Komatsu BULLDOZER D61EXi -23 D61PXi-23 Shop Manual SEN06256-12 PDF

Description

Komatsu BULLDOZER D61EXi -23 D61PXi-23 Shop Manual SEN06256-12 – PDF DOWNLOAD

FILE DETAILS:

Komatsu BULLDOZER D61EXi -23 D61PXi-23 Shop Manual SEN06256-12 – PDF DOWNLOAD

Language : English
Pages :2022
Downloadable : Yes
File Type : PDF

DESCRIPTION:

Komatsu BULLDOZER D61EXi -23 D61PXi-23 Shop Manual SEN06256-12 – PDF DOWNLOAD

SERIAL NUMBERS D61EXi-30324
D61PXi-30324 and up

General precautions

Inappropriate handling causes an extreme danger. Read and understand what is described in the operation and maintenance manual before operating the machine. Read and understand what is described in this manual before starting the work.

• Before performing any greasing or repairs, read all the safety labels stuck to the machine. For the locations of the safety labels and detailed explanation of precautions, see the operation and maintenance manual.
• Locate a place in the repair workshop to keep the tools and removed parts. Always keep the tools and parts in their correct places. Always keep the work area clean and make sure that there is no dirt, water or oil on the floor. Smoke only in the areas provided for smoking. Never smoke while working.
• When performing any work, always wear the safety shoes and helmet. Do not wear loose work cloths, or clothes with buttons missing. 1. Always wear the protective eyeglasses when hitting parts with a hammer. 2. Always wear the protective eyeglasses when grinding parts with a grinder, etc.
• When performing any work with 2 or more workers, always agree on the working procedure before starting. While working, always keep conversations of the work between your fellow workers and your self on any step of the work. During the work, hang the warning tag of “UNDER WORKING” in the operator’s compartment
• Only the approved personnel can do the work in a closed environment or in a prohibited area.
• Only qualified workers must perform the work and operation which require license or qualification.
• Keep the tools in good condition. And learn the correct way to use the tools, and use the proper ones among them. Before starting the work, thoroughly check the tools, lift truck, service vehicle, etc.
• If welding repairs is required, always have a trained and experienced welder with good knowledge of welding perform the work. When performing welding work, always wear welding gloves, apron, shielding goggles, cap, etc.
• Before starting work, warm up your body thoroughly to start work under good condition. • Avoid continuing work for long hours and take rests with proper intervals to keep your body in good condition. Take a rest in a specified safe place.
• When you work in high places, use a platform.
• Before you start the work, use the personal fallarrest equipment to prevent falling. There is a danger of personal accident that you fall by slipping.
• Always do the work correctly. If you find the unsafe behavior of co-worker, give him/her a notice and stop it.
• Because there is a danger that you are caught, be very careful when the work is done in dangerous areas such as: when you go in the range where the lifted load possibly falls, or when you stand directly in front of tire, or when you are near the sliding parts
• When you handle chemical materials (such as nitrogen gas), see the MSDS (safety data sheet) and local guidelines, and get the important information (such as a safe handling method). Also, put on applicable protective equipment (such as protective goggles, gloves, and masks). •
• If necessary, cut out all the power sources (electricity, oil pressure, compressed air, etc.) before you start the work. If the machine has a lock mechanism, set it to the LOCK position and install the warning tag in a position where it is easy to see. Do not release the lock until the work is completed.

TABLE OF CONTENTS:

