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

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Komatsu D61EX-24,D61EX-24E0,D61PX-24,D61PX-24E0 Bulldozer Shop Manual KEBM685505 – PDF DOWNLOAD

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Komatsu D61EX-24,D61EX-24E0,D61PX-24,D61PX-24E0 Bulldozer Shop Manual KEBM685505 – PDF DOWNLOAD

Language : English
Pages : 2818
Downloadable : Yes
File Type : PDF

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TABLE OF CONTENTS:

Komatsu D61EX-24,D61EX-24E0,D61PX-24,D61PX-24E0 Bulldozer Shop Manual KEBM685505 – PDF DOWNLOAD

SERIAL NUMBERS

• D61EX-B65001 and up
• D61PX-B65001 and up

COVER . 0
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
ACTIONS IF FIRE OCCURS . 33
PRECAUTIONS FOR DISPOSING OF WASTE MATERIALS . 34
ACTIONS TAKEN TO MEET EXHAUST GAS REGULATIONS 35
PRECAUTIONS FOR DEF 36
GENERAL CHARACTER AND PRECAUTIONS FOR HANDLING . 36
PRECAUTIONS FOR ADDING . 36
PRECAUTIONS FOR STORING 36
PRECAUTIONS FOR FIRE HAZARD AND LEAKAGE 36
THE OTHER PRECAUTIONS 36
STORE AdBlue/DEF . 37
PRECAUTIONS FOR HANDLING HYDRAULIC EQUIPMENT . 38
PRECAUTIONS FOR DISCONNECTION AND CONNECTION OF PIPINGS 41
PRECAUTIONS FOR HANDLING ELECTRICAL EQUIPMENT 48
PRECAUTIONS FOR HANDLING FUEL SYSTEM EQUIPMENT . 50
PRECAUTIONS FOR HANDLING INTAKE SYSTEM EQUIPMENT . 51
PRACTICAL USE OF KOMTRAX . 52
DISCONNECT AND CONNECT PUSH-PULL TYPE COUPLER 53
METHOD FOR DISCONNECTING AND CONNECTING TYPE 1 PUSH-PULL TYPE COUPLER 53
METHOD FOR DISCONNECTING AND CONNECTING TYPE 2 PUSH-PULL TYPE COUPLER 54
METHOD FOR DISCONNECTING AND CONNECTING TYPE 3 PUSH-PULL TYPE COUPLER 55
PRECAUTIONS FOR DISCONNECTION AND CONNECTION OF CONNECTORS . 57
METHOD FOR DISCONNECTING AND CONNECTING DEUTSCH CONNECTOR 61
METHOD FOR DISCONNECTING AND CONNECTING SLIDE LOCK TYPE CONNECTOR 62
METHOD FOR DISCONNECTING AND CONNECTING CONNECTOR WITH LOCK TO PULL 64
METHOD FOR DISCONNECTING AND CONNECTING CONNECTOR WITH LOCK TO PUSH 65
METHOD FOR DISCONNECTING AND CONNECTING CONNECTOR WITH HOUSING TO ROTATE . 67
HOW TO READ ELECTRICAL WIRE CODE . 68
EXPLANATION OF TERMS FOR MAINTENANCE STANDARD 72
STANDARD TIGHTENING TORQUE TABLE . 75
CONVERSION TABLE . 82
ABBREVIATION LIST 87
01 SPECIFICATIONS 91
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
METHOD FOR USING FUEL, COOLANT AND LUBRICANTS ACCORDING TO AMBIENT TEMPERATURE . 127
FUEL, COOLANT, LUBRICANTS (FOR EUROPEAN UNION) . 129
METHOD FOR USING FUEL, COOLANT AND LUBRICANTS ACCORDING TO AMBIENT TEMPERATURE . 129
10 STRUCTURE AND FUNCTION 131
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 AdBlue/DEF SYSTEM 139
INDUCEMENT STRATEGY 141
COMPONENT PARTS OF UREA SCR SYSTEM . 155
AdBlue/DEF MIXING TUBE . 155
SCR ASSEMBLY . 156
AdBlue/DEF TANK 158
AdBlue/DEF PUMP 160
AdBlue/DEF INJECTOR 161
AdBlue/DEF HOSE 162
AdBlue/DEF TANK HEATING VALVE 163
BOOT-UP SYSTEM . 164
LAYOUT DRAWING OF BOOT-UP SYSTEM . 164
SYSTEM OPERATING LAMP SYSTEM . 165
SYSTEM OPERATING LAMP SYSTEM DIAGRAM . 165
FUNCTION OF SYSTEM OPERATING 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 OF ENGINE CONTROL SYSTEM 171
ENGINE CONTROL SYSTEM DIAGRAM 173
FUNCTION OF ENGINE CONTROL SYSTEM 175
AUTOMATIC IDLE STOP SYSTEM . 177
AUTOMATIC IDLE STOP SYSTEM DIAGRAM . 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
COOLING FAN CONTROL SYSTEM DIAGRAM . 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 215
FUNCTION OF MACHINE MONITOR SYSTEM . 215
KOMTRAX SYSTEM . 216
KOMTRAX SYSTEM DIAGRAM . 216
FUNCTION OF KOMTRAX SYSTEM . 216
COMPONENT PARTS OF CONTROL SYSTEM 217
MACHINE MONITOR 217
GATEWAY FUNCTION CONTROLLER 233
COMMUNICATION TERMINAL . 236
HST CONTROLLER . 238
ENGINE CONTROLLER 242
DECELERATOR AND BRAKE POTENTIOMETER 249
HYDRAULIC SYSTEM . 251
LAYOUT DRAWING OF HYDRAULIC SYSTEM . 251
CLSS . 252
STRUCTURE OF CLSS 252
FUNCTION OF CLSS . 253
COMPONENT PARTS OF HYDRAULIC SYSTEM 255
HYDRAULIC TANK . 255
WORK EQUIPMENT AND COOLING FAN PUMP 257
LS VALVE . 265
PC VALVE . 266
CONTROL VALVE 269
POWER TRAIN SYSTEM . 290
LAYOUT DRAWING OF HST SYSTEM . 290
OPERATION OF HST SYSTEM 291
STEERING AND BRAKE CONTROL SYSTEM 293
LAYOUT DRAWING OF STEERING AND BRAKE CONTROL SYSTEM 293
FUNCTION OF STEERING AND BRAKE CONTROL SYSTEM 293
HST CONTROL SYSTEM . 295
HST CONTROL SYSTEM DIAGRAM . 295
GEAR SHIFT CONTROL FUNCTION 296
ENGINE LOW SPEED MATCHING CONTROL FUNCTION . 300
HST PUMP AND MOTOR SEQUENCE CONTROL FUNCTION . 300
DECELERATION AND BRAKE CONTROL FUNCTION 302
GEAR SHIFT CONTROL FUNCTION BY LOAD 303
TURN CONTROL FUNCTION 303
STRAIGHT TRAVEL CORRECTION CONTROL FUNCTION 304
PARKING BRAKE CONTROL SYSTEM . 306
PARKING BRAKE CONTROL SYSTEM DIAGRAM . 306
FUNCTION OF PARKING BRAKE CONTROL SYSTEM . 307
OPERATION OF PARKING BRAKE CONTROL SYSTEM 308
COMPONENT PARTS OF POWER TRAIN SYSTEM 309
HST PUMP . 309
HST CHARGE PUMP 326
HST MOTOR 327
FINAL DRIVE 339
ELECTRIC STEERING CONTROL LEVER 343
WORK EQUIPMENT SYSTEM 346
WORK EQUIPMENT CONTROL . 346
WORK EQUIPMENT CONTROL SYSTEM DIAGRAM 346
FUNCTION OF WORK EQUIPMENT CONTROL . 347
LAYOUT DRAWING OF FRONT WORK EQUIPMENT . 349
LAYOUT OF FIXED MULTI-SHANK RIPPER . 350
COMPONENT PARTS OF WORK EQUIPMENT SYSTEM . 351
RIPPER PPC VALVE . 351
5-PORT VALVE OF EPC AND SOLENOID . 355
PILOT CIRCUIT ACCUMULATOR 361
ANGLE CONTROL EPC VALVE 362
QUICK DROP VALVE . 365
PISTON VALVE . 367
ELECTRIC BLADE CONTROL LEVER . 368
UNDERCARRIAGE AND FRAME 370
MAIN FRAME . 370
STRUCTURE OF MAIN FRAME 370
SUSPENSION . 371
STRUCTURE OF SUSPENSION 371
SPECIFICATIONS OF SUSPENSION . 372
FUNCTION OF SUSPENSION . 373
TRACK FRAME AND IDLER CUSHION 374
STRUCTURE OF TRACK FRAME AND IDLER CUSHION . 374
FUNCTION OF TRACK FRAME AND IDLER CUSHION 375
WORK EQUIPMENT . 377
STRUCTURE OF FRONT WORK EQUIPMENT 377
STRUCTURE OF FIXED MULTI-SHANK RIPPER 378
CAB AND ITS ATTACHMENTS 379
ROPS CAB . 379
STRUCTURE OF ROPS CAB 379
FUNCTION OF ROPS CAB . 380
CAB MOUNT 381
STRUCTURE OF CAB MOUNT . 381
FUNCTION OF CAB MOUNT 381
20 STANDARD VALUE TABLE 383
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 PROCEDURE FOR MEASURING PERFORMANCE 465
30 TESTING AND ADJUSTING . 467
CONTENTS . 468
RELATED INFORMATION ON TESTING AND ADJUSTING . 472
TOOLS FOR TESTING AND ADJUSTING 472
SKETCH OF TOOLS FOR TESTING AND ADJUSTING 480
ENGINE AND COOLING SYSTEM 483
TEST ENGINE SPEED 483
METHOD FOR TESTING ENGINE SPEED 483
TEST BOOST PRESSURE 485
METHOD FOR TESTING BOOST PRESSURE 485
TEST EXHAUST GAS COLOR . 487
METHOD FOR TESTING EXHAUST GAS COLOR BY HANDY SMOKE CHECKER 487
METHOD FOR TESTING EXHAUST GAS COLOR BY SMOKE METER 489
