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Komatsu D61EX -23, D61PX -23 Bulldozer Service Manual

1,733 pages · Publication SEN06010-03

$179.87
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Models
D61EX -23, D61PX -23
Serial coverage
30001 and up
Manual type
Service Manual
Pages
1,733
Publication
SEN06010-03
Condition
Brand new
Komatsu D61EX -23, D61PX -23 Bulldozer Service Manual, publication SEN06010-03

What's inside

From the manual's own table of contents: 329 sections, 652 entries. See sample pages (PDF, 807 KB)

Index and foreword
Foreword, safety and general information
Important safety notice
How to read the shop manual
Explanation of terms for maintenance standard
Handling equipment of fuel system devices
Handling of intake system parts
Handling of hydraulic equipment
Method of disconnecting and connecting of push-pull type coupler
Handling of electrical equipment
How to read electric wire code
Precautions when performing operation
Practical use of KOMTRAX
Standard tightening torque table
List of abbreviation
Conversion table
Specification
Specifications
Specification drawing
Weight table
Table of fuel, coolant, and lubricants
Structure and function
Engine and cooling system
Engine related parts
Show all 329 sections
KVGT
EGR system piping drawing
EGR system circuit diagram
EGR valve
EGR cooler
KCCV layout drawing
KCCV ventilator
KDPF
Cooling system
Cooling fan motor
Oil cooler bypass and HSTcharge safety valve
Power train
Power train system
Damper
Hydraulic component layout of HST
Steering and brake control
HST pump
HST motor
Charge pump
Solenoid valve
Final drive
Undercarriage and frame
Main frame
Suspension
Track frame and idler cushion
Hydraulic system
Hydraulic component layout of work equipment
Work equipment control system
Hydraulic tank
CLSS6 topics
  • Work equipment and cooling fan pump
  • Control valve
  • Ripper PPC valve
  • Quick drop valve
  • Angle control EPC valve
  • Accumulator
Work equipment3 topics
  • Blade
  • Ripper
  • Piston valve
Cab and its attachments2 topics
  • ROPS cab
  • Cab mount
Electrical system10 topics
  • Engine control system
  • Cooling system control system
  • HSTcontrol system
  • Parking brake control system
  • System operating lamp function
  • Battery disconnect switch function
  • Machine monitor system
  • KOMTRAX system
  • System component parts
  • Sensor
Standard value tables
Standard service value table3 topics
  • Standard value table for engine
  • Standard value table for machine
  • Standard value table for electrical system
Testing and adjusting
Related information on testing and adjusting24 topics
  • Tools for testing and adjusting
  • Sketch of tools for testing and adjusting
  • Testing engine speed
  • Testing boost pressure
  • Testing exhaust gas color
  • Testing and adjusting valve clearance
  • Testing compression pressure
  • Testing blowby pressure
  • Testing engine oil pressure
  • Testing EGR valve and KVGToil pressures
  • Testing fuel pressure
  • Testing fuel discharge, return and leakage
  • Bleeding air from fuel system
  • Testing fuel circuit for leakage
  • Handling cylinder cutout mode operation
  • Handling no-injection cranking operation
  • Testing of KDPF and muffler stack for looseness and damage
  • Testing of installed condition of cylinder heads and manifolds
  • Testing engine piping for damage and looseness
  • Check alternator belt, replace
  • Check auto-tensioner, replace
  • Testing and adjusting HSToil pressure
  • Testing output pressure of solenoid valve
  • Testing if machine travels straight
Simple test procedure for brake performance
Adjusting deceleration/brake pedal
Adjusting parking brake lever
Move disabled machine urgently
Adjusting idler clearance
Checking sprocket wear
Testing and adjusting track tension
Releasing remaining pressure in work equipment cylinder
Testing and adjusting work equipment oil pressure
Testing source pressure of control circuit
Testing outlet pressure of work equipment EPC valve and fan EPC valve
Isolating the parts causing hydraulic drift in blade and ripper
Testing internal oil leakage of work equipment cylinder
Testing fan speed
Testing fan circuit oil pressure
