Komatsu Crawler Doozer D61ex 23 Shop Manual

Komatsu Crawler Doozer D61ex 23 Shop Manual
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SEN06010-02
BULLDOZER D61EX -23

D61PX -23
D61EX- 30001
SERIAL NUMBERS and up
D61PX- 30001
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SHOP MANUAL
BULLDOZER
D61EX-23
D61PX-23
Model Serial Number
D61EX-23 30001 and up

D61PX-23
00 Index and foreword

1 00 Index and foreword
D61EX-23, D61PX-23 00-1

Index
Index (ALL-0310-001-A-00-A)
00 Index and foreword ....................................................................................................................... 00-1
Index ......................................................................................................................................... 00-2
Foreword, safety and general information ................................................................................... 00-15
Important safety notice ....................................................................................................... 00-15
How to read the shop manual.............................................................................................. 00-22
Explanation of terms for maintenance standard .................................................................... 00-24
Handling equipment of fuel system devices .......................................................................... 00-26
Handling of intake system parts........................................................................................... 00-27
Handling of hydraulic equipment.......................................................................................... 00-28
Method of disconnecting and connecting of push-pull type coupler ......................................... 00-30
Handling of electrical equipment.......................................................................................... 00-33
How to read electric wire code............................................................................................. 00-41
Precautions when performing operation ............................................................................... 00-44
Practical use of KOMTRAX ................................................................................................. 00-49
Standard tightening torque table.......................................................................................... 00-50
List of abbreviation ............................................................................................................. 00-56
Conversion table ................................................................................................................ 00-61
01 Specification................................................................................................................................. 01-1
Table of contents ........................................................................................................................ 01-2
Specifications............................................................................................................................. 01-3
Specification drawing ........................................................................................................... 01-3
Specifications ...................................................................................................................... 01-5
Weight table ...................................................................................................................... 01-17
Table of fuel, coolant, and lubricants .................................................................................... 01-21
10 Structure and function ................................................................................................................... 10-1
Engine and cooling system .......................................................................................................... 10-3
Engine related parts ............................................................................................................. 10-3
KVGT.................................................................................................................................. 10-5
EGR system piping drawing ................................................................................................ 10-12
EGR system circuit diagram ................................................................................................ 10-14
EGR valve......................................................................................................................... 10-16
EGR cooler........................................................................................................................ 10-18
KCCV layout drawing ......................................................................................................... 10-19
KCCV ventilator ................................................................................................................. 10-21
KDPF................................................................................................................................ 10-23
Cooling system .................................................................................................................. 10-27
Cooling fan motor............................................................................................................... 10-29
Oil cooler bypass and HST charge safety valve..................................................................... 10-35
Power train............................................................................................................................... 10-41
Power train system............................................................................................................. 10-41
Damper ............................................................................................................................. 10-44
Hydraulic component layout of HST ..................................................................................... 10-45
Steering and brake control .................................................................................................. 10-46
HST pump ......................................................................................................................... 10-48
HST motor......................................................................................................................... 10-63
Charge pump..................................................................................................................... 10-78
Solenoid valve ................................................................................................................... 10-79
Final drive ......................................................................................................................... 10-88
Undercarriage and frame........................................................................................................... 10-92
Main frame ........................................................................................................................ 10-92
Suspension ....................................................................................................................... 10-93
Track frame and idler cushion ............................................................................................. 10-95
Hydraulic system ...................................................................................................................... 10-98
Hydraulic component layout of work equipment .................................................................... 10-98
Work equipment control system......................................................................................... 10-100
Hydraulic tank.................................................................................................................. 10-102
CLSS .............................................................................................................................. 10-104
00-2 D61EX-23, D61PX-23

Index
Work equipment and cooling fan pump .............................................................................. 10-107

Control valve ................................................................................................................... 10-118
Ripper PPC valve............................................................................................................. 10-140
Quick drop valve .............................................................................................................. 10-145
Angle control EPC valve ................................................................................................... 10-148
Accumulator .................................................................................................................... 10-153
Work equipment ..................................................................................................................... 10-155
Blade .............................................................................................................................. 10-155
Ripper ............................................................................................................................. 10-156
Piston valve..................................................................................................................... 10-157
Cab and its attachments .......................................................................................................... 10-158
ROPS cab ....................................................................................................................... 10-158
Cab mount ...................................................................................................................... 10-160
Electrical system .................................................................................................................... 10-161
Engine control system ...................................................................................................... 10-161
Cooling system control system .......................................................................................... 10-164
HST control system .......................................................................................................... 10-166
Parking brake control system ............................................................................................ 10-179
System operating lamp function......................................................................................... 10-181
Battery disconnect switch function ..................................................................................... 10-182
Machine monitor system ................................................................................................... 10-184
KOMTRAX system ........................................................................................................... 10-207
System component parts .................................................................................................. 10-210
Sensor ............................................................................................................................ 10-227
20 Standard value tables.................................................................................................................... 20-1
Standard service value table........................................................................................................ 20-3
Standard value table for engine ............................................................................................. 20-3
Standard value table for machine .......................................................................................... 20-4
Standard value table for electrical system............................................................................. 20-17
30 Testing and adjusting .................................................................................................................... 30-1
Related information on testing and adjusting ................................................................................. 30-4
Tools for testing and adjusting ............................................................................................... 30-4
Sketch of tools for testing and adjusting ................................................................................. 30-7
Testing engine speed ........................................................................................................... 30-9
Testing boost pressure ....................................................................................................... 30-11
Testing exhaust gas color ................................................................................................... 30-13
Testing and adjusting valve clearance .................................................................................. 30-15
Testing compression pressure............................................................................................. 30-18
Testing blowby pressure ..................................................................................................... 30-22
Testing engine oil pressure ................................................................................................. 30-24
Testing EGR valve and KVGT oil pressures .......................................................................... 30-25
Testing fuel pressure .......................................................................................................... 30-26
Testing fuel discharge, return and leakage............................................................................ 30-31
Bleeding air from fuel system .............................................................................................. 30-36
Testing fuel circuit for leakage ............................................................................................. 30-38
Handling cylinder cutout mode operation.............................................................................. 30-39
Handling no-injection cranking operation.............................................................................. 30-40
Testing of KDPF and muffler stack for looseness and damage ............................................... 30-41
Testing of installed condition of cylinder heads and manifolds ................................................ 30-42
Testing engine piping for damage and looseness .................................................................. 30-43
Replacing alternator belt ..................................................................................................... 30-44
Power train............................................................................................................................... 30-45
Testing and adjusting HST oil pressure................................................................................. 30-45
Testing output pressure of solenoid valve ............................................................................. 30-50
Testing if machine travels straight ........................................................................................ 30-54
Simple test procedure for brake performance ....................................................................... 30-55
D61EX-23, D61PX-23 00-3

Index
Adjusting deceleration/brake pedal ...................................................................................... 30-56

