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Komatsu D61EX-15E0, D61PX-15E0 B45001 and up Crawler Bulldozer Shop Manual – PDF DOWNLOAD
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Komatsu D61EX-15E0, D61PX-15E0 B45001 and up Crawler Bulldozer Shop Manual
Book Code: SEN02387-05
SERIAL NUMBERS : D61EX- B45001 and up D61PX- B45001
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Description
Komatsu D61EX-15E0, D61PX-15E0 B45001 and up Crawler Bulldozer Shop Manual
FILE DETAILS:
Komatsu D61EX-15E0, D61PX-15E0 B45001 and up Crawler Bulldozer Shop Manual
Brands: Komatsu
Equipment Type: Crawler Bulldozer
Manuals Type: Shop Manual
Machine Model: D61EX-15E0, D61PX-15E0
Serial Number: B45001 and up
Book Code: SEN02387-05
Language: English
Pages: 1252
File Format: Portable Document Format (PDF)
DESCRIPTION:
Komatsu D61EX-15E0, D61PX-15E0 B45001 and up Crawler Bulldozer Shop Manual
How to read the shop manual:
1. Composition of shop manual:
This shop manual contains the necessary technical information for services performed in a workshop. For ease of understanding, the manual is divided into the following sections.
00. Index and foreword:
This section explains the shop manuals list, table of contents, safety, and basic information.
01. Specification:
This section explains the specifications of the machine.
10. Structure, function and maintenance standard:
This section explains the structure, function, and maintenance standard values of each component. The structure and function sub-section explains the structure and function of each component. It serves not only to give an understanding of the structure, but also serves as reference material for troubleshooting. The maintenance standard sub-section explains the criteria and remedies for disassembly and service.
20. Standard value table:
This section explains the standard values for new machine and judgement criteria for testing, adjusting, and troubleshooting. This standard value table is used to check the standard values in testing and adjusting and to judge parts in troubleshooting.
30. Testing and adjusting:
This section explains measuring instruments and measuring methods for testing and adjusting, and method of adjusting each part. The standard values and judgement criteria for testing and adjusting are explained in Testing and adjusting.
40. Troubleshooting:
This section explains how to find out failed parts and how to repair them. The troubleshooting is divided by failure modes. The “S mode” of the troubleshooting related to the engine may be also explained in the Chassis volume and Engine volume. In this case, see the Chassis volume.
50. Disassembly and assembly:
This section explains the special tools and procedures for removing, installing, disassembling, and assembling each component, as well as precautions for them. In addition, tightening torque and quantity and weight of coating material, oil, grease, and coolant necessary for the work are also explained.
90. Diagrams and drawings (chassis volume)/Repair and replacement of parts (engine volume):
- Chassis volume
This section gives hydraulic circuit diagrams and electrical circuit diagrams. - Engine volume
This section explains the method of reproducing, repairing, and replacing parts.
TABLE OF CONTENTS:
Komatsu D61EX-15E0, D61PX-15E0 B45001 and up Crawler Bulldozer Shop Manual
COVER............................................................................................................................................ 1 00 Index and foreword........................................................................................................................ 3 Index.................................................................................................................................... 3 Composition of shop manual........................................................................................................... 4 Table of contents.................................................................................................................... 6 Foreword and general information......................................................................................................... 17 Safety notice........................................................................................................................ 18 How to read the shop manual.......................................................................................................... 23 Explanation of terms for maintenance standard........................................................................................ 25 Handling electric equipment and hydraulic component.................................................................................. 27 How to read electric wire code....................................................................................................... 39 Precautions when carrying out operation.............................................................................................. 42 Method of disassembling and connecting push-pull type coupler........................................................................ 45 Standard tightening torque table..................................................................................................... 48 Conversion table..................................................................................................................... 52 01 Specification............................................................................................................................. 59 Specification and technical data......................................................................................................... 59 Specification dimension drawing...................................................................................................... 60 Specifications....................................................................................................................... 61 Weight table......................................................................................................................... 66 Table of fuel, coolant and lubricants................................................................................................ 68 10 Structure, function and maintenance standard.............................................................................................. 71 Engine and cooling system................................................................................................................ 71 Cooling system....................................................................................................................... 72 Cooling fan pump..................................................................................................................... 74 Cooling fan motor.................................................................................................................... 82 Power train, Part 1...................................................................................................................... 89 Power train.......................................................................................................................... 90 Power train.......................................................................................................................... 91 HSS system........................................................................................................................... 92 General view of the power train unit................................................................................................. 94 Power train hydraulic piping drawing................................................................................................. 95 Transmission, steering, brake control................................................................................................ 96 Damper and universal joint........................................................................................................... 98 Torque converter, PTO................................................................................................................ 100 Transmission......................................................................................................................... 106 Transmission ECMV.................................................................................................................... 118 Main relief valve and torque converter relief valve.................................................................................. 124 Lubricating oil relief valve......................................................................................................... 