D61PX-15E0
MachineModelSerialnumber
D61EX-15E0B45001andup
D61PX-15E0B45001andup
Compositionofshopmanual 1
ThecontentsofthisshopmanualareshowntogetherwithFormNo.inalist.
Note1:Alwayskeepthelatestversionofthismanualinaccordancewiththislistandutilizeaccordingly. ThemarksshowntotherightofFormNo.denotethefollowing: Q:Newissue(tobefiledadditionally)q:Revision(tobereplacedforeachFormNo.)
Note2:ThisshopmanualcanbesuppliedforeachFormNo.
Note3:Tofilethisshopmanualinthespecialbinderformanagement,handleitasfollows: PlaceadivideronthetopofeachsectioninthefileaftermatchingtheTubNo.withNo.indicated nexttoeachSectionNameshowninthetablebelow: Fileoverviewandothermaterialsinsectionsintheordershownbelowandutilizethemaccordingly.
SectionTitleFormNumber
ShopManual,contentsbinder,binderlabelandtabsSEN02387-03
00IndexandforewordSEN02388-03 IndexSEN02396-03q
ForewordandgeneralinformationSEN02397-00
01SpecificationSEN02389-00
SpecificationandtechnicaldataSEN02398-00
10Structure,functionandmaintenancestandardSEN02390-01
EngineandcoolingsystemSEN02473-00
Powertrain,Part1SEN02474-00
Powertrain,Part2SEN02475-00
UndercarriageandframeSEN02476-01q
Hydraulicsystem,Part1SEN02477-00
Hydraulicsystem,Part2SEN02478-00
Hydraulicsystem,Part3SEN02479-00
WorkequipmentSEN02480-00
CabanditsattachmentsSEN02481-00
ElectricalsystemSEN02482-00
20StandardvaluetableSEN02391-00
StandardservicevaluetableSEN02554-00
30TestingandadjustingSEN02392-00
Testingandadjusting,Part1SEN02555-00
Testingandadjusting,Part2SEN02556-00
Testingandadjusting,Part3SEN02557-00
Testingandadjusting,Part4SEN02558-00
40TroubleshootingSEN02393-00
FailurecodetableandfuselocationsSEN02559-00
GeneralinformationontroubleshootingSEN02560-00
Troubleshootingbyfailurecode(Displayofcode),Part1SEN02561-00
Troubleshootingbyfailurecode(Displayofcode),Part2SEN02563-00
Troubleshootingbyfailurecode(Displayofcode),Part3SEN02564-00
Troubleshootingbyfailurecode(Displayofcode),Part4SEN02565-00
Troubleshootingofelectricalsystem(E-mode)SEN02566-00
Troubleshootingofhydraulicandmechanicalsystem(H-mode)SEN02567-00
Troubleshootingofengine(S-mode)SEN02568-00
50DisassemblyandassemblySEN02394-01
GeneralinformationondisassemblyandassemblySEN02569-01q
Engineandcoolingsystem(SAA6D107E-1)SEN02570-00
Engine(SAA6D170E-1)SEN02571-00
Powertrain,Part1SEN02572-00
Powertrain,Part2SEN02573-00
Undercarriageandframe,Part1SEN02574-01q
Undercarriageandframe,Part2SEN02575-01q
HydraulicsystemSEN02576-00
WorkequipmentSEN02577-00
CabanditsattachmentsSEN02578-00
ElectricalsystemSEN02579-00
90DiagramsanddrawingsSEN02395-01
HydraulicdiagramsanddrawingsSEN02399-00
ElectricaldiagramsanddrawingsSEN02400-01
Tableofcontents 1
00Indexandforeword
ForewordandgeneralinformationSEN02397-00
10Structure,functionandmaintenancestandard EngineandcoolingsystemSEN02473-00
This is the sample of the manual if you need complete manual Click Here to download
Measuringengineoilpressure....................................................................................................17
Handlingfuelsystemequipment.................................................................................................18
Releasingresidualpressureinfuelsystem.................................................................................18
Measuringfuelpressure..............................................................................................................19
Measuringfueldeliveryamount,returnrateandleakage...........................................................21
Bleedingairfromfuelcircuit........................................................................................................25
Testingleakageinfuelsystem....................................................................................................27
Handlingofreducedcylindermodeoperation.............................................................................28
Handlingofnoinjectioncrankingoperation................................................................................28
Testingandadjustingairconditionercompressorbelttension....................................................29
Replacingthefanbelt..................................................................................................................29
Handlingcontrollervoltagecircuit...............................................................................................30
Adjustingfuelcontroldialanddeceleratorpedal.........................................................................31
Testingandadjusting,Part2SEN02556-00
Measuringpowertrainoilpressure.............................................................................................3
Adjustingtransmissionspeedsensor(replacementprocedure).................................................7
Simplemethodoftestingbrakeperformance..............................................................................9
Adjustingbrakepedal..................................................................................................................10
Adjustingparkingbrakelever......................................................................................................12
Emergencyescapemethodwhenpowertrainhastrouble.........................................................13
Adjustingidlerclearance.............................................................................................................16
Inspectingwearofsprocket.........................................................................................................16
Testingandadjustingtrackshoetension....................................................................................17
TestingandadjustingworkequipmentandHSSoilpressure.....................................................18
Testingcontrolcircuitmainpressure...........................................................................................22