TEST MASS AIR FLOW AND TEMPERATURE SENSOR 491
TEST MASS AIR FLOW AND TEMPERATURE SENSOR 491
TEST AND ADJUST VALVE CLEARANCE 493
METHOD FOR TESTING VALVE CLEARANCE . 493
METHOD FOR ADJUSTING VALVE CLEARANCE . 494
TEST COMPRESSION PRESSURE 495
METHOD FOR TESTING COMPRESSION PRESSURE 495
TEST BLOWBY PRESSURE . 500
METHOD FOR TESTING BLOWBY PRESSURE . 500
TEST ENGINE OIL PRESSURE . 503
METHOD FOR TESTING ENGINE OIL PRESSURE . 503
TEST EGR VALVE AND VGT OIL PRESSURE 504
METHOD FOR TESTING EGR VALVE AND VGT OIL PRESSURE 504
TEST FUEL PRESSURE . 506
METHOD FOR TESTING FUEL PRESSURE . 507
TEST FUEL DISCHARGE, RETURN AND LEAKAGE 512
METHOD FOR TESTING FUEL DISCHARGE, RETURN AND LEAKAGE 513
BLEEDING AIR FROM FUEL SYSTEM 519
METHOD FOR BLEEDING AIR FROM FUEL SYSTEM . 519
TEST FUEL CIRCUIT FOR LEAKAGE 520
METHOD FOR TESTING FUEL CIRCUIT FOR LEAKAGE 520
HANDLE CYLINDER CUT-OUT MODE OPERATION . 522
HANDLE NO-INJECTION CRANKING OPERATION . 523
TEST KDPF, SCR AND MUFFLER STACK FOR LOOSENESS AND DAMAGE 524
METHOD FOR TESTING KDPF, SCR AND MUFFLER STACK FOR LOOSENESS AND DAMAGE 524
TEST INSTALLED CONDITION OF CYLINDER HEADS AND MANIFOLDS . 525
METHOD FOR TESTING INSTALLED CONDITION OF CYLINDER HEADS AND MANIFOLDS . 525
TEST ENGINE PIPING FOR DAMAGE AND LOOSENESS 526
METHOD FOR TESTING ENGINE PIPING FOR DAMAGE AND LOOSENESS 526
TEST ALTERNATOR BELT . 527
METHOD FOR REMOVING ALTERNATOR BELT 527
TEST AUTOMATIC TENSIONER . 529
METHOD FOR TESTING AUTOMATIC TENSIONER . 529
WRITE ASH IN SOOT ACCUMULATION CORRECTION TO ENGINE CONTROLLER . 531
METHOD FOR WRITING ASH IN SOOT ACCUMULATION CORRECTION TO ENGINE CONTROLLER 531
TEST SCR RELATED FUNCTIONS . 532
TEST AdBlue/DEF PUMP RAISED PRESSURE . 536
TEST INJECTION AMOUNT FROM AdBlue/DEF INJECTOR . 539
TEST AdBlue/DEF LINE HEATER RELAY 1 544
TEST AdBlue/DEF LINE HEATER RELAY 2 547
TEST AdBlue/DEF PUMP HEATER RELAY 550
TEST AdBlue/DEF TANK HEATER VALVE 554
TEST DENITRATION EFFICIENCY OF SCR . 558
CLEAN AdBlue/DEF TANK 561
METHOD FOR CLEANING AdBlue/DEF TANK 561
CLEAN AdBlue/DEF TANK MOUNTING PORTION . 565
METHOD FOR CLEANING AdBlue/DEF TANK MOUNTING PORTION . 565
CLEAN AdBlue/DEF PUMP 566
CLEAN AdBlue/DEF PUMP 566
POWER TRAIN 572
TEST AND ADJUST HST OIL PRESSURE . 572
METHOD FOR TESTING HST OIL PRESSURE 572
METHOD FOR ADJUSTING HST OIL PRESSURE 575
BLEED AIR FROM HST PUMP 577
METHOD FOR BLEEDING AIR FROM HST PUMP 577
METHOD FOR BLEEDING AIR FROM SERVO VALVE OF HST PUMP . 577
TEST OUTLET PRESSURE OF SOLENOID VALVE . 579
METHOD FOR TESTING OUTLET PRESSURE OF SOLENOID VALVE . 579
TEST TRAVEL DEVIATION 584
METHOD FOR TESTING TRAVEL DEVIATION 584
TEST BRAKE PERFORMANCE SIMPLY 586
METHOD FOR TESTING BRAKE PERFORMANCE SIMPLY 586
TEST AND ADJUST DECELERATION/BRAKE PEDAL . 587
METHOD FOR TESTING DECELERATION/BRAKE PEDAL 587
METHOD FOR ADJUSTING DECELERATION/BRAKE PEDAL 589
ADJUST PARKING BRAKE LEVER . 591
METHOD FOR ADJUSTING PARKING BRAKE LEVER . 591
MOVE MACHINE WHEN IT CANNOT TRAVEL . 593
METHOD FOR MOVING MACHINE WITH HYDRAULIC TYPE PARKING BRAKE RELEASE SYSTEM . 593
METHOD FOR MOVING DISABLED MACHINE BY REMOVING FINAL DRIVE SHAFT . 595
UNDERCARRIAGE AND FRAME 597
CHECK AND ADJUST IDLER CLEARANCE . 597
METHOD FOR CHECKING AND ADJUSTING IDLER CLEARANCE 597
TESTING SPROCKET WEAR 598
METHOD FOR TESTING SPROCKET WEAR . 598
TEST AND ADJUST TRACK TENSION 599
METHOD FOR TESTING TRACK TENSION . 599
METHOD FOR ADJUSTING TRACK TENSION . 599
HYDRAULIC SYSTEM . 601
RELEASE REMAINING PRESSURE FROM HYDRAULIC SYSTEM . 601
METHOD FOR RELEASING REMAINING PRESSURE FROM HYDRAULIC CIRCUIT . 601
TEST AND ADJUST WORK EQUIPMENT OIL PRESSURES . 602
METHOD FOR TESTING WORK EQUIPMENT OIL PRESSURES 602
METHOD FOR ADJUSTING WORK EQUIPMENT OIL PRESSURES 603
TEST AND ADJUST OIL PRESSURE OF CONTROL CIRCUIT 605
METHOD FOR TESTING OIL PRESSURE OF CONTROL CIRCUIT . 605
METHOD FOR ADJUSTING OIL PRESSURE OF CONTROL CIRCUIT . 606
TEST OUTLET PRESSURE OF EPC SOLENOID VALVE . 607
METHOD FOR TESTING OUTLET PRESSURE OF EPC SOLENOID VALVE . 607
BLEED AIR FROM WORK EQUIPMENT, COOLING FAN PUMP, AND CHARGE PUMP . 609
BLEED AIR FROM WORK EQUIPMENT, COOLING FAN PUMP, AND CHARGE PUMP . 609
TEST COOLING FAN SPEED . 610
METHOD FOR TESTING COOLING FAN SPEED . 610
TEST COOLING FAN CIRCUIT OIL PRESSURE 611
METHOD FOR TESTING COOLING FAN CIRCUIT OIL PRESSURE 611
TEST THE PARTS CAUSING HYDRAULIC DRIFT IN WORK EQUIPMENT . 613
METHOD FOR TESTING THE PARTS CAUSING HYDRAULIC DRIFT OF BLADE LIFT CYLINDER 613
METHOD FOR TESTING THE PARTS CAUSING HYDRAULIC DRIFT OF BLADE TILT CYLINDER 613
METHOD FOR TESTING THE PARTS CAUSING HYDRAULIC DRIFT OF RIPPER LIFT CYLINDER . 614
TEST INTERNAL OIL LEAKAGE OF WORK EQUIPMENT CYLINDER . 615
METHOD FOR TESTING INTERNAL OIL LEAKAGE OF WORK EQUIPMENT CYLINDER . 615
BLEED AIR FROM WORK EQUIPMENT CYLINDERS 618
METHOD FOR BLEEDING AIR FROM WORK EQUIPMENT CYLINDERS 618
WORK EQUIPMENT . 619
ADJUST WORK EQUIPMENT LOCK LEVER . 619
METHOD FOR ADJUSTING WORK EQUIPMENT LOCK LEVER . 619
TEST AND ADJUST PLAY OF BLADE ELECTRIC LEVER . 621
TEST PLAY OF BLADE ELECTRIC LEVER 623
ADJUST PLAY OF BLADE ELECTRIC LEVER 623
REPLACE UNIVERSAL JOINT 624
ELECTRICAL SYSTEM 631
SET AND OPERATE MACHINE MONITOR 631
OPERATOR MODE 635
DISPLAY FUNCTION OF TECHNICIAN IDENTIFICATION STATUS SCREEN 635
DISPLAY FUNCTION OF OPERATOR IDENTIFICATION INPUT SCREEN . 635
CHECK FUNCTION BY LCD (LIQUID CRYSTAL DISPLAY) . 636
CHECK FUNCTION OF SERVICE METER 636
USAGE LIMITATION AND CHANGING MAINTENANCE PASSWORD . 636
SERVICE MODE . 639
OPERATE SERVICE MODE . 639
METHOD FOR CHECKING PRE-DEFINED MONITORING INFORMATION . 640
METHOD FOR CHECKING SELF-DEFINE MONITORING INFORMATION . 647
ABNORMALITY RECORD MENU 658
METHOD FOR CONFIRMING MAINTENANCE RECORD . 662
METHOD FOR OPERATING MAINTENANCE MODE SETTING 663
METHOD FOR OPERATING PHONE NUMBER ENTRY SETTING 667
DEFAULT MENU . 669
DIAGNOSTIC TESTS MENU 677
ADJUSTMENT MENU 685
METHOD FOR PERFORMING NO-INJECTION CRANKING 742
KOMTRAX SETTINGS MENU 744
METHOD FOR DISPLAYING SERVICE MESSAGE 746
START UP KOMTRAX SYSTEM 748
STOP USING OF KOMTRAX SYSTEM . 754
ADJUSTMENT WHEN HST CONTROLLER HAS BEEN REPLACED . 756
ADJUSTMENT METHOD WHEN HST CONTROLLER HAS BEEN REPLACED 756
ADJUSTMENT WHEN ELECTRIC OR HYDRAULIC DEVICE HAS BEEN REPLACED . 762
ADJUST REARVIEW CAMERA ANGLE . 764
METHOD FOR ADJUSTING REARVIEW CAMERA ANGLE . 764
SET REGION OF Bluetooth(R) COMPATIBLE RADIO 765
SET REGION OF Bluetooth(R) COMPATIBLE RADIO 765
HANDLE VOLTAGE CIRCUIT OF ENGINE CONTROLLER 767
BATTERY DISCONNECT SWITCH 768
TEST DIODES 769
METHOD FOR TESTING DIODE USING DIGITAL TESTER 769
