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KOMATSU D61EX-23 D61PX-23 BULLDOZER SHOP MANUAL SEN06010-10 – PDF DOWNLOAD
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KOMATSU D61EX-23 D61PX-23 BULLDOZER SHOP MANUAL SEN06010-10 – PDF DOWNLOAD
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KOMATSU D61EX-23 D61PX-23 BULLDOZER SHOP MANUAL SEN06010-10 – PDF DOWNLOAD
Language : English
Pages : 1768
Downloadable : Yes
File Type : PDF
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TABLE OF CONTENTS:
KOMATSU D61EX-23 D61PX-23 BULLDOZER SHOP MANUAL SEN06010-10 – PDF DOWNLOAD
Cover........................................................................................................................................... 1 00 Index and foreword .......................................................................................................................... 3 Index ...................................................................................................................................... 4 Foreword, safety and general information ................................................................................................... 17 Important safety notice ................................................................................................................ 17 How to read the shop manual ............................................................................................................ 24 Explanation of terms for maintenance standard .......................................................................................... 26 Handling equipment of fuel system devices .............................................................................................. 28 Handling of intake system parts ........................................................................................................ 29 Handling of hydraulic equipment ........................................................................................................ 30 Method of disconnecting and connecting of push-pull type coupler ....................................................................... 32 Handling of electrical equipment ....................................................................................................... 35 How to read electric wire code ......................................................................................................... 43 Precautions when performing operation .................................................................................................. 46 Practical use of KOMTRAX ............................................................................................................... 51 Standard tightening torque table ....................................................................................................... 52 List of abbreviation ................................................................................................................... 58 Conversion table ....................................................................................................................... 63 01 Specification ............................................................................................................................... 69 Table of contents .......................................................................................................................... 70 Specifications ............................................................................................................................. 71 Specification drawing .................................................................................................................. 71 Specifications ......................................................................................................................... 73 Weight table ........................................................................................................................... 86 Table of fuel, coolant, and lubricants ................................................................................................. 90 10 Structure and function ...................................................................................................................... 91 Table of contents .......................................................................................................................... 92 Engine and cooling system .................................................................................................................. 93 Engine related parts ................................................................................................................... 93 KVGT ................................................................................................................................... 95 EGR system piping drawing .............................................................................................................. 102 EGR system circuit diagram ............................................................................................................. 104 EGR valve .............................................................................................................................. 106 EGR cooler ............................................................................................................................. 108 KCCV layout drawing .................................................................................................................... 109 KCCV ventilator ........................................................................................................................ 111 KDPF ................................................................................................................................... 113 Cooling system ......................................................................................................................... 117 Cooling fan motor ...................................................................................................................... 119 Oil cooler bypass and HST charge safety valve .......................................................................................... 125 Power train ................................................................................................................................ 131 Power train system ..................................................................................................................... 131 Damper ................................................................................................................................. 134 Hydraulic component layout of HST ...................................................................................................... 135 Steering and brake control ............................................................................................................. 136 HST pump ............................................................................................................................... 138 HST motor .............................................................................................................................. 153 Charge pump ............................................................................................................................ 168 Solenoid valve ......................................................................................................................... 169 Final drive ............................................................................................................................ 178 Undercarriage and frame .................................................................................................................... 182 Main frame ............................................................................................................................. 182 Suspension ............................................................................................................................. 183 Track frame and idler cushion .......................................................................................................... 185 Hydraulic system ........................................................................................................................... 188 Hydraulic component layout of work equipment ........................................................................................... 188 Work equipment control system .......................................................................................................... 190 Hydraulic tank ......................................................................................................................... 192 CLSS ................................................................................................................................... 194 Work equipment and cooling fan pump .................................................................................................... 197 Control valve .......................................................................................................................... 208 Ripper PPC valve ....................................................................................................................... 230 Quick drop valve ....................................................................................................................... 235 Angle control EPC valve ................................................................................................................ 238 Accumulator ............................................................................................................................ 243 Work equipment ............................................................................................................................. 245 Blade .................................................................................................................................. 245 Ripper ................................................................................................................................. 246 Piston valve ........................................................................................................................... 247 Cab and its attachments .................................................................................................................... 248 ROPS cab ............................................................................................................................... 248 Cab mount .............................................................................................................................. 250 Electrical system .......................................................................................................................... 251 Engine control system .................................................................................................................. 251 Cooling system control system .......................................................................................................... 254 HST control system ..................................................................................................................... 256 Parking brake control system ........................................................................................................... 269 System operating lamp function ......................................................................................................... 271 Battery disconnect switch function ..................................................................................................... 272 Machine monitor system ................................................................................................................. 274 KOMTRAX system ......................................................................................................................... 297 System component parts ................................................................................................................. 300 Sensor ................................................................................................................................. 317 20 Standard value tables ....................................................................................................................... 335 Table of contents .......................................................................................................................... 336 Standard service value table ............................................................................................................... 337 Standard value table for engine ........................................................................................................ 