126 Power train, Part 2...................................................................................................................... 129 Bevel gear shaft, HSS and brake...................................................................................................... 130 Brake valve.......................................................................................................................... 146 Final drive.......................................................................................................................... 152 Undercarriage and frame.................................................................................................................. 159 Main frame........................................................................................................................... 161 Suspension........................................................................................................................... 162 Track frame and idler cushion........................................................................................................ 166 Idler................................................................................................................................ 170 Track roller......................................................................................................................... 172 Carrier roller....................................................................................................................... 176 Sprocket............................................................................................................................. 178 Track shoe........................................................................................................................... 182 Single shoe.......................................................................................................................... 186 Swamp shoe........................................................................................................................... 186 Hydraulic system, Part 1................................................................................................................. 189 Layout of hydraulic devices for work equipment....................................................................................... 190 Work equipment control............................................................................................................... 192 Hydraulic tank and filter............................................................................................................ 194 Scavenging pump...................................................................................................................... 196 Power train and steering lubrication pump............................................................................................ 197 HSS pump............................................................................................................................. 198 HSS motor............................................................................................................................ 216 Hydraulic system, Part 2................................................................................................................. 225 Control valve........................................................................................................................ 226 CLSS................................................................................................................................. 234 Self pressure reducing valve......................................................................................................... 261 Hydraulic system, Part 3................................................................................................................. 269 PPC valve............................................................................................................................ 270 Electric lever (Steering)............................................................................................................ 286 Quick drop valve..................................................................................................................... 290 Solenoid valve....................................................................................................................... 292 Accumulator.......................................................................................................................... 294 Work equipment........................................................................................................................... 297 Work equipment....................................................................................................................... 298 Cutting edge and end bit............................................................................................................. 304 Ripper............................................................................................................................... 305 Hydraulic cylinder................................................................................................................... 306 Piston valve......................................................................................................................... 309 Cab and its attachments.................................................................................................................. 311 Cab mount............................................................................................................................ 312 Cab.................................................................................................................................. 313 Air conditioner piping diagram....................................................................................................... 315 Electrical system........................................................................................................................ 317 Monitor system....................................................................................................................... 318 Monitor panel........................................................................................................................ 320 Engine control....................................................................................................................... 328 Engine control system................................................................................................................ 329 Cooling system control system........................................................................................................ 331 System components.................................................................................................................... 333 Palm command control system.......................................................................................................... 341 PPC lock system...................................................................................................................... 343 KOMTRAX terminal system.............................................................................................................. 344 Sensor............................................................................................................................... 346 20 Standard value table...................................................................................................................... 351 Standard service value table............................................................................................................. 351 Standard value table for engine...................................................................................................... 352 Standard value table for machine..................................................................................................... 353 30 Testing and adjusting..................................................................................................................... 363 Testing and adjusting, Part 1............................................................................................................ 363 Standard value table for engine related parts........................................................................................ 365 Measuring engine speed............................................................................................................... 