Komatsu D61EX-24 D61EX-24E0 D61PX-24 D61PX-24E0 Bulldozer Shop Manual PDF

Description

Komatsu D61EX-24 D61EX-24E0 D61PX-24 D61PX-24E0 Bulldozer Shop Manual SEN06855-07 – PDF DOWNLOAD

FILE DETAILS:

Komatsu D61EX-24 D61EX-24E0 D61PX-24 D61PX-24E0 Bulldozer Shop Manual SEN06855-07 – PDF DOWNLOAD 

Language : English
Pages : 2926
Downloadable : Yes
File Type : PDF

IMAGES PREVIEW OF THE MANUAL:

TABLE OF CONTENTS:

Komatsu D61EX-24 D61EX-24E0 D61PX-24 D61PX-24E0 Bulldozer Shop Manual SEN06855-07 – PDF DOWNLOAD 

Cover 1
00 Index and Foreword 3
Index 4
Foreword, Safety, Basic Information 21
How to Read the Shop Manual 21
Safety Notice for Operation 23
Precautions to Prevent Fire 31
Procedures If Fire Occurs 33
Precautions for Disposing of Waste Materials 34
Procedures for Exhaust Gas Regulations 35
Precautions for DEF 36
General Character and Precautions for Handling 36
Precautions for Adding 36
Precautions for Storage 36
Precautions for Fire Hazard and Leakage 36
Other Precautions 36
Store DEF 37
Precautions When You Handle Hydraulic Equipment 38
Precautions When You Disconnect and Connect Pipings 41
Precautions When You Handle Electrical Equipment 48
Precautions When You Handle Fuel System Equipment 50
Precautions When You Handle Intake System Equipment 51
Practical Use of KOMTRAX 52
Disconnect and Connect Push-Pull Type Coupler 53
How to Disconnect and Connect Type 1 Push-Pull Type Coupler 53
How to Disconnect and Connect Type 2 Push-Pull Type Coupler 54
How to Disconnect and Connect Type 3 Push-Pull Type Coupler 55
Precautions for Disconnection and Connection of Connectors 57
How to Disconnect and Connect Deutsch Connector 61
How to Disconnect and Connect Slide Lock Type Connector 62
How to Disconnect and Connect Connector with Lock to Pull 64
How to Disconnect and Connect Connector with Lock to Push 65
How to Disconnect and Connect Connector with Housing to Rotate 67
How to Read the Codes for Electric Cable 68
Explanation of Terms for Maintenance Standard 72
Standard Tightening Torque Table 75
Conversion Table 82
Abbreviation List 87
01 Specifications 91
Table of Contents 92
Specifications 93
Specification Drawing 93
Specification Drawing: D61EX-24 93
Specification Drawing: D61EX-24E0 95
Specification Drawing: D61PX-24 97
Specification Drawing: D61PX-24E0 99
Specifications 101
Specifications: D61EX-24 101
Specifications: D61EX-24E0 106
Specifications: D61PX-24 111
Specifications: D61PX-24E0 115
Weight Table 119
Weight Table: D61EX-24 119
Weight Table: D61EX-24E0 121
Weight Table: D61PX-24 123
Weight Table: D61PX-24E0 125
Fuel, Coolant, Lubricants (For North America) 127
How to Use Fuel, Coolant and Lubricants by Ambient Temperature 127
Fuel, Coolant, Lubricants (For European Union) 129
How to Use Fuel, Coolant and Lubricants by Ambient Temperature 129
10 Structure and Function 131
Table of Contents 132
Urea SCR System 135
Layout Drawing of Urea SCR System 135
Urea SCR System Diagram 138
Function of Urea SCR System 139
Function of DEF System 139
Inducement Strategy 141
Component Parts of Urea SCR System 155
DEF Mixing Tube 155
SCR Assembly 156
DEF Tank 158
DEF Pump 160
DEF Injector 161
DEF Hose 162
DEF Tank Heating Valve 163
Boot-up System 164
Layout Drawing of Boot-up System 164
System Operating Lamp System 165
System Diagram of System Operating Lamp System 165
Function of Operation Lamp System 165
Battery Disconnect Switch 167
Layout Drawing of Battery Disconnect Switch 167
Function of Battery Disconnect Switch 167
Engine System 169
Layout Drawing of Engine System 169
Engine Control System 171
Layout Drawing of Engine Control System 171
System Diagram of Engine Control 173
Function of Engine Control System 175
Automatic Idle Stop System 177
System Diagram of Automatic Idle Stop System 177
Function of Automatic Idle Stop System 177
Component Parts of Engine System 180
Damper 180
VGT 181
EGR System 185
EGR Valve 187
EGR Cooler 189
KCCV System 191
KCCV Ventilator 193
KDPF 195
Cooling System 199
Layout Drawing of Cooling System 199
Specifications of Cooling System 200
Cooling Fan Control System 201
System Diagram of Cooling Fan Control System 201
Function of Cooling Fan Control System 202
Component Parts of Cooling System 204
Cooling Fan Motor 204
Hydraulic Oil Cooler Bypass and HST Charge Safety Valve 209
Hydraulic Oil Cooler Bypass Valve 211
HST Charge Safety Valve 212
Control System 214
Layout Drawing of Control System 214
Machine Monitor System 215
System Diagram of Machine Monitor System 215
Function of Machine Monitor System 215
KOMTRAX System 216
System Diagram of KOMTRAX System 216
Function of KOMTRAX System 216
Component Parts of Control System 217
Machine Monitor 217
Gateway Function Controller 234
Communication Terminal 237
HST Controller 239
Engine Controller 243
Decelerator and Brake Potentiometer 250
Hydraulic System 252
Layout Drawing of Hydraulic System 252
CLSS 253
Structure of CLSS 253
Function of CLSS 254
Component Parts of Hydraulic System 256
Hydraulic Tank 256
Work Equipment and Cooling Fan Pump 258
LS Valve 266
PC Valve 267
Control Valve 270
Power Train System 291
Layout Drawing of HST System 291
Operation of HST System 292
Steering and Brake Control System 294
Layout Drawing of Steering and Brake Control System 294
Function of Steering and Brake Control System 294
HST Control System 296
System Diagram of HST Control System 296
Gear Shift Control Function 297
Engine Low Speed Matching Control Function 301
HST Pump and Motor Sequence Control Function 301
Deceleration and Brake Control Function 303
Gear Shift Control Function by Load 304
Turn Control Function 304
Straight Travel Correction Control Function 305
Parking Brake Control System 307
System Diagram of Parking Brake Control System 307
Function of Parking Brake Control System 308
Operation of Parking Brake Control System 309
Component Parts of Power Train System 310
HST Pump 310
HST Charge Pump 327
HST Motor 328
Final Drive 340
Electric Steering Electric Lever 344
Work Equipment System 347
Work Equipment Control 347
Layout Drawing of Work Equipment Control 347
Function of Work Equipment Control 348
Layout Drawing of Front Work Equipment 350
Layout Drawing of Fixed Multi-Shank Ripper 351
Component Parts of Work Equipment System 352
Ripper PPC Valve 352
5-Spool EPC and Solenoid Valve 356
Pilot Circuit Accumulator 362
Angle Control EPC Valve 363
Quick Drop Valve 366
Piston Valve 368
Electric Blade Control Lever 369
Undercarriage and Frame 371
Main Frame 371
Structure of Main Frame 371
Suspension 372
Structure of Suspension 372
Specifications of Suspension 373
Function of Suspension 374
Track Frame and Idler Cushion 375
Structure of Track Frame and Idler Cushion 375