Bleeding air from hydraulic circuit
Adjusting work equipment lock lever
Adjusting play of blade center ball
Special functions of machine monitor
Adjustment method when HSTcontroller has been replaced
Adjustment method when electric or hydraulic device has been replaced
Adjusting rearview camera angle
Handling voltage circuit of engine controller
Handling battery disconnect switch
Testing diodes
Pm clinic
Pm Clinic service
Pm Clinic check sheet
Troubleshooting
Related information on troubleshooting
Troubleshooting points
Sequence of events in troubleshooting
Checks before troubleshooting
Inspection procedure before troubleshooting
Preparation for troubleshooting of electrical system
Classification and procedures for troubleshooting
Symptom and troubleshooting numbers
Information in troubleshooting table1 topic
  • circuit
Connector list and layout
Connector contact identification
T-branch box and T-branch adapter table
Fuse location table
Precautions for KDPF (KCSF and KDOC) Cleaning and Replacement1 topic
  • sensors)
Failure codes table
Troubleshooting by failure code (Display of code)
Failure code [6091NX] HST Oil Filter Clogging
Failure code [989L00] Engine Controller Lock Caution 1
Failure code [989M00] Engine Controller Lock Caution 259 topics
  • Failure code [989N00] Engine Controller Lock Caution 3
  • Failure code [A1U0N3] HC Desorb Request 1
  • Failure code [A1U0N4] HC Desorb Request 2
  • Failure code [AA10NX] Air Cleaner Clogging
  • Failure code [AB00KE] Charge Voltage Low
  • Failure code [B@BAZG] Eng Oil Press Low
  • Failure code [B@BCNS] Eng Water Overheat
  • Failure code [B@CRNS] HST Oil Overheat
  • Failure code [B@CRZG] HST Charge Press Low
  • Failure code [CA115] Eng Ne and Bkup Speed Sens Error
  • Failure code [CA122] Chg Air Press Sensor High Error
  • Failure code [CA123] Chg Air Press Sensor Low Error
  • Failure code [CA131] Throttle Sensor High Error
  • Failure code [CA132] Throttle Sensor Low Error
  • Failure code [CA144] Coolant Temp Sens High Error
  • Failure code [CA145] Coolant Temp Sens Low Error
  • Failure code [CA153] Chg Air Temp Sensor High Error
  • Failure code [CA154] Chg Air Temp Sensor Low Error
  • Failure code [CA187] Sensor 2 Supply Volt Low Error
  • Failure code [CA234] Eng Overspeed
  • Failure code [CA221] Ambient Press Sensor High Error
  • Failure code [CA222] Ambient Press Sensor Low Error
  • Failure code [CA227] Sensor 2 Supply Volt High Error
  • Failure code [CA238] Ne Speed Sensor Supply Volt Error
  • Failure code [CA239] Ne Speed Sens Supply Volt High Error
  • Failure code [CA271] IMV/PCV1 Short Error
  • Failure code [CA272] IMV/PCV1 Open Error
  • Failure code [CA295] Ambient Pressure Sensor In Range Error
  • Failure code [CA322] Inj #1(L#1) Open/Short Error
  • Failure code [CA323] Inj #5(L#5) Open/Short Error
  • Failure code [CA324] Inj #3(L#3) Open/Short Error
  • Failure code [CA325] Inj #6(L#6) Open/Short Error
  • Failure code [CA331] Inj #2(L#2) Open/Short Error
  • Failure code [CA332] Inj #4(L#4) Open/Short Error
  • Failure code [CA343] ECM Critical Internal Failure
  • Failure code [CA351] Injectors Drive Circuit Error
  • Failure code [CA352] Sensor 1 Supply Volt Low Error
  • Failure code [CA356] Mass Air Flow Sensor High Error
  • Failure code [CA357] Mass Air Flow Sensor Low Error
  • Failure code [CA386] Sensor 1 Supply Volt High Error
  • Failure code [CA428] Water in Fuel Sensor High Error
  • Failure code [CA429] Water in Fuel Sensor Low Error
  • Failure code [CA435] Eng Oil Press Sw Error
  • Failure code [CA441] Battery Voltage Low Error
  • Failure code [CA442] Battery Voltage High Error
  • Failure code [CA449] Rail Press Very High Error
  • Failure code [CA451] Rail Press Sensor High Error
  • Failure code [CA452] Rail Press Sensor Low Error
  • Failure code [CA488] Chg Air Temp High Torque Derate
  • Failure code [CA515] Rail Press Sens Sup Volt High Error
  • Failure code [CA516] Rail Press Sens Sup Volt Low Error
  • Failure code [CA553] Rail Press High Error
  • Failure code [CA555] Crankcase Press High Error 2
  • Failure code [CA556] Crankcase Press High Error 2
  • Failure code [CA559] Rail Press Low Error
  • Failure code [CA595] Turbo Speed High Error 2