368 Measuring intake air pressure (boost pressure)....................................................................................... 370 Measuring exhaust color.............................................................................................................. 372 Adjusting valve clearance............................................................................................................ 373 Measuring compression pressure....................................................................................................... 375 Measuring blow-by pressure........................................................................................................... 378 Measuring engine oil pressure........................................................................................................ 379 Handling fuel system equipment....................................................................................................... 380 Releasing residual pressure in fuel system........................................................................................... 380 Measuring fuel pressure.............................................................................................................. 381 Measuring fuel delivery amount, return rate and leakage.............................................................................. 383 Bleeding air from fuel circuit....................................................................................................... 387 Testing leakage in fuel system....................................................................................................... 389 Handling of reduced cylinder mode operation.......................................................................................... 390 Handling of no injection cranking operation.......................................................................................... 390 Testing and adjusting air conditioner compressor belt tension........................................................................ 391 Replacing the fan belt............................................................................................................... 391 Handling controller voltage circuit.................................................................................................. 392 Adjusting fuel control dial and decelerator pedal.................................................................................... 393 Testing and adjusting, Part 2............................................................................................................ 397 Measuring power train oil pressure................................................................................................... 399 Adjusting transmission speed sensor (replacement procedure).......................................................................... 403 Simple method of testing brake performance........................................................................................... 405 Adjusting brake pedal................................................................................................................ 406 Adjusting parking brake lever........................................................................................................ 408 Emergency escape method when power train has trouble................................................................................. 409 Adjusting idler clearance............................................................................................................ 412 Inspecting wear of sprocket.......................................................................................................... 412 Testing and adjusting track shoe tension............................................................................................. 413 Testing and adjusting work equipment and HSS oil pressure............................................................................ 414 Testing control circuit main pressure................................................................................................ 418 Measuring PPC valve output pressure.................................................................................................. 419 Adjusting play of work equipment PPC valve........................................................................................... 422 Measuring internal leakage of work equipment cylinder................................................................................ 423 Adjusting work equipment lock lever of work equipment................................................................................ 424 Releasing residual pressure in work equipment cylinder (If PPC accumulator is not installed)......................................... 425 Releasing residual pressure in work equipment cylinder (If PPC accumulator is installed)............................................. 425 Bleeding air from work equipment cylinder............................................................................................ 426 Measuring fan motor speed............................................................................................................ 427 Measuring fan pump circuit pressure.................................................................................................. 428 Measuring HSS motor oil leakage...................................................................................................... 429 Bleeding air from fan pump........................................................................................................... 429 Testing and adjusting operator's cab................................................................................................. 430 Testing and adjusting, Part 3............................................................................................................ 437 Testing and adjusting, Part 2........................................................................................................ 438 Special functions of monitor panel (EMMS)............................................................................................ 438 Testing and adjusting, Part 4............................................................................................................ 477 Handling of voltage circuit of engine controller..................................................................................... 478 Adjustment method when controller has been replaced.................................................................................. 478 Preparatory work for troubleshooting for electric system............................................................................. 480 Inspection procedure of diode........................................................................................................ 485 Pm-Clinic service.................................................................................................................... 486 How to start operation of KOMTRAX terminal........................................................................................... 504 Lamp display of KOMTRAX terminal..................................................................................................... 508 40 Troubleshooting........................................................................................................................... 513 Failure code table and fuse locations.................................................................................................... 513 Failure code table................................................................................................................... 514 Fuse locations....................................................................................................................... 521 General information on troubleshooting................................................................................................... 525 Points to remember when troubleshooting.............................................................................................. 526 Sequence of events in troubleshooting................................................................................................ 527 Checks before troubleshooting........................................................................................................ 528 Classification and procedures of troubleshooting..................................................................................... 529 Contents of troubleshooting table.................................................................................................... 