Komatsu BULLDOZER D61EXi -23 D61PXi-23 Shop Manual SEN06256-06 PDF

Description

Komatsu BULLDOZER D61EXi -23 D61PXi-23 Shop Manual SEN06256-06 – PDF DOWNLOAD

FILE DETAILS:

Komatsu BULLDOZER D61EXi -23 D61PXi-23 Shop Manual SEN06256-06 – PDF DOWNLOAD

Language : English
Pages :1977
Downloadable : Yes
File Type : PDF

DESCRIPTION:

Komatsu BULLDOZER D61EXi -23 D61PXi-23 Shop Manual SEN06256-06 – PDF DOWNLOAD

SERIAL NUMBERS D61EXi-30324
D61PXi-30324 and up

General precautions

• Before adding oil or making any repairs, place the machine on a firm and level ground, and apply the parking brake and chock the wheels or tracks to prevent the machine from moving.
• Before starting work, lower the work equipment (blade, ripper, bucket, etc.) to the ground. If it is not possible to lower the equipment to the ground, insert the lock pin or use blocks to prevent the work equipment from falling. And be sure to lock all the work equipment control levers and hang a warning tag on them.
• When performing the disassembling or assembling work, support the machine securely with blocks, jacks, or stands before starting the work.
• Remove all of mud and oil from the steps or other places used to get on and off the machine completely. Always use the handrails, ladders of steps when getting on or off the machine. Never

TABLE OF CONTENTS:

