2012 D61ex-15e0

SEN02387-02
BULLDOZER
D61EX -15E0
D61PX -15E0
D61EX- B45001
SERIAL NUMBERS and up
D61PX- B45001
SEN02396-02
BULLDOZER 1SHOP MANUAL
D61EX-15E0
D61PX-15E0
Machine Model Serial number
D61EX-15E0 B45001 and up

D61PX-15E0 B45001 and up
00 Index and foreword 1

Index
Composition of shop manual................................................................................................................ 2

Table of contents .................................................................................................................................. 4
D61EX, PX-15E0 1
SEN02396-02 00 Index and foreword
Composition of shop manual 1

The contents of this shop manual are shown together with Form No. in a list.
Note 1: Always keep the latest version of this manual in accordance with this list and utilize accordingly.
The marks shown to the right of Form No. denote the following:
Q: New issue (to be filed additionally) q: Revision (to be replaced for each Form No.)
Note 2: This shop manual can be supplied for each Form No.
Note 3: To file this shop manual in the special binder for management, handle it as follows:
• Place a divider on the top of each section in the file after matching the Tub No. with No. indicated
next to each Section Name shown in the table below:
• File overview and other materials in sections in the order shown below and utilize them accord-
ingly.
Section Title Form Number
Shop Manual, contents binder, binder label and tabs SEN02387-02
00 Index and foreword SEN02388-02

Index SEN02396-02 q
Foreword and general information SEN02397-00
01 Specification SEN02389-00
Specification and technical data SEN02398-00
10 Structure, function and maintenance standard SEN02390-00

Engine and cooling system SEN02473-00
Power train, Part 1 SEN02474-00
Undercarriage and frame SEN02476-00
Hydraulic system, Part 1 SEN02477-00
Work equipment SEN02480-00
Cab and its attachments SEN02481-00
Electrical system SEN02482-00
20 Standard value table SEN02391-00

Standard service value table SEN02554-00
30 Testing and adjusting SEN02392-00

Testing and adjusting, Part 1 SEN02555-00
2 D61EX, PX-15E0
40 Troubleshooting SEN02393-00
Failure code table and fuse locations SEN02559-00
General information on troubleshooting SEN02560-00
Troubleshooting by failure code (Display of code), Part 1 SEN02561-00
Troubleshooting of electrical system (E-mode) SEN02566-00
Troubleshooting of hydraulic and mechanical system (H-mode) SEN02567-00
Troubleshooting of engine (S-mode) SEN02568-00
50 Disassembly and assembly SEN02394-00 Q

General information on disassembly and assembly SEN02569-00 Q
Engine and cooling system (SAA6D107E-1) SEN02570-00 Q
Engine (SAA6D170E-1) SEN02571-00 Q
Power train, Part 1 SEN02572-00 Q
Power train, Part 2 SEN02573-00 Q
Undercarriage and frame, Part 1 SEN02574-00 Q
Undercarriage and frame, Part 2 SEN02575-00 Q
Hydraulic system SEN02576-00 Q
Work equipment SEN02577-00 Q
Cab and its attachments SEN02578-00 Q
Electrical system SEN02579-00 Q
90 Diagrams and drawings SEN02395-01

Hydraulic diagrams and drawings SEN02399-00
Electrical diagrams and drawings SEN02400-01
D61EX, PX-15E0 3
Table of contents 1
00 Index and foreword
Index SEN02396-02
Composition of shop manual....................................................................................................... 2
Table of contents ......................................................................................................................... 4
Foreword and general information SEN02397-00

Safety notice................................................................................................................................ 2
How to read the shop manual ..................................................................................................... 7
Explanation of terms for maintenance standard.......................................................................... 9
Handling electric equipment and hydraulic component............................................................... 11
How to read electric wire code .................................................................................................... 23
Precautions when carrying out operation .................................................................................... 26
Method of disassembling and connecting push-pull type coupler ............................................... 29
Standard tightening torque table ................................................................................................. 32
Conversion table ......................................................................................................................... 36
01 Specification
Specification and technical data SEN02398-00
Specification dimension drawing ................................................................................................. 2
Specifications .............................................................................................................................. 3
Weight table ................................................................................................................................ 8
Table of fuel, coolant and lubricants ............................................................................................ 10
10 Structure, function and maintenance standard

Engine and cooling system SEN02473-00
Cooling system............................................................................................................................ 2
Cooling fan pump ........................................................................................................................ 4
Cooling fan motor ........................................................................................................................ 12
Power train .................................................................................................................................. 2
Power train .................................................................................................................................. 3
HSS system................................................................................................................................. 4
General view of the power train unit............................................................................................ 6
Power train hydraulic piping drawing........................................................................................... 7
Transmission, steering, brake control.......................................................................................... 8
Damper and universal joint.......................................................................................................... 10
Torque converter, PTO ................................................................................................................ 12
Transmission ............................................................................................................................... 18
Transmission ECMV.................................................................................................................... 30
Main relief valve and torque converter relief valve ...................................................................... 36
Lubricating oil relief valve ............................................................................................................ 38
Bevel gear shaft, HSS and brake ................................................................................................ 2
Brake valve.................................................................................................................................. 18
Final drive.................................................................................................................................... 24
Undercarriage and frame SEN02476-00
Main frame .................................................................................................................................. 3
Suspension.................................................................................................................................. 4
Track frame and idler cushion ..................................................................................................... 8
Idler ............................................................................................................................................. 12
Track roller................................................................................................................................... 14
Carrier roller ................................................................................................................................ 15
Sprocket ...................................................................................................................................... 16
Track shoe................................................................................................................................... 18
4 D61EX, PX-15E0

Layout of hydraulic devices for work equipment ......................................................................... 2
Work equipment control .............................................................................................................. 4
Hydraulic tank and filter............................................................................................................... 6
Scavenging pump ....................................................................................................................... 8
Power train and steering lubrication pump.................................................................................. 9
HSS pump................................................................................................................................... 10
HSS motor................................................................................................................................... 28
Control valve ............................................................................................................................... 2
CLSS........................................................................................................................................... 10
Self pressure reducing valve....................................................................................................... 37
PPC valve ................................................................................................................................... 2
Electric lever (Steering) ............................................................................................................... 18
Quick drop valve ......................................................................................................................... 22
Solenoid valve............................................................................................................................. 24
Accumulator ................................................................................................................................ 26
Work equipment .......................................................................................................................... 2
Cutting edge and end bit ............................................................................................................. 8
Ripper.......................................................................................................................................... 9
Hydraulic cylinder........................................................................................................................ 10
Piston valve................................................................................................................................. 13
Cab mount................................................................................................................................... 2
Cab.............................................................................................................................................. 3
Air conditioner piping diagram..................................................................................................... 5
Monitor system............................................................................................................................ 2
Monitor panel .............................................................................................................................. 4
Engine control ............................................................................................................................. 9
Engine control system................................................................................................................. 10
Cooling system control system ................................................................................................... 12
System components.................................................................................................................... 14
Palm command control system ................................................................................................... 22
PPC lock system ......................................................................................................................... 24
KOMTRAX terminal system ........................................................................................................ 25
KOMTRAX terminal..................................................................................................................... 26
Sensor......................................................................................................................................... 27
20 Standard value table

Standard service value table SEN02554-00
Standard value table for engine .................................................................................................. 2
Standard value table for machine................................................................................................ 3
30 Testing and adjusting

Standard value table for engine related parts.............................................................................. 3
Measuring engine speed............................................................................................................. 6
Measuring intake air pressure (boost pressure).......................................................................... 8
Measuring exhaust color ............................................................................................................. 10
Adjusting valve clearance ........................................................................................................... 11
Measuring compression pressure ............................................................................................... 13
Measuring blow-by pressure ....................................................................................................... 16
D61EX, PX-15E0 5
Measuring engine oil pressure .................................................................................................... 17

Handling fuel system equipment ................................................................................................. 18
Releasing residual pressure in fuel system................................................................................. 18
Measuring fuel pressure.............................................................................................................. 19
Measuring fuel delivery amount, return rate and leakage ........................................................... 21
Bleeding air from fuel circuit ........................................................................................................ 25
Testing leakage in fuel system .................................................................................................... 27
Handling of reduced cylinder mode operation............................................................................. 28
Handling of no injection cranking operation ................................................................................ 28
Testing and adjusting air conditioner compressor belt tension.................................................... 29
Replacing the fan belt.................................................................................................................. 29
Handling controller voltage circuit ............................................................................................... 30
Adjusting fuel control dial and decelerator pedal......................................................................... 31
Measuring power train oil pressure ............................................................................................. 3
Adjusting transmission speed sensor (replacement procedure) ................................................. 7
Simple method of testing brake performance.............................................................................. 9
Adjusting brake pedal.................................................................................................................. 10
Adjusting parking brake lever ...................................................................................................... 12
Emergency escape method when power train has trouble ......................................................... 13
Adjusting idler clearance ............................................................................................................. 16
Inspecting wear of sprocket......................................................................................................... 16
Testing and adjusting track shoe tension .................................................................................... 17
Testing and adjusting work equipment and HSS oil pressure ..................................................... 18
Testing control circuit main pressure ........................................................................................... 22
Measuring PPC valve output pressure........................................................................................ 23
Adjusting play of work equipment PPC valve.............................................................................. 26
Measuring internal leakage of work equipment cylinder ............................................................. 27
Adjusting work equipment lock lever of work equipment............................................................. 28
Releasing residual pressure in work equipment cylinder (If PPC accumulator is not installed) .. 29
Releasing residual pressure in work equipment cylinder (If PPC accumulator is installed) ........ 29
Bleeding air from work equipment cylinder ................................................................................. 30
Measuring fan motor speed......................................................................................................... 31
Measuring fan pump circuit pressure .......................................................................................... 32
Measuring HSS motor oil leakage............................................................................................... 33
Bleeding air from fan pump ......................................................................................................... 33
Testing and adjusting operator's cab ........................................................................................... 34
Special functions of monitor panel (EMMS) ................................................................................ 2
Handling of voltage circuit of engine controller............................................................................ 2
Adjustment method when controller has been replaced ............................................................. 2
Preparatory work for troubleshooting for electric system ............................................................ 4
Inspection procedure of diode ..................................................................................................... 9
Pm-Clinic service......................................................................................................................... 10
How to start operation of KOMTRAX terminal............................................................................. 22
Lamp display of KOMTRAX terminal........................................................................................... 26
40 Troubleshooting
Failure code table and fuse locations SEN02559-00
Failure code table........................................................................................................................ 2
Fuse locations ............................................................................................................................. 9
General information on troubleshooting SEN02560-00
Points to remember when troubleshooting.................................................................................. 2
Sequence of events in troubleshooting ....................................................................................... 3
Checks before troubleshooting.................................................................................................... 4
6 D61EX, PX-15E0
Classification and procedures of troubleshooting ....................................................................... 5

Contents of troubleshooting table................................................................................................ 6
Wiring table for connector pin numbers ...................................................................................... 10
T-adapter box and T-adapter table .............................................................................................. 43
Failure code [1500L0] Transmission clutch: Dual engagement .................................................. 3
Failure code [15SAL1] Forward clutch: Fill signal is ON when command current is OFF........... 4
Failure code [15SALH] Forward clutch: Fill signal is OFF when command current is ON .......... 6
Failure code [15SBL1] Reverse clutch: Fill signal is ON when command current is OFF .......... 8
Failure code [15SBLH] Reverse clutch: Fill signal is OFF when command current is ON .......... 10
Failure code [15SEL1] 1st clutch: Fill signal is ON when command current is OFF ................... 12
Failure code [15SELH] 1st clutch: Fill signal is OFF when command current is ON .................. 14
Failure code [15SFL1] 2nd clutch: Fill signal is ON when command current is OFF .................. 16
Failure code [15SFLH] 2nd clutch: Fill signal is OFF when command current is ON ................. 18
Failure code [15SGL1] 3rd clutch: Fill signal is ON when command current is OFF .................. 20
Failure code [15SGLH] 3rd clutch: Fill signal is OFF when command current is ON.................. 22
Failure code [AB00MA] Alternator: Malfunction .......................................................................... 24
Failure code [B@BAZG] Engine oil: Oil pressure too low ........................................................... 24
Failure code [B@BCNS] Radiator coolant: Overheat ................................................................. 25
Failure code [B@CENS] Power train oil: Overheat..................................................................... 25
Failure code [B@HANS] Hydraulic oil: Overheat ........................................................................ 26
Failure code [CA111] Engine controller: Abnormality in controller .............................................. 27
Failure code [CA115] Abnormal engine Ne and Bkup speed sensors:
Abnormal speed sensor signal............................................................................................. 27
Failure code [CA122] Charge pressure sensor too high: Excessively high voltage detected ..... 28
Failure code [CA123] Charge pressure sensor too low: Excessively low voltage detected ........ 30
Failure code [CA131] Decelerator pedal sensor too high: Excessively high voltage detected ... 32
Failure code [CA132] Decelerator pedal sensor too low: Excessively low voltage detected ...... 34
Failure code [CA144] Coolant temperature sensor too high: Excessively high voltage detected 36
Failure code [CA145] Coolant temperature sensor too low: Excessively low voltage detected .. 38
Failure code [CA153] Charge temperature sensor too high: Excessively high voltage detected 40
Failure code [CA154] Charge temperature sensor too low: Excessively low voltage detected... 42
Failure code [CA155] Charge temperature too high and engine speed derated:
Exceeded upper control limit of temperature ....................................................................... 44
Failure code [CA187] Sensor power source 2 too low: Excessively low voltage detected ......... 46
Failure code [CA221] Atmospheric pressure sensor too high: Excessively high voltage detected 48
Failure code [CA222] Atmospheric pressure sensor too low: Excessively low voltage detected 50
Failure code [CA227] Sensor power source 2 too high: Excessively high voltage detected....... 52
Failure code [CA234] Engine over speed: Excessively high speed ............................................ 54
Failure code [CA238] Abnormal power source for Ne speed sensor:
Excessively low voltage detected ........................................................................................ 55
Failure code [CA271] IMV/PCV1 short circuit: Short circuit ........................................................ 56
Failure code [CA272] IMV/PCV1 disconnection: Disconnection ................................................. 58
Failure code [CA322] Injector No. 1 system disconnection or short circuit:
disconnection, short circuit................................................................................................... 4
Failure code [CA342] Engine controller data matching error: matching error ............................. 16
D61EX, PX-15E0 7
Failure code [CA352] Sensor power source 1 too low: Excessively low voltage detected.......... 18
Failure code [CA386] Sensor power source 1 too high: Excessively high voltage detected....... 20
Failure code [CA428] Water detection sensor too high: Excessively high voltage detected ....... 22
Failure code [CA429] Water detection sensor too low: Excessively low voltage detected.......... 24
Failure code [CA435] Abnormal engine oil pressure switch: Abnormal signal circuit.................. 26
Failure code [CA441] Power source voltage too low: Excessively low voltage detected ............ 28
Failure code [CA442] Power source voltage too high:
Excessively high voltage has occurred in the controller power source circuit...................... 30
Failure code [CA449] Common rail pressure too high (2):
Excessively high pressure trouble occurred......................................................................... 32
Failure code [CA451] Common rail pressure sensor too high:
Excessively high voltage detected ....................................................................................... 34
Failure code [CA452] Common rail pressure sensor too low:
Excessively low voltage detected......................................................................................... 36
Failure code [CA488] Charge temperature too high and torque derated:
Failure code [CA553] Common rail pressure too high (1): Excessively high pressure detected. 39
Failure code [CA559] Loss of pressure feed from supply pump (1):
Loss of pressure feed detected............................................................................................ 40
Failure code [CA689] Abnormal engine Ne speed sensor: Abnormal signal .............................. 42
Failure code [CA731] Abnormal engine Bkup speed sensor phase: Abnormal phase................ 44
Failure code [CA757] Loss of all engine controller data: Loss of all data.................................... 46
Failure code [CA778] Abnormal engine Bkup speed sensor: Abnormal Bkup signal.................. 48
Failure code [CA1633] Abnormal KOMNET: Abnormal communication...................................... 50
Failure code [CA2185] Decelerator pedal sensor power source too high:
Excessively high voltage detected ....................................................................................... 52
Failure code [CA2186] Decelerator pedal sensor power source too low:
Excessively low voltage detected......................................................................................... 54
Loss of pressure feed detected............................................................................................ 56
Failure code [CA2311] Abnormal IMV solenoid: Abnormal resistance ........................................ 58
Failure code [CA2555] Air intake heater relay disconnection: Disconnection ............................. 60
Failure code [CA2556] Air intake heater relay short circuit: Short circuit .................................... 62
Failure code [D110KA] Battery relay: Short circuit ...................................................................... 4
Failure code [D110KB] Battery relay: Disconnection................................................................... 6
Failure code [D130KA] Neutral safety relay: Short circuit ........................................................... 8
Failure code [D130KB] Neutral safety relay: Disconnection........................................................ 10
Failure code [D161KA] Back-up alarm relay: Disconnection....................................................... 12
Failure code [D161KB] Back-up alarm relay: Short circuit .......................................................... 14
Failure code [DAFRKR] Monitor panel CAN communication: Defective communication ............ 16
Failure code [DAQ0KT] [DB30KT] Steering and transmission controller:
Abnormality in controller....................................................................................................... 18
Failure code [DAQ1KK] [DB31KK] Main power source of steering and transmission
controller: Power source voltage drop and input.................................................................. 20
Failure code [DAQ2KK] [DB32KK] Load power source of steering and transmission
Failure code [DAQ5KK] [DB35KK] Steering and transmission controller sensor 5 V
power source: Power source voltage drop and input ........................................................... 24
Failure code [DAQ6KK] [DB36KK] Steering and transmission controller sensor 24 V
Failure code [DAQ9KQ] [DB39KQ] Steering and transmission controller model selection:
Inconsistency in model select signal .................................................................................... 28
Failure code [DB2RKR] Steering and transmission controller CAN communication:
Defective communication ..................................................................................................... 30
Failure code [DB30KT] [DAQ0KT] Steering and transmission controller:
Abnormality in controller....................................................................................................... 32
8 D61EX, PX-15E0
Failure code [DB31KK] [DAQ1KK] Main power source of steering and transmission
Failure code [DAB32KK] [DAQ2KK] Load power source of steering and transmission
Failure code [DB35KK] [DAQ5KK] Steering and transmission controller sensor 5 V
Failure code [DB36KK] [DAQ6KK] Steering and transmission controller sensor 24 V
Failure code [DB39KQ] [DAQ9KQ] Steering and transmission controller model
selection: Inconsistency in model select signal.................................................................... 32
Failure code [DD12KA] Shift up switch: Disconnection............................................................... 34
Failure code [DD12KB] Shift up switch: Short circuit .................................................................. 36
Failure code [DD13KA] Shift down switch: Disconnection .......................................................... 38
Failure code [DD13KB] Shift down switch: Short circuit.............................................................. 40
Failure code [DD14KA] [DDQ2KA] Parking brake lever switch: Disconnection .......................... 42
Failure code [DD14KB] [DDQ2KB] Parking brake lever switch: Short circuit.............................. 44
Failure code [DDQ2KA] [DD14KA] Parking brake lever switch: Disconnection .......................... 46
Failure code [DDQ2KB] [DD14KB] Parking brake lever switch: Short circuit.............................. 46
Failure code [DGS1KX] Hydraulic oil temperature sensor: Input signal is out of normal range.. 48
Failure code [DGT1KA] Power train oil temperature sensor: Disconnection............................... 50
Failure code [DGT1KX] Power train oil temperature sensor: Input signal is out of normal range 51
Failure code [DK10KA] Fuel dial: Disconnection ........................................................................ 52
Failure code [DK10KB] Fuel dial: Short circuit ............................................................................ 54
Failure code [DK30KA] Steering potentiometer (1): Disconnection ............................................ 56
Failure code [DK30KB] Steering potentiometer (1): Short circuit ................................................ 58
Failure code [DK30KX] Steering potentiometer: Input signal is out of normal range .................. 60
Failure code [DK30KZ] Steering potentiometer: Disconnection or short circuit (Double failure). 61
Failure code [DK30L8] Steering potentiometer: Inconsistent analog signal................................ 61
Failure code [DK31KA] Steering potentiometer (2): Disconnection ............................................ 62
Failure code [DK31KB] Steering potentiometer (2): Short circuit ................................................ 64
Failure code [DK40KA] Brake potentiometer: Disconnection...................................................... 66
Failure code [DK40KB] Brake potentiometer: Short circuit ......................................................... 67
Failure code [DK55KX] Forward-reverse potentiometer: Input signal is out of normal range ..... 3
Failure code [DK55KZ] Forward-reverse potentiometer:
Disconnection or short circuit (Double failure) ..................................................................... 4
Failure code [DK55L8] Forward-reverse potentiometer: Inconsistent analog signal................... 5
Failure code [DK56KA] Forward-reverse potentiometer (1): Short circuit................................... 6
Failure code [DK56KB] Forward-reverse potentiometer (1): Disconnection ............................... 8
Failure code [DK57KA] Forward-reverse potentiometer (2): Disconnection ............................... 10
Failure code [DK57KB] Forward-reverse potentiometer (2): Short circuit................................... 12
Failure code [DKH1KA] [DKH1KX] Pitch angle sensor: Short circuit .......................................... 14
Failure code [DKH1KB] [DKH1KX] Pitch angle sensor: Disconnection ...................................... 16
Failure code [DKH1KX], [DKH1KA] or [DKH1KB] Pitch angle sensor: Input signal out of range 17
Failure code [DLT3KA] Transmission output speed sensor: Disconnection................................ 18
Failure code [DLT3KB] Transmission output speed sensor: Short circuit ................................... 19
Failure code [DV00KB] Alarm buzzer: Short circuit .................................................................... 20
Failure code [DW7BKA] Fan reverse solenoid: Disconnection ................................................... 21
Failure code [DW7BKB] Fan reverse solenoid: Short circuit....................................................... 22
Failure code [DWN1KA] HSS EPC solenoid right: Disconnection .............................................. 23
Failure code [DWN1KB] HSS EPC solenoid right: Short circuit.................................................. 24
Failure code [DWN1KY] HSS EPC solenoid right: Short circuit to power source line................. 25
Failure code [DWN2KA] HSS EPC solenoid left: Disconnection ................................................ 26
Failure code [DWN2KB] HSS EPC solenoid left: Short circuit .................................................... 27
Failure code [DWN2KY] HSS EPC solenoid left: Short circuit to power source line ................... 28
Failure code [DWN5KA] Fan pump TVC solenoid: Disconnection.............................................. 29
Failure code [DWN5KB] Fan pump TVC solenoid: Short circuit ................................................. 30
Failure code [DWN5KY] Fan pump TVC solenoid: Short circuit in power source line ................ 31
D61EX, PX-15E0 9
Failure code [DXA0KA] HSS pump TVC solenoid: Disconnection.............................................. 32

Failure code [DXA0KB] HSS pump TVC solenoid: Short circuit ................................................. 33
Failure code [DXA0KY] HSS pump TVC solenoid: Short circuit to power source line ................ 34
Failure code [DXH4KA] 1st clutch ECMV: Disconnection ........................................................... 35
Failure code [DXH4KB] 1st clutch ECMV: Short circuit............................................................... 36
Failure code [DXH4KY] 1st clutch ECMV: Short circuit to power source line.............................. 38
Failure code [DXH5KA] 2nd clutch ECMV: Disconnection .......................................................... 39
Failure code [DXH5KB] 2nd clutch ECMV: Short circuit.............................................................. 40
Failure code [DXH5KY] 2nd clutch ECMV: Short circuit to power source line ............................ 42
Failure code [DXH6KA] 3rd clutch ECMV: Disconnection........................................................... 43
Failure code [DXH6KB] 3rd clutch ECMV: Short circuit .............................................................. 44
Failure code [DXH6KY] 3rd clutch ECMV: Short circuit to power source line ............................. 46
Failure code [DXH7KA] Reverse clutch ECMV: Disconnection................................................... 47
Failure code [DXH7KB] Reverse clutch ECMV: Short circuit ...................................................... 48
Failure code [DXH7KY] Reverse clutch ECMV: Short circuit to power source line ..................... 49
Failure code [DXH8KA] Forward clutch ECMV: Disconnection................................................... 50
Failure code [DXH8KB] Forward clutch ECMV: Short circuit ...................................................... 52
Failure code [DXH8KY] Forward clutch ECMV: Short circuit to power source line ..................... 54
Troubleshooting of electrical system (E-mode) SEN02566-00
Before troubleshooting of electrical system................................................................................. 3
E-1 The engine does not start (the starting motor does not turn)................................................ 7
E-2 The preheater does not operate ........................................................................................... 11
E-3 The monitor panel does not light up at all when the starting switch is turned ON ................ 14
E-4 When the starting switch is turned on, the monitor panel completely remains lighted
and does not go out ............................................................................................................. 15
E-5 While the engine is running, the battery charge level caution lamp flashes ......................... 16
E-6 While the engine is running, the emergency warning item flashes....................................... 18
E-7 While the preheater is operating, the preheating pilot lamp does not light up ...................... 22
E-8 The coolant temperature gauge does not indicate correctly................................................. 24
E-9 The power train oil temperature gauge does not indicate correctly ...................................... 26
E-10 Hydraulic oil temperature gauge does not indicate properly............................................... 28
E-11 Fuel gauge does not indicate properly ................................................................................ 30
E-12 Gear speed and engine speed are not indicated properly.................................................. 31
E-13 The preset mode service meter does not indicate normally ............................................... 31
E-14 The warning lamp does not flash or does not go out.......................................................... 31
E-15 The alarm buzzer does not sound or does not stop ........................................................... 32
E-16 Auto shift down is not possible or is not released............................................................... 34
E-17 The buzzer cancel switch does not work ............................................................................ 36
E-18 The information switch does not work ................................................................................ 38
E-19 The fan cleaning does not operate or cannot be reset ....................................................... 40
E-20 The preset mode does not operate or cannot be reset....................................................... 42
E-21 The monitor panel cannot be set in the service mode or cannot be set out of the
service mode........................................................................................................................ 44
E-22 The back-up alarm does not sound .................................................................................... 46
E-23 The head lamp and rear lamp do not light up ..................................................................... 49
E-24 The horn does not sound or does not stop ......................................................................... 52
E-25 Malfunction of wipers .......................................................................................................... 54
E-26 Washer does not spray water ............................................................................................. 70
E-27 The air conditioner does not operate .................................................................................. 76
E-28 KOMTRAX system does not operate normally ................................................................... 80
Troubleshooting of hydraulic and mechanical system (H-mode) SEN02567-00
H-1 There is no travel power (no drawbar pull). .......................................................................... 4
H-2 Machine does not move (at 2nd or 3rd speed)..................................................................... 5
H-3 Machine does not move at any gear speed.......................................................................... 6
H-4 Machine travels only in one direction, forward or in reverse ................................................ 7
10 D61EX, PX-15E0
H-5 When gear is shifted or travel direction is changed, large time lag is made ........................ 8
H-6 Machine cannot be steered (Machine does not turn leftward or rightward) ......................... 9
H-7 Steering speed or power is low ............................................................................................ 9
H-8 Brake does not work............................................................................................................. 10
H-9 Overheat of power train oil ................................................................................................... 11
H-10 Abnormal sound comes out from around HSS and work equipment pump or HSS motor. 12
H-11 All work equipment speeds are slow .................................................................................. 12
H-12 Work equipment does not move......................................................................................... 13
H-13 Blade lift speed is slow or lacks power ............................................................................... 13
H-14 Blade tilt speed is slow or lacks power............................................................................... 14
H-15 Angling blade speed is slow or lacks power....................................................................... 14
H-16 Ripper lift speed is slow or lacks power ............................................................................. 15
H-17 Excessive hydraulic drift of blade lift................................................................................... 15
H-18 Excessive hydraulic drift of blade tilt .................................................................................. 16
H-19 Excessive hydraulic drift of blade angle ............................................................................. 16
H-20 Excessive hydraulic drift of ripper lift .................................................................................. 17
Troubleshooting of engine (S-mode) SEN02568-00
Method of using troubleshooting charts ...................................................................................... 3
S-1 Starting performance is poor ................................................................................................ 6
S-2 Engine does not start............................................................................................................ 7
S-3 Engine does not pick up smoothly........................................................................................ 10
S-4 Engine stops during operations ............................................................................................ 11
S-5 Engine does not rotate smoothly .......................................................................................... 12
S-6 Engine lacks output (or lacks power).................................................................................... 13
S-7 Exhaust smoke is black (incomplete combustion)................................................................ 14
S-8 Oil consumption is excessive (or exhaust smoke is blue) .................................................... 15
S-9 Oil becomes contaminated quickly ....................................................................................... 16
S-10 Fuel consumption is excessive........................................................................................... 17
S-11 Oil is in coolant (or coolant spurts back or coolant level goes down) ................................. 18
S-12 Oil pressure drops .............................................................................................................. 19
S-13 Oil level rises (Entry of coolant or fuel)............................................................................... 20
S-14 Coolant temperature becomes too high (overheating) ....................................................... 21
S-15 Abnormal noise is made ..................................................................................................... 22
S-16 Vibration is excessive ......................................................................................................... 23
50 Disassembly and assembly

General information on disassembly and assembly SEN02569-00
How to read this manual ............................................................................................................. 2
Coating materials list................................................................................................................... 4
Special tool list ............................................................................................................................ 7
Sketches of special tools............................................................................................................. 12
Engine and cooling system (SAA6D107E-1) SEN02570-00
Removal and installation of radiator guard assembly ................................................................. 2
Removal and installation of engine assembly ............................................................................. 6
Removal and installation of radiator assembly............................................................................ 11
Removal and installation of aftercooler assembly ....................................................................... 14
Removal and installation of power train oil cooler assembly....................................................... 17
Removal and installation of hydraulic cooler assembly............................................................... 18
Removal and installation of cooling fan drive assembly.............................................................. 21
Removal and installation of cooling fan motor assembly ............................................................ 23
Removal and installation of damper assembly............................................................................ 24
Removal and installation of fuel tank assembly .......................................................................... 29
Removal and installation of engine hood assembly .................................................................... 31
D61EX, PX-15E0 11
Engine (SAA6D170E-1) SEN02571-00

Removal and installation of fuel supply pump assembly ............................................................. 2
Removal and installation of fuel injector assembly...................................................................... 4
Removal and installation of cylinder head assembly................................................................... 13
Removal and installation of engine front seal.............................................................................. 26
Removal and installation of engine rear seal .............................................................................. 29
Removal and installation of PTO, torque converter and transmission assembly ........................ 2
Disconnection and connection of PTO, torque converter and transmission assembly................ 6
Disassembly and assembly of PTO assembly ............................................................................ 8
Disassembly and assembly of torque converter assembly ......................................................... 13
Disassembly and assembly of TORQFLOW transmission assembly.......................................... 17
Removal and installation of torque converter main relief valve assembly ................................... 34
Disassembly and assembly of torque converter main relief valve assembly .............................. 35
Removal and installation of power train and lubricating oil pump assembly ............................... 2
Removal and installation of HSS and work equipment pump assembly ..................................... 4
Removal and installation of scavenging pump assembly ............................................................ 5
Removal and installation of HSS motor assembly ...................................................................... 5
Disassembly and assembly of HSS assembly ............................................................................ 6
Removal and installation of final drive assembly......................................................................... 24
Disassembly and assembly of final drive assembly .................................................................... 25
Undercarriage and frame, Part 1 SEN02574-00
Removal and installation of track frame assembly ...................................................................... 2
Removal and installation of idler assembly ................................................................................. 4
Disassembly and assembly of idler assembly............................................................................. 5
Removal and installation of recoil spring assembly..................................................................... 9
Disassembly and assembly of recoil spring assembly ................................................................ 10
Removal and installation of track roller assembly ....................................................................... 13
Disassembly and assembly of track roller assembly................................................................... 14
Removal and installation of carrier roller assembly..................................................................... 17
Disassembly and assembly of carrier roller assembly ................................................................ 18
Undercarriage and frame, Part 2 SEN02575-00
Check before expanding track shoe assembly............................................................................ 2
Expansion (normal), expansion (internal abnormality) and installation of track shoe assembly . 2
Overall disassembly and overall assembly of track shoe assembly............................................ 4
Link press-fitting jig dimensions table.......................................................................................... 20
Field disassembly and assembly of one link ............................................................................... 23
Removal and installation of pivot shaft assembly........................................................................ 30
Removal and installation of equalizer bar assembly ................................................................... 32
Removal and installation of equalizer bar side bushing .............................................................. 33
Removal and installation of segment teeth ................................................................................. 34
Hydraulic system SEN02576-00
Removal and installation of main control valve assembly ........................................................... 2
Assembly of main control valve assembly................................................................................... 4
Removal and installation of cooling fan pump assembly............................................................. 7
Disassembly and assembly of hydraulic cylinder assembly........................................................ 8
Removal and installation of work equipment assembly............................................................... 2
Disassembly and assembly of work equipment assembly .......................................................... 4
12 D61EX, PX-15E0

Removal and installation of ROPS guard.................................................................................... 2
Removal and installation of operator's cab assembly ................................................................. 3
Removal and installation of operator's cab glass (stuck glass)................................................... 9
Removal and installation of monitor panel assembly .................................................................. 18
Removal and installation of dashboard assembly ....................................................................... 19
Removal and installation of floor frame assembly....................................................................... 22
Removal and installation of engine controller assembly ............................................................. 2
Removal and installation of steering and transmission controller assembly ............................... 3
Removal and installation of KOMTRAX terminal assembly ........................................................ 4
Removal and installation of air conditioner unit assembly .......................................................... 5
90 Diagrams and drawings

Hydraulic diagrams and drawings SEN02399-00
Power train hydraulic circuit diagram .......................................................................................... 3
Work equipment hydraulic circuit diagram .................................................................................. 5
Electrical diagrams and drawings SEN02400-01
Electrical circuit diagram ............................................................................................................. 3
Connector arrangement diagram ................................................................................................ 5
D61EX, PX-15E0 13
SEN02396-02
D61EX, PX-15E0 Bulldozer

Form No. SEN02396-02
© 2007 KOMATSU
All Rights Reserved
Printed in Japan 02-07 (01)
14
SEN02397-00
D61EX-15E0
D61PX-15E0

00 Index and foreword 1

Foreword and general information
Safety notice ................................................................................................................................................... 2
How to read the shop manual ......................................................................................................................... 7
Explanation of terms for maintenance standard ............................................................................................. 9
Handling electric equipment and hydraulic component .................................................................................11
How to read electric wire code...................................................................................................................... 23
Precautions when carrying out operation...................................................................................................... 26
Method of disassembling and connecting push-pull type coupler................................................................. 29
Standard tightening torque table ................................................................................................................... 32
Conversion table ........................................................................................................................................... 36
D61EX, PX-15E0 1
Safety notice 1 (Rev. 2006/09)

Important safety notice
Proper service and repair are extremely important for safe machine operation. The service and repair
techniques recommended by Komatsu and described in this manual are both effective and safe.
Some of these techniques require the use of tools specially designed by Komatsu for the specific
purpose.
To prevent injury to workers, the symbol k is used to mark safety precautions in this manual. The
cautions accompanying these symbols should always be followed carefully. If any dangerous situa-
tion arises or may possibly arise, first consider safety, and take the necessary actions to deal with
the situation.
1. General precautions 7) If welding repairs are needed, always

k Mistakes in operation are extremely have a trained and experienced welder
dangerous. Read the Operation and carry out the work. When carrying out
Maintenance Manual carefully before w e ld in g w o r k, a lw a y s w e a r w e ld i n g
operating the machine. gloves, apron, shielding goggles, cap and
1) Before carrying out any greasing or other clothes suited for welding work.
repairs, read all the safety plates stuck to 8) Before starting work, warm up your body
the machine. For the locations of the thoroughly to start work under good condi-
safety plates and detailed explanation of tion.
precautions, see the Operation and Main-
tenance Manual. Safety points
2) Decide a place in the repair workshop to
keep tools and removed parts. Always 1 Good arrangement
keep the tools and parts in their correct 2 Correct work clothes
places. Always keep the work area clean 3 Following work standard
and make sure that there is no dirt, water,
or oil on the floor. Smoke only in the areas 4 Making and checking signs
provided for smoking. Never smoke while Prohibition of operation and handling by
5
working. unlicensed workers
3) When carrying out any operation, always 6 Safety check before starting work
wear safety shoes and helmet. Do not
Wearing protective goggles
wear loose work clothes, or clothes with 7
(for cleaning or grinding work)
buttons missing.
q Always wear safety glasses when hit- Wearing shielding goggles and protectors
8
ting parts with a hammer. (for welding work)
q Always wear safety glasses when 9 Good physical condition and preparation
grinding parts with a grinder, etc.
Precautions against work which you are
4) When carrying out any operation with 2 or 10
not used to or you are used to too much
more workers, always agree on the oper-
ating procedure before starting. Always
inform your fellow workers before starting 2. Preparations for work
any step of the operation. Before starting 1) Before adding oil or making any repairs,
work, ha ng UNDER REPAIR warning pa rk th e ma ch in e o n h a rd an d le v e l
signs in the operator's compartment. ground, and apply the parking brake and
5) Only qualified workers must carry out work block the wheels or tracks to prevent the
and operation which require license or machine from moving.
qualification. 2) Before starting work, lower the work
6) Keep all tools in good condition, learn the equipment (blade, ripper, bucket, etc.) to
correct way to use them, and use the the ground. If this is not possible, insert
proper ones of them. Before starting work, the lock pin or use blocks to prevent the
thoroughly check the tools, machine, fork- work equipment from falling. In addition,
lift, service car, etc. be sure to lock all the control levers and
hang warning signs on them.
2 D61EX, PX-15E0
3) When disassembling or assembling, sup- 8) When removing piping, stop the fuel or oil
port the machine with blocks, jacks, or from spilling out. If any fuel or oil drips
stands before starting work. onto the floor, wipe it up immediately. Fuel
4) Remove all mud and oil from the steps or or oil on the floor can cause you to slip
other places used to get on and off the and can even start fires.
machine. Always use the handrails, lad- 9) As a general rule, do not use gasoline to
ders or steps when getting on or off the wash parts. Do not use it to clean electri-
m a c h in e . N e v e r j u m p o n o r o f f t h e cal parts, in particular.
machine. If it is impossible to use the 10) Be sure to assemble all parts again in their
handrails, ladders or steps, use a stand to original places. Replace any damaged
provide safe footing. parts and parts which must not be reused
with new parts. When installing hoses and
3. Precautions during work wires, be sure that they will not be dam-
1) Before disconnecting or removing compo- aged by contact with other parts when the
nents of the oil, water, or air circuits, first machine is operated.
release the pressure completely from the 11) When installing high pressure hoses,
circuit. When removing the oil filler cap, a make sure that they are not twisted. Dam-
drain plug, or an oil pressure pickup plug, ag ed tu bes a re da ng erou s, so be
loosen it slowly to prevent the oil from extremely careful when installing tubes for
spurting out. high pressure circuits. In addition, check
2) The coolant and oil in the circuits are hot that connecting parts are correctly
when the engine is stopped, so be careful installed.
not to get scalded. Wait for the oil and 12) When assembling or installing parts,
coolant to cool before carrying out any alwa ys tigh te n the m to the sp ecified
work on the oil or water circuits. torques. When installing protective parts
3) Before starting work, stop the engine. such as guards, or parts which vibrate vio-
When working on or around a rotating lently or rotate at high speed, be particu-
part, in particular, stop the engine. When l a r l y c a r e fu l t o c h e c k th a t t h e y a r e
checking the machine without stopping installed correctly.
th e en g in e ( me as ur ing o il p re ss ur e, 13) When aligning 2 holes, never insert your
revolving speed, temperature, etc.), take fingers or hand. Be careful not to get your
extreme care not to get rolled or caught in fingers caught in a hole.
rotating parts or moving parts. 14) When measuring hydraulic pressure,
4) Before starting work, remove the leads check that the measuring tools are cor-
from the battery. Always remove the lead rectly assembled.
from the negative (–) terminal first. 15) Take care when removing or installing the
5) When raising a heavy component (heavier tra cks of track-type ma chines. When
than 25 kg), use a hoist or crane. Before removing the track, the track separates
starting work, check that the slings (wire suddenly, so never let anyone stand at
ropes, chains, and hooks) are free from either end of the track.
damage. Always use slings which have 16) If the engine is operated for a long time in
ample capacity and install them to proper a place which is not ventilated well, you
places. Operate the hoist or crane slowly may suffer from gas poisoning. Accord-
to prevent the component from hitting any ingly, open the windows and doors to ven-
other part. Do not work with any part still tilate well.
raised by the hoist or crane.
6) When removing a cover which is under
internal pressure or under pressure from a
spring, always leave 2 bolts in diagonal
positions. Loosen those bolts gradually
and alternately to release the pressure,
and then remove the cover.
7) When removing components, be careful
not to break or damage the electrical wir-
ing. Damaged wiring may cause electrical
fires.
D61EX, PX-15E0 3
4. Precautions for sling work and making

signs
1) Only one appointed worker must make
signs and co-workers must communicate
with each other frequently. The appointed
sign maker must make specified signs
clearly at a place where he is seen well
from the operator's seat and where he can
see the working condition easily. The sign
maker must always stand in front of the
load and guide the operator safely.
q Do not stand under the load.
q Do not step on the load.
2) Check the slings before starting sling
work.
8) When installing wire ropes to an angular
3) Keep putting on gloves during sling work.
load, apply pads to protect the wire ropes.
(Put on leather gloves, if available.)
If the load is slippery, apply proper mate-
4) Measure the weight of the load by the eye
rial to prevent the wire rope from slipping.
and check its center of gravity.
9) Use the specified eyebolts and fix wire
5) Use proper sling according to the weight
ropes, chains, etc. to them with shackles,
of the load and method of slinging. If too
etc.
thick wire ropes are used to sling a light
10) Apply wire ropes to the middle portion of
load, the load may slip and fall.
the hook.
6) Do not sling a load with 1 wire rope alone.
q Slinging near the tip of the hook may
If it is slung so, it may rotate and may slip
cause the rope to slip off the hook
out of the rope. Install 2 or more wire
during hoisting. The hook has the
ropes symmetrically.
k Slinging with 1 rope may cause
maximum strength at the middle por-
tion.
turning of the load during hoisting,
untwisting of the rope, or slipping
of the rope from its original wind-
ing position on the load, which can
result in a dangerous accident.
7) Limit the hanging angle to 60°, as a rule.
Do not sling a heavy load with ropes form-
ing a wide hanging angle from the hook.
W hen h oisting a loa d with 2 or more
ropes, the force subjected to each rope
will increase with the hanging angle. The
table below shows the variation of allow-
able load in kN {kg} when hoisting is made
with 2 ropes, each of which is allowed to
sling up to 9.8 kN {1,000 kg} vertically, at
various hanging angles. When the 2 ropes 11) Do not use twisted or kinked wire ropes.
sling a load vertically, up to 19.6 kN {2,000 12) When lifting up a load, observe the follow-
kg} of total weight can be suspended. ing.
This weight is reduced to 9.8 kN {1,000 q Wind in the crane slowly until wire
kg} when the 2 ropes make a hanging ropes are stretched. When settling
angle of 120°. If the 2 ropes sling a 19.6 the wire ropes with the hand, do not
kN {2,000 kg} load at a lifting angle of g ras p th em bu t p res s th em fr om
150°, each of them is subjected to a force above. If you grasp them, your fingers
as large as 39.2 kN {4,000 kg}. may be caught.
q After the wire ropes are stretched,
stop the crane and check the condi-
tion of the slung load, wire ropes, and
pads.
4 D61EX, PX-15E0
q If the load is unstable or the wire rope 13) If the hoist stops because of a power fail-
or chains are twisted, lower the load ure, turn the power switch OFF. When
and lift it up again. turning on a switch which was turned OFF
q Do not lift up the load slantingly. by the electric shock prevention earth
13) When lifting down a load, observe the fol- leakage breaker, check that the devices
lowing. related to that switch are not in operation
q When lifting down a load, stop it tem- state.
porarily at 30 cm above the floor, and 14) If you find an obstacle around the hoist,
then lower it slowly. stop the operation.
q Check that the load is stable, and 15) After finishing the work, stop the hoist at
then remove the sling. the specified position and raise the hook
q Remove kinks and dirt from the wire to at least 2 m above the floor. Do not
ropes and chains used for the sling leave the sling installed to the hook.
work, and put them in the specified
place. 7. Selecting wire ropes
1) Select adequate ropes depending on the
5. Precautions for using mobile crane weight of parts to be hoisted, referring to
a Read the Operation and Maintenance the table below.
Manual of the crane carefully in advance
and operate the crane safely. Wire ropes
(Standard “Z” twist ropes without galvanizing)
6. Precautions for using overhead hoist crane (JIS G3525, No. 6, Type 6X37-A)
k When raising a heavy part (heavier Nominal
Allowable load
than 25 kg), use a hoist, etc. In Disas- diameter of rope
sembly and assembly, the weight of a mm kN ton
part heavier than 25 kg is indicated 10 8.8 0.9
after the mark of 4. 12 12.7 1.3
1) Before starting work, inspect the wire 14 17.3 1.7
ropes, brake, clutch, controller, rails, over
16 22.6 2.3
wind stop device, electric shock preven-
18 28.6 2.9
tion earth leakage breaker, crane collision
20 35.3 3.6
prevention device, and power application
warning lamp, and check safety. 25 55.3 5.6
2) Observe the signs for sling work. 30 79.6 8.1
3) Operate the hoist at a safe place. 40 141.6 14.4
4) Check the direction indicator plates (east, 50 221.6 22.6
west, south, and north) and the directions 60 318.3 32.4
of the control buttons without fail.
5) Do not sling a load slantingly. Do not move a The allowable load is one-sixth of the
the crane while the slung load is swinging. breaking strength of the rope used
6) Do not raise or lower a load while the (Safety coefficient: 6).
crane is moving longitudinally or laterally.
7) Do not drag a sling.
8) When lifting up a load, stop it just after it
leaves the ground and check safety, and
then lift it up.
9) Consider the travel route in advance and
lift up a load to a safe height.
10) Place the control switch on a position
where it will not be an obstacle to work
and passage.
11) After operating the hoist, do not swing the
control switch.
12) Remember the position of the main switch
so that you can turn off the power immedi-
ately in an emergency.
D61EX, PX-15E0 5
8. Precautions for disconnecting and con-

necting hoses and tubes in air conditioner
circuit
1) Disconnection
k Collect the air conditioner refrigerant
gas (R134a).
k If the refrigerant gas (R134a) gets in
your eyes, you may lose your sight.
Accordingly, when collecting or adding
it, you must be qualified for handling
the refrigerant and put on protective
goggles.
2) Connection
1] When installing the air conditioner cir-
cuit hoses and tubes, take care that
dirt, dust, water, etc. will not enter
them.
2] When connecting the air conditioner
hoses and tubes, check that O-rings
(1) are fitted to their joints.
3] Check that each O-ring is not dam-
aged or deteriorated.
4] When connecting the refrigerant pip-
ing, apply compressor oil for refriger-
an t ( R1 34 a ) ( DEN SO : ND -O IL8 ,
ZEXEL: ZXL100PG (equivalent to
PAG46)) to its O-rings.
a Example of O-ring (Fitted to every joint of

hoses and tubes)
a For tightening torque, see the precautions for

installation in each section of "Disassembly
and assembly".
6 D61EX, PX-15E0
How to read the shop manual 1
q Some attachments and optional parts in this shop manual may not be delivered to certain areas. If one
of them is required, consult KOMATSU distributors.
q Materials and specifications are subject to change without notice.
q Shop manuals are divided into the “Chassis volume” and “Engine volume”. For the engine unit, see the
engine volume of the engine model mounted on the machine.
1. Composition of shop manual

This shop manual contains the necessary technical information for services performed in a workshop.
For ease of understanding, the manual is divided into the following sections.
00. Index and foreword

This section explains the shop manuals list, table of contents, safety, and basic information.
01. Specification
This section explains the specifications of the machine.
10. Structure, function and maintenance standard

This section explains the structure, function, and maintenance standard values of each component.
The structure and function sub-section explains the structure and function of each component. It
serves not only to give an understanding of the structure, but also serves as reference material for
troubleshooting. The maintenance standard sub-section explains the criteria and remedies for dis-
assembly and service.
20. Standard value table

This section explains the standard values for new machine and judgement criteria for testing,
adjusting, and troubleshooting. This standard value table is used to check the standard values in
testing and adjusting and to judge parts in troubleshooting.
30. Testing and adjusting

This section explains measuring instruments and measuring methods for testing and adjusting, and
method of adjusting each part. The standard values and judgement criteria for testing and adjusting
are explained in Testing and adjusting.
40. Troubleshooting
This section explains how to find out failed parts and how to repair them. The troubleshooting is
divided by failure modes. The “S mode” of the troubleshooting related to the engine may be also
explained in the Chassis volume and Engine volume. In this case, see the Chassis volume.
50. Disassembly and assembly

This section explains the special tools and procedures for removing, installing, disassembling, and
assembling each component, as well as precautions for them. In addition, tightening torque and
quantity and weight of coating material, oil, grease, and coolant necessary for the work are also
explained.
90. Diagrams and drawings (chassis volume)/Repair and replacement of parts (engine volume)
q Chassis volume
This section gives hydraulic circuit diagrams and electrical circuit diagrams.
q Engine volume
This section explains the method of reproducing, repairing, and replacing parts.
2. Revision and distribution

Any additions, revisions, or other change of notices will be sent to KOMATSU distributors. Get the most
up-to-date information before you start any work.
D61EX, PX-15E0 7
3. Filing method
File by the brochures in the correct order of the form number printed in the shop manual composition
table.
q Revised edition mark

When a manual is revised, the ones and tens digits of the form number of each brochure is
increased by 1. (Example: 00, 01, 02 …)
q Revisions
Revised brochures are shown in the shop manual composition table.
4. Symbols
Important safety and quality portions are marked with the following symbols so that the shop manual will
be used practically.
Symbol Item Remarks
k Safety Special safety precautions are necessary when performing work.
Special technical precautions or other precautions for preserving stan-

a Caution
dards are necessary when performing work.
4
Weight of parts of component or parts. Caution necessary when
Weight
selecting hoisting wire, or when working posture is important, etc.
3
Tightening Places that require special attention for tightening torque during
torque assembly.
2 Coat Places to be coated with adhesives, etc. during assembly.
5
Oil, coolant Places where oil, etc. must be added, and capacity.
6
Drain Places where oil, etc. must be drained, and quantity to be drained.
5. Units
In this shop manual, the units are indicated with International System of units (SI). For reference, con-
ventionally used Gravitational System of units is indicated in parentheses { }.
8 D61EX, PX-15E0
Explanation of terms for maintenance standard 1

The maintenance standard values necessary for judgment of products and parts are described by the follow-
ing terms.
1. Standard size and tolerance

q To be accurate, the finishing size of parts
is a little different from one to another.
q To specify a finishing size of a part, a tem-
porary standard size is set and an allow-
able difference from that size is indicated.
q The above size set temporarily is called
the “standard size” and the range of differ-
ence from the standard size is called the
“tolerance”.
q The tolerance with the symbols of + or – is
indicated on the right side of the standard
size.
Example:
Standard size Tolerance
–0.022
120
–0.126
a The tolerance may be indicated in the text

and a table as [standard size (upper limit
of tolerance/lower limit of tolerance)].
Example) 120 (–0.022/–0.126)
q Usually, the size of a hole and the size of

the shaft to be fitted to that hole are indi-
cated by the same standard size and dif-
ferent tolerances of the hole and shaft.
The tightness of fit is decided by the toler-
ance.
q Indication of size of rotating shaft and hole
and relationship drawing of them
Example:
Tolerance
Standard size
Shaft Hole
–0.030 +0.046
60
–0.076 +0
D61EX, PX-15E0 9
2. Standard clearance and standard value 5. Clearance limit

q The clearance made when new parts are q Parts can be used until the clearance
assembled is called the “standard clear- between them is increased to a certain
ance“, which is indicated by the range limit. The limit at which those parts cannot
from the minimum clearance to the maxi- be used is called the “clearance limit”.
mum clearance. q If the clearance between the parts
q When some parts are repaired, the clear- exceeds the clearance limit, they must be
ance is generally adjusted to the standard replaced or repaired.
clearance.
q A value of performance and function of 6. Interference limit
new products or equivalent is called the q The allowable maximum interference
“standard value“, which is indicated by a between the hole of a part and the shaft of
range or a target value. another part to be assembled is called the
q When some parts are repaired, the value “interference limit”.
of performance/function is set to the stan- q The interference limit shows the repair
dard value. limit of the part of smaller tolerance.
q If the interference between the parts
3. Standard interference exceeds the interference limit, they must
q When the diameter of a hole of a part be replaced or repaired.
shown in the given standard size and tol-
erance table is smaller than that of the
mating shaft, the difference between those
diameters is called the “interference”.
q The range (A – B) from the difference (A)
between the minimum size of the shaft
and the maximum size of the hole to the
difference (B) between the maximum size
of the shaft and the minimum size of the
hole is the “standard interference”.
q After repairing or replacing some parts,
measure the size of their hole and shaft
and check that the interference is in the
standard range.
4. Repair limit and allowable value

q The size of a part changes because of
wear and deformation while it is used. The
limit of changed size is called the “repair
limit”.
q If a part is worn to the repair limit must be
replaced or repaired.
q The performance and function of a prod-
uct lowers while it is used. A value below
which the product can be used without
causing a problem is called the “allowable
value”.
q If a product is worn to the allowable value,
it must be checked or repaired. Since the
permissible value is estimated from vari-
ous tests or experiences in most cases,
however, it must be judged after consider-
ing the operating condition and customer's
requirement.
10 D61EX, PX-15E0
Handling electric equipment and hydraulic component 1

To maintain the performance of the machine over a long period, and to prevent failures or other troubles
before they occur, correct “operation“, “maintenance and inspection“, “troubleshooting“, and “repairs” must
be carried out. This section deals particularly with correct repair procedures for mechatronics and is aimed at
improving the quality of repairs. For this purpose, it gives sections on “Handling electric equipment” and
“Handling hydraulic equipment” (particularly gear oil and hydraulic oil).
Points to remember when handling electric

equipment
1. Handling wiring harnesses and connectors
Wiring harnesses consist of wiring connecting
one component to another component, con-
nectors used for connecting and disconnecting
one wire from another wire, and protectors or
tubes used for protecting the wiring.
Compared with other electrical components fit-
ted in boxes or cases, wiring harnesses are
more likely to be affected by the direct effects
of rain, water, heat, or vibration. Furthermore,
during inspection and repair operations, they
are frequently removed and installed again, so
they are likely to suffer deformation or damage.
For this reason, it is necessary to be extremely
careful when handling wiring harnesses.
2. Main failures occurring in wiring harness

1) Defective contact of connectors (defec-
tive contact between male and female)
Problems with defective contact are likely
to occur because the male connector is
not properly inserted into the female con-
nector, or because one or both of the con-
nectors is deformed or the position is not
correctly aligned, or because there is cor-
rosion or oxidization of the contact sur-
faces. The corroded or oxidized contact
surfaces may become shiny again (and
contact may become normal) by connect-
ing and disconnecting the connector about
10 times.
2) Defective crimping or soldering of connec-

tors
The pins of the male and female connec-
tors are in contact at the crimped terminal
or soldered portion, but if there is exces-
sive force brought to bear on the wiring,
the plating at the joint will peel and cause
improper connection or breakage.
D61EX, PX-15E0 11
3) Disconnections in wiring
If the wiring is held and the connectors are
pulled apart, or components are lifted with
a crane with the wiring still connected, or a
heavy object hits the wiring, the crimping
of the connector may separate, or the sol-
dering may be damaged, or the wiring
may be broken.
4) High-pressure water entering connector

The connector is designed to make it diffi-
cult for water to enter (drip-proof struc-
ture), but if high-pressure water is sprayed
directly on the connector, water may enter
the connector, depending on the direction
of the water jet. Accordingly, take care not
to splash water over the connector. The
connector is designed to prevent water
from entering, but at the same time, if
water does enter, it is difficult for it to be
drained. Therefore, if water should get into
the connector, the pins will be short-cir-
cuited by the water, so if any water gets in,
immediately dry the connector or take
other appropriate action before passing
electricity through it.
5) Oil or dirt stuck to connector

If oil or grease are stuck to the connector
and an oil film is formed on the mating sur-
face between the male and female pins,
the oil will not let the electricity pass, so
there will be defective contact. If there is
oil or grease stuck to the connector, wipe it
off with a dry cloth or blow it dry with com-
pressed air and spray it with a contact
restorer.
a When wiping the mating portion of the
co nn ec tor, be c ar efu l n ot t o u se
excessive force or deform the pins.
a If there is oil or water in the com-
pressed air, the contacts will become
even dirtier, so remove the oil and
water from the compressed air com-
pletely before cleaning with com-
pressed air.
12 D61EX, PX-15E0
3. Removing, installing, and drying connec-

tors and wiring harnesses
1) Disconnecting connectors
1] Hold the connectors when discon-
necting.
When disconnecting the connectors,
hold the connectors. For connectors
held by a screw, loosen the screw
fully, then hold the male and female
connectors in each hand and pull
apart. For connectors which have a
lock stopper, press down the stopper
with your thumb and pull the connec-
tors apart.
a Never pull with one hand.
2] When removing from clips

q Both of the connector and clip have
stoppers, which are engaged with
each other when the connector is
installed.
q When removing a connector from a

clip, pull the connector in a parallel
direction to the clip for removing stop-
pers.
a If the connector is twisted up and
down or to the left or right, the
housing may break.
3] Action to take after removing connec-

tors
After removing any connector, cover it
with a vinyl bag to prevent any dust,
dirt, oil, or water from getting in the
connector portion.
a If the machine is left disassem-
bled for a long time, it is particu-
larly easy for improper contact to
occur, so always cover the con-
nector.
D61EX, PX-15E0 13
2) Connecting connectors
1] Check the connector visually.
Check that there is no oil, dirt, or
water stuck to the connector pins
(mating portion).
Check that there is no deformation,
defective contact, corrosion, or dam-
age to the connector pins.
Check that there is no damage or
breakage to the outside of the con-
nector.
a If there is any oil, water, or dirt
stuck to the connector, wipe it off
with a dry cloth. If any water has
got inside the connector, warm
the inside of the wiring with a
dryer, but be careful not to make
it too hot as this will cause short
circuits.
a If there is any damage or break-
age, replace the connector.
2] Fix the connector securely.
Align the position of the connector
correctly, and then insert it securely.
For connectors with the lock stopper,
push in the connector until the stop-
per clicks into position.
3] Correct any protrusion of the boot and
any misalignment of the wiring har-
ness.
For connectors fitted with boots, cor-
rect any protrusion of the boot. In
addition, if the wiring harness is mis-
aligned, or the clamp is out of posi-
tion, adjust it to its correct position.
a If the connector cannot be cor-
rected easily, remove the clamp
and adjust the position.
q If the connector clamp has been
removed, be sure to return it to
its original position. Check also
that there are no loose clamps.
14 D61EX, PX-15E0
3) Heavy duty wire connector (DT 8-pole, 12- q Disconnection q Connection (Example of
pole) incomplete setting of (a))
Disconnection (Left of figure)
While pressing both sides of locks (a)
and (b), pull out female connector (2).
Connection (Right of figure)
1] Push in female connector (2) horizon-
tally until the lock clicks.
Arrow: 1)
2] Since locks (a) and (b) may not be set
completely, push in female connector
(2) while moving it up and down until
the locks are set normally.
Arrow: 1), 2), 3)
a Right of figure: Lock (a) is pulled
down (not set completely) and
lock (b) is set completely.
(1): Male connector
(2): Female connector
(a), (b): Locks
D61EX, PX-15E0 15
4) Drying wiring harness

If there is any oil or dirt on the wiring har-
ness, wipe it off with a dry cloth. Avoid
washing it in water or using steam. If the
connector must be washed in water, do
not use high-pressure water or steam
directly on the wiring harness. If water
gets directly on the connector, do as fol-
lows.
1] Disconnect the connector and wipe
off the water with a dry cloth.
a If the connector is blown dry with
compressed air, there is the risk
th at oil in t he a ir ma y c au se
defective contact, so remove all
o il a n d w a t e r fr o m t h e c o m -
pressed air before blowing with
air.
2] Dry the inside of the connector with a
dryer.
If water gets inside the connector, use
a dryer to dry the connector.
a Hot air from the dryer can be
used, but regulate the time that
the hot air is used in order not to
make the connector or related
parts too hot, as this will cause
deformation or damage to the
connector.
3] Carry out a continuity test on the con-
nector.
After drying, leave the wiring harness
disconnected and carry out a continu-
ity test to check for any short circuits
between pins caused by water.
a After completely drying the con-
n e c t o r, b l o w i t w i t h c o n t a c t
restorer and reassemble.
16 D61EX, PX-15E0
4. Handling controller
1) The controller contains a microcomputer
and electronic control circuits. These con-
trol all of the electronic circuits on the
machine, so be extremely careful when
handling the controller.
2) Do not place objects on top of the control-
ler.
3) Cover the control connectors with tape or
a vinyl bag. Never touch the connector
contacts with your hand.
4) During rainy weather, do not leave the
controller in a place where it is exposed to
rain.
5) Do not place the controller on oil, water, or
soil, or in any hot place, even for a short
time. (Place it on a suitable dry stand).
6) Precautions when carrying out arc welding
When carrying out arc welding on the
body, disconnect all wiring harness con-
nectors connected to the controller. Fit an
arc welding ground close to the welding
point.
5. Points to remember when troubleshooting

electric circuits
1) Always turn the power OFF before discon-
necting or connecting connectors.
2) Before carrying out troubleshooting, check
that all the related connectors are properly
inserted.
a Disconnect and connect the related
connectors several times to check.
3) Always connect any disconnected con-
nectors before going on to the next step.
a If the power is turned ON with the
connectors still disconnected, unnec-
essary abnormality displays will be
generated.
4) When carrying out troubleshooting of cir-
cuits (measuring the voltage, resistance,
continuity, or current), move the related
wiring and connectors several times and
check that there is no change in the read-
ing of the tester.
a If there is any change, there is proba-
bly defective contact in that circuit.
D61EX, PX-15E0 17
Points to remember when handling hydraulic equipment

With the increase in pressure and precision of hydraulic equipment, the most common cause of failure is dirt
(foreign material) in the hydraulic circuit. When adding hydraulic oil, or when disassembling or assembling
hydraulic equipment, it is necessary to be particularly careful.
1. Be careful of the operating environment.

Avoid adding hydraulic oil, replacing filters, or
repairing the machine in rain or high winds, or
places where there is a lot of dust.
2. Disassembly and maintenance work in the

field
If disassembly or maintenance work is carried
out on hydraulic equipment in the field, there is
danger of dust entering the equipment. It is
also difficult to check the performance after
repairs, so it is desirable to use unit exchange.
Disassembly and maintenance of hydraulic
equipment should be carried out in a specially
prepared dustproof workshop, and the perfor-
mance should be checked with special test
equipment.
3. Sealing openings
After any piping or equipment is removed, the
openings should be sealed with caps, tapes, or
vinyl bags to prevent any dirt or dust from
entering. If the ope ning is left open or is
blocked with a rag, there is danger of dirt
entering or of the surrounding area being
made dirty by leaking oil so never do this. Do
not simply drain oil out onto the ground, but
collect it and ask the customer to dispose of it,
or take it back with you for disposal.
4. Do not let any dirt or dust get in during

refilling operations
Be careful not to let any dirt or dust get in when
refilling with hydraulic oil. Always keep the oil
filler and the area around it clean, and also use
clean pumps and oil containers. If an oil clean-
ing device is used, it is possible to filter out the
dirt that has collected during storage, so this is
an even more effective method.
18 D61EX, PX-15E0
5. Change hydraulic oil when the temperature

is high
When hydraulic oil or other oil is warm, it flows
easily. In addition, the sludge can also be
drained out easily from the circuit together with
the oil, so it is best to change the oil when it is
still warm. When changing the oil, as much as
p ossib le o f the old hydra ulic oil must b e
drained out. (Drain the oil from the hydraulic
tank; also drain the oil from the filter and from
the drain plug in the circuit.) If any old oil is left,
the contaminants and sludge in it will mix with
the new oil and will shorten the life of the
hydraulic oil.
6. Flushing operations
After disassembling and assembling the equip-
ment, or changing the oil, use flushing oil to
remove the contaminants, sludge, and old oil
from the hydraulic circuit. Normally, flushing is
carried out twice: primary flushing is carried
out with flushing oil, and secondary flushing is
carried out with the specified hydraulic oil.
7. Cleaning operations
After repairing the hydraulic equipment (pump,
c on tr ol v alve , e tc. ) o r w h en r un n in g th e
machine, carry out oil cleaning to remove the
sludge or contaminants in the hydraulic oil cir-
cuit. The oil cleaning equipment is used to
remove the ultra fine (about 3 m) particles that
the filter built in the hydraulic equipment can-
not remove, so it is an extremely effective
device.
D61EX, PX-15E0 19
Connectors newly used for Tier 3 engines

1. Slide lock type 2. Pull lock type (PACKARD-2)
(FRAMATOME-3, FRAMATOME-2) q 107 – 170, 12V140 engine
q 107 – 170, 12V140 engines q Various temperature sensors
q Various pressure sensors and NE Example)
speed sensor Intake air temp er atur e se nso r in
Examples) intake manifold: TIM
Intake air pressure in intake manifold: Fuel temperature sensor: TFUEL
PIM (125, 170, 12V140 engines) Oil temperature sensor: TOIL
Oil pressure sensor: POIL Coolant temperature sensor: TWTR,
(125, 170, 12V140 engines) etc.
Oil pressure switch Disconnect the connector by pulling lock
(107, 114 engines) (B) (on the wiring harness side) of connec-
Ne speed sensor of flywheel housing: tor (2) outward.
NE (107 – 170, 12V140 engines)
Ambient pressure sensor: PAMB
(125, 170, 12V140 engines)
Disconnect connector (1) according to the fol-

lowing procedure.
1) Slide lock (L1) to the right.
2) While pressing lock (L2), pull out connec-
tor (1) toward you.
a Even if lock (L2) is pressed, connec-
tor (1) cannot be pulled out toward
you, if part A does not float. In this
case, float part A with a small screw-
driver while press lock (L2), and then
pull out connector (1) toward you.
20 D61EX, PX-15E0
3. Push lock type

q 107, 114 engines
Example)
Fuel pressure sensor in common rail
(BOSCH-03)
Disconnect connector (3) according to the fol-

lowing procedure.
1) While pressing lock (C), pull out connector
(3) in the direction of the arrow.
q 114 engine
q 107, 114 engine

Example)
Intake air pressure/temperature sensor in
intake manifold
(SUMITOMO-04)
3) While pressing lock (D), pull out connector

(4) in the direction of the arrow.
q 107 engine
a If the lock is on the underside, use

flat-head screwdriver [1] since you
cannot insert your fingers.
2) While pressing up lock (C) of the connec-
tor with flat-head screwdriver [1], pull out
connector (3) in the direction of the arrow.
D61EX, PX-15E0 21
q 125 – 170, 12V140 engine 4. Turn-housing type (Round green connector)

4) While pressing lock (E) of the connector, q 140 engine
pullout connector (5) in the direction of the Example)
arrow. Intake air pressure sensor in intake mani-
fold (CANNON-04): PIM etc.
Example)
Fuel pressure in common rail: PFUEL etc. 1) Disconnect connector (6) according to the
(AMP-3) following procedure.
1] Turn housing (H1) in the direction of
the arrow.
a When connector is unlocked,
housing (H1) becomes heavy to
turn.
2] Pull out housing (H1) in the direction
of the arrow.
a Housing (H1) is left on the wiring har-
ness side.
Example)
Injection pressure control valve of fuel
supply pump: PCV (SUMITOMO-2)
2) Connect the connector according to the

following procedure.
1] Insert the connector to the end, while
setting its groove.
2] Turn housing (H1) in the direction of
the arrow until it “clicks”.
Example)
Speed sensor of fuel supply pump:
G (SUMITOMO-3)
a Pull the connector straight up.
22 D61EX, PX-15E0
How to read electric wire code 1

a The information about the wires unique to each machine model is described in Troubleshooting section,
Relational information of troubleshooting.
In the electric circuit diagram, the material, thickness, and color of each electric wire are indicated by sym-
bols. The electric wire code is helpful in understanding the electric circuit diagram.
Example: AEX 0.85 L - - - Indicates blue, heat-resistant, low-voltage wire for automobile, having nomi-
nal No. of 0.85
Indicates color of wire by color code.
Color codes are shown in Table 3.
Indicates size of wire by nominal No.

Size (Nominal No.) is shown in Table 2.
Indicates type of wire by symbol.

Type, symbol, and material of wire are shown in Table 1.
(Since AV and AVS are classified by size (nominal No.), they are not indi-
cated.)
1. Type, symbol, and material

AV and AVS are different in only thickness and outside diameter of the cover. AEX is similar to AV in
thickness and outside diameter of AEX and different from AV and AVS in material of the cover.
(Table 1)
Using
Sym-
Type Material temperature Example of use
bol
range (°C)
Low-voltage Conduc- Annealed copper for elec-
General wiring
wire for AV tor tric appliance
(Nominal No. 5 and above)
automobile Insulator Soft polyvinyl chloride
Thin-cover Conduc- Annealed copper for elec- –30 to +60
low-voltage tor tric appliance General wiring
AVS
wire for (Nominal No. 3 and below)
automobile Insulator Soft polyvinyl chloride
Heat-resis- Conduc- Annealed copper for elec-

General wiring in extremely
tant low-volt- tor tric appliance
AEX –50 to +110 cold district, wiring at high-tem-
age wire for Heat-resistant crosslinked
Insulator perature place
automobile polyethylene
D61EX, PX-15E0 23
2. Dimensions
(Table 2)
Nominal No. 0.5f (0.5) 0.75f (0.85) 1.25f (1.25) 2f 2 3f 3 5
Number of
strands/Diam- 20/0.18 7/0.32 30/0.18 11/0.32 50/0.18 16/0.32 37/0.26 26/0.32 58/0.26 41/0.32 65/0.32
eter of strand
Conductor
Sectional
0.51 0.56 0.76 0.88 1.27 1.29 1.96 2.09 3.08 3.30 5.23
area (mm2)
d (approx.) 1.0 1.2 1.5 1.9 1.9 2.3 2.4 3.0
AVS Standard 2.0 2.2 2.5 2.9 2.9 3.5 3.6 –
Cov-
AV Standard – – – – – – – 4.6
er D
AEX Standard 2.0 2.2 2.7 3.0 3.1 – 3.8 4.6
Nominal No. 8 15 20 30 40 50 60 85 100

Number of
strands/Diam- 50/0.45 84/0.45 41/0.80 70/0.80 85/0.80 108/0.80 127/0.80 169/0.80 217/0.80
eter of strand
Conductor
Sectional
7.95 13.36 20.61 35.19 42.73 54.29 63.84 84.96 109.1
area (mm2)
d (approx.) 3.7 4.8 6.0 8.0 8.6 9.8 10.4 12.0 13.6
AVS Standard – – – – – – – – –
Cov-
AV Standard 5.5 7.0 8.2 10.8 11.4 13.0 13.6 16.0 17.6
er D
AEX Standard 5.3 7.0 8.2 10.8 11.4 13.0 13.6 16.0 17.6
“f” of nominal No. denotes flexible”.
24 D61EX, PX-15E0
3. Color codes table
(Table 3)
Color Code Color of wire Color Code Color of wire
B Black LgW Light green & White
Br Brown LgY Light green & Yellow
BrB Brown & Black LR Blue & Red
BrR Brown & Red LW Blue & White
BrW Brown & White LY Blue & Yellow
BrY Brown & Yellow O Orange
Ch Charcoal P Pink
Dg Dark green R Red
G Green RB Red & Black
GB Green & Black RG Red & Green
GL Green & Blue RL Red & Blue
Gr Gray RW Red & White
GR Green & Red RY Red & Yellow
GW Green & White Sb Sky Blue
GY Green & Yellow Y Yellow
L Blue YB Yellow & Black
LB Blue & Black YG Yellow &Green
Lg Light green YL Yellow & Blue
LgB Light green & Black YR Yellow & Red
LgR Light green & Red YW Yellow & White
Remarks: In a color code consisting of 2 colors, the first color is the color of the background and
the second color is the color of the marking.
Example: “GW” means that the background is Green and marking is White.
4. Types of circuits and color codes
(Table 4)
Type of wire AVS or AV AEX
Charge R WG – – – – R –
Ground B – – – – – B –
Start R – – – – – R –
Light RW RB RY RG RL – D –
Instrument Y YR YB YG YL YW Y Gr
Signal G GW GR GY GB GL G Br
L LW LR LY LB – L –
Type of
Br BrW BrR BrY BrB – – –
circuit
Lg LgR LgY LgB LgW – – –
O – – – – – – –
Others Gr – – – – – – –
P – – – – – – –
Sb – – – – – – –
Dg – – – – – – –
Ch – – – – – – –
D61EX, PX-15E0 25
Precautions when carrying out operation 1

[When carrying out removal or installation (disassembly or assembly) of units, be sure to follow the general
precautions given below when carrying out the operation.]
1. Precautions when carrying out removal work

q If the coolant contains antifreeze, dispose of it correctly.
q After disconnecting hoses or tubes, cover them or fit plugs to prevent dirt or dust from entering.
q When draining oil, prepare a container of adequate size to catch the oil.
q Confirm the match marks showing the installation position, and make match marks in the necessary
places before removal to prevent any mistake when assembling.
q To prevent any excessive force from being applied to the wiring, always hold the connectors when dis-
connecting the connectors. Do not pull the wires.
q Fit wires and hoses with tags to show their installation position to prevent any mistake when installing.
q Check the number and thickness of the shims, and keep in a safe place.
q When raising components, be sure to use lifting equipment of ample strength.
q When using forcing screws to remove any components, tighten the forcing screws uniformly in turn.
q Before removing any unit, clean the surrounding area and fit a cover to prevent any dust or dirt from
entering after removal.
a Precautions when handling piping during disassembly
Fit the following plugs into the piping after disconnecting it during disassembly operations.
1) Face seal type hoses and tubes
Nominal
Plug (nut end) Sleeve nut (elbow end)
number
02 07376-70210 02789-20210
03 07376-70315 02789-20315
04 07376-70422 02789-20422
05 07376-70522 02789-20522
06 07376-70628 02789-20628
10 07376-71034 07221-21034
12 07376-71234 07221-21234
2) Split flange type hoses and tubes

Nominal
Flange (hose end) Sleeve head (tube end) Split flange
number
04 07379-00400 07378-10400 07371-30400
05 07379-00500 07378-10500 07371-30500
3) If the part is not under hydraulic pressure, the following corks can be used.
Nominal Dimensions
Part Number
number D d L
06 07049-00608 6 5 8
08 07049-00811 8 6.5 11
10 07049-01012 10 8.5 12
12 07049-01215 12 10 15
14 07049-01418 14 11.5 18
16 07049-01620 16 13.5 20
18 07049-01822 18 15 22
20 07049-02025 20 17 25
22 07049-02228 22 18.5 28
24 07049-02430 24 20 30
27 07049-02734 27 22.5 34
26 D61EX, PX-15E0
2. Precautions when carrying out installation work

q Tighten all bolts and nuts (sleeve nuts) to the specified (KES) torque.
q Install the hoses without twisting or interference and fix them with intermediate clamps, if there are any.
q Replace all gaskets, O-rings, cotter pins, and lock plates with new parts.
q Bend the cotter pins and lock plates securely.
q When coating with adhesive, clean the part and remove all oil and grease, then coat the threaded por-
tion with 2 – 3 drops of adhesive.
q When coating with gasket sealant, clean the surface and remove all oil and grease, check that there is
no dirt or damage, then coat uniformly with gasket sealant.
q Clean all parts, and correct any damage, dents, burrs, or rust.
q Coat rotating parts and sliding parts with engine oil.
q When press fitting parts, coat the surface with anti-friction compound (LM-P).
q After fitting snap rings, check that the snap ring is fitted securely in the ring groove.
q When connecting wiring connectors, clean the connector to remove all oil, dirt, or water, then connect
securely.
q When using eyebolts, check that there is no deformation or deterioration, screw them in fully, and align
the direction of the hook.
q When tightening split flanges, tighten uniformly in turn to prevent excessive tightening on one side.
a When operating the hydraulic cylinders for the first time after reassembling cylinders, pumps and other
hydraulic equipment removed for repair, always bleed the air as follows:
1) Start the engine and run at low idle.
2) Operate the work equipment control lever to operate the hydraulic cylinder 4 – 5 times, stopping the
cylinder 100 mm from the end of its stroke.
3) Next, operate the hydraulic cylinder 3 – 4 times to the end of its stroke.
4) After doing this, run the engine at normal speed.
a When using the machine for the first time after repair or long storage, follow the same procedure.
3. Precautions when completing the operation

1) Refilling with coolant, oil and grease
q If the coolant has been drained, tighten the drain valve, and add coolant to the specified level.
Run the engine to circulate the coolant through the system. Then check the coolant level
again.
q If the hydraulic equipment has been removed and installed again, add engine oil to the speci-
fied level. Run the engine to circulate the oil through the system. Then check the oil level
again.
q If the piping or hydraulic equipment have been removed, always bleed the air from the system
after reassembling the parts.
a For details, see Testing and adjusting, “Bleeding air”.
q Add the specified amount of grease (molybdenum disulphide grease) to the work equipment
parts.
2) Checking cylinder head and manifolds for looseness
Check the cylinder head and intake and exhaust manifold for looseness.
If any part is loosened, retighten it.
q For the tightening torque, see “Disassembly and assembly”.
3) Checking engine piping for damage and looseness
Intake and exhaust system
Check the piping for damage, the mounting bolts and nuts for looseness, and the joints for air
suction and exhaust gas leakage.
If any part is loosened or damaged, retighten or repair it.
Cooling system
Check the piping for damage, the mounting bolts and nuts for looseness, and the joints for
coolant leakage.
Fuel system
Check the piping for damage, the mounting bolts and nuts for looseness, and the joints for fuel
leakage.
D61EX, PX-15E0 27
4) Checking muffler and exhaust pipe for damage and looseness

1] Visually check the muffler, exhaust pipe and their mounting parts for a crack and damage.
If any part is damaged, replace it.
2] Check the mounting bolts and nuts of the muffler, exhaust pipe and their mounting parts for
looseness.
If any bolt or nut is loosened, retighten it.
5) Checking muffler function
Check the muffler for abnormal sound and sound different from that of a new muffler.
If any abnormal sound is heard, repair the muffler, referring to “Troubleshooting” and “Disassembly
and assembly”.
28 D61EX, PX-15E0
Method of disassembling and connecting push-pull type coupler 1

k Before carrying out the following work, loosen the oil filler cap of the hydraulic tank gradually to
release the residual pressure from the hydraulic tank.
k Even if the residual pressure is released from the hydraulic tank, some hydraulic oil flows out
when the hose is disconnected. Accordingly, prepare an oil receiving container.
Type 1
1. Disconnection
1) Hold adapter (1) and push hose joint (2)
into mating adapter (3). (Fig. 1)
a The adapter can be pushed in about
3.5 mm.
a Do not hold rubber cap portion (4).
2) After hose joint (2) is pushed into adapter
(3), press rubber cap portion (4) against
adapter (3) until it clicks. (Fig. 2)
3) Hold hose adapter (1) or hose (5) and pull
it out. (Fig. 3)
a Since some hydraulic oil flows out,
prepare an oil receiving container.
2. Connection
1) Hold hose adapter (1) or hose (5) and
insert it in mating adapter (3), aligning
them with each other. (Fig. 4)
a Do not hold rubber cap portion (4).
2) After inserting the hose in the mating
adapter perfectly, pull it back to check its
connecting condition. (Fig. 5)
a When the hose is pulled back, the
rubber cap portion moves toward the
hose about 3.5 mm. This does not
indicate abnormality, however.
D61EX, PX-15E0 29
Type 2
1. Disconnection
1) Hold the tightening portion and push body
(7) straight until sliding prevention ring (6)
contacts contact surface (a) of the hexag-
onal portion at the male end. (Fig. 6)
2) While holding the condition of Step 1), turn
lever (8) to the right (clockwise). (Fig. 7)
3) While holding the condition of Steps 1)
and 2), pull out whole body (7) to discon-
nect it. (Fig. 8)
2. Connection
q Hold the tightening portion and push body
contacts contact surface (a) of the hexag-
30 D61EX, PX-15E0
Type 3
1. Disconnection
1) Hold the tightening portion and push body
contacts contact surface (b) of the hexag-
2) While holding the condition of Step 1),
push cover (10) straight until it contacts
contact surface (b) of the hexagonal por-
tion at the male end. (Fig. 11)
3) While holding the condition of Steps 1)
and 2), pull out whole body (9) to discon-
nect it. (Fig. 12)
2. Connection
q Hold the tightening portion and push body
(9) straight until the sliding prevention ring
contacts contact surface (b) of the hexag-
D61EX, PX-15E0 31
Standard tightening torque table 1

1. Table of tightening torques for bolts and nuts
a Unless there are special instructions, tighten metric nuts and bolts to the torque below. (When using
torque wrench)
a The following table corresponds to the bolts in Fig. A.
Thread diameter of bolt Width across flats Tightening torque

mm mm Nm kgm
6 10 11.8 – 14.7 1.2 – 1.5
8 13 27 – 34 2.8 – 3.5
10 17 59 – 74 6.0 – 7.5
12 19 98 – 123 10.0 – 12.5
14 22 153 – 190 15.5 – 19.5
16 24 235 – 285 23.5 – 29.5
18 27 320 – 400 33.0 – 41.0
20 30 455 – 565 46.5 – 58.0
22 32 610 – 765 62.5 – 78.0
24 36 785 – 980 80.0 – 100.0
27 41 1,150 – 1,440 118 – 147
30 46 1,520 – 1,910 155 – 195
33 50 1,960 – 2,450 200 – 250
36 55 2,450 – 3,040 250 – 310
39 60 2,890 – 3,630 295 – 370
a The following table corresponds to the bolts in Fig. B.

mm mm Nm kgm
6 10 5.9 – 9.8 0.6 – 1.0
8 13 13.7 – 23.5 1.4 – 2.4
10 14 34.3 – 46.1 3.5 – 4.7
12 27 74.5 – 90.2 7.6 – 9.2
a Fig. A a Fig. B
32 D61EX, PX-15E0
2. Table of tightening torques for split flange bolts

a Unless there are special instructions, tighten split flange bolts to the torque below.

mm mm Nm kgm
10 14 59 – 74 6.0 – 7.5
12 17 98 – 123 10.0 – 12.5
16 22 235 – 285 23.5 – 29.5
3. Table of tightening torques for O-ring boss piping joints

a Unless there are special instructions, tighten O-ring boss piping joints to the torque below.
Thread diameter Width across flats Tightening torque Nm {kgm}

Nominal No.
mm mm Range Target
02 14 35 – 63 { 3.5 – 6.5} 44 { 4.5}
03,04 20 Varies depending 84 – 132 { 8.5 – 13.5} 103 {10.5}
05,06 24 on type of connec- 128 – 186 {13.0 – 19.0} 157 {16.0}
10,12 33 tor. 363 – 480 {37.0 – 49.0} 422 {43.0}
14 42 746 – 1,010 {76.0 – 103} 883 {90.0}
4. Table of tightening torques for O-ring boss plugs

a Unless there are special instructions, tighten O-ring boss plugs to the torque below.
Nominal Thread diameter Width across flats Tightening torque Nm {kgm}

No. mm mm Range Target
08 8 14 5.88 – 8.82 {0.6 – 0.9} 7.35 {0.75}
10 10 17 9.81 – 12.74 {1.0 – 1.3} 11.27 {1.15}
12 12 19 14.7 – 19.6 {1.5 – 2.0} 17.64 {1.8}
14 14 22 19.6 – 24.5 {2.0 – 2.5} 22.54 {2.3}
16 16 24 24.5 – 34.3 {2.5 – 3.5} 29.4 {3.0}
18 18 27 34.3 – 44.1 {3.5 – 4.5} 39.2 {4.0}
20 20 30 44.1 – 53.9 {4.5 – 5.5} 49.0 {5.0}
24 24 32 58.8 – 78.4 {6.0 – 8.0} 68.6 {7.0}
30 30 32 93.1 – 122.5 { 9.5 – 12.5} 107.8 {11.0}
33 33 – 107.8 – 147.0 {11.0 – 15.0} 127.4 {13.0}
36 36 36 127.4 – 176.4 {13.0 – 18.0} 151.9 {15.5}
42 42 – 181.3 – 240.1 {18.5 – 24.5} 210.7 {21.5}
52 52 – 274.4 – 367.5 {28.0 – 37.5} 323.4 {33.0}
D61EX, PX-15E0 33
5. Table of tightening torques for hoses (taper seal type and face seal type)
a Unless there are special instructions, tighten the hoses (taper seal type and face seal type) to the
torque below.
a Apply the following torque when the threads are coated (wet) with engine oil.
Tightening torque Nm {kgm} Taper seal Face seal

Nominal Width Nominal No. -
Thread diame-
No. of across Thread size Number of
Range Target ter (mm) (Ref-
hose flats (mm) threads, type of
erence)
thread
34 – 54 { 3.5 – 5.5} – 9/16-18UN 14.3
02 19 44 { 4.5}
34 – 63 { 3.5 – 6.5} 14 – –
22 54 – 93 { 5.5 – 9.5} 74 { 7.5} – 11/16-16UN 17.5
03
24 59 – 98 { 6.0 – 10.0} 78 { 8.0} 18 – –
04 27 84 – 132 { 8.5 – 13.5} 103 {10.5} 22 13/16-16UN 20.6
05 32 128 – 186 {13.0 – 19.0} 157 {16.0} 24 1-14UNS 25.4
06 36 177 – 245 {18.0 – 25.0} 216 {22.0} 30 1-3/16-12UN 30.2
(10) 41 177 – 245 {18.0 – 25.0} 216 {22.0} 33 – –
(12) 46 197 – 294 {20.0 – 30.0} 245 {25.0} 36 – –
(14) 55 246 – 343 {25.0 – 35.0} 294 {30.0} 42 – –
6. Table of tightening torques for 102, 107 and 114 engine series (Bolts and nuts)
a Unless there are special instructions, tighten the metric bolts and nuts of the 102, 107 and 114
engine series to the torque below.
Tightening torque
Thread size
Bolts and nuts
mm Nm kgm
6 10 ± 2 1.02 ± 0.20
8 24 ± 4 2.45 ± 0.41
10 43 ± 6 4.38 ± 0.61
12 77 ± 12 7.85 ± 1.22
14 — —
7. Table of tightening torques for 102, 107 and 114 engine series (Eye joints)
a Unless there are special instructions, tighten the metric eye joints of the 102, 107 and 114 engine
series to the torque below.
Thread size Tightening torque

mm Nm kgm
6 8±2 0.81 ± 0.20
8 10 ± 2 1.02 ± 0.20
10 12 ± 2 1.22 ± 0.20
12 24 ± 4 2.45 ± 0.41
14 36 ± 5 3.67 ± 0.51
34 D61EX, PX-15E0
8. Table of tightening torques for 102, 107 and 114 engine series (Taper screws)
a Unless there are special instructions, tighten the taper screws (unit: inch) of the 102, 107 and 114
engine series to the torque below.
Thread size Tightening torque

inch Nm kgm
1/16 3±1 0.31 ± 0.10
1/8 8±2 0.81 ± 0.20
1/4 12 ± 2 1.22 ± 0.20
3/8 15 ± 2 1.53 ± 0.20
1/2 24 ± 4 2.45 ± 0.41
3/4 36 ± 5 3.67 ± 0.51
1 60 ± 9 6.12 ± 0.92
D61EX, PX-15E0 35
Conversion table 1
Method of using the conversion table
The conversion table in this section is provided to enable simple conversion of figures. For details of the
method of using the conversion table, see the example given below.
Example: Method of using the conversion table to convert from millimeters to inches
1. Convert 55 mm into inches.

1) Locate the number 50 in the vertical column at the left side, take this as (A), and then draw a hori-
zontal line from (A).
2) Locate the number 5 in the row across the top, take this as (B), then draw a perpendicular line down
from (B).
3) Take the point where the 2 lines cross as (C). This point (C) gives the value when converting from
millimeters to inches. Therefore, 55 mm = 2.165 inches.
2. Convert 550 mm into inches.

1) The number 550 does not appear in the table, so divide it by 10 (move the decimal point one place
to the left) to convert it to 55 mm.
2) Carry out the same procedure as above to convert 55 mm to 2.165 inches.
3) The original value (550 mm) was divided by 10, so multiply 2.165 inches by 10 (move the decimal
point one place to the right) to return to the original value. This gives 550 mm = 21.65 inches.
Millimeters to inches (B)

1 mm = 0.03937 in
0 1 2 3 4 5 6 7 8 9
0 0 0.039 0.079 0.118 0.157 0.197 0.236 0.276 0.315 0.354
10 0.394 0.433 0.472 0.512 0.551 0.591 0.630 0.669 0.709 0.748
20 0.787 0.827 0.866 0.906 0.945 0.984 1.024 1.063 1.102 1.142
30 1.181 1.220 1.260 1.299 1.339 1.378 1.417 1.457 1.496 1.536
40 1.575 1.614 1.654 1.693 1.732 1.772 1.811 1.850 1.890 1.929
(C)
50 1.969 2.008 2.047 2.087 2.126 2.165 2.205 2.244 2.283 2.323
(A)
60 2.362 2.402 2.441 2.480 2.520 2.559 2.598 2.638 2.677 2.717
70 2.756 2.795 2.835 2.874 2.913 2.953 2.992 3.032 3.071 3.110
80 3.150 3.189 3.228 3.268 3.307 3.346 3.386 3.425 3.465 3.504
90 3.543 3.583 3.622 3.661 3.701 3.740 3.780 3.819 3.858 3.898
36 D61EX, PX-15E0
Millimeters to inches
1 mm = 0.03937 in
0 1 2 3 4 5 6 7 8 9
0 0 0.039 0.079 0.118 0.157 0.197 0.236 0.276 0.315 0.354
10 0.394 0.433 0.472 0.512 0.551 0.591 0.630 0.669 0.709 0.748
20 0.787 0.827 0.866 0.906 0.945 0.984 1.024 1.063 1.102 1.142
30 1.181 1.220 1.260 1.299 1.339 1.378 1.417 1.457 1.496 1.536
40 1.575 1.614 1.654 1.693 1.732 1.772 1.811 1.850 1.890 1.929
50 1.969 2.008 2.047 2.087 2.126 2.165 2.205 2.244 2.283 2.323
60 2.362 2.402 2.441 2.480 2.520 2.559 2.598 2.638 2.677 2.717
70 2.756 2.795 2.835 2.874 2.913 2.953 2.992 3.032 3.071 3.110
80 3.150 3.189 3.228 3.268 3.307 3.346 3.386 3.425 3.465 3.504
90 3.543 3.583 3.622 3.661 3.701 3.740 3.780 3.819 3.858 3.898
Kilogram to pound
1 kg = 2.2046 lb
0 1 2 3 4 5 6 7 8 9
0 0 2.20 4.41 6.61 8.82 11.02 13.23 15.43 17.64 19.84
10 22.05 24.25 26.46 28.66 30.86 33.07 35.27 37.48 39.68 41.89
20 44.09 46.30 48.50 50.71 51.91 55.12 57.32 59.53 61.73 63.93
30 66.14 68.34 70.55 72.75 74.96 77.16 79.37 81.57 83.78 85.98
40 88.18 90.39 92.59 94.80 97.00 99.21 101.41 103.62 105.82 108.03
50 110.23 112.44 114.64 116.85 119.05 121.25 123.46 125.66 127.87 130.07
60 132.28 134.48 136.69 138.89 141.10 143.30 145.51 147.71 149.91 152.12
70 154.32 156.53 158.73 160.94 163.14 165.35 167.55 169.76 171.96 174.17
80 176.37 178.57 180.78 182.98 185.19 187.39 189.60 191.80 194.01 196.21
90 198.42 200.62 202.83 205.03 207.24 209.44 211.64 213.85 216.05 218.26
Liters to U.S. Gallons

1 l = 0.2642 U.S.Gal
0 1 2 3 4 5 6 7 8 9
0 0 0.264 0.528 0.793 1.057 1.321 1.585 1.849 2.113 2.378
10 2.642 2.906 3.170 3.434 3.698 3.963 4.227 4.491 4.755 5.019
20 5.283 5.548 5.812 6.076 6.340 6.604 6.869 7.133 7.397 7.661
30 7.925 8.189 8.454 8.718 8.982 9.246 9.510 9.774 10.039 10.303
40 10.567 10.831 11.095 11.359 11.624 11.888 12.152 12.416 12.680 12.944
50 13.209 13.473 13.737 14.001 14.265 14.529 14.795 15.058 15.322 15.586
60 15.850 16.115 16.379 16.643 16.907 17.171 17.435 17.700 17.964 18.228
70 18.492 18.756 19.020 19.285 19.549 19.813 20.077 20.341 20.605 20.870
80 21.134 21.398 21.662 21.926 22.190 22.455 22.719 22.983 23.247 23.511
90 23.775 24.040 24.304 24.568 24.832 25.096 25.361 25.625 25.889 26.153
D61EX, PX-15E0 37
Liters to U.K. Gallons

1 l = 0.21997 U.K.Gal
0 1 2 3 4 5 6 7 8 9
0 0 0.220 0.440 0.660 0.880 1.100 1.320 1.540 1.760 1.980
10 2.200 2.420 2.640 2.860 3.080 3.300 3.520 3.740 3.950 4.179
20 4.399 4.619 4.839 5.059 5.279 5.499 5.719 5.939 6.159 6.379
30 6.599 6.819 7.039 7.259 7.479 7.699 7.919 8.139 8.359 8.579
40 8.799 9.019 9.239 9.459 9.679 9.899 10.119 10.339 10.559 10.778
50 10.998 11.281 11.438 11.658 11.878 12.098 12.318 12.528 12.758 12.978
60 13.198 13.418 13.638 13.858 14.078 14.298 14.518 14.738 14.958 15.178
70 15.398 15.618 15.838 16.058 16.278 16.498 16.718 16.938 17.158 17.378
80 17.598 17.818 18.037 18.257 18.477 18.697 18.917 19.137 19.357 19.577
90 19.797 20.017 20.237 20.457 20.677 20.897 21.117 21.337 21.557 21.777
kgm to ft.lb
1 kgm = 7.233 ft.lb
0 1 2 3 4 5 6 7 8 9
0 0 7.2 14.5 21.7 28.9 36.2 43.4 50.6 57.9 65.1
10 72.3 79.6 86.8 94.0 101.3 108.5 115.7 123.0 130.2 137.4
20 144.7 151.9 159.1 166.4 173.6 180.8 188.1 195.3 202.5 209.8
30 217.0 224.2 231.5 238.7 245.9 253.2 260.4 267.6 274.9 282.1
40 289.3 296.6 303.8 311.0 318.3 325.5 332.7 340.0 347.2 354.4
50 361.7 368.9 376.1 383.4 390.6 397.8 405.1 412.3 419.5 426.8
60 434.0 441.2 448.5 455.7 462.9 470.2 477.4 484.6 491.8 499.1
70 506.3 513.5 520.8 528.0 535.2 542.5 549.7 556.9 564.2 571.4
80 578.6 585.9 593.1 600.3 607.6 614.8 622.0 629.3 636.5 643.7
90 651.0 658.2 665.4 672.7 679.9 687.1 694.4 701.6 708.8 716.1
100 723.3 730.5 737.8 745.0 752.2 759.5 766.7 773.9 781.2 788.4
110 795.6 802.9 810.1 817.3 824.6 831.8 839.0 846.3 853.5 860.7
120 868.0 875.2 882.4 889.7 896.9 904.1 911.4 918.6 925.8 933.1
130 940.3 947.5 954.8 962.0 969.2 976.5 983.7 990.9 998.2 1005.4
140 1012.6 1019.9 1027.1 1034.3 1041.5 1048.8 1056.0 1063.2 1070.5 1077.7
150 1084.9 1092.2 1099.4 1106.6 1113.9 1121.1 1128.3 1135.6 1142.8 1150.0
160 1157.3 1164.5 1171.7 1179.0 1186.2 1193.4 1200.7 1207.9 1215.1 1222.4
170 1129.6 1236.8 1244.1 1251.3 1258.5 1265.8 1273.0 1280.1 1287.5 1294.7
180 1301.9 1309.2 1316.4 1323.6 1330.9 1338.1 1345.3 1352.6 1359.8 1367.0
190 1374.3 1381.5 1388.7 1396.0 1403.2 1410.4 1417.7 1424.9 1432.1 1439.4
38 D61EX, PX-15E0
kg/cm2 to lb/in2
1 kg/cm2 = 14.2233 lb/in2
0 1 2 3 4 5 6 7 8 9
0 0 14.2 28.4 42.7 56.9 71.1 85.3 99.6 113.8 128.0
10 142.2 156.5 170.7 184.9 199.1 213.4 227.6 241.8 256.0 270.2
20 284.5 298.7 312.9 327.1 341.4 355.6 369.8 384.0 398.3 412.5
30 426.7 440.9 455.1 469.4 483.6 497.8 512.0 526.3 540.5 554.7
40 568.9 583.2 597.4 611.6 625.8 640.1 654.3 668.5 682.7 696.9
50 711.2 725.4 739.6 753.8 768.1 782.3 796.5 810.7 825.0 839.2
60 853.4 867.6 881.8 896.1 910.3 924.5 938.7 953.0 967.2 981.4
70 995.6 1,010 1,024 1,038 1,053 1,067 1,081 1,095 1,109 1,124
80 1,138 1,152 1,166 1,181 1,195 1,209 1,223 1,237 1,252 1,266
90 1,280 1,294 1,309 1,323 1,337 1,351 1,365 1,380 1,394 1,408
100 1,422 1,437 1,451 1,465 1,479 1,493 1,508 1,522 1,536 1,550
110 1,565 1,579 1,593 1,607 1,621 1,636 1,650 1,664 1,678 1,693
120 1,707 1,721 1,735 1,749 1,764 1,778 1,792 1,806 1,821 1,835
130 1,849 1,863 1,877 1,892 1,906 1,920 1,934 1,949 1,963 1,977
140 1,991 2,005 2,020 2,034 2,048 2,062 2,077 2,091 2,105 2,119
150 2,134 2,148 2,162 2,176 2,190 2,205 2,219 2,233 2,247 2,262
160 2,276 2,290 2,304 2,318 2,333 2,347 2,361 2,375 2,389 2,404
170 2,418 2,432 2,446 2,460 2,475 2,489 2,503 2,518 2,532 2,546
180 2,560 2,574 2,589 2,603 2,617 2,631 2,646 2,660 2,674 2,688
190 2,702 2,717 2,731 2,745 2,759 2,773 2,788 2,802 2,816 2,830
200 2,845 2,859 2,873 2,887 2,901 2,916 2,930 2,944 2,958 2,973
210 2,987 3,001 3,015 3,030 3,044 3,058 3,072 3,086 3,101 3,115
220 3,129 3,143 3,158 3,172 3,186 3,200 3,214 3,229 3,243 3,257
230 3,271 3,286 3,300 3,314 3,328 3,343 3,357 3,371 3,385 3,399
240 3,414 3,428 3,442 3,456 3,470 3,485 3,499 3,513 3,527 3,542
D61EX, PX-15E0 39
Temperature
Fahrenheit-Centigrade conversion: A simple way to convert a Fahrenheit temperature reading into a Centi-
grade temperature reading or vice versa is to enter the accompanying table in the center (boldface column)
of figures. These figures refer to the temperature in either Fahrenheit or Centigrade degrees.
When convert from Fahrenheit to Centigrade degrees, consider the center column to be a table of Fahren-
heit temperatures and read the corresponding Centigrade temperature in the column at the left.
When convert from Centigrade to Fahrenheit degrees, consider the center column to be a table of Centi-
grade values, and read the corresponding Fahrenheit temperature on the right.
1°C = 33.8°F
°C °F °C °F °C °F °C °F
–40.4 –40 –40.0 –11.7 11 51.8 7.8 46 114.8 27.2 81 177.8
–37.2 –35 –31.0 –11.1 12 53.6 8.3 47 116.6 27.8 82 179.6
–34.4 –30 –22.0 –10.6 13 55.4 8.9 48 118.4 28.3 83 181.4
–31.7 –25 –13.0 –10.0 14 57.2 9.4 49 120.2 28.9 84 183.2
–28.9 –20 –4.0 –9.4 15 59.0 10.0 50 122.0 29.4 85 185.0
–28.3 –19 –2.2 –8.9 16 60.8 10.6 51 123.8 30.0 86 186.8

–27.8 –18 –0.4 –8.3 17 62.6 11.1 52 125.6 30.6 87 188.6
–27.2 –17 1.4 –7.8 18 64.4 11.7 53 127.4 31.1 88 190.4
–26.7 –16 3.2 –7.2 19 66.2 12.2 54 129.2 31.7 89 192.2
–26.1 –15 5.0 –6.7 20 68.0 12.8 55 131.0 32.2 90 194.0
–25.6 –14 6.8 –6.1 21 69.8 13.3 56 132.8 32.8 91 195.8

–25.0 –13 8.6 –5.6 22 71.6 13.9 57 134.6 33.3 92 197.6
–24.4 –12 10.4 –5.0 23 73.4 14.4 58 136.4 33.9 93 199.4
–23.9 –11 12.2 –4.4 24 75.2 15.0 59 138.2 34.4 94 201.2
–23.3 –10 14.0 –3.9 25 77.0 15.6 60 140.0 35.0 95 203.0
–22.8 –9 15.8 –3.3 26 78.8 16.1 61 141.8 35.6 96 204.8

–22.2 –8 17.6 –2.8 27 80.6 16.7 62 143.6 36.1 97 206.6
–21.7 –7 19.4 –2.2 28 82.4 17.2 63 145.4 36.7 98 208.4
–21.1 –6 21.2 –1.7 29 84.2 17.8 64 147.2 37.2 99 210.2
–20.6 –5 23.0 –1.1 30 86.0 18.3 65 149.0 37.8 100 212.0
–20.0 –4 24.8 –0.6 31 87.8 18.9 66 150.8 40.6 105 221.0

–19.4 –3 26.6 0 32 89.6 19.4 67 152.6 43.3 110 230.0
–18.9 –2 28.4 0.6 33 91.4 20.0 68 154.4 46.1 115 239.0
–18.3 –1 30.2 1.1 34 93.2 20.6 69 156.2 48.9 120 248.0
–17.8 0 32.0 1.7 35 95.0 21.1 70 158.0 51.7 125 257.0
–17.2 1 33.8 2.2 36 96.8 21.7 71 159.8 54.4 130 266.0

–16.7 2 35.6 2.8 37 98.6 22.2 72 161.6 57.2 135 275.0
–16.1 3 37.4 3.3 38 100.4 22.8 73 163.4 60.0 140 284.0
–15.6 4 39.2 3.9 39 102.2 23.3 74 165.2 62.7 145 293.0
–15.0 5 41.0 4.4 40 104.0 23.9 75 167.0 65.6 150 302.0
–14.4 6 42.8 5.0 41 105.8 24.4 76 168.8 68.3 155 311.0

–13.9 7 44.6 5.6 42 107.6 25.0 77 170.6 71.1 160 320.0
–13.3 8 46.4 6.1 43 109.4 25.6 78 172.4 73.9 165 329.0
–12.8 9 48.2 6.7 44 111.2 26.1 79 174.2 76.7 170 338.0
–12.2 10 50.0 7.2 45 113.0 26.7 80 176.0 79.4 175 347.0
40 D61EX, PX-15E0
D61EX, PX-15E0 41
SEN02397-00

© 2006 KOMATSU
All Rights Reserved
42
SEN02398-00
D61EX-15E0
D61PX-15E0
Machine model Serial number

01 Specification 1
Specification and technical data
Specification dimension drawing..................................................................................................................... 2
Specifications .................................................................................................................................................. 3
Weight table .................................................................................................................................................... 8
Table of fuel, coolant and lubricants.............................................................................................................. 10
D61EX, PX-15E0 1
SEN02398-00 01 Specification
Specification dimension drawing 1

D61EX/PX-15E0 Power angle, power tilt dozer with ROPS guard, cab, and air conditioner
D61EX-15E0 D61PX-15E0
Item Unit
PAT dozer PAT dozer
Machine weight kg 17,050 19,050
Engine name — Komatsu SAA6D107E-1 diesel engine
Engine rated output
• Net [ISO 9249/SAE J1349] (*1) kW {HP}/rpm 125 {168}/1,850
• Gross [SAE J1955] (*2) 127 {170}/1,850
A Overall length mm 5,030 5,465
B Overall height (excluding antenna) mm 3,150 3,180
C Overall width mm 3,275 3,860
Travel speed Forward km/h 3.2/5.6/8.7
(1st/2nd/3rd) Reverse km/h 4.3/7.2/11.3
*1: Indicates the value at the minimum speed of cooling fan.

*2: Indicates the value of the engine alone (without cooling fan).
a The engine rated output is indicated in the net value and gross value. Gross denotes the rated output
measured of an independent engine. While, net denotes the value measured of an engine under the
conditions that are essentially the same as that it will be exposed on a machine.
a Following shows the rated output (net) at the maximum cooling fan speed.
116 kW {155 HP} /1,850 rpm
a PAT: Abbreviation for Power Angle power Tilt
2 D61EX, PX-15E0
Specifications 1
D61EX-15E0 D61PX-15E0
Machine name and type
PAT dozer PAT dozer
Serial No. B45001 and up B45001 and up
Machine weight
• Tractor unit kg 13,920 15,620
Weight
• With work equipment kg 16,320 18,320

• With work equipment and ROPS
kg 17,050 19,050
cab
Min. turning radius (counter-rota-
m 3.6 3.7
tion)
Gradeability deg. 30 30
Stability (front, rear, left, right) deg. 35 35
Forward (1st/2nd/3rd) km/h 3.2/5.6/8.7 3.2/5.6/8.7
Performance
Speed
Reverse (1st/2nd/3rd) km/h 4.3/7.2/11.0 4.3/7.2/11.0

kPa 44.1 28.4
Ground pressure
Tractor unit
{kg/cm2} {0.45} {0.29}
kPa 51.0 33.3
With work equipment
{kg/cm2} {0.52} {0.34}
With work equipment and kPa 52.9 34.3
ROPS cab {kg/cm2} {0.54} {0.35}
Tractor unit mm 3,920 4,210
Overall Overall
With work equipment mm 5,030 5,465

Tractor unit mm 2,500 3,000
With work equipment mm 3,275 3,860
Up to exhaust pipe mm 2,945 2,970
Overall height
Dimensions
Up to top of operator’s seat mm 2,270 2,300

When ROPS cab is installed
mm 3,150 3,180
(excluding antenna)
When ROPS canopy is
mm 3,150 3,180
installed
Track gauge mm 1,900 2,140
Length of track on ground mm 2,600 3,170
Track width (standard track shoe) mm 600 860
Minimum ground clearance mm 395 475
D61EX, PX-15E0 3
D61EX-15E0 D61PX-15E0
PAT dozer PAT dozer
Name SAA6D107E-1
4-cycle, water-cooled in-line, direct injection with
Type
turbocharger and air-cooled aftercooler
Number of cylinders – Bore x
mm 6 – 107 x 124
Stroke
Total displacement l {cc} 6.69 {6,690}
kW/rpm
Rated output 125/1,850 {170/1,850}
{HP/rpm}
Nm/rpm
Max. torque 893/1,350 {91/1,350}
{kgm/rpm}
Performance
Engine
High idling speed under no

rpm 2,000 ± 50
load
Low idling speed under no
rpm 915 ± 50
load
g/kWh
Min. fuel consumption ratio 223 {164}
{g/HPh}
Starting motor 24 V, 5.5 kW
Alternator 24 V, 60 A
Battery (*1) 12 V, 140 Ah, 2 pieces (195G51)
Type of radiator core Corrugated aluminum
Torque converter 3-element, 1-stage, 1-phase type
Planetary gear, multi-disc clutch, hydraulic, forced lubrication with
Transmission gear pump, 3-forward gear speed, 3-reverse gear speed,
manual electronic type
Power train
Bevel gear shaft Spiral bevel gear, forced lubrication with gear pump type
Differential planetary gear, hydraulic motor drive,
HSS
HSS unit
manual electronic, hydraulic type

Wet multi-disc, spring pressure,
Brake
foot-drive, hydraulic type
Final drive Double reduction spur gear, splash lubrication type
Type of suspension Semi-rigid, equalizer beam type
Carrier roller 2 pieces on each side
Undercarriage
Track roller 7 pieces on each side 8 pieces on each side

Track shoe
Width: 600 mm Width: 860 mm
• Assembly-type single grouser 40 pieces on each side 46 pieces on each side
Pitch: 190 mm Pitch: 190 mm

*1: The battery capacity (Ah) is on 5-hours rate.
4 D61EX, PX-15E0
D61EX-15E0 D61PX-15E0
PAT dozer PAT dozer
HSS pump
Variable-displacement swash plate piston type,
Type
load sensing type
Theoretical capacity cm3/rev 95
Cooling fan pump
Hydraulic pump
Type Variable-displacement swash plate piston type

Theoretical capacity 3
cm /rev 30
Power train and lubrication oil
pump
Type Fixed-displacement external gear pump (tandem)
Theoretical capacity cm3/rev 40.2 x 2
Scavenging pump
Hydraulic system
Type Fixed-displacement external gear pump

Theoretical capacity 3
cm /rev 61.2
HSS motor
Hydraulic motor
Type Fixed-displacement swash plate piston type with brake valve

Motor capacity 3
cm /rev 80
Cooling fan motor
Type Fixed-displacement swash plate piston type
Motor capacity 3
cm /rev 28
3+1-spool type, 1 unit 3+1-spool type, 1 unit
Control valve
(PAT dozer) (PAT dozer, PT dozer)

Type and quantity
4+1-spool type, 1 unit —
(PAT dozer + Ripper)
Control method Hydraulic assist type Hydraulic assist type
Hydraulic tank Box type (external control valve type)
Hydraulic oil filter Return-to-tank side
Oil cooler Corrugated aluminum

a PT: Abbreviation for Power Tilt
D61EX, PX-15E0 5
Machine name and type D61EX-15E0 D61PX-15E0

Type Double acting piston
Cylinder bore mm 110
Lift cylinder
Piston rod diameter mm 55

Stroke mm 469
Max. distance between pins mm 1,322
Min. distance between pins mm 853
Tilt cylinder
PAT dozer

Stroke mm 190
Min. distance between pins mm 1,036
Angle cylinder

Work equipment hydraulic system

Stroke mm 469
Min. distance between pins mm 883
Type — Double acting piston
Cylinder bore mm — 110
Lift cylinder
Piston rod diameter mm — 55

Stroke mm — 469
Max. distance between pins mm — 1,322
PT dozer
Min. distance between pins mm — 853

Type — Double acting piston
Cylinder bore mm — 140
Tilt cylinder
Piston rod diameter mm — 70

Stroke mm — 143
Max. distance between pins mm — 1,027
Min. distance between pins mm — 884
Type Double acting piston —
Ripper cylinder
Cylinder bore mm 140 —

Piston rod diameter mm 70 —
Stroke mm 330 —
Max. distance between pins mm 1,080 —
Min. distance between pins mm 750 —

6 D61EX, PX-15E0

Type Hydraulic angle tilt dozer
Blade supporting method Right and left: Angle cylinder type
Max. lift (above ground) mm 980 1,110
Dimensions Performance
PAT dozer
Max. drop (below ground) mm 465 495

Max. tilting distance mm 510 600
Blade width mm 3,275 3,860
Blade height mm 1,200 1,160
Work equipment
Blade angle deg. 57 57

Type — Hydraulic angle tilt dozer
Left: Brace type /
Blade supporting method —
Right: Angle cylinder type
Max. lift (above ground) mm — 1,210
Dimensions Performance
PT dozer
Max. drop (below ground) mm — 425

Max. tilting distance mm — 600
Blade angle range deg. — ±7
Blade width mm — 3,600
Blade height mm — 1,070
Blade angle deg. — 57
Type Parallelogram —
Beam length mm 2,170 —
Number of shanks Piece 3 —
Ripper
Digging angle (a/b) deg. 55/45 —

Performance
Digging depth Changeable to 3 levels —

Max. digging depth mm 665 —
Max. lift mm 565 —
Shank position (left/right) mm 950/950 —

D61EX, PX-15E0 7
Weight table 1
k This weight table is prepared for handling and transporting of components.
Unit: kg
Engine and damper assembly (excluding coolant and oil) 743 743
• Engine assembly 700 700
• Damper assembly 35 35
• Parts related to engine (wiring) 8 8
Universal joint 13 13
Cooling assembly (excluding coolant and oil) 110 110
• Radiator assembly (including power train oil cooler) 26 26
• Aftercooler assembly 18 18
• Hydraulic oil cooler 3 3
Cooling fan pump 28 28
Cooling fan motor 13 13
Fuel tank (excluding fuel) 170 170
Power train unit assembly (excluding oil) 2,105 2,105
• Torque converter and PTO assembly 290 290
• Transmission assembly 340 340
• Transmission ECMV assembly 13 13
• Main relief valve assembly 6 6
• HSS unit assembly 1,380 1,380
• Brake valve assembly 6 6
HSS motor 45 45
HSS pump 65 65
Power train and lubricating oil pump 20 20
Scavenging pump 5 5
Hydraulic tank (excluding oil) 60 60
Control valve
• 3+1-spool valve 52 52
(PAT dozer) — 52
(PT dozer)
• 4+1-spool valve
57 —
(PAT dozer + Ripper)
Final drive assembly (each side) 734 734
Sprocket (each side) 7.4 × 9 7.4 × 9
Frame assembly 1,010 1,010
Engine under guard 45 45
Transmission under guard 22 22

8 D61EX, PX-15E0
Unit: kg
Track group assembly (each side) (PAT dozer) 1,378 1,470
(PT dozer) — 1,520
• Track frame (PAT dozer) 467 518
(PT dozer) — 568
• Idler assembly (each side) 184 184
• Recoil spring assembly (each side) 205 205
• Single flange track roller assembly (each side) 45 × 5 45 × 6
• Double flange track roller assembly (each side) 52 × 2 52 × 2
• Carrier roller assembly (each side) 25 × 2 25 × 2
Track shoe assembly (each side)
• Single grouser shoe (600 mm) 1,245 —
• Swamp shoe (860 mm) — 1,570
• Single grouser shoe (860 mm) — 1,785
Pivot shaft (each side) 85 105
Equalizer bar 90 120
Floor frame assembly 300 300
Operator's seat 56 56
Cab assembly 410 410
ROPS guard assembly (for cab) 210 210
ROPS canopy assembly 390 390
PAT dozer assembly 2,300 2,600
• Blade (including center ball) 1,130 1,290
• U-frame 810 960
• Tilt cylinder assembly 75 75
• Angle cylinder assembly 58 × 2 58 × 2
PT dozer assembly — 1,830
• Blade — 1,015
• Straight-frame (each side) — 190
• Tilt cylinder assembly — 65
Lift cylinder assembly (PAT dozer) 48 × 2 48 × 2
(PT dozer) 50 × 2 50 × 2
Ripper assembly 1,530 —
Ripper cylinder assembly 75 —

D61EX, PX-15E0 9
Table of fuel, coolant and lubricants 1

a For details of notes (Notes 1 and 2...) in the table, see Operation and Maintenance Manual.
10 D61EX, PX-15E0
Unit: l
Fuel sulphur content Specified oil level Quantity of replacement oil
Engine oil pan 31 29
Damper case 1.1 1.1
Idler (each of right and left) 0.22 0.22
Hydraulic oil system 95 55
Power train case 100 69
Final drive case
32 28.5
(each of right and left)
Fuel tank 390 —
Cooling system (including sub-tank) 32 —
D61EX, PX-15E0 11
SEN02398-00

© 2006 KOMATSU
All Rights Reserved
12
SEN02473-00
D61EX-15E0
D61PX-15E0

10 Structure, function and

maintenance standard 1
Engine and cooling system
Cooling system ............................................................................................................................................... 2
Cooling fan pump............................................................................................................................................ 4
Cooling fan motor.......................................................................................................................................... 12
D61EX, PX-15E0 1
SEN02473-00 10 Structure, function and maintenance standard
Cooling system 1
2 D61EX, PX-15E0
A: Power train oil cooler inlet

B: Power train oil cooler outlet
C: Hydraulic oil cooler inlet
D: Hydraulic oil cooler outlet
1. Cooling fan motor

2. Radiator
3. Reservoir tank
4. Radiator inlet hose
5. Radiator outlet hose
6. Hydraulic oil cooler
7. Radiator cap
8. Cooling fan
9. Bypass valve
10. Power train oil cooler (built in the radiator lower tank)
11. Drain plug
12. Aftercooler
Specifications
Power train oil Hydraulic oil
Radiator Aftercooler
cooler cooler
Corrugated Corrugated Corrugated
Core type PTO-OL
aluminum aluminum aluminum
Fin pitch (mm) 4.0 — 4.0 4.0
2
Total heat dissipation surface (m ) 52.97 1.722 1.53 16.65
Pressure valve cracking pressure 88.3 ± 14.7
— — —
(kPa {kg/cm2}) {0.9 ± 0.15}
Vacuum valve cracking pressure 0 – 4.9
— — —
(kPa {kg/cm2}) {0 – 0.05}
D61EX, PX-15E0 3
Cooling fan pump 1

Type: LPV30
P1 : Pump discharge T1 : Drain plug

PS : Pump suction PEPC : EPC valve basic pressure input
T0 : Drain PCEPC : EPC output pressure detection plug
4 D61EX, PX-15E0
1. Shaft
2. Oil seal
3. Case
4. Rocker cam
5. Shoe
6. Piston
7. Cylinder block
8. Valve plate
9. Spring
10. Servo piston
D61EX, PX-15E0 5
Function
q The engine speed and torque are transmitted
to the shaft of this pump. Then, this pump con-
verts the speed and torque into oil pressure
and discharges pressurized oil according to
the load.
q It is possible to change the delivery by chang-
ing the swash plate angle.
Structure
q Cylinder block (7) is supported to shaft (1) by
spline (a), and shaft (1) is supported by the
front and rear bearings.
q The tip of piston (6) is a concave ball, and shoe
(5) is caulked to it to form one unit. Piston (6)
and shoe (5) form a spherical bearing.
q Rocker cam (4) has flat surface (A), and shoe
(5) is always pressed against this surface as it
slides in a circle. Rocker cam (4) also slides
around ball (11) using it as fulcrum.
q Piston (6) carries out relative movement in the
axial direction inside each cylinder chamber of
cylinder block (7).
q Cylinder block (7) carries out rotation relative
to valve plate (8) while sealing the pressurized
oil, and this surface ensures that the hydraulic
balance is maintained correctly.
q And oil in each cylinder chamber of cylinder
block (7) is available for suction or discharge
through valve plate (8).
6 D61EX, PX-15E0
Operation
Operation of pump
q Cylinder block (7) rotates together with shaft q When center line (X) of rocker cam (4) is the
(1), and shoe (5) slides on flat surface (A). At same as the axial direction of cylinder block (7)
this point, since rocker cam (4) inclines with [s w a s h p l a te a n g le = 0 ] , t h e d iff e r e n c e
ball (11) as fulcrum, inclination (a) between between volumes (E) and (F) inside cylinder
center line (X) of rocker cam (4) and the axial block (7) is 0, so pump does not suck and dis-
direction of cylinder block (7) changes. (a) is charge, and no pumping is carried out. [The
called swash plate angle. swash plate angle is not set to 0 actually, how-
q With the condition of center line (X) of rocker ever.]
cam (4) has swash plate angle (a) to axial q Swash plate angle (a) and the pump discharge
direction of cylinder block (7), flat surface (A) amount is in relation of proportion.
functions as cam against shoe (5).
q Accordingly, piston (6) slides inside cylinder
block (7) and a difference is made between
volumes (E) and (F) in cylinder block (7). As a
result, each piston (6) sucks and discharges oil
by (F) – (E).
q In other words, cylinder block (7) rotates, and
the volume of chamber (E) becomes smaller,
so pressurized oil is discharged during this
process. At the same time, the volume of
chamber (F) becomes larger and the oil is
sucked in this process. [In the figure, chamber
(F) is at the end of the suction stroke and
chamber (E) is at the end of the discharge
stroke.]
D61EX, PX-15E0 7
Control of delivery
q The delivery (Q) is increased by the increase
of capacity difference of (E) and (F) as swash
plate angle (a) is increased. Swash plate angle
(a) is changed by servo piston (10).
q Servo piston (10) reciprocates straight accord-
ing to the signal pressure of the servo valve.
This straight line motion is transmitted to
rocker cam (4). Then, rocker cam (4) sup-
ported on ball (11) sways around ball (11).
8 D61EX, PX-15E0
Servo valve
P: EPC valve basic pressure

T: Drain
PE: Control piston pressure
PH: Pump discharge pressure
1. Plug
2. Lever
3. Retainer
4. Seat
5. Spool
6. Piston
7. Sleeve
D61EX, PX-15E0 9
A: Drain side
B: Pump discharge pressure input side
C: EPC output pressure received
D: EPC output pressure
10 D61EX, PX-15E0
Function Operation
q The servo valve controls the current input to q The output pressure of EPC valve is applied to
the EPC valve and pump delivery (Q) so that the piston chamber to push piston (6). Piston
they will be related as shown in the diagram. (6) pushes spool (5) until it is balanced with the
spring.
q Then, land (PE) of the servo piston pressure
passage is connected to the pump discharge
passages by the notch of spool (5) and the dis-
charge pressure is led to the servo piston.
q The servo piston is raised by the rocker cam.
Then, the position feedback is applied and the
lever moves to compress the spring.
q If spool (5) is pushed back, the pump dis-
charge circuit and the servo piston circuit are
shut off. The pressure in the servo piston
chamber lowers and the rocker cam returns
toward the maximum swash plate angle.
q These processes are repeated until the swash
q The relationship between the input current (i) plate is fixed to a position where the EPC out-
to the EPC valve and output pressure (F) of put is balanced with the spring force.
EPC valve is as follows. q Accordingly, as the EPC output pressure is
heigh te ne d, th e swa sh plate a ngle is
decreased. As the EPC output pressure is low-
ered, the swash plate angle is increased.
D61EX, PX-15E0 11
Cooling fan motor 1

Type: LMF28
P: From self pressure reducing valve Specifications

T: From oil cooler to tank
Type LMF28
TC: To tank
Motor volume (cc/rev) 28
Rated speed (rpm) 1,700
Rated flow rate (l/min) 47.6
Safety valve cracking pressure
24.5 {250}
(MPa {kg/cm 2})
Check valve cracking pressure
0.044 {0.45}
(MPa {kg/cm 2})
12 D61EX, PX-15E0
1. Output shaft 8. Center spring

2. Case 9. Check valve spring
3. Thrust plate 10. Check valve
4. Piston assembly 11. Pilot valve
5. Cylinder block 12. Spool for reversible valve
6. Valve plate 13. Spring for reversible valve
7. End cover 14. Safety valve
Unit: mm
No. Check item Criteria Remedy
Standard size Repair limit
Free length
Installation Installation Installation Replace spring
x outer Free length
9 Check valve spring length load load if damaged or
diameter
deformed.
3.43 N 2.55 N
13.0 x 6.5 7.0 —
{0.35 kg} {0.26 kg}
D61EX, PX-15E0 13
Hydraulic motor unit
Function
q This hydraulic motor is called a swash plate-
type axial piston motor. It converts the energy
of the pressurized oil sent from the hydraulic
pump into rotary motion.
Principle of operation
q The oil sent from the hydraulic pump flows
through valve plate (7) into cylinder block (5).
This oil can flow on only one side of the (Y-Y)
line connecting the top dead center and bottom
dead center of the stroke of piston (4).
q The oil sent to one side of cylinder block (5)
presses piston (4) [2 or 3 pieces], and gener-
ates force (F1) [F1 = P x xD2/4].
q This force is applied to thrust plate (2). Since
thrust plate (2) is fixed to the angle of (a°)
degrees to the output shaft (1), the force is
divided into components (F2) and (F3).
q The radial component (F3) generates torque [T
= F3 x ri] against the (Y-Y) line connecting the
top dead center and bottom dead center.
q The combined force of all torque [T = s (F3 x
ri)] rotates the cylinder block (5) through the
piston.
q Since this cylinder block (5) is splined to the
output shaft, the output shaft revolves to trans-
mit the torque.
14 D61EX, PX-15E0
Suction valve
Function
q If the fan pump stops, the pressurized oil does
not flow into the motor. Since the motor contin-
ues revolution because of the force of inertia,
however, the pressure on the outlet side of the
motor rises.
q When the oil stops flowing in from inlet port (P),
the suction valve sucks in the oil on the outlet
side and supplies it to port (MA) where there is
not sufficient oil to prevent cavitation.
Operation
When starting When stopping
q When the hydraulic oil from the pump is sup- q If the engine is stopped and the input revolu-
plied to port (P) and the pressure on the (MA) tion of the fan pump lowers to 0 rpm, the
side rises and starting torque is generated in hydraulic oil from the pump is not supplied to
the motor, the motor starts revolution. The oil port (P) any more. As the hydraulic oil is not
on the outlet (MB) side of the motor returns supplied to the (MA) side of the motor, the
through port (T) to the tank. motor speed lowers gradually to stop.
q If the motor shaft is revolved by the force of
inertia while the oil flow in the port (P) is reduc-
ing, the oil in port (T) on the outlet side is sent
by suction valve (1) to the (MA) side to prevent
cavitation.
D61EX, PX-15E0 15
Reversible valve
Operation
When the ON-OFF solenoid for the reversible When ON-OFF solenoid for the reversible valve
valve is “demagnetized” is “energized”
q If ON-OFF solenoid (1) for the reversible valve q If ON-OFF solenoid (1) for reversible valve is
is “demagnetized”, the pressurized oil from the “ e ne r g iz e d” , O N- O FF s e lec to r va lve (2 )
pump is blocked by ON-OFF selector valve (2), changes to let the pressurized oil from the
and port (C) opens for the tank circuit. pump flow through port (C) into spool chamber
q Accordingly, reversible valve spool spring (3) is (D).
pushed by reversible valve spool spring (4) to q The pressurized oil in chamber (D) pushes
the right to open motor port (MA) and then the reversible valve spool (3) to the left against
pressurized oil flows in to revolve the motor reversible valve spring (4). As a result, motor
forward (clockwise). port (MB) opens and pressurized oil flows in to
revolve the motor in reverse (counterclock-
wise).
16 D61EX, PX-15E0
Safety valve
Function
q When the engine is started, the pressure in
port (P) of the fan motor is heightened in some
cases.
q Safety valve (1) is installed to protect the fan
system circuit.
Operation
q If the pressure in port (P) exceeds the cracking
pressure of safety valve (1), valve (2) of safety
valve (1) opens to relieve the oil into port (T).
q By this operation, generation of abnormal pres-
sure in port (P) is prevented.
D61EX, PX-15E0 17
SEN02473-00

© 2006 KOMATSU
All Rights Reserved
18
SEN02474-00
D61EX-15E0
D61PX-15E0


Power train, Part 1
Power train ...................................................................................................................................................... 2
Power train ...................................................................................................................................................... 3
HSS system .................................................................................................................................................... 4
General view of the power train unit ............................................................................................................... 6
Power train hydraulic piping drawing .............................................................................................................. 7
Transmission, steering, brake control ............................................................................................................. 8
Damper and universal joint ........................................................................................................................... 10
Torque converter, PTO .................................................................................................................................. 12
Transmission................................................................................................................................................. 18
Transmission ECMV ..................................................................................................................................... 30
Main relief valve and torque converter relief valve........................................................................................ 36
Lubricating oil relief valve.............................................................................................................................. 38
D61EX, PX-15E0 1
Power train 1
Outline
q The power generated by engine (1) has its tor- It is also possible to use the HSS mechanism
sional vibration dampened by damper (2), and to rotate the right and left sides in opposite
then passes through universal joint (3) and is directions to carry out counter-rotation.
transmitted to torque converter (7). q Brake (12) built in HSS unit (10) is used for
q The power from the engine is transmitted braking the machine. Brake (12) is a wet, multi-
through the oil by torque converter (7) to the ple disc clutch and spring boosted type.
transmission input shaft in accordance with the The power from brake (12) is transferred to
change in load. final drive (13).
q Transmission (8) uses a combination of a plan- q Final drive (13) consists of a single-stage spur
etary gear system and hydraulic clutches to gear and a single-stage planetary gear system.
reduce the speed and shift the gears (3 for- It reduces the speed and rotates sprocket (14)
ward gears and 3 reverse gears). It connects 2 to drive track shoe (15) and move the machine.
sets of clutches selected according to the q Cooling fan motor (19) is rotated with the oil
change in load and transmits the power to discharged from cooling fan pump (6) driven
bevel gear (9) from the bevel pinion at the rear by PTO (5).
end of the transmission.
q The power transmitted to HSS unit (10) is
transmitted through the bevel gear shaft to the
HSS.
HSS pump (4) is driven by PTO (5), and output
oil of the HSS pump drives HSS motor (11).
The rotation of the pair of the HSS gears on
the right and left is controlled by HSS motor
(11). The steering direction is controlled by
generating a difference in speed on the right
and left.
2 D61EX, PX-15E0
Power train 1
1. Engine 11. HSS motor

2. Damper 12. Brake
3. Universal joint 13. Final drive
4. HSS pump 14. Sprocket
5. PTO 15. Track shoe
6. Cooling fan pump 16. Power train pump
7. Torque converter 17. Lubrication oil pump
8. Transmission 18. Scavenging pump
9. Bevel gear 19. Cooling fan motor
10. HSS unit
D61EX, PX-15E0 3
HSS system 1
a HSS: Abbreviation for Hydrostatic Steering System
4 D61EX, PX-15E0
1. Steering, directional and gear shift lever Outline

(PCCS lever) q The HSS system consists of control valve (3),
2. Transmission and steering controller HSS pump (5) and HSS motor (7). It turns the
3. Control valve machine continuously without lowering the
4. EPC valve traveling speed by making a difference in
5. HSS pump speed between both tracks.
6. Servo valve q Transmission and steering controller (2) con-
7. HSS motor trols EPC valve (4) of control valve (3) to con-
8. HSS circuit trol the rotating direction and the rotating
9. Engine speed of HSS motor (7) according to the tilting
10. Final drive direction and angle of steering, directional and
11. Sprocket gear shift lever (1).
12. Hydraulic tank HSS motor (7) acts on the planetary gear
mechanism of the bevel gear shaft making a
Input and output signals difference in speed between both sprockets
a. Forward and reverse signals (11) to turn the machine.
b. Steering signal q Transmission and steering controller (2)
c. Engine control information senses the engine speed and the oil pressure
d. Work equipment oil pressure signal at each part, and controls HSS pump (5) and
control valve (3) so that engine (9) will not stall.
D61EX, PX-15E0 5
General view of the power train unit 1
1. HSS pump Outline

2. Cooling fan pump q The power train unit broadly consists of the
3. HSS motor torque converter and PTO (6), transmission
4. Lubrication oil pump (9), and HSS unit (11). Therefore, after the
5. Power train pump power train unit is removed, it can be divided
6. Torque converter and PTO into the torque converter and PTO (6), trans-
7. Main relief valve mission (9), and HSS unit (11).
8. Transmission ECMV q HSS unit (11) consists of the bevel gear unit,
9. Transmission the bevel gear, HSS motor (3), the planetary
10. Brake valve gear mechanism and the brake.
11. HSS unit
12. Scavenging pump
13. Power train oil strainer
6 D61EX, PX-15E0
Power train hydraulic piping drawing 1
A: HSS pump discharge oil pressure pickup port 1. Centralized pressure pickup port
B: Cooling fan pump discharge oil pressure 2. Transmission ECMV
pickup port 3. Power train oil filter
C: Main relief oil pressure pickup port 4. Oil filler tube
D: Torque converter outlet oil pressure pickup port 5. Brake valve
E: Torque converter inlet oil pressure pickup port 6. Power train pump
F: Brake oil pressure pickup port 7. Lubrication pump
8. Main relief valve
9. Scavenging pump
10. Power train oil cooler
D61EX, PX-15E0 7
Transmission, steering, brake control 1

a PCCS: Abbreviation for Palm Command Control System
8 D61EX, PX-15E0
1. Brake pedal
2. Decelerator pedal
3. Decelerator pedal potentiometer
4. Rod
5. Fuel control dial
6. Steering, directional and gear shift lever
(PCCS lever)
7. Brake pedal potentiometer
8. Parking brake lever
9. Cable
10. Transmission and steering controller
11. Neutral safety limit switch
12. Brake valve
13. Transmission ECMV
Outline
q The transmission, steering system, and brake
are controlled with steering, directional and
gear shift lever (6).
q Steering, directional and gear shift lever (6)
sends electric signals to transmission and
steering controller (10). Upon receiving these
electric signals, the transmission and steering
controller sends signals to the EPC valve of
the control valve to change the discharge of
the HSS pump and control the HSS motor.
q Brake pedal (1) operates brake valve (12)
through rod (4) to control the brake.
q Parking brake lever (8) operates brake valve
(12), which is also used as the parking brake,
through cable (9).
q If parking brake lever (8) is not set in the “lock”
position, neutral safety limit switch (11) does
not work, thus the engine does not start.
D61EX, PX-15E0 9
Damper and universal joint 1
10 D61EX, PX-15E0
Unit: mm
Standard size Tolerance Repair limit Repair by hard
Outer diameter of the oil seal
1 –0.000 chrome plating or
contact surface of the coupling 85 84.8
–0.087 replace
Facial and radial runout of Facial runout: Max. 1.0 (at 148.38), radial runout: Max. 1.5
— Adjust
coupling (when damper shaft and transmission input shaft are rotated simultaneously)
2. Breather Outline
3. Oil filler plug q The damper is a wet friction spring type.
4. Inspection plug Stopper angle: 4°
5. Drain plug Stopper torque: 2,670 Nm {272 kgm}
6. Damper case q The damper dampens the torsional vibration
7. Coupling caused by the engine torque fluctuation and
8. Cross pin the impact torque generated when accelerat-
9. Yoke ing suddenly or carrying out heavy-duty opera-
10. Shaft tion mode. In this way it acts to protect the
11. Bearing torque converter, transmission, and other parts
12. Cover of the power train.
13. Hub
14. Friction spring
15. Friction plate
16. Stopper pin
17. Torsion spring
18. Drive plate
D61EX, PX-15E0 11
Torque converter, PTO 1

a PTO: Abbreviation for Power Take Off
12 D61EX, PX-15E0
D61EX, PX-15E0 13
A: From transmission case (to torque converter) Outline

B: To oil cooler q The torque converter is a 3-element, 1-stage,
C: From transmission case (to scavenging pump) and 1-phase type, which is integral with the
D: From transmission case transmission.
(to power train and lubrication pump) q Pump (15) is integrated with coupling (6), input
E: To transmission case (drain) shaft (7), PTO drive gear (8) and drive case
(12), and rotates by the power from the engine.
1. HSS pump mounting port q Turbine (13) is integrated with transmission
2. Power train and lubrication pump mounting input shaft (17), and rotates by the oil from
port pump (15) as medium.
3. Scavenging pump q Stator (14) is integrated with stator shaft (16),
4. PTO lubrication tube and fixed to PTO case (11).
5. Cooling fan pump mounting port q Each pump installed to PTO case is driven with
6. Coupling the power transmitted through PTO drive gear
7. Input shaft (8) to PTO idler gear (10), and pump drive
8. PTO drive gear (number of teeth: 62) gears (18), (19) and (20).
9. PTO idler gear shaft
10. PTO idler gear (number of teeth: 63)
11. PTO case
12. Drive case
13. Turbine
14. Stator
15. Pump
16. Stator shaft
17. Transmission input shaft
18. HSS, work equipment pump and fan pump
drive gear (number of teeth: 53)
19. Power train and lubrication pump drive gear
(number of teeth: 53)
20. Scavenging pump drive gear (number of teeth:
56)
21. Scavenging pump strainer
22. Power train strainer
23. Sleeve
14 D61EX, PX-15E0
D61EX, PX-15E0 15
16 D61EX, PX-15E0
Unit: mm
Outer diameter of the oil seal Standard size Tolerance Repair limit
1 contact surface of input cou- –0.000 Repair by hard
pling 110 φ109.8
–0.087 chrome plating or
Inner diameter of the seal ring +0.035 replace
2 105 φ105.5
contact surface of the retainer +0.000
Backlash between the PTO
3 drive gear and the PTO idler 0.17 – 0.46
gear
4 idler gear and the HSS pump/ 0.16 – 0.42
cooling fan pump drive gear
Replace
5 idler gear and the power train/ 0.16 – 0.42
lubricating oil pump drive gear
6 drive gear and the scavenging 0.17 – 0.46
pump drive gear
Tolerance
Standard size
Shaft Hole
Fitting tolerance of
7 the PTO idler gear Outer –0.000 –0.010
110
and bearing diameter –0.015 –0.035
Inner –0.000 –0.000
60
diameter –0.019 –0.015
Outer
diameter +0.035
(cover +0.000
Fitting tolerance of side) –0.000
120
HSS pump, cooling Outer –0.015
8
fan pump drive gear diameter +0.022
bearing (case –0.013
side)
Inner +0.021 –0.000 —
55
diameter +0.002 –0.015
Outer
diameter +0.035
(cover +0.000
Fit tolerance of power side) –0.000
120
train and lubricating Outer –0.015
9
oil pump drive gear diameter +0.022
bearing. (case –0.013
side)
Inner +0.021 –0.000
55
diameter +0.002 –0.015
Outer –0.000 +0.030
Fitting tolerance of 72
diameter –0.013 +0.000
10 the scavenging pump
drive gear bearing Inner +0.011 –0.000
35
diameter –0.005 –0.010
D61EX, PX-15E0 17
Transmission 1
18 D61EX, PX-15E0
A: 1st clutch oil pressure pickup port