530 Wiring table for connector pin numbers............................................................................................... 534 T-adapter box and T-adapter table.................................................................................................... 567 Troubleshooting by failure code (Display of code), Part 1................................................................................ 571 Failure code [1500L0] Transmission clutch: Dual engagement........................................................................... 573 Failure code [15SAL1] Forward clutch: Fill signal is ON when command current is OFF.................................................. 574 Failure code [15SALH] Forward clutch: Fill signal is OFF when command current is ON.................................................. 576 Failure code [15SBL1] Reverse clutch: Fill signal is ON when command current is OFF.................................................. 578 Failure code [15SBLH] Reverse clutch: Fill signal is OFF when command current is ON.................................................. 580 Failure code [15SEL1] 1st clutch: Fill signal is ON when command current is OFF...................................................... 582 Failure code [15SELH] 1st clutch: Fill signal is OFF when command current is ON...................................................... 584 Failure code [15SFL1] 2nd clutch: Fill signal is ON when command current is OFF...................................................... 586 Failure code [15SFLH] 2nd clutch: Fill signal is OFF when command current is ON...................................................... 588 Failure code [15SGL1] 3rd clutch: Fill signal is ON when command current is OFF...................................................... 590 Failure code [15SGLH] 3rd clutch: Fill signal is OFF when command current is ON...................................................... 592 Failure code [AB00MA] Alternator: Malfunction........................................................................................ 594 Failure code [B@BAZG] Engine oil: Oil pressure too low............................................................................... 594 Failure code [B@BCNS] Radiator coolant: Overheat..................................................................................... 595 Failure code [B@CENS] Power train oil: Overheat...................................................................................... 595 Failure code [B@HANS] Hydraulic oil: Overheat........................................................................................ 596 Failure code [CA111] Engine controller: Abnormality in controller.................................................................... 597 Failure code [CA115] Abnormal engine Ne and Bkup speed sensors: Abnormal speed sensor signal......................................... 597 Failure code [CA122] Charge pressure sensor too high: Excessively high voltage detected.............................................. 598 Failure code [CA123] Charge pressure sensor too low: Excessively low voltage detected................................................ 600 Failure code [CA131] Decelerator pedal sensor too high: Excessively high voltage detected............................................ 602 Failure code [CA132] Decelerator pedal sensor too low: Excessively low voltage detected.............................................. 604 Failure code [CA144] Coolant temperature sensor too high: Excessively high voltage detected.......................................... 606 Failure code [CA145] Coolant temperature sensor too low: Excessively low voltage detected............................................ 608 Failure code [CA153] Charge temperature sensor too high: Excessively high voltage detected........................................... 610 Failure code [CA154] Charge temperature sensor too low: Excessively low voltage detected............................................. 612 Failure code [CA155] Charge temperature too high and engine speed derated: Exceeded upper control limit of temperature............... 614 Failure code [CA187] Sensor power source 2 too low: Excessively low voltage detected................................................. 616 Failure code [CA221] Atmospheric pressure sensor too high: Excessively high voltage detected......................................... 618 Failure code [CA222] Atmospheric pressure sensor too low: Excessively low voltage detected........................................... 620 Failure code [CA227] Sensor power source 2 too high: Excessively high voltage detected............................................... 622 Failure code [CA234] Engine over speed: Excessively high speed....................................................................... 624 Failure code [CA238] Abnormal power source for Ne speed sensor: Excessively low voltage detected..................................... 625 Failure code [CA271] IMV/PCV1 short circuit: Short circuit........................................................................... 626 Failure code [CA272] IMV/PCV1 disconnection: Disconnection........................................................................... 628 Troubleshooting by failure code (Display of code), Part 2................................................................................ 631 Failure code [CA322] Injector No. 1 system disconnection or short circuit: disconnection, short circuit.............................. 634 Failure code [CA323] Injector No. 5 system disconnection or short circuit: disconnection, short circuit.............................. 636 Failure code [CA324] Injector No. 3 system disconnection or short circuit: disconnection, short circuit.............................. 638 Failure code [CA325] Injector No. 6 system disconnection or short circuit: disconnection, short circuit.............................. 640 Failure code [CA331] Injector No. 2 system disconnection or short circuit: disconnection, short circuit.............................. 642 Failure code [CA332] Injector No. 4 system disconnection or short circuit: disconnection, short circuit.............................. 644 Failure code [CA342] Engine controller data matching error: matching error........................................................... 646 Failure code [CA352] Sensor power source 1 too low: Excessively low voltage detected................................................. 648 Failure code [CA386] Sensor power source 1 too high: Excessively high voltage detected............................................... 650 Failure code [CA428] Water detection sensor too high: Excessively high voltage detected.............................................. 652 Failure code [CA429] Water detection sensor too low: Excessively low voltage detected................................................ 654 Failure code [CA435] Abnormal engine oil pressure switch: Abnormal signal circuit.................................................... 656 Failure code [CA441] Power source voltage too low: Excessively low voltage detected.................................................. 658 Failure code [CA442] Power source voltage too high: Excessively high voltage has occurred in the controller power source circuit..... 660 Failure code [CA449] Common rail pressure too high (2): Excessively high pressure trouble occurred................................... 662 Failure code [CA451] Common rail pressure sensor too high: Excessively high voltage detected......................................... 664 Failure code [CA452] Common rail pressure sensor too low: Excessively low voltage detected........................................... 666 Failure code [CA488] Charge temperature too high and torque derated: Exceeded upper control limit of temperature..................... 668 Failure code [CA553] Common rail pressure too high (1): Excessively high pressure detected........................................... 669 Failure code [CA559] Loss of pressure feed from supply pump (1): Loss of pressure feed detected...................................... 670 Failure code [CA689] Abnormal engine Ne speed sensor: Abnormal signal................................................................ 672 Failure code [CA731] Abnormal engine Bkup speed sensor phase: Abnormal phase......................................................... 674 Failure code [CA757] Loss of all engine controller data: Loss of all data............................................................ 676 Failure code [CA778] Abnormal engine Bkup speed sensor: Abnormal Bkup signal......................................................... 