #5(L#5) Open/Short Error 623
Failure code [CA324] Inj #3(L#3) Open/Short Error 625
Failure code [CA325] Inj #6(L#6) Open/Short Error 627
Failure code [CA331] Inj #2(L#2) Open/Short Error 629
Failure code [CA332] Inj #4(L#4) Open/Short Error 631
Failure code [CA342] Calibration Code Incompatibility 633
Failure code [CA351] Injectors Drive Circuit Error . 634
Failure code [CA352] Sensor 1 Supply Volt Low Error 635
Failure code [CA386] Sensor 1 Supply Volt High Error . 636
Failure code [CA428] Water in Fuel Sensor High Error . 637
Failure code [CA429] Water in Fuel Sensor Low Error 639
Failure code [CA435] Eng Oil Press Sw Error 641
Failure code [CA441] Battery Voltage Low Error . 642
Failure code [CA442] Battery Voltage High Error 644
Failure code [CA449] Rail Press Very High Error 645
Failure code [CA451] Rail Press Sensor High Error 646
Failure code [CA452] Rail Press Sensor Low Error . 648
Failure code [CA488] Chg Air Temp High Torque Derate . 650
Failure code [CA553] Rail Press High Error . 651
Failure code [CA689] Eng Ne Speed Sensor Error . 652
Failure code [CA731] Eng Bkup Speed Sens Phase Error . 654
Failure code [CA757] All continuous Data Lost Error 655
Failure code [CA778] Eng Bkup Speed Sensor Error . 656
Failure code [CA2185] Throt Sensor Sup Volt High Error . 660
Failure code [CA2186] Throt Sensor Sup Volt Low Error 661
Failure code [CA2249] Rail Press Very Low Error 662
Failure code [CA2311] IMV Solenoid Error . 663
Failure code [CA2555] Grid Htr Relay Volt Low Error 664
Failure code [CA2556] Grid Htr Relay Volt High Error . 666
Failure code [D130KA] Neutral relay Open . 668
Failure code [D130KB] Neutral relay Short circuit 670
Failure code [D130KY] Neutral relay: Hot Short . 672
Failure code [D19JKZ] Personal Code Relay Abnormality 674
Failure code [D811MC] KOMTRAX Error 677
Failure code [D862KA] GPS Antenna Open Circuit . 678
Failure code [D8ALKA] Operating Lamp Open Circuit (KOMTRAX) 679
Failure code [D8ALKB] Operating Lamp Short Circuit (KOMTRAX) . 681
Failure code [D8AQKR] CAN2 Discon (KOMTRAX) 682
Failure code [DAF0MB] Monitor ROM Abnormality 683
Failure code [DAF0MC] Monitor Error 684
Failure code [DAF8KB] Camera Power Supply Short Circuit 685
Failure code [DAF9KQ] Model Selection Abnormality 686
Failure code [DAFGMC] GPS Module Error . 687
Failure code [DAFLKA] Operating Lamp Open Circuit (Monitor) 688
Failure code [DAFLKB] Operating Lamp Short Circuit (Monitor) . 690
Failure code [DAFQKR] CAN2 Discon (Monitor) 691
Failure code [DAJ000] HST controller: Abnormality in controller 692
Failure code [DAJ0KQ] HST controller: Type select signal . 693
Failure code [DAJ0KT] HST controller: Abnormality in controller 694
Failure code [DAJ0MC] HST Con Error 695
Failure code [DAJ1KK] HST controller: Source voltage low . 696
Failure code [DAJ2KK] HST controller: Output voltage low . 698
Failure code [DAJ5KK] HST: Sensor volt 5V (0) Out of normal range 700
Failure code [DAJ6KK] HST: Sensor volt 5V (1) Out of normal range 702
Failure code [DAJLKA] Operating Lamp Open Circuit (HST Con) 704
Failure code [DAJLKB] Operating Lamp Short Circuit (HST Con) . 706
Failure code [DAJPMA] Inconsistency of Option Selection (HST) 707
Failure code [DAJQKR] CAN2 Discon (HST Con) 708
Failure code [DAJRKR] CAN1 Discon (HST Con) 709
Failure code [DB2QKR] CAN2 Discon (Engine Con) . 713
Failure code [DD12KA] Shift up SW: Open 717
Failure code [DD12KB] Shift up SW: Short Circuit . 719
Failure code [DD13KA] Shift down SW: Open 721
Failure code [DD13KB] Shift down SW: Short Circuit . 723