Komatsu BULLDOZER D61EXi -23 D61PXi-23 Shop Manual SEN06256-12 – 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
Precautions before work 406
Related information on testing and adjusting 408
Tools for testing and adjusting 408
Sketch of tools for testing and adjusting 413
Engine and cooling system 420
Testing engine speed 420
Testing boost pressure 422
Testing exhaust gas color 424
Testing mass air flow and temperature sensor 426
Testing and adjusting valve clearance 428
Testing compression pressure 431
Testing blowby pressure 435
Testing engine oil pressure 437
Testing EGR valve and KVGT oil pressures 438
Testing fuel pressure 439
Testing fuel discharge, return and leakage 444
Bleeding air from fuel system 449
Testing fuel circuit for leakage 451
Handling cylinder cutout mode operation 452
Handling no-injection cranking operation 453
Testing of KDPF and muffler stack for looseness and damage 454
Testing of installed condition of cylinder heads and manifolds 455
Testing engine piping for damage and looseness 456
Check alternator belt, replace 457
Check auto-tensioner, replace 459
Writing compensation amount for soot accumulation caused by ash on engine controller 461
Power train 463
Testing and adjusting HST oil pressure 463
Testing output pressure of solenoid valve 468
Testing if machine travels straight 472
Simple test procedure for brake performance 473
Adjusting deceleration/brake pedal 474
Adjusting parking brake lever 477
Move disabled machine urgently 479
Undercarriage and frame 482
Adjusting idler clearance 482
Checking sprocket wear 483
Testing and adjusting track tension 484
Hydraulic system 485
Releasing remaining pressure in work equipment cylinder 485
Testing and adjusting work equipment oil pressure 486
Testing source pressure of control circuit 488
Testing outlet pressure of work equipment EPC valve and fan EPC valve 489
Isolating the parts causing hydraulic drift in blade and ripper 491
Testing internal oil leakage of work equipment cylinder 492
Testing fan speed 494
Testing fan circuit oil pressure 495
Bleeding air from hydraulic circuit 496
Work equipment 497
Adjusting work equipment lock lever 497
Adjusting play of blade center ball 499
Testing and adjusting play of blade electric lever 500
Electrical system 508
Special functions of machine monitor 508
Special functions of control box 592
Testing stroke sensor for lift cylinder 627
Testing stroke sensor for tilt cylinder 629
Testing stroke sensor for angle cylinder 630
Testing and adjusting reset sensor for lift cylinder 631
Testing and adjusting reset sensor for angle cylinder 632
Adjustment method when HST controller has been replaced 633
Adjustment method when ICT sensor controller has been replaced 636
Adjustment method when devices have been repaired or replaced 639
KOMTRAX terminal start-up procedure 641
Adjusting rearview camera angle 644
Handling voltage circuit of engine controller 645
Handling battery disconnect switch 646
Testing diodes 647
Pm clinic 648
Pm Clinic service 648
40 Troubleshooting 657
Table of contents 658
Precautions before work 667
Related information on troubleshooting 669
Troubleshooting points 669
Sequence of events in troubleshooting 671
Checks before troubleshooting 673
Inspection procedure before troubleshooting 675
Preparation for troubleshooting of electrical system 692
Classification and procedures for troubleshooting 696
Symptom and troubleshooting numbers 698
Information in troubleshooting table 702
Procedure for troubleshooting wiring harness of pressure sensor system for open circuit 704
Connector list and layout 707
Connector contact identification 721
T-branch box and T-branch adapter table 760
Fuse location table 765
Precautions for KDPF (KCSF and KDOC) Cleaning and Replacement 770
Preparation of dummy temperature sensor (for KDOC and KDPF temperature sensors) 773
Preparation of short circuit electrical connector (for failure codes [CA1883] and [CA3135]) 774
Failure codes table 775
Troubleshooting by failure code (Display of code) 787
Failure code [6091NX] HST Oil Filter Clogging 787
Failure code [989L00] Engine Controller Lock Caution 1 789
Failure code [989M00] Engine Controller Lock Caution 2 790
Failure code [989N00] Engine Controller Lock Caution 3 791
Failure code [A1U0N3] HC Desorb Request 1 792
Failure code [A1U0N4] HC Desorb Request 2 794
Failure code [AA10NX] Air Cleaner Clogging 796
Failure code [AB00KE] Charge Voltage Low 798
Failure code [B@BAZG] Eng Oil Press Low 800
Failure code [B@BCNS] Eng Water Overheat 801
Failure code [B@CRNS] HST Oil Overheat 802
Failure code [B@CRZG] HST Charge Press Low 803
Failure code [CA115] Eng Ne and Bkup Speed Sens Error 804
Failure code [CA122] Chg Air Press Sensor High Error 805
Failure code [CA123] Chg Air Press Sensor Low Error 807
Failure code [CA131] Throttle Sensor High Error 809
Failure code [CA132] Throttle Sensor Low Error 811
Failure code [CA144] Coolant Temp Sens High Error 813
Failure code [CA145] Coolant Temp Sens Low Error 815
Failure code [CA153] Chg Air Temp Sensor High Error 817
Failure code [CA154] Chg Air Temp Sensor Low Error 819
Failure code [CA187] Sensor 2 Supply Volt Low Error 821
Failure code [CA234] Eng Overspeed 823
Failure code [CA221] Ambient Press Sensor High Error 824
Failure code [CA222] Ambient Press Sensor Low Error 826
