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Komatsu Crawler Dozers D50-, D51-, D53- Operation Maintenance Manuals

Complete Operation Maintenance Manuals for Komatsu Crawler Dozers D50P-16, D50PL-16, D51EXi-22, D51PXi-22, D53A-17, D53P-17, D53A-17, D53P-17, with all the service information to maintain & operate.

KEAM019300 – Crawler Dozer D51EXi-22, D51PXi-22 Operation & Maintenance Manual (SN-B13500&up).pdf
SEAM13FC00 – Bulldozer D50P,PL-16 Operation & Maintenance Manual (SN68001&up).pdf
SEAM026300P – Bulldozer D53A,P-17 Operation & Maintenance Manual (SN82727&up).pdf
SEAM01341703 – Bulldozer D53A,P-17 Operation & Maintenance Manual (SN80001&up).pdf

PRODUCT DETAILS:
Total Pages: 613 pages
File Format: PDF (Internal Links, Bookmarked, Table of Contents, Searchable, Printable, high quality)
Language: English

TABLE OF CONTENTS
FOREWORD
BEFORE READING THIS MANUAL . . .
SAFETY INFORMATION . . . .
INTRODUCTION . . .
USE OF MACHINE . . . .
DIRECTIONS OF MACHINE . . . .
PRODUCT IDENTIFICATION . . . .
PRODUCT IDENTIFICATION PLATE . . . .
ENGINE SERIAL NUMBER AND EMISSION LABEL . . .
SERIAL NUMBERS AND DEALER INFORMATION . . .
MODEL: D51EXi/PXi-22 . . . .
INTRODUCTION . . .
MACHINE FEATURES . . .
SAFETY
SAFETY AND WARNING DECALS . . . 1-2
LOCATION OF THE SAFETY DECALS . . . 1-3
GENERAL SAFETY RULES AND PRECAUTIONS . . . 1-8
GENERAL SAFETY RULES . . . 1-8
UNAUTHORIZED MODIFICATIONS . . . . 1-9
GENERAL SAFETY AT JOB SITE . . . 1-9
WORKING ON LOOSE GROUND . . . 1-9
SAFETY FEATURES . . . . 1-10
PERSONAL PROTECTIVE EQUIPMENT . . . 1-10
FIRE AND EXPLOSION PREVENTION . . . . 1-11
FIRE CAUSED BY FUEL OR OIL . . . . 1-11
FIRE CAUSED BY ACCUMULATION OF FLAMMABLE MATERIAL . . . 1-11
FIRE FROM ELECTRICAL SYSTEM . . . 1-12
FIRE FROM HYDRAULIC LINE . . . 1-12
WINDSHIELD WASHER FLUID . . . 1-12
ACTION IF FIRE OCCURS . . . 1-12
DUST HAZARDS . . . 1-12
BLAST ZONE HAZARD . . . 1-13
KEEP OPERATOR’S CAB CLEAN . . . 1-13
UNAUTHORIZED MODIFICATIONS . . . . 1-13
LEAVING OPERATOR’S COMPARTMENT . . . . 1-14
PARKING BRAKE AND EQUIPMENT LOCKS . . . 1-14
PRECAUTIONS WHEN GETTING ON OR OFF MACHINE . . . . 1-15
WHEN STANDING UP FROM OPERATOR’S SEAT . . . 1-15
WHEN LEAVING MACHINE . . . . 1-15
MOUNTING AND DISMOUNTING . . . . 1-16
CRUSH OR PINCH POINT DANGERS . . . 1-16
FIRE EXTINGUISHER AND FIRST AID KIT . . . . 1-16
INSIDE OPERATOR’S COMPARTMENT . . . 1-17
PRECAUTIONS WHEN USING ROPS . . . . 1-17
PRECAUTIONS FOR OPERATION . . . .
IN COLD AREAS . . . .
PRECAUTIONS FOR BLADE AUTOMATIC CONTROL . . . .
PRECAUTIONS BEFORE STARTING OPERATIONS . . . .
PRE-OPERATIONAL CHECKS . . .
STARTING YOUR WORK OPERATIONS . . . .
WORK SITE HAZARDS . . .
AVOIDING DANGEROUS SITUATIONS . . .
HIGH VOLTAGE LINES . . .
RULES FOR ROAD TRAVEL . . . .
PRECAUTIONS WHEN TRAVELING . . . .
USING BRAKES . . . .
RULES FOR TRAVELING IN REVERSE . . .
TRAVELING ON ICY OR SNOW-COVERED SURFACES . . .
WORKING ON LOOSE OR UNSTABLE GROUND . . .
TRAVEL ON SLOPES . . .
PARKING THE MACHINE . . .
PRECAUTIONS DURING MAINTENANCE OPERATIONS . . .
WARNING TAGS . . .
EQUIPMENT STORAGE . . .
WORKING UNDER THE MACHINE . . .
USING DROP LAMPS . . .
KEEPING THE MACHINE CLEAN . . . .
KEEP WORKPLACE CLEAN AND TIDY . . .
APPOINT LEADER WHEN WORKING WITH OTHERS . . .
STOP ENGINE BEFORE CARRYING OUT MAINTENANCE . . . .
RUNNING THE MACHINE DURING MAINTENANCE . . .
RULES FOR REFUELING THE MACHINE . . .
COOLING SYSTEM PRECAUTIONS . . . .
WORK UNDER THE MACHINE . . . .
PRECAUTIONS WHEN USING HAMMER . . . .
TURN THE BATTERY DISCONNECT SWITCH TO THE OFF POSITION . . . .
REPAIR WELDING . . .
ENGINE SYSTEM HIGH VOLTAGE . . .
BATTERY PRECAUTIONS . . . .
STARTING THE MACHINE . . . .
HIGH PRESSURE HOSES . . . .
HANDLING HIGH-PRESSURE HOSES . . . .
PRECAUTION FOR HIGH FUEL PRESSURE . . . .
HIGH TEMPERATURE AREAS . . .
ROTATING PARTS . . .
DISPOSAL OF WASTE MATERIALS . . . .
MERCURY CONTAINING COMPONENT(S) . . . .
USING HIGH-PRESSURE GREASE TO ADJUST TRACK TENSION . . . .
DO NOT DISASSEMBLE RECOIL SPRING . . .
ACCUMULATOR AND GAS SPRING . . . .
CRITICAL PARTS . . . .
PRECAUTIONS FOR CHECK AND MAINTENANCE . . .
PRECAUTIONS FOR iB GNSS ANTENNA . . . .
TRANSPORTING THE MACHINE . . . . 1-37
LOADING AND SECURING THE MACHINE . . . 1-37
TOWING THE MACHINE . . . . 1-38
OPERATION
GENERAL VIEWS . . . . 2-2
VIEW OF MACHINE . . . 2-2
VIEW OF CONTROLS AND GAUGES . . . . 2-4
MACHINE MONITOR SYSTEM . . . . 2-6
MONITOR LAYOUT . . . 2-6
BASIC OPERATION OF MONITOR PANEL . . . 2-7
CHECK MONITOR SYSTEM . . . . 2-8
MONITOR CHECK ITEMS . . . 2-9
EMERGENCY ALERTS . . . . 2-9
ENGINE OIL PRESSURE CAUTION LAMP . . . 2-9
ENGINE COOLANT TEMPERATURE CAUTION LAMP . . . 2-10
HYDRAULIC OIL TEMPERATURE CAUTION LAMP . . . 2-10
HST CHARGE PRESSURE CAUTION LAMP . . . 2-10
CHARGE FILTER CLOG CAUTION LAMP . . . . 2-10
WARNING ALERTS . . . . 2-11
BATTERY CHARGE CAUTION LAMP . . . 2-11
AIR CLEANER CLOGGING CAUTION LAMP . . . 2-12
WATER IN FUEL LAMP . . . . 2-12
MAINTENANCE CAUTION LAMP . . . 2-12
CONSOLE CONTROL SWITCHES . . . 2-13
SWITCH LAYOUT VIEW . . . . 2-13
LAMP SWITCH . . . 2-13
BUZZER CANCEL SWITCH . . . 2-14
INFORMATION SWITCH . . . 2-14
HEATER SWITCH . . . 2-14
IGNITION SWITCH . . . . 2-15
HORN SWITCH . . . 2-16
WIPER SWITCH . . . 2-16
CAB LAMP SWITCH . . . 2-17
CIGARETTE LIGHTER . . . 2-17
ACCESSORY SOCKET . . . 2-17
METER DISPLAY . . . . 2-18
ENGINE COOLANT TEMPERATURE GAUGE . . . 2-18
HYDRAULIC OIL TEMPERATURE GAUGE . . . 2-19
DISPLAY PANEL (A) . . . . 2-19
FUEL LEVEL GAUGE . . . . 2-23
REVERSE TRAVEL SPEED SET SWITCH . . . 2-23
SHIFT MODE SWITCH . . . 2-23
ENGINE INTAKE AIR PRE-HEAT PILOT LAMP . . . 2-23
DISPLAY PANEL (B) . . . . 2-24
FAN ROTATION SELECTOR SWITCH . . . 2-25
FLOAT MODE MONITOR . . . . 2-25
WARNING LAMP VIEW . . . 2-26
WARNING LAMP (1) . . . .
USING FAILURE CODE DISPLAY . . .
USING MAINTENANCE MODE . . .
METHOD OF SELECTING EACH MODE . . . .
USING OIL AND FILTER MAINTENANCE MODE . . .
USING ADJUSTMENT MODE . . .
CONTROL LEVERS AND PEDALS . . .
LEVER LAYOUT VIEW . . . .
LOCK LEVERS . . .
JOYSTICK (STEERING, DIRECTIONAL AND GEAR . . .
SHIFT LEVER) . . . .
BLADE CONTROL LEVER . . .
ANGLING CONTROL . . . .
WORK EQUIPMENT LOCK LEVER . . . .
FUEL CONTROL DIAL . . .
DECELERATOR PEDAL . . . .
BRAKE PEDAL . . .
PARKING BRAKE LEVER . . . .
DOOR AND WINDOW SYSTEM . . .
DOOR – OPEN LOCK . . .
SASH GLASS INTERMEDIATE LOCK . . .
SAFETY LOCKS AND SECURITY . . .
DOOR LOCK . . . .
CAP, COVER WITH LOCK . . .
METHOD OF OPENING OR CLOSING HYDRAULIC TANK CAP . . . .
OPEN AND CLOSE FUEL FILLER PORT CAP . . . .
OPEN . . . .
CLOSE . . .
METHOD OF OPENING AND CLOSING COVER WITH LOCK . . . .
TO OPEN THE COVER (LOCKED COVER) . . . .
TO LOCK THE COVER . . .
LOCKABLE AREAS . . . .
SEAT POCKET . . . .
ADDITIONAL FEATURES AND ACCESSORIES . . .
AIR CONDITIONER AND FEET HEATER . . . .
GENERAL DESCRIPTION OF CONTROL PANEL . . . .
MODE SELECTOR SWITCH . . . .
BLOWER SPEED SELECTOR SWITCH . . .
TEMPERATURE CONTROL SWITCH . . . .
PRECAUTIONS WHEN USING AIR CONDITIONER . . . .
FEET HEATER . . . .
RADIO . . . .
EXPLANATION OF FEATURES . . .
POWER SWITCH/VOLUME . . .
AUTO-STORE/PRESET SCAN BUTTON . . . .
BASS CONTROL KNOB . . . .
TREBLE CONTROL KNOB . . .
LOUDNESS BUTTON . . . .
TIME/RADIO DISPLAY SELECTOR BUTTON . . .
TAPE EJECT BUTTON . . . 2-54
CASSETTE DOOR . . . 2-54
FAST FORWARD, REWIND BUTTONS . . . 2-54
PRESET BUTTONS . . . . 2-54
METAL TAPE BUTTON . . . . 2-55
MANUAL TUNING BUTTONS . . . . 2-55
SEEK TUNING BUTTONS . . . . 2-55
BAND SELECTOR BUTTON . . . . 2-55
METHOD OF OPERATION . . . . 2-56
LISTENING TO RADIO . . . 2-57
LISTENING TO A CASSETTE TAPE . . . . 2-57
REVERSING TAPE . . . . 2-58
PRECAUTION WHEN USING . . . 2-58
ASHTRAY . . . 2-59
LUNCH BOX HOLDER STRAP . . . 2-59
CUP HOLDER . . . 2-59
TOOL BOX . . . . 2-59
GREASE PUMP HOLDER . . . . 2-60
ELECTRICAL POWER ADAPTER . . . 2-60
BATTERY DISCONNECT SWITCH . . . . 2-61
FUSES . . . 2-62
FUSES . . . . 2-62
FUSE CAPACITIES AND CIRCUIT NAMES . . . 2-62
PRECAUTIONS BEFORE STARTING WORK OPERATIONS . . . 2-65
PRE-OPERATIONAL CHECKS . . . 2-65
WALK-AROUND CHECKS . . . 2-65
CHECKS BEFORE STARTING . . . 2-66
ADJUSTMENTS BEFORE OPERATION . . . 2-80
ADJUST ARMREST . . . . 2-81
FASTENING AND REMOVING SEAT BELT . . . 2-81
ADJUSTING MIRROR . . . . 2-82
OPERATIONS AND CHECKS BEFORE . . . 2-82
STARTING ENGINE . . . 2-82
STARTING THE ENGINE . . . . 2-84
NORMAL OR COLD START PROCEDURES . . . 2-84
COLD WEATHER STARTS . . . 2-85
OPERATIONS AND CHECKS AFTER STARTING ENGINE . . . . 2-89
BREAKING IN THE MACHINE . . . 2-89
WARMING UP ENGINE . . . . 2-89
STARTING IN COLD WEATHER . . . . 2-90
STOPPING THE ENGINE . . . . 2-92
MOVING, STEERING, STOPPING AND PARKING THE MACHINE . . . 2-93
PREPARATIONS FOR MOVING THE MACHINE . . . . 2-93
MOVING MACHINE FORWARD OR REVERSE . . . . 2-94
CHANGING SPEED RANGES . . . 2-96
STEERING THE MACHINE . . . . 2-98
NORMAL TURN . . . . 2-98
MAKING A LEFT OR RIGHT TURN . . . . 2-98
MAKING A PIVOT TURN . . . . 2-99
TURNING WHILE DESCENDING A SLOPE . . . 2-99
COUNTER-ROTATION TURN . . . 2-99
STOPPING THE MACHINE . . . 2-100
PARKING MACHINE . . . . 2-102
CHECK AFTER FINISHING WORK . . . 2-103
CHECK AFTER SHUTTING OFF ENGINE . . . . 2-103
STARTING YOUR WORK OPERATIONS . . . . 2-104
AVOIDING DANGEROUS SITUATIONS . . . . 2-104
HIGH VOLTAGE LINES . . . . 2-106
OPERATING THE MACHINE . . . 2-107
PAY ATTENTION TO GAUGES . . . . 2-107
PERMISSIBLE WATER DEPTH . . . 2-107
METHOD OF USING BRAKES . . . 2-107
WHEN TRAVELING UP OR DOWN HILLS . . . 2-107
PRECAUTIONS ON SLOPES . . . . 2-108
BE AWARE OF FUEL LEVEL . . . . 2-108
PRECAUTIONS WHEN ENGINE STOPS ON A SLOPES . . . . 2-108
ALWAYS KEEP THE DOORS CLOSED DURING OPERATIONS . . . 2-108
DO NOT MODIFY THE CAB GLASS IN ANY WAY . . . . 2-108
PRECAUTIONS FOR BLIND SPOTS CAUSED BY CAB STAYS . . . 2-108
CUTTING A GRADE . . . 2-109
DOZING . . . . 2-109
BACK GRADING A SURFACE . . . 2-109
CUTTING HARD OR FROZEN GROUND OR DITCHING . . . 2-110
FELLING TREES, REMOVING STUMPS . . . 2-110
SIDE-CUTTING OPERATIONS . . . 2-110
UNDERCARRIAGE CARE . . . . 2-111
OPERATION METHOD . . . . 2-111
INSPECTION AND ADJUSTMENT . . . . 2-111
INSPECTION AND REPAIR . . . 2-112
MEASURING LINK PITCH . . . 2-112
MEASURING HEIGHT OF GROUSER . . . 2-112
MEASURING OUTSIDE DIAMETER OF TRACK ROLLER . . . . 2-113
TRANSPORTING THE MACHINE . . . 2-114
LOADING OR UNLOADING A TRAILER . . . 2-114
PRE-TRANSPORTATION PROCEDURES . . . . 2-115
SECURING MACHINE . . . . 2-116
UNLOADING THE MACHINE . . . . 2-119
LIFTING THE MACHINE . . . 2-120
FOR BASE MACHINE . . . 2-120
FOR MACHINE EQUIPPED WITH RIPPER . . . 2-121
COLD WEATHER OPERATION . . . . 2-122
FUEL AND LUBRICANTS . . . . 2-122
COOLING SYSTEM COOLANT . . . . 2-122
BATTERY . . . . 2-123
PRECAUTIONS ON PARTICULAR JOBSITES . . . 2-124
DISCHARGED BATTERY . . . . 2-124
REMOVE AND INSTALL BATTERY . . . . 2-125
BATTERY CHARGES . . . 2-125
STARTING ENGINE WITH BOOSTER CABLES . . . 2-126
GENERAL TROUBLESHOOTING . . . 2-128
AFTER RUNNING OUT OF FUEL . . . . 2-128
TOWING THE MACHINE . . . 2-128
WHEN IT IS POSSIBLE TO START ENGINE . . . 2-129
WHEN ENGINE DOES NOT START . . . . 2-129
RELEASING THE BRAKES . . . . 2-129
CONNECTING PUMP TO MACHINE . . . . 2-130
AFTER TOWING MACHINE . . . . 2-132
ELECTRICAL SYSTEM PROBLEMS . . . 2-134
MONITOR PANEL . . . 2-135
CHASSIS PROBLEMS . . . . 2-136
ENGINE PROBLEMS . . . . 2-137
LONG TERM STORAGE . . . 2-138
BEFORE STORAGE . . . . 2-138
DURING STORAGE . . . 2-138
AFTER STORAGE . . . 2-138
MACHINES EQUIPPED WITH KOMTRAX SYSTEMS . . . . 2-139
BASIC PRECAUTIONS . . . 2-139
MAINTENANCE
MAINTENANCE INFORMATION . . .
SERVICE METER READING . . . .
KOMATSU GENUINE REPLACEMENT PARTS . . . .
KOMATSU GENUINE LUBRICANTS . . .
WINDSHIELD WASHER FLUID . . .
FRESH AND CLEAN LUBRICANTS . . . .
CHECK DRAINED OIL AND USED FILTER . . .
FUEL STRAINER . . . .
WELDING INSTRUCTIONS . . .
DO NOT DROP THINGS INSIDE MACHINE . . .
DUSTY JOBSITE . . . .
AVOID MIXING LUBRICANTS . . . .
HYDRAULIC SYSTEM – AIR BLEEDING . . .
HYDRAULIC HOSE INSTALLATION . . . .
CHECKS AFTER INSPECTION AND MAINTENANCE WORKS . . . .
LOCKING THE INSPECTION COVER . . . .
OPENING OR CLOSING RADIATOR GRILL . . .
LUBRICANTS, COOLANT AND FILTERS . . . .
OUTLINE OF SERVICE . . . .
HANDLING OIL, FUEL, COOLANT, AND PERFORMING OIL CLINIC . . . .
OIL . . .
FUEL . . .
COOLING SYSTEM COOLANT . . .
GREASE . . . .
CARRYING OUT KOWA (KOMATSU OIL WEAR ANALYSIS) . . . .
OIL AND FUEL STORAGE . . .
FILTERS . . . .

