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Komatsu D61EXI-23, D61PXI-23 Bulldozer (30324 and up) Shop Manual – SEN06256-02

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This complete Service Repair Workshop Manual PDF Download for the Komatsu D61EXI-23, D61PXI-23 Bulldozer (30324 and up) has easy to read text sections with top quality diagrams, pictures and illustrations. The step by step instructions show you how to fault find or complete any repair or overhaul, correctly and efficiently, saving time and avoiding costly mistakes. All specifications and tolerances are listed. Functions of components and systems are also explained.

APPLICABLE MODELS :

Komatsu D61EXI-23 – S/N: 30324 and up
Komatsu D61PXI-23 – S/N: 30324 and up

TABLE OF CONTENTS :

00 Index and foreword
01 Specification
10 Structure and function
20 Standard value tables
30 Testing and adjusting
40 Troubleshooting
50 Disassembly and assembly
60 Maintenance standard
80 Appendix
90 Diagrams and drawings
— INDEX

MANUAL SPECIFICATION :

File Format : PDF
Language : English
Printable : Yes
Searchable : Yes
Bookmarked : Yes
Product Code : SEN06256-02
Total Pages : 1969

This (OEM) Komatsu Shop Manual has detailed illustrations as well as step by step instructions, It is 100 percents complete and intact. they are specifically written for the do-it-yourself-er as well as the experienced mechanic. With step by step instruction & highly detailed exploded pictures & diagrams to show you how to complete the required job correctly & efficiently Using. Provides step-by-step instructions based on the complete dis-assembly of the machine. It is this level of detail, along with hundreds of photos and illustrations, that guide the reader through each service and repair procedure. Complete download comes in pdf format which can work under all PC based windows operating system and Mac also, All pages are printable. Using this repair manual is an inexpensive way to keep your vehicle working properly.

This service repair workshop manual PDF download has been prepared as an aid to improve the quality of repairs by giving the serviceman an accurate understanding of the product and by showing him the correct way to perform repairs and make judgements. Make sure you understand the contents of this manual and use it to full effect at every opportunity. This is a must for the Do-It-Yourselfer! Saving Yourself $$$$$$ In Service Repair And Maintenance Costs !!!!

This service repair workshop manual PDF download contains specs, diagrams, actual real photo illustrations, and schemes. In addition to space savings, nice thing about having completly searcheble PDF files instead of a hard-printed manual is that you can use the Search feature in your PDF reader software (Adobe Acrobat) to find just what your looking for and just print out the exact pages you need or all manual easily. This is the same Repair Service manual your local dealer will use when doing a repair.

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COVER
00 Index and foreword
Index
Foreword, safety and general information
Important safety notice
How to read the shop manual
Explanation of terms for maintenance standard
Handling equipment of fuel system devices
Handling of intake system parts
Handling of hydraulic equipment
Method of disconnecting and connecting of push-pull type coupler
Handling of electrical equipment
How to read electric wire code
Precautions when performing operation
Practical use of KOMTRAX
Standard tightening torque table
List of abbreviation
Conversion table
01 Specification
Table of contents
Specifications
Specification drawing
Specifications
Weight table
Table of fuel, coolant, and lubricants
10 Structure and function
Table of contents
Engine and cooling system
Engine related parts
KVGT
EGR system piping drawing
EGR system circuit diagram
EGR valve
EGR cooler
KCCV layout drawing
KCCV ventilator
KDPF
Cooling system
Cooling fan motor
Oil cooler bypass and HST charge safety valve
Power train
Power train system
Damper
Hydraulic component layout of HST
Steering and brake control
HST pump
HST motor
Charge pump
Solenoid valve
Final drive
Undercarriage and frame
Main frame
Suspension
Track frame and idler cushion
Hydraulic system
Hydraulic component layout of work equipment
Work equipment control system
Hydraulic tank
CLSS
Work equipment and cooling fan pump
Control valve
Ripper PPC valve
Quick drop valve
Angle control EPC valve
Accumulator
Work equipment
Blade
Ripper
Piston valve
Cab and its attachments
ROPS cab
Cab mount
Electrical system
Electrical control system
Machine monitor system