  • Failure code [CA687] Turbo Speed Low Error
  • Failure code [CA689] Eng Ne Speed Sensor Error
  • Failure code [CA691] Intake Air Temp Sens High Error
Failure code [CA692] Intake Air Temp Sens Low Error
Failure code [CA697] ECM Internal Temp Sensor High Error
Failure code [CA698] ECM Int Temp Sensor Low Error
Failure code [CA731] Eng Bkup Speed Sens Phase Error
Failure code [CA778] Eng Bkup Speed Sensor Error
Failure code [CA1117] Persistent Data Lost Error
Failure code [CA1664] KDOC Malfunction
Failure code [CA1691] Regeneration Ineffective
Failure code [CA1695] Sens 5 Supply Volt High Error
Failure code [CA1696] Sens 5 Supply Volt Low Error
Failure code [CA1843] Crankcase Press Sens High Error
Failure code [CA1844] Crankcase Press Sens Low Error
Failure code [CA1879] KDPF Delta P Sensor High Error
Failure code [CA1881] KDPF Delta P Sensor Low Error
Failure code [CA1883] KDPF Delta P Sens In Range Error
Failure code [CA1921] KDPF Soot Load High Error 1
Failure code [CA1922] KDPF Soot Load High Error 2
Failure code [CA1942] Crankcase Press Sens In Range Error
Failure code [CA1993] KDPF Delta Pressure Low Error
Failure code [CA2185] Throt Sensor Sup Volt High Error
Failure code [CA2186] Throt Sensor Sup Volt Low Error
Failure code [CA2249] Rail Press Very Low Error
Failure code [CA2271] EGR Valve Pos Sens High Error
Failure code [CA2272] EGR Valve Pos Sens Low Error
Failure code [CA2288] Turbo Speed High Error 1
Failure code [CA2311] IMV Solenoid Error
Failure code [CA2349] EGR Valve Solenoid Open Error
Failure code [CA2353] EGR Valve Solenoid Short Error
Failure code [CA2357] EGR Valve Servo Error
Failure code [CA2373] Exhaust Manifold Press Sens High error
Failure code [CA2374] Exhaust Manifold Press Sens Low error
Failure code [CA2375] EGR Orifice Temp Sens High Error
Failure code [CA2376] EGR Orifice Temp Sens Low Error
Failure code [CA2381] KVGT Pos Sens High Error
Failure code [CA2382] KVGT Pos Sens Low Error
Failure code [CA2383] KVGT Solenoid Open Error
Failure code [CA2386] KVGT Solenoid Short Error
Failure code [CA2387] KVGT Servo Error
Failure code [CA2554] Exh Manifold Press Sens In Range Error
Failure code [CA2555] Grid Htr Relay Volt Low Error
Failure code [CA2556] Grid Htr Relay Volt High Error
Failure code [CA2637] KDOC Face Plugging
Failure code [CA2639] Manual Stationary Regeneration Request
Failure code [CA2961] EGR Orifice Temp High Error 1
Failure code [CA2973] Chg Air Press Sensor In Range Error
Failure code [CA3133] KDPF Outlet Press Sens High Error
Failure code [CA3134] KDPF Outlet Press Sens Low Error
Failure code [CA3135] KDPF Outlet Press Sens In Range Error
Failure code [CA3251] KDOC Inlet Temp High Error
Failure code [CA3253] KDOC Temp Error - Non Regeneration
Failure code [CA3254] KDOC Outlet Temp High Error 1
Failure code [CA3255] KDPF Temp Error - Non Regeneration
Failure code [CA3256] KDPF Outlet Temp High Error 1
Failure code [CA3311] KDOC Outlet Temp High Error 2
Failure code [CA3312] KDPF Outlet Temp High Error 2
Failure code [CA3313] KDOC Inlet Temp Sensor Low Error
Failure code [CA3314] KDOC Inlet Temp Sens High Error
Failure code [CA3315] KDOC Inlet Temp Sens In Range Error
Failure code [CA3316] KDOC Outlet Temp Sens Low Error59 topics
  • Failure code [CA3317] KDOC Outlet Temp Sens High Error
  • Failure code [CA3318] KDOC Outlet Temp Sens In Range Error
  • Failure code [CA3319] KDPF Outlet Temp Sens High Error
  • Failure code [CA3321] KDPF Outlet Temp Sens Low Error
  • Failure code [CA3322] KDPF Outlet Temp Sens In Range Error
  • Failure code [CA3419] Mass Air Flow Sensor Sup Volt High Error
  • Failure code [CA3421] Mass Air Flow Sensor Sup Volt Low Error
  • Failure code [CA3741] Rail Press Valve Trip Error
  • Failure code [D130KA] Neutral relay Open
  • Failure code [D130KB] Neutral relay Short circuit
  • Failure code [D130KY] Neutral relay: Hot Short
  • Failure code [D19JKZ] Personal Code Relay Abnormality
  • Failure code [D811MC] KOMTRAX Error
  • Failure code [D862KA] GPS Antenna Open Circuit
  • Failure code [D8ALKA] Operating Lamp Open Circuit (KOMTRAX)
  • Failure code [D8ALKB] Operating Lamp Short Circuit (KOMTRAX)
  • Failure code [D8AQKR] CAN2 Discon (KOMTRAX)