METHOD FOR TESTING DIODE USING 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
CONTENTS . 814
ABBREVIATION LIST 824
RELATED INFORMATION ON TROUBLESHOOTING . 830
GENERAL TROUBLESHOOTING POINTS . 830
TROUBLESHOOTING POINTS FOR UREA SCR SYSTEM . 831
SEQUENCE OF EVENTS IN TROUBLESHOOTING 846
CHECKS BEFORE TROUBLESHOOTING 848
INSPECTION PROCEDURE BEFORE TROUBLESHOOTING 850
WALK-AROUND CHECK 850
TESTING IN ACCORDANCE WITH TESTING PROCEDURE . 852
CHECK FUEL LEVEL AND TYPE 852
CHECK IMPURE INGREDIENT IN FUEL 852
CHECK AdBule/DEF LEVEL AND TYPE 853
CHECK FUEL PREFILTER . 853
CHECK MAIN FILTER 855
CHECK ENGINE OIL LEVEL (OIL AMOUNT IN OIL PAN) AND TYPE 856
CHECK COOLANT LEVEL (RESERVOIR TANK) . 857
CHECK CLOGGING OF AIR CLEANER 858
CLEAN OUTER ELEMENT 858
REPLACE ELEMENT 861
CHECK HYDRAULIC OIL LEVEL 861
CHECK HYDRAULIC OIL STRAINER . 862
CHECK HYDRAULIC FILTER . 865
CHECK OIL LEVEL IN FINAL DRIVE CASE 866
BLEED AIR FROM FUEL SYSTEM . 867
BLEED AIR FROM HYDRAULIC SYSTEM 867
METHOD FOR CHECKING ELECTRIC EQUIPMENT . 867
PREPARATION FOR TROUBLESHOOTING ELECTRICAL SYSTEM 874
PROCEDURE FOR TROUBLESHOOTING 881
INFORMATION DESCRIBED IN TROUBLESHOOTING TABLE . 884
TROUBLESHOOTING METHOD FOR OPEN CIRCUIT IN WIRING HARNESS OF PRESSURE SENSOR SYSTEM 886
CONNECTORS LIST AND LAYOUT . 889
CONNECTOR CONTACT IDENTIFICATION . 907
T-BRANCH BOX AND T-BRANCH ADAPTER TABLE 947
FUSE LOCATION TABLE 953
PRECAUTIONS FOR CLEANING AND REPLACING KDPF (KCSF and KDOC) 957
PREPARATION OF SHORT CIRCUIT ELECTRICAL CONNECTOR (FOR FAILURE CODES [CA1883] AND [CA3135]) 961
FAILURE CODES TABLE 963
TROUBLESHOOTING BY FAILURE CODE (DISPLAY OF CODE) 982
FAILURE CODE [6091NX] 982
FAILURE CODE [989L00] 984
FAILURE CODE [989M00] 985
FAILURE CODE [989N00] 986
FAILURE CODE [A1U0N3] 987
FAILURE CODE [A1U0N4] 989
FAILURE CODE [A900FR] 991
FAILURE CODE [A900N6] 992
FAILURE CODE [A900NY] 993
FAILURE CODE [AA10NX] 994
FAILURE CODE [AB00KE] 996
FAILURE CODE [AQ10N3] 998
FAILURE CODE [AS00N3] 1000
FAILURE CODE [AS00R2] 1002
FAILURE CODE [AS00R3] 1003
FAILURE CODE [AS00R4] 1004
FAILURE CODE [AS00R5] 1005
FAILURE CODE [AS00R6] 1006
FAILURE CODE [AS00ZK] 1007
FAILURE CODE [AS10KM] 1008
FAILURE CODE [AS10NR] 1009
FAILURE CODE [AS10NT] 1010
FAILURE CODE [B@BAZG] 1011
FAILURE CODE [B@BCNS] 1012
FAILURE CODE [B@BCQA] 1013
FAILURE CODE [B@BCZK] 1015
FAILURE CODE [B@CRNS] 1017
FAILURE CODE [B@CRZG] 1018
FAILURE CODE [CA115] .1019
FAILURE CODE [CA122] .1020
FAILURE CODE [CA123] .1022
FAILURE CODE [CA131] .1024
FAILURE CODE [CA132] .1026
FAILURE CODE [CA144] .1028
FAILURE CODE [CA145] .1030
FAILURE CODE [CA153] .1032
FAILURE CODE [CA154] .1035
FAILURE CODE [CA187] .1037
FAILURE CODE [CA221] .1039
FAILURE CODE [CA222] .1041
FAILURE CODE [CA227] .1043
FAILURE CODE [CA234] .1044
FAILURE CODE [CA238] .1045
FAILURE CODE [CA239] .1047
FAILURE CODE [CA249] .1049
FAILURE CODE [CA256] .1051
FAILURE CODE [CA271] .1053
FAILURE CODE [CA272] .1055
FAILURE CODE [CA322] .1057
FAILURE CODE [CA323] .1059
FAILURE CODE [CA324] .1061
FAILURE CODE [CA325] .1063
FAILURE CODE [CA331] .1065
FAILURE CODE [CA332] .1067
FAILURE CODE [CA343] .1069
FAILURE CODE [CA351] .1070
FAILURE CODE [CA352] .1071
FAILURE CODE [CA356] .1074
FAILURE CODE [CA357] .1076
FAILURE CODE [CA386] .1079
FAILURE CODE [CA428] .1080
FAILURE CODE [CA429] .1082
FAILURE CODE [CA435] .1084
FAILURE CODE [CA441] .1086
FAILURE CODE [CA442] .1088
FAILURE CODE [CA449] .1089
FAILURE CODE [CA451] .1090
FAILURE CODE [CA452] .1092
FAILURE CODE [CA488] .1094
FAILURE CODE [CA515] .1095
FAILURE CODE [CA516] .1097
FAILURE CODE [CA553] .1099
FAILURE CODE [CA555] .1100
FAILURE CODE [CA556] .1101
FAILURE CODE [CA559] .1102
FAILURE CODE [CA595] .1105
FAILURE CODE [CA687] .1106
FAILURE CODE [CA689] .1108
FAILURE CODE [CA691] .1111
FAILURE CODE [CA692] .1113
FAILURE CODE [CA697] .1115
FAILURE CODE [CA698] .1116
FAILURE CODE [CA731] .1117
FAILURE CODE [CA778] .1119
FAILURE CODE [CA1117] 1124
FAILURE CODE [CA1664] 1125
FAILURE CODE [CA1669] 1128
FAILURE CODE [CA1673] 1129
FAILURE CODE [CA1677] 1130
FAILURE CODE [CA1678] 1131
FAILURE CODE [CA1682] 1132
FAILURE CODE [CA1683] 1136
FAILURE CODE [CA1684] 1138
FAILURE CODE [CA1686] 1140
FAILURE CODE [CA1691] 1141
FAILURE CODE [CA1694] 1144
FAILURE CODE [CA1695] 1147
FAILURE CODE [CA1696] 1148
FAILURE CODE [CA1712] 1150
FAILURE CODE [CA1713] 1153
FAILURE CODE [CA1714] 1155
FAILURE CODE [CA1715] 1156
FAILURE CODE [CA1776] 1157
FAILURE CODE [CA1777] 1160
FAILURE CODE [CA1843] 1163
FAILURE CODE [CA1844] 1165
FAILURE CODE [CA1879] 1168
FAILURE CODE [CA1881] 1171
FAILURE CODE [CA1883] 1173
FAILURE CODE [CA1885] 1177
FAILURE CODE [CA1887] 1179
FAILURE CODE [CA1921] 1181
FAILURE CODE [CA1922] 1184
FAILURE CODE [CA1942] 1189
FAILURE CODE [CA1993] 1190
FAILURE CODE [CA2185] 1193
FAILURE CODE [CA2186] 1195
FAILURE CODE [CA2249] 1197
FAILURE CODE [CA2271] 1198
FAILURE CODE [CA2272] 1201
FAILURE CODE [CA2288] 1204
FAILURE CODE [CA2311] 1205
FAILURE CODE [CA2349] 1206
FAILURE CODE [CA2353] 1209
FAILURE CODE [CA2357] 1211
FAILURE CODE [CA2381] 1212
FAILURE CODE [CA2382] 1215
FAILURE CODE [CA2383] 1218
FAILURE CODE [CA2386] 1221
FAILURE CODE [CA2387] 1223
TROUBLESHOOTING FLOWCHART 1227
FAILURE CODE [CA2555] 1228
FAILURE CODE [CA2556] 1231
FAILURE CODE [CA2637] 1234
FAILURE CODE [CA2639] 1236
FAILURE CODE [CA2771] 1239
FAILURE CODE [CA2777] 1245
FAILURE CODE [CA2976] 1248
FAILURE CODE [CA3133] 1250
FAILURE CODE [CA3134] 1252
FAILURE CODE [CA3135] 1254
FAILURE CODE [CA3142] 1258
FAILURE CODE [CA3143] 1259
FAILURE CODE [CA3144] 1260
FAILURE CODE [CA3146] 1262
FAILURE CODE [CA3147] 1263
FAILURE CODE [CA3148] 1264
FAILURE CODE [CA3151] 1266
FAILURE CODE [CA3165] 1272
FAILURE CODE [CA3229] 1275
FAILURE CODE [CA3231] 1277
FAILURE CODE [CA3232] 1279
FAILURE CODE [CA3235] 1283
FAILURE CODE [CA3239] 1285
FAILURE CODE [CA3241] 1288
FAILURE CODE [CA3242] 1291
FAILURE CODE [CA3251] 1294
FAILURE CODE [CA3253] 1296
FAILURE CODE [CA3254] 1299
FAILURE CODE [CA3255] 1302
FAILURE CODE [CA3256] 1305
FAILURE CODE [CA3311] 1307
FAILURE CODE [CA3312] 1309
FAILURE CODE [CA3313] 1312
FAILURE CODE [CA3314] 1313
FAILURE CODE [CA3315] 1314
FAILURE CODE [CA3316] 1317
FAILURE CODE [CA3317] 1318
FAILURE CODE [CA3318] 1319
FAILURE CODE [CA3319] 1322
FAILURE CODE [CA3321] 1323
FAILURE CODE [CA3322] 1325
FAILURE CODE [CA3419] 1328
FAILURE CODE [CA3421] 1330
FAILURE CODE [CA3497] 1332
FAILURE CODE [CA3498] 1333
FAILURE CODE [CA3543] 1334
FAILURE CODE [CA3545] 1341
FAILURE CODE [CA3547] 1343
FAILURE CODE [CA3558] 1344
FAILURE CODE [CA3559] 1346