KEAM019300 – Crawler Dozer D51EXi-22, D51PXi-22 Operation & Maintenance Manual (SN-B13500&up)….2
FOREWORD….5
    BEFORE READING THIS MANUAL….5
    SAFETY INFORMATION….6
    INTRODUCTION….7
      USE OF MACHINE….7
      DIRECTIONS OF MACHINE….7
    PRODUCT IDENTIFICATION….8
      PRODUCT IDENTIFICATION PLATE….8
      ENGINE SERIAL NUMBER AND EMISSION LABEL….9
    SERIAL NUMBERS AND DEALER INFORMATION….10
      MODEL: D51EXi/PXi-22….10
    INTRODUCTION….11
      MACHINE FEATURES….11
    CONTENTS….12
SAFETY….26
    SAFETY AND WARNING DECALS….27
      LOCATION OF THE SAFETY DECALS….28
    GENERAL SAFETY RULES AND PRECAUTIONS….33
      GENERAL SAFETY RULES….33
        UNAUTHORIZED MODIFICATIONS….34
        GENERAL SAFETY AT JOB SITE….34
        WORKING ON LOOSE GROUND….34
      SAFETY FEATURES….35
      PERSONAL PROTECTIVE EQUIPMENT….35
      FIRE AND EXPLOSION PREVENTION….36
        FIRE CAUSED BY FUEL OR OIL….36
        FIRE CAUSED BY ACCUMULATION OF FLAMMABLE MATERIAL….36
        FIRE FROM ELECTRICAL SYSTEM….37
        FIRE FROM HYDRAULIC LINE….37
        WINDSHIELD WASHER FLUID….37
      ACTION IF FIRE OCCURS….37
      DUST HAZARDS….37
      BLAST ZONE HAZARD….38
      KEEP OPERATOR'S CAB CLEAN….38
      UNAUTHORIZED MODIFICATIONS….38
      LEAVING OPERATOR’S COMPARTMENT….39
        PARKING BRAKE AND EQUIPMENT LOCKS….39
      PRECAUTIONS WHEN GETTING ON OR OFF MACHINE….40
        WHEN STANDING UP FROM OPERATOR'S SEAT….40
        WHEN LEAVING MACHINE….40
      MOUNTING AND DISMOUNTING….41
      CRUSH OR PINCH POINT DANGERS….41
      FIRE EXTINGUISHER AND FIRST AID KIT….41
      INSIDE OPERATOR’S COMPARTMENT….42
      PRECAUTIONS WHEN USING ROPS….42
      PRECAUTIONS FOR OPERATION….42
        IN COLD AREAS….42
      PRECAUTIONS FOR BLADE AUTOMATIC CONTROL….43
    PRECAUTIONS BEFORE STARTING OPERATIONS….44
      PRE-OPERATIONAL CHECKS….44
      STARTING YOUR WORK OPERATIONS….44
      WORK SITE HAZARDS….44
      AVOIDING DANGEROUS SITUATIONS….45
      HIGH VOLTAGE LINES….47
    RULES FOR ROAD TRAVEL….48
      PRECAUTIONS WHEN TRAVELING….48
        USING BRAKES….48
      RULES FOR TRAVELING IN REVERSE….49
      TRAVELING ON ICY OR SNOW-COVERED SURFACES….49
      WORKING ON LOOSE OR UNSTABLE GROUND….49
      TRAVEL ON SLOPES….49
      PARKING THE MACHINE….50
    PRECAUTIONS DURING MAINTENANCE OPERATIONS….51
      WARNING TAGS….51
      EQUIPMENT STORAGE….51
      WORKING UNDER THE MACHINE….52
      USING DROP LAMPS….52
      KEEPING THE MACHINE CLEAN….52
      KEEP WORKPLACE CLEAN AND TIDY….52
      APPOINT LEADER WHEN WORKING WITH OTHERS….52
      STOP ENGINE BEFORE CARRYING OUT MAINTENANCE….53
      RUNNING THE MACHINE DURING MAINTENANCE….54
      RULES FOR REFUELING THE MACHINE….54
      COOLING SYSTEM PRECAUTIONS….54
      WORK UNDER THE MACHINE….54
      PRECAUTIONS WHEN USING HAMMER….55
      TURN THE BATTERY DISCONNECT SWITCH TO THE OFF POSITION….55
      REPAIR WELDING….55
      ENGINE SYSTEM HIGH VOLTAGE….55
      BATTERY PRECAUTIONS….56
      STARTING THE MACHINE….57
      HIGH PRESSURE HOSES….57
        HANDLING HIGH-PRESSURE HOSES….57
      PRECAUTION FOR HIGH FUEL PRESSURE….58
      HIGH TEMPERATURE AREAS….58
      ROTATING PARTS….58
      DISPOSAL OF WASTE MATERIALS….58
      MERCURY CONTAINING COMPONENT(S)….58
      USING HIGH-PRESSURE GREASE TO ADJUST TRACK TENSION….59
      DO NOT DISASSEMBLE RECOIL SPRING….59
      ACCUMULATOR AND GAS SPRING….59
      CRITICAL PARTS….60
      PRECAUTIONS FOR CHECK AND MAINTENANCE….61
      PRECAUTIONS FOR iB GNSS ANTENNA….61
    TRANSPORTING THE MACHINE….62
      LOADING AND SECURING THE MACHINE….62
      TOWING THE MACHINE….63
OPERATION….66
    GENERAL VIEWS….67
      VIEW OF MACHINE….67
      VIEW OF CONTROLS AND GAUGES….69
    MACHINE MONITOR SYSTEM….71
      MONITOR LAYOUT….71
      BASIC OPERATION OF MONITOR PANEL….72
      CHECK MONITOR SYSTEM….73
    MONITOR CHECK ITEMS….74
      EMERGENCY ALERTS….74
        ENGINE OIL PRESSURE CAUTION LAMP….74
        ENGINE COOLANT TEMPERATURE CAUTION LAMP….75
        HYDRAULIC OIL TEMPERATURE CAUTION LAMP….75
        HST CHARGE PRESSURE CAUTION LAMP….75
        CHARGE FILTER CLOG CAUTION LAMP….75
      WARNING ALERTS….76
        BATTERY CHARGE CAUTION LAMP….76
        AIR CLEANER CLOGGING CAUTION LAMP….77
        WATER IN FUEL LAMP….77
        MAINTENANCE CAUTION LAMP….77
    CONSOLE CONTROL SWITCHES….78
      SWITCH LAYOUT VIEW….78
        LAMP SWITCH….78
        BUZZER CANCEL SWITCH….79
        INFORMATION SWITCH….79
        HEATER SWITCH….79
        IGNITION SWITCH….80
        HORN SWITCH….81
        WIPER SWITCH….81
        CAB LAMP SWITCH….82
        CIGARETTE LIGHTER….82
        ACCESSORY SOCKET….82
      METER DISPLAY….83
        ENGINE COOLANT TEMPERATURE GAUGE….83
        HYDRAULIC OIL TEMPERATURE GAUGE….84
        DISPLAY PANEL (A)….84
        FUEL LEVEL GAUGE….88
        REVERSE TRAVEL SPEED SET SWITCH….88
        SHIFT MODE SWITCH….88
        ENGINE INTAKE AIR PRE-HEAT PILOT LAMP….88
        DISPLAY PANEL (B)….89
        FAN ROTATION SELECTOR SWITCH….90
        FLOAT MODE MONITOR….90
      WARNING LAMP VIEW….91
        WARNING LAMP (1)….91
        USING FAILURE CODE DISPLAY….92
        USING MAINTENANCE MODE….93
        METHOD OF SELECTING EACH MODE….94
        USING OIL AND FILTER MAINTENANCE MODE….95
        USING ADJUSTMENT MODE….96
    CONTROL LEVERS AND PEDALS….99
    LEVER LAYOUT VIEW….99
      LOCK LEVERS….99
      JOYSTICK (STEERING, DIRECTIONAL AND GEAR….100
      SHIFT LEVER)….100
      BLADE CONTROL LEVER….101
      ANGLING CONTROL….102
      WORK EQUIPMENT LOCK LEVER….103
      FUEL CONTROL DIAL….104
      DECELERATOR PEDAL….105
      BRAKE PEDAL….105
      PARKING BRAKE LEVER….106
    DOOR AND WINDOW SYSTEM….107
      DOOR – OPEN LOCK….107
      SASH GLASS INTERMEDIATE LOCK….107
    SAFETY LOCKS AND SECURITY….108
      DOOR LOCK….108
      CAP, COVER WITH LOCK….108
        METHOD OF OPENING OR CLOSING HYDRAULIC TANK CAP….109
      OPEN AND CLOSE FUEL FILLER PORT CAP….110
        OPEN….110
        CLOSE….110
      METHOD OF OPENING AND CLOSING COVER WITH LOCK….110
        TO OPEN THE COVER (LOCKED COVER)….110
        TO LOCK THE COVER….110
      LOCKABLE AREAS….111
        SEAT POCKET….111
    ADDITIONAL FEATURES AND ACCESSORIES….112
      AIR CONDITIONER AND FEET HEATER….112
        GENERAL DESCRIPTION OF CONTROL PANEL….112
        MODE SELECTOR SWITCH….112
        BLOWER SPEED SELECTOR SWITCH….113
        TEMPERATURE CONTROL SWITCH….113
        PRECAUTIONS WHEN USING AIR CONDITIONER….114
        FEET HEATER….115
      RADIO….116
        EXPLANATION OF FEATURES….116
        POWER SWITCH/VOLUME….117
        AUTO-STORE/PRESET SCAN BUTTON….117
        BASS CONTROL KNOB….117
        TREBLE CONTROL KNOB….118
        LOUDNESS BUTTON….118
        TIME/RADIO DISPLAY SELECTOR BUTTON….118
        TAPE EJECT BUTTON….119
        CASSETTE DOOR….119
        FAST FORWARD, REWIND BUTTONS….119
        PRESET BUTTONS….119
        METAL TAPE BUTTON….120
        MANUAL TUNING BUTTONS….120
        SEEK TUNING BUTTONS….120
        BAND SELECTOR BUTTON….120
        METHOD OF OPERATION….121
        LISTENING TO RADIO….122
        LISTENING TO A CASSETTE TAPE….122
        REVERSING TAPE….123
        PRECAUTION WHEN USING….123
      ASHTRAY….124
      LUNCH BOX HOLDER STRAP….124
      CUP HOLDER….124
      TOOL BOX….124
      GREASE PUMP HOLDER….125
      ELECTRICAL POWER ADAPTER….125
    BATTERY DISCONNECT SWITCH….126
    FUSES….127
      FUSES….127
        FUSE CAPACITIES AND CIRCUIT NAMES….127
    PRECAUTIONS BEFORE STARTING WORK OPERATIONS….130
      PRE-OPERATIONAL CHECKS….130
        WALK-AROUND CHECKS….130
        CHECKS BEFORE STARTING….131
        ADJUSTMENTS BEFORE OPERATION….145
        ADJUST ARMREST….146
        FASTENING AND REMOVING SEAT BELT….146
        ADJUSTING MIRROR….147
        OPERATIONS AND CHECKS BEFORE….147
        STARTING ENGINE….147
      STARTING THE ENGINE….149
        NORMAL OR COLD START PROCEDURES….149
        COLD WEATHER STARTS….150
    OPERATIONS AND CHECKS AFTER STARTING ENGINE….154
      BREAKING IN THE MACHINE….154
        WARMING UP ENGINE….154
        STARTING IN COLD WEATHER….155
      STOPPING THE ENGINE….157
    MOVING, STEERING, STOPPING AND PARKING THE MACHINE….158
      PREPARATIONS FOR MOVING THE MACHINE….158
        MOVING MACHINE FORWARD OR REVERSE….159
        CHANGING SPEED RANGES….161
      STEERING THE MACHINE….163
        NORMAL TURN….163
        MAKING A LEFT OR RIGHT TURN….163
        MAKING A PIVOT TURN….164
        TURNING WHILE DESCENDING A SLOPE….164
        COUNTER-ROTATION TURN….164
      STOPPING THE MACHINE….165
      PARKING MACHINE….167
        CHECK AFTER FINISHING WORK….168
        CHECK AFTER SHUTTING OFF ENGINE….168
    STARTING YOUR WORK OPERATIONS….169
      AVOIDING DANGEROUS SITUATIONS….169
      HIGH VOLTAGE LINES….171
      OPERATING THE MACHINE….172
        PAY ATTENTION TO GAUGES….172
        PERMISSIBLE WATER DEPTH….172
        METHOD OF USING BRAKES….172
        WHEN TRAVELING UP OR DOWN HILLS….172
      PRECAUTIONS ON SLOPES….173
        BE AWARE OF FUEL LEVEL….173
        PRECAUTIONS WHEN ENGINE STOPS ON A SLOPES….173
        ALWAYS KEEP THE DOORS CLOSED DURING OPERATIONS….173
        DO NOT MODIFY THE CAB GLASS IN ANY WAY….173
        PRECAUTIONS FOR BLIND SPOTS CAUSED BY CAB STAYS….173
      CUTTING A GRADE….174
        DOZING….174
        BACK GRADING A SURFACE….174
        CUTTING HARD OR FROZEN GROUND OR DITCHING….175
        FELLING TREES, REMOVING STUMPS….175
        SIDE-CUTTING OPERATIONS….175
      UNDERCARRIAGE CARE….176
        OPERATION METHOD….176
        INSPECTION AND ADJUSTMENT….176
      INSPECTION AND REPAIR….177
        MEASURING LINK PITCH….177
        MEASURING HEIGHT OF GROUSER….177
        MEASURING OUTSIDE DIAMETER OF TRACK ROLLER….178
    TRANSPORTING THE MACHINE….179
      LOADING OR UNLOADING A TRAILER….179
        PRE-TRANSPORTATION PROCEDURES….180
        SECURING MACHINE….181
        UNLOADING THE MACHINE….184
      LIFTING THE MACHINE….185
        FOR BASE MACHINE….185
        FOR MACHINE EQUIPPED WITH RIPPER….186
    COLD WEATHER OPERATION….187
      FUEL AND LUBRICANTS….187
      COOLING SYSTEM COOLANT….187
      BATTERY….188
      PRECAUTIONS ON PARTICULAR JOBSITES….189
      DISCHARGED BATTERY….189
        REMOVE AND INSTALL BATTERY….190
        BATTERY CHARGES….190
        STARTING ENGINE WITH BOOSTER CABLES….191
    GENERAL TROUBLESHOOTING….193
      AFTER RUNNING OUT OF FUEL….193
      TOWING THE MACHINE….193
      WHEN IT IS POSSIBLE TO START ENGINE….194
      WHEN ENGINE DOES NOT START….194
        RELEASING THE BRAKES….194
        CONNECTING PUMP TO MACHINE….195
      AFTER TOWING MACHINE….197
      ELECTRICAL SYSTEM PROBLEMS….199
      MONITOR PANEL….200
      CHASSIS PROBLEMS….201
      ENGINE PROBLEMS….202
    LONG TERM STORAGE….203
      BEFORE STORAGE….203
      DURING STORAGE….203
      AFTER STORAGE….203
    MACHINES EQUIPPED WITH KOMTRAX SYSTEMS….204
      BASIC PRECAUTIONS….204
MAINTENANCE….206
    MAINTENANCE INFORMATION….207
      SERVICE METER READING….207
      KOMATSU GENUINE REPLACEMENT PARTS….207
      KOMATSU GENUINE LUBRICANTS….207
      WINDSHIELD WASHER FLUID….207
      FRESH AND CLEAN LUBRICANTS….207
      CHECK DRAINED OIL AND USED FILTER….207
      FUEL STRAINER….207
      WELDING INSTRUCTIONS….207
      DO NOT DROP THINGS INSIDE MACHINE….208
      DUSTY JOBSITE….208
      AVOID MIXING LUBRICANTS….208
      HYDRAULIC SYSTEM – AIR BLEEDING….208
      HYDRAULIC HOSE INSTALLATION….208
      CHECKS AFTER INSPECTION AND MAINTENANCE WORKS….208
      LOCKING THE INSPECTION COVER….209
      OPENING OR CLOSING RADIATOR GRILL….209
    LUBRICANTS, COOLANT AND FILTERS….211
      OUTLINE OF SERVICE….211
      HANDLING OIL, FUEL, COOLANT, AND PERFORMING OIL CLINIC….211
        OIL….211
        FUEL….211
        COOLING SYSTEM COOLANT….212
        GREASE….212
        CARRYING OUT KOWA (KOMATSU OIL WEAR ANALYSIS)….212
        OIL AND FUEL STORAGE….213
        FILTERS….213
      ELECTRIC SYSTEM MAINTENANCE….214
      HANDLING HYDRAULIC SYSTEM….214
    WEAR PARTS LIST….215
    RECOMMENDED FUEL, COOLANT, AND LUBRICANT….216
      RECOMMENDED PRODUCTS OTHER THAN KOMATSU GENUINE OILS….218
      LUBRICANT AND COOLANT SUPPLIER RECOMMENDATIONS….219
    TIGHTENING TORQUE SPECIFICATIONS….221
    PERIODIC REPLACEMENT OF SAFETY CRITICAL PARTS….222
      SAFETY RELATED CRITICAL PARTS….222
    MAINTENANCE SCHEDULE….223
      MAINTENANCE SCHEDULE CHART….223
    WHEN REQUIRED….226
      CLEANING THE MACHINE….226
        CLEAN TIPS….226
        CLEANING THROUGH ACCESS AREAS….226
      CHECK ELECTRICAL INTAKE AIR HEATER….229
      CHECK, CLEAN AND REPLACE AIR CLEANER ELEMENT….229
        CLEANING OR REPLACING OUTER ELEMENT….229
        REPLACING INNER ELEMENT….231
      CLEAN COOLING SYSTEM….233
        FLUSHING THE COOLING SYSTEM….234
      TRACK SYSTEM MAINTENANCE….237
        CHECK AND TIGHTEN TRACK SHOE BOLTS….237
        CHECKING AND ADJUSTING TRACK TENSION….237
        IDLER GUIDE CLEARANCE….239
      REVERSING OR REPLACING END BITS AND CUTTING EDGES….241
        CHECKING IDLER OIL LEVEL….241
      ADJUST PLAY IN CENTER BALL….242
      ADJUST PLAY IN PITCH BALL….242
      MECHANICAL PITCH ROD (ADJUSTABLE)….243
        ADJUSTMENT….243
        SPECIFICATIONS….243
        ADJUSTMENT OF PITCH ANGLE….243
      DOOR HINGES….244
      CHECKING WINDOW WASHER FLUID LEVEL….245
        MIXTURE RATIO OF PURE WASHER FLUID AND WATER….245
      CHECKING AIR CONDITIONER….246
        CHECK LEVEL OF REFRIGERANT….246
        OPERATING AIR CONDITIONER OFF-SEASON….246
      REPLACE WIPER BLADE….247
        REPLACEMENT….247
      RELEASING INTERNAL PRESSURE ON HYDRAULIC SYSTEM….248
      BLEEDING AIR FROM HYDRAULIC SYSTEM….249
        BLEEDING AIR FROM PUMP….249
        BLEEDING AIR FROM CYLINDERS….249
      CLEAN, CHECK RADIATOR FINS….250
        CLEANING BY ROTATING COOLING FAN IN REVERSE DIRECTION….250
        CLEANING WITH COMPRESSED AIR….252
      CLEAN HYDRAULIC TANK BREATHER….254
      CLEAN FUEL TANK BREATHER….254
    INITIAL 250 HOURS SERVICE (ONLY AFTER THE FIRST 250 HOURS)….255
      REPLACE FUEL PRE-FILTER CARTRIDGE….255
    INITIAL 500 HOURS SERVICE (ONLY AFTER THE FIRST 500 HOURS)….257
      REPLACE MAIN FUEL FILTER CARTRIDGE….257
    EVERY 50 HOURS MAINTENANCE….259
      LUBRICATE….259
      DRAINING SEDIMENT FROM FUEL TANK….261
    EVERY 250 HOURS MAINTENANCE….262
      CHECK OIL LEVEL IN FINAL DRIVE CASE….262
        CHECKING FINAL DRIVE OIL LEVEL….262
      LUBRICATING….262
      CHECK LEVEL OF BATTERY ELECTROLYTE….264
      CHECK BRAKE PERFORMANCE….265
      AIR CONDITIONER AIR FILTER (FRESH/RECIRC FILTER)….267
    EVERY 500 HOURS MAINTENANCE….268
      REPLACE FUEL PRE-FILTER CARTRIDGE….268
        CHANGE OIL IN ENGINE OIL PAN, REPLACE ENGINE OIL FILTER CARTRIDGE….271
    EVERY 1000 HOURS MAINTENANCE….273
      CHANGE OIL IN FINAL DRIVE CASE….273
      CHECK ALTERNATOR BELT TENSION….273
      CHECK ALL TIGHTENING POINTS OF ENGINE INTAKE & EXHAUST PIPE CLAMPS….273
      CHECK FOR LOOSE ROPS MOUNT BOLTS….274
      REPLACE PRE AND MAIN FUEL FILTER CARTRIDGES….275
      REPLACE BREATHER ELEMENT IN FUEL TANK….281
      REPLACE BREATHER ELEMENT IN HYDRAULIC TANK….281
    EVERY 2000 HOURS MAINTENANCE….282
      CHANGE OIL IN HYDRAULIC TANK, REPLACE OIL FILTER CARTRIDGE….282
      CHECK ALTERNATOR, STARTING MOTOR….284
      CHECK ENGINE VALVE CLEARANCE, ADJUST….284
      CHECK CHARGE PRESSURE ACCUMULATOR (CONTROL CIRCUIT)….284
        FUNCTION OF ACCUMULATOR….284
        CHECKING FUNCTION OF ACCUMULATOR….285
        RELEASING PRESSURE IN HYDRAULIC CIRCUIT….285
        CHECKING PIVOT SHAFT OIL LEVEL….286
    EVERY 4000 HOURS MAINTENANCE….287
      CHECK WATER PUMP….287
      CHECK VIBRATION DAMPER….287
      REPLACE ACCUMULATOR (FOR CONTROL CIRCUIT)….287
      CHECK FOR LOOSENESS OF HIGH-PRESSURE CLAMP, HARDENING OF RUBBER….288
      CHECK FOR MISSING FUEL SPRAY CAP, HARDENING OF RUBBER….289
SPECIFICATIONS….292
    SPECIFICATIONS….293
      OPERATING WEIGHT….293
    MACHINE DIMENSIONS AND WEIGHTS….294
    MACHINE SYSTEMS SPECIFICATIONS….295
      ENGINE….295
      TRANSMISSION….296
      STEERING SYSTEM….296
      SERVICE REFILL CAPACITIES….296
      UNDERCARRIAGE….296
OPTIONAL ATTACHMENTS….298
    AUTHORIZED OPTIONAL EQUIPMENT….299
      BASIC PRECAUTIONS….299
    AIR SUSPENSION SEAT….300
    FORESTRY KIT….302
      CABIN POLYCARBONATE PANEL FRONT….303
    EQUIPPING FIRE EXTINGUISHER AND FIRST-AID KIT….304
    HANDLING HYDRAULIC RIPPER….305
      GENERAL VIEW….305
      EXPLANATION OF COMPONENTS….306
        RIPPER CONTROL LEVER….306
      MAINTENANCE….310
        EVERY 250 HOURS SERVICE….310
      OPERATION….307
        CHECK BEFORE STARTING ENGINE, ADJUST….307
        PRECAUTIONS WHEN OPERATING….307
        ADJUSTING POSTURE OF WORK EQUIPMENT….307
        REPLACEMENT OF POINT….308
      TROUBLESHOOTING….309
        OTHER TROUBLE….309
iB OPERATION….312
HANDLING iB MONITOR….374
iB INDEX….440
SEAM01341703 – Bulldozer D53A,P-17 Operation & Maintenance Manual (SN80001&up)….444
COVER….444
FOREWORD….445
BREAKING IN YOUR NEW MACHINE….446
CONTENTS….447
SAFETY HINTS….448
GENERAL LOCATIONS AND SPECIFICATIONS….455
OPERATOR'S COMPARTMENT….456
INSTRUMENTS AND CONTROLS….458
CHECK BEFORE STARTING….469
OPERATING YOUR MACHINE….473
COLD WEATHER OPERATION….485
BULLDOZER'S WORK….490
BLADE OPERATION….492
BLADE ADJUSTMENT….495
REVERSING OF CUTTING EDGE AND REPLACEMENT OF END BIT….498
TIPS FOR LONGER UNDERCARRIAGE LIFE….499
HANDLING OF BATTERY….500
TRANSPORTATION….503
PERIODIC MAINTENANCE….504
    PRECAUTIONS FOR MAINTENANCE….505
    MAINTENANCE TABLE….508
    EVERY 50 HOURS SERVICE….511
    EVERY 250 HOURS SERVICE….512
    EVERY 500 HOURS SERVICE….517
    EVERY 1000 HOURS SERVICE….522
    EVERY 2000 HOURS SERVICE….526
    EVERY 4000 HOURS SERVICE….531
    WHEN REQUIRED….532
ADJUSTMENT….542
TROUBLE SHOOTING GUIDE….546
STORAGE….549
SERVICE METER….551
MACHINE AND ENGINE SERIAL NUMBERS….552
FUEL,COOLANT AND LUBRICANTS….553
SEAM026300P – Bulldozer D53A,P-17 Operation & Maintenance Manual (SN82727&up)….558
COVER….558
FOREWORD….559
BREAKING IN YOUR NEW MACHINE….560
CONTENTS….561
SAFETY HINTS….562
POSITION FOR ATTACHING SAFETY LABELS….569
GENERAL LOCATIONS AND SPECIFICATIONS….573
OPERATOR'S COMPARTMENT….574
INSTRUMENTS AND CONTROLS….576
CHECK BEFORE STARTING….587
OPERATING YOUR MACHINE….591
COLD WEATHER OPERATION….603
BULLDOZER'S WORK….608
BLADE OPERATION….610
BLADE ADJUSTMENT….613
REVERSING OF CUTTING EDGE AND REPLACEMENT OF END BIT….616
TIPS FOR LONGER UNDERCARRIAGE LIFE….617
HANDLING OF BATTERY….618
TRANSPORTATION….621
PERIODIC MAINTENANCE….622
    PRECAUTIONS FOR MAINTENANCE….623
    MAINTENANCE TABLE….626
    EVERY 50 HOURS SERVICE ….629
    EVERY 250 HOURS SERVICE ….630
    EVERY 500 HOURS SERVICE ….636
    EVERY 1000 HOURS SERVICE ….641
    EVERY 2000 HOURS SERVICE ….645
    EVERY 4000 HOURS SERVICE ….650
    WHEN REQUIRED….651
ADJUSTMENT….661
TROUBLE SHOOTING GUIDE….665
STORAGE….668
SERVICE METER….670
MACHINE AND ENGINE SERIAL NUMBERS….671
FUEL,COOLANT AND LUBRICANTS….672
SEAM13FC00 – Bulldozer D50P,PL-16 Operation & Maintenance Manual (SN68001&up)….677
COVER….677
FOREWORD….678
BREAKING IN YOUR NEW MACHINE….679
CONTENTS….680
SAFETY HINTS….681
GENERAL LOCATIONS….694
OPERATOR'S COMPARTMENT….696
INSTRUMENTS AND CONTROLS….698
CHECK BEFORE STARTING….705
OPERATING YOUR MACHINE….711
COLD WEATHER OPERATION….723
BULLDOZER'S WORK….728
BLADE OPERATION….730
BLADE ADJUSTMENT….732
REVERSING OF CUTTING EDGE AND REPLACEMENT OF END BIT….733
TIPS FOR LONGER UNDERCARRIAGE LIFE….734
TRANSPORTATION….735
MAINTENANCE….737
    PERIODIC MAINTENANCE….738
      PRECAUTIONS FOR MAINTENANCE….739
      MAINTENANCE TABLE….745
      EVERY 50 HOURS SERVICE….750
      EVERY 250 HOURS SERVICE….751
      EVERY 500 HOURS SERVICE….757
      EVERY 1000 HOURS SERVICE….760
      EVERY 2000 HOURS SERVICE….765
      WHEN REQUIRED….772
    ADJUSTMENT….776
    TROUBLE SHOOTING GUIDE….782
    STORAGE….786
    SERVICE METER….788
    MACHINE AND ENGINE SERIAL NUMBERS….789
    WEAR PARTS….790
    SPECIFICATIONS….791
    FUEL AND LUBRICANTS….793

Komatsu Crawler Dozers D50-, D51-, D53- Operation Maintenance Manuals

INSTANT DOWNLOAD

Posted on June 5, 2025 by admin

Komatsu Bulldozers D39EX, D39PX Repair Service Manuals

INSTANT DOWNLOAD

Complete service repair manual for Komatsu Bulldozers D39EX, D39PX, with all the technical information to maintain, diagnose, repair, and service like professional mechanics.

Komatsu Bulldozers D39EX,PX workshop service repair manual includes:
* Numbered table of contents easy to use so that you can find the information you need fast.
* Detailed sub-steps expand on repair procedure information
* Numbered instructions guide you through every repair procedure step by step.
* Troubleshooting and electrical service procedures are combined with detailed wiring diagrams for ease of use.
* Notes, cautions and warnings throughout each chapter pinpoint critical information.
* Bold figure number help you quickly match illustrations with instructions.
* Detailed illustrations, drawings and photos guide you through every procedure.
* Enlarged inset helps you identify and examine parts in detail.

SEBM023809 – Bulldozer D39EX,PX-21 Shop Manual (SN1001&up).pdf
SEBM023810 – Bulldozer D39EX,PX-21 Shop Manual (SN1001&up).pdf
SEN04041-05 – Bulldozer D39EX,PX-22 Shop Manual (SN3001&up).pdf

PRODUCT DETAILS:
Total Pages: 1,921 pages
File Format: PDF
Language: English

TABLE OF CONTENTS
01 GENERAL … 01-1
10 STRUCTURE AND FUNCTION, MAINTENANCE STANDARD … 10-1
20 TESTING AND ADJUSTING … 20-1
30 DISASSEMBLY AND ASSEMBLY … 30-1
90 OTHERS …90-1