678 Failure code [CA1633] Abnormal KOMNET: Abnormal communication........................................................................ 680 Failure code [CA2185] Decelerator pedal sensor power source too high: Excessively high voltage detected.............................. 682 Failure code [CA2186] Decelerator pedal sensor power source too low: Excessively low voltage detected................................ 684 Failure code [CA2249] Loss of pressure feed from supply pump (2): Loss of pressure feed detected..................................... 686 Failure code [CA2311] Abnormal IMV solenoid: Abnormal resistance..................................................................... 688 Failure code [CA2555] Air intake heater relay disconnection: Disconnection........................................................... 690 Failure code [CA2556] Air intake heater relay short circuit: Short circuit........................................................... 692 Troubleshooting by failure code (Display of code), Part 3................................................................................ 695 Failure code [D110KA] Battery relay: Short circuit................................................................................... 698 Failure code [D110KB] Battery relay: Disconnection................................................................................... 700 Failure code [D130KA] Neutral safety relay: Short circuit............................................................................ 702 Failure code [D130KB] Neutral safety relay: Disconnection............................................................................ 704 Failure code [D161KA] Back-up alarm relay: Disconnection............................................................................. 706 Failure code [D161KB] Back-up alarm relay: Short circuit............................................................................. 708 Failure code [DAFRKR] Monitor panel CAN communication: Defective communication....................................................... 710 Failure code [DAQ0KT] [DB30KT] Steering and transmission controller: Abnormality in controller....................................... 712 Failure code [DAQ1KK] [DB31KK] Main power source of steering and transmission controller: Power source voltage drop and input........ 714 Failure code [DAQ2KK] [DB32KK] Load power source of steering and transmission controller: Power source voltage drop and input........ 716 Failure code [DAQ5KK] [DB35KK] Steering and transmission controller sensor 5 V power source: Power source voltage drop and input..... 718 Failure code [DAQ6KK] [DB36KK] Steering and transmission controller sensor 24 V power source: Power source voltage drop and input.... 720 Failure code [DAQ9KQ] [DB39KQ] Steering and transmission controller model selection: Inconsistency in model select signal............ 722 Failure code [DB2RKR] Steering and transmission controller CAN communication: Defective communication................................ 724 Failure code [DB30KT] [DAQ0KT] Steering and transmission controller: Abnormality in controller....................................... 726 Failure code [DB31KK] [DAQ1KK] Main power source of steering and transmission controller: Power source voltage drop and input........ 726 Failure code [DAB32KK] [DAQ2KK] Load power source of steering and transmission controller: Power source voltage drop and input....... 726 Failure code [DB35KK] [DAQ5KK] Steering and transmission controller sensor 5 V power source: Power source voltage drop and input..... 726 Failure code [DB36KK] [DAQ6KK] Steering and transmission controller sensor 24 V power source: Power source voltage drop and input.... 726 Failure code [DB39KQ] [DAQ9KQ] Steering and transmission controller model selection: Inconsistency in model select signal............ 726 Failure code [DD12KA] Shift up switch: Disconnection................................................................................. 728 Failure code [DD12KB] Shift up switch: Short circuit................................................................................. 730 Failure code [DD13KA] Shift down switch: Disconnection............................................................................... 732 Failure code [DD13KB] Shift down switch: Short circuit............................................................................... 734 Failure code [DD14KA] [DDQ2KA] Parking brake lever switch: Disconnection............................................................. 736 Failure code [DD14KB] [DDQ2KB] Parking brake lever switch: Short circuit............................................................. 738 Failure code [DDQ2KA] [DD14KA] Parking brake lever switch: Disconnection............................................................. 740 Failure code [DDQ2KB] [DD14KB] Parking brake lever switch: Short circuit............................................................. 740 Failure code [DGS1KX] Hydraulic oil temperature sensor: Input signal is out of normal range.......................................... 742 Failure code [DGT1KA] Power train oil temperature sensor: Disconnection.............................................................. 744 Failure code [DGT1KX] Power train oil temperature sensor: Input signal is out of normal range........................................ 745 Failure code [DK10KA] Fuel dial: Disconnection....................................................................................... 746 Failure code [DK10KB] Fuel dial: Short circuit....................................................................................... 748 Failure code [DK30KA] Steering potentiometer (1): Disconnection...................................................................... 750 Failure code [DK30KB] Steering potentiometer (1): Short circuit...................................................................... 752 Failure code [DK30KX] Steering potentiometer: Input signal is out of normal range.................................................... 754 Failure code [DK30KZ] Steering potentiometer: Disconnection or short circuit (Double failure)........................................ 755 Failure code [DK30L8] Steering potentiometer: Inconsistent analog signal............................................................. 755 Failure code [DK31KA] Steering potentiometer (2): Disconnection...................................................................... 756 Failure code [DK31KB] Steering potentiometer (2): Short circuit...................................................................... 758 Failure code [DK40KA] Brake potentiometer: Disconnection............................................................................. 760 Failure code [DK40KB] Brake potentiometer: Short circuit............................................................................. 761 Troubleshooting by failure code (Display of code), Part 4................................................................................ 763 Failure code [DK55KX] Forward-reverse potentiometer: Input signal is out of normal range............................................. 765 Failure code [DK55KZ] Forward-reverse potentiometer: Disconnection or short circuit (Double failure)................................. 766 Failure code [DK55L8] Forward-reverse potentiometer: Inconsistent analog signal...................................................... 767 Failure code [DK56KA] Forward-reverse potentiometer (1): Short circuit............................................................... 768 Failure code [DK56KB] Forward-reverse potentiometer (1): Disconnection............................................................... 770 Failure code [DK57KA] Forward-reverse potentiometer (2): Disconnection............................................................... 772 Failure code [DK57KB] Forward-reverse potentiometer (2): Short circuit............................................................... 774 Failure code [DKH1KA] [DKH1KX] Pitch angle sensor: Short circuit..................................................................... 776 Failure code [DKH1KB] [DKH1KX] Pitch angle sensor: Disconnection..................................................................... 778 Failure code [DKH1KX], [DKH1KA] or [DKH1KB] Pitch angle sensor: Input signal out of range............................................ 779 Failure code [DLT3KA] Transmission output speed sensor: Disconnection................................................................ 780 Failure code [DLT3KB] Transmission output speed sensor: Short circuit................................................................ 781 Failure code [DV00KB] Alarm buzzer: Short circuit.................................................................................... 