337 Standard value table for machine ....................................................................................................... 338 Standard value table for electrical system ............................................................................................. 351 30 Testing and adjusting ....................................................................................................................... 361 Table of contents .......................................................................................................................... 362 Related information on testing and adjusting ............................................................................................... 364 Tools for testing and adjusting ........................................................................................................ 364 Sketch of tools for testing and adjusting .............................................................................................. 369 Engine and cooling system .................................................................................................................. 373 Testing engine speed ................................................................................................................... 373 Testing boost pressure ................................................................................................................. 375 Testing exhaust gas color .............................................................................................................. 377 Testing mass air flow and temperature sensor............................................................................................ 379 Testing and adjusting valve clearance .................................................................................................. 381 Testing compression pressure ........................................................................................................... 384 Testing blowby pressure ................................................................................................................ 388 Testing engine oil pressure ............................................................................................................ 390 Testing EGR valve and KVGT oil pressures ............................................................................................... 391 Testing fuel pressure .................................................................................................................. 392 Testing fuel discharge, return and leakage ............................................................................................. 397 Bleeding air from fuel system .......................................................................................................... 402 Testing fuel circuit for leakage ....................................................................................................... 404 Handling cylinder cutout mode operation ................................................................................................ 405 Handling no-injection cranking operation ............................................................................................... 406 Testing of KDPF and muffler stack for looseness and damage ............................................................................. 407 Testing of installed condition of cylinder heads and manifolds ......................................................................... 408 Testing engine piping for damage and looseness ......................................................................................... 409 Check alternator belt, replace ......................................................................................................... 410 Check auto-tensioner, replace .......................................................................................................... 412 Writing compensation amount for soot accumulation caused by ash on engine controller ................................................... 414 Power train ................................................................................................................................ 416 Testing and adjusting HST oil pressure ................................................................................................. 416 Testing output pressure of solenoid valve .............................................................................................. 421 Testing if machine travels straight .................................................................................................... 425 Simple test procedure for brake performance ............................................................................................ 426 Adjusting deceleration/brake pedal ..................................................................................................... 427 Adjusting parking brake lever .......................................................................................................... 430 Move disabled machine urgently ......................................................................................................... 432 Undercarriage and frame .................................................................................................................... 435 Adjusting idler clearance .............................................................................................................. 435 Checking sprocket wear ................................................................................................................. 436 Testing and adjusting track tension .................................................................................................... 437 Hydraulic system ........................................................................................................................... 438 Releasing remaining pressure in work equipment cylinder ................................................................................ 438 Testing and adjusting work equipment oil pressure ...................................................................................... 439 Testing source pressure of control circuit ............................................................................................. 441 Testing outlet pressure of work equipment EPC valve and fan EPC valve .................................................................. 442 Isolating the parts causing hydraulic drift in blade and ripper ........................................................................ 444 Testing internal oil leakage of work equipment cylinder ................................................................................ 445 Testing fan speed ...................................................................................................................... 447 Testing fan circuit oil pressure ....................................................................................................... 448 Bleeding air from hydraulic circuit .................................................................................................... 449 Work equipment ............................................................................................................................. 450 Adjusting work equipment lock lever .................................................................................................... 450 Adjusting play of blade center ball .................................................................................................... 452 Testing and adjusting play of blade electric lever...................................................................................... 453 Electrical system .......................................................................................................................... 461 Special functions of machine monitor ................................................................................................... 461 Adjustment method when HST controller has been replaced ................................................................................ 540 Adjustment method when electric or hydraulic device has been replaced .................................................................. 543 Adjusting rearview camera angle ........................................................................................................ 544 Handling voltage circuit of engine controller .......................................................................................... 545 Handling battery disconnect switch ..................................................................................................... 546 Testing diodes ......................................................................................................................... 547 Pm clinic .................................................................................................................................. 548 Pm Clinic service ...................................................................................................................... 548 Pm Clinic check sheet .................................................................................................................. 550 40 Troubleshooting ............................................................................................................................. 557 Table of contents .......................................................................................................................... 558 Related information on troubleshooting ..................................................................................................... 565 Troubleshooting points ................................................................................................................. 565 Sequence of events in troubleshooting .................................................................................................. 567 Checks before troubleshooting .......................................................................................................... 569 Inspection procedure before troubleshooting ............................................................................................ 571 Preparation for troubleshooting of electrical system ................................................................................... 588 Classification and procedures for troubleshooting ...................................................................................... 592 Symptom and troubleshooting numbers .................................................................................................... 594 Information in troubleshooting table ................................................................................................... 597 Procedure for troubleshooting wiring harness of pressure sensor system for open circuit ................................................ 599 Connector list and layout .............................................................................................................. 602 Connector contact identification ....................................................................................................... 614 T-branch box and T-branch adapter table ................................................................................................ 653 Fuse location table .................................................................................................................... 658 Precautions for KDPF (KCSF and KDOC) Cleaning and Replacement .......................................................................... 663 Preparation of dummy temperature sensor (for KDOC and KDPF temperature sensors) ........................................................ 666 Preparation of short circuit electrical connector (for failure codes [CA1883] and [CA3135]) ............................................ 667 Failure codes table .................................................................................................................... 668 Troubleshooting by failure code (Display of code) .......................................................................................... 679 Failure code [6091NX] HST Oil Filter Clogging .......................................................................................... 679 Failure code [989L00] Engine Controller Lock Caution 1 ................................................................................. 681 Failure code [989M00] Engine Controller Lock Caution 2 ................................................................................. 