MeasuringPPCvalveoutputpressure........................................................................................23
AdjustingplayofworkequipmentPPCvalve..............................................................................26
Measuringinternalleakageofworkequipmentcylinder.............................................................27
Adjustingworkequipmentlockleverofworkequipment.............................................................28
Releasingresidualpressureinworkequipmentcylinder(IfPPCaccumulatorisnotinstalled)..29
Releasingresidualpressureinworkequipmentcylinder(IfPPCaccumulatorisinstalled)........29
Bleedingairfromworkequipmentcylinder.................................................................................30
Measuringfanmotorspeed.........................................................................................................31
Measuringfanpumpcircuitpressure..........................................................................................32
MeasuringHSSmotoroilleakage...............................................................................................33
Bleedingairfromfanpump.........................................................................................................33
Testingandadjustingoperator'scab...........................................................................................34
Testingandadjusting,Part3SEN02557-00
Specialfunctionsofmonitorpanel(EMMS)................................................................................2
Testingandadjusting,Part4SEN02558-00
Handlingofvoltagecircuitofenginecontroller............................................................................2
Adjustmentmethodwhencontrollerhasbeenreplaced.............................................................2
Preparatoryworkfortroubleshootingforelectricsystem............................................................4
Inspectionprocedureofdiode.....................................................................................................9
Pm-Clinicservice.........................................................................................................................10
HowtostartoperationofKOMTRAXterminal.............................................................................22
LampdisplayofKOMTRAXterminal...........................................................................................26
40Troubleshooting
FailurecodetableandfuselocationsSEN02559-00
Failurecodetable........................................................................................................................2
Fuselocations.............................................................................................................................9
GeneralinformationontroubleshootingSEN02560-00
Pointstorememberwhentroubleshooting..................................................................................2
Sequenceofeventsintroubleshooting.......................................................................................3
Checksbeforetroubleshooting....................................................................................................4
Classificationandproceduresoftroubleshooting.......................................................................5
Contentsoftroubleshootingtable................................................................................................6
Wiringtableforconnectorpinnumbers......................................................................................10
T-adapterboxandT-adaptertable..............................................................................................43
Troubleshootingbyfailurecode(Displayofcode),Part1SEN02561-00
Failurecode[1500L0]Transmissionclutch:Dualengagement..................................................3
Failurecode[15SAL1]Forwardclutch:FillsignalisONwhencommandcurrentisOFF...........4
Failurecode[15SALH]Forwardclutch:FillsignalisOFFwhencommandcurrentisON..........6
Failurecode[15SBL1]Reverseclutch:FillsignalisONwhencommandcurrentisOFF..........8
Failurecode[15SBLH]Reverseclutch:FillsignalisOFFwhencommandcurrentisON..........10
Failurecode[15SEL1]1stclutch:FillsignalisONwhencommandcurrentisOFF...................12
Failurecode[15SELH]1stclutch:FillsignalisOFFwhencommandcurrentisON..................14
Failurecode[15SFL1]2ndclutch:FillsignalisONwhencommandcurrentisOFF..................16
Failurecode[15SFLH]2ndclutch:FillsignalisOFFwhencommandcurrentisON.................18
Failurecode[15SGL1]3rdclutch:FillsignalisONwhencommandcurrentisOFF..................20
Failurecode[15SGLH]3rdclutch:FillsignalisOFFwhencommandcurrentisON..................22
Failurecode[AB00MA]Alternator:Malfunction..........................................................................24
Failurecode[B@BAZG]Engineoil:Oilpressuretoolow...........................................................24
Failurecode[B@BCNS]Radiatorcoolant:Overheat.................................................................25
Failurecode[B@CENS]Powertrainoil:Overheat.....................................................................25
Failurecode[B@HANS]Hydraulicoil:Overheat........................................................................26
Failurecode[CA111]Enginecontroller:Abnormalityincontroller..............................................27
Failurecode[CA115]AbnormalengineNeandBkupspeedsensors: Abnormalspeedsensorsignal.............................................................................................27
Failurecode[CA122]Chargepressuresensortoohigh:Excessivelyhighvoltagedetected.....28
Failurecode[CA123]Chargepressuresensortoolow:Excessivelylowvoltagedetected........30
Failurecode[CA131]Deceleratorpedalsensortoohigh:Excessivelyhighvoltagedetected...32
Failurecode[CA132]Deceleratorpedalsensortoolow:Excessivelylowvoltagedetected......34
Failurecode[CA144]Coolanttemperaturesensortoohigh:Excessivelyhighvoltagedetected36