Function of Track Frame and Idler Cushion 377
Work Equipment 378
Structure of Front Work Equipment 378
Structure of Fixed Multi-Shank Ripper 379
CAB Related Parts 380
ROPS CAB 380
Structure of ROPS CAB 380
Function of ROPS CAB 381
CAB Mount 382
Structure of CAB Mount 382
Function of CAB Mount 382
20 Standard Value Table 383
Table of Contents 384
Standard Value Table for Engine 385
Standard Value Table for Engine: D61EX-24 385
Standard Value Table for Engine: D61EX-24E0 389
Standard Value Table for Engine: D61PX-24 393
Standard Value Table for Engine: D61PX-24E0 397
Standard Value Table for Machine 401
Standard Value Table for Machine: D61EX-24 401
Standard Value Table for Machine: D61EX-24E0 417
Standard Value Table for Machine: D61PX-24 433
Standard Value Table for Machine: D61PX-24E0 449
Machine Posture and Procedures to Measure Performance 465
30 Testing and Adjusting 467
Table of Contents 468
Precautions Before Work 471
Related Information on Testing and Adjusting 472
Differences In Machine Monitor Symbols 472
Tools for Testing and Adjusting 473
Sketch of Tools for Testing and Adjusting 481
Engine and Cooling System 484
Examine Engine Speed 484
How to Examine Engine Speed 484
Examine Boost Pressure 486
How to Examine Boost Pressure 486
Examine Exhaust Gas Color 488
How to Examine Exhaust Gas Color with the Handy Smoke Checker 488
How to Examine Exhaust Gas Color with Smoke Meter 490
Examine Mass Air Flow and Temperature Sensor 492
How to Examine Mass Air Flow and Temperature Sensor 492
Examine and Adjust Valve Clearance 494
How to Examine Valve Clearance 494
How to Adjust Valve Clearance 495
Examine Compression Pressure 496
How to Examine Compression Pressure 496
Examine Blowby Pressure 501
How to Examine Blowby Pressure 501
Examine Engine Oil Pressure 504
How to Examine Engine Oil Pressure 504
Examine EGR Valve and VGT Oil Pressure 505
How to Examine EGR Valve and VGT Oil Pressure 505
Examine Fuel Pressure 507
How to Examine Fuel Pressure 508
Examine Fuel Discharge, Return and Leakage 513
How to Examine Fuel Discharge, Return, and Leakage 514
Bleed Air from Fuel System 520
How to Bleed Air from Fuel System 520
Examine Fuel Circuit for Leakage 521
How to Examine Fuel System for Leakage 521
Handle Cylinder Cut-out Mode Operation 523
Handle No-Injection Cranking Operation 524
Examine KDPF, SCR and Muffler Stack for Looseness and Damage 525
How to Examine KDPF, SCR and Muffler Stack for Looseness and Damage 525
Examine Installed Condition of Cylinder Heads and Manifolds 526
How to Examine Installed Condition of Cylinder Heads and Manifolds 526
Examine Engine Piping for Damage and Looseness 527
How to Examine Engine Piping for Damage and Looseness 527
Examine Alternator Belt 528
How to Examine Alternator Belt 528
Examine Automatic Tensioner 530
How to Examine Automatic Tensioner 530
Write Correction for Ash in Soot Accumulation to Engine Controller 532
How to Write Correction for Ash in Soot Accumulation to Engine Controller 532
Examine SCR Related Functions 533
Examine DEF Pump Raised Pressure 537
Examine Injection Volume from DEF Injector 540
Examine DEF Line Heater Relay 1 545
Examine DEF Line Heater Relay 2 548
Examine DEF Pump Heater Relay 551
Examine DEF Tank Heater Valve 555
Examine SCR Denitration Efficiency 559
Clean DEF Tank 562
How to Clean DEF Tank 562
Clean DEF Tank Mounting Part 566
How to Clean DEF Tank Mounting Part 566
Clean DEF Pump 567
How to Clean DEF Pump 567
Power Train 573
Examine and Adjust HST Oil Pressure 573
How to Examine HST Oil Pressure 573
How to Adjust HST Oil Pressure 576
Bleed Air from HST Pump 578
How to Bleed Air from HST Pump 578
How to Bleed Air from Servo Valve of HST Pump 578
Examine Outlet Pressure of Solenoid Valve 580
How to Examine Outlet Pressure of Solenoid Valve 580
Examine Travel Deviation 585
How to Examine Travel Deviation 585
Examine Brake Performance Simply 587
How to Examine Brake Performance Simply 587
Examine and Adjust Deceleration/Brake Pedal 588
How to Examine Deceleration/Brake Pedal 588
How to Adjust Deceleration/Brake Pedal 590
Adjust Parking Brake Lever 592
How to Adjust Parking Brake Lever 592
Move Machine When It Cannot Travel 594
How to Move Machine with Hydraulic Type Parking Brake Release System 594
How to Move Machine After You Remove Final Drive Shaft 596
Undercarriage and Frame 598
Examine and Adjust Idler Clearance 598
How to Examine and Adjust Idler Clearance 598
Examine Sprocket Wear 599
How to Examine Sprocket Wear 599
Examine and Adjust Track Tension 600
How to Examine Track Tension 600
How to Adjust Track Tension 600
Hydraulic System 602
Release Remained Pressure in Hydraulic Circuit 602
How to Release Remained Pressure in Hydraulic System 602
Examine and Adjust Work Equipment Circuit Oil Pressure 603
How to Examine Work Equipment Circuit Oil Pressure 603
How to Adjust Work Equipment Circuit Oil Pressure 604
Examine and Adjust Oil Pressure in Control Circuit 606
How to Examine Oil Pressure in Control Circuit 606
How to Adjust Oil Pressure in Control Circuit 607
Examine Outlet Pressure of EPC Solenoid Valve 608
How to Examine Outlet Pressure of EPC Solenoid Valve 608
Bleed Air from Work Equipment, Cooling Fan Pump, and Charge Pump 610
How to Bleed Air from Work Equipment, Cooling Fan Pump, and Charge Pump 610
Examine Cooling Fan Speed 611
How to Examine Cooling Fan Speed 611
Examine Cooling Fan Circuit Oil Pressure 612
How to Examine Cooling Fan Circuit Oil Pressure 612
Examine Parts Which Cause Hydraulic Drift of Work Equipment 614
How to Examine Parts Which Cause Hydraulic Drift of Blade Lift Cylinder 614
How to Examine the Parts Which Cause Hydraulic Drift of Blade Tilt Cylinder 614
How to Examine the Parts Which Cause Hydraulic Drift of Ripper Lift Cylinder 615
Examine Oil Leakage from Work Equipment Cylinder 616
How to Examine Internal Oil Leakage of Work Equipment Cylinder 616
Bleed Air from Work Equipment Cylinders 618
How to Bleed Air from Work Equipment Cylinder 618
Work Equipment 619
Adjust Work Equipment Lock Lever 619
How to Adjust Work Equipment Lock Lever 619
Examine and Adjust Play of Blade Electric Lever 621
How to Examine Play of Blade Electric Lever 623
How to Adjust Play of Blade Electric Lever 623
How to Replace Universal Joint 624
Electrical System 631
Set and Operate Machine Monitor 631
Operator Mode 635
Function to Show Technician Identification Status Screen 635
Function to Show Operator Identification Input Screen 635
Examine Function by LCD (Liquid Crystal Display) 636
Examine Function of Service Meter 636
How to Set Usage Limitation and Change Maintenance Password 636
Service Mode 639
How to Operate Service Mode 639
How to See Pre-defined Monitoring Information 640