782 Failure code [DW7BKA] Fan reverse solenoid: Disconnection............................................................................ 783 Failure code [DW7BKB] Fan reverse solenoid: Short circuit............................................................................ 784 Failure code [DWN1KA] HSS EPC solenoid right: Disconnection.......................................................................... 785 Failure code [DWN1KB] HSS EPC solenoid right: Short circuit.......................................................................... 786 Failure code [DWN1KY] HSS EPC solenoid right: Short circuit to power source line..................................................... 787 Failure code [DWN2KA] HSS EPC solenoid left: Disconnection........................................................................... 788 Failure code [DWN2KB] HSS EPC solenoid left: Short circuit........................................................................... 789 Failure code [DWN2KY] HSS EPC solenoid left: Short circuit to power source line...................................................... 790 Failure code [DWN5KA] Fan pump TVC solenoid: Disconnection........................................................................... 791 Failure code [DWN5KB] Fan pump TVC solenoid: Short circuit........................................................................... 792 Failure code [DWN5KY] Fan pump TVC solenoid: Short circuit in power source line...................................................... 793 Failure code [DXA0KA] HSS pump TVC solenoid: Disconnection........................................................................... 794 Failure code [DXA0KB] HSS pump TVC solenoid: Short circuit........................................................................... 795 Failure code [DXA0KY] HSS pump TVC solenoid: Short circuit to power source line...................................................... 796 Failure code [DXH4KA] 1st clutch ECMV: Disconnection................................................................................. 797 Failure code [DXH4KB] 1st clutch ECMV: Short circuit................................................................................. 798 Failure code [DXH4KY] 1st clutch ECMV: Short circuit to power source line............................................................ 800 Failure code [DXH5KA] 2nd clutch ECMV: Disconnection................................................................................. 801 Failure code [DXH5KB] 2nd clutch ECMV: Short circuit................................................................................. 802 Failure code [DXH5KY] 2nd clutch ECMV: Short circuit to power source line............................................................ 804 Failure code [DXH6KA] 3rd clutch ECMV: Disconnection................................................................................. 805 Failure code [DXH6KB] 3rd clutch ECMV: Short circuit................................................................................. 806 Failure code [DXH6KY] 3rd clutch ECMV: Short circuit to power source line............................................................ 808 Failure code [DXH7KA] Reverse clutch ECMV: Disconnection............................................................................. 809 Failure code [DXH7KB] Reverse clutch ECMV: Short circuit............................................................................. 810 Failure code [DXH7KY] Reverse clutch ECMV: Short circuit to power source line........................................................ 811 Failure code [DXH8KA] Forward clutch ECMV: Disconnection............................................................................. 812 Failure code [DXH8KB] Forward clutch ECMV: Short circuit............................................................................. 814 Failure code [DXH8KY] Forward clutch ECMV: Short circuit to power source line........................................................ 816 Troubleshooting of electrical system (E-mode)............................................................................................ 819 Before troubleshooting of electrical system.......................................................................................... 821 Contents of troubleshooting table.................................................................................................... 823 E-1 The engine does not start (the starting motor does not turn)..................................................................... 825 E-2 The preheater does not operate................................................................................................... 829 E-3 The monitor panel does not light up at all when the starting switch is turned ON................................................. 832 E-4 When the starting switch is turned on, the monitor panel completely remains lighted and does not go out.......................... 833 E-5 While the engine is running, the battery charge level caution lamp flashes....................................................... 834 E-6 While the engine is running, the emergency warning item flashes.................................................................. 836 E-7 While the preheater is operating, the preheating pilot lamp does not light up.................................................... 840 E-8 The coolant temperature gauge does not indicate correctly........................................................................ 842 E-9 The power train oil temperature gauge does not indicate correctly................................................................ 844 E-10 Hydraulic oil temperature gauge does not indicate properly...................................................................... 846 E-11 Fuel gauge does not indicate properly........................................................................................... 848 E-12 Gear speed and engine speed are not indicated properly.......................................................................... 849 E-13 The preset mode service meter does not indicate normally........................................................................ 849 E-14 The warning lamp does not flash or does not go out.............................................................................. 849 E-15 The alarm buzzer does not sound or does not stop................................................................................ 850 E-16 Auto shift down is not possible or is not released.............................................................................. 852 E-17 The buzzer cancel switch does not work.......................................................................................... 854 E-18 The information switch does not work............................................................................................ 856 E-19 The fan cleaning does not operate or cannot be reset............................................................................ 858 E-20 The preset mode does not operate or cannot be reset............................................................................. 860 E-21 The monitor panel cannot be set in the service mode or cannot be set out of the service mode.................................... 862 E-22 The back-up alarm does not sound................................................................................................ 864 E-23 The head lamp and rear lamp do not light up..................................................................................... 867 E-24 The horn does not sound or does not stop........................................................................................ 870 E-25 Malfunction of wipers........................................................................................................... 872 E-26 Washer does not spray water..................................................................................................... 888 E-27 The air conditioner does not operate............................................................................................ 894 E-28 KOMTRAX system does not operate normally........................................................................................ 898 Troubleshooting of hydraulic and mechanical system (H-mode).............................................................................. 901 Contents of troubleshooting table.................................................................................................... 903 H-1 There is no travel power (no drawbar pull)....................................................................................... 