Failurecode[CA145]Coolanttemperaturesensortoolow:Excessivelylowvoltagedetected..38
Failurecode[CA153]Chargetemperaturesensortoohigh:Excessivelyhighvoltagedetected40
Failurecode[CA154]Chargetemperaturesensortoolow:Excessivelylowvoltagedetected...42
Failurecode[CA155]Chargetemperaturetoohighandenginespeedderated: Exceededuppercontrollimitoftemperature.......................................................................44
Failurecode[CA187]Sensorpowersource2toolow:Excessivelylowvoltagedetected.........46
Failurecode[CA221]Atmosphericpressuresensortoohigh:Excessivelyhighvoltagedetected48
Failurecode[CA222]Atmosphericpressuresensortoolow:Excessivelylowvoltagedetected50
Failurecode[CA227]Sensorpowersource2toohigh:Excessivelyhighvoltagedetected.......52
Failurecode[CA234]Engineoverspeed:Excessivelyhighspeed............................................54
Failurecode[CA238]AbnormalpowersourceforNespeedsensor: Excessivelylowvoltagedetected........................................................................................55
Failurecode[CA271]IMV/PCV1shortcircuit:Shortcircuit........................................................56
Failurecode[CA272]IMV/PCV1disconnection:Disconnection.................................................58
Troubleshootingbyfailurecode(Displayofcode),Part2SEN02563-00
Failurecode[CA322]InjectorNo.1systemdisconnectionorshortcircuit: disconnection,shortcircuit...................................................................................................4
Failurecode[CA323]InjectorNo.5systemdisconnectionorshortcircuit: disconnection,shortcircuit...................................................................................................6
Failurecode[CA324]InjectorNo.3systemdisconnectionorshortcircuit: disconnection,shortcircuit...................................................................................................8
Failurecode[CA325]InjectorNo.6systemdisconnectionorshortcircuit: disconnection,shortcircuit...................................................................................................10
Failurecode[CA331]InjectorNo.2systemdisconnectionorshortcircuit: disconnection,shortcircuit...................................................................................................12
Failurecode[CA332]InjectorNo.4systemdisconnectionorshortcircuit: disconnection,shortcircuit...................................................................................................14
Failurecode[CA342]Enginecontrollerdatamatchingerror:matchingerror.............................16
Failurecode[CA352]Sensorpowersource1toolow:Excessivelylowvoltagedetected..........18
Failurecode[CA386]Sensorpowersource1toohigh:Excessivelyhighvoltagedetected.......20
Failurecode[CA428]Waterdetectionsensortoohigh:Excessivelyhighvoltagedetected.......22
Failurecode[CA429]Waterdetectionsensortoolow:Excessivelylowvoltagedetected..........24
Failurecode[CA435]Abnormalengineoilpressureswitch:Abnormalsignalcircuit..................26
Failurecode[CA441]Powersourcevoltagetoolow:Excessivelylowvoltagedetected............28
Failurecode[CA442]Powersourcevoltagetoohigh:
Excessivelyhighvoltagehasoccurredinthecontrollerpowersourcecircuit......................30
Failurecode[CA449]Commonrailpressuretoohigh(2):
Excessivelyhighpressuretroubleoccurred.........................................................................32
Failurecode[CA451]Commonrailpressuresensortoohigh:
Excessivelyhighvoltagedetected.......................................................................................34
Failurecode[CA452]Commonrailpressuresensortoolow: Excessivelylowvoltagedetected.........................................................................................36
Failurecode[CA488]Chargetemperaturetoohighandtorquederated: Exceededuppercontrollimitoftemperature.......................................................................38
Failurecode[CA553]Commonrailpressuretoohigh(1):Excessivelyhighpressuredetected.39
Failurecode[CA559]Lossofpressurefeedfromsupplypump(1): Lossofpressurefeeddetected............................................................................................40
Failurecode[CA689]AbnormalengineNespeedsensor:Abnormalsignal..............................42
Failurecode[CA731]AbnormalengineBkupspeedsensorphase:Abnormalphase................44
Failurecode[CA757]Lossofallenginecontrollerdata:Lossofalldata....................................46
Failurecode[CA778]AbnormalengineBkupspeedsensor:AbnormalBkupsignal..................48
Failurecode[CA1633]AbnormalKOMNET:Abnormalcommunication......................................50
Failurecode[CA2185]Deceleratorpedalsensorpowersourcetoohigh: Excessivelyhighvoltagedetected.......................................................................................52
Failurecode[CA2186]Deceleratorpedalsensorpowersourcetoolow: Excessivelylowvoltagedetected.........................................................................................54
Failurecode[CA2249]Lossofpressurefeedfromsupplypump(2): Lossofpressurefeeddetected............................................................................................56
Failurecode[CA2311]AbnormalIMVsolenoid:Abnormalresistance........................................58 Failurecode[CA2555]Airintakeheaterrelaydisconnection:Disconnection.............................60 Failurecode[CA2556]Airintakeheaterrelayshortcircuit:Shortcircuit....................................62
Troubleshootingbyfailurecode(Displayofcode),Part3SEN02564-00
Failurecode[D110KA]Batteryrelay:Shortcircuit......................................................................4
Failurecode[D110KB]Batteryrelay:Disconnection...................................................................6
Failurecode[D130KA]Neutralsafetyrelay:Shortcircuit...........................................................8 Failurecode[D130KB]Neutralsafetyrelay:Disconnection........................................................10