Komatsu BULLDOZER D61EXi -23 D61PXi-23 Shop Manual SEN06256-06 – PDF DOWNLOAD

SERIAL NUMBERS D61EXi-30324
D61PXi-30324 and up

Cover 1
00 Index and foreword 3
Index 4
Foreword, safety and general information 18
Important safety notice 18
How to read the shop manual 25
Explanation of terms for maintenance standard 27
Handling equipment of fuel system devices 29
Handling of intake system parts 30
Handling of hydraulic equipment 31
Method of disconnecting and connecting of push-pull type coupler 33
Handling of electrical equipment 36
How to read electric wire code 44
Precautions when performing operation 47
Practical use of KOMTRAX 52
Standard tightening torque table 53
List of abbreviation 59
Conversion table 64
01 Specification 69
Table of contents 70
Specifications 71
Specification drawing 71
Specifications 73
Weight table 83
Table of fuel, coolant, and lubricants 87
10 Structure and function 89
Table of contents 90
Engine and cooling system 91
Engine related parts 91
KVGT 93
EGR system piping drawing 101
EGR system circuit diagram 103
EGR valve 105
EGR cooler 107
KCCV layout drawing 109
KCCV ventilator 111
KDPF 113
Cooling system 119
Cooling fan motor 121
Oil cooler bypass and HST charge safety valve 128
Power train 134
Power train system 134
Damper 137
Hydraulic component layout of HST 138
Steering and brake control 139
HST pump 141
HST motor 155
Charge pump 170
Solenoid valve 171
Final drive 180
Undercarriage and frame 184
Main frame 184
Suspension 185
Track frame and idler cushion 187
Hydraulic system 190
Hydraulic component layout of work equipment 190
Work equipment control system 192
Hydraulic tank 194
CLSS 196
Work equipment and cooling fan pump 199
Control valve 210
Ripper PPC valve 232
Quick drop valve 238
Angle control EPC valve 241
Accumulator 246
Work equipment 248
Blade 248
Ripper 249
Piston valve 250
Cab and its attachments 251
ROPS cab 251
Cab mount 253
Electrical system 254
Electrical control system 254
Machine monitor system 296
KOMTRAX system 319
System component parts 323
Sensor 349
20 Standard value tables 379
Table of contents 380
Standard service value table 381
Standard value table for engine 381
Standard value table for machine 383
Standard value table for electrical system 393
30 Testing and adjusting 403
Table of contents 404
Related information on testing and adjusting 406
Tools for testing and adjusting 406
Sketch of tools for testing and adjusting 409
Engine and cooling system 414
Testing engine speed 414
Testing boost pressure 416
Testing exhaust gas color 418
Testing and adjusting valve clearance 420
Testing compression pressure 423
Testing blowby pressure 427
Testing engine oil pressure 429
Testing EGR valve and KVGT oil pressures 430
Testing fuel pressure 431
Testing fuel discharge, return and leakage 436
Bleeding air from fuel system 441
Testing fuel circuit for leakage 443
Handling cylinder cutout mode operation 444
Handling no-injection cranking operation 445
Testing of KDPF and muffler stack for looseness and damage 446
Testing of installed condition of cylinder heads and manifolds 447
Testing engine piping for damage and looseness 448
Check alternator belt, replace 449
Check auto-tensioner, replace 451
Writing compensation amount for soot accumulation caused by ash on engine controller 453
Power train 455
Testing and adjusting HST oil pressure 455
Testing output pressure of solenoid valve 460
Testing if machine travels straight 464
Simple test procedure for brake performance 465
Adjusting deceleration/brake pedal 466
Adjusting parking brake lever 469
Move disabled machine urgently 471
Undercarriage and frame 474
Adjusting idler clearance 474
Checking sprocket wear 475
Testing and adjusting track tension 476
Hydraulic system 477
Releasing remaining pressure in work equipment cylinder 477
Testing and adjusting work equipment oil pressure 478
Testing source pressure of control circuit 480
Testing outlet pressure of work equipment EPC valve and fan EPC valve 481
Isolating the parts causing hydraulic drift in blade and ripper 483
Testing internal oil leakage of work equipment cylinder 484
Testing fan speed 486
Testing fan circuit oil pressure 487
Bleeding air from hydraulic circuit 488
Work equipment 489
Adjusting work equipment lock lever 489
Adjusting play of blade center ball 491
Electrical system 492
Special functions of machine monitor 492
Special functions of control box 576
Testing stroke sensor for lift cylinder 611
Testing stroke sensor for tilt cylinder 613
Testing stroke sensor for angle cylinder 614
Testing and adjusting reset sensor for lift cylinder 615
Testing and adjusting reset sensor for angle cylinder 616
Adjustment method when HST controller has been replaced 617
Adjustment method when ICT sensor controller has been replaced 620
Adjustment method when devices have been repaired or replaced 623
KOMTRAX terminal start-up procedure 625
Adjusting rearview camera angle 628
Handling voltage circuit of engine controller 629
Handling battery disconnect switch 630
Testing diodes 631
Pm clinic 632
Pm Clinic service 632
40 Troubleshooting 641
Table of contents 642
Related information on troubleshooting 651
Troubleshooting points 651
Sequence of events in troubleshooting 653
Checks before troubleshooting 655
Inspection procedure before troubleshooting 657
Preparation for troubleshooting of electrical system 674
Classification and procedures for troubleshooting 678
Symptom and troubleshooting numbers 680
Information in troubleshooting table 684
Procedure for troubleshooting wiring harness of pressure sensor system for open circuit 686
Connector list and layout 689