Adjusting parking brake lever .............................................................................................. 30-59
Move disabled machine urgently ......................................................................................... 30-61
Adjusting idler clearance..................................................................................................... 30-64
Checking sprocket wear ..................................................................................................... 30-65
Testing and adjusting track tension ...................................................................................... 30-66
Releasing remaining pressure in work equipment cylinder ..................................................... 30-67
Testing and adjusting work equipment oil pressure................................................................ 30-68
Testing source pressure of control circuit.............................................................................. 30-70
Testing outlet pressure of work equipment EPC valve and fan EPC valve ............................... 30-71
Isolating the parts causing hydraulic drift in blade and ripper .................................................. 30-73
Testing internal oil leakage of work equipment cylinder .......................................................... 30-74
Testing fan speed............................................................................................................... 30-76
Testing fan circuit oil pressure ............................................................................................. 30-77
Bleeding air from hydraulic circuit ........................................................................................ 30-78
Work equipment ....................................................................................................................... 30-79
Adjusting work equipment lock lever .................................................................................... 30-79
Adjusting play of blade center ball........................................................................................ 30-81
Electrical system ...................................................................................................................... 30-82
Special functions of machine monitor ................................................................................... 30-82
Adjustment method when HST controller has been replaced ................................................ 30-161
Adjustment method when electric or hydraulic device has been replaced .............................. 30-164
Adjusting rearview camera angle ....................................................................................... 30-165
Handling voltage circuit of engine controller........................................................................ 30-166
Handling battery disconnect switch .................................................................................... 30-167
Testing diodes ................................................................................................................. 30-168
Pm clinic ................................................................................................................................ 30-169
Pm Clinic service ............................................................................................................. 30-169
Pm Clinic check sheet ...................................................................................................... 30-171
40 Troubleshooting............................................................................................................................ 40-1
Related information on troubleshooting......................................................................................... 40-9
Troubleshooting points ......................................................................................................... 40-9
Sequence of events in troubleshooting................................................................................. 40-11
Checks before troubleshooting ............................................................................................ 40-13
Inspection procedure before troubleshooting ........................................................................ 40-15
Preparation for troubleshooting of electrical system............................................................... 40-32
Classification and procedures for troubleshooting ................................................................. 40-36
Symptom and troubleshooting numbers ............................................................................... 40-38
Information in troubleshooting table ..................................................................................... 40-41
Procedure for troubleshooting wiring harness of pressure sensor system for open
circuit................................................................................................................... 40-43
Connector list and layout .................................................................................................... 40-46
Connector contact identification........................................................................................... 40-58
T-branch box and T-branch adapter table ............................................................................. 40-96
Fuse location table ........................................................................................................... 40-101
Precautions for KDPF (KCSF and KDOC) Cleaning and Replacement ................................. 40-106
Preparation of dummy temperature sensor (for KDOC and KDPF temperature
sensors)............................................................................................................. 40-109
Preparation of short circuit electrical connector (for failure codes [CA1883] and
[CA3135]) .......................................................................................................... 40-110
Failure codes table............................................................................................................40-111
Troubleshooting by failure code (Display of code) ...................................................................... 40-122
Failure code [6091NX] HST Oil Filter Clogging ................................................................... 40-122
Failure code [989L00] Engine Controller Lock Caution 1...................................................... 40-124
Failure code [989M00] Engine Controller Lock Caution 2..................................................... 40-125
Failure code [989N00] Engine Controller Lock Caution 3 ..................................................... 40-126
00-4 D61EX-23, D61PX-23

Index
Failure code [A1U0N3] HC Desorb Request 1 .................................................................... 40-127

Failure code [A1U0N4] HC Desorb Request 2 .................................................................... 40-129
Failure code [AA10NX] Air Cleaner Clogging ...................................................................... 40-131
Failure code [AB00KE] Charge Voltage Low....................................................................... 40-133
Failure code [B@BAZG] Eng Oil Press Low ....................................................................... 40-135
Failure code [B@BCNS] Eng Water Overheat .................................................................... 40-136
Failure code [B@CRNS] HST Oil Overheat ........................................................................ 40-137
Failure code [B@CRZG] HST Charge Press Low ............................................................... 40-138
Failure code [CA115] Eng Ne and Bkup Speed Sens Error .................................................. 40-139
Failure code [CA122] Chg Air Press Sensor High Error ....................................................... 40-140
Failure code [CA123] Chg Air Press Sensor Low Error ........................................................ 40-142
Failure code [CA131] Throttle Sensor High Error................................................................. 40-144
Failure code [CA132] Throttle Sensor Low Error ................................................................. 40-146
Failure code [CA144] Coolant Temp Sens High Error .......................................................... 40-148
Failure code [CA145] Coolant Temp Sens Low Error ........................................................... 40-150
Failure code [CA153] Chg Air Temp Sensor High Error ........................................................ 40-152
Failure code [CA154] Chg Air Temp Sensor Low Error......................................................... 40-154
Failure code [CA187] Sensor 2 Supply Volt Low Error ......................................................... 40-156
Failure code [CA234] Eng Overspeed ................................................................................ 40-158
Failure code [CA221] Ambient Press Sensor High Error ...................................................... 40-159
Failure code [CA222] Ambient Press Sensor Low Error ....................................................... 40-161
Failure code [CA227] Sensor 2 Supply Volt High Error......................................................... 40-163
Failure code [CA238] Ne Speed Sensor Supply Volt Error ................................................... 40-164
Failure code [CA239] Ne Speed Sens Supply Volt High Error............................................... 40-165
Failure code [CA271] IMV/PCV1 Short Error ...................................................................... 40-166
Failure code [CA272] IMV/PCV1 Open Error ...................................................................... 40-168
Failure code [CA295] Ambient Pressure Sensor In Range Error ........................................... 40-170
Failure code [CA322] Inj #1(L#1) Open/Short Error ............................................................. 40-171
Failure code [CA343] ECM Critical Internal Failure.............................................................. 40-183
Failure code [CA351] Injectors Drive Circuit Error ............................................................... 40-184
Failure code [CA352] Sensor 1 Supply Volt Low Error ......................................................... 40-185
Failure code [CA356] Mass Air Flow Sensor High Error ....................................................... 40-187
Failure code [CA357] Mass Air Flow Sensor Low Error ........................................................ 40-189
Failure code [CA386] Sensor 1 Supply Volt High Error......................................................... 40-191
Failure code [CA428] Water in Fuel Sensor High Error ........................................................ 40-192
Failure code [CA429] Water in Fuel Sensor Low Error ......................................................... 40-194
Failure code [CA435] Eng Oil Press Sw Error ..................................................................... 40-196
Failure code [CA441] Battery Voltage Low Error ................................................................. 40-197
Failure code [CA442] Battery Voltage High Error................................................................. 40-199
Failure code [CA449] Rail Press Very High Error................................................................. 40-200
Failure code [CA451] Rail Press Sensor High Error............................................................. 40-201
Failure code [CA452] Rail Press Sensor Low Error ............................................................. 40-203
Failure code [CA488] Chg Air Temp High Torque Derate...................................................... 40-205
Failure code [CA515] Rail Press Sens Sup Volt High Error .................................................. 40-206
Failure code [CA516] Rail Press Sens Sup Volt Low Error ................................................... 40-208
Failure code [CA553] Rail Press High Error ........................................................................ 40-210
Failure code [CA555] Crankcase Press High Error 2 ........................................................... 40-211
Failure code [CA556] Crankcase Press High Error 2 ........................................................... 40-212
Failure code [CA559] Rail Press Low Error......................................................................... 40-213
Failure code [CA595] Turbo Speed High Error 2 ................................................................. 40-215
Failure code [CA687] Turbo Speed Low Error ..................................................................... 40-216
Failure code [CA689] Eng Ne Speed Sensor Error .............................................................. 40-218
Failure code [CA691] Intake Air Temp Sens High Error ........................................................ 40-220
Failure code [CA692] Intake Air Temp Sens Low Error......................................................... 40-222
D61EX-23, D61PX-23 00-5