Failurecode[D161KA]Back-upalarmrelay:Disconnection.......................................................12
Failurecode[D161KB]Back-upalarmrelay:Shortcircuit..........................................................14
Failurecode[DAFRKR]MonitorpanelCANcommunication:Defectivecommunication............16
Failurecode[DAQ0KT][DB30KT]Steeringandtransmissioncontroller: Abnormalityincontroller.......................................................................................................18
Failurecode[DAQ1KK][DB31KK]Mainpowersourceofsteeringandtransmission controller:Powersourcevoltagedropandinput..................................................................20
Failurecode[DAQ2KK][DB32KK]Loadpowersourceofsteeringandtransmission controller:Powersourcevoltagedropandinput..................................................................22
Failurecode[DAQ5KK][DB35KK]Steeringandtransmissioncontrollersensor5V powersource:Powersourcevoltagedropandinput...........................................................24
Failurecode[DAQ6KK][DB36KK]Steeringandtransmissioncontrollersensor24V powersource:Powersourcevoltagedropandinput...........................................................26
Failurecode[DAQ9KQ][DB39KQ]Steeringandtransmissioncontrollermodelselection: Inconsistencyinmodelselectsignal....................................................................................28
Failurecode[DB2RKR]SteeringandtransmissioncontrollerCANcommunication: Defectivecommunication.....................................................................................................30
Failurecode[DB30KT][DAQ0KT]Steeringandtransmissioncontroller: Abnormalityincontroller.......................................................................................................32
Failurecode[DB31KK][DAQ1KK]Mainpowersourceofsteeringandtransmission controller:Powersourcevoltagedropandinput..................................................................32
Failurecode[DAB32KK][DAQ2KK]Loadpowersourceofsteeringandtransmission controller:Powersourcevoltagedropandinput..................................................................32
Failurecode[DB35KK][DAQ5KK]Steeringandtransmissioncontrollersensor5V powersource:Powersourcevoltagedropandinput...........................................................32
Failurecode[DB36KK][DAQ6KK]Steeringandtransmissioncontrollersensor24V powersource:Powersourcevoltagedropandinput...........................................................32
Failurecode[DB39KQ][DAQ9KQ]Steeringandtransmissioncontrollermodel selection:Inconsistencyinmodelselectsignal....................................................................32
Failurecode[DD12KA]Shiftupswitch:Disconnection...............................................................34
Failurecode[DD12KB]Shiftupswitch:Shortcircuit..................................................................36
Failurecode[DD13KA]Shiftdownswitch:Disconnection..........................................................38
Failurecode[DD13KB]Shiftdownswitch:Shortcircuit..............................................................40
Failurecode[DD14KA][DDQ2KA]Parkingbrakeleverswitch:Disconnection..........................42
Failurecode[DD14KB][DDQ2KB]Parkingbrakeleverswitch:Shortcircuit..............................44
Failurecode[DDQ2KA][DD14KA]Parkingbrakeleverswitch:Disconnection..........................46
Failurecode[DDQ2KB][DD14KB]Parkingbrakeleverswitch:Shortcircuit..............................46
Failurecode[DGS1KX]Hydraulicoiltemperaturesensor:Inputsignalisoutofnormalrange..48
Failurecode[DGT1KA]Powertrainoiltemperaturesensor:Disconnection..............................50
Failurecode[DGT1KX]Powertrainoiltemperaturesensor:Inputsignalisoutofnormalrange51
Failurecode[DK10KA]Fueldial:Disconnection........................................................................52
Failurecode[DK10KB]Fueldial:Shortcircuit............................................................................54
Failurecode[DK30KA]Steeringpotentiometer(1):Disconnection............................................56
Failurecode[DK30KB]Steeringpotentiometer(1):Shortcircuit................................................58
Failurecode[DK30KX]Steeringpotentiometer:Inputsignalisoutofnormalrange..................60
Failurecode[DK30KZ]Steeringpotentiometer:Disconnectionorshortcircuit(Doublefailure).61
Failurecode[DK30L8]Steeringpotentiometer:Inconsistentanalogsignal................................61
Failurecode[DK31KA]Steeringpotentiometer(2):Disconnection............................................62
Failurecode[DK31KB]Steeringpotentiometer(2):Shortcircuit................................................64
Failurecode[DK40KA]Brakepotentiometer:Disconnection......................................................66
Failurecode[DK40KB]Brakepotentiometer:Shortcircuit.........................................................67
Troubleshootingbyfailurecode(Displayofcode),Part4SEN02565-00
Failurecode[DK55KX]Forward-reversepotentiometer:Inputsignalisoutofnormalrange.....3
Failurecode[DK55KZ]Forward-reversepotentiometer: Disconnectionorshortcircuit(Doublefailure).....................................................................4
Failurecode[DK55L8]Forward-reversepotentiometer:Inconsistentanalogsignal...................5
Failurecode[DK56KA]Forward-reversepotentiometer(1):Shortcircuit...................................6
Failurecode[DK56KB]Forward-reversepotentiometer(1):Disconnection...............................8
Failurecode[DK57KA]Forward-reversepotentiometer(2):Disconnection...............................10
Failurecode[DK57KB]Forward-reversepotentiometer(2):Shortcircuit...................................12
Failurecode[DKH1KA][DKH1KX]Pitchanglesensor:Shortcircuit..........................................14