  • Failure code [DAF0MB] Monitor ROM Abnormality
  • Failure code [DAF0MC] Monitor Error
  • Failure code [DAF8KB] Camera Power Supply Short Circuit
  • Failure code [DAF9KQ] Model Selection Abnormality
  • Failure code [DAFGMC] GPS Module Error
  • Failure code [DAFLKA] Operating Lamp Open Circuit (Monitor)
  • Failure code [DAFLKB] Operating Lamp Short Circuit (Monitor)
  • Failure code [DAFQKR] CAN2 Discon (Monitor)
  • Failure code [DAJ000] HSTcontroller: Abnormality in controller
  • Failure code [DAJ0KQ] HSTcontroller: Type select signal
  • Failure code [DAJ0KT] HSTcontroller: Abnormality in controller
  • Failure code [DAJ0MC] HST Con Error
  • Failure code [DAJ1KK] HSTcontroller: Source voltage low
  • Failure code [DAJ2KK] HSTcontroller: Output voltage low
  • Failure code [DAJ5KK] HST: Sensor volt 5V (0) Out of normal range
  • Failure code [DAJ6KK] HST: Sensor volt 5V (1) Out of normal range
  • Failure code [DAJLKA] Operating Lamp Open Circuit (HST Con)
  • Failure code [DAJLKB] Operating Lamp Short Circuit (HST Con)
  • Failure code [DAJPMA] Inconsistency of Option Selection (HST)
  • Failure code [DAJQKR] CAN2 Discon (HST Con)
  • Failure code [DAJRKR] CAN1 Discon (HST Con)
  • Failure code [DB2QKR] CAN2 Discon (Engine Con)
  • Failure code [DB2RKR] CAN1 Discon (Engine Con)
  • Failure code [DD12KA] Shift up SW: Open
  • Failure code [DD12KB] Shift up SW: Short Circuit
  • Failure code [DD13KA] Shift down SW: Open
  • Failure code [DD13KB] Shift down SW: Short Circuit
  • Failure code [DD14KA] Parking lever SW: Open
  • Failure code [DD14KB] Parking lever SW: Short circuit
  • Failure code [DDKAKA] Blade float Sw: Open
  • Failure code [DDKAKB] Blade float Sw: Short circuit
  • Failure code [DDKFL4] Left Angle Sw: Signal mismatch
  • Failure code [DDKGL4] Right Angle Sw: Signal mismatch
  • Failure code [DDKHKA] iB Sw: Open
  • Failure code [DDKHKB] iB Sw: Short circuit
  • Failure code [DDNLKA] Weq lock Sw: Open
  • Failure code [DDNLKB] Weq lock Sw: Short circuit
  • Failure code [DDP6KA] Brake Pressure Sensor: Open
  • Failure code [DDP6KB] Brake Pressure Sensor: Hot Short
  • Failure code [DDP6MA] Brake pressure sensor: Malfunction
  • Failure code [DDU1FS] Parking lever Switch 2: Signal mismatch
  • Failure code [DDU1KA] Parking lever Sw2: Open
Failure code [DDU1KY] Parking lever Sw2: Hot Short
Failure code [DFA4KX] Blade lift lever: Main and Sub Error
Failure code [DFA4KZ] Blade lift lever: Main and Sub Error
Failure code [DFA4L8] Blade lift lever: Signal mismatch
Failure code [DFA5KA] Blade lift lever1: Open
Failure code [DFA5KB] Blade lift lever1: Hot Short
Failure code [DFA6KA] Blade lift lever2: Open
Failure code [DFA6KB] Blade lift lever2: Hot Short
Failure code [DFA7KX] Blade tilt lever: Main and Sub Error
Failure code [DFA7KZ] Blade tilt lever: Main and Sub Error
Failure code [DFA7L8] Blade tilt lever: Signal mismatch
Failure code [DFA8KA] Blade tilt lever1: Open
Failure code [DFA8KB] Blade tilt lever1: Hot Short
Failure code [DFA9KA] Blade tilt lever2: Open
Failure code [DFA9KB] Blade tilt lever2: Hot Short
Failure code [DGS1KA] HSToil temp sensor: Open
Failure code [DGS1KX] HSToil temp sensor: Out of normal range
Failure code [DH21KA] Weq pressure sensor: Open
Failure code [DH21KB] Weq pressure sensor: Hot Short
Failure code [DHA4KA] Air Cleaner Clog Sensor Open Circuit
Failure code [DHH7KA] LF HST Pressure Sensor: Open
Failure code [DHH7KB] LF HST Pressure Sensor: Hot Short
Failure code [DHH8KA] RF HST Pressure Sensor: Open
Failure code [DHH8KB] RF HST Pressure Sensor: Hot Short
Failure code [DHH9KA] LR HST Pressure Sensor: Open
Failure code [DHH9KB] LR HST Pressure Sensor: Hot Short
Failure code [DHHAKA] RR HST Pressure Sensor: Open
Failure code [DHHAKB] RR HST Pressure Sensor: Hot Short
Failure code [DK30KA] ST lever1: Open
Failure code [DK30KB] ST lever1: Hot Short
Failure code [DK30KX] ST lever: Main and Sub Error
Failure code [DK30KZ] ST lever: Main and Sub Error
Failure code [DK30L8] ST lever: Signal mismatch
Failure code [DK31KA] ST lever2: Open
Failure code [DK31KB] ST lever2: Hot Short
Failure code [DK40KA] Decel/Brake potentiometer: Open
Failure code [DK40KB] Decel/Brake potentiometer: Hot Short