How to Examine Self-Define Monitor Information 647
Abnormality Record Menu 658
How to See Maintenance Record 662
Maintenance Mode Setting 663
How to Set Phone Number Entry 667
Default Menu 669
Diagnostic Tests Menu 677
Adjustment Menu 685
No-Injection Cranking Operation 742
KOMTRAX Settings Menu 744
How to Show Service Message 746
How to Start Up KOMTRAX System 748
How to Stop Use of KOMTRAX System 754
Adjust After Replacement of HST Controller 756
How to Adjust After Replacement of HST Controller 756
Adjust After Replacement of Electric and Hydraulic Equipment 762
Adjust Rearview Camera Angle 764
How to Adjust Rearview Camera Angle 764
Set Region of Bluetooth(R) Compatible Radio 765
How to Set Region of Bluetooth(R) Compatible Radio 765
Handle Voltage Circuit of Engine Controller 767
Handle Battery Disconnect Switch 768
Examine Diodes 769
How to Examine Diodes by Digital Tester 769
How to Examine Diodes by Analog Tester 769
Pm Clinic 770
Pm Clinic Service 770
Pm Clinic Check Sheet: D61EX-24 772
Pm Clinic Check Sheet: D61EX-24E0 779
Pm Clinic Check Sheet: D61PX-24 786
Pm Clinic Check Sheet: D61PX-24E0 793
Pm Clinic Check Sheet for Undercarriage: D61EX-24 800
Pm Clinic Check Sheet for Undercarriage: D61EX-24E0 803
Pm Clinic Check Sheet for Undercarriage: D61PX-24 806
Pm Clinic Check Sheet for Undercarriage: D61PX-24E0 809
40 Troubleshooting 813
Table of Contents 814
Precautions Before Work 825
Abbreviation List 826
Related Information to Troubleshooting 832
General Troubleshooting Points 832
Troubleshooting Points for Urea SCR System 833
Sequence of Events in Troubleshooting 847
Checks Before Troubleshooting 849
Inspection Procedure Before Troubleshooting 851
Walk-Around Check 851
Test in Accordance with Testing Procedure 853
Examine Fuel Level and Type 853
Examine for Impure Ingredient in Fuel 853
Examine DEF Level and Type 854
Examine Fuel Prefilter 854
Examine Fuel Main Filter 856
Examine Engine Oil Level (Oil Quantity in Oil Pan) and Type 857
Examine Coolant Level (Reservoir Tank) 858
Examine Air Cleaner Clogging 859
Clean Outer Element 859
Replace Element 862
Examine Hydraulic Oil Level 862
Examine Hydraulic Oil Strainer 863
Examine Hydraulic Oil Filter 866
Examine Oil Level in Final Drive Case 867
Bleed Air from Fuel System 868
Bleed Air from Hydraulic System 868
How to Examine Electric Equipment 868
Preparation for Troubleshooting of Electrical System 875
Procedure for Troubleshooting 882
Information Shown in Troubleshooting Table 885
How to Diagnose Open Circuit of Hydraulic Pressure Sensor System Wiring Harness 887
Connector List and Layout 890
Connector Contact Connection Table 908
T-Branch Box and T-Branch Adapter Table 948
Fuse Location Table 954
Precautions When You Clean and Replace KDPF (KCSF and KDOC) 958
Prepare Short Circuit Electrical Connector (For Failure Codes [CA1883] and [CA3135]) 962
Failure Code Table 964
Troubleshooting by Failure Code (Display of Code) 984
Failure Code [6091NX] 984
Failure Code [989L00] 986
Failure Code [989M00] 987
Failure Code [989N00] 988
Failure Code [A1U0N3] 989
Failure Code [A1U0N4] 991
Failure Code [A900FR] 993
Failure Code [A900N6] 994
Failure Code [A900NY] 995
Failure Code [AA10NX] 996
Failure Code [AB00KE] 998
Failure Code [AQ10N3] 1000
Failure Code [AS00N3] 1002
Failure Code [AS00R2] 1004
Failure Code [AS00R3] 1005
Failure Code [AS00R4] 1006
Failure Code [AS00R5] 1007
Failure Code [AS00R6] 1008
Failure Code [AS00ZK] 1009
Failure Code [AS10KM] 1010
Failure Code [AS10NR] 1011
Failure Code [AS10NT] 1012
Failure Code [B@BAZG] 1013
Failure Code [B@BCNS] 1014
Failure Code [B@BCQA] 1015
Failure Code [B@BCZK] 1017
Failure Code [B@CRNS] 1019
Failure Code [B@CRZG] 1020
Failure Code [CA115] 1021
Failure Code [CA122] 1022
Failure Code [CA123] 1024
Failure Code [CA131] 1026
Failure Code [CA132] 1028
Failure Code [CA144] 1030
Failure Code [CA145] 1032
Failure Code [CA153] 1034
Failure Code [CA154] 1037
Failure Code [CA187] 1039
Failure Code [CA221] 1041
Failure Code [CA222] 1043
Failure Code [CA227] 1045
Failure Code [CA234] 1046
Failure Code [CA238] 1047
Failure Code [CA239] 1049
Failure Code [CA249] 1051
Failure Code [CA256] 1053
Failure Code [CA271] 1055
Failure Code [CA272] 1057
Failure Code [CA322] 1059
Failure Code [CA323] 1061
Failure Code [CA324] 1063
Failure Code [CA325] 1065
Failure Code [CA331] 1067
Failure Code [CA332] 1069
Failure Code [CA343] 1071
Failure Code [CA351] 1072
Failure Code [CA352] 1073
Failure Code [CA356] 1076
Failure Code [CA357] 1078
Failure Code [CA386] 1081
Failure Code [CA428] 1082
Failure Code [CA429] 1084
Failure Code [CA435] 1086
Failure Code [CA441] 1088
Failure Code [CA442] 1090
Failure Code [CA449] 1091
Failure Code [CA451] 1092
Failure Code [CA452] 1094
Failure Code [CA488] 1096
Failure Code [CA515] 1097
Failure Code [CA516] 1099
Failure Code [CA553] 1101
Failure Code [CA555] 1102
Failure Code [CA556] 1103
Failure Code [CA559] 1104
Failure Code [CA595] 1107
Failure Code [CA687] 1108
Failure Code [CA689] 1110
Failure Code [CA691] 1113
Failure Code [CA692] 1115
Failure Code [CA697] 1117
Failure Code [CA698] 1118
Failure Code [CA731] 1119
Failure Code [CA778] 1121
Failure Code [CA1117] 1126
Failure Code [CA1664] 1127
Failure Code [CA1669] 1130
Failure Code [CA1673] 1131
Failure Code [CA1677] 1132
Failure Code [CA1678] 1133
Failure Code [CA1682] 1134
Failure Code [CA1683] 1138
Failure Code [CA1684] 1140
Failure Code [CA1686] 1142
Failure Code [CA1691] 1143
Failure Code [CA1694] 1146
Failure Code [CA1695] 1149
Failure Code [CA1696] 1150
Failure Code [CA1712] 1152
Failure Code [CA1713] 1155
Failure Code [CA1714] 1157
Failure Code [CA1715] 1158
Failure Code [CA1776] 1159
Failure Code [CA1777] 1162
Failure Code [CA1843] 1165
Failure Code [CA1844] 1167
Failure Code [CA1879] 1170
Failure Code [CA1881] 1173
Failure Code [CA1883] 1175
Failure Code [CA1885] 1179
Failure Code [CA1887] 1181
Failure Code [CA1921] 1183
Failure Code [CA1922] 1186
Failure Code [CA1942] 1191
Failure Code [CA1993] 1192
Failure Code [CA2185] 1195
Failure Code [CA2186] 1197
Failure Code [CA2249] 1199
Failure Code [CA2271] 1200
Failure Code [CA2272] 1203
Failure Code [CA2288] 1206
Failure Code [CA2311] 1207
Failure Code [CA2349] 1208
Failure Code [CA2353] 1211
Failure Code [CA2357] 1213
Failure Code [CA2381] 1214
Failure Code [CA2382] 1217
Failure Code [CA2383] 1220
Failure Code [CA2386] 1223
Failure Code [CA2387] 1225
Troubleshooting Flowchart 1229
Failure Code [CA2555] 1230
Failure Code [CA2556] 1233
Failure Code [CA2637] 1236
Failure Code [CA2639] 1238
Failure Code [CA2771] 1241
Failure Code [CA2777] 1247
Failure Code [CA2976] 1250
Failure Code [CA3133] 1252
Failure Code [CA3134] 1254