Failure code [CA227] Sensor 2 Supply Volt High Error 828
Failure code [CA238] Ne Speed Sensor Supply Volt Error 829
Failure code [CA239] Ne Speed Sens Supply Volt High Error 830
Failure code [CA271] IMV/PCV1 Short Error 831
Failure code [CA272] IMV/PCV1 Open Error 833
Failure code [CA295] Ambient Pressure Sensor In Range Error 835
Failure code [CA322] Inj #1(L#1) Open/Short Error 836
Failure code [CA323] Inj #5(L#5) Open/Short Error 838
Failure code [CA324] Inj #3(L#3) Open/Short Error 840
Failure code [CA325] Inj #6(L#6) Open/Short Error 842
Failure code [CA331] Inj #2(L#2) Open/Short Error 844
Failure code [CA332] Inj #4(L#4) Open/Short Error 846
Failure code [CA343] ECM Critical Internal Failure 848
Failure code [CA351] Injectors Drive Circuit Error 849
Failure code [CA352] Sensor 1 Supply Volt Low Error 850
Failure code [CA356] Mass Air Flow Sensor High Error 852
Failure code [CA357] Mass Air Flow Sensor Low Error 854
Failure code [CA386] Sensor 1 Supply Volt High Error 856
Failure code [CA428] Water in Fuel Sensor High Error 857
Failure code [CA429] Water in Fuel Sensor Low Error 859
Failure code [CA435] Eng Oil Press Sw Error 861
Failure code [CA441] Battery Voltage Low Error 862
Failure code [CA442] Battery Voltage High Error 864
Failure code [CA449] Rail Press Very High Error 865
Failure code [CA451] Rail Press Sensor High Error 866
Failure code [CA452] Rail Press Sensor Low Error 868
Failure code [CA488] Chg Air Temp High Torque Derate 870
Failure code [CA515] Rail Press Sens Sup Volt High Error 871
Failure code [CA516] Rail Press Sens Sup Volt Low Error 873
Failure code [CA553] Rail Press High Error 875
Failure code [CA555] Crankcase Press High Error 2 876
Failure code [CA556] Crankcase Press High Error 2 877
Failure code [CA559] Rail Press Low Error 878
Failure code [CA595] Turbo Speed High Error 2 880
Failure code [CA687] Turbo Speed Low Error 881
Failure code [CA689] Eng Ne Speed Sensor Error 883
Failure code [CA691] Intake Air Temp Sens High Error 885
Failure code [CA692] Intake Air Temp Sens Low Error 887
Failure code [CA697] ECM Internal Temp Sensor High Error 889
Failure code [CA698] ECM Int Temp Sensor Low Error 890
Failure code [CA731] Eng Bkup Speed Sens Phase Error 891
Failure code [CA778] Eng Bkup Speed Sensor Error 893
Failure code [CA1117] Persistent Data Lost Error 898
Failure code [CA1664] KDOC Malfunction 899
Failure code [CA1691] Regeneration Ineffective 902
Failure code [CA1695] Sens 5 Supply Volt High Error 905
Failure code [CA1696] Sens 5 Supply Volt Low Error 906
Failure code [CA1843] Crankcase Press Sens High Error 908
Failure code [CA1844] Crankcase Press Sens Low Error 910
Failure code [CA1879] KDPF Delta P Sensor High Error 912
Failure code [CA1881] KDPF Delta P Sensor Low Error 914
Failure code [CA1883] KDPF Delta P Sens In Range Error 916
Failure code [CA1921] KDPF Soot Load High Error 1 920
Failure code [CA1922] KDPF Soot Load High Error 2 923
Failure code [CA1942] Crankcase Press Sens In Range Error 928
Failure code [CA1993] KDPF Delta Pressure Low Error 929
Failure code [CA2185] Throt Sensor Sup Volt High Error 932
Failure code [CA2186] Throt Sensor Sup Volt Low Error 933
Failure code [CA2249] Rail Press Very Low Error 934
Failure code [CA2271] EGR Valve Pos Sens High Error 935
Failure code [CA2272] EGR Valve Pos Sens Low Error 937
Failure code [CA2288] Turbo Speed High Error 1 940
Failure code [CA2311] IMV Solenoid Error 941
Failure code [CA2349] EGR Valve Solenoid Open Error 942
Failure code [CA2353] EGR Valve Solenoid Short Error 944
Failure code [CA2357] EGR Valve Servo Error 946
Failure code [CA2373] Exhaust Manifold Press Sens High error 947
Failure code [CA2374] Exhaust Manifold Press Sens Low error 949
Failure code [CA2375] EGR Orifice Temp Sens High Error 951
Failure code [CA2376] EGR Orifice Temp Sens Low Error 953
Failure code [CA2381] KVGT Pos Sens High Error 955
Failure code [CA2382] KVGT Pos Sens Low Error 957
Failure code [CA2383] KVGT Solenoid Open Error 960
Failure code [CA2386] KVGT Solenoid Short Error 962
Failure code [CA2387] KVGT Servo Error 964
Failure code [CA2554] Exh Manifold Press Sens In Range Error 969
Failure code [CA2555] Grid Htr Relay Volt Low Error 972
Failure code [CA2556] Grid Htr Relay Volt High Error 974
Failure code [CA2637] KDOC Face Plugging 976
Failure code [CA2639] Manual Stationary Regeneration Request 978
Failure code [CA2961] EGR Orifice Temp High Error 1 981
Failure code [CA2973] Chg Air Press Sensor In Range Error 982
Failure code [CA3133] KDPF Outlet Press Sens High Error 983
Failure code [CA3134] KDPF Outlet Press Sens Low Error 985
Failure code [CA3135] KDPF Outlet Press Sens In Range Error 987
Failure code [CA3251] KDOC Inlet Temp High Error 991
Failure code [CA3253] KDOC Temp Error – Non Regeneration 994
Failure code [CA3254] KDOC Outlet Temp High Error 1 998
Failure code [CA3255] KDPF Temp Error – Non Regeneration 1001
Failure code [CA3256] KDPF Outlet Temp High Error 1 1006
Failure code [CA3311] KDOC Outlet Temp High Error 2 1009
Failure code [CA3312] KDPF Outlet Temp High Error 2 1013
Failure code [CA3313] KDOC Inlet Temp Sensor Low Error 1017
Failure code [CA3314] KDOC Inlet Temp Sens High Error 1020
Failure code [CA3315] KDOC Inlet Temp Sens In Range Error 1024
Failure code [CA3316] KDOC Outlet Temp Sens Low Error 1028
Failure code [CA3317] KDOC Outlet Temp Sens High Error 1031