B: 3rd clutch oil pressure pickup port
C: R clutch oil pressure pickup port
D: 2nd clutch oil pressure pickup port
E: F clutch oil pressure pickup port
F: From power train pump (to brake valve)
G: To PTO case (to torque converter)
H: From oil cooler
J: To PTO case (to scavenging pump)
K: From PTO case (Drain)
L: To PTO case
(to power train and lubricating oil pump)
M: From the steering case
N: From transmission ECMV (For R clutch)
P: From transmission ECMV (For 3rd clutch)
R: From transmission ECMV (For 1st clutch)
S: From transmission ECMV (For 2nd clutch)
T: From transmission ECMV (For F clutch)
D61EX, PX-15E0 19
1. Main relief valve 19. Output shaft

2. Transmission ECMV cover (3rd sun gear number of teeth: 17)
3. Transmission case 20. 1st carrier
4. Transmission ECMV 21. Rear housing
5. Lubricating oil relief valve 22. 1st ring gear (number of teeth: 75)
6. Transmission input shaft 23. 2nd, 1st clutch housing
7. R sun gear (number of teeth: 26) 24. 2nd planetary pinion (number of teeth: 21)
8. R planetary pinion (number of teeth: 22) 25. 2nd ring gear (number of internal teeth: 75)
9. R ring gear (number of teeth: 70) 26. 3rd clutch housing
10. Disc 27. 2nd, 3rd carrier
11. Plate 28. F, 3rd clutch housing
12. Piston 29. F sun gear (number of teeth: 29)
13. F planetary pinion (number of teeth: 23) 30. F ring gear (number of internal teeth: 75)
14. 3rd planetary pinion (number of teeth: 30) 31. F carrier
15. 3rd ring gear (number of internal teeth: 76) 32. R, F clutch housing
16. 2nd sun gear (number of teeth: 33) 33. Return spring
17. 1st planetary pinion (number of teeth: 18) 34. R ring gear (hub) (number of internal teeth: 75)
18. 1st sun gear (number of teeth: 39) 35. R carrier
20 D61EX, PX-15E0
Outline
q The transmission consists of planetary gear
systems and disc clutches and has “3 forward
gear speeds and 3 reverse gear speeds”.
q Among the 5 sets of planetary gear system
a nd disc clu tche s of the tran smiss ion , 2
clutches are fixed hydraulically with the ECMV
to select 1 rotating direction and gear speed.
q The transmission transfers the power received
by the transmission input shaft to the output
shaft while changing the gear speed (forward
1st – 3rd or reverse 1st – 3rd) by any combina-
tion of the F, R clutches and 3 speed clutches.
Number of plates and discs used
Number of
Clutch No. Number of discs
plates
R clutch 6 5
F clutch 8 7
3rd clutch 5 4
2nd clutch 5 4
1st clutch 4 3
Gear speeds and operated clutches
Reduction
Gear speed Operated clutches
ratio
Forward 1st
F x 1st 1.948
speed
Forward 2nd
F x 2nd 1.096
speed
Forward 3rd
F x 3rd 0.656
speed
Neutral * —
Reverse 1st
R x 1st 1.462
speed
Reverse 2nd R x 2nd 0.823
Reverse 3rd R x 3rd 0.492
*: The 1st, 2nd, or 3rd clutch is filled with low-pressure
oil.
D61EX, PX-15E0 21
22 D61EX, PX-15E0
Unit: mm
Installation Installation Installation
Free length Free length
1 R clutch spring (5 pcs.) length load load
233.2 N 198 N
69.5 58.7 65.3
{23.8 kg} {20.2 kg}
95.2 N 81 N
2 F clutch spring (5 pcs.) 77.0 63.6 72.4
{9.7 kg} {8.2 kg}
146.0 N 125 N
3 3rd clutch spring (5 pcs.) 59.0 44.1 55.5
{14.9 kg} {12.7 kg}
142.1 N 121 N
4 2nd clutch spring (5 pcs.) 59.0 44.5 55.5
{14.5 kg} {12.3 kg}
144.1 N 123 N
5 1st clutch spring (5 pcs.) 59.0 44.3 55.5
{14.7 kg} {12.5 kg}
Total thickness of R clutch Standard size Tolerance Repair limit
6 assembly consisting of 5 discs
and 6 plates 36.2 ±0.33 32.2
Total thickness of F clutch

7 assembly consisting of 7 discs 49.4 ±0.39 43.8
and 8 plates
Total thickness of the 3rd clutch
and 5 plates
Total thickness of the 2nd clutch
9 assembly consisting of 4 discs 29.6 ±0.30 26.4 Replace
and 5 plates
Total thickness of 1st clutch
and 4 plates
11 Thickness of the clutch disc 3.4 ±0.1 2.6
12 Thickness of the clutch plate 3.2 ±0.1 2.9
Wear of transmis- –0.01
Width 3.0 2.70
13 sion input shaft –0.03
seal ring Thickness 2.3 ±0.10 2.15
Backlash between R, F, 2nd
14 and 1st sun gear and planetary 0.11 – 0.30
pinion
Backlash between 3rd sun gear
15 0.11 – 0.29
and planetary pinion
Backlash between planetary
16 pinion and internal teeth of ring 0.12 – 0.33
gear
Backlash between R carrier and
17 0.14 – 0.44
internal teeth of ring gear
Backlash between F carrier and
18 0.14 – 0.38
internal teeth of ring gear
Backlash between 1st carrier
19 0.14 – 0.39
and internal teeth of ring gear
D61EX, PX-15E0 23
Disc clutch When clutch is “disengaged” (released)

q As the oil from ECMV is stopped, piston (2) is
Structure pushed back rightward by return spring (6).
q The disc clutch consists of piston (2), plates q The friction force between plates (3) and discs
(3), discs (4), pin (5), return spring (6) etc. to fix (4) is released and ring gear (1) is released.
ring gear (1).
q Inside teeth of disc (4) are engaged with out-
side teeth of ring gear (1).
q Plate (3) is assembled to clutch housing (7)
with pin (5).
Oil passage in speed clutch

q When the steering/directional/gear shift lever is
set in the “neutral” position, the 1st, 2nd, or 3rd
speed is selected.
Operation q The piston chamber of the clutch correspond-
When clutch is “engaged” (fixed) ing to the selected gear speed is filled with oil
q The oil sent from the ECMV flows through the by electronically controlling the hydraulic circuit
oil passage in clutch housing (7), is pressure- of each clutch.
fed to the back side of piston (2), and pushes q When the steering/directional/gear shift lever is
piston (2) to the left. shifted from the “neutral” position to the “for-
q Piston (2) contacts plate (3) closely against w ard ” o r “re ve rse” po sition , the pu mp is
disc (4) to stop rotation of disc (4) by use of the required to supply oil of quantity to fill the pis-
friction force generated between them. ton chamber of the F clutch or R clutch.
q Since inside teeth of disc (4) are engaged with q When the gear speed is changed from “for-
outside teeth of ring gear (1), move of ring gear w a rd 1 s t” to “ fo rw a rd 2 n d ”, th e p u mp is
(1) is stopped. required to supply oil of only quantity to fit the
plate and disc of the 2nd clutch together since
the F clutch has been filled with the oil.
q The time lag in the gear shifting operation is
reduced by controlling the oil in the clutch cir-
cuit as explained above.
24 D61EX, PX-15E0
Power transmitting route

Forward 1st speed
q When the transmission is set to the forward 1st q Since 2nd ring gear (15) and 1st carrier (16)
s p e e d , t h e F c lu t c h a n d 1 s t c l u t c h a r e are meshed with each other, the power trans-
engaged. The power transmitted from the mitted to 2nd ring gear (15) is transmitted to
torque converter to input shaft (1) is then trans- 1st planetary pinion (17).
mitted to output shaft (21). q Since 1st ring gear (18) is held by the 1st
q The F clutch is actuated by the oil pressure clutch, the power transmitted to 1st planetary
applied to the F clutch piston, and holds F ring pinion (17) is transmitted through 1st sun gear
gear (4). The 1st clutch is actuated by the oil (20) to output shaft (21).
pressure applied to the 1st clutch piston, and
holds 1st clutch inner drum (18).
q The power from the torque converter is trans-
mitted to F planetary pinion (3) through input
shaft (1) and F sun gear (2).
q Since F ring gear (4) is held by the F clutch,
the power transmitted to F planetary pinion (3)
to rotate F carrier (10) on the inside of F ring
gear (4).
q F carrier (10) and 2nd and 3rd carriers (11) are
connected by a spline, and rotate as one unit.
Accordingly, the rotation of F carrier (10) is
transmitted through 2nd planetary pinion (13)
to 2nd ring gear (15).
D61EX, PX-15E0 25
Forward 2nd speed
q When the transmission is set to the forward q Since 2nd ring gear (15) is fixed by the 2nd
2nd speed, the F clutch and 2nd clutch are clutch, the power transmitted to 2nd planetary
engaged. The power transmitted from the pinion (13) is transmitted through 2nd sun gear
torque converter to input shaft (1) is then trans- (19) to output shaft (21).
mitted to output shaft (21).
q The F clutch is actuated by the oil pressure
applied to the F clutch piston, and holds F ring
gear (4). The 2nd clutch is actuated by the oil
pressure applied to the 2nd clutch piston, and
holds 2nd ring gear (15).
gear (4).
transmitted to 2nd planetary pinion (13).
26 D61EX, PX-15E0
Forward 3rd speed
q When the transmission is set to the forward 3rd q Since 3rd ring gear (14) is held by the 3rd
speed, the F clutch and 3rd clutch are clutch, the power transmitted to 3rd planetary
engaged. The power transmitted from the pinion (12) is transmitted to output shaft (21).
torque converter to input shaft (1) is then trans-
mitted to output shaft (21).
q The F clutch is actuated by the oil pressure
applied to the F clutch piston, and holds F ring
gear (4). The 3rd clutch is actuated by the oil
pressure applied to the 3rd clutch piston, and
holds 3rd ring gear (14).
gear (4).
transmitted to 3rd planetary pinion (12).
D61EX, PX-15E0 27
Reverse 1st speed
q When the transmission is set to the reverse 1st q Since 2nd ring gear (15) and 1st carrier (16)
s p e e d , t h e R c l u t c h a n d 1 s t c lu tc h a r e are meshed with each other, the power trans-
engaged. The power transmitted from the mitted to 2nd ring gear (15) is transmitted to
torque converter to input shaft (1) is then trans- 1st planetary pinion (17).
mitted to output shaft (21). q Since 1st ring gear (18) is held by the 1st
q The R clutch is actuated by the oil pressure clutch, the power transmitted to 1st planetary
applied to the R clutch piston, and holds R ring pinion (17) is transmitted through 1st sun gear
gear (7). The 1st clutch is actuated by the oil (20) to output shaft (21).
pressure applied to the 1st clutch piston, and
holds 1st ring gear (18).
mitted to R planetary pinion (6) through input
shaft (1) and R sun gear (5).
q Since ring gear (7) is meshed with carrier (8)
and held by the R clutch, R planetary pinion (6)
rotates R ring gear (9). The rotation of R ring
gear (9), the direction of which is opposite to
that of input shaft (1), rotates F carrier (10).
transmitted through 2nd planetary pinion (13)
to 2nd ring gear (15).
28 D61EX, PX-15E0
D61EX, PX-15E0 29
Transmission ECMV 1
a ECMV: Abbreviation for Electronic Control Modulation Valve
30 D61EX, PX-15E0
P: From power train pump

PF: F clutch oil pressure pickup port
PR: R clutch oil pressure pickup port
P1: 1st clutch oil pressure pickup port
P2: 2nd clutch oil pressure pickup port
P3: 3rd clutch oil pressure pickup port
CF: To F clutch
CR: To R clutch
C1: To 1st clutch
C2: To 2nd clutch
C3: To 3rd clutch
SDF: F fill switch drain
SDR: R fill switch drain
SD1: 1st fill switch drain
SD2: 2nd fill switch drain
SD3: 3rd fill switch drain
Dr: Drain
1. Fill switch (for 1st clutch)

2. Fill switch (for R clutch)
3. Fill switch (for F clutch)
4. Fill switch (for 3rd clutch)
5. Fill switch (for 2nd clutch)
6. Proportional solenoid (for 3rd clutch)
7. Proportional solenoid (for 1st clutch)
8. Proportional solenoid (for R clutch)
9. Proportional solenoid (for F clutch)
10. Proportional solenoid (for 2nd clutch)
11. Connector for fill switch (for 1st clutch)
12. Connector for fill switch (for R clutch)
13. Connector for fill switch (for F clutch)
14. Connector for fill switch (for 3rd clutch)
15. Connector for fill switch (for 2nd clutch)
16. Connector for proportional solenoid (for 1st clutch)
17. Connector for proportional solenoid (for 3rd clutch)
18. Connector for proportional solenoid (for R clutch)
19. Connector for proportional solenoid (for 2nd clutch)
20. Connector for proportional solenoid (for F clutch)
21. Filter
D61EX, PX-15E0 31
1. Fill switch
2. Valve body (upper)
3. Pressure control valve
4. Valve body (lower)
5. Proportional solenoid
6. Oil pressure detection valve
7. Plug
32 D61EX, PX-15E0
Outline of ECMV ECMV and proportional solenoid

q The ECMV consists of 1 pressure control valve q For each ECMV, 1 proportional solenoid is
and 1 fill switch. installed.
q Pressure control valve The proportional solenoid generates thrust
This valve receives the current sent from the shown below according to the command cur-
transmission controller with a proportional rent from the controller.
solenoid, and then converts it into oil pressure. The thrust generated by the proportional sole-
q Fill switch noid is applied to the pressure control valve
This switch detects that the clutch is filled with spool to generate oil pressure as shown in the
oil and has the following functions. figure below. Accordingly, the thrust is changed
1. Outputs a signal (a fill signal) to the controller by controlling the command current to operate
to notify that filling is completed when the the pressure control valve to control the flow
clutch is filled with oil. and pressure of the oil.
2. Keeps outputting signals (fill signals) to the
controller to notify whether oil pressure is Current – propulsion force characteristics of
applied or not while oil pressure is applied to proportional solenoid
the clutch.
Propulsion force – Hydraulic pressure charac-

teristics of proportional solenoid
Range A: Before shifting gear (When draining)

Range B: During filling
Range C: Pressure regulation ECMV and fill switch
Range D: During filling (During triggering) q For each ECMV, 1 fill switch is installed.
Point E: Start of filling If the clutch is filled with oil, the fill switch is
Point F: Finish of filling turned “ON” by the pressure of the clutch. The
oil pressure is built up according to this signal.
a The logic is so made that the controller will not
recognize completion of filling even if the fill
switch is turned “ON” during triggering (Range
D).
D61EX, PX-15E0 33
Operation of ECMV Before shifting gear (when draining) (Range A

q ECMV is controlled with the command current in chart)
sent from the controller to the proportional
solenoid and the fill switch output signal.
The relationship between the proportional
solenoid command current of ECMV, clutch
input pressure, and fill switch output signal is
shown below.
q Under the condition where any current is not

sent to proportional solenoid (1), pressure con-
trol valve (2) drains the oil from clutch port (A)
through drain port (dr).
Since oil pressure is not applied to pressure
detection valve (3) at this time, fill switch (4) is
Range A: Before shifting gear (When draining) turned “off”.
Range B: During filling
Range C: Pressure regulation
Range D: During filling (During triggering)
Point E: Start of filling
Point F: Finish of filling
a The logic is so made that the controller will not

recognize completion of filling even if the fill
switch is turned “ON” during triggering (Range
D).
34 D61EX, PX-15E0
During filling (Range B in chart) Pressure adjustment (Range C in chart)
q If current is supplied to proportional solenoid q If current is applied to proportional solenoid

(1) with no oil in the clutch, the oil pressure (1), the solenoid generates propulsion force
force balanced with the solenoid force is that is proportionate to the current. The pres-
applied to chamber (B) and pushes pressure sure is adjusted by balancing the propulsion
control valve (2) to the right. As a result, pump force of the solenoid, the propulsion force of
port (P) and clutch port (A) open and oil starts clutch port (A), and reaction force of the pres-
filling the clutch. If the clutch is filled with oil, sure control spring (5).
pressure detection valve (3) is actuated and fill
switch (4) is turned “on”.
D61EX, PX-15E0 35
Main relief valve and torque converter relief valve 1
PP: From pump 1. Body

TC: To torque converter 2. Piston
drT: Drain (Torque converter relief) 3. Torque converter relief valve
dr1: Drain 4. Piston
dr2: Drain 5. Main relief valve
P1: Main relief oil pressure pickup port
P8: Torque converter relief oil pressure pickup port
Unit: mm
Standard Tolerance Standard Clearance
Clearance between the main size Shaft Hole clearance limit
6
relief valve and the valve body –0.035 +0.013 0.035 –
28 0.078
–0.045 +0.000 0.058
Clearance between the torque
–0.035 +0.013 0.035 –
7 converter relief valve and the 22 0.078
–0.045 +0.000 0.058
valve body
Replace
Main relief valve spring Free length Free length
8 length load load
(outside)
480 N 457 N
122 78.0 118.3
{49 kg} {46.6 kg}
367.5 N 349 N
9 Main relief valve spring (inside) 108 78.0 104.8
{37.5 kg} {35.6 kg}
Torque converter relief valve 182.1 N 174 N
10 50 40.5 48.5
spring {18.6 kg} {17.7 kg}
36 D61EX, PX-15E0
Outline Operation of main relief valve

q The oil from the hydraulic pump passes
Torque converter relief valve through the filter and enters port (A) of the
q The torque converter relief valve is keeping the relief valve. It then passes through orifice (a) of
oil pressure of the torque converter inlet circuit spool (6) and enters chamber (B).
below the set pressure to protect the torque When the oil from the pump fills the circuit, the
converter from the abnormal high pressure. oil pressure starts to rise.
Set pressure: 1.00 MPa {10.2 kg/cm2}
(Cracking pressure)
Main relief valve

q The main relief valve is keeping each oil pres-
sure circuit of the transmission and the brake
below the set pressure.
Set pressure: 2.84 MPa {29.0 kg/cm2}
(Engine at rated speed)
Operation
Operation of torque converter relief valve

q The oil relieved by the main relief valve flows q As the oil pressure in the circuit rises, the oil
from port (C) into the torque converter and at entering chamber (B) pushes piston (4). The
the same time, passes through orifice (b) of reaction force compresses valve spring (7) and
spool (2) and enters chamber (D). moves spool (6) to the left to open the circuit
When the circuit leading to the torque con- between port (A) and port (C).
verter becomes filled with oil, the oil pressure Whe n th is happ ens, the o il at port (A) is
starts to rise. relieved to port (C) and flows from port (C) to
the torque converter.
q As the oil pressure going to the torque con- The oil pressure at port (A) at this point is 2.84
verter rises, the oil entering chamber (D) MPa {29.0 kg/cm2} (engine at rated speed).
pushes piston (9). The reaction force com-
presses valve spring (3) and moves spool (2)
to the right to open the circuit between port (C)
and port (E).
W hen this happe ns, the oil at port (C) is
relieved to port (E) and drains to the oil tank.
The oil pressure at port (C) at this point is 1.00
MPa {10.2 kg/cm2} (cracking pressure).
D61EX, PX-15E0 37
Lubricating oil relief valve 1
Unit: mm
1 Lubricating oil relief valve spring length load load Replace
12.0 N 11.4 N
26 23.7 25.2
{1.22 kg} {1.16 kg}
2. Piston Outline
3. Spring q The oil leaving the torque converter passes
4. Forward clutch housing through the oil cooler built in the radiator lower
tank. It then goes through the lubricating oil
A: From oil cooler relief valve and lubricates the transmission and
B: Drain PTO.
C: Drain q The lubricating oil relief valve is installed to the
left side face of the forward clutch housing. It
keeps the lubricating oil pressure below the set
pressure.
Specified value
Normal pressure 0.05 – 0.15
(MPa {kg/cm2}) {0.5 – 1.5}
Cracking pressure 0.29
(MPa {kg/cm2}) {3.0}
38 D61EX, PX-15E0
D61EX, PX-15E0 39
SEN02474-00

© 2006 KOMATSU
All Rights Reserved
40
SEN02475-00
D61EX-15E0
D61PX-15E0


Power train, Part 2
Bevel gear shaft, HSS and brake.................................................................................................................... 2
Brake valve ................................................................................................................................................... 18
Final drive ..................................................................................................................................................... 24
D61EX, PX-15E0 1
Bevel gear shaft, HSS and brake 1

a HSS: Abbreviation for Hydrostatic Steering System
2 D61EX, PX-15E0
D61EX, PX-15E0 3
4 D61EX, PX-15E0
1. Brake valve
2. HSS motor
3. Brake spring (large)
4. Brake spring (small)
5. Hub
6. Cage
7. Piston
8. Cover
9. Plate (4 pieces on each side)
10. Disc (5 pieces on each side)
11. Brake drum
12. Brake hub
13. Gear A (Number of teeth: 37/86)
14. Cage
15. Gear B (Number of teeth: 50)
16. Bevel gear (Number of teeth: 41)
17. Bevel gear shaft
18. Shaft
19. Bearing
20. Gear C (Number of teeth: 50)
21. Planetary pinion (Number of teeth: 26)
22. Ring gear (Number of teeth: 91)
23. Pinion shaft
24. Hub
25. Carrier
26. Gear D shaft
27. Gear D (Number of teeth: 76)
28. HSS motor drive gear (Number of teeth: 39)
29. Bevel pinion (Number of teeth: 25)
30. Cage
D61EX, PX-15E0 5
6 D61EX, PX-15E0
Unit: mm
Standard size Tolerance Repair limit
Replace
Thickness 5.0 ± 0.1 4.7
1 Brake plate
Repair or
Distortion — Max. 0.15 0.3
replace
Thickness 5.2 ± 0.1 4.7 Replace
2 Brake disc Repair or
Distortion — Max. 0.25 0.4
replace
Backlash between gear A and
3 46.0 ± 0.3 43.3
gear B
Backlash between gear A and Standard clearance Clearance limit
4
planetary pinion 0.06 – 0.54 —
Replace
Backlash between gear A and
5 0.14 – 0.35 —
planetary pinion
Backlash between planetary
6 0.15 – 0.38 —
pinion and ring gear
If the starting torque is less than 9.8 Nm {1.0 kgm}, adjust the pre-
Preload on bevel gear shaft
7 load. Adjusting
tapered roller bearing
Starting torque after adjustment: 10.3 – 14.7 Nm {1.05 – 1.50 kgm}
D61EX, PX-15E0 7
8 D61EX, PX-15E0
Unit: mm
Backlash between gear A and Standard clearance Clearance limit
1
gear D 0.09 – 0.54 —
Backlash between gear C and Replace
2 0.13 – 0.42 —
gear D
Backlash between gear D and
3 0.09 – 0.35 —
HSS motor drive gear
Backlash between bevel pinion
4 0.18 – 0.23 — Adjusting
and bevel gear
D61EX, PX-15E0 9
Outline
Bevel gear shaft Brake

q The engine power is transmitted through the q The brake is installed to stop the machine and
torque converter to the transmission. Then, the is connected to brake hub (12).
bevel gear shaft device engages bevel pinion q The brake is a wet-type, multiple disc clutch-
(29) with bevel gear (16) to turn the engine type, spring-boosted brake. It is driven hydrau-
power at right angles into the lateral direction lically by the brake valve operated with brake
and reduce the revolving speed. pedal.
q Bevel pinion (29) and bevel gear (16) of the q The brake is pressure-lubricated with oil sup-
bevel gear shaft device are spiral bevel gears, plied by the lubricating oil pump and scaveng-
which are lubricated with oil splashed by the ing pump. The lubricating oil flows through the
lubricating oil pump and scavenging pump. paths in the steering case, cover (8), cage (6),
q The bevel gear shaft device consists of bevel disc (10), and plate (9).
gear (16) meshed with bevel pinion (29), bevel q While the engine is stopped, the back-pressure
gear shaft (17), bearing (19) to support the of the brake piston lowers and the brake is
bevel gear shaft, and bevel gear shaft cage turned "ON" even if the brake pedal is not
(14). pressed. When the engine is started, however,
the oil pressure in the circuit rises and the
HSS brake is "Released". Use Therefore, the park-
q The HSS consists of the transfer section which ing brake must be kept in the "Lock" position.
sets the rotations of the right and left HSS q The brake consists of brake hub (12) coupled
motors in opposite directions and transmits with carrier (25) and hub (5), disc (10) meshed
them to gear A (13) and the planetary gear with the brake hub, plate (9), the periphery of
section which adjusts the input power of ring which is coupled with brake drum (11) by
gear (22) and gear A (13) and outputs the spline, piston (7) and springs (3) and (4) which
adjusted power to carrier (25). press the discs and plates against each other,
Th e t u rn i n g d i re c t io n o f th e m a ch in e i s and cage (6) and cover (8) which support
changed by stopping and changing the revolu- these parts.
tion of HSS motor (2). Brake drum (11) and cover (8) are fixed to the
q The transfer section employs a helical reduc- steering case.
tion gear unit and is lubricated by splashing the
oil from the scavenging pump and lubrication
pump.
q The planetary gear unit is pressure-lubricated
by oil supplied from the scavenging and oil
lubricating pumps.
q The transfer section consists of HSS motor
drive gear (28) connected to HSS motor (2) by
spline, gear D (27) meshed with the HSS
motor driven gear, gear C (20) meshed with
gear D, gear B (15) coupled with shaft (18),
gear A (13) supported on the bearing of the
bevel gear shaft, gear A (13) meshed with gear
D (27), and the case which support these
parts.
q The planetary gear section consists of gear A
(13), planetary pinion (21), pinion shaft (23),
hub (24) coupled with bevel gear shaft (17)
and ring gear (22) by spline, and carrier (25)
coupled with brake hub (12).
10 D61EX, PX-15E0
HSS operation
When steering system is in “Neutral“ (straight travel)
q While the steering system of the PCCS lever is

in "Neutral", HSS motor (1) is stopped. Accord- Rotation direction of HSS motor
ingly, transfer section and right and left gears A Steering operation
Neutral Turning to right Turning to left
( 2 ) o f t he p lan e ta r y g e ar se c tion d o n ot of PCCS lever
revolve. Direction changing * *
For- Re- For- Re-
q Under this condition, the power from bevel operation of PCCS Any Neu- Neu-
ward verse ward verse
lever tral tral
gear shaft (3) is transmitted through hub (4) to
Revolving direc-
ring gear (5). tion of HSS motor
Stopped Left Left Right Right Right Left
q The power transmitted to ring gear (5) is fur- seen from left of
chassis
ther transmitted through planetary pinion (6)
*: Counter-rotation
and planetary pinion shaft (7) to carrier (8).
q The power transmitted to carrier (8) is further
transmitted through brake hub (9) to hub (10).
q Accordingly, the output speeds on both sides
are the same and the machine travels straight.
D61EX, PX-15E0 11
When machine is steered to "Right" (forward)
*A: Transmission power

*B: HSS motor power q Bevel gear shaft (3) and ring gear (5) con-
*C: Resultant power nected to rotate clockwise as seen from the left
side of the machine.
*1. Transmission output speed q Accordingly, because of the difference in the
*2. HSS motor output speed rotating speed between both planetary gear
*3. Left bevel gear shaft output speed (*1.+ *2.) units, the rotating speed of left carrier (8) is
*4. Right bevel gear shaft output speed (*1.– *2.) higher than when traveling straight forward by
the amount of the power of HSS motor. On the
q While the machine is traveling in forward, with other hand, the rotating speed of right carrier
the PCCS lever in the "Turn to the right" posi- (8) is lower than when traveling straight for-
tion while the machine is traveling forward, ward. As a result, the machine travels forward
from the left side of the chassis you will see the and turns to the right, where the output speed
HSS motor (1) rotate to the left, left gear A (2) is lower.
rotates to the right, and right gear A (2) rotates
to the left, when they are seen from the left
side of the chassis.
12 D61EX, PX-15E0
When machine is steered to "Right" (reverse)
*A: Transmission power q Bevel gear shaft (3) and ring gear (5) con-
*B: HSS motor power nected to rotate counterclockwise as seen
*C: Resultant power from the left side of the machine.
q Accordingly, because of the difference in the
*1. Transmission output speed rotating speed between both planetary gear
*2. HSS motor output speed units, the rotating speed of left carrier (8) is
*3. Left bevel gear shaft output speed (*1.+ *2.) higher than when traveling straight in reverse
*4. Right bevel gear shaft output speed (*1.– *2.) by the amount of the power of HSS motor. On
the other hand, the rotating speed of right car-
q While the machine is traveling in reverse, with rier (8) is lower than when traveling straight in
the PCCS lever in the "Turn to the right" posi- reverse. As a result, the machine travels in
tion while the machine is traveling forward, reverse and turns to the right, where the output
from the left side of the chassis you will see the speed is lower.
HSS motor (1) rotate to the right, left gear A (2)
rotates to the left, and right gear A (2) rotates
to the right, when they are seen from the left
side of the chassis.
D61EX, PX-15E0 13
When machine is steered to "Left" (forward)
*B: HSS motor power nected to rotate clockwise as seen from the left
*C: Resultant power side of the machine.
*2. HSS motor output speed units, the rotating speed of right carrier (8) is
*3. Left bevel gear shaft output speed (*1 – *2) higher than when traveling straight forward by
*4. Right bevel gear shaft output speed (*1.+ *2.) the amount of the power of HSS motor. On the
other hand, the rotating speed of left carrier (8)
q While the machine is traveling forward, with is lower than when traveling straight forward.
the PCCS lever in the "Turn to the left" position As a result, the machine travels forward and
while the machine is traveling forward, from turns to the left, where the output speed is
the left side of the chassis you will see the HSS lower.
motor (1) rotate to the right, left gear A (2)
rotates to the left and right gear A (2) rotates to
the right, when they are seen from the left side
of the chassis.
14 D61EX, PX-15E0
When machine is steered to "Left" (reverse)
*B: HSS motor power nected to rotate counterclockwise as seen
*C: Resultant power from the left side of the machine.
*2. HSS motor output speed units, the rotating speed of right carrier (8) is
*3. Left bevel gear shaft output speed (*1 – *2) higher than when traveling straight in reverse
*4. Right bevel gear shaft output speed (*1.+ *2.) by the amount of the power of HSS motor. On
the other hand, the rotating speed of left carrier
q While the machine is traveling in reverse, with (8) is lower than when traveling straight in
the PCCS lever in the "Turn to the left" posi- reverse. As a result, the machine travels in
tion, from the left side of the chassis you will reverse and turns to the left, where the output
see the HSS motor (1) rotate to the left, left speed is lower.
gear A (2) rotates to the right, and right gear A
(2) rotates to the left, when they are seen from
the left side of the chassis.
D61EX, PX-15E0 15
Brake operation
When brake is "Released" When brake is turned "ON"

(when brake pedal is "Pressed")
q While the brake pedal is released, the brake q If the brake pedal is depressed, the brake
valve is in the "Neutral" position and the back- valve switches and the oil in the back-pressure
pressure port of piston (1) is filled with oil. port of piston (1) is drained.
q As the oil pressure rises, piston (1) com- q As the pressure in the back-pressure port low-
presses sprin gs (2) and (3) to th e left to ers, piston (1) is moved to the right by the ten-
release discs (4) and plates (5). sion of springs (2) and (3) to press discs (4)
q The power transmitted from the bevel gear and plates (5) against brake drum (6). Brake
shaft through the HSS to brake hub (7) is fur- drum (6) is connected and fixed to the steering
ther transmitted through hub (8) to the final case.
drive. q The power to brake hub (7) is restricted by fit-
ting discs (2) and plates (3) together.
q The hydraulic force applied to piston (1), or the
braking force, can be controlled by controlling
the depressing distance of the brake pedal.
16 D61EX, PX-15E0
D61EX, PX-15E0 17
Brake valve 1
P: From power train pump Outline

T1: To steering case q The brake valve is in the circuit between the
T2: To steering case power train pump and the brake piston in the
Br(R): To right brake HSS unit and installed to the top of the HSS
Br(L): To left brake unit.
q If the brake pedal is pressed, main brake valve
1. Parking brake valve (6) operates. If the parking brake lever is set in
2. Body the "Lock" position, the parking brake valve
3. Main brake valve operates.
4. Piston q If each valve operates, the oil supplied to the
5. Shaft back-pressure port of the brake piston is
6. Guide stopped and the brake is turned "ON".
q If the HSS is employed, the brake is only used
to stop the machine (it is not used for steering
operation) and the right and left brakes operate
simultaneously.
18 D61EX, PX-15E0
Unit: mm
Clearance between brake valve size Shaft Hole clearance limit
7
and body –0.020 +0.013 0.020 –
ø19 0.07
–0.030 +0.013 0.043
Clearance between brake valve –0.030 +0.015 0.030 –
8 ø9 0.08
and piston –0.040 +0.013 0.055
Clearance between parking –0.034 +0.013 0.034 –
9 ø19 0.08
brake valve and body –0.043 +0.013 0.056
Standard size Repair limit Replace
Installed Installed Installed
10 Brake modulating spring length load load
75.3 N 71.6 N
48 36 46.6
{7.68 kg} {7.3 kg}
157.9 N 150 N
11 Brake valve return spring 52 38 50.4
{16.11 kg} {15.3 kg}
Parking brake valve return 16.7 N 15.7 N
12 36.5 28.5 35.4
spring {1.7 kg} {1.6 kg}
D61EX, PX-15E0 19
Operation
When brake is "Released"

(brake pedal is released and parking brake lever is set in "Free" position)
q While the brake pedal is released (while it is

not pressed), parking brake valve (1) opens
port (P) and chamber (A) with the tension of
return spring (2).
q Main brake valve (3) opens chamber (B) and
port (Br) with the tension of return spring (4).
q The pressure of the oil from the power train
pump is regulated by the main relief valve, and
then the oil flows through port (P), chambers
(A) and (B), and port (Br) to the back-pressure
port of the brake piston.
q The brake piston moves to the left and com-
presses the brake spring to "Release" the
brake.
q At this time, the oil pressure is settled at 2.84
MPa {29.0 kg/cm2} and can be measured at oil
pressure pickup port (Q).
20 D61EX, PX-15E0
When brake is "Turned ON"

(brake pedal is "Pressed" and parking brake lever is set in "Free" position)
q If the brake pedal is depressed, guide (5) and q The oil pressure after port (Br) is decided by
shaft (6) are pushed to the right. the tension of return spring (4), the load on
q As shaft (6) is pushed, it compresses modulat- which changes accordingly to the stroke of the
ing spring (7) and its reaction force moves brake pedal.
main brake valve (3) to the right. Then, ports q If the brake pedal stroke is short, the oil pres-
(Br) and chamber (B) are closed and ports (Br) sure after port (Br) rises and the brake is
and (T2) are opened. applied "Partially". If the brake pedal stroke is
q The oil from the power train pump flows long, the oil pressure lowers and the brake is
through port (P) into chamber (A), and then it is applied "Fully".
stopped in chamber (B).
q A part of the oil flowing into the back-pressure
port of the brake piston is drained through port
(Br) to port (T2) and the oth er pa rt flows
through orifice (a) to chamber (D).
q If the oil after port (Br) is drained through port
(T2) and the oil pressure lowers, the oil flows in
chamber (D) and presses piston (8). Then, the
force which has pushed main brake valve (3)
to the right is reduced and main brake valve (3)
is moved to the left by the tension of return
spring (4).
q If main brake valve (3) moves to the left, ports
(Br) and (T2) are closed, and then the oil pres-
sure after port (Br) is maintained.
q If the brake pedal is pressed further, the above
operation is repeated. If main brake valve (3) is
moved to the stroke end, the brake is turned
on perfectly.
D61EX, PX-15E0 21
When brake is in "Parking brake" position

(brake pedal is "Released" and parking brake lever is in "Lock" position)
q If the parking brake lever is set in the "Lock"

position, parking brake valve (1) is pulled to the
left. Then, port (P) and chamber (A) are closed
and chambers (A) and (C) are opened.
q The oil from the power train pump is stopped in
port (P).
q The oil flowing in the back-pressure port of the
brake piston is drained through port (Br),
chambers (B), (A), and (C), and port (T1).
q Since parking brake valve (1) is kept pulled to
the left, the oil pressure in the back-pressure
port of the brake piston continues lowering.
Then, brake is kept "Turned ON".
q This condition is maintained even after the
engine is started again.
22 D61EX, PX-15E0
D61EX, PX-15E0 23
Final drive 1
Outline
q The final drive is of spur gear double reduction
type.
q The lubrication is of splash type using the rota-
tion of the gears.
q The final drive can be removed and installed
as a single unit.
q Floating seal (1) is installed to the rotating slid-
ing portion of the sprocket to prevent the entry
of dirt or sand and to prevent leakage of lubri-
cating oil.
24 D61EX, PX-15E0
1. Final drive case 9. Cover

2. Bearing cage 10. Sprocket hub
3. 1st pinion (Number of teeth: 14) 11. Floating seal
4. 1st gear (Number of teeth: 64) 12. Cover
5. Bearing cage 13. Sprocket teeth
6. 2nd gear (Number of teeth: 50) 14. Cover
7. Cover 15. 2nd pinion (Number of teeth: 11)
8. Shaft
D61EX, PX-15E0 25
26 D61EX, PX-15E0
Unit: mm
Backlash between 1st pinion Standard clearance Clearance limit
1
and 1st gear 0.24 – 0.62 1.0
Backlash between send pinion
2 0.28 – 0.68 1.0
and 2nd gear Replace
Standard size Tolerance Repair limit
Outside diameter of oil seal
3 –0.074
contact face of 1st pinion ø62 ø61.9
–0.074
Standard shim thickness of 1st
4 1.52
pinion bearing cage
Standard shim thickness of 2st
5 1.7 Adjusting
pinion bearing cage
Standard shim thickness of
6 1.9
shaft bearing plate
Standard size Repair limit Repair by build-
7 Wear of sprocket tooth surface up welding or
298 280 replace
D61EX, PX-15E0 27
Power train route
q The power from the HSS unit is transmitted to 1st

pinion (1), and then further transmitted to 1st
gear (2).
q The power transmitted to 1st gear (2) is further
transmitted to 2nd pinion (3), and then transmit-
ted through 2nd gear (4) and shaft (5) to sprocket
hub (6).
q The rotation force transmitted sprocket hub (6) is
transmitted to sprocket teeth (7).
28 D61EX, PX-15E0
D61EX, PX-15E0 29
SEN02475-00

© 2006 KOMATSU
All Rights Reserved
30
SEN02476-00
D61EX-15E0
D61PX-15E0


Undercarriage and frame
Main frame ...................................................................................................................................................... 3
Suspension ..................................................................................................................................................... 4
Track frame and idler cushion......................................................................................................................... 8
Idler ............................................................................................................................................................... 12
Track roller .................................................................................................................................................... 14
Carrier roller .................................................................................................................................................. 15
Sprocket ........................................................................................................................................................ 16
Track shoe .................................................................................................................................................... 18
D61EX, PX-15E0 1
2 D61EX, PX-15E0
Main frame 1
1. Frame assembly Outline

2. Undercover q Frame assembly (1) has hull frame structure in
3. Engine mount which the main frame and transmission under
guard are formed in one unit.
D61EX, PX-15E0 3
Suspension 1
a The diagram shows D61EX-15E0.
4 D61EX, PX-15E0
1. Equalizer bar Outline

2. Center pin q The track frame moves the front part of the
3. Side pin track frame up and down around pivot shaft (4)
4. Pivot shaft in its rear.
5. Bushing q Equalizer bar (1) rocks around center pin (2)
6. Seal and is connected to both track frames by side
7. Seal pin (3).
8. Bushing
9. Bushing (large) D61EX- D61PX-
10. Plug (oil filler) 15E0 15E0
11. Bushing (small)
Displacement at Upward 46.1 49.7
12. Cover center of equalizer
13. Seal bar side pin (mm) Downward 46.1 49.7
D61EX, PX-15E0 5
Unit: mm
Clearance between pivot shaft size Shaft Hole clearance limit
14
and bushing (large) –0.145 +0.063 0.145 –
ø123 1.0
–0.208 +0.063 0.271
Clearance between pivot shaft –0.120 +0.054 0.120 – Replace bushing
15 ø85 1.0
and bushing (small) –0.174 +0.063 0.228
Clearance between center pin –0.100 +0.174 0.200 –
16 ø70 0.5
and bushing –0.146 +0.100 0.320
Clearance between side pin –0.100 +0.010 0.080 –
17 ø55 0.5
and bushing –0.146 –0.020 0.156
Press-fitting force of pivot shaft
18 48.0 kN {4.9 ton}
bushing (large)
Press-fitting force of pivot shaft
19 33.3 kN {3.4 ton} —
bushing (small)
Quantity of oil in pivot shaft sec-
— 3.5 l (engine oil: SAE30)
tion
6 D61EX, PX-15E0
D61EX, PX-15E0 7
Track frame and idler cushion 1

D61EX-15E0
1. Idler 11. Recoil spring

2. Carrier roller 12. Wear ring
3. Track frame 13. U-packing
4. Sprocket teeth 14. Cabin
5. Track roller end guard 15. Nut
6. Track roller center guard (if equipped) 16. Lubricator
7. Track roller 17. Cylinder
8. Yoke 18. Bushing
9. Seal 19. Holder
10. Piston
8 D61EX, PX-15E0
Unit: mm
Check item Repair limit
20 Deformation of track frame Bend 7 (in length of 3,000) Repair

Twist 3 (in length of 300)
Opening of idler section 5
Free length Installed Installed Installed
Free length
21 Recoil spring x O.D. length load load Replace
163.6 kN 145.7 kN
755 x ø212 593 736
{16,692 kg} {14.856 kg}
Clearance between piston and size Shaft Hole clearance limit
22 Replace bushing
bushing –0.030 +0.291 0.107 –
ø75 1.0
–0.076 +0.077 0.367
23 Press-fitting force of idler yoke 294 kN {30 ton} Adjusting
— Quantity of grease 140 cc (Grease: G2-LI) —
Outline
q Recoil spring (11) is used to adjust the track
shoe tension by supplying grease through
lubricator (16) or discharge existing grease
and moving piston (10) forward or in reverse. It
also damps sudden shocks applied to idler (1).
Flange type and

Q'ty on each side
arrangement
D61EX-15E0 7 pcs. S, D, S, S, D, S, S
S: Single flange
D: Double flange
D61EX, PX-15E0 9
D61PX-15E0
1. Idler 11. Recoil spring

2. Carrier roller 12. Wear ring
3. Track frame 13. U-packing
4. Sprocket teeth 14. Cabin
5. Track roller end guard 15. Nut
6. Track roller center guard 16. Lubricator
7. Track roller 17. Cylinder
8. Yoke 18. Bushing
9. Seal 19. Holder
10. Piston
10 D61EX, PX-15E0
Unit: mm
Check item Repair limit
20 Deformation of track frame Bend 7 (in length of 3,000) Repair

Twist 3 (in length of 300)
Opening of idler section 5
Free length Installed Installed Installed
Free length
21 Recoil spring x O.D. length load load Replace
163.6 kN 145.7 kN
755 x ø212 593 736
{16,692 kg} {14.856 kg}
Clearance between piston and size Shaft Hole clearance limit
22 Replace bushing
bushing –0.030 +0.291 0.107 –
ø75 1.0
–0.076 +0.077 0.367
23 Press-fitting force of idler yoke 294 kN {30 ton} Adjusting
— Quantity of grease 140 cc (Grease: G2-LI) —
Outline
q Recoil spring (11) is used to adjust the track
shoe tension by supplying grease through
lubricator (16) or discharge existing grease
and moving piston (10) forward or in reverse. It
also damps sudden shocks applied to idler (1).
Flange type and

Q'ty on each side
arrangement
D61PX-15E0 8 pcs. S, S, D, S, S, D, S, S
S: Single flange
D: Double flange
D61EX, PX-15E0 11
Idler 1
12 D61EX, PX-15E0
Unit: mm
1 Outside diameter of projection
ø588 —
2 Outside diameter of tread ø550 530 Repair by build-
3 Depth of tread 19 29 up welding or
4 Thickness of tread 24.4 14.4 replace
5 Width of tread 39.5 43.5

6 Overall width 164 —
Clearance between shaft and size Shaft Hole clearance limit
7
bushing –0.215 +0.195 0.215 –
ø60 —
–0.315 +0.090 0.510
Replace
Clearance between shaft and –0.215 +0.046 0.215 –
8 ø60 —
support –0.315 +0.090 0.361
Standard clearance Clearance limit
9 Axial play of shaft
0.26 – 0.66 —
Repair by build-
Clearance between guide plate
10 2.0 — up welding or
and support
replace
Clearance between guide plate
11 1.0 —
and side plate Adjust shim or
Standard shim thickness at side replace plate
12 4.0
plate fitting part
D61EX, PX-15E0 13
Track roller 1
a The following drawing shows the double-flange type.
Unit: mm
Outside diameter of flange Standard size Repair limit
1
(outside) ø233 —
Outside diameter of flange
2 ø227 —
(inside)
3 Outside diameter of tread ø200 ø164
4 Thickness of tread 66.5 48.5 Repair by build-
5 Width of flange (outside) 19.5 13.5 up welding or
replace
6 Width of flange (inside) 18 12
Width of tread
7 44.5 —
(single flange type)
Width of tread
8 43.5 —
(double flange type)
9 Overall width 212 —
10
bushing –0.244 +0.195 0.244 –
ø60 —
–0.290 +0.090 0.485
Replace
Clearance between shaft and –0.250 –0.160 0.020 –
11 ø59.7 —
collar –0.300 –0.230 0.140
12 Axial play of roller
0.26 – 0.66 —
14 D61EX, PX-15E0
Carrier roller 1
Unit: mm
1 Outside diameter of flange
ø190 —
2 Outside diameter of tread ø165 ø143 Repair by build-
up welding or
3 Thickness of tread 27.5 16.5 replace
4 Width of tread 45.5 51.5
5 Width of flange 17 11
6
support –0.100 +0.300 0.100 –
ø61 —
–0.200 +0.300 0.500
Tolerance Standard
Standard Interfer-
interfer- Replace
Interference between shaft and size Shaft Hole ence limit
7 ence
seal guard
+0.150 +0.030 0.100 –
ø61.5 —
+0.130 +0.300 0.150
8 Axial play of roller
0 – 0.32 —
D61EX, PX-15E0 15
Sprocket 1
Unit: mm
1 Wear of tooth root
77 68 up welding or
2 Thickness of tooth root 29.25 20 replace
16 D61EX, PX-15E0
Full-scale drawing of sprocket tooth profile

a Make a copy on an OHP sheet in the full scale.
D61EX, PX-15E0 17
Track shoe 1
Standard bushing type
*1. Single shoe

*2. Swamp shoe
a Part (P) shows the link on bushing fitting side.
18 D61EX, PX-15E0
Unit: mm
1 Link pitch
190.3 193.3
Reverse Turn over or
Standard size
2 Outside diameter of bushing Light load Heavy load replace
65 54.8 57.4
3 Thickness of bushing 13.2 3.0 5.6
Standard size Repair limit Repair or
4 Height of link
119 109 replace
Thickness of link
5 42.5 31.5 Replace
(bushing fitting part)
a. Tightening torque Retightening
Regular (Nm {kgm}) (deg.)
link 539 ± 49 {55 ± 5} 120 ± 10
6 Shoe bolt Retightening Retighten

Tightening torque Lower limit of torque
angle
b. (Nm {kgm}) (Nm {kgm})
(deg.)
Master link
343 ± 39
180 (0/–20) 784 {80}
{35 ± 4}
Tolerance Standard
Standard size
Interference between bushing Shaft Hole interference
7
and link +0.264 +0.074
ø59 0.160 – 0.264
+0.234 +0.074
Interference between regular +0.372 +0.062 Adjust or
8 ø37.8 0.210 – 0.372
pin and link +0.272 +0.074 replace
Tolerance Standard
Standard size
Interference between regular Shaft Hole clearance
9
pin and bushing +0.172 +0.902
ø38 0.230 – 0.830
+0.072 +0.402
D61EX, PX-15E0 19
Single shoe
Unit: mm
1 Height of grouser
57.5 25 up welding
2 Thickness of grouser 71 38.5 or replace
Swamp shoe
Unit: mm
1 Height of grouser
91 76 up welding
2 Thickness of grouser 20 5 or replace
20 D61EX, PX-15E0
D61EX, PX-15E0 21
SEN02476-00

© 2006 KOMATSU
All Rights Reserved
22
SEN02477-00
D61EX-15E0
D61PX-15E0


Hydraulic system, Part 1
Layout of hydraulic devices for work equipment ............................................................................................. 2
Work equipment control .................................................................................................................................. 4
Hydraulic tank and filter .................................................................................................................................. 6
Scavenging pump ........................................................................................................................................... 8
Power train and steering lubrication pump...................................................................................................... 9
HSS pump..................................................................................................................................................... 10
HSS motor .................................................................................................................................................... 28
D61EX, PX-15E0 1
Layout of hydraulic devices for work equipment 1
2 D61EX, PX-15E0
1. Tilt cylinder
2. Angle cylinder
3. Lift cylinder
4. HSS pump
5. Quick drop valve
6. Cooling fan pump
7. Hydraulic tank
8. Power train and lubricating oil pump
9. Hydraulic oil cooler
10. Radiator
11. Cooling fan motor
12. Blade PPC valve
13. Control valve
14. Power train oil filter
15. HSS motor
16. PPC lock solenoid valve
17. Transmission ECMV
19. Scavenging pump
20. Self pressure reducing valve
21. Aftercoller
22. Power train oil cooler
D61EX, PX-15E0 3
Work equipment control 1
4 D61EX, PX-15E0
1. Work equipment lock lever

2. PPC lock switch
3. Blade PPC valve
4. Blade control lever
5. Ripper control lever (if equipped: D61EX-15E0)
6. Ripper PPC valve (if equipped: D61EX-15E0)
7. PPC lock solenoid valve
Outline
q The work equipment is controlled by the PPC
method. Each spool of the control valve is
moved by operating blade PPC valve (3) with
blade control lever (4) or by operating ripper
PPC valve (6) with ripper control lever (5).
q If work equipment lock lever (1) is set in the
"Lock" position PPC lock switch (2) is turned
"ON" and PPC lock solenoid valve (7) oper-
ates. Then, blade control lever (4) and ripper
control lever (5) can be moved but the work
equipment cannot be operated.
q When blade control lever (4) is in the "Float"
position, the hydraulic detent of blade PPC
valve (3) operates and blade control lever (4)
can hold itself.
If work equipment control lever (1) is set in the
"Lock" position, the hydraulic detent is reset
and blade control lever (4) returns to the "Hold"
position by itself.
q When the engine is stopped, the hydraulic
detent does not operate and blade control
lever (4) returns to the "Hold" position by itself,
even if blade control lever (4) is in the "Float"
position.
D61EX, PX-15E0 5
Hydraulic tank and filter 1
6 D61EX, PX-15E0
1. Oil filler cap

2. Hydraulic tank
3. Strainer
4. Drain plug
5. Element
6. Bypass valve
7. Sight gauge
Specifications
Tank capacity (l) 95
Quantity of oil in tank (l) 55
Set pressure of bypass valve 0.15 ± 0.03
(MPa {kg/cm2}) {1.5 ± 0.3}
Pressure valve cracking
38 ± 14
pressure
{0.39 ± 0.15}
(kPa {kg/cm2})
Actuating pressure of
0 – 4.5
vacuum valve
{0 – 0.046}
(kPa {kg/cm2})
D61EX, PX-15E0 7
Scavenging pump 1
Outline
q The scavenging pump is installed to the bot-
tom of the PTO case and driven with the power
from the engine.
q The scavenging pump draws oil collected in
the transmission case bottom through a
strainer and returns it to the steering case.
Specifications
Type Gear pump
Theoretical capacity (cc/rev) 61.2
Max. discharge pressure
0.29 {3.0}
(MPa {kg/cm2})
Max. revolution speed (rpm) 2,500
8 D61EX, PX-15E0
Power train and steering lubrication pump 1

SAL(2)40+40
1. Power train pump

2. Lubricating pump
Unit: mm
Type Standard clearance Clearance limit
3 Side clearance
SAL (2) 40 0.10 – 0.15 0.19
Clearance between inside of plain
4 SAL (2) 40 0.060 – 0.125 0.20
bearing and outside of gear shaft Replace
Type Standard size Tolerance Repair limit
5 Driving depth of pin –0.5
SAL (2) 40 12 —
–0.5
6 Rotating torque of spline 5.8 – 13.8 Nm {0.6 – 1.4 kgm}
Discharge
Revolution Standard Allowable
pressure
Capacity Type speed capacity capacity
(MPa —
— Oil: SAE10W (rpm) (l/min) (l/min)
{kg/cm2})
Oil temperature: 45 – 55°C
0.29
SAL (2) 40 2,500 90 85
{3.0}
D61EX, PX-15E0 9
HSS pump 1
Model name: HPV95
PA: Pump discharge Outline

PS: Pump suction q This pump consists of variable-displacement
PD1: Pump drain plug swash-plate piston pump and servo valve.
PD2: Pump drain
PLS1: Load pressure input
PEN12: Control pressure pick-up plug Specifications
Type HPV95 (112 cm3/rev)
1. Piston pump Theoretical displacement
112 ± 1
2. Servo valve (cm3/rev)
3. Solenoid valve Rated speed (rpm) 2,280
Max. pressure at cut-off
41.2 {420}
(MPa {kg/cm2})
10 D61EX, PX-15E0
Piston pump
PA: Pump discharge port

PS: Suction opening of pump
PA1: Pump pressure signal port
PD2: Pump drain
PNC1: Control pressure port
D61EX, PX-15E0 11
1. Shaft 8. Piston
2. Case 9. Cylinder block
3. Cradle 10. Valve plate
4. Rocker cam 11. End cap
5. Shoe 12. Impeller
6. Servo piston 13. Spline
7. Rod
12 D61EX, PX-15E0
Function
q The engine rotation and torque transmitted to
the pump shaft is converted to hydraulic
energy and pressurized oil is discharged
accordingly to the load.
q It is possible to change the discharge amount
by changing the swash plate angle.
Structure
q Cylinder block (9) is supported to shaft (1) by a q The cylinder block (9) carries out rotation rela-
spline (13), and shaft (1) is supported by the tive to valve plate (10) while sealing the pres-
front and rear bearings. surized oil, and this surface ensures that the
q The end of piston (8) has a concave ball shape hydraulic balance is maintained correctly. The
and shoe (5) is caulked to it to form one unit. oil inside each cylinder chamber of cylinder
Piston (8) and shoe (5) from a spherical bear- block (9) is sucked in and discharged through
ing. valve plate (10).
q Rocker cam (4) holds plane (A), and shoe (5) q Impeller (12) is fixed to shaft (1), and rotates
is always pressed against this surface as it together with the shaft, it makes it easier for
slides in a circle. the oil sucked in from the suction port to be
q Rocker cam (4) forms a static being sending sucked in and sends it into the cylinder cham-
high pressure oil at cylindrical surface (B) of ber by centrifugal force.
cradle (3), which is fixed to the case, and car-
ries out a sliding movement.
q Piston (8) carries out motion relative to the
cylinder block (9).
D61EX, PX-15E0 13
Operation
Pump operation
q Cylinder block (9) rotates together with shaft
(1), and shoe (5) slides on plane (A). When q When center line (X) of rocker cam (4) is the
this happens, rocker cam (4) moves along same as the axial direction of cylinder block (9)
cylindrical surface (a), so angle (a) of center (swash plate angle = (0), the difference
line (X) of rocker cam (4) to the axial direction between volumes (E') and (F') inside cylinder
of cylinder block (9) changes. This angle (a) is block (9) is 0, so pump does not suction and
called the swash plate angle. discharge, and no pumping is carried out.
Actually swash plate angle does not become 0.
q The swash plate angle (a) is proportional to
pump discharge volume.
q With swash plate angle (a) formed by the angle

between center line (X) of rocker cam (4) to the
axial direction of cylinder block (9), plane (A)
acts as a cam for shoe (5).
q In this way, piston (8) slides inside cylinder
block (9), and as a result, a difference is gener-
ated between volumes (E) and (F) inside the
cylinder block. The amount of suction and dis-
charge is equal to difference (F) – (E).
q In other words, cylinder block (9) rotates, and
the volume of chamber (E) becomes smaller,
so oil is discharged during this process. At the
s a m e ti m e , th e v o l u me o f c h am b e r ( E )
becomes larger and oil is sucked in this pro-
cess.
14 D61EX, PX-15E0
Control of discharge amount

q If swash plate angle (a) becomes larger, the
difference between volumes (E) and (F)
becomes larger, and oil discharge (Q) is
increased. Swash plate angle (a) is changed
by servo piston (6).
q Servo piston (6) carries out reciprocal move-
ment in a straight line accordingly to the com-
mand from the servo valve single pressure.
This straight line movement is transmitted to
rocker cam (4) through rod (7), and rocker cam
(4), which is supported on the cylindrical sur-
face by cradle (3) rotates on the cylindrical sur-
face.
q The area receiving the pressure is different at
the left and right sides of servo piston (6), and
the receiving pressure at the small diameter
piston end is always connected with main
pump discharge pressure (self pressure) (PP).
q Output pressure (PNC) of the servo valve is
applied to the chamber receiving the pressure
at the large diameter piston end (which
receives pressure of the pump).
q The movement of servo piston (6) is controlled
by the relationship of the size of pump pres-
sure (PP) and the pressure at the large diame-
ter piston end, and the comparative size of the
ratio of area receiving the pressure at the large
diameter piston end and small diameter piston
end.
D61EX, PX-15E0 15
Servo valve
PA1: Pump self pressure

PEN11: Control pressure
PEN12: Control pressure pick-up plug
PLS1: Load pressure input
PT: Drain port
16 D61EX, PX-15E0
LS valve TVC valve Variable throttle valve

1. Locknut 8. Solenoid 16. Screw
2. Plug 9. Piston 17. Locknut
3. Spring 10. Sleeve 18. Spring
4. Spool 11. Spring 19. Seat
5. Sleeve 12. Spring 20. Spool
6. Piston 13. Piston 21. Block
7. Plug 14. Lever 22. Plug
15. Valve body
D61EX, PX-15E0 17
Outline
LS valve
q The LS valve detects the load and controls the
discharge amount.
q This valve controls main pump discharge
amount (Q) accordingly to differential pressure
(∆PLS) ( = (PP) – (PLS) ) (the difference
between main pump pressure (PP) and control
valve outlet port pressure (PLS)) {called the LS
differential pressure}.
q Main pump pressure (PP), pressure (PLS)
{called the LS pressure} coming from the con-
trol valve output enter this valve.
q The relationship between discharge amount
(Q) and differential pressure (dPLS), (the dif- q When a large load is applied or the engine
ference between main pump pressure (PP) speed lowers during work, a current is supplied
and LS pressure (PLS)) (= (PP) – (PLS)) to the TVC solenoid accordingly to the com-
changes as shown in the graph below. mand from the controller.
q By this operation, the pump delivery (torque
absorbed by the pump) is reduced and the
engine load is reduced.
Variable throttle valve

q Because the main pump controls its own pres-
sure, there is a tendency for the response
speed of the swash plate to be quick at high
pressure and slow at low pressure.
q The variable throttle valve has been installed
for the following reasons.
1) Lower the swash plate speed between the
minimum and maximum deliveries to
reduce the impacts applied to the main
TVC valve pump rod, etc. and prevent an excessive
q When the pump discharge pressure (PP) is stress when high pressure is applied.
high, the TVC valve controls the pump so that 2) Prevent cavitation in the suction port
no more oil than the constant flow (in accor- caused by sudden increase of suction vol-
dance with the discharge pressure) flows even ume from the minimum to the maximum.
if the stroke of the control valve becomes q It has the function and property of maintaining
larger. In this way, it carries out equal horse- the response during operations at low pressure
power control so that the horsepower absorbed by making the area of the opening smaller at
by the pump does not exceed the engine high pressure and the area of the opening
horsepower. larger at low pressure, and by preventing the
q In other words, if the load during the operation above problems 1) and 2) at high pressure.
becomes larger and the pump discharge pres-
sure rises, it reduces the discharge amount
from the pump; and if the pump discharge pres-
sure drops, it increases the discharge amount
from the pump.
q The relationship between pump discharge
pressure (PP) and pump delivery (Q) in this
case is shown in the above right graph, using
the current as a parameter.
18 D61EX, PX-15E0
Operation
LS valve
(1) When control valve is at "Neutral" position
q The LS valve is a three-way selector valve, with q Pump pressure (PP) enters the large diameter
pressure (PLS) (LS pressure) from the outlet end of the piston from port (h). The same
port of the control valve brought to spring pump pressure (PP) also enters the small
chamber (i), and main pump discharge pres- diameter end of the piston, so the swash plate
sure (PP) brought to chamber (j) of plug (6). is moved to the minimum angle by the differ-
q The size of the LS pressure (PLS) + force (F) of ence in area of piston (1).
spring (3) and the main pump pressure (self
pressure) (PP) determines the position of spool
(4).
q Before the engine is started, servo piston (1) is
pushed to the right by spring (7) installed to rod
(2) (see diagram on the right).
q When the engine is started, if the control lever
is in neutral, LS pressure (PLS) is 0 kg/cm2 (it is
interconnected with the drain circuit through the
control valve spool).
q At this point, spool (4) is pushed to the left, and
port (d) and port (c) are connected.
D61EX, PX-15E0 19
(2) Operation in maximum direction for pump discharge amount
q When the difference between main pump pres-

sure (PP) and LS pressure (∆PLS), in other
words, LS differential pressure (PLS) becomes
smaller (for example, when the area of open-
ing of the control valve becomes larger and
pump pressure (PP) drops), spool (4) is
pushed to the right by the combined force of
LS pressure (PLS) and the force of spring (3).
q When spool (4) moves, port (b) and port (c) are
joined and connected to the TVC valve.
q At this time, the TVC valve is connected to the
drain port and the pressure in circuit (c) – (h) is
drain pressure (PT) (the operation of the TVC
valve will be explained later).
q For this reason, the pressure at the large pis-
ton diameter end of servo piston (1) becomes
drain pressure (PT), and pump pressure (PP)
enters the small diameter end, so servo piston
(1) is pushed to the right.
q Therefore, rod (2) moves to the right and
moves the swash plate in the direction to make
the discharge amount larger.
20 D61EX, PX-15E0
(3) Operation in minimum direction for pump discharge amount
q The following explains the situation if servo

piston (1) moves to the left (the discharge
amount becomes smaller).
q When LS pressure (dPLS) becomes larger (for
example, when the area of opening of the con-
trol valve becomes smaller and pump pressure
(PP) rises), pump pressure (PP) pushes spool
(4) to the left.
q When spool (4) moves, main pump pressure
(PP) flows from port (d) to port (c), and from
port (h), it enters the large piston diameter end.
q Main pump pressure (PP) also enters the small
piston diameter end, but because of the differ-
ence in area between the large piston diameter
end of servo piston (1) and the small piston
diameter end, servo piston (1) is pushed to the
left.
q As a result, rod (2) moves in the direction to
make the swash plate angle smaller.
D61EX, PX-15E0 21
(4) When servo piston is balanced
q Let us take the area receiving the pressure at q The force of spring (3) is so adjusted that this
the large piston diameter end as (A1), the area spool (4) will be balanced and stopped at the
receiving the pressure at the small diameter standard center when (PP) – (PLS) = 1.96
end as (A0), and the pressure flowing into the MPa {20 kg/cm2}.
large piston diameter end as (PEN).
q If the main pump pressure (PP) of the LS valve
and the combined force of force (F) of spring
(3) and LS pressure (PLS) are balanced, and
the relationship is (A0) × (PP) = (A1) × (PEN).
q The servo piston (1) will stop in that position,
and the swash plate will be kept at an interme-
diate position (it will stop at a position where
the opening from port (b) to port (c) and from
port (d) to port (c) of spool (4) is approximately
the same).
q At this point, the relationship between the area
receiving the pressure at both ends of piston
(1) is (A0) : (A1) = 1 : 2, so the pressure
applied to both ends of the piston when it is
balanced becomes (PP) : (PEN) C 2 : 1.
22 D61EX, PX-15E0
TVC valve
(1) When transmission and steering controller is normal

1) When the load on the actuator is small and pump pressure PP is low
a. Solenoid (1) function

q A command current (X) from the transmission
and steering controller is flowing in solenoid
(1). This command current (X) changes the
force to press internal solenoid push pin (11).
q Piston (2) stops at a position where the force to
press solenoid push pin (11) is balanced with
the combined force of set force of springs (3)
and (4) and the force to press piston (2) with
pump pressure (PP).
q The pressure output from the TVC valve (the
pressure in port (c)) changes accordingly to
that position.
q The level of command current (X) is decided
by the contents of operation (operation of the
lever), selected working mode, set engine
speed, and actual engine speed.
D61EX, PX-15E0 23
b. Spring function
q The spring load of springs (3) and (4) at the
TVC valve depends on the position of the
swash plate.
q When servo piston (9) moves, cam (7), which
is connected to rod (8), also moves. When this
happens, lever (6) is rotated by the angle of
cam (7), and position (5) moves to the right
and left.
q If piston (5) moves to the right, spring (3) is
compressed first. If piston (5) moves to the
right further, spring (4) touches seat (10), and
then two springs (3) and (4) work.
q In other words, the spring load is changed by
piston (5) extending or contacting springs (3)
and (4).
q If the command current (X) input to solenoid
(1) changes, the force to press solenoid push
pin (11) changes. Accordingly, the spring load
of springs (3) and (4) also changes when the
command current (X) changes.
q Port (c) of the TVC valve is connected to port e
of the LS valve (see "1. LS valve"). Self pres-
sure (PP) is applied to port (b), small diameter
side of servo piston (9), and port (g).
q When pump pressure (PP) is small, piston (2)
is on the right.
q At this point, port (c) and port (d) are con-
nected, and the pressure entering the LS valve
becomes drain pressure (PT).
q At this time, if port (e) of the LS valve is con-
nected to port (h) (see "1. LS valve"), the pres-
sure applied to the large diameter side of the
piston from port (f) is drain pressure (PT) and
servo piston (9) moves to the right.
q In this way, the pump discharge amount moves
in the direction of increase.
q As servo piston (9) moves further, piston (5) is
moved to the left by rod (8), cam (7) and lever
(6). Springs (3) and (4) expand and the spring
force becomes weaker.
q When the spring force becomes weaker, piston
(2) moves to the left, so the connection
between port (c) and port (d) is cut, and the
pump discharge pressure is connected to port
(b).
q As a result, the pressure at port (c) rises, and
the pressure at the large piston diameter end
also rises, so the movement of piston (9) to the
right is stopped.
q That is, the stopping position of piston (9) (= pump
delivery) depends on the position where the
pressing force caused by pressure (PP) applied to
piston (2) and the pressing force of the solenoid
are balanced with the force of springs (3) and (4).
24 D61EX, PX-15E0
2) When load on actuator is small and pump discharge pressure is high
q When the load is large and pump discharge q For this reason, springs (3) and (4) are com-
pressure (PP) is high, the force pushing piston pressed and push back piston (2). Because of
(2) to the left becomes larger and piston (2) this force, piston (2) cuts of the connection
moves to the position shown in the diagram from port (b) to port (c), and port (c) and port
above. (d) are connected.
q When this happens, as shown in the diagram q As a result, the pressure at port (c) (= (f))
above, part of the pressurized oil from port (b) drops, and piston (9) stops moving to the left.
flows out to port (d) and the pressure oil flow- q The position in which piston (9) stops when
ing from port (c) to the LS valve becomes this happens is further to the left than the posi-
approximately half of main pump pressure tion when pump pressure (PP) is low.
(PP).
q When port (h) and port (e) of the LS valve are
connected (see 1. LS valve), the pressure from
port (f) enters the large piston diameter end of
servo piston (9), and servo piston (9) stops.
q If main pump pressure (PP) increases further
and piston (2) moves further to the left, main
pump pressure (PP) flows to port (c) and acts
to make the discharge amount the minimum.
q When piston (9) moves to the left, piston (5) is
moved to the right by cam (7) and lever (6).
D61EX, PX-15E0 25
q The relation of pump pressure (PP) and the

position of servo piston (9) forms a bent line
because of the double-spring effect of springs
(3) and (4). The relationship between pump
pressure (PP) and pump discharge amount (Q)
is shown in the graph below.
26 D61EX, PX-15E0
Variable throttle valve
(1) Operation in maximum direction for pump q At this point, the opening area of part A
discharge amount increases and the oil flowing from the large
q Main pump pressure PP enters the variable diameter end of servo piston (1) through port
throttle valve through port (a). (c) to port (b) is not limited and the moving
speed of servo piston (1) is heightened.
1) When main pump pressure PP is high
(2) Operation to reduce pump discharge
q If the pressure becomes higher than the force
of spring (3) because of the difference in sec- q The hydraulic oil flows from port (b) through
tional area of spool (4) in chamber (e), spool port (c) to the large diameter side of servo pis-
(4) moves to the right. ton (1).
q If spool (4) moves to the right, the opening q Spool (4) operates accordingly to main pump
area between ports (c) and (b) is reduced by pressure (PP) as explained in the above sec-
the notch at part (A). Accordingly, less oil flows tion.
from the large diameter end of servo piston (1)
and the moving speed of servo piston (1) is
lowered.
2) When main pump pressure PP is low

q Even if main pump pressure PP enters cham-
ber (e) through port (a), spool (4) pushes
spring (3) less strongly and moves to the right
for shorter distance.
D61EX, PX-15E0 27
HSS motor 1
Model name: HMF80
PA: From control valve Outline

PB: From control valve q Motor is composed of fixed capacity, fixed
T2: To hydraulic tank swash plate type piston motor, flashing shuttle
valve, bypass valve and charge relief valve.
1. HSS motor assembly
2. Counterbalance valve
3. Safety valve Specifications
4. Check valve
Type HMF80
Theoretical displacement
80
(cc/rev)
Rated pressure
41.2 {420}
(MPa {kg/cm2})
Rated speed (rpm) 2,316
28 D61EX, PX-15E0
1. Output shaft 7. End cover 13. Check valve spring

2. Motor case 8. Brake valve assembly 14. Sub bearing
3. Swash plate 9. Spool return spring 15. Spline
4. Piston 10. Counterbalance valve 16. Shoe
5. Cylinder 11. Safety valve 17. Main bearing
6. Valve plate 12. Check valve
Unit: mm
Free length Installed Installed Free Installed
18 Spool return spring × O.D. length load length load Replace spring if
192 N 154 N damaged or
42.7 × 30.0 40.5 — deformed
{19.6 kg} {15.7 kg}
1.27 N 0.98 N
19 Check valve spring 43 × 13.8 32.9 —
{0.13 kg} {0.10 kg}
D61EX, PX-15E0 29
Outline
q Pressurized oil sent from pump is converted to
rotation torque and is transmitted to output
shaft.
Structure
q Cylinder block (5) is supported by shaft (1) with
spline (15) and shaft (1) is supported by main
and sub bearings (17) and (14).
q The end of piston (4) has a concave ball shape
and shoe (16) is caulked to it to form one unit.
Piston (4) and shoe (16) from a spherical bear-
ing.
q Piston (4) carries out motion relative to the
cylinder block (5).
q Cylinder block (5) moves relatively against
valve plate (6), while sealing the hydraulic
pressure.
q This face is so designed that the hydraulic
pressure will be balanced well.
q The oil inside each cylinder chamber of cylin-
der block (5) is sucked in and discharged
through valve plate (6).
30 D61EX, PX-15E0
Operation
Motor operation Rotation speed and torque control

q The pressurized oil sent from the pump enters q As flow (Q) from the HSS pump is increased,
cylinder block (5) and pushes piston (4) from motor speed (N) is heightened.
the back face. q Since the swash plate angle of the HSS motor
q In the case of the motor, the center line of plate is fixed ((a) is constant), torque (T) is propor-
(3) is always at an angle (swash plate angle a tional to pressure (P).
to the axial direction of cylinder block (5)). q Swash plate angle (a) is approx. 13.4°.
q As a result, if we take the example of one of
pistons (4), oil pressure is applied to the back Q = qN
face of the right, and piston axial force (FO) is (q = E – F)
generated.
q With shoe (16), which is joined to piston (4) by
the spherical surface, reaction force (FR) in a T = Pq/2x
direction at right angles to plane (A) is gener-
ated. The combined force of (FO) and (FR) is
(FP), and this becomes the force to rotate cyl-
Q:Total flow
inder block (5).
q: Flow per 1 turn
N: Rotation speed
P: Pressure
T: Rotating torque
q Shaft (1), which is meshed to cylinder block (5)

by spline (15) transmits this rotation torque to
the output side.
q Cylinder block (5) rotates, and while the condi-
tion changes from volume (E) to volume (F),
pressurized oil from the pump flows into the
cylinder chamber, and pressure (P) is gener-
ated accordingly to the load.
q On the other hand, when the condition goes
beyond volume (F) and changes to volume (E),
the oil is pushed out and returned to the pump.
D61EX, PX-15E0 31
Brake valve operation Counterbalance valve, check valve

q The brake valve consists of check valve (12),
counterbalance valve (10), and safety valve Function
and (11), and forms a circuit such as that q When steering on slopes, the weight on the
shown below. machine produces a force in the downward
q The function and operation of each component direction which makes the machine try to turn
is as given below. faster than the speed of the HSS motor.
q Because of this, if the engine is run at low
speed and the steering is operated, the HSS
motor will overrun, and this will create an
extremely dangerous condition.
q To prevent this, this valve is installed to carry
out the steering in accordance with the engine
speed (pump discharge volume).
Operation when oil is supplied

q When the steering lever is operated, the pres-
surized oil from the control valve is supplied to
port (PA). It pushes open check valve (12a),
and flows from HSS motor inlet port (MA) to
HSS motor outlet port (MB).
q However, the outlet port side of the HSS motor
is closed by check valve (12b) and spool (10),
so the pressure at the side where the oil is
being supplied rises.
32 D61EX, PX-15E0
Brake action when steering downhill

q The pressurized oil at the side where the oil is q When the steering is operated on a down hill
being supplied flows from orifice (E1) of spool slopes, if the machine accelerates too fast
(10) into chamber (S1). And when the pressure while steering downhill, the HSS motor will
in chamber (S1) becomes greater than the rotate under no load, and the oil pressure at
spool switching pressure, spool (10) is pushed the inlet port of the HSS motor will drop. This
to the right. drop in pressure will pass through orifice (E1),
q In this way, port (MB) and port (PB) are con- so the pressure in chamber (S1) will also drop.
nected, so the outlet port side of the HSS q If the pressure in chamber (S1) drops below
motor is opened and the HSS motor starts to the spool switching pressure, spool (10) is
turn. pushed to the left by spring (9), and outlet port
(MB) is throttled.
q As a result, the pressure at the outlet port
rises, and this creates a resistance to the rota-
tion of the HSS motor which prevents the
motor from overrunning.
q In other words, the spool moves to a position
where it balances the pressure at outlet port
(MB) with the force resulting from the weight of
the machine and the pressure at the inlet port.
In this way, it throttles the outlet port circuit and
controls the motor to a speed that matches the
amount of oil discharged from the pump.
D61EX, PX-15E0 33
Safety valve
Function
q When the operation of the steering stops,
counterbalance valve (10) closes the circuit at
the inlet and outlet ports of the HSS motor.
q But the HSS motor continues to turn because
of inertia. As a result, the pressure at the outlet
port of the HSS motor becomes extremely
high, and this will damage the HSS motor and
the piping.
q The safety valve acts to release this abnormal
pressure to the inlet port of the HSS motor to
protect the equipment from damage.
Operation
q When the operation of the steering is stopped, q If the pressure in chamber (E) (or chamber (F))
the check valve of the counterbalance valve rises above the set level, the force of x(D12 –
closes chamber (E) (or chamber (F)) in the out- D22)/4 × Pressure caused by the area differ-
let port circuit, but the pressure at the outlet ence between (D1) and (D2) {or the force of
port side continues to rise because of inertia. x(D32 – D12)/4 × Pressure caused by the area
difference between (D3) and (D1)} presses the
spring and moves the poppet to the right, and
then the oil flows in chamber (F) (or chamber
(E)) in the circuit on the opposite side.
34 D61EX, PX-15E0
D61EX, PX-15E0 35
SEN02477-00

© 2006 KOMATSU
All Rights Reserved
36
SEN02478-00
D61EX-15E0
D61PX-15E0


Control valve ................................................................................................................................................... 2
CLSS............................................................................................................................................................. 10
Self pressure reducing valve......................................................................................................................... 37
D61EX, PX-15E0 1
Control valve 1
Outline
The following 3 types of control valve are set.
q 4-spool valve (lift + tilt + angle + steering)
q 4-spool valve (lift + tilt + ripper + steering)
q 5-spool valve (lift + tilt + angle + ripper + steering)
The outside view and section of only the 4-spool valve are shown.
P: From pump
T: To tank
A1: To HSS motor
A2: To lift cylinder head
A3: To tilt cylinder bottom
A4: To angle cylinder bottom
B1: To HSS motor
B2: To lift cylinder bottom
B3: To tilt cylinder head
B4: To angle cylinder head
LS: To pump port LS
PI: Pump pressure pickup port
TS: To tank
CA1: Connector (from controller)
CB1: Connector (from controller)
PA2: From PPC valve
PA3: From PPC valve
PA4: From PPC valve
PB2: From PPC valve
PB3: From PPC valve
PB4: From PPC valve
PEPC: From self pressure reducing valve
2 D61EX, PX-15E0
4-spool valve
(lift + tilt + angle + steering)
D61EX, PX-15E0 3
Section
(1/4)
4 D61EX, PX-15E0
1. Suction valve
2. Back pressure valve
3. Steering spool
4. Lift spool
5. Tilt spool
6. Angle spool
7. Cover (work equipment valve side)
8. Valve block (blade angle valve)
9. Valve block (blade tilt valve)
10. Valve block (blade lift valve)
11. Block (pump port)
12. Valve block (steering valve)
13. Cover (steering valve side)
Unit: mm
Free length × Installation Installation Installation
Free length
O.D. length load load
14 Suction valve spring
5.1 N 4.1 N
39.2 × 4.45 33.5 —
{0.52 kg} {0.42 kg}
5.5 N 4.4 N
15 Suction valve spring 46.8 × 7.5 40.6 —
{0.56 kg} {0.45 kg}
67.7 N 54.2 N
16 Back pressure valve spring 67.7 × 20 42.5 —
{6.9 kg} {5.5 kg}
Replace spring if
221 N 178 N
17 Spool return spring (steering) 45.7 × 28 43 — damaged or
{22.6 kg} {18.1 kg}
deformed
83.4 N 66.7 N
18 Spool return spring (lift) 41 × 18.6 39 —
{8.5 kg} {6.8 kg}
Spool return spring (tilt), 108 N 86.3 N
19 41.9 × 18.6 39 —
(angle) {11 kg} {8.8 kg}
81.4 N 65.1 N
20 Spool return spring (lift) 40.5 × 24.6 37.5 —
{8.3 kg} {6.64 kg}
51.4 N 41.1 N
21 Spool return spring (lift) 37.3 × 19.4 17 —
{5.24 kg} {4.19 kg}
D61EX, PX-15E0 5
(2/4)
6 D61EX, PX-15E0
R: Pressure reducing valve

F: Flow control valve
1. LS relief valve (for steering valve)

2. Pressure compensation valve R
3. Pressure compensation valve F
4. Pressure reducing valve (for work equipment valve)
5. Steering priority valve
6. Check valve (centralized safety valve)
Unit: mm
Free length
7 Flow control valve spring
9.8 N 7.85 N
36.2 × 5.30 32.0 —
{1.0 kg} {0.80 kg}
17.6 N 14.1 N
8 Pressure reducing valve spring 27.5 × 14.2 18.0 —
{1.8 kg} {1.44 kg}
55.9 N 44.7 N
{5.7 kg} {4.56 kg}
Replace spring if
34.3 N 27.5 N
10 Pressure reducing valve spring 31.9 × 14.4 21.5 — damaged or
{3.5 kg} {2.8 kg}
deformed
27.6 N 22.2 N
11 Flow control valve spring 30.9 × 5.2 20 —
{2.82 kg} {2.26 kg}
473 N 379 N
12 Steering priority valve spring 106.5 × 20 82 —
{48.2 kg} {38.6 kg}
Work equipment valve and 126 N 100 N
13 51.6 × 10.5 44.5 —
pressure reducing valve spring {12.7 kg} {10.2 kg}
3.92 N 3.14 N
14 Check valve spring 27.2 × 6.9 22 —
{0.4 kg} {0.32 kg}
D61EX, PX-15E0 7
(3/4)
1. LS shuttle valve
2. Unload valve
8 D61EX, PX-15E0
(4/4)
1. Centralized safety valve (for work equipment valve)

2. Pressure releasing plug
3. Main relief valve (for work equipment valve)
D61EX, PX-15E0 9
CLSS 1
a CLSS: Closed center Load Sensing System
Outline of CLSS
Features
CLSS is an abbreviation for Closed center Load
Sensing System, which has the following features.
q Fine controllability which is not affected by load
q Controllability for digging in fine control mode
q Flow division performance decided by open
area of spool during compound operation
q Energy saving performance with variable
pump control
Composition
q The CLSS consists of the variable-capacity
piston pump, control valve, and actuators.
q The pump consists of the main pump, variable
throttle valve, TVC valve, and LS valve.
10 D61EX, PX-15E0
Basic principle
Control of pump swash plate angle

q The pump swash plate angle (pump delivery) q If LS differential pressure (dPLS) is lower than
is so controlled that LS differential pressure the set pressure of the LS valve (when the
(dPLS) which is the differen tial pressure actuator load pressure is high), the pump
between pump (discharge) pressure (PP) and swash plate moves toward the maximum end.
LS pressure (PLS) (actuator load pressure) at
the control valve outlet will be constant (LS dif-
ferential pressure (dPLS) = Pump discharge
pressure (PP) – LS pressure (PLS)).
D61EX, PX-15E0 11
Pressure compensation control

q A valve (pressure compensation valve) is
installed to the outlet side of the control valve
to balance the load. This valves works so that
p r e s s u r e d i ff e r e n c e ( d P ) b e t w e e n t h e
upstream (inlet) side of the spool of each valve
and the downstream (outlet) side will be main-
tained, regardless of the load (pressure). By
this operation, the oil from the pump is distrib-
uted (compensated) in proportion to the open
areas (S1) and (S2) of each of the operated
valves.
12 D61EX, PX-15E0
D61EX, PX-15E0 13
Each function and each valve operation
Hydraulic circuit diagram and name of valve
14 D61EX, PX-15E0
1. Unload valve
Set pressure: 3.4 MPa {35 kg/cm2}
5. Pressure compensation valve
6. Suction valve
7. LS shuttle valve
11. Steering valve
12. Lift valve
13. Tilt valve
14. Angle valve
D61EX, PX-15E0 15
Unload valve
When control valve is in neutral
T: Tank circuit (pressure) Operation

PP: Pump circuit (pressure) q Pump discharge pressure (PP) is applied to
PLS: LS circuit (pressure) the right side of spool (3) and LS pressure
(PLS) is applied to the left side.
1. Sleeve q When the control valve is in neutral, LS pres-
2. Spring sure (PLS) is 0. Accordingly, only pump dis-
3. Spool charge pressure (PP) is applied and it is set
with only the spring load of spring (2).
q If pump discharge pressure (PP) rises to the
Function spring load of 3.4 MPa {35 kg/cm2} of spring
q When the control valve is in neutral, delivery (2), spool (3) moves to the left and pump circuit
(Q) at the minimum pump swash plate angle is (PP) is connected to tank circuit (T) through
released to the tank circuit. At this time, pump hole (a) of sleeve (1).
discharge pressure (PP) is set to 3.4 MPa {35 q By this operation, pump discharge (PP) is set
kg/cm2} by spring (2) in the valve (LS pressure to 3.4 MPa {35 kg/cm2}.
(PLS) is 0 MPa {0 kg/cm2}).
16 D61EX, PX-15E0
When control valve is controlled finely
T: Tank circuit (pressure) q At this time, pump discharge pressure (PP)

PP: Pump circuit (pressure) rises to pass all of (Q) min. As a result, the dif-
PLS: LS circuit (pressure) ferential pressure between pump discharge
pre ssur e (PP) a nd LS pr essu re (PL S) is
1. Sleeve increased.
2. Spring q If, As a result, the differential pressure between
3. Spool pump discharge pressure (PP) and LS pres-
sure (PLS) reaches the spring load of 3.4 MPa
{35 kg/cm 2} of spring (2), spool (3) moves to
Function the left and pump circuit (PP) is connected to
q When the control valve is controlled finely, if tank circuit (T).
the demand flow for the actuator is below the q That is, pump discharge pressure (PP) is set to
delivery at the minimum pump swash plate spring force of 3.4 MPa {35 kg/cm2} + LS pres-
angle, pump discharge pressure (PP) is set to sure (PLS) and the flow control differential
LS pressure (PLS) + 3.4 MPa {35 kg/cm 2}. If pressure below the pressure at the minimum
the differential pressure between discharge swash plate (= ∆PLS) becomes 3.4 MPa {35
pres sure (P P) and LS press ure (P LS ) kg/cm2}.
becomes the spring load of spring (2) (3.4 MPa
{35 kg/cm2}), the unload valve opens. LS differ-
ential pressure (∆PLS) is 3.4 MPa {35 kg/cm2}.
Operation
q When the actuator is controlled with a flow rate
be low the delive ry at the minimu m pump
swash plate angle (below (Q) min. in the graph
at right), if the control valve spool is changed,
LS pressure (PLS = Load pressure) is sensed
and applied to the left end of spool (3).
D61EX, PX-15E0 17
When control valve is operated
Function
q When the control valve is operated, if the
demand flow for the actuator exceeds the
delivery at the minimum pump swash plate
angle, the flow to tank circuit (T) is stopped
and all of pump delivery (Q) is supplied to the
actuator circuit.
Operation
q If the control valve is controlled largely, LS
pressure (PLS) is generated and applied to the
left end of spool (3). At this time, since the
open area of the control valve spool is wide,
the difference between LS differential pressure
(∆PLS) and pump discharge pressure (PP) is
little.
q Accordingly, the differential pressure between
pump discharge pressure (PP) and LS pres-
sure (PLS) does not reach the spring load of
3.4 MPa {35 kg/cm 2} of spring (2) and spool (3)
is pushed to the right by spring (2).
q As a result, pump circuit (PP) is disconnected
from tank circuit (T) and all of pump delivery
(Q) is supplied to the actuator circuit.
18 D61EX, PX-15E0
Main relief valve (steering, work equipment)

Centralized safety valve
Function q If pilot poppet (3) opens, the pressure in spring

q If the oil pressure rises above the set level, oil chamber (C) lowers and poppet (1) moves to
is drained into the tank. As a result, the maxi- the right. Then, poppet (1) touches the end of
mum pressure of the work equipment circuit is pilot poppet (3) and the oil is drained through
regulated to protect the circuit. throttle (b) and the hole.
Operation
q Port (A) is connected to the pump circuit and
port (B) is connected to the drain circuit. The
hydraulic oil is supplied through diameter (d1)
and the hole of poppet (1) to diameter (d2) of
main valve (2). Then, main valve (2) is in con-
tact with the sleeve because of the difference
in area (d1 < d2).
q Since the pressure in spring chamber (C) is

lower than the pressure in port (A), main valve
(2) opens and the oil flows from port (A) to port
(B) to prevent abnormal pressure.
q If the pressure in port A reaches the set pres-

sure of spring (4), pilot poppet (3) opens and
the o il flo ws a roun d pilot p oppe t (3) a nd
through hole (a) and port (B), and then it is
drained.
D61EX, PX-15E0 19
Steering priority valve
In compound operation
20 D61EX, PX-15E0
a: Pump circuit
b: Steering pump circuit
c: Work equipment pump circuit
d: Spring chamber
e: Pressure chamber
1. Steering priority valve spool

2. Priority valve spring
3. Steering spool
4. Work equipment spool
Function
q If the steering valve and the work equipment
valves on the downstream side of the steering
priority valve are operated simultaneously, oil
for the steering valve is secured first, and then When pump swash plate does not reach maxi-
the rest of the pump delivery flows to the work mum angle
equipment valve. q If the maximum pump flow is larger than the
total demand flow for the steering valve and
work equipment valve, oil flows in the steering
Operation valve accordingly to the open area of steering
q If steering spool (3) is operated and some oil spool (3) and in the work equipment valve
flows, a difference is made between pump dis- decided by the pump pressure, load pressure,
charge pressure (PP) and LS pressure (PLS). and open area of the spool.
This differential pressure simultaneously con-
trols steering priority valve (1) and pump
swash plate with (∆PLS) ((PP) – (PLS)) = 1.96 When pump swash plate is at maximum angle
MPa {20 kg/cm2} to decide the flow rate to the
q When the maximum pump flow is less than the
steering valve.
total demand for the steering valve and work
q The (PP) pressure is applied to right end (e) of
equipment valve.
priority valve spool (1) and the (PLS) pressure
is applied to spring chamber (d) on the left
1. When steering valve load Z Work equipment
side. Priority valve spool (1) is pressed to the
valve load
right by spring (2).
q Oil flows in the steering valve accordingly
q Accordingly, if the differential pressure
to the open area of steering spool (3) and
between the (PP) pressure and (PLS) pressure
the rest flows in the work equipment valve.
is below the set pressure of the spring, the
open area from chamber (a) to chamber (b)
2. When steering valve load > Work equipment
becomes maximum. If the differential pressure
valve load
is increased, spool (1) moves to the left to
q Pump pressure (PP) is decided by the
decrease the open area for the steering and
steering valve load. If the work equipment
increase the open area for the work equip-
valve on the downstream side, where the
ment.
load is smaller, is operated under this con-
q While steering spool (3) is operated, if work
dition, the oil flows in the work equipment
equipment spool (4) is operated, pump pres-
valve because of the differential pressure,
sure (PP) lowers for a moment.
and then the pump pressure lowers.
q accordingly, the differential pressure between
q At this time, steering priority valve (1)
(PP) and (PLS) is reduced and priority valve
increases the open area for the steering
(1) moves to the right to decrease the open
and decreases the open area for the work
area for the work equipment with the pressure
equipment to secure the flow for the steer-
in chamber (d).
ing.
q At the same time, (∆PLS) becomes smaller, so
q Under this condition, the oil flow is distrib-
the pump swash plate angle moves in the max-
uted at the ratio of the differential pressure
imum direction to supply an oil flow to make up
between (PP) and (P1) to that between
the amount that the pressures drops.
(PP) and (P2). The bigger (P1) – (P2) is,
the smaller the flow of oil to the steering
system becomes.
D61EX, PX-15E0 21
Pressure reducing valve for work equipment
When work equipment valve is operated alone
a: Work equipment pump circuit (pressure) Operation

b: Orifice q If the work equipment valve (lift, tilt, angle,
c: Spring chamber etc.), hydraulic oil (PP) in the pump circuit if
d: Valve pressure receiving chamber applied to right-end chamber (g) to push spring
e: Cut (7) to the left through cut (e) and orifice (f) of
f: Orifice spool (6). As a result, open area (h) of the cut
g: Pressure chamber b e co me s m a x imu m. H yd ra u lic o il f lo w s
h: Cut through cut (i) of valve (4) to work equipment
i: Cut pump circuit (a).
PP: Pump circuit (pressure) q If the pressure reducing valve (1) of work
T: Tank circuit equipment pump circuit (a) becomes the set
pressure of 20.6 MPa {210 kg/cm2}, poppet (2)
1. Pressure reducing valve pushes spring (3) to the right to release the
2. Poppet hydraulic oil in spring chamber (c) to tank cir-
3. Spring cuit (T). Accordingly, the hydraulic oil in pres-
4. Valve sure chamber (d) flows through orifice (b) and
5. Spring spring chamber (c) to tank circuit (T). A pres-
6. Steering priority valve spool sure difference is made between pressure
7. Spring chamber (d) and spring chamber (c) and valve
(4) moves to the right to close cut (i). Accord-
Function ingly, pump circuit (PP) is disconnected from
q The pump circuit pressure on the work equip- work equipment circuit (a).
ment side is controlled to below 20.6 MPa {210 q Even if the steering system is operated and the
kg/cm 2} and the pump circuit pressure on the pump circuit pressure rises to 40.2 MPa {410
steering side is secured to 40.2 MPa {410 kg/ kg/cm2}, the work equipment pump circuit pres-
cm 2} during compound operation (work equip- sure does not exceed 20.6 MPa {210 kg/cm2}.
ment + steering).
22 D61EX, PX-15E0
Pressure compensation valve
Function
q If the load pressure is lower than the pressure
in the other actuator and the flow rate starts
increasing during compound operation, the
pressure compensation valve compensates
the pressure (at this time, the load pressure in
the other actuator operated for the compound
operation (on the upper side) is higher than the
load pressure on this side (lower side)).
D61EX, PX-15E0 23
Operation Suction valve

q If the load pressure in the other actuator (on
the upper side) becomes high, the flow rate in Function
actuator circuit (A) on this side (lower side) q This valve prevents negative pressure in the
starts increasing. cylinder circuit.
q In this case, LS pressure (PLS) in the other
actuator is applied to spring chamber (PLS1)
to push pressure reducing valve (1) and flow Operation
control valve (2) to the left. q Port (A) is connected to the cylinder circuit and
q Flow control valve (2) reduces the open area port (B) is connected to the drain circuit. When
between pump circuit (PP) and spool upstream a load is applied to port (A), main poppet (1)
(PPA) to make a pressure loss in the line opens because of the area difference between
between (PP) and (PPA). (d1) and (d2). Then, the oil flows from port (B)
q Flow control valve (2) and pressure reducing to port (A) to prevent negative pressure.
valve (1) are stopped at a position where the
pressure difference between (PA) and (PLS)
applied to both ends of pressure reducing
valve (2) is the same as the pressure loss
made in the line between (PP) and (PPA) at
the front and rear of flow control valve (2).
q As a result, pressure difference between
upstream pressure (PPA) and downstream
pressure (PA) becomes the same at each
spool operated for the compound operation.
Then, the pump flow is distributed in proportion
to the open area of cut (a) of each spool.
24 D61EX, PX-15E0
Safety-suction valve
Function q Since pilot poppet (4) opens, the pressure in

q If any impact is applied to the cylinder and chamber C lowers and poppet (3) moves to the
abnormal pressure is generated, the abnormal right. Poppet (3) is seated at the end of pilot
pressure is released through the safety valve poppet (4) and the oil is drained through throt-
to protect the cylinder and other hydraulic tle (b) and chamber (D).
parts.
q If negative pressure is generated in the cylin-
der circuit, this valve works as a suction valve.
Operation as safety valve

q Port (A) is connected to the cylinder circuit and
hydraulic oil in port (A) is led through the hole
of poppet (3) to port (C) and safety valve (2) is
seated to the left since (d2) < (d3). The rela-
tionship between diameters (sectional areas)
is as follows (d4) > (d1) > (d3) > (d2).
q Since the pressure in chamber (C) is lower

than the pressure in port (A), safety valve (2)
moves to the right and the oil flows from port
(A) to port (B) to prevent generation of abnor-
mal pressure.
q Even if abnormal pressure is generated, suc-
tion valve (1) having a larger diameter does not
operate since (d1) < (d4).
q If abnormal pressure is generated in port (A)

and it increases to the set pressure of spring
(5), pilot poppet (4) opens and the oil from
chamber (C) is drained through chamber (D)
and periphery (a) of suction valve (1).
D61EX, PX-15E0 25
Operation as suction valve

der circuit, the pressures in port (A) and cham-
ber (C) becomes negative since they are
connected. The tank pressure of port (B) is
applied to port (E) and the oil pressure in suc-
tion valve (1) is increased by the area differ-
ence between (d4) and (d3) because of the
tank pressure of port (E). Then, the increased
pressure moves suction valve (1) to the right
against the tension of spring (6). Accordingly,
the oil flows from port (B) to port (A) to prevent
negative pressure in port (A).
26 D61EX, PX-15E0
LS shuttle valve (used as steering LS bypass plug, too)
a: Clearance filter Operation

b: LS bypass orifice (steering) q The PLS circuit pressure on the steering side
c: LS bypass orifice (work equipment side) presses ball shuttle valve (2) to the right, and
then it is led to the upper (PLS) output port
1. LS Ball shuttle valve and LS bypass plug (when steering system is operated alone or
2. Poppet together with another system (when steering
(PLS) > work equipment (PLS))).
q The PLS hydraulic oil flows from the clearance
Function filter (a) through orifices (b) and (c) to the tank
q Used to release residual LS pressure (PLS) circuit.
q The rising speed of LS pressure (PLS) is low- q The pressure in the PLS circuit on the work
ered and the discarded throttle flow is used to equipment side presses ball shuttle valve (2) to
make pressure loss in the throttle between (P) the left, and then it is let to the upper (PLS)
and (LS) of the pressure compensation valve output port (when steering system is operated
to lower the effective LS differential pressure alone or together with another system (when
and increase the stability. work equipment (PLS) > steering (PLS))).
q The higher LS pressure on the steering side or
work equipment side is selected and output.
D61EX, PX-15E0 27
Steering LS relief valve and main relief valve operation
a: Pump primary circuit 1. Steering spool

b: Pump secondary circuit 2. Steering LS relief valve
c: LS circuit 3. Main relief valve
5. Priority valve spool
28 D61EX, PX-15E0
Function
q If specified the maximum pressure when the
HSS motor is operated.
q The pump LS valve senses the differential
pressure (PP – PLS) generated by the opera-
tion of the LS relief valve and moves the pump
swash plate toward the minimum position. The
pump delivery is balanced at the minimum
position. accordingly, the relief oil flow is
reduced.
q Main relief valve: Cuts the peak pressure
caused by a sudden external load which the
LS relieve valve cannot lower by controlling the
swash plate.
Operation
q Steering spool (1) is moved and HSS motor
drive pressure (4) is increased, steering LS
relief valve (2) operates to drain the oil from
pump circuit (b). As a result, the pressure dif-
ference between pump circuit (b) and LS cir-
cuit (c) is increased.
q For the same reason, if the pressure in LS cir-
cuit (c) is lowered, priority valve spool (5)
moves to the left against spring (6) to reduce
the open areas of pump primary (a) and sec-
ondary (b). As a result, the pressure difference
between (a) and (b) is increased.
q Pump LS valve senses the LS differential pres-
sure (PP – PLS) generated by LS relief valve
(2) and moves the pump swash plate from the
maximum position toward the minimum posi-
tion. The pump swash plate is balanced at the
minimum position when the LS differential
pressure X 2.0MPa {20 kg/cm 2 } (see pump
swash plate control).
q When the pump swash plate is at the minimum
position (minimum flow rate), if the pump cir-
cuit pressure (PP) – LS circuit pressure (PLS)
X 3.4 MPa {35 kg/cm2}, the unload valve oper-
ates to release the excessive oil and balance
the swash plate.
LS relief valve set pressure: 33.1 MPa {338 kg/cm2}

Main relief valve set pressure: 40.2 MPa {410 kg/cm2}
D61EX, PX-15E0 29
Work equipment relief valve operation

2. Pressure reducing valve
3. Main relief valve (work equipment)
4. Main relief valve (steering)
5. Pressure reducing valve spool
30 D61EX, PX-15E0
Function
q The maximum pressure is regulated when the
work equipment is operated.
pressure (PP1 – PP2 C PLS) generated by the
operation of the pressure reducing valve and
the relief valve on the work equipment side and
moves the pump swash plate toward the mini-
mum position. The pump delivery is balanced
at the minimum position. accordingly, the relief
oil flow is reduced.
Operation
q If work equipment spool (1) is moved and work
e q u ip m e n t o p e r a t in g p r e s s u r e ( PP 2 ) is
increased, pressure reducing valve (2) oper-
ates and pressure reducing valve spool (5)
narrows the (PP1) and (PP2) circuits (1.1mm2).
Work equipment pump circuit pressure (PP2)
becomes the pressure reducing valve set pres-
sure of 20.6 MPa {210 kg/cm2}.
q Since steering relief valve (4) is set high pres-
sure, the oil is supplied through the narrow
open area of pressure reducing valve spool (5)
by the override of the pressure reducing valve,
and then the (PP2) circuit pressure rises.
q Then, if the pressure reaches the work equip-
ment relief set pressure, the (PP2) circuit pres-
sure oil is drained through the relief valve.
Since the differential pressure between (PP1)
and (PP2) (C PLS) is generated by the flow
from relief valve (3) and the throttle of orifice
(a) of the pressure reducing valve and it mini-
mizes the pump swash plate angle, the pump
delivery becomes minimum (same as steering
LS relief function).
Reducing valve set pressure: 20.6 MPa {210 kg/cm2}

Relief valve set pressure: 21.6 MPa {220 kg/cm2}
D61EX, PX-15E0 31
Introduction of LS pressure
Steering valve
Function q Since pressure reducing valve (3) also moves

q The LS pressure means the actuator load to the left at this time, pump discharge pres-
pressure on the outlet side of the control valve. sure (PP) introduced through orifice (c) is
q In the work equipment valve, pressure reduc- reduced by the pressure loss in cut (d) and
ing valve (3) of the pressure compensation introduced to LS circuit (PLS), and then further
valve reduces pump discharge pressure (PP) led to spring chamber (PLS1).
to the level of actuator circuit pressure (A), and q At this time, LS circuit (PLS) is connected to
then introduces it to the LS circuit (PLS). Ori- tank circuit (T) through LS bypass plug (4).
fice (c) is installed to piston (5) on the way from q Both ends of pressure reducing valve (3) has
pump circuit (PP) to pressure reducing valve the same area (SA = SLS). Actuator circuit
(3), and it works as a damper. pressure (PA) (= A) is applied to the (SA) side
and reduced pump discharge pressure (PP) is
applied to the (SLS) side.
Operation q Accordingly, pressure reducing valve (3) is bal-
q If spool (1) is operated, pump discharge pres- anced at a position where actuator circuit pres-
sure (PP) flows through flow control valve (2), sure (PA) and the pressure in spring chamber
cut a of the spool, and bridge circuit (b) to actu- (PLS1) are the same. Pump discharge pres-
ator circuit (A). sure (PP) reduced by cut (d) is introduced as
actuator circuit pressure (A) to LS circuit
(PLS).
32 D61EX, PX-15E0
Work equipment valve (lift, tilt, angle, ripper)
When blade is "Raised"

cut (a) of the spool, and bridge circuit (b) to (PLS1) are the same. Pump discharge pres-
actuator circuit (A). sure (PP) reduced by cut (d) is introduced as
q Since pressure reducing valve (3) also moves actuator circuit pressure (A) to LS circuit
to the right at this time, pump discharge pres- (PLS).
sure (PP) introduced through passage (c) is
reduced by the pressure loss in cut (d) and
introduced to LS circuit (PLS), and then further
led to spring chamber (PLS1).
q At this time, LS circuit (PLS) is connected to
tank circuit (T) through LS bypass plug (4).
q Both ends of pressure reducing valve (3) has
the same area (SA = SLS). Actuator circuit
pressure (PA) (= A) is applied to the (SA) side
D61EX, PX-15E0 33
When blade is "Floated"
Operation
q If the lift valve is set in the "Float" position, the
cylinder port is connected to drain port (T) and
no load is applied.
q Even if the lift valve is in the "Float" position,
the pump circuit and cylinder circuit are sepa-
rated so that the other work equipment (tilt,
angle, etc.) can be operated.
q If the work equipment control lever is set in the
"Float" position, spool (1) is set in the maxi-
mum stroke position. Port (B) is connected to
port (A) through bridge passage (b), and port
(A) is connected to circuit (T).
q Accordingly, if the blade is loaded, it can move
up and down.
q While the lift valve is in the "Float" position,
part a of spool (1) is closed. Accordingly, if
other work equipment (tilt, angle, etc.) is oper-
ated, the pump pressure rises and the operator
can start compound operation.
34 D61EX, PX-15E0
Back pressure valve
Function
q When the machine is steered or stopped, the
back pressure valve increases the pressure in
the steering drain circuit to prevent cavitation
in the HSS motor and increase the effect of
suction valve (3).
Operation
q The drain pressure in the steering circuit is
increased by back pressure valve (1) and
spring (2).
D61EX, PX-15E0 35
36 D61EX, PX-15E0
Self pressure reducing valve 1
T: To tank
P1: From pump
P2: To fan motor
PR: Supplied to PPC valve, EPC valve, etc.
D61EX, PX-15E0 37
1. Valve (sequence valve) 6. Spring (pressure reducing valve main)

2. Spring 7. Valve (pressure reducing valve)
3. Screw 8. Spring (safety valve)
4. Poppet 9. Ball
5. Spring (pressure reducing valve pilot) 10. Filter
38 D61EX, PX-15E0
Unit: mm
Free length
Spring O.D. length load load
11
(pressure reducing valve main) 19.6 N 17.7 N
19.2 × 7.20 16.1 —
{2.0 kg} {1.80 kg}
Replace spring if
Spring 31.4 N 28.4 N
12 17.8 × 7.20 12.1 — damaged or
(pressure reducing valve pilot) {3.2 kg} {2.9 kg}
deformed
200 N 186 N
13 Spring 71.0 × 18.0 59.0 —
{20.4 kg} {19.0 kg}
14 16.1 × 7.80 13.4 —
(safety valve) {6.30 kg} {6.0 kg}
Function
q The self pressure reducing valve reduces the
discharge pressure of the fan pump and sup-
plies it to the PPC valve, the EPC valve, etc. as
the control pressure.
D61EX, PX-15E0 39
Operation
At engine stop (total low pressure)
q The spring (6) pushes the poppet (5) the seat,

and the circuit between the ports (PR) and (T)
is closed.
q The spring (7) pushes the valve (8) to the left
side, and the circuit between the ports (P1)
and (PR) is open.
q The spring (3) pushes the valve (2) to the
upper side, and the circuit between the ports
(P1) and (P2) is closed.
40 D61EX, PX-15E0
When the load pressure (P2) is lower than the output pressure (PR) of the self pressure reducing
valve.
q The spring (3) and the (PR) pressure (0 MPa q Therefore, there will occur a differential pres-
{0 kg/cm2} at the time of engine stop) pushes sure around the hole (a) in the spool (8) and
the valve (2) in the direction to close the circuit the spool will move in the direction to close the
between the ports (P1) and (P2). When the port (P1) and the (PR) opening. Then, the (P1)
hydraulic oil enters the port (P1), the expres- pressure is reduced and adjusted to a certain
sion (pressure (P1) C Force of spring (7) + pressure (set pressure) with the opening and is
(area of ø d x pressure (PR))) holds, and the supplied as the (PR) pressure.
self pressure reducing valve will adjust the
openings of the ports (P1) and (P2) so that the
(P1) pressure can be maintained higher than
the (PR) pressure.
q When the (PR) pressure rises above the set
pressure, the poppet (5) will open and the
hydraulic oil flows through the route from the
port (PR), the hole (a) in the spool (8), the pop-
pet (5) opening to the tank port (T).
D61EX, PX-15E0 41
At raise of load pressure (P2)
q If load pressure (P2) and the pump delivery are

increased for digging operation, etc., pressure
(P1) is also increased (pressure (P1) > force of
spring (3) + (area of ød × pressure (PR))) and
valve (2) moves to the right stroke end. As a
result, the opening between the ports (P1) and
(P2) will increase, the passage resistance will
become smaller to reduce engine loss horse-
power.
q Therefore, there will occur a differential pres-
sure around the hole (a) in the spool (8) and
the spool will move in the direction to close the
port (P1) and the (PR) opening. Then, the (P1)
pressure is reduced and adjusted to a certain
pressure (set pressure) with the opening and is
supplied as the (PR) pressure.
42 D61EX, PX-15E0
At occurrence of abnormal high pressure
q When the (PR) pressure of the self pressure

reducing valve rises abnormally high, the ball
(10) will separate from the seat against the
spring (9) force to flow the hydraulic oil to the
output ports (PR) o (T) so as to reduce the PR
pressure. Then, the equipment (PPC valve,
solenoid valve, etc.), to which the oil pressure
is supplied, is protected from the abnormal
high pressure.
D61EX, PX-15E0 43
SEN02478-00

© 2006 KOMATSU
All Rights Reserved
44
SEN02479-00
D61EX-15E0
D61PX-15E0


PPC valve ....................................................................................................................................................... 2
Electric lever (Steering)................................................................................................................................. 18
Quick drop valve ........................................................................................................................................... 22
Solenoid valve............................................................................................................................................... 24
Accumulator .................................................................................................................................................. 26
D61EX, PX-15E0 1
PPC valve 1
a PPC: Abbreviation for Proportional Pressure Control
For blade lift, tilt, and angle
2 D61EX, PX-15E0
P: From control pump 1. Spool

T: To hydraulic tank 2. Metering spring
P1: To blade tilt valve (left tilt) 3. Centering spring
P2: To blade tilt valve (right tilt) 4. Piston
P3: To blade lift valve (raise) 5. Disc
P4: To blade lift valve (lower) 6. Cap (for connecting lever)
P5: To blade angle valve (right angle) 7. Joint
P6: To blade angle valve (left angle) 8. Plate
9. Retainer
10. Body
D61EX, PX-15E0 3
Operation
At neutral
For blade lift For blade tilt
q Ports (P3) and (P4) of the (PA), (PB), and PPC q Ports (P1) and (P2) of the (PA), (PB), and PPC
valves of the blade lift control valve are con- valves of the blade tilt control valve are con-
nected to drain chamber (D) through fine connected to drain chamber (D) through fine con-
trol hole (f) of spool (1). trol hole (f) of spool (1).
4 D61EX, PX-15E0
For blade angle q By the above operation, spool (1) moves

q Ports (P5) and (P6) of the (PA), (PB), and PPC up and down so that the force of metering
valves of the blade angle control valve are con- spring (2) will be balanced with the pres-
nected to drain chamber (D) through fine con- sure in port (P4). The relation between the
trol hole (f) of spool (1). positions of spool (1) and body (10) (fine
control hole (f) is at the midpoint between
drain chamber (D) and pump pressure
chamber (PP)) does not change until
retainer (9) contacts spool (1).
q Accordingly, metering spring (2) is com-
pressed in proportion to the stroke of the
control lever and the pressure in port (P4)
also rises in proportion to the stroke of the
control lever.
q Then, the control valve spool moves to a
position where the pressure in the cham-
ber (PB) (which is the same as the pres-
sure in port (P4)) is balanced with the
force of the control valve spool return
spring.
In fine control mode

1. Neutral o fine control
q When piston (4) is pushed by disc (5),
retainer (9) is pushed, and spool (1) is
also pushed through metering spring (2),
and moves down.
q At almost the same time when fine control
hole (f) is disconnected from drain cham-
ber (D) by the above operation, it is con-
nected to pump pressure chamber (PP)
and the pilot pressure oil of the control
pump flows through fine control hole (f)
and port (P4) to port (PB).
q If the pressure in port (P4) rises, spool (1)
is pushed back. At almost the same time
when fine control hole (f) is disconnected
to pump pressure chamber (PP), it is con-
nected to drain chamber (D) and the pres-
sure in port (P4) is released.
D61EX, PX-15E0 5
2. When control lever is returned When lever is operated fully

q If disc (5) starts being returned, spool (1) is q When disc (5) pushes down piston (4) and
pushed up by the force of centering spring (3) retainer (9) pushes down spool (1), fine control
and the pressure in port (P4). hole (f) is shut off from drain chamber (D) and
q By the above operation, fine control hole (f) is is connected to pump pressure chamber (PP).
connected to drain chamber (D) and hydraulic q Accordingly, the pilot pressure oil from the con-
oil in port (P4) is released. trol pump flows through fine control hole (f),
q If the pressure in port (P4) lowers excessively, port (P4), and chamber (PB) to push the con-
spool (1) is pushed down by metering spring trol valve spool.
(2). At almost the same time when fine control q The oil returning from chamber (PA) flows
hole (f) is disconnected from drain chamber through port (P3) and fine control hole (f') to
(D), it is connected to pump pressure chamber drain chamber (D).
(PP), and then the pump pressure is applied
until the pressure in port (P4) rises to the level
equivalent to the position of the lever.
q When the control valve spool returns, the oil in
drain chamber (D) flows in through fine control
hole (f’) of the valve on the stopped side, and
then it flows through port (P3) to chamber (PA).
6 D61EX, PX-15E0
When blade is operated to "Float" When blade is released from "Float"

q If piston (4) on the "Lower" side of port (P4) is q When disc (5) is returned from the "Float" posi-
pushed down by disc (5), ball (11) touches pro- tion, it is pushed down by a force greater than
trusion (a) of the piston on the stroke. (detent the hydraulic force in chamber (E).
starts to act.) q As a result, chamber (E) is shut off from pas-
q When piston (4) is pushed in further, ball (11) sage d and is connected to the drain chamber.
pushes up collar (12), which is being held by Therefore, the oil pressure inside chamber (E)
detent spring (13). While pushing up collar is lost, and the "Float" position is canceled.
(12), it escapes to the outside and passes over
protrusion (a) of the piston.
q When this happens, piston (4') on the opposite
side is pushed up by spring (14).
q As a result, the oil inside chamber (F) passes
through (b) and (c), and flows to chamber (E),
and piston (4') follows disc (5). Since passage
(d) is connected to port (P4), the pressure in it
is almost the same as the pressure in port
(P4).
q Chamber (E) is normally connected to drain
chamber (D), but if ball (11) passes over pro-
trusion (a) of the piston, passage (d) and
chamber (E), which were shut off, are con-
nected and the pressure oil flows.
q At the same time, the control valve also moves
to the "Float" position and the circuit is set to
the "Float" condition.
q Piston (4') is being pushed up by the oil pres-
sure inside chamber (E), so even if the lever is
released, it is held at the "Float" position.
D61EX, PX-15E0 7
For blade lift and tilt
P: From self pressure reducing valve

T: To hydraulic tank
P1: To blade lift valve port PA3
P2: To blade lift valve port PB3
P3: To blade tilt valve port PA2
P4: To blade tilt valve port PB2
8 D61EX, PX-15E0
1. Disc
2. Plate
3. Body
D61EX, PX-15E0 9
Operation
At neutral
For blade lift For blade tilt
q Ports (PA3) and (PB3) of the blade lift control q Ports (PA2) and (PB2) of the blade tilt control
valve and ports (P1) and (P2) of the PPC valve valve and ports (P3) and (P4) of the PPC valve
are connected to drain chamber (D) through are connected to drain chamber (D) through
fine control hole (f) spool (1). fine control hole (f) of spool (1).
10 D61EX, PX-15E0

q When piston (4) is pushed by disc (5),
retainer (9) is pushed, and spool (1) is
also pushed through metering spring (2),
and moves down.
q As a result, if fine control hole (f) is shut off
from drain chamber (D), at almost the
same time, it is connected with pump
pressure chamber (PP), and the pilot
pressure oil passes through fine control
hole (f) and flows from port (P1) to port
(PA3).
q When the pressure at port (P1) becomes
high, if spool (1) is pushed back and fine
control hole (f) is shut off from pump pres-
sure chamber (PP), at almost the same
time, it is connected with drain chamber
(D) and released the pressure at port (P1).
q As a result, spool (1) moves up and down
so that the force of metering spring (2) is
balanced with the pressure at port (P1).
The relation between the positions of
spool (1) and body (10) (fine control hole
(f) is at the midpoint between drain cham-
ber (D) and pump pressure chamber (PP))
does not change until retainer (9) contacts
spool (1).
q Therefore, metering spring (2) is com-
pressed an amount proportional to the
movement of the control lever, so the
pressure at port (P1) also rises in propor-
tion to the movement of the control lever.
q The control valve spool moves to a posi-
tion where the pressure in chamber (PA3)
(same as pressure at port (P1)) is bal-
anced with the force of the return spring.
D61EX, PX-15E0 11

q When disc (5) starts to be returned, spool (1) is q When disc (5) pushes down piston (4) and
pushed up by the pressure at port (P1) and the retainer (9) pushes down spool (1), fine control
force of centering spring (3). hole (f) is shut off from drain chamber (D) and
q As a result, fine control hole (f) is connected to is connected to pump pressure chamber (PP).
drain chamber (D), so the pressure oil at port q Therefore, the pilot pressure oil passes
(P1) is relieved. through fine control hole (f), is taken from port
q If the pressure at port (P1) goes down too far, (P1) to chamber (PA3), and pushes the control
spool (1) is pushed down by metering spring valve spool.
(2). Fine control hole (f) is shut off from drain q The return oil from chamber (PB3) passes from
chamber (D), and at almost the same time, it is port (P2) through fine control hole (f'), and then
connected to pump pressure chamber (PP). flows to drain chamber (D).
q Pump pressure is supplied until the pressure at
port (P1) recovers to a pressure equivalent to
the position of the lever. When the control
valve spool returns, the oil at drain chamber
(D) flows in from fine control hole (f') in the
valve on the side that is not moving. It passes
through port (P2), is taken to chamber (PB3),
and the oil fills the chamber.
12 D61EX, PX-15E0
When blade is operated to "Float" When blade is released from "Float"

q When piston (4) at the port (P1) "Lower" side is q When disc (5) is returned from the "Float" posi-
pushed by disc (5) and moves down, ball (11) tion, it is pushed down by a force greater than
contacts protrusion (a) of the piston during the the hydraulic force in chamber (E).
stroke (detent starts to act). q As a result, chamber (E) is shut off from pas-
q When piston (4) is pushed in further, ball (11) sage (d) and is connected to the drain cham-
pushes up collar (12), which is being held by ber. Therefore, the oil pressure inside chamber
detent spring (13). While pushing up collar (E) is lost, and the "Float" position is canceled.
(12), it escapes to the outside and passes over
protrusion (a) of the piston.
q When this happens, piston (4') on the opposite
side is pushed up by spring (14).
q As (a) result, the oil inside chamber (F) passes
through (b) and (c), and flows to chamber (E),
and piston (4') follows disc (5). Passage (d) is
connected to port (P1), so more or less the
same pressure is applied as is applied to port
(P1).
q Chamber (E) is normally connected to drain
chamber (D), but if ball (11) passes over pro-
trusion (a) of the piston, passage (d) and
chamber (E), which were shut off, are con-
nected and the pressure oil flows.
q At the same time, the control valve also moves
to the "Float" position and the circuit is set to
the "Float" condition.
q Piston (4') is being pushed up by the oil pres-
sure inside chamber (E), so even if the lever is
released, it is held at the "Float" position.
D61EX, PX-15E0 13
For ripper (if equipped)

D61EX-15E0
T: To tank 1. Spool
P: From self pressure reducing valve 2. Metering spring
P1: To ripper spool (to control valve port PA4) 3. Centering spring
P2: To ripper spool (to control valve port PB4) 4. Piston
5. Lever
6. Plate
7. Retainer
8. Body
14 D61EX, PX-15E0
Unit: mm
Free length
9 Centering spring Replace spring if
125 N 100 N
33.9 × 15.3 28.4 — damaged or
{12.7 kg} {10.2 kg}
deformed
16.7 N 13.3 N
10 Metering spring 22.7 × 8.10 22.0 —
{1.70 kg} {1.36 kg}
D61EX, PX-15E0 15
Operation
At neutral q The relation between the positions of

q (P1) and (P2) ports of the operation valves (A), spool (1) and body (8) (fine control hole (f)
(B) and PPC valve are connected to drain is at the midpoint between drain chamber
chamber (D) via the fine control hole (f) on the (D) and pump pressure chamber (PP))
spool (1). does not change until retainer (7) contacts
spool (1).
q Therefore, metering spring (2) is com-
pressed an amount proportional to the
movement of the control lever, so the
pressure at port (P1) also rises in propor-
tion to the movement of the control lever.
q As the result, the operation valve spool
moves to the position where the pressure
of chamber (A) (the same as port (P1)
pressure) is balanced against force of the
operation valve spool return spring.

q As the piston (4) is pushed by disk (5), the
retainer (7) is pushed too. At the same
time, the spool (1) is also pushed down via
the metering spring (2).
q By this move, connection of the fine con-
trol hole (f) is switched from the drain
chamber (D) to the pump pressure cham-
ber (PP), and pilot pressure oil is con-
ducted from port (P1) to port (A).
q When the pressure at port (P1) becomes
high, if spool (1) is pushed back and fine
control hole (f) is shut off from pump pres-
sure chamber (PP), at almost the same
time, it is connected with drain chamber
(D) and released the pressure at port (P1).
q As a result, spool (1) moves up and down
so that the force of metering spring (2) is
balanced with the pressure at port (P1).
16 D61EX, PX-15E0

q As the lever (5) starts returning, the spool q When the lever (5) pushes down piston (4) and
(1) is pushed up by force of the centering the retainer (7) pushes down the spool (1),
spring (3) and port (P1) pressure. By this connection of the fine control hole (f) is
move, the fine control hole (f) is connected switched from the drain chamber (D), to the
to the drain chamber (D) and relieves pump pressure chamber (PP).
pressurized oil of port (P1) to it. q Thus, pilot pressurized oil from the control
q If port (P1) pressure goes excessively low, pump passes through fine control hole (f) and
the spool (1) is pushed down by the conducted to chamber (A) via port (P1) to push
metering spring (2), and passage between the operation valve spool.
fine control hole (f) and drain chamber (D) q Return oil from chamber (B) is conducted from
is shut down. And, almost at the same port (P2) to the drain chamber (D) via the fine
time, the hole is connected to the pump control hole (f').
pressure chamber (PP) and begins to sup-
ply pressure to a pump. This supply con-
tinues until the port (P1) pressure is
recovered to the level equivalent to the
lever position.
q When the operation valve spool returns,
oil in the drain chamber (D) flows in
through the fine control hole (f') on the not
moving side valve. Oil is then conducted
via port (P2) to the chamber (B) to fill it up.
D61EX, PX-15E0 17
Electric lever (Steering) 1
a Do not disassemble.
If disassembled, the output voltage characteristics and operating effort characteristics will need to be
adjusted.
1. Boots 5. Screw
2. Bracket 6. Lever
3. Plate 7. Connector
4. Bolt
18 D61EX, PX-15E0
Function
Operating effort characteristics

1. Operation for directional 2. Operation for steering
q The control lever is held at 3 positions of q Free return.
Forward, Neutral, and Reverse.
D61EX, PX-15E0 19
Output voltage characteristics

q The control unit is installed to the left control
stand and the control lever is installed directly
onto it.
q The operating angle (stroke) of the control
lever is sensed with potentiometers and signal
voltages are output to the transmission, steer-
ing controller.
q A potentiometer is installed in each of longitu-
dinal direction and lateral direction. Each
potentiometer outputs 2 signal voltages which
are opposite to each other as shown in the
graph at right.
20 D61EX, PX-15E0
D61EX, PX-15E0 21
Quick drop valve 1

(lift cylinder)
Unit: mm

size Shaft Hole clearance limit
1 Clearance between valve and body
–0.034 +0.025 0.034 –
ø33 0.080
–0.050 0 0.075
–0.039 +0.021 0.039 –
2 Clearance between piston and plug ø25
–0.054 0 0.075
0.080
Standard size Repair limit Replace

Installed
Free length Installed load Free length Installed load
3 Valve spring length
88.2 N 79.4 N
108.3 26 97.5
{9.0 kg} {8.1 kg}
4.6 N 4.1 N
4 Piston spring 27.3 26
{0.47 kg}
24.6
{0.42 kg}
5. Plug VH : From control valve blade "Raise"

6. Piston VB : From control valve blade "Lower"
7. Valve CH1: To right lift cylinder head
8. Body CH2: To left lift cylinder head
CB1: To right lift cylinder bottom
CB2: To left lift cylinder bottom
22 D61EX, PX-15E0
Outline
q The quick drop valve is installed between the
control valve and lift cylinder. When the control
lever is operated to "Lower" the blade, this
device prevents a vacuum in the cylinder bot-
tom and shortens the time lag in starting dig-
ging,
q The blade lowering speed is almost decided by
the pump discharge. It can be heightened,
however, by installing the quick drop valve.
Operation
Start of lowering blade While lowering blade
q If the blade control lever is set in the "Lower" q The oil pushed out of the cylinder head side
position, the oil from the control valve flows in flows through ports (CH1) and (CH2) to port
port (VB), and then flows through ports (CB1) (VH). At this time, the oil flow rate is reduced
and (CB2) to the cylinder bottom side and by orifice a and a pressure difference is made
pushes the piston to the left. between before and behind the orifice.
q The oil on the cylinder head side is pushed out q If the oil pressure in ports (CH1) and (CH2)
by the piston, and then it enters ports (CH1) becomes higher than the tension of springs (1)
and (CH2) and flows through port (VH) and and (2), valve (3) and piston (4) move to the
control valve to the hydraulic tank. right.
q Since ports (VB), (CH1), and (CH2) are
opened, a part of the oil flowing from ports
(CH1) and (CH2) to port (VH) merges with the
oil from the control valve and then flows to the
cylinder bottom side.
q Accordingly, the blade lowering speed is
increased by the quantity of the oil flowing into
the cylinder bottom side and a vacuum on the
bottom side is prevented.
D61EX, PX-15E0 23
Solenoid valve 1
PPC lock solenoid valve
a PPC: Abbreviation for Proportional Pressure Control
a The diagram shows a machine equipped with the accumulator (if equipped)
24 D61EX, PX-15E0
P : From cooling fan pump (port P) Operation

P1 : To blade PPC valve (port P) When solenoid is "De-energized"
P2 : To control valve (port PEPC) (when circuit is disconnected)
T : To hydraulic tank q Since the signal current does not flow in the
From blade PPC valve (port T) solenoid valve, coil (1) is "De-energized".
T1 : From control valve (port TS) q Accordingly, spool (3) is pressed to the left by
ACC: To accumulator (for PPC circuit) spring (4).
q As a result, port (P) is closed and the hydraulic
oil from the pump does not flow from port (P1)
1. PPC lock solenoid valve to the actuator.
q At this time, the oil from the actuator flows from
Solenoid valve port (P1) to port (T), and then it is drained.
2. Nut
3. Plunger
4. Coil
5. Push pin
6. Spring
7. Spool
8. Block
Check valve
9. Plug
10. Spring (when accumulator is installed)
11. Poppet (when accumulator is installed)
Outline
q The PPC lock solenoid valve is installed
between the cooling fan and blade PPC valve. When solenoid is "Energized"
If the work equipment lever is set in the "Lock" (when circuit is connected)
position, the PPC lock switch is turned "ON" q If the signal current flows in the solenoid valve,
and the solenoid valve is "Energized" to stop coil (1) is "Energized" and a rightward thrust is
the oil in the PPC circuit, thus the work equip- generated in plunger (2).
ment cannot move. q Accordingly, spool (3) is pushed to the right by
push pin (5).
q As a result, the hydraulic oil from the pump
flows from port (P) through port (P1) to the
actuator.
q At this time, port (T) is closed and the oil is not
drained.
D61EX, PX-15E0 25
Accumulator 1
(for PPC circuit)
1. Gas plug
2. Shell
3. Poppet
4. Holder
5. Bladder
6. Oil port
Outline
q The accumulator is installed to the PPC lock
solenoid valve. Even if the engine is stopped
while the work equipment is raised, the work
equipment can be lowered under its weight by
applying the pilot oil pressure to the control
valve to operate with the pressure of the nitro-
gen gas compressed in the accumulator.
Specifications
Gas used: Nitrogen gas
Volume of gas: 300cc
Gas pressure: 1.18MPa {12kg/cm2} (at 80°C)
Max. using pressure: 6.86MPa {70kg/cm2}
26 D61EX, PX-15E0
D61EX, PX-15E0 27
SEN02479-00

© 2006 KOMATSU
All Rights Reserved
28
SEN02478-00
D61EX-15E0
D61PX-15E0


Control valve ................................................................................................................................................... 2
CLSS............................................................................................................................................................. 10
Self pressure reducing valve......................................................................................................................... 37
D61EX, PX-15E0 1
Control valve 1
Outline
The following 3 types of control valve are set.
q 4-spool valve (lift + tilt + angle + steering)
q 4-spool valve (lift + tilt + ripper + steering)
q 5-spool valve (lift + tilt + angle + ripper + steering)
The outside view and section of only the 4-spool valve are shown.
P: From pump
T: To tank
A1: To HSS motor
A2: To lift cylinder head
A3: To tilt cylinder bottom
A4: To angle cylinder bottom
B1: To HSS motor
B2: To lift cylinder bottom
B3: To tilt cylinder head
B4: To angle cylinder head
LS: To pump port LS
PI: Pump pressure pickup port
TS: To tank
CA1: Connector (from controller)
CB1: Connector (from controller)
PA2: From PPC valve
PA3: From PPC valve
PA4: From PPC valve
PB2: From PPC valve
PB3: From PPC valve
PB4: From PPC valve
PEPC: From self pressure reducing valve
2 D61EX, PX-15E0
4-spool valve
(lift + tilt + angle + steering)
D61EX, PX-15E0 3
Section
(1/4)
4 D61EX, PX-15E0
1. Suction valve
3. Steering spool
4. Lift spool
5. Tilt spool
6. Angle spool
7. Cover (work equipment valve side)
8. Valve block (blade angle valve)
9. Valve block (blade tilt valve)
10. Valve block (blade lift valve)
11. Block (pump port)
12. Valve block (steering valve)
13. Cover (steering valve side)
Unit: mm
Free length
14 Suction valve spring
5.1 N 4.1 N
39.2 × 4.45 33.5 —
{0.52 kg} {0.42 kg}
5.5 N 4.4 N
15 Suction valve spring 46.8 × 7.5 40.6 —
{0.56 kg} {0.45 kg}
67.7 N 54.2 N
16 Back pressure valve spring 67.7 × 20 42.5 —
{6.9 kg} {5.5 kg}
Replace spring if
221 N 178 N
17 Spool return spring (steering) 45.7 × 28 43 — damaged or
{22.6 kg} {18.1 kg}
deformed
83.4 N 66.7 N
18 Spool return spring (lift) 41 × 18.6 39 —
{8.5 kg} {6.8 kg}
Spool return spring (tilt), 108 N 86.3 N
19 41.9 × 18.6 39 —
(angle) {11 kg} {8.8 kg}
81.4 N 65.1 N
20 Spool return spring (lift) 40.5 × 24.6 37.5 —
{8.3 kg} {6.64 kg}
51.4 N 41.1 N
21 Spool return spring (lift) 37.3 × 19.4 17 —
{5.24 kg} {4.19 kg}
D61EX, PX-15E0 5
(2/4)
6 D61EX, PX-15E0
R: Pressure reducing valve

F: Flow control valve

2. Pressure compensation valve R
3. Pressure compensation valve F
6. Check valve (centralized safety valve)
Unit: mm
Free length
7 Flow control valve spring
9.8 N 7.85 N
36.2 × 5.30 32.0 —
{1.0 kg} {0.80 kg}
17.6 N 14.1 N
{1.8 kg} {1.44 kg}
55.9 N 44.7 N
{5.7 kg} {4.56 kg}
Replace spring if
34.3 N 27.5 N
10 Pressure reducing valve spring 31.9 × 14.4 21.5 — damaged or
{3.5 kg} {2.8 kg}
deformed
27.6 N 22.2 N
11 Flow control valve spring 30.9 × 5.2 20 —
{2.82 kg} {2.26 kg}
473 N 379 N
12 Steering priority valve spring 106.5 × 20 82 —
{48.2 kg} {38.6 kg}
Work equipment valve and 126 N 100 N
13 51.6 × 10.5 44.5 —
pressure reducing valve spring {12.7 kg} {10.2 kg}
3.92 N 3.14 N
14 Check valve spring 27.2 × 6.9 22 —
{0.4 kg} {0.32 kg}
D61EX, PX-15E0 7
(3/4)
1. LS shuttle valve
2. Unload valve
8 D61EX, PX-15E0
(4/4)

2. Pressure releasing plug
D61EX, PX-15E0 9
CLSS 1
a CLSS: Closed center Load Sensing System
Outline of CLSS
Features
CLSS is an abbreviation for Closed center Load
Sensing System, which has the following features.
q Fine controllability which is not affected by load
q Controllability for digging in fine control mode
q Flow division performance decided by open
area of spool during compound operation
q Energy saving performance with variable
pump control
Composition
q The CLSS consists of the variable-capacity
piston pump, control valve, and actuators.
q The pump consists of the main pump, variable
throttle valve, TVC valve, and LS valve.
10 D61EX, PX-15E0
Basic principle
Control of pump swash plate angle

q The pump swash plate angle (pump delivery) q If LS differential pressure (dPLS) is lower than
is so controlled that LS differential pressure the set pressure of the LS valve (when the
(dPLS) which is the differen tial pressure actuator load pressure is high), the pump
between pump (discharge) pressure (PP) and swash plate moves toward the maximum end.
LS pressure (PLS) (actuator load pressure) at
the control valve outlet will be constant (LS dif-
ferential pressure (dPLS) = Pump discharge
pressure (PP) – LS pressure (PLS)).
D61EX, PX-15E0 11
Pressure compensation control

q A valve (pressure compensation valve) is
installed to the outlet side of the control valve
to balance the load. This valves works so that
p r e s s u r e d i ff e r e n c e ( d P ) b e t w e e n t h e
upstream (inlet) side of the spool of each valve
and the downstream (outlet) side will be main-
tained, regardless of the load (pressure). By
this operation, the oil from the pump is distrib-
uted (compensated) in proportion to the open
areas (S1) and (S2) of each of the operated
valves.
12 D61EX, PX-15E0
D61EX, PX-15E0 13
Each function and each valve operation
Hydraulic circuit diagram and name of valve
14 D61EX, PX-15E0
1. Unload valve
5. Pressure compensation valve
6. Suction valve
7. LS shuttle valve
11. Steering valve
12. Lift valve
13. Tilt valve
14. Angle valve
D61EX, PX-15E0 15
Unload valve
When control valve is in neutral
T: Tank circuit (pressure) Operation

PP: Pump circuit (pressure) q Pump discharge pressure (PP) is applied to
PLS: LS circuit (pressure) the right side of spool (3) and LS pressure
(PLS) is applied to the left side.
1. Sleeve q When the control valve is in neutral, LS pres-
2. Spring sure (PLS) is 0. Accordingly, only pump dis-
3. Spool charge pressure (PP) is applied and it is set
with only the spring load of spring (2).
q If pump discharge pressure (PP) rises to the
Function spring load of 3.4 MPa {35 kg/cm2} of spring
q When the control valve is in neutral, delivery (2), spool (3) moves to the left and pump circuit
(Q) at the minimum pump swash plate angle is (PP) is connected to tank circuit (T) through
released to the tank circuit. At this time, pump hole (a) of sleeve (1).
discharge pressure (PP) is set to 3.4 MPa {35 q By this operation, pump discharge (PP) is set
kg/cm2} by spring (2) in the valve (LS pressure to 3.4 MPa {35 kg/cm2}.
(PLS) is 0 MPa {0 kg/cm2}).
16 D61EX, PX-15E0
When control valve is controlled finely
T: Tank circuit (pressure) q At this time, pump discharge pressure (PP)