Failure code [DK55KX] FR lever: Main and Sub Error
Failure code [DK55KZ] FR lever: Main and Sub Error
Failure code [DK55L8] FR lever: Signal mismatch
Failure code [DK56KA] FR lever1: Open
Failure code [DK56KB] FR lever1: Hot Short
Failure code [DK57KA] FR lever2: Open
Failure code [DK57KB] FR lever2: Hot Short
Failure code [DLM0KX] HST Motor Speed Sensor: Left/Right Error
Failure code [DLM1KA] Left HST motor speed sensor: Open
Failure code [DLM1KB] Left HST motor speed sensor: Short circuit
Failure code [DLM1MA] Left HST motor speed sensor: Malfunction
Failure code [DLM2KA] Right HST motor speed sensor: Open
Failure code [DLM2KB] Right HST motor speed sensor: Short circuit
Failure code [DLM2MA] Right HST motor speed sensor: Malfunction
Failure code [DLM3KA] Fan rev. sensor: Open
Failure code [DLM3KB] Fan rev. sensor: Short circuit
Failure code [DLM3MB] Fan control: Mismatch
Failure code [DN21FS] Decel/Brake pedal SW: Signal mismatch
Failure code [DR21KX] Camera 2 Picture Rev. Drive Abnormality
Failure code [DR31KX] Camera 3 Picture Rev. Drive Abnormality
Failure code [DV20KB] Back-up alarm: Short circuit
Failure code [DW4BKA] Parking brake solenoid: Open48 topics
  • Failure code [DW4BKB] Parking brake solenoid: Short circuit
  • Failure code [DW4BKY] Parking brake solenoid: Hot Short
  • Failure code [DW7BKA] Fan reverse solenoid: Open
  • Failure code [DW7BKB] Fan reverse solenoid: Short circuit
  • Failure code [DW7EKA] Slow brake solenoid: Open
  • Failure code [DW7EKB] Slow brake solenoid: Short circuit
  • Failure code [DW7EKY] Slow brake solenoid: Hot Short
  • Failure code [DWN5KA] Fan EPC: Open
  • Failure code [DWN5KB] Fan EPC: Short circuit
  • Failure code [DWN5KY] Fan EPC: Hot Short
  • Failure code [DXA4KA] LF HST pump EPC: Open
  • Failure code [DXA4KB] LF HST pump EPC: Short circuit
  • Failure code [DXA4KY] LF HST pump EPC: Hot Short
  • Failure code [DXA5KA] LR HST pump EPC: Open
  • Failure code [DXA5KB] LR HST pump EPC: Short circuit
  • Failure code [DXA5KY] LR HST pump EPC: Hot Short
  • Failure code [DXA6KA] RF HST pump EPC: Open
  • Failure code [DXA6KB] RF HST pump EPC: Short circuit
  • Failure code [DXA6KY] RF HST pump EPC: Hot Short
  • Failure code [DXA7KA] RR HST pump EPC: Open
  • Failure code [DXA7KB] RR HST pump EPC: Short circuit
  • Failure code [DXA7KY] RR HST pump EPC: Hot Short
  • Failure code [DXHRKA] Blade lift up EPC: Open
  • Failure code [DXHRKB] Blade lift up EPC: Short circuit
  • Failure code [DXHRKY] Blade lift up EPC: Hot short
  • Failure code [DXHSKA] Blade lift down EPC: Open
  • Failure code [DXHSKB] Blade lift down EPC: Short circuit
  • Failure code [DXHSKY] Blade lift down EPC: Hot short
  • Failure code [DXHTKA] Blade tilt left EPC: Open
  • Failure code [DXHTKB] Blade tilt left EPC: Short circuit
  • Failure code [DXHTKY] Blade tilt left EPC: Hot short
  • Failure code [DXHUKA] Blade tilt right EPC: Open
  • Failure code [DXHUKB] Blade tilt right EPC: Short circuit
  • Failure code [DXHUKY] Blade tilt right EPC: Hot short
  • Failure code [DXJ4KA] Weq lock Sol.: Open
  • Failure code [DXJ4KB] Weq lock Sol.: Short circuit
  • Failure code [DXJCKA] Blade angle left EPC: Open
  • Failure code [DXJCKB] Blade angle left EPC: Short circuit
  • Failure code [DXJCKY] Blade angle left EPC: Hot short
  • Failure code [DXJDKA] Blade angle right EPC: Open
  • Failure code [DXJDKB] Blade angle right EPC: Short circuit
  • Failure code [DXJDKY] Blade angle right EPC: Hot short
  • Failure code [DXK1KA] Left HST motor EPC: Open
  • Failure code [DXK1KB] Left HST motor EPC: Short circuit
  • Failure code [DXK1KY] Left HST motor EPC: Hot Short
  • Failure code [DXK2KA] Right HST motor EPC: Open
  • Failure code [DXK2KB] Right HST motor EPC: Short circuit
  • Failure code [DXK2KY] Right HST motor EPC: Hot Short
Troubleshooting of electrical system (E-mode)8 topics
  • Engine does not start (Engine does not crank)
  • Manual preheating system does not work
  • Automatic preheating system does not work
  • While preheating is working, preheating monitor does not light up
  • When starting switch is turned to ON position, machine monitor displays nothing
