Komatsu D61EX-23 D61PX-23 Shop Manual – PDF DOWNLOAD

Description

Komatsu D61EX-23 D61PX-23 Shop Manual – PDF DOWNLOAD

FILE DETAILS:

Komatsu D61EX-23 D61PX-23 Shop Manual – PDF DOWNLOAD

Language : English
Pages : 1734
Downloadable : Yes
File Type : PDF

IMAGES PREVIEW OF THE MANUAL:

TABLE OF CONTENTS:

Komatsu D61EX-23 D61PX-23 Shop Manual – 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 367
Engine and cooling system 369
Testing engine speed . 369
Testing boost pressure . 371
Testing exhaust gas color 373
Testing and adjusting valve clearance 375
Testing compression pressure . 378
Testing blowby pressure 382
Testing engine oil pressure 384
Testing EGR valve and KVGT oil pressures . 385
Testing fuel pressure 386
Testing fuel discharge, return and leakage . 391
Bleeding air from fuel system 396
Testing fuel circuit for leakage . 398
Handling cylinder cutout mode operation 399
Handling no-injection cranking operation . 400
Testing of KDPF and muffler stack for looseness and damage . 401
Testing of installed condition of cylinder heads and manifolds . 402
Testing engine piping for damage and looseness . 403
Check alternator belt, replace . 404
Check auto-tensioner, replace 406
Writing compensation amount for soot accumulation caused by ash on engine controller . 408
Power train 410
Testing and adjusting HST oil pressure . 410
Testing output pressure of solenoid valve 415
Testing if machine travels straight 419
Simple test procedure for brake performance 420
Adjusting deceleration/brake pedal . 421
Adjusting parking brake lever 424
Move disabled machine urgently . 426
Undercarriage and frame 429
Adjusting idler clearance 429
Checking sprocket wear . 430
Testing and adjusting track tension 431
Hydraulic system . 432
Releasing remaining pressure in work equipment cylinder 432
Testing and adjusting work equipment oil pressure 433
Testing source pressure of control circuit . 435
Testing outlet pressure of work equipment EPC valve and fan EPC valve 436
Isolating the parts causing hydraulic drift in blade and ripper 438
Testing internal oil leakage of work equipment cylinder 439
Testing fan speed 441
Testing fan circuit oil pressure . 442
Bleeding air from hydraulic circuit 443
Work equipment . 444
Adjusting work equipment lock lever 444
Adjusting play of blade center ball 446
Electrical system 447
Special functions of machine monitor . 447
Adjustment method when HST controller has been replaced 526
Adjustment method when electric or hydraulic device has been replaced 529
Adjusting rearview camera angle 530
Handling voltage circuit of engine controller 531
Handling battery disconnect switch . 532
Testing diodes . 533
Pm clinic 534
Pm Clinic service 534
Pm Clinic check sheet 536
40 Troubleshooting . 543
Table of contents 544
Related information on troubleshooting . 551
Troubleshooting points . 551
Sequence of events in troubleshooting 553
Checks before troubleshooting 555
Inspection procedure before troubleshooting 557
Preparation for troubleshooting of electrical system . 574
Classification and procedures for troubleshooting 578
Symptom and troubleshooting numbers 580
Information in troubleshooting table . 583
Procedure for troubleshooting wiring harness of pressure sensor system for open circuit 585
Connector list and layout 588
Connector contact identification . 600
T-branch box and T-branch adapter table 639
Fuse location table 644
Precautions for KDPF (KCSF and KDOC) Cleaning and Replacement 649
Preparation of dummy temperature sensor (for KDOC and KDPF temperature sensors) 652
Preparation of short circuit electrical connector (for failure codes [CA1883] and [CA3135]) 653
Failure codes table 654
Troubleshooting by failure code (Display of code) 665
Failure code [6091NX] HST Oil Filter Clogging 665
Failure code [989L00] Engine Controller Lock Caution 1 . 667
Failure code [989M00] Engine Controller Lock Caution 2 . 668
Failure code [989N00] Engine Controller Lock Caution 3 . 669