SEBM023809 – Bulldozer D39EX,PX-21 Shop Manual (SN1001&up)…2
COVER…2
CONTENTS…3
SAFETY…8
SAFETY NOTICE…8
FOREWORD…10
GENERAL…10
HOW TO READ THE SHOP MANUAL…11
HOISTING INSTRUCTIONS…12
METHOD OF DISASSEMBLING, CONNECTING PUSH-PULL TYPE COUPLER…13
COATING MATERIALS…15
STANDARD TIGHTENING TORQUE…17
ELECTRIC WIRE CODE…20
CONVERSION TABLE…21
UNITS…27
01 GENERAL…28
SPECIFICATION DRAWING…29
SPECIFICATIONS…30
WEIGHT TABLE…34
TABLE OF FUEL, COOLANT AND LUBRICANTS…36
10 STRUCTURE AND FUNCTION, MAINTENANCE STANDARD…37
COOLING SYSTEM…38
ENGINE CONTROL…39
POWER TRAIN…41
POWER TRAIN SYSTEM…42
HST HYDRAULIC EQUIPMENT ARRANGEMENT DIAGRAM…43
STEERING, BRAKE CONTROL…44
DAMPER…50
SOLENOID VALVE…51
FINAL DRIVE…53
HST PUMP…57
SAFETY-SUCTION VALVE…62
CUT-OFF VALVE…65
CHARGE SAFETY VALVE…66
CHARGE PUMP…68
HST BRAKE QUICK RETURN CIRCUIT…69
TOWING VALVE…70
PARKING BRAKE VALVE…71
AS VALVE…73
HST MOTOR…75
STEERING, DIRECTIONAL PPC VALVE…86
INCHING VALVE…95
AUTOMATIC GEARSHIFITING VALVE…97
FRAME ASSEMBLY…102
TRACK FRAME, RECOIL SPRING…103
IDLER…105
TRACK ROLLER …107
CARRIER ROLLER…108
SPROCKET…109
TRACK SHOE…111
ARRANGEMENT OF HYDRAULIC EQUIPMENT FOR WORK EQUIPMENT…115
WORK EQUIPMENT CONTROL…116
HYDRAULIC TANK, FILTER…118
HYDRAULIC PUMP…119
WORK EQUIPMENT CYLINDER…120
SUCTION VALVE…122
CONTROL VALVE…124
CLSS…132
WORK EQUIPMENT PPC VALVE…142
WORK EQUIPMENT …149
CUTTING EDGE, END BIT…152
CAB RELATED…153
SAFETY MECHANISM WHEN STARTING ENGINE…154
GEARSHIFT CONTROL SYSTEM…155
PARKING BRAKE CONTROL SYSTEM…156
COMPONENT EQUIPMENT OF SYTEM…157
MONITOR SYSTEM…159
SENSORS…163
20 TESTING AND ADJUSTING…166
STANDARD VALUE TABLE…167
STANDARD VALUE TABLE FOR ENGINE…167
STANDARD VALUE FOR CHASSIS…168
STANDARD VALUE TABLE FOR ELECTRICAL PARTS…172
TESTING AND ADJUSTING…175
TOOLS FOR TESTING AND ADJUSTING…176
MEASURING ENGINE SPEED…177
MEASURING EXHAUST COLOR…178
MEASURING BLOW-BY PRESSURE…179
MEASURING INTAKE AIR PRESSURE (BOOST PRESSURE)…180
ADJUSTING VALVE CLEARANCE…181
TESTING AND ADJUSTING FUEL INJECTION TIMING…183
MEASURING COMPRESSION PRESSURE…184
ADJUSTING ENGINE STOP SOLENOID LINKAGE…185
MEASURING ENGINE OIL PRESSURE…186
BLEEDING AIR FROM FUEL CIRCUIT…187
TESTING AND ADJUSTING TENSION OF AIR CONDITIONER COMPRESSOR BELT…188
MEASURING AND ADJUSTING HST OIL PRESSURE…189
MEASURING SOLENOID VALVE OUTPUT PRESSURE…194
MEASURING AND ADJUSTING WORK EQUIPMENT MAIN RELIEF PRESSURE…195
MEASURING PPC VALVE OUTPUT PRESSURE…197
MEASURING LEAKAGE INSIDE CYLINDER…198
BLEEDING AIR FROM HYDRAULIC CYLINDERS…198
TESTING AND ADJUSTING TRACK SHOE TENSION…199
TESTING AND ADJUSTING TRAVEL DEVIATION…200
ADJUSTING FUEL CONTROL LINKAGE…203
ADJUSTING DECELERATION PEDAL LINKAGE…205
ADJUSTING BRAKE PEDAL LINKAGE…206
ADJUSTING STEERING/DIRECTIONAL/GEAR SHIFT LEVER AND LOCK LEVER…208
ADJUSTING BLADE CONTROL LEVER AND LOCK LEVER…211
ADJUSTING WORK EQUIPMENT PPC VALVE…212
PROCEDURE FOR RELEASING PARKING BRAKE…213
PROCEDURE FOR INSPECTING DIODE…215
TROUBLESHOOTING…216
POINTS TO REMEMBER WHEN TROUBLESHOOTING…217
SEQUENCE OF EVENTS IN TROUBLESHOOTING…218
POINTS TO REMEMBER WHEN CARRYING OUT MAINTENANCE…219
CHECKS BEFORE TROUBLESHOOTING…227
METHOD OF USING TROUBLESHOOTING CHARTS…228
TYPES AND LOCATIONS OF CONNECTORS…229
CONNECTOR ARRANGEMENT DIAGRAM…231
CONNECTION TABLE FOR CONNECTOR PIN NUMBERS…233
TROUBLESHOOTING FOR ELECTRICAL SYSTEM (E-MODE)…255
TABLE OF FAILURE MODES AND CAUSES (ELECTRICAL SYSTEM)…256
ELECTRICAL CIRCUIT DIAGRAM FOR EACH SYSTEM…258
E-1 WHEN STARTING SWITCH IS TURNED ON, STARTING MOTOR DOES NOT ROTATE…260
E-2 ENGINE DOES NOT START (ENGINE STOP SOLENOID DOES NOT OPERATE NORMALLY)…262
E-3 HEADLAMP DOES NOT LIGHT UP…263
E-4 WHEN STARTING SWITCH IS TURNED TO HEAT POSITION, ENGINE IS NOT HEATED…265
E-5 WINDSHEILD WIPER DOES NOT OPERATE…266
E-6 WASHING WATER DOES NOT SPOUT …268
E-7 AIR CONDITIONER DOES NOT WORK…270
A) AIR DOES NOT BLOW OUT…270
B) AIR IS NOT COOLED…273
E-8 PARKING BRAKE CANNOT BE RELEASED (PARKING BRAKE SOLENOID DOES NOT OPERATE)…277
E-9 TRAVEL SPEED CONTROL IS ABNORMAL…278
A) WHEN GEAR SHIFT SWITCH IS PRESSED, GEAR SPEED DOES NOT CHANGE OR GEAR SPEED CHANGES BY ITSELF (GEAR SHIFT SWITCH OR CONTRO…278
B) GEAR SPEED CANNOT BE SELECTED NORMALLY (TRAVEL SPEED CHANGEOVER SOLENOID IS ADNORMAL…279
E-10 BACKUP ALARM DOES NOT SOUND DURING REVERSE TRAVEL…281
E-11 HORN DOES NOT SOUND…283
TROUBLESHOOTING FOR HYDRAULIC AND MECHANICAL SYSTEM (H-MODE)…284
TABLE OF FAILURE MODES AND CAUSES (HYDRAULIC AND MECHANICAL SYSTEMS)…285
H-1 MACHINE DOES NOT TRAVEL IN EITHER DIRECTION OR IT STOPS SUDDENLY…287
H-2 MACHINE DOES NOT TRAVEL IN ONE DIRECTION…288
H-3 MACHINE TRAVELS WHILE TRAVEL LEVER IS IN NEUTRAL…288
H-5 MACHINE DEVIATES WHILE TRAVEL LEVER IS IN PARTIAL POSITION …288
H-7 MACHINE SWINGS MOMENTARILY WHEN IT STARTS ON FLAT GROUND…288
H-11 TURNING TIME LAG IS LARGE…288
H-12 WHEN OPERATOR INTENDS TO TURN GRADUALLY, MACHINE TURNS SHARPLY…288
H-13 MACHINE DOES NOT RETURN QUICKLY TO STRAIGHT TRAVEL POSITION…288
H-14 MACHINE IS NOT DECELERATED SMOOTHLY OR TRAVEL SPEED CANNOT BE CONTROLLED ON DOWNHILL GROUND…288
H-15 MACHINE DEVIATES WHEN IT IS DECELERATED…288
H-4 MACHINE DEVIATES WHEN TRAVEL LEVER IS MOVED TO STROKE END…289
H-6 MACHINE MOVES BACK WHEN OPERATOR STARTS ON UPHILL GROUND…289
H-8 MACHINE STARTS SHARPLY…289
H-9 MACHINE SWINGS MOMENTARILY WHEN IT STARTS…290
H-10 STARTING TIME LAG IS LARGE…291
H-16 MAXIMUM TRAVEL SPEED IS LOW OR OUTPUT POWER IS INSUFFICIENT OR ACCELERATION IS LOW…292
H-17 ENGINE STALLS…293
H-18 HST NOISE IS LARGE…294
H-19 HST OIL TEMPERATURE RISES TOO HIGH…295
H-20 GEAR SPEED DOES NOT CHANGE…295
H-21 ABNORMAL SOUND IS HEARD FROM AROUND WORK EQUIPMENT PUMP OR HST PUMP…296
H-22 ANY WORK EQUIPMENT DOES NOT MOVE…296
H-23 SPEED OR POWER OF EACH WORK EQUIPMENT IS LOW…297
H-24 SPEED OR POWER OF BLADE LIFT OF BLADE TILT CYLINDER IS LOW…297
H-25 SPEED OR POWER OF BLADE ANGLE CYLINDER IS LOW…298
H-26 HYDRAULIC DRIFT OF BLADE LIFT CYLINDER IS LARGE…299
H-27 HYDRAULIC DRIFT OF BLADE TILT CYLINDER IS LARGE…299
H-28 HYDRAULIC DRIFT OF BLADE ANGLE CYLINDER IS LARGE…300
TROUBLESHOOTING FOR MACHINE MONITOR SYSTEM (M-MODE)…301
TABLE OF FAILURE MODES AND CAUSES ( MACHINE MONITOR SYSTEMS)…302
ELECTRIC CIRCUIT DIAGRAM FOR EACH SYSTEM…303
M-1 WHEN STARTING SWITCH IS TURNED ON, MONITOR PANEL IS NOT TURNED ON…305
M-2 TROUBLE IN PREHESTING CAUTION LAMP…306
A) PREHEATING MONITOR DOES NOT LIGHT UP…306
B) PREHEATING MONITOR KEEPS LIGHTING UP…306
M-3 CAUTION ITEM LIGHTS UP…307
A) CHARGE CAUTION LAMP LIGHTS UP WHILE ENGINE IS RUNNING…307
B) OIL PRESSURE CAUTION LAMP LIGHTS UP WHILE ENGINE IS RUNNING…308
C) HST FILTER CLOGGING LAMP LIGHTS UP (WHILE FILTER IS NOT CLOGGED)…308
M-4 TROUBLE IS HST OIL TEMPERATURE GAUGE…309
A) GAUGE DOES NOT RISE ABOVE C (LOWEST POINT)…309
B) GAUGE DOES NOT LOWER BELOW H (HIGHEST POINT)…309
C) HST OIL TEMPERATURE INDICATED BY GAUGE IS DIFFERENT FROM ACTUAL TEMPERATURE…310
M-5 TROUBLE IN ENGINE WATER TEMPERATURE GAUGE…311
A) GAUGE DOES NOT RISE ABOVE C (LOWEST POINT)…311
B) GAUGE DOES NOT LOWER BELOW H (HIGHEST POINT)…311
C) HST OIL TEMPERATURE INDICATED BY GAUGE IS DIFFERENT FROM ACTUAL TEMPERATURE…312
M-6 TROUBLE IN FUEL LEVEL GAUGE…313
A) GAUGE DOES NOT RISE ABOVE E (LOWEST POINT)…313
B) GAUGE DOES NOT LOWER BELOW F (HIGHEST POINT)…313
C) FUEL LEVEL INDICATED BY GAUGE IS DIFFERENT FROM ACTUAL LEVEL…314
M-7 SERVICE METER DOES NOT OPERATE AFTER ENGINE IS STARTED…315
M-8 MONITOR PANEL LAMP DOES NOT LIGHT UP (WHILE HEADLAMP IS NORMAL)…316
M-9 TROUBLE IN DISPLAY OF TRAVEL SPEED (WHILE ACTUAL TRAVEL SPEED IS NORMAL)…317
A) TRAVEL SPEED IS NOT DISPLAYED…317
B) DISPLAYED SPEED IS DIFFERENT FROM ACTUAL TRAVEL SPEED…317
30 DISASSEMBLY AND ASSEMBLY…321
METHOD OF USING MANUAL…322
PRECAUTIONS WHEN CARRYING OUT OPERATION…323
SPECIAL TOOL LIST…325
SKETCHES OF SPECIAL TOOLS…327
REMOVAL OF FUEL INJECTION PUMP ASSEMBLY…328
INSTALLATION OF FUEL INJECTION PUMP ASSEMBLY…330
REMOVAL OF CYLINDER HEAD ASSEMBLY…332
INSTALLATION OF CYLINDER HEAD ASSEMBLY…337
REMOVAL OF ENGINE FRONT SEAL…339
INSTALLATION OF ENGINE FRONT SEAL…340
REMOVAL OF ENGINE REAR SEAL…341
INSTALLATION OF ENGINE REAR SEAL…342
REMOVAL OF RADIATOR GUARD ASSEMBLY…343
INSTALLATION OF RADIATOR GUARD ASSEMBLY…345
DISASSEMBLY OF RADIATOR, OIL COOLER, AND CHARGE AIR COOLER ASSEMBLIES…346
ASSEMBLY OF RADIATOR, OIL COOLER, AND CHARGE AIR COOLER ASSEMBLIES…348
REMOVAL OF ENGINE ASSEMBLY…350
INSTALLATION OF ENGINE ASSEMBLY…352
REMOVAL OF DAMPER…353
INSTALLATION OF DAMPER…353
REMOVAL OF TRAVEL MOTOR AND FINAL DRIVE ASSEMBLY…354
INSTALLATION OF TRAVEL MOTOR AND FINAL DRIVE ASSEMBLY…355
DISASSEMBLY OF TRAVEL MOTOR AND FINAL DRIVE ASSEMBLY…356
ASSEMBLY OF TRAVEL MOTOR AND FINAL DRIVE ASSEMBLY…360
REMOVAL OF IDLER AND RECOIL SPRING ASSEMBLY…365
INSTALLATION OF IDLER AND RECOIL SPRING ASSEMBLY…365
DISASSEMBLY OF RECOIL SPRING ASSEMBLY…366
ASSEMBLY OF RECOIL SPRING ASSEMBLY…367
DISASSEMBLY OF IDER ASSEMBLY…369
ASSEMBLY OF IDER ASSEMBLY…370
DISASSEMBLY OF TRACK ROLLER ASSEMBLY…372
ASSEMBLY OF TRACK ROLLER ASSEMBLY…373
DISASSEMBLY OF CARRIER ROLLER ASSEMBLY…376
ASSEMBLY OF CARRIER ROLLER ASSEMBLY…377
SPREADING TRACK SHOE ASSEMBLY…378
INSTALLATION OF TRACK SHOE ASSEMBLY…379
REMOVAL OF HST PUMP ASSEMBLY…380
INSTALLATION OF HST PUMP ASSEMBLY…381
REMOVAL OF MAIN CONTROL VALVE ASSEMBLY…382
INSTALLATION OF MAIN CONTROL VALVE ASSEMBLY…383
DISASSEMBLY OF MAIN CONTROL VALVE ASSEMBLY…384
ASSEMBLY OF MAIN CONTROL VALVE ASSEMBLY…388
DISASSEMBLY OF HYDRAULIC CYLINDER ASSEMBLIES…392
ASSEMBLY OF HYDRAULIC CYLINDER ASSEMBLIES…393
REMOVAL OF BLADE ASSEMBLY…395
INSTALLATION OF BLADE ASSEMBLY…396
REMOVAL OF OPERATOR'S CAB FRAME ASSEMBLY…397
INSTALLATION OF OPERATOR'S CAB FRAME ASSEMBLY…400
REMOVAL OF FUEL TANK ASSEMBLY…401
INSTALLTION OF FUEL TANK ASSEMBLY…401
REMOVAL OF HYDRAULIC TANK ASSEMBLY…402
INSTALLATION OF HYDRAULIC TANK ASSEMBLY…403
90 OTHERS …405
HYDRAULIC CIRCUIT DIAGRAM (1/2) D39EX-21: 1001-1200; D39PX-21: 1001-1208…406
HYDRAULIC CIRCUIT DIAGRAM (1/2) D39EX-21: 1201 and up; D39PX-21: 1209 and up…407
HYDRAULIC CIRCUIT DIAGRAM (2/2)…408
ELECTRICAL CIRCUIT DIAGRAM (1/2)…409
ELECTRICAL CIRCUIT DIAGRAM (2/2)…410
ELECTRICAL CIRCUIT DIAGRAM FOR AIR CONDITIONER…411
SEBM023810 – Bulldozer D39EX,PX-21 Shop Manual (SN1001&up)…412
COVER…412
CONTENTS…413
01 GENERAL…446
SPECIFICATION DRAWING…447
SPECIFICATIONS…448
WEIGHT TABLE…452
TABLE OF FUEL, COOLANT AND LUBRICANTS…454
10 STRUCTURE AND FUNCTION, MAINTENANCE STANDARD…455
COOLING SYSTEM…456
ENGINE CONTROL…457
POWER TRAIN…458
POWER TRAIN SYSTEM…459
HST HYDRAULIC EQUIPMENT ARRANGEMENT DIAGRAM…460
STEERING, BRAKE CONTROL…462
DAMPER…468
SOLENOID VALVE…469
FINAL DRIVE…471
HST PUMP…474
SAFETY-SUCTION VALVE…479
CUT-OFF VALVE…482
CHARGE SAFETY VALVE…483
CHARGE PUMP…485
HST BRAKE QUICK RETURN CIRCUIT…486
TOWING VALVE…487
PARKING BRAKE VALVE…488
AS VALVE…490
HST MOTOR…492
STEERING, DIRECTIONAL PPC VALVE…503
INCHING VALVE…512
AUTOMATIC GEARSHIFTING VALVE…514
FRAME ASSEMBLY…519
TRACK FRAME, RECOIL SPRING…520
IDLER…522
TRACK ROLLER…524
CARRIER ROLLER…525
SPROCKET…526
TRACK SHOE…528
ARRANGEMENT OF HYDRAULIC EQUIPMENT FOR WORK EQUIPMENT…532
WORK EQUIPMENT CONTROL…533
HYDRAULIC TANK, FILTER…535
HYDRAULIC PUMP…536
WORK EQUIPMENT CYLINDER…537
SUCTION VALVE…539
CONTROL VALVE…541
CLSS…549
WORK EQUIPMENT PPC VALVE…559
WORK EQUIPMENT …566
CUTTING EDGE, END BIT…569
CAB RELATED…570
SAFETY MECHANISM WHEN STARTING ENGINE…571
GEARSHIFT CONTROL SYSTEM…572
PARKING BRAKE CONTROL SYSTEM…573
COMPONENT EQUIPMENT OF SYSTEM…574
MONITOR SYSTEM…576
SENSORS…580
20 TESTING AND ADJUSTING…583
STANDARD VALUE TABLE FOR ENGINE…584
STANDARD VALUE TABLE FOR CHASSIS…585
STANDARD VALUE TABLE FOR ELECTRICAL SYSTEM…590
TESTING AND ADJUSTING…592
TOOLS LIST FOR TESTING AND ADJUSTING…593
MEASURING ENGINE SPEED…596
MEASURING EXHAUST COLOR…597
MEASURING BLOW-BY PRESSURE…598
MEASURING INTAKE AIR PRESSURE (BOOST PRESSURE)…599
ADJUSTING VALVE CLEARANCE…600
TESTING ADJUSTING FUEL INJECTION TIMING…602
MEASURING COMPRESSION PRESSURE…603
ADJUSTING ENGINE STOP SOLENOIDE LINKAGE…604
MEASURING ENGINE OIL PRESSURE…605
BLEEDING AIR FROM FUEL CIRCUIT…606
REPLACEMENT OF FAN BELT…607
TESTING AND ADJUSTING TENSION OF AIR CONDITIONER COMPRESSOR BELT…609
MEASURING AND ADJUSTING HST OIL PRESSURE…610
MEASURING SOLENOID VALVE OUTPUT PRESSURE…615
MEASURING AND ADJUSTING WORK EQUIPMENT MAIN RELIEF PRESSURE…616
MEASURING PPC VALVE OUTPUT PRESSURE…618
MEASURING LEAKAGE INSIED CYLINDER…619
BLEEDING AIR FROM HYDRAULIC CYLINDERS…619
TESTING AND ADJUSTING TRACK SHOE TENSION…620
TESTING AND ADJUSTING TRAVEL DEVIATION…621
ADJUSTING FUEL CONTROL LINKAGE…624
ADJUSTING DECELERATOR PEDAL LINKAGE…626
ADJUSTING BRAKE PEDAL LINKAGE…627
ADJUSTING STEERING/DIRECTIONAL/GEAR SHIFT LEVER AND LOCK LEVER…629
ADJUSTING BLADE CONTROL LEVER AND LOCK LEVER…632
ADJUSTING WORK EQUIPMENT PPC VALVE…633
PROCEDURE FOR RELEASING PARKING BRAKE…634
PROCEDURE FOR INSPECTING DIODE…636
TROUBLESHOOTING…637
POINTS TO REMEMBER WHEN TROUBLESHOOTING…638
SEQUENCE OF EVENTS IN TROUBLESHOOTING…639
HANDLING OF ELECTRIC EQUIPMENT AND HYDRAULIC COMPONENT…640
CHECKS BEFORE TROUBLESHOOTING…650
METHOD OF USING TROUBLESHOOTING CHARTS…651
TYPES AND LOCATIONS OF CONNECTORS…652
CONNECTOR ARRANGEMENT DIAGRAM…654
CONNECTION TABLE FOR CONNECTOR PIN NUMBERS…656
T-BRANCH BOX AND T-BRANCH ADAPTER TABLE…692
TROUBLESHOOTING FOR ELECTRICAL SYSTEM (E-MODE)…695
TABLE OF FAILURE MODES AND CAUSES (ELECTRICAL SYSTEM)…696
ELECTRICAL CIRCUIT DIAGRAM FOR EACH SYSTEM…698
E-1. WHEN STARTING SWITCH IS TURNED ON, STARTING MOTOR DOES NOT ROTATE…700
E-2. ENGINE DOES NOT START (ENGINE STOP SOLENOID DOES NOT OPERATE NORMALLY)…702
E-3. HEADLAMP DOES NOT LIGHT UP…703
E-4. WHEN STARTING SWITCH IS TURNED TO HEAT POSITION, ENGINE IS NOT HEATED…705
E-5. WINDSHIELD WIPER DOES NOT OPERATE…706
E-6. WASHING WATER DOES NOT SPOUT…708
E-7. AIR CONDITIONER DOES NOT WORK…710
(a) AIR DOES NOT BLOW OUT…710
(b) AIR IS NOT COOLED…713
E-8. PARKING BRAKE CANNOT BE RELEASED (PARKING BRAKE SOLENOID DOES NOT OPERATE)…717
E-9. TRAVEL SPEED CONTROL IS ABNORMAL…718
(a) WHEN GEAR SHIFT SWITCH IS PRESSED, GEAR SPEED DOES NOT CHANGE OR GEAR SPEED CHANGES BY ITSELF (GEAR SHIFT SWITCH OR CONTROLLER IS ABNORMAL)…718
(b) GEAR SPEED CANNOT BE SELECTED NORMALLY (TRAVEL SPEED CHANGEOVER SOLENOID IS ABNORMAL)…719
E-10. BACKUP ALARM DOES NOT SOUND DURING REVERSE TRAVEL…721
E-11. HORN DOES NOT SOUND…723
TROUBLESHOOTING FOR HYDRAULIC AND MECHANICAL SYSTEM (H-MODE)…724
TABLE OF FAILURE MODES AND CAUSES (HYDRAULIC AND MECHANICAL SYSTEMS)…725
H-1. MACHINE DOES NOT TRAVEL IN EITHER DIRECTION OR IT STOPS SUDDENLY…727
H-2. MACHINE DOES NOT TRAVEL IN ONE DIRECTION…728
H-3. MACHINE TRAVELS WHILE TRAVEL LEVER IS IN NEUTRAL…728
H-5. MACHINE DEVIATES WHILE TRAVEL LEVER IS IN PARTIAL POSITION…728
H-7. MACHINE SWINGS MOMENTARILY WHEN IT STARTS ON FLAT GROUND…728
H-11. TURNING TIME LAG IS LARGE…728
H-12. WHEN OPERATOR INTENDS TO TURN GRADUALLY, MACHINE TURNS SHARPLY…728
H-13. MACHINE DOES NOT RETURN QUICKLY TO STRAIGHT TRAVEL POSITION…728
H-14. MACHINE IS NOT DECELERATED SMOOTHLY OR TRAVEL SPEED CANNOT BE CONTROLLED ON DOWNHILL GROUND…728
H-15. MACHINE DEVIATES WHEN IT IS DECELERATED…728
H-4. MACHINE DEVIATES WHEN TRAVEL LEVER IS MOVED TO STROKE END…729
H-6. MACHINE MOVES BACK WHEN OPERATOR STARTS ON UPHILL GROUND…729
H-8. MACHINE STARTS SHARPLY…729
H-9. MACHINE SWINGS MOMENTARILY WHEN IT STARTS…730
H-10. STARTING TIME LAG IS LARGE…731
H-16. MAXIMUM TRAVEL SPEED IS LOW OR OUTPUT POWER IS INSUFFICIENT OR ACCELERATION IS LOW…732
H-17. ENGINE STALLS…733
H-18. HST NOISE IS LARGE…734
H-19. HST OIL TEMPERATURE RISES TOO HIGH…735
H-20. GEAR SPEED DOES NOT CHANGE…735
H-21. ABNORMAL SOUND IS HEARD FROM AROUND WORK EQUIPMENT PUMP OR HST PUMP…736
H-22. ANY WORK EQUIPMENT DOES NOT MOVE…736
H-23. SPEED OR POWER OF EACH WORK EQUIPMENT IS LOW…737
H-24. SPEED OR POWER OF BLADE LIFT OF BLADE TILT CYLINDER IS LOW…737
H-25. SPEED OR POWER OF BLADE ANGLE CYLINDER IS LOW…738
H-26. HYDRAULIC DRIFT OF BLADE LIFT CYLINDER IS LARGE…739
H-27. HYDRAULIC DRIFT OF BLADE TILT CYLINDER IS LARGE…739
H-28. HYDRAULIC DRIFT OF BLADE ANGLE CYLINDER IS LARGE…740
TROUBLESHOOTING FOR MACHINE MONITOR SYSTEM (M-MODE)…741
TABLE OF FAILURE MODES AND CAUSES (MACHINE MONITOR SYSTEM)…742
ELECTRIC CIRCUIT DIAGRAM FOR EACH SYSTEM…743
M-1. WHEN STARTING SWITCH IS TURNED ON , MONITOR PANEL IS NOT TURNED ON…745
M-2. TROUBLE IN PREHEATING CAUTION LAMP…746
(a) PREHEATING MONITOR DOES NOT LIGHT UP…746
(b) PREHEATING MONITOR KEEPS LIGHTING UP…746
M-3. CAUTION ITEM LIGHTS UP…747
(a) CHARGE CAUTION LAMP LIGHTS UP WHILE ENGINE IS RUNNING…747
(b) OIL PRESSURE CAUTION LAMP LIGHTS UP WHILE ENGINE IS RUNNING…748
(c) HST FILTER CLOGGING CAUTION LAMP LIGHTS UP (WHILE FILTER IS NOT CLOGGED)…748
M-4. TROUBLE IN HST OIL TEMPERATURE GAUGE…749
(a) GAUGE DOES NOT RISE ABOVE C (LOWEST POINT)…749
(b) GAUGE DOES NOT LOWER BELOW H (HIGHEST POINT)…749
(c) HST OIL TEMPERATURE INDICATED BY GAUGE IS DIFFERENT FROM ACTUAL TEMPERATURE…750
M-5. TROUBLE IN ENGINE WATER TEMPERATURE GAUGE…751
(a) GAUGE DOES NOT RISE ABOVE C (LOWEST POINT)…751
(b) GAUGE DOES NOT LOWER BELOW H (HIGHEST POINT)…751
(c) ENGINE WATER TEMPERATURE INDICATED BY GAUGE IS DIFFERENT FROM ACTUAL TEMPERATURE…752
M-6. TROUBLE IN FUEL LEVEL GAUGE…753
(a) GAUGE DOES NOT RISE ABOVE E (LOWEST POINT)…753
(b) GAUGE DOES NOT LOWER BELOW F (HIGHEST POINT)…753
(c) FUEL LEVEL INDICATED BY GAUGE IS DIFFERENT FROM ACTUAL LEVEL…754
M-7. SERVICE METER DOES NOT OPERATE AFTER ENGINE IS STARTED…755
M-8. MONITOR PANEL LAMP DOES NOT LIGHT UP (WHILE HEADLAMP IS NORMAL)…756
M-9. TROUBLE IN DISPLAY OF TRAVEL SPEED (WHILE ACTUAL TRAVEL SPEED IS NORMAL)…757
(a) TRAVEL SPEED IS NOT DISPLAYED…757
(b) DISPLAYED SPEED IS DIFFERENT FROM ACTUAL TRAVEL SPEED…757
TROUBLESHOOTING FOR ENGINE SYSTEM (S-MODE)…759
METHOD OF USING TROUBLESHOOTING CHARTS…760
S-1 STARTING PERFORMANCE IS POOR (STARTING ALWAYS TAKES TIME)…764
S-2 ENGINE DOES NOT START …765
S-3 ENGINE DOES NOT PICK UP SMOOTHLY (FOLLOW-UP IS POOR) …768
S-4 ENGINE STOPS DURING OPERATIONS…769
S-5 ENGINE DOES NOT ROTATE SMOOTHLY (HUNTING)…770
S-6 ENGINE LACKS OUTPUT (OR LACKS POWER)…771
S-7 EXHAUST SMOKE IS BLACK (INCOMPLETE COMBUSTION)…772
S-8 OIL CONSUMPTION IS EXCESSIVE (OR EXHAUST SMOKE IS BLUE)…773
S-9 OIL BECOMES CONTAMINATED QUICKLY…774
S-10 FUEL CONSUMPTION IS EXCESSIVE…775
S-11 OIL IS IN COOLANT, OR COOLANT SPURTS BACK, OR COOLANT LEVEL GOES DOWN …776
S-12 OIL PRESSURE CAUTION LAMP LIGHTS UP (DROP IN OIL PRESSURE)…777
S-13 OIL LEVEL RISES (WATER, FUEL IN OIL)…778
S-14 COOLANT TEMPERATURE BECOMES TOO HIGH (OVERHEATING)…779
S-15 ABNORMAL NOISE IS MADE…780
S-16 VIBRATION IS EXCESSIVE…781
30 DISASSEMBLY AND ASSEMBLY…783
HOW TO READ THIS MANUAL…784
COATING MATERIALS LIST…786
SPECIAL TOOL LIST…789
SKETCHES OF SPECIAL TOOLS…791
REMOVAL OF FUEL INJECTION PUMP ASSEMBLY…792
INSTALLATION OF FUEL INJECTION PUMP ASSEMBLY…794
REMOVAL OF CYLINDER HEAD ASSEMBLY…796
INSTALLATION OF CYLINDER HEAD ASSEMBLY…801
REMOVAL OF ENGINE FRONT SEAL…803
INSTALLATION OF ENGINE FRONT SEAL…804
REMOVAL OF ENGINE REAR SEAL…805
INSTALLATION OF ENGINE REAR SEAL…806
REMOVAL OF RADIATOR GUARD ASSEMBLY…807
INSTALLATION OF RADIATOR GUARD ASSEMBLY…809
DISASSEMBLY OF RADIATOR, OIL COOLER, AND CHARGE AIR COOLER ASSEMBLIES…810
ASSEMBLY OF RADIATOR, OIL COOLER, AND CHARGE AIR COOLER ASSEMBLIES…812
REMOVAL OF ENGINE ASSEMBLY…814
INSTALLATION OF ENGINE ASSEMBLY…816
REMOVAL OF DAMPER…817
INSTALLATION OF DAMPER…817
REMOVAL OF TRAVEL MOTOR AND FINAL DRIVE ASSEMBLY…818
INSTALLATION OF TRAVEL MOTOR AND FINAL DRIVE ASSEMBLY…819
DISASSEMBLY OF TRAVEL MOTOR AND FINAL DRIVE ASSEMBLY…820
ASSEMBLY OF TRAVEL MOTOR AND FINAL DRIVE ASSEMBLY…824
REMOVAL OF IDLER AND RECOIL SPRING ASSEMBLY…829
INSTALLATION OF IDLER AND RECOIL SPRING ASSEMBLY…829
DISASSEMBLY OF RECOIL SPRING ASSEMBLY…830
ASSEMBLY OF RECOIL SPRING ASSEMBLY…831
DISASSEMBLY OF IDLER ASSEMBLY…833
ASSEMBLY OF IDLER ASSEMBLY…834
DISASSEMBLY OF TRACK ROLLER ASSEMBLY…836
ASSEMBLY OF TRACK ROLLER ASSEMBLY…837
DISASSEMBLY OF CARRIER ROLLER ASSEMBLY…840
ASSEMBLY OF CARRIER ROLLER ASSEMBLY…841
SPREADING TRACK SHOE ASSEMBLY…842
INSTALLATION OF TRACK SHOE ASSEMBLY…843
REMOVAL OF HST PUMP ASSEMBLY…844
INSTALLATION OF HST PUMP ASSEMBLY…845
REMOVAL OF MAIN CONTROL VALVE ASSEMBLY…846
INSTALLATION OF MAIN CONTROL VALVE ASSEMBLY…847
DISASSEMBLY OF MAIN CONTROL VALVE ASSEMBLY…848
ASSEMBLY OF MAIN CONTROL VALVE ASSEMBLY…852
DISASSEMBLY OF HYDRAULIC CYLINDER ASSEMBLIES…856
ASSEMBLY OF HYDRAULIC CYLINDER ASSEMBLIES…857
REMOVAL OF BALDE ASSEMBLY…859
INSTALLATION OF BLADE ASSEMBLY…860
REMOVAL OF OPERATOR'S CAB FRAME ASSEMBLY…861
INSTALLATION OF OPERATO'S CAB FRAME ASSEMBLY…865
REMOVAL OF FUEL TANK ASSEMBLY…866
INSTALLATION OF FUEL TANK ASSEMBLY…866
REMOVAL OF HYDRAULIC TANK ASSEMBLY…867
INSTALLATION OF HYDRAULIC TANK ASSEMBLY…868
90 OTHERS…869
HYDRAULIC CIRCUIT DIAGRAM (1/2)(D39EX-21 SERIAL NO.1001-1200 D39PX-21 SERIAL NO.1001-1208)…870
HYDRAULIC CIRCUIT DIAGRAM (1/2) (D39EX-21 SERIAL NO.1201 AND UP D39PX-21 SERIAL NO.1209 AND UP)…871
HYDRAULIC CIRCUIT DIAGRAM (2/2)…872
ELECTRICAL CIRCUIT DIAGRAM (1/2)…873
ELECTRICAL CIRCUIT DIAGRAM (2/2)…874
ELECTRICAL CIRCUIT DIAGRAM FOR AIR CONDITIONER…875
SEN04041-05 – Bulldozer D39EX,PX-22 Shop Manual (SN3001&up)…876
COVER…876
00 Index and foreword…0
100 Index…877
Composition of shop manual…878
Table of contents…880
200 Foreword and general information…889
Safety notice…890
How to read the shop manual…895
Explanation of terms for maintenance standard…897
Handling of electric equipment and hydraulic component…899
Handling of connectors newly used for engines…908
How to read electric wire code…911
Precautions when carrying out operation…914
Method of disassembling and connecting push-pull type coupler…917
Standard tightening torque table…920
Conversion table…924
01 General…0
100 Specification and technical data…931
Specification dimensional drawing…932
Specifications…933
Weight table…937
Table of fuel, coolant and lubricants…939
10 Structure, function and maintenance standard…0
100 Engine and cooling system…941
Engine system parts…942
Cooling system…943
Cooling fan pump…944
Cooling fan motor…945
Oil cooler bypass valve…950
200 Power train…955
Power train…956
Power train system…957
Damper…958
HST hydraulic equipment arrangement diagram…959
Steering and brake control…960
Solenoid valve…962
Final drive…969
HST pump…972
HST motor…984
Charge pump…994
300 Undercarriage and frame…997
Main frame…998
Track frame and idler cushion…1000
Idler…1002
Track roller…1004
Carrier roller…1006
Sprocket…1008
Track shoe…1010
410 Hydraulic system, Part 1…1017
Arrangement of hydraulic equipment for work equipment…1018
Work equipment control…1020
Hydraulic tank and filter…1022
Work equipment and fan pump…1024
Control valve…1032
CLSS…1044
Functions and operation of each valve…1047
420 Hydraulic system, Part 2…1057
Blade PPC valve…1058
Accumulator…1064
500 Work equipment…1067
Work equipment…1068
Cutting edge and end bit…1072
Ripper…1073
Work equipment cylinder…1074
Piston valve…1077
600 Cab and its attachments…1079
ROPS cab…1080
Cab mount…1081
Canopy mount…1082
Air conditioner…1083
700 Electrical system…1087
Monitor system…1088
Engine control…1090
Engine control system…1091
Cooling control system…1092
HST control system…1094
Parking brake control system…1100
KOMTRAX system…1102
Component equipment of system…1104
PCCS lever (for steering)…1112
Sensor…1115
20 Standard value table…0
100 Standard service value table…1127
Standard service value table for engine…1128
Standard service value table for chassis…1129
30 Testing and adjusting…0
110 Testing and adjusting, Part 1…1137
Tools for testing, adjusting, and troubleshooting…1139
Sketches of special tools…1142
Measuring engine speed…1143
Measuring intake air pressure (boost pressure)…1144
Measuring exhaust gas color (boost pressure)…1146
Adjusting valve clearance…1147
Measuring compression pressure…1149
Measuring blow-by pressure…1152
Testing engine oil pressure…1154
Handling fuel system equipment…1155
Releasing residual pressure in fuel system…1155
Bleeding air from fuel circuit…1156
Measuring fuel pressure…1157
Measuring fuel discharge, return and leakage…1159
Testing leakage in fuel system…1163
Measurement of fan circuit pressure and fan speed…1164
Adjustment of fan speed sensor…1165
Handling reduced cylinder mode operation…1166
Handling no-injection cranking operation…1166
Handling controller voltage circuit…1167
Check of muffler and muffler stack for looseness and damage…1168
Check of muffler function…1168
Check of installed condition of cylinder head and manifolds…1169
Check of engine piping for damage and looseness…1169
Replacing alternator belt…1170
120 Testing and adjusting, Part 2…1173
Adjusting decelerator pedal…1174
Testing and adjusting HST oil pressure…1176
Measuring solenoid valve outlet pressure…1181
Testing travel deviation…1184
Adjusting parking brake lever…1185
Simple brake performance test procedure…1187
Adjusting brake pedal…1188
Method of releasing parking brake (Procedure for emergency escape)…1190
Testing and adjusting idler clearance…1192
Testing and adjusting track shoe tension…1193
Testing work equipment pressure…1194
Testing work equipment PPC valve…1196
Adjusting play of work equipment PPC valve…1198
Adjusting work equipment lock lever…1199
Testing internal leakage of work equipment cylinder…1200
Releasing residual pressure in hydraulic circuit…1202
Bleeding air from hydraulic circuit…1203
Adjusting play of blade center ball…1204
Procedure for testing diodes…1205
Preparation work for troubleshooting for electrical system…1206
How to start operation of KOMTRAX terminal…1210
Lamp display of KOMTRAX terminal…1213
130 Testing and adjusting, Part 3…1217
Special functions of monitor panel (EMMS)…1218
Items to be adjusted when electric/hydraulic devices are adjusted/replaced…1280
Adjustment procedure after replacement of HST controller…1281
Adjustment procedure after replacement of monitor panel…1283
Pm-clinic…1284
40 Troubleshooting…0
100 Failure code table and fuse locations…1295
Failure code table…1296
Before carrying out troubleshooting for electrical system (E-mode)…1302
200 General information on troubleshooting…1305
Points to remember when troubleshooting…1306
Sequence of events in troubleshooting…1307
Testing before troubleshooting…1308
Classification and procedures of troubleshooting…1309
Information contained in troubleshooting table…1312
Connection table for connector pin numbers…1314
T- branch box and T- branch adapter table…1350
310 Troubleshooting by failure code (Display of code), Part 1…1355
Failure code [6091NX] HST charge filter element: Clogging…1357
Failure code [AA10NX] Air cleaner: Clogging…1358
Failure code [AB00MA] Alternator: Malfunction…1360
Failure code [B@BAZG] Engine oil: Lowering of oil pressure…1361
Failure code [B@BCNS] Coolant: Overheat…1362
Failure code [B@CRNS] HST oil: Overheating…1363
Failure code [B@CRZG] HST oil: Lowering of oil pressure…1364
Failure code [CA111] Engine controller: Abnormality in controller…1365
Failure code [CA115] Abnormal engine Ne and Bkup speed sensors: Abnormal speed sensor signal…1365
Failure code [CA122] Charge pressure sensor tool high: Excessively high voltage detected…1366
Failure code [CA123] Charge pressure sensor too low: Excessively low voltage detected…1368
Failure code [CA131] Decelerator pedal sensor tool high: Excessively high voltage detected…1370
Failure code [CA132] Decelerator pedal sensor too low: Excessively low voltage detected…1372
Failure code [CA144] Coolant temperature sensor too high: Excessively high voltage detected…1374
Failure code [CA145] Coolant temperature sensor too low: Excessively low voltage detected…1376
Failure code [CA153] Charge air temperature sensor too high: Excessively high voltage detected…1378
Failure code [CA154] Charge temperature sensor too low: Excessively low voltage detected…1380
Failure code [CA187] Sensor power source 2 too low: Excessively low voltage detected…1382
Failure code [CA221] Atmospheric pressure sensor too high: Excessively high voltage detected…1384
Failure code [CA222] Atmospheric pressure sensor too low: Excessively low voltage detected…1386
Failure code [CA227] Sensor power source 2 too high: Excessively high voltage detected…1388
Failure code [CA234] Engine over speed: Excessively high speed…1390
Failure code [CA238] Abnormal power source for Ne speed sensor: Excessively low voltage detected…1391
Failure code [CA271] IMV/PCV1 short circuit: Short circuit…1392
Failure code [CA272] IMV/PCV1 disconnection: Disconnection…1394
320 Troubleshooting by failure code (Display of code), Part 2…1397
Failure code [CA322] Injector No. 1 system disconnection or short circuit: disconnection, short circuit…1400
Failure code [CA324] Injector No. 3 system disconnection or short circuit: disconnection, short circuit…1402
Failure code [CA331] Injector No. 2 system disconnection or short circuit: disconnection, short circuit…1404
Failure code [CA332] Injector No. 4 system disconnection or short circuit: disconnection, short circuit…1406
Failure code [CA342] Engine controller data matching error: matching error…1408
Failure code [CA351] Injector drive circuit abnormality: Abnormal circuit…1410
Failure code [CA352] Sensor power source 1 too low: Excessively low voltage detected…1412
Failure code [CA386] Sensor power source 1 too high: Excessively high voltage detected…1414
Failure code [CA428] Water in fuel sensor too high: Excessively high voltage detected…1416
Failure code [CA429] Water in fuel sensor too low: Excessively low voltage detected…1418
Failure code [CA435] Abnormal engine oil pressure switch: Abnormal signal circuit…1420
Failure code [CA441] Power source voltage too low: Excessively low voltage detected…1422
Failure code [CA442] Power source voltage too high: Excessively high voltage has occurred in the controller power source circuit…1424
Failure code [CA449] Common rail pressure too high (2): Excessively high pressure trouble occurred…1426
Failure code [CA451] Common rail pressure sensor too high: Excessively high voltage detected…1428
Failure code [CA452] Common rail pressure sensor too low: Excessively low voltage detected…1430
Failure code [CA488] Charge temperature too high and torque derated: Exceeded upper control limit of temperature…1432
Failure code [CA553] Common rail pressure too high (1): Excessively high pressure detected…1433
Failure code [CA559] Loss of pressure feed from supply pump (1): Loss of pressure feed detected…1434
Failure code [CA689] Abnormal engine Ne speed sensor: Abnormal signal…1436
Failure code [CA731] Abnormal engine Bkup speed sensor phase: Abnormal phase…1438
Failure code [CA757] Loss of all engine controller data: Loss of all data…1440
Failure code [CA778] Abnormal engine Bkup speed sensor: Abnormal Bkup signal…1442
Failure code [CA1633] Abnormal KOMNET: Abnormal communication…1444
Failure code [CA2185] Decelerator pedal sensor power source too high: Excessively high voltage detected…1446
Failure code [CA2186] Decelerator pedal sensor power source too low: Excessively low voltage detected…1448
Failure code [CA2249] Loss of pressure feed from supply pump (2): Loss of pressure feed detected…1450
Failure code [CA2311] Abnormal IMV solenoid: Abnormal resistance…1452
Failure code [CA2555] Air intake heater relay disconnection: Disconnection…1454
Failure code [CA2556] Air intake heater relay short circuit: Short circuit…1456
330 Troubleshooting by failure code (Display of code), Part 3…1459
Failure code [D130KA] Neutral safety relay: Disconnection…1462
Failure code [D130KB] Neutral safety relay: Short circuit…1464
Failure code [DAFRKR] CAN communication (Monitor panel – HST controller): Defective communication (Abnormality in objective component system)…1466
Failure code [DAFRMC] CAN communication (Monitor panel – ENGINE controller): Defective communication (Abnormality in objective component system)…1469
Failure code [DAJ000] HST controller: Memory error…1472
Failure code [DAJ0KK] HST controller: Lowing of source voltage…1474
Failure code [DAJ0KQ] HST controller: Machine code error…1476
Failure code [DAJ0KT] HST controller: Memory error…1477
Failure code [DAJ5KK] HST controller sensor 5 V power supply No.1: Lowing of source voltage/Input…1478
Failure code [DAJ6KK] HST controller sensor 5 V power supply No.2: Lowing of source voltage/Input…1480
Failure code [DAJRKR] CAN communication (HST controller – Monitor panel): Defective communication (Abnormality in objective component system)…1482
Failure code [DB2RKR] CAN communication (HST controller – Engine controller): Defective communication (Abnormality in objective component system)…1485
Failure code [DD12KA] Shift up switch: Disconnection…1488
Failure code [DD12KB] Shift up switch: Short circuit…1490
Failure code [DD13KA] Shift down switch: Disconnection…1492
Failure code [DD13KB] Shift down switch: Short circuit…1494
Failure code [DD14KB] Travel lock limit switch 1: Short circuit…1496
Failure code [DD1NL4] Fan rotation selector switch: Disagreement of ON, OFF Signals…1498
Failure code [DDDCKB] Reverse travel speed switch: Short circuit…1500
Failure code [DDP6KA] Brake oil pressure sensor: Disconnection…1502
Failure code [DDP6KB] Brake oil pressure sensor: Short circuit…1504
Failure code [DDP6MA] Brake oil pressure sensor: Malfunction…1506
Failure code [DDQ2KA] Travel lock limit switch 1: Disconnection…1508
Failure code [DDT0L4] Shift mode switch: Disagreement of ON/ OFF Signals…1510
Failure code [DDU1FS] Travel lock limit switches 1 and 2: Fixing…1512
Failure code [DDU1KA] Travel lock limit switch 2: Disconnection…1514
Failure code [DDU1KY] Travel lock limit switch 2: Short circuit with power supply line…1516
Failure code [DGS1KA] HST oil temperature sensor: Disconnection…1518
Failure code [DGS1KX] HST oil temperature sensor: Out of Input signal range…1520
340 Troubleshooting by failure code (Display of code), Part 4…1523
Failure code [DHH5KA] Left HST pump pressure sensor: Disconnection…1526
Failure code [DHH5KB] Left HST pump pressure sensor: Short circuit…1528
Failure code [DHH6KA] Right HST pump pressure sensor: Disconnection…1530
Failure code [DHH6KB] Right HST pump pressure sensor: Short circuit…1532
Failure code [DK10KA] Fuel dial sensor: Disconnection…1534
Failure code [DK10KB] Fuel dial sensor: Short circuit…1536
Failure code [DK30KA] Steering angle sensor 1: Disconnection…1538
Failure code [DK30KB] Steering angle sensor 1: Short circuit…1540
Failure code [DK30KX] Steering angle sensor: Out of input signal range…1542
Failure code [DK30KZ] Steering angle sensor: Disconnection or short circuit…1543
Failure code [DK30L8] Steering angle sensor: Disagreement of analog signals…1544
Failure code [DK31KA] Steering angle sensor 2: Disconnection…1546
Failure code [DK31KB] Steering angle sensor 2: Short circuit…1548
Failure code [DK40KA] Brake pedal sensor: Disconnection…1550
Failure code [DK40KB] Brake pedal sensor: Short circuit…1552
Failure code [DK55KX] Directional potentiometer: Out of input signal range…1554
Failure code [DK55KZ] Directional potentiometer: Disconnection or short circuit…1555
Failure code [DK55L8] Directional potentiometer: Disagreement of analog signals…1556
Failure code [DK56KA] Directional potentiometer 1: Disconnection…1558
Failure code [DK56KB] Directional potentiometer 1: Short circuit…1560
Failure code [DK57KA] Directional potentiometer 2: Disconnection…1562
Failure code [DK57KB] Directional potentiometer 2: Short circuit…1564
Failure code [DLM0KX] HST motor speed sensors: Out of input signal range…1566
Failure code [DLM1KA] Left HST motor speed sensor: Disconnection…1568
Failure code [DLM1KB] Left HST motor speed sensor: Short circuit…1570
Failure code [DLM1MA] Left HST motor speed sensor: Malfunction…1572
Failure code [DLM2KA] Right HST motor speed sensor: Disconnection…1574
Failure code [DLM2KB] Right HST motor speed sensor: Short circuit…1576
Failure code [DLM2MA] Right HST motor speed sensor: Malfunction…1578
Failure code [DLM3KA] Fan speed sensor: Disconnection…1580
Failure code [DLM3KB] Fan speed sensor: Short circuit…1582
350 Troubleshooting by failure code (Display of code), Part 5…1585
Failure code [DN21FS] Brake pedal and proximity switch: Fixing…1588
Failure code [DV00KB] Caution buzzer: Short circuit…1590
Failure code [DV20KB] Back alarm buzzer: Short circuit…1591
Failure code [DW4BKA] Parking brake solenoid valve: Disconnection…1592
Failure code [DW4BKB] Parking brake solenoid valve: Short circuit…1594
Failure code [DW4BKY] Parking brake solenoid valve: Short circuit with power supply line…1596
Failure code [DW7BKA] Fan reverse solenoid valve: Disconnection…1598
Failure code [DW7BKB] Fan reverse solenoid valve: Short circuit…1600
Failure code [DW7BKY] Fan reverse solenoid valve: Short circuit with power supply line…1601
Failure code [DW7EKA] Slow brake solenoid valve: Disconnection…1602
Failure code [DW7EKB] Slow brake solenoid valve: Short circuit…1606
Failure code [DW7EKY] Slow brake solenoid valve: Short circuit with power supply line…1608
Failure code [DWN5KA] Fan EPC solenoid valve: Disconnection…1610
Failure code [DWN5KB] Fan EPC solenoid valve: Short circuit…1612
Failure code [DWN5KY] Fan EPC solenoid valve: Short circuit with power supply line…1614
Failure code [DXA4KA] LF HST pump EPC solenoid valve: Disconnection…1616
Failure code [DXA4KB] LF HST pump EPC solenoid valve: Short circuit…1618
Failure code [DXA4KY] LF HST pump EPC solenoid valve: Short circuit with power supply line…1620
Failure code [DXA5KA] LR HST pump EPC solenoid valve: Disconnection…1622
Failure code [DXA5KB] LR HST pump EPC solenoid valve: Short circuit…1624
Failure code [DXA5KY] LR HST pump EPC solenoid valve: Short circuit with power supply line…1626
Failure code [DXA6KA] RF HST pump EPC solenoid valve: Disconnection…1628
Failure code [DXA6KB] RF HST pump EPC solenoid valve: Short circuit…1630
Failure code [DXA6KY] RF HST pump EPC solenoid valve: Short circuit with power supply line…1631
Failure code [DXA7KA] RR HST pump EPC solenoid valve: Disconnection…1632
Failure code [DXA7KB] RR HST pump EPC solenoid valve: Short circuit…1634
Failure code [DXA7KY] RR HST pump EPC solenoid valve: Short circuit with power supply line…1636
Failure code [DXK1KA] Left HST motor EPC solenoid valve: Disconnection…1638
Failure code [DXK1KB] Left HST motor EPC solenoid valve: Short circuit…1639
Failure code [DXK1KY] Left HST motor EPC solenoid valve: Short circuit with power supply line…1640
Failure code [DXK2KA] Right HST motor EPC solenoid valve: Disconnection…1641
Failure code [DXK2KB] Right HST motor EPC solenoid valve: Short circuit…1642
Failure code [DXK2KY] Right HST motor EPC solenoid valve: Short circuit with power supply line…1643
400 Troubleshooting of electrical system (E-mode)…1645
E-1 Engine does not start (Starting motor does not rotate)…1648
E-2 Engine is not preheated…1651
E-3 When starting switch is turned ON, any item does not light up…1654
E-4 Charge level caution flashes while engine is running…1656
E-5 Emergency warning items flash while engine is running…1658
E-6 Preheating pilot lamp does not light up during preheating operation…1664
E-7 The coolant temperature gauge does not indicate correctly…1666
E-8 The HST oil temperature gauge does not indicate correctly…1667
E-9 Fuel level gauge does not indicate properly…1668
E-10 Gear speed, set travel speed, and shift mode indicator does not display normally…1670
E-11 Multi-information unit does not display normally…1670
E-12 Caution lamp does not flash or does not go off…1671
E-13 Caution buzzer does not sound or does not stop…1672
E-14 Reverse travel speed setting switch does not function…1674
E-15 Shift mode switch does not function…1676
E-16 Buzzer cancel switch does not function…1678
E-17 Information switch does not function…1680
E-18 The fan cleaning does not operate or cannot be reset…1682
E-19 Backup alarm does not sound…1684
E-20 The horn does not sound or does not stop…1685
E-21 Work equipment does not move…1686
E-22 Headlamp or rear lamp does not light up…1688
E-23 Foot heater does not operate…1691
E-24 Air conditioner does not operate…1694
E-25 Windshield wiper and window washer do not operate…1699
E-26 KOMTRAX system does not operate normally…1712
500 Troubleshooting of hydraulic and mechanical system (H-mode)…1715
Information in troubleshooting table…1717
H-1 Right and left travel systems do not operate forward and in reverse (No travel systems operate)…1718
H-2 Right or left travel system does not operate forward and in reverse (Only right or left travel system does not operate)…1720
H-3 Right or left travel system does not operate forward or in reverse (Only 1 system does not operate)…1721
H-4 Speed or power of travel is low…1722
H-5 Gear is not shifted…1723
H-6 Large shocks are made when machine starts and stops travel…1724
H-7 Machine deviates largely during travel…1725
H-8 Hydraulic drift of travel is large…1726
H-9 Engine stalls or engine speed lowers extremely during travel…1727
H-10 Abnormal sound comes out from around HST pump and motor…1728
H-11 Work equipment dose not operate at all…1729
H-12 Speed or power of whole work equipment is low…1730
H-13 Speed or power of lifting blade is low…1731
H-14 Speed or power of tilting blade is low…1732
H-15 Speed or power of angling blade is low…1733
H-16 Time lag in lifting blade is large…1734
H-17 Hydraulic drift of lifting blade is large…1734
H-18 Hydraulic drift of tilting blade is large…1734
H-19 Abnormal sound comes out from around work equipment pump and control valve…1735
H-20 HST oil temperature (Hydraulic oil temperature) rises too high…1736
H-21 Fan speed is abnormal (High, low, or 0 rpm)…1738
H-22 Abnormal sound is heard from around fan…1739
600 Troubleshooting of engine (S-mode)…1741
Method of using troubleshooting charts…1743
S-1 Starting performance is poor…1746
S-2 Engine does not start…1747
S-3 Engine does not pick up smoothly…1750
S-4 Engine stops during operations…1751
S-5 Engine does not rotate smoothly…1752
S-6 Engine lacks output (or lacks power)…1753
S-7 Exhaust smoke is black (imcomplete combustion)…1754
S-8 Oil consumption is excessive (or exhaust smoke is blue)…1755
S-9 Oil becomes contaminated quickly…1756
S-10 Fuel consumption is excessive…1757
S-11 Oil is in coolant (or coolant spurts back, or coolant level goes down)…1758
S-12 Oil pressure drops…1759
S-13 Oil level rises (water, fuel in oil)…1760
S-14 Coolant temperature becomes too high (overheating)…1761
S-15 Abnormal noise is made…1762
S-16 Vibration is excessive…1763
50 Disassembly and assembly…0
100 General information on disassembly and assembly…1765
How to read this manual…1766
Coating materials list…1768
Special tools list…1771
Sketches of special tools…1774
200 Engine and cooling system…1779
Removal and installation of fuel supply pump assembly…1780
Removal and installation of fuel injector assembly…1784
Removal and installation of cylinder head assembly…1792
Removal and installation of engine and HST pump assembly…1805
Removal and installation of engine front seal assembly…1808
Removal and installation of engine rear seal assembly…1810
Removal and installation of front guard assembly…1814
Removal and installation of radiator assembly…1816
Removal and installation of hydraulic oil cooler assembly…1818
Removal and installation of aftercooler assembly…1820
Removal and installation of cooling fan and motor assembly…1822
Removal and installation of cooling fan drive motor assembly1…1824
Removal and installation of fuel tank assembly…1826
300 Power train…1829
Removal and installation of HST pump assembly…1830
Removal and installation of HST motor and final drive assembly…1832
Disassembly and assembly of final drive assembly…1834
400 Undercarriage and frame…1845
Spreading and installation of track shoe assembly…1846
Removal and installation of idler and recoil spring assembly…1848
Disassembly and assembly of idler assembly…1849
Disassembly and assembly of recoil spring assembly…1852
Disassembly and assembly of track roller assembly…1856
Disassembly and assembly of carrier roller assembly…1860
500 Hydraulic system…1865
Removal and installation of hydraulic tank assembly…1866
Removal and installation of control valve assembly…1868
Disassembly and assembly of control valve assembly…1869
Disassembly and assembly of hydraulic cylinder assembly…1871
600 Work equipment…1877
Removal and installation of work equipment assembly…1878
700 Cab and its attachments…1883
Removal and installation of ROPS canopy and operator seat frame assembly…1884
Removal and installation of ROPS cab and operator seat frame assembly…1887
Removal and installation of operator’s cab glass (Stuck glass)…1892
800 Electrical system…1899
Removal and installation of HST controller assembly…1900
Removal and installation of KOMTRAX terminal assembly…1901
90 Diagrams and drawings…0
100 Hydraulic diagrams and drawings…1903
Work equipment hydraulic circuit diagram…1905
200 Electrical diagrams and drawings…1908
Electrical circuit diagram…1910
Cab electrical circuit diagram…1915
Air conditioner circuit diagram…1918
Connector list and stereogram…1919