PP: Pump circuit (pressure) rises to pass all of (Q) min. As a result, the dif-
PLS: LS circuit (pressure) ferential pressure between pump discharge
pre ssur e (PP) a nd LS pr essu re (PL S) is
1. Sleeve increased.
2. Spring q If, As a result, the differential pressure between
3. Spool pump discharge pressure (PP) and LS pres-
sure (PLS) reaches the spring load of 3.4 MPa
{35 kg/cm 2} of spring (2), spool (3) moves to
Function the left and pump circuit (PP) is connected to
q When the control valve is controlled finely, if tank circuit (T).
the demand flow for the actuator is below the q That is, pump discharge pressure (PP) is set to
delivery at the minimum pump swash plate spring force of 3.4 MPa {35 kg/cm2} + LS pres-
angle, pump discharge pressure (PP) is set to sure (PLS) and the flow control differential
LS pressure (PLS) + 3.4 MPa {35 kg/cm 2}. If pressure below the pressure at the minimum
the differential pressure between discharge swash plate (= ∆PLS) becomes 3.4 MPa {35
pres sure (P P) and LS press ure (P LS ) kg/cm2}.
becomes the spring load of spring (2) (3.4 MPa
{35 kg/cm2}), the unload valve opens. LS differ-
ential pressure (∆PLS) is 3.4 MPa {35 kg/cm2}.
Operation
q When the actuator is controlled with a flow rate
be low the delive ry at the minimu m pump
swash plate angle (below (Q) min. in the graph
at right), if the control valve spool is changed,
LS pressure (PLS = Load pressure) is sensed
and applied to the left end of spool (3).
D61EX, PX-15E0 17
When control valve is operated
Function
q When the control valve is operated, if the
demand flow for the actuator exceeds the
delivery at the minimum pump swash plate
angle, the flow to tank circuit (T) is stopped
and all of pump delivery (Q) is supplied to the
actuator circuit.
Operation
q If the control valve is controlled largely, LS
pressure (PLS) is generated and applied to the
left end of spool (3). At this time, since the
open area of the control valve spool is wide,
the difference between LS differential pressure
(∆PLS) and pump discharge pressure (PP) is
little.
q Accordingly, the differential pressure between
pump discharge pressure (PP) and LS pres-
sure (PLS) does not reach the spring load of
3.4 MPa {35 kg/cm 2} of spring (2) and spool (3)
is pushed to the right by spring (2).
q As a result, pump circuit (PP) is disconnected
from tank circuit (T) and all of pump delivery
(Q) is supplied to the actuator circuit.
18 D61EX, PX-15E0
Main relief valve (steering, work equipment)

Centralized safety valve
Function q If pilot poppet (3) opens, the pressure in spring

q If the oil pressure rises above the set level, oil chamber (C) lowers and poppet (1) moves to
is drained into the tank. As a result, the maxi- the right. Then, poppet (1) touches the end of
mum pressure of the work equipment circuit is pilot poppet (3) and the oil is drained through
regulated to protect the circuit. throttle (b) and the hole.
Operation
q Port (A) is connected to the pump circuit and
hydraulic oil is supplied through diameter (d1)
and the hole of poppet (1) to diameter (d2) of
main valve (2). Then, main valve (2) is in con-
tact with the sleeve because of the difference
in area (d1 < d2).
q Since the pressure in spring chamber (C) is

lower than the pressure in port (A), main valve
(2) opens and the oil flows from port (A) to port
(B) to prevent abnormal pressure.
q If the pressure in port A reaches the set pres-

sure of spring (4), pilot poppet (3) opens and
the o il flo ws a roun d pilot p oppe t (3) a nd
through hole (a) and port (B), and then it is
drained.
D61EX, PX-15E0 19
Steering priority valve
In compound operation
20 D61EX, PX-15E0
a: Pump circuit
b: Steering pump circuit
c: Work equipment pump circuit
d: Spring chamber
e: Pressure chamber
1. Steering priority valve spool

3. Steering spool
Function
q If the steering valve and the work equipment
valves on the downstream side of the steering
priority valve are operated simultaneously, oil
for the steering valve is secured first, and then When pump swash plate does not reach maxi-
the rest of the pump delivery flows to the work mum angle
equipment valve. q If the maximum pump flow is larger than the
total demand flow for the steering valve and
work equipment valve, oil flows in the steering
Operation valve accordingly to the open area of steering
q If steering spool (3) is operated and some oil spool (3) and in the work equipment valve
flows, a difference is made between pump dis- decided by the pump pressure, load pressure,
charge pressure (PP) and LS pressure (PLS). and open area of the spool.
This differential pressure simultaneously con-
trols steering priority valve (1) and pump
swash plate with (∆PLS) ((PP) – (PLS)) = 1.96 When pump swash plate is at maximum angle
MPa {20 kg/cm2} to decide the flow rate to the
q When the maximum pump flow is less than the
steering valve.
total demand for the steering valve and work
q The (PP) pressure is applied to right end (e) of
equipment valve.
priority valve spool (1) and the (PLS) pressure
is applied to spring chamber (d) on the left
1. When steering valve load Z Work equipment
side. Priority valve spool (1) is pressed to the
valve load
right by spring (2).
q Oil flows in the steering valve accordingly
q Accordingly, if the differential pressure
to the open area of steering spool (3) and
between the (PP) pressure and (PLS) pressure
the rest flows in the work equipment valve.
is below the set pressure of the spring, the
open area from chamber (a) to chamber (b)
2. When steering valve load > Work equipment
becomes maximum. If the differential pressure
valve load
is increased, spool (1) moves to the left to
q Pump pressure (PP) is decided by the
decrease the open area for the steering and
steering valve load. If the work equipment
increase the open area for the work equip-
valve on the downstream side, where the
ment.
load is smaller, is operated under this con-
q While steering spool (3) is operated, if work
dition, the oil flows in the work equipment
equipment spool (4) is operated, pump pres-
valve because of the differential pressure,
sure (PP) lowers for a moment.
and then the pump pressure lowers.
q accordingly, the differential pressure between
q At this time, steering priority valve (1)
(PP) and (PLS) is reduced and priority valve
increases the open area for the steering
(1) moves to the right to decrease the open
and decreases the open area for the work
area for the work equipment with the pressure
equipment to secure the flow for the steer-
in chamber (d).
ing.
q At the same time, (∆PLS) becomes smaller, so
q Under this condition, the oil flow is distrib-
the pump swash plate angle moves in the max-
uted at the ratio of the differential pressure
imum direction to supply an oil flow to make up
between (PP) and (P1) to that between
the amount that the pressures drops.
(PP) and (P2). The bigger (P1) – (P2) is,
the smaller the flow of oil to the steering
system becomes.
D61EX, PX-15E0 21
Pressure reducing valve for work equipment
When work equipment valve is operated alone
a: Work equipment pump circuit (pressure) Operation

b: Orifice q If the work equipment valve (lift, tilt, angle,
c: Spring chamber etc.), hydraulic oil (PP) in the pump circuit if
d: Valve pressure receiving chamber applied to right-end chamber (g) to push spring
e: Cut (7) to the left through cut (e) and orifice (f) of
f: Orifice spool (6). As a result, open area (h) of the cut
g: Pressure chamber b e co me s m a x imu m. H yd ra u lic o il f lo w s
h: Cut through cut (i) of valve (4) to work equipment
i: Cut pump circuit (a).
PP: Pump circuit (pressure) q If the pressure reducing valve (1) of work
T: Tank circuit equipment pump circuit (a) becomes the set
pressure of 20.6 MPa {210 kg/cm2}, poppet (2)
1. Pressure reducing valve pushes spring (3) to the right to release the
2. Poppet hydraulic oil in spring chamber (c) to tank cir-
3. Spring cuit (T). Accordingly, the hydraulic oil in pres-
4. Valve sure chamber (d) flows through orifice (b) and
5. Spring spring chamber (c) to tank circuit (T). A pres-
6. Steering priority valve spool sure difference is made between pressure
7. Spring chamber (d) and spring chamber (c) and valve
(4) moves to the right to close cut (i). Accord-
Function ingly, pump circuit (PP) is disconnected from
q The pump circuit pressure on the work equip- work equipment circuit (a).
ment side is controlled to below 20.6 MPa {210 q Even if the steering system is operated and the
kg/cm 2} and the pump circuit pressure on the pump circuit pressure rises to 40.2 MPa {410
steering side is secured to 40.2 MPa {410 kg/ kg/cm2}, the work equipment pump circuit pres-
cm 2} during compound operation (work equip- sure does not exceed 20.6 MPa {210 kg/cm2}.
ment + steering).
22 D61EX, PX-15E0
Pressure compensation valve
Function
q If the load pressure is lower than the pressure
in the other actuator and the flow rate starts
increasing during compound operation, the
pressure compensation valve compensates
the pressure (at this time, the load pressure in
the other actuator operated for the compound
operation (on the upper side) is higher than the
load pressure on this side (lower side)).
D61EX, PX-15E0 23
Operation Suction valve

q If the load pressure in the other actuator (on
the upper side) becomes high, the flow rate in Function
actuator circuit (A) on this side (lower side) q This valve prevents negative pressure in the
starts increasing. cylinder circuit.
q In this case, LS pressure (PLS) in the other
actuator is applied to spring chamber (PLS1)
to push pressure reducing valve (1) and flow Operation
control valve (2) to the left. q Port (A) is connected to the cylinder circuit and
q Flow control valve (2) reduces the open area port (B) is connected to the drain circuit. When
between pump circuit (PP) and spool upstream a load is applied to port (A), main poppet (1)
(PPA) to make a pressure loss in the line opens because of the area difference between
between (PP) and (PPA). (d1) and (d2). Then, the oil flows from port (B)
q Flow control valve (2) and pressure reducing to port (A) to prevent negative pressure.
valve (1) are stopped at a position where the
pressure difference between (PA) and (PLS)
applied to both ends of pressure reducing
valve (2) is the same as the pressure loss
made in the line between (PP) and (PPA) at
the front and rear of flow control valve (2).
q As a result, pressure difference between
upstream pressure (PPA) and downstream
pressure (PA) becomes the same at each
spool operated for the compound operation.
Then, the pump flow is distributed in proportion
to the open area of cut (a) of each spool.
24 D61EX, PX-15E0
Safety-suction valve
Function q Since pilot poppet (4) opens, the pressure in

q If any impact is applied to the cylinder and chamber C lowers and poppet (3) moves to the
abnormal pressure is generated, the abnormal right. Poppet (3) is seated at the end of pilot
pressure is released through the safety valve poppet (4) and the oil is drained through throt-
to protect the cylinder and other hydraulic tle (b) and chamber (D).
parts.
der circuit, this valve works as a suction valve.
Operation as safety valve

q Port (A) is connected to the cylinder circuit and
hydraulic oil in port (A) is led through the hole
of poppet (3) to port (C) and safety valve (2) is
seated to the left since (d2) < (d3). The rela-
tionship between diameters (sectional areas)
is as follows (d4) > (d1) > (d3) > (d2).
q Since the pressure in chamber (C) is lower

than the pressure in port (A), safety valve (2)
moves to the right and the oil flows from port
(A) to port (B) to prevent generation of abnor-
mal pressure.
q Even if abnormal pressure is generated, suc-
tion valve (1) having a larger diameter does not
operate since (d1) < (d4).
q If abnormal pressure is generated in port (A)

and it increases to the set pressure of spring
(5), pilot poppet (4) opens and the oil from
chamber (C) is drained through chamber (D)
and periphery (a) of suction valve (1).
D61EX, PX-15E0 25
Operation as suction valve

der circuit, the pressures in port (A) and cham-
ber (C) becomes negative since they are
connected. The tank pressure of port (B) is
applied to port (E) and the oil pressure in suc-
tion valve (1) is increased by the area differ-
ence between (d4) and (d3) because of the
tank pressure of port (E). Then, the increased
pressure moves suction valve (1) to the right
against the tension of spring (6). Accordingly,
the oil flows from port (B) to port (A) to prevent
negative pressure in port (A).
26 D61EX, PX-15E0
LS shuttle valve (used as steering LS bypass plug, too)
a: Clearance filter Operation

b: LS bypass orifice (steering) q The PLS circuit pressure on the steering side
c: LS bypass orifice (work equipment side) presses ball shuttle valve (2) to the right, and
then it is led to the upper (PLS) output port
1. LS Ball shuttle valve and LS bypass plug (when steering system is operated alone or
2. Poppet together with another system (when steering
(PLS) > work equipment (PLS))).
q The PLS hydraulic oil flows from the clearance
Function filter (a) through orifices (b) and (c) to the tank
q Used to release residual LS pressure (PLS) circuit.
q The rising speed of LS pressure (PLS) is low- q The pressure in the PLS circuit on the work
ered and the discarded throttle flow is used to equipment side presses ball shuttle valve (2) to
make pressure loss in the throttle between (P) the left, and then it is let to the upper (PLS)
and (LS) of the pressure compensation valve output port (when steering system is operated
to lower the effective LS differential pressure alone or together with another system (when
and increase the stability. work equipment (PLS) > steering (PLS))).
q The higher LS pressure on the steering side or
work equipment side is selected and output.
D61EX, PX-15E0 27
Steering LS relief valve and main relief valve operation
a: Pump primary circuit 1. Steering spool

b: Pump secondary circuit 2. Steering LS relief valve
c: LS circuit 3. Main relief valve
5. Priority valve spool
28 D61EX, PX-15E0
Function
q If specified the maximum pressure when the
HSS motor is operated.
pressure (PP – PLS) generated by the opera-
tion of the LS relief valve and moves the pump
swash plate toward the minimum position. The
pump delivery is balanced at the minimum
position. accordingly, the relief oil flow is
reduced.
q Main relief valve: Cuts the peak pressure
caused by a sudden external load which the
LS relieve valve cannot lower by controlling the
swash plate.
Operation
q Steering spool (1) is moved and HSS motor
drive pressure (4) is increased, steering LS
relief valve (2) operates to drain the oil from
pump circuit (b). As a result, the pressure dif-
ference between pump circuit (b) and LS cir-
cuit (c) is increased.
q For the same reason, if the pressure in LS cir-
cuit (c) is lowered, priority valve spool (5)
moves to the left against spring (6) to reduce
the open areas of pump primary (a) and sec-
ondary (b). As a result, the pressure difference
between (a) and (b) is increased.
q Pump LS valve senses the LS differential pres-
sure (PP – PLS) generated by LS relief valve
(2) and moves the pump swash plate from the
maximum position toward the minimum posi-
tion. The pump swash plate is balanced at the
minimum position when the LS differential
pressure X 2.0MPa {20 kg/cm 2 } (see pump
swash plate control).
q When the pump swash plate is at the minimum
position (minimum flow rate), if the pump cir-
cuit pressure (PP) – LS circuit pressure (PLS)
X 3.4 MPa {35 kg/cm2}, the unload valve oper-
ates to release the excessive oil and balance
the swash plate.
LS relief valve set pressure: 33.1 MPa {338 kg/cm2}

Main relief valve set pressure: 40.2 MPa {410 kg/cm2}
D61EX, PX-15E0 29
Work equipment relief valve operation

2. Pressure reducing valve
3. Main relief valve (work equipment)
4. Main relief valve (steering)
5. Pressure reducing valve spool
30 D61EX, PX-15E0
Function
q The maximum pressure is regulated when the
work equipment is operated.
pressure (PP1 – PP2 C PLS) generated by the
operation of the pressure reducing valve and
the relief valve on the work equipment side and
moves the pump swash plate toward the mini-
mum position. The pump delivery is balanced
at the minimum position. accordingly, the relief
oil flow is reduced.
Operation
q If work equipment spool (1) is moved and work
e q u ip m e n t o p e r a t in g p r e s s u r e ( PP 2 ) is
increased, pressure reducing valve (2) oper-
ates and pressure reducing valve spool (5)
narrows the (PP1) and (PP2) circuits (1.1mm2).
Work equipment pump circuit pressure (PP2)
becomes the pressure reducing valve set pres-
sure of 20.6 MPa {210 kg/cm2}.
q Since steering relief valve (4) is set high pres-
sure, the oil is supplied through the narrow
open area of pressure reducing valve spool (5)
by the override of the pressure reducing valve,
and then the (PP2) circuit pressure rises.
q Then, if the pressure reaches the work equip-
ment relief set pressure, the (PP2) circuit pres-
sure oil is drained through the relief valve.
Since the differential pressure between (PP1)
and (PP2) (C PLS) is generated by the flow
from relief valve (3) and the throttle of orifice
(a) of the pressure reducing valve and it mini-
mizes the pump swash plate angle, the pump
delivery becomes minimum (same as steering
LS relief function).
Reducing valve set pressure: 20.6 MPa {210 kg/cm2}

Relief valve set pressure: 21.6 MPa {220 kg/cm2}
D61EX, PX-15E0 31
Introduction of LS pressure
Steering valve
Function q Since pressure reducing valve (3) also moves

q The LS pressure means the actuator load to the left at this time, pump discharge pres-
pressure on the outlet side of the control valve. sure (PP) introduced through orifice (c) is
q In the work equipment valve, pressure reduc- reduced by the pressure loss in cut (d) and
ing valve (3) of the pressure compensation introduced to LS circuit (PLS), and then further
valve reduces pump discharge pressure (PP) led to spring chamber (PLS1).
to the level of actuator circuit pressure (A), and q At this time, LS circuit (PLS) is connected to
then introduces it to the LS circuit (PLS). Ori- tank circuit (T) through LS bypass plug (4).
fice (c) is installed to piston (5) on the way from q Both ends of pressure reducing valve (3) has
pump circuit (PP) to pressure reducing valve the same area (SA = SLS). Actuator circuit
(3), and it works as a damper. pressure (PA) (= A) is applied to the (SA) side
cut a of the spool, and bridge circuit (b) to actu- (PLS1) are the same. Pump discharge pres-
ator circuit (A). sure (PP) reduced by cut (d) is introduced as
actuator circuit pressure (A) to LS circuit
(PLS).
32 D61EX, PX-15E0
Work equipment valve (lift, tilt, angle, ripper)
When blade is "Raised"

cut (a) of the spool, and bridge circuit (b) to (PLS1) are the same. Pump discharge pres-
actuator circuit (A). sure (PP) reduced by cut (d) is introduced as
q Since pressure reducing valve (3) also moves actuator circuit pressure (A) to LS circuit
to the right at this time, pump discharge pres- (PLS).
sure (PP) introduced through passage (c) is
reduced by the pressure loss in cut (d) and
introduced to LS circuit (PLS), and then further
led to spring chamber (PLS1).
q At this time, LS circuit (PLS) is connected to
tank circuit (T) through LS bypass plug (4).
q Both ends of pressure reducing valve (3) has
the same area (SA = SLS). Actuator circuit
pressure (PA) (= A) is applied to the (SA) side
D61EX, PX-15E0 33
When blade is "Floated"
Operation
q If the lift valve is set in the "Float" position, the
cylinder port is connected to drain port (T) and
no load is applied.
q Even if the lift valve is in the "Float" position,
the pump circuit and cylinder circuit are sepa-
rated so that the other work equipment (tilt,
angle, etc.) can be operated.
q If the work equipment control lever is set in the
"Float" position, spool (1) is set in the maxi-
mum stroke position. Port (B) is connected to
port (A) through bridge passage (b), and port
(A) is connected to circuit (T).
q Accordingly, if the blade is loaded, it can move
up and down.
q While the lift valve is in the "Float" position,
part a of spool (1) is closed. Accordingly, if
other work equipment (tilt, angle, etc.) is oper-
ated, the pump pressure rises and the operator
can start compound operation.
34 D61EX, PX-15E0
Back pressure valve
Function
q When the machine is steered or stopped, the
back pressure valve increases the pressure in
the steering drain circuit to prevent cavitation
in the HSS motor and increase the effect of
suction valve (3).
Operation
q The drain pressure in the steering circuit is
increased by back pressure valve (1) and
spring (2).
D61EX, PX-15E0 35
36 D61EX, PX-15E0
Self pressure reducing valve 1
T: To tank
P1: From pump
P2: To fan motor
PR: Supplied to PPC valve, EPC valve, etc.
D61EX, PX-15E0 37
1. Valve (sequence valve) 6. Spring (pressure reducing valve main)

2. Spring 7. Valve (pressure reducing valve)
3. Screw 8. Spring (safety valve)
4. Poppet 9. Ball
5. Spring (pressure reducing valve pilot) 10. Filter
38 D61EX, PX-15E0
Unit: mm
Free length
Spring O.D. length load load
11
(pressure reducing valve main) 19.6 N 17.7 N
19.2 × 7.20 16.1 —
{2.0 kg} {1.80 kg}
Replace spring if
12 17.8 × 7.20 12.1 — damaged or
(pressure reducing valve pilot) {3.2 kg} {2.9 kg}
deformed
200 N 186 N
13 Spring 71.0 × 18.0 59.0 —
{20.4 kg} {19.0 kg}
14 16.1 × 7.80 13.4 —
(safety valve) {6.30 kg} {6.0 kg}
Function
q The self pressure reducing valve reduces the
discharge pressure of the fan pump and sup-
plies it to the PPC valve, the EPC valve, etc. as
the control pressure.
D61EX, PX-15E0 39
Operation
At engine stop (total low pressure)
q The spring (6) pushes the poppet (5) the seat,

and the circuit between the ports (PR) and (T)
is closed.
q The spring (7) pushes the valve (8) to the left
side, and the circuit between the ports (P1)
and (PR) is open.
q The spring (3) pushes the valve (2) to the
upper side, and the circuit between the ports
(P1) and (P2) is closed.
40 D61EX, PX-15E0
When the load pressure (P2) is lower than the output pressure (PR) of the self pressure reducing
valve.
q The spring (3) and the (PR) pressure (0 MPa q Therefore, there will occur a differential pres-
{0 kg/cm2} at the time of engine stop) pushes sure around the hole (a) in the spool (8) and
the valve (2) in the direction to close the circuit the spool will move in the direction to close the
between the ports (P1) and (P2). When the port (P1) and the (PR) opening. Then, the (P1)
hydraulic oil enters the port (P1), the expres- pressure is reduced and adjusted to a certain
sion (pressure (P1) C Force of spring (7) + pressure (set pressure) with the opening and is
(area of ø d x pressure (PR))) holds, and the supplied as the (PR) pressure.
self pressure reducing valve will adjust the
openings of the ports (P1) and (P2) so that the
(P1) pressure can be maintained higher than
the (PR) pressure.
D61EX, PX-15E0 41
At raise of load pressure (P2)
q If load pressure (P2) and the pump delivery are

increased for digging operation, etc., pressure
(P1) is also increased (pressure (P1) > force of
spring (3) + (area of ød × pressure (PR))) and
valve (2) moves to the right stroke end. As a
result, the opening between the ports (P1) and
(P2) will increase, the passage resistance will
become smaller to reduce engine loss horse-
power.
q Therefore, there will occur a differential pres-
sure around the hole (a) in the spool (8) and
the spool will move in the direction to close the
port (P1) and the (PR) opening. Then, the (P1)
pressure is reduced and adjusted to a certain
pressure (set pressure) with the opening and is
supplied as the (PR) pressure.
42 D61EX, PX-15E0
At occurrence of abnormal high pressure
q When the (PR) pressure of the self pressure

reducing valve rises abnormally high, the ball
(10) will separate from the seat against the
spring (9) force to flow the hydraulic oil to the
output ports (PR) o (T) so as to reduce the PR
pressure. Then, the equipment (PPC valve,
solenoid valve, etc.), to which the oil pressure
is supplied, is protected from the abnormal
high pressure.
D61EX, PX-15E0 43
SEN02478-00

© 2006 KOMATSU
All Rights Reserved
44
SEN02481-00
D61EX-15E0
D61PX-15E0


Cab and its attachments
Cab mount ...................................................................................................................................................... 2
Cab ................................................................................................................................................................. 3
Air conditioner piping diagram ........................................................................................................................ 5
D61EX, PX-15E0 1
Cab mount 1
1. Support Outline
2. Damper mount (front) q Damper mounts (2), (3) are installed at two
3. Damper mount (rear) places in the front of the floor frame assembly
and two places in its rear to secure the floor
frame and cab.
q An oil-filled damper mount is used to absorb
the vibration.
2 D61EX, PX-15E0
Cab 1
1. Front wiper
2. Front window
3. Rear wiper
4. Door
D61EX, PX-15E0 3
a ROPS: Abbreviation for Rollover Protective Structure
1. ROPS guard
4 D61EX, PX-15E0
Air conditioner piping diagram 1
1. Condenser A: Fresh air inlet

2. Hot water pickup piping B: Recirculated air
3. Refrigerant piping C: Hot air/cold air
4. Receiver tank
5. Hot water return piping
6. Compressor
7. Front window defroster
8. Air conditioner unit
9. Vent
10. Blower motor
11. Side window defroster
D61EX, PX-15E0 5
SEN02481-00

© 2006 KOMATSU
All Rights Reserved
6
SEN02482-00
D61EX-15E0
D61PX-15E0


Electrical system
Monitor system................................................................................................................................................ 2
Monitor panel .................................................................................................................................................. 4
Engine control ................................................................................................................................................. 9
Engine control system................................................................................................................................... 10
Cooling system control system ..................................................................................................................... 12
System components ..................................................................................................................................... 14
Palm command control system..................................................................................................................... 22
PPC lock system........................................................................................................................................... 24
KOMTRAX terminal system .......................................................................................................................... 25
KOMTRAX terminal ...................................................................................................................................... 26
Sensor........................................................................................................................................................... 27
D61EX, PX-15E0 1
Monitor system 1
a. Each sensor g. Battery

b. Sensor signal h. Power source
c. Engine controller i. Alarm buzzer
d. Transmission and steering controller j. Alarm buzzer signal
e. CAN signal k. KOMTRAX terminal
f. Controller signal
q The monitor system notifies the operator of the q The monitor system consists of the monitor
machine condition. It monitors the machine panel, controller, sensors, alarm buzzer, and
condition with the sensors installed to the power supply.
machine and processes and displays the q The component parts are connected by wiring
obtained information on the monitor panel harnesses and the monitor panel is powered
immediately. by the battery.
The contents displayed on the panel are q If the machine has any trouble (and a sensor
roughly classified as shown bellow. detects it), the monitor and warning lamp flash
1. Travel direction, gear speed (Display panel and the alarm buzzer sounds to protect the
A) machine. The alarm buzzer can be turned OFF
2. Engine speed, coolant temperature, hydrau- temporarily with the buzzer cancel switch.
lic oil temperature, power train oil tempera-
ture, and fuel level (gauge section)
3. Machine trouble alarm (Monitor section)
4. Current, voltage, error code of each sensor
and solenoid (Display panel B)
2 D61EX, PX-15E0
Processing in monitor panel (Common to all specifications)
Display of monitor panel

Communica-
Contents and conditions of processing Flow of signals
tion method
1. Display of travel direction and gear speed
• Signals (F1, R3, etc.) are sent to the monitor panel according to the CAN signal
information of the transmission and steering controller.
2. Display of engine speed, coolant temperature, hydraulic oil temperature,
power train oil temperature, and fuel level by gauge
CAN signal
• The controller processes the sensor signals and converts them into
gauge levels and sends the result to the monitor panel.
3. Display of trouble Each sensor/solenoid
• If there is any trouble, its failure code signal is sent to the monitor O
panel. Controller
• Information about sounding the alarm buzzer and flashing the caution O
lamp is sent, according to the contents of the trouble. Monitor panel
1) In normal state
An action code is displayed. CAN signal
2) In failure history display mode
A failure code (6-characteristics code) and the following are dis-
played.
• Elapsed time after first occurrence
• Elapsed time after latest occurrence
• Number of occurrences
Display of monitoring
Communica-
tion method
1. Display of each sensor, each solenoid, communicating state of CAN sig-
nal, etc. Each sensor
CAN signal
• The signals of the item No. and condition of each device are sent to O
the monitor panel. Controller
2. Selection of each item with information switch, buzzer cancel switch, O
and up/ down (gear-shift) switch of the steering/directional/gear shift CAN signal Monitor panel
lever. (When using a mode for service, turn the service switch “on”.)
a For details of the operating method, see Testing and adjusting, Special functions of monitor panel
(EMMS).
Other items
Communica-
tion method
1. Filter and oil maintenance mode
2. Pm clinic auxiliary mode
3. Failure code display mode
4. Adjustment mode (User) Each sensor
5. Maintenance interval change mode O
6. Electrical system failure code display mode CAN signal Controller
7. Mechanical system failure code display mode O
8. Adjustment mode (Service) Monitor panel
9. Load saving display mode
10.Real-time monitoring mode
11.Dual display monitoring mode
a For details of the operating method, see Testing and adjusting, Special functions of monitor panel
(EMMS).
D61EX, PX-15E0 3
Monitor panel 1
Outline Check before starting

q The monitor panel consists of the monitor sec- q After the operation performed when the power
tion which outputs an alarm when the machine is turned ON, if there is any abnormal one in
has any trouble and the gauge section and the the check-before-starting items, the lamp of
display panel which display the machine condi- that item flashes or the contents of the abnor-
tion constantly. mality are displayed on display panel B.
The monitor panel has a microcomputer, which
processes and displays the signals from the Caution items
sensors, solenoids, and controllers. q The caution items are checked constantly
The items displayed on the monitor section while the engine is running.
and the gauge section are shown in the topic If any item is abnormal, it and warning lamp
“Display of monitor panel”. flash synchronously. In some abnormal cases,
the alarm buzzer may sound at this time.
Operation
When power is turned ON (When starting switch Buzzer cancel switch
is turned to “on” position) q If the switch is operated while the alarm buzzer
q All the LC segments and lamps of the monitor is sounding, the buzzer is turned off tempo-
panel light up for 2 seconds and the alarm rarily.
buzzer sounds for 2 seconds. While the buzzer is turned OFF, if a new trou-
ble which turns on the buzzer is detected, the
buzzer sounds again.
4 D61EX, PX-15E0
a The lamp lights up and goes off at the intervals

of about 0.8 seconds.
a The flashing intervals of the lamp may change
a little when the temperature is low (below
about –10°C). This does not indicate a trou-
ble.
Input and output signals
AMP070-20P [CN-S03] AMP070-12P [CN-S04]

Input/Output Input/Output
Pin No. Signal name Pin No. Signal name
signal signal
1 Power source (24 V) Input 1 CAN0-H Input/Output
2 Power source (24 V) Input 2 CAN0-H Input/Output
3 GND — 3 CAN0-L Input/Output
4 GND — 4 CAN0-L Input/Output
5 Constant power source (24 V) Input 5 CAN shield —
6 Constant power source (24 V) Input 6 NC —
7 Starting switch (C) Input 7 NC —
8 Night lightning Input 8 NC —
9 Preheating Input 9 Alternator (R) Input
10 NC — 10 Fuel level Input
11 NC — 11 NC —
12 NC — 12 Power train oil temperature Input
13 NC —
14 NC —
15 NC —
16 Service switch Input
17 NC —
18 Alarm buzzer Output
19 NC —
20 NC —
D61EX, PX-15E0 5
Display of monitor panel
6 D61EX, PX-15E0
Warning Alarm
Display Display
No. Display item Display range Display method lamp buzzer Remarks
classification color
output output
Corresponding segment
1a Gauge See diagram at left — — Black LCD
(1 place) lights up
Coolant temperature 102 °C or lower OFF OFF OFF

1b Caution 102 °C – 105 °C Flashing Flashing OFF Red LED
105 °C or higher Flashing Flashing ON
(1 place) lights up
Power train oil 120 °C or lower OFF OFF OFF
temperature
(1 place) lights up
Hydraulic oil 100 °C or lower OFF OFF OFF
temperature
Corresponding and lower
4 Gauge Fuel level See diagram at left — —
segments all light up
P: Parking lever “Lock”, PCCS
lever “Neutral” ON, PCCS lever
Travel direction “Other than Neutral” Flashing
(P, N, F, R) N:PCCS lever “Neutral” ON
F:PCCS lever “Forward” ON
[*1] R:PCCS lever “Reverse” ON
Indicator Display panel A OFF OFF
1: PCCS lever gear speed SW
5 (travel direction, gear
“1st” Black LCD
speed engine
Gear speed 2: PCCS lever gear speed SW
tachometer)
(1, 2, 3) “2nd”
3: PCCS lever gear speed SW
“3rd”
Corresponding and lower seg-
Gauge See diagram at left — —
ments all light up
[*1] Time is counted while engine is
Character
6 Display panel B 0 – 99999.9 h running — —
display
(service meter) (alternator is generating)
Lamp is OFF
OFF OFF
When charge is abnormal (12 V or (while engine is stopped)
7 Charge level
lower) Flashing
Flashing OFF
(while engine is running)
Caution Red
Lamp is OFF
OFF OFF
Specified value or lower (while engine is stopped)
8 Engine oil pressure
(49 kPa {0.5 kg/cm2}) Flashing
Flashing ON
(while engine is running)
9 Pilot Preheating While preheating ON OFF OFF Green
Before the 30 hour point OFF
10 Maintenance After starting switch is turned OFF OFF Orange

Between the 30 hour point to the
“ON” lamp lights up for 30
replacement time LED
seconds
11 Warning lamp See the “Warning lamp output” column of this table. — — Red
Before the 30 hour point OFF
Replacement time Between the 30 hour point to the For 30 seconds Flas
12 OFF OFF Yellow
Caution of filter and oil replacement time after starting switch is hing
After the replacement time turned “ON” ON
• While fan is in forward rotation
OFF
mode
Check of operation of • While fan is in reverse rotation,
13 ON OFF OFF Orange
fan cleaning mode
• Fan and selector switch are oper-
Flashing (3 seconds)
ated while the engine is running
*1: For details of the operating in the service mode, see “Special functions of monitor panel (EMMS)” in Testing and adjusting.
D61EX, PX-15E0 7
8 D61EX, PX-15E0
Engine control 1
1. Battery Function
2. Starting switch q A limit switch is installed to the linkage of the
3. Engine parking brake. The transmission and steering
4. Starting motor controller permits the engine to start only when
5. Engine controller the parking brake is in the “lock” position and
6. Transmission and steering controller the steering/directional/gear shift lever is in the
7. Neutral safety relay “N (Neutral)” position.
8. Limit switch
9. Parking brake lever
10. Electric lever
11. Steering/directional/gear shift lever
(PCCS lever)

a. Battery power source
b. Engine start signal
c. Starting switch ACC signal
d. Parking brake signal
e. Neutral signal
D61EX, PX-15E0 9
Engine control system 1
1. Battery Input and output signals

2. Starting switch a. The 1st throttle signal (fuel control dial signal)
3. Engine controller b. The No.2 throttle signal (decelerator pedal sig-
4. Transmission and steering controller nal)
5. Monitor panel c. The No.3 throttle signal (controller control sig-
6. Fuel control dial nal)
7. Decelerator pedal d. Starting switch ACC signal
8. Engine e. Controller power source
9. Engine speed sensor f. Engine speed signal
10. Coolant temperature sensor g. Coolant temperature signal
11. Engine oil pressure switch h. Engine oil pressure signal
12. Injector i. Sensor signal
j. Monitor display signal
10 D61EX, PX-15E0
Engine speed control mechanism Engine stop mechanism

q The engine controller receives the No. 1 throt- q If the starting switch is set in the OFF position,
tle signal (fuel control dial signal) and No. 2 the starting switch ACC signal to the engine
throttle signal (decelerator pedal signal). It also controller is turned OFF.
receives the No.3 throttle signal (controller q The engine controller stops supplying fuel to
control signal) from the transmission and steer- the engine to stop the engine.
ing controller, and then selects the lowest com-
mand signal and controls the fuel supply pump
and injector.
The 3rd throttle signal has
1) Automatic deceleration (F3, R3)
q The transmission and steering controller calcu-
lates proper engine speed from the information
of 1) and sends it as the No.3 throttle signal to
the engine controller.
q The information from the engine controller is
owned jointly by the other controllers and
transmitted so that the relationship between
the engine and chassis will be optimized.
q The automatic deceleration is a function of
lowering the engine speed temporarily when
the travel direction is changed from F3 or R3.
(for protection of the transmission clutch)
D61EX, PX-15E0 11
Cooling system control system 1
1. Battery Input and output signals

2. Battery relay a. Controller power source
3. Transmission and steering controller b. Fan rotation selector signal
4. Engine controller c. Power train oil temperature signal
5. Monitor panel d. Hydraulic oil temperature signal
6. Cooling fan motor e. Engine speed signal
7. Cooling fan pump f. Coolant temperature signal
8. Fan rotation selector switch g. CAN signal
9. Power train oil temperature sensor h. Pump control signal
10. Hydraulic oil temperature sensor i. Fan reverse signal
11. Engine
12. Engine speed sensor
13. Coolant temperature sensor
12 D61EX, PX-15E0
Outline Selection of fan rotation mode

q The transmission and steering controller moni- q While the starting switch is in the “on” position
tors the coolant, power train oil, and hydraulic and the engine is stopped, one of the following
oil temperatures and controls the fan speed fan rotation modes can be selected with the
according to those temperatures. fan rotation selector switch.
Fan rotation mode includes;
Function 1) Forward rotation mode
Fan speed control 2) Cleaning mode
q The transmission and steering controller con- According to the selected mode, the transmis-
trols the discharge of the cooling fan to set the sion and steering controller operates the
fan speed properly according to the informa- reverse solenoid valve of the cooling fan motor
tion from the coolant, power train oil, and to change the rotation direction of the fan.
hydraulic oil temperature sensors.
q The transmission and steering controller 1) Forward rotation mode
s e l e c ts t h e m a x i m u m ta r g e t f a n s p e e d In this mode, the reverse solenoid valve
obtained from the coolant, power train oil, and does not operate and the fan rotates for-
hydraulic oil temperatures and outputs it as the ward. The fan speed varies with the tem-
pump control signal to the cooling fan pump. perature sensor signal. This mode is
q The cooling fan pump changes its swash plate selected normally.
angle to control its oil discharge for the cooling
fan motor. 2) Cleaning mode
In this mode, the fan rotates in reverse at
high speed to blow off dirt from the radia-
tor fins, regardless of the temperature
sensor signals. If this mode is used peri-
odically, the cleaning interval of the radia-
tor fins can be expanded.
While in the “Cleaning mode”, the
machine does not move for the radiator
protection even if the PCCS lever is
shifted to “forward” or “reverse” position.
The starting switch needs to be turned
from “off” to “on” to restart the machine
under the “forward rotation mode”.
Interlock for changing rotation mode

q If the rotation direction of the fan is changed
while the fan is rotating, the fan drive circuit is
broken. To prevent this, the fan rotation selec-
tor switch signal is ignored while the engine is
running. In this case, the fan operation pilot
lamp on the monitor panel flashes for three
seconds.
D61EX, PX-15E0 13
System components 1
Fuel control dial
1. Knob Function
2. Dial q The fuel control dial is installed to the left side
3. Spring of the operator's seat.
4. Ball q If knob (1) is turned, the shaft of potentiometer
5. Potentiometer (5) is turned to change the resistance of the
6. Connector variable resistor and send a throttle signal to
the engine controller.
q The hatched areas in the following graph is the
abnormality detection areas. In those areas,
the engine speed is reduced to a half.
14 D61EX, PX-15E0
Decelerator pedal potentiometer
1. Lever Function
2. Shaft q The decelerator pedal potentiometer is
3. Coupling installed under the front part of the floor and
4. Body connected to the decelerator pedal by the link-
5. Potentiometer age.
6. Stopper q If the decelerator pedal is operated, the shaft
7. Connector of potentiometer (5) is turned through the link-
age to change the resistance of the variable
resistor and send a deceleration signal to the
engine controller.
D61EX, PX-15E0 15
Engine controller
q The signal classification used in the following

CN-CE01
terminal table is as follows:
Signal
A: Power source Pin No. Signal name
classification
B: Input
11 NC (*) —
C: Ground/shield/return
12 NC (*) —
D: Output
13 NC (*) B
E: Transmission
14 Water detection sensor B
15 Water temperature sensor B
CN-CE01
16 Sensor power source (5V) A
Signal
Pin No. Signal name 17 Oil pressure switch B
classification
1 NC (*) — 18 NC (*) —
2 IMA power source D 19 NC (*) —
3 Atmospheric pressure sensor B 20 NC (*) —
4 NC (*) — 21 NC (*) —
5 NC (*) — 22 NC (*) D
6 CAN (–) E 23 Boost temperature sensor B
7 NC (*) — 24 NC (*) —
8 CAN (+) E 25 Common rail pressure sensor B
9 NC (*) — 26 Bkup sensor (+) B
10 NC (*) — 27 NE sensor (+) B
*: Do not connect to NC since it will cause malfunction and trouble. *: Do not connect to NC since it will cause malfunction and trouble.
16 D61EX, PX-15E0
CN-CE01 CN-CE02
Signal Signal
classification classification
28 NC (*) — 13 NC (*) B
29 NC (*) — 14 NC (*) B
30 NC (*) — 15 NC (*) B
31 NC (*) D 16 NC (*) B
32 NC (*) C 17 NC (*) B
33 GND A 18 NC (*) B
34 NC (*) — 19 NC (*) B
35 NC (*) A 20 NC (*) E
36 NC (*) — 21 NC (*) A
37 NC (*) A 22 Fuel dial (+5V) A
38 NC (*) C 23 Fuel dial (–) C
39 Key switch (ACC) — 24 NC (*) B
40 Intake air heater relay activate — 25 NC (*) B
41 NC (*) — 26 NC (*) B
42 Intake air heater relay deactivate C 27 NC (*) B
43 NC (*) — 28 NC (*) B
44 Boost pressure sensor B 29 NC (*) C
45 Injector #1 (+) D 30 NC (*) B
46 Injector #5 (+) D 31 NC (*) B
47 Sensor GND C 32 NC (*) C
48 Ne sensor (–) C 33 GND C
49 NC (*) — 34 NC (*) C
50 NC (*) — 35 NC (*) B
51 Injector #2 (–) C 36 NC (*) B
52 Injector #3 (–) C 37 NC (*) C
53 Injector #1 (–) C 38 NC (*) D
54 Injector #2 (–) D 39 Key switch (ACC) A
55 Injector #3 (+) D 40 Intake air heater relay (output) D
56 Injector #4 (+) D 41 NC (*) D
57 Injector #6 (+) D 42 Intake air heater relay (return) C
58 Injector #4 (–) C 43 NC (*) D
59 Injector #6 (–) C 44 NC (*) D
60 Injector #5 (–) C 45 NC (*) —
*: Do not connect to NC since it will cause malfunction and trouble. 46 CAN (+) E
47 CAN (–) E
CN-CE02 48 NC (*) D
Signal PWM OUTPUT
Pin No. Signal name 49 D
classification (Power train relay output)
1 NC (*) B 50 NC (*) D
2 NC (*) B *: Do not connect to NC since it will cause malfunction and trouble.
3 NC (*) B
4 NC (*) B
CN-CE03
5 NC (*) B
Signal
6 NC (*) B Pin No. Signal name
classification
7 NC (*) B 1 GND C
8 NC (*) B 2 NC (*) C
9 Fuel dial (+) B 3 Power source (+24V constant) A
10 NC (*) E 4 NC (*) A
11 NC (*) B *: Do not connect to NC since it will cause malfunction and trouble.
12 NC (*) B
*: Do not connect to NC since it will cause malfunction and trouble.
D61EX, PX-15E0 17
Transmission and steering controller
18 D61EX, PX-15E0

DEUTSCH-24P [CN-ST1]
Input and output Input and output
signal signal
1 Fuel control dial Input 13 Travel lever position 3 Input
2 Steering potentiometer 1 Input 14 NC —
3 Brake pedal potentiometer Input 15 Alternator (R) Input
4 GND (signal) — 16 Sensor power source (+24 V) Output
5 NC — 17 Key C signal Input
6 Service SW Input 18 Shift down SW (NO) Input
7 Travel lever position 4 Input 19 Travel lever position 2 Input
8 Pitch angle sensor Input 20 NC —
9 Hydraulic oil temperature sensor Input 21 GND (analog) —
10 GND (signal) — 22 Sensor power source (+5 V) Output
11 NC — 23 NC —
12 Shift up SW (NC) Input 24 Shift down SW (NC) Input
DEUTSCH-40P(1) [CN-ST2]
signal signal
1 NC — 21 NC —
2 NC — 22 CAN0 (L) Input and output
3 NC — 23 NC —
4 NC — 24 Service connector signal Input
5 Parking SW (NC) Input 25 T/M reverse fill SW Input
6 Cursor SW2 Input 26 Select SW Input
7 Fan reverse SW Input 27 NC —
8 Neutral safety relay Input 28 Motoring SW —
9 NC ñ\ 29 GND (Pulse) —
10 Manual mode SW Input 30 Transmission output shaft speed Input
11 NC — 31 NC —
12 CAN shield — 32 CAN0 (H) Input and output
13 NC — 33 NC —
14 NC — 34 NC —
15 Parking SW (NO) Input 35 T/M forward fill SW Input
16 Cursor SW1 Input 36 Alarm buzzer cancel SW Input
17 Fan forward SW Input 37 Automatic shift down SW Input
18 Backup alarm relay Output 38 NC —
19 NC — 39 GND (Pulse) —
20 Immobilizing signal Input 40 NC —
DEUTSCH-40P(2) [CN-ST3]
signal signal
1 Power source (Controller) Input 21 GND (Power source) Input
2 Power source (Solenoid) Input 22 Power source (Solenoid) Input
3 GND (Solenoid, common) Input 23 GND (Solenoid, common) Input
4 For activating battery relay Output 24 Starting switch (ACC) Input
5 NC — 25 HSS spool (Left) Output
6 1st gear speed ECMV Output 26 3rd gear speed ECMV Output
7 HSS pump TVC SOL Output 27 Forward ECMV Output
8 NC — 28 NC —
9 Shift up SW (NO) Input 29 T/M 2nd gear fill SW Input
10 NC — 30 HSS specification selection Input
11 Power source (Controller) Input 31 GND (Power source) —
12 Power source (Solenoid) Input 32 GND (Power source) —
13 GND (Solenoid, common) Input 33 GND (Power source) —
14 Starting switch (ACC) Input 34 NC —
15 NC — 35 HSS spool (Right) Output
16 2nd gear speed ECMV Output 36 Fan control SOL Output
17 NC Output 37 Reverse ECMV Output
18 Fan reverse SOL Output 38 NC —
19 T/M 1st gear fill SW Input 39 T/M 3rd gear fill SW Input
20 NC — 40 C/B specification selection Input
D61EX, PX-15E0 19
Engine oil pressure switch
1. Connector
2. Sensor
3. O-ring
Coolant temperature sensor
1. Connector
2. Sensor
3. O-ring
20 D61EX, PX-15E0
Engine speed sensor
1. Connector
2. Sensor
3. O-ring
Boost pressure sensor

Boost temperature sensor
1. Connector
2. Sensor
3. O-ring
D61EX, PX-15E0 21
Palm command control system 1
1. Monitor panel 9. Torque converter

2. Auto shift-down switch 10. Transmission
3. Preset mode switch 11. Transmission control valve
4. Steering/directional/gear shift lever (PCCS 12. Transmission output shaft speed sensor
lever) 13. HSS unit
5. Engine controller 14. Control valve
6. Transmission and steering controller 14a.Steering control valve
7. Engine speed sensor 15. HSS motor
8. Engine
22 D61EX, PX-15E0
Preset mode function Auto shift-down function

q The gear speed applied for forward travel and q If the travel speed lowers because of the load-
reverse travel can be set in advance. ing condition, the transmission gear is shifted
Preset mode 1: F1 – R1 down automatically.
Preset mode 2: F1 – R2 1) The traction force (load on the chassis) is
Preset mode 3: F2 – R1 calculated from the engine speed, trans-
Preset mode 4: F2 – R2 mission output shaft speed, and the throt-
Preset mode 5: F2 – R3 tle information sent from the transmission
and steering controller, and then the trans-
1. How to use mission gear is shifted down automatically
1) Set the PCCS lever in the “N (Neutral)” according to the load and travel speed.
position. 2) Once the transmission gear is shifted
2) Set the preset mode switch (1) to the automatically, it is not shifted up again
“I (ON)” position. automatically.
3) Press the UP/DOWN switch of the PCCS (It can be shifted up with the UP switch of
lever to select a mode. the PCCS lever, however.)
3) This function is applicable to both forward
and reverse travels.
1. How to use
1) Set the automatic shift-down switch (2) to
the “I (ON)” position.
2. Display
q The selected mode is displayed on display
panel B of the monitor panel.
D61EX, PX-15E0 23
PPC lock system 1
1. Battery Function
2. Battery relay q The PPC lock switch is interlocked with the
3. Fuse box work equipment lock lever. If the work equip-
4. Work equipment lock lever ment lock lever is set in the “lock” position, the
5. PPC lock switch PPC lock switch is turned “off”.
6. PPC lock solenoid valve q If the PPC lock switch is turned “off”, the elec-
7. Engine tric current to the PPC lock solenoid valve is
8. PTO interrupted, and then the work equipment does
9. Cooling fan pump not operate, even if the blade control lever and
10. Self pressure reducing valve the ripper control lever are operated.
11. Blade PPC valve
12. Ripper PPC valve (D61EX-15E0: if equipped)
24 D61EX, PX-15E0
KOMTRAX terminal system 1
q The KOMTRAX controller sends various information on the machine by a wireless communication. The
KOMTRAX operator refers to this information in the office, and various services can be provided for the
customer.
a To be provided with the KOMTRAX system service, it is necessary to sign up separately.
Information that can be sent from KOMATRAX controller is as follows:

1. Traveling map
2. Service meter
3. Location information
4. Error history
etc.
D61EX, PX-15E0 25
KOMTRAX terminal 1
1. Communication antenna connector

2. GPS antenna connector
3. Machine harness connector (DEUTSCH-40P)
DEUTSCH-40P [CN-G01]
signal signal
1 NC — 21 Operation mode selection 1 Input
2 NC — 22 Operation mode selection 2 Input
3 NC — 23 NC —
4 NC — 24 NC —
5 NC — 25 NC —
6 CAN shield GND — 26 NC —
7 CAN signal (L) Input and output 27 Starting switch (C) Input
8 CAN signal (H) Input and output 28 Alternator (R) Input
9 NC — 29 NC —
10 NC — 30 NC —
11 NC — 31 NC —
12 NC — 32 NC —
13 NC — 33 NC —
14 NC — 34 NC —
15 NC — 35 NC —
16 NC — 36 Starting switch (ACC) Input
17 NC — 37 Power source GND —
18 NC — 38 Power source GND —
19 NC — 39 Constant power source (24V) Input
20 Immobilizing signal Output 40 Constant power source (24V) Input
Outline q There are the LED lamp and the 7-segment

q The KOMTRAX controller can send informa- indicator lamp in the display area, and these
tion via wireless communication antenna, lamps are used for the testing and the trouble-
acquiring various information of the machine shooting.
from the network signal in the machine and the q The information of the LED lamp and the 7-
input signal. Also, the controller incorporates segment indicator lamp can be checked on the
CPU (Central Processing Unit) and provide the monitor panel by EMMS.
wireless communication function and the GPS
function.
26 D61EX, PX-15E0
Sensor 1
q The signals from the sensors are input through the controller to the monitor panel.
q The sensor are classified into 3 types: resistance type, electromagnetic type, and capacitor type.
Type of sensor Sensor method When normal When abnormal

Power train oil temperature Resistance — —
Hydraulic oil temperature Resistance — —
Fuel level Resistance — —
Transmission output shaft speed Electromagnetic — —
Pitch angle Capacitor — —
Power train oil temperature sensor

Hydraulic oil temperature sensor
1. Connector 2. Plug 3. Thermistor
Function
q The power train oil temperature sensor is installed to the power train outlet piping. The hydraulic oil tem-
perature sensor is installed to the hydraulic piping. These sensors sense the change of the temperature
by the change of resistance of the thermistors.
The temperature signals are sent through the network to the transmission and steering controller and
used to control the cooling fan.
D61EX, PX-15E0 27
Fuel level sensor
1. Connector 4. Body 7. Spacer

2. Float 5. Spring
3. Arm 6. Contact
Function
q This sensor is installed on the side face of the fuel tank. The float moves up and down according to the
fuel level.
The float moves the variable resistor through the arm. The resistance changes according to the operat-
ing angle and signal voltage is generated from the source voltage according to the change of the resis-
tance.
28 D61EX, PX-15E0
Transmission output shaft speed sensor
1. Magnet 3. Housing 5. Boot

2. Wire 4. Terminal 6. Connector
Function
q The transmission output shaft speed sensor is installed to the bevel gear of steering case. It generates
pulse voltages as the gear rotates.
Pitch angle sensor
1. Body 3. Wire
2. Tube 4. Connector
Function
q The pitch angle sensor is installed to the base of the ROPS in the filter cover on the right side of the
chassis.
q There are multiple electrodes and oil in this sensor. The changes of the oil level made by inclination of
the machine are sensed by the differences in electrostatic capacity between the electrodes, and then
those differences are converted into voltage signals.
D61EX, PX-15E0 29
SEN02482-00

© 2006 KOMATSU
All Rights Reserved
30
SEN02554-00
D61EX-15E0
D61PX-15E0

20 Standard value table 1

Standard service value table
Standard value table for engine ...................................................................................................................... 2
Standard value table for machine ................................................................................................................... 3
D61EX, PX-15E0 1
SEN02554-00 20 Standard value table
Standard value table for engine 1
D61EX-15E0
Applicable model
D61PX-15E0
Engine SAA6D107E-1
Cate- Standard value for

gory
Item Measurement condition Unit Judgement criteria
new machine
High idle rpm 2,000 ± 70 2,000 ± 70

• Coolant
Engine speed temperature: Low idle rpm 915 ± 50 915 ± 50
operating range
Rated speed rpm 1,850 1,850
• Coolant temperature: operating

Intake pressure kPa Min. 140 113
range at rated output
(boost pressure) {mmHg} {Min. 1,050} {850}
• At rated output
At sudden
• Coolant acceleration Max. 2.5 3.5
(Lo o Hi) Bosch
Exhaust gas color temperature:
index
operating range
At high idle — —
Intake valve mm 0.25 0.152 – 0.381

• Normal
Valve clearance
temperature Exhaust
mm 0.51 0.381 – 0.762
valve
Compression MPa Min. 2.41 1.69
Engine
Compression • Oil temperature: pressure {kg/cm2} {Min. 24.6} {17.2}

pressure 40 – 60°C Engine
rpm 250 – 280 250 – 280
speed
• Coolant temperature: operating
kPa Max. 0.98 1.96
Blow-by pressure range at rated output
{mmH2O} {Max. 100} {200}
• At rated output
• SAE0W30E0S,
SAE5W40E0S, MPa Min. 0.29 0.21
High idle
SAE10W30DH, {kg/cm2} {Min. 3.0} {2.1}
SAE15W40DH,
Engine oil
SAE30DH engine
pressure
oil
• Engine oil MPa Min. 0.10 0.07
Low idle
temperature: Min. {kg/cm2} {Min. 1.0} {0.7}
80°C
• Whole speed range (inside oil
Oil temperature °C 80 – 110 120
pan)
• Between idler pulley and
Air conditioner
compressor pulley
compressor belt mm 15 – 18 15 – 18
• Deflection when pressed with
tension
finger force of approx. 98 N {10 kg}
2 D61EX, PX-15E0
Standard value table for machine 1
Mark (*) for only D61EX-15E0

D61EX-15E0
Machine model
D61PX-15E0
Standard value
Cate- Service
Item Measurement conditions Unit for new
gory limit value
machine
• Engine coolant temperature:
Decelerator pedal Within operating range
1,175 ± 25 1,175 ± 25
Engine speed
speed • Power train oil temperature:

Within operating range
rpm
• Hydraulic oil temperature:
Torque converter Within operating range
1,650 ± 100 1,500
stall speed • Decelerator pedal speed: Press pedal.
• Torque converter stall speed: F3
Neutral to
30 ± 10 30 ± 10
Forward Forward
and reverse Neutral to
30 ± 10 30 ± 10
PCCS • Engine stopped Reverse
lever • Center of lever knob Neutral to 40 ± 15 40 ± 15
Left (Play: Max. 3) (Play: Max. 3)
Steering
Neutral to 40 ± 15 40 ± 15
Right (Play: Max. 3) (Play: Max. 3)
• Engine stopped
Decelerator pedal 52 ± 9 52 ± 9
• Center of pedal
• Engine low idle
Brake pedal All stroke 79 ± 12 79 ± 12
Control lever/ Pedal stroke
• Center of pedal
mm
Neutral to
72 ± 11 72±11
Raise/Float
Straight Neutral to
52 ± 9 52 ± 9
tiltdozer Lower
Neutral to
54 ± 8 54 ± 8
Left/Right tilt
• Engine low idle
Neutral to
Blade • Hydraulic oil tempera- 47 ± 9 47 ± 9
Raise/Float
lever ture: 45 – 55°C
• Center of lever knob Neutral to
Power 71 ± 11 71 ± 11
Lower
angle and
Neutral to
power 52 ± 8 52 ± 8
tiltdozer Left/Right tilt
Neutral to
Left/Right ° (deg) 15 ± 3 15 ± 3
angle
• Engine low idling
(*)
• Hydraulic oil tempera- Neutral to
Ripper lever mm 54 ± 8 54 ± 8
ture: 45 – 55°C Raise/Lower
(If equipped)
• Center of lever knob
D61EX, PX-15E0 3

D61EX-15E0
Machine model
D61PX-15E0
Standard value
Cate- Service
gory limit value
machine
Neutral to
56.9 ± 19.6 56.9 ± 19.6
Forward/
{5.8 ± 2.0} {5.8 ± 2.0}
Forward Reverse
and reverse Forward/
51 ± 19.6 51 ± 19.6
Reverse to
{5.2 ± 2.0} {5.2 ± 2.0}
PCCS • Engine stopped Neutral
lever • Center of lever knob
Neutral to 24.5 ± 9.8 24.5 ± 9.8
Left {2.5 ± 1.0} {2.5 ± 1.0}
Steering
Neutral to 27.4 ± 9.8 27.4 ± 9.8
Right {2.8 ± 1.0} {2.8 ± 1.0}
Control lever/ pedal operating effort
• Engine low idle 73.5 ± 24.5 73.5 ± 24.5

Decelerator pedal
• Center of pedal {7.5 ± 2.5} {7.5 ± 2.5}
• Engine low idle 510 ± 88 666
Brake pedal
• Center of pedal {52 ± 9.0} {68}
Neutral to N 29.4 ± 9.8 29.4 ± 9.8
Raise/Lower {kg} {3.0 ± 1.0} {3.0 ± 1.0}
Straight 74.5 ± 19.6 74.5 ± 19.6
Neutral to Float
tiltdozer {7.6 ± 2.0} {7.6 ± 2.0}
Neutral to 25.5 ± 9.8 25.5 ± 9.8
• Engine low idle Left/Right tilt {2.6 ± 1.0} {2.6 ± 1.0}
Blade • Hydraulic oil tempera- Neutral to 25.5 ± 9.8 25.5 ± 9.8
lever ture: 45 – 55°C Raise/Lower {2.6 ± 1.0} {2.6 ± 1.0}
Power • Center of lever knob 69.6 ± 19.6 69.6 ± 19.6
Neutral to Float
angle and {7.1 ± 2.0} {7.1 ± 2.0}
power Neutral to 25.5 ± 9.8 25.5 ± 9.8
tiltdozer Left/Right tilt {2.6 ± 1.0} {2.6 ± 1.0}
Neutral to Left/ 4.4 ± 1.0 4.4 ± 1.0
Right angle {0.45 ± 0.1} {0.45 ± 0.1}
• Engine low idle Neutral to 25.5 ± 9.8 25.5 ± 9.8
(*) Raise {2.6 ± 1.0} {2.6 ± 1.0}
• Hydraulic oil tempera-
Ripper lever
ture: 45 – 55°C Neutral to 25.5 ± 9.8 25.5 ± 9.8
(If equipped)
• Center of lever knob Lower {2.6 ± 1.0} {2.6 ± 1.0}
0.1 – 0.5 0.1 – 0.5
Engine low idle
Torque converter {1 – 5} {1 – 5}
inlet pressure Max. 0.88 Max. 0.88
Engine high idle
Power train oil pressure
{Max. 9} {Max. 9}
0.09 – 0.29 0.09 – 0.29
Engine low idle
Torque converter {0.9 – 3} {0.9 – 3}
• Power train oil temper- MPa
outlet pressure 0.44 – 0.69 0.44 – 0.69
ature: 70 – 80°C Engine high idle {kg/cm2}
{4.5 – 7} {4.5 – 7}
2.65 ± 0.1 Min. 2.35
Engine low idle
{27 ± 1.0} {Min. 24}
Transmission main
+0.24
relief pressure 2.84 +0 Min. 2.65
Engine high idle
+3 {Min. 27}
{29 +0 }
4 D61EX, PX-15E0

D61EX-15E0
Machine model
D61PX-15E0
Standard value
Cate- Service
gory limit value
machine
Engine low 2.65 ± 0.1 Min. 2.35
idle {27 ± 1.0} {Min. 24}
Transmission
+0.24
F clutch pressure Engine high 2.84 +0 Min. 2.65
idle +3 {Min. 27}
{29 +0 }
Engine low 2.65 ± 0.1 Min. 2.35
idle {27 ± 1.0} {Min. 24}
Transmission
+0.24
R clutch pressure Engine high 2.84 +0 Min. 2.65
idle +3 {Min. 27}
{29 +0 }
Engine low 2.65 ± 0.1 Min. 2.35
idle {27 ± 1.0} {Min. 24}
Transmission
+0.24
Power train oil pressure
1st clutch pressure Engine high 2.84 +0 Min. 2.65

idle +3 {Min. 27}
{29 +0 }
Engine low 2.65 ± 0.1 Min. 2.35
• Power train oil temper-
idle {27 ± 1.0} {Min. 24}
Transmission ature: 70 – 80°C
+0.24
2nd clutch pressure Engine high 2.84 +0 Min. 2.65
idle MPa +3 {Min. 27}
{29 +0 }
{kg/cm2}
Engine low 2.65 ± 0.1 Min. 2.35
idle {27 ± 1.0} {Min. 24}
Transmission
+0.24
3rd clutch pressure Engine high 2.84 +0 Min. 2.65
idle +3 {Min. 27}
{29 +0 }
Transmission
lubricating oil Engine high 0.09 – 0.29 0.09 – 0.29
pressure idle {0.9 – 3.0} {0.9 – 3.0}
(For reference)
Engine low 2.75 – 2.94 2.55
idle {28 – 30} {26}
Brake pressure
Engine high 2.75 – 2.94 2.55
idle {28 – 30} {26}
+2.0
Steering relief 35.1 –3.0 Min. 29.9
oil pressure
pressure +20 {Min. 305}

• Hydraulic oil temperature: 45 – 55°C {358 –30 }
HSS
LS pressure • Engine high idle

33.1±2.0 Min. 28.9
(Load sensing
{338±20} {Min. 295}
pressure)
• Flat road F1 3.2 ± 0.2 3.2 ± 0.2
• Engine coolant temperature: F2 5.6 ± 0.3 5.6 ± 0.3
Performance of

power train
F3 8.7 ± 0.5 8.7 ± 0.5

• Power train oil temperature:
Travel speed R1 km/h 4.3 ± 0.3 4.3 ± 0.3
70 – 80°C
• Engine high idle R2 7.2 ± 0.4 7.2 ± 0.4
• Run up distance: 10 – 30 m
R3 11.0 ± 0.6 11.0 ± 0.6
• Measuring distance: 20 m
D61EX, PX-15E0 5

D61EX-15E0
Machine model
D61PX-15E0
Standard value
Cate- Service
gory limit value
machine
+1.37 +1.37
Engine high 3.43 +0 3.43 +0
Unload pressure
idle +14 +14
{35 +0 } {35 +0 }
Engine low Min. 19.1 Min. 19.1
Blade lift relief • Hydraulic oil tempera- idle {Min. 195} {Min. 195}
pressure ture: 45 – 55°C Engine high 20.6 ± 0.98 17.6
• Unload pressure: Set idle {210 ± 10} {180}
all equipment in neu- Engine low Min. 19.1 Min. 19.1
Blade tilt relief tral. idle {Min. 195} {Min. 195}
pressure • Relief pressure: Set Engine high MPa 20.6 ± 0.98 17.6
cylinder to stroke end idle {kg/cm2} {210 ± 10} {180}
Engine low Min. 19.1 Min. 19.1
(*) idle {Min. 195} {Min. 195}
Ripper lift relief
pressure Engine high 20.6 ± 0.98 17.6
idle {210 ± 10} {180}
Control circuit main
3.72 ± 0.49 3.72 ± 0.49
pressure
• Hydraulic oil temperature: 45 – 55°C {38 ± 5} {38 ± 5}
(HSS, PPC, fan)
• Engine high idle
PPC valve output 3.72 ± 0.49 3.72±0.49
pressure {38 ± 5} {38 ± 5}
Work equipment oil pressure
a See figure A
EX: 2.4 ± 0.2
• Hydraulic oil tempera- Raise 3.0
PX: 2.5 ± 0.2
ture: 45 – 55°C
Blade lift • Apply no load to blade.
• Between ground level EX: 1.7 ± 0.2
Lower 2.1
and rising end of blade PX: 1.6 ± 0.2
Power angle
EX: 2.6 ± 0.2 3.1
and
PX: 2.8 ± 0.2 3.3
a See figure B Power tiltdozer
Left tilt
• Hydraulic oil (*)

Straight tiltdozer
Work equipment speed
temperature:
2.6 ± 0.2 3.1
45 – 55°C and
• Apply no load to semi-U dozer
Blade tilt
blade. Power angle sec EX: 2.6 ± 0.2 3.1
• Between left tilt and
PX: 2.8 ± 0.2 3.3
end and right tilt Power tiltdozer
Right tilt
end (*)
• Engine high idle Straight tiltdozer
2.6 ± 0.2 3.1
and
semi-U dozer
a See figure C
Low idle 2.4 ± 0.2 2.9
• Hydraulic oil
Raise
temperature:
(*) 45 – 55°C High idle 1.4 ± 0.2 1.9
Ripper lift • Apply no load to
(If equipped) ripper. Low idle 1.9 ± 0.2 2.4
Lower
• Between ground
level and rising High idle 1.1 ± 0.2 1.6
end of blade
6 D61EX, PX-15E0

D61EX-15E0
Machine model
D61PX-15E0
Standard value
Cate- Service
gory limit value
machine
a See figure D
Work equipment speed
• Hydraulic oil tempera- Angle EX: 3.8 ± 0.3 4.7

ture: 45 – 55°C
(L.H.) PX: 4.2 ± 0.3 5.1
• Blade edge 300 mm
above the ground
Blade angle
• Body level on the flat
ground
Angle EX: 3.8 ± 0.3 4.7
• Left angle end – Right
angle end (R.H.) sec PX: 4.2 ± 0.3 5.1
• Hydraulic oil temperature: 45 – 55°C
• Set lever to full stroke
Time lag
• Lower blade from max. rising position

Blade Max. 1.0 Max. 1.5
and measure time after blade comes in
contact with ground until idler is lifted.
• High idle
a See figure E
Work equipment

Hydraulic drift
• Engine stopped Max. 100 Max. 100
of lifted blade
• Height of the lower edge of blade h
hydraulic drift
Right tilt Left tilt
a See figure F
Hydraulic drift
Max. 200 Max. 200

• Hydraulic oil temperature:
Hydraulic drift mm/
45 – 55°C
of tilted blade 15 min
• Engine stopped
• Reduction of blade tip height Max. 200 Max. 200
a See figure G
(*)
Hydraulic drift
• Engine stopped Max. 50 Max. 50
of lifted ripper
• Height of the lower edge of shank h
(If equipped)
hydraulic drift
Blade tilt
• Engine high idle 4 16
from inside
cylinder
Leakage

cc/min
• Relieve cylinder and measure leakage
Blade lift
for 1 minute. 4 16
cylinder

HSS Motor
• Steering lever: Full

Leakage • Transmission lever: Neutral l/min Max. 15 30
• Brake pedal: Pressed
D61EX, PX-15E0 7

D61EX-15E0
Machine model
D61PX-15E0
Standard value
Cate- Service
gory limit value
machine
• Engine low
idle
• Coolant
Min. speed
tempera-
ture, 600±50 500
Power train
oil temper-
• Hydraulic oil ature 80°C
temperature:
Fan speed or below rpm
45 – 55°C
Cooling fan
• Fan forward
• Engine
Max. speed
high idle
+100
• Fan 100% 1,700 +0 1,600
speed
mode

• Fan forward MPa 16.7 – 19.6 14.7
Fan pump pressure
• Fan 100% speed mode {kg/cm2} {170 – 200} {150}
8 D61EX, PX-15E0
Illustration related to standard value table
Fig. A Fig. D
Fig. B Fig. E
Fig. C Fig. F
D61EX, PX-15E0 9
Fig. G
10 D61EX, PX-15E0
D61EX, PX-15E0 11
SEN02554-00

© 2007 KOMATSU
All Rights Reserved
12
SEN02555-00
D61EX-15E0
D61PX-15E0

30 Testing and adjusting 1

Testing and adjusting, Part 1
Standard value table for engine related parts ................................................................................................. 3
Measuring engine speed................................................................................................................................. 6
Measuring intake air pressure (boost pressure) ............................................................................................. 8
Measuring exhaust color............................................................................................................................... 10
Adjusting valve clearance ..............................................................................................................................11
Measuring compression pressure................................................................................................................. 13
Measuring blow-by pressure......................................................................................................................... 16
Measuring engine oil pressure...................................................................................................................... 17
Handling fuel system equipment................................................................................................................... 18
Releasing residual pressure in fuel system .................................................................................................. 18
Measuring fuel pressure ............................................................................................................................... 19
Measuring fuel delivery amount, return rate and leakage............................................................................. 21
Bleeding air from fuel circuit.......................................................................................................................... 25
Testing leakage in fuel system ...................................................................................................................... 27
Handling of reduced cylinder mode operation .............................................................................................. 28
Handling of no injection cranking operation .................................................................................................. 28
D61EX, PX-15E0 1
SEN02555-00 30 Testing and adjusting
Testing and adjusting air conditioner compressor belt tension...................................................................... 29

Replacing the fan belt ................................................................................................................................... 29
Handling controller voltage circuit ................................................................................................................. 30
Adjusting fuel control dial and decelerator pedal .......................................................................................... 31
2 D61EX, PX-15E0
Standard value table for engine related parts 1
Symbol
Testing and
Q'ty
Part No. Name Remarks
adjusting item
Intake air pressure –101 to 200 kPa

A 799-201-2202 Boost gauge kit 1
(Boost pressure) {–760 to –1,500 mmHg}
Water temperature Digital temperature
B 799-101-1502 1 –99.9 to 1,299°C
and oil temperature gauge
1 799-201-9001 Handy smoke checker 1
Exhaust color C Commercially Bosch index: 0 – 9
2 Smoke meter 1
available
1 795-799-1131 Gear 1
Valve clearance D
2 Purchased Clearance gauge 1 Air intake: 0.25 mm, exhaust: 0.51 mm
1 795-502-1590 Compression gauge 1 0 – 6.9 MPa {0 – 70 kg/cm2}
2 795-799-6700 Puller 1
Compression
E 795-790-4410 Adapter 1 For 107E engine
pressure 3
6754-11-3130 Gasket 1 For 107E engine
4 795-799-8150 Remover 1
Blow-by pressure F 799-201-1504 Blow-by checker 1 0 – 5 kPa {0 – 500 mmH2O}
Pressure gauge:
799-101-5002 Hydraulic tester 1 2.5, 6, 40, 60 MPa
1
{25, 60, 400, 600 kg/cm2}
Engine oil pressure G 790-261-1204 Digital hydraulic tester 1 Pressure gauge: 60 MPa {600 kg/cm2}
2 799-401-2320 Hydraulic tester 1 Pressure gauge: 1.0 MPa {10 kg/cm2}
795-790-4430 Adapter 1 M10 x 1.0 mm o R 1/8
3
6215-81-9710 O-ring 1
799-101-5002 Hydraulic tester 1 *Common to G1
1
790-261-1204 Digital hydraulic tester 1 *Common to G1
795-790-4430 Adapter 1 *Common to G3
Measuring fuel pres- 2
H 6215-81-9710 O-ring 1
sure
–101.3 – 200 kPa
3 799-201-2202 Boost gauge kit 1
{–760 – 1500 mmHg}
4 795-790-5110 Screw 1
Commercially
1 Hose (Ø 14 mm) 1
available
2 795-790-4700 Tester kit 1
6754-71-5340 Connector 1
Measuring fuel deliv- 3
6754-71-5350 Washer 1
ery amount, return J
rate and leakage Commercially
4 Measuring cylinder 1
available
5 795-790-6700 Adapter 1
Commercially
6 Stopwatch 1
available
1
Power train Pressure gauge:
K 2 799-401-2320 Hydraulic tester 1
pressure 1.0 MPa {10 kg/cm2}
799-101-5220 Nipple 1 M10 x 1.25 mm
3
07002-11023 O-ring 1
D61EX, PX-15E0 3
Symbol
Testing and
Q'ty
adjusting item
19M-06-32820 Switch assembly 1

1
134-06-72810 Wiring harness 1
Emergency escape 7824-66-6430 Redundant resistance 1
2
when power train has L 7827-10-1520 Redundant resistance 1
trouble 3 790-190-1601 Pump assembly 1
799-101-5220 Nipple 1 M10 x 1.25 mm
4
07002-11023 O-ring 1
1
Testing and 790-261-1204 Digital hydraulic tester 1 *Common to G1
adjusting work equip- 799-101-5220 Nipple 2 M10 x 1.25 mm
M 2
ment and HSS oil 07002-11023 O-ring 2
pressure 790-261-1321 Elbow 1
3
07002-11023 O-ring 1
Testing control 1
circuit main N
799-101-5220 Nipple 1 M10 x 1.25 mm
pressure 2
07002-11023 O-ring 1
1
Measuring PPC valve 790-261-1204 Digital hydraulic tester 1 *Common to G1
output O Oil pressure pickup
799-401-3100 1
pressure 2 adapter (Size 02)
02896-11008 O-ring 1
Measuring internal
Commercially
leakage of work P Measuring cylinder 1
available
equipment cylinder
Measuring fan motor
Q 799-205-1100 Tachometer kit 1
speed
Measuring fan pump 1
circuit R
799-101-5220 Nipple 1 M10 x 1.25 mm
pressure 2
07002-11023 O-ring 1
79A-264-0021 Push-pull scale 1 0 – 294 N {0 – 30 kg}
Operating effort —
79A-264-0091 Push-pull scale 1 0 – 490 N {0 – 50 kg}
Stroke and Commercially
— Scale 1
hydraulic drift available
Work equipment Commercially
— Stopwatch 1
speed available
Voltage or Commercially
— Tester 1
resistance available
Removal and installa-
tion of boost pressure Commercially 3.26 mm torque wrench (Equivalent to
— Torque wrench 1
and temperature sen- available KTC Q4T15)
sor
Removal and Installa-
tion of engine oil pres- — 795-799-6210 Deep socket 1 27 mm deep socket
sure sensor
Commercially 21 mm deep socket (Equivalent to
tion of engine coolant — Deep socket 1
available MITOLOY 4ML-21)
temperature sensor
4 D61EX, PX-15E0
Symbol
Testing and
Q'ty
adjusting item
— 799-601-7400 T-assembly 1 AMP040 connector, M connector

— 799-601-7500 T-assembly 1 AMP070 connector
— 799-601-9000 T-assembly 1 DT, HD30 connector
— 799-601-9300 T-assembly 1 DRC 26 - 24, 40 pins
— 799-601-7360 Adapter 1 Relay (5 pins)
— 799-601-7370 Adapter 1 Relay (6 pins)
— 799-601-4100 T-assembly 1 Engine related connector
— 795-799-5530 • T-adapter 1 Engine coolant temperature
Troubleshooting of
Boost temperature and pressure sen-
sensors and wiring — 799-601-4230 • T-adapter 1
sor
harnesses
— 799-601-4130 • T-adapter 1 No sensor, CAM sensor
— 795-601-4160 • T-adapter 1 Oil pressure sensor
— 799-601-4211 • T-adapter 1 Controller (50 poles)
— 799-601-4140 • T-adapter 1 Ambient pressure sensor
— 795-601-4340 • T-adapter 1 Pump actuator
— 799-601-4190 • T-adapter 1 Common rail pressure sensor
D61EX, PX-15E0 5
Measuring engine speed 1 3. Measuring high idle speed

1) Start the engine and set the fuel control
a Measure the engine speed under the following dial in the high idle position.
condition. 2) Set the PCCS lever and work equipment
q Coolant temperature: Within operating control lever in neutral and measure the
range engine speed.
q Hydraulic oil temperature: Within operat- a The high idle speed measured in the
ing range “Monitoring mode” or in the “Pm Clinic
q Power train oil temperature: Within operat- auxiliary mode” is the auto-deceleration
ing range speed.
a When measuring the high idle speed of
1. Preparatory work the engine, use the “Adjustment mode”.
Turn the starting switch ON and set the monitor Adjustment code: 0007 (Engine decelera-
panel in the “Monitoring mode” to prepare for tor cut mode)
measurement of the engine speed.
a For the operating method, see “Special
functions of monitor panel (EMMS)”.
q Monitoring code: 01000 (Engine speed)
4. Measuring decelerator pedal speed

1) Start the engine and set the fuel control
dial in the high idle position.
2) Set the PCCS lever and work equipment
2. Measuring low idle speed control lever in neutral, and measure the
1) Start the engine and set the fuel control engine speed with the decelerator pedal
dial in the low idle position. depressed.
2) Set the PCCS lever and work equipment
control lever in neutral and measure the
engine speed.
6 D61EX, PX-15E0
5. Measuring torque converter stall speed a The engine speed can be measured
1) Start the engine and set the fuel control by the following operation:
dial in the low idle position. q “Pm clinic auxiliary mode” of the
2) With the brake pedal depressed securely monitor panel
and the parking brake lever in the “free” q Each time the information switch
position, set the PCCS lever in the “for- is set to the right or left when the
ward” and 3rd gear speed position. monitor panel is in the normal
a Before going to the next step, check display state, the display in the
that the upper display unit of the mon- multi information section turns to
itor panel is set in the normal display the display of service meter or
state and it displays [F3]. engine speed. (However, mea-
a Keep the steering unit in neutral. sure the high idle speed of the
3) Press the decelerator pedal and set the engine in the “Adjustment
fuel control dial in the high idle position. mode“).
4) Return the decelerator pedal slowly to stall
the torque converter with the engine at
high idle.
k Keep pressing the brake pedal
securely and keep your right foot
on the decelerator pedal for safety
until the work is finished.
5) Just after the power train oil temperature
gauge reads the top line of the green
range, return the direction of the PCCS
lever into neutral.
6) Repeat above steps 2) – 5) 3 times.

7) Perform steps 2) – 4) again and measure
the engine speed about 5 seconds after
the power train oil temperature gauge
reads the top line of the green range.
a After finishing measurement, return
the direction of the PCCS lever into
neutral and lower the power train oil
temperature with the engine at high
idle.
D61EX, PX-15E0 7
Measuring intake air pressure 3. Install nipple [2] of boost gauge kit A and con-
(boost pressure) 1 nect gauge [1].
a Measuring instruments for intake air pressure

(boost pressure)
Symbol Part No. Part name
A 799-201-2202 Boost gauge kit
k When installing and removing the measur-

ing instrument, take care not to touch a hot
part of the engine.
a Measure the intake air pressure (boost pres-
sure) under the following condition.
q Coolant temperature: Within operating
range
q Hydraulic oil temperature: Within operat-
ing range 4. Run the engine at medium or higher speed and
q Power train oil temperature: Within operat- drain the oil from the hose.
ing range a Insert the joint of the gauge and hose half-
way and open the self-seal on the hose
1. Open the left side cover (1) of the engine. side repeatedly, and the oil is drained.
a If Pm kit (A) is available, the air bleeding
coupling (790-261-1130) in it may be
used.
a If any oil is left in the hose, the gauge does
not move. Accordingly, be sure to drain
the oil.
5. Measure the intake air pressure (boost pres-

sure) while the engine is running at high idle
and the torque converter is stalling.
a For the procedure for stalling the torque
converter, see “Measuring engine speed”.
a Normally, the intake air pressure (boost
pressure) should be measured while the
engine is running at the rated output. In
2. Remove air intake connector boost pressure
the field, however, an approximate value
pickup plug (2) (R 1/8).
can be obtained by stalling the torque con-
verter.
6. After finishing measurement, remove the mea-

suring instrument and reinstall the removed
parts.
8 D61EX, PX-15E0
a The boost pressure can be measured in the

“Pm Clinic auxiliary mode” of the monitor
panel.
D61EX, PX-15E0 9
Measuring exhaust color 1

a Measuring instrument for exhaust gas color
Symbol Part No. Name

1 799-201-9001 Handy smoke checker
C Commercially
2 Smoke meter
available
k When installing or removing the measuring

instruments, take care not to touch a hot
part.
a If an air source and an electric power source
are not available in the field, use handy smoke
checker C1. When recording official data, use 2) Connect the probe hose, receptacle of the
smoke meter C2. accelerator switch, and air hose to smoke
a Measure the exhaust gas color under the fol- meter C2.
lowing conditions. a Limit the supplied air pressure to 1.5
q Engine coolant temperature: MPa {15 kg/cm2}.
Within operating range 3) Connect the power cable to a receptacle
of AC 100 V.
1. Measuring with handy smoke checker C1 a Before connecting the cable, check
1) Attach a filter paper sheet to smoke that the power switch of the smoke
checker C1. meter is turned off.
2) Insert the exhaust gas intake pipe into 4) Loosen the cap nut of the suction pump
exhaust pipe (1). and fit the filter paper.
3) Start the engine. a Fit the filter paper securely so that the
4) Accelerate the engine sharply or run it at exhaust gas will not leak.
high idle, and operate the handle of 5) Turn on the power switch of smoke meter
smoke checker C1 to make the filter paper C2.
absorb the exhaust gas.
6) Start the engine.

5) Remove the filter paper and compare it 7) Accelerate the engine sharply or run it at
with the attached scale to make decision. high idle, press the accelerator pedal of
6) After finishing measurement, remove the smoke meter C2, and collect the exhaust
measuring instruments and return the gas into the filter paper.
removed parts. 8) Place the contaminated filter paper on the
clean filter paper (at least 10 sheets) in the
2. Measuring with smoke meter C2 filter paper holder and read the indicated
1) Insert probe [1] of smoke meter C2 into value.
the outlet of exhaust pipe (1), and fix it to 9) After finishing measurement, remove the
the exhaust pipe with a clip. measuring instruments and return the
removed parts.
10 D61EX, PX-15E0
Adjusting valve clearance 1 3. Remove 3 bolts (6) and disconnect bracket (7).
q Do not disconnect the link.
a Measuring tools for valve clearance
Symbol Part No. Part name 4. Remove cylinder head cover (8).
1 795-799-1131 Gear
D Commercially
2 Clearance gauge
available
k Stop the machine on a level ground and

lower the work equipment to the ground.
a Measure the valve clearance under the follow-
ing condition.
q Engine coolant temperature: Normal tem-
perature
1. Remove the engine hood assembly. For

details, see Disassembly and assembly,
“Removal and installation of engine hood
assembly”.
5. Remove plug (9) from the top of the starting
2. Remove aftercooler upper hose (1), muffler motor and insert gear D1.
assembly (2) and bracket (3) and disconnect
air conditioner hose clamp (4) and corrosion
resistor (5). For details, see Disassembly and
assembly, “Removal and installation of cylinder
head assembly”.
D61EX, PX-15E0 11
6. Rotate the crankshaft forward (clockwise, see- 8. Adjust the valve clearance according to the fol-
ing from the fan) with gear D1 and set wide slit lowing procedure.
(b) of the rotation sensor ring to projection top 1) While fixing adjustment screw (10), loosen
(a) of front cover. locknut (11).
a Projection top (a) must be within the range 2) Insert clearance gauge D2 in the
of wide slit (b) when it is seen from the air clearance between rocker arm (12) and
conditioner compressor side. crosshead (13) and adjust the valve
a If you can see the yellow marks (c) of pro- clearance with adjustment screw (3).
jection top (a) and the damper periphery, a With the clearance gauge inserted,
you may set them to each other. turn the adjustment screw to a degree
a When the crankshaft is set as above, the that you can move the clearance
piston in the No. 1 or No. 6 cylinder is not gauge lightly.
set to the compression top dead center 3) While fixing adjustment screw (10), tighten
(TDC). Take care. locknut (11).
3 Locknut:
24 ± 4 Nm {2.45 ± 0.41 kgm}
a After tightening the locknut, check the
valve clearance again.
7. Check the movement of the rocker arm of the

No . 1 c y li nd er to ju dg e th e v al v e to b e
adjusted.
a If you can move the rocker arms of air 9. Rotate the crankshaft forward by 1 turn and set
intake valves (IN) with the hand by the wide slit (b) to projection top (a) according to
valve clearance, adjust the valves marked step 6.
with Q in the valve arrangement drawing.
a If you can move the rocker arms of 10. Adjust the other valve clearances according to
exhaust valves (EX) with the hand by the steps (7) and (8).
valve clearance, adjust the valves marked a If the valves marked with q in the valve
with q in the valve arrangement drawing. arrangement drawing were adjusted in
a Valve arrangement drawing s teps ( 7) and (8) , adjust the valves
marked with Q.
a If the valves marked with Q in the valve
arrangement drawing were adjusted in
s teps ( 7) and (8) , adjust the valves
marked with q.
11. After finishing adjustment, remove the adjust-

ing tools and return the removed parts.
a Remove gear D1 without fail.
3 Cylinder head cover mounting nut:
24 ± 4 Nm {2.45 ± 0.41 kgm}
12 D61EX, PX-15E0
Measuring compression pressure1 a While pressing the lock of connector (5)

with flat-head screwdriver [1], disconnect
a Measuring tools for compression pressure connector (5).
1 795-502-1590 Compression gauge
2 795-799-6700 Puller
E 795-790-4410 Adapter
3
6754-11-3130 Gasket
4 795-799-8150 Remover

a Measure the compression pressure under the
following condition.
q Engine oil temperature: 40 – 60°C
1. Remove the engine hood assembly, after-

7. Remove retaining nut (9) and inlet connector
cooler upper hose, muffler assembly and muf-
(10).
fler bracket and disconnect the air conditioner
a Before removing the inlet connector, wash
hose clamp and corrosion resistor. For details,
around it so that sticking mud will not enter
see “Adjusting valve clearance”, Steps 1 and 2.
its hole.
a Tool E4 is set for removal of inlet connec-
2. Remove 4 bolts (1) and air intake elbow (2).
tor (10).
3. Remove 2 clamps (3) and move wiring harness
(4) outward.
4. Disconnect 3 connectors (5).
5. Remove 6 high-pressure pipes (6).
6. Remove 6 nuts (7) and cylinder head cover (8).
D61EX, PX-15E0 13
8. Remove the mounting bolts (11) of rocker arm 12. Install rocker arm assembly (12) on the
assembly on the exhaust side, and then exhaust side and adjust the valve clearance.
remove rocker arm assembly (2). 3 Rocker arm assembly mounting bolt:
a When removing the injector, you do not 36 ± 5 Nm {3.67 ± 0.5 kgm}
need to remove the rocker arm assembly a See “Adjusting valve clearance”.
on the intake side.
9. Disconnect injector wiring harness (13) and

remove 2 injector holder mounting bolts (14)
10. Using tool E2, remove injector assembly (15).
11. Install adapter E3 to the injector assembly

mounting part with the injector holder and con-
nect compression gauge E1.
a Install the gasket to the adapter end with-
out fail.
a Tighten holder mounting bolts alternately
3 Injector holder mounting bolt:
8 ± 0.8 Nm {0.8 ± 0.08 kgm}
a If a little quantity of engine oil is applied to
the joint of the adapter and gauge, air
does not leak easily.
14 D61EX, PX-15E0
13. Disconnect CE03 connector (17) of the engine 15. After finishing measurement, remove the mea-
controller (16). suring tools and return the removed parts.
k If the connector is not disconnected, a Install the injector assembly and inlet con-
the engine will start during measure- nector according to the following proce-
ment and it will be dangerous. dure.
a Since the CE03 connector is a part of the 1) Apply new engine oil (SAE15W-40) to the
power supply circuit of the engine control- O-ring of injector assembly (15) and cylin-
ler, cover the connector on the machine der head.
side with a vinyl sheet, etc. to prevent 2) Install injector assembly (15) with the fuel
electric leakage and ground fault. inlet hole directed to the air intake mani-
fold.
3) Install injector holder (18) and tighten the
mounting bolt by 3 – 4 threads.
4) Install inlet connector (10) and tighten
retaining nut (9) temporarily.
3 Retaining nut:
15 ± 5 Nm {1.5 ± 0.5 kgm}
5) Tighten mounting bolt (14) of holder (18)
securely.
3 Injector holder mounting bolt (14):
8 ± 0.8 Nm {0.8 ± 0.08 kgm}
6) Tighten retaining nut (9) securely.
3 Retaining nut:
50 ± 5 Nm {5.1 ± 0.5 kgm}
14. Rotate the engine with the starting motor and
measure the compression pressure.
a Read the gauge when the pointer is stabi-
lized.
a Tighten the bolts and nuts other than the

injector and inlet connector to the follow-
ing torque.
3 Injector wiring harness nut:
1.5 ± 0.25 Nm {0.15 ± 0.026 kgm}
3 Fuel tube sleeve nut:
35 ± 3.5 Nm {3.6 ± 0.4 kgm}
3 Rocker arm assembly mounting bolt:
36 ± 6 Nm {3.7 ± 0.6 kgm}
a Adjust the valve clearance. For details,
see “Adjusting valve clearance”.
3 Cylinder head cover mounting nut:
24 ± 4 Nm {2.45 ± 0.41 kgm}
D61EX, PX-15E0 15
Measuring blow-by pressure 1 3. Measure the blow-by pressure while the

engine is running at high idle and the torque
a Measuring instrument for blow-by pressure converter is stalling.
Symbol Part No. Part name a For the procedure for stalling the torque
converter, see “Measuring engine speed”.
F 799-201-1504 Blow-by checker
a Normally, the blow-by pressure should be
a Measure the blow-by pressure under the fol- measured while the engine is operated at
lowing condition. the rated output. In the field, however, an
q Coolant temperature: Within operating approximate value can be obtained by
range stalling the torque converter.
q Hydraulic oil temperature: Within operat- a If it is impossible to run the engine at the
ing range rated output or stall the torque converter,
q Power train oil temperature: Within operat- measure while the engine is running at
ing range high idle.
The value obtained in this case is about
1. Open the left side cover (1) of engine hood. 80% of the blow-by pressure at the rated
output.
a The blow-by pressure may vary largely
with the engine condition. If the measured
value is judged abnormal, check for
increase of oil consumption, bad exhaust
gas color, premature deterioration or con-
tamination of oil, etc. which are related to
the abnormal blow-by pressure.
2. Install nozzle [1] of blow-by checker F to blow-

by hose (2) and connect it to gauge [2].

suring instrument and reinstall the removed
parts.
16 D61EX, PX-15E0
Measuring engine oil pressure 1 4. Install adapter G3 and then connect hydraulic
tester G2 (0.98 MPa {10 kg/cm2).
a Engine oil pressure measurement tools
Symbol Part No. Part Name
799-101-5002 Hydraulic tester
1
790-261-1204 Digital hydraulic tester
2 799-401-2320 Hydraulic tester
G
Adapter (M10 x 1.0 mm o R
795-790-4430
3 1/8)
6215-81-9720 O-ring
a Measure the engine oil pressure under the fol-

lowing condition.
q Engine coolant temperature:
5. Start the engine and heighten the coolant tem-
1. Open engine left side cover (1). perature to the operating range.
2. Remove engine left side cover (2). 6. While running the engine at low idle and high
idle, measure the oil pressure.
3. Remove oil pressure measurement plug (3)

(M10 × 1.0 mm). 7. Remove the measurement tool after the mea-
surement, and make sure that the machine is
back to normal condition.
D61EX, PX-15E0 17
Handling fuel system equipment 1 Releasing residual pressure in

a Precautions for testing and maintaining fuel fuel system 1
system a Pressure is generated in the low-pressure cir-
The common rail fuel injection system (CRI) cuit and high-pressure circuit of the fuel sys-
consists of more precise parts than the con- tem while the engine is running.
ventional fuel injection pump and nozzle. If for- Low-pressure circuit:
eign matter enters this system, it can cause a Feed pump – Fuel filter – Supply pump
trouble. High-pressure circuit:
When testing and maintaining the fuel system, Supply pump – Common rail – Injector
take care more than the past. If dust, etc. sticks a The pressure in both low-pressure circuit and
to any part, wash that part thoroughly with high-pressure circuit lowers to a safety level
clean fuel. automatically 30 seconds after the engine is
a Precautions for replacement of fuel filter car- stopped.
tridge a Before the fuel circuit is tested and its parts are
The fuel filter cartridge used must be a genuine removed, the residual pressure in the fuel cir-
Komatsu part. cuit must be released completely. Accordingly,
The fuel injection pump and nozzle of the com- observe the following.
mon rail type fuel injection system (CRI) are k Before testing the fuel system or removing
consisted of more precision parts than those its parts, wait at least 30 seconds after stop-
used for the current pumps and nozzles. This ping the engine until the residual pressure
system, therefore, employs a special filter with in the fuel circuit is released. (Do not start
highly efficient filtering performance to prevent the work just after stopping the engine
mixing of foreign substances. Thus, substitut- since there is residual pressure.)
ing it with a non-genuine filter could cause
troubles in the fuel system. It is strictly prohib-
ited to use such part.
18 D61EX, PX-15E0
Measuring fuel pressure 1

a Measuring tools for fuel pressure
1
Adapter
795-790-4430
H 2 (M10 × 1.0 mm o R1/8)
6215-81-9710 O-ring
3 799-201-2202 Boost gauge kit
4 795-790-5110 Screw

lower the work equipment to the ground. 3) Run the engine at low idle and measure
a Measure only the fuel pressure in the low-pres- the pressure in the fuel low-pressure cir-
sure circuit from the feed pump through the cuit.
fuel main filter to the supply pump and the a If the pressure in the fuel low-pres-
return circuit from the supply pump/common sure circuit is in the following range, it
rail/injector to fuel tank. is normal.
k Since the pressure in the high-pressure cir- 0.5 – 1.3 MPa
cuit from the supply pump through the At low idle
{5.1 – 13.3 kg/cm2}
common rail to the injector is very high, it 0.3 – 1.1 MPa
cannot be measured. During cranking
{3.1 – 11.3 kg/cm2}
1. Measuring pressure in fuel low-pressure k If the engine cannot be started, you

circuit may measure the fuel pressure
1) Open the left cover of engine hood and while rotating the engine with the
remove fuel pressure pickup plug (on the starting motor. Do not rotate for
fuel inlet side) (1) from the fuel main filter. more than 20 seconds continu-
ously, however, for protection of
the starting motor.
2) Install adapter H2 and nipple [1] of

hydraulic tester H1 and connect them to
oil pressure gauge [2] 4) After finishing measurement, remove the
a Use the oil pressure gauge of 2.5 MPa measuring tools and return the removed
{25 kg/cm2}. parts.
3 Fuel pressure pickup plug:
10 ± 2 Nm {1 ± 0.2 kgm}
D61EX, PX-15E0 19
2. Measuring pressure in fuel return circuit

1) Remove fuel pressure pickup plug (2)
(M12 x 1.5 mm) from the fuel return block.
2) Install adapter H2, then install joint [3] of

hydraulic tester H1 and nipple [1] and con-
nect them to pressure gauge H3.
a Joint [3]:
790-301-1181, 07002-11223
3) Run the engine at low idle and measure

the pressure in the fuel return circuit.
a If the pressure in the fuel return circuit
is in the following range, it is normal.
At low idle Max. 18.63 kPa
During cranking {Max. 139.7 mmHg}
k If the engine cannot be started, you

may measure the fuel pressure
while rotating the engine with the
starting motor. Do not rotate for
more than 20 seconds continu-
ously, however, for protection of
the starting motor.
4) After finishing measurement, remove the

measuring tools and return the removed
parts.
3 Fuel pressure pickup plug:
24 ± 4 Nm {2.4 ± 0.4 kgm}
20 D61EX, PX-15E0
Measuring fuel delivery amount, 2) Loosen clamp (2 places) of delivery side

return rate and leakage 1 tube (1) of the supply pump and discon-
nect tube (1).
a Testing tools for leakage from pressure limiter
and return rate from injector

Commercially Hose
1
available (Inside diameter: 14 mm)
2 795-790-4700 Tester kit
6754-71-5340 Connector
3
6754-71-5350 Washer
J
Commercially
4 Measuring cylinder
available
5 795-790-6700 Adapter
Commercially
6 Stopwatch
available
3) Install test hose J1 to the nipple on the
delivery side of the supply pump.
a Prepare a receiver of 20 l for fuel leakage dur- a Fix the hose with a wire etc.
ing testing. a Adjust the route of the test hose so
k Stop the machine on a level ground and that it will not slacken and put its end
lower the work equipment to the ground. in an oil receiving pan.
1. Measuring supply pump delivery amount
1) Open engine hood left cover (1) and
remove bottom cover (2).
D61EX, PX-15E0 21
4) Crank the engine for 30 seconds and 2. Measuring supply pump return rate
measure the delivery amount with mea- 1) Disconnect return hose (2) of supply
suring cylinder J4. pump.
a Do not crank the engine for more than a The return hose is a coupler.
30 seconds to protect the starting
motor in any case other than this
measurement.
a If the supply pump delivery amount is
in the following standard range, it is
normal.
Engine speed Delivery amount [Q]
125 rpm Min. 75 cc
150 rpm Min. 90 cc
195 rpm Min. 117 cc
q Delivery amount Q:
Q = engine speed x 0.6
2) Install connector J3 and cap nut of tester

kit J2 to the return hose to stop the fuel
from flowing out.
3) Connect test hose [1] of tester kit J2 to the
supply pump.
a Adjust the route of the test hose so
that it will not slacken and put its end
in an oil receiving pan.

measuring instruments and return the
removed parts.
3 Tube sleeve nut:
35 ± 4 Nm {3.6 ± 0.4 kgm}
3 Clamp mounting bolt:
10 ± 2 Nm {1.0 ± 0.2 kgm}
22 D61EX, PX-15E0
4) While running the engine at low idle, mea- 3. Measuring leakage from pressure limiter
sure the returning fuel with measuring cyl- 1) Disconnect return hose (3) of the pressure
inder J4 for 25 seconds. limiter.
a If the leakage from the supply pump 2) Install connector J3 and cap nut of tester
is in the following standard range, it is kit J2 to the return hose to stop the fuel
normal. from flowing out.
3) Connect test hose [1] of tester kit J2 to the
Engine speed Fuel return rate
common rail side.
750 rpm Max. 400 cc a Adjust the route of the test hose so
850 rpm Max. 455 cc that it will not slacken and put its end
915 rpm Max. 490 cc in an oil receiving pan.
4) While running the engine at low idle, mea-

5) After finishing measurement, remove the sure the leakage from the pressure limiter
measuring instruments and return the with measuring cylinder J4 for 1 minute.
removed parts. a If the leakage from the pressure lim-
a When measuring the leakage from iter is in the following standard range,
the pressure limiter after the supply it is normal.
pump return rate, return the engine to Low idle 0 cc (No leakage)
the normal condition.
a When measuring the injector return
rate after the supply pump return rate,
leave the engine as it is and keep the
hose end in the oil receiving pan.

removed parts.
D61EX, PX-15E0 23
4. Measuring injector return rate 4) Run the engine at low idle and measure
a The injector return rate must be measured the return rate from the injector in 1 minute
with the pressure limiter return hose con- with measuring cylinder J4.
nected. Accordingly, check that fuel leaks a If the return rate from the injector is in
from the pressure limiter is normal in the following range, it is normal.
advance.
Low idle Max. 180 cc/min.
1) Referring to “Measuring supply pump
return rate”, set the supply pump under Cranking Max. 90 cc/min.
the condition for measurement.
a While the injector return rate is mea- k If the engine cannot be started, you
sured, the fuel flows out of the supply may measure the return rate while
pump. Accordingly, put the test hose rotating the engine with the start-
end on the supply pump in an oil ing motor. Do not rotate for more
receiving pan. than 20 seconds continuously,
2) Remove joint bolt (4) from the return however, for protection of the start-
block. ing motor.
a Fit the seal washer to the return hose.

measuring tools and return the removed
3) Install connector bolt [3] of adapter J5 for parts.
the removed joint bolt and connect test 3 Joint bolt:
hose [4] to it. 19.6 – 29.4 Nm {2.0 – 3.0 kgm}

a Set the test hose so that it will not
slack and put its end in the receiving
pan.
24 D61EX, PX-15E0
Bleeding air from fuel circuit 1

a If fuel is used up or if a fuel circuit part is
removed and installed, bleed air from the fuel
circuit according to the following procedure.
k Stop the machine on a flat ground and
1. Fill the fuel tank with fuel.
2. Open engine hood left cover (1).
3. Loosen knob (2) of the feed pump and pull it

out, and then operate it forward and backward.
a Move the knob until it becomes heavy.
a Do not remove the plug at the top of the
fuel main filter.
4. After bleeding air, push in and tighten knob (2).
D61EX, PX-15E0 25
a Air bleeding route of fuel circuit

Fuel tank o Pre-filter o Feed pump o Main filter o Metering unit o Fuel tank
26 D61EX, PX-15E0
Testing leakage in fuel system 1 9. Inspect the fuel piping and devices for fuel
leakage.
k Very high pressure is generated in the high- a Check mainly around the high-pressure
pressure circuit of the fuel system. If fuel circuit parts coated with the color checker
leaks while the engine is running, it is dan- for fuel leakage.
gerous since it can catch fire. a If fuel leakage is recognized, repeat the
After testing the fuel system or removing procedure from step 1 after repairing the
its parts, test it for fuel leakage according leakage.
to the following procedure. a If no fuel leakage is detected, check is
a Clean and degrease the engine and the parts completed.
around it in advance so that you can test it eas-
ily for fuel leakage.
1. Spray color checker (developer) over the fuel

supply pump, common rail, fuel injector, and
joints of the high-pressure piping.
2. Run the engine at speed below 1,000 rpm and

stop it after its speed is stabilized.
3. Inspect the fuel piping and devices for fuel

leakage.
a Check mainly around the high-pressure
circuit parts coated with the color checker
for fuel leakage.
a If fuel leakage is recognized, repeat the
procedure from step 1 after repairing the
leakage.
4. Run the engine at low idle.

leakage.
for fuel leakage.
leakage.
6. Run the engine at high idle.

leakage.
for fuel leakage.
leakage.
8. Run the engine at high idle and load it.

a When checking while the components to
be checked are mounted on the machine,
stall the torque converter or relieve the
hydraulic pump.
D61EX, PX-15E0 27
Handling of reduced cylinder Handling of no injection cranking

mode operation 1 operation 1
a Reduced cylinder mode operation means to a No injection cranking means to crank the
run the engine with the fuel injectors of 1 or engine with the starting motor while all the
more cylinders disabled electrically to reduce injections are stopped electrically. The purpose
the number of effective cylinders. The pur- and effect of this operation are as follows.
poses and effects of this operation are as fol- q Before the engine is started after it or the
lows. engine unit has been stored for a long period,
1. This operation is used to find out a cylinder the no injection cranking is performed to lubri-
which does not output power normally (or, cate the engine parts and protect them from
combustion in it is abnormal). seizure.
2. When engine speed and output do not change a Use the no-injection cranking function for only
from the normal operation (all cylinder operat- the above purposes while the engine is
ing mode) even though the fuel injection has mounted on the machine.
been cut out for any cylinder, the cylinder is a To implement no injection cranking operation,
suspected to be defective. see “4. Adjustment mode (4-USER ADJUST
The following problems can be considered: MODE)” of Operation and display of operator
q Leaking of cylinder head gasket mode (Outline) in Testing and adjusting, Part 3.
q Defective injection of injector
q Defective piston, piston ring or cylinder
liner
q Defective valve mechanism (valve sys-
tem)
q Defective electrical system
3. Since the injector of each cylinder is separately
controlled electronically in the common rail fuel
injection system, the reduced cylinder mode
operation can be obtained by easier operations
of the switches when compared with the
mechanical fuel injection system. This allows
to narrow down the causes of the incident eas-
ily.
a To implement reduced cylinder mode
operation, see “Special functions of moni-
tor panel (EMMS)”.
a Use the reduced cylinder mode for only
the purpose of troubleshooting.
28 D61EX, PX-15E0
Testing and adjusting air condi- Replacing the fan belt 1

tioner compressor belt tension 1 a The auto-tensioner is provided for the fan belt.
Thus, testing and adjustment of the belt is usu-
Testing ally no necessary.
q Press the middle point between air conditioner a Disconnect air conditioner compressor belt
compressor pulley and drive pulley with a finger before replacing the fan belt.
k
and measure deflection (a) of the belt. Stop the machine on a flat ground and
a Pressing force: Approx. 98 N {Approx. 10 kg} lower the work equipment to the ground.
1. Open engine hood right cover (1).
Adjusting
a If the deflection is abnormal, adjust it according
to the following procedure. 2. Insert a wrench to portion (A) (width across
flats T 12.7 mm) of tensioner assembly (3),
1. Loosen 4 compressor bracket mounting bolts and rotate it to the opposite to the winding-up
(1). direction to decrease fan belt (2) tension.
k Make sure that the wrench is secured
2. Loosen locknut (2) and adjust the belt tension at portion (A) before rotating it. (The
by turning adjustment bolt (3). spring of tensioner assembly (3) is
strong. If the wrench is loosely
3. After the tension is adjusted to the reference inserted, the wrench may accidentally
value, tighten locknut (2) and 4 compressor come off while being rotated and it is
bracket mounting bolts (1). extremely dangerous.)
k After removing fan belt (2), return ten-
sioner assembly (3) slowly with care.
k Be careful not to get your fingers
caught between the pulley and fan belt
(2) during work.
3. Replace fan belt (2).

q Check each pulley for breakage and crack.
D61EX, PX-15E0 29
Handling controller voltage circuit 1

1. Disconnection or connection of the connector
between the engine controller and engine must
be done after turning off the starting switch.
2. It is prohibited to start the engine when T-

adapter is inserted or connected, for trouble-
shooting purpose, to the connector between
the engine controller and engine.
a You may turn the starting switch to the
OFF or ON position but must not turn it to
the START position.
30 D61EX, PX-15E0
Adjusting fuel control dial and 2. Preparatory work

decelerator pedal 1 1) Start the engine, set the monitor panel in
the “Adjustment mode”, and prepare to
1. Outline of fuel control system measure the engine speed.
q The following signals are inputted as rota- a For the operation method, see “Spe-
tion command signals to the engine con- cial functions of monitor panel
troller. (EMMS)”.
q Decelerator pedal potentiometer sig- q Adjustment code: 0007
nal (Engine deceleration cut mode)
q 3rd throttle signal a The engine speed is displayed by 1
The engine controller controls the fuel rpm.
control system of the engine (CRI system)
according to the lowest engine speed sig-
nal among those input signals.
q Adjust the deceleration slow speed by
adjusting the decelerator pedal linkage.
[1] Fuel control dial

[2] Engine controller
[3] Steering and transmission controller
[4] Decelerator pedal
[5] Decelerator potentiometer
[6] Engine (CRI system)
[7] 3rd throttle signal
[8] Rod
D61EX, PX-15E0 31
3. Adjusting decelerator pedal engine speed

With the fuel control dial in the high idle posi-
tion, press decelerator pedal (1) to stopper bolt
(2) and check that the decelerator pedal
engine speed is normal.
q Decelerator pedal engine speed:
1,150 – 1,200 rpm
q Potentiometer output: 3.56 ± 0.1 V
a If the decelerator pedal engine speed is
out of range, adjust installation dimension
(a) of stopper bolt (2).
q Standard installation dimension (a) of
stopper bolt: 24.5 mm
4. Engine speed at high idle

Set the fuel control dial in the high idle position
and check that the engine speed at high idle is
normal.
q Engine speed at high idle:
1,950 – 2,050 rpm
q Potentiometer output: 0.8 ± 0.1 V
q Standard installation dimension (b) of
stopper bolt: 24 mm
a If the engine speed is out of range, per-
form the following.
q When the engine speed is 1,950 rpm or
less:
Adjust the engine speed to the high idle
speed with stopper bolt (3).
32 D61EX, PX-15E0
D61EX, PX-15E0 33
SEN02555-00

© 2007 KOMATSU
All Rights Reserved
34
SEN02556-00
D61EX-15E0
D61PX-15E0


Measuring power train oil pressure................................................................................................................. 3
Adjusting transmission speed sensor (replacement procedure) ..................................................................... 7
Simple method of testing brake performance ................................................................................................. 9
Adjusting brake pedal ................................................................................................................................... 10
Adjusting parking brake lever........................................................................................................................ 12
Emergency escape method when power train has trouble ........................................................................... 13
Adjusting idler clearance............................................................................................................................... 16
Inspecting wear of sprocket .......................................................................................................................... 16
Testing and adjusting track shoe tension ...................................................................................................... 17
Testing and adjusting work equipment and HSS oil pressure....................................................................... 18
Testing control circuit main pressure............................................................................................................. 22
Measuring PPC valve output pressure ......................................................................................................... 23
Adjusting play of work equipment PPC valve ............................................................................................... 26
Measuring internal leakage of work equipment cylinder ............................................................................... 27
Adjusting work equipment lock lever of work equipment .............................................................................. 28
Releasing residual pressure in work equipment cylinder (If PPC accumulator is not installed).................... 29
D61EX, PX-15E0 1
Releasing residual pressure in work equipment cylinder (If PPC accumulator is installed) .......................... 29
Bleeding air from work equipment cylinder ................................................................................................... 30
Measuring fan motor speed .......................................................................................................................... 31
Measuring fan pump circuit pressure ............................................................................................................ 32
Measuring HSS motor oil leakage................................................................................................................. 33
Bleeding air from fan pump ........................................................................................................................... 33
Testing and adjusting operator's cab............................................................................................................. 34
2 D61EX, PX-15E0
Measuring power train oil pressure 1

a Measuring instruments for power train oil pres-
sure

1
Hydraulic tester
K 2 799-401-2320
(1.0 MPa {10 kg/cm2})
799-101-5220 Nipple (10 x 1.25 mm)
3
07002-11023 O-ring
k Stop the machine on a level place, lower

the work equipment to the ground, and set
the parking brake lever and work equip-
ment lock lever in the LOCK position.
1. Measuring brake pressure
a Measure the power train oil pressure under the
1) Remove the plug on oil pressure measur-
following conditions.
ing section (2) and connect nipple K3 and
q Power train oil temperature: 70 – 80°C
oil pressure gauge [1] of hydraulic tester
a The power train oil pressure measuring section
K1 to the plug hole.
(c entr alized pres sure detection port) is
a Use an oil pressure gauge of 6 MPa {60
installed inside inspection cover (1) on the right
kg/cm2}.
outside of the operator's cab.
2) Start the engine and set the parking brake

a List of pressure measuring point and gauges to
lever in the Free position.
use
3) Measure the oil pressure when the engine
is running at low idle and high idle.
Gauge
No. Measuring point
(MPa {kg/cm2})
2 Brake pressure 6 {60}
Torque converter inlet oil
3 2.5 {25}
pressure
Torque converter outlet oil
4 1.0 {10}
pressure
Transmission main relief
5 6 {60}
pressure
D61EX, PX-15E0 3
a Check that the oil pressure is 0 when the

brake pedal is pressed or the parking
brake lever is set in the Lock position.
3. Measuring torque converter outlet pressure

4) After finishing measurement, remove the ing section (4) and connect nipple K3 and
measuring instruments and return the hydraulic tester K2 to the plug hole.
removed parts. a Use an oil pressure gauge of 1.0 MPa {10
kg/cm2}.
2. Measuring torque converter inlet pressure
ing section (3) and connect nipple K3 and
oil pressure gauge [1] of hydraulic tester
K1 to the plug hole.
a Use an oil pressure gauge of 2.5 MPa {25
kg/cm2}.
2) Start the engine and set the PCCS lever in

the full neutral position.

removed parts.

removed parts.
4 D61EX, PX-15E0
4. Measuring transmission main relief oil 5. Measuring clutch pressure

pressure q Remove the operator's seat assembly and
1) Remove the plug on oil pressure measur- measure the clutch oil pressure from the
ing section (5) and connect nipple K3 and top of the floor frame.
oil pressure gauge [1] of hydraulic tester a Table of locations of centralized pressure
K1 to the plug hole. pickup points for measuring oil pressure
a Use an oil pressure gauge of 6 MPa and gauges to use
{60 kg/cm2}.
Gauge
No. Measuring point
(MPa {kg/cm2})
Transmission forward clutch oil
6 6 {60}
pressure
Transmission reverse clutch oil
7 6 {60}
pressure
Transmission 1st clutch oil
8 6 {60}
pressure
Transmission 2nd clutch oil
9 6 {60}
pressure
Transmission 3rd clutch oil
10 6 {60}
pressure


removed parts.
D61EX, PX-15E0 5
1) Measuring transmission forward clutch k To stall the torque converter,

pressure hold the brake pedal pressed
1] Remove oil pressure pickup plug (6) securely.
and connect oil pressure gauge [1] of k Do not raise the engine speed
hydraulic tester K1 to the plug hole. to high idle during the mea-
a Use an oil pressure gauge of 6 surement.
MPa {60 kg/cm2}. 5] After finishing measurement, remove
2] Start the engine and set the parking the measuring instruments and return
brake lever in the FREE position. the removed parts.
3] While pressing the brake pedal, set
the PCCS lever in the Forward and 4) Measuring transmission 2nd clutch pres-
the 3rd gear position. sure
4] Measure the oil pressure when the 1] Remove oil pressure pickup plug (9)
engine is running at high idle. and connect oil pressure gauge [1] of
k To stall the torque converter, hydraulic tester K1 to the plug hole.
hold the brake pedal pressed a Use an oil pressure gauge of 5.9
securely. MPa {60 kg/cm2}.
5] After finishing measurement, remove 2] Start the engine and set the parking
the measuring instruments and return brake lever in the Free position.
the removed parts. 3] While pressing the brake pedal, set
the PCCS lever in the Reverse and
2) Measuring transmission reverse clutch the 2nd gear position.
pressure 4] Measure the oil pressure when the
1] Remove oil pressure pickup plug (7) engine is running at low idle.
and connect oil pressure gauge [1] of k To stall the torque converter,
hydraulic tester K1 to the plug hole. hold the brake pedal pressed
a Use an oil pressure gauge of 6 securely.
MPa {60 kg/cm2}. k Do not raise the engine speed
2] Start the engine and set the parking to high idle during the mea-
brake lever in the Free position. surement.
3] While pressing the brake pedal, set 5] After finishing measurement, remove
the PCCS lever in the Reverse and the measuring instruments and return
the 3rd gear position. the removed parts.
4] Measure the oil pressure when the
engine is running at high idle. 5) Measuring transmission 3rd clutch oil
k To stall the torque converter, pressure
hold the brake pedal pressed 1] Remove oil pressure pickup plug (10)
securely. and connect oil pressure gauge [1] of
5] After finishing measurement, remove hydraulic tester K1 to the plug hole.
the measuring instruments and return a Use an oil pressure gauge of 5.9
the removed parts. MPa {60 kg/cm2}.
2] Start the engine and set the parking
3) Measuring transmission 1st clutch pres- brake lever in the Free position.
sure 3] While pressing the brake pedal, set
1] Remove oil pressure pickup plug (8) the PCCS lever in the Forward and
and connect oil pressure gauge [1] of the 3rd gear position.
hydraulic tester K1 to the plug hole. 4] Measure the oil pressure when the
a Use an oil pressure gauge of 6 engine is running at low idle.
MPa {60 kg/cm2}. k To stall the torque converter,
2] Start the engine and set the parking hold the brake pedal pressed
brake lever in the Free position. securely.
3] While pressing the brake pedal, set k Do not raise the engine speed
the PCCS lever in the Forward and to high idle during the mea-
the 1st gear position. surement.
4] Measure the oil pressure while the 5] After finishing measurement, remove
engine is running at low idle. the measuring instruments and return
the removed parts.
6 D61EX, PX-15E0
Adjusting transmission speed 3. Procedure to assemble the sensor assembly

sensor (replacement procedure) 1 1) Remove only nut (4) from sensor (3), and
insert the connector side of sensor (3) into
1. Remove undercover (8) of the fuel tank. Then the opening at the end of tube (6).
remove transmission speed sensor assembly
(1) from steering case (2).
2) Pull the connector of sensor (3) from the

flange hole of tube (6), and insert it into
connector assembly (7). (Insert it securely
until a click sounds.)
2. Measure installed dimension (L) of removed

sensor (3).
a When replacing the sensor, be sure to 3) Install connector assembly (7) on tube (6).
measure dimension (L). 3 Mounting bolt:
4.9 – 6.9 Nm {0.5 – 0.7 kgm}
4) Insert sensor (3) in the boss of tube (6)
and secure it with nuts (4) and (5).
a Installed dimension of sensor: Dimen-
sion measured when removed (L) ±
0.2 mm
3 Locknut: 49 – 68.7 Nm {5 – 7 kgm}
2 Threads of sensor:
Liquid adhesive (LT-2)
D61EX, PX-15E0 7
4. Install sensor assembly (1) in steering case

(2).
q Install sensor (a) to the front of machine.
q Standard clearance between the bevel
gear and the sensor tip: 0.65 – 1.65 mm
5. After finishing adjustment, set the monitor

panel in the “Real-time monitoring mode” and
check that it displays the transmission speed
normally.
a Monitoring code:
31400 (Transmission speed)
8 D61EX, PX-15E0
Simple method of testing brake

performance 1
a Carry out the simple test of the brake perfor-
mance under the following conditions.
q Power train oil temperature:
1. Set the blade and ripper (if equipped) in the

traveling position on a level place.
2. Start the engine and set the parking lever in the

Free position.
3. While running the engine at low idle and press-

ing the brake pedal, set the PCCS lever in the
Forward and the 2nd gear position.
k If this test is carried out in the 1st gear
position, the brake will be overloaded.
Accordingly, be sure to carry it out in
the 2nd gear position.
a Hold the steering unit in neutral.
4. Press the decelerator pedal and set the fuel

control dial to the high idle position.
5. Return the decelerator pedal slowly. Check

that the machine does not start when the
engine speed reaches the high idle speed.
k To stall the torque converter, hold the
brake pedal pressed securely. Keep
your right foot on the decelerator pedal
for safety until the work is finished.
D61EX, PX-15E0 9
Adjusting brake pedal 1
k Tighten the locknuts of the rods and cables 3. Adjust installed dimension (d) of rod (6) on the
securely, and bend the cotter pins securely. pedal side, then connect the rod to brake pedal
(1).
1. Adjust stroke (a) of brake pedal (1) to installed q Installed dimension (d) of rod: 171 mm
dimension (b) of damper (2).
q Pedal stroke (a): 77.5 mm 4. While pushing lightly rod (3) on the valve side
q Installed dimension (b) of damper: 25 mm toward the rear of the machine, connect rods
(3) and (6) by turning only joint (7).
a Push rod (3) with force of about 9.8 – 19.6
N {1 – 2 kg}.
3 Joint: 34.3 – 58.8 Nm {3.5 – 6.0 kgm}
2. Adjust installed dimension (c) of rod (3) on the

valve side, then connect the rod to brake valve
lever (4).
q Installed dimension (c) of rod: 700 mm
a Screw fully joint (5) into the valve side.
10 D61EX, PX-15E0
5. While keeping brake pedal (1) released, adjust

its play to dimension (e) between the pins of
rod assembly (8).
q Play of pedal: 3 – 8 mm (at the center of
pedal)
q Dimension (e) between pins of rod assem-
bly: 898 mm
a Adjust the play by turning joints (5) and (7)
in the same direction.
6. With brake pedal (1) released, check that

brake pedal (1) touches damper (2).
7. Check the brake oil pressure by referring to

“Measuring power train oil pressure”.
Oil pressure:
Remarks
MPa {kg/cm2}
Brake OFF Min. 2.4 {Min. 24} Engine high idle
Brake ON 0
8. After adjusting the pedal, adjust the zero point

of the brake potentiometer (Adjustment mode:
0005).
D61EX, PX-15E0 11
Adjusting parking brake lever 1
1. Assembling and installing lever assembly 3. Checking brake oil pressure

1) Assemble lever assembly (1) and adjust Check that the brake oil pressure is as follows
the operation of limit switch (2). when the parking brake lever is at the Free and
a When assembling the lever assembly, Lock positions.
disconnect the parking brake cable a For the method of measuring the brake oil
from the lever. pressure, see “Measuring power train oil
q Lever up position: OFF pressure”.
lever down position: ON q Lock position: 0
q Operation stroke of limit switch: 3 mm Free position: Specified pressure
2) Install lever assembly (1).
4. Checking limit switch
2. Adjusting installed length of parking cable Change the monitor panel to the monitoring
1) Connect parking brake cable (3) to the display mode and set the parking brake lever
lever and valve and adjust dimensions (a) in the Free and Lock positions. Then check
and (b). that the limit switch signal is normal.
q Installed dimension (a) of cable: a For the method of operating the monitor-
148.5 mm ing display mode, see “Special functions
q Installed dimension (b) of cable: 166 of monitor panel (EMMS)”.
mm q Monitoring code: 40910 (Steering related
2) Operate parking brake lever (4) at the controller input signal 1)
Free and Lock positions, and adjust the
position of rod end (6) so that spool stroke
(h) of brake valve (5) becomes normal.
q Spool stroke (h): 13.3 mm
12 D61EX, PX-15E0
Emergency escape method when 2) Remove the cover on the left of the toe
power train has trouble 1 board and connect wring harness [2] to
PL1 connector (1) and PL2 connector (2).
a Devices used for emergency escape q PL1 connector (1): Connect to male
side and female side.
Symbol Part No. Part name q PL2 connector (2): Connect to female
19M-06-32820 Switch assembly side.
1 a PL2 connector on the male side is
134-06-72810 Wiring harness
kept disconnected, mask it with a
7824-66-6430 Prolix resistance vinyl sheet, etc.
2
L 7827-10-1520 Prolix resistance
3 790-190-1601 Pump assembly
799-101-5220 Nipple (10 x 1.25 mm)
4
07002-11023 O-ring
1. Emergency escape method by the switch

box (Use L1)
a If the machine cannot be moved because
of a trouble in the electric system of the
power train control unit (travel direction,
gear speed, steering), carry out the emer-
gency escape according to the following
procedure.
a The engine must be able to start during
implementing this procedure. 3) Open the battery cover on the left of the
If the engine cannot be started, see cab and remove the cover of relay box (3).
“Emergency escape method with brake
releasing device”.
1) Connect switch assembly [1] and L2 to
wining harness [2] of emergency escape
device.
k To prevent the machine from start-
ing suddenly, set all the gear speed
switches of switch assembly [1] to
OFF position and the direction
switch in P position.
D61EX, PX-15E0 13
4) Disconnect neutral safety relay (NSF) and 5) Run the engine and set the parking brake
connect pins [3] and [5] of the connector lever in free position.
on the wiring harness side. 6) Operate switch assembly [1] and move
a When the connector (PL2) is discon- the machine to a safe place.
nected, a model selection error is trig- a The electrical circuit of the gear
gered and the neutral safety relay will speed switches is configured so that
not be actuated. Above procedure is the switch on the lower gear speed is
implemented to avoid this condition. operated first.
k If the engine is started by this k Take care that the L.H. and R.H.
method, the neutral safety function steering directions are opposite
does not work. Accordingly, before when reverse.
starting the engine, set the parking
brake lever in lock position and set
the PCCS lever in full neutral posi-
tion.
k Start the engine by this method
only in an emergency. If the engine
does not start in other cases, be
sure to carry out troubleshooting
and repair the trouble.
14 D61EX, PX-15E0
2. Emergency escape method with brake 3) Remove inspection plug for measuring
releasing device (Use L3) brake pressure which is located within the
a If the engine cannot be started and the inspection cover on the right outer side of
parking brake cannot be released, carry the operator cab.
out the emergency escape according to 4) Install nipple L4 and connect hose [2] of
the following procedure. pump assembly L3.
a Operate after putting a block, etc. on the
crawler as a lock so that machine cannot
move on a downhill slope.
1) Assemble pump assembly L3.
5) Turn the starting switch on and set the

parking brake lever in free position.
6) Operate the vacuum pump to raise the
brake releasing oil pressure to the initial
pressure.
q Initial pressure: Approx. 2.74 MPa
{Approx. 28 kg/cm2}
a Since an accumulator is installed in
the circuit, the handle must be oper-
ated 30 – 50 times to raise the oil
pressure.
a If the oil pressure does not rise above
a certain level, the relief valve may be
set to low pressure. In this case,
adjust the set pressure of the relief
valve.
7) Tow the machine to a safe place.
a The brake releasing oil pressure low-
2) Install volume pump [1] of pump assembly ers gradually because of internal
L3 to the outside of the operator cab. leakage and the brake is applied
again about 1 minute after. Therefore,
work immediately.
a If the brake releasing pressure lowers
to about 1.57 MPa {16 kg/cm 2}, the
brake is applied. In this case, operate
the volume pump again to raise the
brake releasing pressure to the initial
pressure.
8) When disconnecting the hose after finish-
ing the work, loosen the screw slowly and
do not stand in the spouting direction of
the oil.
D61EX, PX-15E0 15
Adjusting idler clearance 1 Inspecting wear of sprocket 1

a If the lateral guide plates of the idler are so a Use “Full-scale drawing of sprocket teeth pro-
worn that the idler runs out or slants, adjust the file” as the g auge to measur e the wor n
idler clearance according to the following pro- sprocket. See “Sprocket” in Structure, function
cedure. and maintenance standard.
a Make a copy of the “Full-scale drawing of
Adjustment procedure sprocket teeth profile” on a transparent paper
1) Drive the machine 1 – 2 m on the flat or other sheet and apply it directly to the
ground, then measure clearance (a) sprocket to see if the sprocket is appropriate for
between the track frame and guide plate use.
(at 4 places on both sides, inside, and out-
side).
2) If clearance (a) is larger than 4 mm, adjust
the clearance by loosening bolt (1) and
reducing shim (2).
q Standard clearance (a) on each side:
0.5 – 1.0 mm
q Shim thickness: 1.0 mm
16 D61EX, PX-15E0
Testing and adjusting track shoe Adjusting

tension 1 a If the track shoe tension is abnormal, adjust it
according to the following procedure.
Testing
1. Drive the machine slowly on a level place, then 1. Remove cover (1).
stop it.
a Do not apply the brake when stopping. 2. When tension is too high:
Loosen plug (2) to discharge the grease.
k Since the valve may jump out because
2. Place a straight steel bar between the idler and
front carrier roller, and measure maximum of the high-pressure grease, do not
clearance (a) between the bottom of the steel loosen it more than 1 turn.
3 Plug: 59 – 88 Nm {6 – 9 kgm}
bar and the shoe grouser.
q Standard maximum clearance (a): 20 – 30
mm 3. When tension is low:
Add grease through grease fitting (3).
a If the track shoe is not tensed well, drive
the machine forward and backward slowly.
D61EX, PX-15E0 17
Testing and adjusting work 1. Measuring unload pressure

equipment and HSS oil pressure 1 1) Remove the plug on oil pressure measur-
ing section (2), and connect nipple M2 and
a Instruments for testing and adjusting work oil pressure gauge [1] of hydraulic tester
equipment and HSS oil pressure M1 to the plug hole.
kg/cm2}.
1
799-101-5220 Nipple (10 x 1.25 mm)
M 2
07002-11023 O-ring
790-261-1231 Elbow
3
07002-11023 O-ring
k Stop the machine on a level place, lower the

work equipment to the ground, and set the
parking brake lever and work equipment
lock lever in the LOCK position.
a Measure the work equipment and HSS oil pres-
sure under the following conditions.
ing range
a The work equipment oil pressure measuring
section (centralized pressure detection port) is
2) Start the engine and keep it at high idle,

set the work equipment lever and the
PCCS lever in neutral, then measure the
oil pressure.

removed parts.
18 D61EX, PX-15E0
2. Measuring work equipment and HSS oil 2) Remove load sensing pressure measuring
pressure (steering oil pressure) plug (3) from the main control valve
1) Remove the plug on oil pressure measur- assembly. (Apply only to measure HSS oil
ing section (2), and connect nipple M2 and pressure.)
oil pressure gauge [1] of hydraulic tester 3) Connect elbow M3, nipple [2] of hydraulic
M1 to the plug hole. tester M1 and oil pressure gauge [1] to the
plug hole.
a Use an oil pressure gauge of 60 MPa
{600 kg/cm2}.
D61EX, PX-15E0 19
Work equipment oil pressure HSS oil pressure (steering oil pressure)
4) Start the engine and set the work equip- 7) Start the engine, set the parking lever in
ment lock lever in the Free position. the Free position, and press the brake
5) Run the engine at high idle, operate the pedal.
blade lever and ripper lever to relieve k Because steering circuit is relieved,
each cylinder at the stroke end, then mea- hold the brake pedal pressed securely
sure the oil pressure. and keep your right foot on the deceler-
a Block the return hose of the blade lift cylin- ation pedal for safety until the work is
der. finished.
8) Run the engine at high idle, set PCCS
lever in N (neutral), steer to the right or left
to relieve steering, then measure the oil
pressure.

removed parts.

removed parts.
20 D61EX, PX-15E0
3. Adjusting 2) Work equipment oil pressure

1) LS pressure (Load Sensing pressure) of a Don't adjust the work equipment oil
HSS pressure.
Loosen locknut (5) of HSS LS relief valve
(4) and turn adjustment screw (6) to adjust
the LS pressure.
a Turning the adjustment screw
q clockwise raises the oil pressure;
q turning it counterclockwise lowers
the oil pressure.
a Value adjusted by 1 turn of the adjust-
ment screw: 15.1 MPa {154 kg/cm2}.
3 Locknut:
68.6 – 78.5 Nm {7 – 8 kgm}
q After adjusting, check again the relief
pressure and LS pressure of the work
equipment.
D61EX, PX-15E0 21
Testing control circuit main 1. Remove the plug on oil pressure measuring
pressure 1 section (2) and connect nipple N2 and oil pres-
sure gauge [1] of hydraulic tester N1 to the
a Instruments for testing and adjusting control cir- plug hole.
cuit main pressure a Use an oil pressure gauge of 6 MPa {60
kg/cm2}.
1
N
799-101-5220 Nipple (10 x 1.25 mm)
2
07002-11023 O-ring
a The control circuit main pressure is the pres-

sure lowered by the self-pressure reducing
valve. It is shared by blade PPC, fan pump con-
trol, steering EPC and ripper PPC (if equipped).
Measuring
k Stop the machine on a level place, lower the
work equipment to the ground, and set the
parking brake lever and lock lever in the
LOCK position.
a Measure the reduced control circuit pressure
under the following conditions.
ing range
a The control circuit main pressure measuring
section (centralized pressure detection port) is
2. Start and keep the engine at high idle, set the

blade lever and ripper lever in neutral, then
measure the oil pressure.

suring instruments and return the removed
parts.
Adjusting
a The self-pressure reducing valve is not
adjustable.
22 D61EX, PX-15E0
Measuring PPC valve output 3. Install oil pressure pickup adapter O2 to the
pressure 1 valve, and connect the disconnected hose
again.
a Measuring instruments for PPC valve output
pressure 4. Install nipple [1] of hydraulic tester O1 and con-
nect oil pressure gauge [2].
1
O Oil pressure pickup adapter
799-401-3100
2 (Size 02)
02896-11008 O-ring
k Stop the machine on a level place, place the

work equipment on the ground, and set the
parking lever and work equipment lock
lever in the Lock position.
a Before measuring the PPC valve output pres-
sure, check that the control circuit main pres-
sure is normal. 5. Start the engine and set the work equipment
a Measure the PPC valve output pressure under lock lever in the Free position.
the following conditions.
q Hydraulic oil temperature: Within operat- 6. Run the engine at high idle, operate the control
ing range lever of the circuit to be measured, and mea-
sure the oil pressure.
1. Open the side cover of main control valve on a Measure the oil pressure with the lever at
the right side of the operator's cab. a stroke end.
a When the blade is lowering, operate the
2. Disconnect PPC valve output pressure hose lever up to the Float position.
(1).
a To select the circuit to be measured, see
the drawing on the next page.

parts.
D61EX, PX-15E0 23
a Straight-tiltdozer
1. Main valve A. Blade LOWER

2. Self-pressure reducing valve B. Blade RIGHT TILT
3. PPC lock solenoid valve C. Ripper RAISE
4. Accumulator (if equipped) D. Ripper LOWER
5. Blade PPC valve E. Blade LEFT TILT
6. Ripper PPC valve (if equipped) F. Blade RAISE
24 D61EX, PX-15E0
a Power angle-tiltdozer and power tiltdozer
1. Main valve A. Blade LOWER

2. Self-pressure reducing valve B. Blade LEFT TILT
3. PPC lock solenoid valve C. Left ANGLE
4. Accumulator (if equipped) D. Ripper RAISE
5. Blade PPC valve E. Ripper LOWER
6. Ripper PPC valve (if equipped) F. Right ANGLE
G. Blade RIGHT TILT
H. Blade RAISE
D61EX, PX-15E0 25
Adjusting play of work equipment

PPC valve 1
a The ripper valve is not adjustable.
a If the play of the blade lever end is excessive,
adjust it on the PPC valve side according to the
q Standard play (a):

0.5 – 3.0 mm at 200 mm from revolution center
of lever (in both longitudinal and lateral direc-
tions)
1. Remove boots (1).
2. Loosen locknut (2), and turn disc (3) to adjust

the play.
a Do not move the piston at this time.
3. Fix the position of disc (3) and tighten locknut

(2).
3 Locknut: 98 – 127 Nm {10 – 13 kgm}
4. Install boots (1).
For straight-tiltdozer For power angle-tiltdozer and power tiltdozer
26 D61EX, PX-15E0
Measuring internal leakage of 3. With the engine run at high idle, apply the relief
work equipment cylinder 1 pressure to the cylinder bottom side.
q Blade lift cylinder: Lower operation
a Measuring instruments for internal leakage of q Blade tilt cylinder: Left tilt operation
work equipment cylinder q Blade angle cylinder: Right or left angle
operation
(Apply the relief pressure to the bottom
side of the cylinder from which the hose
P Purchased Measuring cylinder
has been disconnected.)
q Ripper lift cylinder: Lower operation
a Measure the internal leakage in work equip-
4. Measure leakage in one minute after 30 sec-
ment cylinder under the following conditions.
onds elapsed.
q Hydraulic oil temperature: 45 – 55°C
a Since the blade lift cylinder is equipped with a
5. After finishing measurement, return the
piston valve, its internal leakage cannot be
removed parts.
measured.
1. Extend the cylinder to be measured to the

stroke end and set the machine in the measur-
ing position.
1) Blade lift cylinder
Put the front part of the track shoe on a
block, and extend the cylinder rod fully.
2) Blade tilt cylinder
Lower the blade tip to the ground.
3) Blade angle cylinder
Extend the angle cylinder rod fully and
lower the blade to the ground.
4) Ripper lift cylinder (if equipped)
Pull out the shank pin and lower the ripper
to the end.
2. Disconnect hose on the cylinder head side and

block the hose side with a plug.
a Remove the hose cover of the blade tilt
cylinder.
k Take care not to disconnect the hose
on the bottom side.
D61EX, PX-15E0 27
Adjusting work equipment lock

lever of work equipment 1
1. With lock lever (1) of the work equipment set in 2. With lock lever (1) of the work equipment set in
Lock position, make the following adjustment: Free position, make the following adjustment:
1) Adjust length (a) of limit switch (2). 1) Adjust length (d) of the limit switch so that
q Dimension (a) : 29.1 mm its stroke becomes (c).
2) Adjust height (b) of stopper (3). q Dimension (c) : 5 mm
q Dimension (b) : 27.5 mm q Dimension (d) : 24.1 mm
2) Check that the distance from the floor sur-
face to the tip of lever (1) is (e).
q Dimension (e) : 427.6 mm
28 D61EX, PX-15E0
Releasing residual pressure in Releasing residual pressure in

work equipment cylinder work equipment cylinder
(If PPC accumulator is not (If PPC accumulator is installed) 1
installed) 1
a When disconnecting the piping between the
a When disconnecting the piping between the control valve and work equipment cylinder,
control valve and work equipment cylinder, release first the residual pressure in the circuit
release first the residual pressure in the circuit according to the following procedure.
1. Loosen the hydraulic tank cap gradually to
1. Run the engine at low idle and lower the blade release the residual pressure in the tank.
and ripper to the ground without relieving any
hydraulic cylinder. 2. Turn the starting switch ON, set the work
a Lower the blade slowly to the ground. Just equipment lock lever in the Free position, and
after the blade reaches the ground, set the operate the blade lever and ripper lever both in
blade lever in the Float position. the longitudinal and lateral directions.
a Lower the ripper slowly to the ground. a 2 or 3 times of operation will release the
residual pressure in the accumulator.
2. Leave the machine as it is for five or ten min-
utes after the engine stopped. 3. Start the engine, and run it at low idle for about
5 seconds, then stop it.
3. Loosen the hydraulic tank cap gradually to
release the residual pressure in the tank. 4. Repeat steps 2 – 3 mentioned above 2 or 3
times.
4. Apply cloths to the joint of the cylinder piping,
and loosen the sleeve nut gradually to release
the residual pressure while shaking the hose
slowly.
a Check that the residual pressure has been
released and oil does not spout out any
more, then disconnect the piping com-
pletely.
D61EX, PX-15E0 29
Bleeding air from work equipment

cylinder 1
a If the work equipment cylinder is removed and
installed or its piping is disconnected and con-
nected, bleed air from its circuit according to
the following procedure.
1. Start the engine, and run it at low idle for about