Failure Code [CA3135] 1256
Failure Code [CA3142] 1260
Failure Code [CA3143] 1261
Failure Code [CA3144] 1262
Failure Code [CA3146] 1264
Failure Code [CA3147] 1265
Failure Code [CA3148] 1266
Failure Code [CA3151] 1268
Failure Code [CA3165] 1274
Failure Code [CA3229] 1276
Failure Code [CA3231] 1278
Failure Code [CA3232] 1280
Failure Code [CA3235] 1284
Failure Code [CA3239] 1286
Failure Code [CA3241] 1289
Failure Code [CA3242] 1292
Failure Code [CA3251] 1295
Failure Code [CA3253] 1297
Failure Code [CA3254] 1300
Failure Code [CA3255] 1303
Failure Code [CA3256] 1306
Failure Code [CA3311] 1308
Failure Code [CA3312] 1310
Failure Code [CA3313] 1313
Failure Code [CA3314] 1314
Failure Code [CA3315] 1315
Failure Code [CA3316] 1318
Failure Code [CA3317] 1319
Failure Code [CA3318] 1320
Failure Code [CA3319] 1323
Failure Code [CA3321] 1324
Failure Code [CA3322] 1326
Failure Code [CA3419] 1329
Failure Code [CA3421] 1331
Failure Code [CA3497] 1333
Failure Code [CA3498] 1334
Failure Code [CA3543] 1335
Failure Code [CA3545] 1342
Failure Code [CA3547] 1344
Failure Code [CA3558] 1345
Failure Code [CA3559] 1347
Failure Code [CA3562] 1349
Failure Code [CA3563] 1351
Failure Code [CA3567] 1354
Failure Code [CA3568] 1357
Failure Code [CA3571] 1363
Failure Code [CA3572] 1365
Failure Code [CA3574] 1367
Failure Code [CA3575] 1370
Failure Code [CA3577] 1372
Failure Code [CA3578] 1374
Failure Code [CA3582] 1376
Failure Code [CA3583] 1383
Failure Code [CA3596] 1385
Failure Code [CA3649] 1388
Failure Code [CA3681] 1390
Failure Code [CA3682] 1395
Failure Code [CA3713] 1401
Failure Code [CA3717] 1404
Failure Code [CA3718] 1405
Failure Code [CA3725] 1406
Failure Code [CA3741] 1409
Failure Code [CA3748] 1410
Failure Code [CA3751] 1412
Failure Code [CA3755] 1414
Failure Code [CA3866] 1416
Failure Code [CA3867] 1420
Failure Code [CA3868] 1423
Failure Code [CA3899] 1427
Failure Code [CA3911] 1429
Failure Code [CA3912] 1433
Failure Code [CA3932] 1435
Failure Code [CA3933] 1437
Failure Code [CA3934] 1439
Failure Code [CA3935] 1442
Failure Code [CA3936] 1444
Failure Code [CA4151] 1446
Failure Code [CA4152] 1450
Failure Code [CA4155] 1454
Failure Code [CA4156] 1457
Failure Code [CA4157] 1460
Failure Code [CA4158] 1462
Failure Code [CA4159] 1463
Failure Code [CA4161] 1464
Failure Code [CA4162] 1467
Failure Code [CA4163] 1470
Failure Code [CA4164] 1472
Failure Code [CA4165] 1474
Failure Code [CA4166] 1476
Failure Code [CA4168] 1478
Failure Code [CA4169] 1481
Failure Code [CA4171] 1483
Failure Code [CA4249] 1486
Failure Code [CA4251] 1488
Failure Code [CA4259] 1490
Failure Code [CA4261] 1493
Failure Code [CA4277] 1496
Failure Code [CA4281] 1500
Failure Code [CA4459] 1503
Failure Code [CA4461] 1506
Failure Code [CA4658] 1509
Failure Code [CA4731] 1513
Failure Code [CA4732] 1514
Failure Code [CA4739] 1515
Failure Code [CA4768] 1516
Failure Code [CA4769] 1518
Failure Code [CA4842] 1521
Failure Code [CA4952] 1525
Failure Code [CA5115] 1527
Failure Code [CA5383] 1530
Failure Code [D130KA] 1532
Failure Code [D130KB] 1535
Failure Code [D130KY] 1537
Failure Code [D19JKZ] 1539
Failure Code [D19UKA] 1542
Failure Code [D19UKB] 1544
Failure Code [D19UMC] 1546
Failure Code [D811MC] 1548
Failure Code [D862KA] 1549
Failure Code [D8ALKA] 1550
Failure Code [D8ALKB] 1552
Failure Code [D8AQKR] 1554
Failure Code [D8G1KT] 1556
Failure Code [D8G6KT] 1557
Failure Code [DAF0MB] 1558
Failure Code [DAF0MC] 1559
Failure Code [DAF8KB] 1560
Failure Code [DAF9KQ] 1562
Failure Code [DAFGMC] 1563
Failure Code [DAFLKA] 1564
Failure Code [DAFLKB] 1566
Failure Code [DAFQKR] 1568
Failure Code [DAJ000] 1569
Failure Code [DAJ0KQ] 1570
Failure Code [DAJ0KT] 1571
Failure Code [DAJ0MC] 1572
Failure Code [DAJ1KK] 1573
Failure Code [DAJ2KK] 1575
Failure Code [DAJ2KT] 1577
Failure Code [DAJ5KK] 1578
Failure Code [DAJ6KK] 1581
Failure Code [DAJLKA] 1583
Failure Code [DAJLKB] 1585
Failure Code [DAJPMA] 1587
Failure Code [DAJQKR] 1588
Failure Code [DAJRKR] 1589
Failure Code [DB2QKR] 1590
Failure Code [DB2RKR] 1595
Failure Code [DD12KA] 1600
Failure Code [DD12KB] 1602
Failure Code [DD13KA] 1604
Failure Code [DD13KB] 1606
Failure Code [DD14KA] 1608
Failure Code [DD14KB] 1610
Failure Code [DDKAKA] 1612
Failure Code [DDKAKB] 1614
Failure Code [DDKFL4] 1616
Failure Code [DDKGL4] 1618
Failure Code [DDKHKA] 1620
Failure Code [DDKHKB] 1622
Failure Code [DDNLKA] 1624
Failure Code [DDNLKB] 1626
Failure Code [DDP6KA] 1628
Failure Code [DDP6KB] 1631
Failure Code [DDP6MA] 1633
Failure Code [DDU1FS] 1635
Failure Code [DDU1KA] 1637
Failure Code [DDU1KY] 1640
Failure Code [DFA4KX] 1642
Failure Code [DFA4KZ] 1643
Failure Code [DFA4L8] 1644
Failure Code [DFA5KA] 1645
Failure Code [DFA5KB] 1648
Failure Code [DFA6KA] 1651
Failure Code [DFA6KB] 1654
Failure Code [DFA7KX] 1657
Failure Code [DFA7KZ] 1658
Failure Code [DFA7L8] 1659
Failure Code [DFA8KA] 1660
Failure Code [DFA8KB] 1663
Failure Code [DFA9KA] 1666
Failure Code [DFA9KB] 1669
Failure Code [DGS1KA] 1672
Failure Code [DGS1KX] 1675
Failure Code [DH21KA] 1676
Failure Code [DH21KB] 1678
Failure Code [DHA4KA] 1680
Failure Code [DHAAMA] 1682
Failure Code [DHACMA] 1684
Failure Code [DHH7KA] 1686
Failure Code [DHH7KB] 1689
Failure Code [DHH8KA] 1691
Failure Code [DHH8KB] 1694
Failure Code [DHH9KA] 1696
Failure Code [DHH9KB] 1699
Failure Code [DHHAKA] 1701
Failure Code [DHHAKB] 1704
Failure Code [DHRUKA] 1706
Failure Code [DHRUKB] 1708
Failure Code [DHRVKA] 1710
Failure Code [DHRVKB] 1712
Failure Code [DK30KA] 1714
Failure Code [DK30KB] 1717
Failure Code [DK30KX] 1719
Failure Code [DK30KZ] 1720
Failure Code [DK30L8] 1721
Failure Code [DK31KA] 1722
Failure Code [DK31KB] 1725
Failure Code [DK40KA] 1727
Failure Code [DK40KB] 1730
Failure Code [DK55KX] 1732
Failure Code [DK55KZ] 1733
Failure Code [DK55L8] 1734
Failure Code [DK56KA] 1735
Failure Code [DK56KB] 1738
Failure Code [DK57KA] 1740
Failure Code [DK57KB] 1743
Failure Code [DLM0KX] 1745
Failure Code [DLM1KA] 1746
Failure Code [DLM1KB] 1748
Failure Code [DLM1MA] 1750
Failure Code [DLM2KA] 1751
Failure Code [DLM2KB] 1753
Failure Code [DLM2MA] 1755
Failure Code [DLM3KA] 1756
Failure Code [DLM3KB] 1758
Failure Code [DLM3MB] 1760
Failure Code [DN21FS] 1761
Failure Code [DR21KX] 1763
Failure Code [DR31KX] 1764
Failure Code [DV20KB] 1765
Failure Code [DW4BKA] 1767
Failure Code [DW4BKB] 1769
Failure Code [DW4BKY] 1771
Failure Code [DW7BKA] 1773
Failure Code [DW7BKB] 1775
Failure Code [DW7EKA] 1777
Failure Code [DW7EKB] 1779
Failure Code [DW7EKY] 1781
Failure Code [DWN5KA] 1783
Failure Code [DWN5KB] 1785
Failure Code [DWN5KY] 1787
Failure Code [DXA4KA] (Applicable Machine: 45001 to 46273) 1789
Failure Code [DXA4KA] (Applicable Machine: 46274 and Up) 1791