682 Failure code [989N00] Engine Controller Lock Caution 3 ................................................................................. 683 Failure code [A1U0N3] HC Desorb Request 1 .............................................................................................. 684 Failure code [A1U0N4] HC Desorb Request 2 .............................................................................................. 686 Failure code [AA10NX] Air Cleaner Clogging ............................................................................................. 688 Failure code [AB00KE] Charge Voltage Low ............................................................................................... 690 Failure code [B@BAZG] Eng Oil Press Low ................................................................................................ 692 Failure code [B@BCNS] Eng Water Overheat ............................................................................................... 693 Failure code [B@CRNS] HST Oil Overheat ................................................................................................. 694 Failure code [B@CRZG] HST Charge Press Low ............................................................................................. 695 Failure code [CA115] Eng Ne and Bkup Speed Sens Error .................................................................................. 696 Failure code [CA122] Chg Air Press Sensor High Error ................................................................................... 697 Failure code [CA123] Chg Air Press Sensor Low Error .................................................................................... 699 Failure code [CA131] Throttle Sensor High Error ........................................................................................ 701 Failure code [CA132] Throttle Sensor Low Error ......................................................................................... 703 Failure code [CA144] Coolant Temp Sens High Error ...................................................................................... 705 Failure code [CA145] Coolant Temp Sens Low Error ....................................................................................... 707 Failure code [CA153] Chg Air Temp Sensor High Error .................................................................................... 709 Failure code [CA154] Chg Air Temp Sensor Low Error ..................................................................................... 711 Failure code [CA187] Sensor 2 Supply Volt Low Error .................................................................................... 713 Failure code [CA234] Eng Overspeed ..................................................................................................... 715 Failure code [CA221] Ambient Press Sensor High Error ................................................................................... 716 Failure code [CA222] Ambient Press Sensor Low Error .................................................................................... 718 Failure code [CA227] Sensor 2 Supply Volt High Error ................................................................................... 720 Failure code [CA238] Ne Speed Sensor Supply Volt Error ................................................................................. 721 Failure code [CA239] Ne Speed Sens Supply Volt High Error .............................................................................. 722 Failure code [CA271] IMV/PCV1 Short Error .............................................................................................. 723 Failure code [CA272] IMV/PCV1 Open Error ............................................................................................... 725 Failure code [CA295] Ambient Pressure Sensor In Range Error ............................................................................ 727 Failure code [CA322] Inj #1(L#1) Open/Short Error ...................................................................................... 728 Failure code [CA323] Inj #5(L#5) Open/Short Error ...................................................................................... 730 Failure code [CA324] Inj #3(L#3) Open/Short Error ...................................................................................... 732 Failure code [CA325] Inj #6(L#6) Open/Short Error ...................................................................................... 734 Failure code [CA331] Inj #2(L#2) Open/Short Error ...................................................................................... 736 Failure code [CA332] Inj #4(L#4) Open/Short Error ...................................................................................... 738 Failure code [CA343] ECM Critical Internal Failure ..................................................................................... 740 Failure code [CA351] Injectors Drive Circuit Error ..................................................................................... 741 Failure code [CA352] Sensor 1 Supply Volt Low Error .................................................................................... 742 Failure code [CA356] Mass Air Flow Sensor High Error ................................................................................... 744 Failure code [CA357] Mass Air Flow Sensor Low Error .................................................................................... 746 Failure code [CA386] Sensor 1 Supply Volt High Error ................................................................................... 748 Failure code [CA428] Water in Fuel Sensor High Error ................................................................................... 749 Failure code [CA429] Water in Fuel Sensor Low Error .................................................................................... 751 Failure code [CA435] Eng Oil Press Sw Error ............................................................................................ 753 Failure code [CA441] Battery Voltage Low Error ......................................................................................... 754 Failure code [CA442] Battery Voltage High Error ........................................................................................ 756 Failure code [CA449] Rail Press Very High Error ........................................................................................ 757 Failure code [CA451] Rail Press Sensor High Error ...................................................................................... 758 Failure code [CA452] Rail Press Sensor Low Error ....................................................................................... 760 Failure code [CA488] Chg Air Temp High Torque Derate ................................................................................... 762 Failure code [CA515] Rail Press Sens Sup Volt High Error ............................................................................... 763 Failure code [CA516] Rail Press Sens Sup Volt Low Error ................................................................................ 765 Failure code [CA553] Rail Press High Error ............................................................................................. 767 Failure code [CA555] Crankcase Press High Error 2 ...................................................................................... 768 Failure code [CA556] Crankcase Press High Error 2 ...................................................................................... 769 Failure code [CA559] Rail Press Low Error .............................................................................................. 770 Failure code [CA595] Turbo Speed High Error 2 .......................................................................................... 772 Failure code [CA687] Turbo Speed Low Error ............................................................................................. 773 Failure code [CA689] Eng Ne Speed Sensor Error ......................................................................................... 775 Failure code [CA691] Intake Air Temp Sens High Error ................................................................................... 777 Failure code [CA692] Intake Air Temp Sens Low Error .................................................................................... 779 Failure code [CA697] ECM Internal Temp Sensor High Error ............................................................................... 781 Failure code [CA698] ECM Int Temp Sensor Low Error ..................................................................................... 782 Failure code [CA731] Eng Bkup Speed Sens Phase Error ................................................................................... 783 Failure code [CA778] Eng Bkup Speed Sensor Error ....................................................................................... 785 Failure code [CA1117] Persistent Data Lost Error ....................................................................................... 790 Failure code [CA1664] KDOC Malfunction ................................................................................................. 791 Failure code [CA1691] Regeneration Ineffective ......................................................................................... 794 Failure code [CA1695] Sens 5 Supply Volt High Error .................................................................................... 797 Failure code [CA1696] Sens 5 Supply Volt Low Error ..................................................................................... 798 Failure code [CA1843] Crankcase Press Sens High Error .................................................................................. 800 Failure code [CA1844] Crankcase Press Sens Low Error ................................................................................... 802 Failure code [CA1879] KDPF Delta P Sensor High Error ................................................................................... 804 Failure code [CA1881] KDPF Delta P Sensor Low Error .................................................................................... 806 Failure code [CA1883] KDPF Delta P Sens In Range Error ................................................................................. 808 Failure code [CA1921] KDPF Soot Load High Error 1 ...................................................................................... 812 Failure code [CA1922] KDPF Soot Load High Error 2 ...................................................................................... 815 Failure code [CA1942] Crankcase Press Sens In Range Error .............................................................................. 820 Failure code [CA1993] KDPF Delta Pressure Low Error .................................................................................... 821 Failure code [CA2185] Throt Sensor Sup Volt High Error ................................................................................. 824 Failure code [CA2186] Throt Sensor Sup Volt Low Error .................................................................................. 825 Failure code [CA2249] Rail Press Very Low Error ........................................................................................ 826 Failure code [CA2271] EGR Valve Pos Sens High Error .................................................................................... 827 Failure code [CA2272] EGR Valve Pos Sens Low Error ..................................................................................... 829 Failure code [CA2288] Turbo Speed High Error 1 ......................................................................................... 832 Failure code [CA2311] IMV Solenoid Error ............................................................................................... 833 Failure code [CA2349] EGR Valve Solenoid Open Error .................................................................................... 834 Failure code [CA2353] EGR Valve Solenoid Short Error ................................................................................... 836 Failure code [CA2357] EGR Valve Servo Error ............................................................................................ 838 Failure code [CA2373] Exhaust Manifold Press Sens High error ........................................................................... 839 Failure code [CA2374] Exhaust Manifold Press Sens Low error ............................................................................ 841 Failure code [CA2375] EGR Orifice Temp Sens High Error ................................................................................. 843 Failure code [CA2376] EGR Orifice Temp Sens Low Error .................................................................................. 