5 minutes.
2. With the engine run at low idle, extend and

retract the cylinder to be bled 4 or 5 times.
a Move the piston rod within a range of
about 100 mm before the stroke end, and
take care never to cause relief.
3. Do the operation in step 2 with the engine run

at high idle.
4. With the engine run at low idle, move the cylin-

der to the stroke end to cause relief.
30 D61EX, PX-15E0
Measuring fan motor speed 1 5. Close radiator mask (1).

k To avoid possible hazard caused by
a Measuring instruments for fan motor speed turning fan, be sure to close the radia-
tor mask.
Q 799-205-1100 Tachometer kit 6. Start the engine and set the monitor panel in
the adjustment mode.
a For the method of operating the adjust-
1. Open radiator mask (1). ment mode, see “Special functions of
monitor panel (EMMS)”.
2. Remove fan guard (small one) (2). a Adjustment code:
1005 (100% fan speed mode)
7. With the engine run at high idle and low idle,

measure the fan motor speed.
3. Stick one strip of reflecting tape [1] to fan (3).
4. Set probe [2] of tachometer kit Q on stand [3],

matching it to reflecting tape [1], then connect
it to tachometer [4]. 8. After finishing measurement, remove the mea-
k Take care that the probe will not inter-
fere with the fan. parts.
D61EX, PX-15E0 31
Measuring fan pump circuit pres- 4. Install nipple R2 to oil pressure gauge [1] of
sure 1 hydraulic tester R1, connect it to the plug hole.
a Measuring instruments for fun pump circuit kg/cm2}.
pressure

1
R
799-101-5220 Nipple (10 x 1.25 mm)
2
07002-11023 O-ring
1. Open radiator mask (1).
2. Remove fan guard (2).
5. Close radiator mask (1).

k To avoid possible hazard caused by
turning fan, be sure to close the radia-
tor mask.
6. Start the engine and set the monitor panel in

the adjustment mode.
a For the method of operating the adjust-
ment mode, see “Special functions of
monitor panel (EMMS)”.
a Adjustment code:
1005 (100% fan speed mode)
3. Remove plug (3). 7. Measure the fan circuit oil pressure with the
engine running at high idle.

parts.
32 D61EX, PX-15E0
Measuring HSS motor oil leakage1 Bleeding air from fan pump 1
a Hydraulic oil temperature: 45 – 55°C a If the fan pump was removed and installed or
a Lower the work equipment up to the ground its piping was disconnected and connected,
and stop the engine. bleed air from the pump case according to the
k Loosen the hydraulic tank cap gradually to following procedure.
release the pressure in the tank. a Before performing the following procedure,
check that the hydraulic oil is at the specified
1. Disconnect drain hose (1) and install a blind level.
plug to the tank side.
1. Remove cover (1) on the right of the floor bot-
2. Set the gear shift lever in neutral, and press tom.
the brake pedal.
3. With the steering and forward-reverse levers

set to the left or right end, cause the HSS
motor relieve for 1 minute, and measure leak-
age with a measuring cylinder, etc.
a Repeat measurement several times for
each case the levers are set to the right or
left.
2. Loosen air bleeder (2) and leave it for 15 min-

utes.
3. After 15 minutes elapsed, start the engine, and

keep it at low idle.
4. If oil flows out of air bleeder, tighten air bleeder

(2).
D61EX, PX-15E0 33
Testing and adjusting operator's

cab 1
a Enter the testing and adjusting items after
installation of the operator's cab assembly.
1. Measure the internal pressure of the cab.

q Criterion: Measured value X 58.9 Pa {6
mmH2O}
q Engine speed: High idle
q Fan motor speed: Fan 100% speed mode
a For the change to the fan 100%
speed mode, see “Special functions
of monitor panel (EMMS), “8. Adjust-
ment mode”.
q Air conditioner fan switch: High
q EXTERNAL/INTERNAL air changeover
switch: EXTERNAL position
a If the measured value is lower than the
standard value, check the seals of the
holes for wiring harnesses and optional
parts in the cab.
1) A simple method of measuring the internal
pressure is as follows.
1] Prepare a transparent vinyl hose.
q Inside diameter: 6 mm
Length: 3,000 mm
2] Secure the inside end of the hose to
the top of the back seat with a tape.
3] Remove bolt (1) under the left con-
sole box. Pass the other end of the
hose through the bolt hole and take it
out of inspection cover (2) on the left
side of the cab.
4] Seal the hole of bolt (1) with tape (3).
5] Pour water in the hose up to about
half.
6] Set the water level in the vinyl hose
out of the cab to that in the cab.
7] Run the engine at high idle with the
fan at the 100% speed and measure
water level difference (c). (Value (c):
Pa {mmH2O})
a [a] side: Inside of cab
(Pressurized)
[b] side: Out of cab
(Atmospheric pressure)
34 D61EX, PX-15E0
2. Check of searing performance 3. Testing door lock

1) Close the all openings of the cab. Close the door and check the relationship
2) Splash water around the hatched part of between the operator's cab and door. If there is
the cab at the rate of about 19 l/min for 10 any fault, repair it.
minutes. 1) Check of current condition
q At this time, it is not necessary to a Check both sides, 2 places on each
splash pressurized water. side.
3) Splash water horizontally from a hose over q Stick adhesive tape [1] to the contact
sealing surface (4). face of damper rubber (1) and open
4) Check around the dashboard carefully. and close the door 2 – 3 times. Then,
a If water leaks, caulk the leaking part check the contact face of adhesive
and check again. tape [1] against the operator's cab.
Normal: When the door is closed,
the damper rubber
comes in contact lightly.
Abnormal: When the door is closed,
the damper rubber does
not come in contact or
comes in contact so
strongly that the adhesive
tape is removed.
2) Adjusting (Adjusting installed height of

damper rubber)
q Increase or decrease of shims (3)
under damper rubber (1) to adjust the
height of the damper rubber properly.
D61EX, PX-15E0 35
4. Testing door lock (Door link)

Close the door and check the relationship
between the operator's cab and door. If there is
the following fault, repair it.
q When the door open lever (on the inside of
the door) or the door knob (on the outside
of the door) is operated, the door does not
open or it is heavy to open.
q When the door is closed, the door bounds
and does not close.
1) Remove plate (4) from the door link.
2) Check that door link bolts and nuts (5), (6),

(7), (8), (9), and (10) are tightened.
a If they are loosened, tighten them to
the following tightening torque.
3 Tightening torque of M8 nut (Width
across flats: 13 mm) (5), (19):
27 – 34 Nm {2.8 – 3.5 kgm}
3 Tightening torque of M6 hexagon
socket head bolt (Width across flats
of socket: 4 mm) (6): 9.8 Nm {1.0
kgm}
3 Tightening torque of M28 nut
(Width across flats: 36 mm) (7):
11.8 – 14.7 Nm {1.2 – 1.5 kgm}
2 Threads: Adhesive (LT-2)
3 Tightening torque of M6 bolt (Width
across flats: 10 mm) (8):
11.8 – 14.7 Nm {1.2 – 1.5 kgm}
3 Tightening torque of M8 hexagon
socket head bolt (Width across flats
of socket: 5 mm) (9):
25.5 Nm {2.6 kgm}
3 Tightening torque of M6 bolt (Width
across flats: 10 mm) (10):
11.8 – 14.7 Nm {1.2 – 1.5 kgm}
36 D61EX, PX-15E0
3) Check the engagement of the latch and

striker.
q Move the door in the closing direction
and check that latch (12) in lock
assembly (11) on the door side is
aligned with striker (13) on the cab
side.
a If the latch and striker are not aligned,
adjust them according to the following
procedure.
1] Loosen the mounting bolts of striker
(13) and tighten them again lightly.
Then, open and close the door 2 – 3
times to align latch (12) with striker
(13).
2] After tightening the mounting bolts 5) Check stroke (b) of door open lever (15)
permanently, check that latch (12) is and adjust rod end (16) and plate (17) so
aligned with striker (13). that the lock assembly will open when the
4) Check of clearance in lock assembly open lever stroke is at the specified value.
lever q Lever stroke (b): 7 ± 2 mm
Check clearance (a) in lock assembly
open lever (14) and adjust it to the stan- a Procedure for adjusting rod end
dard range. 1] Loosen locknut (5).
q Clearance (a): 0.5 ± 0.2 mm 2] Turn nut (19) to adjust.
a If clearance (a) is above the standard q If the nut is turned to move up rod end
range: The door is heavy to open. (16), lever stroke (b) and clearance
a If clearance (a) is below the standard (a) in the lock assembly open lever
range: The door is heavy to close. are increased. (The door will become
heavy to open.)
q If the nut is turned to move down rod
end (16), lever stroke (b) and clear-
ance (a) in the lock assembly open
lever are reduced. (The door will
become light to open.)
3] Tighten locknut (5).
3 Tightening torque of locknut (5),
(19) (M8, Width across flats: 13
mm): 27 – 34 Nm {2.8 – 3.5 kgm}
D61EX, PX-15E0 37
a Procedure for adjusting plate 7) Operate the door open lever (on the inside
1] Loosen bolt (6). of the door) and door knob (on the outside
2] Move and adjust plate (17). of the door) and check that the door is
q If plate (17) is moved up, lever stroke opens and closes smoothly.
(b) and clearance (a) in the lock If the door does not open or close
assembly open lever are reduced. smoothly (If the door open lever is heavy),
(The door will become light to open.) perform the adjustment procedure again
q If plate (17) is moved down, lever from 1).
stroke (b) and clearance (a) in the q Operating effort of door open lever:
lock assembly open lever are 49 ± 19.6 N {5 ± 2 kg}
increased. (The door will become
heavy to open.) 5. Check of open lock
3] Tighten bolt (6). Check the relationship between the operator's
3 Tightening torque of bolt (6) (M6, cab and door while the door is locked open. If
Width across flats of socket: 4 mm): there is any fault, adjust the open lock.
9.8 Nm {1.0 kgm} 1) Check of current condition
1] Check the relationship between open
lock latch (3) and striker (4) in direc-
tion (B).
a Move the door in the opening
direction and check the engage-
ment of the latch and striker.
6) Apply grease (GII-LI) to latch (12).

a If latch (12) is not greased, the door
open lever and door knob become
heavy.
38 D61EX, PX-15E0
2] Check the installed height of the stop- 2] Adjusting installed height of stopper
per rubber. (Check both sides, 2 rubber
pieces on each side.) a. Loosen locknuts (10) and (11) of
a. Lock the door open and move it stopper rubber (8) (upper one)
in the forward and reverse direc- and (9) (lower one).
tions to check that it does not
have play.
b. Check that the operating effort of
the unlock lever is not heavy.
c. Check that striker (4) is not slant
from center (d) of the latch.
d. Check that latch and center (e) of
the striker are matched to each
other.
q Normal: Deviation of (e) is 0.5
mm or less.
2) Adjusting
1] Adjusting latch and striker
q Loosen the mounting bolts (7) of
striker (4) and adjust the striker b. If there is play, project (heighten)
so that it will not slant, and then the stopper rubber until the play
tighten bolts (7). is eliminated.
a If the door is not locked easily or
the unlock lever is heavy, return
(lower) the stopper rubber in the
range that the door does not
have play.
c. Tighten the locknuts.
D61EX, PX-15E0 39
SEN02556-00

© 2007 KOMATSU
All Rights Reserved
40
SEN02557-00
D61EX-15E0
D61PX-15E0


Special functions of monitor panel (EMMS) .................................................................................................... 2
D61EX, PX-15E0 1
Special functions of monitor panel (EMMS) 1
Display section of special functions Operation section 2 of special functions

1. Upper display section (Gear speed display section) (Changeover operation)
2. Lower display section (Multi-information section) 4. Buzzer cancel switch
5. Information switch
Operation section 1 of special functions 6. Shift-up switch
(Basic operation) 7. Shift-down switch
3. Service switch
a EMMS: Equipment Management Monitoring System
2 D61EX, PX-15E0
Normal function and special functions of monitor panel (EMMS)
The monitor panel (EMMS) has the normal function and special functions and displays information of various
types at the gear speed display section at its center and the multi-information section.
Some items are displayed automatically according to the internal setting of the monitor panel and the others
are displayed according to the operation of the switches.
1) Normal function: Operator mode
With this function, the operator can display and change the items displayed ordinarily.
2) Special function: Service mode
With this function, a serviceman can display and change the displayed items with special switches for
testing, adjusting, and troubleshooting.
D61EX, PX-15E0 3
Operation and display of operator mode information section (2). Reset after completion
(Outline) of the replacement is done in this mode.
a Gear speed display section (1) remains
a In this section, only the outline of operator the normal display.
mode is explained.
See Operation and Maintenance Manual for
details of each function and mode as well as
the operating method.
Normal display (Default)

The following information is normally displayed on
the monitor panel.
Gear speed display section (1):
q Front side: Travel direction (P, N, F, R)
q Rear side: Gear speed (1, 2, 3)
q Graphics: Engine speed
Multi-information section (2):
q Information is displayed in 2 lines of 16 charac-
ters each.
q Left side: Gear shift mode (F1-R1, F1-R2,
F2-R1, F2-R2, F2-R3) (Displayed
when preset mode is set.)
q Right side: Service meter (Unit: 0.1h)
q Each time the information switch is set to the
right or left, the service meter and the engine
speed are displayed alternately.
Replacement interval
1st time 2nd time
Code Display Maintenance item (Can not and after
be (Can be
changed) changed)
01 ENG OIL Engine oil 500 500
02 ENG FILT Engine oil filter 500 500
FUEL
03 Fuel main filter 1000 1000
FILT
04 HYD FILT Hydraulic oil filter 2000 2000
CORR
06 Corrosion resistor 1000 1000
RES
DAMP
07 Damper oil 2000 2000
OIL
08 FNL OIL Final drive oil 1000 1000
10 HYD OIL Hydraulic oil 2000 2000
12 HSS FILT a HSS charge filter — —
POWL
19 Power train oil 1000 1000
OIL
POWL
20 Power train oil filter 500 500
FILT
F.PRE-
41 Fuel pre-filter 500 500
1. Maintenance mode FLT
(1-OIL, FILTER MAINTENANCE MODE)
In this mode, the time up to the next replace- a The items marked with a are displayed
ment of oils and filters is displayed on multi- but not used for this machine.
4 D61EX, PX-15E0
2. Pm clinic auxiliary mode 3. Failure code display mode

(2-PM CLINIC MODE) (3-FAULT CODE DISPLAY MODE)
In this mode, the condition of the machine is In this mode, the contents of each problem in
displayed on multi-information section (2) as the machine are displayed by a 6-character
an auxiliary function of the periodic diagnoses failure code on multi-information section (2).
such as the Pm clinic, even if any measuring When a user or a operator needs to be notified
instrument is not connected. of the failure code of each problem, this mode
a Gear speed display section (1) remains is applied.
the normal display. a Gear speed display section (1) remains
normal.
No. Pm clinic auxiliary item

01 Engine speed a When a serviceman needs to check the
02 Coolant temperature failure codes for troubleshooting, “Electric
Boost pressure: indicated by absolute value system failure code display mode” and
05 “Mechanical system failure code display
(including ambient pressure)
mode” is recommended to use for more
06 Boost temperature
detailed information.
07 Power train oil temperature a Method of checking failure code:
08 Work equipment oil temperature Turn buzzer cancel switch (4) to the [U]
13 Battery voltage position on the screen shown on the
above, and all failure codes detected cur-
rently are displayed at the interval of about
2 seconds. (To finish displaying, turn the
buzzer cancel switch to the [t] position.)
D61EX, PX-15E0 5
4. Adjustment mode (4-USER ADJUST MODE) 3) Contrast of display

In this mode, the display condition of the moni- This mode is to adjust thickness of the liq-
tor panel can be adjusted on multi-information uid crystal at the multi-information section.
section (2). (See Operation and Maintenance Man-
a Gear speed display section (1) remains ual.)
the normal display.
4) Fan 100% mode
This function is to control rotation speed of
the cooling fan forcedly at approximately
100% of the maximum speed.
1] This mode is selected by operating
the information switch.
2] The mode is selected by turning the
buzzer cancel switch to the [U] posi-
tion.
3] The function is effective under this
condition and the rotation speed of
the cooling fan is controlled to
approximately 100% of the maximum
speed.
a Exiting this mode disables the
function.
No. Adjustment item

01 Brightness of LCD
02 Brightness of display
03 Contrast of display
04 Fan 100% mode
05 No injection cranking mode
1) Brightness of LCD
This mode is to adjust brightness of the
backup lamp at the liquid crystal gauge
section. (See Operation and Maintenance
Manual.)
2) Brightness of display
This mode is to adjust brightness of the
backup lamp at the multi-information sec-
tion. (See Operation and Maintenance
Manual.)
6 D61EX, PX-15E0
5) No injection cranking mode a At this time, “NOT AVAILABLE” is dis-

This mode is to circulate the engine oil played on the lower line to indicate
easily while applying no injection condi- that the mode is ineffective.
tions to all engine cylinders before staring
engine after an extended machine stor-
age.
1] This mode is selected by operating
the information switch.
2] The mode is selected by turning the
buzzer cancel switch to the [U] position.
a Exiting from this mode disables this

function.
3] In above 3 seconds, “WAIT” displayed

on the lower line changes to “ACTIVE”
and the mode becomes effective.
4] In this condition, turn the starting

switch to START position to apply no
injection cranking.
5] The mode is released by moving the
starting switch to ON position and
turning the buzzer cancel switch to
the [t] position.
a Do not continue no injection cracking
for more than 20 seconds in order to
protect the starting motor.
k For safety, this mode cannot be
operated while the engine is run-
ning.
D61EX, PX-15E0 7
Action code display function

If a trouble which is to be notified to a operator
occurs during work, an action code and a phone
number are displayed on multi-information section
(2).
a Gear speed display section (1) remains the
normal display.
a The phone number is displayed only for impor-
tant action codes. The display shown below is
an example. (The form of the displayed phone
number depends on the form of the input num-
ber.)
a If an important action code is displayed, the
caution lamp flashes and the alarm buzzer
sounds.
<Reference>
An action code is displayed only when a serious
abnormality occurs.
Even if an action code is not displayed, abnormality
may have occurred. Therefore, if you find any inci-
dent, be sure to check for a failure code in “Electric
system failure code display mode” and “Mechanical
system failure code display mode”.
8 D61EX, PX-15E0
Action code table

Action Remedy requested for
Display method of trouble Examples of abnormality
code an operator
• Only action code is displayed. • Backup alarm does not sound. • Automatic function stops or nor-
• Fan speed is always at maxi- mal function stops partially, but
E01 mum. machine can work.
• Contact your Komatsu distribu-
tor for repair.
• Action code is displayed. • Gear is not shifted up or down. • Stop engine and start it again,
• Warning lamp flashes • Exhaust gas color is bad when and you can operate machine
• Alarm buzzer sounds. temperature is low. without limiting function. You
E02
• Defective coolant temperature must take care, however.
sensor • Contact your Komatsu distribu-
tor for repair.
• The action code is displayed. • Engine boost pressure is abnor- • Move machine to safe place.
• Warning lamp flashes mal. • Contact your Komatsu distribu-
• Alarm buzzer sounds. • Usable gear speeds are limited. tor for repair.
CALL E03
• Engine speed does not rise fully.
• Gear shift shocks become large.
• Steering performance lowers.
• The action code is displayed. • Engine cannot be controlled. • Stop machine immediately.
CALL E04 • Warning lamp flashes • Machine cannot travel. • Contact your Komatsu distribu-
• Alarm buzzer sounds. • Machine stops. tor for repair.
D61EX, PX-15E0 9
Operation and display in service mode

Method of changing to service mode Gear speed
No. Adjustment item
a When using the service mode, change the display section
screen by the following special operation. Maintenance interval change
5 1C
mode
1) Special operation of switches Electric system failure code
Set the monitor panel in the service mode by 6 EE
display mode
operating service switch (3) and buzzer cancel
Mechanical system failure
switch (4). 7 bE
code display mode
a Keeping the service switch in ON position,
hold the buzzer cancel switch in the [U] 8 Cb Adjustment mode
position for more than 2.5 seconds. 9 Ld Load saving display mode
a If the monitor panel is set in the service 10 5R Real-time monitoring mode
mode, [1C] is displayed on gear speed
11 dR Dual display monitoring mode
display section (1).
a Each time the monitor panel is set in the 2) Selecting and executing mode to be used
service mode, “Maintenance interval Select the mode to be used with information
change mode” is displayed first. switch (5) and execute it with buzzer cancel
switch (4).
q [>]: Next mode No.
q [<]: Previous mode No.
q [U]: Execute mode.
a For details of operation in each mode, see
the following pages.
3) Finishing mode and function

The current mode and function can be finished
by either of the following method, regardless of
the current mode and hierarchy.
1] When continuing the operation in another
mode or function or in the operator mode:
Return to the mode screen or function
screen to be used next by operating
buzzer cancel switch (4).
q [t]: Screen returns.
2] When finishing all operations:
Turn off the starting switch.
10 D61EX, PX-15E0
5. Maintenance interval change mode 2) Selecting and displaying maintenance

(5-EXCHG. INTVAL. SET MODE) item
In this mode, you can check and set the main- 1] Operate information switch (5) on the
tenance interval times of various filters and oils maintenance item selection screen to
which are the bases of the maintenance dis- select a maintenance item.
play function in the operator mode. q [>]: Next code
q [<]: Previous code
1) Selecting and implementing a mode 2] Display the maintenance item selec-
1] Select “Maintenance interval change tion screen by operating buzzer can-
mode” on the mode selection screen. cel switch (4).
a If the mode is selected, code q [U]: Execute item.
(1C) is displayed on gear speed
display section (1) and the title is
displayed on multi-information
section (2).
2] Display the maintenance item selec-
tion screen by operating buzzer can-
cel switch (4).
q [U]: Execute mode
3) Contents of information screen

The following items are displayed on the
information section.
1: Code
2: Maintenance item
3: Replacement interval (Set time)
a Below figure shows an example.
a If the replacement interval does not
need to be changed, finish the opera-
tion on this screen.
a If the replacement interval needs to
be changed, go to step 4).
D61EX, PX-15E0 11
4) Updating replacement interval 2] If the input time is correct, enter the

1] Change the set time by operating change of setting by operating buzzer
information switch (5), shift-up switch cancel switch (4).
(6) and shift-down switch (7). q [U]: Enter change.
q [>]: Move cursor to right. a If the change is finished normally,
q [<]: Move cursor to left. the information display screen
q [UP]: Number increases. appears after the screen shown
q [DOWN]: Number decreases. below.
a If the change is not finished nor-

a If you do not use the mainte- mally, the information display
nance function, set all times to 0. screen before the change
appears after the screen shown
below. In this case, execute the
above operation again.
12 D61EX, PX-15E0
Maintenance items table

Replacement interval (H)
Code Display Maintenance item 1st time 2nd time and after
(Can not be changed) (Can be changed)
01 ENG OIL Engine oil 500 500
02 ENG FILT Engine oil filter 500 500
03 FUEL FILT Fuel main filter 1000 1000
04 HYD FILT Hydraulic oil filter 2000 2000
06 CORR RES Corrosion resistor 1000 1000
07 DAMP OIL Damper oil 2000 2000
08 FNL OIL Final drive oil 1000 1000
10 HYD OIL Hydraulic oil 2000 2000
12 HSS FILT HSS charge filter — —
19 POWL OIL Power train oil 1000 1000
20 POWL FILT Power train oil filter 500 500
41 F.PRE-FLT Fuel pre-filter 500 500
a The first replacement interval is the same as the second and after replacement intervals, and the former
cannot be changed.
D61EX, PX-15E0 13
6. Electric system failure code display mode 2) Display in case where no codes are
(6-ELEC. FAULT CODE MODE) recorded
In this mode, you can check the electric sys- If the failure codes which occurred in the
tem failure codes among the information of the past, and the current active failure codes
troubles that occurred on the machine. do not exist, the below display will be
a See “Failure code table and fuse loca- shown.
tions” for failure code list.
1) Selecting and implementing a mode

1] Select “Electric system failure code
display mode” on the mode selection
screen.
2] If the mode is selected, code (EE) is
displayed on gear speed display sec-
tion (1) and the title is displayed on
multi-information section (2).
3] Display the failure code display
screen by operating buzzer cancel
switch (4).
q [U]: Execute mode
3) Display in case where 1 or more codes

are recorded
If any failure codes which happened in the
past or which are currently active exist,
the display will be as shown below.
1] : Record No. (Up to 20)
2] : Failure code
(Flash if currently active.)
3] : Number of occurrences up to now
4] : Elapsed time measured by service
meter after first occurrence
meter after last occurrence
a The below figure shows an example
of the display.
a Flashing and lighting of failure code

Flashing:Code of the failure which is
currently detected.
Lighting: Code of the failure which is
not currently detected.
14 D61EX, PX-15E0
a Conditions for detecting and keeping 7. Mechanical system failure code display
failure code mode
When a failure is detected, the failure (7-MACHINE FAULT CODE MODE)
c ode other th an c omm unic ati on In this mode, you can check the mechanical
related or engine-related keeps flash- system failure codes among the information of
ing until the starting switch is turned the troubles that occurred on the machine.
off. After turning the starting switch a See “Failure code table and fuse loca-
OFF temporarily, if the starting switch tions” for failure code list.
is turn on or the engine is started
again, the failure code keeps lighting 1) Selecting and implementing a mode
until the same trouble is detected. 1] Select “Mechanical system failure
Communication related or engine code display mode” on the mode
related failure code is switched to the selection screen.
lighting when the problem is solved, a If the mode is selected, code
even if the starting switch is not (bE) is displayed on gear speed
turned off. display section (1) and the title is
4) Operations in case that multiple codes are section (2).
recorded 2] Display the failure code display
When multiple codes are recorded, they screen by operating buzzer cancel
can be displayed one by one by operating switch (4).
information switch (5). q [U]: Execute mode.
q [>]: Go to next failure code
q [<]: Return to previous code
a The failure codes are displayed in the
order of their first occurrence times.
5) Method of deleting failure code

While displaying a failure code that is to
be deleted, operate shift up switch (6) or
shift down switch (7).
q [Up] or [Down]: Delete failure code.
a A failure code which is active cur-
rently (code is flashing) cannot be
deleted.
D61EX, PX-15E0 15
2) Display in case where no codes are a Flashing and lighting of failure code
recorded Flashing:Code of the failure which is
If the failure codes which occurred in the currently detected.
past, and the current active failure codes Lighting: Code of the failure which is
do not exist, the below display will be not currently detected.
shown. a Conditions for detecting and keeping
failure code
A failure code of the mechanical sys-
tem is switched to the lighting when
the problem is solved, even if the
starting switch is not turned off.
4) Operations in case that multiple codes are

recorded
When multiple codes are recorded, they
can be displayed one by one by operating
information switch (5).
q [>]: Go to next failure code
q [<]: Return to previous code
a All failure codes, including ones that
did not occurred in the past, are dis-
3) Display in case where 1 or more codes played in numerical order.
are recorded
If any failure codes which happened in the 5) Method of deleting failure code
past or which are currently active exist, The failure codes of the mechanical sys-
the display will be as shown below. tem cannot be deleted.
1] : Recorded codes (Max. 15 items)
2] : Failure code
(Flash if currently active.)
3] : Number of occurrences up to now
meter after first occurrence
meter after last occurrence
a The below figure shows an example
of the display.
16 D61EX, PX-15E0
8. Adjustment mode 2) Selecting adjustment items

(8-SERVICE ADJUST MODE) 1] On the adjustment code input screen,
In this mode, you can adjust the control system input the 4-digit code of the item to be
and various devices of the machine. adjusted by operating information
switch (5), shift up switch (6) and shift
1) Selecting and implementing a mode down switch (7).
1] Select “Adjustment mode” on the q [>]: Moves cursor rightward.
mode selection screen. q [<]: Moves cursor leftward.
2] If the mode is selected, code (Cb) is q [UP]: Increases number.
displayed on gear speed display sec- q [DOWN]: Decreases number.
tion (1) and the title is displayed on 2] After inputting the code, operate
multi-information section (2). buzzer cancel switch (4) to display
3] Display the adjustment code input the monitoring screen.
screen by operating buzzer cancel q [U]: Enters input mode.
switch (4).
q [U]: Executes mode.
a If an incorrect code is input, the

adjustment code input screen
appears again after showing the
below screen. In this case, execute
the above operation again.
D61EX, PX-15E0 17
3) Contents of display on adjustment screen 5) Changing adjustment item (Limited func-

1] : Code tion)
2] : Adjustment item Once the adjustment items are selected,
3] : Related information they can be selected with the information
a For the detailed information and switch without inputting the codes again.
adjustment procedure, see “Adjust- q [>]: Next code
ment mode table and adjustment pro- q [<]: Previous code
cedure”. a This function is limited to the numbers
marked with a in the “Adjustment
items table”.
a Note that this operation is not
accepted while the parking brake
lever is in the released position.
a An adjustment item also can be
selected by returning to the input
screen temporarily and inputting the
code for that item.
4) In case of operating the machine in adjust-

ment mode, if the parking brake lever is
set in the “free” position, gear speed dis-
play section (1) returns to the normal dis-
play and the machine can be operated
normally.
a At this time, even if the shift up or shift
down switch is pressed with the
PCCS lever in the neutral position,
the shift cannot be changed.
(The displayed number is the code of
adjustment mode selection.)
To change the shift, shift the PCCS
lever to the “forward” or “reverse”
position and press the shift up or shift
down switch while the machine is
traveling.
a To select another screen, return the
parking brake lever to the “lock” posi-
tion temporarily and perform the nec-
essary operation.
18 D61EX, PX-15E0
Adjustment mode table and adjustment procedure

Related Disassembly
No. Code Adjustment item
information and assembly
[1] 0001 INP TEL NO. Phone No. input mode Figure/Symbol
Steering and transmission controller specifica-
a[2] 0002 S/T S.CODE Code q
tion set
a[3] 0004 BODY TYPE Machine specification set Code q
a[4] 0005 BRAKE BASE Brake potentiometer zero point adjustment Voltage q
a[5] 0007 ENG.FULL CH Engine deceleration-cut mode Speed
Speed,
[6] 0008 INJ o 123456 Common rail reduced cylinder mode Fuel injection
rate
a[7] 0009 PITCH SENS. Pitch angle sensor initial set Voltage q
Adjustment
a[8] 0010 FAN 70% MODE Fan 70% speed mode
data
a[9] 0021 KMTRX INST KOMTRAX specification set Symbol q
Adjustment
a[10] 1005 FAN 100% MODE Fan 100% speed mode
data
[11] 1012 S/T N-SET Steering control lever neutral set Voltage
[12] 1013 S/T L-SET Steering control lever left set Voltage
[13] 1014 S/T R-SET Steering control lever right set Voltage
[14] 2222 HSS ADJUST HSS lever initial current set Current
[15] 9997 HI IDLE SET High idle limit mode Speed
[16] 9998 SFT INHIBIT Gear speed limit mode Symbol
a Check items marked with q in the Disassembly and assembly column of the above table must be
adjusted after the machine is assembled or any controller is replaced. (For the adjustment procedure,
see “Adjustment after replacement of controller“)
The numbers marked with a can be displayed in order by setting the information switch in the “>” or “<”
position.
D61EX, PX-15E0 19
[1] 0001: Phone No. input mode [2] 0002: Steering and transmission controller spec-
q This code inputs or changes a phone number ification set
to be displayed simultaneously with when the q This code is used to initialize the specification
user code is displayed. codes recognized by the steering and trans-
q The lower part displays a phone number and mission controller and the set values of the
symbols. memory in the controller.
q Available characters: 0 1 2 3 4 5 6 7 8 9 : ; < > ? q The specification code is displayed on the
q How to use: lower line.
1) By operating information switch (5), shift q Adjustment method:
up switch (6), and shift down switch (7),
input a phone number and symbols. 1) Set buzzer cancel switch (4) in the [U]
q [>]: Moves cursor rightward. position and check that the alarm buzzer
q [<]: Moves cursor leftward. sounds.
q [UP]: Advance the numeric character or 2) Check that the displayed specification
character (in the order of available charac- code has changed from [4*4] to [444].
ters). a If specification code [444] is not displayed,
q [DOWN]: Reverse the numeric character the controller wiring harness or the con-
or character. (in the order of available troller unit may be defective.
characters) a Even if this code is turned off, the setting
2) Set buzzer cancel switch (4) in the [U] is effective.
position and check that the alarm buzzer
sounds.
a Sixteen digits of numeric characters are
provided. To avoid confusion, input sym-
bols other than numeric characters at dig-
its you will not use.
a 0 (zero) is input at all places of the lower
part before shipment from our factory. (No
phone number is displayed under this con-
dition.)
a Even if this code is turned off, the setting
is effective.
20 D61EX, PX-15E0
[3] 0004: Machine specification set [4] 0005: Brake potentiometer zero point adjust-
q This code is used to have the machine specifi- ment
cation recognized by the controllers which q This code is used to adjust the zero point of the
compose the system. potentiometer of the brake pedal.
q The machine specification code is displayed q The deviation from the standard is displayed
on the lower line. by voltage on the lower line (Display range:
q Adjustment method: –2500 – 2500).
a Since this code is reset when “Steering q Adjustment method:
and transmission controller specification With the brake pedal released, set buzzer can-
set” is executed, adjust it after that. cel switch (4) in the [U] position and check
1) Select the code of the machine specifica- that the alarm buzzer sounds.
tion by setting shift up switch (6). a Even if the adjustment is carried out, the
2) Set buzzer cancel switch (4) in the [U] display of the lower line does not change.
position and check that the alarm buzzer a Even if this code is turned off, the setting
sounds. is effective.
k If the machine specification is different a This code is not for the adjustment of the
from the setting in the controller, the braking performance, etc..
machine may move abnormally or an
error may take place.
Accordingly, be sure to match the set-
ting to the machine specification.
is effective.
[5] 0007: Engine deceleration-cut mode

q This code is used to stop the auto-deceleration
function of the engine and check the high idle
speed of the engine unit.
q The engine speed is displayed on the lower
line (Display range: 0 – 3000).
No. Specifications q How to use:
While this code is displayed, its function is
000 Standard
enabled and the auto-deceleration function is
stopped.
a If this code is turned off, its function is dis-
abled.
D61EX, PX-15E0 21
[6] 0008: Common rail reduced cylinder mode a The below figure is an example that No. 2
a When the engine common rail system seems cylinder is turned off for reduced cylinder
to be defective, this code is used to stop inject- mode operation and turned on again (The
ing fuel into 1 or more cylinders (reduce the cylinder No. lamp is turned off in the
number of effective cylinders) while the engine reduced cylinder mode operation and on
is running and find out a defective cylinder in the normal mode operation).
from the change of the engine speed.
a Since this function diagnoses a failure based
on the difference of the engine speed in the
reduced cylinder mode operation from that in
the normal mode operation, use this function
while the engine is running.
q The engine speed and fuel injection rate are
displayed on the lower line (Display range: 0 –
3000, 0 – 1000).
q How to use:
Select the cylinders to be turned off for the
reduced cylinder mode operation by operating
information switch (5) and buzzer cancel
switch (4).
Use this method to turn on the selected cylin-
ders again, too.
q [>]: Moves cursor rightward.
q [<]: Moves cursor leftward.
q [U]: Executes or stops reduced cylinder
mode operation.
a Only one or more cylinders can be turned

off for the reduced cylinder mode opera-
tion.
abled.
22 D61EX, PX-15E0
[7] 0009: Pitch angle sensor initial set [9] 0021: KOMTRAX specification set
q This code is used to correct the installation q This code is used to select the installation set-
error of the pitch angle sensor by adjusting its ting of KOMTRAX terminal.
zero point. a Conduct this setting before the starting
q The deviation from the standard neutral posi- operation of KOMTRAX.
tion is displayed by voltage on the lower line q The terminal installation condition is displayed
(Display range: –2500 – 2500). on the lower line.
q Adjustment method: q ACTIVE: KOMTRAX is installed.
Stop the machine on level ground, then set q DEACTIVE: KOMTRAX is not installed.
buzzer cancel switch (4) in the [U] position q Setting method:
and check that the alarm buzzer sounds. 1) By operating shift up switch (6) and shift
a Even if the adjustment is carried out, the down switch (7), select the installation
display of the lower line does not change. condition of KOMTRAX terminal.
a Even if this code is turned off, the setting 2) After correctly selecting the installation
is effective. condition of the terminal, set buzzer can-
cel switch (4) in the [U] position and
check that the alarm buzzer sounds.
is effective.
a If the controller is changed, be sure to
conduct (check) this setting, too.
[8] 0010: Fan 70% speed mode

q This code forcedly sets the speed of cooling
fan at approximately 70% of the maximum
speed.
q The adjustment data is displayed on the lower
line.
q How to use:
The function is effective with this code dis-
played to control the speed of cooling fan to
approximately 70% of the maximum speed.
abled.
D61EX, PX-15E0 23
[10] 1005: Fan 100% speed mode [12] 1013: Steering control lever left set
q This code forcedly sets the speed of cooling q This code is used to adjust the leftmost steer-
fan at approximately 100% of the maximum ing potentiometer position of the PCCS lever.
speed. q The output signal of the steering potentiometer
q The adjustment data is displayed on the lower is displayed by voltage on the lower line (Dis-
line. play range: 0 – 5000).
q How to use: q Adjustment method:
The function is effective with this code dis- 1) Shift the PCCS lever to the steering left
played to control the speed of cooling fan to stroke end.
approximately 100% of the maximum speed. 2) Set buzzer cancel switch (4) in the [U]
a If this code is turned off, its function is dis- position and check that the alarm buzzer
abled. sounds.
a Even if the adjustment is carried out, the
display of the lower line does not change.
is effective.
a This code is not for the adjustment of the
steering performance, etc..
[11] 1012: Steering control lever neutral set

q This code is used to adjust the steering poten-
tiometer neutral position of the PCCS lever.
q The output signal of the steering potentiometer
is displayed by voltage on the lower line (Dis-
play range: 0 – 5000).
q Adjustment method:
1) Shift the PCCS lever in the steering neu-
tral position.
2) Set buzzer cancel switch (4) in the [U]
position and check that the alarm buzzer
sounds.
a Even if the adjustment is carried out, the
display of the lower line does not change.
is effective.
a This code is not for the adjustment of the
steering performance, etc..
24 D61EX, PX-15E0
[13] 1014: Steering control lever right set [14] 2222: HSS lever initial current set
q This code is used to adjust the rightmost steer- q When the steering start feeling is different by
ing potentiometer position of the PCCS lever. the steering direction, this code is used to
q The output signal of the steering potentiometer adjust the turning radius at the start of steering.
is displayed by voltage on the lower line (Dis- q The current to drive the HSS EPC solenoid is
play range: 0 – 5000). displayed on the lower line [Display range:
q Adjustment method: –350 (Left end) – 0 – 350 (Right end)].
1) Shift the PCCS lever to the steering right q Adjustment method:
stroke end. 1) Gradually shifting the PCCS lever to the
2) Set buzzer cancel switch (4) in the [U] left or right, display the current to be set
position and check that the alarm buzzer and keep it.
sounds. q If the lever is shifted to the left, the current
a Even if this code is turned off, the setting becomes negative.
is effective. q If the lever is shifted to the right, the cur-
a This code is not for the adjustment of the rent becomes positive.
steering performance, etc.. 2) Set buzzer cancel switch (4) in the [U]
a Even if the adjustment is carried out, the position and check that the alarm buzzer
display of the lower line does not change. sounds.
a As the set current is increased in the posi-

tive or negative direction, the turning
radius at the start of steering is decreased
(the machine turns more quickly).
a The below figure is an example that the
set current for steering to the left is
reduced to increase the turning radius.
is effective.
D61EX, PX-15E0 25
[15] 9997: High idle limit mode [16] 9998: Gear speed limit mode
q This code is used to limit the high idle speed. q This code is used to restrict the shift to the 3rd
q The limited speed (0 – 400) is displayed on the gear.
lower line. q The usable gear speeds are displayed by bits
q Possible limit range: High idle speed – 1400 on the lower line (in the order of the 3rd, 2nd
rpm and 1st from the left).
q How to use: q How to use:
1) Select a limit speed by setting information Restrict or allow the use of the highest gear
switch (5) in the [>] position or [<] position. speed by operating information switch (5) and
2) Set buzzer cancel switch (4) in the [U] buzzer cancel switch (4).
position and check that the alarm buzzer q [>]: Restricts a shift to 3rd gear speed.
sounds. q [<]: Does not restrict shift to 3rd gear
a If the high idle speed is limited, the engine speed.
speed is not raised to the normal high idle q [U]:Determine the setting.
level even if the fuel control dial is con- q Display on lower line [o]: Gear speed is
trolled so. effective.
a Even if this code is turned off, the setting q Display on lower line [ _] : Gear speed is
is effective. ineffective.
a If the use of a gear speed is restricted, the
transmission is not shifted to that gear
speed even if the gear shift up switch is
operated.
is effective.
26 D61EX, PX-15E0
9. Load memory display mode 2) Changing information screen

(9-LOAD MEMORY DISPLAY MODE) Change the information screen by operat-
In this mode, the load on the machine, forward ing information switch (5).
odometer, and reverse odometer can be q [>]: Next screen
checked. q [<]: Previous screen
No. Displayed information
1] Select “Load memory display mode” 01 1000 rpm service meter
on the mode selection screen. 02 Forward odometer
a If the mode is selected, code (Ld) 03 Reverse odometer
is displayed on gear speed dis-
play section (1) and the title is
displayed on multi-information 3) Displayed information of 1,000 rpm ser-
section (2). vice meter (01)
2] Display the information screen by This code is used to display the service
operating buzzer cancel switch (4). meter which integrates the operation
q [U]: Execute mode hours only while the engine speed is
higher than 1,000 rpm.
a The data cannot be reset.
4) Displayed information of forward odome-

ter (02)
On this screen, the integrated forward
travel distance of the machine is dis-
played.
a The data cannot be reset.
D61EX, PX-15E0 27
5) Displayed information of reverse odome- 10. Real-time monitoring mode

ter (03) (10-REAL TIME MONITORING MODE)
On this screen, the integrated reverse In this mode, the speeds, oil pressures, tem-
travel distance of the machine is dis- peratures, currents, voltages, etc. can be mon-
played. itored by using the signals from sensors,
a The data cannot be reset. switches, and solenoids installed to various
parts of the machine.
a This mode is used to monitor the items
one by one. When monitoring two items
simultaneously, use the “Dual display
monitoring mode”.

1] Select the “Real time monitoring
mode” on the mode selection screen.
a If the mode is selected, code (5R) is
displayed on gear speed display sec-
tion (1) and the title is displayed on
multi-information section (2).
2] Display the monitoring code input
6) When operating machine in the load sav- switch (4).
ing display mode q [U]: Select and decide mode.
If the parking brake lever is set in the
“free” position, gear speed display section
(1) returns to the normal display and the
machine can be operated normally.
load saving display mode.)
traveling.
parking brake lever to the “lock” posi-
essary operation.
28 D61EX, PX-15E0
2) Selecting and entering monitored items a If the input code is not correct, the
1] On the code input screen, input the 5- code input screen appears again after
digits code of the item to be moni- the screen shown below.
tored by operating information switch
(5), shift up switch (6), and shift down
switch (7).
q [>]: Cursor moves rightward.
q [<]: Cursor moves leftward.
q [UP]: Number increases.
q [DOWN]: Number decreases.
3) Displayed information on monitoring screen

(Below figure shows examples)
1] : Code
2] : Monitored item
3] : Information
4] : Unit (Not displayed for some items)
a For the details, see the “Monitoring
2] After inputting the code, operate mode table”.
buzzer cancel switch (4) to display
the monitoring screen.
q [U]: Determine input.
a If the input code is correct, the
monitoring screen shown below
appears.
D61EX, PX-15E0 29
4) Function of holding monitoring information

If an displayed information such as the
engine speed is not stabilized and cannot
be read easily in the monitoring mode, it
can be held and released by operating
buzzer cancel switch (4).
q [U]: Hold and release.
a While the monitored item is held, the
letter “H” is displayed at the left end of
the lower line.
6) Changing monitored items (Limited func-

tion)
Once the monitoring screen is selected in
s te p 2) , t he m o ni t o r e d i t e m c a n b e
changed by operating only information
switch (5) without inputting the code
again.
q [>]: Next code
q [<]: Previous code
a This function is limited to the numbers
5) When operating machine with monitoring marked with a in the “Monitoring
display mode table”.
If the parking brake lever is set in the a Note that this operation is not
“free” position, gear speed display section accepted while the parking brake
(1) returns to the normal display and the lever is in the “free” position.
machine can be operated normally.
monitoring mode.)
traveling.
parking brake lever to the “free” posi-
essary operation.
30 D61EX, PX-15E0
Monitoring mode table
No. Code Monitored item Unit Display range

Char-
1 00201 ENG M ID Engine controller model code
acter
a2 01000 ENG REV Engine speed rpm 0 – 3000
a3 03000 FUEL DIAL Voltage of fuel control dial mV 0 – 5000
a4 03200 BATTERY Battery voltage mV 0 – 30000
5 03201 S/T ACC ACC input voltage of steering controller mV 0 – 30000
6 03202 S/T PWR2 Load power source voltage of steering controller mV 0 – 30000
7 03203 E-ECM PW Power source voltage of engine controller mV 0 – 30000
8 03207 S/T PWR1 Constant power source voltage of steering controller mV 0 – 30000
a9 04104 COOLANT TP Coolant temperature °C –40 – 210
10 04105 COOLANT TP Voltage of coolant temperature sensor mV 0 – 5000
a11 04200 FUEL SENS Voltage of fuel level sensor mV 0 – 5000
a12 04401 HYD.TEMP. Hydraulic oil temperature °C 0 – 150
13 10000 FAN REV O. Command speed of cooling fan rpm 0 – 2000
14 10500 S/T 5V PW1 5V power source voltage of steering controller sensor mV 0 – 30000
15 10700 S/T 24V PW 24V power source voltage of steering controller sensor mV 0 – 30000
16 01300 TVC SOL F/B Output FB current of TVC solenoid mA 0 – 1000
17 01301 TVC SOL OUT Output command current of TVC solenoid mA 0 – 1000
18 14300 FUEL SUMP Fuel consumption amount L 0 – 60000
19 18500 BOOST TMP Boost temperature °C –50 – 200
20 18501 BOOST TMP Voltage of boost temperature sensor mV 0 – 5000
21 18600 INJECT CMD Command fuel injection rate mg/st 0 – 1000
22 18700 ENG TORQUE Engine output torque Nm –2400 – 2400
(See detailed infor-
23 18800 ENG WIF Water level signal of fuel filter Bit
mation)
24 18900 E-ECM TP Engine controller inside temperature °C –40 – 210
Char-
25 19500 ENG MODE Engine control mode
acter
Char-
26 20200 MON.PROGRM Monitor panel (tachometer module) program No.
acter
Char-
27 20202 S/T.PROGRM Steering controller program No.
acter
Char-
28 20216 ENG BLD Engine controller program No.1
acter
Char-
29 20217 ENG CAL Engine controller program No.2
acter
a30 20300 KOMTRAX KOMTRAX LED display —
Char-
31 20400 E-ECM SN Engine controller serial No.
acter
a32 30100 T/C TEMP. Torque converter oil temperature °C 0 – 150
a33 31400 T/M OUT Transmission speed rpm 0 – 5000
34 31520 T/M-FILL Input state of transmission-related fill switch Bit
mation)
35 31602 1st CLUTCH Output command current of 1st clutch ECMV mA 0 – 1000
36 31603 2nd CLUTCH Output command current of 2nd clutch ECMV mA 0 – 1000
37 31604 3rd CLUTCH Output command current of 3rd clutch ECMV mA 0 – 1000
D61EX, PX-15E0 31

38 31606 Rev CLUTCH Output command current of reverse clutch ECMV mA 0 – 1000
39 31608 Frd CLUTCH Output command current of forward clutch ECMV mA 0 – 1000
a40 31612 1 CLUTCH F Output FB current of 1st clutch ECMV mA 0 – 1000
a41 31613 2 CLUTCH F Output FB current of 2nd clutch ECMV mA 0 – 1000
a42 31614 3 CLUTCH F Output FB current of 3rd clutch ECMV mA 0 – 1000
a43 31616 R CLUTCH F Output FB current of reverse clutch ECMV mA 0 – 1000
a44 31622 F CLUTCH F Output FB current of forward clutch ECMV mA 0 – 1000
45 31623 FAN PUMP.O Output command current of cooling fan pump solenoid mA 0 – 1000
46 31624 FAN PUMP.F Output FB current of cooling fan pump solenoid mA 0 – 1000
a47 31701 DECEL Deceleration opening ratio % 0 – 100
a48 31703 DECEL Decelerator potentiometer voltage mV 0 – 5000
a49 31706 F THROTTLE Final accelerator opening angle % 0 – 100
a50 32900 BODY ANGLE Machine pitch angle ° –30 – 30
51 36200 PRESS CMD Command pressure of common rail MPa 0 – 400
52 36300 INJECT CMD Fuel injection timing CA –180 – 180
a53 36400 RAIL PR Common rail pressure MPa 0 – 400
54 36401 RAIL PR Voltage of common rail pressure sensor mV 0 – 5000
Boost pressure: indicated by absolute value (including
a55 36500 BOOST PRS kPa –999.9 – 999.9
ambient pressure)
56 36501 BOOST PRS Voltage of boost pressure sensor mV 0 – 5000
a57 36700 ENG TORQUE Converted torque of engine % 0 – 100
58 37301 FUEL RATE Instantaneous fuel consumption L/h 0 – 999.9
Atmospheric pressure: indicated by absolute value (includ-
59 37400 AMB PRESS kPa –999.9 – 999.9
ing ambient pressure)
60 37401 AMB PRESS Atmospheric pressure sensor voltage mV 0 – 5000
a61 40001 VEHICLE SP Travel speed (theoretical value) km/h 0 – 100
62 40905 T/M-SW1 Transmission-related controller input signal 1 Bit
mation)
63 40906 T/M-SW2 Transmission-related controller input signal 2 Bit
mation)
64 40909 T/M SOL.2 Transmission-related controller output signal 2 Bit
mation)
65 40910 S/T-SW1 Steering-related controller input signal 1 Bit
mation)
mation)
mation)
68 40914 S/T SOL.1 Output signal of steering controller Bit
mation)
a69 50200 T/M LEVR 1 Voltage of forward and reverse potentiometer 1 mV 0 – 5000
a70 50201 T/M LEVR 2 Voltage of forward and reverse potentiometer 2 mV 0 – 5000
a71 50300 S/T LEVR 1 Voltage of steering potentiometer 1 mV 0 – 5000
a72 50301 S/T LEVR 2 Voltage of steering potentiometer 2 mV 0 – 5000
a73 50400 BRAKE PEDL Voltage of brake potentiometer mV 0 – 5000
a74 50600 HSS L.H.F Output FB current of left HSS solenoid mA 0 – 1000
a75 50601 HSS R.H.F Output FB current of right HSS solenoid mA 0 – 1000
76 50602 HSS L.H.O Output command current of left HSS solenoid mA 0 – 1000
32 D61EX, PX-15E0

77 50603 HSS R.H.O Output command current of right HSS solenoid mA 0 – 1000
a78 50900 N-SAFETY Drive voltage of neutral safety relay mV 0 – 30000
79 51000 ENG REG 3rd throttle command speed rpm 0 – 3000
80 51100 FUEL DIAL Command speed of fuel dial rpm 0 – 3000
a81 60000 TRACTION Traction force (theoretical value) W 0–1
82 60100 BODY ANGEL Machine pitch angle sensor voltage mV 0 – 5000
83 60600 BR HOLD Drive voltage of battery relay mV 0 – 30000
Char-
84 60700 S/T MODE Steering state code
acter
Char-
85 60800 FILL MODE Variable for setting fill condition
acter
Char-
86 60909 MOD.MODE Variable for setting modulation condition
acter
Char-
87 70000 CHG.P.MODE Variable for setting condition of gear shift point
acter
88 70200 T/M OUT Transmission speed sensor voltage mV 0 – 5000
89 70400 BACK ALARM Drive voltage of backup alarm relay mV 0 – 30000
The numbers marked with a can be displayed in order by setting the information switch in the “ > ” or “ <”
position.
D61EX, PX-15E0 33
Detailed information on bit display codes 31520:

Input state of transmission-related fill switch
Display of bit information: 1: Forward clutch fill switch: ON
a The display position of the bit information in the 2: Reverse clutch fill switch: ON
“Real-time monitoring mode (Display of only 1 3: 1st clutch fill switch: ON
item)” is different from that in the “Dual display 4: 2nd clutch fill switch: ON
monitoring mode (Simultaneous display of 2 5: 3rd clutch fill switch: ON
items)”. 6: (Unused)
a The bit information is displayed by [ _ ] for OFF 7: (Unused)
and [o] for ON in the places from 1 to 8. 8: (Unused)
a The state of each item shown in this section is
the condition for turning on the bit.
40905:
Transmission-related controller input signal 1
18800: 1: Shift up switch: OFF
Water level signal of fuel filter 2: Shift up switch: ON
1: Water level in fuel filter: When detecting 3: Shift down switch: OFF
2: (Unused) 4: Shift down switch: ON
3: (Unused) 5: (Unused)
7: (Unused)
8: (Unused)
34 D61EX, PX-15E0
40906: 40910:
Transmission-related controller input signal 2 Steering-related controller input signal 1
1: Automatic shift down switch: ON 1: (Unused)
3. Fan speed selecting switch: CLN position 3: (Unused)
5: (Unused) 5: Parking brake lever switch: FREE
6: (Unused) 6: Parking brake lever switch: LOCK
40909: 40911:
Transmission-related controller output signal 2 Steering-related controller input signal 2
1: (Unused) 1: Buzzer cancel switch: At t
2: (Unused) 2: Buzzer cancel switch: At U
3: (Unused) 3: Information switch: At >
4: Back-up alarm relay: ON 4: Information switch: At <
5: Neutral safety relay: ON 5: Service switch: ON
D61EX, PX-15E0 35
40913:
Steering-related controller input signal 5
1: ACC signal: ON
2: (Unused)
3: R signal: ON
4: (Unused)
5: (Unused)
6: (Unused)
7: (Unused)
8: (Unused)
40914:
Steering-related controller output signal
1: (Unused)
2: (Unused)
3: Fan reverse solenoid: ON
4: (Unused)
5: Battery relay drive: ON
6: (Unused)
7: (Unused)
8: (Unused)
36 D61EX, PX-15E0
11. Dual display monitoring mode 2) Selecting and entering monitored items
(11-DUAL DISPLAY MONITORING MODE) 1] On the code input screen, input the 5-
In this mode, 2 monitored items can be dis- digits codes of the items to be moni-
played simultaneously. tored by operating information switch
a Note that only codes and monitoring infor- (5), shift up switch (6), and shift down
mation are displayed in this mode since switch (7).
the available display columns are limited. q [>]: Cursor moves rightward.
(Check item names and units cannot be q [<]: Cursor moves leftward.
displayed.) q [UP]: Number increases.
q [DOWN]: Number decreases.
1) Selecting and implementing a mode 2] After inputting the code, operate
1] Select the “Dual display monitoring buzzer cancel switch (4) to display
mode” on the mode selection screen. the monitoring screen.
a If the mode is selected, code q [U]: Determine input.
(dR) is displayed on gear speed
display section (1) and the title is
section (2).
2] Display the monitoring code input
switch (4).
q [U]: Execute mode
a If the input codes are correct, the

monitoring screen shown below
appears.
D61EX, PX-15E0 37
a If the input codes are not correct, the 4) In case of operating the machine in moni-
code input screen appears again after toring mode, if the parking brake lever is
the screen shown below. set in the “free” position, gear speed dis-
play section (1) returns to the normal dis-
play and the machine can be operated
normally.
monitoring mode.)
traveling.
3) Displayed information on monitoring parking brake lever to the “free” posi-
screen (Below figure shows examples) tion temporarily and perform the nec-
1: Code 1 essary operation.
2: Information 1
3: Code 2
4: Information 2
a For the details, see the “Monitoring
mode table”.
38 D61EX, PX-15E0
D61EX, PX-15E0 39
SEN02557-00

© 2007 KOMATSU
All Rights Reserved
40
SEN02558-00
D61EX-15E0
D61PX-15E0


Handling of voltage circuit of engine controller ............................................................................................... 2
Adjustment method when controller has been replaced ................................................................................. 2
Preparatory work for troubleshooting for electric system ................................................................................ 4
Inspection procedure of diode......................................................................................................................... 9
Pm-Clinic service .......................................................................................................................................... 10
How to start operation of KOMTRAX terminal .............................................................................................. 22
Lamp display of KOMTRAX terminal ............................................................................................................ 26
D61EX, PX-15E0 1
Handling of voltage circuit of Adjustment method when

engine controller 1 controller has been replaced 1
1. When disconnecting or connecting a connec- a After the machine is assembled or steering
tor, be sure to turn off the starting switch. and transmission controller is replaced, adjust
a Before connecting the harness connector, the system according to the following proce-
be sure to completely remove sand, dust, dure.
water, etc., from inside of controller side k If the system is not adjusted, the machine
connector. may not operate normally and may move
suddenly. Accordingly, be sure to adjust it.
2. Do not start the engine with T-adapter inserted a Precautions for replacing a controller:
in or connected to a connector for trouble- If a controller is replaced, the memory of the oil
shooting. and filter maintenance mode is reset. Accord-
a You may turn the starting switch to the ingly, take a record of the next replacement
OFF or ON position but must not turn it to periods of the oils and filters.
the START position. a Precautions for replacing a controller:
When replacing a controller, stop the machine
in a safe place and turn the starting switch off.
1. Setting system in service mode.

Turn the starting switch ON and set the monitor
panel in the “Adjustment mode” of the service
mode.
2. Adjusting steering and transmission con-

troller
Select steering and transmission controller
specification set (0002) and adjust the steering
and transmission controller.
3. Turning power on again.

Turn the starting switch OFF then ON, and set
the monitor panel in the “Adjustment mode” of
the service mode again.
2 D61EX, PX-15E0
4. Adjusting machine specification 7. Adjusting KOMTRAX specification

Select Machine specification set (0004) and Select KOMTRAX specification settings (0021)
adjust the machine specification. and adjust the KOMTRAX specification.
5. Adjusting brake potentiometer 8. Turning power on again.

Select brake potentiometer initial set (0005) Turn the starting switch OFF then ON.
and adjust the brake potentiometer.
9. Checking failure codes
1) Set the monitor panel in the “Electric sys-
tem failure code display mode” of the ser-
vice mode.
2) Check if any active failure codes exist. If
not, delete all the failure codes recorded.
a If any active failure codes exist, elimi-
nate the cause of the incident by trou-
bleshooting, then carry out steps 6
and 7 again.
a Precautions after replacing controller:
If any controller is replaced, the ser-
vice meter in the oil and filter mainte-
nance mode is reset to 0.
As a result, the replacement period
6. Adjusting pitch angle sensor displayed on the monitor panel may
Select the initial setting (0009) of the pitch be different from the actual operating
angle sensor and adjust the pitch angle sen- hours. To solve this problem, deter-
sor. mine the first replacement periods of
the oils and filters after the replace-
ment of the controller according to the
replacement periods recorded before
the replacement of the controller.
D61EX, PX-15E0 3
Preparatory work for troubleshoot- 2. Engine controller

ing for electric system 1 1) Open left upper side cover (1) of engine
and remove under side cover (2).
a When carrying out troubleshooting for an elec-
tric circuit related to the monitor panel, engine
controller or steering and transmission control-
ler, expose the related connectors according to
1. Monitor panel
1) Remove cover (1) above the dashboard.
2) Insert or connect T-adapters in or to con-

nectors CE01, CE02 and CE03 of engine
controller (3).
a Since the connectors (CE01 and
CE02) are secured with screws,
loosen those screws before discon-
necting.
a When connecting the connectors
2) Insert or connect the branch adapters for again, tighten their screws with the
troubleshooting in or to connectors S03 specified torque.
and S04 on the back side of monitor panel 3 Screw: 3 ± 1 Nm {0.3 ± 0.1 kgm}
(2).
4 D61EX, PX-15E0
k In order to prevent malfunction 3. Steering transmission controller

and mistaken system error warn- 1) Remove left console box inspection cover
ing, be sure to completely remove (1).
foreign object (b) such as sand,
dust, water, etc., from inside of
controller side connector (a) with
air blow etc., before connecting to
harness connector.
2) Insert or connect the T-adapters for trou-

bleshooting in or to connectors ST1, ST2,
and ST3 of steering and transmission con-
troller (2).
a If the connectors cannot be discon-
nected and connected easily, remove
the controller from the floor frame in
advance.
a Since the connectors are secured with
screws, loosen those screws before
disconnecting.
again, tighten their screws to the speci-
fied torque.
3 Screw: 2.8 Nm {0.29 kgm}
D61EX, PX-15E0 5
4. KOMTRAX controller 5. Air pressure sensor (AMB AIR SENSOR)

1) Remove inspection cover (1) of left con- Engine Ne speed sensor (CRANK SENSOR)
sole box. Engine Bkup sensor (CAM SENSOR)
Engine oil pressure switch (OIL PRESSURE
SWITCH)
a Disconnecting and connecting connectors
Since the connectors of air pressure sen-
sor, engine Ne speed sensor, engine Bkup
sensor and engine oil pressure switch
have special lock mechanism, disconnect
in the order of (a) – (c) and connect in the
order of (d) – (f) as shown in the below fig-
ure.
Disconnect: (a) slide lever – (b) release
lock – (c) disconnect con-
nector
Connect: (d) connect connector – (e)
mesh lock – (f) slide lever
2) Insert or connect T-adapters in or to G01
connector of KOMTRAX controller (2).
a Since the connectors are secured
with screws, loosen those screws
before disconnecting.
again, tighten their screws with the
specified torque.
3 Screw: 2.8 Nm {0.29 kgm}
a Cable (3) is for GPS communication
antenna.
a Cable (4) is for communication
antenna.
a Removal and installation of sensor

When removing and installing engine oil
pressure switch, use deep sockets. For
details, see “Tools for testing, adjusting
and troubleshooting”.
6 D61EX, PX-15E0
6. Boost pressure sensor and intake manifold 8. Common rail pressure sensor (FUEL RAIL
temperature sensor (BOOST PRES & IMT) PRESS)
a Disconnecting and connecting connectors a Disconnection and connection of connector
Since the connectors of boost pressure The connector of the common rail pres-
and temperature sensor have special lock sure sensor has a special locking mecha-
mechanism, disconnect in the order of (a) nism. Disconnect it according to steps (a)
– (b) and connect in the order of (c) – (d) – (b) and connect it according to steps (c)
as shown in the below figure. – (d) as shown below.
Disconnect: (a) release lock – (b) discon- Disconnection:
nect connector (a) Unlock – (b) Disconnect connector.
Connect: (c) connect connector – (d) Connection:
mesh lock (c) Connect connector – (d) Lock.
a Precautions for disconnecting connector

a Removal and installation of sensor The direction of the lock of the connector
When removing and installing boost pres- varies with the tightened position of the
sure and intake manifold temperature sen- sensor and the lock may be in a direction
sor, use T type torque wrench [bearing in which it is difficult to reset (on the under-
number : T15]. side or engine side).
In this case, pinch the lock in direction (a)
7. Fuel supply pump IMV solenoid (FUEL with bent-nose nippers (commercially
REGULATOR) available), and the lock is reset.
a Disconnecting and connecting connectors Since the lock clicks when it is reset, dis-
Since the connector of fuel supply pump connect the connector after a click is
IMV solenoid has special lock mechanism, heard.
disconnect in the order of (a) – (b) and
connect in the order of (c) – (d) as shown
in the below figure.
Disconnect: (a) release lock – (b) discon-
nect connector
Connect: (c) connect connector – (d)
mesh lock
D61EX, PX-15E0 7
a Precautions for connecting connector

Take care not to connect the connector
reversely.
Engage lock (e) on the wiring harness
side with triangular notch (f) on the sensor
side (Do not engage lock (e) with square
guide (g) on the opposite side of triangular
notch (f)).
9. Engine coolant temperature sensor (COOL-

ANT TEMP)
a Disconnection and connection of connector
The connector of the engine coolant tem-
perature sensor has a special locking
mechanism. Disconnect it according to
steps (a) – (b) and connect it according to
steps (c) – (d) as shown below.
Disconnection:
(a) Unlock – (b) Disconnect connector.
Connection:
(c) Connect connector – (d) Lock.
a Removal and installation of sensor

A deep socket is necessary for removal
and installation of the engine coolant tem-
perature sensor. See Testing adjusting,
“Troubleshooting tools table”.
8 D61EX, PX-15E0
Inspection procedure of diode 1 2. When using analog tester

1) Switch to resistance range.
a The direction of continuity of diode is marked 2) Check the deflection of needle while con-
on the surface of the diode. necting as follows.
i) Set red (+) test lead to diode anode
(P) side and black (–) test lead to
cathode (N) side.
ii) Set red (+) test lead to diode cathode
(N) side and black (–) test lead to
anode (P) side.
3) Based on the deflection of needle, judge
the quality of diode.
q Needle does not deflect with connec-
tion i) but deflects with connection ii):
Normal. (however deflection range
(resistance value) varies depending
on the type of tester and measuring
range.
q Needle deflects with both connection
1. When using digital tester i) and ii): Defective (internal short cir-
1) Switch to diode range and check dis- cuit)
played value. q Needle does not deflect with either
a Voltage of internal battery is disconnection i) or ii): Defective (internal
played by normal tester. disconnection)
2) Set red (+) test lead to diode anode (P)
side and black (–) test lead to cathode (N)
side. Check displayed value.
3) Judge quality of diode from displayed
value.
q Displayed value does not change:
No continuity (defect)
q Displayed value changes:
Continue (normal) (note)
Note: In the case of silicon diode, the
value between 460 – 600 mV is dis-
played.
q Displayed value becomes 0 or near 0
: Short-circuiting of diode internal part
(defect)
D61EX, PX-15E0 9
Pm-Clinic service 1
Model Serial No. Service meter

T D61EX-15E0
h
T D61PX-15E0
User name Date of clinic Serviceman

/ /
Specifications
Blade Attachment Shoe width
T Power angle
T Multi-shank ripper T 600 mm T
T Power tilt blade
T Towing winch T 860 mm T
T Semi-U blade
T CAB T
T Straight tilt blade
T ROPS T
T
Operating conditions
Quarry, mine Construction Type of soil Type of work
(specific gravity)
T Coal T Construction, T Rock T Dozing, digging %
T Gold civil engineering T Gravel T Side cutting %
T Limestone T Roads T Sand T Grading %
T T Tunnels T Clay T Travel %
T
Existence of abnormalities
Oil, coolant level check
T Engine coolant level When necessary
T Engine oil level T Power train T Damper case
T Hydraulic oil level T Final drive T( )
Ambient temperature Height above sea level

Max.
°C
Min.
Operator's opinion
Visual check results
Failure code history

[ ] h [ ] h
Content: Content:
[ ] h [ ] h
Content: Content:
10 D61EX, PX-15E0
a Engine coolant temperature: Max. range a Power train oil temperature: Max. range
D61EX, PX-15E0 11
Pm-clinic measuring points (1/2)
Reference page for measurement procedure

*1. Engine speed : Testing and adjusting, Part 1, pages 6 – 7
*2. Blow-by pressure : Testing and adjusting, Part 1, page 16
*3. Engine oil pressure : Testing and adjusting, Part 1, page 17
*4. Boost pressure : Testing and adjusting, Part 1, pages 8 – 9
12 D61EX, PX-15E0
Pm-clinic measuring points (2/2)
Reference page for measurement procedure

*6. Items related to torque converter : Testing and adjusting, Part 2, page 4
*7. Items related to transmission : Testing and adjusting, Part 2, pages 5 – 6
*8. Items related to steering brake : Testing and adjusting, Part 2, pages 3 – 4
*9. Items related work equipment and HSS : Testing and adjusting, Part 2, pages 18 – 21
D61EX, PX-15E0 13
Machine serial T D61EX-15E0 #

Pm clinic check sheet number T D61PX-15E0 #
Work order No. Date Service meter Serviceman

h
Standard value Service limit Measurement

Item Measurement conditions Unit Pass Fail
for new machine value result
Low idle 865 – 965 865 – 965
Engine High idle Deceleration pedal depressed 1,150 – 1,200 1,150 – 1,200
rpm
speed High idle 1,950 – 2,050 1,950 – 2,050
Torque converter stool 1,550 – 1,750 1,500
Blow-by kPa Max. 0.98 1.96
Torque converter stool
pressure {mmH2O} {Max. 100} {200}
Engine at low
Engine
idle Min. 0.10 0.07

Oil tempera- SAE0W30EDS {Min. 1.0} {0.7}
ture: Min.80°C SAE5W40EDS
Engine oil MPa
SAE10W30DH
pressure Engine at high {kg/cm2}
SAE15W40DH
idle Min. 0.29 0.21
SAE30DH
Oil tempera- {Min. 3.0} {2.1}
ture: Min.80°C
Boost kPa Min. 120 93.3
Torque converter stool
pressure {mmHg} {Min. 900} {700}

Inlet oil 0.1 – 0.5 0.1 – 0.5
pressure {1 – 5} {1 – 5}
Torque converter
Engine at low idle

Outlet oil Transmission : 0.09 – 0.29 0.09 – 0.29
pressure Neutral MPa {0.9 – 3} {0.9 – 3}
Inlet oil Oil temperature: {kg/cm2} Max. 0.88 Max. 0.88
pressure 70 – 80°C {Max. 9} {Max. 9}
Engine at high idle
Outlet oil 0.44 – 0.69 0.44 – 0.69
pressure {4.5 – 7} {4.5 – 7}

2.55 – 2.75 Min. 2.35
Transmission
Engine at low idle

Main relief Transmission : MPa {26 – 28} {Min. 24}
pressure Neutral {kg/cm2} 2.84 – 3.08 Min. 2.65
Engine at high idle
{29 – 32} {Min. 27}
• Fan 100% speed mode Min.
550 – 650 500
• Engine at low idle speed
Fan speed rpm
Cooling fan
• Fan 100% speed mode Max.

1700 – 1800 1,600
• Engine at high idle speed
Fan pump
• Fan 100% speed mode MPa 16.7 – 19.6 14.7
oil pres-
• Engine high idle {kg/cm2} {170 – 200} {150}
sure
14 D61EX, PX-15E0
Machine serial T D61EX-15E0 #

Pm clinic inspection sheet number T D61PX-15E0 #
Work order No. Date Service meter Serviceman

h
Measurement Standard value Service limit Measurement

Item Unit Pass Fail
conditions for new machine value result
31.1 – 35.1 Min. 28.9
Steering load sending pressure
Steering
{318 – 358} {Min. 295}

Engine at high idle
MPa 32.1 – 37.0 Min. 29.9
Steering relief pressure
{kg/cm2} {328 – 378} {Min. 305}
2.75 – 2.94 Min. 2.55
Brake actuating pressure Engine at high idle
{28 – 30} {Min. 26.0}
Brake
Brake perfor- Apply the brakes and bring the engine to high
Machine must not move
mance idle with the transmission at F2.

Min. 19.1 Min. 19.1
Ripper lift relief
{Min. 195} {Min. 195}
Engine at low idle
Min. 19.1 Min. 19.1
Blade tilt relief
HSS and work {Min. 195} {Min. 195}
components
Hydraulic
equipment pump MPa 19.6 – 21.6 Min. 17.6

Ripper lift relief
{kg/cm2} {200 – 220} {Min. 180}
19.6 – 21.6 Min. 17.6
Blade tilt relief Engine at high idle
{200 – 220} {Min. 180}
PPC valve out- 3.82 – 4.12 3.82 – 4.12
Blade tilt relief
put pressure {39 – 42} {39 – 42}

Item Unit Pass Fail
Blade lift Engine at high idle 2.3 – 2.7 Min. 3.0
Work equipment
Single tile (Left o Right) Engine at high idle 2.3 – 2.7 Min. 3.0
speed
sec
Ripper RAISE
Engine at high idle 1.2 – 1.6 Min. 1.9
(D61EX-15 (if equipped))

Item Unit Pass Fail
Hydraulic oil temperature °C 44 – 55 —
Hydraulic
drift
Blade lift cylinder Engine stopped mm/ Max. 100 Max. 100
Blade tilt cylinder 15 min. Max. 200 Max. 200

Item Unit Pass Fail
There must be no excessive
Visual inspection of final drive drain plug Engine stopped —
metal particles
Always fill in the record when repairing, adjusting, or replacing main parts.
Date Service meter Repair record Date Service meter Repair record
D61EX, PX-15E0 15
Pm-clinic
Serial
undercarriage check sheet T D61EX-15E0 #
number
Work order Date Service meter Serviceman

/ / h
q Measure the bushing temperature immediately after operations

Left side of machine
Right side of machine
a Measurement results
Pass Fail Left A: Clearance Right A: Clearance
Left side of machine track between links track between links
Right side of machine Pin Pin

1.2 1.2
No. No.
q Opening of track link
16 D61EX, PX-15E0
Pm-clinic
Serial
undercarriage check sheet T D61PX-15E0 #
number
Work order Date Service meter Serviceman

/ / h
q Measure the bushing temperature immediately after operations

Left side of machine
Right side of machine
a Measurement results
Pass Fail Left A: Clearance Right A: Clearance
Left side of machine track between links track between links
Right side of machine Pin Pin

1.2 1.2
No. No.
q Opening of track link
D61EX, PX-15E0 17
D61EX-15E0 (Normal) (Program form No. : SELA195001)
18 D61EX, PX-15E0
D61EX-15E0 (Impact) (Program form No. : SELA195001)
D61EX, PX-15E0 19
D61PX-15E0 (Normal) (Program form No. : SELA195001)
20 D61EX, PX-15E0
D61PX-15E0 (Impact) (Program form No. : SELA195001)
D61EX, PX-15E0 21
How to start operation of In the case where the KOMTRAX terminal is ret-
KOMTRAX terminal 1 rofitted on the machine after the shipment:
a Implement the following procedure in the case
In the case where the KOMTRAX terminal has
where the KOMTRAX terminal is retrofitted
already been installed at the plant before ship- after shipment of the machine (retrofitted
ment: machine)
a Implement the following procedure in the case
where the KOMTRAX terminal has already 1. Sign-up test on the machine side
been installed at the plant before shipment (as 1) Move the machine to a place with good
standard equipment). visibility of upper direction.
2) Open battery cover (1) at the left side of
1. Notification of model, model number and the operator cab.
serial number
Notify the model, model number and serial
number of the machine to the KOMTRAX oper-
ations administrator.
2. Registration of machine
The KOMTRAX operations administrator regis-
ters the machine using a KOMTRAX client per-
sonal computer.
a Refer to “Manual for KOMTRAX opera-
tions administrator” for the procedure.
a Now the terminal is ready for use.
3) Switch the monitor panel display to “Adjust

mode“, enter “Setting KOMTRAX specifi-
cation“, and enable the KOMTRAX func-
tion.
q Adjust code: 0021
q Specification: ACTIVE
4) Switch the monitor panel display to “Moni-
toring mode” and enter “KOMTRAX LED
display”.
q Monitoring code: 20300
a Refer to “Special functions of monitor
panel (EMMS)” for the operating
method.
5) Disconnect ACC connector (2), and move
on to the next step after confirming that
more than 5 seconds have passed since
the disconnection.
q ACC connector (2): ACF (female) and
ACM (male)
22 D61EX, PX-15E0
6) Check visually that test connector (3) is Monitor panel

connected.
q Test connector (3):
T1F (female) and T1M (male)
KOMTRAX terminal
7) Connect ACC connector (2). Keep that

condition for 5 seconds.
q Check that display (b) on the monitor
panel or KOMTRAX terminal shows
the mark “ – ”.
8) Disconnect test connector (3) and keep
that condition for 5 seconds.
9) Reconnect test connector (3) and keep
that condition for 5 seconds. [Dot (a)
blinks on and off]
q Blinking of dot (a): When the terminal
detects insert or removal of the con-
nector, dot (a) blinks on and off.
10) Check that display (b) on the monitor
a Complete procedure 7) – 9) in 30 sec-
panel or KOMTRAX terminal is displayed
onds.
normally.
a The normal display shows “d” o “0” o
“ – ” repeatedly for 30 seconds on the
monitor panel after 9) is finished.
a Move on to the next step if you can
check that the display is [normal].
a If the display is [abnormal], start from
procedure 1) again.
D61EX, PX-15E0 23
11) Turn the starting switch to the starting

position, keep it more than 5 seconds, and
check that the engine does not start up.
a If the engine starts up or the starting
switch is turned off, start from proce-
dure 1) again.
12) Turn the starting switch to the starting
position again, and check that the engine
starts up.
13) Check that display (b) on the monitor
panel or KOMTRAX terminal is displayed
normally.
a Move on to the next step if you can
check that the display is [A: normal].
(It takes from 90 seconds to 15 min-
utes before the display turns normal.)
a If [B: GPS position data detection
trouble] is indicated, check if there is
any abnormality on the GPS antenna
or cable. If there is any abnormality,
repair it and start from procedure 1)
again.
a If [C: Reception trouble] is indicated,
check if there is any abnormality on
the appearance of the communication
antenna or cable. If there is any
abnormality, repair it then repeat from
procedure 1) again.
a If [D: GPS position data detection
trouble and reception trouble] is indi-
cated, check if there is any
abnormality on the GPS antenna/
cable or communication antenna/
cable. If there is any abnormality,
repair it and start from procedure 1)
again.
a If [E: Network trouble] is indicated,
check the display of [LED-C4] refer-
ring to “Lamp display of KOMTRAX
terminal”. If the CAN is not recog-
nized, check the CAN harness of the
KOMTRAX terminal, and then if there
is any abnormality, repair it and start
from procedure 1) again.
24 D61EX, PX-15E0
14) Disconnect ACC connector (2). 2. Application for the start of use
15) Check that display (b) on the monitor a Application for the start of use should be
panel or KOMTRAX terminal is displayed made only after the sign-up test is fin-
normally in 5 seconds. ished.
a If you can check that the display is 1) Notify to the KOMTRAX operations
[Normal], that is the end of sign-up administrator the following information
test. concerning the machine whose sign-up
a If the display shows [Abnormal], test on the machine side is completed.
r ep eat fr om p ro ce dur e 1) a gai n (1) Information on the machine whose
because the sign-up test has not sign-up test on the machine side is
been completed successfully. completed
(model, model number and serial
number)
(2) Part number and serial number of the
KOMTRAX terminal
(3) Reading of the service meter when
the KOMTRAX terminal is installed
(0.1h unit)
16) Connect ACC connector (2) and turn the

buzzer cancel switch to the right to finish
the “KOMTRAX LED display” mode.
17) Stop the engine and fix the connector
cover with the fixing band.
2) The KOMTRAX operations administrator

registers the machine using a KOMTRAX
client personal computer.
a Refer to “Manual for KOMTRAX oper-
ations administrator” for the proce-
dure.
a Now the terminal is ready for use.
D61EX, PX-15E0 25
Lamp display of KOMTRAX terminal 1
CPU LED 7-segment and dot for CPU

1. LED-C1 (R signal and ACC signal status) 7. 7-segment (number of mails not yet sent)
2. LED-C2 (Engine control signal status) 8. Dot (GPS positioning status)
3. LED-C3 (S-NET and C signal status)
4. LED-C4 (CAN status)
5. LED-C5 (downloading and writing status)
6. LED-C6 (downloading and writing status)
26 D61EX, PX-15E0
In the KOMTRAX system, various information and processing details are displayed on the LED on the upper
surface of the KOMTRAX terminal. Therefore, if a detect is suspected in the system, perform the following
checks.
q Check of antennas
q Check of terminal LED displays
Application for the start of use and sign-up test on the machine side should be completed in advance in order
to use KOMTRAX system.
Check of antennas
a Before checking the LED displays, check that there is no abnormality around the communication
antenna and GPS antenna.
q The communication antenna should not be off or damaged.
q The communication antenna cable should not be broken and normally be connected to the KOMTRAX
terminal.
q The GPS antenna should not be off or damaged.
q The GPS antenna cable should not be broken and normally be connected to the KOMTRAX terminal.
Check of terminal LED displays

1. Meaning of CPU LED displays
a The LED displays should be checked with the starting switch ON, starting switch START, or with the
engine started.
No. LED Name, Function Display (*1) Contents of display
ON Starting switch ACC signal: ON, alternator R signal: ON
Starting switch ACC signal Fast blinking Starting switch ACC signal: OFF, alternator R signal: ON
1 LED-C1 status and alternator R signal
status Slow blinking Starting switch ACC signal: ON, alternator R signal: OFF
OFF Starting switch ACC signal: OFF, alternator R signal: OFF
ON Engine control signal: ON
2 LED-C2 Engine control signal status
OFF Engine control signal: OFF
ON S-NET: connected, starting switch C signal: OFF
S-NET connection status and Fast blinking Starting switch C signal: ON
3 LED-C3
starting switch C signal status Slow blinking (Not used)
OFF S-NET: unconnected, starting switch C signal: OFF
ON CAN: active (fuel sensor: no communication)
Fast blinking CAN: active (fuel sensor: in communication)
4 LED-C4 CAN connection status
Slow blinking CAN: inactive (fuel sensor: in communication)
OFF CAN: inactive (fuel sensor: no communication)
Either one is Downloading and writing status (special function for sys-
5 LED-C5
Downloading and writing sta- ON tem administrator)
tus Both are
6 LED-C6 Normal operation mode
OFF
*1 Type and time of blinking

Fast blinking: blinking on an approximately 1 second cycle
Slow blinking: blinking on an approximately 4 seconds cycle
a The LED displays can be checked in “monitoring mode” of the monitor panel.
D61EX, PX-15E0 27
2. Contents of 7-segment and dot displays for CPU

a LED displays should be checked with the starting switch ON.
No. Display section Name, Function Display (*2) Contents of display
The numbers are numbers of mails not yet sent (If there is
0–9
more than 9 mails, 9 is displayed)
Number of mails not ON
Lighting ON indicates satellite acquisition is in process.
7 7-segment yet sent and satellite
acquisition condition 0–9 The numbers are numbers of mails not yet sent (If there is
Fast blink- more than 9 mails, 9 is displayed)
ing Fast blinking indicates satellite is not being acquired.
GPS positioning has been completed. (Position has been rec-
ON
GPS positioning sta- ognized *3)
8 Dot
tus GPS positioning has not been completed. (Position has not
OFF
been recognized *3)
*2: Type and time of blinking

Fast blinking: blinking on an approximately 1 second cycle
Slow blinking: blinking on an approximately 4 seconds cycle
*3: Remarks on GPS positioning status
It may take more than 1 minute from turning on the starting switch to the completion of positioning
even in an outdoor place where radio wave can reach.
Positioning is impossible in areas with extremely weak radio waves or areas beyond the reach of
radio waves.
a The LED displays can be checked in “monitoring mode” of the monitor panel.
28 D61EX, PX-15E0
D61EX, PX-15E0 29
SEN02558-00

© 2007 KOMATSU
All Rights Reserved
30
SEN02559-00
D61EX-15E0
D61PX-15E0

40 Troubleshooting 1
Failure code table and fuse locations
Failure code table ........................................................................................................................................... 2
Fuse locations................................................................................................................................................. 9
D61EX, PX-15E0 1
SEN02559-00 40 Troubleshooting
Failure code table 1

Com-
History
Failure ponent Action Reference
Failed section Failure symptom classifi-
code in code document No.
cation
charge
Electric
1500L0 Transmission clutch Dual engagement S/T CALL E03
system
Fill signal is ON when command Electric
15SAL1 Forward clutch S/T CALL E03
current is OFF. system
Fill signal is OFF when command Electric
15SALH Forward clutch S/T CALL E03
current is ON. system
15SBL1 Reverse clutch S/T CALL E03
15SBLH Reverse clutch S/T CALL E03
15SEL1 1st clutch S/T CALL E03
15SELH 1st clutch S/T CALL E03
15SFL1 2nd clutch S/T CALL E03
15SFLH 2nd clutch S/T CALL E03
15SGL1 3rd clutch S/T CALL E03
15SGLH 3rd clutch S/T CALL E03
Troubleshoot-
Mechani- ing by failure
AB00MA Alternator Malfunction S/T — cal sys- code, Part 1
tem SEN02561-00
Mechani-
B@BAZG Engine oil Oil pressure reduction ENG — cal sys-
tem
Mechani-
B@BCNS Radiator coolant Overheat ENG — cal sys-
tem
Mechani-
B@CENS Power train oil Overheat S/T — cal sys-
tem
Mechani-
B@HANS Hydraulic oil Overheat S/T — cal sys-
tem
Electric
CA111 Engine controller Abnormality in controller ENG CALL E04
system
Abnormal engine NE, Bkup Electric
CA115 Abnormal speed sensor signal ENG CALL E04
speed sensor system
Charge pressure sensor too Electric
CA122 Excessively high voltage detected ENG CALL E03
high system
Charge pressure sensor too Electric
CA123 Excessively low voltage detected ENG CALL E03
low system
Decelerator pedal sensor Electric
too high system
2 D61EX, PX-15E0
Com-
History
cation
charge
too low system
Coolant temperature sensor Electric
CA144 Excessively high voltage detected ENG E01
too high system
Coolant temperature sensor Electric
CA145 Excessively low voltage detected ENG E01
too low system
Charge temperature sensor Electric
too high system
Charge temperature sensor Electric
too low system
Charge temperature tool
Exceeded upper control limit of Electric
CA155 high and engine speed der- ENG CALL E03
temperature system
ated
Sensor power source 2 too Electric Troubleshoot-
low system ing by failure
Atmospheric pressure sen- Electric code, Part 1
CA221 Excessively high voltage detected ENG E01 SEN02561-00
sor too high system
Atmospheric pressure sen- Electric
sor too low system
Sensor power source 2 too Electric
high system
Mechani-
CA234 Engine overspeed Excessively high speed ENG — cal sys-
tem
Abnormal power source for Electric
Ne speed sensor system
Electric
CA271 IMV/PCV1 short circuit Short circuit ENG CALL E03
system
Electric
CA272 IMV/PCV1 disconnection Disconnection ENG CALL E03
system
Disconnection and short cir- Electric
CA322 Disconnection and short circuit ENG CALL E03
cuit in injector #1 system
Disconnection and short cir- Electric Troubleshoot-
cuit in injector #2 system ing by failure
Disconnection and short cir- Electric code, Part 2
CA332 Disconnection and short circuit ENG CALL E03 SEN02563-00
Abnormal engine controller Electric
CA342 Matching inconsistency ENG CALL E04
data matching consistency system
low system
high system
Water detection sensor too Electric
high system
D61EX, PX-15E0 3
Com-
History
cation
charge
Water detection sensor too Electric
low system
Abnormal engine oil pres- Electric
CA435 Abnormal signal circuit ENG E01
sure switch system
Power supply voltage too Electric
low system
Power supply voltage too Electric
high system
Common rail pressure too Electric
CA449 Excessively high pressure detected ENG CALL E03
high (2) system
Common rail pressure sen- Electric
sor too high system
Common rail pressure sen- Electric
sor too low system
Charge temperature too Exceeded upper control limit of Electric
CA488 ENG CALL E03
high torque derated temperature system
Common rail pressure too Electric
CA553 Excessively high pressure detected ENG CALL E03
high (1) system
Supply pump no pressure Electric
CA559 No pressure feeding detected ENG E02
(1) system Troubleshoot-
Abnormal engine Ne speed Electric ing by failure
CA689 Abnormality in signal ENG CALL E03
sensor system code, Part 2
Abnormal engine Bkup Electric SEN02563-00
CA731 Abnormal phase ENG CALL E03
speed sensor phase system
Loss of all data of engine Electric
CA757 Loss of all data ENG CALL E04
controller system
Abnormal engine Bkup Electric
CA778 Abnormal Bkup signal ENG CALL E03
speed sensor system
Electric
CA1633 Abnormal KOMNET Abnormal communication ENG CALL E03
system
power source too high system
power source too low system
Supply pump no pressure Electric
CA2249 No pressure feeding detected ENG CALL E03
(2) system
Electric
CA2311 Abnormal IMV solenoid Abnormal resistance ENG CALL E03
system
Disconnection in air intake Electric
CA2555 Disconnection ENG E01
heater relay system
Short circuit in air intake Electric
CA2556 Short circuit ENG E01
heater relay system
Electric
D110KA Battery relay Short circuit S/T —
system
Electric Troubleshoot-
D110KB Battery relay Disconnection S/T —
system ing by failure
Electric code, Part 3
D130KA Neutral safety relay Disconnection S/T E02 SEN02564-00
system
Electric
D130KB Neutral safety relay Short circuit S/T E02
system
4 D61EX, PX-15E0
Com-
History
cation
charge
Electric
D161KA Backup alarm relay Disconnection S/T E01
system
Electric
D161KB Backup alarm relay Short circuit S/T E01
system
Monitor panel CAN commu- Electric
DAFRKR Defective communication MON CALL E03
nication system
DAQ0KT Steering and transmission Electric
Abnormality in controller S/T E01
(DB30KT) controller system
Main power source of steer-
DAQ1KK Electric
ing and transmission con- Power supply voltage drop, input S/T CALL E04
(DB31KK) system
troller
DAQ2KK Steering and transmission Electric
Power supply voltage drop, input S/T CALL E04
(DB32KK) controller load power source system
5 V power source of steering
DAQ5KK Electric
and transmission controller Power supply voltage drop, input S/T CALL E03
(DB35KK) system
sensor
24 V power source of steer-
DAQ6KK Electric
(DB36KK) system
troller sensor
DAQ9KQ Steering and transmission Electric
Model select signal inconsistency S/T CALL E04
(DB39KQ) controller model selection system
Steering and transmission
Defective communication (Abnor- Electric
DB2RKR controller CAN communica- S/T CALL E03
mality in target component system) system
tion
DB30KT Steering and transmission Electric Troubleshoot-
Abnormality in controller S/T E01 ing by failure
(DAQ0KT) controller system
code, Part 3
Main power source of steer- SEN02564-00
DB31KK Electric
(DAQ1KK) system
troller
DB32KK steering and transmission Electric
Power supply voltage drop, input S/T CALL E04
(DAQ2KK) controller load power source system
5 V power source of steering
DB35KK Electric
and transmission controller Power supply voltage drop, input S/T CALL E03
(DAQ5KK) system
sensor
24 V power source of steer-
DB36KK Electric
(DAQ6KK) system
troller sensor
DB39KQ Steering and transmission Electric
Model select signal inconsistency S/T CALL E04
(DAQ9KQ) controller model selection system
Electric
DD12KA Shift up switch Disconnection S/T E02
system
Electric
DD12KB Shift up switch Short circuit S/T E02
system
Electric
DD13KA Shift down switch Disconnection S/T E02
system
Electric
DD13KB Shift down switch Short circuit S/T E02
system
DD14KA Electric
Parking brake lever switch Disconnection S/T CALL E03
(DDQ2KA) system
DD14KB Electric
Parking brake lever switch Short circuit S/T CALL E03
(DDQ2KB) system
D61EX, PX-15E0 5
Com-
History
cation
charge
DDQ2KA Electric
Parking brake lever switch Disconnection S/T CALL E03
(DD14KA) system
DDQ2KB Electric
Parking brake lever switch Short circuit S/T CALL E03
(DD14KB) system
Hydraulic oil temperature Electric
DGS1KX Input signal out of range S/T —
sensor system
Power train oil temperature Electric
DGT1KA Disconnection S/T E01
sensor system
Power train oil temperature Electric
DGT1KX Input signal out of range S/T E01
sensor system
Electric
DK10KA Fuel control dial Disconnection S/T CALL E03
system
Electric
DK10KB Fuel control dial Short circuit S/T CALL E03
system
DK30KA Steering potentiometer (1) Disconnection S/T CALL E03
system ing by failure
Electric code, Part 3
DK30KB Steering potentiometer (1) Short circuit S/T CALL E03 SEN02564-00
system
Electric
DK30KX Steering potentiometer Input signal out of range S/T CALL E04
system
Electric
DK30KZ Steering potentiometer Disconnection or short circuit S/T CALL E04
system
Electric
DK30L8 Steering potentiometer Inconsistent analog signals S/T CALL E03
system
Electric
DK31KA Steering potentiometer (2) Disconnection S/T CALL E03
system
Electric
DK31KB Steering potentiometer (2) Short circuit S/T CALL E03
system
Electric
DK40KA Brake potentiometer Disconnection S/T E01
system
Electric
DK40KB Brake potentiometer Short circuit S/T E01
system
Forward-reverse potentiom- Electric
DK55KX Input signal out of range S/T CALL E04
eter system
DK55KZ Disconnection or short circuit S/T CALL E04
eter system
DK55L8 Inconsistent analog signals S/T CALL E03
eter system
DK56KA Short circuit S/T CALL E03
eter (1) system Troubleshoot-
Forward-reverse potentiom- Electric ing by failure
DK56KB Disconnection S/T CALL E03
eter (1) system code, Part 4
Forward-reverse potentiom- Electric SEN02565-00
DK57KA Disconnection S/T CALL E03
eter (2) system
DK57KB Short circuit S/T CALL E03
eter (2) system
DKH1KA Electric
Pitch angle sensor Short circuit S/T CALL E03
(DKH1KX) system
DKH1KB Electric
Pitch angle sensor Disconnection S/T CALL E03
(DKH1KX) system
6 D61EX, PX-15E0
Com-
History
cation
charge
DKH1KX
Electric
(DKH1KA) Pitch angle sensor Input signal out of range S/T CALL E03
system
(DKH1KB)
Transmission output speed Electric
DLT3KA Disconnection S/T E01
sensor system
Transmission output speed Electric
DLT3KB Short circuit S/T E01
sensor system
Electric
DV00KB Alarm buzzer Short circuit MON —
system
Electric
DW7BKA Fan reverse solenoid Disconnection S/T E01
system
Electric
DW7BKB Fan reverse solenoid Short circuit S/T E01
system
Electric
DWN1KA HSS EPC solenoid right Disconnection S/T CALL E03
system
Electric
DWN1KB HSS EPC solenoid right Short circuit S/T CALL E03
system
Electric
DWN1KY HSS EPC solenoid right Short circuit to power source line S/T CALL E04
system
Electric
DWN2KA HSS EPC solenoid left Disconnection S/T CALL E03
system
Electric
DWN2KB HSS EPC solenoid left Short circuit S/T CALL E03
system
DWN2KY HSS EPC solenoid left Short circuit to power source line S/T CALL E04 ing by failure
system
code, Part 4
Electric SEN02565-00
DWN5KA Fan pump TVC solenoid Disconnection S/T E01
system
Electric
DWN5KB Fan pump TVC solenoid Short circuit S/T E01
system
Electric
DWN5KY Fan pump TVC solenoid Short circuit to power source line S/T E02
system
Electric
DXA0KA HSS pump TVC solenoid Disconnection S/T E01
system
Electric
DXA0KB HSS pump TVC solenoid Short circuit S/T E01
system
Electric
DXA0KY HSS pump TVC solenoid Short circuit to power source line S/T E01
system
Electric
DXH4KA 1st clutch ECMV solenoid Disconnection S/T CALL E03
system
Electric
DXH4KB 1st clutch ECMV solenoid Short circuit S/T CALL E03
system
Electric
DXH4KY 1st clutch ECMV solenoid Short circuit to power source line S/T CALL E03
system
Electric
DXH5KA 2nd clutch ECMV solenoid Disconnection S/T CALL E03
system
Electric
DXH5KB 2nd clutch ECMV solenoid Short circuit S/T CALL E03
system
Electric
DXH5KY 2nd clutch ECMV solenoid Short circuit to power source line S/T CALL E03
system
D61EX, PX-15E0 7
Com-
History
cation
charge
Electric
DXH6KA 3rd clutch ECMV solenoid Disconnection S/T CALL E03
system
Electric
DXH6KB 3rd clutch ECMV solenoid Short circuit S/T CALL E03
system
Electric
DXH6KY 3rd clutch ECMV solenoid Short circuit to power source line S/T CALL E03
system
Reverse clutch ECMV sole- Electric
DXH7KA Disconnection S/T CALL E03
noid system Troubleshoot-
Reverse clutch ECMV sole- Electric ing by failure
DXH7KB Short circuit S/T CALL E03
noid system code, Part 4
Reverse clutch ECMV sole- Electric SEN02565-00
DXH7KY Short circuit to power source line S/T CALL E03
noid system
Forward clutch ECMV sole- Electric
DXH8KA Disconnection S/T CALL E03
noid system
DXH8KB Short circuit S/T CALL E03
noid system
DXH8KY Short circuit to power source line S/T CALL E03
noid system
8 D61EX, PX-15E0
Fuse locations 1
Connection table of fuse box
a This connection table shows the devices to which each power supply of the fuse box supplies power (A switch power
supply is a device which supplies power while the starting switch is in the ON position and a constant power supply is
a device which supplies power while the starting switch is in the OFF and ON positions).
a When carrying out troubleshooting related to the electrical system, you should check the fuses and fusible links to see
if the power is supplied normally.
Fuse box A [FS2]

Fuse Electric supply Fuse
Destinations of electric power distribution
No. source capacity (A)
Switched electric
1 5 Backup alarm
power supply
Steering and transmission controller (main electric power supply),
2 15
Constant power Radio
3 source 30 Electric power supply of machine (with 20A circuit breaker in the circuit)
4 30 Engine controller (main electric power supply)
Switched electric
5 30 Air conditioner (with 20A circuit breaker in the circuit)
power supply
Fuse box B [FS1]

1 20 Standby electric power supply
2 20 Horn, electrical intake air heater, air suspension seat
Switched electric
3 20 Front lamp, rear lamp
power supply
4 20 Steering and transmission controller (electric power supply to solenoid)
5 5 Engine controller (ACC signal)
Cab fuse box C

1 10 Accessory electric power supply (12 V electric power supply)
2 20 Radio, room lamp, cigarette lighter, additional light
3 Switched electric 20 Glass with heating wire
4 power supply 10 Rear wiper
5 10 Front wiper
6 10 Left and right door wipers
D61EX, PX-15E0 9
Fuse installation position and No.
Circuit breaker
No Connector No. Capacity (A) Circuit Remarks
Starting switch power supply (constant power
1 CB1 20 Installed in cover at bottom
supply)
of control panel
2 CB2 20 Air conditioner power supply
a Resetting operation of circuit breaker

Turn the starting switch OFF and push in projected reset button (3). If the reset button returns immedi-
ately, carry out troubleshooting to repair failed part.
10 D61EX, PX-15E0
D61EX, PX-15E0 11
SEN02559-00

© 2007 KOMATSU
All Rights Reserved
12
SEN02560-00
D61EX-15E0
D61PX-15E0

General information on troubleshooting
Points to remember when troubleshooting ..................................................................................................... 2
Sequence of events in troubleshooting........................................................................................................... 3
Checks before troubleshooting ....................................................................................................................... 4
Classification and procedures of troubleshooting ........................................................................................... 5
Contents of troubleshooting table ................................................................................................................... 6
Wiring table for connector pin numbers ........................................................................................................ 10
T-adapter box and T-adapter table................................................................................................................ 43
D61EX, PX-15E0 1
Points to remember when troubleshooting 1

k Stop the machine in a level place, and check that the safety pin, blocks, and parking brake are
securely fitted.
k When carrying out the operation with 2 or more workers, keep strictly to the agreed signals, and
do not allow any unauthorized person to come near.
k If the radiator cap is removed when the engine is hot, hot coolant may spurt out and cause
burns, so wait for the engine to cool down before starting troubleshooting.
k Be extremely careful not to touch any hot parts or to get caught in any rotating parts.
k When disconnecting wiring, always disconnect the negative (–) terminal of the battery first.
k When removing the plug or cap from a location which is under pressure from oil, water, or air,
always release the internal pressure first. When installing measuring equipment, be sure to con-
nect it properly.
The aim of troubleshooting is to pinpoint the basic cause of the failure, to carry out repairs swiftly, and to pre-
vent reoccurrence of the failure. When carrying out troubleshooting, and important point is of course to
understand the structure and function. However, a short cut to effective troubleshooting is to ask the operator
various questions to form some idea of possible causes of the failure that would produce the reported symp-
toms.
1. When carrying out troubleshooting, do not hurry to disassemble the components.

If components are disassembled immediately any failure occurs:
q Parts that have no connection with the failure or other unnecessary parts will be disassembled.
q It will become impossible to find the cause of the failure.
It will also cause a waste of manhours, parts, or oil or grease, and at the same time, will also lose the
confidence of the user or operator. For this reason, when carrying out troubleshooting, it is necessary to
carry out thorough prior investigation and to carry out troubleshooting in accordance with the fixed pro-
cedure.
2. Points to ask user or operator
1) Have any other problems occurred apart from the problem that has been reported?
2) Was there anything strange about the machine before the failure occurred?
3) Did the failure occur suddenly, or were there problems with the machine condition before this?
4) Under what conditions did the failure occur?
5) Had any repairs been carried out before the failure? When were these repairs carried out?
6) Has the same kind of failure occurred before?
3. Check before troubleshooting
1) Are abnormal symptoms detected in the machine?
2) Make checks before starting day's work.
3) Make checks of other items.
4) Check other maintenance items which can be visually checked and are considered necessary.
4. Confirming failure
Confirm the extent of the failure by yourself, and judge whether to treat it as a real failure or as a
problem of handling, operation, etc.
a When operating the machine to reenact the troubleshooting symptoms, do not carry out any inves-
tigation or measurement that may make the problem worse.
5. Troubleshooting
Use the results of the investigation and inspection in items 2 – 4 to narrow down the causes of
failure, then use the troubleshooting table or flowchart (matrix) to find out the failure part
exactly.
a The basic procedure for troubleshooting is as follows.
1] Start from the simple points.
2] Start from the most likely points.
3] Investigate other related parts or information.
6. Measures to remove root cause of failure
Even if the immediate failure is repaired, the same failure may occur again, unless the root cause
of the failure is repaired. To prevent this, always investigate why the cause of the failure
occurred. Then, remove the root cause.
2 D61EX, PX-15E0
Sequence of events in troubleshooting 1
D61EX, PX-15E0 3
Checks before troubleshooting 1
Judgement
Item Action
Value
1. Check fuel level — Add fuel
2. Check for impurities in fuel — Clean, drain
3. Check fuel filter — Replace
Lubricating oil, coolant
4. Check hydraulic oil level H–L Add oil

5. Check hydraulic oil strainer — Clean, drain
6. Check oil level in damper case — Add oil
7. Check power train oil level H–L Add oil
8. Check engine oil level (engine oil pan level) H–L Add oil
9. Check coolant level H–L Add water
10.Check dust indicator for clogging — Clean or replace
11. Check travel of brake pedal — Adjust
1. Check for abnormal noise, smell — Repair
mechanical
equipment
Hydraulic,
2. Check for oil leakage — Repair

3. Carry out air bleeding — Bleed air
1. Check for looseness, corrosion of battery terminal, wiring 20 – 30 V Tighten or replace

2. Check for looseness, corrosion of alternator terminal, wir- — Tighten or replace
ing
3. Check for looseness, corrosion of starting motor terminal, — Tighten or replace
wiring
4. Check battery voltage (engine stopped) — Replace
Electrical equipment
5. Check battery electrolyte level U. L – L. L Add or replace

6. Check for discolored, burnt, exposed wiring — Replace
7. Check for missing wiring clamps, hanging wire — Repair
8. Check for water leaking on wiring (pay particularly careful — Disconnect connec-
attention to water leaking on connectors or terminals) tor and dry
9. Check for blown, corroded fuses — Replace
10.Check alternator voltage (engine running at 1/2 throttle or After running Replace
above) for several
minutes:
27.5 – 29.5 V
11. Check operating sound of battery relay (starting switch — Replace
ON, OFF)
4 D61EX, PX-15E0
Classification and procedures of troubleshooting 1

Classification of troubleshooting
Mode Contents
Display of
Troubleshooting by failure code (Display of code)
code
E-mode Troubleshooting of electrical system
H-mode Troubleshooting of hydraulic and mechanical system
S-mode Troubleshooting of engine
Procedure for troubleshooting

If a phenomenon looking like a trouble occurs in the machine, select a proper troubleshooting No. according
to the following procedure, and then go to the corresponding troubleshooting section.
1. Procedure for troubleshooting to be taken when action code is displayed on machine monitor:
If an action code is displayed on the machine monitor, display the failure code in the failure code display
mode (for the electrical system and the mechanical system) of the machine monitor (EMMS).
Carry out troubleshooting in [Display of failure code] according to the displayed failure code.
a Each failure code “flashes” when the trouble corresponding to it is detected. Even if a failure code
“lights up” when the starting switch is turned ON, the trouble corresponding to that failure code may
not have been repaired (Some troubles can be detected by simply turning the starting switch ON).
a If a failure code is recorded, be sure to perform the operation for reproducing it to see if the trouble
corresponding to it has been repaired (For the method of reproducing the failure code, see the trou-
bleshooting in [Display of code]).
2. Procedure for troubleshooting to be taken when failure code is recorded:

If an action code is not displayed on the machine monitor, check for a failure code in the failure code dis-
play mode (for the electrical system and the mechanical system) of the machine monitor (EMMS).
If a failure code is recorded, carry out troubleshooting in [Display of code] according to that failure code.
a Each failure code “flashes” when the trouble corresponding to it is detected. Even if a failure code
“lights up” when the starting switch is turned ON, the trouble corresponding to that failure code may
not have been repaired (Some troubles can be detected by simply turning the starting switch ON).
a If a failure code is recorded, be sure to perform the operation for reproducing it to see if the trouble
corresponding to it has been repaired (For the method of reproducing the failure code, see the trou-
bleshooting in [Display of code]).
3. Procedure of troubleshooting to be taken when action code is not displayed and failure code is
not recorded:
If a failure code is not recorded in the machine monitor (EMMS), a trouble that the machine cannot find
out by itself may have occurred in the electrical system or hydraulic and mechanical system.
In this case, check the phenomenon looking like a trouble again and select the same phenomenon from
the table of “Phenomena looking like troubles and troubleshooting Nos.“, and then carry out trouble-
shooting related to that phenomenon in the “E-mode“, “H-mode“, or “S-mode“.
D61EX, PX-15E0 5
Contents of troubleshooting table 1

a The following information is summarized in the troubleshooting table and the related electrical circuit
diagram. Before carrying out troubleshooting, understand that information fully.
Action code Failure code

Machine Machine Trouble Trouble that appears in the machine
monitor monitor
display display
Contents of
State where the monitor panel or controller detects the trouble
trouble
Action of Action to be taken to protect the system and equipment when the monitor panel or controller
controller detects a trouble
Problem that
Problem that appears as an abnormality in the main unit by the action taken by the monitor
appears on
panel or controller (above)
machine
Related
Information related to troubles occurred or troubleshooting
information
Cause Standard value in normal state/Remarks on troubleshooting

<Described contents>
• Standard value in normal state required to judge the assumed
cause (good or not)
• Remarks required to judge whether the cause is good
1
<Phenomenon of defective harness>
• Disconnection in wiring
The connector connection is defective or wiring harness is discon-
nected.
• Ground fault
A harness not connected to the ground (earth) circuit comes into
contact with the ground (earth) circuit.
• Hot short circuit
2 A harness not connected to the power (24 V) circuit comes into
contact with the power (24 V) circuit.
Causes by which a • Short circuit
Possible trouble is assumed to A harness of an independent circuit abnormally comes into con-
causes and be defected tact with one of another circuit.
standard value (The order number
in normal state indicates a serial <Notes on troubleshooting>
number, not a priority (1) Method of indicating connector numbers and handling of T-
sequence.) adapter
For troubleshooting, insert or connect T-adapter shown below
3 unless especially specified.
• When “male” or “female” is not indicated for a connector num-
ber, disconnect the connector, and insert the T-adapters in
both the male and female.
• When “male” or “female” is indicated for a connector number,
disconnect connector, and insert the T-adapter in only either
the male or female.
(2) Pin number description sequence and tester lead handling For
troubleshooting, connect the plus (+) and minus (–) leads as
4 shown below unless especially specified.
• Connect the plus (+) lead to a pin or harness indicated in the
front.
• Connect the minus (–) lead to a pin or harness indicated in the
rear.
6 D61EX, PX-15E0
Related circuit diagram
This is the excerpted circuit diagram related to trouble

• Connector No.: Indicates (Model – No. of pins) (Color)
• “Connector No. and pin No.” from each branching/
merging point: Shows the ends of branch or source of
merging within the parts of the same wiring harness.
• Arrow (io): Roughly shows the location on the
machine.
D61EX, PX-15E0 7
Phenomena supposed to be failure and troubleshooting
Troubleshooting
No. Phenomena supposed to be failure Code
E-mode H-mode S-mode
display
Phenomena related to action code or error code
1 Action codes are displayed on monitor panel. Check error codes.
2 Error codes are displayed in error code display mode. q
Phenomena related to engine
3 Engine does not start easily (It always takes time to start) S-1
4 Engine does not crank E-1 (1) S-2 a)
Engine does not Engine cranks but exhaust smoke does not come
5 E-1 (2) S-2 b)
start out.
6 Exhaust smoke comes out but engine does not start S-2 c)
7 Engine speed does not rise sharply (Follow-up performance is low) S-3
8 Engine stops during operation S-4
9 Engine rotation is abnormal (Hunting) S-5
10 Output is insufficient (Power is low) S-6
11 Exhaust gas color is bad (Incomplete combustion) S-7
12 Oil is consumed much (or exhaust gas color is bad). S-8
13 Oil becomes dirty quickly. S-9
14 Fuel is consumed much S-10
15 Coolant contains oil (or it blows back or reduces) S-11
16 Engine oil pressure warning lamp lights up (Oil pressure lowers). S-12
17 Oil level rises (Water or fuel is mixed in oil). S-13
18 Water temperature rises too high (Overheat). S-14
19 Abnormal sound comes out. S-15
20 Vibration is excessive. S-16
21 Engine is not preheated normally (Manual preheating mechanism). E-2
Phenomena related to power train
22 There is no travel power (No drawbar pull). H-1
23 Machine does not move (At 2nd or 3rd speed). H-2
24 Machine does not move at all gear speeds. H-3
25 Machine travels only in one direction forward or in reverse. H-4
26 Time lag is excessive when shifting gear or changing direction. H-5
Machine does not turn.
27 H-6
(The machine does not turn leftward or rightward.)
28 Steering speed or power is insufficient. H-7
29 Brake does not work. H-8
30 The oil temperature of the power train overheats. H-9
Abnormal sound comes out from around HSS and work equipment pump
31 H-10
or HSS motor.
Phenomena related to work equipment
32 All work equipment speeds are slow. H-11
33 Work equipment does not move. H-12
34 Speed or power of blade lift is low H-13
35 Speed or power of blade tilt is low. H-14
36 Speed or power of blade angle is low. H-15
37 Speed or power of ripper lift is low. H-16
38 Hydraulic drift of blade lift is large. H-17
39 Hydraulic drift of blade tilt is large. H-18
40 Hydraulic drift of blade angle is large. H-19
41 Hydraulic drift of ripper lift is large. H-20
8 D61EX, PX-15E0
Troubleshooting
No. Phenomena supposed to be failure Code
E-mode H-mode S-mode
display
Phenomena related to monitor panel (Operator mode: Ordinary screen)
42 When starting switch is turned ON, any item does not light up E-3
When starting switch is turned ON, all items light up and none of them
43 E-4
goes off.
44 Charge level warning lamp flashes while engine is running E-5
45 Emergency warning items flash while engine is running. E-6
46 Preheating pilot lamp does not light up during preheating operation. E-7
47 Indication of engine coolant temperature gauge. E-8
48 Indication of power train temperature gauge is abnormal. E-9
49 Indication of hydraulic oil temperature gauge is abnormal. E-10
50 Indication of fuel level gauge is abnormal. E-11
51 Indication of gear speed, engine speed is abnormal. E-12
52 Indication of preset mode service meter is abnormal. E-13
53 Warning lamp does not flash or does not go off. E-14
54 Alarm buzzer does not sound or does not stop E-15
55 Auto shift-down does not work or is not released. E-16
56 Buzzer cancel switch does not work. E-17
57 Information switch does not work. E-18
58 Cleaning of fan are not work or cancelled. E-19
59 The preset mode does not be operated or cancelled. E-20
Phenomena related to monitor panel (Service mode: Special function screen)
60 System is not set in service mode or is not set out of service mode. E-21
Other phenomena
61 Backup alarm does not sound. E-22
62 Headlamp or rear lamp does not light up. E-23
63 Horn does not sound or does not stop. E-24
64 Wiper malfunctions E-25
65 Washing water does not come out. E-26
66 The air conditioner does not operate. E-27
67 KOMTRAX system malfunctions. E-28
D61EX, PX-15E0 9
Wiring table for connector pin numbers (Rev. 2006.11)
a The terms of male and female refer to the pins, while the terms of male housing and female housing
refer to the mating portion of the housing.
10 D61EX, PX-15E0
D61EX, PX-15E0 11
12 D61EX, PX-15E0
D61EX, PX-15E0 13
14 D61EX, PX-15E0
D61EX, PX-15E0 15
16 D61EX, PX-15E0
D61EX, PX-15E0 17
18 D61EX, PX-15E0
D61EX, PX-15E0 19
20 D61EX, PX-15E0
D61EX, PX-15E0 21
22 D61EX, PX-15E0
D61EX, PX-15E0 23
24 D61EX, PX-15E0
D61EX, PX-15E0 25
26 D61EX, PX-15E0
D61EX, PX-15E0 27
28 D61EX, PX-15E0
D61EX, PX-15E0 29
30 D61EX, PX-15E0
D61EX, PX-15E0 31
32 D61EX, PX-15E0
D61EX, PX-15E0 33
34 D61EX, PX-15E0
D61EX, PX-15E0 35
36 D61EX, PX-15E0
D61EX, PX-15E0 37
38 D61EX, PX-15E0
D61EX, PX-15E0 39
40 D61EX, PX-15E0
D61EX, PX-15E0 41
42 D61EX, PX-15E0
T-adapter box and T-adapter table0 1

(Rev. 2006.11)
a The vertical column indicates a part number of T-branch box or T-branch adapter while the horizontal
column indicates a part number of harness checker assembly.
T-adapter kit
Number of pins
799-601-2500
799-601-2700
799-601-2800
799-601-7000
799-601-7100
799-601-7400
799-601-7500
799-601-8000
799-601-9000
799-601-9100
799-601-9200
799-601-9300
799-601-4100
799-601-4200
Out of kit
Identification
Part No. Part name
symbol
799-601-2600 T-box (for ECONO) 21 q q q q q

799-601-3100 T-box (for MS) 37
799-601-3200 T-box (for MS) 37
799-601-3380 • Plate for MS (14-pin) q
799-601-3410 Adapter for BENDIX (MS) 24 MS-24P q
799-601-3510 Adapter for BENDIX (MS) 5 MS-5S q
799-601-3470 Case q
799-601-2710 Adapter for MIC 5 MIC-5P q q q
799-601-2720 Adapter for MIC 13 MIC-13P q q q
799-601-2730 Adapter for MIC 17 MIC-17P q q q q q q
799-601-2740 Adapter for MIC 21 MIC-21P q q q q q q
799-601-2950 Adapter for MIC 9 MIC-9P q q q q
799-601-2750 Adapter for ECONO 2 ECONO2P q q
799-601-2810 Adapter for DLI 8 DLI-8P q q
799-601-2840 Extension cable (ECONO type) 12 ECONO12P q q q
799-601-2850 Case q
799-601-4210 Adapter for DRC 50 DRC50 q
799-601-7010 Adapter for X (T-adapter) 1 q q
799-601-7020 Adapter for X 2 X2P q q q q
799-601-7050 Adapter for SWP 6 SW6P q q q
799-601-7060 Adapter for SWP 8 SW8P q q q
799-601-7310 Adapter for SWP 12 SW12P q
799-601-7070 Adapter for SWP 14 SW14P q q
799-601-7320 Adapter for SWP 16 SW16P q
799-601-7080 Adapter for M (T-adapter) 1 q q
799-601-7090 Adapter for M 2 M2P q q q q
D61EX, PX-15E0 43
T-adapter kit
Number of pins
799-601-2500
799-601-2700
799-601-2800
799-601-7000
799-601-7100
799-601-7400
799-601-7500
799-601-8000
799-601-9000
799-601-9100
799-601-9200
799-601-9300
799-601-4100
799-601-4200
Out of kit
Identification
Part No. Part name
symbol

799-601-7340 Adapter for M 8 M8P q
799-601-7140 Adapter for S 8 S8P q q q q
799-601-7150 Adapter for S (White) 10 S10P q q q q
799-601-7160 Adapter for S (Blue) 12 S12P q q q
799-601-7170 Adapter for S (Blue) 16 S16P q q q q
799-601-7330 Adapter for S (White) 16 S16PW q
799-601-7350 Adapter for S (White) 12 S12PW q
799-601-7180 Adapter for AMP040 8 A8P q
799-601-7190 Adapter for AMP040 12 A12P q q
799-601-7210 Adapter for AMP040 16 A16P q q q q
799-601-7220 Adapter for AMP040 20 A20P q q q q
799-601-7230 Short connector for X 2 q q q q
799-601-7240 Case q q
799-601-7270 Case q
799-601-7510 Adapter for 070 10 07-10 q
799-601-7520 Adapter for 070 12 07-12 q
799-601-7530 Adapter for 070 14 07-14 q
799-601-7540 Adapter for 070 18 07-18 q
799-601-7550 Adapter for 070 20 07-20 q
799-601-7360 Adapter for relay 5 REL-5P q
799-601-7370 Adapter for relay 6 REL-6P q
799-601-7380 Adapter for JFC 2 q
799-601-9010 Adapter for DTM 2 DTM2 q q
799-601-9020 Adapter for DT 2 DT2 q q q q
799-601-9030 Adapter for DT 3 DT3 q q
799-601-9040 Adapter for DT 4 DT4 q q q q
799-601-9050 Adapter for DT 6 DT6 q q
799-601-9060 Adapter for DT (Gray) 8 DT8GR q q
799-601-9070 Adapter for DT (Black) 8 DT8B q q
799-601-9080 Adapter for DT (Green) 8 DT8G q q
799-601-9090 Adapter for DT (Brown) 8 DT8BR q q
799-601-9110 Adapter for DT (Gray) 12 DT12GR q q
799-601-9120 Adapter for DT (Black) 12 DT12B q q
799-601-9130 Adapter for DT (Green) 12 DT12G q q
799-601-9140 Adapter for DT 12 DT12BR q q
799-601-9210 Adapter for HD30-18 8 D18-8 q q
799-601-9310 Plate for HD30 (24-pin) q q q
44 D61EX, PX-15E0
T-adapter kit
Number of pins
799-601-2500
799-601-2700
799-601-2800
799-601-7000
799-601-7100
799-601-7400
799-601-7500
799-601-8000
799-601-9000
799-601-9100
799-601-9200
799-601-9300
799-601-4100
799-601-4200
Out of kit
Identification
Part No. Part name
symbol
799-601-9320 T-box (for DT/HD) 12 q q q

799-601-9330 Case q
799-601-9340 Case q
799-601-9350 Adapter for DRC 40 DRC-40 q
799-601-9360 Adapter for DRC 24 DRC-24 q
799-601-9410* Socket for engine (CRI-T2) 2 G q
Adapter for engine (CRI-T2)
799-601-9420 3 A3 q q
Adapter for engine (CRI-T3) PFUEL
Socket for engine (CRI-T2)
799-601-9430* 2 P q q
Socket for engine (CRI-T3) PCV
799-601-9440* Socket for engine (CRI-T2) 3 1,2,3 q
795-799-5520* Socket for engine (HPI-T2) 2 S q
Socket for engine (HPI-T2)
795-799-5530* Socket for engine (CRI-T3) 2 C q q
Temperature sensor
Socket for engine (HPI-T2)
795-799-5540* 2 A q q
Socket for engine (CRI-T3) TIM
795-799-5460 Cable for engine (HPI-T2) 3 q
799-601-4110 Adapter for engine (140-T3) PIM 4 ITT3N q
799-601-4130 Adapter for engine (CRI-T3) NE, CAM 3 FCIN q q
799-601-4140 3 FCIG q q
Atomosphere pressure
799-601-4150 Adapter for engine (CRI-T3) POIL 3 FCIB q q
799-601-4160 2 4160 q q
Oil pressure switch
799-601-4180 Adapter for engine (CRI-T3) PEVA 3 4180 q q
799-601-4190* 3 1,2,3L q q
Commonrail pressure
799-601-4230* 4 1,2,3,4C q q
Air intake pressure/temperature
799-601-4240* Socket for engine (CRI-T3) PAMB 3 1,2,3A q q
799-601-4250* Socket for engine (CRI-T3) PIM 3 1,2,3B q q
799-601-4330* Socket for engine (CRI-T3) G 3 1,2,3,G q q
799-601-4340* 2 2,PA q q
Pump actuator
Socket for engine (CRI-T3)(95)
799-601-4380* 4 1,2,3,4T q
Air intake pressure/temperature
799-601-4260 Adapter for controller (ENG) 4 DTP4 q q
799-601-4211 Adapter for controller (ENG) 50 DRC50 q
799-601-4220 Adapter for controller (ENG) 60 DRC60 q
799-601-4390* Socket for controller (95 ENG) 60 q
799-601-4280 Box for controller (PUMP) 121 q
799-601-9720 Adapter for controller (HST) 16 HST16A q
799-601-9710 Adapter for controller (HST) 16 HST16B q
799-601-9370 Adapter for controller (HST) 26 HST26A q
“*” Shows not T-adapter but socket.
D61EX, PX-15E0 45
SEN02560-00

© 2007 KOMATSU
All Rights Reserved
46
SEN02561-00
D61EX-15E0
D61PX-15E0

Troubleshooting by failure code
(Display of code), Part 1
Failure code [1500L0] Transmission clutch: Dual engagement ...................................................................... 3
Failure code [15SAL1] Forward clutch: Fill signal is ON when command current is OFF .............................. 4
Failure code [15SALH] Forward clutch: Fill signal is OFF when command current is ON.............................. 6
Failure code [15SBL1] Reverse clutch: Fill signal is ON when command current is OFF .............................. 8
Failure code [15SBLH] Reverse clutch: Fill signal is OFF when command current is ON............................ 10
Failure code [15SEL1] 1st clutch: Fill signal is ON when command current is OFF ..................................... 12
Failure code [15SELH] 1st clutch: Fill signal is OFF when command current is ON .................................... 14
Failure code [15SFL1] 2nd clutch: Fill signal is ON when command current is OFF .................................... 16
Failure code [15SFLH] 2nd clutch: Fill signal is OFF when command current is ON ................................... 18
Failure code [15SGL1] 3rd clutch: Fill signal is ON when command current is OFF .................................... 20
Failure code [15SGLH] 3rd clutch: Fill signal is OFF when command current is ON ................................... 22
Failure code [AB00MA] Alternator: Malfunction ............................................................................................ 24
Failure code [B@BAZG] Engine oil: Oil pressure too low............................................................................. 24
Failure code [B@BCNS] Radiator coolant: Overheat ................................................................................... 25
D61EX, PX-15E0 1
Failure code [B@CENS] Power train oil: Overheat....................................................................................... 25

Failure code [B@HANS] Hydraulic oil: Overheat .......................................................................................... 26
Failure code [CA111] Engine controller: Abnormality in controller ................................................................ 27
Abnormal speed sensor signal.................................................................................................................. 27
Failure code [CA122] Charge pressure sensor too high: Excessively high voltage detected ....................... 28
Failure code [CA123] Charge pressure sensor too low: Excessively low voltage detected.......................... 30
Failure code [CA131] Decelerator pedal sensor too high: Excessively high voltage detected ..................... 32
Failure code [CA132] Decelerator pedal sensor too low: Excessively low voltage detected ........................ 34
Failure code [CA144] Coolant temperature sensor too high: Excessively high voltage detected ................. 36
Failure code [CA145] Coolant temperature sensor too low: Excessively low voltage detected .................... 38
Failure code [CA153] Charge temperature sensor too high: Excessively high voltage detected.................. 40
Failure code [CA154] Charge temperature sensor too low: Excessively low voltage detected .................... 42
Failure code [CA155] Charge temperature too high and engine speed derated:
Exceeded upper control limit of temperature ............................................................................................ 44
Failure code [CA187] Sensor power source 2 too low: Excessively low voltage detected ........................... 46
Failure code [CA221] Atmospheric pressure sensor too high: Excessively high voltage detected ............... 48
Failure code [CA222] Atmospheric pressure sensor too low: Excessively low voltage detected.................. 50
Failure code [CA227] Sensor power source 2 too high: Excessively high voltage detected......................... 52
Failure code [CA234] Engine over speed: Excessively high speed .............................................................. 54
Excessively low voltage detected.............................................................................................................. 55
Failure code [CA271] IMV/PCV1 short circuit: Short circuit .......................................................................... 56
Failure code [CA272] IMV/PCV1 disconnection: Disconnection ................................................................... 58
2 D61EX, PX-15E0
Failure code [1500L0] Transmission clutch: Dual engagement 1

Action code Failure code Transmission clutch: Dual engagement
Trouble
CALL E03 1500L0 (Steering and transmission controller system)
• Of the failure codes related to the transmission clutch, the following codes were displayed at the
same time. (Gear speed is limited.)
(1) Either [DXH4KA] or [DXH4KB] and either [DXH5KA] or [DXH5KB]
• Of the failure codes related to the transmission clutch, the following codes were displayed at the
same time. (Machine can not travel.)
(2) Either [DXH8KA] or [DXH8KB] and either [DXH7KA] or [DXH7KB]
Contents of
(3) Either of [DXH6KA] or [DXH6KB] and (1) above
trouble
(4) [15SALH] and [15SBLH]
(5) Either [15SAL1] or [DXH8KY] and either [15SBL1] or [DXH7KY]
(6) [15SELH], [15SFLH], and [15SGLH]
(7) Either [15SEL1] or [DXH4KY] and either [15SFL1] or [DXH5KY]
(8) Either [15SEL1] or [DXH4KY] and either [15SGL1] or [DXH6KY]
(9) Either [15SFL1] or [DXH5KY] and either [15SGL1] or [DXH6KY]
Action of • Flashes warning lamp and turns on alarm buzzer.
controller • Limits operation of engine and transmission.
• The auto shift down function does not work.
Problem that
• Once machine is stopped, engine speed is limited to medium (half).
appears on
• Once machine is stopped, traveling is limited to specific gear speeds.
machine
• Machine cannot travel.
Related
• Duplication of failure code: Engine start + travel
information

Possible Confirm the failure codes displayed at the same time, then carry out troubleshooting for the codes.
causes and [15SAL1], [15SALH], [15SBL1], [15SBLH], [15SEL1], [15SELH], [15SFL1], [15SFLH], [15SGL1],
standard value [15SGLH]
in normal state [DXH4KA], [DXH4KB], [DXH4KY], [DXH5KA, [DXH5KB], [DXH5KY], [DXH6KA], [DXH6KB],
[DXH6KY], [DXH7KA, [DXH7KB], [DXH7KY], [DXH8KA], [DXH8KB], [DXH8KY]
D61EX, PX-15E0 3
Failure code [15SAL1] Forward clutch: Fill signal is ON when command

current is OFF 1
Action code Failure code Forward clutch: Fill signal is ON when command current is OFF
Trouble
CALL E03 15SAL1 (Steering and transmission controller system)
Contents of • The fill switch signal does not become off when the output of the transmission forward clutch sole-
trouble noid circuit has stopped.
• Flashes warning lamp and turns on alarm buzzer.
Action of
• Decides that engine speed is neutral (N) at reverse operation.
controller
• Limits operation of engine and transmission.
Problem that
appears on
• Once machine is stopped, travel is limited to F1.
machine
• The input state (ON/OFF) from the forward clutch fill switch can be checked in monitoring mode.
Related
(Code 31520: Transmission fill switch input state)
information
• Duplication of failure code: Engine start + travel neutral or travel reverse

a Prepare with starting switch OFF, then start the engine for troubleshoot-
ing.
Defective forward
1 clutch fill switch FSW (male) PCCS lever Resistance
(internal short circuit) Between (1) – N Min. 1 Mz
chassis ground F (Forward) Max. 1 z
Defective harness a Prepare with starting switch OFF, then start troubleshooting with starting
Possible grounding switch OFF.
2
causes and (Contact with ground Between ground and wiring harness between ST2
standard value circuit) Resistance Min. 1 Mz
(female) (35) – FSW (female) (1)
in normal state
ing.
Defective steering and ST2 PCCS lever Voltage
3
transmission controller
Between (35) – N 5 – 11 V
chassis ground F (Forward) Max. 1 V
When no fault is detected in the electric system, the hydraulic pressure
Defective hydraulic
4 system is assumed to be abnormal. Carry out the related troubleshooting
pressure system
(H-mode).
4 D61EX, PX-15E0
Circuit diagram related to transmission forward clutch ECMV
D61EX, PX-15E0 5
Failure code [15SALH] Forward clutch: Fill signal is OFF when

command current is ON 1
Action code Failure code Forward clutch: Fill signal is OFF when command current is ON
Trouble
CALL E03 15SALH (Steering and transmission controller system)
Contents of • The fill switch signal does not become ON when the output of the transmission forward clutch sole-
trouble noid circuit is ON.
Action of
• Determines to apply neutral (N) to forward operation.
controller
Problem that
appears on
• Once machine is stopped, travel is limited to R1.
machine
• The input state (ON/OFF) from the forward clutch fill switch can be checked in monitoring mode.
Related
information
• Duplication of failure code: Engine start + Forward travel

ing.
Defective forward
1 clutch fill switch FSW (male) PCCS lever Resistance
chassis ground F (Forward) Max. 1 z
Disconnection in wiring a Prepare with starting switch OFF, then start troubleshooting with starting
harness switch OFF.
Possible
2 (Disconnection in wiring
causes and
or loose connection of Wiring harness between ST2 (female) (35) – Resistance Max. 1 z
standard value FSW (female) (1)
connector)
in normal state
ing.
3
Between (35) – N 5 – 11 V
chassis ground F (Forward) Max. 1 V
Defective hydraulic
pressure system
(H-mode).
6 D61EX, PX-15E0
D61EX, PX-15E0 7
Failure code [15SBL1] Reverse clutch: Fill signal is ON when command

current is OFF 1
Action code Failure code Reverse clutch: Fill signal is ON when command current is OFF
Trouble
CALL E03 15SBL1 (Steering and transmission controller system)
Contents of • The fill switch signal does not become off when the output of the transmission reverse clutch sole-
trouble noid circuit has stopped.
Action of
• Determines to apply neutral (N) to forward operation.
controller
Problem that
appears on
machine
• The input state (ON/OFF) from the reverse clutch fill switch can be checked in monitoring mode.
Related
information
• Duplication of failure code: Engine start + travel neutral or travel forward

ing.
Defective reverse
1 clutch fill switch RSW (male) PCCS lever Resistance
chassis ground R (Reverse) Max. 1 z
2
(female) (25) – RSW (female) (1)
in normal state
ing.
3
Between (25) – N 5 – 11 V
chassis ground R (Reverse) Max. 1 V
Defective hydraulic
pressure system
(H-mode).
8 D61EX, PX-15E0
Circuit diagram related to transmission reverse clutch ECMV
D61EX, PX-15E0 9
Failure code [15SBLH] Reverse clutch: Fill signal is OFF when

command current is ON 1
Action code Failure code Reverse clutch: Fill signal is OFF when command current is ON
Trouble
CALL E03 15SBLH (Steering and transmission controller system)
Contents of • The fill switch signal does not become ON when the output of the transmission reverse clutch sole-
trouble noid circuit is ON.
Action of
• Decides that engine speed is neutral (N) at reverse operation.
controller
Problem that
appears on
machine
• The input state (ON/OFF) from the reverse clutch fill switch can be checked in monitoring mode.
Related
information
• Duplication of failure code: Engine start + reverse travel

ing.
Defective reverse
1 clutch fill switch RSW (male) PCCS lever Resistance
chassis ground R (Reverse) Max. 1 z
Possible harness switch OFF.
2
causes and (Disconnection or poor Wiring harness between ST2 (female) (25) –
standard value connector contact) Resistance Max. 1 z
RSW (female) (1)
in normal state
ing.
3
Between (25) – N 5 – 11 V
chassis ground R (Reverse) Max. 1 V
Defective hydraulic
pressure system
(H-mode).
10 D61EX, PX-15E0
D61EX, PX-15E0 11
Failure code [15SEL1] 1st clutch: Fill signal is ON when command

current is OFF 1
Action code Failure code 1st clutch: Fill signal is ON when command current is OFF
Trouble
CALL E03 15SEL1 (Steering and transmission controller system)
Contents of • The fill switch signal does not become off when the output of the transmission 1st clutch solenoid
trouble circuit has stopped.
Problem that
appears on
• Once machine is stopped, travel is limited to F1 and R1.
machine
• The input state (ON/OFF) from the 1st clutch fill switch can be checked in monitoring mode.
Related
information
• Duplication of failure code: Engine start + F1 or R1 o travel neutral

ing.
Defective 1st clutch fill
1 switch 1SW (male) PCCS lever Resistance
(internal short circuit) Between (1) – Other than F1 and R1 Min. 1 Mz
chassis ground F1 and R1 Max. 1 z
2
(female) (19) – 1SW (female) (1)
in normal state
ing.
3
Between (19) – Other than F1 and R1 5 – 11 V
chassis ground F1 and R1 Max. 1 V
Defective hydraulic
pressure system
(H-mode).
12 D61EX, PX-15E0
Circuit diagram related to transmission 1st clutch ECMV
D61EX, PX-15E0 13
Failure code [15SELH] 1st clutch: Fill signal is OFF when command
current is ON 1
Action code Failure code 1st clutch: Fill signal is OFF when command current is ON
Trouble
CALL E03 15SELH (Steering and transmission controller system)
Contents of • The fill switch signal does not become ON when the output of the transmission 1st clutch solenoid
trouble circuit is ON.
Problem that • The auto shift down function does not work.
appears on • Once machine is stopped, engine speed is limited to medium (half).
machine • Once machine is stopped, travel is limited to F2 and R2.
• The input state (ON/OFF) from the 1st clutch fill switch can be checked in monitoring mode.
Related
information
• Duplication of failure code: Engine start + F1 or R1 travel

ing.
Defective 1st clutch fill
2
1SW (female) (1)
in normal state
ing.
3
Defective hydraulic
pressure system
(H-mode).
14 D61EX, PX-15E0
D61EX, PX-15E0 15
Failure code [15SFL1] 2nd clutch: Fill signal is ON when command

current is OFF 1
Action code Failure code 2nd clutch: Fill signal is ON when command current is OFF
Trouble
CALL E03 15SFL1 (Steering and transmission controller system)
Contents of • The fill switch signal does not become off when the output of the transmission 2nd clutch solenoid
• The input state (ON/OFF) from the 2nd clutch fill switch can be checked in monitoring mode.
Related
information

ing.
Defective 2nd clutch fill
2
in normal state
ing.
3
Defective hydraulic
pressure system
(H-mode).
16 D61EX, PX-15E0
Circuit diagram related to transmission 2nd clutch ECMV
D61EX, PX-15E0 17
Failure code [15SFLH] 2nd clutch: Fill signal is OFF when command
current is ON 1
Action code Failure code 2nd clutch: Fill signal is OFF when command current is ON
Trouble
CALL E03 15SFLH (Steering and transmission controller system)
Contents of • The fill switch signal does not become ON when the output of the transmission 2nd clutch solenoid
Problem that
appears on
machine
• The input state (ON/OFF) from the 2nd clutch fill switch can be checked in monitoring mode.
Related
information

ing.
Defective 2nd clutch fill
2
2SW (female) (1)
in normal state
ing.
3
Defective hydraulic
pressure system
(H-mode).
18 D61EX, PX-15E0
D61EX, PX-15E0 19
Failure code [15SGL1] 3rd clutch: Fill signal is ON when command

current is OFF 1
Action code Failure code 3rd clutch: Fill signal is ON when command current is OFF
Trouble
CALL E03 15SGL1 (Steering and transmission controller system)
Contents of • The fill switch signal does not become off when the output of the transmission 3rd clutch solenoid
• The input state (ON/OFF) from the 3rd clutch fill switch can be checked in monitoring mode.
Related
information

ing.
Defective 3rd clutch fill
2
in normal state
ing.
3
Defective hydraulic
pressure system
(H-mode).
20 D61EX, PX-15E0
Circuit diagram related to transmission 3rd clutch ECMV
D61EX, PX-15E0 21
Failure code [15SGLH] 3rd clutch: Fill signal is OFF when command
current is ON 1
Action code Failure code 3rd clutch: Fill signal is OFF when command current is ON
Trouble
CALL E03 15SGLH (Steering and transmission controller system)
Contents of • The fill switch signal does not become ON when the output of the transmission 3rd clutch solenoid
Problem that
appears on
machine
• The input state (ON/OFF) from the 3rd clutch fill switch can be checked in monitoring mode.
Related
information

ing.
Defective 3rd clutch fill
2
3SW (female) (1)
in normal state
ing.
3
Defective hydraulic
pressure system
(H-mode).
22 D61EX, PX-15E0
D61EX, PX-15E0 23
Failure code [AB00MA] Alternator: Malfunction 1

Action code Failure code Alternator: Malfunction
Trouble
— AB00MA (Mechanical system)
Contents of
• While engine is running, charge level caution lamp flashes.
trouble
Action of
• Flashes warning lamp.
controller
Problem that
appears on • If the machine is operated in the same condition, battery may be discharged.
machine
Related
• Duplication of failure code: Start the engine.
information

Defective battery
It is suspected that the problem causing the detection of defective battery
Possible charge
1 charge is currently occurring or occurred in the past. Investigate the cause
causes and (When system is nor-
and damage condition, and correct it.
standard value mal)
in normal state Carry out troubleshooting of charge level caution lamp system in accor-
Defective charge level
2 dance with ‚“While engine is running, battery charge level caution lamp
caution lamp system
flashes” in E-mode.
Failure code [B@BAZG] Engine oil: Oil pressure too low 1

Action code Failure code Engine oil: Oil pressure too low
Trouble
— B@BAZG (Mechanical system)
Contents of
• While engine is running, engine oil pressure abnormality occurred.
trouble
Action of • Flashes warning lamp and turns on alarm buzzer. (Function of monitor panel)
controller • Limits operation of engine.
Problem that
• If the machine is operated in the same condition, engine may be damaged.
appears on
• After warning, engine speed is limited to medium (half).
machine
Related • Engine oil pressure caution symbol of monitor panel flashes and the failure code is recorded.
information • Duplication of failure code: Start the engine.