Failure code [CA3318] KDOC Outlet Temp Sens In Range Error 1035
Failure code [CA3319] KDPF Outlet Temp Sens High Error 1039
Failure code [CA3321] KDPF Outlet Temp Sens Low Error 1043
Failure code [CA3322] KDPF Outlet Temp Sens In Range Error 1046
Failure code [CA3419] Mass Air Flow Sensor Sup Volt High Error 1050
Failure code [CA3421] Mass Air Flow Sensor Sup Volt Low Error 1052
Failure code [CA3741] Rail Press Valve Trip Error 1054
Failure code [D130KA] Neutral relay Open 1055
Failure code [D130KB] Neutral relay Short circuit 1057
Failure code [D130KY] Neutral relay: Hot Short 1059
Failure code [D19JKZ] Personal Code Relay Abnormality 1061
Failure code [D811MC] KOMTRAX Error 1064
Failure code [D862KA] GPS Antenna Open Circuit 1065
Failure code [D8ALKA] Operating Lamp Open Circuit (KOMTRAX) 1066
Failure code [D8ALKB] Operating Lamp Short Circuit (KOMTRAX) 1068
Failure code [D8AQKR] CAN2 Discon (KOMTRAX) 1069
Failure code [DAF0MB] Monitor ROM Abnormality 1070
Failure code [DAF0MC] Monitor Error 1071
Failure code [DAF8KB] Camera Power Supply Short Circuit 1072
Failure code [DAF9KQ] Model Selection Abnormality 1073
Failure code [DAFGMC] GPS Module Error 1074
Failure code [DAFLKA] Operating Lamp Open Circuit (Monitor) 1075
Failure code [DAFLKB] Operating Lamp Short Circuit (Monitor) 1077
Failure code [DAFQKR] CAN2 Discon (Monitor) 1078
Failure code [DAJ000] HST controller: Abnormality in controller 1079
Failure code [DAJ0KQ] HST controller: Type select signal 1080
Failure code [DAJ0KT] HST controller: Abnormality in controller 1081
Failure code [DAJ0MC] HST Con Error 1082
Failure code [DAJ1KK] HST controller: Source voltage low 1083
Failure code [DAJ2KK] HST controller: Output voltage low 1085
Failure code [DAJ5KK] HST: Sensor volt 5V (0) Out of normal range 1087
Failure code [DAJ6KK] HST: Sensor volt 5V (1) Out of normal range 1089
Failure code [DAJLKA] Operating Lamp Open Circuit (HST Con) 1091
Failure code [DAJLKB] Operating Lamp Short Circuit (HST Con) 1093
Failure code [DAJPMA] Inconsistency of Option Selection (HST) 1094
Failure code [DAJQKR] CAN2 Discon ( HST Con) 1095
Failure code [DAJRKR] CAN1 Discon ( HST Con) 1096
Failure code [DB2QKR] CAN2 Discon (Engine Con) 1097
Failure code [DB2RKR] CAN1 Discon (Engine Con) 1102
Failure code [DBR0KT] ICT Controller: Abnormality in controller 1107
Failure code [DBR0MC] ICT Con Error 1108
Failure code [DBR1KK] ICT controller: Source voltage low 1109
Failure code [DBR2KK] ICT controller: Output voltage low 1111
Failure code [DBR5KK] ICT: Sensor volt 5V (0) Out of normal range 1113
Failure code [DBRLKA] Operating Lamp Open Circuit (ICT Con) 1115
Failure code [DBRLKB] Operating Lamp Short Circuit (ICT Con) 1117
Failure code [DBRPMA] Inconsistency of Option Selection (ICT) 1118
Failure code [DBRQKR] CAN2 Discon (ICT Con) 1119
Failure code [DBRRKR] CAN1 Discon (ICT Con) 1122
Failure code [DBTSKR] LAN Discon (iB Monitor) 1123
Failure code [DBUTKA] GNSS Antenna Open Circuit 1125
Failure code [DD12KA] Shift up SW: Open 1126
Failure code [DD12KB] Shift up SW: Short Circuit 1128
Failure code [DD13KA] Shift down SW: Open 1130
Failure code [DD13KB] Shift down SW: Short Circuit 1132
Failure code [DD14KA] Parking lever SW: Open 1134
Failure code [DD14KB] Parking lever SW: Short circuit 1136
Failure code [DDKAKA] Blade float Sw: Open 1138
Failure code [DDKAKB] Blade float Sw: Short circuit 1140
Failure code [DDKFL4] Left Angle Sw: Signal mismatch 1142
Failure code [DDKGL4] Right Angle Sw: Signal mismatch 1144
Failure code [DDKHKA] iB Sw: Open 1146
Failure code [DDKHKB] iB Sw: Short circuit 1148
Failure code [DDNLKA] Weq lock Sw: Open 1150
Failure code [DDNLKB] Weq lock Sw: Short circuit 1152
Failure code [DDP6KA] Brake Pressure Sensor: Open 1154
Failure code [DDP6KB] Brake Pressure Sensor: Hot Short 1156
Failure code [DDP6MA] Brake pressure sensor: Malfunction 1158
Failure code [DDU1FS] Parking lever Switch 2: Signal mismatch 1160
Failure code [DDU1KA] Parking lever Sw2: Open 1162
Failure code [DDU1KY] Parking lever Sw2: Hot Short 1164
Failure code [DFA4KX] Blade lift lever: Main and Sub Error 1166
Failure code [DFA4KZ] Blade lift lever: Main and Sub Error 1167
Failure code [DFA4L8] Blade lift lever: Signal mismatch 1168
Failure code [DFA5KA] Blade lift lever1: Open 1169
Failure code [DFA5KB] Blade lift lever1: Hot Short 1172
Failure code [DFA6KA] Blade lift lever2: Open 1174
Failure code [DFA6KB] Blade lift lever2: Hot Short 1176
Failure code [DFA7KX] Blade tilt lever: Main and Sub Error 1178
Failure code [DFA7KZ] Blade tilt lever: Main and Sub Error 1179
Failure code [DFA7L8] Blade tilt lever: Signal mismatch 1180
Failure code [DFA8KA] Blade tilt lever1: Open 1181
Failure code [DFA8KB] Blade tilt lever1: Hot Short 1184
Failure code [DFA9KA] Blade tilt lever2: Open 1186
Failure code [DFA9KB] Blade tilt lever2: Hot Short 1189
Failure code [DGS1KA] HST oil temp sensor: Open 1191
Failure code [DGS1KX] HST oil temp sensor: Out of normal range 1193
Failure code [DH21KA] Weq pressure sensor: Open 1194
Failure code [DH21KB] Weq pressure sensor: Hot Short 1196
Failure code [DHA4KA] Air Cleaner Clog Sensor Open Circuit 1198
Failure code [DHH7KA] LF HST Pressure Sensor: Open 1200
Failure code [DHH7KB] LF HST Pressure Sensor: Hot Short 1202
Failure code [DHH8KA] RF HST Pressure Sensor: Open 1204