Index
Failure code [CA697] ECM Internal Temp Sensor High Error................................................ 40-224
Failure code [CA698] ECM Int Temp Sensor Low Error........................................................ 40-225
Failure code [CA731] Eng Bkup Speed Sens Phase Error ................................................... 40-226
Failure code [CA778] Eng Bkup Speed Sensor Error........................................................... 40-228
Failure code [CA1117] Persistent Data Lost Error................................................................ 40-233
Failure code [CA1664] KDOC Malfunction.......................................................................... 40-234
Failure code [CA1691] Regeneration Ineffective ................................................................. 40-237
Failure code [CA1695] Sens 5 Supply Volt High Error.......................................................... 40-240
Failure code [CA1696] Sens 5 Supply Volt Low Error .......................................................... 40-241
Failure code [CA1843] Crankcase Press Sens High Error.................................................... 40-243
Failure code [CA1844] Crankcase Press Sens Low Error .................................................... 40-245
Failure code [CA1879] KDPF Delta P Sensor High Error ..................................................... 40-247
Failure code [CA1881] KDPF Delta P Sensor Low Error ...................................................... 40-249
Failure code [CA1883] KDPF Delta P Sens In Range Error.................................................. 40-251
Failure code [CA1921] KDPF Soot Load High Error 1.......................................................... 40-255
Failure code [CA1922] KDPF Soot Load High Error 2.......................................................... 40-258
Failure code [CA1942] Crankcase Press Sens In Range Error ............................................. 40-263
Failure code [CA1993] KDPF Delta Pressure Low Error ...................................................... 40-264
Failure code [CA2185] Throt Sensor Sup Volt High Error ..................................................... 40-267
Failure code [CA2186] Throt Sensor Sup Volt Low Error...................................................... 40-268
Failure code [CA2249] Rail Press Very Low Error ............................................................... 40-269
Failure code [CA2271] EGR Valve Pos Sens High Error ...................................................... 40-270
Failure code [CA2272] EGR Valve Pos Sens Low Error ....................................................... 40-272
Failure code [CA2288] Turbo Speed High Error 1................................................................ 40-275
Failure code [CA2311] IMV Solenoid Error ......................................................................... 40-276
Failure code [CA2349] EGR Valve Solenoid Open Error ...................................................... 40-277
Failure code [CA2353] EGR Valve Solenoid Short Error ...................................................... 40-279
Failure code [CA2357] EGR Valve Servo Error ................................................................... 40-281
Failure code [CA2373] Exhaust Manifold Press Sens High error........................................... 40-282
Failure code [CA2374] Exhaust Manifold Press Sens Low error ........................................... 40-284
Failure code [CA2375] EGR Orifice Temp Sens High Error .................................................. 40-286
Failure code [CA2376] EGR Orifice Temp Sens Low Error ................................................... 40-288
Failure code [CA2381] KVGT Pos Sens High Error ............................................................. 40-290
Failure code [CA2382] KVGT Pos Sens Low Error .............................................................. 40-292
Failure code [CA2383] KVGT Solenoid Open Error ............................................................. 40-295
Failure code [CA2386] KVGT Solenoid Short Error ............................................................. 40-297
Failure code [CA2387] KVGT Servo Error .......................................................................... 40-299
Failure code [CA2554] Exh Manifold Press Sens In Range Error .......................................... 40-300
Failure code [CA2555] Grid Htr Relay Volt Low Error ........................................................... 40-301
Failure code [CA2556] Grid Htr Relay Volt High Error .......................................................... 40-303
Failure code [CA2637] KDOC Face Plugging ..................................................................... 40-305
Failure code [CA2639] Manual Stationary Regeneration Request......................................... 40-307
Failure code [CA2961] EGR Orifice Temp High Error 1 ........................................................ 40-310
Failure code [CA2973] Chg Air Press Sensor In Range Error ............................................... 40-311
Failure code [CA3133] KDPF Outlet Press Sens High Error ................................................. 40-312
Failure code [CA3134] KDPF Outlet Press Sens Low Error.................................................. 40-314
Failure code [CA3135] KDPF Outlet Press Sens In Range Error .......................................... 40-316
Failure code [CA3251] KDOC Inlet Temp High Error............................................................ 40-320
Failure code [CA3253] KDOC Temp Error - Non Regeneration............................................. 40-323
Failure code [CA3254] KDOC Outlet Temp High Error 1 ...................................................... 40-326
Failure code [CA3255] KDPF Temp Error - Non Regeneration.............................................. 40-329
Failure code [CA3256] KDPF Outlet Temp High Error 1 ....................................................... 40-333
Failure code [CA3311] KDOC Outlet Temp High Error 2....................................................... 40-336
Failure code [CA3312] KDPF Outlet Temp High Error 2 ....................................................... 40-339
Failure code [CA3313] KDOC Inlet Temp Sensor Low Error ................................................. 40-342
Failure code [CA3314] KDOC Inlet Temp Sens High Error ................................................... 40-345
Failure code [CA3315] KDOC Inlet Temp Sens In Range Error............................................. 40-349
Failure code [CA3316] KDOC Outlet Temp Sens Low Error ................................................. 40-353
Failure code [CA3317] KDOC Outlet Temp Sens High Error................................................. 40-356
00-6 D61EX-23, D61PX-23

Index
Failure code [CA3318] KDOC Outlet Temp Sens In Range Error .......................................... 40-360
Failure code [CA3319] KDPF Outlet Temp Sens High Error ................................................. 40-364
Failure code [CA3321] KDPF Outlet Temp Sens Low Error .................................................. 40-368
Failure code [CA3322] KDPF Outlet Temp Sens In Range Error........................................... 40-371
Failure code [CA3419] Mass Air Flow Sensor Sup Volt High Error ........................................ 40-375
Failure code [CA3421] Mass Air Flow Sensor Sup Volt Low Error ......................................... 40-377
Failure code [CA3741] Rail Press Valve Trip Error............................................................... 40-379
Failure code [D130KA] Neutral relay Open ......................................................................... 40-380
Failure code [D130KB] Neutral relay Short circuit................................................................ 40-382
Failure code [D130KY] Neutral relay: Hot Short .................................................................. 40-384
Failure code [D19JKZ] Personal Code Relay Abnormality.................................................... 40-386
Failure code [D811MC] KOMTRAX Error............................................................................ 40-389
Failure code [D862KA] GPS Antenna Open Circuit ............................................................. 40-390
Failure code [D8ALKA] Operating Lamp Open Circuit (KOMTRAX) ...................................... 40-391
Failure code [D8ALKB] Operating Lamp Short Circuit (KOMTRAX) ...................................... 40-393
Failure code [D8AQKR] CAN2 Discon (KOMTRAX) ............................................................ 40-394
Failure code [DAF0MB] Monitor ROM Abnormality.............................................................. 40-395
Failure code [DAF0MC] Monitor Error ................................................................................ 40-396
Failure code [DAF8KB] Camera Power Supply Short Circuit ................................................ 40-397
Failure code [DAF9KQ] Model Selection Abnormality .......................................................... 40-398
Failure code [DAFGMC] GPS Module Error........................................................................ 40-399
Failure code [DAFLKA] Operating Lamp Open Circuit (Monitor) ........................................... 40-400
Failure code [DAFLKB] Operating Lamp Short Circuit (Monitor)............................................ 40-402
Failure code [DAFQKR] CAN2 Discon (Monitor) ................................................................. 40-403
Failure code [DAJ000] HST controller: Abnormality in controller ........................................... 40-404
Failure code [DAJ0KQ] HST controller: Type select signal ................................................... 40-405
Failure code [DAJ0KT] HST controller: Abnormality in controller ........................................... 40-406
Failure code [DAJ0MC] HST Con Error .............................................................................. 40-407
Failure code [DAJ1KK] HST controller: Source voltage low .................................................. 40-408
Failure code [DAJ2KK] HST controller: Output voltage low................................................... 40-410
Failure code [DAJ5KK] HST: Sensor volt 5V (0) Out of normal range .................................... 40-412
Failure code [DAJ6KK] HST: Sensor volt 5V (1) Out of normal range .................................... 40-414
Failure code [DAJLKA] Operating Lamp Open Circuit (HST Con) ......................................... 40-416
Failure code [DAJLKB] Operating Lamp Short Circuit (HST Con) ......................................... 40-418
Failure code [DAJPMA] Inconsistency of Option Selection (HST) ......................................... 40-419
Failure code [DAJQKR] CAN2 Discon (HST Con) ............................................................... 40-420
Failure code [DAJRKR] CAN1 Discon (HST Con) ............................................................... 40-421
Failure code [DB2QKR] CAN2 Discon (Engine Con) ........................................................... 40-422
Failure code [DB2RKR] CAN1 Discon (Engine Con) ........................................................... 40-426
Failure code [DD12KA] Shift up SW: Open ......................................................................... 40-430
Failure code [DD12KB] Shift up SW: Short Circuit ............................................................... 40-432
Failure code [DD13KA] Shift down SW: Open..................................................................... 40-434
Failure code [DD13KB] Shift down SW: Short Circuit........................................................... 40-436
Failure code [DD14KA] Parking lever SW: Open................................................................. 40-438
Failure code [DD14KB] Parking lever SW: Short circuit........................................................ 40-440
Failure code [DDKAKA] Blade float Sw: Open .................................................................... 40-442
Failure code [DDKAKB] Blade float Sw: Short circuit ........................................................... 40-444
Failure code [DDKFL4] Left Angle Sw: Signal mismatch ...................................................... 40-446
Failure code [DDKGL4] Right Angle Sw: Signal mismatch ................................................... 40-448
Failure code [DDKHKA] iB Sw: Open ................................................................................. 40-450
Failure code [DDKHKB] iB Sw: Short circuit........................................................................ 40-452
Failure code [DDNLKA] Weq lock Sw: Open....................................................................... 40-454
Failure code [DDNLKB] Weq lock Sw: Short circuit ............................................................. 40-456
Failure code [DDP6KA] Brake Pressure Sensor: Open........................................................ 40-458
Failure code [DDP6KB] Brake Pressure Sensor: Hot Short .................................................. 40-460
Failure code [DDP6MA] Brake pressure sensor: Malfunction ............................................... 40-462
Failure code [DDU1FS] Parking lever Switch 2: Signal mismatch ......................................... 40-464
Failure code [DDU1KA] Parking lever Sw2: Open ............................................................... 40-466
Failure code [DDU1KY] Parking lever Sw2: Hot Short ......................................................... 40-468
D61EX-23, D61PX-23 00-7