Reduction of engine oil
It is suspected that the problem causing the detection of engine oil pres-
Possible pressure
1 sure reduction is currently occurring or occurred in the past. Investigate
the cause and damage condition, and correct it.
standard value mal)
in normal state Defective engine oil Engine oil pressure switch system is possibly defective if no problem is
2 pressure switch sys- found in cause 1.
tem Carry out troubleshooting for failure code [CA435].
24 D61EX, PX-15E0
Failure code [B@BCNS] Radiator coolant: Overheat 1

Action code Failure code Radiator coolant: Overheat
Trouble
— B@BCNS (Mechanical system)
Contents of
• While engine is running, radiator coolant temperature caution lamp flashes.
trouble
Action of • Flashes warning lamp and turns on alarm buzzer. (Function of monitor panel)
controller • Limits operation of engine.
Problem that
• If the machine is operated in the same condition, engine may be damaged.
appears on
• After warning, engine output is limited to half of rated hosepower.
machine
Related
information

Engine coolant over-
It is suspected that the problem causing a detection of engine coolant
Possible heats
1 overheat is currently occurring or occurred in the past. Investigate the
cause and damage condition, and correct it.
standard value mal)
in normal state Defective engine cool- Engine coolant temperature sensor is possibly defective if no problem is
2 ant temperature sen- found in cause 1.
sor system Carry out troubleshooting for failure codes [CA144] and [CA145].
Failure code [B@CENS] Power train oil: Overheat 1

Action code Failure code Power train oil: Overheat
Trouble
— B@CENS (Mechanical system)
Contents of
• While engine is running, power train oil temperature caution lamp flashes.
trouble
Action of
• Flashes warning lamp and turns on alarm buzzer. (Function of monitor panel)
controller
Problem that
appears on • If the machine is operated in the same condition, power train may be damaged.
machine
Related
information

Power train oil temper-
It is suspected that the problem causing a detection of power train oil over-
Possible ature overheat
1 heat is currently occurring or occurred in the past. Investigate the cause
and damage condition, and correct it.
standard value mal)
in normal state Defective caution lamp Carry out troubleshooting of power train oil temperature caution lamp sys-
2 system for power train tem in accordance with‚ “While engine is running, emergency warning item
oil temperature flashes” in E-mode.
D61EX, PX-15E0 25
Failure code [B@HANS] Hydraulic oil: Overheat 1

Action code Failure code Hydraulic oil: Overheat
Trouble
— B@HANS (Mechanical system)
Contents of
• While engine is running, hydraulic oil temperature caution lamp flashes.
trouble
Action of
• Flashes warning lamp and turns on alarm buzzer. (Function of monitor panel)
controller
Problem that
• If the machine is operated in the same condition, the devices for hydraulic circuit of the work equip-
appears on
ment may be damaged.
machine
Related
information

Hydraulic oil overheat It is suspected that the problem causing a detection of hydraulic oil over-
Possible
1 (When system is nor- heat is currently occurring or occurred in the past. Investigate the cause
causes and
mal) and damage condition, and correct it.
standard value
in normal state Defective hydraulic oil Carry out troubleshooting of hydraulic oil temperature caution lamp circuit
2 temperature caution in accordance with “While engine is running, emergency warning item
lamp system flashes” in E-mode.
26 D61EX, PX-15E0
Failure code [CA111] Engine controller: Abnormality in controller 1

Action code Failure code Engine controller: Abnormality in controller
Trouble
CALL E04 CA111 (Engine controller system)
Contents of
• An abnormality occurs in internal memory or internal power supply circuit.
trouble
Action of
• Takes no particular action.
controller
Problem that
• Engine can not start.
appears on
• Engine may stop during operation or may not start during a stop.
machine
Related
information
Possible Cause Standard value in normal state/Remarks on troubleshooting

causes and
standard value 1 Carry out troubleshooting for failure code [CA757].
in normal state

Abnormal speed sensor signal 1
Action code Failure code Abnormal engine Ne and Bkup speed sensors: Abnormal speed sensor
Trouble signal
Contents of
• Abnormality occurred in both signals of engine Ne speed sensor and engine Bkup speed sensor.
trouble
Action of
• Takes no particular action.
controller
Problem that
• Engine stops.
appears on
• Engine does not start.
machine
Related
• Duplication of failure code: start the engine.
information

Defective Ne speed
1 Carry out troubleshooting for failure code [CA689].
sensor system
Defective Bkup speed
2 Carry out troubleshooting for failure code [CA778].
sensor system
Possible Defective installation of Ne speed sensor may be installed defectively. Check it directly.
3
causes and Ne speed sensor (Defective installation of sensor itself, internal defect of supply pump, etc.)
standard value Defective installation of Bkup speed sensor may be installed defectively. Check it directly.
in normal state 4
Bkup speed sensor (Defective installation of sensor itself, internal defect of supply pump, etc.)
Defective connection
Ne speed sensor and Bkup speed sensor may be connected defectively
5 of sensor connector
(or connected to wrong parts). Check them directly.
(Wrong connection)
Defective engine con- If causes 1 – 5 are not detected, engine controller may be defective.
6
troller (Since trouble is in system, troubleshooting cannot be carried out.)
D61EX, PX-15E0 27
Failure code [CA122] Charge pressure sensor too high: Excessively

high voltage detected 1
Action code Failure code Charge pressure sensor too high: excessively high voltage detected
Trouble
Contents of • Excessively high voltage is detected at pressure signal circuit of boost pressure and temperature
trouble sensor.
Action of
• Operates with a fixed charge pressure.
controller
Problem that
appears on • Engine output is reduced.
machine
• The signal voltage of boost pressure and temperature sensor on boost pressure side can be
Related checked in monitoring function.
information (Code: 36501 Boost pressure sensor voltage)
• Duplication of failure code: turn ON the starting switch.

Defective sensor If failure code [CA227] is displayed at the same time, carry out trouble-
1
power source 2 system shooting for that in advance.
a Prepare with starting switch OFF, then start troubleshooting with starting
switch ON.
Defective boost pres- C4 Voltage
sure and temperature
2 Between (2) – (4) Power source 4.75 – 5.25 V
sensor
[pressure signal circuit] Since voltage is measured with the harness connected, further diagnose
the harness and the controller if the voltage is not normal, and then make
judgment after it is determined that there is no other defective cause.
Hot short of harness a Prepare with starting switch OFF, then start troubleshooting with starting
(a contact with 5 V cir- switch ON.
3
cuit or Between ground and wiring harness between
Possible 24 V circuit) Voltage Max. 1 V
CE01 (female) (44) – C4 (female) (1)
causes and
standard value
Harness short switch OFF.
in normal state
4 (Harness internal Wiring harness between CE01(female) (44) – C4
short) Min.
(female) (1) and wiring harness among Resistance
100 kz
CE01(female) (37) – S10 – C4 (female) (2)
The connections among boost pressure and temperature sensor – engine
harness – engine controller are suspected to be defective. Visually check
it.
Defective wiring
5 • Connector is loose, lock is broken, seal is broken
harness connector
• Pin is corroded, bent, broken, pushed in, expanded.
• Moisture in connector, entry of dirt or sand, etc., and insufficient insula-
tion
Defective engine switch ON.
6
controller CE01 Voltage
Between (37) – (47) Power source 4.75 – 5.25 V
28 D61EX, PX-15E0
Circuit diagram related to boost pressure and temperature sensor
D61EX, PX-15E0 29
Failure code [CA123] Charge pressure sensor too low: Excessively low
voltage detected 1
Action code Failure code Charge pressure sensor too low: Excessively low voltage detected
Trouble
Contents of • Excessively low voltage is detected at pressure signal circuit of boost pressure and temperature
trouble sensor.
Action of
• Operates with a fixed charge pressure.
controller
Problem that
machine
• The signal voltage of boost pressure and temperature sensor on boost pressure side can be
information (Code: 36501 Boost pressure sensor voltage)

1
power source 2 system shooting for that first.
switch ON.
Defective boost pres- C4 Voltage
sensor
[pressure signal circuit] Since voltage is measured with the harness connected, further diagnose
grounding switch OFF.
3
(Contact with ground Between ground and wiring harness between Min.
Possible Resistance
circuit) CE01 (female) (44) – C4 (female) (1) 100 kz
causes and
standard value a Prepare with starting switch OFF, then start troubleshooting with starting
in normal state Harness short switch OFF.
4 (Harness internal Wiring harness between CE01(female) (44) – C4
short) Min.
(female) (1) and wiring harness among Resistance
100 kz
CE01(female) (47) – S11 – C4 (female) (4)
harness – engine controller are suspected to be defective. Visually check it.
Defective wiring • Connector is loose, lock is broken, seal is broken
5
harness connector • Pin is corroded, bent, broken, pushed in, expanded.
tion
6
30 D61EX, PX-15E0
D61EX, PX-15E0 31
Failure code [CA131] Decelerator pedal sensor too high: Excessively

Action code Failure code Decelerator pedal sensor too high: Excessively high voltage detected
Trouble
Contents of
• Excessively high voltage is detected at signal circuit of decelerator pedal.
trouble
• Operates with the fixed value that is same as the value just before the abnormality is detected, if
Action of abnormality occurs with the starting switch in the ON position.
controller • If the starting switch is turned to the ON position in the same abnormal condition, the controller
operates with 100% value.
Problem that
appears on • Engine speed cannot be controlled by decelerator pedal.
machine
• The signal voltage of decelerator pedal can be checked in monitoring mode.
Related
(Code: 31703 Decelerator voltage)
information

Defective decelerator
If failure code [CA2185] is displayed at the same time, carry out trouble-
1 pedal sensor power
shooting for that first.
supply circuit
switch ON.
DCL Voltage
2 Between (A) – (C) Power source 4.75 – 5.25 V
pedal
Since voltage is measured with the harness connected, further diagnose
Hot short of harness switch ON.
3 (a contact with 5 V cir-
Possible Between ground and wiring harness between
cuit or 24 V circuit) Voltage Max. 1 V
causes and CE02 (female) (9) – DCL (female) (B)
standard value
in normal state
4 (Harness internal Wiring harness between CE02 (female) (9) – DCL
short) Min.
(female) (B) and wiring harness between CE02 Resistance
100 kz
(female) (22) – DCL (female) (A)
The connections among decelerator pedal – body harness – engine con-
troller are suspected to be defective. Visually check it.
5
tion
6
32 D61EX, PX-15E0
Circuit diagram related to decelerator pedal
D61EX, PX-15E0 33
Failure code [CA132] Decelerator pedal sensor too low: Excessively low
voltage detected 1
Action code Failure code Decelerator pedal sensor too low: excessively low voltage detected
Trouble
Contents of
• Excessively low voltage is detected at signal circuit of decelerator pedal.
trouble
Problem that
machine
• The signal voltage of decelerator pedal can be checked in monitoring mode.
Related
(Code: 31703 Decelerator voltage)
information

1 pedal sensor power
shooting for that first.
supply circuit
switch ON.
DCL Voltage
2 Between (A) – (C) Power source 4.75 – 5.25 V
pedal
3
Possible (Contact with ground Between ground and wiring harness between Min.
causes and circuit) Resistance
CE02 (female) (9) – DCL (female) (B) 100 kz
standard value
in normal state
4 (Harness internal Wiring harness between CE02 (female) (9) – DCL
short) Min.
(female) (B) and wiring harness between CE02 Resistance
100 kz
(female) (23) – DCL (female) (C)
The connections among decelerator pedal – body harness – engine con-
troller are suspected to be defective. Visually check it.
5
tion
6
34 D61EX, PX-15E0
D61EX, PX-15E0 35
Failure code [CA144] Coolant temperature sensor too high: Excessively

Action code Failure code Coolant temperature sensor too high: Excessively high voltage detected
Trouble
E01 CA144 (Engine controller system)
Contents of
• Excessively high voltage is detected at signal circuit of engine coolant temperature sensor.
trouble
Action of
• Operates with a fixed engine coolant temperature.
controller
Problem that
• Exhaust gas color becomes white.
appears on
• Overheat prevention function does not work.
machine
• The signal voltage of engine coolant sensor can be checked in monitoring mode.
Related
(Code: 04105 Engine coolant sensor voltage)
information

Defective engine cool- switch OFF.
1 ant temperature sen-
C5 (male) Resistance
sor
Between (A) – (B) 0.18 – 160 kz
Disconnection in wiring switch OFF.
harness Wiring harness between CE01 (female) (15) – C5
2 Resistance Max. 10 z
(Disconnection or poor (female) (B)
connector contact) Wiring harness among CE01 (female) (38) – S13
Resistance Max. 10 z
– C5 (female) (A)
Possible Harness short switch OFF.
causes and 3 (Harness internal Between CE01 (female) (15) – CE01 (female) all
standard value short) Min.
pins (With all connectors in the harness discon- Resistance
in normal state 100 kz
nected)
The connections among engine coolant temperature sensor – engine har-
ness – engine controller are suspected to be defective. Visually check it.
4
tion
Defect in other loca- switch OFF.
5 tions than engine
CE01 (female) Resistance
controller
Between (15) – (38) 0.18 – 160 kz
Defective engine Engine controller is possibly defective if no problem is found in causes 1 –
6
controller 5. (Internal failure which cannot be diagnosed)
36 D61EX, PX-15E0
Circuit diagram related to coolant temperature sensor
D61EX, PX-15E0 37
Failure code [CA145] Coolant temperature sensor too low: Excessively

low voltage detected 1
Action code Failure code Coolant temperature sensor too low: Excessively low voltage detected
Trouble
Contents of
• Excessively low voltage is detected at signal circuit of engine coolant temperature sensor.
trouble
Action of
• Operates with a fixed engine coolant temperature.
controller
Problem that
appears on
• Overheat prevention function does not work.
machine
• The signal voltage of engine coolant sensor can be checked in monitoring mode.
Related
(Code: 04105 Engine coolant sensor voltage)
information

switch OFF.
Defective engine cool- C5 (male) Resistance
1 ant temperature sen-
sor Between (A) – (B) 0.18 – 160 kz
Between (B) –
Min. 100 kz
chassis ground
2
circuit) Resistance
CE01 (female) (15) – C5 (female) (B) 100 kz
Possible
short) Min.
standard value pins (With all connectors in the harness discon- Resistance
100 kz
in normal state nected)
The connections among engine coolant temperature sensor – engine har-
ness – engine controller are suspected to be defective. Visually check it.
4
tion
switch OFF.
Defect in other loca-
5 tions than engine CE01 (female) Resistance
controller Between (15) – (38) 0.18 – 160 kz
Between (15) – chassis ground Min. 100 kz
6
38 D61EX, PX-15E0
Circuit diagram related to coolant temperature sensor
D61EX, PX-15E0 39
Failure code [CA153] Charge temperature sensor too high: Excessively

Action code Failure code Charge temperature sensor too high: Excessively high voltage detected
Trouble
Contents of • Excessively high voltage is detected at temperature signal circuit of boost pressure and temperature
trouble sensor.
Action of
• Operates with a fixed charge temperature.
controller
Problem that
appears on
• Engine protection function by boost temperature does not work.
machine
• The signal voltage of boost pressure and temperature sensor on boost temperature side can be
information (Code: 18501 Boost temperature sensor voltage)

Defective boost pres- a Prepare with starting switch OFF, then start troubleshooting with starting
sure and temperature switch OFF.
1 sensor C4 (male) Resistance
[temperature signal cir-
cuit] Between (3) – (4) 0.18 – 160 kz
harness Wiring harness between CE01 (female) (23) – C4
(Disconnection or poor (female) (3)
connector contact) Wiring harness among CE01 (female) (47) – S11
– C4 (female) (4)
Possible Harness short switch OFF.
standard value short) Min.
in normal state 100 kz
nected)
it.
Defective wiring
harness connector
tion
5 tions than engine
controller
Between (23) – (47) 0.18 – 160 kz
6
40 D61EX, PX-15E0
D61EX, PX-15E0 41
Failure code [CA154] Charge temperature sensor too low: Excessively

low voltage detected 1
Action code Failure code Charge temperature sensor too low: Excessively low voltage detected
Trouble
Contents of • Excessively low voltage is detected at temperature signal circuit of boost pressure and temperature
trouble sensor.
Action of
• Operates with a fixed charge temperature.
controller
Problem that
appears on
• Engine protection function by boost temperature does not work.
machine
• The signal voltage of boost pressure and temperature sensor on boost temperature side can be
information (Code: 18501 Boost temperature sensor voltage)

Defective boost pres-
switch OFF.
1 sensor C4 (male) Resistance
[temperature signal cir- Between (3) – (4) 0.18 – 160 kz
cuit]
2
circuit) Resistance
CE01 (female) (23) – C4 (female) (3) 100 kz
Possible 3 (Harness internal Between CE01 (female) (23) – CE01 (female) all
short) Min.
causes and pins (With all connectors in the harness discon- Resistance
100 kz
standard value nected)
in normal state The connections among boost pressure and temperature sensor – engine
it.
Defective wiring
harness connector
tion
switch OFF.
controller Between (23) – (47) 0.18 – 160 kz
6
42 D61EX, PX-15E0
D61EX, PX-15E0 43
Failure code [CA155] Charge temperature too high and engine speed
derated: Exceeded upper control limit of temperature 1
Action code Failure code Charge air temperature too high and engine speed derated: Exceeded
Trouble upper control limit of temperature
Contents of • The temperature signal of boost pressure and temperature sensor exceeds upper control limit tem-
trouble perature.
Action of
• Operates with limited output.
controller
Problem that
• Engine output is reduced.
appears on
• Engine stops.
machine
• The boost temperature can be checked in monitoring function.
Related
(Code: 18500 Boost temperature)
information

The degradation of aftercooler cooling performance is suspected. Directly
Degradation of cooling check the following points:
1 performance of after- • Looseness and damage of fun belt
Possible cooler • Insufficient cooling air amount
causes and • Clogging of aftercooler fin
standard value
in normal state Abnormal rise in turbo-
The abnormal rise in turbocharger outlet temperature is suspected.
2 charger outlet temper-
Directly check the related parts.
ature
3
44 D61EX, PX-15E0
D61EX, PX-15E0 45
Failure code [CA187] Sensor power source 2 too low: Excessively low
voltage detected 1
Action code Failure code Sensor power source 2 too low: Excessively low voltage detected
Trouble
Contents of
• Excessively low voltage has been detected at sensor power source 2 circuit.
trouble
• Operates with a fixed boost pressure.
Action of
• Operates with fixed charge temperature.
controller
• Runs by limiting output.
Problem that
machine
Related
information

a Disconnect connectors with starting switch OFF, then turn it ON for trouble-
shooting.
Disconnect the devices Boost pressure and
C4
on the right temperature sensor
one at a time and try to Common rail pressure
Defective sensor or duplicate the problem. C8
1 sensor
harness If the failure code
changes from Bkup sensor C13
Possible
flashing to continuously
causes and
illuminating,
standard value Engine harness CE01
that device or harness
in normal state
is defective.
The connections among each sensor – engine harness – engine controller
are suspected to be defective.
Defective harness • Connector is loose, lock is broken, seal is broken
2
connector • Pin is corroded, bent, broken, pushed in, expanded.
tion
3
46 D61EX, PX-15E0
Circuit diagram related to sensor power supply 2
D61EX, PX-15E0 47
Failure code [CA221] Atmospheric pressure sensor too high:

Excessively high voltage detected 1
Action code Failure code Atmospheric pressure sensor too high: Excessively high voltage detected
Trouble
Contents of
• Excessively high voltage is detected at signal circuit of atmospheric pressure sensor.
trouble
Action of
• Operates with a fixed atmospheric pressure.
controller
Problem that
• Startability gets worse.
appears on
machine
• The signal voltage of the atmospheric pressure sensor can be checked in monitoring mode.
Related
(Code: 37401 Atmospheric pressure sensor voltage)
information

1
switch ON.
C29 Voltage
Defective atmospheric
pressure sensor
3 (a contact with 5 V cir-
Possible cuit or 24 V circuit) Between ground and wiring harness between
Voltage Max. 1 V
causes and CE01 (female) (3) – C29 (female) (3)
4 (Harness internal Wiring harness between CE01 (female) (3) – C29
short) Min.
(female) (3) and wiring harness between CE01 Resistance
100 kz
(female) (33) – C29 (female) (1)
The connections among atmospheric pressure sensor – engine harness –
engine controller are suspected to be defective. Visually check it.
5
tion
6
48 D61EX, PX-15E0
Circuit diagram related to atmospheric pressure sensor
D61EX, PX-15E0 49
Failure code [CA222] Atmospheric pressure sensor too low:

Excessively low voltage detected 1
Action code Failure code Atmospheric pressure sensor too low: Excessively low voltage detected
Trouble
Contents of
• Excessively low voltage is detected at signal circuit of atmospheric pressure sensor.
trouble
Action of
controller
Problem that
• Startability gets worse.
appears on
machine
• The signal voltage of the atmospheric pressure sensor can be checked in monitoring mode.
Related
(Code: 37401 Atmospheric pressure sensor voltage)
information

1
switch ON.
C29 Voltage
Defective atmospheric
pressure sensor
3
Possible Resistance
causes and
4 (Harness internal Wiring harness between CE01 (female) (3) – C29
short) Min.
(female) (3) and wiring harness between CE01 Resistance
100 kz
(female) (38) – S13 – C29 (female) (2)
The connections among atmospheric pressure sensor – engine harness –
engine controller are suspected to be defective. Visually check it.
5
tion
6
50 D61EX, PX-15E0
Circuit diagram related to atmospheric pressure sensor
D61EX, PX-15E0 51
Failure code [CA227] Sensor power source 2 too high: Excessively high
voltage detected 1
Action code Failure code Sensor power source 2 too high: Excessively high voltage detected
Trouble
Contents of
• Excessively high voltage has been detected in sensor power source 2 circuit.
trouble
• Operates with a fixed boost pressure.
Action of
• Operates with fixed charge temperature.
controller
• Runs by limiting output.
Problem that
machine
Related
information

Possible
causes and 1
standard value
in normal state
tion
Defective engine Engine controller is possibly defective if no problem is found in cause 1.
2
controller (Internal failure which cannot be diagnosed)
52 D61EX, PX-15E0
D61EX, PX-15E0 53
Failure code [CA234] Engine over speed: Excessively high speed 1

Action code Failure code Engine over speed: Excessively high speed
Trouble
— CA234 (Engine controller system)
Contents of
• The engine speed exceeds upper control limit speed.
trouble
Action of
• Stops operation of injector until the engine speed drops to the normal speed.
controller
Problem that
appears on • Engine speed fluctuates.
machine
• The engine speed can be checked in monitoring function.
Related
(Code: 01000 Engine speed)
information
• Duplication of failure code: Start engine and operate at high idle.

Improper fuel has been
Possible 1 The use of improper fuel is suspected. Visually check it.
used.
causes and
standard value The improper usage of equipped machine is suspected. Instruct the
2 Improper usage
in normal state proper usage.
3
54 D61EX, PX-15E0

Action code Failure code Abnormal power source for Ne speed sensor: Excessively low voltage
Trouble detected
Contents of
• Excessively low voltage is detected at power source circuit of engine Ne speed sensor.
trouble
Action of
• Continues the control by engine Bkup speed sensor signal.
controller
Problem that
• Engine is hard to start.
appears on
• Engine is hunting.
machine
Related
information

a Prepare with starting switch OFF, then turn it ON for troubleshooting.
Disconnect the devices
on the right
one at a time and try to Ne speed sensor C15
Defective sensor or duplicate the problem.
1 If the failure code
wiring harness
Possible changes from
causes and flashing to continuously
standard value illuminating, Engine harness CE01
in normal state that device or harness
is defective.
2
tion
Circuit diagram related to engine Ne speed sensor
D61EX, PX-15E0 55
Failure code [CA271] IMV/PCV1 short circuit: Short circuit 1

Action code Failure code IMV/PCV1 short circuit: Short circuit
Trouble
Contents of
• Short circuit has been detected at drive circuit of supply pump actuator.
trouble
Action of
• No particular action
controller
Problem that • Engine speed does not increase from low idle.
machine • Fuel pressure of common rail increases above command value.
Related
information

Defective supply pump switch OFF.
1
actuator C17 (male) Resistance
2
circuit) Resistance
Possible 3 (Harness internal Between CE01 (female) (2) – CE01 (female) all
causes and short) Min.
standard value 100 kz
nected)
in normal state
The connections among inlet metering valve – engine harness – engine
controller are suspected to be defective. Visually check it.
4
tion
5 tions than engine
controller
6
56 D61EX, PX-15E0
Circuit diagram related to supply pump actuator (metering unit)
D61EX, PX-15E0 57
Failure code [CA272] IMV/PCV1 disconnection: Disconnection 1

Action code Failure code IMV/PCV1 disconnection: Disconnection
Trouble
Contents of
• Disconnection is detected at drive circuit of supply pump actuator.
trouble
Action of
controller
Problem that
• Engine runs, but it does not stabilize.
appears on
• Fuel pressure of common rail increases above commanded value.
machine
Related
information

Defective supply pump switch OFF.
1
actuator C17 (male) Resistance
Between (1) – (2) Max. 5 z
harness Wiring harness between CE01 (female) (2) –
(Disconnection or poor C17 (female) (1)
connector contact) Wiring harness between CE01 (female) (32) –
C17 (female) (2)
3 (a contact with 24 V
circuit) Between ground and wiring harness between
Possible Voltage Max. 3 V
causes and
standard value
in normal state
4 (Harness internal Between CE01 (female) (2) – CE01 (female) all
short) Min.
100 kz
nected)
The connections among inlet metering valve – engine harness – engine
controller are suspected to be defective. Visually check it.
5
tion
6 tions than engine
controller
7
58 D61EX, PX-15E0
Circuit diagram related to supply pump actuator (metering unit)
D61EX, PX-15E0 59
SEN02561-00

© 2007 KOMATSU
All Rights Reserved
60
SEN02563-00
D61EX-15E0
D61PX-15E0

disconnection, short circuit .................................................................................................... 4
disconnection, short circuit .................................................................................................. 10
Failure code [CA342] Engine controller data matching error: matching error .................................... 16
Failure code [CA352] Sensor power source 1 too low: Excessively low voltage detected ................ 18
D61EX, PX-15E0 1
Failure code [CA386] Sensor power source 1 too high: Excessively high voltage detected.............. 20
Failure code [CA428] Water detection sensor too high: Excessively high voltage detected .............. 22
Failure code [CA429] Water detection sensor too low: Excessively low voltage detected................. 24
Failure code [CA435] Abnormal engine oil pressure switch: Abnormal signal circuit......................... 26
Failure code [CA441] Power source voltage too low: Excessively low voltage detected ................... 28
Failure code [CA442] Power source voltage too high:
Excessively high voltage has occurred in the controller power source circuit ..................... 30
Failure code [CA449] Common rail pressure too high (2):
Excessively high pressure trouble occurred ........................................................................ 32
Failure code [CA451] Common rail pressure sensor too high: Excessively high voltage detected.... 34
Failure code [CA452] Common rail pressure sensor too low: Excessively low voltage detected ...... 36
Failure code [CA553] Common rail pressure too high (1): Excessively high pressure detected........ 39
Failure code [CA559] Loss of pressure feed from supply pump (1): Loss of pressure feed detected 40
Failure code [CA689] Abnormal engine Ne speed sensor: Abnormal signal ..................................... 42
Failure code [CA731] Abnormal engine Bkup speed sensor phase: Abnormal phase....................... 44
Failure code [CA757] Loss of all engine controller data: Loss of all data........................................... 46
Failure code [CA778] Abnormal engine Bkup speed sensor: Abnormal Bkup signal......................... 48
Failure code [CA1633] Abnormal KOMNET: Abnormal communication............................................. 50
Excessively high voltage detected....................................................................................... 52
Excessively low voltage detected ........................................................................................ 54
Loss of pressure feed detected ........................................................................................... 56
Failure code [CA2311] Abnormal IMV solenoid: Abnormal resistance ............................................... 58
Failure code [CA2555] Air intake heater relay disconnection: Disconnection .................................... 60
Failure code [CA2556] Air intake heater relay short circuit: Short circuit ........................................... 62
2 D61EX, PX-15E0
D61EX, PX-15E0 3
Failure code [CA322] Injector No. 1 system disconnection or short

circuit: disconnection, short circuit 1
Action code Failure code Injector No. 1 system disconnection or short circuit: disconnection, short
Trouble circuit
Contents of
• A disconnection or short circuit has been detected in No. 1 injector drive circuit.
trouble
Action of
controller
Problem that
• Poor combustions or hunting occurs.
appears on
machine
Related
information

a Prepare with starting switch OFF and diagnose with starting switch still
OFF.
1 Defective No. 1 injector C9 (male) Resistance
Disconnection in wiring OFF.
harness
Wiring harness between CE01 (female) (45) –C9
2 (Disconnection or Resistance Max. 2 z
(3) – No. 1 injector (1)
defective contact of
connectors) Wiring harness between CE01 (female) (53) – C9
Resistance Max. 2 z
(4) – No. 1 injector (2)
Defective harness a Prepare with starting switch OFF and diagnose with starting switch still
Possible grounding OFF.
3
causes and (Contact with ground Between ground and wiring harness between Min.
standard value circuit) Resistance
CE01 (female) (45) – C9 (3) – No. 1 injector (1) 100 kz
in normal state
OFF.
Harness short
Between CE01 (female) (45) – CE01 (female) all Min.
4 (Harness internal Resistance
pins (All connectors in the harness disconnected) 100 kz
short)
Resistance
Since the problem is possibly at the connections between No. 1 injector –
engine harness – engine controller, check for a defective connection.
5
tion
Defective injector of
If another failure code for injector abnormality is displayed, carry out trou-
6 another cylinder or wir-
bleshooting for it.
ing harness
4 D61EX, PX-15E0

OFF.
Possible Defect in other loca-
causes and 7 tions than engine con- CE01 (female) Resistance
standard value troller Between (45) – (53) Max. 2 z
in normal state
Defective engine Engine controller is possibly defective if no problem is found in causes 1-
8
controller 7. (Since this is an internal defect, it cannot be diagnosed.)
Circuit diagram related to injector No. 1
D61EX, PX-15E0 5

disconnection, short circuit 1
Trouble circuit
Contents of
• A disconnection or short circuit has been detected in No. 5 injector drive circuit
trouble
Action of
controller
Problem that
appears on
machine
Related
information

OFF.
harness
Wiring harness between CE01 (female) (46) –
C11 (3) – No. 5 injector (1)
connectors) Wiring harness between CE01 (female) (60) –
Resistance Max. 2 z
C11 (4) – No. 5 injector (2)
3
in normal state
OFF.
Harness short
4 (Harness internal Resistance
short)
Resistance
5
tion
bleshooting for it.
ing harness
6 D61EX, PX-15E0

OFF.
Possible Defect in other loca-
causes and 7 tions than engine con- CE01 (female) Resistance
standard value troller Between (46) – (60) Max. 2 z
in normal state
8
D61EX, PX-15E0 7

Trouble circuit
Contents of
trouble
Action of
controller
Problem that
appears on
machine
Related
information

OFF.
harness
C10 (3) – No. 3 injector (1)
Resistance Max. 2 z
C10 (4) – No. 3 injector (2)
grounding OFF.
3
circuit) Resistance
Possible OFF.
causes and Harness short
standard value 4 (Harness internal Resistance
in normal state short)
Resistance
Since problem is possibly at the connections between No. 3 injector –
5
tion
bleshooting for it.
ing harness
Defect in other loca- OFF.
controller Between (55) – (52) Max. 2 z
Between (55) – ground Min. 100 kz
8
8 D61EX, PX-15E0
D61EX, PX-15E0 9

Trouble circuit
Contents of
trouble
Action of
controller
Problem that
appears on
machine
Related
information

OFF.
harness
C11 (2) – No. 6 injector (1)
Resistance Max. 2 z
C11 (1) – No. 6 injector (2)
grounding OFF.
3
circuit) Resistance
Possible OFF.
Resistance
5
tion
6 another cylinder or
bleshooting for it.
wiring harness
8
10 D61EX, PX-15E0
D61EX, PX-15E0 11

Trouble circuit
Contents of
trouble
Action of
controller
Problem that
appears on
machine
Related
information

OFF.
harness
C9 (2) – No. 2 injector (1)
Resistance Max. 2 z
C9 (1) – No. 2 injector (2)
grounding OFF.
3
circuit) Resistance
Possible OFF.
Resistance
5
harness connector Pin is corroded, bent, broken, pushed in, expanded.
Moisture in connector, entry of dirt or sand, etc., and insufficient insula-
tion
bleshooting for it.
ing harness
8
12 D61EX, PX-15E0
D61EX, PX-15E0 13

Trouble circuit
Contents of
trouble
Action of
controller
Problem that
appears on
machine
Related
information

OFF.
harness
C10 (2) – No. 4 injector (1)
Resistance Max. 2 z
C10 (1) – No. 4 injector (2)
grounding OFF.
3
circuit) Resistance
Possible OFF.
Resistance
5
tion
6 another cylinder or
bleshooting for it.
wiring harness
8
14 D61EX, PX-15E0
D61EX, PX-15E0 15
Failure code [CA342] Engine controller data matching error: matching

error 1
Action code Failure code Engine controller data matching error: matching error
Trouble
Contents of
• Data matching error has been detected in engine controller.
trouble
Action of
controller
Problem that
• Normal operation is continued.
appears on
• Engine stops or engine does not start.
machine
Related
information

causes and
standard value Carry out troubleshooting for failure code [CA757].
in normal state
16 D61EX, PX-15E0
D61EX, PX-15E0 17
Failure code [CA352] Sensor power source 1 too low:

Action code Failure code Sensor power source 1 too low: Excessively low voltage detected
Trouble
Contents of
• Excessively low voltage has been detected in sensor power source 1 circuit
trouble
Action of
controller
Problem that
• Startability of engine deteriorates.
appears on
machine
Related
information

a Prepare with starting switch OFF and diagnose with starting switch ON.
Disconnect the devices

on the right one at a time Atmospheric pressure
C29
and try to duplicate the sensor
Defective sensor or problem.
1
wiring harness If the failure code
changes from flashing to
Possible continuously illuminating,
causes and that device or harness is Engine harness CE01
standard value defective.
in normal state
Since the connections among atmospheric pressure sensor – engine har-
ness – engine controller are suspected to be defective, check for a defec-
tive connection.
Defective wiring
harness connector
tion
3
18 D61EX, PX-15E0
D61EX, PX-15E0 19
Failure code [CA386] Sensor power source 1 too high: Excessively high
voltage detected 1
Action code Failure code Sensor power source 1 too high: excessively high voltage detected
Trouble
Contents of
• Excessively high voltage has been detected in sensor power source 1 circuit
trouble
Action of
controller
Problem that
• Startability of engine deteriorates.
appears on
machine
Related
information

Since the connections among atmospheric pressure sensor – engine har-
ness – engine controller are suspected to be defective, check for a defec-
Possible tive connection.
Defective wiring
causes and 1 • Connector is loose, lock is broken, seal is broken
harness connector
standard value Pin is corroded, bent, broken, pushed in, expanded.
in normal state Moisture in connector, entry of dirt or sand, etc., and insufficient insula-
tion
Defective engine Engine controller is possibly defective if no problem is found in cause 1.
2
controller (Since this is an internal defect, it cannot be diagnosed.)
20 D61EX, PX-15E0
D61EX, PX-15E0 21
Failure code [CA428] Water detection sensor too high: Excessively high
voltage detected 1
Action code Failure code Water detection sensor too high: Excessively high voltage detected
Trouble
Contents of
• Excessively high voltage has occurred in the fuel water detection sensor signal circuit
trouble
Action of
controller
Problem that
appears on • Water separator monitor does not display normally.
machine
• The signal status of the fuel water detection sensor can be checked with the monitoring function.
Related
(Code: 18800 Fuel filter water level signal)
information

Defective fuel water OFF.
1
detection sensor WIF (female) Resistance
harness
WIF (male) (1)
S11 – WIF (male) (2)
Possible a Prepare with starting switch OFF and diagnose with starting switch still
Harness short OFF.
causes and 3 (Harness internal
standard value short) Between CE01 (female) (14) – CE01 (female) all Min.
Resistance
in normal state pins (All connectors in the harness disconnected) 100 kz
Problem is possibly at the connections between fuel water detection sen-
sor – engine harness – engine controller, so inspect them directly.
4
tion
5 tions than engine
controller
Between (14) – (47) Max. 10 z
6
22 D61EX, PX-15E0
Circuit diagram related to fuel water sensor
D61EX, PX-15E0 23
Failure code [CA429] Water detection sensor too low: Excessively low
voltage detected 1
Action code Failure code Water detection sensor too low: Excessively low voltage detected
Trouble
Contents of
• Excessively low voltage has occurred in the fuel water detection sensor signal circuit
trouble
Action of
controller
Problem that
appears on • Water separator monitor does not display normally.
machine
• The signal status of the fuel water detection sensor can be checked with the monitoring function.
Related
(Code: 18800 Fuel filter water level signal)
information

OFF.
Defective fuel water WIF (female) Resistance
1
detection sensor
grounding OFF.
2
circuit) Resistance
CE01 (female) (14) – WIF (male) (1) 100 kz
Harness short OFF.
Possible 3 (Harness internal
causes and short) Between CE01 (female) (14) – CE01 (female) all Min.
Resistance
standard value pins (All connectors in the harness disconnected) 100 kz
in normal state Problem is possibly at the connections between fuel water detection sen-
sor – engine harness – engine controller, so inspect them directly.
4
tion
OFF.
6
24 D61EX, PX-15E0
Circuit diagram related to fuel water sensor
D61EX, PX-15E0 25
Failure code [CA435] Abnormal engine oil pressure switch: Abnormal

signal circuit 1
Action code Failure code Abnormal engine oil pressure switch: Abnormal signal circuit
Trouble
Contents of
• A problem has occurred in the engine oil pressure switch signal circuit
trouble
Action of
controller
Problem that
• Protection function by engine oil pressure does not operate.
appears on
• Engine oil pressure monitor does not display normally.
machine
Related
• Duplication of failure code: turn ON the starting switch or start the engine.
information

Defective engine oil OFF.
1
switch C2 (male) Resistance
Between (1) – body Max. 10 z
Disconnection in wiring a Prepare with starting switch OFF and diagnose with starting switch still
harness OFF.
2 (Disconnection or
defective contact of Wiring harness between CE01 (female) (17) –
connectors) C2 (female) (1)
Harness short OFF.
Possible 3 (Harness internal
causes and short) Between CE01 (female) (17) – CE01 (female) all Min.
Resistance
standard value pins (All connectors in the harness disconnected) 100 kz
in normal state Since the problem is possibly at the connections between engine oil pres-
sure switch – engine harness – engine controller, check for a defective
connection.
Defective wiring
harness connector
tion
5 tions than engine
controller
Between (17) – ground Max. 10 z
6
26 D61EX, PX-15E0
Circuit diagram related to engine oil pressure switch
D61EX, PX-15E0 27
Failure code [CA441] Power source voltage too low: Excessively low
voltage detected 1
Action code Failure code Power source voltage too low: Excessively low voltage detected
Trouble
Contents of
• Excessively low voltage has occurred in the controller power source voltage circuit
trouble
Action of
controller
Problem that
• Engine stops.
appears on
machine
Related
information

Loose or corroded
1 Battery terminal is possibly loose or corroded, so inspect it directly.
battery terminal
a Prepare with starting switch OFF and diagnose with starting switch OFF
and START.
Defective battery Battery (1 unit) Starting switch Voltage
2
voltage
Between (+) – OFF Min. 12 V
(–) terminals START Min. 6.2 V
If fuse is blown, it is highly possible that a defective harness grounding,
3 Defective fuse No. 9
etc. has occurred in the circuit (refer to cause 5).
harness
Wiring harness between FS2 (9) – CE03
(female) (3), (4)
connectors) Wiring harness between CE03 (female) (1), (2) –
ground 1
5
FS2 (9) – CE03 (female) (3), (4) 100 kz
in normal state
Harness short OFF.
6 (Harness internal Between pins CE03 (female) (3), (4) – CE03
short) Min.
(female) (1), (2) Resistance
100 kz
(Battery terminals disconnected)
• Since the problem is possibly at the connections between FS2 (9) – body
harness – engine controller, check for a defective connection.
7
tion
a Prepare with starting switch OFF and diagnose with starting switch ON
and START.
CE03 (female) Starting switch Voltage
8 tions than engine
controller ON Min. 24 V
Between (3), (4) –
(1), (2) START Min. 12 V

9
28 D61EX, PX-15E0
Circuit diagram related to engine controller power supply
D61EX, PX-15E0 29
Failure code [CA442] Power source voltage too high: Excessively high
voltage has occurred in the controller power source circuit 1
Action code Failure code Power source voltage too high: Excessively high voltage has occurred in
Trouble the controller power source circuit
Contents of
• Excessively high voltage (36 V or more) has occurred in the controller power source voltage circuit
trouble
Action of
controller
Problem that
appears on • Engine may stop.
machine
Related
information

Defective battery OFF.
1
voltage Battery Voltage
Between (+) – (–) terminals Max. 32 V
Possible
causes and a Prepare with starting switch OFF and start the engine to diagnose.
standard value E22 (male) Engine speed Voltage
in normal state 2 Defective alternator
Medium speed or
Between (4) – ground 27.5 – 29.5 V
higher
Defective engine
3 CE03 (female) Voltage
controller
Between (3), (4) – (1), (2) Max. 32 V
30 D61EX, PX-15E0
D61EX, PX-15E0 31
Failure code [CA449] Common rail pressure too high (2): Excessively high
pressure trouble occurred 1
Action code Failure code Common rail pressure too high (2): Excessively high pressure trouble
Trouble occurred
Contents of
• Excessively high pressure trouble (2) has occurred in the common rail circuit.
trouble
Action of
controller
Problem that
• Engine noise becomes louder at no or light load.
appears on
machine
• Common rail pressure can be checked with the monitoring function.
Related
(Code: 36400 Common rail pressure)
information

Defective related Check the failure codes that are displayed at the same time. If any other
1
circuits codes are displayed, carry out troubleshooting for those codes.
Air has possibly entered into the low pressure circuit, so inspect directly in
the following procedure:
Air in the low pressure 1) Remove pressure inspection plug (on the outlet port) for the fuel main
2
circuit filter.
2) Operate the feed pump for the fuel pre-filter.
3) Inspect the fuel and air leaking from the pressure inspection plug.
a Refer to Testing and adjusting “Testing fuel pressure” for testing fuel
return circuit pressure.
Possible Defective equipment of
3 At low idle
causes and fuel return circuit Fuel return circuit Max. 18.63 kPa
or
standard value pressure {Max. 0.19 kg/cm2}
At cranking
in normal state
a Prepare with starting switch ON and diagnose with starting switch ON.
Monitoring code
Defective common rail Monitoring information
4 (Monitor panel)
pressure sensor
36400 When engine is 0 ± 0.39 MPa
Common rail pressure stopped {0 ± 4 kg/cm2}
a Refer to Testing and adjusting “Testing fuel delivery amount, return rate
Defective pressure and leakage” for testing leakage from pressure limiter.
5
limiter Leakage from pressure
At low idle 0 cc (No leakage)
limiter
6 Defective supply pump Supply pump is possibly defective if no problem is found in causes 1 – 5.
32 D61EX, PX-15E0
Circuit diagram related to common rail pressure sensor
D61EX, PX-15E0 33
Failure code [CA451] Common rail pressure sensor too high:

Action code Failure code Common rail pressure sensor too high: Excessively high voltage detected
Trouble
Contents of
• Excessively high voltage has occurred in the common rail pressure sensor signal circuit
trouble
Action of
controller
Problem that
appears on
• Engine speed or output is reduced.
machine
• The signal voltage of the common rail pressure sensor can be checked with the monitoring function.
Related
(Code: 36401 Common rail pressure sensor voltage)
information

1
power source 2 circuit shooting for it first.
C8 Voltage
Defective common rail Between (3) – (1) Power source 4.75 – 5.25 V
2
pressure sensor
Hot short of harness a Prepare with starting switch OFF and diagnose with starting switch ON.
3 (a contact with 5 V cir- Between ground and wiring harness between
cuit or 24 V circuit) Voltage Max. 1 V
Possible CE01 (female) (25) – C8 (female) (2)
causes and a Prepare with starting switch OFF and diagnose with starting switch still
standard value Harness short OFF.
in normal state 4 (Harness internal Wiring harness between CE01 (female) (25) –
short) Min.
C8 (female) (2) and wiring harness between Resistance
100 kz
CE01 (female) (37) – S10 – C8 (female) (3)
Since the problem is possibly at the connections between common rail
pressure sensor – engine harness – engine controller, check for a defec-
tive connection.
Defective wiring
harness connector
tion
Defective engine
6 CE01 Voltage
controller
34 D61EX, PX-15E0
D61EX, PX-15E0 35
Failure code [CA452] Common rail pressure sensor too low:

Action code Failure code Common rail pressure sensor too low: Excessively low voltage detected
Trouble
Contents of
• Excessively low voltage is detected in the common rail pressure sensor signal circuit
trouble
Action of
controller
Problem that
appears on
• Engine speed or output is reduced.
machine
• The signal voltage of the common rail pressure sensor can be checked with the monitoring function.
Related
(Code: 36401 Common rail pressure sensor voltage)
information

1
C8 Voltage
Defective common rail Between (3) – (1) Power source 4.75 – 5.25 V
2
pressure sensor
grounding OFF.
3
Possible circuit) Resistance
causes and
standard value
Harness short OFF.
in normal state
4 (Harness internal Wiring harnesses between CE01 (female) (25) –
short) Min.
C8 (female) (2) and among CE01 (female) (47) – Resistance
100 kz
S11 – C8 (female) (1)
Since the problem is possibly at the connections between common rail
pressure sensor – engine harness – engine controller, check for a defec-
tive connection.
Defective wiring
harness connector
tion
Defective engine
6 CE01 Voltage
controller
36 D61EX, PX-15E0
D61EX, PX-15E0 37
Exceeded upper control limit of temperature 1
Action code Failure code Charge air temperature too high and torque derated: Exceeded upper
Trouble control limit of temperature
Contents of • The temperature signal of boost pressure and temperature sensor exceeds upper control limit tem-
trouble perature.
Action of
controller
Problem that
appears on • Engine output decreases.
machine
• The boost temperature can be checked in monitoring function.
Related
(Code: 18500 Boost temperature)
information

The degradation of aftercooler cooling performance is suspected. Directly
Degradation of cooling check the following points:
1 performance of after- • Looseness and damage of fan belt
Possible cooler • Insufficient cooling air amount
causes and • Clogging of aftercooler fin
standard value
in normal state Abnormal rise in turbo-
The abnormal rise in turbocharger outlet temperature is suspected.
2 charger outlet temper-
Directly check the related parts.
ature
3
38 D61EX, PX-15E0
Failure code [CA553] Common rail pressure too high (1): Excessively
high pressure detected 1
Action code Failure code Common rail pressure high trouble (1): Excessively high pressure trouble
Trouble occurred
Contents of
• Excessively high pressure trouble (1) has occurred in the common rail circuit.
trouble
Action of
controller
Problem that
• Engine noise becomes louder at no or light load.
appears on
machine
Related
information

1
Possible Defective connection of the ground terminal is suspected. Check the fol-
causes and lowing terminals directly:
standard value Defective connection • Ground terminal of the machine body (negative terminal of the battery)
2
in normal state of the ground terminal • Ground terminal of the engine
• Ground terminal of the engine controller
• Ground terminal of the starting motor
Damaged O-ring of Since a damage of O-ring of supply pump actuator is suspected, visually
3
supply pump actuator check the O-ring.
D61EX, PX-15E0 39
Failure code [CA559] Loss of pressure feed from supply pump (1): Loss
of pressure feed detected 1
Action code Failure code Loss of pressure feed from supply pump (1): Loss of pressure feed
Trouble detected
Contents of
• Loss of pressure feed (1) occurred in the common rail circuit.
trouble
Action of
controller
Problem that • Engine does not start or engine is hard to start.
appears on • Exhaust gas color becomes black.
machine • Engine output is reduced.
Related
information

1 Improper fuel used Since the use of improper fuel is suspected, check the fuel directly.
a Refer to Testing and adjusting “Fuel Pressure Inspection” for fuel low
pressure circuit pressure inspection.
Fuel supply pump inlet At high idle
Max. –50.7 kPa
negative pressure (Fuel (When engine can be
{Max. –380 mmHg}
prefilter outlet side) started)
Defective low pres-
2 During cranking
sure circuit device 0.3 – 1.1 MPa
(When engine can not
{3.1 – 11.3 kg/cm2}
Fuel main filter intel be started)
pressure At low idle
0.5 – 1.3 MPa
(When engine can be
{5.1 – 13.3 kg/cm2}
started)
Defective pressure and leakage” for testing leakage from pressure limiter.
3
Possible limiter Pressure limiter
At low idle 0 cc (No leakage)
causes and leak amount
standard value a As for testing return amount of injector, see testing and adjusting “Test-
in normal state ing fuel delivery amount, return amount and leakage”.
Defective injector When cranking
(Including high-pres- (When engine cannot Max. 90 cc/min.
4
sure pipes within the start)
head) Injector return amount
At low idle
(When engine can be Max. 180 cc/min.
started)
and leakage” for testing delivery amount and return rate of supply
pump.
• Delivery amount Q (cc) = Engine speed x 0.6
5 Defective supply pump Engine speed: 125 rpm Min. 75 cc/30 sec.
Supply pump amount
Engine speed: 155 rpm Min. 90 cc/30 sec.
delivery amount
Engine speed: 195 rpm Min. 117 cc/30 sec.
Supply pump return
At low idle: 750 rpm Max. 400 cc/25 sec.
rate
40 D61EX, PX-15E0
Note 1. If fuel low-pressure circuit parts seem to be defective, check the following items.
1) Fuel level
2) Clogging of fuel tank cap air bleeding hole
3) Leaking or clogging of fuel low-pressure piping
4) Clogging of fuel prefilter
5) Clogging of fuel main filter
D61EX, PX-15E0 41
Failure code [CA689] Abnormal engine Ne speed sensor: Abnormal signal 1

Action code Failure code Abnormal engine Ne speed sensor: Abnormal signal
Trouble
Contents of
• Abnormal signal of the engine Ne speed sensor has been detected.
trouble
Action of
• Continues the control by engine Bkup speed sensor signal.
controller
Problem that • Engine is hunting.
appears on • Engine is hard to start.
machine • Engine output is reduced.
Related
information

Defective Ne speed
1 sensor power source
shooting for it first.
circuit
C15 Voltage
Defective engine Ne Between (1) – (2) Power source 4.75 – 5.25 V
2
speed sensor
Damaged engine Ne
Since a damage or improper mounting gap of engine Ne speed sensor is
3 speed sensor or
Possible suspected, inspect it visually.
improper gap
causes and
standard value Damaged speed
4 Since a damage of speed detection wheel is suspected, visually check it.
in normal state detection wheel
harness OFF.
5 (Disconnection or
defective contact of Wiring harness between CE01 (female) (27) – Max.
Resistance
connectors) C15 (female) (3) 10 z
grounding OFF.
6
circuit) Resistance
Hot short in wiring har- a Prepare with starting switch OFF and diagnose with starting switch ON.
7 ness (a contact with 5 V Between ground and wiring harness between
or 24 V circuit) Voltage Max. 1 V
42 D61EX, PX-15E0

OFF.
Wiring harnesses between CE01 (female) (27) –
Harness short Min.
C15 (female) (3) and between CE01 (female) Resistance
8 (Harness internal 100 kz
(16) – C15 (female) (1)
short)
Min.
C15 (female) (3) and between CE01 (female) Resistance
Possible 100 kz
(48) – C15 (female) (2)
causes and
standard value Since the connections among engine Ne speed sensor – engine harness
in normal state – engine controller are suspected to be defective, check a the defective
connection.
Defective wiring
harness connector
tion
Defective engine
10 CE01 Voltage
controller
Circuit diagram related to engine Ne speed sensor
D61EX, PX-15E0 43
Failure code [CA731] Abnormal engine Bkup speed sensor phase:

Abnormal phase 1
Action code Failure code Abnormal engine Bkup speed sensor phase: Abnormal phase
Trouble
Contents of • Abnormal phase is detected from the signals of engine Ne speed sensor and engine Bkup speed
trouble sensor.
Action of
• Continues the control using engine Ne speed sensor signal.
controller
Problem that • Engine can not start or engine is hard to start.
appears on • Idle speed is not stable.
machine • Exhaust gas color becomes black.
Related
information

Damaged engine Ne Since a damage of engine Ne speed sensor is suspected, visually check
1
speed sensor it.
Damaged engine Bkup Since a damage of engine Bkup speed sensor is suspected, visually
2
speed sensor check it.
Since a defective mounting or a damage of speed detection ring on the
crankshaft side is suspected, carry out the inspection according to the fol-
Defective mounting or
lowing procedure.
damage of speed
3 1) Set the No.1 cylinder to the compression top dead center (align the
detection ring on the
marks).
crankshaft side
2) If the center of the cut-out portion on the speed detection ring is aligned
with the tip of Ne speed sensor, the mounting is normal.
Possible Since a defective mounting or a damage of speed detection gear on the
causes and camshaft side is suspected, carry out the inspection according to the fol-
standard value Defective mounting or lowing procedure.
in normal state damage of speed 1) Set the No.1 cylinder to the compression top dead center (align the
4
detection gear on the marks).
camshaft side 2) Remove the Bkup speed sensor.
3) If you can see a groove on a side face of speed detection gear through
the mounting hole of the sensor, the mounting is normal.
Defective timing
Since a defective timing adjustment of crankshaft and camshaft is sus-
5 adjustment of crank-
pected, inspect directly.
shaft and camshaft
Defective connection of the ground terminal is suspected. Check the fol-
lowing terminals directly:
Defective connection • Ground terminal of the machine body (negative terminal of the battery)
6
of the ground terminal • Ground terminal of the engine
• Ground terminal of the engine controller
• Ground terminal of the starting motor
44 D61EX, PX-15E0
D61EX, PX-15E0 45
Failure code [CA757] Loss of all engine controller data: Loss of all data1
Action code Failure code Loss of all engine controller data: Loss of all data
Trouble
Contents of
• Loss of all data in engine controller has been detected.
trouble
Action of
controller
Problem that
• Engine may stop and can not restart.
appears on
• Monitoring function of monitor panel (engine controller system) may not operate normally.
machine
Related
information

1
Loose or corroded
2 Battery terminal is possibly loose or corroded, so inspect it directly.
battery terminal
a Prepare with starting switch OFF and diagnose with starting switch OFF
and START.
Defective battery Battery (1 unit) Starting switch Voltage
3
voltage
Between (+) – OFF Min. 12 V
(–) terminals START Min. 6.2 V
If fuse is blown, it is highly possible that a defective harness grounding,
4 Defective fuse No. 9
etc. has occurred in the circuit.
causes and
harness
standard value Wiring harness between FS2 (9) – CE03
in normal state (female) (3), (4)
connectors) Wiring harness between CE03 (female) (1), (2) –
ground 1
Since the problem is possibly at the connections between FS2 (9) – body
harness – engine controller, check for a defective connection.
6
tion
a Prepare with starting switch OFF and diagnose with starting switch ON
and START.
Defective engine CE03 (female) Starting switch Voltage
7
controller
Between (3), (4) – ON Min. 24 V
(1), (2) START Min. 12 V
46 D61EX, PX-15E0
D61EX, PX-15E0 47
Failure code [CA778] Abnormal engine Bkup speed sensor: Abnormal

Bkup signal 1
Action code Failure code Abnormal engine Bkup speed sensor: Abnormal Bkup signal
Trouble
Contents of
• Abnormal engine Bkup speed sensor signal has been detected.
trouble
Action of
• Continue the control using engine Ne speed sensor signal.
controller
Problem that
appears on
• Output decreases.
machine
Related
information

1
C13 Voltage
Defective engine Bkup Between (1) – (2) Power source 4.75 – 5.25 V
2
speed sensor
Damaged engine Bkup
Since a damage of engine Bkup speed sensor or improper gap is sus-
3 speed sensor or
pected, visually check it.
Possible improper gap
causes and Damaged speed
standard value 4 Since a damage of speed detection gear is suspected, visually check it.
detection gear
in normal state
harness OFF.
5 (Disconnection or
defective contact of Wiring harness between CE01 (female) (26) – Max.
Resistance
connectors) C13 (female) (3) 10 z
grounding OFF.
6
circuit) Resistance
Hot short in wiring har- a Prepare with starting switch OFF and diagnose with starting switch ON.
7 ness (a contact with 5 Between ground and wiring harness between
V or 24 V circuit) Voltage Max. 1 V
48 D61EX, PX-15E0

OFF.
Harness short Min.
C13 (female) (3) and among CE01 (female) (37) Resistance
– S10 – C13 (female) (1)
short)
Min.
C13 (female) (3) and among CE01 (female) (47) Resistance
Possible 100 kz
– S11 – C13 (female) (2)
causes and
standard value Since the connections among engine Bkup speed sensor – engine har-
in normal state ness – engine controller are suspected to be defective, check a the defec-
tive connection.
Defective wiring
harness connector
tion
Defective engine
10 CE01 Voltage
controller
Circuit diagram related to engine Bkup speed sensor
D61EX, PX-15E0 49
Failure code [CA1633] Abnormal KOMNET: Abnormal communication 1

Action code Failure code Abnormal KOMNET: Abnormal communication
Trouble
Contents of • Engine controller detected an abnormal communication in the KOMNET communication circuit
trouble between pump controller and monitor panel.
Action of • Operate in a default mode.
controller • When the cause of the failure has been eliminated, it returns to normal.
Problem that • Machine may not operate normally because the informations which are exchanged through KOM-
appears on NET communication are not transmitted properly.
machine (A symptom of failure depends on the location where it occurs.)
Related
information

OFF.
Disconnection in wiring
Wiring harnesses between S04 (female) (1), (2)
harness
– CE02 (female) (46), ST2 (female) (32), Resistance Max. 1 z
1 (Disconnection or
CA2 (female) (A), and CA1 (female) (A)
connectors) Wiring harnesses between S04 (female) (3), (4)
– CE02 (female) (47), ST2 (female) (22), Resistance Max. 1 z
CA2 (female) (B), and CA1 (female) (B)
OFF.
Between ground and wiring harnesses between
Defective harness S04 (female) (1), (2) – CE02 (female) (46), ST2
Resistance Min. 1 Mz
grounding (female) (32), CA2 (female) (A), CA1 (female)
2
(Contact with ground (A) and SRV (male) (3)
circuit) Between ground and wiring harnesses between
Possible
causes and S04 (female) (3), (4) – CE02 (female) (47), ST2
standard value (female) (22), CA2 (female) (B), CA1 (female)
in normal state (B) and SRV (male) (10)
Between ground and wiring harnesses between
S04 (female) (1), (2) – CE02 (female) (46), ST2 Max.
Hot short of wiring har- Voltage
(female) (32), CA2 (female) (A), CA1 (female) 5.5 V
ness
3 (A) and SRV (male) (3)
(a contact with 24 V
S04 (female) (3), (4) – CE02 (female) (47), ST2 Max.
Voltage
(female) (22), CA2 (female) (B), CA1 (female) 5.5 V
(B) and SRV (male) (10)
Defective terminal a Prepare with starting switch OFF and diagnose with starting switch still
resistance in CAN OFF.
4
(Internal short circuit CA1 (male) and CA2 (male) Resistance
and disconnection) Between (A) – (B) 120 ± 12 z
5
50 D61EX, PX-15E0
Circuit diagram related CAN communication
D61EX, PX-15E0 51
Action code Failure code Decelerator pedal sensor power source too high: Excessively high voltage
Trouble detected
Contents of • Excessively high voltage (Min. 5.25 V) is detected in the circuit of decelerator pedal sensor power
trouble source.
Problem that
machine
Related
information

OFF.
Between CE02 (female) (22) – all pins of CE02
Harness short Min.
(female) Resistance
(with DCL disconnected)
short)
Possible Wiring harness between CE02 (female) (9) –
Min.
causes and DCL (female) (B) and wiring harness between Resistance
100 kz
standard value CE02 (female) (22) – DCL (female) (A)
in normal state Since the connections among decelerator pedal – body harness – engine
controller are suspected to be defective, visually check them.
2
tion
3
52 D61EX, PX-15E0
D61EX, PX-15E0 53
Action code Failure code Decelerator pedal sensor power source too low: Excessively low voltage
Trouble detected
Contents of
• Excessively low voltage is detected at decelerator pedal sensor power source circuit.
trouble
Problem that
machine
Related
information

grounding OFF.
1
circuit) Resistance
CE02 (female) (22) – DCL (female) (A) 100 kz
Harness short OFF.
Possible 2 (Harness internal Between CE02 (female) (9) – all pins of CE02
causes and short) Min.
(female) Resistance
standard value 100 kz
(with DCL also disconnected)
in normal state
Since the connections among decelerator pedal – body harness – engine
controller are suspected to be defective, visually check them.
3
tion
4
54 D61EX, PX-15E0
D61EX, PX-15E0 55
Loss of pressure feed detected 1
Action code Failure code Loss of pressure feed from supply pump (2): Loss of pressure feed
Trouble detected
Contents of
• Loss of pressure feed (2) occurred in the common rail circuit.
trouble
Action of
controller
Problem that • Engine is hard to start.
appears on • Exhaust gas color becomes black.
machine • Output decreases.
Related
information

causes and
standard value 1 Carry out troubleshooting of [CA559].
in normal state
56 D61EX, PX-15E0
D61EX, PX-15E0 57
Failure code [CA2311] Abnormal IMV solenoid: Abnormal resistance 1

Action code Failure code Abnormal IMV solenoid: Abnormal resistance
Trouble
Contents of
• Resistance value of supply pump actuator circuit is abnormaly high or low.
trouble
Action of
controller
Problem that
appears on • Engine output decreases.
machine
Related
information

1
OFF.
Defective supply pump C17 (male) Resistance
2
actuator
harness
C17 (female) (1)
Resistance Max. 5 z
C17 (female) (2)
Defective harness
causes and OFF.
grounding
standard value 4
in normal state Resistance
Since the connections among inlet metering valve – engine harness –
engine controller are suspected to be defective, visually check for a defec-
tive connection.
Defective wiring
harness connector
tion
OFF.
7
58 D61EX, PX-15E0
Circuit diagram related to inlet metering
D61EX, PX-15E0 59
Failure code [CA2555] Air intake heater relay disconnection:

Disconnection 1
Action code Failure code Air intake heater relay disconnection: Disconnection
Trouble
Contents of
• Disconnection is detected in the drive circuit of air intake heater relay.
trouble
Action of
controller
Problem that
• Air intake heater does not operate (Startability deteriorates in a low temperature and white smoke is
appears on
exhausted.)
machine
Related
• Duplication of failure code: Turn the starting switch ON with coolant temperature below -4°C.
information

OFF (diagnose by itself).
RHR (male) Resistance
Defective preheat relay Between (1) – (2) 300 – 600 z
1 (internal disconnec- a Prepare with starting switch OFF and diagnose with starting switch ON
tion) (diagnose by replacing with other relay)
Replace preheat relay (RHR) with other relay and carry out the procedure
to duplicate the failure code. If failure code changes from flashing to
steady ON, the relay is defective.
harness
Wiring harness between CE02 (female) (40) – RHR Max.
2 (Disconnection or Resistance
(female) (1) 10 z
Possible connectors) Wiring harness between CE02 (female) (42) – RHR Max.
Resistance
causes and (female) (2) 10 z
standard value a Prepare with starting switch OFF and diagnose with starting switch still
in normal state Harness short OFF.
3 (Harness internal Between CE02 (female) (40) – all pins of CE02
short) Min.
(female) Resistance
100 kz
(with RHR also disconnected)
The connections among preheat relay – body harness – engine controller
are suspected to be defective. Visually check them.
4
tion
5 tions than engine
controller
Between (40) – (42) 300 – 600 z
6
60 D61EX, PX-15E0
Circuit diagram related to engine preheat
D61EX, PX-15E0 61
Failure code [CA2556] Air intake heater relay short circuit: Short circuit1
Action code Failure code Air intake heater relay short circuit: Short circuit
Trouble
Contents of
• Short circuit is detected in the drive circuit of air intake heater relay.
trouble
Action of
controller
Problem that
• Air intake heater does not operate (Startability deteriorates in a low temperature and white smoke is
appears on
exhausted.)
machine
Related
• Duplication of failure code: Turn the starting switch ON with coolant temperature below –4°C.
information

OFF (diagnose by itself).
RHR (male) Resistance
Defective preheat relay Between (1) – (2) 300 – 600 z
1 (internal disconnec- a Prepare with starting switch OFF and diagnose with starting switch ON
tion) (diagnose by replacing with other relay)
Replace preheat relay (RHR) with other relay and carry out the procedure
to duplicate the failure code. If failure code changes from flashing to
steady ON, the relay is defective.
grounding OFF.
2
circuit) Resistance
CE02 (female) (40) – RHR (female) (1) 100 kz
Possible
standard value Harness short OFF.
in normal state 3 (Harness internal Between CE02 (female) (40) – all pins of CE02
short) Min.
(female) Resistance
100 kz
(with RHR also disconnected)
The connections among preheat relay – body harness – engine controller
are suspected to be defective. Visually check them.
4
tion
5 tions than engine
controller
Between (40) – (42) 300 – 600 z
6
62 D61EX, PX-15E0
D61EX, PX-15E0 63
SEN02563-00

© 2007 KOMATSU
All Rights Reserved
64
SEN02564-00
D61EX-15E0
D61PX-15E0

Failure code [D110KA] Battery relay: Short circuit ............................................................................... 4
Failure code [D110KB] Battery relay: Disconnection ........................................................................... 6
Failure code [D130KA] Neutral safety relay: Short circuit .................................................................... 8
Failure code [D130KB] Neutral safety relay: Disconnection .............................................................. 10
Failure code [D161KA] Back-up alarm relay: Disconnection ............................................................. 12
Failure code [D161KB] Back-up alarm relay: Short circuit ................................................................. 14
Failure code [DAFRKR] Monitor panel CAN communication: Defective communication ................... 16
Failure code [DAQ0KT] [DB30KT] Steering and transmission controller: Abnormality in controller... 18
Failure code [DAQ1KK] [DB31KK] Main power source of steering and transmission controller:
Power source voltage drop and input .................................................................................. 20
Failure code [DAQ2KK] [DB32KK] Load power source of steering and transmission controller:
Power source voltage drop and input .................................................................................. 22
Failure code [DAQ5KK] [DB35KK] Steering and transmission controller sensor
5 V power source: Power source voltage drop and input .................................................... 24
D61EX, PX-15E0 1
Failure code [DAQ6KK] [DB36KK] Steering and transmission controller sensor

24 V power source: Power source voltage drop and input .................................................. 26
Failure code [DAQ9KQ] [DB39KQ] Steering and transmission controller model selection:
Inconsistency in model select signal ................................................................................... 28
Failure code [DB2RKR] Steering and transmission controller CAN communication:
Defective communication .................................................................................................... 30
Failure code [DB30KT] [DAQ0KT] Steering and transmission controller: Abnormality in controller... 32
Failure code [DB31KK] [DAQ1KK] Main power source of steering
and transmission controller: Power source voltage drop and input ..................................... 32
Failure code [DAB32KK] [DAQ2KK] Load power source of steering
and transmission controller: Power source voltage drop and input ..................................... 32
Failure code [DB35KK] [DAQ5KK] Steering and transmission controller sensor
5 V power source: Power source voltage drop and input .................................................... 32
Failure code [DB36KK] [DAQ6KK] Steering and transmission controller sensor
24 V power source: Power source voltage drop and input .................................................. 32
Failure code [DB39KQ] [DAQ9KQ] Steering and transmission controller model selection:
Inconsistency in model select signal ................................................................................... 32
Failure code [DD12KA] Shift up switch: Disconnection ...................................................................... 34
Failure code [DD12KB] Shift up switch: Short circuit ......................................................................... 36
Failure code [DD13KA] Shift down switch: Disconnection ................................................................. 38
Failure code [DD13KB] Shift down switch: Short circuit..................................................................... 40
Failure code [DD14KA] [DDQ2KA] Parking brake lever switch: Disconnection ................................. 42
Failure code [DD14KB] [DDQ2KB] Parking brake lever switch: Short circuit..................................... 44
Failure code [DDQ2KA] [DD14KA] Parking brake lever switch: Disconnection ................................. 46
Failure code [DDQ2KB] [DD14KB] Parking brake lever switch: Short circuit..................................... 46
Failure code [DGS1KX] Hydraulic oil temperature sensor: Input signal is out of normal range ......... 48
Failure code [DGT1KA] Power train oil temperature sensor: Disconnection ...................................... 50
Failure code [DGT1KX] Power train oil temperature sensor: Input signal is out of normal range ...... 51
Failure code [DK10KA] Fuel dial: Disconnection................................................................................ 52
Failure code [DK10KB] Fuel dial: Short circuit ................................................................................... 54
Failure code [DK30KA] Steering potentiometer (1): Disconnection.................................................... 56
Failure code [DK30KB] Steering potentiometer (1): Short circuit ....................................................... 58
Failure code [DK30KX] Steering potentiometer: Input signal is out of normal range ......................... 60
Failure code [DK30KZ] Steering potentiometer: Disconnection or short circuit (Double failure) ........ 61
Failure code [DK30L8] Steering potentiometer: Inconsistent analog signal ....................................... 61
Failure code [DK31KA] Steering potentiometer (2): Disconnection.................................................... 62
Failure code [DK31KB] Steering potentiometer (2): Short circuit ....................................................... 64
Failure code [DK40KA] Brake potentiometer: Disconnection............................................................. 66
Failure code [DK40KB] Brake potentiometer: Short circuit ................................................................ 67
2 D61EX, PX-15E0
D61EX, PX-15E0 3
Failure code [D110KA] Battery relay: Short circuit 1

Action code Failure code Battery relay: Short circuit
Trouble
— D110KA (Steering and transmission controller system)
Contents of
• Abnormal current flowed to battery relay circuit when outputting it.
trouble
Action of
• Stops output to battery relay circuit.
controller
Problem that
appears on • Problem may occur in data writing to ROM (nonvolatile memory) of each controller.
machine
• Output status (voltage) to battery relay can be checked in monitoring mode.
Related
(Code 60600: Battery relay drive voltage)
information
• Method of reproducing failure code: Switch starting switch from ON o OFF.

OFF.
Defective battery relay Battery relay Continuity
1 (Internal disconnec-
tion) Between SW terminal –
Continue
SWG terminal
Between SW terminal – ground Min. 1 Mz
Possible
harness OFF.
causes and
standard value 2 (Disconnection or Wiring harness between ST3 (female) (4) – bat-
in normal state defective contact of tery relay SW terminal and S13 (female) (10) – Resistance Min. 1 Mz
connectors) RSD (female) (1) with ground
Defective diode
3 (Internal short-circuit- See the section of testing procedure of diode (Testing and adjusting).
ing)
Defective steering and ST3 (female) Starting switch Voltage
4
transmission controller Between (4) –
ON 20 – 30 V
chassis ground
4 D61EX, PX-15E0
Circuit diagram related to battery relay
D61EX, PX-15E0 5
Failure code [D110KB] Battery relay: Disconnection 1

Action code Failure code Battery relay: Disconnection
Trouble
— D110KB (Steering and transmission controller system)
Contents of
• Current does not flow when outputting it to battery relay circuit.
trouble
Action of
• Stops output to battery relay circuit.
controller
Problem that
appears on • Problem may occur in data writing to ROM (nonvolatile memory) of each controller.
machine
• Output status (voltage) to battery relay can be checked in monitoring mode.
Related
(Code 60600: Battery relay drive voltage)
information
• Method of reproducing failure code: Switch starting switch from ON o OFF.

Defective battery relay OFF.
1 (Internal disconnec- Battery relay Continuity
tion) Between SW terminal –
Continue
SWG terminal
harness
Wiring harnesses between ST3 (female) (4) –
Possible battery relay SW terminal
causes and connectors) Wiring harnesses between SWG terminal –
standard value Resistance Max. 1 z
GND03
in normal state
Hot short of wiring har- OFF.
ness Wiring harness between ST3 (female) (4) – bat-
3
(Contact with 24 V cir- tery relay SW terminal and S13 (female) (10) –
cuit) Voltage Max. 1 V
RSD (female) (1) with ground
(In or out of contact with constant power supply)
Defective steering and OFF.
4
transmission controller ST3 (female) Continuity
Between (4) – chassis ground Continue
6 D61EX, PX-15E0
Circuit diagram related to battery relay
D61EX, PX-15E0 7
Failure code [D130KA] Neutral safety relay: Short circuit 1

Action code Failure code Neutral safety relay: Short circuit
Trouble
E02 D130KA (Steering and transmission controller system)
Contents of
• Abnormal current flowed in neutral safety relay circuit at the time of ground output.
trouble
controller • Stops ground output to neutral safety relay circuit.
Problem that
appears on • Engine does not start.
machine
• Output status (voltage) to neutral safety relay can be checked in monitoring mode.
(Code 50900: Neutral safety relay drive voltage)
• Method of reproducing failure code: Turn starting switch ON + Shift parking brake lever (to lock position)
Related
a This failure code detects abnormality in primary side (coil side) of neutral safety relay, but not in sec-
information
ondary side (contact side).
• “KB” is usually displayed for symptom code when short circuit occurs. However, “KA” is displayed for
short circuit in the neutral safety relay circuit.
Defective neutral a Prepare with starting switch OFF and diagnose with starting switch still
safety relay OFF.
1
(Internal disconnec- NSF (male) Resistance
tion) Between (1) – (2) 200 – 400 z
Possible
Hot short of wiring har- a Prepare with starting switch OFF and diagnose with starting switch ON.
causes and
ness
standard value 2
(Contact with 24 V cir- Wiring harness between ST2 (female) (8) – NSF Voltage Max. 1 V
in normal state (female) (2) with ground.
cuit)
Defective steering and ST2 Parking lever Voltage
3
transmission controller Between (8) – Free position 20 – 30 V
chassis ground Lock position Max. 1 V
8 D61EX, PX-15E0
Circuit diagram related to neutral safety relay
D61EX, PX-15E0 9
Failure code [D130KB] Neutral safety relay: Disconnection 1

Action code Failure code Neutral safety relay: Disconnection
Trouble
E02 D130KB (Steering and transmission controller system)
Contents of
• 24 V is not generated at neutral relay circuit when ground is shut off.
trouble
controller • Stops ground output to neutral safety relay circuit.
Problem that
• Engine can not start (Disconnection).
appears on
• Engine can start, regardless of position of parking brake lever (Grounding).
machine
• Output status (voltage) to neutral safety relay can be checked in monitoring mode.
(Code 50900: Neutral safety relay drive voltage)
• Method of reproducing failure code: Turn starting switch ON + Shift parking brake lever (to free posi-
Related tion)
information a This failure code detects abnormality in primary side (coil side) of neutral safety relay, but not in sec-
ondary side (contact side).
• “KA” is usually displayed for symptom code when disconnection occurs. However, “KB” is displayed for
disconnection in the neutral safety relay circuit.
Defective neutral a Prepare with starting switch OFF and diagnose with starting switch still
safety relay OFF.
1
(Internal disconnec- NSF (male) Resistance
tion) Between (1) – (2) 200 – 400 z
harness
Wiring harness between ST2 (female) (8) – NSF
(female) (2)
Possible Wiring harness between NSF (female) (1) – start-
connectors) Resistance Max. 1 z
causes and ing switch ACC (270)
standard value
in normal state a Prepare with starting switch OFF and diagnose with starting switch still
Defective harness OFF.
grounding Wiring harness between ST2 (female) (8) – NSF
3 Resistance Min. 1 Mz
(Contact with ground (female) (2) with ground.
circuit) Wiring harness between NSF (female) (1) – start-
ing switch ACC (270) with ground
4
transmission controller Between (8) – Free position 20 – 30 V
chassis ground Lock position Max. 1 V
10 D61EX, PX-15E0
Circuit diagram related to neutral safety relay
D61EX, PX-15E0 11
Failure code [D161KA] Back-up alarm relay: Disconnection 1

Action code Failure code Back-up alarm relay: Disconnection
Trouble
E01 D161KA (Steering and transmission controller system)
Contents of
• 24 V is not generated at neutral safety relay circuit when ground is shut off.
trouble
Action of
• Stops ground output to back-up alarm relay circuit.
controller
Problem that • Back-up alarm does not turn on.
appears on • Back-up alarm turns on, regardless of positions of steering and forward-reverse lever and gear shift
machine lever.
• Output status (voltage) to back-up alarm relay can be checked in monitoring mode.
(Code 70400: Back-up alarm relay drive voltage)
Related • Method of reproducing failure code: Turn starting switch ON + Shift steering and forward-reverse
information lever and gear shift lever to neutral
a This failure code detects abnormality in primary side (coil side) of back-up alarm relay, but not in
secondary side (contact side).

If fuse is blown, circuit probably has short circuiting
1 Defective fuse FS2-6
with ground.
Defective back-up a Prepare with starting switch OFF and diagnose with starting switch still
alarm relay OFF.
2
(Internal disconnec- BKA (male) Resistance
tion) Between (1) – (2) 200 – 400 z
harness
Wiring harness between ST2 (female) (18) –
Possible 3 (Disconnection or Resistance Max. 1 z
BKA (female) (2)
causes and defective contact of
connectors) Wiring harnesses between BKA (female) (1) –
FS2-6 outlet
in normal state
grounding Wiring harness between ST2 (female) (18) –
(Contact with ground BKA (female) (2) with ground.
circuit) Between wiring harnesses of BKA (female) (1) –
FS2-6 outlet and ground
5
transmission controller Between (18) – Neutral position 20 – 30 V
chassis ground Reverse position Max. 1 V
12 D61EX, PX-15E0
Circuit diagram related to back-up alarm relay
D61EX, PX-15E0 13
Failure code [D161KB] Back-up alarm relay: Short circuit 1

Action code Failure code Back-up alarm relay: Short circuit
Trouble
E01 D161KB (Steering and transmission controller system)
Contents of
• Abnormal current flowed in back-up alarm relay circuit at the time of ground output.
trouble
Action of
• Stops ground output to back-up alarm relay circuit.
controller
Problem that
appears on • Back-up alarm does not turn on.
machine
• Output status (voltage) to back-up alarm relay can be checked in monitoring mode.
(Code 70400: Back-up alarm relay drive voltage)
Related • Method of reproducing failure code: Turn starting switch ON + Shift steering and forward-reverse
information lever and gear shift lever (to reverse)
a This failure code detects abnormality in primary side (coil side) of back-up alarm relay, but not in
secondary side (contact side).
Defective back-up a Prepare with starting switch OFF and diagnose with starting switch still
alarm relay OFF.
1
(Internal disconnec- BKA (male) Resistance
tion) Between (1) – (2) 200 – 400 z
Possible
causes and
ness
standard value 2
(Contact with 24 V cir- Wiring harness between ST2 (female) (18) – Voltage Max. 1 V
in normal state BKA (female) (2) with ground.
cuit)
3
transmission controller Between (18) – Neutral position 20 – 30 V
chassis ground Reverse position Max. 1 V
14 D61EX, PX-15E0
Circuit diagram related to back-up alarm relay
D61EX, PX-15E0 15
Failure code [DAFRKR] Monitor panel CAN communication: Defective

communication 1
Action code Failure code Monitor panel CAN communication: Defective communication
Trouble
CALL E03 DAFRKR (Monitor panel system)
Contents of
• Monitor panel cannot recognize steering and transmission controller with CAN communication circuit.
trouble
Problem that • System may not operate normally.
Related
information

OFF.
Wiring harness between S04 (female) (1) (2) –
ST2 (female) (32), – CE02 (female) (46), – CA1
harness Resistance Max. 1 z
(female) (A), – CA2 (female) (A), – G01 (female)
1 (Disconnection or
(8), and – SRV (male) (3)
connectors) Wiring harness between S04 (female) (3) (4) –
Resistance Max. 1 z
(female) (B), – CA2 (female) (B), – G01 (female)
(7), and – SRV (male) (10)
OFF.
Defective harness ST2 (female) (32), – CE02 (female) (46), – CA1
grounding (female) (A), – CA2 (female) (A), – G01 (female)
2
(Contact with ground (8), and – SRV (male) (3) with ground
circuit) Wiring harness between S04 (female) (3) (4) –
Possible
causes and ST2 (female) (22), – CE02 (female) (47), – CA1
standard value (female) (B), – CA2 (female) (B), – G01 (female)
in normal state (7), and – SRV (male) (10) with ground
Hot short of wiring har- Voltage Max. 1 V
ness
3 (8), and – SRV (male) (3) with ground
(Contact with 24 V cir-
cuit) Wiring harness between S04 (female) (3) (4) –
Voltage Max. 1 V
(7), and – SRV (male) (10) with ground
Defective CAN termi- OFF.
4
nal resistance CA1 (male), CA2 (male) Resistance
Between (A) – (B) 100 – 400 z
Defective monitor
If no problem is found in causes 1 – 4, it is suspected that monitor panel or
panel or defective
5 steering and transmission controller is defective.
steering and transmis-
(Troubleshooting cannot be carried out since it is internal defect.)
sion controller
16 D61EX, PX-15E0
Circuit diagram related CAN communication
D61EX, PX-15E0 17
Failure code [DAQ0KT] [DB30KT] Steering and transmission controller:

Abnormality in controller 1
Steering and transmission controller: Abnormality in controller
DAQ0KT Trouble
E01 (Steering and transmission controller system)
DB30KT
Contents of
• Information of ROM (nonvolatile memory) of steering and transmission controller is not normal.
trouble
Action of
• Defaults internal adjustment value.
controller
Problem that
appears on • Gear shift feeling of transmission may become worse.
machine
Related • Both of DAQ0KT and DB30KT are displayed.
information • Duplication of failure code: turn ON the starting switch.

Possible
causes and Troubleshooting cannot be carried out since it is internal defect.
standard value Defective steering and • Adjust once in adjustment mode (Code 0002).
1
in normal state transmission controller (There is no problem to keep using controller unless any visible problem
appears on machine.)
18 D61EX, PX-15E0
D61EX, PX-15E0 19
Failure code [DAQ1KK] [DB31KK] Main power source of steering and

transmission controller: Power source voltage drop and input 1
Action code Failure code Main power supply of steering and transmission controller: Power source
DAQ1KK Trouble voltage drop and input
CALL E04 (Steering and transmission controller system)
DB31KK
Contents of
• Power source voltage of steering and transmission controller is less than 17 V.
trouble
• Monitor panel may not display normally.
Problem that
• Relay and solenoid may not drive and therefore, system may not operate normally.
appears on
machine
• Once machine is stopped, it becomes impossible to travel.
• Both of DAQ1KK and DB31KK are displayed.
Related • Battery charge condition (voltage) can be checked in monitoring mode.
information (Code 03200: Battery voltage)

1 Defective fuse FS2-7 If fuse FS2-7 is blown, circuit probably has short circuiting with ground.
OFF.
Disconnection in wiring Wiring harness between ST3 (female) (1) (11) –
FS2-7
2 (Disconnection or
defective contact of Wiring harness between FS2-3 – battery relay H
Resistance Max. 1 z
connectors) terminal
Possible Wiring harness between ST3 (female) (21) (31)
Resistance Max. 1 z
causes and (32) (33) – ground
in normal state OFF.
Defective harness
grounding Wiring harness between ST3 (female) (1) (11) –
(Contact with ground FS2-7 with ground
circuit) Wiring harness between FS2-3 – battery relay H
terminal with ground
Defective steering and ST3 Voltage
4
transmission controller Between (1) (11) –
20 – 30 V
(21) (31) (32) (33)
20 D61EX, PX-15E0
Circuit diagram related to steering and transmission power source
D61EX, PX-15E0 21
Failure code [DAQ2KK] [DB32KK] Load power source of steering and

Action code Failure code Load power source of steering and transmission controller: Power source
DAQ2KK Trouble voltage drop and input
DB32KK
Contents of • Power source voltage of load (relay, solenoid and etc,) on steering and transmission controller
trouble is less than 17 V.
Problem that • Relay and solenoid may not drive and therefore, system may not operate normally.
machine • Once machine is stopped, it becomes impossible to travel.
• Both of DAQ2KK and DB32KK are displayed.
Related • Battery charge condition (voltage) can be checked in monitoring mode.
information (Code 03200: Battery voltage)

1 Defective fuse FS1-9 If fuse FS1-9 is blown, circuit probably has short circuiting with ground.
OFF.
Disconnection in wiring Wiring harness between ST3 (female) (2) (12)
(22) – FS1-9
2 (Disconnection or
defective contact of Wiring harness between FS1-3 – battery relay C
Resistance Max. 1 z
connectors) terminal
Possible Wiring harness between ST3 (female) (21) (31)
Resistance Max. 1 z
causes and (32) (33) – ground
Defective harness
grounding Wiring harness between ST3 (female) (2) (12)
(Contact with ground (22) – FS1-9 with ground
circuit) Wiring harness between FS1-3 – battery relay C
terminal with ground
4
transmission controller Between (2) (12) (22) –
20 – 30 V
(21) (31) (32) (33)
22 D61EX, PX-15E0
Circuit diagram related to steering and transmission power source
D61EX, PX-15E0 23
Failure code [DAQ5KK] [DB35KK] Steering and transmission controller

sensor 5 V power source: Power source voltage drop and input 1
Action code Failure code Steering and transmission controller sensor 5 V power source:
DAQ5KK Trouble Power source voltage drop and input
DB35KK
• Voltage of 5 V power source circuit of steering and transmission controller sensor is less than 4.5 V
Contents of
or more than 5.5 V.
trouble
• Abnormal current flowed in 5 V power source circuit of steering and transmission controller sensor.
Action of
• Stops output to 5 V power source circuit if abnormal voltage flows.
controller
Related • Both of DAQ5KK and DB35KK are displayed.

If right-hand connector is disconnected and failure code lights
Defective brake potenti- up (to indicate returning to normal), the cause is an internal
BRK
1 ometer trouble,
connector
(Internal short circuit) a Turn starting switch OFF, disconnect connector, turn the
switch ON and carry out troubleshooting.
If right-hand connector is disconnected and failure code lights
Defective fuel dial up (to indicate returning to normal), the cause is an internal
DIAL
2 potentiometer trouble,
connector
OFF.
Defective forward- TL2 (male) Resistance
3 reverse potentiometer
(Internal short circuit) Between (4) – (1) 3.2 kz ± 20%
Sensor Between (4) –
Min. 1 Mz
chassis ground
Possible
standard value OFF.
in normal state Defective steering TL2 (male) Resistance
4 potentiometer
(Internal short circuit) Between (5) – (8) 3.2 kz ± 20%
Sensor Between (5) –
Min. 1 Mz
chassis ground
grounding
5 Wiring harness between ST1 (female) (22) – TL2
(Contact with ground
circuit) (female) (5), – TL2 (female) (4) – DIAL (female) Resistance Min. 1 Mz
(A) – BRK (female) (C) with ground.
ness Wiring harness between ST1 (female) (22) – TL2
6
(Contact with 24 V cir- (female) (5), – TL2 (female) (4) – DIAL (female) Voltage Max. 1 V
cuit) (A) – BRK (female) (C) with ground.
Defective steering and
7 ST1 Voltage
Between (22) – (21) 4.5 – 5.5 V
24 D61EX, PX-15E0
Circuit diagram related to steering and transmission controller sensor 5 V power source
D61EX, PX-15E0 25
Failure code [DAQ6KK] [DB36KK] Steering and transmission controller

Action code Failure code Steering and transmission controller sensor 24 V power source: Power
DAQ6KK Trouble source voltage drop and input
DB36KK
• Voltage of 24 V power source circuit of steering and transmission controller sensor is less than 12 V
Contents of
or more than 30 V.
trouble
• Abnormal current flowed in 24 V power source circuit of steering and transmission controller sensor.
Action of
controller
• Stops output to 24 V power source circuit if abnormal voltage flows.
Related • Both of DAQ6KK and DB36KK are displayed.

If right-hand connector is disconnected and service code
Defective pitch angle lights up (to indicate returning to normal), the cause is an
PT1
1 sensor internal trouble,
connector
Possible
causes and Defective harness a Prepare with starting switch OFF and diagnose with starting switch still
standard value grounding OFF.
2
in normal state (Contact with ground Wiring harness between ST1 (female) (16) – PT1
circuit) Resistance Min. 1 Mz
(female) (C) with ground.
3
transmission controller ST1 Voltage
Between (16) – (21) 20 – 30 V
26 D61EX, PX-15E0
Circuit diagram related to steering and transmission controller sensor 24 V power source
D61EX, PX-15E0 27
Failure code [DAQ9KQ] [DB39KQ] Steering and transmission controller

model selection: Inconsistency in model select signal 1
Action code Failure code Steering and transmission controller model selection: Inconsistency in
DAQ9KQ Trouble model select signal
DB39KQ
• Internal specification setting of steering and transmission controller is inconsistent with specification
Contents of
setting signal.
trouble
(Steering and transmission controller cannot be recognized normally.)
Action of
• Stops all outputs to steering and transmission controller.
controller
• Limits operation of engine, transmission and brake.
Problem that • Machine does not operate at all.
machine • Once machine is stopped, it becomes impossible to travel.
Related • Both of DAQ9KQ and DB39KQ are displayed.

It is normal if failure code lights on (to indicate returning to normal) after
carrying out adjustment mode.
1 transmission controller
• Adjustment code 0002: Steering and transmission controller
adjustment
specification set
harness OFF.
2 (Disconnection, defec-
Possible tive contact of connec- Wiring harnesses between ST3 (female) (30) – Resistance Max. 1 z
causes and tors) GND01
standard value
in normal state Defective harness a Prepare with starting switch OFF and diagnose with starting switch still
grounding OFF.
3
(Contact with ground Between ST3 (female) (40) – PL2 (18) and
ground
4
transmission controller Between (30) – chassis ground Max. 1 V
Between (40) – chassis ground 5 – 11 V
28 D61EX, PX-15E0
Circuit diagram related to steering and transmission controller model selection
D61EX, PX-15E0 29
Failure code [DB2RKR] Steering and transmission controller CAN

communication: Defective communication 1
Action code Failure code Steering and transmission controller CAN communication: Defective com-
Trouble munication
CALL E03 DB2RKR (Steering and transmission controller system)
Contents of • Steering and transmission controller cannot recognize engine controller with CAN communication
trouble circuit.
• System may not operate normally.
Problem that
• When machine is traveling, engine speed is limited up to medium (half) at a certain rate.
appears on
machine
Related
information

OFF.
1 (Disconnection or
(8), and – SRV (male) (3)
connectors) Wiring harness between S04 (female) (3) (4) –
Resistance Max. 1 z
(7), and – SRV (male) (10)
OFF.
Defective harness ST2 (female) (32), – CE02 (female) (46), – CA1
grounding (female) (A), – CA2 (female) (A), – G01 (female)
2
(Contact with ground (8), and – SRV (male) (3) with ground
circuit) Wiring harness between S04 (female) (3) (4) –
Possible
causes and ST2 (female) (22), – CE02 (female) (47), – CA1
standard value (female) (B), – CA2 (female) (B), – G01 (female)
in normal state (7), and – SRV (male) (10) with ground
Hot short of wiring har- Voltage Max. 1 V
ness
3 (8), and – SRV (male) (3) with ground
cuit) Wiring harness between S04 (female) (3) (4) –
Voltage Max. 1 V
(7), and – SRV (male) (10) with ground
Defective CAN termi- OFF.
4
nal resistance CA1 (male), CA2 (male) Resistance
Between (A) – (B) 100 – 140 z
Defective monitor
If no problem is found in causes 1 – 4, it is suspected that monitor panel or
panel or defective
5 steering and transmission controller is defective.
steering and transmis-
(Troubleshooting cannot be carried out since it is internal defect.)
sion controller
30 D61EX, PX-15E0
Circuit diagram related to CAN communication
D61EX, PX-15E0 31
Failure code [DB30KT] [DAQ0KT] Steering and transmission controller:

Abnormality in controller 1
a See DAQ0KT
Failure code [DB31KK] [DAQ1KK] Main power source of steering and

a See DAQ1KK
Failure code [DAB32KK] [DAQ2KK] Load power source of steering and

a See DAQ2KK
Failure code [DB35KK] [DAQ5KK] Steering and transmission controller

a See DAQ5KK
Failure code [DB36KK] [DAQ6KK] Steering and transmission controller

a See DAQ6KK
Failure code [DB39KQ] [DAQ9KQ] Steering and transmission controller

model selection: Inconsistency in model select signal 1
a See DAQ9KQ
32 D61EX, PX-15E0
D61EX, PX-15E0 33
Failure code [DD12KA] Shift up switch: Disconnection 1

Action code Failure code Shift up switch: Disconnection
Trouble
E02 DD12KA (Steering and transmission controller system)
Contents of
• Signals of two systems of shift up switch circuit were turned OFF (OPEN) at the same time.
trouble
controller • Recognizes that switch is not pressed.
Problem that
• Cannot shift up.
appears on
machine
• Of signals of two systems of switch, NO is for operation detection and NC is for error detection.
Related • Input status (ON / OFF) from shift up switch can be checked in monitoring mode.
information (Code 40905: Transmission-related controller input signal 1)
• Method of reproducing failure code: Turn starting switch ON + Operate shift up switch

OFF.
Defective shift up Shift up switch

SFTU (male)
switch OFF (Release) ON (Press)
1
(Internal disconnec- Resistance between
tion) Max. 1 z Min. 1 Mz
(2) – (3)
Resistance between
Min. 1 Mz Max. 1 z
(2) – (1)
OFF.
Disconnection in wiring Wiring harness between ST1 (female) (12) –
SFTU (female) (3)
Possible 2 (Disconnection or
defective contact of Wiring harness between ST3 (female) (9) –
causes and Resistance Max. 1 z
connectors) SFTU (female) (1)
standard value
in normal state Wiring harness between ST1 (female) (4) –
Resistance Max. 1 z
SFTU (female) (2)
Hot short of wiring har-
ness Voltage Max. 1 V
3 SFTU (female) (3) with ground
cuit) Wiring harness between ST3 (female) (9) –
Voltage Max. 1 V
SFTU (female) (1) with ground
Shift up switch
ST1, ST3
OFF (Release) ON (Press)
4 Voltage between
transmission controller Max. 1 V 5 – 11 V
ST1 (12) – ST1 (4)
Voltage between
5 – 11 V Max. 1 V
ST3 (9) – ST1 (4)
34 D61EX, PX-15E0
Circuit diagram related to shift up and shift down switch
D61EX, PX-15E0 35
Failure code [DD12KB] Shift up switch: Short circuit 1

Action code Failure code Shift up switch: Short circuit
Trouble
E02 DD12KB (Steering and transmission controller system)
Contents of
• Signals of two systems of shift up switch circuit were turned ON (CLOSE) at the same time.
trouble
Problem that
• Cannot shift up.
appears on
machine
Related • Input status (ON / OFF) from shift up switch can be checked in monitoring mode.
• Method of reproducing failure code: Turn starting switch ON + Operate shift up switch

OFF.
Shift up switch
Defective shift up SFTU (male)
1 switch
(Internal short circuit) Resistance between
Max. 1 z Min. 1 Mz
(2) – (3)
Resistance between
Min. 1 Mz Max. 1 z
(2) – (1)
causes and Defective harness OFF.
standard value grounding Wiring harness between ST1 (female) (12) –
in normal state 2 Resistance Min. 1 Mz
(Contact with ground SFTU (female) (3) with ground
circuit) Wiring harness between ST3 (female) (9) –
SFTU (female) (1) with ground
Shift up switch
ST1, ST3
3 Voltage between
ST1 (12) – ST1 (4)
Voltage between
5 – 11 V Max. 1 V
ST3 (9) – ST1 (4)
36 D61EX, PX-15E0
D61EX, PX-15E0 37
Failure code [DD13KA] Shift down switch: Disconnection 1

Action code Failure code Shift down switch: Disconnection
Trouble
E02 DD13KA (Steering and transmission controller system)
Contents of
• Signals of two systems of shift down switch circuit were turned OFF (OPEN) at the same time.
trouble
Problem that
• Cannot shift down.
appears on
machine
Related • Input status (ON / OFF) from shift down switch can be checked in monitoring mode.
• Method of reproducing failure code: Turn starting switch ON + Operate shift down switch

OFF.
Defective shift down Shift down switch

SFTD (female)
switch OFF (Release) ON (Press)
1
(2) – (3)
Resistance between
Min. 1 Mz Max. 1 z
(2) – (1)
OFF.
SFTD (male) (3)
connectors) SFTD (male) (1)
standard value
in normal state Wiring harness between ST1 (female) (4) –
Resistance Max. 1 z
SFTD (male) (2)
3 SFTD (male) (3) with ground
cuit) Wiring harness between ST1 (female) (18) –
Voltage Max. 1 V
SFTD (male) (1) with ground
Shift down switch
ST1
4 Voltage between
ST1 (24) – ST1 (4)
Voltage between
5 – 11 V Max. 1 V
ST1 (18) – ST1 (4)
38 D61EX, PX-15E0
D61EX, PX-15E0 39
Failure code [DD13KB] Shift down switch: Short circuit 1

Action code Failure code Shift down switch: Short circuit
Trouble
E02 DD13KB (Steering and transmission controller system)
Contents of
• Signals of two systems of shift down switch circuit were turned ON (CLOSE) at the same time.
trouble
Problem that
• Cannot shift down.
appears on
machine
Related • Input status (ON / OFF) from shift down switch can be checked in monitoring mode.
• Method of reproducing failure code: Turn starting switch ON + Operate shift down switch

OFF.
Shift down switch
Defective shift down SFTD (female)
1 switch
Max. 1 z Min. 1 Mz
(2) – (3)
Resistance between
Min. 1 Mz Max. 1 z
(2) – (1)
standard value grounding Wiring harness between ST1 (female) (24) –
(Contact with ground SFTD (male) (3) with ground
circuit) Wiring harness between ST1 (female) (18) –
SFTD (male) (1) with ground
Shift down switch
ST1
3 Voltage between
ST1 (24) – ST1 (4)
Voltage between
5 – 11 V Max. 1 V
ST1 (18) – ST1 (4)
40 D61EX, PX-15E0
D61EX, PX-15E0 41
Failure code [DD14KA] [DDQ2KA] Parking brake lever switch:

Disconnection 1
Parking brake lever switch: Disconnection
DD14KA Trouble
DDQ2KA
Contents of • Signals of two systems of parking brake lever switch circuit were turned OFF (OPEN) at the same
trouble time.
Action of
• Recognizes that parking brake lever is in free position.
controller
Problem that • Once machine is stopped, engine speed is limited to medium (half).
appears on • Once machine is stopped, travel is limited to F1 and R1.
machine • Engine cannot be started.
• Both of DD14KA and DDQ2KA are displayed.
Related
• Input status (ON / OFF) from parking brake switch can be checked in monitoring mode.
information
(Code 40910: Steering-related controller input signal 1)
• Method of reproducing failure code: Turn starting switch ON + Shift parking brake lever

OFF.
Defective parking Parking brake lever

NSW (male)
brake lever switch Free position Lock position
1
ground (A) – (B)
Resistance between
Min. 1 Mz Max. 1 z
ground (A) – (C)
OFF.
NSW (female) (C)
defective contact of Wiring harness between ST2 (female) (5) – NSW
connectors) (female) (B)
standard value
in normal state Wiring harness between ST1 (female) (4) – NSW
Resistance Max. 1 z
(female) (A)
Hot short circuiting in
wiring harness Voltage Max. 1 V
3 NSW (female) (C) with ground.
cuit) Wiring harness between ST2 (female) (5) – NSW
Voltage Max. 1 V
(female) (B) with ground.
Parking brake lever
ST2
Free position Lock position
4 Voltage between
(5) – ground
Voltage between
5 – 11 V Max. 1 V
(15) – ground
42 D61EX, PX-15E0
Circuit diagram related to parking brake lever switch
D61EX, PX-15E0 43
Failure code [DD14KB] [DDQ2KB] Parking brake lever switch: Short

circuit 1
Parking brake lever switch: Short circuit
DD14KB Trouble
DDQ2KB
Contents of • Signals of two systems of parking brake lever switch circuit were turned ON (CLOSE) at the same
trouble time.
Action of
• Recognizes that parking brake lever is in free position.
controller
Problem that • Once machine is stopped, engine speed is limited to medium (half).
appears on • Once machine is stopped, travel is limited to F1 and R1.
machine • Engine cannot be started.
• Both of DD14KB and DDQ2KB are displayed.
Related
• Input status (ON / OFF) from parking brake switch can be checked in monitoring mode.
information
(Code 40910: Steering-related controller input signal 1)
• Method of reproducing failure code: Turn starting switch ON + Shift parking brake lever

OFF.
Parking brake lever
Defective parking NSW (male)
1 brake lever switch
Max. 1 z Min. 1 Mz
(A) – (B)
Resistance between
Min. 1 Mz Max. 1 z
(A) – (C)
standard value grounding Wiring harness between NSW (female) (B) –
(Contact with ground ST2 (female) (5) with ground.
circuit) Wiring harness between NSW (female) (C) –
ST2 (female) (15) with ground.
Parking brake lever
ST2
3 Voltage between
(5) – ground
Voltage between
5 – 11 V Max. 1 V
(15) – ground
44 D61EX, PX-15E0
Circuit diagram related to parking brake lever switch
D61EX, PX-15E0 45
Failure code [DDQ2KA] [DD14KA] Parking brake lever switch:

Disconnection 1
a See DD14KA
Failure code [DDQ2KB] [DD14KB] Parking brake lever switch: Short

circuit 1
a See DD14KB
46 D61EX, PX-15E0
D61EX, PX-15E0 47
Failure code [DGS1KX] Hydraulic oil temperature sensor: Input signal is

out of normal range 1
Action code Failure code Hydraulic oil temperature sensor: Input signal is out of normal range
Trouble
— DGS1KX (Steering and transmission controller system)
Contents of
• Hydraulic oil temperature sensor signal is out of normal range.
trouble
Action of
• Only memorizes the trouble. There is no need to raise an alarm in particular.
controller
Problem that
• Hydraulic oil temperature on monitor panel is not displayed normally.
appears on
• Fan speed is limited to half.
machine
• Hydraulic oil temperature status (temperature) can be checked in monitoring mode.
Related
(Code 04401: Hydraulic oil temperature)
information
• Method of reproducing failure code: Turn starting switch ON or start engine.

Defective hydraulic oil OFF.
temperature sensor SDS (male) Resistance
1
(Internal disconnec-
tion and short circuit) Between (1) – (2) 3.5 kz – 90 kz (10 – 100°C)
Between (1), (2) – chassis ground Min. 1 Mz
harness
Wiring harness between ST1 (female) (9) – SDS
(female) (1)
connectors) Wiring harness between ST1 (female) (21) –
Possible Resistance Max. 1 z
SDS (female) (2)
causes and
standard value Defective harness a Prepare with starting switch OFF and diagnose with starting switch still
in normal state grounding OFF.
3
(Contact with ground Between ground and wiring harness between
ST1 (female) (9) – SDS (female) (1)
ness
4
(Contact with 24 V cir- Between ground and wiring harness between Voltage Max. 1 V
cuit) ST1 (female) (9) – SDS (female) (1)
OFF.
Defective steering and ST1 (female) Resistance
5
Between (9) – (21) 3.5 kz – 90 kz (10 – 100°C)
Between (9) – chassis ground Min. 1 Mz
48 D61EX, PX-15E0
Circuit diagram related to hydraulic oil temperature sensor
D61EX, PX-15E0 49
Failure code [DGT1KA] Power train oil temperature sensor:

Disconnection 1
Action code Failure code Power train oil temperature sensor: Disconnection
Trouble
E01 DGT1KA (Steering and transmission controller system)
Contents of • Even though coolant temperature rises, power train oil temperature sensor signal remains to be low
trouble temperature.
Action of
• Nothing particular.
controller
Problem that • Power train oil temperature on monitor panel is not displayed normally.
appears on • Fan speed is limited to half.
machine • Gear shift shock of transmission increases.
• Power train oil temperature status (temperature) can be checked in monitoring mode.
Related
(Code 30100: Power train oil temperature)
information

Defective power train OFF.
oil temperature sensor 453 (male) Resistance
1
tion) Between (1) – (2) 3.5 kz – 90 kz (10 – 100°C)
causes and Disconnection in wiring OFF.
standard value harness
Wiring harness between S04 (female) (12) – 453
in normal state 2 (Disconnection or Resistance Max. 1 z
(female) (1)
connectors) Wiring harness between S03 (female) (3) (4) – 453
Resistance Max. 1 z
(female) (2)
Defective monitor OFF.
3
panel S03, S04 (female) Resistance
S04 (12) – S03 (3) (4) 3.5 kz – 90 kz (10 – 100°C)
Circuit diagram related to power train oil temperature sensor
50 D61EX, PX-15E0
Failure code [DGT1KX] Power train oil temperature sensor: Input signal
is out of normal range 1
Action code Failure code Power train oil temperature sensor: Input signal is out of normal range
Trouble
E01 DGT1KX (Steering and transmission controller system)
Contents of
• Power train oil temperature sensor signal is out of normal range.
trouble
Action of
controller
Problem that • Power train oil temperature on monitor panel is not displayed normally.
appears on • Fan speed is limited to half.
machine • Gear shift shock of transmission increases.
• Power train oil temperature status (temperature) can be checked in monitoring mode.
Related
information

OFF.
Defective power train
1 oil temperature sensor 453 (male) Resistance
(Short-circuiting) Between (1) – (2) 3.5 kz – 90 kz (10 – 100°C)
grounding OFF.
Possible 2
(Contact with ground Wiring harness between S04 (female) (12) – 453
causes and Resistance Min. 1 Mz
circuit) (female) (1) with ground
standard value
in normal state Hot short of wiring har- a Prepare with starting switch OFF and diagnose with starting switch ON.
ness
3
(Contact with 24 V cir- Wiring harness between S04 (female) (12) – 453 Voltage Max. 1 V
cuit) (female) (1) with ground
OFF.
Defective machine S03, S04 (female) Resistance
4
monitor
S04 (12) – S03 (3) (4) 3.5 kz – 90 kz (10 – 100°C)
Between S04 (12) – ground Min. 1 Mz
D61EX, PX-15E0 51
Failure code [DK10KA] Fuel dial: Disconnection 1

Action code Failure code Fuel dial: Disconnection
Trouble
CALL E03 DK10KA (Steering and transmission controller system)
Contents of
• Signal voltage of fuel dial circuit is less than 0.5 V.
trouble
Action of
• Continues to keep it under control with decelerator pedal potentiometer signal.
controller
• Operation of engine and transmission is limited.
Problem that
appears on
machine
• Input status (voltage) from fuel dial can be checked in monitoring mode.
Related
(Code 03000: Fuel dial voltage)
information

Defective sensor 5 V Check displays of failure codes [DAQ5KK] [DB35KK] and if there is any
1
power source system display, carry out that troubleshooting first.
OFF.
Defective fuel dial DIAL (male) Resistance
Between (A) – (C) 4.0 – 6.0 kz
tion and short circuit)
Between (A) – (B) 0.5 – 4.5 kz
Between (B) – (C) 0.5 – 4.5 kz
Possible harness
causes and 3 (Disconnection or Resistance Max. 1 z
DIAL (female) (A)
standard value defective contact of
in normal state connectors) Wiring harness between ST1 (female) (1) – DIAL
Resistance Max. 1 z
(female) (B)
grounding Wiring harness between ST1 (female) (22) –
(Contact with ground DIAL (female) (A) with ground
circuit) Wiring harness between ST1 (female) (1) – DIAL
(female) (B) with ground
5
transmission controller Between (22) – (21) 4.6 – 5.4 V
Between (1) – (21) 0.5 – 4.5 V
52 D61EX, PX-15E0
Circuit diagram related to fuel dial
D61EX, PX-15E0 53
Failure code [DK10KB] Fuel dial: Short circuit 1

Action code Failure code Fuel dial: Short circuit
Trouble
CALL E03 DK10KB (Steering and transmission controller system)
Contents of
• Signal voltage of fuel dial circuit is more than 4.5 V.
trouble
Action of
• Continues to keep it under control with decelerator pedal potentiometer signal.
controller
• Operation of engine and transmission is limited.
Problem that
appears on
machine
• Input status (voltage) from fuel dial can be checked in monitoring mode.
Related
(Code 03000: Fuel dial voltage)
information

1
OFF.
Defective fuel dial DIAL (male) Resistance
Between (A) – (C) 4.0 – 6.0 kz
tion and short circuit)
Between (A) – (B) 0.5 – 4.5 kz
Between (B) – (C) 0.5 – 4.5 kz
harness OFF.
causes and defective contact of Wiring harness between ST1 (female) (21) –
Resistance Max. 1 z
standard value connectors) DIAL (female) (C)
in normal state
Hot short of wiring har- DIAL (female) (A) with ground Voltage Max. 1 V
ness
4
(Contact with 24 V cir- Wiring harness between ST1 (female) (1) – DIAL Voltage Max. 1 V
cuit) (female) (B) with ground
Voltage Max. 1 V
DIAL (female) (C) with ground
5
transmission controller Between (22) – (21) 4.6 – 5.4 V
Between (1) – (21) 0.5 – 4.5 V
54 D61EX, PX-15E0
Circuit diagram related to fuel dial
D61EX, PX-15E0 55
Failure code [DK30KA] Steering potentiometer (1): Disconnection 1

Action code Failure code Steering potentiometer (1): Disconnection
Trouble
Contents of
• Signal voltage of steering potentiometer (1) system is more than 4.5 V.
trouble
Action of
• Continues to keep it under control with signal of steering potentiometer (2) system.
controller
Problem that
appears on
machine
• Input status (voltage) from steering potentiometer (1) can be checked in monitoring mode.
Related
(Code 50300: Steering potentiometer (1) voltage)
information
• Method of reproducing failure code: Turn starting switch ON + (Shift PCCS lever (steering))

1
OFF.
Defective steering
potentiometer (1) TL2 (male) Resistance
2
(Internal disconnec- Between (5) – (8) 3.2 kz ± 20%
tion and short circuit) Between (7) – (5) 1 – 6 kz (right – left steering)
Between (7) – (8) 6 – 1 kz (right – left steering)
Wiring harness between ST1 (female) (21) – TL2
(female) (8)
connectors) Wiring harness between ST1 (female) (2) – TL2
Resistance Max. 1 z
(female) (7)
ness
4
(Contact with 24 V cir- Wiring harness between ST1 (female) (2) – TL2 Voltage Max. 1 V
5 ST1 Voltage
Between (2) – (21) 0.5 – 4.5 V
56 D61EX, PX-15E0
Circuit diagram related to steering potentiometer
D61EX, PX-15E0 57
Failure code [DK30KB] Steering potentiometer (1): Short circuit 1

Action code Failure code Steering potentiometer (1): Short circuit
Trouble
Contents of
• Signal voltage of steering potentiometer (1) system is less than 0.5 V.
trouble
Action of
controller
Problem that
appears on
machine
Related
information

1
OFF.
Defective steering
2
Between (7) – (8) 6 – 1 kz (right – left steering)
Possible
causes and Defective harness a Prepare with starting switch OFF and diagnose with starting switch still
standard value grounding OFF.
3
in normal state (Contact with ground Wiring harness between ST1 (female) (2) – TL2
(female) (7) with ground
harness OFF.
4 (Disconnection or
defective contact of Wiring harness between ST1 (female) (22) – TL2
Resistance Max. 1 z
connectors) (female) (5)
5 ST1 Voltage
Between (2) – (21) 0.5 – 4.5 V
58 D61EX, PX-15E0
D61EX, PX-15E0 59
Failure code [DK30KX] Steering potentiometer: Input signal is out of

normal range 1
Action code Failure code Steering potentiometer: Input signal is out of normal range
Trouble
CALL E04 DK30KX (Steering and transmission controller system)
Contents of • Either failure code [DK30KA] or [DK30KB] and either failure code [DK31KA] or [DK31KB] occurred
trouble at the same time at steering potentiometer systems 1 and 2.
controller • Limits operation of engine, transmission and brake.
Problem that
appears on
machine
• Input status (voltage) from steering potentiometer can be checked in monitoring mode.
Related (Code 50300: Steering potentiometer 1 voltage)
information (Code 50301: Steering potentiometer 2 voltage)

causes and
standard value Carry out troubleshooting for failure code [DK30KA] [DK30KB] [DK31KA] [DK31KB]
in normal state
60 D61EX, PX-15E0
Failure code [DK30KZ] Steering potentiometer: Disconnection or short

circuit (Double failure) 1
Action code Failure code Steering potentiometer: Disconnection or short circuit
Trouble
CALL E04 DK30KZ (Steering and transmission controller system)
• At steering potentiometer systems 1 and 2, when starting switch was turned ON, only either of them
Contents of
showed abnormality and later, either failure code [DK30KA] or [DK30KB] or either failure code
trouble
[DK31KA] or [DK31KB] occurred at the same time.
controller • Limits operation of engine, transmission and brake.
Problem that
appears on
machine

causes and
in normal state
Failure code [DK30L8] Steering potentiometer: Inconsistent analog

signal 1
Action code Failure code Steering potentiometer: Inconsistent analog signal
Trouble
CALL E03 DK30L8 (Steering and transmission controller system)
Contents of • Total signal voltage of steering potentiometer systems 1 and 2 is less than 4.41 V or more than
trouble 5.59 V.
Action of • Continues to keep it under control with the normal signal of either steering potentiometer system 1 or
controller 2.
Problem that
appears on
machine
• Method of reproducing failure code: Turn starting switch ON + (Shift PCCS lever (forward-reverse))

causes and
in normal state
D61EX, PX-15E0 61
Failure code [DK31KA] Steering potentiometer (2): Disconnection 1

Action code Failure code Steering potentiometer (2): Disconnection
Trouble
Contents of
• Signal voltage of steering potentiometer (2) system is less than 0.5 V.
trouble
Action of
controller
Problem that
appears on
machine
Related
information

Defective sensor Check displays of failure codes [DAQ5KK] [DB35KK] and if there is any
1
OFF.
Defective steering
2
tion and short circuit) Between (6) – (5) 6 – 1 z (right – left steering)
Between (6) – (8) 1 – 6 z (right – left steering)
(female) (5)
Resistance Max. 1 z
(female) (6)
grounding OFF.
4
(Contact with ground Wiring harness between ST1 (female) (19) – TL2
5 ST1 Voltage
Between (19) – (21) 0.5 – 4.5
62 D61EX, PX-15E0
D61EX, PX-15E0 63
Failure code [DK31KB] Steering potentiometer (2): Short circuit 1

Action code Failure code Steering potentiometer (2): Short circuit
Trouble
Contents of
• Signal voltage of steering potentiometer (2) system is more than 4.5 V.
trouble
Action of
controller
Problem that
appears on
machine
Related
information

1
OFF.
Defective steering
2
Possible Between (6) – (8) 6 – 1 kz (right – left steering)

causes and Hot short of wiring har- a Prepare with starting switch OFF and diagnose with starting switch ON.
standard value ness
3
in normal state (Contact with 24 V cir- Wiring harness between ST1 (female) (19) – TL2 Voltage Max. 1 V
harness OFF.
4 (Disconnection or
Resistance Max. 1 z
5 ST1 Voltage
Between (19) – (21) 0.5 – 4.5 V
64 D61EX, PX-15E0
D61EX, PX-15E0 65
Failure code [DK40KA] Brake potentiometer: Disconnection 1

Action code Failure code Brake potentiometer: Disconnection
Trouble
E01 DK40KA (Steering and transmission controller system)
Contents of
• Signal voltage of brake potentiometer circuit is less than 0.5 V.
trouble
Action of
controller
Problem that
• Automatic shift-down does not function properly
appears on
• Gear shift shock of transmission increases.
machine
• Input status (voltage) from brake potentiometer can be checked in monitoring mode.
Related
(Code 50400: Brake potentiometer voltage)
information
• Method of reproducing failure code: Turn starting switch ON + (Operate brake pedal)

Defective sensor Check displays of failure codes [DAQ5KK] [DB35KK] and if there is any
1
• Defective brake OFF.
potentiometer. BRK (male) Resistance
Between (A) – (C) 4.0 – 6.0 kz
2 tion and short cir-
cuit) 1.5 – 4.5 kz
Between (A) – (B)
• Defective installation (free – full stroke)
of potentiometer. 4.5 – 1.5 kz
Between (B) – (C)
Possible (free – full stroke)
standard value Disconnection in wiring OFF.
in normal state harness
BRK (female) (C)
connectors) Wiring harness between ST1 (female) (3) – BRK
Resistance Max. 1 z
(female) (B)
grounding OFF.
4
(Contact with ground Wiring harness between ST1 (female) (3) – BRK
(female) (B) with ground
5 ST1 Voltage
Between (3) – (21) 1.5 – 4.5 V
Circuit diagram related to brake potentiometer
66 D61EX, PX-15E0
Failure code [DK40KB] Brake potentiometer: Short circuit 1

Action code Failure code Brake potentiometer: Short circuit
Trouble
E01 DK40KB (Steering and transmission controller system)
Contents of
• Signal voltage of brake potentiometer circuit is more than 4.5 V.
trouble
Action of
controller
Problem that
• Automatic shift-down does not function properly
appears on
• Gear shift shock of transmission increases.
machine
• Input status (voltage) from brake potentiometer can be checked in monitoring mode.
Related
(Code 50400: Brake potentiometer voltage)
information
• Method of reproducing failure code: Turn starting switch ON + (Operate brake pedal)

1
• Defective brake OFF.
potentiometer. BRK (male) Resistance
Between (A) – (C) 4.0 – 6.0 kz
2 tion and short cir-
cuit) 1.5 – 4.5 kz
Between (A) – (B)
• Defective installation (free – full stroke)
of potentiometer. 4.5 – 1.5 kz
Possible Between (B) – (C)
causes and (free – full stroke)
standard value Hot short of wiring har- a Prepare with starting switch OFF and diagnose with starting switch ON.
in normal state ness
3
(Contact with 24 V cir- Wiring harness between ST1 (female) (3) – BRK Voltage Max. 1 V
cuit) (female) (B) with ground
harness OFF.
4 (Disconnection or
Resistance Min. 1 z
connectors) BRK (female) (A)
5 ST1 Voltage
Between (3) – (21) 1.5 – 4.5 V
Circuit diagram related to brake potentiometer
D61EX, PX-15E0 67
SEN02564-00

© 2007 KOMATSU
All Rights Reserved
68
SEN02565-00
D61EX-15E0
D61PX-15E0

Failure code [DK55KX] Forward-reverse potentiometer: Input signal is out of normal range .............. 3
Failure code [DK55KZ] Forward-reverse potentiometer:
Disconnection or short circuit (Double failure)....................................................................... 4
Failure code [DK55L8] Forward-reverse potentiometer: Inconsistent analog signal............................ 5
Failure code [DK56KA] Forward-reverse potentiometer (1): Short circuit............................................ 6
Failure code [DK56KB] Forward-reverse potentiometer (1): Disconnection ........................................ 8
Failure code [DK57KA] Forward-reverse potentiometer (2): Disconnection ...................................... 10
Failure code [DK57KB] Forward-reverse potentiometer (2): Short circuit.......................................... 12
Failure code [DKH1KA] [DKH1KX] Pitch angle sensor: Short circuit ................................................. 14
Failure code [DKH1KB] [DKH1KX] Pitch angle sensor: Disconnection ............................................. 16
Failure code [DKH1KX], [DKH1KA] or [DKH1KB] Pitch angle sensor: Input signal out of range ....... 17
Failure code [DLT3KA] Transmission output speed sensor: Disconnection....................................... 18
Failure code [DLT3KB] Transmission output speed sensor: Short circuit .......................................... 19
Failure code [DV00KB] Alarm buzzer: Short circuit ........................................................................... 20
D61EX, PX-15E0 1
Failure code [DW7BKA] Fan reverse solenoid: Disconnection .......................................................... 21

Failure code [DW7BKB] Fan reverse solenoid: Short circuit.............................................................. 22
Failure code [DWN1KA] HSS EPC solenoid right: Disconnection ..................................................... 23
Failure code [DWN1KB] HSS EPC solenoid right: Short circuit ......................................................... 24
Failure code [DWN1KY] HSS EPC solenoid right: Short circuit to power source line........................ 25
Failure code [DWN2KA] HSS EPC solenoid left: Disconnection........................................................ 26
Failure code [DWN2KB] HSS EPC solenoid left: Short circuit ........................................................... 27
Failure code [DWN2KY] HSS EPC solenoid left: Short circuit to power source line .......................... 28
Failure code [DWN5KA] Fan pump TVC solenoid: Disconnection..................................................... 29
Failure code [DWN5KB] Fan pump TVC solenoid: Short circuit ........................................................ 30
Failure code [DWN5KY] Fan pump TVC solenoid: Short circuit in power source line ....................... 31
Failure code [DXA0KA] HSS pump TVC solenoid: Disconnection..................................................... 32
Failure code [DXA0KB] HSS pump TVC solenoid: Short circuit ........................................................ 33
Failure code [DXA0KY] HSS pump TVC solenoid: Short circuit to power source line ....................... 34
Failure code [DXH4KA] 1st clutch ECMV: Disconnection .................................................................. 35
Failure code [DXH4KB] 1st clutch ECMV: Short circuit...................................................................... 36
Failure code [DXH4KY] 1st clutch ECMV: Short circuit to power source line..................................... 38
Failure code [DXH5KA] 2nd clutch ECMV: Disconnection ................................................................. 39
Failure code [DXH5KB] 2nd clutch ECMV: Short circuit..................................................................... 40
Failure code [DXH5KY] 2nd clutch ECMV: Short circuit to power source line ................................... 42
Failure code [DXH6KA] 3rd clutch ECMV: Disconnection.................................................................. 43
Failure code [DXH6KB] 3rd clutch ECMV: Short circuit ..................................................................... 44
Failure code [DXH6KY] 3rd clutch ECMV: Short circuit to power source line .................................... 46
Failure code [DXH7KA] Reverse clutch ECMV: Disconnection.......................................................... 47
Failure code [DXH7KB] Reverse clutch ECMV: Short circuit ............................................................. 48
Failure code [DXH7KY] Reverse clutch ECMV: Short circuit to power source line ............................ 49
Failure code [DXH8KA] Forward clutch ECMV: Disconnection.......................................................... 50
Failure code [DXH8KB] Forward clutch ECMV: Short circuit ............................................................. 52
Failure code [DXH8KY] Forward clutch ECMV: Short circuit to power source line ............................ 54
2 D61EX, PX-15E0
Failure code [DK55KX] Forward-reverse potentiometer: Input signal is

out of normal range 1
Action code Failure code Forward-reverse potentiometer: Input signal is out of normal range
Trouble
CALL E04 DK55KX (Steering and transmission controller system)
Contents of • Either failure code [DK56KA] or [DK56KB] and either failure code [DK57KA] or [DK57KB] occurred
trouble at the same time at forward-reverse potentiometer systems 1 and 2.
Problem that
appears on
machine
• Input status (voltage) from forward-reverse potentiometer can be checked in monitoring mode.
Related (Code 50200: Forward-reverse potentiometer 1 voltage)
information (Code 50201: Forward-reverse potentiometer 2 voltage)
• Method of reproducing failure code: Turn starting switch ON + (Shift PCCS lever (forward-reverse)

causes and
in normal state
D61EX, PX-15E0 3
Failure code [DK55KZ] Forward-reverse potentiometer: Disconnection

or short circuit (Double failure) 1
Action code Failure code Forward-reverse potentiometer: Disconnection or short circuit
Trouble (Double failure)
CALL E04 DK55KZ (Steering and transmission controller system)
• At forward-reverse potentiometer systems 1 and 2, when starting switch was turned ON, only either
Contents of
of them showed abnormality, and later either failure code [DK56KA] or [DK56KB] and either failure
trouble
code [DK57KA] or [DK57KB] occurred at the same time.
Problem that
appears on
machine
• Method of reproducing failure code: Turn starting switch ON + (shift PCCS lever (forward-reverse))

causes and
in normal state
4 D61EX, PX-15E0
Failure code [DK55L8] Forward-reverse potentiometer: Inconsistent

analog signal 1
Action code Failure code Forward-reverse potentiometer: Inconsistent analog signal
Trouble
CALL E03 DK55L8 (Steering and transmission controller system)
Contents of • Total signal voltage of forward-reverse potentiometer systems 1 and 2 is less than 4.41 V or more
trouble than 5.59 V.
Action of • Continues to keep it under control with the normal signal of either forward-reverse potentiometer
controller system 1 or 2.
Problem that
appears on
machine

causes and
in normal state
D61EX, PX-15E0 5
Failure code [DK56KA] Forward-reverse potentiometer (1): Short circuit1

Action code Failure code Forward-reverse potentiometer (1): Short circuit
Trouble
Contents of
• Signal voltage of forward-reverse potentiometer (1) system is more than 4.5 V.
trouble
Action of
• Continues to keep it under control with signal of forward-reverse potentiometer (2) system.
controller
Problem that
appears on
machine
• Input status (voltage) from forward-reverse potentiometer (1) can be checked in monitoring mode.
Related
(Code 50200: Forward-reverse potentiometer (1) voltage)
information

1
Defective directional OFF.
Between (4) – (1) 3.2 kz ± 20%
tion and short-circuit-
ing) Between (3) – (4) 5.5 – 1.5 kz (forward – reverse)
Possible Between (3) – (1) 1.5 – 5.5 kz (forward – reverse)

standard value ness
3
harness OFF.
4 (Disconnection or
Resistance Max. 1 z
5 ST1 Voltage
Between (13) – (21) 0.5 – 4.5 V
6 D61EX, PX-15E0
Circuit diagram related to forward-reverse potentiometer
D61EX, PX-15E0 7
Failure code [DK56KB] Forward-reverse potentiometer (1):

Disconnection 1
Action code Failure code Forward-reverse potentiometer (1): Disconnection
Trouble
Contents of
• Signal voltage of forward-reverse potentiometer (1) system is less than 0.5 V.
trouble
Action of
controller
Problem that
appears on
machine
Related
information
• Method of reproducing failure code: Turn starting switch ON +(Shift PCCS lever (forward-reverse))

1
OFF.
Defective forward-
reverse potentiometer TL2 (male) Resistance
2
(1) (Internal disconnec- Between (4) – (1) 3.2 kz ± 20%
tion and short-circuiting) Between (3) – (4) 5.5 – 1.5 kz (forward – reverse)
Between (3) – (1) 1.5 – 5.5 kz (forward – reverse)
(female) (4)
Resistance Max. 1 z
(female) (3)
grounding OFF.
4
5 ST1 Voltage
Between (13) – (21) 0.5 – 4.5 V
8 D61EX, PX-15E0
D61EX, PX-15E0 9
Failure code [DK57KA] Forward-reverse potentiometer (2):

Disconnection 1
Action code Failure code Forward-reverse potentiometer (2): Disconnection
Trouble
Contents of
• Signal voltage of forward-reverse potentiometer (2) system is less than 0.5 V.
trouble
Action of
controller
Problem that
appears on
machine
Related
information

1
OFF.
Defective forward-
2
Between (2) – (1) 5.5 – 1.5 kz (forward – reverse)
(female) (4)
Resistance Max. 1 z
(female) (2)
grounding OFF.
4
5 ST1 Voltage
Between (7) – (21) 0.5 – 4.5 V
10 D61EX, PX-15E0
D61EX, PX-15E0 11
Failure code [DK57KB] Forward-reverse potentiometer (2): Short circuit1

Action code Failure code Forward-reverse potentiometer (2): Short circuit
Trouble
Contents of
• Signal voltage of forward-reverse potentiometer (2) system is more than 4.5 V.
trouble
Action of
controller
Problem that
appears on
machine
Related
information

1
OFF.
Defective forward-
2
Possible Between (2) – (1) 5.5 – 1.5 kz (forward – reverse)

standard value ness
3
harness OFF.
4 (Disconnection or
Resistance Max. 1 z
5 ST1 Voltage
Between (7) – (21) 0.5 – 4.5 V
12 D61EX, PX-15E0
D61EX, PX-15E0 13
Failure code [DKH1KA] [DKH1KX] Pitch angle sensor: Short circuit 1

Pitch angle sensor: Short circuit
DKH1KA Trouble
DKH1KX
Contents of
• Signal voltage of pitch angle sensor is above 4.85 V.
trouble
Action of
• Cannot recognize pitch angle.
controller
Problem that • Excessive gear shift shock is felt on a slope.
• Both DKH1KA and DKH1KX are displayed
Related • Input state (voltage) from pitch angle sensor can be checked in monitoring mode.
information (Code 60100: Voltage of pitch angle sensor)

Defective sensor 24 V Check if failure code [DAQ6KK] or [DB36KK] is displayed. If it is dis-
1
power supply circuit played, carry out troubleshooting for it first.
Defective pitch angle a Prepare with starting switch OFF and diagnose with starting switch ON.
2 sensor PT1 Voltage
Possible (Internal defect) Between (B) – (A) 0.15 – 4.85 V
causes and
standard value Hot short of wiring har- a Prepare with starting switch OFF and diagnose with starting switch ON.
in normal state ness
3 Between ground and wiring harness between
(a contact with 24 V Voltage Max. 1 V
circuit) ST1 (female) (8) – PT1 (female) (B)
4 ST1 Voltage
Between (8) – (21) 0.15 – 4.85 V
Circuit diagram related to pitch angle sensor
14 D61EX, PX-15E0
D61EX, PX-15E0 15
Failure code [DKH1KB] [DKH1KX] Pitch angle sensor: Disconnection 1

Pitch angle sensor: Disconnection
DKH1KB Trouble
DKH1KX
Contents of
• Signal voltage of pitch angle sensor is below 0.15 V.
trouble
Action of
• Cannot recognize pitch angle.
controller
Problem that • Excessive gear shift shock is felt on a slope.
• Both DKH1KB and DKH1KX are displayed.
Related • Input state (voltage) from pitch angle sensor can be checked in monitoring mode.
information (Code 60100: Voltage of pitch angle sensor)

Defective sensor 24 V Check if failure code [DAQ6KK] or [DB36KK] is displayed. If it is dis-
1
power supply circuit played, carry out troubleshooting for it first.
Defective pitch angle a Prepare with starting switch OFF and diagnose with starting switch ON.
2 sensor PT1 Voltage
(Internal defect) Between (B) – (A) 0.15 – 4.85 V
Possible harness
Wiring harness between ST1 (female) (16) – PT1
causes and 3 (Disconnection or Resistance Max. 1 z
(female) (C)
standard value defective contact of
in normal state connectors) Wiring harness between ST1 (female) (8) – PT1
Resistance Max. 1 z
(female) (B)
grounding OFF.
4
ST1 (female) (8) – PT1 (female) (B)
5 ST1 Voltage
Between (8) – (21) 0.15 – 4.85 V
16 D61EX, PX-15E0
Circuit diagram related to pitch angle sensor
Failure code [DKH1KX], [DKH1KA] or [DKH1KB] Pitch angle sensor:

Input signal out of range 1
a Refer to DKH1KA or DKH1KB
D61EX, PX-15E0 17
Failure code [DLT3KA] Transmission output speed sensor: Disconnection1

Action code Failure code Transmission output speed sensor: Disconnection
Trouble
E01 DLT3KA (Steering and transmission controller system)
Contents of
• Signal is not input from transmission output speed sensor.
trouble
Action of
• Assumes that transmission output speed is 0 rpm.
controller
Problem that • Transmission speed cannot be monitored.
appears on • Traction force cannot be calculated.
machine • Automatic shift-down does not function properly
• Transmission output speed can be checked in monitoring mode.
Related
(Code 31400: Transmission speed)
information
• Duplication of failure code: Start engine and travel machine actually.
Defective transmission a Prepare with starting switch OFF and diagnose with starting switch still
output speed sensor OFF.
1
(Internal disconnec- TM1 (male) Resistance
tion) Between (1) – (2) 400 – 1,000 z
harness
Possible TM1 (female) (1)
causes and connectors) Wiring harness between ST2 (female) (29) –
TM1 (female) (2)
in normal state
ness
3 Between ground and wiring harness between ST2
circuit) (female) (30) – TM1 (female) (1)
OFF.
4
Between (30) – (29) 400 – 1,000 z
Circuit diagram related to transmission output speed sensor
18 D61EX, PX-15E0
Failure code [DLT3KB] Transmission output speed sensor: Short circuit1

Action code Failure code Transmission output speed sensor: Short circuit
Trouble
E01 DLT3KB (Steering and transmission controller system)
Contents of
• Signal from transmission output sensor stays in OFF(OPEN) even though the machine is traveling.
trouble
Action of
• Assumes that transmission output speed is 0 rpm.
controller
Problem that • Transmission speed cannot be monitored.
appears on • Traction force cannot be calculated.
machine • Automatic shift-down does not function properly
• Transmission output speed can be checked in monitoring mode.
Related
(Code 31400: Transmission speed)
information
• Duplication of failure code: Start engine and travel machine actually.

Defective installation of
Make adjustment according to Testing and adjusting “Adjusting transmis-
1 transmission output
sion speed sensor”.
speed sensor
OFF.
Defective transmission
2 output speed sensor TM1 (male) Resistance
(Internal short circuit) Between (1) – (2) 400 – 1,000 z
Possible
causes and Between (1) – chassis ground Min. 1 Mz
standard value Defective harness a Prepare with starting switch OFF and diagnose with starting switch still
in normal state grounding OFF.
3
(Contact with ground Between ground and wiring harness between ST2
(female) (30) – TM1 (female) (1)
OFF.
4
Between (30) – (29) 400 – 1,000 z
Circuit diagram related to transmission output speed sensor
D61EX, PX-15E0 19
Failure code [DV00KB] Alarm buzzer: Short circuit 1

Trouble Alarm buzzer: Short circuit (monitor panel circuit)
— DV00KB
Contents of
• Abnormal current flowed in the alarm buzzer circuit when the GND is outputted.
trouble
Action of
• Stops the GND output for alarm buzzer circuit.
controller
Problem that
appears on • Alarm buzzer does not sound.
machine
Related • Duplication of failure code: Turn starting switch ON (When it is turned ON, buzzer sounds for 1 sec-
information ond).