Failure code [DHH8KB] RF HST Pressure Sensor: Hot Short 1206
Failure code [DHH9KA] LR HST Pressure Sensor: Open 1208
Failure code [DHH9KB] LR HST Pressure Sensor: Hot Short 1210
Failure code [DHHAKA] RR HST Pressure Sensor: Open 1212
Failure code [DHHAKB] RR HST Pressure Sensor: Hot Short 1214
Failure code [DK30KA] ST lever1: Open 1216
Failure code [DK30KB] ST lever1: Hot Short 1218
Failure code [DK30KX] ST lever: Main and Sub Error 1220
Failure code [DK30KZ] ST lever: Main and Sub Error 1221
Failure code [DK30L8] ST lever: Signal mismatch 1222
Failure code [DK31KA] ST lever2: Open 1223
Failure code [DK31KB] ST lever2: Hot Short 1225
Failure code [DK40KA] Decel/Brake potentiometer: Open 1227
Failure code [DK40KB] Decel/Brake potentiometer: Hot Short 1230
Failure code [DK55KX] FR lever: Main and Sub Error 1232
Failure code [DK55KZ] FR lever: Main and Sub Error 1233
Failure code [DK55L8] FR lever: Signal mismatch 1234
Failure code [DK56KA] FR lever1: Open 1235
Failure code [DK56KB] FR lever1: Hot Short 1237
Failure code [DK57KA] FR lever2: Open 1239
Failure code [DK57KB] FR lever2: Hot Short 1241
Failure code [DK80KA] IMU Sensor: Open 1243
Failure code [DKS0L8] Blade lift Stroke sensor: Signal mismatch 1245
Failure code [DKS1KA] Blade lift Stroke sensor A: Open 1246
Failure code [DKS1KB] Blade lift Stroke sensor A: Hot Short 1248
Failure code [DKS2KA] Blade lift Stroke sensor B: Open 1250
Failure code [DKS2KB] Blade lift Stroke sensor B: Hot Short 1252
Failure code [DKS3KA] Blade lift Reset sensor: Open 1254
Failure code [DKS3KB] Blade lift Reset sensor: Hot Short 1256
Failure code [DKS3MB] Blade lift Reset sensor: Signal mismatch 1258
Failure code [DKS4L8] Blade tilt Stroke sensor: Signal mismatch 1259
Failure code [DKS5KA] Blade tilt Stroke sensor A: Open 1260
Failure code [DKS5KB] Blade tilt Stroke sensor A: Hot Short 1262
Failure code [DKS6KA] Blade tilt Stroke sensor B: Open 1264
Failure code [DKS6KB] Blade tilt Stroke sensor B: Hot Short 1266
Failure code [DKS7MB] Blade tilt Reset sensor: Signal mismatch 1268
Failure code [DKSCL8] Angle left Stroke sensor: Signal mismatch 1269
Failure code [DKSDKA] Angle left Stroke sensor A: Open 1270
Failure code [DKSDKB] Angle left Stroke sensor A: Hot Short 1272
Failure code [DKSEKA] Angle left Stroke sensor B: Open 1274
Failure code [DKSEKB] Angle left Stroke sensor B: Hot Short 1276
Failure code [DKSFKA] Angle left Reset sensor: Open 1278
Failure code [DKSFKB] Angle left Reset sensor: Hot Short 1280
Failure code [DKSFMB] Angle left Reset sensor: Signal mismatch 1282
Failure code [DLM0KX] HST Motor Speed Sensor: Left/Right Error 1283
Failure code [DLM0MA] HST motor speed sensor: Malfunction 1284
Failure code [DLM1KA] Left HST motor speed sensor: Open 1285
Failure code [DLM1KB] Left HST motor speed sensor: Short circuit 1287
Failure code [DLM1MA] Left HST motor speed sensor: Malfunction 1289
Failure code [DLM2KA] Right HST motor speed sensor: Open 1290
Failure code [DLM2KB] Right HST motor speed sensor: Short circuit 1292
Failure code [DLM2MA] Right HST motor speed sensor: Malfunction 1294
Failure code [DLM3KA] Fan rev sensor: Open 1295
Failure code [DLM3KB] Fan rev sensor: Short circuit 1297
Failure code [DLM3MB] Fan control: Mismatch 1299
Failure code [DN21FS] Decel/Brake pedal SW: Signal mismatch 1300
Failure code [DR21KX] Camera 2 Picture Rev Drive Abnormality 1302
Failure code [DR31KX] Camera 3 Picture Rev Drive Abnormality 1303
Failure code [DV20KB] Back-up alarm: Short circuit 1304
Failure code [DW4BKA] Parking brake solenoid: Open 1306
Failure code [DW4BKB] Parking brake solenoid: Short circuit 1308
Failure code [DW4BKY] Parking brake solenoid: Hot Short 1310
Failure code [DW7BKA] Fan reverse solenoid: Open 1312
Failure code [DW7BKB] Fan reverse solenoid: Short circuit 1314
Failure code [DW7EKA] Slow brake solenoid: Open 1315
Failure code [DW7EKB] Slow brake solenoid: Short circuit 1317
Failure code [DW7EKY] Slow brake solenoid: Hot Short 1319
Failure code [DWN5KA] Fan EPC: Open 1321
Failure code [DWN5KB] Fan EPC: Short circuit 1323
Failure code [DWN5KY] Fan EPC: Hot Short 1324
Failure code [DXA4KA] LF HST pump EPC: Open 1326
Failure code [DXA4KB] LF HST pump EPC: Short circuit 1328
Failure code [DXA4KY] LF HST pump EPC: Hot Short 1329
Failure code [DXA5KA] LR HST pump EPC: Open 1331
Failure code [DXA5KB] LR HST pump EPC: Short circuit 1333
Failure code [DXA5KY] LR HST pump EPC: Hot Short 1335
Failure code [DXA6KA] RF HST pump EPC: Open 1337
Failure code [DXA6KB] RF HST pump EPC: Short circuit 1339
Failure code [DXA6KY] RF HST pump EPC: Hot Short 1340
Failure code [DXA7KA] RR HST pump EPC: Open 1342
Failure code [DXA7KB] RR HST pump EPC: Short circuit 1344
Failure code [DXA7KY] RR HST pump EPC: Hot Short 1345
Failure code [DXHRKA] Blade lift up EPC: Open 1347
Failure code [DXHRKB] Blade lift up EPC: Short circuit 1349
Failure code [DXHRKY] Blade lift up EPC: Hot short 1350
Failure code [DXHSKA] Blade lift down EPC: Open 1352
Failure code [DXHSKB] Blade lift down EPC: Short circuit 1354
Failure code [DXHSKY] Blade lift down EPC: Hot short 1355
Failure code [DXHTKA] Blade tilt left EPC: Open 1357
Failure code [DXHTKB] Blade tilt left EPC: Short circuit 1359
Failure code [DXHTKY] Blade tilt left EPC: Hot short 1360
Failure code [DXHUKA] Blade tilt right EPC: Open 1362
Failure code [DXHUKB] Blade tilt right EPC: Short circuit 1364