904 H-2 Machine does not move (at 2nd or 3rd speed)...................................................................................... 905 H-3 Machine does not move at any gear speed.......................................................................................... 906 H-4 Machine travels only in one direction, forward or in reverse..................................................................... 907 H-5 When gear is shifted or travel direction is changed, large time lag is made...................................................... 908 H-6 Machine cannot be steered (Machine does not turn leftward or rightward).......................................................... 909 H-7 Steering speed or power is low................................................................................................... 909 H-8 Brake does not work.............................................................................................................. 910 H-9 Overheat of power train oil...................................................................................................... 911 H-10 Abnormal sound comes out from around HSS and work equipment pump or HSS motor................................................... 912 H-11 All work equipment speeds are slow.............................................................................................. 912 H-12 Work equipment does not move.................................................................................................... 913 H-13 Blade lift speed is slow or lacks power......................................................................................... 913 H-14 Blade tilt speed is slow or lacks power......................................................................................... 914 H-15 Angling blade speed is slow or lacks power...................................................................................... 914 H-16 Ripper lift speed is slow or lacks power........................................................................................ 915 H-17 Excessive hydraulic drift of blade lift......................................................................................... 915 H-18 Excessive hydraulic drift of blade tilt......................................................................................... 916 H-19 Excessive hydraulic drift of blade angle........................................................................................ 916 H-20 Excessive hydraulic drift of ripper lift........................................................................................ 917 Troubleshooting of engine (S-mode)....................................................................................................... 919 Method of using troubleshooting charts............................................................................................... 921 S-1 Starting performance is poor..................................................................................................... 924 S-2 Engine does not start............................................................................................................ 925 S-3 Engine does not pick up smoothly................................................................................................. 928 S-4 Engine stops during operations................................................................................................... 929 S-5 Engine does not rotate smoothly.................................................................................................. 930 S-6 Engine lacks output (or lacks power)............................................................................................. 931 S-7 Exhaust smoke is black (incomplete combustion)................................................................................... 932 S-8 Oil consumption is excessive (or exhaust smoke is blue).......................................................................... 933 S-9 Oil becomes contaminated quickly................................................................................................. 934 S-10 Fuel consumption is excessive................................................................................................... 935 S-11 Oil is in coolant (or coolant spurts back or coolant level goes down)........................................................... 936 S-12 Oil pressure drops.............................................................................................................. 937 S-13 Oil level rises (Entry of coolant or fuel)...................................................................................... 938 S-14 Coolant temperature becomes too high (overheating).............................................................................. 939 S-15 Abnormal noise is made.......................................................................................................... 940 S-16 Vibration is excessive.......................................................................................................... 941 50 Disassembly and assembly.................................................................................................................. 943 General information on disassembly and assembly.......................................................................................... 943 How to read this manual.............................................................................................................. 944 Coating materials list............................................................................................................... 946 Special tool list.................................................................................................................... 949 Sketches of special tools............................................................................................................ 956 Engine and cooling system (SAA6D107E-1).................................................................................................. 967 Removal and installation of radiator guard assembly.................................................................................. 968 Removal and installation of engine assembly.......................................................................................... 972 Removal and installation of radiator assembly........................................................................................ 977 Removal and installation of aftercooler assembly..................................................................................... 980 Removal and installation of power train oil cooler assembly.......................................................................... 983 Removal and installation of hydraulic cooler assembly................................................................................ 984 Removal and installation of cooling fan drive assembly............................................................................... 987 Removal and installation of cooling fan motor assembly............................................................................... 989 Removal and installation of damper assembly.......................................................................................... 990 Removal and installation of fuel tank assembly....................................................................................... 995 Removal and installation of engine hood assembly..................................................................................... 997 Engine (SAA6D170E-1)..................................................................................................................... 