Index
Failure code [DFA4KX] Blade lift lever: Main and Sub Error ................................................. 40-470
Failure code [DFA4KZ] Blade lift lever: Main and Sub Error.................................................. 40-471
Failure code [DFA4L8] Blade lift lever: Signal mismatch ...................................................... 40-472
Failure code [DFA5KA] Blade lift lever1: Open .................................................................... 40-473
Failure code [DFA5KB] Blade lift lever1: Hot Short .............................................................. 40-476
Failure code [DFA6KA] Blade lift lever2: Open .................................................................... 40-478
Failure code [DFA6KB] Blade lift lever2: Hot Short .............................................................. 40-480
Failure code [DFA7KX] Blade tilt lever: Main and Sub Error ................................................. 40-482
Failure code [DFA7KZ] Blade tilt lever: Main and Sub Error.................................................. 40-483
Failure code [DFA7L8] Blade tilt lever: Signal mismatch ...................................................... 40-484
Failure code [DFA8KA] Blade tilt lever1: Open .................................................................... 40-485
Failure code [DFA8KB] Blade tilt lever1: Hot Short .............................................................. 40-488
Failure code [DFA9KA] Blade tilt lever2: Open .................................................................... 40-490
Failure code [DFA9KB] Blade tilt lever2: Hot Short .............................................................. 40-493
Failure code [DGS1KA] HST oil temp sensor: Open ............................................................ 40-495
Failure code [DGS1KX] HST oil temp sensor: Out of normal range ....................................... 40-497
Failure code [DH21KA] Weq pressure sensor: Open ........................................................... 40-498
Failure code [DH21KB] Weq pressure sensor: Hot Short ..................................................... 40-500
Failure code [DHA4KA] Air Cleaner Clog Sensor Open Circuit ............................................. 40-502
Failure code [DHH7KA] LF HST Pressure Sensor: Open ..................................................... 40-504
Failure code [DHH7KB] LF HST Pressure Sensor: Hot Short ............................................... 40-506
Failure code [DHH8KA] RF HST Pressure Sensor: Open .................................................... 40-508
Failure code [DHH8KB] RF HST Pressure Sensor: Hot Short............................................... 40-510
Failure code [DHH9KA] LR HST Pressure Sensor: Open..................................................... 40-512
Failure code [DHH9KB] LR HST Pressure Sensor: Hot Short............................................... 40-514
Failure code [DHHAKA] RR HST Pressure Sensor: Open.................................................... 40-516
Failure code [DHHAKB] RR HST Pressure Sensor: Hot Short.............................................. 40-518
Failure code [DK30KA] ST lever1: Open ............................................................................ 40-520
Failure code [DK30KB] ST lever1: Hot Short....................................................................... 40-522
Failure code [DK30KX] ST lever: Main and Sub Error .......................................................... 40-524
Failure code [DK30KZ] ST lever: Main and Sub Error .......................................................... 40-525
Failure code [DK30L8] ST lever: Signal mismatch ............................................................... 40-526
Failure code [DK31KA] ST lever2: Open ............................................................................ 40-527
Failure code [DK31KB] ST lever2: Hot Short....................................................................... 40-529
Failure code [DK40KA] Decel/Brake potentiometer: Open ................................................... 40-531
Failure code [DK40KB] Decel/Brake potentiometer: Hot Short.............................................. 40-534
Failure code [DK55KX] FR lever: Main and Sub Error.......................................................... 40-536
Failure code [DK55KZ] FR lever: Main and Sub Error .......................................................... 40-537
Failure code [DK55L8] FR lever: Signal mismatch............................................................... 40-538
Failure code [DK56KA] FR lever1: Open ............................................................................ 40-539
Failure code [DK56KB] FR lever1: Hot Short ...................................................................... 40-541
Failure code [DK57KA] FR lever2: Open ............................................................................ 40-543
Failure code [DK57KB] FR lever2: Hot Short ...................................................................... 40-545
Failure code [DLM0KX] HST Motor Speed Sensor: Left/Right Error ...................................... 40-547
Failure code [DLM1KA] Left HST motor speed sensor: Open ............................................... 40-548
Failure code [DLM1KB] Left HST motor speed sensor: Short circuit...................................... 40-550
Failure code [DLM1MA] Left HST motor speed sensor: Malfunction...................................... 40-552
Failure code [DLM2KA] Right HST motor speed sensor: Open............................................. 40-553
Failure code [DLM2KB] Right HST motor speed sensor: Short circuit ................................... 40-555
Failure code [DLM2MA] Right HST motor speed sensor: Malfunction ................................... 40-557
Failure code [DLM3KA] Fan rev. sensor: Open ................................................................... 40-558
Failure code [DLM3KB] Fan rev. sensor: Short circuit .......................................................... 40-560
Failure code [DLM3MB] Fan control: Mismatch ................................................................... 40-562
Failure code [DN21FS] Decel/Brake pedal SW: Signal mismatch ......................................... 40-563
Failure code [DR21KX] Camera 2 Picture Rev. Drive Abnormality ........................................ 40-565
Failure code [DR31KX] Camera 3 Picture Rev. Drive Abnormality ........................................ 40-566
Failure code [DV20KB] Back-up alarm: Short circuit ............................................................ 40-567
Failure code [DW4BKA] Parking brake solenoid: Open........................................................ 40-569
Failure code [DW4BKB] Parking brake solenoid: Short circuit .............................................. 40-571
00-8 D61EX-23, D61PX-23

Index
Failure code [DW4BKY] Parking brake solenoid: Hot Short.................................................. 40-573