Failure code [A1U0N3] HC Desorb Request 1 670
Failure code [A1U0N4] HC Desorb Request 2 672
Failure code [AA10NX] Air Cleaner Clogging . 674
Failure code [AB00KE] Charge Voltage Low . 676
Failure code [B@BAZG] Eng Oil Press Low 678
Failure code [B@BCNS] Eng Water Overheat . 679
Failure code [B@CRNS] HST Oil Overheat . 680
Failure code [B@CRZG] HST Charge Press Low . 681
Failure code [CA115] Eng Ne and Bkup Speed Sens Error 682
Failure code [CA122] Chg Air Press Sensor High Error . 683
Failure code [CA123] Chg Air Press Sensor Low Error 685
Failure code [CA131] Throttle Sensor High Error 687
Failure code [CA132] Throttle Sensor Low Error . 689
Failure code [CA144] Coolant Temp Sens High Error 691
Failure code [CA145] Coolant Temp Sens Low Error . 693
Failure code [CA153] Chg Air Temp Sensor High Error 695
Failure code [CA154] Chg Air Temp Sensor Low Error . 697
Failure code [CA187] Sensor 2 Supply Volt Low Error 699
Failure code [CA234] Eng Overspeed . 701
Failure code [CA221] Ambient Press Sensor High Error . 702
Failure code [CA222] Ambient Press Sensor Low Error 704
Failure code [CA227] Sensor 2 Supply Volt High Error . 706
Failure code [CA238] Ne Speed Sensor Supply Volt Error . 707
Failure code [CA239] Ne Speed Sens Supply Volt High Error 708
Failure code [CA271] IMV/PCV1 Short Error 709
Failure code [CA272] IMV/PCV1 Open Error . 711
Failure code [CA295] Ambient Pressure Sensor In Range Error 713
Failure code [CA322] Inj #1(L#1) Open/Short Error 714
Failure code [CA323] Inj #5(L#5) Open/Short Error 716
Failure code [CA324] Inj #3(L#3) Open/Short Error 718
Failure code [CA325] Inj #6(L#6) Open/Short Error 720
Failure code [CA331] Inj #2(L#2) Open/Short Error 722
Failure code [CA332] Inj #4(L#4) Open/Short Error 724
Failure code [CA343] ECM Critical Internal Failure . 726
Failure code [CA351] Injectors Drive Circuit Error . 727
Failure code [CA352] Sensor 1 Supply Volt Low Error 728
Failure code [CA356] Mass Air Flow Sensor High Error . 730
Failure code [CA357] Mass Air Flow Sensor Low Error 732
Failure code [CA386] Sensor 1 Supply Volt High Error . 734
Failure code [CA428] Water in Fuel Sensor High Error . 735
Failure code [CA429] Water in Fuel Sensor Low Error 737
Failure code [CA435] Eng Oil Press Sw Error 739
Failure code [CA441] Battery Voltage Low Error . 740
Failure code [CA442] Battery Voltage High Error 742
Failure code [CA449] Rail Press Very High Error 743
Failure code [CA451] Rail Press Sensor High Error 744
Failure code [CA452] Rail Press Sensor Low Error . 746
Failure code [CA488] Chg Air Temp High Torque Derate . 748
Failure code [CA515] Rail Press Sens Sup Volt High Error . 749
Failure code [CA516] Rail Press Sens Sup Volt Low Error 751
Failure code [CA553] Rail Press High Error . 753
Failure code [CA555] Crankcase Press High Error 2 754
Failure code [CA556] Crankcase Press High Error 2 755
Failure code [CA559] Rail Press Low Error 756
Failure code [CA595] Turbo Speed High Error 2 758
Failure code [CA687] Turbo Speed Low Error . 759
Failure code [CA689] Eng Ne Speed Sensor Error . 761
Failure code [CA691] Intake Air Temp Sens High Error . 763
Failure code [CA692] Intake Air Temp Sens Low Error 765
Failure code [CA697] ECM Internal Temp Sensor High Error . 767
Failure code [CA698] ECM Int Temp Sensor Low Error . 768
Failure code [CA731] Eng Bkup Speed Sens Phase Error . 769
Failure code [CA778] Eng Bkup Speed Sensor Error . 771
Failure code [CA1117] Persistent Data Lost Error . 776
Failure code [CA1664] KDOC Malfunction . 777
Failure code [CA1691] Regeneration Ineffective . 780
Failure code [CA1695] Sens 5 Supply Volt High Error 783
Failure code [CA1696] Sens 5 Supply Volt Low Error . 784
Failure code [CA1843] Crankcase Press Sens High Error 786
Failure code [CA1844] Crankcase Press Sens Low Error . 788
Failure code [CA1879] KDPF Delta P Sensor High Error . 790
Failure code [CA1881] KDPF Delta P Sensor Low Error 792
Failure code [CA1883] KDPF Delta P Sens In Range Error . 794