845 Failure code [CA2381] KVGT Pos Sens High Error ......................................................................................... 847 Failure code [CA2382] KVGT Pos Sens Low Error .......................................................................................... 849 Failure code [CA2383] KVGT Solenoid Open Error ......................................................................................... 852 Failure code [CA2386] KVGT Solenoid Short Error ........................................................................................ 854 Failure code [CA2387] KVGT Servo Error ................................................................................................. 856 Failure code [CA2554] Exh Manifold Press Sens In Range Error ........................................................................... 861 Failure code [CA2555] Grid Htr Relay Volt Low Error .................................................................................... 864 Failure code [CA2556] Grid Htr Relay Volt High Error ................................................................................... 866 Failure code [CA2637] KDOC Face Plugging ............................................................................................... 868 Failure code [CA2639] Manual Stationary Regeneration Request ........................................................................... 870 Failure code [CA2961] EGR Orifice Temp High Error 1 .................................................................................... 873 Failure code [CA2973] Chg Air Press Sensor In Range Error .............................................................................. 874 Failure code [CA3133] KDPF Outlet Press Sens High Error ................................................................................ 875 Failure code [CA3134] KDPF Outlet Press Sens Low Error ................................................................................. 877 Failure code [CA3135] KDPF Outlet Press Sens In Range Error ............................................................................ 879 Failure code [CA3251] KDOC Inlet Temp High Error ....................................................................................... 883 Failure code [CA3253] KDOC Temp Error - Non Regeneration ............................................................................... 886 Failure code [CA3254] KDOC Outlet Temp High Error 1 .................................................................................... 890 Failure code [CA3255] KDPF Temp Error - Non Regeneration ............................................................................... 893 Failure code [CA3256] KDPF Outlet Temp High Error 1 .................................................................................... 898 Failure code [CA3311] KDOC Outlet Temp High Error 2 .................................................................................... 901 Failure code [CA3312] KDPF Outlet Temp High Error 2 .................................................................................... 905 Failure code [CA3313] KDOC Inlet Temp Sensor Low Error ................................................................................. 909 Failure code [CA3314] KDOC Inlet Temp Sens High Error .................................................................................. 912 Failure code [CA3315] KDOC Inlet Temp Sens In Range Error .............................................................................. 916 Failure code [CA3316] KDOC Outlet Temp Sens Low Error .................................................................................. 920 Failure code [CA3317] KDOC Outlet Temp Sens High Error ................................................................................. 923 Failure code [CA3318] KDOC Outlet Temp Sens In Range Error ............................................................................. 927 Failure code [CA3319] KDPF Outlet Temp Sens High Error ................................................................................. 931 Failure code [CA3321] KDPF Outlet Temp Sens Low Error .................................................................................. 935 Failure code [CA3322] KDPF Outlet Temp Sens In Range Error ............................................................................. 938 Failure code [CA3419] Mass Air Flow Sensor Sup Volt High Error ......................................................................... 942 Failure code [CA3421] Mass Air Flow Sensor Sup Volt Low Error .......................................................................... 944 Failure code [CA3741] Rail Press Valve Trip Error ...................................................................................... 946 Failure code [D130KA] Neutral relay Open ............................................................................................... 947 Failure code [D130KB] Neutral relay Short circuit ...................................................................................... 949 Failure code [D130KY] Neutral relay: Hot Short ......................................................................................... 951 Failure code [D19JKZ] Personal Code Relay Abnormality .................................................................................. 953 Failure code [D811MC] KOMTRAX Error .................................................................................................... 956 Failure code [D862KA] GPS Antenna Open Circuit ......................................................................................... 957 Failure code [D8ALKA] Operating Lamp Open Circuit (KOMTRAX) ............................................................................ 958 Failure code [D8ALKB] Operating Lamp Short Circuit (KOMTRAX) ........................................................................... 960 Failure code [D8AQKR] CAN2 Discon (KOMTRAX) ............................................................................................ 961 Failure code [DAF0MB] Monitor ROM Abnormality .......................................................................................... 962 Failure code [DAF0MC] Monitor Error .................................................................................................... 963 Failure code [DAF8KB] Camera Power Supply Short Circuit ................................................................................ 964 Failure code [DAF9KQ] Model Selection Abnormality ...................................................................................... 965 Failure code [DAFGMC] GPS Module Error ................................................................................................. 966 Failure code [DAFLKA] Operating Lamp Open Circuit (Monitor) ............................................................................ 967 Failure code [DAFLKB] Operating Lamp Short Circuit (Monitor) ........................................................................... 969 Failure code [DAFQKR] CAN2 Discon (Monitor) ............................................................................................ 970 Failure code [DAJ000] HST controller: Abnormality in controller ........................................................................ 971 Failure code [DAJ0KQ] HST controller: Type select signal ............................................................................... 972 Failure code [DAJ0KT] HST controller: Abnormality in controller ........................................................................ 973 Failure code [DAJ0MC] HST Con Error .................................................................................................... 974 Failure code [DAJ1KK] HST controller: Source voltage low ............................................................................... 975 Failure code [DAJ2KK] HST controller: Output voltage low ............................................................................... 977 Failure code [DAJ5KK] HST: Sensor volt 5V (0) Out of normal range ...................................................................... 979 Failure code [DAJ6KK] HST: Sensor volt 5V (1) Out of normal range ...................................................................... 981 Failure code [DAJLKA] Operating Lamp Open Circuit (HST Con) ............................................................................ 983 Failure code [DAJLKB] Operating Lamp Short Circuit (HST Con) ........................................................................... 985 Failure code [DAJPMA] Inconsistency of Option Selection (HST) .......................................................................... 986 Failure code [DAJQKR] CAN2 Discon (HST Con) ............................................................................................ 987 Failure code [DAJRKR] CAN1 Discon (HST Con) ............................................................................................ 988 Failure code [DB2QKR] CAN2 Discon (Engine Con) ......................................................................................... 989 Failure code [DB2RKR] CAN1 Discon (Engine Con) ......................................................................................... 993 Failure code [DD12KA] Shift up SW: Open ................................................................................................ 997 Failure code [DD12KB] Shift up SW: Short Circuit ....................................................................................... 999 Failure code [DD13KA] Shift down SW: Open ..............................................................................................1001 Failure code [DD13KB] Shift down SW: Short Circuit .....................................................................................1003 Failure code [DD14KA] Parking lever SW: Open ...........................................................................................1005 Failure code [DD14KB] Parking lever SW: Short circuit ..................................................................................1007 Failure code [DDKAKA] Blade float Sw: Open .............................................................................................1009 Failure code [DDKAKB] Blade float Sw: Short circuit ....................................................................................1011 Failure code [DDKFL4] Left Angle Sw: Signal mismatch ...................................................................................1013 Failure code [DDKGL4] Right Angle Sw: Signal mismatch ..................................................................................1015 Failure code [DDKHKA] iB Sw: Open ......................................................................................................1017 Failure code [DDKHKB] iB Sw: Short circuit .............................................................................................1019 Failure code [DDNLKA] Weq lock Sw: Open ................................................................................................1021 Failure code [DDNLKB] Weq lock Sw: Short circuit .......................................................................................1023 Failure code [DDP6KA] Brake Pressure Sensor: Open ......................................................................................1025 Failure code [DDP6KB] Brake Pressure Sensor: Hot Short .................................................................................1027 Failure code [DDP6MA] Brake pressure sensor: Malfunction ...............................................................................1029 Failure code [DDU1FS] Parking lever Switch 2: Signal mismatch ..........................................................................1031 Failure code [DDU1KA] Parking lever Sw2: Open ..........................................................................................1033 Failure code [DDU1KY] Parking lever Sw2: Hot Short .....................................................................................1035 Failure code [DFA4KX] Blade lift lever: Main and Sub Error .............................................................................1037 Failure code [DFA4KZ] Blade lift lever: Main and Sub Error .............................................................................1038 Failure code [DFA4L8] Blade lift lever: Signal mismatch ................................................................................1039 Failure code [DFA5KA] Blade lift lever1: Open ..........................................................................................1040 Failure code [DFA5KB] Blade lift lever1: Hot Short .....................................................................................1043 