FAILURE CODE [CA3562] 1348
FAILURE CODE [CA3563] 1350
FAILURE CODE [CA3567] 1353
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] 1384
FAILURE CODE [CA3596] 1386
FAILURE CODE [CA3649] 1389
FAILURE CODE [CA3681] 1391
FAILURE CODE [CA3682] 1396
FAILURE CODE [CA3713] 1402
FAILURE CODE [CA3717] 1405
FAILURE CODE [CA3718] 1406
FAILURE CODE [CA3725] 1407
FAILURE CODE [CA3741] 1410
FAILURE CODE [CA3748] 1411
FAILURE CODE [CA3751] 1413
FAILURE CODE [CA3755] 1415
FAILURE CODE [CA3866] 1417
FAILURE CODE [CA3867] 1421
FAILURE CODE [CA3868] 1424
FAILURE CODE [CA3899] 1428
FAILURE CODE [CA3911] 1430
FAILURE CODE [CA3912] 1434
FAILURE CODE [CA3932] 1436
FAILURE CODE [CA3933] 1438
FAILURE CODE [CA3934] 1440
FAILURE CODE [CA3935] 1443
FAILURE CODE [CA3936] 1445
FAILURE CODE [CA4151] 1447
FAILURE CODE [CA4152] 1451
FAILURE CODE [CA4155] 1455
FAILURE CODE [CA4156] 1458
FAILURE CODE [CA4157] 1461
FAILURE CODE [CA4158] 1463
FAILURE CODE [CA4159] 1464
FAILURE CODE [CA4161] 1465
FAILURE CODE [CA4162] 1468
FAILURE CODE [CA4163] 1471
FAILURE CODE [CA4164] 1473
FAILURE CODE [CA4165] 1475
FAILURE CODE [CA4166] 1477
FAILURE CODE [CA4168] 1479
FAILURE CODE [CA4169] 1482
FAILURE CODE [CA4171] 1484
FAILURE CODE [CA4249] 1487
FAILURE CODE [CA4251] 1489
FAILURE CODE [CA4259] 1491
FAILURE CODE [CA4261] 1494
FAILURE CODE [CA4277] 1497
FAILURE CODE [CA4281] 1501
FAILURE CODE [CA4459] 1504
FAILURE CODE [CA4461] 1507
FAILURE CODE [CA4658] 1510
FAILURE CODE [CA4731] 1514
FAILURE CODE [CA4732] 1515
FAILURE CODE [CA4739] 1516
FAILURE CODE [CA4768] 1517
FAILURE CODE [CA4769] 1519
FAILURE CODE [CA4842] 1522
FAILURE CODE [CA4952] 1526
FAILURE CODE [CA5115] 1528
FAILURE CODE [CA5383] 1531
FAILURE CODE [D130KA] 1533
FAILURE CODE [D130KB] 1536
FAILURE CODE [D130KY] 1538
FAILURE CODE [D19JKZ] 1540
FAILURE CODE [D811MC] 1543
FAILURE CODE [D862KA] 1544
FAILURE CODE [D8ALKA] 1545
FAILURE CODE [D8ALKB] 1547
FAILURE CODE [D8AQKR] 1549
FAILURE CODE [D8G1KT] 1551
FAILURE CODE [D8G6KT] 1552
FAILURE CODE [DAF0MB] 1553
FAILURE CODE [DAF0MC] 1554
FAILURE CODE [DAF8KB] 1555
FAILURE CODE [DAF9KQ] 1557
FAILURE CODE [DAFGMC] 1558
FAILURE CODE [DAFLKA] 1559
FAILURE CODE [DAFLKB] 1561
FAILURE CODE [DAFQKR] 1563
FAILURE CODE [DAJ000] 1564
FAILURE CODE [DAJ0KQ] 1565
FAILURE CODE [DAJ0KT] 1566
FAILURE CODE [DAJ0MC] 1567
FAILURE CODE [DAJ1KK] 1568
FAILURE CODE [DAJ2KK] 1570
FAILURE CODE [DAJ5KK] 1572
FAILURE CODE [DAJ6KK] 1575
FAILURE CODE [DAJLKA] 1577
FAILURE CODE [DAJLKB] 1579
FAILURE CODE [DAJPMA] 1581
FAILURE CODE [DAJQKR] 1582
FAILURE CODE [DAJRKR] 1583
FAILURE CODE [DB2QKR] 1584
FAILURE CODE [DB2RKR] 1589
FAILURE CODE [DD12KA] 1594
FAILURE CODE [DD12KB] 1596
FAILURE CODE [DD13KA] 1598
FAILURE CODE [DD13KB] 1600
FAILURE CODE [DD14KA] 1602
FAILURE CODE [DD14KB] 1604
FAILURE CODE [DDKAKA] 1606
FAILURE CODE [DDKAKB] 1608
FAILURE CODE [DDKFL4] 1610
FAILURE CODE [DDKGL4] 1612
FAILURE CODE [DDKHKA] 1614
FAILURE CODE [DDKHKB] 1616
FAILURE CODE [DDNLKA] 1618
FAILURE CODE [DDNLKB] 1620
FAILURE CODE [DDP6KA] 1622
FAILURE CODE [DDP6KB] 1625
FAILURE CODE [DDP6MA] 1627
FAILURE CODE [DDU1FS] 1629
FAILURE CODE [DDU1KA] 1631
FAILURE CODE [DDU1KY] 1634
FAILURE CODE [DFA4KX] 1636
FAILURE CODE [DFA4KZ] 1637
FAILURE CODE [DFA4L8] 1638
FAILURE CODE [DFA5KA] 1639
FAILURE CODE [DFA5KB] 1642
FAILURE CODE [DFA6KA] 1645
FAILURE CODE [DFA6KB] 1648
FAILURE CODE [DFA7KX] 1651
FAILURE CODE [DFA7KZ] 1652
FAILURE CODE [DFA7L8] 1653
FAILURE CODE [DFA8KA] 1654
FAILURE CODE [DFA8KB] 1657
FAILURE CODE [DFA9KA] 1660
FAILURE CODE [DFA9KB] 1663
FAILURE CODE [DGS1KA] 1666
FAILURE CODE [DGS1KX] 1669
FAILURE CODE [DH21KA] 1670
FAILURE CODE [DH21KB] 1672
FAILURE CODE [DHA4KA] 1674
FAILURE CODE [DHAAMA] 1676
FAILURE CODE [DHACMA] 1678
FAILURE CODE [DHH7KA] 1680
FAILURE CODE [DHH7KB] 1683
FAILURE CODE [DHH8KA] 1685
FAILURE CODE [DHH8KB] 1688
FAILURE CODE [DHH9KA] 1690
FAILURE CODE [DHH9KB] 1693
FAILURE CODE [DHHAKA] 1695
FAILURE CODE [DHHAKB] 1698
FAILURE CODE [DHRUKA] 1700
FAILURE CODE [DHRUKB] 1702
FAILURE CODE [DHRVKA] 1704
FAILURE CODE [DHRVKB] 1706
FAILURE CODE [DK30KA] 1708
FAILURE CODE [DK30KB] 1711
FAILURE CODE [DK30KX] 1713
FAILURE CODE [DK30KZ] 1714
FAILURE CODE [DK30L8] 1715
FAILURE CODE [DK31KA] 1716
FAILURE CODE [DK31KB] 1719
FAILURE CODE [DK40KA] 1721
FAILURE CODE [DK40KB] 1724
FAILURE CODE [DK55KX] 1726
FAILURE CODE [DK55KZ] 1727
FAILURE CODE [DK55L8] 1728
FAILURE CODE [DK56KA] 1729
FAILURE CODE [DK56KB] 1732
FAILURE CODE [DK57KA] 1734
FAILURE CODE [DK57KB] 1737
FAILURE CODE [DLM0KX] 1739
FAILURE CODE [DLM1KA] 1740
FAILURE CODE [DLM1KB] 1742
FAILURE CODE [DLM1MA] 1744
FAILURE CODE [DLM2KA] 1745
FAILURE CODE [DLM2KB] 1747
FAILURE CODE [DLM2MA] 1749
FAILURE CODE [DLM3KA] 1750
FAILURE CODE [DLM3KB] 1752
FAILURE CODE [DLM3MB] 1754
FAILURE CODE [DN21FS] 1755
FAILURE CODE [DR21KX] 1757
FAILURE CODE [DR31KX] 1758
FAILURE CODE [DV20KB] 1759
FAILURE CODE [DW4BKA] 1761
FAILURE CODE [DW4BKB] 1763
FAILURE CODE [DW4BKY] 1765
FAILURE CODE [DW7BKA] 1767
FAILURE CODE [DW7BKB] 1769
FAILURE CODE [DW7EKA] 1771
FAILURE CODE [DW7EKB] 1773
FAILURE CODE [DW7EKY] 1775
FAILURE CODE [DWN5KA] 1777
FAILURE CODE [DWN5KB] 1779
FAILURE CODE [DWN5KY] 1781
FAILURE CODE [DXA4KA] 1783
FAILURE CODE [DXA4KB] 1785
FAILURE CODE [DXA4KY] 1787
FAILURE CODE [DXA5KA] 1789
FAILURE CODE [DXA5KB] 1791
FAILURE CODE [DXA5KY] 1793
FAILURE CODE [DXA6KA] 1795
FAILURE CODE [DXA6KB] 1797
FAILURE CODE [DXA6KY] 1799
FAILURE CODE [DXA7KA] 1801
FAILURE CODE [DXA7KB] 1803
FAILURE CODE [DXA7KY] 1805
FAILURE CODE [DXHRKA] 1807
FAILURE CODE [DXHRKB] 1809
FAILURE CODE [DXHRKY] 1811
FAILURE CODE [DXHSKA] 1813
FAILURE CODE [DXHSKB] 1815
FAILURE CODE [DXHSKY] 1817
FAILURE CODE [DXHTKA] 1819
FAILURE CODE [DXHTKB] 1821
FAILURE CODE [DXHTKY] 1823
FAILURE CODE [DXHUKA] 1825
FAILURE CODE [DXHUKB] 1827
FAILURE CODE [DXHUKY] 1829
FAILURE CODE [DXJ4KA] 1831
FAILURE CODE [DXJ4KB] 1833
FAILURE CODE [DXJCKA] 1835
FAILURE CODE [DXJCKB] 1837
FAILURE CODE [DXJCKY] 1839
FAILURE CODE [DXJDKA] 1841
FAILURE CODE [DXJDKB] 1843
FAILURE CODE [DXJDKY] 1845
FAILURE CODE [DXK1KA] 1847
FAILURE CODE [DXK1KB] 1849
FAILURE CODE [DXK1KY] 1851
FAILURE CODE [DXK2KA] 1853
FAILURE CODE [DXK2KB] 1855
FAILURE CODE [DXK2KY] 1857
FAILURE CODE [F313KA] 1859
FAILURE CODE [F313KB] 1860
FAILURE CODE [F318KB] 1861
FAILURE CODE [F318KY] 1862
TROUBLESHOOTING OF ELECTRICAL SYSTEM (E-MODE) 1863
ENGINE DOES NOT START (ENGINE DOES NOT CRANK) 1863
MANUAL PREHEATING SYSTEM DOES NOT WORK .1870
AUTOMATIC PREHEATING SYSTEM DOES NOT WORK 1873
WHILE PREHEATING IS WORKING, PREHEATING MONITOR DOES NOT LIGHT UP 1875