Connector contact identification 703
T-branch box and T-branch adapter table 742
Fuse location table 747
Precautions for KDPF (KCSF and KDOC) Cleaning and Replacement 752
Preparation of dummy temperature sensor (for KDOC and KDPF temperature sensors) 755
Preparation of short circuit electrical connector (for failure codes [CA1883] and [CA3135]) 756
Failure codes table 757
Troubleshooting by failure code (Display of code) 769
Failure code [6091NX] HST Oil Filter Clogging 769
Failure code [989L00] Engine Controller Lock Caution 1 771
Failure code [989M00] Engine Controller Lock Caution 2 772
Failure code [989N00] Engine Controller Lock Caution 3 773
Failure code [A1U0N3] HC Desorb Request 1 774
Failure code [A1U0N4] HC Desorb Request 2 776
Failure code [AA10NX] Air Cleaner Clogging 778
Failure code [AB00KE] Charge Voltage Low 780
Failure code [B@BAZG] Eng Oil Press Low 782
Failure code [B@BCNS] Eng Water Overheat 783
Failure code [B@CRNS] HST Oil Overheat 784
Failure code [B@CRZG] HST Charge Press Low 785
Failure code [CA115] Eng Ne and Bkup Speed Sens Error 786
Failure code [CA122] Chg Air Press Sensor High Error 787
Failure code [CA123] Chg Air Press Sensor Low Error 789
Failure code [CA131] Throttle Sensor High Error 791
Failure code [CA132] Throttle Sensor Low Error 793
Failure code [CA144] Coolant Temp Sens High Error 795
Failure code [CA145] Coolant Temp Sens Low Error 797
Failure code [CA153] Chg Air Temp Sensor High Error 799
Failure code [CA154] Chg Air Temp Sensor Low Error 801
Failure code [CA187] Sensor 2 Supply Volt Low Error 803
Failure code [CA234] Eng Overspeed 805
Failure code [CA221] Ambient Press Sensor High Error 806
Failure code [CA222] Ambient Press Sensor Low Error 808
Failure code [CA227] Sensor 2 Supply Volt High Error 810
Failure code [CA238] Ne Speed Sensor Supply Volt Error 811
Failure code [CA239] Ne Speed Sens Supply Volt High Error 812
Failure code [CA271] IMV/PCV1 Short Error 813
Failure code [CA272] IMV/PCV1 Open Error 815
Failure code [CA295] Ambient Pressure Sensor In Range Error 817
Failure code [CA322] Inj #1(L#1) Open/Short Error 818
Failure code [CA323] Inj #5(L#5) Open/Short Error 820
Failure code [CA324] Inj #3(L#3) Open/Short Error 822
Failure code [CA325] Inj #6(L#6) Open/Short Error 824
Failure code [CA331] Inj #2(L#2) Open/Short Error 826
Failure code [CA332] Inj #4(L#4) Open/Short Error 828
Failure code [CA343] ECM Critical Internal Failure 830
Failure code [CA351] Injectors Drive Circuit Error 831
Failure code [CA352] Sensor 1 Supply Volt Low Error 832
Failure code [CA356] Mass Air Flow Sensor High Error 834
Failure code [CA357] Mass Air Flow Sensor Low Error 836
Failure code [CA386] Sensor 1 Supply Volt High Error 838
Failure code [CA428] Water in Fuel Sensor High Error 839
Failure code [CA429] Water in Fuel Sensor Low Error 841
Failure code [CA435] Eng Oil Press Sw Error 843
Failure code [CA441] Battery Voltage Low Error 844
Failure code [CA442] Battery Voltage High Error 846
Failure code [CA449] Rail Press Very High Error 847
Failure code [CA451] Rail Press Sensor High Error 848
Failure code [CA452] Rail Press Sensor Low Error 850
Failure code [CA488] Chg Air Temp High Torque Derate 852
Failure code [CA515] Rail Press Sens Sup Volt High Error 853
Failure code [CA516] Rail Press Sens Sup Volt Low Error 855
Failure code [CA553] Rail Press High Error 857
Failure code [CA555] Crankcase Press High Error 2 858
Failure code [CA556] Crankcase Press High Error 2 859
Failure code [CA559] Rail Press Low Error 860
Failure code [CA595] Turbo Speed High Error 2 862
Failure code [CA687] Turbo Speed Low Error 863
Failure code [CA689] Eng Ne Speed Sensor Error 865
Failure code [CA691] Intake Air Temp Sens High Error 867
Failure code [CA692] Intake Air Temp Sens Low Error 869
Failure code [CA697] ECM Internal Temp Sensor High Error 871
Failure code [CA698] ECM Int Temp Sensor Low Error 872
Failure code [CA731] Eng Bkup Speed Sens Phase Error 873
Failure code [CA778] Eng Bkup Speed Sensor Error 875
Failure code [CA1117] Persistent Data Lost Error 880
Failure code [CA1664] KDOC Malfunction 881
Failure code [CA1691] Regeneration Ineffective 884
Failure code [CA1695] Sens 5 Supply Volt High Error 887
Failure code [CA1696] Sens 5 Supply Volt Low Error 888
Failure code [CA1843] Crankcase Press Sens High Error 890
Failure code [CA1844] Crankcase Press Sens Low Error 892
Failure code [CA1879] KDPF Delta P Sensor High Error 894
Failure code [CA1881] KDPF Delta P Sensor Low Error 896
Failure code [CA1883] KDPF Delta P Sens In Range Error 898
Failure code [CA1921] KDPF Soot Load High Error 1 902
Failure code [CA1922] KDPF Soot Load High Error 2 905
Failure code [CA1942] Crankcase Press Sens In Range Error 910
Failure code [CA1993] KDPF Delta Pressure Low Error 911
Failure code [CA2185] Throt Sensor Sup Volt High Error 914
Failure code [CA2186] Throt Sensor Sup Volt Low Error 915
Failure code [CA2249] Rail Press Very Low Error 916
Failure code [CA2271] EGR Valve Pos Sens High Error 917
Failure code [CA2272] EGR Valve Pos Sens Low Error 919
Failure code [CA2288] Turbo Speed High Error 1 922
Failure code [CA2311] IMV Solenoid Error 923
Failure code [CA2349] EGR Valve Solenoid Open Error 924
Failure code [CA2353] EGR Valve Solenoid Short Error 926
Failure code [CA2357] EGR Valve Servo Error 928
Failure code [CA2373] Exhaust Manifold Press Sens High error 929
Failure code [CA2374] Exhaust Manifold Press Sens Low error 931
Failure code [CA2375] EGR Orifice Temp Sens High Error 933
Failure code [CA2376] EGR Orifice Temp Sens Low Error 935
Failure code [CA2381] KVGT Pos Sens High Error 937
Failure code [CA2382] KVGT Pos Sens Low Error 939
