Description
Komatsu D61EXi-24 D61PXi-24 Workshop Manual for crawler bulldozers with serial numbers B60001 and up.
This comprehensive 2,909-page workshop manual provides detailed technical information for servicing, maintaining, diagnosing and repairing the Komatsu D61EXi-24 and D61PXi-24 bulldozers. It is intended for professional mechanics, plant engineers, service technicians and experienced owners responsible for maintaining these advanced machines.
The Komatsu D61EXi-24 D61PXi-24 Workshop Manual explains the construction and operation of the machine’s mechanical, hydraulic, electrical, electronic and intelligent control systems. Detailed specifications, technical diagrams, component illustrations and step-by-step procedures support accurate fault diagnosis and repair.
This manual specifically covers Komatsu D61EXi-24 and D61PXi-24 machines beginning with serial number B60001. Machines manufactured for different serial-number ranges or regional markets may use different components, settings and procedures, so the complete model and serial number should always be confirmed before work begins.
Workshop manual coverage includes:
Engine and related equipment – Detailed information covering the diesel engine, fuel system, lubrication system, cooling equipment, air intake, exhaust system, engine mounting and associated components.
Power train – Technical descriptions, testing information and repair procedures for the torque converter, transmission, drive shafts, steering system, brakes, final drives and related power-transmission components.
Undercarriage – Inspection, adjustment, servicing and repair information for the track assemblies, track frames, rollers, carrier rollers, idlers, sprockets, recoil mechanisms and track-tension equipment.
Hydraulic system – Structure, operation, testing and repair procedures for hydraulic pumps, control valves, cylinders, tanks, filters, hoses, pipework and hydraulic circuits.
Work equipment – Service and repair procedures for the blade, lift cylinders, tilt mechanism, linkages, pins, mountings and ripper equipment where fitted.
Electrical system – Information covering batteries, starting equipment, charging system, wiring, connectors, switches, sensors, lighting, monitoring equipment and electrical controls.
Electronic control equipment – Explanations and diagnostic procedures for electronic control units, sensors, warning systems, machine monitors and connected electronic components.
Intelligent machine-control system – Technical information relating to the integrated machine-control equipment fitted to the D61EXi-24 and D61PXi-24, including components associated with automated blade-control operation.
Operator’s compartment – Removal, installation and servicing information covering the cab, seat, pedals, control levers, display equipment, heating, ventilation and air-conditioning components.
Testing and adjustment – Procedures for checking hydraulic pressures, operating speeds, electrical values, component clearances and overall machine performance.
Troubleshooting – Symptom-based diagnostic information for identifying mechanical, hydraulic, electrical and electronic problems. Possible causes and recommended checks help technicians follow a logical testing sequence.
Disassembly and assembly – Step-by-step instructions for removing, dismantling, inspecting, rebuilding and reinstalling major components and assemblies.
Maintenance standards – Standard dimensions, permissible wear limits, clearances and inspection criteria used to determine whether components can be reused or require replacement.
The Komatsu D61EXi-24 D61PXi-24 Workshop Manual is particularly valuable when investigating difficult starting, reduced engine performance, overheating, transmission faults, steering difficulties, brake problems, hydraulic weakness, slow blade movement, electrical failures or machine warning indications.
Following the correct diagnostic sequence helps identify the cause of a fault before unnecessary dismantling begins. Hydraulic pressures, electrical signals, operating speeds and mechanical clearances can be compared with the specified values to determine whether the affected system is operating correctly.
The structure and function sections explain how the machine’s systems and individual components operate. This background information is valuable when a problem involves several connected systems, such as an electrical control issue affecting hydraulic operation or a sensor signal influencing machine performance.
Testing and adjustment procedures allow technicians to measure machine condition before beginning repairs. The same tests can be repeated after the work has been completed to confirm that the machine has been correctly assembled, adjusted and returned to the required operating standard.
Detailed removal, disassembly and assembly procedures support workshop operations involving the engine, transmission, steering and brake equipment, final drives, hydraulic pumps, control valves, cylinders, work equipment and undercarriage assemblies.
Important precautions, measurements and tightening requirements are included throughout the manual. Following this information reduces the risk of damage, contamination, incorrect adjustment or improper component installation during servicing and overhaul work.
The intelligent machine-control sections provide the specialised technical information required for the “i” models. These systems combine electronic controls, sensors and hydraulic functions to assist blade operation, making the correct workshop information essential for effective diagnosis and repair.
The Komatsu D61EXi-24 D61PXi-24 Workshop Manual can also support planned maintenance and preventative repair work. Regular inspection of the undercarriage, hydraulic system, work equipment and electrical components can help identify developing wear before it results in an expensive breakdown.
Maintenance standards provide the measurements required to assess component condition. Workshops can use these limits when deciding whether parts remain serviceable or require adjustment, repair or replacement.
Machine coverage:
Komatsu D61EXi-24 Bulldozer – Serial Number B60001 and up
Komatsu D61PXi-24 Bulldozer – Serial Number B60001 and up
The EX and PX versions use different track and undercarriage arrangements to suit different operating conditions. The exact model should therefore be confirmed before applying specifications, performing adjustments or ordering replacement components.
This publication should not be confused with manuals for the standard D61EX-24 and D61PX-24 machines without the “i” designation. The intelligent machine-control equipment fitted to these models requires the correct diagnostic and service procedures.
With 2,909 pages of comprehensive technical information, the Komatsu D61EXi-24 D61PXi-24 Workshop Manual is an essential reference for routine servicing, troubleshooting, testing, adjustment, component repair and complete bulldozer overhaul.
Supplied as a digital PDF workshop manual for convenient use on a workshop computer, laptop or compatible device.
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