BULLDOZER
SEN06010-02
D61EX
-23
D61PX
-23
SERIAL NUMBERS
D61EX- 30001
D61PX- 30001
and up
SHOP MANUAL
BULLDOZER
D61EX-23
D61PX-23
Model
D61EX-23
D61PX-23
Serial Number
30001 and up
00 Index and foreword
1 00 Index and foreword
D61EX-23, D61PX-23
00-1
00 Index and foreword
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
Table of contents ........................................................................................................................ 10-2
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
00 Index and foreword
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
Table of contents ........................................................................................................................ 20-2
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
Table of contents ........................................................................................................................ 30-2
Related information on testing and adjusting ................................................................................. 30-4
Tools for testing and adjusting ............................................................................................... 30-4
Sketch of tools for testing and adjusting ................................................................................. 30-7
Engine and cooling system .......................................................................................................... 30-9
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 KVGToil 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 HSToil 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
00 Index and foreword
Index
Adjusting deceleration/brake pedal ...................................................................................... 30-56
Adjusting parking brake lever .............................................................................................. 30-59
Move disabled machine urgently ......................................................................................... 30-61
Undercarriage and frame ........................................................................................................... 30-64
Adjusting idler clearance ..................................................................................................... 30-64
Checking sprocket wear ..................................................................................................... 30-65
Testing and adjusting track tension ...................................................................................... 30-66
Hydraulic system ...................................................................................................................... 30-67
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
Table of contents ........................................................................................................................ 40-2
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
00 Index and foreword
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 [CA323] Inj #5(L#5) Open/Short Error ............................................................. 40-173
Failure code [CA324] Inj #3(L#3) Open/Short Error ............................................................. 40-175
Failure code [CA325] Inj #6(L#6) Open/Short Error ............................................................. 40-177
Failure code [CA331] Inj #2(L#2) Open/Short Error ............................................................. 40-179
Failure code [CA332] Inj #4(L#4) Open/Short Error ............................................................. 40-181
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
00 Index and foreword
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
00 Index and foreword
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
00 Index and foreword
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
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Komatsu Crawler Dozers D61EX-23 sn:30001 and up, D61PX-23 sn:30001 and up Workshop Service Manual
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Description
These illustrated factory workshop service manuals for Komatsu Crawler Dozers D61 are essential resources for anyone involved in the maintenance and repair of these vehicles. The manuals contain a wealth of high-quality images, circuit diagrams, and detailed instructions to assist with operations, maintenance, and repairs. They are available in English and are designed to be printable, with searchable text and navigation bookmarks for ease of use.
The manuals cover the following models: D61EX-23 sn:30001 and up, and D61PX-23 sn:30001 and up, spanning a comprehensive 1724 pages.
The contents of the manuals are organized into several sections, including:
- Index and foreword, safety, and general information
- Specifications and weight tables
- Structural and functional details of various components such as the engine, cooling system, power train, hydraulic system, undercarriage, frame, work equipment, and electrical system
- Standard value tables for service, engine, machine, and electrical system
- Testing and adjusting procedures for engine, cooling system, power train, undercarriage, hydraulic system, work equipment, and electrical system
- Troubleshooting guidelines and procedures for electrical, hydraulic, mechanical, and engine systems
- Disassembly and assembly instructions for various components
- Maintenance standards for engine, cooling system, power train, undercarriage, hydraulic system, work equipment, and electrical system
- Appendix containing information on air conditioner components, refrigeration cycle, electrical circuit diagrams, troubleshooting charts, and precautions
- Diagrams and drawings including hydraulic circuit diagrams, electric circuit diagrams, and an index
These manuals are invaluable resources for professional mechanics and DIY enthusiasts alike, providing comprehensive guidance for maintaining and repairing Komatsu Crawler Dozers D61.