Failure code [CA2383] KVGT Solenoid Open Error 942
Failure code [CA2386] KVGT Solenoid Short Error 944
Failure code [CA2387] KVGT Servo Error 946
Failure code [CA2554] Exh Manifold Press Sens In Range Error 947
Failure code [CA2555] Grid Htr Relay Volt Low Error 948
Failure code [CA2556] Grid Htr Relay Volt High Error 950
Failure code [CA2637] KDOC Face Plugging 952
Failure code [CA2639] Manual Stationary Regeneration Request 954
Failure code [CA2961] EGR Orifice Temp High Error 1 957
Failure code [CA2973] Chg Air Press Sensor In Range Error 958
Failure code [CA3133] KDPF Outlet Press Sens High Error 959
Failure code [CA3134] KDPF Outlet Press Sens Low Error 961
Failure code [CA3135] KDPF Outlet Press Sens In Range Error 963
Failure code [CA3251] KDOC Inlet Temp High Error 967
Failure code [CA3253] KDOC Temp Error – Non Regeneration 970
Failure code [CA3254] KDOC Outlet Temp High Error 1 974
Failure code [CA3255] KDPF Temp Error – Non Regeneration 977
Failure code [CA3256] KDPF Outlet Temp High Error 1 982
Failure code [CA3311] KDOC Outlet Temp High Error 2 985
Failure code [CA3312] KDPF Outlet Temp High Error 2 989
Failure code [CA3313] KDOC Inlet Temp Sensor Low Error 993
Failure code [CA3314] KDOC Inlet Temp Sens High Error 996
Failure code [CA3315] KDOC Inlet Temp Sens In Range Error 1000
Failure code [CA3316] KDOC Outlet Temp Sens Low Error 1004
Failure code [CA3317] KDOC Outlet Temp Sens High Error 1007
Failure code [CA3318] KDOC Outlet Temp Sens In Range Error 1011
Failure code [CA3319] KDPF Outlet Temp Sens High Error 1015
Failure code [CA3321] KDPF Outlet Temp Sens Low Error 1019
Failure code [CA3322] KDPF Outlet Temp Sens In Range Error 1022
Failure code [CA3419] Mass Air Flow Sensor Sup Volt High Error 1026
Failure code [CA3421] Mass Air Flow Sensor Sup Volt Low Error 1028
Failure code [CA3741] Rail Press Valve Trip Error 1030
Failure code [D130KA] Neutral relay Open 1031
Failure code [D130KB] Neutral relay Short circuit 1033
Failure code [D130KY] Neutral relay: Hot Short 1035
Failure code [D19JKZ] Personal Code Relay Abnormality 1037
Failure code [D811MC] KOMTRAX Error 1040
Failure code [D862KA] GPS Antenna Open Circuit 1041
Failure code [D8ALKA] Operating Lamp Open Circuit (KOMTRAX) 1042
Failure code [D8ALKB] Operating Lamp Short Circuit (KOMTRAX) 1044
Failure code [D8AQKR] CAN2 Discon (KOMTRAX) 1045
Failure code [DAF0MB] Monitor ROM Abnormality 1046
Failure code [DAF0MC] Monitor Error 1047
Failure code [DAF8KB] Camera Power Supply Short Circuit 1048
Failure code [DAF9KQ] Model Selection Abnormality 1049
Failure code [DAFGMC] GPS Module Error 1050
Failure code [DAFLKA] Operating Lamp Open Circuit (Monitor) 1051
Failure code [DAFLKB] Operating Lamp Short Circuit (Monitor) 1053
Failure code [DAFQKR] CAN2 Discon (Monitor) 1054
Failure code [DAJ000] HST controller: Abnormality in controller 1055
Failure code [DAJ0KQ] HST controller: Type select signal 1056
Failure code [DAJ0KT] HST controller: Abnormality in controller 1057
Failure code [DAJ0MC] HST Con Error 1058
Failure code [DAJ1KK] HST controller: Source voltage low 1059
Failure code [DAJ2KK] HST controller: Output voltage low 1061
Failure code [DAJ5KK] HST: Sensor volt 5V (0) Out of normal range 1063
Failure code [DAJ6KK] HST: Sensor volt 5V (1) Out of normal range 1065
Failure code [DAJLKA] Operating Lamp Open Circuit (HST Con) 1067
Failure code [DAJLKB] Operating Lamp Short Circuit (HST Con) 1069
Failure code [DAJPMA] Inconsistency of Option Selection (HST) 1070
Failure code [DAJQKR] CAN2 Discon ( HST Con) 1071
Failure code [DAJRKR] CAN1 Discon ( HST Con) 1072
Failure code [DB2QKR] CAN2 Discon (Engine Con) 1073
Failure code [DB2RKR] CAN1 Discon (Engine Con) 1078
Failure code [DBR0KT] ICT Controller: Abnormality in controller 1083
Failure code [DBR0MC] ICT Con Error 1084
Failure code [DBR1KK] ICT controller: Source voltage low 1085
Failure code [DBR2KK] ICT controller: Output voltage low 1087
Failure code [DBR5KK] ICT: Sensor volt 5V (0) Out of normal range 1089
Failure code [DBRLKA] Operating Lamp Open Circuit (ICT Con) 1091
Failure code [DBRLKB] Operating Lamp Short Circuit (ICT Con) 1093
Failure code [DBRPMA] Inconsistency of Option Selection (ICT) 1094
Failure code [DBRQKR] CAN2 Discon (ICT Con) 1095
Failure code [DBRRKR] CAN1 Discon (ICT Con) 1098
Failure code [DBTSKR] LAN Discon (iB Monitor) 1099
Failure code [DBUTKA] GNSS Antenna Open Circuit 1101
Failure code [DD12KA] Shift up SW: Open 1102
Failure code [DD12KB] Shift up SW: Short Circuit 1104
Failure code [DD13KA] Shift down SW: Open 1106
Failure code [DD13KB] Shift down SW: Short Circuit 1108
Failure code [DD14KA] Parking lever SW: Open 1110
Failure code [DD14KB] Parking lever SW: Short circuit 1112
Failure code [DDKAKA] Blade float Sw: Open 1114
Failure code [DDKAKB] Blade float Sw: Short circuit 1116
Failure code [DDKFL4] Left Angle Sw: Signal mismatch 1118
Failure code [DDKGL4] Right Angle Sw: Signal mismatch 1120
Failure code [DDKHKA] iB Sw: Open 1122
Failure code [DDKHKB] iB Sw: Short circuit 1124
Failure code [DDNLKA] Weq lock Sw: Open 1126
Failure code [DDNLKB] Weq lock Sw: Short circuit 1128
Failure code [DDP6KA] Brake Pressure Sensor: Open 1130
Failure code [DDP6KB] Brake Pressure Sensor: Hot Short 1132
Failure code [DDP6MA] Brake pressure sensor: Malfunction 1134
Failure code [DDU1FS] Parking lever Switch 2: Signal mismatch 1136
Failure code [DDU1KA] Parking lever Sw2: Open 1138
Failure code [DDU1KY] Parking lever Sw2: Hot Short 1140
Failure code [DFA4KX] Blade lift lever: Main and Sub Error 1142
Failure code [DFA4KZ] Blade lift lever: Main and Sub Error 1143