Failure code [DW7BKA] Fan reverse solenoid: Open .......................................................... 40-575
Failure code [DW7BKB] Fan reverse solenoid: Short circuit ................................................. 40-577
Failure code [DW7EKA] Slow brake solenoid: Open............................................................ 40-578
Failure code [DW7EKB] Slow brake solenoid: Short circuit .................................................. 40-580
Failure code [DW7EKY] Slow brake solenoid: Hot Short...................................................... 40-582
Failure code [DWN5KA] Fan EPC: Open............................................................................ 40-584
Failure code [DWN5KB] Fan EPC: Short circuit .................................................................. 40-586
Failure code [DWN5KY] Fan EPC: Hot Short...................................................................... 40-587
Failure code [DXA4KA] LF HST pump EPC: Open .............................................................. 40-589
Failure code [DXA4KB] LF HST pump EPC: Short circuit..................................................... 40-591
Failure code [DXA4KY] LF HST pump EPC: Hot Short ........................................................ 40-592
Failure code [DXA5KA] LR HST pump EPC: Open ............................................................. 40-594
Failure code [DXA5KB] LR HST pump EPC: Short circuit .................................................... 40-596
Failure code [DXA5KY] LR HST pump EPC: Hot Short........................................................ 40-598
Failure code [DXA6KA] RF HST pump EPC: Open ............................................................. 40-600
Failure code [DXA6KB] RF HST pump EPC: Short circuit .................................................... 40-602
Failure code [DXA6KY] RF HST pump EPC: Hot Short........................................................ 40-603
Failure code [DXA7KA] RR HST pump EPC: Open ............................................................. 40-605
Failure code [DXA7KB] RR HST pump EPC: Short circuit.................................................... 40-607
Failure code [DXA7KY] RR HST pump EPC: Hot Short ....................................................... 40-608
Failure code [DXHRKA] Blade lift up EPC: Open ................................................................ 40-610
Failure code [DXHRKB] Blade lift up EPC: Short circuit ....................................................... 40-612
Failure code [DXHRKY] Blade lift up EPC: Hot short ........................................................... 40-613
Failure code [DXHSKA] Blade lift down EPC: Open ............................................................ 40-615
Failure code [DXHSKB] Blade lift down EPC: Short circuit ................................................... 40-617
Failure code [DXHSKY] Blade lift down EPC: Hot short ....................................................... 40-618
Failure code [DXHTKA] Blade tilt left EPC: Open ................................................................ 40-620
Failure code [DXHTKB] Blade tilt left EPC: Short circuit ....................................................... 40-622
Failure code [DXHTKY] Blade tilt left EPC: Hot short ........................................................... 40-623
Failure code [DXHUKA] Blade tilt right EPC: Open.............................................................. 40-625
Failure code [DXHUKB] Blade tilt right EPC: Short circuit..................................................... 40-627
Failure code [DXHUKY] Blade tilt right EPC: Hot short......................................................... 40-628
Failure code [DXJ4KA] Weq lock Sol.: Open ...................................................................... 40-630
Failure code [DXJ4KB] Weq lock Sol.: Short circuit ............................................................. 40-632
Failure code [DXJCKA] Blade angle left EPC: Open............................................................ 40-634
Failure code [DXJCKB] Blade angle left EPC: Short circuit .................................................. 40-635
Failure code [DXJCKY] Blade angle left EPC: Hot short ...................................................... 40-636
Failure code [DXJDKA] Blade angle right EPC: Open.......................................................... 40-638
Failure code [DXJDKB] Blade angle right EPC: Short circuit ................................................ 40-639
Failure code [DXJDKY] Blade angle right EPC: Hot short .................................................... 40-640
Failure code [DXK1KA] Left HST motor EPC: Open ............................................................ 40-642
Failure code [DXK1KB] Left HST motor EPC: Short circuit ................................................... 40-644
Failure code [DXK1KY] Left HST motor EPC: Hot Short ...................................................... 40-645
Failure code [DXK2KA] Right HST motor EPC: Open .......................................................... 40-647
Failure code [DXK2KB] Right HST motor EPC: Short circuit................................................. 40-649
Failure code [DXK2KY] Right HST motor EPC: Hot Short .................................................... 40-650
Troubleshooting of electrical system (E-mode) .......................................................................... 40-652
E-1 Engine does not start (Engine does not crank) .............................................................. 40-652
E-2 Manual preheating system does not work..................................................................... 40-658
E-3 Automatic preheating system does not work................................................................. 40-661
E-4 While preheating is working, preheating monitor does not light up .................................. 40-663
E-5 When starting switch is turned to ON position, machine monitor displays nothing............. 40-665
E-6 When starting switch is turned to ON position (with engine stopped), basic check monitor
lights up ............................................................................................................. 40-668
E-7 Air cleaner clogging monitor lights up in yellow while engine is running ........................... 40-669
E-8 Charge level monitor lights up in red while engine is running .......................................... 40-670
E-9 Engine coolant temperature monitor lights up in red while engine is running .................... 40-671
E-10 Engine oil pressure monitor lights up in red while engine is running .............................. 40-672
D61EX-23, D61PX-23 00-9

Index
E-11 HST charge pressure monitor lights up in red while engine is running ............................ 40-673
E-12 Hydraulic oil temperature monitor lights up in red while engine is running ...................... 40-674
E-13 HST oil filter clogging monitor lights up in red while engine is running ............................ 40-675
E-14 Fuel level gauge does not indicate correct level .......................................................... 40-676
E-15 Engine coolant temperature gauge does not indicate correct temperature ..................... 40-679
E-16 Hydraulic oil temperature gauge does not indicate correct temperature ......................... 40-680
E-17 Operation mode does not change .............................................................................. 40-681
E-18 Service mode cannot be selected .............................................................................. 40-682
E-19 Operating customize switch does not display customize screen ................................... 40-683
E-20 Modifying setting on customize screen does not change setting of machine .................. 40-684
E-21 Service meter is not displayed, while starting switch is in OFF position.......................... 40-685
E-22 Work equipment does not operate ............................................................................. 40-686
E-23 Foot heater does not operate .................................................................................... 40-688
E-24 Horn does not sound ................................................................................................ 40-693
E-25 Horn does not stop sounding..................................................................................... 40-695
E-26 Backup alarm does not sound ................................................................................... 40-696
E-27 Backup alarm does not stop sounding........................................................................ 40-697
E-28 Headlamp does not light up....................................................................................... 40-698
E-29 Rear lamp does not light up....................................................................................... 40-701
E-30 No wiper operates continuously or intermittently.......................................................... 40-704
E-31 Front wiper does not operate ..................................................................................... 40-706
E-32 Rear wiper does not operate ..................................................................................... 40-708
E-33 Left door wiper does not operate (failed in both continuous and intermittent
operations)......................................................................................................... 40-710
E-34 Right door wiper does not operate (failed in both continuous and intermittent
operations)......................................................................................................... 40-714
E-35 Front washer does not operate .................................................................................. 40-718
E-36 Rear washer does not operate................................................................................... 40-720
E-37 Left door washer does not operate ............................................................................. 40-722
E-38 Right door washer does not operate........................................................................... 40-724
E-39 KOMTRAX system does not operate normally ............................................................ 40-726
Troubleshooting of hydraulic and mechanical system (H-mode) .................................................. 40-728
Information described in troubleshooting table (H-mode) ..................................................... 40-728
System chart of hydraulic and mechanical systems............................................................. 40-729
Failure mode and cause table ........................................................................................... 40-731
H-1 Neither RH nor LH of tracks does not travel forward nor reverse (None of the travel system
operates) ........................................................................................................... 40-735
H-2 Either RH or LH of track does not travel forward nor reverse (Only RH or LH of travel
system operates) ................................................................................................ 40-737
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)................................................................... 40-738
H-4 Travel speed or power is low ....................................................................................... 40-740
H-5 Travel speed range does not change ........................................................................... 40-741
H-6 Shock is large when machine starts or stops ................................................................ 40-742
H-7 Machine deviates largely ............................................................................................ 40-743
H-8 Machine drift on a slope is large .................................................................................. 40-745
H-9 Engine stalls during travel or engine speed drops significantly ....................................... 40-746
H-10 Unusual noise is heard from around HST pump or motor ............................................. 40-747
H-11 All work equipment do not operate ............................................................................. 40-748
H-12 All work equipment operates slowly or lacks power ..................................................... 40-750
H-13 Blade lift speed or power is low ................................................................................. 40-751
H-14 Blade tilt speed or power is low ................................................................................. 40-752
H-15 Blade angle speed or power is low............................................................................. 40-753
H-16 Time lag of blade lift is large ...................................................................................... 40-754
H-17 Hydraulic drift of lifted blade is large........................................................................... 40-755
H-18 Hydraulic drift of tilted blade is large........................................................................... 40-756
H-19 Unusual noise is heard from around work equipment pump or control valve .................. 40-757
H-20 HST oil temperature (hydraulic oil temperature) rises too high ...................................... 40-758
H-21 Fans speed is abnormal (high, low, or no rotation)....................................................... 40-760
00-10 D61EX-23, D61PX-23

Index
H-22 Unusual noise is heard from around fan ..................................................................... 40-762