Failure Code [DXA4KB] (Applicable Machine: 45001 to 46273) 1793
Failure Code [DXA4KB] (Applicable Machine: 46274 and Up) 1795
Failure Code [DXA4KY] (Applicable Machine: 45001 to 46273) 1797
Failure Code [DXA4KY] (Applicable Machine: 46274 and Up) 1799
Failure Code [DXA5KA] (Applicable Machine: 45001 to 46273) 1801
Failure Code [DXA5KA] (Applicable Machine: 46274 and Up) 1803
Failure Code [DXA5KB] (Applicable Machine: 45001 to 46273) 1805
Failure Code [DXA5KB] (Applicable Machine: 46274 and Up) 1807
Failure Code [DXA5KY] (Applicable Machine: 45001 to 46273) 1809
Failure Code [DXA5KY] (Applicable Machine: 46274 and Up) 1811
Failure Code [DXA6KA] (Applicable Machine: 45001 to 46273) 1813
Failure Code [DXA6KA] (Applicable Machine: 46274 and Up) 1815
Failure Code [DXA6KB] (Applicable Machine: 45001 to 46273) 1817
Failure Code [DXA6KB] (Applicable Machine: 46274 and Up) 1819
Failure Code [DXA6KY] (Applicable Machine: 45001 to 46273) 1821
Failure Code [DXA6KY] (Applicable Machine: 46274 and Up) 1823
Failure Code [DXA7KA] (Applicable Machine: 45001 to 46273) 1825
Failure Code [DXA7KA] (Applicable Machine: 46274 and Up) 1827
Failure Code [DXA7KB] (Applicable Machine: 45001 to 46273) 1829
Failure Code [DXA7KB] (Applicable Machine: 46274 and Up) 1831
Failure Code [DXA7KY] (Applicable Machine: 45001 to 46273) 1833
Failure Code [DXA7KY] (Applicable Machine: 46274 and Up) 1835
Failure Code [DXHRKA] 1837
Failure Code [DXHRKB] 1839
Failure Code [DXHRKY] 1841
Failure Code [DXHSKA] 1843
Failure Code [DXHSKB] 1845
Failure Code [DXHSKY] 1847
Failure Code [DXHTKA] 1849
Failure Code [DXHTKB] 1851
Failure Code [DXHTKY] 1853
Failure Code [DXHUKA] 1855
Failure Code [DXHUKB] 1857
Failure Code [DXHUKY] 1859
Failure Code [DXJ4KA] 1861
Failure Code [DXJ4KB] 1863
Failure Code [DXJCKA] 1865
Failure Code [DXJCKB] 1867
Failure Code [DXJCKY] 1869
Failure Code [DXJDKA] 1871
Failure Code [DXJDKB] 1873
Failure Code [DXJDKY] 1875
Failure Code [DXK1KA] 1877
Failure Code [DXK1KB] 1879
Failure Code [DXK1KY] 1881
Failure Code [DXK2KA] 1883
Failure Code [DXK2KB] 1885
Failure Code [DXK2KY] 1887
Failure Code [F311KA] 1889
Failure Code [F311KB] 1891
Failure Code [F312KA] 1893
Failure Code [F312KB] 1895
Failure Code [F313KA] 1897
Failure Code [F313KB] 1899
Failure Code [F314KA] 1902
Failure Code [F314KB] 1904
Failure Code [F315KB] 1906
Failure Code [F315KY] 1908
Failure Code [F316KB] 1910
Failure Code [F316KY] 1912
Failure Code [F318KB] 1914
Failure Code [F318KY] 1917
Failure Code [F31AKB] 1919
Failure Code [F31AKY] 1921
Failure Code [F31BKB] 1923
Failure Code [F31BKY] 1925
Failure Code [F31CKB] 1927
Failure Code [F31CKY] 1929
Failure Code [F31DKB] 1931
Failure Code [F31DKY] 1933
Failure Code [F31EKB] 1935
Failure Code [F31EKY] 1937
Failure Code [FS10ZE] 1939
Troubleshooting of Electrical System (E-Mode) 1940
Engine Does Not Start (Engine Does Not Crank) 1940
Manual Preheating System Does Not Operate 1947
Automatic Preheating System Does Not Operate 1950
While Preheating is in Operation, Preheating Monitor Does Not Come On 1952
When Starting Switch is Turned to ON Position, Machine Monitor Shows Nothing 1954
When Starting Switch is Turned to ON Position (with Engine Stopped), Basic Check Monitor Comes On 1958
Air Cleaner Clogging Monitor Comes On in Yellow While Engine is in Operation 1959
Charge Level Monitor Comes On in Red While Engine is in Operation 1960
Engine Coolant Temperature Monitor Comes On in Red While Engine is in Operation 1961
Engine Oil Pressure Monitor Comes On in Red While Engine is in Operation 1962
HST Charge Pressure Monitor Comes On in Red While Engine Runs 1963
Hydraulic Oil Temperature Monitor Comes On in Red While Engine is in Operation 1964
HST Oil Filter Clogging Monitor Comes On in Red While Engine Runs 1965
Engine Coolant Temperature Gauge Does Not Show Correct Temperature 1966
Fuel Gauge Does Not Show Normally 1967
Hydraulic Oil Temperature Gauge Does Not Show Correct Temperature 1970
Operation Mode Does Not Change 1971
When You Operate Customize Switch Does Not Show Customize Screen 1972
When You Change Setting on Customize Screen, Setting of Machine is Not Changed 1973
Service Meter is Not Shown While Starting Switch is in OFF Position 1974
Service Mode Cannot be Selected 1975
Work Equipment Does Not Operate 1976
Foot Heater Does Not Operate 1978
Horn Does Not Sound 1984
Horn Does Not Stop 1986
Backup Alarm Does Not Sound 1987
Backup Alarm Does Not Stop Operation 1988
Headlamp Does Not Come On 1989
Rear Lamp Does Not Come On 1993
No Wiper Operates 1996
Front Wiper Does Not Operate 1998
Rear Wiper Does Not Operate 2000
Left Door Wiper Does Not Operate 2002
Right Door Wiper Does Not Operate 2006
Front Washer Does Not Operate 2010
Rear Washer Does Not Operate 2012
Left Door Washer Does Not Operate 2014
Right Door Washer Does Not Operate 2016
KOMTRAX System Does Not Operate Correctly 2018
Troubleshooting for Hydraulic and Mechanical Systems (H Mode) 2019
Information Shown in Troubleshooting Table (H-Mode) 2019
Failure Mode and Cause Table 2020
R H and L H Tracks Cannot Travel FORWARD and REVERSE (None of the Travel Systems Operate) 2026
R H or L H Track Cannot Travel FORWARD and REVERSE (One of R H or L H Travel Systems Cannot Operate) 2028
R H or L H Track Cannot Travel FORWARD or REVERSE (Only One of the Travel Systems Cannot Operate in One Direction) 2030
Travel Speed or Power is Low 2032
Speed Range Does Not Change 2034
Shock is Large When Machine Moves Off or Stops 2035
Travel Deviation is Large 2036
Machine Drift on a Slope is Large 2039
Engine Speed Drops Largely or Engine Stops 2041
Unusual Noise is Heard from Around HST Pump or Motor 2043
HST Oil Temperature (Hydraulic Oil Temperature) Increases Too High 2045
All Work Equipment Do Not Operate 2047
All Work Equipment Speed or Power is Low 2049
Blade Lift Speed or Power is Low 2050
Blade Tilt Speed or Power is Low 2052
Blade Angle Speed or Power is Low 2053
Time Lag of Blade Lift is Large 2054
Hydraulic Drift of Blade Lift is Large 2055
Hydraulic Drift of Tilted Blade is Large 2056
Unusual Noise is Heard from Around Work Equipment and Cooling Fan Pump or Control Valve 2057
Fan Speed is Abnormal (Too High or Low, or Does Not Rotate) 2058
Unusual Noise is Heard from Around Fan 2060
Troubleshooting of Engine (S-Mode) 2061
Information Shown in Troubleshooting Table (S-Mode) 2061
Engine Does Not Crank When Starting Switch is Turned to Start Position 2062
Engine Cranks but No Exhaust Smoke Comes Out 2063
Fuel is Sprayed but Engine Does Not Start (Misfiring: Engine Cranks but Does Not Start) 2064
Engine Startability is Unsatisfactory 2066
Engine Does Not Pick Up Smoothly 2068
Engine Stops During Operation 2070
Engine Does Not Rotate Smoothly 2072