Failure code [DFA6KA] Blade lift lever2: Open ..........................................................................................1045 Failure code [DFA6KB] Blade lift lever2: Hot Short .....................................................................................1047 Failure code [DFA7KX] Blade tilt lever: Main and Sub Error .............................................................................1049 Failure code [DFA7KZ] Blade tilt lever: Main and Sub Error .............................................................................1050 Failure code [DFA7L8] Blade tilt lever: Signal mismatch ................................................................................1051 Failure code [DFA8KA] Blade tilt lever1: Open ..........................................................................................1052 Failure code [DFA8KB] Blade tilt lever1: Hot Short .....................................................................................1055 Failure code [DFA9KA] Blade tilt lever2: Open ..........................................................................................1057 Failure code [DFA9KB] Blade tilt lever2: Hot Short .....................................................................................1060 Failure code [DGS1KA] HST oil temp sensor: Open ........................................................................................1062 Failure code [DGS1KX] HST oil temp sensor: Out of normal range .........................................................................1064 Failure code [DH21KA] Weq pressure sensor: Open ........................................................................................1065 Failure code [DH21KB] Weq pressure sensor: Hot Short ...................................................................................1067 Failure code [DHA4KA] Air Cleaner Clog Sensor Open Circuit .............................................................................1069 Failure code [DHH7KA] LF HST Pressure Sensor: Open .....................................................................................1071 Failure code [DHH7KB] LF HST Pressure Sensor: Hot Short ................................................................................1073 Failure code [DHH8KA] RF HST Pressure Sensor: Open .....................................................................................1075 Failure code [DHH8KB] RF HST Pressure Sensor: Hot Short ................................................................................1077 Failure code [DHH9KA] LR HST Pressure Sensor: Open .....................................................................................1079 Failure code [DHH9KB] LR HST Pressure Sensor: Hot Short ................................................................................1081 Failure code [DHHAKA] RR HST Pressure Sensor: Open .....................................................................................1083 Failure code [DHHAKB] RR HST Pressure Sensor: Hot Short ................................................................................1085 Failure code [DK30KA] ST lever1: Open ..................................................................................................1087 Failure code [DK30KB] ST lever1: Hot Short .............................................................................................1089 Failure code [DK30KX] ST lever: Main and Sub Error .....................................................................................1091 Failure code [DK30KZ] ST lever: Main and Sub Error .....................................................................................1092 Failure code [DK30L8] ST lever: Signal mismatch ........................................................................................1093 Failure code [DK31KA] ST lever2: Open ..................................................................................................1094 Failure code [DK31KB] ST lever2: Hot Short .............................................................................................1096 Failure code [DK40KA] Decel/Brake potentiometer: Open ..................................................................................1098 Failure code [DK40KB] Decel/Brake potentiometer: Hot Short .............................................................................1101 Failure code [DK55KX] FR lever: Main and Sub Error .....................................................................................1103 Failure code [DK55KZ] FR lever: Main and Sub Error .....................................................................................1104 Failure code [DK55L8] FR lever: Signal mismatch ........................................................................................1105 Failure code [DK56KA] FR lever1: Open ..................................................................................................1106 Failure code [DK56KB] FR lever1: Hot Short .............................................................................................1108 Failure code [DK57KA] FR lever2: Open ..................................................................................................1110 Failure code [DK57KB] FR lever2: Hot Short .............................................................................................1112 Failure code [DLM0KX] HST Motor Speed Sensor: Left/Right Error .........................................................................1114 Failure code [DLM1KA] Left HST motor speed sensor: Open ................................................................................1115 Failure code [DLM1KB] Left HST motor speed sensor: Short circuit .......................................................................1117 Failure code [DLM1MA] Left HST motor speed sensor: Malfunction .........................................................................1119 Failure code [DLM2KA] Right HST motor speed sensor: Open ...............................................................................1120 Failure code [DLM2KB] Right HST motor speed sensor: Short circuit ......................................................................1122 Failure code [DLM2MA] Right HST motor speed sensor: Malfunction ........................................................................1124 Failure code [DLM3KA] Fan rev. sensor: Open ............................................................................................1125 Failure code [DLM3KB] Fan rev. sensor: Short circuit ...................................................................................1127 Failure code [DLM3MB] Fan control: Mismatch ............................................................................................1129 Failure code [DN21FS] Decel/Brake pedal SW: Signal mismatch ............................................................................1130 Failure code [DR21KX] Camera 2 Picture Rev. Drive Abnormality ..........................................................................1132 Failure code [DR31KX] Camera 3 Picture Rev. Drive Abnormality ..........................................................................1133 Failure code [DV20KB] Back-up alarm: Short circuit .....................................................................................1134 Failure code [DW4BKA] Parking brake solenoid: Open .....................................................................................1136 Failure code [DW4BKB] Parking brake solenoid: Short circuit ............................................................................1138 Failure code [DW4BKY] Parking brake solenoid: Hot Short ................................................................................1140 Failure code [DW7BKA] Fan reverse solenoid: Open .......................................................................................1142 Failure code [DW7BKB] Fan reverse solenoid: Short circuit ..............................................................................1144 Failure code [DW7EKA] Slow brake solenoid: Open ........................................................................................1145 Failure code [DW7EKB] Slow brake solenoid: Short circuit ...............................................................................1147 Failure code [DW7EKY] Slow brake solenoid: Hot Short ...................................................................................1149 Failure code [DWN5KA] Fan EPC: Open ....................................................................................................1151 Failure code [DWN5KB] Fan EPC: Short circuit ...........................................................................................1153 Failure code [DWN5KY] Fan EPC: Hot Short ...............................................................................................1154 Failure code [DXA4KA] LF HST pump EPC: Open ............................................................................................1156 Failure code [DXA4KB] LF HST pump EPC: Short circuit ...................................................................................1158 Failure code [DXA4KY] LF HST pump EPC: Hot Short .......................................................................................1159 Failure code [DXA5KA] LR HST pump EPC: Open ............................................................................................1161 Failure code [DXA5KB] LR HST pump EPC: Short circuit ...................................................................................1163 Failure code [DXA5KY] LR HST pump EPC: Hot Short .......................................................................................1165 Failure code [DXA6KA] RF HST pump EPC: Open ............................................................................................1167 Failure code [DXA6KB] RF HST pump EPC: Short circuit ...................................................................................1169 Failure code [DXA6KY] RF HST pump EPC: Hot Short .......................................................................................1170 Failure code [DXA7KA] RR HST pump EPC: Open ............................................................................................1172 Failure code [DXA7KB] RR HST pump EPC: Short circuit ...................................................................................1174 Failure code [DXA7KY] RR HST pump EPC: Hot Short .......................................................................................1175 Failure code [DXHRKA] Blade lift up EPC: Open ..........................................................................................1177 Failure code [DXHRKB] Blade lift up EPC: Short circuit .................................................................................1179 Failure code [DXHRKY] Blade lift up EPC: Hot short .....................................................................................1180 Failure code [DXHSKA] Blade lift down EPC: Open ........................................................................................1182 Failure code [DXHSKB] Blade lift down EPC: Short circuit ...............................................................................1184 Failure code [DXHSKY] Blade lift down EPC: Hot short ...................................................................................1185 Failure code [DXHTKA] Blade tilt left EPC: Open ........................................................................................1187 Failure code [DXHTKB] Blade tilt left EPC: Short circuit ...............................................................................1189 Failure code [DXHTKY] Blade tilt left EPC: Hot short ...................................................................................1190 Failure code [DXHUKA] Blade tilt right EPC: Open .......................................................................................1192 Failure code [DXHUKB] Blade tilt right EPC: Short circuit ..............................................................................1194 Failure code [DXHUKY] Blade tilt right EPC: Hot short ..................................................................................1195 Failure code [DXJ4KA] Weq lock Sol.: Open ..............................................................................................1197 Failure code [DXJ4KB] Weq lock Sol.: Short circuit .....................................................................................1199 Failure code [DXJCKA] Blade angle left EPC: Open .......................................................................................1201 Failure code [DXJCKB] Blade angle left EPC: Short circuit ..............................................................................1202 