Komatsu D61EXi-24 D61PXi-24 Bulldozer Shop Manual SEN06578-00 – Complete PDF Service & Repair Guide

Description

Komatsu D61EXi-24 & D61PXi-24 Shop Manual – SEN06578-00

This is the complete Komatsu shop manual for the D61EXi-24 and D61PXi-24 bulldozers, document number SEN06578-00. It covers serial numbers D61EXi-40001 and up and D61PXi-40001 and up, and is written for technicians who need the same procedures, values, and diagrams used in a professional workshop. Whether you are diagnosing an HST fault, setting valve clearance, or rebuilding a final drive, this manual gives you the exact sequence and specifications.

File Details

• Manual type: Shop Manual (Service & Repair)
• Brand: Komatsu
• Models covered: D61EXi-24, D61PXi-24
• Serial numbers: D61EXi-40001 and up; D61PXi-40001 and up
• Engine: Komatsu SAA6D107E-3 diesel engine
• Language: English
• Document number: SEN06578-00
• File format: PDF
• Page count: 2000+ pages

Chapters Covered

• 00 – Index and Foreword
• 01 – Specifications
• 10 – Structure and Function
• 20 – Standard Value Table
• 30 – Testing and Adjusting
• 40 – Troubleshooting
• 50 – Disassembly and Assembly
• 60 – Maintenance Standard
• 80 – Appendix
• 90 – Circuit Diagrams

00 – Index and Foreword

Safety notices, fire prevention, waste disposal, DEF handling, hydraulic and electrical precautions, connector disconnection and connection methods, tightening torque tables, and conversion tables. This section sets the safety and procedural foundation for every job in the manual.

01 – Specifications

Complete specifications for both D61EXi-24 and D61PXi-24, including specification drawings, machine weights, engine output ratings, travel speeds, track shoe dimensions, ground pressure, and a full table of fuel, coolant, and lubricants.

10 – Structure and Function

Detailed explanations of every major system: the urea SCR system and its layout, engine control, automatic idle stop, cooling fan control, KDPF and aftertreatment, HST pump and motor operation, steering and brake control, work equipment control, ICT system with GNSS and IMU sensors, undercarriage, and cab mounts. This chapter explains how components work, which is essential before troubleshooting.

20 – Standard Value Table

Standard values and repair limits for engine, machine, and undercarriage. Includes engine speed at high and low idle, boost pressure, exhaust gas color, valve clearance, compression pressure, blowby pressure, fuel pressure, engine oil pressure, HST oil pressure, cooling fan speed, work equipment speeds, hydraulic drift limits, and ICT accuracy values. Use this chapter to judge whether a component is within specification or needs repair.

30 – Testing and Adjusting

Measuring tools and methods for every testable system. Covers testing engine speed, boost pressure, exhaust gas color, valve clearance adjustment, compression pressure, blowby, engine oil pressure, EGR and KVGT oil pressure, fuel pressure, fuel discharge and return, bleeding the fuel system, HST oil pressure, travel deviation, brake performance, decelerator/brake pedal, parking brake lever, track tension, work equipment oil pressures, control circuit pressure, EPC solenoid outlet pressure, cooling fan speed and circuit pressure, hydraulic drift diagnosis, internal cylinder leakage, and the complete SCR-related function tests including AdBlue/DEF pump pressure, injection quantity, heater relay tests, and denitration efficiency.

40 – Troubleshooting

The largest chapter, with failure code troubleshooting for every code the machine can display: engine codes (CA-series), SCR and AdBlue/DEF codes (AS-series), HST codes, monitor codes, sensor codes, and solenoid codes. Also includes E-mode troubleshooting for electrical system symptoms, H-mode for hydraulic and mechanical symptoms, and S-mode for engine symptoms. Each failure code entry gives the cause, controller action, phenomenon on the machine, and a step-by-step diagnostic procedure with measuring points, criteria, and circuit diagrams.

50 – Disassembly and Assembly

Step-by-step removal, installation, disassembly, and assembly procedures for the engine and cooling system, power train, undercarriage and frame, hydraulic system, work equipment, cab and attachments, and electrical system. Includes special tools list, coating materials list, tightening torques, and sketches of special tools.

60 – Maintenance Standard

Maintenance standards for engine mount, damper, cooling system, cooling fan motor, work equipment and cooling fan pump, HST charge pump, HST motor, final drive, sprocket, suspension, track frame, idler, track roller, carrier roller, track shoe, hydraulic tank, control valve, PPC valve, EPC valve, quick drop valve, work equipment cylinders, stroke and reset sensors, ripper, cab mount, and electric steering control lever.

80 – Appendix

Air conditioner refrigerant precautions, component locations, specifications, refrigeration cycle configuration and function, air conditioner unit and component parts, compressor, condenser, receiver drier, testing and troubleshooting procedures, circuit diagram, system diagram, control function, relay testing, and troubleshooting charts.

90 – Circuit Diagrams

Hydraulic circuit diagram with symbols, and a 14-page electrical circuit diagram with symbols. Essential for tracing circuits during troubleshooting and repair.

Why This Manual Matters

The D61EXi-24 and D61PXi-24 are intelligent machine control bulldozers with complex electronic, hydraulic, and aftertreatment systems. Guessing at a repair on these machines can be expensive. This shop manual gives you the exact specifications, torque values, diagnostic sequences, and wiring information that Komatsu technicians use. Whether you are a professional workshop, a fleet maintenance operation, or an owner-operator who wants to understand the machine, this manual is the reference you need.

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This is a digital PDF download — no shipping, no waiting. After payment you can download the file immediately and access it on any computer, tablet, or smartphone. Print individual pages or the entire manual for use in the workshop. The PDF format lets you navigate the 2000+ pages quickly and reference the exact section you need.