KOMTRAX system
System component parts
Sensor
20 Standard value tables
Table of contents
Standard service value table
Standard value table for engine
Standard value table for machine
Standard value table for electrical system
30 Testing and adjusting
Table of contents
Related information on testing and adjusting
Tools for testing and adjusting
Sketch of tools for testing and adjusting
Engine and cooling system
Testing engine speed
Testing boost pressure
Testing exhaust gas color
Testing and adjusting valve clearance
Testing compression pressure
Testing blowby pressure
Testing engine oil pressure
Testing EGR valve and KVGT oil pressures
Testing fuel pressure
Testing fuel discharge, return and leakage
Bleeding air from fuel system
Testing fuel circuit for leakage
Handling cylinder cutout mode operation
Handling no-injection cranking operation
Testing of KDPF and muffler stack for looseness and damage
Testing of installed condition of cylinder heads and manifolds
Testing engine piping for damage and looseness
Replacing alternator belt
Power train
Testing and adjusting HST oil pressure
Testing output pressure of solenoid valve
Testing if machine travels straight
Simple test procedure for brake performance
Adjusting deceleration/brake pedal
Adjusting parking brake lever
Move disabled machine urgently
Undercarriage and frame
Adjusting idler clearance
Checking sprocket wear
Testing and adjusting track tension
Hydraulic system
Releasing remaining pressure in work equipment cylinder
Testing and adjusting work equipment oil pressure
Testing source pressure of control circuit
Testing outlet pressure of work equipment EPC valve and fan EPC valve
Isolating the parts causing hydraulic drift in blade and ripper
Testing internal oil leakage of work equipment cylinder
Testing fan speed
Testing fan circuit oil pressure
Bleeding air from hydraulic circuit
Work equipment
Adjusting work equipment lock lever
Adjusting play of blade center ball
Electrical system
Special functions of machine monitor
Special functions of control box
Testing stroke sensor for lift cylinder
Testing stroke sensor for tilt cylinder
Testing stroke sensor for angle cylinder
Testing and adjusting reset sensor for lift cylinder
Testing and adjusting reset sensor for angle cylinder
Adjustment method when HST controller has been replaced
Adjustment method when ICT sensor controller has been replaced
Adjustment method when devices have been repaired or replaced
KOMTRAX terminal start-up procedure
Adjusting rearview camera angle
Handling voltage circuit of engine controller
Handling battery disconnect switch
Testing diodes
Pm clinic
Pm Clinic service
40 Troubleshooting
Table of contents
Related information on troubleshooting
Troubleshooting points
Sequence of events in troubleshooting
Checks before troubleshooting
Inspection procedure before troubleshooting
Preparation for troubleshooting of electrical system
Classification and procedures for troubleshooting
Symptom and troubleshooting numbers
Information in troubleshooting table
Procedure for troubleshooting wiring harness of pressure sensor system for open circuit
Connector list and layout
Connector contact identification
T-branch box and T-branch adapter table
Fuse location table
Precautions for KDPF (KCSF and KDOC) Cleaning and Replacement
Preparation of dummy temperature sensor (for KDOC and KDPF temperature sensors)
Preparation of short circuit electrical connector (for failure codes [CA1883] and [CA3135])
Failure codes table
Troubleshooting by failure code (Display of code)
Failure code [6091NX] HST Oil Filter Clogging
Failure code [989L00] Engine Controller Lock Caution 1
Failure code [989M00] Engine Controller Lock Caution 2
Failure code [989N00] Engine Controller Lock Caution 3
Failure code [A1U0N3] HC Desorb Request 1
Failure code [A1U0N4] HC Desorb Request 2
Failure code [AA10NX] Air Cleaner Clogging
Failure code [AB00KE] Charge Voltage Low
Failure code [[email protected]] Eng Oil Press Low
Failure code [[email protected]] Eng Water Overheat
Failure code [[email protected]] HST Oil Overheat
Failure code [[email protected]] HST Charge Press Low
Failure code [CA115] Eng Ne and Bkup Speed Sens Error
Failure code [CA122] Chg Air Press Sensor High Error
Failure code [CA123] Chg Air Press Sensor Low Error
Failure code [CA131] Throttle Sensor High Error
Failure code [CA132] Throttle Sensor Low Error
Failure code [CA144] Coolant Temp Sens High Error
Failure code [CA145] Coolant Temp Sens Low Error
Failure code [CA153] Chg Air Temp Sensor High Error
Failure code [CA154] Chg Air Temp Sensor Low Error