Failure code [DXJCKY] Blade angle left EPC: Hot short ..................................................................................1203 Failure code [DXJDKA] Blade angle right EPC: Open ......................................................................................1205 Failure code [DXJDKB] Blade angle right EPC: Short circuit .............................................................................1206 Failure code [DXJDKY] Blade angle right EPC: Hot short .................................................................................1207 Failure code [DXK1KA] Left HST motor EPC: Open .........................................................................................1209 Failure code [DXK1KB] Left HST motor EPC: Short circuit ................................................................................1211 Failure code [DXK1KY] Left HST motor EPC: Hot Short ....................................................................................1212 Failure code [DXK2KA] Right HST motor EPC: Open ........................................................................................1214 Failure code [DXK2KB] Right HST motor EPC: Short circuit ...............................................................................1216 Failure code [DXK2KY] Right HST motor EPC: Hot Short ...................................................................................1217 Troubleshooting of electrical system (E-mode) ..............................................................................................1219 E-1 Engine does not start (Engine does not crank) ......................................................................................1219 E-2 Manual preheating system does not work .............................................................................................1225 E-3 Automatic preheating system does not work ..........................................................................................1228 E-4 While preheating is working, preheating monitor does not light up ..................................................................1230 E-5 When starting switch is turned to ON position, machine monitor displays nothing ....................................................1232 E-6 When starting switch is turned to ON position (with engine stopped), basic check monitor lights up .................................1235 E-7 Air cleaner clogging monitor lights up in yellow while engine is running ...........................................................1236 E-8 Charge level monitor lights up in red while engine is running ......................................................................1237 E-9 Engine coolant temperature monitor lights up in red while engine is running ........................................................1238 E-10 Engine oil pressure monitor lights up in red while engine is running ..............................................................1239 E-11 HST charge pressure monitor lights up in red while engine is running ..............................................................1240 E-12 Hydraulic oil temperature monitor lights up in red while engine is running ........................................................1241 E-13 HST oil filter clogging monitor lights up in red while engine is running ..........................................................1242 E-14 Fuel level gauge does not indicate correct level ..................................................................................1243 E-15 Engine coolant temperature gauge does not indicate correct temperature ............................................................1246 E-16 Hydraulic oil temperature gauge does not indicate correct temperature .............................................................1247 E-17 Operation mode does not change ....................................................................................................1248 E-18 Service mode cannot be selected ...................................................................................................1249 E-19 Operating customize switch does not display customize screen ......................................................................1250 E-20 Modifying setting on customize screen does not change setting of machine ..........................................................1251 E-21 Service meter is not displayed, while starting switch is in OFF position ..........................................................1252 E-22 Work equipment does not operate ...................................................................................................1253 E-23 Foot heater does not operate ......................................................................................................1255 E-24 Horn does not sound ...............................................................................................................1260 E-25 Horn does not stop sounding .......................................................................................................1262 E-26 Backup alarm does not sound .......................................................................................................1263 E-27 Backup alarm does not stop sounding ...............................................................................................1264 E-28 Headlamp does not light up ........................................................................................................1265 E-29 Rear lamp does not light up .......................................................................................................1268 E-30 No wiper operates continuously or intermittently ..................................................................................1271 E-31 Front wiper does not operate ......................................................................................................1273 E-32 Rear wiper does not operate .......................................................................................................1275 E-33 Left door wiper does not operate (failed in both continuous and intermittent operations) ..........................................1277 E-34 Right door wiper does not operate (failed in both continuous and intermittent operations) .........................................1281 E-35 Front washer does not operate .....................................................................................................1285 E-36 Rear washer does not operate ......................................................................................................1287 E-37 Left door washer does not operate .................................................................................................1289 E-38 Right door washer does not operate ................................................................................................1291 E-39 KOMTRAX system does not operate normally ..........................................................................................1293 Troubleshooting of hydraulic and mechanical system (H-mode) ................................................................................1295 Information described in troubleshooting table (H-mode) ................................................................................1295 System chart of hydraulic and mechanical systems .......................................................................................1296 Failure mode and cause table ...........................................................................................................1298 H-1 Neither RH nor LH of tracks does not travel forward nor reverse (None of the travel system operates) ...............................1302 H-2 Either RH or LH of track does not travel forward nor reverse (Only RH or LH of travel system operates) .............................1304 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) ....1305 H-4 Travel speed or power is low .......................................................................................................1307 H-5 Travel speed range does not change .................................................................................................1308 H-6 Shock is large when machine starts or stops ........................................................................................1309 H-7 Machine deviates largely ...........................................................................................................1310 H-8 Machine drift on a slope is large ..................................................................................................1312 H-9 Engine stalls during travel or engine speed drops significantly ....................................................................1313 H-10 Unusual noise is heard from around HST pump or motor ..............................................................................1314 H-11 All work equipment do not operate .................................................................................................1315 H-12 All work equipment operates slowly or lacks power .................................................................................1317 H-13 Blade lift speed or power is low ..................................................................................................1318 H-14 Blade tilt speed or power is low ..................................................................................................1319 H-15 Blade angle speed or power is low .................................................................................................1320 H-16 Time lag of blade lift is large ...................................................................................................1321 H-17 Hydraulic drift of lifted blade is large ..........................................................................................1322 H-18 Hydraulic drift of tilted blade is large ..........................................................................................1323 H-19 Unusual noise is heard from around work equipment pump or control valve ...........................................................1324 H-20 HST oil temperature (hydraulic oil temperature) rises too high ....................................................................1325 H-21 Fans speed is abnormal (high, low, or no rotation) ................................................................................1327 H-22 Unusual noise is heard from around fan ............................................................................................1329 Troubleshooting of engine (S-mode) .........................................................................................................1330 Information described in troubleshooting table (S mode) ................................................................................1330 S-1 Engine does not crank when starting switch is turned to START position .............................................................1331 S-2 Engine cranks but no exhaust smoke comes out .......................................................................................1332 S-3 Fuel is being injected but engine does not start (misfiring: engine cranks but does not start) .....................................1333 S-4 Engine startability is poor ........................................................................................................1334 S-5 Engine does not pick up smoothly ...................................................................................................1336 S-6 Engine stops during operation ......................................................................................................1338 S-7 Engine runs rough or is unstable ...................................................................................................1340 S-8 Engine lacks power .................................................................................................................1341 S-9 KDPF gets clogged in a short time ..................................................................................................1343 S-10 Engine oil consumption is excessive ...............................................................................................1345 S-11 Engine oil becomes contaminated early .............................................................................................1346 S-12 Fuel consumption is excessive .....................................................................................................1347 S-13 Oil is in coolant (or coolant spurts or coolant level goes down) ..................................................................1348 S-14 Oil pressure drops ................................................................................................................1349 S-15 Fuel mixes into engine oil ........................................................................................................1350 S-16 Water mixes into engine oil (milky) ...............................................................................................1351 S-17 Coolant temperature rises too high (overheating) ..................................................................................1352 S-18 Unusual noise is heard ............................................................................................................1353 S-19 Vibration is excessive ............................................................................................................1354 S-20 Air cannot be bled from fuel circuit ..............................................................................................1355 S-21 Active regeneration is executed frequently ........................................................................................1356 S-22 Active regeneration takes time ....................................................................................................1357 S-23 White smoke is exhausted during active regeneration ...............................................................................1358 50 Disassembly and assembly ....................................................................................................................1359 Table of contents ..........................................................................................................................1360 Related information on disassembly and assembly ............................................................................................1362 How to read this manual ................................................................................................................1362 Coating materials list .................................................................................................................1364 Special tools list .....................................................................................................................1368 Sketches of special tools ..............................................................................................................1374 Engine and cooling system ..................................................................................................................1387 Removal and installation of supply pump assembly .......................................................................................1387 Removal and installation of fuel injector assembly .....................................................................................1392 Removal and installation of cylinder head assembly .....................................................................................1400 Removal and installation of radiator assembly ..........................................................................................1416 Removal and installation of aftercooler assembly .......................................................................................1420 Removal and installation of hydraulic oil cooler assembly ..............................................................................1423 Removal and installation of cooling fan drive assembly .................................................................................1426 Removal and installation of cooling fan motor assembly .................................................................................1429 Removal and installation of engine assembly ............................................................................................1431 Disassembly and assembly of damper assembly ............................................................................................1438 Removal and installation of engine front oil seal ......................................................................................1439 Removal and installation of engine rear oil seal .......................................................................................1441 Removal and installation of engine hood assembly .......................................................................................1444 Removal and installation of fuel tank assembly .........................................................................................1447 Removal and installation of KDPF assembly ..............................................................................................1451 Disassembly and assembly of KDPF assembly ..............................................................................................1454 Removal and installation of KCCV assembly ..............................................................................................1463 Removal and installation of KVGT assembly ..............................................................................................1464 Removal and installation of EGR (Exhaust Gas Recirculation) cooler assembly ............................................................1467 Removal and installation of EGR (Exhaust Gas Recirculation) valve assembly .............................................................1470 Removal and installation of belt for alternator and air conditioner compressor .........................................................1471 Removal and installation of air cleaner assembly .......................................................................................1472 Power train ................................................................................................................................1474 Removal and installation of HST pump assembly ..........................................................................................1474 Removal and installation of HST motor and final drive assembly .........................................................................1476 Disassembly and assembly of final drive ................................................................................................1479 Undercarriage and frame ....................................................................................................................1489 Removal and installation of track frame assembly .......................................................................................1489 Removal and installation of idler assembly .............................................................................................1493 Disassembly and assembly of idler ......................................................................................................1495 Removal and installation of recoil spring assembly .....................................................................................1499 Disassembly and assembly of recoil spring ..............................................................................................1500 Removal and installation of track roller assembly ......................................................................................1504 Disassembly and assembly of track roller assembly ......................................................................................1506 Removal and installation of carrier roller assembly ....................................................................................1509 Disassembly and assembly of carrier roller assembly ....................................................................................1511 Removal and installation of segment teeth ..............................................................................................1513 Separation and connection of track shoe assembly (Standard type track shoe) ............................................................1514 Separation and connection of track shoe assembly (PLUS type track shoe) ................................................................1519 Overall disassembly and assembly of track shoe assembly (Standard type track shoe) .....................................................1520 Overall disassembly and assembly of track shoe assembly (PLUS type track shoe) .........................................................1536 Disassembly and assembly of one track link assembly in field (Standard type track shoe) ................................................1543 Disassembly and assembly of one track link assembly in field (PLUS type track shoe) ....................................................1549 Removal and installation of pivot shaft assembly .......................................................................................1554 Removal and installation of equalizer bar assembly .....................................................................................1556 Removal and installation of equalizer bar side bushing .................................................................................1558 Hydraulic system ...........................................................................................................................1559 Removal and installation of hydraulic tank assembly ....................................................................................1559 Removal and installation of control valve assembly .....................................................................................1563 Disassembly and assembly of hydraulic cylinder assembly ................................................................................1566 Work equipment .............................................................................................................................1570 Removal and installation of work equipment assembly ....................................................................................1570 Removal and installation of blade assembly .............................................................................................1572 Removal and installation of U-frame assembly ...........................................................................................1574 Cab and its attachments ....................................................................................................................1576 Removal and installation of ROPS cab assembly ..........................................................................................1576 Removal and installation of operator's cab glass (adhesion glass) ......................................................................1580 Removal and installation of operator's seat ............................................................................................1586 Removal and installation of seat belt ..................................................................................................1587 Removal and installation of foot heater assembly .......................................................................................1588 Disassembly and assembly of foot heater assembly .......................................................................................1590 Removal and installation of air conditioner unit assembly ..............................................................................1591 Removal and installation of air conditioner compressor assembly ........................................................................1595 Electrical system ..........................................................................................................................1597 Removal and installation of machine monitor assembly ...................................................................................1597 Removal and installation of engine controller assembly .................................................................................1598 Removal and installation of HST controller assembly ....................................................................................1600 Removal and installation of mass air flow and temperature sensor .......................................................................1601 Removal and installation of KOMTRAX terminal ...........................................................................................1602 60 Maintenance standard ........................................................................................................................1603 Table of contents ..........................................................................................................................1604 Engine and cooling system ..................................................................................................................1605 Engine mount ...........................................................................................................................1605 Cooling fan motor ......................................................................................................................1606 Oil cooler bypass and HST charge safety valve ..........................................................................................1608 Power train ................................................................................................................................1609 Damper .................................................................................................................................1609 HST pump ...............................................................................................................................1610 HST motor ..............................................................................................................................1612 Charge pump ............................................................................................................................1613 Solenoid valve .........................................................................................................................1614 Final drive ............................................................................................................................1615 Sprocket ...............................................................................................................................1616 Full-scale drawing of sprocket tooth profile ...........................................................................................1617 Undercarriage and frame ....................................................................................................................1619 Suspension .............................................................................................................................1619 Track frame and idler cushion ..........................................................................................................1621 Idler ..................................................................................................................................1623 Track roller ...........................................................................................................................1625 Carrier roller .........................................................................................................................1629 Track shoe .............................................................................................................................1631 Hydraulic system ...........................................................................................................................1637 Hydraulic tank .........................................................................................................................1637 Work equipment and cooling fan pump ....................................................................................................1638 Control valve ..........................................................................................................................1641 Ripper PPC valve .......................................................................................................................1648 Quick drop valve .......................................................................................................................1650 Angle control EPC valve ................................................................................................................1652 Work equipment .............................................................................................................................1653 Blade ..................................................................................................................................1653 Cutting edge and end bit ...............................................................................................................1656 Ripper .................................................................................................................................1657 Lift cylinder ..........................................................................................................................1659 Tilt cylinder ..........................................................................................................................1660 Angle cylinder .........................................................................................................................1661 Ripper cylinder ........................................................................................................................1662 Cab and its attachments ....................................................................................................................1663 Cab mount ..............................................................................................................................1663 Electrical system ..........................................................................................................................1664 Electric steering lever ................................................................................................................1664 80 Appendix ....................................................................................................................................1665 Table of contents ..........................................................................................................................1666 Air conditioner components .................................................................................................................1667 Precautions for refrigerant ............................................................................................................1667 Air conditioner component ..............................................................................................................1668 Configuration and function of refrigeration cycle ......................................................................................1671 Outline of refrigeration cycle .........................................................................................................1672 Air conditioner unit ...................................................................................................................1674 Dual pressure switch ...................................................................................................................1678 Pressure switch ........................................................................................................................1679 Compressor .............................................................................................................................1680 Condenser ..............................................................................................................................1681 Receiver drier .........................................................................................................................1683 Procedure for testing and troubleshooting ..............................................................................................1684 Electrical circuit diagram .............................................................................................................1687 System diagram .........................................................................................................................1688 Parts and connectors layout ............................................................................................................1690 Testing relays .........................................................................................................................1695 Troubleshooting chart 1 ................................................................................................................1697 Troubleshooting chart 2 ................................................................................................................1698 Information described in troubleshooting table .........................................................................................1700 A-1 Troubleshooting for condenser fan ..................................................................................................1701 A-2 Troubleshooting for compressor and refrigerant system (Air is not cooled) ..........................................................1704 A-3 Troubleshooting for blower motor system (No air comes out or air flow is abnormal) .................................................1708 A-4 Troubleshooting for temperature control ............................................................................................1710 Troubleshooting with gauge pressure ....................................................................................................1713 Connection of service tool .............................................................................................................1716 Precautions for disconnecting and connecting hoses and tubes in air conditioner circuit ................................................1718 Handling of compressor oil .............................................................................................................1720 90 Diagrams and drawings .......................................................................................................................1723 Table of contents ..........................................................................................................................1724 Hydraulic circuit diagram ..................................................................................................................1725 Symbols in hydraulic circuit diagram ...................................................................................................1725 Hydraulic circuit diagram ..............................................................................................................1729 Electric circuit diagram ...................................................................................................................1731 Symbols in electric circuit diagram ....................................................................................................1731 Electrical circuit diagram .............................................................................................................1735 INDEX...........................................................................................................................................1757
DESCRIPTION:
KOMATSU D61EX-23 D61PX-23 BULLDOZER SHOP MANUAL SEN06010-10 – PDF DOWNLOAD
Composition of shop manual
• This shop manual describes the technical information required for the services performed in a workshop.
The shop manual is divided into the following chapters for the convenience of use.
00. Index and foreword
• This section includes the index, foreword, safety and basic information.
01. Specification
• This section explains the specifications of the machine.
10. Structure and function
• This section explains the structure and function of the machine. The section of “Structure and function” serves not only to give an understanding for the structure of each component, but also serves as reference material for troubleshooting.
20. Standard value table
• The standard values for a new machine and trouble shooting are indicated. This standard value table is used for testing and adjusting, and determining a failure at troubleshooting.
30. Testing and adjusting
• This section describes the measuring tools and how to measure, and how to adjust various parts. As for the standard value and failure criterion, see the standard value table.
40. Troubleshooting
• This section describes the troubleshooting in a suspected area when a failure occurs and the remedy for the failure. Troubleshooting is described by each failure mode.
50. Disassembly and assembly
• This section explains the procedures for removing, installing, disassembling, and assembling each part or component and the special tools for the works as well as precautions for doing them safely. In addition, tightening torque, and quantity and weight of coating material, oil, grease, and coolant required for the works are also explained.
60. Maintenance standard
• This section describes the maintenance standard values for each component. This section gives the criterion values for each component and required remedy at disassembly or maintenance.
80. Appendix
• The structure and function, testing and adjusting, and troubleshooting for all of the other components or equipment which can not be separately classified are explained together in the appendix.
90. Diagrams and drawings
• This section gives hydraulic circuit diagrams and electrical circuit diagrams.
S.S 26/12/24