Failure code [DFA4L8] Blade lift lever: Signal mismatch 1144
Failure code [DFA5KA] Blade lift lever1: Open 1145
Failure code [DFA5KB] Blade lift lever1: Hot Short 1148
Failure code [DFA6KA] Blade lift lever2: Open 1150
Failure code [DFA6KB] Blade lift lever2: Hot Short 1152
Failure code [DFA7KX] Blade tilt lever: Main and Sub Error 1154
Failure code [DFA7KZ] Blade tilt lever: Main and Sub Error 1155
Failure code [DFA7L8] Blade tilt lever: Signal mismatch 1156
Failure code [DFA8KA] Blade tilt lever1: Open 1157
Failure code [DFA8KB] Blade tilt lever1: Hot Short 1160
Failure code [DFA9KA] Blade tilt lever2: Open 1162
Failure code [DFA9KB] Blade tilt lever2: Hot Short 1165
Failure code [DGS1KA] HST oil temp sensor: Open 1167
Failure code [DGS1KX] HST oil temp sensor: Out of normal range 1169
Failure code [DH21KA] Weq pressure sensor: Open 1170
Failure code [DH21KB] Weq pressure sensor: Hot Short 1172
Failure code [DHA4KA] Air Cleaner Clog Sensor Open Circuit 1174
Failure code [DHH7KA] LF HST Pressure Sensor: Open 1176
Failure code [DHH7KB] LF HST Pressure Sensor: Hot Short 1178
Failure code [DHH8KA] RF HST Pressure Sensor: Open 1180
Failure code [DHH8KB] RF HST Pressure Sensor: Hot Short 1182
Failure code [DHH9KA] LR HST Pressure Sensor: Open 1184
Failure code [DHH9KB] LR HST Pressure Sensor: Hot Short 1186
Failure code [DHHAKA] RR HST Pressure Sensor: Open 1188
Failure code [DHHAKB] RR HST Pressure Sensor: Hot Short 1190
Failure code [DK30KA] ST lever1: Open 1192
Failure code [DK30KB] ST lever1: Hot Short 1194
Failure code [DK30KX] ST lever: Main and Sub Error 1196
Failure code [DK30KZ] ST lever: Main and Sub Error 1197
Failure code [DK30L8] ST lever: Signal mismatch 1198
Failure code [DK31KA] ST lever2: Open 1199
Failure code [DK31KB] ST lever2: Hot Short 1201
Failure code [DK40KA] Decel/Brake potentiometer: Open 1203
Failure code [DK40KB] Decel/Brake potentiometer: Hot Short 1206
Failure code [DK55KX] FR lever: Main and Sub Error 1208
Failure code [DK55KZ] FR lever: Main and Sub Error 1209
Failure code [DK55L8] FR lever: Signal mismatch 1210
Failure code [DK56KA] FR lever1: Open 1211
Failure code [DK56KB] FR lever1: Hot Short 1213
Failure code [DK57KA] FR lever2: Open 1215
Failure code [DK57KB] FR lever2: Hot Short 1217
Failure code [DK80KA] IMU Sensor: Open 1219
Failure code [DKS0L8] Blade lift Stroke sensor: Signal mismatch 1221
Failure code [DKS1KA] Blade lift Stroke sensor A: Open 1222
Failure code [DKS1KB] Blade lift Stroke sensor A: Hot Short 1224
Failure code [DKS2KA] Blade lift Stroke sensor B: Open 1226
Failure code [DKS2KB] Blade lift Stroke sensor B: Hot Short 1228
Failure code [DKS3KA] Blade lift Reset sensor: Open 1230
Failure code [DKS3KB] Blade lift Reset sensor: Hot Short 1232
Failure code [DKS3MB] Blade lift Reset sensor: Signal mismatch 1234
Failure code [DKS4L8] Blade tilt Stroke sensor: Signal mismatch 1235
Failure code [DKS5KA] Blade tilt Stroke sensor A: Open 1236
Failure code [DKS5KB] Blade tilt Stroke sensor A: Hot Short 1238
Failure code [DKS6KA] Blade tilt Stroke sensor B: Open 1240
Failure code [DKS6KB] Blade tilt Stroke sensor B: Hot Short 1242
Failure code [DKS7MB] Blade tilt Reset sensor: Signal mismatch 1244
Failure code [DKSCL8] Angle left Stroke sensor: Signal mismatch 1245
Failure code [DKSDKA] Angle left Stroke sensor A: Open 1246
Failure code [DKSDKB] Angle left Stroke sensor A: Hot Short 1248
Failure code [DKSEKA] Angle left Stroke sensor B: Open 1250
Failure code [DKSEKB] Angle left Stroke sensor B: Hot Short 1252
Failure code [DKSFKA] Angle left Reset sensor: Open 1254
Failure code [DKSFKB] Angle left Reset sensor: Hot Short 1256
Failure code [DKSFMB] Angle left Reset sensor: Signal mismatch 1258
Failure code [DLM0KX] HST Motor Speed Sensor: Left/Right Error 1259
Failure code [DLM0MA] HST motor speed sensor: Malfunction 1260
Failure code [DLM1KA] Left HST motor speed sensor: Open 1261
Failure code [DLM1KB] Left HST motor speed sensor: Short circuit 1263
Failure code [DLM1MA] Left HST motor speed sensor: Malfunction 1265
Failure code [DLM2KA] Right HST motor speed sensor: Open 1266
Failure code [DLM2KB] Right HST motor speed sensor: Short circuit 1268
Failure code [DLM2MA] Right HST motor speed sensor: Malfunction 1270
Failure code [DLM3KA] Fan rev sensor: Open 1271
Failure code [DLM3KB] Fan rev sensor: Short circuit 1273
Failure code [DLM3MB] Fan control: Mismatch 1275
Failure code [DN21FS] Decel/Brake pedal SW: Signal mismatch 1276
Failure code [DR21KX] Camera 2 Picture Rev Drive Abnormality 1278
Failure code [DR31KX] Camera 3 Picture Rev Drive Abnormality 1279
Failure code [DV20KB] Back-up alarm: Short circuit 1280
Failure code [DW4BKA] Parking brake solenoid: Open 1282
Failure code [DW4BKB] Parking brake solenoid: Short circuit 1284
Failure code [DW4BKY] Parking brake solenoid: Hot Short 1286
Failure code [DW7BKA] Fan reverse solenoid: Open 1288
Failure code [DW7BKB] Fan reverse solenoid: Short circuit 1290
Failure code [DW7EKA] Slow brake solenoid: Open 1291
Failure code [DW7EKB] Slow brake solenoid: Short circuit 1293
Failure code [DW7EKY] Slow brake solenoid: Hot Short 1295
Failure code [DWN5KA] Fan EPC: Open 1297
Failure code [DWN5KB] Fan EPC: Short circuit 1299
Failure code [DWN5KY] Fan EPC: Hot Short 1300
Failure code [DXA4KA] LF HST pump EPC: Open 1302
Failure code [DXA4KB] LF HST pump EPC: Short circuit 1304
Failure code [DXA4KY] LF HST pump EPC: Hot Short 1305
Failure code [DXA5KA] LR HST pump EPC: Open 1307
Failure code [DXA5KB] LR HST pump EPC: Short circuit 1309
Failure code [DXA5KY] LR HST pump EPC: Hot Short 1311
Failure code [DXA6KA] RF HST pump EPC: Open 1313