Failure code [CA1921] KDPF Soot Load High Error 1 798
Failure code [CA1922] KDPF Soot Load High Error 2 801
Failure code [CA1942] Crankcase Press Sens In Range Error 806
Failure code [CA1993] KDPF Delta Pressure Low Error 807
Failure code [CA2185] Throt Sensor Sup Volt High Error . 810
Failure code [CA2186] Throt Sensor Sup Volt Low Error 811
Failure code [CA2249] Rail Press Very Low Error 812
Failure code [CA2271] EGR Valve Pos Sens High Error 813
Failure code [CA2272] EGR Valve Pos Sens Low Error . 815
Failure code [CA2288] Turbo Speed High Error 1 . 818
Failure code [CA2311] IMV Solenoid Error . 819
Failure code [CA2349] EGR Valve Solenoid Open Error 820
Failure code [CA2353] EGR Valve Solenoid Short Error . 822
Failure code [CA2357] EGR Valve Servo Error 824
Failure code [CA2373] Exhaust Manifold Press Sens High error . 825
Failure code [CA2374] Exhaust Manifold Press Sens Low error 827
Failure code [CA2375] EGR Orifice Temp Sens High Error . 829
Failure code [CA2376] EGR Orifice Temp Sens Low Error 831
Failure code [CA2381] KVGT Pos Sens High Error . 833
Failure code [CA2382] KVGT Pos Sens Low Error 835
Failure code [CA2383] KVGT Solenoid Open Error . 838
Failure code [CA2386] KVGT Solenoid Short Error 840
Failure code [CA2387] KVGT Servo Error . 842
Failure code [CA2554] Exh Manifold Press Sens In Range Error . 843
Failure code [CA2555] Grid Htr Relay Volt Low Error 844
Failure code [CA2556] Grid Htr Relay Volt High Error . 846
Failure code [CA2637] KDOC Face Plugging . 848
Failure code [CA2639] Manual Stationary Regeneration Request . 850
Failure code [CA2961] EGR Orifice Temp High Error 1 853
Failure code [CA2973] Chg Air Press Sensor In Range Error 854
Failure code [CA3133] KDPF Outlet Press Sens High Error 855
Failure code [CA3134] KDPF Outlet Press Sens Low Error . 857
Failure code [CA3135] KDPF Outlet Press Sens In Range Error 859
Failure code [CA3251] KDOC Inlet Temp High Error . 863
Failure code [CA3253] KDOC Temp Error – Non Regeneration . 866
Failure code [CA3254] KDOC Outlet Temp High Error 1 870
Failure code [CA3255] KDPF Temp Error – Non Regeneration . 873
Failure code [CA3256] KDPF Outlet Temp High Error 1 878
Failure code [CA3311] KDOC Outlet Temp High Error 2 881
Failure code [CA3312] KDPF Outlet Temp High Error 2 885
Failure code [CA3313] KDOC Inlet Temp Sensor Low Error . 889
Failure code [CA3314] KDOC Inlet Temp Sens High Error 892
Failure code [CA3315] KDOC Inlet Temp Sens In Range Error 896
Failure code [CA3316] KDOC Outlet Temp Sens Low Error 900
Failure code [CA3317] KDOC Outlet Temp Sens High Error . 903
Failure code [CA3318] KDOC Outlet Temp Sens In Range Error . 907
Failure code [CA3319] KDPF Outlet Temp Sens High Error . 911
Failure code [CA3321] KDPF Outlet Temp Sens Low Error 915
Failure code [CA3322] KDPF Outlet Temp Sens In Range Error . 918
Failure code [CA3419] Mass Air Flow Sensor Sup Volt High Error . 922
Failure code [CA3421] Mass Air Flow Sensor Sup Volt Low Error 924
Failure code [CA3741] Rail Press Valve Trip Error 926
Failure code [D130KA] Neutral relay Open . 927
Failure code [D130KB] Neutral relay Short circuit 929
Failure code [D130KY] Neutral relay: Hot Short . 931
Failure code [D19JKZ] Personal Code Relay Abnormality 933
Failure code [D811MC] KOMTRAX Error 936
Failure code [D862KA] GPS Antenna Open Circuit . 937
Failure code [D8ALKA] Operating Lamp Open Circuit (KOMTRAX) 938
Failure code [D8ALKB] Operating Lamp Short Circuit (KOMTRAX) . 940
Failure code [D8AQKR] CAN2 Discon (KOMTRAX) 941
Failure code [DAF0MB] Monitor ROM Abnormality 942
Failure code [DAF0MC] Monitor Error 943
Failure code [DAF8KB] Camera Power Supply Short Circuit 944
Failure code [DAF9KQ] Model Selection Abnormality 945
Failure code [DAFGMC] GPS Module Error . 946
Failure code [DAFLKA] Operating Lamp Open Circuit (Monitor) 947
Failure code [DAFLKB] Operating Lamp Short Circuit (Monitor) . 949
Failure code [DAFQKR] CAN2 Discon (Monitor) 950