Troubleshooting of engine (S-mode)......................................................................................... 40-763
Information described in troubleshooting table (S mode)...................................................... 40-763
S-1 Engine does not crank when starting switch is turned to START position......................... 40-764
S-2 Engine cranks but no exhaust smoke comes out........................................................... 40-765
S-3 Fuel is being injected but engine does not start (misfiring: engine cranks but does not
start).................................................................................................................. 40-766
S-4 Engine startability is poor ............................................................................................ 40-767
S-5 Engine does not pick up smoothly ............................................................................... 40-769
S-6 Engine stops during operation ..................................................................................... 40-771
S-7 Engine runs rough or is unstable ................................................................................. 40-773
S-8 Engine lacks power .................................................................................................... 40-774
S-9 KDPF gets clogged in a short time ............................................................................... 40-776
S-10 Engine oil consumption is excessive .......................................................................... 40-778
S-11 Engine oil becomes contaminated early...................................................................... 40-779
S-12 Fuel consumption is excessive .................................................................................. 40-780
S-13 Oil is in coolant (or coolant spurts or coolant level goes down)...................................... 40-781
S-14 Oil pressure drops .................................................................................................... 40-782
S-15 Fuel mixes into engine oil.......................................................................................... 40-783
S-16 Water mixes into engine oil (milky) ............................................................................. 40-784
S-17 Coolant temperature rises too high (overheating) ........................................................ 40-785
S-18 Unusual noise is heard ............................................................................................. 40-786
S-19 Vibration is excessive ............................................................................................... 40-787
S-20 Air cannot be bled from fuel circuit ............................................................................. 40-788
S-21 Active regeneration is executed frequently ................................................................. 40-789
S-22 Active regeneration takes time................................................................................... 40-790
S-23 White smoke is exhausted during active regeneration ................................................. 40-791
50 Disassembly and assembly ........................................................................................................... 50-1
Related information on disassembly and assembly ........................................................................ 50-4
How to read this manual ....................................................................................................... 50-4
Coating materials list ............................................................................................................ 50-6
Special tools list ................................................................................................................. 50-10
Sketches of special tools .................................................................................................... 50-16
Engine and cooling system ........................................................................................................ 50-29
Removal and installation of supply pump assembly............................................................... 50-29
Removal and installation of fuel injector assembly................................................................. 50-34
Removal and installation of cylinder head assembly.............................................................. 50-42
Removal and installation of radiator assembly ...................................................................... 50-58
Removal and installation of aftercooler assembly .................................................................. 50-62
Removal and installation of hydraulic oil cooler assembly ...................................................... 50-65
Removal and installation of cooling fan drive assembly ......................................................... 50-68
Removal and installation of cooling fan motor assembly ........................................................ 50-71
Removal and installation of engine assembly ....................................................................... 50-73
Disassembly and assembly of damper assembly .................................................................. 50-80
Removal and installation of engine front oil seal .................................................................... 50-81
Removal and installation of engine rear oil seal..................................................................... 50-83
Removal and installation of engine hood assembly ............................................................... 50-86
Removal and installation of fuel tank assembly ..................................................................... 50-89
Removal and installation of KDPF assembly......................................................................... 50-93
Disassembly and assembly of KDPF assembly .................................................................... 50-96
Removal and installation of KCCV assembly ...................................................................... 50-105
Removal and installation of KVGT assembly....................................................................... 50-106
Removal and installation of EGR (Exhaust Gas Recirculation) cooler assembly..................... 50-109
Removal and installation of EGR (Exhaust Gas Recirculation) valve assembly...................... 50-112
Removal and installation of belt for alternator and air conditioner compressor........................ 50-113
Removal and installation of air cleaner assembly ................................................................ 50-114
Power train............................................................................................................................. 50-116
Removal and installation of HST pump assembly................................................................ 50-116
D61EX-23, D61PX-23 00-11

Index
Removal and installation of HST motor and final drive assembly .......................................... 50-118
Disassembly and assembly of final drive ............................................................................ 50-121
Undercarriage and frame......................................................................................................... 50-131
Removal and installation of track frame assembly ............................................................... 50-131
Removal and installation of idler assembly ......................................................................... 50-135
Disassembly and assembly of idler .................................................................................... 50-137
Removal and installation of recoil spring assembly.............................................................. 50-141
Disassembly and assembly of recoil spring ........................................................................ 50-142
Removal and installation of track roller assembly ................................................................ 50-146
Disassembly and assembly of track roller assembly ............................................................ 50-148
Removal and installation of carrier roller assembly .............................................................. 50-151
Disassembly and assembly of carrier roller assembly .......................................................... 50-153
Removal and installation of segment teeth ......................................................................... 50-155
Separation and connection of track shoe assembly (Standard type track shoe) ..................... 50-156
Separation and connection of track shoe assembly (PLUS type track shoe) .......................... 50-159
Overall disassembly and assembly of track shoe assembly (Standard type track
shoe) ................................................................................................................. 50-160
Overall disassembly and assembly of track shoe assembly (PLUS type track shoe)............... 50-176
Disassembly and assembly of one track link assembly in field (Standard type track
shoe) ................................................................................................................. 50-183
Disassembly and assembly of one track link assembly in field (PLUS type track
shoe) ................................................................................................................. 50-189
Removal and installation of pivot shaft assembly ................................................................ 50-194
Removal and installation of equalizer bar assembly ............................................................ 50-196
Removal and installation of equalizer bar side bushing ........................................................ 50-198
Hydraulic system .................................................................................................................... 50-199
Removal and installation of hydraulic tank assembly ........................................................... 50-199
Removal and installation of control valve assembly ............................................................. 50-203
Disassembly and assembly of hydraulic cylinder assembly.................................................. 50-206
Work equipment ..................................................................................................................... 50-210
Removal and installation of work equipment assembly ........................................................ 50-210
Removal and installation of blade assembly ....................................................................... 50-212
Removal and installation of U-frame assembly.................................................................... 50-214
Cab and its attachments .......................................................................................................... 50-216
Removal and installation of ROPS cab assembly................................................................ 50-216
Removal and installation of operator's cab glass (adhesion glass) ........................................ 50-220
Removal and installation of operator's seat......................................................................... 50-226
Removal and installation of seat belt .................................................................................. 50-227
Removal and installation of foot heater assembly................................................................ 50-228
Disassembly and assembly of foot heater assembly............................................................ 50-230
Removal and installation of air conditioner unit assembly..................................................... 50-231
Removal and installation of air conditioner compressor assembly......................................... 50-235
Electrical system .................................................................................................................... 50-237
Removal and installation of machine monitor assembly ....................................................... 50-237
Removal and installation of engine controller assembly ....................................................... 50-238
Removal and installation of HST controller assembly........................................................... 50-240
Removal and installation of mass air flow and temperature sensor ....................................... 50-241
Removal and installation of KOMTRAX terminal ................................................................. 50-242
60 Maintenance standard................................................................................................................... 60-1
Engine mount ...................................................................................................................... 60-3
Cooling fan motor................................................................................................................. 60-4
Oil cooler bypass and HST charge safety valve....................................................................... 60-6
Power train................................................................................................................................. 60-7
Damper ............................................................................................................................... 60-7
HST pump ........................................................................................................................... 60-8
HST motor......................................................................................................................... 60-10
Charge pump..................................................................................................................... 60-11
00-12 D61EX-23, D61PX-23

Index
Solenoid valve ................................................................................................................... 60-12

Final drive ......................................................................................................................... 60-13
Sprocket............................................................................................................................ 60-14
Full-scale drawing of sprocket tooth profile ........................................................................... 60-15
Suspension ....................................................................................................................... 60-17
Track frame and idler cushion ............................................................................................. 60-19
Idler .................................................................................................................................. 60-21
Track roller ........................................................................................................................ 60-23
Carrier roller ...................................................................................................................... 60-27
Track shoe ........................................................................................................................ 60-29
Hydraulic tank.................................................................................................................... 60-35
Work equipment and cooling fan pump ................................................................................ 60-36
Control valve ..................................................................................................................... 60-39
Ripper PPC valve............................................................................................................... 60-46
Quick drop valve ................................................................................................................ 60-48
Angle control EPC valve ..................................................................................................... 60-50
Work equipment ....................................................................................................................... 60-51
Blade ................................................................................................................................ 60-51
Cutting edge and end bit ..................................................................................................... 60-54
Ripper ............................................................................................................................... 60-55
Lift cylinder ........................................................................................................................ 60-57
Tilt cylinder ........................................................................................................................ 60-58
Angle cylinder .................................................................................................................... 60-59
Ripper cylinder................................................................................................................... 60-60
Cab and its attachments ............................................................................................................ 60-61
Cab mount ........................................................................................................................ 60-61
Electrical system ...................................................................................................................... 60-62
Electric steering lever ......................................................................................................... 60-62
80 Appendix...................................................................................................................................... 80-1
Air conditioner components ......................................................................................................... 80-3
Precautions for refrigerant..................................................................................................... 80-3
Air conditioner component .................................................................................................... 80-4
Configuration and function of refrigeration cycle...................................................................... 80-7
Outline of refrigeration cycle.................................................................................................. 80-8
Air conditioner unit ............................................................................................................. 80-10
Dual pressure switch .......................................................................................................... 80-14
Pressure switch ................................................................................................................. 80-15
Compressor....................................................................................................................... 80-16
Condenser ........................................................................................................................ 80-17
Receiver drier .................................................................................................................... 80-19
Procedure for testing and troubleshooting ............................................................................ 80-20
Electrical circuit diagram ..................................................................................................... 80-23
System diagram................................................................................................................. 80-24
Parts and connectors layout................................................................................................ 80-26
Testing relays .................................................................................................................... 80-31
Troubleshooting chart 1 ...................................................................................................... 80-33
Troubleshooting chart 2 ...................................................................................................... 80-34
Information described in troubleshooting table ...................................................................... 80-36
A-1 Troubleshooting for condenser fan................................................................................. 80-37
A-2 Troubleshooting for compressor and refrigerant system (Air is not cooled) ........................ 80-40
A-3 Troubleshooting for blower motor system (No air comes out or air flow is
abnormal) ............................................................................................................ 80-44
A-4 Troubleshooting for temperature control ......................................................................... 80-46
Troubleshooting with gauge pressure................................................................................... 80-49
Connection of service tool................................................................................................... 80-52
D61EX-23, D61PX-23 00-13