Failure code [DD14KA] Parking lever SW: Open . 725
Failure code [DD14KB] Parking lever SW: Short circuit 727
Failure code [DDKAKA] Blade float Sw: Open . 729
Failure code [DDKAKB] Blade float Sw: Short circuit 731
Failure code [DDKFL4] Left Angle Sw: Signal mismatch . 733
Failure code [DDKGL4] Right Angle Sw: Signal mismatch 735
Failure code [DDKHKA] iB Sw: Open 737
Failure code [DDKHKB] iB Sw: Short circuit . 739
Failure code [DDNLKA] Weq lock Sw: Open 741
Failure code [DDNLKB] Weq lock Sw: Short circuit . 743
Failure code [DDP6KA] Brake Pressure Sensor: Open 745
Failure code [DDP6KB] Brake Pressure Sensor: Hot Short . 747
Failure code [DDP6MA] Brake pressure sensor: Malfunction . 749
Failure code [DDU1FS] Parking lever Switch 2: Signal mismatch 751
Failure code [DDU1KA] Parking lever Sw2: Open 753
Failure code [DDU1KY] Parking lever Sw2: Hot Short . 755
Failure code [DFA4KX] Blade lift lever: Main and Sub Error . 757
Failure code [DFA4KZ] Blade lift lever: Main and Sub Error . 758
Failure code [DFA4L8] Blade lift lever: Signal mismatch 759
Failure code [DFA5KA] Blade lift lever1: Open 760
Failure code [DFA5KB] Blade lift lever1: Hot Short . 763
Failure code [DFA6KA] Blade lift lever2: Open 765
Failure code [DFA6KB] Blade lift lever2: Hot Short . 767
Failure code [DFA7KX] Blade tilt lever: Main and Sub Error . 769
Failure code [DFA7KZ] Blade tilt lever: Main and Sub Error . 770
Failure code [DFA7L8] Blade tilt lever: Signal mismatch 771
Failure code [DFA8KA] Blade tilt lever1: Open 772
Failure code [DFA8KB] Blade tilt lever1: Hot Short . 775
Failure code [DFA9KA] Blade tilt lever2: Open 777
Failure code [DFA9KB] Blade tilt lever2: Hot Short . 780
Failure code [DGS1KA] HST oil temp sensor: Open 782
Failure code [DGS1KX] HST oil temp sensor: Out of normal range . 784
Failure code [DH21KA] Weq pressure sensor: Open 785
Failure code [DH21KB] Weq pressure sensor: Hot Short . 787
Failure code [DHA4KA] Air Cleaner Clog Sensor Open Circuit . 789
Failure code [DHH7KA] LF HST Pressure Sensor: Open . 791
Failure code [DHH7KB] LF HST Pressure Sensor: Hot Short 793
Failure code [DHH8KA] RF HST Pressure Sensor: Open . 795
Failure code [DHH8KB] RF HST Pressure Sensor: Hot Short 797
Failure code [DHH9KA] LR HST Pressure Sensor: Open . 799
Failure code [DHH9KB] LR HST Pressure Sensor: Hot Short 801
Failure code [DHHAKA] RR HST Pressure Sensor: Open . 803
Failure code [DHHAKB] RR HST Pressure Sensor: Hot Short 805
Failure code [DK30KA] ST lever1: Open 807
Failure code [DK30KB] ST lever1: Hot Short . 809
Failure code [DK30KX] ST lever: Main and Sub Error . 811
Failure code [DK30KZ] ST lever: Main and Sub Error . 812
Failure code [DK30L8] ST lever: Signal mismatch 813
Failure code [DK31KA] ST lever2: Open 814
Failure code [DK31KB] ST lever2: Hot Short . 816
Failure code [DK40KA] Decel/Brake potentiometer: Open 818
Failure code [DK40KB] Decel/Brake potentiometer: Hot Short . 821
Failure code [DK55KX] FR lever: Main and Sub Error . 823
Failure code [DK55KZ] FR lever: Main and Sub Error . 824
Failure code [DK55L8] FR lever: Signal mismatch 825
Failure code [DK56KA] FR lever1: Open 826
Failure code [DK56KB] FR lever1: Hot Short . 828
Failure code [DK57KA] FR lever2: Open 830
Failure code [DK57KB] FR lever2: Hot Short . 832
Failure code [DLM0KX] HST Motor Speed Sensor: Left/Right Error . 834
Failure code [DLM1KA] Left HST motor speed sensor: Open 835
Failure code [DLM1KB] Left HST motor speed sensor: Short circuit . 837
Failure code [DLM1MA] Left HST motor speed sensor: Malfunction . 839