WHEN STARTING SWITCH IS TURNED TO ON POSITION, MACHINE MONITOR DISPLAYS NOTHING 1877
WHEN STARTING SWITCH IS TURNED TO ON POSITION (WITH ENGINE STOPPED), BASIC CHECK MONITOR LIGHTS UP .1881
AIR CLEANER CLOGGING MONITOR LIGHTS UP IN YELLOW WHILE ENGINE IS RUNNING .1882
CHARGE LEVEL MONITOR LIGHTS UP IN RED WHILE ENGINE IS RUNNING 1883
ENGINE COOLANT TEMPERATURE MONITOR LIGHTS UP IN RED WHILE ENGINE IS RUNNING 1884
ENGINE OIL PRESSURE MONITOR LIGHTS UP IN RED WHILE ENGINE IS RUNNING .1885
HST CHARGE PRESSURE MONITOR LIGHTS UP IN RED WHILE ENGINE IS RUNNING .1886
HYDRAULIC OIL TEMPERATURE MONITOR LIGHTS UP IN RED WHILE ENGINE IS RUNNING .1887
HST OIL FILTER CLOGGING MONITOR LIGHTS UP IN RED WHILE ENGINE IS RUNNING .1888
ENGINE COOLANT TEMPERATURE GAUGE DOES NOT INDICATE CORRECT TEMPERATURE .1889
FUEL LEVEL GAUGE DOES NOT INDICATE CORRECT LEVEL .1890
HYDRAULIC OIL TEMPERATURE GAUGE DOES NOT INDICATE CORRECT TEMPERATURE 1893
OPERATION MODE DOES NOT CHANGE .1894
OPERATING CUSTOMIZE SWITCH DOES NOT DISPLAY CUSTOMIZE SCREEN .1895
MODIFYING SETTING ON CUSTOMIZE SCREEN DOES NOT CHANGE SETTING OF MACHINE .1896
SERVICE METER IS NOT DISPLAYED, WHILE STARTING SWITCH IS IN OFF POSITION .1897
SERVICE MODE CANNOT BE SELECTED 1898
WORK EQUIPMENT DOES NOT OPERATE 1899
FOOT HEATER DOES NOT OPERATE .1901
HORN DOES NOT SOUND 1907
HORN DOES NOT STOP SOUNDING 1909
BACKUP ALARM DOES NOT SOUND 1910
BACKUP ALARM DOES NOT STOP SOUNDING 1911
HEADLAMP DOES NOT LIGHT UP .1912
REAR LAMP DOES NOT LIGHT UP 1916
ALL WIPERS DO NOT OPERATE 1919
FRONT WIPER DOES NOT OPERATE .1921
REAR WIPER DOES NOT OPERATE 1923
LEFT DOOR WIPER DOES NOT OPERATE .1925
RIGHT DOOR WIPER DOES NOT OPERATE 1929
FRONT WASHER DOES NOT OPERATE 1933
REAR WASHER DOES NOT OPERATE .1935
LEFT DOOR WASHER DOES NOT OPERATE 1937
RIGHT DOOR WASHER DOES NOT OPERATE .1939
KOMTRAX SYSTEM DOES NOT OPERATE NORMALLY .1941
TROUBLESHOOTING FOR HYDRAULIC AND MECHANICAL SYSTEMS (H MODE) 1942
INFORMATION MENTIONED IN TROUBLESHOOTING TABLE (H MODE) 1942
FAILURE MODE AND CAUSE TABLE .1943
NEITHER R.H. NOR L.H. OF TRACKS CAN TRAVEL FORWARD OR REVERSE (NONE OF THE TRAVEL SYSTEMS OPERATE) .1949
EITHER R.H. OR L.H. OF TRACK CANNOT TRAVEL BOTH FORWARD AND REVERSE (ONE OF R.H. OR L.H. TRAVEL SYSTEMS CANNOT OPERATE) 1951
EITHER R.H. OR L.H. OF TRACK CANNOT TRAVEL ONE OF FORWARD OR REVERSE (ONLY ONE OF THE TRAVEL SYSTEMS CANNOT OPERATE IN ONE DIRECTION) 1953
TRAVEL SPEED OR POWER IS LOW .1955
SPEED RANGE DOES NOT CHANGE 1957
SHOCK IS LARGE WHEN MACHINE MOVES OFF OR STOPS .1958
MACHINE DEVIATES LARGELY .1959
MACHINE DRIFT ON A SLOPE IS LARGE 1962
ENGINE SPEED DROPS LARGELY OR ENGINE STOPS .1964
UNUSUAL NOISE IS HEARD FROM AROUND HST PUMP OR MOTOR .1966
HST OIL TEMPERATURE (HYDRAULIC OIL TEMPERATURE) RISES TOO HIGH .1968
ALL WORK EQUIPMENT DO NOT OPERATE 1970
ALL WORK EQUIPMENTS SPEED OR POWER IS LOW 1972
BLADE LIFT SPEED OR POWER IS LOW .1973
BLADE TILT SPEED OR POWER IS LOW .1975
BLADE ANGLE SPEED OR POWER IS LOW 1976
TIME LAG OF BLADE LIFT IS LARGE 1977
HYDRAULIC DRIFT OF LIFTED BLADE IS LARGE .1978
HYDRAULIC DRIFT OF TILTED BLADE IS LARGE .1979
UNUSUAL NOISE IS HEARD FROM AROUND WORK EQUIPMENT AND COOLING FAN PUMP OR CONTROL VALVE 1980
FAN SPEED IS ABNORMAL (TOO HIGH OR LOW, OR STATIONARY) .1981
UNUSUAL NOISE IS HEARD FROM AROUND FAN .1983
TROUBLESHOOTING OF ENGINE (S-MODE) .1984
INFORMATION MENTIONED IN TROUBLESHOOTING TABLE (S MODE) 1984
ENGINE DOES NOT CRANK WHEN STARTING SWITCH IS TURNED TO START POSITION .1985
ENGINE CRANKS BUT NO EXHAUST GAS COMES OUT .1986
FUEL IS BEING INJECTED BUT ENGINE DOES NOT START (MISFIRING: ENGINE CRANKS BUT DOES NOT START) .1987
ENGINE STARTABILITY IS POOR 1989
ENGINE DOES NOT PICK UP SMOOTHLY .1991
ENGINE STOPS DURING OPERATION 1993
ENGINE RUNS ROUGH OR IS UNSTABLE .1995
ENGINE LACKS POWER .1996
KDPF GETS CLOGGED IN A SHORT TIME 1998
ENGINE OIL CONSUMPTION IS EXCESSIVE 2000
OIL BECOMES CONTAMINATED QUICKLY .2001
FUEL CONSUMPTION IS EXCESSIVE 2002
OIL IS IN COOLANT (OR COOLANT SPURTS BACK OR COOLANT LEVEL GOES DOWN) 2003
OIL PRESSURE DROPS .2004
FUEL MIXES INTO ENGINE OIL .2006
WATER MIXES INTO ENGINE OIL (MILKY) 2007
COOLANT TEMPERATURE RISES TOO HIGH (OVERHEATING) .2008
UNUSUAL NOISE IS HEARD .2009
VIBRATION IS EXCESSIVE .2010
AIR CANNOT BE BLED FROM FUEL CIRCUIT .2011
ACTIVE REGENERATION IS EXECUTED FREQUENTLY .2012
ACTIVE REGENERATION TAKES TIME .2014
WHITE SMOKE IS EXHAUSTED DURING ACTIVE REGENERATION 2015
AdBlue/DEF CONSUMPTION IS EXCESSIVE 2016
THERE IS UNUSUAL SMELL (IRRITATING ODOR) .2018
FOREIGN MATERIALS ENTER AdBlue/DEF (AdBlue/DEF INCREASES) 2019
50 DISASSEMBLY AND ASSEMBLY 2021
CONTENTS .2022
ABBREVIATION LIST 2027
RELATED INFORMATION ON DISASSEMBLY AND ASSEMBLY 2033
HOW TO READ THIS MANUAL 2033
COATING MATERIALS LIST .2035
SPECIAL TOOLS LIST .2039
SKETCHES OF SPECIAL TOOLS 2058
ENGINE AND COOLING SYSTEM 2071
REMOVE AND INSTALL SUPPLY PUMP ASSEMBLY 2071
METHOD FOR REMOVING SUPPLY PUMP ASSEMBLY .2072
METHOD FOR INSTALLING SUPPLY PUMP ASSEMBLY .2077
REMOVE AND INSTALL INJECTOR ASSEMBLY .2084
METHOD FOR REMOVING INJECTOR ASSEMBLY 2084
METHOD FOR INSTALLING INJECTOR ASSEMBLY 2091
REMOVE AND INSTALL CYLINDER HEAD ASSEMBLY 2101
METHOD FOR REMOVING CYLINDER HEAD ASSEMBLY .2101
METHOD FOR INSTALLING CYLINDER HEAD ASSEMBLY .2113
REMOVE AND INSTALL EGR VALVE ASSEMBLY 2131
METHOD FOR REMOVING EGR VALVE ASSEMBLY .2131
METHOD FOR INSTALLING EGR VALVE ASSEMBLY .2132
REMOVE AND INSTALL EGR COOLER ASSEMBLY .2134
METHOD FOR REMOVING EGR COOLER ASSEMBLY 2134
METHOD FOR INSTALLING EGR COOLER ASSEMBLY 2136
REMOVE AND INSTALL STARTING MOTOR ASSEMBLY .2139
METHOD FOR REMOVING STARTING MOTOR ASSEMBLY 2139
METHOD FOR INSTALLING STARTING MOTOR ASSEMBLY 2141
REMOVE AND INSTALL ALTERNATOR BELT .2143
METHOD FOR REMOVING ALTERNATOR BELT 2143
METHOD FOR INSTALLING ALTERNATOR BELT 2144
REMOVE AND INSTALL AUTOMATIC TENSIONER .2146
METHOD FOR REMOVING AUTOMATIC TENSIONER 2146
METHOD FOR INSTALLING AUTOMATIC TENSIONER 2146
REMOVE AND INSTALL RADIATOR ASSEMBLY .2147
METHOD FOR REMOVING RADIATOR ASSEMBLY 2147
METHOD FOR INSTALLING RADIATOR ASSEMBLY 2150
REMOVE AND INSTALL HYDRAULIC OIL COOLER ASSEMBLY .2154
METHOD FOR REMOVING HYDRAULIC OIL COOLER ASSEMBLY 2154
METHOD FOR INSTALLING HYDRAULIC OIL COOLER ASSEMBLY 2157
REMOVE AND INSTALL AFTERCOOLER ASSEMBLY 2160
METHOD FOR REMOVING AFTERCOOLER ASSEMBLY .2160
METHOD FOR INSTALLING AFTERCOOLER ASSEMBLY .2163
REMOVE AND INSTALL COOLING FAN DRIVE ASSEMBLY 2167
METHOD FOR REMOVING COOLING FAN DRIVE ASSEMBLY .2167