Engine Lacks Output (or Lacks Power) 2073
KDPF Becomes Clogged in a Short Time 2075
Engine Oil Consumption is Excessive 2077
Engine Oil Becomes Dirty Quickly 2078
Fuel Consumption is Excessive 2079
Oil is in Coolant (or Coolant Spurts Back or Coolant Level Goes Down) 2080
Engine Oil Pressure Drops 2081
Fuel Mixes Into Engine Oil 2083
Water Mixes Into Engine Oil (Milky) 2084
Coolant Temperature Increases Too High (Overheat) 2085
Unusual Noise is Heard 2086
Vibration is Excessive 2087
Air Cannot be Bled from Fuel Circuit 2088
Active Regeneration is Done Frequently 2089
Active Regeneration Continues Long 2091
White Smoke is Exhausted During Active Regeneration 2092
DEF Consumption is Excessive 2093
There is an Unusual Smell (Irritating Odor) 2095
Foreign Materials Enter DEF (DEF Increases) 2096
50 Disassembly and Assembly 2097
Table of Contents 2098
Precautions Before Work 2103
Abbreviation List 2104
Related Information on Disassembly and Assembly 2110
How to Read This Manual 2110
Coating Materials List 2111
Special Tool List 2116
Sketches of Special Tools 2135
Engine and Cooling System 2148
Remove and Install Supply Pump Assembly 2148
How to Remove Supply Pump Assembly 2148
How to Install Supply Pump Assembly 2154
Remove and Install Injector Assembly 2161
How to Remove Injector Assembly 2161
How to Install Injector Assembly 2168
Remove and Install Cylinder Head Assembly 2178
How to Remove Cylinder Head Assembly 2178
How to Install Cylinder Head Assembly 2190
Remove and Install EGR Valve Assembly 2208
How to Remove EGR Valve Assembly 2208
How to Install EGR Valve Assembly 2209
Remove and Install EGR Cooler Assembly 2211
How to Remove EGR Cooler Assembly 2211
How to Install EGR Cooler Assembly 2213
Remove and Install Starter Assembly 2216
How to Remove Starting Motor Assembly 2216
How to Install Starting Motor Assembly 2218
Remove and Install Alternator Belt 2220
How to Remove Alternator Belt 2220
How to Install Alternator Belt 2221
Remove and Install Automatic Tensioner 2223
How to Remove Automatic Tensioner 2223
How to Install Automatic Tensioner 2223
Remove and Install Radiator Assembly 2224
How to Remove Radiator Assembly 2224
How to Install Radiator Assembly 2227
Remove and Install Hydraulic Oil Cooler Assembly 2231
How to Remove Hydraulic Oil Cooler Assembly 2231
How to Install Hydraulic Oil Cooler Assembly 2233
Remove and Install Aftercooler Assembly 2236
How to Remove Aftercooler Assembly 2236
How to Install Aftercooler Assembly 2239
Remove and Install Cooling Fan Drive Assembly 2243
How to Remove Cooling Fan Drive Assembly 2243
How to Install Cooling Fan Drive Assembly 2246
Remove and Install Cooling Fan Motor Assembly 2250
How to Remove Cooling Fan Motor Assembly 2250
How to Install Cooling Fan Motor Assembly 2253
Remove and Install Engine and HST Pump Assembly 2257
How to Remove Engine and HST Pump Assembly 2257
How to Install Engine and HST Pump Assembly 2266
Remove and Install Engine Front Oil Seal 2277
How to Remove Engine Front Oil Seal 2277
How to Install Engine Front Oil Seal 2278
Remove and Install Engine Rear Oil Seal 2280
How to Remove Engine Rear Oil Seal 2280
How to Install Engine Rear Oil Seal 2282
Remove and Install Engine Hood Assembly 2285
How to Remove Engine Hood Assembly 2285
How to Install Engine Hood Assembly 2288
Remove and Install KDPF Assembly 2292
How to Remove KDPF Assembly 2293
How to Install KDPF Assembly 2296
Disassemble and Assemble KDPF Assembly 2299
How to Disassemble KDPF Assembly 2299
How to Assemble KDPF Assembly 2302
Remove and Install KDPF and SCR Assembly 2309
How to Remove KDPF and SCR Assembly 2310
How to Install KDPF and SCR Assembly 2316
Remove and Install Fuel Tank Assembly 2323
How to Remove Fuel Tank Assembly 2323
How to Install Fuel Tank Assembly 2329
Remove and Install DEF Tank Assembly 2336
How to Remove DEF Tank Assembly 2336
How to Install DEF Tank Assembly 2342
Remove and Install DEF Tank Sensor Flange Assembly 2348
How to Remove DEF Tank Sensor Flange Assembly 2348
How to Install DEF Tank Sensor Flange Assembly 2349
Remove and Install DEF Tank Sensor 2352
How to Remove DEF Tank Sensor 2352
How to Install DEF Tank Sensor 2353
Remove and Install DEF Tank Strainer 2360
How to Remove DEF Tank Strainer 2360
How to Install DEF Tank Strainer 2361
Remove and Install SCR Assembly 2362
How to Remove SCR Assembly 2362
How to Install SCR Assembly 2364
Remove and Install KCCV Assembly 2368
How to Remove KCCV Assembly 2368
How to Install KCCV Assembly 2370
Remove and Install VGT Assembly 2372
How to Remove VGT Assembly 2372
How to Install VGT Assembly 2374
Remove and Install DEF Mixing Tube 2377
How to Remove DEF Mixing Tube 2377
How to Install DEF Mixing Tube 2379
Remove and Install DEF Injector 2383
How to Remove DEF Injector 2383
How to Install DEF Injector 2386
Remove and Install DEF Pump 2390
How to Remove DEF Pump 2390
How to Install DEF Pump 2393
Remove and Install DEF Hose 2396
How to Remove DEF Hose 2396
How to Install DEF Hose 2400
Remove and Install Air Cleaner Assembly 2406
How to Remove Air Cleaner Assembly 2406
How to Install Air Cleaner Assembly 2408
Remove and Install Air Conditioner Compressor Assembly 2411
How to Remove Air Conditioner Compressor Assembly 2411
How to Install Air Conditioner Compressor Assembly 2412
Remove and Install Air Conditioner Condenser Assembly 2414
How to Remove Air Conditioner Condenser Assembly 2414
How to Install Air Conditioner Condenser Assembly 2418
Power Train 2422
Remove and Install Damper Assembly 2422
How to Remove Damper Assembly 2422
How to Install Damper Assembly 2423
Remove and Install HST Pump Assembly 2425
How to Remove HST Pump Assembly 2425
How to Install HST Pump Assembly 2427
Remove and Install HST Motor and Final Drive Assembly 2429
How to Remove HST Motor and Final Drive Assembly 2429
How to Install HST Motor and Final Drive Assembly 2432
Disassemble and Assemble Final Drive Assembly 2435
How to Disassemble Final Drive Assembly 2436
How to Assemble Final Drive Assembly 2441
Undercarriage and Frame 2450
Remove and Install Track Frame Assembly 2450
How to Remove Track Frame Assembly 2450
How to Install Track Frame Assembly 2455
Remove and Install Idler Assembly 2460
How to Remove Idler Assembly 2460
How to Install Idler Assembly 2462
Disassemble and Assemble Idler Assembly 2464
How to Disassemble Idler Assembly 2464
How to Assemble Idler Assembly 2466
Remove and Install Recoil Spring Assembly 2471
How to Remove Recoil Spring Assembly 2471
How to Install Recoil Spring Assembly 2472
Disassemble and Assemble Recoil Spring Assembly 2473
How to Disassemble Recoil Spring Assembly 2473
How to Assemble Recoil Spring Assembly 2476