Failurecode[DKH1KB][DKH1KX]Pitchanglesensor:Disconnection......................................16
Failurecode[DKH1KX],[DKH1KA]or[DKH1KB]Pitchanglesensor:Inputsignaloutofrange17
Failurecode[DLT3KA]Transmissionoutputspeedsensor:Disconnection................................18
Failurecode[DLT3KB]Transmissionoutputspeedsensor:Shortcircuit...................................19
Failurecode[DV00KB]Alarmbuzzer:Shortcircuit....................................................................20
Failurecode[DW7BKA]Fanreversesolenoid:Disconnection...................................................21
Failurecode[DW7BKB]Fanreversesolenoid:Shortcircuit.......................................................22
Failurecode[DWN1KA]HSSEPCsolenoidright:Disconnection..............................................23
Failurecode[DWN1KB]HSSEPCsolenoidright:Shortcircuit..................................................24
Failurecode[DWN1KY]HSSEPCsolenoidright:Shortcircuittopowersourceline.................25
Failurecode[DWN2KA]HSSEPCsolenoidleft:Disconnection................................................26
Failurecode[DWN2KB]HSSEPCsolenoidleft:Shortcircuit....................................................27
Failurecode[DWN2KY]HSSEPCsolenoidleft:Shortcircuittopowersourceline...................28
Failurecode[DWN5KA]FanpumpTVCsolenoid:Disconnection..............................................29
Failurecode[DWN5KB]FanpumpTVCsolenoid:Shortcircuit.................................................30
Failurecode[DWN5KY]FanpumpTVCsolenoid:Shortcircuitinpowersourceline................31
Failurecode[DXA0KA]HSSpumpTVCsolenoid:Disconnection..............................................32
Failurecode[DXA0KB]HSSpumpTVCsolenoid:Shortcircuit.................................................33
Failurecode[DXA0KY]HSSpumpTVCsolenoid:Shortcircuittopowersourceline................34
Failurecode[DXH4KA]1stclutchECMV:Disconnection...........................................................35
Failurecode[DXH4KB]1stclutchECMV:Shortcircuit...............................................................36
Failurecode[DXH4KY]1stclutchECMV:Shortcircuittopowersourceline..............................38
Failurecode[DXH5KA]2ndclutchECMV:Disconnection..........................................................39
Failurecode[DXH5KB]2ndclutchECMV:Shortcircuit..............................................................40
Failurecode[DXH5KY]2ndclutchECMV:Shortcircuittopowersourceline............................42
Failurecode[DXH6KA]3rdclutchECMV:Disconnection...........................................................43
Failurecode[DXH6KB]3rdclutchECMV:Shortcircuit..............................................................44
Failurecode[DXH6KY]3rdclutchECMV:Shortcircuittopowersourceline.............................46
Failurecode[DXH7KA]ReverseclutchECMV:Disconnection...................................................47
Failurecode[DXH7KB]ReverseclutchECMV:Shortcircuit......................................................48
Failurecode[DXH7KY]ReverseclutchECMV:Shortcircuittopowersourceline.....................49
Failurecode[DXH8KA]ForwardclutchECMV:Disconnection...................................................50
Failurecode[DXH8KB]ForwardclutchECMV:Shortcircuit......................................................52
Failurecode[DXH8KY]ForwardclutchECMV:Shortcircuittopowersourceline.....................54
Troubleshootingofelectricalsystem(E-mode)SEN02566-00
Beforetroubleshootingofelectricalsystem.................................................................................3
Contentsoftroubleshootingtable................................................................................................5
E-1Theenginedoesnotstart(thestartingmotordoesnotturn)................................................7
E-2Thepreheaterdoesnotoperate...........................................................................................11
E-3ThemonitorpaneldoesnotlightupatallwhenthestartingswitchisturnedON................14
E-4Whenthestartingswitchisturnedon,themonitorpanelcompletelyremainslighted anddoesnotgoout.............................................................................................................15
E-5Whiletheengineisrunning,thebatterychargelevelcautionlampflashes.........................16
E-6Whiletheengineisrunning,theemergencywarningitemflashes.......................................18
E-7Whilethepreheaterisoperating,thepreheatingpilotlampdoesnotlightup......................22
E-8Thecoolanttemperaturegaugedoesnotindicatecorrectly.................................................24
E-9Thepowertrainoiltemperaturegaugedoesnotindicatecorrectly......................................26
E-10Hydraulicoiltemperaturegaugedoesnotindicateproperly...............................................28
E-11Fuelgaugedoesnotindicateproperly................................................................................30
E-12Gearspeedandenginespeedarenotindicatedproperly..................................................31
E-13Thepresetmodeservicemeterdoesnotindicatenormally...............................................31
E-14Thewarninglampdoesnotflashordoesnotgoout..........................................................31
E-15Thealarmbuzzerdoesnotsoundordoesnotstop...........................................................32
E-16Autoshiftdownisnotpossibleorisnotreleased...............................................................34
E-17Thebuzzercancelswitchdoesnotwork............................................................................36
E-18Theinformationswitchdoesnotwork................................................................................38
E-19Thefancleaningdoesnotoperateorcannotbereset.......................................................40
E-20Thepresetmodedoesnotoperateorcannotbereset.......................................................42