METHOD FOR INSTALLING COOLING FAN DRIVE ASSEMBLY .2170
REMOVE AND INSTALL COOLING FAN MOTOR ASSEMBLY 2174
METHOD FOR REMOVING COOLING FAN MOTOR ASSEMBLY .2174
METHOD FOR INSTALLING COOLING FAN MOTOR ASSEMBLY .2177
REMOVE AND INSTALL ENGINE, HST PUMP ASSEMBLY .2181
METHOD FOR REMOVING ENGINE, HST PUMP ASSEMBLY 2181
METHOD FOR INSTALLING ENGINE, HST PUMP ASSEMBLY 2190
REMOVE AND INSTALL ENGINE FRONT OIL SEAL .2201
METHOD FOR REMOVING ENGINE FRONT OIL SEAL 2201
METHOD FOR INSTALLING ENGINE FRONT OIL SEAL 2202
REMOVE AND INSTALL ENGINE REAR OIL SEAL 2204
METHOD FOR REMOVING ENGINE REAR OIL SEAL .2204
METHOD FOR INSTALLING ENGINE REAR OIL SEAL .2206
REMOVE AND INSTALL ENGINE HOOD ASSEMBLY 2209
REMOVE ENGINE HOOD ASSEMBLY 2209
INSTALL ENGINE HOOD ASSEMBLY .2212
REMOVE AND INSTALL KDPF ASSEMBLY .2216
METHOD FOR REMOVING KDPF ASSEMBLY 2217
METHOD FOR INSTALLING KDPF ASSEMBLY 2220
DISASSEMBLE AND ASSEMBLE OF KDPF ASSEMBLY 2223
METHOD FOR DISASSEMBLING KDPF ASSEMBLY .2223
METHOD FOR ASSEMBLING KDPF ASSEMBLY 2226
REMOVE AND INSTALL KDPF, SCR ASSEMBLY 2233
METHOD FOR REMOVING KDPF, SCR ASSEMBLY .2234
METHOD FOR INSTALLING KDPF, SCR ASSEMBLY .2240
REMOVE AND INSTALL FUEL TANK ASSEMBLY 2247
REMOVE FUEL TANK ASSEMBLY 2247
INSTALL FUEL TANK ASSEMBLY .2253
REMOVE AND INSTALL AdBlue/DEF TANK ASSEMBLY 2260
METHOD FOR REMOVING AdBlue/DEF TANK ASSEMBLY .2260
METHOD FOR INSTALLING AdBlue/DEF TANK ASSEMBLY .2266
REMOVE AND INSTALL AdBlue/DEF TANK SENSOR FLANGE ASSEMBLY 2272
METHOD FOR REMOVING AdBlue/DEF TANK SENSOR FLANGE ASSEMBLY .2272
METHOD FOR INSTALLING AdBlue/DEF TANK SENSOR FLANGE ASSEMBLY .2273
REMOVE AND INSTALL AdBlue/DEF TANK SENSOR 2276
METHOD FOR REMOVING AdBlue/DEF TANK SENSOR .2276
METHOD FOR INSTALLING AdBlue/DEF TANK SENSOR .2277
REMOVE AND INSTALL AdBlue/DEF TANK STRAINER 2284
METHOD FOR REMOVING AdBlue/DEF TANK STRAINER .2284
METHOD FOR INSTALLING AdBlue/DEF TANK STRAINER .2285
REMOVE AND INSTALL AdBlue/DEF TANK FILLER PORT FILTER 2286
METHOD FOR REMOVING AdBlue/DEF TANK FILLER PORT FILTER .2286
METHOD FOR INSTALLING AdBlue/DEF TANK FILLER PORT FILTER .2287
REMOVE AND INSTALL SCR ASSEMBLY 2290
METHOD FOR REMOVING SCR ASSEMBLY .2290
METHOD FOR INSTALLING SCR ASSEMBLY .2292
REMOVE AND INSTALL KCCV ASSEMBLY .2296
METHOD FOR REMOVING KCCV ASSEMBLY 2296
METHOD FOR INSTALLING KCCV ASSEMBLY 2298
REMOVE AND INSTALL VGT ASSEMBLY 2300
METHOD FOR REMOVING VGT ASSEMBLY .2300
METHOD FOR INSTALLING VGT ASSEMBLY .2302
REMOVE AND INSTALL AdBlue/DEF MIXING TUBE 2305
METHOD FOR REMOVING AdBlue/DEF MIXING TUBE .2306
METHOD FOR INSTALLING AdBlue/DEF MIXING TUBE .2308
REMOVE AND INSTALL AdBlue/DEF INJECTOR .2312
METHOD FOR REMOVING AdBlue/DEF INJECTOR 2312
METHOD FOR INSTALLING AdBlue/DEF INJECTOR 2315
REMOVE AND INSTALL AdBlue/DEF PUMP .2319
METHOD FOR REMOVING AdBlue/DEF PUMP 2319
METHOD FOR INSTALLING AdBlue/DEF PUMP 2322
REMOVE AND INSTALL AdBlue/DEF HOSE .2325
METHOD FOR REMOVING AdBlue/DEF HOSE 2325
METHOD FOR INSTALLING AdBlue/DEF HOSE 2329
REMOVE AND INSTALL AIR CLEANER ASSEMBLY 2335
METHOD FOR REMOVING AIR CLEANER ASSEMBLY .2335
METHOD FOR INSTALLING AIR CLEANER ASSEMBLY .2337
REMOVE AND INSTALL AIR CONDITIONER COMPRESSOR ASSEMBLY .2340
METHOD FOR REMOVING AIR CONDITIONER COMPRESSOR ASSEMBLY 2340
METHOD FOR INSTALLING AIR CONDITIONER COMPRESSOR ASSEMBLY 2341
REMOVE AND INSTALL AIR CONDITIONER CONDENSER ASSEMBLY 2343
METHOD FOR REMOVING AIR CONDITIONER CONDENSER ASSEMBLY .2343
METHOD FOR INSTALLING AIR CONDITIONER CONDENSER ASSEMBLY .2347
POWER TRAIN 2351
REMOVE AND INSTALL DAMPER ASSEMBLY .2351
METHOD FOR REMOVING DAMPER ASSEMBLY 2351
METHOD FOR INSTALLING DAMPER ASSEMBLY 2352
REMOVE AND INSTALL HST PUMP ASSEMBLY .2354
METHOD FOR REMOVING HST PUMP ASSEMBLY 2354
METHOD FOR INSTALLING HST PUMP ASSEMBLY 2356
REMOVE AND INSTALL HST MOTOR AND FINAL DRIVE ASSEMBLY 2358
METHOD FOR REMOVING HST MOTOR AND FINAL DRIVE ASSEMBLY .2358
METHOD FOR INSTALLING HST MOTOR AND FINAL DRIVE ASSEMBLY .2361
DISASSEMBLE AND ASSEMBLE FINAL DRIVE ASSEMBLY 2364
METHOD FOR DISASSEMBLING FINAL DRIVE ASSEMBLY 2365
METHOD FOR ASSEMBLING FINAL DRIVE ASSEMBLY .2370
UNDERCARRIAGE AND FRAME 2379
REMOVE AND INSTALL TRACK FRAME ASSEMBLY 2379
REMOVE TRACK FRAME ASSEMBLY 2379
INSTALL TRACK FRAME ASSEMBLY .2384
REMOVE AND INSTALL IDLER ASSEMBLY 2389
METHOD FOR REMOVING IDLER ASSEMBLY .2389
METHOD FOR INSTALLING IDLER ASSEMBLY .2391
DISASSEMBLE AND ASSEMBLE IDLER ASSEMBLY 2393
METHOD FOR DISASSEMBLING IDLER ASSEMBLY 2393
METHOD FOR ASSEMBLING IDLER ASSEMBLY .2395
REMOVE AND INSTALL RECOIL SPRING ASSEMBLY 2400
METHOD FOR REMOVING RECOIL SPRING ASSEMBLY .2400
METHOD FOR INSTALLING RECOIL SPRING ASSEMBLY .2401
DISASSEMBLE AND ASSEMBLE RECOIL SPRING ASSEMBLY 2402
METHOD FOR DISASSEMBLING AND ASSEMBLING RECOIL SPRING ASSEMBLY .2402
METHOD FOR ASSEMBLING RECOIL SPRING ASSEMBLY .2405
REMOVE AND INSTALL TRACK ROLLER ASSEMBLY .2408
METHOD FOR REMOVING TRACK ROLLER ASSEMBLY 2408
METHOD FOR INSTALLING TRACK ROLLER ASSEMBLY 2409
DISASSEMBLE AND ASSEMBLE TRACK ROLLER ASSEMBLY .2412
METHOD FOR DISASSEMBLING TRACK ROLLER ASSEMBLY .2412
METHOD FOR ASSEMBLING TRACK ROLLER ASSEMBLY 2414
REMOVE AND INSTALL CARRIER ROLLER ASSEMBLY .2418
METHOD FOR REMOVING CARRIER ROLLER ASSEMBLY 2418
METHOD FOR INSTALLING CARRIER ROLLER ASSEMBLY 2419
DISASSEMBLE AND ASSEMBLE CARRIER ROLLER ASSEMBLY .2421
METHOD FOR DISASSEMBLING CARRIER ROLLER ASSEMBLY .2421
METHOD FOR ASSEMBLING CARRIER ROLLER ASSEMBLY 2422
REMOVE AND INSTALL PIVOT SHAFT ASSEMBLY 2425
METHOD FOR REMOVING PIVOT SHAFT ASSEMBLY .2425
METHOD FOR INSTALLING PIVOT SHAFT ASSEMBLY .2426
SEPARATE AND CONNECT TRACK ASSEMBLY 2428
METHOD FOR CHECKING BEFORE SEPARATING TRACK ASSEMBLY .2428
METHOD FOR SEPARATING TRACK ASSEMBLY (NORMAL) 2429
METHOD FOR SEPARATING TRACK ASSEMBLY (WHEN TRACK FRAME HAS INTERNAL DEFECT) 2430
METHOD FOR CONNECTING TRACK ASSEMBLY .2431
SEPARATE AND CONNECT PLUS TYPE TRACK ASSEMBLY 2433
METHOD FOR SEPARATING PLUS TYPE TRACK ASSEMBLY .2433
METHOD FOR CONNECTING PLUS TYPE TRACK ASSEMBLY .2433
DISASSEMBLE AND ASSEMBLE TRACK ASSEMBLY GENERALLY 2435
METHOD FOR DISASSEMBLING TRACK ASSEMBLY GENERALLY 2435
METHOD FOR ASSEMBLING TRACK ASSEMBLY GENERALLY .2440
DISASSEMBLE AND ASSEMBLE PLUS TYPE TRACK ASSEMBLY GENERALLY 2453
METHOD FOR DISASSEMBLING PLUS TYPE TRACK ASSEMBLY GENERALLY 2454
METHOD FOR ASSEMBLING PLUS TYPE TRACK ASSEMBLY GENERALLY .2455
DISASSEMBLE AND ASSEMBLE ONE LINK OF TRACK SHOE ASSEMBLY ON THE FIELD 2470
METHOD FOR DISASSEMBLING ONE LINK OF TRACK SHOE ASSEMBLY ON THE FIELD 2471