Remove and Install Track Roller Assembly 2479
How to Remove Track Roller Assembly 2479
How to Install Track Roller Assembly 2480
Disassemble and Assemble Track Roller Assembly 2483
How to Disassemble Track Roller Assembly 2483
How to Assemble Track Roller Assembly 2485
Remove and Install Carrier Roller Assembly 2489
How to Remove Carrier Roller Assembly 2489
How to Install Carrier Roller Assembly 2490
Disassemble and Assemble Carrier Roller Assembly 2492
How to Disassemble Carrier Roller Assembly 2492
How to Assemble Carrier Roller Assembly 2493
Remove and Install Pivot Shaft Assembly 2496
How to Remove Pivot Shaft Assembly 2496
How to Install Pivot Shaft Assembly 2497
Separate and Connect Track Assembly 2499
How to Examine Before Separation of Track Assembly 2499
How to Separate Track Assembly (Standard) 2500
How to Separate Track Assembly (When Track Frame Has Internal Defect) 2501
How to Install Track Assembly 2502
Separate and Connect PLUS Type Track Assembly 2504
Separate PLUS Type Track Assembly Generally 2504
Install PLUS Type Track Assembly 2504
Disassemble and Assemble Track Assembly Generally 2506
How to Disassemble Full Track Shoes Assembly 2506
How to Assemble Full Track Shoes Assembly 2511
Disassemble and Assemble PLUS Type Track Assembly Generally 2524
Disassemble PLUS Type Track Assembly Generally 2525
How to Assemble PLUS Type Track Shoes Assembly Generally 2526
Disassemble and Assemble One Track Link Assembly in Field (Track Assembly) 2541
How to Disassemble One Track Link Assembly in Field (Track Assembly) 2542
How to Assemble One Track Link Assembly in Field (Track Assembly) 2543
Disassemble and Assemble One Track Link Assembly in Field (PLUS Type Track Assembly) 2550
Disassemble One Track Link Assembly in Field (PLUS Type Track Assembly) 2551
Assemble One Track Link Assembly in Field (PLUS Type Track Assembly) 2553
Remove and Install Equalizer Bar Assembly 2557
How to Remove Equalizer Bar Assembly 2557
How to Install Equalizer Bar Assembly 2559
Remove and Install Equalizer Bar Side Bushing 2562
How to Remove Equalizer Bar Side Bushings 2562
How to Install Equalizer Bar Side Bushings 2562
Remove and Install Segment Teeth 2564
How to Remove Segment Teeth 2564
How to Install Segment Teeth 2565
Hydraulic System 2566
Remove and Install Hydraulic Tank Assembly 2566
How to Remove Hydraulic Tank Assembly 2567
How to Install Hydraulic Tank Assembly 2571
Remove and Install Control Valve Assembly 2576
How to Remove Control Valve Assembly 2576
How to Install Control Valve Assembly 2581
Work Equipment 2586
Remove and Install Blade Assembly 2586
How to Remove Blade Assembly 2586
How to Install Blade Assembly 2588
Remove and Install Work Equipment Assembly 2591
How to Remove Work Equipment Assembly 2591
How to Install Work Equipment Assembly 2593
How to Disassemble and Assemble Work Equipment Cylinder Assembly 2595
How to Disassemble Work Equipment Cylinder Assembly 2596
How to Assemble Work Equipment Cylinder Assembly 2597
Remove and Install U-Frame Assembly 2601
How to Remove U-Frame Assembly 2601
How to Install U-Frame Assembly 2603
CAB Related Parts 2605
Remove and Install Operator Cab Assembly 2605
How to Remove Operator Cab Assembly 2605
How to Install Operator Cab Assembly 2612
Remove and Install Operator Cab Glass (Adhered Glass) 2620
How to Remove Operator Cab Glass (Adhered Glass) 2622
How to Install Operator Cab Glass (Adhered Glass) 2622
Remove and Install Air Conditioner Unit Assembly 2628
How to Remove Air Conditioner Unit Assembly 2628
How to Install Air Conditioner Unit Assembly 2634
Remove and Install Receiver Drier 2641
How to Remove Receiver Drier 2641
How to Install Receiver Drier 2642
Remove and Install Operator Seat 2645
How to Remove Operator Seat 2645
How to Install Operator Seat 2646
How to Remove and Install Seat Belt 2647
How to Remove Seat Belt 2647
How to Install Seatbelt 2647
Remove and Install Foot Heater Assembly 2649
How to Remove Foot Heater Assembly 2649
How to Install Foot Heater Assembly 2651
Disassemble and Assemble Foot Heater Assembly 2654
How to Disassemble Foot Heater Assembly 2654
How to Assemble Foot Heater Assembly 2655
Electrical System 2656
Remove and Install Engine Controller Assembly 2656
How to Remove Engine Controller Assembly 2656
How to Install Engine Controller Assembly 2658
Remove and Install HST Controller Assembly 2661
How to Remove HST Controller Assembly 2661
How to Install HST Controller Assembly 2662
Remove and Install Machine Monitor Assembly 2663
How to Remove Machine Monitor Assembly 2663
How to Install Machine Monitor Assembly 2664
Remove and Install Mass Air Flow and Temperature Sensor 2666
How to Remove Mass Air Flow and Temperature Sensor 2666
How to Install Mass Air Flow and Temperature Sensor 2668
Remove and Install KCCV Crankcase Pressure Sensor 2669
How to Remove KCCV Crankcase Pressure Sensor 2669
How to Install KCCV Crankcase Pressure Sensor 2671
Remove and Install SCR Temperature Sensor 2673
How to Remove SCR Temperature Sensor 2673
How to Install SCR Temperature Sensor 2674
Remove and Install Gateway Function Controller Assembly 2676
How to Remove Gateway Function Controller Assembly 2676
How to Install Gateway Function Controller Assembly 2677
Remove and Install Communication Terminal 2678
How to Remove Communication Terminal 2678
How to Install Communication Terminal 2681
60 Maintenance Standard 2685
Table of Contents 2686
Abbreviation List 2687
Engine and Cooling System 2693
Maintenance Standard for Engine Mount 2693
Maintenance Standard for Damper 2694
Maintenance Standard for Cooling System 2695
Maintenance Standard for Cooling Fan Motor 2697
Maintenance Standard for Hydraulic Oil Cooler Bypass and HST Charge Safety Valve 2699
Power Train 2700
Maintenance Standard for HST Pump 2700
Maintenance Standard for EPC Valve of HST Pump 2701
Maintenance Standard for Tow Receiving Valve of HST Pump 2702
Maintenance Standard for HST Charge Pump 2703
Maintenance Standard for HST Motor 2705
Maintenance Standard for Final Drive 2706
Maintenance Standard for Sprocket for Conventional Type Track Shoes 2708
Maintenance Standard for Sprocket Tooth Profile Full-Scale Drawing for Conventional Type Track Shoes 2709
Maintenance Standard for Sprocket for PLUS Type Track Shoes 2711
Maintenance Standard for Sprocket Tooth Profile Full-Scale Drawing for PLUS Type Track Shoes 2712
Undercarriage and Frame 2714
Maintenance Standard for Suspension 2714
Maintenance Standard for Track Frame and Idler Cushion 2716
Maintenance Standard for Idler 2718
Maintenance Standard for Track Roller for Conventional Type Track Shoes (Single Flange Type) 2720
Maintenance Standard for Track Roller for Conventional Type Track Shoes (Double Flange Type) 2721