Failure code [DLM2KA] Right HST motor speed sensor: Open . 840
Failure code [DLM2KB] Right HST motor speed sensor: Short circuit 842
Failure code [DLM2MA] Right HST motor speed sensor: Malfunction 844
Failure code [DLM3KA] Fan rev. sensor: Open 845
Failure code [DLM3KB] Fan rev. sensor: Short circuit . 847
Failure code [DLM3MB] Fan control: Mismatch 849
Failure code [DN21FS] Decel/Brake pedal SW: Signal mismatch 850
Failure code [DR21KX] Camera 2 Picture Rev. Drive Abnormality 852
Failure code [DR31KX] Camera 3 Picture Rev. Drive Abnormality 853
Failure code [DV20KB] Back-up alarm: Short circuit . 854
Failure code [DW4BKA] Parking brake solenoid: Open . 856
Failure code [DW4BKB] Parking brake solenoid: Short circuit 858
Failure code [DW4BKY] Parking brake solenoid: Hot Short 860
Failure code [DW7BKA] Fan reverse solenoid: Open . 862
Failure code [DW7BKB] Fan reverse solenoid: Short circuit 864
Failure code [DW7EKA] Slow brake solenoid: Open 865
Failure code [DW7EKB] Slow brake solenoid: Short circuit . 867
Failure code [DW7EKY] Slow brake solenoid: Hot Short . 869
Failure code [DWN5KA] Fan EPC: Open 871
Failure code [DWN5KB] Fan EPC: Short circuit . 873
Failure code [DWN5KY] Fan EPC: Hot Short . 874
Failure code [DXA4KA] LF HST pump EPC: Open 876
Failure code [DXA4KB] LF HST pump EPC: Short circuit . 878
Failure code [DXA4KY] LF HST pump EPC: Hot Short . 879
Failure code [DXA5KA] LR HST pump EPC: Open 881
Failure code [DXA5KB] LR HST pump EPC: Short circuit . 883
Failure code [DXA5KY] LR HST pump EPC: Hot Short . 885
Failure code [DXA6KA] RF HST pump EPC: Open 887
Failure code [DXA6KB] RF HST pump EPC: Short circuit . 889
Failure code [DXA6KY] RF HST pump EPC: Hot Short . 890
Failure code [DXA7KA] RR HST pump EPC: Open 892
Failure code [DXA7KB] RR HST pump EPC: Short circuit . 894
Failure code [DXA7KY] RR HST pump EPC: Hot Short . 895
Failure code [DXHRKA] Blade lift up EPC: Open 897
Failure code [DXHRKB] Blade lift up EPC: Short circuit . 899
Failure code [DXHRKY] Blade lift up EPC: Hot short . 900
Failure code [DXHSKA] Blade lift down EPC: Open 902
Failure code [DXHSKB] Blade lift down EPC: Short circuit . 904
Failure code [DXHSKY] Blade lift down EPC: Hot short . 905
Failure code [DXHTKA] Blade tilt left EPC: Open 907
Failure code [DXHTKB] Blade tilt left EPC: Short circuit . 909
Failure code [DXHTKY] Blade tilt left EPC: Hot short . 910
Failure code [DXHUKA] Blade tilt right EPC: Open . 912
Failure code [DXHUKB] Blade tilt right EPC: Short circuit 914
Failure code [DXHUKY] Blade tilt right EPC: Hot short 915
Failure code [DXJ4KA] Weq lock Sol.: Open 917
Failure code [DXJ4KB] Weq lock Sol.: Short circuit . 919
Failure code [DXJCKA] Blade angle left EPC: Open . 921
Failure code [DXJCKB] Blade angle left EPC: Short circuit 922
Failure code [DXJCKY] Blade angle left EPC: Hot short 923
Failure code [DXJDKA] Blade angle right EPC: Open 925
Failure code [DXJDKB] Blade angle right EPC: Short circuit . 926
Failure code [DXJDKY] Blade angle right EPC: Hot short . 927
Failure code [DXK1KA] Left HST motor EPC: Open . 929
Failure code [DXK1KB] Left HST motor EPC: Short circuit 931
Failure code [DXK1KY] Left HST motor EPC: Hot Short 932
Failure code [DXK2KA] Right HST motor EPC: Open 934
Failure code [DXK2KB] Right HST motor EPC: Short circuit . 936
Failure code [DXK2KY] Right HST motor EPC: Hot Short . 937
Troubleshooting of electrical system (E-mode) 939
E-1 Engine does not start (Engine does not crank) 939
E-2 Manual preheating system does not work . 945