Komatsu Bulldozers D39EX,PX Repair Service Manuals

INSTANT DOWNLOAD

Posted on June 5, 2025 by admin

Komatsu Bulldozer D37EXi, D37PXi, D39EXi, D39PXi Repair Service Manuals

INSTANT DOWNLOAD

Complete service repair manual for Komatsu Bulldozers D37EXi, D37PXi, D39EXi, D39PXi, with all the technical information to maintain, diagnose, repair, and service like professional mechanics.

Komatsu Bulldozer D37EXi, D37PXi, D39EXi, D39PXi workshop service repair manual includes:
* Numbered table of contents easy to use so that you can find the information you need fast.
* Detailed sub-steps expand on repair procedure information
* Numbered instructions guide you through every repair procedure step by step.
* Troubleshooting and electrical service procedures are combined with detailed wiring diagrams for ease of use.
* Notes, cautions and warnings throughout each chapter pinpoint critical information.
* Bold figure number help you quickly match illustrations with instructions.
* Detailed illustrations, drawings and photos guide you through every procedure.
* Enlarged inset helps you identify and examine parts in detail.

SEN06593-06 – Bulldozer D37EXi-24, D37PXi-24, D39EXi-24, D39PXi-24 Shop Manual (SN80001&up).pdf

PRODUCT DETAILS:
Total Pages: 2,910 pages
File Format: PDF
Language: English

TABLE OF CONTENTS
00 INDEX AND FOREWORD
01 SPECIFICATIONS
10 STRUCTURE AND FUNCTION
20 STANDARD VALUE TABLE
30 TESTING AND ADJUSTING
40 TROUBLESHOOTING
50 DISASSEMBLY AND ASSEMBLY
60 MAINTENANCE STANDARD.
80 APPENDIX
90 CIRCUIT DIAGRAMS