E-21Themonitorpanelcannotbesetintheservicemodeorcannotbesetoutofthe servicemode........................................................................................................................44
E-22Theback-upalarmdoesnotsound....................................................................................46
E-23Theheadlampandrearlampdonotlightup.....................................................................49
E-24Thehorndoesnotsoundordoesnotstop.........................................................................52
E-25Malfunctionofwipers..........................................................................................................54
E-26Washerdoesnotspraywater.............................................................................................70
E-27Theairconditionerdoesnotoperate..................................................................................76
E-28KOMTRAXsystemdoesnotoperatenormally...................................................................80
Troubleshootingofhydraulicandmechanicalsystem(H-mode)SEN02567-00 Contentsoftroubleshootingtable................................................................................................3
H-1Thereisnotravelpower(nodrawbarpull)...........................................................................4
H-2Machinedoesnotmove(at2ndor3rdspeed).....................................................................5
H-3Machinedoesnotmoveatanygearspeed..........................................................................6
H-4Machinetravelsonlyinonedirection,forwardorinreverse................................................7
H-5Whengearisshiftedortraveldirectionischanged,largetimelagismade........................8
H-6Machinecannotbesteered(Machinedoesnotturnleftwardorrightward).........................9
H-7Steeringspeedorpowerislow............................................................................................9
H-8Brakedoesnotwork.............................................................................................................10
H-9Overheatofpowertrainoil...................................................................................................11
H-10AbnormalsoundcomesoutfromaroundHSSandworkequipmentpumporHSSmotor.12
H-11Allworkequipmentspeedsareslow..................................................................................12
H-12Workequipmentdoesnotmove.........................................................................................13
H-13Bladeliftspeedissloworlackspower...............................................................................13
H-14Bladetiltspeedissloworlackspower...............................................................................14
H-15Anglingbladespeedissloworlackspower.......................................................................14
H-16Ripperliftspeedissloworlackspower.............................................................................15
H-17Excessivehydraulicdriftofbladelift...................................................................................15
H-18Excessivehydraulicdriftofbladetilt..................................................................................16
H-19Excessivehydraulicdriftofbladeangle.............................................................................16
H-20Excessivehydraulicdriftofripperlift..................................................................................17
Troubleshootingofengine(S-mode)SEN02568-00 Methodofusingtroubleshootingcharts......................................................................................3
S-1Startingperformanceispoor................................................................................................6
S-2Enginedoesnotstart............................................................................................................7
S-3Enginedoesnotpickupsmoothly........................................................................................10
S-4Enginestopsduringoperations............................................................................................11
S-5Enginedoesnotrotatesmoothly..........................................................................................12
S-6Enginelacksoutput(orlackspower)....................................................................................13
S-7Exhaustsmokeisblack(incompletecombustion)................................................................14
S-8Oilconsumptionisexcessive(orexhaustsmokeisblue)....................................................15
S-9Oilbecomescontaminatedquickly.......................................................................................16
S-10Fuelconsumptionisexcessive...........................................................................................17
S-11Oilisincoolant(orcoolantspurtsbackorcoolantlevelgoesdown).................................18
S-12Oilpressuredrops..............................................................................................................19
S-13Oillevelrises(Entryofcoolantorfuel)...............................................................................20
S-14Coolanttemperaturebecomestoohigh(overheating).......................................................21
S-15Abnormalnoiseismade.....................................................................................................22
S-16Vibrationisexcessive.........................................................................................................23
50Disassemblyandassembly
GeneralinformationondisassemblyandassemblySEN02569-01 Howtoreadthismanual.............................................................................................................2
Coatingmaterialslist...................................................................................................................4