E-3 Automatic preheating system does not work 948
E-4 While preheating is working, preheating monitor does not light up 950
E-5 When starting switch is turned to ON position, machine monitor displays nothing 952
E-6 When starting switch is turned to ON position (with engine stopped), basic check monitor lights up . 955
E-7 Air cleaner clogging monitor lights up in yellow while engine is running . 956
E-8 Charge level monitor lights up in red while engine is running 957
E-9 Engine coolant temperature monitor lights up in red while engine is running 958
E-10 Engine oil pressure monitor lights up in red while engine is running 959
E-11 HST charge pressure monitor lights up in red while engine is running 960
E-12 Hydraulic oil temperature monitor lights up in red while engine is running 961
E-13 HST oil filter clogging monitor lights up in red while engine is running 962
E-14 Fuel level gauge does not indicate correct level 963
E-15 Engine coolant temperature gauge does not indicate correct temperature 966
E-16 Hydraulic oil temperature gauge does not indicate correct temperature . 967
E-17 Operation mode does not change 968
E-18 Service mode cannot be selected . 969
E-19 Operating customize switch does not display customize screen 970
E-20 Modifying setting on customize screen does not change setting of machine 971
E-21 Service meter is not displayed, while starting switch is in OFF position 972
E-22 Work equipment does not operate . 973
E-23 Foot heater does not operate 975
E-24 Horn does not sound . 980
E-25 Horn does not stop sounding . 982
E-26 Backup alarm does not sound . 983
E-27 Backup alarm does not stop sounding . 984
E-28 Headlamp does not light up 985
E-29 Rear lamp does not light up . 988
E-30 No wiper operates continuously or intermittently 991
E-31 Front wiper does not operate 993
E-32 Rear wiper does not operate . 995
E-33 Left door wiper does not operate (failed in both continuous and intermittent operations) 997
E-34 Right door wiper does not operate (failed in both continuous and intermittent operations) .1001
E-35 Front washer does not operate .1005
E-36 Rear washer does not operate 1007
E-37 Left door washer does not operate .1009
E-38 Right door washer does not operate 1011
E-39 KOMTRAX system does not operate normally 1013
Troubleshooting of hydraulic and mechanical system (H-mode) 1015
Information described in troubleshooting table (H-mode) 1015
System chart of hydraulic and mechanical systems .1016
Failure mode and cause table .1018
H-1 Neither RH nor LH of tracks does not travel forward nor reverse (None of the travel system operates) .1022
H-2 Either RH or LH of track does not travel forward nor reverse (Only RH or LH of travel system operates) .1024
H-3 Either RH or LH of track travel only forward or reverse (Only forward or reverse of RH or LH of travel system does not operate) 1025
H-4 Travel speed or power is low .1027
H-5 Travel speed range does not change .1028
H-6 Shock is large when machine starts or stops 1029
H-7 Machine deviates largely .1030
H-8 Machine drift on a slope is large 1032
H-9 Engine stalls during travel or engine speed drops significantly 1033
H-10 Unusual noise is heard from around HST pump or motor 1034
H-11 All work equipment do not operate .1035
H-12 All work equipment operates slowly or lacks power .1037
H-13 Blade lift speed or power is low 1038
H-14 Blade tilt speed or power is low 1039
H-15 Blade angle speed or power is low .1040
H-16 Time lag of blade lift is large .1041