Maintenance Standard for Track Roller for PLUS Type Track Shoes (Single Flange Type) 2722
Maintenance Standard for Track Roller for PLUS Type Track Shoes (Double Flange Type) 2723
Maintenance Standard for Carrier Roller for Conventional Type Track Shoes 2724
Maintenance Standard for Carrier Roller for PLUS Type Track Shoes 2725
Maintenance Standard for Conventional Type Track Shoes 2726
Maintenance Standard for PLUS Type Track Shoes 2728
Maintenance Standard for Single Shoes 2730
Maintenance Standard for Swamp Shoes 2731
Hydraulic System 2732
Maintenance Standard for Hydraulic Tank 2732
Maintenance Standard for Work Equipment and Cooling Fan Pump 2733
Maintenance Standard for Servo Valve of Work Equipment and Cooling Fan Pump 2734
Maintenance Standard for Control Valve 2736
Maintenance Standard for Ripper PPC Valve 2743
Maintenance Standard for 5-Spool EPC and Solenoid Valve 2745
Maintenance Standard for EPC Valve 2746
Maintenance Standard for Angle Control EPC Valve 2747
Maintenance Standard for Quick Drop Valve 2748
Work Equipment 2750
Maintenance Standard for Front Work Equipment 2750
Maintenance Standard for Cutting Edge and End Bit 2753
Maintenance Standard for Blade Lift Cylinder 2754
Maintenance Standard for Blade Tilt Cylinder 2755
Maintenance Standard for Blade Angle Cylinder 2756
Maintenance Standard for Fixed Multi-Shank Ripper 2757
Maintenance Standard for Ripper Lift Cylinder 2759
CAB Related Parts 2760
Maintenance Standard for CAB Mount 2760
Electrical System 2761
Maintenance Standard for Steering Electric Lever 2761
80 Appendix 2763
Table of Contents 2764
Precautions Before Work 2765
Abbreviation List 2766
Air Conditioner System 2772
Precautions for Refrigerant 2772
Air Conditioner Component 2773
Specifications of Air Conditioner 2776
Structure and Function of Refrigeration Cycle 2777
Outline of Refrigeration Cycle 2778
Component Parts of Air Conditioner System 2780
Air Conditioner Unit 2780
Configuration Diagram of Air Conditioner Unit 2780
Function of Air Conditioner Unit 2781
Component Parts of Air Conditioner Unit 2782
Function of Evaporator as Air Conditioner Unit Component 2782
Function of Heater Core as Air Conditioner Unit Component 2782
Function of Thermostat as Air Conditioner Unit Component 2782
Structure of Expansion Valve as Air Conditioner Unit Component 2783
Function of Expansion Valve as Air Conditioner Unit Component 2783
Operate Expansion Valve as Air Conditioner Unit Component 2783
Function of Dual Pressure Switch 2784
Function of Pressure Switch 2784
Compressor 2785
Structure of Compressor 2785
Specifications of Compressor 2785
Function of Compressor 2785
Condenser 2786
Structure of Condenser 2786
Specifications of Condenser 2786
Function of Condenser 2787
Receiver Drier 2788
Structure of Receiver Dryer 2788
Specifications of Receiver Dryer 2788
Function of Receiver Dryer 2788
Explanation of Procedure for Test of and Troubleshooting of Air Conditioner 2790
Circuit Diagram of Air Conditioner 2793
System Diagram of Air Conditioner 2794
Control Function of Air Conditioner 2795
Locations of Air Conditioner Parts and Layout of Connectors 2796
Examine Relay 2800
How to Examine Relay 2800
Air Conditioner Troubleshooting Chart 1 2802
Air Conditioner Troubleshooting Chart 2 2803
Information Shown in Troubleshooting Table 2806
Troubleshooting for Condenser Fan 2807
Troubleshooting for Compressor and Refrigerant System (Air is Not Cooled) 2810
Troubleshooting for Blower Motor System (No Air Comes Out or Air Flow is Abnormal) 2814
Troubleshooting for Temperature Control Function 2817
Troubleshooting by Gauge Pressure 2821
Connect Service Tool 2823
How to Connect Service Tool 2823
Precautions for Disconnection and Connection of Air Conditioner Piping 2824
Handle Compressor Oil 2826
90 Circuit Diagrams 2829
Table of Contents 2830
Hydraulic Circuit Diagram 2831
Symbols Used in Hydraulic Circuit Diagram 2831
Hydraulic Circuit Diagram 2835
Electrical Circuit Diagram 2837
Symbols Used in Electric Circuit Diagram 2837
Electrical Circuit Diagram (Applicable Machine: 45001 to 46273) (1/16) 2841
Electrical Circuit Diagram (Applicable Machine: 45001 to 46273) (2/16) 2843
Electrical Circuit Diagram (Applicable Machine: 45001 to 46273) (3/16) 2845
Electrical Circuit Diagram (Applicable Machine: 45001 to 46273) (4/16) 2847
Electrical Circuit Diagram (Applicable Machine: 45001 to 46273) (5/16) 2849
Electrical Circuit Diagram (Applicable Machine: 45001 to 46273) (6/16) 2851
Electrical Circuit Diagram (Applicable Machine: 45001 to 46273) (7/16) 2853
Electrical Circuit Diagram (Applicable Machine: 45001 to 46273) (8/16) 2855
Electrical Circuit Diagram (Applicable Machine: 45001 to 46273) (9/16) 2857
Electrical Circuit Diagram (Applicable Machine: 45001 to 46273) (10/16) 2859
Electrical Circuit Diagram (Applicable Machine: 45001 to 46273) (11/16) 2861
Electrical Circuit Diagram (Applicable Machine: 45001 to 46273) (12/16) 2863
Electrical Circuit Diagram (Applicable Machine: 45001 to 46273) (13/16) 2865
Electrical Circuit Diagram (Applicable Machine: 45001 to 46273) (14/16) 2867
Electrical Circuit Diagram (Applicable Machine: 45001 to 46273) (15/16) 2869
Electrical Circuit Diagram (Applicable Machine: 45001 to 46273) (16/16) 2871
Electrical Circuit Diagram (Applicable Machine: 46274 and Up) (1/17) 2873
Electrical Circuit Diagram (Applicable Machine: 46274 and Up) (2/17) 2875
Electrical Circuit Diagram (Applicable Machine: 46274 and Up) (3/17) 2877
Electrical Circuit Diagram (Applicable Machine: 46274 and Up) (4/17) 2879
Electrical Circuit Diagram (Applicable Machine: 46274 and Up) (5/17) 2881
Electrical Circuit Diagram (Applicable Machine: 46274 and Up) (6/17) 2883
Electrical Circuit Diagram (Applicable Machine: 46274 and Up) (7/17) 2885
Electrical Circuit Diagram (Applicable Machine: 46274 and Up) (8/17) 2887
Electrical Circuit Diagram (Applicable Machine: 46274 and Up) (9/17) 2889
Electrical Circuit Diagram (Applicable Machine: 46274 and Up) (10/17) 2891
Electrical Circuit Diagram (Applicable Machine: 46274 and Up) (11/17) 2893
Electrical Circuit Diagram (Applicable Machine: 46274 and Up) (12/17) 2895
Electrical Circuit Diagram (Applicable Machine: 46274 and Up) (13/17) 2897
Electrical Circuit Diagram (Applicable Machine: 46274 and Up) (14/17) 2899
Electrical Circuit Diagram (Applicable Machine: 46274 and Up) (15/17) 2901
Electrical Circuit Diagram (Applicable Machine: 46274 and Up) (16/17) 2903
Electrical Circuit Diagram (Applicable Machine: 46274 and Up) (17/17) 2905
Index 2907

DESCRIPTION:

Komatsu D61EX-24 D61EX-24E0 D61PX-24 D61PX-24E0 Bulldozer Shop Manual SEN06855-07 – PDF DOWNLOAD 

S.V 26/12/24