Index
Precautions for disconnecting and connecting hoses and tubes in air conditioner
circuit................................................................................................................... 80-54
Handling of compressor oil.................................................................................................. 80-56
90 Diagrams and drawings................................................................................................................. 90-1
Hydraulic circuit diagram ............................................................................................................. 90-3
Symbols in hydraulic circuit diagram ...................................................................................... 90-3
Hydraulic circuit diagram....................................................................................................... 90-7
Electric circuit diagram ................................................................................................................ 90-9
Symbols in electric circuit diagram ......................................................................................... 90-9
Electrical circuit diagram ..................................................................................................... 90-13
Index.................................................................................................................................................................... 1
00-14 D61EX-23, D61PX-23

Foreword, safety and general information
Foreword, safety and general information (ALL-0370-001-A-00-A)
Important safety notice (ALL-1120-012-A-01-A)
(Rev. 2012/10)
• Appropriate servicing and repair are extremely important to ensure safe operation of the machine. The
shop manual describes the effective and safe servicing and repair methods recommended by Komatsu.
Some of these methods require the use of the special tools designed by Komatsu for the specific purpose.
• The symbol mark k is used for such matters that require special cautions during the work. The work
indicated by the caution mark should be performed according to the instructions with special attention to
the cautions. Should hazardous situation occur or be anticipated during such work, be sure to keep safe
first and take every necessary measure.
General precautions knowledge of welding perform the work. When

performing welding work, always wear welding
k Inappropriate handling causes an extreme gloves, apron, shielding goggles, cap, etc.
danger. Read and understand what is • Before starting work, warm up your body
described in the operation and maintenance thoroughly to start work under good condition.
manual before operating the machine. Read • Avoid continuing work for long hours and take
and understand what is described in this rests with proper intervals to keep your body in
manual before starting the work. good condition. Take a rest in a specified safe
place.
• Before performing any greasing or repairs, read
all the safety labels stuck to the machine. For Safety points
the locations of the safety labels and detailed 1 Good arrangement
explanation of precautions, see the operation 2 Correct work clothes
and maintenance manual.
3 Observance of work standard
• Locate a place in the repair workshop to keep
4 Practice of making and checking signals
the tools and removed parts. Always keep the
Prohibition of operation and handling by
tools and parts in their correct places. Always 5
unlicensed workers
keep the work area clean and make sure that Safety check before starting work
6
there is no dirt, water or oil on the floor. Smoke
Wearing protective goggles (for cleaning or
only in the areas provided for smoking. Never 7 grinding work)
smoke while working.
Wearing shielding goggles and protectors (for
• When performing any work, always wear the 8 welding work)
safety shoes and helmet. Do not wear loose
9 Good physical condition and preparation
work cloths, or clothes with buttons missing.
Precautions against work which you are not
1. Always wear the protective eyeglasses when 10 used to or you are used to too much
hitting parts with a hammer.
2. Always wear the protective eyeglasses when Preparation
grinding parts with a grinder, etc. • Before adding oil or making any repairs, place
• When performing any work with 2 or more the machine on a firm and level ground, and
workers, always agree on the working procedure apply the parking brake and chock the wheels or
before starting. While working, always keep tracks to prevent the machine from moving.
conversations of the work between your fellow • Before starting work, lower the work equipment
workers and your self on any step of the work. (blade, ripper, bucket, etc.) to the ground. If it is
During the work, hang the warning tag of not possible to lower the equipment to the
"UNDER WORKING" in the operator's ground, insert the lock pin or use blocks to
compartment. prevent the work equipment from falling. And be
• Only qualified workers must perform the work sure to lock all the work equipment control levers
and operation which require license or and hang a warning tag on them.
qualification. • When performing the disassembling or
• Keep the tools in good condition. And learn the assembling work, support the machine securely
correct way to use the tools, and use the proper with blocks, jacks, or stands before starting the
ones among them. Before starting the work, work.
thoroughly check the tools, lift truck, service • Remove all of mud and oil from the steps or
vehicle, etc. other places used to get on and off the machine
• If welding repairs is required, always have a completely. Always use the handrails, ladders of
trained and experienced welder with good
D61EX-23, D61PX-23 00-15

steps when getting on or off the machine. Never • When removing piping, prevent the fuel or oil
jump on or off the machine. When the scaffold is from spilling out. If any fuel or oil drips onto the
not provided, use steps or stepladder to secure floor, wipe it off immediately. Fuel or oil on the
your footing. floor can cause you to slip and can even cause
fires.
Precautions during work • As a general rule, do not use gasoline to wash
• For the machine equipped with the battery parts. Do not use gasoline to clean the electrical
disconnect switch, check that the system parts, in particular.
operating lamp is turned off before starting the • Reinstall the parts removed to their original
work. Then, turn the battery disconnect switch to places. Replace the damaged parts and the
OFF (Q) position and remove the switch key. For parts which must not be used with new ones.
the machine not equipped with the battery When installing the hoses and wiring harnesses,
disconnect switch, remove the cable from the be careful that they are not damaged by
battery before starting the work. Be sure to contacting with other parts when the machine is
remove the negative end (-) of the battery cable operated.
first. • When connecting the high pressure hoses and
• Release the remaining pressure in the circuits tubes, make sure that they are not twisted. The
completely before the work when the parts in the damaged high pressure hoses and tubes are
circuits of oil, fuel, coolant and air are very dangerous when they are installed. So, be
disconnected or removed. When the cap of the extremely careful when connecting the high
oil filter, drain plug or oil pressure pickup plug is pressure pipings. In addition, check that their
removed, loose them slowly to prevent the oil connections are correct.
from spurting out. • When assembling or installing the parts, be sure
• When removing or installing the checking plug or to tighten the bolts to the specified torque. When
the piping in the fuel circuit, wait 30 seconds or installing the protective parts such as guards, or
longer after the engine is shut down and start the parts which vibrate violently or rotate at high
the work after the remaining pressure is speeds, be sure to check that they are installed
released from the fuel circuit. correctly.
• Immediately after the engine is shut down, the • When aligning 2 holes, never insert your fingers
coolant and oil in the circuits are hot. Be careful or hand into the holes. Align the holes with care
not to get scalded by the hot coolant and oil. so that your fingers are not caught in the hole.
Start the work after checking that the coolant • When measuring hydraulic pressure, check that
and oil are cooled down sufficiently. the measuring tools are correctly installed.
• Start the work after the engine is shut down. Be • Pay attention to safety when removing and
sure to shut down the engine when working on installing the tracks of the track type machines.
or around the rotating parts in particular. When When removing the track, it separates suddenly.
checking the machine without shutting down the The workers should not stand at either end of
engine (measuring oil pressure, rotational speed, the track.
oil or coolant temperature), take extreme care • If the engine is operated for a long time in a
not to get caught in the rotating parts or the closed place which is not ventilated well, you
working equipment. may suffer from gas poisoning. Accordingly,
• The hoist or crane must be used to sling the open the windows and doors to ventilate the
components weighing 25 kg or heavier. Check place well.
the slings (wire rope, nylon sling, chain and
hook) for damage before the work. Use the Precautions for slinging work and making
slings with ample capacity and install them to signals
the proper places. Operate the hoist or crane • Only one appointed worker must make signals
slowly to prevent the component from hitting any and co-worker must communicate with each
other part. Do not work with any part still raised other frequently. The appointed signaler must
by the hoist or crane. make specified signals clearly at the place
• When removing the part which is under internal where the signaler is well seen from the
pressure or reaction force of the spring, always operator's seat and where the signaler can see
leave 2 bolts in diagonal positions. Loosen those the working condition easily. The signaler must
2 bolts gradually and alternately and release the always stand in front of the load and guide the
pressure, then, remove the part. operator safely.
• When removing the part, be careful not to break 1. Do not stand under the load.
or damage the electrical wiring. The damaged 2. Do not step on the load.
wiring may cause electrical fires. • Check the slings before starting sling work.
00-16 D61EX-23, D61PX-23