Failure code [CA187] Sensor 2 Supply Volt Low Error
Failure code [CA234] Eng Overspeed
Failure code [CA221] Ambient Press Sensor High Error
Failure code [CA222] Ambient Press Sensor Low Error
Failure code [CA227] Sensor 2 Supply Volt High Error
Failure code [CA238] Ne Speed Sensor Supply Volt Error
Failure code [CA239] Ne Speed Sens Supply Volt High Error
Failure code [CA271] IMV/PCV1 Short Error
Failure code [CA272] IMV/PCV1 Open Error
Failure code [CA295] Ambient Pressure Sensor In Range Error
Failure code [CA322] Inj #1(L#1) Open/Short Error
Failure code [CA323] Inj #5(L#5) Open/Short Error
Failure code [CA324] Inj #3(L#3) Open/Short Error
Failure code [CA325] Inj #6(L#6) Open/Short Error
Failure code [CA331] Inj #2(L#2) Open/Short Error
Failure code [CA332] Inj #4(L#4) Open/Short Error
Failure code [CA343] ECM Critical Internal Failure
Failure code [CA351] Injectors Drive Circuit Error
Failure code [CA352] Sensor 1 Supply Volt Low Error
Failure code [CA356] Mass Air Flow Sensor High Error
Failure code [CA357] Mass Air Flow Sensor Low Error
Failure code [CA386] Sensor 1 Supply Volt High Error
Failure code [CA428] Water in Fuel Sensor High Error
Failure code [CA429] Water in Fuel Sensor Low Error
Failure code [CA435] Eng Oil Press Sw Error
Failure code [CA441] Battery Voltage Low Error
Failure code [CA442] Battery Voltage High Error
Failure code [CA449] Rail Press Very High Error
Failure code [CA451] Rail Press Sensor High Error
Failure code [CA452] Rail Press Sensor Low Error
Failure code [CA488] Chg Air Temp High Torque Derate
Failure code [CA515] Rail Press Sens Sup Volt High Error
Failure code [CA516] Rail Press Sens Sup Volt Low Error
Failure code [CA553] Rail Press High Error
Failure code [CA555] Crankcase Press High Error 2
Failure code [CA556] Crankcase Press High Error 2
Failure code [CA559] Rail Press Low Error
Failure code [CA595] Turbo Speed High Error 2
Failure code [CA687] Turbo Speed Low Error
Failure code [CA689] Eng Ne Speed Sensor Error
Failure code [CA691] Intake Air Temp Sens High Error
Failure code [CA692] Intake Air Temp Sens Low Error
Failure code [CA697] ECM Internal Temp Sensor High Error
Failure code [CA698] ECM Int Temp Sensor Low Error
Failure code [CA731] Eng Bkup Speed Sens Phase Error
Failure code [CA778] Eng Bkup Speed Sensor Error
Failure code [CA1117] Persistent Data Lost Error
Failure code [CA1664] KDOC Malfunction
Failure code [CA1691] Regeneration Ineffective
Failure code [CA1695] Sens 5 Supply Volt High Error
Failure code [CA1696] Sens 5 Supply Volt Low Error
Failure code [CA1843] Crankcase Press Sens High Error
Failure code [CA1844] Crankcase Press Sens Low Error
Failure code [CA1879] KDPF Delta P Sensor High Error
Failure code [CA1881] KDPF Delta P Sensor Low Error
Failure code [CA1883] KDPF Delta P Sens In Range Error
Failure code [CA1921] KDPF Soot Load High Error 1
Failure code [CA1922] KDPF Soot Load High Error 2
Failure code [CA1942] Crankcase Press Sens In Range Error
Failure code [CA1993] KDPF Delta Pressure Low Error
Failure code [CA2185] Throt Sensor Sup Volt High Error
Failure code [CA2186] Throt Sensor Sup Volt Low Error
Failure code [CA2249] Rail Press Very Low Error
Failure code [CA2271] EGR Valve Pos Sens High Error
Failure code [CA2272] EGR Valve Pos Sens Low Error
Failure code [CA2288] Turbo Speed High Error 1
Failure code [CA2311] IMV Solenoid Error
Failure code [CA2349] EGR Valve Solenoid Open Error
Failure code [CA2353] EGR Valve Solenoid Short Error
Failure code [CA2357] EGR Valve Servo Error
Failure code [CA2373] Exhaust Manifold Press Sens High error
Failure code [CA2374] Exhaust Manifold Press Sens Low error
Failure code [CA2375] EGR Orifice Temp Sens High Error
Failure code [CA2376] EGR Orifice Temp Sens Low Error
Failure code [CA2381] KVGT Pos Sens High Error
Failure code [CA2382] KVGT Pos Sens Low Error
Failure code [CA2383] KVGT Solenoid Open Error
Failure code [CA2386] KVGT Solenoid Short Error
Failure code [CA2387] KVGT Servo Error
Failure code [CA2554] Exh Manifold Press Sens In Range Error
Failure code [CA2555] Grid Htr Relay Volt Low Error
Failure code [CA2556] Grid Htr Relay Volt High Error
Failure code [CA2637] KDOC Face Plugging
Failure code [CA2639] Manual Stationary Regeneration Request
Failure code [CA2961] EGR Orifice Temp High Error 1
Failure code [CA2973] Chg Air Press Sensor In Range Error
Failure code [CA3133] KDPF Outlet Press Sens High Error
Failure code [CA3134] KDPF Outlet Press Sens Low Error
Failure code [CA3135] KDPF Outlet Press Sens In Range Error
Failure code [CA3251] KDOC Inlet Temp High Error
Failure code [CA3253] KDOC Temp Error – Non Regeneration