H-17 Hydraulic drift of lifted blade is large 1042
H-18 Hydraulic drift of tilted blade is large 1043
H-19 Unusual noise is heard from around work equipment pump or control valve .1044
H-20 HST oil temperature (hydraulic oil temperature) rises too high 1045
H-21 Fans speed is abnormal (high, low, or no rotation) 1047
H-22 Unusual noise is heard from around fan 1049
Troubleshooting of engine (S-mode) .1050
Method of using troubleshooting charts .1050
S-1 Starting performance is poor .1054
S-2 Engine does not start 1055
S-3 Engine does not pick up smoothly .1058
S-4 Engine stops during operations .1059
S-5 Engine does not rotate smoothly 1060
S-6 Engine lacks output (or lacks power) .1061
S-7 Exhaust smoke is black (incomplete combustion) .1062
S-8 Oil consumption is excessive (or exhaust smoke is blue) 1063
S-9 Oil becomes contaminated quickly .1064
S-10 Fuel consumption is excessive .1065
S-11 Oil is in coolant (or coolant spurts back or coolant level goes down) .1066
S-12 Oil pressure drops 1067
S-13 Oil level rises (Entry of coolant or fuel) 1068
S-14 Coolant temperature becomes too high (overheating) 1069
S-15 Abnormal noise is made 1070
S-16 Vibration is excessive 1071
50 Disassembly and assembly 1073
Table of contents 1074
Related information on disassembly and assembly 1076
How to read this manual 1076
Coating materials list .1078
Special tools list .1082
Sketches of special tools 1088
Engine and cooling system 1101
Removal and installation of supply pump assembly .1101
Removal and installation of fuel injector assembly .1105
Removal and installation of cylinder head assembly .1112
Removal and installation of radiator assembly 1126
Removal and installation of aftercooler assembly .1130
Removal and installation of hydraulic oil cooler assembly 1133
Removal and installation of cooling fan drive assembly .1136
Removal and installation of cooling fan motor assembly .1139
Removal and installation of engine assembly 1141
Disassembly and assembly of damper assembly 1148
Removal and installation of engine front oil seal 1149
Removal and installation of engine rear oil seal .1151
Removal and installation of engine hood assembly .1154
Removal and installation of fuel tank assembly .1157
Removal and installation of muffler 1161
Removal and installation of belt for alternator and air conditioner compressor .1163
Removal and installation of air cleaner assembly .1164
Power train 1166
Removal and installation of HST pump assembly 1166
Removal and installation of HST motor and final drive assembly .1168
Disassembly and assembly of final drive 1171
Undercarriage and frame 1181
Removal and installation of track frame assembly .1181
Removal and installation of idler assembly .1185
Disassembly and assembly of idler 1187
Removal and installation of recoil spring assembly .1191
Disassembly and assembly of recoil spring 1192
Removal and installation of track roller assembly 1196
Disassembly and assembly of track roller assembly 1198
Removal and installation of carrier roller assembly 1201
Disassembly and assembly of carrier roller assembly 1203
Removal and installation of segment teeth 1205
Separation and connection of track shoe assembly (Standard type track shoe) 1206
Overall disassembly and assembly of track shoe assembly (Standard type track shoe) .1209
Disassembly and assembly of one track link assembly in field (Standard type track shoe) 1225
Removal and installation of pivot shaft assembly .1231
Removal and installation of equalizer bar assembly .1233
Removal and installation of equalizer bar side bushing .1235