  • Air cleaner clogging monitor lights up in yellow while engine is running
  • Charge level monitor lights up in red while engine is running
  • Engine coolant temperature monitor lights up in red while engine is running
Engine oil pressure monitor lights up in red while engine is running
HSTcharge pressure monitor lights up in red while engine is running
Hydraulic oil temperature monitor lights up in red while engine is running
HSToil filter clogging monitor lights up in red while engine is running
Fuel level gauge does not indicate correct level
Engine coolant temperature gauge does not indicate correct temperature
Hydraulic oil temperature gauge does not indicate correct temperature
Operation mode does not change
Service mode cannot be selected
Operating customize switch does not display customize screen
Modifying setting on customize screen does not change setting of machine
Service meter is not displayed, while starting switch is in OFF position
Work equipment does not operate
Foot heater does not operate
Horn does not sound
Horn does not stop sounding
Backup alarm does not sound
Backup alarm does not stop sounding
Headlamp does not light up
Rear lamp does not light up
No wiper operates continuously or intermittently
Front wiper does not operate
Rear wiper does not operate1 topic
  • operations)
Front washer does not operate
Rear washer does not operate
Left door washer does not operate
Right door washer does not operate
KOMTRAX system does not operate normally
Troubleshooting of hydraulic and mechanical system (H-mode)
Information described in troubleshooting table (H-mode)
System chart of hydraulic and mechanical systems
Failure mode and cause table3 topics
  • operates)
    • system operates)
    • LH of travel system does not operate)
Travel speed or power is low
Travel speed range does not change
Shock is large when machine starts or stops
Machine deviates largely
Machine drift on a slope is large
Engine stalls during travel or engine speed drops significantly
Unusual noise is heard from around HST pump or motor
All work equipment do not operate
All work equipment operates slowly or lacks power
Blade lift speed or power is low
Blade tilt speed or power is low
Blade angle speed or power is low
Time lag of blade lift is large
Hydraulic drift of lifted blade is large
Hydraulic drift of tilted blade is large
Unusual noise is heard from around work equipment pump or control valve
HSToil temperature (hydraulic oil temperature) rises too high2 topics
  • Fans speed is abnormal (high, low, or no rotation)
  • Unusual noise is heard from around fan
Troubleshooting of engine (S-mode)23 topics
  • Information described in troubleshooting table (S mode)
  • Engine does not crank when starting switch is turned to START position
  • Engine cranks but no exhaust smoke comes out
  • Engine startability is poor
  • Engine does not pick up smoothly
  • Engine stops during operation
  • Engine runs rough or is unstable
  • Engine lacks power
  • KDPF gets clogged in a short time
  • Engine oil consumption is excessive
  • Engine oil becomes contaminated early
  • Fuel consumption is excessive
  • Oil is in coolant (or coolant spurts or coolant level goes down)
  • Oil pressure drops
  • Fuel mixes into engine oil
  • Water mixes into engine oil (milky)
  • Coolant temperature rises too high (overheating)
  • Unusual noise is heard
  • Vibration is excessive
  • Air cannot be bled from fuel circuit
  • Active regeneration is executed frequently
  • Active regeneration takes time
  • White smoke is exhausted during active regeneration
Disassembly and assembly
Related information on disassembly and assembly26 topics
  • How to read this manual
  • Coating materials list
  • Special tools list
  • Sketches of special tools
  • Removal and installation of supply pump assembly
  • Removal and installation of fuel injector assembly
  • Removal and installation of cylinder head assembly
  • Removal and installation of radiator assembly
  • Removal and installation of aftercooler assembly
  • Removal and installation of hydraulic oil cooler assembly
  • Removal and installation of cooling fan drive assembly
  • Removal and installation of cooling fan motor assembly