Defective alarm buzzer OFF.
1
(Internal short circuit) 217 (male) Continuity
Between (2) – (1) Continue
Possible Hot short of wiring har- a Prepare with starting switch OFF and diagnose with starting switch ON.
causes and ness
2 Between ground and wiring harness between 217
standard value (a contact with 24 V Voltage Max. 1 V
in normal state circuit) (female) (1) – S03 (female) (18)
S03 Alarm buzzer Voltage
Defective monitor
3 When stopping 20 – 30 V
panel Between (18) –
chassis ground When turned ON
Max. 3 V
(sounding)
Circuit diagram related to alarm buzzer
20 D61EX, PX-15E0
Failure code [DW7BKA] Fan reverse solenoid: Disconnection 1

Action code Failure code Fan reverse solenoid: Disconnection
Trouble
E01 DW7BKA (Steering and transmission controller system)
Contents of
• Current does not flow when power is output to fan reverse solenoid circuit.
trouble
Action of
• Stops outputting power to fan reverse solenoid circuit.
controller
Problem that
appears on • The fan reversing function cannot be used.
machine
• Output state (ON/OFF) to fan reverse solenoid can be checked in monitoring mode.
Related
(Code 40914: Steering-related controller output signal)
information
• Duplication of failure code: Turn starting switch ON and operate cleaning.
Defective fan reverse a Prepare with starting switch OFF and diagnose with starting switch still
solenoid OFF.
1
(Internal disconnec- FAR (male) Resistance
tion) Between (1) – (2) 34 – 44 z
harness
FAR (female) (1)
standard value connectors) Wiring harness between ST3 (female) (13) –
Resistance Max. 1 z
in normal state FAR (female) (2)
ness
circuit) (female) (18) – FAR (female) (1)
4
transmission controller ST3 (female) Resistance
Between (18) – (13) 34 – 44 z
Circuit diagram related to fan reverse solenoid
D61EX, PX-15E0 21
Failure code [DW7BKB] Fan reverse solenoid: Short circuit 1

Action code Failure code Fan reverse solenoid: Short circuit
Trouble
E01 DW7BKB (Steering and transmission controller system)
Contents of
• Current flowed when power is output to fan reverse solenoid circuit.
trouble
Action of
• Stops outputting power to fan reverse solenoid circuit.
controller
Problem that
appears on • The fan reversing function cannot be used.
machine
• Output state (ON/OFF) to fan reverse solenoid can be checked in monitoring mode.
Related
(Code 40914: Steering-related controller output signal)
information
• Duplication of failure code: Turn starting switch ON and operate cleaning.

OFF.
Defective fan reverse FAR (male) Resistance
1 solenoid
(Internal short circuit) Between (1) – (2) 34 – 44 z
Between (1) –
Min. 1 Mz
chassis ground
grounding OFF.
Possible 2
(Contact with ground Between ground and wiring harness between ST3
causes and circuit) Resistance Min. 1 Mz
(female) (18) – FAR (female) (1)
standard value
Harness short OFF.
3 (Harness internal Wiring harnesses between ST3 (female) (18) –
short) FAR (female) (1) and between ST3 (female) (13) – Resistance Min. 1 Mz
FAR (female) (2)
OFF.
4
Between (18) – (13) 34 – 44 z
Circuit diagram related to fan reverse solenoid
22 D61EX, PX-15E0
Failure code [DWN1KA] HSS EPC solenoid right: Disconnection 1

Action code Failure code HSS EPC solenoid right: Disconnection
Trouble
CALL E03 DWN1KA (Steering and transmission controller system)
Contents of
• Current does not flow when power is output to HSS EPC solenoid right circuit.
trouble
Action of
• Stops outputting to HSS EPC solenoid right circuit.
controller
Problem that • Can not turn to the right.
• Output state (current) to HSS EPS solenoid right can be checked in monitoring mode.
Related
(Code 50603: Right HSS solenoid output current value)
information
• Duplication of failure code: Turn starting switch ON and operate PCCS lever (for steering to right).
Defective HSS EPC a Prepare with starting switch OFF and diagnose with starting switch still
solenoid right OFF.
1
(Internal disconnec- HSB (male) Resistance
tion) Between (1) – (2) 5 – 15 z
Possible Disconnection in wiring OFF.
causes and harness
standard value Wiring harness between ST3 (female) (35) –
in normal state HSB (female) (1)
connectors) Wiring harness between ST3 (female) (3) – HSB
Resistance Max. 1 z
(female) (2)
3
Between (35) – (3) 5 – 15 z
Circuit diagram related to HSS EPC solenoid right
D61EX, PX-15E0 23
Failure code [DWN1KB] HSS EPC solenoid right: Short circuit 1

Action code Failure code HSS EPC solenoid right: Short circuit
Trouble
CALL E03 DWN1KB (Steering and transmission controller system)
Contents of
• Current flowed when power was output to HSS EPC solenoid right circuit.
trouble
Action of
controller
Problem that • Can not turn to the right.
Related
information

OFF.
Defective HSS EPC
1 solenoid right HSB (male) Resistance
grounding OFF.
2
Possible (Contact with ground Between ground and wiring harness between
causes and ST3 (female) (35) – HSB (female) (1)
Harness short
short) HSB (female) (1) and between ST3 (female) (3) Resistance Min. 1 Mz
– HSB (female) (2)
OFF.
4
Between (35) – (3) 5 – 15 z
24 D61EX, PX-15E0
Failure code [DWN1KY] HSS EPC solenoid right: Short circuit to power
source line 1
Action code Failure code HSS EPC solenoid right: Short circuit to power source line
Trouble
CALL E04 DWN1KY (Steering and transmission controller system)
Contents of
• Current flows constantly to HSS EPC solenoid right circuit.
trouble
Action of
controller
Problem that • Continues to turn to the right.
machine • Can not travel once machine is stopped.
Related
information
solenoid right OFF.
1
(Internal disconnec- HSB (male) Resistance
tion and short circuit) Between (1) – (2) 5 – 15 z
Possible
causes and
ness
standard value 2 Between ground and wiring harness between
in normal state ST3 (female) (35) – HSB (female) (1)
circuit)
3
transmission controller Right 5 – 15 V
Between (35) – (3)
N Max. 1 V
D61EX, PX-15E0 25
Failure code [DWN2KA] HSS EPC solenoid left: Disconnection 1

Action code Failure code HSS EPC solenoid left: Disconnection
Trouble
CALL E03 DWN2KA (Steering and transmission controller system)
Contents of
• Current does not flow when power is output to HSS EPC solenoid left circuit.
trouble
Action of
• Stops outputting to HSS EPC solenoid left circuit.
controller
Problem that • Can not turn to the left.
• Output state (current) to HSS EPS solenoid left can be checked in monitoring mode.
Related
(Code 50602: Left HSS solenoid output current value)
information
• Duplication of failure code: Turn starting switch ON and operate PCCS lever (for steering to left).
solenoid left OFF.
1
(Internal disconnec- HSA (male) Resistance
tion) Between (1) – (2) 5 – 15 z
causes and harness
in normal state HSA (female) (1)
connectors) Wiring harness between ST3 (female) (3) – HSA
Resistance Max. 1 z
(female) (2)
3
Between (25) – (3) 5 – 15 z
Circuit diagram related to HSS EPC solenoid left
26 D61EX, PX-15E0
Failure code [DWN2KB] HSS EPC solenoid left: Short circuit 1

Action code Failure code HSS EPC solenoid left: Short circuit
Trouble
CALL E03 DWN2KB (Steering and transmission controller system)
Contents of
• Current flowed when power was output to HSS EPC solenoid left circuit.
trouble
Action of
controller
Problem that • Can not turn to the left.
Related
information

OFF.
Defective HSS EPC
1 solenoid left HSA (male) Resistance
grounding OFF.
2
causes and ST3 (female) (25) – HSA (female) (1)
Harness short
short) HSA (female) (1) and between ST3 (female) (3) Resistance Min. 1 Mz
– HSA (female) (2)
OFF.
4
Between (25) – (3) 5 – 15 z
D61EX, PX-15E0 27
Failure code [DWN2KY] HSS EPC solenoid left: Short circuit to power
source line 1
Action code Failure code HSS EPC solenoid left: Short circuit to power source line
Trouble
CALL E04 DWN2KY (Steering and transmission controller system)
Contents of
• Current flows constantly to HSS EPC solenoid left circuit.
trouble
Action of
controller
Problem that • Continues to turn to the left.
machine • Can not travel once machine is stopped.
Related
information
solenoid left OFF.
1
(Internal disconnec- HSA (male) Resistance
Possible
causes and
ness
in normal state ST3 (female) (25) – HSA (female) (1)
circuit)
3
transmission controller Left 5 – 15 V
Between (25) – (3)
N Max. 1 V
28 D61EX, PX-15E0
Failure code [DWN5KA] Fan pump TVC solenoid: Disconnection 1

Action code Failure code Fan pump solenoid: Disconnection
Trouble
E01 DWN5KA (Steering and transmission controller system)
Contents of
• Current does not flow when power is output to fan pump TVC solenoid circuit.
trouble
Action of
• Stops outputting power to fan pump TVC solenoid circuit.
controller
Problem that
appears on • Fan speed is kept at maximum level
machine
• Output state (current) to fan pump TVC solenoid can be checked in monitoring mode.
Related
(Code 31623, 31624: Cooling fan solenoid output current)
information
Defective fan pump a Prepare with starting switch OFF and diagnose with starting switch still
solenoid OFF.
1
(Internal disconnec- FAC (male) Resistance
tion) Between (1) – (2) 5 – 15 z
causes and harness
in normal state FAC (female) (1)
Resistance Max. 1 z
FAC (female) (2)
3
Between (36) – (23) 5 – 15 z
Circuit diagram related to fan pump TVC solenoid
D61EX, PX-15E0 29
Failure code [DWN5KB] Fan pump TVC solenoid: Short circuit 1

Action code Failure code Fan pump solenoid: Short circuit
Trouble
E01 DWN5KB (Steering and transmission controller system)
Contents of
• Current flowed when power is output to fan pump TVC solenoid circuit.
trouble
Action of
• Stops outputting power to fan pump TVC solenoid circuit.
controller
Problem that
appears on • Fan speed is kept at maximum level
machine
Related
information

OFF.
Defective fan pump
1 solenoid FAC (male) Resistance
grounding OFF.
2
causes and ST3 (female) (36) – FAC (female) (1)
Harness short
short) FAC (female) (1) and between ST3 (female) (23) Resistance Min. 1 Mz
– FAC (female) (2)
OFF.
4
Between (36) – (23) 5 – 15 z
30 D61EX, PX-15E0
Failure code [DWN5KY] Fan pump TVC solenoid: Short circuit in power
source line 1
Action code Failure code Fan pump solenoid: Short circuit to power source line
Trouble
E02 DWN5KY (Steering and transmission controller system)
Contents of
• Current flows constantly to fan pump TVC solenoid circuit.
trouble
controller • Stops outputting power to fan pump TVC solenoid circuit.
Problem that
• Fan speed is kept at minimum level.
appears on
• Overheat easily.
machine
Related
information
Defective fan pump a Prepare with starting switch OFF and diagnose with starting switch still
solenoid OFF.
1
(Internal disconnec- FAC (male) Resistance
Possible
causes and
ness
in normal state ST3 (female) (36) – FAC (female) (1)
circuit)
a Prepare with starting switch OFF and start the engine to diagnose.
Defective steering and ST3 Fan speed Voltage
3
transmission controller Minimum speed 5 – 15 V
Between (36) – (23)
Maximum speed Max. 5 V
D61EX, PX-15E0 31
Failure code [DXA0KA] HSS pump TVC solenoid: Disconnection 1

Action code Failure code HSS pump TVC solenoid: Disconnection
Trouble
E01 DXA0KA (Steering and transmission controller system)
Contents of • Any current does not flow when power is output to HSS and work equipment pump TVC solenoid
trouble circuit.
Action of
• Stops outputting power to HSS and work equipment TVC solenoid circuit.
controller
Problem that
appears on • When load is applied while engine is running at low speed, engine will stall.
machine
• Output state (current) to HSS and work equipment pump TVC solenoid left can be checked in mon-
Related itoring mode.
information (Code 01300, 01301: Output current of TVC solenoid)
Defective HSS and a Prepare with starting switch OFF and diagnose with starting switch still
work equipment pump OFF.
1
TVC solenoid (Internal HSP (male) Resistance
disconnection) Between (1) – (2) 9 – 19 z
causes and harness
standard value Wiring harness between ST3 (female) (7) – HSP
in normal state (female) (1)
connectors) Wiring harness between ST3 (female) (3) – HSP
Resistance Max. 1 z
(female) (2)
3
Between (7) – (3) 9 – 19 z
Circuit diagram of HSS pump TVC solenoid
32 D61EX, PX-15E0
Failure code [DXA0KB] HSS pump TVC solenoid: Short circuit 1

Action code Failure code HSS pump TVC solenoid: Short circuit
Trouble
E01 DXA0KB (Steering and transmission controller system)
Contents of • Abnormal current flowed when power is outputted to HSS and work equipment pump TVC solenoid
trouble circuit.
Action of
• Stops outputting power to HSS and work equipment TVC solenoid.
controller
Problem that
appears on • When load is applied while engine is running at low speed, engine will stall.
machine
Related
itoring mode. (Code 01300, 01301: Output current of TVC solenoid)
information

Defective HSS and OFF.
work equipment pump HSP (male) Resistance
1
TVC solenoid
grounding OFF.
2
causes and ST3 (female) (7) – HSP (female) (1)
Harness short
short) HSP (female) (1) and between ST3 (female) (3) Resistance Min. 1 Mz
– HSP (female) (2)
OFF.
4
Between (7) – (3) 9 – 19 z
D61EX, PX-15E0 33
Failure code [DXA0KY] HSS pump TVC solenoid: Short circuit to power
source line 1
Action code Failure code HSS pump TVC solenoid: Short circuit to power source line
Trouble
E01 DXA0KY (Steering and transmission controller system)
Contents of
• Current flows constantly to HSS and work equipment pump TVC solenoid circuit.
trouble
Action of
• Stops outputting power to HSS and work equipment TVC solenoid circuit.
controller
Problem that
• Large turning radius
appears on
• Work equipment speed is slow.
machine
Related itoring mode.
information (Code 01300, 01301: Output current of TVC solenoid)

Defective HSS and a Prepare with starting switch OFF and diagnose with starting switch still
work equipment pump OFF.
1 TVC solenoid HSP (male) Resistance
tion) Between (1) – (2) 9 – 19 z
Possible
standard value ness
in normal state (a contact with 24 V Voltage Max. 1 V
circuit) ST3 (female) (7) – HSP (female) (1)
Defective steering and ST3 Engine speed Voltage
3
transmission controller Low idle 9 – 19
Between (7) – (3)
High idle Max. 1 V
34 D61EX, PX-15E0
Failure code [DXH4KA] 1st clutch ECMV: Disconnection 1

Action code Failure code 1st clutch ECMV: Disconnection
Trouble
CALL E03 DXH4KA (Steering and transmission controller system)
Contents of
• Current does not flow when power is output to transmission 1st clutch solenoid circuit.
trouble
Action of
• Stops outputting to transmission 1st clutch solenoid circuit.
controller
• Output state (current) to 1st clutch solenoid can be checked in monitoring mode.
Related
(Code 31602, 31612: 1st clutch ECMV output current value)
information
Defective 1st clutch a Prepare with starting switch OFF and diagnose with starting switch still
ECMV OFF.
1
(Internal disconnec- 1SOL (male) Resistance
tion) Between (1) – (2) 5 – 25 z
causes and harness
in normal state 1SOL (female) (1)
Resistance Max. 1 z
2SOL (female) (2)
3
Between (6) – (23) 5 – 25 z
D61EX, PX-15E0 35
Failure code [DXH4KB] 1st clutch ECMV: Short circuit 1

Action code Failure code 1st clutch ECMV: Short circuit
Trouble
CALL E03 DXH4KB (Steering and transmission controller system)
Contents of
• Abnormal current flowed when power was outputted to transmission 1st clutch solenoid circuit.
trouble
Action of
controller
Related
information

OFF.
Defective 1st clutch
1 ECMV 1SOL (male) Resistance
grounding OFF.
2
Possible (Contact with ground Between ground and wiring harness between ST3
causes and (female) (6) – 1SOL (female) (1)
Harness short
short) 1SOL (female) (1) and between ST3 (female) Resistance Min. 1 Mz
(23) – 1SOL (female) (2)
OFF.
4
Between (6) – (23) 5 – 25 z
36 D61EX, PX-15E0
D61EX, PX-15E0 37
Failure code [DXH4KY] 1st clutch ECMV: Short circuit to power source line1
Action code Failure code 1st clutch ECMV: Short circuit to power source line
Trouble
CALL E03 DXH4KY (Steering and transmission controller system)
Contents of
• Current flows constantly to transmission 1st clutch solenoid circuit.
trouble
Action of
controller
Related
information
Defective 1st clutch a Prepare with starting switch OFF and diagnose with starting switch still
ECMV OFF.
1
Possible
causes and
ness
in normal state ST3 (female) (6) – 1SOL (female) (1)
circuit)
3
transmission controller F1 and R1 5 – 25 V
Between (6) – (23)
Other than F1 and R1 Max. 1 V
Circuit diagram related to transmission 1st clutch ECMV solenoid
38 D61EX, PX-15E0
Failure code [DXH5KA] 2nd clutch ECMV: Disconnection 1

Action code Failure code 2nd clutch ECMV: Disconnection
Trouble
Contents of
• Current does not flow when power is output to transmission 2nd clutch solenoid circuit.
trouble
Action of
• Stops outputting to transmission 2nd clutch solenoid circuit.
controller
• Output state (current) to 2nd clutch solenoid can be checked in monitoring mode.
Related
(Code 31603, 31613: 2nd clutch ECMV output current value)
information
Defective 2nd clutch a Prepare with starting switch OFF and diagnose with starting switch still
ECMV. OFF.
1
tion) Between (1) – (2) 5 – 25 z
causes and harness
Resistance Max. 1 z
2SOL (female) (2)
3
Between (16) – (23) 5 – 25 z
D61EX, PX-15E0 39
Failure code [DXH5KB] 2nd clutch ECMV: Short circuit 1

Action code Failure code 2nd clutch ECMV: Short circuit
Trouble
Contents of
• Abnormal current flowed when power was outputted to transmission 2nd clutch solenoid circuit.
trouble
Action of
controller
Problem that
appears on
machine
Related
information

OFF.
Defective 2nd clutch
1 ECMV. 2SOL (male) Resistance
grounding OFF.
2
causes and ST3 (female) (16) – 1SOL (female) (1)
(23) – 2SOL (female) (2)
OFF.
4
Between (16) – (23) 5 – 25 z
40 D61EX, PX-15E0
D61EX, PX-15E0 41
Failure code [DXH5KY] 2nd clutch ECMV: Short circuit to power source
line 1
Action code Failure code 2nd clutch ECMV: Short circuit to power source line
Trouble
Contents of
• Current flows constantly to transmission 2nd clutch solenoid circuit.
trouble
Action of
controller
Related
information
Defective 2nd clutch a Prepare with starting switch OFF and diagnose with starting switch still
ECMV. OFF.
1
Possible
causes and
ness
circuit)
3
Between (16) – (23)
42 D61EX, PX-15E0
Failure code [DXH6KA] 3rd clutch ECMV: Disconnection 1

Action code Failure code 3rd clutch ECMV: Disconnection
Trouble
Contents of
• Current does not flow when power is output to transmission 3rd clutch solenoid circuit.
trouble
Action of
• Stops outputting to transmission 3rd clutch solenoid circuit.
controller
• Output state (current) to 3rd clutch solenoid can be checked in monitoring mode.
Related
• (Code 31604, 31614: 3rd clutch ECMV output current value)
information
Defective 3rd clutch a Prepare with starting switch OFF and diagnose with starting switch still
ECMV OFF.
1
tion) Between (1) – (2) 5 – 25 z
causes and harness
Resistance Max. 1 z
3SOL (female) (2)
3
Between (26) – (23) 5 – 25 z
D61EX, PX-15E0 43
Failure code [DXH6KB] 3rd clutch ECMV: Short circuit 1

Action code Failure code 3rd clutch ECMV: Short circuit
Trouble
Contents of
• Abnormal current flowed when power was output to transmission 3rd clutch solenoid circuit.
trouble
Action of
controller
Problem that
appears on
machine
Related
(Code 31604, 31614: 3rd clutch ECMV output current value)
information

OFF.
Defective 3rd clutch
1 ECMV 3SOL (male) Resistance
grounding OFF.
2
Possible (Contact with ground Between ground and wiring harness between ST3
causes and (female) (26) – 3SOL (female) (1)
Harness short
(23) – 3SOL (female) (2)
OFF.
4
Between (26) – (23) 5 – 25 z
44 D61EX, PX-15E0
D61EX, PX-15E0 45
Failure code [DXH6KY] 3rd clutch ECMV: Short circuit to power source line1
Action code Failure code 3rd clutch ECMV: Short circuit to power source line
Trouble
Contents of
• Current flows constantly to transmission 3rd clutch solenoid circuit.
trouble
Action of
controller
Related
(Code 31604, 31614: 3rd clutch ECMV output current value)
information
Defective 3rd clutch a Prepare with starting switch OFF and diagnose with starting switch still
ECMV OFF.
1
Possible
causes and
ness
circuit)
3
Between (26) – (23)
46 D61EX, PX-15E0
Failure code [DXH7KA] Reverse clutch ECMV: Disconnection 1

Action code Failure code Reverse clutch ECMV: Disconnection
Trouble
Contents of
• Current does not flow when power is output to transmission reverse clutch solenoid circuit.
trouble
Action of
• Stops outputting to transmission reverse clutch solenoid circuit.
controller
Problem that
appears on
machine
• Output state (current) to reverse clutch solenoid can be checked in monitoring mode.
Related
(Code 31606, 31616: Output current of reverse clutch ECMV)
information
Defective reverse a Prepare with starting switch OFF and diagnose with starting switch still
clutch ECMV OFF.
1
(Internal disconnec- RSOL (male) Resistance
tion) Between (1) – (2) 5 – 25 z
causes and harness
in normal state RSOL (female) (1)
Resistance Max. 1 z
RSOL (female) (2)
3
Between (37) – (13) 5 – 25 z
D61EX, PX-15E0 47
Failure code [DXH7KB] Reverse clutch ECMV: Short circuit 1

Action code Failure code Reverse clutch ECMV: Short circuit
Trouble
Contents of
• Abnormal current flowed when power was output to transmission reverse clutch solenoid circuit.
trouble
Action of
controller
Problem that
appears on
machine
Related
information

OFF.
Defective reverse
1 clutch solenoid RSOL (male) Resistance
grounding OFF.
2
causes and ST3 (female) (37) – RSOL (female) (1)
Harness short
short) RSOL (female) (1) and between ST3 (female) Resistance Min. 1 Mz
(13) – RSOL (female) (2)
OFF.
4
Between (37) – (13) 5 – 25 z
48 D61EX, PX-15E0
Failure code [DXH7KY] Reverse clutch ECMV: Short circuit to power

source line 1
Action code Failure code Reverse clutch ECMV: Short circuit to power source line
Trouble
Contents of
• Current flows constantly to transmission reverse clutch solenoid circuit.
trouble
Action of
controller
Problem that
appears on
machine
Related
information
Defective reverse a Prepare with starting switch OFF and diagnose with starting switch still
clutch ECMV OFF.
1
(Internal disconnec- RSOL (male) Resistance
Possible
causes and
ness
in normal state ST3 (female) (37) – RSOL (female) (1)
circuit)
3
transmission controller R 5 – 25 V
Between (37) – (13)
N Max. 1 V
D61EX, PX-15E0 49
Failure code [DXH8KA] Forward clutch ECMV: Disconnection 1

Action code Failure code Forward clutch ECMV: Disconnection
Trouble
Contents of
• Current does not flow when power is output to transmission forward clutch solenoid circuit.
trouble
Action of
• Stops outputting to transmission forward clutch solenoid circuit.
controller
Problem that
appears on
machine
• Output state (current) to forward clutch solenoid can be checked in monitoring mode.
Related
(Code 31608, 31622: Output current of forward clutch ECMV)
information
Defective forward a Prepare with starting switch OFF and diagnose with starting switch still
clutch ECMV OFF.
1
(Internal disconnec- FSOL (male) Resistance
tion) Between (1) – (2) 5 – 25 z
causes and harness
in normal state FSOL (female) (1)
Resistance Max. 1 z
FSOL (female) (2)
3
Between (27) – (13) 5 – 25 z
50 D61EX, PX-15E0
D61EX, PX-15E0 51
Failure code [DXH8KB] Forward clutch ECMV: Short circuit 1

Action code Failure code Forward clutch ECMV: Short circuit
Trouble
Contents of
• Abnormal current flowed when power was output to transmission forward clutch solenoid circuit.
trouble
Action of
controller
Problem that
appears on
machine
Related
information

OFF.
Defective forward
1 clutch ECMV FSOL (male) Resistance
grounding OFF.
2
causes and ST3 (female) (27) – FSOL (female) (1)
short) FSOL (female) (1) and between ST3 (female) Resistance Min. 1 Mz
(13) – FSOL (female) (2)
OFF.
4
Between (27) – (13) 5 – 25 z
52 D61EX, PX-15E0
D61EX, PX-15E0 53
Failure code [DXH8KY] Forward clutch ECMV: Short circuit to power

source line 1
Action code Failure code Forward clutch ECMV: Short circuit to power source line
Trouble
Contents of
• Current flows constantly to transmission forward clutch solenoid circuit.
trouble
Action of
controller
Problem that
appears on
machine
Related
information
Defective forward a Prepare with starting switch OFF and diagnose with starting switch still
clutch ECMV OFF.
1
(Internal disconnec- FSOL (male) Resistance
Possible
causes and
ness
in normal state ST3 (female) (27) – FSOL (female) (1)
circuit)
3
transmission controller F 5 – 25 V
Between (27) – (13)
N Max. 1 V
54 D61EX, PX-15E0
D61EX, PX-15E0 55
SEN02565-00

© 2007 KOMATSU
All Rights Reserved
56
SEN02566-00
D61EX-15E0
D61PX-15E0

Troubleshooting of electrical system
(E-mode)
Before troubleshooting of electrical system ......................................................................................... 3
Contents of troubleshooting table......................................................................................................... 5
E-1 The engine does not start (the starting motor does not turn)......................................................... 7
E-2 The preheater does not operate ...................................................................................................11
E-3 The monitor panel does not light up at all when the starting switch is turned ON ....................... 14
E-4 When the starting switch is turned on, the monitor panel completely remains lighted
and does not go out............................................................................................................. 15
E-5 While the engine is running, the battery charge level caution lamp flashes ................................ 16
E-6 While the engine is running, the emergency warning item flashes.............................................. 18
E-7 While the preheater is operating, the preheating pilot lamp does not light up............................. 22
E-8 The coolant temperature gauge does not indicate correctly........................................................ 24
E-9 The power train oil temperature gauge does not indicate correctly............................................. 26
E-10 Hydraulic oil temperature gauge does not indicate properly ..................................................... 28
E-11 Fuel gauge does not indicate properly....................................................................................... 30
D61EX, PX-15E0 1
E-12 Gear speed and engine speed are not indicated properly......................................................... 31
E-13 The preset mode service meter does not indicate normally ...................................................... 31
E-14 The warning lamp does not flash or does not go out................................................................. 31
E-15 The alarm buzzer does not sound or does not stop .................................................................. 32
E-16 Auto shift down is not possible or is not released...................................................................... 34
E-17 The buzzer cancel switch does not work ................................................................................... 36
E-18 The information switch does not work ....................................................................................... 38
E-19 The fan cleaning does not operate or cannot be reset .............................................................. 40
E-20 The preset mode does not operate or cannot be reset.............................................................. 42
E-21 The monitor panel cannot be set in the service mode
or cannot be set out of the service mode ............................................................................ 44
E-22 The back-up alarm does not sound ........................................................................................... 46
E-23 The head lamp and rear lamp do not light up ............................................................................ 49
E-24 The horn does not sound or does not stop ................................................................................ 52
E-25 Malfunction of wipers ................................................................................................................. 54
E-26 Washer does not spray water .................................................................................................... 70
E-27 The air conditioner does not operate ......................................................................................... 76
E-28 KOMTRAX system does not operate normally .......................................................................... 80
2 D61EX, PX-15E0
Before troubleshooting of electrical system 1
Wiring table for fuse box

a This wiring diagram shows apparatuses to which electric power is supplied through the fuse box. (A
switching electric power supply supplies power with the starting switch ON. Constant electric power sup-
ply supplies power with starting switch either ON or OFF.)
a When you do troubleshooting related to the electrical systems, you should first check the fuse or the fus-
ible link to see whether the power is supplied normally or not.
Fuse box A [FS2]

Switched electric
1 5 Backup alarm
power supply
Steering and transmission controller (main electric power supply),
2 15
Constant power Radio
3 source 30 Electric power supply of machine (with 20A circuit breaker in the circuit)
4 30 Engine controller (main electric power supply)
Switched electric
5 30 Air conditioner (with 20A circuit breaker in the circuit)
power supply
Fuse box B [FS1]

1 20 Standby electric power supply
2 20 Horn, electrical intake air heater, air suspension seat
Switched electric
3 20 Front lamp, rear lamp
power supply
4 20 Steering and transmission controller (electric power supply to solenoid)
5 5 Engine controller (ACC signal)
Cab fuse box C

1 10 Accessory electric power supply (12 V electric power supply)
2 20 Radio, room lamp, cigarette lighter, additional light
3 Switched electric 20 Glass with heating wire
4 power supply 10 Rear wiper
5 10 Front wiper
6 10 Left and right door wipers
D61EX, PX-15E0 3
Fuse installation position and No.
Circuit breaker
No Connector No. Capacity (A) Circuit Remarks
Starting switch power supply (constant power
1 CB1 20 Installed in cover at bottom
supply)
of control panel
2 CB2 20 Air conditioner power supply
a Resetting operation of circuit breaker

Turn the starting switch OFF and push in projected reset button (3). If the reset button returns immedi-
ately, carry out troubleshooting to repair failed part.
4 D61EX, PX-15E0

a The following information is summarized in the troubleshooting table and the related electrical circuit
diagram. Before carrying out troubleshooting, understand that information fully.
Symptom of
Symptom of failure that has appeared in the machine
failure
General
information
<Described contents>
• Standard value when normal required to judge the possible cause
• Remarks required to judge whether the cause is right or not
1
<Symptoms of defective harness>
• Disconnection in wiring
The connector contact is defective or the wiring harness is discon-
nected.
• Defective grounding
A harness not connected to GND (ground) circuit comes into con-
tact with the GND (ground) circuit.
• Hot short defect
A harness not connected to the electric power supply (24 V) circuit
2 comes into contact with the electric power supply (24 V) circuit.
• Short circuit
Cause by which a A harness abnormally comes into contact with a harness of sepa-
Possible trouble is assumed to rate circuit.
causes and be caused
standard value (The order number
in normal state indicates a serial
number, not a priority <Points to remember when troubleshooting>
sequence.) (1) Method of indicating connector numbers and handling T-adapter
For troubleshooting, insert or connect the T- adapter as described
3 below unless especially specified.
• When “male” or “female” is not indicated for a connector num-
ber, disconnect the connector, and insert the T- adapter in both
the male and female.
• When “male”or “female” is indicated for a connector number,
disconnect the connector, and insert the T-adapter in only either
the male or female.
(2) Pin number description sequence and tester lead handling
For troubleshooting, connect the plus (+) and minus (–) leads of
the tester as described below unless especially specified.
4 • Connect the plus (+) lead to a pin number or harness indicated
in the front.
• Connect the minus (–) lead to a pin number or harness indicated
in the rear.
Related circuit diagram
• This is the excerpted circuit diagram related to troubleshooting.

• Connector No.: Indicates (model – number of pins) (color)
• Indication of “Connector No. and Pin No.” from the branch or junction point:
Indicates the branch destination or the splice location in the same harness
• Arrow ( ): Indicates the approximate mounting place on machine
D61EX, PX-15E0 5
6 D61EX, PX-15E0
E-1 The engine does not start (the starting motor does not turn) 1
Symptom of
• The starting motor does not turn and accordingly the engine does not start.
failure
• Since the engine start circuit has the neutral safety function, the engine does not start unless the
parking brake lever is in the lock position and the travel lever is in the neutral position.
• Since KOMTRAX has the start lock function, the engine cannot be started unless the start lock func-
tion is canceled.
General • If “the monitor panel does not light up”or “the battery relay does not make operating sound” when
information turning the starting switch ON, the main electric power supply system is supposed to be defective.
So, check the main electric power supply system.
• Before starting the troubleshooting, validate that the related failure code is not displayed.
(If the failure code [D130KA], [D130KB], [DD14KA], [DD14KB], [DDQ2KA] or [DDQ2KB] is dis-
played, conduct troubleshooting for the displayed code first.)

Insufficient battery Battery voltage Battery specific gravity
1
capacity Min. 25 V Min. 1.26
Defective starting OFF.
switch Starting switch Switch position Resistance
2
tion) Between 250(B) and OFF Min. 1 Mz
280(C) START Max. 1 z
Defective parking Parking brake lever
brake lever switch
3 Free position Lock position
(Internal defect or Monitor panel
defective adjustment) Other than “P” is
“P” is displayed.
displayed.
Possible Defective neutral a Prepare with starting switch OFF and start the engine to diagnose.
causes and safety relay
4 If the engine starts in accordance with the engine starting operation after the
standard value (Internal disconnec- neutral safety relay (NSF) is replaced with another one while the starting
in normal state tion) switch is set to OFF, the neutral safety relay is defective.
Defective alternator
5 Alternator Voltage
(Internal short circuit)
Terminal R – ground Max. 12 V
Starting motor Voltage
Electric power supply:
20 – 30 V
between terminal B and ground
Detective starting
6 motor Charge:
Max. 12 V
(Internal defect) between ST (2) and ground
Starting:
20 – 30 V
between ST (1) and ground
When each voltage of electric power supply, charging, and starting is nor-
mal but the starting motor does not rotate, the starting motor is defective.
D61EX, PX-15E0 7

OFF.
Defective diode
7 Diagnose diode RSD (male)
• See the “Inspection procedure of diode” in the “Testing and adjusting”
section.
harness
Wiring harness between 280 (C) – NSF (female)
(3)
connectors) Wiring harness between NSF (female) (5) – ST
Resistance Max. 1 z
(female) (1)
Possible
causes and a Prepare with starting switch OFF and diagnose with starting switch ON.
standard value Between ground and wiring harness between
in normal state alternator terminal R – ST (female) (2), wiring
ness
9 harness between alternator terminal R – ST1
circuit) (female) (15), and wiring harness among alterna-
tor terminal R – S04 (female) (9) – G01 (female)
(28)
OFF.
Defective harness Between ground and wiring harness between
grounding 280 (C) – NSF (female) (3)
10
NSF (female) (5) – ST (female) (1)
Between ground and wiring harness between
ST2 (female) (20) – G01 (female) (20)
8 D61EX, PX-15E0
Circuit diagram related to engine start and charge
D61EX, PX-15E0 9
10 D61EX, PX-15E0
E-2 The preheater does not operate 1

Symptom of
• The preheater does not operate.
failure
a This troubleshooting describes the procedures to be followed when the automatic and manual pre-
heating does not function to heat the electrical intake air heater mounting section.
(When only the preheating lamp does not light up, carry out the troubleshooting of “E-7 The preheat-
ing pilot lamp does not light up”)
• For preheating, both the “Automatic preheating function” and “Manual preheating function” are avail-
General able. When either function is performed, the preheating lamp comes on.
information • If “the monitor panel does not light up ”or “the battery relay does not make operating sound” when
turning the starting switch ON, the main electric power supply system is supposed to be defective.
So, check the main electric power supply system.
(If the failure code [CA153], [CA154], [CA2555] or [CA2556] is displayed, firstly conduct this trou-
bleshooting.)

Defective starting OFF.
1
tion) Between 250 (B) – 255 OFF Min. 1 Mz
(R1) HEAT (R1) Max. 1 z
Defective fuse If fuse is burnt, it is highly possible that a defective harness grounding, etc.
2
(FL2, FS1, FS2) has occurred in the circuit.
Defective preheater a Prepare with starting switch OFF and diagnose with starting switch ON.
relay If preheating starts normally at the intake air temperature below
3
(Internal disconnec- –5°C after the preheater relay RHR is replaced with another one, the pre-
tion) heater relay RHR is defective.
a Prepare with the starting switch OFF and diagnose with the starting
Possible switch HEAT.
causes and Heater relay Voltage
standard value
Electric power supply:
in normal state Defective heater relay 20 – 30 V
4 between terminal HT/B and ground
(Internal defect)
Signal:
20 – 30 V
between terminal HT/C and ground
When the both voltages of electric power supply and signal are normal
and no operating sound is heard, the heater relay is defective.
OFF.
Defective diode
5 Diagnose diode GND (male)
• See the “Inspection procedure of diode” in the “Testing and adjusting”
section.
Defective electrical OFF.
6 intake air heater
Electrical intake air heater Continuity
(Internal defect)
Between terminals Continue
D61EX, PX-15E0 11

OFF.
Wiring harness among starting switch 255 (R1) –
Disconnection in wiring Resistance Max. 1 z
RHR (female) (3) – HT/C
harness
Wiring harness between RHR (female) (5) – FS1
(7)
connectors) Wiring harness between battery relay terminal C –
Resistance Max. 1 z
HT/B terminal
Possible Wiring harness between heater relay HT/A termi-
Resistance Max. 1 z
causes and nal – electrical intake air heater
Between ground and wiring harness among
starting witch 255 (R1) – RHR (3) – HT/C
Defective harness
grounding Resistance Min. 1 Mz
8 RHR (female) (5) – FS1 (7)
battery relay terminal C – HT/B
heater relay HT/A – electrical intake air heater Resistance Min. 1 Mz
terminal
12 D61EX, PX-15E0
D61EX, PX-15E0 13
E-3 The monitor panel does not light up at all when the starting switch
is turned ON 1
• If “the battery relay does not make operating sound” when the starting switch is turned on, the main
Symptom of electric power supply system is supposed to be defective. So, check the main electric power supply
failure system.
• The monitor panel does not light up at all when the starting switch is turned ON.
General • When the starting switch is turned ON, the gear speed indicator, multi-information section, gauge
information section, and lamp section light up for approximately 2 sec. and then go out.

1 Defective fuse FS2-7 When the fuse FS2-7 is blown, the circuit probably has a grounding fault.
OFF.
Disconnection in wiring Wiring harness between S03 (female) (1) (2) –
starting switch 270 (ACC)
2 (Disconnection or
defective contact of Wiring harness between S03 (female) (5) (6) –
Resistance Max. 1 z
connectors) fuse FS2-7
Possible Wiring harness between S03 (female) (3) (4) –

Resistance Max. 1 z
causes and GND01
in normal state Defective harness OFF.
grounding Between ground wiring harness between S03
(Contact with ground (female) (1) (2) – starting switch 270 (ACC)
S03 (female) (5) (6) – fuse FS2-7
Defective monitor S03 Voltage
4
panel Between (1) (2) – (3) (4) 20 – 30 V
Between (5) (6) – (3) (4) 20 – 30 V
Circuit diagram related to electric power supply to monitor panel
14 D61EX, PX-15E0
E-4 When the starting switch is turned on, the monitor panel
completely remains lighted and does not go out 1
Symptom of • When the starting switch is turned ON, the monitor panel completely remains lighted and does not go
failure out.
General • When the starting switch is turned ON, the gear speed indicator, multi-information section, gauge
information section, and lamp section light up for approximately 2 sec. and then go out.

causes and
standard value Defective monitor
1 Since this is an internal defect, it cannot be diagnosed.
in normal state panel
D61EX, PX-15E0 15
E-5 While the engine is running, the battery charge level caution lamp
flashes 1
Symptom of
• The battery charge level caution lamp flashes.
failure
General • When any abnormality is detected during engine operating, the battery charge level caution lamp
information flashes.

Alternator Engine speed Voltage
1 (insufficient power gen-
eration) Min. medium speed
Terminal R – ground 20 – 30 V
(half)
harness
Wiring harness between S04 (female) (9) – alter-
nator terminal R
connectors) Between ground and wiring harness between AL/
E – GND3
causes and
standard value
OFF.
in normal state
Defective harness Between ground and wiring harness between
grounding S04 (female) (9) – alternator AL/R terminal,
3 wiring harness between S04 (female) (9) – ST1
circuit) (female) (15), wiring harness among S04 Resistance Min. 1 Mz
(female) (9) – G01 (female) (28) – ST3 (female)
(4), and wiring harness among S04 (female) (9) –
starting switch 260 (BR) – SW (battery relay)
Defective monitor S04 Engine speed Voltage
4
panel Min. medium speed
Between (9) – ground 20 – 30 V
(half)
16 D61EX, PX-15E0
Circuit diagram related to engine start and charge
D61EX, PX-15E0 17
E-6 While the engine is running, the emergency warning item flashes 1
Symptom of
(1) The engine oil pressure caution lamp flashes.
failure
• When any abnormality is detected during engine running, the engine oil pressure caution lamp
General
flashes and the alarm buzzer sounds.
information
• The engine oil pressure switch signal is used to communicate with the engine controller.

Reduction of engine oil
Check the engine oil pressure as the drop of engine oil pressure is
pressure
1 detected.
Possible (When system is nor-
• Carry out the troubleshooting of “S-12 The oil pressure drops.”
causes and mal)
standard value When the possible cause 1 is not the real cause, the engine oil pressure
in normal state Defective engine oil
2 switch circuit is supposed to be defective. So, carry out the troubleshoot-
pressure system
ing of “Failure code [CA435] Abnormal engine oil pressure switch.”
Defective monitor
panel
Symptom of
(2) The coolant temperature caution lamp flashes.
failure
• When any abnormality is detected while engine is running, the coolant temperature caution lamp
flashes and the alarm buzzer sounds.
• The coolant temperature caution lamp flashes or goes out in accordance with an indication on the
General
engine coolant temperature gauge.
information
• The input state (temperature) from the coolant temperature sensor can be checked in the monitor-
ing mode.
(Code 04104: Coolant temperature)

Coolant overheats Since the coolant overheat is detected, check the coolant temperature. (At
1 (When system is nor- the coolant temperature over 105°C, the lamp flashes and the buzzer
mal) sounds. Over 102°C, just the lamp flashes.)
Possible
causes and Defective coolant tem-
standard value perature sensor sys- When the cause 1 is not the real cause, the coolant temperature sensor
in normal state 2 tem circuit is supposed to be defective. So, carry out the troubleshooting of “E-
(Engine controller cir- 8 The coolant temperature gauge does not indicate correctly.”
cuit)
Defective monitor
panel
18 D61EX, PX-15E0
Symptom of
(3) The power train oil temperature caution lamp flashes.
failure
• When any abnormality is detected while engine is running, the power train oil temperature caution
lamp flashes and the alarm buzzer sounds.
• The power train oil temperature caution lamp flashes or goes out in accordance with indication on
the power train oil temperature gauge.
General
information • The input state (temperature) from the power train oil temperature sensor can be checked in the
monitoring mode.
(If the failure code [DGT1KA] or [DGT1KX] is displayed, firstly diagnose the displayed code.)

Power train oil temper- Since the power train oil overheat is detected, check the power train oil
ature overheats temperature.
1
(When system is nor- (At the oil temperature over 130°C, the lamp flashes and the buzzer
Possible mal) sounds. Over 120°C, just the lamp flashes.)
causes and
standard value Defective power train When the cause 1 is not the real cause, the power train oil temperature
in normal state oil temperature sensor sensor circuit is supposed to be defective. So, carry out the troubleshoot-
2
circuits ing of “E-9 The power train oil temperature gauge does not indicate cor-
(Monitor panel circuit) rectly.”
Defective monitor
panel
Symptom of
(4) The hydraulic oil temperature caution lamp flashes.
failure
• When any abnormality is detected while engine is running, the hydraulic oil temperature caution
lamp flashes and the alarm buzzer sounds.
• The hydraulic oil temperature caution lamp flashes or goes out in accordance with indication on the
hydraulic oil temperature gauge.
General
information • The input state (temperature) from the hydraulic oil temperature sensor can be checked at monitor-
ing mode.
(If the failure code [DGS1KX] is displayed, firstly diagnose the displayed code.)

Hydraulic oil overheats Since the hydraulic oil overheat is detected, check the hydraulic oil tem-
1 (When system is nor- perature. (At the hydraulic oil temperature over 110°C, the lamp flashes
Possible mal) and the buzzer sounds. Over 100°C, just the lamp flashes.)
causes and Defective hydraulic oil
standard value When the cause 1 is not the real cause, the hydraulic oil temperature sen-
temperature sensor
in normal state 2 sor circuit is supposed to be defective. So, carry out the troubleshooting of
circuit
“E-10 The hydraulic oil temperature gauge does not indicate correctly”
(Monitor panel circuit)
Defective monitor
panel
D61EX, PX-15E0 19
Symptom of
(5) The caution lamp of water level in the fuel filter lights up.
failure
General • The caution lamp of water level in the fuel filter lights up when the water level in the water separator
information located under the fuel preheater rises, and goes out by draining the water.

The water level in the
water separator rises Since the water in the water separator is detected, check the water sepa-
1
(When the system is rator and drain the water.
Possible normal.)
causes and
standard value Defective fuel filter
When the possible cause 1 is not the real cause, the fuel filter circuit is
in normal state sensor circuit
2 supposed to be defective. So, carry out the troubleshooting of “Failure
(Engine controller cir-
codes [CA428] [CA429] Abnormal water detection sensor”
cuit)
Defective monitor
panel
20 D61EX, PX-15E0
D61EX, PX-15E0 21
E-7 While the preheater is operating, the preheating pilot lamp does
not light up 1
Symptom of
While the preheater is operating, the preheating pilot lamp does not light up.
failure
a This troubleshooting describes the procedures to be followed when the preheating lamp doe not
light up. (When the electrical intake air heater mounting section is not heated, carry out the trouble-
General
shooting of “E-2 The preheater does not operate.”)
information
• For preheating, both the “Automatic preheating function” and “Manual preheating function” are avail-
able. When either function is performed, the preheating lamp comes on.

harness OFF.
1 (Disconnection or
defective contact of Wiring harness between S03 (female) (9) – RHR
Resistance Max. 1 z
Possible
causes and
grounding OFF.
standard value 2
in normal state (Contact with ground Between ground and wiring harness between
S03 (female) (9) – RHR (female) (3)
Defective monitor S03 Starting switch Voltage
3
panel ON Min. 1 V
Between (9) – ground
HEAT Min. 7 V
22 D61EX, PX-15E0
D61EX, PX-15E0 23
E-8 The coolant temperature gauge does not indicate correctly 1

(1)Although the coolant temperature is rising normally, the indication of the coolant temperature stays
Symptom of in white range (a).
failure (2)Although the coolant temperature is stabilized normally, the indication of the coolant temperature
rises to red range (c).
• Signals of the coolant temperature sensor are input into the engine controller and that information is
transmitted to the monitor panel through communication system.
General
information • The input state (temperature) from the coolant temperature sensor can be checked in the monitor-
ing mode.
(Code 04104: Coolant temperature)

Possible Defective coolant tem-
Since the coolant temperature sensor circuit is supposed to be defective,
causes and 1 perature
carry out the troubleshooting of failure codes [CA144] and [CA145].
standard value sensor circuit
in normal state Defective monitor When the possible cause 1 is not the real cause, the monitor panel is sup-
2
panel posed to be defective. (As it is an internal defect, it cannot be diagnosed.)
Symptom of (3)The coolant temperature does not match to the indication of coolant temperature gauge.
failure (4)The coolant temperature gauge does not match with the indication of coolant temperature monitor.
• Signals of the coolant temperature sensor are input into the engine controller and that information is
General transmitted to the monitor panel through communication system.
information • The input state (temperature) from the coolant temperature sensor can be checked in the monitor-
ing mode. (Code 04104: Coolant temperature)
Possible a Diagnose with starting switch ON or with engine started.

causes and Caution lamp (d)
1 OFF Flashing
White range (a)
Red range (c)
Green range (b)
Coolant temperature gauge and caution lamp
24 D61EX, PX-15E0
D61EX, PX-15E0 25
E-9 The power train oil temperature gauge does not indicate correctly1
(1)Although the power train oil temperature is rising normally, the indication of the power train oil tem-
Symptom of perature stays in white range (a).
failure (2)Although the power train oil temperature is stabilized normally, the indication of the power train oil
temperature rises to red range (c).
• The input state (temperature) from the power train oil temperature sensor can be checked in the
monitoring mode.
General
information
• If an abnormality takes place in the power train oil temperature sensor circuit, the failure code
[DGT1KA] or [DGT1KX] may be displayed.

OFF.
Defective power train Torque converter
oil temperature sensor 453 (male) Resistance
1 oil temperature
tion or short circuit) Between (1) – (2) 3.5 – 90 kz
Between (1) – 10 – 100°C
Min. 1 Mz
chassis ground
harness
(female) (1)
connectors) Wiring harness between 453 (female) (2) – S03
(female) (3)
causes and
standard value Defective grounding of a Prepare with starting switch OFF and diagnose with starting switch still
in normal state wiring harness OFF.
3
(a contact with GND Between ground and wiring harness between
S04 (female) (12) – 453 (female) (1)
4 S04 (female) (12) – 453 (female) (1)
Voltage Max. 1 V
453 (female) (2) – S03 (female) (3)
OFF.
Defective monitor Power train
5 S04 (female) Resistance
panel oil temperature
Between (12) –
10 – 100°C 3.5 – 90 kz
ground
26 D61EX, PX-15E0
(3)The power train oil temperature does not match with the indication of oil temperature gauge.
Symptom of
(4)The power train oil temperature gauge does not match with the indication of the power train oil tem-
failure
perature monitor.
• The input state (temperature) from the power train oil temperature sensor can be checked in the
General
monitoring mode.
information

1 OFF Flashing
White range (a)
Red range (c)
Green range (b)
Power train oil temperature gauge and caution lamp
D61EX, PX-15E0 27
E-10 Hydraulic oil temperature gauge does not indicate properly 1

(1)Though the hydraulic oil temperature rises normally, but the gauge indication does not rise from
Symptom of
white range (a).
failure
(2)Although the hydraulic oil temperature is stabilized normally, but gauge indication rises to red range (c).
• Signals of the hydraulic oil temperature sensor are inputted to the steering and transmission control-
ler and the information is transmitted to monitor panel through communication system.
• When any abnormality occurred in the hydraulic oil temperature sensor system, the failure code
General
[DGS1KX] may be displayed.
information
• The input state (temperature) from the hydraulic oil temperature sensor can be checked at monitor-
ing mode.
(Code: 04401 Hydraulic oil temperature)

Defective hydraulic oil OFF.
temperature sensor SDS (male) Resistance
1
tion and short circuit) Between (1) – (2) 3.5 – 90 kz
harness
Wiring harness between ST1 (female) (9) – SDS
(female) (1)
Resistance Max. 1 z
SDS (female) (2)
Possible Defective grounding of a Prepare with starting switch OFF and diagnose with starting switch still
causes and wiring harness OFF.
3
standard value (a contact with GND Between ground and wiring harness between
in normal state circuit) Resistance Min. 1 Mz
4 ST1 (female) (9) – SDS (female) (1)
Voltage Max. 1 V
OFF.
5
Between (9) – (21) 3.5 – 90 kz
Between (9) – ground Min. 1 Mz
Defective monitor
panel
28 D61EX, PX-15E0
Circuit diagram related to hydraulic oil temperature sensor
Symptom of (3)Actual temperature of the hydraulic oil and the indication of the oil temperature gauge do not match.
failure (4)Indication of hydraulic oil temperature gauge and hydraulic oil temperature monitor do not match.
• The input state (temperature) from the hydraulic oil temperature sensor can be checked at monitor-
General
ing mode.
information

1 OFF Flashing
White range (a)
Red range (c)
Green range (b)
Hydraulic oil temperature gauge and caution lamp
D61EX, PX-15E0 29
E-11 Fuel gauge does not indicate properly 1

Symptom of
Fuel gauge does not indicate properly.
failure
General • The input state (voltage signal) from the fuel level sensor can be checked in monitoring mode.
information (Code: 04200 Fuel level sensor voltage)

Defective fuel level OFF.
sensor 423 (male) Fuel level Resistance
1
tion and short circuit) Between (1) – (2) Full Approx. 4 z
ground Empty Approx. 85 z
harness
(female) (1)
Possible defective contact of
causes and connectors) Wiring harness among 423 (female) (2) – S03
Resistance Max. 1 z
standard value (female) (3), (4) – ground
in normal state Defective grounding of a Prepare with starting switch OFF and diagnose with starting switch still
wiring harness OFF.
3
(a contact with GND Between ground and wiring harness between
S04 (female) (10) – 423 (female) (1)
4 S04 (female) (10) – 423 (female) (1)
Voltage Max. 1 V
423 (female) (2) – S03 (female) (3) (4)
Defective monitor
panel
Circuit diagram related to fuel level sensor
30 D61EX, PX-15E0
E-12 Gear speed and engine speed are not indicated properly 1
Symptom of
• Gear speed and engine speed are not indicated properly.
failure
General • Signals of gear speed and engine speed are sent and received through communication by steering
information and transmission controller and engine controller.

causes and
E-13 The preset mode service meter does not indicate normally 1
Symptom of
(1) During engine operation, the service meter does not advance.
failure
• The service meter measures time while the monitor panel is receiving engine drive signals (alterna-
General tor signals).
information • The display data of the preset mode and service meter are sent and received through communica-
tion by the steering and transmission controller.

When the battery charge level caution lamp flashes during engine opera-
Possible 1 tion, carry out the troubleshooting of “E-5 While the engine is operating,
signals system
causes and battery charge level caution flashes”.
(Gauge or lamp mod-
ule)
Symptom of
(2) Shift mode and service meter are not displayed at all.
failure
General • The display data are sent and received through communication by the steering and transmission
information controller.

causes and
E-14 The warning lamp does not flash or does not go out 1
Symptom of
• The warning lamp does not flash or does not go out.
failure
General
information

causes and
D61EX, PX-15E0 31
E-15 The alarm buzzer does not sound or does not stop 1
Symptom of
• The alarm buzzer does not sound or does not stop.
failure
General • When a short circuit occurs in the alarm buzzer system, the failure code [DV00KB] is displayed but
information no other failure codes are displayed.

a Prepare with the starting switch OFF, then carry out troubleshooting
Defective starting without turning the starting switch ON.
1
tion) Between (B) – 270 OFF Min. 1 Mz
(ACC) ON(ACC) Max. 1 z
OFF.
Defective alarm buzzer
2 (Internal disconnec- 217 (male) Continuity
tion and short circuit) Between (2) – (1) Continue
Between (1), (2) – ground No continuity
causes and harness
standard value 3 (Disconnection or Resistance Max. 1 z
(female) (1)
in normal state defective contact of
connectors) Wiring harness between 217 (female) (2) – start-
Resistance Max. 1 z
ing switch 270 (ACC)
Defective grounding of OFF.
wiring harness Between ground wiring harness between starting
(a contact with GND switch 270 (ACC) – 271 (female) (2)
217 (female) (1) – S03 (female) (18)
Defective monitor S03 Alarm buzzer Voltage
panel
5 When stopping 20 – 30 V
(Gauge or lamp mod-
ule) Between (18) – ground When turned ON
Max. 3 V
(sounding)
32 D61EX, PX-15E0
Circuit diagram related to alarm buzzer
D61EX, PX-15E0 33
E-16 Auto shift down is not possible or is not released 1

Symptom of
• Auto shift down is not possible or is not released.
failure
General
information

OFF.
Defective auto shift
down switch Auto shift down
1 ASD (male) Resistance
(Internal disconnec- switch
tion or short circuit) OFF(0) Min. 1 Mz
Between (2) – (3)
ON(1) Max. 1 z
harness
Possible ASD (female) (2)
causes and connectors) Wiring harness between ASD (female) (3) –
ground
in normal state
Defective grounding of a Prepare with starting switch OFF and diagnose with starting switch ON.
wiring harness
(a contact with GND Voltage Max. 1 V
circuit) (female) (37) – ASD (female) (2)
Auto shift down
Defective steering and Between ST2 (37) – Voltage
4 switch
transmission controller ST3 (21), (31), (32) and
OFF(0) 5 – 11 V
(33)
ON(1) Max. 1 V
Limitation of function When Causes 1 to 4 are not applicable, the steering and transmission
5
by controller controller may be restricting the function because of other causes.
34 D61EX, PX-15E0
Circuit diagram related to auto shift down switch
D61EX, PX-15E0 35
E-17 The buzzer cancel switch does not work 1

Symptom of
• The buzzer cancel switch does not work.
failure
General
information

OFF.
Buzzer cancel
Defective buzzer can- BUZ (male) Resistance
switch
cel switch
1 OFF(0) Min. 1 Mz
Between (1) – (2)
tion or short circuit) t Max. 1 z
OFF(0) Min. 1 Mz
Between (1) – (3)
U Max. 1 z
OFF.
BUZ (female) (2)
2 (Disconnection or
connectors) BUZ (female) (3)
causes and
Wiring harness between BUZ (female) (1) –
GND04
in normal state
grounding Between ground and wiring harness between
(Contact with ground ST2 (female) (36) – BUZ (female) (2)
ST2 (female) (26) – BUZ (female) (3)
Steering and transmis- Buzzer cancel
Voltage
sion controller switch
Defective steering and Between ST2 (36) – OFF(0) 5 – 11 V

4 ST3 (21), (31), (32) and
transmission controller t Max. 1 V
(33)
Between ST2 (26) – OFF(0) 5 – 11 V
ST3 (21), (31), (32) and
(33) U Max. 1 V
36 D61EX, PX-15E0
Circuit diagram related to buzzer cancel switch
D61EX, PX-15E0 37
E-18 The information switch does not work 1

Symptom of
• The information switch does not work.
failure
General
information

OFF.
Information
Defective information CUR (male) Resistance
switch
switch
1 OFF(0) Min. 1 Mz
Between (1) – (2)
tion and short circuit) > Max. 1 z
OFF(0) Min. 1 Mz
Between (1) – (3)
< Max. 1 z
OFF.
CUR (female) (2)
2 (Disconnection or
defective contact of Wiring harness between ST2 (female) (6) – CUR
causes and
Wiring harness between CUR (female) (1) –
GND04
in normal state
grounding Between ground and wiring harness between
(Contact with ground ST2 (female) (16) – CUR (female) (2)
ST2 (female) (6) – CUR (female) (3)
Steering and transmis-
Information switch Voltage
sion controller
Defective steering and Between ST2 (16) and OFF(0) 5 – 11 V

4 ST3 (21),
transmission controller > Max. 1 V
(31), (32), (33)
Between ST2 (6) and OFF(0) 5 – 11 V
ST3 (21),
(31), (32), (33) < Max. 1 V
38 D61EX, PX-15E0
Circuit diagram related to information switch
D61EX, PX-15E0 39
E-19 The fan cleaning does not operate or cannot be reset 1

Symptom of
The fan cleaning does not operate or cannot be reset.
failure
a This troubleshooting describes the procedures to be followed when the fan rotation selector switch
General is abnormal.
information • In case fan operation confirmation lamp correctly lights up and go off by switch operation, but fan
does not reverse or reverses, carry out troubleshooting for failure codes [DW7BKA], [DW7BKB].

OFF.
Defective fan rotation
selector switch Fan rotation selector
1 FAM (male) Resistance
tion and short circuit) OFF(0) Min. 1 Mz
Between (1) – (2)
CLN Max. 1 z
harness
Wiring harness between ST2 (female) (7) – FAM
(female) (2)
standard value connectors) Wiring harness between FAM (female) (1) –
Resistance Max. 1 z
in normal state GND04
grounding OFF.
3
(Contact with ground Between ground and wiring harness between Max.
circuit) Resistance
ST2 (female) (7) – FAM (female) (2) 1 Mz
Steering and transmis- Fan rotation selector
Voltage
Defective steering and sion controller switch
4
transmission controller Between ST2 (7) and OFF(0) 5 – 11 V
ST3 (21),
(31), (32), (33) CLN Max. 1 V
40 D61EX, PX-15E0
Circuit diagram related to fan rotation selector switch
D61EX, PX-15E0 41
E-20 The preset mode does not operate or cannot be reset 1

Symptom of
• The preset mode does not operate or cannot be reset.
failure
General
information

OFF.
Defective manual
mode switch Preset mode
1 MAM (male) Resistance
tion) OFF(0) Min. 1 Mz
Between (2) – (3)
ON(1) Max. 1 z
grounding
2 (Disconnection in wir- Resistance Max. 1 z
Possible MAM (female) (2)
ing or defective con-
causes and tact) Wiring harness between MAM (female) (3) –
Resistance Max. 1 z
standard value ground
Defective harness
grounding OFF.
3
(Contact with ground Between ground and wiring harness between Max.
circuit) Resistance
ST2 (female) (10) – MAM (female) (2) 1 Mz
Preset mode
4 switch
OFF(0) 5 – 11 V
ON(1) Max. 1 V
Limitation of function When causes 1 to 4 are not applicable, steering and transmission control-
5
by controller ler may be limiting function because of another reason.
42 D61EX, PX-15E0
Circuit diagram related to preset mode
D61EX, PX-15E0 43
E-21 The monitor panel cannot be set in the service mode or cannot be
set out of the service mode 1
Symptom of
• The monitor panel cannot be set in the service mode or cannot be set out of the service mode.
failure
General
information

Since the buzzer cancel switch system is supposed to be out of order,
Defective buzzer can-
1 carry out the troubleshooting of ”E-17 The buzzer cancel switch does not
cel switch system
work”.
Defective information Since the information switch system is supposed to be out of order, carry
2
switch system out the troubleshooting of “E-18 The information switch does not work”.
When the fuse FS2 (7) is cut off, a ground fault may have possibly
3 Defective fuse FS2(7)
occurred in the circuit.
Defective service OFF.
switch S24 Service switch Resistance
4
(Internal short circuit or
disconnection) Between (1) – (2) OFF Min. 1 Mz
Between (5) – (4) ON Max. 1 z
OFF.
Disconnection in wiring Wiring harness between FS2 (7) outlet – S24 (1) Resistance Max. 1 z
harness
Wiring harness between S24 (4) – ground Resistance Max. 1 z
5 (Disconnection or
defective contact of Wiring harness between S03 (female) (16) – S24
connectors) (2)
causes and
Wiring harness between ST1 (female) (6) – S24
(5)
in normal state
grounding Between ground and wiring harness among FS2 Max.
6 Resistance
(Contact with ground (7) – S24 (1) – S03 (female) (5) (6) 1 Mz
circuit) Between ground and wiring harness between Max.
Resistance
S24 (5) – ST1 (female) (6) 1 Mz
ness
circuit) S24 (2) – S03 (female) (16)
Defective monitor S03 Service switch Voltage
8
panel OFF Max. 1 V
ON 20 – 30 V
Defective steering and ST1 Service switch Voltage
9
transmission controller OFF 5 – 11 V
ON Max. 1 V
44 D61EX, PX-15E0
Circuit diagram related to service switch
D61EX, PX-15E0 45
E-22 The back-up alarm does not sound 1

Symptom of
• The back-up alarm does not sound.
failure
When a failure occurs on the primary side (coil side) of the back-up alarm relay, relevant failure codes
General
[D161KA], [D161KB] are displayed, but in case of failure on the secondary side (contact side), no fail-
information
ure code is displayed.

When the fuse is blown, a ground fault may have probably occurred in the
1 Defective fuse (FS2-6)
circuit.
Defective back-up
alarm relay When the relay is replaced with another relay while the starting switch is
2 set to OFF and the alarm sounds after the starting switch is turned on and
tion) the machine is operated in reverse, the back-up alarm relay (BKA) is
defective.
OFF.
Wiring harness between FS2-6 – BKA (female)
Disconnection in wiring Resistance Max. 1 z
(1) (3)
harness
Possible Wiring harness between BKA (female) (2) – ST2
causes and (female) (18)
standard value Wiring harness between BKA (female) (5) and
connectors) Resistance Max. 1 z
in normal state back-up alarm positive (+) terminal
Wiring harness between back-up alarm negative
Resistance Max. 1 z
(–) terminal and GND03
OFF.
Defective harness
Between wiring harness related to FS2-6 and
4 BKA (female) (1), (3) and ground
circuit) Between wiring harness between BKA (female)
(5) and back-up alarm positive (+) terminal and Resistance Min. 1 Mz
ground
Defective back-up
When Causes 1 to 4 are not applicable, the back-up alarm is supposed to
5 alarm
be defective.
(Internal defect)
46 D61EX, PX-15E0
Circuit diagram related to back-up alarm
D61EX, PX-15E0 47
48 D61EX, PX-15E0
E-23 The head lamp and rear lamp do not light up 1

Symptom of
(1) The head lamp does not light up.
failure
General
information

Defective head lamp
1 Since the head lamp may be defective, check its bulb for breakage.
(Breakage of bulb)
2 Defective fuse (FS1-8) If the fuse is broken, the circuit probably has a grounding fault, etc.
Defective head lamp OFF.
switch FWL (male) Switch Resistance
3
tion) OFF Min. 1 Mz
Between (2) – (3)
ON Max. 1 z
Possible OFF.
causes and Disconnection in wiring Wiring harness between FWL (female) (2) –
standard value harness Resistance Max. 1 z
FS1-8
in normal state 4 (Disconnection or
defective contact of Wiring harness between FWL (female) (3) – 203
Resistance Max. 1 z
connectors) (female) (2) and 204 (female) (2)
Wiring harness among 203 (female) (1) – 204
Resistance Max. 1 z
(female) (1) – GND04
OFF.
Defective harness
5 FWL (female) (2) – FS1-8
FWL (female) (3) – 203 (female) (2) and FWL Resistance Min. 1 Mz
(female) (3) – 204 (female) (2)
D61EX, PX-15E0 49
Symptom of
(2) The rear lamp does not light up.
failure
General
information

Defective rear lamp
1 Since the rear lamp may be defective, check its bulb for breakage.
(Breakage of bulb)
2 Defective fuse (FS1-8) If the fuse is broken, the circuit probably has a grounding fault, etc.
Defective rear lamp OFF.
switch RWL (male) Switch Resistance
3
tion) OFF Min. 1 Mz
Between (2) – (3)
ON Max. 1 z
Possible OFF.
causes and Disconnection in wiring Wiring harness between RWL (female) (2) –
standard value harness Resistance Max. 1 z
FS1-8
in normal state 4 (Disconnection or
defective contact of Wiring harness between RWL (female) (3) –
Resistance Max. 1 z
connectors) 224 (female) (2), 228 (female) (1)
Wiring harness among 224 (female) (1) – 228
Resistance Max. 1 z
(female) (2) – GND03
OFF.
Defective harness
5 RWL (female) (2) – FS1-8
RWL (female) (3) – 224 (female) (2) and RWL Resistance Min. 1 Mz
(female) (3) – 228 (female) (1)
50 D61EX, PX-15E0
Circuit diagram related to panel lamp, head lamp and rear lamp
D61EX, PX-15E0 51
E-24 The horn does not sound or does not stop 1

Symptom of
• The horn does not sound or does not stop.
failure
General
information

Disconnection of fuse If fuse is burnt, it is highly possible that a defective harness grounding, etc.
1
(FS1-7) has occurred in the circuit.
OFF.
Defective horn switch
2 (Internal short circuit Terminal (switch) Horn switch Resistance
and disconnection) OFF Min. 1 Mz
265 – 266
ON Max. 1 z
harness OFF.
Possible 3 (Disconnection or Wiring harness between FS1-7 – 266 Resistance Max. 1 z
connectors) Wiring harness between 265 – 205 (female) (1) Resistance Max. 1 z
standard value
Defective grounding of OFF.
wiring harness Between ground and wiring harness between
(a contact with GND FS1-7 – 266
265 – 205 (female) (1)
ness
circuit) 265 – 205 (female) (1)
Defective horn When Causes 1 to 5 are not applicable, the horn is supposed to be defec-
6
(Internal defect) tive.
Circuit diagram related to horn
52 D61EX, PX-15E0
D61EX, PX-15E0 53
E-25 Malfunction of wipers 1

Symptom of
(1) The front wiper does not operate. (Continuous operation is defective.)
failure
• When only the front wiper is defective
General • If fuse (5) in the cab is blown, intermittent operation of the all wipers becomes defective.
information • If any wiper does not operate, check fusible link (FL1).
• Diagnose with intermittent switch OFF and with wiper switch ON.

Defective fusible link
1 If the fusible link is burnout, the circuit probably has a grounding fault, etc.
(FL1)
Since fuse (5) in the cab is used for the front wiper circuit and intermittent
Defective fuse (5) in
2 switch circuit, either circuit of those two probably have a grounding fault,
cab
etc.
Between CN23 (6) – ground Voltage 20 – 30 V
Defective front wiper a Prepare with starting switch OFF and diagnose with starting switch still
3
motor OFF.
Wiring harness between CN23 (female) (1) –
Resistance Max. 1 z
ground
OFF.
Possible Defective front wiper
causes and 4 CN14 (male) Position of switch Resistance
switch
standard value ON Max. 1 z
in normal state Between (3) – (4)
OFF Min. 1 Mz
• If the problem is eliminated by replacing the relay (CN27), (CN31) or
(CN33) with another one, the relay is defective.
Defective front wiper a Prepare with starting switch OFF and diagnose with starting switch ON.
5 intermittent selector
relay
Between CN29 (1) – ground Voltage Max. 1 V
Defective front wiper a Prepare with starting switch OFF and diagnose with starting switch ON.
6
intermittent relay Between CN28 (4) – ground Voltage 20 – 30 V
54 D61EX, PX-15E0

OFF.
Resistance Max. 1 z
CN29 (female) (3)
CN14 (female) (4) – CN29 (female) (3)
Resistance Max. 1 z
CN28 (female) (4)
Disconnection or short Resistance Min. 1 Mz
Possible circuit with ground in
causes and Wiring harnesses between fuse (5) – CN14
wiring harness
standard value (female) (2) (3) and CN23 (female) (3) – CN28 Resistance Max. 1 z
7 (Disconnection in wir-
in normal state (female) (3)
ing or defective contact
of connectors or con- Between ground and wiring harnesses between
tact with ground circuit) fuse (5) – CN14 (female) (2) (3) and CN23 Resistance Min. 1 Mz
(female) (3) – CN28 (female) (3)
Resistance Max. 1 z
CN23 (female) (6)
Resistance Max. 1 z
ground
Resistance Max. 1 z
ground
D61EX, PX-15E0 55
Symptom of
(2) Front wiper malfunctions in the intermittent mode.
failure
• When the ordinary operation is normal.
General
• When carrying out the troubleshooting, turn the wiper switch and intermittent switch ON.
information
• The wiper stops for about 5 seconds after a single wiping operation.

• If the ordinary operation is normal and the other wiper also malfunctions
in the intermittent mode, the intermittent switch is probably defective.
Defective intermittent OFF.
1
switch
CN11 (male) Position of switch Resistance
ON Max. 1 z
Between (1) – (2)
OFF Min. 1 Mz
Defective front wiper
2 intermittent selector a Prepare with starting switch OFF and diagnose with starting switch ON.
relay Between CN29 (1) – ground Voltage 20 – 30 V
Possible
causes and • If the problem is eliminated by replacing the relay (CN26), (CN30) or
standard value Defective front wiper (CN32) with another one, the relay is defective.
in normal state 3
intermittent relay a Prepare with starting switch OFF and diagnose with starting switch ON.
OFF.
Resistance Max. 1 z
Disconnection or short CN29 (female) (1)
circuit with ground in Between ground and wiring harness between
wiring harness Resistance Min. 1 Mz
ing or defective contact Wiring harness between CN29 (female) (5) –
Resistance Max. 1 z
of connectors or con- CN28 (female) (2)
tact with ground circuit) Between ground and wiring harness between
Resistance Max. 1 z
ground
56 D61EX, PX-15E0
Circuit diagram related to wiper system
D61EX, PX-15E0 57
Symptom of
(3) The rear wiper does not operate (Continuous operation is defective)
failure
• When only the rear wiper is defective
General
• If any wiper does not operate, check fusible link (FL1).
information
• Diagnose with intermittent switch OFF and with wiper switch ON.

(FL1)
Defective fuse (4) in Since fuse (4) in the cab is used only for the rear wiper circuit, the rear
2
cab wiper circuit probably has a grounding fault, etc.
Defective rear wiper a Prepare with starting switch OFF and diagnose with starting switch still
3
motor OFF.
Resistance Max. 1 z
ground
OFF.
Possible Defective rear wiper CN12 (male) Position of switch Resistance
4
causes and switch
ON Max. 1 z
standard value Between (3) – (4)
in normal state OFF Min. 1 Mz
Defective rear wiper a Prepare with starting switch OFF and diagnose with starting switch ON.
5 intermittent selector
relay
Defective rear wiper a Prepare with starting switch OFF and diagnose with starting switch ON.
6
intermittent relay Between CN32 (4) – ground Voltage 20 – 30 V
58 D61EX, PX-15E0

OFF.
Resistance Max. 1 z
CN33 (female) (3)
Resistance Max. 1 z
CN32 (female) (4)
Disconnection or short Wiring harness between fuse (4) – CN12
Possible circuit with ground in Resistance Max. 1 z
(female) (2) (3)
causes and wiring harness
standard value Between ground and wiring harness between
7 (Disconnection in wir- Resistance Min. 1 Mz
in normal state fuse (4) – CN12 (female) (2) (3)
of connectors or con- Wiring harness among fuse (4) – CN32 (female)
Resistance Max. 1 z
tact with ground circuit) (3) – CN37 (female) (3)
Between ground and wiring harness among fuse
(4) – CN32 (female) (3) – CN37 (female) (3)
Resistance Max. 1 z
CN37 (female) (1)
Resistance Max. 1 z
ground
Resistance Max. 1 z
ground
D61EX, PX-15E0 59
Symptom of
(4) Rear wiper malfunctions in the intermittent mode.
failure
General
information

1
switch
ON Max. 1 z
Between (1) – (2)
OFF Min. 1 Mz
Defective rear wiper
2 intermittent selector a Prepare with starting switch OFF and diagnose with starting switch ON.
relay Between CN33 (1) – ground Voltage 20 – 30 V
Possible
standard value Defective rear wiper (CN30) with another one, the relay is defective.
in normal state 3
intermittent relay a Prepare with starting switch OFF and diagnose with starting switch ON.
OFF.
Resistance Max. 1 z
Resistance Max. 1 z
in connector or contact CN32 (female) (2)
with ground circuit) Between ground and wiring harness between
Resistance Max. 1 z
ground
60 D61EX, PX-15E0
D61EX, PX-15E0 61
Symptom of
(5) The right door wiper does not operate. (Continuous operation is defective.)
failure
• When only the right door wiper is defective (If fuse (6) in the cab is blown, the left door wiper does
General not operate either.)
• When carrying out the troubleshooting, turn the intermittent switch OFF and turn the wiper switch ON.

(FL1)
Defective fuse (6) in Since fuse (6) in the cab is used for the right and left wiper system, either
2
cab circuit of those two probably has a grounding fault, etc.
Between connector (3) just before motor –
Voltage 20 – 30 V
ground
Defective right door
3 a Prepare with starting switch OFF and diagnose with starting switch still
wiper motor
OFF.
Wiring harness between connector (1) just
Resistance Max. 1 z
before motor – ground
OFF.
Possible Defective right door
wiper switch
OFF Min. 1 Mz
Defective right door a Prepare with starting switch OFF and diagnose with starting switch ON.
5 wiper intermittent
selector relay
6
wiper intermittent relay Between CN30 (4) – ground Voltage 20 – 30 V
62 D61EX, PX-15E0

OFF.
Resistance Max. 1 z
CN31 (female) (3)
Resistance Max. 1 z
CN30 (female) (4)
Wiring harnesses among fuse (6) – CN13
(female) (2) (3) – CN17 (4) – connector just Resistance Max. 1 z
Disconnection or short before motor (female) (4) – CN13 (female) (2) (3)
Possible circuit with ground in Between ground and wiring harnesses among
causes and wiring harness fuse (6) – CN13 (female) (2) (3) – CN17 (4) –
standard value Resistance Min. 1 Mz
7 (Disconnection in wir- connector just before motor (female) (4) – CN13
in normal state ing or defective contact (female) (2) (3)
of connectors or con- Wiring harness between fuse (6) – CN30
tact with ground circuit) (female) (3) Resistance Max. 1 z

fuse (6) – CN30 (female) (3)
Wiring harness among connector just before
motor (female) (3) – CN17 (3) – CN30 (female) Resistance Max. 1 z
(5)
connector just before motor (female) (3) – CN17 Resistance Min. 1 Mz
(3) – CN30 (female)(5)
Resistance Max. 1 z
ground
Resistance Max. 1 z
motor (female) (1) – CN17(1) – ground
D61EX, PX-15E0 63
Symptom of
(6) Right door wiper malfunctions in the intermittent mode.
failure
General
information

1
switch
CN11 (female) Position of switch Resistance
ON Max. 1 z
Between (1) – (2)
OFF Min. 1 Mz
Defective right door
2 wiper intermittent a Prepare with starting switch OFF and diagnose with starting switch ON.
selector relay Between CN31 (1) – ground Voltage 20 – 30 V
Possible
standard value Defective right door (CN32) with another one, the relay is defective.
in normal state 3
wiper intermittent relay a Prepare with starting switch OFF and diagnose with starting switch ON.
OFF.
Resistance Max. 1 z
Resistance Max. 1 z
Resistance Max. 1 z
ground
64 D61EX, PX-15E0
D61EX, PX-15E0 65
Symptom of
(7) The left door wiper does not operate. (Continuous operation is defective.)
failure
• When only the left door wiper is defective (If fuse (6) in the cab is blown, the right door wiper does
General not operate either.)
• When carrying out the troubleshooting, turn the intermittent switch OFF and turn the wiper switch ON.

(FL1)
Defective fuse (6) in Since fuse (6) in the cab is used for the right and left wiper system, either
2
cab circuit of those two probably has a grounding fault, etc.
Between connector (3) just before motor –
Voltage 20 – 30 V
ground
Defective left door
wiper motor
OFF.
Wiring harness between connector (1) just
Resistance Max. 1 z
before motor – ground
OFF.
Possible Defective left door
wiper switch
OFF Min. 1 Mz
Defective left door a Prepare with starting switch OFF and diagnose with starting switch ON.
5 wiper intermittent
selector relay
6
wiper intermittent relay Between CN26 (4) – ground Voltage 20 – 30 V
66 D61EX, PX-15E0

OFF.
Resistance Max. 1 z
CN27 (female) (3)
Resistance Max. 1 z
CN26 (female) (4)
Wiring harness among fuse (6) – CN26 (female)
(3) – CN24 (4) – connector just before motor Resistance Max. 1 z
Disconnection or short (female) (4)
Possible circuit with ground in
causes and Between ground and wiring harness among fuse
wiring harness
standard value (6) – CN26 (female) (3) – CN24 (4) – connector Resistance Min. 1 Mz
in normal state just before motor (female) (4)
of connectors or con- Wiring harness between fuse (6) – CN15 Resistance Max. 1 z
tact with ground circuit) (female) (2) (3)
fuse (6) – CN15 (female) (2) (3)
motor (female) (3) – CN24(3) – CN26 (female) Resistance Max. 1 z
(5)
connector just before motor (female) (3) – CN24 Resistance Min. 1 Mz
(3) – CN26 (female) (5)
Resistance Max. 1 z
ground
Resistance Max. 1 z
motor (female) (1) – CN24 (1) – ground
D61EX, PX-15E0 67
Symptom of
(8) Left door wiper malfunctions in the intermittent mode.
failure
General
information
• When wiper stops for about 5 seconds after a single wiping operation.

1
switch
ON Max. 1 z
Between (1) – (2)
OFF Min. 1 Mz
Defective left door
2 wiper intermittent a Prepare with starting switch OFF and diagnose with starting switch ON.
selector relay Between CN27 (1) – ground Voltage 20 – 30 V
Possible
standard value Defective left door (CN32) with another one, the relay is defective.
in normal state 3
wiper intermittent relay a Prepare with starting switch OFF and diagnose with starting switch ON.
OFF.
Resistance Max. 1 z
Resistance Max. 1 z
Resistance Max. 1 z
ground
68 D61EX, PX-15E0
D61EX, PX-15E0 69
E-26 Washer does not spray water 1

Symptom of
(1) Washer does not spray water
failure
• When the front wiper operates normally
General
(If the wiper does not operate either, carry out troubleshooting in “E-25 (1) The front wiper does not
information
operate.” first.)

OFF.
Defective front washer Wiring harness between 11 (female) (1) – ground Resistance Max. 1 z
1
motor a Prepare with starting switch OFF and diagnose with starting switch ON.
(switch position: W/I)
Between 11 (2) – ground Voltage 20 – 30 V
OFF.
Defective front wiper CN14 (female) Position of switch Resistance
2
switch
Possible W/I or W/II Max. 1 z
causes and Between (2) – (1)
OFF Min. 1 Mz
standard value
OFF.
Wiring harness between fuse (5) – CN14
Resistance Max. 1 z
ing or defective contact Wiring harness among CN14 (female) (1) – 19
Resistance Max. 1 z
of connectors or con- (3) – 13 (3) – 11 (female) (2)
tact with ground circuit) Between ground and wiring harness among
CN14 (female) (1) – 19 (3) – 13 (3) – 11 (female) Resistance Min. 1 Mz
(2)
Wiring harness between 11 (female) (1) – ground Resistance Max. 1 z
70 D61EX, PX-15E0
Circuit diagram related to washer system
D61EX, PX-15E0 71
Symptom of
(2) Rear washer does not spray water
failure
• When the rear wiper operates normally
General
(If the wiper does not operate either, carry out troubleshooting in “E-25 (3) The rear wiper does not
information
operate.” first.)

OFF.
Defective rear washer Wiring harness between 12 (female) (1) – ground Resistance Max. 1 z
1
motor a Prepare with starting switch OFF and diagnose with starting switch ON.
OFF.
Defective rear wiper CN12 (female) Position of switch Resistance
2
switch
OFF Min. 1 Mz
standard value
OFF.
Resistance Max. 1 z
Resistance Max. 1 z
(2)
* For the electric diagram of each system, see Trouble (1).
72 D61EX, PX-15E0
Symptom of
(3) Left door washer does not spray water
failure
• When the left door wiper operates normally
(If the wiper does not operate either, carry out troubleshooting in “E-25 (7) The left wiper does not
General
operate.” first.)
information
• Since the left door wiper switch and right door wiper switch use fuse (6) jointly, if fuse (6) is blown,
both wipers do not operate.

OFF.
Defective left door Wiring harness between 9 (female) (1) – ground Resistance Max. 1 z
1
washer motor a Prepare with starting switch OFF and diagnose with starting switch ON.
OFF.
Defective left door CN15 (female) Position of switch Resistance
2
wiper switch
OFF Min. 1 Mz
standard value
OFF.
Resistance Max. 1 z
ing or defective contact Wiring harness between CN15 (female) (1) – 19
Resistance Max. 1 z
(2)
D61EX, PX-15E0 73
Symptom of
(4) Right door washer does not spray water
failure
• When the right door wiper operates normally
(If the wiper does not operate either, carry out troubleshooting in “E-25 (5) The right wiper does not
General
operate.” first.)
information
• Since the right door wiper switch and left door wiper switch use fuse (6) jointly, if fuse (6) is blown,
both wiper do not operate.

OFF.
Defective right door Wiring harness between 10 (female) (1) – ground Resistance Max. 1 z
1
washer motor a Prepare with starting switch OFF and diagnose with starting switch ON.
OFF.
Defective right door CN13 (female) Position of switch Resistance
2
wiper switch
OFF Min. 1 Mz
standard value
OFF.
Resistance Max. 1 z
Resistance Max. 1 z
(2)
74 D61EX, PX-15E0
D61EX, PX-15E0 75
E-27 The air conditioner does not operate 1

Symptom of
• Air does not blow out
failure
General
information

Defective circuit When the circuit breaker is cut off, a defective grounding may have possi-
1
breaker (CB2) bly occurred in the circuit.
Defective blower main OFF.
2 relay
CN-R1 (male) Resistance
(Coil side)
Between (1) – (2) 240 ± 40 z
Defective blower main a Prepare with starting switch OFF and diagnose with starting switch ON.
3 relay CN-R1 Voltage
(Contact side) Between (8C) – ground 20 – 30 V
Defective blower Hi OFF.
4 relay
(Coil side)
Between (1) – (2) 240 ± 40 z
Defective blower Hi a Prepare with starting switch OFF and diagnose with starting switch ON.
Possible 5 relay It is normal if the motor rotates with the starting switch and the blower Hi
causes and (Contact side) switch turned ON.
in normal state Defective blower Mi1 OFF.
6 relay
(Coil side)
Between (1) – (2) 240 ± 40 z
Defective blower Mi1 a Prepare with starting switch OFF and diagnose with starting switch ON.
7 relay It is normal if the motor rotates with the starting switch and the blower Mi
(Contact side) switch turned ON.
Defective blower Mi2 OFF.
8 relay
(Coil side)
Between (1) – (2) 240 ± 40 z
Defective blower Mi2 a Prepare with starting switch OFF and diagnose with starting switch ON.
9 relay It is normal if the motor rotates with the starting switch and the blower Lo
(Contact side) switch turned ON.
10 Defective blower motor It is normal if the motor rotates with the starting switch and the blower Lo
switch turned ON.
76 D61EX, PX-15E0

OFF.
Wiring harness among CN-R4 (female) (14C) –
AC1 (female) (14A) – CN-R (female) (S141) –
Resistance Max. 1 z
CN-R2 (female) (14E) – CN-R3 (female) (14N) –
ground
Wiring harness between CN-B (female) (11B) –
Resistance Max. 1 z
CN-R1(female) (11A)
Disconnection or Wiring harness among CN-B (female) (12A) –

Resistance Max. 1 z
defective grounding in CN-R2 (female) (12B) – CN-R (female) (12C)
Possible wiring harness Wiring harness among CB2 out – AC1 (female)
11
causes and (Disconnection in wir- (1A) – CN-R1 (female) (1D) – CN-R2 (female)
Resistance Max. 1 z
standard value ing or defective contact (1E) – CN-R3 (female) (1N) – CN-R4 (female)
in normal state of connectors) (1I)
Wiring harness between CN-R1 (female) (2B) –
Resistance Max. 1 z
AC1 (female) (2A)
Resistance Max. 1 z
AC1 (female) (3A)
Resistance Max. 1 z
AC1 (female) (5A)
Resistance Max. 1 z
AC1 (female) (4A)
12 Defective control panel Control panel is possibly defective if no problem is found in causes 1-11.
Symptom of failure is When the cause cannot be identified, the symptom of failure may be incor-
13
incorrect. rect. Carry out the troubleshooting of “It does not get cool.”
D61EX, PX-15E0 77
Symptom of
• It does not get cool.
failure
General
information

Defective pressure
1 CN-P Blower switch Voltage
switch
Between (6B) – ground ON 20 – 30 V
Defective compressor OFF.
2 clutch relay
(Coil side)
Between (1) – (2) 240 ± 40 z
a Prepare with starting switch OFF and diagnose starting switch and air
Defective compressor conditioner switch ON.
3 clutch relay
CN-R5 Voltage
(Contact side)
Between (18A) – ground 20 – 30 V
OFF.
4 Defective thermistor
CN-T (male) Resistance
Between (1) – (2) Max. 3,500 z
Defective blower resis- OFF.
5
tor Blower resistor Resistance
Between terminals 2.8 z ± 5%
Possible
causes and a Start the engine to diagnose.
Defective compressor
standard value 6 The compressor magnet clutch is supposed to be defective, so inspect
magnet clutch
in normal state itself.
a Start the engine to diagnose.
7 Defective compressor Since the compressor is supposed to be defective, inspect the compres-
sor.
Diagnose diode ACG (male).
Defective diode
8 • See the “Inspection procedure of diode” in the “Testing and adjusting”
section.
OFF.
Wiring harness among CB2 out – AC1 (female)
(1A) – CN-R1 (female) (1D) – CN-R2 (female)
Resistance Max. 1 z
(1E) – CN-R3 (female) (1N) – CN-R4 (female)
Disconnection in wiring (1I) – CN-R5 (female) (1K)
harness Wiring harness among CN-T (female) (13B) –
9 (Disconnection in wir- AC1 (female) (13A) – CN-W (female) (13C) Resistance Max. 1 z
of connectors) Wiring harness between CN-T (female) (9B) –
Resistance Max. 1 z
AC1 (female) (9A)
Wiring harness between CN-P (female) (7B) –
Resistance Max. 1 z
CN-R5 (female) (7A)
Wiring harness between CN-P (female) (6B) –
Resistance Max. 1 z
AC1 (female) (6A)
10 Defective control panel Control panel is possibly defective if no problem is found in causes 1-9.
78 D61EX, PX-15E0
Circuit diagram related to air conditioner
D61EX, PX-15E0 79
E-28 KOMTRAX system does not operate normally 1
Symptom of
• KOMTRAX system does not operate properly.
failure
• If KOMTRAX system administrator makes request for checking system on machine side for trouble,
General
carry out the following troubleshooting.
information
• Even if KOMTRAX system has a trouble, it does not particularly appear on machine.
Cause Standard values when normal and remarks for troubleshooting

Defective specification Check the code 0021: KOMTRAX specification setting in adjustment
1
setting mode and set to “ACTIVE”.
OFF.
Defective electric
2 G01 Signal Voltage
power supply
Between (39) (40) –
Constant power source 20 – 30 V
(37) (38)
a Diagnose with starting switch ON and with the engine started.
LED(1) Normal condition
LED-C1 ON
Defective starting a Prepare with starting switch OFF and start the engine to diagnose.
3 switch ACC signal and G01 Signal Voltage
alternator R signal
Between (36) –
Starting switch ACC 20 – 30 V
(37) (38)
Between (28) –
Alternator R 20 – 30 V
(37) (38)
G01 Signal Voltage
Possible Between (27) –
causes and Starting switch C Max. 1 V
Defective starting (37) (38)
standard value 4
switch C signal a Prepare with starting switch OFF and start the engine to diagnose.
in normal state
G01 Signal Voltage
Between (27) –
Starting switch C 20 – 30 V
(37) (38)
a Diagnose with starting switch ON.
LED-C4 ON
Defective CAN con-
necting condition
OFF.
G01 (female) Signal Resistance
Between (7) – (8) CAN 40 – 80 z
Number of mails not
6 LED(7) Normal condition
yet sent
7 segments 0–9
Defective GPS posi- Dot ON
7
tioning status
It may take more than 1 minute from turning on the starting switch to the
completion of positioning even in an outdoor place where radio wave can
reach.
80 D61EX, PX-15E0
LED display section of KOMTRAX terminal G01 connector
CPU LED
1. LED-C1 (R signal and ACC signal status)
2. LED-C2 (starting output status)
3. LED-C3 (S-NET, C signal status)
4. LED-C4 (CAN status)
5. LED-C5 (download writing condition)
6. LED-C6 (download writing condition)
7-segment and dot for CPU
7. 7-segment (number of mails not yet sent)
8. Dot (GPS positioning in progress)
a CPU LED and 7-segment and dot for CPU can

be also checked by monitoring function of
monitor panel.
a See “Special functions of monitor panel

(EMMS)” of Testing and adjusting, Part 3 for
operation of monitoring functions.
D61EX, PX-15E0 81
SEN02566-00

© 2007 KOMATSU
All Rights Reserved
82
SEN02567-00
D61EX-15E0
D61PX-15E0

Troubleshooting of hydraulic and
mechanical system (H-mode)
Contents of troubleshooting table......................................................................................................... 3
H-1 There is no travel power (no drawbar pull).................................................................................... 4
H-2 Machine does not move (at 2nd or 3rd speed).............................................................................. 5
H-3 Machine does not move at any gear speed .................................................................................. 6
H-4 Machine travels only in one direction, forward or in reverse ......................................................... 7
H-5 When gear is shifted or travel direction is changed, large time lag is made ................................. 8
H-6 Machine cannot be steered (Machine does not turn leftward or rightward) .................................. 9
H-7 Steering speed or power is low ..................................................................................................... 9
H-8 Brake does not work.................................................................................................................... 10
H-9 Overheat of power train oil ...........................................................................................................11
H-10 Abnormal sound comes out from around HSS and work equipment pump or HSS motor........ 12
H-11 All work equipment speeds are slow ......................................................................................... 12
H-12 Work equipment does not move................................................................................................ 13
H-13 Blade lift speed is slow or lacks power ...................................................................................... 13
D61EX, PX-15E0 1
H-14 Blade tilt speed is slow or lacks power ...................................................................................... 14

H-15 Angling blade speed is slow or lacks power .............................................................................. 14
H-16 Ripper lift speed is slow or lacks power..................................................................................... 15
H-17 Excessive hydraulic drift of blade lift.......................................................................................... 15
H-18 Excessive hydraulic drift of blade tilt.......................................................................................... 16
H-19 Excessive hydraulic drift of blade angle .................................................................................... 16
H-20 Excessive hydraulic drift of ripper lift ......................................................................................... 17
2 D61EX, PX-15E0

a Troubleshooting lists contain the following information all together. Understand the contents carefully
and troubleshoot the machine.
Symptom of
Symptom of failure that has appeared in the machine
failure
General
information
2 Cause by which a
Possible trouble is assumed to
causes and be caused <Described contents>
standard value (The order number • Standard value when normal required to judge the possible cause
in normal state indicates a serial • Remarks required to judge whether the cause is right or not
number, not a priority
3 sequence.)
D61EX, PX-15E0 3
H-1 There is no travel power (no drawbar pull). 1

Symptom of
• There is no travel power (no drawbar pull).
failure
General
• Check that the power train oil level is normal before troubleshooting.
information

a Prepare with the starting switch OFF, and then run the engine at high
idle for troubleshooting.
1 Defective engine
Measurement conditions Engine speed
F3 stall 1,620 rpm
2 The power train pump is assumed to be defective; visually check it.
pump
Internally defective Torque converter Torque converter
3 PCCS lever
torque converter inlet pressure outlet pressure
Max. 0.88 MPa 0.44 – 0.69 MPa
Full neutral
{Max. 9 kg/cm2} {4.5 – 7 kg/cm2}
PCCS lever Transmission main relief pressure
Full neutral Min. 2.65 MPa {Min. 24 kg/cm2}
Defective set pressure
or internal defect of a Prepare with starting switch OFF and diagnose with starting switch still
4
transmission main OFF.
Possible relief valve Visually check that the free length of spring and the number of shims are
causes and normal and also that the spool rotates smoothly.
standard value • Free length of large spring: 122 mm
in normal state • Free length of small spring: 108 mm
• Number of shims: 6
a Prepare with the starting switch OFF, and then run the engine at low idle
for troubleshooting.
Transmission clutch Clutch pressure
Defective operation of FWD Min. 2.65 MPa {Min. 27 kg/cm2}
5 transmission valve REV Min. 2.65 MPa {Min. 27 kg/cm2}
(ECMV)
1ST Min. 2.65 MPa {Min. 27 kg/cm2}
2ND Min. 2.65 MPa {Min. 27 kg/cm2}
3RD Min. 2.65 MPa {Min. 27 kg/cm2}
6 Defective brake valve
Parking lever Brake pressure
Free Min. 2.55 MPa {Min. 26 kg/cm2}
Parking lever or brake If the result of the troubleshooting in cause 6 is abnormal, the parking
7 pedal linkage out of lever or brake pedal linkage is assumed to be out of adjustment; visually
adjustment check it.
Internally defective
8 The transmission is assumed to be defective internally; visually check it.
transmission
4 D61EX, PX-15E0
H-2 Machine does not move (at 2nd or 3rd speed) 1

Symptom of
• Machine does not move (at 2nd or 3rd speed)
failure
General
Check that the transmission main relief pressure is normal before troubleshooting.
information
(See H-1 “There is no travel power”.)

1 PCCS lever
Max. 0.88 MPa 0.44 – 0.69 MPa
Full neutral
{Max. 9 kg/cm2} {4.5 – 7 kg/cm2}
Defective operation of
2 transmission valve Transmission clutch Clutch pressure
Possible (ECMV) 2ND Min. 2.65 MPa {Min. 27 kg/cm2}
causes and
standard value 3RD Min. 2.65 MPa {Min. 27 kg/cm2}
in normal state Internally defective The transmission clutch (2nd or 3rd speed) is assumed to be defective
3
transmission clutch internally; visually check it.
The parking brake operation is assumed to be defective (dragging); check
4 parking brake
the linkage valves.
(Dragging)
a Move to a flat place (a hard road), and start the engine for troubleshoot-
Defective operation of ing.
5 brake
(Dragging) If the machine does not run by low idle + F2 operation, brake dragging
occurs. (Carry out troubleshooting “H-8 Brake does not work“.)
6 The transmission is assumed to be defective internally; visually check it.
transmission
D61EX, PX-15E0 5
H-3 Machine does not move at any gear speed 1

Symptom of
• Machine does not move at any gear speed.
failure
General
information

pump
2
relief valve Visually check that the free length of spring and the number of shims are
normal and also that the spool rotates smoothly.
• Free length of large spring: 122 mm
• Free length of small spring: 108 mm
Possible for troubleshooting.
causes and (Before this, check that the transmission main relief pressure is normal.)
standard value Transmission clutch Clutch pressure
in normal state Defective operation of
FWD Min. 2.65 MPa {Min. 27 kg/cm2}
3 transmission valve
(ECMV) REV Min. 2.65 MPa {Min. 27 kg/cm2}
Internally defective The transmission clutch is assumed to be defective internally; visually
4
transmission check it.
a Move to a flat place, and run the engine at high idle for troubleshooting.
(Before this, check that the transmission main relief pressure is normal.)
Brake pedal Brake oil pressure (left/right)
5 Defective brake valve Release Min. 2.55 MPa {Min. 26 kg/cm2}
Depress 0 MPa {0 kg/cm2}
When the oil pressure is abnormal, carry out troubleshooting “H-8 Brake
does not work”.
6 D61EX, PX-15E0
H-4 Machine travels only in one direction, forward or in reverse 1

Symptom of
• Machine travels only in one direction, forward or in reverse.
failure
General
information

pump
2
relief valve Visually check that the free length of spring and the number of shims are
Possible normal and also that the spool rotates smoothly.
causes and • Free length of large spring: 122 mm
standard value • Free length of small spring: 108 mm
in normal state • Number of shims: 6
Defective operation of (Before this, check that the transmission main relief pressure is normal.)
3 transmission valve Transmission clutch Clutch pressure
(ECMV)
REV Min. 2.65 MPa {Min. 27 kg/cm2}
Defective transmission If the result of the troubleshooting in cause 3 is abnormal, the clutch seal
4
clutch seal is assumed to be defective; visually check it.
Internally defective The transmission clutch (forward or reverse) is assumed to be defective
5
transmission clutch internally; visually check it.
D61EX, PX-15E0 7
H-5 When gear is shifted or travel direction is changed, large time lag
is made 1
Symptom of
• Time lag is excessive when shifting gear or changing direction.
failure
General
information

pump
2
relief valve • Visually check that the free length of spring and the number of shims
are normal and also that the spool rotates smoothly.
• Free length of large spring: 128 mm
• Free length of small spring: 108 mm
Possible a Prepare with the starting switch OFF, and then run the engine at low idle
causes and for troubleshooting.
standard value (Before this, check that the transmission main relief pressure is normal.)
in normal state Transmission clutch Clutch pressure
3 transmission valve
(ECMV) REV Min. 2.65 MPa {Min. 27 kg/cm2}
Defective transmission If the result of the troubleshooting in cause 3 is abnormal, the clutch seal
4
clutch seal is assumed to be defective; visually check it.
Internally defective The transmission clutch is assumed to be defective internally; visually
5
transmission clutch check it.
a Move to a flat place (a hard road), and start the engine for troubleshoot-
Defective operation of ing.
6
brake (Dragging) If the machine does not run by low idle + F2 operation, brake dragging
occurs. (Carry out troubleshooting “H-8 Brake does not work”.)
8 D61EX, PX-15E0
H-6 Machine cannot be steered (Machine does not turn leftward or

rightward) 1
Symptom of
• Machine cannot be steered. (Machine does not turn leftward or rightward.)
failure
General
• Check that the hydraulic oil level is normal before troubleshooting.
information

a Prepare with the engine started, and then run the engine at high idle for
troubleshooting.
or defective operation
Possible
1 of self pressure reduc- PCCS lever Basic pressure of control circuit
causes and
ing valve (PPC basic 3.72 ± 0.49 MPa
standard value Neutral
pressure)
in normal state {38 ± 5 kg/cm2}
Abnormal sound from If an abnormal sound occurs in the HSS peripheral equipment, carry out
2 HSS peripheral equip- troubleshooting “H-10 Abnormal sound comes out from around HSS and
ment work equipment pump or HSS motor”.
H-7 Steering speed or power is low 1

Symptom of
• Steering speed or power is insufficient.
failure
General
information

a Prepare with the engine started, and then run the engine at high idle for
troubleshooting.
or defective operation
1
of HSS main relief PCCS lever HSS relief pressure
valve Left or right stroke end
Possible Min. 28.9 MPa {295 kg/cm2}
causes and Defective set pressure a Prepare with the engine started, and then run the engine at high idle for
standard value or defective operation troubleshooting.
in normal state 2 of self pressure reduc- PCCS lever Basic pressure of control circuit
ing valve
(PPC basic pressure) Neutral 3.72 ± 0.49 MPa {38 ± 5 kg/cm2}
Abnormal sound from If an abnormal sound occurs in the HSS peripheral equipment, carry out
3 HSS peripheral equip- troubleshooting “H-10 Abnormal sound comes out from around HSS and
ment work equipment pump or HSS motor”.
D61EX, PX-15E0 9
H-8 Brake does not work 1

Symptom of
• Brake does not work.
failure
General
• Check that the transmission main relief pressure is normal before troubleshooting.
information
(See H-1 “There is no travel power”)

Defective operation of Brake pedal Brake oil pressure
1
brake valve
Possible When released Min. 2.55 MPa {Min. 26 kg/cm2}
causes and When depressed 0 MPa {0 kg/cm2}
standard value
in normal state Brake pedal linkage If the result of the troubleshooting in cause 1 is abnormal, the brake pedal
2
out of adjustment linkage is assumed to be out of adjustment; visually check it.
If the result of the troubleshooting in cause 1 is abnormal, the brake seal is
3 Defective brake seal
assumed to be defective; visually check it.
Slip or abrasive wear
4 Slip or abrasive wear of the brake disc plate is suspected; visually check it.
of brake disc plate
10 D61EX, PX-15E0
H-9 Overheat of power train oil 1

Symptom of
• The power train oil overheats.
failure
• Check that the reading on the power train oil temperature gauge matches the actual oil temperature
General before troubleshooting. (If they do not match, carry out troubleshooting “Reading on power train oil
information temperature gauge is incorrect”.
• Check that the transmission main relief pressure is normal before troubleshooting.
(See H-1 “There is no travel power”)

Defective engine sys- The engine cooling system is assumed to be defective or the engine out-
1
tem put is assumed to be increased; see the shop manual of engine volume.
The power train pump is assumed to be defective or residual air from the
2 pump or residual air
suction circuit is assumed to remain; visually check it.
from suction circuit
Possible 3 PCCS lever
causes and
standard value Max. 0.88 MPa 0.44 – 0.69 MPa
Full neutral
in normal state {Max. 9 kg/cm2} {4.5 – 7 kg/cm2}
The transmission clutch is assumed to be defective internally (slip); visu-
4 transmission clutch
ally check it.
(Slip)
a Start the engine to diagnose.
Defective operation of 1. Run the engine at low idle on a flat place (a hard road).
5 brake 2. Set the gearshift lever in F2.
(Dragging) 3. See if the machine moves (travels). If it does not move, brake dragging
occurs.
(Carry out troubleshooting “H-8 Brake does not work”.)
D61EX, PX-15E0 11
H-10 Abnormal sound comes out from around HSS and work equipment
pump or HSS motor 1
Symptom of
• Abnormal noise comes from around HSS and work equipment pump.
failure
General
information

1 Inappropriate oil The oil used is assumed to be inappropriate; visually check it.
Clogged hydraulic tank
2 The hydraulic tank strainer is assumed to be clogged; visually check it.
Possible strainer
causes and Air inhaled in suction Air is assumed to be inhaled in the suction circuit of the HSS and work
standard value 3
circuit equipment pump; visually check the pipes.
in normal state
Internally defective The HSS and work equipment pump is assumed to be defective internally;
4
HSS pump visually check it.
5 The HSS motor is assumed to be defective internally; visually check it.
HSS motor
H-11 All work equipment speeds are slow 1

Symptom of
• All work equipment speeds are slow.
failure
General
• Check that the oil level in the hydraulic tank is normal before troubleshooting.
information

Defective PTO
(Pump drive unit of The PTO pump drive unit of the HSS and work equipment is assumed to
1
HSS and work equip- be defective; visually check it.
ment)
Defective HSS and The HSS and work equipment pump is assumed to be defective; visually
2
work equipment pump check it.
Defective operation
3 Work equipment control lever Unload pressure
Possible of unload valve
3.43 (+1.37/0) MPa
causes and Full neutral
{35 (+14/0) kg/cm2}
standard value
in normal state a Prepare with the starting switch OFF, and then run the engine at high
or
4
defective operation of Work equipment control lever Main relief pressure
main relief valve Stroke end Min. 19.1 MPa {Min. 195 kg/cm2}
self pressure reducing
5
valve (PPC basic pres- Work equipment control lever Basic pressure of control circuit
sure) Full neutral 3.72 ± 0.49 MPa {38 ± 5 kg/cm2}
Internally defective If the result of the troubleshooting in cause 5 is abnormal, the PPC valve is
6
PPC valve assumed to be defective internally; visually check it.
12 D61EX, PX-15E0
H-12 Work equipment does not move 1

Symptom of
• Work equipment does not move.
failure
General
information

Defective PTO
(Pump drive unit of The PTO pump drive unit of the HSS and work equipment is assumed to
1
HSS and work equip- be defective; visually check it.
ment)
Defective HSS and The HSS and work equipment pump is assumed to be defective; visually
2
work equipment pump check it.
Possible Defective operation
3 Work equipment control lever Unload pressure
causes and of unload valve
standard value 3.43 (+1.37/0) MPa
Full neutral
in normal state {35 (+14/0) kg/cm2}
or
4
defective operation of Work equipment control lever Main relief pressure
main relief valve Stroke end Min. 19.1 MPa {Min. 195 kg/cm2}
self pressure reducing
5
valve (PPC basic pres- Work equipment control lever Basic pressure of control circuit
sure) Full neutral 3.72 ± 0.49 MPa {38 ± 5 kg/cm2}
H-13 Blade lift speed is slow or lacks power 1

Symptom of
• Blade lift speed is slow or lacks power.
failure
General • Check for modifications to the blade.
information • If the hydraulic drift of blade lift is also excessive, carry out the troubleshooting of “H-17 Excessive
hydraulic drift of blade lift” first.

1 Blade control lever PPC valve output pressure
Possible PPC valve
causes and 3.72 ± 0.49 MPa
Lift stroke end
standard value {38 ± 5 kg/cm2}
in normal state Defective operation of
The operation of the blade lift control valve spool is assumed to be defec-
2 blade lift control valve
tive; visually check it.
(Spool)
Residual air in blade lift Residual air is assumed to remain in the blade lift cylinder; bleed air and
3
cylinder observe how the phenomenon changes.
D61EX, PX-15E0 13
H-14 Blade tilt speed is slow or lacks power 1

Symptom of
• Speed or power of tilting blade is low.
failure
• Confirm that oil quantity of hydraulic oil tank is normal before troubleshooting.
General • Confirm whether the blade is remodeled.
information • When hydraulic drift rate of blade tilt is also high, carry out troubleshooting “H-18 Excessive
hydraulic drift of blade tilt”.

a Prepare with starting switch OFF, then drive engine in high idling mode
Defective PPC valve for troubleshooting.
1
Possible function Blade lever PPC valve output pressure
causes and Tilt stroke end 3.72 ± 0.49 MPa {38 ± 5 kg/cm2}
standard value Defective function of
in normal state 2 blade tilt control valve Spool of blade tilt control valve may be malfunctioning. Check it directly.
(Spool)
Blade tilt cylinder is assumed to be aired; carry out air bleed and observe
3 Aired blade tilt cylinder
how the phenomenon changes.
H-15 Angling blade speed is slow or lacks power 1

Symptom of
• Speed or power of angling blade is low.
failure
information • When hydraulic drift rate of angling blade is also high, carry out troubleshooting “H-19 Excessive
hydraulic drift of blade angle”.

1
Possible function Blade lever PPC valve output pressure
causes and Angle stroke end 3.72 ± 0.49 MPa {38 ± 5 kg/cm2}
standard value Defective function of
in normal state Spool of blade angle control valve may be malfunctioning. Check it
2 blade angle control
directly.
valve (Spool)
Aired blade angle Blade angle cylinder is assumed to be aired; carry out air bleed and
3
cylinder observe how the phenomenon changes.
14 D61EX, PX-15E0
H-16 Ripper lift speed is slow or lacks power 1

Symptom of
• Speed or power of ripper lift is low.
failure
General • Confirm whether the ripper is remodeled.
information • When hydraulic drift rate of ripper lift is also high, carry out troubleshooting “H-20 Excessive
hydraulic drift of ripper lift”.

1
function Ripper control lever PPC valve output pressure
Lift stroke end 3.72 ± 0.49 MPa {38 ± 5 kg/cm2}
Possible Defective function of
causes and Spool function of ripper lift control valve is assumed to be defective;
2 ripper lift control valve
standard value directly check it.
(Spool)
in normal state Suction valve of ripper lift control valve is assumed to be defective;
Defective function of
directly check it.
3 ripper lift control valve
a Replace suction valve in the head with one at the bottom, and observe
(Suction valve)
Ripper lift cylinder is assumed to be aired; carry out air bleed and observe
4 Aired ripper lift cylinder
H-17 Excessive hydraulic drift of blade lift 1

Symptom of
• Hydraulic drift of lifting blade is large
failure
information • Confirm that no oil leaks circuits in work equipment before troubleshooting.

a Prepare with starting engine, then stop the engine for troubleshooting.
1. Raise the blade (about 800 mm).
Possible Defective seal of blade
2. Disconnect hose on cylinder head side and block it.
causes and 1 lift control valve
3. Measure hydraulic drift of blade tip.
standard value (Spool)
in normal state Blade lift Hydraulic drift
Block blade lift circuit 100 mm/15 min
Defective seal of blade
2 Seal of blade lift cylinder is assumed to be defective; directly check it.
lift cylinder
D61EX, PX-15E0 15
H-18 Excessive hydraulic drift of blade tilt 1

Symptom of
• Hydraulic drift of tilting blade is large
failure

a Prepare with starting engine, then carry out troubleshooting when
engine stops.
Possible Defective seal of blade 1. Fully extend blade tilt cylinder.
causes and 1 tilt control valve 2. Disconnect hose on cylinder head side and block it.
standard value (Spool) 3. Measure hydraulic drift of blade tip.
in normal state Blade tilt Hydraulic drift
Block blade tilt circuit 200 mm/15 min
2 Seal of blade tilt cylinder is assumed to be defective; directly check it.
tilt cylinder
H-19 Excessive hydraulic drift of blade angle 1

Symptom of
• Hydraulic drift of angling blade is large.
failure

1. Fully extend blade angle cylinder.
2. Lower the blade to the ground.
Possible Defective seal of blade 3. Disconnect hose on cylinder head side and block it.
1
causes and angle cylinder 4. Operate right or left angle cylinder and apply relief pressure to the bot-
standard value tom side of the disconnected cylinder.
in normal state 5. Cylinder internal leakage
Blade angle Cylinder internal leakage
Block blade angle circuit Max. 8 cc/min
Blade angle control valve seal and centralized safety valve are assumed
2 angle control valve
to be defective. Check them directly.
(Spool)
16 D61EX, PX-15E0
H-20 Excessive hydraulic drift of ripper lift 1

Symptom of
• Hydraulic drift of lifting ripper is large
failure
General • Confirm whether the ripper is remodeled.

a Prepare with starting engine, then stop the engine for troubleshooting.
Defective seal of ripper
Possible 1. Pull out shank pin and raise the ripper to the maximum.
lift control valve
causes and 1 2. Disconnect hose on cylinder head side and block it.
(Spool) or defective
standard value Ripper lift Hydraulic drift
suction safety valve
in normal state Block ripper lift circuit 50 mm/15 min
Defective seal of ripper
2 Seal of ripper lift cylinder is assumed to be defective; directly check it.
lift cylinder
D61EX, PX-15E0 17
SEN02567-00

© 2007 KOMATSU
All Rights Reserved
18
SEN02568-00
D61EX-15E0
D61PX-15E0

Troubleshooting of engine (S-mode)
Method of using troubleshooting charts ............................................................................................... 3
S-1 Starting performance is poor ......................................................................................................... 6
S-2 Engine does not start..................................................................................................................... 7
S-3 Engine does not pick up smoothly............................................................................................... 10
S-4 Engine stops during operations ....................................................................................................11
S-5 Engine does not rotate smoothly ................................................................................................. 12
S-6 Engine lacks output (or lacks power)........................................................................................... 13
S-7 Exhaust smoke is black (incomplete combustion)....................................................................... 14
S-8 Oil consumption is excessive (or exhaust smoke is blue) ........................................................... 15
S-9 Oil becomes contaminated quickly .............................................................................................. 16
S-10 Fuel consumption is excessive.................................................................................................. 17
S-11 Oil is in coolant (or coolant spurts back or coolant level goes down) ........................................ 18
S-12 Oil pressure drops ..................................................................................................................... 19
S-13 Oil level rises (Entry of coolant or fuel) ...................................................................................... 20
S-14 Coolant temperature becomes too high (overheating) .............................................................. 21
S-15 Abnormal noise is made ............................................................................................................ 22
D61EX, PX-15E0 1
S-16 Vibration is excessive ................................................................................................................ 23
2 D61EX, PX-15E0
Method of using troubleshooting charts 1

The troubleshooting chart consists of the “ques-
tions”, “check items”, “causes”, and “troubleshoot-
ing” blocks.
The questions and check items are used to pinpoint
high probability causes by simple inspection or
from phenomena without using troubleshooting
tools.
Next, troubleshooting tools or direct inspection are
applied to check the narrowed causes in order from
the most probable one to make final confirmation
according to the troubleshooting procedure.
[Questions]:
Items to be drawn from the user or operator.
They correspond to A and B in the chart on the
right.
The items in A are basic ones.
The items in B can be drawn from the user or
operator, depending on their level.
[Check items]:
Items to be simply checked by the serviceman
to narrow down causes.
They correspond to C in the chart on the right.
[Causes]:
Items to be narrowed from the questions and
check items.
The serviceman narrows down the probable
causes from A, B, and C.
[Troubleshooting]:
Items to finally verify whether the narrowed
down causes are undoubtedly the real causes
using the troubleshooting tools and direct
inspections.
Items listed in the [Questions] and [Check items]

and related to the [Causes] are marked with E, Q,
or w.
E: Causes to be referred to for questions and
check items
Q: Causes related to questions and check
items
w: Causes highly probable among ones
marked with Q
a When narrowing the “causes“, apply the items
marked with w before those marked with Q.
When narrowing the causes, do not apply the
items marked with E. (If no items have other
marks and the causes cannot be narrowed,
however, you may apply them.)
D61EX, PX-15E0 3
<Example of troubleshooting> Exhaust gas is black

Let us assume that a trouble of "Exhaust gas is black" occurred and we checked the [Question] and [Check
items] and found the following 3 items to be the causal symptoms; [Exhaust gas slowly became black],
[Power slowly became weaker], and [Dust indicator is lighting red].
4 D61EX, PX-15E0
There is a causal relationship between 3 items in the [Questions] and [Check items] sections and 5 items in
the [Causes] section.
The method of pinpointing the "cause" from the causal relationship and approaching the "troubleshooting" is
explained according to Step 1 – Step 3 shown below.
D61EX, PX-15E0 5
S-1 Starting performance is poor 1

General causes why starting performance is poor Causes
Leaking or clogged fuel piping, entry of air

Clogged air breather hole of fuel tank cap
Defective contact of valve and valve seat
Insufficient supply of fuel
Defective alternator (generator section)

q
Defective alternator (regulator section)

q Insufficient intake of air
Stuck, seized supply pump plunger
Defective intake air heater system

Improper selection of fuel
Defective or deteriorated battery

q
a The common rail fuel injection system (CRI) controls the
Clogged air cleaner element

fuel injection timing electrically. Accordingly, even if the
Worn piston ring, cylinder

starting operation is carried out, the engine may not start
until the crankshaft revolves 2 turns at maximum. This phe-
Clogged fuel filter
Defective injector
nomenon does not indicate a trouble, however.
Confirm recent repair history

Degree of use of machine Operated for long period E E E
Became worse gradually Q w w Q
Starting performance
Engine starts easily when warm w w
Questions
Non-specified fuel is being used Q Q Q

Replacement of filters has not been carried out according to Operation and
Maintenance Manual w w Q Q
Oil must be added more frequently w

When engine is preheated or when temperature is low, preheating monitor does not
w
indicate normally (if monitor is installed)
During operation, charge level monitor indicates abnormal charge (if monitor is installed) w w
Dust indicator is red (if indicator is installed) w
Air breather hole of fuel tank cap is clogged w
Fuel is leaking from fuel piping w Q
When priming pump is operated, it makes no reaction or it is heavy w Q
Starting motor cranks engine slowly w
If air bleeding plug of fuel filter is removed, fuel does not
While engine is cranked flow out w
with starting motor,
Much fuel returns from the injector w
Check items
When exhaust manifold is touched immediately after starting engine, temperature of

w
some cylinders is low
Engine does not pick up smoothly and combustion is irregular Q Q w
There is hunting from engine (rotation is irregular) Q w Q
Blow-by gas is excessive w
Inspect air cleaner directly q

When compression pressure is measured, it is found to be low q q
When air is bled from fuel system, air comes out q
Inspect fuel filter directly q
Troubleshooting
Carry out troubleshooting according to “No-pressure feed by supply pump (*1)” indicated q
by code
When a cylinder is cut out for reduced cylinder mode operation, engine speed does not
change q
When starting switch is turned to HEAT, intake air heater mount does not become warm q
Is voltage 20 – 30 V between alternator terminal B and terminal E with Yes q

engine at low idle? No q
When specific gravity of electrolyte and voltage of battery are measured, they are low q
Replace
Replace
Replace
Replace
Replace
Replace
Replace
Replace
Replace
Correct
Clean
Clean
Remedy
*1: Displayed failure codes [CA559] and [CA2249]
6 D61EX, PX-15E0
S-2 Engine does not start 1

a) Engine does not turn Causes
General causes why engine does not turn
Defective connection of battery terminal
Defective starting motor (motor section)

q Seized parts inside engine
o See “S-4 Engine stops during operations”
Defective or deteriorated battery
Defective steering circuit wiring

Broken flywheel ring gear
Defective starting switch

Defective battery relay
Defective safety relay

Questions
Degree of use of machine Operated for long period E E
Condition of horn when Horn does not sound Q Q w

starting switch is turned ON Horn volume is low w
Battery electrolyte is low w
Battery terminal is loose w
When starting switch is turned ON, there is no operating sound from battery relay Q w
When starting switch is turned to START, starting pinion does not move out Q Q w
Check items
Speed of rotation is low w

When starting switch is Makes grating noise w w
turned to START, starting
pinion moves out, but Soon disengages again w
Makes rattling noise and does not turn Q Q Q
Inspect flywheel ring gear directly q

Carry out troubleshooting

There is not voltage (20 – 30 V) between battery relay terminal B q
and terminal E
Troubleshooting
in E-mode
When terminal B and terminal C of starting switch are connected,
q
engine starts
Turn starting switch OFF,
connect cord, and carry out When terminal B and terminal C at safety relay outlet are q
connected, engine starts
troubleshooting at ON
Even if terminal B and terminal C at safety relay outlet are
connected, engine does not start q
When terminal at safety switch and terminal B at starting motor are

q
connected, engine starts
Replace
Replace
Replace
Replace
Replace
Replace
Correct
Remedy —
D61EX, PX-15E0 7
b) Engine turns but no exhaust smoke comes out Causes

General causes why engine turns but no exhaust smoke comes
Defective operation of pressure relief valve

out
Defective common rail pressure limiter

Fuel is not being supplied
Seized, abnormally worn feed pump

q

q Supply of fuel is extremely small
q Improper selection of fuel (particularly in winter)
Defective supply pump IMV

Broken supply pump shaft
Insufficient fuel in tank
Defective fuel injector

Use of improper fuel
Clogged fuel filter

Questions
Exhaust smoke suddenly stopped coming out (when starting again) w Q w w E

Fuel other than specified one is used w
Maintenance Manual w E Q
When fuel tank is inspected, it is found to be empty w

Air breather hole of fuel tank cap is clogged Q w
Rust and water are found when fuel tank is drained Q E E E
When fuel filter is removed, there is not fuel in it w w
Fuel is leaking from fuel piping w
Check items

While engine is cranked with flow out Q Q w Q
starting motor,
If spill hose from injector is disconnected, little fuel spills Q w w w Q

Troubleshooting
Inspect feed pump directly q

Carry out troubleshooting according to “No-pressure feed by supply pump (*1)”
indicated by code q q
Carry out troubleshooting according to “Abnormality in supply pump PCV (*2)” indicated
q
by code
Inspect pressure relief valve directly q
Fuel flows out when pressure limiter return piping is disconnected q
Replace
Replace
Replace
Replace
Replace
Replace
Replace
Replace
Replace
Correct
Clean
Add
Remedy

8 D61EX, PX-15E0
c) Exhaust smoke comes out but engine does not start Causes
(fuel is being injected)
Worn dynamic valve system (Valve, rocker lever, etc.)
Defective coolant temperature sensor, wiring harness

General causes why exhaust smoke comes out but engine does
not start
Leaking or clogged fuel system, entry of air

q Lack of rotating force due to defective electrical system

q Insufficient supply of fuel
Defective intake air heater system

Improper selection of fuel
Clogged injector, defective spray

q
Defective, deteriorated battery

Clogging of fuel filter

Use of improper fuel
Suddenly failed to start w w Q
Questions
Non-specified fuel is being used Q Q

w w
Maintenance Manual
When engine is preheated or when temperature is low, preheating monitor does not w
indicate normally (if monitor is installed)
Air breather hole of fuel tank cap is clogged Q
Rust and water are found when fuel tank is drained w
Starting motor cranks engine slowly w
When engine is cranked, abnormal sound is generated around cylinder head w
Check items

While engine is cranked with flow out Q w
starting motor,
If spill hose from injector is disconnected, little fuel spills w

Inspect dynamic valve system directly q
When compression pressure is measured, it is found to be low q
Troubleshooting

Carry out troubleshooting according to “No-pressure feed by supply pump (*1)” indicated q
by code
Coolant temperature gauge does not indicate normally (if coolant temperature gauge is
installed) q
When starting switch is turned to HEAT, intake air heater mount does not become warm q
Replace
Replace
Replace
Replace
Replace
Replace
Replace
Replace
Replace
Replace
Clean
Clean
Remedy
D61EX, PX-15E0 9
S-3 Engine does not pick up smoothly 1

General causes why engine does not pick up smoothly Causes
Seized turbocharger, interference of turbocharger

q Defective condition of fuel injection

q Improper selection of fuel
q Controller is controlling in derate mode

(limiting injection rate (output) because of an error in electrical system)
Clogged injector, defective spray


Improper valve clearance

Degree of use of machine Operated for long period E E E E
Questions
Engine pick-up suddenly became worse w Q Q Q

Non-specified fuel is being used w w w
Replacement of filters has not been carried out according to Operation and Maintenance
w w
Manual
When exhaust manifold is touched immediately after starting engine, temperature of some Q w
cylinders is low
Blue under light load w
Color of exhaust gas is
w Q w w
Check items
Black
When engine is cranked, interference sound is generated around turbocharger w
High idle speed under no load is normal, but speed suddenly drops when load is applied Q w
There is hunting from engine (rotation is irregular) Q Q Q

Inspect valve clearance directly q
Troubleshooting
When turbocharger is rotated by hand, it is found to be heavy q

Inspect fuel filter, strainer directly q
Carry out troubleshooting according to “No-pressure feed by supply pump (*1)” indicated by
q
code
When a cylinder is cut out for reduced cylinder mode operation, engine speed does not change q
Replace
Replace
Replace
Replace
Replace
Correct
Correct
Adjust
Clean
Clean
Remedy
10 D61EX, PX-15E0
S-4 Engine stops during operations 1

General causes why engine stops during operations Causes
Internal parts of engine seized
Broken dynamic valve system (valve, rocker arm, etc.)

q
Broken auxiliary equipment (pump, compressor, etc.)

q There is overheating
Defective engine controller power supply wiring

q Malfunctions of hydraulic pump

Broken, seized piston, connecting rod

Broken, seized crankshaft bearing
Defective starting switch wiring

Clogging of fuel filter, strainer
Leaking, clogged fuel piping
Broken, seized feed pump

Broken supply pump shaft
Defective hydraulic pump

Broken, seized gear train
Degree of use of machine Operated for long period E
Abnormal noise was heard and engine
stopped suddenly w w w w Q w Q w w
Condition when engine w Q Q
Questions
Engine overheated and stopped

stopped
Engine stopped slowly w Q Q Q
There was hunting and engine stopped w Q Q Q Q Q
w
Maintenance Manual
Fuel level monitor indicates low level w
Metal particles are found when oil pan is drained w w w Q
Check items
Does not turn at all w w

When engine is cranked by Turns in opposite direction w
hand Moves by amount of gear backlash w w
Supply pump shaft does not turn w
Engine turns, but stops when load is applied to machine w

Carry out troubleshooting in H-mode
Inspect piston, connecting rod directly q

Inspect crankshaft bearing directly q
Inspect gear train directly q
Troubleshooting

Inspect feed pump directly q
Carry out troubleshooting according to “No-pressure feed by supply pump
(*1)” indicated by code q q
Engine rotates when pump auxiliary equipment (pump, compressor, etc.) is
q
removed
Check controller power supply wiring q
Check starting switch wiring q
Replace
Replace
Replace
Replace
Replace
Replace
Replace
Replace
Correct
Correct
Correct
Clean
Clean
Add
Remedy
—
D61EX, PX-15E0 11
S-5 Engine does not rotate smoothly 1

General causes why engine does not rotate smoothly Causes
q Air in fuel system
Clogged injector, defective spray (dirt in injector)

q Defective speed sensor (Error at degree that it is not indicated)
Defective Ne speed sensor, wiring harness

Defective G speed sensor, wiring harness


Occurs at a certain speed range Q Q
Questions
Occurs at low idle Q Q Q Q Q

Hunting
Occurs even when speed is raised Q Q Q
Occurs on slopes w
Replacement of filters has not been carried out according to Operation and Maintenance Manual w
Check items
Rust and water are found when fuel tank is drained Q


Troubleshooting

Carry out troubleshooting according to “Abnormality in Ne speed sensor (*1)” indicated by code q
Carry out troubleshooting according to “Abnormality in Bkup speed sensor (*2)” indicated by code q
Replace
Replace
Replace
Replace
Replace
Clean
Add
Remedy
*1: Displayed failure code [CA689]

*2: Displayed failure code [CA778]
12 D61EX, PX-15E0
S-6 Engine lacks output (or lacks power) 1

General causes why engine lacks output Causes
Clogged injector, defective spray (dirt in injector)
Defective boost pressure sensor, wiring harness

Insufficient supply of fuel
Defective installation of boost pressure sensor

q
Defective drive of injector (signal, solenoid)



Air leakage from air intake piping

o See “S-14 Coolant temperature becomes too
Leaking, clogged fuel piping

high (Overheating)“

Clogged fuel spill piping


(limiting injection rate (output) because of an
error in electrical system)
(air leakage)
Suddenly Q w Q Q Q Q
Questions
Power was lost

Gradually Q Q Q Q Q Q
w w
Maintenance Manual
Oil must be added more frequently Q Q
Dust indicator is red (if indicator is installed) w Q
Output becomes insufficient after short stop of operation Q
Black Q w w
some cylinders is low w w
w
Check items
When engine is cranked, interference sound is generated around turbocharger

High idle speed is too high Q
High idle speed under no load is normal, but speed suddenly drops when load is applied Q w Q Q
Engine does not pick up smoothly and combustion is irregular w w Q Q w
There is hunting from engine (rotation is irregular) Q Q Q Q Q
Blow-by gas is excessive w w

Inspect air intake piping directly q
When boost pressure is measured, it is found to be low q q q
Troubleshooting
Inspect fuel piping q

Inspect spill port check valve directly q
Carry out troubleshooting according to “No-pressure feed by supply pump (*1)” q
indicated by code
When a cylinder is cut out for reduced cylinder mode operation, engine speed does
q q
not change
Inspect boost pressure sensor mount directly q
Carry out troubleshooting according to “Abnormality in boost pressure sensor (*2)”
q
indicated by code
Replace
Replace
Replace
Replace
Replace
Replace
Replace
Replace
Replace
Correct
Correct
Correct
Adjust
Clean
Clean
Remedy

D61EX, PX-15E0 13
S-7 Exhaust smoke is black (incomplete combustion) 1

General causes why exhaust smoke is black Causes
Insufficient intake of air
Leakage of air between turbocharger and cylinder head

q



o See “S-14 Coolant temperature becomes too high
(Overheating)“

Improper fuel injection pressure

(limiting injection rate (output) because of an error in

Crushed, clogged muffler

electrical system)
Abnormally worn injector

Improper injection timing
Clogged, seized injector
Suddenly became black w w Q Q Q
Color of exhaust gas is Gradually became black w Q Q
Questions

Non-specified fuel is being used Q Q
Suddenly w Q Q Q
Power was lost
Gradually Q Q Q Q
Muffler is crushed w
Air leaks between turbocharger and cylinder head, clamp is loosened w
Engine is operated in low-temperature mode at normal temperature Q Q Q
When exhaust manifold is touched immediately after starting engine, temperature of some
cylinders is low Q w

Check items

Torque converter stall speed or pump relief speed is high (Fuel is injected excessively) Q
Exhaust noise is abnormal Q w Q
Engine does not pick up smoothly and combustion is irregular Q Q Q Q Q w
Much fuel returns from the injector w

When turbocharger is rotated by hand, it is fount to be heavy q
Troubleshooting

When muffler is removed, exhaust sound improves q
Carry out troubleshooting according to “No-pressure feed by supply pump (*1)” indicated by
q q
code
Carry out troubleshooting according to “Abnormality in coolant temperature sensor (*2)”
q
indicated by code
Confirm with INSITE or with monitoring function on applicable machine side q q
Replace
Replace
Replace
Replace
Replace
Replace
Replace
Replace
Replace
Correct
Correct
Adjust
Clean
Remedy

14 D61EX, PX-15E0
S-8 Oil consumption is excessive (or exhaust smoke is blue) 1

General causes why oil consumption is excessive Causes
q Abnormal consumption of oil
Turbocharger
Oil leakage from oil pan, cylinder head, etc.