METHOD FOR ASSEMBLING ONE LINK OF TRACK SHOE ASSEMBLY ON THE FIELD .2472
DISASSEMBLE AND ASSEMBLE ONE LINK OF PLUS TYPE TRACK SHOE ASSEMBLY ON THE FIELD 2479
METHOD FOR DISASSEMBLING ONE LINK OF PLUS TYPE TRACK SHOE ASSEMBLY ON THE FIELD 2480
METHOD FOR ASSEMBLING ONE LINK OF PLUS TYPE TRACK SHOE ASSEMBLY ON THE FIELD .2482
REMOVE AND INSTALL EQUALIZER BAR ASSEMBLY 2486
METHOD FOR REMOVING EQUALIZER BAR ASSEMBLY .2486
METHOD FOR INSTALLING EQUALIZER BAR ASSEMBLY .2488
REMOVE AND INSTALL EQUALIZER BAR SIDE BUSHINGS .2491
METHOD FOR REMOVING EQUALIZER BAR SIDE BUSHINGS 2491
METHOD FOR INSTALLING EQUALIZER BAR SIDE BUSHINGS 2491
REMOVE AND INSTALL SEGMENT TEETH .2493
METHOD FOR REMOVING SEGMENT TEETH 2493
METHOD FOR INSTALLING SEGMENT TEETH 2494
HYDRAULIC SYSTEM .2495
REMOVE AND INSTALL HYDRAULIC TANK ASSEMBLY .2495
METHOD FOR REMOVING HYDRAULIC TANK ASSEMBLY 2496
METHOD FOR INSTALLING HYDRAULIC TANK ASSEMBLY 2500
REMOVE AND INSTALL CONTROL VALVE ASSEMBLY 2505
METHOD FOR REMOVING CONTROL VALVE ASSEMBLY .2505
METHOD FOR INSTALLING CONTROL VALVE ASSEMBLY .2510
WORK EQUIPMENT .2515
REMOVE AND INSTALL BLADE ASSEMBLY 2515
METHOD FOR REMOVING BLADE ASSEMBLY .2515
METHOD FOR INSTALLING BLADE ASSEMBLY .2517
REMOVE AND INSTALL WORK EQUIPMENT ASSEMBLY .2520
METHOD FOR REMOVING WORK EQUIPMENT ASSEMBLY 2520
METHOD FOR INSTALLING WORK EQUIPMENT ASSEMBLY 2522
METHOD FOR DISASSEMBLING AND ASSEMBLING WORK EQUIPMENT CYLINDER ASSEMBLY .2524
METHOD FOR DISASSEMBLING WORK EQUIPMENT CYLINDER ASSEMBLY 2525
METHOD FOR ASSEMBLING WORK EQUIPMENT CYLINDER ASSEMBLY .2526
REMOVE AND INSTALL U-FRAME ASSEMBLY 2530
METHOD FOR REMOVING U-FRAME ASSEMBLY .2530
METHOD FOR INSTALLING U-FRAME ASSEMBLY .2532
CAB AND ITS ATTACHMENTS 2534
REMOVE AND INSTALL OPERATOR’S CAB ASSEMBLY .2534
REMOVE OPERATOR CAB ASSEMBLY .2534
INSTALL OPERATOR CAB ASSEMBLY 2541
REMOVE AND INSTALL OPERATOR’S CAB GLASS (ADHERED GLASS) 2549
METHOD FOR REMOVING OPERATOR’S CAB GLASS (ADHERED GLASS) .2551
METHOD FOR INSTALLING OPERATOR’S CAB GLASS (ADHERED GLASS) .2551
REMOVE AND INSTALL AIR CONDITIONER UNIT ASSEMBLY .2557
METHOD FOR REMOVING AIR CONDITIONER UNIT ASSEMBLY 2557
METHOD FOR INSTALLING AIR CONDITIONER UNIT ASSEMBLY 2563
REMOVE AND INSTALL RECEIVER DRIER 2570
METHOD FOR REMOVING RECEIVER DRIER .2570
METHOD FOR INSTALLING RECEIVER DRIER .2571
REMOVE AND INSTALL OPERATOR’S SEAT .2574
METHOD FOR REMOVING OPERATOR’S SEAT 2574
METHOD FOR INSTALLING OPERATOR’S SEAT 2575
REMOVE AND INSTALL SEAT BELT .2576
METHOD FOR REMOVING SEAT BELT 2576
METHOD FOR INSTALLING SEAT BELT 2576
REMOVE AND INSTALL FOOT HEATER ASSEMBLY 2578
METHOD FOR REMOVING FOOT HEATER ASSEMBLY .2578
METHOD FOR INSTALLING FOOT HEATER ASSEMBLY .2580
DISASSEMBLE AND ASSEMBLE FOOT HEATER ASSEMBLY 2583
METHOD FOR DISASSEMBLING FOOT HEATER ASSEMBLY 2583
METHOD FOR ASSEMBLING FOOT HEATER ASSEMBLY .2584
ELECTRICAL SYSTEM 2585
REMOVE AND INSTALL ENGINE CONTROLLER ASSEMBLY 2585
METHOD FOR REMOVING ENGINE CONTROLLER ASSEMBLY .2585
METHOD FOR INSTALLING ENGINE CONTROLLER ASSEMBLY .2587
REMOVE AND INSTALL HST CONTROLLER ASSEMBLY .2590
METHOD FOR REMOVING HST CONTROLLER ASSEMBLY 2590
METHOD FOR INSTALLING HST CONTROLLER ASSEMBLY 2591
REMOVE AND INSTALL MACHINE MONITOR ASSEMBLY 2592
REMOVE MACHINE MONITOR ASSEMBLY 2592
INSTALL MACHINE MONITOR ASSEMBLY .2593
REMOVE AND INSTALL MASS AIR FLOW AND TEMPERATURE SENSOR 2595
METHOD FOR REMOVING MASS AIR FLOW AND TEMPERATURE SENSOR .2595
METHOD FOR INSTALLING MASS AIR FLOW AND TEMPERATURE SENSOR .2597
REMOVE AND INSTALL KCCV CRANKCASE PRESSURE SENSOR 2598
METHOD FOR REMOVING KCCV CRANKCASE PRESSURE SENSOR .2598
METHOD FOR INSTALLING KCCV CRANKCASE PRESSURE SENSOR .2600
REMOVE AND INSTALL SCR TEMPERATURE SENSOR 2602
METHOD FOR REMOVING SCR TEMPERATURE SENSOR .2602
METHOD FOR INSTALLING SCR TEMPERATURE SENSOR .2603
REMOVE AND INSTALL GATEWAY FUNCTION CONTROLLER ASSEMBLY 2605
REMOVE GATEWAY FUNCTION CONTROLLER ASSEMBLY 2605
INSTALL GATEWAY FUNCTION CONTROLLER ASSEMBLY .2606
REMOVE AND INSTALL COMMUNICATION TERMINAL 2607
REMOVE COMMUNICATION TERMINAL 2607
INSTALL COMMUNICATION TERMINAL .2610
60 MAINTENANCE STANDARD 2613
CONTENTS .2614
ABBREVIATION LIST 2616
ENGINE AND COOLING SYSTEM 2622
MAINTENANCE STANDARD OF ENGINE MOUNT .2622
MAINTENANCE STANDARD OF DAMPER .2623
MAINTENANCE STANDARD OF COOLING SYSTEM .2624
MAINTENANCE STANDARD OF COOLING FAN MOTOR 2626
MAINTENANCE STANDARD OF WORK EQUIPMENT AND COOLING FAN PUMP 2628
POWER TRAIN 2629
MAINTENANCE STANDARD OF HST PUMP .2629
MAINTENANCE STANDARD OF EPC VALVE OF HST PUMP 2630
MAINTENANCE STANDARD OF TOW RECEIVING VALVE OF HST PUMP 2631
MAINTENANCE STANDARD OF HST CHARGE PUMP 2632
MAINTENANCE STANDARD OF HST MOTOR 2634
MAINTENANCE STANDARD OF FINAL DRIVE 2635
MAINTENANCE STANDARD OF SPROCKET FOR CONVENTIONAL TYPE TRACK SHOE 2637
MAINTENANCE STANDARD OF SPROCKET TOOTH PROFILE FULL-SCALE DRAWING FOR CONVENTIONAL TYPE TRACK SHOE .2638
MAINTENANCE STANDARD OF SPROCKET FOR PLUS TYPE TRACK SHOE 2640
MAINTENANCE STANDARD OF SPROCKET TOOTH PROFILE FULL-SCALE DRAWING FOR PLUS TYPE TRACK SHOE .2641
UNDERCARRIAGE AND FRAME 2643
MAINTENANCE STANDARD OF SUSPENSION .2643
MAINTENANCE STANDARD OF TRACK FRAME AND IDLER CUSHION 2645
MAINTENANCE STANDARD OF IDLER 2647
MAINTENANCE STANDARD OF TRACK ROLLER FOR CONVENTIONAL TYPE TRACK SHOES (SINGLE FLANGE TYPE) 2649
MAINTENANCE STANDARD OF TRACK ROLLER FOR CONVENTIONAL TYPE TRACK SHOES (DOUBLE FLANGE TYPE) 2650
MAINTENANCE STANDARD OF TRACK ROLLER FOR PLUS TYPE TRACK SHOES (SINGLE FLANGE TYPE) 2651
MAINTENANCE STANDARD OF TRACK ROLLER FOR PLUS TYPE TRACK SHOES (DOUBLE FLANGE TYPE) 2652
MAINTENANCE STANDARD OF CARRIER ROLLER FOR CONVENTIONAL TYPE TRACK SHOE 2653
MAINTENANCE STANDARD OF CARRIER ROLLER FOR PLUS TYPE TRACK SHOE 2654
MAINTENANCE STANDARD OF CONVENTIONAL TYPE TRACK SHOE .2655
MAINTENANCE STANDARD OF PLUS TYPE TRACK SHOE .2657
MAINTENANCE STANDARD OF SINGLE SHOE 2659
MAINTENANCE STANDARD OF SWAMP SHOE .2660
HYDRAULIC SYSTEM .2661
MAINTENANCE STANDARD OF HYDRAULIC TANK .2661
MAINTENANCE STANDARD OF WORK EQUIPMENT AND COOLING FAN PUMP 2662
MAINTENANCE STANDARD OF SERVO VALVE OF WORK EQUIPMENT AND COOLING FAN PUMP .2663
MAINTENANCE STANDARD OF CONTROL VALVE 2665
MAINTENANCE STANDARD OF RIPPER PPC VALVE .2672
MAINTENANCE STANDARD OF 5-PORT VALVE OF EPC AND SOLENOID .2674
MAINTENANCE STANDARD OF EPC VALVE 2675
MAINTENANCE STANDARD OF ANGLE OPERATION EPC VALVE 2676
MAINTENANCE STANDARD OF QUICK DROP VALVE .2677
WORK EQUIPMENT .2679
MAINTENANCE STANDARD OF FRONT WORK EQUIPMENT .2679
MAINTENANCE STANDARD OF CUTTING EDGE AND END BIT .2682