  • Removal and installation of engine assembly
  • Disassembly and assembly of damper assembly
  • Removal and installation of engine front oil seal
  • Removal and installation of engine rear oil seal
  • Removal and installation of engine hood assembly
  • Removal and installation of fuel tank assembly
  • Removal and installation of KDPF assembly
  • Disassembly and assembly of KDPF assembly
  • Removal and installation of KCCV assembly
  • Removal and installation of KVGT assembly
  • Removal and installation of EGR (Exhaust Gas Recirculation) cooler assembly
  • Removal and installation of EGR (Exhaust Gas Recirculation) valve assembly
  • Removal and installation of belt for alternator and air conditioner compressor
  • Removal and installation of air cleaner assembly
Removal and installation of HST pump assembly
Removal and installation of HST motor and final drive assembly
Disassembly and assembly of final drive
Removal and installation of track frame assembly
Removal and installation of idler assembly
Disassembly and assembly of idler
Removal and installation of recoil spring assembly
Disassembly and assembly of recoil spring
Removal and installation of track roller assembly
Disassembly and assembly of track roller assembly
Removal and installation of carrier roller assembly
Disassembly and assembly of carrier roller assembly
Removal and installation of segment teeth
Separation and connection of track shoe assembly (Standard type track shoe)
Separation and connection of track shoe assembly (PLUS type track shoe)1 topic
  • shoe)
Overall disassembly and assembly of track shoe assembly (PLUS type track shoe)1 topic
  • shoe)
Removal and installation of pivot shaft assembly
Removal and installation of equalizer bar assembly
Removal and installation of equalizer bar side bushing
Removal and installation of hydraulic tank assembly
Removal and installation of control valve assembly
Disassembly and assembly of hydraulic cylinder assembly
Removal and installation of work equipment assembly
Removal and installation of blade assembly
Removal and installation of U-frame assembly
Removal and installation of ROPS cab assembly
Removal and installation of operator's cab glass (adhesion glass)
Removal and installation of operator's seat
Removal and installation of seat belt
Removal and installation of foot heater assembly
Disassembly and assembly of foot heater assembly
Removal and installation of air conditioner unit assembly
Removal and installation of air conditioner compressor assembly
Removal and installation of machine monitor assembly
Removal and installation of engine controller assembly
Removal and installation of HSTcontroller assembly
Removal and installation of mass air flow and temperature sensor
Removal and installation of KOMTRAX terminal
Maintenance standard
Engine mount18 topics
  • Charge pump
  • Solenoid valve
  • Final drive
  • Sprocket
  • Full-scale drawing of sprocket tooth profile
  • Suspension
  • Track frame and idler cushion
  • Idler
  • Track roller
  • Carrier roller
  • Track shoe
  • Hydraulic tank
  • Cutting edge and end bit
  • Lift cylinder
  • Tilt cylinder
  • Angle cylinder
  • Ripper cylinder
  • Electric steering lever
Appendix
Air conditioner components24 topics
  • Precautions for refrigerant
  • Air conditioner component
  • Configuration and function of refrigeration cycle
  • Outline of refrigeration cycle
  • Air conditioner unit
  • Dual pressure switch
  • Pressure switch
  • Compressor
  • Condenser
  • Receiver drier
  • Procedure for testing and troubleshooting
  • Electrical circuit diagram
  • System diagram
  • Parts and connectors layout
  • Testing relays
  • Troubleshooting chart 1
  • Troubleshooting chart 2
  • Information described in troubleshooting table
  • Troubleshooting for condenser fan
  • Troubleshooting for compressor and refrigerant system (Air is not cooled)
  • Troubleshooting for temperature control
  • Troubleshooting with gauge pressure
  • Connection of service tool
    • circuit
Handling of compressor oil
Diagrams and drawings
Hydraulic circuit diagram
Symbols in hydraulic circuit diagram
Electric circuit diagram
Symbols in electric circuit diagram
Electrical circuit diagram