999 Removal and installation of fuel supply pump assembly................................................................................1000 Removal and installation of fuel injector assembly...................................................................................1002 Removal and installation of cylinder head assembly...................................................................................1011 Removal and installation of engine front seal........................................................................................1024 Removal and installation of engine rear seal.........................................................................................1027 Power train, Part 1......................................................................................................................1031 Removal and installation of PTO, torque converter and transmission assembly..........................................................1032 Disconnection and connection of PTO, torque converter and transmission assembly......................................................1036 Disassembly and assembly of PTO assembly.............................................................................................1038 Disassembly and assembly of torque converter assembly................................................................................1043 Disassembly and assembly of TORQFLOW transmission assembly...........................................................................1047 Removal and installation of torque converter main relief valve assembly..............................................................1064 Disassembly and assembly of torque converter main relief valve assembly..............................................................1065 Power train, Part 2......................................................................................................................1067 Removal and installation of power train and lubricating oil pump assembly............................................................1068 Removal and installation of HSS and work equipment pump assembly.....................................................................1070 Removal and installation of scavenging pump assembly.................................................................................1071 Removal and installation of HSS motor assembly.......................................................................................1071 Disassembly and assembly of HSS assembly.............................................................................................1072 Removal and installation of final drive assembly.....................................................................................1090 Disassembly and assembly of final drive assembly.....................................................................................1091 Undercarriage and frame, Part 1..........................................................................................................1105 Removal and installation of track frame assembly.....................................................................................1106 Removal and installation of idler assembly...........................................................................................1108 Disassembly and assembly of idler assembly...........................................................................................1109 Removal and installation of recoil spring assembly...................................................................................1113 Disassembly and assembly of recoil spring assembly...................................................................................1114 Removal and installation of track roller assembly....................................................................................1117 Disassembly and assembly of track roller assembly....................................................................................1118 Removal and installation of carrier roller assembly..................................................................................1121 Disassembly and assembly of carrier roller assembly..................................................................................1122 Expansion and installation of track shoe assembly (Plus type track shoe).............................................................1130 Undercarriage and frame, Part 2..........................................................................................................1127 Check before expanding track shoe assembly...........................................................................................1128 Expansion (normal), expansion (internal abnormality) and installation of track shoe assembly (Conventional type track shoe)..........1128 Overall disassembly and overall assembly of track shoe assembly (Conventional type track shoe).......................................1131 Link press-fitting jig dimensions table..............................................................................................1147 Field disassembly and assembly of one link (Conventional type track shoe)............................................................1155 Field disassembly and assembly of one link (PLUS type track shoe)....................................................................1162 Removal and installation of pivot shaft assembly.....................................................................................1167 Removal and installation of equalizer bar assembly...................................................................................1169 Removal and installation of equalizer bar side bushing...............................................................................1170 Removal and installation of segment teeth............................................................................................1171 Overall disassembly and overall assembly of track shoe assembly (PLUS type track shoe)...............................................1148 Hydraulic system.........................................................................................................................1173 Removal and installation of main control valve assembly..............................................................................1174 Assembly of main control valve assembly..............................................................................................1176 Removal and installation of cooling fan pump assembly................................................................................1179 Disassembly and assembly of hydraulic cylinder assembly..............................................................................1180 Work equipment...........................................................................................................................1187 Removal and installation of work equipment assembly..................................................................................1188 Disassembly and assembly of work equipment assembly..................................................................................1190 Cab and its attachments..................................................................................................................1195 Removal and installation of ROPS guard...............................................................................................1196 Removal and installation of operator's cab assembly..................................................................................1197 Removal and installation of operator's cab glass (stuck glass).......................................................................1203 Removal and installation of monitor panel assembly...................................................................................1212 Removal and installation of dashboard assembly.......................................................................................1213 Removal and installation of floor frame assembly.....................................................................................1216 Electrical system........................................................................................................................1223 Removal and installation of engine controller assembly...............................................................................1224 Removal and installation of steering and transmission controller assembly............................................................1225 Removal and installation of KOMTRAX terminal assembly................................................................................1226 Removal and installation of air conditioner unit assembly............................................................................1227 90 Diagrams and drawings.....................................................................................................................1233 Power train hydraulic circuit diagram....................................................................................................1235 Work equipment hydraulic circuit diagram.................................................................................................1236 Electrical diagrams and drawings.........................................................................................................1240 Connector arrangement diagram........................................................................................................1250
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