Failure code [DXHUKY] Blade tilt right EPC: Hot short 1365
Failure code [DXJ4KA] Weq lock Sol: Open 1367
Failure code [DXJ4KB] Weq lock Sol: Short circuit 1369
Failure code [DXJCKA] Blade angle left EPC: Open 1371
Failure code [DXJCKB] Blade angle left EPC: Short circuit 1372
Failure code [DXJCKY] Blade angle left EPC: Hot short 1373
Failure code [DXJDKA] Blade angle right EPC: Open 1375
Failure code [DXJDKB] Blade angle right EPC: Short circuit 1376
Failure code [DXJDKY] Blade angle right EPC: Hot short 1377
Failure code [DXK1KA] Left HST motor EPC: Open 1379
Failure code [DXK1KB] Left HST motor EPC: Short circuit 1381
Failure code [DXK1KY] Left HST motor EPC: Hot Short 1382
Failure code [DXK2KA] Right HST motor EPC: Open 1384
Failure code [DXK2KB] Right HST motor EPC: Short circuit 1386
Failure code [DXK2KY] Right HST motor EPC: Hot Short 1387
Troubleshooting of electrical system (E-mode) 1389
E-1 Engine does not start (Engine does not crank) 1389
E-2 Manual preheating system does not work 1395
E-3 Automatic preheating system does not work 1398
E-4 While preheating is working, preheating monitor does not light up 1400
E-5 When starting switch is turned to ON position, machine monitor displays nothing 1402
E-6 When starting switch is turned to ON position (with engine stopped), basic check monitor lights up 1405
E-7 Air cleaner clogging monitor lights up in yellow while engine is running 1406
E-8 Charge level monitor lights up in red while engine is running 1407
E-9 Engine coolant temperature monitor lights up in red while engine is running 1408
E-10 Engine oil pressure monitor lights up in red while engine is running 1409
E-11 HST charge pressure monitor lights up in red while engine is running 1410
E-12 Hydraulic oil temperature monitor lights up in red while engine is running 1411
E-13 HST oil filter clogging monitor lights up in red while engine is running 1412
E-14 Fuel level gauge does not indicate correct level 1413
E-15 Engine coolant temperature gauge does not indicate correct temperature 1416
E-16 Hydraulic oil temperature gauge does not indicate correct temperature 1417
E-17 Operation mode does not change 1418
E-18 Service mode cannot be selected 1419
E-19 Operating customize switch does not display customize screen 1420
E-20 Modifying setting on customize screen does not change setting of machine 1421
E-21 Service meter is not displayed, while starting switch is in OFF position 1422
E-22 Work equipment does not operate 1423
E-23 Foot heater does not operate 1425
E-24 Horn does not sound 1430
E-25 Horn does not stop sounding 1432
E-26 Backup alarm does not sound 1433
E-27 Backup alarm does not stop sounding 1434
E-28 Headlamp does not light up 1435
E-29 Rear lamp does not light up 1438
E-30 No wiper operates continuously or intermittently 1441
E-31 Front wiper does not operate 1443
E-32 Rear wiper does not operate 1445
E-33 Left door wiper does not operate (failed in both continuous and intermittent operations) 1447
E-34 Right door wiper does not operate (failed in both continuous and intermittent operations) 1451
E-35 Front washer does not operate 1455
E-36 Rear washer does not operate 1457
E-37 Left door washer does not operate 1459
E-38 Right door washer does not operate 1461
E-39 KOMTRAX system does not operate normally 1463
E-40 Control box shuts down after displaying the messages [GPS receiver not connected!] and [Slope sensor not connected!] 1465
E-41 Control box displays the messages [GPS receiver not connected!] and [Slope sensor not connected!] 1469
E-42 Control box displays the message [Waiting for radio link] 1472
E-43 Control box displays the message [IMU sensor not connected] 1473
E-44 Control box displays the message [Waiting for satellites] 1474
E-45 Control box displays the message [Komatsu controller not connected!] 1475
E-46 Control box displays the message [Cylinder Stroke Reading Abnormal] 1477
E-47 Control box displays the message [Komatsu CAN Comms Abnormal] 1478
E-48 Control box displays the message [Komatsu Machine Trouble] 1479
E-49 Control box displays the message [Waiting to initialize] 1480
E-50 Control box displays the message [System Initializing] 1481
E-51 Control box displays the message [Initializing] 1482
E-52 Control box displays the message [Configuring GPS] 1483
E-53 Control box displays the message [No GPS Localization] 1484
E-54 Control box displays the message [Low precisions] 1485
E-55 Control box displays the message [Heading Initializing] 1486
E-56 Control box displays [Out of design area] 1487
E-57 Control box can not be turned on 1488
E-58 Control box does not display intelligent Machine Control screen 1489
E-59 Control box does not display bulldozer image 1490
E-60 Control box does not display design surface 1491
E-61 Control box touch panel does not respond 1492
E-62 Control box touch panel is inaccurate 1493
E-63 Cylinder stroke reset indication does not go out 1494
E-64 AUTO is not displayed when Auto/manual switch is pressed (AUTO indication goes out) 1495
E-65 Blade automatic lower control does not start while AUTO is displayed 1496
E-66 Blade automatic raise control does not start while AUTO is displayed 1497
E-67 Blade automatic control function is not activated while AUTO is displayed (Blade automatic control stops) 1498