COVER…..1
00 INDEX AND FOREWORD…..3
INDEX…..4
ABBREVIATION LIST…..22
FOREWORD, SAFETY, BASIC INFORMATION…..28
    HOW TO READ THE SHOP MANUAL…..28
    SAFETY NOTICE FOR OPERATION…..30
    PRECAUTIONS TO PREVENT FIRE…..38
    ACTIONS IF FIRE OCCURS…..40
    PRECAUTIONS FOR DISPOSING OF WASTE MATERIALS…..41
    ACTIONS TAKEN TO MEET EXHAUST GAS REGULATIONS…..42
    PRECAUTIONS FOR DEF…..43
      GENERAL CHARACTER AND PRECAUTIONS FOR HANDLING…..43
      PRECAUTIONS FOR ADDING…..43
      PRECAUTIONS FOR STORING…..43
      PRECAUTIONS FOR FIRE HAZARD AND LEAKAGE…..43
      THE OTHER PRECAUTIONS…..43
    STORE AdBlue/DEF…..44
    PRECAUTIONS FOR HANDLING HYDRAULIC EQUIPMENT…..45
    PRECAUTIONS FOR DISCONNECTION AND CONNECTION OF PIPINGS…..48
    PRECAUTIONS FOR HANDLING ELECTRICAL EQUIPMENT…..55
    PRECAUTIONS FOR HANDLING FUEL SYSTEM EQUIPMENT…..57
    PRECAUTIONS FOR HANDLING INTAKE SYSTEM EQUIPMENT…..58
    PRACTICAL USE OF KOMTRAX…..59
    DISCONNECT AND CONNECT PUSH-PULL TYPE COUPLER…..60
      METHOD FOR DISCONNECTING AND CONNECTING TYPE 1 PUSH-PULL TYPE COUPLER…..60
      METHOD FOR DISCONNECTING AND CONNECTING TYPE 2 PUSH-PULL TYPE COUPLER…..61
      METHOD FOR DISCONNECTING AND CONNECTING TYPE 3 PUSH-PULL TYPE COUPLER…..62
    PRECAUTIONS FOR DISCONNECTION AND CONNECTION OF CONNECTORS…..64
    METHOD FOR DISCONNECTING AND CONNECTING DEUTSCH CONNECTOR…..68
    METHOD FOR DISCONNECTING AND CONNECTING SLIDE LOCK TYPE CONNECTOR…..69
    METHOD FOR DISCONNECTING AND CONNECTING CONNECTOR WITH LOCK TO PULL…..71
    METHOD FOR DISCONNECTING AND CONNECTING CONNECTOR WITH LOCK TO PUSH…..72
    METHOD FOR DISCONNECTING AND CONNECTING CONNECTOR WITH HOUSING TO ROTATE…..74
    HOW TO READ ELECTRICAL WIRE CODE…..75
    EXPLANATION OF TERMS FOR MAINTENANCE STANDARD…..79
    STANDARD TIGHTENING TORQUE TABLE…..82
    CONVERSION TABLE…..89
01 SPECIFICATIONS…..95
CONTENTS…..96
ABBREVIATION LIST…..97
SPECIFICATIONS…..103
    SPECIFICATION DRAWING…..103
      SPECIFICATION DRAWING: D37EXI-24…..104
      SPECIFICATION DRAWING: D37PXI-24…..105
      SPECIFICATION DRAWING: D39EXI-24…..106
      SPECIFICATION DRAWING: D39PXI-24…..107
    SPECIFICATIONS…..109
      SPECIFICATIONS: D37EXI-24…..109
      SPECIFICATIONS: D37PXI-24…..114
      SPECIFICATIONS: D39EXI-24…..118
      SPECIFICATIONS: D39PXI-24…..123
    WEIGHT TABLE…..131
      WEIGHT TABLE: D37EXI-24…..132
      WEIGHT TABLE: D37PXI-24…..134
      WEIGHT TABLE: D39EXI-24…..136
      WEIGHT TABLE: D39PXI-24…..138
    TABLE OF FUEL, COOLANT, AND LUBRICANTS…..142
10 STRUCTURE AND FUNCTION…..143
CONTENTS…..144
ABBREVIATION LIST…..147
UREA SCR SYSTEM…..153
    LAYOUT DRAWING OF UREA SCR SYSTEM…..153
    UREA SCR SYSTEM DIAGRAM…..155
    FUNCTION OF UREA SCR SYSTEM…..156
      FUNCTION OF AdBlue/DEF SYSTEM…..156
      INDUCEMENT STRATEGY…..158
    COMPONENT PARTS OF UREA SCR SYSTEM…..172
      AdBlue/DEF MIXING TUBE…..172
      SCR ASSEMBLY…..173
      AdBlue/DEF TANK…..175
      AdBlue/DEF PUMP…..177
      AdBlue/DEF INJECTOR…..178
      AdBlue/DEF HOSE…..179
      AdBlue/DEF TANK HEATING VALVE…..180
BOOT-UP SYSTEM…..181
    LAYOUT DRAWING OF BOOT-UP SYSTEM…..181
    SYSTEM OPERATING LAMP SYSTEM…..182
      SYSTEM OPERATING LAMP SYSTEM DIAGRAM…..182
      FUNCTION OF SYSTEM OPERATING LAMP SYSTEM…..183
    BATTERY DISCONNECT SWITCH…..184
      FUNCTION OF BATTERY DISCONNECT SWITCH…..184
ENGINE SYSTEM…..185
    LAYOUT DRAWING OF ENGINE SYSTEM…..185
    ENGINE CONTROL SYSTEM…..187
      LAYOUT OF ENGINE CONTROL SYSTEM…..187
      ENGINE CONTROL SYSTEM DIAGRAM…..189
      FUNCTION OF ENGINE CONTROL SYSTEM…..191
    AUTOMATIC IDLE STOP SYSTEM…..193
      AUTOMATIC IDLE STOP SYSTEM DIAGRAM…..193
      FUNCTION OF AUTOMATIC IDLE STOP SYSTEM…..194
    COMPONENT PARTS OF ENGINE SYSTEM…..196
      DAMPER…..196
      VARIABLE FLOW TURBOCHARGER…..197
      EGR SYSTEM…..200
      EGR VALVE…..203
      EGR COOLER…..205
      KCCV SYSTEM…..207
      KCCV VENTILATOR…..210
      EXHAUST THROTTLE VALVE…..212
      KDOC…..213
COOLING SYSTEM…..216
    LAYOUT DRAWING OF COOLING SYSTEM…..216
      SPECIFICATIONS OF COOLING SYSTEM…..217
    COOLING FAN CONTROL SYSTEM…..218
      COOLING FAN CONTROL SYSTEM DIAGRAM…..218
      FUNCTION OF COOLING FAN CONTROL SYSTEM…..219
    COMPONENT PARTS OF COOLING SYSTEM…..221
      COOLING FAN MOTOR…..221
      HYDRAULIC OIL COOLER BYPASS AND HST CHARGE SAFETY VALVE…..226
      HYDRAULIC OIL COOLER BYPASS VALVE…..228
      HST CHARGE SAFETY VALVE…..229
CONTROL SYSTEM…..231
    LAYOUT DRAWING OF CONTROL SYSTEM…..231
    MACHINE MONITOR SYSTEM…..232
      MACHINE MONITOR SYSTEM DIAGRAM…..232
      FUNCTION OF MACHINE MONITOR SYSTEM…..233
    KOMTRAX SYSTEM…..234
      KOMTRAX SYSTEM DIAGRAM…..234
      FUNCTION OF KOMTRAX SYSTEM…..235
    COMPONENT PARTS OF CONTROL SYSTEM…..236
      MACHINE MONITOR…..236
      KOMTRAX TERMINAL…..251
      HST CONTROLLER…..253
      ENGINE CONTROLLER…..257
      FUEL CONTROL DIAL…..264
      DECELERATOR AND BRAKE POTENTIOMETER…..266
HYDRAULIC SYSTEM…..268
    LAYOUT DRAWING OF HYDRAULIC SYSTEM…..268
    CLSS…..269
      STRUCTURE OF CLSS…..269
      FUNCTION OF CLSS…..270
    COMPONENT PARTS OF HYDRAULIC SYSTEM…..272
      HYDRAULIC TANK…..272
      WORK EQUIPMENT AND COOLING FAN PUMP…..274
      LS VALVE…..281
      PC VALVE…..282
      CONTROL VALVE…..285
POWER TRAIN SYSTEM…..306
    LAYOUT DRAWING OF HST SYSTEM…..306
    OPERATION OF HST SYSTEM…..307
    STEERING AND BRAKE CONTROL SYSTEM…..309
      LAYOUT DRAWING OF STEERING AND BRAKE CONTROL SYSTEM…..309
      FUNCTION OF STEERING AND BRAKE CONTROL SYSTEM…..310
    HST CONTROL SYSTEM…..311
      HST CONTROL SYSTEM DIAGRAM…..311
      GEAR SHIFT CONTROL FUNCTION…..312
      ENGINE LOW SPEED MATCHING CONTROL FUNCTION…..316
      HST PUMP AND MOTOR SEQUENCE CONTROL FUNCTION…..317
      DECELERATION AND BRAKE CONTROL FUNCTION…..319
      GEAR SHIFT CONTROL FUNCTION BY LOAD…..321
      TURN CONTROL FUNCTION…..322
      STRAIGHT TRAVEL CORRECTION CONTROL FUNCTION…..323
    PARKING BRAKE CONTROL SYSTEM…..324
      PARKING BRAKE CONTROL SYSTEM DIAGRAM…..324
      FUNCTION OF PARKING BRAKE CONTROL SYSTEM…..325
      OPERATION OF PARKING BRAKE CONTROL SYSTEM…..326
    COMPONENT PARTS OF POWER TRAIN SYSTEM…..327
      HST PUMP…..327
      HST CHARGE PUMP…..344
      HST MOTOR…..345
      FINAL DRIVE…..357
      ELECTRIC STEERING CONTROL LEVER…..361
WORK EQUIPMENT SYSTEM…..363
    WORK EQUIPMENT CONTROL…..363
      WORK EQUIPMENT CONTROL SYSTEM DIAGRAM…..363
      FUNCTION OF WORK EQUIPMENT CONTROL…..365
    LAYOUT DRAWING OF FRONT WORK EQUIPMENT…..367
    LAYOUT OF FIXED MULTI-SHANK RIPPER…..368
    COMPONENT PARTS OF WORK EQUIPMENT SYSTEM…..369
      RIPPER PPC VALVE…..369
      5-PORT VALVE OF EPC AND SOLENOID…..373
      PILOT CIRCUIT ACCUMULATOR…..380
      ANGLE CONTROL EPC VALVE…..381
      PISTON VALVE…..384
      ELECTRIC BLADE CONTROL LEVER…..385
ICT SYSTEM…..387
    LAYOUT DRAWING OF ICT SYSTEM…..387
    ICT CONTROL SYSTEM DIAGRAM…..389
    BLADE CONTROL SYSTEM…..391
      FUNCTION OF BLADE CONTROL SYSTEM…..392
      LEVELING MODE SYSTEM DIAGRAM…..394
      FUNCTION OF LEVELING MODE…..396
      OPERATION OF LEVELING MODE…..397
      DOZING MODE SYSTEM DIAGRAM…..398
      FUNCTION OF DOZING MODE…..399
      OPERATION OF DOZING MODE…..400
    SMOOTH START SYSTEM…..401
      SMOOTH START SYSTEM DIAGRAM…..401
      FUNCTION OF SMOOTH START SYSTEM…..402
      OPERATION OF SMOOTH START SYSTEM…..403
    SLIP CONTROL SYSTEM…..404
      SLIP CONTROL SYSTEM DIAGRAM…..404
      FUNCTION OF SLIP CONTROL SYSTEM…..405
      OPERATION OF SLIP CONTROL SYSTEM…..406
    ASSIST CONTROL SYSTEM…..407
      ASSIST CONTROL SYSTEM DIAGRAM…..407
      FUNCTION OF ASSIST CONTROL SYSTEM…..408
      OPERATION OF ASSIST CONTROL SYSTEM…..409
    HST SPEED RANGE CONTROL SYSTEM…..410
      HST SPEED RANGE CONTROL SYSTEM DIAGRAM…..410
      FUNCTION OF HST SPEED RANGE CONTROL SYSTEM…..411
      OPERATION OF HST SPEED RANGE CONTROL SYSTEM…..412
    COMPONENT PARTS OF ICT SYSTEM…..413
      ICT SENSOR CONTROLLER…..413
      CONTROL BOX…..417
      GNSS RECEIVER…..419
      GNSS ANTENNA…..423
      IMU SENSOR…..424
      STROKE AND RESET SENSOR FOR BLADE LIFT CYLINDER…..428
      STROKE SENSOR FOR BLADE TILT CYLINDER…..431
      STROKE SENSOR FOR BLADE ANGLE CYLINDER…..433
UNDERCARRIAGE AND FRAME…..435
    MAIN FRAME…..435
      STRUCTURE OF MAIN FRAME…..435
    TRACK FRAME AND IDLER CUSHION…..436
      STRUCTURE OF TRACK FRAME AND IDLER CUSHION…..436
      FUNCTION OF TRACK FRAME AND IDLER CUSHION…..438
WORK EQUIPMENT…..439
    STRUCTURE OF FRONT WORK EQUIPMENT…..439
    STRUCTURE OF FIXED MULTI-SHANK RIPPER…..440
CAB AND ITS ATTACHMENTS…..441
    ROPS CAB…..441
      STRUCTURE OF ROPS CAB…..441
      FUNCTION OF ROPS CAB…..442
    CAB MOUNT…..443
      STRUCTURE OF CAB MOUNT…..443
      FUNCTION OF CAB MOUNT…..444
20 STANDARD VALUE TABLE…..445
CONTENTS…..446
ABBREVIATION LIST…..447
STANDARD VALUE TABLE FOR ENGINE…..453
    STANDARD VALUE TABLE FOR ENGINE: D37EXI-24…..453
    STANDARD VALUE TABLE FOR ENGINE: D37PXI-24…..456
    STANDARD VALUE TABLE FOR ENGINE: D39EXI-24…..459
    STANDARD VALUE TABLE FOR ENGINE: D39PXI-24…..462
STANDARD VALUE TABLE FOR MACHINE…..465
    STANDARD VALUE TABLE FOR MACHINE: D37EXI-24…..465
    STANDARD VALUE TABLE FOR MACHINE: D37PXI-24…..482
    STANDARD VALUE TABLE FOR MACHINE: D39EXI-24…..497
    STANDARD VALUE TABLE FOR MACHINE: D39PXI-24…..514
    MACHINE POSTURE AND PROCEDURE FOR MEASURING PERFORMANCE…..529
30 TESTING AND ADJUSTING…..531
CONTENTS…..532
ABBREVIATION LIST…..536
RELATED INFORMATION ON TESTING AND ADJUSTING…..542
    TOOLS FOR TESTING AND ADJUSTING…..542
    SKETCH OF TOOLS FOR TESTING AND ADJUSTING…..549
ENGINE AND COOLING SYSTEM…..552
    TEST ENGINE SPEED…..552
      METHOD FOR TESTING ENGINE SPEED…..552
    TEST EXHAUST GAS COLOR…..554
      METHOD FOR TESTING EXHAUST GAS COLOR BY HANDY SMOKE CHECKER…..554
      METHOD FOR TESTING EXHAUST GAS COLOR BY SMOKE METER…..555
    TEST THE CLEARANCE OF THE EXHAUST THROTTLE VALVE…..556
      METHOD FOR MEASURING THE CLEARANCE OF THE EXHAUST THROTTLE VALVE…..556
    TEST AND ADJUST VALVE CLEARANCE…..558
      METHOD FOR TESTING VALVE CLEARANCE…..558
      METHOD FOR ADJUSTING VALVE CLEARANCE…..559
    TEST COMPRESSION PRESSURE…..560
      METHOD FOR TESTING COMPRESSION PRESSURE…..560
    TEST BLOWBY PRESSURE…..563
      METHOD FOR TESTING BLOWBY PRESSURE…..563
    TEST ENGINE OIL PRESSURE…..565
      METHOD FOR TESTING ENGINE OIL PRESSURE…..565
    TEST FUEL PRESSURE…..567
      METHOD FOR TESTING FUEL PRESSURE…..567
    TEST FUEL RETURN RATE AND LEAKAGE…..569
      METHOD FOR TESTING FUEL RETURN RATE AND LEAKAGE…..570
    BLEEDING AIR FROM FUEL SYSTEM…..574
      METHOD FOR BLEEDING AIR FROM FUEL SYSTEM…..574
    TEST FUEL CIRCUIT FOR LEAKAGE…..576
      METHOD FOR TESTING FUEL CIRCUIT FOR LEAKAGE…..576
    HANDLE CYLINDER CUT-OUT MODE OPERATION…..578
    HANDLE NO-INJECTION CRANKING OPERATION…..579
    TEST KDOC, SCR AND MUFFLER STACK FOR LOOSENESS AND DAMAGE…..580
      METHOD FOR TESTING KDOC, SCR AND MUFFLER STACK FOR LOOSENESS AND DAMAGE…..580
    TEST INSTALLED CONDITION OF CYLINDER HEADS AND MANIFOLDS…..581
      METHOD FOR TESTING INSTALLED CONDITION OF CYLINDER HEADS AND MANIFOLDS…..581
    TEST ENGINE PIPING FOR DAMAGE AND LOOSENESS…..582
      METHOD FOR TESTING ENGINE PIPING FOR DAMAGE AND LOOSENESS…..582
    TEST ALTERNATOR BELT…..583
      METHOD FOR TESTING ALTERNATOR BELT…..583
    TEST AUTOMATIC TENSIONER…..584
      METHOD FOR TESTING AUTOMATIC TENSIONER…..584
    WRITE INJECTOR COMPENSATION VALUE TO ENGINE CONTROLLER…..586
      METHOD FOR WRITING INJECTOR COMPENSATION VALUE…..586
    TEST SCR RELATED FUNCTIONS…..592
      TEST AdBlue/DEF PUMP RAISED PRESSURE…..596
      TEST INJECTION AMOUNT FROM AdBlue/DEF INJECTOR…..599
      TEST AdBlue/DEF LINE HEATER RELAY 1…..604
      TEST AdBlue/DEF LINE HEATER RELAY 2…..607
      TEST AdBlue/DEF PUMP HEATER RELAY…..610
      TEST AdBlue/DEF TANK HEATER VALVE…..614
      TEST DENITRATION EFFICIENCY OF SCR…..618
    CLEAN AdBlue/DEF TANK…..621
      METHOD FOR CLEANING AdBlue/DEF TANK…..621
    CLEAN AdBlue/DEF TANK MOUNTING PORTION…..626
      METHOD FOR CLEANING AdBlue/DEF TANK MOUNTING PORTION…..626
POWER TRAIN…..627
    TEST AND ADJUST HST OIL PRESSURE…..627
      METHOD FOR TESTING HST OIL PRESSURE…..627
      METHOD FOR ADJUSTING HST OIL PRESSURE…..630
    BLEED AIR FROM HST PUMP…..632
      METHOD FOR BLEEDING AIR FROM HST PUMP…..632
      METHOD FOR BLEEDING AIR FROM SERVO VALVE OF HST PUMP…..632
    TEST OUTLET PRESSURE OF SOLENOID VALVE…..634
      METHOD FOR TESTING OUTLET PRESSURE OF SOLENOID VALVE…..634
    TEST TRAVEL DEVIATION…..639
      METHOD FOR TESTING TRAVEL DEVIATION…..639
    TEST BRAKE PERFORMANCE SIMPLY…..641
      METHOD FOR TESTING BRAKE PERFORMANCE SIMPLY…..641
    TEST AND ADJUST DECELERATION/BRAKE PEDAL…..642
      METHOD FOR TESTING DECELERATION/BRAKE PEDAL…..642
      METHOD FOR ADJUSTING DECELERATION/BRAKE PEDAL…..644
    ADJUST PARKING BRAKE LEVER…..646
      METHOD FOR ADJUSTING PARKING BRAKE LEVER…..646
    MOVE MACHINE WHEN IT CANNOT TRAVEL…..648
      METHOD FOR MOVING MACHINE WITH HYDRAULIC TYPE PARKING BRAKE RELEASE SYSTEM…..648
      METHOD FOR MOVING DISABLED MACHINE BY REMOVING FINAL DRIVE SHAFT…..650
UNDERCARRIAGE AND FRAME…..652
    ADJUST IDLER CLEARANCE…..652
      METHOD FOR ADJUSTING IDLER CLEARANCE…..652
    TESTING SPROCKET WEAR…..653
      METHOD FOR TESTING SPROCKET WEAR…..653
    TEST AND ADJUST TRACK TENSION…..654
      METHOD FOR TESTING TRACK TENSION…..654
      METHOD FOR ADJUSTING TRACK TENSION…..654
HYDRAULIC SYSTEM…..656
    RELEASE REMAINING PRESSURE FROM HYDRAULIC SYSTEM…..656
      METHOD FOR RELEASING REMAINING PRESSURE FROM HYDRAULIC CIRCUIT…..656
    TEST AND ADJUST WORK EQUIPMENT OIL PRESSURES…..657
      METHOD FOR TESTING WORK EQUIPMENT OIL PRESSURES…..657
      METHOD FOR ADJUSTING WORK EQUIPMENT OIL PRESSURES…..658
    TEST AND ADJUST OIL PRESSURE OF CONTROL CIRCUIT…..660
      METHOD FOR TESTING OIL PRESSURE OF CONTROL CIRCUIT…..660
      METHOD FOR ADJUSTING OIL PRESSURE OF CONTROL CIRCUIT…..661
    TEST OUTLET PRESSURE OF EPC SOLENOID VALVE…..662
      METHOD FOR TESTING OUTLET PRESSURE OF EPC SOLENOID VALVE…..662
    BLEED AIR FROM WORK EQUIPMENT AND COOLING FAN PUMP…..664
      METHOD FOR BLEEDING AIR FROM WORK EQUIPMENT AND COOLING FAN PUMP…..664
    TEST COOLING FAN SPEED…..665
      METHOD FOR TESTING COOLING FAN SPEED…..665
    TEST COOLING FAN CIRCUIT OIL PRESSURE…..666
      METHOD FOR TESTING COOLING FAN CIRCUIT OIL PRESSURE…..666
    TEST THE PARTS CAUSING HYDRAULIC DRIFT IN WORK EQUIPMENT…..668
      METHOD FOR TESTING THE PARTS CAUSING HYDRAULIC DRIFT OF BLADE LIFT CYLINDER…..668
      METHOD FOR TESTING THE PARTS CAUSING HYDRAULIC DRIFT OF BLADE TILT CYLINDER…..668
      METHOD FOR TESTING THE PARTS CAUSING HYDRAULIC DRIFT OF RIPPER LIFT CYLINDER…..669
    TEST INTERNAL OIL LEAKAGE OF WORK EQUIPMENT CYLINDER…..670
      METHOD FOR TESTING INTERNAL OIL LEAKAGE OF WORK EQUIPMENT CYLINDER…..670
    BLEED AIR FROM WORK EQUIPMENT CYLINDERS…..672
      METHOD FOR BLEEDING AIR FROM WORK EQUIPMENT CYLINDERS…..672
WORK EQUIPMENT…..673
    ADJUST WORK EQUIPMENT LOCK LEVER…..673
      METHOD FOR ADJUSTING WORK EQUIPMENT LOCK LEVER…..673
ELECTRICAL SYSTEM…..675
    SET AND OPERATE MACHINE MONITOR…..675
      OPERATOR MODE…..679
      DISPLAY FUNCTION OF TECHNICIAN IDENTIFICATION STATUS SCREEN…..679
      DISPLAY FUNCTION OF OPERATOR IDENTIFICATION INPUT SCREEN…..679
      CHECKING FUNCTION BY LCD (LIQUID CRYSTAL DISPLAY)…..680
      CHECKING FUNCTION OF SERVICE METER…..680
      METHOD FOR SETTING USAGE LIMITATION AND CHANGING MAINTENANCE PASSWORD…..680
      SERVICE MODE…..683
      METHOD FOR OPERATING SERVICE MODE…..683
      METHOD FOR CHECKING PRE-DEFINED MONITORING INFORMATION…..685
      METHOD FOR CHECKING SELF-DEFINE MONITORING INFORMATION…..691
      ABNORMALITY RECORD MENU…..702
      METHOD FOR CONFIRMING MAINTENANCE RECORD…..706
      METHOD FOR OPERATING MAINTENANCE MODE SETTING…..707
      METHOD FOR OPERATING PHONE NUMBER ENTRY SETTING…..711
      DEFAULT MENU…..712
      DIAGNOSTIC TESTS MENU…..719
      ADJUSTMENT MENU…..727
      METHOD FOR PERFORMING NO-INJECTION CRANKING…..796
      KOMTRAX SETTINGS MENU…..799
      METHOD FOR DISPLAYING SERVICE MESSAGE…..801
    METHOD FOR STARTING UP KOMTRAX TERMINAL…..803
    ADJUSTMENT WHEN HST CONTROLLER HAS BEEN REPLACED…..808
      ADJUSTMENT METHOD WHEN HST CONTROLLER HAS BEEN REPLACED…..808
    ADJUSTMENT WHEN ELECTRIC OR HYDRAULIC DEVICE HAS BEEN REPLACED…..814
    ADJUST REARVIEW CAMERA ANGLE…..816
      METHOD FOR ADJUSTING REARVIEW CAMERA ANGLE…..816
    HANDLE VOLTAGE CIRCUIT OF ENGINE CONTROLLER…..817
    HANDLE BATTERY DISCONNECT SWITCH…..818
    TEST DIODES…..819
      METHOD FOR TESTING DIODE USING DIGITAL TESTER…..819
      METHOD FOR TESTING DIODE USING ANALOG TESTER…..819
ICT SYSTEM…..820
    SET AND OPERATE CONTROL BOX…..820
      TEST AND ADJUST ICT RELATED DEVICES…..820
    CALIBRATE BLADE EDGE POSITION…..823
      METHOD FOR OPERATING BLADE CALIBRATION MENU (PITCH ROD CALIBRATION)…..824
      METHOD FOR OPERATING BLADE CALIBRATION MENU (MACHINE CAL STEP A)…..826
      METHOD FOR OPERATING BLADE CALIBRATION MENU (MACHINE CAL STEP B)…..831
    CALIBRATE IMU SENSOR…..845
      METHOD FOR CALIBRATING IMU SENSOR…..845
    RESET CYLINDER STROKE END…..852
      RESET LIFT CYLINDER STROKE END…..852
      RESET TILT CYLINDER STROKE END…..853
      RESET ANGLE CYLINDER STROKE END…..853
    METHOD FOR INPUTTING WEAR AMOUNT OF BLADE EDGE AND TRACK SHOE…..855
    CHECK BLADE ELEVATION, ADJUST…..857
      CHECK BLADE ELEVATION…..857
      ADJUST BLADE ELEVATION…..859
    TEST STROKE SENSOR FOR LIFT CYLINDER…..861
      METHOD FOR TESTING STROKE SENSOR FOR LIFT CYLINDER…..861
    TEST STROKE SENSOR FOR TILT CYLINDER…..863
      METHOD FOR TESTING STROKE SENSOR FOR TILT CYLINDER…..863
    TEST STROKE SENSOR FOR ANGLE CYLINDER…..865
      METHOD FOR TESTING STROKE SENSOR FOR ANGLE CYLINDER…..865
    TEST AND ADJUST RESET SENSOR FOR LIFT CYLINDER…..867
      METHOD FOR TESTING RESET SENSOR FOR LIFT CYLINDER…..867
      METHOD FOR ADJUSTING RESET SENSOR FOR LIFT CYLINDER…..868
    ADJUST WHEN ICT SENSOR CONTROLLER IS REPLACED…..869
      METHOD FOR ADJUSTING WHEN ICT SENSOR CONTROLLER IS REPLACED…..869
    METHOD FOR ADJUSTING WHEN ICT RELATED DEVICES ARE REPAIRED OR REPLACED…..872
Pm CLINIC…..875
    Pm CLINIC SERVICE…..875
      Pm CLINIC CHECK SHEET: D37EXI-24…..877
      Pm CLINIC CHECK SHEET: D37PXI-24…..885
      Pm CLINIC CHECK SHEET: D39EXI-24…..893
      Pm CLINIC CHECK SHEET: D39PXI-24…..900
      Pm CLINIC CHECK SHEET FOR UNDERCARRIAGE: D37EXI-24…..907
      Pm CLINIC CHECK SHEET FOR UNDERCARRIAGE: D37PXI-24…..914
      Pm CLINIC CHECK SHEET FOR UNDERCARRIAGE: D39EXI-24…..921
      Pm CLINIC CHECK SHEET FOR UNDERCARRIAGE: D39PXI-24…..928
40 TROUBLESHOOTING…..937
CONTENTS…..938
ABBREVIATION LIST…..949
RELATED INFORMATION ON TROUBLESHOOTING…..955
    GENERAL TROUBLESHOOTING POINTS…..955
    TROUBLESHOOTING POINTS FOR UREA SCR SYSTEM…..956
    SEQUENCE OF EVENTS IN TROUBLESHOOTING…..968
    CHECKS BEFORE TROUBLESHOOTING…..970
    INSPECTION PROCEDURE BEFORE TROUBLESHOOTING…..972
      WALK-AROUND CHECK…..972
    TESTING IN ACCORDANCE WITH TESTING PROCEDURE…..974
      CHECK FUEL LEVEL AND TYPE…..974
      CHECK IMPURE INGREDIENT IN FUEL…..974
      CHECK AdBule/DEF LEVEL AND TYPE…..975
      CHECK FUEL PREFILTER…..975
      CHECK MAIN FILTER…..977
      CHECK ENGINE OIL LEVEL (OIL AMOUNT IN OIL PAN) AND TYPE…..979
      CHECK COOLANT LEVEL (RESERVOIR TANK)…..980
      CHECK CLOGGING OF AIR CLEANER…..980
      CLEAN OUTER ELEMENT…..981
      REPLACE ELEMENT…..982
      CHECK HYDRAULIC OIL LEVEL…..983
      CHECK HYDRAULIC OIL STRAINER…..984
      CHECK OIL LEVEL IN FINAL DRIVE CASE…..988
      BLEED AIR FROM FUEL SYSTEM…..988
      BLEED AIR FROM HYDRAULIC SYSTEM…..988
      METHOD FOR CHECKING ELECTRIC EQUIPMENT…..988
    PREPARATION FOR TROUBLESHOOTING OF ELECTRICAL SYSTEM…..995
    PROCEDURE FOR TROUBLESHOOTING…..1002
    SYMPTOM AND TROUBLESHOOTING NUMBERS…..1005
    INFORMATION DESCRIBED IN TROUBLESHOOTING TABLE…..1010
    TROUBLESHOOTING METHOD FOR OPEN CIRCUIT IN WIRING HARNESS OF PRESSURE SENSOR SYSTEM…..1012
    CONNECTORS LIST AND LAYOUT…..1015
    CONNECTOR CONTACT IDENTIFICATION…..1032
    T-BRANCH BOX AND T-BRANCH ADAPTER TABLE…..1072
    FUSE LOCATION TABLE…..1078
    PRECAUTIONS FOR REPLACING KDOC…..1082
    FAILURE CODES TABLE…..1083
TROUBLESHOOTING BY FAILURE CODE (DISPLAY OF CODE)…..1102
    FAILURE CODE [6091NX]…..1102
    FAILURE CODE [989L00]…..1104
    FAILURE CODE [989M00]…..1105
    FAILURE CODE [989N00]…..1106
    FAILURE CODE [A1U0N3]…..1107
    FAILURE CODE [A1U0N4]…..1109
    FAILURE CODE [A900FR]…..1111
    FAILURE CODE [A900N6]…..1112
    FAILURE CODE [A900NY]…..1113
    FAILURE CODE [AA10NX]…..1114
    FAILURE CODE [AB00KE]…..1116
    FAILURE CODE [AQ10MB]…..1118
    FAILURE CODE [AQ10N3]…..1120
    FAILURE CODE [AS00R2]…..1121
    FAILURE CODE [AS00R3]…..1122
    FAILURE CODE [AS00R4]…..1123
    FAILURE CODE [AS00R5]…..1124
    FAILURE CODE [AS00R6]…..1125
    FAILURE CODE [AS00ZK]…..1126
    FAILURE CODE [AS10KM]…..1127
    FAILURE CODE [AS10NR]…..1128
    FAILURE CODE [AS10NT]…..1129
    FAILURE CODE [AU10QA]…..1130
    FAILURE CODE [B@BAZG]…..1131
    FAILURE CODE [B@BCNS]…..1132
    FAILURE CODE [B@CRNS]…..1133
    FAILURE CODE [B@CRZG]…..1134
    FAILURE CODE [CA115]…..1135
    FAILURE CODE [CA122]…..1136