Worn, damaged valve (stem, guide, seal)
q Long-time operation of engine at low idle or high idle
(Do not run engine at idle for more than 20 minutes
Dust sucked in from intake system

continuously)
Clogged breather, breather hose

q External leakage of oil
Oil leakage from oil drain plug

Worn, damaged rear oil seal
q Wear of pats in lubrication system
Oil leakage from oil cooler
Oil leakage from oil piping

Worn seal at turbine end
Worn seal at blower end
Oil leakage from oil filter

Broken piston ring
Broken oil cooler

Questions
Oil consumption suddenly increased w Q

Oil must be added more frequently w Q
Oil becomes contaminated quickly Q Q w
Outside of engine is dirty with oil w w w w w
There are loose piping clamps in intake system w
Inside of turbocharger intake outlet pipe is dirty with oil w
Inside of turbocharger exhaust outlet pipe is dirty with oil Q w
Check items
There is oil in coolant w

Oil level in clutch chamber or damper chamber is high w
Exhaust smoke is blue under light load w w
Excessive Q Q w w
Amount of blow-by gas
None w
When intake manifold is removed, dust is found inside q

When intake manifold is removed, inside is found to be dirty abnormally q
Troubleshooting
Excessive play of turbocharger shaft q q

Check breather and breather hose directly q
Inspect rear oil seal directly q
Pressure-tightness test of oil cooler shows there is leakage q q
There is external leakage of oil from engine q q q q
Replace
Replace
Replace
Replace
Replace
Replace
Replace
Correct
Correct
Correct
Correct
Correct
Correct
Clean
Remedy
D61EX, PX-15E0 15
S-9 Oil becomes contaminated quickly 1

General causes why oil becomes contaminated quickly Causes
q Entry of exhaust gas into oil due to internal wear
Clogged turbocharger lubrication drain tube

Defective seal at turbocharger turbine end
q Clogging of lubrication passage
q Use of improper fuel
q Use of improper oil
Clogged breather, breather hose

q Operation under excessive load
Defective oil filter safety valve

Worn valve, valve guide
Exhaust smoke is bad

Clogged oil cooler
Clogged oil filter
Questions

Non-specified oil is being used Q Q
Metal particles are found when oil filter is drained Q Q w
Inside of exhaust pipe is dirty with oil w
Engine oil temperature rises quickly w
Check items

Black w
Excessive Q Q w Q
Amount of blow-by gas
None w
Excessive play of turbocharger shaft q

Troubleshooting
Check breather and breather hose directly q
See S-7
Inspect oil cooler directly q
Inspect oil filter directly q
Spring of oil filter safety valve is hitched or broken q
Inspect turbocharger lubrication drain tube directly q
Replace
Replace
Replace
Replace
Replace
Clean
Clean
Clean
Remedy —
16 D61EX, PX-15E0
S-10 Fuel consumption is excessive 1

General causes why fuel consumption is excessive Causes
q Leakage of fuel

q Defective condition of fuel injection (fuel pressure, injection timing)
q Excessive injection of fuel
Fuel leakage from fuel filter, piping, etc.
Defective common rail fuel pressure

Defective fuel supply pump oil seal
Fuel leakage inside head cover
Defective supply pump plunger
Defective operation of injector

Defective spray by injector
Improper injection timing

Questions
More than for other machines of same model Q Q Q Q

Condition of fuel Gradually increased Q Q
consumption
Suddenly increased Q Q
There is external leakage of fuel from engine w
Combustion is irregular w
Engine oil level rises and oil smells of diesel fuel w w
When exhaust manifold is touched immediately after starting engine, temperature of some
w
cylinders is low
Check items
Low idle speed is high Q

Torque converter stall speed or pump relief speed is high Q
Black Q Q Q Q
White Q
Remove head cover and inspect directly q

Inspect fuel supply pump oil seal directly q
Troubleshooting
Carry out troubleshooting according to “No-pressure feed by supply pump (*1)” indicated by code q
Much fuel returns from the injector q
Carry out troubleshooting according to “Abnormality in coolant temperature sensor (*2)” indicated
by code q
Confirm with INSITE or with monitoring function on applicable machine side q q

Replace
Replace
Replace
Replace
Replace
Replace
Correct
Correct
Correct
Remedy

D61EX, PX-15E0 17
S-11 Oil is in coolant (or coolant spurts back or coolant level goes
down) 1
General causes why oil is in coolant Causes
q Internal leakage in lubrication system
Broken cylinder head, head gasket

q Internal leakage in cooling system
Broken oil cooler core, O-ring

Cracks inside cylinder block
Holes caused by pitting
Questions
Suddenly rose Q Q
Oil level
Gradually rose Q Q
Hard water is being used as coolant Q Q
Oil level has risen and oil is milky Q Q w
There are excessive air bubbles in radiator, coolant spurts back w
Check items
Pressure-tightness test of cylinder head shows there is leakage q

shooting
Trouble-
Inspect cylinder block directly q q

Pressure-tightness test of oil cooler shows there is leakage q
Replace
Replace
Replace
Replace
Remedy
18 D61EX, PX-15E0
S-12 Oil pressure drops 1

General causes why oil pressure drops Causes
q Leakage, clogging, wear or lubrication system
Leaking, crushed, clogged hydraulic piping

Defective oil level sensor, wiring harness
q Defective oil pressure control
q Improper selection of fuel (improper viscosity)
q Deterioration of oil due to overheating
Clogged, broken pipe in oil pan

Clogged strainer in oil pan
Defective regulator valve

Worn journal of bearing
Lack of oil in oil pan
Defective oil pump

Coolant, fuel in oil
Clogged oil filter

Questions
Oil pressure monitor indicates low oil pressure (if monitor is installed) Q w
Replacement of filters has not been carried out according to Operation and Maintenance w
Manual
Indicates pressure drop at low idle w
Oil pressure monitor Indicates pressure drop at low, high idle Q w w w Q

(if installed) Indicates pressure drop on slopes w
Sometimes indicates pressure drop w Q
Oil level monitor indicates oil level drop (if monitor is installed) w w
Oil level in oil pan is low w
External hydraulic piping is leaking, crushed w
Check items
Oil is milky or smells of diesel oil w

Metal particles are found when oil pan is drained w
Metal particles are found when oil filter is drained w Q
Metal particles are found in oil filter q

Troubleshooting
Inspect oil pan strainer, pipe directly q q

See S-13
Oil pump rotation is heavy, there is play in oil pump q

Valve and spring of regulator valve are fatigued, damaged q
Inspect oil filter directly q
If oil level sensor is replaced, oil level monitor indicates normally q
Replace
Replace
Replace
Replace
Correct
Adjust
Clean
Clean
Add
Remedy —
D61EX, PX-15E0 19
S-13 Oil level rises (Entry of coolant or fuel) 1

General causes why oil level rises Causes
q Coolant in oil (milky)
Defective seal of auxiliary equipment (pump, compressor)

q Fuel in oil (smells diluted diesel fuel)
a If oil is in coolant, carry out troubleshooting for “S-11 Oil is in coolant”
Broken oil cooler core, O-ring

Worn, damaged rear oil seal
Defects in supply pump

Broken injector, O-ring
Questions

Fuel must be added more frequently w w
Coolant must be added more frequently Q Q
There is oil in coolant Q Q Q Q w
Oil smells of diesel fuel w w
Oil is milky Q Q
When engine is started, drops of water come from muffler Q
When radiator cap is removed and engine is run at low idle, an abnormal number of bubbles appears,
w Q
Check items
or coolant spurts back

Exhaust smoke is white Q
Oil level in clutch chamber or damper chamber is low w
Oil level in hydraulic tank of machine is low w

Remove injector and inspect O-ring. q
Troubleshooting

Inspect rear oil seal directly q
Pressure-tightness test of oil cooler shows there is leakage q
Remove and inspect supply pump directly q
Inspect seal of auxiliary equipment directly q
Replace
Replace
Replace
Replace
Replace
Replace
Replace
Correct
Remedy
20 D61EX, PX-15E0
S-14 Coolant temperature becomes too high (overheating) 1

General causes why coolant temperature becomes too high Causes
q Lack of cooling air (deformation, damage of fan)
Defective radiator cap (pressure valve)
Defective coolant temperature gauge

q Drop in heat dissipation efficiency
Defective operation of thermostat

Problem in coolant circulation system
Slipping fan belt, worn fan pulley
Rise of hydraulic oil temperature

q
Clogged, crushed radiator fins

Clogged, broken oil cooler
Broken fan pulley bearing

Clogged radiator core

Lack of coolant
Questions
Sudden overheated Q w Q
Condition overheating
Always tends to overheat Q Q w w Q
Coolant temperature gauge Rises quickly Q Q w

(if installed) Does not go down from red range w
Radiator coolant level monitor indicates drop of coolant level (if monitor is installed) Q w
Engine oil level has risen, oil is milky w w Q
Fan belt tension is low w
When fan pulley is turned, it has play w
Milky oil is floating on coolant Q Q w
There are excessive air bubbles in radiator, coolant spurts back w
When light bulb is held behind radiator core, no light passes through w
Check items
Radiator shroud, inside of underguard on applicable machine side are clogged with
w w
dirt or mud
Coolant is leaking because of cracks in hose or loose clamps w
Coolant flows out from radiator overflow hose w
Fan belt whines under sudden acceleration w
Power train oil temperature enters red range faster than engine coolant
temperature (if oil temperature gauge and coolant temperature gauge are w
installed)
When compression pressure is measured, it is found to be low q Carry out troubleshooting in H-mode
Inspect oil cooler directly q
Temperature difference between upper and lower tanks of radiator is large q
Troubleshooting
When operation of thermostat is carried out, it does not open at cracking q

temperature
Temperature difference between upper and lower tanks of radiator is slight q
Inspect radiator core directly q
When operation of radiator cap is carried out, its cracking pressure is low q
Inspect fan belt, pulley directly q
When coolant temperature is measured, it is found to be normal q
Replace
Replace
Replace
Replace
Replace
Replace
Replace
Replace
Correct
Correct
Correct
Add
Remedy —
D61EX, PX-15E0 21
S-15 Abnormal noise is made 1

General causes why abnormal noise is made Causes
q Abnormality due to defective parts
Deformed cooling fan, loose fan belt, interference of fan belt

Abnormal combustion
Defective inside of muffler (dividing board out of position)

q
Leakage of air between turbocharger and cylinder head

q Air sucked in from intake system
Improper fuel injection timing (abnormality in coolant

a Judge if the noise is an internal noise or an external
Broken dynamic valve system (valve, rocker lever)

Interference of turbocharger, seized turbocharger
temperature sensor, boost temperature sensor)

noise before starting troubleshooting.
a The engine is operated in the low-temperature mode
while it is not warmed up sufficiently. Accordingly, the
Excessive wear of piston ring, cylinder

engine sound becomes a little larger. This does not indi-
cate abnormality, however.
a When the engine is accelerated, it is operated in the
Improper gear train backlash

acceleration mode and its sound becomes a little larger
Removed, seized bushing

Clogged, seized injector

for up to about 3 seconds. This does not indicate abnor-
Dirt caught in injector

mality, however.

Questions
Gradually occurred Q Q
Condition of abnormal noise
Suddenly occurred Q Q Q
Non-specified fuel is being used Q
Metal particles are found when oil filter is drained w w
Air leaks between turbocharger and cylinder head w
When engine is cranked, abnormal sound is generated around cylinder head w w
When engine is cranked, beat noise is generated around muffler w
Check items
some cylinders is low w Q

Black Q w Q
Engine does not pick up smoothly and combustion is irregular w
Abnormal noise is loud when engine is accelerated Q Q Q Q
When turbocharger is rotated by hand, it is found to be heavy q

When muffler is removed, abnormal noise disappears q
Troubleshooting

Inspect gear train directly q q
Inspect fan and fan belt directly q
When a cylinder is cut out for reduced cylinder mode operation, engine speed does
q q
not change
Abnormal noise is heard only when engine is started q
Confirm with INSITE or with monitoring function on applicable machine side q
Replace
Replace
Replace
Replace
Replace
Replace
Replace
Replace
Replace
Replace
Correct
Adjust
Remedy
22 D61EX, PX-15E0
S-16 Vibration is excessive 1

General causes why vibration is excessive Causes
q Defective parts (abnormal wear, breakage)
Improper fuel injection timing (abnormality in coolant temperature
Broken output shaft, parts in damper on applicable machine side

q Misalignment between engine and chassis
q Abnormal combustion
a If abnormal noise is made and vibration is excessive, carry out trouble-
shooting for “S-15 Abnormal noise is made“, too.
Stuck dynamic valve system (valve, rocker lever)
Loose engine mounting bolts, broken cushions

Worn main bearing, connecting rod bearing
sensor, boost temperature sensor)

Improper gear train backlash
Worn camshaft bushing
Questions
Suddenly increased Q Q
Condition of vibration
Gradually increased Q Q Q
Metal particles are found when oil filter is drained w w
Metal particles are found when oil pan is drained w w
Oil pressure is low at low idle Q Q
Check items
Vibration occurs at mid-range speed Q Q

Vibration follows engine speed Q Q Q
Exhaust smoke is black w Q

Inspect main bearing and connecting rod bearing directly q
Troubleshooting
Inspect gear train directly q

Inspect camshaft bushing directly q
Confirm with INSITE or with monitoring function on applicable machine side q
Inspect engine mounting bolts and cushions directly q
When alignment is checked, radial runout or facial runout is detected
Inspect output shaft or inside of damper directly q
Replace
Replace
Replace
Replace
Replace
Replace
Replace
Remedy
D61EX, PX-15E0 23
SEN02568-00

© 2007 KOMATSU
All Rights Reserved
24
SEN02569-00
D61EX-15E0
D61PX-15E0

50 Disassembly and assembly1

General information on disassembly and
assembly
How to read this manual ................................................................................................................................. 2
Coating materials list....................................................................................................................................... 4
Special tool list ................................................................................................................................................ 7
Sketches of special tools .............................................................................................................................. 12
D61EX, PX-15E0 1
SEN02569-00 50 Disassembly and assembly
How to read this manual 1 Removal

q The [Removal] section contains procedures
and precautions for implementing the work,
1. Removal and installation of assemblies
know how and the amount of oil or coolant to
be drained.
Special tools
q Various symbols used in the Removal Section
q Special tools which are deemed neces-
are explained and listed below.
k : This mark indicates safety-related pre-
sary for removal or installation of parts are
described as A1,•••X1 etc. and their part
cautions that must be followed when
names, part numbers and quantities are
implementing the work.
described in the special tool list.
a : Know-how or precautions for work
q Also the following information is described
[*1] : This mark shows that there are instructions
in the special tool list.
or precautions for installing parts.
6 : This mark shows the amount of oil or coolant
1) Necessity
t : Special tools that cannot be substi-
to be drained.
4 : Weight of part or component
tuted and should always be used
(installed).
q : Special tools that will be useful if avail-
able and are substitutable with com-
mercially available tools. Installation
2) Distinction of new and existing special q Except where otherwise instructed, installation
tools of parts is done in the reverse order of
N: Tools newly developed for this removal.
model. They respectively have a q Instructions and precautions for installing parts
new part number. are shown with [*1] mark in the Installation
R: Tools with upgraded part numbers. Section, identifying which step the instructions
They are remodeled from already are intended for.
available tools for other models. q Marks shown in the Installation Section stand
Blank: Tools already available for other for the following.
models. They can be used without k : Precautions related to safety in execu-
any modification. tion of work.

3) Circle mark Q in sketch column: a : This mark gives guidance or precautions
The sketch of the special tool is pre- when doing the procedure.
2 : Type of coating material
q
sented in the section of “Sketches of
3 : Tightening torque
special tools”.
q Part No. of special tools starting with 5 : Quantity of oil or coolant to be added
* *** ****
79 T- - :
means that they can not be supplied Sketches of special tools
from Komatsu in Japan (i.e. locally q Various special tools are illustrated for the con-
made parts). venience of local manufacture.
a General tools that are necessary for

removal or installation are described as
[1],[2]•••etc. and their part names, part
numbers and quantities are not described.
2 D61EX, PX-15E0
50 Disassembly and assembly SEN02569-00
2. Disassembly and assembly of assemblies Disassembly

q In Disassembly section, the work procedures,
Special tools precautions and know-how for carrying out
q Special tools which are deemed neces- those procedures, and quantity of the oil and
sary for disassembly and assembly of coolant drained are described.
parts are described as A1,•••X1 etc. and q The meanings of the symbols used in Disas-
their part names, part numbers and quan- sembly section are as follows.
tities are described in the special tool list. k : This mark indicates safety-related pre-
q Also the following information is described cautions that must be followed when
in the special tool list. implementing the work.
1) Necessity a : Know-how or precautions for work
t : Special tools that cannot be substi- 6 : Quantity of oil or coolant drained
tuted and should always be used
(installed).
q : Special tools that will be useful if avail-
able and are substitutable with com- Assembly
mercially available tools. q In Assembly section, the work procedures, pre-
2) Distinction of new and existing special cautions and know-how for carrying out those
tools procedures, and quantity of the oil and coolant
N : Tools newly developed for this added are described.
model. They respectively have a q The meanings of the symbols used in Assem-
new part number. bly section are as follows.
R : Tools with upgraded part numbers. k : Precautions related to safety in execu-
They are remodeled from already tion of work.
available tools for other models. a : This mark gives guidance or precautions
Blank : Tools already available for other when doing the procedure.
models. They can be used without 2 : Type of coating material
4
any modification.
: Tightening torque
3) Circle mark Q in sketch column:
5 : Quantity of oil or coolant to be added
q The sketch of the special tool is pre-
sented in the section of “Sketches of
special tools”. Sketches of special tools
q Part No. of special tools starting with q Various special tools are illustrated for the con-
venience of local manufacture.
* *** ****
79 T- - :
means that they can not be supplied
from Komatsu in Japan (i.e. locally
made parts).
a General tools that are necessary for

disassembly and assembly are
described as [1],[2]•••etc. and their
part names, part numbers and quanti-
ties are not described.
D61EX, PX-15E0 3
Coating materials list 1

a The recommended coating materials such as adhesives, gasket sealants, and greases used for disas-
sembly and assembly are listed below.
a For coating materials not listed below, use the equivalent of products shown in this manual.
Cate- Komatsu
Part number Q'ty Container Main features and applications
gory code
• Used to prevent rubber gaskets, rubber cush-
LT-1A 790-129-9030 150 g Tube
ions, and cork plugs from coming out.
• Used for plastic (except polyethylene,
polypropylene, tetrafluoroethylene and vinyl
20 g Polyethylene
LT-1B 790-129-9050 chloride), rubber, metal, and non-metal parts
(2 pcs.) container
which require immediate and strong adhe-
sion.
Polyethylene • Features: Resistance to heat and chemicals.
LT-2 09940-00030 50 g
container • Used to fix and seal bolts and plugs.
790-129-9060
Adhesive: 1 kg • Used to stick and seal metal, glass, and plas-
LT-3 (Set of adhesive Can
Hardener: 500 g tics.
and hardener)
Adhesive
Polyethylene
LT-4 790-129-9040 250 g • Used to seal plugs.
container
Holtz MH 705 790-129-9120 75 g Tube • Heat-resistant seal used to repair engines.
• Quick-setting adhesive.
ThreeBond Polyethylene • Setting time: Within 5 sec. to 3 min.
790-129-9140 50 g
1735 container • Used mainly to stick metals, rubbers, plastics,
and woods.
• Quick-setting adhesive.
• Quick-setting type.
Aron-alpha Polyethylene
790-129-9130 2g (max. strength is obtained after 30 minutes)
201 container
• Used mainly to stick rubbers, plastics, and
metals.
• Features: Resistance to heat and chemicals.
Loctite Polyethylene
79A-129-9110 50 cc • Used for fitted portions used at high tempera-
648-50 container
tures.
• Used to stick or seal gaskets and packings of
LG-1 790-129-9010 200 g Tube
power train case, etc.
• Used to seal various threaded portions, pipe
Polyethylene joints, and flanges.
LG-5 790-129-9080 1 kg
container • Used to seal tapered plugs, elbows, and nip-
ples of hydraulic piping.
• Features: Silicon-based heat and cold-resis-
tant sealant.
Gasket sealant
LG-6 790-129-9020 200 g Tube • Used to seal flange surfaces and threaded
portions.
• Used to seal oil pan, final drive case, etc.
• Features: Silicon-based quick-setting sealant.
LG-7 790-129-9070 1 kg Tube • Used to seal flywheel housing, intake mani-
fold, oil pan, thermostat housing, etc.
ThreeBond
790-129-9090 100 g Tube • Gasket sealant used to repair engine.
1211
• Features: Silicon-based, heat and cold-resis-
ThreeBond tant, vibration-resistant, impact-resistant seal-
419-15-18131 100 g Tube
1207B ant.
• Used to seal transfer case, etc.
4 D61EX, PX-15E0
Cate-
Komatsu code Part number Q'ty Container Main features and applications
gory
• Used to lubricate sliding portions.
disulfide lubricant
LM-G 09940-00051 60 g Can

Molybdenum
(to prevent squeaking)

• Used to prevent scuffing and seizure of press-
fitted portions, shrink-fitted portions, and
LM-P 09940-00040 200 g Tube
threaded portions.
• Used to lubricate linkages, bearings, etc.
SYG2-400LI
G2-LI SYG2-350LI
G0-LI (*) SYG2-400LI-A
SYG2-160LI Various Various • General purpose type.
*: For cold SYGA-160CNLI
district SYG0-400LI-A (*)
SYG0-16CNLI (*)
SYG2-400CA
SYG2-350CA • Used for bearings used at normal temperature
G2-CA SYG2-400CA-A Various Various
SYG2-160CA under light load in contact with water or steam.
SYGA-160CNCA
• Used for parts under heavy load.
Caution:
Grease
Molybdenum SYG2-400M 400 g x 10 Bellows-type • Do not apply grease to ball bearings like swing
disulfide grease SYG2-400M-A 400 g x 20 container circle bearings, etc.
LM-G (G2-M) SYGA-16CNM 16 kg Can
• The grease should be applied to work equip-
ment pins at their assembly only, not applied for
greasing afterwards.
Hyper White • Seizure resistance and heat resistance higher
SYG2-400T-A
Grease G2-T, 400 g Bellows-type than molybdenum disulfide grease.
SYG2-16CNT
G0-T (*) container
SYG0-400T-A (*) • Not conspicuous on machine since color is
*: For cold 16 kg Can
SYG0-16CNT (*) white.
district
Biogrease SYG2-400B
G2-B, G2-BT (*) SYGA-16CNB 400 g Bellows-type • Since this grease is decomposed by natural
*: For use at
high tempera- SYG2-400BT (*) container bacteria in short period, it has less effects on
ture and under SYGA-16CNBT 16 kg Can microorganisms, animals, and plants.
(*)
high load
SUNSTAR • Used as primer for cab side.
Glass con-
PAINT PRIMER 20 ml (Using limit: 4 months after date of manu-
tainer
580 SUPER facture)
417-926-3910
SUNSTAR • Used as primer for glass side.
GLASS Glass con-
20 ml (Using limit: 4 months after date of manu-
PRIMER 580 tainer
SUPER facture)
Adhesive for cab glass
• Used as primer for painted surface on cab

SUNSTAR side.
Glass con-
PAINT PRIMER 22M-54-27230 20 ml
Primer
tainer (Using limit: 4 months after date of manu-

435-95
facture)
• Used as primer for black ceramic-coated
SUNSTAR surface on glass side and for hard polycar-
GLASS 22M-54-27240 150 ml Can bonate-coated surface.
PRIMER
435-41 (Using limit: 4 months after date of manu-
facture)
SUNSTAR • Used as primer for sash (Almite).
Glass con-
SASH PRIMER 22M-54-27250 20 ml (Using limit: 4 months after date of manu-
tainer
GP-402 facture)
D61EX, PX-15E0 5
Cate- Komatsu code Part number Q'ty Container Main features and applications
gory
SUNSTAR • “S” is used for high-temperature season

PENGUINE Polyethyl- and “W” for low-temperature season as
SEAL 580 417-926-3910 320 ml ene con- adhesive for glass.
SUPER “S” or tainer (Using limit: 4 months after date of manu-
“W” facture)
Adhesive
Polyethyl- • Used as adhesive for glass.

Sika Japan, 20Y-54-39850 310 ml ene con- (Using limit: 6 months after date of manu-
Sikaflex 256HV tainer
Adhesive for cab glass

facture)
SUNSTAR Ecocart • Used as adhesive for glass.
PENGUINE 22M-54-27210 320 ml (Special (Using limit: 6 months after date of manu-
SUPER 560 container) facture)
SUNSTAR Polyethyl- • Used to seal joints of glass parts.
PENGUINE 417-926-3920 320 ml ene con- (Using limit: 4 months after date of manu-
SEAL No. 2505 tainer facture)
Caulking material
SEKISUI Polyethyl- • Used to seal front window.

SILICONE 20Y-54-55130 333 ml ene con- (Using limit: 6 months after date of manu-
SEALANT tainer facture)
• Used to seal joint of glasses.
GE TOSHIBA Translucent white seal.
SILICONES 22M-54-27220 333 ml Cartridge
TOSSEAL 381 (Using limit: 12 months after date of manu-
facture)
6 D61EX, PX-15E0
Special tool list 1
a Tool part number 79QT-QQQ-QQQQ cannot be supplied (they are items to be locally manufactured).
a Necessity: t ........... Cannot be substituted, must always be installed (used)
q ........... Extremely useful if available or can be substituted with commercially available
part
a New/Remodel: N ........... Tools with new part numbers, newly developed for this model
R:........... Tools with upgraded part numbers, remodeled from items already available for
other models
Blank: ... Tools already available for other models, can be used without any modification
a Tools marked Q in the Sketch column are tools introduced in the sketches of the special tools (See
Sketches of special tools)
New/Remodel
Necessity
Sketch
Q'ty
Component Symbol Part No. Part name Nature of work, remarks
Installation of engine front

Engine front seal 1 795-799-6400 Seal puller t 1 N
seal
Installation of engine rear
Engine rear seal 2 795-799-6500 Seal puller t 1 N
seal
3 795-799-6700 Puller t 1 N Removal of fuel injector
Cylinder head assembly, Positioning with 3rd and 4th
A 4 795-799-1131 Gear t 1
fuel injector assembly cylinder top
5 795-799-8150 Remover q 1 N Removal of inlet connector
Wrench
Cylinder head assem- 6 790-331-1120 q 1 Angle tightening of bolt
(Angle)
bly, engine front seal
assembly Judgment of cylinder head
7 795-790-4510 Gauge q 1 N
bolt length
Disassembly and
assembly of TORQ- Operation check of clutch
D 1 799-301-1600 Oil leak tester t 1
FLOW transmission piston
assembly
Removal and installation of
1 709-302-1500 Wrench kit q 1
bevel pinion nut
Disassembly and 2 796-730-2140 Wrench q 1
assembly of HSS E Commercially Adjustment of preload on
assembly available bevel gear shaft and bevel
3 Torque wrench q 1 gear assembly
products or
795-630-1810
796-730-2300 Wrench t 1 Measurement of rotation
1
795-630-1803 Torque wrench t 1 torque of No. 1 pinion
Disassembly and
2 791T-427-1330 Guide t 1 Q Positioning of No. 1 gear
assembly of final drive J
assembly 3 791-545-1510 Installer t 1 Installation of floating seal
Press fitting of bearing into
4 791T-427-1280 Push tool t 1 Q
output shaft
D61EX, PX-15E0 7
New/Remodel
Necessity
Sketch
Q'ty
Disassembly and 1 791-515-1520 Installer t 1 Press fitting of floating seal

assembly of idler
assembly 2 791-601-1000 Oil pump q 1 Oil charging
Disassembly and
assembly of track roller L 3 791-515-1520 Installer t 1
assembly
Press fitting of floating seal
Disassembly and
assembly of carrier 4 796-230-1110 Installer t 1
roller assembly
791-685-8006 Compressor (B) t 1
791-635-3160 Extension t 1
Disassembly and
790-201-2770 Spacer t 1 Disassembly and assembly
assembly of recoil M
791-101-1102 Pump t 1 of recoil spring
spring assembly
Cylinder
790-101-1600 t 1
(686 kN{70 tons})
791-450-1100 Remover t 1
Puller Removal of equalizer center
tion of equalizer bar N 790-101-2102 t 1
(294 kN{30 tons}) pin
assembly
790-101-1102 Pump t 1
791T-450-1130 Push tool t 1 Q
791T-450-1140 Plate t 1 Q
791-181-1010 Adapter t 1
791-520-4140 Screw t 1
791-201-2750 Spacer t 1 Press fitting of pivot shaft
tion of pivot shaft P
790-101-2540 Washer t 1 ring
assembly
791-112-1180 Nut t 1
790-101-2102 Puller t 1
Pump
790-101-1102 t 1
(294 kN{30 tons})
1 791-646-7531 Remover t 1 Removal of pin plug
Cleaning of lubricated track
2 791-660-7460 Pin brush t 1
Whole disassembly and pin
whole assembly of track 3 791-432-1110 Push tool for plug t 1 Driving of pin plug (large)
shoe assembly 4 791-932-1110 Push tool for plug t 1 Driving of pin plug (small)
Check of track link for air-
R 5 790-701-3000 Seal checker t 1
tightness and oil filling
790-101-1102 Pump t 1
6 Cylinder Removal of pin
Field disassembly and 790-101-1300 t 1
(980 kN{100 tons})
assembly of one link
790-101-1102 Pump t 1
7 Disconnection of links
790-105-2300 Jack (294 kN{30 tons}) t 1
8 D61EX, PX-15E0
New/Remodel
Necessity
Sketch
Q'ty
791-635-3110 Frame t 1
791-635-3160 Extension t 1
791-635-3170 Nut t 4
8 791-635-3180 Screw t 2 Removal of pin
791-635-3190 Screw t 1
791-645-3510 Adapter t 1
791-646-3260 Pusher t 1
9 791-630-3560 Pusher t 1 Installation of bushing
10 791-432-1110 Push tool t 1 Driving of pin plug (large)
11 791T-630-3570 Guide t 1 Q Installation of link
791-635-3110 Frame t 1
791-635-3160 Extension t 1
791-635-3170 Nut t 4
791-635-3180 Screw t 2
12 Installation of pin
791-635-3190 Screw t 1
791-645-3510 Adapter t 1
791-645-3520 Adapter t 1
791-645-3530 Pusher t 1
Field disassembly and
R 791-635-3110 Frame t 1
assembly of one link
791-635-3160 Extension t 1
791-635-3170 Nut t 4
791-635-3180 Screw t 2
13 Installation of bushing
791-635-3190 Screw t 1
791-645-3520 Adapter t 1
791T-630-3570 Guide t 1 Q
791-630-3560 Pusher t 1
790-101-1102 Pump t 1
14 Installation of link
790-105-2300 Jack t 1
15 791-646-3270 Guide t 1 Installation of pin
791-635-3110 Frame t 1
791-635-3160 Extension t 1
791-635-3170 Nut t 4
16 Installation of pin
791-635-3180 Screw t 2
791-635-3190 Screw t 1
791-645-3510 Adapter t 1
17 791-646-8002 Lubricator t 1 Lubrication
18 791-932-1110 Push tool for plug t 1 Driving of pin plug (small)
D61EX, PX-15E0 9
New/Remodel
Necessity
Sketch
Q'ty
790-502-1003 Repair stand t 1 Disassembly, assembly of

1
790-101-1102 Hydraulic pump t 1 hydraulic cylinder
Wrench assembly Removal
Lift cylinder
790-330-1100 • Angle and lift 1 and
Angle cylinder
2 (ST, PAT) t installation
of round
790-102-3802 • Tilt (PAT) 1 Tilt cylinder head
Socket
790-302-1280 • Width across flats 1
(55 mm)
• Width across flats
790-302-1290 1 Removal and installation of
3 (60 mm) t
piston nut
790-302-1340 1
(80 mm)
790-302-1320 1
(70 mm)
1 790-720-1000 Expander q 1 Expansion of piston ring
796-720-1660 Ring q 1 Lift (ST, PAT)
07281-01159 Clamp q 1 and angle
Disassembly and
assembly of hydraulic U 4 769-720-1670 Ring q 1 Installation
cylinder assembly 2 Tilt (PAT) of piston
07281-01279 Clamp q 1 ring
796-720-1680 Ring q 1 Tilt (ST) and
07281-01589 Clamp q 1 ripper
790-201-1702 Push tool kit t 1 Common to the
790-101-5021 • Grip 1 following cylin-
01010-50816 • Bolt 1 ders.
Press fitting
5 790-201-1771 • Push tool 1 Lift (ST, PAT) of roll bush
Tilt (ST, PAT)
790-201-1811 • Push tool 1
and ripper
790-201-1791 • Push tool 1 Angle
790-201-1500 Push tool kit t 1 Common to the
790-101-5021 • Grip 1 following cylin-
01010-50816 • Bolt 1 ders
Press fitting
6 790-201-1580 • Plate 1 Lift (ST, PAT) of dust seal
Tilt (ST, PAT)
790-201-1620 • Plate 1
and ripper
790-201-1610 • Plate 1 Angle
tion of operator's cab Installation of windshield
X1 793-498-1210 Lifter (Suction cup) t 2
glass glass
(Stuck glass)
10 D61EX, PX-15E0
New/Remodel
Necessity
Sketch
Q'ty
Removal and installa- 799-703-1200 Service tool kit t 1

tion of air conditioner 799-703-1100 Vacuum pump (100 V) t 1
unit assembly
Removal and installa- 799-703-1111 Vacuum pump (220 V) t 1
Charging air conditioner with
tion of floor frame X2 799-703-1121 Vacuum pump (240 V) t 1 refrigerant
assembly
tion of dashboard 799-703-1401 Gas leak tester t 1
assembly
D61EX, PX-15E0 11
Sketches of special tools 1

Note: Komatsu cannot accept any responsibility for special tools manufactured according to these sketches.
J2 Guide
J4 Push tool
12 D61EX, PX-15E0
P Push tool
P Plate
D61EX, PX-15E0 13
R11 and R13 Guides
14 D61EX, PX-15E0
D61EX, PX-15E0 15
SEN02569-00

© 2007 KOMATSU
All Rights Reserved
16
SEN02570-00
D61EX-15E0
D61PX-15E0


Engine and cooling system (SAA6D107E-1)
Removal and installation of radiator guard assembly ..................................................................................... 2
Removal and installation of engine assembly ................................................................................................. 6
Removal and installation of radiator assembly ..............................................................................................11
Removal and installation of aftercooler assembly......................................................................................... 14
Removal and installation of power train oil cooler assembly ........................................................................ 17
Removal and installation of hydraulic cooler assembly ................................................................................ 18
Removal and installation of cooling fan drive assembly ............................................................................... 21
Removal and installation of cooling fan motor assembly .............................................................................. 23
Removal and installation of damper assembly ............................................................................................. 24
Removal and installation of fuel tank assembly ............................................................................................ 29
Removal and installation of engine hood assembly ...................................................................................... 31
D61EX, PX-15E0 1
Removal and installation of 5. Disconnect reservoir tank hoses (1) and (2).
radiator guard assembly 1
6. Remove reservoir tank (3).
Removal
k Disconnect the cable from the negative (–) 7. Remove aftercooler upper hose (4) and
terminal of the battery. bracket (5). [*1]
k Lower the work equipment to the ground
and stop the engine. Then, loosen the
hydraulic oil filler cap slowly to release the
internal pressure of the hydraulic tank.
k Operate the work equipment control lever 2
– 3 times to release the residual pressure in
the work equipment circuit.
k If the coolant temperature is high, you may
scald yourself with the hot coolant. Wait
until the coolant is cooled, and then drain
the coolant.
1. Loosen the radiator cap to drain the coolant.

6 Radiator: Approx. 44 l
8. Disconnect radiator upper hose (6) from the
radiator. [*2]
2. Drain the hydraulic oil.
6 Hydraulic tank: Approx. 55 l

details, see "Removal and installation of
engine hood assembly".
4. Remove right and left engine side covers (1a).
9. Disconnect connector (8) of air conditioner

compressor (7).
10. Remove 2 clamps (9).
11. Remove 4 bracket mounting bolts (10). Loosen

adjustment bolt (11) and remove belt (12). [*3]
12. Remove 4 condenser mounting bolts (13), 2

each on the right and left side, and remove
hose clamp (14).
13. Remove air conditioner compressor and

bracket assembly (7) and condenser (15).
a Since the compressor and condenser are
connected by the hoses, fix them together
to the machine.
2 D61EX, PX-15E0
15. Disconnect aftercooler lower hose (17) from

the intake manifold. [*4]
16. Disconnect radiator lower hose (18) from the

radiator. [*5]
17. Remove 6 mounting bolts (19) and open radia-

tor mask (20) to the right.
18. Lift off radiator mask (20).

4 Radiator mask: 50 kg
14. Remove undercover (16) from the radiator bot-

tom.
19. Remove right upper cover (21).
20. Remove fan guard (22).
D61EX, PX-15E0 3
21. Pull lock bar (23) out of bracket (24) and 25. Remove 2 wiring harness clamps (30) on the
remove the bracket. right side of the engine.
22. Remove covers (25) and (26). 26. Disconnect connector (31).
23. Disconnect hose TC (27) and discharge pres- 27. Using sling (M16, P = 2 mm), sling the radiator
sure hose (28). guard assembly.
a Plug the disconnected hoses to prevent oil
from flowing out. 28. Remove 4 mounting bolts (32), 2 each on the
right and left sides, at the rear of the radiator
guard. [*6]
24. Remove 2 hose clamps (29) from the radiator

bottom.
29. Remove 4 mounting bolts (33) on the front side
of the radiator guard. [*7]
4 D61EX, PX-15E0
30. Lift off radiator guard assembly (34). q Refilling with coolant
4
Add coolant through the coolant filler to the
Radiator guard assembly: 430 kg
specified level. Run the engine to circulate the
coolant through the system. Then, check the
coolant level again.
5 Total amount of coolant: Approx. 44 l
q Refilling with oil (Hydraulic tank)

Add oil through the oil filler to the specified
level. Run the engine to circulate the oil
through the system. Then, check the oil level
again.
(For the oil specification, see "Table of
fuel, coolant and lubricants")
Installation q Bleeding air (Fan pump and work equip-

q Carry out installation in the reverse order to ment cylinder circuit)
removal. a Bleed air from the circuit. For details, see
Testing and adjusting, "Bleeding air from
[*1] fan pump".
2 Aftercooler upper hose insertion area: a Bleed air from the circuit. For details, see
Gasket sealant (LG-6 or LG-7) Testing and adjusting, "Bleeding air from
3 Aftercooler upper hose clamp: work equipment cylinder".
10.5 ± 0.5 Nm {1.07 ± 0.05 kgm}
[*2]
2 Radiator upper hose insertion area:
Gasket sealant (LG-6 or LG-7)
3 Radiator upper hose clamp:
8.8 ± 0.5 Nm {0.9 ± 0.05 kgm}
[*3]
Adjust the air conditioner compressor belt tension.
For details, see "Adjusting air conditioner compres-
sor belt tension".
[*4]
2 Aftercooler lower hose insertion area:
3 Aftercooler lower hose clamp:
10.5 ± 0.5 Nm {1.07 ± 0.05 kgm}
[*5]
2 Radiator lower hose insertion area:
3 Radiator lower hose clamp:
8.8 ± 0.5 Nm {0.9 ± 0.05 kgm}
[*6]
3 Mounting bolt at rear of radiator guard:
455 – 565 Nm {46.5 – 58 kgm}
[*7]
3 Mounting bolt at front of radiator guard:
455 – 565 Nm {46.5 – 58 kgm}
D61EX, PX-15E0 5
Removal and installation of 7. Remove right and left power train side covers
engine assembly 1 (2).
Removal
k Disconnect the cable from the negative (–)
terminal of the battery.
the coolant. 8. Disconnect washer tank wiring harness con-
nector (3) and 4 hoses (4) on the right side of
1. Loosen the radiator cap to drain the coolant. the engine.
9. Remove 2 washer tanks (5).

3. Close the fuel stop valve at the fuel tank bot-

tom.

5. Remove the radiator guard assembly. For

details, see "Removal and installation of radia-
tor guard assembly". 10. Remove 3 clamps (6).
6. Remove right and left engine side covers (1). 11. Disconnect wiring harness connectors (7), (8)
and (9).
12. Disconnect starting motor wiring harness ter-

minal (10). [*1]
6 D61EX, PX-15E0
13. Disconnect the 2 clamps and remove muffler 19. Wiring on left side of engine
water drain pipe (11). 1) Disconnect wiring harness terminal (16) of
the electrical intake air heater sensor. [*3]
14. Sling the muffler assembly.
15. Remove 4 mounting nuts (12).
2) Remove wiring harness clamp (17).
16. Lift off muffler assembly (13).

4 Muffler assembly: 30 kg
17. Remove air conditioner duct (14).
3) Disconnect wiring harness connector (18).

4) Remove wiring harness clamp (19).
18. Disconnect ground wiring harness terminal

(15) on the right side of the engine. [*2]
D61EX, PX-15E0 7
20. Fuel prefilter 21. Remove 2 air conditioner receiver drier mount-
1) Disconnect hose clamp (20) between the ing bolts (24) and receiver drier (25).
fuel prefilter and fuel supply pump. a Fix the receiver drier to the machine.
2) Remove joint bolt (20a) of fuel return
hose.
22. Remove 2 heater hose clamps (26).
3) Disconnect hose (21). 23. Disconnect heater hoses (27) and (28).
a Plug the disconnected hose to pre-
vent oil from flowing out. 24. Remove 2 corrosion resistor bracket mounting
4) Remove 2 fuel prefilter mounting bolts bolts (29).
(22) and fuel prefilter bracket assembly a Fix the corrosion resistor bracket assem-
(23). bly to the engine.
a Fix the fuel prefilter bracket assembly
to the machine.
8 D61EX, PX-15E0
25. Disconnect power train oil cooler coolant outlet 29. Remove the undercover from the power train
hose (31). [*4] bottom.
26. Disconnect heater hose (32). 30. Remove universal joint assembly (35) down.
[*7]
27. Remove front engine mounting bolts (33) on

the right and left sides. [*5] 31. Lift off engine assembly (36).
4 Engine assembly: 700 kg
a Check that all the wirings and pipings are
disconnected.
28. Remove rear engine mounting bolts (34) on

the right and left sides. [*6]
D61EX, PX-15E0 9
Installation q Refilling with coolant

q Carry out installation in the reverse order to Add coolant through the coolant filler to the
removal. specified level. Run the engine to circulate the
[*1] coolant level again.
3
5
Starting motor wiring harness terminal
Total amount of coolant: Approx. 44 l
mounting nut:
17.7 – 24.5 Nm {1.8 – 2.5 kgm}
[*2] Add oil through the oil filler to the specified
3 Engine ground wiring harness terminal level. Run the engine to circulate the oil
mounting nut: through the system. Then, check the oil level
59 – 74 Nm {6 – 7.5 kgm} again.
[*3]
3 Electrical intake air heater wiring harness
terminal mounting bolt:
2.45 – 2.94 Nm {0.25 – 0.3 kgm}
q Bleeding air (Fan pump and work equip-
[*4] ment cylinder circuit)
2 Power train oil cooler coolant outlet hose a Bleed air from the circuit. For details, see
insertion area: Testing and adjusting, "Bleeding air from
Gasket sealant (LG-6 or LG-7) fan pump".
3 Power train oil cooler coolant outlet hose a Bleed air from the circuit. For details, see
clamp: 8.8 ± 0.5 Nm {0.9 ± 0.05 kgm} Testing and adjusting, "Bleeding air from
work equipment cylinder".
[*5] [*6]
3 Engine mounting bolt:
455 – 565 Nm {46.5 – 58 kgm}
[*7]
2 Universal joint mounting bolt:
Adhesive (LT-2)
98.1 – 122.6 m {10 – 12.5 kgm}
10 D61EX, PX-15E0
Removal and installation of 7. Disconnect radiator upper hose (6) from the
radiator assembly 1 radiator. [*2]
Removal
the coolant.


details, see "Removal and installation of 8. Disconnect connector (8) of air conditioner
engine hood assembly". compressor (7).
3. Remove right and left engine side covers (1a) 9. Remove 2 clamps (9).


hose clamp (14).

to the machine.
4. Disconnect reservoir tank hoses (1) and (2).
6. Remove aftercooler upper hose (4) and

bracket (5). [*1]
D61EX, PX-15E0 11
15. Disconnect radiator lower hose (20) from the

radiator. [*4]
13. Remove 4 mounting bolts (16) and bracket

(17).
a Remove hydraulic oil cooler (18) from 16. Disconnect wiring harness connector (21) from
bracket (17) and bind it with strings. the bracket and fix it to the radiator guard.
17. Remove 4 bracket mounting bolts (22) and 4

bracket mounting bolts (23) to remove 2 brack-
ets (24). [*5]
14. Remove undercover (19) from the radiator bot-

tom.
18. Remove 2 bypass pipe clamps (25).
12 D61EX, PX-15E0
19. Using slings (M10, P = 1.5 mm), lift off radiator [*6]
assembly (26). [*6]. Check that the projections at (A) on the radiator
4
bottom are set in the holes securely.
Radiator assembly: 25 kg
q Refilling with coolant

Installation specified level. Run the engine to circulate the
q Carry out installation in the reverse order to coolant through the system. Then, check the
removal. coolant level again.
[*1]
2 Aftercooler upper hose insertion area:
3 Aftercooler upper hose clamp:
10.5 ± 0.5 Nm {1.07 ± 0.05 kgm}
[*2]
8.8 ± 0.5 Nm {0.9 ± 0.05 kgm}
[*3]
sor belt tension".
[*4]
2 Radiator lower hose insertion area:
3 Radiator lower hose clamp:
8.8 ± 0.5 Nm {0.9 ± 0.05 kgm}
[*5]
3 Radiator bracket mounting bolt (22):
98 – 123 Nm {10 – 12.5 kgm}
3 Bracket mounting bolt (23):
29.4 – 44.1 Nm {3.0 – 4.5 kgm}
D61EX, PX-15E0 13
Removal and installation of 7. Disconnect radiator upper hose (6) from the
aftercooler assembly 1 radiator. [*2]
Removal
the coolant.


details, see "Removal and installation of 8. Disconnect connector (8) of air conditioner
engine hood assembly". compressor (7).
3. Remove right and left engine side covers (1a) 9. Remove 2 clamps (9).


hose clamp (14).

to the machine.
4. Disconnect reservoir tank hoses (1) and (2).
6. Remove aftercooler upper hose (4) and

bracket (5). [*1]
14 D61EX, PX-15E0
15. Disconnect aftercooler lower hose (20) from

the intake manifold. [*4]

(17).
a Remove hydraulic oil cooler (18) from 16. Remove 2 bracket mounting bolts (21). [*5]
bracket (17) and bind it with strings.
17. Install slings to the bracket and lift off after-

14. Remove undercover (19) from the radiator bot- cooler assembly (22). [*6]
4
tom.
Aftercooler assembly: 25 kg
D61EX, PX-15E0 15
Installation q Refilling with coolant

q Carry out installation in the reverse order to Add coolant through the coolant filler to the
removal. specified level. Run the engine to circulate the
[*1] coolant level again.
2
6
Aftercooler upper hose insertion area:
Total amount of coolant: Approx. 44 l
10.5 ± 0.5 Nm {1.07 ± 0.05 kgm}
[*2]
8.8 ± 0.5 Nm {0.9 ± 0.05 kgm}
[*3]
sor belt tension".
[*4]
10.5 ± 0.5 Nm {1.07 ± 0.05 kgm}
[*5]
3 Aftercooler bracket mounting bolt:
98 – 123 Nm {10 – 12.5 kgm}
[*6]
Check that the projections at (A) on the aftercooler
bottom are set in the holes securely.
16 D61EX, PX-15E0
Removal and installation of power 9. Remove power train oil cooler assembly (6).
train oil cooler assembly 1
Removal
the coolant. Installation
q Carry out installation in the reverse order to
1. Loosen the radiator cap to drain the coolant. removal.
6 Radiator: Approx. 44 l [*1]
2 Power train oil cooler coolant outlet hose
2. Drain the hydraulic oil. insertion area:
6
3
Hydraulic tank: Approx. 55 l Power train oil cooler coolant outlet hose
clamp: 8.8 ± 0.5 Nm {0.9 ± 0.05 kgm}
details, see "Removal and installation of q Refilling with coolant
engine hood assembly". Add coolant through the coolant filler to the
4. Remove the radiator guard assembly. For coolant through the system. Then, check the
details, see "Removal and installation of radia- coolant level again.
5
tor guard assembly". Total amount of coolant: Approx. 44 l
5. Disconnect hoses (1) and (2).
again.

ment cylinder circuit)
a Bleed air from the circuit. For details, see
6. Disconnect heater hose (3). fan pump".
7. Disconnect power train oil cooler coolant outlet Testing and adjusting, "Bleeding air from
hose (4). [*1] work equipment cylinder".
8. Remove 4 mounting bolts (5).
D61EX, PX-15E0 17
hydraulic cooler assembly 1
Removal
k Disconnect the cable from the negative (–) 7. Remove aftercooler upper hose (4) and
terminal of the battery. bracket (5). [*1]
the coolant.

8. Disconnect radiator upper hose (6) from the
radiator. [*2]

18 D61EX, PX-15E0
9. Disconnect connector (8) of air conditioner 14. Remove 4 mounting bolts (16) and bracket
compressor (7). (17).


hose clamp (14).

to the machine. 15. Disconnect inlet hose (18) and outlet hose
(19).
from flowing out.
16. Remove 3 mounting bolts (20).
17. Remove hydraulic oil cooler (21) from bracket

(17).
D61EX, PX-15E0 19
Installation
removal.
[*1]
10.5 ± 0.5 Nm {1.07 ± 0.05 kgm}
[*2]
8.8 ± 0.5 Nm {0.9 ± 0.05 kgm}
[*3]
sor belt tension".


again.

fan pump".
20 D61EX, PX-15E0
Removal and installation of 6. Pull lock bar (5) out of bracket (6) and remove
cooling fan drive assembly 1 bracket (6).
Removal 7. Remove covers (7) and (8).


2. Remove 6 mounting bolts (1) and open radia- 8. Disconnect wiring harness connector FAR (9).
tor mask (2).
3. Lift off radiator mask (2).

3 Radiator mask: 50 kg
9. Disconnect hose TC9 (10), discharge hose

(11) and drain hose (12).
from flowing out.
4. Remove right upper cover (3).
10. Remove piping TC (13), discharge piping (14)
5. Remove fan guard (4). and drain piping (15).
11. Remove cooling fan drive assembly (16).

4 Cooling fan drive assembly: 60 kg
D61EX, PX-15E0 21
Installation
removal.

again.

fan pump".
22 D61EX, PX-15E0
Removal and installation of 4. Using puller [1], disconnect fan (4) from the fan
cooling fan motor assembly 1 motor shaft.
Removal 5. Remove the nut and fan (4).

1. Remove the cooling fan drive assembly. For
details, see "Removal and installation of cool-
ing fan drive assembly".
2. Remove mounting bolt (1) and lock plate (2).

[*1]
6. Remove the 4 mounting bolts and cooling fan

motor assembly (5). [*3]
3. Loosen mounting nut (3). [*2]

a Do not remove the nut but keep it screwed
in by 2 – 3 turns.
Installation
removal.
[*1] [*2]
3 Mounting nut (3):
132 – 157 Nm {13.5 – 16 kgm}
1. Align the bolt holes on the front and back sides
of lock plate (2). Retighten mounting nut (3) by
the less amount of adjustment of both sides.
2. Tighten mounting bolt (1).

2 Mounting bolt: Adhesive (LT-2)
[*3]
q Wipe off dirt from the fitting parts of the fan
motor shaft and fan bushing and then
degrease them.
D61EX, PX-15E0 23
Removal and installation of 6. Remove the power train and lubricating oil
damper assembly 1 pump assembly (3). For details, see "Removal
and installation of power train and lubricating
Special tools oil pump assembly".
New/Remodel
Symbol
Necessity
Part No. Part name
Sketch
Q'ty
795-703-1200 Service tool kit t 1
Vacuum pump
795-703-1100 (100 V) t 1
Vacuum pump
X2 795-703-1111 (220 V) t 1
Vacuum pump
795-703-1121 (240 V) t 1
795-703-1401 Gas leak detector t 1

7. Remove the undercover from the power train
Removal unit bottom.
and release the residual pressure in the 8. Lift off universal joint assembly (4).
piping, referring to Testing and adjusting,
"Releasing residual pressure in work
equipment cylinder".
k Collect the air conditioner refrigerant (R134a).
k If refrigerant (R134a) gets in your eyes, you
may lose your sight. Accordingly, you must
be qualified for handling the refrigerant and
put on protective goggles while you are
collecting the refrigerant or charging the air
conditioner with refrigerant.
1. Remove the ROPS guard assembly. For

details, see "Removal and installation of ROPS 9. Remove drain plug (5) and drain the damper
guard assembly". oil.
2. Remove the operator's cab assembly. For 6 Damper case: Approx. 1.1 l
details, see "Removal and installation of opera-
tor's cab assembly".

4. Remove the floor frame assembly. For details,

see "Removal and installation of floor frame
assembly".
5. Remove clamp (1) and hose elbow (2).

a These part must be removed, since the
power train and lubricating oil pump
assembly (3) interferes with them when it
is removed.
24 D61EX, PX-15E0
10. Remove coupling (6). 14. Remove 8 mounting bolts (9).
11. Remove 12 cover mounting bolts (7). 15. Remove damper assembly (10).
12. Using guide bolt [1] and forcing screw [2], dis- 16. Remove bearing (11) from the flywheel.
connect damper cover assembly (8) from the
housing.
17. Disassemble the damper cover assembly

13. Lift off damper cover assembly (8). 1) Remove snap ring (13) from damper cover
4
assembly (12).
Damper cover assembly: 30 kg
2) Reverse the damper cover assembly and
set it on the block. Using plastic hammer
[3], drive out shaft assembly (14).
D61EX, PX-15E0 25
3) Remove oil seal (15) from the damper Installation

cover assembly. 1. Assemble the damper cover assembly accord-
4) Remove snap rings (17) and (18) from ing to the following procedure.
shaft assembly (16). 1) Install snap ring (18) to shaft (16).
5) Using push tool [4] and a press, remove 2) Using push tool [4] and a press, press fit
bearing (19) from shaft assembly (16). bearing (19).
3) Install snap ring (17) to shaft (16).

a Check that the snap ring is fitted
securely to the groove of the shaft.
4) Set damper cover (12) on the block and
drive in shaft assembly (14) with plastic
hammer [3].
5) Install snap ring (13) to damper cover

assembly (12).
a Check that the snap ring is fitted
securely to the groove of the shaft.
6) Reverse the damper cover assembly and
install oil seal (15).
2 Press fitting face of oil seal:
Gasket sealant (LG-5)
a Apply gasket sealant thinly to the
inside face of the mounting hole and
then press fit the oil seal.
26 D61EX, PX-15E0
a Take care that gasket sealant will not 4. Install the damper cover assembly according
stick to the oil seal lip. to the following procedure.
2 Oil seal lip: Grease (G2-LI) 1) Using guide bolt [1], install damper cover
assembly (8) to the housing.
4 Damper cover assembly: 30 kg
2 Damper cover mounting face:
2. Install bearing (11) to the flywheel.

2 Inside wall, outside wall and inside of
bearing: Grease (G2-LI)
2) Install damper cover mounting bolts (7)

and (7a).
2 Only threaded part of damper cover
mounting bolt (7a):
3 11 damper cover mounting bolts (7)
and 1 (7a):
98.1 – 122.6 Nm {10 – 12.5 kgm}
3) Install coupling (6).
4) Install drain plug (20).
5) Add oil to the damper case.
6) After adding oil, install level plug (21) and
oil filler plug (22).
3. Install damper assembly (10). 3 Plugs (20), (21) and (22):
3 Damper mounting bolt (9): 58.8 – 78.5 Nm {6 – 8 kgm}

57 – 73 Nm {6 – 7.5 kgm} 5 Damper case: Approx. 1.1 l
D61EX, PX-15E0 27
5. Sling and install universal joint (4).

Adhesive (LT-2)
98.1 – 122.6 Nm {10 – 12.5 kgm}
q Carry out the following installation in the

reverse order to removal.
q Charging air conditioner with refrigerant

Using tool X2, charge the air conditioner circuit
with refrigerant (R134a). (Filling quantity:
1,000 ± 50 g)
q Refilling with coolant (Supplying coolant

only by shortage)
28 D61EX, PX-15E0
Removal and installation of fuel 6. Open battery cover (6).

tank assembly 1
7. Disconnect wiring harness connector FFC (7),
Removal ground GND03 (8) and clamp (9).
terminal of the battery. 8. Put wiring harness (10) back.
1. Drain the fuel from the fuel tank.

6 Fuel tank: Approx. 390 l
2. Remove the cap and mounting bolts to remove

cover (1) from the fuel tank bottom.
3. Remove caps (2).

a The cap must be removed to remove the
mounting bolts on the back side.
9. Remove cover (11) at the rear of the operator's

seat.
4. Remove fuel outlet hose (3) and fuel drain

valve (4).
5. Disconnect wiring harness connector (5).
10. Disconnect fuel spill hose (12).
D61EX, PX-15E0 29
11. Disconnect 2 wiring harness connectors (13) 15. Remove 4 mounting bolts (16), 2 each on the
on the fuel tank top. right and left sides, at the rear of the fuel tank.
[*2]
16. Lift off fuel tank assembly (17).

4 Fuel tank assembly:
190 kg (When empty)
12. Remove cover (14).
13. Remove 2 mounting bolts (15), 1 each on the

right and left sides, at the front of the fuel tank.
[*1]
Installation
removal.
[*1] [*2]
3 Fuel tank mounting bolts (front and rear
sides): 455 – 565 Nm {46.5 – 58 kgm}
14. Sling the fuel tank.
30 D61EX, PX-15E0
Removal and installation of 5. Disconnect air hose (5) on the right side of the
engine hood assembly 1 engine from the turbocharger.
Removal
1. Remove the rubber caps and remove 2 mount-
ing bolts (1) on the front side.
6. Lift off engine hood assembly (6).

4 Engine hood assembly: 130 kg
2. Open up engine right and left wing covers (2)

and lock them.
Installation
3. Remove 4 mounting bolts (3), 2 each on the removal.
right and left sides, on the rear side.
4. Disconnect air conditioner duct (4) on the left

side of the engine.
D61EX, PX-15E0 31
SEN02570-00

© 2007 KOMATSU
All Rights Reserved
32
SEN02571-00
D61EX-15E0
D61PX-15E0


Engine (SAA6D170E-1)
Removal and installation of fuel supply pump assembly ................................................................................ 2
Removal and installation of fuel injector assembly ......................................................................................... 4
Removal and installation of cylinder head assembly .................................................................................... 13
Removal and installation of engine front seal ............................................................................................... 26
Removal and installation of engine rear seal ................................................................................................ 29
D61EX, PX-15E0 1
Removal and installation of fuel 9. Remove bellows (10) and disconnect fuel high-
supply pump assembly 1 pressure pipe (11). [*3]
a If mud is sticking, lock (L) may become
Removal hard. Clean the connections.
k Disconnect the cable from the negative (–) a Press lock (L) from both sides and discon-
terminal of the battery. nect hose (5).
a Plug the disconnected hose to prevent oil
1. Close the fuel stop valve on the fuel tank bot- from flowing out.
tom.
2. Open up engine left wing cover (1) and lock it.
3. Remove engine left side cover (2).
10. Remove 3 nuts (A) and fuel supply pump

assembly (12). [*4]
4. Remove fuel filter and bracket assembly (3).

a Fix the fuel filter and bracket assembly to
the machine.
a Remove fuel supply pump assembly (12)

together with the gear. The gear does not
have a positioning mark (missing tooth).
5. Disconnect fuel filter hoses (5) and (6) from

fuel supply pump (4). [*1]
6. Disconnect wiring harness connector CP3 (7).
7. Disconnect fuel return hose (8). [*1]
8. Disconnect fuel supply hose (9). [*2]
2 D61EX, PX-15E0
Installation q Bleeding air

q Carry out installation in the reverse order to Bleed air from the fuel system. For details, see
removal. Testing and adjusting, "Bleeding air from fuel
a See the removal procedure. system".
[*1]
a The internal parts of the hose adapter may be
damaged when the hose is removed. Accord-
ingly, do not reuse the hose but use new one
for reassembly, as a rule.
[*2]
3 Joint bolt: 19.6 – 29.4 Nm {2.0 – 3.0 kgm}
[*3]
q Procedure for installing fuel high-pressure pipe
(11)
1. Finger-tighten the sleeve nut.
2. Check that the fuel high-pressure pipe is not

installed forcibly and then tighten the sleeve
nut to the following torque.
3 Sleeve nut:
35 ± 3.5 Nm {3.57 ± 0.36 kgm}
3. Install bellows (10).

a Install the bellows with the slits down.
a The bellows is installed so that fuel will not
spout over the hot parts of the engine and
catch fire when it leaks for some reason.
[*4]
a Do not apply too much grease to O-ring (13). It
will ooze out. (Apply grease to only O-ring area
(B).)
a When replacing fuel supply pump mounting
stud bolts (14), apply LOCTITE to new stud
bolts (14).
Install fuel supply pump (12).
3 Fuel supply pump mounting nut:
24 ± 4 Nm {2.45 ± 0.41 kgm}
D61EX, PX-15E0 3
Removal and installation of fuel 4. Disconnect reservoir tank hoses (1) and (2).
injector assembly 1
Special tools
New/Remodel
Symbol
Necessity
Part No. Part name
Sketch
Q'ty
3 795-799-6700 Puller t 1 N
A 4 795-799-1131 Gear t 1
5 795-799-8150 Remover q 1 N
Removal
k If the coolant temperature is high, you may 6. Remove aftercooler upper hose (4) and
scald yourself with the hot coolant. Wait bracket (5). [*1]
the coolant. 7. Remove 2 air conditioner hose clamps (6).



compressor (7).
10. Loosen 4 bracket mounting bolts (10) and


hose clamp (14). See Testing and adjusting,
"Testing and adjusting valve clearance".

to the machine.
4 D61EX, PX-15E0
16. Lift off muffler assembly (18).

4 Muffler assembly: 28 kg
17. Remove clamps (19) and (20).
18. Disconnect connector (21).
19. Remove air conditioner compressor bracket

(22).
13. Disconnect the 2 clamps and remove muffler

water drain pipe (16).
20. Disconnect connector (23) and washer hose

(24).
21. Remove 2 washer tanks (25).
D61EX, PX-15E0 5
22. Remove exhaust pipe heat insulation plates 26. Remove 4 mounting bolts (32) and air intake
(26) and (27). elbow (33). [*3]
a Fix air intake elbow (33) to the machine.
23. Remove muffler bracket (28).

4
Muffler bracket: 25 kg
a While pressing the lock of the connector,
pull out the connector in the direction of
the arrow.
29. Disconnect 3 connectors (36). [*4]

a While pressing the lock of the connector
with flat-head screwdriver [1], pull out the
connector.
a Move wiring harness (37) toward the fuel
filter.
24. Remove the 2 mounting bolts and corrosion

resistor assembly (29).
a Fix corrosion resistor assembly (29) to the
machine.
25. Remove 2 clamps (30) and disconnect 2

heater hoses (31).
6 D61EX, PX-15E0
34. Remove 6 mounting bolts (42) and intake man-

ifold connector (43). [*7]
a Remove these parts so that the inlet con-
nector of the fuel injector can be removed
and installed easily.
30. Remove 6 bellows (38). [*5]
35. Remove 3 mounting bolts (44) so that turbo-

charger wastegate actuator bracket (45) can
move.
a This work must be done since the cylinder
head cover interferes with bracket (45)
when it is removed.
31. Remove 6 fuel high-pressure pipes (39). [*6]

a Loosen the sleeve nuts on the common
rail side.
32. Disconnect ambient pressure sensor connec-

tor (40).
33. Disconnect intake air pressure sensor connec-

tor (41).
D61EX, PX-15E0 7
36. Remove blow-by duct (46). [*8]
37. Remove 6 mounting nuts (47) and cylinder

head cover (48). [*9]
40. Remove the 12 mounting bolts and rocker

arms (51).
a Loosen locknuts (52) and loosen adjust-
38. Remove plug (49) on the starting motor top ment screws (53) 2 – 3 turns so that an
and set tool A4. excessive force will not be applied to the
push rod when the rocker arm is installed.
39. Rotate the crankshaft forward (counterclock-
wise when viewed from the flywheel side) and
set mark (M1) to mark (M2).
Mark (M1): Top of projection of front cover
Mark (M2): Wide slit on revolution sensor slit
disc at rear of crankshaft pulley
a Set the projection top of mark (M1) in the
range of wide slit (M2).
a Note that the target is not 1.6TOP but
3.4TOP. (This point is 76 – 88 degrees
before the top dead center.)
a See Testing and adjusting, "Adjusting
valve clearance".
a Use tool A4 to rotate the crankshaft.
8 D61EX, PX-15E0
41. Remove 12 crossheads (51a). 43. Remove wiring harness mounting nut (50) from
a Record the position of each cross head fuel injector (56).
and the shapes of holes (a) and (b). a Installed positions of wiring harnesses
(Install the cross head in the same direc-
Wiring harness color Cylinder No.
tion.)
White 1, 3, 5
Black 2, 4, 6
44. Remove 2 mounting bolts (57) of fuel injector

assembly (56).
45. Using tool A3, remove fuel injector assembly

(56).
a Take care that dirt or foreign matter will not
enter the mounting area of the fuel injector
assembly.
42. Remove retaining nut (54) and 6 inlet connec-

tors (55).
a Clean the inlet connector carefully so that
mud, etc. sticking around it will not enter
its hole.
a Tool A5 is prepared for removal of inlet
connector (55). (See the tool table.)
D61EX, PX-15E0 9
Installation 7) Apply engine oil (EO15W-40) to the

a The internal parts of the hose adapter may be mounting hole of inlet connector (55) on
damaged when the hose is removed. Accord- the cylinder head side.
ingly, do not reuse the hose but use new one 8) Apply engine oil (EO15W-40) to O-ring
for reassembly, as a rule. (61) of inlet connector (55).
1. Fuel injector assembly 9) Insert inlet connector (55) perfectly, setting
a Check that the fuel injector sleeve is free its part (B) to the groove on the cylinder
from flaw and dirt. head side.
1) Fit O-ring (58) and gasket (59) to fuel
injector (56).
2) Apply engine oil (EO15W-40) to O-ring
(58) of fuel injector (56) and the mounting
hole on the cylinder head side.
3) Matching convex and concave parts (A),
install holder (60) to fuel injector (56).
10) Secure inlet connector (55) by tightening

retaining nut (54) with the fingers. (Push
the inlet connector into the hole of the fuel
injector.)
11) Tighten mounting bolts (57) of fuel injector
(56) alternately.
3 Fuel injector mounting bolt:
4) Insert fuel injector (56) in the cylinder 8 ± 0.8 Nm {0.8 ± 0.08 kgm}
head, directing its fuel inlet hole toward 12) Tighten retaining nut (54).
the air intake manifold. 3 Retaining nut:
5) Tighten mounting bolts (57) of fuel injector 50 ± 5 Nm {5.1 ± 0.5 kgm}
(56) by 3 – 4 turns.
6) Install the wiring harnesses to fuel injector
(56) and tighten mounting nuts (50).
3 Wiring harness mounting nut:
1.5 ± 0.25 Nm {0.15 ± 0.03 kgm}
a Installed positions of wiring harnesses

White 1, 3, 5
Black 2, 4, 6
10 D61EX, PX-15E0
q Precautions for installing inlet connector 2. Crosshead and rocker arm assembly
1) When replacing the fuel injector assembly 1) Install the crosshead and rocker arm.
with new one, be sure to replace inlet con- a The shapes of holes (a) and (b) of
nector, too. each crosshead are different. Accord-
2) Check the inlet connector visually. If it has ingly, when reusing the crossheads,
any of the following faults, replace it. install each of them to the same
1] There is a bur or a worn part at front intake/exhaust valve in the same
end (a) or rear end (b) of the inlet direction as it has been installed.
connector. 2) Check that the ball of adjustment screw
2] There is foreign matter in the edge fil- (53) is set in the push rod socket securely
ter at rear end (c) of the inlet connec- and then tighten mounting bolts (62).
tor. 3 Rocker arm mounting bolt (62):
3] The O-ring at upper part (d) of the 36 ± 5 Nm {3.7 ± 0.5 kgm}
inlet connector is cracked or deterio- 3) Adjust the valve clearance. For details,
rated. see Testing and adjusting, "Adjusting
valve clearance".
3 Locknut (52):
24 ± 4 {2.4 ± 0.4 kgm}
3) Check the inlet connector visually. If it has

any of the following faults, replace it and
fuel injector assembly together.
q There is a worn part or an uneven
seat contact mark on sealing face (e)
at the front end of the inlet connector.
a If high-pressure fuel leaks
through the inlet connector, the
seal face has fine streaks or
cracks.
D61EX, PX-15E0 11
q Carry out the following installation in the 2) Tighten fuel high-pressure pipes (63) –
reverse order to removal. (68) in the following order.
1] Tighten cylinder head side of fuel
[*1] high-pressure pipes (63) and (68).
2 Aftercooler upper hose insertion area: 2] Tighten common rail side of fuel high-
Gasket sealant (LG-6 or LG-7) pressure pipes (63) and (68)
3 Aftercooler upper hose clamp: 3] Tighten cylinder head side of fuel
10.5 ± 0.5 Nm {1.07 ± 0.05 kgm} high-pressure pipes (64), (65), (66)
and (67)
[*2] 4] Tighten common rail side of fuel high-
Adjust the air conditioner compressor belt tension. pressure pipes (64), (65), (66) and
For details, see "Adjusting air conditioner compres- (67)
sor belt tension". 3 Sleeve nut:
35 ± 3.5 Nm {3.6 ± 0.4 kgm}
[*3] 3) Install bellows (38) to each fuel high-pres-
3 Air intake elbow mounting bolt (32): sure pipe.
24 ± 4 Nm {2.4 ± 0.4 kgm} a Install each bellows with the slits out
and down.
[*4] a The bellows are installed so that fuel
k Install each fuel high-pressure pipe and will not spout over the hot parts of the
wiring harness at least 10 mm apart from engine to catch fire when it leaks for
each other. some reason.
[*5] [*6]
k Do not bend the fuel high-pressure pipe to
correct before installing.
k Be sure to use the genuine fuel high-pres-
sure pipe clamps and observe the tighten-
ing torque.
a If the taper seal area of the fuel high-pressure
pipe has any of the following defects, replace
the fuel high-pressure pipe.
q There is visible lengthwise slit (b) or dent
(c) in range (a) of 2 mm from the end.
q Taper seal end (d) at 2 mm from the end
has stepped-type wear which your nail
can feel. [*7]
3 Intake manifold connector mounting bolt
(42): 24 ± 4 Nm {2.4 ± 0.4 kgm}
[*8]
3 Blow-by duct mounting bolt:
10 ± 2 Nm {1.0 ± 0.2 kgm}
[*9]
3 Cylinder head cover mounting nut (47):
24 ± 4 Nm {2.4 ± 0.4 kgm}

1) Temporarily install fuel high-pressure coolant through the system. Then, check the
pipes (63) – (68). coolant level again.
3 Sleeve nut:
0.2 – 0.8 Nm {0.02 – 0.08 kgm}
12 D61EX, PX-15E0
cylinder head assembly 1
Special tools
New/Remodel
Symbol
Necessity
Part No. Part name
Sketch
Q'ty
3 795-799-6700 Puller t 1 N
4 795-799-1131 Gear t 1
A 5 795-799-8150 Remover q 1 N
6 790-331-1120 Wrench (angle) q 1
7 795-790-4510 Gauge q 1 N
Removal 6. Remove aftercooler upper hose (4) and

k Disconnect the cable from the negative (–) bracket (5). [*1]
k If the coolant temperature is high, you may 7. Remove 2 air conditioner hose clamps (6).
the coolant.


D61EX, PX-15E0 13

compressor (7).
10. Loosen 4 bracket mounting bolts (10) and


hose clamp (14).

a Since the compressor and condenser are 17. Lift off muffler assembly (19).
to the machine. 4 Muffler assembly: 28 kg
13. Remove radiator upper hose (16). [*3]
18. Remove clamps (20) and (21).
20. Remove air conditioner compressor bracket

(23).
14. Disconnect the 2 clamps and remove muffler

water drain pipe (17).
14 D61EX, PX-15E0
21. Disconnect connector (24) and washer hose 25. Remove the 2 mounting bolts and corrosion
(25). resistor assembly (30).
a Fix corrosion resistor assembly (30) to the
22. Remove 2 washer tanks (26). machine.
26. Remove 2 clamps (31) and disconnect 2

heater hoses (32).
23. Remove exhaust pipe heat insulation plates

(27) and (28).
27. Remove 4 mounting bolts (33) and air intake

elbow (34). [*4]
a Fix air intake elbow (34) to the machine.
24. Remove muffler bracket (29).

4 Muffler bracket: 25 kg
D61EX, PX-15E0 15
28. Remove 2 clamps (35). 32. Remove 6 bellows (39). [*6]
29. Disconnect coolant temperature sensor con-

nector (36a).

a While pressing the lock of the connector,
pull out the connector in the direction of
the arrow.
31. Disconnect 3 connectors (37). [*5]

a While pressing the lock of the connector
with flat-head screwdriver [1], pull out the
connector.
a Move wiring harness (38) toward the fuel
filter. 33. Disconnect ambient pressure sensor connec-
tor (40).
34. Disconnect intake air pressure sensor connec-

tor (41).
35. Remove 6 mounting bolts (42) and intake man-

ifold connector (43). [*7]
a Remove these parts so that the inlet con-
nector of the fuel injector can be removed
and installed easily.
16 D61EX, PX-15E0
36. Remove 6 fuel high-pressure pipes (44). [*8] 46. Lift off exhaust manifold and turbocharger
assembly (57).
4
37. Remove fuel drain hose (45). [*8]
Exhaust manifold and turbocharger
assembly: 25 kg
38. Remove fuel high-pressure pipe (46). [*8]
39. Remove fuel hoses (47) and (48). 47. Set a wrench to part (B) of the tension pulley to
lower the belt tension and remove belt (58).
40. Remove clamp (49) and engine oil level gauge
(50).
41. Disconnect fuel inlet hose (51) and outlet hose

(52).
42. Remove fuel filter and bracket assembly (53).
48. Disconnect connectors AB (59) and E12 (60).
49. Remove alternator assembly (61).
43. Remove lubricating oil inlet tube (54) and out-

let hose (55). [*9]
44. Remove the mounting bolts of exhaust mani-

fold (56). Leave some of them installed, how-
ever. [*10]
45. Sling exhaust manifold and turbocharger

assembly (57) and remove the remaining
mounting bolts.
D61EX, PX-15E0 17
50. Remove blow-by duct (62). [*11]
51. Remove 6 mounting nuts (63) and cylinder

head cover (64). [*12]
54. Remove the 12 mounting bolts and rocker

arms (67).
a Loosen locknuts (68) and loosen adjust-
52. Remove plug (65) on the starting motor top ment screws (69) 2 – 3 turns so that an
and set tool A4. excessive force will not be applied to the
push rod when the rocker arm is installed.
53. Rotate the crankshaft forward (counterclock-
wise when viewed from the flywheel side) and
set mark (M1) to mark (M2).
Mark (M1): Top of projection of front cover
Mark (M2): Wide slit on revolution sensor slit
disc at rear of crankshaft pulley
a Set the projection top of mark (M1) in the
range of wide slit (M2).
a Note that the target is not 1.6TOP but
3.4TOP. (This point is 76 – 88 degrees
before the top dead center.)
a See Testing and adjusting, "Adjusting
valve clearance".
a Use tool A4 to rotate the crankshaft.
18 D61EX, PX-15E0
55. Remove 12 crossheads (67a). 57. Remove wiring harness mounting nuts (66)
a Record the position of each cross head from fuel injector (72).
and the shapes of holes (a) and (b). a Installed positions of wiring harnesses
(Install the cross head in the same direc-
tion.)
White 1, 3, 5
Black 2, 4, 6
58. Remove 2 mounting bolts (73) of fuel injector

assembly (72).
59. Using tool A3, remove fuel injector assembly

(72).
a Take care that dirt or foreign matter will not
enter the mounting area of the fuel injector
assembly.
56. Remove retaining nut (70) and 6 inlet connec-

tors (71).
a Clean the inlet connector carefully so that
mud, etc. sticking around it will not enter
its hole.
a Tool A5 is prepared for removal of inlet
connector (71). (See the tool table.)
D61EX, PX-15E0 19
60. Remove push rods (75). Installation

a The internal parts of the hose adapter may be
61. Remove 7 mounting bolts (76) and rocker damaged when the hose is removed. Accord-
housing (77). ingly, do not reuse the hose but use new one
for reassembly, as a rule.
1. Cylinder head assembly

1) Using tool A7, measure stem length (a) of
every cylinder head mounting bolt and
check that it is less than the following
using limit. (See the tool table.)
q Using limit length of bolt stem:
132.1 mm
a If a bolt is longer than the using
limit, replace it.
62. Remove 26 mounting bolts (78) and lift off cyl-

inder head assembly (79).
4 Cylinder head assembly: 75 kg
63. Remove cylinder head gasket (80).
2) Set cylinder head gasket (80).

a Check that there is no dirt and foreign
matter on the cylinder head mounting
face and in the cylinders.
a Check that the holes of the cylinder
head gasket are matched to the holes
of the cylinder head.
3) Set cylinder head (79) on the cylinder
block.
4) Tighten 26 mounting bolts (78) at least 2 –
3 turns with the fingers and then tighten
them according to the following proce-
dure.
2 Threaded part of mounting bolt and
seat of mounting bolt head:
Engine oil (EO15W-40)
20 D61EX, PX-15E0
q Method of tightening mounting bolts (78) 2. Fuel injector assembly

1] 90 ± 3 Nm {9.2 ± 0.3 kgm} a Check that the fuel injector sleeve is free
2] Check the torque of 90 ± 3 Nm {9.2 ± from flaw and dirt.
0.3 kgm}. 1) Fit O-ring (81) and gasket (82) to fuel
3] 90 ± 5° (Use angle tightening tool) injector (72).
a Tighten the mounting bolts in the 2) Apply engine oil (EO15W-40) to O-ring
order shown in the following fig- (81) of fuel injector (72) and the mounting
ure. hole on the cylinder head side.
a Tool A6 is prepared for angle 3) Matching convex and concave parts (A),
tightening. (See the tool table.) install holder (83) to fuel injector (72).
q When not using angle tightening tool 4) Install rocker housing (77).
4] After 1] – 2] above, make marks on 3 Rocker housing mounting bolt (76):
the cylinder head and each mounting 24 ± 4 Nm {2.4 ± 0.4 kgm}
bolt with a marker. 5) Install push rods (75).
5] Tighten the bolt by 90 ± 5°.
D61EX, PX-15E0 21
6) Insert fuel injector (72) in the cylinder 12) Secure inlet connector (71) by tightening
head, directing its fuel inlet hole toward retaining nut (70) with the fingers. (Push
the air intake manifold. the inlet connector into the hole of the fuel
7) Tighten mounting bolt (73) of fuel injector injector.)
(72) by 3 – 4 turns. 13) Tighten mounting bolts (73) of fuel injector
8) Install the wiring harnesses to fuel injector (72) alternately.
(72) and tighten mounting nut (66). 3 Fuel injector mounting bolt:
3 Wiring harness mounting nut: 8 ± 0.8 Nm {0.8 ± 0.08 kgm}
1.5 ± 0.25 Nm {0.15 ± 0.03 kgm} 14) Tighten retaining nut (70).
3 Retaining nut:
a Installed positions of wiring harnesses 50 ± 5 Nm {5.1 ± 0.5 kgm}
White 1, 3, 5
Black 2, 4, 6
q Precautions for installing inlet connector

1) When replacing the fuel injector assembly
with new one, be sure to replace inlet con-
nector, too.
any of the following faults, replace it.
9) Apply engine oil (EO15W-40) to the
1] There is a bur or a worn part at front
mounting hole of inlet connector (71) on
end (a) or rear end (b) of the inlet
the cylinder head side.
connector.
10) Apply engine oil (EO15W-40) to O-ring
2] There is foreign matter in the edge fil-
(81) of inlet connector (71).
ter at rear end (c) of the inlet connec-
11) Insert inlet connector (71) perfectly, setting
tor.
its part (B) to the groove on the cylinder
3] The O-ring at upper part (d) of the
head side.
inlet connector is cracked or deterio-
rated.
22 D61EX, PX-15E0

any of the following faults, replace it and
fuel injector assembly together.
q There is a worn part or an uneven
seat contact mark on sealing face (e)
at the front end of the inlet connector.
a If high-pressure fuel leaks
through the inlet connector, the
seal face has fine streaks or
cracks.

[*1]
10.5 ± 0.5 Nm {1.07 ± 0.05 kgm}
[*2]
3. Crosshead and rocker arm assembly Adjust the air conditioner compressor belt tension.
1) Install the crosshead and rocker arm. For details, see "Adjusting air conditioner compres-
a The shapes of holes (a) and (b) of sor belt tension".
each crosshead are different. Accord-
ingly, when reusing the crossheads, [*3]
install each of them to the same 2 Radiator upper hose insertion area:
intake/exhaust valve in the same Gasket sealant (LG-6 or LG-7)
direction as it has been installed. 3 Radiator upper hose clamp:
2) Check that the ball of adjustment screw 8.8 ± 0.5 Nm {0.9 ± 0.05 kgm}
(69) is set in the push rod socket securely
and then tighten mounting bolts (84). [*4]
3 Rocker arm mounting bolt (84): 3 Air intake elbow mounting bolt (32):
36 ± 5 Nm {3.7 ± 0.5 kgm} 24 ± 4 Nm {2.4 ± 0.4 kgm}
3) Adjust the valve clearance. For details,
see Testing and adjusting, "Adjusting [*5]
valve clearance". k Install each fuel high-pressure pipe and
3 Locknut (68): wiring harness at least 10 mm apart from
24 ± 4 {2.4 ± 0.4 kgm} each other.
D61EX, PX-15E0 23
[*6] [*8]
k Do not bend the fuel high-pressure pipe to
collect before installing.
k Be sure to use the genuine fuel high-pres-
sure pipe clamps and observe the tighten-
ing torque.
a If the taper seal area of the fuel high-pressure
pipe has any of the following defects, replace
the fuel high-pressure pipe.
q There is visible lengthwise slit (b) or dent
(c) in range (a) of 2 mm from the end.
q Taper seal end (d) at 2 mm from the end
has stepped-type wear which your nail
can feel.
[*7]
3 Intake manifold connector mounting bolt
(42): 24 ± 4 Nm {2.4 ± 0.4 kgm}
[*9]
3 Turbocharger lubricating oil inlet tube mount-
ing bolt: 35 ± 5 Nm {3.5 ± 0.5 kgm}
3 Turbocharger lubricating oil outlet tube
mounting bolt: 24 ± 4 Nm {2.4 ± 0.4 kgm}
[*10]
q Tighten the exhaust manifold mounting bolts
3 Exhaust manifold mounting bolt:
1) Temporarily install fuel high-pressure 1st time: 24 ± 4 Nm {2.4 ± 0.4 kgm} in order
pipes (85) – (91). of [1] – [12]
3 Sleeve nut: 2nd time:53 ± 6 Nm {5.4 ± 0.5 kgm} in order
0.2 – 0.8 Nm {0.02 – 0.08 kgm} of [1] – [12]
2) Tighten fuel high-pressure pipes (85) – 3rd time: Only bolts [1] – [4] to 53 ± 6 Nm
(91) in the following order. {5.4 ± 0.5 kgm} in this order
high-pressure pipes (85) and (90).
2] Tighten common rail side of fuel high-
pressure pipes (85) and (90).
high-pressure pipes (86), (87), (88)
and (89)
4] Tighten common rail side of fuel high-
pressure pipes (86), (87), (88) and
(89)
3 Sleeve nut:
0.2 – 0.8 Nm {0.02 – 0.08 kgm}
3) Install bellows (92) to each fuel high-pres-
sure pipe.
a Install each bellows with the slits out
and down.
a The bellows are installed so that fuel
will not spout over the hot parts of the
engine to catch fire when it leaks for
some reason.
4) Install fuel drain hose (93).
3 Joint bolt:
24 ± 4 Nm {2.4 ± 0.4 kgm}
24 D61EX, PX-15E0
[*11]
3 Blow-by duct mounting bolt:
10 ± 2 Nm {1.0 ± 0.2 kgm}
[*12]
3 Cylinder head cover mounting nut (63):
24 ± 4 Nm {2.4 ± 0.4 kgm}

D61EX, PX-15E0 25
Removal and installation of 5. Set a wrench to part (A) of the tension pulley to
engine front seal 1 lower the belt tension and remove belt (1).
Special tools 6. Remove 6 mounting bolts (2) and vibration

damper (3).
New/Remodel
Symbol
Necessity
Part No. Part name
Sketch
Q'ty
1 795-799-6400 Seal puller t 1 N
A
6 790-331-1120 Wrench (angle) q 1
Removal
internal pressure of the hydraulic tank. 7. Remove oil seal (4).
the coolant.



4. Remove the radiator guard assembly. For

details, see "Removal and installation of radia-
tor guard assembly".
26 D61EX, PX-15E0
Installation 2. Vibration damper

1. Using tool A1, install oil seal (4). 1) Install vibration damper (3), while setting
a Before installing the oil seal, check that its dowel pin hole to dowel pin (a) of the
the end corners of the crankshaft and seal crankshaft.
lip sliding face are free from flaw of the 2) Tighten mounting bolts (2) according to
housing, burr, sharp fin, rust, etc. the following procedure.
a Before installing the oil seal, degrease, 1] Tighten to 55 ± 5 Nm {5.6 ± 0.5 kgm}
clean and dry the seal contact face of the in the diagonal order.
crankshaft to prevent oil leakage. 2] Loosen by 180°.
a When installing the oil seal, do not apply 3] Tighten to 55 ± 5 Nm {5.6 ± 0.5 kgm}
oil, grease, etc. to the crankshaft and seal in the diagonal order.
lip. 4] Tighten by 90 ± 5°.
a Tool A6 (wrench) is prepared for
angle tightening. (See the tool
table.)
a The dimensions of oil seal (4) from cover

(5) must be in the following ranges.
q Projection (x): Max. 0.38 mm
q Facial runout (TIR: Total Indicator Read- q When not using angle tightening tool
ing) (y): Max. 0.25 mm 5] After 1] – 3] above, make marks on
the vibration damper and mounting
bolt with a marker.
6] Tighten by 90 ± 5°.

D61EX, PX-15E0 27


again.
(For the oil specification, see “Table of
fuel, coolant and lubricants”)

fan pump".
28 D61EX, PX-15E0
Removal and installation of 9. Remove the damper assembly. For details,

engine rear seal 1 see "Removal and installation of damper
assembly".
Special tools
10. Install eyebolt [1] to a damper mounting bolt
New/Remodel
hole and sling flywheel assembly (2).
Symbol
Necessity
Part No. Part name
11. Remove 8 mounting bolts (1) and lift off fly-
Sketch
wheel assembly (2). [*1]
Q'ty
2 Flywheel assembly: 50 kg
A2 795-799-6500 Seal puller t 1 N
Removal
until the coolant is cooled, and then drain 12. Oil seal
the coolant. 1) Install tool A2 to the crankshaft.
2) Tighten tapping screw [2] of tool A2 into
1. Loosen the radiator cap to drain the coolant. seal carrier of oil seal (3).
6 Radiator: Approx. 44 l a Fix the oil seal by tightening the tap-
ping screw into it.
3) Rotate the handle of the wrench clockwise
2. Drain the hydraulic oil. to remove oil seal (3).

details, see "Removal and installation of ROPS
guard assembly".
4. Remove the operator's cab assembly. For



assembly".
7. Remove the power train and lubricating oil

pump assembly. For details, see "Removal and
installation of power train and lubricating oil
pump assembly".
8. Drain the damper oil.

6 Damper case: Approx. 1.1 l
D61EX, PX-15E0 29
2. Insert pilot [3] in crankshaft (4) and push oil

seal (3) into flywheel housing (5).
3. Push in oil seal (3) further and pull out pilot [3].
Installation
1. Keep pilot [3] installed to oil seal (3) until it is
inserted in the crankshaft.
a Before installing the oil seal, check that 4. Using tool A2, install oil seal (3) to flywheel
the end corners of the crankshaft and seal housing (5).
lip sliding surface are free from flaw of the a When pushing in oil seal (3), take care not
housing, burr, sharp fin, rust, etc. to bend it.
a Before installing the oil seal, degrease, a Projection (x) of oil seal (3):
clean and dry the seal contact face of the Max. 0.38 mm
crankshaft to prevent oil leakage.
a When installing the oil seal, do not apply
oil, grease, etc. to the crankshaft and seal
lip.

30 D61EX, PX-15E0
[*1] q Measurement of facial runout

a Tighten the 8 flywheel assembly mounting a Facial runout: Max. 0.20 mm
bolts in the order of [1] – [8] as shown in the 1) Attach a stand to dial gauge [5] and install
following figure. them to flywheel housing (5).
3 Flywheel mounting bolt: 2) Set the dial gauge so that its probe will be
137 ± 7 Nm {13.97 ± 0.71 kgm} applied perpendicularly to end face (b) of
the flywheel near the periphery.
3) Rotate the flywheel 1 turn and measure
the difference between the maximum
readings.
a After rotating the flywheel 1 turn,
check that the dial gauge reads the
same value as before rotation.
a Using bar [4], lock the flywheel.

q Measurement of radial runout

a Radial runout: Max. 0.13 mm q Refilling with oil (Hydraulic tank)
1) Attach a stand to dial gauge [5] and install Add oil through the oil filler to the specified
them to flywheel housing (5). level. Run the engine to circulate the oil
2) Set the dial gauge so that its probe will be through the system. Then, check the oil level
applied perpendicularly to faucet joint por- again.
tion (a) or periphery of the flywheel. 5 Hydraulic tank: Approx. 55 l
3) Rotate the flywheel 1 turn and measure (For the oil specification, see “Table of
the difference between the maximum fuel, coolant and lubricants”)
readings.
a After rotating the flywheel 1 turn,
check that the dial gauge reads the q Bleeding air (Fan pump and work equip-
same value as before rotation. ment cylinder circuit)
fan pump".
D61EX, PX-15E0 31
SEN02571-00

© 2007 KOMATSU
All Rights Reserved
32
SEN02572-00
D61EX-15E0
D61PX-15E0


Power train, Part 1
Removal and installation of PTO, torque converter and transmission assembly ............................................ 2
Disconnection and connection of PTO, torque converter and transmission assembly ................................... 6
Disassembly and assembly of PTO assembly ................................................................................................ 8
Disassembly and assembly of torque converter assembly ........................................................................... 13
Disassembly and assembly of TORQFLOW transmission assembly ........................................................... 17
Removal and installation of torque converter main relief valve assembly .................................................... 34
Disassembly and assembly of torque converter main relief valve assembly ................................................ 35
D61EX, PX-15E0 1
Removal and installation of PTO, a View showing hose connections

torque converter and
transmission assembly 1
Removal

2. Drain oil from the HSS.

6 HSS case: 69 l
(excluding oil contained in the transmis-
sion case)
10. Remove the right transmission cover.
see "Removal and installation of floor frame 11. Remove the undercover of the universal joint.
assembly".
12. HSS and hydraulic pump assembly (17)
4. Remove the control valve assembly. For 1) Disconnect connector HSP (9) and 2 clips
details, see "Removal and installation of con- (10).
trol valve assembly". 2) Disconnect the following pipes.
a Discharge hose (A) connected to the
5. Disconnect clip (1). control valve has already been dis-
connected when the control valve
6. Loosen locknut (2) to remove pins (3) and (4). assembly was removed.
a Before disconnecting this cable, measure a Prepare a plug before disconnecting
its installed length. the hose.
a Identify all hoses using labels or any
7. Remove parking brake wire (5). other appropriate means.
q (11): Drain hose (connected to drain
8. Remove pin (6) and nut (7). block)
q (12): LS press fit hose (connected
9. Remove brake rod (8). from control valve)
q (13): Oil pressure pickup hose that
measures pump discharge pres-
sure
(connected to the right fender
pressure detection port)
q (14): Block
2 D61EX, PX-15E0
q (15): Suction pipe 13. Power train and lubricating oil pump
(connected from hydraulic tank) assembly (22).
q (16): Block 1) Disconnect the following pipes.
q (19): Pump discharge hose
(connected to HSS lubrication)
q (20): Pump discharge pressure hose
(connected to power train filter)
q (21): Suction pipe
(connected from pipe)
2) Remove power train and lubricating oil
pump assembly (22). [*2]
3) Lift off HSS and hydraulic pump assembly

(17) to remove it. [*1]
4 HSS and hydraulic pump assem-
bly (17): 70 kg
14. Disconnect clips (23), (24), (25) and (26) on

the left hand side.
16. Disconnect power train oil cooler hoses (27)

and (28) and disconnect oil pressure pickup
hoses (29).
a Connector (C): PL1 and PL2 have been

d i s c o n n e c te d w h e n th e f l o o r f r a m e
assembly was removed.
D61EX, PX-15E0 3
17. Disconnect clip (30).
18. Disconnect drain hoses (31) and (32).
19. Disconnect brake hose (33).
20. Disconnect HSS lubrication hose (34) from the

scavenging pump and disconnect hose (35)
from the power train and lubrication pump.
21. Disconnect 2 clips (36) and (37).
22. Remove hose and tube (38).
23. Remove hose (39). 32. Remove fuel tank undercover (51).
24. Disconnect oil pressure pickup hose (40).
25. Disconnect PPC basic pressure hoses (41) 34. Disconnect connector TM1 (53) and clip (54).
and (42) from fan pump assembly (B).
26. Disconnect oil pressure pickup hose (43).
27. Disconnect blowoff hose (44) from the pump.
28. Disconnect 2 clips (45) and (46).
29. Disconnect drain hoses (47) and (48) from the

fan pump assembly side.
30. Remove drain block (49).
31. Disconnect transmission lubrication hose (50)

from the power train filter.
4 D61EX, PX-15E0
35. Disconnect universal joint assembly (55). [*3] Installation

removal.
[*1] [*2]
a Check that there are no missing O-rings and/or
no O-rings get caught on components before
installing the pump.
[*3]
[*4]
36. Lift off PTO, torque converter and transmission 3 Mounting bolt:
assembly (56) to remove it. [*4] 235 – 285Nm {23.5 – 29.5 kgm}
4 PTO, torque converter and transmission

assembly (56): 850 kg q Refilling with oil (hydraulic tank)
a Move the assembly towards the front of Add oil through the oil filler to the specified
the machine body until the bevel shaft level. Run the engine to circulate the oil
comes off the bevel pinion. through the system. Then, check the oil level
a Take care not to damage the pipes and again.
5
harnesses. Hydraulic tank: 55 l
(See "Table of fuel, coolant and lubri-
cants")
q Refilling with oil (transmission and HSS)

again.
5 HSS case: 69 l
(excluding oil contained in the transmis-
sion case) (TO30)
q Bleeding air from fan pump and work

equipment cylinder
a Bleed air from the fan pump circuit, refer-
ring to the section of "Bleeding air from fan
pump" in Testing and adjusting.
a Bleed air from the work equipment cylin-
der circuit, referring to the section of
"Bleeding air from work equipment cylin-
der circuit" in Testing and adjusting.
D61EX, PX-15E0 5
Disconnection and connection of 7. Remove scavenging pump (7).

PTO, torque converter and
8. Remove power train and lubrication pump suc-
transmission assembly 1 tion pipe (8).
Disconnection
9. Remove bolt (9) and holder (10) to remove
1. Drain oil from the transmission case. coupling (11). [*1]
6 Transmission case:
2. Remove tubes (1) and (2).
10. Lift off the PTO, torque converter, and trans-

mission assembly and re-set it on the block
with the PTO pointing upward.
3. Remove suction pipe and hose (3). 11. Remove sleeves (12) and (13).
4. Remove suction hose (4).
5. Remove harness (5).
6. Remove fan drive assembly (6).

4 Fan drive assembly (6): 25 kg
6 D61EX, PX-15E0
12. Sling PTO assembly (14) temporarily, remove Connection

13 mounting bolts and disconnect it from trans-
mission assembly (15). [*2] q Connect the assemblies in the reverse order of
4 PTO and torque converter case assem- disconnection.
blies: 250 kg
[*1]
a Since the torque converter assembly is left 2 Coupling mounting bolt:
on the transmission side, it is not included Liquid adhesive (LT-2)
in the weight. 3 Coupling mounting bolt:
4
245.1 – 309.0 Nm {25.0 – 31.5 kgm}
PTO and torque converter assembly:
320 kg (Reference)
[*2]
3 Mounting bolt between torque converter
case and transmission case:
98 – 123 Nm {10 – 12.5 kgm}
[*3]
3 Mounting bolt between torque converter
assembly and transmission:
58.8 – 73.5 Nm {6.0 – 7.5 kgm}
13. Remove 8 mounting bolts. Using eyebolt [3],

remove torque converter assembly (19).
[*3]
4 Torque converter assembly: 150 kg
D61EX, PX-15E0 7
Disassembly and assembly of 4. Cover assembly (left)

PTO assembly 1 1) Remove mounting bolts, then using forc-
ing screw [2] remove cover assembly (8).
Disassembly
1. Remove lubrication tubes (1) and (2).
2) Knock out gear assembly (9) from cover

(10) and remove.
3. Cover assembly (right)

1) Remove mounting bolts, then using forc-
ing screw [1] remove cover assembly (3).
3) Remove bearings (11) from gear (12).
2) Knock out gear assembly (4) from cover

(5) and remove.
3) Remove bearings (6) from gear (7).
8 D61EX, PX-15E0
5. Idler gear 6. Scavenging pump drive gear

1) Remove mounting bolt to remove plate 1) Remove snap ring (21).
(13). 2) Knock out gear (22) from snap ring side.
2) Remove mounting bolts, then using forc- 3) Remove snap ring (24).
ing screw [3] remove shaft (14). 4) Remove bearing (23).
3) Remove bearing (16) and spacer (17)

from gear (15).
a If these parts are to be used again, do
not change the sets. Put them in sets
with the outer race and keep them in
a safe place.
4) Remove outer race (18) from gear (15).
D61EX, PX-15E0 9
7. Input shaft Assembly

1) Remove retainer (25).
2) Remove oil seal (26) from retainer (25). a Clean the all parts and check them for dirt or
3) Remove snap ring (27) and input shaft damage before assembling them.
bearing (28). a Apply 6 cc of power train oil (TO30) to the
rotating portion of the bearing and then rotate it
10 turns.
a Check that the snap ring is fitted securely in
the groove.
1. Input shaft
1) Using push tool [1], install oil seal (26) to
retainer (25).
2) Press fit bearing (28), and install snap ring

(27).
a See the figure above.
3) Install retainer (25).
a See the figure above.
2. Scavenging pump drive gear

1) Install bearing (23) and snap ring (24).
10 D61EX, PX-15E0
2) Holding the inner race of bearing (23), 3) Install spacer (17).

install gear (22) to the bearing. 4) Install outer race (18) to gear (15).
3) Install snap ring (21). 5) Install gear (15).

6) Install bearing (16).
a Press fit inner race side.
3. Idler gear
1) Fit the O-ring onto the shaft, then install
shaft (14). 7) Fit plate (13) and tighten bolts.
2) Install bearing (16). 2 Mounting bolt:
3 Mounting bolt:
156.9 – 196.1Nm {16.0 – 20.0 kgm}
D61EX, PX-15E0 11
4. Cover assembly (left) 5. Cover assembly (right)

1) Install bearings (11) to gear (12). 1) Install bearings (6) to gear (7).
2) Install gear assembly (4) to cover (5).
2) Install gear assembly (9) to cover (10).

3) Push the O-ring onto cover assembly (3)
and install it so that it engages the idler
gear.
3) Push the O-ring onto cover assembly (8)

and install it so that it engages the idler
gear.
6. Install cover (20).
7. Install lubrication tubes (2) and (1).

3 Joint bolt:
19.6 – 29.4 Nm {2.0 – 3.0 kgm}
12 D61EX, PX-15E0
Disassembly and assembly of 3) Using puller [2], disconnect case assem-

torque converter assembly 1 bly (10) from turbine (11).
Disassembly
1. Remove 24 bolts from the bottom of the

assembly. Lift off case, turbine assembly (1)
using eyebolts [1] to remove it.
4. Remove snap ring (14) to remove stator (15).
2. Remove bolts (2) to remove gear (3) and input

shaft (4).
5. Pump assembly
1) Using forcing screws [3] on the stator shaft
end, remove pump assembly (16) from
stator shaft (17).
3. Case
1) Remove snap ring (8).
2) Remove spacer (9).
D61EX, PX-15E0 13
2) Pull cage (18) out of pump (19). Assembly
a Clean the all parts and check them for dirt or

damage before assembling them.
a Apply 6 cc of power train oil (TO30) to the
rotating portion of the bearing and then rotate it
10 turns.
a Check that the snap ring is fitted securely in
the groove.
a Apply a thin coat of grease (G2-LI) to the seal
ring.
1. Pump assembly
1) Press fit bearing (21) to cage (18), and
install snap ring (22).
3) Remove snap ring (22) and bearing (21)
from cage (18).
2) Install cage (18) to pump (19).
14 D61EX, PX-15E0
3) Install pump assembly (16) to stator shaft 2) Push inner race end of bearing and install
(17). case assembly (10) to boss portion of tur-
a Push the inner race of the bearing to bine (11).
press fit.
a Apply 6 cc of power train oil (TO30) to
the rotating portion of the bearing and
then rotate pump assembly (16) more
than 10 turns.
3) Install spacer (9).

4) Install snap ring (8).
2. Stator
1) Install stator (15).
4. Gear and input shaft

1) Press fit inner race (7) to collar (6).
2) Install collar (6) to input shaft (5).
3. Case
1) Install bearing (13) to case (12).
a Apply 6 cc of power train oil (TO30) to
the bearing and then rotate the bear-
ing more than ten turns.
D61EX, PX-15E0 15
3) Install input shaft (4) and gear (3).

4) Install bolts (2).
2 Mounting bolt:
3 Mounting bolt:
58.9 – 73.6 Nm {6 – 7.5 kgm}
5. Case, turbine assembly

1) Using eyebolt [1], install case and turbine
assembly (1) so that the drain plug is fully
seated in the groove of the case.
2 Mounting bolt:
3 Mounting bolt:
49.0 – 58.8 Nm {5.0 – 6.0 kgm}
2) Install drain plug.

3 Drain plug:
5.9 – 8.8 Nm {0.6 – 0.9 kgm}
16 D61EX, PX-15E0
Disassembly and assembly of 4) Disconnect 10 connectors (6) of the

TORQFLOW transmission ECMV.
5) Remove cover (7) and wiring harness (8)
assembly 1 as a single unit.
Special tools a Only the bolt marked with is coated
with gasket sealant (LG-6).
New/Remodel
Necessity
Symbol
Sketch
Q'ty
Part No. Part name
D 1 799-301-1600 Oil leak tester q 1
Disassembly
a Keep the removed discs and plates on a flat

place so that they will not be warped.
1. Remove relief valve assembly (1).
2. Remove sleeve (2). 6) Remove control valve assembly (9).
3. Control valve assembly

1) Remove cover (3).
4. Transmission case
1) Set the transmission assembly on the
block securely with the torque converter
2) Remove flange (4). side up.
3) Using eyebolt [1], remove sleeve (5). 2) Remove 11 tie bolts (10) (used to secure
the transmission case).
D61EX, PX-15E0 17
3) Using eyebolt [2], remove transmission 4) Remove snap ring (21).

case (11). 5) Drive out input shaft (22) from the torque
a Hang the transmission case vertically converter side and remove front plate
by using a lever block. assembly (23).
5. Input shaft, front plate and No. 1 carrier 6) Remove snap ring (24), then remove input
assembly shaft (22) by driving it out to the torque
1) Remove remaining 3 tie bolts (12). converter side.
2) Using eyebolts [3], remove input shaft, front
plate and No. 1 carrier assembly (13).
7) Remove snap ring (25) to remove No. 1

ring gear (26).
6. Disassemble the input shaft, front plate and 8) Pull out shaft (27) and remove thrust
No. 1 carrier assembly as follows. washer (28), gear (29), bearing (30), and
1) Remove snap ring (14) to remove No. 2 ball (31).
sun gear (15) and snap ring (16). a Take care not to lose the ball (31).
2) Remove snap ring (17) to remove No. 1
sun gear (18).
3) Remove snap rings (19) and (20).
18 D61EX, PX-15E0
7. No. 1 discs, plates, and springs 12. No. 2 housing and No. 2 carrier assembly
1) Remove 5 springs (32). 1) Push up the output shaft lightly from
2) Remove 6 plates (33) and 5 discs (34). underside.
3) Using eyebolts [5], remove No. 2 housing
and No. 2 carrier assembly (43).
8. No. 1 housing assembly

1) Using eyebolts [4], remove No. 1 housing
assembly (35).
2) Remove No. 1 piston (36) from the hous- 13. Disassemble No. 2 housing and No. 2 carrier
ing. assembly as follows.
1) Remove snap ring (44) and pull No. 2 car-
rier assembly (45) out of No. 2 housing
(46).
9. Remove No. 2 piston (37).
10. Remove 5 guide pins (38).

2) Remove spacer (47) from No. 2 carrier
11. No. 2 discs, plates, and springs assembly (45).
1) Remove 5 No. 2 clutch springs (39). 3) Remove No. 2 ring gear (48).
2) Remove 7 discs (40) and 8 plates (41).
D61EX, PX-15E0 19
4) Pull out shaft (49) and remove thrust 15. Remove No.3 ring gear (60).
washer (50), gear (51), bearing (52), and
ball (53). 16. Using eyebolt [7], remove No. 3 and No. 4 car-
a Take care not to lose ball (53). riers and output shaft assembly (61).
5) Remove snap ring (54). 17. Disassemble No. 3 and No. 4 carriers and out-
6) Remove snap ring (55) to remove ring put shaft assembly as follows.
gear (56). 1) Remove snap ring (62), then remove out-
a Contract snap ring (55) by inserting put shaft assembly (63) from No. 3 and
round rods [6] with a diameter of less No. 4 carriers (64) with push tool [8].
than 3 mm in 2 diagonal holes of 4 on
the ring gear and pull out ring gear
(56).
2) Remove seal ring (65).

3) Drive pin (66) into shaft (67).
4) Drive out shaft (67) from No. 3 carrier
14. No. 3 discs, plates, and springs side.
1) Remove five No. 3 springs (57).
2) Remove four No. 5 discs (58) and five
plates (59).
20 D61EX, PX-15E0
5) Remove thrust washer (68), No. 4 plane- 18. No. 3 housing

tary gear (69), and bearing (70). 1) Using eyebolts [9], remove No. 3 housing
a Pull the pin (66) out of shaft (67). (83).
2) Remove No. 3 piston (84).
6) Drive out shaft (71) and remove thrust

washer (72), No. 3 planetary gear (73), 19. No. 4 discs, plates, and springs
bearing (74), and ball (75). 1) Remove 5 springs (85).
a Take care not to lose ball (75). 2) Remove 4 discs (86) and 5 plates (87).
7) Remove snap ring (76), then remove No. 20. No. 5 carrier and No. 4 ring gear assembly
4 sun gear (77) from output shaft (78). 1) Remove 4 mounting bolts (88).
8) Remove snap rings (79) and (80), then 2) Remove No. 5 carrier and No. 4 ring gear
remove No. 5 sun gear (81) from output assembly (89).
shaft (78).
9) Remove inner race (82) from the bearing.
D61EX, PX-15E0 21
21. Disassemble No. 5 carrier and No. 4 ring gear 23. Remove 5 guide pins (100) and No. 5 piston
assembly as follows. (101).
1) Drive out shaft (90) and remove thrust
washer (91), gear (92), bearing (93), and
ball (94).
a Take care not to lose ball (94).
24. Remove 5 springs (102), 3 discs (103), and 4

plates (104).
2) Remove snap ring (95), then remove No.

4 ring gear (96) from carrier (97).
25. Remove No. 5 ring gear (105).

1) Remove No. 4 housing assembly (98).
2) Remove No. 4 piston (99).
22 D61EX, PX-15E0
26. Cage (for fixing No. 5 carrier) 27. Output shaft bearing
1) Remove snap ring (106). 1] Remove snap ring (110).
2] Remove bearing (111) from housing
(112).
2) Using forcing screws [10], remove cage

(107) and bearing (108) as a single unit.
Assembly
q Precautions for assembly

a Clean the all parts and check them for dirt
or damage before assembling them.
a Coat the sliding surfaces of each part with
power train oil (TO30) before assembling.
a Install seal ring (a) for the piston and pis-

ton housing with power receiving side (b)
facing to housing (c) as shown in the fig-
ure.
a Apply grease (G2-LI) to the seal ring and
3) Remove seal ring (109) and bearing (108) install it evenly.
from cage (107). a Before cooling the bearing in dry ice, etc.
for expansion fit, apply approximately 6 cc
of power train oil (TO30) to the bearing
and rotate it ten turns.
D61EX, PX-15E0 23
1. Output shaft bearing 3. Install No. 5 ring gear (105).

1) Using push tool [11], install bearing (111)
to housing (112).
4. Install 5 guide pins (100).
5. No. 5 discs, plates, and springs

2. Cage (for fixing No. 5 carrier) 1) Install plates (104) and discs (103) alter-
1) Install bearing (108) to cage (107) with the nately from the bottom.
push tool. a 3 discs and 4 plates
2) Install seal ring (109) to cage (107). 2) Install 5 springs (102).
a Free length of spring: 59 mm
3) Install cage (107) to housing (112) with

push tool [12].
a Press fit the inner race side of bearing
(108).
24 D61EX, PX-15E0
6. No. 5 piston 3) Install No. 4 piston (99) to No. 4 housing

1) Install seal ring (113) to No. 5 piston (101). (98).
a When installing the seal ring, check 4) Install No. 4 housing (98), matching it to
the direction of the pressure receiving No. 5 piston.
side.
2) Install No. 5 piston (101), matching it to
springs (102).
a Check that the springs are fitted
securely in the grooves of the piston.
8. Assemble No. 5 carrier and No. 4 ring gear

assembly as follows.
1) Set No. 4 ring gear (96) to carrier (97) and
7. No. 4 housing
1) Install seal ring (114) to No. 4 housing
(98).
a When installing the seal ring, check
the direction of the pressure receiving
side.
2) Install seal ring (115) to No. 4 piston (99).
side.
2) Install bearing (93) into gear (92) and fit

thrust washers (91) to both sides, then set
them to the carrier.
3) Install ball (94) and shaft (90).
D61EX, PX-15E0 25
9. Using a guide bolt, install No. 5 carrier and No.

4 ring gear assembly (89) and tighten bolts
(88).
2 Mounting bolt: Liquid adhesive (LT-2)
3 Mounting bolt:
27 – 34 Nm {2.8 – 3.5 kgm}
4) Using 2 forcing screws [13], tighten No. 3

housing (83) and insert dowel pin into the
housing securely.
a Keep 2 forcing screws [13] installed
until step 13.
10. No. 4 discs, plates, and springs

1) Install plates (87) and discs (86) alter-
nately from the bottom.
a 4 discs and 5 plates
2) Install 5 springs (85).
a Free length of spring: 59 mm
12. Assemble No. 3 and No. 4 carrier and output

shaft assembly as follows.
1) Install inner race (82) to output shaft (78).
2) Install No. 5 sun gear (81) and snap rings
(80) and (79).
3) Install No. 4 sun gear (77) and snap ring
(76).
11. No. 3 housing
1) Install the seal ring to No. 3 housing (83)
and No. 3 piston (84).
side.
2) Install the No. 3 piston into the No. 3 hous-
ing.
3) Using eyebolts [9], install No. 3 housing
(83).
a Check that the springs are fitted
securely into the grooves.
26 D61EX, PX-15E0
4) Press fit bearing (116) to No. 3 carrier and

11) Set No. 3 and No. 4 carrier assemblies

(64) to output shaft (78).
5) Install bearing (74) into No. 3 planetary 12) Set jig [14] on the inner race side of bear-
gear (73) and fit thrust washers (72) to ing (116) and tighten bolt [15] to press fit
both sides, then set them to the carrier. bearing (116) to output shaft (78).
6) Install ball (75) and shaft (71). a Dimensions of tap hole:
M10 × 1.5, 32 mm depth
7) Install bearing (70) into No. 4 planetary

gear (69) and fit thrust washers (68) to 13) Install snap ring (62).
both sides, then set them to the carrier.
8) Align the pin hole in the shaft with the one 13. No. 3 and No. 4 carrier assemblies and out-
in the carrier and install shaft (67). put shaft assembly.
9) Check that the pin holes are aligned 1) Using eyebolt [7], install No. 3 and No. 4
before driving pin (66). carriers and output shaft assembly (61).
a Check the pin hole in carrier (64) for 2) Remove 2 forcing screws [13].
burrs before driving pin (66). If found,
deburr the hole using a sand paper
before driving pin (66).
10) Install seal ring (65).
D61EX, PX-15E0 27
14. Install No. 3 ring gear (60). 2) Set ring gear (56) to No. 2 carrier (45) and
a Direct the notched side of the outside install snap ring (55).
teeth down.

15. Install guide pin (38). thrust washers (50) to both sides, then set
them to the carrier.
16. Install plates (59) and discs (58) alternately 4) Install ball (53) and shaft (49).
from the bottom. a After assembling 2 gear sets, install
a 4 discs and 5 plates snap ring (42).
17. Assemble No. 2 housing and No. 2 carrier 5) Install the seal ring to No. 2 housing.
assembly as follows. 6) Install No. 2 ring gear (48).
1) Press fit bearing (118) to No. 2 housing 7) Install spacer (47).
(46) and install snap ring (44). a Install the spacer with the cut inside
end directed to the carrier.
28 D61EX, PX-15E0
8) Install No. 2 housing (46) to carrier assem- 4) Install sleeve (119).

bly (45). a If the sleeve has been removed,
a Press fit the inner race side of the install it to the bolt hole marked in
housing bearing. the figure with the slit side (d) facing
9) Install snap ring (44). down.
18. No. 2 housing and No. 2 carrier assembly

and No. 2 carrier assembly (43).
5) Install spring (120) and valve (121).
2) Clamp No. 2 housing with tie bolt (10) and

pipe [17] and push the dowel pin into the
housing securely.
3) Push up output shaft (42) lightly from
underside and install snap ring (63).
D61EX, PX-15E0 29
19. Install plates (41) and discs (40) alternately

from the bottom.
23. Assemble input shaft and No. 1 carrier assem-

bly as follows.
20. Install 5 springs (39). thrust washers (28) to both sides, then set
a Free length of spring: 77.0 mm them to the carrier.
2) Install ball (31) and shaft (27).
21. No. 2 piston
1) Install the seal ring to the No. 2 piston.
side.
2) Install No. 2 piston (37).
a Align spring (39) with the spring
groove in the piston.
3) Set No. 1 ring gear (26) to No. 1 carrier

and install snap ring (25).
4) Press fit bearing (122) to input shaft (22).
5) Install snap rings (20) and (19) to the input
shaft.

1) Install the seal ring to the No. 1 housing
and No. 1 piston.
side.
2) Install No. 1 piston (36) to housing.
assembly (35) so that it is aligned with No.
2 piston.
a Press the housing and hit the dowel
pin.
30 D61EX, PX-15E0
6) Install input shaft (22) to No. 1 carrier 24. Using eyebolt [3], lift off input shaft and No. 1
assembly (123), and then install snap ring carrier assembly (124) and install it so that No.
(24). 2 sun gear engages with No. 2 planetary gear.
7) Install No. 1 sun gear (18). 25. No. 1 discs, plates, and springs
1) Install plates (33) and discs (34) alter-
nately from the bottom.
a Free length of spring: 69.5mm
2) Install 5 springs (32).
8) Install snap rings (17) and (16).

9) Install No. 2 sun gear (15) and snap ring
(14).
26. Front plate assembly

1) Press fit bearing (126) to front plate (125).
2) Install seal ring (127).
D61EX, PX-15E0 31
3) Install collar (128) to No. 1 carrier (129). Using tool D1, check operation and stroke of
each piston.
Piston Standard stroke (mm)
No. 1 5
No. 2 7
No. 3 4
No. 4 4
No. 5 3
4) Using eyebolts [18], install front plate

assembly (23) so that it is aligned with the
guide pin and spring.
5) Press fit the inner race side of bearing
(126) to input shaft (22) and install snap
ring (21).
a Check that the spring is fitted to the
cover securely.
29. Transmission case

1) Fit the O-ring and install transmission
case (11) using eyebolts [2].
27. Install 3 tie bolts (12).

3 Tie bolts:
156.9 – 176.5 Nm {16.0 – 18.0 kgm}
28. Checking operation of piston
32 D61EX, PX-15E0
2) Tighten 11 tie bolts (10) (to secure the 5) Fit the O-ring and install sleeve (5) using
transmission case). eyebolt [1].
3 Tie bolts 6) Install flange (4).
156.9 – 176.5 Nm {16.0 – 18.0 kgm}
7) Install cover (3).

30. Control valve 3 Cover: Gasket sealant (LG-6)
1) Set the transmission assembly on its side.
2) Fit the O-ring and install control valve 31. Install sleeve (2).
assembly (9).
3 Mounting bolt: 32. Install relief valve assembly (1).
44.1 – 53.9 Nm {4.5 – 5.5 kgm} 3 Mounting bolt:
44.1 – 53.9 Nm {4.5 – 5.5 kgm}
3) Install cover (7) and wiring harness (8) as

a single unit.
2 Cover: Gasket sealant (LG-6)
2 1 bolt marked with an asterisk ( ):
4) Connect 10 ECMV connectors (6).
D61EX, PX-15E0 33
Removal and installation of torque

converter main relief valve
assembly 1
Removal
1. Remove the left side transmission cover.
2. Remove oil pressure pickup hoses (1) and (2).
3. Remove torque converter relief valve assem-

bly (3). [*1]
Installation
removal.
[*1]
3 Mounting bolt for torque converter main
relief valve: 44.1 – 53.9 Nm {4.5 – 5.5 kgm}
34 D61EX, PX-15E0
Disassembly and assembly of Assembly

torque converter main relief valve
a Clean all parts and check them for dirt or dam-
assembly 1 age. Coat the sliding surfaces of each part
Disassembly with power train oil (TO30) before assembling.
1. Remove plug (1) and remove valve (2), spring 1. Assemble spring (15) and guide (14) onto
(3), valve (4), valve (5), 2 shims (6), and spool (16).
springs (7) and (8) from valve body (9).
a Check the quantity and thickness of the 2. Assemble valve (19), spring (18), and valve
shims and keep in a safe place. (17) onto spool (16), assemble them onto
valve body (9), and install plugs (20) and (13).
2. Remove plug (10).
3. Assemble springs (8) and (7) onto plug (10)
3. Remove plug (13) and remove guide (14), and install them to valve body (9).
spring (15), spool (16), valve (17), spring (18),
and valve (19). 4. Assemble valve (2), spring (3), and valve (4),
assemble them onto valve (5), and install
4. Remove plug (20). shims (6) on opposite side.
a Check the thickness and quantity of shims
when assembling.
Standard shim thickness: 0.5 mm
5. Assemble valve (5) onto valve body (9), and

install plug (1).
6. Tighten plugs (10) and (1).
D61EX, PX-15E0 35
SEN02572-00

© 2007 KOMATSU
All Rights Reserved
36
SEN02573-00
D61EX-15E0
D61PX-15E0


Power train, Part 2
Removal and installation of power train and lubricating oil pump assembly ................................................... 2
Removal and installation of HSS and work equipment pump assembly ......................................................... 4
Removal and installation of scavenging pump assembly ............................................................................... 5
Removal and installation of HSS motor assembly .......................................................................................... 5
Disassembly and assembly of HSS assembly................................................................................................ 6
Removal and installation of final drive assembly .......................................................................................... 24
Disassembly and assembly of final drive assembly...................................................................................... 25
D61EX, PX-15E0 1
Removal and installation of power

train and lubricating oil pump
assembly 1
Removal
fully and stop the engine. Then, loosen the

details, see "Removal of operator's cab
assembly". (Only when the operator's cab is
installed.)

3. Remove cover (1) and disconnect cover (2)

mounting bolt.
7. Remove the bottom cover of the universal

joint.
8. Disconnect pump discharge hoses (9) and

(10).
a Prepare plugs before disconnecting these
hoses
4. Raise cover (2) with block [1]. a Have tags or the like handy to match the
areas to which hoses are connected.
5. Remove deceleration pedal (3) as below:
1) Disconnect bracket (4) and fuel control 9. Disconnect pump suction hose (11).
cable (5). [*1]
2) Disconnect connector DCL (6). 10. Remove power train and lubricating oil pump
assembly (12). [*3]
6. Remove cover (2) as below:
1) Disconnect brake cable (7). [*2]
a Before disconnecting this cable, mea-
sure its installed dimensions length.
2) Disconnect connector BRK (8).
2 D61EX, PX-15E0
Installation

removal.
[*1]
a Adjust the deceleration cable. For details, see
Testing and adjusting, "Adjusting fuel control
linkage".
[*2]
a Adjust the deceleration cable. For details, see
Testing and adjusting, "Adjusting brake pedal
linkage".
[*3]
a When installing, check that the O-ring is not
dropped off or caught in the assembly.

again.
5 Hydraulic tank: 55 l (See "Table of fuel,
coolant and lubricants")
D61EX, PX-15E0 3
Removal and installation of HSS q (8): Suction pipe

and work equipment pump Hydraulic tank
q (9): Block
assembly 1
Removal

fully and stop the engine. Then, loosen the
k Operate the work equipment control levers
a couple of times and release the residual
pressure from the work equipment circuit.

6. Lift off HSS and work equipment pump assem-
2. Remove the floor frame assembly. For details, bly (10). [*1]
4
see "Removal and installation of floor frame HSS and work equipment pump assem-
assembly". bly: 70 kg
3. Remove the transmission right side cover.
4. Disconnect connector HSP (1) and clip (2).
5. Disconnect the following pipes and blocks.

pipes and blocks.
a Have tags or the like handy to match the
areas to which hoses are connected.
q (3): Discharge hose
(Connected to control valve)
q (4): Pump discharge pressure detection
hose
(Connected to the right fender pres-
sure detection port)
q (5): Block Installation
q (6): Drain hose (Connected to drain block)
q (7): LS pressure input hose q Carry out installation in the reverse order to
(Connected from control valve) removal.
a (A) is a pump servo valve.
[*1]
a Be careful not to damage the hose nipple when
removing.
a When installing, check that the O-ring is not
dropped off or caught in the assembly.

again.
5 Hydraulic tank: 55 l (See "Table of fuel,
4 D61EX, PX-15E0
Removal and installation of Removal and installation of HSS

scavenging pump assembly 1 motor assembly 1
Removal Removal
1. Drain oil from the transmission case. 1. Remove the fuel tank assembly. For details,
6
see "Removal and installation of fuel tank
Transmission case: 69 l
assembly."
(including oil in the HSS case)
2. Disconnect hoses (1) and (2) (between the
2. Remove the undercover of the universal joint. main control valve and HSS motor).
3. Remove hose (1). hoses.
a Have tags or the like handy to match the
4. Remove scavenging pump assembly (2) from areas to which hoses are connected.
the bottom of the machine.
3. Disconnect hydraulic tank return hose (3).
5. Lift off HSS motor assembly (5).

4 HSS motor assembly: 50 kg
Installation

removal.
q Refilling with oil (Transmission case)

Add oil through the oil filler to the specified Installation
through the system. Then, check the oil level q Carry out installation in the reverse order to
again. removal.
5 Transmission case: 69 l
(including oil in the HSS case) (TO30)
again.
D61EX, PX-15E0 5
Disassembly and assembly of Disassembly

HSS assembly 1
1. Removal of upper cover assembly
Special tool 1) Disconnect clip (1).
2) Loosen locknut (2) and remove pins (3)
New/Remodel
and (4).
Necessity
Symbol
a Before disconnecting them, measure
Sketch
Q'ty
Part No. Part name
their installed dimensions lengths.
3) Disconnect parking brake cable (5). [*1]
4) Remove pin (6) and nut (7).
1 709-302-1500 Wrench kit q 1
5) Remove brake rod (8). [*2]
2 796-730-2140 Wrench q 1
E Commercially
3 available or Torque wrench q 1
795-630-1810
q Setup
1. To disassemble the upper cover assembly
only:
1) Remove the floor frame assembly. For
floor frame assembly".
2) Remove the fuel tank assembly. For
fuel tank assembly".
3) Remove the HSS motor assembly. For 6) Disconnect HSS lubrication hoses (9)
details, see "Removal and installation of (connected from scavenging pump) and
HSS motor assembly". (10) (connected from power train and
lubricating pump).
2. To disassemble the brake and carrier assem- a Prepare plugs before disconnecting
bly only: these hoses.
a Carry out disassembly of one side or both a Have tags or the like handy to match
sides as necessary. the areas to which hoses are con-
1) Remove the track shoe assembly. For nected.
details, see "Removal of track shoe 7) Disconnect brake hose (11).
assembly". 8) Disconnect drain hoses (12) and (13).
2) Remove the final drive assembly. For 9) Remove hose and tube (14).
details, see "Removal and installation of 10) Remove hose (15).
final drive assembly". 11) Disconnect pressure detection hose (16).
a Perform the steps after "3. Removal 12) Disconnect clip (17).
of the brake assembly".
3. To disassemble the bevel pinion and bevel

gear shaft assembly (all):
1) Perform the steps 2. 1) and 2) (both sides)
and then 1. 1) - 3) above.
2) Remove the PTO and torque converter
transmission assembly. For details, see
"Removal and installation of PTO, toque
converter and transmission assembly".
a Perform the steps after 1.13) on the
following page.
6 D61EX, PX-15E0
13) Disconnect clip (18). 19) Remove 5 sleeves (24) and 2 sleeves (25)
14) Remove cover (19) and disconnect con- from the HSS case.
nector (20). 20) Remove 4 dowel pins (90) from the HSS
15) Remove bracket (21). case (as they may be left in the cover).
k Be sure to remove 4 dowel pins
(90). Failure to do so could damage
sleeves (24) and (25) and cut the O-
ring when assembling.
16) Remove brake valve assembly (22).

17) Remove cover assembly (23) mounting
bolt.
18) Using forcing screw [1], remove the pilot
portion and lift off upper cover assembly 2. Disassembly of upper cover assembly
(23). 1) Remove oil temperature sensor (26),
a Slowly raise horizontally as there are tubes (27) and (28).
sleeves, tubes, etc. (indicated by
mark (a)).
4 Upper cover assembly (23): 140 kg
2) Input gear assembly

1] Remove snap ring (29).
D61EX, PX-15E0 7
2] Pull out gear assembly (30) and cage 4] Tap out shaft (40) from the bolt side
(31) together with puller [2], and then and remove gear (39).
remove gear assembly (30) from a Take care not to lose ball (41).
cage (31).
a Take care not to lose ball (32).
3] Remove bearing (33) from gear
assembly (30).
5] Remove bearing (42) and spacer

(42a) from gear assembly (39).
3) Intermediate gear
1] Take off bolt (35) and remove holder
(36).
a Remove them from both sides.
2] Remove gear (37).
3] Take off the bolt and remove holder
(38).
6] Using gear puller [3], push out shaft

(43).
7] Remove snap ring (44) and bearing
(45) from cover (A).
8] Remove outer race (46) from cover
(B).
8 D61EX, PX-15E0
2) Bring down the assembly to the ground by

balancing with brake carrier assembly (48)
weighing 150 kg.
k Be careful not to drop brake
assembly (48) from pipe [4] (with a
bar inside). (A load of 150 kg will
be imposed suddenly.)
9] Remove bearing (47) from shaft (43).
4. Disassembly of brake assembly

1) Remove flange (49).
2) Detach snap ring (50) and remove spacer
(51).
3. Removal of brake assembly

1) Sling the brake assembly temporarily with
pipe [4] (with a bar inside), take off the
mounting bolt, and disconnect brake car-
rier assembly (48), using forcing screw [5]
and guide bolt [6]. (with the assembly put
on guide bolt [6])
a Do not remove 4 hexagon socket
head bolts.
k Set tool [8] so that the cover won't fly

off by the spring force.
3) Set puller [7] and tool [8] and tighten bolt
(C) while loosening 4 hexagon socket
head bolts and tool [8].
4) Even after the 4 hexagon socket head
bolts have been removed, continue to
tighten bolt (C) while slowly loosening tool
[8] evenly.
a The inner race side of the bearing
comes out.
5) Temporarily fix the piston (at the rear) with
bolt (D) and lift off cover assembly (52).
a Since the piston (at the rear) is
attached to the cover with a spring,
remove the assembly altogether after
temporarily fixing the piston.
D61EX, PX-15E0 9
11) Remove spring (59), disc (60), and plate

(61) in this order from drum (62).
q Spring (59) and disc (60): 5 pieces
q Plate (61): 4 pieces
6) Remove bearing (53) from cover (52).
12) Remove drum (62).

13) Detach snap ring (63), then remove bear-
ing (64).
a Pry up the bearing from the notch of
the hub.
14) Take off 18 mounting bolts, then remove
hub (65) from hub (66).
7) Turn over cover assembly (52) and

remove bolt (D).
8) Remove cage (54) and piston (55).
9) Remove seal rings (56) and (57) from
cage (54).
10) Remove double springs (58).
15) Remove bushing (67) from hub (65).
10 D61EX, PX-15E0
5. Disassembly of carrier assembly 6. Sun gear

1) Reverse hub (66), detach bolt (68) and 1) Take off snap ring (79) and remove collar
remove carrier assembly (69). (80).
2) Extract cage assembly (70) from hub (66). 2) Using gear puller [9], remove sun gear
3) Reverse cage assembly (70), take off (81) and bearing (82).
snap ring (71) and remove ring gear (72).
3) Using the bearing race puller, remove

4) Drive in roll pin (73) into shaft (74). bearing (83).
5) Pull out shaft (74) and remove gear (75), 4) Remove collar (84).
thrust washer (76), and bearing (77). 5) Remove snap ring (85).
a Pull roll pin (73) out of the shaft. a Only the right side of the machine.
6) Remove bushing (78).
D61EX, PX-15E0 11
7. Bevel pinion assembly 4] Remove bearing (104).

1) Remove mounting bolt (94). 5] Remove outer races (105) and (107)
2) Using the guide bolt and forcing screw, from cage (103).
remove bevel pinion assembly (95).
a Check the quantity and thickness of
the shims and store them.
6] Remove bearing (106) and spacer

(108) from bevel pinion (102).
3) Disassembly of bevel pinion assembly

1] Take off bolt (97) and remove plate
(99) and pin (100).
8. Bevel gear shaft and bevel gear assembly

1) Sling bevel gear and shaft assembly (110)
temporarily.
2) Remove cage assemblies (111) and (112).
2] Secure the pinion with a press and a Check the thickness, quantity, and
remove nut (101) with tool E1. positions of shims (113).
3] Using push tool [11], remove bevel a Since both cages are different from
pinion (102) from cage (103). each other, mark them.
12 D61EX, PX-15E0
3) Move bevel gear and shaft assembly (110) 9) Remove seal rings (121) from bevel gear
to the left end fully and remove bearing shaft (117).
(114) with puller [12].
a Remove only the bearing on the left
Assembly
4) Lift bevel gear (115), take off mounting nut q Precautions for assembly
(116), and remove bevel gear (115) from a Clean all parts and check them for dirt or dam-
bevel gear shaft assembly (117). age before installing.
5) Extract bevel gear shaft assembly (117) to a Drop power train oil (TO30) onto the rotating
the left of the machine and remove it. parts of each bearing and rotate it several
turns.
a Coat the sliding parts with power train oil
(TO30) before installing.
2 Rotary seal ring: Fix each seal ring with
grease (G2-LI) and install it very carefully not
to get caught in the parts.
a Check that the snap rings are fitted in the
grooves.
1. Bevel gear shaft and bevel gear assembly

1) Install seal rings (121) to bevel gear shaft
(117).
6) Remove bearing (118).

7) Remove bolts (119).
8) Remove outer races (120) from cages
(111) and (112).
D61EX, PX-15E0 13
2) Install bolt (119) to bevel gear shaft (117). 6) Heat bearing (114) with a bearing heater,
3) Heat bearing (118) with a bearing heater, etc. and install it to the left side of the
etc. and install it to the left side of the bevel gear shaft by shrink fit.
bevel gear shaft by shrink fit. a If the bearing is heated too much, its
a If the bearing is heated too much, its heat treatment hardness is lowered.
heat treatment hardness is lowered. Accordingly, do not raise the bearing
Accordingly, do not raise the bearing temperature more than 120°C.
temperature more than 120°C. a After installing the bearing, drop
a After installing the bearing, drop power train oil (TO30) onto its rotating
power train oil (TO30) onto its rotating parts and rotate it several turns.
parts and rotate it several turns. a Check that the clearance at the bear-
a Check that the clearance at the bearing end is 0.03 mm or less.
ing end is 0.03 mm or less.
4) Install outer race (120) to cages (111) and
(112).
7) Install cages (111) and (112) to bevel gear

and shaft assembly (110).
a Since both cages are different from
5) Insert bevel gear shaft (117) in bevel gear each other, take care not to mistake
(115) slung at the center of the case from them.
the right side of the machine. a Install shims (113) of the thickness
a Temporarily tighten mounting nut and quantity recorded when removed.
(116) in advance. q Standard shim thickness:1.5 mm
q Type of shim thickness:
0.2 mm, 0.3 mm, and 0.5 mm
3 Mounting bolt:
98.1 – 122.6 Nm {10 – 12.5 kgm}
8) Place a plastic hammer or the like
between the bevel gear and the case to
stop rotation.
3 Mounting nut:
245 – 309 Nm {25 – 31.5 kgm}
14 D61EX, PX-15E0
9) Adjusting pre-load 2] Using the push tool, press fit outer

a Adjust the pre-load with the bevel pin- races (105) and (107) to cage (103).
ion assembly removed. 3] Place bevel pinion (102) on the press
1] Rotate the bevel gear and shaft stand and set cage (103).
assembly several turns to fit the bear-
ing.
2] Install tool E2 to the end of bevel gear
shaft (110) and measure the rotation
torque with a torque wrench E3.
q Standard rotation torque:
10.3 – 14.7 Nm {1.05 – 1.5 kgm}
a If the rotation torque is lower than
the standard value, reduce the
quantity of shims (113) in step 7.
If the former is higher, increase
the latter.
4] Press fit bearing (104) into cage (103)

with the press.
5] Secure the pinion with the press and
tighten locknut (101) with tool E1.
2 Locknut:
3 Locknut:
392 – 441 Nm {40 – 45 kgm}
6] After tightening the nut, return it until
one of its pin holes (8 places) aligns
with one of the pin holes of the pinion
shaft (5 places).
2. Bevel pinion assembly a Return the nut by 0 – 9°.
1) Assembly of bevel pinion a Tighten the nut while turning the
1] Using push tool, press fit bearing cage.
(106) to bevel pinion (102) and install a After tightening the nut, check
spacer (108). that the bevel pinion rotates
smoothly.
D61EX, PX-15E0 15
7] Install pin (100) then tighten plate (99)

mounting bolt (97).
3 Bolt:
11.8 – 14.7 Nm {1.2 – 1.5 kgm}
a Increase or decrease the number of

right and left shims to adjust back-
lash. Do not change the total thick-
ness of both shims so that the pre-
2) Install shims and bevel pinion assembly load will not change. (If the thickness
(95) with a guide bolt. of the shim on one side is increased,
a Install shims of the thickness and equally decrease the thickness of the
quantity recorded when removed. other side, and vice versa.)
q Standard shim thickness: 2 mm 1] When backlash is insufficient
q Type of shim thickness: Decrease the thickness of the shim
0.2, 0.3, and 1.0 mm on the right side of the machine body
and equally increase the thickness on
the left side.
(Move the bevel gear in the direction
(A).)
2] When backlash is too large
Decrease the thickness of the shim
on the left side of the machine body
and equally increase the thickness on
the right side. (Move the bevel gear in
the direction (B))
3. Adjusting backlash and tooth contact

1) Adjusting backlash
Apply the probe of dial gauge [13] to the
tooth tip at the end of the bevel gear at
right angles. Fix the bevel pinion and
move the bevel gear forward and back-
ward, and read the value at this time.
a Backlash standard value:
0.18 – 0.23 mm
a Measure the backlash diagonally at 3
or more places.
q If the measured backlash is out of the
standard range, adjust it using he fol-
lowing procedure.
16 D61EX, PX-15E0
2) Adjusting tooth contact Adjusting

Inspection If the tooth contact pattern is not proper, adjust the
1] Apply red lead thinly to the tooth sur- tooth contact using the following procedure.
faces of the bevel gear and turn the 1] If the bevel pinion is too far from the center line
bevel gear in the forward and reverse of the bevel gear, the contact is at the small end
directions, then check the tooth con- of the bevel gear tooth faces curved outward
tact pattern on the bevel gear. and at the large end of the bevel gear tooth
2] The tooth contact must be as follows: faces curved inward.
(The standard distance is measured q In this case, adjust the tooth contact using the
from the tooth tip of the bevel pinion.) following procedure.
(a): Center of tooth contact: 20 – Adjust the thickness of the shims on the bevel
40% of face width (from the small pinion side to move the bevel pinion in the
end) direction (A).
(b): Width of tooth contact: 30 – 50% Move the bevel gear in the direction (B), then
of the face width check the tooth contact pattern and backlash
(c): Center of tooth contact: 35 – again.
65% of tooth depth
(d): Width of tooth contact: 60 – 80%
of tooth depth
Check that tooth tip (A), bottom
(B), small end (C), and large end
(D) of the teeth are not subject to
any strong tooth contact.
a If the bevel gear and bevel pinion
are adjusted in this way, their
teeth come in contact with each
other correctly when they are
loaded.
2] If the bevel pinion is too close to the center line

of the bevel gear, contact is at the large end of
the bevel gear tooth faces curved outward and
the small end of the bevel gear tooth faces
curved inward.
q In this case, adjust the tooth contact using the
Adjust the thickness of the shims on the bevel
pinion side to move the bevel pinion in the
direction (A).
Move the bevel gear in the direction (B), then
check the tooth contact pattern and backlash
again.
a Do not change the total thickness of the shims
on both sides.
3] When adjustment is finished, tighten the
mounting bolts of the cage and bevel pinion
assembly to the specified torque.
3 Mounting bolts of cage and bevel pinion
assembly:
98 – 123 Nm {10 – 12.5 kgm)
D61EX, PX-15E0 17
5. Assembly of carrier assembly

a Check roll pin (73) hole for sharp fin.
Remove the sharp fin with a paper if any.
1) Install bushing (78) to carrier assembly
(69).
2) Install bearing (77) to gear (75). Fit thrust
washers (76) to the top and bottom of the
bearing, then set them to the carrier.
3) Install shaft (74), aligning the inside of the
thrust washers and bearing with the shaft
hole of the carrier.
a Align the roll pin hole accurately.
4) Install roll pin (73).
After installation, caulk 3 spots around the
4. Sun gear roll pin hole.
1) Install snap ring (85) to the shaft.
a Perform this work only for the right
2) Install collar (84).
3) Install bearing (83) with a push tool.
5) Set cage (70) in ring gear (72) and install

snap ring (71).
6) Reverse cage assembly (70) to install it to
hub (66).
4) Install sun gear (81).

5) Install bearing (82) with the push tool.
a Press fit the inner race and outer race
simultaneously.
6) Install collar (80) and snap ring (79).
18 D61EX, PX-15E0
7) Install carrier assembly (69) in hub (66) 7) Install disc (60), spring (59), and plate (61)
and install bolts (68). in this order to drum (62).
3 Mounting bolt: q Spring (59) and disc (60): 5 pieces
59 – 74 Nm {6.0 – 7.5 kgm} q Plate (61): 4 pieces
6. Assembly of brake assembly 8) Install spring (58) to cover (52).