Failure code [DAJ000] HST controller: Abnormality in controller 951
Failure code [DAJ0KQ] HST controller: Type select signal . 952
Failure code [DAJ0KT] HST controller: Abnormality in controller 953
Failure code [DAJ0MC] HST Con Error 954
Failure code [DAJ1KK] HST controller: Source voltage low . 955
Failure code [DAJ2KK] HST controller: Output voltage low . 957
Failure code [DAJ5KK] HST: Sensor volt 5V (0) Out of normal range 959
Failure code [DAJ6KK] HST: Sensor volt 5V (1) Out of normal range 961
Failure code [DAJLKA] Operating Lamp Open Circuit (HST Con) 963
Failure code [DAJLKB] Operating Lamp Short Circuit (HST Con) . 965
Failure code [DAJPMA] Inconsistency of Option Selection (HST) 966
Failure code [DAJQKR] CAN2 Discon (HST Con) 967
Failure code [DAJRKR] CAN1 Discon (HST Con) 968
Failure code [DB2QKR] CAN2 Discon (Engine Con) . 969
Failure code [DB2RKR] CAN1 Discon (Engine Con) . 973
Failure code [DD12KA] Shift up SW: Open 977
Failure code [DD12KB] Shift up SW: Short Circuit . 979
Failure code [DD13KA] Shift down SW: Open 981
Failure code [DD13KB] Shift down SW: Short Circuit . 983
Failure code [DD14KA] Parking lever SW: Open . 985
Failure code [DD14KB] Parking lever SW: Short circuit 987
Failure code [DDKAKA] Blade float Sw: Open . 989
Failure code [DDKAKB] Blade float Sw: Short circuit 991
Failure code [DDKFL4] Left Angle Sw: Signal mismatch . 993
Failure code [DDKGL4] Right Angle Sw: Signal mismatch 995
Failure code [DDKHKA] iB Sw: Open 997
Failure code [DDKHKB] iB Sw: Short circuit . 999
Failure code [DDNLKA] Weq lock Sw: Open 1001
Failure code [DDNLKB] Weq lock Sw: Short circuit .1003
Failure code [DDP6KA] Brake Pressure Sensor: Open 1005
Failure code [DDP6KB] Brake Pressure Sensor: Hot Short .1007
Failure code [DDP6MA] Brake pressure sensor: Malfunction .1009
Failure code [DDU1FS] Parking lever Switch 2: Signal mismatch 1011
Failure code [DDU1KA] Parking lever Sw2: Open 1013
Failure code [DDU1KY] Parking lever Sw2: Hot Short .1015
Failure code [DFA4KX] Blade lift lever: Main and Sub Error .1017
Failure code [DFA4KZ] Blade lift lever: Main and Sub Error .1018
Failure code [DFA4L8] Blade lift lever: Signal mismatch 1019
Failure code [DFA5KA] Blade lift lever1: Open 1020
Failure code [DFA5KB] Blade lift lever1: Hot Short .1023
Failure code [DFA6KA] Blade lift lever2: Open 1025
Failure code [DFA6KB] Blade lift lever2: Hot Short .1027
Failure code [DFA7KX] Blade tilt lever: Main and Sub Error .1029
Failure code [DFA7KZ] Blade tilt lever: Main and Sub Error .1030
Failure code [DFA7L8] Blade tilt lever: Signal mismatch 1031
Failure code [DFA8KA] Blade tilt lever1: Open 1032
Failure code [DFA8KB] Blade tilt lever1: Hot Short .1035
Failure code [DFA9KA] Blade tilt lever2: Open 1037
Failure code [DFA9KB] Blade tilt lever2: Hot Short .1040
Failure code [DGS1KA] HST oil temp sensor: Open 1042
Failure code [DGS1KX] HST oil temp sensor: Out of normal range .1044
Failure code [DH21KA] Weq pressure sensor: Open 1045
Failure code [DH21KB] Weq pressure sensor: Hot Short .1047
Failure code [DHA4KA] Air Cleaner Clog Sensor Open Circuit .1049
Failure code [DHH7KA] LF HST Pressure Sensor: Open .1051
Failure code [DHH7KB] LF HST Pressure Sensor: Hot Short 1053
Failure code [DHH8KA] RF HST Pressure Sensor: Open .1055
Failure code [DHH8KB] RF HST Pressure Sensor: Hot Short 1057
Failure code [DHH9KA] LR HST Pressure Sensor: Open .1059
Failure code [DHH9KB] LR HST Pressure Sensor: Hot Short 1061
Failure code [DHHAKA] RR HST Pressure Sensor: Open .1063
Failure code [DHHAKB] RR HST Pressure Sensor: Hot Short 1065
Failure code [DK30KA] ST lever1: Open 1067
Failure code [DK30KB] ST lever1: Hot Short .1069
Failure code [DK30KX] ST lever: Main and Sub Error .1071
Failure code [DK30KZ] ST lever: Main and Sub Error .1072
Failure code [DK30L8] ST lever: Signal mismatch 1073
Failure code [DK31KA] ST lever2: Open 1074
Failure code [DK31KB] ST lever2: Hot Short .1076
Failure code [DK40KA] Decel/Brake potentiometer: Open 1078