Failure code [CA3254] KDOC Outlet Temp High Error 1
Failure code [CA3255] KDPF Temp Error – Non Regeneration
Failure code [CA3256] KDPF Outlet Temp High Error 1
Failure code [CA3311] KDOC Outlet Temp High Error 2
Failure code [CA3312] KDPF Outlet Temp High Error 2
Failure code [CA3313] KDOC Inlet Temp Sensor Low Error
Failure code [CA3314] KDOC Inlet Temp Sens High Error
Failure code [CA3315] KDOC Inlet Temp Sens In Range Error
Failure code [CA3316] KDOC Outlet Temp Sens Low Error
Failure code [CA3317] KDOC Outlet Temp Sens High Error
Failure code [CA3318] KDOC Outlet Temp Sens In Range Error
Failure code [CA3319] KDPF Outlet Temp Sens High Error
Failure code [CA3321] KDPF Outlet Temp Sens Low Error
Failure code [CA3322] KDPF Outlet Temp Sens In Range Error
Failure code [CA3419] Mass Air Flow Sensor Sup Volt High Error
Failure code [CA3421] Mass Air Flow Sensor Sup Volt Low Error
Failure code [CA3741] Rail Press Valve Trip Error
Failure code [D130KA] Neutral relay Open
Failure code [D130KB] Neutral relay Short circuit
Failure code [D130KY] Neutral relay: Hot Short
Failure code [D19JKZ] Personal Code Relay Abnormality
Failure code [D811MC] KOMTRAX Error
Failure code [D862KA] GPS Antenna Open Circuit
Failure code [D8ALKA] Operating Lamp Open Circuit (KOMTRAX)
Failure code [D8ALKB] Operating Lamp Short Circuit (KOMTRAX)
Failure code [D8AQKR] CAN2 Discon (KOMTRAX)
Failure code [DAF0MB] Monitor ROM Abnormality
Failure code [DAF0MC] Monitor Error
Failure code [DAF8KB] Camera Power Supply Short Circuit
Failure code [DAF9KQ] Model Selection Abnormality
Failure code [DAFGMC] GPS Module Error
Failure code [DAFLKA] Operating Lamp Open Circuit (Monitor)
Failure code [DAFLKB] Operating Lamp Short Circuit (Monitor)
Failure code [DAFQKR] CAN2 Discon (Monitor)
Failure code [DAJ000] HST controller: Abnormality in controller
Failure code [DAJ0KQ] HST controller: Type select signal
Failure code [DAJ0KT] HST controller: Abnormality in controller
Failure code [DAJ0MC] HST Con Error
Failure code [DAJ1KK] HST controller: Source voltage low
Failure code [DAJ2KK] HST controller: Output voltage low
Failure code [DAJ5KK] HST: Sensor volt 5V (0) Out of normal range
Failure code [DAJ6KK] HST: Sensor volt 5V (1) Out of normal range
Failure code [DAJLKA] Operating Lamp Open Circuit (HST Con)
Failure code [DAJLKB] Operating Lamp Short Circuit (HST Con)
Failure code [DAJPMA] Inconsistency of Option Selection (HST)
Failure code [DAJQKR] CAN2 Discon ( HST Con)
Failure code [DAJRKR] CAN1 Discon ( HST Con)
Failure code [DB2QKR] CAN2 Discon (Engine Con)
Failure code [DB2RKR] CAN1 Discon (Engine Con)
Failure code [DBR0KT] ICT Controller: Abnormality in controller
Failure code [DBR0MC] ICT Con Error
Failure code [DBR1KK] ICT controller: Source voltage low
Failure code [DBR2KK] ICT controller: Output voltage low
Failure code [DBR5KK] ICT: Sensor volt 5V (0) Out of normal range
Failure code [DBRLKA] Operating Lamp Open Circuit (ICT Con)
Failure code [DBRLKB] Operating Lamp Short Circuit (ICT Con)
Failure code [DBRPMA] Inconsistency of Option Selection (ICT)
Failure code [DBRQKR] CAN2 Discon (ICT Con)
Failure code [DBRRKR] CAN1 Discon (ICT Con)
Failure code [DBTSKR] LAN Discon (iB Monitor)
Failure code [DBUTKA] GNSS Antenna Open Circuit
Failure code [DD12KA] Shift up SW: Open
Failure code [DD12KB] Shift up SW: Short Circuit
Failure code [DD13KA] Shift down SW: Open
Failure code [DD13KB] Shift down SW: Short Circuit
Failure code [DD14KA] Parking lever SW: Open
Failure code [DD14KB] Parking lever SW: Short circuit
Failure code [DDKAKA] Blade float Sw: Open
Failure code [DDKAKB] Blade float Sw: Short circuit
Failure code [DDKFL4] Left Angle Sw: Signal mismatch
Failure code [DDKGL4] Right Angle Sw: Signal mismatch
Failure code [DDKHKA] iB Sw: Open
Failure code [DDKHKB] iB Sw: Short circuit
Failure code [DDNLKA] Weq lock Sw: Open
Failure code [DDNLKB] Weq lock Sw: Short circuit
Failure code [DDP6KA] Brake Pressure Sensor: Open
Failure code [DDP6KB] Brake Pressure Sensor: Hot Short
Failure code [DDP6MA] Brake pressure sensor: Malfunction
Failure code [DDU1FS] Parking lever Switch 2: Signal mismatch
Failure code [DDU1KA] Parking lever Sw2: Open
Failure code [DDU1KY] Parking lever Sw2: Hot Short
Failure code [DFA4KX] Blade lift lever: Main and Sub Error
Failure code [DFA4KZ] Blade lift lever: Main and Sub Error
Failure code [DFA4L8] Blade lift lever: Signal mismatch
Failure code [DFA5KA] Blade lift lever1: Open
Failure code [DFA5KB] Blade lift lever1: Hot Short
Failure code [DFA6KA] Blade lift lever2: Open
Failure code [DFA6KB] Blade lift lever2: Hot Short