E-68 When checking and adjusting the blade elevation, the value is different from actual machine 1499
E-69 Finished surface is inaccurate (The average height of finished surface is lower than designed surface or blade does not touch the surface) 1500
E-70 Finished surface is inaccurate (The finished surface is not smooth) 1501
E-71 Finished surface is inaccurate (When finishing slope horizontally, steps are made in each direction) 1502
E-72 Machine can not escape from shoes slip while blade automatic control is activated (Shoes frequently slips) 1504
E-73 Machine speed does not increase while blade automatic control is activated 1505
E-74 Blade tilt angle does not coincide with design surface 1506
E-75 Blade tilts back while blade automatic control is activated 1508
E-76 When pressing cut/fill level switch (RAISE), the design surface does not rise 1510
E-77 When pressing cut/fill level switch (LOWER), the design surface does not lower 1512
E-78 When starting switch is turned to ON position, reverse leveling mode switch LED does not light up or does not go out 1514
E-79 When reverse leveling mode switch is pressed, buzzer does not sound (does not switch to reverse leveling mode) 1516
Troubleshooting of hydraulic and mechanical system (H-mode) 1518
Information described in troubleshooting table (H-mode) 1518
System chart of hydraulic and mechanical systems 1519
Failure mode and cause table 1521
H-1 Neither RH nor LH of tracks does not travel forward nor reverse (None of the travel system operates) 1525
H-2 Either RH or LH of track does not travel forward nor reverse (Only RH or LH of travel system operates) 1527
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) 1528
H-4 Travel speed or power is low 1530
H-5 Travel speed range does not change 1531
H-6 Shock is large when machine starts or stops 1532
H-7 Machine deviates largely 1533
H-8 Machine drift on a slope is large 1535
H-9 Engine stalls during travel or engine speed drops significantly 1536
H-10 Unusual noise is heard from around HST pump or motor 1537
H-11 All work equipment do not operate 1538
H-12 All work equipment operates slowly or lacks power 1540
H-13 Blade lift speed or power is low 1541
H-14 Blade tilt speed or power is low 1542
H-15 Blade angle speed or power is low 1543
H-16 Time lag of blade lift is large 1544
H-17 Hydraulic drift of lifted blade is large 1545
H-18 Hydraulic drift of tilted blade is large 1546
H-19 Unusual noise is heard from around work equipment pump or control valve 1547
H-20 HST oil temperature (hydraulic oil temperature) rises too high 1548
H-21 Fans speed is abnormal (high, low, or no rotation) 1550
H-22 Unusual noise is heard from around fan 1552
Troubleshooting of engine (S-mode) 1553
Information described in troubleshooting table (S mode) 1553
S-1 Engine does not crank when starting switch is turned to START position 1554
S-2 Engine cranks but no exhaust smoke comes out 1555
S-3 Fuel is being injected but engine does not start (misfiring: engine cranks but does not start) 1556
S-4 Engine startability is poor 1557
S-5 Engine does not pick up smoothly 1559
S-6 Engine stops during operation 1561
S-7 Engine runs rough or is unstable 1563
S-8 Engine lacks power 1564
S-9 KDPF gets clogged in a short time 1566
S-10 Engine oil consumption is excessive 1568
S-11 Engine oil becomes contaminated early 1569
S-12 Fuel consumption is excessive 1570
S-13 Oil is in coolant (or coolant spurts or coolant level goes down) 1571
S-14 Oil pressure drops 1572
S-15 Fuel mixes into engine oil 1573
S-16 Water mixes into engine oil (milky) 1574
S-17 Coolant temperature rises too high (overheating) 1575
S-18 Unusual noise is heard 1576
S-19 Vibration is excessive 1577
S-20 Air cannot be bled from fuel circuit 1578
S-21 Active regeneration is executed frequently 1579
S-22 Active regeneration takes time 1580
S-23 White smoke is exhausted during active regeneration 1581
50 Disassembly and assembly 1583
Table of contents 1584
Precautions before work1586
Related information on disassembly and assembly 1588
How to read this manual 1588
Coating materials list 1590
Special tools list 1594
Sketches of special tools 1600
Engine and cooling system 1614
Removal and installation of supply pump assembly 1614
Removal and installation of fuel injector assembly 1619
Removal and installation of cylinder head assembly 1627
Removal and installation of radiator assembly 1644
Removal and installation of aftercooler assembly 1648
Removal and installation of hydraulic oil cooler assembly 1651
Removal and installation of cooling fan drive assembly 1654
Removal and installation of cooling fan motor assembly 1657
Removal and installation of engine assembly 1659
Disassembly and assembly of damper assembly 1666
Removal and installation of engine front oil seal 1667
Removal and installation of engine rear oil seal 1669
Removal and installation of engine hood assembly 1672
Removal and installation of fuel tank assembly 1675
Removal and installation of KDPF assembly 1679
Disassembly and assembly of KDPF assembly 1682
Removal and installation of KCCV assembly 1691
Removal and installation of KVGT assembly 1692
Removal and installation of EGR (Exhaust Gas Recirculation) cooler assembly 1695
Removal and installation of EGR (Exhaust Gas Recirculation) valve assembly 1698
Removal and installation of belt for alternator and air conditioner compressor 1700