Failure code [DK40KB] Decel/Brake potentiometer: Hot Short .1081
Failure code [DK55KX] FR lever: Main and Sub Error .1083
Failure code [DK55KZ] FR lever: Main and Sub Error .1084
Failure code [DK55L8] FR lever: Signal mismatch 1085
Failure code [DK56KA] FR lever1: Open 1086
Failure code [DK56KB] FR lever1: Hot Short .1088
Failure code [DK57KA] FR lever2: Open 1090
Failure code [DK57KB] FR lever2: Hot Short .1092
Failure code [DLM0KX] HST Motor Speed Sensor: Left/Right Error .1094
Failure code [DLM1KA] Left HST motor speed sensor: Open 1095
Failure code [DLM1KB] Left HST motor speed sensor: Short circuit .1097
Failure code [DLM1MA] Left HST motor speed sensor: Malfunction .1099
Failure code [DLM2KA] Right HST motor speed sensor: Open .1100
Failure code [DLM2KB] Right HST motor speed sensor: Short circuit 1102
Failure code [DLM2MA] Right HST motor speed sensor: Malfunction 1104
Failure code [DLM3KA] Fan rev. sensor: Open 1105
Failure code [DLM3KB] Fan rev. sensor: Short circuit .1107
Failure code [DLM3MB] Fan control: Mismatch 1109
Failure code [DN21FS] Decel/Brake pedal SW: Signal mismatch 1110
Failure code [DR21KX] Camera 2 Picture Rev. Drive Abnormality 1112
Failure code [DR31KX] Camera 3 Picture Rev. Drive Abnormality 1113
Failure code [DV20KB] Back-up alarm: Short circuit .1114
Failure code [DW4BKA] Parking brake solenoid: Open .1116
Failure code [DW4BKB] Parking brake solenoid: Short circuit 1118
Failure code [DW4BKY] Parking brake solenoid: Hot Short 1120
Failure code [DW7BKA] Fan reverse solenoid: Open .1122
Failure code [DW7BKB] Fan reverse solenoid: Short circuit 1124
Failure code [DW7EKA] Slow brake solenoid: Open 1125
Failure code [DW7EKB] Slow brake solenoid: Short circuit .1127
Failure code [DW7EKY] Slow brake solenoid: Hot Short .1129
Failure code [DWN5KA] Fan EPC: Open 1131
Failure code [DWN5KB] Fan EPC: Short circuit .1133
Failure code [DWN5KY] Fan EPC: Hot Short .1134
Failure code [DXA4KA] LF HST pump EPC: Open 1136
Failure code [DXA4KB] LF HST pump EPC: Short circuit .1138
Failure code [DXA4KY] LF HST pump EPC: Hot Short .1139
Failure code [DXA5KA] LR HST pump EPC: Open 1141
Failure code [DXA5KB] LR HST pump EPC: Short circuit .1143
Failure code [DXA5KY] LR HST pump EPC: Hot Short .1145
Failure code [DXA6KA] RF HST pump EPC: Open 1147
Failure code [DXA6KB] RF HST pump EPC: Short circuit .1149
Failure code [DXA6KY] RF HST pump EPC: Hot Short .1150
Failure code [DXA7KA] RR HST pump EPC: Open 1152
Failure code [DXA7KB] RR HST pump EPC: Short circuit .1154
Failure code [DXA7KY] RR HST pump EPC: Hot Short .1155
Failure code [DXHRKA] Blade lift up EPC: Open 1157
Failure code [DXHRKB] Blade lift up EPC: Short circuit .1159
Failure code [DXHRKY] Blade lift up EPC: Hot short .1160
Failure code [DXHSKA] Blade lift down EPC: Open 1162
Failure code [DXHSKB] Blade lift down EPC: Short circuit .1164
Failure code [DXHSKY] Blade lift down EPC: Hot short .1165
Failure code [DXHTKA] Blade tilt left EPC: Open 1167
Failure code [DXHTKB] Blade tilt left EPC: Short circuit .1169
Failure code [DXHTKY] Blade tilt left EPC: Hot short .1170
Failure code [DXHUKA] Blade tilt right EPC: Open .1172
Failure code [DXHUKB] Blade tilt right EPC: Short circuit 1174
Failure code [DXHUKY] Blade tilt right EPC: Hot short 1175
Failure code [DXJ4KA] Weq lock Sol.: Open 1177
Failure code [DXJ4KB] Weq lock Sol.: Short circuit .1179
Failure code [DXJCKA] Blade angle left EPC: Open .1181
Failure code [DXJCKB] Blade angle left EPC: Short circuit 1182
Failure code [DXJCKY] Blade angle left EPC: Hot short 1183
Failure code [DXJDKA] Blade angle right EPC: Open 1185
Failure code [DXJDKB] Blade angle right EPC: Short circuit .1186
Failure code [DXJDKY] Blade angle right EPC: Hot short .1187
Failure code [DXK1KA] Left HST motor EPC: Open .1189
Failure code [DXK1KB] Left HST motor EPC: Short circuit 1191
Failure code [DXK1KY] Left HST motor EPC: Hot Short 1192
Failure code [DXK2KA] Right HST motor EPC: Open 1194