Failure code [DFA7KX] Blade tilt lever: Main and Sub Error
Failure code [DFA7KZ] Blade tilt lever: Main and Sub Error
Failure code [DFA7L8] Blade tilt lever: Signal mismatch
Failure code [DFA8KA] Blade tilt lever1: Open
Failure code [DFA8KB] Blade tilt lever1: Hot Short
Failure code [DFA9KA] Blade tilt lever2: Open
Failure code [DFA9KB] Blade tilt lever2: Hot Short
Failure code [DGS1KA] HST oil temp sensor: Open
Failure code [DGS1KX] HST oil temp sensor: Out of normal range
Failure code [DH21KA] Weq pressure sensor: Open
Failure code [DH21KB] Weq pressure sensor: Hot Short
Failure code [DHA4KA] Air Cleaner Clog Sensor Open Circuit
Failure code [DHH7KA] LF HST Pressure Sensor: Open
Failure code [DHH7KB] LF HST Pressure Sensor: Hot Short
Failure code [DHH8KA] RF HST Pressure Sensor: Open
Failure code [DHH8KB] RF HST Pressure Sensor: Hot Short
Failure code [DHH9KA] LR HST Pressure Sensor: Open
Failure code [DHH9KB] LR HST Pressure Sensor: Hot Short
Failure code [DHHAKA] RR HST Pressure Sensor: Open
Failure code [DHHAKB] RR HST Pressure Sensor: Hot Short
Failure code [DK30KA] ST lever1: Open
Failure code [DK30KB] ST lever1: Hot Short
Failure code [DK30KX] ST lever: Main and Sub Error
Failure code [DK30KZ] ST lever: Main and Sub Error
Failure code [DK30L8] ST lever: Signal mismatch
Failure code [DK31KA] ST lever2: Open
Failure code [DK31KB] ST lever2: Hot Short
Failure code [DK40KA] Decel/Brake potentiometer: Open
Failure code [DK40KB] Decel/Brake potentiometer: Hot Short
Failure code [DK55KX] FR lever: Main and Sub Error
Failure code [DK55KZ] FR lever: Main and Sub Error
Failure code [DK55L8] FR lever: Signal mismatch
Failure code [DK56KA] FR lever1: Open
Failure code [DK56KB] FR lever1: Hot Short
Failure code [DK57KA] FR lever2: Open
Failure code [DK57KB] FR lever2: Hot Short
Failure code [DK80KA] IMU Sensor: Open
Failure code [DKS0L8] Blade lift Stroke sensor: Signal mismatch
Failure code [DKS1KA] Blade lift Stroke sensor A: Open
Failure code [DKS1KB] Blade lift Stroke sensor A: Hot Short
Failure code [DKS2KA] Blade lift Stroke sensor B: Open
Failure code [DKS2KB] Blade lift Stroke sensor B: Hot Short
Failure code [DKS3KA] Blade lift Reset sensor: Open
Failure code [DKS3KB] Blade lift Reset sensor: Hot Short
Failure code [DKS3MB] Blade lift Reset sensor: Signal mismatch
Failure code [DKS4L8] Blade tilt Stroke sensor: Signal mismatch
Failure code [DKS5KA] Blade tilt Stroke sensor A: Open
Failure code [DKS5KB] Blade tilt Stroke sensor A: Hot Short
Failure code [DKS6KA] Blade tilt Stroke sensor B: Open
Failure code [DKS6KB] Blade tilt Stroke sensor B: Hot Short
Failure code [DKS7MB] Blade tilt Reset sensor: Signal mismatch
Failure code [DKSCL8] Angle left Stroke sensor: Signal mismatch
Failure code [DKSDKA] Angle left Stroke sensor A: Open
Failure code [DKSDKB] Angle left Stroke sensor A: Hot Short
Failure code [DKSEKA] Angle left Stroke sensor B: Open
Failure code [DKSEKB] Angle left Stroke sensor B: Hot Short
Failure code [DKSFKA] Angle left Reset sensor: Open
Failure code [DKSFKB] Angle left Reset sensor: Hot Short
Failure code [DKSFMB] Angle left Reset sensor: Signal mismatch
Failure code [DLM0KX] HST Motor Speed Sensor: Left/Right Error
Failure code [DLM0MA] HST motor speed sensor: Malfunction
Failure code [DLM1KA] Left HST motor speed sensor: Open
Failure code [DLM1KB] Left HST motor speed sensor: Short circuit
Failure code [DLM1MA] Left HST motor speed sensor: Malfunction
Failure code [DLM2KA] Right HST motor speed sensor: Open
Failure code [DLM2KB] Right HST motor speed sensor: Short circuit
Failure code [DLM2MA] Right HST motor speed sensor: Malfunction
Failure code [DLM3KA] Fan rev. sensor: Open
Failure code [DLM3KB] Fan rev. sensor: Short circuit
Failure code [DLM3MB] Fan control: Mismatch
Failure code [DN21FS] Decel/Brake pedal SW: Signal mismatch
Failure code [DR21KX] Camera 2 Picture Rev. Drive Abnormality
Failure code [DR31KX] Camera 3 Picture Rev. Drive Abnormality
Failure code [DV20KB] Back-up alarm: Short circuit
Failure code [DW4BKA] Parking brake solenoid: Open
Failure code [DW4BKB] Parking brake solenoid: Short circuit
Failure code [DW4BKY] Parking brake solenoid: Hot Short
Failure code [DW7BKA] Fan reverse solenoid: Open
Failure code [DW7BKB] Fan reverse solenoid: Short circuit
Failure code [DW7EKA] Slow brake solenoid: Open
Failure code [DW7EKB] Slow brake solenoid: Short circuit
Failure code [DW7EKY] Slow brake solenoid: Hot Short
Failure code [DWN5KA] Fan EPC: Open
Failure code [DWN5KB] Fan EPC: Short circuit
Failure code [DWN5KY] Fan EPC: Hot Short
Failure code [DXA4KA] LF HST pump EPC: Open