Specialtoollist............................................................................................................................7
Sketchesofspecialtools.............................................................................................................14
Engineandcoolingsystem(SAA6D107E-1)SEN02570-00
Removalandinstallationofradiatorguardassembly.................................................................2
Removalandinstallationofengineassembly.............................................................................6
Removalandinstallationofradiatorassembly............................................................................11
Removalandinstallationofaftercoolerassembly.......................................................................14
Removalandinstallationofpowertrainoilcoolerassembly.......................................................17
Removalandinstallationofhydrauliccoolerassembly...............................................................18
Removalandinstallationofcoolingfandriveassembly..............................................................21
Removalandinstallationofcoolingfanmotorassembly............................................................23
Removalandinstallationofdamperassembly............................................................................24
Removalandinstallationoffueltankassembly..........................................................................29 Removalandinstallationofenginehoodassembly....................................................................31
Engine(SAA6D170E-1)SEN02571-00
Removalandinstallationoffuelsupplypumpassembly.............................................................2
Removalandinstallationoffuelinjectorassembly......................................................................4
Removalandinstallationofcylinderheadassembly...................................................................13
Removalandinstallationofenginefrontseal..............................................................................26
Removalandinstallationofenginerearseal..............................................................................29
Powertrain,Part1SEN02572-00
RemovalandinstallationofPTO,torqueconverterandtransmissionassembly........................2
DisconnectionandconnectionofPTO,torqueconverterandtransmissionassembly...............6
DisassemblyandassemblyofPTOassembly............................................................................8
Disassemblyandassemblyoftorqueconverterassembly.........................................................13
DisassemblyandassemblyofTORQFLOWtransmissionassembly..........................................17
Removalandinstallationoftorqueconvertermainreliefvalveassembly...................................34
Disassemblyandassemblyoftorqueconvertermainreliefvalveassembly..............................35
Powertrain,Part2SEN02573-00
Removalandinstallationofpowertrainandlubricatingoilpumpassembly...............................2
RemovalandinstallationofHSSandworkequipmentpumpassembly.....................................4
Removalandinstallationofscavengingpumpassembly............................................................5
RemovalandinstallationofHSSmotorassembly......................................................................5
DisassemblyandassemblyofHSSassembly............................................................................6
Removalandinstallationoffinaldriveassembly.........................................................................24
Disassemblyandassemblyoffinaldriveassembly....................................................................25
Undercarriageandframe,Part1SEN02574-01
Removalandinstallationoftrackframeassembly......................................................................2
Removalandinstallationofidlerassembly.................................................................................4
Disassemblyandassemblyofidlerassembly.............................................................................5
Removalandinstallationofrecoilspringassembly.....................................................................9
Disassemblyandassemblyofrecoilspringassembly................................................................10
Removalandinstallationoftrackrollerassembly.......................................................................13
Disassemblyandassemblyoftrackrollerassembly...................................................................14
Removalandinstallationofcarrierrollerassembly.....................................................................17
Disassemblyandassemblyofcarrierrollerassembly................................................................18
Undercarriageandframe,Part2SEN02575-01
Checkbeforeexpandingtrackshoeassembly............................................................................2
Expansion(normal),expansion(internalabnormality)andinstallationoftrackshoeassembly(Conventionaltypetrackshoe)....................................................................................................2
Expansionandinstallationoftrackshoeassembly(Plustypetrackshoe).................................4
Overalldisassemblyandoverallassemblyoftrackshoeassembly(Conventionaltypetrackshoe)5 Linkpress-fittingjigdimensionstable..........................................................................................21
Overalldisassemblyandoverallassemblyoftrackshoeassembly(PLUStypetrackshoe).....22
Fielddisassemblyandassemblyofonelink(Conventionaltypetrackshoe).............................29
Fielddisassemblyandassemblyofonelink(PLUStypetrackshoe).........................................36
Removalandinstallationofpivotshaftassembly........................................................................41