Failure code [DXK2KB] Right HST motor EPC: Short circuit .1196
Failure code [DXK2KY] Right HST motor EPC: Hot Short .1197
Troubleshooting of electrical system (E-mode) 1199
E-1 Engine does not start (Engine does not crank) 1199
E-2 Manual preheating system does not work .1205
E-3 Automatic preheating system does not work 1208
E-4 While preheating is working, preheating monitor does not light up 1210
E-5 When starting switch is turned to ON position, machine monitor displays nothing 1212
E-6 When starting switch is turned to ON position (with engine stopped), basic check monitor lights up .1215
E-7 Air cleaner clogging monitor lights up in yellow while engine is running .1216
E-8 Charge level monitor lights up in red while engine is running 1217
E-9 Engine coolant temperature monitor lights up in red while engine is running 1218
E-10 Engine oil pressure monitor lights up in red while engine is running 1219
E-11 HST charge pressure monitor lights up in red while engine is running 1220
E-12 Hydraulic oil temperature monitor lights up in red while engine is running 1221
E-13 HST oil filter clogging monitor lights up in red while engine is running 1222
E-14 Fuel level gauge does not indicate correct level 1223
E-15 Engine coolant temperature gauge does not indicate correct temperature 1226
E-16 Hydraulic oil temperature gauge does not indicate correct temperature .1227
E-17 Operation mode does not change 1228
E-18 Service mode cannot be selected .1229
E-19 Operating customize switch does not display customize screen 1230
E-20 Modifying setting on customize screen does not change setting of machine 1231
E-21 Service meter is not displayed, while starting switch is in OFF position 1232
E-22 Work equipment does not operate .1233
E-23 Foot heater does not operate 1235
E-24 Horn does not sound .1240
E-25 Horn does not stop sounding .1242
E-26 Backup alarm does not sound .1243
E-27 Backup alarm does not stop sounding .1244
E-28 Headlamp does not light up 1245
E-29 Rear lamp does not light up .1248
E-30 No wiper operates continuously or intermittently 1251
E-31 Front wiper does not operate 1253
E-32 Rear wiper does not operate .1255
E-33 Left door wiper does not operate (failed in both continuous and intermittent operations) 1257
E-34 Right door wiper does not operate (failed in both continuous and intermittent operations) .1261
E-35 Front washer does not operate .1265
E-36 Rear washer does not operate 1267
E-37 Left door washer does not operate .1269
E-38 Right door washer does not operate 1271
E-39 KOMTRAX system does not operate normally 1273
Troubleshooting of hydraulic and mechanical system (H-mode) 1275
Information described in troubleshooting table (H-mode) 1275
System chart of hydraulic and mechanical systems .1276
Failure mode and cause table .1278
H-1 Neither RH nor LH of tracks does not travel forward nor reverse (None of the travel system operates) .1282
H-2 Either RH or LH of track does not travel forward nor reverse (Only RH or LH of travel system operates) .1284
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) 1285
H-4 Travel speed or power is low .1287
H-5 Travel speed range does not change .1288
H-6 Shock is large when machine starts or stops 1289
H-7 Machine deviates largely .1290
H-8 Machine drift on a slope is large 1292
H-9 Engine stalls during travel or engine speed drops significantly 1293
H-10 Unusual noise is heard from around HST pump or motor 1294
H-11 All work equipment do not operate .1295
H-12 All work equipment operates slowly or lacks power .1297
H-13 Blade lift speed or power is low 1298
H-14 Blade tilt speed or power is low 1299
H-15 Blade angle speed or power is low .1300
H-16 Time lag of blade lift is large .1301
H-17 Hydraulic drift of lifted blade is large 1302
H-18 Hydraulic drift of tilted blade is large 1303
H-19 Unusual noise is heard from around work equipment pump or control valve .1304
H-20 HST oil temperature (hydraulic oil temperature) rises too high 1305