Hydraulic system .1236
Removal and installation of hydraulic tank assembly 1236
Removal and installation of control valve assembly .1240
Disassembly and assembly of hydraulic cylinder assembly 1243
Work equipment .1247
Removal and installation of work equipment assembly 1247
Removal and installation of blade assembly .1249
Removal and installation of U-frame assembly .1251
Cab and its attachments 1253
Removal and installation of ROPS cab assembly 1253
Removal and installation of operator’s cab glass (adhesion glass) 1257
Removal and installation of operator’s seat 1263
Removal and installation of seat belt 1264
Removal and installation of foot heater assembly .1265
Disassembly and assembly of foot heater assembly .1267
Removal and installation of air conditioner unit assembly 1268
Removal and installation of air conditioner compressor assembly 1272
Electrical system 1274
Removal and installation of machine monitor assembly .1274
Removal and installation of engine controller assembly .1275
Removal and installation of HST controller assembly 1277
Removal and installation of KOMTRAX terminal .1278
60 Maintenance standard 1279
Table of contents 1280
Engine and cooling system 1281
Engine mount .1281
Cooling fan motor 1282
Oil cooler bypass and HST charge safety valve 1284
Power train 1285
Damper .1285
HST pump .1286
HST motor 1288
Charge pump 1289
Solenoid valve .1290
Final drive 1291
Sprocket .1292
Full-scale drawing of sprocket tooth profile .1293
Undercarriage and frame 1294
Suspension .1294
Track frame and idler cushion 1296
Idler 1298
Track roller .1300
Carrier roller .1302
Hydraulic system .1306
Hydraulic tank .1306
Work equipment and cooling fan pump 1307
Control valve 1310
Ripper PPC valve .1317
Quick drop valve .1319
Angle control EPC valve 1321
Work equipment .1322
Blade 1322
Cutting edge and end bit .1325
Ripper .1326
Lift cylinder 1328
Tilt cylinder 1329
Angle cylinder .1330
Ripper cylinder 1331
Cab and its attachments 1332
Cab mount 1332
Electrical system 1333
Electric steering lever 1333
80 Appendix 1335
Table of contents 1336
Air conditioner components .1337
Precautions for refrigerant 1337
Air conditioner component 1338
Configuration and function of refrigeration cycle 1341
Outline of refrigeration cycle .1342
Air conditioner unit .1344
Dual pressure switch .1348
Pressure switch 1349
Compressor .1350
Condenser 1351
Receiver drier .1353
Procedure for testing and troubleshooting 1354
Electrical circuit diagram .1357
System diagram .1358
Parts and connectors layout 1360
Testing relays .1365
Troubleshooting chart 1 1367
Troubleshooting chart 2 1368
Information described in troubleshooting table .1370
A-1 Troubleshooting for condenser fan 1371
A-2 Troubleshooting for compressor and refrigerant system (Air is not cooled) 1374
A-3 Troubleshooting for blower motor system (No air comes out or air flow is abnormal) .1378
A-4 Troubleshooting for temperature control 1380
Troubleshooting with gauge pressure 1383
Connection of service tool .1386
Precautions for disconnecting and connecting hoses and tubes in air conditioner circuit 1388
Handling of compressor oil .1390
90 Diagrams and drawings . 0
Table of contents 0
Hydraulic circuit diagram 0
Symbols in hydraulic circuit diagram . 0
Hydraulic circuit diagram 0
Electric circuit diagram . 0
Symbols in electric circuit diagram 0
Electrical circuit diagram . 0

DESCRIPTION:

Komatsu Bulldozer D61EX-23M0 Shop Manual KEBM601001  – PDF  DOWNLOAD

• Serial Numbers B50001 and up

G.B 22/ 12/24