    FAILURE CODE [CA123]…..1138
    FAILURE CODE [CA131]…..1140
    FAILURE CODE [CA132]…..1142
    FAILURE CODE [CA144]…..1144
    FAILURE CODE [CA145]…..1146
    FAILURE CODE [CA153]…..1148
    FAILURE CODE [CA154]…..1151
    FAILURE CODE [CA187]…..1154
    FAILURE CODE [CA221]…..1156
    FAILURE CODE [CA222]…..1158
    FAILURE CODE [CA227]…..1160
    FAILURE CODE [CA234]…..1161
    FAILURE CODE [CA238]…..1162
    FAILURE CODE [CA239]…..1164
    FAILURE CODE [CA249]…..1166
    FAILURE CODE [CA256]…..1168
    FAILURE CODE [CA271]…..1170
    FAILURE CODE [CA272]…..1172
    FAILURE CODE [CA322]…..1174
    FAILURE CODE [CA324]…..1176
    FAILURE CODE [CA331]…..1178
    FAILURE CODE [CA332]…..1180
    FAILURE CODE [CA343]…..1182
    FAILURE CODE [CA351]…..1183
    FAILURE CODE [CA352]…..1184
    FAILURE CODE [CA356]…..1187
    FAILURE CODE [CA357]…..1189
    FAILURE CODE [CA386]…..1191
    FAILURE CODE [CA435]…..1192
    FAILURE CODE [CA441]…..1194
    FAILURE CODE [CA442]…..1196
    FAILURE CODE [CA449]…..1197
    FAILURE CODE [CA451]…..1198
    FAILURE CODE [CA452]…..1200
    FAILURE CODE [CA515]…..1202
    FAILURE CODE [CA516]…..1204
    FAILURE CODE [CA553]…..1206
    FAILURE CODE [CA555]…..1207
    FAILURE CODE [CA556]…..1208
    FAILURE CODE [CA559]…..1209
    FAILURE CODE [CA689]…..1213
    FAILURE CODE [CA691]…..1215
    FAILURE CODE [CA692]…..1217
    FAILURE CODE [CA697]…..1219
    FAILURE CODE [CA698]…..1220
    FAILURE CODE [CA731]…..1221
    FAILURE CODE [CA778]…..1223
    FAILURE CODE [CA1117]…..1228
    FAILURE CODE [CA1664]…..1229
    FAILURE CODE [CA1669]…..1231
    FAILURE CODE [CA1673]…..1232
    FAILURE CODE [CA1677]…..1233
    FAILURE CODE [CA1678]…..1234
    FAILURE CODE [CA1682]…..1235
    FAILURE CODE [CA1683]…..1240
    FAILURE CODE [CA1684]…..1242
    FAILURE CODE [CA1686]…..1244
    FAILURE CODE [CA1691]…..1245
    FAILURE CODE [CA1694]…..1247
    FAILURE CODE [CA1695]…..1249
    FAILURE CODE [CA1696]…..1250
    FAILURE CODE [CA1712]…..1252
    FAILURE CODE [CA1713]…..1255
    FAILURE CODE [CA1714]…..1257
    FAILURE CODE [CA1715]…..1258
    FAILURE CODE [CA1776]…..1259
    FAILURE CODE [CA1777]…..1262
    FAILURE CODE [CA1843]…..1265
    FAILURE CODE [CA1844]…..1267
    FAILURE CODE [CA1885]…..1270
    FAILURE CODE [CA1887]…..1272
    FAILURE CODE [CA1896]…..1274
    FAILURE CODE [CA1938]…..1275
    FAILURE CODE [CA1942]…..1277
    FAILURE CODE [CA1961]…..1278
    FAILURE CODE [CA2185]…..1279
    FAILURE CODE [CA2186]…..1281
    FAILURE CODE [CA2249]…..1283
    FAILURE CODE [CA2272]…..1284
    FAILURE CODE [CA2311]…..1287
    FAILURE CODE [CA2349]…..1288
    FAILURE CODE [CA2353]…..1290
    FAILURE CODE [CA2357]…..1292
    FAILURE CODE [CA2555]…..1293
    FAILURE CODE [CA2556]…..1295
    FAILURE CODE [CA2636]…..1297
    FAILURE CODE [CA2637]…..1300
    FAILURE CODE [CA2765]…..1302
    FAILURE CODE [CA2771]…..1303
    FAILURE CODE [CA2976]…..1309
    FAILURE CODE [CA3142]…..1311
    FAILURE CODE [CA3143]…..1312
    FAILURE CODE [CA3144]…..1313
    FAILURE CODE [CA3146]…..1315
    FAILURE CODE [CA3147]…..1316
    FAILURE CODE [CA3148]…..1317
    FAILURE CODE [CA3151]…..1319
    FAILURE CODE [CA3165]…..1325
    FAILURE CODE [CA3229]…..1327
    FAILURE CODE [CA3231]…..1329
    FAILURE CODE [CA3232]…..1331
    FAILURE CODE [CA3235]…..1335
    FAILURE CODE [CA3239]…..1337
    FAILURE CODE [CA3241]…..1340
    FAILURE CODE [CA3242]…..1343
    FAILURE CODE [CA3251]…..1346
    FAILURE CODE [CA3313]…..1348
    FAILURE CODE [CA3314]…..1349
    FAILURE CODE [CA3315]…..1350
    FAILURE CODE [CA3419]…..1352
    FAILURE CODE [CA3421]…..1354
    FAILURE CODE [CA3497]…..1356
    FAILURE CODE [CA3498]…..1357
    FAILURE CODE [CA3543]…..1358
    FAILURE CODE [CA3545]…..1364
    FAILURE CODE [CA3547]…..1366
    FAILURE CODE [CA3558]…..1367
    FAILURE CODE [CA3559]…..1369
    FAILURE CODE [CA3562]…..1371
    FAILURE CODE [CA3563]…..1373
    FAILURE CODE [CA3567]…..1376
    FAILURE CODE [CA3568]…..1379
    FAILURE CODE [CA3571]…..1384
    FAILURE CODE [CA3572]…..1386
    FAILURE CODE [CA3574]…..1388
    FAILURE CODE [CA3575]…..1390
    FAILURE CODE [CA3577]…..1392
    FAILURE CODE [CA3578]…..1394
    FAILURE CODE [CA3582]…..1396
    FAILURE CODE [CA3583]…..1403
    FAILURE CODE [CA3596]…..1405
    FAILURE CODE [CA3649]…..1408
    FAILURE CODE [CA3681]…..1410
    FAILURE CODE [CA3682]…..1415
    FAILURE CODE [CA3713]…..1420
    FAILURE CODE [CA3717]…..1423
    FAILURE CODE [CA3718]…..1424
    FAILURE CODE [CA3724]…..1425
    FAILURE CODE [CA3725]…..1426
    FAILURE CODE [CA3748]…..1429
    FAILURE CODE [CA3755]…..1432
    FAILURE CODE [CA3866]…..1434
    FAILURE CODE [CA3867]…..1437
    FAILURE CODE [CA3868]…..1440
    FAILURE CODE [CA3899]…..1444
    FAILURE CODE [CA3911]…..1446
    FAILURE CODE [CA3912]…..1450
    FAILURE CODE [CA3918]…..1452
    FAILURE CODE [CA3921]…..1454
    FAILURE CODE [CA3928]…..1455
    FAILURE CODE [CA3932]…..1456
    FAILURE CODE [CA3933]…..1458
    FAILURE CODE [CA3934]…..1460
    FAILURE CODE [CA3935]…..1463
    FAILURE CODE [CA3936]…..1465
    FAILURE CODE [CA4152]…..1467
    FAILURE CODE [CA4155]…..1471
    FAILURE CODE [CA4156]…..1474
    FAILURE CODE [CA4157]…..1477
    FAILURE CODE [CA4159]…..1479
    FAILURE CODE [CA4164]…..1480
    FAILURE CODE [CA4165]…..1482
    FAILURE CODE [CA4166]…..1484
    FAILURE CODE [CA4168]…..1485
    FAILURE CODE [CA4169]…..1488
    FAILURE CODE [CA4171]…..1490
    FAILURE CODE [CA4249]…..1494
    FAILURE CODE [CA4251]…..1496
    FAILURE CODE [CA4261]…..1498
    FAILURE CODE [CA4277]…..1501
    FAILURE CODE [CA4281]…..1504
    FAILURE CODE [CA4459]…..1508
    FAILURE CODE [CA4461]…..1511
    FAILURE CODE [CA4533]…..1514
    FAILURE CODE [CA4534]…..1515
    FAILURE CODE [CA4731]…..1516
    FAILURE CODE [CA4732]…..1517
    FAILURE CODE [CA4739]…..1518
    FAILURE CODE [CA4768]…..1519
    FAILURE CODE [CA4769]…..1521
    FAILURE CODE [CA4842]…..1524
    FAILURE CODE [CA4952]…..1527
    FAILURE CODE [CA5115]…..1529
    FAILURE CODE [CA5179]…..1532
    FAILURE CODE [CA5181]…..1534
    FAILURE CODE [CA5271]…..1536
    FAILURE CODE [CA5272]…..1538
    FAILURE CODE [CA5273]…..1540
    FAILURE CODE [CA5274]…..1542
    FAILURE CODE [CA5275]…..1543
    FAILURE CODE [CA5276]…..1545
    FAILURE CODE [CA5277]…..1547
    FAILURE CODE [CA5387]…..1548
    FAILURE CODE [CA5388]…..1550
    FAILURE CODE [CA5389]…..1552
    FAILURE CODE [CA5391]…..1554
    FAILURE CODE [CA5392]…..1558
    FAILURE CODE [CA5393]…..1559
    FAILURE CODE [CA5394]…..1562
    FAILURE CODE [CA5395]…..1565
    FAILURE CODE [CA5396]…..1568
    FAILURE CODE [CA5631]…..1569
    FAILURE CODE [CA5938]…..1571
    FAILURE CODE [D130KA]…..1573
    FAILURE CODE [D130KB]…..1575
    FAILURE CODE [D130KY]…..1577
    FAILURE CODE [D19JKZ]…..1579
    FAILURE CODE [D811MC]…..1582
    FAILURE CODE [D862KA]…..1583
    FAILURE CODE [D8ALKA]…..1584
    FAILURE CODE [D8ALKB]…..1586
    FAILURE CODE [D8AQKR]…..1588
    FAILURE CODE [DAF0MB]…..1591
    FAILURE CODE [DAF0MC]…..1592
    FAILURE CODE [DAF8KB]…..1593
    FAILURE CODE [DAF9KQ]…..1595
    FAILURE CODE [DAFGMC]…..1596
    FAILURE CODE [DAFLKA]…..1597
    FAILURE CODE [DAFLKB]…..1599
    FAILURE CODE [DAFQKR]…..1601
    FAILURE CODE [DAJ000]…..1605
    FAILURE CODE [DAJ0KQ]…..1606
    FAILURE CODE [DAJ0KT]…..1607
    FAILURE CODE [DAJ0MC]…..1608
    FAILURE CODE [DAJ1KK]…..1609
    FAILURE CODE [DAJ2KK]…..1611
    FAILURE CODE [DAJ5KK]…..1613
    FAILURE CODE [DAJ6KK]…..1616
    FAILURE CODE [DAJLKA]…..1618
    FAILURE CODE [DAJLKB]…..1620
    FAILURE CODE [DAJPMA]…..1622
    FAILURE CODE [DAJQKR]…..1623
    FAILURE CODE [DAJRKR]…..1627
    FAILURE CODE [DB2QKR]…..1631
    FAILURE CODE [DB2RKR]…..1635
    FAILURE CODE [DBR0KT]…..1639
    FAILURE CODE [DBR0MC]…..1640
    FAILURE CODE [DBR1KK]…..1641
    FAILURE CODE [DBR2KK]…..1644
    FAILURE CODE [DBR5KK]…..1647
    FAILURE CODE [DBRLKA]…..1649
    FAILURE CODE [DBRLKB]…..1651
    FAILURE CODE [DBRPMA]…..1653
    FAILURE CODE [DBRQKR]…..1654
    FAILURE CODE [DBRRKR]…..1658
    FAILURE CODE [DBTSKR]…..1662
    FAILURE CODE [DBUTKA]…..1664
    FAILURE CODE [DD12KA]…..1665
    FAILURE CODE [DD12KB]…..1667
    FAILURE CODE [DD13KA]…..1669
    FAILURE CODE [DD13KB]…..1671
    FAILURE CODE [DD14KA]…..1673
    FAILURE CODE [DD14KB]…..1675
    FAILURE CODE [DDKAKA]…..1677
    FAILURE CODE [DDKAKB]…..1679
    FAILURE CODE [DDKFL4]…..1681
    FAILURE CODE [DDKGL4]…..1683
    FAILURE CODE [DDKHKA]…..1685
    FAILURE CODE [DDKHKB]…..1687
    FAILURE CODE [DDNLKA]…..1689
    FAILURE CODE [DDNLKB]…..1691
    FAILURE CODE [DDP6KA]…..1693
    FAILURE CODE [DDP6KB]…..1695
    FAILURE CODE [DDP6MA]…..1697
    FAILURE CODE [DDU1FS]…..1699
    FAILURE CODE [DDU1KA]…..1701
    FAILURE CODE [DDU1KY]…..1703
    FAILURE CODE [DFA4KX]…..1705
    FAILURE CODE [DFA4KZ]…..1706
    FAILURE CODE [DFA4L8]…..1707
    FAILURE CODE [DFA5KA]…..1708
    FAILURE CODE [DFA5KB]…..1710
    FAILURE CODE [DFA6KA]…..1712
    FAILURE CODE [DFA6KB]…..1714
    FAILURE CODE [DFA7KX]…..1716
    FAILURE CODE [DFA7KZ]…..1717
    FAILURE CODE [DFA7L8]…..1718
    FAILURE CODE [DFA8KA]…..1719
    FAILURE CODE [DFA8KB]…..1721
    FAILURE CODE [DFA9KA]…..1723
    FAILURE CODE [DFA9KB]…..1725
    FAILURE CODE [DGS1KA]…..1727
    FAILURE CODE [DGS1KX]…..1729
    FAILURE CODE [DH21KA]…..1731
    FAILURE CODE [DH21KB]…..1733
    FAILURE CODE [DHA4KA]…..1734
    FAILURE CODE [DHH7KA]…..1736
    FAILURE CODE [DHH7KB]…..1738
    FAILURE CODE [DHH8KA]…..1740
    FAILURE CODE [DHH8KB]…..1742
    FAILURE CODE [DHH9KA]…..1744
    FAILURE CODE [DHH9KB]…..1746
    FAILURE CODE [DHHAKA]…..1748
    FAILURE CODE [DHHAKB]…..1750
    FAILURE CODE [DK30KA]…..1752
    FAILURE CODE [DK30KB]…..1754
    FAILURE CODE [DK30KX]…..1756
    FAILURE CODE [DK30KZ]…..1757
    FAILURE CODE [DK30L8]…..1758
    FAILURE CODE [DK31KA]…..1761
    FAILURE CODE [DK31KB]…..1763
    FAILURE CODE [DK40KA]…..1765
    FAILURE CODE [DK40KB]…..1767
    FAILURE CODE [DK55KX]…..1769
    FAILURE CODE [DK55KZ]…..1770
    FAILURE CODE [DK55L8]…..1771
    FAILURE CODE [DK56KA]…..1773
    FAILURE CODE [DK56KB]…..1775
    FAILURE CODE [DK57KA]…..1777
    FAILURE CODE [DK57KB]…..1779
    FAILURE CODE [DK80KA]…..1781
    FAILURE CODE [DKS0L8]…..1783
    FAILURE CODE [DKS1KA]…..1784
    FAILURE CODE [DKS1KB]…..1786
    FAILURE CODE [DKS2KA]…..1787
    FAILURE CODE [DKS2KB]…..1789
    FAILURE CODE [DKS3KA]…..1790
    FAILURE CODE [DKS3KB]…..1792
    FAILURE CODE [DKS3MB]…..1793
    FAILURE CODE [DKS4L8]…..1795
    FAILURE CODE [DKS5KA]…..1796
    FAILURE CODE [DKS5KB]…..1798
    FAILURE CODE [DKS6KA]…..1799
    FAILURE CODE [DKS6KB]…..1801
    FAILURE CODE [DKS7MB]…..1802
    FAILURE CODE [DKSCL8]…..1803
    FAILURE CODE [DKSDKA]…..1804
    FAILURE CODE [DKSDKB]…..1806
    FAILURE CODE [DKSEKA]…..1807
    FAILURE CODE [DKSEKB]…..1809
    FAILURE CODE [DKSFKA]…..1810
    FAILURE CODE [DKSFKB]…..1812
    FAILURE CODE [DKSFMB]…..1813
    FAILURE CODE [DLM0KX]…..1814
    FAILURE CODE [DLM0MA]…..1815
    FAILURE CODE [DLM1KA]…..1816
    FAILURE CODE [DLM1KB]…..1818
    FAILURE CODE [DLM1MA]…..1820
    FAILURE CODE [DLM2KA]…..1821
    FAILURE CODE [DLM2KB]…..1823
    FAILURE CODE [DLM2MA]…..1825
    FAILURE CODE [DLM3KA]…..1826
    FAILURE CODE [DLM3KB]…..1828
    FAILURE CODE [DLM3MB]…..1830
    FAILURE CODE [DN21FS]…..1831
    FAILURE CODE [DR21KX]…..1833
    FAILURE CODE [DR31KX]…..1834
    FAILURE CODE [DV20KB]…..1835
    FAILURE CODE [DW4BKA]…..1837
    FAILURE CODE [DW4BKB]…..1839
    FAILURE CODE [DW4BKY]…..1841
    FAILURE CODE [DW7BKA]…..1842
    FAILURE CODE [DW7BKB]…..1844
    FAILURE CODE [DW7EKA]…..1845
    FAILURE CODE [DW7EKB]…..1848
    FAILURE CODE [DW7EKY]…..1851
    FAILURE CODE [DWN5KA]…..1853
    FAILURE CODE [DWN5KB]…..1855
    FAILURE CODE [DWN5KY]…..1856
    FAILURE CODE [DXA4KA]…..1857
    FAILURE CODE [DXA4KB]…..1859
    FAILURE CODE [DXA4KY]…..1861
    FAILURE CODE [DXA5KA]…..1862
    FAILURE CODE [DXA5KB]…..1864
    FAILURE CODE [DXA5KY]…..1866
    FAILURE CODE [DXA6KA]…..1867
    FAILURE CODE [DXA6KB]…..1869
    FAILURE CODE [DXA6KY]…..1871
    FAILURE CODE [DXA7KA]…..1872
    FAILURE CODE [DXA7KB]…..1874
    FAILURE CODE [DXA7KY]…..1876
    FAILURE CODE [DXHRKA]…..1877
    FAILURE CODE [DXHRKB]…..1879
    FAILURE CODE [DXHRKY]…..1880
    FAILURE CODE [DXHSKA]…..1881
    FAILURE CODE [DXHSKB]…..1883
    FAILURE CODE [DXHSKY]…..1884
    FAILURE CODE [DXHTKA]…..1885
    FAILURE CODE [DXHTKB]…..1887
    FAILURE CODE [DXHTKY]…..1888
    FAILURE CODE [DXHUKA]…..1889
    FAILURE CODE [DXHUKB]…..1891
    FAILURE CODE [DXHUKY]…..1892
    FAILURE CODE [DXJ4KA]…..1893
    FAILURE CODE [DXJ4KB]…..1895
    FAILURE CODE [DXJCKA]…..1897
    FAILURE CODE [DXJCKB]…..1899
    FAILURE CODE [DXJCKY]…..1900
    FAILURE CODE [DXJDKA]…..1901
    FAILURE CODE [DXJDKB]…..1903
    FAILURE CODE [DXJDKY]…..1904
    FAILURE CODE [DXK1KA]…..1905
    FAILURE CODE [DXK1KB]…..1907
    FAILURE CODE [DXK1KY]…..1908
    FAILURE CODE [DXK2KA]…..1909
    FAILURE CODE [DXK2KB]…..1911
    FAILURE CODE [DXK2KY]…..1912
TROUBLESHOOTING OF ELECTRICAL SYSTEM (E-MODE)…..1913
    E-1 ENGINE DOES NOT START (ENGINE DOES NOT CRANK)…..1913
    E-2 MANUAL PREHEATING SYSTEM DOES NOT WORK…..1920
    E-3 AUTOMATIC PREHEATING SYSTEM DOES NOT WORK…..1923
    E-4 WHILE PREHEATING IS WORKING, PREHEATING MONITOR DOES NOT LIGHT UP…..1925
    E-5 WHEN STARTING SWITCH IS TURNED TO ON POSITION, MACHINE MONITOR DISPLAYS NOTHING…..1927
    E-6 WHEN STARTING SWITCH IS TURNED TO ON POSITION (WITH ENGINE STOPPED), BASIC CHECK MONITOR LIGHTS UP…..1930
    E-7 AIR CLEANER CLOGGING MONITOR LIGHTS UP IN YELLOW WHILE ENGINE IS RUNNING…..1931
    E-8 CHARGE LEVEL MONITOR LIGHTS UP IN RED WHILE ENGINE IS RUNNING…..1932
    E-9 ENGINE COOLANT TEMPERATURE MONITOR LIGHTS UP IN RED WHILE ENGINE IS RUNNING…..1933
    E-10 ENGINE OIL PRESSURE MONITOR LIGHTS UP IN RED WHILE ENGINE IS RUNNING…..1934
    E-11 HST CHARGE PRESSURE MONITOR LIGHTS UP IN RED WHILE ENGINE IS RUNNING…..1935
    E-12 HYDRAULIC OIL TEMPERATURE MONITOR LIGHTS UP IN RED WHILE ENGINE IS RUNNING…..1936
    E-13 HST OIL FILTER CLOGGING MONITOR LIGHTS UP IN RED WHILE ENGINE IS RUNNING…..1937
    E-14 ENGINE COOLANT TEMPERATURE GAUGE DOES NOT INDICATE CORRECT TEMPERATURE…..1938
    E-15 FUEL LEVEL GAUGE DOES NOT INDICATE CORRECT LEVEL…..1939
    E-16 HYDRAULIC OIL TEMPERATURE GAUGE DOES NOT INDICATE CORRECT TEMPERATURE…..1942
    E-17 OPERATION MODE DOES NOT CHANGE…..1943
    E-18 OPERATING CUSTOMIZE SWITCH DOES NOT DISPLAY CUSTOMIZE SCREEN…..1944
    E-19 MODIFYING SETTING ON CUSTOMIZE SCREEN DOES NOT CHANGE SETTING OF MACHINE…..1945
    E-20 SERVICE METER IS NOT DISPLAYED, WHILE STARTING SWITCH IS IN OFF POSITION…..1946
    E-21 SERVICE MODE CANNOT BE SELECTED…..1947
    E-22 WORK EQUIPMENT DOES NOT OPERATE…..1948
    E-23 FOOT HEATER DOES NOT OPERATE…..1950
    E-24 HORN DOES NOT SOUND…..1956
    E-25 HORN DOES NOT STOP SOUNDING…..1958
    E-26 BACKUP ALARM DOES NOT SOUND…..1959
    E-27 BACKUP ALARM DOES NOT STOP SOUNDING…..1960
    E-28 HEADLAMP DOES NOT LIGHT UP…..1961
    E-29 REAR LAMP DOES NOT LIGHT UP…..1965
    E-30 ALL WIPERS DO NOT OPERATE…..1968
    E-31 FRONT WIPER DOES NOT OPERATE…..1970
    E-32 REAR WIPER DOES NOT OPERATE…..1972
    E-33 LEFT DOOR WIPER DOES NOT OPERATE…..1974
    E-34 RIGHT DOOR WIPER DOES NOT OPERATE…..1978
    E-35 FRONT WASHER DOES NOT OPERATE…..1982
    E-36 REAR WASHER DOES NOT OPERATE…..1984
    E-37 LEFT DOOR WASHER DOES NOT OPERATE…..1986
    E-38 RIGHT DOOR WASHER DOES NOT OPERATE…..1988
    E-39 KOMTRAX SYSTEM DOES NOT OPERATE NORMALLY…..1990
    E-40 CONTROL BOX SHUTS DOWN AFTER DISPLAYING THE MESSAGES [GPS receiver not connected !] AND [Slope sensor not connected !]…..1991
    E-41 CONTROL BOX DISPLAYS THE MESSAGES [GPS receiver not connected !] AND [Slope sensor not connected !]…..1995
    E-42 CONTROL BOX DISPLAYS THE MESSAGE [Waiting for radio link…]…..2000
    E-43 CONTROL BOX DISPLAYS THE MESSAGE [IMU sensor not connected]…..2001
    E-44 CONTROL BOX DISPLAYS THE MESSAGE [Waiting for satellites…]…..2002
    E-45 CONTROL BOX DISPLAYS THE MESSAGE [Komatsu controller not connected!]…..2003
    E-46 CONTROL BOX DISPLAYS THE MESSAGE [Cylinder Stroke Reading Abnormal]…..2005
    E-47 CONTROL BOX DISPLAYS THE MESSAGE [Komatsu CAN Comms Abnormal]…..2006
    E-48 CONTROL BOX DISPLAYS THE MESSAGE [Komatsu Machine Trouble]…..2007
    E-49 CONTROL BOX DISPLAYS THE MESSAGE [Waiting to initialize…]…..2008
    E-50 CONTROL BOX DISPLAYS THE MESSAGE [System Initializing]…..2009
    E-51 CONTROL BOX DISPLAYS THE MESSAGE [Initializing…]…..2010
    E-52 CONTROL BOX DISPLAYS THE MESSAGE [Configuring GPS]…..2011
    E-53 CONTROL BOX DISPLAYS THE MESSAGE [No GPS Localization…]…..2012
    E-54 CONTROL BOX DISPLAYS THE MESSAGE [Low precisions…]…..2013
    E-55 CONTROL BOX DISPLAYS THE MESSAGE [Heading Initializing]…..2014
    E-56 CONTROL BOX DISPLAYS [Out of design area…]…..2015
    E-57 CONTROL BOX CAN NOT BE TURNED ON…..2016
    E-58 CONTROL BOX DOES NOT DISPLAY INTELLIGENT MACHINE CONTROL SCREEN…..2017
    E-59 CONTROL BOX DOES NOT DISPLAY BULLDOZER IMAGE…..2018
    E-60 CONTROL BOX DOES NOT DISPLAY DESIGN SURFACE…..2019
    E-61 CONTROL BOX TOUCH PANEL DOES NOT RESPOND…..2020
    E-62 CONTROL BOX TOUCH PANEL IS INACCURATE…..2021
    E-63 CYLINDER STROKE RESET INDICATION DOES NOT GO OUT…..2022
    E-64 AUTO IS NOT DISPLAYED WHEN AUTO/MANUAL SWITCH IS PRESSED (AUTO INDICATION GOES OUT)…..2023
    E-65 BLADE AUTOMATIC LOWER CONTROL DOES NOT START WHILE AUTO IS DISPLAYED…..2025
    E-66 BLADE AUTOMATIC RAISE CONTROL DOES NOT START WHILE AUTO IS DISPLAYED…..2026
    E-67 BLADE AUTOMATIC CONTROL FUNCTION IS NOT ACTIVATED WHILE AUTO IS DISPLAYED (BLADE AUTOMATIC CONTROL STOPS)…..2027
    E-68 WHEN CHECKING AND ADJUSTING THE BLADE ELEVATION, THE VALUE IS DIFFERENT FROM ACTUAL MACHINE…..2028
    E-69 FINISHED SURFACE IS INACCURATE (THE AVERAGE HEIGHT OF FINISHED SURFACE IS LOWER THAN DESIGNED SURFACE OR BLADE DOES NOT TOUCH THE SURFACE)…..2029
    E-70 FINISHED SURFACE IS INACCURATE (THE FINISHED SURFACE IS NOT SMOOTH)…..2030
    E-71 FINISHED SURFACE IS INACCURATE (WHEN FINISHING SLOPE HORIZONTALLY, STEPS ARE MADE IN EACH DIRECTION)…..2031
    E-72 MACHINE CAN NOT ESCAPE FROM SHOES SLIP WHILE BLADE AUTOMATIC CONTROL IS ACTIVATED (SHOES FREQUENTLY SLIPS)…..2033
    E-73 MACHINE SPEED DOES NOT INCREASE WHILE BLADE AUTOMATIC CONTROL IS ACTIVATED…..2034
    E-74 BLADE TILT ANGLE DOES NOT COINCIDE WITH DESIGN SURFACE…..2035
    E-75 BLADE TILTS BACK WHILE BLADE AUTOMATIC CONTROL IS ACTIVATED…..2037
    E-76 WHEN PRESSING CUT/FILL LEVEL SWITCH (RAISE), THE DESIGN SURFACE DOES NOT RISE…..2039
    E-77 WHEN PRESSING CUT/FILL LEVEL SWITCH (LOWER), THE DESIGN SURFACE DOES NOT LOWER…..2042
    E-78 WHEN STARTING SWITCH IS TURNED TO ON POSITION, REVERSE LEVELING MODE SWITCH LED DOES NOT LIGHT UP OR DOES NOT GO OUT…..2045
    E-79 WHEN REVERSE LEVELING MODE SWITCH IS PRESSED, BUZZER DOES NOT SOUND (DOES NOT SWITCH TO REVERSE LEVELING MODE)…..2047
TROUBLESHOOTING FOR HYDRAULIC AND MECHANICAL SYSTEMS (H MODE)…..2050
    INFORMATION MENTIONED IN TROUBLESHOOTING TABLE (H MODE)…..2050
    FAILURE MODE AND CAUSE TABLE…..2051
    H-1 NEITHER R.H. NOR L.H. OF TRACKS CAN TRAVEL FORWARD OR REVERSE (NONE OF THE TRAVEL SYSTEMS OPERATE)…..2057
    H-2 EITHER R.H. OR L.H. OF TRACK CANNOT TRAVEL BOTH FORWARD AND REVERSE (ONE OF R.H. OR L.H. TRAVEL SYSTEMS CANNOT OPERATE)…..2059
    H-3 EITHER R.H. OR L.H. OF TRACK CANNOT TRAVEL ONE OF FORWARD OR REVERSE (ONLY ONE OF THE TRAVEL SYSTEMS CANNOT OPERATE IN ONE DIRECTION)…..2061
    H-4 TRAVEL SPEED OR POWER IS LOW…..2063
    H-5 SPEED RANGE DOES NOT CHANGE…..2065
    H-6 SHOCK IS LARGE WHEN MACHINE MOVES OFF OR STOPS…..2066
    H-7 MACHINE DEVIATES LARGELY…..2067
    H-8 MACHINE DRIFT ON A SLOPE IS LARGE…..2070
    H-9 ENGINE SPEED DROPS LARGELY OR ENGINE STOPS…..2072
    H-10 UNUSUAL NOISE IS HEARD FROM AROUND HST PUMP OR MOTOR…..2074
    H-11 HST OIL TEMPERATURE (HYDRAULIC OIL TEMPERATURE) RISES TOO HIGH…..2076
    H-12 ALL WORK EQUIPMENT DO NOT OPERATE…..2078
    H-13 ALL WORK EQUIPMENTS SPEED OR POWER IS LOW…..2080
    H-14 BLADE LIFT SPEED OR POWER IS LOW…..2081
    H-15 BLADE TILT SPEED OR POWER IS LOW…..2083
    H-16 BLADE ANGLE SPEED OR POWER IS LOW…..2084
    H-17 TIME LAG OF BLADE LIFT IS LARGE…..2085
    H-18 HYDRAULIC DRIFT OF LIFTED BLADE IS LARGE…..2086
    H-19 HYDRAULIC DRIFT OF TILTED BLADE IS LARGE…..2087
    H-20 UNUSUAL NOISE IS HEARD FROM AROUND WORK EQUIPMENT AND COOLING FAN PUMP OR CONTROL VALVE…..2088
    H-21 FAN SPEED IS ABNORMAL (TOO HIGH OR LOW, OR STATIONARY)…..2089
    H-22 UNUSUAL NOISE IS HEARD FROM AROUND FAN…..2091
TROUBLESHOOTING OF ENGINE (S-MODE)…..2092
    INFORMATION MENTIONED IN TROUBLESHOOTING TABLE (S MODE)…..2092
    S-1 ENGINE DOES NOT CRANK WHEN STARTING SWITCH IS TURNED TO START POSITION…..2093
    S-2 ENGINE CRANKS BUT NO EXHAUST GAS COMES OUT…..2094
    S-3 FUEL IS BEING INJECTED BUT ENGINE DOES NOT START (MISFIRING: ENGINE CRANKS BUT DOES NOT START)…..2095
    S-4 ENGINE STARTABILITY IS POOR…..2096
    S-5 ENGINE DOES NOT PICK UP SMOOTHLY…..2098
    S-6 ENGINE STOPS DURING OPERATION…..2100
    S-7 ENGINE RUNS ROUGH OR IS UNSTABLE…..2102
    S-8 ENGINE LACKS POWER…..2103
    S-9 EXHAUST SMOKE IS BLACK…..2105
    S-10 ENGINE OIL CONSUMPTION IS EXCESSIVE…..2107
    S-11 OIL BECOMES CONTAMINATED QUICKLY…..2108
    S-12 FUEL CONSUMPTION IS EXCESSIVE…..2109
    S-13 OIL IS IN COOLANT (OR COOLANT SPURTS BACK OR COOLANT LEVEL GOES DOWN)…..2110
    S-14 OIL PRESSURE DROPS…..2111
    S-15 FUEL MIXES INTO ENGINE OIL…..2112