H-21 Fans speed is abnormal (high, low, or no rotation) 1307
H-22 Unusual noise is heard from around fan 1309
Troubleshooting of engine (S-mode) .1310
Information described in troubleshooting table (S mode) 1310
S-1 Engine does not crank when starting switch is turned to START position .1311
S-2 Engine cranks but no exhaust smoke comes out .1312
S-3 Fuel is being injected but engine does not start (misfiring: engine cranks but does not start) .1313
S-4 Engine startability is poor 1314
S-5 Engine does not pick up smoothly .1316
S-6 Engine stops during operation 1318
S-7 Engine runs rough or is unstable .1320
S-8 Engine lacks power .1321
S-9 KDPF gets clogged in a short time 1323
S-10 Engine oil consumption is excessive .1325
S-11 Engine oil becomes contaminated early .1326
S-12 Fuel consumption is excessive .1327
S-13 Oil is in coolant (or coolant spurts or coolant level goes down) 1328
S-14 Oil pressure drops 1329
S-15 Fuel mixes into engine oil 1330
S-16 Water mixes into engine oil (milky) .1331
S-17 Coolant temperature rises too high (overheating) 1332
S-18 Unusual noise is heard 1333
S-19 Vibration is excessive 1334
S-20 Air cannot be bled from fuel circuit 1335
S-21 Active regeneration is executed frequently 1336
S-22 Active regeneration takes time 1337
S-23 White smoke is exhausted during active regeneration .1338
50 Disassembly and assembly 1339
Table of contents 1340
Related information on disassembly and assembly 1342
How to read this manual 1342
Coating materials list .1344
Special tools list .1348
Sketches of special tools 1354
Engine and cooling system 1367
Removal and installation of supply pump assembly .1367
Removal and installation of fuel injector assembly .1372
Removal and installation of cylinder head assembly .1380
Removal and installation of radiator assembly 1396
Removal and installation of aftercooler assembly .1400
Removal and installation of hydraulic oil cooler assembly 1403
Removal and installation of cooling fan drive assembly .1406
Removal and installation of cooling fan motor assembly .1409
Removal and installation of engine assembly 1411
Disassembly and assembly of damper assembly 1418
Removal and installation of engine front oil seal 1419
Removal and installation of engine rear oil seal .1421
Removal and installation of engine hood assembly .1424
Removal and installation of fuel tank assembly .1427
Removal and installation of KDPF assembly 1431
Disassembly and assembly of KDPF assembly 1434
Removal and installation of KCCV assembly 1443
Removal and installation of KVGT assembly 1444
Removal and installation of EGR (Exhaust Gas Recirculation) cooler assembly 1447
Removal and installation of EGR (Exhaust Gas Recirculation) valve assembly .1450
Removal and installation of belt for alternator and air conditioner compressor .1451
Removal and installation of air cleaner assembly .1452
Power train 1454
Removal and installation of HST pump assembly 1454
Removal and installation of HST motor and final drive assembly .1456
Disassembly and assembly of final drive 1459
Undercarriage and frame 1469
Removal and installation of track frame assembly .1469
Removal and installation of idler assembly .1473
Disassembly and assembly of idler 1475
Removal and installation of recoil spring assembly .1479
Disassembly and assembly of recoil spring 1480
Removal and installation of track roller assembly 1484
Disassembly and assembly of track roller assembly 1486
Removal and installation of carrier roller assembly 1489
Disassembly and assembly of carrier roller assembly 1491
Removal and installation of segment teeth 1493
Separation and connection of track shoe assembly (Standard type track shoe) 1494
Separation and connection of track shoe assembly (PLUS type track shoe) 1497
Overall disassembly and assembly of track shoe assembly (Standard type track shoe) .1498
Overall disassembly and assembly of track shoe assembly (PLUS type track shoe) .1514