Removalandinstallationofequalizerbarassembly...................................................................43
Removalandinstallationofequalizerbarsidebushing..............................................................44
Removalandinstallationofsegmentteeth.................................................................................45
HydraulicsystemSEN02576-00
Removalandinstallationofmaincontrolvalveassembly...........................................................2
Assemblyofmaincontrolvalveassembly...................................................................................4
Removalandinstallationofcoolingfanpumpassembly.............................................................7
Disassemblyandassemblyofhydrauliccylinderassembly........................................................8
WorkequipmentSEN02577-00
Removalandinstallationofworkequipmentassembly...............................................................2
Disassemblyandassemblyofworkequipmentassembly..........................................................4
CabanditsattachmentsSEN02578-00
RemovalandinstallationofROPSguard....................................................................................2
Removalandinstallationofoperator'scabassembly.................................................................3
Removalandinstallationofoperator'scabglass(stuckglass)...................................................9
Removalandinstallationofmonitorpanelassembly..................................................................18
Removalandinstallationofdashboardassembly.......................................................................19
Removalandinstallationoffloorframeassembly.......................................................................22
ElectricalsystemSEN02579-00
Removalandinstallationofenginecontrollerassembly.............................................................2
Removalandinstallationofsteeringandtransmissioncontrollerassembly...............................3
RemovalandinstallationofKOMTRAXterminalassembly........................................................4
Removalandinstallationofairconditionerunitassembly..........................................................5
90Diagramsanddrawings
HydraulicdiagramsanddrawingsSEN02399-00
Powertrainhydrauliccircuitdiagram..........................................................................................3
Workequipmenthydrauliccircuitdiagram..................................................................................5
ElectricaldiagramsanddrawingsSEN02400-01
Electricalcircuitdiagram.............................................................................................................3
Connectorarrangementdiagram................................................................................................5
FormNo.SEN02396-03
©2009KOMATSU AllRightsReserved PrintedinBrazil02-09(01)
D61EX,PX-15E0Bulldozer
Safetynotice 1
Importantsafetynotice
(Rev.2006/09)
Properserviceandrepairareextremelyimportantforsafemachineoperation.Theserviceandrepair techniquesrecommendedbyKomatsuanddescribedinthismanualarebotheffectiveandsafe. SomeofthesetechniquesrequiretheuseoftoolsspeciallydesignedbyKomatsuforthespecific purpose.
Topreventinjurytoworkers,thesymbolkisusedtomarksafetyprecautionsinthismanual.The cautionsaccompanyingthesesymbolsshouldalwaysbefollowedcarefully.Ifanydangeroussituationarisesormaypossiblyarise,firstconsidersafety,andtakethenecessaryactionstodealwith thesituation.
1.Generalprecautions
kMistakesinoperationareextremely dangerous.ReadtheOperationand MaintenanceManualcarefullybefore operatingthemachine.
1)Beforecarryingoutanygreasingor repairs,readallthesafetyplatesstuckto themachine.Forthelocationsofthe safetyplatesanddetailedexplanationof precautions,seetheOperationandMaintenanceManual.
2)Decideaplaceintherepairworkshopto keeptoolsandremovedparts.Always keepthetoolsandpartsintheircorrect places.Alwayskeeptheworkareaclean andmakesurethatthereisnodirt,water, oroilonthefloor.Smokeonlyintheareas providedforsmoking.Neversmokewhile working.
3)Whencarryingoutanyoperation,always wearsafetyshoesandhelmet.Donot wearlooseworkclothes,orclotheswith buttonsmissing.
qAlwayswearsafetyglasseswhenhittingpartswithahammer.
qAlwayswearsafetyglasseswhen grindingpartswithagrinder,etc.
4)Whencarryingoutanyoperationwith2or moreworkers,alwaysagreeontheoperatingprocedurebeforestarting.Always informyourfellowworkersbeforestarting anystepoftheoperation.Beforestarting work,hangUNDERREPAIRwarning signsintheoperator'scompartment.
5)Onlyqualifiedworkersmustcarryoutwork andoperationwhichrequirelicenseor qualification.
6)Keepalltoolsingoodcondition,learnthe correctwaytousethem,andusethe properonesofthem.Beforestartingwork, thoroughlycheckthetools,machine,forklift,servicecar,etc.
7)Ifweldingrepairsareneeded,always haveatrainedandexperiencedwelder carryoutthework.Whencarryingout weldingwork,alwayswearwelding gloves,apron,shieldinggoggles,capand otherclothessuitedforweldingwork.
8)Beforestartingwork,warmupyourbody thoroughlytostartworkundergoodcondition.
Safetypoints
1Goodarrangement
2Correctworkclothes
3Followingworkstandard
4Makingandcheckingsigns
5Prohibitionofoperationandhandlingby unlicensedworkers
6Safetycheckbeforestartingwork
7Wearingprotectivegoggles (forcleaningorgrindingwork)
8Wearingshieldinggogglesandprotectors (forweldingwork)
9Goodphysicalconditionandpreparation
10Precautionsagainstworkwhichyouare notusedtooryouareusedtotoomuch
2.Preparationsforwork
1)Beforeaddingoilormakinganyrepairs, parkthemachineonhardandlevel ground,andapplytheparkingbrakeand blockthewheelsortrackstopreventthe machinefrommoving.
2)Beforestartingwork,lowerthework equipment(blade,ripper,bucket,etc.)to theground.Ifthisisnotpossible,insert thelockpinoruseblockstopreventthe workequipmentfromfalling.Inaddition, besuretolockallthecontrolleversand hangwarningsignsonthem.
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