    S-16 WATER MIXES INTO ENGINE OIL (MILKY)…..2113
    S-17 COOLANT TEMPERATURE RISES TOO HIGH (OVERHEATING)…..2114
    S-18 UNUSUAL NOISE IS HEARD…..2115
    S-19 VIBRATION IS EXCESSIVE…..2117
    S-20 AIR CANNOT BE BLED FROM FUEL CIRCUIT…..2118
    S-21 ACTIVE REGENERATION IS EXECUTED FREQUENTLY…..2119
    S-22 ACTIVE REGENERATION TAKES TIME…..2120
    S-23 WHITE SMOKE IS EXHAUSTED DURING ACTIVE REGENERATION…..2121
    S-24 AdBlue/DEF CONSUMPTION IS EXCESSIVE…..2122
    S-25 THERE IS UNUSUAL SMELL (IRRITATING ODOR)…..2124
    S-26 FOREIGN MATERIALS ENTER AdBlue/DEF (AdBlue/DEF INCREASES)…..2125
50 DISASSEMBLY AND ASSEMBLY…..2127
CONTENTS…..2128
ABBREVIATION LIST…..2133
RELATED INFORMATION ON DISASSEMBLY AND ASSEMBLY…..2139
    HOW TO READ THIS MANUAL…..2139
    COATING MATERIALS LIST…..2141
    SPECIAL TOOLS LIST…..2145
    SKETCHES OF SPECIAL TOOLS…..2164
ENGINE AND COOLING SYSTEM…..2180
    REMOVE AND INSTALL SUPPLY PUMP ASSEMBLY…..2180
      METHOD FOR REMOVING SUPPLY PUMP ASSEMBLY…..2180
      METHOD FOR INSTALLING SUPPLY PUMP ASSEMBLY…..2184
    REMOVE AND INSTALL INJECTOR ASSEMBLY…..2188
      METHOD FOR REMOVING INJECTOR ASSEMBLY…..2188
      METHOD FOR INSTALLING INJECTOR ASSEMBLY…..2191
    REMOVE AND INSTALL CYLINDER HEAD ASSEMBLY…..2197
      METHOD FOR REMOVING CYLINDER HEAD ASSEMBLY…..2197
      METHOD FOR INSTALLING CYLINDER HEAD ASSEMBLY…..2211
    REMOVE AND INSTALL EGR VALVE ASSEMBLY…..2231
      METHOD FOR REMOVING EGR VALVE ASSEMBLY…..2231
      METHOD FOR INSTALLING EGR VALVE ASSEMBLY…..2232
    REMOVE AND INSTALL EGR COOLER ASSEMBLY…..2234
      METHOD FOR REMOVING EGR COOLER ASSEMBLY…..2234
      METHOD FOR INSTALLING EGR COOLER ASSEMBLY…..2235
    REMOVE AND INSTALL STARTER ASSEMBLY…..2238
      METHOD FOR REMOVING STARTER ASSEMBLY…..2238
      METHOD FOR INSTALLING STARTER ASSEMBLY…..2239
    REMOVE AND INSTALL ALTERNATOR BELT…..2241
      METHOD FOR REMOVING ALTERNATOR BELT…..2241
      METHOD FOR INSTALLING ALTERNATOR BELT…..2242
    REMOVE AND INSTALL AUTOMATIC TENSIONER…..2244
      METHOD FOR REMOVING AUTOMATIC TENSIONER…..2244
      METHOD FOR INSTALLING AUTOMATIC TENSIONER…..2244
    REMOVE AND INSTALL RADIATOR ASSEMBLY…..2245
      METHOD FOR REMOVING RADIATOR ASSEMBLY…..2245
      METHOD FOR INSTALLING RADIATOR ASSEMBLY…..2248
    REMOVE AND INSTALL HYDRAULIC OIL COOLER ASSEMBLY…..2252
      METHOD FOR REMOVING HYDRAULIC OIL COOLER ASSEMBLY…..2252
      METHOD FOR INSTALLING HYDRAULIC OIL COOLER ASSEMBLY…..2254
    REMOVE AND INSTALL AFTERCOOLER ASSEMBLY…..2257
      METHOD FOR REMOVING AFTERCOOLER ASSEMBLY…..2257
      METHOD FOR INSTALLING AFTERCOOLER ASSEMBLY…..2259
    REMOVE AND INSTALL COOLING FAN DRIVE ASSEMBLY…..2263
      METHOD FOR REMOVING COOLING FAN DRIVE ASSEMBLY…..2263
      METHOD FOR INSTALLING COOLING FAN DRIVE ASSEMBLY…..2265
    REMOVE AND INSTALL COOLING FAN MOTOR ASSEMBLY…..2267
      METHOD FOR REMOVING COOLING FAN MOTOR ASSEMBLY…..2267
      METHOD FOR INSTALLING COOLING FAN MOTOR ASSEMBLY…..2268
    REMOVE AND INSTALL ENGINE, HST PUMP ASSEMBLY…..2270
      METHOD FOR REMOVING ENGINE, HST PUMP ASSEMBLY…..2270
      METHOD FOR INSTALLING ENGINE, HST PUMP ASSEMBLY…..2276
    REMOVE AND INSTALL ENGINE FRONT OIL SEAL…..2284
      METHOD FOR REMOVING ENGINE FRONT OIL SEAL…..2284
      METHOD FOR INSTALLING ENGINE FRONT OIL SEAL…..2285
    REMOVE AND INSTALL ENGINE REAR OIL SEAL…..2287
      METHOD FOR REMOVING ENGINE REAR OIL SEAL…..2287
      METHOD FOR INSTALLING ENGINE REAR OIL SEAL…..2288
    REMOVE AND INSTALL ENGINE HOOD ASSEMBLY…..2291
      METHOD FOR REMOVING ENGINE HOOD ASSEMBLY…..2291
      METHOD FOR INSTALLING ENGINE HOOD ASSEMBLY…..2293
    REMOVE AND INSTALL KDOC ASSEMBLY…..2297
      METHOD FOR REMOVING KDOC ASSEMBLY…..2297
      METHOD FOR INSTALLING KDOC ASSEMBLY…..2301
    REMOVE AND INSTALL KDOC AND SCR ASSEMBLY…..2308
      METHOD FOR REMOVING KDOC AND SCR ASSEMBLY…..2309
      METHOD FOR INSTALLING KDOC AND SCR ASSEMBLY…..2318
    REMOVE AND INSTALL BELLOWS PIPE ASSEMBLY…..2328
      METHOD FOR REMOVING BELLOWS PIPE ASSEMBLY…..2328
      METHOD FOR INSTALLING BELLOWS PIPE ASSEMBLY…..2330
    REMOVE AND INSTALL FUEL TANK ASSEMBLY…..2335
      METHOD FOR REMOVING FUEL TANK ASSEMBLY…..2335
      METHOD FOR INSTALLING FUEL TANK ASSEMBLY…..2338
    REMOVE AND INSTALL AdBlue/DEF TANK ASSEMBLY…..2342
      METHOD FOR REMOVING AdBlue/DEF TANK ASSEMBLY…..2342
      METHOD FOR INSTALLING AdBlue/DEF TANK ASSEMBLY…..2348
    REMOVE AND INSTALL AdBlue/DEF TANK SENSOR FLANGE ASSEMBLY…..2354
      METHOD FOR REMOVING AdBlue/DEF TANK SENSOR FLANGE ASSEMBLY…..2354
      METHOD FOR INSTALLING AdBlue/DEF TANK SENSOR FLANGE ASSEMBLY…..2355
    REMOVE AND INSTALL AdBlue/DEF TANK SENSOR…..2358
      METHOD FOR REMOVING AdBlue/DEF TANK SENSOR…..2358
      METHOD FOR INSTALLING AdBlue/DEF TANK SENSOR…..2359
    REMOVE AND INSTALL AdBlue/DEF TANK STRAINER…..2361
      METHOD FOR REMOVING AdBlue/DEF TANK STRAINER…..2361
      METHOD FOR INSTALLING AdBlue/DEF TANK STRAINER…..2362
    REMOVE AND INSTALL SCR ASSEMBLY…..2363
      METHOD FOR REMOVING SCR ASSEMBLY…..2363
      METHOD FOR INSTALLING SCR ASSEMBLY…..2367
    REMOVE AND INSTALL KCCV ASSEMBLY…..2371
      METHOD FOR REMOVING KCCV ASSEMBLY…..2371
      METHOD FOR INSTALLING KCCV ASSEMBLY…..2372
    REMOVE AND INSTALL TURBO CHARGER ASSEMBLY…..2373
      METHOD FOR REMOVING TURBO CHARGER ASSEMBLY…..2373
      METHOD FOR INSTALLING TURBO CHARGER ASSEMBLY…..2377
    REMOVE AND INSTALL EXHAUST THROTTLE VALVE…..2382
      METHOD FOR REMOVING EXHAUST THROTTLE VALVE…..2382
      METHOD FOR INSTALLING EXHAUST THROTTLE VALVE…..2386
    REMOVE AND INSTALL AdBlue/DEF MIXING TUBE…..2392
      METHOD FOR REMOVING AdBlue/DEF MIXING TUBE…..2393
      METHOD FOR INSTALLING AdBlue/DEF MIXING TUBE…..2397
    REMOVE AND INSTALL AdBlue/DEF INJECTOR…..2405
      METHOD FOR REMOVING AdBlue/DEF INJECTOR…..2405
      METHOD FOR INSTALLING AdBlue/DEF INJECTOR…..2408
    REMOVE AND INSTALL AdBlue/DEF PUMP…..2412
      METHOD FOR REMOVING AdBlue/DEF PUMP…..2412
      METHOD FOR INSTALLING AdBlue/DEF PUMP…..2415
    REMOVE AND INSTALL AdBlue/DEF HOSE…..2418
      METHOD FOR REMOVING AdBlue/DEF HOSE…..2418
      METHOD FOR INSTALLING AdBlue/DEF HOSE…..2426
    REMOVE AND INSTALL AIR CLEANER ASSEMBLY…..2436
      METHOD FOR REMOVING AIR CLEANER ASSEMBLY…..2436
      METHOD FOR INSTALLING AIR CLEANER ASSEMBLY…..2437
    REMOVE AND INSTALL AIR CONDITIONER COMPRESSOR ASSEMBLY…..2439
      METHOD FOR REMOVING AIR CONDITIONER COMPRESSOR ASSEMBLY…..2439
      METHOD FOR INSTALLING AIR CONDITIONER COMPRESSOR ASSEMBLY…..2440
POWER TRAIN…..2442
    REMOVE AND INSTALL DAMPER ASSEMBLY…..2442
      METHOD FOR REMOVING DAMPER ASSEMBLY…..2442
      METHOD FOR INSTALLING DAMPER ASSEMBLY…..2443
    REMOVE AND INSTALL HST PUMP ASSEMBLY…..2444
      METHOD FOR REMOVING HST PUMP ASSEMBLY…..2444
      METHOD FOR INSTALLING HST PUMP ASSEMBLY…..2447
    REMOVE AND INSTALL HST MOTOR AND FINAL DRIVE ASSEMBLY…..2450
      METHOD FOR REMOVING HST MOTOR AND FINAL DRIVE ASSEMBLY…..2450
      METHOD FOR INSTALLING HST MOTOR AND FINAL DRIVE ASSEMBLY…..2452
    DISASSEMBLE AND ASSEMBLE FINAL DRIVE ASSEMBLY…..2454
      METHOD FOR DISASSEMBLING FINAL DRIVE ASSEMBLY…..2454
      METHOD FOR ASSEMBLING FINAL DRIVE ASSEMBLY…..2459
UNDERCARRIAGE AND FRAME…..2469
    REMOVE AND INSTALL IDLER AND RECOIL SPRING ASSEMBLY…..2469
      METHOD FOR REMOVING IDLER AND RECOIL SPRING ASSEMBLY…..2469
      METHOD FOR INSTALLING IDLER AND RECOIL SPRING ASSEMBLY…..2469
    DISASSEMBLE AND ASSEMBLE IDLER ASSEMBLY…..2471
      METHOD FOR DISASSEMBLING IDLER ASSEMBLY…..2471
      METHOD FOR ASSEMBLING IDLER ASSEMBLY…..2473
    DISASSEMBLE AND ASSEMBLE RECOIL SPRING…..2477
      METHOD FOR DISASSEMBLING AND ASSEMBLING RECOIL SPRING…..2478
      METHOD FOR ASSEMNLING RECOIL SPRING ASSEMBLY…..2479
    DISASSEMBLE AND ASSEMBLE TRACK ROLLER ASSEMBLY…..2481
      METHOD FOR DISASSEMBLING TRACK ROLLER ASSEMBLY…..2481
      METHOD FOR ASSEMBLING TRACK ROLLER ASSEMBLY…..2483
    DISASSEMBLEAND ASSEMBLE CARRIER ROLLER ASSEMBLY…..2487
      METHOD FOR DISASSEMBLING CARRIER ROLLER ASSEMBLY…..2487
      METHOD FOR ASSEMBLING CARRIER ROLLER ASSEMBLY…..2488
    SEPARATE AND CONNECT TRACK ASSEMBLY…..2491
      METHOD FOR SEPARATING TRACK ASSEMBLY (NORMAL)…..2491
      METHOD FOR CONNECTING TRACK ASSEMBLY…..2492
    SEPARATE AND CONNECT PLUS TYPE TRACK ASSEMBLY…..2494
      METHOD FOR SEPARATING PLUS TYPE TRACK ASSEMBLY…..2494
      METHOD FOR CONNECTING PLUS TYPE TRACK ASSEMBLY…..2494
    DISASSEMBLE AND ASSEMBLE TRACK ASSEMBLY GENERALLY…..2496
      METHOD FOR DISASSEMBLING TRACK ASSEMBLY GENERALLY…..2497
      METHOD FOR ASSEMBLING TRACK ASSEMBLY GENERALLY…..2499
    DISASSEMBLE AND ASSEMBLE PLUS TYPE TRACK ASSEMBLY GENERALLY…..2512
      METHOD FOR DISASSEMBLING PLUS TYPE TRACK ASSEMBLY GENERALLY…..2513
      METHOD FOR ASSEMBLING PLUS TYPE TRACK ASSEMBLY GENERALLY…..2514
    DISASSEMBLE AND ASSEMBLE ONE LINK OF TRACK SHOE ASSEMBLY ON THE FIELD…..2529
      METHOD FOR DISASSEMBLING ONE LINK OF TRACK SHOE ASSEMBLY ON THE FIELD…..2531
      METHOD FOR ASSEMBLING ONE LINK OF TRACK SHOE ASSEMBLY ON THE FIELD…..2532
    DISASSEMBLE AND ASSEMBLE ONE LINK OF PLUS TYPE TRACK SHOE ASSEMBLY ON THE FIELD…..2540
      METHOD FOR DISASSEMBLING ONE LINK OF PLUS TYPE TRACK SHOE ASSEMBLY ON THE FIELD…..2541
      METHOD FOR ASSEMBLING ONE LINK OF PLUS TYPE TRACK SHOE ASSEMBLY ON THE FIELD…..2543
HYDRAULIC SYSTEM…..2548
    REMOVE AND INSTALL HYDRAULIC TANK ASSEMBLY…..2548
      METHOD FOR REMOVING HYDRAULIC TANK ASSEMBLY…..2548
      METHOD FOR INSTALLING HYDRAULIC TANK ASSEMBLY…..2553
    REMOVE AND INSTALL CONTROL VALVE ASSEMBLY…..2558
      METHOD FOR REMOVING CONTROL VALVE ASSEMBLY…..2558
      METHOD FOR INSTALLING CONTROL VALVE ASSEMBLY…..2560
WORK EQUIPMENT…..2563
    REMOVE AND INSTALL BLADE ASSEMBLY (POWER ANGLE POWER TILT DOZER)…..2563
      METHOD FOR REMOVING BLADE ASSEMBLY (POWER ANGLE POWER TILT DOZER)…..2563
      METHOD FOR INSTALLING BLADE ASSEMBLY…..2565
    REMOVE AND INSTALL WORK EQUIPMENT ASSEMBLY…..2568
      METHOD FOR REMOVING WORK EQUIPMENT ASSEMBLY…..2568
      METHOD FOR INSTALLING WORK EQUIPMENT ASSEMBLY…..2570
    REMOVE AND INSTALL STROKE SENSING BLADE LIFT CYLINDER ASSEMBLY…..2573
      METHOD FOR REMOVING STROKE SENSING BLADE LIFT CYLINDER ASSEMBLY…..2573
      METHOD FOR INSTALLING STROKE SENSING BLADE LIFT CYLINDER ASSEMBLY…..2575
    DISASSEMBLE AND ASSEMBLE STROKE SENSING BLADE LIFT CYLINDER ASSEMBLY…..2577
      METHOD FOR DISASSEMBLING STROKE SENSING BLADE LIFT CYLINDER ASSEMBLY…..2578
      METHOD FOR ASSEMBLING STROKE SENSING BLADE LIFT CYLINDER ASSEMBLY…..2582
    REMOVE AND INSTALL STROKE SENSING BLADE TILT CYLINDER ASSEMBLY…..2590
      METHOD FOR REMOVING STROKE SENSING BLADE TILT CYLINDER ASSEMBLY…..2590
      METHOD FOR INSTALLING STROKE SENSING BLADE TILT CYLINDER ASSEMBLY…..2593
    DISASSEMBLE AND ASSEMBLE STROKE SENSING BLADE TILT CYLINDER ASSEMBLY…..2597
      METHOD FOR DISASSEMBLING STROKE SENSING BLADE TILT CYLINDER ASSEMBLY…..2597
      METHOD FOR ASSEMBLING STROKE SENSING BLADE TILT CYLINDER ASSEMBLY…..2601
    REMOVE AND INSTALL STROKE SENSING BLADE ANGLE CYLINDER ASSEMBLY…..2606
      METHOD FOR REMOVING STROKE SENSING BLADE ANGLE CYLINDER ASSEMBLY…..2606
      METHOD FOR INSTALLING STROKE SENSING BLADE ANGLE CYLINDER ASSEMBLY…..2608
    DISASSEMBLE AND ASSEMBLE STROKE SENSING BLADE ANGLE CYLINDER ASSEMBLY…..2612
      METHOD FOR DISASSEMBLING STROKE SENSING BLADE ANGLE CYLINDER ASSEMBLY…..2612
      METHOD FOR ASSEMBLING STROKE SENSING BLADE ANGLE CYLINDER ASSEMBLY…..2616
    REMOVE AND INSTALL U-FRAME ASSEMBLY…..2622
      METHOD FOR REMOVING U-FRAME ASSEMBLY…..2622
      METHOD FOR INSTALLING U-FRAME ASSEMBLY…..2624
CAB AND ITS ATTACHMENTS…..2627
    REMOVE AND INSTALL OPERATOR'S CAB ASSEMBLY…..2627
      METHOD FOR REMOVING OPERATOR'S CAB ASSEMBLY…..2627
      METHOD FOR INSTALLING OPERATOR'S CAB ASSEMBLY…..2633
    REMOVE AND INSTALL WIPER ARM…..2640
      METHOD FOR REMOVING WIPER ARM…..2640
      METHOD FOR INSTALLING WIPER ARM…..2641
    REMOVE AND INSTALL OPERATOR'S CAB GLASS (ADHERED GLASS)…..2643
      METHOD FOR REMOVING OPERATOR'S CAB GLASS (ADHERED GLASS)…..2645
      METHOD FOR INSTALLING OPERATOR'S CAB GLASS (ADHERED GLASS)…..2645
    REMOVE AND INSTALL AIR CONDITIONER UNIT ASSEMBLY…..2651
      METHOD FOR REMOVING AIR CONDITIONER UNIT ASSEMBLY…..2651
      METHOD FOR INSTALLING AIR CONDITIONER UNIT ASSEMBLY…..2657
    REMOVE AND INSTALL OPERATOR'S SEAT…..2665
      METHOD FOR REMOVING OPERATOR'S SEAT…..2665
      METHOD FOR INSTALLING OPERATOR'S SEAT…..2666
    REMOVE AND INSTALL SEAT BELT…..2667
      METHOD FOR REMOVING SEAT BELT…..2667
      METHOD FOR INSTALLING SEAT BELT…..2667
    REMOVE AND INSTALL FOOT HEATER ASSEMBLY…..2669
      METHOD FOR REMOVING FOOT HEATER ASSEMBLY…..2669
      METHOD FOR INSTALLING FOOT HEATER ASSEMBLY…..2671
    DISASSEMBLE AND ASSEMBLE FOOT HEATER ASSEMBLY…..2673
      METHOD FOR DISASSEMBLING FOOT HEATER ASSEMBLY…..2673
      METHOD FOR ASSEMBLING FOOT HEATER ASSEMBLY…..2674
ELECTRICAL SYSTEM…..2675
    REMOVE AND INSTALL ENGINE CONTROLLER ASSEMBLY…..2675
      METHOD FOR REMOVING ENGINE CONTROLLER ASSEMBLY…..2675
      METHOD FOR INSTALLING ENGINE CONTROLLER ASSEMBLY…..2677
    REMOVE AND INSTALL HST CONTROLLER ASSEMBLY…..2681
      METHOD FOR REMOVING HST CONTROLLER ASSEMBLY…..2681
      METHOD FOR INSTALLING HST CONTROLLER ASSEMBLY…..2682
    REMOVE AND INSTALL MACHINE MONITOR ASSEMBLY…..2683
      METHOD FOR REMOVING MACHINE MONITOR ASSEMBLY…..2683
      METHOD FOR INSTALLING MACHINE MONITOR ASSEMBLY…..2684
    REMOVE AND INSTALL MASS AIR FLOW AND TEMPERATURE SENSOR…..2686
      METHOD FOR REMOVING MASS AIR FLOW AND TEMPERATURE SENSOR…..2686
      METHOD FOR INSTALLING MASS AIR FLOW AND TEMPERATURE SENSOR…..2688
    REMOVE AND INSTALL KCCV CRANKCASE PRESSURE SENSOR…..2689
      METHOD FOR REMOVING KCCV CRANKCASE PRESSURE SENSOR…..2689
      METHOD FOR INSTALLING KCCV CRANKCASE PRESSURE SENSOR…..2690
    REMOVE AND INSTALL SCR TEMPERATURE SENSOR…..2692
      METHOD FOR REMOVING SCR TEMPERATURE SENSOR…..2692
      METHOD FOR INSTALLING SCR TEMPERATURE SENSOR…..2694
    REMOVE AND INSTALL KOMTRAX TERMINAL ASSEMBLY…..2696
      METHOD FOR REMOVING KOMTRAX TERMINAL ASSEMBLY…..2696
      METHOD FOR INSTALLING KOMTRAX TERMINAL ASSEMBLY…..2697
    REMOVE AND INSTALL ICT SENSOR CONTROLLER ASSEMBLY…..2698
      METHOD FOR REMOVING ICT SENSOR CONTROLLER ASSEMBLY…..2698
      METHOD FOR INSTALLING ICT SENSOR CONTROLLER ASSEMBLY…..2698
    REMOVE AND INSTALL CONTROL BOX…..2700
      METHOD FOR REMOVING CONTROL BOX…..2700
      METHOD FOR INSTALLING CONTROL BOX…..2701
    REMOVE AND INSTALL GNSS RECEIVER…..2702
      METHOD FOR REMOVING GNSS RECEIVER…..2702
      METHOD FOR INSTALLING GNSS RECEIVER…..2702
    REMOVE AND INSTALL GNSS ANTENNA…..2704
      METHOD FOR REMOVING GNSS ANTENNA…..2704
      METHOD FOR INSTALLING GNSS ANTENNA…..2705
    REMOVE AND INSTALL IMU SENSOR…..2710
      METHOD FOR REMOVING IMU SENSOR…..2710
      METHOD FOR INSTALLING IMU SENSOR…..2711
60 MAINTENANCE STANDARD…..2715
CONTENTS…..2716
ABBREVIATION LIST…..2718
ENGINE AND COOLING SYSTEM…..2724
    MAINTENANCE STANDARD OF ENGINE MOUNT…..2724
    MAINTENANCE STANDARD OF DAMPER…..2725
    MAINTENANCE STANDARD OF COOLING SYSTEM…..2726
    MAINTENANCE STANDARD OF COOLING FAN MOTOR…..2728
    MAINTENANCE STANDARD OF WORK EQUIPMENT AND COOLING FAN PUMP…..2730
POWER TRAIN…..2731
    MAINTENANCE STANDARD OF HST PUMP…..2731
      MAINTENANCE STANDARD OF EPC VALVE OF HST PUMP…..2732
      MAINTENANCE STANDARD OF TOW RECEIVING VALVE OF HST PUMP…..2733
    MAINTENANCE STANDARD OF HST CHARGE PUMP…..2734
    MAINTENANCE STANDARD OF HST MOTOR…..2736
    MAINTENANCE STANDARD OF FINAL DRIVE…..2737
    MAINTENANCE STANDARD OF SPROCKET FOR PLUS TYPE TRACK SHOE: D37EXI-24,D37PXI-24…..2739
    MAINTENANCE STANDARD OF SPROCKET FOR PLUS TYPE TRACK SHOE: D39EXI-24,D39PXI-24…..2741
    MAINTENANCE STANDARD OF SPROCKET TOOTH PROFILE FULL-SCALE DRAWING FOR PLUS TYPE TRACK SHOE: D37EXI-24,D37PXI-24…..2743
    MAINTENANCE STANDARD OF SPROCKET TOOTH PROFILE FULL-SCALE DRAWING FOR PLUS TYPE TRACK SHOE: D39EXI-24,D39PXI-24…..2744
UNDERCARRIAGE AND FRAME…..2745
    MAINTENANCE STANDARD OF TRACK FRAME AND IDLER CUSHION…..2745
    MAINTENANCE STANDARD OF TRACK SHOE FOR CONVENTIONAL PLUS TYPE TRACK SHOES:D37EXI-24,D37PXI-24…..2750
    MAINTENANCE STANDARD OF TRACK SHOE FOR CONVENTIONAL PLUS TYPE TRACK SHOES:D39EXI-24,D39PXI-24…..2752
    MAINTENANCE STANDARD OF TRACK ROLLER FOR PLUS TYPE TRACK SHOES (SINGLE FLANGE TYPE)…..2754
    MAINTENANCE STANDARD OF TRACK ROLLER FOR PLUS TYPE TRACK SHOES (DOUBLE FLANGE TYPE)…..2756
    MAINTENANCE STANDARD OF CARRIER ROLLER FOR PLUS TYPE TRACK SHOE…..2758
    MAINTENANCE STANDARD OF PLUS TYPE TRACK SHOE…..2760
    MAINTENANCE STANDARD OF SINGLE SHOE…..2764
HYDRAULIC SYSTEM…..2765
    MAINTENANCE STANDARD OF HYDRAULIC TANK…..2765
    MAINTENANCE STANDARD OF WORK EQUIPMENT AND COOLING FAN PUMP…..2766
      MAINTENANCE STANDARD OF SERVO VALVE OF WORK EQUIPMENT AND COOLING FAN PUMP…..2767
    MAINTENANCE STANDARD OF CONTROL VALVE…..2769
    MAINTENANCE STANDARD OF RIPPER PPC VALVE…..2776
    MAINTENANCE STANDARD OF 5-PORT VALVE OF EPC AND SOLENOID…..2778
      MAINTENANCE STANDARD OF EPC VALVE…..2779
    MAINTENANCE STANDARD OF ANGLE OPERATION EPC VALVE…..2780
WORK EQUIPMENT…..2781
    MAINTENANCE STANDARD OF FRONT WORK EQUIPMENT…..2781
    MAINTENANCE STANDARD OF CUTTING EDGE AND END BIT…..2784
    MAINTENANCE STANDARD OF STROKE SENSING BLADE LIFT CYLINDER…..2785
    MAINTENANCE STANDARD OF STROKE SENSING BLADE TILT CYLINDER…..2786
    MAINTENANCE STANDARD OF STROKE SENSING BLADE ANGLE CYLINDER…..2787
    MAINTENANCE STANDARD OF STROKE AND RESET SENSOR FOR BLADE LIFT CYLINDER…..2788
    MAINTENANCE STANDARD OF STROKE SENSOR FOR BLADE TILT CYLINDER…..2789
    MAINTENANCE STANDARD OF STROKE SENSOR FOR BLADE ANGLE CYLINDER…..2790
    MAINTENANCE STANDARD OF FIXED MULTI-SHANK RIPPER…..2791
    MAINTENANCE STANDARD OF RIPPER LIFT CYLINDER…..2793
CAB AND ITS ATTACHMENTS…..2794
    MAINTENANCE STANDARD OF CAB MOUNT…..2794
ELECTRICAL SYSTEM…..2795
    MAINTENANCE STANDARD OF ELECTRIC STEERING CONTROL LEVER…..2795
80 APPENDIX…..2797
CONTENTS…..2798
ABBREVIATION LIST…..2799
AIR CONDITIONER SYSTEM…..2805
    PRECAUTIONS FOR REFRIGERANT…..2805
    AIR CONDITIONER COMPONENT…..2806
    SPECIFICATIONS OF AIR CONDITIONER…..2809
    CONFIGURATION AND FUNCTION OF REFRIGERATION CYCLE…..2810
    OUTLINE OF REFRIGERATION CYCLE…..2811
COMPONENT PARTS OF AIR CONDITIONER SYSTEM…..2813
    AIR CONDITIONER UNIT…..2813
      CONFIGURATION DIAGRAM OF AIR CONDITIONER UNIT…..2813
      FUNCTION OF AIR CONDITIONER UNIT…..2814
    COMPONENT PARTS OF AIR CONDITIONER UNIT…..2815
      FUNCTION OF EVAPORATOR AS AIR CONDITIONER UNIT COMPONENT…..2815
      FUNCTION OF HEATER CORE AS AIR CONDITIONER UNIT COMPONENT…..2815
      FUNCTION OF THERMOSTAT AS AIR CONDITIONER UNIT COMPONENT…..2815
      STRUCTURE OF EXPANSION VALVE AS AIR CONDITIONER UNIT COMPONENT…..2816
      FUNCTION OF EXPANSION VALVE AS AIR CONDITIONER UNIT COMPONENT…..2816
      OPERATE EXPANSION VALVE AS AIR CONDITIONER UNIT COMPONENT…..2816
      FUNCTION OF DUAL PRESSURE SWITCH…..2817
      FUNCTION OF PRESSURE SWITCH…..2817
    COMPRESSOR…..2818
      STRUCTURE OF COMPRESSOR…..2818
      SPECIFICATIONS OF COMPRESSOR…..2818
      FUNCTION OF COMPRESSOR…..2818
    CONDENSER…..2819
      STRUCTURE OF CONDENSER…..2819
      SPECIFICATIONS OF CONDENSER…..2819
      FUNCTION OF CONDENSER…..2820
    RECEIVER DRIER…..2821
      STRUCTURE OF RECEIVER DRIER…..2821
      SPECIFICATIONS OF RECEIVER DRIER…..2821
      FUNCTION OF RECEIVER DRIER…..2821
EXPLANATION OF PROCEDURE FOR TESTING AND TROUBLESHOOTING OF AIR CONDITIONER…..2823
CIRCUIT DIAGRAM OF AIR CONDITIONER…..2826
AIR CONDITIONER SYSTEM DIAGRAM…..2827
CONTROL FUNCTION OF AIR CONDITIONER…..2828
INSTALLATION LOCATIONS OF AIR CONDITIONER PARTS AND ARRANGEMENT OF CONNECTORS…..2829
TEST RELAYS…..2833
    METHOD FOR TESTING RELAYS…..2833
AIR CONDITIONER TROUBLESHOOTING CHART 1…..2835
AIR CONDITIONER TROUBLESHOOTING CHART 2…..2836
INFORMATION DESCRIBED IN TROUBLESHOOTING TABLE…..2839
A-1 TROUBLESHOOTING FOR CONDENSER FAN…..2841
A-2 TROUBLESHOOTING FOR COMPRESSOR AND REFRIGERANT SYSTEM (AIR IS NOT COOLED)…..2844
A-3 TROUBLESHOOTING FOR BLOWER MOTOR SYSTEM (NO AIR COMES OUT OR AIR FLOW IS ABNORMAL)…..2848
A-4 TROUBLESHOOTING FOR TEMPERATURE CONTROL FUNCTION…..2851
TROUBLESHOOTING USING GAUGE PRESSURE…..2855
CONNECTION OF SERVICE TOOL…..2857
    METHOD FOR CONNECTING SERVICE TOOL…..2857
PRECAUTIONS FOR DISCONNECTING AND CONNECTING HOSES AND TUBES IN AIR CONDITIONER PIPINGS…..2858
HANDLE COMPRESSOR OIL…..2860
90 CIRCUIT DIAGRAMS…..2863
CONTENTS…..2864
ABBREVIATION LIST…..2865
HYDRAULIC CIRCUIT DIAGRAM…..2871
    SYMBOLS USED IN HYDRAULIC CIRCUIT DIAGRAM…..2871
    HYDRAULIC CIRCUIT DIAGRAM…..2875
ELECTRICAL CIRCUIT DIAGRAM…..2876
    SYMBOLS USED IN ELECTRICAL CIRCUIT DIAGRAM…..2876
    ELECTRICAL CIRCUIT DIAGRAM (1/11)…..2880
    ELECTRICAL CIRCUIT DIAGRAM (2/11)…..2881
    ELECTRICAL CIRCUIT DIAGRAM (3/11)…..2882
    ELECTRICAL CIRCUIT DIAGRAM (4/11)…..2883
    ELECTRICAL CIRCUIT DIAGRAM (5/11)…..2884
    ELECTRICAL CIRCUIT DIAGRAM (6/11)…..2885
    ELECTRICAL CIRCUIT DIAGRAM (7/11)…..2886
    ELECTRICAL CIRCUIT DIAGRAM (8/11)…..2887
    ELECTRICAL CIRCUIT DIAGRAM (9/11)…..2888
    ELECTRICAL CIRCUIT DIAGRAM (10/11)…..2889
    ELECTRICAL CIRCUIT DIAGRAM (11/11)…..2890
INDEX…..2891