Failure code [DXA6KB] RF HST pump EPC: Short circuit 1315
Failure code [DXA6KY] RF HST pump EPC: Hot Short 1316
Failure code [DXA7KA] RR HST pump EPC: Open 1318
Failure code [DXA7KB] RR HST pump EPC: Short circuit 1320
Failure code [DXA7KY] RR HST pump EPC: Hot Short 1321
Failure code [DXHRKA] Blade lift up EPC: Open 1323
Failure code [DXHRKB] Blade lift up EPC: Short circuit 1325
Failure code [DXHRKY] Blade lift up EPC: Hot short 1326
Failure code [DXHSKA] Blade lift down EPC: Open 1328
Failure code [DXHSKB] Blade lift down EPC: Short circuit 1330
Failure code [DXHSKY] Blade lift down EPC: Hot short 1331
Failure code [DXHTKA] Blade tilt left EPC: Open 1333
Failure code [DXHTKB] Blade tilt left EPC: Short circuit 1335
Failure code [DXHTKY] Blade tilt left EPC: Hot short 1336
Failure code [DXHUKA] Blade tilt right EPC: Open 1338
Failure code [DXHUKB] Blade tilt right EPC: Short circuit 1340
Failure code [DXHUKY] Blade tilt right EPC: Hot short 1341
Failure code [DXJ4KA] Weq lock Sol: Open 1343
Failure code [DXJ4KB] Weq lock Sol: Short circuit 1345
Failure code [DXJCKA] Blade angle left EPC: Open 1347
Failure code [DXJCKB] Blade angle left EPC: Short circuit 1348
Failure code [DXJCKY] Blade angle left EPC: Hot short 1349
Failure code [DXJDKA] Blade angle right EPC: Open 1351
Failure code [DXJDKB] Blade angle right EPC: Short circuit 1352
Failure code [DXJDKY] Blade angle right EPC: Hot short 1353
Failure code [DXK1KA] Left HST motor EPC: Open 1355
Failure code [DXK1KB] Left HST motor EPC: Short circuit 1357
Failure code [DXK1KY] Left HST motor EPC: Hot Short 1358
Failure code [DXK2KA] Right HST motor EPC: Open 1360
Failure code [DXK2KB] Right HST motor EPC: Short circuit 1362
Failure code [DXK2KY] Right HST motor EPC: Hot Short 1363
Troubleshooting of electrical system (E-mode) 1365
E-1 Engine does not start (Engine does not crank) 1365
E-2 Manual preheating system does not work 1371
E-3 Automatic preheating system does not work 1374
E-4 While preheating is working, preheating monitor does not light up 1376
E-5 When starting switch is turned to ON position, machine monitor displays nothing 1378
E-6 When starting switch is turned to ON position (with engine stopped), basic check monitor lights up 1381
E-7 Air cleaner clogging monitor lights up in yellow while engine is running 1382
E-8 Charge level monitor lights up in red while engine is running 1383
E-9 Engine coolant temperature monitor lights up in red while engine is running 1384
E-10 Engine oil pressure monitor lights up in red while engine is running 1385
E-11 HST charge pressure monitor lights up in red while engine is running 1386
E-12 Hydraulic oil temperature monitor lights up in red while engine is running 1387
E-13 HST oil filter clogging monitor lights up in red while engine is running 1388
E-14 Fuel level gauge does not indicate correct level 1389
E-15 Engine coolant temperature gauge does not indicate correct temperature 1392
E-16 Hydraulic oil temperature gauge does not indicate correct temperature 1393
E-17 Operation mode does not change 1394
E-18 Service mode cannot be selected 1395
E-19 Operating customize switch does not display customize screen 1396
E-20 Modifying setting on customize screen does not change setting of machine 1397
E-21 Service meter is not displayed, while starting switch is in OFF position 1398
E-22 Work equipment does not operate 1399
E-23 Foot heater does not operate 1401
E-24 Horn does not sound 1406
E-25 Horn does not stop sounding 1408
E-26 Backup alarm does not sound 1409
E-27 Backup alarm does not stop sounding 1410
E-28 Headlamp does not light up 1411
E-29 Rear lamp does not light up 1414
E-30 No wiper operates continuously or intermittently 1417
E-31 Front wiper does not operate 1419
E-32 Rear wiper does not operate 1421
E-33 Left door wiper does not operate (failed in both continuous and intermittent operations) 1423
E-34 Right door wiper does not operate (failed in both continuous and intermittent operations) 1427
E-35 Front washer does not operate 1431
E-36 Rear washer does not operate 1433
E-37 Left door washer does not operate 1435
E-38 Right door washer does not operate 1437
E-39 KOMTRAX system does not operate normally 1439
E-40 Control box shuts down after displaying the messages [GPS receiver not connected!] and [Slope sensor not connected!] 1441
E-41 Control box displays the messages [GPS receiver not connected!] and [Slope sensor not connected!] 1445
E-42 Control box displays the message [Waiting for radio link] 1448
E-43 Control box displays the message [IMU sensor not connected] 1449
E-44 Control box displays the message [Waiting for satellites] 1450
E-45 Control box displays the message [Komatsu controller not connected!] 1451
E-46 Control box displays the message [Cylinder Stroke Reading Abnormal] 1453
E-47 Control box displays the message [Komatsu CAN Comms Abnormal] 1454
E-48 Control box displays the message [Komatsu Machine Trouble] 1455
E-49 Control box displays the message [Waiting to initialize] 1456
E-50 Control box displays the message [System Initializing] 1457
E-51 Control box displays the message [Initializing] 1458
E-52 Control box displays the message [Configuring GPS] 1459
E-53 Control box displays the message [No GPS Localization] 1460
E-54 Control box displays the message [Low precisions] 1461
E-55 Control box displays the message [Heading Initializing] 1462
E-56 Control box displays [Out of design area] 1463
E-57 Control box can not be turned on 1464
E-58 Control box does not display intelligent Machine Control screen 1465
E-59 Control box does not display bulldozer image 1466