MAINTENANCE STANDARD OF BLADE LIFT CYLINDER 2683
MAINTENANCE STANDARD OF BLADE TILT CYLINDER 2684
MAINTENANCE STANDARD OF BLADE ANGLE CYLINDER .2685
MAINTENANCE STANDARD OF FIXED MULTI-SHANK RIPPER .2686
MAINTENANCE STANDARD OF RIPPER LIFT CYLINDER .2688
CAB AND ITS ATTACHMENTS 2689
MAINTENANCE STANDARD OF CAB MOUNT 2689
ELECTRICAL SYSTEM 2690
MAINTENANCE STANDARD OF ELECTRIC STEERING CONTROL LEVER 2690
80 APPENDIX 2691
CONTENTS .2692
ABBREVIATION LIST 2693
AIR CONDITIONER SYSTEM .2699
PRECAUTIONS FOR REFRIGERANT 2699
AIR CONDITIONER COMPONENT 2700
SPECIFICATIONS OF AIR CONDITIONER 2703
CONFIGURATION AND FUNCTION OF REFRIGERATION CYCLE 2704
OUTLINE OF REFRIGERATION CYCLE .2705
COMPONENT PARTS OF AIR CONDITIONER SYSTEM 2707
AIR CONDITIONER UNIT .2707
CONFIGURATION DIAGRAM OF AIR CONDITIONER UNIT 2707
FUNCTION OF AIR CONDITIONER UNIT .2708
COMPONENT PARTS OF AIR CONDITIONER UNIT 2709
FUNCTION OF EVAPORATOR AS AIR CONDITIONER UNIT COMPONENT .2709
FUNCTION OF HEATER CORE AS AIR CONDITIONER UNIT COMPONENT 2709
FUNCTION OF THERMOSTAT AS AIR CONDITIONER UNIT COMPONENT .2709
STRUCTURE OF EXPANSION VALVE AS AIR CONDITIONER UNIT COMPONENT .2710
FUNCTION OF EXPANSION VALVE AS AIR CONDITIONER UNIT COMPONENT 2710
OPERATE EXPANSION VALVE AS AIR CONDITIONER UNIT COMPONENT 2710
FUNCTION OF DUAL PRESSURE SWITCH .2711
FUNCTION OF PRESSURE SWITCH 2711
COMPRESSOR .2712
STRUCTURE OF COMPRESSOR 2712
SPECIFICATIONS OF COMPRESSOR .2712
FUNCTION OF COMPRESSOR .2712
CONDENSER 2713
STRUCTURE OF CONDENSER .2713
SPECIFICATIONS OF CONDENSER 2713
FUNCTION OF CONDENSER 2714
RECEIVER DRIER .2715
STRUCTURE OF RECEIVER DRIER 2715
SPECIFICATIONS OF RECEIVER DRIER .2715
FUNCTION OF RECEIVER DRIER .2715
EXPLANATION OF PROCEDURE FOR TESTING AND TROUBLESHOOTING OF AIR CONDITIONER 2717
CIRCUIT DIAGRAM OF AIR CONDITIONER .2720
AIR CONDITIONER SYSTEM DIAGRAM .2721
CONTROL FUNCTION OF AIR CONDITIONER 2722
INSTALLATION LOCATIONS OF AIR CONDITIONER PARTS AND ARRANGEMENT OF CONNECTORS 2723
TEST RELAYS 2727
METHOD FOR TESTING RELAYS 2727
AIR CONDITIONER TROUBLESHOOTING CHART 1 2729
AIR CONDITIONER TROUBLESHOOTING CHART 2 2730
INFORMATION DESCRIBED IN TROUBLESHOOTING TABLE .2733
TROUBLESHOOTING FOR CONDENSER FAN 2735
TROUBLESHOOTING FOR COMPRESSOR AND REFRIGERANT SYSTEM (AIR IS NOT COOLED) 2738
TROUBLESHOOTING FOR BLOWER MOTOR SYSTEM (NO AIR COMES OUT OR AIR FLOW IS ABNORMAL) .2742
TROUBLESHOOTING FOR TEMPERATURE CONTROL FUNCTION .2745
TROUBLESHOOTING USING GAUGE PRESSURE .2749
CONNECTION OF SERVICE TOOL .2751
METHOD FOR CONNECTING SERVICE TOOL .2751
PRECAUTIONS FOR DISCONNECTING AND CONNECTING HOSES AND TUBES IN AIR CONDITIONER PIPINGS 2752
HANDLE COMPRESSOR OIL 2754
90 CIRCUIT DIAGRAMS 2757
CONTENTS .2758
HYDRAULIC CIRCUIT DIAGRAM 2759
SYMBOLS USED IN HYDRAULIC CIRCUIT DIAGRAM 2759
HYDRAULIC CIRCUIT DIAGRAM 2763
ELECTRICAL CIRCUIT DIAGRAM .2765
SYMBOLS USED IN ELECTRICAL CIRCUIT DIAGRAM .2765
ELECTRICAL CIRCUIT DIAGRAM (1/16) 2769
ELECTRICAL CIRCUIT DIAGRAM (2/16) 2771
ELECTRICAL CIRCUIT DIAGRAM (3/16) 2773
ELECTRICAL CIRCUIT DIAGRAM (4/16) 2775
ELECTRICAL CIRCUIT DIAGRAM (5/16) 2777
ELECTRICAL CIRCUIT DIAGRAM (6/16) 2779
ELECTRICAL CIRCUIT DIAGRAM (7/16) 2781
ELECTRICAL CIRCUIT DIAGRAM (8/16) 2783
ELECTRICAL CIRCUIT DIAGRAM (9/16) 2785
ELECTRICAL CIRCUIT DIAGRAM (10/16) .2787
ELECTRICAL CIRCUIT DIAGRAM (11/16) .2789
ELECTRICAL CIRCUIT DIAGRAM (12/16) .2791
ELECTRICAL CIRCUIT DIAGRAM (13/16) .2793
ELECTRICAL CIRCUIT DIAGRAM (14/16) .2795
ELECTRICAL CIRCUIT DIAGRAM (15/16) .2797
ELECTRICAL CIRCUIT DIAGRAM (16/16) .2799
INDEX .2801

DESCRIPTION:

Komatsu D61EX-24,D61EX-24E0,D61PX-24,D61PX-24E0 Bulldozer Shop Manual KEBM685505 – PDF DOWNLOAD

SERIAL NUMBERS

• D61EX-B65001 and up
• D61PX-B65001 and up

FOREWORD, SAFETY, BASIC INFORMATION
HOW TO READ THE SHOP MANUAL
• Some of the attachments and options described in this shop manual may not be available in some areas. If
they are required, consult your Komatsu distributor.
• The materials and specifications are subject to change without notice.
• Shop Manuals are available for “machine part” and “engine part”. For the engine unit, see the shop manual
for the machine which has the same engine model.
• Actual machine may differ from the images which are contained in this manual. A typical model is shown in
the illustrations of this shop manual.
Composition of the shop manual
This shop manual contains technical information necessary to perform services in workshops. It is divided into
the following chapters for the ease of use.
00 INDEX AND FOREWORD
This section describes the index, foreword, safety, and basic information.
01 SPECIFICATIONS
This section describes the specifications of the machine.
10 STRUCTURE AND FUNCTION
This section describes the structure and operation of each component with respect to each system. “STRUCTURE
AND FUNCTION” is helpful in not only understanding the structure of each component but performing
troubleshooting.
20 STANDARD VALUE TABLE
This section describes the standard values for new machine and failure criteria for testing and adjusting, and
troubleshooting. Use the standard values table to check the standard values for testing and adjusting, and judge
troubles in troubleshooting.
30 TESTING AND ADJUSTING
This section describes the measuring tools and measuring methods for testing and adjusting as well as the adjusting
method of each part. The standard values and repair limit for TESTING AND ADJUSTING are described
in “STANDARD VALUE TABLE”.
40 TROUBLESHOOTING
This section describes troubleshooting of failure part and its remedy method on the occurrence of the failure.
Descriptions of troubleshooting are sorted by failure mode.
50 DISASSEMBLY AND ASSEMBLY
This section describes the special tools, work procedures, and safety precautions necessary for removal, installation,
disassembly, and assembly of the components and parts. In addition, tightening torques, quantity, and
weight of the coating materials, lubricants, and coolant necessary to these works are shown.
60 MAINTENANCE STANDARD
This section describes the maintenance standard value of each component. The maintenance standard shows
the criteria and remedies for disassembly and assembly.
80 THE OTHER INFORMATION
This section describes the structure and function, testing and adjusting, and troubleshooting for all of the other
components or equipment which cannot be separately classified in the appendix.
90 Circuit diagrams
This section describes hydraulic circuit diagrams and electrical circuit diagrams.

G.B 30/12/24