Failure code [DXA4KB] LF HST pump EPC: Short circuit
Failure code [DXA4KY] LF HST pump EPC: Hot Short
Failure code [DXA5KA] LR HST pump EPC: Open
Failure code [DXA5KB] LR HST pump EPC: Short circuit
Failure code [DXA5KY] LR HST pump EPC: Hot Short
Failure code [DXA6KA] RF HST pump EPC: Open
Failure code [DXA6KB] RF HST pump EPC: Short circuit
Failure code [DXA6KY] RF HST pump EPC: Hot Short
Failure code [DXA7KA] RR HST pump EPC: Open
Failure code [DXA7KB] RR HST pump EPC: Short circuit
Failure code [DXA7KY] RR HST pump EPC: Hot Short
Failure code [DXHRKA] Blade lift up EPC: Open
Failure code [DXHRKB] Blade lift up EPC: Short circuit
Failure code [DXHRKY] Blade lift up EPC: Hot short
Failure code [DXHSKA] Blade lift down EPC: Open
Failure code [DXHSKB] Blade lift down EPC: Short circuit
Failure code [DXHSKY] Blade lift down EPC: Hot short
Failure code [DXHTKA] Blade tilt left EPC: Open
Failure code [DXHTKB] Blade tilt left EPC: Short circuit
Failure code [DXHTKY] Blade tilt left EPC: Hot short
Failure code [DXHUKA] Blade tilt right EPC: Open
Failure code [DXHUKB] Blade tilt right EPC: Short circuit
Failure code [DXHUKY] Blade tilt right EPC: Hot short
Failure code [DXJ4KA] Weq lock Sol.: Open
Failure code [DXJ4KB] Weq lock Sol.: Short circuit
Failure code [DXJCKA] Blade angle left EPC: Open
Failure code [DXJCKB] Blade angle left EPC: Short circuit
Failure code [DXJCKY] Blade angle left EPC: Hot short
Failure code [DXJDKA] Blade angle right EPC: Open
Failure code [DXJDKB] Blade angle right EPC: Short circuit
Failure code [DXJDKY] Blade angle right EPC: Hot short
Failure code [DXK1KA] Left HST motor EPC: Open
Failure code [DXK1KB] Left HST motor EPC: Short circuit
Failure code [DXK1KY] Left HST motor EPC: Hot Short
Failure code [DXK2KA] Right HST motor EPC: Open
Failure code [DXK2KB] Right HST motor EPC: Short circuit
Failure code [DXK2KY] Right HST motor EPC: Hot Short
Troubleshooting of electrical system (E-mode)
E-1 Engine does not start (Engine does not crank)
E-2 Manual preheating system does not work
E-3 Automatic preheating system does not work
E-4 While preheating is working, preheating monitor does not light up
E-5 When starting switch is turned to ON position, machine monitor displays nothing
E-6 When starting switch is turned to ON position (with engine stopped), basic check monitor lights up
E-7 Air cleaner clogging monitor lights up in yellow while engine is running
E-8 Charge level monitor lights up in red while engine is running
E-9 Engine coolant temperature monitor lights up in red while engine is running
E-10 Engine oil pressure monitor lights up in red while engine is running
E-11 HST charge pressure monitor lights up in red while engine is running
E-12 Hydraulic oil temperature monitor lights up in red while engine is running
E-13 HST oil filter clogging monitor lights up in red while engine is running
E-14 Fuel level gauge does not indicate correct level
E-15 Engine coolant temperature gauge does not indicate correct temperature
E-16 Hydraulic oil temperature gauge does not indicate correct temperature
E-17 Operation mode does not change
E-18 Service mode cannot be selected
E-19 Operating customize switch does not display customize screen
E-20 Modifying setting on customize screen does not change setting of machine
E-21 Service meter is not displayed, while starting switch is in OFF position
E-22 Work equipment does not operate
E-23 Foot heater does not operate
E-24 Horn does not sound
E-25 Horn does not stop sounding
E-26 Backup alarm does not sound
E-27 Backup alarm does not stop sounding
E-28 Headlamp does not light up
E-29 Rear lamp does not light up
E-30 No wiper operates continuously or intermittently
E-31 Front wiper does not operate
E-32 Rear wiper does not operate
E-33 Left door wiper does not operate (failed in both continuous and intermittent operations)
E-34 Right door wiper does not operate (failed in both continuous and intermittent operations)
E-35 Front washer does not operate
E-36 Rear washer does not operate
E-37 Left door washer does not operate
E-38 Right door washer does not operate
E-39 KOMTRAX system does not operate normally
E-40 Control box shuts down after displaying the messages [GPS receiver not connected!] and [Slope sensor not connected!]
E-41 Control box displays the messages [GPS receiver not connected!] and [Slope sensor not connected!]
E-42 Control box displays the message [Waiting for radio link…]
E-43 Control box displays the message [IMU sensor not connected]
E-44 Control box displays the message [Waiting for satellites…]
E-45 Control box displays the message [Komatsu controller not connected!]