E-60 Control box does not display design surface 1467
E-61 Control box touch panel does not respond 1468
E-62 Control box touch panel is inaccurate 1469
E-63 Cylinder stroke reset indication does not go out 1470
E-64 AUTO is not displayed when Auto/manual switch is pressed (AUTO indication goes out) 1471
E-65 Blade automatic lower control does not start while AUTO is displayed 1472
E-66 Blade automatic raise control does not start while AUTO is displayed 1473
E-67 Blade automatic control function is not activated while AUTO is displayed (Blade automatic control stops) 1474
E-68 When checking and adjusting the blade elevation, the value is different from actual machine 1475
E-69 Finished surface is inaccurate (The average height of finished surface is lower than designed surface or blade does not touch the surface) 1476
E-70 Finished surface is inaccurate (The finished surface is not smooth) 1477
E-71 Finished surface is inaccurate (When finishing slope horizontally, steps are made in each direction) 1478
E-72 Machine can not escape from shoes slip while blade automatic control is activated (Shoes frequently slips) 1480
E-73 Machine speed does not increase while blade automatic control is activated 1481
E-74 Blade tilt angle does not coincide with design surface 1482
E-75 Blade tilts back while blade automatic control is activated 1484
E-76 When pressing cut/fill level switch (RAISE), the design surface does not rise 1486
E-77 When pressing cut/fill level switch (LOWER), the design surface does not lower 1488
E-78 When starting switch is turned to ON position, reverse leveling mode switch LED does not light up or does not go out 1490
E-79 When reverse leveling mode switch is pressed, buzzer does not sound (does not switch to reverse leveling mode) 1492
Troubleshooting of hydraulic and mechanical system (H-mode) 1494
Information described in troubleshooting table (H-mode) 1494
System chart of hydraulic and mechanical systems 1495
Failure mode and cause table 1497
H-1 Neither RH nor LH of tracks does not travel forward nor reverse (None of the travel system operates) 1501
H-2 Either RH or LH of track does not travel forward nor reverse (Only RH or LH of travel system operates) 1503
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) 1504
H-4 Travel speed or power is low 1506
H-5 Travel speed range does not change 1507
H-6 Shock is large when machine starts or stops 1508
H-7 Machine deviates largely 1509
H-8 Machine drift on a slope is large 1511
H-9 Engine stalls during travel or engine speed drops significantly 1512
H-10 Unusual noise is heard from around HST pump or motor 1513
H-11 All work equipment do not operate 1514
H-12 All work equipment operates slowly or lacks power 1516
H-13 Blade lift speed or power is low 1517
H-14 Blade tilt speed or power is low 1518
H-15 Blade angle speed or power is low 1519
H-16 Time lag of blade lift is large 1520
H-17 Hydraulic drift of lifted blade is large 1521
H-18 Hydraulic drift of tilted blade is large 1522
H-19 Unusual noise is heard from around work equipment pump or control valve 1523
H-20 HST oil temperature (hydraulic oil temperature) rises too high 1524
H-21 Fans speed is abnormal (high, low, or no rotation) 1526
H-22 Unusual noise is heard from around fan 1528
Troubleshooting of engine (S-mode) 1529
Information described in troubleshooting table (S mode) 1529
S-1 Engine does not crank when starting switch is turned to START position 1530
S-2 Engine cranks but no exhaust smoke comes out 1531
S-3 Fuel is being injected but engine does not start (misfiring: engine cranks but does not start) 1532
S-4 Engine startability is poor 1533
S-5 Engine does not pick up smoothly 1535
S-6 Engine stops during operation 1537
S-7 Engine runs rough or is unstable 1539
S-8 Engine lacks power 1540
S-9 KDPF gets clogged in a short time 1542
S-10 Engine oil consumption is excessive 1544
S-11 Engine oil becomes contaminated early 1545
S-12 Fuel consumption is excessive 1546
S-13 Oil is in coolant (or coolant spurts or coolant level goes down) 1547
S-14 Oil pressure drops 1548
S-15 Fuel mixes into engine oil 1549
S-16 Water mixes into engine oil (milky) 1550
S-17 Coolant temperature rises too high (overheating) 1551
S-18 Unusual noise is heard 1552
S-19 Vibration is excessive 1553
S-20 Air cannot be bled from fuel circuit 1554
S-21 Active regeneration is executed frequently 1555
S-22 Active regeneration takes time 1556
S-23 White smoke is exhausted during active regeneration 1557
50 Disassembly and assembly 1559
Table of contents 1560
Related information on disassembly and assembly 1562
How to read this manual 1562
Coating materials list 1564
Special tools list 1568
Sketches of special tools 1574
Engine and cooling system 1588
Removal and installation of supply pump assembly 1588
Removal and installation of fuel injector assembly 1593
Removal and installation of cylinder head assembly 1601
Removal and installation of radiator assembly 1617
Removal and installation of aftercooler assembly 1621
Removal and installation of hydraulic oil cooler assembly 1624
Removal and installation of cooling fan drive assembly 1627
Removal and installation of cooling fan motor assembly 1630
Removal and installation of engine assembly 1632
Disassembly and assembly of damper assembly 1639
Removal and installation of engine front oil seal 1640
Removal and installation of engine rear oil seal 1642
Removal and installation of engine hood assembly 1645
Removal and installation of fuel tank assembly 1648
Removal and installation of KDPF assembly 1652
Disassembly and assembly of KDPF assembly 1655
Removal and installation of KCCV assembly 1664