Removal and installation of air cleaner assembly 1701
Power train 1703
Removal and installation of HST pump assembly 1703
Removal and installation of HST motor and final drive assembly 1705
Disassembly and assembly of final drive 1708
Undercarriage and frame 1718
Removal and installation of track frame assembly 1718
Removal and installation of idler assembly 1722
Disassembly and assembly of idler 1724
Removal and installation of recoil spring assembly 1729
Disassembly and assembly of recoil spring 1730
Removal and installation of track roller assembly 1734
Disassembly and assembly of track roller assembly 1736
Removal and installation of carrier roller assembly 1739
Disassembly and assembly of carrier roller assembly 1741
Removal and installation of segment teeth 1743
Separation and connection of track shoe assembly (Standard type track shoe) 1744
Separation and connection of track shoe assembly (PLUS type track shoe) 1748
Overall disassembly and assembly of track shoe assembly (Standard type track shoe) 1749
Overall disassembly and assembly of track shoe assembly (PLUS type track shoe) 1765
Disassembly and assembly of one track link assembly in field (Standard type track shoe) 1772
Disassembly and assembly of one track link assembly in field (PLUS type track shoe) 1778
Removal and installation of pivot shaft assembly 1783
Removal and installation of equalizer bar assembly 1785
Removal and installation of equalizer bar side bushing 1787
Hydraulic system 1788
Removal and installation of hydraulic tank assembly 1788
Removal and installation of control valve assembly 1792
Disassembly and assembly of hydraulic cylinder assembly 1795
Work equipment 1803
Removal and installation of work equipment assembly 1803
Removal and installation of blade assembly 1805
Removal and installation of U-frame assembly 1808
Cab and its attachments 1811
Removal and installation of ROPS cab assembly 1811
Removal and installation of operator’s cab glass (adhesion glass) 1816
Removal and installation of operator’s seat 1822
Removal and installation of seat belt 1823
Removal and installation of foot heater assembly 1824
Disassembly and assembly of foot heater assembly 1826
Removal and installation of air conditioner unit assembly 1827
Removal and installation of air conditioner compressor assembly 1831
Electrical system 1833
Removal and installation of machine monitor assembly 1833
Removal and installation of engine controller assembly 1834
Removal and installation of HST controller assembly 1836
Removal and installation of mass air flow and temperature sensor 1837
Removal and installation of KOMTRAX terminal 1838
Removal and installation of ICT sensor controller assembly 1839
Removal and installation of control box 1840
Removal and installation of GNSS receiver 1841
Removal and installation of GNSS antenna 1842
Removal and installation of IMU sensor 1845
60 Maintenance standard 1847
Table of contents 1848
Engine and cooling system 1849
Engine mount 1849
Cooling fan motor 1850
Oil cooler bypass and HST charge safety valve 1852
Power train 1853
Damper 1853
HST pump 1854
HST motor 1856
Charge pump 1857
Solenoid valve 1858
Final drive 1859
Sprocket 1860
Full-scale drawing of sprocket tooth profile 1861
Undercarriage and frame 1863
Suspension 1863
Track frame and idler cushion 1865
Idler 1867
Track roller 1869
Carrier roller 1873
Track shoe 1875
Hydraulic system 1881
Hydraulic tank 1881
Work equipment and cooling fan pump 1882
Control valve 1885
Ripper PPC valve 1892
Quick drop valve 1894
Angle control EPC valve 1896
Work equipment 1897
Blade 1897
Cutting edge and end bit 1900
Ripper 1901
Lift cylinder 1903
Lift cylinder with stroke and reset sensor 1904
Tilt cylinder with stroke sensor 1905
Angle cylinder 1906
Angle cylinder with stroke and reset sensor 1907
Ripper cylinder 1908
Cab and its attachments 1909
Cab mount 1909
Electrical system 1910
System component parts 1910
Sensor 1911
80 Appendix 1915
Table of contents 1916
Precautions before work1917
Air conditioner components 1919
Precautions for refrigerant 1919
Air conditioner component 1920
Configuration and function of refrigeration cycle 1923
Outline of refrigeration cycle 1924
Air conditioner unit 1926
Dual pressure switch 1930
Pressure switch 1931
Compressor 1932
Condenser 1933
Receiver drier 1935
Procedure for testing and troubleshooting 1936
Electrical circuit diagram 1939
System diagram 1940
Parts and connectors layout 1942
Testing relays 1947
Troubleshooting chart 1 1949
Troubleshooting chart 2 1950
Information described in troubleshooting table 1952
A-1 Troubleshooting for condenser fan 1953
A-2 Troubleshooting for compressor and refrigerant system (Air is not cooled) 1956
A-3 Troubleshooting for blower motor system (No air comes out or air flow is abnormal) 1960
A-4 Troubleshooting for temperature control 1962
Troubleshooting with gauge pressure 1965
Connection of service tool 1968
Precautions for disconnecting and connecting hoses and tubes in air conditioner circuit 1970
Handling of compressor oil 1972
90 Diagrams and drawings 1975
Table of contents 1976
Hydraulic circuit diagram 1977
Symbols in hydraulic circuit diagram 1977
Hydraulic circuit diagram 1981
Electric circuit diagram 1983
Symbols in electric circuit diagram 1983
Electrical circuit diagram 1987
INDEX2011

IMAGES PREVIEW OF THE MANUAL:

S.M 26/12/24