1) Fit bushing (67) in hub (65).
9) Install piston seal rings (56) and (57) to

2) Reverse hub (66). cage (54).
3) Install hub (65) to hub (66) and tighten 18 a Install the seal rings evenly, being
mounting bolts. careful to the pressure receiving side.
3 Mounting bolt: 2 Seal ring: G2-LI grease
59 – 74 Nm {6.0 – 7.5 kgm}
4) Install bearing (64).
6) Set brake drum (62) in hub (66).
D61EX, PX-15E0 19
10) Fit O-ring (130) in cage (54). 16) Install bearing (53).
11) Install piston (55). 17) Install spacer (51) and attach snap ring
a Check that the spring is fitted in both (50).
piston and case. 18) Install flange (49).
12) Align O-ring (130) with oil hole (E) and
install cage (54).
13) Temporarily fix cage (54) with the bolt (D)
from underneath.
14) Lift and install cover assembly (52).
a Align the cover with the 4 oil holes (F)
on the drum. ((FF) is an oil path.)
15) Set tool [8], tighten cover (52), and install
4 hexagon socket head bolts (131).
7. Installation of brake and carrier assembly

1) Install brake carrier assembly (48) weigh-
ing 150 kg to the guide bolt by balancing,
using pipe [4] (with a bar inside) and guide
bolt [6].
a Align the assembly with 4 oil holes
(FF).
k Check that the bar is deep inside
and take care not to drop brake
assembly (48) weighing 150 kg.
2) Using block [15] and jack [16], install
brake carrier assembly (48).
20 D61EX, PX-15E0
8. Assembly of cover assembly 2) Intermediate gear assembly

1) Left carrier drive gear 1] Install bearings (42) and spacer (42a)
1] Press fit bearing (47) to shaft (43). to gear (39).
2] Press fit bearing (45) to cover (A), 2] Align ball (41) and press fit shaft (40)
then install snap ring (44). to the bearing inner race side of gear
3] Press fit outer race (46) to cover (B). (39).
3] Install ball (41) during the press fitting
of the shaft and install shaft (40) and
gear (39).
4] Using puller [18], press fit shaft (43)

to the inner race side of bearing (45).
a Replace the bolt with one having
different length. 4] Install gear (37).
5] Install holder (36) and tighten bolt
(35).
3 Mounting bolt:
98 – 123 Nm {10 – 12.5 kgm}
6] Install holder (38).
3 Mounting bolt:
98 – 123 Nm {10 – 12.5 kgm}
D61EX, PX-15E0 21
3) Install the valve and spring in the cover, 9. Installation of cover assembly
then install plug (34). 1) Install 2 sleeves (25) and 5 sleeves (24)
on the HSS case.
2) Be sure to remove the dowel pin (marked
with an asterisk ) from the cover (23)
and case.
k Be sure to check that no dowel pin
is installed, because it can damage
sleeves (24) and (25) and cut O-
ring.
4) Input gear assembly

1] Install bearings (33) to gear (30).
2] Install gear assembly (30).
3] Install cage (31) and ball (32), align-
ing them with ball (32) hole.
4] Install snap ring (29).
q Apply gasket sealant to the cover mounting

face using the following procedure.
a The mating faces of the case and cover must
be free of dent, rust, oil and grease, and water.
a Seamlessly apply gasket sealant to both sides
of the mating faces of the case and cover in
the following manner.
2 The cover mating face on the HSS:
5) Install tubes (27) and (28) and oil temper-

ature sensor (26).
22 D61EX, PX-15E0
3) Install cover assembly (23) horizontally, 6) Install brake valve assembly (22).
being careful with the tube, sleeves, etc. 3 Mounting bolt:
(indicated by mark (a)) 44.1 – 53.9 Nm {4.5 – 5.5 kgm}
k Check that sleeves (24) and (25) 7) Install connector (20) and cover (19).
are properly engaged with the mat- 8) Install clip (18).
ing parts. (They should not be
raised when cover assembly (23) is
placed. If the sleeves are raised,
swing cover assembly (23) back
and forth and around.) Damaged
sleeves (24) and (25) and O-ring
could cause serious damage
including defective lubrication of
power line.
q To install from then on, reverse the removal

procedure.
[*1]
a Adjust the parking brake lever. For details, see
Testing and adjusting, "Adjusting parking brake
lever".
[*2]
4) Install dowel pins (see an asterisk in 2)) a Adjust the brake pedal. For details, see Test-
in 4 places. ing and adjusting, "Adjusting brake pedal".
5) Install cover assembly (23).
3 Mounting bolt:
245 – 309 Nm {25.0 – 31.5 kgm}
a Since there are 5 different lengths of a
mounting bold, check positions by refer-
ring to the figure.
Bolt (A): 70 mm (1 bolt)
Bolt (B): 55 mm (14 bolts)
Bolt (C): 75 mm (3 bolts)
Bolt (D): 85 mm (2 bolts)
Bolt (E): 140 mm (1 bolt)
a Secure bracket (21) (see the diagram
below).
D61EX, PX-15E0 23
Removal and installation of final 8. Remove final drive assembly (3) slowly by pull-
drive assembly 1 ing it outward. [*2]
4 Final drive assembly: 800 kg (one side)
Removal
1. Remove the track shoe assembly. For details,
see "Expansion (normal), expansion (internal
abnormality) and installation of track shoe
assembly".
2. Using jacks, lift up machine body and support

front frame and HSS case on stands or blocks
[1] and [2], then lower equipment to ground.
k Set the stands securely.
Installation

removal.
[*1]
2 Guard mounting bolt:
3 Guard mounting bolt:
3. Drain oil from final drive case.
235 – 285 Nm {23.5 – 29.5 kgm}
4 Final drive: 28.5 l (one side)
[*2]
4. Remove guards (1) and (2). [*1] Since connection is made with a spline, align
engagement using transmission jack [5], plate [6],
lever block [7], bar [8], etc.
3 Final drive mounting bolt:
490 – 608 Nm {50 – 62 kgm}
5. Remove all mounting bolts of final drive

assembly, except 2 – 3 on top.
6. Sling final drive assembly (3) temporarily and

support the lower side on transmission jack [3]. q Refilling with oil (final drive case)
k Do not sling the final drive assembly by Add oil through the oil filler to the specified
its sprocket. If it is slung so, it will level. Run the engine to circulate the oil
rotate. through the system. Then, check the oil level
again.
7. Remove remaining mounting bolts, then dis-
5 Final drive case: Approx. 32 l (TO30)
connect final drive assembly from HSS case,
using forcing screws [4].
24 D61EX, PX-15E0
Disassembly and assembly of 2) Remove output shaft cover (3).

final drive assembly 1
Special tool
New/Remodel
Necessity
Symbol
Sketch
Q'ty
Part No. Part name
796-730-2300 Wrench t 1
1
795-630-1803 Torque wrench t 1
J 2 791T-427-1330 Guide t 1 Q
3 791-545-1510 Installer t 1
4 791T-427-1280 Push tool t 1 Q
3) Remove 3 bolts to remove plate (4).
a Check the thickness and quantity of
shim (5).
Disassembly
1. Sprocket assembly
1) Place final drive assembly (1) on block [1]
with the sprocket side up.
2) Remove mounting bolts and lift off
sprocket assembly (2).
4) Using plates [3] and [4], puller [5] and bolt

[6], push out output shaft assembly (6).
a The bearing is removed together with
the output shaft.
2. Output shaft
1) Sling final drive assembly (1) and turn it
over, then support it on jacks or blocks [2]
securely.
a Distance (a) between the output shaft
and ground must be at least 50 mm.
D61EX, PX-15E0 25
5) Using eyebolt [7], remove case assembly 3. No.2 gear

(7) from output shaft assembly (6). 1) Support case assembly (7) on blocks or
jacks [8] securely.
2) Remove floating seal (40).
a Store the floating seal so that its
metallic contact surfaces will not be
damaged.
3) Remove cover (12).
6) Disassemble output shaft assembly

1] Remove floating seal (8) from output
shaft (9).
a Store the floating seal so that its
metallic contact surfaces will not
be damaged. 4) Remove spacer (13).
2] Remove spacer (10).
3] Remove bearing (11).
5) Pull No.2 gear (14) out of case, then lift it

off.
26 D61EX, PX-15E0
4. No.2 pinion 4) Using plates [10] and [11], puller [12] and
1) Remove No.2 pinion cover (15). 3 bolts [13], push out and remove No.2
pinion and bearing assembly (20).
a The No. 2 pinion and bearing assem-
bly is removed together with the bear-
ing (on the HSS side) and outer race
(on the sprocket side).
2) Remove No.2 pinion cage and outer race

assembly (16) and shim (17).
a Use forcing screw [9] to remove these
assembly and shim.
a Check the thickness, quantity, and
location of the shim. 5) Remove gear cover (21).
6) Remove No.1 gear (22).
3) Remove outer race (18) from No.2 pinion

cage (19). 7) Disassemble No.2 pinion and bearing
assembly.
1] Remove bearing (23) from No.2 pin-
ion (24).
D61EX, PX-15E0 27
5. No.1 pinion cage 2) Remove bearings (31) and (32) from No.1
1) Remove No.1 pinion cage assembly (25) pinion (33).
and shims (26).
a Remove the assembly using forcing
screw [14].
a Check the thickness, quantity, and
positions of shims.
7. Outer race
1) Remove outer races (34) and (35) from
output shaft of case (36).
2) Remove outer races (37) from No.1 pinion
of case (36).
2) Remove oil seal (27) from No.1 pinion
cage (28).
3) Remove outer race (29).
8. Cover
1) Turn over case assembly and place it on
blocks [15].
6. No.1 pinion 2) Remove cover (38) from case (39).
1) Remove No.1 pinion and bearing assem-
bly (30).
28 D61EX, PX-15E0
Assembly
a Clean and dry all parts thoroughly, and check

them for dirt, dent. etc. Coat the sliding sur-
faces of all parts with power train oil (TO30)
before reinstalling them.
1. Cover
1) Place case (39) on blocks [15].
2) Fit the O-ring, then install cover (38) to
output shaft portion of case.
2 Mounting bolt:
3 Mounting bolt:
98 – 123 Nm {10 – 12.5 kgm} 3. No.1 pinion
1) Using push tool [15] and press, press fit
bearing (31) to No.1 pinion (33).
a Press fit bearing (32) with the same
way.
a Press fit bearing (32) following bear-
ing (31). If the bearings are press fit-
ted in reverse order, it may damage
roller cage (a) of bearing (32).
a To temporarily place the bearings with
bearing (32) side down, have table [P]
handy.
a After press fitting, check that there is
no clearance between the bearing
and No.1 pin (using a 0.03 mm-clear-
2. Outer race ance gauge).
1) Press fit outer race (37) until it touches
case (36).
a Install it on No.1 pinion shaft.
no clearance between the outer race
and the case (using a 0.03 mm-clear-
ance gauge).
a Apply power train oil (TO30) to the
rolling surfaces of the bearing.
2) Press fit outer races (34) and (35) until
they touch case (36).
a Install them on the output shaft.
and the case (using a 0.03 mm-clear-
ance gauge).
a Apply power train oil (TO30) to the
rolling surfaces of the bearing.
D61EX, PX-15E0 29
2) Install the No.1 pinion and bearing assem- 2) Using push tool [16], press fit oil seal (27).
bly (30) in the case. 2 Oil seal press fitting surface:
a Replace the oil seal with new one.
a Apply gasket sealant thinly to the No.
1 pinion cage side, and wipe off pro-
jected sealant.
2 Oil seal lip: Grease (G2-LI)
4. No.1 pinion cage

1) Press fit outer race (29) until it touches
No.1 pinion cage (28).
and the cage (using a 0.03 mm-clear-
ance gauge). 3) Insert shims (26) between No.1 pinion
a Apply power train oil (TO30) to the cage assembly (25) and case (36), then
rolling surfaces of the bearing. tighten 8 mounting bolts evenly.
a Set the thickness of shim (26) to
2.5mm.
a When installing the No. 1 pinion cage
assembly, take care not to damage
the oil seal lip with the No. 1 pinion
spline.
3 Mounting bolt:
98 – 123 Nm {10 – 12.5 kgm}
30 D61EX, PX-15E0
5. No.2 pinion
1) Using push tool [17] and press, press fit
bearing (on the sprocket side) (23) to No.2
pinion (24).
and No.2 pinion (using a 0.03 mm-
clearance gauge).
7) Using push tool [19], press fit outer race

(41) into case (36).
a Do not press fit outer race (41) completely,
but press fit only about 19 mm from end of
case. (Leave about 5 mm.)
2) Install No.1 gear positioning tool J2 to

case (36).
3) Reverse the case to set tool J2 side down.
4) Set No.1 gear (22) to tool J2.
5) Install gear cover (21).
2 Mounting bolt:
3 Mounting bolt:
98 – 123 Nm {10 – 12.5 kgm}
8) Fit the O-ring, then install No.2 pinion

cover (15).
3 Mounting bolt:
98 – 123 Nm {10 – 12.5 kgm}
a Press fit outer race (41) completely by
installing No. 2 pinion cover (to elimi-
nate the clearance between the outer
race and No.2 pinion cover).
6) Using eyebolt [18], sling and install No.2

pinion and bearing assembly (20) in No.1
gear.
D61EX, PX-15E0 31
9) Turn over case assembly to set No.1 pin- 13) Insert shims (17) between No.2 pinion
ion spline side up. cage and outer race assembly (16) and
10) Remove tool J2. the case, then tighten 10 mounting bolts
11) Heat bearing (42) with a bearing heater or evenly.
the like and install it to No.2 pinion (24) by a Install shims (17) as thick as 3.0mm.
shrink fit. 3 Mounting bolt:
a If the bearing is heated too much, its 98 – 123 Nm {10 – 12.5 kgm}
heat treatment hardness is lowered.
Accordingly, do not raise the bearing
temperature more than 120°C.
6. Floating seal
1) Turn over case assembly to set No. 1 pin-
ion spline down.
12) Press fit outer race (18) until it touches 2) Using tool J3, press fit floating seal (40)
No.2 pinion cage (19). into case (36).
a After press fitting, check that there is a Remove all oil and grease from the
no clearance between the outer race O-ring and O-ring contact surface,
and the cage (using a 0.03 mm-clear- and dry before installing.
ance gauge). a After installing the floating seal, check
a Apply engine oil to the rolling surfaces that its inclination is 1 mm or less.
of the bearing. a Check that the metallic contact sur-
faces of the floating seal are free from
dirt.
32 D61EX, PX-15E0
3) Using tool J3, press fit floating seal (8) to 8. Output shaft
output shaft (9). 1) Using tool J4, press fit bearing (11) onto
a For precautions when fitting the float- output shaft (9).
ing seal, see 2) above. a After press fitting, check that there is
and the output shaft (using a 0.03
mm-clearance gauge).
2) Install spacer (10) to output shaft.
7. No.2 gear
1) Turn over case assembly to set No.1 pin-
ion spline side up.
2) Sling No.2 gear (14) and install it to inside
of case. 3) Using eyebolt [7], sling and insert case
assembly (7) in output shaft assembly (6).
a Take care not to damage the outer
race of the bearing with the output
shaft.
a Check that the metallic contact sur-
faces of the floating seal are free from
damage, dirt, oil, and grease.
a Float case assembly (7) about 10 mm
so that the metallic contact surfaces
of the floating seal will not be dam-
aged.
3) Install cover (12) to case assembly (7).

2 Mating face of the cover:
2 Mounting bolt:
3 Mounting bolt:
455 – 565 Nm {46.5 – 58 kgm}
D61EX, PX-15E0 33
1] Heat bearing (43) with bearing heater, 2] Using tool J1, measure the rotation
etc. and fit it to output shaft assembly torque of No.1 pinion (30).
(6) by shrink fit. q Standard rotation torque:
a If the bearing is heated too much, 4 – 5 Nm {0.4 – 0.5 kgm}
its heat treatment hardness is a At this time, rotate the output
lowered. Accordingly, do not shaft at least one full turn.
raise the bearing temperature a When the rotation torque is out-
more than 120°C. side the standard value, further
a Insert the bearing while slowly tighten the bolts 1/6 turn accord-
lowering the case assembly. At ing to 1] above again.
this time, take care not to dam-
age the metallic contact surfaces
of the floating seal or not to
cause an inclination in the float-
ing seal.
3] Remove plate (4) and measure the

step height (d) between the top face
of output shaft assembly (6) and that
of bearing (43).
a Under this condition, check that
4) Select shim (5) for plate (4) according to the vertical play of the output
the following procedure. shaft on case assembly (7) is
a Perform the following procedure while 0.1 mm maximum
bearing is lubricated with a little
amount of oil and it is at the normal
temperature
1] Clamp shim (5) between plate (4) and
output shaft assembly (6) with 3
mounting bolts evenly.
a Install shims (5) as thick as
3.3mm.
a Tighten 3 mounting bolts evenly
by 1/6 turn
3 Mounting bolt:
588 – 1,030 Nm {60 – 105 kgm}
34 D61EX, PX-15E0
4] Select and insert shim (5) so that its 5) Fit the O-ring, then install output shaft
thickness will be level difference (d) cover (3).
measured above + 0 to 0.1 mm. 3 Mounting bolt:
q Standard shim thickness:1.9 mm 98 – 123 Nm {10 – 12.5 kgm}
0.2, 0.3, and 1.0 mm
5] Install plate (4).
3 Mounting bolt:
824 – 1,030 Nm {84 – 105 kgm}
9. Adjusting shims of No.2 pinion cage

assembly
1) Select shim (17) for No.2 pinion (19)
a Perform the following procedure while
(Reference): Clearance between cover (38) bearing is lubricated with a little
and output shaft assembly (6) amount of oil and it is at the normal
after adjustment of shim (5). temperature
Clearance (e) standard value: 1.8 – 3.3 mm 1] Clamp No. 2 pinion cage and outer
race assembly (16) with 4 mounting
bolts evenly.
a Do not insert any shim.
a Rotating No. 1 gear (22) 1 turn or
more, tighten the mounting bolts.
3 Mounting bolt:
15 Nm {1.5 kgm}
2] Measure clearance (c) between No.2
pinion cage, outer race assembly (16)
and case (36).
a Measure the clearance at 2 to 4
places and calculate the aver-
age.
D61EX, PX-15E0 35
3] Select and insert shims (17) so that 10. Adjusting shim of No.1 pinion cage assem-
their thickness will be average clear- bly
ance calculated in the above step + 1) Select shim (26) for No. 1 pinion cage
0.1 mm. assembly (25) according to the following
q Standard shim thickness:1.7 mm procedure.
q Type of shim thickness: a Perform the following procedure while
0.2, 0.3, and 1.0 mm bearing is lubricated with a little
4] Fit the O-ring, then tighten 10 mount- amount of power train oil (TO30) and
ing bolts of No.2 pinion cage and it is at the normal temperature
outer race assembly (16) evenly. 1] Clamp No. 1 pinion cage assembly
3 Mounting bolt: (25) with 4 mounting bolts evenly.
98 – 123 Nm {10 – 12.5 kgm} a Do not insert any shim.
a Rotate No.1 pinion 1 full turn or
more and tighten the mounting
bolts.
3 Mounting bolt:
15 Nm {1.5 kgm}
2] Measure clearance (b) between No.1
pinion cage assembly (25) and case
(36).
a Measure the clearance at 2 to 4
places and calculate the aver-
age.
2) Using tool J1, measure the rotation torque

of No.1 pinion (30).
q Standard rotation torque: Rotation
torque measured in step 8.-4) + 0 to 3
Nm {+ 0 to 0.3 kgm}
a If the rotation torque is out of the stan-
dard range, select shim according to
step 1) again.
3] Select and insert shims (26) so that

their thickness will be average clear-
ance calculated in the above step +
0.1 mm.
q Standard shim thickness:1.52 mm
0.2, 0.3, and 1.0 mm
36 D61EX, PX-15E0
4] Fit the O-ring, then tighten 8 mounting 11. Sprocket assembly

bolts of No.1 pinion cage assembly 1) Turn over case assembly to set No.1 pin-
(25) evenly. ion spline down.
3 Mounting bolt: 2) Sling and install sprocket assembly (2).
98 – 123 Nm {10 – 12.5 kgm} 3 Mounting bolt:
1,010 – 1,157 Nm {103 – 118 kgm}
2) Using tool J1, measure the rotation torque

of No.1 pinion (30).
q Standard rotation torque: Rotation
torque measured in step 9.-2) + 0 to 5
Nm {+ 0 to 0.5 kgm}
a If the rotation torque is outside the
standard value, select shims again as
in step 1) above.
D61EX, PX-15E0 37
SEN02573-00

© 2007 KOMATSU
All Rights Reserved
38
SEN02574-00
D61EX-15E0
D61PX-15E0


Undercarriage and frame, Part 1
Removal and installation of track frame assembly.......................................................................................... 2
Removal and installation of idler assembly ..................................................................................................... 4
Disassembly and assembly of idler assembly ................................................................................................ 5
Removal and installation of recoil spring assembly ........................................................................................ 9
Disassembly and assembly of recoil spring assembly .................................................................................. 10
Removal and installation of track roller assembly ......................................................................................... 13
Disassembly and assembly of track roller assembly .................................................................................... 14
Removal and installation of carrier roller assembly ...................................................................................... 17
Disassembly and assembly of carrier roller assembly .................................................................................. 18
D61EX, PX-15E0 1
Removal and installation of track 7. Remove pivot shaft cover (4). [*2]
frame assembly 1
Removal
1. Expand the track shoe assembly. For details,

see "Expansion (normal), expansion (internal
assembly."
2. Using jacks, lift up machine body and support

front frame and HSS case on stands or blocks
[1] and [2], then lower equipment to ground.
k Set the stands securely.
8. Remove plate (5). [*3]
3. Support track shoe on opposite side of track

frame to be removed on blocks, etc.
k If the equalizer bar side pin is removed, 9. Sling track frame assembly (6), pull it out to the
the track frame on the opposite side outside of the machine until it comes off the
falls. Accordingly, support the track pivot shaft and remove it. [*4]
shoe on the opposite side securely. a Since oil flows out of the pivot chamber,
place an oil receiver under the pivot shaft.
4. Remove cover (1) from equalizer bar (A).
4 Track frame assembly:
5. Remove grease tube (2). 1,350 kg (D61EX)
a Remove elbow, also. 1,500 kg (D61PX)
6 Pivot chamber: 3.5 l
6. Sling track frame assembly with 2 carrier roll-
ers temporarily, then remove lock plate and
side pin (3). [*1]
2 D61EX, PX-15E0
Installation

removal.
[*1]
2 Between seal and bushing:
Charge with grease (G2-LI)
[*2][*3]
3 Pivot shaft cover and plate mounting bolt:
245 – 309 Nm (25 – 31.5 kgm)
[*4]
a Apply oil (TO30) to face (a) of the track frame
which will be in contact with the pivot shaft oil
seal.
a Remove oil filler plug (7) and supply oil to the

pivot chamber until distance (b) between the
oil filler plug hole becomes 120 mm, then
tighten the oil filler plug.
5 Pivot: 3.5 l (TO30)
D61EX, PX-15E0 3
Removal and installation of idler Installation

assembly 1
Removal removal.
1. Expand the track shoe assembly. For details, [*1]

see "Expansion (normal), expansion (internal 3 Lubricator: 58.8 – 88.2 Nm {6 – 9 kgm}
assembly." [*2]
2 Support mounting bolt:
2. Detach lock plate (1), then remove lubricator Liquid adhesive (LT-2)
(2). [*1} 3 Support mounting bolt:
235 – 285 Nm {23.5 – 29.5 kgm}
k Negative pressure is applied inside the
recoil spring. Accordingly, if the lubri-
cator is not removed, the yoke is pulled
back toward the cylinder when the idler
mounting bolts are removed.
k Never stand in front of the idler yoke to
avoid danger.
3. Raise the idler assembly and pull it out, then

remove mounting bolts (5) of support (3) and
yoke (4). [*2]
4. Lift off idler assembly (6).

4 Idler assembly: 190 kg (one side)
4 D61EX, PX-15E0
Disassembly and assembly of 2) Sling idler (5) and pull it out of shaft and
idler assembly 1 support assembly (8).
a Prevent the sling wires [2] from open-
Special tool ing with wires or ropes. (Part A)
3) Remove floating seals (9) and (10) from
New/Remodel
idler (5).
Symbol
Necessity
Part No. Part name
Sketch
Q'ty
1 791-515-1520 Installer t 1
L
2 791-601-1000 Oil pump q 1
Disassembly
1. Support
1) Remove guide (1) and shims (2).
a Check the thickness and quantity of
shims.
2) Remove nut (3) and drive out bolt (4) from
the nut side.
4) Remove floating seal (11) from the shaft

3) Using push puller [1], pull support (6) out and support assembly.
of idler (5).
3. Shaft
2. Floating seal 1) Remove nut (12) and drive out bolt (13)
1) Remove floating seal (7) from support (6). from the nut side.
2) Similarly to step 1.-3), using the push
puller, pull shaft (15) out of support (14)
D61EX, PX-15E0 5
4. Remove 2 bushings (16) from idler (5). 3) Using tool L1, install floating seal (11) to
shaft and support assembly (8), then
assemble O-ring to shaft.
a When assembling the floating seal,
clean the thick line portion (O-ring
and O-ring contact surface), remove
all oil and grease, and dry it.
a After fitting the floating seal, check
that its inclination is 1 mm maximum.
that its projection (a) is 7 – 11 mm.
Assembly
1. Using push tool [2], press fit piston (16) to idler

(5).
2. Idler
1) Fit the O-ring to shaft (15) and install them
to support (14).
a When installing the shaft, match it to
the groove of the support.
2) Drive in bolt (13) and tighten nut (12).
3 Nut:
230.4 – 308.9 Nm {23.5 – 31.5 kgm}
6 D61EX, PX-15E0
4) Using tool L1, install floating seals (10) 6) Using tool L1, install floating seals (9) into
into idler (5). idler (5).
a When assembling the floating seal, a When assembling the floating seal,
clean the thick line portion (O-ring clean the thick line portion (O-ring
and O-ring contact surface), remove and O-ring contact surface), remove
all oil and grease, and dry it. all oil and grease, and dry it. See the
a After installing the floating seals, figure below.
check that their slant is less than 1 a After installing the floating seals,
mm and their projection (a) is 7 – 11 check that their slant is less than 1
mm. (See 3) in the above section.) mm and their projection (a) is 7 – 11
mm. See the figure below.
5) Sling and install idler (3) to shaft and sup-

port assembly (6). 3. Refilling with oil
a Prevent sling wires [2] from opening Fill the idler with oil.
5
with wires or ropes. (Part A)
Idler: 220 cc {TO30}
4. Support
1) Using tool L1, install floating seals (7) to
support (6).
that its inclination is 1 mm maximum.
that its projection (a) is 7 – 11 mm.
D61EX, PX-15E0 7
5. Charge the idler assembly with oil.

1) For the standard method of oil feeding:
1] Remove plug (17) from the shaft and
fill the assembly with the specified
level of oil through oil filler port.
5 Idler: 220 cc {TO30}
2] After oil feeding, install plug (17) onto
the shaft.
2) Install support (6) to idler (5) with bolt (4)

and nut (3).
3 Nut:
230.4 – 308.9 Nm {23.5 – 31.5 kgm}
3) Install guide (1) with shims (2) inserted.
q Standard shim thickness: 4 mm
q Per sheet thickness of shim: 1 mm
2) For the method of evacuating the sys-

tem before feeding oil:
1] Remove plug (17) from the shaft.
2] Using tool L2, tighten plug (17) after
filling the idler assembly with oil.
5 Idler: 220 cc {TO30}
8 D61EX, PX-15E0
Removal and installation of recoil Installation

spring assembly 1
Removal removal.
1. Remove the idler assembly. For details, see [*1]

"Removal and installation of idler assembly." a After inserting recoil spring assembly (1),
slightly raise it on the lubricator side and push
2. Lift off recoil spring assembly (1). [*1] in the idler until the recoil spring is housed fully.
a Take care not to damage the grease fit-
ting.
4 Recoil spring assembly: 350 kg (one
side)
D61EX, PX-15E0 9
Disassembly and assembly of 3) Using push tool [1], remove piston (10)
recoil spring assembly 1 from yoke (9) with press.
Special tool
New/Remodel
Symbol
Necessity
Part No. Part name
Sketch
Q'ty
791-685-8006 Compressor (B) t 1
790-201-2770 Spacer t 1
791-635-3160 Extension t 1
M
Cylinder
790-101-1600 (686 kN {70 tons}) t 1
790-101-1102 Pump t 1
3. Seal
2) Remove spacer (12) and seal (13).
Disassembly
1. Yoke and piston assembly

Remove yoke and piston assembly (2) from
recoil spring assembly (1).
4. Cylinder
1) Set recoil spring assembly (1) to tool M.
k The spring is under a high installed
load, so be careful to set it cor-
rectly.
2. Disassembly of yoke and piston assembly a Installed load of spring:
1) Remove snap ring (3), then remove pack- 163.6 kN {16,692 kg}
ing (4) and rings (5).
2) Remove bolt (6), then remove lockplate
(7) and washer (8).
10 D61EX, PX-15E0
2) Apply hydraulic pressure slowly to com- Assembly

press the spring and tighten nut (14) until
spacer (15) comes out. 1. Cylinder
3) Then remove spacer (15), nut (14), and 1) Press fit bushing (19) into cylinder (17).
pilot (16). 2 Bushing: Grease (G2-LI)
2) Temporarily assemble spring (18) and cyl-
inder (17), then set to tool M.
k The spring is under a high installed
load, so be careful to set it cor-
rectly.
3) Apply hydraulic pressure slowly to com-
press the spring and set it so that the
installed length of the spring is the stan-
dard value.
a When compressing the spring, be
careful not to damage the thread. Use
lever block [2] and carry out centering
while compressing the spring.
a Installed length of spring: 593 mm
4) Gradually release hydraulic pressure to a Installed load of spring:
remove tension of spring. 163.6 kN {16,692 kg}
5) Remove spring (18) from cylinder (17).
6) Remove bushing (19) from cylinder (17).
D61EX, PX-15E0 11
4) Install pilot (16), then install nut (14) and 2) Assemble washer (8) and plate (7), and
spacer (15). tighten bolt (6).
5) Gradually release hydraulic pressure to a Bend the plate securely.
completely loosen spring tension, then 3) Fit rings (5) and packing (4) and then
remove recoil spring assembly (1) from install snap ring (3).
tool M.
4. Assemble yoke and piston assembly (2) to

2. Seal recoil spring assembly (1).
1) Install seal (13).
2 Seal lip: Grease (G2-LI)
2) Install spacer (12) and snap ring (11).
2 Spacer: Grease (G2-LI)
3. Assembly of yoke and piston assembly

1) Using push tool [1], press fit piston (10) to
yoke (9).
12 D61EX, PX-15E0
Removal and installation of track 5. Remove track roller assembly (5). [*3]
roller assembly 1 4 Track roller assembly:
45 kg (1 piece of single flange type)
Removal 52 kg (1 piece of double flange type)
1. Remove top cover of track frame, and loosen

lubricator (1), then loosen "track shoe tension".
[*1]
k Do not loosen lubricator (1) more than
1 turn.
a If the track shoe assembly is not loosened
after the lubricator is loosened, move the
machine forward and in reverse.
Installation

removal.
[*1]
a Referring to the "Operation and maintenance
manual", adjust the "track shoe tension".
2. Remove mounting bolts from guard (2) and
track roller guard (3). [*2] [*2]
2 Guard (2) and (3) mounting bolt:
3. Remove track roller mounting bolts (4). Liquid adhesive (LT-2)
3 Guard (2) and (3) mounting bolt:
235 – 285 Nm {23.5 – 29.5 kgm}
[*3]
2 Track roller mounting bolt:
3 Track roller mounting bolt:
235 – 285 Nm {23.5 – 29.5 kgm}
a Install so that the oil plug is on the outside of
the chassis.
4. Start the engine and operate the blade and the

ripper or hydraulic jack to jack up the machine.
k After jacking up the machine, set
blocks on top of the track shoe and
lock the work equipment control levers
and brake lock lever.
D61EX, PX-15E0 13
Disassembly and assembly of 6. Sling roller (7) and pull it out of shaft assembly
track roller assembly 1 (8).
Special tool 7. Remove floating seal (9) from roller (7).
New/Remodel
Symbol
Necessity
Part No. Part name
Sketch
Q'ty
L 3 791-651-1520 Installer t 1
Disassembly
1. Remove plug (2) from roller assembly (1) and

drain oil.
6 Track roller: 250 cc (GO140) 8. Remove floating seal (10) from shaft assembly
(8).
2. Set track roller assembly (1) on block [1].
9. Remove lock pin (11), then remove collar (13)
3. Using push puller [2], push in collar (3), and from shaft (12).
then remove lock (4) and collar (3).
10. Remove floating seal (14) from collar (13).

4. Remove floating seal (5) from collar (3).
11. Remove bushing (15) from roller (7), then turn
5. Remove floating seal (6) from track roller it over, and remove bushing (16).
assembly (1).
14 D61EX, PX-15E0
Assembly 3. Fit the O-ring to shaft (12), then install collar

(13) and lock pin (11).
1. Using push tool [3], press fit bushings (16) and
(15) into roller (7). 4. Using tool L3, install floating seal (10) to shaft
assembly (8).
a When assembling the floating seal, clean
the thick line portion (O-ring and O-ring
contact surface), remove all oil and
grease, and dry it. (See 2. in the above
section.)
a After installing the floating seals, check
that their slant is less than 1 mm and their
projection (a) is 7 to 11 mm. (See 2. in the
above section.)
2. Using tool L3, install floating seal (14) to collar

(13).
grease, and dry it.
a Check that its inclination is 1 mm maxi-
mum.
a After fitting the floating seal, check that its
projection (a) is 7 to 11 mm.
(7).
section.)
above section.)
D61EX, PX-15E0 15
6. Sling roller (7) and install shaft assembly (8).
9. Fill the roller with oil.

5
7. Using tool L3, install floating seal (6).
Track roller: 250 cc (GO140)
contact surface), remove all oil and 10. Fit the O-ring to the shaft and install collar (3).
section.) 11. Using push puller [2], push in collar (3) and
a After installing the floating seals, check install lock (4).
above section.)
12. Check the oil level and tighten plug (2) to roller
assembly (1).
3 Plug: 98 – 137.2 Nm {10 – 14 kgm}
(3).
section.)
above section.)
16 D61EX, PX-15E0
Removal and installation of 3. Remove mounting bolt (2).

carrier roller assembly 1
4. Sling carrier roller assembly (3) and pull and
Removal remove it out of support (4). [*2]
4 Carrier roller assembly: 25 kg (1 piece)
1. Remove top cover of track frame, and loosen
lubricator (1), then loosen "track shoe tension".
[*1]
1 turn.
Installation

removal.
[*1]
2. Using hydraulic jack [1], raise the track shoe. a Referring to the "Operation and maintenance
manual", adjust the "track shoe tension".
[*2]
a Set 3 mm for the clearance (a) between the
carrier roller and the support when installing.
D61EX, PX-15E0 17
Disassembly and assembly of 7. Disassemble the shaft assembly according to

carrier roller assembly 1 the following procedure.
1) Remove collar (8) from shaft assembly
Special tool (6).
2) Remove floating seal (9).
New/Remodel
3) Remove floating seal (10) from collar (8).
Symbol
Necessity
Part No. Part name
Sketch
Q'ty
L 4 796-230-1110 Installer t 1
Disassembly
1. Remove plug (1) and drain oil

6 Carrier roller: 215 cc (GO140)
2. Remove snap ring (2) and cover (3).

4) Remove bearing (12) from shaft (11).
3. Remove bolt (4) and spacer (5).
8. Remove outer race (14) from roller (13), then
turn it over and remove outer race (15).
4. Set the carrier roller on block [1].
5. Using push tool [2] and a press, pull out shaft

assembly (6).
6. Remove bearing (7).
18 D61EX, PX-15E0
Assembly
1. Press fit outer races (15) and (14) to roller (13).
2. Disassemble the shaft assembly according to

1) Using push tool [3], press fit collar (8) to
shaft (11).
3. Set shaft assembly (6) to block [5] and install

roller (13).
4. Using push tool [6], install bearing (7) and

press fit it.
a Rotate the roller when press fitting the
bearing, and press fit until the rotation of
the roller starts to become heavy.
2) Using tool L4, install floating seal (10).
3) Install floating seal (9) and using push tool
[4], press fit bearing (12).
a Check that its inclination is 1 mm
maximum.
that its projection (a) is 7 to 11 mm.
D61EX, PX-15E0 19
5. Install spacer (5) with bolts (4).

3 Bolt: 245 – 309 Nm {25 – 31.5 kgm}
6. Supply oil to the carrier roller.

5 Carrier roller: 215 cc (GO140)
7. Fit the O-ring to cover (3) and install them to

the roller, and then install snap ring (2).
8. Check the oil level and tighten plug (1).
20 D61EX, PX-15E0
D61EX, PX-15E0 21
SEN02574-00

© 2007 KOMATSU
All Rights Reserved
22
SEN02575-00
D61EX-15E0
D61PX-15E0


Undercarriage and frame, Part 2
Check before expanding track shoe assembly ............................................................................................... 2
Expansion (normal), expansion (internal abnormality) and installation of track shoe assembly ..................... 2
Overall disassembly and overall assembly of track shoe assembly ............................................................... 4
Link press-fitting jig dimensions table ........................................................................................................... 20
Field disassembly and assembly of one link................................................................................................. 23
Removal and installation of pivot shaft assembly ......................................................................................... 30
Removal and installation of equalizer bar assembly ..................................................................................... 32
Removal and installation of equalizer bar side bushing ................................................................................ 33
Removal and installation of segment teeth ................................................................................................... 34
D61EX, PX-15E0 1
Check before expanding track Expansion (normal), expansion

shoe assembly 1 (internal abnormality) and
k Since it may be very dangerous to expand installation of track shoe
the track shoe assembly, check the follow- assembly 1
ing items in advance.
Expansion (normal)
q Check before starting
1. Loosen lubricator (1) at the adjustment cylin- a If any abnormality is not detected by "Check
der, remove the grease, move the machine before expanding track shoe assembly", per-
backwards and forwards a short distance, and form the following procedure.
check that the track tension is relieved. If the
track tension is not relieved and the track shoe 1. Set the master link position.
assembly remains tense, there may be an a Set the block (300 mm high) or hydraulic
abnormality inside the track frame (recoil jack [1] so as to position the master link at
spring cylinder (2) is broken, or nut (3) at the about 500 mm from the ground on the
end of shaft has fallen off). front side.
k Do not loosen the lubricator more than
one turn. 2. Loosen the track shoe. [*1]
one turn.
3. Remove mounting bolts of track shoe (4) and

master link (5). [*2]
4. Raise the tip of the master link, move the

machine slowly in reverse, and lay out track
shoe assembly (4).
2 D61EX, PX-15E0
Expand (When track frame has internal

trouble)
a If any abnormality is detected by "Check

before expanding track shoe assembly", per-
form the following procedure.
k If there is any abnormality inside the track

frame, there is danger that the track shoe
assembly may spring back when it is
removed or that the idler may spring out
when the track shoe assembly is removed.
This may lead to serious injury, so remove
the track shoe assembly as follows.
k If there is any interference or abnormal
catching around the idler assembly, exam- Installation
ine carefully and remove the problem
before starting. q Carry out installation in the reverse order to
removal.
1. Loosen lubricator (1) of the adjustment cylin-
der, then move machine backwards and for- [*1]
wards to release grease. [*1] a Referring to the "Operation and maintenance
k Do not loosen the lubricator more than manual", adjust the tack shoe tension.
one turn.
a Check that the all grease has been [*2]
removed. a Tighten the shoe bolts in the order of [1] – [4].
2 Shoe bolt:
Lubricant containing molybdenum
disulfide (LM-P)
3 Shoe bolt (Master link):
Initial torque: 343 ± 39 Nm (35 ± 4 kgm}
Tightening angle:180 +0°
-20
2. Move the machine slowly forward against large

block [1] or a wall (or the blade of another
machine of the similar size of the machine to
be repaired, if available) to press the track
shoe on the idler side. When the recoil spring
and track shoe are slacken, stop and apply the
brake. When doing this, set so that master link
is between idler and front carrier roller. For
safety reason, fit a lever block between carrier
roller support and link to prevent the shoe from
springing.
q Remove track shoe (4) and disconnect
master link (5). [*2]
k Be extremely careful to ensure safety
when disconnecting the track shoe.
q Move the machine slowly in reverse, and
lay out track shoe assembly.
D61EX, PX-15E0 3
Overall disassembly and overall 3. Sling the shoe assembly and set it with the
assembly of track shoe shoe up on the floor and remove the shoe of
regular link by using an impact wrench.
assembly 1 a When moving the shoe assembly, take
Special tools care not to damage the master link.
a If it is obliged to cut a shoe nut with gas
New/Remodel
cutter, keep the seal temperature below
Necessity
80°C to prevent thermal deterioration of
Symbol
Sketch
Q'ty
Part No. Part name the seal and take measures to prevent the
spatters from entering through the clear-
ances among the links.
1 791-646-7531 Remover t 1
2 791-660-7460 Pin brush t 1
R 3 791-432-1110 Plug push tool t 1
4 791-932-1110 Plug push tool t 1
5 790-701-3000 Seal checker t 1
Overall disassembly
a This section describes only the procedure

for the lubricated track.
1. Set the shoe assembly on a flat floor with the

shoe facing up and remove the shoe bolt at the 4. Oil drain
master link and remove the shoe. Before disassembling the link assembly, drain
a Do not use an impact wrench when loos- the oil from inside the pin and take precautions
ening the master link bolt. so that the link press does not become dirty
with oil.
a Before disassembling, if it is judged that it
is necessary to rebuild the tack as a dry
type track, the following work need not be
carried out.
1) Set the link assembly on a flat floor with
the large plug side facing up, then cham-
fer the burrs on the end face of the pin
with a grinder.
a If the shoe is disassembled with burrs
still at the end face of the pin, the pin
press-fitting hole of the link will be
scratched, and this will cause leakage
from the pin press-fitting portion after
2. Because of the weight of the track assembly, if rebuilding.
the 1/2 assembly is too large and there are
problems with disassembly and assembly
work, divide into 1/4 assemblies.
4 D61EX, PX-15E0
2) Using a drill (ø10 mm), make a hole in the

large plug, then remove the large plug.
a If any dirt or deteriorated oil is stuck to
the pin hole, drill through with a
longer drill to remove it. When doing
this, be careful not to damage the oil
hole of the pin.
5. Disassembly of link
1) Set the link assembly on a link press and
hit it with a hammer so that the bushing
will be fitted to jaw [1].
a If the link tread, outside diameter of
the bushing, etc. are worn, adjust the
height of jaw [1] or guide plate and
3) After removing the large plug, use a baby align the left and right disassembly jig
grinder (angle of grinder tip: 45 – 60°), and [2], [3] with the pin and bushing cen-
chamfer the pin hole so that the plug is not ter so that the link hole will not be
damaged when the plug is knocked in. damaged during disassembly work.
a If the pin and bushing are not aligned
well, the link hole may be damaged
and the pin and bushing may be bro-
ken during disassembly work.
4) Turn over the link assembly so that the

small plug side is facing up, remove the
burrs at the end face of the pin with a
grinder, then use tool R1 to knock the
small plug to the inside.
a If the small plug hole is blocked with
burrs, grind with a grinder until the
hole can be seen completely.
5) Using a drill (ø10 mm), chamfer the small
plug hole.
6) Blow with compressed air to remove the
oil inside the pin and the metal particles
produced when removing the burrs, then
wash the link assembly with high-pressure
water or steam.
D61EX, PX-15E0 5
2) Operate the left cylinder to pull out the pin 4) Return the right cylinder and take out the
and bushing press-fitting portion from the links, pins, bushings, and spacers on both
left link simultaneously. sides and feed the next 1 set of the link
a Check the pulling out force of the pin assembly to the jaw.
and bushing to see if the necessary a To decide if the seal can be used
press fitting force for the pin and again, carry out inspection with the
b u s h i n g c a n b e o b ta i n e d w h e n seal installed to the link. So do not
reversed and assembled again. remove the seal from the link.
a Do not push the disassembly jig a If oil is remaining, this can be used as
inside more than necessary as the a guideline for reuse of the seal, so
spacer may break. mark such links or seals.
a If the bushing ends and sealing sur-
faces are damaged, oil will leak.
Accordingly, handle them carefully.
3) Return the left cylinder and operate the

right cylinder to pull out the pin and bush-
ing press-fitting portion from the right link
simultaneously. 6. Inspection
Check the parts for the following items to see if
they can be used for a lubricated track or a
grease-filled track, then examine them gener-
ally and determine to use them for a lubricated
track or grease-filled track.
a For judgment of reuse of the parts, see
Guidance for Reusable Parts, "Undercar-
riage, Lubricated Track".
1) Visually check damaged state of pin,
bushing, link and spacer. Check question-
able parts with color check or magnetic
flaw detector. Cracked parts are not reus-
able. Scrap them.
2) Visually check the external appearance of
the seal and the end face of the bushing to
determine if they can be used again.
a If only the bushing is replaced with a
new part, the worn or damaged part
of the seal lip will contact the end face
of the bushing directly, so it may not
be able to carry out its sealing func-
tion. For this reason, always replace
the seal together with the bushing, or
rebuild as a grease-filled track.
6 D61EX, PX-15E0
3) Using calipers, measure spacer thickness 5) Using a micrometer and cylinder gauge,
(a) and overall length (b) of the sliding por- measure the outside diameter of the pin
tion of the bushing and spacer. Check if it and bushing press-fitting portion, and the
is possible to obtain the specified seal inside diameter of the pin and bushing
mounting dimension when reassembling. press-fitting portion of the link to deter-
a If the amount of wear of the spacer mine if the allowable interference can be
and bushing is greater than the speci- obtained. However, when rebuilding as a
fied amount, the assembly precision lubricated track, check that the standard
of the seal portion cannot be guaran- interference for the pin and the link can be
teed, so replace with new parts or obtained.
rebuild as a grease-filled track. a If the allowable fitting interference is
not obtained, replace the parts with
new ones or over size parts.
a For details of the dimensions when
making judgment, see "Structure,
function and maintenance standard".
4) Using calipers, micrometer and cylinder

gauge, measure the outside diameter of
the pin and the inside diameter of the
bushing at the worn portion, and judge if
the parts can be used again.
a If the amount of wear is greater than
the specified amount, there will be
play during travel, and it will cause oil
leakage, so replace with new parts or
rebuild as a grease-filled track.
a For details of the dimensions when
making judgment, see "Structure,
function and maintenance standard".
D61EX, PX-15E0 7
a Precautions for storage 3] Mark on the end face at the small

plug end to show the direction of the
1) Store the seal without removing it from the link side hole (hole in the radial direction)
so that the counterbore portion will not be in the pin when assembling.
rusted and take care not to damage the seal a When reusing the pin, assemble
lip. in the same direction as when
2) Apply rust-preventive oil to the pin and bushing the part is new (side hole on the
fitting parts, shoe mating surface, and master link tread side).
link mating surface of the link.
3) When storing, apply rust-preventive oil to the
all surfaces of the pin, bushing, and spacer.
Take care not to damage the ends of the bush-
ing in particular.
Overall assembly
1. When reusing for lubricated track

1) Preparation work
1] Cleaning seal assembly
a W7 type seal
For seals to be reused, leave
them installed to the link, and do 4] If any link, pin, bushing and spacer
not wash them. are dirty, wash them. Use a grinder to
2] When reusing the pin, chamfer the remove any protruding parts stuck to
corner of the end face smooth with a the ring and bushing.
grinder. Use a grinder to remove any a Since these parts rust easily,
protruding parts stuck to the press fit- clean them just before assem-
ting portion. bling them.
a If the ends are worn and sharp- a Use tool R2 to wash the pin hole.
ened, they may scuff the press a Do not polish the bushing ends. If
fitting parts and cause oil leak- they are polished, oil may leak.
age.
8 D61EX, PX-15E0
5] Using tools R3, drive in large plugs

(3).
a Coat the outside circumference
of large plug (3) with oil (GO90)
and knock in the smaller diame-
ter part first.
1> Insert large plug (3) into the
gui de hol e th ro ugh the pl ug
insertion window.
2> Push the bar of tool R3 with the
hand until the large plug stops.
3> Push large plug (3) with the bar
of R3 and push the pin to the
guide itself.
4> Drive in the bar with a hammer. 7] Adjust the dimensions of the press fit-
a Driving distance (a) from pin ting jig of the link press to keep the
end: projection of the pin and bushing con-
6 ± 2 mm stant and keep the installed dimen-
a If the chamfered part of the sions of the seal within the standard
pin hole has been worn, range.
chamfer it with a small-sized a For details of the standard
grinder (grindstone tip angle: dimensions, see "Link press-fit-
45 – 60°) so that the plug will ting jig dimensions table".
not be damaged. a To leave a small space for the pin
when assembling, ensure that
the dimension (dimension (a')) is
greater than dimension (a) at the
pin pushing portion of the left
press-fitting jig.
When assembling in order of [1]
press fitting left link and [2] press
fitting right link, provide the extra
space for the pin on the right
press-fitting jig.
a If the pin end (part (P)) or link
sides (parts (Q) and (R)) are
worn, add the dimensions of the
worn parts to the standard
6] Installation of seal assembly dimension when adjusting the
q F5 type seal dimension of the press-fitting jig
When reusing the link and so that the projections of the left
replacing the seal with a new and right pins and bushings on
part, clean the link counterbore both sides will be even.
(section (A)) then push the seal
in fully to the bottom.
a If oil or grease is sticking to the
counterbore portion of the link
and seal assembly, the seal will
turn and its sealing performance
will lower. Accordingly, do not
apply any oil or grease to that
portion. In addition, be careful not
to let oil get into the counterbore
portion of the seal when pushing
in.
D61EX, PX-15E0 9
2) Assembly of link
1] Apply oil (GO90) to the mating sur-
faces of the pin and bushing with a
clean brush and assemble them, then
set them before the jaw of the link
press.
a When reusing (reversing) the
bushing, set the worn outside
surface of the bushing on the
shoe fitting side of the link (facing
upward on the link press).
8] Adjust the relief pressure of the link

press so that the pressing force of the
press will not exceed the standard
value.
a If the pressing force is too strong,
the spacer will be pressed forc-
ibly against the bushing. As a
result, the spacer may be broken
and it and bushing may be worn
abnormally.
)
2] Press fit the master links on both

bushing sides to the bushing with the
shoe fitting surface facing up.
a At this time, use the master links
on the pin side as supports.
a Press fitting force for bushing:
49 – 196 Nm {5 – 20 tons}
a If the interference at the press-fit-

ting portion is different from when
the part is new, as when reusing
a pin or bushing, measure sev-
eral of the press-fitting portions,
and determine the set pressing
force according to the average
interference.
a Pushing force for pin and bush-
ing: 588 kN {60 tons}
Pushing force C 1.8 × average
press-fitting force (Adjust the
relief pressure of the link press
and set the pushing force).
10 D61EX, PX-15E0
3] Using the shoe bolt hole pitch gauge,

press fit the master links until the dis-
tance between the shoe bolt holes of
both links is the standard value.
a Remove the all steel chips caused by
press fitting of the bushing with com-
pressed air.
7] To prevent oil from leaking out from

scuff marks on the pin press-fitting
portion, coat the pin press-fitting hole
in the link and the outside diameter of
the pin press-fitting portion with gas-
ket sealant (198-32-19890).
4] Turn over the master links and check

that they are press fitted in parallel.
5] Measure the projections of the bush-
ing on both sides with a depth gauge.
a Adjust the press fitting jig of the
link press so that the projections
on both sides will be even.
8] Set the right link and install the spacer

to the pin.
a Check that there is no dirt or dust
stuck to the surface of the seal or
the end face on the bushing, then
coat with oil (GO90) using a
clean cloth or small brush.
a When installing the spacer, wipe
6] Feed the master links and set the it with a clean cloth.
next pin and bushing.
a When reusing a pin, install it so
that the side hole will be on the
link tread side similarly to a new
one. If it is not installed as speci-
fied, its strength may be lowered.
Accordingly, indicate the direc-
tion of the side hole (i) on the end
face to prevent a mistake.
a Align the large plugs so that they
are on the left side facing the link
press when assembling.
D61EX, PX-15E0 11
9] Set the right jig on the receiving side 11] Set the right link and install the spacer
and the left one on the pushing side to the pin.
and press fit the pin and bushing a Apply oil similarly to the right link.
simultaneously.
a If the pin and bushing have play
when they are press fitted, the
seal may come off the link. To
prevent this, press fit smoothly.
If the seal comes off the link, stop
press fitting and set the seal to
the link correctly, then start press
fitting again.
a Press-fitting force for pin and
bushing:
196 – 392 kN {20 – 40 tons}
12] Set the left jig on the receiving side

and the right one on the pushing side
and press fit the left link.
a When press fitting, take care that
both seals and spacers will not
come off.
a Provide enough play on the left
jig so that the end face of the pin
does not contact with the bottom
of the jig.
a Press-fitting force for link:
196 – 392 kN {20 – 40 tons}
10] Using spacer [6] for fine adjustment,
press fit the pin and bushing until the
pin end is fitted to the bottom of the
receiving jig.
a Adjust the depth of the receiving
jig hole so that the projections of
the pin on both sides will be
even.
12 D61EX, PX-15E0
13] Press fit until the link, spacer, and 15] Using a shoe bolt hole pitch gauge,
bushing are fitted together. measure the distance between the
a Actually, you cannot see from shoe bolt holes and check that the
outside if the above parts are fit- result is within the standard range.
ted. Accordingly, control the a If the distance between the shoe
bolt holes is longer than the stan-
hydraulic pressure of the link
dard range, disassemble and
press. Set the relief pressure to a check for abnormality, then press
proper level and heighten the fit again.
hydraulic pressure to that level. a If the distance between the shoe
a For setting of the relief pressure, bolt holes is shorter than the
see "1) Preparation work." standard range and the shoe
a Check that adjacent links swivel cannot be installed, the spacer or
freely in relation to each other. bushing end may be worn more
than the allowable limit. In this
case, disassemble and replace
the parts.
a If the end play is too large, the
sealing performance will drop, so
set the end play to a small value.
14] After assembling each link, use a dial

gauge and pinch bar to measure the
end play with a preceding link to
check that the link is assembled
within the specified value.
a If the end play does not come 16] After each link is assembled, bleed air
within 0 to 0.13 mm even when from the pin by using tool R5 and
applying the pushing force until check the sealing performance.
the relief valve is actuated, raise a Hold the space inside the pin at a
the relief pressure setting gradu- vacuum of 92.7 ± 2.0 kPa {695 ±
ally to adjust. 15 mmHg} for 5 seconds and
a Adjust the relief pressure setting check that there is no change in
carefully and be sure not to raise pressure.
the pushing force of the link If the pressure changes, disas-
press higher than necessary. semble and check the seal for any
abnormality, then assemble again.
D61EX, PX-15E0 13
17] Assemble the master link on the pin

side at last.
a Check that the master links on
both sides are press fitted in par-
allel.
3) Charging with oil

After completion of assembly of the link
assembly, add oil through the pin hole.
1] Using tool R5, remove the air inside
the pin from the small plug hole. Set
to a vacuum of 92.7 ± 2.0 kPa {69 ±
15 mmHg}, then fill with oil (GO90)
until the pressure is 0.2 to 0.3 MPa {2
to 3 kg/cm2}. 2] After supplying oil, drive in the small
a In cold or very cold areas, plug to the following specified posi-
instead of GO90, fill with tion, using tool R4.
Komatsu genuine oil (150-09- a Apply oil (GO90) around the
19270) which has excellent low- small plug.
temperature qualities. a The depth to knock in the plug is
a If the oil pressure is heightened as follows.
too much, it has bad effects on Driving depth from end:
the seal. Take care. 2.5 ± 1 mm
a To determine the oil amount, set 4) Set the link assembly on the bed and
the large plug end (B) facing install the shoe with a shoe bolt impact
downward (stand the link assem- wrench and a torque wrench.
bly on its side), leave for 30 min- 3 Shoe bolt (regular link):
utes, then fill with oil so that depth Initial torque:
(J) of the space at the pin hole is 539 ± 49 Nm {55 ± 5 kgm}
within the specified value below: Tightening angle: 120 ± 10°
Dimension (J): 30 – 50 mm
14 D61EX, PX-15E0
5) Connecting to make 1/2 assembly a Do not use an impact wrench for the
Set 2 completely assembled portions of master link.
shoe on a flat surface in a straight line with
the shoes facing up. Pull master link (5) at
the pin end to master link (6) at the bush-
ing end, and set them at the mating sur-
faces. Then put shoe (7) on top, check
that shoe bolt (8) goes in easily by hand,
and connect the 2 parts with the master
bolt.
2 Shoe bolt: Lubricant containing
molybdenum disulfide (LM-P)
Initial torque:
343 ± 39 Nm {35 ± 4 kgm}
+0°
Tightening angle:180 –20
a Tighten the shoe bolts in the order of 2. When reusing for grease-filled track
[1] – [4]. 1) Preparation work
1] Cleaning seal assembly
a F5 type seal
For seals to be reused, leave
them installed to the link, and do
not wash them.
2] When reusing the pin, chamfer its end

corners carefully with a grinder so
that it will be press fitted smoothly.
D61EX, PX-15E0 15
3] Mark on the end face at the small

plug end to show the direction of the
side hole (hole in the radial direction)
in the pin when assembling.
a When reusing the pin, assemble
in the same direction as when
the part is new (side hole on the
link tread side).
7] Installation of seal assembly

F5 type seal
When reusing the link and replacing
the seal with a new part, clean the link
counterbore (section A) then push the
seal in fully to the bottom.
a If oil or grease is sticking to the
counterbore portion of the link
4] Using tools R3 and R4, drive in the and seal assembly (section A),
large and small plugs. the seal will turn and its sealing
q Tool R3 (large plug) performance will lower. Accord-
q Tool R4 (small plug) ingly, do not apply any oil or
1> Insert plug (3) into the guide hole grease to that portion.
through the plug insertion win-
dow. (Coat plug (3) with oil.)
2> Push the bar of tool R3, R4 with
the hand until plug (3) stops.
3> Push plug (3) with the bar of R3,
R4 and push pin (4) to the guide
itself.
4> Drive in the bar of tools R3, R4
with a hammer.
a Driving distance (a) from pin
end:
Small plug: 2.5 ± 1 mm
Large plug: 6 ± 2 mm
a If the plugs were not pulled
out when the shoe was dis-
assembled, reuse them as
they are.
5] If the outside of the pin, surfaces of
the spacer, and ends and inside of
the bushing are dirty, clean them.
6] Apply grease to the outside of the pin
and surfaces of the spacer.
16 D61EX, PX-15E0
8] Adjust the dimensions of the press fit- 2] Press fit the master links on both
ting jig of the link press to keep the bushing sides to the bushing with the
projection of the pin and bushing con- shoe fitting surface facing up.
stant and keep the installed dimen- a At this time, use the master links
sions of the seal within the standard on the pin side as supports.
range. a Press fitting force for bushing:
a For details of the standard 49 – 196 Nm {5 – 20 tons}
dimensions, see "Link press-fit-
ting jig dimensions table".
a If the pin end (part (P)) or link
sides (parts (Q) and (R)) are
worn, add the dimensions of the
worn parts to the standard
dimension when adjusting the
dimension of the press-fitting jig
so that the projections of the left
and right pins and bushings on
both sides will be even.
3] Using the shoe bolt hole pitch gauge,

press fit the master links until the dis-
tance between the shoe bolt holes of
both links is the standard value.
a Remove the all steel chips
caused by press fitting of the
bushing with compressed air.
2) Assembly of link
1] Apply lithium grease (G2-LI) to the
mating surfaces of the pin and bush-
ing and assemble them, then set
them before the jaw of the link press.
a When reusing (reversing) the
bushing, set the worn outside
surface of the bushing on the
shoe fitting side of the link (facing
upward on the link press).
D61EX, PX-15E0 17
4] Turn over the master links and check 7] Set both links and operate both push-
that they are press fitted in parallel. ing jigs to press fit the pin and bush-
5] Measure the projections of the bushing simultaneously.
ing on both sides with a depth gauge. a If the pin and bushing have play
a Adjust the press fitting jig of the when they are press fitted, the
link press so that the projections seal may come off the link. To
on both sides will be even. prevent this, press fit smoothly.
If the seal comes off the link, stop
press fitting and set the seal to
the link correctly, then start press
fitting again.
a Pushing force for pin and bush-
ing: 588 kN {60 tons}
Pushing force C 1.8 × average
press-fitting force (Adjust the
relief pressure of the link press
and set the pushing force.)
6] Feed the master links and set the

next pin and bushing.
a When reusing a pin, install it so
that its side hole will be on the
link tread side similarly to a new
one. If it is not installed as speci-
fied, its strength may be lowered.
Accordingly, indicate the direc-
tion of the side hole on the end
face to prevent a mistake.
a If the outside of the pin is worn, 8] Using a shoe bolt hole pitch gauge,
install it so that the un-worn sur- measure the distance between the
face will be on the traction side. shoe bolt holes. When the distance is
In this case, install the pin so that in the standard range, stop press fit-
its side hole will face the link ting.
tread side, too. 9] Assemble the master link on the pin
side at last.
a Check that the master links on
both sides are press fitted in par-
allel.
18 D61EX, PX-15E0
3) Shoe bolt (regular link)

Set the link assembly on the bed and
install the shoe with a shoe bolt impact
wrench and a torque wrench.
3 Shoe bolt (regular link):
Initial torque:
539 ± 49 Nm {55 ± 5 kgm}
Tightening angle: 120 ± 10°
a Do not use an impact wrench for the

master link.
4) Connecting to make 1/2 assembly

Set 2 completely assembled portions of
shoe on a flat surface in a straight line with
the shoes facing up. Pull master link (5) at
the pin end to master link (6) at the bush-
ing end, and set them at the mating sur-
faces. Then put shoe (7) on top, check
that shoe bolt (8) goes in easily by hand,
and connect the 2 parts with the master
bolt.
2 Shoe bolt: Lubricant containing
molybdenum disulfide (LM-P)
Initial torque:
343 ± 39 Nm {35 ± 4 kgm}
+0
Tightening angle: 180 -20°
a Tighten the bolts in the order of [1] –
[4].
D61EX, PX-15E0 19
Link press-fitting jig dimensions

table 1
Jig dimensions (mm)

a 4.0 ± 2
b 3.05 ± 0.13
c 45.8
20 D61EX, PX-15E0
Assembly instructions for rotary-bushing track 3. Caulking ends of link

1) Set caulking jigs [1] to both ends of the
a Only the parts of the instructions for the rotary- link. Using pressing jigs [2], press both
bushing track different from the standard track caulking jigs simultaneously until they are
are explained below. fitted to both ends of the link.
a Disassemble and inspect the rotary-bushing a For details of caulking jig [1] and
track similarly to the standard track. pressing jig [2], see the following
a Apply the following procedure in the field, too. page.
a Set caulking jigs [1] so that the un-
1. Setting pin and bushing machined parts of the link will be
Set the sub-assembly of pin (1), rotary bushing deformed.
(2), seal (3), and fixed bushing (4) to the press a If caulking jigs [1] are pressed too
line. strongly, the spacers will be broken.
Accordingly, limit the pressing force to
the following value.
q Max. pressing force:
588 kN {60 tons}
2. Press fitting pin and bushing to link

Press fit the pin and bushing to link (5) simulta-
neously.
a Before press fitting, check that the hole of
the bushing is aligned with the hole to fit 2) Check that the link has been caulked cor-
the bushing. rectly from (c) to (d) as shown in the fol-
a Press fit the pin and bushing so that pro- lowing figure.
jection (a) of the pin and projection (b) of
the bushing will be in the following ranges.
q Dimension (a): 4.45 ± 0.6 mm
q Dimension (b): 3.05 ± 0.2 mm
D61EX, PX-15E0 21
a Caulking jig [1]
a Pressing jig [2] q Dimension of pressing jig

(e) : 48.2 mm
(f) : 4.45 mm
(g) : 3.05 mm
(h) : 70 mm
22 D61EX, PX-15E0
Field disassembly and assembly Disassembly

of one link 1
1. Positioning track shoe assembly
Special tools Set track shoe assembly on block [1] (approx.
300 mm high).
New/Remodel
Necessity
Symbol
Sketch
Q'ty
Part No. Part name
790-101-1102
Pump t 1
6
790-101-1300 Cylinder t 1
(980 kN {100 ton})
790-101-1102 Pump t 1
7
790-105-2300 Jack t 1
(294 kN {30 tons})
791-635-3110 Frame t 1
791-635-3160 Extension t 1
791-635-3170 Nut t 4
8 791-635-3180 Screw t 2
2. Pin
791-635-3190 Screw t 1
Using tool R8 (frame, extension, nut, screw,
791-645-3510 Adapter t 1
adapter, pusher), and tool R6 (pump, cylinder),
791-646-3260 Pusher t 1
remove pins (1) and (2).
9 791-630-3560 Pusher t 1 a If the tip of the pin or the side of the link
10 791-432-1110 Push tool t 1 are unevenly worn, correct with a hand
11 791T-630-3570 Guide t 1 grinder to ensure that the part is at a right
791-635-3110 Frame t 1 angle to tool R8.
R 791-635-3160 Extension t 1
791-635-3170 Nut t 4
791-635-3180 Screw t 2
12
791-635-3190 Screw t 1
791-645-3510 Adapter t 1
791-645-3520 Adapter t 1
791-645-3530 Pusher t 1
791-635-3110 Frame t 1
791-635-3160 Extension t 1
791-635-3170 Nut t 4
791-635-3180 Screw t 2
13
791-635-3190 Screw t 1
791-645-3520 Adapter t 1
791T-630-3570 Guide t 1 Q
791-630-3560 Pusher t 1
790-101-1102 Pump t 1
14
790-105-2300 Jack t 1
15 791-646-3270 Guide t 1
791-635-3110 Frame t 1
16 791-635-3160 Extension t 1
791-635-3170 Nut t 4
R 791-635-3180 Screw t 2
16 791-635-3190 Screw t 1
791-645-3510 Adapter t 1
17 791-646-8002 Lubricator t 1
18 791-932-1110 Plug push tool t 1
D61EX, PX-15E0 23
3. Link Assembly
1) Put tool R7 and spacer [2] of the dimen-
sions given below in contact with the tread 1. Bushing
of links (3) and (4). Applying tool R9 to the end of link (4) and
a Set tool R7 as close to the tip of the using a press or a remover, press fit bushing
link as possible. (7).
49 – 147 kN {5 – 15 tons}
a Always use a new bushing.
2) Apply hydraulic pressure slowly to the

puller until the tip of the link opens 6 – 8
mm, then disconnect the link.
a There is danger that the bushing will 2. Pin
come out, so do not apply more 1) Using tool R10, knock a large plug into the
hydraulic pressure than necessary. oil hole of pin (1).
a If an electric pump is used, there is a Always use a new pin.
danger that more hydraulic pressure
will be applied than necessary, so
always use a hand pump.
3) Disconnect links (5) and (6) in the same
way.
Spacer [2] dimensions:
outside diameter 55 mm × thickness
47 mm
2) To determine the pushing pressure when

carrying out the final assembly, measure
the outside diameter of the pin with a
micrometer.
24 D61EX, PX-15E0
3. Seal
Install seal (8).
a Check that there is no oil on the contact
surface of the link and seal.
a Carry out steps 1 – 3 in advance.
3) Coat the press-fitting hole for the pin in

link (4) with gasket sealant (198-32-
19890).
a If the link is used again, finish the
press fitting hole for the pin smoothly
with sandpaper. 4. Link sub-assembly
1) Install link sub-assembly (10).
stuck to the surface of the seal or the
end face on the bushing, then coat
with oil (GO90) using a clean cloth or
small brush.
4) Applying tool R9 to the end of link (4) and

using a press or a remover, press fit pin
(1).
a Press fit so that the side hole (a) in
the pin is on the same side as the link
tread.
a Press-fitting force for pin: 2) Install tool R11 (guide used when press fit-
147 – 245 kN {15 – 25 tons} ting link) to bushing (7).
a Always use a new pin.
D61EX, PX-15E0 25
5. Link
1) To determine the pushing pressure when
carrying out the final assembly, measure
the press-fitting hole dimensions of link (3)
with a cylinder gauge.
4) Using tool R12, press fit pin portion of link

(3) to link sub-assembly (10).
a Press-fitting force for pin:
294 – 490 kN {30 – 50 tons}
a (G): Guide
19890).
a If the link is used again, finish the
press fitting hole for the pin smoothly
with sandpaper.
5) Using tool R13, press fit bushing portion of

link (3) to link sub-assembly (10).
a To prevent the use of any excessive
force, press fit the pin portion and
bushing portion gradually in turn.
a Press-fitting force for pin and bush-
3) Install seal (8). ing: 196 – 392 kN {20 – 40 tons}
a Check that there is no oil on the con-
tact surface of the link and seal.
end face on the bushing, then coat
small brush.
26 D61EX, PX-15E0
6. Connecting link 4) Install seals (13) and (14) to links (5) and
1) Finish the inside surface of the press-fit- (6).
ting hole for the pin in links (5) and (6) a Always use new seals.
smoothly with sandpaper. a Check that there is no oil on the con-
tact surface of the link and seal.
end face on bushing (7), then coat
small brush.
2) Remove block [1], and lower the track

shoe assembly to the ground.
3) Set lever block [3] to the left and right link
assemblies as shown in the figure below.
Put tool R14 and spacer [2] in contact with
the tread of links (5) and (6).
a Set tool R14 as close to the tip of the 5) Apply hydraulic pressure slowly to the
link as possible. puller until the tips of links (5) and (6) open
6 – 8 mm.
a There is danger that the bushing will
come out, so do not apply more
hydraulic pressure than necessary.
a If an electric pump is used, there is
danger that more hydraulic pressure
will be applied than necessary, so
always use a hand pump.
6) Operate lever block [3], align the centers
of the link hole and bushing hole, and con-
nect the links with tool R15 (guide pin).
a Operate lever block [3] slowly and be
careful not to damage the seal or get
sand stuck to the seal surface.
D61EX, PX-15E0 27
7. Pin
1) Using tool R10, knock a large plug into the
oil hole of pin (2).
a Always use a new pin.
8) Using tool R12, apply the specified pres-

sure to links (3) and (4) and links (5) and
(6).
a Pushing force for pin and bushing:
2) To determine the pushing pressure, mea- 588 kN {60 tons}
sure the outside diameter of pin (2) with a Pushing force C 1.8 × average press-
micrometer. fitting force (Adjust the relief pressure
3) Set the track shoe assembly on block [1] of the link press and set the pushing
again. force.)
4) Using tool R16, press fit pin (2) to links (5)
and (6).
a Press fit so that the side hole in the
pin is on the same side as the link
tread.
49 – 147 kN {5 – 15 tons}
5) Temporarily stop press fitting when there
is 15 – 20 mm left for press fitting pin (2).
8. Vacuum test
Using hand vacuum pump [4], remove the air
from the small plug hole at the end face of pins
(1) and (2) and check the sealing performance.
a Check that the airtightness is maintained
for 5 seconds at a negative pressure of
92.7 ± 2.0 kPa {695 ± 15 mmHg}.
6) Coat the remaining press-fitting portion of

pin (2) with gasket sealant (198-32-
19890).
19890), then continue to press fit pin (2).
28 D61EX, PX-15E0
9. Charging with oil

1) Using tool R17, charge with oil (GO90)
through the small plug hole in the pin.
a Be careful not to raise the pressure
too high when charging with oil. This
will have an adverse effect on the
seal.
a Take into consideration the expansion
of the oil under heat, and be careful
not to charge with too much oil.
2) Using tool R18, drive in the small plug

quickly.
a Apply oil (GO90) around the small
plug.
a The depth to drive in the plug is as
follows.
Driving depth from end: 2.5 ± 1 mm
D61EX, PX-15E0 29
Removal and installation of pivot 4. Remove seal (2). [*2]

shaft assembly 1
5. Remove ring (3). [*3]
Special tools
New/Remodel
Necessity
Symbol
Sketch
Q'ty
Part No. Part name
791T-450-1130 Push tool t 1 Q

791T-450-1140 Plate t 1 Q
791-181-1010 Adapter t 1
791-520-4140 Screw t 1
791-201-2750 Spacer t 1
P
790-101-2540 Washer t 1
791-112-1180 Nut t 1
790-101-2102 Puller t 1
Pump
790-101-1102 (294 kN {30 tons}) t 1
Removal
1. Remove track frame assembly. For details, see

"Removal and installation of track frame
assembly".
2. Sling pivot shaft assembly (1) temporarily.
3. Remove mounting bolts, then using forcing

screws [1], raise pivot shaft assembly and pull
out. [*1]
4 Pivot shaft assembly:85 kg (D61EX)
105kg(D61PX)
30 D61EX, PX-15E0
Installation

removal.
[*1]
3 Pivot shaft mounting bolt:
455 – 565 Nm {46.5 – 58 kgm}
[*2]
a Assemble the seal as follows. (See diagram
below.)
1) Turn over the seal so that the embossed
letters on the seal are on the inside. (Turn
Over)
2) With the seal turned over, insert seal (2)
on the shaft.
a Insert seal (2) to ring (3).
a When inserting the seal, be careful
not to damage the surface.
[*3]
a Press fit ring (3) using tool P.
a Press fitting force: 18.6 kN {1.9 tons}
D61EX, PX-15E0 31
Removal and installation of 6. Remove seal (4) from the side pin fitting por-
equalizer bar assembly 1 tion. [*1]
Special tools
New/Remodel
Necessity
Symbol
Sketch
Q'ty
Part No. Part name
791-450-1100 Remover t 1
Puller
N 790-101-2102 (294 kN {30 tons}) t 1
790-101-1102 Pump t 1
Removal 7. Remove grease hose (5) from center pin (7).

a Remove the elbow too.
1. Remove track frame assembly. For details, see
"Removal and installation of track frame 8. Remove lock plate (6) from center pin (7).
assembly".
9. Using tool N, pull out center pin (7). [*2]
2. Remove the bottom cover of the universal
joint.
3. Remove cover (1) from equalizer bar (A) on

the opposite side of removed track frame
4. Remove grease tube (2).

a Remove the elbow too.
5. Remove the lock plate and then side pin (3).

[*1]
k Before removing the side pin, support
the track shoe on blocks, etc. securely.
32 D61EX, PX-15E0
10. Pull equalizer bar (8) out of the frame with fork- Removal and installation of
lift, etc. equalizer bar side bushing 1
11. Lift off equalizer bar. Removal
4 Equalizer bar assembly:180 kg (D61EX) 1. Remove equalizer bar assembly. For details,
200 kg (D61PX) see "Removal and installation of equalizer bar
assembly".
2. Remove 2 seals (1).
3. Remove 2 snap rings (2).
4. Remove spherical bushing (3).
Installation

removal.
[*1]
2 Between seal and bushing:
Fill with grease (G2-LI)
Installation
[*2]
2
1. Install ring (2) to one side.
Joint of pin and bushing: Grease (G2-LI)
2 Between bushings: Fill with grease (G2-LI)
2
2. Using push tool [1] and a press, press fit
Boss of frame:
spherical bushing (3).
Lubricant containing molybdenum
a Press fitting force: 15.68 kN {1.6 tons}
disulfide (LM-P)
3. Install ring (2) to opposite side.
4. Install seal (1).

2 Between bushing and seal:
Fill grease (G2-LI)
5. Install equalizer bar assembly. For details, see

"Removal and installation of equalizer bar
assembly".
D61EX, PX-15E0 33

segment teeth 1
Removal
1. Stop machine at place where teeth can be

removed easily (between shoe and track
frame).
2. Remove mounting bolts (1) to remove teeth

(2). [*1]
Installation

removal.
[*1]
2 Threads of teeth mounting bolt:
3 Teeth mounting nut:
461 – 559 Nm {47 – 57 kgm}
a Assemble the teeth so that clearance (a) in
them will be even all round.
q Clearance (a): 0 – 2 mm
q Level difference (b): max. 0.5 mm
34 D61EX, PX-15E0
D61EX, PX-15E0 35
SEN02575-00

© 2007 KOMATSU
All Rights Reserved
36
SEN02576-00
D61EX-15E0
D61PX-15E0


Hydraulic system
Removal and installation of main control valve assembly............................................................................... 2
Assembly of main control valve assembly ...................................................................................................... 4
Removal and installation of cooling fan pump assembly ................................................................................ 7
Disassembly and assembly of hydraulic cylinder assembly ........................................................................... 8
D61EX, PX-15E0 1
Removal and installation of main 8. Disconnect the following hoses.

control valve assembly 1 q (11), (12): HSS motor
q (13): HSS/work equipment pump
Removal q (14): HSS/work equipment pump
q (15) 2 hoses: lift cylinder
k Lower the work equipment fully to the q (16) 2 hoses: tilt cylinder
ground and stop the engine. Then loosen q (17) 2 hoses: angle cylinder
the hydraulic oil filler cap slowly to release
the internal pressure of the hydraulic tank.
– 3 times to release the residual pressure
from the work equipment circuit.


assembly".
3. Disconnect hose (2) from ripper operation con- 9. Disconnect connectors HAS (18) and HSB
trol lever assembly (1). (If equipped) (19).
a Prepare a plug before disconnecting the
hose. 10. Disconnect TS port hose (20) and EPC pres-
a Arrange for the tags to indicate the corre- sure hose (21).
sponding hose to joint to.
4. Disconnect clips (3) and (4). (If equipped)
5. Disconnect drain hose (5).
6. Disconnect PPC hose. From inside

q (6): Red
q (7): Brown
q (8): Green
q (9): White (Ripper operation control lever
assembly (1): If equipped)

a (A) is the blade operation PPC valve. 11. Remove inside mounting bolts (22).
2 D61EX, PX-15E0
12. Remove outside mounting bolts (section (B))

and lift main control valve assembly (27).
4 Main control valve assembly
(Ripper + lift + tilt angle + steering):
80 kg
13. Disconnect the lower PPC hose (multi-cou-

pler). From outside
q (23): none
Wound with a spiral tube. (If equipped)
q (24): blue
q (25): white
q (26): Brown
14. Lift off main control valve assembly (27).
Installation

removal.
q Refilling oil (hydraulic oil tank)

through the piping system. Then, check the oil
level again.
5 Hydraulic oil tank: 55 l (See "Table of
D61EX, PX-15E0 3
Assembly of main control valve

assembly 1
a This section describes only cautions in assembling the main control valve assembly.
a 4-spool control valve

(Lift + tilt + angle + steering)
4 D61EX, PX-15E0
a Be careful for the tightening torque as follows.

(For others, see Main control valve of structure
and function.)
1. T (mounting of upper cover):
q Tighten the nuts in 3 times in the order of 1
– 4.
3 1st time: 19.6 – 29.4 Nm {2 – 3 kgm}
3 2nd time: 39.2 – 49.0 Nm {4 – 5 kgm}
3 3rd time: 58.8 – 49.0 Nm {6 – 5 kgm}
2. TT (mounting of lower cover):

q Tighten the nuts in 3 times in the order of 1
– 4.
3 1st time: 58.8 – 68.6 Nm {6 – 7 kgm}
3 2nd time: 78.5 – 88.3 Nm {8 – 9 kgm}
3 3rd time: 98.1 – 113 Nm {10 – 11.5
kgm}
3. Plug T1-5L:
2 Plug T1-5L: Apply a drop of Loctite
No.638 (see the diagram below)
3 Plug T1-5L:
14.7 – 19.6 Nm {1.5 – 2 kgm}
a Degrease and clean plug T1-5L and the
female thread portion with drysol, etc. and
dry. Do not apply pressure 2 hours after
tightening.
D61EX, PX-15E0 5
a Be careful for the following during assem-

bly.
1. Assemble steering spool (STSPL) in direction
by which the groove will be on the side of (A1)
port.
2. Assemble washer (W) of section G-G so that

slit face will be on the side of spool (SPL).
6 D61EX, PX-15E0
Removal and installation of 13. Remove cooling fan pump assembly (10).
cooling fan pump assembly 1 4 Cooling fan pump assembly: 25 kg
Removal



assembly."
3. Remove both mounting bolts (20) of control

valve assembly (A) and retain assembly (A) in
floated condition using blocks, etc.
a (10) is the cooling fan pump assembly.
a (B): Ripper control lever assembly
(If equipped) Installation

removal.
[*1]
3 Hose clamp: 8.8 ± 0.5 Nm {90 ± 5 kgcm}

level again.
5 Hydraulic oil tank: 55 l (See "Table of
4. Disconnect clip (1). fuel, coolant and lubricants")
5. Disconnect PPC basic pressure hoses (2) and

(3) from fan pump assembly (10). q Air bleeding
a Bleed air from the circuit by referring to the
6. Disconnect pressure pick-up hose (4). section of "Bleeding air from fan pump" in
Testing and adjusting.
7. Disconnect pump discharge hose (5).
8. Disconnect connector FAC (6).
9. Remove bracket (7) of main control valve

assembly.
10. Disconnect drain hose (8).
11. Remove the right fender lower cover (upper

side).
12. Remove the suction tube under the fan pump

and suction hose (9).
D61EX, PX-15E0 7
Disassembly and assembly of Disassembly

hydraulic cylinder assembly 1
1. Piston rod assembly
Special tools 1) Set cylinder assembly (1) to tool U1.
2) Using hydraulic pump or power wrench,
New/Remodel
disconnect cylinder head assembly (2)
Necessity
Symbol
Sketch
with tool U2.
Q'ty
Part No. Part name
a Angle cylinder, tilt cylinder (inside pat
specifications), lift cylinder
790-502-1003 Repair stand t 1
1
790-101-1102 Hydraulic pump t 1
Wrench assembly
790-330-1100 1
2 • Angle, lift (ST, PAT) t
790-102-3802 • Tilt (PAT) 1
Socket
790-302-1280 • Width across flats 1
(55 mm)
790-302-1290 1
3 (60 mm) t
790-302-1340 1
(80 mm)
790-302-1320 1
(70 mm)
1 790-720-1000 Expander q 1 3) Remove mounting bolts and disconnect
Ring cylinder head assembly (2).
796-720-1660 q 1
• Angle, lift (ST, PAT) a Ripper cylinder, tilt cylinder (straight
Clamp tilt, semi-U dozer specifications)
07281-01159 q 1
• Angle, lift (ST, PAT) a Portion (A) is not installed to the rip-
U Ring per cylinder.
796-720-1670 q 1
• Tilt (PAT)
4
2 07281-01279 Clamp q 1
• Tilt (PAT)
Ring
796-720-1680 • Tilt (ST) q 1
• Ripper
Clamp
07281-01589 • Tilt (ST) q 1
• Ripper
790-201-1702 Push tool kit t 1
790-101-5021 • Grip 1
01010-50816 • Bolt 1
• Push tool
790-201-1771 1
5 Lift (ST, PAT)
• Push tool
790-201-1811 Tilt (ST, PAT) 1
Ripper
• Push tool
790-201-1791 1
Angle
790-201-1500 Push tool kit t 1
790-101-5021 • Grip 1
01010-50816 Bolt 1
• Plate
790-201-1580 1
U 6 Lift (ST, PAT)
• Plate
790-201-1620 Tilt (ST, PAT) 1
Ripper
• Plate
790-201-1610 1
Angle
8 D61EX, PX-15E0
4) Pull out piston rod assembly (3) from cyl- 3. Disassembly of piston assembly
inder (4). 1) Remove wear ring (7).
a Set a container under the cylinder to catch 2) Remove piston ring (8).
the oil. a Ripper cylinder, tilt cylinder, angle cyl-
inder, lift cylinder (inside PAT specifi-
cations)
2. Piston assembly, head assembly

1) Set piston rod assembly (3) to tool U1.
2) Using tool U3, loosen nylon nut (5) and a Lift cylinder (straight tilt, semi-U dozer
remove. specifications)
Width across
Name of cylinder
flats of nut (mm)
Blade lift
60
(inside PAT specification)
Blade lift
(straight tilt, semi-U dozer specifica- 55
tions)
Blade angle 70
Blade tilt 80
Ripper 80
3) Remove piston assembly (6) and head

assembly (2).
a Perform 3) and 4) for only the lift cyl-

inder of straight tilt and semi-U dozer
specifications.
3) Remove 2 covers (9) and 2 pins (10).
4) Remove 4 shafts (11) and 8 seats (12).
D61EX, PX-15E0 9
4. Disassembly of head assembly Assembly

1) Remove O-ring and backup ring (15). a Coat the sliding surfaces of all parts with
2) Remove snap ring (16), then remove dust engine oil before installing. Take care not to
seal (17). damage the rod, packing, dust seal and O-
3) Remove rod packing (18). rings when assembling.
4) Remove buffer ring (19). a Do not try to force the backup ring into posi-
5) Remove bushing (20). tion. Warm it in warm water of approx. 50 –
6) Remove O-ring (21). 60°C before installation.
a Lift, angle and tilt (inside PAT) cylin-
ders only 1. Assembly of head assembly
1) Using tool U5, press fit bushing (20).
2) Install buffer ring (19).
3) Install rod packing (18).
4) Using tool U6, install dust seal (17), and
install snap ring (16) to fix.
5) Install backup ring and O-ring (15).
a Lift, angle and tilt (inside PAT) cylin-
ders only
6) Install O-ring (21).
10 D61EX, PX-15E0
2. Assembly of piston assembly a Perform 5) and 6) for only the lift cyl-
1) Set piston ring (8) on tool U4-1 and turn inder of straight tilt specification.
the handle 8 - 10 times to expand the ring. 5) Install 8 seats (12) and 4 shafts (11).
2) Remove piston ring (8) from tool U4-1, 6) Install 2 pins (10), then install 2 covers (9).
and install to piston (6).
3) Using tool U4-2, compress piston ring (8).
3. Piston rod assembly

1) Set piston rod to tool U1, and assemble
4) Install wear ring (7). head assembly (2) and piston assembly
(6), then using tool U3, tighten nut (5).
a Lift cylinder (for straight tilt and semi-

U dozer) has 2 wear rings (7). 3 Piston nut:
Width across Tightening
Name of cylinder flats of nuts torque
(mm) (kNm {kgm})
Blade lift (inside PAT dozer 1.77 ± 0.18
60
specification) {180 ± 18.0}
Blade lift (straight tilt, semi- 1.42 ± 0.14
55
U dozer specifications) {145 ± 14.5}
2.60 ± 0.26
Blade angle 70
{265 ± 26.5}
3.97 ± 0.4
Blade tilt 80
{405 ± 40.5}
3.97 ± 0.4
Ripper 80
{405 ± 40.5}
D61EX, PX-15E0 11
a Thoroughly clean the thread of the 4) Tighten mounting bolt of cylinder head (2).
piston rod and remove all oil and a Ripper cylinder, tilt cylinder (straight
grease before assembling the nut. tilt, semi-U dozer specifications)
2 Rod thread: Liquid adhesive 3 Mounting bolt:
(Loctite No. 262 or equivalent) 162 ± 14.7 Nm {16.5 ± 1.5 kgm}
2) Set cylinder (1) to tool U1, and assemble a Portion (A) is not installed to the rip-
piston rod assembly (3) in cylinder (4). per cylinder.
3) Using hydraulic pump or power wrench,

tighten cylinder head assembly (2) with
tool U2.
a Perform 4) for ripper cylinder and tilt
cylinder (straight tilt, semi-U dozer
specifications).
3 Cylinder head:
Name of
Cylinder head tightening torque
cylinder
Blade lift 932 ± 93.2 Nm {95 ± 95 kgcm}
1st time: Tighten with torque of 1,225
Nm {125 kgm}.
Blade angle 2nd time: Loosen to 0 Nm {0 kgm}.
3rd time: Tighten with torque of 1,225
Nm {125 kgm}.
Blade tilt
1.03 ± 0.10 kNm {105 ± 10.5 kgm}
(inside PAT)
12 D61EX, PX-15E0
D61EX, PX-15E0 13
SEN02576-00

© 2007 KOMATSU
All Rights Reserved
14
SEN02577-00
D61EX-15E0
D61PX-15E0


Work equipment
Removal and installation of work equipment assembly .................................................................................. 2
Disassembly and assembly of work equipment assembly.............................................................................. 4
D61EX, PX-15E0 1
Removal and installation of work 4. Remove right hose cover (4) and left hose
equipment assembly 1 cover (5).
Removal
k Move the machine to a flat surface.

k Lower the work equipment fully to the
ground and stop the engine. Then loosen
the hydraulic oil filler cap slowly to release
the internal pressure of the hydraulic tank.
– 3 times to release the residual pressure
from the work equipment circuit.
1. Set block [1] to under the work equipment

frame.
5. Disconnect 4 cylinder hoses (6) from the right
side of the machine and 2 cylinder hoses (7)
from the left side.
2. Remove lockplate (1).
3. Sling lift cylinder assembly (2) temporarily and

remove head pin (3). [*1] 6. Sling work equipment assembly (8) tempo-
a Using removed head pin hole, fasten lift rarily.
cylinder assembly (2) to handrail (A) with a Sling by 4 points; left and right sides of the
rope, etc. blade for the front side and the work
a Both lift cylinders equipment frame (lift cylinder head pin
mounting portions) for the rear side. In
addition, use a chain block.
2 D61EX, PX-15E0
7. Remove 2 work equipment frame pins (9) on Installation

the left and right. Gradually move work equip-
ment assembly (8) in front of the machine to q Carry out installation in the reverse order to
remove. [*2] removal.
[*1] [*2]
2 Pin: Grease (G2-LI) or Hyper White
Grease (G2-T)

level again.
5 Hydraulic oil tank: 55 l (See "Table of fuel,
4 Work equipment assembly: q Air bleeding

2,100 kg (D61EX) Bleed air from the cylinder by referring to the
1,900 kg (D61PX) section of "Bleeding air from hydraulic cylinder"
in Testing and adjusting.
D61EX, PX-15E0 3
Disassembly and assembly of 2. Blade

work equipment assembly 1 1) Sling blade (6) temporarily, then remove 2
head pins (8) from both blade angle cylin-
Disassembly der assemblies (7).
a Before removing the head pins, sup-
k Set 3 blocks [1] under the work equipment port the cylinders on blocks, etc.
frame, then secure the work equipment 2) Remove cap (9) of blade connecting por-
assembly. tion and the mounting bolts (8 to 10 bolts)
of trunnion (10) on U frame side (10a) or
on the blade side.
a Trunnion (10) blade side: Check the
thickness, quantity and location of the
shim installed to cap (10b).
3) Lift off blade (6).
4 Blade: 1,250 kg (D61EX)
: 1,050 kg (D61PX)
1. Blade tilt cylinder

1) Disconnect head hose (1) and bottom
hose (2).
k Plug the pipes to prevent dirt from
entering them.
2) Sling cylinder temporarily, then remove
head pin (3).
3) Remove bottom pin (4), then lift off blade
tilt cylinder assembly (5).
4 Blade tilt cylinder assembly: 80 kg
4 D61EX, PX-15E0
3. Blade angle cylinder 4) Remove cover (20) from work equipment

1) Remove cover (11). frame (19), then remove 6 hoses (21).
4
2) Disconnect grease hose (12).
Work equipment frame: 900 kg
a Disconnect the hose clamps, too.
3) Disconnect hoses (13) and (14).
4) Remove bottom pin (15), then lift off blade
angle cylinder assemblies (16) on both
sides.
4 Blade angle cylinder assembly:
55 kg (one side)
Assembly
k Set 3 blocks [1] under the work equipment

frame and secure the work equipment
assembly.
4. Work equipment frame 1. Work equipment frame

1) Remove pin (17). 1) Install 6 hoses (21) to work equipment
2) Remove lever (18). frame (19), then install covers (20).
3) Set blocks [1] under the work equipment 2) Install lever (18).
frame (19). 3) Install pin (17).
D61EX, PX-15E0 5
2. Blade angle cylinder

1) Sling and install blade angle cylinder
assembly (16), then install bottom pin
(15).
4 Blade angle cylinder assembly:
55 kg (one side)
2 Pin: Grease (G2-LI) or Hyper
White Grease (G2-T)
2) Connect hoses (13) and (14).
3) Connect grease hose (12).
a Connect the hose clamp, too.
4) Install cover (11).
3. Blade
1) Install trunnion (10) to blade (6) with cap
(10b). 4. Blade tilt cylinder
a Adjust clearance between cap (10b) 1) Sling and install blade tilt cylinder assem-
and the ball to 0.5 mm with the shim. bly (5), then install bottom pin (4).
q Standard shim thickness: 3.0 mm 4 Blade tilt cylinder assembly: 80 kg
q Thickness of shim unit: 0.5 mm, 1.0
mm 2 Pin: Grease (G2-LI) or Hyper
3 Mounting bolt of cap (10b): White Grease (G2-T)
785 – 980 Nm {80 – 100 kgm} 2) Install head pin (3).
2) Sling blade (6) and set it to the connecting 2 Pin: Grease (G2-LI) or Hyper
position of work equipment frame. White Grease (G2-T)

3) Connect head hose (1) and bottom hose
4 Blade: 1,250 kg (D61EX) (2).
: 1,050 kg (D61PX)
3) Install blade connecting position cap (9)
and trunnion (10).
3 Mounting bolt (10a) of trunnion
(10):
455 – 565 Nm {46.5 – 58 kgm}
4) Install head pins (8) to both blade angle
cylinder assemblies (7).
6 D61EX, PX-15E0
D61EX, PX-15E0 7
SEN02577-00

© 2007 KOMATSU
All Rights Reserved
8
SEN02578-00
D61EX-15E0
D61PX-15E0


Cab and its attachments
Removal and installation of ROPS guard ....................................................................................................... 2
Removal and installation of operator's cab assembly ..................................................................................... 3
Removal and installation of operator's cab glass (stuck glass)....................................................................... 9
Removal and installation of monitor panel assembly .................................................................................... 18
Removal and installation of dashboard assembly......................................................................................... 19
Removal and installation of floor frame assembly ........................................................................................ 22
D61EX, PX-15E0 1
Removal and installation of ROPS

guard 1
Removal
1. Sling the ROPS guard assembly.
2. Remove 8 mounting bolts (1), 4 each on the

right and left sides. [*1]
3. Lift off ROPS guard assembly (2).

4 ROPS guard assembly: 220 kg
Installation

removal.
[*1]
3 Mounting bolt:
785 – 980 Nm {80 – 100 kgm}
2 D61EX, PX-15E0
Removal and installation of 6. Remove covers (7) and (8).

operator's cab assembly 1
7. Reverse cover (9) and disconnect wiring har-
Removal ness connectors SIG (10) and ACC (11).


guard assembly".
2. Remove operator's seat assembly (1)

4 Operator's seat assembly: 40 kg
3. Remove cover (2) under the left armrest.
4. Remove bellows (4) from KOMTRAX terminal

(3) and remove wiring harness clamp (4a). 8. Remove antenna wiring harness clamp (12).
a Check that all the wiring harness clamps
5. Disconnect wiring harness connectors (5) and are removed and then pull up wiring har-
(6). ness (13).
q Connector (5): Press the lock and pull out.
q Connector (6): Turn and pull out.
D61EX, PX-15E0 3
9. Open battery cover (14). 14. Remove cooler box (22) at the front in the
operator's cab.
10. Disconnect wiring harness connectors CN19

(15), CN21 (16) and CN20 (17). 15. Remove 6 mounting bolts (23) and bracket
(24).
11. Disconnect 4 washer hoses (18).
16. Remove 21 operator's cab mounting bolts

12. Pull grommet (19) at the left door hinge into the marked with q.
operator's cab. [*1]
13. Remove right left covers (20) and (21).
4 D61EX, PX-15E0
17. Lift off operator's cab assembly (25). [*2] Installation

a Check that all the wirings and pipings are
disconnected. q Carry out installation in the reverse order to
4 Operator's cab assembly: 410 kg removal.
[*1]
a After connecting the wiring harness connector,
install the grommet securely to the through
hole of the operator's cab.
[*2]
a If the operator's cab has been removed from
the floor frame, prepare the following sealants
to secure pressurizing performance and water-
tightness of the operator's cab after installa-
tion.
17A-Z11-3552: 1 piece (Seal (B))
17A-Z11-3541: 5 pieces (Seals (D) – (G))
17A-Z11-2320: 2 pieces (Seals (C))
198-Z11-3960 Threebond (1207B):
1 piece (Liquid sealant (A))
D61EX, PX-15E0 5
1. Installation of seals to air conditioner box 6) Fit seal (B) to guide plate (33) of the air
conditioner box.
1) Remove dirt, oil and grease from the liquid a Pull and install seal (B) down, while
seal application faces of the floor frame pressing the sealant applied in 2)
top on both right and left sides. above.
2) Apply liquid sealant Threebond 1207B to a Fill the gap (marked with a) between
part (A) of the top of floor frame (31). (See seal (B) and floor frame with adhesive
the above figure.) (LT-1A).
3) Install air conditioner box (32).
4) Apply liquid sealant Threebond 1207B to
the frame contact part (the range shown in
the following figure) to a thickness of 8
mm.
7) Apply grease (G2-LI) to the outside face

of seal (B) (sealing face to the operator's
cab).
a Apply grease so that the installed
operator's cab will slide well and the
5) Apply adhesive (LT-1A) to the inside face seal will not be moved or deformed.
of seal (B) (the sealing face to the air con-
ditioner box).
6 D61EX, PX-15E0
2. Installation of seals to operator's cab q Detail

mounting face 1] Press the ends of seal (G) against the
1) Sling the operator's cab assembly. wall to eliminate gaps. (See parts A
2) Remove dirt, oil and grease from the seal in the above figure.)
sticking face. 2] Before cutting the ends of (C), stick
a Do not allow a person to stand under seal (D) to the groove and then stick
the slung operator's cab to avoid dan- seal (E).
ger. a Eliminate gaps between (D) and
(E) ends and (C).
q Outline 3] Cut seal (C) so that it will be flush with
Referring to the figure, install seals (C), (D), seal (E).
(E), (F) and (G) in order. a Use the rest of seal (E) as seal (F).
a Eliminate gaps from the seal joints.
D61EX, PX-15E0 7
3. Precautions for installing operator's cab 5) Check that clearance (e) between air con-
1) Lower the operator's cab assembly slowly ditioner duct (26) on the operator's cab
to the floor frame. side and monitor (27) is even on the right
a Lower carefully since the reaction and left sides. Also, check that air condi-
force of the seal sponge is large. tioner duct seal (f) on the operator's cab
a Check that the seal of the air condi- side is closely stuck to the centers of right
tioner duct on the operator's cab is in and left faces (C) of air conditioner duct on
close contact with the air conditioner the dashboard side.
duct on the dashboard side. a If clearance (e) between the air condi-
a Lower carefully since the clearance tioner duct on the operator's cab side
between the air conditioner duct on and monitor is not even, loosen the
the operator's cab and monitor is nar- mounting screws of the air condi-
row. tioner duct on the operator's cab side
2) Tighten the operator's cab mounting bolts and move the duct to adjust the clear-
temporarily. ance evenly. Similarly, adjust the
3) Check that the seals between air condi- directions of the operator's cab and
tioner bracket (23) and operator's cab (22) air conditioner if necessary.
are stuck securely. 6) Tighten the mounting bolts of the dash-
4) Check that there is no gap in joint (a) board mounting bracket.
between the seal and floor frame.
8 D61EX, PX-15E0

operator's cab glass (stuck glass)1
a Among the operator's cab window glasses, (1) : Front window glass
adhesive type glass is 3 consisting of (1) and (2) : Left door window glass
(2) for the left and right as shown in the dia- : Right door window glass
gram. This section describes replacement pro- (3) : Dam rubber
cedure for adhesive type glass. (4) : Trim seal
(5) : Door handle
D61EX, PX-15E0 9
Special tools
New/Remodel
Symbol
Necessity
Part No. Part name
Sketch
Q'ty
X1 793-498-1210 Lifter (Suction cup) t 2
Removal
k Remove the window glass for replacement
according to the following instructions.
1. Using seal cutter [1], cut through adhesive

between broken window glass (6) and opera-
a When removing window glass broken in
tor's cab (sheet metal) (7).
pieces, cutter knife [4] and a driver may be
used.
a Expand a section with a standard-tipped
driver, and cut the dam rubber and adhe-
sive with a cutter knife [4].
(The diagram below shows an operator's
cab on a wheel loader.)
a If seal cutter is unavailable, use a reamer

to drill a hole to the adhesive and dam
rubber, then put a fine wire (piano wire,
etc.) [2] through the hole. Hold both ends
of the fine wire put through the hole with
pliers [3] (or winding each end on a piece
of wood, etc. to fix), and cut the adhesive
2. Remove the window glass.
and dam rubber by moving the wire left
and right.
The wire may be sheared by friction heat.
Apply lubricant to the wire and carry on
work.
(The diagram shows an operator's cab on
a wheel loader.)
10 D61EX, PX-15E0
Installation 3. Install dam rubber (double adhesive tape) (3)

along the inner edges of the front window
1. Using the cutter knife and scraper [5], remove glass, left and right window glasses mounting
residual adhesive and dam rubber on the section.
sheet metal side (adhesion face) of operator's a Do not remove the tape from the glass
cab. adhesion side of dam rubber before
a Residual adhesive and dam rubber on the installing glass.
sheet metal surface may be removed to a a When installing dam rubber, avoid touch-
state that does not give adverse effect on ing the cleaned surfaces as much as pos-
newly applied adhesive. Take care not to sible.
damage coated surface by excessive a Regarding adhesion of dam rubber to the
scraping. corners, special care should be taken not
(Damaged coated surface causes deterio- to allow dam rubber to float.
ration of adhesive force.) a Install dam rubber (3) so that it will not
(The diagram below shows an operator's overlap each other at the joint portion
cab on a wheel loader.) where the starting and ending dam rub-
bers meet.
Or provide the mating portion (a) with a
clearance of approx. 5 mm.
2. Remove oil, grease, dust, contamination, etc.

on the adhesion surfaces on cab (7) and win-
dow glass (8) with white gasoline.
a Clean thoroughly as incomplete cleaning
causes defective adhesion.
a Wholly clean the rear black portion of the
window glasses.
a After cleaning, let glasses dry spontane-
ously for over 5 minutes.
D61EX, PX-15E0 11
4. Install trim seal (4) to the left and right door a Start positioning front window glass
window glasses (2). (1) from inside operator's cab (7).
Adjust the front window glass so that
the gap between the black coated
portion (black ceramic) and operator's
cab (7) sheet metal will be equal to
the left, right and up and down.
a For positioning the left and right door
window glasses (2), align the center
of handle holes (d) of door (9) (glass
side, and door sheet metal side).
Then adjust the door window glass so
that the relation of glass and door
sheet metal position will be equal all
round.
2) After positioning, paste tape [6] at 3 posi-
a Install trim seal (4) so that it will be jointed tions, left, right and bottom, across front
at position (c) where dimension (b) from window glass (1) and operator's cab (7),
the corner reads 90 mm. and at 3 positions, left, right and bottom,
across door window glass (2) and door (9)
on both sides. Draw line (e) on each tape
for positioning purpose.
3) Cut the tape with a cutter knife, etc.
between window glasses (1), (2) and
operator's cab (7), and then remove
respective window glasses.
a Do not remove tapes left on the win-
dow glasses and operator's cab until
installing window glass.
5. Position window glass to be replaced.

1) Using tool X1, set the window glass to the
installation position. Check left, right, up
and down clearance with operator's cab
and adjust the window glass so that the
clearance will be equal.
12 D61EX, PX-15E0
6. Coat with adhesive. 3) Set adhesive cartridge (10) to calking gun

2 Adhesive: [7].
Sika Ltd. Japan Sikaflex 256HV a Electric calking gun has better work-
a Do not use primer. ability.
a Since the effective limit of adhesive
agents is 6 months after the date of manu-
facture, do not use adhesives beyond the
effective service limit.
a Store adhesives in a cold, dark place at
under 25°C.
a Never heat adhesives to higher than
30°C.
a When reusing adhesive, completely
remove hardened adhesive at the nozzle
tip before using.
1) Break aluminum moistureproof film (11)
covering the outlet end of adhesive car-
tridge (10), and install the nozzle.
4) Peel tape (3a) covering the glass adhe-
sion side of dam rubber off.
2) Cut the tip of adhesive nozzle (12) to the

dimensions of (f) and (g) as shown in the
diagram. 5) Apply adhesive (13) to the outside of dam
q (f) dimension: 10 mm rubber (3) for the operator's cab.
q (g) dimension: 15 mm
D61EX, PX-15E0 13
7. Install front window glass.

1) Aligning with line (e) on position-matching
tape [6] in preceding 5, install operator's
cab (7) and front window glass (1) using
tool X1.
a As it is not possible to correct the
pasting of window glass once
installed, paste with utmost care.
a Paste window glass within 5 minutes
after applying adhesive.
2) After pasting window glass, press window
glass all around until it is closely adhered
to dam rubber.
a Press corners of window glass firmly.
a To dam rubber (3) of operator's cab
(7), apply adhesive (13) to the dimen-
sions of (h) and (j) in the diagram.
q (h) dimension: 10 mm
q (j) dimension: 15 mm
a Apply adhesive (13) higher than dam
rubber (3).
a Apply adhesive uniformly without
irregularity in height.
3) Apply masking tape [8] to front window

glass (1) and operator's cab (7).
4) Apply calking agent (14) to the gap
between front window glass (1) and oper-
ator's cab (7) all around.
2 Calking agent:
Sekisui Silicone Sealant
a Since the effective limit of adhesive
agents is 6 months after the date of
manufacture, do not use adhesives
beyond the effective service limit.
14 D61EX, PX-15E0
5) After applying calking agent (14) to front 8. Install the left and right window glasses.
window glass (1), adjust the contour of 1) Aligning with line (e) on position-matching
calking agent as follows: tape [6] in preceding 5, install doors (9)
a Use rubber spatula [9] to around the and left and right door window glasses (2)
handrail, etc. where it is difficult to fin- using tool X1.
ish the contour with a finger a As it is not possible to correct the
pasting of window glass once
installed, paste with utmost care.
a Paste window glass within 5 minutes
after applying adhesive.
2) After pasting window glass, press window
glass all around until it is closely adhered
to dam rubber.
a Press corners of window glass firmly.
D61EX, PX-15E0 15
a If excessive adhesive agent (13) pro- 3) Calk between the left and right door win-
trudes from trim seal (4) of the pasted left dow glasses and trim seal within the range
and right door window glasses, remove it of dimension (k).
with rubber spatula [9]. 1] Mask the left and right door window
glasses within the range of dimension
(k).
2] Apply calking agent to the clearance
(m) between the left and right door
window glasses (2) and trim seal (4).
a Since the effective limit of calking
agents is 6 months after the date
of manufacture, do not use calk-
ing agent beyond the effective
service limit.
a Apply calking agent to trim seal
joint position (c) too.
2 Calking agent:
Sekisui Silicone Sealant
16 D61EX, PX-15E0
9. Fix window glass (9).

1) To completely fix the front window glass in
close contact with the cab, use Styrofoam
[10] and rubber band [11] to fix it securely
for curing.
a Or use adhesive tape for fixing.
(The diagram shows an operator's
cab on a hydraulic excavator.)
2) Install and fix door handle (5) to the door

window glass on both sides immediately
after pasting.
10. After completing the pasting of window

glasses, remove excessive primer and adhe-
sive attached to window glasses and opera-
tor's cab.
a Using white gasoline, wipe adhesive off
before drying.
a During cleaning, take care not to give
impact to the window glasses.
11. Cure the pasted window glasses.

1) Leave them fixed for 10 hours without
removing stopper rubber, Styrofoam and
rubber bands,
(Temperature 20°C/ humidity 65%)
2) Cure adhesive for 24 hours before actually
operating the machine.
D61EX, PX-15E0 17
Removal and installation of 3. Pull out monitor panel (3) toward the operator's
monitor panel assembly 1 seat.
Removal 4. Disconnect connectors CNS03 (4) and CNS04

k Disconnect the cable from the negative (–) (5).
5. Remove monitor panel assembly (3).
1. Remove cooler box (1) at the front in the oper-
ator's cab.
2. Remove 3 monitor panel bracket mounting

bolts (2).
Installation

removal.
18 D61EX, PX-15E0
Removal and installation of 6. Remove clamp (5a).

dashboard assembly 1
7. Disconnect connectors S13 (6), S214 (7),
Special tools S215 (8) and S218 (9) of wiring harness (5).
a Move the wiring harnesses toward the
New/Remodel
engine and fix them.
Symbol
q S13 (6): Gray
Necessity
Part No. Part name
q S214 (7): Black
Sketch
q S215 (8): Green
Q'ty
q S218 (9): Brown
Vacuum pump
795-703-1100 (100 V) t 1
Vacuum pump
X2 795-703-1111 (220 V) t 1
Vacuum pump
795-703-1121 (240 V) t 1
Removal
(R134a).

guard assembly".

8. Remove air inlet cover (10) of the air condi-
3. Remove the engine hood assembly. For tioner in the operator's cab.
4. Remove 2 clamps (1) and clamp (2).
5. Disconnect 2 heater hoses (3) and 2 air condi-

tioner hoses (4). [*1]
a Move the disconnected hoses toward the
D61EX, PX-15E0 19
9. Remove 2 air filters (11). 13. Lift off dashboard assembly (14).
a Check that all the bolts, wirings and pip-
ings are removed.
4 Dashboard assembly: 75 kg
10. Sling the dashboard assembly.
11. Remove 2 dashboard rear mounting bolts (12).
12. Remove 4 dashboard front mounting bolts

(13), 2 each on the right and left sides.
20 D61EX, PX-15E0
Installation

removal.
[*1]
a When installing each hose, check that it is not
twisted.
a When installing each air conditioner hose, take
care extremely that dirt, dust, water, etc. will
not enter it.
a When tightening an air conditioner hose joint,
check that O-ring [1] is in it.
a Apply compressor oil for R134a (DENSO-ND-
OIL8 or ZEXEL ZXL 100PG (equivalent to
PAG46) to O-ring [1].
3 Tightening torque for air conditioner refriger-

ant piping:
Thread size Tightening torque (Nm {kgm})
16 × 1.5 11.8 – 14.7 {1.2 – 1.5}
22 × 1.5 19.6 – 24.5 {2.0 – 2.5}
24 × 1.5 29.4 – 34.3 {3.0 – 3.5}

1,000 ± 50 g)

only by shortage)
D61EX, PX-15E0 21
Removal and installation of floor 4. Remove 2 clamps (1) and clamp (2).
frame assembly 1
Special tools tioner hoses (4). [*1]
a Move the disconnected hoses toward the
New/Remodel
Symbol
Necessity
Part No. Part name
Sketch
Q'ty
Vacuum pump
795-703-1100 (100 V) t 1
Vacuum pump
X2 795-703-1111 (220 V) t 1
Vacuum pump
795-703-1121 (240 V) t 1
Removal
k Lower the work equipment to the ground 6. Remove 2 clamps (5).
and release the residual pressure in the
piping, referring to Testing and adjusting, 7. Disconnect electrical intake air heater terminal
"Releasing residual pressure in work (6). [*2]
equipment cylinder".
(R134a).

guard assembly". 8. Remove floor cover (7).

22 D61EX, PX-15E0
9. Disconnect wiring harness connectors PL1 (8) 13. Disconnect 3 PPC hoses (14) from the control
and PL2 (9). valve.
14. Disconnect 2 pilot pressure hoses (15).

from flowing out.
10. Open right cover (10) and remove cover

assembly (11).
15. Remove clamp (16).
16. Disconnect horizontal sensor wiring harness

connectors PT1 (17) and PSL (18).
12. Disconnect 3 PPC hoses (13) from the PPC

valve.
from flowing out.
17. Remove right and left engine side covers (19).
D61EX, PX-15E0 23
18. Remove right and left power train side covers 24. Open left covers (29) and (30) and lift off bat-
(20). tery cover assembly (31).
4 Battery cover assembly: 55 kg
19. Disconnect washer tank wiring harness con-

nector (21) and hose (22) on the right side of
the engine. 25. Remove 2 clamps (32) and 2 clamps (33).
20. Remove 2 washer tanks (23). 26. Disconnect wiring harness connectors (34)
and (35) and relay terminal (36).
27. Disconnect ground cable (37).
28. Remove bracket (38).
22. Disconnect wiring harness connectors (25),

(26) and (27).
23. Disconnect starting motor wiring harness ter-

minal (28). [*3]
24 D61EX, PX-15E0
29. Disconnect brake rod (39) on the power train 32. Remove 2 brackets (43), 1 each on the right
unit top from the brake. [*4] and left side.
a Before disconnecting the brake rod,
record the brake pedal stroke. 33. Remove 8 mounting bolts (44), 4 each on the
right and left side, at the rear of the floor frame.
30. Remove clamp (40) and disconnect parking [*7]
brake lever cable (41) from the brake. [*5].
a Before disconnecting the parking brake
lever cable, record the dimensions of the
mounting area.
34. Using a sling (M10, P = 1.5mm), lift off floor

frame assembly (45).
a Check that all the bolts, wirings and pip-
ings are removed.
31. Remove 2 mounting bolts (42), 1 each on the 3 Floor frame assembly: 400 kg
right and left sides, at the front of the floor
frame. [*6].
D61EX, PX-15E0 25
Installation [*6]
3 Floor frame front mounting bolt:
q Carry out installation in the reverse order to 642 ± 29 Nm {65.5 ± 3 kgm}
removal.
[*7]
[*1] 3 Floor frame rear mounting bolt:
a When installing each hose, check that it is not 235 – 285 Nm {23.5 – 29.0 kgm}
twisted.
care extremely that dirt, dust, water, etc. will q Charging air conditioner with refrigerant
not enter it. Using tool X2, charge the air conditioner circuit
a When tightening an air conditioner hose joint, with refrigerant (R134a). (Filling quantity:
check that O-ring [1] is in it. 1,000 ± 50 g)
OIL8 or ZEXEL ZXL 100PG (equivalent to q Refilling with coolant (Supplying coolant
PAG46) to O-ring [1]. only by shortage)

ant piping:
16 × 1.5 11.8 – 14.7 {1.2 – 1.5}
22 × 1.5 19.6 – 24.5 {2.0 – 2.5}
24 × 1.5 29.4 – 34.3 {3.0 – 3.5}
[*2]
3 Electrical intake air heater terminal mounting
bolt: 2.45 – 2.94 Nm {0.25 – 0.3 kgm}
[*3]
3 Starting motor wiring harness terminal
mounting bolt:
19.6 – 25.5 Nm {2.0 – 2.6 kgm}
[*4]
Adjust the brake pedal. For details, see Testing and
adjusting, "Adjusting brake pedal".
[*5]
Adjust the parking brake lever. For details, see
Testing and adjusting, "Adjusting parking brake
lever".
26 D61EX, PX-15E0
D61EX, PX-15E0 27
SEN02578-00

© 2007 KOMATSU
All Rights Reserved
28
SEN02579-00
D61EX-15E0
D61PX-15E0


Electrical system
Removal and installation of engine controller assembly ................................................................................. 2
Removal and installation of steering and transmission controller assembly ................................................... 3
Removal and installation of KOMTRAX terminal assembly ............................................................................ 4
Removal and installation of air conditioner unit assembly .............................................................................. 5
D61EX, PX-15E0 1

engine controller assembly 1
Removal
1. Open up engine left wing cover (1) and lock it.
2. Remove engine left side cover (2).
6. Remove 5 mounting bolts (7) and engine con-

troller assembly (8). [*3]
3. Disconnect aftercooler lower hose (3) from the

intake manifold. [*1]
Installation

removal.
a Before installing the engine controller assem-
bly, remove all dirt, etc. from its wiring harness
connectors.
[*1]
4. Remove hexagon socket head screws (4a)
and (5a) at the center of the connector. [*2] Gasket sealant (LG-6 or LG-7)
5. Disconnect wiring harness connectors EC2 10.5 ± 0.5 Nm {1.07 ± 0.05 kgm}
(4), ENGINE MODULE (5) and EC3 (6).
a Width across flats of hexagon socket: [*2]
3 Hexagon socket head screws (4a) and (5a)
4 mm
at center of connector:
2.82 Nm {0.288 kgm}
[*3]
3 Engine controller assembly mounting bolt:
24 ± 4 Nm {2.45 ± 0.41 kgm}
2 D61EX, PX-15E0

steering and transmission
controller assembly 1
Removal
1. Remove operator's seat assembly (1).

4 Operator's seat assembly: 40 kg
2. Remove cover (2) under the left armrest.
Installation

removal.
[*1]
3 Hexagon socket head screw (8) at center of
each connector: 2.82 Nm {0.288 kgm}
3. Remove 4 mounting bolts (3) and lower steer-

ing and transmission controller assembly (4)
slowly to the floor.
4. Loosen hexagon socket head screw (8) at the

center of each connector. [*1]
a Width across flats of hexagon socket:
4 mm
5. Disconnect wiring harness connectors ST1 (5),

ST2 (6) and ST3 (7).
D61EX, PX-15E0 3
Removal and installation of 4. Remove wiring harness clamp (4).

KOMTRAX terminal assembly 1
5. Disconnect wiring harness connectors (5) and
Removal (6).
k Disconnect the cable from the negative (–) q Connector (5): Turn and pull out.
terminal of the battery. q Connector (6): Press the lock and pull out.
1. Remove operator's seat assembly (1). 6. Loosen hexagon socket head screw (7) at the
center of the connector and disconnect wiring
4 Operator's seat assembly: 40 kg harness connector (8). [*1]
a Width across flats of hexagon socket:
2. Remove cover (2) under the left armrest. 4 mm
7. Remove 4 mounting bolts (9) and KOMTRAX

terminal assembly (10).
3. Remove bellows (3).
Installation

removal.
[*1]
3 Hexagon socket head screw (7) at center of
connector: 2.82 Nm {0.288 kgm}
4 D61EX, PX-15E0
Removal and installation of air 2. Remove air conditioner duct (2) on the left side
conditioner unit assembly 1 of the engine.
Special tools
New/Remodel
Symbol
Necessity
Part No. Part name
Sketch
Q'ty
Vacuum pump
795-703-1100 t 1
(100 V)
Vacuum pump
X2 795-703-1111 t 1
(220 V)
Vacuum pump
795-703-1121 t 1
(240 V)
795-703-1401 Gas leak detector t 1 tioner hoses (4). [*1]
Removal
(R134a).
may lose your sight. Accordingly, you
must be qualified for handling the refriger-
ant and put on protective goggles while
you are collecting the refrigerant or charg-
ing the air conditioner with refrigerant.
1. Open up engine right and left wing covers (1)

and lock them. 4. Remove air inlet cover (5) of the air conditioner
in the operator's cab.
D61EX, PX-15E0 5
5. Remove 2 air filters (6). 8. Pull out monitor panel (9) toward the operator's
seat and disconnect connectors CNS03 (10)
and CNS04 (11).
9. Remove monitor panel assembly (9).
6. Remove cooler box (7) at the front in the oper-

ator's cab.
10. Remove switch panel (12).
11. Remove starting switch ring nut (13).
7. Remove 3 monitor panel bracket mounting

bolts (8).
12. Pull starting switch (14) out of the switch panel.
13. Disconnect wiring harness connectors PUZ

(15), CUP (16), FAM (17), RWL (18), FWL
(19), MAM (20), ASD (21), AC3 (22), AC2 (23).
6 D61EX, PX-15E0
14. Remove right and left ducts (24). 19. Disconnect buzzer wiring harness connector
and remove buzzer (30).

(32).
21. Disconnect wiring harnesses CB1 (33a) and

CB2 (33b).
22. Remove service switch (34).
15. Disconnect wiring harness connector (25).
23. Disconnect wiring harness connectors (35),

(36), (37) and (38) from bracket (32).
16. Disconnect 2 air conditioner unit drain hoses

(26) from the floor.
17. Remove covers (27) and (28).
18. Remove grommet (29) from cover (27) and pull

out the wiring harness through the hole.
24. Remove 3 mounting bolts (39) and blower

assembly (40).
D61EX, PX-15E0 7
Installation

removal.
[*1]
a When installing each hose, check that it is not
twisted.
care extremely that dirt, dust, water, etc. will
not enter it.
a When tightening an air conditioner hose joint,
check that O-ring [1] is in it.
25. Remove air conditioner unit assembly (41). OIL8 or ZEXEL ZXL 100PG (equivalent to
a Check that all the bolts, wirings and pip- PAG46) to O-ring [1].
ings are removed.

ant piping:
16 × 1.5 11.8 – 14.7 {1.2 – 1.5}
22 × 1.5 19.6 – 24.5 {2.0 – 2.5}
24 × 1.5 29.4 – 34.3 {3.0 – 3.5}

1,000 ± 50 g)

only by shortage)
8 D61EX, PX-15E0
D61EX, PX-15E0 9
SEN02579-00

© 2007 KOMATSU
All Rights Reserved
10
SEN02399-00
D61EX-15E0
D61PX-15E0

90 Diagrams and drawings 1

Hydraulic diagrams and drawings
Power train hydraulic circuit diagram .............................................................................................................. 3
Work equipment hydraulic circuit diagram ...................................................................................................... 5
D61EX, PX-15E0 1
SEN02399-00 90 Diagrams and drawings
2 D61EX, PX-15E0
D61EX, PX-15E0 9
SEN02399-00

© 2006 KOMATSU
All Rights Reserved
10
Power train hydraulic circuit diagram 1 Hydraulic circuit diagram
1 D61EX, PX-15E0
D61EX, PX-15E0 SEN02399-00

3
Work equipment hydraulic circuit diagram 1 Hydraulic circuit diagram
D61EX, PX-15E0
Power angle, power tilt dozer (PAT)
1
D61EX, PX-15E0 SEN02399-00

5
Power tilt dozer (PT) Hydraulic circuit diagram
1 D61EX, PX-15E0
D61EX, PX-15E0 SEN02399-00

7
SEN02400-01
D61EX-15E0
D61PX-15E0

90 Diagrams and drawings 1

Electrical diagrams and drawings
Electrical circuit diagram ................................................................................................................................. 3
Connector arrangement diagram .................................................................................................................... 5
D61EX, PX-15E0 1
SEN02400-01 90 Diagrams and drawings
2 D61EX, PX-15E0
D61EX, PX-15E0 7
SEN02400-01

© 2007 KOMATSU
All Rights Reserved
8
Electrical circuit diagram
Electrical circuit diagram D61EX, PX-15E0 1
1
SEN02400-01
D61EX, PX-15E0 3
Connector arrangement diagram
D61EX, PX-15E0
Connector arrangement diagram D61EX, PX-15E0 1
Connector Number Address of Connector Number Address of

Type of Location Type of Location
No. pins stereogram No. pins stereogram
1 DT 4 Intermediate connector [Cab specification] L-8 Right front lamp [ROPS Canopy specification] (If additional
CFR DT 2 —
2 KES1 2 Rear speaker (Left) [Cab specification] L-8 work lamp is equipped)
4 KES1 2 Rear speaker (Right) [Cab specification] K-9 CIG YAZAKI 2 Cigarette lighter E-6
One-pin Intermediate connector [ROPS canopy specification] (If
6 1 Heater wire glass [Cab specification] K-9 CNL DT 3 —
connector additional work lamp is equipped)
7 PA 9 Radio [Cab specification] C-9 Lamp relay [ROPS canopy specification] (If additional work
CNR Relay 6 —
lamp is equipped)
8 DT 2 Accessory (12 V) [Cab specification] C-9
Left rear lamp [ROPS canopy specification] (If additional work
9 YAZAKI 3 Heater wire glass switch [Cab specification] C-8 CRL DT 2 lamp is equipped) —
9 KES1 2 Washer motor (Left) I-1 Right rear lamp [ROPS Canopy specification] (If additional
CRR DT 2 work lamp is equipped) —
10 M 2 Additional light switch [Cab specification] C-8
10 KES1 2 Washer motor (Right) G-6 CUR KES1 3 Information switch R-7
11 M 2 Wiper intermittent switch [Cab specification] C-9 DCL DT 3 Decelerator pedal R-5
11 M 2 Washer motor (Front) G-5 DIAL DT 3 Fuel control dial potentiometer Y-8
12 KES1 6 Rear wiper switch [Cab specification] B-9 E21 DT-A 12 Intermediate connector (Engine controller) G-1, AH-2
12 M 2 Washer motor (Rear) J-1 E22 DT 6 Intermediate connector (Engine controller) F-1, AH-2
13 KES1 6 Right door wiper switch [Cab specification] B-9 E23 DTP 4 Intermediate connector (Engine controller) D-2, AH-3
14 KES1 6 Front wiper switch [Cab specification] B-9 FAC DT 2 Fan pump TVC solenoid AJ-8
15 KES1 6 Left door wiper switch [Cab specification] B-9 FAM KES1 3 Fan reverse mode switch R-7
16 KES1 2 Room lamp [Cab specification] C-7 FAR DT 2 Fan reverse solenoid D-3
17 DT 4 Right door wiper [Cab specification] C-7 Intermediate connector [ROPS canopy specification]
FCF DT 6 —
(If equipped)
18 DT 4 Intermediate connector [Cab specification] H-8
Intermediate connector [ROPS canopy specification]
Intermediate connector (Windshield washer motor) [Cab FCM DT 6 —
19 DT 4 D-5, Z-3 (If equipped)
specification]
FFC DT 6 Intermediate connector (Fender) M-2
20 DTHD#8 1 Cab power supply [Cab specification] D-5, Z-3
FL DT 2 Front additional light (Left) [Cab specification] I-9
21 DTHD#12 1 Cab power supply (Battery direct) [Cab specification] D-6, Z-3
FL1 L 2 Fusible link [Cab specification] Z-3
23 DT 6 Front wiper [Cab specification] H-8
FL2 Terminal 2 Fusible link Z-4
24 DT 4 Left door wiper [Cab specification] D-5
FR DT 2 Front additional light (Right) [Cab specification] H-8
25 Relay (YAZAKI) 4 For light [Cab specification] C-8
FS1 — — Fuse box Z-4
26 Relay (YAZAKI) 6 Left wiper intermittent relay [Cab specification] D-8
FS2 — — Fuse box Z-4
27 Relay 5 Left wiper intermittent selector relay [Cab specification] D-7
FSOL DT 2 Forward clutch ECMV solenoid AK-2
28 Relay (YAZAKI) 6 Front wiper intermittent relay [Cab specification] D-8
FSW DT 2 Forward clutch ECMV (Fill switch) AK-2
29 Relay 5 Front wiper intermittent selector relay [Cab specification] D-7
FWL KES1 4 Headlamp switch R-7
30 Relay (YAZAKI) 6 Right wiper intermittent relay [Cab specification] D-8
G01 DRC26 40 KOMTRAX controller AB-1
31 Relay 5 Right wiper intermittent selector relay [Cab specification] D-7
GND DT 2 Diode (Heater relay) AF-9
32 Relay (YAZAKI) 6 Rear wiper intermittent relay [Cab specification] D-8
GND01 Terminal 1 Ground (Floor) X-1
33 Relay 5 Rear wiper intermittent selector relay [Cab specification] E-8
GND03 Terminal 1 Ground (Fender) L-1
34 Relay (YAZAKI) 4 Heater wire glass relay [Cab specification] D-8
GND04 Terminal 1 Ground (Floor) U-1
35 M 4 Converter [Cab specification] D-8
GND1 Terminal 1 Ground [Cab specification] C-8
36 One-pin 1 Heater wire glass [Cab specification] M-8
connector GND1 Terminal 1 Ground [Engine] AF-6
37 KES1 4 Rear wiper [Cab specification] K-9 GND2 Terminal 1 Ground [Cab specification] C-9
99 DT 6 Intermediate connector (Radiator guard) F-5 GND2 Terminal 1 Ground (Engine) AE-9
100 SWP 6 Intermediate connector (Headlamp) H-1 GND3 Terminal 1 Ground [Cab specification] D-7
203 DT 2 Right head lamp D-4 GND3 Terminal 1 Ground (Engine) AH-2
204 DT 2 Left head lamp D-4 GND4 Terminal 1 Ground [Cab specification] K-9
One-pin GND4 Terminal 1 Ground (Engine) AC-7
205 1 Horn D-3
connector H Terminal 1 Battery relay power supply inlet Z-4
214 DT-B 12 Intermediate connector [Dashboard] S-1 HSA DT 2 HSS-EPC solenoid (Left swing) AK-9
215 DT-C 12 Intermediate connector [Dashboard] T-1 HSB DT 2 HSS-EPC solenoid (Right swing) AK-8
217 DT 2 Caution buzzer R-3 HSP DT 2 TVC solenoid for HSS & work equipment pump AI-7
218 DT-D 12 Intermediate connector (Air conditioner) T-1 HT/A Terminal 1 Heater relay AG-7
224 DT 2 Left working lamp L-8 HT/B Terminal 1 Heater relay AF-9
228 DT 2 Working lamp N-7 HT/C Terminal 1 Heater relay AD-9
244 DT 2 Backup alarm M-7 Intermediate connector [ROPS canopy specification]
KEY DT 6 (If starting switch is equipped) R-9
247 DT 2 Intermediate connector (Left working lamp) M-8
250 Terminal 1 Starting switch terminal B Q-5 KOM2 GT5 1 KOMTRAX controller AB-1
255 Terminal 1 Starting switch terminal R1 Q-4 KOM3 BNC 1 KOMTRAX controller AA-1
260 Terminal 1 Starting switch terminal BR P-4 KOM4 ML 1 KOMTRAX antenna J-9
262 DT 2 Horn switch V-9 M26 M 6 Air conditioner controller R-6
270 Terminal 1 Starting switch terminal ACC P-5 MAM KES1 4 Manual mode switch Q-7
280 Terminal 1 Starting switch terminal C P-5 NSF Relay 5 Neutral safety relay X-1
423 DT 2 Fuel level sensor M-7 NSW DT 3 Travel lock switch Z-8
453 DT 2 Torque converter oil temperature sensor AM-3 PL1 HD-24 23 Intermediate connector (Power train) V-1, AL-3
800 DTHD#12 1 Service power supply X-1 PL2 HD-24 31 Intermediate connector (Power train) V-1, AL-3
1SOL DT 2 1st clutch ECMV solenoid AI-2 PSL DT 2 PPC lock solenoid T-9
1SW DT 2 1st clutch ECMV (Fill switch) AJ-3 PSW DT 2 PPC lock solenoid switch T-9
2SOL DT 2 2nd clutch ECMV solenoid AK-3 PT1 DT 3 Slope sensor T-8
2SW DT 2 2nd clutch ECMV (Fill switch) AJ-3 R1 Relay (YAZAKI) 4 Air conditioner relay R-4
3SOL DT 2 3rd clutch ECMV solenoid AI-3 R2 Relay (YAZAKI) 4 Air conditioner relay R-4
3SW DT 2 3rd clutch ECMV (Fill switch) AI-2 R3 Relay (YAZAKI) 4 Air conditioner relay R-4
A/C DT 2 A/C air compressor AD-9 R4 Relay (YAZAKI) 4 Air conditioner relay R-3
AC1 MIC 17 Air conditioner unit R-7 RH Terminal 1 Electrical intake air heater (Engine) AG-7
AC2 AMP 16 Air conditioner controller S-7 RHR Relay 5 Pre-heater relay Y-1
AC3 AMP 12 Air conditioner controller S-7 RL DT 2 Rear additional light (Left) [Cab specification] L-8
ACC YAZAKI 2 Accessory socket [Cab specification] E-6 RR DT 2 Rear additional light (Right) [Cab specification] J-9
ACF DT 3 Check connector (KOMTRAX) AA-3 RSD DT 2 Diode (Battery relay) W-1
ACG DT 2 Diode (A/C compressor) AF-5 RSOL DT 2 Reverse clutch ECMV solenoid AJ-3
ACM DT 3 Check connector (KOMTRAX) AA-3 RSW DT 2 Reverse clutch ECMV (Fill switch) AJ-3
AL/B Terminal 1 Alternator terminal B AH-4 RWL KES1 4 Rear lamp switch R-7
AL/E Terminal 1 Alternator terminal E AH-4 S03 AMP070 20 Monitor panel Q-9
AL/R Terminal 1 Alternator terminal R AH-4 S04 AMP070 12 Monitor panel Q-9
ASA DT 2 Intermediate connector (Air suspension seat) V-9 S13 DT-A 12 Intermediate connector (Dashboard) S-1
ASD KES1 4 Auto shift-down switch Q-7 S24 Terminal 4 Service switch P-7
BKA Relay 5 Backup alarm relay Z-2 SDS DT 2 Hydraulic oil temperature sensor AI-4
BRK DT 3 Brake pedal U-1 SFTD — 3 Shift-down switch X-9
BUZ KES1 3 Buzzer cancel switch R-8 SFTU — 3 Shift-up switch X-9
C Terminal 1 Battery relay power supply outlet Z-5 SRV DT-A 12 Intermediate connector (Dashboard) R-5
C2 FRAMATOME 2 Engine oil pressure switch AG-6 SR/B Terminal 1 Starting motor safety relay terminal B AG-1
C4 SUMITOMO 4 Boost pressure, air intake manifold temperature sensor AC-8 SR/C Terminal 1 Starting motor safety relay terminal C AG-1
C5 PACKARD 2 Engine coolant temperature sensor AC-8 ST DT 2 Intermediate connector (Starting motor) AH-3
C8 BOSCH 3 Common rail pressure sensor AG-8 ST/B Terminal 1 Starting motor terminal B AG-1
C9 DT 4 Intermediate connector (Injector #1, #2) AC-8 ST/C Terminal 1 Starting motor terminal C AF-1
C10 DT 4 Intermediate connector (Injector #3, #4) AG-8 ST1 DRC26 24 Steering and transmission controller Z-2
C11 DT 4 Intermediate connector (Injector #5, #6) AF-9 ST2 DRC26 40 Steering and transmission controller Z-2
C12 DT 3 Tool port (CAN) AC-6 ST3 DRC26 40 Steering and transmission controller Z-2
C13 FRAMATOME 3 Backup sensor (Camshaft) AC-6 SW Terminal 1 Battery relay terminal BR Z-5
C15 FRAMATOME 3 Ne sensor (Crank) AC-5 SWG Terminal 1 Battery relay ground Z-5
C17 BOSCH 2 Supply pump AG-7 T1F DT 2 Check connector (KOMTRAX) AB-3
C28 DT 2 Intermediate connector (Water-in-fuel sensor) AF-6 T1M DT 2 Check connector (KOMTRAX) AB-3
C29 FRAMATOME 3 Ambient pressure sensor AC-7 TL1 HD-24 12 Intermediate connector (Console) Z-8
CA1 DT 3 CAN terminating resistor AA-1 TL2 DT-B 8 Travel lever Y-8
CA2 DT 3 CAN terminating resistor S-7 TL3 DT 6 Intermediate connector (Shift switch) Y-9
CAN DT-A 12 Intermediate connector (KOMTRAX) AA-3 TL4 DT 6 Intermediate connector (Console) Z-8
One-pin TM1 DT 2 Transmission output shaft speed sensor AM-8
CB1 2 Circuit breaker (Starting switch) P-7
connector TMV HD-24 23 Intermediate connector (Transmission ECMV) AI-3
One-pin WIF DT 2 Water-in-fuel sensor AF-9
CB2 2 Circuit breaker (Air conditioner) Q-6
connector
WSW DT 6 Intermediate connector (Washer motor) [Cab specification] F-5
CE01 DRC26 60 Engine controller AE-5
CE02 DRC26 50 Engine controller AE-5 a The color symbols of the bodies of the heavy duty wire connectors (DT-8 poles, 12 poles) are as follows.
CE03 DTP 4 Engine controller AE-5 DT-A = Gray, DT-B = Black, DT-C = Green, DT-D = Brown
Left front lamp [ROPS Canopy specification] (If additional
CFL DT 2 —
work lamp is equipped)
SEN02400-01
D61EX, PX-15E0
5

2012 D61ex-15e0

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SEN02387-02

BULLDOZER 1SHOP MANUAL

Machine Model Serial number

D61EX-15E0 B45001 and up

00 Index and foreword 1

Composition of shop manual................................................................................................................ 2

Composition of shop manual 1

Section Title Form Number

Shop Manual, contents binder, binder label and tabs SEN02387-02

00 Index and foreword SEN02388-02

10 Structure, function and maintenance standard SEN02390-00

20 Standard value table SEN02391-00

30 Testing and adjusting SEN02392-00

50 Disassembly and assembly SEN02394-00 Q

90 Diagrams and drawings SEN02395-01

Foreword and general information SEN02397-00

10 Structure, function and maintenance standard

Hydraulic system, Part 1 SEN02477-00

20 Standard value table

30 Testing and adjusting

Measuring engine oil pressure .................................................................................................... 17

Classification and procedures of troubleshooting ....................................................................... 5

Failure code [DXA0KA] HSS pump TVC solenoid: Disconnection.............................................. 32

50 Disassembly and assembly

Engine (SAA6D170E-1) SEN02571-00

Cab and its attachments SEN02578-00

90 Diagrams and drawings

D61EX, PX-15E0 Bulldozer

BULLDOZER 1SHOP MANUAL

Machine Model Serial number

D61EX-15E0 B45001 and up

00 Index and foreword 1

Safety notice 1 (Rev. 2006/09)

1. General precautions 7) If welding repairs are needed, always

4. Precautions for sling work and making

8. Precautions for disconnecting and con-

a Example of O-ring (Fitted to every joint of

a For tightening torque, see the precautions for

How to read the shop manual 1

1. Composition of shop manual

00. Index and foreword

10. Structure, function and maintenance standard

20. Standard value table

30. Testing and adjusting

50. Disassembly and assembly

2. Revision and distribution

q Revised edition mark

Symbol Item Remarks

k Safety Special safety precautions are necessary when performing work.

Special technical precautions or other precautions for preserving stan-

2 Coat Places to be coated with adhesives, etc. during assembly.

Explanation of terms for maintenance standard 1

1. Standard size and tolerance

a The tolerance may be indicated in the text

q Usually, the size of a hole and the size of

2. Standard clearance and standard value 5. Clearance limit

4. Repair limit and allowable value

Handling electric equipment and hydraulic component 1

Points to remember when handling electric

2. Main failures occurring in wiring harness

2) Defective crimping or soldering of connec-

4) High-pressure water entering connector

5) Oil or dirt stuck to connector