Komatsu Bulldozer D37EXi, D37PXi, D39EXi, D39PXi Repair Service Manuals

INSTANT DOWNLOAD

Posted on June 5, 2025 by admin

Komatsu Crawler Tractors/Bulldozers D32E,P, D38E,P, D39E,P Repair Service Manuals

INSTANT DOWNLOAD

Complete service repair manual for Komatsu Crawler Tractors / Bulldozers D32E, D32P, D38E, D38P, D39E, D39P, with all the shop information to maintain, diagnose, repair, and service like professional mechanics.

Komatsu Crawler Tractors/Bulldozers D32E,P, D38E,P, D39E,P workshop service repair manual includes:
* Numbered table of contents easy to use so that you can find the information you need fast.
* Detailed sub-steps expand on repair procedure information
* Numbered instructions guide you through every repair procedure step by step.
* Troubleshooting and electrical service procedures are combined with detailed wiring diagrams for ease of use.
* Notes, cautions and warnings throughout each chapter pinpoint critical information.
* Bold figure number help you quickly match illustrations with instructions.
* Detailed illustrations, drawings and photos guide you through every procedure.
* Enlarged inset helps you identify and examine parts in detail.

CEBM000301 – Bulldozer D32E,P-1, D38E,P-1, D39E,P-1 Shop Manual.pdf
CEBM003100 – Crawler Tractor D32E-1,P-1, D38E-1,P-1, D39E-1,P-1 Shop Manual.pdf
CEBM004302 – Crawler Tractor D32E,P-1A, D38E,P-1A, D39E,P-1A Shop Manual.pdf

PRODUCT DETAILS:
Total Pages: 1,881 pages
File Format: PDF
Language: English

TABLE OF CONTENTS
01 GENERAL . . . 01-1
10 STRUCTURE, FUNCTION AND MAINTENANCE STANDARD . . . . 10-1
20 TESTING, ADJUSTING AND TROUBLESHOOTING . . . . 20-1
30 DISASSEMBLY AND ASSEMBLY. . . 30-1
90 OTHER . . . . 90-1

CEBM000301 – Bulldozer D32E,P-1, D38E,P-1, D39E,P-1 Shop Manual….2
SECTION INDEX….10
INDEX TO SECTIONS….11
SECTION 1 – INTRODUCTION….12
    SAFETY PRECAUTIONS….13
      GENERAL….13
      BEFORE STARTING THE ENGINE….13
      OPERATION….14
      MAINTENANCE….16
      SHUTDOWN….18
      SAFETY PRODUCT GRAPHICS AND LOCATION….19
    SERVICE INFORMATION….21
      GENERAL….21
      PIN AND SERIAL NUMBERS….21
      SERVICE TOOL AND PARTS….22
      INSPECTION AND REPAIR….22
    LOCTITE USAGE….23
      SURFACE PREPARATION….23
      APPLICATION….23
      SETTING TIME….24
      REMOVAL….24
      APPLICATIONS AT LOW TEMPERATURES….24
SECTION 2 – MISCELLANEOUS….26
    DIMENSIONS….27
      D32E-1 DIMENSIONS….27
      D32P-1 DIMENSIONS….28
      D38E-1 DIMENSIONS….29
      D38P-1 DIMENSIONS….30
      D39E-1 DIMENSIONS….31
      D39P-1 DIMENSIONS….32
    SPECIFICATIONS….33
      D32E-1, D32P-1 SPECIFICATIONS….33
      D38E-1, D38P-1 SPECIFICATIONS….34
      D39E-1, D39P-1 SPECIFICATIONS….35
    CAPACITIES AND LUBRICANTS….36
      CAPACITIES AND LUBRICANTS….36
    SPECIAL TORQUES….38
    STANDARD TORQUES….40
      INTRODUCTION OF TOOLS….40
      BOLT IDENTIFICATION CHART….41
      GRADE 5 AND 8 NON-PHOSPHATE HARDWARE….42
      GRADE 8 PHOSPHATE COATED HARDWARE….43
      STANDARD METRIC FASTENERS….43
      HOSE CLAMPS….44
      SPLIT FLANGE CONNECTIONS….44
SECTION 6 – COOLING….46
    GENERAL….47
      DESCRIPTION….47
      OPERATION….47
      SPECIFICATIONS….47
    SERVICE DIAGNOSIS….48
    RADIATOR….49
      REMOVAL….51
      DISASSEMBLY….56
      REASSEMBLY….60
      INSTALLATION….64
SECTION 7 – DRIVE TRAIN….70
    GENERAL….71
      SPECIFICATIONS….71
      DRIVE TRAIN SCHEMATIC….72
      DESCRIPTION….74
      OPERATION….74
      PRESSURES….76
      BRAKE CYLINDER RELEASE….77
      TRANSMISSION CLUTCH….77
      STALL SPEEDS….78
SECTION 7B – TORQUE CONVERTER….80
    GENERAL….81
      DESCRIPTION….81
      OPERATION….81
      SPECIAL TOOLS….81
      SPECIFICATIONS….83
      SERVICE DIAGNOSIS….83
    REMOVAL….84
    DISASSEMBLY….92
      COMPLETE ASSEMBLY….92
      CONVERTER ASSEMBLY….96
      REAR HOUSING….100
    REASSEMBLY….103
      REAR HOUSING….103
      CONVERTER ASSEMBLY….107
      COMPLETE ASSEMBLY….111
    INSTALLATION….118
SECTION 7C – TRANSMISSION….126
    GENERAL….127
      DESCRIPTION….128
      OPERATION….128
      SPECIFICATIONS….130
    REMOVAL….131
    COMPLETE ASSEMBLY….147
      DISASSEMBLY….148
      REASSEMBLY….153
    DIRECTIONAL (INPUT) SHAFT….163
      GENERAL….163
      PISTON RETURN SPRING CRITERION….165
      DISASSEMBLY….165
      REASSEMBLY….170
    COUNTERSHAFT….179
      GENERAL….179
      DISASSEMBLY….180
      REASSEMBLY….180
    RANGE (OUTPUT) SHAFT….182
      GENERAL….182
      PISTON RETURN SPRING CRITERION….184
      DISASSEMBLY….184
      REASSEMBLY….191
    REVERSE IDLER SHAFT….205
      GENERAL….205
      DISASSEMBLY….206
      REASSEMBLY….206
    MAIN REGULATOR VALVE….208
      DESCRIPTION….209
      THEORY OF OPERATION….209
      SPECIFICATIONS….210
      DISASSEMBLY….210
      REASSEMBLY….213
    RANGE SELECTOR VALVE….217
      DESCRIPTION….218
      THEORY OF OPERATION….218
      SPECIFICATIONS….219
      DISASSEMBLY….219
      REASSEMBLY….221
    RATE OF RISE VALVE….224
      SPECIFICATIONS….229
      DISASSEMBLY….230
      REASSEMBLY….232
    INSTALLATION….236
    TRANSMISSION/ISTEERING VALVE….254
      DESCRIPTION….256
      THEORY OF OPERATION….256
      SPECIFICATIONS….257
      REMOVAL….258
      DISASSEMBLY….260
      REASSEMBLY….268
      ADJUSTMENT….276
      INSTALLATION….277
    DRIVE SHAFT….280
      SPECIFICATIONS….280
      SERVICE….281
SECTION 7E – STEERING DRIVE….284
    GENERAL….285
      DESCRIPTION….285
      OPERATION….285
      SPECIFICATIONS….286
    REMOVAL….287
    DISASSEMBLY….297
    BRAKE CYLINDER….307
      SPECIFICATIONS….309
      DISASSEMBLY….309
      REASSEMBLY….311
    STEERING CYLINDER….313
      DESCRIPTION….314
      DISASSEMBLY….314
      REASSEMBLY….316
    MOUNTING PLATE….318
      SERVICE….319
    BRAKE/STEERING SHOES….321
      SPECIFICATIONS….323
      SERVICE….323
    BEARING CARRIER….326
      SERVICE….326
    PLANET GEAR CARRIER….329
      SERVICE….329
    REASSEMBLY….331
    INSTALLATION….350
    BRAKE ADJUSTMENT….361
    BRAKE CYLINDER VALVE….364
      GENERAL….364
      SPECIFICATIONS….365
      OPERATION….365
      REMOVAL….366
      DISASSEMBLY….368
      REASSEMBLY….369
      INSTALLATION….370
SECTION 7F – FINAL DRIVE….372
    GENERAL….373
      DESCRIPTION AND OPERATION….374
      SPECIFICATION….374
      SERVICE DIAGNOSIS….375
    REMOVAL….376
    DISASSEMBLY….378
      D32E-1, D32P-1, D38E-1 OR D38P-1….379
      D39E-1 OR D39P-1….382
    REASSEMBLY….387
      D32E-1, D32P-1, D38E-1 OR D38P-1….388
      D39E-1 OR D39P-1….391
    METAL TYPE FACE SEALS….395
      SEAL INSPECTION….395
      SEAL INSTALLATION….396
    INSTALLATION….397
SECTION 8 – ELECTRICAL….400
    GENERAL….401
      DESCRIPTION….401
      SPECIFICATIONS….401
      SPECIAL TOOLS….401
      TORQUE DATA….401
    WIRING DIAGRAM….402
SECTION 10 – HYDRAULICS….404
    GENERAL….405
      DESCRIPTION….406
      OPERATION….406
      SPECIFICATIONS….407
      SPECIAL TOOLS….407
      WORK EQUIPMENT….408
      BLADE EQUIPMENT LEVER….411
      REAR EQUIPMENT LEVER….412
SECTION 10A – PUMP AND MOTORS….414
    CHARGE AND SCAVENGE PUMP….415
      GENERAL….416
      REMOVAL….417
      DISASSEMBLY….418
      INSPECTION….422
      REASSEMBLY….422
      INSTALLATION….426
    EQUIPMENT PUMP….427
      GENERAL….428
      REMOVAL….429
      DISASSEMBLY….430
      INSPECTION….432
      REASSEMBLY….432
      INSTALLATION….434
SECTION 10B – CONTROL VALVE….436
    REMOVAL….437
    COMPLETE ASSEMBLY….445
      DISASSEMBLY….445
      REASSEMBLY….448
    SYSTEM RELIEF VALVE….450
      DISASSEMBLY….452
      REASSEMBLY….453
    BLADE LIFT SECTION….455
      DISASSEMBLY….458
      REASSEMBLY….459
    BLADE TILT SECTION….464
      DISASSEMBLY….466
      REASSEMBLY….466
    BLADE ANGLE OR RIPPER SECTION….469
      DISASSEMBLY….469
      REASSEMBLY….469
    INSTALLATION….474
SECTION 10C – CYLINDERS….482
    BLADE EQUIPMENT….483
      SPECIFICATIONS….484
      REMOVAL….484
      DISASSEMBLY….486
      REASSEMBLY….489
      INSTALLATION….491
    RIPPER….493
      SPECIFICATIONS….494
      REMOVAL….494
      DISASSEMBLY….495
      BUSHINGS….497
      REASSEMBLY….498
      INSTALLATION….501
SECTION 12 – POWER….502
    ENGINE….503
      STANDARD VALUE TABLE FOR ENGINE D32E AND D32P….503
      STANDARD VALUE TABLE FOR ENGINE D38E AND D38P….504
      STANDARD VALUE TABLE FOR ENGINE D39E AND D39P….505
      REMOVAL….506
      INSTALLATION….518
    THROTTLE….529
      ADJUSTMENT….529
      FUEL CONTROL LINKAGE….532
SECTION 14 – SUSPENSION….534
    GENERAL….535
      DESCRIPTION….536
      FRONT IDLER….536
      TRACK ADJUSTER….536
      TRACK SPRING….536
      TRACK TOP IDLER….536
      TRACK ROLLER….536
      FRONT CROSSBAR….536
      REAR RIGID BAR….536
      MAINTENANCE….536
    SERVICE DIAGNOSIS….537
    WEAR LIMIT CHECKS….539
      SPECIFICATIONS….539
      GENERAL….541
      TRACK SHOE GROUSER HEIGHT….541
      LINK HEIGHT….541
      BUSHING OUTSIDE DIAMETER….541
      INTERNAL PIN AND BUSHING WEAR (PITCH)….542
      FRONT IDLER FLANGE HEIGHT….542
      TRACK ROLLER ROLLING DIAMETER….542
      TOP IDLER ROLLING DIAMETER….542
    FRONT IDLER….543
      SPECIFICATIONS….544
      REMOVAL….545
      DISASSEMBLY….545
      CLEARANCES….549
      REASSEMBLY….551
      INSTALLATION….555
    TRACK ADJUSTER….560
      SPECIFICATIONS….561
      SERVICE….561
    TOP IDLER….565
      SPECIFICATIONS….566
      REMOVAL….566
      DISASSEMBLY….567
      REASSEMBLY….570
      INSTALLATION….573
    TRACK ROLLER….575
      SPECIFICATIONS….576
      REMOVAL….576
      DISASSEMBLY….577
      CLEARANCES….580
      REASSEMBLY….582
      INSTALLATION….585
    METAL TYPE FACE SEALS….586
      SEAL INSPECTION….586
      SEAL INSTALLATION….587
    TRACK FRAME….589
      REMOVAL….589
      INSTALLATION….590
    TRACK SPRING….591
      SPECIFICATIONS….592
      SPECIAL TOOLS….592
      REPLACEMENT….593
    FRONT CROSSBAR….600
      REMOVAL….600
      INSTALLATION….601
    REAR RIGID BAR….604
      REPLACEMENT….604
    TRACK FRAME ALIGNMENT….605
SECTION 15 – TRACK CHAIN….610
    SPLIT LINK TYPE CHAINS….611
      SPECIFICATIONS….613
      DESCRIPTION….614
      MAINTENANCE….614
      REMOVAL….615
      INSTALLATION….615
      COMPLETE CHAIN REBUILD….615
      SINGLE TRACK CHAIN JOINT REBUILD….617
SECTION 17 – MOUNTED EQUIPMENT….622
    C FRAME RUB BARS….623
      MOUNTING….623
    ANGLING FRAME….625
      BUSHING REPLACEMENT….625
      SPECIFICATIONS….626
      ADJUSTING….626
    C FRAME PIN….627
      PIN SHIMS….627
    C FRAME….628
      BUSHING REPLACEMENT….628
    BLADE BUSHINGS….629
      BUSHING REPLACEMENT….629
CEBM003100 – Crawler Tractor D32E-1,P-1, D38E-1,P-1, D39E-1,P-1 Shop Manual….631
CEBM004302 – Crawler Tractor D32E,P-1A, D38E,P-1A, D39E,P-1A Shop Manual….1267
COVER….1267
CONTENTS….1268
FOREWORD….1268
    SAFETY….1277
      SAFETY NOTICE….1277
    GENERAL….1279
    HOW TO READ THE SHOP MANUAL….1280
    HOISTING INSTRUCTIONS….1281
    COATING MATERIALS….1282
    STANDARD TIGHTENING TORQUE….1284
    ELECTRIC WIRE CODE….1286
    CONVERSION TABLES….1287
01 GENERAL….1293
    VIEW OF MACHINE….1294
    DIMENSIONAL DRAWINGS….1295
      D32E-1A….1295
      D32P-1A….1296
      D38E-1A….1297
      D38P-1A….1298
      D39E-1A….1299
      D39P-1A….1300
    SPECIFICATIONS….1301
      D32E/P-1A….1301
      D38E/P-1A….1303
      D39E/P-1A….1305
    WEIGHT TABLE….1307
    USE OF FUEL, COOLANT AND LUBRICANTS….1308
      PROPER SELECTION….1308
        D32E-1A, D32P-1A, D38E-1A OR D38P-1A….1308
        D39E-1A OR D39P-1A….1308
        ABBREVIATIONS….1309
      ENGINE OIL SPECIFICATIONS….1309
        NORMAL OPERATION….1309
        ARCTIC OPERATION….1309
      DRIVE TRAIN OIL SPECIFICATIONS….1310
      TRACK FRONT IDLER, TRACK ROLLER, TOP IDLER OIL SPECIFICATIONS….1310
      EQUIPMENT SYSTEM OIL SPECIFICATIONS….1310
      FINAL DRIVE OIL OR PIVOT SHAFT HOUSING SPECIFICATIONS….1310
      COOLING SYSTEM….1310
      FUEL SYSTEM….1310
10 STRUCTURE, FUNCTION & MAINTENANCE STANDARDS….1311
    ENGINE MOUNT….1313
    ENGINE CONTROLS….1314
    FUEL LINES….1315
    RADIATOR, OIL COOLER….1316
    DRIVE TRAIN….1317
      GENERAL….1317
      OUTLINE….1317
      SCHEMATIC….1319
      PIPING DIAGRAM….1320
        OUTLINE….1320
        PRESSURE PORTS….1321
      TORQUE CONVERTER….1322
        TWO PIECE HOUSING….1322
        OUTLINE….1323
        ONE PIECE HOUSING….1324
        OUTLINE….1325
      TRANSMISSION CONTROL….1326
        OUTLINE….1326
      DRIVE SHAFT….1327
      TRANSMISSION MOUNTING….1328
      TRANSMISSION….1329
        OUTLINE….1330
        CLUTCH OPERATION….1330
        GEAR SHIFT OPERATION….1331
        VALVES AND MANIFOLD MOUNTING….1333
        DIRECTIONAL (INPUT) CLUTCH SHAFT….1334
        RANGE (OUTPUT) CLUTCH SHAFT….1336
        COUNTERSHAFT….1338
        REVERSE IDLER SHAFT….1339
        PRESSURE REGULATOR VALVE….1340
        RANGE SELECTOR VALVE….1342
        RATE OF RISE VALVE….1344
      TASC VALVE….1347
        DESCRIPTION….1348
        THEORY OF OPERATION….1348
        DIRECTION….1349
        RANGE….1349
        STEERING….1349
      NEUTRAL START VALVE….1350
      CHARGE AND SCAVENGE PUMP….1351
        SUCTION STRAINER….1352
      BRAKE CYLINDER VALVE….1353
        OPERATION….1354
      STEERING DRIVE….1355
        OUTLINE….1357
        STEERING BRAKE CYLINDER….1359
        STEERING CYLINDER….1361
        BRAKE OR STEERING SHOES….1362
      FINAL DRIVE….1363
        DESCRIPTION….1365
    UNDERCARRIAGE….1366
      GENERAL….1366
      TRACK ROLLER….1368
      TRACK SPRING….1370
      TRACK ADJUSTER….1372
        DESCRIPTION….1373
      FRONT IDLER….1374
      TOP IDLER….1376
      TRACK CHAIN….1377
    MAIN FRAME….1379
    EQUIPMENT HYDRAULICS….1380
      HYDRAULIC DIAGRAM….1380
      HYDRAULIC SCHEMATIC….1380
      DESCRIPTION….1381
        BLADE CONTROL….1381
        RIPPER CONTROL….1382
        WORK EQUIPMENT CONTROLS….1383
      RESERVOIR AND RETURN FILTER….1384
      PUMP….1385
        DESCRIPTION….1385
      BLADE AND/OR RIPPER VALVE BANK….1386
        MAIN RELIEF VALVE….1388
        LOAD CHECK VALVE….1388
        ANTI CAVITATION – LOAD CHECK VALVE….1389
        BLADE LIFT VALVE SECTION….1390
        BLADE TILT VALVE SECTION….1392
        BLADE ANGLE OR RIPPER VALVE SECTION….1394
      BLADE CYLINDERS….1396
        BLADE LIFT AND TILT….1396
        BLADE ANGLE….1397
      RIPPER CYLINDERS….1398
    CAB….1399
    BLADE EQUIPMENT….1400
      C FRAME WEAR BARS….1400
        C FRAME PIN SHIMS….1401
        ANGLING FRAME….1401
        TRUNNION MOUNTING….1403
    ELECTRICAL SYSTEM….1405
      WIRING SCHEMATIC….1405
      ELECTRICAL COMPONENTS….1407
        DESCRIPTION….1407
        STARTING AND CHARGING GROUP….1407
        LIGHTING GROUP….1407
        INDICATOR GROUP….1407
        ACCESSORY GROUP….1407
      INSTRUMENT PANEL….1408
        OUTLINE….1408
        OPERATION….1408
        GAUGE DISPLAY….1409
    SPECIAL TORQUE CHART….1410
20 TESTING, ADJUSTING AND TROUBLESHOOTING….1411
    STANDARD VALUE TABLES FOR ENGINE….1412
    STANDARD VALUE TABLE FOR CHASSIS….1415
    TOOLS FOR TESTING AND ADJUSTING….1420
    ENGINE….1421
    EXHAUST COLOR….1424
    BELT TENSION….1425
    STALL SPEEDS….1426
    FUEL CONTROL LINKAGE….1427
    TASC VALVE….1430
    BRAKE AND DECELERATOR PEDAL….1431
    SECONDARY BRAKE PEDAL….1434
    SAFETY LOCK LEVER….1435
    BLADE EQUIPMENT LEVER….1436
    REAR EQUIPMENT LEVER….1438
    DRIVE TRAIN PRESSURES….1439
    BRAKE CYLINDER RELEASE….1440
    TRANSMISSION CLUTCH….1441
    WORK EQUIPMENT….1442
    SERVICE DIAGNOSIS….1445
30 DISASSEMBLY AND ASSEMBLY….1457
    METHOD OF USING MANUAL….1459
      PRECAUTIONS WHEN CARRYING OUT OPERATION….1463
    SPECIAL TOOL LIST….1466
    ENGINE CRANKCASE GUARD….1468
      REMOVAL….1468
      INSTALLATION….1468
    TRANSMISSION GUARD….1469
      REMOVAL….1469
      INSTALLATION….1469
    ENGINE HOOD….1470
      REMOVAL….1470
      INSTALLATION….1470
    ROPS CANOPY….1471
      REMOVAL….1471
      INSTALLATION….1471
    DASHBOARD….1472
      REMOVAL….1472
      INSTALLATION….1474
    OPERATOR’S SEAT….1475
      REMOVAL….1475
      INSTALLATION….1475
    FUEL TANK….1476
      REMOVAL….1476
      INSTALLATION….1478
    BATTERY BOX….1480
      REMOVAL….1480
      INSTALLATION….1484
    BRAKE PEDAL CONNECTIONS….1485
      GENERAL….1485
      BRAKE AND DECELERATOR PEDAL….1486
      BRAKE PAD….1491
      SECONDARY BRAKE PEDAL….1495
    RADIATOR….1498
      REMOVAL….1498
      DISASSEMBLY….1500
      REASSEMBLY….1505
      INSTALLATION….1509
    ENGINE….1513
      REMOVAL….1513
      ENGINE MOUNTING….1518
      INSTALLATION….1520
    TORQUE CONVERTER….1521
      REMOVAL….1521
      INSTALLATION….1524
      TWO PIECE HOUSING STYLE….1525
      ONE PIECE HOUSING STYLE….1545
    CHARGE AND SCAVENGE PUMP….1558
      REMOVAL….1558
      INSTALLATION….1558
      DISASSEMBLY….1560
      REASSEMBLY….1564
    DRIVE SHAFT….1568
      SERVICE….1568
    TRANSMISSION….1570
      REMOVAL….1570
      MOUNTING TRANSMISSION….1574
      INSTALLATION….1577
      COMPLETE ASSEMBLY….1578
      DIRECTIONAL (INPUT) SHAFT….1594
      COUNTERSHAFT….1608
      RANGE (OUTPUT) SHAFT….1611
      REVERSE IDLER SHAFT….1632
      MAIN REGULATOR VALVE….1635
      RANGE SELECTOR VALVE….1642
      RATE OF RISE VALVE….1648
    TASC VALVE….1655
      REMOVAL….1655
      INSTALLATION….1657
      DISASSEMBLY….1659
      REASSEMBLY….1667
      ADJUSTMENT….1675
    NEUTRAL START VALVE….1676
      REMOVAL….1676
      INSTALLATION….1676
      SERVICE….1677
    STEERING DRIVE….1679
      REMOVAL….1679
      INSTALLATION….1681
      DISASSEMBLY….1684
      REASSEMBLY….1692
    BRAKE CYLINDER….1710
      REMOVAL OR INSTALLATION….1711
      DISASSEMBLY….1711
      REASSEMBLY….1712
    STEERING CYLINDER….1714
      REMOVAL OR INSTALLATION….1714
      DISASSEMBLY….1715
      REASSEMBLY….1716
    BRAKE/STEERING SHOES….1719
      REMOVAL OR INSTALLATION….1719
      APPLY SHOES….1720
      BACK UP SHOES….1721
    BRAKE CYLINDER VALVE….1722
      REMOVAL….1722
      INSTALLATION….1723
      DISASSEMBLY….1725
      REASSEMBLY….1726
    FINAL DRIVE….1727
      REMOVAL….1727
      INSTALLATION….1730
      DISASSEMBLY….1732
      REASSEMBLY….1735
    EQUIPMENT PUMP….1741
      REMOVAL….1741
      INSTALLATION….1741
      DISASSEMBLY….1743
      REASSEMBLY….1745
    EQUIPMENT CONTROL VALVE….1748
      REMOVAL….1748
      INSTALLATION….1755
      COMPLETE ASSEMBLY….1756
      SYSTEM RELIEF VALVE….1760
      BLADE LIFT SECTION….1764
      BLADE TILT SECTION….1770
      BLADE ANGLE OR RIPPER SECTION….1774
    BLADE CYLINDERS….1778
      REMOVAL….1778
      INSTALLATION….1780
      DISASSEMBLY….1781
      REASSEMBLY….1784
    RIPPER CYLINDERS….1786
      REMOVAL….1786
      INSTALLATION….1786
      DISASSEMBLY….1787
      BUSHINGS….1790
      REASSEMBLY….1791
    UNDERCARRIAGE WEAR LIMITS….1794
      SPECIFICATIONS – D32E/P-1A OR D38E/P-1A….1794
      SPECIFICATIONS – D39E/P-1A….1795
      GENERAL….1796
      TRACK SHOE GROUSER HEIGHT….1796
      LINK HEIGHT….1796
      BUSHING OUTSIDE DIAMETER….1796
      INTERNAL PIN AND BUSHING WEAR (PITCH)….1797
      FRONT IDLER FLANGE HEIGHT….1797
      TRACK ROLLER ROLLING DIAMETER….1797
      TOP IDLER ROLLING DIAMETER….1797
    TRACK FRAME….1798
      REMOVAL….1798
      INSTALLATION….1799
    FRONT IDLER….1800
      REMOVAL….1800
      INSTALLATION….1801
      DISASSEMBLY….1806
      CLEARANCES….1810
      REASSEMBLY….1812
    TRACK ADJUSTER….1817
      SERVICE….1818
    RECOIL SPRING….1822
      REPLACEMENT….1822
    TRACK ROLLER….1830
      REMOVAL….1830
      INSTALLATION….1831
      DISASSEMBLY….1832
      CLEARANCES….1836
      REASSEMBLY….1838
    TOP IDLER….1842
      REMOVAL….1842
      INSTALLATION….1843
      DISASSEMBLY….1845
      REASSEMBLY….1849
      METAL TYPE FACE SEALS….1854
      SEAL INSTALLATION….1855
    FRONT CROSSBAR….1857
      REMOVAL….1857
      INSTALLATION….1859
    REAR RIGID BAR….1861
      REPLACEMENT….1861
    TRACK FRAME ALIGNMENT….1862
    TRACK CHAIN….1867
      MAINTENANCE….1869
      REMOVAL….1869
      INSTALLATION….1870
      COMPLETE CHAIN REBUILD….1870
      SINGLE JOINT REBUILD….1872
    MOUNTED EQUIPMENT….1876
      C FRAME RUB BARS….1876
      ANGLING FRAME….1877
      C FRAME PIN SHIMS….1879
      C FRAME BUSHINGS….1880
      BLADE BUSHINGS….1881
90 OTHERS….1883
    DRIVE TRAIN SCHEMATIC….1884
    ELECTRICAL WIRING DIAGRAM….1885

Komatsu Crawler Tractors/Bulldozers D32E,P, D38E,P, D39E,P Repair Service Manuals

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Posted on June 5, 2025 by admin

Komatsu Crawler Tractors D31S & D31Q Repair Service Manuals

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Complete service repair manual for Komatsu Crawler Tractors D31S & D31Q, with all the shop information to maintain, diagnose, repair, and service like professional mechanics.

Komatsu Crawler Tractors D31S & D31Q workshop service & repair manual includes:
* Numbered table of contents easy to use so that you can find the information you need fast.
* Detailed sub-steps expand on repair procedure information
* Numbered instructions guide you through every repair procedure step by step.
* Troubleshooting and electrical service procedures are combined with detailed wiring diagrams for ease of use.
* Notes, cautions and warnings throughout each chapter pinpoint critical information.
* Bold figure number help you quickly match illustrations with instructions.
* Detailed illustrations, drawings and photos guide you through every procedure.
* Enlarged inset helps you identify and examine parts in detail.

D31S-Q-BE1 – Crawler Tractor D31S-16 & D31Q-16 Shop Manual.pdf
SEBM0113B01 – Crawler Dozer D31S-16, D31Q-16 Shop Manual (SN25001&up).pdf

PRODUCT DETAILS:
Total Pages: 921 pages
File Format: PDF
Language: English

TABLE OF CONTENTS
0 GENERAL DESCRIPTION
1 ENGINE
2 POWER TRAIN
3 UNDERCARRIAGE
6 HYDRAULIC SYSTEM
7 WORK EQUIPMENT

Komatsu Crawler Tractors D31S & D31Q Repair Service Manuals

INSTANT DOWNLOAD