Disassembly and assembly of one track link assembly in field (Standard type track shoe) 1521
Disassembly and assembly of one track link assembly in field (PLUS type track shoe) 1527
Removal and installation of pivot shaft assembly .1532
Removal and installation of equalizer bar assembly .1534
Removal and installation of equalizer bar side bushing .1536
Hydraulic system .1537
Removal and installation of hydraulic tank assembly 1537
Removal and installation of control valve assembly .1541
Disassembly and assembly of hydraulic cylinder assembly 1544
Work equipment .1548
Removal and installation of work equipment assembly 1548
Removal and installation of blade assembly .1550
Removal and installation of U-frame assembly .1552
Cab and its attachments 1554
Removal and installation of ROPS cab assembly 1554
Removal and installation of operator’s cab glass (adhesion glass) 1558
Removal and installation of operator’s seat 1564
Removal and installation of seat belt 1565
Removal and installation of foot heater assembly .1566
Disassembly and assembly of foot heater assembly .1568
Removal and installation of air conditioner unit assembly 1569
Removal and installation of air conditioner compressor assembly 1573
Electrical system 1575
Removal and installation of machine monitor assembly .1575
Removal and installation of engine controller assembly .1576
Removal and installation of HST controller assembly 1578
Removal and installation of mass air flow and temperature sensor .1579
Removal and installation of KOMTRAX terminal .1580
60 Maintenance standard 1581
Table of contents 1582
Engine and cooling system 1583
Engine mount .1583
Cooling fan motor 1584
Oil cooler bypass and HST charge safety valve 1586
Power train 1587
Damper .1587
HST pump .1588
HST motor 1590
Charge pump 1591
Solenoid valve .1592
Final drive 1593
Sprocket .1594
Full-scale drawing of sprocket tooth profile .1595
Undercarriage and frame 1597
Suspension .1597
Track frame and idler cushion 1599
Idler 1601
Track roller .1603
Carrier roller .1607
Track shoe .1609
Hydraulic system .1615
Hydraulic tank .1615
Work equipment and cooling fan pump 1616
Control valve 1619
Ripper PPC valve .1626
Quick drop valve .1628
Angle control EPC valve 1630
Work equipment .1631
Blade 1631
Cutting edge and end bit .1634
Ripper .1635
Lift cylinder 1637
Tilt cylinder 1638
Angle cylinder .1639
Ripper cylinder 1640
Cab and its attachments 1641
Cab mount 1641
Electrical system 1642
Electric steering lever 1642
80 Appendix 1643
Table of contents 1644
Air conditioner components .1645
Precautions for refrigerant 1645
Air conditioner component 1646
Configuration and function of refrigeration cycle 1649
Outline of refrigeration cycle .1650
Air conditioner unit .1652
Dual pressure switch .1656
Pressure switch 1657
Compressor .1658
Condenser 1659
Receiver drier .1661
Procedure for testing and troubleshooting 1662
Electrical circuit diagram .1665
System diagram .1666
Parts and connectors layout 1668
Testing relays .1673
Troubleshooting chart 1 1675
Troubleshooting chart 2 1676
Information described in troubleshooting table .1678
A-1 Troubleshooting for condenser fan 1679
A-2 Troubleshooting for compressor and refrigerant system (Air is not cooled) 1682
A-3 Troubleshooting for blower motor system (No air comes out or air flow is abnormal) .1686
A-4 Troubleshooting for temperature control 1688
Troubleshooting with gauge pressure 1691
Connection of service tool .1694
Precautions for disconnecting and connecting hoses and tubes in air conditioner circuit 1696
Handling of compressor oil .1698
90 Diagrams and drawings .1701
Table of contents 1702
Hydraulic circuit diagram 1703
Symbols in hydraulic circuit diagram .1703
Hydraulic circuit diagram 1707
Electric circuit diagram .1708
Symbols in electric circuit diagram 1708
Electrical circuit diagram .1712
INDEX.1723

DESCRIPTION:

Komatsu D61EX-23 D61PX-23 Shop Manual – PDF DOWNLOAD

SERIAL NUMBERS

D61EX-30001
D61PX-30001

General precautions:

G. B 12/12/24