Inside this manual

Real pages from this service manual (1,733 pages). Open the sample pages (PDF, 806 KB)

Sample pages from the Komatsu D61EX -23, D61PX -23 Bulldozer Service Manual: Specifications, Diagram, Troubleshooting, Foldout diagram
  • Specifications, page 72: 01 Specification
  • Diagram, page 722: Short circuit in wiring harness
  • Troubleshooting, page 1,034: Failure code [DFA8KB] Blade tilt lever1: Hot Short
  • Foldout diagram, page 1,713: D61EX-23, D61PX-23

Other manuals for this machine

Save 10% on 2 manuals, 15% on 3 or more. Other manuals for the D61EX -23, D61PX -23 are listed below. Editions cover different serial number ranges: check the serial coverage and tick only the ones that match your machine.

This manual: Service Manual SEN06010-03$179.87
Other manuals for the D61EX -23, D61PX -23

Operator's manuals

Details

This is a service manual

Here's how it compares to the other manual types.

This manual

Service manual

Factory repair procedures and technical information such as specifications, troubleshooting, and wiring and hydraulic diagrams, for the models and systems the manual covers. See What's inside for its topics.

Operator's manual

Safe operation, controls, maintenance schedules, lubrication points, inspections, and basic checks. Repair procedures are in the service manual.

Parts manual

Illustrated diagrams with factory part numbers for identifying components and ordering parts. Repair procedures are in the service manual.

Engine service manuals are sometimes sold separately, since certain machine models were offered with more than one engine option.

What it's used for

Factory manual for in-house farm and construction shop use. Straightforward, complete, and easy to follow. It contains the OEM information dealership service departments and parts counters use to diagnose problems, identify components, and perform maintenance or repairs correctly.

Service shops and owner/operators who repair their own equipment

Identifying correct parts and seeing how assemblies come apart and go back together

Keeping equipment running with less downtime

Factory manual, 1,733 pages

Quantity one is the manual described above.

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60-day returns

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Binder not included

Manuals over about 300 pages may need a standard 3-ring binder, which you can buy locally to keep the pages organized for shop use.

Other editions and similar models

Komatsu D61EX-15E0, D61PX 15E0Service Manual · SEN02387-05 · $129.95

Questions about model, serial number, engine coverage or contents? Contact us before purchasing and we'll help confirm it's the right manual. Please verify the manual type, machine model, serial number range and engine coverage before purchasing: manuals ordered in error carry a 20% restocking fee (return policy).