E-46 Control box displays the message [Cylinder Stroke Reading Abnormal]
E-47 Control box displays the message [Komatsu CAN Comms Abnormal]
E-48 Control box displays the message [Komatsu Machine Trouble]
E-49 Control box displays the message [Waiting to initialize….]
E-50 Control box displays the message [System Initializing…]
E-51 Control box displays the message [Initializing….]
E-52 Control box displays the message [Configuring GPS]
E-53 Control box displays the message [No GPS Localization…]
E-54 Control box displays the message [Low precisions…]
E-55 Control box displays the message [Heading Initializing]
E-56 Control box displays [Out of design area…]
E-57 Control box can not be turned on
E-58 Control box does not display intelligent Machine Control screen
E-59 Control box does not display bulldozer image
E-60 Control box does not display design surface
E-61 Control box touch panel does not respond
E-62 Control box touch panel is inaccurate
E-63 Cylinder stroke reset indication does not go out
E-64 AUTO is not displayed when Auto/manual switch is pressed (AUTO indication goes out)
E-65 Blade automatic lower control does not start while AUTO is displayed
E-66 Blade automatic raise control does not start while AUTO is displayed
E-67 Blade automatic control function is not activated while AUTO is displayed (Blade automatic control stops)
E-68 When checking and adjusting the blade elevation, the value is different from actual machine
E-69 Finished surface is inaccurate (The average height of finished surface is lower than designed surface or blade does not touch the surface)
E-70 Finished surface is inaccurate (The finished surface is not smooth)
E-71 Finished surface is inaccurate (When finishing slope horizontally, steps are made in each direction)
E-72 Machine can not escape from shoes slip while blade automatic control is activated (Shoes frequently slips)
E-73 Machine speed does not increase while blade automatic control is activated
E-74 Blade tilt angle does not coincide with design surface
E-75 Blade tilts back while blade automatic control is activated
E-76 When pressing cut/fill level switch (RAISE), the design surface does not rise
E-77 When pressing cut/fill level switch (LOWER), the design surface does not lower
E-78 When starting switch is turned to ON position, reverse leveling mode switch LED does not light up or does not go out
E-79 When reverse leveling mode switch is pressed, buzzer does not sound (does not switch to reverse leveling mode)
Troubleshooting of hydraulic and mechanical system (H-mode)
Information described in troubleshooting table (H-mode)
System chart of hydraulic and mechanical systems
Failure mode and cause table
H-1 Neither RH nor LH of tracks does not travel forward nor reverse (None of the travel system operates)
H-2 Either RH or LH of track does not travel forward nor reverse (Only RH or LH of travel system operates)
H-3 Either RH or LH of track travel only forward or reverse (Only forward or reverse of RH or LH of travel system does not operate)
H-4 Travel speed or power is low
H-5 Travel speed range does not change
H-6 Shock is large when machine starts or stops
H-7 Machine deviates largely
H-8 Machine drift on a slope is large
H-9 Engine stalls during travel or engine speed drops significantly
H-10 Unusual noise is heard from around HST pump or motor
H-11 All work equipment do not operate
H-12 All work equipment operates slowly or lacks power
H-13 Blade lift speed or power is low
H-14 Blade tilt speed or power is low
H-15 Blade angle speed or power is low
H-16 Time lag of blade lift is large
H-17 Hydraulic drift of lifted blade is large
H-18 Hydraulic drift of tilted blade is large
H-19 Unusual noise is heard from around work equipment pump or control valve
H-20 HST oil temperature (hydraulic oil temperature) rises too high
H-21 Fans speed is abnormal (high, low, or no rotation)
H-22 Unusual noise is heard from around fan
Troubleshooting of engine (S-mode)
Information described in troubleshooting table (S mode)
S-1 Engine does not crank when starting switch is turned to START position
S-2 Engine cranks but no exhaust smoke comes out
S-3 Fuel is being injected but engine does not start (misfiring: engine cranks but does not start)
S-4 Engine startability is poor
S-5 Engine does not pick up smoothly
S-6 Engine stops during operation
S-7 Engine runs rough or is unstable
S-8 Engine lacks power
S-9 KDPF gets clogged in a short time
S-10 Engine oil consumption is excessive
S-11 Engine oil becomes contaminated early
S-12 Fuel consumption is excessive
S-13 Oil is in coolant (or coolant spurts or coolant level goes down)
S-14 Oil pressure drops
S-15 Fuel mixes into engine oil
S-16 Water mixes into engine oil (milky)
S-17 Coolant temperature rises too high (overheating)
S-18 Unusual noise is heard
S-19 Vibration is excessive
S-20 Air cannot be bled from fuel circuit
S-21 Active regeneration is executed frequently
S-22 Active regeneration takes time
S-23 White smoke is exhausted during active regeneration
50 Disassembly and assembly
Table of contents
Related information on disassembly and assembly
How to read this manual
Coating materials list
Special tools list
Sketches of special tools
Engine and cooling system
Removal and installation of supply pump assembly
Removal and installation of fuel injector assembly
Removal and installation of cylinder head assembly
Removal and installation of radiator assembly
Removal and installation of aftercooler assembly
Removal and installation of hydraulic oil cooler assembly