Removal and installation of KVGT assembly 1665
Removal and installation of EGR (Exhaust Gas Recirculation) cooler assembly 1668
Removal and installation of EGR (Exhaust Gas Recirculation) valve assembly 1671
Removal and installation of belt for alternator and air conditioner compressor 1672
Removal and installation of air cleaner assembly 1673
Power train 1675
Removal and installation of HST pump assembly 1675
Removal and installation of HST motor and final drive assembly 1677
Disassembly and assembly of final drive 1680
Undercarriage and frame 1690
Removal and installation of track frame assembly 1690
Removal and installation of idler assembly 1694
Disassembly and assembly of idler 1696
Removal and installation of recoil spring assembly 1700
Disassembly and assembly of recoil spring 1701
Removal and installation of track roller assembly 1705
Disassembly and assembly of track roller assembly 1707
Removal and installation of carrier roller assembly 1710
Disassembly and assembly of carrier roller assembly 1712
Removal and installation of segment teeth 1714
Separation and connection of track shoe assembly (Standard type track shoe) 1715
Separation and connection of track shoe assembly (PLUS type track shoe) 1718
Overall disassembly and assembly of track shoe assembly (Standard type track shoe) 1719
Overall disassembly and assembly of track shoe assembly (PLUS type track shoe) 1735
Disassembly and assembly of one track link assembly in field (Standard type track shoe) 1742
Disassembly and assembly of one track link assembly in field (PLUS type track shoe) 1748
Removal and installation of pivot shaft assembly 1753
Removal and installation of equalizer bar assembly 1755
Removal and installation of equalizer bar side bushing 1757
Hydraulic system 1758
Removal and installation of hydraulic tank assembly 1758
Removal and installation of control valve assembly 1762
Disassembly and assembly of hydraulic cylinder assembly 1765
Work equipment 1773
Removal and installation of work equipment assembly 1773
Removal and installation of blade assembly 1775
Removal and installation of U-frame assembly 1778
Cab and its attachments 1781
Removal and installation of ROPS cab assembly 1781
Removal and installation of operator’s cab glass (adhesion glass) 1786
Removal and installation of operator’s seat 1792
Removal and installation of seat belt 1793
Removal and installation of foot heater assembly 1794
Disassembly and assembly of foot heater assembly 1796
Removal and installation of air conditioner unit assembly 1797
Removal and installation of air conditioner compressor assembly 1801
Electrical system 1803
Removal and installation of machine monitor assembly 1803
Removal and installation of engine controller assembly 1804
Removal and installation of HST controller assembly 1806
Removal and installation of mass air flow and temperature sensor 1807
Removal and installation of KOMTRAX terminal 1808
Removal and installation of ICT sensor controller assembly 1809
Removal and installation of control box 1810
Removal and installation of GNSS receiver 1811
Removal and installation of GNSS antenna 1812
Removal and installation of IMU sensor 1815
60 Maintenance standard 1817
Table of contents 1818
Engine and cooling system 1819
Engine mount 1819
Cooling fan motor 1820
Oil cooler bypass and HST charge safety valve 1822
Power train 1823
Damper 1823
HST pump 1824
HST motor 1826
Charge pump 1827
Solenoid valve 1828
Final drive 1829
Sprocket 1830
Full-scale drawing of sprocket tooth profile 1831
Undercarriage and frame 1833
Suspension 1833
Track frame and idler cushion 1835
Idler 1837
Track roller 1839
Carrier roller 1843
Track shoe 1845
Hydraulic system 1851
Hydraulic tank 1851
Work equipment and cooling fan pump 1852
Control valve 1855
Ripper PPC valve 1862
Quick drop valve 1864
Angle control EPC valve 1866
Work equipment 1867
Blade 1867
Cutting edge and end bit 1870
Ripper 1871
Lift cylinder 1873
Lift cylinder with stroke and reset sensor 1874
Tilt cylinder with stroke sensor 1875
Angle cylinder 1876
Angle cylinder with stroke and reset sensor 1877
Ripper cylinder 1878
Cab and its attachments 1879
Cab mount 1879
Electrical system 1880
System component parts 1880
Sensor 1881
80 Appendix 1885
Table of contents 1886
Air conditioner components 1887
Precautions for refrigerant 1887
Air conditioner component 1888
Configuration and function of refrigeration cycle 1891
Outline of refrigeration cycle 1892
Air conditioner unit 1894
Dual pressure switch 1898
Pressure switch 1899
Compressor 1900
Condenser 1901
Receiver drier 1903
Procedure for testing and troubleshooting 1904
Electrical circuit diagram 1907
System diagram 1908
Parts and connectors layout 1910
Testing relays 1915
Troubleshooting chart 1 1917
Troubleshooting chart 2 1918
Information described in troubleshooting table 1920
A-1 Troubleshooting for condenser fan 1921
A-2 Troubleshooting for compressor and refrigerant system (Air is not cooled) 1924
A-3 Troubleshooting for blower motor system (No air comes out or air flow is abnormal) 1928
A-4 Troubleshooting for temperature control 1930
Troubleshooting with gauge pressure 1933
Connection of service tool 1936
Precautions for disconnecting and connecting hoses and tubes in air conditioner circuit 1938
Handling of compressor oil 1940
90 Diagrams and drawings 1943
Table of contents 1944
Hydraulic circuit diagram 1945
Symbols in hydraulic circuit diagram 1945
Hydraulic circuit diagram1949
Electric circuit diagram 1950
Symbols in electric circuit diagram 1950
Electrical circuit diagram1954
INDEX1966

IMAGES PREVIEW OF THE MANUAL:

S.M 26/12/24