• Keep putting on the gloves during sling work. • Apply wire ropes to the middle part of the hook.
(Put on the leather gloves, if available.)
a Slinging near the tip of the hook may cause
• Measure the weight of the load by the eye and
the rope to slip off the hook during hoisting.
check its center of gravity.
The strength of the hook is maximum at its
• Use the proper sling according to the weight of
central part.
the load and method of slinging. If too thick wire
ropes are used to sling a light load, the load may
slip and fall.
• Do not sling a load with 1 wire rope only. If do so,
the load may rotate or the sling gets loose and
the sling may slip off. Install 2 or more wire ropes
symmetrically.
k Slinging with one rope may cause turning

of the load during hoisting, untwisting of
the rope, or slipping of the rope from its
original slinging position on the load,
which can result in a dangerous accident.
• Hanging angle must be 60 deg. or smaller as a • Do not use twisted or kinked wire ropes.
rule. • When slinging up a load, observe the following.
• When hanging a heavy load (25kg or heavier),
1. Wind up the rope slowly until the wire rope
the hanging angle of the rope must be narrower
tensions. When putting your hands on the
than that of the hook.
wire ropes, do not grasp them but press them
a When slinging a load with 2 ropes or more, down from above. If you grasp them, your
the larger the hanging angle is, the larger the fingers may be caught.
tension of each rope. The figure bellow 2. After the wire ropes are stretched, stop the
shows the variation of allowable load in kg crane and check the condition of the slung
when hoisting is made with 2 ropes, each of load, wire ropes, and pads.
which is allowed to sling up to 9.8 kN 3. If the load is unstable or the wire rope or
{1,000kg} a load vertically, at various chains are twisted, lower the load and lift it
hanging angles. When the 2 ropes sling a up again.
load vertically, up to 2,000 kg of total weight 4. Do not lift up the load at an angle.
can be suspended. This weight is reduced to • When lowering a load, pay attention to the
1,000 kg when the 2 ropes make a hanging following.
angle of 120 deg.. If the 2 ropes sling a 2,000 1. When lifting down a load, stop it temporarily
kg load at a hanging angle of 150 deg., each at 30 cm above the floor, and then lower it
rope is subjected to a force as large as 4,000 slowly.
kg. 2. Check that the load is stable, and then
remove the sling.
3. Remove kinks and dirt from the wire ropes
and chains used for the sling work, and put
them in the specified place.
Precautions for using mobile crane

a Read the Operation and Maintenance Manual of
the crane carefully in advance and operate the
crane safely.
Precautions for using overhead traveling crane

k The hoist or crane must be used to sling the
components weighing 25 kg or heavier. A
• When installing wire ropes to an angular load,
part weighing 25 kg or heavier in
apply pads to protect the wire ropes. If the load
"disassembly and assembly" section is
is slippery, apply proper material to prevent the
wire rope from slipping. indicated with the symbol of 4 .
• Use the specified eye bolts and fix wire ropes,
chains, etc. to them with shackles, etc.
D61EX-23, D61PX-23 00-17

Komatsu Crawler Doozer D61ex 23 Shop Manual
Full download: http://manualplace.com/download/komatsu-crawler-doozer-d61ex-23-shop-manual/
• Before starting work, check the wire ropes, Nominal

diameter of rope Allowable load
brake, clutch, controller, rails, over winding
prevention device, ground fault circuit interrupter mm kN ton
for electric shock prevention, crane collision 50 221.6 22.6
prevention device, and energizing warning lamp, 60 318.3 32.4
and check the following safety items.
• Observe the signals for sling work. a The allowable load is calculated as one sixth of
• Operate the hoist at a safe place. the breaking load of the rope to be used (safety
• Be sure to check the directions of the direction coefficient: 6).
indication plate (north, south, east and west) and
the operating button. Precautions for disconnecting and connecting
hoses and tubes in air conditioner circuit
• Do not sling a load at an angle. Do not move the
crane while the slung load is swinging. Disconnection
• Do not raise or lower a load while the crane is
k When replacing the air conditioner unit, air
moving longitudinally or laterally.
• Do not drag a sling. conditioner compressor, condenser or
• When lifting up a load, stop it just after it leaves receiver drier, etc., collect the refrigerant (air
the ground and check safety, and then lift it up. conditioner gas: R134a) from the air
• Consider the travel route in advance and lift up a conditioner circuit before disconnecting the
load to a safe height. air conditioner hoses.
• Place the control switch in a position where it will
a Ask a qualified person for collecting, adding and
not be an obstacle to work and passage.
filling operations of the refrigerant (air
• After operating the hoist, do not swing the
conditioner gas: R134a). (Only registered
control switch.
persons can work.)
• Remember the position of the main switch so
that you can turn off the power immediately in an a Never release the refrigerant (air conditioner
emergency. gas: R134a) to the atmosphere.
• Shut down the main switch when the hoist stops
k If refrigerant gas (air conditioner gas: R134a)
because of a blackout. When turning on a switch
which is turned OFF by the ground fault circuit gets in your eyes, you may lose your sight.
interrupter for electric shock prevention, check And if it touches your skin, you may suffer
that the devices related to that switch are not in from frostbite. Put on protective eyeglasses,
operating condition. gloves and working clothes with long
• If you find an obstacle around the hoist, stop the sleeves while collecting the refrigerant or
operation. filling the air conditioner circuit with the
• After finishing the work, stop the hoist at the refrigerant.
specified position and raise the hook to at least 2
• When loosening the nuts fixing air conditioner
meters above the floor. Do not leave the sling
hoses and tubes, be sure to use 2 wrenches;
attached to the hook.
use one wrench to fix and use the other one to
Selecting wire ropes loosen the nut.
• Select adequate ropes depending on the weight
Connection
of the parts to be hoisted, referring to the table
• When installing the hose for the air conditioner
below
circuit, take care not to allow invasion of dirt,
Wire rope (JIS G3525, 6 x 37 - Type A)
dusts and water into the hose.
(Standard Z twist wire ropes without galvanizing) • Check that the O-rings are fitted to the joints
Nominal when connecting the air conditioner piping.
diameter of rope Allowable load • Once an O-ring is used, it is deformed and
mm kN ton deteriorated. Accordingly, do not reuse it.
10 8.8 0.9 • When removing the O-rings, use a soft tool so
that the piping is not damaged.
12 12.7 1.3
• Check that the O-ring is not damaged or
14 17.3 1.7
deteriorated.
16 22.6 2.3 • Apply compressor oil for refrigerant (R134a) to
18 28.6 2.9 the O-ring.
20 35.3 3.6
25 55.3 5.6 a However, do not apply oil to the threaded
part of a bolt, nut or union.
30 79.6 8.1
40 141.6 14.4
00-18 D61EX-23, D61PX-23
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BULLDOZER D61EX -23

D61EX-23 30001 and up

00 Index and foreword

D61EX-23, D61PX-23 00-1

00-2 D61EX-23, D61PX-23

Work equipment and cooling fan pump .............................................................................. 10-107

D61EX-23, D61PX-23 00-3

Adjusting deceleration/brake pedal ...................................................................................... 30-56

00-4 D61EX-23, D61PX-23

Failure code [A1U0N3] HC Desorb Request 1 .................................................................... 40-127

D61EX-23, D61PX-23 00-5

00-6 D61EX-23, D61PX-23

D61EX-23, D61PX-23 00-7

00-8 D61EX-23, D61PX-23

Failure code [DW4BKY] Parking brake solenoid: Hot Short.................................................. 40-573

D61EX-23, D61PX-23 00-9

00-10 D61EX-23, D61PX-23

H-22 Unusual noise is heard from around fan ..................................................................... 40-762

D61EX-23, D61PX-23 00-11

00-12 D61EX-23, D61PX-23

Solenoid valve ................................................................................................................... 60-12

D61EX-23, D61PX-23 00-13

00-14 D61EX-23, D61PX-23

Foreword, safety and general information (ALL-0370-001-A-00-A)

Important safety notice (ALL-1120-012-A-01-A)

General precautions knowledge of welding perform the work. When

D61EX-23, D61PX-23 00-15

00-16 D61EX-23, D61PX-23

k Slinging with one rope may cause turning

Precautions for using mobile crane

Precautions for using overhead traveling crane

D61EX-23, D61PX-23 00-17

• Before starting work, check the wire ropes, Nominal

00-18 D61EX-23, D61PX-23

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