Removal and installation of cooling fan drive assembly
Removal and installation of cooling fan motor assembly
Removal and installation of engine assembly
Disassembly and assembly of damper assembly
Removal and installation of engine front oil seal
Removal and installation of engine rear oil seal
Removal and installation of engine hood assembly
Removal and installation of fuel tank assembly
Removal and installation of KDPF assembly
Disassembly and assembly of KDPF assembly
Removal and installation of KCCV assembly
Removal and installation of KVGT assembly
Removal and installation of EGR (Exhaust Gas Recirculation) cooler assembly
Removal and installation of EGR (Exhaust Gas Recirculation) valve assembly
Removal and installation of belt for alternator and air conditioner compressor
Removal and installation of air cleaner assembly
Power train
Removal and installation of HST pump assembly
Removal and installation of HST motor and final drive assembly
Disassembly and assembly of final drive
Undercarriage and frame
Removal and installation of track frame assembly
Removal and installation of idler assembly
Disassembly and assembly of idler
Removal and installation of recoil spring assembly
Disassembly and assembly of recoil spring
Removal and installation of track roller assembly
Disassembly and assembly of track roller assembly
Removal and installation of carrier roller assembly
Disassembly and assembly of carrier roller assembly
Removal and installation of segment teeth
Separation and connection of track shoe assembly (Standard type track shoe)
Separation and connection of track shoe assembly (PLUS type track shoe)
Overall disassembly and assembly of track shoe assembly (Standard type track shoe)
Overall disassembly and assembly of track shoe assembly (PLUS type track shoe)
Disassembly and assembly of one track link assembly in field (Standard type track shoe)
Disassembly and assembly of one track link assembly in field (PLUS type track shoe)
Removal and installation of pivot shaft assembly
Removal and installation of equalizer bar assembly
Removal and installation of equalizer bar side bushing
Hydraulic system
Removal and installation of hydraulic tank assembly
Removal and installation of control valve assembly
Disassembly and assembly of hydraulic cylinder assembly
Work equipment
Removal and installation of work equipment assembly
Removal and installation of blade assembly
Removal and installation of U-frame assembly
Cab and its attachments
Removal and installation of ROPS cab assembly
Removal and installation of operator’s cab glass (adhesion glass)
Removal and installation of operator’s seat
Removal and installation of seat belt
Removal and installation of foot heater assembly
Disassembly and assembly of foot heater assembly
Removal and installation of air conditioner unit assembly
Removal and installation of air conditioner compressor assembly
Electrical system
Removal and installation of machine monitor assembly
Removal and installation of engine controller assembly
Removal and installation of HST controller assembly
Removal and installation of mass air flow and temperature sensor
Removal and installation of KOMTRAX terminal
Removal and installation of ICT sensor controller assembly
Removal and installation of control box
Removal and installation of GNSS receiver
Removal and installation of GNSS antenna
Removal and installation of IMU sensor
60 Maintenance standard
Table of contents
Engine and cooling system
Engine mount
Cooling fan motor
Oil cooler bypass and HST charge safety valve
Power train
Damper
HST pump
HST motor
Charge pump
Solenoid valve
Final drive
Sprocket
Full-scale drawing of sprocket tooth profile
Undercarriage and frame
Suspension
Track frame and idler cushion
Idler
Track roller
Carrier roller
Track shoe
Hydraulic system
Hydraulic tank
Work equipment and cooling fan pump
Control valve
Ripper PPC valve
Quick drop valve
Angle control EPC valve
Work equipment
Blade
Cutting edge and end bit
Ripper
Lift cylinder
Lift cylinder with stroke and reset sensor
Tilt cylinder with stroke sensor
Angle cylinder
Angle cylinder with stroke and reset sensor
Ripper cylinder
Cab and its attachments
Cab mount
Electrical system
System component parts
Sensor
80 Appendix
Table of contents
Air conditioner components
Precautions for refrigerant
Air conditioner component
Configuration and function of refrigeration cycle
Outline of refrigeration cycle
Air conditioner unit
Dual pressure switch
Pressure switch
Compressor
Condenser
Receiver drier
Procedure for testing and troubleshooting
Electrical circuit diagram
System diagram
Parts and connectors layout
Testing relays
Troubleshooting chart 1
Troubleshooting chart 2
Information described in troubleshooting table
A-1 Troubleshooting for condenser fan
A-2 Troubleshooting for compressor and refrigerant system (Air is not cooled)
A-3 Troubleshooting for blower motor system (No air comes out or air flow is abnormal)
A-4 Troubleshooting for temperature control
Troubleshooting with gauge pressure
Connection of service tool
Precautions for disconnecting and connecting hoses and tubes in air conditioner circuit
Handling of compressor oil
90 Diagrams and drawings
Table of contents
Hydraulic circuit diagram
Symbols in hydraulic circuit diagram
Hydraulic circuit diagram
Electric circuit diagram
Symbols in electric circuit diagram
Electrical circuit diagram
INDEX

 

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Komatsu D61EXI-23, D61PXI-23 Bulldozer (30324 and up) Shop Manual – SEN06256-02.pdf

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